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Document NO.T-1480E-R5

Operation Manual

for

JK-2 Field Test System

FUKUISEISAKUSHO Co., LTO

Contents

1.

System Overview

 

1.1

What is jacking test

1.2

System configuration

1.3

How to determine setting pressure

2.

Components

 

2.1

Names and functions

2.2

Functions of JK-2

2.2.1 Front of JK-2

2.2.2 Right flank of JK-2

3.

How to Use System

 

3.1 Selecting sensors

3.2 Assembling load cell

3.3 Installing pressure sensor

3.4 Connecting load cell and pressure sensor to JK-2

3.5 Installing mechanical components of jack

3.6 Operation hydraulic pump

3.7 Activating JK-2 and conducting jacking test

3.8 Auxiliary functions in jacking test mode

3.8.1 Confirming or changing sensor calibration values

3.8.2 Changing effective area of hydraulic cylinder

3.8.3 Changing parameter of blow off detection

3.8.4 Changing data after blow off detection

3.9

Entering data after testing (batch processing mode)

3.10

Troubleshooting during jacking test

4.

Miscellaneous Functions of JK-2

 

4.1

Digital display mode

4.2 Sensor calibration mode

5. Precautions in Handling

Appendices

Appendix 1.

Area of valves exposed to pressure

Appendix 2.

Standards for sensor selection

Appendix 3.

Comparison table of turnbuckles

Appendix 4.

JK-2 screen flow in jacking test mode

2

1.

System Overview

1.1

What is jacking test?

It is important that a safety valve should pop off at a preset pressure. The popping (opening) pressures of

safety valves in power plants are checked and adjusted during routine inspections of the boilers.

During check and adjustment, safety valves installed on actual equipment are actually operated under raised pressures. This is what is known as a field test.

Field tests on the actual installation are very expensive and unproductive. Besides, a large amount of spouting fluid produces loud noise, and the sonic flow of fluid passing through valve openings wears valve seats and impairs seat tightness.

Under these circumstances, jacking test has found increasing use recently, thanks to its low energy consumption and low cost.

Jacking test measures the pressure difference between the pressure (held constant) inside the equipment and the popping pressure of the safety valve to make it possible to adjust and verify the popping pressure.

Jacking test allows to.

1) use normal operating pressures inside the equipment during testing, which offers following advantages:

• automatic equipment operation requiring less staff,

• reduced fuel costs, and

• no overload on equipment, and

2) keep the amount of spouting fluid at a very low level, which offers following advantages:

• no rapid change in pressure and temperature produced and conducted to equipment by safety valve,

• no fear of impairing seat tightness of the safety valve,

• reduced test time due to eliminated necessity to raise pressure inside the equipment, and

• low noise

3

1.2 System configuration

JK-2 field test system is an up-to-date safety valve jacking test system incorporating a microcomputer

based sensors.

As shown in Figure 1, the system consists of a hydraulic jack for applying load on the spring of safety valves, sensors (load cell and pressure sensor) for measuring the pressure difference between set pressure and popping pressure of the safety valve, and an input I output device (JK-2) for processing sensor signals and producing output.

The system is very easy to operate and you can rely on it completely. Once you have installed the system on the safety valve and switched on the input I output device (JK-2), the system measures the popping pressure of the safety valve automatically. The operator has only to operate the hydraulic pump.

lIydrauli e PlIlIIP

~~ _r--_--<CJ

~-~

':'--"1. . JK-2 I
':'--"1.
.
JK-2
I

Figure 1

4

-> --::.:~

.

,"

Hydraulic cyIi nder

Turnbuckle

I

10k.

,,_,,_, _
,,_,,_,
_

Valve stem!

I

Safety 'ahe

1

1.3 How to determine setting pressure

Forces acting on the disk of a safety valve are given by,

F !

= Fs = (Ps*As)

(1)

F

t = Pb x As

(2)

Where,

F !

F

l

: Down load

: Up load Fs: Spring setting load Ps: Safety valve popping pressure As: Valve disk pressure area Pb: Primary pressure (base pressure) of safety valve

When the safety valve is closed, the relationship between forces

is F ! >F t , creating a valve closing pressure (.LIF):

