NEOMETRIX DEFENCE LIMITED

Hydraulic & Pressure Testing Challenges in Indian Defence Manufacturing

Complex Operating Conditions in Defence Systems
Indian defence manufacturing operates under extreme conditions — high altitude, desert heat, naval corrosion, and high-pressure combat environments. Hydraulic systems in tanks, missile launchers, aircraft, and artillery must perform flawlessly. From nitrogen-charged suspension struts on T-90 MBTs absorbing battlefield shocks at 400 Bar, to bootstrap hydraulic modules maintaining cavitation-free flow in combat helicopters during negative-G manoeuvres — every system demands validated, repeatable performance before deployment.

Critical Role of High-Pressure Validation
Defence hydraulic systems routinely operate at 300–1800 Bar. Artillery casings require hydrostatic proof pressure up to 1800 Bar. Aerospace pumps are validated at 270 Bar and 130 LPM. Hydrogen cylinders are burst-tested to 5,000 Bar in dual-wall containment chambers. Simulating real battlefield loads with full traceability is non-negotiable.

Material Integrity & Fatigue Testing
Bomb casings forged from 40Ni6Cr4Mo3 alloy (yield ≥ 880 MPa, tensile 1,100–1,250 MPa), LP turbine shafts under combined torsion and 100–350°C thermal gradients, and bearings at 70,000 RPM — all undergo severe cyclic stress. Testing must identify micro-cracks and structural weaknesses before field deployment.

Zero-Failure Requirement
Defence operates on zero-failure tolerance. A single hydraulic valve failure can compromise missions. This demands automated testing with PLC/SCADA control, real-time DAQ at up to 5 kS/s, automated pass/fail decisions, and audit-ready digital reports

Compliance with Defence Standards

Standard	Scope
IS 1184	Pressure vessel structural integrity — proof pressures up to 1800 Bar
MIL-H-5606 / MIL-PRF-5606	Hydraulic fluid compatibility — OM-15 fluid across −20°C to +120°C
MIL-STD-810 / MIL-STD-461	Environmental extremes & EMC — validated with ±0.05% FS instrumentation
NATO STANAG	Interoperability — vibration, shock, pressure cycling, salt-water immersion qualification
DGQA	Traceable testing with NABL-certified calibration, ISO/IEC 17025 records
MIL-STD-3000 / ICAO Annex 14	Aircraft arresting systems — runway safety compliance

All systems integrate PLC automation, SCADA interfaces, and automated report generation with e-signatures and audit trails for complete traceability.

Defence Test Equipment Solutions by Neometrix

Ammunition & Ordnance Systems
• 155mm Bomb Shell Pressure Testing Machine — Hydrostatic proof testing up to 1800 Bar for artillery shells, smoke shells, and explosive shells. Automated cycles, digital logging, operator-safe enclosures.
• MK-84 2000 lb Bomb Casing — Forged 40Ni6Cr4Mo3 alloy (Vickers 352–375 HV). Full NDT — ultrasonic, magnetic particle, radiography. NABL-certified. Compatible with laser-guided and GPS/INS munitions.
• Copper Band Press — Precision hydraulic press for shrink-fitting driving bands on medium-to-large calibre projectiles. Programmable multi-calibre support.
• Stun Grenade Production Line — 17-station automated line, 500 units/hour, ±0.05g dosing. ATEX/MIL-STD compliant.

Hydraulic Component Test Benches
• Automated Hydraulic Control Valve Test Bench (350 kW) — Up to 400 LPM / 420 Bar. Flow vs. ΔP mapping, hysteresis, response time, leakage, endurance cycling. Multi-channel instrumentation with automated sequencing.
• 1000 Bar Proof Pressure Test Bench — Static testing of HSU N2 chambers for armoured vehicles.
• Hydraulic Proof Pressure Test Rig (700 Bar) — ISO 19879, SAE J343, MIL-STD-810 compliant. PLC-controlled ramp/dwell/depressurise cycles.

Armoured Vehicle Testing
• Hydro-Gas Suspension (HSU) Validation System — For T-72, T-90, BMP-II, K9 Vajra, Arjun MBT. 400 Bar actuation, NAS 1638 Class 6 filtration, LabVIEW DAQ (1 kS/s). Static proof, dynamic damping characterisation, and automated MIL-H-5606 fluid recharge.
• Inertial Loading Test Facility — ±160 kN dynamic force, 2000 kg modular mass, 2g acceleration, sub-micron positional repeatability.

