Details
The Marine Pipe Pressure Test System – Hydro & Pneumatic is a dual-mode, precision-engineered testing rig developed to verify the mechanical strength, sealing integrity, and pressure endurance of critical piping components used in marine and submarine environments. It is designed to qualify pipes and fittings before deployment in high-risk applications such as submarines, naval ships, offshore structures, and underwater energy systems. This test system supports both hydraulic and pneumatic testing regimes, offering a complete validation platform for a wide range of metallic pipe assemblies and fittings. It ensures reliable performance under static and dynamic pressure conditions, simulating the most demanding operational environments. Functional Overview Hydraulic Testing Module The hydraulic testing module uses deionized water as the working fluid and is capable of generating pressures from 50 Bar to 600 Bar. It operates through a high-ratio pneumatic pump that converts low-pressure air into high-pressure hydraulic force. The system applies pressure incrementally in defined stages, holding each level for a set duration to assess the material’s resistance to burst and deformation. The hydraulic module is suited for simulating long-duration static pressure conditions typical in deep-sea operations. Pneumatic Testing Module The pneumatic testing module uses compressed air to simulate pressurization scenarios in gaseous environments. It can generate air pressure up to 400 Bar, using either a built-in compressor or a high-pressure cylinder bank. Pneumatic testing is performed to detect leakage, joint integrity, and structural behavior under fluctuating or peak air pressures. This mode is especially critical for ensuring the performance of fittings such as tees, elbows, and connectors used in high-integrity marine systems. Testing Sequences Hydraulic Testing Sequence The hydraulic testing process involves a controlled pressure ramp-up in multiple stages: 50 Bar, 100 Bar, 150 Bar, 200 Bar, 250 Bar, 300 Bar, 400 Bar, and 600 Bar. Each intermediate pressure is held for approximately two minutes, and the maximum pressure of 600 Bar is maintained for ten minutes. These conditions replicate the extreme operating environments that submarine and marine components are expected to withstand. Pneumatic Testing Programs The system provides three standard pneumatic testing programs that can be customized as needed: • Program 1 includes testing at 20 Bar, 100 Bar, and 150 Bar, with the final stage held for ten minutes. • Program 2 includes testing at 20 Bar, 100 Bar, 150 Bar, and 200 Bar, with the 200 Bar stage held for ten minutes. • Program 3 includes testing at 20 Bar, 100 Bar, 150 Bar, 200 Bar, 300 Bar, and 400 Bar. The final 400 Bar stage is held for ten minutes, and the others are held for two minutes each. All programs are configurable through the automated test interface. Modes of Operation Automatic Mode • Operated via a dedicated PC-based Data Acquisition System (DAS). • Allows selection of test type, pressure levels, duration, and sequencing. • Real-time monitoring of pressure sensors, safety systems, and chamber status. • Digital logging of test data for traceability, certification, and reporting. • Remote video monitoring of the testing chamber during active testing. • Includes interlocks, threshold alarms, and automatic shutdown routines for safety. Manual Mode • Controlled through front-panel toggle switches, potentiometers, and analog gauges. • Ideal for R&D trials, prototyping, and custom component testing. • Allows operator discretion and direct interaction with pressure stages and timing. • Includes safety features such as interlocks, manual emergency stop, and redundant monitoring. Cylinder Filling and Nitrogen Purging The integrated air compressor fills high-pressure air banks up to 400 Bar. Once the preset pressure is reached, the compressor automatically shuts off. Relief valves set at 410 Bar protect the system against overpressurization. Nitrogen purging is used to remove contaminants and moisture from internal lines before and after pneumatic testing. The system utilizes two nitrogen banks at 150 Bar. Controlled purging ensures the accuracy of pneumatic tests and extends the service life of valves and sensors. Exhaust gases are safely released through silencers to minimize acoustic impact. Safety Features • Electrically interlocked rolling gate ensures testing cannot commence unless the chamber is sealed. • Pressure relief valves are calibrated and preset at 410 Bar for both hydraulic and pneumatic circuits. • Emergency vent valves allow rapid depressurization in case of fault detection. • Emergency stop buttons are positioned at key operator stations. • Redundant pressure monitoring through digital transmitters and analog gauges. • All test fixtures and hoses are rated well above maximum operating pressures for added security. • Live chamber video monitoring ensures testing personnel remain outside during active pressurization. Technical Specifications • Hydraulic testing pressure range: 50 Bar to 600 Bar • Pneumatic testing pressure range: 20 Bar to 400 Bar • Hydraulic medium: Deionized or filtered water • Pneumatic medium: Clean, dry compressed air • Hydraulic flow rate: Approximately 40 CFM • Pneumatic flow rate: Approximately 80 CFM • Ambient operating temperature range: 25°C to 45°C • Drive air pressure required (for hydraulic operation): 8 to 10 Bar • Pressure regulation: Manual potentiometer or electronic controller, depending on mode • Pressure sensing: High-accuracy digital transmitters and analog glycerin-filled gauges • Pressure relief threshold: 410 Bar (for both hydraulic and pneumatic circuits) • Component compatibility: Pipes, flanges, elbows, tees, reducers, threaded and flanged connectors • Modes of operation: Fully automatic via PC (DAS), and manual via control panel • Data logging and traceability: Enabled via PC software with historical test records • Nitrogen purge pressure: 150 Bar • Cylinder bank maximum fill pressure: 400 Bar • Safety systems: Gate interlock, relief valves, vent silencers, emergency stops, redundant monitoring • Venting: Silenced exhaust via noise-reducing outlet systems • Monitoring: Integrated CCTV for remote chamber observation Core Components and Features • High-pressure pneumatic pumps from Haskel, USA, delivering efficient conversion of drive air to test pressure. • Pressure transmitters interfaced with the DAS to provide accurate and real-time data. • Glycerin-filled mechanical gauges for local monitoring and secondary verification. • Precision needle valves and ball valves for manual control of pressurization and venting. • Solenoid-operated valves for automated sequencing and safety control. • Check valves to prevent backflow during dynamic pressurization cycles. • Strainers and suction filters to protect pumps and flow circuits from debris or cavitation. • Fluid level indicators and low-level switches to ensure safe operation of pumps and prevent dry runs. • Modular test fixtures to accommodate pipes and fittings of varying sizes and standards. • Silenced venting systems to mitigate noise during air exhaust and nitrogen purging. Compliance and Standards The Marine Pipe Pressure Test System – Hydro & Pneumatic is designed and manufactured in accordance with global engineering and safety standards, including: • ASME Boiler and Pressure Vessel Code (BPVC) for high-pressure systems • ISO 9001 for quality management • ISO 45001 for occupational health and safety management • ISO 14001 for environmental management compliance • Pressure Equipment Directive (PED) and EN 13445 for European market applicability • Defense and military standard compatibility as per MIL-STD guidelines (as required)
