High Temperature Clearance and Vibration Monitoring Systems

A Solutions Company
Tyco Thermal Controls is the world leader in products and solutions for the industrial, commercial and residential markets. Employing over 2500 people globally, Tyco Thermal Controls has the experience and product breadth to meet your requirements.

Worldwide Approach
With operations in 56 countries and worldwide experience, Tyco Thermal Controls supports your project efforts anywhere, anytime. Whether its top-notch products or turnkey services, Tyco Thermal Controls has the solution.

The Market Demands We Supply

From Heat-Tracing Systems, Specialty Heaters and Floor Warming to Wiring, Temperature Measurement, Leak Detection and Blade Condition Monitoring, we are able to offer innovative solutions worldwide. Furthermore, we proudly provide turnkey services for eachWORLDWIDE!

OVERVIEW

Monitor Blades in an Operational Turbine, Even at High Temperatures

bandwidth electronics to provide two sets of data from one state-of-the-art turbine sensor. With sensors (probes) that are able to withstand temperatures of 1400C/2550F, CapaciSense systems enable you to monitor at turbine temperatures in continuous operation. By providing a virtual window to see inside your operating turbine engine, CapaciSense condition monitoring systems: Provide accurate real-time data to help you achieve smaller clearances, optimising the machines efficiency, therefore, cutting down fuel costs
Monitor differential thermal growth during warm restarts to prevent tip damage caused by blade rubbing Monitor vibrations through tip timing to provide an early warning of problems or potential failure, preventing unplanned and expensive outages or even catastrophic failure

apaciSenseTM systems combine blade tip

CapaciSense systems are used in gas turbines within the power generation and aerospace industries, although they are also suitable for other applications where a conventional proximity probe would not survive the environment. CapaciSense systems are based on capacitance theory and contain sensors, turbine mounted/local electronics, remote electronics and a control and processing module with software. This document gives a brief overview of what CapaciSense has to offer. Contact your local representative to discuss your needs.

clearance and vibration monitoring using high

BACKGROUND INFORMATION

the market leader in high temperature mineral insulated cable. Now part of Tyco Thermal Controls, the CapaciSense product has matured into a full system and service package. Currently employed worldwide within the power generation and aerospace industries, CapaciSense sensors are favoured for their ability to survive extreme temperatures for several years, enabling the whole engine to be monitored continuously, not only the lower temperature compressor areas. CapaciSense is at the forefront of solutions for blade condition monitoring in extreme environments.

apaciSense systems were developed in the 1980s with the support of Pyrotenax,

Key Developments and Milestones 1988 First triax cable for capacitive
sensors supplied

1996 First development sensor design 1997 Sensor patent granted 2003 First sensors into production engines 2006 CapaciSense brand launched,
150th sensor designed

2006 Industrialised ATEX and FM

approved systems

2007 First retrofit installation and

5 Series demodulator launched

2008 5 Series oscillator launched 2009 5 Series ATEX approval and

blade clearance and vibration software launch

2010 5 Series FM approval

APPLICATIONS
Engine Design Verification

Retrofit
As downtime for maintenance is expensive, it is imperative that this is minimised and performed at the right time with informed knowledge of current engine conditions. By retrofitting with a CapaciSense system, the operator can be given forward notice of potential blade failure due to blade rubbing or vibration. This additional intelligence on the engine operation allows warm restarts to be safely performed with the knowledge that differential thermal expansion isnt going to cause a blade rub which will result in costly repairs. With approvals including ATEX and FM, our systems can be used safely in hazardous areas. This is of particular interest for those considering retrofitting turbines with additional condition monitoring sensors for predictive maintenance or to check blades in near rubbing conditions.

driving factor when designing gas turbines, whether it be power generation or aerospace, is their fuel

efficiency. Higher fuel efficiency means lower operating costs, often driving the decision on which turbine to adopt. Most of the worlds leading developers of power generation turbines have used our systems for design verification of blade tip to shroud clearances at high temperatures, supplanting the older technologies. By using our CapaciSense system, turbine designers can get a live picture of the blade tip clearances in prototype engines during all phases of the engines operation.

