• Aircraft Production Lines: for acceptance testing of oxygen subsystem LRUs before aircraft installation. • Maintenance, Repair & Overhaul (MRO) Facilities: for routine inspection and post-service validation. • Aerospace Training Institutions: for maintenance personnel instruction and demonstration. • R&D Laboratories: for design validation of new-generation oxygen valves, regulators, and system prototypes.
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Introduction The Advanced Life Support Oxygen Test Bench is a high-precision, aerospace-grade pneumatic testing system designed for functional validation, leak analysis, and calibration of oxygen distribution components used in aircraft pilot Life Support Systems(LSS). In high-altitude flight, human life depends on an uninterrupted and correctly regulated supply of oxygen. As altitude increases, air density drops sharply, causing oxygen partial pressure to fall below the threshold required for normal brain and body function. Within seconds, hypoxia can set in — impairing cognitive response, muscle coordination, and eventually consciousness. The aircraft’s LSS mitigates this danger by automatically adjusting the flow and pressure of oxygen to the pilot’s breathing mask, maintaining safe and consistent oxygenation even during rapid altitude transitions or high-g maneuvers. The LSS operates in an extremely harsh environment — subject to vibration, thermal variation, pressure cycling, and constant oxygen exposure. Every component within the system, from valves to regulators, must therefore meet stringent reliability and leak-free performance standards. Even microscopic contamination or a minor pressure irregularity can cause catastrophic oxygen system failure, posing direct risk to flight safety. Recognizing the need for repeatable, ground-based verification of oxygen system components, Neometrix Defence Ltd. developed this Advanced LSS Test Bench The rig reproduces the full pneumatic behavior of an in-flight oxygen delivery circuit — including static high-pressure storage, flow regulation, and low-pressure breathing simulation. It allows precise testing of each Line Replaceable Unit (LRU) in the oxygen supply chain, ensuring mechanical integrity, functional accuracy, and long-term stability before installation or post-maintenance release. In essence, this system serves as the final ground gatekeeper of flight safety — guaranteeing that the oxygen subsystem protecting the pilot has been tested, measured, and verified before takeoff. Purpose and Scope The Advanced Life Support Oxygen Test Bench provides a single integrated platform for testing, verifying, and certifying all major oxygen-handling components that make up an aircraft’s LSS. It enables both pre-installation validation (before fitting the components onto the aircraft) and periodic recertification (during maintenance cycles). The rig is capable of performing end-to-end functional testing of the following oxygen LRUs: 1. Filler Valve (P/N DKR-130) – validates sealing, inlet tightness, and crack pressure behavior during cylinder charging. 2. Non-Return Valve (P/N 2124A-3TT) – verifies directionality of oxygen flow, forward cracking pressure, and reverse leakage resistance. 3. Pressure Reducing Valve (P/N 444-00389-700) – simulates pilot-demand conditions to measure outlet pressure regulation, stability under varying flow rates, and relief-valve accuracy. 4. Oxygen Cylinder & Valve Assembly (P/N 211-6512) – checks cylinder leak rate, built-in gauge calibration, and valve seat performance over 48-hour pressure retention cycles. Each component represents a safety-critical node in the pilot’s breathing circuit. The filler valve governs charging safety, the NRV prevents backflow contamination, the PRV ensures regulated delivery pressure, and the cylinder assembly guarantees clean, stable oxygen storage. The test bench allows engineers to simulate real pneumatic behavior of these subsystems using pressurized oxygen up to 200 bar, controlled depressurization, and measured flow rates up to 600 LPM — replicating the operational envelope of an aircraft LSS at altitude. Design and Construction The bench is engineered as a modular, transportable, and all-weather testing system, constructed