FIELD OF INVENTION
[001] The present invention generally relates to method of hydro testing of
forged steel valves for high temperature and high pressure applications.
Particularly, the invention relates to hydro testing of forged steel valves
without actuators and without electric power supply. More particularly the
invention relates to have a new clamping device clamped with conventional
torque wrench for hydro testing.
BACKGROUND OF THE INVENTION
[002] Normally, Forged High pressure valves are used for various systems
like feed water system, flow discharge line, feed water line (economizer
inlet), spray system and turbine extraction line. The size of valve ranging
from 1/4” to 2-1/2” depends upon the pipeline where these valves are used
for high temperature and high pressure (1500, 2500, 3000, 3500 and 4000
Class rating) applications. Materials used for the valves are SA105 grade
material (carbon steel), F22 grade material (low alloy steel), F91 grade
material (high alloy steel), Stain less steel and F92 grade material.
Generally, Valves are classified by two types: one is motorized valve and
the other one is hand operated valve. Manufacturing of motorized valve
consists of the following steps, valve body machining, yoke machining,
Body-yoke welding, RT inspection, heat treatment, shot blasting,
Phosphating, valve assembly, Actuator mounting, Motor function testing,
hydro testing and final inspection. Among the all processes, ‘Hydro testing’
is an important process where the customer witnesses the product, how it

is performing under elevated pressure. In hydro testing, the motorized
valve is tested with actuator whereas hand operated valve is merely tested
with handle. Thereby actuator mounting and dismantling, actuator
function testing, movement work from one station to another station,
crane and vehicle utilization for movement work, deploying more man
power for above works, lead to more resources wastage to the organization.
[003] In existing method, an actuator is a device used for hydro testing the
forged steel valve in the hydro testing bench. The existing method consists
of, actuator mounting and dismantling, actuator function testing,
movement work from one station to another station, crane and vehicle
utilization for movement work, deploying more man power for above works.
No of valves hydro testing per day is limited. Therefore, the cycle time of
valve increased drastically thus affects the timely delivery. Apart from that
the lot of resources are wasted due to the long cycle.
[004] Hence, there has been a need to find out a method for conducting
the hydro testing of valve assembly without actuator and also these
problems are to be addressed while developing a method of hydro testing
for the above applications. No such method of hydro testing has been
developed without using actuator.

OBJECTIVE OF THE INVENTION
[005] It is therefore, an object of the invention is to perform hydro testing
of forged steel valves without actuators and without electric supply to
valve.
[006] A further object of the invention is to reduce the cycle time of
manufacturing of forged steel valves.
[007] A further object of the invention is to have a new clamping device
with torque wrench for hydro testing.
[008] Another object of the invention is to hydro testing of forged steel
valves without strain.
[009] Yet another object of the present invention is to perform hydro testing
with only one clamping device for different category of valves.
[010] These and other objects and advantages of the present invention will
be apparent from the ensuing description.
SUMMARY OF THIS INVENTION
[011] The present invention discloses a method of hydro testing that
involves the checking the performance of valve and not actuator. In the
present disclosure a method is used for hydro testing that involves use of
‘clamping device’ instead of actuator, wherein the said clamping device
consists of, set of bearings, casing, sleeve, lock ring. Clamping devices are
designed and developed according to the specification of valves with same
configuration. During Hydro testing the forged valve, the tapped hole

embedded in clamping device assembles the said clamping device with
valve by means of bolts. In case any leakage is found during ‘seat’,
‘backseat’ or ‘shell’ test, the clamping device is disassembled and repair
work for the valve is done. Finally, the hydro testing of the forged valve is
performed.
[012] The present invention develops a new method of hydro testing that
increases the productivity and utilizes lot of resources in better way. It
simplifies the existing methods and cycle time of valve is reduced
substantially.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[013] Various objects, features, aspects, and advantages of the inventive
subject matter will become more apparent from the following detailed
description of preferred embodiments, along with the accompanying
drawing figures in which like numerals represent like components.
[014] The foregoing summary is illustrative only and is not intended to be
in any way limiting. In addition to the illustrative aspects, embodiments,
and features described above, further aspects, embodiments, and features
will become apparent by reference to the drawings and the following
detailed description.
[015] The figures depict embodiments of the disclosure for purposes of
illustration only. One skilled in the art will readily recognize from the

following description that alternative embodiments of the structures and
methods illustrated herein may be employed without departing from the
principles of the disclosure described herein.
[016] Figure 1: Sectional view of clamping device assembly (12N)
[017] Figure 2: The sectional views of Forged steel valve assembly with
clamping device (12N) and hydro testing bench (10)
[018] The different components shown in above mentioned Figures are as
follows:
01-BOTTOM PLUNGER 12N-CLAMPING DEVICE
02-TOP PLUNGER 13N-TAPPED HOLE
03-INLET 14N-GROOVE
05-VALVE 15N-BEARING
6- STEM 16N-CASING
7- BOLT 17N-THREADING PORTION
08-OUTLET 18N-SLEEVE
09-PRESSURE GAUGE 19N-SLOT
10-HYDRO TESTING BENCH 20N-LOCK RING
11-TORQUE WRENCH