Operating Engine
Designers of some of the worlds largest power generating turbines are now choosing to install our condition monitoring system to continuously monitor blade clearances and vibration. Our system offers data for informed user control of adaptive clearance systems.

Non-Gas Turbines
While CapaciSense systems primary application is in gas turbines, it can be used for proximity applications where conventional systems are inadequate, for example gas seal clearances or piston clearance measurement.

WHY CHOOSE A CAPACISENSE SYSTEM?

Improved Reliability and Reduced Maintenance Costs

Improved Output and Efficiency

Due to the high temperatures our sensors can sustain 1400C/2552F, even the turbine stage blade clearance can be measured, an important factor as this means the whole engine can be monitored, not just the lower temperature compressor areas. This raises the possibility of controlling the various stages differentially and optimising the whole turbine rather than just one zone. As the turbines fuel efficiency is directly affected by the size of the clearance, designers and manufacturers are using the live outputs to adjust clearances to a minimum on working turbines and therefore gaining greater fuel efficiencies.

y providing real time data, you will access early warning signals of

potential problems, which will help you to make decisions and avoid unplanned and expensive outages or even catastrophic failure. Turbines are extremely sensitive to blade tip rubbing, which can be the cause of failure. Our tip clearance functionality will monitor differential thermal growth during warm restarts, and the information provided helps you to prevent tip damage caused by blade rubbing. Our tip timing functionality will monitor the arrival time of a blade tip and use this to calculate blade deflections and identify vibration.

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Suitable for Hazardous Locations

With ATEX and FM approval, our fully industrialised systems are suitable for use in hazardous locations. The engine mounted FM oscillator enclosure is ATEX and FM approved, allowing intrinsically safe operation when systems are used for condition monitoring of running engines. Nonhazardous area enclosures are also available for occasions when the oscillators are to be mounted outside of turbine compartment using sensor cable lengths of up to 10 m (32.8 ft).

Trusted History
Our systems have been successfully used worldwide by gas turbine manufacturers to verify the frame clearances in extreme environments for many years.

Customised Solutions
The CapaciSense team provides a full design and development service on every project in order to meet the requirements of your application. We custom make our sensors to suit your environment: Extremes of temperature (>1400C/2250F)

Tip Timing and Clearance from One Sensor

CapaciSense systems can provide both tip clearance and tip timing from one state-of-the-art sensor. With the advent of the new high speed 5 Series electronics and software, the blade passing signal, which has traditionally provided only clearance information is now capable of resolving blade time of arrival. Traditional methods for measuring blade fatigue include strain gauging and optical tip timing. Whilst strain gauges provide accurate information, they only provide that information for the blades which are instrumented and these gauges are not suitable for a production environment. Optical sensors provide excellent tip timing data but only for short periods of time before their optics became fogged with contamination. By using already proven CapaciSense clearance sensors, additional data can be derived on blade vibration without the need to install additional instrumentation.

Temperature cycling Vibration Moisture (including on-line water wash) Calibration disc design and manufacture to replicate actual blade tip profiles, sensor calibration and a full installation service are offered as part of our solution. It is our goal not to provide components but to provide the whole solution.

Long Lasting
For condition monitoring applications, sensors need to perform well over extended periods of time. CapaciSense sensors are proved to be robust. The four sensors pictured to the right have had years in the hottest turbine zone in one of the worlds largest turbines. They were removed during regular servicing and are still functional. One sensor has been polished to remove combustion product depositsit shows it is still close to its original condition. All CapaciSense sensors have patented fully captive components which limits the risk of the sensor breaking apart into the engineeven if it is damaged.

HOW CAPACISENSE WORKS

apaciSense is a non-contact measurement system that uses capacitance to detect the distance of an

As the returned capacitance from a system such as this is extremely small (tens of femto farrads), advanced techniques need to be utilised to accurately measure themsee our FM and AM options described later.

object and its time of arrival.

