Since 1962 VALVE TEST & REPAIR EQUIPMENT · S-5-80/6-5 DN up to 80 mm 41 Test benches for safety...

VALVE TEST & REPAIR EQUIPMENT

Catalogue 2016

Since 1962

Production workshop №1

Production workshop №2

PKTBA CJSC, introduces the ''REVALVE'' as our international brand delivering cutting edge technologies for valve testing, manufacturing and repair operations.

All these features embodied at our wide product range: • brand new line of horizontal and vertical valve test

units with range of DN from ½'' up to 56'' and clamping force up to 4000 tones;

• advanced product line of grinding /lapping units; • stationary machining centers; • welding overlaying and hard-facing automation; • portable valve test and repair systems; • mobile workshops. Above listed range of equipment has been created

by using of innovative technologies and modular design features, that brings flexibility to correspond challenging market demands.

Our wide product range and in-house engineering bureau, allows provide consultancy services and create design projects of maintenance workshops as per clients demands.

Premium quality of the REVALVE products is ensured by company QMS system certified as per ISO 9001-2015, unique half-century equipment designing and manufacturing experience, and confirmed by successful projects execution references.

Since 1962

CONTENT

Equipment for disassembling-assembling of valvesRMR 4UPG 6

Welding automationUN 7UNG-400-1300-800-KN 8USKSH 9UNG-KNV 10RMS-1 12

Machines for grinding and lappingSP 13

Machines and tooling for lathing (edge cutting)SR 14

Machines for grinding and lappingSPSH 16

Portable machines for grinding and lappingPUR-1, PUR-2 18PUR-5 19

Equipment for testingHorizontal test benches for shut-off valve 20

S-6-1400/4000, S-6-1400/3200, S-6-1400/2800 DN up to 1400 mm (56″) 21S-6-1200/2000, S-6-1050/1600, S-6-800/750 DN up to 1400 mm (56″) 22S-5-1050/1300, S-5-1000/600, S-5-900/850 DN up to 1200 mm (48″) 23S-5-600/500, S-5-600/350, S-5-500/250 DN up to 800 mm (32″) 24S-5-350/140, S-5-300/65, S-5-150/38 DN up to 400 mm (16″) 25S-5P-600/500 DN up to 600 mm (16″) 26

Vertical test benches for shut-off valve 28S-3-800/160, S-3-600/220, S-3-600/160 DN up to 800 mm (32″) 29S-3-600/100, S-3-500/160, S-3-500/100, S-3-500/60 DN up to 600 mm (24″) 30S-3-400/60, S-3-400/38, S-3-300/38, S-3-250/15 DN up to 400 mm (16″) 31

Tilting test benches for shut-off valve 32S-4-400/270, S-4-300/40 DN up to 400 mm (16″) 33

Test benches for control valve 34SI-26-CV, SI-26-1-CV DN up to 600 mm (24″) 35

Multi-station test benches for shut-off valve 36S-3-600/110-2 DN up to 600 mm (24″) 37S-3-250/180-3 DN up to 250 mm (10″) 38S-35-200/18-3 DN up to 200 mm (8″) 40S-5-80/6-5 DN up to 80 mm (3″) 41

Test benches for safety valves 42S-1-400/38, S-1-300/38, S-1-250/15 DN up to 400 mm (16″) 43SI-25M DN up to 300 mm (12″) 44D-14 portable measuring systems 45MP-PSV DN up to 400 mm (16″) 46

Test equipment for christmas tree valves & anti-blowout equipmentSI-PVO complex for testing 48UNIT №1 DN up to 280 mm (11″) 50UNIT №4 DN up to 425 mm (17″) 51UNIT №5 DN up to 425 mm (17″) 52

Optional equipmentCRS computer registration system 54UK automated compressor units 55PGS control stations 56SOV recycling water supply station 58VU vacuum system 58B safety fence 59SI-PRA leakage measuring unit 60BR test unit 60MG hydraulic drive unit 61

MSSH muffler for high pressure PSV gas testing 61

SPVP machines for cutting gaskets and drilling operations 62

Our certificates 63Contact 63

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9

RMRWORK STATION FOR VALVES ASSEMBLING/DISASSEMBLING

PURPOSE:• RMR-4, RMR-5 - disassembling and assembling of the wedge, stop,

control, and shut-off valves.• RMR-4-1 - disassembling and assembling and performing preliminary

pneumatic tests of the wedge, stop, control, and shut-off valves at a pressure of up to 6 bar (87 psi).

• RMR-6 - disassembling and assembling of the wedge and parallel-seat gate valve.

• RMR-PPK - disassembling and assembling of the safety valves.• RMR-SH - disassembling and assembling of the slab gate valves.• RMR-AFK - disassembling and assembling of the wellhead valves

(Cross-type Christmas Tree).

OPTIONAL:• Machine for disassembly and assembly of threaded joints (UPG) (p. 6).• Rail trolley.

ADVANTAGES:■ RMR is a set of accessory equipment to ensure fast and

efficient disassembly and assembly of the pipeline valves.■ The work bench with lockers, safety screen and lamp (1).■ The bench for disassembly and assembly of the pipeline

valves DN 15...300 mm (1/2…12″) and safety valves (2).■ For convenience, the bench can be adjusted by height.■ The bench for disassembly and assembly of the pipeline

valves with nominal bore DN 300...600 mm (12…24″) ( 3).■ For convenience, the bench is equipped with a ladder (4).■ The bench for preliminary pneumatic tests of the pipeline

valves DN 50...300 (1/2…12″) mm (5).■ The stand with swinging boom, balance beam, replaceable

screwdrivers and air preparation unit (6).■ The hydraulic press for pressing-in (pressing-out) of bush

sleeves of the gate valves (7).

SPECIFICATIONS:Model Usable range DN, mm (″) Weight, kg (lbs)RMR-4 15…300 (½...12) 502 (1007)RMR-4-1 50…350 (2...14) 1305 (2877)RMR-5 15…600 (½...24) 813 (1792)RMR-6 700...1200 (28…48) 3800 (8378)RMR-PPK 15…300 (½...12) 492 (1084)RMR-SH 65, 80 (2½, 3) 1280 (2822)RMR-AFK 65 (2½) 370 (815)

■ The device for compressing the disk springs of the gate valves (8).

■ The drilling machine for repair jobs (9).■ The vice for disassembly and assembly of the pipeline

valves with nominal bore DN 15...40 mm (1/2…1 ½″) (10).■ The stand with pneumatic screwdriver for installation and

fixing of the Christmas Tree valves (11).■ The height-adjusted movable support (12).■ The hydraulic crane with load-carrying capacity 500 kg

(1102 lbs) (13).■ Each work station delivery set includes a fitting tool kit (14),

rechargeable flashlight (15), and the first aid kit (15).■ The stand for safety valves disassembly/assembly (16).■ The bench for disassembly and assembly of the pipeline

valves DN 700...1200 mm (28…48″) (17). For convenience, the bench is equipped with a repair site (18).

5

RMRWORK STATION FOR VALVES ASSEMBLING/DISASSEMBLING

11

3COMPLETE SET:COMPLETE SET RMR-4 RMR-4-1 RMR-5 RMR-6 RMR-PPK RMR-SH RMR-AFKWork bench with lockers and safety screen (1) + + + + + +Bench (2) + + + +Bench (3) +Ladder (4) +Bench for preliminary pneumatic tests up to 6 bar (87 psi) (5) +Stand with swinging zigzag boom and pneumatic screwdriver (6) + + + + +Hydraulic press (7) +Device for compressing the disk springs of the gate valves (8). +Bench drilling machine (9) + + + + + +Vice (10) + + + + + +Stand (11) +Movable support (12) +Hydraulic crane (13) +Fitting tool kit (14) + + + + + + +Rechargeable flashlight (15) + + + + + +First aid kit (15) + + + + + + +Stand for safety valves disassembly/assembly (16) +Bench for disassembly/assembly of the wedge and parallel-seat gate valve (17)

+

Repair site (18) +

12 13

16

6

4

2

7

18

17

5

6

ADVANTAGES:■ The set includes the tools required for disassembly and

assembly of threaded joints, which do not damage the threaded surface of bolts or stud bolts.

■ When requested by customer, it can be fitted out with various additional screwdrivers and nut cutters.

SPECIFICATIONS:Parameter UPGWidth across flats of unscrewed/ screwed nuts, mm (″) 24…42 (1...1½)*Width across flats of cut nuts, mm (″) 24…60 (1...2⅜)*Hydraulic screwdriver torque, kgm 42…385Overall dimensions of the trolley-mounted unit, mm (″) 1530х560х1270 (61x22⅜ x51)Weight of the unit, kg (lbs) 147 (324)

UPGPORTABLE UNIT FOR DISASSEMBLING AND ASSEMBLING OF THREADED JOINTS

PURPOSE:• unit is designed for unscrewing, screwing, and cutting

(where it is impossible to unscrew) nuts.

COMPLETE SET:• trolley;• high-pressure hoses;• pump station;• hydraulic nut socket driver;• hydraulic nut splitters;• hydraulic hand pump.

* Other dimensions can be offered when requested by customer.

■ Nut cutters ensure simple and safe removal of damaged and rusted nuts, which cannot be unscrewed (removal of one nut takes about two minutes).

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PURPOSE:• automated hardfacing / overlaying of pipeline parts and elements with

diameter from 50 up to 1200 mm (2...48") with or without electrode oscillation with submerged arc process or in an atmosphere of shielding gases (MIG/MAG processes) with full wire.

UNMACHINES FOR HARDFACING / OVERLAYING OF PIPELINE VALVES PARTS

ADVANTAGES:■ The machine is fitted out with forced cooling of the

welding unit and a set of water-cooled welding heads.■ The electrode oscillating mechanism allows to increase

the width of the overlayed seam up to 60 mm (2⅜").■ Advanced construction of rotator allows to fix overlaid

workpiece in three coordinates (tilt angle and position along the x and y axes).

■ Machine control system is based on industrial controller thus allowing operator to set hardfacing / overlaying parameters (oscillation amplitude, amplitude velocity, number of faceplate revolutions, and length of welding seam) through a touch screen control panel.

Weld pad

SPECIFICATIONS:Parameter UN-1 UN-2 UN-3

G F G F G FValve range, DN, mm (″) 50…300 (2...12) 50…600 (2...24) 300…1200 (12...48)Faceplate rotation speed, rpm 0,08...4,5 0,0125...1,25Arc protection method gas (flux)Power supply, V/Hz 400/50 (480/60*)Welding current, А up to 600Electrode-wire diameter, mm (″) 1…1,6

(0,039...0,063)2…4

(0,079...0,157)1…1,6

(0,039...0,063)2…4

(0,079...0,157)1…1,6

(0,039...0,063)2…4

(0,079...0,157)Wire feed rate, m/h (in/h) 100…1500

(3937...59055)50…400

(1969...15748)100…1500

(3937...59055)50…400

(1969...15748)100…1500

(3937...59055)50…400

(1969...15748)Capacity, kg/h (lbs/h) up to 5 (11) up to 10 (22)Overall dimensions, mm (″) 1732x900x3190

(69x36x128)1735x922x3580

(69x37x143)3900х1800х5112

(156x72x204)Weight (machine/power source/con-trol panel), kg (lbs)

1120/240/70(2470/529/154)

1300/240/70(2866/529/154)

4800/240/70(10582/529/154)

* Upon customer request.** While using appropriate welding materials.

■ The unit is equipped with remote controller.■ Time for readjustment from "gas" to flux" – not

more than 10 min.■ The set of spare parts includes a set of tools,

wearing parts kit and first aid kit. ■ Welding zone backlighting.■ The machine allows hardfacing / overlaying of

internal cylindrical surfaces and perform welding of girth welding seams located in the horizontal plane (overlaying of sealing rings, welding of flanges).*

■ The machine allows to reach a hardness of surfacing of 60 HRC and above.**

8

PURPOSE:• automated hardfacing / overlaying of shafts, spindles and rods

with diameter of up to 400 mm (16") with consumable electrode in an atmosphere of shielding gases (MIG / MAG / TIG* processes).

ADVANTAGES:■ The machine is completed with forced cooling welding head

and bended water-cooled burner for welding of fillet welds.■ The machine allows hardfacing / overlaying of cylindrical

workpieces with length up to 1250 mm (49").■ The control system of the machine is implemented on the

basis of industrial controller, which allows the operator to set the parameters of welding (range of oscillations, velocity of the oscillations, number of the faceplate revolutions, length of overlaying etc.) on the touch screen of control panel and to perform welding process in automatic mode.

