Apparatus and method of monitoring operating parameters of a gas turbine

• US 8,742,944 B2
• Filed: 08/31/2009
• Issued: 06/03/2014
• Est. Priority Date: 06/21/2004
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Energy Incorporated (Siemens AG)
• Inventors: Mitchell, David J., Kulkarni, Anand A., Subramanian, Ramesh
• Primary Examiner(s): Phan, Hai
• Assistant Examiner(s): Benlagsir, Amine
• Application Number:
  US12/550,715
• Publication Number:
  US 20100117859A1
• Time in Patent Office: 1,737 Days
• Field of Search: 340/870.01, 340/870.16
• US Class Current: 340/870.01
• 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: F05D 2230/30 with deposition of material
• CPC Class Codes: F05D 2230/90 Coating; Surface treatment
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: G01K 1/024 for remote indication
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

An integrated, self-powered, sensing and transmitting module (300) that can be placed within an operating environment, such as by being affixed to a gas turbine engine component, in order to sense the local operating environment and to deliver real-time operating environment data to a location outside of the environment. Such a module may integrate a power element (302); a sensing element 9304); and a transmitting element (308) on a single substrate (320) within a single housing (310). Both sensors and circuitry components are formed directly on or in the substrate in novel configurations to decrease the size and weight of the module.

Claims

1. A self-powered sensing and transmitting module for monitoring an operating parameter of a component within a turbine section of a combustion turbine, comprising:

a power element;

a sensing element powered by the power element for generating a sensor signal responsive to a local operating environment;

a transmitting element powered by the power element for transmitting an output signal responsive to the sensor signal to a receiving location remote from the module; and

a housing containing the power element, sensing element and transmitting element,

wherein the power element, sensing element and transmitting element are all formed on a single circuit board substrate, and the circuit board substrate comprises alumina or an insulated silicon carbide including an insulating material disposed between the silicon carbide substrate and each of the power element, sensing element, transmitting element,

the module, including the single circuit board substrate having the power element, sensing element and transmitting element thereon, is mounted on the component of the turbine section and, for a circuit board substrate composed of alumina, the module is in an operating environment having temperature that does not exceed about 450°

C. and, for a circuit board substrate composed of insulated silicon carbide, the module is in an operating environment having temperature that is up to about 600°

C.; and

wherein the module is positioned in or on a combustion turbine, wherein the component comprises;

a substrate having a thermal barrier coating;

a sensor for detecting an operating parameter of the component, the sensor being configured to transmit one or more signals indicative of the operating parameter, and the sensor is affixed to the thermal barrier and remote relative to the module, and the component and the sensor are disposed within a hot gas path having a temperature exceeding about 650°

C.; and

the transmitting element is in electrical communication with the sensor on the substrate for transmitting an output signal responsive to the one or more signals received from the sensor to a receiving location remote from the module.

2. The module of claim 1, wherein the power element comprises an energy harvesting element for creating electrical power in response to non-electrical energy present in a local environment.

3. The module of claim 1, wherein the transmitting element comprises an RF antenna comprising a patch of material sized to be resonant at a predetermined wavelength.

4. The module of claim 3, wherein the antenna comprises polysilicon formed into a planar pattern to provide a radiation pattern for 17.5 GHz RF transmission.

5. The module of claim 3, wherein the antenna comprises a magnetic metamaterials.

6. The module of claim 3, wherein the antenna comprises an FeCo or NiFe composite.

7. The module of claim 3, wherein the transmitting element is configured for multi-channel communications and comprises two RF antennae configured to be resonant at two different frequencies.

8. The module of claim 1, wherein the transmitting element comprises a first antenna optimized for RF radiation for data transfer at a first frequency;

and

wherein the power element comprises a second antenna optimized for RF power reception at a second frequency different than the first frequency.

9. The module of claim 1, wherein the sensing element comprises a temperature or heat flux sensor formed on the circuit board substrate by depositing a material onto a surface of the circuit board substrate or into a via formed in the surface of the circuit board substrate, wherein the deposited material is selected to have a desired temperature coefficient of resistance.

