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."API StandardDesign and production are required to meet the test pressure requirements of specifications such as API598.

This unit integrates a hydraulic, mechanical, electrical system, pressure supply unit, and a medium storage circulating water tank into one. The entire testing process is automatically controlled and executed by hydraulic and electrical components. It boasts advantages such as a reasonable structure, comprehensive functions, stable performance, ease of operation, and high degree of automation. It is widely used in high, medium, and low pressure sealing performance and shell strength pressure tests for butterfly valves. Suitable valve types include flanged and clamped butterfly valves, knife gates, etc. It is suitable for valve manufacturers, the petrochemical industry, and hydropower stations.Natural GasIdeal valve testing and inspection equipment for industries such as pipeline components, wastewater treatment plants, valve maintenance stations, and more.

Section II: Specification Range:

Single station: 50-2200mm

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

IV. Performance Features:

Suitable for direct connection flanged and wafer butterfly valves, featuring face seal at the flange end, a set of movable hydraulic clamping systems is evenly installed on the workbench. It can automatically synchronize and adjust the position of the clamping jaws for various valve specifications, achieving automatic centering and positioning. During valve testing, the hydraulic clamping jaws automatically clamp the flange face of the valve, with adjustable clamping force, having no external force impact on the valve being tested. The clamping process is fully controlled by integrated buttons 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: Principle of Operation for YFA-D Type

YFA-D Type Butterfly Valve Hydraulic Valve Test Bench is a specialized testing equipment for butterfly valve sealing performance and housing strength pressure tests. The machine integrates hydraulic system, clamping cylinders, mechanical components, high and low-pressure water pumps, pressure gauges, valve control switches, clamping workbench, electrical control system, and medium storage circulating water tank into one.A hydraulic clamping cylinder is installed on the clamping workbench, directly driving the clamping jaws to clamp the butterfly valve's flat surface for testing, ensuring even force distribution among the jaws for reliable clamping. The radial movement function of the clamping jaws is achieved using a cylinder and lever assembly, allowing synchronous radial movement of all clamping jaws. The clamping cylinder is regulated by a hydraulic分流er to synchronize the axial clamping cylinders. This ensures testing of butterfly valves of different sizes. During the butterfly valve sealing test, select a sealing disc compatible with the test valve and install it on the machine. Place the butterfly valve on the sealing disc, and it is clamped by the hydraulic jaws directly pressing the butterfly valve flange surface. This allows for the injection of test medium. During the test, it is possible to visually inspect for leaks or bubbles inside the butterfly valve. For strength tests, simply add a sealing cover plate to the upper surface of the butterfly valve. The equipment is equipped with high and low-pressure liquid supply pumps, allowing direct liquid pressure tests. The liquid medium can be recycled and stored for use, preventing rust and corrosion of check valves and affecting normal equipment operation. Antirust agents must be added to the water.

Section 2: Instructions for Use

1. Fill the hydraulic system oil tank with 30#-46# hydraulic oil or 20# mechanical oil; the oil level must not be below the oil gauge's lower limit.

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

Adjust the hydraulic system pressure to 5.0 MPa for 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 disc.

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

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

8. Engage the point-action clamp to securely hold the test butterfly valve flange face; conduct 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 tightly with the clamps, and then perform the strength test of the butterfly valve housing.

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

Section 3: Gas Pressure Test：

1.  Seal Pressure Test: Valve mounting complete (1)Shut off: Total inlet valve → Pressure relief valve → Test butterfly valve. (2) Open: Pressure gauge switch → Total inlet valve to inject gas. Close (inlet valve) when the pressure reaches the desired level. Add water inside the butterfly valve chamber. (3) Enter the pressure holding timing phase. When the pressure holding time is up, check for bubble formation on the valve sealing surface and body, and pressure gauge drop to assess the valve's sealing performance.

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 pressure reaches the required value. Spray foam agent on the butterfly valve body surface (3) Enter the pressure holding timing phase. Check for bubble leakage at the valve connection sealing surface and valve body surface, and if the pressure gauge has dropped, 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). Adjust the electrical contact pressure gauge (with a sealed pressure of 1.6MPa as an example) by moving the red pointer 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 chamber is already filled with water. The low-pressure pump will automatically stop, and the high-pressure pump will automatically start to supply pressure. When the high-pressure water reaches the set value of 2.5 (MPa), the high-pressure pump will automatically stop, and enter the pressure holding timing period (such as 2 minutes/client-defined), to check for any leakage on the valve sealing surface and the valve body surface, and to confirm if the pressure gauge has any dips, in order to verify 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 (use 4.0 MPa as an example for strength pressure) by moving the red pointer to 4.0 MPa. (2) Close: Total intake valve → Pressure relief valve → Pressure gauge switch. (3) Open: Total intake valve → Valve under test. (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. The low-pressure pump will stop automatically, and the high-pressure pump will start to supply pressure automatically. When the high-pressure water reaches the set value of 4.0 (MPa), the high-pressure pump will stop automatically, and enter the pressure holding timing period (e.g., 2 minutes/client-defined). Check for any leaks at the valve connection surfaces and the valve body, 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. Ideally, the site should be arranged in a level indoor space, the horizontal position checked, and the base fixed with concrete. The environmental temperature should be between (1-40)°C, suitable for use in a normal temperature or heated workshop during winter. Surroundings should be free of 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 starting work, adhere to standard procedures, and strictly prohibit the use beyond 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 to prevent it from exceeding the safe limit.

4. After the test is completed, the pressure must be released to zero before the clamps can be released. The power should be disconnected when not in use.

5. All moving parts of the testing bench should be regularly lubricated to maintain clean and smooth operation.

6. Use 46-grade anti-wear hydraulic oil (for temperatures below 0℃, use antifreeze 46-grade anti-wear hydraulic oil). The oil level must not be below the lower limit on the oil gauge. Regularly check the oil level and hydraulic oil; after one year of use, it should be cleaned.Wash OilBox, change to new oil.

7. Water source must be clean and free of impurities. In case of turbidity or deterioration, timely replacement is required. Add new rust inhibitor powder to meet testing requirements. To ensure that the testing valve is not corroded, it is typically necessary to regularly add rust inhibitor powder 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 anti-rust powders include:Sodium NitriteSodium sulfonate, sodium benzenesulfonate (non-toxic powder).

8. The work surface of the equipment should be kept clean, and there should be no debris between the valve flange under test and the pressure test blank flange.