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FOREVER STARS OF HYDRAULIC CO.

, LTD

Op erat io n Ma n u a l
( Simply Version ) Safety Valve Test Bench Model YFT-D400

Forever stars of hydraulic co., ltd www.China-yysb.com benqpan@gmail.com

TEL: 86 577 67317333 FAX: 86 577 67310059 benqpan@gmail.com www.china-yysb.com

FOREVER STARS OF HYDRAULIC CO., LTD

TABLE OF CONTENTS
1. 2. General Product Description
2.1 Safety Valve Control Cabinet YFT-D400

2.1.1 General View 2.1.2 Connections 2.1.3 Inside View 2.2 Auto Clamping Cabinet

2.2.1 General View 2.2.2 Connections 2.3 Portable Computer Recorder AT-31

3.

Schematic Diagram and Main Components


3.1 Schematic Diagram 3.2 Main Components

4.

Operation 4.1 4.2 4.3 Notes on Safety Installation Operation

4.3.1 Preparations 4.3.2 Airintake 4.3.3 Clamping 4.3.4 Build-up Pressure 4.3.5 Gas Test 4.3.6 Liquid Test 4.3.7 Gas Bottle Using Statement

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5. 6.
7.

Maintenance Troubleshooting Operation Software SVTester100


7.1 7.2 7.3 General Operation Test Steps

8. 9.

Common Unit Conversion Appendix


- Operation and Maintenance Manual for Sprague S-86-JN Series Air-operated Gas Boosters - Operation and Service Handbook for Sprague PowerStar4 Air Driven Pumps - Specification of Main Components

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1.

General
YONGYE Gas or Liquid Double Seat Safety Valve Test Bench YFT-D400 is developed by our company. It is an advanced testing equipment allowing you to test safety valve cracking pressure and sealed pressure. Features: - With Sprague Products -USA air driven hydraulic pumps or boosters, build-up pressure quickly and keep up pressure well. By using a pressure regulator on the operating air supply line, the outlet gas pressure can be accurately adjusted to any pressure level between the precharge pressure and the maximum discharge pressure.

- Test with gas or liquid medium. - Automatic clamping. -Measurable range of valve: DN 15-200-400mm (big clamping bench: DN200-400mm, small clamping bench: DN15-200mm). Maximum liquid test pressure: 62MPa, maximun gas test pressure: 34.5MPa. -Equipped with a Portable Computer Recorder AT-31, which can automatically record safety valve cracking pressure and sealed pressure, and directly print the pressure curve and test report. -With rapid connections between devices, convenient and reliable.

Specifications
Driving Air Pressure (MPa) 0.17~0.69

Model of Equipment

Max. Output Pressure (MPa)

Dimensions (L*B*H/mm)

Weight (Kg)

YFT-D400 AJJT-3100 AT-31 Measurable range of valve (mm)

34.5 (gas)

62 (liquid)

1000*720*1600 1600*950*990 500*450*140

198 845 8

Max. clamping pressure 40 tons Portable Computer Recorder

DN 15-200-400mm

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2.
2.1

Product Description
Safety Valve Control Cabinet YFT-D400

2.1.1 General View

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2.1.2 Connections

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2.1.3 Inside View

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2.2 Auto Clamping Cabinet AJJT-3100 2.2.1 General View

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2.2.2 Connections

2.3

Portable Computer Recorder AT-31 Computer

Electrical cabinet

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3.

Schematic Diagram and Main Components


Schematic Diagram

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3.2 Main Components

Item 1 2 3 4 5

Description Air Driven Pump Air Driven Pump Air-operated Gas Booster H.P. Regulator 1 H.P. Regulator 2 Test Pressure Gauge

Qty 1 1 1 1 1

0-100MPa; 0-4MPa; 0-10MPa; 0-25MPa; 0-60MPa; 0.4%FS

Each 1 pc

4.

