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with these extremes of operation must be surfaced and corrected early in the engine development program to ensure a successful flight clearance program. In general, nearly all control system component structural and environmental testing occurs in a bench environment rather than on the engine. The only engine-level validation activities where no attempt is made to qualify on the bench are high-energy surge events, engine ingestion tests (water, ice, bird) and blade-out tests (turbomachinery blades are intentionally liberated to ensure case containment and engine mount structural capabilities). In these cases, the test environments carry a high degree of uncertainty due to the complex nature of the events themselves. Since a good deal of the component validation activities can be accomplished in the bench environment, the GTA development concept lends itself very well to control system components since they can be tested thoroughly, economically, and in a concentrated manner once the final configuration is defined and produced. As usually occurs during flight clearance testing, several units undergo various tests such as burst for pressure vessels, vibration, fire protection, Low Cycle Fatigue (LCF), bench endurance, etc. simultaneously by utilizing different test facilities. Since components that participate in the GTA development concept will be delivered late in the development program relative to those that follow the "normal" process, significant attention needs to be paid to the bench validation process. Components developed to the new process must undergo intense and highly concentrated bench testing to quickly bring the component up to an appropriate maturity level. For GTA-process components, a "right-to-left" development program anchored at the flight certification date required by the program should be planned. The development program should include tasks for engine data gathering, data analysis, component design, and manufacturing lead-time. A high-level program plan including these tasks is shown in Figure 103PDF Image | Improving Gas Turbine Engine Control System
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