Details

Introduction
The Neometrix Test Rig for Running-In and Calibration of Reheat and Nozzle Control Units is a turnkey, floor-mounted facility engineered to perform the full suite of functional, leakage, sensitivity, and hysteresis tests on turbine fuel control units under realistic, simulated service conditions. Designed for aerospace applications, it integrates fuel, lubrication, pneumatic, vacuum, thermal control, drive, and data-acquisition subsystems into a compact, ergonomic layout with centralized controls and robust safety/interlock features.

Applications
• Reheat & Nozzle Control Unit Calibration: Static and dynamic adjustment of PRC settings, pilot-valve sensitivity, vortex-diode response, and nozzle turndown.
• Leakage & Hysteresis Testing: Comprehensive air/fuel leakage checks and full hysteresis loops across operating envelopes up to 30,000 RPM.
• Service-Simulation Trials: Altitude simulation, shut-down sequences, and thermal cycling to verify performance under low/high pressure and temperature extremes.
• Durability & Endurance Testing: Extended run-in cycles to assess component fatigue and long-term performance.
• Functional Validation: Confirmation of sensor and actuator compatibility within integrated engine control systems.
• Performance Benchmarking: Comparative analysis of new vs. refurbished control units under identical test protocols.
• Troubleshooting & Diagnostics: Rapid fault isolation using integrated data analytics and test-report generation.

Key Features
• Over 30 test procedures covering pump bearing checks, LP/HP leakage, response times, flow-control sensitivity, and full hysteresis characterization.
• Automated Test Sequencing: Pre-programmed test profiles for consistent, repeatable procedures with minimal operator intervention.
• Environmental Simulation: Chilled-water heat exchangers, dry-air supply, vacuum headers, and programmable altitude simulation.
• Precision Drive System: 150 HP TEFC AC motor with encoder feedback (0–6000 RPM, ±1 RPM) coupled via gearbox to reach 30,000 RPM.
• Integrated Safety Hierarchy: Multi-level interlocks, emergency shutdown, and explosion-proof enclosure per NEMA 7/IS 60079.
• Modular Skid Design: Quick-swap quill interface and manifold trays allow rapid configuration changes between different UUTs.
• Advanced Diagnostics: Real-time data visualization, automated fault detection, and customizable alert thresholds.
• Remote Connectivity: Secure Ethernet interface for remote control, monitoring, and data export.
• Energy-Efficient Operation: Variable-frequency drive and optimized thermal management reduce power consumption.

Technical Specifications

  

    

      
Subsystem
      
Specification
    
  
  

    

      
Fuel Supply
      
1,500 L SS tank; booster pump 4000 IGPH @120 PSI; HP gear pump 500 IGPH @1800 PSI
    
    

      
Lubrication
      
DERD 2487 oil at 6.5 GPM @60 PSI; heat exchanger; dry-run protection
    
    

      
Pneumatic & Vacuum
      
Dry air header (–40 °C dew point); dome-loaded regulators; vacuum header with manometers
    
    

      
Drive & Interface
      
150 HP AC motor + IP20 VFD; braking resistor; gearbox to 30,000 RPM; splined quill interface
    
    

      
Thermal Control
      
Plate heat exchangers: 30 kW & 100 kW
    
    

      
Pressure Measurement
      
40+ Monel bourdon gauges (±0.25% FS) with snubbers
    
    

      
Flow Measurement
      
Screw meters (±0.25%), glass rotameters (1.6% class)
    
    

      
Temperature Measurement
      
K-type thermocouples (±0.5%)
    
    

      
Data Recording
      
X–Y plotter, U–V recorder
    
  


Design & Engineering Philosophy
At its core, the Neometrix rig philosophy emphasizes modularity for rapid reconfiguration, precision for consistent test results, safety for regulatory compliance, and operator-centric design for intuitive use. Every assembly is designed as a plug-and-play module, from skid-
mounted filtration units to quick-connect manifolds, reducing changeover times and maintenance complexity.

Quality Assurance & Calibration Procedures
All sensors and actuators undergo a stringent factory calibration process traceable to national metrology institutes. The commissioning phase includes on-site cross-verification with portable standards, followed by detailed calibration certificates. A built-in calibration alert system flags approaching due dates and logs historical calibration data for audit readiness.

Software & Data Management
The optional PC-based DAQ software provides customizable dashboards, automated report templates, and deep analytics tools, including FFT for vibration data and statistical trend analysis. A secure REST API allows integration with enterprise asset-management systems and
digital-twin platforms.

Customization & Upgrade Path
Neometrix offers plug-in modules for advanced capabilities, including high-altitude simulation packs, vibration and acoustic monitoring, and high-speed video capture. Future firmware upgrades can enable predictive maintenance algorithms and AI-driven anomaly detection.
Industry Use Cases & Case Studies Major engine OEMs have deployed this test rig to certify next-gen fuel-control modules, reducing calibration cycles by 30%. Military MRO depots leverage its durability tests to extend component service life by 20%. Research labs use its
hysteresis mapping to develop adaptive control strategies in unmanned aerial vehicles.

Installation & Commissioning
Site requirements include a 3 m × 2 m footprint with 2,500 kg floor loading capacity, plus utility hookups: 415 VAC 3-phase power, chilled water at 10 °C, and 150 SCFM dry air. Commissioning covers mechanical alignment, electrical hook-up, fluid leak checks, performance validation, and a comprehensive training workshop for operators and maintenance staff.

Environmental & Facility Requirements
Designed for ambient ranges of 10–40 °C and relative humidity below 85%. Requires a ventilated room with exhaust for fuel vapors and an air-purged electrical enclosure. Acoustic dampening features ensure workplace noise remains below 75 dBA.

Physical Dimensions & Weight
Overall dimensions: 3 m (L) × 2 m (W) × 2 m (H). Process tank: 1 m × 1 m × 1.5 m, mounted at 0.5 m elevation. System weight approximately 2,000 kg, excluding optional chiller and air skid.

Electrical Requirements
Primary drive: 150 HP TEFC motor with encoder, powered through an IP20 VFD capable of 0–200 Hz control and 150 % overload. Control panel: 230 VAC for instrumentation, including digital stepper potentiometers, meters, and air-purge system.

Maintenance & Calibration
Routine checks include weekly visual inspections and filter replacements every 500 operating hours. Calibration cycles: pressure and flow sensors annually; thermocouples every six months.
A two-year spare parts kit includes critical consumables and seals. 

Benefits & Advantages
Achieves high throughput with minimal setup times, delivers traceable accuracy for critical aerospace components, and supports future upgrades through its modular architecture. Energy-efficient design lowers operating costs while ensuring regulatory compliance and data integrity.

Conclusion
By blending advanced simulation capabilities, modular engineering, and comprehensive data-integrity features, the Neometrix Test Rig stands as the definitive platform for turbine fuel-control verification. Its adaptability, precision, and lifecycle support make it an indispensable asset for OEMs, MRO providers, and R&D facilities worldwide.