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 conforms to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves."American Petroleum Institute StandardDesign and production must comply with the test pressure requirements of specifications such as API598.

Widely used in high, medium, and low pressure applications for direct flanged and焊接valves, featuring pressure seal performance and shell strength pressure tests. Suitable valve types include gate valves, stop valves, check valves, ball valves, and more. 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.

Two, Specifications Range: Nominal Bore 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 unit, and medium storage circulating water tank. 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 tested valve is adjustable with infinite pressure control, ensuring complete avoidance of damage to the tested valve. The operation guarantees sensitive actuation and precise positioning throughout the use process.Boasts well-structured design, comprehensive features, stable performance, user-friendly operation, broad application scope, and high level of automation.

2. The left and right workbench arches are connected by two rods, secured by a handle cap lock. A movable workboard is installed in the middle, allowing for forward and backward movement. The structure length is not restricted during valve testing, making it suitable for sealing and strength pressure tests of both direct passage flanged and welded valves. During valve testing, the sealing is achieved using bevel or flat法兰 surfaces. The top pressure cylinder directly drives the central moving plate to the valve face, applying a tightening force thatContinuous pressure regulation or automatic boost to the desired pressure level via button actuation.

3. The test bench is equipped with a dual-system for both air and water usage, featuring bidirectional pressure inlet and exhaust, with a leak test port. The system comes pre-configured with high and low-pressure pumps, allowing direct water pressure testing. Both high and low-pressure pumps are equipped with automatic control functions. The gas source is user-supplied. The liquid test medium can be recycled and stored for reuse, 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 inside the valve cavity is completely exhausted, at which point the button can be released. This prevents accidental operation hazards, ensuring safe use.

V. Instructions for Use:

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, and check if the motor rotates in the correct direction (counterclockwise).

Adjust the hydraulic system pressure to 5.0 MPa and it will operate normally.

4. Select a sealing disc suitable for valve testing and install it on the left and right working plates.

4. Engage the point-of-action hydraulic cylinder's tightening button, move the intermediate sealing plate to closely seal against the valve end face. Adjust according to the valve orifice diameter and pressure.Adjust the clamping pressure according to the (Pressure Chart for Cylinder Clamping), for pressures exceeding 5.0 Mpa above the pump source, press the (Cylinder Pressure Increase) button to increase the pressure to the required level.The boost button can be pressed multiple times, with intervals of about 3-5 seconds each, reaching a maximum pressure of 30MPa.

Section 6: Gas Pressure TestingRight-justified

1.  Seal Pressure Test: Valve mounting 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 gas into the total air inlet valve. Close (total air 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 pressure drop to determine if the valve's sealing performance is qualified.

2. Gas Strength Pressure Test: Based on the sealed test fixtureBased on 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. When the pressure holding time is up, check for bubble leakage at the valve connection seals 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 Sealing 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, use 2.5MPa as an example) by moving the red pointer to 2.5MPa. (2) Close: Main intake valve → Left and right pressure relief valves → Right pressure gauge switch → Test valve. (3) Open: Main 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 from the (left leakage check valve), then close the (left water inlet valve). When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the right 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 enter the pressure maintenance timing period (such as 2 minutes/client-defined). Check for any leaks at the left leakage check 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, the valve mounting for the pressure intensity pressure test is complete. (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Adjust the electrical contact pressure gauge (use 4.0 MPa as an example for strength pressure) by moving the red pointer to 4.0 MPa. (2) Shutdown: Total intake valve → Left and right pressure relief valves → Left and right leak detection switches → Left and right pressure gauge switches. (3) Startup: Total water intake 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 enter the pressure holding timing period (e.g., 2 minutes/client-defined). Check for any leaks at the valve connection surfaces and the valve body, and if the pressure gauge is stable, to determine if the valve's strength pressure test is passed. (5) After testing, release all pressure, release the button, and remove the valve.

Section 8: Usage Precautions and Requirements：

1. Ideally, the location should be arranged in a level indoor space, the level position should be checked, and the footings should be secured with concrete. It should be used in an environment with a temperature range of (1-40)℃ at room temperature or in a heated workshop during winter. There should be no high concentration of dust or corrosive gases stored nearby. It should not be used near areas with bench grinders or polishing machines with poor conditions. Good ventilation is required, and at least a space of ≥1m around the equipment installation should be reserved 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 completion of the test, 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 (use antifreeze 46-grade anti-wear hydraulic oil below 0℃), 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, change to new oil.

7. The water source must be clean and free of impurities. If the water quality becomes turbid and worsens, it should be replaced immediately. Add new rust preventive powder as needed, meet testing requirements. To ensure that test valves are not corroded, it is typically necessary to regularly add rust preventive powder to the circulating water tank to prevent rust caused by the medium water from affecting the normal operation of pipes, pumps, and check valves.

Note: Common rust prevention powders include:Sodium nitriteSodium sulfonate, sodium potassium sulfonate (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 blank flange.