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Hydrostatic Pressure Testing Equipment
What Is Hydrostatic Testing?
Hydrostatic testing, or a hydrotest, is the process of testing piping systems, pressure vessels, gas cylinders, fuel tanks, and boilers for leaks. The test involves filling the system with a test liquid, usually water, and raising the pressure to a desired level. Test operators then monitor the system for measurable or visible leaks during the specified test period.
Hydrotesting is an important process that helps analyze a pressurized system’s integrity. It plays a critical role in identifying faulty equipment and preventing potentially dangerous consequences for people and infrastructure in the surrounding environment. Learn more about hydrostatic testing, key considerations, and the hydrotesting equipment we offer at MAXPRO® Technologies.
When Is Hydrostatic Pressure Testing Required?
Hydrostatic pressure testing is a mandatory requirement to ensure compliance with the ASME B31 Pressure Piping Code and Department of Transportation (DOT) standards. Compliance with these regulations helps to ensure worker safety and avoid legal sanctions and liabilities.
Below is an overview of regulatory timelines for hydrostatic pressure testing for different systems.
Fire Extinguisher Systems
For dry chemical fire extinguishers, hydrostatic pressure testing should be done every 12 years. Carbon dioxide, pressurized water, and wet chemical fire extinguishers require more frequent testing—every five years.
For pipeline systems, federal regulations require a hydrostatic test before any operation commences. Routine water pressure testing may be conducted once per year, or more frequently if leaks are suspected.
The DOT requires hydrostatic testing for cylinders every three, five, or 10 years depending on age, material type, cylinder content, and any special permits from the manufacturer.
Boilers and Heat Exchangers
Hydrostatic pressure testing for boilers and heat exchange units involves filling the system with water and pressurizing it to one and a half times the MAWP for a short period of time. If there are any leaks, the boiler cannot be used for routine use. This test ensures that the system can tolerate the high pressures and temperatures required during operation.
Considerations for Your Hydrostatic Pressure Testing Application
The following are important things to consider when selecting hydrostatic test equipment.
Hydrostatic testing involves two types of pressure: initial pressure and testing pressure. The initial pressure is the pressure after the test specimen is prefilled. The testing pressure is the required pressure the specimen is raised to for testing.
Your choice of hydrostatic test equipment should be able to handle the frequency of tests required, whether it’s daily, weekly, monthly, or yearly.
Flow Rate Required or Volume of the Specimen to Be Tested
You’ll need to know the flow rate required for the test or the volume of the specimen that requires testing. This will allow you to select properly sized testing equipment.
It’s also important to know how much time is available for the test to reach the desired pressure. Economic option: A smaller pump can be specified if time to pressurize is not critical.
Also decide on the type of driver preferred, such as engine, electric motor, power take-off or pneumatic.
Our Hydrostatic Pressure Testing Equipment
At MAXPRO® Technologies, we provide the following high-quality hydrostatic pressure testing equipment.
- MAXPRO® PowerCube: Designed for on-the-spot, accurate hydrostatic testing, the MAXPRO® PowerCube features large dual pumps, high flow, and an intuitive control panel, all in a compact stainless steel design.
- MAXPRO® Two-Wheeled Test Carts: Portable test carts are crucial for oilfield environments. We offer multiple test cart arrangements depending on your testing needs and applications.
- MAXPRO® Hydrostatic Power Packs: With a lightweight, portable, and self-contained design, our power packs are cost-effective hydraulic power options suitable for elevating pressures in water, oil or even chemical mixes.
- MAXPRO® Pump Skid Systems: We provide compact and complete pump skid systems for water or oil service, with pressure capacities between 500 and 60,000 psi.
- MAXPRO® Test Benches: We also provide test benches for water, air, gas, and oil service. Options include vertical or horizontal test chambers and manual, semi-automated, or PLC controls. In addition to hydrostatic testing, our test benches can be used for leak testing and burst testing.
- MAXPRO® High-Pressure Air-Driven Liquid Pumps: Our high-pressure data logger simplifies test data recording from MAXPRO® Liquid Pump systems.
Let MAXPRO® Handle Your Hydrostatic Testing Equipment Needs
It’s important to select the right hydrostatic testing equipment for safe, efficient, accurate, and regulatory-compliant leak detection service. Contact MAXPRO® Technologies for high-quality hydrostatic pressure testing equipment for your needs. We specialize in engineer-to-order package systems, custom-designed and built to meet your hydrostatic test requirements.
Fairview, PA — April 11, 2022 — Maxpro Technologies Inc. now offers offers high-pressure testing services with the acquisition of Maximator Test, LLC, in Gurnee, IL.
Maximator Test offers a full range of high-pressure testing services, including leak, impulse and proof testing with pressures to 65,000 psi, and burst testing with pressures to 145,000 psi. Maximator Test also offers autofrettage services to 145,000 psi.
