详情描述

 

I. Product Overview:

YFA-FQ Type hydraulic valve testing bench, which is based on our years of experience in manufacturing valve testing equipment, strictly conforms to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves."American Petroleum Institute StandardDesign and production require test pressure in accordance with standards such as API 598.

This unit integrates a hydraulic, mechanical, electrical system, pressure supply unit, and 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, easy operation, and high degree of automation. It is widely used in high, medium, and low-pressure direct flanged valve 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.

II. Specification Range:

DN15-800mm

Section 3: Pressure Range: 1.6-63.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

Valves suitable for direct flange connection types, including gate valves, stop valves, check valves, ball valves, etc., use flange face sealing for tightness and hydraulic clamps to secure the flange backside, with adjustable clamping force. Test results show no external force interference. During the valve testing process, the right-hand operating disc features a 90-degree flip function, particularly suitable for air tightness performance testing. The other operating disc can move forward and backward, with freely adjustable length spacing, 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, having no external force impact on the tested valve itself. The clamping process is fully controlled by an integrated button and executed by hydraulic components.

This test bench features up and down lifting capabilities, allowing both the machine and the tested valve to be submerged simultaneously in water. It is particularly suitable for strength, sealing, and gas pressure performance tests of valves, revolutionizing the traditional testing method of using foam agents to scrub the surface of the valve housing. It shortens testing time and significantly enhances work efficiency, making it the most ideal choice for a dual-gas-water testing device.

 

Hydraulic Valve Test Bench Working Principle and Usage Method:

I. Working Principle:

Select a sealing blank compatible with the valve model and install it on the equipment. Push the electric switch, the equipment power indicator light illuminates. Press the oil pump start button to activate the hydraulic system motor, ensuring the motor runs in the correct direction (clockwise). Move the left side bracket back beyond the length of the valve being tested. Radially move the left and right clamps beyond the outer diameter of the valve flange. Extend the left and right clamps axially beyond the thickness of the valve flange.

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

Move the left-hand carriage to the right-hand workbench, positioning it close to the other end's valve flange. Press against the left-hand test blind flange, aligning with the center. Move the left radial clamp closer to the valve flange, press the clamp button to shorten the clamp travel, and securely press against the back of the valve flange. 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.

 

Section 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 lower limit of the oil gauge.

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 commence 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 close to 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. Close: Left inlet valve → Main 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 (cylinder clamping pressure reference table) to adjust the clamping pressure. For pressures exceeding the pump source by more than 5.0 Mpa, press the (right claw boost) button to increase the pressure to the required clamping level. Press the (upper right flip) button to flip the right working disk up to a horizontal position.

8. All assembly 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 chamber is fully 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 sealing surface of the valve, the connection parts, and whether there is any leakage on the valve body surface, and whether the pressure gauge has any deflection, 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 of loading and the testing method for left-hand assembly are the same as for right-hand assembly.

Section 3: Tensile Strength Testing Method:

1. Intensity pressure test: Based on the sealed test fixture process, advance the left-hand moving bracket towards the right-hand workbench, approaching the opposite end's test valve flange. Press against the left-hand test blind plate, aligning with the central position. Move the left radial clamp, approach the valve flange, press the clamp button to shorten the clamp stroke, and press against the back of the valve flange, completing the overall fixture of the valve.

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

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

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

5. Start the low-pressure water pump, and when the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve chamber is fully filled with water. The low-pressure pump will then automatically shut off, and the high-pressure pump will automatically begin to supply pressure. When the high-pressure water reaches the set value of 6.0 (MPa), the high-pressure pump will automatically stop, and the pressure holding time will begin (e.g., 2 minutes/client-defined). Check the valve connection areas and the valve body surface for any leaks and ensure the pressure gauge is stable, to confirm the valve's pressure strength test passes. After the test, open the (pressure relief valve) switch to release all pressure, relax the clamps, and remove the valve.

 

VI. Usage Precautions and Requirements：

1. Ideally, the location should be arranged in a level indoor space, with the horizontal position adjusted and the base anchored with concrete. The environmental temperature should be between (1-40)℃ for normal conditions or in a heated workshop during winter. The area should be free from high concentrations of dust and corrosive gases, and should not be near sanding machines or grinding wheels in poor conditions. Good ventilation is essential. Leave at least a 1m space around the installed equipment for ease of operation and maintenance.

2. Operators must undergo professional training before starting work, 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 pressure.

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

6. Use 46-grade anti-wear hydraulic oil (use anti-freeze 46-grade anti-wear hydraulic oil below 0℃), and ensure the oil level is not 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, change to new oil.

7. Water source must be clean and free of impurities. If water quality deteriorates, it must be changed 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 may affect normal operation.

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

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