CONTENT
i.
Brief Introduction....................... Introduction........... ........................ ........................... ........................... .................. ...... 2
ii.
Structure and Working Principle...................... Principle.......... ........................... ..................... ...... 2
iii.
Valve Test Bench Drawing........................... Drawing............ ........................... ........................ .............. .. 4
iv.
Installation Considerations and Requirements……… ......... 5
v.
Main Technical Parameters and Specifications .................. ............. ..... 9
vi.
Clamping Cylinder Pressure Table ........................... ............... ........................ ............ 9
vii.
Valve Test Bench Operation Manual.......................... Manual........... ........................ ......... 10
viii.
Water-Vapor Schematic................ Schematic............................ ........................ ........................ ............... ... 13
ix.
Hydraulic Schematic........................ Schematic............ .......................... ............................ ...................... ........ 14
x.
Electrical Circuit Schematic.......................... Schematic........... ........................... ...................... .......... 15
xi.
Common Fault Diagnosis and Solution......................... Solution............. ................ .... 17
xii.
Hydraulic Devices Maintenance......................... Maintenance........... .......................... ................. ..... 19
xiii.
Supply Water System...................... System......... .......................... ........................... ........................ .......... 22
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i.
Brief Introduction The valve hydraulic test bench of VTB-H series is widely used in the intensity and leakage tests of all kinds of high, medium and low pressure valves with nominal diameter 1/2” – 40” (DN15-1000). It is particularly designed to perform test Flange/NPT/BW/ SW end connection valves on one machine. (For testing sockets and threaded valves, the fixture tools shall be prepared by the user, we will dispatch one set seal plates/Adapters for BW/Thread end, one set for Flange ends valves)
ii.
Structure and Working Principle The test bench integrates hydraulic system, electro-mechanical system, pressure testing, and hydraulic medium storage and recycle system. It has the characteristics of reasonable structure, completed function, easy operation and so on. The machine brings hydraulic system, machinery, electric control system and hydraulic water supplying pump together, and adopts the way of hydraulic oil cylinder impaction to test the valves. The hydraulic system is the main driving source of the oil cylinder and water supplying pump. The work pressure of the hydraulic cylinder impaction is adjusted according to the different testing pressure grade. The credible clamping capability meets the requirement for testing various size and pressure valves. The hydraulic water -2-
supplying device is composed by high and low water pressure pump whose pressure range is designed as per clients’ request.
The pressure test is performed according to the following operation method under the controls of the electrics and electric-contact pressure gauge. There is a recirculation water tank for user at the bottom of the test bench.
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iii.
Valve Test Bench Drawing
1. Spell cap
8. Moveable Sealing Adapter
15. Low Pressure Pump
2. Leakage cup control valve
9. Cylinder piston rod
16. Gas-driven Pump
3. Skid
10. Right Adapter
17. Hydraulic Oil Tank Inlet
4. Pressure relief valve
11. Press Cylinder
5. Left Sealing Adapter
12. Oil Pump
6. Sealing Plates
13. Pressurized Cylinder
7. Pulling Rod
14. Hydraulic Assembly
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iv.
