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Standard Turbine Engine Component
Air Flow Test System - Front View.
High Flow Configuration
Dimensions: 65 in. H x 62 in. W x 36 in. D
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JET ENGINE / GAS TURBINE
COMPONENTS
Air Flow - High Flow Test Stand
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DESCRIPTION
Aerospace OEMs and their suppliers require quality air flow 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 Test System.
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SYSTEM REQUIREMENTS
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Accurate Measurement
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Highly Repeatable Results
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Flexible for various Customer/Supplier/OEM Testing
Specifications
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Wide Range of Part Test Pressures and Mass Flow Rates
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User-friendly Controller Software
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Maximum Throughput
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High System Availability |
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SOLUTION
FLOW SYSTEMS has designed and engineered a fully automated "standard" turbine component flow bench, including hardware and software, that is fully customizable for each application or customer. As a "standard" product offered by FLOW SYSTEMS, the test stand is continually 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 US, Pratt & Whitney Canada, General Electric Aircraft Engines, General Electric Power Systems, 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.)
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High
Flow Turbine Engine Component Air
Flow Test Stand
With Panels Removed
Front View |
High
Flow Turbine Engine Component Air Flow Test Stand
With Panels Removed
Back View |
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SYSTEM SCHEMATICS
The Test Stand is an Air Flow Metering System that employees a set of
Ten (10) Sonic Nozzles (Critical Flow
Venturis) housed in a common-inlet / common-exit manifold to meter the air flow through each Unit Under Test
(UUT).
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SYSTEM CONTROLLER SOFTWARE
The System Controller handles the opening and closing of sonic nozzle flow paths, sets the proper pressure at the inlet of the UUT and calculates the mass flow through the sonic nozzle manifold. The controller also monitors the airflow conditions to insure the sonic nozzles are in a "choked" state and that the flow is stable within +/-0.1% of the pressure ratio set point. Shown below is a picture of the system standard Production Screen.
Control System Operator Interface
The System Controller Software contains procedures for performing the following functions:
Part Test Measure Finder
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Determines the mass flow, flow parameter, reduced mass flow at a user specified part test pressure or pressure ratio.
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Sets an upper and lower acceptance limit based upon the measured value and a user defined tolerance.
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Determines a Sonic Nozzle Pattern that meets the
Unit Under Test (UUT) test criteria.
Auto Proportional-Integral-Derivative (PID) Tuning Routine
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The system flows the UUT and uses the natural response of the system to calculate Proportional-Integral-Derivative (PID) parameters.
Part Master Routine
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Measures the repeatability, average and percent difference (measured to calculated) of a series of consecutive flow tests through a master Unit Under Test (UUT).
Test Scheduler
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Automated Test Sequencer.
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Allows any number of configured tests to be executed in a sequence.
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Virtual tests can be programmed in to calculate and evaluate results based on previous test values in algebraic equations.
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Enables stop/retest of tests in the schedule.
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Programmable Pause.
Pressure Probing
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Allows the operator to measure the Pressure Ratio of a single hole.
Pressure and Temperature Instrumentation Calibration
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Capabilities for complete on-bench instrument calibration.
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Common reference port and manifold with automatic valves for a calibration pressure standard.
System Accuracy Test (Audit Test)
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Measures the repeatability, average and percent difference of a calibrated master sonic nozzle against the installed system nozzles.
Leak Testing
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System Leak - for ensuring the integrity of the entire system.
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Part Leak - for measuring any leakage in the path from upstream of the sonic nozzle to the part fixture.
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This routine compensates for varying fixture volumes.
Fixture Flow Restriction
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For testing the air flow restriction caused by the Unit Under Test (UUT) part fixturing.
Maintenance
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Allows the user to manipulate all system controls and read all system sensors.
As with 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 a high-availability for the Test System.
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AIR FLOW TEST SYSTEM SPECIFICATIONS
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Flow Elements:
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Standard:
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9 Sonic Nozzles with a binary progression in throat area
(diameters range from 0.044" to 0.707")
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Option 1:
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10 Sonic Nozzles with a binary progression in throat area (diameters range from 0.031" to 0.707").
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Option 2:
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11 Sonic Nozzles with a binary progression in throat area (diameters range from 0.031" to
1.000").
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Air Mass Flow Range:
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Standard:
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0.001 to 0.9
lbm/sec 900:1 Turndown
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Option 1:
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0.0005 to 0.9
lbm/sec 1800:1 Turndown
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Option 2:
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0.0005 to
2.0 lbm/sec 4000:1 Turndown
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(Refer to FLOW SYSTEMS' Technical Note "Flow Bench
Capabilities" for detailed Test Measure Ranges,
Effective Area, Flow Parameter, Reduced Mass Flow. All Technical Data available in hard copy or online.)
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Part Pressure Range:
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1.0 to 20.0 psig
(other, custom ranges available upon request).
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Part Pressure Ratio Range:
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1.07
to 2.36 psig (other, custom ranges available
on request). |
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Accuracy:
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+/- 0.48 % of reading, traceable to NIST standards.
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(Refer to FLOW SYSTEMS' Technical Note "Low & High Flow Systems Uncertainty
Analysis".)
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Repeatability:
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Less than +/- 0.25% as defined as 2 standard deviations divided by the mean of 20 identical samples.
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Cycle Time:
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20 to 60 seconds depending on percent of maximum capacity.
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Connections: |
Flow Ports:
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Low Flow Port - 2.5" Sanitary Flange
High Flow Port - 6.0" Sanitary Flange
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Pressure:
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-4 Swagelok Instrumentation Female Quick Connectors QC series, color keyed
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Dimensions:
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65 in. H x 62 in. W x 36 in. D
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Weight:
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1000 lbs.
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Facility Requirements* |
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Electrical Power |
100
- 240 VAC / 50 - 60Hz /
1pH, 7.5 - 15Amp
(Option: 230VAC / 50Hz / 1pH) |
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Inlet Air Connection |
2" 150# ANSI Flange |
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Pressure Range |
70 to
100 psig |
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Temperature Range |
60° to
90°F |
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Particulates |
Less than
5 microns |
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Oil Content |
Less than 10 ppm |
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Dew Point @ >100psig |
Less than
39°F |
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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 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.
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OPTIONS
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Dual Regulators for Ultra High Flow.
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Software Customization including database integration, networking, SPC (Statistical Process Control) and more.
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Part Fixturing and Tooling.
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Compressors, dryers, filters and receivers.
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On-site installation, training, commissioning and upgrades.
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Heat exchangers, Dewpoint alarm.
SYSTEM
CHECK STANDARDS
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Sonic Nozzles
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Inlet Sections
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Silencers
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Flow Computers - FC175,
FC500
REFERENCE
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Technical Notes Available.
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Accuracy / Uncertainty Analysis.
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Capabilities.
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Custom Software.
Sonic Nozzle
Air Calibration Cart with High Flow Bench for Audit
Checks.
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