The Systems Division of Wilson Company (Wilson Systems), specialists in the design of automated industrial systems combining intelligent electronics with the power of hydraulics, has launched IntelliTest, the first fully-automated non-destructive hydrostatic pressure tester, for testing and re-certification of critical iron parts for oil and gas fracking applications.
Its distinguishing feature, when compared to competing systems, is its fully-automated intelligent operation. Once started, the test requires no operator intervention. The automation ensures test integrity, repeatability and traceability, and prevents over pressurizing the test specimen.
The system is operated either locally or remotely with a PC or mobile device through a touchscreen. The screen provides test status and results. Many customers also currently choose to interface with the IntelliTest from an information database for test parameters and results storage.
Although available with or without an integrated cabinet enclosure, IntelliTest is more commonly provided without the cabinet and simply placed in the test chamber (or field bunker) with the test specimen. This installation method removes any and all high-pressure components from the operator’s vicinity, increasing the margin of safety in high-pressure testing.
“The automation, control and repeatability delivered by our proprietary design provide a distinct advantage over traditional manual or limited automated test systems, which may display some measurable variables but offer no discernible controllability, response or comparable technology,” said Dave Pellerin, Wilson’s VP.
“Our system does not depend on operator ability to react to overpressure events once a maximum pressure set point is entered into the system’s HMI. The IntelliTest system allows pressure ramping to multiple pressure levels without operator interaction. You can run a test on a hose at 150 psi and the next test can be on a 22,500 psi plug valve—all at the touch of a button,” he continued.
IntelliTest’s automation simplifies the testing operation. The operator is now available for other tasks during the test cycle increasing throughput. Closed-loop control decreases inconsistency from test to test. Consistency and repeatability allow the component designer more flexibility in material selection and component size, continually designing closer to the material limits.
Scalable from 50 to 60,000 psi, each IntelliTest system is provided with onboard air and fluid conditioning. The extensive filtration increases uptime and simplifies maintenance. In existing customer installations, the highest wear items tested and certified with IntelliTest have lasted more than 10,000 cycles and take less than 20 minutes to maintain.
“The Intellitest System is equally important in the 3,000 to 10,000 psi pressure range as it is in any other range. The system verifies the fluid conveyance integrity. Mobile equipment/systems, by their nature, are difficult to assemble and maintain. Often the space allotted for hoses, fittings, manifold and other devices is limited. If these key components are pretested there is no wasted time assembling defective product and maintaining or replacing when resulting leaks occur,” said Steve Rink of Wilson.
“Any product going into a final assembly will benefit from the hydrostatic testing. It simply increases the confidence that the part will function as required. The opportunity for leaks is minimized and early failures are prevented. As part of a quality assurance plan with proper sampling, the Intellitest System is a valuable tool and more efficient and exact than manual or limited automated testers,” he added.
There are more than 20 systems already in service in the U.S. Whether re-certifying or manufacturing new components, industry professionals have found an increase in productivity and reductions in scrap loss. While initially supporting the oil and gas industry, Wilson’s Systems division also foresees applications in the manufacture and certification of hose, tubing, cylinder, air tank, accumulators, pumps and more. In the mobile equipment market, the company said the system is a viable option for agriculture, fire fighting, construction, material handling, mining and waste management, among a myriad of other applications.
Wilson Company
www.wilson–company.com
Wilson Systems Division
wilsonsystemsdiv.net
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