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VG4400GC qualification testing report

By Danielle Ferguson,2014-10-15 20:50
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VG4400GC qualification testing report

    PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 1 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center SUBJECT: VG4400GC RESULT: GOOD PURPOSE: Localization valve qualification AVERAGE POOR CONTINUE TEST REQUESTED BY: APPH REFERENCE: 06-88024-32 MAKE DISCUSSION

    PREPARED BY: Xiaopeng Chen/ Wenbin Liu APPROVED BY: Xianzhong Wu

; New Equipment Description

    Forging brass valve bodies manufactured by Dunan were investigated as possible low cost replacement for the

    original JCI casting bronze valve bodies currently used on the VG4400GC.

; Problems/Concerns(Resolved and unresolved)

    A set of samples were used for this validation testing, the total amount are 20 pcs. The samples were tested for

    body leakage test, seat leakage test, valve stroke test, max flow rate test, valve body burst pressure test, body

    connection torque test and life test

; Conclusion

    VG4400GC new valve body

    Validation test results have been shown the new valve body testing values were within the specification.

    No. Testing Items Testing Results Pass/Fail

    1 Body leakage test No leaks at 3MPa water pressure Pass

    2 Seat leakage test No leaks at 350kPa diff. air pressure Pass

    3 Valve stroke test Pass Within the range of 3.25?0.25mm 34 Max flow rate test Max. kv is more than 2.5m/h Pass

    5 Valve body burst No leaks and distortion at the burst pressure Pass

    pressure test more than 14MPa

    6 Body connection No body and seat leaks and distortion found Pass

    torque test after torque test

    7 Life test One valve body and seat leaks found after life NG

    test

    Process capability (Cp for dimension and flow characteristic) has been improved

    New Supplier has to be considered validated to reduce cost and shorten delivery time.

     F-340

    PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 2 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center

    1. Valve body leakage test

    Valve body leakage test is carried out on a set of 20 samples. Test conditions:

     Medium Ambient temperature water

     Pressure Pressure 3MPa

     Test duration time 15 sec.

     Max. leakage zero leakage by visual inspection

To check for leakage, the valve inlet thread connects to the hydraulic hand pump outlet side, install a blind plug on the open

    end of the valve. Fill the pump with water, prime the water into the test valve while the valve should be in the opened

    position. Increase the water pressure rises to 1MPa, hold this pressure for five seconds. If no leaks are present, increase

    pressure to 3MPa and hold for 15 seconds, check valve visually for leaks. Repeat until all the valves have been tested.

    See picture 1 Test fixture of Hydro-test for valve body

     Figure 1 Hydro-test fixture

    Instrumentation used:

     - Pressure gauge

     - Stopwatch

     - Hydraulic hand pump

Test results

    No leak was found on 20 samples

2. Seat leakage test

    Seat leakage test is carried out on the same set of 20 samples. Test conditions:

     Medium Air

     Diff. Pressure 350(?10kPa)

     Test duration time 15 sec.

     Max. leakage zero bubble found by visual inspection

To check for leakage, the valve inlet thread connects to the regulator outlet side, the valve should be in the closed

    position, oriented vertical, and sit below the water tank. Submerge the valve in a water tank, use the regulator to adjust the

     F-340

PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 3 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center air pressure to 350kPa, supply air pressure to the valve for at least 15 seconds, check valve visually for leaks. Repeat until all the valves have been tested.

    See picture 2 and 3 Test fixture of leakage test for valve seat

     Figure 2 Leakage testing fixture Figure 3 Seat leakage tested sample

    Instrumentation used:

     - Pressure gauge

     - Pressure regulator

     - Pneumatic reducer

     - Water tank

Test results

    No leak was found on 20 samples

3. Valve stroke test

    All 20 valve bodies assembled with the original JCI imported center piece were tested for nominal stroke. Test method:

    To measure the stem extension of valve with Vernier calipers, then record the original value. After that, push the stem to open the valve till the stem can not be moved, record a new value. The valve stroke is the difference of these two values. Repeat until all the valves have been tested.

See figure 4 Valve stroke test

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PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 4 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center

     Figure 4 Stroke test

    Instrumentation used:

     - Vernier calipers

Test results

    All stroke values of 20 valves are within 3.25?0.25mm.

