Hydrostatic strength and leak testing of long-distance pipelines in the Middle East places extreme demands on the machinery used. In addition to ambient temperatures of up to 50 °C, the use of raw, unfiltered seawater as the test medium places particular demands on the material composition and structural design of the high-pressure systems. KAMAT has successfully completed and delivered two mobile high-pressure units on base frames for this application segment. The systems are used for hydrostatic testing of pipeline infrastructure.
Volumetric Precision During Continuous Pressure Build-Up
The process technology is based on two KAMAT quintuplex plunger pumps from the K55040M1-5G series. Unlike hydrodynamic centrifugal pumps, whose flow rate decreases as system back pressure increases, KAMAT positive displacement pumps operate almost independently of back pressure with a constant efficiency of over 90%.
The system is driven by a CAT diesel engine. The integrated programmable logic controller (PLC) regulates the system pressure via a precisely defined pressure ramp.
Technical Specifications of the Units:
| Technical Parameter | Meteric Values | US Units |
| Maximum Operating Pressure (p) | 680 bar | ca. 10.000 psi |
| Nominal Flow Rate | 225bis 409 l/min} | ca. 100 gpm |
| Configuration | 5 Cylinders (Quintuplex-Design) | |
| Installed Configuration | Mobile Skid Mounted Unit |
Technical Note: The Physics of Water Compressibility in Large Volumes
When pressure testing long pipeline sections, the compressibility of the test medium becomes a critical factor. At a pressure of 680 bar, water compresses by approximately 3 to 4% of its initial volume. After the pipeline has been completely filled, significant additional volumes must therefore be forced into the closed system to build up the test pressure.
To prevent pressure surges that could damage the material at the pipeline’s weld seams, KAMAT units are designed for variable flow rates and feature stepless speed control with a 1:10 ratio. This allows for switch-free, continuous regulation of the flow rate and protects the entire pipeline system during the compression phase.
Material Concept for High-Pressure Pumps for Seawater Applications up to 50 °C
Since the water used has high chloride content and may contain particles down to a filtration limit of 350 µm, KAMAT consistently relies on solid, high-strength materials rather than surface coatings that are prone to failure:
- One-piece duplex stainless steel pump head: The entire pump head housing is forged from a single piece of high-strength stainless steel and X-rayed. It offers complete resistance to pitting and crevice corrosion caused by seawater. The number of seals is minimized.
- All-ceramic plungers: The plungers used are made of solid all-ceramic material. They are characterized by extreme wear resistance against abrasive solids in the water, conduct hardly any heat, and require no additional cooling or lubrication.
- Sealing system without external lubrication: The self-adjusting KAMAT plunger seal operates as a maintenance-free cartridge system from 0 bar up to the maximum operating pressure completely without external lubricants, thereby also preventing contamination of the medium.
- Seawater-resistant safety valves: The full-stroke spring-loaded safety valve installed directly on the skid is also made of duplex steel and protects the system against impermissible pressure surges across the maximum flow cross-section.
Reduced Lifecycle Costs Through Modular Engineering
For operators in the Middle East, total cost of ownership (TCO) is a key investment criterion. The mechanical design of the KAMAT units minimizes downtime in the field: Thanks to the horizontal design and the well-thought-out head design, every internal part of the pump (valves, seals, plungers) can be replaced directly on site without having to dismantle the heavy pump head or the gearbox housing.
The integrated reduction gearbox features a quiet-running double helical gear set. This design prevents the generation of axial forces, protects the crankshaft bearings from uneven loading, and enables highly efficient power transmission with minimal heat generation.
Are you planning to design test benches or looking for high-pressure systems for harsh environmental conditions? You can find detailed technical specifications and modular options on our dedicated page for hydrostatic pressure testing.