Installation Considerations and Requirements
1) Installation:
After choosing the suitable location of the test bench, make sure the test bench is in the horizontal line; use the concrete to fasten the root bolt and let the air source connected c onnected to the inlet air connection. 2) Oil inpouring:
Selection of N32 # -N46 # anti-wear hydraulic oil into the Hydraulic Oil Tank(17). The oil volume can’t be lower than the lowest limit of
the oil gauge. 3) Testing medium:
Water and kerosene are both ok. Make sure it is clean and won’t rust the tested valve and meets the requirement of the test. When you use water as the test medium, add a rust inhibitor (sodium nitrite, non-toxic powder) in the circular water to prevent the water to rust the water pipeline and the tested valve. Make sure it is clean and won’t rust the tested valve and meets the requirement of the
test. Test medium amount not less than the liquid lowest level. 4) Connect to the electric power:
Plug in, turn on the machine. Push button Oil Pump Start, check whether the moving direction of motor is right(should be clockwise), after 5-10minutes empty loading running, adjust the pressure of oil -5-
pump to 5.0Mpa(50Bar), (by Adjusting pressure valve Y-25B)check whether every pipeline has leakage or not, if there is any abnormality please stop the machine and eliminate it. Please touch the buttons of cylinder pressurized and released so that the oil pump pressure gauges can show pressure values. 5) Pressure adjustment:
When testing the valves, firstly according to the tested valve size and pressure check the table list of “Clamping Cylinder Pressure Contrast table” , increase the pressure to the required pressure,
when the required pressure is below 5.0Mpa(50Bar), no need to pressurizing. Oil pump pressure adjusting range is 0-6.3Mpa (0-63Bar), Pressurized cylinder pressurizing range is 5.0-31.5Mpa (50-315Bar) pressurized cylinder pressure is in direct ratio to the oil pump pressure. When you find the left and right clamping pressure gauge is not holding the pressure, please stop working and eliminate the failure. Beyond specification range and beyond pressure range to test valve is forbidden. 6) High and low pressure water pump:
Pour the water in the high and low pressure water pump before you use it, and then open the pump till the water comes out normally, if there is some noisy from the high pressure pump, it is normal ( The high pressure water pump pressure is in direct ratio to the oil pump -6-
pressure). When the pump is pouring water to the tested valves, the operator CAN NOT leaves the test bench, in case the function of automatically stop of the electrical contact pressure gauge failed. If it happens, press the button of “high pressure water pump stop” to stop water inpouring, to avoid any accident. acc ident. 7) Pressure Gauge
The pressure gauges in the test bench should calibrated by the official measurement department, and make sure in their valid time, The range of the pressure gauge should not less the 1.5 times of the testing pressure, the accuracy degree should not less 1.5 degree. 8) Testing Cast Iron Valves When testing cast iron valves, don’t use hammer to hit , the
operator should be careful and operate the test bench correctly, pay special attention to the testing medium over-pressure cause the damage of the valves. Release all pressure inside of the valve body. 9) The selection and check of the hydraulic oil
The hydraulic oil should be checked, replaced regularly. Clean the oil tank, replace the oil after 3 months of first time using the test bench, and after that you should clean and replace it at least once a year ( Depends on the detailed condition), the oil should not below -7-
the oil limitation indicator , the temperature of the oil tank should not above 55 Degree C. 10) Daily maintenance
The test bench working plate should keep clean, there shall be no dirty between the tested valve ends/flanges and seal plates. The moving parts should be lubricated frequently and keep clean. Check the O ring timely and replace it if necessary. 11) Interlock function:
Pressure gauge green needle must be adjusted to be more than zero when the water pressure black needle drops across the green needle loosen the button and then can c an release. 12) Timing 12) Timing Relay:
Set the pressure hold time, when the pressure reaches the test pressure, pressing the start button to start timing; when reach the setting time, the alarm beep reminder. 13) Attention:
When testing pressure over 50 bar, the low pressure pump water inlet valve must be closed. When the testing pressure over the pressure gauge max range, must close the related pressure gauge switch or replaced with bigger range pressure gauge.
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v.
Main Technical Parameters and Specifications
Model: VTB-H300 Nominal Diameter 2”to 12”(DN50-DN300) Nominal Pressure (see detailed test range table) Max. Clamping Force: 110Ton Diameter of Clamping Cylinder: Ø220 Distance between the sealing adapter: 170-950mm Oil Pump Motor: 5.0kw 380V 60HZ POWER SUPPLY: 380V 60Hz Outside Dimension: 2850×950×1800
vi.
Clamping Cylinder Pressure Contrast Table
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vii.