Aerospace & Aircraft Systems
• Aircraft Arrester Barrier System — Net-type and pendant-type for 6–40 ton aircraft. ≤10 min re-arm. MIL-STD-3000 / ICAO Annex 14 compliant.
• Aircraft Arresting Gear (AAG) — 58m Nylon-66 net, dual 20T+40T water-twister absorber, ≈3g controlled deceleration within 270m. 3-second deployment.
• Integrated Hydraulic Reservoir & Intensifier Module — Bootstrap design (2.75L/4.25L) for combat helicopters. 82.4:1 intensifier ratio, 310 Bar proof, MIL-H-5606G compatible, –20°C to +120°C.
• Aerospace Hydraulic Pump Test Bench — 270 Bar / 130 LPM / 6,000 RPM. Proof, endurance, compensator calibration, and stability testing.
• Life Support Oxygen Test Bench — 200 Bar, 600 L/min. SS-316L construction for pilot oxygen system validation.
• Oxygen Component Test Benches (10-bench suite) — 0–250 Bar GOX, helium leak detection ≤1×10−6 mbar·L/s, ASTM G93 compliant.
• 70,000 RPM Bearing Test Rig — 113 kW drive, 25 kN radial load. Aero-engine bearing qualification and lubricant validation.

Ground Support Equipment
• Weapon Loading Trolley — 750 kg scissor lift, 310–2,340 mm range, true vertical lift. For bombs, missiles, and training rounds.
• Universal Hydraulic Charging Rig — 25L SS-304, 3 μm filtration, ISO 4406 cleanliness. Quick-change adaptors for Su-30 / MiG-29.
• Missile Canister Transportation Module — 4-canister capacity, 1,400 kg dynamic / 2,000 kg static. 360° steerable, positive mechanical locking.
• Air Droppable Container (150 kg) — Parachute-assisted delivery for naval resupply. Waterproof, impact-resistant.
• Aerospace Fuel Supply System — 500 LPM, FAUDI 1 μm filtration, KRAL metering (±0.2%). Flame-proof (Ex-d IP65).

Defence Vehicle Platforms
• Light Strike Vehicle Upgrade — Converts LSVs into mobile C3 platforms. Sealed 1.6mm steel capsule, comms rack, dual-zone HVAC (–10°C to +50°C), 9.35″ Full-HD nav display. ISO 9001/14001/45001 certified.
• Command-and-Control Carrier (CCC-MT) — Tracked mobile command post with NBC filtration, encrypted consoles, ruggedised displays, and scalable electronics.
• Battery Command Post (BCP) — Artillery mobile HQ on TATA 2.5T platform. Expandable shelter, fibre-optic comms, 10m telescopic mast, 2.5 kVA generator, six-operator workspace.

Weapon Disposal & Demilitarisation
• Chemical Weapon Destruction Facility — Fully unmanned, remotely operated. 3,600 warheads neutralised with zero human exposure. Automated conveyor, precision drilling, sealed containment.
• Automatic Weapon Disposal System — Dual-stage shredding + induction melting for INSAS, AK-47, LMG. Irreversible destruction with PLC automation.

Why Neometrix for Defence

Strength	Details
Engineering Precision	±0.1% FS transducers, ±0.2% flow meters, 24-bit DAQ, NABL-certified traceability
Standards Compliance	IS, MIL-STD, NATO STANAG, DGQA, ICAO, ATEX, ISO 13849
208 Engineered Products	From 750 kg weapon trolleys to 3,600-warhead destruction facilities
Proven Deployments	T-90, Arjun MBT, Su-30, MiG-29, IAF arresting gear, combat helicopter hydraulics
End-to-End Delivery	Design → manufacture → FAT/SAT → installation → training → lifecycle support

Partner with Neometrix for Mission-Critical Defence Systems

Supporting Indian Armed Forces, Defence PSUs (HAL, BEL, OFB, DRDO), and private manufacturers with engineered testing, validation, and ground support systems.

Submit your defence requirement:
• Share technical specifications or tender requirements for customised system proposals
• Request product demonstrations, factory acceptance trials, or site visits
• Access detailed engineering catalogues and 3D CAD models for 200+ products
• Discuss turnkey solutions from concept through lifecycle support

Contact Us Today to Strengthen Your Defence Capabilities

Neometrix Defence Limited – Advancing Defence Capabilities
Neometrix Defence specializes in advanced military solutions that enhance operational effectiveness, mobility, and security.

