S & M Water Consultants Test Procedures In This Manual TEST Reduced Pressure Assembly One Hose Method PAGE 1 Double Check Assembly One Hose Method 5 Pressure Vacuum Breaker One Hose Method 7 Spill Proof Vacuum Breaker One Hose Method 9 Reduced Pressure Assembly Five Valve Method 11 Double Check Assembly Five Valve Method 13 Pressure Vacuum Breaker Five Valve Method 15
PROCEDURES THAT ARE REQUIRED BEFORE ANY TEST IS PREFORMED IMPORTANT ALL TEST SHALL BE PREFORMED WITH THE GAUGE AT THE CRITICAL LEVEL OF THE CHECK and THE UNIT IN A STATIC FLOW CONDITION 1. Notify the property owner or representative that the water will be off for a short time. 2. If the device is on a fire sprinkler system, other agencies will need to be notified. 3. A check for alarm systems must be made. 4. USE CAUTION when disarming any alarm. 5. Notify appropriate agencies. 6. Ask about any water cooled equipment that could be damaged by water shut off. 7. Locate the device. 8. Inspect the device for damage and insure it has operable valves and test cocks. 9. Check serial No. To verify the correct device is being tested. 10. Determine the direction of flow. 11. Locate test cock No. 2. (Device failure is common if the hoses are not attached correctly). NOTE: 1. Some field test procedures require that shut off valve No. 1 be closed. This procedure may introduce debris, such as rust or tuberculin, into the valve that will impact against check valve No 1 or check valve No. 2 and compromise the sealing quality. This potential problem should be considered prior to selection of a test method. 2. To test the check valve when the shut off valve No, 1 is leaking, a tee or other method must be used to flow water from test cock No. 2 and compensate for the leaking valve. A accurate differential pressure cannot be determined with a large leak through shut off valve No. 1, because a flow of water through the tee or other method will create a false indication on the gauge.
Reduced pressure assembly 1 HOSE FIELD TEST PROCEDURE Prepare the assembly to attach the gauge: Install adapters and flush test cocks. Install a three way valve at test cock 2 and adapters in test cocks 1,2, 3, and 4. A second three way valve may be used at test cock 3 to Compensate for a leaking shutoff valve. Open test cock 4, then open and close test cocks 1, 2, and 3. Close test cock 4. Purpose: Water flowing through check valve 1 increases the differentia Pressure and reduces the risk of prematurely opening the relief valve while flushing test cock 1and 2. Typical Reduced Pressure Assembly with gauge 1
Check #2 in direction of flow test Check 2 Direction of flow Criteria: Gauge value must be 1.0 psid or greater. 1.Remove low pressure and bypass hoses from gauge and maintain gauge at assembly center line. 2.Attach the high pressure hose to test cock 3. 3.Open gauge high bleed, then slowly open test cock 3 and close high bleed. 4.Close shut off valve 2, then shut off valve 1. 5.Slowly open test cock 4. 6.When water stops flowing from test cock 4, record the gauge reading. * If water continues to flow, it may be a leak at shut off valve 2 with back pressure or shut off valve #1. Close test cock 4 and observe the gauge for movement. If needle increases, shut off valve #1 may be leaking. Re open test cock #4. Open Test Cock #2, very slowly, and flow water until the water stops flowing at test cock #4, or the needle holds steady, record this reading. If water continues to flow from Test Cock #4, Shut off valve #2 is leaking with back pressure. If needle holds steady the reading will be accurate. Close all test cocks and remove the high pressure hose. Check 1 Direction of flow Criteria: Gauge value must be 5.0 psid or greater. 1.Install 1/4 inch three way valve at test cock 2 and open test cock 2. 2.Attach 14 inch hose from test cock 1 to test cock 2. 3.Slowly open test cock 1 and 2. 4.Re pressurize assembly Shut off valves 1 and 2 remain closed. 5.Attach gauge high pressure hose to three way valve at test cock 2. 6.Open gauge high bleed valve and three way valve at test cock 2. 2