Maximator Test is a resource for Production Part Approval Process (PPAP) testing, component/assembly validation testing, and material validation testing. Maximator Test offers unique test equipment to provide accurate data needed to make cost-saving decisions.
Paul Bowser, President of Maxpro Technologies said “Maximator Test is a good fit for the Maxpro brand because we are the exclusive North American distributor of Maximator high pressure products, including valves, fittings, tubing, air amplifiers, gas boosters and liquid pumps and also standard and custom-designed high pressure packaged power systems”.
If you would like to learn more about high pressure testing services offered by Maximator Test, please contact our team here.
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Changing Coning Blades and Die Chasers on the Coning & Threading Machines
Since 2011, MAXPRO Technologies has been building patented, easy-to-operate coning and threading machines. Coned and threaded connections are a safe and reliable option for medium, high, and ultra-high pressure tubing. Follow these instructions for changing the coning blades and die chasers. Click here to watch a video.
Things You’ll Need
- Screwdriver or rod
- Die chasers
- Coning blades
- Tommy bar (supplied with the machine)
- Setting tool (Supplied in the tool kit)
Coning Blade Installation
- Two coning blades are required for each size and pressure, ¼” through ¾”, and must be identical.
- One or two coning blades may be used for 1” OD tubing, 15,200 psi or 22,500 psi pressure rated tubing. Two identical blade operation is standard for 1” OD tubing. One blade may be used, especially if paired with optional 1” deburring blade for the ID of the tube.
- One coning blade and one ID deburring blade is used for coning 1½” OD 15,200 psig tubing.
- Countersunk hole is on the top blade surface to accept a #8-32 flat head cap screw.
- Check to make sure there are no chips in the blade pocket on the Tool Holder.
- Set each coning blade Part # side up in the pocket and tighten firmly with 3/32” Allen wrench (provided).
Thread Chaser Installation
1. Access Die Head by sliding the carriage with the lever handle into the CONE position and lift the plastic shield.
2. Trip head into open position
3. Open Head for Chaser Insertion
4. Inserting Chasers
5. Closing the Die Head
Coning Pitch Adjustment
1. With the Die Head in the closed, ready to thread position, check for the proper thread diameter by attempting to screw in a known good threaded tube, or, alternatively use a rod with an outside diameter equal to the minor thread diameter. If the test tube does not thread in, or threads in too tight or loose, adjusting ring binding (set) screw (5/32″ Allen wrench provided) on the adjusting ring must be loosened and the adjusting ring rotated with a 5/16″ diameter pin (provided) inserted into a hold on the adjusting ring.
Loosen adjusting ring binding screw using provided hex key
2. There are two marks on the adjusting ring. Rotating the ring towards “S” makes the thread diameter smaller (moving ring CCW as you’re facing the Die Head). Rotating the ring towards “L” makes the thread diameter larger (moving the ring CW as you’re facing the Die Head).
By means of a pin inserted into the hold of the adjusting ring, turn until desired thread size is obtained.
3. Check for proper thread diameter using matching size minor thread setup gauge (provided with complete tooling kits). Care should be taken not to force the chasers onto the setup gauge. Alternatively, a known good threaded tube can be screwed into the chasers. Ensure the tube does not thread in too tightly or loosely. Further minor adjustments necessary to obtain correct size settings are achieved by repeating steps 1 and 2.
4. Re-tighten the adjusting ring binding (set) screw on the adjusting ring.
5. A trial cone and thread should be made on a scrap piece of tubing (or excessively long tube) to confirm proper threading sizing. Threading a collar onto the tubing smoothly with little clearance will confirm an acceptable thread diameter.
MAXPRO Field Services, Installation, and Repair
MAXPRO’s Maximator coning and threading machines are designed for easy operation and maintenance.
Please contact us if you need help maintaining any Maxpro product. We offer phone support, in-house repair services or service at your facility. Contact us today to learn more about our capabilities.
MAXPRO’s Data Logger
I have been in the oil and gas testing industry for over 24 years and found that one of the essential elements of testing is collecting data to create a snapshot of what occurred during the testing process. Testing is crucial when proving new designs and determining if component can withstand the elements before being put into service. These elements could include axial loading in tension/compression, applied bending, torsion, internal/external pressure, and elevated/sub-zero temperatures in tubular type products. Testing can introduce all these elements independently or in a combination of two or more simultaneously. The applications of simulated environments are pretty much endless. Proper equipment is vital to retrieve the best results to create a snapshot of everything that occurred during testing. (more…)
Coning & Threading of High-Pressure Tubing
In medium- and high-pressure systems, coned and threaded tubing connections ensure safety and reliability.
- Bottle of cutting oil
- Collet wrench
- Coning blades (and spare)
- Coning tool
- Deburring tool
- Threading tool
- Tube holder
- Optional Complete Coning and Threading Kit includes everything you need!