Valve Test Bench Operation Manual Before any operating, make sure the oil pump is under working and open the pressure relief switches if test bench need working over one hour. 1) The loading of the tested valves
According to the valve size , Touch the button of “Cylinder Pressurized” or “ Cylinder released” , ( Please noted that the oil
cylinder clamping button touched the oil cylinder is moving, when you stop touch this button the cylinder is also moving, only you touch the button of cylinder release so that the cylinder will stop, and for the cylinder release button, if you touch it, the cylinder will move backward, if you stop touching it, it will stop).
Move the moveable span to the suitable place of the face to face of the tested valves, and make sure the center of the valve and the seal plates are matching and then touch the button” Cylinder Clamped” to clamp the valves, according to the table of clamping
cylinder pressure required contrast table to see if need pressurized or not, if needed, touch the button of “ Cylinder pressurized”, make sure the clamping cylinder pressure increased to the required pressure ( The pressurized button can be touched several times), after loading the valve, you can do the body bod y shell test. - 10 -
2)
The performance test
Due to the various valve models with different testing methods, we take globe valve for example: Test 2’’ below valves don’t need to open the low pressure pump,
use the air driven high pressure pump to perform the testing directly, according the pressure holding time adjust the time relay in the distribution box ( range 0-5 0 -5 min). A: Shell test
1. Open the tested valve 2. Open the low pressure pump ( 2’’ below don’t open), left pressure relief valve, shut the air inlet valve, right pressure relief valve. 3. Touch the low pressure pump start to start the pump. pump. Check if there is any water coming out, shut the pressure relief valve 4. Check the low pressure pump pressure gauge, when the pressure increasing to 13-16 bar, shut the low pressure pump low pressure pump water inlet valve. 5. According to the tested tested valve pressure , adjust adjust the air driven driven high pressure pump pressure adjusting valve (0-7bar), open the air driven pump switch, the air driven high pressure pump start to work 6. Check the pressure pressure gauge, when the pressure reaches to the - 11 -
required pressure, shut the air driven high pressure pump switch 7. Open the alarm switch, start start pressure pressure holding 8. When the pressure holding time reaches to the required time, the alarm start to alarm. Shut the alarm switch, after qualification and then do the seal test B: Seal test
1. Slowly open the pressure relied valve and make sure the pressure decrease to the sealing pressure requirements, shut the pressure relief valve and tested valves 2. Open the left side pressure relief valve empty the left side pressure, checkthe water pressure gauge holding situation and the left side if any leakages 3. Open the alarm switch , start the the pressure pressure holding 4. When the pressure holding time reaches reaches to the required time, the alarm start to alarm. Shut the alarm switch 5. After qualification, qualification, open the left side pressure pressure relief valve, right pressure relief valve and empty the pressure 6. Check the pressure come to zero, prepare to discharge discharge the valve, touch the relax button, unload the valve and finish the testing . - 12 -
viii.
Water-Vapor Schematic
- 13 -
ix.
Hydraulic Schematic
- 14 -
x.
- 15 -
Electrical Circuit Schematic
- 16 -
xi.
