One,Product Overview:
YFA-L Type 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 shall comply with the pressure requirements of specifications such as API598.
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. It boasts advantages such as a rational structure, comprehensive functions, stable performance, easy operation, and high degree of automation. It is widely used in high, medium, and low-pressure direct flanged valve pressure-sealing performance and shell strength endurance tests. Suitable valve types include gate valves, stop valves, check valves, ball valves, and butterfly valves, making it 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.
Section II: Specification Range:
DN15-300mm
Three, Pressure Range: 1.6-42.0 (MPa) / 150-2500 (Class)
Four: Performance Features:
1. The equipment features a structure with a workbench installed below, equipped with a set of 3-jaw hydraulic clamping mechanism evenly distributed on the workbench. A movable hydraulic thrust cylinder is mounted on the workbench, allowing the thrust cylinder to rotate backward by 90 degrees during valve clamping and sealing tests for easy observation. Suitable for various types of valves including flanged, welded, socket-weld, gate valves, stop valves, check valves, ball valves, and butterfly valves. The clamping does not exert any external force on the tested valve.
2. The sealing method uses a valve face seal. During the valve sealing test, the hydraulic clamp is used to tightly grip the back of the flange. For strength tests, either the bevel face or the flange plane is sealed, and is firmly pressed in place by the top pressure cylinder. The clamping force is able to...Continuous pressure adjustment or stepless boost to the desired pressure level via button press.
3. The test bench features a dual-system with both air and water capabilities, offering bidirectional pressure intake and release, and is equipped with a leak testing port. The system is pre-configured with high and low-pressure water pumps, allowing for direct hydrostatic testing. The high and low-pressure water pumps are equipped with automatic control functions. The gas source is user-supplied, and the liquid testing medium can be recycled and stored for use, boasting energy-saving, environmental protection, low initial investment, and high work efficiency.
4. The equipment features reliable safety protection measures, with interlocked联动 functionality on the clamping mechanism. When pressure is present in the valve chamber, the clamping cylinder locks and releases its action until the pressure inside the valve chamber is fully drained, at which point the release button can be activated. 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 (counterclockwise).
3. Adjust the hydraulic system pressure to 5.0 MPa to operate normally.
4. Sealing Test Clamping Method: Retract the point-to-point gripper beyond 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. Retract the gripper to a position above the valve flange thickness. Advance the gripper, moving it close to the valve flange, and then clamp and grip the back of the valve flange. Strength Test Clamping Method: Secured by a thrust cylinder pressing against the opposite end face seal, depending on valve bore size and pressureAdjust the clamping pressure according to the (pressure required for cylinder clamping chart). For pressures exceeding the pump source by more than 5.0 Mpa, press the (clamping gripper boost) button to increase the pressure to the desired level.The boost button can be pressed multiple times, with each interval being approximately 3-5 seconds, and the maximum pressure reaching 30MPa.
Section 6: Gas Pressure Test：
1. Gas Sealing Pressure Test: All assembly completed according to the sealing test fixture method (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 gas into the main air valve. Close (main air valve) when the air pressure reaches the required pressure value. (3) Enter the pressure-holding timing phase. Upon the end of the pressure-holding time, 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 up to standard.
2. Gas strength pressure test: Based on the sealed test fixtureSealed by a top-tight cylinder pressing against the opposite end face, depending on the valve port diameter and pressureAdjust the clamping pressure according to the (Pressure Comparison Chart for Cylinder Clamping).（1）Shut off: Total inlet valve → Left and right pressure relief valves → Leak detection switch. (2) Open: Test valve → Upper and lower pressure gauge switches → Inject gas into the total inlet valve. Close (total inlet valve) when the pressure reaches the required value, and spray foam agent on the valve body surface. (3) Enter the pressure-holding timing phase, check for bubble formation at the valve connection seal and the valve body surface, and if there's pressure drop on the pressure gauge, 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-tight pressure test
Similarly, pressure seal 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 inlet valve → Upper water inlet valve → Lower pressure relief valve → Lower pressure gauge switch → Test valve. (4) Open: Total water inlet valve → Lower water inlet valve. (4) Start the low-pressure pump to fill with water. When the low-pressure pump pressure reaches the set value of 1.8 (MPa), it indicates that the right 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 enter the pressure holding timing period (e.g., 2 minutes/client-defined). Check for any leaks on the valve sealing surface and housing surface, and ensure the pressure gauge is stable, to determine if the valve's strength and pressure are up to standard.
2、Water Strength Pressure Test:
Similarly, the pressure intensity pressure test valve mounting is all done, (1)Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Adjust the electrical contact pressure gauge (use 4.0MPa as an example for the intensity pressure) by moving the red pointer to 4.0MPa. (2) Turn off: total inlet valve → upper and lower pressure relief valves → upper and lower pressure gauge switches. (3) Turn on: total inlet water valve → valve under test. (4) Start the low-pressure pump to fill water. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is full of 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 (e.g., 2 minutes/client-defined). Check for any leaks at the valve connection surfaces and the valve body, and ensure the pressure gauge is stable, to determine if the valve's strength pressure test is合格. (5) After testing, release all 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 feet anchored with concrete. It is suitable for use in a temperature range of (1-40)℃ in a normal or heated workshop during winter, with no high concentration of dust or corrosive gases nearby. Avoid locations close to grinding wheels or polishing machines with poor conditions. Ensure good ventilation, and leave at least a 1m space around the equipment for easy operation and maintenance.
2. Operators must undergo professional training before starting work, adhere to standard procedures, and strictly avoid exceeding 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 turned off when not in use.
5. Regularly apply lubricant to all moving parts of the test bench to maintain cleanliness and smooth operation.
6. Use 46# anti-wear hydraulic oil (use anti-freeze 46# anti-wear hydraulic oil below 0℃), and ensure the oil level does not fall below the indicator. Regularly check the oil level and hydraulic oil; it should be flushed after one year of use.Wash OilBox, replace with new oil.
7. Water source must be clean with no impurities. Change water quality promptly if it becomes turbid. Replenish with rust inhibitor powder, meet testing requirements. To ensure the test valves are not corroded, it's typically necessary to regularly add rust inhibitor powder to the recirculating water tank, preventing the medium water from causing rust on pipes, pumps, and check valves, thus affecting their normal operation.
Note: Common anti-rust powders include:Sodium nitriteSodium sulfonate, potassium benzenesulfonate (non-toxic, powdered form).
8. The equipment worktop should be kept clean, and there should be no debris between the test valve flange and the pressure test blanking plate.