Weapon Disposal Systems
We provide fully automated weapon disposal systems for secure demilitarization of firearms like SLR 303, INSAS, LMG 7.62MM, and AK-47.

Key features:
1. Automated loading/unloading
2. Two-stage shredding & melting
3. Complete and irreversible destruction
4. Military Vehicle Modifications

We upgrade military vehicles for high-performance battlefield operations.
Key projects include:
1. Battery Command Post Conversion: 2.5/7.5 TON trucks with ISO shelter, auto pneumatic mast, and EMI-shielded interiors
2. LSV Enhancements: Reinforced armor, weapon mounts, off-road upgrades, and secure comms for rapid deployment

Defense Testing Facilities
Our T-90/T-72 gearbox testing facility delivers advanced diagnostics and fault detection using hydraulic + electrical systems — ensuring tank readiness and reliability in combat.

Mission-Focused Innovation
From weapon disposal to combat vehicle upgrades and critical testing infrastructure — Neometrix delivers mission-ready, precision-engineered defense solutions that ensure tactical superiority and national security.

Aviation & Aerospace Testing Challenges

Mission-Critical Performance Validation
Modern military and commercial aircraft depend on thousands of hydraulic, pneumatic, fuel, and electrical subsystems operating in perfect concert. A servo valve lag of milliseconds, a fuel pump cavitation event, or a hydraulic reservoir air ingestion during a negative-G pull can cascade into loss of flight control. Every component must be validated under conditions that replicate the harshest real-world scenarios — from sea-level tropical heat to high-altitude arctic cold — before it ever leaves the ground.

Extreme Operating Envelopes
Aerospace hydraulic systems operate at up to 270 Bar and 130 LPM flow at 6,000 RPM. Fuel systems require thermal simulation up to 120°C with ATF pressures of 250 kg/cm². Oxygen systems demand SS-316L purity at 200 Bar and 600 L/min. Bearings spin at 70,000 RPM under 25 kN radial loads. Navigation electronics require RF validation from 960–1250 MHz. Each parameter must be tested with ±0.25% accuracy and full traceability.

Platform Coverage
Neometrix has delivered test systems and GSE for military platforms including Su-30MKI, Mirage 2000, MiG-29, Jaguar, LCA Tejas, Hawk, C-130J Super Hercules, Chinook, and Apache helicopters — as well as commercial aircraft including Boeing 737/777/787, Airbus A320/A350, ATR series, and Airbus H135/H145 and Bell 412 rotorcraft.

Standards & Certifications

Standard	Scope
DGAQA	Directorate General of Aeronautical Quality Assurance — mandatory for Indian military aviation
ISO 9001 / 14001 / 45001	Quality, environmental, and occupational safety management systems
MIL-H-5606G	Hydraulic fluid compatibility for military aircraft systems
MIL-STD-810 / 461	Environmental and EMC qualification for avionics and components
RTCA DO-160	Environmental conditions and test procedures for airborne equipment
ICAO Annex 10 / 14	Navigation aids and aerodrome safety standards
ASTM G93 / CGA G-4.1	Oxygen-clean assembly and handling for aerospace oxygen systems
ISO 4406 / NAS 1638	Hydraulic fluid cleanliness for aerospace-grade systems

Aerospace Test Equipment & GSE Solutions

Hydraulic System Test Benches
• Aerospace Hydraulic Pump / Motor Test Bench — 270 Bar / 130 LPM / 6,000 RPM. Proof pressure, endurance cycling, compensator calibration, and stability testing for variable-delivery axial piston pumps.
• Aircraft Servo Valve Hydraulic Test Equipment — ATF supply at 120 and 250 kg/cm², thermal control up to 120°C, multi-stage filtration (β >1000), flameproof design. Servo valve priming, de-aeration, and drain pressure emulation.
• Aircraft Electro-Hydraulic Multi-Channel Power Drive Loading Rig — 24,000 kgf max force, ±125 mm stroke, 380 mm/s speed. 64-channel 32-bit DAQ (±0.25%). Simulates real aerodynamic loads for flight-control actuator qualification.
• Hydraulic Filter Test Bench — 35 Bar, 5–150 LPM, NAS Class 4 cleanliness delivery. Acceptance testing of aircraft hydraulic filters.

