Pages from A1-580EF-240-010_2023-05-11_08-36-52.pdf
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- M6700123Q1154
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United States Marine Corps
About this file
This technical document outlines test procedures for a pressure regulator valve. It describes several required tests for the valve, including bench calibration, servo recovery, actuator housing proof pressure, internal and external leakage, sense port leakage, solenoid performance and opening/closing time, pressure relief valve operation, position switch operation, and burn-in cycles. Tests will evaluate parameters such as regulator adjusting screw calibration, valve pressures and flow rates at various inlet pressures and solenoid voltages, leakage rates, opening and closing times, supply pressure of the pressure relief valve, position switch actuation angles, and cycling the valve through temperature and pressure conditions. The valve must pass all tests in order to meet specification requirements for the opportunity.
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A1-580EF-240-010 001 00
NOTE
Final adjustment of regulator adjusting screw (121, figure 40) should only be made in the clockwise direction.
65. BENCH CALIBRATION PROCEDURES.
a. Set up test as shown in figure 29.
b. Increase valve inlet pressure (Pvi) to 140 ± 1 psig.
c. Energize solenoid with 28 ± 2 VDC.
d. Increase sense port pressure (Preg) to 125 ±
0.5 psig.
e. Adjust regulator adjusting screw (121, figure
40) to achieve test port pressure (Ptest) of 80 ± 0.5 psig as follows:
(1) If test port pressure (Ptest) is below 80 ±
0.5 psig, turn regulator adjusting screw (121) clockwise to increase test port pressure (Ptest) to 80 ± 0.5 psig.
(2) If test port pressure (Ptest) is above 80 ±
0.5 psig, turn regulator adjusting screw (121) counterclockwise to decrease test port pressure (Ptest) below 75 psig, then turn regulator adjusting screw (121) clockwise to increase test port pressure (Ptest) to 80 ± 0.5 psig.
f. Record valve inlet pressure (Pvi), sense port pressure (Preg), and test port pressure (Ptest).
g. Decrease valve inlet pressure (Pvi) to zero psig and de-energize solenoid (zero VDC).
66. SERVO RECOVERY TEST.
a. Set up test as shown in figure 29.
b. Energize solenoid with 28 ± 2 VDC.
c. Increase valve inlet pressure (Pvi) to 100 ± 5 psig.
d. Test port pressure (Ptest) shall be 80 psig or greater. Record valve inlet pressure (Pvi) and test port pressure (Ptest).
e. De-energize solenoid (zero VDC).
f. Test port pressure (Ptest) shall be 5 psig or less. Record valve inlet pressure (Pvi) and test port pressure (Ptest).
g. Decrease valve inlet pressure (Pvi) to zero psig.
67. ACTUATOR HOUSING PROOF PRESSURE
TEST.
a. Set up test as shown in figure 30 using proof chamber on pneumatic component test stand.
b. Energize solenoid with 28 ± 2 VDC.
c. Increase valve inlet pressure (Pvi) until test port pressure (Ptest) is 554 ± 10 psig and hold for 2 minutes minimum.
d. Decrease valve inlet pressure (Pvi) to zero psig and de-energize solenoid (zero VDC).
e. Valve shall show no sign of permanent deformation or other damage. Record results.
f. Increase valve inlet pressure (Pvi) to 919 ± 10 psig with solenoid de-energized (zero VDC) and hold for 2 minutes minimum.
g. Decrease valve inlet pressure (Pvi) to zero psig.
h. Valve shall show no sign of permanent deformation or other damage. Record results.
68. LEAKAGE TESTS.
69. Internal Leakage Test.
a. Set up test as shown in figure 31.
b. Increase valve inlet pressure (Pvi) to 110 ± 2 psig with solenoid de-energized (zero VDC).
c. Leakage past butterfly shall not exceed 1.15 lbs/min. Record leakage.
d. Decrease valve inlet pressure (Pvi) to zero psig.
Figure 29. Bench Calibration Bench Check and Servo Recovery Test
Figure 28. Electrical Bonding Test
Figure 31. Internal Leakage Test
Figure 30. Actuator Housing Proof Pressure Test
70. External Leakage Test.
a. Set up test as shown in figure 32.
b. Energize solenoid with 28 ± 2 VDC.
c. Increase valve inlet pressure (Pvi) to 110 ± 2 psig.
d. Leakage shall not exceed 0.20 lb/min. Record leakage.
e. Increase valve inlet pressure (Pvi) to 200 ± 5 psig.
Airflow felt approximately 4 inches from butterfly shaft upper seal area is considered excessive and constitutes failure. External leakage felt at higher inlet pressures during subsequent testing does not constitute failure due to leakage.
f. No airflow should be felt from any single location with hands placed 3 to 4 inches from valve.
g. Decrease valve inlet pressure (Pvi) to zero psig and de-energize solenoid (zero VDC).
71. Sense Port External Leakage Test.
a. Set up test as shown in figure 33.
b. Increase sense port pressure (Preg) to 125 ± 5 psig.
c. Leakage shall not exceed 0.0001 lb/min.
Record leakage.
d. Decrease sense port pressure (Preg) to zero psig.
