Case Studies
Case Study 2: Automated High-Pressure Testing System
The Challenge
A manufacturer required a safe and reliable way to pressure test composite pipes up to 4000bar (60,000psi) across multiple test cells. Their existing setup lacked automation, operator safety features, and comprehensive data recording. The system must perform fully autonomous test unsupervised.
Our Solution
Fife Control Systems Ltd designed and delivered a complete automated pressure testing system with integrated safety and SCADA controls:
- Hydraulic Power Units (HPUs): one oil-based for two test cells, one water-based for a third test cell
- Safety PLC for interlock control and pressure monitoring (ISO13849-1, PL d)
- Operator Safety: interlocked doors, dual-channel emergency stops, and safety venting valves
- SCADA System (VTScada):
- Dedicated control stations for each test cell
- Each station has dual monitors for SCADA – detailing system status and chart recording
- Live data recording and automated leak detection – passed test detection
- Safety monitoring of 14 emergency stops and e interlocked guards
- Remote Access: secure VPN with Thin Client support
- UPS Protection for safe pause and controlled shutdown
The Results
- Unsupervised automated 4000bar (60,000psi) pressure testing – testing can be complete through the night
- Safer working environment
- Automated tests improved repeatability and product R&D and included:
- Full data logging for compliance and QA
- Reduced downtime with remote support
- Flexible design across three test cells
