Patent Description:
Gas turbines are used to generate power for various applications. Typically, testing and validation are performed on these gas turbines prior to their utilization (e.g., in a power generating station). Effective testing and validation can increase the efficiency of and productivity of the gas turbines as well as the power generating station. Sometimes, measurement systems may be invasively coupled to the gas turbines, which require the disassembly of the turbines for the coupling of the measurement systems and/or the introduction of holes in the casings for sensors. In addition, removal of the measurement systems may also necessitate the disassembly of the casings and/or shut down of the gas turbines. Thus, testing and validation of the gas turbines may be time consuming and expensive and may risk damage to the gas turbine engines.

<CIT> discloses a measurement device for the characteristics of an air flow in a turbine engine, wherein the measurement device comprises base plates that are intended to be mounted in one opening in the radially external annual wall. <CIT> describes an active control system for reducing flatter or force vibrations in a turbo fan aero engine. The control system comprises an array of sensors, an electric controller and an array of actuators, wherein the array of sensors comprises one row mounted near the leading edge of the fan blade and another row mounted near the trailing edge of the tips of the fan blade. <CIT> discloses a system with a turbine and an imaging system, wherein the imaging system is configured to receive a broad wavelength band image of at least one component that is in fluid communication with the working fluid during operation of the turbine. <CIT> B <NUM> describes an optical probe that can be utilized to perform a visual inspection of a gas turbine, wherein the gas turbine comprises a plurality of access ports through which the optical probe is inserted. <CIT> describes a monitoring system for providing images of a component in a gas turbine engine, the monitoring system including a viewing tube assembly having an inner end and an outer end.

The above-mentioned problem is solved by the system according to claim <NUM>.

In another embodiment, a system is provided. The system includes a gas turbine engine including a compressor including a compressor casing having an inner diameter, a combustor downstream of the compressor, and a turbine downstream of the combustor. The gas turbine engine also includes a circumferential track embedded within an inner diameter of the compressor casing, wherein the circumferential track extends about at least a portion of the inner diameter of the compressor casing in a circumferential direction relative to a longitudinal axis of the gas turbine engine. The system also includes a measurement system. The measurement system includes a sensor assembly, which includes multiple sensors coupled to the sensor assembly. The sensor assembly is configured to be removably inserted within the circumferential track without having to disassemble the compressor casing.

In an example that does not fall within the scope of the claims a method is provided. The method includes inserting a sensor assembly having multiple sensors into a cavity formed by a circumferential track embedded within an inner surfaceof a compressor casing of a gas turbine engine without having to disassemble the compressor casing. The method also includes acquiring, via the multiple sensors, baseline data for validating an operation of the gas turbine engine independent of a control system for the gas turbine engine.

These and other features, aspects, and advantages of the present subject matter will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:.

Embodiments of the present disclosure include a measurement system (e.g., aeromechanics measurement system) for validating the operation of a gas turbine engine. The measurement system may include a sensor assembly (e.g., a wire rope, tube, or chain) to which are coupled a plurality of sensors. The sensor assembly is configured to be inserted within a circumferential track embedded within an inner diameter of a casing (e.g., compressor casing) of the gas turbine engine. In particular, the sensor assembly is inserted within a space or cavity defined between the inner diameter of the casing and the circumferential track. The circumferential track extends in a circumferential direction relative to a longitudinal axis of the gas turbine engine. The sensor assembly is configured to be inserted and/or removed via a single port coupled to, and in communication with, the space or cavity formed by the circumferential track without the casing being disassembled and/or shut down.

The measurement system may collect validation data (e.g., data associated with one or more operational parameters of the gas turbine engine) independent of a control system for the gas turbine engine. In addition, the data collected by the measurement system may be collected after removal of the sensor assembly from the casing, thus avoiding the use of a slip ring or telemetry. The measurement system may be rapidly deployed. In addition, the measurement system is configured to be utilized with gas turbine engines of different sizes and from different manufacturers.

Turning to the figures, <FIG> is a block diagram of an embodiment of a turbine system <NUM> having a gas turbine engine <NUM>. For reference, the gas turbine engine <NUM> may extend in axial direction <NUM> (e.g., relative to a longitudinal axis <NUM> of gas turbine engine <NUM>, see <FIG> ), a radial direction <NUM> toward or away from the longitudinal axis <NUM>, and a circumferential direction <NUM> around the longitudinal axis <NUM>. As described in detail below, the disclosed turbine system <NUM> employs a removable measurement system <NUM> (e.g., aerodynamics measurement system). The measurement system <NUM> may include a sensor assembly (wire rope or tube or chain) to which a plurality of sensors are coupled, which measure a variety of operational parameters utilized to provide baseline data in validating the operation of the gas turbine engine <NUM>. The measurement system <NUM> operates independent of the control system for the gas turbine engine <NUM>. In certain embodiments, the measurement system <NUM> may be coupled to the control system of the gas turbine engine <NUM> to enable real-time monitoring and/or control.

