详情描述

  

One,Product Overview:

YFA-L Type Hydraulic Valve Test 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 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 a rational structure, comprehensive functions, stable performance, easy operation, and high degree of automation. It is widely used in high, medium, and low-pressure direct flanged valves for pressure-sealing performance and shell strength endurance tests. Suitable valve types include gate valves, stop valves, check valves, ball valves, butterfly 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 pipeline fittings manufacturers, wastewater treatment plants, and valve maintenance stations.

II. Specification Range:

DN15-300mm

Three, Pressure Range: 1.6-42.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

1. The equipment features a structure with a worktable installed below, equipped with a set of 3-jaw hydraulic clamping mechanism evenly distributed on the worktable. A movable hydraulic thrust cylinder is mounted on the worktable, allowing the thrust cylinder to rotate backward by 90 degrees when clamping valves, facilitating observation during valve installation and sealing tests. Suitable for various types of valves including flanged, welded, socket-weld, gate valves, stop valves, check valves, ball valves, and butterfly valves. The clamping does not exert any external force on the tested valve.

2. The sealing method employs a valve face seal. During the valve sealing test, the hydraulic clamp grips the back of the flange. For strength tests, a bevel face or flange surface seal is used, with the top pressure cylinder pressing it securely in place. The clamping force isContinuous pressure adjustment or stepless pressure increase to the desired pressure value via button presses.

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

4. The equipment features reliable safety protection measures, with interlocked联动 functionality in the clamping mechanism. When pressure is present in the valve chamber, the clamping cylinder locks and releases the action until the pressure in the valve chamber is completely relieved, at which point the button can be released. This prevents accidental operation hazards, ensuring safe use.

V. Instructions for Use:

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 limit of the oil gauge.

2. Power on the unit, press the oil pump start button, and check if the motor rotates in the correct direction (clockwise).

3. Adjust the hydraulic system pressure to 5.0 MPa and it will operate normally.

4. Sealing Test Clamping Method: Move the clamping jaw in a point-to-point motion to a position larger than the outer diameter of the valve flange. Select a sealing disk compatible with the valve test and install it on the workbench. Place the valve on the sealing plate. Move the clamping jaw in a point-to-point motion to a position above the valve flange thickness. Advance the clamping jaw to a position close to the valve flange, then tighten and grip the backside of the valve flange. Strength Test Clamping Method: Secured by the top-tightening cylinder pressing against the opposite end face seal, based on the valve port diameter and pressureAdjust the clamping pressure according to the (Pressure Required for Cylinder Clamping Chart). For pressures exceeding the pump source by more than 5.0 Mpa, press the (Clamping Pressure Increase) button to increase the pressure to the required level.The boost button can be pressed multiple times, with intervals of about 3-5 seconds each, reaching a maximum pressure of 30MPa.

 

Section 6: Gas Pressure Test：

1.  Seal Pressure Test: Assemble according to the seal test fixture method, all assembly completed (1)Shut off: Total inlet valve → Upper inlet valve → Lower pressure relief valve → Test butterfly valve. (2) Open: Lower pressure gauge switch → Lower inlet valve → Inject gas into the total inlet valve. Close (total inlet valve) when the air pressure reaches the required pressure value. (3) Enter the pressure-holding timing phase. Upon completion of the pressure-holding time, check for bubble leakage on the sealing surface and pressure drop on the gauge to determine if the valve's sealing performance is up to standard.

2. Gas Strength Pressure Test: Based on the sealed test fixtureTightened by a top-acting hydraulic cylinder against the opposite end face seal, based on the valve port diameter and pressureAdjust the clamping pressure according to the (pressure chart for cylinder clamping).（1）Shut off: Main water inlet valve → Left and right pressure relief valves → Leak detection switch. (2) Open: Valve under test → Top and bottom pressure gauge switches → Inject gas into main air inlet valve, close (main air inlet valve) when the pressure reaches the required value, then spray foam agent on the valve body surface. (3) Enter the pressure holding timing phase, check for bubbles at the valve connection seal and valve body surface, and pressure drop on the gauge to determine if the valve's strength performance is up to standard. (4) After testing, open the pressure relief valve, exhaust the pressure, and remove the valve.

Section 7: Water Pressure Test

1. Water Seal Pressure Test

Similarly, pressure seal 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 to 2.5MPa as an example) by moving the red pointer to 2.5MPa. (2) Close: Total inlet valve → Upper water inlet valve → Lower pressure relief valve → Lower pressure gauge switch → Valve under test. (3) Open: Total water inlet valve → Lower water inlet valve. (4) Start the low-pressure pump to fill with water. When the low-pressure pump pressure reaches the set value of 1.8 (MPa), it indicates that the right valve chamber is 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 the pressure holding time (such as 2 minutes/client-defined) will begin. Check for any leaks on the valve sealing surface and housing surface, and ensure the pressure gauge is stable, to determine if the valve's strength and pressure are qualified.

2、Water Strength Pressure Test:

Similarly, the pressure intensity pressure test valve mounting is all done, (1)Set the low-pressure pump electrical contact pressure to 1.8 (MPa). Adjust the electrical contact pressure gauge (use 4.0 MPa as an example for strength pressure) by moving the red pointer to 4.0 MPa. (2) Close: Total inlet valve → Upper and lower pressure relief valves → Upper and lower pressure gauge switches. (3) Open: Total inlet water valve → Valve under test. (4) Start the low-pressure pump to fill 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 enter the pressure holding timing period (e.g., 2 minutes/client-defined). Check for any leaks at the valve connection surfaces and the valve body, and if the pressure gauge is submersed, to determine if the valve's strength pressure test is合格. (5) After testing, exhaust the 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, properly leveled, and the footings anchored with concrete. It is suitable for use in a temperature range of (1-40)℃ in a normal or heated workshop during winter. The surrounding area should be free from high concentrations of dust and corrosive gases. Avoid using near grinding wheel or polishing machines in poor conditions. Ensure good ventilation, and leave at least a 1m space around the installed equipment for ease of operation and maintenance.

2. Operators must undergo professional training before starting work, adhere to standard procedures, and strictly prohibit exceeding 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 the safe limit.

4. After the test is completed, the pressure must be released to zero before the clamps can be released. The power should be turned off when not in use.

5. Regularly apply lubricant to all moving parts of the test bench to maintain cleanliness 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). The oil level must not be below the oil gauge's lower limit. Regularly check the oil level and hydraulic oil; after one year of use, it should be cleanedWash OilBox, change to new oil.

7. Water source must be clean and free of impurities. If water quality deteriorates, it must be changed promptly. Add new rust prevention powder to meet testing requirements. To ensure that the testing valves are not corroded, it is typically necessary to regularly add rust prevention powder to the circulating water tank to prevent rust from affecting the normal operation of pipes, pumps, and check valves due to medium water.

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

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