Patent Publication Number: US-2013227929-A1

Title: System and device for monitoring contaminants in a fluid

Description:
BACKGROUND OF THE INVENTION 
     The subject matter disclosed herein relates to air quality monitoring and, in particular, to embodiments of a system and a device for monitoring contaminants in sample air that enters a turbo-machine. 
     Gas turbines, aero-derivatives, and other varieties of turbo-machinery use an air inlet system that channels incoming air towards a compressor. The inlet system can have a filter section to screen foreign objects and other materials from the air. Typically, the inlet system and the compressor comprise metals that may corrode when in contact with certain contaminants, which come from the environment in which the turbo-machine operates. 
     Some turbo-machines may develop microenvironments, e.g., areas of the turbo-machine in which the air flows with different flow properties (e.g., velocity and pressure). These flow properties can increase the rate of corrosion. Moreover, the differences in the flow properties across the turbo-machine prevents the use of ambient conditions to identify the rate of corrosion that will occur throughout the various parts, areas, and microenvironments. Techniques to determine the environmental effects of the air on the turbo-machine, e.g., on the compressor components, may necessarily monitor air downstream of the turbo-machine. 
     One technique to measure the rate of corrosion is to place strips (hereinafter “coupons”) in the stream of air. This configuration exposes the coupons, which will over time become corroded and fail. An end user (e.g., a technician) can monitor the progress of corrosion and time to failure through, for example, periodic visual examination of coupons. For more accurate determination, however, the coupons are sent to a lab for more time consuming and expensive testing to determine the type(s) of corrosives that caused the failure. 
     Use of coupons can cause a few problems. The coupons may, for example, dislodge and become a projectile that can potentially cause damage to the compressor components. The coupons may also create flow distortion waves that can also damage turbo-machine components. Furthermore, access to the coupons may require shut down of the turbo-machine, which reduces the overall operating performance of the turbo-machine. 
     The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter. 
     BRIEF DESCRIPTION OF THE INVENTION 
     This disclosure describes embodiments of a system and device to measure contaminants found in fluids, e.g., air flowing downstream of a turbo-machine. An advantage that the practice of some embodiments of the system and device is to provide real-time data about the constituent components of the fluids, including corrosive components. This data can accurately represent the rate of corrosion of components of the turbo-machine and help to identify and diagnose potential problems before damage to the turbo-machine may occur. 
     The disclosure describes, in one embodiment, a device to monitor corrosion in an asset. The device comprises a flow generating module generating a flow of sample air with selected flow characteristics. The device also comprises a detection module coupled to the flow generating module to receive the flow of sample air. The detection module comprises a manifold that directs the sample air in contact with a sensing element responsive to constituent components in the sample air. The device also comprises a fluid flow module that couples with the flow generating module, the fluid flow module comprising one or more elements to measure the flow characteristics of the flow of sample air. 
     The disclosure describes, in another embodiment, a monitoring device to measure constituent components in air. The monitoring device comprises a detection element comprising a computing device, one or more sensing elements coupled with the computing device and responsive to the constituent components, and a manifold in surrounding relation to the sensing elements to prevent exposure of the sensing elements to outside air. The monitoring device also comprises a pump in flow connection with the manifold for delivering a flow of sample air with selected flow characteristics, and a pressure meter coupled with the pump and to an air supply port. In one example, the selected flow characteristics are pre-set to effectuate detecting characteristics of the detection module. 
     The disclosure describes, in yet another embodiment, a system for generating power. The system comprises a turbo-machine and an inlet system coupled to the turbo-machine, the inlet system directing air from the surrounding environment to the turbo-machine. The system also includes a sampling device coupled to the inlet system and a monitoring device coupled to the sampling device. The monitoring device comprises a fluid circuit with a detection module having sensing elements to detect contaminants in sample air drawn from the inlet system by the sampling device. In one example, sample air flows through the fluid circuit with flow characteristics that are pre-set to effectuate detecting characteristics of the detection module. 
