Mobile Workshop Tests PSV Valves

TECHNICAL SPECIFICATION
Mobile workshop for PSV testing

Model: PKTBA-MM-1
DN 15 – 300 (NPS ½ - 12)
Pmax up to 500 bar
P.O. 440060 Russian Federation, Penza, Prospect Pobedy, 75

www.revalve.com Tel./fax: +7 (8412) 200-201
e-mail: sales@revalve.com
Test mobile workshop is designed for PSV testing DN 15 - 300 (NPS ½ - 12) according to common
international standards:
 Set pressure test of PSVs according to API 526 and ISO 4126-1
 Seat tightness test of PSVs according to API 527
 Vacuum & air test and seat leakage test of breather valves according to API 2000
Due to modern engineering solutions our equipment meets the requirements of the following standards:
 API RP 576
 ASME BPVC Section VIII
 ASME PTC 25
Mobile workshop provides the procedure of verification, testing and repair of safety valves according
to API RP 576. Moreover, mobile workshop allows:
 to save time of valve revision, testing and repair due to close proximity to the valve place of
operation
 to save costs on the valve service due to less equipment downtime and involve fewer staff for
operations
Item Name Quantity

Mobile container 10 ft. certified with DNV 2.7-1
1 1 ea.
Contains all necessary equipment for PSV testing
Clamping system PKTBA-S-1-300/40-PSV
2 Designed for testing of pressure safety valves with DN 15 - 300 (NPS 1 ea.
1/2 - 12) with clamping force 40 tones
Control station PKTBA-PGS-103-B-M
3 Provides control of the clamping system, test medium supply and 1 ea.
accurate parameters readings
Computer registration system PKTBA-CRS-M-A-40
4 Designed for on-line recording of the testing parameters and test reports 1 ea.
creating
PSV assembling and disassembling workstation PKTBA-RMR-PSV
5 Provides an opportunity of convenient valves visual inspection and 1 ea.
assembling/disassembling for further service
Portable machine for grinding and lapping PKTBA-PUR-KP-150
6 Designed for grinding and lapping of flat sealing surfaces of the housing 1 ea.
and wedges of the safety valves within the range DN 8 – 150 mm
Annex
The mobile workshop general layout 1 ea.
A
Technical specification
No. 2222 dated 12-Dec-2018 2
1. Mobile container 10 ft. certified with DNV 2.7-1
Mobile sea container 10 ft. with gates is designed to perform PSV

testing. Container is ready to use and includes:
 electric wiring
1 Description  LED lighting system
 split air conditioning system
 input for HP and LP air supply
 fire extinguisher
The mobile workshop general view
The offshore container is certified according to DNV 2.7-1 / EN 12079

with set of certified 4-leg slings. The offshore container is designed for
2 Certification
permanently installed equipment, handled in open seas, to, from or
between fixed and/or floating installations and ships.
No. 2222 dated 12-Dec-2018 3
Mobile workshop is equipped with jib crane with lifting capacity 0,5
ton installed on the wall of container and designed for quick tested
valve mounting on the clamping system (the crane lifting capacity
could be increased up to 1 ton up to request)
3 Lifting mechanism
All electric cables are mounted in cable ducts according to electric

4 Electric wiring
safety requirements
LED lighting provides less power consumption and longer service life
5 LED lighting system than incandescent lamps
Split air conditioning Included. Serves for creation of comfortable operating temperature
6
system inside the container
All test medium required for stable operation should be supplied to the
Input for HP and LP air test system via special socket placed in the container’s wall. That
7
supply solution allows to save space inside the container and exclude noise
level more than 40 dB
8 External dimensions, mm 2991 x 2438 x 2591
Required electrical
9 1 phase 230 V, 50 Hz
supply
10 Required air supply Not less than 500 bar
Options available up on request
Usually mobile workshops are placed under a shelter or inside a

1 Thermal insulation premises. In this case air conditioning system provides comfortable
operating conditions inside the container. If there is no possibility to
place the container under the shelter Revalve strongly recommends
No. 2222 dated 12-Dec-2018 4
provide it with thermal insulation because air conditioning system is

not effective when walls and roof plate heating under influence of
direct sunlight.
No. 2222 dated 12-Dec-2018 5
2. Clamping system PKTBA-S-1-300/40-PSV

