Pressure Vessel Inspection Systems

STARMANS DIO 2000 Automated Ultrasonic Cylinder Testing Device

Advanced Automated Ultrasonic Testing for Gas Cylinders & Pressure Vessels

The STARMANS DIO 2000 Cylinder Testing Device represents the pinnacle of automated ultrasonic inspection technology for gas cylinders and pressure vessels. Engineered for both high-volume production environments and periodic re-qualification operations, this comprehensive system delivers superior defect detection while reducing inspection costs and time.

Versatile Testing Configuration

Our standard stationary testing device seamlessly adapts to:

• In-Line Production Testing: Automated integration with manufacturing lines
• Off-Line Re-Qualification: Manual or service-based periodic cylinder inspection
• Flexible Operation: Single platform for both production and maintenance testing

Superior Detection Capabilities

Comprehensive Defect Identification

Advanced Ultrasonic Analysis

• Wall Thickness Separation: Precise detection of laminar defects and delamination
• Crack Detection: Surface and subsurface crack identification
• Wall Thickness Verification: Accurate measurement and monitoring of minimum wall thickness
• Enhanced Sensitivity: Superior detection compared to conventional testing methods

Multi-Channel Ultrasonic Technology

High-Performance Testing Parameters

• Frequency Range: 2 to 15 MHz for optimal defect detection
• Testing Sensitivity: From 1 mm FBH (Flat Bottom Hole)
• Multiple Transducers: 5 transducers combined in each testing head
• Simultaneous Operation: 2 to 5 testing heads operating concurrently
• Individual Channel Control: Independent parameter settings for each channel

Standards Compliance & Certification

International Standards Conformity

Comprehensive Regulatory Compliance

The STARMANS DIO 2000 has been designed to comply with international standards for cylinder and pressure vessel testing:

• ISO 11439: Gas cylinders for natural gas vehicles
• EN 1964-1: Ultrasonic testing of pressure vessels
• EN ISO 9809: Gas cylinder design and construction standards
• EN 10246-6: Non-destructive testing of steel tubes
• EN 10246-7: Automatic full peripheral ultrasonic testing
• BS 5045: British Standard for transportable gas containers
• SEP 1915 / SEP 1918: German pressure vessel testing specifications

Technical Specifications

Cylinder Testing Range

*Parameters subject to customer agreement and customisation

System Capabilities

• Multi-Channel Architecture: Simultaneous multi-zone inspection
• Automatic Sorting: Visual/acoustic signalisation with automated sorting device
• High Throughput: Rapid testing cycles for production environments
• Precision Measurement: Accurate wall thickness and defect characterisation

Advanced System Components

Robust Mechanical Design

Durable Construction

• Rigid Frame Structure: Stable platform for consistent testing accuracy
• Testing Tank: Purpose-built immersion system for ultrasonic coupling
• Loading/Unloading Zone: Efficient cylinder handling for streamlined workflow
• Rotation System: Precision rollers ensure complete circumferential scanning
• Probe Holders: Adjustable mounting for optimal transducer positioning
• Water & Pressure Systems: Integrated coupling and handling systems

Modular Electronics Architecture

Flexible & Reliable

• Centralised Control: All mechanical functions managed by integrated electronics
• Ultrasonic Processing: Advanced signal processing from all probe channels
• Module-Wise Design: Electronic components and UT cards in organised cabinet configuration
• Individual Channel Setup: Independent parameter configuration for each channel
• Expandable Platform: Modular design allows system expansion

Intelligent Control Systems

Siemens PLC Integration

Industrial-Grade Automation

• Touch Screen Interface: Intuitive operator control panel
• Network Connectivity: Integration with company information systems
• Automated Operation: Fully automatic testing without continuous operator presence
• Remote Diagnostics: System monitoring and troubleshooting capabilities

Advanced Software Features

Comprehensive Test Management

• Settings Management: Easy configuration and adjustment of test parameters
• Real-Time Measuring: Continuous monitoring during testing operations
• Data Monitoring: Live visualisation of ultrasonic signals and results
• Calibration Tools: Integrated calibration procedures and verification
• User-Friendly Interface: Intuitive operation with minimal training requirements

Data Management & Reporting

Comprehensive Record Keeping

Advanced Analytics & Documentation

• Automatic Documentation: Immediate archiving of all test results
• Analysis Tools: Statistical data processing based on customisable criteria
• Report Generation: Individual vessel reports and batch order summaries
• Large Database: Extensive data storage for historical tracking
• Custom Formatting: Records arranged according to customer specifications
• Printing Capabilities: Professional report output for quality documentation

Information System Integration

• Central System Transfer: Automated data export to company information systems
• Network Integration: Seamless connectivity with existing IT infrastructure
• Parameter Storage: All test functions and parameters saved on hard drive
• Traceability: Complete inspection history for regulatory compliance

Automated Testing Advantages

Operational Excellence

Superior Performance Benefits

• Fully Automatic Operation: Modern computer control enables unattended testing
• Automatic Manipulation: Integrated cylinder handling reduces manual labor
• Rapid Testing Cycles: Short inspection time per vessel maximises throughput
• Simple Control: User-friendly software minimises training and operational complexity
• Remote Diagnostics: Off-site system monitoring and troubleshooting

Quality & Efficiency

Enhanced Testing Outcomes

• Immediate Results: Real-time signalisation of accepted/rejected vessels
• Automated Sorting: Automatic separation of good and defective cylinders
• Consistent Quality: Eliminates operator variability in test results
• Cost Reduction: Lower inspection costs through automation and efficiency
• Time Savings: Significantly reduced testing time compared to manual methods

NDT Methods for Pressure Vessel Inspection

Surface Defect Detection

• Visual Testing (VT): External surface examination
• Eddy Current Testing (ET): Conductive material surface defects
• Magnetic Particle Testing (MT): Ferromagnetic material surface cracks

Internal Defect Detection

• Ultrasonic Testing (UT): Volumetric inspection for internal defects (STARMANS Specialty)
• Radiographic Testing (RT): X-ray/gamma ray internal examination

The STARMANS DIO 2000 specialises in ultrasonic testing, providing the most comprehensive internal defect detection capabilities.

Applications & Industries

Primary Markets

• Gas Cylinder Manufacturing: Production line quality control
• Cylinder Re-Qualification Facilities: Periodic inspection and certification
• Compressed Gas Suppliers: Fleet maintenance and safety verification
• Industrial Gas Companies: CNG, LPG, and specialty gas cylinder testing
• Fire Suppression Systems: CO₂ and fire extinguisher cylinder inspection
• Medical Gas Suppliers: Healthcare cylinder certification

Testing Applications

• New cylinder production quality control
• Periodic re-qualification testing
• In-service inspection programs
• Post-repair verification
• Fleet management and tracking
• Regulatory compliance testing