Download - Thermal Barrier Sensor Coatings
Thermal Barrier Sensor CoatingsThermal Barrier Sensor Coatingsfor Gas Turbine Applicationsfor Gas Turbine Applications
Southside ThermalSciences (STS) Limited
Power Generation Power Generation Aircraft Aircraft
July 10, CAME-GT 2003Brussels
Jörg P Feist
OutlineOutline
• Background STS Ltd.
• “Sensor” Coating technology
• Applications and User benefits
• Further development
• Summary, Questions
• Spin-off Imperial College, London, UK
• Early stage technology
• Owner of IP for “Sensor” Coating technology
• Start of operations end 2002
• Access to Imperial College R&D facilities
• IMechE prize 2002 for most innovative paper
S T S
Condition Monitoring Hot SectionCondition Monitoring Hot Section
Current temperature measurement hot sectionØat compressor discharge and exhaust
Øno measurement in between
Ømost costly and hazardous part of turbine
“ no current way to assess wear of components in real time,
...maintenance scheduled on conservative design practices
….. temperatures in hot gas path can vary by up to 100°F”
DoE Press Release, Energy Technology Lab, Dec. 2000
“Sensor” Coating Technology“Sensor” Coating Technology
• Standard TBC plus dopant = Sensor Coating
• UV light ⇒⇒ coating “phosphoresces”
• Data on coating & components
Non Destructive Evaluation
Condition Monitoring
0 1000 2000 3000 4000 5000
2000
4000
6000
8000
10000
at 600 Celsius
at 500 celsius
at 380 Celsius
Time / microsec onds
Doped layersStandard coating
UV light
Measured Variables
ErosionDegradationTemperatureImage
0 1000 2000 3000 4000 5000
2000
4000
6000
8000
10000
at 600 Celsius
at 500 celsius
at 380 Celsius
Time / microseconds
Temperature MeasurementTemperature Measurement11stst Method: Phosphor Lifetime Decay Method: Phosphor Lifetime Decay
Shorter decay times at higher temperatures
Standard PhosphorsStandard Phosphors
0 200 400 600 800 1000 1200 1400 16001
10
100
1000
YAG: Dy (paint)
YAG: Tb
YAG: Dy(powder)Y
2O
2S: Sm
YSZ: Eu(powder)
Y2O
3: Eu
(paint)
Y2O
2S: Pr
τ ( µ
s )
Temperature ( oC )
0 100 200 300 400 500 600 700 8001
10
100
1000
10mol% coating
1 atomic % 0.005 mol%
ττ ( µµ
s)
Temperature (Celsius)
3 mol%0.005mol%
Response of YSZ: Dy powderResponse of YSZ: Dy powder• Lifetime decay changes with concentration
Smart TBC ResponseSmart TBC Response
0 100 200 300 400 500 600 700 800 9001
10
100
1000
YSZ single coating YSZ dual coating
τ (
µs )
Temperature ( oC )
•Lifetime decay response of the YSZ: Eu coating•Subsurface temperature measurements
0 200 400 600 800 1000 1200300
400
500
600
700
800τ
(µs)
Temperature (Celsius)
Novel YSZ based composition: Temperature limit higher than 1130 Celsius
0.0007 0.0008 0.0009 0.0010 0.0011 0.0012
-0.6
-0.4
-0.2
0.0
0.2
0.4
900 K1100 K1250 K 1000 K
Slope: ∆E=1490 cm-1
ln (
ratio
)
Temperature-1( K-1 )440 450 460 470 480 490 500 5100
250
500
750
1000
1250
1500
1100 C1050 C
1000 C
900 C
800 C
700 C
600 C
400 C
206 C
26 C and 76 C
Inte
nsity
( a.
u. )
Wavelength ( nm )Wavelength (nm)
Temperature Measurement Temperature Measurement22ndnd Method: Phosphor Intensity Ratio Method: Phosphor Intensity Ratio•Spectrum changes with temperature; example: •Potential temperature distribution measurements using
Application: Combustor MeasurementsApplication: Combustor Measurements
Measurementregion
Measurementregion
Y2O3:Eu
Crack in window
•Lifetime decay•Y2O3: Eu•Looking through flame
Combustor Surface TemperatureCombustor Surface TemperatureDistributionDistribution
0 1 2 3 4 5 6 78
7
6
5
4
3
2
1
Dow
n st
ream
Horizontal axis
Ver
tical
axi
s
584.2 -- 610.0 558.3 -- 584.2 532.5 -- 558.3 506.7 -- 532.5 480.8 -- 506.7 455.0 -- 480.8 429.2 -- 455.0 403.3 -- 429.2 377.5 -- 403.3 351.7 -- 377.5 325.8 -- 351.7 300.0 -- 325.8
• Point measurements• Scanned surface (8 x 7.5 mm2)
• cooling holes visible
DegradationDegradationMaterial Phase MeasurementMaterial Phase Measurement
560 580 600 620 640 660
EACVD Powder
Inte
nsi
ty (
a.u
. )
Wavelength ( nm )
ESAVD
• Indications that changes in the material are reflected inchanges in phosphorescence• example YSZ: Eu
heat treatedno heat treatment
Erosion MeasurementErosion Measurement
Missing dopant layers allow detection ofcoating erosion and spallation
0 1000 2000 3000 4000 5000
2000
4000
6000
8000
10000
at 600 Celsius
at 500 celsius
at 380 Celsius
Ti m e / m i cr o se co nd s
Doped layers
UV light
Applications inApplications inCondition MonitoringCondition Monitoring
• Lifetime prediction for coatings and bladeØ Spallation, erosion, degradation, avoid overheating
• Operation at optimum efficiency level, full/part loadØOn-line temperature measurement
• Development tool for new designsØ Shorter development times
User BenefitsUser Benefits
“understand what is going on”
• Tool for predictive maintenance, improved RAM• Lower Operation & Maintenance Costs• Control Risk, balance Performance vs. Costs• Efficiency gains through temperature control• Improved emissions control
0 1000 2000 3000 4000 5000
2000
4000
6000
8000
10000
at 600 Celsius
at 500 celsius
at 380 Celsius
Time / microseconds
Technology DevelopmentTechnology Development
STS
OEMs
Users
licence to OEMs
integrate in existing systems
1 2 3 4 5 Year
Aircraft Sector Power Generation
Development
Co-operation in development
SummarySummary
• Enabling Technology for data collection
• Development is required until ready for application
• Integration in existing O&M systems
• Contact:Jörg P Feist13 Prince’s GateLondon, SW7 1NAUnited KingdomTel.: (+44) 0207 / 594 [email protected]
The Wall Street Journal EuropeNovember 22nd 2002
European Innovations Award 2002
“Winner Base Technology/Materials”
Southside ThermalSciences (STS) Limited