Standard for design of aero-engine test cell
1 General provisions
1.0.1 This standard is formulated to unify the standard for design of aero-engine test cell, ensure the design quality of test cell, and realize safety, reliability, technology advancement and economical applicability.
1.0.2 This standard is applicable to the design of enclosed test cell of constructed and renovated aviation turbojet engine, turbofan engine, turboprop engine and turboshaft engine using aviation kerosene fuel.
1.0.3 In addition to this standard, the design of enclosed test cell shall also comply with those stipulated in the current relevant national standards.
2 Terms
2.0.1 aero-engine enclosed test cell
ground test facility used for running test of aero-engine indoors, usually composed of aero-engine test cell building and aero-engine test equipment, hereinafter referred to as test cell
2.0.2 aero-engine test cell building
building used for ground test of the complete aero-engine, usually composed of test chamber, inlet plenum, exhaust stack, and auxiliary functional rooms such as control room, instrument room and preparation room
2.0.3 aero-engine test equipment
process equipment for aero-engine test, including test stand, exhaust augmentor, fuel heating device, reverse thrust exhaust collector, test process system, measurement and control system, etc.
2.0.4 test chamber
space used for engine test in aero-engine test cell building
2.0.5 inlet plenum
passage of external ambient air flowing into the test chamber, composed of structures such as inlet tower or inlet chamber as well as equipment such as silencing device, rectifying device and foreign object protection net
2.0.6 exhaust stack
passage of air flow from test chamber to the external environment, composed of structures such as exhaust tower, exhaust silencing room and augmentor room as well as equipment such as exhaust augmentor and silencing device
2.0.7 augmentor room
structure used for installing exhaust augmentor and isolating noise
2.0.8 test stand
equipment used for fixing aero-engine and measuring its thrust or power
2.0.9 engine handling system
suspended rail transport system used for lifting engine and matching test equipment, and completing air transport of engine between test chamber and preparation room
2.0.10 control room
room equipped with measuring and control equipment such as control console, and used for engine test control and monitoring
2.0.11 instrument room
room equipped with measuring instrument and used for test of engine parameters
2.0.12 hydraulic room
room equipped with lubricating oil and hydraulic equipment for test
2.0.13 preparation room
room used for preparation of engine and aero-engine test equipment before test and temporary storage after test
2.0.14 electrical room
room equipped with equipment such as power supply and electrical cabinet for test
2.0.15 fuel room
room equipped with equipment such as fuel pipeline, filter, valve and flow measuring device for test
2.0.16 fuel heating room
room equipped with fuel heating equipment for test
3 Process
3.1 General requirements
3.1.1 During the design of test cell, the structural type and technical index of test cell shall be determined according to the type and parameters of engine.
3.1.2 When the exhaust direction of the engine deviates from its centerline, the exhaust system of test cell shall be kept smooth.
3.1.3 The test cell with engine reverse thrust test function shall be equipped with a reverse thrust exhaust collector.
3.1.4 The high-temperature exhaust stack of engine and normal-temperature exhaust stack of propeller should be arranged separately on the turboprop engine test cell.
3.1.5 The basic design parameters of test cell should include sectional area of inlet plenum, length of test chamber, sectional area of test chamber, sectional area of exhaust stack, diameter of exhaust augmentor, length of exhaust augmentor and center elevation of engine.
3.1.6 The room for development should be reserved in the design of building and main equipment.
3.1.7 The exhaust emission design of test cell shall meet the relevant requirements of the current national standard GB 16297 Comprehensive emission standard of air pollutants.
3.2 Aerodynamic design
3.2.1 The pressure drop of test chamber shall meet the following requirements:
1 the inlet pressure drop of test chamber shall not be greater than 500Pa, and that of test chamber for large-bypass-ratio turbofan engine test cell shall not be greater than 1,000Pa;
2 the static pressure difference between the inlet section and the exhaust section of the engine in test chamber shall not be greater than 100Pa.
3.2.2 The average airflow velocity of test cell shall meet the following requirements:
1 the average airflow velocity in the test chamber for the test cell of turbojet engine, small-bypass-ratio turbofan engine, turboprop engine tested without propeller and turboshaft engine shall not be greater than 10m/s;
2 the average airflow velocity in the test chamber for the test cell of large-bypass-ratio turbofan engine and turboprop engine tested with propeller should not be greater than 15m/s, and the ejector coefficient of large-bypass-ratio turbofan engine test cell shall not be less than 0.8;
3 the average airflow velocity in the inlet silencing device channel for test cell of turbojet engine and small-bypass-ratio turbofan engine shall not be greater than 20m/s;
4 the average airflow velocity in the inlet silencing device channel for test cell of large-bypass-ratio turbofan engine and turboprop engine tested with propeller should not be greater than 30m/s;
5 the average airflow velocity in the exhaust silencing device channel should not be greater than 50m/s;
6 the average airflow velocity at the outlet of exhaust stack should not be greater than 30m/s.
