Pressure tests

We perform pressure tests on:

• gas coolers,
• oil coolers,
• heater cores,
• air coolers,
• condensers,
• CO₂ condensers,

• water coolers,
• pipes and cables,
• brake hoses,
• brake callipers,
• brake pumps,
• brake cylinders,
• and various other components.

We have several modular stands that permit us to carry out various pressure tests using different media under different temperature conditions. Among others, testing resistance to bursting pressure or high-pressure pulsation tests are carried out.

High-pressure pulsation testing

High-pressure pulsations or pressure change resistance tests are usually performed in the pressure range from 0 to 200 bar; to meet special requirements it is also possible to carry out such tests at higher pressures. Testing can be performed using different types of media at a wide range of temperatures.

Pressure range

• 0-250 bar
• > 250 bar – be agreement

Medium

• hydraulic oil
• water
• glycol
• brake fluid
• other media on request

Temperature range

• From -40°C to +180°C
• From ambient to +300°C

Pulse shape

• practically any – to be agreed with customer
• high accuracy of tracking the required pulse shape

Data acquisition

• Pressure and temperature data acquisition throughout the entire test
• Testing several objects simultaneously (to be agreed)

Tests may apply to

• Heat exchangers
• Brake master cylinders
• Brake callipers
• Wheel brake cylinder
• Brake lines
• Brake hoses
• others

Pressure cycles – air

Technical parameters

• Operating pressure: up to 5 bar
• Air temperature: up to 250°C
• Chamber temperature: up to 200°C
• Cycle time: 1-20 s

Pressure cycles – glycol+oil

Testing the resistance of radiators with oil coolers

Bursting pressure resistance tests (burst tests)

Burst tests, commonly called burst pressure resistance tests, are typically carried out at pressures up to 1000 bar with different media at varying ambient temperatures.

Pressure range

• 0 – 1100 bar – standard
• > 1100 bar – by agreement

Medium

• hydraulic oil
• water
• glycol
• brake fluid
• other media, to be agreed

Temperature range

• from -40°C to 180°C
• from ambient temperature to 250°C

Pressure change shape

• practically any – to be agreed with the customer
• high accuracy of tracking the required pressure shape

Data acquisition

• Pressure and temperature data acquisition throughout the test

Tests may apply to

• Heat exchangers
• Brake master cylinders
• Brake callipers
• Wheel brake cylinder
• Brake lines
• Brake hoses
• others

Charts: Examples of Burst Tests

Product, subassembly and coupling tightness tests

Subassembly and coupling tightness tests

Objects tested

• we conduct tightness tests of elements and couplings (for example: clamp – brake hose) at both low and high pressure.

Pressure range

• fluids up to 1100 bar (above 1100 bar – to be agreed)

We can conduct tightness tests with any holding time and at a constant pressure value, or with a variable pressure trace.

Temperature range

• tests can be conducted at temperatures from -40°C to +180°C.

Available working fluids

• brake fluid
• hydraulic oil
• water
• glycol
• other media on request.

Product tightness tests

Tests of objects’ tightness following ageing tests (or taking samples from the production process) concern subjecting the object to the required pressure (or underpressure), under specified environmental conditions. The object’s medium can be gas (for example air, helium, nitrogen, cooling fluids, etc.) or liquid (water, ethyl glycol, etc.). Entire components, such as, for example heat exchangers, tanks, hoses, specific closed systems, etc. can be subjected to tightness tests.

Equipment

• Phoenix L500i helium leak detector (range: from <5E^-12 to 1000 mbar•l/s)
• Agilent 7820A gas chromatograph
• Alicat electric flowmeter (object gas leakage measurement: from 0 to 50 cm³/min)
• ball rotameter (object gas leakage measurement: from 0 to 150 cm³/min)
• Wika pressure converter (range: from 0 to 400 bar abs.)

Testing norms

• PN-EN 60068-2-17

Customer norms

• Ford, CEVT, Volvo, VW, Renault, GMW, PSA, Audi, BMW, Daimler, Chrysler, Toyota, Nissan, Honda, Kia, Fiat, Jaguar, Rover, others.

Helium tightness – product tightness tests

Tightness tests of objects can be carried out using various techniques. The choice of technique depends on the expected accuracy of the measurement or the magnitude of the leak – the most accurate leak testing technique is the use of a vacuum method with a mass detector. The test is carried out on an object filled with helium, at atmospheric or elevated pressure (up to 250 bar or more), placed in a vacuum chamber connected to a mass detector. The test can detect leaks of the order of 10^-12 mbar•l/s. Using an additional sensor (a sniffer), it is possible to locate points/areas of leakage on the order of 10^-7 mbar•l/s.

Devices

• Phoenix L500i helium leak detector (range from 1000 mbar*l/s do <5*10^-12 mbar*l/s)
• Haskel Ag-75 compressor, permitting helium pressures of over 400 bar to be created
• Test chambers: 300 × 300 × 500 mm; 800 × 800 × 1000 mm

Norms

• DIN 8964-2
• DIN 74104
• QV 64037
• other product and industry norms

Resistance to vacuum – product tightness tests

By means of this test, we check the tightness of the product, e.g. a heat exchanger.

Technical parameters of the test

• Pressure: up to 13 or 30 bar abs. (controlled pressure increase)
• Vacuum: less than 3 mbar abs. (parameter acquisition from 0 to 250 mbar abs.)