Benefit from Knowledge and Experience

Here you can find out more about the topics and challenges where we have been able to apply our expertise in the past to develop and implement project-specific solutions for our customers.

Some IfTA References

Siemens Energy CEC (Clean Energy Center)

Siemens energy - CEC
Berlin - SGT5-8000H

Product: ArgusOMDS

Investigation of combustion oscillations in gas turbines under real conditions.

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SWM Munich, early
warning system

Product: ArgusOMDS + Precursor

Increasing the effectiveness of gas turbines by using an early warning system.

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MTU &
UniBw M

Product: AIC-System

Aeronautical research program for active compressor control.

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Large furnaces in industry

Product: consulting and service

Avoidance of combustion oscillations in differently sized large burner geometries.

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Small Furnaces in daily life

Product: consulting and service

Avoidance of combustion oscillations in gas ovens, large kitchen and heating appliances.

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Signal Testing on Gas turbines

Product: Charge signal Generator

Measurement chain testing on stationary gas turbines for power generation.

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Siemens Energy, CEC Berlin - SGT5-8000H

Produkt: DynaMaster

Mit intelligenter Schwingungsmesstechnik zur sauberen Energie

Der zunehmende Einsatz von regenerativen Energien aus Photovoltaik und Windkraft führt zu einem gesteigerten Bedarf an schnell erzeugbarer elektrischer Energie, wenn es zu Schwankungen in der solaren Einstrahlung oder der Windversorgung kommt. Moderne Gaskraftwerke überbrücken diese Versorgungslücke perfekt, da sie schnell hochfahren und ihre Leistung in einem weiten Bereich variieren. Dieses komplexe Zusammenspiel wird durch intelligente Schwingungsmesstechnik signifikant unterstützt. Fünf entscheidende Anforderungen, um Komplexes einfach messbar zu machen. Der Gas- und Dampfturbinen (GuD)-Betrieb verfügt über einen sehr guten Wirkungsgrad bei gleichzeitig geringem CO2-Ausstoß - circa 60 % weniger als aus Braunkohlekraftwerken. Das aktuell modernste Kraftwerk von diesem Typ steht nördlich von München in Irsching und hat einen Wirkungsgrad von 60,75 %. Die weltweit leistungsstärkste Maschine der Firma Siemens Energy, die Gasturbine SGT5-8000H mit einer elektrischen Leistung von über 375 MW, ist dort im Einsatz.

Prüfstände zur Optimierung von Gasturbinen

Um die Verbrennungseffizienz seiner Kraftwerke kontinuierlich zu optimieren, hat Siemens Energy ein hochmodernes Testcenter, das Clean Energy Center (CEC) in Ludwigsfelde nahe Berlin, errichtet. Einzelne Brennkammern der Gasturbine werden unter hohem Druck und vorgeheizter Luft oder Gas - das heißt unter realistischen Bedingungen - betrieben. Neben den Emissionen sind thermoakustische Phänomene bzw. Verbrennungsschwingungen in der Brennkammer und die dynamischen Materialbelastungen Teil der Untersuchung. Zur Messung dieser Signale kommen Hochtemperaturdruck- und -beschleunigungsaufnehmer, Dehnmessstreifen und diverse andere Sensoren zum Einsatz.

Die IfTA Lösung

Nun ist ein besonderes Schwingungsmessgerät Teil der fortschrittlichen Technologie im Ludwigsfelder CEC: der IfTA DynaMaster. Er ist eine Weiterentwicklung basierend auf den bewährten IfTA Argus-Systemen, die seit über einem Jahrzehnt an verschiedenen Gasturbinentypen wie der SGT5-8000H weltweit im Einsatz sind. Fünf entscheidende Anforderungen lassen sich durch die bereits erprobten Integration herausstellen.

Flexibilität durch Modularität

Alle Teststände des CECs sind mit IfTA DynaMastern mit jeweils 32 Kanälen ausgestattet. Die Kanäle werden für phasensynchrone Messungen simultan mit 24 Bit und bis zu 51,2 kHz abgetastet. Neben den schnellen Eingängen können zusätzlich 32 langsame Spannungs- oder Stromsignale erfasst werden. Für digitale Signale stehen 16 Eingänge zur Verfügung. Die schnellen analogen Eingänge können über gepufferte Ausgänge abgegriffen werden. Abgerundet wird das Schwingungsmesssystem durch eine leistungsstarke modulare Softwareplattform. Drehscheibe des Messdatenhandlings ist der IfTA DataHub, der direkt auf dem IfTA DynaMaster läuft. Er erlaubt wahlweise die gesteuerte oder automatische Speicherung der Daten auf dem integrierten Speichermedium, wo zwischen SSD oder HD gewählt werden kann.

