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The development of new products (aero engines, industrial gas turbines and steam turbines) requires validation and verification to demonstrate that design assumptions are realistic and have been met. This is mandatory to predict safe operation, for design optimisation and to assess the life cycle and maintenance cycle of the product.
A validation strategy is necessary with regards to the information that has to be measured for the new product. It defines the point in time during the development cycle in which data will have to be measured using test vehicles (instrumented engines / gas turbines / steam turbines) and support the development team in optimising the design, based on a set database for decision-making.
Instrumentation design is the integration of measurement devices into a test vehicle (or test engine) in order to measure real physical conditions during operation of the engine or test vehicle.
It provides a database of real conditions (temperatures, pressures, vibrations, strain, clearances etc.) during the test and as such serves as a comparison with assumptions made by the customer product design team, as well as validating the codes (stress SW, thermal SW) used during the design phase.
It therefore provides the basis for checking the actual status. Instrumentation can be designed for testing complete engines as well as components.
A separate test vehicle (rig) is used as a test bed for gas turbine component testing.
The instrumentation design forms the basis for the application team. The application team installs the measurement sensors to the test vehicle during the manufacturing and application phase, based on the design definitions.
Example: Validation of the design of a turbine blade
The design of a turbine blade is to be validated. The instrumentation designer gives all relevant information on hardware modifications and new hardware in order for the required sensor to be applied.
The designer gives instructions on all processes for mounting the sensor in a defined environment as well as the lead-out routing to generate a data connection between the sensor (mounted on a turbine blade) and the test facility.
Instrumentation design is part of the overall development and validation process of a gas turbine.
Therefore, the instrumentation design team works in on-going cooperation with the interface departments (analyses, application, manufacturing, test & measurement).
During the instrumentation design phase, the design team is constantly supported by the analysis, manufacturing, application and test & measurement teams.
From the customer request up to preparation of the test, the instrumentation design team develops and coordinates the activities, from start to finish.
Engineering Support can provide a self-contained service (technical method and criteria, project-managed or managed service) which is integrated into the customer organisation. Thanks to years of working with OEMs, we have extensive instrumentation design and development experience of aero engines, industrial gas turbines and steam turbines.
Based on project and customer requirements, instrumentation design can be carried out in accordance with the AneCom AeroTest instrumentation design standards or in accordance with customer design standards.
- We utilise tools such as: Unigraphics (NX) & TeamCenter (TC), Ansys, SC03, NX mesh tool, VBA (Excel) and Matlab
- Our team includes more than 100 technical specialists and engineers
- Analysis activities include: Thermal stress, rotor dynamics, life assessment, resonance frequency, harmonic analysis and model shape determination
- Design activities include: Component design and integrated instrumentation design
Thank you for the excellent cooperation with your staff. I have always been able to rely on both AneCom team members that share my profession who were working with me, and we really appreciate the fact that we were also able to successfully achieve the second test under major time pressure thanks to your flexibility.
High quality. Everything was to our complete satisfaction.
In this respect, I would also like to emphasise on behalf of my colleagues the high degree of flexibility in the face of changing requirements. Thank you for the superb and timely cooperation.
An excellent performance delivered under difficult and pressing time constraints, which enabled the project to commence as planned.
Thanks to an early delivery date at our request, the instrumentation was ready in less than 1/3 of the original time. The service was carried out with the usual high quality. This feat could not be anywhere near replicated by internal departments and therefore deserves the highest recognition.
It was a remarkable job to coordinate the efforts between both teams. Every employee demonstrated a high level of technical knowledge and was very helpful. AneCom AeroTest delivered what was promised and we believe they will maintain the high level of service for future projects.
Very good communication during the whole project.