How to Change the Coning Blades in the Coning Tool
To begin, the coning blades need to be properly installed in the coning tool. Locate the part numbers etched on one side of the blade and place the blade in the coning tool with the numbers facing outward. Once the blade is correctly installed, tighten the set screws on either side of the tool to secure the blade in place
Now that the tool has been prepped, the following steps will guide you through the coning and threading process:
- Insert the tube into the tube holder until it can be seen at the top of the viewing window.
- Place the flat end of the tube holder into a vice and tighten the collet nut to secure it in place.
- Cover the coning blades in cutting oil and install the coning tool onto the side of the tube holder opposite the tube by turning the knurled nut.
- Begin rapidly turning the handle of the coning tool while gradually turning the knurled nut to drive the blades into the cone on the end of the tube.
- Remove the coning tool by loosening the knurled nut.
- Loosen the collet nut and move the tube further into the tube holder and tighten it to allow you to hold the tube during the threading process.
- To start the first thread, install the die holder onto the end of the tube and firmly press down.
- Add cutting oil into the die holder.
- To obtain the appropriate amount of thread for a ¼” tube, turn the die holder approximately 12 times.
- Every few turns, reverse the die holder to break off any chips.
- The tube now has a cone and left-hand thread and can be removed from the die holder and the tube holder.
- Install the gland and collar on the tube with 1 to 2 threads visible above the collar.
- Lubricate the threads on the gland to prevent them from galling when the stainless parts are joined.
- Install the tube into the fitting by hand tightening it.
- Place the assembly into the vice to torque the fitting using the appropriate sized torque wrench for your tubing.
MAXPRO Field Services, Installation, & Repair
Since 1995, MAXPRO Technologies has provided industry-leading high-pressure solutions. With a team of highly qualified engineers and technicians, we install every piece of equipment sold to ensure accuracy and optimal performance. We provide support for our products throughout their life cycle and offer field and in-house repair to allow customers to get the most out of their purchase. To learn more about our coning and threading services and equipment, contact us today.
Main Types of High Pressure Valves & When to Use Them
High pressure valves are used to regulate the flow of liquids, gases and other media through tubing, pipes, tanks, and other containers. There are several valve types to choose from, including some that provide on/off control. The type of high pressure valve you choose depends on the specific requirements of your application. Here, we will discuss the various types of valves and the key factors you should consider when selecting a valve for your application.
Features to Consider When Choosing a Valve
There are several things to consider when selecting a valve, including:
- Media Type. When determining the best valve for your needs, it is important to consider your process. For example, Is the fluid corrosive? Are you using gas?
- Application. It’s crucial to select the correct valve sizing based on your application’s requirements. It’s also important to consider the environment where the valve will operate. Understanding conditions such as temperature, flow rate, and pressure will help you determine the best valve option.
- Valve Function. Consider how you need the valve to function and whether it will be used for on/off control or flow control in a system. It is also important to determine if the valve you require will be operated by hand or via an actuator for remote control applications.
- Actuation. Consider whether the valve should be “air to close–normally open” or “air to open–normally closed”.
Types of Valves
At Maxpro, we carry several valve styles to suit many applications:
Air to close valves are held in the open position by the valve spring and require air pressure to move them into the closed position. Choose this valve if you want to vent pressure in the line if you were to lose power.
Air to open valves are held in the closed position by the valve spring and require air pressure to move them into the open position. Choose this valve to maintain pressure in the line during a power failure.
Maximator ball valves are capable of handling liquids and gases up to 21,000 psi at room temperature. Ball valves have larger orifices resulting in increased flow. Choose this valve for your control panel or other hydraulic system if flow is the most important factor.
Maximator block and bleed valves are compact and easy to use. Block and bleed valves are two-stem manifold valves designed for blocking, bleeding and calibrating pressure gauges and transmitters up to 22,500 psi @ room temperature.
Maximator cryogenic needle valves are designed to work with line temperatures to -423°F. For example: This valve can be used on high pressure nitrogen injection trucks and skids to control the flow of nitrogen.
Electric flow control valves use an electric control signal to meter small flow rates with repeatable and precise control for liquids and gases. These valves are for metering only and are not ideal for complete shutoff applications. One example of an application would be simulating a down hole environment by pressurizing or venting a large volume vessel with a controlled pressure ramp rate.
Maxpro proportional pressure relief valves are designed to protect systems and components from over-pressure for both gas and liquid applications. The unique poppet design allows for chatter free pressure release and excellent deadband pressure control.
High pressure check valves permit fluid flow in one direction only, thus preventing backflow in high pressure applications.
Maximator high pressure needle valves provide on/off control of fluids and gases. These valves are used in conjunction with high pressure fittings and tubing to plumb systems to 101,000 psi.