F! =.LIF+F t

(3)

~~~. Load cell

-Uydraulie cy Ii nder

Va I ve stem

Spring

Valve disk

During jacking test, the primary pressure (Pb) is held constant and .LIF is raised by hydraulic pressure to cause the valve to pop off.

By substituting (1) and (2) in (3) and rearranging the result, we obtain,

Ps=.LIF I As + Pb

(4)

Thus. using expression (4), we can derive the popping pressure

of the safety valve from .LI F and Pb.

5

FiB,ure 2

2.

Components

2.1

Names and functions

JK·2 ~~'""'"""Mela. rill' gaskels Hydra lie Turnbuck Ie . Yoke Safdy- valve ,-
JK·2
~~'""'"""Mela. rill' gaskels
Hydra
lie
Turnbuck Ie .
Yoke
Safdy- valve
,-
<-:
Iiiglt pressure hose
!
" ,.J
~

crt inlier

Iii gure ·3

• JK-2: A simple device for testing safety valves with the aid of hydraulic pressure jacked from a hydraulic pump. Measures and displays the popping (opening) pressure of safety valves.

• Pressure sensor: Detects the primary pressure (base pressure) of safety valves.

• Sensor cable: Connects JK-2 with the pressure sensor.

• Gauge adapter: Installed between the primary pressure tap of the safety valve and the master gauge, for connecting the pressure sensor.

• Metal ring gaskets: Used when installing the gauge adapter, master gauge, and pressure sensor.

• Power supply cable: Connects to an external power supply (85V-265V AC, 50 160Hz).

• Load cell: Detects pressure difference between safety valve popping pressure and base pressure.

• Yoke: Mounts on top of the safety valve and connects the hydraulic cylinder with the load cell.

• Turnbuckle: Connects the valve stem of the safety valve and the hydraulic cylinder.

• Hydraulic cylinder: Lifts the valve stem of the safety valve by hydraulic pressure.

• Hydraulic pump: Applies pressure on the hydraulic cylinder.

• High pressure hose: Connects the hydraulic cylinder and the hydraulic pump.

6

2.2

Functions of JK-2 JK-2 has 4 operation modes:

 

1.

Jacking test mode: Automatically monitors the behavior of a safety valve during jacking test, and displays and prints out the popping pressure of the safety valve.

2.

Digital display mode: Functions as an ordinary digital display unit, and prints out the readings of the sensors at a given interval with the help of an interval timer.

3.

Sensor calibration mode: Calibrates the sensor being used, under actual load.

 

4.

Batch processing mode: Prints out and deletes the test results stored during the jacking test mode.

You can select one of the modes by choosing the appropriate key from the Select Mode screen (Screen I) after switching on your JK-2.

 

ACTION

=

F1

Jacking test mode:

[F1]

DISPLAY

=

F2

Digital display mode:

[F2]

CALIBRATION

=

F3

Sensor calibration mode:

[F3]

BATCH

=

F4

Batch processing mode:

[F4]

Screen 1

2.2.1

Front of JK-2

• Liquid crystal screen

Interactively displays sensor readings, measurement results, and instructions for operations.

• Mode display

Normally, indicates the operation mode with LED. In the jacking test mode. this indicates states of popping pressure detection. See Figure 1.

• Keys

Used for selecting modes, setting functions, and entering numeric data. See Figures 2 and 3.

• Printer

Prints out. results of jacking test and readings of sensors.

• Table of sensor calibration values Lists calibration values of the sensors included with the system.

U~id tt7d&1 scrten
U~id tt7d&1
scrten

T'.:' .f

ealibnll

,

I••J

values of the sensors included with the system. U~id tt7d&1 scrten T'.:' .f ealibnll , I••

7

Table 1: Mode display

 

LED for mode display

   

Description

ACT

DISP

CAL

Set P

 

0

0

0

Indicates that the system is operating in the jacking test mode. (Red LED) Indicates that the system is operating in the digital display mode. (Yellow LED) Indicates that the system is operating in the sensor calibration mode. (Green LED) Indicates that jacking test is ready or that zero adjustment is in process. Indicates in the jacking test mode that calculation of popping pressure is completed.

*

0

0

0

0

0

0

0

0

*

0

0

 

O

LED is off

 

LED is on

LED

is flickering

 

Table2: Functions of keys during mode selection and function setting

 

[CANCEL]

 

Goes back to previous screens one by one. Starts measuring popping pressure (in the jacking test mode) Sets the interval timer (digital display mode) Starts calculating sensor calibration values (sensor calibration mode) Starts printing Confirms existing or entered values

[START]

[PRINT]

[ENT]

[F1 I

!]

Selects

a mode. Switches to a sub screen

 

[F21 -]

 

Selects a mode. Selects a sensor option Selects a mode. Selects a sensor option Selects a mode. Selects a sensor option

[F31 -]

[F41 T]

8

Table3: Functions of keys for numeric data entry

[0] to [9]:

Correspond to digits 0 to 9.

[.]

Decimal Point

[SP]

Space key (Erases existing data digit by digit to the right)

[CANCEL]

Goes back to previous screens one by one.

[ENT]

Confirms values entered

[F2 I -]

Moves the cursor to the left

[F31

-]

Moves the cursor to the right

[F4\

]

Moves the cursor to the head of the next line

Table 4: Sensor calibration values

TYPE

Rated capacity

Rated output

Serial No.

[PG-20KU]

[20MPa]

[2.005mVN]

[YG021 0006]

TYPE:

Indicates the type of sensors. Basically, TYPE of a pressure sensor begins with letters PG, and TYPE of a load cell begins with letters LUK.

Rated capacity:

Indicates the maximum permissible capacity of a sensor.

Rated output:

Indicates the output characteristic (calibration value) of a sensor.

SERIAL No.:

Indicates the manufacture's serial number of a sensor.

 

Note: The sensor calibration value is the value of rated capacity plus the value of rated output. Before conducting a jacking test, make sure that the sensor calibration values preset on JK-2 agrees with the calibration values of the sensors being used.

9

2.2.2 Right flank of JK-2

Sensor

for load cell

connector (CH1, CH2)

Receptacl

/

Sensor connector (CH3)-_ for pressure sensor

/

Power switch

FigureS

3. How to Use System

• Sensor connectors (CH1, CH2, CH3): Connectors for connecting sensors. In the jacking test mode, make sure to connect the load cell to CH 1 or CH2 and the pressure sensor to CH3.

• Power switch

• Receptacle: Plug socket for receiving the power supply cord.

• Power cord: Plugged into an external power supply to activate JK-2.

JK-2 processes the Valve-closing load (LlF in expression (4) in Section 1.3 above) from the load cell and the safety valve primary pressure (Pb in the same expression) from the pressure sensor, and automatically calculates and displays the popping pressure of the safety valve. Even if a pressure sensor cannot be connected to the actual equipment on which safety valves are installed, you can measure the popping pressure by manually entering the safety valve primary pressure. (However, we recommend you to use a pressure sensor to take full advantage of this system.)

