The DYFJ-E500 valve test 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 systems, 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 shell strength (pores) testing of various high, medium, and low-pressure valves with nominal diameters of 200-500mm, in the form of straight-through flanges. Test media: water, gas, oil.
The equipment is hydraulically driven and electrically controlled throughout the entire process, exerting no external force on the valves that could affect test results, significantly enhancing work efficiency and reducing labor intensity. It is an ideal new pressure testing and inspection equipment for valve manufacturing enterprises, users, and maintenance units.
DYFJ-E500 type valve test bench working principle and structure
The DYFJ-E500 valve test bench operates by positioning the valve flange and clamping the back of the flange with movable claws, ensuring no external forces that could affect the test results. It meets the national standard requirements for valve testing.
The equipment is roughly divided into hydraulic pressure supply systems, electrical control systems, water circulation systems, and various operating devices.
The equipment features a horizontal-laying top pressure design. Both workbenches are sealed with blind flanges, with the left workbench equipped with an in/out function mechanism, directly driven by a hydraulic cylinder for even force distribution on the valve sealing surface and reliable tightness. The right workbench is fixed, allowing for bidirectional water intake and drainage. The sealing disk is fitted with drainage and exhaust valves for convenient checks of the gas-tightness test and observations of the valve sealing surface, boasting good performance and a simple, compact structure.
Operation Instructions
1. Valve Mounting Method
Select a valve with the nominal bore size corresponding to 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, Drainage)
After the valve bracket is installed, 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 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 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 holding state.
Upon reaching the pressure-holding time, the valve is problem-free. First, open the water drain valve to release the pressure inside the valve cavity, then remove the valve.
3. Pressure Test Methods (Bi-directional Intake, Venting)
The equipment does not come with a gas supply. 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, typically not exceeding 10 kg), 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 highest pressure, and the equipment is in a pressure-holding state.
Upon reaching the pressure-holding time, there are no issues with the valve. First, open the vent valve to release the pressure inside the valve chamber, then remove the valve.
Handling Precautions and Requirements
1. Align the equipment horizontally during installation or secure the anchor slots 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, and replace it promptly when the water quality deteriorates.
4. The equipment worktop should be kept clean, and there should be no debris between the valve flange under test and the pressure test blind plate.
5. Add lubricant to all moving parts of the test bench to ensure clean and smooth operation.
6. Operators must undergo professional training before starting work, adhere to standardized procedures, and prioritize safety.
