Quote Originally Posted by Gasbot
I think I'm banging my head against a wall here. Fail safes, removable links, power lights - pressure components that are suitable... anyone catch my drift?
No, I'm probably to stupid.

Maddox10,

We are not building combat robots or bumper cars! We are building pressurized vessels & systems which are all designed to a maximum working pressure which is specified by a manufacturer.
Probably there ain't a difference between working pressure and pressure rating.

In 'your opinion' a 50 bar device is suitable for 69 bar (even if that pressure cannot be reached). The manufacturers maximum working pressure is 50 Bar, hence without any further information from the manufacturer (these are not home built devices we are talking about) we should surely assume that the maximum safe working pressure is also 50 Bar? (and we're not taking burst pressure here)
My opinion is backed up by pressure tests done to get UK machine to participate in Battlebots.

I do not have opinions when it comes to pressure components, I have a fact that there is a design pressure of X, a design temperature of Y and a test pressure of Z.Your opinions are only opinions and you are relying on the in built factor of safety used in the valves construction.
Sorry that English ain't my motherlaguage (nor father). I should have used another word. Maybe that this semantism satisfies your thirst for accuracy.
To my knowledge a Burkert is overdesigned concerning pressure rating, for the job it does.

I designed my gas systems to 90 BarG, hence I can say that everything in my system excluding the CO2 bottles and pressure relief valve is designed to operate or have a safe working pressure of 90 BarG (the hoses, control valves and couplings are rated higher). I know for a fact that the components I manufactured have a safety factor of 4 due to the stress values I used when calculating the minimum shell thicknesses. I know for a fact that the hydro pressure test was successful on the system to a pressure of roughly 128 BarG for 1 hour.
Tough as Nails has had active pressure tests at 130 bar with nitrogen.

I remember when people thought it was acceptable to use 10 or 16 Bar rams at bottle pressure, along with the plastic tubing and push fittings. This is the same but to a lesser extent - even if 69 Barg cannot be reached.
Those we still have. I just hope we can inform those people before they hurt themselfs.

Regardless of the above, the build rules say 50 BarG components (because 50 Bar is what the manufacturers rate them at) must be protected by a pressure relief device rated to 110% of the working pressure, or independently tested to 120% of the maximum system pressure, which with a 69 Bar relief valve fitted would be around 83 Bar - which I personally consider to be too low.

The gas system I put into Mute complies with the build rules - do you yours? Or is it just in your opinion that they do?
Yes they do. After consulting with event organisers and some other knowledgable people. yes.

9.7 Rating
All pneumatic components used with pressures greater than 50psi (3.4bar) must be rated/ tested to at least
the maximum pressure available in that part of the system. You may be required to provide documentation/
certification to support this.

I can produce the pressure test results of the systems I did build. All can stand hydrostatic pressure testing @1500 psi.

Perhaps the rules do need changing so that I can skim 2 or 3mm off the CO2 bottles (in 'my opinion' they're over rated anyway) and thin the other components down too I can throw more armour on then!
1.5mm from a 6mm wall. It will still stand the normal pressure. But the 3000psi burst disk could be stronger than the wall then.
Oh well, if you want to gain those few 100 grams that way. Sorry, but I would buy a smaller battery, or one with a better chemistry, like LiFePo4.

9.3 Cylinders
The compressed gas shall be stored in a commercially manufactured gas cylinder of appropriate design,
specification and certification. Except where the maximum storage pressure is less than 50psi (3.4bar).
Some events may have further restrictions on bottle sizes/ weights used, please contact the event organiser
for clarification.