Common Fault Diagnosis and Solution
Phenomenon
C in
Failure Reason
Solution
1. Loose joints of the cylinder and exhaust
H
cylinder sometimes run and sometimes
the air
d
stop, and shake continuously
u
2.System pressure is lower than the
2. Adjust the required pressure of the
S
friction
system
yl
1. Air enters to the hydraulic system, the
y ra d e r C
lic e in
s
y
resistance
m
3. Cylinder and the valve are not fully
re p te g
3. Install and replace the sealing ( O ring)
sealed, there is air inside. 1.Slide valve damaged or blocked
1. Clean and repair the slide valve
R
2.Control the pressure, and the oil
2. Increase the pressure of the control
ve
pressure is too low
pressure oil
in
3.Control oil tube blocked
3. Get through the control oil pipeline
v
4.Failure of reversing, Valve core cannot
4. Check and clean
lv
be
e rs C y
g lin d
a e r
e D
reset o e s
E
1.Bad insulation of coil of solenoid valve
1. Replace the solenoid valve
2. There is some dirty in the iron part of
2.Sanding clean
ic
tr
c rk
o
’t
n
solenoid valve
E
l
3.Damage of control buttons( Panel)
3.Replace
u
4. Wrong Voltage
4. Correct the voltage
5. Bad welding of the wires and loosen
5. Weld again and fasten the screws
t
n
e
m
joints
le W
a q ip
1.Dirty blocked the check valve P re
valve s
2. Damage of the valve core of check o
d
u
s
valve
k re
e P e p re
n
s
’t
su ri ze d
2. Damage of the pressurized cylinder and
2. Replace
sealing components
a e
3. Damage of the cone of pressurized
o
n
re
adjust valve
re s d t
a N (
o
O
il
o a
re
P
il P
ke
4. Damage of pressurized control buttons
4. Replace
1. Wrong rotating direction of the motor
1. Change the power wire, and correct the
2. Oil lever is too low, oil cannot be sucked 2. Examine the oil in the cylinder
u
te s
regularly, and add oil to the standard line
m s u p re
d
- 17 -
3. Grind, clean and replace
direction
o
n r)
4. Check and replace the O rings
su
e
re c
r
c
4. Oil leakage at the jointing parts
s
in d
su
3. Check and clean 1. Check and clean
lin
w
3. Spring distorting of the check valve 1. Dirt in the solenoid reversing valve
y
d
2. Grinding and replace
P
C
n
1. Check and clean the hydraulic check
3.Viscosity of oil is too high cause the
3. Change to low viscosity (Equivalent to
infeasible movements movements of the impeller
ISOVG46,56,68 oil)
4.Failure of the pressure gauge or get blocked, can’t indicate the pressure
4. Measure, clean and replace
1. Wrong direction of the rotating of the
1. Change the power wire, and correct the
w
motor
direction (clockwise)
p
2. Water lever is to low, screw is loosen
2. Check timely, add water and fasten the
o
L re P s u
screws
su m re
3. There is air in the water pump
3. Pour water in the water pump
a
4. Water outlet check valve is blocked
4. Clean and check
r
5. Electric or low pressure pump is burnt
5. Repair and replace
1. Water lever is to low, screw is loosen
1.Check timely , add water and fasten the
p W te
screws valve is blocked or damaged 3. The sealing damaged in the high
s
s
re
P
pressure water pump
re
4. The sealing damaged in the high
u
pressure water equipment cylinder
p
5. Solenoids reversing valve blocked or
u
2. Water sucking ( water outlet) check
h
ig
H
P m
2. Clean, Repair and replace 3. Replace 4. Replace 5. Check, Repair, and replace
damaged
F
6. Electrical pipeline or buttons damaged
6. Check, Repair, and replace
1. The valve core blocked at the ful
1. Get rid of failure of blocking
opening position, position, no oil enter into the
a ilu re B
ju
f
e
system
a d
o s n p
e
th
2.Burrs and dirt in the valve core
2. Check, Repair ,Grind, and clean
d
ti
3.Damping hole blocked
3.Get through the damping hole and clean
a
4.Bad contact of cone valve, and valve
4.Repair or replace the cone valve
v
le lv
g re
e s s
seat
re
5.The space between the valve disc and
5. Replace the valve disc, adjust the
body is too big
space
1. There is air in the oil sucking tube, The
1. Check ,Fasten ,Grind, Clean, or replace
u
oil filter is blocked
O
2. Oil in the oil tank is not enough, air
u
inside
p
P
il S
m e ve
2. Add hydraulic oil, As per standard lines
3. Oil pump long time working, the stator
3. Repair the impeller, repair the parts by
re
and impeller wears .
grinding,
o
1. The spring of the bleed valve is
1. Check and replace the spring
n is e
distorted, cannot reset
a n d
2. Damping hole in the valve core blocked
2. Use o1mm steel thread get through
h k
by dirt
the valve damping hole and clean it
a
V
d
e
le
B
3. The viscosity of the oil is too high
3. Decrease the viscosity of the oil
s a e lv
suitably
e 4. Resonance with others, impact with the tubes
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4. Separate the longer tubes
xii.
