][]

Article

Design of a Test Bench for Overpressure Valves for Diving

Activity Compressors

Diseño de un banco de pruebas para válvulas de

sobrepresión para los compresores de actividades de buceo

Daniel Ramírez Ramírez ¹∗ Katherine Prada ²

and Edwin Sánchez ³

1

Diving School, Escuela Naval de Suboﬁciales “ARC Barranquilla”, Barranquilla, 111071, Colombia; danielramirez2545@gmail.com;

kpradasanchezz1017@gmail.com; edward.sanchez@armada.mil.co

∗

Correspondence: danielramirez2545@gmail.com

Citation: Ramirez, D.; Prada, K.; Sánchez, E. Design of a Test Bench for Overpressure Valves for Diving Activity Compressors. OnBoard

Knowledge Journal 2025, 1, 8. https://doi.org/10.70554/OBJK2025.v01n01.09

Received: 25/06/2025, Accepted: 02/07/2025, Published: 22/07/2025

DOI: https://doi.org/10.70554/OBJK2025.v01n01.09

Abstract: The objective of this research was to design a test bench for pressure relief valves used in compressors

employed in diving operations conducted by the Diving and Salvage Department of the National Navy, based in

Cartagena, Colombia. The objective was to optimize operational safety and safeguard both the equipment and the

safety of the personnel involved, as there are currently no speciﬁc test benches for these valves. This lack of essential

tools not only increases operating costs and the risk of damage to vital equipment, but also compromises the safety of

underwater operations. The methodology adopted was a mixed approach, which allowed for a thorough analysis of the

technical requirements. The results show that the valves tested on the designed test bench met the established pressure

parameters, validating the reliability and functionality of the prototype bench. Its modular conﬁguration allowed for its

application in various operating scenarios, representing a strategic advantage by generating opportunities for economic

and operational improvement in the medium and long term. In conclusion, the project solved the identiﬁed problem

through the implementation of a versatile test bench, contributing to the strengthening of preventive maintenance, risk

mitigation in critical diving and rescue activities, and increased competitiveness in the corresponding industrial sector.

Keywords: Compressors; Pressure relief valve; Safety; Test bench

Resumen: Esta investigación tuvo como objetivo diseñar un banco de pruebas para válvulas de sobrepresión utilizadas

en compresores empleados en operaciones de buceo realizadas por el Departamento de Buceo y Salvamento de la Armada

Nacional, con sede en la ciudad de Cartagena D.T y C; el propósito era optimizar la seguridad operacional y salvaguardar

tanto los equipos como la integridad del personal involucrado, ya que actualmente no se cuenta con bancos de prueba

especíﬁcos para dichas válvulas. Esta carencia de herramientas esenciales no solo incrementa los costos operativos y

el riesgo de daños a equipos vitales, sino que también compromete la seguridad de las operaciones subacuáticas. La

metodología adoptada tuvo un enfoque mixto, el cual permitió un análisis exhaustivo de los requerimientos técnicos.

Los resultados evidencian que las válvulas sometidas a prueba en el banco diseñado cumplieron con los parámetros de

presión establecidos, validando la conﬁabilidad y funcionalidad del prototipo del banco, cuya conﬁguración modular

permitió proyectar su aplicación en diversos escenarios operativos, lo que representa una ventaja estratégica al generar

OnBoard Knowledge Journal 2025, 1, 8.

https://revistasescuelanaval.com/obk/

Licensed by Escuela Naval de Cadetes "Almirante Padilla", COL.

This article is freely accessible and distributed under the terms and conditions

of Creative Commons Attribution (https://creativecommons.org/licenses/by/4.0/).

OnBoard Knowledge Journal 2025, 1, 8

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oportunidades de mejora económica y operativa a mediano y largo plazo. En conclusión, el proyecto dio solución al

problema identiﬁcado, a través de la implementación de un banco de pruebas versátil contribuyendo al fortalecimiento

del mantenimiento preventivo, la mitigación de riesgos en actividades críticas de buceo y salvamento, y al incremento de

la competitividad en el sector industrial correspondiente.

Palabras clave: Banco de pruebas; Compresores; Seguridad; Válvulas de sobrepresión

1. Introduction

In the mechanical engineering industry, the safety of compression equipment is of utmost importance

to ensure optimal operation and to prevent potential catastrophic failures. Compressors, as fundamental

components in a wide range of industrial applications, require control systems to maintain process integrity

and to protect both the equipment and the personnel involved in their operation.

In this context, overpressure valves are critical elements for safeguarding the integrity of compression

systems, as they release excess pressure in emergency situations and prevent potential damage to the National

Navy’s Diving and Rescue Department (DEBUS), located at the facilities of the ARC Bolívar Naval Base in

the city of Cartagena D.T. y C.

During the development of this research, various aspects related to the design and implementation

of the test bench were addressed, including component selection, control system conﬁguration, testing

procedures, and evaluation criteria.