3.2.3 The air flow field and assurance facilities of the test chamber shall meet the following requirements:
1 the airflow field at the engine inlet shall be uniform and stable, and the uniformity of the air flow field at the inlet section of test chamber shall meet the requirements of engine test;
2 the distance from the front face of engine inlet or propeller disk face to inlet plenum shall not be too small. For vertical inlet plenum, the distance shall be greater than the length of diagonal in test chamber cross section, and for horizontal inlet plenum, the distance shall be greater than the height of test chamber;
3 the turboprop engine test cell should be equipped with a guide ring at the propeller disk surface;
4 where vertical or turning inlet plenum is adopted, the test cell should be equipped with a deflector or rectifying device at the air flow turning;
5 the engine installation centerline on test cell of large-bypass-ratio turbofan engine or turboprop engine tested with propeller should be the same as the geometric centerline of the cross section of the test chamber;
6 the windward area of the test stand and the distance between the front edge of test stand and the propeller disk surface shall not adversely affect the vibration and other performance of the engine;
7 the exhaust stack shall collect all the engine exhaust, the test chamber shall not produce exhaust backflow and exhaust back pressure oscillation, and the airflow discharged from the test cell shall not flow into the inlet plenum again.
3.2.4 Cooling measures shall be taken for the exhaust of test cell of turbojet engine and turbofan engine.
3.2.5 The measurement methods for aerodynamic design parameters of test cell, such as inlet pressure drop in test chamber, static pressure difference between inlet section and exhaust section of engine, average airflow velocity in test chamber and ejector coefficient, shall meet the relevant requirement of Annex A.
3.2.6 The aerodynamic load in the structural design of aero-engine test cell building shall meet the following requirements:
1 The aerodynamic load of test chamber shall meet the following requirements:
1) the aerodynamic load of test chamber for engine tested without propeller shall be -1,500Pa;
2) the aerodynamic load of test chamber for engine tested with propeller shall be -1,500Pa in front of propeller disc and 2,000Pa behind propeller disc.
2 The aerodynamic loads of the inlet plenum and exhaust stack shall be determined through aerodynamic calculation.
3.3 Aero-engine test equipment design
3.3.1 The design of test stand shall meet the following requirements:
1 the dynamic characteristics of the test stand shall meet the relevant requirements of national military standards GJB 242A-2018 General specification for engine, aircraft, turbojet and turbofan and GJB 242A-2018 General specification for engines, aircraft, turboprop and turboshaft or meet the technical requirements for aero-engine products;
2 suspended test stand should be adopted for turbojet engine, turbofan engine and turboprop engine tested with propeller, supported test stand should be adopted for turboprop engine and turboshaft engine with dynamometer as measuring equipment, and engine handling system and fast connection device should be arranged for test cell for batch production of aero-engines;
3 the structural strength of the test sand shall be able to bear various loads that may occur during engine test;
4 the layout of various pipelines and cables connected with the engine should reduce the effect on thrust measurement;
5 the test cell shall be able to measure the engine thrust or power, and the allowable deviation of the accuracy of the engine thrust or power measurement system shall be ±0.5%. The accuracy of the engine thrust or power measurement system may also meet the technical requirements for aero-engine products;
6 The test cell of vector thrust engine shall be able to measure the thrust components along three mutually vertical directions, and the allowable deviation of the accuracy of measuring thrust component in heading directions shall be ±0.5%, and that of measuring thrust component vertical to heading direction shall be ±2%;
7 The force transmission route of thrust calibration device of test stand should be consistent with that of engine, and the vector force should be adopted for the test stand for measuring vector thrust for central loading calibration.
3.3.2 The exhaust augmentor shall meet the following requirements:
1 the structural dimensions shall meet the aerodynamic design requirements;
2 the structural strength shall be able to bear the vibration load caused by engine exhaust;
3 the inlet dimension of exhaust augmentor shall meet the engine nozzle deflection requirements;
4 the structural design shall meet the stress requirements caused by thermal expansion;
5 the exhaust augmentor/exhaust pipe installed in the test chamber of the turboshaft engine test cell should be axially telescopic, and heat insulation measures should be taken.
3.3.3 The design of fuel heating device shall meet the following requirements:
1 the heating capability shall meet the requirements of engine fuel heating test;
2 the structural design shall be safe and reliable, and shall be convenient for inspection and maintenance;
3 the heating device shall be arranged in a separate explosion-proof room.
