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Standard Turbine Engine Component
Air Flow Test System
Front View
Low Flow Configuration
Dimensions: 65 in. H x 58 in. W x 36 in. D
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JET ENGINE / GAS TURBINE COMPONENTS
Air Flow - Low Flow Test Stand
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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 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
America, Pratt & Whitney Canada, General
Electric Aircraft Engines, General Electric Power
Systems, Mitsubishi Power Systems, Mitsubishi Heavy Industries, Allison
Engine, Rolls-Royce, Solar Turbines, Siemens,
Siemens-Westinghouse, Snecma,
and many others.
(Click Here for a complete Client
List.)
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| Operator and Connection Panel (on System Front) |
System Back View
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The Test Stand is an Air Flow Metering System that employees a set of up to Nine (9)
Sonic Nozzles (Critical Flow
Venturis) housed in a common-inlet / common-exit manifold to meter the airflow through each Unit Under Test
(UUT).
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
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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 and 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 UUT.
Test Scheduler
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Automated Test Sequencer.
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Allows configured tests to be executed in a sequence.
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Virtual tests can be programmed in the schedule 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 and Temperature Instrumentation Calibration
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Software for complete on-bench instrument calibration.
System Accuracy Test (Audit Test)
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Measures the repeatability, average and percent difference of a calibrated master sonic nozzle (critical flow venturi) 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 airflow restriction caused by the UUT part
fixturing.
Maintenance
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Allows the user to manipulate all system controls and read all system sensors.
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All FLOW SYSTEMS' Test System Designs, Test System Controllers, 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.
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AIR FLOW TEST SYSTEM SPECIFICATIONS
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Flow Elements:
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Standard:
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6 Sonic Nozzles with a binary progression in throat area (diameters range from 0.031" to 0.177").
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Option 1:
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7 Sonic Nozzles with a binary progression in throat area (diameters range from 0.022" to 0.177").
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Option 2:
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7 Sonic Nozzles with a binary progression in throat area (diameters range from
0.031" to 0.250").
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Air Mass Flow Range: |
Standard:
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0.0005 to 0.1 lbm/sec 200:1 Turndown
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Option 1:
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0.0003 to 0.1 lbm/sec 333:1 Turndown
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Option 2:
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0.0005 to 0.22 lbm/sec 440:1 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
is available in hard copy or online.)
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Part Pressure Range:
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0.5 to 50 psig (Other, custom ranges available upon request).
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Part Pressure Ratio Range:
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1.04 to 4.4 (Other, custom ranges available upon 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 40 seconds depending on percent of maximum capacity.
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Connections: |
Flow Ports: |
-12 Swagelok Full Flow Female Quick Connectors QF
(-16 on Option 2.) |
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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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66 in. H x 58 in. W x 36 in. D
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Weight:
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800 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 |
¾ in. FNPT |
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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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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
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