The structure of this article is organized as: Section 2 presents the main contributions of this research,

emphasizing the need for a specialized test bench and the safety considerations involved. Section 3 provides

a review of related literature, including previous developments in pressure relief valve testing, industry

standards, and applicable regulations. Section 4 describes the methodological approach used for the design,

modeling, and validation of the test bench. Section 5 details the results obtained from testing the prototype,

including valve performance, system behavior, and operational veriﬁcation. Section 6 discusses the implica-

tions of the ﬁndings, improvement opportunities, and the broader impact of the system in industrial and

diving safety contexts. Finally, Section 7 summarizes the conclusions of the study and highlights future

perspectives for expanding the functionality and applications of the test bench.

2. Contributions

The need to develop a test bench for overpressure valves used in diving operation compressors arises

from the urgency to ensure safe and efﬁcient operations, which are essential for the preparation and execution

of critical safety and rescue tasks. This project is justiﬁed by its ability to introduce a testing method

that signiﬁcantly enhances both equipment and personnel safety, while also contributing to more effective

compressor maintenance.

The contributions of this research are summarized as follows:

i.

Identiﬁcation of a critical safety gap in the current maintenance and veriﬁcation protocols of overpres-

sure valves used in diving operation compressors within the National Navy.

Development of a structured testing method that strengthens both operational safety and preventive

maintenance processes for compressors.

Establishment of safety conditions for both operators and equipment, through the implementation

of appropriate protective measures, standardized operation procedures, and continuous personnel

training.

ii.

iii.

iv.

Review and deﬁnition of the minimum technical speciﬁcations required to guarantee safe operation,

based on a comparison between current conditions in the diving department and applicable national

and international standards.

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3. Related Works

The pressure relief valve, also referred to as a safety or relief valve, is an essential device in air com-

pression systems. Its primary function is to release excess pressure when operating limits are exceeded,

preventing structural failures or explosions [16]. It is activated automatically when a critical pressure level is

reached and closes once safe conditions are restored [14]. Its reliability is crucial for the operational safety of

industrial equipment [8;9].

Operations involving the use of compressors and pressure relief valves (Figure 1) in diving and rescue

range from the charging and storage of breathable air for ﬁlling SCUBA or semi-autonomous cylinders; the

generation of breathing gas mixtures (air, Nitrox, Trimix) for deep or technical diving; respiratory autonomy in

underwater rescue during search and recovery operations using SCUBA; the continuous supply of breathable

air in surface-supplied diving; and technical testing and calibrations for testing regulators, hoses, or valves,

among others. All these activities involve inherent risks due to high pressure; therefore, the validation of

these valves in compressors is essential to ensure operational safety.

(a) Air compressor

(b) Overpressure valve

Figure 1. Compressor of the National Navy Diving Department: (a) air compressor; (b) overpressure valve.

Source: The authors.

The technologies employed include conventional test benches, online systems, and computational

simulations. Smith and Brown [16] highlight that test benches allow valves to be evaluated under con-

trolled conditions, while others emphasize the usefulness of online systems for continuous monitoring and

predictive maintenance. Likewise, García and Pérez [4] emphasize the incorporation of advanced sensors

and automation to improve test accuracy, while Rodríguez and Martínez [14] illustrate the value of CFD

simulation for optimizing design prior to physical testing.

Advances in test bench design are aimed at improving precision, durability, and adaptability. García

and Pérez [4] highlight the integration of real-time measurement systems and automated control with

optimization algorithms. In addition, computational modeling is being explored to predict structural failures.

Rodríguez and Martínez [14] discuss the introduction of wear-resistant materials, such as ceramic coatings

and additive manufacturing, which extend the equipment’s service life.

Since their origins in the Industrial Revolution, pressure relief valves have evolved into intelligent

systems with integrated sensors, automated control, and remote communication. Advances in materials

and machine learning algorithms have improved their durability, adaptability, and real-time response

capability [4;16]. Case studies in sectors such as oil, chemicals, and power generation have demonstrated the

effectiveness of test benches in ensuring valve performance under extreme conditions. Lessons learned in

these industries, particularly in risk management and safety regulations, are applicable to contexts such as

industrial diving.

The United States, Germany, and Japan lead the development and standardization of technologies for

testing pressure relief valves. Standards such as ASME, DIN, and JIS ensure high levels of safety and quality.

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In contrast, Colombia faces limitations in speciﬁc regulations, investment in R&D, and specialized technical

training [ 11]. Institutions such as the National University are beginning to engage in the development of

4;

technologies associated with compressors and underwater safety [14]. However, testing is still carried out

manually and with limited infrastructure, which restricts the country’s competitiveness. The adoption of

international standards and cooperation could help close these technological gaps [15]. Technology transfer

and international collaboration are key to strengthening local capabilities. Participation in networks such as

the Ibero-American Network for Education in Industrial Safety can facilitate access to advanced technologies

and specialized training [14]. Training technical personnel and importing modern equipment are necessary

strategies to strengthen institutional development.

