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Abstract: As a general-purpose mechanical product, valves are widely used in petroleum, petrochemical, natural gas engineering and other industries. The specificity and importance of their use occasions require strength tests and water (gas) sealing tests before the valves are shipped. The working principle, structure and characteristics of the 100-ton valve testing machine are introduced, and the working process is described.
[Keywords] valve tester; valve; gas drive pump valve as a general-purpose mechanical products are widely used in petroleum, petrochemical, natural gas engineering and other industries, due to the particularity and importance of its use of the occasion, the valve assembly needs to be completed before the factory Strength test and water (gas) seal test. In order to improve detection efficiency, reduce the number of equipment and floor space, and reduce the labor intensity of testers, we have designed and developed valve testing machines for water (gas) sealing tests specifically for 3-24†butterfly valves, ball valves, and other tests. The valve tester is designed and developed in accordance with the requirements of relevant national standards and enterprise standards based on the production requirements and the structure of various similar valve testers.
First, the working principle of the use of the valve flange face positioning and sealing, the use of two cylinders can move axially clamping valve flange face pressure test, can avoid the valve in the test process by other external forces on the valve. The valve is clamped with a hydraulic cylinder, and the water (gas) sealing test of the valve can be performed by switching on the gas or water circuit. The clamping cylinder is supplied by the gear pump of the hydraulic system during the idle stroke. After the valve is clamped, the gas pump drives the high pressure press test, so that the heating of the hydraulic system can be avoided.
Second, structure and characteristics (A) 100 tons of valve testing machine structure 100 tons of valve testing machine using "C" type structure, the device body size is 3500mm long, 950mm wide, 1600mm high, opening space is 1100mm, both ends of the clamping cylinder Opening and closing stroke is 800mm. 100-ton valve tester mainly consists of 3-12†valve test station, 14-24†valve test station, base, large clamping cylinder, large valve lower support device, valve clamping tooling, electrical control console, hydraulic station Small valve lower support device, small clamping cylinder, hydraulic station and other components. Figure 1 shows the structure of a 100-ton valve tester.
The 3-12†valve tester position can test 3-12†valves, and the 14-24†valve tester position can test 14-24†valves. The base is used to fix and connect all the components of the tester. The exact working position between the components is the basic part of the tester. The function of the lower valve support device and the lower valve support device of the large valve is to allow the valve to be raised and lowered during installation so that the valve can be quickly installed and tested. The large clamping cylinder and the small clamping cylinder are devices for clamping and positioning the valve under test. The replaceable sealing tooling and the like are used. The end face of the sealing tooling is equipped with an O-ring for sealing the end face. The hydraulic station is a hydraulic oil supply for the operation of the hydraulic cylinder. It can provide 4 MPa of low pressure oil and 30 MPa of high pressure oil.
1.3-12†Valve Tester Position 2.14-24†Valve Test Station 3. Base 4. Large Clamp Cylinder 5. Large Valve Under Test 6. Large Valve Lower Support Device 7. Valve Clamp Tooling 8. Workstation 9. Hydraulic station 10. Small valve under test 11. Small valve lower support device 12. Small clamping cylinder (2) Hydraulic control system Hydraulic system mainly includes hydraulic oil tank, gear pump, air drive pump, pneumatic proportional pressure reducing valve, and stacking type Electromagnetic reversing valve, superimposed throttle valve, superimposed check valve, superimposed relief valve, radiator, oil filter and piping. The hydraulic oil tank is installed on the right side of the testing machine. The hydraulic system can pressurize the valves according to different types of measurement, and the hydraulic pressure is combined with the electric joint control. Each device of the testing machine can work in coordination and meet the requirements of the valve testing process. For the convenience of observation and operation, various inlet and outlet (gas) fittings, various valves, pressure gauges and other components as well as tester operation control panels are all brought together. The maximum working pressure of the hydraulic station is 30MPa, which can realize two groups of hydraulic work at the same time to meet the simultaneous test of the two sizes of valves. 100 tons valve tester hydraulic system diagram.
(C) Electrical Control System The electrical control system mainly includes operation control cabinet, S7-300 PLC, HMI touch screen, drive controller, and pressure/position detection sensor. The system realizes the control and protection of the valve test automatic clamping force, the test data is automatically recorded and stored, the fault diagnosis is provided, and the printing function is provided. The PLC is equipped with an Ethernet interface and can realize the MES/EPR management system of the device accessing the user unit.
