HPTM DETAILS:

HPTM machine also called as Hydro pressure testing machine is used at LANCO Industries to test the pipes for its defects. It is used to ensure 100 percent quality check to the customer. The features and application of various components of HPTM are described as follows. The machine is mounted on a rigid base. It has two columns to which dies are attached. One is a fixed die and other is a moveable die. Fixed die:

It is made of steel. It has grooves in which O-Rings are placed which seal the sockets end of the pipe. When O Rings are worn-out due to usage they are replaced by new ones. In these machines die change does not take place on fixed die. Depending on die design it can allow variable sizes. The die has a central hole through main water supply to the pipe is connected.

O Ring

Machine column

Fixed die

Moveable die:

It is made of steel. The moveable die is operated hydraulically for movement and it seals the plug end of the pipe. It has a piston like arrangement which supports clamping pressure when internal pressure of pipe is increased. The moveable die can be detached from hydraulic arrangement which aids for movement of die. The die has to be changed for each diameter since the hole in the die depends on the diameter. The contact portion of die is attached with a Teflon plate for effective sealing. If die is worn-out Teflon plate is changed. Provision for chain Teflon plate

Machine column

Walking beam mechanism:

Walking beam mechanism is used to load pipes in between the dies. Walking beam is pneumatically powered and it contains provision to hold pipes. It takes pipes from upstream and feds into the machine and leaves them on downstream after test is completed. Hydraulic jack for die

A certain clamping force is applied against the open ends of the pipe is required to seal the ends when pipe is filled with water for hydrostatic testing. To apply clamping force a moveable die is used which is operated with a hydraulic jack. Low pressure pump:

A low pressure pump is used to fill the pipe with water. The pump is connected to inlet at head stock. The pipe is filled with water until internal pressure in the pipe equals atmospheric pressure. High pressure pump:

High pressure pump is used to increase the internal pressure of the pipe to test pressure. In large capacity machine a reciprocating pump is used to increase the pressure. In small capacity machines a hydraulic pressure accumulator is used to increase the pressure. Directional control valve:

Directional control valves are one of the most fundamental parts in hydraulic machinery they allow fluid flow into different paths from one or more sources. They usually consist of a spool inside a cylinder which is mechanically or electrically controlled. The movement of the spool restricts or permits the flow, thus it controls the fluid flow. Here it is used to control the direction of water from pump to the machine or to the sump. Non Return valve:

This valve is used to prevent flow of water to the low pressure pump when high pressure is applied and also to prevent flow to high pressure pump to low pressure pump is filling water into the pipe. Check valve: This valve is used to know whether low pressure pump has filled with water. It is used as an indication to operator to switch off the low pressure pump and increase the pressure to test pressure. During high pressure phase this valve is switched off. After the test to release the pressure the check valve is opened again.

Working procedure: The working of HPTM can be divided into 5 steps. These steps are explained using schematic diagram of the machine. STEP 1: Loading of the pipe: The pipe is loaded into the machine using pneumatically operated walking beam mechanism. Clamping pressure is applied on the pipe using hydraulically operated moveable die to hold the pipe.

H.P TANK

Directional Control valve No return valve M Aerated valve Pressure gauge

High pressure pump

LANCO

SUMP

Low pressure pump

STEP2: Filling water into the pipe: The check valve on the dies is opened. The direction control valve is switched on such that water from the low pressure pump is filled into the pipe.

H.P TANK

Directional Control valve No return valve M Aerated valve Pressure gauge

High pressure pump

LANCO

SUMP

Low pressure pump

STEP3: Closing the Low pressure pump: After the low pressure pump fills water into the pipe water from the check valve, The direction control valve is closed as an indication that pipe is filled and check valve is also closed for further procedure.

H.P TANK

Directional Control valve No return valve M Aerated valve Pressure gauge

High pressure pump

LANCO

SUMP

Low pressure pump

STEP4: Increasing the pressure: After water is filled in the pipe the directional valve from the High pressure pump is switched on such that internal pressure equalizes the test pressure. As test pressure is reached the directional valve is switched off. During increase of internal pressure water will

H.P TANK

Directional Control valve No return valve M Aerated valve Pressure gauge

High pressure pump

LANCO

SUMP

Low pressure pump

STEP5: Release the pressure: Leakages are observed for defects in the pipe. If any leakages are present they are marked. After a specified test time the pressure is release by opening the check valve. The moveable die is released of clamping pressure and pipe falls onto the walking beam. The tested pipe is transported to downstream and new pipe is loaded between the dies.

H.P TANK

Directional Control valve No return valve M Aerated valve Pressure gauge

High pressure pump

LANCO

SUMP

Low pressure pump