Pressure verification of high-pressure gas sampler units (210 bar)
Barair Systems was commissioned by Fluimix Ltd to evaluate the structural integrity and operational readiness of two high-pressure gas sampling units intended for demanding industrial environments. The objective was formal verification that the units could operate safely at 210 bar, combining engineering assessment with physical hydrostatic testing.
This case study focuses on the pressure verification 210 bar of high-pressure gas sampling units, ensuring safety and efficiency in industrial applications.
The problem
Two pressure-retaining sampling units required verification for high-pressure duty, with demonstrable evidence of both design adequacy and test performance at the specified operating pressure.
Constraints and inputs
- Operating pressure requirement: 210 bar
- Pressure-critical components requiring verification (e.g., chamber body, end caps, isolation tube)
- Material selection: 316L stainless steel and Super Duplex stainless steel
- Precision manufacture to tight tolerances (reported ±0.05 mm)
Work performed
- Mechanical design and material review of pressure-critical components
- Pressure integrity assessment using established pressure design methodology (including Barlow’s formula for minimum wall thickness checks)
- Review of safety margins, including the benefit of Super Duplex strength and corrosion resistance for high-duty service
- Development and oversight of a hydrostatic pressure test procedure to validate real-world performance
Hydrostatic pressure testing
Testing was completed by Turner Hydraulic Site Services using UKAS-calibrated instrumentation.
Test method (summary):
- Gradual pressurisation to 210 bar
- 10-minute hold at full pressure
- Inspection for leakage and deformation
Deliverables
- Engineering assessment summary for pressure integrity at 210 bar
- Defined hydrostatic test procedure and recorded outcomes
- Practical conclusions and sign-off-ready verification narrative for stakeholders
Outcome
Both sampling units demonstrated theoretical compliance and physical integrity at full operating pressure. The project showcased Barair’s ability to combine calculation-led verification with hands-on validation for critical high-pressure systems.
Adrian Lowes BEng(hons) CEng MIMechE ASME
Adrian Lowes is a Chartered Mechanical Engineer and the founder of Barair Systems Limited, with over two decades of experience delivering innovative engineering solutions.
A graduate of the University of Bradford, he has worked on projects from automated vision systems for the automotive industry to oil and gas research with Cranfield University. He has developed products for brands including Microsoft, ICI, Toyota, and Florette. His expertise spans machinery design, finite element analysis, CE marking, and industrial accident investigation.
A lifelong musician, Adrian has directed Skipton Brass and Brass Ten, and served on the Alumni Committee of the National Youth Brass Band of Great Britain. Based in West Yorkshire, he combines technical precision with creative problem-solving in every project.