详情描述

 

I. Product Overview:

YFA-FQ type hydraulic valve testing bench, which is developed based on our company's many years of experience in manufacturing valve testing equipment, strictly in accordance with GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves."American Petroleum Institute 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-supplying device, 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 rational structure, comprehensive functions, stable performance, ease of operation, and high degree of automation. It is widely used in high, medium, and low-pressure direct flanged valves for pressure-sealing performance and shell strength endurance tests. Applicable valve types include gate valves, stop valves, check valves, ball valves, and more. It is suitable for valve manufacturers, the petrochemical industry, and hydropower stations.Natural GasIdeal valve testing and inspection equipment for industries such as pipe fitting manufacturers, wastewater treatment plants, and valve maintenance stations.

Section 2: Specifications Range:

DN15-800mm

Three, Pressure Range: 1.6-63.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

Valves suitable for direct flange connections, including gate valves, stop valves, check valves, ball valves, etc., utilize flange face sealing for the tightening method. The hydraulic clamp grips the back of the flange, with adjustable clamping force. Test results show no external force interference. During the valve testing process, the right-hand working disc can be flipped 90 degrees, making it particularly suitable for air seal performance testing. The other working disc can be moved forward and backward, with the length spacing freely adjustable, allowing for unrestricted valve length, significantly enhancing work efficiency.

Clamping Method: Each bidirectional working disc is equipped with a removable hydraulic clamping mechanism. It can automatically synchronize and adjust the position of the clamping jaws according to various valve specifications, achieving automatic centering and positioning. The hydraulic clamping jaws automatically clamp the back of the valve flange, with adjustable clamping force, without any external force affecting the tested valve itself. The clamping process is fully controlled by an integrated button and executed by hydraulic components.

The test bench features an up-and-down lifting function, allowing both the machine and the valve under test to be submerged simultaneously in water. It is particularly suitable for testing the strength, sealing, and gas pressure performance of the valve's upper seal. It changes the traditional testing method of brushing the valve housing surface with a foaming agent, shortens the testing time, and greatly enhances work efficiency, making it the most ideal choice for a dual-gas-water testing device.

 

Hydraulic Valve Test Bench Working Principle and Operation Method:

I. Working Principle:

Select a sealing blank that matches the valve model and install it on the equipment. Push the electrical switch, the equipment power indicator light illuminates, press the oil pump start button, and allow the hydraulic system motor to run. Ensure the motor runs in the correct direction (clockwise), then retract the left moving bracket beyond the length of the test valve. Radially move the left and right clamps beyond the outer diameter of the valve flange, and extend the left and right clamps axially beyond the thickness of the valve flange.

Secure the test valve flange tightly against the right-hand workbench with a blind flange in place, aligning it with the center position. Move the radial chuck closer to the valve flange, press the chuck clamping button to shorten the chuck gap, and press against the back of the valve flange to ensure it won't come loose.

Move the left-hand trolley to the right-hand workbench, positioning it close to the opposite end of the valve flange being tested. Press against the left-hand test blind flange, aligning with the center position. Move the left radial clamp closer to the valve flange, press the clamp button to shorten the clamp stroke, and press against the back of the valve flange to secure it. The overall clamping of the valve is complete.

During gas pressure testing, the machine and the valve under test can be submerged together in water. For hydrostatic testing, simply raise the machine to the proper position.

 

II. Sealing Pressure Test Method:

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).

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

4、Secure the test valve flange flat against the right-hand workbench with a blind flange, aligning it to the center position. Move the radial clamp, position it near the valve flange, press the clamp button to reduce the gap between the jaws, and press against the back of the valve flange to ensure it won't come loose.

5. Shut off: Left water inlet valve → Total air inlet valve → Right pressure relief valve → Test valve → Right pressure gauge switch.

6. Open: Right water inlet valve → Main water inlet valve.

7. Refer to the (Pressure Requirement Chart for Cylinder Clamping) to adjust the clamping pressure. For pressures exceeding the pump source by 5.0 Mpa or more, press the (Right Claw Pressure Boost) button to increase the pressure to the required clamping level. To flip the right working plate to a horizontal position, press the (Top-Right Flip) button.

8. All assembly and clamping completed. Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure (take the valve sealed at 4.0MPa as an example; adjust the red pointer of the electrical contact pressure gauge to 4.0MPa).

9. 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 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 4.0 (MPa), the high-pressure pump will automatically stop, and enter the pressure maintenance timing period (such as 2 minutes/client-defined). Check the valve sealing surface and connection areas, as well as any leaks on the valve body surface, and whether the pressure gauge has a dip, to confirm if the sealing surface performance is qualified. After the test is complete, open the (pressure relief valve) switch, exhaust the pressure, and proceed to the next test.

Note: The process and testing method for the left-side loading are the same as for the right-side.

Section 3: Tensile Strength Testing Method:

1. Strength pressure test: On the basis of the sealed test fixture process, advance the left moving frame to the right workbench, approaching the opposite end of the valve flange being tested. Press against the left test blind plate, aligning with the center position. Move the left radial clamp jaw towards the valve flange, press the clamp button to shorten the jaw travel, and firmly press against the back of the valve flange. The overall clamping of the valve is completed.

2. Refer to the pressure table for cylinder clamping requirements, increase the pressure to the required value. Once everything is clamped, set the low-pressure pump's electrical contact pressure to 1.8 (Mpa), and adjust the electrical contact pressure gauge (for strength pressure, use a valve at 6.0MPa) by moving the red pointer to 6.0MPa.

3. Open: Right inlet valve → Left inlet valve → valve under test.

4. Shut off: Total intake valve → Right pressure relief valve → Left pressure relief valve → Right pressure gauge switch → Left pressure gauge switch.

5. 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 filled with water, and the low-pressure pump will automatically shut off. The high-pressure pump will then automatically start to supply pressure. When the high-pressure water reaches the set value of 6.0 (MPa), the high-pressure pump will automatically shut off, and enter the pressure maintenance timing period (such as 2 minutes/client-defined). Check for any leaks at the valve connection points, the valve body surface, and if the pressure gauge has any drops, to confirm the valve's pressure strength test is合格. After the test, open the (pressure relief valve) switch, release all pressure, loosen the clamps, and remove the valve.

 

Section 6: Usage Precautions and Requirements：

1. The site should be arranged in a level indoor space, properly leveled, with concrete footings secured. It is suitable for use in a temperature range of (1-40)℃ in a normal or heated workshop during winter. The surroundings should be free of high concentrations of dust and corrosive gases, and should not be near areas with abrasive wheels or polishing machines with poor conditions. Good ventilation is essential. At least 1m of space should be left around the equipment installation for easy operation and maintenance.

2. Operators must undergo professional training before taking their posts, adhere to standard procedures, 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 supply should be disconnected when not in use.

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

6. Use 46-grade anti-wear hydraulic oil (for temperatures below 0°C, use anti-freeze 46-grade anti-wear hydraulic oil), ensuring the oil level does not fall below the gauge's lower limit. Regularly check the oil level and hydraulic oil; it should be flushed after one year of use.Wash OilBox, replace with new oil.

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

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

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