I. Product Overview:

YFA-F Type hydraulic valve test bench, which is developed based on our years of experience in manufacturing valve testing equipment, strictly in accordance with GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves".API 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 units, and a 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 reasonable structure, comprehensive functions, stable performance, easy operation, and high degree of automation. It is widely used in high, medium, and low-pressure direct flange valves for 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, 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.

Section 2: Specifications Range:

DN15-1200mm

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 clamping jaws secure the back of the flange, allowing adjustable clamping force. Test results showed no external force influence. During the valve testing, the right-hand working disc can be flipped 90 degrees, particularly suitable for gas sealing performance tests. The other working disc can be moved forward and backward, with the length clearance spacing freely adjustable. There are no restrictions on the valve length, significantly enhancing work efficiency.

Clamping Method: Each of the bidirectional working disks 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 valve itself. The entire clamping process is controlled by an integrated button, with hydraulic components executing the operation.

Hydraulic Valve Test Bench Working Principle and Operation 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 illuminates. Press the oil pump start button to operate the hydraulic system motor. Ensure the motor runs in the correct direction (clockwise). The left moving frame retracts beyond the length of the test valve. The left and right clamps move radially beyond the outer diameter of the valve flange. The left and right clamps extend axially beyond the thickness of the valve flange.

Secure the tested valve flange against the right-hand workbench with a blind flange, aligning it to the central position. Move the radial clamp jaws close to the valve flange, press the clamp button to shorten the jaw spacing, and press against the back of the valve flange to ensure it won't come loose.

Move the left-hand carriage to the right-hand workbench, positioning it close to the opposite end of the valve flange being tested. Press against the left-hand test blind flange, aligning with the center position. Move the left radial clamp closer to the valve flange, press the clamp button to shorten the clamp stroke, and press against the back of the valve flange, completing the overall clamping of the valve.

Section 2: Sealing Pressure Test Method:

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 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).

3. Adjust the hydraulic system pressure to 5.0 MPa and it will be ready for normal operation.

4、Secure the tested valve flange to the right workbench with a blind plate, aligning it with the center position. Move the radial clamp, approach 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. Shut off: 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 required for cylinder clamping table) to adjust the clamping pressure. For pressures exceeding the pump source by 5.0 Mpa or more, press the (right paw boost) button to increase the pressure to the required clamping level. Press the (upper right flip) button to flip the working plate to a horizontal position on the right side.

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

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 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 4.0 (MPa), the high-pressure pump will automatically stop, and enter the pressure holding timing period (such as 2 minutes/client-defined). Check the sealing surface and connection areas of the valve, as well as for any leaks on the valve body surface and if the pressure gauge is submersed, to confirm the sealing surface performance is qualified. After the test is complete, open the (pressure relief valve) switch to exhaust the pressure and proceed to the next test.

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

Section 3: Tensile Strength Testing Method:

1. Intensity pressure test: Based on the sealed test fixture process, advance the left-hand moving frame to the right-hand workbench, approaching the other end's valve flange. Press 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 required for clamping cylinder (compare with the pressure chart), increase the pressure to the required value. Once everything is clamped, set the low-pressure pump electrical contact pressure to 1.8 (Mpa), and adjust the electrical contact pressure gauge (for strength pressure, use the 6.0MPa valve as an example) by moving the red pointer to 6.0MPa.

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

4. Close: Total inlet 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 then 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's specification). Check the valve connection points, as well as for any leaks on the valve body surface and if the pressure gauge is functioning properly, to confirm if the valve's strength and pressure test is合格. After the test, open the (pressure relief valve) switch, release all pressure, loosen the clamps, and remove the valve.

Section 6: Usage Precautions and Requirements：

1. The site should be arranged in a level indoor space, properly leveled, and the footings anchored with concrete. It is suitable for use in a workshop with an ambient temperature of (1-40)℃ at normal temperatures or with heating in winter. Surroundings should be free from high concentrations of dust and corrosive gases. Avoid areas near grinding wheels and polishing machines with poor conditions. Ensure good ventilation. Leave at least a 1m space around the installed equipment for ease of operation and maintenance.

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

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. 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°C, use anti-freeze 46-grade anti-wear hydraulic oil). The oil level must not be below the minimum indicated on the dipstick. Regularly check the oil level and hydraulic oil; after one year of use, it should be drained and replaced.Wash OilBox, change to new oil.

7. Water source must be clean and free of impurities. Change the water quality promptly if it becomes turbid. Add new rust prevention powder, meet testing requirements. To ensure that test valves are not corroded, it is typically 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 could affect normal operation.

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

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