I. Overview

YFA-H Type Top-Pressure Hydraulic Valve Test Bench, which is based on our company's years of experience in manufacturing valve testing equipment, is 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 are required to meet the test pressure requirements of specifications such as API598.

Widely applied to high, medium, and low-pressure direct connection and welding type valves, featuring pressure-sealing performance and shell strength endurance tests. Suitable valve types include gate valves, stop valves, check valves, ball valves, etc. Ideal for valve manufacturers, the petrochemical industry, and hydropower stations.Natural GasIdeal valve testing and inspection equipment for industries such as pipe fitting manufacturers, wastewater treatment plants, and valve maintenance stations.

Specification Range: Nominal Pipe Size 15-mm to 1000-mm

Section 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 a medium storage and circulation water tank. The entire testing process is automatically controlled and executed by hydraulic and electrical components.The complete hydraulic system utilizes the most reliable form of hydraulic control currently available. The clamping force applied to the tested valve is adjustable with infinite pressure regulation, ensuring it completely avoids damaging the tested valve. The operation guarantees sensitive movement execution and precise positioning throughout the use process.Well-structured, fully functional, stable performance, easy to operate, wide application range, and high degree of automation.

2. The workbench canopy is connected by two rods and secured with a handle cap lock. A movable workboard is installed in the middle, allowing for easy forward and backward movement. The structure length is unrestricted during valve testing, making it suitable for sealing and strength pressure tests on both direct-connection flanged and welded valves. During valve testing, a bevel face or flange plane is used for sealing. The top pressure cylinder directly drives the middle movable plate to the valve face for tight sealing, with the clamping force beingContinuous pressure adjustment or automatic boost to the desired pressure level via button operation.

3. The test bench features a dual-system for both air and water usage, with bidirectional pressure input and discharge, 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 pumps come with automatic control functions. The air source is user-supplied, and the liquid testing medium can be recycled and stored for use, offering energy-saving, environmentally friendly, 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 in the valve cavity is completely exhausted, at which point the release button can be pressed. This prevents accidental operation and ensures safe use.

V. Usage Instructions:

1. Inject 30#-46# hydraulic oil or 20# mechanical oil into the hydraulic system's oil tank, ensuring the oil level does not fall below the lower mark on the dipstick.

2. Power on, press the oil pump start button, and check if the motor rotates in the correct direction (clockwise).

Adjust the hydraulic system pressure to 5.0 MPa to operate normally.

4. Select a sealing disc suitable for valve testing and install it on both work plates.

4. Engage the point-of-action cylinder's tightening button, move the middle seal plate to closely seal against the valve end face, based on the valve diameter and pressure.Adjust the clamping pressure according to the (Pressure Chart for Cylinder Clamping), for pressures exceeding the pump source by more than 5.0 Mpa, press the (Cylinder Pressure Boost) button to increase the pressure to the required level.The boost button can be pressed multiple times, with each press separated by approximately 3-5 seconds, reaching a maximum pressure of 30MPa.

Section 6: Gas Pressure TestRight-hand side

1.  Seal Pressure Test: Valve fixture complete (1)Shut off: Total inlet valve → Left inlet valve → Right pressure relief valve → Test butterfly valve. (2) Open: Right pressure gauge switch → Right inlet valve → Inject air into the total inlet valve; close (total inlet valve) when the air pressure reaches the required pressure value. (3) Proceed to the pressure maintenance timing phase. Upon completion of the pressure maintenance time, open the leak detection switch to check for bubbles at the leak detection port and if the pressure gauge shows a pressure drop to judge whether the valve's sealing performance is qualified.

2. Gas Strength Pressure Test: Based on the sealed test fixture, Based on valve port 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 until the pressure reaches the required value, then close (total inlet valve) and spray foam on the valve body surface. (3) Enter the pressure holding timing phase, check for bubble leakage at the valve connection surfaces and valve body surface, and pressure gauge drop to assess if the valve's strength performance is up to standard. (4) After testing, open the pressure relief valve, exhaust the pressure, and remove the valve.

Section 7: Hydrostatic Test: Right as column

1. Water Seal Pressure Test:

Similarly, pressure-sealed test fixture, (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure gauge (for sealed pressure, list at 2.5MPa, adjust the red pointer of the electrical contact pressure gauge to 2.5MPa). (2) Close: Main inlet valve → Left and right pressure relief valves → Right pressure gauge switch → Valve under test. (3) Open: Main water inlet valve → Left and right water inlet 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 cavity 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 ensure the pressure gauge is stable, to determine if the valve's pressure strength is up to standard.

2、Water Strength Pressure Test:

Similarly, the valve mounting for pressure strength pressure test is all set, (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Adjust the electrical contact pressure gauge (with 4.0 Mpa as the reference strength pressure) by moving the red pointer to 4.0 Mpa. (2) Close: Main intake valve → Left and right pressure relief valves → Left and right leak detection switches → Left and right pressure gauge switches. (3) Open: Main water intake valve → Valve under test. (4) Start the low-pressure pump to fill water, and when the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity 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 holding timing period (such as 2 minutes/client's specification), to check for any leaks at the valve connection seal surfaces and the valve body surface, and to ensure the pressure gauge is stable, in order to determine if the valve strength pressure test is qualified. (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 area, properly leveled, and the footings secured with concrete. It should be used in a room with an ambient temperature of (1-40)℃ at normal temperatures or in a heated workshop during winter. Surroundings should be free from high concentrations of dust and corrosive gases, and should not be near areas with grinding wheels or polishing machines with poor conditions. Good ventilation is essential, and at least a 1m space channel should be left 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 testing is completed, the pressure must be relieved to zero before releasing the clamps. The power should be disconnected when not in use.

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

6. Use 46-grade anti-wear hydraulic oil (for temperatures below 0℃, use anti-freeze 46-grade anti-wear hydraulic oil), ensuring the oil level is not below the oil gauge's lower limit. Regularly check the oil level and hydraulic oil; it should be flushed after one year of use.Wash OilBox, change to 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 to meet testing requirements. To ensure that the test valves are not corroded, it is usually necessary to add rust inhibitor 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 preventive powders include:Sodium nitriteSodium sulfonate, potassium benzenesulfonate (non-toxic, powdered form).

8. The work surface of the equipment should be kept clean, and there should be no debris between the valve flange under test and the pressure testing blank flange.