PRESSURE & LEAK TEST RIG / Rev 01 / 3 Circuits · 70 bar · PC-Based DAQ / India 2026 · Product Page

Pressure & Leak Test Rig

Prove fluid-circuit integrity to 70 bar.

Three independent power packs — hydraulic oil, gearbox oil, and aviation fuel — run real pressure-loss and leak-detection tests on heat exchangers and fluid-system hardware, built for secondary power system (SPS) components on platforms such as the LCA Tejas.

Request proposal Circuit architecture

Three Neometrix Aerospace Pressure and Leak Test Rig power-pack cabinets on the factory floor

Fig · 01 Hydraulic oil, gearbox oil and aviation fuel power packs — assembled and ready for dispatch

Qualification testing supported to:

DEF STAN STANAG MIL-SPEC DO-160

Max Pressure

70bar

Max Flow

90LPM

Circuits

3independent

Leak Accuracy

±0.01%

Gauge Range

100bar

Overview

Real leak data, not assumed tolerances.

The Pressure Loss and Leak Test Rig — an aerospace test rig built for aeronautical leak testing — is a high-performance system designed to test the integrity and efficiency of fluid circuits under real-world conditions — built for the aerospace, defence, and automotive sectors where a missed micro-leak is not an option.

Aerospace Pressure and Leak Test Rig — three power-pack cabinets with control panels and gauges

Fig · 02 Control-panel bank — analog gauges, digital indicators and cabinet-mounted power packs

Developed for applications in the aerospace and defence industries, the rig is a turnkey solution built for components within the secondary power systems (SPS) of advanced military aircraft such as the LCA Tejas. It integrates sensors, controllers, and hydraulic power systems into a single instrumented platform for accurate pressure-loss and leak-detection testing.

Three specialised circuits — hydraulic oil, gearbox oil, and aviation fuel — are each equipped with precision sensors, flow control systems, and both analog and digital monitoring tools. Output pressures reach up to 70 bar on the hydraulic circuit, with real-time data logging, automated control, and alarm systems for enhanced safety and performance.

A missed micro-leak in a secondary power system is not a paperwork problem — it is a flight-safety problem.

Built with high-grade stainless steel and state-of-the-art automation, the rig ensures compliance with stringent industry standards and enables efficient, repeatable component testing for mission-critical applications.

Three independent circuits — hydraulic oil, gearbox oil, and aviation fuel — for comprehensive pressure-loss and leak testing
Hydraulic oil circuit delivers up to 90 LPM at 0-70 bar, powered by a 15 kW motor with an SS 304 stainless steel reservoir
High-sensitivity differential pressure transducers detect micro-leaks to ±0.01% accuracy across all three circuits
PC-based automation with National Instruments hardware enables real-time data logging, graphical analysis, and HMI control

Circuit Architecture

Three circuits, one test cell.

Each circuit runs as an independent power pack sized to its own fluid, pressure range, and flow rate — so hydraulic, gearbox, and aviation fuel components can each be tested to their real service conditions.

CKT · 01 | Hydraulic Oil

Hydraulic Oil Power Pack

150-litre SS 304 stainless steel reservoir, fixed-displacement vane pump, up to 90 LPM at 0-70 bar, driven by a 15 kW motor. High-pressure hoses with quick-disconnect couplings rated to 150 bar.

90 LPM · 0-70 bar · 15 kW

CKT · 02 | Gearbox Oil

Gearbox Oil Power Pack

Up to 50 LPM at 0-50 bar, driven by a 5.5 kW motor. 10-micron pressure-line filters for fluid purity, Siemens pressure/temperature sensors, and analog plus digital indicators for performance tracking.

50 LPM · 0-50 bar · 5.5 kW

CKT · 03 | Aviation Fuel

Aviation Oil Power Pack

Handles aviation oils conforming to MIL and DERD standards, up to 30 LPM at 0-30 bar, driven by a 3.7 kW motor. Digital display units continuously monitor pressure, temperature, and flow.

30 LPM · 0-30 bar · 3.7 kW

Instrumentation

Every micro-leak, fully logged.

PC-based automation with National Instruments hardware ties every sensor on the rig into one HMI, so pressure loss and leak decay are captured, graphed, and stored automatically — not read off a gauge by eye.

