High-performance test rig for large butterfly valves
The test bench system in the production hall weighs around 120 tonnes.
SAMSON LEUSCH GmbH Industriearmaturen has set up a high-performance facility especially for large butterfly valves. The test rig ensures the quality of the company's control and butterfly valves. The employees test the valves for their pressure resistance. The centrepiece of the testing process is the triple eccentric butterfly valve LTR 43.
A pressure is generated in the test bench that is also present in the intended application. If the pressurised components of the valve withstand the test pressure, customers can be sure that the valve will function stably and for a long time under operating conditions. The system enables the following pressure tests to be carried out in accordance with the specified standards:
Strength test: the test serves to verify the pressure resistance of the pressure-bearing components against the internal pressure. A water-oil mixture stored in a 3000 litre tank is used as the test medium.
Tightness test against internal pressure: the test serves to verify the tightness of the seals against the internal pressure.
Seat tightness: the test is used to verify that the specified leakage rate of the seat is maintained.
Testing is carried out with liquid (water) or gases (air, nitrogen or helium). During the test process, laser technology is used to measure the leakage in bubbles or drops. This allows even the smallest leaks to be detected.
Delivery on six articulated lorries
An important parameter with regard to the technical data of the test rig is the nominal width. It is up to 84 inches. This means that the flap can have an internal diameter of up to 2.10 metres. Another relevant parameter is the maximum test pressure. With the SAMSON LEUSCH test bench, this is a maximum of 650 bar (water) or 250 bar (gas).
The maximum clamping pressure of 3,600 tonnes is not insignificant. The test bench has a weight of 120 tonnes and stands on a 50 m² footprint. The test rig enables SAMSON LEUSCH to test valves weighing up to 20 tonnes with a length of up to three metres “face to face”. To ensure the quality of the industrial valves in accordance with international standards ex works in Neuss, LEUSCH decided in 2019 to set up another valve test bench for large nominal sizes in the production hall.
“The test bench was delivered on six articulated lorries at the time”, recalls Production Manager Sebastian Schulz. To protect the personnel, the system was enclosed by a 3 metre high protective wall. LEUSCH wanted to maximise flexibility during installation. This is why the test stand was set around 2.5 metres into the floor. This allows the company to test large valves with high superstructures in the system.
As part of the optimisation of the material flow, SAMSON LEUSCH installed a rail system in the floor of the production hall. This allows the employees to move the valve including actuator to the test bench.
“It's good that we at SAMSON LEUSCH have such a high performer at our disposal”, says Managing Director Bernd Jenner, looking at the test bench: “The completed and assembled butterfly valves are tested 100 % in order to offer our customers 100 % safety and top quality.”