     This brief description of the invention is intended only to provide a brief overview of the subject matter disclosed herein according to one or more illustrative embodiments, and does not serve as a guide to interpreting the claims or to define or limit the scope of the invention, which is defined only by the appended claims. This brief description is provided to introduce an illustrative selection of concepts in a simplified form that are further described below in the detailed description. This brief description is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       So that the manner in which the features of the invention can be understood, a detailed description of the invention may be had by reference to certain embodiments, some of which are illustrated in the accompanying drawings. It is to be noted, however, that the drawings illustrate only certain embodiments of this invention and are therefore not to be considered limiting of its scope, for the scope of the invention encompasses other equally effective embodiments. The drawings are not necessarily to scale, emphasis generally being placed upon illustrating the features of certain embodiments of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views. Thus, for further understanding of the invention, reference can be made to the following detailed description, read in connection with the drawings in which: 
         FIG. 1  depicts an exemplary air sampling system that couples with an inlet system to measure contaminants in air flowing to a turbo-machine; 
         FIG. 2  depicts a schematic diagram of an exemplary monitoring device for use in the air sampling system of  FIG. 1 ; 
         FIG. 3  depicts a front view of another exemplary monitoring device for use in the air sampling system of  FIG. 1 ; 
         FIG. 4  depicts a front view of the monitoring device of  FIG. 3  with its access door in its closed position; and 
         FIG. 5  depicts perspective view of an exemplary detection module for use in the monitoring devices of  FIGS. 2 ,  3 , and  4 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of systems and devices below can provide dynamic corrosion monitoring for turbo-machines and related systems. These embodiments deploy sensitive computing devices to collect data from sample air in real-time, thereby generating extensive information about qualities and properties of the air that is flowing into the turbo-machine. However, in one aspect, the system and devices only expose certain elements of the computing devices to the contaminants in the sample air. This features protects the sensitive equipment from damage that can interrupt operation and, often, disable the computing devices and prevent implementation of the computing devices altogether. 
       FIG. 1  depicts an exemplary air sampling system  100  (also “system  100 ”) that can detect, measure, and/or monitor components in a fluid (e.g., air) to prevent damage to an asset, e.g., a turbo-machine  102 . For example, the sampling system  100  can detect corrosive elements in air. These corrosive elements can damage components of the turbo-machine  102 . An advantage of the present design, however, is that service and/or maintenance of the system  100  can occur without disturbing operation of the turbo-machine  102 . Thus, there is no need to turn off or power down the turbo-machine  102 , e.g., to retrieve coupons or other devices that are in contact with or in position for exposure to air flowing to the turbo-machine  102 . 
     The turbo-machine  102  can couple with an inlet system  104  that directs air from the surrounding environment. In one example, a compressor  106  couples with the inlet system  104  to move air through the inlet system  104  and into the turbo-machine  102 . As shown in  FIG. 1 , the system  100  couples with the inlet system  104  at one or more sampling locations (e.g., a first sampling location  108 , a second location  110 , a third location  112 , a fourth location  114 , and a fifth location  116 ). The sampling locations  108 ,  110 ,  112 ,  114 ,  116  expose the system  100  to air (and/or other fluids) that flow through the interior of the inlet system  104 . For example, during operation of the turbo-machine  102 , the system  100  can draw off a small sample of air to determine the scope and content of contaminates that are dispersed therein. 
     In one embodiment, the system  100  includes a sampling device, generally denoted by the numeral  120 , and a monitoring device  122 . A processing device  124  couples with the monitoring device  122 . The processing device  124  can comprise a computing device (e.g., a computer, laptop, mobile device) with one or more programs and/or executable instructions. Examples of the sampling device  120  can have a probe (e.g., an isokinetic probe) or nozzle in position (e.g., at sampling locations  108 ,  110 ,  112 ,  114 ,  116 ) to extract air at the average velocity of the air moving through the inlet system  102 . This sample air has representative concentrations of dissolved, suspended, volatile, and corrosive constituents components. The monitoring device  122  can detect these constituent components and, in response, generate information (e.g., data and electrical signals) representative of some measure of the constituent components in the air. The processing device  124  receives this information via., e.g., wired and or wired connection between the sampling device  122  and the monitoring device  124 . Execution of one or more of the computer programs can read and display the information to an end user (e.g., a technician). 
