DYFJ-F100 Pressure-Test Bench for Top-Pressure Valves

The DYFJ-F100 valve test bench is the fourth-generation valve pressure testing and inspection equipment independently developed by Duojia Hydraulic Co., Ltd., based on years of production experience and in accordance with national standards and specifications.

The DYFJ-F100 type valve testing bench integrates mechanical and electrical, hydraulic systems, pressure testing, and the storage and recycling of liquid media. It features complete functions, stable performance, and high level of automation. It is widely used for sealing surface leakage tests and shell strength (pinhole) tests on various high, medium, and low-pressure valves with nominal diameters of 15-100mm, including straight through flanges, welded, threaded, and clamp-type valves. Test media: water, gas, oil.

The equipment is driven by hydraulic power and controlled by electricity, exerting no additional external force on valves that could affect test results. This significantly enhances work efficiency and reduces labor intensity, making it an ideal new generation pressure testing and inspection equipment for valve manufacturing companies, users, and maintenance units.

DYFJ-F100 Type Valve Test Bench Operating Principle and Structure

The DYFJ-F100 type valve test bench operates by using valve flange face positioning and a hydraulic cylinder to tighten the flange surface, ensuring no external forces that could affect the test results during valve testing. It meets the national standard requirements for valve testing.

Equipment is generally divided into hydraulic pressure supply systems, electrical control systems, water circulation systems, and various operating devices.

The equipment features vertical top pressure, with both the upper and lower workbenches sealed with blind flanges. The upper workbench is equipped with a reciprocating mechanism, directly driven by a hydraulic cylinder to ensure uniform force distribution on the valve sealing surface and reliable clamping. The lower workbench is fixed and allows bidirectional water intake and drainage. The sealing disk is fitted with drainage and exhaust valves, facilitating the inspection of gas-tightness tests and observation of the valve sealing surface. It boasts excellent performance and a simple, compact structure.

Operation Instructions

1. Valve Mounting Method

Select a valve with the nominal diameter that matches the equipment model, turn on the power, and start the hydraulic system. Move the upper cylinder back until it is longer than the valve being tested. Place the valve flange face tightly against the lower workbench test blind plate, aligning with the center hole. Lower the upper movable frame onto the lower fixed workbench, ensuring the other end of the valve being tested is pressed against the lower test blind plate, aligned with the center hole. The valve is in a horizontal position overall.

2. Water Pressure Testing Methods (Bi-directional Inflow and Drainage)

After the valve clamp is assembled, refer to the "Clamping Cylinder Pressure Comparison Table" to increase the hydraulic clamp's gripping force to the required pressure. Adjust the electrical contact pressure gauge (for a 25 kg valve, adjust the pointer to 2.5 MPa). Open the main water intake, upper and lower water intake valves, close the air intake, drain, and vent valves. Start the low-pressure water pump, observe the movement of the water pressure gauge pointer. When the pointer stops rising, it indicates the valve cavity is filled with water. Start the high-pressure water pump; the pump will automatically stop when the water pressure reaches the set pressure on the electrical contact pressure gauge. The equipment then enters the water pressure maintenance state.

Upon reaching the pressure-holding time, there are no issues with the valve. It is recommended to first open the water drain valve to relieve the pressure inside the valve cavity before removing the valve.

3. Pressure Test Methods (Bi-directional Inlet, Exhaust)

The equipment does not come with a gas source. The user must provide a separate gas source. Please consult the manufacturer before using high-pressure gases.

After the valve bracket is installed (for example, using pressure air, generally not exceeding 10 kg), open the inlet and air inlet valves, and close the outlet and air outlet valves. Close the inlet and air inlet valves when the pressure gauge reaches the maximum pressure, and the equipment is in a pressure-holding state.

Upon reaching the pressure-holding time, there are no issues with the valve. It should first be opened to release the air pressure inside the valve chamber, and then the valve should be removed.

Handling Instructions and Requirements

1. Align the equipment horizontally during installation or secure the anchor flange steel with concrete.

2. Use 46-grade anti-wear hydraulic oil (for temperatures below 0°C, use anti-freeze 46-grade anti-wear hydraulic oil). Ensure the oil level does not fall below the gauge's lower limit. Regularly check the oil level and hydraulic oil. After one year of use, clean the oil tank and replace the hydraulic oil.

3. Add anti-rust powder to the recirculating water, and change the water promptly when the water quality degrades.

4. The equipment work surface should be kept clean, and there should be no debris between the valve flange being tested and the pressure test blank flange.

5. All moving parts of the test bench should be lubricated and kept clean for smooth operation.

6. Operators must undergo professional training before starting work, adhere to standard procedures, and prioritize safety.