3.1. Regulations and Standards in Colombia

In Colombia, the regulation of air compression systems and the implementation of testing equipment

are governed by various industrial safety, energy, and occupational risk prevention standards. Some of the

key regulations are those described in Table 1.

Table 1. Regulations and standards applicable in Colombia

Type of Requirement

Description

This resolution issued by the Colombian Ministry of Labor establishes provisions

on occupational health and safety in workplaces. Speciﬁcally, it regulates the

conditions under which machinery and equipment must operate in working

environments, including systems that use compressed air.

Resolution 2400 of 1979

This standard establishes the requirements for the installation, operation, and

maintenance of compressed air systems. NTC 2885 deﬁnes the technical speciﬁca-

tions that compression equipment and overpressure valves must meet, with an

emphasis on safety and operational performance.

Colombian Technical Standard

(NTC) 2885

Although primarily focused on work at heights, this resolution issued by the

Ministry of Labor includes provisions on the use of safety equipment and risk

management practices that may also be applied to the operation of test benches

involving air compressors and high-pressure valves.

Resolution 1409 of 2012

This code, although not mandatory, provides guidelines for the design of industrial

equipment, including the implementation of control and safety mechanisms for

pressure-related systems such as overpressure valves.

ICONTEC Code of Good

Practice

Source: The authors.

3.2. Applicable International Standards

At the international level, there are widely recognized standards and regulations that deﬁne the

requirements for the design, testing, and operation of air compression systems and overpressure (safety)

valves. These standards are essential to ensure that the test bench meets the highest quality and safety

requirements. Some of the most relevant standards are presented in Table 2.

3.3. Manuals and Procedures

In addition to ofﬁcial standards and regulations, the manuals provided by manufacturers of overpressure

valves and compressors are also fundamental to the design and construction process of the test bench. These

manuals offer detailed speciﬁcations of the components used, as well as recommended procedures for the

installation, operation, and maintenance of the equipment.

•

Bauer Kompressoren operation manual: provides speciﬁc details on the operating conditions of the

overpressure valves installed in Bauer Junior 2 and Mariner II compressors. This information includes

operating pressures, recommended maintenance, and safety procedures that must be followed during

testing.

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Table 2. Applicable international regulations and standards

Type of Requirement

Description

This standard is one of the most internationally recognized regulations for

the construction and operation of pressure vessels and overpressure valves. It

deﬁnes the technical requirements for pressure equipment construction and

establishes speciﬁc methods for testing and calibrating overpressure valves.

Section VIII, Division 1, is particularly relevant to ensure that the test bench is

designed and built in accordance with the necessary safety standards.

This standard establishes procedures for testing and evaluating the performance

of safety and relief valves. The test bench must follow these procedures to

ensure that valves operate correctly under test conditions.

ASME Boiler and Pressure

Vessel Code, Section VIII

ASME PTC 25-2014

This European Union directive regulates the design and manufacture of pres-

sure equipment, including safety and relief valves. The test bench must comply

with the requirements established by the PED to ensure that the valves tested

meet European safety standards. In addition, it ensures that equipment is

designed to prevent leaks and failures under high-pressure conditions.

ISO 4126: Safety devices for protection against excessive pressure establishes

requirements for the design, operation, and testing of safety valves, ensuring

that the test bench can accurately measure opening and closing pressures.

ISO 8573: Compressed air quality focuses on the purity of compressed air and

is relevant because compressors used during testing must comply with these

standards to prevent system contamination.

European Pressure Equipment

Directive (PED) 2014/68/EU

International Organization for

Standardization (ISO)

DIN EN 12266-1 establishes requirements for the testing of industrial valves,

including safety and overpressure valves. It deﬁnes methods for pressure

resistance testing, leakage assessment, and performance evaluation under ex-

treme operating conditions, ensuring that the tests conducted on the bench are

accurate and reliable.

Deutsches Institut für

Normung (DIN)

Source: The authors.

•

Bauer safety valve calibration manual: describes the procedures for calibrating safety valves in air

compressors. It is recommended that these procedures be strictly followed on the test bench to ensure

that the overpressure valves are properly calibrated before being used in critical operations.

High-pressure compressor safety manual: provides key information on the safety measures that must

be implemented during the operation of high-pressure air compressors, including the use of additional

safety devices such as secondary relief valves and real-time pressure monitoring systems.

4. Materials and Methods

The study adopted a mixed-methods methodological approach, combining quantitative and qualitative

techniques to comprehensively address the design of a test bench for overpressure valves used in compressors

for diving and rescue operations. According to Hernández et al. [6], this research can be classiﬁed as applied

research, aimed at solving a speciﬁc operational safety problem through the implementation of theoretical

knowledge in a practical context.

From a quantitative perspective, descriptive and inferential methods were employed to objectively

assess the impact of the test bench on improving operational safety [1]. In parallel, as indicated by [2], the

qualitative approach enabled an in-depth understanding of the experiences and perceptions of technical

personnel through in-depth interviews and focus groups.

