Instrumented component for use in an operating environment

• US 20100226756A1
• Filed: 09/14/2006
• Published: 09/09/2010
• Est. Priority Date: 06/21/2004
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Power Generation, Inc.
• Inventors: Kulkarni, Anand A., Subramanian, Ramesh, Roesch, Edward R., Mitchell, David J.
• Granted Patent: US 8,004,423 B2
• Time in Patent Office: Days
• US Class Current: 415/118
• CPC Class Codes: C23C 28/321 with at least one metal alloy layer
• CPC Class Codes: C23C 28/3215 at least one MCrAlX layer
• CPC Class Codes: C23C 28/34 including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
• CPC Class Codes: C23C 28/341 with at least one carbide layer
• CPC Class Codes: C23C 28/345 with at least one oxide layer
• CPC Class Codes: C23C 28/3455 with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer
• CPC Class Codes: F01D 17/02 Arrangement of sensing elements
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F01D 21/10 responsive to unwanted deposits on blades, in working-fluid conduits or the like
• CPC Class Codes: F01D 5/288 Protective coatings for blades
• CPC Class Codes: F05D 2230/90 Coating; Surface treatment
• CPC Class Codes: F05D 2300/611 Coating
• CPC Class Codes: F23R 3/007 constructed mainly of ceramic components
• CPC Class Codes: G01D 3/08 with provision for safeguarding the apparatus, e.g. against abnormal operation, against breakdown
• CPC Class Codes: H04Q 2209/40 using a wireless architecture
• CPC Class Codes: H04Q 2209/50 using a mobile data collecting device, e.g. walk by or drive by
• CPC Class Codes: H04Q 9/00 Arrangements in telecontrol or telemetry systems for selectively calling a substation from a main station, in which substation desired apparatus is selected for applying a control signal thereto or for obtaining measured values therefrom
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

An instrumented component (18, 19) for use in various operating environments such as the hot gas path section of a combustion turbine engine (10). The component (18, 19) may have a substrate, a sensor (50, 204, 210) connected with the substrate for sensing a condition of the component (18, 19) within the casing during operation of the combustion turbine (10) and a connector (52, 202) attached to the substrate and in communication with the sensor (50, 204, 210) for routing a data signal from the sensor (50, 204, 210) to a termination location (53). The component (18, 19) may include a wireless telemetry device (54, 202) in communication with the connector (52, 202) for wirelessly transmitting the data signal outside the casing. A transceiver (56) may be located outside the casing for receiving the data signal and transmitting it to a processing module (30) for developing information with respect to a condition of the component (18, 19) or a coating (26) deposited on the component (18, 19).

Claims

1. ) An instrumented component for use in a combustion turbine engine including a compressor and a turbine, the instrumented component comprising:

a substrate;

at least one sensor deposited in connection with the substrate for sensing a condition of the instrumented component;

a wireless telemetry device connected with the substrate, the wireless telemetry device comprising an electroceramic chip containing a plurality of electronic components configured to receive a data signal from the at least one sensor and wirelessly transmit the data signal to a receiving device; and

a connector electrically connecting the at least one sensor to the wireless telemetry device for communicating the data signal from the at least one sensor to the wireless telemetry device.

2. ) The instrumented component of claim 1 further comprising:

a bond coat deposited on at least a portion of the substrate;

a thermally grown oxide layer forming an upper surface portion of the bond coat;

the at least one sensor deposited on the thermally grown oxide layer; and

a thermal barrier coating deposited over at least a portion of the thermally grown oxide layer.

3. ) The instrumented component of claim 2 further comprising the at least one sensor comprising at least one material selected from the group of an oxide, a carbide and a silicide.

4. ) The instrumented component of claim 2 further comprising the at least one sensor comprising an indium tin oxide material deposited on the thermally grown oxide layer to form a sensor selected from the group of a strain gage sensor and a heat flux sensor.

5. ) The instrumented component of claim 1, the substrate comprising a turbine blade and the wireless telemetry device connected to a root of the turbine blade.