The sensor assembly may be removably and rapidly inserted within a space or cavity defined by a circumferential track embedded within an inner surface or diameter of a casing (e.g., compressor casing) of the gas turbine engine <NUM>. The circumferential track extends in the circumferential direction <NUM> relative to a longitudinal axis <NUM> of the gas turbine engine <NUM>. In certain embodiments (as shown in <FIG> ), the casing may include a plurality of circumferential tracks spaced apart from each apart in the axial direction <NUM>. The sensor assembly may be utilized in any of the circumferential tracks. In certain embodiments, the measurement system <NUM> may include a plurality of sensor assemblies each having a plurality of sensors, where the sensor assemblies may be inserted into multiple circumferential tracks.

The number of sensors may range from a dozen to a hundred to thousands of sensors. At least some of the sensors may employ optics and/or fiber optics. The operational parameters measured by the sensors may include blade tip timing (e.g., for displacement, stress, frequency, etc.), blade tip clearance, temperature, dynamic pressure, static pressure, rotor vibration, stall detection, and rotor speed. The sensors may acquire the data and, once the sensor assembly is removed from the circumferential track, the data may be collected from the sensors, thus avoiding the need for a slip ring or telemetry. In certain embodiments, extensions of cabling may be coupled to the measurement system <NUM> from outside the gas turbine engine <NUM> to enable real-time monitoring.

The turbine system <NUM> may use liquid or gas fuel, such as natural gas and/or a synthetic gas, to drive the turbine system <NUM>. As depicted, one or more fuel nozzles <NUM> in a combustor <NUM> intake a fuel supply <NUM>, partially mix the fuel with air, and distribute the fuel and the air-fuel mixture into the combustor <NUM> where further mixing occurs between the fuel and air. The air-fuel mixture combusts in a chamber within the combustor <NUM>, thereby creating hot pressurized exhaust gases. The combustor <NUM> directs the exhaust gases through a turbine <NUM> toward an exhaust outlet <NUM>. As the exhaust gases pass through the turbine <NUM>, the gases force turbine blades to rotate a shaft <NUM> along an axis of the turbine system <NUM>. As illustrated, the shaft <NUM> is connected to various components of the turbine system <NUM>, including a compressor <NUM>. The compressor <NUM> also includes blades coupled to the shaft <NUM>. As the shaft <NUM> rotates, the blades within the compressor <NUM> also rotate, thereby compressing air from an air intake <NUM> through the compressor <NUM> and into the fuel nozzles <NUM> and/or combustor <NUM>. The shaft <NUM> may also be connected to a load <NUM>, which may be a vehicle or a stationary load, such as an electrical generator in a power plant or a propeller on an aircraft, for example. The load <NUM> may include any suitable device capable of being powered by the rotational output of turbine system <NUM>.

<FIG> is a cross-sectional side view of an embodiment of the gas turbine engine <NUM> as illustrated in <FIG>. The gas turbine engine <NUM> has a longitudinal axis <NUM>. In operation, air enters the gas turbine engine <NUM> through the air intake <NUM> and is pressurized in the compressor <NUM>. The compressed air then mixes with gas for combustion within the combustor <NUM>. For example, the fuel nozzles <NUM> may inject a fuel-air mixture into the combustor <NUM> in a suitable ratio for optimal combustion, emissions, fuel consumption, and/or power output. The combustion process generates hot pressurized exhaust gases, which then drive turbine blades <NUM> within the turbine <NUM> to rotate the shaft <NUM> and, thus, the compressor <NUM> and the load <NUM>. The rotation of the turbine blades <NUM> causes a rotation of the shaft <NUM>, thereby causing blades <NUM> (e.g., compressor blades) within the compressor <NUM> to draw in and pressurize the air received by the intake <NUM>.

