I. Product Overview:

YFA-FQ Type hydraulic valve testing bench, which is developed based on our years of experience in manufacturing valve testing equipment, strictly adheres to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Valve Testing and Inspection."American Petroleum Institute StandardDesign and production in compliance with API 598 and other specifications' test pressure requirements.

This unit integrates a hydraulic, mechanical, electrical system, pressure supply unit, and medium storage circulating water tank into one. 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 degree of automation. It is widely used in high, medium, and low-pressure direct flanged valves for pressure sealing performance and shell strength and pressure tests. Applicable valve types include gate valves, stop valves, check valves, ball valves, and more. 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.

Section II: Specification Range:

DN15-800mm

Section 3: Pressure Range: 1.6-63.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

Valves suitable for direct flange connections, including gate valves, stop valves, check valves, ball valves, etc., utilize flange face sealing for the tightening method. The hydraulic clamp grips the back of the flange, allowing for adjustable clamping force. Test results were unaffected by external forces. During the valve testing process, the right-hand operating disc can be flipped 90 degrees, making it particularly suitable for air seal performance testing. The other operating disc can be moved forward and backward, with the length opening spacing freely adjustable. The valve length is unrestricted, significantly enhancing work efficiency.

Clamping Method: Each bidirectional working plate is equipped with a removable hydraulic clamping mechanism. It can automatically synchronize and adjust the position of the clamping jaws according to different valve specifications, achieving automatic centering and positioning. The hydraulic clamping jaws automatically grip the back of the valve flange, with adjustable clamping force, exerting no external force on the tested valve itself. The entire clamping process is controlled by an integrated button and executed by hydraulic components.

The test bench features up and down lifting capabilities, allowing both the machine and the valve under test to be submerged simultaneously. It is particularly suitable for testing the strength, sealing, and gas pressure performance of valve sealing surfaces, revolutionizing the traditional testing method of brushing valve body surfaces with foam agents. It shortens testing time and significantly enhances work efficiency, making it the most ideal choice for a dual-air-water testing device.

Hydraulic Valve Test Bench Working Principle and Operation Method:

I. Working Principle:

Select a sealing blank compatible with the valve model and install it on the equipment. Push the circuit breaker, the equipment power indicator light will turn on. Press the oil pump start button to operate the hydraulic system motor. Ensure the motor runs in the correct direction (clockwise). The left moving bracket retracts to a length greater than the test valve. The left and right clamps move radially to a diameter larger than the test valve flange outer diameter, and the left and right clamps extend axially to a thickness greater than the valve flange.

Secure the tested valve flange against the right-hand workbench with a blind flange, aligning it to the center position. Move the radial clamp jaws towards the valve flange, press the clamp jaws tightening button to reduce the jaw spacing, and press against the back of the valve flange to ensure it does not come loose.

Slide the left-hand shelf towards the right-hand workbench, positioning it close to the opposite end of the valve flange, pressing against the left-hand test blind flange, and aligning with the central position. Move the left radial clamp closer to the valve flange, press the clamp button to shorten the clamp stroke, and securely press against the back of the valve flange, completing the overall clamping of the valve.

During gas pressure testing, the machine and the valve under test can be submerged in water simultaneously. For hydrostatic testing, simply raise the machine to the correct position.

Section II: Sealing Pressure Test Method:

Fill the hydraulic system oil tank with 30#-46# hydraulic oil or 20# mechanical oil, ensuring the oil level does not fall below the lower limit of the oil gauge.

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

3. Adjust the hydraulic system pressure to 5.0 MPa for normal operation.

4、Secure the tested valve flange to the right workbench with the blind plate for pressure testing, aligning it with the center position. Move the radial clamp jaws close to the valve flange, press the clamp button to shorten the jaw spacing, and press the back of the valve flange tightly to ensure it won't come loose.

5. Shut down: Left water inlet valve → Main air inlet valve → Right pressure relief valve → Test valve → Right pressure gauge switch.

6. Open: Right inlet valve → Main inlet valve.

7. Refer to the (pressure required for cylinder clamping table) to adjust the clamping pressure. For pressures exceeding the pump source by 5.0 MPa or more, press the (right paw pressure boost) button to increase the pressure to the required clamping level. Press the (upper right flip) button to flip the working disk on the right side to a horizontal position.

8. All assembly is complete. Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure (take the valve sealed at 4.0 MPa as an example; adjust the red pointer of the electrical contact pressure gauge to 4.0 MPa).

9. Start the low-pressure water pump. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is already 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-defined). Check the valve sealing surface and connection areas, as well as any leaks on the valve body surface and if the pressure gauge has any dips, to confirm the sealing surface performance is up to standard. After the test is complete, open the (pressure relief valve) switch to exhaust the pressure and proceed to the next test.

Note: The process of loading and the testing methods for left-hand are the same as for right-hand.

Section 3: Tensile Strength Testing Method:

1. Intensity pressure test: Based on the sealed test fixture process, advance the left-hand moving bracket to the right-hand workbench, close to the法兰 of the other end valve under test, abut the left-hand blind flange, aligning with the center position. Move the left radial chuck towards the valve flange, press the clamping button to shorten the chuck stroke, and press against the back of the valve flange tightly, completing the overall fixture of the valve.

2. Refer to the pressure comparison table for cylinder clamping requirements and increase the pressure to the required value. Once all clamping is complete, set the low-pressure pump electrical contact pressure to 1.8 (MPa), and adjust the electrical contact pressure gauge (using a 6.0 MPa valve as an example) by moving the red pointer to 6.0 MPa.

3. Open: Right inlet valve → Left inlet valve → valve under test.

4. Shut off: Total intake valve → Right pressure relief valve → Left pressure relief valve → Right pressure gauge switch → Left pressure gauge switch.

5. Start the low-pressure water pump. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is already 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 6.0 (MPa), the high-pressure pump will automatically stop, and the pressure maintenance timing (such as 2 minutes/client's specification) will begin. Check for any leaks at the valve connection points and the valve body surface, and ensure the pressure gauge is functioning properly. This is to confirm if the valve strength and pressure test is合格. After the test is complete, open the (bleed valve) switch to exhaust the pressure, release the clamp, and remove the valve.

Section 6: Usage Precautions and Requirements：

1. The site should be arranged in a level indoor space, properly leveled, with concrete footings in place. It should be used in an environment with a temperature range of (1-40)℃ at normal temperature or in a heated workshop during winter. The area should be free from high concentrations of dust and corrosive gases. Avoid placing it near grinding wheels or polishing machines in 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 standardized 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 the test is completed, the pressure must be relieved to zero before the clamp can be released. The power should be disconnected during non-operational periods.

5. All moving parts of the testing bench should be regularly lubricated to maintain clean and smooth operation.

6. Select No. 46 anti-wear hydraulic oil (use anti-freeze No. 46 anti-wear hydraulic oil below 0℃), and ensure the oil level is not below the indicator's lower limit. Regularly check the oil level and hydraulic oil; after one year of use, it should be drained and cleaned.Wash OilBox, replace with new oil.

7. Water source must be clean and free of impurities. Change water quality promptly if it becomes turbid. Add new rust inhibitor powder to meet testing requirements. To ensure the test valve is not corroded, it is typically necessary to regularly add rust inhibitor powder to the circulating water tank and prevent rusting of the medium water affecting the normal operation of pipes, pumps, and check valves.

Note: Common rust preventive powders include:Sodium nitrateSodium sulfonate, sodium potassium sulfonate (non-toxic, powdered form).

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