Details

Introduction
In modern aerospace, the fuel system is the lifeline of an aircraft. Every second of flight depends on an uninterrupted, precisely regulated flow of Aviation Turbine Fuel (ATF) delivered to the engines. At the heart of this system lie the main fuel pumps and injection nozzles. If either underperforms, even momentarily, the consequences can be catastrophic — ranging from power loss and flameout to reduced thrust efficiency and, ultimately, mission failure.

Aircraft such as the Sukhoi SU-30, Mirage, Jaguar, MiG series, and multi-role helicopters operate in extreme environments where fuel systems are pushed to their absolute limits. Pumps must handle rapid throttle changes, high-G maneuvers, varying altitudes, and extreme temperatures without fail. Meanwhile, nozzles must maintain a perfect spray pattern and pressure ratio, ensuring optimal atomization for complete combustion. Even small deviations in performance can mean increased fuel consumption, loss of range, reduced reliability, and safety risks.

The Fuel (ATF) Pump and Nozzle Pressure Ratio Test Stand has been engineered as the definitive solution to this challenge. By combining pump performance validation and nozzle calibration into a single integrated platform, it allows air forces, OEMs, and MRO facilities to simulate real-world flight conditions with laboratory precision. This ensures that every pump and nozzle leaving the test bay is certified for flawless performance in the air, directly supporting mission readiness, operational safety, and reduced life-cycle costs.

System Overview & Design
The system is designed to replicate the complex operating conditions encountered in flight with high fidelity.

Thermal Simulation: Integrated fuel tank with controlled heating up to 120 °C, replicating the high-temperature environment within engine bays and fuel lines. This allows performance verification across varying fuel viscosities and thermal stresses.

Pressure & Suction Simulation: Equipped with a dry nitrogen pressurization system and a vacuum pump, the stand reproduces suction and discharge conditions, including negative pressure states. This enables testing for cavitation, vapor lock, air entrapment, and other critical failure modes.

High-Power Drive System: A variable-speed gearbox delivers up to 10,000 RPM at 160 kW, enabling testing of pumps under steady, transient, and overload conditions. This covers rapid throttle shifts, high-altitude performance, and extreme combat maneuvers.

Measurement & Instrumentation: Advanced electronic flowmeters, dedicated flow circuits, and precision regulators provide high-resolution data on flow, pressure, and pump efficiency. Sampling at fine intervals allows for trend analysis, predictive maintenance, and detailed performance mapping.

Dual Nozzle Testing Capability: Integrated fuel, nitrogen, and vacuum circuits allow nozzle pressure ratio testing with mmHg-level accuracy, enabling precise calibration of spray characteristics critical for efficient combustion and emission control.

Automation & Control: Controlled via a modern HMI/SCADA interface, operators can run fully automated test sequences, semi-automated routines, or manual override for troubleshooting. Automated report generation ensures traceability and certification compliance.

Safety & Reliability: Comprehensive safety systems, including emergency shutdowns, automatic bleed valves, and interlocks, safeguard both operators and equipment during high-pressure, high-temperature testing.

Applications
The test stand is designed for multi-role deployment across the aerospace ecosystem:
Fuel Pump Testing
  ▹ Qualification and acceptance of new production pumps.
  ▹ Preventive maintenance to detect early-stage degradation.
  ▹ Failure analysis and troubleshooting of returned components.
  ▹ Endurance and life-cycle testing for reliability programs.

Nozzle Pressure Ratio Testing
  ▹ Calibration of fuel nozzles for optimal atomization and spray consistency.
  ▹ Measurement of pressure ratios under variable operating environments.
  ▹ Certification testing for compliance with military and civil aviation standards.
  ▹ Quality control in manufacturing and assembly lines.

Integrated Aerospace Support
  ▹ Essential ground support tool for air force maintenance depots.
  ▹ Enables OEMs to conduct both pump and nozzle validation in one system.
  ▹ Supports R&D centers and universities developing advanced fuel systems.
  ▹ Reduces test bay footprint and overall cost of ownership by eliminating the need for multiple rigs.

Key Advantages
• Dual Functionality: Combines fuel pump testing and nozzle pressure ratio calibration in one platform.
• True Flight Simulation: Recreates in-flight thermal, pressure, and suction environments with precision.
• High-Capacity Testing: Handles pumps up to 10,000 RPM / 160 kW.
• Nozzle Calibration Accuracy: Measurement resolution down to millimeters of mercury (mmHg).
• Advanced Automation: Automatic, semi-automatic, and manual modes ensure flexibility.
• Data-Driven Insights: Real-time data logging with trend analysis and report generation.
• Rugged & Proven: Designed for continuous operation in defense and commercial aerospace sectors.
• Enhanced Safety: Integrated interlocks and shutdown systems prevent operator and equipment hazards.

Technical Specifications

  

    
Parameter
    
Specification
  
  

    
Fuel Type
    
Aviation Turbine Fuel (ATF)
  
  

    
Fuel Tank Capacity
    
Integrated tank with heating up to 120 °C
  
  

    
Pressure Simulation
    
Dry Nitrogen pressurization & Vacuum pump for suction simulation
  
  

    
Drive System
    
Variable-speed gearbox drive
  
  

    
Maximum Speed
    
10,000 RPM
  
  

    
Drive Power
    
Up to 160 kW
  
  

    
Flow Measurement
    
Multiple electronic flowmeters with dedicated flow measurement circuits
  
  

    
Pressure Control
    
Electronic pressure regulators with mmHg accuracy
  
  

    
Nozzle Testing
    
Pressure ratio measurement with Fuel + Nitrogen + Vacuum circuits
  
  

    
Control Modes
    
Automatic, Semi-automatic, and Manual
  
  

    
Data Management
    
Computerized logging, trend analysis, and report generation
  
  

    
Safety Features
    
Protective interlocks, emergency shutdown, automatic pressure bleed
  


Conclusion
The Fuel (ATF) Pump and Nozzle Pressure Ratio Test Stand is not just a test bench — it is a mission assurance system. By ensuring that both pumps and nozzles are rigorously validated before returning to service, it directly enhances flight safety, combat readiness, and operational efficiency. For defense forces, OEMs, and MRO providers, this system eliminates uncertainty, reduces downtime, and delivers the confidence that every aircraft can perform flawlessly under the harshest conditions. With its powerful drive capability, precision instrumentation, and dual-function design, it stands as the benchmark in aviation fuel system testing technology.