WIDDER TOOLS HPIC-10000-D-HV User manual

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WIDDER®TOOLS
HPIC-10000-D-HV Hydrostatic Test Pump
PRODUCT INFORMATION AND OPERATING INSTRUCTIONS
Description: The WIDDER Hydrostatic Test Systems® C Series is a portable, self-
contained, air driven hydrostatic test system. The C Series comes standard with a stainless
steel, 140 Mesh (100 Micron) input water filter, as well as full air filtration and lubrication.
This meets all pump manufacturer warrantee requirements. All available digital gage
options are certified Intrinsically Safe and at least .25% Full Scale Accurate. The optional
Digital Logger unit also records up to 60,000 measurements with date stamp and
temperature. The standard Isolation Lock out Valve on WIDDER Hydrostatic Systems®
allows complete isolation from the pump input where higher system integrity is required.
This HV –High Volume system utilizes ¾” NPT fluid input and output to achieve up to 20
GPM fill flow-rate (requires a minimum 40 PSI x ¾” input hose). This allows for fast fill
direct to testing without hose change over. This unit is supplied standard with a 10,000 PSI
x ¾” x 15’ output hose.

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IMPORTANT: FOR YOUR SAFETY BEFORE OPERATING THIS UNIT, READ
THIS OPERATOR’S MANUAL CAREFULLY AND COMPLETELY. LEARN THE
OPERATION, APPLICATIONS, AND POTENTIAL HAZARDS PETICULIAR TO THIS
TOOL.
SAFETY PRECAUTIONS:
1. Be sure all pressure on air and water fittings is relieved before dis-connecting any
hoses or fittings
2. Wear eye protection
3. Pressurization of any materials is dangerous- follow OSHA procedures for stored
energy and any pressurization cautions pertaining to the fluids used
4. This system can develop pressure up to the nameplate pressure- do not over pressure
test vessels as damage can occur.
5. Do not run air pump without water input as you can damage the pump
6. Oil lubricator on air input must be filled with standard air tool oil before operating.
Operating without oil voids tool warrantee
OPERATING INSTRUCTIONS:
A. Leak Test Only
1. Attach water (Front of Unit) and air input (Rear of Unit) with water and air supply
turned off.
2. Attach water output to test vessel (pre-fill if necessary for faster fill).
3. Turn on input water supply at street pressure and check for any obvious hook-up leaks.
4. Bleed the system through the needle relief valve until no more water comes out.
5. Close needle valve firmly. Do not over tighten.
6. With Regulator opened all the way (counter clock-wise) turn on the air input valve.
7. Slowly close the regulator (clock-wise) causing the system pressure to build. The unit
will stroke a few times quickly to build pressure and will slow as the system charges
and fills.
8. Observe system output pressure gage carefully. Do not over pressure test vessel.
9. As desired pressure is approached, slow air input by backing off regulator. The system
will hold this pressure within about 1% and will make-up any drop by recycling the
pump.
10. Inspect pressurized system for leaks.
11. Once the leak test inspection is complete, refer to section C to shut down the system.

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B. Isolated Pressure Leak Test
For tighter control of pressures, WIDDER Hydrostatic Pressure Test Systems® include a
secondary high-pressure Isolation Valve. This valve is downstream from the pressurizing pump
and allows the operator to isolate the pressurized test loop from the pump check valves. At high
pressures, the pump check valves can leak some system pressure. Usually, this is well within test
pressure drop parameters (API 6A on annex F.1.1.10 b. for example, states: “Pressure shall
remain within 5% of the test pressure or 3,45 MPa (500 psi), whichever is less, during the test
period.”)
1. To isolate pressure, follow section A until system is pressured to desired pressure.
2. Close the Isolation Valve. Closing the isolation valve may raise test pressure
slightly as the isolation valve displaces fluid in the system.
3. Once the isolation valve is closed, the test area is isolated from the pump and check
valves.
4. Monitor pressure gage for drop in pressure over allotted time.
5. When test is complete, be sure to turn off input air, open regulator completely, crack
bleed valve and re-open isolation valve. Do not store system under pressure- always be
sure bleed valve is cracked and isolation vale is open.
C. System Shut Down and Storage
1. Once tests and inspections are complete, shut down the system by first opening the
regulator to relieve air pressure (counter clock-wise) until gage reads “0”.
2. Turn off water and air input.
3. Gently crack the needle bleed valve until output pressure drops to “0”.
4. Once all pressure gages read “0” and inputs are off, drain and disconnect test vessel.
5. To store unit, add a small amount of water displacing oil to the water input and hook-
up an airline to the water input.
6. With all needle valves open, blow air through the water input. Water and air will come
out the discharge side of the unit.
7. Blow off until mostly dry.
D. Digital Gage
The WIDDER Hydrostatic Test Systems® C Series are supplied with a digital gage. This gage
is accurate to .025% full scale and detects even tiny changes in test conditions. See enclosed
manual for gage use. Because WIDDER Hydrostatic Test Systems® are so accurate and can
read down to a 1.0 PSI change in system pressure, the operator must be aware that minor
pressure changes are caused by many factors including: temperature fluctuation, hose stretch,
sealant settling, and material assembly movement. Vessel size is critical to this issue; a small test
vessel will show dramatically more pressure change than a large one. (Note: For long term
storage, remove batteries to extend life.)

