Pneumatic Testing

When is Pneumatic Testing Used?

Typical systems and components which Element U.S. Space & Defense 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 1000°F, 120 lbs/min air input
• Discharge air up to 300 psig @50 lbs/min @ 1000°F
• Example: Flow rate of 220 lbs/min @ 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 1200°F at UUT, 300 psig, 350 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 psig at design conditions as stated above.
• State of the art, low NOx burners 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 a Honeywell PLC is located in the control room and gives the operator full visibility (including trending) of operating parameters.

Air Compressor Systems

Ingersoll Rand Compressor Bank

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.

• 4 each: Single stage rotary screw air compressor (145 psig @ 200 HP) w/ air dryer, coalescing and particle filter
• 3 each: Kaeser booster  145 psig inlet / 300 psig discharge @ 50 HP
• Compressed Air Pressure Receivers (ullage)

Kaeser Compressor Bank:

• 3 each: Single stage rotary screw air compressor (175 psig @150 HP) w/ air dryer, coalescing and particle filter
• 3 each: Kaeser booster 170 psig inlet / 300 psig discharge @ 50 HP Compressed Air Pressure Receivers (ullage)
• Air Receiver #1, 13,696 gallons (US liquid), 1831 ft³, 300 psig
• Air Receiver #2, 7,500 gallons (US liquid), 1,002 ft³, 300 psig

Other Supporting Capabilities

• Thermal control chambers
• High pressure compressors up to 42 lbs/min at 1,000 psig
• High temp oven up to 2,000°F
• House GN2 @ up to 2,300 psig
• Low volume pneumatic pumps up to 40,000 psig 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 2,000°F, at full flow capability (300 lbs/min)
• Air delivery at flow, temperature and pressure to large vibration exciters (45K lb/Force) > 200 lbs/min @ > 3,000 psig and temperatures from -280°F  to > 1,000°F

South Pneumatics Facility

Flow Facility Highlights

• Up to 300 lbs/min at 300 psig and 1,200°F temperature delivery to UUT
• 3 test bays
• 15,000 scfm low pressure blower (4 psig)

High Pressure Facility Highlights

• GN2 and GHe testing up to 6,000 psig
• High pressure blow downs for rated flow, pressure drop, etc.
• High temperature furnace for testing up to 2,500°F
• Helium recovery system to reduce program costs

Other Supporting Capabilities

• Thermal control chambers
• High pressure compressors up to 42 lbs/min at 1,000 psig
• High temp oven up to 2,000°F
• House GN2 @ up to 2,300 psig
• Low volume pneumatic pumps up to 40,000 psig 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 2,000°F, at full flow capability (300 lbs/min)
• Air delivery at flow, temperature and pressure to large vibration exciters (45K lb/Force) > 200 lbs/min @ > 3,000 psig and temperatures from -280°F  to > 1,000°F