SPECIFICATIONS:Parameter UNG-400-1300-800-KNRange of workpiece diameters, mm (″) 25...400 (1...16)Maximum weight of welded workpiece, kg (lbs) 800 (1760)Maximum length of welded workpiece, mm (″) 1250 (49)Vertical travel of welding head, mm (″) 190(7)*Horizontal travel of welding head, mm (″) 1300 (51)Welded workpiece rotation speed, rpm (continuously adjustable) 0,05...3Horizontal travel of welding head along welding seam, mm (″) ±50 (±2)Tailstock displacement, mm (″) 1300 (51)Amount of the quill movement, mm (″) 40 (1,6)Arc protection method gasCore wire diameter, mm (″) 1,0; 1,2; 1,6 (0,039; 0.047; 0,069)Rated welding current at 100% duty cycle (40 ° C), A 450Power supply, V / Hz 400 / 50Overall dimensions (machine / power supply unit) (LxWxH), mm (″) 2400х1150х2000 / 1100х455х1000

(94x45x79/44x18x40)Weight (machine / power supply unit), kg (lbs) 850 /129

(1870/284)

* Upon customer request.

UNG-400-1300-800-KNMACHINE FOR HARDFACING / OVERLAYING OF ROTATING BODIES

■ Electrode oscillating mechanism provides greater performance of the hardfacing / overlaying process.

■ The machine allows to perform hardfacing / overlaying of cylindrical surfaces and welding of girth seams with automatic filling of the cutting edge.

■ The machine can be equipped with an additional (second) welding head to provide its greater performance.

9

PURPOSE:• girth seam welding of pipeline parts with diameter from 15 up to

1400 mm (½ ... 56") with MIG/MAG process.

USKSHWELDING UNIT FOR GIRTH SEAM WELDING OF PIPELINE PARTS

ADVANTAGES:■ Simultaneous operation of two welding heads provides

high performance of the unit.■ Standard set of the unit includes: rotator, gantry, two

welding heads and two welders.■ Tilting rotator face-plate. ■ Continuous adjustment of welding speed.■ Control system of the unit is based on industrial controller,

thus allowing operator to set welding parameters (welding speed, number of faceplate revolutions etc.) while using touch sensitive control panel.

SPECIFICATIONS:Parameter USKSH-1G USKSH-2G(F) USKSH-3G(F) USKSH-4FNominal internal diameter of welded valves (DN), mm (″)

15...125(½...5)

100...300(4...12)

300...700(12...28)

700...1400(28...56)

Load capacity including the device, kg (lbs)

1000(2205)

2000(4410)

6300(13890)

30000(66139)

Welding head number, pcs 2Arc protection gas gas (flux) fluxDiameter of electrode wire, mm (″) 1,0; 1,2; 1,6

(0,039; 0,047; 0,069)1,0; 1,2; 1,6; 2,0

(0,039; 0.047; 0,069; 0,079)1,6; 2,0

(0,069; 0,079)2...5

(0,079...0,197 )Rated welding current, at 100% duty cycle, A 350 550(600) 550(1000) 1000Overall dimensions (LxWxH), mm (″) 2150х2000х2600

(85х79х102)2500х2200х2800

(98х86х110)3000х2500х3100

(118х98х122)8150х7000х6000 (321х275х236)


USKSH-1G

USKSH-4F

■ The welding unit can be optionally completed with the following accessories:*

• flux recovery system (for “F” version); • seam tracking system; • electrode oscillating mechanism; • water recycling station (SOV); • video control system; • idle roller bed.■ Simplicity and ease of operation.

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PURPOSE:• automated hardfacing/overlaying of the external and internal

surfaces of cylinders with consumable electrode in an atmosphere of shielding gas or by flux-cored wire (MIG/MAG).

UNG-KNVMACHINE FOR HARDFACING / OVERLAYING OF CYLINDERS

ADVANTAGES:■ Compact size.■ The control system of the machine allows to program the unit

to perform hardfacing/overlaying of several types of parts.■ The hardfacing/overlaying process may consist of several

passes with different overlaying rate, the presence of transverse oscillation, different oscillation parameters (range, speed etc.).

UNG-750-400-400-KNV-А

■ Automation of hardfacing/overlaying process provides higher quality of the final result, excluding human factor.

■ Availability of flat surfaces hardfacing/overlaying.■ Minimum internal diameter of overlayed

workpiece is 16 mm (½ ″) . ■ Water-cooled welding head.

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UNG-KNVMACHINE FOR HARDFACING / OVERLAYING OF CYLINDERS

SPECIFICATIONS: Parameter UNG-750-400-400-KNV-А UNG-850-850-1000-KNVHorizontal travel of welding head, mm (″) 550 (27) 1400 (55)Travel of a welding head along “zenith”, mm (″) 100 (4) 100 (4)Vertical travel of a welding head, mm (″) 400 (16) 1000 (39)Rotator load capacity, kg (lbs) 400 (880) 300 (12)Rotator faceplate rotation speed, rpm 0,05 ÷ 7 0,2 ÷5Tilt angle of a rotator faceplate, deg. 0 ÷ 50 -Electrode-wire diameter, mm (″) 1,6; 2,8 (0,069; 0,11) 1,0; 1,2; 1,6 (0,039; 0,047; 0,063)Rated welding current, at 100% duty cycle, A 350 420Welding current adjustment range, А 5 ÷ 380 5 ÷450Range of welding voltage, V 14 ÷ 35 14 ÷31Arc protection method gas газMaximum power consumption, kW 35 45Power supply, V/Hz 400/50Overall dimensions, (LxWxH), mm (″):- machine; 2040х1000х3410 (80x40x134) 2295х1508х2845 (90x59x112)- power source. 1100х455х950 (44x18x37) 1100х455х1000 (43x18x39)Weight (machine/power source), kg (lbs) 880/104 (1936/229) 1220/129 (2689/284)

UNG-850-850-1000-KNV

12

RMS-1WELDER’S WORK STATION №1

PURPOSE:• mechanization of semi-automatic welding machine.

ADVANTAGES:■ Multi-purpose work station allows to optimize the process

of welding and to clear the floor space.■ Flexible console of a column allows placing a wire feeding

device into a convenient position in the service area.■ Large service area.

SPECIFICATIONS: Parameter RMS-1Maximum load capacity of the platform, mm (″) 50 (2)Maximum diameter of service area, mm (″) 5000 (197)Maximum lifting height, mm (″) 2450 (96)Minimum lifting height, mm (″) 950 (37)Maximum torque on the axis of rotation, Nm 6300Maximum torque in relation to faceplate supporting plane, Nm 16000Maximum load capacity, kg (lbs) 3150 (6930)Maximum diameter of girth welds, mm (″) 1800 (71)Maximum faceplate tilt angle, deg. 135Adjustment of faceplate rotation speed smoothThe height from the floor to the axis of rotation of the spindle when the faceplate in a horizontal position, mm (″) 950 (37)Overall dimensions (LхWхH), mm (″): - column; 3150×501×2670 (124x20x105)- platform; 700×300×90 (28x12x4)- rotator. 1690х1500х1100 (67x59x43)Weight, kg (lbs):- column with platform; 265 (583)- rotator. 1400 (3080)

■ The range of faceplate rotation speed allows to weld products with a big range of diameters.

■ Faceplate rotation is switched on / off by a footswitch (pedal).

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SPFLAT LAPPING (POLISHING) MACHINE

PURPOSE:• machine is designed for lapping (polishing) of the flat

sealing surfaces of the gate valve wedges, valve spools, and сhristmas-tree wedges;

• special-configuration SP-600 is used for lapping the end-seal rings.

ADVANTAGES:■ Each point of the lapped surface of the parts makes complex

plane-parallel motion on the lapping-plate surface.■ The machine is equipped with the polishing-compound

supply device. ■ The spent compound is collected in a special tank.■ A timer automatically controls lapping time.

SPECIFICATOIN:Parameter SP-1000 SP-600Nominal diameter of the valve, DN, mm (″) 50…500 (2...20) 15...150**/50...150** (½...6**/2...6)Lapping-plate diameter, mm (″) 1000 (40) 620 (24)Number of cartridges 3/1 3Internal diameter of the cartridges, mm (″) 478/672 (19/27) 266 (10)Machined-surface roughness, μm 0,2…0,4 0,08...0,1Machined-surface nonflatness (accuracy), mm (″) 0,01 (3,9x10-4) 0,0006 (0,00024)Lapping-plate speed, rpm 0…60 10...60Motor power, kW 4,5 2,5Electric power supply, V/Hz 400/50 (480/60*)Working pressure of network air, bar (psi) 6,3 (91) -Overall dimensions (LхWхH), mm (″) 1650х1500х1265 (65x60x50) 1270х960х1040 (50x38x41)Weight, kg (lbs) 1410 (3102) 812 (1786)

* Upon customer request.** Valve spools.

TYPES OF MACHINED PARTS:• wedges of the gate and christmas-tree valves;• valve (global valve) spools;• end-seal rings of the pumps;• other flat-surface parts.

LAPPING-PLATE DIAMETER: • SP-1000: Ø 1000 mm (40″). Approximately, DN 50…500 mm (2...20″) for the wedges

of the gate valves, and DN 40…200 mm (2...8″) for the spools of the valves.

• SP-600: Ø 620 mm (24″). For the wedges of the gate valves DN 50…150 mm (2...6″).

SP-1000SP-600

■ The machine is equipped with the smooth start device with the lapping-plate speed adjustment.

■ The machine is designed so that the lapping disc can be adjusted during its operation.

■ The "loading" mode ensures the cartridge supply to the part-installation area on the lapping plate (as required by operator).

14

SR-1200

SRSPECIALIZED BORING MACHINE FOR LATHING (EDGE CUTTING) OF PIPELINE VALVES DN 50…1200 MM (2...48″)

ADVANTAGES:■ An advanced high performance machine with automated

continuous control system.■ Precise cutting and a wide range of technological

functions create conditions for its versatile application thus providing treatment of both seal faces of the valve body as well as a flanges at a single placement on the bench.

PURPOSE:• treatment (drilling, boring, milling) of pipeline valves, including

treatment of main-line and medium sized flanges, seal faces of bodies and gate wedges, flanges and welding ends edges for welding of DN up to 1200 mm (48″).

TREATED ITEMS:• wedge gate valves.

■ CNC control system provides continuous machine control at 4 controlled axes (X, Y, Z, and W) and provides automated tilted positioning of the table, allowing treatment of seal faces of the fittings with different angles of a wedge chamber.

■ Implementation of placing and clamping devices provides quick placement of the valves and fittings to the machine table.

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SRSPECIALIZED BORING MACHINE FOR LATHING (EDGE CUTTING) OF PIPELINE VALVES

DN 50…1200 MM (2...48″)

SR-800 SR-600

SPECIFICATIONS:Parameter SR-1200 SR-800 SR-600Range of diameters of treated products, mm (″) 600...1200 (24...48) 50...800 (2...32) 50...600 (2...24)Diameter of carrier spindle, mm (″) 130 (5) - 110 (4)Cone cavity of the carrier spindle - - ISO 50Traverse displacement of table, mm (″) 2000 (79) ±100 (4) 1600 (63)Vertical travel of spindle head, mm (″) 1800 (78) 1200 (47) -Carrier spindle extend, mm (″) - - 600 (24)Tilt angle of the table, degrees - ±12 -Securing face of the table, mm (″) 1800х1600 (71х63) 1000х1200 (39х47) 1250х1100 (49...43)Maximal weight of treated detail, kg (lbs) 10000 (22046) 2000 (4409) 3000 (6614)Total power consumption, kW 15 27,5 12Electric power supply, V/Hz 400/50Weight, kg (lbs) 29300 (64595) 11500 (25353) 18000 (39683)

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SPSHMACHINES FOR GRINDING AND LAPPING OF THE PIPELINE VALVES DN 50...1000 MM (2...40″)PURPOSE:

• machines are designed for grinding and lapping the flat sealing surfaces of the housings and wedges of the gate valves, housings and spools of the stop valves (globe valves), safety valves and other flat surfaces.

ADVANTAGES:■ The tilted table with adjustable tilt angle simplifies the

installation procedure and allows machining of sealing surfaces at various tilt angles.