Flight Control & Actuator Testing
• Main Rotor Actuator Test Rig — Proof pressure, leakage, load-speed, drift, and frequency response testing for helicopter MRA/TRA systems with real-time DAQ.
• Rudder & Tailplane Test Equipment — Dedicated rigs for validating flight control surface actuators under simulated aerodynamic loads.
• Portable Pneumatic Test Rig for Rudder Actuator — Field-deployable pneumatic test capability for MRO at forward bases.
• General Purpose Pneumatic Test Rig — 0–200 kgf/cm² high line, 0–8 kgf/cm² low line. Dew point –55°C, <2 μm purity. ISO 8573 / ISO 6358 / MIL-STD compliant.

Fuel System Testing
• Aerospace Fuel Supply System (AFSS) — 500 LPM, 0–10 Bar, dual 18.65 kW pumps, FAUDI 1 μm filtration, KRAL metering (±0.2%). Flame-proof (Ex-d IP65). For aero-engine test cells.
• Fuel Pump & Nozzle Pressure Ratio Test Stand — 10,000 RPM / 160 kW drive. ATF thermal simulation up to 120°C. Cavitation, vapor lock, and nozzle calibration testing.
• Advanced Fuel Pump/Controller Calibration Bench — 50 LPM, 3 μm filtration, 500–6,200 RPM (±1 RPM closed-loop). Includes preservation cycle at 70°C.

Ground Support Equipment (GSE)
• Ground Power Unit (GPU) — 45 kVA dual output: 200V/115V 400 Hz AC (150A) + 28.5V DC (800A) simultaneously. External power for aircraft ground maintenance.
• Mobile Aviation 400 Hz Load Bank — Air-cooled (5–60 kVA) and water-cooled (up to 180 kVA). Modular load steps, PLC/HMI control, PF correction. GPU validation and starter-generator testing.
• Universal Hydraulic Charging Rig — 25L SS-304, 3 μm filtration, ISO 4406. Quick-change adaptors for Su-30 / MiG-29. 30 kg portable.
• Weapon Loading Trolley — 750 kg scissor lift, 310–2,340 mm range, true vertical lift. For bombs, missiles, and training rounds on aircraft hardpoints.

Runway Safety Systems
• Aircraft Arrester Barrier System — Net-type and pendant-type for 6–40 ton aircraft. ≤10 min re-arm. MIL-STD-3000 / ICAO Annex 14. –20°C to +60°C.
• Aircraft Arresting Gear (AAG) — 58m Nylon-66 net, dual 20T+40T water-twister absorber, ≈3g deceleration within 270m. 3-second deployment.

Why Neometrix for Aviation & Aerospace

Strength	Details
20+ Years of Expertise	Trusted by Indian Air Force, international air forces, and commercial aviation OEMs
Platform-Proven	Su-30MKI, MiG-29, LCA Tejas, C-130J, Apache, Boeing 787, Airbus A320, and more
DGAQA Certified	Full aeronautical quality assurance with ISO 9001/14001/45001 compliance
Precision Instrumentation	±0.25% FS accuracy, 24-bit DAQ, NAS Class 4 cleanliness, NABL traceability

Neometrix Defence Limited is a leading manufacturer of Aerospace Test Benches and Ground Support Equipment (GSE) for the Indian Air Force, global air forces, and the commercial aviation sector. With 20+ years of experience, we deliver high-precision solutions that ensure reliability, safety, and performance for military and civilian aircraft.

We’ve built test benches for:

Fighter jets: Su-30MKI, Mirage 2000, MiG-29, LCA Tejas

Transport & rotorcraft: C-130J, Chinook, Apache

Airliners: Boeing 737/787, Airbus A320/A350, ATR

Helicopters: H135/H145, Bell 412

Certified by DGAQA, ISO 9001, ISO 45001, and ISO 14001, we are trusted by air forces, airlines, MROs, and aerospace leaders worldwide.

Hydrogen Infrastructure Testing Challenges

Unboxing Hydrogen’s True Potential
The hydrogen economy demands infrastructure that can safely generate, compress, store, transport, and convert hydrogen at pressures from 30 to 700+ Bar. Every cylinder, valve, regulator, and pipeline must be validated for burst strength, cyclic fatigue, leak integrity, and volumetric expansion — under conditions that replicate decades of real-world service in months of accelerated testing.

