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 producing valve testing equipment, strictly adheres to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves."American Petroleum Institute StandardDesign and production require test pressure specifications in accordance with API 598 and other standards.

This unit integrates hydraulic, mechanical, electrical systems, pressure-supply devices, and medium storage circulating water tanks into one. The entire testing process is automatically controlled and executed by hydraulic and electrical components, featuring reasonable structure, comprehensive functions, stable performance, easy operation, and high level of automation. It is widely used in high, medium, and low-pressure direct flanged valve tests for pressure sealing performance and shell strength, applicable to various valves such as gate valves, stop valves, check valves, ball valves, and butterfly valves. It is suitable for valve manufacturers, the petrochemical industry, and hydropower stations.Natural GasIdeal valve testing and inspection equipment for industries such as pipe fitting 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 workbench installed below, equipped with a set of 3-jaw hydraulic clamping mechanism evenly distributed on the workbench. A movable hydraulic thrust cylinder is mounted on the workbench, allowing the thrust cylinder to rotate backward by 90 degrees during valve clamping and sealing tests for easy observation. Suitable for various types of valves including flanged, welded, socket-weld, gate valves, stop valves, check valves, ball valves, and butterfly valves. The test does not exert any external force on the valve itself.

2. The sealing method employs a valve face seal. During valve sealing tests, the hydraulic clamp jaws secure the back of the flange. For strength tests, either a bevel face or flange flat seal is used, and the tightness is achieved by a top-press cylinder. The clamping force isContinuous pressure adjustment or stepless pressure increase to the desired pressure value via button control.

3. The test bench features a dual-system for air and water, with bidirectional pressure and pressure release, equipped with a leak detection testing port. The system is pre-configured with high and low-pressure water pumps, enabling direct hydrostatic testing. The high and low-pressure water pumps are equipped with automatic control functions. The air source is to be self-provided by the user. The liquid test medium can be stored and reused in a cycle, offering energy saving, environmental protection, low investment cost, and high work efficiency.

4. The equipment features reliable safety protection measures. The clamping mechanism has interlocking联动 functionality. When pressure is present in the valve chamber, the clamping cylinder locks and releases its action until the pressure inside the valve chamber is completely relieved, at which point the release button can be pressed. This prevents accidental operation and ensures safe use.

V. Usage Instructions:

1. Inject 30#-46# hydraulic oil or 20# mechanical oil into the hydraulic system's oil tank, 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 is rotating in the correct direction (counterclockwise).

3. Adjust the hydraulic system pressure to 5.0 MPa to proceed with normal operation.

4. Sealing Test Clamping Method: Move the point-to-point clamp back to exceed the outer diameter of the valve flange being tested. Select a sealing disk compatible with valve testing and install it on the workbench. Place the valve on the sealing plate. Release the point-to-point clamp to a height above the valve flange thickness. Advance the point-to-point clamp and move it close to the valve flange. Engage and grip the backside of the valve flange with the clamp. Strength Test Clamping Method: Sealed by the pressure cylinder pressing against the opposite end face. Depending on the valve orifice size and pressureAdjust the clamping pressure according to the (pressure requirement table for cylinder clamping). For pressures exceeding the pump source by more than 5.0 Mpa, press the (claw pressure increase) 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, and the maximum pressure is 30MPa.

 

Section 6: Gas Pressure Test：

1.  Sealing Pressure Test: After the assembly of the sealing test fixture is complete (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 main air valve. Close (main air valve) when the air pressure reaches the required pressure value. (3) Enter the pressure maintenance timing phase. Upon the end of pressure maintenance time, inspect for bubble leakage at the sealing surface and check for pressure drop on the pressure 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 orifice diameter 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 → 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 on the valve body surface. (3) Enter the pressure holding timing phase, check for bubbles at the valve connection sealing surface 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: Water Pressure Test

Water-tight seal 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, use 2.5MPa as an example) by moving the red pointer to 2.5MPa. (2) Close: Total intake valve → Upper water intake valve → Lower pressure relief valve → Lower pressure gauge switch → Test valve. (4) Open: Total water intake valve → Lower water intake valve. (4) Start the low-pressure pump to fill with water. When the pressure of the low-pressure pump reaches the set value of 1.8 (MPa), it indicates that the right 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 (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 judge if the valve's strength pressure is qualified.

2、Water Strength Pressure Test:

Similarly, the pressure test valve mounting is complete, (1)Set the low-pressure pump electrical contact pressure to 1.8 (MPa). Adjust the electrical contact pressure gauge (with a strength pressure of 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 → Test valve. (4) Start the low-pressure pump to fill water, and the pump will automatically stop once the low-pressure water pressure reaches the set value of 1.8 (MPa), indicating that the valve chamber is filled with water. The high-pressure pump will then automatically start to supply pressure. The high-pressure pump will stop automatically when the high-pressure water reaches the set value of 4.0 (MPa), and enter a pressure-holding timing period (such as 2 minutes/client-defined), during which check for any leakage at the valve connection surfaces and the valve body, and whether the pressure gauge has any sag, to determine if the valve's strength pressure test is passed. (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 area, with the horizontal position adjusted and the footer fixed with concrete. It is suitable for use in a temperature range of (1-40)℃ in a normal or heated workshop during winter, away from high-concentration dust and corrosive gas storage. It should not be used near areas with grinding wheels or polishing machines with poor conditions. Good ventilation is required, and at least a 1m space channel should be reserved around the equipment installation for ease of operation and maintenance.

2. Operators must undergo professional training before assuming their positions, 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 safe levels.

4. After the test is completed, the pressure must be released to zero before the clamping jaws can be released. The power supply 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 (select anti-freeze 46-grade anti-wear hydraulic oil below 0℃), and ensure the oil level does not fall below the indicator. Regularly check the oil level and hydraulic oil; after one year of use, it should be cleaned.Wash OilCase, 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 as needed to meet testing requirements. To ensure that the test valves are not corroded, it is typically necessary to add rust inhibitor powder regularly to the circulating water tank to prevent rusting of the medium water affecting the normal operation of pipes, pumps, and check valves.

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

8. The equipment worktop should be kept clean. There should be no debris between the test valve flange and the test pressure blind plate.