Operation
4.1 Notes on Safety -Prescribed air or gas can cause severe injury or death if misused; -For maximum pump life, driving air should be filtered to 10 micron. Liquid return should be filtered to 5 micron; -Loose connections will result in high pressure leaks and can cause serious injury or death; -Do not exceed 6.9 bar driving air pressure. Pressure in excess of 6.9 bar can cause equipment damage and serious injury or death in the event of an explosion; -H.P. outlet should not be directly facing people, especially the vital parts on the body, for example, eyes; -Prior to disassembly or maintenance being performed, the system must be completely disconnected from power, and completely without pressure; -Only for Nitrogen (N2), do not use any other gases such as Oxygen (O2), Hydrogen (H2) etc. -Close bleed valve lightly; -Appropriately handle gas or liquid release port to prevent any dangerous situation; -Do not use L.P. sensor when doing H.P. test; -For Liquid Test, open Accumulator Shut-off Valve only when liquid test pressure 28MPa (when liquid test pressure 28MPa, safety Valve will relief automatically);

-Best serviceable range of liquid pressure for Safety Valve : 2.5~28MPa (when liquid pressure ranges 0~2.5MPa, it is normal the pressure gauge pointer moves around);
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-Test according to Safety Valve Clamping Pressure Chart: Big Clamping Bench for valve DN200-400, Small Clamping Bench for valve DN15-200. Do not test valve DN200-400 with Small Clamping Bench; -Make sure to move three clamping plates to the center of the valve to be tested at the same time (the max. displacement for Big and Small Clamping Bench to center of the valve to be tested is 20mm). 4.2 Installation All inside installations are finished by the manufacturer, you only need to connect the Safety Valve Control Cabinet, Auto Clamping Cabinet and Portable Computer Recorder. Refer to 4.3 Operation. 4.3 Operation

4.3.1 Preparations - Fill oil to cylinder: the oil cylinder shall be emptied before transportation for safety. The common oil used is YB-N46-68. Prior to operation, check Air Compressor pressure, Nitrogen gas bottle pressure, oil cylinder, gauges etc., and make sure periodic maintenance. - Connect the Auto Clamping Cabinet AJJT-3100 to the Safety Valve Control Cabinet using a H.P. hose. Connect H.P. outlet and H.P. inlet by a H.P. hose; Connect H.P. outlet and H.P. inlet by a H.P. hose; Connect Oil Cylinder A & B to A1 & B1 or A2 & B2 by a H.P. hose, make sure all connections correct and reliable.

4.3.2 Air intake - Connect Precharge Inlet to Nitrogen gas bottle by a Nitrogen gas bottle hose; prior to connection, make sure nitrogen gas bottle pressure is within precharge pressure range of pump (300psi-6100psi). - Connect Air driving Inlet: connect the equipment to Air Compressor by L.P. hose. - Connect Liquid Inlet: connect the equipment to reservoir by L.P. hose. Check all lines are connected well before further actions.

4.3.3 Clamping -Use Air Gun to blow down dust and dirt on sealing plates of Safety Valve Control Cabinet and Auto Clamping Cabinet. -Choose proper seal disc and O-rings according to orifice of the safety valve to be tested, move claw to the position where able to clamp the safety valve. When testing safety valve DN15-200, make sure the big and small clamping bench oil cylinder are connected by H.P. Oil Hose.

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-Turn " Air Pressure Regulator

" counterclockwise until air pressure is zero reading (pull up

Air Pressure Regulator for control mode; press down for locked-in ). Set "L.P. Changing" valve to "Manual Clamping" position. -Set "Clamping Direction" valve to "Clamp", check the safety valve to be tested and claw, then do pre clamping. -After pre clamping, move "L.P. Changing" valve to "Manual Clamping", adjust "Air Pressure Regulator

" clockwise according to "Safety Valve Clamping Pressure Chart" until desired

clamping pressure is reached.

Unless otherwise specified, turn valve clockwise to close and counterclockwise to open,
all valves are closed before using. 4.3.4 Build-up Pressure - Firstly, close "Bleed Valve " and "Bleed Valve ", move " Precharge Direction Valve" to "Gas", turn "H.P. Regulator " and "Air Pressure Regulator " counterclockwise to lowest position; open "Air Shut-off V-1" and slowly turn "Air Pressure Regulator " clockwise until pump starts running and the desired pressure is reached. (note: when pretest pressure is less than 35Mpa, "Gas Bottle Shut-off" valve can be opened. )

- Slowly adjust "H.P. Regulator " until "H.P. "gauge reading get closer to pretest pressure. Then open "H.P. V-1"by turning counterclockwise. If the pretest H.P. outlet is connected to "H.P. Outlet II" it is necessary to fit a test pressure gauge whose range close to test pressure near "Test Pressure " gauge. Open "H.P. V-4" to start test. Adjust "H.P. Regulator " until the desired pretest pressure is reached.

