Rice Hydro HP-20 Pneumatic Hydrostatic Test Pump User Manual

1. Introduction and Product Overview

The Rice Hydro HP-20 is a pneumatic hydrostatic test pump designed for high-pressure testing of various lines, including oil, gas, and steam. This robust and compact unit is pneumatically driven, requiring only 100 PSI of standard shop air for maximum operation, making it suitable for use in confined spaces, remote locations, and marine environments. It is capable of handling various fuels, oils, and chemicals, offering a pressure range from 2,000 to 20,000 PSI. Key features include built-in high-pressure ball valves and fittings, a stainless steel liquid-filled gauge for accurate readings, and rugged roll cage construction for protection.

Key Features:

• Pneumatic Hydrostatic Test Pump
• Designed for high pressure testing of oil, gas, and steam lines
• Requires only 100 PSI of standard shop air for maximum operation
• Lightweight and compact design
• Ideal for use in confined spaces, remote locations, and on ships
• Pressure Range from 2,000 to 20,000 PSI
• Built-in High Pressure Ball valves and Fittings
• Able to Start/Stop while under pressure
• Stainless Steel liquid-filled gauge ensures accurate readings
• Rugged roll cage construction protects pump from damage

Figure 1: Rice Hydro HP-20 Pneumatic Hydrostatic Test Pump. This image displays the compact design of the HP-20 pump, featuring its red roll cage frame, the central pump unit (blue and bronze components), a pressure gauge, and various valves and fittings.

2. Safety Information

Operating high-pressure equipment requires strict adherence to safety protocols to prevent injury and equipment damage. Always read and understand this manual completely before operating the HP-20 pump.

• Personal Protective Equipment (PPE): Always wear appropriate PPE, including safety glasses, gloves, and protective clothing, when operating the pump.
• Pressure Hazards: High-pressure fluid can cause severe injury. Never place hands or body parts near pressure leaks or discharge points. Ensure all connections are secure before pressurizing.
• Air Supply: Ensure the air supply is clean, dry, and regulated to the specified 100 PSI maximum. Exceeding this pressure can damage the pump.
• Ventilation: Operate the pump in a well-ventilated area, especially when testing with hazardous fluids.
• Fluid Compatibility: Verify that the fluids being tested are compatible with the pump's internal components to prevent corrosion or damage.
• Emergency Shutdown: Familiarize yourself with the emergency shutdown procedures and the location of the air supply shut-off valve.
• Maintenance: Perform all maintenance and repairs only when the pump is depressurized and disconnected from the air supply.

3. Components Overview

The Rice Hydro HP-20 pump consists of several key components integrated into a rugged frame for portability and protection.

• Roll Cage Frame: A durable red tubular frame that protects the internal components and provides handles for transport.
• Pneumatic Drive Unit: The main pump assembly (blue and bronze sections) that converts compressed air into hydraulic pressure.
• Pressure Gauge: A stainless steel liquid-filled gauge for accurate monitoring of output pressure.
• Air Regulator/Filter: Located near the air inlet, this unit ensures the incoming air supply is clean and at the correct pressure.
• High-Pressure Ball Valves: Integrated valves for controlling fluid flow and pressure within the system.
• Inlet/Outlet Ports: Connections for the air supply, fluid source, and the object being tested.

4. Setup

Proper setup is crucial for safe and effective operation of the HP-20 pump.

1. Placement: Position the pump on a stable, level surface in a well-ventilated area.
2. Air Supply Connection: Connect a clean, dry compressed air line to the pump's air inlet. Ensure the air supply is capable of providing a minimum of 100 PSI.
3. Fluid Source Connection: Connect the pump's fluid inlet to the desired fluid source (e.g., water tank, oil reservoir). Ensure the fluid is clean and free of debris.
4. Test Object Connection: Connect the pump's high-pressure outlet to the object or system being tested. Use appropriate high-pressure hoses and fittings rated for the maximum expected pressure. Ensure all connections are tight and leak-free.
5. Pre-fill (if applicable): For some applications, it may be beneficial to pre-fill the test object and connecting lines with fluid to minimize air pockets.

5. Operation

Follow these steps for safe operation of the Rice Hydro HP-20 pump.

1. Verify Connections: Double-check all air and fluid connections for tightness and proper sealing.
2. Open Inlet Valve: Ensure the fluid inlet valve on the pump is open to allow fluid flow.
3. Open Test Object Vent: If the test object has a vent, open it to allow air to escape during initial filling.
4. Apply Air Pressure: Slowly open the main air supply valve to the pump. The pump will begin to cycle, drawing fluid and building pressure.
5. Purge Air: Allow the pump to run until all air is purged from the system and a steady stream of fluid emerges from the test object's vent. Close the vent.
6. Increase Pressure: Continue to allow the pump to operate, monitoring the pressure gauge. The pump will automatically stop when the set pressure is reached or when the air supply is cut off.
7. Hold Pressure: Once the desired test pressure is achieved, close the high-pressure outlet valve on the pump to isolate the test object. You can then shut off the air supply to the pump.
8. Monitor: Observe the pressure gauge on the test object for any pressure drops, indicating leaks.
9. Depressurize: To safely depressurize the system, slowly open the relief valve or a controlled bleed valve on the test object or pump. Never rapidly release high pressure.
10. Disconnect: Once pressure is fully relieved, disconnect the pump from the test object and fluid source.

6. Maintenance

Regular maintenance ensures the longevity and reliable performance of your HP-20 pump.

• Cleanliness: Keep the pump clean and free of dirt, debris, and corrosive substances.
• Fluid Quality: Always use clean, filtered fluids for testing. Contaminants can damage internal pump components.
• Air Quality: Ensure your compressed air supply is dry and free of oil and particulates. Regularly check and drain the air filter/regulator.
• Connections: Periodically inspect all hoses, fittings, and connections for wear, damage, or leaks. Replace any compromised components immediately.
• Gauge Calibration: The liquid-filled pressure gauge is designed for accuracy, but periodic calibration by a qualified technician is recommended to ensure continued precision.
• Storage: When not in use, store the pump in a dry, clean environment, protected from extreme temperatures.

7. Troubleshooting

This section provides solutions to common issues encountered during operation.

8. Specifications

Detailed technical specifications for the Rice Hydro HP-20 Pneumatic Hydrostatic Test Pump.

• Model Number: HP-20
• Pressure Range: 2,000 to 20,000 PSI
• Air Supply Requirement: 100 PSI (standard shop air) for maximum operation
• Product Dimensions: 48.26 x 58.42 x 71.12 cm (19 x 23 x 28 inches)
• Product Weight: 29.48 kg (65 lbs)
• Shipping Weight: Approximately 68 lbs
• Manufacturer: Rice Hydro
• Features: Built-in High Pressure Ball valves and Fittings, Stainless Steel liquid-filled gauge, Rugged roll cage construction, Start/Stop while under pressure capability.

9. Warranty and Support

For specific warranty information, technical support, or service inquiries regarding your Rice Hydro HP-20 pump, please contact Rice Hydro directly or your authorized distributor. Ensure you have your model number and purchase details available when contacting support.

Note: Unauthorized modifications or repairs may void the product warranty.