In the high-pressure testing and inspection industry, the precision of pressure control, the stability of airflow, and the safety of equipment operation directly determine the reliability of test results and the safety of the tested components. Whether it’s burst testing of pressure vessels, airtightness testing of pipelines, or verification of valve sealing performance, a core device capable of continuously outputting a stable and precise air source under extreme pressure environments is essential. Traditional testing equipment often faces problems such as large pressure fluctuations, weak pressure holding capacity, and high safety risks. High-pressure screw compressors, with their two-stage compression technology, intelligent pressure control system, and explosion-proof safety design, are gradually becoming an indispensable piece of equipment in high-pressure testing scenarios. This article will explain in detail why high-pressure screw compressors can become a reliable support for critical tests from the perspectives of technical principles, core advantages, and application scenarios.
I. Technical Introduction: The “High-Precision Output” Principle of High-Precision Screw Compressors
The core reason why high-pressure screw compressors can meet the stringent requirements of high-pressure testing lies in their innovative technology of two-stage compression + precision screw meshing, which is also the key to achieving high-pressure, stable, and low-loss output.
Traditional reciprocating compressors compress gas through the reciprocating motion of a piston within a cylinder. Single-stage compression is insufficient to achieve pressures exceeding 30 MPa, and friction between the piston and cylinder wall leads to significant pressure fluctuations and noticeable airflow pulsations, potentially damaging sensitive test components. High-pressure screw compressors, however, employ a “two-stage compression” design, dividing the gas compression process into two phases: the first-stage screw compresses the gas to a medium pressure (typically 10-15 MPa), which, after cooling, is fed into the second-stage screw for further compression to 30-45 MPa. This staged compression method not only reduces the energy consumption of single-stage compression (saving 10-15% compared to single-stage compression) but also effectively controls temperature rise during compression, preventing changes in gas properties or equipment damage caused by high temperatures.
Its core working components are a pair of precision-ground twin screws made of 38CrMoAlA alloy. This material possesses high strength and high wear resistance; after precision machining, the meshing gap between the screws is only at the micrometer level. When the motor drives the screw to rotate, gas is drawn into the sealed chamber formed by the screw engagement. As the chamber volume gradually decreases, the gas is compressed stage by stage and pushed to the exhaust port. Compared to the pulsed exhaust of a reciprocating compressor, the continuous meshing motion of the screw results in a more stable airflow output, with pressure fluctuations controlled within ±5%, perfectly meeting the airflow stability requirements of high-pressure testing.
Furthermore, the equipment is equipped with permanent magnet variable frequency drive (PMVSD) technology, which further enhances operational flexibility. The motor speed can be automatically adjusted according to actual gas demand, reducing speed during low-load testing phases (such as the pressure holding process) to reduce energy consumption; and increasing speed during rapid pressure boosting to ensure high efficiency and compliance, achieving energy savings of over 35% compared to fixed-speed models.
II. Core Advantages: Meeting the Stringent Requirements of the High-Pressure Testing
Industry High-pressure testing scenarios place far greater demands on equipment than ordinary industrial applications. It requires not only extreme pressure accuracy and stability but also explosion-proof, long-term pressure holding, and adaptability to complex operating conditions. Minnuo, a company with 37 years of experience in the gas equipment field, has developed high-pressure screw compressors that precisely match industry demands in various core indicators, showcasing multiple core advantages.
1.High Pressure Precision: 45MPa Ultimate Output + ±0.1MPa Pressure Control Accuracy
The core requirement of high-pressure testing is “precise controllability.” Jiangsu Minnuo’s high-pressure screw compressors have a rated pressure of up to 45MPa, sufficient to cover extreme pressure requirements such as pressure vessel burst testing and gas cylinder hydrostatic testing. In terms of pressure regulation, the equipment supports ±0.1MPa step adjustment accuracy, enabling multi-stage programmable pressurization, such as gradually increasing from 0MPa to 30MPa, with a specified dwell time at each stage, accurately simulating the actual working conditions of the tested component. This high-precision pressure control capability effectively avoids damage to the test component due to sudden pressure changes, ensuring that the test results truly reflect the product’s pressure resistance limit.