- Prior to stop operation, close "H.P. V-1" valve and open "Bleed Valve ". If not use the equipment for a long time, open all bleed valves on lines. At this time "H.P. V-4" valve is open. - It depends on the user if use the gas bottle or not, if use, open the "Gas Bottle Shut-off" Valve. For more details please refer to the H.P. gas bottle operation manual. 4.3.5 Gas Test When the pretest pressure is lower than gas bottle pressure, go head below test, please note before this test all bleed valves are closed. - Firstly, move "Precharge Direction" Valve to "Gas". - Adjust valve "H.P. Regulator

" until " gauge "H.P. "reading get close to pretest Pressure.

- Open valve "H.P. V-2", when "H.P. Outlet I" is the H.P. outlet, open Valve "H.P. V-3" to start Test.
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", If not - Prior to stop operation, close Valve "H.P. V-2", then open "Bleed Valve use the equipment for a long time, open all bleed valves on lines. At this time "H.P. V-3" valve is open. 4.3.6 Liquid Test - Two bleed valves are closed prior to liquid test. - Turn "Air Pressure Regulator

" counterclockwise to lowest position;

- Open "Air Shut-off V-2" , when "H.P. Outlet I" is the H.P. outlet, open Valve "H.P. V-3" to start Test.

- Slowly adjust "Air Pressure Regulator II" until desired pretest pressure is reached. - Prior to stop operation, turn "Air Pressure Regulator " counterclockwise to lowest position. close "Air Shut-off V-2", then open "Bleed Valve I". If not use the equipment for a long time, open all bleed valves on lines. At this time "H.P. V-3" valve is open. - It depends on the user if use the Accumulator or not, if use, open the "Accumulator Shut-off" Valve. For more details please refer to the accumulator operation manual. 4.3.7 Gas Bottle Using Statement Gas bottle (High pressure steel seamless cylinder) Using statement: -Manufacture and inspection of cylinders accord with Q/20197423-1.26 standard <High pressure seamless steel cylinder>. -Environment temperature of using condition must be -40

60.

-Cylinder`s loading medium must accord with RULES OF CYLINDER`S SAFETY SUPERISE, and must not been loaded beyond permitting pressure, and must not been changed the loading medium. -Cylinder must been inspected periodically according with RULES OF CYLINDER`S SAFETY SUPERISE. a. Cylinder which loads caustic gases and uses in diving must been inspected every double years. b. Cylinder which loads normal gases must been inspected every three years. c. Cylinder which loads inert gases must been inspected every five years. If find serious cautery, scathe or have suspicion in safety, user must inspect ahead of schedule; If cylinder stores and pauses beyond one inspection period, user must inspect before using.

storage and using must accord below: a. Cylinder must been acted gently, strictly prohibit throwsliproll and bump. b. Cylinder must not been stored and transfered with flammableexplosive and caustic goods
-Cylinder`s transfer together.
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c. Cylinder must not been changed stamp colour and sign. d. Cylinder must not been mended by replacing a damaged part,and repaired by welding, strictly prohibit weld and act arc on cylinder surface. e. Strictly prohibit use exceed 40 hot to heat up cylinder. f. Gas in cylinder must not been used completely,pressure in cylinder must been remained beyond 0.05MPa. -Using life of cylinder design would be 20 years.

-If cylinder happens to accident, department of accident must report for charge department and boiler pressure vessle supervise department in time according with report process of boiler pressure vessle`s accident.

5.

Maintenance
This test unit requires minimum maintenance. To maintain a reliable and effective working, the test unit only requires to be kept clean. Periodical maintenance: Weekly: Check sealing plates and shop air inlet filter / strainer. Yearly: Calibrate pressure gauges, flow meters and checking oil level.

