详情描述

I. Product Overview:

YFA-D Type Butterfly Valve Hydraulic Test Bench, a specialized testing equipment for butterfly valves. Based on years of experience in manufacturing valve testing equipment, the company strictly adheres to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves."American Petroleum Institute StandardDesign and production in compliance with API 598 and other specifications require testing at specific pressure levels.

This unit integrates hydraulic, mechanical, electrical systems, pressure-supply units, and a medium storage circulating water tank. The testing process is fully controlled and executed by automatic hydraulic and electrical components, boasting advantages such as reasonable structure, comprehensive functions, stable performance, convenient operation, and high level of automation. It is widely used in high, medium, and low pressure sealing performance tests and shell strength endurance tests for butterfly valves. Applicable valve types include flanged and waist-type butterfly valves, knife gates, and more, making it suitable for valve manufacturers, the petrochemical industry, hydroelectric power stations, etc.Natural GasIdeal valve testing and inspection equipment for industries such as pipe fitting manufacturers, wastewater treatment plants, and valve maintenance stations.

Section II: Specifications Range:

Single Station: 50-2200mm

Three, Pressure Range: 0.6-10.0 (MPa) / 150-600 (Class)

Four: Performance Features:

Suitable for direct connection flanged and wafer butterfly valves, featuring face-to-face flange sealing. The workbench is equipped with a removable hydraulic clamping system, which can be adjusted automatically to fit various valve specifications. It synchronizes the position of the clamping jaws and achieves automatic centering and positioning. During valve testing, the hydraulic clamping jaws automatically secure the valve flange face, with adjustable clamping force, exerting no external force on the valve itself. The clamping process is controlled by an integrated button and executed by hydraulic components.

The equipment is equipped with high and low-pressure water pumps, allowing for direct hydrostatic testing. It features a dual air-water system, with the gas source to be provided by the user.

          Principle and Operation of Butterfly Valve Hydraulic Test Bench

  Section 1: Working Principle of YFA-D Type

YFA-D type butterfly valve hydraulic testing bench, a specialized testing equipment for butterfly valve sealing performance and housing strength pressure tests. It integrates a hydraulic system, clamping cylinders, mechanical components, high and low-pressure pump pressure supply units, pressure gauges, valve control switches, clamping workbench, electrical control system, and medium storage circulating water tank.A hydraulic clamping cylinder is installed on the workbench to evenly distribute the clamping force, directly driving the jaw to clamp the butterfly valve's flat surface for testing, ensuring uniform force distribution and reliable clamping. The radial movement function of the clamping jaws is achieved through a combination of the cylinder and rods, allowing for synchronous radial movement of all clamping jaws. The clamping cylinder is regulated through a hydraulic分流er to synchronize the axial clamping cylinders. This ensures testing for butterfly valves of various sizes. During the sealing test of the butterfly valve, a sealing disc compatible with the test valve is installed on the machine, and the butterfly valve is placed on it. The hydraulic clamp then directly presses the butterfly valve flange to secure it, allowing for the injection of test medium. During the test, it is possible to visually inspect for leaks or air bubbles inside the butterfly valve. For strength tests, simply add a sealing cover plate to the upper surface of the butterfly valve. This equipment is equipped with high and low-pressure liquid supply pumps, enabling direct liquid pressure tests. The liquid medium can be recycled and stored for use, preventing rust on valves after testing and corrosion of check valves and regulators, which can affect normal equipment operation. Antirust agents must be added to the water to prevent rust.

Section II: Usage Instructions:

1. Inject 30#-46# hydraulic oil or 20# mechanical oil into the hydraulic system's oil tank, ensuring the oil level does not fall below the oil gauge's lower mark.

2. Power on, press the oil pump start button, and check if the motor is rotating in the correct direction (counterclockwise).

3. Adjust the hydraulic system pressure to 5.0 MPa to proceed with normal operation.

4. Retract the point actuated clamp to a position greater than the outer diameter of the test butterfly valve flange.

5. Place the test butterfly valve at the center of the workbench sealing disk.

6. Release the point-action clamp to a height above the height of the tested butterfly valve.

7. Advance the point actuated clamp to the required position for the test butterfly valve flange.

8. Engage the point-action clamp to securely grip the tested butterfly valve flange face; perform a butterfly valve sealing test.

9. Place a sealing cover plate on the flat surface of the butterfly valve flange, clamp the sealing cover plate securely with the clamps, and then perform the strength test on the butterfly valve housing.

(6) Adjust the clamping pressure according to the (Pressure Chart for Cylinder Clamping). For pressures exceeding the pump source by more than 5.0 Mpa, press the (Clamping Jaws Pressure Increase) button to increase the pressure to the required clamping pressure.The boost button can be pressed multiple times, with each interval being approximately 3-5 seconds, and the maximum pressure reaching 30MPa.

