详情描述

  

One,Product Overview:

YFA-L Type Hydraulic Valve Test Bench, which is based on our years of experience in manufacturing valve testing equipment, strictly conforms to 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 hydraulic, mechanical, electrical systems, pressure supply devices, and a medium storage circulating water tank. The entire testing process is automatically controlled and executed by hydraulic and electrical components. It boasts advantages such as a reasonable structure, comprehensive functions, stable performance, convenient operation, and high level 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, etc. It is suitable for valve manufacturers, the petroleum and petrochemical industry, hydropower stations, etc.Natural GasIdeal valve testing and inspection equipment for industries such as pipeline fittings, 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 at the bottom. A set of 3-jaw hydraulic clamping mechanism is evenly mounted on the worktable, along with a movable hydraulic cylinder for pressing. The cylinder can rotate backward by 90 degrees when clamping valves, facilitating observation during valve assembly and sealing tests. It is suitable for various types of valves, including flanged, welded, socket, gate valves, stop valves, check valves, ball valves, and butterfly valves. The clamping mechanism has no external force impact on the tested valve.

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 the bevel face or the flat face of the flange is sealed, with the top pressure cylinder pressing it securely in place. The clamping force is able to...Continuous pressure adjustment or stepless pressure increase to the desired pressure value via button presses.

3. The test bench features a dual-system with both air and water, offering bidirectional pressure and pressure relief, equipped with a leak testing 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-provided. The liquid testing medium can be recycled and stored for use, offering energy-saving, environmental protection, low cost of investment, and high work efficiency.

4. The equipment is equipped with reliable safety protection measures. The locking interlock function of the clamping mechanism ensures that the clamping cylinder locks and releases only after the pressure in the valve cavity is fully relieved, preventing accidental operation and 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. Power on, 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 the normal operation can be performed.

4. Sealing Test Clamping Method: Retract the point actuated clamp jaws to a position larger than the outer diameter of the valve flange being tested. Select a sealing disc compatible with the valve test and install it on the workbench. Place the valve on the sealing plate. Retract the point actuated clamp jaws to a height above the valve flange thickness. Advance the clamp jaws, moving them close to the valve flange, and then securely clamp and grip the backside of the valve flange. Strength Test Clamping Method: Sealed by the thrust cylinder pressing against the opposite end face, based on the valve orifice size 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 (clamp 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.  Seal Pressure Test: Assemble and secure 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 → Inject gas into the total outlet valve. Close (total outlet valve) when the air pressure reaches the required pressure value. (3) Enter the pressure holding timing phase. When the pressure holding time is up, check for bubble leakage on the sealing surface and pressure drop on the gauge to determine if the valve's sealing performance is qualified.

2. Gas Strength Pressure Test: Based on the sealed test fixtureThe other end face is sealed by a top-tight cylinder pressing against it, depending on the valve orifice diameter and pressure.Refer to the (cylinder clamping pressure reference table) to adjust the pressing force.（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. When the pressure holding time is up, check for bubble leakage at the valve connection seal and valve body surface, and if 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: Water Pressure Test

Water-tight 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 (with sealed pressure listed at 2.5MPa) 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 → Test valve. (4) 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 enter the pressure holding timing period (e.g., 2 minutes/client-defined). Check for any leaks on the valve sealing surface and housing surface, and ensure the pressure gauge is stable, to judge if the valve's strength and pressure are qualified.

2、Water Strength Pressure Test:

Similarly, the pressure test valve clamping is all set up, (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) Shutdown: Main inlet valve → Upper and lower pressure relief valves → Upper and lower pressure gauge switches. (3) Startup: Main water inlet valve → Valve under test. (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, 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 (e.g., 2 minutes/client-defined) will begin. Check for any leaks at the valve connection seals and the valve body surface, and ensure the pressure gauge is stable, to determine if the valve's strength pressure test is passed. (5) After testing, exhaust the pressure, release the button, and remove the valve.

Section 8: Usage Precautions and Requirements：

1. Preferably, the location should be indoors on a level surface, properly leveled, with the base fixed with concrete. The ambient temperature should be between 1-40℃ for normal conditions or in a heated workshop during winter. It should not be near areas with high concentrations of dust and corrosive gases, avoid sanding machines and polishing machines in poor conditions. Ensure good ventilation. Leave at least a 1m space around the equipment for easy operation and maintenance.

2. Operators must undergo professional training before starting work, adhere to standard procedures, and strictly prohibit the use beyond specifications and 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 to prevent it from exceeding safe levels.

4. After the test 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 (for temperatures below 0℃, use antifreeze 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.Washing 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 prevention powder, meet testing requirements. To ensure the test valve is not corroded, it is usually necessary to add rust prevention powder regularly to the circulating water tank to prevent the medium water from causing rust on pipes, pumps, and check valves, affecting their normal operation.

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

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