Specification - HS590-2 High Speed Hydraulic Dynamometer

1.0 INTRODUCTION

The Froude HS590-2 hydraulic dynamometer is rated at 6 000 kW (8 000 bhp) and has
a maximum operating speed of 16 500 rpm with non-continuous overspeed capacity to
17 500 rpm.

The HS range of dynamometers is designed to test industrial and marine gas and steam
turbines and module testing of aircraft gas turbines in many applications including
Research and Development, Production and Overhaul.

The HS range covers powers from 1,865 kW to 14,915 kW (1,210 BHP to 20,000 BHP)
in one direction of rotation. To cater for engines of opposing rotation the dynamometers
are fitted with two half couplings and can be turned through 180o, either by crane or an
optional pneumatic turntable.

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2.0 STANDARD FEATURES

• High accuracy strain gauge torque measurement system

• Electro-magnetic speed sensors (2 off)
• Two half couplings
• Low inertia
• Servo Electro-hydraulic water inlet and outlet valves
• Forced oil rolling element main shaft bearings
• Rolling element trunnion bearings
• Water inlet pressure switch
• Water inlet and outlet valve failsafe locking solenoids
• Water inlet thermocouple
• Water outlet thermocouple
• Shaft bearing thermocouples (2 off)
• Stand-alone hydraulic power pack
• Non-drive end water inlet connection
• Central bottom water outlet

3.0 OPTIONAL FEATURES (Refer to quotation)

• Calibration equipment comprising of lever arm weight pan and counter balance arm
• Twenty-Five 20kg cast iron weights certified to traceable national standards
• Twenty-Three 40lb cast iron weights certified to traceable national standards
• Alternative paint colour to Traffic Blue
• Drive end water inlet connection

4.0 DYNAMOMETER OPERATION AND CONSTRUCTION

The working compartment of a hydraulic dynamometer comprises of a shaft mounted

rotor and stators fixed in a casing. Each rotor and opposing stator face contain a series
of semi-circular cups and vanes arranged to accelerate and decelerate water flowing in a
toroidal vortex pattern around the working compartment. The constant exchange of
momentum of the water creates a torque reaction on the stator, and hence casing, which
is resisted and measured by a load cell bolted to the bedplate. The energy absorbed
heats the water, which is discharged through the outlet valve and away from the
dynamometer. Varying the amount of the water in the dynamometer controls the load.
This is achieved by modulating the outlet valve. The inlet valve controls the flow of water
into the dynamometer and should be reduced to a minimum when the dynamometer
shaft is stationary.

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A cross-sectional diagram of a typical dynamometer is shown below.

STATOR AIR VENT STATOR

STATOR WATER INLET COUPLING

SHAFT & ROTOR

PULSE PICK UP FORGING

STATOR WATER OUTLET RETURN RING

CHARACTERISED OUTLET
SHAFT SEAL DRAIN PIPING CONTROL VALVE

4.1 Shaft and Rotor Assembly

The shaft with integral cropped rotor is machined from a single stainless-steel forging to
resist the mechanical stresses generated by rotation at high speed and the effects of
high velocity water flow. The twin half couplings are produced in alloy steel and are oil
injected onto the main shaft forging maintaining a high degree of dynamic balance and
eliminating stress raising keyways and their related fatigue problems. The shaft
assembly rotates in precision, deep groove, rolling element bearings that are lubricated
by a force feed oil system. These bearings are protected from water leakage along the
shaft by a series of rotating multiple labyrinths, throwers, bush and air barrier seals.

4.2 Casing Assembly

The stators and return rings are precision cast in stainless steel to provide a long
working life. They are housed in a vertically split cast iron casing. The casing is
supported via rolling element bearings mounted in trunnion housings on the robust steel
fabricated bedplate. The fit of the trunnion bearings in the housings allows limited axial
float of the carcase to cater for any thermal growth of the engine and driveline, whilst the
use of high capacity trunnion bearings effectively eliminates the potential problem of
brinelling of the bearing surfaces.

The Froude water flow path through the working compartment ensures a long life for the
rotor and stators and allows fast fill and drain times increasing dynamometer response
rate. The inlet water is introduced at the low-pressure vortex centre and discharged at
the high-pressure vortex rim through the bottom of the stator cup.

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The Froude water outlet valve fitted at the bottom of the casing is ‘characterised’ to
approximate a linear control relationship. This maintains the dynamometers fast
response rate even at the extremes of the valve’s travel. An electro-hydraulic servo
valve and hydraulic actuator rotate the valve. Position is monitored by a feedback
potentiometer.

