Details

The 1000 Bar Hydraulic Proof Pressure Test Bench is a high-precision testing machine designed to assess the structural integrity of nitrogen (N₂) bottles under extreme static pressure conditions. It operates by filling the test bottle with Servo 636 hydraulic oil and pressurizing it up to 1000 bar using a Rexroth high-pressure pump and Haskel air booster, ensuring reliability in high-pressure applications such as aerospace, defense, and industrial gas storage. The system features automatic and manual testing modes, a Data Acquisition (DAQ) system for real-time pressure monitoring, and LabView interface integration for automated report generation. With built-in safety mechanisms, including secure chamber locking, pressure venting, and emergency shutdown features, this test bench guarantees accurate, safe, and efficient pressure testing for critical industrial applications.

Technical Specifications and Key Features
The test bench is built with high-performance hydraulic and pneumatic components to ensure accuracy, reliability, and safety during testing.

The system operates with a 100-liter SS304 stainless steel tank that serves as the hydraulic oil reservoir. The test is conducted using Servo 636 oil, which has been selected for its stability under extreme pressure conditions. The hydraulic system is powered by an ABB electric motor coupled with a Rexroth high-pressure pump, which delivers a flow rate of 6 liters per minute (LPM) to fill the test bottle efficiently.

To control and regulate the pressure, the system is equipped with BUTECH needle valves, which are used to isolate and vent pressure when required. The nitrogen bottle is securely mounted inside the test chamber, which is designed to withstand 1000 bar pressure. The bottle is connected to a manifold, ensuring that pressure is evenly distributed.

For pressurization, a dedicated air supply line is provided, utilizing a Haskel booster to increase air pressure as needed. The system includes FESTO pressure regulators and drive valves, which allow for precise control over airflow during manual operation. During automatic testing, a solenoid valve is used to regulate the ON/OFF condition of the air booster, allowing for seamless operation.

The test bench also incorporates a temperature gauge, filler breather, and high-efficiency filters to maintain optimal hydraulic system performance. The control system includes a Variable Frequency Drive (VFD) panel, which ensures smooth operation and allows for better energy efficiency.

Working Principle and Procedure
The proof pressure test bench operates by filling the nitrogen bottle with hydraulic oil and subjecting it to 1000 bar static pressure. This process ensures that the bottle is structurally sound and capable of maintaining high-pressure conditions without failure.

Automatic Testing Procedure
The automatic testing process begins with system initialization. The operator first switches on the main supply from the VFD panel, ensuring that the emergency stop is turned off. The UPS and industrial computer are then switched on, and the user logs into the LabView interface, which provides a digital platform for monitoring and executing the test.

The operator navigates to the Proof Pressure Test Mode and enters the necessary details, including the unit part number, model number, and test pressure. The system verifies that all necessary valves, such as the vent valve, isolation valve, and drive valve, are open before proceeding.

Once the test parameters are set, the bottle filling time is determined, and the filling and venting process is initiated. The test chamber is gradually filled with hydraulic oil while maintaining strict control over the pressure buildup. After filling is completed, the operator confirms that all valves are properly closed before entering the test duration.

Pressurization begins with the click of a button, and the system automatically regulates the 1000 bar pressure using the hydraulic pump and air booster. The Data Acquisition (DAQ) system continuously monitors the pressure and generates a real-time pressure graph and test report.

Once the test is completed, the system safely vents the pressure inside the bottle through the release valve. The air supply is shut off via the ball valve, and the test bottle is carefully removed from the chamber. The test report and graph are stored in the system, which can be accessed later from the STATIC Report Section on the desktop.

Manual Testing Procedure
The manual testing process follows similar steps but requires direct operator intervention at key stages.

After the initial installation of the test bottle in the chamber, the operator starts the ABB motor, which begins filling the bottle with hydraulic oil. The filling process takes approximately two minutes. Once the bottle is filled, the vent and isolation valves are manually closed.

Next, the drive valve is turned on to activate the air booster, increasing the pressure inside the test chamber. The operator monitors the pressure gauge until the value reaches 1000 bar, ensuring that the bottle maintains pressure without any drop.

Once the required pressure is achieved, the drive valve is closed, and the system is observed for any changes in pressure that could indicate a leakage or structural weakness. After completing the test, the pressure is released through the vent valve, and the bottle is carefully removed from the test chamber. It is essential to ensure that the bottle’s threads remain undamaged during the removal process.

Safety Instructions
To ensure safe operation of the 1000 Bar Hydraulic Proof Pressure Test Bench, the following safety measures must be strictly followed:

 • The main ball valve at the booster inlet must always be turned ON to prevent damage to the booster from dry running.
 • The pressure regulator settings must not be altered without proper supervision. The regulator pressure should never exceed 5.2 bar.
 • Before testing, the test bottle must be securely tightened, along with the adapters, to avoid leakage.
 • The safety chamber must be properly closed before initiating the test to prevent accidents.
 • The hydraulic oil level should always be checked before operation. In automatic mode, a level switch will shut down the system if oil levels are insufficient.
 • During the filling process, the vent valve and isolation valve must be open to allow smooth flow of hydraulic oil.
 • After the test, the vent valve must be opened to safely release pressure before removing the test bottle.
 • The motor rotation direction must be checked to ensure it follows the correct signage.
 • Once an automatic test begins, operators must maintain a safe distance from the test bench.
 • The pressure should never be increased beyond the system’s limit to avoid equipment failure or hazards.
 • In case of an electrical short circuit, the main supply to the test bench must be cut off immediately from the VFD panel.
 • Proper earthing must be ensured to prevent electrical hazards.
 • Maintenance and Troubleshooting
 • To ensure consistent performance and longevity of the 1000 Bar Hydraulic Proof Pressure Test Bench, regular maintenance and troubleshooting should be performed.

If the power pack supply does not turn ON, the main supply should be checked, along with internal panel connections. If the motor does not start from the DAQ panel, it is essential to verify that the Local/DAQ knob is set to DAQ mode.

If the pump is not generating pressure, the operator should confirm that the pressure regulator setting is correct and make necessary adjustments. In cases where analog input is not being registered by the DAQ system, the MCB switch on the DAQ panel should be checked to ensure it is turned ON.

If flow is not detected in the flowmeter, the operator should confirm that both loading valves are properly engaged. In case of a clogged filter, the filter code should be checked, and a replacement filter should be arranged through Neometrix. Operating the test bench with a clogged filter can cause permanent damage to the servo valve.

If there is leakage from fittings or hose connections, the fittings should be tightened, and hoses should be inspected for any signs of wear or damage.

Conclusion
The 1000 Bar Hydraulic Proof Pressure Test Bench is a highly specialized, precision-engineered system designed for high-pressure testing of nitrogen bottles. Equipped with automated data acquisition, real-time pressure monitoring, and comprehensive safety features, this test bench ensures accuracy, reliability, and compliance with industry standards. Its dual-mode operation (automatic and manual) makes it a versatile testing solution for aerospace, defense, and industrial applications where extreme pressure conditions must be verified.