Blog

Every innovation is the result of a journey involving design, testing, validation, and continuous improvement. Silea's new Pump Test Bench 4.0 was developed following this very philosophy: transforming years of experience into a solution that is even more efficient, reliable, and safe.

After exploring the features and benefits of the new test bench, let's take a closer look at how the project was developed and the expertise that contributed to its successful implementation.

From design to implementation

The construction of the test bench progressed largely according to the original plan. As with any complex engineering project, several solutions were refined during the assembly and testing phases, thanks to direct observation of the machine under real operating conditions.

• The first modification involved the return hose support. During testing, it became clear that removing the support significantly improved hose handling, making operations easier and faster for the operator.

• A second refinement concerned the bilge pump circuit used to drain the pump under test. The original design envisaged returning the liquid to the return pipeline, but testing showed that the bilge pump was unable to overcome the pressure generated by the liquid column inside the tank. The solution was to connect the pump directly to the tank's upper inlet nozzle.

These improvements enhanced the overall performance of the system without affecting the original project objectives.

Technical challenges along the way

In addition to the planned refinements, the team encountered two significant technical challenges during the development phase. The first concerned the 5-bar air pressure leak test. During pressure release, a hydraulic shock effect occurred inside the tank. To solve this issue, Silea worked together with its pneumatic systems supplier, who developed a solution capable of gradually reducing and dissipating the pressure, effectively eliminating the phenomenon.

The second challenge emerged during the testing of the pump bypass system, a key function for verifying the proper operation of the overpressure protection device. During the test procedure, a valve located downstream of the pump was rapidly closed to simulate a pipeline blockage, causing a sudden increase in pressure inside the line. This abrupt operation required a higher driving torque to keep the pump running, causing the selected V-belts to slip. To overcome this issue, larger toothed pulleys were installed, ensuring reliable power transmission even under the most demanding operating conditions.

A significant step forward

The new Pump Test Bench 4.0 represents a major advancement compared to the previous generation. Among the most significant improvements are:

• improved ergonomics when handling the connection hoses;

• a safer and more secure pump positioning and fastening system;

• leak-free connections thanks to the use of quick couplings;

• automated testing sequences;

• complete digitalization of the testing process with automatic generation of the final test report;

• enhanced operator safety through sensors that prevent the testing cycle from starting if the couplings or the pump drive connection are not correctly installed, or if anomalies are detected.

The result is a system that is more efficient, easier to operate, and capable of delivering an even higher level of product quality control.

A project built through teamwork

The successful development of the Pump Test Bench 4.0 was made possible by the collaboration of professionals with complementary expertise and a shared objective.

Fabrizio Cannone was responsible for the design and assembly of the test bench, while Michele Molinari managed the project and oversaw the certification activities. Antonio Corrado contributed to the assembly of the bench, and Stefano Calarota was responsible for installing the tank and the external piping.

External partners also played a key role. ITS carried out the electrical and pneumatic wiring of the system, while Medensystem developed the software that manages and automates the testing procedures.

Innovation driven by experience

Every project is an opportunity to improve. The Pump Test Bench 4.0 is the result of a development process that successfully transformed years of practical experience into concrete engineering solutions, addressing every technical challenge with a focus on achieving the most effective result.

This project further demonstrates Silea's commitment to designing increasingly reliable, safe, and technologically advanced systems that enhance product quality and deliver greater value to customers.