The following chart outlines the procedures for conducting a jacking test with this system.

* The numbers in [

] indicate the sections where you can find detailed descriptions.

Select sensors and decide base pressure for testing [3.1]

!

Install load cell and pressure sensor [3.2, 3.3]

!

Connect sensors to JK-2 [3.4]

!

Switch on JK-2 and zero adjust sensors [3.7]

!

Install mechanical components of jack [3.5]

!

Operate hldrauliC pump (to measure popping pressure) [3.6]

Process test results (output, store, retest) [3.7]

10

3.1 Selecting sensors

When conducting a jacking test, you should use the most suitable sensors to improve the accuracy of measurement. Each sensor has its measuring range and using it outside its measuring range will result in increased errors and may break the sensor itself.

To select sensors, proceed as follows:

1) Determine the following values. a) Specified popping pressure of safety valve to be tested (Ps) MPa b) Surface area of valve exposed to pressure *1 (As) cm 2

c) Base pressure at the time of testing *2

(Pb) MPa

*1: See Appendix 1 for safety valves manufactured by our company. For other company's products, use the values recommended by the manufacturer. *2: Base pressure is the primary pressure of the safety valve. This should be set at 60% to 85% of the specified popping pressure of the safety valve.

2) Determine the test load (Lt) by substituting the values of Ps, As, and Pb defined above in the following

. Test load (Lt) = (Ps - Pb) x As /10 (kN) 3) Select the type of sensors from Table5 using the values of Pb and Lt determined above.

expression.

Table 5

 

Measuring range of sensor

Type

Pressure sensor

   

O. 2MPa

 

Pb

1.8MPa

PG-20KU

 

lMPa

Pb

9MPa

PG-100KU

2MPa

Pb

18MPa

PG-200KU

5MPa

Pb

45MPa

PG-500KU

*Load

cell

 

0.25

kN

Lt

4.5

kN

LUK-A- 5KN

1.0

kN

Lt

s

18: 0

kN

LUK-A-20KN

4.5

kN

Lt

s

45.0 kN

LUK-A-50KN

Example:

Assume that Ps = 14 MPaG, As = 5.007 cm 2 , and Pb = 10 MPaG. Substituting the values into the above equation, We obtain, Lt =(14 - 10) x 5.007/10 =2.0028 kN

Which indicates that suitable sensors are,

Pressure sensor

PG-200KU

Load cell

LUK-A-5KN

* LUK-A-5KN and LUK-A-20KN shall be supplied as standard. In case that the safety valve specification is over the range of Table 4, LUK-A-50KN shall be supplied instead of LUK-A-20KN. Please inform us before order if LUK-A-50KN is required.

11

3.2 Assembling load cell

Assemble the selected load cell on the hydraulic cylinder as follows (see Figures 6 and 7).

1) Install the load cell [(2) or (11)] on the top face of the cylinder: pass the pull rod [(2-2) or (11-2)] connected to the load cell through the center hole of the cylinder and fit the under surface of the load cell into the top face of the cylinder.

2) Fasten the load cell andcylinder with 4 hexagon socket head cap screws [(2-4) or (11-4)].

with 4 hexagon socket head cap screws [(2-4) or (11-4)]. Figure 6: LUK-A-5KN Figure 7: LUK-A-20KN

Figure 6: LUK-A-5KN

head cap screws [(2-4) or (11-4)]. Figure 6: LUK-A-5KN Figure 7: LUK-A-20KN Caution: Make sure to

Figure 7: LUK-A-20KN

Caution: Make sure to turn the correct surface of the load cell to the cylinder. The letters on the name plate on the load cell flank should be upside down.

12

3.2 Installing pressure sensor

Connect the gauge adapter to a gauge mounting hole where safety valve primary pressure can be measured, and install the pressure sensor selected in 3.1. Refer to Figure 8 and follow the procedure below.

1) Connect gauge adapter (4-1) to siphon pipe. 2) Connect pressure sensor (3-1) to gauge adapter. (When mounting and dismounting pressure sensor, grip its flatted round face.) 3) Insert sensor cable (3-2) into pressure sensor to the root and fasten them with the screw on sensor cable. (Sensor cable has its orientation. Align the notches and insert it correctly.) 4) Attach Bourdon gauge to gauge adapter. *For installation of metal ring gaskets, See Figure 9.

*For installation of metal ring gaskets, See Figure 9. Figure 8 13 Gauge adapter, Bourdon gauge

Figure 8

installation of metal ring gaskets, See Figure 9. Figure 8 13 Gauge adapter, Bourdon gauge ~ressure

13

Gauge adapter,

Bourdon gauge

~ressure sensor .

-----­

COUPI ing

Meta 1 r i "If

gaske1

Gauge adapter.

siphon pipe

Figure 9

3.4 Connecting load cell and pressure sensor to JK-2.

Connect to JK-2 the load cell and pressure sensor you have installed in Sections 3.2 and 3.3 respectively (See Figure 10).

in Sections 3.2 and 3.3 respectively (See Figure 10). p""", """~ Figure 10 1) Connect

p""", """~

Figure 10

1) Connect load cell to upper or middle connector, and pressure sensor to lower connector. (Incorrect connections will cause incorrect measurements.)

2) After connections, render sensors unloaded. Install load cellI hydraulic cylinder assembly to yoke and place them on a plat place free of vibrations (Figure 11). Close the main valve of Bourdon gauge of pressure sensor and loosen the drain plug

(Figure12).

Figure Fi gure 12
Figure
Fi gure 12

Caution: Align the match mark on the plug (from pressure sensor and load cell) with the match mark on the corresponding connector (on the JK-2 body) and insert the plug until you hear a click.

If the pressure sensor cable does not reach JK-2 due to a long distance between pressure sensor installation site and safety valve, you can use up to 2 extension cables (Figure 13) which will make the total distance equal to 13m.

Fi gure 13

14

Pressure sensor

\

up to 2 extension cables (Figure 13) which will make the total distance equal to 13m.

3.5 Installing mechanical components of jack

When you have zero-adjusted the sensors with JK-2 switched on (Step 4 in 3.7), install the mechanical components of the jack on the safety valve, as described below.

1) Screw turnbuckle (10) into pull rod (2-2) or (11-2). (See Figure 14.) Note that the thread is left handed.

2) Install safety valve (with adjusting screw up) on yoke (8). (See Figure 15.) If yoke is shaky, use yoke spacers (9) provided. (Valve stem thread sizes of up to M22 can be used.)

3) Screw hydraulic cylinder / turnbuckle assembly (assembled above) into yoke from above, and screw turnbuckle into valve stem of safety valve (Figure 16), holding cylinder by hand and turning turnbuckle.

4)Turning turnbuckle to the right reduces the clearance (L) between cylinder and yoke (Figure 17). Tighten turnbuckle lightly, paying attention to the fit between yoke top and cylinder bottom, until they come into close contact. Then loosen turnbuckle a 1/6 turn.

5) Connect hydraulic pump, high pressure hose, and hydraulic cylinder (Figure 18): plug nipple at each end of hose snugly into collar on cylinder and pump, and screw couplings of collars over nipples securely.

Figure 14

Figure 17

Figure 15

15

Figure 16

Figore i8

3.6 Operating hydraulic pump

