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Mega Air Flow Test System
(Dimensions vary by Application,
Contact FLOW SYSTEMS for Details)
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home
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JET ENGINE / GAS TURBINE COMPONENTS
Air Flow -
Mega Flow Test
System
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DESCRIPTION
Aerospace
OEMs and their suppliers require quality airflow
measurements of large Effective Area (>13in^2@ PR =
1.05) passages in both aircraft and land-based turbine
engine components such as Combustion Liners and Vane
Segments. Accuracy,
repeatability, throughput and availability are critical
elements in the design of the Mega Air Flow Test System.
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SYSTEM REQUIREMENTS
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Large Flow Rate, > 2.0 lbm/sec
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Accurate Measurement
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Highly Repeatable Results
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Small Footprint
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Flexible Testing for various Customer / Supplier /
OEM Testing
Specifications
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Dedicated Air Receiver Tank
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User-friendly Controller Software
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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 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, Siemens-Power Generation, Snecma, and
many others. (Click here for a complete List
of Clients.)
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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.
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Shown
with Optional, Multiple Tank Arrangement
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SYSTEM SCHEMATICS
The Test Stand is an Air Flow Metering System that employs a
single, manually interchangeable Sonic Nozzles (Critical Flow
Venturis) 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 that the sonic nozzles are in a "choked" state and that the flow is stable within +/-0.1% of the pressure ratio setpoint.
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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Measures the
repeatability, average and percent difference
(measured-to-calculated) of a series of consecutive
flow tests through a master UUT.
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 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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AIR FLOW TEST SYSTEM SPECIFICATIONS
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Flow Elements:
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Configuration A -
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1.414"
throat diameter Sonic Nozzle. |
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Configuration B -
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2.000" throat
diameter Sonic Nozzle. |
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Configuration C -
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2.828" throat
diameter Sonic Nozzle. |
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Configuration D -
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4.000" throat
diameter Sonic Nozzle. |
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Air Mass Flow Range:
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Configuration A -
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1.0
to 2.0 lbm/sec 2:1 Turndown |
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Configuration B -
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2.0
to 4.0 lbm/sec 2: 1 Turndown |
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Configuration C -
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4.0
to 8.0 lbm/sec 2: 1 Turndown |
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Configuration D -
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8.0
to 16.0 lbm/sec 2: 1 Turndown |
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If Pressure Ratio Equals 1.049, multiply
lbm/sec values above by 6.45 to estimate
Effective Area in square inches.
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Part Pressure Ratio Range:
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(1.02 to 1.15) (8 to 55" H2O at 68°F)
(Other, custom ranges available upon request.) |
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Accuracy:
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+/- 0.48% of reading.
Refer to
FLOW SYSTEMS' Technical Document, "Error Analysis -
Flow Measurement Accuracy FLOW SYSTEMS Low
& High Flow Sonic
Nozzle-Based Turbine Component Airflow Test Stand".
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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:
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Flow Ports -
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To
be determined based on system requirements. |
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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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To be determined based on system requirements.
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Weight:
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To be determined based on system requirements.
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Facility Requirements* |
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Electrical Power |
100-240VAC
/ 50-60Hz / 1pH, 7.5-15 Amp |
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Inlet Air Connection |
¾ in. to 1.5 in. FNPT based on configuration |
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Pressure |
70 to
100 psig |
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Temperature |
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: 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.
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FLOW SYSTEMS Turbine Engine Component
Mega Air Flow Test System
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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