Buxton-IOM TEST PUMP S10G-M THRU S30G-M TestUnits IOM rvB1 2

INSTALLATION,OPERATIONS,
MAINTENANCE & TROUBLESHOOTING

INSTRUCTIONS MANUAL
FOR
S10G-M thru S30G-M

TEST UNITS
Buxton Interests, Inc. & Buxton Repair Center L.P.

9346 Telge Road, Houston, TX. 77095 USA, 281-855-4237 , Fax: 281-855-4287
www.buxtonint.com Email: sales@buxtonint.com
INSTALLATION INSTRUCTIONS
TEST UNIT
1. Caution – These test units are designed & manufactured to operate at a maximum (See
Chart) PSI/BAR W.P. and is equipped with a burst disc relief set @ (See Chart)
PSI/BAR. DO NOT EXCEED THAT PRESSURE.
HIGH PRESSURE TEST UNITS

Model Number Maximum Pressure Burst Disc Relief Set @
PSI/BAR Pressure/(Bar)
S10G-M 10,000/690 12,500/(862)
S15G-M 15,000/1034 17,500/(1207)
S20G-M 20,000/1380 22,500/(1551)
S30G-M 30,000/2070 32,500/(2241)
2. Introduction – It is necessary to verify the rated working pressure of all components

to be used during the test before beginning installation of the equipment. This is
very important to ensure the safety of operating personnel and the elimination of possible
property damage. Working pressure rating should be specified on all equipment. It is
usually found on the manufacturer’s nameplate. DO NOT use any piece of equipment if
you are unsure as to its’ rated working pressure (See Equipment Specification).
3. Setup Location – The equipment should be installed in a firm and level area with
adequate air and water supplies. There should be adequate lighting and sufficient
drainage for vented or leaking fluid. The location selected should be in an area that will
not interfere or interrupt other operations. Location should also be isolated enough that
malfunctions in the test equipment or equipment tested would not cause personal injury
or damage to other equipment. All equipment should be properly secured.
4. Installation Preparation – The equipment should be visually inspected for any physical
damage. Every item with physical damage should be replaced before proceeding with
any test. In high pressure testing all components must be in optimum working
condition to prevent accidents. The item numbers listed refer to the illustrations located
in the Operation Section.
A. Installation Check (ref. Flow Schematic pg 7)

** Remove Plugs From Pump Air Exhaust Ports/Outlets
1. Check that air lubricator (item 3) is full of SAE 10W lubricating oil.
2. Check that suction strainer (item 9) is clean.
3. Check that rupture disk (item 13) is installed and that opening is NOT
plugged.
4. Zero adjust the test pressure gauge (item 12).
Buxton Interests, Inc.

9346 Telge Road, Houston TX 77095, 281-855-4237, fax: 281-855-4287
e-mail: sales@buxtonint.com
SG-M Combo rvB.doc
5. Unit includes test pressure recorder; (optional and separately mounted)
a Check that a clean chart is installed.

b. Check that ink well is full and pen operates. If recorder requires ink
or pen is clogged, (See Maintenance Section).
c. Check that clock is wound by using key provided inside the recorder
enclosure.
d. Check that pen sets on “zero” indication. If adjustments are
required, (See Maintenance Section).
e. Connect 10 ft length high pressure hose from chart recorder to outlet.
B. Initial Hookup
1. Close all valves (items 4 & 11).
2. Connect water supply hose or pipe to customer water supply connection;
Note: For self-contained units that include a reservoir, either a lightweight
SAE 10W oil or water can be used for testing. Fill to approximately 8” from
the top.
3. Connect air supply hose or pipe to customer air supply connection;
(See Equipment Specifications).
C. Test Unit Start-Up

(Before Start-Up: Ensure plugs have been removed from Pump Air Exhaust Outlets)
1. Open test outlet valve and bleeder valve (items 11).
2. Plug high-pressure test connection .
3. Open air supply valve (item 4) ONLY on low-pressure pump (item 5).
4. Purge lines with water to remove air and then close bleeder valve (item 11).
5. When pressure reaches 3,000 psi, open-air supply valve (item 4) to high-
pressure pump (item 6 & 7).
6. Adjust air regulator (item 2) to stop pumps at desired test pressure.
a. Rotate the regulator adjustment handle:

(1) To increase pressure – rotate clockwise.
(2) To decrease pressure – rotate counterclockwise.
b. Read air regulator pressure gauge for pressure setting of the
regulator.
c. Set at required testing pressure.
7. Observe complete system for leaks.

