Airbus Canada required the design and commissioning of a dedicated endurance test rig to address in-service fuel system reliability concerns on the A220 programme, with stringent safety and validation requirements.
KDC is acting as an integrated delivery partner under a fixed-price, task-driven model, leading multi-disciplinary rig design, control system development, V&V and commissioning through to operational testing.
This established a controlled endurance test capability, reduced through-life risk, and provided validated evidence to support component life extension decisions.

Requirement

Airbus Canada approached KDC with a requirement to test a fuel system component to determine in service reliability concerns. This was an endurance test designed to validate the increase to the component life.

Skills & Tools 

• Structural design and analysis, explosive atmosphere electrical system design, control system design, fluid mechanical and thermal design.
• Creation of SOP, training manuals/plans and supervisory protocols. LabView, Python and TCL.

Tasking

Mechanical, fluid mechanical, electronics/electrical, rig management control system and GUI design. Commissioning of the entire test rig including full requirements V&V. Development of operating & training procedure and delivery of endurance testing.

Deliverables 

• Design phase – final acceptance.
• ATEX – final acceptance.
• V&V report.
• Commissioning report – final acceptance.
• Rig operation as per SOPs by KDC SQEP.

Outcome

Endurance test has been in successful operation for 18 months. Testing 50% complete and on schedule to complete in 2027.