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Valves used in the petroleum, gas, and petrochemical industries must meet the highest standards of performance due to their crucial role in these applications. To ensure their reliability, valve testing systems are utilized to evaluate their performance under defined ranges and conditions. The most critical parameter in these tests is the pressure-bearing capacity of the valve. In order to test the leakage at the required pressure, one or both flanges of the valve must be completely closed and sealed. The press method is utilized to seal the valve flange during the test.Â
A schematic diagram of the designed system is depicted in the figure to the right. As shown, valve sealing is carried out at the entrance of the valve's flanges. In this method, the valve is initially placed between the press jaws, which receive force from the power screws. The force applied at this stage is much lower than the final force needed to control the valve during the pressure test. Subsequently, by applying hydrostatic pressure to the valve, the pressure jaws transfer the pressure force to the body of the test system and remain in position. The body of the test apparatus is able to withstand the force of the hydrostatic pressure, and the components experience only slight displacement. After the test, the jaws open, and the valve is removed.
In the following, I will outline the different steps involved in the design and fabrication of a test bench for gas ball valves up to 36 inches. Each phase of the project is listed below in bullet points for easy reference:
1. In the conceptual design phase, I analyzed the requirements of the gas ball valve testing industry and developed a design concept for a test bench that meets those requirements. This involved considerations such as the size of the valves being tested, the required testing parameters such as pressure, and the need for automation and data collection.
2. Once I had a design concept, I used SOLIDWORKS Simulation to perform FEM simulations to confirm the design's feasibility and optimize it for performance. This involved analyzing the stresses, deformations, and thermal properties of the test bench under various operating conditions.
3. Based on the results of the simulations, I selected the appropriate materials and manufacturing processes for the test bench. This included calculating the load-bearing capacity of different materials and analyzing the cost-effectiveness of various manufacturing methods. I ensured that the design complied with relevant industry standards and regulations.
4. I then provided detailed manufacturing CAD drawings that specified the dimensions, tolerances, and material specifications of the various parts needed for the test bench. These drawings were used by manufacturers to produce the parts to exact specifications.
5. During the machining and assembly phase, I supervised the production of the parts and ensured that they were machined to the correct dimensions and specifications. I also oversaw the assembly of the final test bench to ensure that it met the design requirements and was of high quality.
6. Finally, I conducted thorough testing of the test bench to ensure that it met the required performance specifications. This involved testing the bench's ability to handle gas ball valves up to 36 inches, as well as testing for pressure stability and accuracy.
Overall, this project demonstrates my expertise in designing and fabricating test benches for the gas ball valve testing industry. I prioritized accuracy, attention to detail, and compliance with industry standards throughout the entire process to ensure that the final product met the client's requirements and expectations.
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