     Continuing with the discussion of the inlet system  104 , and moving from left to right in the diagram of  FIG. 1 , in one example, the inlet system  104  includes a weather hood  126  and an inlet filter housing  128 . A cooling module  130  may be found inside of the inlet filter housing  128 . The cooling module  130  may include a washing system that disperses fluid (e.g., water) into the inlet filter housing  128  to facilitate filtering of the air flowing therethrough. A transition piece  132  couples the inlet filter housing  128  to an inlet duct  134 . The physical characteristics of these elements help to develop certain flow characteristics (e.g., velocity, pressure, etc.) in the flow of air as the air transits the inlet system  104  to the turbo-machine  102 . Inside of inlet duct  134 , that air can encounter one or more other elements, e.g., a silencer section  136 , heating system  138 , and screen element  140 . The elements  136 ,  138 ,  140  are useful for condition the air as the air travels through the inlet system  104  to the turbo-machine  102 . 
       FIG. 2  illustrates a schematic diagram of an exemplary monitoring device  200  for use in air sampling system  100  of  FIG. 1 . The monitoring device  200  includes a fluid circuit  202  with a fluid flow module  204 , a detection module  206 , and a flow generating module  208 . The fluid circuit  202  also includes tubing  210  and one or more fluid ports that permit ingress and egress of air and other fluids into and out of the monitoring device  200 . In one example, the ports include a sample air port  211 , an air supply port  212 , and an exhaust port  213 . The sample air port  211  couples with the testing location to provide sample air that flows through the flow circuit  202  in a flow pattern  214 . The air supply port  212  can receive a compressed fluid (e.g., compressed air) from a separate supply and/or source. The compressed air operates the flow generating module  208 . In one example, the detection module  206  couples with a data port  215 , e.g., via an electrical wire, to exchange information with one or more remote devices that can couple with the data port  215  and/or directly to the electrical wire and/or directly to the detection module  206 , as desired. 
     The data port  215  may include one or more connectors (e.g., USB connectors, RS-232 connectors) for wired connection of the monitoring device  200  to external computing resources, e.g., processing device  124  of  FIG. 1 . In one example, the data port  215  can also comprise one or more wireless devices (e.g., RF devices) to transmit information from the monitoring device  200  to locations remote from the monitoring device  200 . Examples of the fluid ports (e.g., the sample air port  211 , the air supply port  212 , and the exhaust port  213 ) can accommodate tubes, pipes, and conduits that deliver fluids to the monitoring device  200 . These fluids can comprise sample air taken upstream of a turbo-machine (e.g., turbo-machine  102 ). As discussed more below, the fluids can also include various supply fluids, including supply air to operate and/or facilitate operation of one or more elements of the monitoring device  200 . The fluid ports can incorporate various types of couplings (e.g., quick-release fluid couplings) that can receive tubular-type elements. 
     Broadly, during operation of monitoring device  200 , sample air enters the flow circuit  202  for testing at the detection module  206  via one or more of the fluid ports  210 . The flow generating module  208  can induce certain flow characteristics (e.g., flow rate) in the sample air. The flow generating module  208  can, for example, change the pressure of the fluid to increase and decrease velocity of air in the fluid circuit  202 . The flow control module  204  monitors these flow characteristics as well as other operating parameters of the sample air in the flow circuit  202 . 
     Exemplary operating parameters can include flow characteristics (e.g., flow rate and fluid velocity) as well as temperature, pressure, contaminant levels, and similar metrics as desired. In one example, the flow characteristics are pre-set as part of a calibration and/or set-up procedure to effectuate detecting characteristics of the detection module  206 . These detecting characteristics may, for example, define certain parameters of operation for the detection module  206 , e.g., certain flow rate and/or velocity of air flowing across the detection module  206  that permits detection of contaminants of certain pre-determined size threshold. In another example, the flow control module  204  and the flow generating module  208  may operate in combination to manage the flow of sample air through the detection module  206 . This combination may create a feedback loop to allow dynamic control of the flow of sample air to improve the results of detection, e.g., detection of contaminants in the sample air, and/or a feedback loop to modify flow characteristics of the flow of sample air to change detecting characteristics of the detection module  206 . 
     Examples of the detection module  206  detect these contaminants. In one example, the detection module  206  includes one or more elements that react with contaminants. These reactions can register certain electrical signals and/or other signals to measure levels of corrosive contaminants (and/or other contaminant generally) found in the sample air. The electrical signals can include information (also “data”) that reflects the levels of contaminants, e.g., levels consistent with air flowing in an inlet system (e.g., inlet system  102  of  FIG. 1 ). Details of one exemplary device for use as the detection module  206  is found in  FIG. 5  and discussed more below. 