Section 3: Gas Pressure Test：

1.  Seal Pressure Test: Valve mounting complete (1)Shut off: Total inlet valve → Relief valve → Test butterfly valve. (2) Open: Pressure gauge switch → Total inlet valve to inject gas. Close (inlet valve) when the air pressure reaches the required pressure value, then add water to the butterfly valve chamber. (3) Proceed to the pressure holding timing phase. When the pressure holding time is up, inspect for bubbles on the valve sealing surface and body surface, and check the pressure gauge for pressure drop to determine if the valve's sealing performance is up to standard.

2. Gas Strength Pressure TestValve mounting complete, (1)Shut off: Total inlet valve → Pressure relief valve. (2) Open: Test butterfly valve → Pressure gauge switch → Total inlet valve to inject gas. Close (total inlet valve) when the air pressure reaches the required pressure value. Spray foam agent on the butterfly valve body surface (3). Enter the pressure maintenance timing phase. When the pressure maintenance time is up, check for bubble leakage at the valve connection seals and valve body surface, and if the pressure gauge has dropped pressure, to determine if the valve's strength performance is up to standard. (4) After testing, open the pressure relief valve, exhaust the pressure, and remove the butterfly valve.

Four: Water Pressure Test

1. Water-tight pressure test completed, valve mounting all done, (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure gauge (with a sealed pressure of 1.6MPa as an example, adjust the red pointer of the electrical contact pressure gauge to 2.5MPa). (2) Close: Main inlet valve → Pressure relief valve → Pressure gauge switch → Test butterfly valve. (3) Open: Main water inlet valve → Test valve.

(4) Start the low-pressure water pump. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is fully filled with water. The low-pressure pump will then automatically shut off, and the high-pressure pump will automatically start to supply pressure. Once the high-pressure water reaches the set value of 2.5 (MPa), the high-pressure pump will automatically stop, and a pressure holding timer (such as 2 minutes/client-specified) will begin. Check for any leaks on the valve sealing surface and the body surface, as well as any dips on the pressure gauge, to confirm if the valve's strength and pressure test is合格.

2、Water strength pressure test completed, valve mounting all done, (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Adjust the electrical contact pressure gauge (with a reference strength pressure of 4.0 MPa) by moving the red pointer to 4.0 MPa. (2) Shutdown: Main intake valve → Pressure relief valve → Pressure gauge switch. (3) Startup: Main water intake valve → Test valve. (4) Start the low-pressure pump; when the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is filled with water, and the low-pressure pump will automatically stop. The high-pressure pump will then automatically start to supply pressure. When the high-pressure water reaches the set value of 4.0 (MPa), the high-pressure pump will automatically stop, and the pressure holding time (such as 2 minutes/client-defined) will begin. Check for any leaks at the valve connection and on the valve body surface, and ensure the pressure gauge is stable, to confirm if the valve's strength pressure test is合格. (5) After testing, exhaust the pressure, release the button, and remove the butterfly valve.

Section 6: Usage Precautions and Requirements：

1. The site should be arranged in a level indoor space, properly leveled, and the footings anchored with concrete. It is suitable for use in a workshop with an ambient temperature of (1-40)℃ at room temperature or with heating in winter. The area should be free from high concentrations of dust and corrosive gases, and should not be near areas with grinding wheels or polishing machines with poor conditions. Good ventilation is required, and at least a 1m space channel should be reserved around the equipment installation for ease of operation and maintenance.

2. Operators must undergo professional training before taking their posts, adhere to standard operations, and strictly prohibit exceeding specifications or pressure. Non-specialists are advised not to operate.

3. Operators are strictly prohibited from leaving their posts during the pressure testing process. They must continuously monitor pressure levels to prevent exceeding the maximum allowable limit.

4. After the test is completed, the pressure must be released to zero before the clamping jaws can be released. The power should be turned off when not in use.

5. Regularly apply lubricant to all moving parts of the test bench to maintain cleanliness and smooth operation.

6. Use 46-grade anti-wear hydraulic oil (use antifreeze 46-grade anti-wear hydraulic oil below 0℃), ensuring the oil level does not fall below the indicator's lower limit. Regularly check the oil level and hydraulic oil; after one year of use, it should be cleanedWashing OilBox, replace with new oil.

7. Water source must be clean and free of impurities. If water quality deteriorates, it should be changed promptly. Add new rust inhibitor powder to meet testing requirements. To ensure that the testing valves are not corroded, it is usually necessary to add rust inhibitor powder regularly to the circulating water tank to prevent rust from affecting the normal operation of pipes, pumps, and check valves due to medium water.

Note: Common rust prevention powders include:Sodium nitriteSodium sulfonate, sodium benzenesulfonate (non-toxic powder).

8. The work surface of the equipment should be kept clean, and no debris is allowed between the valve flange being tested and the test blank flange.