1 Name Clamping system PKTBA-S-1-300/40-PSV
General view of vertical clamping system
Clamping system is designed for gas testing of pressure safety valves

2 Purpose DN 15 – 300 (NPS ½ – 12) according to common international
standards.
Clamping system is a vertical test unit designed for fast mounting,

clamping and testing of pressure safety valves.
3 Unit description and
special features To fix the tested valve on the unit operator should turn the control
handle for simultaneous moving of three claws towards to the valve
body.
No. 2222 dated 12-Dec-2018 6
For fast and easy clamping and sealing of the

tested valve, the system is equipped with
hydraulic cylinder that is operated from control
station or by using foot pedal, located directly
besides the bench
Multi-table installed on the hydraulic cylinder rod allows to test most
of standards pressure safety valves with RF & RTJ types of flange.
Sealing is performed at the flange flat surfaces using rubber O-rings.
Clamping system has enlarged inner bore of pipes (20mm) and high
pressure hoses to increase air amount released during PSV opening
for accurate set point determination and smooth disc reseating without
any damage to sealing surfaces.
Special coating and elements of stainless steel are used to provide
stable operation both in moderate and tropical types of climate.
4 Flanged PSV DN 15 – 300 mm (1/2 – 12'') with RF and RTJ type of

Types of tested valves
connection (as per ASME B16.5)
Set of sealing adapter consists of:

5 Sealing adapters Multi-table with O-rings for the face sealing of flanged safety valves
DN 15 – 300 mm (1/2 – 12”) suitable for RF and RTJ. Adapters are
suitable for both: high and low pressure testing.
No. 2222 dated 12-Dec-2018 7
Rubber adapters DN 25 – 250 (1 – 10'') and aluminum DN 15, 300 –

400 (12 – 16'') for flanged outlets for seat leakage test with quick-
release couplings for an air/water pipe connection to the leakage
bubblers for seat leakage test.
Special adapters for threaded safety valves could be included in the

scope of supply up on request.
No. 2222 dated 12-Dec-2018 8
Maximum test pressure depending on the tested valve size:

Valve inlet size Maximum pressure
NPS DN, mm Bar
½“ 15 500
¾“ 20 500
1” 25 500
1 ¼” 32 500
1½“ 40 500
6 Maximum test pressure 2” 50 500
2 ½'' 65 500
3'' 80 500
4'' 100 405
5” 125 250
6'' 150 190
8'' 200 105
10'' 250 70
12” 300 45
7 Test medium Compressed air
8 Valve clamping type Vertical by clamping of inlet flange with three zinc coated claws
9 Maximum clamping
40
force, tones
10 Maximum diameter of 480*

the clamped flange, mm *Please check with your flange dimensions
11 Maximum thickness of 115*

the clamped flange, mm *Please check with your flange dimensions
13 Dimensions (LxWxH),
900 x 850 x 850
mm, not exceeding
14 Weight, kg, not

600
exceeding
No. 2222 dated 12-Dec-2018 9
3. Control station PKTBA-PGS-103-B-M

1 Name Control station PKTBA-PGS-103-B-M
General view of control station
The station is designed for test and control medium high pressure
creating, as well as for test process control during clamping unit
operation.
The control units are placed on the front panel of the station. The slots
for control pressure gauges are placed on the top of the station that
might be used for calibration of installed test gauges. Control of the
clamping unit is performed from control panel of the station and control
2 Station purpose pedal.
The control station has module construction and equipped with the
following systems:
High pressure hydraulic clamping control system.
Mandatory system providing comfortable and quick operation of the
clamping unit. Clamping with pressure up to 250 bar is provided by oil
tank included in the control station. Working medium - oil from the
control station tank.
No. 2222 dated 12-Dec-2018 10
Pneumatic PSV test system up to 500 Bar

The system is specially designed for
smooth testing by air and precise
adjusting of PSV (according to API
526/527). System operation requires
external compressed air source with
maximum pressure not less than 500 Bar.
Optional high-pressure compressor can
feed the system.
The system is equipped with additional test
vessel with for increasing of test line
volume. Additional test medium volume
provides dynamic spool lifting and precise
determination of PSV set point, test line
residual pressure, helps in accurate re-
seating point determination, saving PSV
sealing surfaces from damages while re-
seating.
Equipment complies with following standards:
ISO 4126 -1, API RP 576, ASME BPVC
Section Vlll, which establish the requirements for the accuracy of the
safety valves setting, and the ASME PTC 25-2014 standard, which
regulates the speed of the pressure gaining when 90% of the set
pressure is reached.
Outlet hose for this system has enlarged inner bore (20mm). This
hose is connected directly to the PSV clamping unit and serves both
for water and air testing.
Hydraulic clamp: 1 x 400 Bar; Ø 100/150 mm, accuracy class 1,0%

