Safety valve

>
Test 2.0
E I N N OVATION
TH itu s
Testing in

>
> Testing carried out under operating conditions
> Testing at system pressure or unpressurised
> Testing of safety valves under additional stress
and their control boxes
> Time savings
> Cost reduction

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 Safety valves

>
N NOVAT ION
THE I situ
Testing of safety valves Testing in
in situ
under full operating conditions

By using our TÜV-approved testing systems for safety valves, To test the opening and closing point of spring-loaded
we can carry out valve testing under normal operating con- proportional or full-stroke safety valves in situ we use a
ditions and test the valve for its response pressure. specially developed procedure.

Advantages of the testing procedure

The basic physical principle
> Testing method can be used for all makes
> Testing and adjustment even under operating pressure p (bar) = F (N) / A (cm2)
> Testing method can be used for all nominal sizes (Pressure = Force/Surface Area)
> No need to remove/refit or transport the valve
> Test certificate for every valve tested
> Cost savings > The variable sought is p (opening pressure)
> TÜV-approved testing system > One of the measured variables during testing is F
(tension on valve spindle)
> The known valve-dependent parameter is A
Requirements (effective valve seat area)

> Pure fluids, e.g. steam, condensate, water, gas The additional metrics while the testing of the safey valves
> Clearance above valve spindle (approx. 500 mm) are the spindle stroke s (mm) and the operating pressure p2
> Power supply (230 V/50 Hz) (bar).

Safety valve with lifting device

ll common
We test a
lves!
safety va

Testing of safety valves in situ while in operation

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 Safety valve testing

Combination of individual components of computer-based testing system

ertified
System c
V
by RWTÜ

Testing rig Laptop Power-Box

> Hydraulic cylinder > Software > Control electronics
> Force sensor > Printer > Mobile hydraulics
> Vertical travel sensor > Hydraulic control system

ing
or increas
e m ov in g the valve is n ot
R ure
ting press tem!
the opera h e n u s in g this sys
e s s a ry w
nec
Advantages of the testing procedure

Safety valves are subject to regular testing according to

TDR 421, which must ascertain whether and at what
pressure the safety valve opens.

In the case of spring-loaded proportional or full-stroke

safety valves, a special procedure is employed in which the
missing differential pressure between operating pressure
and specified opening pressure is simulated by a tensile
force.

In contrast with normal testing methods, online testing

takes account of the spring characteristic in the test analysis.
Consequently, the significant opening point of the safety
valve can be precisely determined.

Modern measurement systems in combination with highly

qualified engineers ensure smooth operation of the tests.

The measured variables of tension F (N), spindle stroke s

(mm) and operating pressure p (bar) are recorded and
simultaneously processed by an IT system. For every valve
tested, the client is provided with full documentation of
the test results.

This method can be used with all purely spring-loaded proportional or

full-stroke safety valves regardless of nominal size and make

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 Safety valves under additional stress

>
Testing of safety valves under additional
stress and their control units

Audit log
By the use of a 6-channel chart recorder and specially
adapted testing software, the test graphs for the pressure
switches, the actuating force reserves and the characteristic
curve calculations are simultaneously registered
and recorded.

The testing of valves subject to additional stress, e.g.

superheater or drum valves with compressed-air retention
and lifting, is performed by means of a 6-channel chart
recorder and specially developed software. For testing the
setting points on the pressure switches, the system pressure
is simulated by means of a spindle press. This can be used
to test all control systems, e.g. Series 700, PC 50-53,
STE 4 and STE 5.

Advantages of the system

The control units are subject to annual testing, during

which the function of the control unit and the safety
valves is examined.

Vorteile des Verfahrens

> Testing and adjustment without system downtimes

> No need to remove/refit or transport the valve
> Test certificate for every stage of the test
> Documentation and servicing from a single provider

6-channel chart recorder with computer and printer Requirements

> Pre-testing points available

> Reduction of operating pressure by approx. 10%
may be required
> Power supply (230 V/50 Hz)

Spindle press with pressure sensors for testing

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 Safety valve testing

Control unit testing for any make

and nominal size

The measured variables of operating pressure, retention

air pressure, lifting air pressure and spindle travel can be
>
Advantages of the testing procedure

simultaneously recorded. Pressure switch, actuating force > Testing and documentation can be carried out in the presence of the TÜV
reserve, action, valve and opening point measurements > Best performance
can be performed. > Rapid response times when called out

If damage to pressure switches, solenoid valves, hose

connections or ring seals on the lifting pistons is identified,
Makes and models
TESmT INGsed makes
we can arrange repairs in consultation with the client. > Series 700 monly u
All co
> PC 50 and PC 53
> STE 4 and STE 5

