Hydraulic Valve Test Bench Installation/Operation/ Maintenance
VTB H300 Series For BW / SW / NPT / Flange Ends Valves
CONTENT
i.
Brief Introduction.................................................................... 2
ii.
Structure and Working Principle........................................... 2
iii.
Valve Test Bench 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................................... 10
viii.
Water-Vapor Schematic....................................................... 13
ix.
Hydraulic Schematic............................................................ 14
x.
Electrical Circuit Schematic................................................ 15
xi.
Common Fault Diagnosis and Solution............................. 17
xii.
Hydraulic Devices Maintenance.......................................... 19
xiii.
Supply Water 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 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. 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 release. 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 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 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. 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 valve pressure , adjust the air 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 gauge, when the pressure reaches to the - 11 -
required pressure, shut the air driven high pressure pump switch 7. Open the alarm switch, start 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 pressure holding 4. When the pressure holding time reaches to the required time, the alarm start to alarm. Shut the alarm switch 5. After qualification, open the left side pressure relief valve, right pressure relief valve and empty the pressure 6. Check the pressure come to zero, prepare to discharge the valve, touch the relax button, unload the valve and finish the testing . - 12 -
viii.
Water-Vapor Schematic
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ix.
Hydraulic Schematic
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x.
Electrical Circuit Schematic
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xi.
Common Fault Diagnosis and Solution 1. Air enters to the hydraulic system, the cylinder sometimes run and sometimes stop, and shake continuously
1. Loose joints of the cylinder and exhaust the air
2.System pressure is lower than the friction resistance
2. Adjust the required pressure of the system
3. Cylinder and the valve are not fully sealed, there is air inside.
3. Install and replace the sealing ( O ring)
1.Slide valve damaged or blocked
1. Clean and repair the slide valve
2.Control the pressure, and the oil pressure is too low
2. Increase the pressure of the control pressure oil
3.Control oil tube blocked
3. Get through the control oil pipeline
4.Failure of reversing, Valve core cannot be reset
4. Check and clean
Electrical Equipment
Cylinder Doesn’t Work
Solution
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
Hydraulic System
Cylinder Creeping
Failure Reason
Reversing valve
Phenomenon
Pressure don’t keep Pressure not increased
Pressurized Cylinder
Oil Pump
No Pressure ( water) and no oil sucked
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solenoid valve
3.Damage of control buttons( Panel)
3.Replace
4. Wrong Voltage
4. Correct the voltage
5. Bad welding of the wires and loosen joints
5. Weld again and fasten the screws
1.Dirty blocked the check valve
1. Check and clean the hydraulic check valve
2. Damage of the valve core of check valve
2. Grinding and replace
3. Spring distorting of the check valve
3. Check and clean
4. Oil leakage at the jointing parts
4. Check and replace the O rings
1. Dirt in the solenoid reversing valve
1. Check and clean
2. Damage of the pressurized cylinder and sealing components
2. Replace
3. Damage of the cone of pressurized adjust valve
3. Grind, clean and replace
4. Damage of pressurized control buttons
4. Replace
1. Wrong rotating direction of the motor
1. Change the power wire, and correct the direction
2. Oil lever is too low, oil cannot be sucked
2. Examine the oil in the cylinder regularly, and add oil to the standard line
3.Viscosity of oil is too high cause the infeasible movements of the impeller
3. Change to low viscosity (Equivalent to ISOVG46,56,68 oil)
Low pressure Water Pump High Pressure Pump Bleed valve
Failure of the pressure adjusting
Oil Pump Bleed Valve
Severe noise and shake
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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 motor
1. Change the power wire, and correct the direction (clockwise)
2. Water lever is to low, screw is loosen
2. Check timely, add water and fasten the screws
3. There is air in the water pump
3. Pour water in the water pump
4. Water outlet check valve is blocked
4. Clean and check
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 screws
2. Water sucking ( water outlet) check valve is blocked or damaged
2. Clean, Repair and replace
3. The sealing damaged in the high pressure water pump
3. Replace
4. The sealing damaged in the high pressure water equipment cylinder
4. Replace
5. Solenoids reversing valve blocked or damaged
5. Check, Repair, and replace
6. Electrical pipeline or buttons damaged
6. Check, Repair, and replace
1. The valve core blocked at the ful opening position, no oil enter into the system
1. Get rid of failure of blocking
2.Burrs and dirt in the valve core
2. Check, Repair ,Grind, and clean
3.Damping hole blocked
3.Get through the damping hole and clean
4.Bad contact of cone valve, and valve seat
4.Repair or replace the cone valve
5.The space between the valve disc and body is too big
5. Replace the valve disc, adjust the space
1. There is air in the oil sucking tube, The oil filter is blocked
1. Check ,Fasten ,Grind, Clean, or replace
2. Oil in the oil tank is not enough, air inside
2. Add hydraulic oil, As per standard lines
3. Oil pump long time working, the stator and impeller wears .
3. Repair the impeller, repair the parts by grinding,
1. The spring of the bleed valve is distorted, cannot reset
1. Check and replace the spring
2. Damping hole in the valve core blocked by dirt
2. Use o1mm steel thread get through the valve damping hole and clean it
3. The viscosity of the oil is too high
3. Decrease the viscosity of the oil suitably
4. Resonance with others, impact with the tubes
4. Separate the longer tubes
xii.
Hydraulic Devices Maintenance
Checked Parts
Type
Checked Items
Method of Examination （Measuring Instrument ）
Status Time/ Period
Run
Stop
Motor Controllin g Electric
Electric
Insulation
Measure by 500volt megohm
1/Year
○
The insulation resistance between the ground wires should be higher than 10mn.
Oil Volume
Check the oil indication line
1/Day
○
Within the standard
Oil Temp.
Temp.Meter
1/Day
Electric
Hydraulic Cylinder
Pressure gauge
Hydraulic
Solenoid Valve
Hydraulic Cylinder
Soft Tubes
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Requirements of the maintenance
Clean Degree
○
1/3Mo nths
As per Hydraulic Standard Min.tolerance within 1/2
Replace when Big tolerance or damage
No abnormal sound
Check and repair
○
No abrasion of the end surface
Replace when abrasion
○
No loosen of the parts
Fix the loosen screw
As per Design
Check and repair
○
No leakage
Check and replace the Sealing Check and replace the sealing
Measure
1/Year
○
Working Sound
Hear by ears
1/Year
○
Abrasion of the lifter
Check the appearance
1/Year
Screw
Connect the lifter, body, screw loosen and drop
1/3 Month
Working Condition
Check reliable
1/3 Month 1/3 Month
20℃~55℃ ○
Pressure Measure ment
Outside Leakage
As per related motor standard
○
○
Inside Leakage
Leakage of piston seal
1/3 Month
○
As per Oil Cylinder Movement
Outside damage
Visual and touch
1/3 Month
○
No Damage
Replace
Oil
Visual and
1/3
○
No Oil
Oil
Leakage
Distort
touch
Month
Visual
1/3 Month
â—‹
â—‹
Leakage
leakage, repair the O ring s
No Distort
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. 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 7. Check valve disc
10.O ring 11.Cover
12. Hex bolts
Oil Check Valve Drawing
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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: sale@valvetestbench.com Phone:+86 15058707868 Skype:alanchen0086
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