3 Measuring devices and of F.S., liquid-filled, double scale bar/psi
features
Digital pressure gauges with peak hold function , accuracy class 0,2
4 Test process control Manual – using the control units at the main panel of the station
5 Hydraulic clamping: up to 300 bar

Test pressure range
Pneumatic testing of PSV with smooth adjustment: up to 500 Bar
6 Included. Prevents valve unclamping while being under the pressure

Safety interlock system
above 3 bar
7 Dimensions (LxWxH),
1200 х 800 х 1700
mm, not exceeding
8 Weight, kg, not

425
exceeding
No. 2222 dated 12-Dec-2018 11
To increase safety and comfort level the station could be equipped

with rigid safety fence made of protective transparent 10mm thick
material. Especially required if the clamping unit is located near the
control station and the operator could be affected by splashes during
the pressure testing.
1 Safety fence
No. 2222 dated 12-Dec-2018 12
4. Computer registration system PKTBA-CRS-M-A-40

1 Name Computer registration system PKTBA-CRS-M-A-40
CRS-M general view on the base of the laptop
The unit allows:

 to record the results of PSV testing, to store the results in the form
of protocols at internal memory or company server
 to measure leakages through the valve gate
2 Purpose of the unit  to control test medium pressure during pneumatic and hydraulic
tests with error no more than 0,6%
 to measure temperature of test medium and ambient air during
pneumatic and hydraulic tests
 to register “pop” pressure and set pressure of PSV
Computer registration system arrangement includes industrial semi

rugged laptop with water resistant mechanical membrane keyboard
and high definition display, that allows to reduce the sunlight's
3 Unit description reflectivity and provides an effective contrast ratio seven times better
than other displays. Moreover, industrial application provides more
special features than commercial one such us possibility to operate in
demanding environments with temperature, shock and vibration
concern
1 digital gauge x 600 bar, 0.2% F.S. with peak hold function.
4 Test pressure Digital calibration gauge from Control station with connection to CRS
measuring transducers feature providing fine readings with subsequent test report generation.
CRS shall be equipped with 40 or 60 Bar sensors to meet strict
No. 2222 dated 12-Dec-2018 13
requirements of API/ISO standards and codes with regard to set

pressure determination accuracy of ±3% out of set pressure in case
of PSV Set pressure below 30 bar.
Important note: additional pressure sensors of different nominal
could be supplied upon request
The range of test
medium leakage flow
5 From 0 up to 11,0 cm3/min - when tested with air
measurement (through
the valve gate)
Ingress Protection
6 IP 40
Marking, not less
7
Dimensions, mm 450 х 340 х 180 - of the laptop
(LxWxH), not exceeding 160 х 260 х 260 - of the control unit
Automatically generated final report could be printed by workshop

printer via Wi-Fi. The report includes the following lines and could be
customized complying with required international codes and internal
procedures:
 Manufacturer
 Company name
 Report №
 Testing Date
 Installation
8 Example of test report site/location
 Valve type
 DN / PN
 Test medium, time
 Leakage
 Results and others

1 Swivel bracket Swivel bracket for the laptop wall mounting
No. 2222 dated 12-Dec-2018 14
To increase final test measured results during low

pressure PSVs testing, when strict accuracy is required,
the registration system could be equipped with
Additional pressure additional high-accuracy 0,25% F.S. pressure sensors
2 to be connected to the control station.
sensors
The following sensors with different nominals could be
provided: 10 bar, 25 bar, 60 bar, 160 bar, 250 bar.
No. 2222 dated 12-Dec-2018 15
5. PSV assembling and disassembling workstation PKTBA-RMR-PSV

1 Name PSV assembling and disassembling workstation PKTBA-RMR-PSV
General view of PKTBA-RMR-PSV
Workbench with two drawer units and vice

