Barair Systems was commissioned by Fluimix Ltd to evaluate two high-pressure gas sampling units intended for demanding industrial service. The purpose of the project was to provide formal verification that the units could operate safely at 210 bar, using a combination of engineering assessment and physical hydrostatic testing to demonstrate both design adequacy and practical performance.
The problem was straightforward but high consequence: two pressure-retaining sampling units needed to be verified for high-pressure duty, and the evidence had to be clear enough to support stakeholder confidence in both the design and the completed test results. In applications of this kind, pressure integrity cannot rely on calculation alone or testing alone; the most credible position comes from combining both.
The units included pressure-critical components such as the chamber body, end caps and isolation tube, manufactured using 316L stainless steel and Super Duplex stainless steel. Tight manufacturing tolerances were also a relevant input, as these affect both fit and confidence in wall thickness and pressure-retaining geometry. Barair reviewed the design of the pressure-critical components, carried out wall-thickness verification using established pressure design methods, and assessed the available safety margin, including the additional strength and corrosion-resistance benefits offered by Super Duplex material in high-duty service.
To validate the design in real-world conditions, Barair also developed and oversaw a hydrostatic pressure test procedure. Testing was undertaken by Turner Hydraulic Site Services using UKAS-calibrated instrumentation. The units were gradually pressurised to 210 bar, held for ten minutes at full pressure, and inspected for leakage or visible deformation. This provided a direct check that the theoretical assessment aligned with actual behaviour under the required operating pressure.
The final output combined the engineering narrative and the physical test evidence into a sign-off-ready verification package. Both sampling units demonstrated theoretical compliance and physical integrity at full operating pressure, giving Fluimix a clear basis for acceptance. The project showed Barair’s ability to combine calculation-led design verification with practical, witnessed validation for critical high-pressure equipment.