■ The coordinate device ensures the part installation by three coordinates (tilt angle and positioning with respect to the x and y axes).

■ To make installation procedure of workpiece more simple the column can turn on 290° relatively its base.

■ Digital indication of spindle rotational speed is provided.■ The tool drawer unit allows to store replaceable

accessories.

TYPE OF VALVE: • gate valve;• globe valve;• safety valve.*

DN OF VALVE: Stationary units:• SPSH-600-N: DN 50…600 mm (2...24″);• SPSH-1000-N: DN 300…1000 mm (12...40″).

Unit with two tilting tables:• SPSH-600-NN: DN 50…600 mm (2...24″).

Table base units:• SPSH-300-NN: DN 15…300 mm (½...12″);• SPSH-300-VV: DN 8…300 mm (0,3...12″).

SPSH-600-N

■ Uniform lapping plate and the adapter with eccentric allows to achieve high flatness of the surface.

■ Machines allow to conduct processing of valve parts on the first of the tables and to execute installation work and valve fastening on the second one (SPSH-600-NN, SPSH-300-NN, SPSH-300-VV).

■ Rotating table with adjustable axially offset is serving to increase the capacity of sealing surfaces treatment process (SPSH-300-VV).

■ Lathe three-jaw chuck allows to install the valve bodies and spools of small size (SPSH-300-VV).


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SPSHMACHINES FOR GRINDING AND LAPPING OF THE PIPELINE VALVES

DN 50...1000 MM (2...40″)

SPSH-600-NN

SPSH-300-VV

SPECIFICATIONS: Parameter SPSH-1000-N SPSH-600-N SPSH-600-NN SPSH-300-NN SPSH-300-VVUsable range, DN, mm (″) 300…1000

(12...39)50…600(2...24)

15…300(½...12″)

8…300 (0,3...12″)

Maximum diameter of the mounted valve flange, mm (″) 1255 (50) 890 (36) 500 (19)Maximum face-to-face length of the mounted valve, mm (″) 1750 (69) 1150 (46) 700 (27)Maximum weight of the mounted part, kg (lbs) 2500 (5500) 1000 (2204) 500 (19)Dimensions of the table working surface, mm (″) 1200х1200 (48x48) 900х900 (36x36) 500х500 (19х19) Ø 500 (19)Tilt angle of the table, degrees 0…12Spindle rotation speed adjustment steplessSpindle rotation speed, rpm 10…150 14…200 10…240Machined surface roughness, μm 0,2…0,4Installed power, kW 2,0 2,45 2,0 3Power supply, V/Hz 400/50Overall dimensions (LхWхH), mm (″) 2175х1550х3250

(86x61x128)1490х900х2950

(60x41x118)2500х900х3025

(98x41x119)1692х830х2365

(66х32х93)Weight, kg (lbs) 3100 (6820) 1420 (3091) 2120 (4664) 1200 (2645) 1000 (2204)

18

PUR-1, PUR-2PORTABLE MACHINES FOR REPAIR OF GATE VALVES

ADVANTAGES:■ Grinding and lapping of the sealing surfaces of the trim directly

in the pipeline without cutting out the valves from the pipeline.■ Small weight of the unit makes it convenient for use in hard-

to-reach locations.■ The quality is achieved due to design of the working head and

the mandrel, which generate complex plane parallel motion of the tool across the processed surface.

■ The set includes the wedge processing unit, replaceable discs for grinding and lapping, and a tool storage box.

SPECIFICATION:Parameter PUR-1 PUR-2Usable range, DN, mm (″) 50…250 (2...10″) 200…600 (8...24″)Immersion depth - T, mm (″) 635 (25) 1000 (40)Minimum size - А, mm (″) 40 (2) 87 (3)Electric drive:- power consumption, kW; 1,2 1,5- supply voltage, V. 220 (110*) 220 (110*)Pneumatic drive:- power, kW; 0,83 1,17- air flow rate, m³/min (gl/min); 1,6 (423) 1,6 (423)- compressed-air working pressure, bar (psi). 6,3 (91)Weight, kg (lbs):- the heaviest mounted assembly; 13,6 (30) 22 (49)- set. 50 (110) 190 (419)


COMPLETE SET:• portable unit;• professional pneumatic (Atlas Copco) and/or electric (Bosch) drives;*• device for mounting on the middle flange;• device for machining the gate valve wedges;• replaceable grinding and lapping discs;• a set of self-adhesive grinding wheels;• air preparation unit with a sleeve for compressed air supply;• plastic case;• set of spindles with the abrasive wheels based on electrocorundum (PUR-1, PUR-2);• set of spindles coated with the boron nitride (PUR-1, PUR-2).

PURPOSE:• portable machine is designed for grinding and lapping the

sealing surfaces of the gate valve trim and wedges without their dismantling from the pipeline.

MACHINED-SURFACE TYPES: • sealing surfaces of the gate valve trim and wedges.

DN OF VALVE: • 50…250 mm (2...10″) (PUR-1); • 200…600 mm (8...24″) (PUR-2).

■ To ensure more reliable operation, the complete set of pneumatic drive includes air preparation unit.

■ Grinding wheels on the basis of the CBN and electrocorundum ensure high productivity of the process for removing the workpiece material and have a high resistance to wear. This reduces the time of grinding and lapping, extends the life of the working surface lapping.

19

С

B1

PUR-5PORTABLE MACHINE FOR GRINDING AND LAPPING OF STOP VALVES (PLUG VALVES)

PURPOSE:• portable device is designed for grinding and lapping

the sealing surfaces of the plug valve trim without their dismantling from the pipeline.

MACHINED-SURFACE TYPES: • sealing surfaces of the PSV and plug valve trim and spools.

DN OF VALVE: • 32...200 mm (1...8″).

COMPLETE SET:• portable unit (А);• professional pneumatic (Atlas Copco) (B1) and/or electric

(Bosch) (B2) drives;*• stand for spool machining (С);• multi-function installation device (D);• replaceable grinding and lapping discs;• a set of self-adhesive grinding rings;• air preparation unit with a sleeve for compressed air supply;• plastic case;• a set of spare parts, tools and accessories.

ADVANTAGES:■ Grinding and lapping of the sealing surfaces of the trim

directly in the pipeline without cutting out the valves from the pipeline.

■ The quality is achieved due to design of the working head and the mandrel, which generate complex plane parallel motion of the tool across the processed surface.

SPECIFICATIONS:Parameter PUR-5Usable range, DN, mm (″) 32…200 (1...8)Electric drive:- power consumption, kW; 1,1- supply voltage, V. 220 (110*)Pneumatic drive:- power, kW; 0,83- air flow rate, m³/min (gl/min); 1,6 (423)- compressed-air working pressure, bar (psi). 6,3 (91)Maximum immersion depth into the valve housing, mm (″) 200 (8)Weight, kg (lbs):- the heaviest mounted assembly; 7 (15)- set (with pneumatic and electric drive). 60 (132)


B1

B2

A

D

■ Small weight of the unit makes it convenient for use at hard-to-reach locations.

■ The set includes the wedge processing unit, replaceable discs for grinding and lapping, and a tool storage box.

20

HORIZONTAL TEST BENCHESFOR HYDRAULIC AND PNEUMATIC TESTING OF SHUT OFF VALVES

PURPOSE: • testing of the body part materials for strength and density (shell test);• gate tightness tests (leakage test);• environmental leakage tests (including gland seals), backseat test;• operation test (functional test).

OPTIONAL:

TESTED ITEMS: • gate valves;• ball valves;• butterfly valves;• check valves;• plug valves.

TESTED UNIT CONNECTION TYPE:• flanged (according ASME B 16.5, ASME B 16.47,

GOST 12815 etc.);• welded ends (according ASME B 16.25, GOST, etc.);*• set of sealing adapters available.*

CONFORMED WITH STANDARD: API 6D; API 598; DIN EN 12266; ISO 5208; ASTM E 1003-05; GOST 5762-2002;GOST 9544-2005, etc.

VU

p. 58

PGS

p. 56

SOV

p. 58

B, SVN

p. 59

CRS

p. 54

UK

p. 55

ADVANTAGES:■ Clamping of tested valve provided by hydraulic cylinder,

optionally test bench can be equipped with proportional clamping control system, which excluding axial compression applied to the valve body during clamping by hydraulic cylinder, during high pressure testing.*

■ Clamping unit can be provided with radial sealing type or self-sealing adapters.*

■ The two-sided gate sealing during tests do not require the tested valve rearrangement, which significantly reduces the test time.

■ The bench is equipped with a special system for air removal from the tested valve, which improves safety, productivity, reliability of the obtained data, and obviates the need for additional air drain.*

■ The bench is equipped with the water-collection tray with stainless steel tank.*

■ The test preparation time is significantly reduced by using the high-pressure quick-connect hoses.

■ The bench is quickly adjusted to face-to-face dimensions of valve by using the hydraulically or electrically driven cross-head.

■ The patented design of the self-sealing adapters exclude axial compression during the tests, which ensures the test reliability, protects the valves against deformation, and extends the valve life.*

■ All water-wetted parts are corrosion-proof.■ The bench can be equipped with replaceable sealing

adapters.* ■ Increased-diameter hoses reduce the time of the valve

filling with the test medium.■ Test-bench can be equipped with valve lifting platforms

for valve positioning and support during testing.*


21

S-6-1400/4000, S-6-1400/3200, S-6-1400/2800TEST BENCHES FOR SHUT OFF VALVES DN 400...1400 MM (16...56″)

SPECIFICATIONS:Parameter S-6-1400/4000 S-6-1400/3200 S-6-1400/2800Maximum clamping force, t (lbs) 4000 (8818490) 3200 (7054792) 2800 (6172943)Min./max. distance between the moving and stationary cross-heads, mm (″) 800/3400 (31/134) 800/3400 (31/134) 600/3400 (23/134)Distance between the columns, mm (″) 2900 (115) 2810 (110) 2620 (103)Overall dimensions (LхWхH), mm (″) 8500х4200х3000

(334х165х118)8000х4000х2900

(315х157х114)7800х3800х2900

(307х149х114)Weight, kg (lbs) 80000 (176370) 70000 (154323) 60000 (132277)

S-6-1400/4000Maximum test pressure, bar (psi)

DN, mm (″)240

(3481)320

(4641)400

(5801)420

(6091)550

(7977)690

(10007)600...800 (24..32)

900 (35)1000 (40)1050 (41)1200 (48)1400 (56)


DN, mm (″)190

(2756)250

(3626)300

(4351)375

(5439)450

(6527)550

(7977)690

(10007)500...700 (20...28)

800 (32)900 (35)

1000 (40)1050 (41)1200 (48)1400 (56)


DN, mm (″)150

(2175)225

(3263)290

(4206)310

(4496)375

(5439)450

(6527)650

(9427)690

(10007)400...600 (16...24)

700 (28)800 (32)900 (35)

1000 (40)1050 (41)1200 (48)1400 (56)

22


DN, mm (″)120

(1740)160

(2520)220

(3191)240

(3481)290

(4206)370

(5366)480

(6962)660

(9572)690

(10007)400...500 (16...20)

600 (24)700 (28)800 (32)900 (35)

1000 (40)1050 (41)1200 (48)

1400 (56)*


(259x145x86)7200х3300х2100

(282x130x82)5500х2000х2000

(216x78x78)Weight, kg (lbs) 38000 (83775) 34000 (74957) 18000 (39683)


DN, mm (″)100

(1450)120

(1740)160

(2320)200

(2900)250

(3626)375

(5439)420

(6091)690

(10007)400...500 (16...20)

600 (24)700 (28)800 (32)900 (35)

1000 (40)1050 (41)*1200 (48)*1400 (56)*

S-6-1200/2000, S-6-1050/1600, S-6-800/750TEST BENCHES FOR SHUT OFF VALVES DN 150...1400 MM (6...56″)

* The maximum diameter for wedge gate valves (except for ball valves).

