详情描述

  

I. Overview

YFA-H Type Top-Pressure Hydraulic Valve Test Bench, which is based on our company's many years of experience in manufacturing valve testing equipment, strictly conforms to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Valve Testing and Inspection."American Petroleum Institute StandardDesign and production requirements are in accordance with specifications such as API 598.

Widely applicable to high, medium, and low-pressure direct flanged and焊接 valves, pressure sealing performance and casing strength pressure tests, suitable valve types include gate valves, stop valves, check valves, ball valves, etc. Ideal for valve manufacturers, the petrochemical industry, and hydroelectric power stations.Natural GasIdeal valve testing and inspection equipment for industries such as pipe fitting manufacturers, wastewater treatment plants, and valve maintenance stations.

Section 2: Nominal Bore Size Range: 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, mechanical, electrical system, pressure supply device, 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 currently available. The clamping force applied to the tested valve is infinitely adjustable in pressure, ensuring complete avoidance of damage to the tested valve. The operation guarantees sensitive actuation and precise positioning throughout the usage process.Well-structured, fully functional, stable performance, easy to operate, broad application range, and high degree of automation.

2. The workbench canopy on both sides is connected by two rods, with a handle cap for locking. A movable workboard is installed in the middle, which can be moved forward and backward. The structure length is not restricted during valve testing, making it suitable for sealing tests and strength endurance tests of both direct passage flanged and welded valves. During valve testing, the bevel face or flange plane is used for sealing. The top pressure cylinder directly drives the middle moving board to the valve face for tightness, with the clamping force able toContinuous pressure regulation or automatic pressure increase to the desired value via button press.

3. The test bench features a dual-system for air and water, with both bidirectional pressure inlet and exhaust, equipped with a leak testing port. The system is pre-configured with high and low-pressure water pumps, allowing direct hydrostatic testing. The pressure supply from the high and low-pressure water pumps is equipped with automatic control functionality. The gas source is provided by the user. The liquid testing medium can be recycled and stored for use, offering energy-saving, environmental-friendly, low-cost investment, and high work efficiency.

4. The equipment features reliable safety protection measures. The top locking mechanism has an interlocking function. When pressure is present within the valve cavity, the top locking hydraulic cylinder locks the relaxation action until the pressure in the valve cavity is completely exhausted, at which point the button can be released. This prevents any risk of erroneous operation, ensuring safe use.

 

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 dipstick.

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 for normal operation.

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

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

Section 6: Gas Pressure Test: Right as rows

1.  Seal Pressure Test: Valve mounting complete (1)Close: 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 pressure value. (3) Enter the pressure holding timing phase. When the pressure holding time is up, open the leak detection switch, check for bubble leakage at the leak detection port, and observe if the pressure gauge loses pressure to determine if the valve's sealing performance is qualified.

2. Gas Strength Pressure Test: Based on the sealed test fixtureBased on the valve port size and pressureAdjust the clamping pressure according to the (pressure chart 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 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 seals and the valve body surface, and whether the pressure gauge has dropped pressure, to determine 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 and 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 (for sealed pressure, set the gauge to 2.5MPa) by moving the red pointer to 2.5MPa. (2) Close: Main inlet valve → Left and right pressure relief valves → Right pressure gauge switch → Test valve. (3) Open: Main water inlet valve → Left and right water inlet valves → Left leak detection switch.

(4) Start the low-pressure water pump to fill water to the outlet of the (left leak detection switch), then close the (left water inlet valve). When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the right valve chamber is fully filled with water, and the low-pressure water pump will automatically stop. The high-pressure water pump will then automatically start to supply pressure. When the high-pressure water reaches the set value of 4.0 (MPa), the high-pressure water pump will automatically stop, and enter the pressure holding timing period (such as 2 minutes/client-defined). Check for any leaks at the left leak detection port and ensure the pressure gauge is stable, to judge if the valve's pressure strength is qualified.

2、Water Strength Pressure Test:

Similarly, the pressure intensity test valve mounting is complete, (1)Set the low-pressure pump electrical contact pressure to 1.8 (MPa), adjust the electrical contact pressure gauge (for strength pressure, use 4.0 MPa as an example) by moving the red pointer to 4.0 MPa. (2) Shutdown: Main intake valve → Left and right pressure relief valves → Left and right leak detection switches → Left and right pressure gauge switches. (3) Startup: Main water intake valve → Test valve. (4) Start the low-pressure pump to fill with water, the pump will automatically stop when the low-pressure water pressure reaches the set value of 1.8 (MPa), indicating the valve chamber is full of water. The high-pressure pump will then automatically start to supply pressure. The high-pressure pump will stop automatically when the water pressure reaches the set value of 4.0 (MPa), entering the pressure maintenance timing period (such as 2 minutes/client-defined), check for any leakage at the valve connection seal and the valve body surface, and whether the pressure gauge is functioning properly, to determine if the valve strength pressure test is passable. (5) After testing, release all pressure, release the button, and remove the valve.

Section 8: Usage Precautions and Requirements：

1. The site should be arranged in a level indoor space, with the level position set and the footings anchored with concrete. The environmental temperature should be between 1-40℃ for normal conditions or in a heated workshop during winter. Surroundings should be free of high concentrations of dust and corrosive gases. Avoid using near grinding wheels or polishing machines in 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 taking their positions, adhere to standardized procedures, and are strictly prohibited from using equipment beyond its specifications or pressure limits. Non-professionals are advised not to operate the equipment.

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 maximum allowed.

4. After the test is completed, the pressure must be released to zero before the clamps can be released. The power should be disconnected during non-use periods.

5. Regularly apply lubricant to the moving parts of the testing bench to maintain clean and smooth operation.

6. Use 46-grade anti-wear hydraulic oil (use antifreeze 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 cleaned.Wash OilBox, replace with new oil.

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

Note: Common rust prevention powders include:Sodium NitriteSodium sulfonate, sodium potassium sulfonate (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 blanking plate.