详情描述

  

One,Product Overview:

YFA-L Type Hydraulic Valve Test Bench, which is developed based on our company's years of experience in manufacturing valve testing equipment, strictly in accordance with GB/T 13927-2008 "General Valve Pressure Test" and JB/T 26480-2011 "Testing and Inspection of Valves."American Petroleum Institute StandardDesign and production shall comply with the 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 reasonable structure, comprehensive functions, stable performance, ease of operation, and high degree of automation. It is widely used in high, medium, and low-pressure direct flanged valve testing for pressure sealing performance and shell strength. 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 hydroelectric power 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)

Four: Performance Features:

1. The equipment features a structure with a workbench installed below, equipped with a set of three-jaw hydraulic clamping mechanism evenly mounted on the workbench. A movable hydraulic thrust cylinder is installed on the workbench, allowing the thrust cylinder to rotate 90 degrees backward during valve clamping and sealing tests for convenient observation. Suitable for various types of valves such as 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 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 surface seal is used, with the top pressure cylinder securely pressing it in place. The clamping force is able to...Continuous pressure adjustment or stepless boost to the desired pressure via button press.

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. 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 the locking interlock 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 exhausted, at which point the button can be released. This prevents accidental operation hazards and ensures 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 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 (in a clockwise manner).

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

4. Sealing test fixture method: Retract the point motion clamp to a position larger than the outer diameter of the valve flange being tested. Select a sealing disk compatible with the valve test and install it on the workbench. Place the valve on the sealing plate. Release the point motion clamp to a height above the valve flange thickness, then advance the clamp, moving it close to the valve flange. Engage and grip the back of the valve flange with the clamp. Strength test fixture method: The opposite end face seal is held in place by a thrust cylinder, based on the valve bore diameter 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.  Seal Pressure Test: After the assembly of the seal 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 total inlet valve. Close (total inlet 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 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, based on the valve port diameter and pressureAdjust the clamping pressure according to the (pressure required for cylinder clamping table).（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. When the pressure-holding time is up, check for bubble leakage at the valve connection sealing surface and the valve body surface, and if the pressure gauge has dropped, 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

1. Water-tightness 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 2.5 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 with 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, 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/customary by the customer) will begin. Check for any water leakage on the valve sealing surface and the housing surface, and if the pressure gauge has any dips, to determine 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 up, (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Adjust the electrical contact pressure gauge (use 4.0MPa as an example for strength pressure) by moving the red pointer to 4.0MPa. (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 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 surfaces and the valve body, and ensure the pressure gauge is stable, 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, with the level position set and the base feet anchored with concrete. The environment temperature should be between 1-40℃ for normal conditions or in a heated workshop during winter. The area should be free from high concentrations of dust and corrosive gases. Avoid locations near grinding wheels or polishing machines with poor conditions. Ensure good ventilation, and leave at least a 1m space around the equipment installation for ease of operation and maintenance.

2. Operators must undergo professional training before taking up their positions. Standardized operation is mandatory, and using equipment beyond its specifications or pressure is strictly prohibited. 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 the pressure to prevent it from exceeding safe limits.

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. The moving parts of the test bench should be regularly lubricated to maintain cleanliness 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 must be changed promptly. Add new rust prevention powder to meet testing requirements. To ensure that the test valves are 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, which may affect normal operation.

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

8. The equipment work surface should be kept clean, and no debris is allowed between the valve flange being tested and the pressure test blanking plate.