Pressure regulator test machine FE

Company name

Pietro Fiorentini S.p.A.

project title

Pressure regulator test machine FE

dimension and location

Large enterprise - Desenzano del Garda (BS)

PARTNER

MetalWork

technologies

Collaborative robotics and intelligent worker assistance systems
Smart energy monitoring and control

Pietro Fiorentini S.p.A. is the driving force behind the Pietro Fiorentini Group. With roots firmly anchored in the treatment, transport and distribution of natural gas, it has played a key role in the development of the international energy industry for decades. Today, it is actively working to make the energy supply chain more sustainable by embracing renewable gases such as biomethane and hydrogen, and applying its expertise in gas network measurement and management to the water supply chain. All of this while continuing to lead innovation in the sector, promoting eco-friendly solutions for the benefit of future generations and the planet.

The problem

The process of testing the sealing of gas pressure regulators, which are instruments used for pressure reduction and regulation in gas networks, is critical and currently still manual. This project aims to automate the manual testing cycle for the “FE” pressure regulators, designed by Pietro Fiorentini for the U.S. market, and to create a system for acquiring process parameters that will be integrated for analysis within the company’s MES system.

The solution

A CE-certified machine has been developed to automate the external seal and internal leakage tests of the Pietro Fiorentini S.p.A. FE regulator.
It also allows the collection, use, and verification of process data such as:

  • Specific values of safety device calibrations, such as the valley overpressure block and the pressure relief valve;
  • Values of inlet, outlet, and internal losses;
  • Association of data with each product via QR code;
  • Full product traceability via integration with company IT systems;
  • Estimation of the carbon footprint of the process by measuring air consumption and electrical energy usage.

Technologies

  1. Specific testing unit for verifying safety device intervention pressures, self-reconfiguring from product code.
  2. Monitoring of air consumption using hot-wire anemometers and calculating the associated carbon footprint.
  3. Precise traceability through QR codes for process data and the construction of dashboards for data analysis.

Desired Impacts

  • Increased production capacity to meet rising market demand.
  • Higher product margins through increased line productivity.
  • Enhanced product traceability through the integration of test benches with a data storage structure and interfacing with company IT systems.
  • Increased quality gates (process checks performed at each cycle), with precise monitoring of safety device calibration and data storage.
  • Improved health and safety ensured by the new workbench, in line with Directive 2006/42/EC and the latest harmonized standards and internal safety directives at Pietro Fiorentini for test benches.
  • Monitoring of consumption and automatic calculation of the process carbon footprint in terms of sustainability.

Benefits for the company

This machine will increase production capacity and line productivity while providing greater operator safety through reduced ergonomic strain.

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