Cycle Test Equipment for Pressure Vessels
The cycle test device for tanks is designed to evaluate the performance, durability, and resistance of pressure vessels under fluctuating pressure conditions. This test is typically performed on compressed gas tanks (CNG, hydrogen, oxygen) and other industrial vessels subjected to continuous pressurization and depressurization cycles. It is a crucial tool in the automotive, oil and gas, and transportation industries. By applying repeated pressure cycles, the test determines the vessel’s strength and lifespan, ensuring its safety.
Applications of the Cycle Test Device
- Tank lifespan testing: Determines the number of cycles a tank can withstand without leakage or failure.
- Simulation of real conditions: Applies pressure cycles similar to actual working conditions to ensure tank safety.
- Quality control: Checks the quality of welding, raw materials, and tank design.
Operation of the Cycle Test Device
- Connecting the tank: The pressure vessel is attached to the cycle test device.
- Pressure application: The vessel is pressurized to a set level and then depressurized.
- Repeated cycling: The cycle is repeated thousands of times until the vessel fails or the required number of cycles is reached.
- Data analysis: Results are analyzed to assess strength and compliance with safety standards.
Objectives of Tank Cycle Testing
- Assess vessel lifespan: Determines how many pressure cycles a tank can endure without failure.
- Ensure safety and quality: Prevents cracking, leakage, or explosion during the tank’s service life.
- Simulate real-world conditions: Tests vessel performance under industrial or automotive usage scenarios.
- Compliance with standards: Meets international approvals such as ISO 11439, DOT, ECER 110, and other high-pressure vessel standards.
Cycle Test Procedure
a) Preparing the tank for testing
- Connect the high-pressure tank to the cycle test device.
- Install high-pressure fittings and sensors for temperature and pressure monitoring.
- Set the high and low pressure limits according to the defined standard.
b) Performing the pressure cycle test
- Place the vessel in a secure chamber to prevent hazards in case of failure.
- Increase pressure from the initial value (e.g., 0 bar) to the working pressure (e.g., 250 bar).
- Reduce pressure and repeat the cycle.
- This process can be repeated 50,000 to 100,000 times.
c) Evaluating test results
- Leakage or cracking: Test stops if the vessel leaks or cracks.
- Cycle count: Determines how many cycles the vessel withstands before failure.
- Data logging: Pressure, temperature, and vessel deformation are recorded for analysis.
Relevant Standards for Cycle Testing
- ISO 11439: For automotive CNG tanks.
- ECER 110: European standard for automotive CNG tanks.
- DOT (Department of Transportation): U.S. standard for high-pressure transport tanks.
- ISO 9809: For high-pressure seamless metal tanks.
Advantages of Cycle Test Equipment
- Enhanced safety: Ensures no leakage or rupture under real conditions.
- Improved production quality: Detects design or manufacturing flaws before release.
- Reduced maintenance costs: Prevents premature failure and industrial accidents.
- Extended tank lifespan: Evaluates long-term vessel performance.
Technical Features and Capabilities
- Precise automatic pressure control with programmable pressurization and depressurization.
- Pressure range: High-pressure testing up to 700 bar or more.
- Data recording and display:
- Digital and touchscreen interface.
- Records cycle count, pressure, and temperature changes.
- Data storage and export for analysis and reporting.
- Advanced safety systems:
- Pressure and temperature sensors for automatic shutdown.
- Secure test chamber to prevent hazards in case of explosion.
- Relief valves and emergency shut-off.
- Versatile vessel testing:
- Metal tanks (steel, aluminum).
- Composite tanks (CNG Type 3 & 4).
- Automotive, industrial, and medical tanks.
- Environmental simulation:
- Testing at varying temperatures.
- Option to apply mechanical vibration or shock during pressure cycles.
Software and Automation
- Remote monitoring and control software.
- Online observation of tests via computer or mobile device.
- Programmable number of cycles and test conditions.
- Data analysis and reporting.
- Integration with industrial production and testing lines.
- Digital and analog outputs for connection with other equipment.
After-Sales Service and Support
- Installation and training for operators.
- Initial commissioning and setup by the technical team.
- Warranty and repair services.
- Spare parts and performance guarantee.
- Technical support for software and hardware issues.
- Periodic calibration of sensors for higher accuracy.
- Software and hardware upgrades based on new requirements.
This company, leveraging years of valuable experience, provides diverse capabilities and features to meet the needs of various industries efficiently.