When you have prepared for testing (Step 8 in 3.7), operate the hydraulic pump to test the safety valve, following the steps described below.

Lever

valve, following the steps described below. L e v e r Fi gure 19 1) Fully
valve, following the steps described below. L e v e r Fi gure 19 1) Fully

Fi gure 19

1) Fully close release valve of hydraulic pump.

2) Raise hydraulic pressure by moving the lever up and down. Begin to raise hydraulic pressure slowly, when "Reduced P" has exceeded 90% of "Set Pop. P" or "Load" has exceeded 90% of "Est. load". Continue applying pressure until safety valve blows off and "Set P" on mode display comes on.

3) When "Set P" has lit, fully open release valve of hydraulic pump to lower the pressure. (However, if pressure sensor is not connected, read base pressure when safety valve pops off).

Caution: For some low pressure small valves, fully opening the release valve may not close the safety valve. In that case, loosen the turnbuckle immediately and close the safety valve.

16

Step

Screen display or printout

Descriptions of operations

 

Example of entry

   

Enter the date. format is YY/MM/DD Press [ENT] key to confirm.

 

Enter date and press ENT key

08/10/01

 

081001

[ENT]

 

Oct. 01 '08

5

Note: Cursor "_" is placed at the left end of line for date entry. As you enter data, cursor moves rightward. To correct input errors, move cursor by [-] or [-] key and overwrite data.

Screen 4

   

Enter data about valve to be tested. Meanings of screen terms, number of digits you can enter, and units of data are as follows:

Serial No.: Manufacturer's serial number of valve to be tested. (8 digits, numeric only) Change alphabetic characters into numeric. Valve area: Pressure area of valve to be tested. (5 digits, up to 3 decimal

811234

[T]

7.985

[T]

16.45

[T]

12.5

[ENT]

Serial No. =811234

Valve area =7.985 cm 2

6

Serial No.

Valve area

= 811234

= 7.985

positions)

Popping P: Specified popping pressure of valve to be tested. (4 digits, up to 2 decimal points) Base press. = Base pressure at the time of testing (4 digits, up to 2 decimal positions)

Units of data area: area cm 2

Popping pressure

=16.45 MPa

Popping P

= 16.45

Base press.

= 12.5

Base pressure

Screen 5

 

=12.5 MPa

   

pressure

MPa

Enter all data and press [ENT] key Note: To move cursor to next item, use

[T] key. (After "Base press." cursor wraps around to "Serial No.")

   

Jacking test is pending. "Set P" on

mode display flickers, prompting you to start testing. When preparations listed below are completed, press [START] key.

[START] Starts jacking test

Press START key to

 

7

start measurement

1)

Install jack to safety valve. Tighten drain plug of pressure sensor manually. Fully open main valve of gauge, and apply pressure to Bourdon gauge and pressure sensor.

 

2)

Screen 6

 

3)

18

3.7 Activating JK-2 and conducting jacking test

When you have completed preparations, switch on JK-2 and start jacking test. The procedures for the operation of JK-2 are interactively displayed on the screen, and keys to be used are indicated. If you make inappropriate keyboard entries, you are warned by 2 beeps.

The basic keys are as follows:

Function keys (F1 to F4: START, PRINT, ENT): Allow you to select a mode or set a function.

Ten-key pad:

CANCEL: Allows you to return to the previous screen (Use this key when you made a mistake in entering data or setting a function).

Allows you to enter numeric data.

The f0 II owmg tab e

I

=

=

IStS t h e b

r

asic operations.

.

Screen display or printout

Descriptions of operations

Turn

ON

switch

on

flank

of

JK-2

ACTION DISPLAY CALI BRAT ION = BATCH

=

=

=

FI

F2

F3

F4

Select Mode screen appears. Enter [FI] key to select jacking test

mode. Red LED comes on under "ACT" on mode display.

Screen 1

Select load sensor channel CH1 or

CH2.

If you want to use pressure sensor, enter [F4] key. If you are not going to use pressure sensor, enter [F3] key.

If you are not going to use pressure sensor, enter [F3] key. Select load sensor CH.

Select load sensor CH.

CHl

CH2 = F2

= Fl

enter [F3] key. Select load sensor CH. CHl CH2 = F2 = Fl use you No

use

you

No

Yes

Screen 2-1

want

F3

F4

to

Note: When you select [F4] base popping pressure of safety valve is automatically read into JK-2 If you select [F3], you have to correctly read base popping pressure from another gauge and enter it manually in Step 9.

You are going to zero-adjust. sensors. JK-2 display loaded conditions of sensors, and "Set P" on mode display flickers. Remove load from sensors (Section 3.4), and when sensor readings (CH1, CH2) become stable,

press [ENT] key. Sensor readings on

display are forcefully set at zero.

Note: To ensure accuracy of zero adjustment, [ENT] key is locked while "Set P" is flickering (approx. 3 min.) Press [ENT] key after "Set P" goes off.

Do

pressure sensor?

Screen 2-2

When reading become stable, press ENT

CHl

CH3

= 0.2

= -0.3

Screen 3

Example of entry

[FI]

Selects

mode

jacking

test

[F1] or [F2]

[F4]

You

sensor.

will

use

pressure

[ENT]

Confirms zero

adjustment.

17

Step

Screen display or printout

Descriptions of operations

Example of entry

 

Set Pop.

P

=

16

45

***** Measuring *****

Jacking test starts, and states of measurement are displayed. Operate hydraulic pump as described in Section 3.6. As hydraulic pressure is raised, value of "Reduced P" or "Load"

 

8

increases. JK-2 automatically detects blow off of safety valve, and after turning on "Set P" on mode display, advances to step 9.

If you are not using pressure sensor, read base pressure when "Set P" comes on, and enter the data in step 9.

Note: Screen 7-1 is default screen in this step. However, you can access to screen 7-2 by using [F1] key.

Data displayed are: <Screen 7-1> Set Pop. P: popping pressure you have set in step 6, which is also specified popping pressure of valve being tested.

Reduced P: Pressure being applied to

 
   

safety valve (measured from load of lifting valve stem and base pressure). Base press.: Primary pressure (pressure sensor reading) of safety

 
   

valve (base pressure entered in step 6, if no pressure sensor is connected). <Screen 7-2> Estm. Load: Estimated load of blow off of valve being tested. Load: Current value (load cell reading)

 

of load of lifting valve stem.

   

Pressure: The same as base value in screen 7-1

 

9

Set Pop.

P

= 16.45

*****

Results

******

Display specified popping pressure of valve tested and results of testing. Confirm and press [ENT] key.

[ENT]

Confirms popping pressure measured

Note: If you are not using a pressure

 

Screen 8

sensor, read and enter base pressure as described in Section 3.8.4 below.

 

19

Step

Screen display or printout

Descriptions of operations

 

Example of entry

   

