Getting a leak tester to 250 bar sounds like it just needs a bigger compressor. It doesn't -- it needs amplification. Neometrix's High Pressure Leak Testing Machine takes a completely ordinary 6-8 bar shop-air supply and runs it through a Haskel-equivalent air-driven gas booster and a 44:1 dome-loaded regulator to hit 5000 psi output on demand, with 6-liter receiver tanks buffering both a 350 bar high-pressure side and a 16 bar low-pressure side.
That amplification approach only makes sense if the safety envelope around it is solid, and it's built independent of the control logic on purpose: a spring-loaded relief valve set between 275 and 344 bar, a pilot pressure switch at 300 bar, Ham-Let pneumatically actuated ball valves, and an interlocked emergency-vent path -- none of it routed through the Schneider PLC running the actual test sequence, so a PLC fault can't leave the DUT unprotected.
On top of that hardware, four test protocols run through the same 10-inch HMI: static pressure decay for the standard pass/fail check, pressure vs. time profiling for endurance and burst-limit work, direct outlet pressure mode for real-time calibration, and stepwise pressure ramp for simulating cyclic loading on parts with pressure-dependent deformation. Every reading is captured twice -- a WIKA 0-400 bar glycerine-filled analog gauge alongside a 0.25% full-scale digital transmitter -- because the result is only as credible as the measurement underneath it, and this covers components from 1.2 to 20 liters across automotive, aerospace, defense, and rail applications.
Full writeup: https://neometrixgroup.com/products/high-pressure-leak-testing-machine
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