Details

         
1. Introduction
The CNG Circuit Leak Testing Machine is a sophisticated and mission-critical solution meticulously developed to address the challenges of high-pressure gas circuit testing in modern CNG-powered buses, especially those used by Volvo. In light of the transportation industry's shift towards cleaner fuels like compressed natural gas (CNG), this machine ensures that gas delivery systems meet stringent safety, efficiency, and environmental standards.
Built around the renowned Haskel air-driven booster technology, this system generates extreme pressures of up to 345 bar (5000 PSI) purely pneumatically—without any electrical dependency—making it ideal for deployment in explosion-prone or flammable gas environments. Its design incorporates modular components and space-saving architecture, enabling installation within compact maintenance bays, portable test rigs, or fixed stations in production and research facilities.

2. Applications
The machine's versatility lies in its ability to perform a broad range of tests and filling operations under varying pressure profiles. While it is tailored for leak testing and pressure validation in Volvo buses' CNG circuits, it also proves invaluable in diverse industrial and scientific use cases. Key applications include:
- Detection of micro and macro leaks in gas pipelines, regulators, valves, and fittings using calibrated pressure decay methods.
- Pressure endurance testing of flexible hoses and static gas assemblies under cyclic load conditions.
- Controlled high-pressure filling of gas cylinders for vehicle tanks or laboratory use.
- Testing with various gases, e.g., N2 for inert testing, H2 for emerging hydrogen fuel cell tech, He for ultra-fine leak detection, and O2 for medical and aerospace applications.
- Integration into OEM testing cells, third-party validation labs, or mobile service vans.
By accommodating these varied needs, the machine ensures regulatory compliance and equipment validation in R&D, production, and MRO (maintenance, repair, overhaul) environments.

3. Key Features
The system is packed with features that prioritize safety, ease of use, and high performance:
- Pressure Boosting up to 345 bar: Suitable for high-pressure endurance testing and certification protocols.
- Dual Booster Configuration: Primary and standby oxygen boosters ensure uninterrupted operations.
- Non-Electric Pneumatic Operation: Completely air-driven mechanism eliminates ignition risks in volatile areas.
- Ultra-Fine Filtration: Equipped with 5-micron inlet filters to safeguard the booster and enhance gas purity.
- Multiple Pressure Ranges: Operators can seamlessly switch between 10, 50, 100, and 200 kg/cm2 profiles.
- Manual and Stepped Pressurization: Enables progressive ramp-up of pressure to prevent damage to sensitive components.
- Space-Conscious Design: Engineered to occupy minimal real estate, ideal for mobile setups or integrated systems.
- Quick-Change Connectors: Reduces downtime during multiple testing cycles, improving shop floor productivity.

4. Technical Specifications

  

    

      
Specification
      
Detail & Functional Importance
    
  
  

    

      
Drive Pressure (Air)
      
Minimum 4 kg/cm² input ensures efficient booster operation
    
    

      
Drive Air Purity (2.0)
      
7 Micron filtering for general use
    
    

      
Drive Air Purity (6.0)
      
5 Micron filtering required for high-purity gases like O₂
    
    

      
Drive Flow Rate
      
60 SCFM (adjustable based on booster load profile)
    
    

      
Dew Point Temperature
      
−40 °C to prevent condensation and freezing
    
    

      
Inlet Nitrogen Pressure
      
17–150 kg/cm² standard range
    
    

      
Inlet Nitrogen Purity
      
5 Micron for clean operation and extended equipment life
    
    

      
Output Pressure Range
      
10, 50, 100, 200 kg/cm²—adjustable based on testing needs
    
    

      
Booster Max Pressure
      
345 bar—suitable for high-pressure applications
    
    

      
Medium Compatibility
      
Compatible with Air, N₂, He, O₂, H₂ (materials chosen accordingly)
    
  



5. Operating Procedure
To ensure a safe and effective test process, the machine must be operated following a clearly defined sequence:
1. Preparation: Inspect all connection points, check filters, and confirm availability of the drive air source (min 4 kg/cm2, -40°C dew point).
2. Inlet Gas Setup: Attach high-pressure gas cylinder (e.g., N2 or O2) and verify filter and regulator conditions.
3. Controlled Pressurization: Set desired output pressure using manual or stepped valves.
4. Test Execution: Monitor pressure hold, drop, or cycling per test specification; record data.
5. Safe Venting: After test completion, vent system gradually using built-in safety valves and disconnect components with caution.
The system’s built-in safety features, including relief valves and vent silencers, safeguard both equipment and operators from over-pressure incidents.

6. Maintenance
Designed for rugged industrial use, the machine has a low-maintenance footprint.
Nevertheless, the following best practices are recommended:
- Weekly: Visual inspection of all hoses, connectors, and valves; check for pressure stability.
- Monthly: Replace all air and gas filters; inspect O-rings and seals for wear.
- Annually: Conduct full calibration of gauges and pressure regulators; service Haskel booster as per OEM guidelines.
Because the system lacks complex electronics or motors, its service intervals are longer, making it highly reliable and cost-effective over its lifecycle.

7. Conclusion
In conclusion, the CNG Circuit Leak Testing Machine from Neometrix Defence Limited is more than a testing tool—it’s a strategic asset for ensuring safety, compliance, and performance in high-pressure gas systems. Designed to accommodate both current and future testing needs across multiple gases and industrial verticals, it empowers operators with precision control, robust safety features, and operational simplicity. Whether integrated into a production line, used in routine maintenance of public transport fleets, or deployed in cutting-edge R&D setups, this machine delivers reliable results with minimal operational costs, embodying a new benchmark in leak testing technology.