System and method for on line monitoring within a gas turbine combustor section

• US 9,255,526 B2
• Filed: 04/04/2013
• Issued: 02/09/2016
• Est. Priority Date: 08/23/2012
• Status: Active Grant

• Current Assignee: Siemens Energy Incorporated (Siemens AG)
• Original Assignee: Siemens Energy Incorporated (Siemens AG)
• Inventors: Hatcher, Clifford Jr., Hatley, Richard, Genc, Yakup, Ruhge, Forrest R.
• Primary Examiner(s): Toatley, Gregory J
• Assistant Examiner(s): SMITH, MAURICE C
• Application Number:
  US13/856,673
• Publication Number:
  US 20140053568A1
• Time in Patent Office: 1,041 Days
• US Class Current: 1/1
• CPC Class Codes: F02C 7/00 Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants controlling F02C9/00
• CPC Class Codes: F02C 9/00 Controlling gas-turbine plants; Controlling fuel supply in air- breathing jet-propulsion plants controlling air intakes F02C7/057; controlling turbines F01D; controlling compressors F04D27/00; controlling in general G05
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: G01H 9/00 Measuring mechanical vibrations or ultrasonic, sonic or infrasonic waves by using radiation-sensitive means, e.g. optical means
• CPC Class Codes: G01J 2005/0077 Imaging
• CPC Class Codes: G01J 5/0088 in turbines
• CPC Class Codes: G01M 11/081 by using a contact-less detection method, i.e. with a camera
• CPC Class Codes: G01M 15/14 Testing gas-turbine engines or jet-propulsion engines
• CPC Class Codes: G01N 2021/8893 providing a video image and a processed signal for helping visual decision
• CPC Class Codes: G01N 21/8806 Specially adapted optical and illumination features
• CPC Class Codes: G01N 21/8851 Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges G01N21/8806 and G01N21/93 - G01N21/95692 take precedence; optical measurement of dimensions G01B11/00; optical scanning G02B26/10; image transformation G06T3/00; computerised image enhancement G06T5/00; image processing per se for flaw detection G06T7/0002
• CPC Class Codes: G01N 21/9515 Objects of complex shape, e.g. examined with use of a surface follower device measuring contours and curvatures G01B11/24
• CPC Class Codes: G01N 21/954 Inspecting the inner surface of hollow bodies, e.g. bores
• CPC Class Codes: G01N 25/72 Investigating presence of flaws

Abstract

An on-line optical inspection and monitoring system is externally mounted to existing man way service access within the combustor housing. A replacement man way cover having an optical window is mounted to the combustor housing. One or more optical cameras are oriented so that the camera field of view (FOV) is directed through the man way cover optical window. The camera FOV is moved to plural positions within the combustion section, such as under control of an automated motion control system, and images are captured. Multiple images are combined to form a composite image, which may include an image of an entire transition within the combustion section. Visual images and/or infrared (IR) thermal images may be captured. Thermal image information is correlated with component temperature. Image information is utilized to determine vibration characteristics of the imaged components.

Claims

1. A method for on-line optical operational monitoring of an industrial gas turbine combustion section, comprising:

coupling a man way cover having an optical window to a combustion section service man way;

directing the field of view (FOV) of an optical camera located outside the man way cover through the optical window, so that the FOV is capable of capturing images of areas of interest within the combustion section;

moving the camera FOV to plural positions within the combustion section and capturing respective images at each position; and

combining the respective captured images in a composite image

remote vibration monitoring of the areas of interest by monitoring relative motion of the areas of interest and correlating the motion with vibrational frequency.

2. The method of claim 1, comprising moving the camera FOV along a length of a combustion section transition between its entrance and exit to form a composite image thereof.

3. The method of claim 1, further comprising remote monitoring temperature of areas of interest within an infrared camera FOV by correlating captured image infrared intensity with temperature.

4. The method of claim 3, the correlating step performed by comparing captured FOV image intensity with blackbody intensity calibration data and fine tuning the calibration data with independently obtained temperature information that is relevant to the area of interest within the FOV.