Capacitive Technology
The core functionality of the system is relatively simple and uses capacitance parallel plate theory. The overlapping electrode area, which is specific to blade profile (A1) and electrode dimensions (A2), is assumed to be constant. The permittivity can also be considered to be constant as the small changes which do occur due to combustion, have been proved to be negligible. This theory gives us the ability to calculate the distance separating blade tip to sensor plates by measuring the capacitance. The advanced electronics of the system convert this capacitance into a voltage, allowing a direct correlation between voltage and distance to be established while the blade is passing at over the speed of sound. The effects of plasma charge in the turbine can effect the output from AM based systems which is why we use FM technology in turbine blade measurements to eliminate those effects.

Distance (d)

Conductive plates (A) Dielectric

0r

Capacitance (C)

C=e0er A / d

Where:
l

e =
r

= Capacitance Relative permittivity (constant in this application)

d
A2
l

e
A d

= Permittivity of free space (constant) = Overlapping electrode area (constant in this application) = Electrode separation

A1

As C is proportional to 1/d, by measuring C, d can be determined.

Tip Clearance
Sensor Engine casing Clearance Blades Reduced clearance

Blade passing signal output showing how measuring pulse amplitude is used for clearance monitoring

Tip Timing
Blade timing Sensor Engine casing Blades Vibrating blade

Blade passing signal

u u

output showing how measuring time of arrival is used for vibration monitoring

5 Series FM System
An FM (frequency modulated) system is chosen to monitor intermittent signals from blades. The system works on the principal of measuring the capacitance change between the sensor electrode and a passing blade. This blade to sensor tip capacitance change forms part of a tuned oscillating circuit. Changes in capacitance at the sensor tip due to the passing blades cause a frequency modulation of the 2 MHz carrier signal. This change is demodulated to a change in output voltage each time a blade passes the sensor tip. Due to the high and low speed capabilities of the 5 Series electronics, they can operate on engines with blade passing events from around 10 Hz to 50 Hz and with a blade passing time, leading edge to trailing edge, of approximately 4s. The two main factors which govern changes in sensor tip capacitance are the sensor/blade tip geometry and blade tip clearance. During operation the sensor/ blade tip geometry usually remains constant; therefore

any changes in capacitance at the sensor tip are the direct result of variations in tip clearance. Use of frequency modulation makes the system sensitive to carrier frequency variations and ignores ESD (Electro Static Discharge) or EM (Electro Magnetic) varying fields. The FM system also operates via a low carrier voltage making it ideal for hazardous area application, unlike some high voltage systems available. The oscillator electronics are designed to minimise and compensate for cable and sensor capacitance variations which may change as the ambient temperature surrounding the sensor increases to 1400C/2552F. Backed by more than fifty years of mineral cable expertise, our triaxial cables provides reliable, low noise signals in the harsh operating environment of a gas turbine. With over 175 bespoke sensor designs manufactured and in operation, the FM system pro vides a turnkey solution for condition monitoring.

APPROVALS AND CERTIFICATIONS

CapaciSense high temperature clearance and vibration monitoring systems are approved and certified for use in nonhazardous and hazardous locations by FM Approvals and Baseefa.

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FM Systems

5 Series Surpasses Legacy 4 Series FM System

4 Series
Demodulator only Raw Blade Passing Signal (BPS) Average Blade Clearance (RMS) Blade By Blade Clearance Oscillator Tuning MIN/MAX/Mean Clearance Linearised MIN/MAX/Mean Clearance High Speed Blade per Sec Low Speed Blade per Sec Remote Configuration Digitised (Remote Readable) Results Blade Tip Timing (Blade Vibration) Total Rack Size for 12 Channels Automatic Configuration of Linearisation
II 19 Rack 6 U High

5 Series
Demodulator + Sig Con + Lineariser
Analogue Dynamic Staircase (DNS)

Demodulator + Sig Con

Analogue Dynamic Staircase (DNS)

