Endress+Hauser (Reinach, Switzerland; www.endress.com) invested nearly $1 million in a pressure test rig at its U.S. headquarters in Greenwood, Indiana. The rig allows it to test complete instrument assemblies to customer specifications, and provides a 100% test indicating a specific instrument can withstand the design process pressure, up to 15,000 psi.
Previously, Endress+Hauser—like most other U.S.-based instrument manufacturers—did not have local high-pressure testing capability. For example, Endress+Hauser performed such tests at its production plant in Maulburg, Germany. With the new high pressure test rig located in the Greenwood, IN, production center, instruments can be tested and certified quickly, for faster delivery to customers in the U.S. and the Americas. And because the test facility is in the U.S., it makes it easier for customers to schedule and witness the test.
Being able to certify the entire instrument assembly—not just the process connection—is important for customers in the oil & gas, chemical, power, energy and other heavy industries. In many cases, engineering firms, end users and insurance companies have detailed and specific internal codes and specifications for instruments that will be installed in critical, high-pressure applications, such as high pressure boilers, reactors or catalytic crackers.
The test rig, located in an underground concrete pit for safety reasons, can generate pressure up to 15,000 psi (1000 bar) to test devices up to 16 feet (4 meters) long and with up to a 2-inch diameter. Each test is automated to execute customer-specific test and ramp up times. The test rig is specially designed to test Endress+Hauser’s Levelflex guided wave radar level instruments, capacitance probes, Liquiphant tuning forks, Micropilot free space radar level instruments, and high pressure thermowell assemblies—all products built in the Greenwood, Indiana, plant—but it can also test other instruments.
The test rig can produce relevant certification and documentation to ensure there is a level of safety built into the system and reduce risk of failure. This certification and documentation is also often required by engineering firms, end users or insurance companies.