SALIENT CHARACTERISTICS.pdf

Specification for Hydrostatic Testing System and Enclosure

1) Salient Characteristics for a pneumatically-powered testing enclosure and pressurization system for hydrostatically testing hoses (also known as “Hose Proof Tester” or “Hydro bench”):

a. Test Enclosure dimensions (+/- 12”): 72" x 48" x 24",

b. Bench working height approx. 36”.

c. Operates via compressed shop air at 85-115 psig.

d. Onboard Low and High pressure hydrostatic pressure pumps, piping and controls rated for and capable of providing:

i. Low Pressure testing: Up to 6,000 psig.

ii. High Pressure testing: 6,000-20,000 psig

e. 2 ea. Auxiliary Gauge Ports per each test system for installation of customer supplied digital gauges.

f. 1 ea. Auxiliary Port per test system for customer supplied relief valves.

g. All Auxiliary Ports located at top of Control Console within easy view of operator.

h. System controls, to include:

i. Low and High pressure Vent, Supply and Drain valves

ii. Air, water and flush controls

iii. Hydrostatic pump control valve(s) and regulator(s)

iv. Top and Front shield pneumatic actuator controls

v. Mufflers on air exhausts as needed.

i. Flow indicators on vent outlets to verify air purges.

j. NPT or quick-disconnect ports for air, water inlet and outlets as needed.

k. Lid and Front panel to be clear polycarbonate for ease of viewing, both pneumatically actuated for part loading and bed cleaning.

l. All sides of enclosure shall be of adequate thickness to contain catastrophic hose failure/rupture at quoted pressures.

m. Adjustable feet to allow leveling of bench.

2) Engineering design documentation shall be provided showing capacity of system to withstand catastrophic hose failure/rupture during testing at quoted pressures.

3) Testing: Equipment shall be factory pressure tested to 1.5 times labeled maximum allowable working pressure (20,000 psig x 1.5 = 30,000 psig).

4) Safety Signs and Labels: Corrosion resistant safety signs and labels in accordance with NEMA/ANSI Z535.4 shall be securely attached to the equipment in visible locations, at the point of hazard(s), with any safety precautions to be observed by the operator or maintenance personnel permanently marked on the signs. Warnings shall describe dangers from mechanical injury (including pinch points) and stored energy (including pressurized systems), if any, and any others as appropriate. However, warning signs shall not be installed in lieu of properly designed systems in accordance with requirements of this document.

5) Safety Guarding: Covers, guards, or other safety devices shall be provided. The safety devices shall not interfere with the operation of the Hydrostatic Test Bench. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts. Include Pinch Point warning labels.

6) Audible Noise Level: Audible noise emitted by the equipment shall not exceed 85 decibels (dBA), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment during normal operation.

7) Air Entrapment Warning Plate: A warning plate shall be located at the operator control warning of air entrapment and shall read as follows: “To prevent air entrapment, hoses shall be flushed of entrapped air prior to hydrostatic testing. Capping of one hose end or creating closed-loops for hydrostatic testing is prohibited and may cause explosion and injury”.

8) Flow Arrows: Apply flow arrows on piping. Flow arrows shall be sized and oriented to be easily viewed by operator or maintenance mechanic.

9) Nameplate: A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

a. Nomenclature or Description.

b. Manufacturer's name

c. Manufacturer's model designation

d. Manufacturer's serial number

e. Contract Number or Order Number

f. Date of manufacture

10) Operation and Maintenance manuals: Manuals shall contain technical information, specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language. Technical Data shall contain at a minimum:

a. Data shall enable an average journeyman mechanic to operate, program, maintain, and repair the equipment.

b. Complete instructions and information for all equipment, components, assemblies, subassemblies, attachments, and accessories.

c. Operating instructions including pre-operational checks, start up, shut down and emergency shutdown procedures.

d. Maintenance and service instructions, including all preventive maintenance schedules, and lubrication charts and troubleshooting guides.

e. Parts list containing: illustrations, part numbers, part nomenclature, original manufacturer, cross reference numbers, and recommended spare parts, including quantities and listed or approved (e.g. “UL” or other NRTL) items.

f. Energy control procedure, in accordance with 29 CFR 1910.147, to bring equipment to a zero energy state for maintenance.

g. Schematics and drawings for the specific model of equipment supplied.

h. Units displayed in the inch/pound system or both inch/pound and metric systems.