8. Observe that chart recorder (separately mounted) is tracking the same pressure
as the test pressure gauge (item 12). If adjustments are required, (See
Maintenance Section).
9. Close air supply valves to Air Pump(s) (items 4).
10. Open Bleeder valve (item 11).
11. Repair any leaks. If leaks are in high pressure tubing connections,
(See Maintenance Section).

SG-M Combo rvB.doc
D. Test Hookup
1. Remove plug from high-pressure test connections.
2. Connect high-pressure test hose to high-pressure test connection.
(See Equipment Specifications)
3. Optional: Connect bleeder hose to bleeder line connection (item 11). Run
other end of hose to nearest drain and safely secure.
4. Open air supply valve (item 4) only to low-pressure pump (item 5).
5. Close bleeder valve (item 11).
6. Purge high-pressure test hose to remove air and close air supply valve
(item 4).
7. Connect test hose to inlet of equipment to be tested.
8. Use an auxiliary water supply line to fill up cavity of equipment to be tested.
9. Open-air supply valve (item 4) to low-pressure pump.
10. Purge entire test circuit to remove air then close air supply valve (item 4).
11. Plug cavity connection at auxiliary water fill up line.
12. System is now ready for test.
THE HIGH PRESSURE TEST UNIT IS USED FOR HIGH

PRESSURE – LOW FLOW. IT IS NOT A VOLUME PUMP
ASSEMBLY. USING IT TO FILL THE TEST CAVITY WILL
ONLY DELAY TESTING.

SG-M Combo rvB.doc
OPERATION INSTRUCTIONS
TEST UNIT
1. Introduction - High-pressure hydrostatic tests must be conducted with an approved test

procedure. The test procedures should be developed by your own company or a standard
accepted test procedures should specify, in detail, the test criteria such as: test pressure,
test duration, acceptable test results, and a blank data sheet to record the test results.
2. Description – The high pressure test unit assembly uses the air supply to power the air
motor of one low and one high pressure pump, item 5 is a double acting, 60:1 ratio pump,
items 6 & 7 are a bi-directional 140:1 ratio pump. The supplied air pressure passes
through a lubricator (item 3) and is impregnated with 10W oil. The air supply is then
routed through an air pressure-relieving regulator equipped with a pressure gauge (item
2). The regulator serves as the system’s test pressure controller. The air regulator
contains a diaphragm whose pressure side connects to the outlet port of the regulator so
that, as pressure increases, the diaphragm compresses the adjusted spring and the load
from the regulated pressure. The load exerted by the adjusting spring controls the valve
position to maintain the desired regulated pressure.
The air supply valve (item 4) starts up the low-pressure pump and pulls the water supply
through a strainer (item 9) located in the low pressure pump suction line. This fluid
suction line enters the fluid end of the low-pressure pump. The flow in the air supply line
to the high-pressure pump is controlled by the opening of the air supply valve (item 4).
When the air supply valve is opened to start up the high-pressure pump, the fluid end
pressurizes the fluid discharged from the low-pressure pump. Both the upstream and
discharge lines of the high-pressure pump contain check valves (item 10) to prevent
backflow of the high-pressure fluid. When the backpressure fluid force discharged by the
pumps equals the regulated air pressure force in the high-pressure air motor, the pumps
will stall out.
The pump discharge line is directed through the isolator valve (item 11) and controls the
high-pressure flow through the high-pressure test connection to the equipment being
tested. An additional vent or bleeder line is provided with a bleeder valve (item 11) to
control the release of the system fluid and pressure. A rupture disk (item 13) serves to
protect the test unit assembly against over pressurizing. The rupture pressure of this disc
will vary according to the rated working pressure of the test unit.
The pressure in the test line is monitored through a tubed connection to a test pressure
gauge (item 12). Units equipped with a test pressure recorder connect to the tubing cross
for indication of test pressures on the recording chart.

