Extreme Fuel Temperature Testing

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Aerospace component suppliers to both the commercial and military markets need to meet stringent program requirements requiring specialized test set ups. NTS has developed a specialized hydraulic rig specifically for the testing of fuel delivery and metering units.

Key benefits:

  • Flexible rig accommodates difference components and configurations
  • Dedicated test set up allows for fast test starts
  • Automated control and data acquisition for accurate reports
  • In-house expertise for mitigation and engineering services

System Details and Specifications

The hydraulic test rig was developed for testing fuel delivery and metering units for use in both commercial and military aircraft. The rig consists primarily of drive system, fuel conditioning system and ambient air control system. Fuels such as JP-4, Jet A, JP-8 as MIL-C-7024 can be used in this system. Full automations allows for accurate control of drive speed, fuel flows, inlet pressure, output pressures and chamber air pressures over the course of a test profile. Typical profiles simulate idle, take-off, cruise, landing and reverse thrust conditions. Although this system was designed for fuel delivery and metering units, any test unit that requires some, or all of the capabilities listed below are suitable for this rig. Figure 1 below shows the typical flight profile controlling drive speed, unit flow and output pressure.

Capabilities

  • Fuel Temp: -67°F to 300°F
  • Ambient Air Temp: -70°F to 350°F
  • Ramp Rate: up to 50°F/min
  • Drive Speed: up to 20,000rpm
  • Drive Torque: up to 25hp
  • Fuel Flow: up to 12gpm
  • Boost Pressure: unit inlet pressure from 10psig to 80psig

Unique Abilities

Our cold fuel capabilities exceed that of most manufacturers. We are able to bring fuel down to -67°F and maintain the fuel below -40°F consistently. Most rigs of this type require the operators to stop after each cycle and cool the fuel back down to the desired cold temp. Our NTS designed Brine Tanks utilize LN2 and D-Limonene in a manner that dramatically increases cooling capacity.Figure 2 below is an example of 26 flight profiles performed with inlet fuel temp requirements of -55°F to -40°F and chamber air requirement of -67°F.

The hot fuel capabilities are also exceed most manufacturers’ capabilities as well. We can heat fuel to 300°F and maintain the inlet temp within 2 degrees. Often hot fuel temp can be maintained within .5°F due to the 36kW of heating power and precise control methods. Figure 3 below shows an example of fuel inlet temp of 200° +/- 2&def; and chamber air cycling between 200°F and 300°F with a 2 minute ramp between temperatures.

Unit outputs can be monitored or controlled via custom designed hydraulic boards. We have a large stock of calibrated pressure transducers, flow meters, thermocouples and valves designed for fuel that can quickly be installed to monitor and/or control any number of unit outputs.Pictured below are two examples of custom output monitoring plumbing and instrumentation