4. Max flow rate test

    Test procedure:

    a. Install the test specimens in accordance with the piping requirement per ANSI/ISA 75.02 b. Connect a differential pressure sensor to the upstream pressure tap and the downstream pressure tap c. Mount an actuator to the valve, and turn on power to open the valve in the fully open position. d. The flow rate of the test specimens is measured from 80kPa, 100kPa to 120kPa, then test Kv at 100kPa again, record

    the flow rate.

    e. Calculate the Kv of valve using the testing data, and average the calculation Kv values in different Diff. pressure

    See picture 5, 6 and 7 Flow rate testing facility of JCI Asia engineering center

     Figure 5 Flow test pipe system

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PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 5 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center

     Figure 6 Differential pressure sensor Figure 7 Electromagnetic flow meter Instrumentation used:

     - Pressure gauge

     - Differential pressure sensor

     - Electromagnetic flow meter

     - Flow rate testing facility

Test results

    Kv Factor of VG4400GC Localization Product with Dunan Valve Body, the test is acceptable 33CTQ: Valve Flow Characteristic Kv Factor (Unit: m/h) LSL=2.5m/h Sample# 1 2 3 4 5 6 7 8 9 10 Cpk Ppk Kv 2.625 2.612 2.658 2.678 2.658 2.692 2.725 2.636 2.662 2.637 1.60 1.52 Sample# 11 12 13 14 15 16 17 18 19 20

    Kv 2.623 2.686 2.691 2.701 2.663 2.744 2.639 2.693 2.65 2.625

    Note: Acceptable limit for capability/1.33Cpk

    Process Capacity Chart of Localization Dunan Valve Kv Factor

    See Attachment 1 Valve Flow Characteristic Kv Testing Data

     F-340

PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 6 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center

    5. Valve body burst pressure test

    Internal burst pressure test is carried out on three valve bodies.

    Test conditions:

     Medium Ambient temperature water

     Pressure 5 times of design pressure 2.8MPa=14MPa

     Test duration time 1 minute.

     Max. leakage zero leakage and no distortion by visual inspection

    To check for leakage, the valve inlet hose connects to the hydraulic hand pump outlet side, install a blind plug on the open end of the valve. Fill the pump with water, prime the water into the test valve while the valve should be in the opened

    position. Increase the water pressure rises to 1MPa, hold this pressure for 10 seconds. If no leaks are present, slowly increase pressure to 14MPa and hold for at least 1 minute, check valve visually for leaks and distortion. Repeat until all the valves have been tested.

    See picture 1 Test fixture of Hydro-test for valve body

Instrumentation used:

     - Pressure gauge

     - Stopwatch

     - Hydraulic hand pump

Test results

    No leak and distortion was found on valve body.

6. Body connection torque test

    Torque test was conducted to check the turning effects exerted by assembling to piping under ambient temperature conditions on three valve bodies.

    A section of pipe tooling was connected to the female threaded of one end of valve body, the pipe tooling was then to be tightened with the wrench to the applicable torque of 64N.m. After the torque force has been applied to the connected pipe tooling for 15 minutes, repeat the procedure at another end of valve body, the test sample is to be subjected to the body leakage test and seat leakage test.

    See picture 8 and 9 Test fixture of body torque test for valve body

     Figure 8 Face picture of torque test Figure 9 Rear picture of torque test

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PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 7 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center Instrumentation used:

     - Torque wrench

     - Stopwatch

    - Hydraulic hand pump

     - Pressure gauge

     - Pressure regulator

     - Valve to pneumatic reducer

     - Water tank

Test results

    No leakage and distortion or broken was found on valve body thread.

7. Life test

    Number of samples to be tested: 5 pcs. Test requires a relay equipment to control the actuator ON and OFF

    Test method:

    - The VG4400GC valves with Dunan valve body were all mounted on VA7010-8503 actuators from JCI - Nominal 220V/50Hz was supplied and turned on&off with an electric timer box. Set the time delay to the cycle time.

    The cycle consisted on 12 seconds ON and 8 seconds OFF to drive closed the valve and spring return the actuator. - Run the valve OPEN and CLOSED for 100,000 cycles, then pause cycling to test for leakage at 10k, 30k, 60k and 100k

    cycles.

