Portable Air Flow Test System
Flow Computer Dimensions: 21 in. L x 19 in. W x 14 in. H
Transport Case Dimensions: 32 in. L x 24 in. W x 17 in. H

Portable Airflow Test System (PATS)

(Wo rk bench not included.)

Note: Unit will extend 10” below the mounting plate

 

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JET ENGINE / GAS TURBINE COMPONENTS

Portable Air Flow Test System, 
(PATS)
 

DESCRIPTION
Aerospace OEMs and their suppliers require quality airflow measurements of passages in both aircraft and land-based turbine engine components.  Each OEM has a unique testing specification and their suppliers must be flexible with the test procedures in order to comply with each OEM Test Specification.  Accuracy, repeatability, throughput and availability are critical elements in the design of the Portable Air Flow Test System.
SYSTEM FEATURES
»  Accurate Measurement

»  Highly Repeatable Results

»  Portable or Bench-Top Mountable

»  Flexible for various Customer/Supplier/OEM Test Specifications

»  Wide Range of Part Test Pressures and Mass Flow Rates

»  User-friendly Controller Software 

»  High System Availability
SOLUTION

Flow Systems has designed and engineered a fully automated “standard” turbine component flow system, including hardware and software that is fully customizable for each application or customer.  As a “standard” product offered by Flow Systems, the test system is constantly undergoing improvements in both the hardware components and the controlling software. This continuous improvement process has produced a system that is used and accepted worldwide by many OEMs and suppliers in the Aerospace Industry. The system currently complies with the in-house testing procedures of ABB/Alstom Power, ABB Gas Turbines, Pratt & Whitney America , Pratt & Whitney Canada , General Electric Aircraft Engines, General Electric Power Systems, Honeywell, Mitsubishi Power Systems, Mitsubishi Heavy Industries, Solar Turbines, Allison Engine, Rolls-Royce, Siemens, Snecma, Siemens-Westinghouse and others.

SYSTEM SCHEMATICS 

The PATS is an Air Flow Metering System that employs up to 4 automatically selectable Sonic Nozzle (Critical Flow Venturi) to meter the air flow through each Unit Under Test (UUT).   For more information on Sonic Nozzles, see our Sonic Nozzle Brochure, or visit the “Products” section of our website at www.flowsystemsinc.com. 

For a Primer on “Critical Flow,” visit the “Technical Data” Page at www.flowsystemsinc.com

 

 

 

LAPTOP AND SOFTWARE


The System Controller sets the proper pressure at the inlet of the UUT, and calculates the mass flow through the sonic nozzle. The controller also monitors the airflow conditions to insure that the sonic nozzle is in a “choked” state and that the flow is stable within +/-0.1% of the pressure ratio setpoint.

Unit includes a commercial, off-the-shelf Laptop (DellTM or equal) with 10.1” screen. Laptop Specifications:  Dell Latitude 2110, 1GB RAM, 64GB mobility solid state drive, Windows 7 Home premium, 2 USB 2.0, Integrated Network Connector, Windows MS Office Basic, 0.9" Height x 10.4" Width x 7.4" Depth 2.9 lbs.

Shown below is a picture of the System Standard Production Screen.

 

Control System Operator Interface
 

The System Controller Software includes the following Automated Functions:
Part Test Measure Finder

»  Determines the mass flow, flow parameter and reduced mass flow at a user-specified part test pressure or pressure ratio.
»  Sets an upper and lower acceptance limit based upon the measured value and a user-defined tolerance.
»  Determines that the Sonic Nozzle meets the Unit Under Test (UUT) test criteria.


Auto Proportional-Integral-Derivative (PID) Tuning Routine

» The system flows the UUT and uses the natural response of the system to calculate Proportional-Integral-Derivative (PID) parameters.


Part Master Routine
 
»  Measures the repeatability, average and percent difference (measured to calculated) of a series of consecutive flow tests through a master UUT.


System Accuracy Test (Audit Test)

»  Measures the repeatability, average, and percent difference of a calibrated master sonic nozzle (critical flow venturi) against the installed system nozzles.