Select one of options according to what you want to do with test results. [START]: Retests valve. When you press this key, you return to step 7. [PRINT]: Prints out test results. (See example) [ENT]: Stores test results. For output and deletion of stored test results, see Section 3.9 (batch processing mode). [ ! ]: Feeds paper for printer.

 

Select one option.

[PRINT]

Retest

 

= START

<Print out>

Print out =PRINT Store data = ENT

[ENT]

 

<Stores data>

 

Screen 9

[START]

 

<Retests valve>

TEST No.

1

 

10

DATE : 08/10/01

<Data to be printed out and stored> TEST No.: Number assigned to test results to be stored DATE: Date when test was conducted S No.: Serial No.

Ao:

Area of hydraulic cylinder

S No.

: 811234

AO = 34.361

 

As

=

7.985

 

Pb

= 12.32

 

As:

Pressure area of

valve

(cm 2 ) (cm 2 )

Lt

=

3. 194

 

Po

=

O. 93

Pk = 4.0 Ps = 16.32

 

Pb: Base pressure of blow off (MPa) Lt: Load of blow off on valve stem (kN)

Po: Reduced pressure

(MPa)

Pk: Corrected pressure (MPa) Ps: Measured popping pressure (MPa)

 

Example of printout

These 10 steps complete a series of operations. When you adjust the popping pressure of a safety valve, use the results of at least two tests instead of one to allow them to level off. Also, allow an interval of at least 3 minutes between two successive tests. Turn off the power after testing, regardless of the instructions on the screen.

20

3.8 Auxiliary functions in jacking test mode

In addition to those basic functions described above, the jacking test mode has several auxiliary functions.

3.8.1 Confirming or changing sensor calibration values

To confirm or change the sensor calibration values preset on the system, proceed as follows on screen 2 (See Step 3 in Section 3.7 above).

Do you want to use pressure sensor?

No

Yes

= F3

=

F4

Screen 2-2

[F1]

Change calibration

(2.000)

CH2=20kN (2.000)

CH3= 2 MPa

CH1= 5kN

(2.001)

Screen 2-1-1

1) Press the [FI]

key when Screen 2-2 is on display.

[ENT]

Do you want to

pressure sensor?

use

No

Yes

= F3

=

F4

Screen 2-2

2) The sensor calibration values currently registered on JK-2 will appear on the screen (Screen 2-1-1). The screen displays the rated capacity and rated output (in the parentheses) for the load cell in CH1, CH2 and for the pressure sensor in CH3. 3) Check the SER No. or TYPE on the body of the load cell and pressure sensor to be used for testing. 4) Compare the values on the screen to those from the table on the JK-2 body for the given SER No. or TYPE. If they differ, overwrite the values on the screen with the correct ones from the table.

<Example of entry> Suppose you replace the values on the screen with the following values. Load cell for CH2 rated capacity: 20 kN, Load cell rated output: 2.05 mVN. Pressure sensor rated capacity: 20 MPa, Pressure sensor rated output: 1.998 mVN.

Screen

Keyboard entry

Change calibration

 

CH1

= go kN

(2.000)

20 [~]

CH2 =

20 kN

(2.050)

CH3

=

20 MPa

(1.998)

 

1.998

[ENT]

5) After making changes, press the [ENT] key to update the sensor calibration values (or to confirm the existinq values, if you chose not to update them) and to return to Screen2-2.

Caution: Make sure to confirm or update the sensor calibration values registered on JK-2, before conducting tests and after changing sensors. The registered values are retained, even while the power is OFF.

21

3.8.2 Changing effective area of hydraulic cylinder

If you prefer to use a hydraulic cylinder other than that provided with this system, proceed as follows on

Screen 5.

Serial No.

= 81123

Valve area

=7.985

Popping P

=

Base press.

=

Screen 5

[F1]

------+

Enter cyl inder area

Cyl.

area = 34.361

Screen 5-1

[ENT]

Serial No.

= 811234

 

Valve area

= 7.985

 

Popping P

=

Base press.

=

Screen 5

1) Press the [F1] key when the Screen 5 is on display. 2) The effective area of the hydraulic cylinder provided with this system is displayed (Screen 5-1). Overwrite the data with new data (significant digit: 5; up to 3 decimal positions). 3) After entering digits, press the [ENT] key to update the data and to return to Screen 5. (To return to Screen 5 without updating the data, press the [CANCEL] key.)

3.8.3 Changing parameter of blow off detection

If "Set P" does not come on when the safety valve blow off, or "Set P" comes on when safety valve does not blow off, change the parameter of blow off detection. Proceed as follows on Screen 6 (Step 7in Section 3.7 above).

Press START key to start measurement

Screen 6

[F1]

Change parameter of blow off detection Parameter = 4

Screen 6-1

[ENT]

Press START key to

start measurement

Screen 6

1) Press the [F1] key when the Screen 6 is on display. 2) The standard parameter (4%) appears on the screen (Screen 6.-1). 3) If "Set P" does not come on when the safety valve blows off, enter a value smaller than the standard parameter. If "Set P" comes on when safety valve does not blow off, enter a value larger than the standard parameter. Overwrite the existinq data with a valid value, which is between 0.1 and 99, of which

a value of 1 to 10 is normally used.

4) After entering new data, press the [ENT] key to update the data and to return to Screen 6. (To return to Screen 6 without updating the data, press the [CANCEL] key.

22

3.8.4 Changing parameter of blow off detection

If you entered wrong data in Step 6, or if you are not using sensors and you have to enter the base pressure manually, reenter data on Screen 8 (Step 9 in Section 3.7 above), as follows.

P = 16.45

*****ResuI ts****

= 16.35

Base press. = 12.35

Popping P

Set PoP.

Screen 8

Enter cyl inder area

 

Cyl.

area = 34.361

[F1]

r

~[ENT] or [CANCEL]

[F1]
[F1]

Ser iaI No. =811234 Valve area = 7.985 Popping P =16.35 Base press. =12. 45

Screen 8-1

[ENT]

7.985 Popping P =16.35 Base press. =12. 45 Screen 8-1 [ENT] 1) Press the [F1] key

1) Press the [F1] key when the Screen 6 is on display.

Set Pop. P = 16.45

*****Results****

=16.45

Base press. =12.45

Popping P

Screen 8

2) The data entered in Step 6 appears on the screen (Screen 8-1). Overwrite the data you want to change (as described in Step 8). To change the effective area of the hydraulic cylinder exposed to pressure, use the [F1] key and follow the same procedure as in Section 3.8.2.

3) After entering new data, press the [ENT] key to update the data and to return to Section 8. To return to Screen 8 without updating the data, press the [CANCEL] key.

Note: If you have changed "valve area" or "Base press." (when you are not using a pressure sensor), the "Results" (Screen 8) are recalculated.

<Example: when you are not using a pressure sensor>

P = 16.45

*****ResuI ts****

= 16.35

Base press. = 12.35

Popping P

Set Pop.

Screen 8

[F1]

Serial No. =811234 Valve area =7.985 Popping P = 16.35 Base press. =12. 35

Screen 8-1

(Before changes)

23

(Changed only base pressure)

Serial No. =811234 Valve area =7.985 Popping P = 16.35 Base press. =12. 40

