The proposed Mobile Test Facility for Aircraft Engines is a roadworthy self-sufficient test facility for testing of “Expandable Turbo Propulsion system (Expandable Engines) of up to 450kgf class” and is devised for Field Tests at various altitude sites in India ranging from sea level to High Altitudes.
GENERAL CATALOG
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Introduction The Mobile Test Facility (MTF) is a turnkey, trailer-mounted system engineered for on-site aerodynamic and performance evaluation of small to medium aft-burn turbo-propulsion units (up to 450 kgf thrust). Designed for rapid deployment across India’s varied terrains, the MTF enables complete engine health checks, performance mapping, transient response analysis, and environmental qualification without reliance on fixed test-cell infrastructure. Its modular architecture ensures each subsystem—from fuel handling to data acquisition—is road-legal, pre-commissioned, and compliant with DOT/ADR transport regulations. Modular Trailer Architecture Utility Support Module (Trailer 1): • Power Generation: 40 kVA diesel generator set (415 VAC, 3-phase), remote start/stop, integrated shore-power inlet. • Compressed Air: VFD-driven rotary air compressor (15 kW) supplying shop-air (0–12 bar) for pneumatic actuations and start-assist systems. • Fuel System: Dual-compartment, 1,000 L total capacity (Jet-A1 & diesel), automatic switchover manifold, filtration to ISO 4548-12 Class 4. • Tools & Storage: ISO-lock tool chest, hose reels, spill-containment tray. Control Cabin Module (Trailer 2): • Operator Cabin: Climate-controlled (–10 °C to +50 °C), vibration-isolated seating for two engineers. • HMI & Control: Six-screen setup (3×34o, 3×24o) running SCADA with Auto/Manual/Remote modes, user-management (Admin/Operator) and paperless logbook. • PLC & DAQ Rack: Redundant PLC, DAQ with 14 AI (4–20 mA), 4 AO (0–10 V), 10 DI, 10 DO channels, all calibrated traceable to ISO 17025. • Uninterruptible Power: 5 kVA UPS, 1 hour runtime, automatic generator-backup switchover. Engine Test Section Module (Trailer 3): • Mounting & Thrust Stand: Universal adapter interface, ±0.5 % full-scale thrust accuracy, direct-coupled load cell. • Acoustic Enclosure: Removable panels with noise attenuation to <85 dBA at 15 m, equipped with emergency-stop interlocks. • Environmental Ports: Thermocouple arrays, Pitot-static ports, vibration accelerometers, bore-scope inspection port. High-Pressure Compressor Module (Trailer 4): • Provided by GTRE: 30 bar high-pressure air supply for turbine start and tip-clearance tests, with filtration down to 0.01 μm. Advanced Instrumentation & Data Management Sensor Suite: • Thermocouples: Type K and Type T at 32 locations (combustor exit, bearing housings, manifold). • Pressure Transducers: Piezo-resistive sensors (0–100 bar) with ±0.1 % accuracy. • Vibration Monitoring: Tri-axial accelerometers on rotor bearings and skid frame. • Oil Analysis Port: Online particle counter and viscometer. Data Handling: • Real-time Telemetry: 4G/5G and satellite modem connectivity for remote monitoring and expert support. • Data Storage & Reports: RAID-5 NAS (4 TB), automatic test report generation in PDF/CSV, customizable templates, and trending dashboards. Environmental & Safety Systems Climate Control: • HVAC units in each cabin module rated for 10 kW cooling, filtration to ISO 16890 ePM1. • Dehumidifier capability to maintain 40 %–60 % RH during cold-start trials. Fire & Emergency: • CO2 and dry-chemical fire suppression with manual pull stations. • Pressure-relief vents and explosion-protected light fiƫngs. • Emergency-stop chain integrated across all modules, triggering controlled shutdown and generator trip. Grounding & Lightning Protection: • High-conductivity grounding straps (<0.5 Ω), static-dissipative mats, and lightning-arrestor rods. Deployment, Logistics & Infrastructure • Setup Time: ≤ 8 hours from trailer parking to “engine-on” readiness. • Transport Compliance: DOT ADR-compliant chassis, gross weight ≈ 24 000 kg per trailer. • Site Requirements: Flat surface (6 m × 25 m), 230/415 VAC power, 0.5 bar instrument air for skid leveling. • Mobility: Air-ride suspension, hydraulic leveling jacks, and on-trailer crane (2 t) for engine handling. Optional Expansion Modules • Altitude Simulation: Vacuum skids to emulate up to 8,000 m MSL for high-altitude engine qualification. • Emission Analysis Unit: FTIR stack-gas analyser for NOx, CO, HC, and particulates. • Noise Monitoring Van: Portable acoustic survey station for OHS and environmental compliance. Key Features Fully Mobile, Road-Legal Design • Modular, trailer-mounted units built on DOT/ADR-compliant chassis with air-ride suspension and hydraulic leveling jacks—ready to roll to any test site and deploy in under 8 hours. Turnkey Utility Support • Onboard 40 kVA diesel generator, VFD-driven rotary air compressor, dual-compartment 1,000 L fuel system with automatic switchover, and spill-containment trays for true “plug-and-play” operation. Climate-Controlled Control Cabin • Vibration-isolated operator cabin rated –10 °C to +50 °C, featuring six SCADA-driven HMI displays (3×34o, 3×24o), 5 kVA UPS backup, and paperless logging for uninterrupted test control. Universal Engine Mount & Thrust Stand • Quick-change adapter interface with ±0.5 % full-scale accuracy load cell, integrated acoustic enclosure reducing noise to <85 dBA at 15m, and emergency-stop interlocks. Comprehensive Sensor Suite • Over 50 channels of data: 32 thermocouples (Type K/T), piezo-resistive pressure transducers (0–100 bar), tri-axial vibration accelerometers, and online oil-analysis ports for real-time health monitoring. High-Pressure Air Supply • GTRE-provided 30 bar compressor skid with 0.01 μm filtration—ideal for turbine start, tip-clearance, and bleed-air system testing. Advanced Data Management & Connectivity • RAID-5 NAS (4 TB) with automated PDF/CSV report generation, trending dashboards, and remote telemetry via 4G/5G and satellite links for live expert review. Robust Safety & Environmental Controls • CO2/dry-chemical fire suppression, explosion-protected lighting, full emergency-stop chain, HVAC-based humidity control (40 %–60 % RH), and grounding/lightning protection to ISO standards. Optional Expansion Capabilities • Add-on altitude simulation skids (up to 8,000 m MSL), FTIR emission analyzers, and portable noise-survey vans for turnkey compliance testing. Technical specification
