Details

1. Introduction
The Neometrix Tube Pressurization Test Setup is a purpose-built, turnkey solution designed for rigorous validation of metallic tubes under combined high-pressure and high-temperature conditions. At its core, the system delivers hydrostatic pressures up to 250kgf/cm2 (≈ 245 bar) and maintains thermal environments up to 350 °C, enabling comprehensive endurance, burst, and fatigue testing of specimens up to 1,200 mm in length with outer diameters of 90.12 mm and wall thicknesses of 3 mm. This wide operating envelope makes it ideally suited for qualifying materials and tube assemblies in critical sectors—such as aerospace, power generation, oil & gas, and nuclear—where failure is not an option. Built around an air-driven Haskel intensifier pump and precision WIKA pressure instrumentation, the bench achieves smooth pressure ramping, stable dwell holds, and accurate burst profiling. Integrated PID-controlled heater blocks and thermocouple feedback ensure uniform temperature distribution and tight thermal tolerances. Together, these features replicate real-world service stresses in a controlled laboratory environment, providing engineers with actionable data on yield strength, creep behavior, and leakage performance before tubes are deployed in the field.Beyond its core capabilities, the system’s modular design and open 4–20 mA control loops offer seamless integration with external PLC or DAQ platforms (e.g., National Instruments LabVIEW, Chant DataTESTTM). Recipe management, automated safety interlocks, and high-speed data logging (≥ 10 Hz) streamline repeated test cycles and simplify compliance with standards such as ASTM A312/A213, EN 10216-2, and API 5L. With turnkey commissioning, operator training, and full calibration support included, Neometrix delivers not just a test bench, but a complete quality-assurance ecosystem—ready to adapt, expand, and evolve with your most
demanding R&D and production requirements.

2. System Components & Architecture
- Hydraulic Pressure Generation
- Haskel Air-Driven Intensifier Pump (Model MS-110): Smooth, controllable pressure ramps up to 250 kgf/cm2 with pneumatic fail-safe operation.
- Pressure Sensing: Dual WIKA analog gauges (0–16 bar auxiliary; 0–600 bar main) with ±0.5 % accuracy, plus a 4–20 mA transmitter for digital feedback.
- Valving Network: Stainless-steel ball valves, needle valves, and precision regulators (1⁄4′′BSP, ≥ 150 psi) for fine control of pressurization, hold, and safe venting.
- Thermal Management
- PID-Controlled Heater Blocks: Cartridge heaters in aluminum blocks deliver up to 350 °C, maintained within ±10 °C via K-type thermocouple feedback.
- Cooling Coil Assembly: Three SS-304 coils (6 m each) circulate coolant to protect seals and accelerate cooldown; thermostatic mixing valve prevents thermal shock.
- Safety & Enclosure
- Galvanized-Iron Safety Cage: Interlocked access panels, emergency-stop button, and an over-pressure relief valve set at 300 bar.
- Electrical Protection: Circuit breakers, surge suppressors, and heater-circuit fuses ensure CE/UL compliance.
- Control & Data Acquisition Interface
- Analog I/O: Four 4–20 mA loops (two pressure, two temperature) integrate with external DAQ/PLC systems (LabVIEW, DataTESTTM).
- Recipe Storage: Touchscreen HMI or PC software stores user-definable test profiles (ramp rates, dwell times, alarm thresholds).

Key Features
- Accurate Pressure Profiling: Smooth ramp rates up to 10 bar/min, stable dwell holds, and ±0.5 % gauge accuracy allow precise proof and burst testing.
- Precise Thermal Control: PID-controlled heaters provide uniform temperature distribution, with ±10 °C stability at setpoints up to 350 °C.
- Robust Safety Systems: Interlocked safety cage, over-pressure relief valve, emergency-stop, and automatic shutdown on parameter deviations ensure operator protection.
- Modular Design: Quick-disconnect fittings and standardized interfaces simplify component swaps, system reconfiguration, and future upgrades.
- Data Acquisition Ready: 4–20 mA loops, optional LVDTs, and high-speed logging (≥ 10 Hz) integrate with LabVIEW or DataTESTTM for turnkey reporting.
- Multi-Test Capability: Supports hydrostatic, burst, cyclic fatigue, and helium leak detection modes on the same platform.

