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» How to use the RYCO proof test rig – Machine Operation

In this second part of this series on impulse testing, we discuss how to use the proof test rig to safely test your hydraulic equipment set up.

Machine Operation

Connect the assembly

Prepare the connection.

Select an adaptor to suit your hose assembly and fit it to the rig.

RYCO Proof Test Rig - Connect the Hose

Ensure you’re not damaging any thread at this point.

Fit your hose assembly to the rig. Use two spanners to tighten the hex, so as to not damage any parts.

NOTE: When fitting an adaptor, it is vital that the connection is leak free. When the rig creates a high pressure, it does so with a minimal amount of fluid. A small leak will limit the amount of pressure that can be produced.

Purge the hose

Leave the other end of the hose uncapped.

RYCO Proof Test Rig - Vent Fluid Through Hose

Open up the High Pressure valve by turning anti-clockwise, and open up the pre-fill valve by turning it to the “‘on” position.

Allow the fluid to vent through the hose.

Cap the hose assembly

Elevating the hose will ensure that all of the air is purged from it.

RYCO Proof Test Rig - Elevate the Hose

Once all of the air has been evacuated through the hose, close the prefill valve, but leave the hose elevated.

Loosely fit a blanking plug or cap to the end of the hose.

Slightly open the prefill valve again to be sure that all air is exhausted.

Finally, tighten the plug or cap, and ensure it is positively sealed.

You may want to straighten the hose in preparation for the test.

Release the safety chain and close the door

Close the door, ensuring you’re standing well clear.

RYCO Proof Test Rig - Close the Door

Note: The door movement may be erratic and sudden movements may occur. If there are others in the vicinity, ensure that they are well clear also.

Close the High Pressure Valve

Close the High Pressure valve by turning it clockwise.

RYCO Proof Test Rig - Close HP Valve

NOTE: Take care not to over-crank the valve, or damage to the needle or sealing seat will occur.

Open the Air Valve

Next, open the Air Valve.

RYCO Proof Test Rig - Open Air Valve

IMPORTANT: Insure that the regulator is set to its minimum set pressure before opening this valve. (Ensure that it is fully wound back, and the gauge is as close as possible to zero).

Apply a low pressure to the hose

Slowly increase the pressure by winding the regulator clockwise.

RYCO Proof Test Rig - Apply Low Pressure

Pressure is displayed on the digital gauge.

Stop when the gauge displays around about 3Mpa, or 30 Bar. (Aproximately. 400 psi).

Check for leaks

Inspect the hose to ensure that there are no leaks.

RYCO Proof Test Rig - Check for Leaks

Apply the test pressure to the hose

Finally, wind the regulator clockwise until the required test pressure is reached.

Stabilize the test pressure

Once the test pressure is reached, back off the regulator to stop the pump.

RYCO Proof Test Rig - Stabilize test pressure

NOTE: Care must be exercised due to the time it takes to wind back the pressure on the regulator.

Check for leaks

Once the test pressure is set, back off the regulator fully to stop the pump.

RYCO Proof Test Rig - Look For Leaks

The pressure should stay constant. If the pressure drops, it is most likely due to leaks.

If there are leaks, locate them by observing the assembly through the windows.

DO NOT ATTEMPT TO LIFT THE DOOR WHILE THE ASSEMBLY IS PRESSURISED.

Wait

Normal test duration is between 30s and 60s.

RYCO Proof Test Rig - Wait for test to complete

Some hoses (e.g. TEFLON hose) use a different proof test pressure or duration.

Have a clear understanding of the required testing process before you begin.

Relieve the pressure

When the test is complete, relieve the pressure by opening the High Pressure valve. (Turn counter-clockwise).

RYCO Proof Test Rig - Relieve the Pressure

IMPORTANT: Check the pressure gauges have returned to zero before opening the door.

Remove the assembly from the rig

Remove the cap or plug from the loose end of the hydraulic hose.

Remove the hose assembly.

RYCO Proof Test Rig - Remove Hose Assembly

Gently clear the test fluid from the hydraulic hose by using compressed air.

Clean the inside of the hose with a foam pellet

Complete any relevant paperwork. Prepare the assembly for shipping.

Important Safety Tips

Remember that fluid pressure is extremely dangerous.

If used as per instructions, the pressure will be inside, with the people outside.

RYCO Proof Test Rig - Safety Warning

Do not under any circumstances try to override the pressure safety dump switch on the door.

Do not “Burst Test” any parts or assemblies in this rig.

Want more information?

Read part 1 of our information on using RYCO’s proof test rigs to understand the important safety procedures and the controls that are available on the test rig machine.

Make sure you select the right hydraulic hose for your next project. Download our 15 Keys To Selecting The Right Hose guide today.