Use Cases
Blade health monitoring (BTC/BTT)
under Gas Turbines fast ramp conditions
Summary
Under fast ramp conditions in gas turbines and critical rotating machines, blade integrity is a key enabler of operational performance and safety. Fogale’s non-contact measurement systems provide real-time insight into blade vibration, clearance, and deflection—even during transient regimes
The challenge
Gas turbines used in peaking or load-following applications must handle frequent start-stop cycles and rapid ramp-up conditions. Monitoring blade dynamics in these conditions is critical to ensure safe, efficient, and damage-free operation.
- Frequent high-speed ramp-up increases mechanical stress on rotating blades.
- Contact between blade tips and casing can lead to catastrophic failure.
- Traditional monitoring systems may not capture rapid transients accurately.
- Operators need actionable, real-time data to support predictive maintenance.
Application Examples
- Fast-ramping gas turbines in power plants
- Aero-derivative turbines for temporary power generation
- Research test benches simulating overload scenarios
- Long-term fleet management and reliability optimization
The solution
FOGALE Sensors offers a fully integrated non-contact measurement chain to monitor tip clearance and vibration amplitude in real time during turbine operation — including fast acceleration phases.
- Capacitive or eddy current sensors measure clearance and vibration of each blade during rotation.
- Synchronized electronics provide real-time time-of-arrival (ToA) and amplitude data.
- System enables Blade Tip Timing (BTT) and Blade Tip Clearance (BTC) with nanosecond precision.
- Integrated software processes results for online condition monitoring and predictive maintenance.
Key Advantages
Feature | Benefit |
|---|---|
Non-contact measurement chain | No mechanical wear, no risk to turbine integrity |
Real-time data acquisition | Detects issues during fast transient events |
BTT + BTC from same system | Reduces cost and simplifies installation |
High-speed electronics (MHz bandwidth) | Enables use in high-frequency rotating machines |
Modular architecture | Easily scalable to multiple measurement points |
The results
The Fogale BTC/BTT solution enables safe and efficient turbine ramp-up beyond standard specs, with precise monitoring that reduces unplanned shutdowns and enhances maintenance planning. Our systems are already contributing to improved turbine longevity and operational flexibility.