7, Close high bleed valve. 8. Close test cock 1. 9. Slowly open test cock 3. When water stops flowing from test cock 3, record the gauge reading. If water continues to flow through the test cock #3, Shut off valve #1 is leaking. Remove the hose between test cocks 1 and 2 and open the three way valve slightly until water stops flowing at test cock 3. Record this reading. If not using 3 way valve, open High Gauge Valve and very slowly open Gauge By Pass valve to flow water until water stops flowing at Test Cock #3. Relief valve opening test Relief valve Opening Criteria: Vent must open before differential gauge reads 2.0 psid. 1. Observe gauge and slowly open the high bleed valve. 2. Record gauge reading when first drops are felt. 3. Continue opening high bleed valve to verify that the relief valve is fully open. Re pressurize assembly 1. Re pressurize the assembly using supply pressure from test cock 1 through the 3 way valve at test cock 2. 2. Remove trapped air from downstream test cocks. 3. Close all test cocks and remove fittings. 4. Remove gauge. 5. Open shut off valve 1 and then restore the customer to service. 3
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Double Check Valve Assembly 1 HOSE FIELD TEST PROCEDURE Prepare the assembly to attach the gauge: Install adapters and Flush test cocks. Install a three way valve at test cock 2 and adapters In test cocks 1, 2, 3, and 4. A second three way valve may be used at test cock 3 to compensate for a leaking shutoff valve No. 1. Once the adapters are installed, flush the test cocks by opening Test cock 4, then open and close test cocks 1, 2, and 3. Close test cock 4. CHECK 2 DIRECTION OF FLOW Criteria: Gauge value must be 1.0 psid or greater. 1. Remove low pressure and bypass hoses from gauge and maintain gauge at assembly center line. 2. Attach high pressure hose to test cock 3. 3. Open gauge high bleed, then slowly open test cock 3 and close high bleed. 4. Close shut off valve 2, then shut off valve 1. 5. Slowly open test cock 4. 6. When water stops flowing from test cock 4, record the gauge reading. * If water continues to flow, it may be a leak at shut off valve 2 with back pressure or shut off valve #1 7. Close test cock 4 and observe the gauge for movement. If needle increases, shut off valve #1 may be leaking. Re open test cock #4. Open Test Cock #2, and flow water until the water stops flowing at test cock #4, record this reading. If water continues to flow from Test Cock #4, Shut off valve #2 is leaking with back pressure. If needle holds steady the reading will be accurate. Record this reading. 5
7. Close test cock 4 and observe the gauge for movement. If needle increases, shut off valve #1 may be leaking. Re open test cock #4. Open Test Cock #2, and flow water until the water stops flowing at test cock #4, record this reading. If water continues to flow from Test Cock #4, Shut off valve #2 is leaking with back pressure. If needle holds steady the reading will be accurate. 8. Close all test cocks and remove the high pressure hose. Check 1 Direction of flow Criteria: Gauge value must be 1.0 psid or greater. 1. Install 1/4 inch three way valve at test cock 2 and open test cock 2. Attached 1/4 inch hose from test cock 1 to test cock 2. 3. Slowly open test cock 1 and 2. 4. Re pressurize assembly Shut off valves 1 and 2 remain closed. 5. Attach gauge high pressure hose to three way valve at test cock 2. 6. Open gauge high bleed valve and three way valve at test cock 2. 7. Close high bleed valve. 8. Close test cock 1. 