Simultaneously, the equipment possesses excellent pressure holding performance, with a pressure drop of ≤0.5% per hour after shutdown, far exceeding the industry average. In scenarios such as valve sealing testing and pipeline airtightness testing, long-term stable pressure holding capability can accurately detect minute leaks, avoiding misjudgments caused by excessively rapid pressure decay, and providing a reliable basis for product quality inspection.
2.Safe and Reliable: Explosion-proof Design + Triple Safety Protection
High-pressure testing often involves flammable and explosive gases (such as hydrogen cylinder testing) or high-pressure containers, making equipment safety paramount. Jiangsu Minnuo’s high-pressure screw compressor uses an IP54 explosion-proof motor with F-class insulation and meets ExdIIBT4Ga explosion-proof certification, allowing safe operation in flammable and explosive environments and eliminating safety hazards caused by motor sparks.
Furthermore, the equipment is equipped with a triple safety protection system: firstly, multi-level overpressure protection, automatically depressurizing and shutting down when the pressure exceeds a set threshold; secondly, real-time leak monitoring, capturing gas leak signals through sensors, promptly alarming and cutting off the gas supply; and thirdly, manual + remote dual emergency shutdown function, allowing operators to quickly terminate equipment operation on-site or in the control room, maximizing the safety of personnel and the testing environment. These safety designs fully comply with international safety standards such as GB, CE, and API, ensuring safe high-pressure testing.
3.Stable and Efficient: Dual-Mode Cooling + Low-Loss Design
High-pressure compression generates a large amount of heat. Excessive temperature can lead to lubricant failure, shortened equipment lifespan, and even affect testing accuracy. Jiangsu Minnuo’s high-pressure screw compressor is equipped with a dual-mode cooling system (water and air cooling), which automatically switches according to the testing environment to ensure the equipment maintains a stable temperature (≤90℃) under different operating conditions. For example, water cooling is used in environments with abundant water resources, such as laboratories, for higher cooling efficiency; air cooling is used in outdoor or mobile testing environments for easier installation.
Regarding the lubrication system, the equipment uses VG68 special lubricating oil and is equipped with a real-time temperature and oil level monitoring system. When the lubricating oil temperature is too high or the oil level is too low, the equipment automatically alarms and shuts down to prevent damage to components caused by dry friction. The core screw is made of 38CrMoAlA alloy, which undergoes nitriding treatment to significantly increase its hardness. Combined with precision grinding, it exhibits extremely low wear rate and a service life far exceeding that of ordinary screws, reducing maintenance frequency and downtime losses.
4. Clean Air Source: Multi-stage Filtration + Oil-free Output
In high-pressure testing, the cleanliness of the air source directly affects the accuracy of test results, especially in the testing of precision components. Oil mist, particulate matter, and other impurities can cause wear on sealing surfaces or deviations in test data. Jiangsu Minnuo’s high-pressure screw compressor is equipped with a multi-stage filtration system, including a coalescing filter, a desiccant dryer, and a HEPA high-efficiency filter, which removes oil mist, moisture, and particulate matter from the air, achieving truly oil-free and dry air source output. A clean air source not only ensures testing accuracy but also reduces contamination of the air path system, extending the service life of equipment and test pieces.
III. Scenario Application: Covering All Core Areas of High-Pressure Testing
With its core advantages of high-pressure precision, safety, and stability, the high-pressure screw compressor has been widely applied in multiple key scenarios of high-pressure testing and inspection, providing reliable support for product quality verification in various industries.