Valve area =7.985 Popping P = 16.35 Base press. =12. 40 1 [ENT] Screen 8 (After

1[ENT]

Screen 8

(After changes)

Set Pop. P = 16.45

*****Results****

= 16.40

Base press.= 12.40

Popping P

Screen 8

3.9 Entering data after testing (batch processing mode)

To print out data after completing all tests of safety valves, or to delete stored data, select the batch processing mode. Data stored durill9 testlrtq are retained, even while the power is OFF (setup 10 in Section 3.7). Two methods of data identification are available for printing out or deleting stored data:

1) Specify TEST No.: Prints out or deletes all data with matching TEST No. 2)Specify SERIAL No.: Prints out or deletes all data with matching SERIAL No.

The basic functions of the keys are the same as in Section 3.7.

The following table lists the basic operations.

Step

Screen display or printout

Descriptions of operations

 

Example of entry

1

 

Turn ON switch on flank of JK-2

   

ACTION DISPLAY

=

F1

Select mode screen appears. Press [F4] key to select batch

[F4]

=

F2

2

CALI BRA Tl ON = BATCH

=

F3

processing mode

 

Selects batch

F4

 

processing mode

 

Screen 1

 

Do you want

to

pr i nt

     

TEST No.1 SERIAL No.?

Press either [F1] or [ENT] key.

[F1]

 

YES

=

F1

[F1]: Prints out a list of all test numbers and serial numbers, starting from TEST

Prints out data

NO

=

ENT

 

Screen 2

 

NO.1.

 

TEST

1 I

811234

(If you want to discontinue printing, press [CANCEL] key.)

3

TEST

2 I 811234 3 I 811234 4 I 811234

 

TEST

 
 

TEST

[ENT]:

No

printout.

Transfers you

to

 

Step 4.

-----­ -------­ ------­ ----.----­ Example of printing

Select one action

Select

one

of options

according

to

[F1]

Delete

=

F1

what you want to do with data. [F1]: Deletes specified data.

Deletes data

Print out = PRINT

4

Exit

= ENT

[PRINT]: Prints out specified data. [ENT]: Transfers you to select mode screen. (Step 1, Screen 1) Note: When you select [F1] or [ENT], you are transferred to Step 1.

[PRINT] Prints out data

Screen 3

 

24

 

Screen display or printout

Descriptions of operations

Example of entry

   

Specify a method of data retrieval. (The second line includes the action you selected in Step 4.)

[F1]

Speci fy

data ID

(Action = Print out)

Selects data with matching serial number

TEST No. SERIAL No =

=

F1

 

F2

[F1]: Carried out (in Step 6) action

[F2]

5

Screen 4

 

specified in Step 4 on all data with a test number that matches the one you will specify in Step 6. (Go to step 6.) [F2]: Carries out (in Step 7) action specified in Step 4 on all data with a serial number that matches the one you will specify in Step 7. (Go to step 7.)

Selects data with matching test number

Speci tv

TEST No.

Specify range of test numbers you want to delete or print (The second line indicates the action you selected in Step 4.) Relationship between entered numeric and result of action is:

10 [T] 20 [ENT]

(Action = Printout)

Start

=

10

Specifies range of test numbers from 10 to 20.

End

= 20

Screen 5

   
 

1)

Start = 0

]

Printing CANCEL = Stop printing

 

All data

 

End

=0

 

2)

Start

=X ] Data

 

Screen 5-1

X only

   

End

= 0

 

Delete

3)

Start = X] Data between X and Y

TEST No.

10-20

6

YES = F1

 

NO

= ENT

 

End

=Y

Screen 5-2

After specifying "Start" and "End", carry out action by pressing [ENT] key. If you have selected "Printout" in step 4, Screen 5-1 appears and prints out results of measurement. (If you want to cancel printout, press [CANCEL] key.) If you have selected "Delete" in step 4, Screen 5-2 appears. If range of test numbers you selected is correct, press [F1]. If it is wrong, press [ENT].

 

When action is completed or canceled, you are transferred back to step 4.

25

7 Screen display or printout Specify SERIAL No. (Action = Printout) SERIAL NO. = 811234

7

Screen display or printout

Specify SERIAL No. (Action =Printout)

SERIAL NO.

= 811234

Screen 6

Printing

CANCEL =

Stop pr i nt i ns Screen 6-1

Delete data with

SERIAL No.

811234?

YES = F1

NO

= ENT

Screen 6-2

Descriptions of operations

Specify serial number on which you want to carry out action on. (The second line indicates the action you select in step 4.)

Enter serial number, and press [ENT] key to carry out action on all applicable data.

If you have selected "Printout" in step 4.

Screen 6-1 appears and prints out

results of measurement. If you want to cancel printout, press [CANCEL] key. If you have selected "Delete" in step 4, Screen 6-2 appears. If serial number you selected is correct, press [F1] key. If is wrong, press [ENT] key.

When action is completed or canceled, you are transferred back to step 4.

Example of entry

811234 [ENT]

Specifies serial No.

811234

3.10 Trouble shooting during jacking test

If something is wrong with .IK-2 or results of measurement, check the system referring to the following table. If the cause of a malfunction would turn out to be operational errors, read this manual once more and use the system correctly.

Problem

 

Possible causes

 

Solutions

Readings unstable during zero adjustment.

1)

Sensor cables connected improperly. External noise present. Sensors subject to vibrations or loaded. Lower adjust ring out of adjustment. Parameter of blow off detection set inappropriately. Insufficient hydraulic pressure Hydraulic pressure raised irregularly.

1)

Connect Sensor cables properly. Remove causes of noise. Remove vibrations or Loads.

2)

2)

 

3)

3)

Safety valve blow off does not turn "Set P" ON

1)

1)

Check position of ring. Set smaller value as described in Section 3.8.3. Boost pressure by hydraulic pump until "Set P" comes on.

2)

 

2)

3)

3)

"Set P" comes ON before safety valve blow off

1)

1)

Operate hydraulic pump properly to avoid fluctuation of "Reduced P" and "Load". Set larger value as described in Section 3.8.3.

2)

Parameter of

blow off

detection set inappropriately.

2)

26

 

Problem

 

Possible causes

 

Solutions

 

1)

Too many tests at too short intervals. Pressure raised too quickly.

1)

Allow a sufficient interval between tests (approx. 3 min.) Regulate hydraulic pump to make lowest-order digit of "Reduced P" or "Load" increase slowly just before blow off. Check and change sensor calibration values as described in section 3.8.1. (Turn off power once, then turn it on again.) Check sensor connections (See Section 3.4). Check direction of load cell (See section 3.2). (When changing connections or reinstalling load cell, turn off power once, then turn it on aqain.) Check and change sensor calibration values (See 3.8.1)

Results of measurement do not level off

2)

2)

Readings during measurement (Step 8 in section 3.7) too large or small compared to rated capacity of sensors.

1)

Inappropriate sensor

1)

calibration values present on

JK-2.

