SRP 003x PRESSURE TEST PROCEDURE
SRP 003x PRESSURE TEST PROCEDURE
SRP 003x PRESSURE TEST PROCEDURE
SRP SP-F04-003
FutureFLEX®
PARA. CONTENTS
1.0 General
2.0 Safety Precautions
3.0 Reference Documents
4.0 Equipment / Tools Required
5.0 Equipment Layout
6.0 Pressure Source Set-up
7.0 Test Equipment Set-up
8.0 Pressure Test Set-up
9.0 Pressure Testing
10.0 Pressure Test Completion
a bottle. Exercise care and use proper lifting Note: Tube Test Kit (BEPT001) is not part of
techniques. Blowing Head Equipment Kit (BE200RM,
BE200RS, or BE200RY) and must be purchased
3.0 Reference Documents separately.
3.1 Sumitomo Recommended Procedure, 4.4 Large Adjustable Wrench (Installer provided);
FutureFLEX Blowing Equipment Set-up at least 10” suggested.
Procedure, SRP SP-F04-001.
4.5 Tubing Cutter (BETC001).
3.2 Sumitomo Recommended Procedure,
FutureFLEX Fiber Bundle Installation Procedure, 4.6 8mm tubing (any type) for miscellaneous
SRP SP-F04-002. connections (Installer provided); 10’ - 20’
suggested.
3.3 Sumitomo Recommended Procedure,
FutureFLEX Tube Obstruction Testing Procedure, 4.7 Tube Couplings (DE08MC2) (Installer
SRP SP-F04-004. provided).
4.1 Nitrogen Cylinder (Installer provided) 4.9 Means of communicating across tube span
• Dry Industrial Grade Nitrogen; preferred (e.g.: two-way radios or similar).
pressure source
• Inert (nonflammable) gas 4.10 Alternate Pressure Source – Although
• Dry or with no more than 4 ppm moisture bottled nitrogen is the preferred pressure source
content (H2O) because of its cleanliness, general convenience,
• Oil / contaminant free output inexpensive cost, and ease of portability,
• 300 cu. ft. (approx.) volume bottle size compressed air from either a Compressed Air
recommended Cylinder or an Air Compressor can be used as an
• 2000-to-2500 psi (approx.) pressure charge alternate pressure source.
4.2 One Pressure Regulator Assembly with male 4.11 Compressed Air Cylinder (Installer provided)
quick-release 8mm Tubing Adapter (BEREG01 • “Dry Grade” Compressed Air
Two-Stage or BEREG02 Single-Stage). • Nonflammable gas (atmospheric air)
• Dry or with no more than 10 ppm moisture
Note: If a Blowing Head Equipment Kit content (H2O)
(BE200RM, BE200RS, or BE200RY) is available, • Oil / contaminant free
use Pressure Regulator with 8mm Tubing • 300 cu. ft. (approx.) volume bottle size
Adapter supplied with the Kit to perform Pressure recommended
Testing. However, if not available, the Pressure • 2000-to-2500 psi (approx.) pressure charge
Regulator with 8mm Tubing Adapter should be
purchased separately in order to support testing Note: Different types or “grades” of Compressed
requirements. Air are available. The “purer” grades with such
names as Zero Grade, Vehicle Emission Grade,
4.3 Tube Test Kit (BEPT001) includes the Scientific Grade, and Accurate Grade undergo
following items: additional refining processes so they contain
• One Bypass Switch (BEPTSW) fewer impurities (hydrocarbons) and have less
• One 0-200 psi range Hand-Held Pressure moisture content. It is not necessary to use
Gauge (BEPTGA) these ”purer” grades of air for testing operations.
• One hundred (100) 5mm OD plastic beads
(BEBB01)
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Document: SP-F04-003
Date Issued: 04/09
Revision: 11
Entry Exit
FTU
FTU FTU
0 – 200 psi
Bypass Pressure Gauge
Switch
Figure 2
Pressure Test Equipment Layout
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Document: SP-F04-003
Date Issued: 04/09
Revision: 11
6.1 Begin Pressure Test procedures with both 7.1 Locate numbers #1, #2, and #3 stamped on
Installers at entry point Fiber Termination Unit body of Bypass Switch (#1 and #2 are located
(FTU) location. under 8mm push-fit couplings and #3 is on
bottom of valve). #1 is Inlet port. #2 is Outlet
6.2 Ensure Gas Bottle is securely chained in port. #3 port is “Bypass” or vent port. See Fig. 4.
place and remove valve cap.
CAUTION: Inlet and Outlet tubing must be
6.3 Thread Pressure Regulator fitting onto bottle connected to correct push-fit couplings (#1 Inlet
valve housing and tighten with large adjustable and #2 Outlet) or Bypass Switch will not function
wrench. properly and can be damaged.
Note: Do not use a serrated jaw tools (e.g.: pipe Note: Inspect tubing ends before connecting to
wrench, vise grips, channel locks, etc.) to push-fit couplings. Use Tubing Cutter (Installer
tighten brass fitting of Pressure Regulator. provided) to trim tubing ends with straight, clean
cut for best seat and seal in push-fit couplings.
