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INTEGRATED TEST RIG FOR HTFE-25 (A5157)
O P E R A T I N G P R O C E D U R E
 INDEX
S.No. Description Slide No.
1. Cover Page 01
2. Index 02
3. Introduction 03
4. Specification of UUTs 04
5. Test carried out for LP FUEL PUMP 06-08
6. Test carried out for HP FUEL PUMP 09-12
7. Test carried out for OIL PUMP 13-14
8. Test carried out for FCOC 15-16
 INTRODUCTION
The purpose of Integrated Test Rig is to assess performance of Fuel Cooled Oil Cooler
(FCOC), HP Pump & Oil Pump prior to fitment on Aero Engine. The design of rig is such
that it can cater to individual testing of individual LRU or integrated testing of all the LRU’s
installed together (in combination). The pumps under test shall be mounted directly on
the high-speed electric motor flange through adapter quill shaft assembly. Variable speed
drives shall be provided for all the pumps under testing. The rig shall cater for real time
monitoring and recording of performance parameters.
 SPECIFICATION OF UUT’s
Sl.
No.
UUT FLUID TYPE INLET
PRESSURE
(bar-g)
FLOW RATE OF
PUMP (lpm)
OUTLET
PRESSURE
(bar-g)
MAX SPEED
(rpm)
1 LP PUMP ATF JET-A1 2±0.1 70 (RATED)
90 (MAX)
4.5 (RATED)
10 (MAX)
8000 (RATED)
12000 (MAX)
2 HP PUMP ATF JET-A1 2±0.1 70 (RATED)
90 (MAX)
75 (RATED)
90 (MAX)
8000 (RATED)
12000 (MAX)
3 OIL PUMP AVIATION TURBINE
OIL (OX-27)
0.3±0.05 17.5 (RATED)
20 (MAX)
5 (RATED)
20 (MAX)
10500 (RATED)
15000 (MAX)
4 FCOC OIL: OX-27
FUEL: ATF JET-A1
OIL: 4.5
FUEL: 4.5
OIL: 16 (RATED)
FUEL: 45 (RATED)
 TEST CARRIED OUT FOR LP FUEL PUMP
I. FREE FLOW TEST
II. FLOW CHECK WITH BACK PRESSURE TEST
I. FREE FLOW TEST:
Free flow test is carriedout by turningMotorPump assembly (CircuitCode 58.1 & 5.1) on. Fuel
will start flowing through6 & 3µ Filters (56.2, 7.2), Pneumaticallyoperated valve (33.2) will be
opened while (33.3 & 33.4) remains close, for this particulartestingand LP fuel pump will be
feeded with ATF Fuel @1±0.1 bar-g.
At the outlet of ATF LP Pump FCV (19.1) will be fully opened while (33.9)
remainclosed and fuel will flow throughFilters and Flow meter (6.3, 56.4 & 21.2) respectively.
Test data will be recordedin tabularformas given Below:-
Sl. No. Speed (rpm) Pressure Difference (bar-g) Flow rate Duration (Min)
1 1000 2
2 2000 2
3 3000 2
4 4000 2
5 5000 2
6 6000 2
7 7000 2
8 8000 2
9 7000 2
10 6000 2
11 5000 2
12 4000 2
13 3000 2
14 2000 2
15 1000 2
II. FLOW CHECK WITH BACK PRESSURE TEST:
Tis test is carried out by turning MotorPump assembly (Circuit Code 58.1 & 5.1) on. Fuel will
start flowingthrough6 & 3µ Filters(56.2, 7.2), Pneumatically operated valve (33.2) will be
opened while (33.3 & 33.4) remains close, for this particulartestingand LP fuel pump will be
feeded with ATF Fuel @1±0.1 bar-g.
