I. Overview

YFA-H Type Top-Pressure Hydraulic Valve Test Bench, which is based on our years of experience in manufacturing 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 StandardsDesign and production are required to meet the test pressure requirements of specifications such as API598.

Widely applied to high, medium, and low-pressure direct flanged and焊接valves, pressure sealing performance and shell strength pressure tests, suitable valve types include gate valves, stop valves, check valves, ball valves, etc. It is used by valve manufacturers, the petrochemical industry, hydropower stations,Natural GasIdeal valve testing and inspection equipment for industries such as pipe fitting manufacturers, sewage treatment plants, valve maintenance stations, etc.

Two, Specifications Range: Nominal Pipe Size 15-mm to 1000-mm

3. Pressure Range: Nominal Pressure 1.6-42.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

1、This unit integrates a hydraulic, mechanical, electrical system, pressure supply device, and medium storage circulating water tank into one. The entire testing process is automatically controlled and executed by hydraulic and electrical components.The complete hydraulic system employs the most reliable hydraulic control form currently available. The clamping force applied to the valve under test is infinitely adjustable in pressure, ensuring no damage to the valve. The operation guarantees sensitive actuation and precise positioning throughout the use process.Well-structured, fully functional, stable performance, easy to operate, broad application range, and high level of automation.

2. The left and right workbench pavilions are connected by two rods and secured with a handle cap lock. A movable worktop is installed in the middle, allowing for forward and backward movement. The structure length is not restricted during valve testing, making it suitable for both direct connection flange and welded type valve sealing and strength endurance tests. During valve testing, a bevel face or flange plane seal is used. The top pressure cylinder directly drives the middle moving plate to the valve face for tightness, with the clamping force beingContinuous pressure regulation or automatic pressure boost to the desired pressure value through button actuation.

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 is equipped with reliable safety protection measures. The clamping mechanism features interlocking interlock function. When pressure is present within the valve cavity, the clamping cylinder locks and releases, only allowing the button to be released after the pressure within the valve cavity is fully exhausted. This prevents accidental operation and ensures safe usage.

V. Usage Instructions:

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

2. Power on, press the oil pump start button, 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. Select a sealing disk suitable for valve testing and install it on both working plates.

4. Engage the point-motion cylinder's tightening button, move the intermediate sealing plate to seal against the valve end face, based on the valve diameter and pressureAdjust the clamping pressure according to the (Pressure Required for Cylinder Clamping Chart). For pressures exceeding the pump source by 5.0 Mpa or more, press the (Cylinder Pressure Increase) button to increase the pressure to the required 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 TestRight-hand column

1.  Gas-tight Pressure Test: Valve mounting complete (1)Shut off: Main Inlet Valve → Left Inlet Valve → Right Pressure Relief Valve → Test Butterfly Valve. (2) Open: Right Pressure Gauge Switch → Right Inlet Valve → Inject gas into the Main Inlet Valve. Close (Main 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, open the leak detection switch to check for bubble leakage at the leak detection port and whether the pressure gauge shows a pressure drop to determine if the valve's sealing performance is up to standard.

2. Gas Strength Pressure Test: Based on the sealed test fixtureBased on the valve size 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 → Left and right 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 bubble leakage at the valve connection seal 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: Hydrostatic Test: Right as column

1. Water-tight pressure test:

Similarly, for the 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, set the gauge to 2.5MPa) by moving the red pointer to 2.5MPa. (2) Close: Total intake valve → Left and right pressure relief valves → Right pressure gauge switch → Valve under test. (3) Open: Total water intake valve → Left and right water intake valves → Left directional leak detection switch.

(4) Start the low-pressure water pump to fill water until it exits through the (leftward leak detection switch), then close the (leftward water inlet valve). When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the rightward valve chamber is fully filled with water, and the low-pressure water pump will automatically stop. The high-pressure water pump will then automatically start to supply pressure. When the high-pressure water reaches the set value of 4.0 (MPa), the high-pressure water pump will automatically stop, and the pressure maintenance timing (such as 2 minutes/client-defined) will begin. Check for leaks at the leftward leak detection port and any drops on the pressure gauge to determine if the valve's pressure strength is up to standard.

2、Water Strength Pressure Test:

Similarly, all the pressure testing valve fixtures are completed, (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 a reference) by moving the red pointer to 4.0 MPa. (2) Close: Main inlet valve → Left and right pressure relief valves → Left and right leak detection switches → Left and right pressure gauge switches. (3) Open: Main water inlet 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 filled with 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 maintenance timer (such as 2 minutes/client-defined) will begin. Check for any leaks at the valve connection surfaces and the valve body, as well as any downward deflection on the pressure gauge, 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, properly leveled, and the footings anchored with concrete. It is suitable for use in a temperature range of (1-40)℃ in a normal or heated workshop during winter. The surrounding area should be free from high concentrations of dust and corrosive gases. Avoid using near grinding wheel or polishing machines in poor conditions. Ensure good ventilation, and leave at least a 1m space around the equipment for ease of operation and maintenance.

2. Operators must undergo professional training before starting work, adhere to standard procedures, and strictly prohibit using 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 test. They must continuously monitor the pressure to prevent it from exceeding safe limits.

4. After completion of the test, the pressure must be relieved to zero before the clamps can be released. The power supply should be disconnected during non-operation periods.

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

6. Use 46-grade anti-wear hydraulic oil (select antifreeze 46-grade anti-wear hydraulic oil below 0℃), and ensure 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 must be changed promptly. Add new rust-proof powder as needed, meeting testing requirements. To ensure that testing valves are not corroded, it is typically necessary to add rust-proof 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 rust prevention powders include:Sodium NitriteSodium sulfonate, sodium potassium sulfonate (non-toxic powder).

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