1. Pressure Vessel Burst and Durability Testing
The burst pressure and durability of pressure vessels (such as storage tanks and reactors) are key indicators for ensuring industrial production safety. Jiangsu Minnuo’s high-pressure screw compressor provides a stable pressurization process, gradually increasing from atmospheric pressure to the burst pressure, avoiding non-destructive damage to the vessel from pressure shocks, and accurately capturing the actual burst threshold of the vessel. In durability testing, the equipment supports multi-stage pressurization-holding-depressurization cycles, simulating the long-term working conditions of the vessel. Its pressure control accuracy of ±0.1MPa and holding pressure attenuation rate of ≤0.5% ensure the consistency of cyclic testing, providing accurate data for vessel life assessment. After adopting this equipment, a valve manufacturer in the United States saw a 20% increase in the success rate of burst tests and a significant improvement in the repeatability of test data.
2.Valve Sealing and Leakage Detection
The sealing performance of valves is directly related to the safety of fluid transport systems. Leakage detection is a core testing step before valves leave the factory. Jiangsu Minnuo’s high-pressure screw compressor can stably maintain pressure at the required test value (e.g., 10-30MPa) and monitor pressure changes in real time through high-precision pressure sensors, accurately detecting even minute leaks (e.g., a pressure drop of 0.1% per hour). The equipment’s low-airflow pulsation design avoids instantaneous failure of the sealing surface due to airflow impact, ensuring that the test results truly reflect the long-term sealing performance of the valve. After using this equipment, a Japanese pipeline engineering company reduced the false alarm rate for valve leak detection to below 1%, significantly improving product quality.
3.Gas Cylinder Hydrostatic Test
The hydrostatic test of gas cylinders (such as hydrogen and oxygen cylinders) is a mandatory requirement for verifying their pressure resistance. The equipment needs to rapidly output high-pressure, high-flow-rate gas to raise the water pressure inside the cylinder to the test pressure and maintain it for a specified time. Jiangsu Minnuo’s high-pressure screw compressors boast an airflow capacity of 1-20 m³/min, rapidly meeting the flow requirements for filling and pressurizing gas cylinders, thus shortening the testing cycle. Its two-stage compression technology ensures stable output even at 45 MPa high pressure, with pressure fluctuations during the pressure holding process ≤ ±0.1 MPa, avoiding test result deviations caused by pressure instability. A Russian gas storage company, after adopting this equipment, saw a 30% increase in gas cylinder water pressure testing efficiency, reducing the single-batch testing time from 8 hours to 5.5 hours.
4.Pipeline Pressure Integrity Testing
Pressure integrity testing of long-distance pipelines (such as oil and gas pipelines) requires equipment with long-term continuous pressurization and pressure holding capabilities. Jiangsu Minnuo’s high-pressure screw compressors support 24-hour uninterrupted operation, providing continuous pressurization for pipelines hundreds of kilometers long until the test pressure (typically 20-30 MPa) is reached. Its long-term pressure holding design controls pressure decay to ≤0.5% per hour, ensuring the detection of minute leaks at pipeline welds, joints, and other locations. A Singaporean energy company used this equipment to complete a pressure test on a natural gas pipeline in Southeast Asia. During the test, the equipment operated stably and successfully detected three hidden leaks, ensuring the pipeline’s operational safety.
5. Heat Exchanger Pressure Fatigue Testing
Heat exchangers are core equipment in the petrochemical and power industries, and their pressure fatigue performance directly affects their service life and operational safety. Fatigue testing requires simulating the pressure fluctuations faced by heat exchangers during long-term operation, verifying their fatigue resistance through multi-stage pressurization-depressurization cycles (e.g., 0-15MPa-0-20MPa-0). Jiangsu Minnuo’s high-pressure screw compressor supports programmable multi-stage pressurization curves, allowing for customized pressure change rhythms according to test requirements. An adjustment accuracy of ±0.1MPa ensures that the pressure value of each cycle accurately meets the standards. Its stable airflow output avoids damage to the internal structure of the heat exchanger caused by sudden pressure changes, ensuring that the test can simulate real working conditions. After adopting this equipment, a German chemical company saw improved repeatability of its heat exchanger fatigue test data, providing a reliable basis for equipment optimization design.