At the outlet of ATF LP Pump pressuredifference is created via FCV (19.1) by
opening/closingit gradually, while (33.9) remain closed and fuel will flow throughFilters and
Flow meter (6.3, 56.4 & 21.2) respectively. Test data will be recorded in tabularform as given
Below:-
Speed (rpm) 5000 6000 7000 8000
Sl. No. ΔP
(bar-g)
Flow
(lpm)
ΔP
(bar-g)
Flow
(lpm)
ΔP
(bar-g)
Flow
(lpm)
ΔP
(bar-g)
Flow
(lpm)
1 1.00 - -
2 1.25 - -
3 1.5 1.5 -
4 1.75 1.75 -
5 2.00 2.00 2.00 2.00
6 2.25 2.25 2.25
7 2.50 2.50 2.50
8 2.75 2.75 2.75
9 3.00 3.00 3.00
10 3.25
11 3.50
12 4.00
13 4.25
14 4.50
15 4.75
 TEST CARRIED OUT FOR HP FUEL PUMP
I. FREE FLOW TEST
II. LOAD TEST
I. FREE FLOW TEST:
Free flow test is carriedout by turningMotorPump assembly (CircuitCode 58.1 & 5.1) on. Fuel
will start flowing through6 & 3µ Filters (56.2, 7.2), Pneumaticallyoperated valve (33.3) will be
opened while (33.2 & 33.4) remains close, for this particulartestingand HP fuel pump will be
feeded with ATF Fuel @2±0.1 bar-g.
At the outlet of ATF HP Pump FCV (19.3) will be fully opened and fuel will flow
throughFilters and Flow meter (6.3, 56.4 & 21.2) respectively. Test data will be recorded in
tabularformas given Below:-
Sl. No. Speed (rpm) Pressure Difference (bar-g) Flow rate Duration (Min)
1 1000 2
2 2000 2
3 3000 2
4 4000 2
5 5000 2
6 6000 2
7 7000 2
8 8000 2
9 7000 2
10 6000 2
11 5000 2
12 4000 2
13 3000 2
14 2000 2
15 1000 2
II. LOAD TEST:
Tis test is carried out by turning MotorPump assembly (Circuit Code 58.1 & 5.1) on. Fuel will
start flowingthrough6 & 3µ Filters(56.2, 7.2), Pneumatically operated valve (33.3) will be
opened while (33.2 & 33.4) remains close, for this particulartestingand HP fuel pump will be
feeded with ATF Fuel @2±0.1 bar-g.
At the outlet of ATF HP Pump pressuredifference is created via FCV (19.3) by
opening/closingit gradually, and fuel will flow throughFilters and Flow meter (6.3, 56.4 & 21.2)
respectively. Test data will be recorded in tabularform as given Below:-
Speed (rpm) 5000 6000 7000 8000
Sl. No. ΔP
(bar-g)
Flow
(lpm)
ΔP
(bar-g)
Flow
(lpm)
ΔP
(bar-g)
Flow
(lpm)
ΔP
(bar-g)
Flow
(lpm)
1 1.00 - -
2 1.25 - -
3 1.5 1.5 -
4 1.75 1.75 -
5 2.00 2.00 2.00 2.00
6 2.25 2.25 2.25
7 2.50 2.50 2.50
8 2.75 2.75 2.75
9 3.00 3.00 3.00
10 3.25
11 3.50
12 4.00
13 4.25
14 4.50
15 4.75
 TEST CARRIED OUT FOR OIL PUMP (31.0)
I. PERFORMANCE TEST OF PP PUMP
I. PP PUMP
Performancetest of PP Pump at various pressure settings,temperatureand rpms is carried out.
PP Pump can be feed by two circuits.One throughMotorPump assembly (45.0) and other
directlythroughpressurized tank (29.0).
A. Oil feeding throughMotorPump assembly (45.0):
Turn on Motorand oil will start flowing, there are two separateheating system
is provided to raise temperatureof Oil, we can choose between two valves (57.3, 57.4) depending
on which heating source is to be used to raise oil temperatures.