5. The method of claim 4, the calibrating step performed by obtaining temperature information from a thermocouple or known emissivity object within the combustion section.

6. The method of claim 1, further comprising remote monitoring visual images of areas of interest within a visible light spectrum camera FOV.

7. The method of claim 1 further comprising simultaneous monitoring of the FOV with an infrared camera and a visible light spectrum camera coupled to a shared common optical path beam splitter.

8. The method of claim 1, the orienting FOV step performed with an automated motion control system coupled to the optical camera that automatically positions the camera and captures images along a selected path within the combustion section.

9. The method of claim 8, comprising automatically positioning the camera FOV along a length of a combustion section transition between its entrance and exit with the automated motion control system and capturing images to form a composite image thereof.

10. The method of claim 1 comprising cooling the camera and associated monitoring system components by isolating them within an enclosure outside the man way and circulating cooling fluid within the enclosure.

11. An on-line optical operational monitoring system for an industrial gas turbine combustion section, comprising:

a man way cover having an optical window, adapted for coupling to a combustion section service man way;

an optical camera located outside the man way cover, having a field of view (FOV) directed through the optical window, so that the FOV is capable of capturing images of areas of interest within the combustion section;

a motion control drive system coupled to the camera for moving the camera FOV to plural positions within the combustion section;

a control system coupled to the motion control system and the camera, for causing the motion control drive system to position the camera and for capturing respective images at each position; and

an image processing system for combining the respective captured images in a composite image

a remote vibration monitoring system correlating a motion of the areas of interest with vibrational frequency.

12. The system of claim 11, comprising an infrared camera capable of capturing FOV image intensity and the image processing system capable of correlating captured image intensity with temperature.

13. The system of claim 12, the correlation performed by the image processing system comparing captured FOV image intensity with blackbody intensity emission/temperature calibration and adjusting the calibration with temperature information obtained from a thermocouple or known emissivity object within the camera FOV.

14. The system of claim 11, comprising a visible light spectrum camera for capturing visible images.

15. The system of claim 11, comprising an infrared camera and a visible light spectrum camera coupled to a shared common optical path beam splitter, with both cameras having the same shared FOV.

16. The system of claim 15, cameras having respective remote focusing systems coupled to the control system.

17. The system of claim 16, the motion control drive system comprising camera FOV translation, roll and tilt motion axes.

18. The system of claim 11, the control system automatically positioning the camera FOV along a selected path with the motion control system and capturing images to form a composite image.

19. The system of claim 18, the control system automatically positioning the camera FOV along a length of a combustion section transition between its entrance and exit with the automated motion control system and capturing images to form a composite image thereof.

20. The system of claim 11, further comprising a cooling enclosure outside the man way enclosing the camera and motion control system, and a cooling system coupled to the enclosure, for circulating cooling fluid within the enclosure.

21. An on-line optical operational monitoring system for an industrial gas turbine combustion section, comprising:

a man way cover having an optical window, adapted for coupling to a combustion section service man way;

a paired infrared camera and a visible light spectrum camera coupled to a shared common optical path beam splitter, with both cameras having the same shared field of view (FOV), the cameras located outside the man way cover, with the shared FOV directed through the optical window, so that the FOV is capable of capturing images of areas of interest within the combustion section;

respective remote focusing systems coupled to each camera;

a motion control drive system coupled to the cameras and beam splitter, for moving the camera FOV along translation, roll and tilt motion axes to plural positions within the combustion section;

a control system coupled to the motion control system the respective remote focusing systems and the respective cameras, for causing the motion control drive system to position the FOV along a selected path and for capturing respective images at each position;

an image processing system for combining the respective captured images in a composite image that may include temperature information derived from image intensity information captured by the infrared camera and vibration frequency information derived from motion information captured by the visible light spectrum camera; and

a cooling enclosure outside the man way enclosing the camera and motion control system, and a cooling system coupled to the enclosure, for circulating cooling fluid within the enclosure.