S-6-800/750 Maximum test pressure, bar (psi)

DN, mm (″)80

(1160)100

(1450)120

(1740)150

(2175)200

(2900)250

(3626)420

(6091)690

(10007)150...350 (6...14)

400 (16)500 (20)600 (24)700 (28)800 (32)

900 (35)*1000 (40)*

23


DN, mm (″)100

(1450)150

(2175)170

(2538)200

(2900)250

(3626)375

(5439)420

(6091)690

(10007)150...400 (8...16)

500 (20)600 (24)700 (28)800 (32)900 (35)

1000 (40)1050 (41)

1200 (48)*


DN, mm (″)60

(870)125

(1813)150

(2175)200

(2900)250

(3626)375

(5439)420

(6091)690

(10007)200...350 (8...14)

400 (16)500 (20)600 (24)700 (28)800 (32)900 (35)

1000 (40)*

S-5-1050/1300, S-5-1000/600, S-5-900/850 TEST BENCHES FOR SHUT OFF VALVES DN 100...1200 MM (4...48″)


(236x102x102)6000х2500х2150

(236x98x84)5700х2200х2000

(224x86x78)Weight, kg (lbs) 30000 (66138) 16000 (35274) 24000 (52911)


DN, mm (″)40

(580)50

(725)70

(1015)100

(1450)140

(2030)180

(2611)250

(3626)400

(5801)550

(7977)690

(10007)100...300 (4...12)

350 (14)400 (16)500 (20)600 (24)700 (28)800 (32)

1000 (40)1200 (48)*1400 (56)*


24


DN, mm (″)80

(1160)120

(1740)160

(2320)230

(3336)360

(5221)450

(6526)620

(8992)690

(10007)100...250 (4...10)

300 (12)350 (14)400 (16)500 (20)600 (24)

700 (28)*800 (32)*


(163x74x78)3506х1805х1794

(138x71x70)2802х1565х1640

(110x61x64)Weight, kg (lbs) 8000 (17637) 5296 (11675) 3255 (7176)

S-5-600/500, S-5-600/350, S-5-500/250 TEST BENCHES FOR SHUT OFF VALVES DN 50...800 MM (2...32″)


DN, mm (″)60

(870)110

(1595)160

(2320)250

(3626)320

(4641)430

(6236)630

(9137)690

(10007)50...200 (2...8)

250 (10)300 (12)350 (14)400 (16)500 (20)600 (24)

700 (28)*


DN, mm (″)100

(1450)150

(2175)250

(3626)375

(5439)420

(6091)690

(10007)50...150 (2...6)

200 (8)250 (10)300 (12)350 (14)400 (16)500 (20)


25


DN, mm (″)50

(725)100

(1450)150

(2175)225

(3263)250

(3626)420

(6091)690

(10007)50...100 (2...4)

150 (6)200 (8)

250 (10)300 (12)350 (14)

400 (16)*


DN, mm (″)50

(725)75

(1087)100

(1450)150

(2175)250

(3626)420

(6091)690

(10007)10...80 (⅜...3)

100 (4)150 (6)200 (8)

250 (10)300 (12)

350 (14)*


DN, mm (″)150

(2175)250

(3626)420

(6091)690

(10007)10...65 (⅜...2½)

80 (3)100 (4)150 (6)

S-5-350/140, S-5-300/65, S-5-150/38TEST BENCHES FOR SHUT OFF VALVES DN 10...400 MM (⅜...16″)


(131x51x59)2714х901х1559

(107x35x61)2014х692х1610

(79x27x63)Weight, kg (lbs) 2656 (5855) 1675 (3692) 885 (1951)


26

PURPOSE:• submerged gas testing of pipeline valves;• testing of the body part materials for strength and density;• gate tightness tests;• environmental leakage tests (including gland seals).

TESTED ITEMS:• cryogenic valves; • gate valves;• ball valves;• butterfly valves;• check valves;• plug valves.

TESTED UNIT CONNECTION TYPE:• flanged (according ASME B 16.5, ASME B 16.47, GOST 12815 etc.);• welded ends (according ASME B 16.25, GOST, etc.);*• threaded-ends for a small size valves;*• set of sealing adapters available.*

S-5P-600/500TEST BENCHES FOR SHUT OFF VALVES DN 15...600 MM (⅔....24″)



■ Clamping unit can be provided with radial sealing type or self-sealing adapters.*


■ The bench is equipped with a special system for air removal from the tested valve, which improves safety, productivity, reliability of the obtained data, and obviates the need for additional air drain.*

■ The bench is equipped with the water-collection tray with stainless steel tank.*


■ The bench is quickly adjusted to face-to-face dimensions of valve by using the hydraulically or electrically driven cross-head.

■ The patented design of the self-sealing adapters exclude axial compression during the tests, which ensures the test reliability, protects the valves against deformation, and extends the valve life.*

■ All water-wetted parts are corrosion-proof.■ The bench can be equipped with replaceable sealing

adapters.* ■ Increased-diameter hoses reduce the time of the valve

filling with the test medium.■ Test-bench can be equipped with valve lifting platforms for

valve positioning and support during testing.*

OPTIONAL:

CONFORMED WITH STANDARD: API 6D; API 598; DIN EN 12266; ISO 5208; ASTM E 1003-05; GOST 5762-2002;GOST 9544-2005, etc.

VU

p. 58

PGS

p. 56

SOV

p. 58

B, SVN

p. 59

CRS

p. 54

UK

p. 55

27

S-5P-600/500TEST BENCHES FOR SHUT OFF VALVES DN 15...600 MM (⅔....24″)

SPECIFICATIONS:Parameter S-5P-600/500Maximum clamping force, t (lbs) 500 (1102311)Min./max. distance between the moving and stationary cross-heads, mm (″) 180/1850 (7/73)Distance between the columns, mm (″) 1300 (51)Power supply, V/Hz 400/50Motor power, kW 18 Overall dimensions (LхWхH), mm (″) 6720х3580х3270 (264х148х128)Weight, kg (lbs) 12300 (27117)

S-5P-600/500 Maximum test pressure, bar (psi)

DN, mm (″)100

(1450)125

(1813)160

(2320)220

(3191)320

(4641)450

(6525)15...350 (⅔...14)

400 (16)500 (20)600 (24)

28

VERTICAL TEST BENCHESFOR HYDRAULIC AND PNEUMATIC TESTING OF SHUT OFF VALVES

PURPOSE: • testing the valve's body for strength and density;• gate tightness tests;• environmental leakage tests (including gland seals);• operation test;• pressure safety valves gate tightness test;• pressure safety valves operation tests.

TESTED ITEMS:

• gate valves;• ball valves;• stop valves (globe valves);• check valves;• butterfly gates;• plug valves.

TESTED UNIT CONNECTION TYPE:• flanged (according ASME B 16.5, GOST 12815 etc.);• welded ends (according ASME B 16.25, GOST, etc.);• threaded-end;*• true union.*

ADVANTAGES:■ Clamping of tested valve provided by hydraulic cylinder, optionally test bench can

be equipped with proportional clamping control system, which excluding axial compression applied to the valve body during clamping by hydraulic cylinder, during high pressure testing.*


■ The bench is equipped with the water-collection tray with stainless steel tank.*■ The test preparation time is significantly reduced by using the high-pressure fast

coupling hoses.■ The bench is quickly adjusted to face-to-face dimensions of valve by using the

electrically driven cross-head.■ The patented design of the self-sealing adapters exclude axial compression

during the tests, which ensures the test reliability, protects the valves against deformation, and extends the valve life.*

■ All water-wetted parts are corrosion-proof.■ The bench can be equipped with replaceable sealing adapters.* ■ Increased-diameter hoses reduce the time of the valve filling with the test medium.■ Turning upper cross-head is used to simplify the valve installation procedure

before testing.■ The test preparation time is significantly reduced by using the high-pressure

quick-connect hoses.■ Fast clamping and centering of the tested valve is ensured due to synchronized

travel of the straps.■ Test bench allows visual detection of seat leakage point.

CONFORMED WITH STANDARD: API 6D; API 527; API 598; DIN EN 12266;ISO 5208; ASTM E 1003-05; GOST 5762-2002; GOST 9544-2005, etc.

OPTIONAL:PGS

p. 56

SOV

p. 58

B, SVN

p. 59

CRS

p. 54

UK

p. 55

29

S-3-800/160, S-3-600/220, S-3-600/160 TEST BENCHES FOR SHUT OFF VALVES DN 10...800 MM (⅜...32″)


DN, mm (″)25

(362)37,5(544)

45(652)

65(942)

95(1378)

125(1813)

170(2465)

250(3626)

345(5003)

555(8049)

690(10007)

10...100 (⅜...4)150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)500 (20)600 (24)700 (28)800 (32)


DN, mm (″)65

(942)90

(1305)130

(1885)170

(2465)230

(3336)340

(4931)480

(6962)765

(11095)1100

(15954)10...100 (⅜...4)

150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)500 (20)600 (24)

SPECIFICATIONS:Parameter S-3-800/160 S-3-600/220 S-3-600/160Maximum clamping force, t (lbs) 160 (352739) 220 (485017) 160 (352739)Min./max. diameter of the clamped flange, mm (″) 160/1020 (6/40) 160/910 (6/36) 90/840 (3/33)Maximum thickness of the clamped flange, mm (″) 82 (3) 95 (4) 82 (3)Min./max. distance between the moving and stationary cross-heads, mm (″) 188/1466 (7/57) 182/1460 (7/57) 152/1275 (6/50)Distance between the columns, mm (″) 1150 (45) 970 (38) 900 (35)Overall dimensions (LхWхH), mm (″) 1925х1325х4385

(75x52x172)1565х1050х4510

(61x41x177)1674х1500х3984

(65x59x157)Weight, kg (lbs) 4465 (9843) 3855 (8499) 3535 (7793)


DN, mm (″)45

(652)65

(942)95

(1378)125

(1813)170

(2465)250

(3626)345

(5003)555

(8049)690

(10007)10...100 (⅜...4)

150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)500 (20)600 (24)

30


DN, mm (″)30

(435)40

(580)60

(870)75

(1087)105

(1523)155

(2249)215

(3118)345

(5003)690

(10007)10...100 (⅜...4)

150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)500 (20)600 (24)


DN, mm (″)65

(942)95

(1378)125

(1813)170

(2465)250

(3626)345

(5003)555

(8049)690

(10007)10...100 (⅜...4)

150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)500 (20)


DN, mm (″)40

(580)60

(870)75

(1087)105

(1523)155

(2249)215

(3118)345

(5003)690

(10007)10...100 (⅜...4)

150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)500 (20)

SPECIFICATIONS:Parameter S-3-600/100 S-3-500/160 S-3-500/100 S-3-500/60Maximum clamping force, t (lbs) 100 (220462) 160 (352739) 100 (220462) 60 (132277)Min./max. diameter of the clamped flange, mm (″) 90/840 (4/33) 90/730 (4/28) 90/730 (4/28) 90/730 (4/28)Maximum thickness of the clamped flange, mm (″) 82 (3) 82 (3) 82 (3) 92 (3)Min./max. distance between the moving and stationary cross-heads, mm (″) 72/1252 (3/49) 95/1165 (4/46) 70/1182 (2/46) 70/1000 (3/39)Distance between the columns, mm (″) 900 (35) 750 (29) 770 (30) 775 (31)Overall dimensions (LхWхH), mm (″) 1675х1495х3922

(66x59x154)1435х1405х3707

(56x55x146)1435х1402х3670

(56x55x144)1330х1347х3106

(52x53x122)Weight, kg (lbs) 2869 (6325) 3074 (6777) 2640 (5820) 1825 (4023)


DN, mm (″)25

(362)35

(507)45

(652)60

(870)90

(1305)130

(1885)210

(3045)430

(6236)635

(9210)690

(10007)10...65 (⅜...2½)

80 (3)100 (4)150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)500 (20)

S-3-600/100, S-3-500/160, S-3-500/100, S-3-500/60 TEST BENCHES FOR SHUT OFF VALVES DN 10...600 MM (⅜...24″)

31


DN, mm (″)35

(362)45

(652)60

(870)90

(1305)130

(1885)210

(3045)430

(6236)635

(9210)690

(10007)10...65 (⅜...2½)

80 (3)100 (4)150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)


DN, mm (″)20

(290)30

(435)40

(580)60

(870)96

(1392)160

(2320)300

(4351)420

(6091)650

(9427)690

(10007)10...50 (⅜...2)

65 (2½)80 (3)

100 (4)150 (6)200 (8)

250 (10)300 (12)350 (14)400 (16)


DN, mm (″)40

(580)60

(870)85

(1233)130

(1885)270

(3916)400

(5801)650

(9427)690

(10007)10...50 (⅜...2)

65 (2½)80 (3)

100 (4)150 (6)200 (8)

250 (10)300 (12)


DN, mm (″)25

(362)35

(507)50

(725)105

(1523)160

(2320)260

(3771)530

(7687)690

(10007)10...32 (⅜...1¼)

40...50 (⅔...2)65 (2½)

80 (3)100 (4)150 (6)200 (8)

250 (10)SPECIFICATIONS:Parameter S-3-400/60 S-3-400/38 S-3-300/38 S-3-250/15Maximum clamping force, t (lbs) 60 (132277) 38 (83775) 38 (83775) 15 (33069)Min./max. diameter of the clamped flange, mm (″) 90/580 (4/23) 90/580 (4/23) 90/460 (4/18) 90/460 (4/18)Maximum thickness of the clamped flange, mm (″) 82 (3) 75 (2) 75 (2) 75 (2)Min./max. distance between the moving and stationary cross-heads, mm (″) 70/1000 (2/39) 66/956 (2/37) 45/870 (2/34) 30/639 (1/25)Distance between the columns, mm (″) 630 (25) 645 (25) 500 (19) 500 (19)Overall dimensions (LхWхH), mm (″) 1120х1323х3112

(44x52x122)1214х1130х2980

(48x44x117)1021х1043х2666

(40x41x105)1022х1043х2215

(40x41x87)Weight, kg (lbs) 1627 (3587) 1334 (2941) 815 (1796) 610 (1344)

S-3-400/60, S-3-400/38, S-3-300/38, S-3-250/15 TEST BENCHES FOR SHUT OFF VALVES DN 10...400 MM (⅜... 16″)

32




■ The bench is equipped with the water-collection tray.*■ The test preparation time is significantly reduced by

using the high-pressure fast coupling hoses.■ The bench is quickly adjusted to face-to-face dimensions

of valve by using the electrically driven cross-head.■ The patented design of the self-sealing adapters

exclude axial compression during the tests, which ensures the test reliability, protects the valves against deformation, and extends the valve life.*

■ All water-wetted parts are corrosion-proof.