DETAIL DESCRIPTION OF THE PRESENT INVENTION WITH
REFERENCE TO THE ACCOMPANYING DRAWINGS OF PREFERRED
EMBODIMENTS
[019] While the embodiments of the disclosure are subject to various
modifications and alternative forms, specific embodiment thereof has been
shown by way of example in the figures and will be described below. It
should be understood, however, that it is not intended to limit the
disclosure to the particular forms disclosed, but on the contrary, the
disclosure is to cover all modifications, equivalents, and alternative falling
within the scope of the disclosure.
[020] During Hydro testing operation, if any leakages found during the
testing, valve assembly is sent back to actuator mounting station to
dismantle the actuator from the valve for rectification work. The valve is
further dismantled for rework the components if necessary. After
completing the rework, valve is re-assembled and sent for remounting the
actuator. Whole corresponding processes are repeated again to complete
the final inspection of valve assembly. Hence, these processes takes more
time to complete the valve manufacturing cycle. Number of valves for hydro
testing per day is limited. The present invention aims to develop a system
of hydro testing of Forged steel valve assembly without using actuator in
lesser time than the existing art.

[021] Figure 1 shows the sectional view of clamping device (12N) assembly
used in the present invention. The clamping device (12N) is configured
with a set of bearing (15N), a casing (16N) with tapped holes (13N), a
threading portion (17N), a sleeve (18N) with groove (14N), slot (19N) and
lock ring (20N). The casing (16N) made up of cast iron is machined as per
required dimensions and a plurality of (four) tapped holes (13N) are made
in it. A cylindrical rod is machined to cover the cylindrical member sleeve
(18N) and an internal threading (17N) is done according to specification of
valve. A slot (19N) is provided on one end of sleeve (18N) opposite to the
position of (13N), to engage the convention torque wrench (11) (Figure 2).
A set of bearings (15N) are inserted between sleeve (18N) and casing (16N)
for carrying the thrust load while testing ‘seat’ leakage and ‘backseat’
leakage. The sleeve (18N) is inserted into the casing (16N) and screwed by
means of lock ring (20N). Additionally, a groove (14N) is provided in the
lock ring (20N) for better tightness.
[022] Generally, there are three type of tests that are conducted in valve
assembly, first one is ‘Seat test’, second one is ‘Back seat test’ and third
one is ‘Shell test’. In a preferred embodiment, a valve (05) is assembled on
hydro-testing bench (10) as shown in Figure 2. The valve assembly is
located between the top plunger (02) and bottom plunger (01) in the hydro
testing bench (10) with a rigid hold. Prior to conducting the hydro testing,
the calibration of bench (10) and pressure gauges (09) is ensured,

checking of water level in the tank and the electrical connectivity to hydro
testing bench (10) are done properly by the operators.
[023] Water is allowed into valve (05) through the inlet (03) path. Pressure
gauge (09) shows the testing pressure during operation. A suitable
clamping device (12N) is selected according to the specification of stem
(06) of valve (05). The tapped hole (13N) embedded in clamping device
(12N) assembles the said clamping device (12N) with valve (05) by means
of bolts (07). ‘Torque’ required to close/open the valve (05) is achieved by
conventional torque wrench (11) inserted in the slot (19N). Next, threading
portion (17N) of sleeve (18N) in the clamping device (12N) is engaged with
stem (06) of valve (05) then fully screwed till close to top of the valve (05).
The Cylindrical member (18N) is responsible for closing and opening the
valve (05) during testing. Water is allowed into valve (05) through the inlet
(03) path with the valve (05) positioned in fully closed condition. Water is
pressurized from inlet (03) to outlet (08) to check the ‘seat test’.
[024] In the succeeding step, the valve (05) is positioned in fully opened
condition to check the ‘backseat test’ followed by the valve positioned
partially opened condition to conduct the ‘shell test’. If any leakages found
during the testing, valve assembly is directly sent back to assembly section
for rectification work. There, valve (05) is further dismantled for rework
the components. After completing the rework, valve (05) is re-assembled
and sent to hydro testing station directly for the valve (05) to be hydro
tested. Finally, valve (05) is mounted with actuator (not shown in figure)