The electrical operation control cabinet is installed above the hydraulic oil tank. First, it can reduce the area, and the second is that the electrical components are not affected by the leakage of hydraulic oil.
Third, the working process 1. According to the measured size of the valve and the pressure level, according to the "clamp cylinder pressure required table" to adjust the required working pressure.
2. Use the workshop lifting equipment to lift the valve under test to the installation position, operate the lower support device to the appropriate position, operate the button of the clamping cylinder, and clamp the valve under test.
3. According to the test requirements of the valve, connect the test water, gas, and oil circuits respectively, and use different clamping assemblies to clamp the measured valve. The left and right clamping devices respectively clamp the measured valve.
4. After the test is completed, lift the tested valve from the tester with the workshop lifting equipment.
Fourth, 100 tons of valve testing machine performance indicators (a) the type of valve being tested The 100 tons of testing machine can test valves including straight-through flanged ball valves, gate valves, globe valves, butterfly valves and other types of high, medium and low pressure valves .
(B) Testing the range of 100 tons of valve testing capabilities to meet the 3-24 "butterfly valve, ball valve test. 3-12" valve clamping cylinder bore 80mm; stroke of 400mm, the maximum clamping force of 20 tons. 14-24†valve clamping cylinder bore 200mm; stroke 400mm, maximum clamping force 100 tons.
(3) Test items The valves (water) airtight seals and endoleak test tests can be performed according to the relevant standards ASMEB16.34/GBT17213.10.
V. Conclusion The 100-ton valve tester is a testing machine that integrates mechanical, electrical, and hydraulic components. The entire process of the test valve is automatically controlled by a PLC-controlled hydraulic system. It has the advantages of advanced technology, compact structure, reliable performance, complete functions, convenient operation and maintenance, and high degree of automation. The two workstations are designed on a test machine with a base, sharing a set of electrical and hydraulic test systems and a set of hydraulic pressure. The fuel tank not only solves the problem that a variety of valve tests are completed on a test machine, but also greatly reduces the equipment footprint, improves the test efficiency, and reduces the labor intensity of the test personnel. It is an ideal detection device for valve production units.
references:
[1] Cheng Daxian. Mechanical Design Manual (Third Edition) [M]. Chemical Industry Press, 1998.
[Keywords] valve tester; valve; gas drive pump valve as a general-purpose mechanical products are widely used in petroleum, petrochemical, natural gas engineering and other industries, due to the particularity and importance of its use of the occasion, the valve assembly needs to be completed before the factory Strength test and water (gas) seal test. In order to improve detection efficiency, reduce the number of equipment and floor space, and reduce the labor intensity of testers, we have designed and developed valve testing machines for water (gas) sealing tests specifically for 3-24†butterfly valves, ball valves, and other tests. The valve tester is designed and developed in accordance with the requirements of relevant national standards and enterprise standards based on the production requirements and the structure of various similar valve testers.
First, the working principle of the use of the valve flange face positioning and sealing, the use of two cylinders can move axially clamping valve flange face pressure test, can avoid the valve in the test process by other external forces on the valve. The valve is clamped with a hydraulic cylinder, and the water (gas) sealing test of the valve can be performed by switching on the gas or water circuit. The clamping cylinder is supplied by the gear pump of the hydraulic system during the idle stroke. After the valve is clamped, the gas pump drives the high pressure press test, so that the heating of the hydraulic system can be avoided.
Second, structure and characteristics (A) 100 tons of valve testing machine structure 100 tons of valve testing machine using "C" type structure, the device body size is 3500mm long, 950mm wide, 1600mm high, opening space is 1100mm, both ends of the clamping cylinder Opening and closing stroke is 800mm. 100-ton valve tester mainly consists of 3-12†valve test station, 14-24†valve test station, base, large clamping cylinder, large valve lower support device, valve clamping tooling, electrical control console, hydraulic station Small valve lower support device, small clamping cylinder, hydraulic station and other components. Figure 1 shows the structure of a 100-ton valve tester.