IN · 01 | Sensing & Transducers

Pressure & Differential Sensing

WIKA pressure transducers and high-sensitivity differential pressure transducers detect micro-leaks to ±0.01% accuracy across all three circuits, with Siemens pressure/temperature sensors on the gearbox oil circuit.

WIKA · ±0.01% Accuracy

IN · 02 | PC-Based DAQ & HMI

Data Acquisition & HMI

National Instruments hardware and software drive PC-based automation — real-time data logging, graphical trend analysis, and an HMI that lets operators configure test parameters and minimise manual error.

NI Hardware · Real-Time Logging

IN · 03 | Local Indicators & Alarms

Panel Readouts & Annunciator

Masibus digital temperature indicators and analog Bourdon-tube pressure gauges (SS 316, 100 bar range, 15% overpressure protection) plus an annunciator panel that alerts operators to critical alarms.

Masibus · Annunciator Panel

Safety Systems

Protected at every circuit.

High-pressure fluid testing carries real risk to operators and equipment. The rig is built with layered protective interlocks and durable construction to keep both safe through long test campaigns.

Automatic protective interlocks

Automatic emergency shutdown activates on overpressure, high temperature, or electrical phase failure
Overpressure relief valves fitted across all three circuits
Phase sequence protection guards motors against incorrect wiring or incoming power faults

Construction & wiring safeguards

SS 316 stainless steel wetted parts and structure for long-term durability in high-pressure service
Comprehensive earthing and wiring checks eliminate electrical hazards
MS powder-coated skid (60-80 micron coating) protects the base structure
Supply hoses rated to 150 bar — more than double the 70 bar maximum test pressure — with QDC end connections

Gallery

The rig, as built.

Real photographs of the assembled power packs, cabinet interiors, and control panels on the shop floor.

Three pressure and leak test rig power packs on the factory floor

Pressure and leak test rig cabinets, closed panel view

Pressure and leak test rig cabinet interior with power pack pump and motor

01 / 03

Downloads

Catalog & general arrangement.

The general catalog and both real design GA drawings, for procurement review and technical pre-screening.

General Arrangement — Design 1

PDF · 108 KB

Pressure and leak test rig design 2 GA drawing thumbnail

Drawing · Design 2

General Arrangement — Design 2

PDF · 137 KB

Specifications

Full technical parameters.

Typical configuration of the Aerospace Pressure and Leak Test Rig. Values can be customised to user requirements.

Application	Pressure-loss and leak testing of hydraulic, gearbox oil, and aviation fuel circuits
Motor Power (Supply)	Input voltage 415 V, three-phase
Hydraulic Circuit	Max flow 90 LPM, output pressure up to 70 bar, 15 kW motor, SS 304 reservoir
Gearbox Oil Circuit	Up to 50 LPM at 0-50 bar, 5.5 kW motor, 10-micron pressure-line filters
Aviation Fuel Circuit	Up to 30 LPM at 0-30 bar, 3.7 kW motor, aviation oils to MIL/DERD standards
Working Media	Hydraulic oil, gearbox oil, aviation fuel
Machine Pressure Range	0-70 bar
Outlet Flow Rate	Variable, as per requirement
Cleaning Duty	Oxygen-service cleanliness
Inlet Pressure Gauge Range	100 bar
Outlet Pressure Gauge Range	100 bar
Gauge Type / Material / Design	Analogue, SS 316, Bourdon-tube design, 15% overpressure protection
Leak Detection Accuracy	±0.01% via differential pressure transducers
Supply Hose	Length 6 m, dia. 1/4 in, working pressure 150 bar, OF QDC coupling end connection
Instrumentation	WIKA pressure transducers, Masibus digital indicators, annunciator alarm system
Automation & Control	PC-based, National Instruments hardware, real-time logging, HMI
Safety Systems	Auto emergency shutdown (overpressure / high temp / phase failure), overpressure relief valves, phase sequence protection
Wetted / Structural Material	SS 316 stainless steel
Skid MOC	MS powder coated, 60-80 micron coating thickness

Applications

Where it runs.

Organisations that must validate fluid-circuit integrity before hydraulic, fuel, or cooling-system hardware is cleared for mission-critical service.

