Hydratron Featured Projects

Hydratron engineers have developed bespoke systems across a range of disciplines including Hydraulic, Pneumatic, Structural & PLC/PC engineering. The featured projects below detail a selection of the engineered systems we have developed.

We take great care to work closely with our clients at every stage of the development of their custom-designed system. These project write-ups offer an insight into the Hydratron design process and some of the engineering challenges that we have helped clients overcome.

Are you looking for a custom designed system? Our engineers are here to help.

In this feature we are highlighting a project that required our engineers to work closely with the customer to design a flushing HPU that delivered on size, performance and quality.

A North African client approached Hydratron to design and manufacture a portable flushing/hydrotest hydraulic power unit (HPU). The HPU would need to achieve NAS class 6 fluid cleanliness and 15,000 PSI test pressure using TOTAL AZOLLA ZS 32 as the operating fluid.

In this feature we are highlighting an innovative valve testing solution which was delivered and installed in our Global customers facility in the Caspian Region.

The client’s pressure testing requirements were complex and therefore called on the expertise of the entire Hydratron team, testing with both gas and water up to pressures of 690 Bar, accommodating valve sizes ranging from 1/2″ up to 24″ with various orientations from single flange type relief valves to angle pattern or straight pattern control valves.

In this feature we are highlighting an upgrade we carried out for one of our global customers.  Our longstanding customer had an original Hydratron gas test rig, which was supplied 20 years ago and configured for single item, manual operation only.

The purpose of the upgrade was to increase throughput and replace the original equipment with a new gas test bench equipped to perform high-pressure nitrogen testing and external helium leak testing on up to 5 devices under vacuum simultaneously. The system is installed in a class 100 (ISO5) cleanroom.

Designed for a well known sealless pump manufacturer and is suitable for carrying out hydrostatic body shell testing of pump casings, bearing housings, coupling housings and casing plates.

The Hydratron 3 Station Sealless Pump Casing/Shroud Pressure Test Rig has been designed for a well known sealless pump manufacturer and is suitable for carrying out hydrostatic body shell testing of four items (pump casings, bearing housings, coupling housings and casing plates) simultaneously at pressures up to 285 bar using water (containing a surfactant) as the test medium. It is also configured such that individual items can also be tested.

A large aerospace manufacturer approached Hydratron with a requirement to design a pressure testing solution that could be used to test a wide range of stainless-steel aerospace components; used on various types of aircraft.

The tests that were required varied from component to component but the rig had to be able to carry out hydraulic testing with pressures to 1,250PSI, gas testing with pressures to 600 PSI and low pressure air testing to 100 PSI. Submerged gas testing was also required to allow the operator to visually identify gas leak locations on the components if there was a failure.

A global manufacturer operating in the food and drink industry approached Hydratron with a demanding requirement to take on the design and manufacture of a production type pressure cylinder burst test rig rated to a maximum working pressure of 1000 Bar.

The client needed to burst a rolling sample of their total production of pressure cylinders as part of the manufacturing standards they needed to adhere to. This translated to a maximum allowable test time (including loading and removing) of 6 minutes. The burst test machine needed to be simple to setup, reliable and robust enough to run continuously, 24 hours a day, 7 days a week. As part of the workflow, Full data logging of all test results needed to be recorded and exported directly to the client’s network.

A global valve manufacturer approached Hydratron with an enquiry to design and manufacture a relief valve test rig to increase their production capacity and improve current operations. A new rig was required to run pressure tests on their relief valves, including high volume gas ‘pop’ testing and lower pressure gas back-pressure testing.

The client had a wide range of valves to be tested, including ½” to 8” flanged valves and ½” to 2” screwed valves. The testing pressures required included 6,500psi Water, 6,500psi Gas (pop test) and 800psi Gas (back pressure).

A Global Manufacturer of Subsea electrical equipment approached Hydratron asking for help in developing a “showpiece” Multi-Station Test Facility that could conduct hyperbaric pressure testing on a range of subsea products, up to 20,000psi to simulate extreme subsea pressures.

It became evident that whilst the testing regime required was very highly specified, the aesthetics of the pressure testing unit was equally important to them since the system would be operated in full view of staff, customers and suppliers visiting their facility. The design also needed to take into account the transportation of the test unit to the USA and had to minimise cost through design.

A large filter manufacturer approached Hydratron with a requirement to design and manufacture a test rig that would be capable of pressure testing two 8″ or larger filters at once whilst simultaneously flow testing a third filter.

The sales engineer ensured there was regular communication with the customer to re-examine points and options available, this ensured that the final specifications would meet their requirements and exceed their expectations.

A large manufacturer of hoses had completed construction of a new factory and required a dedicated hose testing system that could meet the challenging testing requirements for their hoses.

The test rig would need to handle hoses ranging from 6mm all the way up to 300mm in diameter with a range of different fittings. Hose lengths would vary up to a maximum of 20m and hose testing pressures was required from 2 Bar to 100 Bar.

A customer in the automotive industry approached Hydratron to design and manufacture a test rig that could perform leak testing on their motorsport and automotive product.

The customer required the rig to be able to pressure test their products to 10bar. This would ensure that the product is assembled correctly and does not leak. They also required the leak testing rig to produce reports for their traceability records.

Wellhead Control panel projects typically start with a user created functional specification for the simultaneous hydraulic actuation of Shutdown valves, Surface and Downhole Safety Valves, Master valves and Choke valves. Normally driven by a particular site or field demand, there have also been many speculative builds with a broader range of capabilities for use by a service company to add to their fleet.

Large, UK-based valve manufacture, Colson X-Cel contacted Hydratron to provide a valve test solution capable of testing their wide variety of process valves during production. The diverse range of valves to be tested varied in size from 1/2″ to 12″ and would need to be tested using both liquid and gas test mediums with pressures up to 10,000 PSI.