The 3-12†valve tester position can test 3-12†valves, and the 14-24†valve tester position can test 14-24†valves. The base is used to fix and connect all the components of the tester. The exact working position between the components is the basic part of the tester. The function of the lower valve support device and the lower valve support device of the large valve is to allow the valve to be raised and lowered during installation so that the valve can be quickly installed and tested. The large clamping cylinder and the small clamping cylinder are devices for clamping and positioning the valve under test. The replaceable sealing tooling and the like are used. The end face of the sealing tooling is equipped with an O-ring for sealing the end face. The hydraulic station is a hydraulic oil supply for the operation of the hydraulic cylinder. It can provide 4 MPa of low pressure oil and 30 MPa of high pressure oil.
1.3-12†Valve Tester Position 2.14-24†Valve Test Station 3. Base 4. Large Clamp Cylinder 5. Large Valve Under Test 6. Large Valve Lower Support Device 7. Valve Clamp Tooling 8. Workstation 9. Hydraulic station 10. Small valve under test 11. Small valve lower support device 12. Small clamping cylinder (2) Hydraulic control system Hydraulic system mainly includes hydraulic oil tank, gear pump, air drive pump, pneumatic proportional pressure reducing valve, and stacking type Electromagnetic reversing valve, superimposed throttle valve, superimposed check valve, superimposed relief valve, radiator, oil filter and piping. The hydraulic oil tank is installed on the right side of the testing machine. The hydraulic system can pressurize the valves according to different types of measurement, and the hydraulic pressure is combined with the electric joint control. Each device of the testing machine can work in coordination and meet the requirements of the valve testing process. For the convenience of observation and operation, various inlet and outlet (gas) fittings, various valves, pressure gauges and other components as well as tester operation control panels are all brought together. The maximum working pressure of the hydraulic station is 30MPa, which can realize two groups of hydraulic work at the same time to meet the simultaneous test of the two sizes of valves. 100 tons valve tester hydraulic system diagram.
(C) Electrical Control System The electrical control system mainly includes operation control cabinet, S7-300 PLC, HMI touch screen, drive controller, and pressure/position detection sensor. The system realizes the control and protection of the valve test automatic clamping force, the test data is automatically recorded and stored, the fault diagnosis is provided, and the printing function is provided. The PLC is equipped with an Ethernet interface and can realize the MES/EPR management system of the device accessing the user unit.
The electrical operation control cabinet is installed above the hydraulic oil tank. First, it can reduce the area, and the second is that the electrical components are not affected by the leakage of hydraulic oil.
Third, the working process 1. According to the measured size of the valve and the pressure level, according to the "clamp cylinder pressure required table" to adjust the required working pressure.
2. Use the workshop lifting equipment to lift the valve under test to the installation position, operate the lower support device to the appropriate position, operate the button of the clamping cylinder, and clamp the valve under test.
3. According to the test requirements of the valve, connect the test water, gas, and oil circuits respectively, and use different clamping assemblies to clamp the measured valve. The left and right clamping devices respectively clamp the measured valve.
4. After the test is completed, lift the tested valve from the tester with the workshop lifting equipment.
Fourth, 100 tons of valve testing machine performance indicators (a) the type of valve being tested The 100 tons of testing machine can test valves including straight-through flanged ball valves, gate valves, globe valves, butterfly valves and other types of high, medium and low pressure valves .
(B) Testing the range of 100 tons of valve testing capabilities to meet the 3-24 "butterfly valve, ball valve test. 3-12" valve clamping cylinder bore 80mm; stroke of 400mm, the maximum clamping force of 20 tons. 14-24†valve clamping cylinder bore 200mm; stroke 400mm, maximum clamping force 100 tons.
(3) Test items The valves (water) airtight seals and endoleak test tests can be performed according to the relevant standards ASMEB16.34/GBT17213.10.
V. Conclusion The 100-ton valve tester is a testing machine that integrates mechanical, electrical, and hydraulic components. The entire process of the test valve is automatically controlled by a PLC-controlled hydraulic system. It has the advantages of advanced technology, compact structure, reliable performance, complete functions, convenient operation and maintenance, and high degree of automation. The two workstations are designed on a test machine with a base, sharing a set of electrical and hydraulic test systems and a set of hydraulic pressure. The fuel tank not only solves the problem that a variety of valve tests are completed on a test machine, but also greatly reduces the equipment footprint, improves the test efficiency, and reduces the labor intensity of the test personnel. It is an ideal detection device for valve production units.
references:
[1] Cheng Daxian. Mechanical Design Manual (Third Edition) [M]. Chemical Industry Press, 1998.
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