Hydraulic and Pneumatic Leak Testing
Accurate hydraulic and pneumatic leak testing systems engineered for safety, compliance, and long-term reliability.
Hydraulic and Pneumatic Leak Testing
Curtis Assemble & Test Ltd design and manufacture high-pressure leak testing systems for hydraulic and pneumatic applications. Our systems are used to accurately detect and quantify internal and external leaks in components, ensuring performance, safety, and compliance with industry standards.
Each system is engineered to suit the component under test, using proven leak detection methods including flow meters, pressure chambers, transducers, pressure decay, and mass flow measurement techniques. From development and validation through to production testing, CAT leak testing systems deliver reliable repeatable results across demanding industrial environments.
High-Pressure Leak Testing Capability
Our hydraulic and pneumatic leak testing systems are capable of testing at pressures up to 3000 bar for hydraulic systems and up to 250 bar for pneumatic systems. This allows manufacturers to validate sealing integrity, monitor performance over time, and verify compliance with international standards.
Systems can be configured to suit a wide range of component sizes, test pressures, and cycle times, providing accurate and repeatable leak detection while maintaining operator safety and process stability.
Integrated Vision Systems
For applications where leaks are visible externally or where forming a seal is impractical, CAT systems can incorporate integrated vision inspection. Vision systems detect changes around the leak area using carefully selected lighting and optics, providing a reliable, non-contact inspection method.
This approach is particularly effective for complex components, enabling external leak detection alongside pressure-based testing methods.
Advanced Data Logging & Historical Leak Rate Analysis
CAT leak testing systems incorporate advanced data acquisition and historical performance monitoring to provide full visibility of leak rates, flow behaviour, and pressure stability over time. Real-time graphical trending enables engineers to analyse pressure decay, minimum and maximum leak thresholds, and station-to-station performance across production cycles.
By capturing and storing historical test data, our systems support traceability, process validation, and continuous improvement initiatives. Operators can quickly identify variation trends, monitor system health, and verify compliance against defined acceptance criteria. This data-driven approach enhances quality control, reduces diagnostic time, and ensures reliable, repeatable leak detection performance in both development and production environments.
Leak Detection System Capabilities
⚙️ Test pressure: 70 mbar to 3000 bar
⚙️ Temperature range: Ambient to 60°C (higher options available)
⚙️ Flow range: 0.01 cc/min to 20 cc/sec and higher
⚙️ Cycle time: From 10 seconds
⚙️Pressure Decay & Pressure Change Testing: Accurate leak detection using sealed pressure chambers and monitored pressure varia
⚙️ Flow measurement: Leak rate quantification using calibrated flow measurement
⚙️ Evaluation criteria: Pressure change over time (pressure decay / pressure rise), timed pressure drop, measured flow (flow measurement / mass flow), blob growth
⚙️ Test media: Air, hydraulic oil, calibration fluid, and water
⚙️ Mass Flow Leak Testing: High-sensitivity leak measurement using calibrated mass flow technology for demanding applications
⚙️ Integrated Instrumentation – Systems using flow meters, pressure transducers, sensors, and live monitoring for precise test control
Our hydraulic and pneumatic leak testing systems are trusted by global manufacturers to deliver precise, repeatable leak detection across a wide range of components and applications. Each system is engineered to meet defined acceptance criteria while maintaining safety and reliability.
COMMON APPLICATIONS
Hydraulic and pneumatic leak testing plays a critical role across industries where reliability, safety, and performance cannot be compromised. Typical applications include:
Hydraulic Component
Leak Testing
Testing of pumps, manifolds, valves, and actuators to detect internal and external hydraulic leaks under controlled pressure conditions.
Pneumatic System &
Air Circuit Testing
Leak detection for pneumatic assemblies, fittings, and air circuits to ensure efficiency, safety, and repeatable operation..
Valve & Seal
Integrity Testing
Verification of sealing performance across valve seats, O-rings, gaskets, and sealing faces under static and dynamic pressure conditions.
Pre-Production Validation
& Prototype Testing
Leak testing during product development to validate designs, establish acceptance criteria, and optimise performance before production.t
End-of-Line
Leak Testing
Automated or manual leak testing integrated into production environments to verify every component meets defined leak rate limits.
Failure Analysis &
Root Cause Investigation
Investigative testing to identify leak paths, pressure loss, or sealing failures in returned or suspect components.
Industries We Support
- Automotive – leak testing of hydraulic valves, air circuits, pumps, and fuel system components.
- Hydraulics & Pneumatics – validation of seals, manifolds, regulators, and pressure assemblies.
- Aerospace – high-integrity leak testing of critical components where failure is not an option.
- Industrial Manufacturing – automated leak testing integrated into production and end-of-line processes.
WHAT WE CAN DELIVER
Automated or manual hydraulic and pneumatic leak test machines
Accurate detection of internal and external leaks using proven test methods
Integrated sensors, flow measurement, and data acquisition
Pressure decay, pressure rise, and flow-based leak detection techniques
Full software, PLC, and HMI control for reliable and repeatable testing
Custom fixtures and tooling designed around your components
Integrated vision inspection for external leak detection where required
In-house system build, commissioning, and validation
Full documentation and CE / UKCA compliance
Looking for a reliable hydraulic or pneumatic leak testing solution?
Our engineers will help define the right system to meet your component and performance requirements.
Talk to our engineering team, we’ll help define the right leak testing solution for your application.
Why Choose CAT?
☑️ Bespoke Leak Testing Solutions
Each system is engineered around your component, test pressure, and acceptance criteria.
☑️ Accurate, Repeatable Results
Proven leak detection methods deliver consistent results across repeated test cycles.
☑️ Multiple Detection Techniques
Pressure decay, pressure rise, flow measurement, and vision-based inspection.
☑️ High-Pressure Capability
Systems designed to support demanding hydraulic and pneumatic applications.
☑️ Safety-Focused Design
Engineered guarding, pressure-rated components, and interlocks for operator protection.
☑️ Proven Engineering Expertise
Decades of experience delivering leak testing systems across industry.
Real-World Performance, Real-World Trust
Looking for a trusted partner to deliver your hydraulic or pneumatic leak testing system?
Our engineers will design and manufacture a bespoke solution tailored to your testing requirements.