THREE60 Energy was engaged by an international valve manufacturer to design and build a bespoke high-pressure testing system for use at the client’s own facility.
The turnkey solution was developed to provide both hydrostatic and gas testing capability, allowing the client to independently test valves under pressures representative of their demanding operating environments.
Challenge
The client required the capability to conduct hydrostatic testing at pressures of up to 31,000 psi, alongside gas testing across a wide pressure range.
Rather than continuing to use external testing facilities, the client required a dedicated in-house solution capable of supporting efficient testing across multiple test pieces, with precise control over pressurisation and venting.
Solution
THREE60 engineered a bespoke high-pressure test unit with five independently controlled outlets, allowing pressure to be routed according to individual testing requirements.
The system incorporated Hydratron pumping and gas booster technology, providing hydrostatic pressure up to 31,000 psi and gas testing from 30 to 21,000 psi. Integrated pressure monitoring and an electrically actuated micro-metering valve enabled controlled gas vent-down, while a diaphragm pump supported rapid filling of test items.
All functions were connected to a Programmable Logic Controller (PLC), enabling remote operation via laptop or touchscreen, supported by visual pressure indication and accessible emergency shut-offs.
Result
The completed system provided the client with a turnkey, in-house hydrostatic and gas testing capability, reducing its reliance on external testing services.
Combining five independent test outlets with automated control and specialist high-pressure technology gave the client a flexible and efficient solution capable of supporting its ongoing valve qualification and testing requirements.