Extreme Pressure & Safety Requirements
Hydrogen’s low molecular weight makes it the most leak-prone gas in existence. Storage cylinders (Type III/IV composites) must survive burst tests at 5,000 Bar inside explosion-resistant containment. Boosting stations compress hydrogen from 30 to 150+ Bar for refueling infrastructure. Leak detection must reach 10−8 mbar·L/s using mass-spectrometer technology. A single undetected leak in a high-pressure hydrogen system can be catastrophic.

Power-to-Power: The Full Cycle
Green hydrogen systems complete the renewable energy loop — electrolysis converts surplus solar/wind power into hydrogen, metal hydride or compressed tanks store it, and PEM fuel cells convert it back to electricity on demand. Testing each stage requires integrated platforms that validate electrolyser efficiency, storage integrity, fuel cell performance, and power electronics simultaneously.

Standards & Certifications

Standard	Scope
ISO 11119 / ISO 11623	Composite cylinder design, testing, and periodic inspection
ASTM G-93	Oxygen-clean and hydrogen-compatible material handling
PED 2014/68/EU	Pressure Equipment Directive for vessels and piping
ATEX Zone 2	Explosive atmosphere certification for hydrogen environments
CE Marking	European conformity for pressure and safety equipment

Hydrogen & Green Energy Solutions

Hydrogen Cylinder Testing
• Burst Chamber for Hydrogen Cylinder Testing — 5,000 Bar max pressure. Dual-wall containment (SS inner, MS outer). Haskel air-driven pump. PLC + HMI with ±0.25% FS transducers and 2-second emergency depressurization. Containerized in 20-ft ISO container.
• Automatic Volumetric Expansion Test System — Hydrostatic proof at 1.5x working pressure. Measures elastic and permanent expansion. Cylinders with ≤10% permanent expansion pass. For CNG, H2, O2, N2, CO2, Argon, and SCBA cylinders.

Hydrogen Compression & Storage
• Hydrogen Gas Boosting Station — Inlet 30 Bar → Outlet 150 Bar. 4 Nm³/h compression rate. Hydraulic (glycol) drive, 500–750W. For refueling stations, storage transfer, and cylinder filling.

Power-to-Power Systems
• Hydrogen Power-to-Power (P2P) System — PEM electrolyser (1.0 Nm³/h) + Metal Hydride storage (5 kg H2) + PEM fuel cell (5 kW) + Li-ion buffer (5 kWh). Turnkey lab cabinet with PLC/HMI, SCADA-ready. Layered safety: gas detection, interlocks, forced ventilation.

High-Pressure Testing Infrastructure
• Hose Test Bench — Up to 4,500 Bar. Burst, impulse, and endurance testing for high-pressure hydrogen and industrial hoses.
• CNG High Pressure Regulator Test Bench — 10–260 Bar auto (310 Bar manual). Haskel AG-15/75 booster, 60 cycles/min. Leak detection ≤15 cm³/hr.
• CNG Circuit Leak Testing Machine — 345 Bar max. Air-driven Haskel booster (no electrical dependency). Multi-gas compatible.

Gas Leak Detection
Mass-spectrometer based helium leak detection reaching 10−8 mbar·L/s with metal-sealed vacuum chambers and real-time leak-rate monitoring.

Why Neometrix for Hydrogen & Green Energy

Strength	Details
5,000 Bar Capability	Burst testing of Type III/IV composite cylinders in explosion-resistant containment
Containerized Deployment	ISO container-ready systems — crane into place, connect utilities, begin testing
Full Hydrogen Cycle	Electrolyser → storage → fuel cell → power: end-to-end P2P validation
Precision & Safety	±0.25% FS transducers, 2-second emergency shutdown, dual-redundant relief

Neometrix Hydrogen Test & Power-Generation Platforms
Neometrix delivers fully containerized, plug-and-play hydrogen test and power-generation platforms that are crane-ready and operational from day one.

Key Advantages
• Instant Deployment: ISO-certified containers arrive fully commissioned—just crane into place, hook up utilities, and go.
• Portability & Consistency: Rugged designs move easily between labs, factories, and remote sites while delivering factory-tested performance.

