Hydraulic Pressure Test Bench, hydrostatic & burst testing proven to 500 bar.

1. Introduction

The Hydraulic Pressure Test Bench – Model A3101 is a fully automated, PLC-controlled, SCADA-integrated test system developed to perform high-precision hydrostatic and burst pressure testing of metallic tube assemblies. Engineered and manufactured by Neometrix, a leading defence and aerospace test-equipment provider, this hydraulic line pressure tester is tailored to meet the stringent quality standards of clients such as Tata Sikorsky Aerospace Limited (TSAL). Built to simulate real-world operating pressures and failure scenarios, the A3101 provides unmatched reliability, traceability, and safety, supporting simultaneous testing of up to four tubes up to 3965 mm in length without compromising accuracy.

2. System Functionality and Overview

The test bench performs hydraulic proof testing and burst validation of aerospace fluid lines and metal tubes through controlled pressurization using water as the test medium, capable of both low-pressure and high-pressure tests including automatic detection of burst events. Dual pumping systems, multi-tube manifold support, and a hot air drying station combine into one automated hydraulic testing machine. Each tube assembly is subjected to the exact test pressure for a precise duration, while all critical data — pressure, time, burst point, and test outcome — is captured digitally. Post-testing, the integrated Hot Air Blower Station dries components fully to prevent corrosion and meet aerospace cleanliness standards.

3. Mechanical Design and Chamber Construction

The test chamber is fabricated from SS304 for corrosion resistance and strength, with a structural frame of powder-coated mild steel. The internal layout accommodates four tube assemblies simultaneously, each securely mounted on a slide-in manifold plate. The chamber includes a transparent acrylic shield, metal mesh guards, and top-mounted safety locks, ensuring safe operation even during high-pressure bursts.

Chamber highlights

• External dimensions: 4500 mm (L) × 750 mm (W) × 1200 mm (H)
• Tube compatibility: Up to 3965 mm in length and 32 mm in diameter
• Manifold system: Four independent tube connection ports
• Slide-in plate: Ergonomic, with locking knobs for quick tube setup
• Base systems: Integrated drainage and filtration

The chamber also includes viewing panels and LED status indicators for real-time monitoring of the testing process.

4. Pressure Generation and Pumping Architecture

To enable accurate testing across a wide range of pressure levels, the A3101 incorporates dual air-driven liquid pumps — one for high pressure and one for precise low-pressure control. Both pumps operate on a 6 Bar compressed air supply and connect through an intelligent control valve arrangement to the central manifold.

High-pressure pump — Haskel 4B-150

• Nominal ratio: 150:1
• Max outlet pressure: 15,000 PSI (intermittent)
• Flow rate: 42 cu.in./min
• Cycle rate: 225 cycles/min
• Application: Proof and burst testing up to 500 Bar

Low-pressure pump — Haskel MS-7

• Nominal ratio: 7:1
• Max outlet pressure: 900 PSI
• Flow rate: 366 cu.in./min
• High-accuracy control for tests ≤20 Bar

Filling pump — Kirloskar TINY

• Head: 3 to 15 metres
• Flow rate: 1600 to 600 LPH
• Power: 0.25 HP (single-phase, 230V)

A 50-litre SS water tank serves as the test medium reservoir, equipped with a low-level switch, filler breather, strainers, and a level gauge. The tank is preheated to 65°C ± 5°C, ensuring consistent fluid characteristics during testing.

5. Air-Supply Conditioning

Since both Haskel pumps are air-driven, the 6 Bar compressed-air supply feeding them is conditioned by a dedicated pneumatic control circuit: an FRL (filter-regulator-lubricator) unit with 1/2″ BSP female end connections rated to 10 Bar working pressure, a brass safety relief valve set between 2 and 7 Bar, a 3/2-way solenoid valve on the 1/2″ supply line, a brass Y-type strainer, and a stainless check valve. An SMC ITV3050 electronic pressure regulator (0–10V input, 0–0.9 MPa output), a 0–16 Bar pressure transmitter (4–20 mA, 0.25% accuracy), and a 0–100°C temperature transmitter close the loop into the SCADA system for consistent pump behaviour on every cycle.