PURPOSE:• testing the valve's body for strength and density;• gate tightness tests;• environmental leakage tests (including gland seals);• operation test;• pressure safety valves gate tightness test;• pressure safety valves operation tests.

TESTED ITEMS: • gate valves; • ball valves;• stop valves (globe valves);• check valves;• butterfly gates;• plug valves;• safety valves.

TESTED UNIT CONNECTION TYPE:• flanged (according ASME B 16.5, GOST 12815 etc.);• welded ends (according ASME B 16.25, GOST, etc.).

TILTING TEST BENCHESFOR HYDRAULIC AND PNEUMATIC TESTING OF SHUT OFF VALVES

CONFORMED WITH STANDARD: API 598; DIN EN 12266; ISO 5208;ASTM E 1003-05; GOST 5762-2002;GOST 9544-2005.

OPTIONAL:PGS

p. 56

SOV

p. 58

B, SVN

p. 59

CRS

p. 54

UK

p. 55

■ The bench can be equipped with replaceable sealing adapters.*

■ Increased-diameter hoses reduce the time of the valve filling with the test medium.

■ Tiltable upper cross-head is used to simplify the valve installation procedure before testing. The test preparation time is significantly reduced by using the high-pressure quick-connect hoses.

■ Fast clamping and centering of the tested valve is ensured due to synchronized travel of the straps.

■ The tested valve clamping technique is used to ensure visual control of leakage points.

■ It is possible to conduct the testing for gate tightness of flanged valves with vertical and horizontal axes position of the main branch pipes with provision of visual inspection of the valve's gate.

33

S-4-400/270, S-4-300/40TEST BENCHES FOR SHUT OFF VALVES DN 10...400 MM (⅜...16″)

SPECIFICATIONS:


DN, mm (″)

150(2175)

180(2610)

250(3626)

420(6091)

450(6525)

50...200 (2...8)

250 (10)

300 (12)

350 (14)

400 (16)

Parameter s-4-400/270 s-4-300/40Maximum clamping force, t (lbs) 270 (595248) 40 (88185)Min./max. diameter of the clamped flange, mm (″) 160/670 (6/26) 160/460 (6/18)Maximum thickness of the clamped flange, mm (″) 110 (4) 44 (2)Min./max. distance between the moving and stationarycross-heads, mm (″) 180/800 (7/31) 170/730 (7/29)Distance between the columns, mm (″) 1115 (44) 760 (30)Power supply, V/Hz 400/50Motor power, kW 5,5Overall dimensions (LхWхH), mm (″) 2000x2060x3370 (79х81х132) 1655x1038x2786 (65х41х110)Weight, kg (bench/set of replacement parts) (lbs) 5500/2210 (12125/4872) 1320/470 (2910/1037)


DN, mm (″)

40(580)

60(870)

100(1450)

10...200 (⅜...8)

250 (10)

300 (12)


34

TEST BENCHESFOR HYDRAULIC AND PNEUMATIC TESTS OF CONTROL VALVES

PURPOSE: • testing the body part materials for strength and density;• gate tightness tests acc. to ANSI FCI 70.2 (Class II-VI);• environmental leakage tests (including gland seals);• operation test.

TESTED ITEMS: • сontrol valves;• shut off valves.

TESTED UNIT CONNECTION TYPE:• flanged (ASME B 16.5);• welded ends (ASME B 16.25).

EQUIPMENT ADVANTAGES:■ Clamping of tested valve provided by hydraulic cylinder, optionally test bench can be equipped with proportional clamping

control system, which excluding axial compression applied to the valve body during clamping by hydraulic cylinder.*■ The two-sided gate sealing during tests do not require the tested valve rearrangement, which significantly reduces the test

time.■ The bench can be equipped with special system for air removal from the tested valve bodies, which improves safety,

productivity, reliability of the obtained data, and obviates the need for additional air drain.*■ The bench is equipped with water-collection tray and drainage system.*■ The test preparation time is significantly reduced by using the high-pressure quick-connect hoses.■ The bench is quickly adjusted to face-to-face dimensions of valve by using the electrically driven cross-head.■ The patented design of the self-sealing adapters exclude axial compression during the tests, which ensures the test

reliability, protects the valves against deformation, and extends the valve life.*■ All water-wetted parts are corrosion-proof.■ The bench can be equipped with replaceable sealing adapters.* ■ Increased-diameter hoses reduce the time of the valve filling with the test medium.■ Test-bench can be equipped with valve lifting platforms for valve positioning and support during testing.*■ The tested valve clamping technique is used to ensure visual control of leakage points for vertical version.■ Quick clipping and centering of the tested item is ensured due to synchronized travel of the straps at vertical version.

OPTIONAL:

CONFORMED WITH STANDARD: API 598; ANSI/ISA-75.19-1995; DIN EN 12266; ISO 5208; ASTM E 1003-05; GOST 5762-2002; GOST 9544-2005.

VU

p. 58

SI-PRA

p. 60

PGS

p. 56

BR

p. 60

SOV

p. 58

B, SVN

p. 59

CRS

p. 54

35

PKTBA-SI-26-CV, PKTBA-SI-26-1-CVTEST BENCHES FOR CONTROL VALVES DN 10…600 MM (⅜...24″)

Parameter PKTBA-SI-26-CV PKTBA-SI-26-1-CVMaximum clamping force, t (lbs) 90 (198416) 300 (661387)Min./max. distance between the moving and stationary cross-heads, mm (″) 150/975 (6/39) 264/1602 (10/64)Distance between the columns, mm (″) 745 (30) 1360 (54)Weight, kg (bench) (lbs) 2005 (4420) 5500 (12125)

SPECIFICATIONS:

PKTBA-SI-26-1-CVMaximum test pressure, bar (psi)

DN, mm (″)100

(1450)120

(1740)150

(2175)240

(3480)375

(5437,5)450

(6525)50...250 (2...10)

300 (12)

350 (14)

400 (16)

500 (20)

600 (24)

* Increased clamping force available upon customer request.

PKTBA-SI-26-CVMaximum test pressure, bar (psi)

DN, mm (″)60

(870)100

(1450)150

(2175)240

(3480)10...200 (⅜...8)

250 (10)

300 (12)

350...400 (14...16)

36

MULTI-STATION TEST BENCHESFOR HYDRAULIC AND PNEUMATIC TESTING OF SHUT OFF VALVES

PURPOSE: • testing of valve’s body for strength and density;• gate tightness tests;• environmental leakage tests (including gland seals);• operation test.

TESTED ITEMS:

• gate valves; • stop valves (globe valves); • check valves; • butterfly gates; • ball and plug valves.

TESTED UNIT CONNECTION TYPE:• flanged (according ASME B 16.5, GOST 12815, etc.); • welded ends (according ASME B 16.25, GOST, etc.).

EQUIPMENT ADVANTAGES:■ Clamping of tested valve provided by hydraulic cylinder, optionally test

bench can be equipped with proportional clamping control system, which excluding axial compression applied to the valve body during clamping by hydraulic cylinder, during high pressure testing.*


■ The bench is equipped with the water-collection tray.■ The test preparation time is significantly reduced by using the high-pressure

fast coupling hoses.■ The bench is quickly adjusted to face-to-face dimensions of valve by using

the electrically driven cross-head.■ All water-wetted parts are corrosion-proof.■ The bench can be equipped with replaceable sealing adapters.* ■ Increased-diameter hoses reduce the time of the valve filling with the test

medium.■ Fast clamping and centering of the tested valve is ensured due to

synchronized travel of the straps. Allows quick and precise testing of large number of serial manufactured valves.

CONFORMED WITH STANDARD: API 598; DIN EN 12266; ISO 5208; ASTM E 1003-05; GOST 5762-2002; GOST 9544-2005, etc.

OPTIONAL:

CRS

p. 54

SOV

p. 58

VU

p. 58

37

S-3-600/110-2MULTI-STATION TEST BENCH FOR SHUT OFF VALVES DN 50...600 MM (2...24″)

S-3-600/110-2Maximum test pressure, bar (psi)

DN, mm (″)25

(362,5)40

(580)65

(942,5)80

(1160)110

(1595)165

(2392,5)210

(3045)50...200 (2...8)

250 (10)

300 (12)

350 (14)

400 (16)

500 (20)

600 (24)

SPECIFICATIONS:Parameter S-3-600/110-2Maximum clamping force, t (lbs) 110 (242508)Min./max. diameter of the clamped flange, mm (″) 160/840 (5/33)Maximum thickness of the clamped flange, mm (″) 80 (4)Min./max. distance between the moving and stationary cross-heads, mm (″) 150/1250 (6/50) Distance between the columns, mm (″) 900 (36)Power supply, V/Hz 400/50Motor power, kW 8,5Overall dimensions (LхWхH), mm (″) 5100х2500х4120 (204x100x165)Weight, kg (bench/set of replacement parts) (lbs) 9250/1675 (20393/3692)


38


PURPOSE:• strength and density testing the of the body parts materials and welds under pressurized test medium;• gate tightness tests;• environmental leakage tests (including gland seals);• operation test.

TESTED ITEMS: • gate valves; • stop valves (globe valves); • check valves; • butterfly gates; • ball and plug valves.


ADVANTAGES:■ All water-wetted parts are corrosion-proof.■ Quantity of clamping units could be changed.*■ Test bench equipped with vacuuming system, to remove air

from the tested valve. This system allows to ensure safety, reliability and preciseness of test results, as well as eliminates operator from the air drainage operations.*


■ Testing is carried out in manual mode (semi-automatic and automatic modes optionally*).

■ Mounting and testing processes are fully mechanized to make operations even more safe and comfortable for operators.

■ Hydraulic system of the test bench is powered by oil pump station, to ensure service life and reliability of the test unit.

SPECIFICATIONS:Parameter S-3-250/180-3Maximum clamping force(central / outermost / two outermosts / three statoins), t (lbs) 100/180/150/60 (220462/398832/330693/132277)Min./max. diameter of the clamped flange, mm (″) 160/670 (6/26)Min./max. length of the tested valve, mm (″) 170/850 (7/33)Distance between axes of adjacent posts, mm (″) 800 (31)Power supply, V/Hz 11Motor power, kW 400/50Overall dimensions (LхWхH), mm (″):

- clamping device; 3383х2517х3325 (133х99х131)- pnevmogidraulic pumping station; 1164х822х1767 (46х32х69)- pump station. 963х673х924 (38х26х36)

Weight, kg (lbs):- clamping device; 10100 (22267)- pnevmogidraulic pumping station; 362 (798)- pump station. 465 (1025)


CONFORMED WITH STANDARD: API 598; DIN EN 12266; ISO 5208; ASTM E 1003-05; GOST 5762-2002; GOST 9544-2005, etc.

