Details

Introduction
Flow dividers are the quiet “truth tellers” of fuel and fluid circuits. Wherever one supply line needs to be split into multiple outlets with predictable, repeatable distribution, a flow divider is the component that decides whether the system runs smoothly or slowly drifts into trouble. They are commonly used in fuel distribution manifolds, engine and propulsion test rigs, multi-injector or multi-nozzle supply circuits, hydraulic and lubrication systems, industrial burners and dosing lines, and other applications where several consumers must receive near-equal flow under changing load and operating conditions.

The criticality is simple: if a divider does not distribute flow accurately, the downstream system may see uneven fueling/dosing, localized heating, performance imbalance, component stress, and repeatability failures that are notoriously hard to diagnose because they can appear only at certain combinations of RPM, pressure, viscosity, and temperature. A divider might look acceptable at one steady condition and still misbehave in real operation—especially at low flow (where internal leakage and friction dominate) or at high load (where differential pressure drives error). That’s why a proper test bench matters: it creates a controlled environment where distribution can be measured port-by-port, under stable and repeatable conditions, and the results can be logged and compared across units, batches, or life-cycle tests.

This system is a purpose-built 16-port flow divider characterization test bench for diesel/fuel circuits. It combines a stable fuel supply loop, dual-range flow measurement, controlled back-pressure loading, sequential outlet switching, and SCADA/HMI-based automation to deliver high-confidence, repeatable distribution data—with a build philosophy suitable for fuel-handling and hazardous-area type environments.

What the system is designed to achieve
1) Port-wise distribution mapping (the core purpose)
The bench measures the flow at each outlet one port at a time using an automated switching strategy:
• The selected port is routed to the Test Header for measurement.
• All non-selected ports are routed to the Return Header and recirculated back to the tank.
• The system repeats this sequence for all 16 ports, automatically or manually.

This approach produces a clean and comparable “port map” showing:
• Flow per port at a given RPM, pressure, and temperature
• Average flow across ports
• Deviation of each port from average
• Repeatability across cycles and across different flow divider units

2) Coverage of real-world operating regimes
The bench is intended to evaluate performance across the regimes where flow dividers typically show their true behavior:
• Low-flow metering: where leakage, friction, and internal clearances strongly influence distribution.
• Rated-flow distribution: where hydraulic loading, back pressure, and stability dominate.
• Start-up / breakaway behavior (where applicable): capturing transient response and the conditions required to initiate stable operation.

3) Repeatability that is not dependent on operator technique
Manual testing often suffers from timing differences, inconsistent valve handling, and unstable stabilization time. This bench supports:
• automatic port sequencing
• defined dwell/stabilization intervals
• consistent measurement timing
• structured data logging and reporting

4) Qualification-style traceable output
The control system is built to deliver practical outputs:
• time-stamped logs
• port-wise tables
• acceptance verdicts based on defined criteria (deviation limits, stability thresholds, pressure window, etc.)
• alarm/trip history and operator actions (useful during investigations and audits)

System architecture (how it works)
A) Fuel supply and conditioning loop (diesel service)
At the core is a closed-loop diesel circuit engineered for stable test conditions:
• Diesel reservoir tank in stainless construction, sized to provide thermal mass and stable suction conditions.
• Drain-friendly bottom geometry to support cleanout and maintenance.
• Suction protection to prevent pump damage from coarse contaminants.
• Multi-stage filtration to protect the DUT, switching valves, and meters while ensuring stable measurements.
• Temperature conditioning using a chiller/heat exchanger so the same divider can be tested at repeatable temperatures (important because viscosity changes with temperature and affects flow distribution).
• Level monitoring and protection to avoid dry running, aeration, and unsafe operation.
Practical benefit: this loop prevents “false failures” caused by unstable fluid temperature, air entrainment, or contamination.

B) Pumping and flow stability
A high-capacity positive displacement pumping package supplies the necessary total flow for a 16-outlet DUT. The drive is VFD-controlled so speed (and therefore flow) can be ramped and stabilized smoothly. Stable inlet conditions are critical—any pulsation or starvation can appear as distribution error and distort results.

C) 16-port switching and header logic (the key enabler)
Each outlet port is connected through a dedicated switching element so the bench can route:
• Port N → Test Header → Flow measurement → Return
• All other ports → Return Header → Tank

This design makes the testing fast, repeatable, and safe compared to manual hose swapping. It also maintains continuous recirculation so the fluid condition remains stable while ports are tested sequentially.