As depicted, a casing <NUM> (e.g., compressor casing) surrounds the blades <NUM> (and stator vanes) of the compressor <NUM>. The casing <NUM> may include multiple sections (e.g., two halves) that together extend completely about the longitudinal axis <NUM> to define the interior of the compressor <NUM>. A circumferential track <NUM> is embedded within an inner surface or diameter <NUM> of the casing <NUM>. The measurement system <NUM> includes the sensor assembly <NUM> having the plurality of sensors, which is disposed within a space or cavity defined between the circumferential track <NUM> and the inner diameter <NUM> of the casing <NUM>. The sensor assembly <NUM> is at least slightly flexible or bendable to enable it bend in the circumferential direction <NUM> when disposed within the space or cavity. The circumferential track <NUM> is axially <NUM> disposed between the rows of stator vanes (not separately numbered) so that the circumferential track <NUM> and the sensors of the sensor assembly <NUM> are in the plane of (and axially <NUM> aligned with) the rotating blades <NUM>. The circumferential track <NUM> extends in the circumferential direction <NUM> about at least a portion of the inner diameter <NUM> of the casing <NUM>. In certain embodiments, the circumferential track <NUM> extends about the entire inner diameter <NUM> of the casing <NUM>.

<FIG> is a perspective view of an embodiment of the inner surface <NUM> of a portion of the casing <NUM> (e.g., compressor casing) for the gas turbine engine <NUM> having multiple circumferential tracks <NUM>. The stator vanes and the respective slots for receiving them are not shown. The number of circumferential tracks <NUM> may vary. In certain embodiments, the number of circumferential tracks <NUM> may correspond to the number of stages of blades <NUM>. In other embodiments, the number of circumferential tracks <NUM> may be less than or greater than the number of stages of blades <NUM>. As depicted, the circumferential tracks <NUM> are axially <NUM> spaced apart from each other relative to the longitudinal axis <NUM>. As mentioned above, each circumferential track <NUM> is axially <NUM> disposed between the rows of stator vanes so that the respective circumferential track <NUM> and the sensors of the sensor assembly <NUM> are in the plane of (and axially <NUM> aligned with) the rotating blades <NUM>. Each circumferential track <NUM> extends in the circumferential direction <NUM> about at least a portion of the inner diameter <NUM> of the casing <NUM>. In certain embodiments, at least one of the circumferential tracks <NUM> extends about the entire inner diameter <NUM> of the casing <NUM>.

In certain embodiments, the circumferential track <NUM> is a single segment <NUM> as depicted with circumferential track <NUM>. In other embodiments, the circumferential track <NUM> may include multiple segments <NUM> as depicted with circumferential track <NUM>. Each circumferential track <NUM> includes openings <NUM> that enable the sensors of a sensor assembly <NUM> (see also <FIG> ) to face toward an interior of the compressor <NUM> (e.g., toward the blades <NUM>) when the sensor assembly <NUM> is properly inserted within the space defined by the circumferential track <NUM> and the inner diameter <NUM> of the casing <NUM>. The openings <NUM> may include larger openings <NUM> and smaller openings <NUM> sized for specific sensors. In certain embodiments, the openings <NUM> may be aligned in the circumferential direction <NUM> or in the axial direction <NUM>. Each opening <NUM> represents a measurement point that consists of a sensor head and a sensor receptacle for receiving the sensor head as described in greater detail below. The opening <NUM> provides a viewport for the respective sensor head when inserted within the sensor receptacle. The position of each sensor receptacle may be permanently fixed. Each sensor receptacle may be integrated within the circumferential track <NUM> or embedded directly within the inner diameter <NUM> of the casing <NUM>.

As depicted in <FIG> , a space or cavity <NUM> is defined between the circumferential track <NUM> and the inner surface <NUM> of the casing <NUM>. The sensor assembly <NUM> may be inserted and/or removed into the space or cavity <NUM>. As depicted in <FIG> , sensors <NUM> coupled to the sensor assembly <NUM> are spaced apart or spatially arranged so that the sensors <NUM> align with the openings <NUM> on the circumferential track <NUM> when the sensor assembly <NUM> is completely inserted into the space or cavity <NUM>.

<FIG> is schematic view of the measurement system <NUM> being inserted into the cavity <NUM> defined by the circumferential track <NUM> and the inner surface <NUM> of the casing <NUM>. The sensor assembly <NUM> with the sensors <NUM> is inserted, as indicated by the arrows <NUM>, from outside the casing <NUM> (e.g., with the entire gas turbine engine <NUM> assembled) into the cavity defined by circumferential track <NUM> and the inner surface of the casing <NUM> via a single port <NUM> that is coupled to the cavity <NUM>. The sensor assembly <NUM> is fed through the port <NUM> and curves within the cavity <NUM> in the circumferential direction <NUM>. The sensor assembly <NUM> may be removed in the opposite direction via the same port <NUM> as indicated by the arrows <NUM>.