9. Slowly open test cock 3. When water stops flowing from test cock 3, record the gauge reading. If water continues to flow through the test cock #3, Shut off valve # 1 is leaking. remove the hose between test cocks 1 and 2, and open the three way valve slightly until water stops flowing at test cock 3. Record this reading. If not using 3 way valve, open High Gauge Valve and very slowly open Gauge By Pass valve to flow water until water stops flowing at Test Cock #3. Re pressurize assembly Re pressurize the assembly using supply pressure from test cock 1 through the three way valve at test cock 2. Remove trapped air from downstream test cocks. Close all test cocks and remove fittings, Remove gauge. Open shut off valve 1 and then restore the customer to service. (If shut off 2 was closed on arrival, the valve will remain closed.) 6
PRESSURE VACUUM BREAKER 1 HOSE FIELD TEST PROCEDURE 1. Inspect assembly for correct components. 2. Remove canopy and clean any debris around air inlet. 3. Flush test cocks, install 3 way valve at test cock 1 with adapters and re flush test cocks. 4. Remove low and bypass hose from gauge. 5. Close shut off valve number 2. 6. Open high bleed on differential gauge. Air inlet / vent test. Criteria: Determine if the inlet valve opens to atmosphere before the valves internal pressure reaches 1.0 psi. 1. Attach high pressure hose to test cock 2 and slowly open the test cock. 2. Close gauge high bleed when air is purged. 3. Close shut off valve number 1. Important: Observe that the gauge is stationary. If the gauge differential begins to drop before the high bleed is opened, there is a leak in the system, such as shut off valve 2 or a gauge valve is open. 4. Place a finger on top of the air inlet valve. With the gauge centerline at the same elevation as the assembly body, slowly open the high bleed valve. Note: If the gauge differential pressure does not begin to drop with a slight valve opening, and it is necessary to continue opening the high bleed valve, supply pressure may be leaking past a bad shut off valve 1. Open 3 way valve to compensate for #1 shut off leak. Or Open High Gauge valve fully and slowly open the By Pass valve until water stops flowing at test cock #2 5. Observe and record the gauge reading at the inlet opening. 7
Note: Do not watch valve for opening and then attempt to read the gauge. 6. Close test cock 2 and remove the hose. 7. Open shut off valve 1. Check valve test. Criteria: Determine if the check valve maintains 1.0 psi. 1. Open high bleed on differential gauge. 2. Attach high pressure hose to test cock 1 and slowly open test cock. 3. Close gauge high bleed when air is purged and top of air inlet is filled with water. 4. Close shut off valve number 1. 5. With the gauge centerline at the same elevation as the assembly body, slowly open test cock 2 6. Observe and record the gauge reading when water stops flowing from the test cock. Note: lf water continues to flow from test cock 2, it may be a leak from shut off valve 1 or 2. lt may be necessary to compensate for a leaking shut off valve 1 at test cock #1. Open 3 way valve to compensate for #1 shut off leak. Or Open High Gauge valve fully and slowly open the By Pass valve until water stops flowing at test cock #2 7. Close test cock 1. Evaluate for backpressure. Criteria: If backpressure is present, it is wrong for the application and the assembly fails. 1. Open shut off valve 2.* Note: If water continues to flow from test cock 2, there is a downstream source of pressure. If the downstream system is large, this test may take a minute or two. 2. Close test cock 2. 3. Close shut off valve 2, open shut off valve 1 and return the assembly to service. 8