Temperatureis recorded at TT (13.5 and 13.6), Valve (57.7, 57.10) will be
closed and (57.8 & 57.9) will remainopen and oil is feeded to PP Pump throughManifold (43)
and FCV (61.7). At outlet of oil pump Pressurerelief valve, FCV is provided.Oil throughfilters and
flow meter return back to tank and performance is recorded in tabularform as given Below:-
Oil inlet temperature (Room, 26°C/ 80°C/ 110°C/ 135°C/165°C)
Sl. No. P. IN
(bar-g)
P. OUT
(bar-g)
2400 rpm 6300 rpm 8400 rpm 10500 rpm Remarks
P. IN
(bar-g)
Q
(lpm)
P. IN
(bar-g)
Q
(lpm)
Q
(lpm)
Q
(lpm)
1 0.59 Outlet valve fully open Note P. OUT
2 1.9
3 3.4
4 4.5
5 5.0
6 6.4
7 0.39 Outlet valve fully open Note P. OUT
8 1.9
9 3.4
10 4.5
11 5.0
12 6.4
13 0.19 Outlet valve fully open Note P. OUT
14 1.9
15 3.4
16 4.5
17 5.0
 TEST CARRIED OUT FOR FCOC
I. THERMAL PERFORMANCETEST AT 25°C & 110 °C:
Maintain110°C in tank using either Oil heatingsystem (53.0 or 46.0) and Heat Exchanger(20.0),
read temperature on TT (13.7) and at the oil outlet of FCOC, FCV (19.4) is operated for desired
Pressure.
At Fuel side, obtaintemperature25°C, via Coolingcircuit heat exchanger(27.0), Open valve
(33.4) while (33.2, 33.3) remains closed. Read temperature on TT (12.3) and operateFCV (19.2)
for desired pressuredifference.Record Oil inlet/outletand Fuel inlet/Outletdata in tabularform
as given Below:-
Oil inlet temperature (Room, 25°C/ 80°C/ 110°C/ 135°C/165°C)
Sl. No. T (FUEL
IN) °C
T (OIL IN)
°C
Q (FUEL)
lpm
Q (OIL)
lpm
P (FUEL IN)
bar
P (FUEL OUT)
bar
P (OIL IN)
bar
P (OIL OUT)
bar
T (FUEL OUT)
°C
T (OIL OUT)
°C
1 25 110 3 12
2 25 110 3 14
3 25 110 3 16
4 25 110 6 12
5 25 110 6 14
6 25 110 6 16
7 25 110 12 12
8 25 110 12 14
9 25 110 12 16
10 25 110 24 12
11 25 110 24 14
12 25 110 24 16
13 25 110 45 12
14 25 110 45 14
15 25 110 45 16

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Integrated Test Rig For HTFE-25 - Neometrix

  • 1. INTEGRATED TEST RIG FOR HTFE-25 (A5157) O P E R A T I N G P R O C E D U R E
  • 2.  INDEX S.No. Description Slide No. 1. Cover Page 01 2. Index 02 3. Introduction 03 4. Specification of UUTs 04 5. Test carried out for LP FUEL PUMP 06-08 6. Test carried out for HP FUEL PUMP 09-12 7. Test carried out for OIL PUMP 13-14 8. Test carried out for FCOC 15-16
  • 3.  INTRODUCTION The purpose of Integrated Test Rig is to assess performance of Fuel Cooled Oil Cooler (FCOC), HP Pump & Oil Pump prior to fitment on Aero Engine. The design of rig is such that it can cater to individual testing of individual LRU or integrated testing of all the LRU’s installed together (in combination). The pumps under test shall be mounted directly on the high-speed electric motor flange through adapter quill shaft assembly. Variable speed drives shall be provided for all the pumps under testing. The rig shall cater for real time monitoring and recording of performance parameters.