4.3 Bedplate Assembly

The inlet water connection flange is mounted on the dynamometer bedplate and is
connected to the casing assembly by a rigid axial transfer tube. The design permits
movement of the casing whilst minimising the effects of varying water supply pressure
on torque measurement. Water is discharged from the outlet valve and directed via an
outlet chute vertically to the water outlet connection flange on the bedplate. There is no
physical connection, and the water is open to atmospheric pressure on discharge. On
failure of electrical power, a failsafe solenoid valve hydraulically locks the outlet valve in
position.

High-pressure oil for the actuation of the water valves and shaft bearing lubrication is
supplied by a stand-alone hydraulic power pack. The bearing oil is scavenged from and
returned to tank through a heat exchanger.

Torque is measured using a load cell that is connected between the casing’s torque arm
and bedplate. It is accurately calibrated in the one direction by simply loading weights
onto a set of calibration arms attached to the casing. The calibration arms and weights
are offered as options with the dynamometer.

Shaft speed is measured by two pulse pick up sensors mounted on the casing detecting
a 60-tooth wheel on one half coupling.

4.4 Control System

Froude can supply a Texcel VX100 PRO dynamometer controller that also incorporates
signal conditioning for the dynamometer protection channels. Texcel VX100 PRO
provides constant speed, constant torque, power law and constant outlet valve position
modes of control.

The system uses feedback signals from the dynamometer’s speed sensor, load cell and
water valve’s position potentiometers. It has a low speed interlock that closes the water
inlet valve to prevent possible flooding of the shaft bearings when the dynamometer is
stationary. See separate Texcel VX100 PRO specification for details.

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5.0 PHYSICAL DIMENSIONS OF HS590-2 DYNAMOMETER

DIMENSIONS in mm .
A B B1 C D E F
1 061 565 650 1 120 650 390 1478
F1 G H J K
1085 425 510 318 271

Water Inlet Dimensions : 100mm nominal bore with 4x M16 tapped holes equally
spaced on a 170mm PCD. (BS EN1092-1 DN100 PN6
Flange)

Water Outlet dimensions : Bedplate bottom is counter bored 400mm diameter by

8mm deep. Water outlet is 250mm nominal bore with
12x M12 tapped holes by 20mm deep equally spaced on
a 335mm PCD. Water outlet chute protrudes 148mm
below base by 260mm outside diameter.

Half Coupling Size : Having a flange of 215mm diameter by 16 thick, with 6x

holes 16.018-16.000mm diameter through equally
spaced on a 180mm PCD and a male location spigot of
140.015-140.000mm diameter by 2mm high.

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5.1 Technical Data HS590-2 Hydraulic Dynamometer

General Arrangement Drawing : AH5900005

Dynamometer Weight (approx.) : 2 500 kg
Power Pack Weight (with oil) : 280 kg (with oil)
Inertia : 0.279 kgm2
Torsional Stiffness (half shaft) : 1.0 MNm/rad
Colour : Traffic Blue - RAL5017

Duty
Maximum Power : 6 000 kW (8 000 bhp)
Maximum Torque : 5 000 Nm (3 690 lbf.ft)
Maximum Speed : 16 500 rpm with non-continuous overspeed
capacity to 17 500 rpm
Capacity Diagram : M011669 (Based on a water temperature rise of
33ºC through the dynamometer)
Tandem Operation : Not possible with this model of dynamometer

Measurement Accuracy
Torque : Better than  12.5 Nm (0.25% of full-scale load) *
Speed :  1rpm *
Note: - * With Froude Texcel VX100 PRO Control System

Environmental Conditions
Operating Temperature : -10oC to 60oC
Maximum Humidity : 90% RH non-condensing
Note: - At low temperatures the water should be treated to prevent freezing within the
machine.

Dynamometer Water Supply

Outlet Temperature :
Not to exceed 71ºC
Flow Rate :
26.1 l/kW.h (Based on a water temperature rise
of 33ºC through the dynamometer)
Recommended Supply Pressure : 3.45 bar for full coverage of rated operating
curve. Lower pressures may be used for reduced
capacity operation, refer to factory
Note: - Inlet pressure should not exceed 4 bar at any time.

Acidity : 7.4 to 8.4 pH

Suspended Particles : < 400 ppm
Recommended Filtration : 140 microns (140m).

Dynamometer Air Supply : Free flow of 0.283 m3/min at 0.7 bar.

Powerpack - Water Supply : ¾” BSP inlet and 1” BSP outlet connections for
18 l/min of water with a maximum inlet
temperature of 25oC and pressure up to 7 bar.
Power Supplies : 2.2kW and four 0.37kW 220-240 / 380-440 50Hz
or 250-280 / 440-480 60Hz
Optional heater : 0.75kW 220-240 50Hz or 60Hz
Note: - DOL starters excluded.
Froude Policy is one of continual improvement and the right is reserved to change specification without notice.

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