"Reduced P" or' Load" does not increase, even though hydraulic pump is operating.

1)

Sensors connected to wrong connectors Load cell installed on wrong side (wrong side of load cell facing hydraulic cylinder).

1)

2)

2)

   

Readings of pressure sensor differ from those of other gauges.

2)

Inappropriate sensor

2)

calibration values present on

 

.IK-2.

 

Sensor readings exceeded rated capacity.

1)

Sensor selection inappropriate. Inappropriate sensor

1)

Select other sensors (see 3.1). Check and change sensor

2)

 

2)

calibration values (see 3.8.1). (When changing sensors or their calibration values, turn off power once, then turn it on again.) 1) Delete or print out stored data (Step 9 in 3.9): If number of data items in subsequent tests are likely to exceed "Remaining space", press [CANCEL] key to return to select mode screen, printout or delete stored data in batch mode, and then select jacking test mode again. If expected number of data items does not exceed "Remaining space", press [ENT] key. 1) Close release valve fully. 2) Remove constriction or bend. 3) Check connection (See 3.5). 4) Check and fill fluid. 5) Lower the piston.

calibration values preset on

JK-2.

 

Following message displayed in jacking test mode.

1) Number of data items stored in JK-2 has exceeded 70. (This is a warning message reminding you of special available for further date storage.) Meaning of terms:

 

Running out of

memory. Stored data Remaining space

 

=

71

=

28

 

Stored data: Number of test results already stored. Remaining space: Number of test results that can still be stored.

 
 

Hydraulic pump does not raise pressure.

1) Release valve open. 2) High pressure hose constricted or bent sharply. 3) High pressure hose connected improperly. 4) Low fluid level. 5) Cylinder piston at too.

 

27

4.

Miscellaneous Functions of JK-2

4.1

Digital display mode

To use JK-2 as an ordinary digital display unit, select the digital display mode. In addition, JK-2 has an

ability to print out sensor readings at a reset interval (interval timer function).

After connecting sensors, proceed as foows.II

Step

Screen display or print out

Descriptions of operations

Example of entry

1

 

Turn ON switch on flank of JK-2

 
   

ACTION DISPLAY CALI BRA TI ON = BATCH

=

=

=

F1

Select Mode screen appears. Enter [F2] key to

[F2]

F2

select digital display mode.

Selects digital

2

F3

Yellow LED on mode display comes on.

display mode

F4

 

Screen 1

 

Select

load sensor

CH

 

Select one of options according to which sensor Channel you want to use. [F1]: To use only sensor connector 1.

[F1]

 

CH1

CH2

=

F1

= F2

To select CH1

     
 

CH3

USE

= F3

[F2]: To use only sensor connector 2. To use CH3, press [F3] and go to next screen

   

Screen 2-1

 

2-2.

3

 

Select

load sensor CH &CH3 = F3

 

Press [F4] to enter sensor calibration mode on screen 2-1. [F3]: To use both sensor connectors 1 and 3. [F4]: To use both sensor connectors 2 and 4. Note: For sensor connector numbers, see Figure 5 in 2.2.2. To enter sensor calibration values, change screens by using [F1] key and follow procedure described in 3.8.1.

 

CH1

CH2 &CH3

= F4

 

[F4]

Screen 2-2

 

To use both sensor channels 2 and 3.

 
 

When readings become

Zero-adjust sensors: First remove load from sensors, and when sensor readings (CH1, CH3) become stable, press [ENT] key (See step 4 in

[ENT]

stable,

press ENT

 

CH1

=

0.2

 

Confirms zero

4

CH3

=

-0.3

section 3.7) Note: To ensure accuracy of zero adjustment, [ENT] key is locked while "Set P" is flickering (approx. 3min.). Press [ENT] key when "Set P" goes off.

adjustment.

 

Screen 3

   

*****Measuring****

Displays sensor readings. On this screen, keys have following functions. [START]: Used to set or cancel interval timer. When you press this key, you are transferred to step 6. [PRINT]: Prints sensor reading of the moment

[PRINT]

CH1

=

15.35

 

Prints sensor

Ch3

=

12.32

readings

 
 

5

PRINT = printout Screen 4

--------­

 

when this key was pressed. [ ! ]: Feeds paper for printer.

 

CH1

=

15.35

 

CH3

=

12.32

-------------­

Example of printout

28

Step

Screen display or print out

Descriptions of operations

Example of entry

   

Set interval timer

 

Set an interval on interval timer. If timer is already in operation, cancel setting and return to step 5. Enter data in the order of hours, minutes, and seconds, and press [ENT] key to confirm. (Then

you are transferred to step 5). Note: Method of numeric data entry is the same as in step 5 in section 3.7. Minimum interval that can be set is 15 seconds.

[-] [-] [-]

Time = H M

15S

[-]

15

Press ENT to confirm

   

6

 

Screen 5

Sets interval at 15 seconds.

 

------------------­

CH1

=

15.35

CH3

=

12.32

------------------­

 

Example of printout

29

4.2 Sensor calibration mode

To calibrate the sensors used with .1K-2, select the sensor calibration mode. The method consists of applying a known pressure on the sensor and calculating calibration values from the result of the load

application. After connecting sensors, proceed as follows.

Step

Screen display or print out

Descriptions of operations

Example of entry

1

 

Turn ON switch on flank of .IK-2

 

ACTION DISPLAY

 

=

Fl

Select Mode screen appears. Enter [F3] key to select sensor calibration mode.

[F3]

=

F2

Selects sensor

2

CALI BRA TI ON = BATCH

=

F3

Green LED comes on under "CAL" on mode display.

Calibration mode

F4

 

Screen 1

 

3&4

 

Steps 3 and 4 are the same as in Section 4.1.

 
 

Select load sensor CH.

 

Select sensor channel CH1, CH2 or CH3. [F1]: To calibrate sensor connected to sensor connector 1. (Go to step 6) [F2]: To calibrate sensor connected to sensor connector 2. (Go to step 6) [F3]: To calibrate sensor connected to sensor connector 3. (Go to step 6)

[F1]

 

CHl

=

Fl

To calibrate

CH2

=

F2

sensor

CH3

=

F3

connected to

   

CH1.

 

Screen 4-1

When readings become

 

stable,

press ENT

Zero-adjust sensors: First remove load from sensors, and when sensor readings become

[ENT]

CHl

=

0.2

 

Confirms zero

5

Screen 4-2

stable, press [ENT] key.

adjustment.

   

System is ready to measure load. Apply a stable known load on sensor with a standard or a

[START]

Apply load on sensor

 

Starts

6

and press START key.

testing machine. Use a load as close to rated capacity of sensor as possible. Then press [START] key to go to step 7.

measurement

 

Screen 5

30

Step

Step 7 8

7

Step 7 8
Step 7 8
Step 7 8
Step 7 8

8

Step 7 8
Step 7 8

9

Step 7 8 9 Screen display or print out Enter CHl sensor data, press ENT. Act

Screen display or print out

Enter CHl sensor data, press ENT.

Act load

=5.000 kN

Screen 6

Cal ibration results. Press ENT to confirm

Rt Capacity

=5

Rt Output = 2.005

Screen 7

Select one option. Once more = S T A R T Update / print =

