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.
Connect the assembly
Prepare the connection.
Select an adaptor to suit your hose assembly and fit it to the rig.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Normal test duration is between 30s and 60s.
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).
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.
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.
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.