  • 4.  SPECIFICATION OF UUT’s Sl. No. UUT FLUID TYPE INLET PRESSURE (bar-g) FLOW RATE OF PUMP (lpm) OUTLET PRESSURE (bar-g) MAX SPEED (rpm) 1 LP PUMP ATF JET-A1 2±0.1 70 (RATED) 90 (MAX) 4.5 (RATED) 10 (MAX) 8000 (RATED) 12000 (MAX) 2 HP PUMP ATF JET-A1 2±0.1 70 (RATED) 90 (MAX) 75 (RATED) 90 (MAX) 8000 (RATED) 12000 (MAX) 3 OIL PUMP AVIATION TURBINE OIL (OX-27) 0.3±0.05 17.5 (RATED) 20 (MAX) 5 (RATED) 20 (MAX) 10500 (RATED) 15000 (MAX) 4 FCOC OIL: OX-27 FUEL: ATF JET-A1 OIL: 4.5 FUEL: 4.5 OIL: 16 (RATED) FUEL: 45 (RATED)
  • 5.  TEST CARRIED OUT FOR LP FUEL PUMP I. FREE FLOW TEST II. FLOW CHECK WITH BACK PRESSURE TEST I. FREE FLOW TEST: Free flow test is carriedout by turningMotorPump assembly (CircuitCode 58.1 & 5.1) on. Fuel will start flowing through6 & 3µ Filters (56.2, 7.2), Pneumaticallyoperated valve (33.2) will be opened while (33.3 & 33.4) remains close, for this particulartestingand LP fuel pump will be feeded with ATF Fuel @1±0.1 bar-g. At the outlet of ATF LP Pump FCV (19.1) will be fully opened while (33.9) remainclosed and fuel will flow throughFilters and Flow meter (6.3, 56.4 & 21.2) respectively. Test data will be recordedin tabularformas given Below:-
  • 6. Sl. No. Speed (rpm) Pressure Difference (bar-g) Flow rate Duration (Min) 1 1000 2 2 2000 2 3 3000 2 4 4000 2 5 5000 2 6 6000 2 7 7000 2 8 8000 2 9 7000 2 10 6000 2 11 5000 2 12 4000 2 13 3000 2 14 2000 2 15 1000 2
  • 7. II. FLOW CHECK WITH BACK PRESSURE TEST: Tis test is carried out by turning MotorPump assembly (Circuit Code 58.1 & 5.1) on. Fuel will start flowingthrough6 & 3µ Filters(56.2, 7.2), Pneumatically operated valve (33.2) will be opened while (33.3 & 33.4) remains close, for this particulartestingand LP fuel pump will be feeded with ATF Fuel @1±0.1 bar-g. At the outlet of ATF LP Pump pressuredifference is created via FCV (19.1) by opening/closingit gradually, while (33.9) remain closed and fuel will flow throughFilters and Flow meter (6.3, 56.4 & 21.2) respectively. Test data will be recorded in tabularform as given Below:-
  • 8. Speed (rpm) 5000 6000 7000 8000 Sl. No. ΔP (bar-g) Flow (lpm) ΔP (bar-g) Flow (lpm) ΔP (bar-g) Flow (lpm) ΔP (bar-g) Flow (lpm) 1 1.00 - - 2 1.25 - - 3 1.5 1.5 - 4 1.75 1.75 - 5 2.00 2.00 2.00 2.00 6 2.25 2.25 2.25 7 2.50 2.50 2.50 8 2.75 2.75 2.75 9 3.00 3.00 3.00 10 3.25 11 3.50 12 4.00 13 4.25 14 4.50 15 4.75
  • 9.  TEST CARRIED OUT FOR HP FUEL PUMP I. FREE FLOW TEST II. LOAD TEST I. FREE FLOW TEST: Free flow test is carriedout by turningMotorPump assembly (CircuitCode 58.1 & 5.1) on. Fuel will start flowing through6 & 3µ Filters (56.2, 7.2), Pneumaticallyoperated valve (33.3) will be opened while (33.2 & 33.4) remains close, for this particulartestingand HP fuel pump will be feeded with ATF Fuel @2±0.1 bar-g. At the outlet of ATF HP Pump FCV (19.3) will be fully opened and fuel will flow throughFilters and Flow meter (6.3, 56.4 & 21.2) respectively. Test data will be recorded in tabularformas given Below:-
  • 10. Sl. No. Speed (rpm) Pressure Difference (bar-g) Flow rate Duration (Min) 1 1000 2 2 2000 2 3 3000 2 4 4000 2 5 5000 2 6 6000 2 7 7000 2 8 8000 2 9 7000 2 10 6000 2 11 5000 2 12 4000 2 13 3000 2 14 2000 2 15 1000 2
