© 2009 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used

© 2009 Rolls-Royce plcThe information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc.This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.

Measurement technology requirements for gas turbine propulsion systems

James P Roberts

Sensors and Instrumentation KTN: ISP Meeting 01/04/09

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Agenda Principal drivers for measurement for gas turbine engines

Most important measureands

The challenges

Current capabilities

Future opportunities

Rolls-Royce Proprietary Data © 2009

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Agenda Principal drivers for measurement for gas turbine engines:

Why do we need to measure?

Most important measureands: What do we need to measure?

The challenges: The engine environment: Where do we need to measure? The practical/operational constraints: What makes it difficult/expensive?

Current capabilities: What can we do today? Where do we need more capability?

Future opportunities: What can we do to fill the capability gaps?


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Our four marketsWhy do we need to measure?


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Key statisticsWhy do we need to measure?


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Drivers for measurement for gas turbine engines

Instrumentation for product development and method validation.

Instrumentation for Engine Health Monitoring

(On- board and NDT)

Manufacturing process control and inspection

Sensors within the engine control system

Increased

matu

rity of tech

no

log

y

Why do we need to measure?


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Measurands of importance: What do we need to measure?

Structural measurements Measurements to validate/monitor the integrity of the engine Key inputs to component life and maintenance prediction Validation of FE modelling methods

Component temperaturesComponent vibrationEngine vibrationLoads and displacements

NDE/Inspection Manufacturing and assembly process control

Performance measurements Measurements to validate/monitor/control the efficiency of the engine Validation of CFD and performance models of engine

Gas temperatures, pressures and velocitiesFuel and oil flows and propertiesTorque and thrustRunning ClearancesEmissionsNoise


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The engine environment: Where do we need to measure?

Three Shaft Civil Turbofan Engine:- Main Components-

Fan IP CompressorHP Compressor

Combustor

HP Turbine

IP Turbine

LP Turbine


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Three Shaft Civil Turbofan Engine – Typical Environmental Conditions For Instruments

Core casing vibration 90mm sec-1 / 40 g pk

Turbine entry gas 1900-2400K 40 bar/600psi

HP turbine blade metal temperature ~1100°C, thermal barrier coating surface temperature to >1300°C

350°C air temperature beneath core covers

HPC delivery >900K, >42 bar

Oil system 250C+

The engine environment: Where do we need to measure?


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The challenges of large volumes of instrumentation on development engines: The practical/operational constraints: What makes it difficult/expensive?

Historically every measurement point is led out

to test facility signal conditioning:

- 1000 thermocouples (low bandwidth)

- 1500 pneumatic lines (low bandwidth)

- 500 s/g, accelerometers, dynamic

pressures etc (up to 40kHz)

Instrumentation leadout ‘ties’ the modular

engine together

Leadout routing involves large design effort

Very difficult to swap out failed instruments

Leadout material can be expensive 12km t/c cable fitted to a single engine

Potential for large time and cost savings


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The challenges of large volumes of instrumentation on development engines:

Currently moving over to a modular wiring approach, with some local signal conditioning, but longer term we need progress to:

- Widespread on engine conditioning and multiplexing

- Wireless sensing

To meet these longterm goals, numerous technical issues need to be addressed:

- Interconnects- Power supply- Electronics temperature limitations

– Cooling, insulation and higher temperature capabilities

- EM interference- Data throughput- Transmission range- Transfer security


MCU

MCU

LCU

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Example current capabilitiesComponent Temperature Measurements

Thermal Paints/MeltsThermocouplesPyrometry and Thermography

Component Vibration and Load Measurements

StraingaugesBlade tip timingBearing end loads

Gas path aerodynamic measurementsTotal and static pressuresTotal TemperaturesDynamic Pressures

Fluid measurementsFuel and oil flowFuel and oil condition

Signal transferRadio Telemetry for rotating sensorsModular hardwired static sensors


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Example opportunities to improve current capabilitiesComponent Temperature Measurements

Thermal Paints/Melts Improved/automated reading methodsThermocouples Higher temperature capabilities, stabilityPyrometry and Thermography Accuracy, resolution, intrusiveness

Component Vibration and Load MeasurementsStraingauges High temperature lifeBlade tip timingBearing end loads ‘Smart bearings?’

Gas path aerodynamic measurementsTotal and static pressures Higher temperatureTotal Temperatures Higher temperature, accuracyDynamic Pressures

Fluid measurementsFuel and oil flow Accuracy, multiphase flows, oil filmsFuel and oil condition Oil health, Fuel quality

Signal transferRadio Telemetry for rotating sensors Smaller higher temperature electronicsModular hardwired static sensors Wired and wireless networks


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Future opportunities: What can we do to fill the capability gaps?

Pre-competitive work with other OEMs to define agreed measurement

capability gaps

Involvement of academia and the supply chain to identify opportunities

to close the gaps

Collaborative research to provide validated solutions


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Gas Turbine Engine Measurement Requirements:Industry groups co-ordinating requirements and pre-competitive collaborative

measurement R+D for gas turbine instrumentation EU: EVI-GTI

- European Virtual Institute for Gas Turbine Instrumentation- Engine Companies including: RRplc, RRD, Alstom, Safran(Snecma, Turbomeca),

MTU, ABB Turbo, Siemens, Fiat Avio, Volvo.- INPA registered in Belgium, Administrated by VKI- Instr research, supply and application companies.- website: //www.evi-gti.com

USA: PIWG- Propulsion Instrumentation Working Group - Engine Companies including: P+W, GE, Honeywell, RRC, Seimens Westinghouse,

Williams International.- Users: including: NASA, AEDC, AFRL, NAWCAD, NETL - Strategy Advisory Board: Accademia, researchers and supply chain- website: //www.piwg.org/


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Collaborative research examples

UK: ODESSA (complete) DTI ‘Micro and Nano’ call Oxsensis, CCLRC and Rolls-Royce. Development of 1000C dynamic pressure sensor. Through to in-engine validation.

EU: HEATTOP (on-going) ‘STREP’ in Call 3 of EU Framework 6: 42 month prog from August 2006 Full Title:“Accurate High Temperature Engine Aero-Thermal Measurements for Gas-Turbine Life Optimization,

Performance and Condition Monitoring” Partners: RR, Volvo, Siemens, Kema, VKI, Vibometer (CH), Vibrometer (UK), Auxitrol, Onera, CESI, Farran,

Oxsensis, AOS, IPHT, Oxford, Cambridge, Lund. Main topics: High temperature gas path temperature and pressure measurement, plus tip clearance. Development

through to in-engine validation.

UK: WITNESSS (on-going) ‘Gathering Data in Complex Environments’ call AgustaWestland, Airbus UK, BAE, Bombardier, GE Aviation, Qinetiq, QM Systems, Rolls-Royce, SLI Ltd, TRW

Conekt, Ultra Electronics BCF. Wireless sensor deployment in aerospace environments.

UK: WIDAGATE (on-going) TSB ‘Gathering Data in Complex Environments’ call Selex, Strathclyde Univ, UCL, Rolls-Royce. Modelling of wireless networks in the on-engine environment.


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Summary

High quality measurements are vital for the validation, in-

service monitoring and control of propulsion gas turbines.

The gas turbine environment provides extreme challenges

for measurement technology.

Collaborative research between academia, the

instrumentation supply chain and the end users can

develop and validate the new measurement technology

needed.


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© 2009 Rolls-Royce plc The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used