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STARGATE: A project overview

Sensors

Towards

Advanced

Monitoring

And

Control

Of Gas

Turbine

Engines

Mark Langley

Chief Engineer –Meggitt Sensing Systems

STARGATE Project Coordinator

October 2015

• Project started in November 2012 under the auspices of EC Framework 7

• 3 years in duration

• Objective to develop an advanced suite of sensors and associated systems to support the development and monitoring of the next generation of gas turbines

• Due to complete end of October 2015 (although a 6-month extension has just been granted)

• 7M€ budget

• 16 Partners

• Coordinated by Meggitt UK

STARGATE: Project Summary

• 5 OEMS

• 2 Supply Chain

• 6 Universities

• 3 SMEs

The Partners

UK

CH

(UK and De)

• Objectives of work based around EVI-GTI/PIWG instrumentation gap matrix

• Too many gaps to consider in one project

• Typically focus has been on high temperature applications where most gaps exist

The Rationale

• Work Package 3: Gas Path Performance Measurements

Primary Technical Work Packages

• 3.1: High temperature dynamic

pressure and entropy probes

• 3.2: Accurate performance

instrumentation for unsteady flows

• 3.3: High temperature thermocouples

• 3.4: Dynamic pressure with self test

© Von-Karman Institute 2015

• Work Package 4: Non-contact structural and mechanical

measurements


• 4.1: High temperature strain gauges

• 4.2: High temperature optical

accelerometer

• 4.3: High temperature microwave tip-

timing sensor

• 4.4: Optical tip clearance/tip timing sensor

• 4.5: Long wave pyrometry for TBC

measurement

• 4.6: Non-intrusive scanning pyrometer

© ONERA 2015

• Work Package 5: Wireless and Less-Wired Measurements


• 5.1: Energy harvesting in harsh

environments

• 5.2: Power management and

efficient data transfer

• 5.3: High performance rotating

signal transfer

• 5.4: Mixed wireless and less-

wired large on-engine sensor

networks© Rolls Royce 2015

• Work Package 6: Uncertainty Analysis


• Determine uncertainty of

measurements at 3 stages

• Prior to lab evaluation

• After lab evaluation

• After rig/engine tests

• Based on accepted international

standards

• Advice and workshops with world-

expert Ron Dieck

• Work Package 7: Rig and Engine Trials


© Loughborough University 2015

• Validate sensors in representative

environments

• Existing rigs

• Bespoke rigs

• OEM test engines

Flow of Work

TIME

Technolo

gy R

eadin

ess L

evel

SpecificationsUncertainty

assessment

Uncertainty

analysis

Uncertainty

analysis


• WP 3.2: Accurate Performance Instrumentation for Unsteady Flows

Measurement of total temperature in unsteady flows present in turbomachinery

are prone to error. Has significant effect in low pressure ratio stages

Development of advanced jet facility to understand effects of velocity deficit in

wakes on temperature measurement accuracy

Development of accurate probes to measure and compare against standard

temperature probes (e.g. Kiel shrouded)

STARGATE: Technical Highlights

stainless-steel

stagnation tube

vent

holes

lead

wires

thin-film

PRT sensor

ceramic

tube

ceramic

cement

© Loughborough University 2015



• WP 3.3: High Temperature Thermocouples

Double wall system developed to mitigate effects of contaminants from sheath

that cause drift

Investigation of special coatings to limit external oxidation and increase life

Results at 1200C show ~80% reduction in drift over conventional thermocouples

© Cambridge University 2015


• WP 3.4: Piezoelectric dynamic pressure sensor with incorporated self check

and redundancy capabilities for safety critical high temp. applications

Self check capability combined with fail safe behaviour.

Increased safety and availability (redundancy) of the measuring chain

Validated in laboratory and on HP combustion test rig

Achieved TRL5


Sensor head integral to HT cable

Signal conditioning unit© Meggitt SA 2015


• Work Package 4: Structural and Mechanical Measurements

• WP 4.1: High temperature strain gauges

Advanced Pd-Cr strain gauges developed by ONERA

Tested up to 500C

Currently under further evaluation with GKN

© Onera 2015


• WP 4.2: High temperature optical accelerometer

Based on Fabry-Perot interferometry

Flat response over frequency range

Uniform temperature response to 750C

Acceleration testing at high temperature in progress


© Oxsensis 2015


• WP 4.3: High temperature microwave tip timing sensor

Microwave based Tip Timing (TT) sensor with high temp. capability up to 750C

Validation of a prototype capable of working for long-term in harsh environment

Targeted application: Blade health monitoring for land based turbines

Prototypes validated in laboratory (performance and environment)