The temporal design of the research followed a sequential transformative approach, beginning with

an exploratory phase that included a literature review, preliminary interviews, and contextual analysis,

followed by a descriptive phase focused on the design of the device, adapting to the complexity of the

phenomenon under study [

6]. During the conceptual and bibliographic phase, previous studies, standards,

and experiences related to test benches and underwater safety were reviewed, allowing for the establishment

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of a robust theoretical framework for the prototype design. This process included the deﬁnition of technical

requirements, preparation of technical drawings, component development, and expert validation.

The prototype was manufactured in accordance with technical speciﬁcations and evaluated through

pressure, strength, and stability tests, as well as surveys and interviews with personnel, which provided

information on its usability, effectiveness, and acceptance. Finally, during the results analysis phase, improve-

ments aimed at optimizing the design, ergonomics, and control systems were identiﬁed and implemented,

ensuring compliance with technical and operational standards.

5. Results

The development of the project began with the determination of the minimum requirements of the test

bench based on a technical and functional analysis of the overpressure valves used in high- and low-pressure

compressors. This diagnostic process made it possible to identify the operating ranges, materials, and safety

parameters required to ensure the accuracy and reliability of the system. Subsequently, the design of the test

bench was proposed, integrating speciﬁc components (pressure gauges, control valves, pressure lines, and

discharge systems) tailored to the conditions inherent to diving and rescue operations, with priority given to

stability, safety, and ease of maintenance. Based on these speciﬁcations, a functional prototype was developed

capable of replicating the real operating conditions of Mariner II compressors, ensuring compatibility with

valves covering different pressure ranges.

Finally, the operational veriﬁcation of the test bench was conducted through controlled testing, commis-

sioning procedures, and review of the operation checklist, which made it possible to conﬁrm the accuracy of

the measurements, the proper response of the valves, and the overall efﬁciency of the system in preventing

failures associated with overpressure conditions. The results obtained are described below.

5.1. Minimum Requirements of the Test Bench Based on the Analysis of Technical and Functional Speciﬁcations of

Overpressure Valves

In the design of a test bench for overpressure valves, it is essential to understand the technical and

functional characteristics of each valve involved. Table 3 anf Figure 2 presents the overpressure valves used

in the Bauer Junior 2 and Mariner II compressors, which are integrated into the test bench.

Table 3. Characteristics of overpressure valves

Valve

Type

Opening Pressure

Stage

Airtek P.T valve

Low-pressure relief

valve

120–130 psi

Stage 1

Bauer Safety Valve

072935

Bauer Safety Valve

059410-330

Medium-pressure

safety valve

High-pressure safety

valve

Ultra-high-pressure

safety valve

860–870 psi

3,000–3,010 psi

5,000 psi

Stage 2

Final pressure

stage

High-pressure

stage

Bauer Valve 0169

Source: The authors.

Airtek P.T Valve: This valve is ideal for low-pressure compression systems, primarily in the ﬁrst

stage of compressors. It operates by releasing excess pressure when it reaches 120 psi. This type of valve

is essential for regulating systems that must maintain pressure within a safe range to prevent damage to

internal components. According to Rodriguez and Martinez [14], pressure relief valves protect compression

systems from mechanical failures by preventing overpressurization that could compromise system integrity.

This valve requires regular inspection of the opening diaphragm and cleaning to remove debris. Calibration

is performed by adjusting the spring under controlled pressure conditions.

Bauer Safety Valve 072935: This valve is essential in the second stage of compressors, where pressure is

signiﬁcantly higher than in the ﬁrst stage. Its function is to release excess pressure to prevent overpressur-

ization damage, thereby protecting both the equipment and the operators. As noted by [5], safety valves in

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(a) Airtek P.T valve

(b) Bauer safety valve 860 psi (072935)

(c) Bauer safety valve 3,000 psi (059410-330)

(d) Bauer valve 0169 (5,000 psi)

Figure 2. Overpressure valves: (a) Airtek P.T valve; (b) Bauer safety valve 860 psi (072935); (c) Bauer safety valve 3,000

psi (059410-330); (d) Bauer valve 0169 (5,000 psi).

Source: The authors.

medium-pressure systems ensure uninterrupted operation by releasing accumulated pressure and allowing

the compressor to maintain normal functioning. This valve is particularly useful in applications where

pressure ﬂuctuations are common. It requires inspection of the spring and high-pressure seals to prevent

wear. Calibration is carried out on a specialized test bench to ensure that the valve opens precisely at 860 psi.

Bauer Safety Valve 059410-330: The 3000 psi safety valve is critical in the ﬁnal compression stage,

where pressures are extremely high. This valve ensures that the system does not exceed safe limits by

releasing compressed air once the threshold pressure is reached. High-pressure valves are fundamental in

preventing catastrophic accidents in industrial systems operating under extreme pressures. Its robust design

and high-strength materials ensure reliable performance under demanding conditions. Maintenance involves

cleaning the valve body and inspecting the spring and seals. Calibration is performed using a test bench that

veriﬁes precise opening at 3000 psi.