Neben den Schwingungsdaten kann der IfTA DataHub auch Daten über OPC oder Datasocket verteilen und empfangen. Das Zusammenführen von allen Datenströmen aus unterschiedlichen Quellen ermöglicht das schnelle und effiziente Auswerten komplexer Zusammenhänge, wie z.B. die Auswirkung von Umgebungsparametern oder Brennstoffzusammensetzung auf Verbrennungsinstabilitäten. Aus hohen Abtastraten und großer Kanalanzahl resultieren bei dieser Anwendung enorme Datenmengen, sodass das CEC sehr spezielle Anforderungen an die Fähigkeiten der Datenauswertung stellt. Neben den Rohdatenströmen werden auch über der Zeit zusammengefasste Datenströme erzeugt. Diese ermöglichen eine schnelle Übersicht über lange Zeiträume.

Jeder Sensor passt an jeden Eingang

Herzstück des Systems ist die IfTA AD4Pro, eine vierkanalige dynamische Messkarte mit universellen Messeingängen. Unterstützt wird auf dieser Karte je Kanal die Messung von Spannungs- und Stromsignalen. Darüber hinaus erlaubt ein integrierter differentieller Ladungsverstärker den direkten Anschluss von piezoelektrischen Hochtemperatursensoren für Druck und Beschleunigung. Ebenfalls enthalten ist ein Messverstärker für Dehnmessstreifen. An diesem können Viertel-, Halb- und Vollbrücken direkt angeschlossen werden. Weiterhin werden piezoresistive Druck- und Beschleunigungssensoren, wie z.B. Kulite-Sensoren, unterstützt und für IEPE-Sensoren steht eine entsprechende Speisung zur Verfügung. Ausgewählt wird der gewünschte Eingangsmodus einfach per Software.

Fehlerquellen vermeiden und Kosten reduzieren

Um störende Netzschleifen zu vermeiden, ist jeder Kanal der Karte potentialgetrennt. Dies erlaubt die gemeinsame Messung von Sensoren an Orten mit hohen Potentialunterschieden wie im Umfeld von großen Testanlagen, zum Beispiel des CEC. Die Potentialtrennung ist dabei so ausgeführt, dass sie sich nicht negativ auf die Signalqualität auswirkt. Damit wird insgesamt ein Signalrauschabstand von bis zu 145 dB erreicht. Die Integration der Verstärker reduziert Kosten und vermeidet Fehlerquellen durch einen wesentlich vereinfachten Messaufbau. Änderungen der Verstärkereinstellungen werden automatisch durch das System mitprotokolliert und sind somit immer nachvollziehbar. Eine potentiell fehlerträchtige händische Dokumentation externer Verstärkungsfaktoren ist nicht mehr notwendig. Zudem reduziert sich der jährliche Kalibrieraufwand erheblich.

SWM Munich, Early Warning System PreCursor

Product: ArgusOMDS + Precursor

Efficiency increases in gas power plants in the context of energy transition

The cogeneration plant South of SWM shows how it is possible to meet the challenges of the energy revolution under the conditions that no base load is required: Utilization of wind and solar radiation in combination with control power from gas turbines. IfTA's monitoring and early warning system ensures the necessary economic efficiency.

The energy transition and the development towards renewable resources pose new challenges for the energy market. In concrete terms, this means that more and more renewable energy is flowing into the electricity grids with fluctuations due to solar radiation and wind. Control energy is provided to compensate for these fluctuations. Since gas turbines can be flexibly adapted to the electricity demand, they are often used to supply this control energy and thus stabilize the grid. At present, they are not competitive at the electricity price in base-load operation compared with other plants such as coal power plants. In order to supply this control energy, the machines are operated at partial load and thus react quickly to increasing or decreasing energy requirements. A wide usable power range as well as a low partial load limit are important.

