Hydraulic Connector Pressure Testing With a Local Intensifier
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Solution Overview
Problem
Conventional hydraulic connector pressure testing methods are inefficient and risky due to manual operation and the need for high-pressure fluid lines extending from the connector to a separate supply system, posing safety hazards.
Innovation Solution
An automated pressure testing system integrated with the hydraulic connector, utilizing an intensifier to pressurize hydraulic fluid, which is controlled by a computer system and secured outside the hazardous redzone, reducing the need for manual intervention and extended high-pressure lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual hand pump operation is used for pressure testing, then the testing can be performed, but the procedure is highly inefficient and requires operator proximity to the redzone creating safety risks
Solution Approach 1:
The system uses automated control valves and a remote-operated hand pump to perform pressure testing without requiring operator proximity to the connector. The automated valve sequence automatically isolates the test line, pressurizes it to test pressure, holds pressure for testing, and then depressurizes it, making the system self-servicing and eliminating the need for manual intervention in the hazardous zone.
Solution Approach 2:
The hydraulic system is segmented into separate functional zones: the redzone contains only the connector and minimal testing components, while the remote operating area contains the hand pump and control system. This segmentation allows the testing function to be performed remotely, improving safety and efficiency by separating the hazardous high-pressure zone from the operator.
2Ease of operation
If high pressure fluid lines are extended from the connector to remote testing location, then testing can be performed remotely, but the system complexity and safety hazards increase
Solution Approach 1:
The high-pressure testing function is extracted from the remote location and brought to the connector site through the intensifier. Instead of extending high-pressure lines from a remote pump to the connector, the system uses a low-pressure hydraulic line to the connector, then locally intensifies the pressure at the connector for testing. This eliminates the need for extended high-pressure fluid lines and reduces system complexity.
Solution Approach 2:
The intensifier acts as an intermediary device that converts low-pressure hydraulic fluid into high-pressure test fluid at the connector location. This intermediary mechanism allows remote operation while avoiding the complexity and safety hazards of extending high-pressure lines across the worksite.
3Reliability
If automated pressure testing system with intensifier is used, then safety risks are reduced and efficiency improved, but the device complexity increases
Solution Approach 1:
The pressure testing system is merged with the existing hydraulic connector system by using the same hydraulic fluid supply line to power both the hydraulic lock and the intensifier. The control valves are integrated into the connector assembly, and the testing function is combined with the locking function, reducing overall system complexity while maintaining safety and automation.
Solution Approach 2:
The hydraulic supply line serves multiple functions: it provides hydraulic fluid to operate the hydraulic lock for connection and to power the intensifier for pressure testing. The control valves perform multiple functions including isolating the test line, directing fluid to the intensifier, and controlling pressure release. This multi-functionality reduces the number of separate components needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides efficient, automated pressure testing with reduced safety risks by using a compact, integrated design that pressurizes only a small volume of fluid, eliminating the need for manual operation and minimizing exposure to hazardous conditions.
Implementation Method 1
using an intensifier in the pressure testing system to pressurize the portion of hydraulic fluid to a testing pressure
Implementation Method 2
using the intensifier to pressurize the testing portion of hydraulic fluid at the hydraulic pressure to provide a pressurized testing hydraulic fluid having a testing pressure
Data Source
AI summary
A method includes providing a hydraulic connector having a hydraulic lock, wherein the hydraulic lock is operated using a hydraulic supply line and a hydraulic outlet line, and connecting the hydraulic connector to a component by activating the hydraulic lock. While the hydraulic lock is activated, a connection between the hydraulic connector and the component is pressure tested by directing a portion of the hydraulic fluid from the hydraulic supply line to a pressure testing system, using an intensifier in the pressure testing system to pressurize the portion of hydraulic fluid to a testing pressure, and directing the pressurized portion of hydraulic fluid to the connection to test a pressure rating of the connection.