Bauer Valve 0169: Designed to operate at ultra-high pressures of up to 5,000 psi, this valve plays a

crucial role in ensuring the safety of systems handling extreme compression. These valves are engineered

to release accumulated pressure in critical situations, thereby preventing equipment damage and potential

explosions. Martínez and Gómez [10] and Fernández and López [3] highlight that ultra-high-pressure valves

are indispensable in industrial systems requiring precise control of operating conditions, ensuring operational

continuity even under the highest pressure levels. Calibration is carried out using a high-precision pressure

gauge. This valve is ideal for applications in ultra-high-pressure compression systems that demand maximum

precision and safety.

5.2. Components of the Overpressure Valve Test Bench

For the initial development of the prototype overpressure valve test bench for diving compressors, the

process began with the creation of a 3D design. These models enabled precise visualization of the arrangement

of each component and the assessment of feasibility prior to fabrication. Through these drawings, potential

improvements and adjustments were also identiﬁed, thereby optimizing the design to meet the speciﬁc

pressure and control requirements of the project.

The 3D drawings included detailed representations of the test bench structure, the compressed air

supply system, and the control system, which together constitute the main components of the prototype.

The digital representation of each component allowed veriﬁcation of compatibility between parts and the

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execution of virtual simulations to ensure that the structure could withstand the required pressure conditions.

This approach provided a solid foundation for assembly and facilitated the technical documentation necessary

for the manufacturing and installation of the prototype. The 3D visualization (Figure 3) made it possible

to precisely adjust the system, ensuring stable pressure during testing and preventing potential leaks or

structural failures.

The main technical characteristics of the overpressure valve test bench are detailed below:

•

Pressure range: 70 MPa (10,000 psi)

Connection ports: 1/4 NPT female

Piston seal material: Viton

Recommended hydraulic ﬂuid: demineralized water or hydraulic oil

Screw press displacement: 20 cm³ (1.2 in³)

Reservoir volume: 75 cm³

Fine adjustment displacement: 0.06 cm³ (0.004 in³)

Figure 3. Plan of the test bench prototype.

Source: The authors.

The pressure generator consists of the following components: connection posts made of AISI 304

stainless steel with 1/4 NPT connection ports; a 1/2 pump cylinder made of AISI 304 stainless steel with

a 2 mm schedule; and a copper-free aluminum plate measuring 30 cm × 30 cm × 1/4. The reservoir water

valve screw is designed to withstand pressures of up to 10,000 psi. The system also includes a 2 × 4 AISI

304 stainless steel reservoir with Schedule 40 thickness, as well as a clamping handle for the screw press

mechanism.

The ﬂuid conduit is an essential component responsible for transporting the working ﬂuid from the

pressure source to the different points of the test system. Its cylindrical design ensures a constant and stable

ﬂow, allowing the ﬂuid to reach the valves under test under optimal conditions. This ﬂow stability is crucial

for maintaining measurement accuracy, particularly in high-pressure systems such as those used in diving

and rescue operations.

The ﬂuid conduit withstands the high pressures applied during the testing process without undergoing

deformation or premature wear. Its resistance to corrosion and mechanical fatigue ensures durability and

operational safety under demanding conditions. In addition, its structure prevents pressure losses and

ensures that the ﬂow of distilled water or oil remains within the established parameters for each test. The

use of this component optimizes the overall performance of the test bench by enabling accurate and safe

evaluation of overpressure valves, maintaining a controlled environment free from pressure ﬂow ﬂuctuations.

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The coupling holders represent the test bench couplings and are designed to ensure a ﬁrm and secure

connection for each type of valve subjected to testing. These couplings feature an internal thread that allows

the attachment of valves of different sizes and types, providing versatility to the system by adapting to

various overpressure valve speciﬁcations. Their robustness and machining precision ensure a tight seal,

preventing potential ﬂuid leaks and guaranteeing test stability.

The primary function of the couplings is to facilitate the rapid assembly and disassembly of the valves

to be evaluated. By offering a standardized connection, these couplings allow the operator to conﬁgure the

system according to the characteristics of each valve, optimizing the testing process and reducing setup times.

This modular design is a key feature of the test bench, as it enables faster and more precise testing of different

valves. The design ensures that the compressed ﬂuid ﬂow is directed in a controlled manner toward the

connected valve, preserving test integrity and minimizing the risk of pressure loss or mechanical failure

during the evaluation process.

The piston support is a fundamental component within the structure of the test bench, designed to

support and align the pistons that regulate ﬂuid ﬂow and pressure within the system. These supports

ensure that the pistons remain in a stable and precise position, allowing uniform ﬂuid control during the

overpressure valve testing process. Their robust design ensures structural durability, withstanding the forces

generated by the system’s high-pressure conditions.

