Computer-based Off-line Safety Valve Test Bench

Scope of Application：

This equipment is suitable for testing performance indicators such as set pressure, reseating pressure and tightness of various full-lift and low-lift safety valves.

Reference Standards：

TSG 92-2026, Safety Technology Regulation for Safety Accessories of Special Pressure Equipment
TSG ZF001-2006, Safety Technical Supervision Regulations for Safety Valves
GB/T 12241-2021, Safety valves—General requirements
GB/T 12242-2021, Pressure relief devices—Performance test code
GB/T 12243-2021, Spring loaded safety valves
GB/T 32291-2015, Offline inspection and evaluation of high and super-high pressure safety valves

Main Technical Parameters：

(1) Maximum applicable nominal diameter: DN400 mm. Larger sizes are available upon custom request from our company;
(2) Maximum test pressure: 160 MPa. Higher pressure versions can be customized on request;
(3) Pressure measurement accuracy: Equipped with 0.4-class pressure gauge. Higher accuracy gauges are optional as required;
(4) Test medium: Nitrogen, compressed air or clean water. Gas-water dual-purpose unit is available for customization.

Main Functions and Features：

(1) The pressure calibration of the safety valve under test is performed manually. During the whole process, the test pressure is collected by pressure sensors, and the test curves and data are displayed, recorded and stored by computer software.
(2) Test procedure: The built-in pneumatic gas booster system of the control console delivers high-pressure gas to the gas storage vessel (high-pressure gas tank). High-pressure gas from the vessel is charged into the safety valve under test. The pipeline on-off is controlled by the calibration switch. The safety valve is judged qualified if it opens when the pressure reaches the set calibration pressure; otherwise, it is unqualified.
(3) The clamping of the calibration bench seat adopts hydraulic clamping. Electric hydraulic clamping technology is applied with adjustable output pressure. Pressure stabilizing and holding operations are simple, enabling fast clamping of the tested valve.
(4) The clamping seats adopt a three-jaw design with uniform force distribution and stable output force. The jaws are equipped with a new type of bidirectional high-low clamping feet, suitable for clamping valves of various shapes and dimensions.
(5) The calibration bench is equipped with two clamping seats: one for DN15 ~ DN200 and the other for DN200 ~ DN400.

Calibration Bench

(6) Pressure gauges: All calibration pressure gauges are high-precision 0.4-class gauges. There are 6 measuring ranges with 2 gauges for each range, totaling 12 high-precision pressure gauges. Each range of pressure gauges is independently controlled by a control valve. The low-pressure gauges are fitted with safety relief devices to prevent damage caused by misoperation.

high-precision pressure gauge

(7) The booster pumps adopted in the gas boosting system built into the control console are independently designed, processed and manufactured by our company. All internal seals are originally imported to ensure stable system pressure during clamping and continuous output of high-pressure gas during testing.
(8) Gas test: Compressed air of 0.3–0.8 MPa is used as the driving power for the gas booster pump HA60. Nitrogen from nitrogen cylinders serves as the test pressure source. The bottled nitrogen is pressurized by the gas booster pump and then charged into the gas storage vessel for calibration.
(9) In accordance with the new regulation TSG 92-2026, test vessels are installed inside the equipment. One 2 L high-pressure vessel with a pressure rating of 40 MPa is used for calibrating safety valves with a nominal diameter ≤ DN65; one 12 L high-pressure vessel with a pressure rating of 40 MPa is for safety valves with a nominal diameter > DN65 and ≤ DN150. An additional 6 L high-pressure vessel with a pressure rating of 40 MPa is also equipped. When the three test vessels (2 L, 12 L and 6 L) are opened together, the total volume reaches 20 L for calibrating safety valves with a nominal diameter > DN150.

(10) In accordance with the new regulation TSG 92-2026, the inner diameter of the test pipelines and valves between the test vessels and the clamping port of the calibration equipment manufactured by our company is ≥ 8 mm.
(11) In accordance with the new regulation TSG 92-2026, the pressure tapping point of the precision pressure gauge measurement system is modified and connected between the high-pressure test outlet inside the clamping bench and the test vessel.
(12) In accordance with the new regulation TSG 92-2026, the equipment is equipped with an automatic bubble counting leak detection device. It automatically counts bubbles during the tightness test after three calibration runs and automatically records the data into the calibration record.

automatic bubble counting leak detection device

(13) Adopts NI software from the United States. It can dynamically display, automatically record and save the time-pressure curves of safety valve calibration. Calibration reports and curves can be printed directly.

Control Software Interface

test curve

Test Report Form (in compliance with TSG 92 new regulation)

(14) All valves, pipe fittings and connectors are made of stainless steel.
(15) Multiple test toolings are provided, including center gaskets and male reducing adapters (imperial size). Customization is available upon request to meet the test requirements of various series of safety valves.

test tooling

FD1Equipment Configuration：

FD2Equipment Configuration：