Technical Specifications

  

    

      
Parameter
      
Value
    
  
  

    

      
Maximum Pressure
      
250 kgf/cm² (≈ 245 bar)
    
    

      
Temperature Range
      
Ambient to 350 °C
    
    

      
Test Tube Outer Diameter (OD)
      
90.12 mm (f8 tolerance)
    
    

      
Test Tube Wall Thickness
      
3 mm
    
    

      
Test Tube Length
      
1,200 mm
    
    

      
Oil Reservoir Capacity
      
10 L SS-304
    
    

      
Hydraulic Pump Model
      
Haskel MS-110
    
    

      
Pressure Gauge Ranges
      
0–16 bar auxiliary; 0–600 bar main
    
    

      
Temperature Controller Accuracy
      
±10 °C
    
    

      
Heater Power
      
3 kW (typical)
    
    

      
Cooling Coil
      
3 × 6 m SS-304
    
    

      
Safety Relief Valve Setpoint
      
300 bar
    
    

      
Electrical Supply
      
415 VAC, 50 Hz, 3-phase
    
    

      
Compressed Air Requirement
      
6 bar, oil-free
    
  


3. Operating Principle & Workflow
3.1. Specimen Mounting: Secure the test tube between insulated heater blocks and pressure-sealing end-fittings; verify thermocouple placement at mid-span.
3.2. System Checkout: Fill the SS-304 oil reservoir; inspect fittings; confirm cooling-water flow; test interlock status.
3.3. Pressure Ramp-Up: Evacuate air via bleed valves, then engage the Haskel pump to ramp at a programmable rate (e.g., 10 bar/min) to the setpoint.
3.4. Thermal Ramp & Dwell: Activate PID control to reach up to 350 °C; hold pressure and temperature for the specified duration (commonly 30 min).
3.5. Monitoring & Alarm Handling: Log pressure, temperature, and optional displacement (via LVDT) at ≥ 10 Hz; automatic alarms pause or abort tests on deviations.
3.6. Controlled Shutdown: Power down heaters, slowly vent pressure to avoid hydraulic shock, allow cooldown to < 50 °C, then disassemble.

4. Standards Compliance & Test Modes
- Compliance Standards:
- ASTM A312/A213: Proof-test seamless and welded stainless-steel tubes at 1.25× MAOP.
- EN 10216-2: Steel tubes for pressure applications.
- API 5L: Line-pipe hydrostatic test to 1.25× MAOP with permanent set limits.
- Test Variants:
- Hydrostatic Proof Test: Static pressurization to verify no leaks or permanent deformation.
- Burst Test: Ramp until failure, capturing burst pressure and fracture mode.
- Cyclic Fatigue Test: Automated cycling (± 10 % of MAOP at up to 1 Hz) to assess fatigue life.
- Helium Leak Detection (Optional): Mass-spectrometer integration for sensitivity < 10−5 mbar·L/s.

5. Advanced Automation & Reporting
- Recipe Management: Store and recall multiple profiles with per-step ramp rates, dwell times, and alarm criteria—ideal for production sampling and R&D studies.
- Real-Time Data Acquisition: High-speed logging (≥ 10 Hz) of all analog inputs; configurable alarm setpoints trigger interlocks or HMI alerts.
- Reporting & Traceability: Generate standardized PDF/CSV reports with time-stamped data, calibration certificates, and operator notes; export directly from HMI or PC.

6. Installation, Calibration & Support
- Site Requirements:
- Electrical: 415 VAC ±10 %, 50 Hz, 3-phase, 20 A breaker.
- Utilities: 6 bar dry, oil-free compressed air; cooling-water inlet/outlet; gravity drain.
- Factory Acceptance Test (FAT): Pre-shipment validation against client protocols for pressure, temperature, control logic, and safety interlocks.
- On-Site Commissioning: Installation by Neometrix engineers, instrument calibration, and operator training covering operation, safety, and maintenance.
- Maintenance & Calibration: Annual calibration of gauges/transmitters; quarterly inspection of seals, O-rings, and heater cartridges. Spare kits ensure < 24h downtime.

7. Customization & Future Upgrades
- Higher-Pressure Intensifiers: Upgrade to 400–600 bar capability for high-strength alloys.
- Extended-Range Heating: Inert-gas-purged ceramic heaters up to 500 °C for oxidation-sensitive materials.
- Multi-Specimen Fixtures: Rotary or manifold designs allow sequential testing of up to four tubes without teardown, boosting QA throughput.

8. Applications
- Aerospace & Defense: Qualification of hydraulic and fuel-line tubes under flight-cycle pressures and temperatures.
- Power Generation & Oil & Gas: Creep and burst testing for steam-generator tubing, subsea pipelines, and high-pressure process lines.
- Nuclear & Research: R&D of new alloy compositions and geometries, plus compliance testing to RCC-M and ASME BPVC.

9. Conclusion
The Neometrix Tube Pressurization Test Setup delivers end-to-end capability—from precise pressure and temperature control through automated data acquisition and reporting—within a modular, safety-certified platform. Compliant with all major international standards and easily upgradable, it provides engineers and QA teams the confidence and flexibility needed for material qualification, R&D exploration, and production validation in today’s most demanding applications. Future-proof your testing infrastructure with Neometrix’s comprehensive solution, designed to evolve alongside your technical challenges.