This component also plays a critical role in reducing vibrations and unwanted displacements during

testing. By ﬁxing the pistons in an exact position, it prevents lateral movement or misalignment that could

affect test accuracy and valve performance. The stability provided by the piston support is essential to ensure

that each test is conducted under controlled and repeatable conditions, thereby increasing the reliability

of the results. Furthermore, this component is designed to withstand wear and the demanding operating

conditions of the test bench. Its ability to maintain piston alignment and structural integrity contributes

signiﬁcantly to the overall safety and reliability of the system, minimizing the risk of leaks and ensuring that

the valves under test operate optimally under the established conditions.

The ﬁnal connection for the overpressure valves is the component that ensures the direct coupling

between the valves to be tested and the pressure system of the test bench. This connector, designed to

withstand high pressures, allows each overpressure valve to be securely and efﬁciently mounted on the test

bench. The ﬁnal connection maintains a hermetic seal, preventing leaks and ensuring that the ﬂuid ﬂow

remains constant and controlled throughout the testing process. Its robust design is essential to prevent

deformation or failure under extreme conditions, which is critical for ensuring accuracy in the evaluation of

each overpressure valve. In addition, this ﬁnal connection enables quick and ﬁrm installation of the valves,

facilitating the assembly and disassembly process for each test. By ensuring proper valve ﬁtting within the

system, this connection contributes to the overall operability of the test bench and guarantees that each test is

conducted under optimal conditions, ensuring the reliability and safety of the results obtained.

The pressure piston is responsible for generating the pressure required to evaluate the performance of

the overpressure valves. This piston operates through a screw-driven mechanism that allows pressure to be

increased in a controlled and gradual manner, providing a precise and safe testing environment. The ﬁne

adjustment capability of this mechanism ensures that the pressure applied to the valves can be regulated with

high accuracy, which is essential for tests requiring speciﬁc pressure levels. In addition, the pressure piston

is constructed from high-strength materials capable of withstanding mechanical stress and the pressures

generated during testing, enabling repeated use without compromising structural integrity and ensuring the

durability and reliability of the test bench. The incorporation of the pressure piston allows the test bench to

perform accurate and safe evaluations, facilitating the validation of overpressure valves under controlled

conditions.

The digital pressure gauge is a key measuring instrument in the test bench, designed to provide precise

readings of the pressure generated in the system and, in particular, to measure the opening pressure of

the overpressure valves. This device enables real-time monitoring of the pressure at which each valve is

activated, which is essential for verifying compliance with safety and performance speciﬁcations.

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The use of a digital pressure gauge instead of an analog one improves measurement accuracy and

facilitates data interpretation by allowing fast and precise readings. Its digital display provides clear

visualization and eliminates the human error margin associated with analog scale readings, thereby increasing

test reliability. This level of precision is essential for documenting valve performance and for making

adjustments when necessary. The threaded connection ensures secure attachment to the system, preventing

pressure leaks and maintaining the integrity of the test bench. Beyond continuous monitoring, the digital

pressure gauge also contributes to system safety by alerting the operator to any pressure deviations during

valve testing.

The reservoir is an essential component responsible for storing the ﬂuid used to pressurize the system

during overpressure valve testing. Its inverted conical design facilitates ﬂuid accumulation and controlled

release, ensuring that constant pressure is maintained in the system when the testing process is activated.

This reservoir allows the test bench to maintain an adequate ﬂuid supply to perform multiple tests without

the need for immediate reﬁlling. Its design ensures that the stored ﬂuid remains fully sealed, preventing

pressure losses and leaks, critical factors for maintaining the integrity and accuracy of the tests conducted on

the bench. Furthermore, the reservoir is integrated in a way that facilitates its connection with the rest of the

system, ensuring continuous and controlled ﬂow toward the pressure piston and enabling precise pressure

adjustment within the test bench. As such, the reservoir plays a key role in the overall operation of the system

by providing the required ﬂuid volume to ensure that each valve test is conducted safely and reliably.

5.3. Prototype of the Overpressure Valve Test Bench for Compressors

The fabrication of the device was carried out entirely using AISI 304 stainless steel, with the exception

of the piston and the press screw. The piston was manufactured from phosphor bronze, while the press screw

was made of AISI 4140 steel. The base and support structure were constructed from copper-free aluminum,

with approximate dimensions of 30 cm × 30 cm and a thickness of 1/4, as shown in Figure 4.

Figure 4. Test bench prototype.

Source: The authors.

The prototype integrates all the essential components required to perform controlled and safe pressure

tests, enabling accurate evaluation of valve performance under simulated operational conditions. Its modular

and detailed design ensures an efﬁcient and secure conﬁguration, optimizing ﬂuid ﬂow and pressure

regulation at each stage of the testing process.

