yft-d400 operation manual

FOREVER STARS OF HYDRAULIC CO., LTD

TEL: 86 577 67317333 FAX: 86 577 67310059 [email protected] www.china-yysb.com

Operation Manual ( Simply Version )

Safety Valve Test Bench

Model YFT-D400

Forever stars of hydraulic co., ltd

www.China-yysb.com [email protected]



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TABLE OF CONTENTS 1. General 2. 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 Notes on Safety 4.2 Installation

4.3 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. Maintenance 6. Troubleshooting 7. Operation Software SVTester100

7.1 General

7.2 Operation

7.3 Test Steps 8. Common Unit Conversion 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



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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

Model of Equipment

Driving Air Pressure

(MPa)

Max. Output Pressure (MPa)

Dimensions (L*B*H/mm)

Weight (Kg)

YFT-D400 0.17~0.69 34.5 (gas) 62 (liquid) 1000*720*1600 198

AJJT-3100 Max. clamping pressure 40 tons 1600*950*990 845

AT-31 Portable Computer Recorder 500*450*140 8

Measurable range of valve

(mm) DN 15-200-400mm



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2. Product Description 2.1 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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Computer

Electrical cabinet

2.2.2 Connections

2.3 Portable Computer Recorder AT-31



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3. Schematic Diagram and Main Components

Schematic Diagram



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3.2 Main Components

Item Description Qty

1 Air Driven Pump 1

2 Air Driven Pump 1

3 Air-operated Gas Booster 1

4 H.P. Regulator 1 1

5 H.P. Regulator 2 1

6

Test Pressure Gauge

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 Ⅱ will relief automatically); -Best serviceable range of liquid pressure for Safety Valve Ⅱ: 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 ”Ⅰ and “ H.P. inlet Ⅰ” by a “H.P. hose”; Connect “H.P. outlet ”Ⅱ and “ H.P. inlet ”Ⅱ 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 Ⅲ" 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 Ⅲ" 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 Ⅰ" and "Bleed Valve Ⅱ", move " Precharge Direction Valve" to "Gas", turn "H.P. Regulator Ⅰ" and "Air Pressure Regulator Ⅰ" counterclockwise to lowest position; open "Air Shut-off V-1" and slowly turn "Air Pressure Regulator Ⅰ" 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 Ⅰ" until "H.P. Ⅰ"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 Ⅱ" gauge. Open "H.P. V-4" to start test. Adjust "H.P. Regulator Ⅰ" until the desired pretest pressure is reached. - Prior to stop operation, close "H.P. V-1" valve and open "Bleed Valve Ⅱ". 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 Ⅱ" until " gauge "H.P. Ⅱ"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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- Prior to stop operation, close Valve "H.P. 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.

4.3.6 Liquid Test - Two bleed valves are closed prior to liquid test. - Turn "Air Pressure Regulator Ⅱ" 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 Ⅱ" 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. -Cylinder`s transfer、storage and using must accord below: a. Cylinder must been acted gently, strictly prohibit throw、slip、roll and bump. b. Cylinder must not been stored and transfered with flammable、explosive and caustic goods 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

Trouble Probable Cause Correction (1) Auto clamping cabinet is not working

a. fail to move “Manual Direction” valve to clamping position.

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

b1: connect air driving source b2: - adjust pressure regulator until pressure higher than pump starting pressure. - maintenance

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. c1: add liquid as required.

c2: connect interface as required. c3: remove and clean check valve as required.

(2) Test pressure gauge or H.P. gauge display zero reading.

a. Pump not running a. Refer to pump operation manual.

b. pump running b1: no precharge gas or precharge pressure is lower than required. b2: fail to move precharge derection valve to “Gas”.

b1: check precharge pressure,make sure precharge gas bottle open. b2: move precharge derection valve to “Gas”.



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7. Operation Software SVTester100 7.1 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 1µ = 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.

yft-d400 operation manual

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