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

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.

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