Integrated Test Rig for Pumps and Fuel Coolers

About

The Integrated Test Rig for Pumps and Fuel Coolers is a high-performance, multi-functional testing system designed to validate the performance of key aero engine components—namely the LP Pump, HP Pump, Oil Pump, and Fuel Cooled Oil Cooler (FCOC)—prior to engine integration. Engineered for aerospace applications, the rig supports both individual and combined testing of these units under real-world operating conditions, including high-speed, high-pressure, and high-temperature scenarios. It features dual insulated power packs, precise fluid control systems, dedicated heating up to 200°C, and an advanced data acquisition system for real-time performance monitoring. Ideal for both R&D and production environments, this rig ensures reliable, safe, and accurate qualification of aviation components.

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Technical Details

Specifications

Applications

One of its application is to test LP Pump of Aircraft. It is designed for functional testing of LP Pump.
a. Free Flow Test
b. Load Test
It is used to test HP Pump of Aircraft. It is designed for functional testing of HP Pump.
a. Free Flow Test
b. Load Test
It is used to test Oil Pump of Aircraft. It is designed for functional testing of Oil Pump.
It is used to test FCOC of Aircraft.

FAQ

Key Features

It has separate power packs for both the fluids i.e. ATF Power pack for ATF Fluid, OX Power Pack for OX-27 Oil.
This Rig is designed for high temperature Application. It works on 200 deg. Celsius.
Two Dedicated heating systems have been integrated with this Rig to raise the temperature of OX-27 Oil.
In both Power Packs insulated tanks are being used, which is good for safe operation and safety of operator.

This rig is designed in such a way, that it’s OX power pack is in its left side, ATF Power pack is in right Side and test bed is in Centre.
A big Test bed have been provided for smooth testing of UUT’s.
All piping is being insulated for safe operation and maintenance.
It comprises with DAQ System.
This rig can test several components at a time, together or separately.

Details

1. Product Introduction
The Integrated Test Rig is a state-of-the-art, high-performance equipment designed to carry out precision testing of critical aircraft engine components such as the Low Pressure (LP) Pump, High Pressure (HP) Pump, Oil Pump, and Fuel Cooled Oil Cooler (FCOC). Developed with a deep understanding of the operational demands in aerospace
environments, this rig ensures comprehensive functional validation of these components before installation on aero engines such as the HTFE-25.

With its modular configuration and sophisticated control systems, this rig enables both individual testing of Line Replaceable Units (LRUs) and integrated system-level testing, simulating real-world operational conditions with high fidelity. The test bed supports simultaneous or independent operation of all units, making it ideal for R&D validation, production quality checks, and pre-delivery acceptance tests.

2. Test Capabilities and Applications
The rig provides a platform for simulating realistic flow, pressure, and thermal conditions experienced by each unit during engine operation. The major test functions include:
- Free Flow Test
- Load Test
- Thermal Testing
- Pressure Drop and Leakage Testing

Application-wise Coverage:
LP Pump: Free flow test, Load test (HTFE-25 Aero Engine)
HP Pump: Free flow test, Load test (HTFE-25 Aero Engine)
Oil Pump: Functional testing under varying speed, temperature & load (HTFE-25 Aero Engine)
FCOC: Thermal performance and fluid flow integrity testing (Aircraft Oil/Fuel Cooling)

3. Technical Specifications


4. System Architecture and Design Highlights
Mechanical Layout:
- Left: OX-27 Oil Power Pack
- Right: ATF Power Pack
- Center: Common Test Bed
Test Bed Features:
- High-speed motor mount
- Quill shaft coupling
- Large workspace for UUT

5. Power Packs & Thermal System
- Dual Power Packs (OX-27, ATF)
- 400L Insulated Tanks
- Two dedicated heaters
- Thermal capacity: up to 200°C

6. Instrumentation & Data Acquisition
- Real-time DAQ
- Pressure, Temperature, Flow & Speed sensors
- Digital display with alerts
- Emergency interlocks

7. Safety & Operational Integrity
- Fully insulated tanks and piping
- Over-temperature and over-speed protection
- Modular structure
- Emergency shutdown

8. Structural Components and Materials
| Component | Material | Remarks |
| Inner Tank  | SS-304 | 3mm, 72.5 kg |
| Outer Tank | MS | 3mm, 109 kg |
| Support Plate | MS | 3mm, 11.5 kg |
| Top Plate | MS | 3mm, 36 kg |
| Insulation | Glass Wool + Cork | 100mm thick |

9. Advantages and USP
- All-in-One Testing
- Scalable & Modular
- Precision Engineering
- Operator Safety
- Plug-and-Play Setup