39


S-3-250/180-3Maximum test pressure, bar (psi)

DN, mm (″)100

(1450)150

(2175)250

(3626)400

(5801)700

(10153)50 (2)

65 (2 ½)

80 (3)

100 (4)

150 (6)

200 (8)

250 (10)

40

PURPOSE:• pneumatic and hydraulic testing of shut off valve;• gate tightness tests;• environmental leakage tests (including gland seals);• operation test.

S-35-200/18-3MULTI-STATION TEST BENCH FOR SHUT OFF VALVES DN 10...200 MM (⅜...8″)

SPECIFICATIONS:Parameter S-35-200/18-3Maximum clamping force, t (lbs) (station №1 / stations №2,3) 18/2,2 (39683/4850)Min./max. length of the tested valve, mm (″) 130/400 (5/15,94)Min./max. diameter of the clamped flange, mm (″) 95/335 (4/13)Overall dimensions (LхWхH), mm (″) 2582х1478х2206 (101х58х87)Weight, kg (lbs) 1650 (3638)


ADVANTAGES:■ The test bench consists of a station for hydraulic tests and

station for pneumatic tests. ■ Quantity of clamping units could be changed upon customer

request.*■ The test bench can be produced with vertical or horizontal

test stations, and with the combination of two of them.*■ The test bench includes a control panel.■ Units and details of the test bench are protected from

corrosion.

S-35-200/18-3 Maximum test pressure, bar (psi)

DN, mm (″)40

(580)70

(1015)

10...150 (⅜...6)

200 (8)TESTED ITEMS: • gate valves; • globe valves; • ball valves.

CONFORMED WITH STANDARD: API 598; DIN EN 12266; ISO 5208; ASTM E 1003-05; GOST 5762-2002; GOST 9544-2005.


■ Allows fast and accurate testing of a large quantity of serial products.

■ The test bench is equipped with a control system that provides:

• light indication on the presence of pressure in the valve; • the system that prevents the tested valve unclamping in

the presence of pressure therein; • setting the time of tests; • automatic detection of tested valve’s gate leakage with a

light signal.

41

CONFORMED WITH STANDARD: API 598; DIN EN 12266; ISO 5208;

ASTM E 1003-05; GOST 5762-2002; GOST 9544-2005.

S-5-80/6-5Maximum test pressure, bar (psi)*

DN, mm (″)75

(1088)120

(1740)180

(2610)250

(3625)

15...40 (½...⅔)

50 (2)

65 (2½)

80 (3)

PURPOSE:• submerged gas testing of pipeline valves; • testing of valve’s body for strength and density;• gate tightness tests;• environmental leakage tests (including gland seals).

S-5-80/6-5MULTI-STATION TEST BENCH FOR SUBMERGED GAS TESTING OF SHUT OFF VALVES DN 15...80 MM (½...3″)

SPECIFICATIONS:Parameter S-5-80/6-5Maximum clamping force of each test station, t (lbs) 6 (13228)Total maximal clamping force, t (lbs) 30 (66138)Min./max. distance between the moving and stationary cross-heads, mm (″) 115/510 (4/18)Distance between the columns, mm (″) 270 (11)Power supply, V/Hz 400/50Overall dimensions (LхWхH), mm (″) 2730x1750x1370 (107х69х54)Weight, kg (lbs) 2650 (5842)


ADVANTAGES:■ The tank, power rack, piping and all parts of the test bench

that are submerged under water are made of stainless steel. The two-sided gate seal tests do not require the tested valve rearrangement, which significantly reduces the test time. Test from one to five valves is executed simultaneously.

■ The clamp of tested valves is made by hydraulic cylinders mounted on each test station, independently of each other.

■ The power frame is disposed within the water tank and submerged under water to a depth from 0 to 600 mm (24″).

TESTED ITEMS: • cryogenic valves; • gate valves; • stop valves (globe valves).


■ For easy installation of valves to be tested the power rack rises above the tank.

■ For easy inspection of tested valves the tank of the test bench is provided with an internal illumination.


■ Stainless steel power rack of test bench actuated by two pneumatic cylinders.

42

VU

p. 58

PGS

p. 56

RMR

p. 4

SOV

p. 58

B, SVN

p. 59

CRS

p. 54

UK

p. 55

MSSH

p. 61

ADVANTAGES:■ Fast clamping and centering of tested valve by synchronized

movement of two or three clamps.■ Sealing of tested valve is carried out by the hydraulic cylinder.■ Compact size of clamping unit with integrated stainless steel

water collection tray.

TEST BENCHESFOR PNEUMATIC AND HYDRAULIC TESTING AND ADJUSTMENT OF SAFETY VALVES

OPTIONAL:

PURPOSE: • leakage test of disk and seat sealing;• gate tightness test;• performance test and working pressure adjustment.

TESTED ITEMS: • safety valves.

TESTED UNIT CONNECTION TYPE:*• flanged;• threaded-ends;

CONFORMED WITH STANDARD: API 527; DIN EN 12266; ISO 5208; ASTM E 1003-05; GOST 5762-2002; GOST 9544-2005.

■ All water-wetted parts are corrosion-proof.■ Equipped with set of sealing adapters for each DN

and spare parts kit.

43

S-1-400/38, S-1-300/38, S-1-250/15TEST BENCH FOR SAFETY VALVES DN 10...400 MM (⅜...16″)

SPECIFICATIONS:Parameter S-1-400/38 S-1-300/38 S-1-250/15Maximum clamping force, t (lbs) 38 (83775) 38 (83775) 15 (33069)Min./max. diameter of the clamped flange, mm (″) 90/610 (4/24) 90/460 (4/18) 90/460 (4/18)Maximum thickness of the clamped flange, mm (″) 80 (3) 75 (2) 75 (2)Overall dimensions (LхWхH), mm (″) 1183х1100х947 (46x43x37) 1021х1043х974 (40x41x37) 925x1045x946 (36x41x37)Weight, kg (lbs) 565 (1245) 624 (1375) 502 (1106)

* Unit can be supplied with set of sealing adapters as per customer specifications.


DN, mm (″)20

(290)30

(435)40

(580)60

(870)85

(1233)130

(1885)270

(3916)400

(5801)650

(9427)690

(10007)10...50 (⅜...2)

65 (2½)

80 (3)

100 (4)

150 (6)

200 (8)

250 (10)

300 (12)

350 (14)

400 (16)


DN, mm (″) 40(580)

60 (870)

85(1233)

130(1885)

270(3916)

400 (5801)

650(9427)

690(10007)

10...50 (⅜...2)

65 (2½)

80 (3)

100 (4)

150 (6)

200 (8)

250 (10)

300 (12)


DN, mm (″)25

(362)35

(507)50

(725)105

(1523)160

(2320)260

(3771)530

(7687)690

(10007)10...32 (⅜...1¼)

40...50 (⅔...2)65 (2½)

80 (3)100 (4)150 (6)200 (8)

250 (10)

44

SI-25MTEST BENCH FOR TESTING SPRINGS OF SAFETY VALVES Ø 25...300 MM (1...12″)

PURPOSE: • computerized automatic triple compression of the spring to the

preset deformation with residual deformation measurement;• computerized automatic triple compression of the spring to the

preset load with residual deformation measurement;• computerized automatic compression of the spring by

maximum load and the axial displacement measurement;• computerized automatic generated force measurement under

the specified deformation of the spring;• system provides test protocol printing-out and saving.

TESTED ITEMS: • springs Ø 25...300 mm (1...12″).

ADVANTAGES:■ Computer-aided automated control system with a touch

screen display.■ Tests of all the main standard sizes of springs used in

safety valves. ■ Integrated testing facility without additional accessories.

SPECIFICATIONS:Parameter SI-25MExternal diameter of springs, mm (″) 25…300 (1...12)Free height of springs, mm (″) 50…500 (2...20)Controlled-load range, kg (lbs) 5…10000 (11...22046)Maximum travel of the cross-arm, mm (″) 500 (20)Power supply, V/Hz 400/50Motor power, kW 4,5Overall dimensions (LхWхH), mm (″) 780х940х2100 (31x38x84)Overall dimensions of the control panel, mm (″) 650х550х1215 (26x22x48)The weight of the bench and the control panel, kg (lbs) 1100 (2425)

■ Recording, archiving, and printing-out of the test protocols. No human factor influence on the test results.

■ Integration into the company local network.

45

■ Small device weight makes it comfortable to work in remote places.

■ Does not require connection to any sources of energy during testing.

■ Universal mounting bracket simplify installation of the unit.

■ Allows testing of Pressure Safety Valves on the pipeline under pressure and without it.

SPECIFICATIONS:Parameter D-14-1 D-14-EPSpool traveling mechanism actuator electric actuator hydraulic actuatorMaximum effort of spool traveling mechanism, kN 1,0 2,0Availability of explosion-proof protection no yesMaximum measurable pressure, Bar 250Reduced pressure measurement error,% ±0,6Maximum measured effort, kN 20Reduced efforts measurement error,% ±0,2Measuring stroke of the valve spool, mm from 0 to ½Operating temperature, ºС -10...+40Overall dimensions (LxWxH), mm (″): - spool traveling mechanism; 405х152х600 (16x6x23) 600х180х205 (23x7x8) - control unit; not required not required - remote control. 300х250х70 (12x10x2)Weight, kg (lbs) (without a set of replacement parts) 20 (44) 35 (77)

D-14PORTABLE MEASURING SYSTEMS

PURPOSE: • D-14 is designed for testing of all types of spring operated Pressure Safety

Valves in their operational pipeline position without plant shut-down.

ADVANTAGES:■ Essential when working with flangeless valves (allows testing

of spring operated safety valve directly on their operational pipeline position without plant shut-down).

■ High accuracy of test results due to use of four interchangeable pressure sensors with accuracy class of 0.25% (with ranges of 16, 40, 100 and 250 Bar) as well as two interchangeable force sensors with class of accuracy 0.03% (with ranges of 0.2 and 2.0 ton).

MACHINE CONFIGURATION CHART:• spool travelingmechanism;• control unit ;• remote control;• pressure sensors;• force sensors;• extension cables;• accessory kit.

TESTED PRODUCTS: • spring-loaded safety valves with manual

override device.

LISTED IN THE REGISTER OF AN PPROVED TYPE MEASURING INSTRUMENTS OF RUSSIAN FEDERATION

46

MP-PSVMOBILE PLATFORM FOR HYDRAULIC AND PNEUMATIC TESTING OF PRESSURE SAFETY VALVES DN 15...400 MM (½...16”)

PURPOSE:• seat leakage test.• functional test and working pressure ajustment.

TESTED ITEMS: • safety valves.

COMLETE SET:• Vertical test bench SI-14 RS • Pneumo-hydraulic pumping station PGS.• Pressure compressor unit UK-3.*• Protection fence with bulletproof windows.• Basement platform.• Set of testing adapters for flanged valves with O-ring sealing.• Computer registration system for Pressure Safety Valves CRS-M.*• Portable grinding and lapping machine PUR-5.*

ADVANTAGES:■ Safety fence provide safety of operator's during high-

pressure gas testing. ■ Sealing of tested valves is carried out by clamping of

mounted valve in between claws and testing table by hydraulic cylinder installed in basement of test bench.

■ Dimensions of test complex allows its delivery to sites by truck.

47

MP-PSVMOBILE PLATFORM FOR HYDRAULIC AND PNEUMATIC TESTING OF PRESSURE

SAFETY VALVES DN 10...300 MM (½...16”)

SPECIFICATION:Parametr MP-PSVMaximum pressure pneumatic testing, bar (psi) 690 (10007)Maximum pressure hydro testing, bar (psi) 690 (10007)The maximum pressure in the hydraulic clamp, bar (psi) 250 (3673)Maximum clamping force, tones (lbs) 100 (220462)Overall dimensions (LхWхH), mm (″) 2600х1124х1960 (102х44х77)Weight, kg (lbs) 2155 (4750)

* Design of mobile testing platform is modular and can be customized as per customer requirements.

48

PURPOSE:• strength and density testing of the body parts materials and welds under pressurized test medium;• environmental leakage tests;• gate tightness tests;• anti-blowout equipment tightness tests.

TESTED ITEMS:• christmas tree valves;• swivels;• drilling heads;• gate valves;• adapter spools;• casing heads;• well flushing equipment set;• preventers (ram and annular BOPs);• packers;• high-pressure hoses;• wellhead.

