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Clamp Saddle Test Apparatus for Leakage, Hydrostatic and Endurance Testing

Estimated Cost

Fig. 01

Fig. 2

Introduction:

The Clamp on Saddle is a device which is used as adaptor for connecting service line to supply pipe line (main line). It is a full encirclement saddle and is in two halves which are encircled around the mains (supply pipe) and is tightened with help of bolts or “V” grooved clamps. It is consisting of one side outlet or two outlets in both pieces. The service line could be connected by means of solvent cement socket, threaded joint or compression fit. Test to be conducted for clamp saddle is as follows.

Test 1: Body test; Resistance to internal pressure of the body and of all pressure containing components

Test 2: Leakage test; High pressure liquid test for leak tightness to internal pressure (seal properties) (1.1 x PN Rate specified by manufacturer)

Test 3:Vacuum test; Resistance to vacuum generated in pipe line

Test 4:Durability Test;Durability shall be based on the fatigue failure due to internal pressure fluctuation inside the pipeaccording to the different magnitude of soil resistance experienced on the clamp saddle vertically and horizontally on variation of internal pressure of the pipe

The cost estimated in the document includes only the cost involved in equipment of endurance and vacuum tests and their fabrication work. The main items in endurance test apparatus are shown in Fig. 3 and are listed as follows.

------Save Name: Clamp Saddle Test Apparatus.doc By: NJ Date: 14.02.2014

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  1. Geared motor 1Kw with VFD unit
  2. Cam of 15 mm lift
  3. Cam of 20 mm lift
  4. Cam of 30 mm lift
  5. Cam follower – roller unit
  6. Cam follower – stem
  7. Guide bush Bracket
  8. Motor mounting Bracket
  9. Test piece mounting Table
  10. Vacuum pump and accessories
  11. Vacuum tank and piping
  12. Vacuum tank and piping

------Save Name: Clamp Saddle Test Apparatus.doc By: NJ Date: 14.02.2014

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Estimated Cost:

  1. Geared motor 1Kw with VFD unit- Rs 750,000.00
  2. Manufacture of 4 nos of cams- Rs 100,000.00
  3. Manufacture of 1 unit of cam follower -roller- Rs 35,000.00
  4. Manufacture of 1 pc of cam follower -stem- Rs 30,000.00
  5. Manufacture of 1 unit of guide bush bracket- Rs 45,000.00
  6. Fabrication of motor mounting bracket- Rs 35,000.00
  7. Fabrication of test piece mounting bracket- Rs 25,000.00
  8. Vacuum pump and accessories- Rs 225,000.00
  9. Vacuum tank and piping- Rs 150,000.00
  10. Test piece immersing tank and piping- Rs 125,000.00

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Total- Rs 1,520,000.00

Fig. 3

Technical Detail and Specifications:

  1. Gear motor with VFD unit; speed range from 0.25 rpm to 15 rpm
  2. Gear motor
  3. Motor speed:shall be able to produce final speedbetween 10 to 15 rpm with help of inbuilt reduction gear box
  4. Motor Power:Not less than 0.5 Kw and not grater that 1 KW
  5. Motor Type:Single phase/Three phase induction motor and shall be able to run at low speed varied (reduced) by VFD in order to obtain speed range from 0.25 rpm to 15 rpm and run minimum for 18 h continuous operation
  6. Power source:230 V / 415 V; 50 Hz
  7. Power supply to motor:Single phase/Three phase AC through VFD unit
  8. No of poles:shall be matched to produce final speed between 10 to 15 rpm with help of inbuilt reduction gear box
  9. Motor Protection:protection against wetting and dusting; IP 68
  10. Frame:shall be matched with inbuilt gear box
  11. Reduction ratio:shall be matched to obtain final speed of 0.25 rpm with input speed of motor
  12. Gear box:Casting two piece box and shall be direct coupled with the motor
  13. Gear wheels:Standard Helical
  14. Material of shaft:SS 316
  15. Lubrication:in oil bath
  16. VFD Unit
  17. Shall be matched with the motor
  18. Power supply:230 V /415 V; 50 Hz
  19. Mm

Available make and models of Geared Motor and VFD unit

  1. Cams – 4 Nos cams for lifting capacity of 15 mm, 20 mm, 25 mm and 30 mm as per drawing
  1. Cam Follower –Roller Unit as per drawing
  1. Cam follower – stem and Guide Bush Bracket as per drawing
  1. Motor mounting Bracket as per drawing
  1. Test piece mounting Table

------Save Name: Clamp Saddle Test Apparatus.doc By: NJ Date: 14.02.2014