D) Back-pressure module (realistic load simulation)
A controlled back-pressure valve provides adjustable loading so the divider can be tested at realistic system pressures. This is crucial because distribution can change under load: back-pressure stability is what makes port-to-port comparisons valid.

E) Instrumentation and metrology (wide range without compromise)
To get meaningful data across operating regimes, the bench employs:
• Dual-range flow measurement (high-flow and low-flow meters) to maintain accuracy from very low flows up to full system flow.
• Pressure and temperature transmitters for stable monitoring and SCADA logging.
• Local gauges for quick operator sanity checks during setup and troubleshooting.
This gives the bench both high-resolution low-flow metering capability and full-capacity rated-flow capability without sacrificing measurement quality.

F) Control, automation, and operator interface
The bench is designed for both production-like repeatability and development flexibility:
• Automatic mode: port sequencing, stabilization, logging, pass/fail.
• Manual mode: direct operator control for engineering trials, troubleshooting, and calibration checks.
• HMI interface: setpoints (RPM, pressure), port selection status, live readings (flow/pressure/temp), alarms/trips.
• SCADA logging: structured test results for traceability and comparisons.

G) Safety and fuel-handling readiness
Fuel circuits demand a safety-oriented design approach. The bench includes:
• emergency stop and controlled shutdown
• overload/overpressure protections
• interlocks and alarm logic
• appropriate component selection for fuel service and hazardous-area type environments
• good industrial practices: earthing/bonding provisions, protected routing, and robust enclosure selection

Typical test workflows (how a test run looks)
Workflow 1: Low-flow distribution test
1. Stabilize tank level and temperature.
2. Set low RPM and target back pressure (if needed).
3. Run automatic port sequencing with a defined dwell per port.
4. Record port-wise flows, compute deviations, and assess repeatability by running multiple cycles.
What it catches: leakage imbalance, internal friction issues, sensitivity to viscosity, early-life defects.

Workflow 2: Rated-flow distribution test (low pressure + high pressure)
1. Ramp to rated RPM under controlled conditions.
2. Run a complete port map at low pressure.
3. Increase back pressure to high condition and repeat.
4. Compare deviation signatures across both conditions.
What it proves: performance under realistic load and stability across pressure conditions.

Workflow 3: Start-up / breakaway behavior (where applicable)
1. Start from a controlled initial condition.
2. Observe transient response and stabilization behavior.
3. Identify abnormal signatures indicating sticking, high friction, or internal wear.

Technical Specifications (Detailed)
Where parameters are application-dependent, the bench is configurable within its hardware capability. The following table describes a detailed capability set aligned to this system’s build class.
1) General & Mechanical

  

    
Parameter
    
Specification
  
  

    
System type
    
Multi-port flow divider test bench (diesel/fuel circuit)
  
  

    
DUT capacity
    
16 outlet ports
  
  

    
Measurement method
    
Sequential port routing to Test Header; non-selected ports to Return Header
  
  

    
Operating modes
    
Automatic sequencing + Manual testing
  
  

    
Approx. overall footprint
    
~2600 mm (L) × ~1200 mm (W)
  
  

    
Approx. overall height
    
~1800 mm
  
  

    
Mounting / frame
    
Industrial skid-mounted structure with service access for valves, filters, meters
  
  

    
Hose assemblies (typical)
    
~20 hoses (test + return + utility connections)
  


2) Test Fluid, Reservoir & Conditioning

  

    
Parameter
    
Specification
  
  

    
Working fluid
    
Diesel / fuel media
  
  

    
Reservoir construction
    
Stainless steel tank, drain-friendly geometry
  
  

    
Tank capacity class
    
800 L class (typical) / 500 L class (alternate configuration)
  
  

    
Temperature conditioning
    
Chiller / heat exchanger loop for controlled fluid temperature
  
  

    
Temperature sensing
    
Transmitter for logging + local indicator (gauge)
  
  

    
Level monitoring
    
Level gauge + level switch (alarm/trip logic capable)
  
  

    
Drain / maintenance
    
Drain points and service access provisions for cleaning and filter changes
  


3) Pumping & Drive System

  

    
Parameter
    
Specification
  
  

    
Pump type
    
Positive displacement pump (gear type class)
  
  

    
Nominal system flow capability
    
~250 L/min class
  
  

