Details

Introduction
The Universal Self-Generating Nitrogen Service Cart (U-SGNSC) is an advanced, self-contained ground support system engineered to meet the demanding requirements of modern military aviation. Unlike conventional nitrogen trolleys that rely on pre-filled bottles, the U-SGNSC generates high-purity nitrogen gas (>99.5%) on demand, ensuring autonomy and reducing logistical dependency.

This system is particularly designed for the Indian Air Force (IAF) and is deployed in flight line environments for on-ground maintenance, servicing, and mission readiness of aircraft and helicopters. Its diesel-powered, trailer-mounted design makes it rugged, mobile, and suitable for forward operating bases, where reliability and independence are crucial.

Applications
• Aircraft Tire Inflation – Safe and precise nitrogen filling for enhanced fire resistance and stability under extreme conditions.
• Landing Gear Strut Servicing – Controlled high-pressure nitrogen charging ensures correct damping and load absorption during operations.
• Hydraulic Accumulator Charging – Supplies inert nitrogen to accumulators used in braking and control systems.
• On-Ground Engine Start Support – Provides nitrogen supply for auxiliary maintenance during engine starting cycles.
• General Flight Line Operations – Multi-role use in ground maintenance across a wide range of military aircraft.
• Support for Remote Operations – Enables field units to operate independently without dependence on gas cylinder logistics.

System Overview
The U-SGNSC integrates advanced gas generation, compression, and storage subsystems into a modular towable trailer unit. The system is enclosed within an equipment protective canopy painted in standard military olive green, providing weather protection, acoustic damping, and ease of maintenance access.

Major Subsystems
1. Power Source – 80 HP BS-VI compliant diesel engine (Ashok Leyland P15), complete with CRDI fuel system, radiator, ECU, exhaust after-treatment, and AVM mounts.
2. Feed Air Compressor – 75 CFM at 12 bar, providing clean compressed air for separation membranes.
3. Air Filtration and Drying – Multi-stage system: suction filter, pre-filter, activated carbon filter, fine filter,moisture separator,
and twin dryers achieving -40°C dew point.
4. Nitrogen Membrane Separation – Dual Parker SmartFluxx SA1508 membranes producing >99.5% nitrogen purity.
5. Booster Compression & Hydraulic Intensifier – Hydraulic-powered intensifier raises nitrogen pressure up to 303 bar / 4400 psi.
6. High-Pressure Storage Cylinders – Two ISO 9809-2 certified cylinders with total storage ~850 ft3 nitrogen.
7. Heat Exchangers & Cooling Subsystem – Controls process temperature for both air and hydraulic circuits.
8. Control and Automation – PLC-based operator panel with nitrogen purity analyzer (digital, Honeywell A02), safety alarms, gauges, and protective interlocks.
9. Service Hoses and Reels – Two × 50 ft reels: LP line (0–400 psi) and HP line (400–4000 psi).
10. Trailer & Running Gear – Gull-wing service panels, front steering with tow-bar, lunette eye (3” dia), rear towing pintle, and parking brake.

Technical Specifications

  

    
Parameter
    
Specification
  
  

    
Nitrogen Purity
    
≥ 99.5%
  
  

    
Maximum Delivery Pressure
    
303 bar (4400 psi)
  
  

    
Flow Rate
    
10 SCFM
  
  

    
High-Pressure Storage
    
2 × 1.53 ft³ cylinders (~850 ft³ N₂ at STP)
  
  

    
Nitrogen Membrane
    
Parker SmartFluxx SA1508
  
  

    
Feed Air Compressor
    
75 CFM, 12 bar
  
  

    
Dryer Performance
    
Dew Point: -40°C
  
  

    
Hydraulic Intensifier Output
    
18 Nm³/hr at 303 bar
  
  

    
Diesel Engine
    
80 HP, BS VI compliant (Ashok Leyland P15)
  
  

    
Power Transmission
    
Hydraulic system driving booster compressor
  
  

    
Operator Interface
    
PLC-based control panel with digital nitrogen purity meter
  
  

    
Safety Systems
    
Pressure relief valves, oxygen sensor, auto shutdown interlocks
  
  

    
Service Lines
    
LP (0–400 psi, 90° chuck) / HP (400–4000 psi, 70° chuck)
  
  

    
Chassis Type
    
Towable trailer, gull-wing enclosure
  
  

    
Overall Dimensions
    
L: 2100 mm × W: 1830 mm × H: 1600 mm
  
  

    
Weight
    
~1500 kg
  
  

    
Operating Temperature
    
-20°C to +55°C
  
  

    
Compliance Standards
    
ISO 9809-2 (cylinders), AS9100/ISO9001/DGAQA
  


Quality and Reliability
• Inspection & Qualification: Designed as per IAF RFP requirements with prototype trials, qualification tests (QTP), and acceptance test procedures (ATP) approved by RCMA/CEMILAC.
• Durability: Designed for long-term use in field environments, with robust chassis and corrosion-resistant SS components in hydraulic tanks and filters.
• Safety: Redundant safety relief valves, pressure transmitters, and purity monitoring guarantee operational security.
• Maintainability: Modular subsystems for quick replacement, with illustrated parts catalogues and O&M manuals provided.
• Training Support: OEM provides training to IAF personnel for operation, first-level maintenance, and troubleshooting.

Operational Advantages
• Self-Sufficient Operation – Eliminates reliance on bottled nitrogen logistics.
• High Mobility – Towable on airbase roads and adaptable to forward locations.
• Cost Efficiency – Reduces recurring expenditure on pre-filled nitrogen cylinders.
• Mission Readiness – Provides continuous nitrogen supply for multiple aircraft simultaneously.
• Compliance with Indigenisation Drive – Fully developed and manufactured in India, aligning with self-reliance goals of the Indian Air Force.

Conclusion
The Universal Self-Generating Nitrogen Service Cart (U-SGNSC, Model A4029) represents a next-generation ground support asset for military aviation. Combining advanced nitrogen separation, high-pressure boosting, and rugged field-ready mobility, it ensures reliable servicing of mission-critical systems. With its high purity, high-pressure output, and PLC-controlled safety, the cart provides uninterrupted operational readiness, making it indispensable for air bases and combat deployment scenarios.