I. Product Overview:

YFA-F Type hydraulic valve test bench, which is based on our company's many years of experience in producing valve testing equipment, strictly in accordance with GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves".American Petroleum Institute StandardDesign and production shall 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 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, ease of operation, and high degree 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, and more. It is ideal 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:

DN15-1200mm

Section 3: Pressure Range: 1.6-63.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

Valves suitable for direct flange connection types, including gate valves, stop valves, check valves, and ball valves, utilize flange face sealing for tightness. The hydraulic clamp secures the back of the flange, with adjustable clamping force. Test results show no additional force influence. During valve testing, the right-hand operating disk features a 90-degree flip function, particularly suitable for air seal performance tests. The other operating disk can move forward and backward, with freely adjustable length spacing. The valve length is unrestricted, greatly enhancing work efficiency.

Clamping Method: Each双向working disc is equipped with a removable hydraulic clamping mechanism. It can automatically synchronize and adjust the position of the pressure jaws according to various valve specifications, achieving automatic centering and positioning. The hydraulic clamping jaws automatically grip the back of the valve flange, with adjustable clamping force, without any external force affecting the tested valve itself. The clamping process is fully controlled by an integrated button, with hydraulic components executing the operation.

Hydraulic Valve Test Bench Working Principle and Operation Method:

I. Operating Principle:

Select a sealing blank compatible with 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). Retract the left-hand moving bracket 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 against the right-hand workbench with a blind flange, aligning it with the center 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 other end of the valve flange. Press it against the left-hand test blind flange and align it to the center. Move the left radial clamp closer to the valve flange, press the clamp button to shorten the clamp stroke, and press it firmly against the back of the valve flange, completing the overall clamping of the valve.

Section II: Sealing Pressure Testing Method:

1. Inject 30#-46# hydraulic oil or 20# mechanical oil into the hydraulic system's oil tank; 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 (in a clockwise manner).

3. Adjust the hydraulic system pressure to 5.0 MPa to commence 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 won't 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 water inlet valve → Main water inlet valve.

7. Refer to the pressure reference table (for the clamping pressure required by the hydraulic cylinder) 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 right working disk up to a horizontal position.

8. All assembly is complete. Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). For 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 chamber is 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 maintenance timing period (such as 2 minutes/client-defined). Check the valve sealing surface and connection points, as well as for any leaks on the valve body surface and for any pressure gauge deflection, to confirm the sealing surface performance is up to standard. After the test is complete, open the (pressure relief valve) switch, 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 Test Method:

1. Intensity pressure test: Based on the sealed test fixture process, advance the left-hand movable frame to the right-hand workbench, approaching the other end's valve flange. Press against the left-hand test blind flange, aligning with the center position. Move the left radial clamp jaw towards the valve flange, press the clamp button to shorten the jaw travel, and firmly press against the back of the valve flange, completing the overall fixture of the valve.

2. Refer to the pressure table for the required pressure for the hydraulic cylinder clamping, and increase the pressure to the desired value. Once everything is clamped, set the low-pressure pump electrical contact pressure to 1.8 (Mpa), and adjust the electrical contact pressure gauge (use a 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 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 (e.g., 2 minutes/client-defined). Check for any leaks at the valve connection points, the surface of the valve body, and if the pressure gauge is functioning properly, to confirm the valve's pressure strength test is合格. After the test, open the (pressure relief valve) switch, release all pressure, loosen the clamps, and remove the valve.

VI. Usage Precautions and Requirements：

1. The site should be arranged in a level indoor space, the horizontal position should be calibrated, and the base should be fixed with concrete. It is suitable for use in a workshop with an ambient temperature of (1-40)℃ at room temperature or with heating in winter, free from high concentrations of dust and corrosive gases. It should not be used near areas with grinding wheels or polishing machines where conditions are poor. 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 the use of equipment beyond its specifications or pressure limits. 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 limits.

4. After the test is completed, the pressure must be released to zero before the clamp can be released. The power should be disconnected when not in use.

5. Regularly add lubricant to all moving parts of the test bench to maintain cleanliness and smooth operation.

6. Select 46-grade anti-wear hydraulic oil (use antifreeze 46-grade anti-wear hydraulic oil below 0℃), ensuring oil level is not below the gauge's lower limit. Regularly check oil levels and hydraulic oil; after one year of use, it should be drained and replaced.Wash 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 inhibitor powder as needed to meet testing requirements. To ensure that test valves are not corroded, it is usually necessary to add rust inhibitor powder regularly to the circulating water tank and prevent the medium water from causing rust on pipes, pumps, and check valves, which may affect normal operation.

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

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