Operating Manual
for
TEST RIG SHIP

 
 

 
 
 

REV. 00

     
  
 
PRES-VAC ENGINEERING ApS  PHONE: +45 4817 4055 
SVANEVANG 3-5  TELEFAX: +45 4817 1788 
DK-3450 ALLERØD  E-MAIL: pres-vac@pres-vac.com 
DENMARK 
  
 
 

Operating Manual for Test Rig Ship

Table of Content:

1 - General: 1.1 Lifting of valves to be tested Page

1.2 Installation 3
1.3 Utilities
2 - Purpose: 2.1 General 4

3 - Test Rig 3.1 Components 5

Arrangement:
4 - Testing: 4.1 Fitting of P/V valve 6-7
4.2 Pressure gauge
4.3 Test of opening pressure for pres-
sure unit
4.4 Test of opening pressure for vacu-
um unit

5 - Trouble Shooting: 5.1 Trouble Shooting Table 8

6 - Spare Parts: 6.1 Ordering 9

6.2 Spare parts for Test Rig:
7 - Option: 7.1 Pressure Tank 10
7.2 Tank Leakage Test
8 - Contact 8.1 Who to contact 11
Information:
9 - Additional 9.1 Enclosed information 12
information:

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Operating Manual for Test Rig Ship

1 - General:

1.1 Lifting of valves to be tested

WARNING Depending of valve size then please use crane or other lifting aids when
lifting the valves.

CAUTION Transport, storage and handling of the valves, shall take place with the
valves in upright position. Please see lifting drawing under additional In-
formation for further details.
Always lift valves as instructed as this might damage the valves and cause malfunction of the valves.
Use a round sling made from fabric intended for the load of the valve in question.
Never use wire or chain.

1.2 Installation
We recommend to install the Test Rig in rooms below deck such as Engine Room Work Shop or similar.
The rig has to be bolted onto the deck before use.

1.3 Utilities
Only compressed air supply to be connected:
Max. inlet pressure: 8 bar
Only dry and clean Air (free from oil vapours) to be used.

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Operating Manual for Test Rig Ship

2 - Purpose:

2.1 General
This Test Rig Ship is only intended for on-board final testing of PRES-VAC P/V valves type:
HS-ISO+VAC
HS-ISO2-VAC
HSM-IMO2-VAC
HSE-IMO2+VAC
HS+VAC
HS-ISO+VAC
up to max. DN 150 in flange size. Larger sizes can be tested after advice from PRES-VAC.

The final test is performed to assure correct opening pressure of PRES-VAC P/V valves.
Leakage rate can also be tested by this Test Rig if the rig is equipped with an additional air pressure tank.
Please see 6 - Options.

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Operating Manual for Test Rig Ship

3 - Test Rig Arrangement:

3.1 Components
The Test Rig Ship consist of the following main components:
1: Foundation and Air Reservoir
2: Drain valve Air Reservoir
3: Compressed Air Inlet (connection: ø13 mm hose—alternative ½” BSP female)
4: Control Panel
5: Pressure Gauge
6: Outlet Plate
7: Down Holders(3 pcs.)
8: Connection for pressure tank (optional)

    7 

  6 
    5 

  4 

  1     3 

  8  

  2  

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Operating Manual for Test Rig Ship

4 - Testing:

4.1 Fitting of P/V valve

Check/clean connection flange on the PRES-VAC P/V, which is to be tested, before fitting it onto the Out-
let Plate using the three Down Holders.

4.2 Pressure gauge

Acutal Value
RESET With the RESET-function, the Max.- and Min.-value
is set to the actual pressure value.
OFF Turns off the instrument
Max.-/Min. Va-
lue MANO Releases the following functions:

ZERO SET Sets a new pressure zero reference.

Enter
ZERO RES Sets the pressure zero til factory settings
(Max./Min.)
CONT on Deactivates the automatic turn-off function

Select/Turn-on CONT off Activates the automatic turn-off fuction(the instru-

ment turns off 15 min. After the last key operation

All standard instruments are calibrated in bar. The

UNITS pressure can be indicated in the the following units:
bar, mbar/hPa, kPa, MPa, PSI, kp/cm2.

The Pressure gauge has two operating keys:

The left key is to turn the instrument on, to select the functions and the pressure units.
The right key executes the selected function or unit. The right key is also used to switch between the Max.
- and Min.-value.
Note:
1) The functions and units can also be called up by keeping the SELECT-key depressed. Releasing the
key enables the displayed function or unit to be activated with the ENTER-key.
2) If the selected function or unit is not activated within 5 seconds with the ENTER-key, the display returns
to the measuring mode without changing any settings.
3) Turning display on and off does not influence any of the previous settings.
4) If the CONT on function is activated, it is indicated with a flashing sign on the display (OFF flashes
when CONT on is set).
5) If a pressure can not be represented on the display, OFL (overflow) or UFL (underflow) appears on the
display.
6) If the actual pressure goes beyond the measuring range, the last valid pressure value starts flashing on
the display (overload warning).
7) Temperatures outside of 0…60 °C could impair the readability of the display.

