Details
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 Defence Limited, a leading defence and aerospace systems provider, this test bench 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. It supports simultaneous testing of up to four tubes, enabling high-throughput operations without compromising on accuracy. Designed to accommodate tube assemblies up to 3965 mm in length, it integrates seamlessly into modern aerospace and industrial testing workflows. 2. System Functionality and Overview The test bench is intended for the hydraulic proof testing and burst validation of aerospace fluid lines and metal tubes. It performs controlled pressurization using water as the test medium and is capable of both low-pressure and high-pressure tests, including the automatic detection of burst events. The bench is equipped with dual pumping systems, multi-tube manifold support, and a hot air drying station to offer a comprehensive testing solution. The system ensures that 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 facilitates complete drying of components to prevent corrosion and meet aerospace cleanliness standards. 3. Mechanical Design and Chamber Construction The test chamber is fabricated from SS 304 for corrosion resistance and strength, with a structural frame of powder-coated mild steel. The internal layout is designed to accommodate 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 • Integrated manifold system with four independent tube connection ports • Ergonomic slide-in plate with locking knobs for quick tube setup • Drainage and filtration systems integrated into the base 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 the other for precise low-pressure control. Both pumps operate on a 6 Bar compressed air supply and are connected through an intelligent control valve arrangement to the central manifold. High-Pressure Pump – Haskel 4B-150 • Nominal Ratio: 150:1 • Max Outlet Pressure: 15000 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 meters • Flow Rate: 1600 to 600 LPH • Power: 0.25 HP (Single-phase, 230V) A 50-litre SS water tank is used for the test medium, 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. Automation, Controls, and Data Acquisition At the core of the A3101 lies a powerful Siemens SIMATIC S7-1200 PLC, integrated with a high-resolution HMI touch panel and a proprietary SCADA software system developed by Neometrix Defence Limited. 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 also maintains historical test data logs, allows exporting to spreadsheets, and enables remote diagnostics and support when connected to a network. 6. Instrumentation and Components The A3101 is fitted with a range of 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 Valves, Check Valves, Relief Valves: Festo, Butech, Cair • Emergency Stop Switches and Interlocks: Schneider All instrumentation is integrated with the control logic to ensure real-time diagnostics, and redundant safety systems are in place to immediately shut down operations during anomalies. 7. 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. This station uses a heated airflow system to purge the interior of the 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 Vaisala sensor • Cycle timing and airflow control through SCADA • Ensures dryness to aerospace-grade standards This drying station ensures that the internal surfaces of tubes are completely free of moisture, crucial for corrosion prevention and cleanliness compliance in aerospace applications. 8. 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 user 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 • Multicolor 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. 9. Technical Specifications Parameter Specification Tube Length Up to 3965 mm Tube Diameter 6 mm to 32 mm No. of Tubes per Batch 4 Chamber Size 4500 × 750 × 1200 mm Test Pressure Range 1 – 414 Bar Max System Pressure 500 Bar Test Duration 3 to 10 minutes Test Media Water (65°C ± 5°C) Pressure Accuracy ±5% Pumps Haskel 4B-150 & MS-7 Filling Pump Kirloskar TINY Sensors WIKA, SMC, Vaisala Control Siemens S7-1200 PLC + HMI Data Logging SCADA enabled Moisture Removal Hot Air Blower + Dew Point Monitoring 10. Application Areas The A3101 Test Bench is a versatile solution designed 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
