详情描述

  

I. Product Overview:

YFA-F 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 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. It boasts advantages such as 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 flange valves for pressure sealing performance and shell strength and pressure tests. Suitable valve types include gate valves, stop valves, check valves, ball valves, and more. It is suitable for valve manufacturers, the petrochemical industry, hydropower stations, and more.Natural GasIdeal valve testing and inspection equipment for industries such as pipeline fittings, wastewater treatment plants, valve maintenance stations, etc.

II. Specification Range:

DN15-1200mm

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

IV. Performance Features:

Gate valves, stop valves, check valves, ball valves, etc., suitable for direct flange connection types, utilize flange face sealing for clamping. The hydraulic jaw clamps the backside of the flange, with adjustable clamping force. Test results were unaffected by external forces. During the valve test, the right working disc can rotate 90 degrees, especially suitable for gas-tightness performance testing. The other working disc can move forward and backward, with freely adjustable length spacing. Valve length is unrestricted, greatly 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, without any external force affecting the tested valve itself. The clamping process is fully controlled by integrated buttons and executed by hydraulic components.

 

Hydraulic Valve Test Bench Working Principle and Operating Instructions:

I. Working Principle:

Select a sealing blank compatible with 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 to operate the hydraulic system motor. Ensure the motor runs in the correct direction (clockwise). The left moving frame retracts to a length greater than the test valve. The left and right clamps move radially to exceed the outer diameter of the test valve flange. The left and right clamps extend axially to exceed 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, 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 does not come loose.

Slide the left-hand shelf to the right towards the workbench, aligning it with the opposite end of the valve flange being tested. Press it tightly against the left pressure-test blanking plate and position it centrally. 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 II: Sealing Pressure Test Method:

1. Fill the hydraulic system's oil tank with 30#-46# hydraulic oil or 20# mechanical oil; the oil level must not fall 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 (clockwise).

Adjust the hydraulic system pressure to 5.0 MPa to operate normally.

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, and press the clamp button to reduce the clamp spacing, pressing firmly against the back of the valve flange to ensure the valve does not 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 water inlet valve → Main water inlet valve.

7. Refer to the (pressure required for cylinder clamping table) to adjust the clamping pressure. For pressures exceeding the pump source by 5.0 Mpa or more, press the (right claw boost) button to increase the pressure to the required clamping level. Press the (upper right flip) button to flip the working plate to a horizontal position on the right side.

8. All clamping completed, set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure (for example, with a 4.0MPa valve for sealing, 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 fully 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 enter the pressure-holding timing period (e.g., 2 minutes/client-defined). Check the valve sealing surfaces and connection points, as well as any leaks on the valve body surface and the pressure gauge for any downward deflection, to confirm the sealing surface performance is qualified. After the test is complete, open the (pressure relief valve) switch to exhaust the pressure and proceed to the next test.

Note: The process of loading and testing in the leftward direction is the same as in the rightward direction.

Section 3: Tensile Strength Testing Methods:

1. Strength pressure test: Based on the sealed test fixture process, advance the left-hand moving frame towards the right-hand workbench, approaching the other end of the valve flange being tested. Press against the left-hand test blind flange and align with the central position. Move the left radial chuck closer to the valve flange, press the clamping button to shorten the chuck stroke, and press against the back of the valve flange tightly, completing the overall fixture of the valve.

2. Refer to the pressure comparison table for the clamping pressure required for hydraulic cylinders, and increase the pressure to the required value. Once all clamping is complete, set the low-pressure pump's electrical contact pressure to 1.8 (Mpa). For the electrical contact pressure (with the 6.0MPa valve as an example for strength pressure), adjust the red pointer on the electrical contact pressure gauge to 6.0MPa.

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

4. Close: 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. Once the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve chamber is fully filled with water, at which point 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 the pressure holding time (such as 2 minutes, customizable by the customer) will begin. During this time, inspect the valve connection areas, the valve body surface for any leaks, and the pressure gauge for any drops, to confirm the valve's pressure test integrity. After the test is complete, open the (bleeder valve) switch to exhaust the pressure, release the clamps, and remove the valve.

 

Section 6: Usage Precautions and Requirements：

1. Ideally, the site should be arranged in a level indoor space, properly leveled, and the footings secured with concrete. The operating 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 sanding or polishing machines, which have poor conditions. Good ventilation is essential. At least a 1m space should be left around the equipment for ease of operation and maintenance.

2. Operators must undergo professional training before taking up their positions. Standard operating procedures must be followed, and the use of equipment beyond specifications or pressure is strictly prohibited. Non-professionals are advised not to operate.

3. Operators are strictly prohibited from leaving their posts during the pressure testing process. They must continuously monitor the pressure to prevent it from exceeding safe limits.

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

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

6. Select 46-grade anti-wear hydraulic oil (use anti-freeze 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 flushed.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 prevention powder, meet testing requirements. To ensure that the test valves are not corroded, it is usually necessary to add rust prevention powder regularly to the circulating water tank and prevent the medium water from causing rust on pipes, pumps, and check valves, which may affect normal operation.

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

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