Hydraulic Devices Maintenance Method of
Type
Status
Checked
Checked
Examination
Time/
Parts
Items
（Measuring
Period
Run
Requirements Stop
Instrument ）
maintenance
Motor
The insulation
Controllin
resistance Measure by
g Electric
of the
Electric
Insulation
500volt
between the ○
1/Year
megohm
ground wires should be higher than
Electric
As per related motor standard
10mn.
Hydraulic Cylinder
Pressure gauge
Oil
Check the oil
Volume
indication line
Oil Temp.
Temp.Meter
1/3Mo
Degree
nths
Measure
Valve
of the lifter
standard As per
○
Hydraulic Standard Replace
Measure
1/Year
○
○
ment
Abrasion
Within the 20℃~55℃
○
Pressure
Sound
Hydraulic
1/Day
Clean
Working
Solenoid
○
1/Day
Min.tolerance
when Big
within 1/2
tolerance or damage
Hear by ears Check the appearance
1/Year
○
○
1/Year
No abnormal
Check and
sound
repair
No abrasion
Replace
of the end
when
surface
abrasion
Connect the Screw
lifter, body,
1/3
screw loosen
Month
○
No loosen of the parts
and drop
Hydraulic Cylinder
Soft Tubes
- 19 -
Working
Check
1/3
Condition
reliable
Month
Outside
1/3
Leakage
Month
Inside
Leakage of
1/3
Leakage
piston seal
Month
Outside
Visual and
1/3
damage
touch
Month
Oil
Visual and
1/3
○
Fix the loosen screw
As per
Check and
Design
repair Check and
○
No leakage
replace the Sealing
As per Oil
Check and
Cylinder
replace the
Movement
sealing
○
No Damage
Replace
○
No Oil
Oil
○
Leakage
touch
Month
Leakage
leakage, repair the O ring s
Distort
Visual
○
1/3
○
No Distort
Month
Correct it on time
34B-B10H-T Solenoid Valve Drawing
1. Screw 2. Solenoid Valve 3.Valve core seat 4. Spring 5.Spring Seat 6. Valve core 7. O Ring 8. 8 . Solenoid Valve body A1Y-Ha10B Hydraulic Check Valve Drawing
1. Hex Bolts
2.Hydraulic Bonnet
3. O ring
4.Hydraulic Piston
5.Hex Bolts
6.Body
10.O ring
7. Check valve disc
11.Cover
12. Hex bolts
Oil Check Valve Drawing
- 20 -
8.Hydraulic Disc
9. Spring
1. Connecting joint 2. O ring 3. Oil outlet Body 4.Oil outlet core 5. Spring 6. Assembly gaskets 7. Body Y-25B Bleed Valve Drawing
1. Hex Bolts
2. Adjust hand wheel
3.Spring
4. Disc
5.Hex
Bolts 6.Block
xiii.
Supply Water System A. No water is sucked: if the pressure of hydraulic system is normal,
examine the circulation water level, check whether the water suction joints are loose or air enters. B. Valve core of hydraulic component trapped: the installation
position of components refers to assembly installation diagram. Disassemble the reversing valve of the hydraulic water pump and install them back after cleaning. If they were damaged badly, should replace them. C. No water comes out from the high pressure water pump:
disassemble the water inlet one-way valve and water outlet check valve, cleaning them in the diesel oil. If they were damaged badly, - 21 -
should replace them. D. Water outlet quantity is normal, but pressure gauge descends
and cannot keep the pressure: disassemble the water outlet one-way valve, clean the spring, stem, core of the oil outlet valve, grind and repair. Replace if damaged badly. E. Water tank sealing ring used in the dirt medium will shorten the
service life and cause the water outlet pressure unable to increase. It should be replaced and add appropriate antirust on time. If there are any questions, please feel free to contact us
VTB VASAR COMPANY Website: www.valvetestbench.com Email:
[email protected] Phone:+86 15058707868 Skype:alanchen0086
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