    
Motor type
    
Industrial flameproof / fuel-handling suitable motor
  
  

    
Motor power class
    
~11 kW (typical build class)
  
  

    
Speed control
    
VFD with smooth ramping and stable RPM holding
  
  

    
Purpose of VFD
    
Repeatable RPM setpoint control, controlled start/stop, reduced hydraulic shock
  


4) Flow Measurement (Dual-Range)

  

    
Parameter
    
Specification
  
  

    
High-range meter purpose
    
Full system / rated-flow operation
  
  

    
High-range flow capability
    
~1 to 250 L/min class
  
  

    
Low-range meter purpose
    
Low-flow metering and high-resolution distribution checks
  
  

    
Low-range flow capability
    
~0.03 to 40 L/min class
  
  

    
Measurement principle
    
Positive displacement / gear-type metering suitable for hydrocarbon fuels
  
  

    
Instrument interfacing
    
Industrial analog/pulse interfacing with safe signal conditioning
  
  

    
Per-port flow capability
    
Up to ~14 L/min (3.5 GPM) per port
  


5) Pressure Control, Loading & Protection

  

    
Parameter
    
Specification
  
  

    
Back-pressure control
    
Adjustable back-pressure control valve
  
  

    
Typical test pressure capability
    
Up to ~300 psi class
  
  

    
Pressure measurement
    
Transmitters for logging + local gauges
  
  

    
Circuit protection
    
Relief valves, trips, safe shutdown logic
  


6) Filtration & Cleanliness Control

  

    
Parameter
    
Specification
  
  

    
Suction protection
    
High-flow suction strainer
  
  

    
Fine filtration
    
Multi-stage filtration (typical 10 µm + 6 µm)
  
  

    
Filter serviceability
    
Accessible housings with clog indication provisions
  
  

    
Benefit
    
Protects DUT and metering equipment; improves repeatability
  


7) Port Switching & Headers

  

    
Parameter
    
Specification
  
  

    
Number of switching points
    
16 (one per port)
  
  

    
Switching logic
    
One port to Test Header; remaining ports to Return Header
  
  

    
Valve type
    
Solenoid / actuated switching valves for fuel service
  
  

    
Header arrangement
    
Dedicated Test Header and Return Header
  
  

    
Key benefit
    
Fast, repeatable testing without hose swapping
  


8) Controls, HMI/SCADA & Reporting

  

    
Parameter
    
Specification
  
  

    
Automation platform
    
HMI + SCADA based control and monitoring
  
  

    
Automatic functions
    
Port sequencing, stabilization/dwell timing, logging, report generation
  
  

    
Manual functions
    
Direct port selection, jog/override, troubleshooting mode
  
  

    
Data logging
    
Time-stamped flow/pressure/temp/RPM data + per-port results
  
  

    
Output format
    
Port-wise tables, deviation %, acceptance verdict, alarms/trips history
  
  

    
Operator interface
    
Live mimic with valve status, trips, key process values
  


9) Safety & Fuel-Handling Readiness

  

    
Parameter
    
Specification
  
  

    
Safety systems
    
E-stop, interlocks, trips, overload protection, controlled shutdown
  
  

    
Electrical philosophy
    
Fuel-handling / hazardous-area oriented component selection
  
  

    
Earthing / bonding
    
Provisioned to minimise static risk
  
  

    
Service safety
    
Drain points, isolation provisions, maintenance-friendly layout
  


Key advantages (why this bench is the right approach)
• Port-by-port certainty: you don’t infer distribution—you measure it.
• Fast testing: 16 ports can be mapped quickly with sequencing rather than manual replumbing.
• Realistic operating conditions: back-pressure loading and temperature conditioning reveal real behavior.
• Wide measurement range: dual-range metering keeps accuracy intact at both low and rated flow.
• Traceable results: SCADA logging and structured reporting support qualification, audits, and comparisons.
• Reduced troubleshooting time: abnormal divider signatures become visible immediately in a port map.

Common options (if you want to make it even more powerful)
• Recipe-based testing (predefined RPM/pressure/temperature profiles)
• Auto-stability detection (log only after values settle within tolerance)
• Statistical reporting (mean, standard deviation, repeatability index per port)
• Serial number / barcode tracking for batch testing
• Additional temperature points (tank + inlet + outlet) for tighter viscosity control
• Higher pressure variant or additional loading module (if future DUTs require it)
• Remote monitoring and automatic report export