Select one option.

Once more

=START

Select one option. Once more = S T A R T

Update / print = ENT

Screen 8

Update / print = ENT Screen 8

Rt Capacity =5.000 kN

Descriptions of operations

Enter rated capacity and actual load applied in step 7, and then press [ENT] key to

confirm (Go to Step 8).

step 7, and then press [ENT] key to confirm (Go to Step 8). Displays results of
step 7, and then press [ENT] key to confirm (Go to Step 8). Displays results of
step 7, and then press [ENT] key to confirm (Go to Step 8). Displays results of
step 7, and then press [ENT] key to confirm (Go to Step 8). Displays results of

Displays results of sensor calibration. Press [ENT] to confirm.

results of sensor calibration. Press [ENT] to confirm. Select either option according to what you want
results of sensor calibration. Press [ENT] to confirm. Select either option according to what you want
results of sensor calibration. Press [ENT] to confirm. Select either option according to what you want
results of sensor calibration. Press [ENT] to confirm. Select either option according to what you want

Select either option according to what you want to do with results of calibration. [START]: Cancels results of calibration and

returns to step 5. [ENT]: Updates existing data with new results and prints out new results. Then returns to step 5.

results and prints out new results. Then returns to step 5. Example of entry 5.0 5.0

Example of entry

5.0

5.0

[~]

[ENT]

returns to step 5. Example of entry 5.0 5.0 [~] [ENT] Rated capacity: 5kN Actual capacity:
returns to step 5. Example of entry 5.0 5.0 [~] [ENT] Rated capacity: 5kN Actual capacity:

Rated capacity: 5kN Actual capacity: 5kN

5. Example of entry 5.0 5.0 [~] [ENT] Rated capacity: 5kN Actual capacity: 5kN [ENT] Confirm

[ENT]

Confirm

5. Example of entry 5.0 5.0 [~] [ENT] Rated capacity: 5kN Actual capacity: 5kN [ENT] Confirm
5. Example of entry 5.0 5.0 [~] [ENT] Rated capacity: 5kN Actual capacity: 5kN [ENT] Confirm
5. Example of entry 5.0 5.0 [~] [ENT] Rated capacity: 5kN Actual capacity: 5kN [ENT] Confirm

[ENT] Update / print

5. Example of entry 5.0 5.0 [~] [ENT] Rated capacity: 5kN Actual capacity: 5kN [ENT] Confirm

5. Precautions in handling

* JK-2 and sensors

• These are precision instruments. Never drop them or give shocks to them.

• Do not use or store them under hot humid conditions. (Use them at temperatures of 10 to 40 "C and humidity of below 90% RH.)

• They are not dust proof or water proof. Do not use them in places exposed to rain.

• When you connect .IK-2 to an external power supply, use AC85 to 265V 50 / 60 Hz.

• Connect the sensors securely to the sensor connectors and keep the connections free of water, oil, dust, and other foreign matters.

• Check the rated capacities and calibrated values of the sensors before testing. Do not put the sensors under loads greater than their rated capacity.

• Do not constrict or bend the sensor cables and power cable. Constrictions and bends may cause disconnection.

• Thoroughly remove oil and water from the equipment and store it properly.

* Mechanical components of jack.

• Always bleed air from the hydraulic cylinder and high pressure hose before testing. Insufficient bleeding may results in incorrect measurements.

• When connecting the high pressure hose, avoid constrictions and bends.

• Check the oil level of the hydraulic pump before testing. Oil level should be 80% of the full capacity.

• When installing a safety valve on the jack, make sure that the safety valve is horizontal.

• Do not store the jack under extremely hot humid conditions.

31

Appendices

Appendix 1. Area of valves exposed to pressure (excerpts)

This table applies to standard valves as of 1st October 2008. Some of the figures may not apply to older valves.

<Table 1: Pressure areas for valves of SL series>

[Standard valves as of 1st August 20]

~Class

F

F1

G

G1

H

J

K,J3

K2

K3,L

SL100-300

3.157

-

5.208

-

8.683

12.914

18.857

-

28.369

SL400

4.909

-

4.909

-

8.683

12.914

18.857

25.518

27.572

SL500-1000

-

8.683

-

8.683

8.683

12.914

18.857

24.85

27.572

Class

M,M2

N

N2

P

00

01

a

R

T

SL100-300

37.122

49.327

-

65.755

-

-

106.6

152.84

263.02

SL400

37.122

 

- 49.327

62.912

78.54

92.033

106.6

152.84

246.06

SL500-800

36.853

 

- 49.327

62.211

78.148

91.609

106.6

152.84

-

<Table 2: Pressure areas for valves of SJ series>

[Standard valves as of 1S October 2008]

Clas

F2

G2

H2

J2

L1

M

N3

P2

02

03

R

T

 

SJ100­

                       

300

5.208

8.683

12.914

18.857

28.369

37.122

54.106

65.755

92.033

106.60

152.84

263.02

 

Class

 

25

 

32

 

40

 

50

 

65

 

80

90

100

115

125

150

 

SJ400

4.909

6.720

10.463

16.439

27.572

 

37.122

49.327

62.912

78.540

92.033

127.68

32

Appendix 2.

Comparison table of turnbuckles

p p e n d i x 2 . Comparison table of turnbuckles (Left -hand thread)

(Left -hand thread)

Hydralll ic cr l inder side

Coarse screw thread Valve slem side

Valve stem size

M8

M10

M12

M16

M20

M22

M24

M27

M30

M33

M36

 

SL100.200

F-H

J

K-M

N,P

Q

R,T

         

SL300

F,G

H

J,K

L-N

P,Q

R,T

         

SL400

F,G

 

H.J

K-L

M

N2

P

QO

Q1

Q

R,T

SL500

   

F-H

J,K

K2,L

M

N2

P

QO

Q1

 

SL600

   

F-H

J

K

K2

L

M-N2

     

Model

SL700,800

   

F,G

H

J

K

K2,L

 

M,M2

   

SL900

       

H,F1,G1

J

K,L

     

K2,L

M,M2,N2

SL1000

             

J3

   

L,M,M2

SJ100,200

F2,G2

H2

J2-M

N3,P

Q2,Q3

R,T

         

SJ300

F2

G2

H2,J2

L1­

P2

Q2­

         

N3

R

SJ400

25mm

32mm

40,50mm

65mm

80mm

90mm

100mm

115mm

125mm

 

150mm

Appendix 3.

Standards for sensor selection (excerpts from SL100 to 1000)

<Selecting pressure sensor>

Table 3: Table for pressure sensor selection

Popping pressure (MPa)

Base pressure (%)

60

-2

PG-20KU

-3

-10

PG-100KU

-12

-14

-21

PG-200KU

-37

PG-500KU

60-65

65-70

70-75

75-80

80-85

33

<Selecting load cell>

Table 4: Table for load cell selection

   

Measuring range of popping pressure (MPa)

 
 

Load cell

   

LUK-A-5KN

   

LUK-A-20KN

 

Size

 

60-65

65-70

70-80

80-85

60-65

65-70

70-80

80-85

 

D-F

2.3-3.8

2.7-3.8

 

G

1.4-3.8

1.6-3.8

2.4-3.8

3.2-3.8

 

Out of range

 

H

0.9-3.8

1.0-3.8

1.5-3.8

2.0-3.8

J

0.6-3.8

0.7-3.8

1.0-3.8

1.3-3.8

1.6-3.8

1.8-3.8

2.7-3.8

 

0

K

 

0.4-3.8

0.5-3.8

0.7-3.8

0.9-3.8

1.6-3.8

1.8-3.8

2.7-3.8

0

M

                 

l

L

0.3-3.8

0.3-3.8

0.5-3.8

0.6-3.8

1.1-3.8

1.2-3.8

1.8-3.8

2.4-3.8

0

                 

0

M

0.2-3.0

0.3-3.4

0.4-3.8

0.5-3.8

0.8-3.8

0.9-3.8

1.4-3.8

1.9-3.8

-

-I

N

 

0.2-2.2

0.2-2.6

0.3-3.0

0.4-3.8

0.6-3.8

0.7-3.8

1.1-3.8

1.4-3.8

CJ)

 

P

0.2-1.6

0.2-1.9

0.2-2.2

0.3-3.3

0.5-3.8

0.6-3.8

0.8-3.8

1.1-3.8

Q

0.1-1.0

0.1-1.1

0.2-1.3

0.2-2.0

0.3-2.1

0.4-2.1