SG-M Combo rvB.doc
Special - Self-contained test units include a reservoir for storage of the operational fluid.
They also contain a special circuit for open and close operation of the preventer or valve
being tested. The circuit consists of a four-way control valve, strainer, 6,000-psi gauge,
and a 3,500-relief valve.
NOTE: Preventer and valves that have been tested with water should be purged
with oil after testing.
** Ensure plugs have been removed from Pump Air Exhaust Outlet Ports.
TYPICAL TEST START-UP*

1. Open the air supply valve (item 4) to the low pressure pump (item 5).
2. When test pressure reaches 3,000 psi, open the air supply valve (item 4) to
the high pressure pump (items 6 & 7).
3. The test unit should automatically stall out at the required test pressure as
set in the Installation Section. If not, adjust the air regulator (item 2) to
desired test pressure.
4. After pressure stabilizes, close the air supply valves (items 4) and test
outlet valve (item 11).
TEST IS NOW IN PROGRESS

1. Follow specified duration of this hydrostatic test as stated in the applicable
test procedure.
2. Observe the test pressure gauge (item 12), or recorder chart, if so
equipped, for any pressure losses. If there is a constant drop in pressure,
there is a leak in the test circuit.
TEST SHUT-DOWN**
1. Carefully open bleeder valve (item 11).
2. Carefully open the test outlet valve (item 11)
3. When test pressure reaches “zero”, disconnect all interconnecting hoses.
• All phases of installation must be completed before beginning any test.

• All equipment tested with water should be purged with oil after testing is
complete.

SG-M Combo rvB.doc
TYPICAL FLOW SCHEMATIC – HIGH PRESSURE TEST UNITS WITH
OPTIONAL RECORDER

SG-M Combo rvB.doc
MAINTENANCE INSTRUCTIONS
TEST UNIT
1. Introduction – All maintenance and troubleshooting to be performed on the test unit

components should be done while the test unit is removed from service. Routine
maintenance of the equipment can prolong the service life and ensure optimum
operational performance. Maintenance should be performed on the equipment
immediately after conclusion of functional operations so that equipment will be ready for
the next test. No special tools are required to work on the test unit. To ensure safety of
maintenance personnel, workmen should work in pairs so a backup is near in case of
emergency. All high-pressure hose lines should be double-checked that pressures have
been relieved before attempting maintenance.
2. Maintenance Instructions – The following instructions are categorized by component

maintenance. The item numbers refer to the illustrations located in the Operation
Section.
A. Air Lubricator (Item 3)
1. Open the petcock of the lubricator to drain moisture that may have
accumulated.
2. Fill with SAE 10W lubricating oil.
3. Check that drip setting is six (6) drops per minute (See Troubleshooting
Section).
B. Strainer (Item 9)
1. On a regular basis remove strainer element and wash with warm water or
kerosene.
C. Gauge (Item 12)

1. Use “zero adjustment” screw to reset needle to zero setting.
D. Air Regulator with Gauge (Item 2)

1. Vary the regulator pressure setting to eliminate permanent “seating wear” to
the shear seals.
2. Apply 10W oil to the regulator adjustment screw.
3. Use “zero adjustment” screw to reset gauge needle to zero setting.
4. Unscrew the bottom plug of regulator, remove the enclosed strainer screen,
clean and replace.
E. Pumps (Item 5), (Items 6 & 7)

1. Low-pressure pumps – The pump packing is spring loaded to provide
automatic adjustment. No maintenance is required.
2. High-pressure pump – Periodic adjustment of the packing may be required.
Tighten only when pump is running and tighten enough to lubricate rod, but
not tight enough to burn up the packing.

