DYFJ-C800 Type Valve Test Bench

The DYFJ-C800 type valve testing bench is the fourth generation valve pressure testing equipment independently developed by Duojia Hydraulics on the basis of many years of production experience, in accordance with national standards and specifications.

The DYFJ-C800 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 levels of 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 400-800mm, in the form of straight-through flanges. Test mediums: water, gas, oil.

The equipment is hydraulically driven and electrically controlled throughout the 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 generation pressure testing and inspection equipment for valve manufacturing companies, users, and maintenance units.

DYFJ-C800 type valve test bench working principle and structure

The DYFJ-C800 valve test bench operates by positioning the valve flange and clamping the back of the flange with a live paw, ensuring no external forces affect the test results during valve testing, in compliance with 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 diving double flip design, with each workbench (left and right) sealed with a blind plate. The left workbench is equipped with an in/out mechanism, directly driven by a hydraulic cylinder, ensuring even force distribution on the valve sealing surface and reliable clamping. Both left and right workbenches can be flipped 90 degrees, allowing the entire workbench surface to submerge into the external water tank, fully immersing the tested valve. This facilitates the inspection of gas-tightness tests and observation of the valve sealing surface. It boasts good performance and a simple, compact structure.

Technical Specifications

Operation Instructions

1. Valve Mounting Method

Select a valve with the nominal pipe size corresponding to the equipment model, turn on the power, and start the hydraulic system. Move the left carriage back to a position longer than the valve being tested. Radially move the actuating clamp to a diameter larger than the法兰outer diameter of the valve being tested. 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. 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 clamping system, ensuring the valve will not fall off.

The sliding bracket moves from the left to the right fixed workbench, with the other end of the valve being tightly sealed against the right test blind flange, aligned with the center opening. Radially move the clamping jaws close to the valve flange, and axially move the jaws to ensure they are flush against the back of the valve flange. At this point, the valve should be securely held by the right-side clamping system, with the valve as a whole in a horizontal position.

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

After the valve clamp is installed, refer to the "Clamping Cylinder Pressure Comparison 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 needle to 2.5 MPa). Open the main water inlets, left and right water inlets, close the air intake, drain, and vent valves. Start the low-pressure water pump, observe the movement of the water pressure gauge needle. When the needle stops rising, it indicates that the valve cavity is fully filled with water. Start the high-pressure water pump; the high-pressure water pump automatically stops when the water pressure reaches the set pressure on the electrical contact pressure gauge. The equipment enters a water pressure maintenance state.

Upon reaching the pressure-holding time, the valve is free of any issues. It should first be opened to release the water pressure within the valve chamber, then remove the valve.

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

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 fixture is completed (for example, using pressurized air, generally 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 maintenance state.

Upon reaching the pressure-holding time, the valve has no issues. It is recommended to first open the vent valve to release the pressure inside the valve chamber, then remove the valve.

Handling Instructions and Requirements

1. Align the equipment horizontally during installation or secure the foot slot 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 oil 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-inhibiting powder to the recirculating water, and replace it promptly when the water quality degrades.

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 ensure clean and smooth operation.

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