The system includes a reservoir located at the top, which acts as the pressure ﬂuid container and ensures

a constant supply to the system. Through a ﬁne internal thread, the ﬂuid is directed toward the pressure

piston located at the center of the system, which generates the pressure required for testing. This piston

allows ﬁne pressure adjustment, while the needle screw installed in the reservoir precisely controls the ﬂuid

ﬂow toward the piston.

On the upper right side, a digital pressure gauge is installed, enabling real-time pressure monitoring.

This gauge is critical for recording the exact pressure at which the valve activates, ensuring measurement

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accuracy. The ﬁnal connection ensures a hermetic ﬁt for the overpressure valve, facilitating a controlled

testing environment. The arrangement of components on a rigid base provides system stability, enabling

efﬁcient operation and minimizing the risk of leaks or failures during testing. This integrated design ensures

that the test bench meets the required safety and functional standards.

5.4. Operation of the Test Bench and Operating Checklist

As a result of commissioning the overpressure valve test bench, multiple systematic tests were conducted

to verify the performance of each valve under controlled conditions. In all cases, the valves subjected to testing

met the expected opening parameters, with consistent pressure values conﬁrmed across ﬁve consecutive tests.

No signiﬁcant variations were identiﬁed that could compromise performance, demonstrating the accuracy

and reliability of the test bench for validating and adjusting the operational settings of the valves.

During the functional evaluation of the safety valve test bench prototype for the Mariner II compressor,

accuracy, consistency, and reliability were veriﬁed across different pressure stages.

In the ﬁrst stage, the Airtek P.T 9 bar PN 25 D 6 mm Q2101 valve, classiﬁed as a low-pressure relief

valve (120 psi), exhibited an exact and repeatable response at the established opening point, conﬁrming its

effectiveness in preventing overpressure conditions that could compromise the integrity of the compressor’s

initial components.

In the second stage, the Bauer Safety Valve 60 BAR 072935, identiﬁed as a medium-pressure safety

valve (6870 psi), demonstrated precise and stable activation in the ﬁve consecutive tests performed, ensuring

compliance with operational safety standards and protection of the system’s intermediate components.

Regarding the ﬁnal stage, the Bauer Safety Valve 330 Bars 059410-330, classiﬁed as a high-pressure safety

valve (4786.25 psi), operated consistently at its nominal opening pressure, preventing exceedances that could

lead to structural failures and thereby guaranteeing the overall safety of the compression process.

Finally, the Bauer Valve 0169 (6500 psi), classiﬁed as an ultra-high-pressure safety valve, was reliably

activated under no-load conditions, preventing unnecessary pressurization of the system. Its stable behavior

conﬁrms its critical role in equipment protection and risk prevention during operation.

During the development of the tests using the prototype, several improvement opportunities were

identiﬁed. These include the implementation of a ﬁxed safety valve for the entire system to ensure that,

in the event a valve is not properly calibrated at its designated set point, unreleased pressure does not

become a safety hazard. Additionally, the implementation of a protective cover over the valve under test is

recommended so that, in the event of abrupt pressure release, the discharge of ﬂuid is safely contained by the

enclosure.

In summary, the tests conducted demonstrate that the evaluated valves adequately meet their design

parameters, ensuring sequential protection of the compression system across all operational stages.

The following steps describe the procedure required for the proper operation of the prototype overpres-

sure valve test bench used for compressors employed in diving operations carried out by the National Navy

Diving and Salvage Department:

•

Step 1. System purging: Turn the regulating spindle clockwise until it reaches its stop to remove any

residual air inside the system. This step is essential to ensure that the system starts under optimal

conditions.

•

Step 2. Connection preparation: Apply Teﬂon tape to the threads of the valve and the pressure gauge.

This ensures a hermetic seal and prevents leaks during testing.

Step 3. Connection tightening: Use an appropriate adjustable wrench to secure the system connections,

tightening each component precisely according to the required size.

Step 4. Fluid loading: Fill the reservoir with distilled water.

•

Step 5. Filling the piston chamber: Turn the spindle counterclockwise to allow the ﬂuid to completely

ﬁll the piston chamber, ensuring it is ready for pressure generation.

•

Step 6. Reservoir sealing: Install the reservoir cap and tighten it ﬁrmly to prevent any potential ﬂuid

leakage.

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•

Step 7. Leak inspection: Perform a visual inspection of the entire system to conﬁrm that there are no

leaks at the connections or at the reservoir before proceeding.

Step 8. Test initiation: Turn the spindle clockwise to gradually increase system pressure. Monitor the

digital pressure gauge throughout this process to control the pressure increase.

Step 9. Valve opening veriﬁcation: Observe the pressure gauge as pressure increases and record the

exact moment at which the valve is activated. Visually inspect the valve to conﬁrm proper opening.

6. Discussion

The project demonstrates a signiﬁcant scope, as it not only enables the calibration of overpressure valves

used in industrial compressors, but also allows for the calibration of valves employed in hyperbaric chambers

and pressure gauges with set points not exceeding 10,000 psi. This achievement opens opportunities to

diversify the applications of the test bench, thereby increasing its usefulness across different industrial

environments. However, to fully maximize its potential, further studies are recommended, along with design

enhancements and additional testing aimed at expanding its scope and overall impact.