6. ) The instrumented component of claim 5 further comprising the wireless telemetry device capable of operation at temperatures of at least about 250°

C. and the plurality of electronic components comprising an electroceramic material forming an electronic circuit.

7. ) The instrumented component of claim 6 further comprising the electroceramic material selected from the group of SiC, AIN and GaN.

8. ) The instrumented component of claim 5 further comprising:

a bond coat deposited on at least a portion of the substrate;

a thermally grown oxide layer forming an upper surface portion of the bond coat;

the at least one sensor deposited on the thermally grown oxide layer;

a thermal barrier coating deposited over at least a portion of the thermally grown oxide layer; and

the wireless telemetry device comprising a combination of electroceramic materials and metallic materials forming the plurality of electronic components.

9. ) The instrumented component of claim 1 further comprising the wireless telemetry device comprising a combination of electroceramic materials and metallic materials forming the plurality of electronic components.

10. ) The instrumented component of claim 1 further comprising:

the at least one sensor deposited on a surface of the substrate; and

the wireless telemetry device connected to a root of the substrate.

11. ) The instrumented component of claim 1 further comprising the at least one sensor comprising a ceramic-based thermocouple material embedded within a thermal barrier coating deposited on the substrate.

12. ) The instrumented component of claim 1 further comprising the plurality of electronic components comprising an oscillator, an amplifier and an antenna.

13. ) An instrumented component for use in a casing of a combustion turbine engine, the component comprising:

a substrate having a root portion;

a sensing material deposited in connection with the substrate;

a wireless telemetry device secured with the root portion; and

a connector electrically connecting the sensing material with the wireless telemetry device.

14. ) The component of claim 13 further comprising:

a bond coat deposited on a surface of the substrate;

an insulating layer formed on the bond coat;

the sensing material deposited on the insulating layer forming a sensor; and

a thermal barrier coating deposited over the sensor.

15. ) The component of claim 13 further comprising the wireless telemetry device comprising an electroceramic material deposited on an electroceramic chip to form at least one electronic circuit configured to receive a data signal over the connector and wirelessly transmit the data signal to a receiving device.

16. ) The component of claim 14 further comprising:

a transmitter secured with the root portion;

an antenna secured with the root portion; and

a ceramic material covering the transmitter and the antenna.

17. ) A combustion turbine engine comprising:

a compressor having a casing;

a compressor blade assembly comprising a hub and a plurality of compressor blades having respective compressor blade roots connecting the plurality of compressor blades to the hub;

a first sensing material deposited on a surface of one of the plurality of compressor blades;

a connector in communication with the first sensing material for routing a first data signal from the first sensing material to a termination point;

a first wireless telemetry device secured with the hub, the first wireless telemetry device receiving the first data signal from the first sensing material;

a ceramic material covering the first wireless telemetry device;

a transceiver external to the compressor casing for receiving a wirelessly transmitted data signal from the first wireless telemetry device;

a combustor; and

a turbine having a casing.

18. ) The combustion turbine engine of claim 17 further comprising the wireless telemetry device comprising a semiconducting material forming an electronic circuit, an antenna and a transmitter.

19. ) The combustion turbine engine of claim 17 further comprising:

a turbine blade assembly comprising a hub and a plurality of turbine blades having respective blade roots connecting the plurality of turbine blades to the hub;

a second sensing material deposited on the turbine blade assembly, the second sensing material comprising a material selected from the group of a carbide, a silicide and an oxide;

a connector in communication with the second sensing material for routing a second data signal from the second sensing material to a termination point proximate at least one turbine blade root;

a second wireless telemetry device affixed to the at least one turbine blade root; and

a transceiver external to the turbine casing for receiving the wirelessly transmitted data signals.

20. ) The combustion turbine engine of claim 19 further comprising the wireless telemetry device comprising an electroceramic material deposited on an electroceramic chip forming at least one electronic circuit configured to receive the second data signal and wirelessly transmit the second data signal to the transceiver, the electroceramic material selected from the group of SiC, AIN and GaN.