Testable Series 700 control unit

Testable STE 4 and STE 5 control unit

Testable PC 50 and PC 53 control unit

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 Sequence of a safety valve test

Summary of how a safety valve test functions

> Removal of valve cap Standard chart

> Selection of suitable clamping device
> Preparation of pressure connection
> Set-up of central unit/data input
> Entry of valve parameters
> Assembly of tension rig on valve
> Checking of valve and sensor data
> Start of automatic test sequence
> Start of results analysis
> Adjustment of safety valve opening point to specified setting

With hydraulic line and data cable lengths of up to 50

Force, lift and system pressure are recorded during the testing sequence
metres, testing can be carried over a wide radius with
short apparatus transfer and set-up times.
Spring characteristic
A tension rig is installed after removing the valve cap.
Sensors measure the tension directly on the spindle, the
valve spindle travel and the operating pressure present.

The force at the graph transition point determined during

the subsequent tension test is applied by reference to
PRESSURE = FORCE/SURFACE AREA. The missing surface
area variable is a given value which is calculated from
the safety valve specifications.

The force/travel diagram enables definite identification of the response point.

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 Our services
Competence, quality of service and availability
Valve servicing
We take over the inspection planning, maintenance and
repair of your valves as well as the manufacturing of any
necessary parts. With our mobile workshop equipment, we
guarantee cost-effective performance of all work with no
delay.
We thoroughly document our work and test results to offer
the highest possible level of transparency. As the life spans
of power plant and industry systems lengthen, operation-
related wear and the failure of components and installations
increase, making maintenance work essential.
We are happy to take over this responsibility for you, from
inspection management to all necessary maintenance work.
The use of mobile processing technology on site makes it
possible to perform almost any type of operation on valve
components and the materials commonly used in valve
construction.
Repair of complex valves of all makes
> HP bypass stations
> Intermediate superheater safety valves
> MP/LP bypass stations
> Control valves
> Safety valves
> High pressure gate valves
> High pressure non-return valves
> Low pressure gate valves
> Low pressure non-return valves
> Butterfly valves (soft seal/metallic seal)
> Pilot valves
> Minimum flow valves
> Automatic recirculation valves
> Shut-off valves
> Special valves subject
to consultation
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>
Repairs and spare parts
Our customers do not expect just any solution from us;
they want exactly the right one for them. The thorough and
competent aas experts approach every new task with an eye
for perfection, delivering concepts and products that are
technically implementable and cost-optimised.
Repairs in site workshop
> Inspection and assessment, damage analysis and
recalculation
> Non-destructive material testing
> Determination of extent and cost of repairs
> Documentation of damage pattern
> Design evaluation/coordination discussions
> Performance of repair measures after approval by
the client
> Production of repair drawings/welding plans
> Production of pre-testing documents for repairs
> Welding supervision
> Quality monitoring
> Final testing by the quality department
> Documentation
Reverse engineering
The aas spare parts service manufactures replacement parts
for valves of all makes. Reverse engineering allows us to
rapidly and expertly manufacture high-quality valve com-
ponents. Spare parts can be replicated at short notice.
We need only a sample or the original dimensions to repli-
cate quality components.
Convincing customer benefits
> Short delivery times
> Spares for genuine manufacturer parts that are no
longer available
> Longer service life due to design improvements
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 Expertise engenders trust

Whether you are a new customer or a long-standing part- Our long customer list includes many established
ner, whether your order is large or small: we do everything companies and global players in the following industries:
to satisfy your needs. Quality, compliance with timeline
and reliability characterise all of our work. Every company > Industrial enterprises
has its own interests and strategies that differentiate it > IOperators of municipal facilities
from others. We view every job as an opportunity for deve- > IEnergy providers
loping individualised concepts and solutions to support > IPlant manufacturers
our customers. > IChemicals/petrochemicals

ions
Certific90a0t1
DIN ISO
001
DIN ISO 14
SCC **
WHG
KTA 1401 007
S 18001:2
BS OHSA

We think
in solutions
aas GmbH aas GmbH
Head Office Central Region Sales
Mercatorstr. 36a Krotzenburger Str. 21
46485 Wesel 63796 Kahl am Main
Germany Germany
Phone +49 (0)281 206980 0 Phone +49 (0)6188 9142 770
Fax +49 (0)281 206980 29 +49 (0)6188 9142 771
info@aasgmbh.de Fax +49 (0)6188 9142 772
www.aasgmbh.de

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