TESTING MEDIUM:• water;• water with corrosion inhibitor of purity class not

rougher than 14 according to GOST 17216-99 (code 19/16 according to ISO 4406-99).

Using of other testing substances, specified in technical conditions or construction documentation for specific valve, is acceptable in agreement with REVALVE.

ADVANTAGES:■ Two-sided gate tightness tests do not require the

tested-valve rearrangement, which significantly reduces the test time.

■ The patented design of the self-sealing blind flanges rules out axial compression during the tests,which ensures the test reliability, protects the valves against deformation, and extends the valve life.*

■ Accuracy and veracity of testing results are provided by controlling and additional gages as well as by computer registration system CRS.


SI-PVOCOMPLEX FOR TESTING WELLHEAD AND ANTI-BLOWOUT EQUIPMENT

49

SI-PVOCOMPLEX FOR TESTING WELLHEAD AND ANTI-BLOWOUT EQUIPMENT

50

PURPOSE:• strength and density testing of the body parts

materials and welds under pressurized test medium;• environmental leakage tests;• gate tightness tests;• anti-blowout equipment tightness tests.

TESTED ITEMS:• wellhead equipment (slab gate valves, spools, tee-

bends, crossheads etc.);• anti-blowout equipment (small-sized preventors).

TYPE OF CONNECTION:• flanged;• non-flanged.

TESTING MEDIUM:• water;• water with corrosion inhibitor of purity class not

rougher than 14 according to GOST 17216-99 (code 19/16 according to ISO 4406-99).

Using of other testing mediums, specified in technical conditions or manufacturer documentation for specific valve, is acceptable in agreement with REVALVE.

UNIT №1VERTICAL TEST BENCH FOR TESTING THE WELLHEAD AND ANTI-BLOWOUT EQUIPMENTDN 50...280 MM (2...11”)

SPECIFICATIONS:Parameter UNIT №1Maximum clamping force, t (lbs):-using cross-head; 220 (537224)-using clamps. 160 (390709)Motor power, kW 1,1Actuating medium of hydraulic cylinder clamp Industrial oil of purity class not lower than 14 according to GOST 17216Overall dimensions (LхWхH), mm (″) 1702x1040x4425 (67х41х174)Weight, kg (lbs) 3010 (6636)


UNIT №1

DN, mm (″)

Maximum test pressure, bar (psi)280

(4061)420

(6090)700

(10150)1050

(15225) 50...80 (2...3)

100 (4)

180...230 (7...9)

280 (11)

ADVANTAGES:■ The bench is equipped with replaceable blind

flanges for testing non-flanged valves*. This releases the operation from welding (lock-pin screwing) of the blind flanges to the pipes.

■ Side opening upper crosshead simplifies the valve installation procedure before testing.

■ Use of high-pressure hoses with fast couplings reduces test preparation time.

51

PURPOSE:• strength and density testing of the body parts materials

and welds under pressurized test medium;• environmental leakage tests;• gate tightness tests.

TESTED ITEMS:• wellhead and anti-blowout equipment.

TYPE OF CONNECTION:• flanged;• non-flanged.

TESTING MEDIUM:• water;• water with corrosion inhibitor of purity class not rougher

than 14 according to GOST 17216-99 (code 19/16 according to ISO 4406-99).

Using of other testing mediums, specified in technical conditions or manufacturer documentation for specific valve, is acceptable in agreement with REVALVE.

UNIT №4VERTICAL TEST BENCH FOR TESTING THE WELLHEAD AND ANTI-BLOWOUT EQUIPMENTDN 100...425 MM (4...17”)

SPECIFICATIONS:Parameter UNIT №4Min./max. Diameter of the clamping flange, mm (″) 275/872 (11/34)Overall dimensions (LхWхH), mm (″) 740х740х500 (29х29х20)

UNIT №4

DN, mm (″)

Maximum test pressure, bar (psi)280

(4061)420

(6090)700

(10150)1050

(15225) 1400

(20305)100 (4)

180 (7)

230 (9)

280 (11)

350 (14)

425 (17)

52

ADVANTAGES:■ The bench allows to perform tests without axial compression,

which protects the valves against deformation and ensures the test reliability.

■ The floor, caisson (pit) and safety fence installations are offered as options.

■ Clamping unit equipped with powerful hydraulic cylinder installed in the basement of the test bench. Hydraulic system of the clamping unit use oil as operating medium, which extends the bench service life.

■ Fast clamping of the tested product is provided with pneumatic cylinders providing synchronized travel of the clamps.

■ Optional application of hydraulic clamping unit with self-sealing adapters and medium separator allows to achieve even wider range of tested products.

UNIT №5VERTICAL TEST BENCH FOR TESTING THE WELLHEAD AND ANTI-BLOWOUT EQUIPMENT DN 50...425 MM (2...17″)

PURPOSE:• wellhead and anti-blowout equipment;• christmas tree and injection tree valves.

TESTED ITEMS:• christmas tree;• injection tree;• blowout prevention equipment.

TYPE OF CONNECTION:• flanged.

TESTING MEDIUM:• water;• water with corrosion inhibitor of purity class not rougher than 14 according to GOST 17216-99

(code 19/16 according to ISO 4406-99).Using of other testing mediums, specified in technical conditions or manufacturer documentation for specific valve, is acceptable in agreement with REVALVE.

OPTIONAL:

CONFORMED WITH STANDARD: API 6A.

PGS

p. 56

SOV

p. 58

CRS

p. 54

B, SVN

p. 59

53

UNIT №5 VERTICAL TEST BENCH FOR TESTING THE WELLHEAD AND ANTI-BLOWOUT EQUIPMENT

DN 50...425 MM (2...17″)

SPECIFICATIONS:Parameter UNIT №5Maximum clamping force, t (lbs): 700 (1543236)Min./max. diameter of clamped flange, mm (″) 165/560 (550/705*)Maximum pressure of the clamping system, bar (psi) 250 (3626) (20 (290)*)Air pressure, supplied to pneumatic cylinders providing travel of the clamps, bar (psi) 4+2 (58+29)Overall dimensions (LхWхH), mm (″) 1660х1220х1340 (66x49x53)Weight, kg (bench) (lbs) 3575 (7882)

* If using of the hydroclamped blind flanges.

UNIT №5 Maximum test pressure, bar (psi)*

DN, mm (″)280

(4061)420

(6090)700

(10150)1050

(15225)50...230 (2...4)

280 (11)

350 (14)

425 (17)

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ADVANTAGES:■ No human influence on the test results. Automatic

recording of the test results. Integration into the company network is possible.

■ High reliability and accuracy of the results are ensured by the pressure and leakage gauges, as well as industrial computer.

■ Software package is made for easy operation with the system, and allows to input necessary valve data as: DN, PN, test standard, types of test, operator and manufacturer details, sensor calibration parameters. When testing process has been finalized CRS system will generates a report with real time testing conditions showed in a graphics. Reports are saved in archive on internal HDD.

CRS COMPUTER REGISTRATION SYSTEM

PURPOSE: • the system is designed for measuring pressure, test medium leakage through

the valve gate, temperature of the test medium and ambient air, HDD saving and printing out of the test protocols (testing in accordance with API, ANSI FCI, ISO, GOST, DIN and other standards).

TEST TYPES:• hydraulic and pneumatic tests of the valves for strength and density;• hydraulic and pneumatic tests of the shut-off valves for leakage;• hydraulic and pneumatic tests of the safety valve gate seal by the adjustment

pressure;• hydraulic and pneumatic tests of the well-head and anti-blowout equipment

by the working pressure;• safety valve adjustment (measuring the valve completely open (valve

response) / closed pressure).

Parameter CRSOperating medium water, air*Maximum measured test pressure, bar (psi) 1600 (23200)Maximum measured leakage volume for water (air), cm3/min (fl oz) 7,2/11,0 (0,24/0,37)Reduced pressure measurement error, % +0,6Reduced leakage measurement error, % +5,0Test medium and surrounding air temperature measurement range, C° (F°) +5...+50 (+41...+122)Absolute error of the temperature measurement, C° (F°) +1,5 (+34,7)Power supply, V/Hz 230/50 (110/60**)Power consumption, kW 1,2Overall dimensions (LхWхH), mm (″) 760х520х1210 (30x21x48)Weight, kg (bench) (lbs) 120 (264)

SPECIFICATIONS:

FUNCTIONS: 1. Leakage measurement by bubbles (drops) and actual volume

during the shut-off valve tests and the leakage class (A, B, С, D) determination during hydraulic and pneumatic tests. For measurement of leakages according to ANSI FCI 70.2 (Class II-VI) ANSI B16.104 unit requires upgrade to CRS-R version.

2. Measuring the test-medium pressure during hydraulic and pneumatic tests of the shut-off and safety valves with an error of 0.6% or smaller.

3. Test medium and surrounding air temperature measurement during hydraulic tests. (Not included in CRS-M.)

4. Pressure measurement at the time of popping, full opening, and closing of the safety valve gate during the valve test and adjustment.

5. Graphic output of the test results.6. Electronic and paper saving and storing of the test protocols with

possible data transmission.7. Test data base development for each item.8. Test result printout.9. Leakage measurement during the control valve tests, if using

additional flowmeters.

* Requirements for water: in 100 cubic centimeters (milliliters) (3,38 fl oz) of water should contain no more than 400 solid particles: size from 50 up to 100 microns (0,002-0,004″). Requirements for air: size of solid particles no more than 40 microns (0,002″).** Upon customer request.

OPTIONS: • CRS-M - mobile version of CRS designed for computer

registration of test parameters and generating of test protocols during testing of valves at sites with blind flanges or in mobile testing workshops.

• CRS-R - special version of CRS designed for measurement of leakage of control valves in accordance with ANSI FCI 70.2 (Class II-VI) with computer registration of test parameters and generating of test protocols

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UKAUTOMATED COMPRESSOR UNIT

PURPOSE:• pressure source for high pressure pneumatic tests of

valves and pressure vessels;• independent pressure source.

COMPLETE SET:• air compression and supply unit: - compressor unit; - cylinder set 3х50 l (3х13gl); - monitoring, adjustment, and control unit; - piping and automatic equipment system; - additional available boosters (in UK-2 and UK-3).• spare parts, tools, and accessories.

ADVANTAGES:■ High pressure compressor unit with 150 l receivers, will

provide you with long term reliable operation of testing unit, instead of air boosters which are require monthly overhauling, and replacing of piston rings, which requires time and skilled operators.

■ The compressor unit is specially designed for use with test bench, which reduces its cost compared with large compressors supplying the required pressure.

■ The compressor unit is designed for long-term continuous operation.

SPECIFICATIONS:Parameter UK-1 UK-2 UK-3Maximum pressure at, bar (psi) 64 (928) 200 (2900) 350* (5075)Pneumatic unit capacity reduced to initial conditions, l/min 250Pressure buildup time, min: - up to maximum pressure in a 50 l (13 gl) receiver; 15 40 70 - up to maximum pressure in a one-liter (0.3 gl) tank. 0,3 0,8 1,75Receiver volume, l (gl) 150 (40) 100 (27)Motor power, kW 5,5Power supply, V/Hz 400/50Overall dimensions (LхWхH), mm (″) 1212×1568×1972 (48x63x79)Weight, kg (lbs) 695 (1433)

* Upon customer request 400 bar (5800 psi).

Pressure up to 400 bar (5800 psi)

■ The unit control system automatically maintains the cylinder pressure within the specified limits and ensures the unit shutdown in case of emergency.

■ It has 2 individually adjusted high- and low-pressure output lines.

■ Compressed air backup is up to 150 l (3x13 gl).■ Stepwise air volume adjustment in the cylinders

(50 - 100 - 150 l (13-26-40 gl)) allows us to reduce the high pressure generation time.

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PGSCONTROL STATIONS

PURPOSE:• pressure source for hydraulic tests of valves and pressure vessels;• supplies as a control panel of the test bench;• as well as independent pressure source.

OPTIONS:• PGS-PS edition equipped with the automatic

proportional clamping control system. PLC controlled system allow to perform testing of valves in a safe mode excluding axial compression applied to the valve body during testing, by automated proportional clamping pressure adjustment in hydraulic cylinder, relatively to testing pressure.