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WIDDER®HPIC Hydrostatic Test Pump
Front View

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Back Panel View

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Inner Air System

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Small High Pressure System

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Main Water In/Out System

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High Flow Bypass System

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WIDDER®HPIC HV Hydrostatic Test Pump
Item
Description
Part #
Front View
HPIC-10000-D
HPIC-10000
1
Wheel Spacer
03-1014
03-1014
2
Wheel Collar
PI7000-29
PI7000-29
3
10” Wheel
PI7000-21
PI7000-21
4
Flange Screw, 2 ½” Gage
PI7000-20
PI7000-20
5
2 ½” Flange
PI7000-11A
PI7000-11A
6
2 ½”-160 psi Gage
PI7000-11
PI7000-11
7
Flange Screw, 4” Gage
PI7000-19
PI7000-19
8
4” Flange
PI7000-06A
PI7000-06A
9
4”-15k psi Gage
PI7000-06
PI7000-06
10
Cabinet
PI7000-38
PI7000-38
11
10k psi Pump
PI7000-01
PI7000-01
12
Pump Hex Bolt
PI7000-41
PI7000-41
13
Pump Standoff
PI7000-88
PI7000-88
14
3” Gage Adapter Ring
PI7000-206
15
3” Adapter Ring Screw
PI7000-209
16
3” 10k psi Digital Gage
PI7000-205
17
3” Gage Screw
PI7000-207
18
Finishing Plug
PI7000-208
19
Isolation Needle Valve
PI7000-216
PI7000-216
19H
Handle, Isolator Valve
PI7000-216-RH
PI7000-216-RH
20
Valve Mount Washer
PI7000-217
PI7000-217
21
Regulator
PI7000-16
PI7000-16
22
Bleed Needle Valve
PI7000-36
PI7000-36
22H
Handle, Bleed Valve
PI7000-36-RH
PI7000-36-RH

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Back Panel View
Item
Description
Part #
HPIC-10000-D
HPIC-10000
23
Universal Coupling
36-1010
36-1010
24
90° Elbow
PI7000-96
PI7000-96
25
½ x 3” Brass Nipple
PMI014
PMI014
26
Ball Valve
PI7000-14
PI7000-14
27
Small Clamp
PI7000-59
PI7000-59
28
Small Clamp Spacer
PI7000-61
PI7000-61
29
Small Clamp Screw
PI7000-50
PI7000-50
30
Washer
PI7000-26
PI7000-26
31
Locknut
PI7000-27
PI7000-27
32
½ x 3” Brass Nipple
PMI014
PMI014
33
90° Elbow
PI7000-96
PI7000-96
34
½ x Close Brass Nipple
PMI035
PMI035
35
Handle
PI7000-31
PI7000-31
36
Handle Mounting Bolt
PI7000-23
PI7000-23
37
Washer
PI7000-24
PI7000-24
38
½ x Close Brass Nipple
PMI035
PMI035
39
Large Clamp
PI7000-60
PI7000-60
40
Large Clamp Spacer
PI7000-62
PI7000-62
41
½ x 2-1/2” Brass Nipple
PMI037
PMI037
42
90° Elbow
PI7000-96
PI7000-96
43
1/2 x 2” Brass Nipple
PMI023
PMI023
44
Large Clamp Screw
PI7000-51
PI7000-51
45
Washer (Outer)
PI7000-54
PI7000-54
46
Washer (Inner)
PI7000-53
PI7000-53
47
Locknut
PI7000-52
PI7000-52
48
Panel Mounting Bolt
PI7000-23
PI7000-23

