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Mini Air Flow Test System
Nominal Dimensions:
54 in. H x 50 in. W x 24 in. D
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JET ENGINE / GAS TURBINE COMPONENTS
Air Flow - Mini Air Flow Test
System
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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 Mini Air Flow 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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Small Footprint for Manufacturing Cells
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Flexible for various Customer/Supplier/OEM Test 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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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 and Canada, General Electric Aircraft Engines, General Electric Power Systems, 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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Internal Components:
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SYSTEM SCHEMATICS
The Test Stand is an Air Flow Metering System that employs a set of
Six (6) 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 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 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.
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 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.
Optional 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 the schedule to calculate and evaluate results based on previous test values in algebraic equations.
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Enables stop/re-test of tests in the schedule.
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Programmable Pause.
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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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AIR FLOW TEST SYSTEM SPECIFICATIONS
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Flow Elements:
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Configuration A -
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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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Configuration B -
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6 Sonic Nozzles with a binary progression in throat area
(diameters range from 0.044" to 0.250").
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Configuration C -
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3 Sonic Nozzles with a binary progression in throat area
(diameters range from 0.354" to 0.707").
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Configuration D -
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4
Sonic Nozzles with a binary progression in throat area
(diameters range from 0.354" to 1.000"). |
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Air Mass Flow Range:
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Configuration A -
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0.0005 to 0.1 lbm/sec 200: 1 Turndown
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Configuration B -
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0.001 to 0.2 lbm/sec 200: 1 Turndown
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Configuration C -
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0.1 to 0.9 lbm/sec 9: 1 Turndown
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Configuration D -
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0.1 to 2.0 lbm/sec 20: 1 Turndown
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Contact FLOW SYSTEMS for High Flow Configurations.
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Part Pressure Range:
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1 to 20 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 upon request.)
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Accuracy:
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+/- 0.96% of reading.
Refer to FLOW SYSTEMS' Technical Document, "Error Analysis -
Flow Measurement Accuracy FLOW SYSTEMS Mini 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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Configuration A - 1.5" Sanitary Flange
Configuration B - 2.5" Sanitary Flange
Configuration C/D - 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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Nominal 54 in. H x 50 in. W x 24 in. D
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Weight:
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400 lbs. to 600 lbs. based on configuration.
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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: 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.
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*The Above Facility Requirements are to be supplied by the Customer at the Installation Site.
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FLOW SYSTEMS Turbine Engine Component Mini 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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