Custom High-Pressure Flow Sight Glass Solution for Demanding Testing Environments
A publicly traded existing customer from the oil and gas industry approached us with a challenging request through our contact form. The aim was to develop a high-pressure fitting for use in a renowned technology and research center in Northern Europe. Here, complex testing environments are simulated that place the highest demands on the components used.
Our expertise in designing pressure-bearing equipment parts and our ability to meet individual customer requirements were crucial for the successful implementation of this project.
Requirements and challenges
The client's specifications defined clear and demanding requirements:
Operating safety at pressures up to 250 bar(g) had to be ensured.
The fitting was specified with a connection of 6” and Class 1500 lbs (RTJ).
The sight glass should be used in an environment with seawater, CO₂, crude oil, as well as natural gas and gas from shale.
Variable test conditions required the highest material and manufacturing quality.
Development of a Customized Solution
Our design and development team decided to use the proven Type 520A as a basis and adapt it to the specific requirements. The essential steps and features of the development were:
The housing and flanges were made of stainless steel 1.4571 (F316Ti) to ensure high corrosion resistance and mechanical load-bearing capacity. Borosilicate glass according to DIN 7080 was used for process observation, complemented by two mica discs on the media side to increase pressure resistance.
An optimized seal between the glass support flange and the external atmosphere ensured maximum tightness, even under high loads. The sealing surface shape RTJ (Ring Type Joint) was implemented according to customer requirements.
The high-pressure flow sight glass has been developed in accordance with the Pressure Equipment Directive 2014/68/EU, Category IV, Module G. The certificate of conformity and acceptance were carried out by Lloyd’s Register Deutschland GmbH, a notified body.
The customized pressure test was carried out on our high-pressure test stand, which allows test pressures of up to 1,000 bar. The fitting not only easily withstood the required 60-minute holding time at test pressure but also surpassed all expectations with a 72-hour load without leakage.
Results and Conclusion
The high-pressure Type 520A flow sight glass was successfully developed, manufactured, and tested. It meets all requirements regarding pressure resistance, material quality, and tightness and was safely delivered to the customer site in Northern Europe. Since then, it has been an integral part of the test operations in a state-of-the-art research center.
This project once again underscores the expertise and commitment of our team in solving complex technical challenges. We are proud to be a reliable partner for tailored solutions in the oil and gas industry.
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