Spill Proof Vacuum Breaker 1 HOSE FIELD TEST PROCEDURE 1. Inspect assembly for correct components. 2. Remove canopy and clean any debris around the air inlet. 3. Flush test cock(s), install 3 way valve at test cock (1) with adapters and re flush test cock(s). 4. Remove low and bypass hose from gauge. 5. Close shut off valve number 2. 6. Open high bleed on differential gauge Check valve test. Criteria: Determine if the check valve maintains 1.0 psi. 1. Attach high pressure hose to test cock 1 and slowly open test cock. 2. Close gauge high bleed when air is purged and top of air inlet is filled with water. 3. Close shut off valve number 1. 4. * important: Observe that gauge is stationary. If the gauge differential begins to drop, there is a leak in the system, such as shut off valve 2 or a gauge valve is open. VERY SLOWLY loosen the vent screw on assembly and remove screw. Note: No water will come from vent hole. Observe and record the gauge reading for the check valve. 9
Air inlet opening Criteria: Determine that the inlet opens with a minimum of 1.0 psid. 1. VERY SLOWLY one drip at a time open the high pressure bleed valve and watch the differential gauge and standing water at the air inlet (bonnet). When the water starts to ripple, a drop may discharge from the vent. 2. Record the gauge reading with the drip from the vent screw hole as the inlet opening point. This value must be 1.0 psid or greater. 3. Close test cock (1), remove hose and install canopy cover. Evaluate for backpressure. Criteria: lf backpressure is present, it is wrong for the application AND the assembly fails. 1. Open shut off valve 2. Note: lf water continues to flow from test cock 2, there is a downstream source of pressure. lf the downstream system is large, this test may take a minute or two.2. 2. Close test cock 2. 3. Close shut off valve 2, open shut off valve 1 and return the assembly to service. 10
Five Valve Test on an ASSE 1013 Reduced Pressure Valve Assembly Field Testing Requirements Flush Test Cocks (TC) Install test adapters (if applicable 1 Open TC #4 let trickle 2 Open TC #1 Close 3 Open TC #2 Close 4 Open TC #'3 Close 5 Close TC #4 Attach Test Kit 1 Close Hi, Lo and Bypass valves and Hi and Lo bleed valves on test kit 2 Attach Hi hose to TC #2 3 Attach Lo hose to TC #3 4 Open TC #3 5 Open TC #2 6 Open Lo bleed valve bleed air 7 Open Hi bleed valve bleed air close 8 Close Lo bleed valve 9 Attach bypass hose to TC #4 10 Open Hi valve 11 Open bypass valve 12 Loosen bypass hose at TC #4 bleed air tighten 13 Slowly open low bleed valve to cause differential reading to icrease Close low bleed valve.. Test #1 #2 Check w/back Pressure Test 1 Close #2 shut off valve 2 Open TC #4 If the differential gage remains steady, record #2 check valve as tight. Test #2 Tightness of the #2 Shut Off Valve 3 Close TC #2 If the differential gage reading remains steady, record #2 shut off valve as tight 11
Test #3 #1 Check Differential 1 Close TC #4 2 Close bypass valve 3 Remove bypass from TC #4 4 Open TC #2 5 Open Lo Bleed valve to cause differential gauge reading to increase 6 Close Lo Bleed valve Test Results Record the actual pressure differential across #1 check valve. If the differential reading is 5 psid or above, record #1 check valve as tight Test #4 Relief valve opening 1 Slowly open Lo valve Test Results Record relief valve psid opening point. The relief valve must drip when the differential gage is 2 psid or above for the RP and 1 psid or above for the RPF. Test #5 Tightness of #2 Check Valve (Spring tension} 1 Close TC #2 and TC #3 2 Remove Lo hoses and Attach Lo hose to TC #4 3 Remove Hi hose and Attach Hi hose to TC #3 4 Open TC #4 5 Open TC #3 6 Open Lo bleed valve 7 Open Hi bleed valve bleed air close 8 Close Lo bleed valve Test Results If differential reading holds steady at 1 psid or higher for the DC and.5 psid or higher for the DCF, record #2 check valve as tight. Restore System 1 Close all TC's 2 Remove hoses 3 Open all valves on test kit to drain water 4 Restore #2 shutoff valve to pre test state The tester shall provide copies of the test results to the owner and other appropriate parties as required. The tester shall maintain a copy for his/her records. 12
