Products Description
The GSY219 Dual‑Station Hydrostatic Testing Machine is a fully automatic high‑performance steel pipe pressure testing unit for metal pipe flaw inspection by high-pressure water test. It suits outer diameters from Φ60–219mm (2-3/8" to 8-5/8") and pipe lengths 6–12m, max test pressure up to 50MPa (7250psi). Adopting Siemens S7‑1200 PLC and 19-inch industrial PC, it completes automatic feeding, sealing, pressurization and data recording. Dual-station design greatly improves working efficiency, widely used for quality checking of API tubing, casing and industrial steel pipes, customized service is supported.
Equipment Video
Key Features & Specs
Extreme Pressure & Axial Capacity
Supports up to 50MPa (7,250psi) maximum test pressure, matched with 350‑ton axial thrust bearing capacity, stable and reliable for medium‑diameter pipe integrity testing.
Dual‑Station High Efficiency
Dual‑station design enables continuous testing with significantly reduced idle time, achieving testing capacity of ≥120 pieces per hour under standard conditions (Φ89mm pipe, 50MPa, 5s).
Advanced Sealing System
Adopts radial large‑gap sealing structure with premium polyurethane hydraulic rings, service life over 3,000 working cycles. Clamshell‑style sealing heads enable fast mold replacement and low maintenance downtime.
Intelligent Control & Data Traceability
Configured with Siemens S7‑1200 PLC and 19‑inch industrial computer, supporting automatic, manual and debugging modes. All test pressure, time and result data are automatically stored in the database to achieve full‑process traceability.
Equipment Parameters
| Specification | Value |
|---|---|
| Model | GSY219 (Double-station: 2 pipes per cycle) |
| Pipe Size | Ф60–219 mm (Deviation Accuracy ≤ ±1.0%), Length: 6-12m (Bending Curvature ≤ 2 mm per 1000 mm, Customizable for longer or shorter range) |
| Working Capacity | Capacity ≥ 120 pcs/h (Ф89, Pressure=50MPa, Holding Time=5s); Capacity ≥ 70 pcs/h (Ф89, Pressure=21MPa, Holding Time=5s) |
| Max. Pressure | 50MPa (7,250psi, Customizable); Axial bearing capacity: 350T |
| Application Scenarios | Hydrostatic pressure testing for seamless steel pipes, welded pipes (longitudinal welded pipes ERW, spiral welded pipes SSAW, etc.), stainless steel tubes, oil tubings and casings (API testing), titanium tubes, alloy steel pipes, aluminum tubes, copper pipes, etc. |
| Operation Mode | Auto / Manual / Debugging & Maintenance |
| Pipe End Condition | Plain End |
| Pipe Material | Stainless Steel / Duplex / SuperDuplex / Inconel Grades (Soft contact system, avoid contact with carbon steel materials) |
| Pressure Holding Time | 0~100s (Adjustable) |
| Sealing Mode | Radial large-gap sealing; Polyurethane hydraulic ring + Bearing circular block; Long service time (Durability > 3000 times); Open seal heads: The fixture is equipped with a clamshell-style sealing head, which allows for easy and efficient replacement, improving operational efficiency |
| Testing Pressure Accuracy | Pressure Sensor Accuracy: 0.5%, Control Accuracy: ±2% (Max. Testing Pressure) |
| Pressure Fluctuation | Holding time 5s, fluctuations <100 psi Holding time 25s, fluctuations < 500 psi |
| Daily Working Time | ≥ 20 hours per day |
| Ambient Condition | Temperature: 5~40℃, Humidity: 10%~100% |
| Electric Supply | Voltage AC 380V±10%, Frequency 50HZ±1, Max. Installation Power: 160 kVA |
| Industrial Filtered Water | Suspended Solids ≤ 100mg/L, Hardness ≤ 10.6Dh, Pressure ≥ 0.3MPa |
| Clean Circulating Water | Pressure 0.20~0.50MPa |
Compressed Air | 0.4~0.6 MPa, < 6 m³/min |
| Emulsion | 120 m³ for one tim |
Hydraulic Oil | HLP46 antiwear hydraulic oil (1200L required for one installation) |
| Total Weight | 70T (Customizable) |
Note: The conversion for 50 MPa to psi is approximately 7,250 psi.
I. GSY219 Dual-Station Hydrostatic Testing Machine Structures and Features
1. Overview
The GSY219 Double-Station Hydrostatic Tester is used to perform hydrostatic pressure tests on steel pipes to detect defects. The machine seals both ends of the pipe using a radial large-gap sealing method, fills it with high-pressure water, and holds the pressure for a specified time to check for leaks. Test results are saved in a database for traceability.
The process begins with the pipe entering the feeding rack, where it is moved to the alignment station and aligned with a fixed-end stopper. After a swirling water flush, the pipe is transferred to the test station. The test head moves to seal the pipe ends, and the pre-sealing booster starts sealing. After low-pressure water injection and venting, the main booster pressurizes the pipe. Pressure is held, and the test data is automatically recorded in the database.