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Item
Description
Part #
HPIC-10000-D
HPIC-10000
49
Washer
PI7000-26
PI7000-26
50
Back Panel
PI7000-39
PI7000-39
51
Lubricator
PI7000-18
PI7000-18
52
Filter
PI7000-17
PI7000-17
Inner Air System
53
Foot
PI7000-33
PI7000-33
54
Hex Jam Nut, Foot
PI7000-32
PI7000-32
55
Split Lock Washer, Foot
PI7000-34
PI7000-34
56
Washer, Foot
PI7000-30
PI7000-30
57
Air In To Regulator Hose
PI7000-84
PI7000-84
58
90° Elbow
PI7000-63
PI7000-63
59
Regulator
PI7000-16
PI7000-16
60
Pump Air Out Hose
PI7000-87
PI7000-87
61
90° Elbow
PI7000-63
PI7000-63
62
Hex Adapter
PI7000-45
PI7000-45
63
Hex Nipple
PI7000-73
PI7000-73
64
90° Elbow
PI7000-63
PI7000-63
65
Regulator To Pump Hose
PI7000-86
PI7000-86
66
90° Elbow
PI7000-63
PI7000-63
67
Regulator To Air Gage Hose
PI7000-83
PI7000-83
Small High Pressure System
68
Bulkhead Plate Assy., Outlet
PI7000-328
PI7000-328
69
Hex Bolt
PI7000-23
PI7000-23
70
Washer (Outer)
PI7000-26
PI7000-26
71
Washer (Inner)
PI7000-24
PI7000-24
72
Locknut
PI7000-27
PI7000-27
73
Cross
PI7000-303
PI7000-303
74
Flare Adapter
PI7000-301
PI7000-301
75
Bulkhead To Bleed Flare Tube
PI7000-232
PI7000-232

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Item
Description
Part #
HPIC-10000-D
HPIC-10000
76
¼” Flare Seal (2 per Tube)
PI7000-221
PI7000-221
77
Tee
PI7000-94
PI7000-94
78
90° Elbow
PI7000-215
PI7000-215
79
Flare Adapter
PI7000-95
PI7000-95
80
Gage To Gage Flare Tube
PI7000-230
PI7000-230
81
¼” Flare Seal (2 Per Tube)
PI7000-221
PI7000-221
82
Gage To Bleed Flare Tube
PI7000-231
PI7000-231
83
¼” Flare Seal (2 per Tube)
PI7000-221
PI7000-221
84
Tee
PI7000-94
PI7000-94
85
Bleed Needle Valve
PI7000-36
PI7000-36
86
Flareless Adapter
PI7000-78
PI7000-78
87
Bleed Tube
PI7000-82
PI7000-82
Main Water In/Out System
88
Flare Adapter
PI7000-302
PI7000-302
89
Bulkhead to Iso. Valve Tube
PI7000-233
PI7000-233
90
½” Flare Seal (2 per Tube)
PI7000-220
PI7000-220
91
90° Elbow
PI7000-63
PI7000-63
92
Flare Adapter
PI7000-71
PI7000-71
93
90° Elbow
PI7000-74
PI7000-74
94
Check Valve, Outlet
PI7000-223
PI7000-223
95
½” x 15 Foot HP Hose
PI7000-89
PI7000-89
96
Check Valve, Inlet
PI7000-222
PI7000-222
97
1/2M x 1/2F SW 90
PI7000-74
PI7000-74
98
Pump Outlet Hose
PI7000-218
PI7000-218
99
Strainer To Pump In Hose
PI7000-321
PI7000-321
100
¾” x Close Brass Nipple
PI7000-310
PI7000-310
101
¾” Strainer –100m
PI7000-308
PI7000-308
102
Hex Bolt
PI7000-23
PI7000-23
103
Washer (Outer)
PI7000-26
PI7000-26

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Item
Description
Part #
HPIC-10000-D
HPIC-10000
104
Washer (Inner)
PI7000-24
PI7000-24
105
Locknut
PI7000-27
PI7000-27
106
Bulkhead Plate Assy., Inlet
PI7000-328
PI7000-328
High Flow Bypass System
107
Bulkhead Plate Assy., Outlet
PI7000-328
PI7000-328
108
Cross
PI7000-303
PI7000-303
109
90° Elbow
PI7000-304
PI7000-304
110
High Flow Check Valve
PI7000-300
PI7000-300
111
90° Street Elbow
PI7000-311
PI7000-311
112
High Flow Hose Assy.
PI7000-320
PI7000-320
113
90° Street Elbow
PI7000-311
PI7000-311
114
Tee
PI7000-307
PI7000-307
115
¾” Strainer – 100m
PI7000-308
PI7000-308
116
¾” x Close Brass Nipple
PI7000-310
PI7000-310
117
Bulkhead Plate Assy., Inlet
PI7000-328
PI7000-328