Top Pressure Valve Test Bench 500kn Top Pressure 4 Independent Test Stations Asme B16.34

Top Pressure Valve Test Bench 500kn Top Pressure 4 Independent Test Stations Asme B16.34

Product Introduction

WPT-3 achieves efficient and accurate detection of high-pressure valves through top-pressure structure and multi-station design:

• Top-pressure sealing technology: 500kN hydraulic top-press (adjustable pressure 20-500kN) with automatic centering fixture to ensure zero leakage of flange/butt-welded valve sealing surface, solve the stress unevenness problem of traditional side-pressure clamping, and is suitable for PN16-PN1000 pressure level valves.
• Multi-station parallel testing: 4 groups of independent stations (optional up to 8 stations), support gate valve, stop valve, safety valve synchronous testing, each group of stations can independently set pressure (0-150MPa), pressure holding time (0-300 minutes) and medium type (water/gas), detection efficiency increased by 60%.
• Intelligent measurement and control system: 10-inch color touch screen (Chinese and English switch) starts the test process with one button, PLC links servo motor to drive high-pressure plunger pump (pressure resolution 0.1MPa), real-time display of pressure curve, leakage, top pressure data, support USB / Ethernet data export.
• Safety redundant design: stainless steel high-pressure chamber (pressure resistance 200MPa) with double-layer explosion-proof glass observation window, built-in pressure sensor (accuracy ±0.3% FS) and leakage monitor (accuracy 0.05mL/min), overpressure automatic unloading (110% set pressure), in line with EN 61010-1 electrical safety standards.

Product Features

High-pressure full compatibility

• Supports 0-150MPa water pressure test (standard) and 0-100MPa air pressure test (optional module), suitable for API 6A wellhead equipment, nuclear power grade high-pressure valves and other extreme working conditions detection.
• The top pressure range is 20-500kN. The real-time feedback from the pressure sensor ensures that the sealing force is dynamically matched with the test pressure (such as automatically applying 400kN top pressure during 100MPa test).

Multi-dimensional detection capability

• Performance test: shell strength (1.5 times the nominal pressure), upper seal test (1.1 times the nominal pressure), gas seal leakage (bubble method/pressure decay method).
• Special test: pressure stability test of low-temperature valves (-196℃ liquid nitrogen environment) and high-temperature valves (350℃ hot air) (temperature control module is required).
• Life test: 500 cycles of pressurization, monitoring of sealing surface wear (accuracy 0.01mm) and pressure decay rate (≤0.5%).

Intelligent data management

• Built-in 64G memory, automatically records 30+ parameters such as top pressure, test pressure, leakage, ambient temperature and humidity, and supports the host computer software to generate PDF reports (including ASME standard compliance determination).
• The touch screen displays single-station SPC statistical charts (such as CPK value, process capability analysis) in real time, and abnormal data is automatically marked in red and triggers sound and light alarms.

Quick clamping design

• The electric lifting fixture (stroke 300mm) is combined with a three-dimensional adjustment bracket to complete the replacement of DN800 valves within 10 minutes, which is 80% more efficient than traditional manual clamping.
• The universal fixture is compatible with flange (RF/RTJ), butt welding (BW), and threaded (NPT) connection valves to reduce the cost of customized tooling.

International reference standards

• ASME B16.34: Valve pressure rating (Clause 10 strength test; Clause 11 sealing test).
• API 598: Valve pressure test specification (Section 4 hydraulic pressure test procedure; Section 5 air pressure test requirements).
• GB/T 13927: Industrial valve pressure test (5.2 shell test; 5.3 sealing test).
• ISO 12266-1: Valve life test method (Part 1 Mechanical life; Part 2 Sealing life).
• EN 12266-1: Industrial valve pressure test (Annex A Leakage measurement method).

Product use

• Petrochemical: Detect the corrosion resistance and sealing of high-pressure ball valves and check valves (such as cryogenic valves for LNG pipelines).
• Nuclear power industry: Verify the seismic performance of safety valves and isolation valves (simulate pressure stability under earthquake conditions).
• High-pressure pipeline engineering: Re-test the shell strength of PN1000 gate valves before installation to avoid the risk of rupture under ultra-high pressure conditions.
• Valve research and development: Life test of new sealing materials (such as metal bellows) to optimize the design of high-pressure valves.

Technical Parameters

Test objects and inspection items

Test objects:

High-pressure flange valves (gate valves, stop valves, ball valves, PN ≥ 100)

Butt-welded valves (such as high-temperature and high-pressure valves for power stations)

Threaded safety valves (such as compressor bypass valves)

Special working condition valves (corrosion-resistant, impact-resistant, and low-temperature valves)

Inspection items:

Shell strength test: 1.5 times the nominal pressure for 30 minutes, no deformation, no leakage.

Seal test:

Upper seal: 1.1 times the nominal pressure, leakage ≤ 0.1mL/min (DN50).

Sealing surface: Bubble method detection, no continuous bubbles are generated (equivalent leakage ≤ 0.05mL/min).

Air sealing test: 0.6MPa air pressure, pressure maintenance for 60 minutes, pressure decay ≤ 0.2%.

Top pressure matching test: Calculation of minimum sealing force under different test pressures (optimization of clamping efficiency).

Fatigue test: 1000 cycles of pressurization, sealing surface wear ≤ 0.05mm.