6. Automation, Controls, and Data Acquisition

At the core of the A3101 lies a Siemens SIMATIC S7-1200 PLC, integrated with a high-resolution HMI touch panel and a proprietary SCADA software system developed by Neometrix. The automation suite allows full control over test parameters, pump operation, pressure cycles, and safety interlocks.

Control features

• Digital configuration of pressure levels, test durations, and burst limits
• Real-time monitoring of pressure vs. time curves
• Automatic detection and recording of burst events
• Secure user access control
• Test report generation and export
• Visual and audible system status via tower light and buzzer

The SCADA system maintains historical test data logs, allows exporting to spreadsheets, and enables remote diagnostics and support when connected to a network.

7. Instrumentation and Components

As a hydraulic test bench, sensor accuracy is critical: the A3101 is fitted with high-precision sensors and valves from globally reputed brands to ensure consistent and traceable measurements across all test cycles.

Key instruments

• Pressure gauges (WIKA 233.50.100): 0–600 Bar, SS316, glycerin-filled
• Pressure transmitters (WIKA S-20): 0–600 Bar, 4–20 mA output, 0.25% FS accuracy
• Electronic pressure regulator (SMC ITV3050): 0–10V input, 0–0.9 MPa output
• Dew point meter (Vaisala DMT143): −70°C to +60°C, accuracy ±2°C
• Solenoid, check & relief valves: Festo, Butech, Cair
• Emergency stop switches and interlocks: Schneider

All instrumentation is integrated with the control logic to ensure real-time diagnostics, with redundant safety systems in place to immediately shut down operations during anomalies.

8. Moisture Removal Station

To eliminate residual moisture from tubes after testing, the system includes a Hot Air Blower Station located adjacent to the test chamber, using a heated airflow system to purge the interior of tested components via dedicated blower lines.

Moisture removal features

• Four-port outlet manifold for simultaneous drying
• Integrated temperature control and airflow regulation
• Real-time dew point monitoring using a Vaisala sensor
• Cycle timing and airflow control through SCADA
• Ensures dryness to aerospace-grade standards

This drying station ensures the internal surfaces of tubes are completely free of moisture — crucial for corrosion prevention and cleanliness compliance in aerospace applications.

9. Safety and Ergonomics

Operator safety is paramount in high-pressure environments. The A3101 is designed with multiple passive and active safety features to protect the operator throughout the test cycle.

Safety features

• Fully enclosed SS chamber with acrylic viewing shield
• Mechanical locks and interlocks to prevent access during operation
• Emergency stop button at key operator locations
• Multicolour tower light and buzzer for real-time status indication
• Low-voltage control circuit with fault monitoring

The system is also ergonomically laid out, with all controls at operator height, easy-access service points, and quick-connect tube fittings to minimize setup time.

10. Technical Specifications

11. Application Areas

The A3101 Test Bench is a versatile solution for industries where fluid-system reliability under pressure is mission-critical. Its robust construction, automation, and traceability features make it ideal for:

Aerospace & Defence

• Hydraulic tube testing for aircraft and helicopters
• Pressure-proofing of structural and fluid components
• Burst validation of mission-critical lines

Rail & Metro

• Testing of brake and pneumatic tube assemblies
• Fatigue testing of undercarriage and onboard hydraulic lines

Automotive & EV

• High-pressure hose and tube testing for electric vehicles
• Cooling system tube validation for hybrid systems

Cryogenics & Gas

• Proof testing of gas transfer lines in cryogenic and industrial gas plants
• Hydrogen, oxygen, and nitrogen system validation

Industrial R&D

• Component testing in laboratories for pressure integrity, failure mode analysis, and qualification of new products

12. Delivery and Support

Neometrix provides comprehensive after-sales support including installation, commissioning, operator training, preventive maintenance, and on-site service for the Hydraulic Pressure Test Bench, and exports the A3101 to global customers across defence, aerospace, and industrial sectors.

Conclusion

The Hydraulic Pressure Test Bench A3101 sets a dependable benchmark for hydrostatic and burst pressure testing. As a hydraulic pressure test bench manufacturer and supplier in India, Neometrix combines SCADA-integrated automation, aerospace-grade drying, and traceable instrumentation into a single custom hydraulic pressure stand suited to defence, aerospace, automotive, rail, and industrial R&D programmes worldwide.