2 Workstation Stand for valve assembling / disassembling with lathe chuck
arrangement Set of tools and accessories necessary for valve disassembling /
assembling
Maximum face-to-face
3 length of the assembled
700
/ disassembled valves,
mm
Disassembled and
4 assembled valves 200
nominal pressure, bar
5 Dimensions (LxWxH), 1120 x 1500 x 777 – the workbench

mm 600 x 500 x 440 – the stand
6 305 – the workbench

Weight, kg
196 – the stand
No. 2222 dated 12-Dec-2018 16
6. Portable machine for grinding and lapping PKTBA-PUR-KP-150
1 Name Portable machine for grinding and lapping PKTBA-PUR-KP-150
General view of portable grinding and lapping machine
2 Machine is designed for grinding and lapping flat sealing surfaces of

Unit purpose
the PSV with DN 8 – 150 mm.
Tail spindle assembled with electric actuator serves to transfer torque

3 Equipment and its from actuator to disc or lap during processing. The machine with
components description electric drive is controlled with buttons and switches according to the
documentation for the drill.
4 Processed valves
8 – 150
nominal diameter, mm
Maximum depth of item

5 submerging into valve 260
body, mm
6 Compressed air
working pressure, bar 6,3 ± 0,5
7 Weight, kg, up to 42
No. 2222 dated 12-Dec-2018 17
Annex A. The mobile workshop general layout
No. 2222 dated 12-Dec-2018 18
GENERAL REQUIREMENTS
The equipment complies with European union technical regulation

“On safety of machines and equipment” Directive 2006/42 CE.
1 Safety
The equipment complies with European union technical regulation
“On safety of low voltage equipment” Directive 2014/35 CE.
The warranty period of equipment - 12 months from the date of

commissioning or 18 months from the date of dispatch whatever is
2 Reliability earlier.
The total period of operation, taking into account proper service and
the replacement of worn units - at least 8 years.
Informative aluminum tag-plates on English / Russian language for
3 Language easy identification of components and items.
Temperature: +5-50 °C
Humidity (at + 25ºC): 30-90% (non condensing).
Indoor use under the following conditions:
 work site should be equipped with a ventilation system;
 height above the mean sea level – not exceeding 1000 m;
4 Operating conditions  no shock allowed.

 the use in conditions of the explosive and electric current conducting
mediums or mediums, containing caustic vapors and gases, is not
allowed.
Important note: Test complex includes 2-year service spare parts &
consumables for long and safe operation with less unplanned
maintenance downtime.
DOCUMENTATION
Passport / Technical certificate

(including test and calibration certificates for all installed test pressure
1 Each unit gauges and sensors)
Operation / Maintenance Manuals
CE Declaration
2 Complex Passport (Quality certificate) complying with EN 10204:2004.
Attention! Dimensions are provided for the reference and could be a subject for amendment during
the design phase without changes in the complex performance parameters.
Attention! This is a preliminary version. The set of equipment or it's specification can be altered
upon request to meet customer's requirements.
No. 2222 dated 12-Dec-2018 19
Spare parts, consumables, additional services:

1. Set of spare parts and consumables for 2 years of operation.
Set of spare parts includes all necessary consumables for two years of normal operation of the equipment.
Spare parts kit is included to the scope of supply and will be supplied along with equipment.
2. Factory acceptance, testing and supervision during installation and start-up. Training on
customer site. Warranty and after sales service.
In accordance with internal QMS system (certified and based on ISO 9001-2015 requirements), our
Quality Department will provide FAT program and corresponding agenda upon customer's request for
participation in factory acceptance testing of the manufactured equipment before it's dispatch.
All the equipment stated above is certified in accordance with EN 60204-1, EN ISO12100:2010, EN
2006/42/EC, EN 2004/108/EC, EN 2014/35/EC requirements, supplied with the EU Declaration of
Conformity and has the CE Marking.
Upon request, qualified and experienced engineers of REVALVE can perform control over the installation
and commissioning of the equipment.
Installation period should begin only after receiving the following confirmation:
 All the equipment is received at the installation site;
 All the installation requirements (procedures, equipment, accessories, qualified personnel etc.) are
fulfilled (the list of requirements will be prepared in advance by REVALVE service team).
Under request, our qualified engineers can:
 Supervise the installation of the equipment and its launch;
 Perform the final preparation of the equipment assisting customer personnel.
Personnel training on customer's site:
We assign the utmost value to appropriate customer personnel user-training to ensure safe and efficient
running and maintenance of the equipment. We consider that personnel user-training is sufficiently
required, especially in cases where the personnel have no experience operating our precise equipment.
The proper study of equipment design features, safe operation requirements and maintenance methods
increases the performance of the equipment, and prolongs its service life.
Training can be conducted both in Russian and in English languages.
The expected time period required for start-up supervision, commissioning and training will be determined
in a due time upon request.
Warranty and after sales service.
REVALVE provides 18-month warranty after the equipment dispatch and 12-month warranty after the
launch date of the equipment at customer site or 18 months since the date of dispatch. The assumed
service life of our equipment is 8 years, at least.
REVALVE is a customer-centric company and our assistance policy is based on a long-term partnership
with our customers.
We have a full-cycle in-house manufacturing:
 Designing.
 Raw materials preparation treatment;
 All types of machining procedures using high-duty CNC centers (our production facilities;
No. 2222 dated 12-Dec-2018 20
 account more than 200 machining units);