10. The module of claim 1, wherein the sensing element comprises one of the group consisting of aluminum, platinum and gold.

11. The module of claim 1, wherein the sensing element comprises a pressure sensor formed the circuit board substrate by depositing a material onto a surface of the circuit board substrate or into a via formed in the surface of the circuit board substrate, where the deposited material has a desired piezoresistive or capacitive response.

12. The module of claim 11, wherein the deposited material comprises silicon or SiC.

13. The module of claim 1, wherein at least one of the elements comprises a capacitor formed as a surface feature of a conductive material in a shape that provides a parallel plate arrangement.

14. The module of claim 13, wherein the capacitor comprises a first set of conductive fingers interspaced between a second set of respective conductive fingers, the two sets of conductive fingers being separated by respective gaps providing a capacitance there between.

15. The module of claim 1, wherein at least one of the elements comprises a capacitor formed as at least two layers of electrically conductive material separated by a dielectric material disposed within a via in a substrate of the module.

16. The module of claim 1, wherein at least one of the elements comprises a capacitor formed as at least two layers of electrically conductive material deposited on opposed surfaces of the substrate of the module.

17. The module of claim 1, wherein the sensor element comprises a resistance temperature detector comprising an MCrAlY material.

18. The module of claim 17, wherein the resistance temperature detector comprises an NiCoCrAlY alloy.

19. The module of claim 1, wherein the sensor element comprises a strain gage formed by depositing a single conductive line of an MCrAlY material in a surface pattern on a substrate of the module.

20. The module of claim 1, wherein the sensor on the substrate is a MEMS device.

21. The module of claim 1, wherein the module is mounted to a face of a turbine blade root and the turbine blade rotates about a rotary axis of the combustion turbine during operation.

22. A turbine component for use in a combustion turbine and in connection with a self-powered transmitting module for monitoring one or more operating parameters of one more components within a turbine section of a combustion turbine, comprising:

a substrate having a thermal barrier coating;

a sensor for detecting an operating parameter of the component, the sensor being configured to transmit one or signals indicative of the operating parameter, and the sensor is affixed to the thermal barrier, and the component and sensor are disposed within a hot gas path having a temperature exceeding about 650°

C.;

the module is in electrical communication with the sensor and is positioned remotely relative to the sensor, and the module comprising;

a power element;

a transmitting element in electrical communication with the sensor and powered by the power element for transmitting an output signal responsive to the one or signals received from the sensor to a receiving location remote from the module; and

,

a housing containing the power element and transmitting element;

wherein the power element and transmitting element are formed on a single circuit board substrate, and the circuit board substrate comprises alumina or an insulated silicon carbide including an insulating material disposed between silicon carbide substrate and each of the power element and the transmitting element; and

,

the module, including the single circuit board substrate having the power element and transmitting element thereon, is mounted on the component of the turbine section and, for circuit board substrate composed of alumina, the module is in an operating environment having temperatures that do not exceed about 450°

C., and for circuit board substrate composed of insulated silicon carbide, the module is in an operating environment having temperatures that is up to about 600°

C.

23. The turbine component of claim 22, wherein the sensor is a MEMS device.

24. The turbine component of claim 22, wherein the power element and transmission element are both formed on a single circuit board substrate.

25. The turbine component of claim 24, further comprising a sensing element formed on the single circuit board substrate and powered by the power element for generating a sensor signal responsive to a local operating environment.

26. The turbine component of claim 22, wherein the sensor is mounted to an airfoil of a turbine blade in the turbine section of the combustion turbine, and the module is mounted to a turbine blade root and an electrically connecting material is on the turbine blade connecting the sensor to the transmitting element.

27. The turbine component of claim 22, wherein the temperature of the hot gas path in which the sensor and component are disposed is from about 600°

C. to about 1600°

C.