A · 01Aircraft hydraulic, fuel, and cooling system reliability — including SPS components for platforms such as the LCA Tejas

A · 02Defence maintenance and validation of key hydraulic/fuel components used in combat vehicles

A · 03Automotive cooling-system efficiency evaluation, including radiators and oil coolers

A · 04Industrial manufacturing — fluid-circuit testing in large, complex machinery

A · 05Heat-exchanger compatibility testing across hydraulic and aviation oil systems, 30-70 bar

A · 06MRO / overhaul leak-tightness verification of hydraulic, gearbox oil, and fuel system components

In Depth

The complete technical read.

Engineering narrative for test engineers, procurement teams, and reliability engineers evaluating the rig before commissioning a test programme.

Turnkey pressure-loss and leak testing for secondary power systems

The Pressure Loss and Leak Test Rig by Neometrix Engineering Pvt. Ltd. is a high-precision system designed to evaluate fluid-circuit integrity and performance under real-world conditions. It is developed for applications in the aerospace and defence industries, particularly for components within secondary power systems (SPS) of advanced military aircraft such as the LCA Tejas. The rig is a turnkey solution, integrating advanced sensors, controllers, and hydraulic power systems, offering unparalleled accuracy in both pressure-loss and leak-detection tests.

Key testing capabilities

The rig is capable of performing three crucial classes of test:

Test Type	What It Verifies
Pressure loss testing	Simulates real operational conditions and measures pressure drop within hydraulic, gearbox, and fuel systems to ensure flow consistency and efficiency
Leak testing	Monitors system pressure under static conditions and uses high-sensitivity differential pressure transducers to identify micro-leaks with high accuracy
Component compatibility testing	Verifies compatibility and robustness of heat exchangers for both hydraulic and aviation oil systems, across 30-70 bar operating pressures

Circuit configuration & functional elements

The rig incorporates three independent fluid circuits, each optimised for a specific task.

Hydraulic oil circuit

A 150-litre reservoir made of SS 304 stainless steel, operating with a fixed-displacement vane pump capable of a maximum flow of 90 LPM and a pressure range of 0-70 bar. High-pressure hoses with quick-disconnect couplings are rated to 150 bar.

Gearbox oil circuit

Supports a flow rate of up to 50 LPM at a pressure range of 0-50 bar. Features 10-micron pressure-line filters for fluid purity, Siemens sensors for pressure and temperature monitoring, and analog plus digital indicators for system performance tracking.

Aviation fuel circuit

Handles specialised aviation oils conforming to MIL and DERD standards. Designed for a maximum flow rate of 30 LPM and a pressure of up to 30 bar, with digital display units continuously monitoring pressure, temperature, and flow data.

Technical specifications

The hydraulic oil circuit is powered by a 15 kW motor operating at 415 V (three-phase), with output pressure up to 70 bar and variable outlet flow as required. The gearbox oil circuit is powered by a 5.5 kW motor, supporting up to 50 LPM of flow and output pressures up to 50 bar. The aviation fuel circuit uses a 3.7 kW motor, offering 30 LPM of flow and 30 bar of maximum output pressure. All circuits feature SS 304 reservoirs, analog pressure gauges ranging from 0 to 70 bar, and digital indicators with accuracy to ±0.01%.

Advanced monitoring & control

The system is designed with PC-based automation for easy and precise control, incorporating National Instruments (NI) hardware and software for efficient test management. Key automation features include an annunciator system that alerts operators to critical alarms, digital and analog pressure monitoring using WIKA transducers and gauges, and temperature monitoring through Masibus digital indicators for precise control over test conditions. Real-time data is logged and stored for performance analysis, giving complete traceability of tests conducted. Operators can customise test parameters via a user-friendly HMI, minimising errors and ensuring smooth operation.

Safety features

The rig includes several safety mechanisms to protect both personnel and equipment:

Automatic emergency shutdown system that triggers on overpressure, high temperature, or electrical phase failure events
Phase sequence protection to prevent motor damage from incorrect wiring or power issues
Overpressure relief valves installed across all circuits
Comprehensive earthing and wiring checks to eliminate electrical hazards

The entire system is built with SS 316 stainless steel components to withstand high-pressure environments and ensure long-term durability.

