One,Product Overview:

YFA-L Type hydraulic valve testing bench, which is based on our company's many years of production experience in valve testing equipment, strictly adheres to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Valve Testing and Inspection."API StandardDesign and production are required to meet the test pressure requirements of specifications such as API598.

This unit integrates a hydraulic, mechanical, electrical system, pressure-supply device, 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 reasonable structure, comprehensive functions, stable performance, easy operation, and high automation level. It is widely used in high, medium, and low-pressure direct connection flanged valve tests for pressure sealing performance and shell strength resistance. Applicable valve types include gate valves, stop valves, check valves, ball valves, and butterfly valves, etc. It is suitable 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.

II. Specification 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 at the bottom. The table is equipped with a 3-jaw hydraulic clamping mechanism and an adjustable hydraulic thrust cylinder. The thrust cylinder can rotate 90 degrees backward for valve clamping and sealing tests, facilitating observation. It is suitable for various types of valves including flanged,焊接, socket, gate, stop, ball, and butterfly valves. There is no external force affecting the tested valve, ensuring a secure clamp.

2. The sealing method uses valve face sealing. During valve sealing tests, the hydraulic clamp holds the back of the flange tightly. For strength tests, the groove face or flange surface is sealed, and the top pressure cylinder presses it firmly. The clamping force canContinuous pressure adjustment or stepless boost to the desired pressure value via a button press.

3. The test bench features a dual-system for both air and water usage, with bidirectional pressure inlet and outlet, equipped with a leak testing port. The system is pre-configured with high and low-pressure pumps, allowing direct hydrostatic testing. The high and low-pressure pumps are equipped with automatic control functions. The gas source is provided by the user, and the liquid testing medium can be circulated and reused, 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 top-tightening mechanism. When pressure is present in the valve cavity, the top-tightening cylinder locks and releases its action until the pressure inside the valve cavity is completely exhausted, at which point the release button can be activated. This prevents erroneous 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 mark on the dipstick.

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 for normal operation.

4. Sealing Test Clamping Method: Retract the point-action clamp to a position greater than the outer diameter of the valve flange being tested. Select a sealing disk compatible with valve testing and install it on the workbench. Place the valve on the sealing plate. Gently release the point-action clamp to a height above the valve flange thickness, then advance the clamp to close proximity to the valve flange. Securely clamp and grip the backside of the valve flange. Strength Test Clamping Method: Secured by a thrust cylinder pressing against the opposite end face seal, depending on the valve's orifice diameter 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 required level.The boost button can be pressed multiple times, with each press separated by approximately 3-5 seconds, and the maximum pressure is 30MPa.

Section 6: Gas Pressure Test：

1.  Airtight seal pressure test: All assembly completed according to the sealing test assembly 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 total outlet valve. Close (total outlet valve) when the air pressure reaches the required pressure value. (3) Enter the pressure holding timing phase. When the pressure holding time is up, check for bubbles on the sealing surface and pressure drop on the gauge to determine if the valve's sealing performance is qualified.

2. Gas Strength Pressure Test: Based on the sealed test fixtureTightened by a top-acting cylinder sealing the opposite end face, based on valve orifice size 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 air pressure reaches the required pressure value, and spray foam agent 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 sealing surface 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

1. 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 (with a sealed pressure of 2.5 MPa as an example) by moving the red pointer to 2.5 MPa. (2) Close: Total inlet valve → Upper water inlet valve → Lower pressure relief valve → Lower pressure gauge switch → Valve under test. (3) 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 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 holding time (such as 2 minutes/client-defined) will begin. Check for any leaks on the valve sealing surface and housing surface, and ensure the pressure gauge is not tilted, to determine if the valve's strength and pressure are 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 (use 4.0MPa as the reference point) by moving the red pointer to 4.0MPa. (2) Turn off: Total intake valve → Upper and lower pressure relief valves → Upper and lower pressure gauge switches. (3) Turn on: Total water intake valve → Test valve. (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 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 holding time (such as 2 minutes/client-defined) will begin. Check for any leaks at the valve connection and body surfaces, and ensure the pressure gauge is stable, to determine if the valve's strength pressure test is passed. (5) After testing, exhaust the pressure, release the button, and remove the valve.

Section 8: Usage Precautions and Requirements：

1. Ideally, the site should be arranged in a level indoor space, with the level position set and the footings anchored with concrete. Use in an environment with a temperature range of (1-40)℃; for normal temperature or heated workshops in winter. Surroundings should not contain high concentrations of dust or corrosive gases. Avoid proximity to areas with grinders or polishing machines with poor conditions. Ensure good ventilation conditions. Leave at least a 1m space around the equipment installation for easy operation and maintenance.

2. Operators must undergo professional training before starting work, adhere to standard procedures, and strictly refrain from 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 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 relieved 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. Use 46-grade anti-wear hydraulic oil (for temperatures below 0°C, use antifreeze 46-grade anti-wear hydraulic oil), 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, replace with new oil.

7. Water source must be clean and free of impurities. Change the water promptly if it becomes cloudy. Add new rust-proof powder, meet testing requirements. To ensure the test valve is not corroded, it is usually necessary to add rust-proof powder regularly 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-proof powders include:Sodium nitriteSodium sulfonate, potassium benzenesulfonate (non-toxic powder).

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