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.

How to use the RYCO proof test rig – Safety & Controls

How to use the RYCO proof test rig – Safety & Controls

In this first part of this series on impulse testing, we discuss the importance of safety procedures and the controls that are available on the RYCO proof test rig.

Supporting Documents for the RYCO Proof Test Rig

Refer to these supporting document to ensure you fully understand the process and safety measures required. RH-SWP-9 Safe Work Procedure – Proof Test Rigs RH-Wl-13 Work Instruction – Internal Proof Pressure Test SAE J343 Test and Test Procedures for SAE IOOR Series Hydraulic Hose and Hose Assemblies AS 1180.5-1999 Methods of test for hose made from elastomeric materials – Hydrostatic pressure.

Safe Work Procedure

Before operating the machine, refer to the latest edition of RYCO Safe Work Procedure RH-SWP-9. (Step 1 – Preparation)

RYCO Proof Test Rig - Safety Procedures

Prior to switching on power, check the condition of the power cord to ensure that the plug is secure, that the cord is not damaged or frayed, and that a current electrical safety test tag attached.

Ensure the electrical plug is securely fitted in the socket. This applies to both the Air Compressor and the Test Rig in general.

If an extension lead, or power board is used, the above also applies. Ensure that the cord is correctly routed and clear of the floor, so as not to cause a tripping hazard, and to reduce the possibility of the cord being damaged by sharp edges or falling objects.

Ensure that the area where work is being carried out is well lit, and that there are no trip hazards, or other debris.

Ensure that the viewing windows are in good condition, are clean and can be seen through.

Before applying power to either the compressor or test rig, ensure that the air receiver of the compressor receiver is drained and that the drain cock closed. Ensure that there is adequate fluid in the reservoir of the test rig. Check the compressor oil level before starting.

Connect the air supply to the test rig.

  • Safety Glasses
  • Safety Boots
  • Protective Clothing
  • Waterproof Gloves and Apron are optional

CAUTION

This rig is designed for Non Destructive Testing Only!

RYCO Proof Test Rig - Safety Warning

Under no circumstances are assemblies to be burst tested.

Proof Test Rig Machine Controls

Overview

This unit uses ‘air over oil’ pumps to pressurise a fluid.

Proof testing is a process where a hose assembly is pressurised to prove that it can hold pressure. Therefore this can be regarded as a test to ensure that a manufactured assembly is ‘Fit for Purpose’ before it is fitted.

RYCO Proof Test Rig - Controls Overview

This is often a required test where the hose will be fitted in close proximity to personnel.

This test rig creates a static and regulated high pressure to safely test the hydraulic hose in an enclosed environment.

An emulsion of Water and Oil is used as the pressure medium.

Compressed air is made available to an ‘Air over Oil’ piston pump at a regulated pressure. The air pressure is intensified (amplified), and applied to the test fluid. The ratio of Air to Fluid pressure is 200:1.

RYCO Proof Test Rig - Overview of System Design

Therefore if 50 psi air pressure is applied, the static hydraulic pressure output is 200 times 50 psi, (10,000 psi).

Controls: Low Pressure

Air Valve

This valve isolates the air supply to the air over oil piston pump. This is a “Ball Valve”, and therefore turns on and off over a 1/4 turn.

RYCO Proof Test Rig - Air Valve

The valve is shown in the photo in the “On” position. To turn it off, turn the handle clockwise 1/4 turn. (The air supply is isolated when the handle is pointing downwards).

Air Gauge

This Gauge displays the pressure available to the air over oil pump. This pressure is controlled by the regulator.

RYCO Proof Test Rig - Air Gauge

Regulator

This control varies the pressure available to the air over oil pump. Turn the knob clockwise to increase the pressure, and counter- clockwise to decrease the pressure.

RYCO Proof Test Rig - Regulator

The controlled pressure can be read on the Air Gauge.

The knob incorporates a lock. Pushing the knob downward will lock the knob, and not allow adjustments. Pulling the knob upwards, (as shown), will allow pressure changes to be made.

Controls: Lid Control

Lid control

This is the lever for the pneumatic valve that operates the lid.

RYCO Proof Test Rig - Lid Control

Be aware that the lid may operate at different speeds up and down.

Ensure you are well clear of the moving lid.

Controls: High Pressure

HP Valve

This is the knob for a needle valve that vents the High Pressure. (Test Pressure).

RYCO Proof Test Rig - High Pressure Valve

Turn the valve fully clockwide to close the valve and allow pressure to build up.

Turning the valve counter-clockwise will open the valve and vent the pressure to tank.

HP Gauge

This gauge is an analogue read out for the high pressure side.

RYCO Proof Test Rig - High Pressure Gauge

It incorporates an adjustable red pointer needle which is used as a “quick glance” indicator.

Digital Read Out

A digital read out for the high pressure side. This gauge displays Megapascals, (Mpa).

RYCO Proof Test Rig - Digital Read Out

Conversion to Mpa:

10 Bar = 1 Mpa.

To convert from Bar to Mpa, move the decimal point one position to the left. (e.g. 600 Bar = 60.0 Mpa).

145 psi = 1 Mpa.

To convert from Psi to Mpa, multiply by 0.0069 (e.g. 5000 Psi = 34.5 Mpa).

HP Outlet

The high pressure outlet port is 1/2″ BSPT.

RYCO Proof Test Rig - High Pressure Outlet

The flat plate has a threaded boss into which an adaptor is fitted. This adaptor is sealed by the use of a high pressure face to face seal. It does not seal on the thread.

This adaptor can be removed and placed in a vice to facilitate the fitment of a test adaptor.

Care must be taken when re-installing, as damage can occur to the sealing faces.

Want more information?

Read part 2 of our information on using RYCO’s proof test rigs, and discover how to safely operate the machine to perform a test..

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