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

May 15, 2018

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)

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!

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.

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.

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.

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.

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.

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.

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).

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.

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).

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.

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.