Comprehensive Cylinder Testing
• Burst, hydrostatic, volumetric, and endurance tests in one compact rig
• Precision up to 5 000 bar with automatic shutdowns and redundant safety valves
• Explosion-resistant containment for maximum operator protection

Ultra-Sensitive Leak Detection
• Mass-spectrometer based, detects leaks down to 10⁻⁸ mbar·L/s
• Metal-sealed vacuum chambers, catalytic purging, automated safety protocols

Integrated Power-to-Power Microgrids
• Store excess renewables as hydrogen and reconvert to electricity on demand
• Intuitive touchscreen control of the full energy cycle

Why Neometrix?
• Speed & Savings: Rapid setup cuts project timelines and costs
• Modular Growth: Future-proof, upgradable solutions for evolving needs

Oil, Gas & Nuclear Testing Challenges

High-Consequence Environments
Oil, gas, and nuclear facilities operate under conditions where component failure can result in environmental catastrophe, radiation release, or loss of life. Hydraulic snubbers protecting critical piping in nuclear plants, high-pressure compressors in offshore platforms, and control valves in refinery process lines must all undergo rigorous validation — often on-site, within operating facilities, without disrupting production.

Pressure, Fatigue & Endurance
Subsea and process piping operates at pressures up to 600 Bar. Marine pipe systems on submarines require both hydrostatic and pneumatic validation. Hydraulic snubbers must absorb dynamic shocks up to 200 kN while maintaining 300 Bar system pressure. Pressure-cycle fatigue testing subjects components to thousands of repeating stress cycles to predict field life. Impulse testing combines pressure transients with external shear loads to expose hidden failure modes.

On-Site & Containerized Testing
Nuclear and offshore facilities cannot always ship critical components to distant laboratories. Containerized, mobile test benches bring the laboratory to the plant — enabling in-situ snubber testing, valve qualification, and compressor validation without costly shutdowns or regulatory delays.

Standards & Certifications

Standard	Scope
ASME Section VIII / IX	Pressure vessel design and welding qualification
ASME B31.3	Process piping design and testing
ISO 19879 / EN 12266-1	Hydraulic hose and fitting proof testing
SAE J343 / J517	Hydraulic hose assembly testing standards
MIL-STD-810	Environmental qualification for harsh conditions

Oil, Gas & Nuclear Solutions

Snubber & Piping Protection Testing
• Dynamic Snubber Shock Arrestor Test Facility — 200 kN load, 250 mm stroke, 12.57 mm/s speed, 300 Bar system pressure. Automated servo-hydraulic actuation. For nuclear and high-consequence process piping systems.
• Containerised Hydraulic Snubber Test Bench — Mobile container-based platform for on-site snubber evaluation. Eliminates off-site laboratory transport for nuclear, thermal, and petrochemical plants.
• Impulse and Load Test Rig — Combined pressure-impulse transients with dynamic shear loading. Cycle-by-cycle monitoring with long-run stability trending. Exposes hidden failure modes under combined loading.

Pressure & Proof Testing
• Hydraulic Proof Pressure Test Rig (700 Bar) — Multi-stage filtration (10 μm / 3 μm), PLC-Advantech control, automated ramp/dwell/depressurise. ISO 19879, SAE J343, EN 12266-1, MIL-STD-810 compliant.
• High Pressure Air Compressor Test Stand — 400 Bar sustained, 90 kW VFD drive, 150,000 kcal/hr heat rejection. Two-stage cooling, SS316 piping. For multi-stage reciprocating compressor validation in naval and industrial environments.
• Marine Pipe Pressure Test System — Hydraulic testing up to 600 Bar, pneumatic up to 400 Bar. Dual-mode (auto/manual). For submarines, naval vessels, and marine infrastructure.

Valve & Component Testing
• Valve Test Rig — 135 Bar, butterfly and check valves up to 12 inches. 65-ton vertical clamping press, dual-motor hydraulic power pack, integrated leak detection camera.
• Automated Hydraulic Control Valve Test Bench (350 kW) — 400 LPM / 420 Bar. Flow vs. ΔP, hysteresis, response time, leakage, endurance cycling. For process control and safety valve qualification.
• High Pressure Leak Testing Machine — 1.2–20 litre components, up to 250 Bar. Static leak, pressure hold, stepwise, and real-time profiling modes. PLC automation with ±0.25% FS accuracy.

Why Neometrix for Oil, Gas & Nuclear

Strength	Details
On-Site Capability	Containerised mobile test benches — bring the lab to the plant, not the plant to the lab
600 Bar Pressure Range	Hydrostatic and pneumatic validation for subsea, marine, and process piping
Nuclear-Grade Safety	200 kN snubber testing with servo-hydraulic precision and traceable quality records
Combined Loading	Impulse + shear testing exposes failure modes invisible to pressure-only methods

Neometrix engineering has been involved in doing major critical projects for Indian Defense Aviation to meet their specific requirements starting from their test systems, advance test systems, PC based hydraulic/pneumatic/electrical test benches to various gas based turnkey projects in Oil, Gas and Nuclear sectors.

