Products Description
The GSY180 Dual‑Station Hydrostatic Testing Machine is a fully automatic high‑performance steel pipe pressure testing device for metal pipe defect detection via high‑pressure water testing. It accommodates pipes with outer diameters of Φ60–178mm (2-3/8" to 7") and lengths of 6–12.5m, with a maximum test pressure of 70MPa (10,152psi). Equipped with a professional Siemens S7‑1200 PLC control system and 19‑inch industrial computer, it realizes full automation from feeding, sealing and pressurization to automatic data logging. Dual‑station design significantly boosts production efficiency. It is perfectly applicable to quality inspection of API tubing, casing and industrial steel pipe production lines, with customized technical solutions available.
Equipment Video
Key Features & Specs
Extreme Pressure & Axial Capacity
Supports up to 70MPa (10,152psi) max test pressure, matched with 300-ton axial thrust, stable for medium-diameter pipe testing of API tubing and casing.
Dual-Station High Efficiency
Dual-station layout cuts idle time obviously, reaching testing capacity ≥120 pieces per hour, perfect for mass production of steel pipe hydrostatic testing.
Advanced Sealing System
Adopts radial large-gap sealing structure with high-grade polyurethane hydraulic rings, service life over 3,000 working cycles. Clamshell sealing head supports fast replacement and low maintenance cost.
Intelligent Control & Data Traceability
Built with Siemens S7-1200 PLC and 19-inch industrial computer, covering automatic, manual and debugging modes. All pressure, time and test results are auto-saved, realizing full-process data traceability for every steel pipe.
Equipment Parameters
| Specification | Value |
|---|---|
| Model | GSY180 (Double-station: 2 pipes per cycle) |
| Pipe Size | Ф60–178 mm (Deviation Accuracy ≤ ±1.0%), Length: 6-12.5m (Bending Curvature ≤ 2 mm per 1000 mm, Customizable for longer or shorter range) |
| Working Capacity | Capacity ≥ 120 pcs/h (Ф89, Pressure=70MPa, Holding Time=5s) |
| Max. Pressure | 70MPa (10,152psi, Customizable); Axial bearing capacity: 300T |
| 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 | 80T (Customizable) |
Note: The conversion for 70 MPa to psi is approximately 10,152 psi.
I. GSY180 Dual-Station Hydrostatic Testing Machine Structures and Features
1. Overview
The GSY180 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 GSY180 Double-station Hydro Tester
(1) Loading Table (Auxiliary Machine)
(2) Air Blow-off Device
(3) Hydrostatic Tester Main Unit
4) Frame
5) Water Injection Test Head
6) Exhausting Test Head
7) Pipe Inlet/Outlet Conveyor System
8) Clamping Device
9) 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" |
III. Referenced Images of GSY180 Double-Station Hydrostatic Tester
1. GSY180/70 Dual-Station Hydro Tester to Indonesia
1.1 Overview of Hydro Tester
2. GSY180/50 Hydrostatic Tester for CNPC China, API testing for casing pipe and oil tubing
FAQ
Q1. What pipe specifications and types can the GSY180 dual-station hydrostatic testing machine test?
A1. GSY180 dual-station hydrostatic testing machine applies to pipes Φ60–178mm in diameter and 6–12.5m in length (customizable). It is widely used for API tubing, API casing, seamless steel pipes, welded steel pipes, stainless steel and alloy steel pipe hydrostatic testing.
Q2. What is the maximum test pressure and axial bearing capacity of the GSY180 equipment?
A2. Standard max test pressure reaches 70MPa (10,152psi), with 300-ton axial bearing capacity to keep stable operation under high pressure. Test pressure can be customized per site requirements.
Q3. How efficient is the GSY180 dual-station hydrostatic testing machine?
A3. With standard Φ89mm pipe, 70MPa pressure and 5s holding time, the efficiency reaches ≥120 pieces per hour. Dual-station design greatly improves throughput for API tubing and casing production line inspection.
Q4. What control system does it use, and is test data traceable?
A4. It adopts core Siemens S7-1200 PLC and 19-inch industrial computer, supporting multiple operation modes. All test parameters and inspection data are automatically recorded and stored, achieving complete traceability for steel pipe pressure test.
Q5. What are the advantages of the dual-station design and sealing system?
A5. Dual-station design supports simultaneous testing to raise overall efficiency. It adopts mature radial large-gap sealing technology with long-life sealing rings; clamshell structure enables quick mold replacement, simple operation and lower maintenance downtime.
Boyu Petroleum Equipment has over 30 years of R&D and manufacturing experience in steel pipe hydrostatic testing machines, hydraulic bucking units and pipe straightening machines.
If you need reliable dual-station pipeline hydrostatic testing equipment and professional oilfield supporting solutions, contact us to get detailed technical parameters and official quotation of GSY180.
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