  • 11. II. LOAD TEST: Tis test is carried out by turning MotorPump assembly (Circuit Code 58.1 & 5.1) on. Fuel will start flowingthrough6 & 3µ Filters(56.2, 7.2), Pneumatically operated valve (33.3) will be opened while (33.2 & 33.4) remains close, for this particulartestingand HP fuel pump will be feeded with ATF Fuel @2±0.1 bar-g. At the outlet of ATF HP Pump pressuredifference is created via FCV (19.3) by opening/closingit gradually, and fuel will flow throughFilters and Flow meter (6.3, 56.4 & 21.2) respectively. Test data will be recorded in tabularform as given Below:-
  • 12. Speed (rpm) 5000 6000 7000 8000 Sl. No. ΔP (bar-g) Flow (lpm) ΔP (bar-g) Flow (lpm) ΔP (bar-g) Flow (lpm) ΔP (bar-g) Flow (lpm) 1 1.00 - - 2 1.25 - - 3 1.5 1.5 - 4 1.75 1.75 - 5 2.00 2.00 2.00 2.00 6 2.25 2.25 2.25 7 2.50 2.50 2.50 8 2.75 2.75 2.75 9 3.00 3.00 3.00 10 3.25 11 3.50 12 4.00 13 4.25 14 4.50 15 4.75
  • 13.  TEST CARRIED OUT FOR OIL PUMP (31.0) I. PERFORMANCE TEST OF PP PUMP I. PP PUMP Performancetest of PP Pump at various pressure settings,temperatureand rpms is carried out. PP Pump can be feed by two circuits.One throughMotorPump assembly (45.0) and other directlythroughpressurized tank (29.0). A. Oil feeding throughMotorPump assembly (45.0): Turn on Motorand oil will start flowing, there are two separateheating system is provided to raise temperatureof Oil, we can choose between two valves (57.3, 57.4) depending on which heating source is to be used to raise oil temperatures. Temperatureis recorded at TT (13.5 and 13.6), Valve (57.7, 57.10) will be closed and (57.8 & 57.9) will remainopen and oil is feeded to PP Pump throughManifold (43) and FCV (61.7). At outlet of oil pump Pressurerelief valve, FCV is provided.Oil throughfilters and flow meter return back to tank and performance is recorded in tabularform as given Below:-
  • 14. Oil inlet temperature (Room, 26°C/ 80°C/ 110°C/ 135°C/165°C) Sl. No. P. IN (bar-g) P. OUT (bar-g) 2400 rpm 6300 rpm 8400 rpm 10500 rpm Remarks P. IN (bar-g) Q (lpm) P. IN (bar-g) Q (lpm) Q (lpm) Q (lpm) 1 0.59 Outlet valve fully open Note P. OUT 2 1.9 3 3.4 4 4.5 5 5.0 6 6.4 7 0.39 Outlet valve fully open Note P. OUT 8 1.9 9 3.4 10 4.5 11 5.0 12 6.4 13 0.19 Outlet valve fully open Note P. OUT 14 1.9 15 3.4 16 4.5 17 5.0
  • 15.  TEST CARRIED OUT FOR FCOC I. THERMAL PERFORMANCETEST AT 25°C & 110 °C: Maintain110°C in tank using either Oil heatingsystem (53.0 or 46.0) and Heat Exchanger(20.0), read temperature on TT (13.7) and at the oil outlet of FCOC, FCV (19.4) is operated for desired Pressure. At Fuel side, obtaintemperature25°C, via Coolingcircuit heat exchanger(27.0), Open valve (33.4) while (33.2, 33.3) remains closed. Read temperature on TT (12.3) and operateFCV (19.2) for desired pressuredifference.Record Oil inlet/outletand Fuel inlet/Outletdata in tabularform as given Below:-
  • 16. Oil inlet temperature (Room, 25°C/ 80°C/ 110°C/ 135°C/165°C) Sl. No. T (FUEL IN) °C T (OIL IN) °C Q (FUEL) lpm Q (OIL) lpm P (FUEL IN) bar P (FUEL OUT) bar P (OIL IN) bar P (OIL OUT) bar T (FUEL OUT) °C T (OIL OUT) °C 1 25 110 3 12 2 25 110 3 14 3 25 110 3 16 4 25 110 6 12 5 25 110 6 14 6 25 110 6 16 7 25 110 12 12 8 25 110 12 14 9 25 110 12 16 10 25 110 24 12 11 25 110 24 14 12 25 110 24 16 13 25 110 45 12 14 25 110 45 14 15 25 110 45 16