Railway Testing Challenges

Safety-Critical Braking Systems
Railway braking systems are the primary safety mechanism protecting passengers and cargo across India’s vast rail network. LHB coaches, locomotives, and metro systems rely on complex pneumatic and hydraulic brake circuits with dozens of valves, distributors, and actuators. A single faulty relay valve or improperly sealed brake panel can lead to brake failure at speeds exceeding 160 km/h. Every component must be validated with automated, repeatable, traceable testing before entering service.

Rolling Stock Integrity
Coach shells, door seals, window assemblies, HVAC ducts, and underframe joints must withstand monsoon rains, desert dust, and temperature extremes across Indian Railways’ diverse operating conditions. Water ingress compromises electrical systems, accelerates corrosion, and degrades passenger comfort. Standardised rain simulation — not subjective manual spraying — is essential for quality assurance.

Powertrain & Transmission Validation
Modern locomotives and defence vehicles use power shuttle transmissions, gearboxes, and hydraulic dampers that require precise characterisation of pressure profiles, flow behaviour, torque response, and thermal performance under automated test conditions.

Standards & Certifications

Standard	Scope
COFMOW / IR Standards	Controller of Stores, Indian Railways — mandatory brake equipment specifications
RDSO Guidelines	Research Designs & Standards Organisation — rolling stock design and testing norms
ISO 9001 / IRIS	Quality management for railway industry supply chain
ISO 12100	Safety of machinery — general design principles for test equipment

Railway Test Equipment Solutions

Brake System Testing
• Computerized Test Bench for LHB Coach Brake Panels — PC-based automated testing of 18 critical pneumatic valves. Microprocessor-controlled with real-time pressure measurement, leak assessment, and predictive analytics. For LHB coach brake control, DDU, and PEAS panels.
• E-70 Brake Equipment Test Rig — Fully automated turnkey solution. Hydraulic to 1,060 kg/cm², pneumatic to 10 kg/cm² (≤5°C dew point). PLC-driven with high-speed DAQ. NIST-traceable gauges. COFMOW/IR compliant. 15-year spare availability.
• Friction Brake Test Bench — Up to 160 Bar, 90 kN force measurement. Recipe-based automation for hydraulically-applied and spring-applied/hydraulically-released (fail-safe) calipers. Automated PDF reporting.

Rolling Stock Validation
• Water Leak Testing System (Standard & Broad Gauge) — 25m × 5m × 6m SS-304 rain chamber. 252 nozzles at 15.3 m/s spray velocity, ∼1,865 L/min total flow. Dual 20 HP pump redundancy. Closed-loop recycling reduces water consumption by 80%. ≤15 min per coach. ISO 12100 / ASME B31.3 compliant.

Powertrain & Transmission Testing
• Power Shuttle Transmission Test Rig (Arjun NOVO) — 3.7 kW VFD-controlled pump (0.1 Hz steps), triple-channel turbine flow metering (±0.5%), 100 Bar max, 1 kHz analog sampling. Rockwell/Siemens PLC. Automated sequencing with barcode logging and PDF/CSV/XML reports. ISO 13849 Cat 3 safety.
• Gear Box Test Bench — Dual hydraulic power packs, torque/RPM sensors, PLC/PC control. NVH analysis, thermal behaviour, endurance testing. IIoT connectivity with digital-twin integration. For helical, planetary, and heavy-duty gearbox validation.

Why Neometrix for Railways

Strength	Details
COFMOW / RDSO Compliant	Test benches meeting Indian Railways mandatory specifications
18-Valve Brake Testing	Automated validation of every critical pneumatic component in LHB coach panels
Rain Simulation at Scale	25m chamber with 252 nozzles — standardized, measurable, ISO-documented
NIST-Traceable	Every measurement certified for regulatory compliance and audit readiness

Neometrix Engineering has successfully executed state of art test systems and various data acquisition systems for railway research establishment, ensuring critical braking and train integrity.

Gas & Cryogenic Infrastructure Challenges

Medical & Industrial Gas Supply
Hospitals, semiconductor fabs, metal fabrication plants, and research laboratories depend on uninterrupted supply of high-purity oxygen, nitrogen, argon, and specialty gases. Traditional cylinder-based supply is costly, logistically complex, and creates dangerous dependencies on external suppliers. On-site PSA generation, cryogenic bulk storage, and automated boosting systems eliminate these bottlenecks while ensuring purity, availability, and cost control.

