Pneumatics Test Facility
NTS Santa Clarita is home to our largest pneumatics test capabilities. The pneumatics test facility is designs to conduct testing of air flow, pressure and temperature management subsystems and components requiring compressed air in a controlled environment. Other environments which can be combined with pneumatic testing include; external thermal control, structural stress, and vibration.
The pneumatics test system is comprised of four high-capacity convection heaters, seven air compressors with boosters, two compressed air receivers (ullage tanks), air distribution piping and controls, high flow, low pressure air blowers, and supporting capabilities such as thermal chambers, small air compressors, LN2 and GN2.
The system is operated from the adjacent control room outfitted with a data acquisition and control system for the monitoring, control, and recording of unit under test (UUT) requirements, including streaming video. The data acquisition and control system has the capacity to support up to ten tests in parallel at seven workstations, including four large/complex test programs. The system has virtually unlimited capacity for temperature, pressure, flow and other customer and facility data channel requirements, with portable data interface, signal conditioning, and control cabinets. Multiple direct Ethernet data connections from test cell to control room allow for easy reconfiguration and expansion of localized data interface cabinets. Additionally, the workstations can be configured for independent customer data viewing and analysis, while the control room can be segmented to isolate proprietary customer usage when needed.
When is Pneumatic Testing used?
Typical systems and components which NTS tests in our pneumatics testing facility include:
- Jet engine bleed air systems and associated components (valves, instrumentation, etc.)
- Aerospace environmental control systems and associated components (heat exchangers, valves, instrumentation, etc.)
- Transportation and industrial combustion and exhaust management systems and associated components (heat exchangers, valves, turbo chargers, instrumentation, etc.)
- Other subsystems and components that require compressed air at varying pressures, flows and temperatures for sustained periods.
Pneumatic Test System Highlights
Process Convection Heaters
Heaters 1 and 2
Discharge air up to 1000F, 2 lbs/sec air input
- Discharge air up to 300 psi *50 PPM @ 1000°F
- Example: Flow rate of 220 PPM @ 400°F
- Automated control for test point temperatures using ambient mix valve.
Allows for continuous feedback temperature control and dynamic control of cycling temperatures
Heaters 3 and 4
Discharge air up to 1200F at UUT, 300 psi, 300 lbs/min air input.
- Heaters can be operated in parallel to support one test cell or separately to support two test cells.
- Pressure drop across heaters varies with flow, temperature and pressure. It is projected to be approximately 20 psi at design conditions as stated above.
- State of the art, low NOx burners (Zeeco GLSF 8) and Flue Gas Recirculation (FGR) to meet very stringent 9 ppm SCAQMD NOx requirement.
- Control system provides fully automatic start-up sequencing; control of VFD driven induced draft, FGR, and forced draft fans; firing rate and safety oversight.
- Primary control loop is closed on process air outlet temperature.
- Oxygen analyzers in the flue gas and oxidant streams facilitate very accurate combustion control.
- The main control panel based on the Honeywell ML-50 PLC is located in the control room and gives the operator full visibility (including trending) of operating parameters.
Air Compressor Systems
The air compressor system is capable of supplying compressed air from both banks to one test cell or to several test cells in parallel depending on the individual test pressure and flow requirements.
Ingersoll Rand Compressor Bank:
- 4 each: Single stage rotary screw air compressor R160i-145 PSI (200 HP)
- w/ air dryer, coalescing and particle filter
- 3 each: Kaeser booster (N2001-G/GW, 50HP), 145 PSI inlet / 290 psi discharge
Kaeser Compressor Bank:
3 each: DSD150-175psi (150 HP)
- w/ air dryer, coalescing and particle filter
- 3 each: Kaeser booster (N2001-G/GW, 50HP), 170 PSI inlet / 290 psi discharge
Compressed Air Pressure Receivers (ullage)
- Air Receiver #1, carbon steel, 13,696 gallons (US liquid), 1831 ft3, 300 PSI
- Air Receiver #2, carbon steel, 7,500 gallons (US liquid), 1,002 ft3, 300 PSI
Other Supporting Capabilities
- Thermal control chambers
- High pressure compressors up to 42 PPM at 1000 PSIG
- High temp oven up to 2000°F
- House GN2 @ up to 2300 psi
- Low volume pneumatic pumps up to 40,000 PSI for burst tests
- Several methods of heating pneumatic systems besides our flow heaters, such as electrical and gas burners, SuE burners
- SuE burners and combustors capable of temperatures in excess of 2000°F, at full flow capability (300 PPM)
- Air delivery at flow, temperature and pressure to large vibration exciters (45K lb/Force)