72. SOLENOID PERFORMANCE,
CLOSING/OPENING TIME TESTS. Full open position is defined as the position at which valve disc and shaft set stops when valve is pneumatically positioned by actuator with solenoid energized with 28 ± 2 VDC and valve inlet pressure (Pvi) set to 25 ± 1 psig. Full closed position is defined as the position at which valve disc and shaft stops when valve is pneumatically positioned by the actuator with solenoid de-energized (zero VDC) and valve inlet pressure (Pvi) set to 25 ± 1 psig.
73. Low Pressure Performance Test.
a. Set up test in accordance with figure 34.
b. Increase valve inlet pressure (Pvi) to 25 ± 1 psig.
c. Energize solenoid with 11.5 ± 0.5 VDC and valve shall go full open within 8 seconds. Record time.
d. De-energize solenoid (zero VDC) and valve shall go full closed within 2 seconds. Record time.
e. Decrease valve inlet pressure (Pvi) to zero psig.
74. High Pressure Performance Test.
a. Set up test as shown in figure 34.
b. Increase valve inlet pressure (Pvi) to 543 +10/- 0 psig.
c. Energize solenoid with 11.5 ± 0.5 VDC and Valve shall go full open within 8 seconds. Record time.
d. De-energize solenoid (zero VDC) and valve shall go full closed within 2 seconds. Record time.
e. Decrease valve inlet pressure (Pvi) to zero psig.
75. PRESSURE RELIEF VALVE OPERATION
TEST.
a. Remove transfer tube (11, figure 40).
b. Install transfer tube (GS24304-1).
c. Set up test as shown in figure 35.
d. Increase valve inlet pressure (Pvi) to 500 ± 10 psig.
e. Supply pressure (Psupply) shall be 178 ± 2 psig. Record supply pressure (Psupply).
f. Decrease valve inlet pressure (Pvi) to zero psig.
g. If supply pressure (Psupply) is outside tolerance, add shims (95, figure 40) to increase supply pressure (Psupply) and subtract shims to decrease supply pressure (Psupply) and re-test.
Figure 32. External Leakage Test
Figure 33. Sense Port Leakage Test
Figure 35. Pressure Relief Valve Operation Test
Figure 34. Solenoid Performance and Opening/Closing Time Tests
TRANSFER TUBE
(GS24304-1)
Change 2 Page 78
h. Torque ball sleeve (91, figure 40) to 30 to 35 ft-lbs.
i. Remove transfer tube (GS24304-1).
j. Install transfer tube (11). Torque transfer tube
(11) nuts 20 to 25 in-lbs above run-on torque. (QA)
76. POSITION SWITCH OPERATION TEST.
Adjust position switch (10, figure 40) as required to meet test requirements.
a. Set up test as shown in figure 36.
b. Set valve inlet port pressure (Pvi) to 25 ± 1 psig.
c. Adjust protractor to read zero degrees at full closed position.
d. Verify continuity between pins C and D.
Decrease valve inlet pressure (Pvi) to zero psig.
e. Slowly open valve, by hand, until continuity between pins C and D is broken. Record valve angle.
f. Open valve a minimum of 10 degrees further, then slowly close valve until continuity is established between pins C and D. Record valve angle.
g. Valve shall make and break continuity 3 to 9 degrees from full closed position.
h. Remove valve from test set-up.
i. Reinstall plug (29, figure 40). Torque plug (29) 8 to 12 in-lbs above run-on torque.
77. FUNCTIONAL/OPERATIONAL TESTS. The following tests shall be performed on the high temperature/high pressure test channel (valve test console, 3791500-1, and high pressure valve test holder, 3791480-1) using power cable (18D11611-9) from power cable kit (18D11611-1), clamps (AS1895/1-250 ), seals (AS1895/7-250 ), and support equipment as required to satisfy test requirements.
Valve must be run for 30 minutes at conditions specified in Burn-In Cycles prior to performing Droop Test, Valve Operation and Hysteresis Test, and Stability Test. All FUNCTIONAL/OPERATIONAL TESTS must be performed without any interruption to test stand. Any shutdown of stand requires re-performance of FUNCTIONAL/OPERATIONAL
TESTS.
Final adjustment of regulator adjusting screw (121, figure 40) should only be made in the clockwise direction.
Full open position is defined as the position at which valve disc and shaft set stops when valve is pneumatically positioned by actuator with solenoid energized with 28 ± 2 VDC and valve inlet pressure (Pvi) set to 25 ± 1 psig. Full closed position is defined as the position at which valve disc and shaft stops when valve is pneumatically positioned by the actuator with solenoid de-energized (zero VDC) and valve inlet pressure (Pvi) set to 25 ± 1 psig.
a. Set up test as shown in figure 37.
b. Adjust protractor to read zero degrees at full closed position.
c. Verify 1.500 inch diameter orifice is installed in flow measuring section of high temperature/high pressure test channel and ensure 1.500 inch orifice size is entered in valve test console.
78. Burn-In Cycles.
a. Energize solenoid with 28 ± 2 VDC.
Thermal burns can result from exposure to or contact with Hot Materials with a temperature above 115ºF. Long, asbestos free heat-resistant gloves, chemical goggles and a full faceshield must be worn when handling hot materials.
b. Increase valve inlet pressure (Pvi) to 140 ± 2 psig and valve inlet temperature (Tvi) to 625° ± 25°F.
c. Adjust rig back pressure valve to set weight flow (Wf) to 35 ± 5 lbs/min.
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