Leak Testing

»  System Leak - for ensuring the integrity of the entire system.
»  Part Leak - for measuring any leakage in the path from upstream of the Sonic Nozzle to the part fixture.
»  This routine compensates for varying fixture volumes.


Fixture Flow Restriction
»  For testing the air flow restriction caused by the UUT part fixturing.


Maintenance

»  Allows the user to manipulate all system controls and read all system sensors.


Database

»  All test results are stored in a Microsoft Access Database. Other databases may be optional.


Report Generator

»  All test results can be queried using the Report Generator which allows the user to filter and select results based on date, work order, part number, serial number, operator and pass/fail.

 

All FLOW SYSTEMS Test System designs, the Test System Controller, Data Acquisition and Control Subsystems, and all Instrumentation are standard, readily available Commercial Off-The-Shelf (COTS) items. This ensures that servicing or replacement of any item can be achieved in a timely manner, providing for high availability of the Test System.
 

AIR FLOW TEST SYSTEM SPECIFICATIONS

» Flow Elements:

 

 Sonic Nozzles with throat diameters ranging from 0.016” to 0.250”.

 
» Air Mass Flow Range:

Config 1:

CFV’s:  0.063, 0.125, 0.177 and 0.250”

0.002 to 0.2 lbm/sec

If PR=1.25 à Ae: 0.005 to 0.59 in2

 

Config 2:

CFV’s:  0.031, 0.063, 0.125 and 0.250”

0.0006 to 0.15 lbm/sec

 

Config 3:

CFV’s:  0.016, 0.031, 0.063 and 0.125”

0.00015 to 0.05 lbm/sec

 

 

» Part Pressure Range:
 1 to 10 psig  (other, custom ranges available upon request)

 
» Part Pressure Ratio Range: 1.07 to 1.68 psig  (Other, custom ranges available on request.)

 
» Accuracy:

+/- 0.87% of reading, traceable to NIST standards. 

Refer to FLOW SYSTEMS' Technical Document, "Error Analysis -Flow Measurement Accuracy FLOW SYSTEMS Mini / Portable Sonic Nozzle-Based Turbine Component Airflow Test Stand".

 

» Repeatability: Less than +/- 0.25% as defined as 2 standard deviations divided by the mean of 20 identical samples.

 
» Cycle Time: 20 to 60 seconds depending on percent of maximum capacity.

 
» Connections

Air In:     ¾” (-12) Swagelok

Air Out:  QF Female Quick Connect 1” (-16) Swagelok  

Pressure:  4 CPC Female Quick Connectors –PLC series, green  color keyed.
» Unit Dimensions: 

» Case Dimensions:  		3 in. H x 17 in. W x 17 in. D

32 in. L x 24 in. W x 17 in. H

 
» Unit, Base & Equipment Weight: 
 Unit 55 lbs, case with hoses 50 lbs

 

 

Facility Requirements*
Electrical Power  100-240 VAC  /  50 - 60Hz  /  1pH  /  5 - 7.5 Amp
Inlet Air Connection ¾ in. Male NPT
Pressure 70 to 150 psig
Temperature 60° to 90°F
Particulates  Less than 5 microns
Oil Content  Less than 10 ppm
Pressure Dew Point @>100psig  Less than 39°F

Flow Rate:  Equal to the lesser of the maximum capacity of the flow bench or the requirement of the largest part for a 100% duty cycle.  An air receiver tank will allow for maximum flow at less than 100% duty cycle. 
Contact FLOW SYSTEMS for more information.

*The Above Facility Requirements are to be supplied by the Customer at the Installation Site.

 

OPTIONS

»  Dew point Alarm
»  Part Fixturing and Tooling.
»  Compressors, dryers, filters and receivers.
»  On-site installation, training, commissioning and upgrades.
»  Software Customization including database integration, networking, SPC (Statistical Process Control), and more.

SYSTEM CHECK STANDARDS

»  Sonic Nozzles
»  Inlet Sections
»  Silencers

REFERENCE

»  Technical Notes Available
»  Accuracy / Uncertainty Analysis
»  Capabilities
»  Custom Software

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