Use Cases
Blade health and monitoring systems
for rotating machines
Summary
In Turbomachinery, Every Blade Counts
High-performance turbines demand precision at every rotation. Blade damage, excessive clearance, or vibrational failures can lead to reduced efficiency, increased fuel consumption, and catastrophic failures. Real-time insight into blade behavior is no longer optional—it’s essential.
Ensuring Blade Integrity Across All Conditions with FOGALE CAPABLADE Blade Health Monitoring Solutions
The challenge
Turbomachinery blades operate under extreme mechanical, thermal, and aerodynamic stress. Across power generation, aviation, and industrial applications, operators face several critical challenges:
- Blade Tip Rubbing & Clearance Drift – Thermal growth and centrifugal force cause variations in tip clearance, risking mechanical contact.
- Vibration-Induced Damage – Resonance and fatigue can lead to cracks or catastrophic failure, especially under high cycle loading.
- Limited Visibility in Harsh Environments – Monitoring blades at high speed, high temperature, and high pressure is difficult using conventional methods.
- Unplanned Downtime & Maintenance Risks – Without predictive insight, inspection intervals are conservative, costly, and disruptive.
The solution
CAPABLADE by FOGALE Sensors is a suite of modular, rugged solutions that deliver real-time, non-invasive measurement of blade tip clearance (BTC) and blade tip timing (BTT).
Whether in a test rig or an operational turbine, the system enables continuous monitoring of each blade’s condition with unmatched precision.
- Dual BTC+BTT Measurement – Each blade passing is analyzed to extract clearance and vibrational data using the same sensor
- Up to 12 Channels per Rack and multi-racks simultaneous synchronisation - Compact rack design integrates multiple conditioning modules MC900, MC925 or MC935
- Capacitive Sensors for all environments – From -85°C to +1400°C and up to 200 bar, sensor designs cover all application needs.
- Digital compensation & line monitoring – ensures accuracy despite long cables (up to 36m) or extreme temperature gradients.
- A wide range of computing systems designed to operate across diverse environments — from controlled laboratory settings to the most hostile conditions.
- Software for real-time processing – The CAPABLADE suite offers real-time alarming, trending, post-processing, modal analysis, and shaft orbiting information.
APPLICATIONS IN BLADE MONITORING
- Ground Test Rigs & Validation Campaigns – Capture high-speed blade behavior under controlled load conditions.
- On-Wing Engine and Turbine Monitoring – Monitor performance evolution, fouling, stall, and rubbing from real-world operation with CAPABLADE for FTB (Flying Test Beds)
- Operational Troubleshooting & Condition-Based Maintenance – Shift from reactive to predictive strategies with deep blade health insight.
- Turbochargers & Compressors – Identify clearance issues or resonance in high-speed rotating machinery.
KEY ADVANTAGES OF CAPABLADE
| Feature | Benefit |
|---|---|
| Combined BTC + BTT Measurements | Simultaneous clearance and vibration diagnostics with the same sensor |
| High-Temperature & Pressure Capable | Sensors operate up to +1400°C and 200 bar |
| Digital Signal Conditioning | Accurate and noise-resistant measurements |
| Real-Time Software | Alarm systems, analysis, data export, and trend visualization |
| Scalable & Compact Architecture | Up to 12 channels in a small footprint per rack with adapted computing systems |
The results
CAPABLADE delivers proven Blade Health Monitoring solutions to optimize turbomachinery performance, reduce risk, and extend the life of critical components. Designed for flexibility and precision in the harshest environments, it turns data into foresight—and foresight into action.