详情描述

  

I. Product Overview:

YFA-F Type Hydraulic Valve Test Bench, which is developed based on our years of experience in manufacturing valve testing equipment, 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 require test pressure specifications in accordance with API 598 and similar standards.

This unit integrates hydraulic, mechanical, electrical systems, pressure supply devices, and a medium storage circulating water tank into one. The entire testing process is automatically controlled and executed by hydraulic and electrical components, featuring rational structure, comprehensive functions, stable performance, ease of operation, and high level of automation. It is widely used in high, medium, and low pressure sealing performance and shell strength endurance tests for direct flanged valves. 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, valve maintenance stations, etc.

II. Specification Range:

DN15-1200mm

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

Four: Performance Features:

Valves such as gate valves, stop valves, check valves, and ball valves suitable for direct flange connections. The tightening method employs flange face sealing with a hydraulic claw clamping the back of the flange, allowing adjustable clamping force. Test results showed no external force influence. During valve testing, the right-hand operating disc can be flipped 90 degrees, particularly suitable for air seal performance testing. The other operating disc can move forward and backward, with the length spacing adjustable freely, unrestricted by valve length, significantly enhancing work efficiency.

Clamping Method: Each bidirectional working plate is equipped with a removable hydraulic clamping mechanism. It can automatically synchronize and adjust the position of the clamping jaws to accommodate various valve specifications, achieving automatic centering and positioning. The hydraulic clamping jaws automatically grip the back of the valve flange, with adjustable clamping force, exerting no external force on the valve itself. The clamping process is fully controlled by integrated buttons and executed by hydraulic components.

 

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 operate the hydraulic system motor. Ensure the motor runs in the correct direction (clockwise). The left moving frame retracts beyond the length of the valve being tested. The left and right clamps move radially to exceed the outer diameter of the valve flange. The left and right clamps extend 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 towards the valve flange, press the clamp button to reduce the jaw spacing, 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 firmly press against the back of the valve flange, completing the overall clamping of the valve.

 

Section 2: 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 (in a clockwise manner).

Adjust the hydraulic system pressure to 5.0 MPa and it can then be operated normally.

4、Ensure the tested valve flange is tightly pressed against the right workbench with a blind flange, aligned to the center position. Move the radial clamps close to the valve flange and press the clamp button to shorten the distance between the clamps, pressing against the back of the valve flange to ensure it doesn't come loose.

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

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

7. Refer to the (Pressure Comparison 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 Increase) button to increase the pressure to the required clamping level. Press the (Top-Right Flip) button to flip the working plate to a horizontal position.

8. All assembly is complete. 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 already 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 4.0 (MPa), the high-pressure pump will automatically shut off, entering a pressure holding timer (such as 2 minutes/client-defined). Check the sealing surface of the valve and the connection areas, as well as any leakage on the valve body surface and the pressure gauge for any low points, to confirm if the sealing surface performance is up to standard. After the test is complete, open the (pressure relief valve) switch to exhaust the pressure and proceed to the next test.

Note: The process and testing methods for left-side mounting are similar to those for right-side mounting.

Section 3: Tensile Strength Testing Methods:

1. Strength pressure test: On the basis of the sealed test fixture process, advance the left-hand moving frame towards the right-hand workbench, close to the other end of the valve flange being tested. Press against the left-hand test blind flange, aligning with the central position. Move the left radial clamp jaw towards the valve flange, press the clamp button to shorten the clamp jaw travel, and securely press against the back of the valve flange. The overall fixture of the valve is completed.

2. Refer to the pressure comparison table for the required pressure of the hydraulic cylinder clamping, and increase the pressure to the required value. Once everything is clamped, set the low-pressure pump's electrical contact pressure to 1.8 (Mpa). For the electrical contact pressure (take a valve with a strength pressure of 6.0 Mpa as an example), adjust the red pointer of the electrical contact pressure gauge to 6.0 Mpa.

3. Open: Right inlet valve → Left inlet valve → Test valve.

4. Shut off: Main 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. 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 6.0 (MPa), the high-pressure pump will automatically stop, and enter the pressure holding timing period (such as 2 minutes/client-defined). Check for any leaks at the valve connection points, as well as on the valve body surface, and ensure the pressure gauge is not bottomed out, to confirm if the valve strength and pressure test is qualified. After the test is complete, open the (pressure relief valve) switch to exhaust the pressure, release 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, and the footings anchored with concrete. The environment 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 areas with grinding wheels or polishing machines with poor conditions. Good ventilation is required, and at least a 1m space 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 levels to prevent them from exceeding the safe limit.

4. After testing is complete, the pressure must be released to zero before the clamps can be released. The power should be disconnected during non-operational periods.

5. The moving parts of the testing bench often require the addition of lubricating oil to maintain clean and smooth operation.

6. Use 46-grade anti-wear hydraulic oil (for temperatures below 0°C, use antifreeze 46-grade anti-wear hydraulic oil), 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 cleaned.Wash OilBox, change to new oil.

7. Water source must be clean and free of impurities. In case of turbidity or degradation in water quality, it should be replaced promptly. Add new rust inhibitor powder as needed to meet testing requirements. To ensure the testing valve is not corroded, it is typically necessary to add rust inhibitor powder regularly to the recirculating water tank and prevent rusting of the pipes, pumps, and check valves, which may affect their normal operation.

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

8. The equipment worktop should be kept clean, and there should be no debris between the test valve flange and the pressure test blanking plate.