One,Product Overview:
YFA-L Type Hydraulic Valve Test Bench, which is based on our company's many 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 requirements for test pressures according to specifications such as API 598.
This unit integrates a hydraulic system, mechanical system, electrical system, pressure supply unit, and a medium storage circulating water tank. The entire testing process is automatically controlled and executed by hydraulic and electrical components, featuring rational structure, comprehensive functions, stable performance, easy operation, and high automation. It is widely used in high, medium, and low-pressure direct flange valves for pressure seal performance and shell strength endurance tests. Applicable valve types include gate valves, stop valves, check valves, ball valves, butterfly valves, etc. 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 II: Specifications Range:
DN15-300mm
Three, Pressure Range: 1.6-42.0 (MPa) / 150-2500 (Class)
IV. Performance Features:
1. The equipment features a structure with a worktable installed below, equipped with a set of three-jaw hydraulic clamping mechanism evenly distributed on the worktable. A portable hydraulic cylinder for clamping is mounted on the worktable, allowing the cylinder to rotate 90 degrees backward during valve clamping and sealing tests for easy observation. Suitable for various types of valves such as flanged, welded, socket-union gate valves, stop valves, check valves, ball valves, and butterfly valves. The test valve is unaffected by any external force during clamping.
2. The sealing method uses valve face sealing. During the valve sealing test, the hydraulic clamp grips the back of the flange. For strength tests, the bevel face or flange plane is sealed, and is firmly pressed by the top pressure cylinder, with the clamping force beingContinuous pressure regulation or stepless boost to the desired pressure value via button press.
3. The testing bench features a dual-system for air and water usage, with bidirectional pressure input and relief, equipped with a leak testing port. The system is pre-configured with high and low-pressure water pumps, allowing direct hydrostatic testing. Both high and low-pressure pumps are equipped with automatic control functions. The gas source is user-provided, and the liquid testing medium can be recycled and stored for use, offering energy-saving, environmental protection, low initial investment, and high work efficiency.
4. The equipment features reliable safety protection measures. The clamping mechanism has interlocking联动 function. When pressure is present in the valve cavity, the clamping cylinder locks and releases the action until the pressure in the valve cavity is fully released, at which point the button can be released. This prevents erroneous operation and ensures safety in use.
V. Usage Instructions:
1. Inject 30#-46# hydraulic oil or 20# mechanical oil into the hydraulic system oil tank; the oil level must not fall 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 (in a clockwise manner).
Adjust the hydraulic system pressure to 5.0 MPa to operate normally.
4. Sealing test fixture method: Retract the point actuated clamp to a position larger than the outer diameter of the valve flange being tested. Select a sealing disc compatible with valve testing and install it on the workbench. Place the valve on the sealing plate. Gently release the point actuated clamp to a height above the valve flange thickness. Advance the point actuated clamp, moving it close to the valve flange, and then clamp and grip the back of the valve flange. Strength test fixture method: The opposite end face seal is held in place by a thrust cylinder, based on the valve orifice size and pressureAdjust the clamping pressure according to the (Pressure Requirement Chart for Cylinder Clamping). For pressures exceeding the pump source by more than 5.0 Mpa, press the (Clamping Pressure Increase) button to increase the pressure to the desired level.The boost button can be pressed multiple times, with each interval around 3-5 seconds, and the maximum pressure up to 30MPa.
Section 6: Gas Pressure Test：
1. Seal Pressure Test: After assembly according to the sealing test fixture method, all assembly is complete (1).Shut off: Total inlet valve → Upper inlet valve → Lower pressure relief valve → Test butterfly valve. (2) Open: Lower pressure gauge switch → Lower inlet valve → Inject air into total outlet valve. Close (total outlet valve) when the air pressure reaches the required pressure value. (3) Proceed to the pressure maintenance timing phase. When the maintenance time is up, inspect for bubble leakage on the sealing surface and check for pressure drop on the pressure gauge to determine if the valve's sealing performance is qualified.
2. Gas Strength Pressure Test: Based on the sealed test fixtureSealed by a top-tight cylinder pressing against the opposite end face, based on valve orifice diameter and pressureAdjust the clamping pressure according to the (pressure chart for cylinder clamping).（1）Shut off: Main inlet valve → Left and right pressure relief valves → Leak detection switch. (2) Open: Test valve → Upper and lower pressure gauge switches → Inject air into the main inlet valve. Close (main inlet valve) when the pressure reaches the required value, and spray foam on the valve body surface. (3) Proceed to the pressure holding timing phase. Upon completion of the pressure holding time, check for bubble leakage at the valve connection seals and the valve body surface, and if the pressure gauge has dropped, to determine 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: Water Pressure Test
Water-tightness 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 (with sealed pressure at 2.5 MPa, adjust the red pointer to 2.5 MPa). (2) Close: Main inlet valve → Upper water inlet valve → Lower pressure relief valve → Lower pressure gauge switch → Test valve. (3) Open: Main water inlet valve → Lower water inlet valve. (4) Start the low-pressure pump to fill with water. When the pressure of the low-pressure pump reaches the set value of 1.8 (MPa), it indicates that the right valve cavity is full of water, and the low-pressure pump will automatically stop. 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 choice), to check for any leakage at the valve sealing surface and housing surface, and the pressure gauge for any dip, to judge if the valve's strength pressure is qualified.
2、Water Strength Pressure Test:
Similarly, the pressure testing valve mounting is complete. (1)Set the low-pressure pump electrical contact pressure to 1.8 (MPa), adjust the electrical contact pressure gauge (with a reference strength pressure of 4.0 MPa) by moving the red pointer to 4.0 MPa. (2) Shutdown: Total intake valve → Upper and lower pressure relief valves → Upper and lower 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 chamber is fully 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 timing (e.g., 2 minutes/client-defined) will begin. Check for any leaks at the valve connection seals and on the valve body surface, and verify if the pressure gauge has any drops, to determine if the valve's strength pressure test is passed. (5) After testing, exhaust the pressure, release the button, and remove the valve.
8. Usage Precautions and Requirements：
1. Ideally, the location should be a flat indoor space, with the level adjusted and the footings secured with concrete. The environment temperature should be between 1-40℃ for normal conditions or in a heated workshop during winter. It should be free from high concentrations of dust and corrosive gases, not near areas with sanding or polishing machines, and have good ventilation. At least 1m of space should be left 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 exceeding specifications or pressure. Non-specialists are advised not to operate.
3. Operators are strictly prohibited from leaving their posts during the pressure test. Continuous monitoring of the pressure is required to prevent excessive pressure.
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 test bench to maintain cleanliness and smooth operation.
6. Select 46-grade anti-wear hydraulic oil (use anti-freeze 46-grade anti-wear hydraulic oil below 0℃), ensuring oil level is not below the indicator's lower limit. Regularly check oil levels 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 replaced promptly. Add new rust prevention powder as needed to meet testing requirements. To ensure that testing valves are not corroded, it is typically necessary to add rust prevention powder regularly to the circulating water tank to prevent rust from affecting the normal operation of pipes, pumps, and check valves due to medium water.
Note: Common rust prevention powders include:Sodium NitriteSodium sulfonate, potassium benzenesulfonate (non-toxic powder).
8. The equipment work surface should be kept clean, and no debris is allowed between the test valve flange and the pressure test blank.
