Hydrostatic Leak Testing Rig for Fire Suppression Valves

Johnson Controls required an end-of-production hydrostatic pressure test rig to leak test multiple fire suppression valves with a variable flow and pressure from 20 bar up to 600 bar, both of which needed to be infinitely adjustable. Each test piece needed to be dry after the tests had been carried out.

Hydrotechnik has a long standing relationship with Johnson Controls through past test and measurement equipment, including our well-known range of MultiHandy & MultiSystem series of data loggers. They had seen that we design and manufacture test rigs, via browsing our website.

Johnson Controls sent us the following requirements for the testing rig:

  • Pressure test for leaks up to 600 bar
  • Operator led software
  • A bunded water tank with level gauge
  • Measure flow rates of 5 l/min
  • Remove remaining fluid after the test is carried out
  • Three different test bays
  • Serviceable tank


With all the test rigs that we design and build, safety and functionality are paramount. The operator is well protected with a stainless, fully bunded test area, finished with gas struts for smooth opening and closing, polycarbonate safety viewing windows, and powerful LED light fittings.


Hydrotechnik UK have been supplying hydraulic test and measurement instrumentation for over 25 years to leading companies. Johnson Controls required the fire suppression valve to be pressure tested and the flow to be measured. We fitted UKAS calibrated PR140 pressure sensors to the rig, providing accurate rising and falling pressures. Minimess test points were chosen for leak-free pressure testing. Proportional valves were fitted to control the flow direction of the water, flow volume and pressure on the components. The testing rig was also fitted with an air purge / heat circuit, to remove the majority of the contained fluid after the tests have been carried out.


Our in-house test rig team have the expertise and experience to develop software to suit. On this test rig, our custom-made software was designed in partnership with Johnson Controls. We wrote the software in-house tailor-made for them. The operator is taken step-by-step through the testing procedure, from start to finish. This process covers setting the pressure and flow, as well as displaying the rising and falling pressures and flow rate whilst the test is carried out. All data can be transferred with ease via the built-in USB port. The test rig was designed and built at our testing facilities in Nottingham.


After each test rig is built, our customers come on-site and carry out tests to their specifications, to clarify the rig performs as expected.


After installation, the company are now able to test more fire suppression valves, to ensure they meet all safety regulations and can be sold. All operators are trained in both hardware and software procedures after installation.

Feel free to browse our library of testing rigs. Furthermore, if you would like more information about this test rig or any others, email us on sales@hydrotechnik.co.uk or telephone 0115 9003 550.

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