详情描述

  

I. Overview

YFA-H Type Pressure-Testing Hydraulic Valve Test Bench, which is developed based on our years of experience in manufacturing valve testing equipment, strictly adheres to GB/T 13927-2008 "General Valve Pressure Test" and JB/T 26480-2011 "Testing and Inspection of Valves."American Petroleum Institute StandardDesign and production shall comply with test pressure requirements of specifications such as API 598.

Widely applicable to high, medium, and low-pressure direct flanged and welded type valves, featuring pressure seal performance and shell strength endurance tests. Suitable valve types include gate valves, stop valves, check valves, ball valves, etc. Ideal 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.

Two, Specification Range: Nominal Bore Size 15-mm to 1000-mm

Section 3: Pressure Range: Nominal Pressure 1.6-42.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

1、This unit integrates a hydraulic system, mechanical system, electrical system, pressure supply unit, and a medium storage circulating water tank into one. The entire testing process is automatically controlled and executed by hydraulic and electrical components.The complete hydraulic system utilizes the most reliable hydraulic control form available. The clamping force applied to the tested valve is infinitely adjustable in pressure, ensuring no damage to the tested valve. The operation guarantees the responsiveness of the action and the precision of the position.Features include well-structured design, comprehensive functionality, stable performance, user-friendly operation, broad application scope, and high degree of automation.

2. The left and right workbench pavilions are connected by two rods and secured with a handle cap lock. A movable workboard is installed in the middle, allowing for forward and backward movement. The structure length is not restricted during valve testing, making it suitable for sealing and strength pressure tests of both direct-connection flanged and welded valves. During valve testing, a bevel face or flange plane seal is used. The top pressure cylinder directly drives the central moving plate to the valve face for tightness, with the clamping force able toContinuous pressure adjustment or automatic boost to the desired pressure value with the push of a button.

3. The test bench features a dual-system for both air and water, with bidirectional pressure and pressure relief, equipped with a leak detection test port. The system is pre-configured with high and low-pressure water pumps, allowing for direct hydrostatic testing. The high and low-pressure water pumps are equipped with automatic control functions. The gas source is user-supplied, and the liquid testing medium can be recycled and stored for use, offering energy-saving, environmental protection, low investment cost, and high work efficiency.

4. The equipment features reliable safety protection measures. The locking mechanism between the top tightening devices has an interlock function. When pressure is present in the valve cavity, the top tightening cylinder locks and releases its action until the pressure inside the valve cavity is fully relieved, at which point the release button can be activated. This prevents any accidental operation hazards and ensures safe usage.

 

V. Usage Instructions:

1. Fill the hydraulic system oil tank with 30#-46# hydraulic oil or 20# mechanical oil, ensuring the oil level does not fall below the lower mark on 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 for normal operation.

4. Select a sealing disk suitable for valve testing and install it on both working plates.

4. Engage the point motion cylinder's tightening button, move the middle seal plate to closely seal against the valve end face, based on the valve orifice diameter and pressure.Adjust the clamping pressure according to the (Pressure Comparison Table for Cylinder Clamping). For pressures exceeding the pump source by more than 5.0 Mpa, press the (Cylinder Pressure Boost) button to increase the pressure to the desired level.The boost button can be pressed multiple times, with each interval being approximately 3-5 seconds, and the maximum pressure reaching 30MPa.

Section 6: Gas Pressure Test: Right-hand side

1.  Gas-tight pressure test: Valve mounting complete (1)Shut off: Total inlet valve → Left inlet valve → Right pressure relief valve → Test butterfly valve. (2) Open: Right pressure gauge switch → Right inlet valve → Inject gas into total outlet valve, close (total outlet valve) when the pressure reaches the required level. (3) Enter the pressure-holding timing phase. When the pressure-holding time is up, open the leak test switch to check for bubble formation at the leak test port and pressure drop on the pressure gauge to determine if the valve's sealing performance is up to standard.

2. Gas Intensity Pressure Test: Based on the sealed test fixture, Based on valve port size and pressureAdjust the clamping pressure according to the (Pressure Comparison Table for Cylinder Clamping)（1）Shut off: Total inlet valve → Left and right pressure relief valves → Leak detection switch. (2) Open: Test valve → Left and right pressure gauge switches → Inject gas into the total inlet valve. Close (total inlet valve) when the pressure reaches the required value, and spray foam agent on the valve body surface. (3) Enter the pressure holding timing phase. When the pressure holding time is up, check for bubble leakage at the valve connection seal and the valve body surface, and whether the pressure gauge has dropped pressure to judge if the valve's strength performance is qualified. (4) After testing, open the pressure relief valve, exhaust the pressure, and remove the valve.

Section 7: Hydrostatic Test: Right as column

1. Water-tightness Pressure Test

Similarly, pressure-sealed test fixture, (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Adjust the electrical contact pressure gauge (with a sealing pressure of 2.5MPa as an example) by turning the red pointer to 2.5MPa. (2) Shutdown: Main intake valve → Left and right pressure relief valves → Right pressure gauge switch → Test valve. (3) Open: Main water intake valve → Left and right water intake valves → Leftward leak detection switch.

(4) Start the low-pressure water pump to fill the system to the outlet of the (left-side leak detection switch), then close the (left-side water inlet valve). When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the right-side valve chamber is full of 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 4.0 (MPa), the high-pressure pump will automatically stop, and enter the pressure maintenance timing period (e.g., 2 minutes/client-defined). Check for any leaks at the left-side leak detection port and ensure the pressure gauge is stable to determine if the valve's strength and pressure are within specifications.

2、Water Strength Pressure Test:

Similarly, the pressure testing valve mounting is complete, (1)Set the low-pressure pump's electrical contact pressure to 1.8 (MPa). Adjust the electrical contact pressure gauge (with 4.0 MPa as the reference) by moving the red pointer to 4.0 MPa. (2) Close: Main inlet valve → Left and right pressure relief valves → Left and right leak detection switches → Left and right pressure gauge switches. (3) Open: Main water inlet valve → Test valve. (4) Start the low-pressure pump to fill with water. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is full of 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 the pressure holding timing (such as 2 minutes/client's specification) will begin. Check for leaks at the valve connection seals and the surface of the valve body, as well as for any pointer dip on the pressure gauge, to determine if the valve's strength pressure test is qualified. (5) After testing, release the pressure, release the button, and remove the valve.

Section 8: Usage Precautions and Requirements：

1. Preferably, arrange the site in a level indoor space, set the level position, and secure the footings with concrete. The environment temperature should be between 1-40℃ for normal conditions or in a heated workshop during winter. The area should not have high concentrations of dust or corrosive gases. Avoid placing it near areas with grinding wheels, polishers, or poor conditions. Ensure good ventilation, and leave at least 1m of space 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 the pressure to prevent it from exceeding safe limits.

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

5. The moving parts of the test bench should be regularly lubricated to maintain clean 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 indicator's lower limit. Regularly check the oil level and hydraulic oil; after one year of use, it should be drained and replaced.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 the testing valves are not corroded, it is usually necessary to add rust inhibitor powder regularly to the circulating water tank and prevent the medium water from causing rust on the pipes, pumps, and check valves, which could affect their normal operation.

Note: Common rust-preventing powders include:Sodium NitriteSodium sulfonate, 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 pressure test blank.