 Spare parts supplied by the approved world-famous manufacturers;
 Full-cycle paint coating;
 Assembling and testing of manufactured equipment with load 1,5 times exceeding nominal;
 Installation and start-up supervision;
 Comprehensive user-training.
Our customer-centric approach to the support policy ensures a due time spare parts supply and support
through all service life of the products.
No. 2222 dated 12-Dec-2018 21

Mobile Workshop Tests PSV Valves

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TECHNICAL SPECIFICATION

Mobile workshop for PSV testing

P.O. 440060 Russian Federation, Penza, Prospect Pobedy, 75

Item Name Quantity

1. Mobile container 10 ft. certified with DNV 2.7-1

Mobile sea container 10 ft. with gates is designed to perform PSV

The mobile workshop general view

The offshore container is certified according to DNV 2.7-1 / EN 12079

All electric cables are mounted in cable ducts according to electric

8 External dimensions, mm 2991 x 2438 x 2591

10 Required air supply Not less than 500 bar

Options available up on request

Usually mobile workshops are placed under a shelter or inside a

provide it with thermal insulation because air conditioning system is

2. Clamping system PKTBA-S-1-300/40-PSV

General view of vertical clamping system

Clamping system is designed for gas testing of pressure safety valves

Clamping system is a vertical test unit designed for fast mounting,

For fast and easy clamping and sealing of the

4 Flanged PSV DN 15 – 300 mm (1/2 – 12'') with RF and RTJ type of

Set of sealing adapter consists of:

Rubber adapters DN 25 – 250 (1 – 10'') and aluminum DN 15, 300 –

Special adapters for threaded safety valves could be included in the

Maximum test pressure depending on the tested valve size:

10 Maximum diameter of 480*

11 Maximum thickness of 115*

14 Weight, kg, not

3. Control station PKTBA-PGS-103-B-M

General view of control station

Pneumatic PSV test system up to 500 Bar

Hydraulic clamp: 1 x 400 Bar; Ø 100/150 mm, accuracy class 1,0%

5 Hydraulic clamping: up to 300 bar

6 Included. Prevents valve unclamping while being under the pressure

8 Weight, kg, not

Options available up on request

To increase safety and comfort level the station could be equipped

4. Computer registration system PKTBA-CRS-M-A-40

CRS-M general view on the base of the laptop

The unit allows:

Computer registration system arrangement includes industrial semi

requirements of API/ISO standards and codes with regard to set

Automatically generated final report could be printed by workshop

Options available up on request

To increase final test measured results during low

5. PSV assembling and disassembling workstation PKTBA-RMR-PSV

General view of PKTBA-RMR-PSV

Workbench with two drawer units and vice

5 Dimensions (LxWxH), 1120 x 1500 x 777 – the workbench

6 305 – the workbench

6. Portable machine for grinding and lapping PKTBA-PUR-KP-150

1 Name Portable machine for grinding and lapping PKTBA-PUR-KP-150

General view of portable grinding and lapping machine

2 Machine is designed for grinding and lapping flat sealing surfaces of

Tail spindle assembled with electric actuator serves to transfer torque

Maximum depth of item

Annex A. The mobile workshop general layout

The equipment complies with European union technical regulation

The warranty period of equipment - 12 months from the date of

4 Operating conditions  no shock allowed.

Passport / Technical certificate

2 Complex Passport (Quality certificate) complying with EN 10204:2004.

Spare parts, consumables, additional services:

 account more than 200 machining units);