Body Leakage Test Stand - 2nd GenerationProduct Summary

The Gas Flow Calibrator is a piston-prover-based test stand utilizing sonic nozzles to provide metrology for all gas metering technologies.
This system:

  • calibrates flow meters at pressures ranging from atmospheric to 150 psig
  • tests flow meters both at atmospheric and elevated pressures
  • supports a wide variety of meter types (listed below)
  • does not require tight environmental temperature control
  • supports common calibration gasses

Key Features
  • Scaleable expansion in mass flow and accuracy
  • No constraints on test-section diameter or length
  • Scaleable range and accuracy utilizing a single system controller
  • No oils or hazardous materials (Mercury) required
  • Total automation with closed loop control

Meter Types Supported

The Gas Flow Calibrator can calibrate flow meters for the following meter types:

  • Turbine
  • Vortex
  • Dp (Venturi, Flow Nozzle, Orifice, Annubar, Vcone) (Dp Transducer Optional)
  • Laminar Flow (Dp Transducer Optional)
  • Thermal Mass
  • Visual (Variable Area (Rotameter), Target)
  • Sonic Nozzle / Critical Flow Venturi
  • Positive Displacement / Rotary
  • Ultrasonic
  • Coriolis

How does this calibrator work?

The test stand utilizes a dried and filtered, compressed gas supply, provided by the customer. Metering is provided by a manifold of Flow Systems’ sonic nozzles, having a binary progression in throat area. Low flow capacity is achieved using a Bios International Dry Cal ML Series Dry Seal Piston Prover (no Mercury). The system may be configured with one, two, or three manifolds depending on the desired flow range. Calibrations may be performed by installing a Unit Under Test either upstream or downstream of the sonic nozzles. The upstream location is for testing at elevated pressures, while the downstream location is designed to test Unit Under Tests at near atmospheric conditions. Instrumentation (pressure and temperature) monitors the inlet conditions to both the sonic nozzles and Unit Under Test.

Vacuum System Model

A vacuum version of this system is available for customers needing only to calibrate meters with air at atmospheric conditions. This system uses a single sonic nozzle manifold that may be populated with 11 nozzles having a binary progression on throat area. The Gas Flow Calibrator Vacuum system includes a dew point sensor.

Traceable to NIST

All Flow Systems air test stand sonic nozzles and instruments are traceable to National Institute of Standards and Technology (NIST).

System Specifications

The following are the specifications for the Gas Flow Calibrator:

System Inputs

The scaling for the signal is selected by the operator. A differential pressure transducer or signal conditioning for the input signal are also available options.

Input Type Measurement Range Accuracy # of Channels
Frequency 10 to 5000 Hz ± 1 Microsecond 1
Current 4 to 20ma dc ±0.015% of Reading 1
Voltage 0 to 10v dc ±0.06% of Reading 1

System Outputs
Outputs Type Measurement Range Accuracy # of Channels
Current 4 to 20ma dc ±0.015% of Reading 1
Voltage 0 to 10v dc ±0.06% of Reading 1

These channels in addition to all pressure, temperature, and flow measurements are calibrated against NIST traceable standards.

System Accuracy
Reading Type Accuracy Rating
Mass Flow ±0.39% of Reading (Standard)
±0.30% of Reading (Optional)
±0.17% of Reading (Optional)
Volume Flow through Unit Under Test ±0.42% of Reading (Standard)
±0.34% of Reading (Optional)
±0.20% of Reading (Optional)
Pressure (Barometric to 100 psig) ±0.12% of Reading (Standard)
±0.07% of Reading (Optional)
Temperature ((10° to 32°C) 1000Ω, Thermister) ±0.03% of Reading, ±0.1°C
Currrent (4 to 20 ma dc) ±0.015% of Reading
Voltage (0 to 10vdc) ±0.06% of Reading
Frequency (10 to 5000Hz) ±1 Microsecond

Additional Specifications
Specification Value(s)
Repeatability Less than ±0.25% as defined as 2 standard deviations divided by the mean of 20 identical samples using a sonic nozzle
Cycle Time 90 to 120 seconds depending on flow rate
Base Unit Dimensions 67″ H x 53″ W x 32″ D

Uncertainty Analysis

For information on uncertainty analysis for this equipment refer to Uncertainty Analysis in Gas Flow Measurement When Using Sonic Nozzles.

Operating Envelope Diagrams

A Scalable pressurized system that can be configured with 6, 9, 12 or 13 Sonic Nozzles for a range of 8,192:1 for upstream (elevated pressure) testing or 24,576:1 for downstream (atmospheric pressure) testing with most common calibration gasses.

Vacuum system with 11 Sonic Nozzles will provide a 2088:1 range for testing meters at atmospheric conditions using ambient air.

Gas Flow Calibrator Specifications Image 1

Production Screen: Graph View

Gas Flow Calibrator Specifications Image 2

Production Screen: Graph View

Gas Flow Calibrator Specifications Image 3

Production Screen: Graph View

Software

National Instruments LabVIEW Logo
Control System Operator Interface

The system controller software manages and measures flowrates based on user-definedtest plans. These test plans are used to control flow rate by adjusting the configuration of the internal sonic nozzles. Controller software is written using National Instruments LabVIEW™.