MTU & UniBW M

Product: AIC

IfTA research project with University Bundeswehr München and MTU Aero Engines

Interdisciplinary research and development at a high level was successfully carried out as part of a project sponsored by the Free State of Bavaria. After three years of project work, all initially defined goals were achieved: the project partners ISA of university Bundeswehr München, MTU Aero Engines and IfTA GmbH were able to significantly increase the stable operating range of ISA's own Larzac engine with the help of active compressor control using the controller developed by IfTA GmbH. This project was carried out as part of an aviation research program sponsored by the Free State of Bavaria and initiated by university Bundeswehr München.

The project investigated the possibility of actively controlling compressor instabilities on an aircraft gas turbine. The aim of the research was to shift the pump limit of the LARZAC 04 C5 engine compressor available at the Institute for Jet Propulsion with the help of active measures, i.e. the use of a controller, in such a way that the stable operating range is increased and thus the efficiency of the compressor is enhanced.

IfTA as a competent partner

After the first successful control tests of other research institutions on pure test compressors, this work represented a first application on a real and complete aircraft engine. IfTA GmbH supplied the entire controller hardware and software for this project and supported the university in signal acquisition (measurement technology, recording) and interpretation (analysis, algorithms). In addition, further and new developments of the hardware and software were of course carried out during the course of the project in order to enable optimized control.

Thematic of the Central Phenomenon

The range of application of a compressor is limited by the so-called compressor surge, which is expressed in the phenomenon of "pumping" by a flow reversing across the entire cross-section of the compressor. As a weaker and therefore safer "preliminary stage" of this phenomenon, partial flow disturbances, also known as rotating separations, circulating around the circumference of the compressor can also occur. The basic idea behind the active control of a compressor is now to detect the so-called forerunners of a pumping impulse or a rotating separation in good time and to influence the system via a controller and an actuator in such a way that this undesired operation of the compressor does not occur. Modulated air injection at the blade tip area of the first compressor stage has proven to be advantageous, as this is exactly where the instabilities are triggered.

Active control with IfTA systems

Based on a modified form of the AIC system tested in the active instability control of combustion dynamics on stationary gas turbines, various control strategies were developed in the course of the project which were optimized for the respective problem. With the help of these strategies and specially adapted actuators, the research project, which lasted three years, successfully demonstrated the functionality of the active compressor stabilization system. Overall, it was possible to actively shift the pumping limit over the entire speed range of the compressor, thus demonstrating the possibility of industrial application of this innovative technology. Compared to pure constant injection, active stabilization was more efficient, i.e. the same stabilization effect could be achieved with less air or, with the same air consumption, the stable working range was extended beyond the range achievable with constant injection.

The innovative and research-relevant content of this collaboration is reflected in two joint publications at international symposia.

Large Industrial Furnaces

Service: Vibration Diagnostics

Initial Situation

The output of the large combustion burners lies in the upper kW to lower MW range. They are used, for example, in larger offices or department stores, in stadiums or in airports. They no longer have their own combustion chamber, but are operated with various boilers from other manufacturers. This means that the burners must be stable in different geometries under varying conditions. Therefore it is important to know exactly the tendency of the burners to vibrate in order to estimate their instability risk when used in different geometries.

Occurrence of combustion instabilities caused by the burner

In comparison to small furnaces, i.e. condensing boilers, heating appliances, etc., which are intended primarily for domestic use and are offered as complete units, e.g. with burner, combustion chamber, heat exchanger and exhaust system, components from different manufacturers are individually combined in large furnaces. The products manufactured by the burner manufacturer are used, for example, with boilers from another manufacturer. Although combustion instabilities always depend on the overall system, i.e. burner, combustion chamber, exhaust gas and intake system, certain tendencies towards unstable behavior can be identified directly at the burner. For example, combustion phenomena based on fluid mechanical properties generate certain frequency components stronger than others. If these areas are close to an acoustic natural frequency of a boiler and other unfavorable conditions are also met, coupling between combustion and acoustics is probable, i.e. combustion instabilities are stimulated.

IfTA - a competent partner

IfTA GmbH offers various investigations into the causes of combustion dynamics as described above. These investigations include measurements directly on the affected plant or on our customers' test benches. To support the experimental investigations of the phenomena, a numerical simulation of the acoustic behavior of the boiler geometries is also recommended. As a customer, you can rely on a competent, fast and cost-effective handling of your problems, as in the other areas. It goes without saying that we treat every issue confidentially.