Five Valve Test for an ASSE 1015 Double Check Assembly Field Testing Requirements Flush Test Cocks (TC) Step #1 Install test adapters (if applicable) Step #2 Open TC 4 let trickle Step #3 Open TC #1 Close Step #4 Open TC #2 Close Step #5 Open TC #3 Close Step #6 Close TC #4 Attach Test Kit Step #1 Close Hi, Lo and Bypass valves and Hi and Lo bleed valves on test kit Step #2 Attach Hi hose to TC #2 Step #3 Attach Lo hose to TC #3 Step #4 Open TC #3 Step #5 Open TC #2 Step #6 Open Lo bleed valve bleed air Step #7 Open Hi bleed valve bleed air close Step #8 Close Lo bleed valve Step #9 Attach bypass hose to TC #4 Step #10 Open Hi valve Step #11 Open bypass valve Step #12 Loosen bypass hose at TC #4 bleed air tighten Step #13 Slowly open low bleed valve to cause differential reading to increase Close. Test #1 #2 Check w/back Pressure Test Step #1 Close #2 shut off valve Step #2 Open TC #4 If the differential gage remains steady, record #2 check valve as tight. 13
Test #2 Tightness of the #2 Shut Off Valve Step #3 Close TC #2 If the differential gage reading remains steady, record #2 shut off valve as tight Test #3 Tightness of # 1 Check Valve Step #1 Close TC #4 Step #2 Close Bypass valve Step #3 Remove bypass hose from TC #4 Step #4 Open TC #2 Step #5 Slowly open low bleed valve to cause differential reading to rise close Test Results If differential reading holds steady at 1 psid or higher for the DC and.5 psid or higher for the DCF, record #1check valve as tight. Test #4 Tightness of #2 Check Valve (spring tension) Step #1 Close TC #2 and TC #3 Step #2 Remove Lo hoses and Attach Lo hose to TC #4 Step #3 Remove Hi hose and Attach Hi hose to TC #3 Step #4 Open TC #4 Step #5 Open TC #3 Step #6 Open Lo bleed valve Step #7 Open Hi bleed valve bleed air close Step #8 Close Lo bleed valve Test Results If differential reading holds steady at 1 psid or higher for the DC and.5 psid or higher for the DCF, record #2 check valve as tight. 14
5 Five Valve Test on an ASSE 1020 Pressure Vacuum Breaker Field Testing Requirements Flush Test Cocks (TC) Step #1 Install test adapters (if applicable) Step #2 Open TC # 1 Close Step #3 Open TC #2 Close Attach Test Kit Step #1 Close Hi, Lo and Bypass valves and Hi and Lo Bleed valves on test kit Step #2 Attach Hi to TC #'1 Step #3 Attach Lo hose to TC #2 Step #4 Open TC #1 Step #5 Open Hi bleed valve bleed air close Step #6 Open TC #2 Step #7 Open Lo bleed valve bleed air close Test #1 Tightness of #2 Shut off Valve Step #1 Close #2 shutoff valve Step #2 Open Hi valve Step #3 Open Lo valve (differential will read zero) Step #4 Close Hi valve Step #5 Close Lo valve Step #6 Close Test Cock #1 Test Results If differential gage reading does not rise above zero (0), record #2 shutoff as tight. Test #2 Tightness of Check Valve Step #1 Open #1 Test Cock Step #2 Open Lo bleed valve close Test Results If differential gage reading holds steady at 1 psid or higher, record check valve as tight 15
Test #3 Air Inlet Opening Step #1 Close TC #1 and TC #2 Step #2 Remove hoses from TC # 1 and TC #2 Step #3 Attach Hi hose to TC #2 Step #4 Remove air inlet canopy/hood Step #5 Open TC #2 Step #6 Open Hi bleed valve bleed air close Step #7 Close #1 shut off valve Step #8 Center differential gage at TC #2 Step #9 Open Hi bleed valve and record the dif ferential gage reading when the air inlet canopy/hood opens Test Results If air inlet is visibly open, when differential reading is 1 psid or higher, record valve as passed. Replace Air Inlet Canopy/Hood Restore System Step #1 Close TC #2 Step #2 Remove Hi hose Step #3 Open all valves on test kit to drain water Step #4 Open #2 shut off valve Step #5 Open # 1 shut off valve The tester shall provide copies of the test results to the owner and other appropriate parties as required. The tester shall maintain a copy for his/her records. 16