       FIG. 3  depicts another exemplary monitoring device  300 , which like monitoring device  200  of  FIG. 2  has a flow control module  304 , a detection module  306 , and a flow generating module  308 . Tubing  316  connects these modules together. The monitoring device  300  has an enclosure  318  with a housing  320  and an access panel  322 . The elements of the enclosure  318  can work together to seal and protect the modules from the surrounding environment. Inside of the enclosure  318 , the flow control module  304  includes one or more flow monitoring elements (e.g., a flow meter  324  and a pressure meter  326 ) to measure flow parameters of sample air flowing throughout the monitoring device  300 . The detection module  306  has a computing device  328  and a manifold  330 , through which the sample air enters and exits the detection module  306 . The pressure meter  326  couples with a pump  332  to manage the flow of sample air through the detection module  306 . In one embodiment, the monitoring device  300  includes a damping assembly  334  including one or more vibration mounts (e.g., a first mount  336 , a second mount  338 , and a third mount  340 ). 
     In one implementation, operation of the pump  332  draws sample air into the enclosure  318  through the manifold  330  and the flow meter  324  to form, in one example, a flow of sample air with selected flow characteristics. Examples of the pump  332  include vacuum-assisted pumps, which utilize separate supply air that flows into the enclosure  318 . As shown in  FIG. 3 , the flow meter  324  monitors the flow rate (and/or velocity) of the flow of sample air, providing data and information to one or more external devices. In one example, the data from the flow meter  324  and the pressure meter  326  are useful to modify operation of the pump  332  to tune the flow characteristics to improve and or optimize detection of certain types of contaminants as desired. 
     Construction of the enclosure  318  can comprise metals, plastics, and composites of varying material properties. Suitable materials will resist severe environmental conditions to provide long lasting protection of the components found inside of the enclosure  318 . Likewise, materials to construct the manifold  330  are resistant and/or inert to corrosive elements. This feature prevents breakdown of the manifold  330 , which may allow the sample air to mix with air from the surrounding environment. 
       FIG. 4  depicts the monitoring device  300  of  FIG. 3  with the access panel  322  in its closed position proximate the housing  320  to prevent access to the components of found therein. The housing  320  has a front wall  342  that forms an inlet/outlet (I/O) panel  344  to receive connections for various fluid and data devices. The I/O panel  344  includes fluid I/O  346  and data I/O  348 , each of which can include connectors of various configurations discussed above and contemplated herein. In one example, the data I/O  348  include a flow meter I/O  350 , a detection module I/O  352 , and one or more extra I/O  354 . The fluid I/O  346  can include an ambient air supply  356 , a sample air supply  358 , and a vent  360 . The ambient air supply  356  can couple with an air tank or other external supply. As discussed above, air from this external supply drive the pump  332  ( FIG. 3 ). The sample air supply  358  couples with the probe that extends into and provides sample air, e.g., from the inlet system (e.g., inlet system  104  of  FIG. 1 ). In one example, the pump  332  couples with the vent  360  to expel the supply air during operation. 
       FIG. 5  depicts an example of a detection module  400  to detect constituent components of the sample of air flowing to a turbo-machine. The detection module  400  has a manifold  402  and a sensing system. A computing device  404  and one or more sensing elements (e.g., a first sensing element  406  and a second sensing element  408 ) embody the sensing system in the example of  FIG. 5 . However, the present disclosure contemplates other configurations of devices/elements that satisfy the measurement criteria and other aspects of the subject matter described herein The manifold  402  includes a manifold housing  410  that surrounds the sensing elements  406 ,  408  in an interior cavity  412 . Although not shown, the manifold may include a cover over the interior cavity  412 , which works with the manifold housing  410  to protect and segregate the sensing elements  406 ,  408 . This configuration prevents mixing of sample air with air from the environment surrounding the manifold  402  In one example, the manifold housing  410  includes ports (e.g., a first port  412  and a second port  414 ) outfit with connectors (e.g., a first connector  416  and a second connector  418 ). 
     As used herein, an element or function recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or functions, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the claimed invention should not be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.