As depicted, the port <NUM> (e.g., a funnel) is external to the casing <NUM>. In certain embodiments, as depicted in <FIG> , the casing <NUM> defines a port <NUM>, which extends to the cavity <NUM> defined by the circumferential track <NUM> and the inner surface <NUM> of the casing <NUM>. An external port (e.g., a funnel, such as port <NUM>) may be inserted into the port <NUM> to help guide the insertion and/or removal of the sensor assembly <NUM> from within the space or cavity <NUM>.

In certain embodiments, where the inner surface <NUM> of the casing <NUM> has more than one circumferential track <NUM>, the casing <NUM> may include multiple ports with a single port dedicated (i.e., for exclusive use) for each respective circumferential track <NUM> for the insertion and/or removal of a respective sensor assembly <NUM>. In other embodiments, where the circumferential track <NUM> includes two or more segments <NUM>, multiple ports <NUM> may be disposed in communication with a respective cavity <NUM> defined by the cavity <NUM> of the segment <NUM>.

<FIG> is a flow chart of an example of a method <NUM> for utilizing the measurement system <NUM> that does not fall within the scope of the claims. The method <NUM> includes inserting the sensor assembly <NUM> having the sensors <NUM> into the cavity <NUM> formed by the circumferential track <NUM> and the inner diameter <NUM> of the casing <NUM> without having to disassemble the casing <NUM> and/or without having to shut down the gas turbine engine <NUM> (block <NUM>). The insertion occurs via a single port coupled to, or in communication, with the cavity <NUM>.

The method <NUM> also includes acquiring, via the sensors <NUM>, baseline data (e.g., during operation of the gas turbine engine <NUM>) for validating an operation of the gas turbine engine <NUM> (block <NUM>). The data is acquired independent of a control system of the gas turbine engine <NUM>. The data is stored in a r memory.

The method <NUM> further includes removing the sensor assembly <NUM> from the cavity <NUM> (e.g., via the same port utilized for insertion) without having to disassemble the casing <NUM> and/or without having to shut down the gas turbine engine <NUM> (block <NUM>).

The method <NUM> still further includes collecting the acquired baseline data from the sensors <NUM> after the removal of the sensor assembly <NUM> from the cavity <NUM> (block <NUM>). In other embodiments, the data may be collected from the sensors <NUM> in real-time, while the sensor assembly <NUM> is still installed within the cavity <NUM> of the circumferential track <NUM>.

<FIG> is a schematic view of an embodiment of a sensor receptacle <NUM> coupled to a guide tube <NUM>. Each sensor receptacle <NUM> may be integrated within the circumferential track <NUM> or embedded directly within the inner diameter <NUM> of the casing <NUM>. The position of each sensor receptacle <NUM> may be permanently fixed. The sensor receptacle <NUM> includes a sensor viewport or opening <NUM> (e.g., opening <NUM> in <FIG> ) that provides a viewport for a sensor head when inserted within the sensor receptacle <NUM>. The sensor receptacle <NUM> is coupled to the guide tube <NUM> which includes an internal passage <NUM> for receiving the sensor head. The guide tube <NUM> has an inner diameter <NUM> that is larger than the sensor that will be through it. The guide tube <NUM> is generally flexible or semi-flexible to permit routing. As described in greater detail below, the guide tube <NUM> is routed circumferentially in a passage machined in the casing <NUM> to a point at which it passes through a port in the casing to the outside, where it can be accessed. In certain embodiments, the guide tube <NUM> may be inside of the track <NUM> that is installed on the inner diameter <NUM> of the casing <NUM>.

The sensor receptacle <NUM> includes an alignment feature <NUM> (e.g., clocking key) for orienting the sensor head within the sensor receptacle <NUM> so that the sensor head is aligned with the viewport <NUM>. The sensor head includes a corresponding feature (e.g., keyway) to engage the alignment feature <NUM>. An operator may need to twist a cable associated with the sensor head to line up the alignment feature and the keyway. In certain embodiments, the sensor receptacle <NUM> and/or the sensor head may include a self-aligning feature that automatically turns the sensor head to the proper orientation.

The sensor receptacle <NUM> also includes a feature <NUM> (e.g., locking feature) for locking the inserted sensor head. In certain embodiments, the feature <NUM> may be a one-time, irreversible locking feature. In other embodiments, the feature <NUM> may be a reversible locking feature that can be overcome by a force or released by an unlocking mechanism. As depicted in <FIG> , the feature <NUM> one or more spring-loaded ball detents <NUM> (e.g., two ball detents are depicted in <FIG> ). Each ball detent <NUM> includes a ball <NUM> and one or more springs <NUM>. The spring-loaded ball detents <NUM> engage a corresponding feature in the sensor head. The spring load of the balls <NUM> is sufficient to keep inadvertent pulling on the sensor cable from dislodging the sensor head from the sensor receptacle <NUM>. In certain embodiments, an intentional and large enough pulling force is able to overcome the spring loaded ball detents <NUM> to release the sensor head from the sensor receptacle <NUM>.