3.3.4 The reverse thrust exhaust collector shall meet the following requirements:
1 the design of the reverse thrust exhaust collector shall ensure that the reverse thrust airflow of the engine is discharged smoothly and shall not be inhaled by the engine;
2 the structure of the reverse thrust exhaust collector, which may be fixed or transportable, shall be safe and reliable.
3.3.5 The test process system shall meet the following requirements:
1 the functions of the test process system shall meet the requirements of the tested engine, and the equipment should be arranged close to the engine;
2 the technical indexes of the test process system shall meet the technical requirements of the engine and other equipment thereon;
3 the measuring accuracy of design parameters of test process system shall meet the relevant requirements of national military standard JB 241A-2010 General specification for engine, aircraft, turbojet and turbofan and GJB 242A-2018General specification for engines, aircraft, turboprop and turboshaft or meet the technical requirements for aero-engine products;
4 the system design shall be safe and reliable, and shall be convenient for maintenance.
3.3.6 The design of measurement and control system shall meet the following requirements:
1 the measurement and control system shall include the control, measurement, video monitoring and communication system of engine and aero-engine test equipment. The system setting shall meet the requirements of engine control and test. The instruments of measurement and control system shall be accurate and the linkage device shall be reliable;
2 water, oil, gas and other pipelines used for measurement shall not be introduced into the control room;
3 the data recorded by the measurement and control system shall be replayed in the form of curves and printed in the form of data points and curves, and the sampling interval of data points shall truly reflect the change of engine test parameters in transition state;
4 the whole-process data recording and image recording of the measurement and control system shall be able to start and stop automatically, and the recording start should be interlocked with the engine starting;
5 the measurement and control system shall be able to automatically inspect the disk volume and the calibration of sensors, and shall be able to remind the test personnel of the problems automatically found out;
6 the data recorded by the measurement and control system should be stored in the database;
7 the measurement and control system software should have safety functions such as operation authority management, over-limit alarm of important parameters, emergency automatic shutdown, etc.;
8 the electric throttle control system with self-calibration function should be adopted for the engine throttle control, the DC motor should be adopted for actuator, and the sensor matched with the electronic controller should be selected for full authority digital control engine throttle control;
9 the design of measurement and control system shall meet the requirements of shielding and isolation. Twisted pair shielded measuring cable or special cable shall be used for measuring wires and cables with anti-interference requirements. The cable laying shall comply with the relevant requirements of the current national standard GB 50343 Technical code for protection of building electronic information system against lighting. The selection of wires and cables for measurement and control system shall meet the requirements of engine test for wires;
10 clock synchronization equipment should be arranged in the measurement and control system.
3.4 Building layout
3.4.1 The sectional dimensions of test chamber, inlet plenum and exhaust stack shall be determined according to aerodynamic design requirements.
3.4.2 The structural dimensions of test chamber shall meet the requirements of transportation, installation, disassembly, use and maintenance of engines and equipment. Access doors and drainage facilities shall be arranged in the inlet plenum and exhaust stack, and foreign object protection net should be arranged in the inlet plenum.
3.4.3 The control room and instrument room should be arranged on the same side of the test chamber, and their location shall meet the requirements of engine observation, operation and test.
3.4.4 The electrical room should be arranged close to test chamber, hydraulic room and control room.
3.4.5 The pipelines of oil media such as fuel oil, lubricating oil and hydraulic oil shall not pass through the electrical room.
3.4.6 The area of the preparation room shall meet the requirements for temporary storage and preparation of engine and aero-engine test equipment.
3.5 Technical safety measures
3.5.1 The soundproof doors and observation windows of the test chamber shall be kept away from the rotating parts of engine and rotating plane of propeller, and multiple soundproof doors shall be arranged in a staggered way.
3.5.2 Guardrails shall be arranged and anti-skid measures shall be taken for the working platform.
3.5.3 The protection net which is convenient for disassembly and assembly should be arranged at the engine inlet.
3.5.4 The engine starting system shall be interlocked with the state of equipment such as the gate of test chamber and the locking device of test stand.
3.5.5 The fuel supply pipeline in test chamber shall be provided with an emergency cut-off valve with manual and automatic cut-off functions, and the fuel heating device shall be closed in conjunction with the emergency cut-off valve.
3.5.6 Audible and photoelectric warning devices shall be installed in the test chamber.
3.5.7 Video cameras shall be installed in the engine test site in test chamber, hydraulic room and fuel room, and the test personnel shall be able to monitor and record in the control room.
3.5.8 Anti-looseness and locking measures shall be taken for connecting fasteners of equipment in the test chamber.
3.5.9 Measures for eliminating static electricity shall be taken for the fuel pipeline, and human body static electricity elimination facilities shall be arranged at the entrance of fuel room and fuel heating room.
