AERO ENGINE & COMPONENT TEST FACILITIES
Consultants & Specialists in Aero Engine Test
Facilities & Ground Support Equipment
Mobile Engine
Test System (METS)
For Lockheed Martin C130H/J and P3 Orion Aircraft
Overview:
A METS Facility comprises of:
• As part of the total integrated logistics support for the Lockheed
Martin C130 and P3 Orion aircraft, Aerotest Limited have
designed, developed and supplied advanced open air Mobile
Engine Test Systems (METS) which are capable of performance
testing the following:
• Hercules C-130H Allison T56-A15 power plant installed into a
Quick Engine Change Unit with a Hamilton Standard 54H60-91
propeller installed.
• Allison T56/ 501 bare power plant with a Hamilton Standard
54H60-91 propeller installed.
• Hercules C-130J AE2100D3 power plant installed into a Quick
Engine Change Unit with a Dowty Aerospace R391 six bladed
composite propeller installed.
• Adaptability to support the Lockheed Martin P3 Orion Allison
T56-A14 power plant installed into a Quick Engine Change Unit
with a Hamilton Standard 54H60-77 propeller installed.
Test Trailer & Mounting Frame including the following:
A METS Facility provides the following advantages:
• A flexible testing solution within a safe and efficient environment.
• Proves the quality of the overhauled power plant, propeller and
nacelle as individually or a complete assembly - fully tested and
ready for a ONE TIME aircraft installation.
• A Dynamometer Test Cell for bare engine testing is no longer
required.
• “State of the Art” data acquisition system and full performance
analysis software, including on-line, real time, test and digital
• fault diagnosis via high-speed computers and optional autocueing software for a faster, more accurate way of repeatable
and recording test data.
• Prevents the aircraft being used as an expensive test facility, thus
increases aircraft availability.
• One facility catering for multiple aircraft platform.
• Long wheelbase test trailer with turntable steering, adjustable
tow-arm equipped with NATO standard towing eye, brake
system and foam filled tyres.
• QECU’s and power plants are installed onto an aircraft standard
Duplex stainless steel mounting frame at the same propeller
centreline height as that of the aircraft wing. This reduces the
amount of propeller ground-tip vortices and FOD hazards, which
can damage the propeller and power plant.
• Test trailer retention & safety system thrust tie-down chains
which include integral spindle tensioners connecting to ground
anchor plates complete with chemical anchors rated for C130J
maximum thrust loads, QECU mounting frame seizure reaction
tie-down wire assemblies with integral spindle tensioners
connecting to ground anchor plates complete with chemical
anchors and an integral fifteen ton stabilizing jacks and integral
run-away trip wire.
• The Aerotest METS test trailer is the only unique facility in the
world to be equipped with front and rear hydraulic access
scissor lift platforms reducing aerodynamic backwash blockage
and resultant induced strain on the installed propeller.
AERO ENGINE & COMPONENT TEST FACILITIES
A METS Facility comprises of:
Test trailer & Mounting Frame including the following:
• The front and rear hydraulic scissor lift platforms have several
safety features to prevent injury to personnel during the platform
operation, these include safety edge strips, light beams and
collapsible skirts attached to the underside of each platform.
• The front and rear hydraulic scissor lift platforms have stainless
steel anti-slip decking which provides a safe working surface for
personnel.
• Personnel access steps located either side of the trailer to gain
access to the front and rear hydraulic scissor lift platforms.
• Test trailer mounted weatherproof and fully computerized
resistive electrical load bank and power supply.
• Electro/ Pneumatic throttle actuation unit controlled via the engine
control panel and the facility programmable logic controller (PLC)
located in the METS acoustic control cabin. The throttle system
comprises of an electro/pneumatic actuator assembly installed
onto the QECU mounting support frame.
• The actuator unit provides the drive pulley system that interface
to the QEC Pulley through a sprag unit. A similar DC actuator
is mounted alongside to interface to the QEC Propeller Pitch
control pulley.
• The METS facility includes a fire extinguishing system using
C130J aircraft Halon storage system. The METS facility includes
a hydraulic loading system which is used to test the QEC on-test
hydraulic pump accessory.
• Air start pipe work and bleed air control & measurement system
includes a stainless steel air start pipe routed up the QECU.
• The rear section of the METS test trailer is stainless steel anti-slip
decking which provides a mounting surface for the stainless steel
weatherproof IP65 termination cabinets. Interrup tible test point
terminations are installed for easy diagnostics.
• The entire METS Test trailer IP65 termination cabinets are
interconnected with moulded QEC interfacing engine control
harnesses.
METS Facility Jib Crane - Optional
The Aerotest METS facility includes an optional 3000Kg lift capacity,
5.700m reach Jib Crane to install and remove C130/ P3 QEC’s and
propellers on and off the Duplex QEC support frame.
• Each harness utilises aircraft
standard PTFE screened cabling
with mating multi-pin firewall
connectors, all pre-tested during
manufacture for continuity, routed
from the control cabin bulkhead
up to the QEC bulkhead.
AERO ENGINE & COMPONENT TEST FACILITIES
Acoustic control cabin
A METS Facility comprises of:
Acoustic control cabin including the following:
The 45 Db rated “state of the art” Acoustic Control Cabin is a
high quality unit, based on the external dimensions of an ISO 20ft
shipping container, to make transportation and handling easier.
The METS operators will benefit from the cabins enhanced
acoustics, consol ergonomics and integrated air-conditioning
system.
The Control Cabin can be de-mounted for transportation purposes
only and can be transported by air, road and sea.
The Cabin is fitted with acoustic ducts for electrical and electronic
cable feeds as well as personnel fresh air make-up.