Create Flow Rate Test Plans Specifying a Variety of Parameters
  • Flow rates can be measured in: mass rate, actual volumetric rate, standard volumetric rate, pipe Reynolds number, throat Reynolds number, pressure range or dp range
  • Readings can be taken for: pressure, temperature, frequency, voltage and current
  • Values such as number of points, time between points, flow direction, etc. can be specified
  • Test plans can be run repeatedly
Report Live Data and Compare to Historical Data
  • On-screen tabular and graphed results displayed in real-time
  • Live data can be plotted against previous data for historical analysis
  • Variety of user-customizable reports
  • Allows the operator to read all system sensors, and read status and error messages
Customize Controller Software and Integrate Data
  • Controller software can be customized to fit a wide variety of customer needs
  • Data can be integrated with customer’s local databases and/or information systems
Data Storage Formats
  • Standard storage format is SQL database
  • Customized data storage options available
Specify Settings for When Data Points Are Recorded
  • “Last Match”: The user records a data point, then configures the system so that future data points must be within a specific percent difference from the original data point
  • “All Data”: All data points are recorded– there is no filtering based on user or system defined parameters
  • “All Within Limits”: The user enters the parameters (temperature, pressure, flowrate, etc.) that define a valid data point, then the system only records a sampling of data points that fall within these parameters
  • “Averaging Length”: The system records all data points taken for a user-defined time limit
Configure Instrument Calibration Settings
  • Calibration coefficients for instruments connected to the Gas Flow Calibrator (i.e. pressure transducers, RTD’s, and dew point transmitters) can be generated then saved to file, which can then be associated with instruments
Determine Average Value & Repeatability of Master/System Unit Under Test
  • Measures the repeatability, average and percent difference (measured and calculated) of a series of consecutive flow tests through a master Unit Under Test
  • Performs test stand audits by measuring the repeatability, average and percent difference of a calibrated master sonic nozzle against the installed system nozzles
System Accuracy Check
  • Measures the repeatability, mass flow and percent difference of a calibrated master sonic nozzle against one or more installed system sonic nozzles
Troubleshoot & Diagnose System and Part Leaks
  • Leak Test Diagnostics: Test the system and attached customer part fixtures for leaks
  • Critical Flow Venturi (CFV) Valve Leak Check Diagnostics: Determine the seal integrity of the CFV valves
  • Data Acquisition Device Diagnostics: Self-check to determine status and communication with data acquisition hardware and instrumentation
Troubleshoot Issues Using Internet-based Support – Optional
  • After connecting the test stand to the internet, receive technical support from Flow Systems
Additional Software Screenshots
Calibration Profile Configuration

Calibration Profile Configuration

Graphing Configuration

Graphing Configuration

Main Production Screen

Main Production Screen

System Diagnostics

System Diagnostics

Report Configuration

Report Configuration

View Data Point Details

View Data Point Details

System Audit Configuration

System Audit Configuration

Data Graphing Tool

Data Graphing Tool

Instrument Calibration Coefficients Entry

Instrument Calibration Coefficients Entry

System Exerciser (troubleshooting utility): Pressure Model

System Exerciser (troubleshooting utility): Pressure Model

System Exerciser (troubleshooting utility): Vacuum Model

System Exerciser (troubleshooting utility): Vacuum Model

Facility Requirements

The facility requirements below are to be supplied by the customer at the installation site.

Electrical Power: 100 – 240 VAC / 50 – 60Hz / 1pH / 7.5 – 15 Amp (Option: 220VAC / 50Hz / 3pH)

Compressed Air Requirements
Pressure Range: 70 to 150 psig
Temperature Range: 60° to 90°F
Particulates: < 5 microns
Oil Content: < 10 ppm
Pressure Dew Point (Air only): < 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 will allow for maximum flow at less than 100% duty cycle.

Photos & Schematics

Additional Software Screenshots

Gas Flow Calibrator with Attachment Cart

Gas Flow Calibrator with Attachment Cart

Gas Flow Calibrator: Top View Close-up

Gas Flow Calibrator: Top View Close-up

Gas Flow Calibrator – Vacuum System Schematic

Gas Flow Calibrator - Vacuum System Schematic

Gas Flow Calibrator – Physical Schematic

Download / View Schematic as PDF Gas Flow Calibrator - Physical Schematic

Gas Flow Calibrator: Vacuum System – Front View

Download /View Physical Schematic as PDF Gas Flow Calibrator: Vacuum System - Front View

Gas Flow Calibrator: Front View with Gray Panels

Gas Flow Calibrator: Front View with Gray Panels

Gas Flow Calibrator: Vacuum System – Rear View

Gas Flow Calibrator: Vacuum System - Rear View

Gas Flow Calibrator

Gas Flow Calibrator

Gas Flow Calibrator: Pneumatic and Instrumentation Diagram

Download /View Pneumatic and Instrumentation Diagram as PDF Gas Flow Calibrator: Pneumatic and Instrumentation Diagram

Gas Flow Calibrator: Pneumatic and Instrumentation Diagram

Gas Flow Calibrator: Pneumatic and Instrumentation Diagram

Gas Flow Calibrator Vacuum System Being Constructed

Gas Flow Calibrator Vacuum System Being Constructed

Gas Flow Calibrator Vacuum System Being Constructed

Gas Flow Calibrator Vacuum System Being Constructed

Options

The following is a list of options available for this test system:

  • Heat exchangers
  • Receiver tanks
  • Filters
  • Compressors and dryers
  • Humidity/Dewpoint instrumentation
  • Test section piping and adapters
  • System check sonic nozzles and instrumentation
  • On-site installation,training, commissioning and upgrades
  • Calibration
  • Software customization including database integration, networking, SPC (Statistical Process Control) and more
System Check Standards

The following optional additions are available to monitor the ongoing system accuracy and can also be used to diagnose problems: