DYFJ-E500 High-Pressure Hydraulic Valve Test Bench

The DYFJ-E500 valve testing bench is the fourth-generation pressure testing and inspection equipment independently developed by Duojia Hydraulics, based on many years of production experience and in accordance with national standards and specifications.

The DYFJ-E500 valve test bench integrates mechanical and electrical, hydraulic systems, pressure testing, and the storage and recycling of liquid mediums. It features comprehensive functions, stable performance, and high automation. It is widely used for sealing surface leakage tests and other performance tests, such as shell strength (pinhole), on various high, medium, and low-pressure valves with nominal bore sizes of 200-500mm and direct flange connections. Test media: water, gas, oil.

The equipment is driven and controlled by hydraulics and electricity, exerting no additional external force on valves that could affect test results, greatly enhancing work efficiency and reducing labor intensity. It is an ideal new generation pressure testing and inspection equipment for valve manufacturing companies, users, and maintenance units.

DYFJ-E500 type valve test bench working principle and structure

The DYFJ-E500 type valve test bench operates by positioning the valve flange and clamping the back of the flange with movable claws, ensuring no external forces affecting the test results during valve testing, which complies with the national standard requirements for valve testing.

The equipment is broadly categorized into hydraulic pressure supply systems, electrical control systems, water circulation systems, and various operational devices.

The equipment features a horizontal卧式顶压 design, with each side of the workbench equipped with a sealed blind plate. The left workbench is fitted with a forward and reverse mechanism, directly driven by a hydraulic cylinder, ensuring uniform force on the valve sealing surface and reliable tightness. The right workbench is fixed, allowing for bidirectional water intake and drainage. The sealing disk is equipped with drainage and exhaust valves, facilitating the inspection of air-sealing tests and the 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 a nominal bore size that matches the equipment model, turn on the power, and start the hydraulic system. Move the left-hand cylinder back until it is longer than the valve being tested. Place the valve flange face tightly against the right-hand workbench test blind plate, aligning with the center opening. Advance the left-hand movable frame to the right-hand fixed workbench, with the other end of the valve being tested pressed against the left-hand test blind plate, aligning with the center opening. The valve is in a horizontal position overall.

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

After the valve mount is completed, refer to the "Clamping Cylinder Pressure Chart" 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 gauge pointer to 2.5 MPa). Open the main water intake, left and right 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 that the valve cavity is fully 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 release valve to relieve the water pressure inside the valve chamber, then remove the valve.

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

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

After the valve mounting is complete (for example, using compressed air, generally not exceeding 10 kg of pressure), open the water and air intake valves, and close the water and air release valves. Close the water and air intake valves when the pressure gauge reaches the maximum pressure, and the equipment is in a pressure-holding state.

Upon reaching the pressure-holding time, the valve has no issues. It should first be opened to release the pressure inside the valve chamber before removing the valve.

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 (use antifreeze 46-grade anti-wear hydraulic oil below 0℃), ensuring 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 rust inhibitor to the recirculating water; replace the water promptly when the water quality deteriorates.

4. The work surface of the equipment should be kept clean, and there should be no debris between the valve flange under test and the pressure test blind plate.

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

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