Systems and methods for monitoring energy system components

• US 7,715,991 B2
• Filed: 05/17/2007
• Issued: 05/11/2010
• Est. Priority Date: 05/17/2007
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (General Electric Company)
• Original Assignee: General Electric Company
• Inventors: Welch, David Ernest, Chau, David Wing, Potdar, Yogesh Kesrinath
• Primary Examiner(s): Wachsman; Hal D
• Application Number:
  US11/750,025
• Publication Number:
  US 20080288183A1
• Time in Patent Office: 1,090 Days
• Field of Search: 702/34, 702/35, 702/36
• US Class Current: 702/34
• CPC Class Codes: G01M 5/00 Investigating the elasticity of structures, e.g. deflection of bridges or air-craft wings G01M9/00 takes precedence
• CPC Class Codes: G01M 5/0033 by determining damage, crack or wear

Abstract

A method for estimating an amount of damages sustained by a component operating in an energy system by monitoring the component is provided. The method includes generating a transfer function that is dependent upon an input of at least one operating condition of the component and an output of a crack-initiation time and/or a crack propagation for at least one critical region. The method further includes receiving data from at least one sensor coupled to the component, wherein the data relates to the at least one operating condition of the component, and inputting the received data from the at least one sensor into the transfer function to calculate at least one of the crack-initiation time and the crack propagation for the at least one critical region. The method also includes recording at least one of the crack-initiation time and the crack propagation on a memory storage device.

Claims

1. A method for estimating an amount of damage sustained by a component operating in an energy system by monitoring the component, the method comprising:

generating a transfer function that is dependent upon an input of at least one operating condition of the component and an output of at least one of a crack-initiation time and a crack propagation for at least one critical region;

receiving data from at least one sensor coupled to the component, wherein the data relates to the at least one operating condition of the component;

inputting the received data from the at least one sensor into the transfer function to calculate the at least one of the crack-initiation time and the crack propagation for the at least one critical region; and

recording at least one of the crack-initiation time and the crack propagation on a memory storage device.

2. A method in accordance with claim 1 wherein monitoring a component further comprises monitoring a globe valve that includes a plurality of critical regions.

3. A method in accordance with claim 1 further comprising estimating the remaining time until the critical damage level or failure occurs for the component being monitored.

4. A method in accordance with claim 1 wherein generating a transfer function further comprises developing the transfer function based on at least one of measured temperature gradients and low-cycle-fatigue (LCF) life consumed.

5. A method in accordance with claim 1 further comprising:

inspecting the component to obtain information indicative of an amount of damage to the component; and

applying the information indicative of the amount of damage to the component to the transfer function to enable at least one of the crack-initiation time and the crack propagation to be re-calculated.

6. A method in accordance with claim 1 wherein receiving data from at least one sensor comprises receiving data from a plurality of sensors coupled to the component.

7. A method of operating an energy system including a component that has at least one critical region which may develop a crack therein, said method comprising:

developing a transfer function for the at least one critical region, wherein the transfer function is based upon an input of at least one operating condition and an output of at least one of a crack-initiation time and a crack propagation for the at least one critical region;

receiving data from at least one sensor coupled to the component, wherein the data relates to the at least one operating condition;

applying the data received from the at least one sensor to the transfer function of the at least one critical region to calculate the at least one of the crack-initiation time and the crack propagation for the at least one critical region; and

determining at least one of an operating schedule and an operating parameter for the energy system based on at least one of the crack-initiation time and the crack propagation.

8. A method in accordance with claim 7 further comprising monitoring the operation of at least one globe valve which includes a plurality of critical regions.

9. A method in accordance with claim 7 wherein developing a transfer function for the at least one critical region further comprises developing the transfer function between measured temperature gradients and low-cycle-fatigue (LCF) life consumed.

10. A method in accordance with claim 7 further comprising adjusting the operating schedule based on the calculation of at least one of the crack-initiation time and the crack propagation for the at least one critical region.

11. A method in accordance with claim 10 wherein adjusting the operating schedule comprises using the data received from the at least one sensor relating to a change in the at least one operating condition and a life expectancy adjustment to calculate an inspection time adjustment.

12. A method in accordance with claim 10 wherein adjusting the operating schedule comprises increasing the time until the next inspection based on a previous inspection resulting in no observable cracks.

13. A method in accordance with claim 7 further comprising:

inspecting the component to obtain information relating to an amount of damage of the component; and

applying the information to the transfer function to re-calculate at least one of the crack-initiation time and the crack propagation.

14. A method in accordance with claim 7 wherein receiving data from at least one sensor comprises receiving data from a plurality of sensors that are each coupled to the component.

15. A control system for use in monitoring and operating an energy system, said control system comprising:

a component comprising a predetermined transfer function based on an input of at least one operating condition of the energy system and an output of at least one of a crack-initiation time and a crack propagation within at least one critical region;

at least one sensor coupled to said component for monitoring the at least one operating condition of said component; and

a processor configured to;

receive data from said at least one sensor, wherein the data relates to at least one operating condition of said component;

apply the data to the transfer function to calculate at least one of the crack-initiation time and the crack propagation within the at least one critical region; and

record at least one of the crack-initiation time and the crack propagation of the at least one critical region on a memory storage device.

16. A control system in accordance with claim 15, wherein said component further comprises at least one critical region.

17. A control system in accordance with claim 15, said system configured to:

determine a first life expectancy using the transfer function and data regarding at least one operating condition;

receive data relating to a change in the at least one operating condition for the at least one critical region of the component; and

calculate a life expectancy adjustment using the transfer function and data relating to the change in the at least one operating condition.

18. A control system in accordance with claim 15, said processor further configured to determine a first life expectancy using the transfer function and the data received from at least one sensor relating to at least one operating condition.

19. A control system in accordance with claim 15, said processor further configured to receive data relating to a change in the at least one operating condition for the at least one critical region of the component.

20. A control system in accordance with claim 15, said processor further configured to calculate a life expectancy adjustment using the transfer function and the data relating to a change in that at least one operating condition.