SYSTEM TO PROGNOSE GAS TURBINE REMAINING USEFUL LIFE

• US 20160301880A1
• Filed: 04/13/2015
• Published: 10/13/2016
• Est. Priority Date: 04/13/2015
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Energy Incorporated (Siemens AG)
• Inventors: Iyer, Arun Meenakshinatha, Licata, Kevin, Kulkarni, Anand A.
• Granted Patent: US 10,101,577 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: G01J 2005/0077 Imaging
• CPC Class Codes: G01J 5/0088 in turbines
• CPC Class Codes: G01J 5/041 Mountings in enclosures or in a particular environment
• CPC Class Codes: G01J 5/0818 Waveguides
• CPC Class Codes: G01J 5/0896 using a light source, e.g. for illuminating a surface
• CPC Class Codes: G02B 23/24 Instruments or systems for viewing the inside of hollow bodies, e.g. fibrescopes
• CPC Class Codes: G02B 23/2453 of the proximal end
• CPC Class Codes: G02B 23/2492 Arrangements for use in a hostile environment, e.g. a very hot, cold or radioactive environment

Abstract

A flash thermography device for generating an infrared image of a turbine component located inside a turbine, wherein the turbine includes at least one inspection port. The device includes a flash source that generates a light pulse that heats the turbine component and an infrared sensor for detecting thermal energy radiated by the turbine component. The device also includes a borescope having a sensor end, a viewing end that includes the flash source and an interior hollow that extends between the sensor and viewing ends. The borescope is positioned in the inspection port such that the viewing end is located inside the turbine. Thermal energy radiated from the turbine component is transmitted through the hollow to the infrared sensor to enable generation of the infrared image. The device further includes a reflector located on the viewing end that directs the light pulse toward the turbine component and a flash power supply for energizing the flash source.

Claims

1. A flash thermography device for generating an infrared image of a turbine component located inside a turbine, wherein the turbine includes at least one inspection port, comprising:

a flash source that generates a light pulse that heats the turbine component;

an infrared sensor for detecting thermal energy radiated by the turbine component;

a borescope having a sensor end and a viewing end, wherein the sensor end is adjacent the infrared sensor and the viewing end includes the flash source wherein the borescope is positioned in the inspection port to locate the viewing end inside the turbine and wherein thermal energy radiated from the turbine component is transmitted through the borescope to the infrared sensor to enable generation of the infrared image; and

a reflector that directs the light pulse toward the turbine component, wherein the reflector is located on the viewing end.

2. The device according to claim 1, wherein the infrared sensor is an infrared camera.

3. The device according to claim 1, wherein the component is a hot gas path component selected from the group consisting of a combustor, transition, vane and blade.

4. The device according to claim 1, further including an infrared filter located on the viewing end to enable detection of thermal energy that is in the middle infrared region of the electromagnetic spectrum.

5. The device according to claim 1, wherein a duration of the light pulse is approximately 2 to 15 milliseconds.

6. The device according to claim 5, wherein the component includes a thin coating and a signal collection time for the infrared sensor is approximately 2 seconds when using a light pulse having a duration of approximately 2 seconds.

7. The device according to claim 5, wherein the component includes a thick coating and a signal collection time for the infrared sensor is approximately 15 seconds when using a light pulse having a duration of approximately 15 seconds.

8. The device according to claim 1, wherein the flash source includes a plurality of sectors.

9. The device according to claim 1, wherein the borescope includes at least one lens.

10. The device according to claim 9, wherein the lens is an objective lens.

11. A flash thermography device for generating an infrared image of a turbine component located inside a turbine, wherein the turbine includes at least one inspection port, comprising:

a flash source that generates a light pulse that heats the turbine component;

an infrared sensor for detecting thermal energy radiated by the turbine component;

a borescope having a sensor end, a viewing end and an interior hollow that extends between the sensor and viewing ends, wherein the sensor end is adjacent the infrared sensor and the viewing end includes the flash source wherein the borescope is positioned in the inspection port to locate the viewing end inside the turbine and wherein thermal energy radiated from the turbine component is transmitted through the hollow to the infrared sensor to enable generation of the infrared image;

a reflector that directs the light pulse toward the turbine component, wherein the reflector is located on the viewing end; and

a flash power supply for energizing the flash source.

12. The device according to claim 11, wherein the infrared sensor is an infrared camera.

13. The device according to claim 11, wherein the component is a turbine airfoil.

14. The device according to claim 11, further including an infrared filter located on the viewing end to enable detection of thermal energy that is in the middle infrared region of the electromagnetic spectrum.

15. The device according to claim 11, wherein a duration of the light pulse is approximately 2 to 15 milliseconds.

16. The device according to claim 15, wherein the component includes a thin coating and a signal collection time for the infrared sensor is approximately 2 seconds when using a light pulse having a duration of approximately 2 seconds.

17. The device according to claim 15, wherein the component includes a thick coating and a signal collection time for the infrared sensor is approximately 15 seconds when using a light pulse having a duration of approximately 15 seconds.

18. The device according to claim 11, wherein the flash source includes a plurality of sectors.

19. The device according to claim 11, wherein the borescope includes at least one lens.

20. A method for generating an infrared image of a turbine component located inside a turbine, wherein the turbine includes at least one inspection port, comprising:

providing a flash source that generates a light pulse that heats the turbine component;

providing an infrared sensor for detecting thermal energy radiated by the turbine component;

providing a borescope having a viewing end and an interior hollow that extends from the viewing end to the infrared sensor;

inserting the borescope into the inspection port to locate the viewing end inside the turbine; and

transmitting thermal energy radiated from the turbine component through the hollow to the infrared sensor to enable generation of the infrared image.

21. A method for inspecting a turbine component located inside a turbine system, wherein the turbine includes at least one inspection port, comprising:

providing a flash source that generates a light pulse that heats the turbine component;

providing an infrared sensor for detecting thermal energy radiated by the turbine component;

providing a borescope having a viewing end and an interior hollow that extends from the viewing end to the infrared sensor;

inserting the borescope into the inspection port to locate the viewing end inside the turbine system;

transmitting thermal energy radiated from the turbine component through the hollow to the infrared sensor to enable generation of the infrared image; and

inspecting a turbine characteristic.

22. The method according to claim 21, wherein the turbine characteristic is a back flow margin for a stationary or rotating component including a thermal barrier coating and/or a bond coating wherein the back flow margin is estimated soon after shutdown of the turbine system, without waiting for a cool down period thereby enabling adjustment of modulated cooling flows to improve performance for future turbine operation.

23. The method according to claim 21, wherein the turbine characteristic is an impingement pressure ratio that is estimated soon after shutdown without waiting for a cool down period.

24. The method according to claim 21, wherein inspection of the turbine characteristic provides information used to increase a firing temperature during operation of the turbine system thereby improving turbine efficiency and power output.

25. The method according to claim 21, wherein inspection of the turbine characteristic enables determination of a useful life of the turbine component without waiting for a cool down period and without removal of a turbine shell cover.

26. The method according to claim 21, wherein the turbine characteristic is a thermal barrier coating and/or bond coating thickness on the component and/or a delamination level wherein the turbine characteristic is inspected to enable prediction of whether the turbine system is able to withstand a level of chipping in the thermal barrier and/or bond coating by estimation of base metal temperature.

27. The method according to claim 21, wherein inspection of the turbine characteristic provides real time feedback to enable turbine efficiency and performance improvements.