6.4 Open Bottle Supply Valve and check for
leakage around fitting. If leakage is detected,
close Bottle Supply Valve and see Sumitomo
Tubing from Pressure
Recommended Procedure SRP SP-F04-001.
Regulator must be
connected to Inlet Port 1
6.5 Close Bottle Supply Valve.
Figure 4
Bypass Switch
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Document: SP-F04-003
Date Issued: 04/09
Revision: 11
0 – 200 psi
Pressure Gauge psi
Toggle Switch
OFF or Bleed Toggle Switch
Position ON Position
Short piece of
Tubing from 1 2 8mm Tubing
Pressure FLOW
Regulator
Figure 5
Bypass Switch Positions and Pressure Gauge
Note: Bypass Switch is “OFF” when toggle 7.6 Once 150 psi reading is obtained on 0-200 psi
switch / handle is positioned back towards #1 Hand-Held Pressure Gage, do not move / adjust
Inlet coupling or pressure source (Bleed Pressure Regulator Valve from its (now) “pre-set”
Position). Bypass Switch is “ON” when toggle position. Maintaining a constant 150 psi pressure
switch / handle is positioned forward towards #2 setting will ensure better test accuracy throughout
Outlet coupling or tube span (Pressurizing remainder of Pressure Test.
Position).
7.7 Close Bottle Supply Valve and turn Bypass
7.4 Open Bottle Supply Valve and turn Bypass Switch OFF. Any pressure in tubing and 0-200
Switch ON. psi Hand-Held Pressure Gage will vent to
atmosphere through #3 vent port on bottom of
7.5 Slowly adjust Pressure Regulator Valve, Bypass Switch (a hissing sound will be heard).
increasing output pressure until 0-200 psi Hand-
Held Pressure Gauge reads 150 psi. 7.8 Verify 0-200 psi Hand-Held Pressure Gage
reads zero.
Note: The Pressure Regulator’s (0-400 psi)
Pressure Gauge and the 0-200 psi Hand-Held 7.9 Uncouple 0-200 psi Hand-Held Pressure
Pressure Gauge readings may be different at Gage from short 8mm tubing and uncouple short
this point. This is not unusual due to the 8mm tubing from #2 Outlet coupling on Bypass
differences in accuracy between the two Switch.
gauges. Use the more accurate 0-200 psi
Hand-Held Pressure Gage reading.
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Document: SP-F04-003
Date Issued: 04/09
Revision: 11
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Document: SP-F04-003
Date Issued: 04/09
Revision: 11
10.3 When tube span has de-pressurized, 11.4.2 Tube end has slanted or jagged cut
disconnect Bypass Switch and 0-200 psi Hand- De-pressurize tube span, disconnect tube, and
Held Pressure Gage and repeat steps 9.1 trim end using Tubing Cutter (BETC001) to obtain
through 10.2 for remaining tube spans. straight, clean cut. Firmly push tube back into
Tube Coupling. See Fig. 6.
CAUTION: When securing from Pressure
Testing operations, always de-pressurize / vent
the Pressure Regulator by turning its valve
counterclockwise until the Output Pressure
Gage reads zero. This step is vital to prevent
damaging the Regulator’s internal diaphragm.
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Document: SP-F04-003
Date Issued: 04/09
Revision: 11
11.5 Another Troubleshooting Method 12.2 The basic procedure to test two tube spans
Another effective troubleshooting method to help at the same time is identical to testing one tube
find pressure leaks is to “isolate” a long tube span with the following exceptions.
span into shorter segments / sections.
12.2.1 At exit point FTU, use 8mm jumper
11.5.1 For example, at a mid-point TDU, tubing and Tube Couplings to connect the two
disconnect Tube Coupling in faulty tube span and span ends together. See Fig. 7.
connect 0-200 psi Hand-Held Pressure Gage to
front half of span. 12.2.2 At entry point FTU, connect Bypass
Switch to one tube span (serves as supply leg)
11.5.2 Perform normal pressure testing steps 9.1 and 0-200 psi Hand-Held Pressure Gage to
through 10.3. other tube span (serves as return leg). See Fig.
7.
11.5.3 If front half of tube span holds 150 psi for
about 10 seconds, leakage is located in the back 12.2.3 Conduct Pressure Test following normal
half of tube span. Further troubleshooting efforts test procedures.
should be concentrated in this area.
Note: It is recommended to limit “multiple” tube
11.6 After repairs have been made, always testing to just two tube spans at the same time.
conduct another Pressure Test (per steps 9.1 In the event there are pressure leaks,
through 10.3) to verify the total end-to-end airtight troubleshooting efforts can quickly become
integrity of the tube span. more complex and time consuming when
dealing with multiple tube spans.
12.0 Alternate Pressure Test Method
Entry Exit
FTU FTU
Tube Coupling-
Jumper Tubing-
Tube Coupling
Bypass “Loop Back”
Switch 0 -200 psi
Pressure Gage
Figure 7
Alternate Pressure Test Method
To Test Two (2) Tubes at Same Time
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Document: SP-F04-003
Date Issued: 04/09
ADDENDUM A
FUTUREFLEX®
TUBE PRESSURE TEST DATA SHEET
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