Moreover, this development represents an initial step toward valve certiﬁcation, enabling the future

provision of calibration and certiﬁcation services using the constructed test bench. For this to become a reality

and generate a positive economic impact, continued research is required to support process standardization

and compliance with international regulations. This will ensure the commercial viability of the service

while strengthening operational safety through the implementation of advanced monitoring technologies

and proactive risk management strategies, which allow deviations or anomalies to be detected before they

lead to critical failures. In this regard, the studies conducted by Zonta et al. [18] demonstrate that early

fault detection through predictive systems based on artiﬁcial intelligence and real-time analysis signiﬁcantly

increases the reliability of industrial equipment.

Similarly, a comprehensive safety approach spanning from design to operation has been promoted

by model-based engineering methodologies, such as Model-Based Safety Analysis, which integrate risk

management throughout the system life cycle. According to Rajabalinejad and Van Dongen [13], the Safety

Cube method facilitates the traceability of safety requirements and optimizes the validation of complex

systems. In addition, the adoption of international standards, such as ISO 9001 and ISO 45001, strengthens

systematic safety and occupational health management. Recent studies show that ISO 45001 certiﬁcation

contributes to improved performance indicators and the development of a preventive safety culture within

organizations [12].

Finally, intersectoral collaboration constitutes a key component in the consolidation of sustainable safety

practices, particularly in the design and implementation of specialized technical equipment. According to

Tancred et al. [17] and the International Journal of Health Policy and Management [7], shared governance

approaches promote coordination among technical, industrial, and regulatory sectors, generating synergies

that enhance organizational resilience and comprehensive risk management. In this context, the design and

implementation of the overpressure valve test bench effectively integrate these sectors, taking into account

compliance with both national and international regulations and standards that deﬁne safety, quality, and

operational requirements. This integration ultimately ensures reliable system performance and the protection

of both operators and equipment.

7. Conclusions

The development and commissioning of a test bench for overpressure valves used in compressors

proved to be an effective technological solution for ensuring operational safety in diving and rescue activities.

Its performance was shown to be reliable, repeatable, and precise, thereby reducing the likelihood of failures

during critical operations.

Furthermore, validation through experimental testing conﬁrmed that all evaluated valves met their

speciﬁed pressure thresholds, demonstrating the test bench’s capability to identify deviations in opening

pressure and to verify that pressure relief mechanisms are properly conﬁgured. Its technical feasibility and

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potential for industrial certiﬁcation are further strengthened by the incorporation of advanced control systems

and the use of components that comply with international standards.

The modular and adaptable structure of the test bench provides enhanced design versatility, as it can be

adjusted to accommodate different valve speciﬁcations and operating conditions. This feature, combined

with its functional stability, positions the system as a strategic platform for calibration and certiﬁcation

services in the ﬁeld of underwater and industrial safety.

Finally, this research effectively addressed the identiﬁed technical need: the lack of a veriﬁcation

system for overpressure valves in compressors used for diving and rescue operations. The proposed solution

improves preventive maintenance procedures, complies with the necessary technical standards, and reinforces

operational safety in critical applications. Additionally, it is expected to serve as a foundation for the future

integration of emerging technologies, such as real-time data analysis and remote monitoring, which will

further enhance innovation capacity and technical competitiveness within the sector.

Author Contributions: Daniel Ramírez: Conceptualization, Methodology, Formal analysis, Investigation, Writing

– original draft, Writing – review & editing, Supervision, Project administration. Katherine Prada: Methodology,

Software, Validation, Data curation, Visualization, Writing – original draft, Writing – review & editing. Edwin Sánchez:

Investigation, Resources, Validation, Formal analysis, Writing – review & editing, Funding acquisition.

All authors have read and agreed to the published version of the manuscript. Please refer to the CRediT taxonomy for the

deﬁnitions of the terms. Authorship is limited to those who have made substantial contributions to the reported work.

Funding: This research received no external funding.

Institutional Review Board Statement: Not applicable, since the present study does not involvehuman personnel or

animals."

Informed Consent Statement: This study is limited to the use of technological resources, so nohuman personnel or

animals are involved.

Conﬂicts of Interest: Under the authorship of this research, it is declared that there is no conﬂict of interest with the

present research.

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Authors’ Biography

Daniel Ramírez Ramírez Student at the Escuela Naval de Suboﬁciales “ARC

Barranquilla”

Katherine Prada Student at the Escuela Naval de Suboﬁciales “ARC Barranquilla”

Edwin Sánchez Student at the Escuela Naval de Suboﬁciales “ARC Barranquilla”

Disclaimer/Editor’s Note: Statements, opinions, and data contained in all publications are solely those of the individual

authors and contributors and not of the OnBoard Knowledge Journal and/or the editor(s), disclaiming any responsibility

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content.