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

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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

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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

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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

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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.

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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

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 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

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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
Phenomenon Failure Reason Solution
1. Air enters to the hydraulic system, the 1. Loose joints of the cylinder and exhaust
cylinder sometimes run and sometimes the air
Cylinder Creeping

Hydraulic System

stop, and shake continuously

2.System pressure is lower than the 2. Adjust the required pressure of the
friction system
resistance
3. Cylinder and the valve are not fully 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
Reversing valve

2.Control the pressure, and the oil 2. Increase the pressure of the control
pressure is too low pressure oil
3.Control oil tube blocked 3. Get through the control oil pipeline
Cylinder Doesn’t Work

4.Failure of reversing, Valve core cannot 4. Check and clean

be
reset
1.Bad insulation of coil of solenoid valve 1. Replace the solenoid valve
Electrical Equipment

2. There is some dirty in the iron part of 2.Sanding clean

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 5. Weld again and fasten the screws
joints
1.Dirty blocked the check valve 1. Check and clean the hydraulic check
Pressure don’t

valve
2. Damage of the valve core of check 2. Grinding and replace
keep
Pressurized Cylinder

valve
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
Pressure not

2. Damage of the pressurized cylinder and 2. Replace

increased

sealing components
3. Damage of the cone of pressurized 3. Grind, clean and replace
adjust valve
4. Damage of pressurized control buttons 4. Replace
1. Wrong rotating direction of the motor 1. Change the power wire, and correct the
and no oil sucked

No Pressure

direction
Oil Pump
( water)

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 3. Change to low viscosity (Equivalent to
infeasible movements of the impeller ISOVG46,56,68 oil)

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 4.Failure of the pressure gauge or get
4. Measure, clean and replace
blocked, can’t indicate the pressure
Low pressure Water 1. Wrong direction of the rotating of the 1. Change the power wire, and correct the
motor direction (clockwise)
2. Water lever is to low, screw is loosen 2. Check timely, add water and fasten the
Pump

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 2. Clean, Repair and replace
High Pressure Pump

valve is blocked or damaged

3. The sealing damaged in the high 3. Replace
pressure water pump
4. The sealing damaged in the high 4. Replace
pressure water equipment cylinder
5. Solenoids reversing valve blocked or 5. Check, Repair, and replace
damaged
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
Failure of the pressure

opening position, no oil enter into the

system
Bleed valve
adjusting

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 4.Repair or replace the cone valve
seat
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
oil filter is blocked
Oil Pump

2. Oil in the oil tank is not enough, air 2. Add hydraulic oil, As per standard lines
inside
Severe noise and shake

3. Oil pump long time working, the stator 3. Repair the impeller, repair the parts by
and impeller wears . grinding,
1. The spring of the bleed valve is 1. Check and replace the spring
distorted, cannot reset
Bleed Valve

2. Damping hole in the valve core blocked 2. Use o1mm steel thread get through
by dirt 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 4. Separate the longer tubes
tubes

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 xii. Hydraulic Devices Maintenance

Method of Status
Requirements
Checked Checked Examination Time/
Type of the
Parts Items （Measuring Period Run Stop
maintenance
Instrument ）
Motor The insulation
Controllin resistance
As per
g Measure by between the
related
Electric Electric Insulation 500volt 1/Year ○ ground wires
motor
megohm should be
standard
Electric higher than
10mn.
Oil Check the oil Within the
1/Day ○
Volume indication line standard
Hydraulic Oil Temp. Temp.Meter 1/Day ○ 20℃~55℃
Cylinder As per
Clean 1/3Mo
○ Hydraulic
Degree nths
Standard
Replace
Pressure
Pressure Min.tolerance when Big
Measure Measure 1/Year ○ ○
gauge within 1/2 tolerance
ment
or damage
Working No abnormal Check and
Hear by ears 1/Year ○
Sound sound repair
Abrasion No abrasion Replace
Check the
of 1/Year ○ of the end when
Solenoid appearance
the lifter surface abrasion
Hydraulic Valve
Connect the
Fix the
lifter, body, 1/3 No loosen of
Screw ○ loosen
screw loosen Month the parts
screw
and drop
Working Check 1/3 As per Check and
○
Condition reliable Month Design repair
Check and
Outside 1/3
Hydraulic ○ No leakage replace the
Leakage Month
Cylinder Sealing
As per Oil Check and
Inside Leakage of 1/3
○ Cylinder replace the
Leakage piston seal Month
Movement sealing
Outside Visual and 1/3
Soft ○ No Damage Replace
damage touch Month
Tubes
Oil Visual and 1/3 ○ No Oil Oil

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 Leakage touch Month Leakage leakage,
repair the
O ring s
Visual 1/3 ○ ○ No Distort Correct it
Distort
Month 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 8.Hydraulic Disc 9. Spring

10.O ring 11.Cover 12. Hex bolts

Oil Check Valve Drawing

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 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,
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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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