4 Noise control
4.1 General requirements
4.1.1 The noise control design shall be determined according to design parameters such as engine type, aerodynamic characteristics, noise characteristics and protection distance requirements.
4.1.2 Silencing devices and acoustic elements convenient for replacement should be adopted for noise control facilities. The acoustic elements should be streamlined.
4.1.3 Protective measures shall be taken for the members and materials used for noise control according to climate characteristics, temperature and flow velocity in the silencing channel, and substances such as dust and fiber shall not be emitted into the atmosphere.
4.1.4 Low-noise products should be selected for test process system and construction equipment. When the noise still fails to meet the requirements, noise control measures shall be taken for the test process system and construction equipment.
4.1.5 The noise control design shall comply with the current national standards GB/T 50087 Specifications for the design of noise control system in industrial enterprises and GB 12348 Emission standard for industrial enterprises noise at boundary and the relevant requirements of the current national hygienic standards for the design of industrial enterprises.
4.2 Noise control standard
4.2.1 The noise control standard of the control room, instrument room and preparation room in the aero-engine test cell building shall meet the requirements of Table 4.2.1.
Table 4.2.1 Noise control standard
Location Noise limit [dB(A)] Ergonomic limit [dB(A)]
Control room and instrument room ≤80 ≤70
Preparation room ≤85 ≤75
4.2.2 In the building area, the limit of noise radiated by the test cell in the place 30m away from the test chamber, inlet plenum and exhaust stack shall not be greater than 80dB(A).
4.2.3 The environmental noise emission at boundary of aero-engine test cell building shall be implemented according to the relevant requirements of the current national standard GB 12348 Emission standard for industrial enterprises noise at boundary, and the noise design evaluation indexes shall include equivalent continuous sound level A during the day, equivalent continuous sound level A at night and maximum sound level at night. Engine test noise shall be monitored in representative period or the whole normal working period according to the non-steady noise measurement method. The noise test requirements of test cell shall meet the relevant requirements in Annex B.
4.3 Insulation and absorption design
4.3.1 The weighted sound insulation of test chamber, inlet plenum and exhaust stack enclosure should not be less than 65dB. The weighted sound insulation of the common wall between control room and test chamber should not be less than 70dB.
4.3.2 Soundproof observation windows and sound lock composed of multiple soundproof doors may be arranged on the partition between control room and test chamber, and the corresponding weighted sound insulation should not be less than 55dB.
4.3.3 The weighted sound insulation of the entrance gate of test chamber should not be less than 50dB.
4.3.4 The access door of the inlet plenum and exhaust stack should be arranged in the middle or rear of the multi-section silencing device, and its weighted sound insulation should not be less than 40dB.
4.3.5 The sound absorption characteristics of the sound absorption layer arranged for test chamber shall be determined according to the noise characteristics of the engine. The acoustic ceiling and wall surface in the control room and instrument room shall ensure that the arithmetic average of acoustic absorption coefficient is not less than 0.30 at the frequency of 250Hz, 500Hz, 1,000Hz and 2,000Hz.
4.3.6 Sealing and sound insulation measures shall be taken for wall-through pipes and cables leading from the test chamber to other rooms.
Foreword i
1 General provisions
2 Terms
3 Process
3.1 General requirements
3.2 Aerodynamic design
3.3 Aero-engine test equipment design
3.4 Building layout
3.5 Technical safety measures
4 Noise control
4.1 General requirements
4.2 Noise control standard
4.3 Insulation and absorption design
4.4 Noise elimination design
5 Architecture and structure
5.1 General requirements
5.2 Building layout
5.3 Fire and explosion protection design of building
5.4 Span and height of building
5.5 Selection of enclosure structure
5.6 Calculation of main structure
5.7 Seismic design
5.8 Construction of main structure
6 Electric system
6.1 Power supply
6.2 Lighting
6.3 Lightning protection and grounding
6.4 Weak current
7 Water supply, drainage and fire protection facilities
7.1 General requirements
7.2 Water supply
7.3 Drainage
7.4 Fire protection facilities
8 Heating, ventilating and air conditioning
8.1 Heating
8.2 Ventilating and air conditioning
8.3 Fire, explosion and smoke protection, smoke exhausting system
9 Motive power
9.1 Compressed air supply
9.2 Fuel supply
9.3 Waste oil tank
Annex A Field measurement and verification method of aerodynamic design parameters of test cell
Annex B Requirements for noise test of test cell
Annex C Reference mixture ratio and test requirements of special concrete, heat-resistant concrete and heat-resistant mortar
Explanation of wording in this standard
List of quoted standards
