I. Product Overview:

YFA-FQ Type hydraulic valve testing 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 in compliance with API 598 and other specifications for test pressure requirements.

This unit integrates a hydraulic system, mechanical system, 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, easy operation, and high level of automation. It is widely used in high, medium, and low-pressure direct flanged valve pressure-sealing performance and shell strength endurance tests. Applicable valve types include gate valves, stop valves, check valves, ball valves, and more. It is suitable for valve manufacturers, the petrochemical industry, hydropower stations, and other applications.Natural GasIdeal valve testing and inspection equipment for industries such as pipeline fittings, wastewater treatment plants, and valve maintenance stations.

II. Specification Range:

DN15-800mm

Three, Pressure Range: 1.6-63.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

Valves suitable for direct flange connections, including gate valves, stop valves, check valves, ball valves, etc., utilize flange face sealing for the tightening method. The hydraulic claw clamps the back of the flange, with adjustable clamping force. Test results show no additional force influence. During the valve testing process, the right-hand operating disc can be flipped 90 degrees, making it particularly suitable for air seal performance testing. The other operating disc can be moved forward and backward, with the length spacing freely adjustable, allowing unrestricted valve length, significantly enhancing work efficiency.

Clamping Method: Each bidirectional working plate is equipped with a removable hydraulic clamping mechanism. It can automatically synchronize and adjust the position of the clamping jaws to accommodate various valve specifications, achieving automatic centering and positioning. The hydraulic clamping jaws automatically grip the back of the valve flange, with adjustable clamping force, exerting no external force on the tested valve itself. The entire clamping process is controlled by an integrated button and executed by hydraulic components.

This testing bench features an up-and-down lifting function, allowing both the machine and the valve under test to be submerged in water simultaneously. It is particularly suitable for testing the strength, sealing, and gas pressure performance of the upper seal of valves. It revolutionizes the traditional testing method of brushing the valve housing surface with a foaming agent, shortens the testing time, and greatly enhances work efficiency, making it the most ideal choice for a dual-gas-water testing equipment.

Hydraulic Valve Test Bench Working Principle and Usage Method:

I. Working Principle:

Select a sealing blank that matches the valve model and install it on the equipment. Push the circuit breaker, the equipment power indicator light turns on. Press the oil pump start button to activate the hydraulic system motor. Ensure the motor runs in the correct direction (clockwise), then retract the left moving frame to a length greater than the test valve. Radially move the left and right clamps to exceed the outer diameter of the test valve flange. Extend the left and right clamps axially to exceed the thickness of the valve flange.

Secure the test valve flange tightly against the right-hand workbench with a blind flange in the center position. Move the radial clamp jaws close to the valve flange, press the clamp jaws tighten button to reduce the jaw spacing, and press against the back of the valve flange to ensure it won't come loose.

Move the left-hand trolley to the right-hand workbench, approaching the法兰at the other end of the valve to be tested. Press against the left-hand test blind flange, aligning to the center position. Move the left-hand radial clamp closer to the valve flange, press the clamp button to shorten the clamp stroke, and securely press against the back of the valve flange, completing the overall clamping of the valve.

During gas pressure testing, the machine and the valve under test can be submerged together in water. For hydrostatic testing, simply raise the machine to the correct position.

Section 2: Sealing Pressure Test Method:

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

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 it is ready for normal operation.

4、Secure the test valve flange flat against the right-hand workbench with a blind flange, aligning it to the center position. Move the radial clamp, position it close to the valve flange, press the clamp button to reduce the gap between the jaws, and press against the back of the valve flange to ensure it does not come loose.

5. Close: Left water inlet valve → Main air inlet valve → Right pressure relief valve → Test valve → Right pressure gauge switch.

6. Open: Right inlet valve → Main inlet valve.

7. Refer to the pressure comparison table (for cylinder clamping) to adjust the clamping pressure. For pressures exceeding 5.0 MPa above the pump source, press the (right claw boost) button to increase the pressure to the required clamping pressure. Press the (upper right flip) button to flip the working disk on the right side to a horizontal position.

8. All clamping is complete. Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure (take the valve sealed at 4.0MPa as an example, adjust the red pointer of the electrical contact pressure gauge to 4.0MPa).

9. Start the low-pressure water pump. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is already filled with water, and the low-pressure pump will automatically shut off. 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 maintenance timer (such as 2 minutes/client's specification) will begin. Check the valve sealing surfaces and connection points, as well as for any leaks on the valve body surface and the pressure gauge for any signs of tilting, to confirm the sealing surface performance is up to standard. After the test is complete, open the (bleed valve) switch to exhaust the pressure and proceed to the next test.

Note: The process of loading and the testing methods for the left-hand are the same as those for the right-hand.

Section 3: Method of Strength and Pressure Testing

1. Intensity pressure test: Based on the sealed test fixture process, move the left-hand carriage to the right-hand workbench, approaching the other end of the valve flange being tested. Press tightly against the left-hand test blind flange, aligning with the central position. Move the left radial clamp jaw towards the valve flange, press the clamp button to shorten the jaw travel, and securely press against the back of the valve flange, completing the overall fixture of the valve.

2. Refer to the pressure chart (for the clamping pressure required for hydraulic cylinders) and increase the pressure to the desired value. Once all clamping is complete, set the low-pressure water pump's electrical contact pressure to 1.8 (Mpa), and adjust the electrical contact pressure gauge (use 6.0 MPa valve as an example) by moving the red pointer to 6.0 MPa.

3. Open: Right inlet valve → Left inlet valve → Test valve.

4. Close: Total intake valve → Right pressure relief valve → Left pressure relief valve → Right pressure gauge switch → Left pressure gauge switch.

5. Start the low-pressure water pump. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve chamber is fully filled with 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 6.0 (MPa), the high-pressure pump will automatically stop, and enter the pressure holding timing period (such as 2 minutes/client-defined). Check the valve connection areas, the valve body surface for any leaks, and the pressure gauge for any dips, to confirm if the valve strength pressure test is合格. After the test, open the (pressure relief valve) switch, exhaust the pressure, release the clamps, and remove the valve.

Section 6: Usage Precautions and Requirements：

1. The site should be arranged in a level indoor area, with the level position checked and the footer fixed with concrete. The environment temperature should be between (1-40)℃ for normal conditions or in a heated workshop during winter. It should be free from high concentration of dust and corrosive gases, and should not be near areas with grinding wheels or polishing machines, which have poor conditions. Good ventilation is required. At least a 1m space channel should be reserved around the installed equipment for ease of operation and maintenance.

2. Operators must undergo professional training before taking their posts, adhere to standard operations, 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 disconnected when not in use.

5. All moving parts of the test bench should be regularly lubricated to maintain cleanliness and smooth operation.

6. Use 46-grade anti-wear hydraulic oil (for temperatures below 0°C, use antifreeze 46-grade anti-wear hydraulic oil), ensuring the oil level does not fall below the gauge'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, and anti-rust powder should be added anew to meet testing requirements. To ensure that test valves are not corroded, it is typically necessary to regularly add anti-rust powder to the recirculating water tank and prevent the medium water from causing rust on pipes, pumps, and check valves, thereby affecting their normal operation.

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

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