THREE60 Energy was engaged by an oil and gas OEM to design and manufacture a mobile hydrostatic test container and hydraulic power unit (HPU).
The bespoke system needed to provide flexible high-pressure testing capability for components of varying sizes, while creating a self-contained working environment suitable for both indoor and outdoor use.
Challenge
The client required hydrostatic testing at pressures of up to 22,500 psi, across up to four test lines that could be independently pressurised and vented.
The range of component sizes created an additional challenge. Smaller test pieces required precise pressure control, while larger components required higher flow rates for efficient testing. The complete system also needed to be mobile and provide technicians with a practical and safe working environment.
Solution
THREE60 designed an HPU incorporating two independently selectable pumps, providing fine pressure control for smaller components and high-volume pumping for larger test pieces.
The HPU was integrated into a customised offshore container featuring easy-clean internal surfaces, electrical connections, workspace and a viewing window. A camera system and wall-mounted screen were also incorporated to enable technicians to remotely monitor test pieces while under pressure.
Following manufacture, THREE60 supported installation and commissioning at the client’s facility and provided training to ensure operators understood the system and its controls.
Result
The completed system provided the client with a mobile, self-contained hydrostatic testing capability up to 22,500 psi, with four independently controlled test lines and the flexibility to accommodate different component sizes.
The combination of precision and high-volume pumping, remote monitoring and an integrated workspace provided a practical solution for ongoing testing requirements, with THREE60 continuing to support the equipment through maintenance and servicing.