6.

Troubleshooting
Probable Cause a. fail to move Manual Direction valve to clamping position. b. pump not running: b1: with air driving pressure b2: no air driving pressure - pressure too low - pump failure c. pump running c1:reservoir liquid supply is low c2: oil cylinder interface wrong. c3:liquid supply line to pump inlet check valve is clogged. Correction move Manual Direction valve to clamping position. b1: connect air driving source b2: - adjust pressure regulator until pressure higher than pump starting pressure. - maintenance c1: add liquid as required. c2: connect interface as required. c3: remove and clean check valve as required. a. Refer to pump operation manual. b1: check precharge pressure,make sure precharge gas bottle open. b2: move precharge derection valve to Gas.

Trouble (1) Auto clamping cabinet is not working

(2) Test pressure gauge or a. Pump not running H.P. gauge display zero reading. b. pump running b1: no precharge gas or precharge pressure is lower than required. b2: fail to move precharge derection valve to Gas.

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7.
7.1

Operation Software SVTester100


General The SafeValveTester is developed for - Digital reading of the test pressure, time and leakage - Storing the test results and valve specification in a clear database, available for future use - Printing a full size test certificate The Windows XP software is designed for workshop use with very simple and effective question answer operation. There is no computer knowledge required for operation.

7.2

Operation Start SVTester100, main display as follows:

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-Picture Box: display pressure curve. -Current Pressure: the current pressure detected when sampling is activated. -Sampling Enable (A): activate or close sampling. Hotkey: Ctrl+A. -Parameter Setting: click Parameter Setting to save parameters for the next time the system starts. The sensor range is the same as the actual sensor range. -Sealed Pressure & OK: when sampling is activated, click this button the sealed pressure will be chosen as current pressure; when sampling is closed, click this button the sealed pressure will be chosen as pressure on Y axis span. -Curve Toolbox Visable: show or hide curve toolbox.

Cursor Button: when this button is concave, there will be a black horizontal line on picture box, use computer mouse to move the line up and down. The line position shows the value on Y axis span. - Curve Data SaveAs: save as .dat format, available for future use. (add .dat to filename in case of any conflicts with other files). - Curve Picture SaveAs: save as .bmp format, available for future report operation. (add .bmp to filename in case of any conflicts with other files). - Save Testing Result: test three times, click this button to save testing data for every test. - Get Curve Data: find history curve. - Report Operation: report operation interface as follows.

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7.3 Test Steps

- Step 1, click Sampling Enable or ctrl+A to start sampling. Current Pressure will display real time actual detecting pressure, Actual Pressure will display the maximum pressure during sampling. - Step 2, open Safety Valve and observe curve which will be steady after pressure drop for a while. Click Sealed Pressure and OK, this sealed pressure is actual detecting pressure at that time. - Step 3, click Sampling Enable or ctrl+A to stop sampling, then click Curve Data Save As to save current curve data, click Curve Picture Save As to save current curve picture as bitmap format. - Step 4, click Curve Toolbar Visible or double left click to display the curve toolbar, move the cursor to get cracking pressure and sealed pressure (sealed pressure should not be higher than cracking pressure, or else it will result in failure to calculate pressure difference). Click Save Testing Result to save testing result, or click Zoom box and move cursor to get any part of the curve manually, then click Save Testing Result to save testing result. - Step 5, repeat Steps 1 through 4 twice, then the system will ask you for report operation. - Step 6, click Report Operation to enter report operation interface. - Step 7, click Get Picture to extract one of the bitmaps saved to report. - Step 8, fill in other blanks of the report, click Print Preview, then click Print to print the report.

8.

Common Unit Conversion


1 bar = 100 KPa = 14.5 psi = 1 kgf/cm2 1 MPa = 10 kgf/cm2 = 1000 KPa = 10 bar 1 = 0.00004 in = 0.001 mm

9.

Appendix
- Operation and Maintenance Manual for Sprague S-86-JN Series Air-operated Gas Boosters - Operation and Service Handbook for Sprague PowerStar4 Air Driven Pumps - Specification of Main Components

More detail operation manul will be supplied together with goods.


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