Valve Testing Solutions

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Howard Walton
6 years ago
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1 Valve Testing Solutions MVT Machine Series Precision. Performance. Possibilities.

For over 45 years, Merrill Engineering & Integration s success has been built on a strong foundation.

and form the foundation for a safe and reliable machine. Our engineering services are augmented by our 400,000 sq. ft.

ft. precision machining facility for finishing.

2 For over 45 years, Merrill Engineering & Integration s success has been built on a strong foundation. Utilizing the latest finite element analysis tools, our engineering team develops base and column structures that are extremely rigid and form the foundation for a safe and reliable machine. Our engineering services are augmented by our 400,000 sq. ft. fabrication division. This is where construction of these massive structures occurs. Structures are then transferred to our 150,000 sq. ft. precision machining facility for finishing. Merrill Engineering & Integration then brings those parts to life in the final assembly process, controls programs and test menus. It is this type of in-house control that allows us to produce quality test equipment, in a short timeframe, at an economical price.

rigorous testing demands of the petro-chemical industry. The integrated control system is easy to use and can be customized to meet your exacting specifications.

3 Merrill Engineering & Integration provides standard and custom built fully automated systems for a wide verity of industries. Our Merrill Valve Test (MVT) line of robust pneumatic and hydrostatic valve test machines allows you to safely and accurately increase throughput, while meeting the rigorous testing demands of the petro-chemical industry. The integrated control system is easy to use and can be customized to meet your exacting specifications. Data from the test sequence is displayed at the operator station, stored in the local PLC and can be interfaced with your in plant manufacturing monitoring system. Contact us for more information at

from ½ in diameter to 60 in diameter, for pressures up to 30,000 psi.

4 If our standard series of machines do not fit your requirements, Merrill Engineering & Integration manufactures custom vertical and horizontal machines for valves ranging from ½ in diameter to 60 in diameter, for pressures up to 30,000 psi. We also provide single and multi-station machines, depending on your production requirements.

To insure a safe and reliable test, machine and process; a risk assessment will be performed for all custom designed applications, in accordance with the Risks Associated with Machine Tools ANSI B11

5 To insure a safe and reliable test, machine and process; a risk assessment will be performed for all custom designed applications, in accordance with the Risks Associated with Machine Tools ANSI B11 TR All of Merrill Engineering & Integration s machines conform to the following specifications and guidelines: Selection of Programmable Electronic Systems (PES/PLC) for Machine Tools ANSI B11.TR Control Reliable Circuits and Servo Drive Technology, ANSI B11.TR6-200X National Electrical Code, 2005, UL508A Supplement B ANSI /NFPA OSHA, Subpart S, 29 CFR Part 1910 Safety Requirements for Integrated Manufacturing Systems, ANSI B Machine/Machinery Guarding, ANSI B Performance Criteria for Safeguarding, ANSI B Robots for Industrial Environments Safety Requirements ANSI/RIA, ISO :2006 ISO 9001 Registered Contact us for more information at

MODEL H W 20/2106 39 32 20/2110 44 34 20/2116 49 36 H MVT 20/2116 MVT 20/2110 MVT 20/2106 W The MVT series of machines are designed for hydrostatic and pneumatic testing of valves from 2 in diameter

Vertical models feature a shuttle system to accommodate easy loading of the valve. Standard tooling is available to either face seal or plug seal the valve.

6 MODEL H W 20/ / / H MVT 20/2116 MVT 20/2110 MVT 20/2106 W The MVT series of machines are designed for hydrostatic and pneumatic testing of valves from 2 in diameter to 16 in diameter, at pressures up to 10,000 psi, and forces up to 950,000 pounds. The machines are available to test valves either in a horizontal or vertical attitude. Vertical models feature a shuttle system to accommodate easy loading of the valve. Standard tooling is available to either face seal or plug seal the valve. An optional stem actuator can be coupled to the valve for automated testing. The stem actuator will open and close the valve while monitoring torque and rotation. Given the wide variety of valve stem configurations, you will need to contact our engineering group to ensure proper fit and size.

7 Standard Machine Capacity for Face Sealing Valves Valve Size Class Class Class Class Class Class Standard Machine Capacity for Plug Sealing Valves Valve Size Class Class Class Class Class Class / / /2116 The machine model selection charts are based on API testing requirements for the respective ANSI class valves. Contact us for more information at

A robust servo driven screw ram engages the valve and reliably withstands test pressures. This programmable system monitors force and distance to ensure excessive loads are not placed on the valve.

8 A robust servo driven screw ram engages the valve and reliably withstands test pressures. This programmable system monitors force and distance to ensure excessive loads are not placed on the valve. The long precision ram screw accommodates a large range of valve lengths without set-up changes and additional tooling. Designed for a rigorous, continuous production environment, this maintenance free drive system outperforms the competition.

Merrill Engineering & Integration s custom user interface is easy to use.

Pressure, time and temperature are monitored and stored in a database.

