How Do I Construct a Manually-operated Pressure Test Header?

Why by hand? Is the line small? Is it a one time test? If I were doing one test from time to time I would rent a spray pressure washer. I would stall a PRV between the hose of the washer set just above test pressure and install a good valve you should be fine.

If the header has closed ends it is OK,otherwise you may have to use an inflateable plug at one end and other end - another inflatable plug with a water injection nozzle.(Otherwise welded dished ends will be needed)

You will need a pressure gauge,an NRV and a needle valve.Sequence will be inflatable plug, nipple,gauge,needle valve on a tee connection to release the pressure and finally an NRV.

You will have to make sure that there are no air bubbles left in the header during test - otherwise it would take too long.

Usually a centrifugal pump is used for quick filling of the job under hydro test till the air is bled out - esp when large volume of water is needed to fill in-(this is done by providing an small outlet at the highest point with a valve).Isolate the centrifugal pump from charging line.After this,a small high pressure pump - usually plunger or diaphragm operated by air /motor driven-is used to pressurize to required pressure.A Pressure relief valve is recommended with power driven pumps as these will quickly achieve the pressure and if not stopped at the right moment may actually burst the job under test!With manually operated pump it is a slow build up and the operator can observe the gauge at every stroke of the pump.

Cowlagi

We always rented the hand pumps from one of the larger tool rental companies. They work very well and I have been involved with testing some pretty big lines at high pressures by hand many times. The trick is to get the air out before you start pumping or it will take forever to get it to pressure. The hand pumps we used on the bigger piping and higher pressures were two man type that had the sea-saw handle. Two men could get few hundred feet of 12-18" Sch.. 160 wall turbine pipe to around 1000 psi in 30-45 minutes once they got the air out of the system. Nowadays we use the pressure washer and a pop off valve set to the test pressure on most things. It is allot easier and quicker than the hand method.

Pipewelder

http://www.niedner.com/en/fire-hose-testing.aspx

These people manufacture pressure testing machines that are designed to test fire hose. ( a yearly job ) They have an adjustable pressure regulator, and have a flow restrictor built in to prevent catastrophic failure. Good luck.