with materials and safety features suitable for continuous oxygen service. Mechanical Framework • Base chassis fabricated from Mild Steel (IS-2062) for strength and vibration resistance. • Powder-coated to RAL 5005 Signal Blue, 60–80 μm coating thickness, corrosion-resistant finish. • Mounted inside a military-grade FRP outer case with internal vibration isolation foam to absorb mechanical shocks during transport. • Ergonomic layout: all gauges, regulators, and controls positioned on a front control panel for direct visibility and operator accessibility. Materials and Compatibility • All oxygen-contact components made from SS-316L or equivalent austenitic stainless steel with low carbon content for corrosion and ignition resistance. • Fittings and connectors are degreased and oxygen-cleaned to ASTM G93 and CGA G-4.1 standards. • Sealing elements fabricated from PTFE or Viton O-rings, ensuring compatibility with gaseous oxygen under high pressure. • No use of oil-based lubricants, zinc-plated materials, or elastomers prone to exothermic reactions in oxygen service. Construction Highlights • System built as a closed-loop pneumatic circuit with independent high-pressure (HP) and low-pressure (LP) regulation paths. • Incorporates dedicated sub-panels for filtration, regulation, flow measurement, and safety interlocks. • Designed for maintenance ease — modular manifolds with quick disconnect couplers, allowing easy replacement of test lines and adapters. Subsystem Overview 1. High-Pressure (HP) Regulation Section • Accepts oxygen inlet up to 200 bar from a high-pressure cylinder. • Includes: - HP regulator (200 → 125 bar) with fine-thread control for gradual pressurization. - Dual Bourdon-tube pressure gauges (0–200 bar) for inlet and outlet monitoring. - Safety relief valve set at 126 ± 0.5 bar to prevent over-pressurization. • The regulator assembly ensures steady, pulsation-free supply to downstream circuits and test articles. 2. Low-Pressure (LP) Regulation Section • Utilizes a precision LP regulator (10 → 0.05 bar) to simulate low-pressure breathing environments. • Provides fine control for flow-regulated tests such as PRV outlet verification. • Includes calibrated gauges: - 0–15 PSI gauge for ultra-low pressure readouts. - 0–20 bar gauge for intermediate pressures. 3. Flow Measurement & Distribution Section • Equipped with a transparent flow indicator (0–600 LPM) for direct visual and quantitative observation. • Used for mapping pressure vs. flow curves during regulator and valve characterization. • Fitted with isolation valves and needle valves for dynamic control during testing. 4. Filtration & Safety Section • Integrates a 25-micron SS filter to remove particulates and moisture, maintaining oxygen purity. • Bleed valve for pressure relief after each test cycle. • Vent valve enables complete purging of trapped gases, ensuring safety and repeatability. 5. Electrical Grounding and Static Control • The bench includes grounding terminals and anti-static braided hoses to prevent electrostatic discharge. • All components meet intrinsic safety norms for oxygen service environments. 6. Dimensions and Mobility • Approximate system envelope: 1100 mm (L) × 700 mm (W) × 510 mm (H). • Weight: ~85 kg (without gas source). • Rugged handles and lockable castors for easy relocation. Functional Testing Capability Each LRU undergoes a complete functional validation sequence: Filler Valve (DKR-130) • Inlet pressure varied 3.5–125 bar; verify no inlet leakage. • Crack-open pressure confirmed ≤ 8 bar (116 psi). • Tested for sealing consistency under cyclic pressurization. Non-Return Valve (2124A-3TT) • Forward opening verified at > 0.5 psi. • Reverse pressure held at 50, 400, and 1000 psi for 60 seconds each; zero leakage permissible. • Ensures unidirectional protection against backflow contamination. Oxygen Cylinder & Valve Assembly (211-6512) • Cylinder filled to 128 bar (1850 psi). • Static leak test for 48 hours: mass loss ≤ 4 g (equivalent 0.001 LPM). • Pressure gauge correlation: - At 100 bar → 100 ± 7.5 bar. - At 50 bar → 50 ± 7.5 bar. • Confirms long-term seal integrity and gauge accuracy. Pressure Reducing Valve (444-00389-700) • Regulator performance mapped across variable flow conditions:
