The DYFJ-A1000 valve testing bench is the fourth-generation pressure testing and inspection equipment independently developed by Duojia Hydraulics, based on years of production experience and in accordance with national standards and specifications.

The DYFJ-A1000 valve testing bench integrates mechanical, 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 shell strength (pore) tests on various high, medium, and low-pressure valves with nominal diameters of 500-1000mm, 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 additional external force on valves that could affect test results. This significantly enhances work efficiency and reduces labor intensity, making it an ideal new pressure testing and inspection equipment for valve manufacturing companies, users, and maintenance units.

DYFJ-A1000 Type Valve Test Bench Working Principle and Structure

The DYFJ-A1000 type valve test bench operates by positioning the valve flange and clamping the back of the flange with a live paw, ensuring that no external forces affecting the test results are present during valve testing, in compliance with national standard valve testing requirements.

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 clamping design, with each side of the workbench sealed with a blind flange. The left workbench is equipped with an in/out function mechanism, directly driven by a hydraulic cylinder, ensuring even force distribution on the valve sealing surface for reliable tightness. (Left) The right workbench can be flipped 90 degrees for easy inspection of gas-tightness tests and observation of the valve sealing surface, boasting good performance and a simple, compact structure.

Operating 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 sliding frame 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 tightly against the left workbench test blind plate, aligning with the center opening. Radially move the clamp close to the valve flange, and axially move the clamp to ensure it snugly contacts the back of the valve flange. At this point, the valve should be securely held and fixed by the left clamping system, ensuring the valve does not fall off.

The sliding bracket moves from the left to the right fixed workbench, with the other end of the valve tightly sealed against the right pressure test blanking plate, aligned with the center opening. 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-side clamping system, with the valve overall in a horizontal position.

2. Water Pressure Testing Methods (Double-direction Inflow and Drainage)

After the valve clamp is installed, 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 pressure set on the electrical contact pressure gauge, and the equipment will enter the water pressure maintenance state.

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

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

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

After the valve fixture is completed (for example, using pressure air, generally not exceeding 10 kg), open the inlet and air inlet valves, and close the drain and air vent valves. Close the inlet and air inlet valves when the pressure gauge reaches the maximum pressure, and the equipment is in a pressure maintenance state.

Upon reaching the pressure-holding time, the valve shows no issues. First, open the vent valve to release the pressure inside the valve chamber, then remove the valve.

Handling Instructions and Requirements

1. Ensure the equipment is level during installation or use concrete to secure the foot slot steel.

2. Use 46-grade anti-wear hydraulic oil (for temperatures below 0°C, use antifreeze 46-grade anti-wear hydraulic oil). Ensure the oil level is not below the indicator. 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 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 test valve flange and the pressure test blank.

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

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