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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 defense industries, particularly for components within secondary power systems (SPS) of advanced military aircraft such as the LCA Tejas. This testing 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 the following crucial tests: 1. Pressure Loss Testing: Simulates real operational conditions across various fluid circuits. • Measures the pressure drop within hydraulic, gearbox, and fuel systems to ensure flow consistency and efficiency. 2. Leak Testing: • Monitors system pressure under static conditions to detect fluid leakage. • Utilizes high-sensitivity differential pressure transducers to identify micro-leaks with high accuracy. 3. Component Compatibility Testing: • Verifies the compatibility and robustness of heat exchangers for both hydraulic and aviation oil systems. • Tests various operating pressures ranging from 30 to 70 bar, depending on the circuit. Circuit Configuration and Functional Elements The rig incorporates three independent fluid circuits, each optimized for specific tasks. The circuits include: 1. Hydraulic Oil Circuit This circuit has a 150-liter reservoir made of SS 304 stainless steel. It operates with a fixed-displacement vane pump capable of providing a maximum flow of 90 LPM and a pressure range of 0-70 bar. The circuit also includes high-pressure hoses with quick-disconnect couplings rated for 150 bar pressure. 2. Gearbox Oil Circuit This circuit supports a flow rate of up to 50 LPM and uses a pressure range of 0-50 bar. It features 10-micron pressure line filters for fluid purity, Siemens sensors for pressure and temperature monitoring, and analog as well as digital indicators for system performance tracking. 3. Aviation Fuel Circuit The aviation circuit handles specialized aviation oils conforming to MIL and DERD standards. It is designed for a maximum flow rate of 30 LPM and a pressure of up to 30 bar. The system is equipped with digital display units to continuously monitor pressure, temperature, and flow data. Technical Specifications The hydraulic oil circuit is powered by a 15 kW motor operating at 415V (three-phase). The circuit's output pressure can reach up to 70 bar, with 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 stainless steel (SS 304) reservoirs, analog pressure gauges ranging from 0 to 70 bar, and digital indicators with a high accuracy of ±0.01%. • The working media for the rig include hydraulic oil, gearbox oil, and aviation fuel, depending on the circuit being tested. Advanced Monitoring and Control The system is designed with PC-based automation to facilitate easy and precise control. It incorporates National Instruments (NI) hardware and software for efficient test management. The key automation features include: • Annunciator system to alert operators of any critical alarms. • Digital and analog pressure monitoring using WIKA transducers and gauges. • Temperature monitoring through Masibus digital indicators, ensuring precise control over test conditions. Real-time data is logged and stored for performance analysis, allowing for complete traceability of tests conducted. Operators can customize test parameters via a user-friendly human-machine interface (HMI), minimizing errors and ensuring smooth operation. Safety Features The Pressure Loss and Leak Test Rig includes several safety mechanisms to protect both personnel and equipment: • An automatic emergency shutdown system that triggers during overpressure, high temperature, or electrical phase failure events. • Phase sequence protection to prevent motor damage in case of 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 high-grade stainless steel (SS 316) components to withstand high-pressure environments and ensure long-term durability. Applications This test rig is highly versatile and applicable across various industries: • In aerospace, it ensures the reliability of hydraulic, fuel, and cooling systems in aircraft. • In defense, 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 and Support To keep the system operating at peak performance, Neometrix offers a comprehensive maintenance plan, which includes: • Quarterly inspections to check and tighten motor connections, control panel wiring, and sensor installations. • Calibration services to ensure measurement accuracy. • Training programs to equip operators with the skills needed for safe and efficient system use. • Rapid spare parts replacement and technical support for troubleshooting issues. Troubleshooting instructions are outlined in the user manual, providing a step-by-step guide to resolve common problems.
