Checkout Testing of the New Basic Process Control System at the Aerodynamic and Propulsion Test Unit

Abstract

This paper describes the test campaign conducted to support the final development and activation of the new Aerodynamic and Propulsion Test Unit (APTU) Basic Process Control System (BPCS). The testing was conducted in two phases. Cold flow tests were conducted to define the installed effective area of the individual flow control valves as a function of the valve’s percentage open. Cold flow tests were also used to demonstrate the safe, reliable, and effective operation of the BPCS and facility before initiating hot flow tests. Hot flow tests were then used to demonstrate full operation of the APTU with the new BPCS. Three supersonic and hypersonic Mach number freejet nozzles were used during the checkout tests. Cold and hot runs were intermixed between the different nozzles due to operational constraints on various hardware components. The new BPCS has been shown to provide significantly improved control over the previous control system by maintaining flow rates to within .5% of steady-state set point value and within 2% of set point values during flight representative facility transients. The new control system is now operational and is being used to support test customers.