Product Summary
The Mega Flow Air Test Stand is an air flow measurement system specially designed for highly accurate and repeatable measurement at high flowrates. It measures air flow for large aircraft and land-based, gas turbine parts, and meets a wide range of component flow range air testing needs of OEMs and their suppliers.
Key Features
Large Flow Rates (Up to 16 lbm/sec)
Highly Repeatable Results (Less than ±0.25%)
Measures airflow of large effective area (greater than 13 inch2 at PR = 1.05) passages in both aircraft and land-based turbine engine components (like Combustion Liners and Vane Segments)
Small Footprint
Dedicated Air Receiver Tank
Uses a single, manually interchangeable sonic nozzle to measure flow
Highly customizable controller software for test automation and data management
How does this flow controller work?
This test stand is a sonic nozzle (critical flow Venturis) based airflow test instrument for measuring the flow parameters of flow circuits. The test station contains critical flow Venturi manifolds, piping and pneumatic control hardware, a data acquisition and switching control hardware, pressure and temperature measurement instrumentation, and a computer with control software. The computer software handles the opening and closing of critical flow Venturi flow paths and calculates airflow rates based on sensor inputs. The software also monitors the airflow conditions to ensure the sonic nozzles are in a “choked” state and that the flow is stable. The software allows for generating, saving, and recalling test configuration data as well as configuring, saving and printing test results data.
Related Products for Measuring Different Flow Ranges
The Low Flow Air Test Stand is one in a series of air flow test stands designed for the aerospace and turbine engine-based component industries. These test stands are designed to provide complete, automated solutions for flow measurement.
For information on related products, read the Air Flow Test Stand Product Comparison.
Complies with OEM Test Specifications
OEMs and their suppliers worldwide require quality airflow measurement 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 these test systems. These air flow test systems currently comply 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 Infra, Aviation), General Electric Power Systems (General Electric Infra, Energy), Honeywell, Mitsubishi Power Systems, Mitsubishi Heavy Industries, Allison Engine, Rolls-Royce, Solar Turbines, Siemens, Siemens-Westinghouse, Snecma, and many others.
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 Mega Flow Air Test Stand come in four configurations:
Configuration | Air Mass Flow Range | Sonic Nozzle Throat Diameter |
---|---|---|
Conifuration A | 1.0 to 2.0 lbm/sec* | 1.414″ |
Conifuration B | 2.0 to 4.0 lbm/sec* | 2.000″ |
Conifuration C | 4.0 to 8.0 lbm/sec* | 2.828″ |
Conifuration D | 8.0 to 16.0 lbm/sec* | 4.000″ |
* If Pressure Ratio Equals 1.049, multiply lbm/sec values above by 6.45 to estimate Effective Area in square inches.
Additional Specifications
Specification | Value(s) |
---|---|
Part Pressure Ratio Range | 1.02 – 1.15, custom ranges available |
Accuracy | ±0.48% of reading |
Turndown | 2:1 |
Repeatability | Less than ±0.25%, defined as 2 standard deviations divided by the mean of 20 samples |
Cycle Time | 20 – 60 seconds, capacity dependent |
Flow Ports Connections | Based on customer requirement |
Pressure Connections | 1/4″ (-4) Swagelok Instrumentation Female Quick Connectors – QC series, color keyed |
Dimensions | Based on customer requirements |
Weight | Based on customer requirements |
Uncertainty Analysis
For information on uncertainty analysis for this equipment refer to Uncertainty Analysis in Gas Flow Measurement When Using Sonic Nozzles.
Built with Commercial Off-The-Shelf (COTS) Components
All Flow Systems air flow test system designs, the test system controller, data acquisition and control subsystems, and all instrumentation are standard and readily available Commercial Off-The-Shelf (COTS) items. This ensures that service or replacement of any item can be achieved in a timely manner, providing for high availability of our products. When applicable, this includes all of the Unit Under Test related instrumentation specified by the customer.
Software


The system controller software handles the opening and closing of sonic nozzle flow paths, sets the proper pressure at the inlet of the Unit Under Test and calculates the mass flow through the sonic nozzle manifold. The controller also monitors the airflow conditions to ensure the sonic nozzles are in a “choked” state and that the flow is stable within ±0.1% of the pressure ratio set point. Controller software is written using National Instruments LabVIEW™.
Report Live Data and Compare to Historical Data
On-screen tabular and graphical results are displayed in real-time
Variety of user-customizable reports
Allows the operator to read all system sensors, read status and error messages
Determines Test Measure Value Ranges of a Part
Allows the operator determine the “test measure” or flow value without knowing anything about the part other than the test setpoint
Used primarily for research and development to determine the test measures of a new or test part
Sets an upper and lower acceptance limit based upon the measured value and a user defined tolerance
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
Monitor Performance using Statistical Process Control (SPC) – Optional
SPC features provide the customer a method for monitoring the performance of the Unit Under Test in real-time and in relation to previous production parts to identify variations in the part production process
Develop and manage flow test configurations in conjunction with shop floor controlling information system
SPC features can be customized to suit customer’s quality control criteria
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
Allows the flow results of a master part to be included in the test report for other production parts, which allows the repeatability of the test bench to be monitored over time
Performs test stand audits by measuring the repeatability, average and percent difference of a calibrated master sonic nozzle against the installed system nozzles
Tests and Suggests Proportional-Integral-Derivative (PID) Parameters
The system flows the Unit Under Test and uses the natural response of the system to calculate Proportional-Integral-Derivative (PID) parameters
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
Manifold Leak Test Diagnostics: Determine the leakage of internal test stand pressure manifolds to ensure integrity of test stand
Data Acquisition Device Diagnostics: Self-check to determine status and communication with data acquisition hardware and instrumentation
Test Fixture Flow Restrictions
Test the air flow restriction caused by the part fixturing
Troubleshoot Issues Using Internet-based Support – Optional
After connecting the test stand to the internet, receive technical support from Flow Systems
Additional Software Screenshots
Main Menu
Main Production Screen
System Diagnostics
Main Production Screen
System Diagnostics
Test Configuration
Facility Requirements
The facility requirements below are to be supplied by the customer at the installation site.
Electrical Power: | 100-240VAC / 50-60Hz / 1pH, 7.5-15 Amp |
Compressed Air Requirements
Electrical Power: | 100-240VAC / 50-60Hz / 1pH, 7.5-15 Amp | |
Inlet Air Connection: | 3/4″ – 1.5″ FNPT based on configuration | |
Pressure Range: | 70 – 120 psig | |
Temperature Range: | 60° – 90°F | |
Particulates: | < 5 microns | |
Oil Content: | < 10 ppm | |
Pressure Dew Point @ >100 psig: | < 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
The following are pictures and schematics of the Mega Flow Air Test Stand.
System Schematic
Mega Flow Air Test Stand
Pneumatic and Instrumentation Diagram
Shown with Optional, Multiple Tank Arrangement
Options
The following is a list of options available for this test stand:
Software customization including database integration, networking, SPC (Statistical Process Control), and more
Custom Fixturing Options
Compressors, dryers, filters and receivers
On-site installation, training, commissioning and upgrades
Heat exchangers and Dewpoint alarm
Silencers
System Check Standards
The following optional additions are available to monitor the ongoing system accuracy and can also be used to diagnose problems:
Sonic Nozzles
Flow Computer: FC175