Hydraulic Loading System / 270-295 bar · 20-210 LPM / ±0.5% Accuracy / India

HLS · AEROSPACE & DEFENCE PUMP TEST RIG

Hydraulic Loading System, rated to 295 bar / 210 LPM.

An 8-module, skid-mounted test rig built by Neometrix Defence Limited to replicate the demanding operating conditions of engine-driven hydraulic pumps. The HLS applies a precisely controlled, variable back-pressure to the pump outlet, enabling performance validation, endurance cycling and fault-finding under repeatable, traceable conditions for aerospace, defence and industrial qualification.

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Hydraulic Loading System full skid view - 8-module engine-driven hydraulic pump test rig by Neometrix

Fig · 01 HLS skid assembly · oil tank, outlet and loading valve modules

Built around:

MIL-H-5606 / FH-51 FAR/JAR Endurance Testing ISO 4406 Cleanliness

Working Pressure

270-295bar

Max Design Pressure

340bar

Flow Capacity

20-210LPM

Reservoir Volume

175L

Pressure Accuracy

±0.5%

Overview

Real-world load, on the bench.

A fully modular, skid-mounted rig that reproduces the back-pressure profiles engine-driven hydraulic pumps see in service, so pumps can be qualified before they ever fly, sail, or roll.

Hydraulic Loading System general arrangement drawing - modular skid layout for engine-driven hydraulic pump testing by Neometrix

Fig · 02 HLS general arrangement · module layout drawing

The Hydraulic Loading System (HLS) is a purpose-built test rig engineered to replicate the demanding operating conditions of engine-driven hydraulic pumps. It delivers a controlled, variable back-pressure to the pump outlet, allowing precise simulation of real-world loading profiles encountered in aerospace, defence and industrial applications.

By integrating high-accuracy sensors and instrumentation, the HLS enables comprehensive performance validation, endurance cycling and fault-finding under repeatable, traceable conditions — key steps in qualifying pumps for flight, marine or heavy-equipment service.

Eight modules. One repeatable load profile.

The rig is organized into eight skid-mounted, plug-and-play modules, each fulfilling a critical subsystem role — from oil conditioning and air regulation through to loading-valve cycling, heat exchange and a portable oil-filling unit for rapid top-ups.

Architecture

Eight modules, one test skid.

Every subsystem of the HLS is skid-mounted and plug-and-play, so the rig can be relocated or reconfigured for a different pump model without a rebuild.

Mod · 01

Oil Tank Module

175 L reservoir with level transmitter and over-temperature switch; in-line 5 µm filters keep fluid cleanliness within test tolerance.

Mod · 02

Air Regulation Module

Delivers up to 10 kg/cm2 for accumulator charging and pneumatic control of the loading valve manifold.

Mod · 03

Inlet Module

Monitors suction pressure below 10 bar to prevent cavitation, with optional pre-heat for oil viscosity stability.

Mod · 04

Outlet Module

Variable orifice bank and fine flow-control valve for precise, repeatable back-pressure adjustment.

Mod · 05

Drain Module

Handles return flow up to 30 bar, venting cleanly back to the reservoir without disturbing test conditions.

Mod · 06

Loading Valve Module

Pneumatically actuated manifold with nitrogen accumulator for rapid, controlled pressure cycling.

Mod · 07

Heat Exchanger Module

PID-controlled shell-and-tube exchanger holding outlet ≤ 100 °C and inlet ≤ 80 °C within ±2 °C.

Mod · 08

Portable Oil Filling Module

50 L trolley-mounted tank with pump and metering system for quick top-ups between test runs.

Working Principle

How a test cycle runs.

Five stages take a pump from fluid conditioning through to a logged, repeatable load profile.

Hydraulic Loading System working principle diagram - pressure and flow control loop for hydraulic pump testing by Neometrix

Fig · 03 Load imposition and control loop · design drawing

Fluid supply and conditioning: oil conforming to MIL-H-5606/FH-51 is filtered to 5 µm and temperature-controlled before it reaches the pump under test.
Suction control: an inlet pressure transmitter prevents cavitation by holding suction pressure below 10 bar.
Load imposition: selectable orifices and a high-resolution globe valve create back-pressure between 270 and 295 bar.
Temperature management: PID-regulated coolant flow in the heat exchanger stabilizes oil temperature to within ±2 °C.
Data acquisition and control: the PLC/HMI logs pressure, temperature and flow, and executes custom test scripts and alarms.

Key Features

Built for repeatable data.

Eight design decisions that make the HLS a dependable pump-qualification tool.

F · 01

Modular Skid Design

Eight plug-and-play modules enable rapid relocation and reconfiguration across pump models and test cells.

8-Module Skid

F · 02

High-Accuracy Instrumentation

±0.5% pressure and ±1% flow accuracy feed PLC loops for repeatable hydraulic load application.

±0.5% Pressure

F · 03

Customizable Test Profiles

Static, ramp, step and sine waveform loading profiles are configurable through the PLC/HMI control interface.

Static / Ramp / Sine

F · 04

Automated Safety Interlocks

Interlocks halt the rig on over-pressure, over-temperature and low-oil-level conditions, with logged fault records.

Interlock Protected

F · 05

Quick-Swap Orifice Sets

The outlet module's variable orifice bank swaps quickly to change load profile without extended downtime.

Minimal Downtime

F · 06

Remote Monitoring

Modbus/ProfiNet interfaces integrate live HLS data with SCADA and MES platforms for plant-wide test monitoring.

IIoT Ready

F · 07

Nitrogen Accumulator

The loading valve module's nitrogen accumulator provides rapid pre-charge for smooth hydraulic impulse cycles.

Rapid Cycling

F · 08

Skid-Mount Installation

The compact skid footprint eases installation at aircraft test cells, hydraulic labs and system integration benches.

Compact Footprint

Image Gallery

Design drawings, module by module.

GA and layout drawings from the HLS design package — module assemblies, piping and control layout.

Hydraulic Loading System design drawing 4 - module assembly detail for engine-driven hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 5 - piping and instrumentation layout for hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 6 - control panel and PLC layout for hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 7 - heat exchanger module detail for hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 8 - loading valve module detail for hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 9 - outlet module and orifice bank detail for hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 10 - inlet and drain module detail for hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 11 - portable oil filling module detail for hydraulic pump test rig by Neometrix

Hydraulic Loading System design drawing 12 - skid frame and air regulation module detail for hydraulic pump test rig by Neometrix

Fig · 04–12 Design drawing set · module assemblies, piping and control layout

Downloads

Datasheets and drawings.

General datasheet, design drawings and catalog for the Hydraulic Loading System, available as PDF for procurement and technical review.

Hydraulic Loading System datasheet thumbnail

Document · General

HLS — General Datasheet

PDF

Hydraulic Loading System design drawing 1 thumbnail

Drawing · Design 1

HLS — Design Drawing 1

PDF

Hydraulic Loading System design drawing 2 thumbnail

Drawing · Design 2

HLS — Design Drawing 2

PDF

Hydraulic Loading System catalog thumbnail

Document · Catalog

HLS — Product Catalog

PDF

Specifications

Full technical parameters.

Key parameters for the standard Neometrix Hydraulic Loading System configuration.

Maximum Design Pressure	340 kg/cm2 (≈4,834 psi)
Working Pressure Range	270-295 kg/cm2 (≈3,837-4,195 psi)
Flow Capacity	20-210 LPM (≈5.3-55 gpm)
Hydraulic Fluid	MIL-H-5606/FH-51 (density 0.8735 kg/L @ 15.6 °C)
Kinematic Viscosity	15 cSt @ 40 °C
Reservoir Volume	175 L; pressurization up to 10 kg/cm2
Temperature Limits	Inlet ≤ 80 °C; Outlet ≤ 100 °C
Air Supply	6-10 kg/cm2 (≈85-142 psi)
Power Requirements	3-phase 415 VAC, 50 Hz, 10 kW
Control Interface	7″ HMI, PLC with Ethernet, USB export
Pressure / Flow Accuracy	±0.5% pressure, ±1% flow
Manufacturer	Neometrix Defence Limited

Applications

Where it qualifies pumps.

The HLS spans pump qualification, R&D, maintenance and training across nine sectors.

A · 01Aerospace pump qualification — meets FAR/JAR environmental and endurance testing standards for aircraft hydraulic systems

A · 02Defence vehicle systems — validates performance of armored-vehicle hydraulic drives under varying loads

A · 03Industrial machinery R&D — benchmarks pump efficiency, cavitation margins and transient response

A · 04Maintenance and overhaul shops — rapid acceptance tests on rebuilt pumps before return to service

A · 05Marine and offshore systems — simulates high-pressure conditions to qualify pumps for ships, rigs and subsea use

A · 06OEM production quality assurance — end-of-line functional testing of newly manufactured hydraulic pumps

A · 07Mobile hydraulic equipment validation — tests pumps for excavators, cranes and agricultural machinery

A · 08Educational and training facilities — hands-on rig for vocational institutes and OEM service centers

A · 09Energy sector applications — validates pump performance for hydroelectric and wind-pitch control systems

In Depth

The complete technical read.

System composition, construction and materials for the Hydraulic Loading System.

Introduction

The Hydraulic Loading System (HLS) by Neometrix Defence Limited is a purpose-built test rig engineered to replicate the demanding operating conditions of engine-driven hydraulic pumps. It delivers a controlled, variable back-pressure to the pump outlet, allowing precise simulation of real-world loading profiles encountered in aerospace, defense and industrial applications. By integrating high-accuracy sensors and instrumentation, the HLS enables comprehensive performance validation, endurance cycling and fault-finding under repeatable, traceable conditions — key steps in qualifying pumps for flight, marine or heavy-equipment service.