Applications

This test rig is versatile across several industries:

In aerospace, it ensures the reliability of hydraulic, fuel, and cooling systems in aircraft
In defence, it aids in the maintenance and validation of key components used in combat vehicles
In the automotive sector, the rig evaluates cooling-system efficiency, including radiators and oil coolers
It is also used in industrial manufacturing for testing fluid circuits in large, complex machinery

Maintenance & support

To keep the system operating at peak performance, Neometrix offers a comprehensive maintenance plan:

Quarterly inspections to check and tighten motor connections, control-panel wiring, and sensor installations
Calibration services to ensure measurement accuracy
Training programmes to equip operators with the skills needed for safe and efficient system use
Rapid spare-parts replacement and technical support for troubleshooting issues

Watch

See it in operation.

Video from Neometrix Defence Limited: Pressure Loss Test And Leak Test Rig.

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 What is the Aerospace Pressure and Leak Test Rig used for?

It tests pressure loss and leak-tightness of hydraulic, gearbox oil, and aviation fuel circuits and components such as heat exchangers, used in aircraft secondary power systems (SPS) — including components qualified for platforms such as the LCA Tejas.

Q · 02 What pressure range does the rig cover?

The hydraulic oil circuit runs up to 70 bar, the gearbox oil circuit up to 50 bar, and the aviation fuel circuit up to 30 bar, with analog gauges rated to 100 bar and 15% overpressure protection built in.

Q · 03 How many test circuits does the rig have?

Three independent circuits — hydraulic oil (up to 90 LPM at 0-70 bar), gearbox oil (up to 50 LPM at 0-50 bar), and aviation fuel (up to 30 LPM at 0-30 bar) — each with its own power pack.

Q · 04 How sensitive is the leak detection?

High-sensitivity differential pressure transducers detect micro-leaks to within ±0.01% accuracy across all three fluid circuits.

Q · 05 What automation and control does the rig use?

PC-based automation built on National Instruments hardware and software, WIKA pressure transducers, Masibus digital temperature indicators, an annunciator alarm system, and a user HMI for test-parameter configuration with real-time data logging.

Q · 06 What safety systems are built into the rig?

Automatic emergency shutdown on overpressure, high temperature, or electrical phase failure; overpressure relief valves on all three circuits; phase sequence protection; and comprehensive earthing and wiring checks.

Q · 07 What materials is the rig built from?

SS 316 stainless steel wetted components and structure, SS 304 stainless steel reservoirs, and an MS powder-coated skid (60-80 micron coating) for long-term durability in high-pressure service.

Q · 08 Is the Aerospace Pressure and Leak Test Rig customizable?

Yes, Neometrix configures circuit count, pressure/flow ranges, gauge ranges, and instrumentation to specific client requirements and applicable standards.

Q · 09 Which industries and programmes use this rig?

Aerospace (aircraft hydraulic, fuel, and cooling-system reliability, including SPS components for platforms such as the LCA Tejas), defence combat-vehicle maintenance, automotive cooling-system validation, and industrial fluid-circuit testing.

Q · 10 What after-sales support does Neometrix provide?

Installation, commissioning, operator training, calibration services, quarterly preventive-maintenance inspections, rapid spare-parts support, and on-site troubleshooting for the Aerospace Pressure and Leak Test Rig.

Get a proposal

Tell us your circuits
and pressure requirements.

We size the power packs, propose an instrumentation set, and walk through the pressure-loss and leak-test programme with your engineering team before you commit.

Request proposal +91 7777 876 876

Prove fluid-circuit integrity to 70 bar.

Real leak data, not assumed tolerances.

Three circuits, one test cell.

Hydraulic Oil Power Pack

Gearbox Oil Power Pack

Aviation Oil Power Pack

Every micro-leak, fully logged.

Pressure & Differential Sensing

Data Acquisition & HMI

Panel Readouts & Annunciator

Protected at every circuit.

Automatic protective interlocks

Construction & wiring safeguards

The rig, as built.

Catalog & general arrangement.

Full technical parameters.

Where it runs.

The complete technical read.

Turnkey pressure-loss and leak testing for secondary power systems

Key testing capabilities

Circuit configuration & functional elements

Hydraulic oil circuit

Gearbox oil circuit

Aviation fuel circuit

Technical specifications

Advanced monitoring & control

Safety features

Applications

Maintenance & support

See it in operation.

Common questions.

Tell us your circuitsand pressure requirements.

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