CNG High Pressure Regulator Test Bench

CNG Regulator Test Benches – High-Pressure Validation and QA Solutions The CNG Regulator Test Bench is engineered for precise testing, calibration, and certification of high-pressure compressed natural gas regulators. Designed for automotive, industrial, and laboratory applications, it supports CNG pressure regulator testing, endurance evaluation, and leak detection to ensure safe and reliable performance. Core capabilities include high-pressure regulator testing, PLC-controlled CNG test benches, mobile CNG test rigs, and ISO 15500-compliant regulator testers. Advanced setups accommodate 300 bar CNG testing, stainless steel reservoir evaluation, and regulator cycle testing, providing repeatable and fully documented validation. Additional features include gas booster test benches, precision leak testers, regulator performance testing, and lifecycle and fatigue evaluation. On-site and laboratory solutions support regulator calibration, certification testing, and full CNG equipment QA operations. The CNG Regulator Test Bench ensures high-precision, safety-compliant, and efficient testing for automotive regulators, industrial gas systems, and research laboratories, combining modular design, high-pressure capability, and automated validation for reliable and repeatable results

About

The CNG High-Pressure Regulator Test Bench is a mobile, PLC-controlled system designed for rigorous endurance and leak testing of CNG pressure regulators. It features a 6 L, 300 bar stainless-steel reservoir and a high-precision booster that cycles regulators through up to 50,000 pressurization/depressurization loops (10–260 bar, expandable to 310 bar) per ISO 15500-9:2001(E), while monitoring leaks down to 15 cm3/hr. An intuitive touchscreen HMI and scheduling software enable repeatable, data-rich testing with real-time pressure curves, CSV/PDF exports, and LIMS integration. Robust safety measures—including dual- channel interlocks, emergency stops, and guarded enclosures—ensure operator protection at pressures up to 330 bar. Quick-release fixtures, lockable-wheel mobility, and optional environmental conditioning make the bench ideal for OEM QA, R&D validation, certification labs, and field service operations.

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Technical Details

Specifications

• Drive Air Supply: ≥ 5 bar, 50 CFM; 5 μm filtration; dew point –40 °C
• Booster Model: Haskel AG-15/75; inlet ≥ 100 psi; outlet to 15,000 psi
• Inlet Pressure Range: 10–260 bar (auto) / up to 310 bar (manual)
• Leak Detection Threshold: ≤ 15 cm3/hr
• Cycling Speed: Up to 60 cycles/min under PLC control
• Temperature Range: –20 °C to +50 °C (with optional thermal chamber)
• Reservoir Capacity: 6 L SS @ 300 bar
• Data Acquisition: 16-bit ADC; 100 Hz sampling; networked export
• Software Compatibility: LIMS, OPC UA, CSV, PDF

Applications

• OEM Production & End-of-Line QA: Rapid certification of CNG regulators with LED pass/fail feedback.
• R&D & Design Validation: Life-cycle testing at accelerated rates uncovers wear patterns.
• Certification & Compliance: Complements labs for type-approval under local standards (e.g., ECE R110, CSA B149.1).
• Field Service Centers: Portable bench enables on-site testing and recalibration, reducing vehicle downtime.

FAQ

Details

Introduction & Industry Context
Modern CNG regulators must endure thousands of actuation cycles while guaranteeing zero unacceptable leakage. The CNG High-Pressure Regulator Test Bench meets this challenge head-on by combining a 6 L, 300 bar stainless-steel reservoir, a high-precision gas booster, and PLC-driven cycling to execute up to 50,000 full-pressure cycles per ISO 15500-9:2001(E) (≤ 15 cm3/hr leak threshold). Its ±0.25 % FS digital pressure indicator with bi-color LED pass/fail feedback ensures immediate quality assessment on every cycle.

Key Benefits & Advanced Features
1. Superior Accuracy & Traceability: ±0.25 % FS digital pressure indicator with tare, peak-hold, and multi-unit support.
2. Robust Endurance Testing: Up to 60 cycles/minute under automated PLC control simulates real-world regulator fatigue.
3. Integrated Safety Mechanisms: Dual-channel interlocks, emergency-stop buttons, and relief valves protect at pressures up to 330 bar.
4. Environmental Conditioning: Optional heat-exchanger module conditions gas via engine coolant, minimizing thermal shock.
5. Data-Rich Reporting: Network-ready CSV/PDF exports, LIMS integration, and on-demand printed reports for full traceability.
6. Modular, Mobile Design: Lockable-wheel chassis and quick-release fixturing allow rapid changeover between regulator types.

Enhanced Technical Specifications
• Drive Air Supply: ≥ 5 bar, 50 CFM; 5 μm filtration; dew point –40 °C
• Booster Model: Haskel AG-15/75; inlet ≥ 100 psi; outlet to 15,000 psi
• Inlet Pressure Range: 10–260 bar (auto) / up to 310 bar (manual)
• Leak Detection Threshold: ≤ 15 cm3/hr
• Cycling Speed: Up to 60 cycles/min under PLC control
• Temperature Range: –20 °C to +50 °C (with optional thermal chamber)
• Reservoir Capacity: 6 L SS @ 300 bar
• Data Acquisition: 16-bit ADC; 100 Hz sampling; networked export
• Software Compatibility: LIMS, OPC UA, CSV, PDF

Expanded Applications
• OEM Production & End-of-Line QA: Rapid certification of CNG regulators with LED pass/fail feedback.
• R&D & Design Validation: Life-cycle testing at accelerated rates uncovers wear patterns.
• Certification & Compliance: Complements labs for type-approval under local standards (e.g., ECE R110, CSA B149.1).
• Field Service Centers: Portable bench enables on-site testing and recalibration, reducing vehicle downtime.

Principle of Operation (Deep Dive)
1. Gas Conditioning & Pressurization: Supply air dehumidified to –40 °C dew point, filtered to 5 μm, then routed to the Haskel booster to raise pressure < 1% overshoot.
2. Leak Test & Decay Analysis: Inlet valves isolate the UUT; pressure decay recorded at 100Hz; >15 cm3/hr triggers abort.
3. Controlled Depressurization: PLC modulates exhaust valves to vent the UUT in a user-defined profile.
4. Automated Cycling Logic: Customizable dwell times and pressure ramps replicate service conditions; auto-tuning algorithms optimize test duration.

Maintenance, Calibration & Support
• Predictive Maintenance Alerts: On-screen diagnostics forecast service needs by monitoring booster oil quality, valve counts, and filter differential.
• Traceable Calibration: Bi-annual calibration kits with ISO 17025 traceability ensure ±0.25% FS accuracy.
• Global Service Network: Field engineers in Asia, Europe, and North America provide on-site calibration, spare parts, and training.

Safety & Compliance
• ISO 15500-9:2001(E) Compliance: Meets regulator endurance testing standards.
• Dual-Channel Interlocks: Prevent over-pressure events; emergency-stop buttons on all sides.
• CE & PED-Ready: Designed for quick CE marking and Pressure Equipment Directive compliance.
• Operator Protection: Polycarbonate guards and clear safety signage throughout.

Conclusion & Value Proposition
By integrating industry-leading accuracy, robust endurance cycling, advanced safety interlocks, and data-centric reporting, the CNG High-Pressure Regulator Test Bench elevates regulator validation to meet stringent safety and emissions regulations. Its modular, mobile architecture and optional environmental conditioning make it equally adept for R&D labs, OEM production lines, and field service operations—delivering reliable, repeatable, and fully traceable testing that drives product quality and efficiency.