SG-M Combo rvB.doc
F. Rupture Disc (Item 13)
1. Remove and inspect for damage. Replace if necessary.
2. Do not operate test unit without rupture disc installed. Do not plug
opening. Always keep spare rupture discs on hand. (item 13)
G. High Pressure Fittings

1. Use a torque wrench when tightening gland nuts on high-pressure fittings and
valves to stop leaks.
2. Over tightening may cause seat damage. Torque requirements are:
a. Valve stem glands – 85 ft – lbs.
b. Tubing connection glands – 55 ft – lbs.
H. Recorder (separately mounted)

1. Pen
a. Press forefinger over end of pen box to start ink flow through pen.
This should cause pressure to build up and ink to flow through
capillary.
2. Clogged Pen
a. Pull pen box off of pen arm and soak in water or alcohol.
b. Insert a cleaner wire up the capillary hole and into the box reservoir.
c. Reinstall the pen box by pushing pen all the way on the pen arm
until the top of the pen arm touches the capillary.
3. Adjusting Time Line Tracking
a. Remove the connecting link from its bearing point by rotating the
retainer clip on the end of the connecting link to allow the bearing
pin to slip out of its bearing hole on the calibration arm.
b. Position the pen arm so that the pen rests on the fine line near the
center of the chart. If it:
(1) Follows the time line, the pen arc is correct.
(2) Goes above the time arc, the pen arc is too short.
(3) Goes below the time arc, the pen arc is too long.
c. Loosen the clamp screw at the upper end of the pen arm and adjust
the length.
d. Tighten the clamp screws and reconnect the link to the calibration
arm.
I. Reservoir (if so equipped)
The fluid reservoir should be check regularly, drained, and cleaned. Fill to
approximately 8” from the top with a lightweight SAE 10W oil or water. “Never use
fuel oil, kerosene, or salt water in the reservoir.”

SG-M Combo rvB.doc
TROUBLESHOOTING INSTRUCTIONS
TEST UNIT
1. Introduction – The troubleshooting section provides a guide in locating and remedying

operational problems by identifying the problem or symptom. All troubleshooting should
be done by experienced personnel so as to eliminate possible personal or property
damage. All maintenance and troubleshooting to be performed on the test unit
components should be done while the test unit is removed from service. To ensure safety
of maintenance personnel, workmen should work in pairs so a backup is near in case of
an emergency. All high-pressure hose lines should be double-checked that pressures
have been relieved before attempting maintenance.
2. Troubleshooting
Problem 1:
Erratic Pump Operation
Possible Cause:
No oil in air lubricator
Remedy:
a. Cut off air supply to test unit.
b. Open petcock at bottom of air lubricator.
c. Drain off any moisture or emulsified oil.
d. Unscrew fill cap and refill with 10W motor oil.
Caution: DO NOT USE SYNTHETIC OR AROMATIC TYPE OIL.
e. Turn on air supply to test unit.
Problem 2:
Excessive Oil in pump air exhaust
Possible Cause:
Air lubricator out of adjustment
Remedy:
a. Open test outlet valve.
b. Open-air supply valve.
c. Open lubricator fill cap.
d. Use a thin screwdriver to adjust lubricator to flow six drops of oil(max.) per minute.
(1) Clockwise rotation increases flow.
(2) Counterclockwise rotation decreases flow.
e. Close lubricator fill cap.
f. Close air supply valve.
g. Close test inlet valve.

