Advanced Life Support Oxygen Test Bench for Pilot Safety Systems, rated to 200 bar / 600 L/min.

Introduction

The LSS operates in an extremely harsh environment — subject to vibration, thermal variation, pressure cycling and constant oxygen exposure. Every component, from valves to regulators, must 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, Neometrix Defence Ltd. developed this Advanced LSS Test Bench as the final ground gatekeeper of flight safety — guaranteeing that the oxygen subsystem protecting the pilot has been tested, measured and verified before takeoff.

Materials & compatibility

• Wetted parts: all oxygen-contact components made from SS-316L or equivalent austenitic stainless steel with low carbon content for corrosion and ignition resistance.
• Cleaning standards: fittings and connectors degreased and oxygen-cleaned to ASTM G93 and CGA G-4.1 standards.
• Sealing: PTFE or Viton O-rings, compatible with gaseous oxygen under high pressure.
• Exclusions: no oil-based lubricants, zinc-plated materials, or elastomers prone to exothermic reactions in oxygen service.

Functional testing capability

Each LRU undergoes a complete functional validation sequence:

• Filler Valve (DKR-130): inlet pressure varied 3.5–125 bar, verified for 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 — ensuring unidirectional protection against backflow contamination.
• Oxygen Cylinder & Valve Assembly (211-6512): cylinder filled to 128 bar (1850 psi); static leak test for 48 hours with mass loss ≤ 4 g (equivalent 0.001 LPM); pressure-gauge correlation checked at 100 bar (± 7.5 bar) and 50 bar (± 7.5 bar).
• Pressure Reducing Valve (444-00389-700): regulator performance mapped across flow from 0–150 LPM at supply pressures of 14–125 bar, with a relief test at 8 +1/−0.8 bar to confirm relief-valve activation accuracy.

Operational procedure

• Preparation: ensure all control valves are closed, connect the oxygen source, and confirm gauges read zero pressure.
• Pressurization: gradually open the inlet and adjust the HP regulator to the desired setpoint.
• Functional testing: route oxygen to the LRU under test using ON/OFF valves, observing gauge and flowmeter readings.
• Data recording: compare observed performance against acceptance criteria and log results for certification.
• Depressurization: close all valves, vent through the bleed valve, and confirm complete pressure discharge.

Safety, quality & compliance

• Classification: Type-4 Ground Test Equipment (TTGE) under aerospace ground support standards.
• Manufacturing: produced in ISO 9001 / ISO 14001 / ISO 45001 certified facilities.
• Oxygen-service compliance: components meet ASTM G93, ISO 7291 and EN 12021 requirements.
• Calibration: every gauge, flowmeter and regulator delivered with a traceable ISO 17025 calibration certificate.
• Safety devices: redundant relief valves on HP and LP circuits, anti-spark grounding connections, pressure-decay monitoring before disconnection, and a fail-safe vent path for trapped gases.
• Environmental range: designed for −30°C to +70°C ambient temperature, ensuring reliability across climatic conditions.

Conclusion

The Advanced Life Support Oxygen Test Bench represents Neometrix Defence Ltd.'s experience in aerospace pneumatic systems, combining precision engineering, robust safety design and oxygen-service expertise into one versatile testing solution. It ensures that every valve, regulator and oxygen assembly destined for flight is validated under real conditions — for leak integrity, stability, repeatability and safety — serving as both a quality-assurance instrument and a pilot-protection system validator that directly contributes to aircrew survivability.