Small Furnaces in Everyday Life

Service: Vibration Diagnostics

Initial Situation

By small firing systems we understand combustion systems in the lower kW range, which are used e.g. as gas heaters, condensing boilers, oil burners etc. in apartments, single-family houses and apartment buildings. Furthermore, these include gas ovens or roasters for canteen kitchens, gas heaters in camping areas and similar systems with a defined combustion chamber geometry in which acoustic natural oscillations can establish themselves, as well as a flame burning in them.

Effects

Especially in the field of heaters, in addition to low-emission and efficient operation, quiet combustion is of particular importance, since direct or indirect noise generation by the combustion system can lead to a considerable impairment of the quality of living and thus also of the quality of life. As with large systems, combustion oscillations in small combustion systems can be caused by inconspicuous environmental changes (gas composition, installation conditions, operating point, ambient temperature, etc.). The effects of these changes can be manifold: low-frequency humming with fixed or variable frequency when starting up, sudden, short-term occurrence of instabilities, e.g. caused by closing a door (and the associated pressure surge), high-frequency whistling (about 800Hz, 120dB) when operating at a certain operating point, etc.

Occurrence of combustion instabilities caused by the burner

In comparison to small furnaces, i.e. condensing boilers, heating appliances, etc., which are intended more for domestic use and are offered complete with burner, combustion chamber, heat exchanger and flue gas system, components from different manufacturers are individually combined in large furnaces. The products manufactured by the burner manufacturer are used, for example, with boilers from another manufacturer. Although combustion instabilities always depend on the overall system, i.e. burner, combustion chamber, exhaust gas and intake system, certain tendencies towards unstable behavior can be identified directly at the burner. For example, combustion phenomena based on fluid mechanical properties generate certain frequency components more strongly than others. If these areas are close to an acoustic natural frequency of a boiler and other unfavorable conditions are also met, coupling between combustion and acoustics is probable, i.e. combustion instabilities can be excited.

IfTA as a competent partner

IfTA GmbH offers a wide range of investigations into the causes of combustion instabilities described above. These investigations include measurements directly on the affected plant or on our customers' test benches. To support the experimental investigations of the phenomenon, a numerical simulation of the acoustic behavior of the boiler geometries is also recommended. As a customer, you can rely on a competent, fast and cost-effective handling of your problems, as in the other areas. It is a self-evident fact for us that we treat your problem confidentially.

Measurement Chain Testing on Gas Turbines

Product: Charge Signal Generator

Testing of Measurement Chains Saves Costs

Up to 16 dynamic high-temperature pressure sensors continuously monitor the combustion process of modern heavy-duty gas turbines. All of them are connected to a central measurement system via external charge amplifiers. The complexity of such setups requires the careful and systematic testing of all measurement chains by use of a charge signal generator (CSG). An undetected faulty wiring or damage can lead to gas turbine failure, which may cause high costs very quickly.

Common Mistakes

Wrongly wired measurement chains are one of the most common errors we see in the field. If such errors are not detected, damages due to excessive pressure amplitudes may be assigned to the wrong combustion chamber. As a consequence, inspection and maintenance may be carried out at the wrong place.
Polarity errors occur rather frequently, as well. If undetected, they can limit proper monitoring and protection, for example, by the early warning system IfTA PreCursor.
Occasionally, sensor cables are connected incorrectly to the charge amplifier, which can lead to mains hum.
Due to the constant vibrations of the gas turbine, the cables can chafe, come loose or be damaged by hot gases in case of leakage, which can ultimately lead to their failure.
The charge amplifiers can also show signs of aging over time, which may lead to a decrease in signal quality.

In the latter two cases, there is a risk that a measurement chain goes "blind" and thus can no longer fulfill its monitoring task. Routine checks of all measurement chains are hence essential, especially after a new installation, a replacement or a modification in the course of maintenance works. A portable charge signal generator is an important tool for this task. It simulates the output signal of a sensor with a clearly defined frequency and amplitude and can therefore be used to test the electrical part of a measurement chain.

