Pressure Design Qualifications

The KGTM Kelley Pack is certified to transport pressurized specialty gasses via rail, highway, barge, and air; this certification makes safety a first priority. KGTM Kelley Pack are subject to a barrage of pressure tests that are designed to test, re-test, and verify the safety factor of KGTM Kelley Packs. Pressure integrity tests are vital in verifying the integrity of any pressure containment system as any substance under pressure creates a reason for caution. Therefore, Kelley Packs are subject to extreme circumstance to ensure that our product offers the highest ratings in reliability and safety to users and the communities and the environment in which they operate.

Cycle Testing: All cycle testing is performed by hydrostatically pressuring the tube between zero and the designated pressure up to 4 cycles per minute. Hydrostatic testing filling the vessel with a liquid, in the KGTM hydraulic fluid is used for the pressurization of the vessel to the specified test pressure.

Ambient Temperature Testing: A KGTM tube was tested at ambient temperature without showing visible evidence of distortion, deterioration or failure by withstanding 10,000 pressurizations between zero and service pressure, followed by 30 pressurizations between zero and test pressure. Upon completion, the KGTM tube is pressurized to burst in accordance with DOT requirements.

Environmental Testing: A KGTM tube was tested without showing visible evidence of distortion, deterioration or failure by pressurizing from zero to service pressure for 5,000 cycles at a minimum of 140⁰F and a minimum of 95% relative humidity. The tube is then stabilized to average temperatures then again pressurized from zero to service pressure for another 5,000 cycles at -60⁰F or lower. The tube is again stabilized to average temperatures then pressurized for 30 additional cycles at ambient temperature.

Environmental tests were designed to test and prove the validity and safety of KGTM Kelley Pack functionalities in extreme conditions so that our product is a proven system in every application regardless of the environmental conditions and challenges.

Thermal Cycle Testing: A KGTM tube was tested without showing visible evidence of distortion, deterioration or failure by repeated, temperature controlled pressure cycles. First a cylinder is cycled from zero to service pressure (3,250 psi) for 10,000 cycles. This set cycle pressurizations is then followed by a second cycle from zero to test pressure (5,417 psi) for 30 cycles. The tube is then hydrostatically tested to service pressure for 10 minutes while submerged in a 200⁰F liquid environment, then transferred to a -60⁰F liquid environment where it must hold pressure, without fail, for an additional 10 minutes. Transfer times are deemed to be between one and three minutes with the pressure of the tube to be within the allowable range of service pressure to test pressure. This process is repeated 20 times.

Thermal Cycling tests were designed to test ad prove the validity and safety of KGTM vessels in varying thermal conditions. Thus, the KGTM module is proven to extreme temperatures and conditions proving to be the most safety conscious and proven reliable solution for specialty gas storage, collection, and transportation—even in extreme and varying conditions.

Hydraulic Burst Test: One tube of every 200 tubes manufactured will be hydrostatically pressurized to failure with a passing rate being that of 2.4 times the official working service pressure of the tube. Successful tests will result in tube failure initiated in the sidewall and the tube must remain in one piece.

This hydraulic test is designed to verify the working pressure of each KGTM vessel, compete to the safety factor of 2.4 times the working pressure. KGTM modules are consciously manufactured with the safety of our customers and end users as our first concern. It is our goal to ensure the safe utilization of every KGTM module.


Gunfire Test: One representative tube charged to service pressure with air or nitrogen will be impacted by a .50 caliber, armor piercing projectile at a distance not exceeding 50 yards. Successful tests will leave tubes intact without evidence of fragmentation failure.

The gunfire test was most probable the KGTM team’s favorite to witness and perform. It is designed to ensure and verify the safety of KGTM end users in extreme circumstance while in utilization by our armed forces. The KGTM module has been used by the United States Military and has been in active duty in helping to protect our troops.

Fire Engulfment Test: One representative tube and a complete KGTM module must pass a fire test utilizing a minimum of 150 gallons of diesel or JP-4 fuel. Upon ignition, a successful test will result with the tube staying within test pressure of the finished composite and sans content venting. Upon completion, representative tube must then be pressurized to burst.

Fire Engulfment tests were formulated to verify the safety factor of KGTM’s in times of duress. In the event of fire, the KGTM unit proved to be a safe containment solution for the pressurized contents.

Rollover Test: The complete assembly, charged to service pressure shall be rolled or dropped from a height representing the actual configuration during transportation. The assembly shall be robust enough to withstand a minimum 8g load as evidenced by typical shock load indicators. Results are acceptable if there is no apparent damage to the piping, valves, or fittings resulting in loss of contents.

Over the road equipment is always subject to accidental incidents and rollovers. Therefore the KGTM was tested to qualify them for safe over the road transport systems. For KGTM modules 8g refers to the force equal to the weight of the unit time eight.

Container Impact Test: A KGTM unit was mounted on a rail transport system and collided at a speed of 6.7 miles per hour and a 8g force with a representative rail car. Inspection of the ISO container revealed no sustained or visible damage to the containment unit. The corner-to-corner measurements on each side of the frame showed no measurable changes as a result of the impact test. The KGTM results of this impact test prove the units be solid and safe in their construction.

Forklift Puncture Test: The complete assembly shall be puncture tested as a minimum any tube within the assembly will be capable of withstanding damage.

Qualification Test Results: Reports of all tests are submitted to OHMSPA and kept on public record.


For detailed information regarding DOT-SP14867 go here.