详情描述

  

One,Product Overview:

YFA-L Type hydraulic valve testing bench, which is based on our company's years of experience in producing valve testing equipment, strictly conforms to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves".API StandardDesign and production shall comply with the test pressure requirements of specifications such as API 598.

This unit integrates hydraulic, mechanical, electrical systems, pressure supply units, and medium storage circulating water tanks 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, convenient 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 and pressure resistance tests. Applicable 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, sewage treatment plants, valve maintenance stations, and more.

Section 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 table. An adjustable hydraulic thrust cylinder is mounted on the worktable, allowing the thrust cylinder to rotate 90 degrees backward when clamping valves, facilitating observation during valve installation and sealing tests. Suitable for various types of valves including flanged, welded, socket, gate, stop, ball, and butterfly valves. The test does not exert any external force on the valve itself, ensuring a secure grip.

2. The sealing method uses a valve face seal. During the valve sealing test, the hydraulic clamp is used to tightly grip the back of the flange. For strength tests, either a bevel face or flange plane seal is employed, with the top pressure cylinder securing it tightly. The clamping force isContinuous pressure adjustment or boost to the desired pressure level via button point operation.

3. The test bench features a dual-system for air and water, with bidirectional pressure intake and release, equipped with a leak detection test port. The system is pre-configured with high and low-pressure water pumps, allowing 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 cost investment, and high work efficiency.

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

V. Usage Instructions:

1. Fill the hydraulic system oil tank with 30#-46# hydraulic oil or 20# mechanical oil; the oil level must not be below the lower limit of the oil gauge.

2. Plug in the power supply, press the oil pump start button, and check if the motor rotates in the correct direction (counterclockwise).

Adjust the hydraulic system pressure to 5.0 MPa and it's ready for normal operation.

4. Sealing test fixture method: Retract the point actuated clamp to a position larger than the outer diameter of the valve flange being tested. Select a sealing disc compatible with valve testing and install it on the workbench. Place the valve on the sealing plate. Gently release the point actuated clamp to a height above the valve flange thickness. Advance the point actuated clamp, moving it close to the valve flange, and then clamp and grip the backside of the valve flange. Strength test fixture method: Sealed by the thrust cylinder pressing against the opposite end face, based on valve orifice size and pressureAdjust 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 (Clamping Pressure Increase) button to increase the pressure to the desired level.The boost button can be pressed multiple times, with each interval around 3-5 seconds, and the maximum pressure is 30MPa.

 

Section 6: Gas Pressure Test：

1.  Gas-tight pressure test: Assemble all components according to the sealing test assembly method (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 → Total air inlet valve to inject gas. Close (total air inlet valve) when the air pressure reaches the required pressure value. (3) Enter the pressure holding time check phase. Check for bubble leakage at 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 fixtureSealed by a top-tight cylinder pressing against the opposite end face, depending on the valve port diameter and pressureRefer to the (cylinder clamping pressure reference table) to adjust the clamping pressure.（1）Shut off: Total inlet valve → Left and right pressure relief valves → Leak detection switch. (2) Open: Test valve → Upper and lower 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, check for bubble formation at the valve connection seals and the valve body surface, and pressure gauge drop to assess 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: Water Pressure Test

1. Water-tight 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 2.5 MPa as an example) by moving the red pointer to 2.5 MPa. (2) Close: Total inlet valve → Upper water inlet valve → Lower pressure relief valve → Lower pressure gauge switch → Test valve. (4) Open: Total water inlet valve → Lower water inlet valve. (4) Start the low-pressure pump to fill water. When the pressure of the low-pressure pump reaches the set value of 1.8 (MPa), it indicates that the right valve chamber 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 maintenance timing period (e.g., 2 minutes/client-defined). Check for any water leakage on the valve sealing surface and the housing surface, and whether the pressure gauge has any downward deflection, to judge if the valve's strength and pressure are qualified.

2、Water Strength Pressure Test:

Similarly, the valve mounting for pressure strength pressure test is all set, (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) 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 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 time (e.g., 2 minutes/client-defined). Check for any leakage at the valve connection seal and the surface of the valve body, and whether the pressure gauge has a dip, to determine if the valve strength pressure test is qualified. (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 area, properly leveled, and the footings secured with concrete. It is suitable for use in a room with an ambient temperature of (1-40)℃ or a heated workshop in winter, and should be free from high concentrations of dust and corrosive gases. Avoid placing it near areas with grinding wheels or polishing machines due to poor conditions. Good ventilation is essential, and at least a 1m space channel should be left 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 of equipment 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 pressure levels to prevent exceeding the maximum limit.

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

5. All moving parts of the test bench should be regularly lubricated 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 changed promptly. Add new rust inhibitor powder to meet testing requirements. To ensure that testing valves are not corroded, it is typically necessary to regularly add rust inhibitor powder to the recirculating water tank to prevent rusting that could affect the normal operation of pipes, pumps, and check valves.

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

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