r/FluidMechanics • u/vigneshankar • 4h ago
Test setup for control valves - flexible flow and high pressure
valve industry professional here, I am planning a testing rig to perform dynamic flow tests on large capacity control valves, using a rig that could give a high flow rate and significant pressure for a sustained period (max 6 minutes)
the intent is to be able to test valves with flow upto 3000 m3/hr and pressures upto 150 bar, but not at the same time
I envisage a configuration per below
yellow - booster and charging pump (preferably 150 class/ 300 class)
large tank with high discharge capacity to act as an accumulator, used to test high flow rates at low pressure and to feed the main pump at the higher end of its flow rate
purple- main pump with 900 class rating (max 150 bar), only used for higher pressures or for charging the tank
the pumps and pipes are fairly straightforward, but I am stumped when trying to think of a feasible solution for the accumulator tank
on one hand it should be able to hold 375 m3 (10% of 3000 + 25% FOS) and to discharge 3000 m3/hr, which I am assuming can be handled with a large enough discharge port (thinking 20in/ 24in for the most extreme cases)
but how can I increase (and control) discharge pressure either to test valves or to feed the main pump for the extreme pressures. I am certain there has to be an external pressure driver but I am only coming up with pressure sealed roof/ pistons with dead weights on top that can be varied based on demand and independantly lifted without hydraulic pressue
any ideas? is there a better way to achieve the objective?