Achieved TRL4


0 0.5 1 1.5 2 2.5 3 3.5

x 104

-0.2

0

0.2

0.4

0.6

0.8

1

1.2

Samples

Re

l. m

ag

nitu

de

Blade pattern - STARGATE low temp. probe

Clearance 2mm

Clearance 6mm

Clearance 10mm

Blade pattern for 3 different clearance values

© Meggitt SA 2015


• WP 4.6: Non-intrusive scanning pyrometer

Multiple radial points can be seen on the blade in one “viewing” using complex

optics to split incident radiation

Sits flush to the casing and does not require a traverse (no effect on engine

performance)

Tested on Siemens Lincoln gas turbine with very encouraging results


© Siemens AG 2015 © Siemens AG 2015


• WP 5.1: Energy Harvesting for Extreme Environments


Design, simulation and measurements for a clamped-

clamped coupled piezoelectric harvester

Peak open circuit voltage of 11.7 V for 0.1 g

Synthesized novel thermoelectric material Ba8Ga16Ge30

with high zT-value at 725°C

Module built from n-type Ba8Ga16Ge30 and p-type La-

doped Yb14MnSb11, both materials with highest figure of

merit at 700-750°C

-3

2

7

12

340 360 380 400

Op

en

cir

cuit

vo

ltag

e (

V)

Frequency (Hz)

M1 Moving weight M1 Fixed weight

M2 Loose screw M2 Extremely loose

© Chalmers 2015

© Chalmers 2015


• WP 5.2: Power Management and Efficient Data Transfer


Parameters: Temperature & Acceleration

Approach: model-based transmission reduction

Reduce transmissions by > 99% in some cases

7 rig tests with RR, Chalmers, Scitek (wireless

temperature)

Performance vs. off-the-shelf operation:

– Reduced avg. energy by 75% (4-fold

improvement)

– Reduced start-up energy requirements by

95%

Demonstrated battery-free operation with

Chalmers energy harvesters

© Coventry University AG 2015


• WP 5.3: Rotating Signal transfer


On rotor signal conditioning and RF

transfer to static structure and test

facility DAS.

Large increase in simultaneous

capacity, up to 240 high bandwidth

dynamic channels for inductively

powered core systems achieved

through

New high density on rotor signal

conditioning.

New close coupled antenna

designs.

Significant increase in temperature

capability for battery powered shaft end

systems (125C from 85C).

Low TRL trials of higher temperature

capability electronics(>210C).

© Scitek 2015


• WP 5.4: Mixed Wireless and Less-Wired Networks


Highly configurable wireless and battery

powered data acquisition systems for high

speed data from a range of sensors.

Data can be synchronised via GPS to

microsecond accuracy with other data

acquisition systems.

Can be configured as wired and/or wireless

with other units, thus reducing the wiring

count

Customised National Instruments Single-

Board RIO (sbRio) utilising field

programmable gate arrays (FPGA)

This device has so far been used to record

vibration measurements on an aero-engine

mounted on the casing of the engine.

© Scitek 2015

• Firstly, it can be seen that many of the technologies have

reached an excellent level of maturity (TRL 4-5) as a result

of successful trials on representative of full-engine rigs

• These technologies will continue to be developed

(probably under local auspices) to reach full

application

• Other technologies where the development has proved

more challenging will look to continue the research

possible under an H2020 schemes

• Currently most of the technologies are only applicable to

ground-based test or industrial gas turbines

• Application to aero-engine monitoring and control

applications are still some way off. Not just because of the

high level of certification required, but also because of the

limited window of opportunity of new platform introduction

STARGATE: Next Steps

• If you wish to find out more about specific sensors that have been developed during STARGATE, please contact me and I can forward you the contact details of the relevant person

• There are quite a few of the STARGATE team attending Aerodays, so you may be able to speak to the right person one-to-one

• Alternatively, please visit our stand on Floor 5 and we can talk further

• Several papers to be presented by the STARGATE partners at the EVI-GTI conference at the IET London in November

STARGATE: Following-Up

[email protected]

+44 (0)1256 349266

mailto:[email protected]

Thank you

This work was partially funded under the auspices of the European Union Framework 7 Aeronautics and Air Transport

programme. Funding Scheme: FP7-AAT-2012-RTD-1

stargate: a project overview - aerodays2015.com · stargate: a project overview sensors towards...

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