After pressure holding, the system checks if the pipe passes the test. Unloading valves are opened to release pressure, and the pipe is flipped out of the tester. Failed products are sent to the waste bin, while qualified products proceed to the next process, completing one test cycle.
2. Process Workflow
Feeding Pipe → Pipe Flipping → Alignment, Swirling Flush Pipe → Hydrostatic Tester Feeding → Water Injection Test Head Positioning → Fixture Clamping → Pre-Sealing → Water Injection and Exhausting→ Pipe Pressurization → Pressure Holding → Pressure Release → Pipe Discharge from Hydrostatic Tester (Signal for Failed Products) → Air Blow for Water Evacuation → Discharge to Output Rack (Failed Products Directly to Waste Bin) → Next Cycle
3. Main Parts of GSY219 Double-station Hydro Tester
(1) Loading Table (Auxiliary Machine)
(2) Air Blow-off Device
(3) Hydrostatic Tester Main Unit
1) Frame
2) Water Injection Test Head
3) Exhausting Test Head
4) Pipe Inlet/Outlet Conveyor System
5) Clamping Device
6) Test Molds
(4) Water System
1) Low-pressure water system
2) High-pressure water system
(5) Electrical-hydraulic Control System
(6) Control System (Siemens S7-1200 PLC + 19'' Upper Computer)
II. Scope of Supply
1. Mechanical Equipment
| No. | Equipment Name | Quantity (Set) |
|---|---|---|
| 1 | Hydrostatic Testing Machine Main Unit | 1 |
| 2 | Booster (Integrated) | 1 |
| 3 | Filling Tank (4 cubic meters) | 1 |
| Alignment and Water Control | 1 |
2. Pneumatic System
| No. | Equipment Name | Quantity (Set) |
|---|---|---|
| 1 | Piping Accessories | 1 |
| 2 | Control System | 1 |
3. Hydraulic System
| No. | Equipment Name | Quantity (Set) |
|---|---|---|
| 1 | Hydraulic Pump Station | 1 |
| 2 | Hydraulic Cylinder and its Control | 1 |
4. Electrical Control System
| No. | Equipment Name | Quantity (Set) |
|---|---|---|
| 1 | Power Control Cabinet | 1 |
| 2 | Switch Control Cabinet | 1 |
| 3 | On-site Operation Box | 1 |
| 4 | Main Operation Control Panel | 1 |
| 5 | Upper-level Industrial Computer | 1 |
5. Pressure Testing Molds
| No. | Size (mm) | Qty. (Set) |
|---|---|---|
| 1 | 73 (76) | 3" |
| 2 | 88.9 | 3.5" |
| 3 | 101.6 | 4" |
| 4 | 120 | 5" |
| 5 | 168.3 | 6" |
| 6 | 177.8 | 7" |
| 7 | 219.1 | 8" |
III. Referenced Images of GSY Double-Station Hydrostatic Tester
1. GSY219/50 Dual-Station Hydro Tester to Hebei, China
1.1 Overview of Hydro Tester
1.2 Working Images
2. GSY219/21 Dual-Station Hydro Tester Exported to India
2.1 Assembly Images
2.2 Client-Site Images
FAQ
Q1. What pipe specifications and types can the GSY219 dual‑station hydrostatic testing machine test?
A1. The GSY219 dual‑station hydrostatic testing machine is suitable for pipes with outer diameter Φ60–219mm and length 6–12m (customizable), with diameter deviation accuracy ≤±1.0%. It is widely used for hydrostatic testing of API tubing, API casing, seamless steel pipes, ERW and SSAW welded steel pipes, stainless steel tubes, and alloy steel pipes.
Q2. What is the maximum test pressure and axial bearing capacity of the GSY219 equipment?
A2. The standard maximum test pressure is 50MPa (about 7,250psi), supported by a 350‑ton axial bearing capacity to ensure stable operation under high pressure. Test pressure can be customized according to user site demands.
Q3. How efficient is the GSY219 dual‑station hydrostatic testing machine?
A3. Under standard test conditions with Φ89mm pipe, 50MPa pressure and 5s holding time, the efficiency is no less than 120 pieces per hour. The dual‑station design doubles throughput compared to single‑station units, adapting to high‑volume tubing and casing production line quality inspection.
Q4. What control system does it use, and is test data traceable?
A4. It uses Siemens S7‑1200 PLC and 19‑inch industrial computer as the core control system, supporting automatic, manual and debugging modes. All test parameters and inspection results are automatically recorded and saved, realizing complete data traceability for each steel pipe.
Q5. What are the advantages of the dual‑station design and sealing system?
A5. The dual‑station design allows simultaneous testing on two stations, significantly improving production efficiency. The machine adopts radial large‑gap sealing technology with combined polyurethane sealing rings (>3,000 cycles). The clamshell sealing head design allows quick mold replacement, simple operation and greatly improved maintenance efficiency..
Boyu Petroleum Equipment owns over 30 years of professional experience in R&D and manufacturing of steel pipe hydrostatic testing machines, hydraulic bucking units, and pipe straightening machines.
If you need professional dual‑station pipeline hydrostatic testing equipment and oilfield supporting solutions, feel free to contact us to get detailed technical parameters and official quotation of GSY219.
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