IV. Selection Guide: How should high-pressure testing companies choose suitable equipment?
The performance of a high-pressure screw compressor directly determines the reliability of test results and the safety of the testing process. When selecting a compressor, companies should start from their core needs and focus on the following four dimensions:
1. Matching Pressure and Flow Requirements: Different testing scenarios have significantly different requirements for pressure and flow. Pressure vessel burst testing prioritizes “ultimate pressure” (e.g., ≥30MPa), gas cylinder hydrostatic testing needs to consider both “flow rate” (e.g., ≥5m³/min) and “high-pressure output,” while valve leakage detection focuses more on “pressure holding stability” (e.g., ≤0.3%/hour pressure decay). Companies need to select equipment whose pressure and flow parameters are precisely matched to their testing requirements based on their core testing scenarios to avoid cost waste due to parameter redundancy or testing difficulties caused by insufficient parameters.
2. Verifying Safety and Compliance Certifications: Compliance of high-pressure testing equipment is a prerequisite for safe production. When selecting a compressor, it is necessary to confirm whether the equipment has explosion-proof certification (e.g., ExdIIBT4Ga), pressure equipment license, ISO9001 quality management system certification, etc., and must also comply with international industry standards such as GB, CE, and API. For scenarios involving the testing of flammable and explosive gases, equipment with explosion-proof ratings and multiple safety protections (such as overpressure relief and leakage alarms) must be selected to eliminate safety hazards.
3. Focus on Equipment Stability and Maintenance Costs: The stability of high-pressure testing equipment directly affects testing efficiency. It is recommended to choose brands with excellent materials and mature structural designs for core components (such as screws and motors). For example, Jiangsu Minnuo’s high-pressure screw compressors use 38CrMoAlA alloy screws and IP54 explosion-proof motors, resulting in long maintenance intervals and a low failure rate. At the same time, pay attention to the ease of maintenance, such as whether it is equipped with quick filter replacement and real-time lubricant level monitoring functions to reduce downtime and labor costs during maintenance.
4. Assess Brand Strength and After-Sales Service: High-pressure screw compressors have high technical barriers to entry, and the brand’s R&D strength and production experience directly determine the equipment quality. It is recommended to choose brands that have been deeply involved in the gas equipment field for many years and have rich industry experience. For example, since its establishment in 1987, Minnuo has provided reliable equipment to many high-pressure testing companies worldwide, accumulating mature technical solutions and service experience. Meanwhile, focus on after-sales service guarantees, choosing brands that can provide on-site service within 48 hours, 24-hour technical response, and global spare parts supply to ensure rapid resolution of equipment failures and minimize test interruption losses.
V. Conclusion: High-Pressure Screw Compressors – “Guardians of Safety and Precision” for Critical Testing
In the high-pressure testing and inspection industry, accuracy, safety, and stability are insurmountable core requirements. High-pressure screw compressors, through two-stage compression technology, intelligent pressure control systems, and comprehensive safety design, fundamentally solve the pain points of traditional equipment such as large pressure fluctuations, high safety risks, and low testing efficiency, becoming core equipment for quality verification of pressure vessels, valves, pipelines, and other products.
With 37 years of technological accumulation and a deep understanding of the needs of the high-pressure testing industry, Minnuo has created high-pressure screw compressors that not only achieve industry-leading levels in core indicators such as pressure accuracy, stability, and safety, but also provide reliable support to global customers through a global after-sales service network. In the future, as the high-voltage testing industry continues to demand higher testing accuracy and efficiency, high-voltage screw compressors will continue to develop towards greater intelligence, efficiency, and safety, injecting strong momentum into product quality assurance and safe production in key areas.
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