pipe hydro testing machine

pipe hydro testing machine

The pipe hydrostatic testing machine is a machine that uses oil-water balance control to perform hydrostatic pressure tests on steel pipes. It mainly consists of the following parts: a steel pipe conveyor, a water system, an oil system, and a control system.

Introduction of Marley pipe hydro testing machine

The steel pipe conveying device is responsible for the in and out transmission of steel pipes. The water system is responsible for filling water into the steel pipe to pressurize it during the hydrostatic pressure test of the steel pipe. The oil system is responsible for controlling the head to achieve oil-water pressure balance at the pipe end during the hydrostatic pressure test of the steel pipe. The control system is responsible for the automatic operation control of the entire equipment, the automatic storage of test data, and the management of historical data.

The control system of the pipe hydraulic testing machine is a simple DCS control system, which consists of three parts: hardware system, software system and human.

Pipe hydraulic testing machine system composition

The Marley pipe hydrostatic testing machine primarily consists of a host computer, a slave computer, a human-machine interface (HMI), field sensors, and executable components.

The host computer includes an engineer station and an operator station, which share a common computer. The host computer also serves as a data server, storing test data.

The slave computer, a Siemens S7-200 PLC, transmits signals detected by the field sensors to the host computer for signal processing. It also translates the host computer's control commands into execution instructions to control the actions of the field executable components, thereby achieving automated coordinated system operation and completing the hydrostatic test of steel pipes.

The HMI includes a keyboard, mouse, and control panel. Using the keyboard and mouse, the computer's operation screen allows for parameter transfer, real-time monitoring, and data report printing. The control panel controls the operation of peripheral auxiliary equipment, including pipe transport, starting and stopping oil and water pumps, and moving pipe end caps.

The field sensors include water and oil pressure sensors, which monitor the pressures of the water and oil systems in real time, converting them into electrical signals and transmitting them to the PLC for further processing. Executable components include electro-hydraulic proportional valves, solenoid directional control valves, motors, and signal indicators, which are responsible for implementing the specific machine actions and related signal indications.

Software System

The Marley pipe hydrostatic testing machine software system includes monitoring configuration software, historical data management software, and PLC operation development software.

The monitoring configuration software consists of a development environment system and an operation environment system. These software are installed on the engineer and operator stations. Engineers have permission to run both the development and operation environments, while operators can only run the operation environment system. The operation environment system is protected by hierarchical passwords, with operators of varying permissions limited to operations corresponding to their permissions. Engineers have the highest permissions and can perform all operations. Engineers use the development environment system to develop monitoring programs, while the operation environment system is responsible for collecting and storing real-time data on-site.

The historical data management software includes a database system (Access database), data report query software (an executable file developed using Visual Basic), and a Visual Basic development system, which is responsible for querying historical data reports.

Engineers use the PLC development software to develop control software, which performs the required actions through the PLC system. The PLC operation software is downloaded to the PLC memory and automatically controls the actions of the executable components on-site. Staff Composition

The staff consists of engineers and operators. Engineers are responsible for software maintenance and hardware technical support for the control system.

Operators are responsible for the detailed operations and complete all functions of the hydraulic press.