Cryogenic Storage & Handling
Liquid oxygen, nitrogen, and argon must be stored at temperatures down to –196°C in vacuum-insulated vessels rated to 17 Bar gauge. Boil-off rates must stay below 0.45%/day. Dual relief valves, burst discs, and continuous vacuum monitoring ensure safety. Vaporisation on demand via pressure-building coils must deliver stable outlet pressure without external equipment.

High-Pressure Gas Boosting
Medical oxygen cylinders, aviation emergency bottles, dive-shop tanks, and industrial process feeds all require compression from low-pressure PSA output (3–6 Bar) to cylinder fill pressures of 140–350 Bar. Boosting must be oil-free, oxygen-clean (ASTM G-93), and intrinsically safe for explosive-atmosphere environments.

Standards & Certifications

Standard	Scope
EN 13458 / ASME VIII-1	Cryogenic vessel design and pressure testing
PED 2014/68/EU	Pressure Equipment Directive for EU market compliance
CCOE / PESO	Indian Chief Controller of Explosives certification for pressure vessels
ASTM G-93 / CGA G-4.1	Oxygen-clean material handling and assembly

Gas & Cryogenic Solutions

Cryogenic Storage Tanks
• Cryogenic Liquid Medical Oxygen Vertical Storage Tank — 10,000L and 20,000L capacities. SS-304 inner / S355J2 outer. Vacuum-insulated with perlite (≤0.45%/day boil-off). Working pressure 17 Bar. –196°C to +40°C. Dual relief valves + burst discs. Pressure-building coil for stable vaporisation. EN 13458 / ASME VIII / PED certified. CCOE/PESO approved.

PSA Oxygen Generation
• PSA Oxygen Generation Plant — 200 LPM — 93±3% purity. Screw-type compressor, twin-tower PSA, multi-stage filtration. PLC-automated, energy-efficient. ISO 8573 Class 4 air quality. Eliminates cylinder dependency for hospitals and clinics.
• Oxygen Boosting System for PSA Plants — PSA output (3–6 Bar) → 140 Bar cylinder fill. Dual Haskel stages with interstage cooling. 1,600 NLPM @ 20 Bar / 700 NLPM @ 140 Bar. 316L electropolished (Ra ≤0.4 μm). Siemens S7-1200 PLC. ∼200 K-size cylinders per 8-hour shift. CE / ISO 13485 / ASTM G-93 / ATEX Zone 2 certified.

Gas Boosting & Distribution
• Oxygen Gas Boosting System — 350 Bar max. Air-driven multi-stage with intercooling. >99.5% O2 purity, dew point <–40°C. ASTM G-93 oxygen-clean. PLC/HMI with SCADA connectivity. <75 dB(A). For cylinder filling, medical ICU backup, aviation emergency oxygen, and industrial manufacturing.
• Nitrogen Gas Boosting System — Haskel AG-75 (75:1 ratio), 4–8 Bar plant air drive. Oil-free, 60 cycles/min. NIST-traceable gauges. For cylinder filling, pressure-vessel purging, leak testing, and accumulator charging.
• Portable Single Cylinder Nitrogen Trolley with Booster — 75:1 boost ratio, 415 Bar max outlet (±1% FS). 15m SS-braid hose with ISO 7241 quick-disconnects. 75 kg, pneumatic wheels. Dual redundant relief (405 + 430 Bar). For aerospace accumulator charging, field service, and laboratory research.

Why Neometrix for Gas & Cryogenics

Strength	Details
Full Gas Ecosystem	Generation → boosting → storage → distribution → filling: complete turnkey solutions
Cryogenic Expertise	–196°C vacuum-insulated tanks with ≤0.45%/day boil-off, EN 13458/ASME/PED certified
Medical-Grade Purity	93±3% O2 via PSA, ASTM G-93 oxygen-clean boosting, ISO 13485 quality management
350 Bar Boosting	Multi-stage compression with interstage cooling and intrinsically safe pneumatic drive
Modular & Scalable	80–500 LPM PSA plants, 10,000–20,000L cryo tanks, skid-mounted for rapid deployment

Neometrix delivers complete high-purity oxygen, nitrogen, and cryogenic solutions for hospitals, labs, and industrial gas applications. We ensure continuous safety and supply with modular scalable systems.