A single acoustically treated door equipped with a “panic-release”
luminous button lock and double-glazed acoustic viewing panel for
operational safety.
Four anti vibration acoustic shock mounts.
Access steps with stainless steel handrails for entry and exiting the
cabin.
Internally the cabin is equipped with:
• Integrated air conditioning with digital thermostatic control.
• Ergonomically designed consol to allow two operators to
view and control all of the required functions from their seated
position, this allows the operators to observe the QECU under
test through the panoramic acoustic window.
• The consol design conforms to The UK Health and Safety (Display
Screen Equipment) Regulations, which require employers to
minimise risks in visual display unit (VDU) work by ensuring that
work stations are appropriately designed.
• The consol design allows the operator to carry out his tasks
without suffering physical discomfort.
• High Resolution Colour Monitors, keyboard and mouse.
• Touch screen technology screen.
• Tower PCs.
• Reversionary hard wired emergency control panel
• Wireless communications control panel.
• Hand held radio charging station.
• Terminations cabinet with circuit breaker protection.
• Mains Power Single 240 volt 50/ 60 Hz electrical distribution
board.
• Three channel vibration suite with variable software filtering and
with common set of accelerometer pick-ups
• Un-interruptible mains power supply unit (UPS).
• 28/5VDC Power Supply
• CCTV System controls with picture in picture displays.
• Dual channel 1553 data bus analysis card.
• Dual channel 1553 bus terminal card for asynchronous
communications.
• 90 kW load bank control panel using RS 485.
• A light control panel inside the cabin for external floodlight control.
• Dimmable VDU/Console low voltage internal spot lighting
• Data Acquisition System for analogue signals measurement and
• digital I/O control.
• Vibration monitoring suite with programmable filters
• PLC touch screen controlled throttle demand systems.
• PLC touch screen controlled C130J resolver servo driver motor
and gearbox system.
• Large triple pane acoustic and hermetically sealed viewing
window.
• Fully suspended anti-static computer flooring.
• Hand-held foam fire extinguisher.
• Two operators chairs with wall-mounted whiteboard and pens.
AERO ENGINE & COMPONENT TEST FACILITIES
• Aerotest provides a ‘state of the art’ system for the control and
instrumentation requirements for the METS Test Facility.
• The software has been configured to allow the operator to select
between the different power plants to be tested.
• This method of controlling both the power plants and the test
facility provides the Customer with an easy method of upgrading
the facility for future engine test applications as required.
• The system includes optional Auto-prompting Test Application
Software which provides a “test schedule” for the power plant
under test. The “test schedule” is embedded in the software
application to enable the test technician to be prompted through
each individual test.
• The “prompting” instructs the test technician which power plant
condition settings are required and when they are met, upon this
event, the system will automatically record the required data and
simultaneously display test results and progress onto the next
line.
• The system includes
touch screen control
technology
for
the
QECU, power plant and
facility plant control.
• The
touch
screen
control panel provides
the
operator
with
many
automated
functions, which has
the benefit of not only
ease of operation, but
also repeatable test
procedures. This enables the operators to repeat functions
accurately and produce consistent and comparable test results.
The Aerotest METS Facility also offers additional features:
QECU Air Start System
• The Aerotest METS air start system replaces the high
maintenance cost of aircraft / GSE Auxiliary Power System (APU)
to provide compressed air to the test trailer and engine interface
connection flange.
• The system comprises of a vertical air receiver/pressure vessel,
a purpose built compressed air skid package to accommodate
a rotary screw compressor, desiccant/ refrigerant dryer and
necessary filteration.
QECU Fuel System
• The Aerotest METS facility fuel system consists of a 20,000
litre Fuel Tank/Pump Unit which incorporates a secure cabinet
housing the fuel pumping system which is located within a
bunded concrete foundation at a safe distance away from both
the METS Acoustic Control cabin and Test trailer.
• An optional trailer mounted fuel tank can also be offered as an
alternative to the permanent bunded fuel tank installation.
• A fuel pump assembly is mounted adjacent to the fuel tank
inclusive of an inlet strainer, fuel pump, fuel filter, pressure
regulator, and a flow measurement turbine flow meter with fuel
temperature sensing.
• Also included is the inter-connecting pipe-work from the Fuel
Tank/Pump Unit to a Fuel Control Module which is mounted on
the Test Trailer.
Externally the acoustic cabin Is Equipped with:
• Wind-speed and direction transducer interfaced to test program
software (propeller wind speed and directions limits file)
• Two cabin mounted halogen floodlights for night-time running.
• A Flashing beacon interlinked to engine running.
• Lightning protection conductor aerial and earthing connections
• Air-conditioning condenser unit with integral heat pump.
• Public address safety speaker horn.
Slave Oil System
• When testing an Allison T56/ 501 ‘bare’ engine, the METS facility
also includes a ‘slave oil system’ which is required to provide
a pressure and temperature controlled oil supply to the Engine
Power Section (PS) and Propeller Reduction Gearbox (RG) in
place of the T56-QEC integral system normally used as part of
an indoor Dynamometer Test Cell set-up.
Ordering Information:
NCAGE Number: Consultants & Specialists in Aero Engine Test
Facilities & Ground Support Equipment
T: +44 (0) 1442 235557 F: +44 (0) 1442 235547 E: info@aerotest.com W: www.aerotest.com
Unit 5 Sovereign Park, Cleveland Way, Hemel Hempstead, Hertfordshire, HP2 7DA, England
Aerotest Limited is an ISO BS EN 9001:2008 registered company with a quality approval certificate, number FM66648.
KE 160