详情描述

  

One,Product Overview:

YFA-F Type hydraulic valve testing bench, which is based on our company's many years of production experience in 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 shall comply with the pressure requirements of specifications 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 reasonable 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 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 repair stations.

II. Specification Range:

DN15-1200mm

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

IV. Performance Features:

Valves such as gate valves, stop valves, check valves, ball valves, etc., suitable for direct flange connections, utilize flange face sealing with hydraulic clamps securing the back of the flange, allowing adjustable clamping force. Test results show no influence from external forces. During valve testing, the right working disk can be flipped 90 degrees, particularly suitable for gas-tightness performance testing. The other working disk can be moved forward and backward, with the length clearance spacing freely adjustable, unrestricted by the valve length, greatly improving 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 grip the back of the valve flange, with adjustable clamping force, exerting no external force on the tested valve itself. The clamping process is fully controlled by an integrated button, with hydraulic components executing the operation.

 

Hydraulic Valve Test Bench Working Principle and Usage Method:

I. Working Principle:

Select a sealing blank that matches the valve model and install it on the equipment. Push the circuit breaker, the equipment power indicator light illuminates, press the oil pump start button, and let the hydraulic system motor run. Ensure the motor operates in the correct direction (clockwise), retract the left-moving frame to a length greater than the valve being tested, radially move the left and right clamps to a diameter greater than the outer diameter of the valve flange, and extend the left and right clamps axially to a thickness greater than the valve flange.

Secure the tested valve flange against the right-hand workbench with a blind flange in place, 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 firmly press against the back of the valve flange to ensure it does not come loose.

Move the left-hand shelf carriage to the right-hand workbench, positioning it close to the opposite end of the valve flange. Press it against the left-hand test blind flange and align it with the central position. Move the left radial clamp closer to the valve flange, press the clamp button to shorten the clamp stroke, and press it tightly against the back of the valve flange to complete 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 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 jaws towards the valve flange, press the clamp button to reduce the jaw spacing, and firmly press against the back of the valve flange to ensure the valve does not come loose.

5. Shutdown: 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 (clamp pressure required for hydraulic cylinder) chart to adjust the clamp pressure. For pressures exceeding the pump source by more than 5.0 Mpa, press the (right paw pressure boost) button to increase the pressure to the required clamp level. Press the (upper right flip) button to flip the right working disk horizontally.

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

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 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 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 sealing surface and connection parts of the valve, as well as for any leaks on the valve body surface and for any downward deflection on the pressure gauge, to confirm if 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 the testing methods are the same for the left-hand as for the right-hand direction.

Section 3: Tensile Strength Testing Methods:

1. Intensity pressure test: Based on the sealed test fixture process, advance the left-hand moving frame to the right-hand workbench, approaching the opposite end valve flange. 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 jaw travel, and securely press against the back of the valve flange, completing the overall fixture of the valve.

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

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

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. 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 will begin (e.g., 2 minutes/client-defined). Inspect the valve connection points, as well as for any leaks on the valve body surface and for any downward deflection on the pressure gauge, to confirm if the valve's strength and pressure test is合格. After the test is complete, open the: (pressure relief valve) switch, 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, the horizontal position calibrated, and the footer anchored with concrete. Use in environments with a temperature range of (1-40)°C, either at room temperature or in a heated workshop during winter. Surroundings should be free of high concentrations of dust and corrosive gases. Avoid areas near grinding wheels and polishing machines with poor conditions. Ensure good ventilation, and leave at least ≥1m of space around the equipment for easy operation and maintenance.

2. Operators must undergo professional training before assuming their positions, adhere to standard procedures, and strictly prohibit the use of equipment beyond its specifications or pressure limits. 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 the pressure to prevent it from exceeding safe limits.

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

5. Regularly apply lubricant to all moving parts of the testing bench to maintain clean 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 does not fall below the indicator. Regularly check the oil level and hydraulic oil; after one year of use, it should be drained and refilled.Wash OilBox, replace with new oil.

7. Water source must be clean and free of impurities. If water quality deteriorates, it should be changed promptly. Add new rust prevention powder to meet testing requirements. To ensure that 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 could affect normal operation.

Note: Common rust-inhibiting powders include:Sodium NitriteSodium sulfonate, potassium benzenesulfonate (non-toxic, powdered form).

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