    - To check for leakage, the valve inlet hose connects to the regulator outlet side, the valve should be in the closed

    position, oriented vertical, and sit below the water tank.

    - Submerge the valve in a water tank, use the regulator to adjust the air pressure to 350kPa, supply air pressure to the

    valve for at least 15 seconds, check valve visually for leaks. Repeat until all the valves have been tested, then resume

    cycling.

    - Repeat step 2-5 until 100,000 cycles have been completed.

    - If failure occurs, stop test and evaluation of failure, after that, continue with test.

Remark

    Because of testing facility availability, life test has not been performed with contaminated water in different ambient and fluid medium conditions.

    See picture 10, 11 and 12 Testing facility of life test for valve

     Figure 10 Tested valve on pipe Figure 11 Cycling equipment

     F-340

    PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 8 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center

     Figure 12 Air pressure line and water sink

Instrumentation used:

     - Water pump and tank

     - Time delay relay

     - Electric counter

     - Air pressure line

     - Water sink

Test results

    Life test summary

    Failure rate 10,000 cycles 30,000 cycles 60,000 cycles 100,000 cycles

    Dunan valve body 0.0% 0.0% 0.0% 20.0%

    See Attachment 2 Leakage inspection testing data after life test at different cycles

    After 100000 life cycles,the 15# sample was leaked when done the seat leakage test.

    The reason is anello elastico elastic ring of the centerpiece subassembly shed.

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PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 9 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center

    Before life test

    After 100000

    life cycles

8. Valve body drawing

    See Attachment 3 New valve body redesign drawing

9. List of Equipment

    No. Instr. Measure Range Accuracy Cal Date 1 Pressure gauge 0-1.0MPa 0.05Mpa 2008.03.26 2 Hydraulic hand pump 0-25MPa 0.5Mpa 2008.03.26 3 Vernier calipers 0-150mm 0.02mm 2008.04.12 4 Pressure gauge 0-1.6MPa 0.01MPa 2008.05.06 5 Differential pressure sensor 0-400kPa 0.5%FS 2007.09.06 36 Electromagnetic flow meter 0-16m/h 0.5%FS 2008.02.27 7 Torque wrench 120-300N.M 2N.M 2008.04.09

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PRODUCT TEST REPORT

     NUMBER: DATE : 25-06-08 SHEET: 10 OF: 14 ATTACHMENT: 3 DISTRIBUTION: Asia Engineering Center Attachment 1 Valve Flow Characteristic Kvs Testing Data

    Testing Data Recording Table

    Upstream Diff. Flow Gauge Downstream pressureSamples No. Measured Capacity Kv Diff. pressurekPa 3(kPa) (m/h) (kPa) kPa

    JCI standard 100.19 2.94 2.937 225 125 100 sample

    1 98.09 2.6 2.625 210 110 100

    78.78 2.32 2.61 175 100 75

    100.63 2.63 2.62 210 110 100 2 120.49 2.87 2.61 250 125 125

    100.81 2.61 2.60 210 110 100 Average 2.612

    80.24 2.37 2.65 200 125 75

    99.03 2.65 2.66 225 125 100 3 120.95 2.92 2.66 250 140 110

    100.28 2.67 2.67 230 130 100 Average 2.658

    79.35 2.4 2.69 180 110 70

    99.49 2.67 2.68 220 125 95 4 121.35 2.94 2.67 240 140 100

    99.88 2.67 2.67 225 130 95 Average 2.678

    80.17 2.36 2.64 180 110 70

    100.2 2.66 2.66 220 120 100 5 119.74 2.92 2.67 224 125 99

    99.32 2.66 2.67 220 125 95 Average 2.658

    79.85 2.62 2.93 200 110 90

    100.73 2.93 2.92 230 125 105 JCI standard

    sample 121.18 3.22 2.93 260 125 135

    99.24 2.92 2.93 230 130 100 Average 2.927

    80.3 2.42 2.70 200 120 80

    100.08 2.68 2.68 230 125 105 6 120.23 2.95 2.69 250 130 120

    99.4 2.69 2.70 230 130 100 Average 2.692

    80.06 2.43 2.72 200 120 80 7 99.69 2.72 2.72 225 125 100

    119.86 2.99 2.73 250 135 115

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