FUNCTIONS: 1. Hydraulic test medium pressure up to 1600 bar (23200 psi).2. Continuous (stepless) pressure control for: - hydraulic tests 10...1600 bar (145…23200 psi); - pneumatic tests 0.5...10 bar (7…145 psi) (5...400 bar (72.5…5801 psi)

upon customer request).*3. Smooth control of the test-bench hydraulic clamping cylinder.4. Automatic maintaining of achieved test pressure.5. Valve gate leakage measurement by the drop and bubble methods (see B).6. Control of the test process by the pressure-gage panel with the measurement

accuracy of 1.0 % (0.6% as requested by customer).7. The PGS is equipped with sockets to connect additional calibration test

gages with the required accuracy (see А).8. The PGS, can be connected to the CRS for recording of test data.

В

E


Pressure up to 1600 bar (23200 psi)

• PGS-M mobile version of control station, that allow to perform testing at sites (blind flanges are not included).

• PGS-A edition allow to perform testing of valves in automatic mode. Also can be provided with proportional clamping control system. The range of process automation should be negotiated and stated at the order stage in technical specification to the contract of supply.

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В

С

D

E

А

COMPLETE SET:• pressure source unit with the bench control panel: - 1 or 2 pneumohydraulic boosters (according to model); - monitoring, adjustment, and control equipment;• air preparation unit (С);• preliminary and fine water filters (D);• pedal for the valve-clipping control during the test (Е);• air and water leakage control unit (В);• a set of high-pressure quick-connect hoses;• a set of spare parts, tools, and accessories.

PGSCONTROL STATIONS

А

D

EQUIPMENT ADVANTAGES:■ The PGS control circuit uses pneumatically controlled gate

elements. This releases the operator from opening and closing numerous needle valves and makes the unit control process simple and reliable.

■ The equipment has separate filling line to reduce the test preparation time.

■ For convenience, control of the hydraulic clamping cylinder of the test bench can be performed from the control panel and remote pedal (see E).

■ The PGS external connection diagram uses fast coupling joints with warranted operation life of 10,000 cycles, which significantly reduces the time required to complete preparation and final operations.

■ The compressed-air supply line has the air-preparation unit and ensures class 0 air supply even when the pneumatic network contains polluted air (see C).

■ To extend the unit operation time, the PGS water input is equipped with a fine water filter (see D).

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PURPOSE:• autonomous recycling process water supply

station for test benches and pneumohydraulic stations included in composition thereof as well as for other units applying process water.

ADVANTAGES:■ Operation in automated mode with maintained

set output water pressure.■ The unit provides water supply for consumers

through two lines with a separate adjustment of pressure for each one.

■ The unit stops automatically when water level in the tank reaches minimum.

■ Modular structure of the unit allow increasing of SOV tank volume up to 12 m³.*

■ Provides hydraulic testing without main process water supply line in the workshop.

■ Water drainage from several consumers (up to 4) to the tank. Resource saving in case of a closed cycle of process water use.

■ High precision of water pressure maintaining and measuring at the installation output. The tank may be placed at 10 m distance from the control panel.

■ Possible application of water with corrosion inhibitors.*

SOVRECYCLING WATER SUPPLY STATION


VUVACUUM SYSTEM

PURPOSE:• air drainage from tested pipeline valves clamped

at the test bench before filling with process water. Recommended for use with horizontal test benches.

ADVANTAGES:■ Provides significant reduction of time for filling of the tested

products with water excluding need of remained air removal from the valves and pressure relive fittings. Recommended to use with horizontal clamping units in case if tested valves are not equipped with relieve valves.

■ High degree of vacuumizing (up to -0.95 bar). ■ Essential for horizontal bench for testing of large inner

diameter valves and fittings from DN 400 mm (16") and higher.

■ Equipped with automated control system which allows switching off the unit when the required level of vacuumization is reached.

■ Can be used as vacuum creation unit in set with PGS unit in other fields of applications as breather valves testing.

■ Compatible with all types of test benches from REVALVE product range as well as for use as a component with other manufacturer’s test bench.

SVN

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BSAFETY FENCE FOR HIGH PRESSURE TESTING

PURPOSE:• provision of safety protection in case of depressurization of the tested

items or connecting elements during hydraulic and pneumatic testing.

ADVANTAGES:■ Set of modules allows mounting of safety fence of various types

and sizes with possible placement of gates at various sides.■ The panels of safety fence are provided with viewing windows of

certified armoured glass.■ In the safety fencing provided the locking mechanism of the

entrance gates during gas testing.

COMPLETE SET:• uprights;• panels (with or without window);• swing gates (sliding*);• sliding roof*;• lighting / warning panel;• electrical cabinet;• pneumatic safety locking device.*

OPTIONAL:• Video control system (SVN).


SPECIFICATIONS:Parameter BHeight, mm (″) 2500 (96)Blank panel width, mm (″) 1000 (40)Width of blank panel with windows, mm (″) 2000, 1500 (80, 60)Window dimensions, mm (″) 500х500 (20x20)Width of swinging gates, mm (″) 1700/2700 (69/115)Width of sliding gates, mm (″) 1600 (64)Minimal length of an armoured protection wall with sliding gates, mm (″) 6000 (240)

■ Armoured protection is mounted at the site. Uprights are installed at foundations using foundation (anchor) bolts.

■ In order to provide electrical safety panels and gate leaves are facilitated with grounding bolts.

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SI-PRATEST UNIT FOR TESTING OF CONTROL VALVE ACTUATORS

PURPOSE:• operation testing, valve closure element harmonization and insensitivity

adjustment for valves with diaphragm actuators and actuators of control valves with pneumatic and electric control.

SPECIFICATIONS:Parameter SI-PRAAir pressure control range , bar (psi):

- channel I; from 0 to 4 (58)- channel II. from 0 to 7 (102)

Pressure gauge accuracy rating, at least 0,6Adjustment range of current acc. to load, not exceeding 1kOhm, mA from 0 to 20Adjustment range of voltage acc. to load, at least 30 Ohm, V from 0 to 30Fixed values:

- of current acc. to load, not exceeding 1kOhm, mA; 4, 8, 12, 16, 20- voltage acc. to load, at least 30 Ohm, V. 24

Power voltage of the tested products, V/W 24/20Milliammeter and voltmeter accuracy rating, at least 0,6Air pressure supplied to the bench, bar (psi), at least 7,5 (109)*Supply power, V/Hz 230/50Overall dimensions, (LxWxH), mm (″) 600х700х1700

(24x28x68)Weight, kg (lbs) 70 (154)

* Allowes to supply air with lower pressure to narrow the range of air control in the channel II.

BRLEAKAGE MEASURING UNIT FOR CONTROL VALVES

PURPOSE:• measuring of leakages through the gate element of control valve during

testing with air.

SPECIFICATIONS:Parameter BRThe range of measurement of airflow rate:

- bobble/drop counter I, Sm3/min.; 0...11,0- flow meter II, Sm3/min.; 11,0...110,0- flow meter III, Nl/Min.; 0,1...1,0- flow meter IV, Nl/Min.; 0,83...8,3- flow meter V, Nl/Min.; 8,3...83,0- flow meter VI, Nl/Min. 81,6...816,0

Class of sensor accuracy II-VI (50% scale),% 1Operation conditions:- ambient air temperature, °C (ºF); from +5 (+41) to +40 (+104)

- relative humidity (at + 25 °C)%. 45...80Overall dimensions (LxWxH), mm (″) 950х710х2100 (37х28х83)Weight, kg (lbs) 40 (88)


EQUIPMENT ADVANTAGES:■ High precision and visibility when testing for gate tightness with air.■ A large range of measured leakage allows testing of control valves with

tightness class II-VI as per GOST 54808-2011 (ANSI / FCI 70-2).■ Unit allows to connect additional flow sensors to register the leakages by using

computer registration system CRS.*■ Mobile design of the unit allows to move it between the different benches,

depending on the need for testing of control valves.■ Built-in filter eliminates the need to clean the flowmeters in contact with foreign

particles from the tested valves.

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ADVANTAGES:■ A large volume of hydraulic tank with the possibility of

refitting* allows to perform a wide range of tasks in connection with hydraulics.

■ Fixed and remote control to enable / disable the unit.■ Built-in sensor shuts off the unit automatically when oil

achieves a minimum level.

PURPOSE:• pressurized oil supply unit, with pressure rate adjustment by safety valve

settings into system, for various hydroficated equipment.

COMPLETE SET:• hydraulic tank volume 160 l;• pumping unit;• control system;• filters (suction, inlet, drain);

MGHYDRAULIC DRIVE UNIT

SPECIFICATIONS:Parameter MGHydraulic tank rated capacity, dm³ 160Pumping unit type gearRated pumping capacity, l/min 14Pumping unit motor power, kW 5,5Supply voltage, V/Hz 400/50Min./max. hydraulic drive unit pressure, bar (psi) 5/210 (72,5/3046)Overall dimensions, (LxWxH), mm (″) 1100х670х1000 (43x26x39)Weight without oil, kg (lbs), not exceeding 170 (375)

■ Air heat exchange unit with integrated temperature sensor provides long smooth operation of the hydraulic drive unit due to oil cooling.

■ Pollution indication of a drain filter allows to replace the filter element in time for guaranteed oil purity.

■ Gear pump is oil-immersed to reduce noise and to provide favorable conditions for the unit operation.

• safety valves;• gauge;• heat exchange unit;• oil level indicator.


MSSHMUFFLER FOR HIGH PRESSURE PSV GAS TESTING

PURPOSE: • reducing noise and providing exhaust filtration during

pneumatic testing of safety valves DN 50…300 мм (2...12″).

EQUIPMENT ADVANTAGES:■ Using the unit, reducing noise of output air from the safety valve

up to 25 times.■ Provides filtration of the exhaust air from safety valve by

reducing the mechanical impurities (dust, particles, scale, etc).■ Specially designed on a mobile stand with height adjustment.■ Adapters kit allows you to connect unit to almost any safety

valve with DN up to 300 mm (12″) (more than DN 300 mm (12″) - on request).

TECHNICAL CHARACTERISTICS:Parameter MSSHHeight adjustment (on the axis of the transition pipe), mm (″) 925…1555 (37…62)Reduction in sound level, dB 14...16Weight, kg (reduction noise/set of replacement parts) (lbs) 210/80 (463/176)

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SPVP-1 SPVP-2

TECHNICAL CHARACTERISTICS:

SPVPMACHINES FOR CUTTING GASKETS AND DRILLING OPERATIONS WHEN REPAIRING PIPELINE VALVES

PURPOSE:• the machines are designed for cutting gaskets from

paronite and other nonmetallic materials as well as drilling, hole enlarging, squaring, boring, and thread tapping.

GASKET SIZES:• SPVP-1: 60...500 mm (2⅜...20″).• SPVP-2: 100...1200 mm (4...48″).

EQUIPMENT ADVANTAGES:■ High-precision manufacturing of gaskets of various

materials rules out manual labor, reduces injury risks, and improves production standards.

■ The construction has protective cover to isolate the cutting area.

Parameter SPVP-1 SPVP-2Sizes of cut gaskets, mm (″) 60…500 (2⅜...20) 100…1200 (4...48)Steel drilling range, mm (″) 3...32 (0.12...1) 3...50 (0.12...2)Range of cut threads, mm (″) М3-М33 М3-М33Spindle taper Morse 4 Morse 4Overall dimensions, mm (″) 1055х850х2680 (42x34x107) 2730х970х2630 (109x39x105)Weight, kg (lbs) 1500 (3307) 3500 (7716)

COMPLETE SET:• base;• replaceable clamp set;• two sets of cutters;• shank end;• protective cover.

■ The frequency converter ensures stepless adjustment of the spindle speed, which allows us to machine various construction materials in the most efficient cutting mode (SPVP-2).

CONTACT:

• Export DepartmentTel.: +7 (8412) 200-201 E-mail: [email protected]

OUR CERTIFICATES:

ADDRESS:

75 Prospekt Pobedy, Penza 440060, Russia.

REVALVE by «PKTBA» CJSC 75 Prospekt Pobedy, Penza, 440060, RussiaTel./fax: +7 (8412) 200-201e-mail: [email protected]

Since 1962 VALVE TEST & REPAIR EQUIPMENT · S-5-80/6-5 DN up to 80 mm 41 Test benches for safety...

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Transcript of Since 1962 VALVE TEST & REPAIR EQUIPMENT · S-5-80/6-5 DN up to 80 mm 41 Test benches for safety...