System composition

The HLS is organized into eight skid-mounted, plug-and-play modules, each fulfilling a critical subsystem role:

Oil Tank Module: 175 L reservoir with level transmitter and over-temperature switch; in-line 5 µm filters.
Air Regulation Module: delivers up to 10 kg/cm2 for accumulator charging and pneumatic controls.
Inlet Module: monitors suction pressure (< 10 bar) and optionally pre-heats oil for viscosity stability.
Outlet Module: variable orifice bank and fine flow control valve for precise back-pressure adjustment.
Drain Module: handles return flow up to 30 bar, venting back to the reservoir.
Loading Valve Module: pneumatically actuated manifold with nitrogen accumulator for rapid pressure cycling.
Heat Exchanger Module: PID-controlled shell-and-tube exchanger maintaining outlet ≤ 100 °C and inlet ≤ 80 °C.
Portable Oil Filling Module: 50 L trolley-mounted tank with pump and metering system for quick top-ups.

Construction and materials

Frame and skid: carbon-steel with epoxy powder-coat finish.
Pressure piping: stainless-steel 316L tubing and fittings rated to 400 bar.
Valve manifolds: austenitic stainless-steel blocks with precision ports.
Heat exchanger: copper-nickel tubes in a stainless-steel shell.
Seals and hoses: PTFE seals and reinforced hoses rated to 350 bar.

Conclusion

Neometrix's Hydraulic Loading System sets the benchmark for hydraulic pump testing by combining modular flexibility, precise control and comprehensive safety features. It delivers repeatable, data-driven insights critical for reliability and performance in aerospace, defense and industrial applications.

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 What is the Hydraulic Loading System?

The Hydraulic Loading System (HLS) is an 8-module, skid-mounted test rig that replicates the operating conditions of engine-driven hydraulic pumps by applying a controlled, variable back-pressure to the pump outlet, enabling performance validation, endurance cycling and fault-finding under repeatable, traceable conditions.

Q · 02 What pressure and flow range does the HLS cover?

The HLS applies a working back-pressure of 270-295 kg/cm2 (up to a 340 kg/cm2 maximum design pressure) across a flow capacity of 20-210 LPM, with pressure held to within ±0.5% accuracy and flow to within ±1%.

Q · 03 What are the eight modules of the Hydraulic Loading System?

The HLS comprises an Oil Tank Module, Air Regulation Module, Inlet Module, Outlet Module, Drain Module, Loading Valve Module, Heat Exchanger Module and a Portable Oil Filling Module, each skid-mounted and plug-and-play for rapid relocation and reconfiguration.

Q · 04 What hydraulic fluid does the HLS use, and how is temperature controlled?

The HLS runs on MIL-H-5606/FH-51 hydraulic fluid (density 0.8735 kg/L at 15.6 °C, 15 cSt kinematic viscosity at 40 °C), filtered to 5 µm and PID-regulated through a shell-and-tube heat exchanger to keep inlet temperature at or below 80 °C and outlet at or below 100 °C, within ±2 °C.

Q · 05 What safety features are built into the Hydraulic Loading System?

Automated safety interlocks stop the test on over-pressure, over-temperature and low-oil-level conditions, with a PLC/HMI logging pressure, temperature and flow and executing custom test scripts and alarms in real time.

Q · 06 What industries and applications use the Hydraulic Loading System?

The HLS is used for aerospace pump qualification, defence vehicle hydraulic systems, industrial machinery R&D, maintenance and overhaul acceptance testing, marine and offshore pump qualification, OEM end-of-line production QA, mobile hydraulic equipment validation, and vocational training on hydraulic system diagnostics.

Q · 07 Can the Hydraulic Loading System be monitored or integrated remotely?

Yes, the HLS control interface is a 7-inch HMI paired with a PLC offering Ethernet connectivity, USB data export, and Modbus/ProfiNet interfaces for integration with SCADA, MES and IIoT monitoring platforms.

Q · 08 Is the Hydraulic Loading System customizable?

Yes, Neometrix configures the HLS orifice sets, instrumentation ranges, reservoir capacity and control software to match specific pump models, test profiles and customer facility requirements.

Q · 09 How can I get a quotation for the Hydraulic Loading System?

You can request a quotation for the Hydraulic Loading System by contacting Neometrix Engineering Pvt Ltd through https://neometrixgroup.com/products/hydraulic-loading-system-v1 or the site contact form.

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Tell us your pump model
and test profile requirements.

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Hydraulic Loading System, rated to 295 bar / 210 LPM.

Real-world load, on the bench.