Demodulator only

Demodulator + CPM Digitised Numeric

Analogue Dynamic Staircase (DNS)

Manual

Manual

Manual

Automatic

Automatic

20k 100 20k 100 20k 100 50k 100

50k 10

19II Rack 9 U High

19II Rack 9 U High

19II Rack 3 U High 19II Rack 6 U High Lock Confirmation for system health Lock Confirmation and 12 Customisable Software TCP/IP Network Connection Digitised 85-264 V

Alarm Contacts

Bandwidth Adjustment

Soldiering Required

Soldiering Required

Soldiering Required

Jumpers

Connections

Analogue Voltage

Analogue Voltage

Analogue Voltage

Analogue Voltage

Power Supply

110 V/240 V

110 V/240 V

110 V/240 V

85-264 V

Noise Comparison
Oscillator (Series) Demodular (Series) Noise 40 kHz B.W.
rms
4 4 5 5 4 5 4 5

Noise 90 kHz B.W.

rms 132 123 pk-pk 132 106 88 47

Noise 200 kHz B.W.

rms pk-pk

Noise 400 kHz B.W.

rms pk-pk

pk-pk 100

100

165

147

216

206

61

59

81 48

61

74

71

88

Noise show as a percentage of 4 Series system set at 40 kHz

Our 5 Series is backwards compatible with our 4 Series, contact us for details of limitations.

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5 Series FM System Components

10 m (32.8 ft) limit

Oscillators

Sensors 100 m (328 ft) limit

Remote network access

Demodulators

CPM

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High Temperature Sensors

Used predominantly for turbine applications. The inclusion of flutes and cooling apertures has advanced the operational capa bilities of these designs over to 1400C/2552F, allowing several years of operation.

Mid Range Temperature Sensors

Typically for FM compressor applications or AM systems, the mid temperature range of designs have an operating temperature of up to 1000C/1832F. The sensors have the same characteristics as the high temperature range without the cooling functionality. These sensors can be used at higher temperatures although their life will be shortened.

Lower Temperature Sensors

For operational use at temperatures below 200C/392F, the low temperature design incorporates flexible triaxial cable as opposed to mineral insulated cable. Whilst still using the specialist assembly techniques, the sensors benefit from a lower cost and easier installation.

Sensor and Cable Assembly

The sensors are of triaxial construction Centre electrode
(induced modified by target)
Inner guard (driven) Outer screen/body (noise reduction) All inner components are captive on all temperature designs Super-alloys are employed to reach tip temperatures of 1400C/2552F. All sensors are custom designed.

have a bandwidth of 400 kHz, giving a high resolution to our blade vibration measurements.

Control and Processing Module with Software

Used initially to configure the system and to present the data in values, figures and visual plots and charts: Up to 10 MHz simultaneous sampling in control and processing modules (CPM) from analogue BPS signal Built-in data acquisition and software means
no analogue data for the user to acquire
and analyse
Gain and bandwidth settings (90/200/400 kHz)
controlled via CPM
Auto download of sensor calibration means you can never mix your signals Auto setupno jumper settings Sync signalused to synchronise multiple
racks for the pooling of data
Hard disc for data storage and further analysis 5 Series oscillator will allow Ultra Slow Mode Once per rev input (engine speed/blade identification) Configurable alarm volt-free contacts for basic
remote monitoring
Addition of blade vibration monitoring from the
same system that gives you the tip clearance
(simple software update)
Smaller footprint12 (5 Series) channels in the space of 8 (4 Series), remote access from Microsoft Windows or Linux based machinesno software needs to be installed.

Oscillator
The oscillator drives the sensor with a 2 MHz oscillating carrier frequency (typically), the control circuit is then used to keep this constant and compensate for changes in temperature. Changes in capacitance at the sensor tip modulate this frequency. This modulation is then translated into an output voltage by the demodulator. The 5 Series also features an onboard memory which stores calibration. This eliminates human error at installation by removing the need to manually enter calibration data. Oscillators are usually engine mounted in a cooled enclosure or mounted externally with a 10 m (32.8 ft) cable.