Maximator pipe valves with metal to metal seats provide on/off control for fluids and gases and are rated up to 15,200 psi.
A manifold is a component used to simultaneously connect multiple parts into a system so all parts are exposed to the same circuit conditions (such as media or pressure). A manifold is used in place of multiple connections between components. For example: A manifold can be used to hydrostatically test multiple parts at the same time.
Micro-metering valves are designed for metering small flow rates with precise, repeatable control for both gases and liquids.
MAXPRO Technologies’ High Pressure Valves
Since 2007, MAXPRO® Technologies has provided top-quality high pressure valve solutions for customers across a diverse range of industries. Our high pressure valves offer a variety of body pattern options, metal-to-metal seat, non-rotating stem design, and performance in a wide range of temperatures. Our products meet the highest industry standards and can be used in various demanding applications, including food processing, oil and gas, waterjet, and chemical processing.
When you partner with MAXPRO, we will work with you to determine the best possible solution for your high pressure valve needs. To learn more about our products and capabilities, check out our High Pressure Valve catalog or contact us today.
Because they are dependable, reusable and safe, coned and threaded connections are the industry standard for medium-, high-, and ultra-high-pressure systems. That’s why MAXPRO® Technologies is pleased to introduce the MTCAT-1.5, the only coning and threading machine available capable of handling up to 1-1/2 inch OD medium-pressure tubing.
Advantages of Coned and Threaded Connections for Your Application:
- Dependable. If the user starts with high quality components and tooling from Maxpro Technologies, follows prescribed instructions for tube preparation, lubrication requirements and torque specifications, this metal-to-metal joint is recognized as a world standard for dependability.
- Reusable. The coned and threaded connection utilizes a gland nut to grip a collar threaded onto the tubing. This arrangement creates an intentional high stress, metal-to-metal contact ring, employing slightly differing contact angles to affect the seal. Following proper assembly procedures, this seal can be remade many times without compromising the effectiveness.
- Safe. The design of this type of seal minimizes the internal pressure loaded area to allow efficient use of materials, while assuring a suitable factor of safety. If a leak should occur, weep holes are provided to allow venting of the fitting to avoid unsafe pressure loading conditions.
Industries that commonly benefit from coned and threaded connections include food processing, oil and gas, pressure testing, and waterjet cutting to name a few.
MAXPRO’s MTCAT-1.5 and MTCAT Features:
While coned and threaded connections are dependable, reusable, and safe, the coning and threading process can carry high labor costs. Manual coning and threading operators must be carefully trained in how to prepare and process the tube ends. MAXPRO coning and threading machines make it much easier and cost-efficient to cone and thread high-strength tubing. The original MTCAT and new MTCAT-1.5 Coning & Threading Machines integrate the following features:
MAXPRO ‘s MTCAT and MTCAT-1.5 both offer a semi-automated design engineered for speed. They offer faster set-up and operation for better efficiency. The tube only needs to be fixtured once for both coning and threading operations, which eliminates extra set-up and downtime between the two processes. The die head automatically resets after threading, allowing for easy unloading and preparing for the next tube.
Ease of Use
Both the MTCAT and MTCAT-1.5 are designed for intuitive use. After completing either a brief training program or reviewing the comprehensive instruction manual provided with all machines, operators can produce quality components. One of the main control mechanisms of the MTCAT-1.5 and MTCAT is a simple selector knob that allows the operator to choose thread length automatically depending on the size of the tube.
The MTCAT-1.5 and MTCAT are both available in right-hand and left-hand thread variations. Customers can choose whichever design suits their needs. MTCAT can cone and thread ¼” through 1” OD tubing and MTCAT-1.5 can cone and thread ¼” through 1-½” OD tubing
Hardened blades made of high-quality, durable tool steel deliver precise results with a clean surface finish typically lasting over hundreds of tubes.
The MTCAT-1.5 and MTCAT Coning and Threading Machines are fully enclosed with Plexiglass shields and other suitable machine guarding. This design minimizes pinch points and protects operators from metal chips and cutting oil.
Both MATCAT-1.5 and MTCAT Coning and Threading Machines provide excellent cutting oil delivery right through the rotating spindles accurately to the cutting blade area. No external gooseneck nozzles to mess with! They also provide for a two-fold filtering process for clean and easy removal of the strained chips with a convenient handle. A suction strainer further removes chips before pumping oil back to cutting action.
Contact MAXPRO for Your Coning and Threading Machine Needs Today
Looking for quality coning and threading machines? MAXPRO is here to help! We’ve designed and manufactured equipment and fittings for high-pressure applications for over 25 years. MTCAT-1.5 is the newest addition to our catalog of the industry’s best tools for coning and threading. Whether you need speed, ease of use, versatility, tool quality, safety, or mess-free operation, this machine has got it all. For additional information on MTCAT-1.5, download our eBook or contact us today.