SG-M Combo rvB.doc
Problem 3:
No or Slow Pressure build up
Possible Cause:
Low Air Supply pressure
Remedy:
a. Check air compressor for volume and pressure output specifications (See Installation
Data Sheet).
b. Check and correct operational problems with air compressor.
Possible Cause:
Insufficient water supply
Remedy:
a. Check that water supply is connected and turned on.
b. Check for low water pressure and/or leaks in connecting lines.
Possible Cause:
High pressure fitting (s) leak
Remedy:
a. Identify leak & depressurize unit.
b. Only use a torque wrench when tightening gland nuts on high
pressure fittings and valves. Over torqueing can cause seat damage
and hair-line cracks which will break at high pressure.
c. Torque valve stem glands to 85 ft./lbs.
d. Torque connection glands to 55 ft./lbs.
Possible Cause:
Faulty ball check in fluid end of low pressure pump
Remedy:
a. Shut off air and water supply.
b. Open test outlet and bleeder valves.
c. Remove fluid end from low-pressure pump.
d. Disassemble fluid end and install repair kit.
e. Replace repaired fluid end.
Possible Cause:
Faulty in-line high-pressure check valve
Remedy:
c. Remove and replace faulty check valve.
d. For torque specifications (See Maintenance Section).

SG-M Combo rvB.doc
Possible Cause:
Bleeder valve leaking
Remedy:
c. Remove faulty bleeder valve.
d. Replace with new bleeder valve (See Maintenance Section for torque specifications).
Problem 4:
Recorder Pen not writing
Possible Cause:
No ink or pen clogged
Remedy:
a. Check to see if ink reservoir is filled with standard chart ink.
b. Press forefinger over end of pen box to start pen flow, if a clog
is indicated, remove pen box.
c. Soak box in alcohol or warm water.
d. Insert a small cleaner wire up the capillary hole and to the box
reservoir.
e. Rinse with warm water and reinstall by pushing pen all the way
on the pen arm until the top of the arm is touching the capillary.
Fill ink reservoir & start flow.
Problem 5:
Recorder Not Tracking Chart Properly
Possible cause:
Time line tracking out of adjustment
Remedy:
a. Remove connecting link from its bearing point by rotating the
retainer clip on the end of the connecting link. This allows the
bearing pin to slip out of its bearing hole on the calibration arm.
b. Position pen arm to rest pen on the fine line near the center of
the chart.
c. Rotate chart to determine arc.
d. If arc tracks above the time line, the pen arc is too short. Lengthen
pen arm.
e. If arc tracks below the time line, the pen arc is too long. Shorten
pen arm.
f. Loosen the clamp screws at the upper end of the pen arm and adjust length.
g. Tighten clamp screw and reconnect the link to the calibration arm.
h. Repeat if necessary.

SG-M Combo rvB.doc
BUXTON INTERESTS, INC.
S10G-M TEST UNIT
AND 15K CHART RECORDER
S10G-M TEST UNIT

Recommended Spare Parts List for 1 year usage
QTY PART NO. DESCRIPTION
1 3012-1199 Repair Kit, f/ 3012-1100 (7 3/8")
1 3022-0199 Repair Kit, Air Motor, 7 3/8"
1 3035-0299 Repair Kit, Fluid End, 140:1
2 1700-9210 Rupture Disc, 12,500 PSI
1 1523-5001 Needle Valve, 9/16"MP, 20K
1 1510-1100B Ball Valve, 1/2", 600 WOG
1 1670-0700 Check Valve, 9/16"MP, 20K
1 8132-0120 Adapter, 9/16" x 1/4"
1 811910 Hose Ass'y, 9/16" Swivel,10K, 50 ft.
SSR-15 CHART RECORDER

1 4230-0181 Charts, 0-15,000 PSI (100/Box)
1 4230-0110 Pens, red, package of 6
1 818916 Hose Ass'y, 1/4" MP X 9/16"MP,10 ft, 15K
Buxton Interests,Inc Buxton Repair Center L.P.

9346 Telge Rd. Houston, Texas 77095 USA, 281-855-4237, Fax: 281-855-4287,email: sales@buxtonint.com
www.buxtonint.com
S15G-M TEST UNIT
S15G-M TEST UNIT

1 3012-1199 Repair Kit, f/ 3012-1100 (7 3/8")
2 1700-9211 Rupture Disc, 17,500 PSI
1 1523-5001 Needle Valve, 9/16"MP, 20K
1 1510-1100B Ball Valve, 1/2", 600 WOG
1 1670-0700 Check Valve, 9/16"MP, 20K
1 8132-0120 Adapter, 9/16" x 1/4"