Screens are provided to create your own custom test recipes.

9 Merrill Engineering & Integration s custom user interface is easy to use. The test sequence is clearly displayed and machine functions are graphically depicted. Pressure, time and temperature are monitored and stored in a database. The information can be passed to your plant monitoring system. Screens are provided to create your own custom test recipes. Additional screens are provided for maintenance including online machine operation and a maintenance manual. Contact us for more information at

The machines can be outfitted with one of two servo controlled stem actuators, depending on the required torque, to open and close the valve during an automated test sequence.

10 The machines can be outfitted with one of two servo controlled stem actuators, depending on the required torque, to open and close the valve during an automated test sequence. The actuator is mounted to a pneumatically counterbalanced ergonomic arm. This allows the operator to effortlessly connect the actuator to the valve stem. A braking system holds the position of the actuator when the sequence is started. Quick-change tooling allows you to adapt to different stem configurations. The standard servo stem actuators are available with a constant torque of 550 Nm (406 lb.-ft.) with a maximum torque output of 990 Nm (730 lb.-ft.). The high torque servo stem actuator provides a constant torque output of 2,000 Nm (1,476 lb.-ft.) with a maximum torque output of 5,400 Nm (3986 lb.-ft.). During an automated test, the servo stem actuator will find the open and closed positions, register the required torque to operate the valve and then operate the valve for the required tests.

Designed for maximum productivity and ease of use, the machine comes with a

An optional automatic tool change system is available on the vertical

Several camera options further enhance your production and inspection

11 Designed for maximum productivity and ease of use, the machine comes with a quick-change tool feature. An optional automatic tool change system is available on the vertical series of machines. Several camera options further enhance your production and inspection requirements. The pan and zoom feature allows you to visually inspect a valve closely while under pressure without entering the test environment. Contact us for more information at

12 The vertical series of machines are provided with a servo operated shuttle system. The shuttle positions the lower tooling to the front of the machine, outside of the guarding. This allows for clear crane access to the valve for loading and connection of the stem actuator. The valve is then shuttled into the totally enclosed test environment and the automated sequence is started.

13 Safety is of the utmost importance. The test environment of the MVT series of machines is totally enclosed and meets and exceeds UL safety requirements. The test can be viewed through thick bullet resistant glass. Camera systems are used for further inspection of the valve under pressure. The standard safety interlocked automatic doors and articulating operator pendant make the machines ergonomically friendly and easy to use. While digital gauge output is displayed on the operator screen, additional analog gauges are also supplied at the front of the machine. A machine status light is provided to monitor uptime and availability. Contact us for more information at

Vertical Machines Model MVT 2006 Vertical Test Machine For valves ranging from 2 to 6 diameter... $619,000.00 Model MVT 2010 Vertical Test Machine For valves ranging from 2 to 10 diameter...$639,000.

14 Vertical Machines Model MVT 2006 Vertical Test Machine For valves ranging from 2 to 6 diameter... $619, Model MVT 2010 Vertical Test Machine For valves ranging from 2 to 10 diameter...$639, Model MVT 2016 Vertical Test Machine For valves ranging from 6 to 16 diameter...$664, Horizontal Machines Model MVT 2106 Horizontal Test Machine For valves ranging from 2 to 6 diameter... $539, Model MVT 2110 Horizontal Test Machine For valves ranging from 2 to 10 diameter... $559, Model MVT 2116 Horizontal Test Machine For valves ranging from 6 to 16 diameter...$584, *Prices subject to change without notice.

Standard options: Servo torque actuator and ergonomic arm... $29,500.

..consult factory Fixed mount camera with ring light... $6,150.00 ea. Pan and tilt camera with light...$47,710.

.. $4,450.00 ea. set Face seal plates 12 to 16 range... $4,850.00 ea. set Plug seal plates 2 to 6 range.

.. $6,150.00 ea. set * Each plug seal plate for one diameter only Allen Bradley PLC controller.

15 Standard options: Servo torque actuator and ergonomic arm... $29, Servo high torque actuator and ergonomic arm... $32, Stem mounting tools...consult factory Fixed mount camera with ring light... $6, ea. Pan and tilt camera with light...$47, ea. 24 LCD monitor...$2, ea. Face seal plates 2 to 6 range... $3, ea. set Face seal plates 6 to 12 range... $4, ea. set Face seal plates 12 to 16 range... $4, ea. set Plug seal plates 2 to 6 range... $4, ea. set Plug seal plates 6 to 12 range... $5, ea. set Plug seal plates 12 to 16 range... $6, ea. set * Each plug seal plate for one diameter only Allen Bradley PLC controller... Included in base machine Siemens PLC controller...consult factory Deliveries...Consult factory *Prices subject to change without notice. Contact us for more information at

16 Contact Merrill Engineering & Integration for standard and custom machine configurations to meet your specific needs. 400 Florence Street Saginaw, MI Merrill Technologies Group. All Rights Reserved.

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