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Operating Manual for Test Rig Ship

4.3 Test of opening pressure for pressure unit

1: Set all three switches in lower position
2: Adjust pressure to opening pressure by turning the knob
(FLOW) counter clockwise
3: Adjust valve to correct opening pressure as instructed in
Instruction Manual for PRES-VAC P/V valve
4: Check for leakages by pouring soap water on all parts of
the valve. If big bubbles are observed then a leakage is
present and has to be corrected.
5: Adjust down the pressure.

NOTE Some bubbles will always be present around the valve seat as it is not
possible to make a valve completely free for leakages.
A Leakage Test has to be made in order to determine if the leakage is too
large. Please see 6 - Option

4.4 Test of opening pressure for vacuum unit

1: Depressurize the valve by lifting the Check Lift Handle on
the P/V valve
2: Set all three switches in upper position
3: Adjust pressure to opening pressure by turning the knob
(FLOW) counter clockwise
4: Adjust valve to correct opening pressure as instructed in
Instruction Manual for PRES-VAC P/V valve

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Operating Manual for Test Rig Ship

5 - Trouble Shooting:
Please note that this trouble shooting is only applicable for the Test Rig, and not for the P/V valve. Please see In-
struction manual for the P/V valve in question

5.1 Trouble Shooting Table

Problem Cause Remediation

Test Rig

Water in air The compressed air contains Drain Test Rig Air Reservoir using drain valve (pos. no
to much water 2)
No pressure Closed inlet valve Open valve and adjust on knob on control panel.

No pressure hose connected Connect pressure hose from ship air pressure system

No pressure in ship air pres- Check ship air pressure system

sure system

Pressure gauge

No reading in display Pressure gauge not turn-on Turn-on pressure gauge

No battery power in pressure Open the battery compartment and change the battery
gauge (type CR 2430)

Pressure gauge defect Replace pressure gauge

BAT LOW Internal battery in pressure Open the battery compartment and change the battery
gauge is weakning (type CR 2430)

OFL(Overflow) The pressure is above the Adjust pressure

pressure range
UFL(Underflow) The pressure is below the Adjust pressure
pressure range

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Operating Manual for Test Rig Ship

6 - Spare Parts:

6.1 Ordering
Remember always, when ordering spare parts, to:
1: Identify component/part and amount of parts required.
2: Identify ship by yard name - hull number - IMO number or PRES-VAC order number

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Operating Manual for Test Rig Ship

7 - Option:

7.1 Pressure Tank

In order to carry out a Leakage Test then the Test Rig has to be fitted with a pressure tank connected to
ball valve—pos. 8). We recommend to choose a tank size no less than 90 litres in order to carry out the
Leakage Test.

The pressure tank most comply with the following data:

1: Required certification for ship use (class requirements)
2: Designed for 2 bar (Pabs.)
3: Connected to the Test Rig with piping suitable for the pressure.

7.2 Tank Leakage Test

1: Adjust pressure to 80% of opening pressure for the P/V valve
2: Allow the temperature to stabilize for approx. 2 minutes.
3: Note reading on pressure gauge and wait approx. 1 minute
4: Wait approx. 1 minute and note reading on pressure gauge.
5: Compare pressure drop to table for max. allowable leakage

Leakage ‐ Pressure drop             
          
tank size  90 liter         
temp  20 degrees C           
               
  valve size,  Max allowable  Max allowable pressure drop   
  pressure side  leakage, litres   Mbar  PSI  mmwg  mmHg   
  1  1  11  0,2  111  8   
  2  1  11  0,2  111  8   
  3  1  11  0,2  111  8   
  4  1,5  17  0,2  167  13   
  5  2  22  0,3  222  17   
  6  2,5  28  0,4  278  21   
  7  4  44  0,6  444  33   

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Operating Manual for Test Rig Ship

8 - Contact Information:

8.1 Who to contact

Spare parts for P/V valves can also be required via below-mentioned contact information, along with
spare parts for the Test Rig.

PRES-VAC ENGINEERING
Svanevang 3-5
DK-3450 Allerød
Denmark

Tel.: +45 48 17 40 55
Fax.: +45 48 17 17 88
www.pres-vac.com
E-mail: aftersales@pres-vac.com

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Operating Manual for Test Rig Ship

9 - Additional information:

9.1 Enclosed information

The following information is enclosed this operating manual:
1: General arrangement drawing
2: Hook-up drawing.

Page 12
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VIEW4 ( 1 : 5 )

D VIEW1 ( 1 : 10 ) D

987

899

C C

B R145,0 B
505

WorkInProgress

Scale 1:10 Projection

597 Format A3 Sheet 1/1

Draft HM Date 19-04-2011
Material Description TR-Ship
A A
Process Assembly Costumer Pres-Vac Engineering ApS

Surface Treatment Marine Coat RAL 5017 Project No. Std.

Approval
Design: HM Rev. No. V5 Drawing No. 1200-959
Confidential: Property of Pres-Vac Engineering ApS. Not to be handed over to, copied or used by third party. 2D/3D reproduction of contents to be authorized by Pres-Vac Engineering ApS.

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