Portable Air Flow Test System
Flow Computer Dimensions: 3 in. H x 17 in. W x 17 in. D
Mounting Base Unit Dimensions: 1 in. H x 42 in. W x 12 in. D

Shown with Customer-Supplied Laptop and Optional Fixturing.  
Contact FLOW SYSTEMS for Custom Fixture Price Quote.

Shown Complete in Optional Shipping Case with Customer-supplied Laptop.
(Other packaging configurations available.)

 

 

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JET ENGINE / GAS TURBINE COMPONENTS

Portable Air Flow Test System, 
Model FC200-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, GE Energy, Mitsubishi Power Systems, Mitsubishi Heavy Industries, Solar Turbines, Allison Engine, Rolls-Royce, Siemens, Siemens-Westinghouse, Snecma and many others.  (Click here for a complete List of Clients.)

SYSTEM SCHEMATICS 

The FC200-PATS is an Air Flow Metering System that employs one manually interchangeable Sonic Nozzle (Critical Flow Venturi) to meter the air flow through each Unit Under Test (UUT).   

 

 

 

SYSTEM CONTROLLER SOFTWARE 


The System Controller sets the proper pressure at the inlet of the Unit Under Test (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. 

Shown below is the System Standard Production Screen.

 

Control System Operator Interface
 

The System Controller Software contains procedures for performing the following 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.


Optional Test Scheduler

»  Automated Test Sequencer.
»  Allows any number of configured tests to be executed in a sequence.
»  Virtual tests can be programmed in to calculate and evaluate results based on previous test values in algebraic equations.
»  Enables stop/retest of tests in the schedule.
»  Programmable Pause.


Optional Internet Support and Diagnostics

»  Allows FLOW SYSTEMS to observe and/or control a system remotely for training, optimization, or troubleshooting purposes.  Requires a temporary, high-speed data line.

 

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 0.022” to 1.000”.

 
» Air Mass Flow Range: Performance Est. of Std. Size Sonic Nozzles (CFV Chart 1)
Performance Est. of Std. Size Sonic Nozzles (CFV Chart 2)
Performance Est. of Std. Size Sonic Nozzles (CFV Chart 3)

 

» Part Pressure Range:
 1 to 20 psig  (Other, custom ranges available on request.)

 
» Part Pressure Ratio Range: 1.07 to 2.36 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: Flow Ports              -16 (1" AN Flare)
                               -24 (1.5" AN Flare)
                               -32 (2" AN Flare)
Pressure                 -4 CPC Female Quick Connectors -PLC series,
                                 color-keyed.		  

 
» Unit Dimensions: 

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

Nominal: 1 in. H  x  42 in. W  x  12 in. D

 
» Unit, Base & Equipment Weight: 

» Stand Weight/ Dimensions:		 60 lbs.

Varies, based on requirement.

 

Facility Requirements*
Electrical Power  100-240 VAC  /  50 - 60Hz  /  1pH  /  5 - 7.5 Amp
Inlet Air Connection ¾ in. to 1.5 in. FNPT based on configuration
Pressure 70 to 100 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.

 

 

 

 

Portable Air Flow Test System, with connecting Sonic Nozzle and Meter Run:

 

 

Click to view enlarged image

 

OPTIONS

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

SYSTEM CHECK STANDARDS

»  Sonic Nozzles
»  Inlet Sections
»  Silencers
»  Flow Computers - FC175, FC500

REFERENCE

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

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