1 4230-0181 Charts, 0-15,000 PSI (100/Box)
1 818916 Hose, Recorder to Test Unit, 1/4" MP X 9/16"MP,10 ft, 15K

www.buxtonint.com
S20G-M TEST UNIT
S20G-M TEST UNIT

1 3012-1199 Repair Kit, f/ 3012-1100 (7 3/8")
2 1700-9212 Rupture Disc, 22,500 PSI
1 1523-5001 Needle Valve, 9/16"MP, 20K
1 1510-1100B Ball Valve, 1/2", 600 WOG
1 1670-0700 Check Valve, 9/16"MP, 20K
1 8132-0120 Adapter, 9/16" x 1/4"

1 4230-0181 Charts, 15K-30K (100/Box)
1 819261 Hose, Recorder toTest Unit, 1/4" HP X 9/16"MP,10 ft, 20K

www.buxtonint.com
S30G-M TEST UNIT
S30G-M TEST UNIT

1 3012-1199 Repair Kit, f/ 3012-1100 (7 3/8")
1 3023-0199 Repair Kit, Air Motor, 8-1/2"
2 1700-9213 Rupture Disc, 32,500 PSI
1 1524-5001 Needle Valve, 9/16"HP, 30K
1 1510-1100B Ball Valve, 1/2", 600 WOG
1 1670-0600 Check Valve, 9/16"HP, 30K

1 4230-0181 Charts, 15K-30K (100/Box)
1 819460 Hose, Recorder toTest Unit, 1/4" HP X 9/16"HP,10 ft, 30K

www.buxtonint.com

Buxton-IOM TEST PUMP S10G-M THRU S30G-M TestUnits IOM rvB1 2

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Buxton-IOM TEST PUMP S10G-M THRU S30G-M TestUnits IOM rvB1 2

Uploaded by

Copyright:

Available Formats

INSTALLATION,OPERATIONS,

MAINTENANCE & TROUBLESHOOTING

S10G-M thru S30G-M

Buxton Interests, Inc. & Buxton Repair Center L.P.

HIGH PRESSURE TEST UNITS

2. Introduction – It is necessary to verify the rated working pressure of all components

A. Installation Check (ref. Flow Schematic pg 7)

Buxton Interests, Inc.

a Check that a clean chart is installed.

C. Test Unit Start-Up

a. Rotate the regulator adjustment handle:

7. Observe complete system for leaks.

Buxton Interests, Inc.

THE HIGH PRESSURE TEST UNIT IS USED FOR HIGH

Buxton Interests, Inc.

1. Introduction - High-pressure hydrostatic tests must be conducted with an approved test

Buxton Interests, Inc.

TYPICAL TEST START-UP*

TEST IS NOW IN PROGRESS

• All phases of installation must be completed before beginning any test.

Buxton Interests, Inc.

Buxton Interests, Inc.

1. Introduction – All maintenance and troubleshooting to be performed on the test unit

2. Maintenance Instructions – The following instructions are categorized by component

C. Gauge (Item 12)

D. Air Regulator with Gauge (Item 2)

E. Pumps (Item 5), (Items 6 & 7)

Buxton Interests, Inc.

G. High Pressure Fittings

H. Recorder (separately mounted)

I. Reservoir (if so equipped)

Buxton Interests, Inc.

1. Introduction – The troubleshooting section provides a guide in locating and remedying

Buxton Interests, Inc.

Buxton Interests, Inc.

Buxton Interests, Inc.

S10G-M TEST UNIT

SSR-15 CHART RECORDER

Buxton Interests,Inc Buxton Repair Center L.P.

S15G-M TEST UNIT

SSR-15 CHART RECORDER

Buxton Interests,Inc Buxton Repair Center L.P.

S20G-M TEST UNIT

SSR-20 CHART RECORDER

Buxton Interests,Inc Buxton Repair Center L.P.

S30G-M TEST UNIT

SSR-30 CHART RECORDER

Buxton Interests,Inc Buxton Repair Center L.P.

You might also like