In the picture to the left, the technician standing next to a single gas turbine combustion chamber illustrates the dimensions of the machine. One realizes that checking the measurement chains involves a considerable amount of work, as one technician has to climb to each sensor while another is sitting in the control room. In most cases, the situation is aggravated by the fact that direct communication between the two is not possible due to the distances between the turbine and the control room. Often the inspection of the electrode must even be carried out by a single person.

Product Overview

Ben­e­fit from Knowl­edge and Ex­pe­ri­ence

Siemens en­er­gy - CECBer­lin - SGT5-8000H

Prod­uct: Ar­gusOMDS

SWM Mu­nich, earlywarn­ing sys­tem

Prod­uct: Ar­gusOMDS + Pre­cur­sor

MTU &UniBw M

Prod­uct: AIC-Sys­tem

Large fur­naces in in­dus­try

Prod­uct: con­sult­ing and ser­vice

Small Fur­naces in daily life

Prod­uct: con­sult­ing and ser­vice

Sig­nal Test­ing on Ga­s tur­bi­nes

Prod­uct: Charge sig­nal Gen­er­a­tor

Mit in­­tel­li­­gen­ter Sch­win­­gungs­mess­tech­nik zur sau­be­ren En­er­gie

Prüf­stände zur Op­ti­mierung von Gas­tur­binen

Die IfTA Lö­sung

Flex­i­bil­ität durch Mo­du­lar­ität

Jeder Sen­­sor passt an jeden Ein­­gang

Fe­h­ler­quel­len ver­mei­­den und Kos­ten re­­du­zie­ren

Zeit­gemäße Da­te­n­anal­yse durch ein­fach be­di­en­bare Soft­ware

Prüf­s­tand­schutz le­icht gemacht

Ef­fi­cien­cy in­creas­es in gas power plants in the con­text of en­er­gy tran­si­tion

Chal­lenges of par­tial load op­er­a­tion

Knowl­edge as a basis for ef­fec­tive op­er­a­tion

IfTA re­search project with Univer­si­ty Bun­deswehr München and MTU Aero Engines

IfTA as a com­pe­tent part­ner

The­mat­ic of the Cen­tral Phenomenon

Ac­tive con­trol with IfTA sys­tems

Ini­tial Si­t­u­a­tion

Oc­cur­rence of com­bus­tion in­sta­bil­i­ties caused by the burn­er

IfTA - a com­pe­tent part­ner

Ini­tial Si­t­u­a­tion

Ef­fects

Oc­cur­rence of com­bus­tion in­sta­bil­i­ties caused by the burn­er

IfTA as a com­pe­tent part­ner

Test­ing of Meas­ure­­ment Chains Saves Costs

Com­plex Mea­sure­ment Se­tups

Com­mon Mis­takes

IfTA Charge Sig­­nal Gen­er­at­or Helps to Elim­in­ate Er­rors

Test bench pro­tec­tion fa­cil­i­tat­ed

Benefit from Knowledge and Experience

Siemens energy - CEC
Berlin - SGT5-8000H

Product: ArgusOMDS

SWM Munich, early
warning system

Product: ArgusOMDS + Precursor

MTU &
UniBw M

Product: AIC-System

Large furnaces in industry

Product: consulting and service

Small Furnaces in daily life

Product: consulting and service

Signal Testing on Gas turbines

Product: Charge signal Generator

Mit intelligenter Schwingungsmesstechnik zur sauberen Energie

Prüfstände zur Optimierung von Gasturbinen

Die IfTA Lösung

Flexibilität durch Modularität

Jeder Sensor passt an jeden Eingang

Fehlerquellen vermeiden und Kosten reduzieren

Zeitgemäße Datenanalyse durch einfach bedienbare Software

Prüfstandschutz leicht gemacht

Efficiency increases in gas power plants in the context of energy transition

Challenges of partial load operation

Knowledge as a basis for effective operation

IfTA research project with University Bundeswehr München and MTU Aero Engines

IfTA as a competent partner

Thematic of the Central Phenomenon

Active control with IfTA systems

Initial Situation

Occurrence of combustion instabilities caused by the burner

IfTA - a competent partner

Initial Situation

Effects

Occurrence of combustion instabilities caused by the burner

IfTA as a competent partner

Testing of Measurement Chains Saves Costs

Complex Measurement Setups

Common Mistakes

IfTA Charge Signal Generator Helps to Eliminate Errors

Test bench protection facilitated