to conduct the actuator function test and valve (05) is completed with final
inspection thereafter.
[025] The specification of valves (05) are of different dimensions, types,
materials depending on mode of operations. There are multiple categories
under particular dimension of the said valve (05). The present invention
discloses the system of clamping device (12N) that can be embedded in all
categories under particular dimension of the valve. Only one clamping
device (12N) can be embedded for all 24 categories of 1” valve (05) and so
for other dimension.
[026] Thereby in the invention disclosed herein, actuator mounting and
dismantling, actuator function testing, movement work from one station
to another station, crane and vehicle utilization for movement work,
deploying more man power for above works, are completely not required
for entire valve manufacturing cycle during hydro testing operation.
Therefore, it eliminates the lengthy processes in hydro testing so that the
resources are utilized in better way, thereby, saving substantial time and
money. In addition to that, electric supply in the valve is not required in
the hydro testing station, thus improves the safety. In Edge preparation
process, in which preparation of inlet and outlet of valve is done after
completion of hydro testing, in case actuators get damaged, dismantling
and assembling once again the actuator consumes time. The electric
connectivity is made to Hydro testing bench only not to the valve. The
present invention intends to overcome that said problems.

[027] Each of the appended claims defines a separate invention, which for
infringement purposes is recognized as including equivalents to the
various elements or limitations specified in the claims. Groupings of
alternative elements or embodiments of the invention disclosed herein are
not to be construed as limitations. Each group member can be referred to
and claimed individually or in any combination with other members of the
group or other elements found herein. One or more members of a group
can be included in, or deleted from, a group for reasons of convenience
and/or patentability. When any such inclusion or deletion occurs, the
specification is herein deemed to contain the group as modified thus
fulfilling the written description of all groups used in the appended claims.
[028] It will be understood by those within the art that, in general, terms
used herein, and especially in the appended claims (e.g., bodies of the
appended claims) are generally intended as “open” terms (e.g., the term
“including” should be interpreted as “including but not limited to,” the
term “having” should be interpreted as “having at least,” the term
“includes” should be interpreted as “includes but is not limited to,” etc.).
It will be further understood by those within the art that if a specific
number of an introduced claim recitation is intended, such an intent will
be explicitly recited in the claim, and in the absence of such recitation no
such intent is present. For example, as an aid to understanding, the
following appended claims may contain usage of the introductory phrases
“at least one” and “one or more” to introduce claim recitations. However,

the use of such phrases should not be construed to imply that the
introduction of a claim recitation by the indefinite articles “a” or “an” limits
any particular claim containing such introduced claim recitation to
inventions containing only one such recitation, even when the same claim
includes the introductory phrases “one or more” or “at least one” and
indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically
be interpreted to mean “at least one” or “one or more”); the same holds
true for the use of definite articles used to introduce claim recitations. In
addition, even if a specific number of an introduced claim recitation is
explicitly recited, those skilled in the art will recognize that such recitation
should typically be interpreted to mean at least the recited number (e.g.,
the bare recitation of “two recitations,” without other modifiers, typically
means at least two recitations, or two or more recitations). Furthermore,
in those instances where a convention analogous to “at least one of A, B,
and C, etc.” is used, in general such a construction is intended in the sense
one having skill in the art would understand the convention (e.g., “a
system having at least one of A, B, and C” would include but not be limited
to systems that have A alone, B alone, C alone, A and B together, A and C
together, B and C together, and/or A, B, and C together, etc.). In those
instances where a convention analogous to “at least one of A, B, or C, etc.”
is used, in general such a construction is intended in the sense one having
skill in the art would understand the convention (e.g., “a system having at
least one of A, B, or C” would include but not be limited to systems that
have A alone, B alone, C alone, A and B together, A and C together, B and

C together, and/or A, B, and C together, etc.). It will be further understood
by those within the art that virtually any disjunctive word and/or phrase
presenting two or more alternative terms, whether in the description,
claims, or drawings, should be understood to contemplate the possibilities
of including one of the terms, either of the terms, or both terms. For
example, the phrase “A or B” will be understood to include the possibilities
of “A” or “B” or “A and B.”
[029] It will be further appreciated that functions or structures of a
plurality of components or steps may be combined into a single component
or step, or the functions or structures of one-step or component may be
split among plural steps or components. The present invention
contemplates all of these combinations. Unless stated otherwise,
dimensions and geometries of the various structures depicted herein are
not intended to be restrictive of the invention, and other dimensions or
geometries are possible. In addition, while a feature of the present
invention may have been described in the context of only one of the
illustrated embodiments, such feature may be combined with one or more
other features of other embodiments, for any given application. It will also
be appreciated from the above that the fabrication of the unique structures
herein and the operation thereof also constitute methods in accordance
with the present invention. The present invention also encompasses
intermediate and end products resulting from the practice of the methods
herein. The use of “comprising” or “including” also contemplates
embodiments that “consist essentially of” or “consist of” the recited feature.

The terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting of the present
disclosure. It will be appreciated that several of the above-disclosed and
other features and functions, or alternatives thereof, may be combined into
other systems or applications. Various presently unforeseen or
unanticipated alternatives, modifications, variations, or improvements
therein may subsequently be made by those skilled in the art without
departing from the scope of the present disclosure as encompassed by the
following claims.
[030] The claims, as originally presented and as they may be amended,
encompass variations, alternatives, modifications, improvements,
equivalents, and substantial equivalents of the embodiments and
teachings disclosed herein, including those that are presently unforeseen
or unappreciated, and that, for example, may arise from
applicants/patentees and others.
ADVANTAGE OF THE INVENTION
[031] The advantage of the invention is that it performs hydro testing of
forged steel valves without actuators and without electric supply to valve.
Another advantage of the present invention is that it provides a new
clamping device with torque wrench for hydro testing.

[032] Another advantage of the present invention is that it reduces the
cycle time for manufacturing of forged steel valves.
[033] A further object of the invention is that it performs hydro testing of
forged steel valves without strain.
[034] Yet another advantage of the present invention is that it involves only
one clamping device for different types of valves under particular
dimension of valve.

We Claim:
1. A system of clamping device (12N) for replacing actuator during
Hydro testing of forged valve, comprises of:
- A cylindrical member sleeve (18N) embedded with an internal
threading (17N) for closing and opening the valve required for hydro
testing;
- A casing (16N) for placing the said (18N) therewithin and screwed
by means of lock ring (20N), wherein a groove (14N) is provided in
the lock ring (20N) for better tightness;
- A set of bearings (15N) inserted between the sleeve (18N) and the
casing (16N) for carrying the thrust load while testing ‘seat’ leakage
and ‘backseat’ leakage prior to Hydro testing;
- A plurality of tapped holes (13N) made in the said casing (16N) for
assembling the said clamping device (12N) with valve in operation;
and
- A slot (19N) provided on one end of sleeve (18N) opposite to the
position of (13N) for engaging a torque wrench for fitting the valve in
hydro testing bench.
2. The system of clamping device as claimed in claim 1, wherein it fits
to multiple categories of valves (05) of particular dimension.

3. A method of hydro testing of forged valve with clamping device
(12N), comprises the steps of:
- Calibrating hydro testing bench (10) and pressure gauges (09),
checking fluid level in the tank and the electrical connectivity to
hydro testing bench (10);
- Assembling the valve (05) on hydro-testing bench (10) between the
top plunger (02) and bottom plunger (01) with a rigid hold;
- Selecting the clamping device (12N) according to the specification of
stem (06) of valve (05);
- Assembling the said clamping device (12N) with valve (05) with the
aid of the tapped hole (13N) embedded in clamping device (12N) and
the bolts (07);
- Inserting the torque wrench (11) in the slot (19N) for providing
required torque to open or close the valve (05) ;
- Engaging the threading portion (17N) of sleeve (18N) in the clamping
device (12N) with stem (06) of valve (05) fully screwed till close to
top of the valve (05);
- Allowing water into valve (05) from inlet (03) to outlet (08) to perform
the ‘seat test’ with the said (05) positioned in fully closed condition
with the aid of torque wrench (11);
- Performing the ‘backseat test’ with the valve (05) positioned in fully
opened condition and ‘shell test’ with the valve (05) positioned in
partially opened condition; and

- Performing the Hydro testing of the forged valve (05), wherein in case
of leakage found in the said ‘seat’ or ‘backseat’ or ‘shell’ test, the
valve (05) is sent to valve assembly section for rectification work,
reassembled and sent back for Hydro testing.
4. The method as claimed in claim 3, wherein it replaces actuator during
performance of Hydro testing of forged valve (05), thus eliminates the
process of actuator mounting and dismantling or actuator function
testing.
5. The method as claimed in claim 3, wherein it facilitates Hydro testing
of forged valve (05) eliminating electric connection to it.