Industry: Infrastructure & Mechanical Plumbing
Testing Application: High Pressure Steam Durability and Safety Validation
A world leader in mechanical pipe joining and flow control solutions approached Associated Environmental Systems (AES) in need of a specialized, high-capacity test system to validate the performance and safety of pressurized specimens under extreme thermal stress. The challenge? The project required a system capable of handling 1,500 lb loads while simulating temperatures up to 500°F (260°C), all while integrating complex safety logic to prevent "steam events" during the testing of pressurized components.
The AES Solution
AES engineered a custom fleet of 10 BD-927 Laboratory Ovens, high-performance floor-model systems built to meet the unique demands of high-pressure mechanical testing.
- Custom Safety Interlock System: AES developed a redundant safety logic that locks the chamber door whenever sample temperatures exceed 120°F or internal pressure is above 10 psi, protecting personnel from accidental exposure to high-pressure steam.
- Extreme Thermal Range & Precision: These ovens were upgraded to reach a maximum temperature of 500°F (260°C), utilizing dual-redundant thermocouples and pressure transducers to maintain a stability of ±0.5°C during week-long "cooking" cycles.
- Variable Speed Fresh Air Cooling: To meet the client's need for specific cooling rates, AES integrated a variable speed blower with a backflow damper, allowing for an adjustable, password-protected cooldown process that prevents thermal shock.
- Heavy-Duty Reinforced Flooring: Engineered to support the weight of industrial-grade pipe fittings, each 27 cu. ft. workspace was reinforced to accommodate up to 1,500 lbs of evenly distributed weight.
Crafting Your Perfect Test Set-Up
This solution was custom-engineered to meet the rigorous testing demands of the mechanical flow control industry, specifically addressing the risk of disconnecting pressurized specimens. By combining a high-capacity structural design with sophisticated safety redundancies and AESONE CONNECT® software, AES delivered a system that ensures total operator safety while accelerating development cycles through automated, reliable testing.
This project highlights AES’s commitment to designing advanced, customized test solutions that go far beyond standard specifications. To ensure the solution was perfect, AES hosted the client's engineering team at our factory for a comprehensive on-site performance validation. Our software engineers worked side-by-side with the client to refine the custom safety logic and test profiles. This collaborative approach ,and the subsequent production of 10 identical, high-performance units, proves that no ask is too challenging for AES when it comes to supporting innovation.
