DYFJ-C1000 Type Valve Test Bench

The DYFJ-C1000 valve test bench is the fourth-generation pressure testing and inspection equipment developed by Duojia Hydraulic Co., Ltd. based on years of production experience and in accordance with national standards and specifications.

The DYFJ-C1000 valve test bench integrates mechanical and 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 testing and other performance tests, such as shell strength (pinhole) on various high, medium, and low-pressure valves with nominal bore sizes of 500-100mm and direct connection flanges. Test mediums: water, gas, oil.

The equipment is hydraulically driven and electrically controlled throughout the entire process, with no external forces affecting the valve 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-C1000 Type Valve Test Bench Working Principle and Structure

The DYFJ-C1000 type valve test bench operates by positioning the valve flange and clamping the back of the flange with movable claws, ensuring that no external forces that could affect the test results are present during valve testing, thereby meeting 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 operating devices.

The equipment features a diving double flip design, with each 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 even force distribution on the valve sealing surface and reliable tightness. Both left and right workbenches can be flipped 90 degrees, and the entire workbench surface can be submerged into the external water tank, allowing the tested valve to be fully immersed in water. This facilitates the inspection of gas-tightness tests and observation of the valve sealing surface. It boasts excellent performance and a simple, compact structure.

Technical Specifications

Operation Instructions

1. Valve Mounting Method

Select a valve with the nominal bore diameter corresponding to the equipment model, turn on the power, and start the hydraulic system. Move the left-hand carriage back to a position longer than the valve being tested. Radially move the adjustable clamp to exceed the outer diameter of the valve flange. Extend the clamp axially to exceed the thickness of the valve flange. Place the valve flange face against the left-hand workbench test blind plate, aligning with the center hole. Radially move the clamp close to the valve flange. Axially move the clamp to ensure the clamp is tightly against the back of the valve flange. At this point, the valve should be securely clamped and fixed by the left-hand clamping system, ensuring the valve does not fall off.

The left-hand movable bracket advances to the right-hand fixed workbench. The other end of the valve to be tested is tightly sealed against the right-hand pressure test blank flange, aligned with the center hole. Radially move the clamping jaws close to the valve flange. Axially move the clamping jaws to make the jaws tightly adhere to the back of the valve flange. At this point, the valve should be securely held and fixed by the right-hand clamping system, with the valve in an overall horizontal position.

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

After the valve fixture 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 inlet, left and right water inlet valves, close the air inlet, 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 pressure set on the electrical contact pressure gauge, and the equipment enters the water pressure holding state.

Upon reaching the pressure-holding time, the valve is free of any issues. First, open the water valve to relieve the pressure inside the valve chamber, and then remove the valve.

3. Pressure Testing Methods (Bidirectional Intake, Exhaust)

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

After the valve mount is completed (using pressure air as an example, the general pressure does not exceed 10 kg), open the inlet water and air valves, and close the drain water and air valves. Close the inlet water and air valves when the pressure gauge reaches the highest pressure, and the equipment is in a pressure maintenance 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 can be removed.

Handling Instructions and Requirements

1. Align the equipment horizontally during installation or secure the foot trough with concrete.

2. Choose 46-grade anti-wear hydraulic oil (use anti-freeze 46-grade anti-wear hydraulic oil below 0℃), ensuring oil level is not below the gauge's lower limit. Regularly check oil levels and hydraulic oil. After one year of use, clean the oil tank and replace the hydraulic oil.

3. Add rust-inhibiting powder to the recirculating water and change the water promptly when the water quality deteriorates.

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

5. Add lubricant to all moving parts of the test bench to maintain clean and smooth operation.

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