Reliable hydrostatic testing depends on more than high pressure. Every stage of the testing cycle must be completed in the correct sequence with stable pressure control and accurate data collection.

The Marley pipe hydro testing machine combines hydraulic control, water pressure control, Siemens PLC automation, and intelligent monitoring into one integrated system. From pipe loading to unloading, the entire hydrostatic testing process is completed automatically, helping manufacturers improve testing consistency, production efficiency, and product traceability.

System Configuration

The is built around four core systems that work together throughout every testing cycle.

Each system communicates continuously during production to maintain stable pressure, reliable sealing performance, and repeatable testing results.

Oil-Water Pressure Balancing Technology

One of the key technologies of the Marley  pipe hydro testing machine is its oil-water pressure balancing system.

During testing, hydraulic cylinders position and seal both ends of the pipe before water is introduced into the test section. After the air inside the pipe has been discharged, a high-pressure plunger pump gradually increases the internal pressure until the preset testing value is reached.

Hydraulic pressure and water pressure remain balanced throughout the pressure holding stage, helping maintain sealing stability and testing accuracy even during high-pressure operation.

This design reduces pressure fluctuation, minimizes leakage, and supports continuous production with consistent testing performance.

Siemens PLC Automatic Control

The complete testing sequence is controlled by a Siemens S7-200 PLC, eliminating the need for manual coordination between different machine components.

Pressure signals collected from field sensors are processed in real time, allowing the PLC to automatically control hydraulic cylinders, proportional valves, solenoid valves, pumps, and other actuators.

Every operation—from pipe positioning and water filling to pressure holding and pressure release—is executed according to the programmed testing sequence, ensuring stable operation and repeatable results.

Human-Machine Interface (HMI)

Daily operation is managed through an intuitive Human-Machine Interface (HMI).

Operators can complete routine production tasks directly from the control screen, including:

• Selecting testing programs
• Setting test pressure and holding time
• Monitoring machine status in real time
• Viewing pressure curves
• Printing test reports
• Accessing historical testing records
• Managing alarm information

Role-based access permissions allow engineers and operators to use different system functions while protecting critical machine settings.

Intelligent Monitoring System

Pressure monitoring is continuous throughout every testing cycle.

Water pressure sensors and hydraulic pressure sensors transmit real-time operating data to the PLC, allowing the control system to monitor pressure changes, detect abnormal conditions, and automatically adjust machine operation when required.

Every completed pressure test is recorded automatically, providing reliable production records for quality control, customer documentation, and future traceability.

Software Platform

The integrated software platform combines machine operation, production monitoring, and testing data management into one system.

Its main functions include:

System Architecture

The control architecture integrates industrial hardware and intelligent software into a unified testing platform.

Together, these components ensure stable machine operation, accurate pressure control, and reliable hydrostatic testing performance for continuous steel pipe production.