Demodulator
The demodulator extracts the frequency changes from the oscillator and converts this to a voltage. This voltage is proportional to changes in capacitance at the sensor tip. Using the calibration data, this voltage can be used to determine the clearance. CapaciSense systems

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AM System
An AM (amplitude modulated) system is chosen to monitor non-contact capacitive proximity on a continuous surface such as a shaft or shrouded blades. The sensor is a triaxial device with the cable central conductor connected to the sensor electrode. The guard surrounds the electrode and similarly, the outer screen, or body, surrounds the guard. Each component is specifically designed to be completely captive, meaning even in the worst case scenario the sensor remains intact. The locally mounted oscillator drives the guard at 16 kHz at a constant amplitude. This induces an identical sinusoidal oscillation on the centre wire and hence the electrode. As a target comes into the sensor tips range the additional capacitance coupled between the sensor tip and target modifies the electric field. This causes a reduction in the amplitude of oscillation of the centre wire/electrode. Output from the oscillator is a reference oscillation which, when compared with the signal oscillation, gives a difference proportional to the capacitance at the sensor tip. The oscillator also contains a differential amplifier into which both the signal oscillation and reference oscillation are fed. The output from the differential amplifier is a 16 kHz sine wave, the amplitude of which is the difference between the signal oscillation and the reference oscillation. After modulation the resultant voltage is fed along a 50 coaxial cable to a receiver. The oscillator contains line drive amplifiers to enable up to 100 m (328 ft) of cable to be driven.

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AM Systems

System Components

Sensors

AM Oscillators

6m (19.7 ft) limit

100 m (328 ft) limit

Receivers and Min/Max/Mean Signal Conditioners

PC with A-D card showing orbital plot of shaft eccentricity

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Worldwide Headquarters Tyco Thermal Controls 307 Constitution Drive

Menlo Park, CA 94025-1164
USA
Tel: 800-545-6258
Tel: 650-216-1526
Fax: 800-527-5703
Fax: 650-474-7711
info@tycothermal.com
www.tycothermal.com
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Houston, TX 77036
Tel: 713-868-4800
Tel: 713-735-8645
Fax: 713868-2333
Tyco Thermal Controls 4F KC Bldg. 3-16-1
Shin-Yokohama, Kohoku-ku
Yokohama, Kanagawa, 222-0033
Japan
Tel: +81 45 471 7630
Fax: +81 45 471 7631

CapaciSense Headquarters Tyco Thermal Controls (UK) Ltd 3 Rutherford Road

Stephenson Industrial Estate
Washington, Tyne & Wear
NE37 3HX, United Kingdom
Tel: +44 191 4198200
Fax: +44 191 4198201
washington_tech@tycothermal.com www.capacisense.com Tyco Thermal Controls GmbH Englerstrasse 11
69126 Heidelberg
Germany
Tel: +49 6221 30430
Fax: +49 6221 3043956

Tyco, CapaciSense, Pyrotenax, Tracer, DigiTrace, Isopad and TraceTek are trademarks of
Tyco Thermal Controls LLC or its affiliates.
Windows is a trademark of Microsoft Corporation.
Important: All information, including illustrations, is believed to be reliable. Users, however, should independently evalu ate the suitability of each product for their particular application. Tyco Thermal Controls makes no warranties as to the accuracy or completeness of the information, and disclaims any liability regarding its use. Tyco Thermal Controls only obligations are those in the Tyco Thermal Controls Standard Terms and Conditions of Sale for this product, and in no case will Tyco Thermal Controls or its distributors be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product. Specifications are subject to change without notice. In addition, Tyco Thermal Controls reserves the right to make changeswithout notification to Buyerto processing or materials that do not affect compliance with any applicable specification.

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2010 Tyco Thermal Controls LLC

H58659

06/10