<FIG> and <FIG> are schematic views of an embodiment of a sensor <NUM> coupled to a cable <NUM>. In particular, the sensor <NUM> is part of a sensor head <NUM> coupled to the cable <NUM>. The sensor head <NUM> includes a corresponding alignment feature <NUM> (e.g., keyway slot) that enables alignment of the sensor <NUM> with the viewport <NUM> as described above when interacting with alignment feature <NUM>. The sensor head <NUM> also includes a corresponding locking feature <NUM> (e.g., ball detent locking feature) that interacts with the locking feature <NUM> to lock the sensor head <NUM> in place with the sensor receptacle <NUM>. For example, the corresponding locking feature <NUM> includes a groove <NUM> on an outer surface <NUM> of the sensor head <NUM>.

The cable <NUM> acts as a conduit for signals <NUM> to pass from the sensor to a remotely located data recording system. The signals may be optical, electrical, or any other form of data/power transmission. An end <NUM> of the cable <NUM> opposite the sensor head <NUM> includes a connector interface <NUM> (see <FIG>) to interface with the data recording system <NUM>.

The semi-flexible, semi-rigid cable <NUM> connected to the sensor head <NUM> enables the operator to push the sensor head <NUM> (and cable <NUM>) down a length of the guide tube <NUM>. When the sensor head <NUM> reaches the sensor receptacle <NUM>, the operator will initially feel resistance as the sensor head <NUM> pushes against the spring-loaded ball detents <NUM>. With a reasonable amount of force, the sensor head <NUM> will seat in the sensor receptacle <NUM> and the ball detents <NUM> will engage the sensor head <NUM> as illustrated in <FIG>. In addition, as depicted in <FIG> , the sensor <NUM> is aligned with the sensor viewport <NUM> due to the interaction between the alignment features <NUM>, <NUM>. The same cable <NUM> also enables the removal of the sensor head from the guide tube <NUM>. For example, if the sensor <NUM> fails or at the conclusion of a test, the operator can withdraw the sensor head <NUM> from the guide tube <NUM> by pulling on the cable <NUM> attached to the sensor head <NUM>. In certain embodiments, the sensor head <NUM> and/or the sensor receptacle <NUM> may include a release feature to unlock the sensor head <NUM> from the sensor receptacle <NUM>.

The operator can confirm that the sensor head <NUM> is seated in a number of ways. In a certain embodiments, the sensor head <NUM> is seated via feel by the operator and the operator's experience with how ball detents <NUM> operate. In other embodiments, the operator may receive feedback from the sensor <NUM> that indicates that it can see the target (i.e., sensor receptacle <NUM>). In some embodiments, the sensor head <NUM> and/or sensor receptacle <NUM> may be equipped with a simple electrical contact that provide confirmation that the sensor head <NUM> is properly seated (e.g., via completion of an electrical circuit).

<FIG> is a schematic view of an embodiment of the guide tubes <NUM> for the sensors <NUM> extending from the port <NUM> into a cavity between the circumferential track <NUM> and the inner surface <NUM> of the casing <NUM>. As depicted, only a portion of casing <NUM> and the circumferential track <NUM> are shown. The circumferential track <NUM> includes a number of receptacles <NUM> (e.g., receptacles A, B, C, D, and E) for receiving the sensors <NUM>. In certain embodiments, the receptacles <NUM> may be embedded on the inner surface <NUM> of the casing <NUM>. The casing <NUM> includes the opening or port <NUM> as described above that extends from a cavity between the circumferential track <NUM> and the inner surface <NUM> of the casing <NUM> to an outer surface of the casing <NUM>. The external port, receptacle, or funnel <NUM> is disposed within the port <NUM> and extends from the cavity between the circumferential track <NUM> and the inner surface <NUM> of the casing <NUM> to outside of the casing <NUM>. As depicted in <FIG> (and in greater detail in <FIG> ), a plurality of guides tubes <NUM> for the a plurality of the sensors <NUM> (e.g., sensors A, B, C, D, and E) may be disposed within the cavity between the circumferential track <NUM> and the inner surface <NUM> of the casing <NUM> (as described above) and extend from the external port <NUM>. The operator feeds the sensor head <NUM> into the appropriate guide tube <NUM> accessible on the outside of the casing <NUM> through the external port <NUM>. In embodiments with multiple guide tubes <NUM>, the guide tubes may be labeled or mapped. In certain embodiments, instead of guide tubes <NUM>, discrete passages for receiving the sensor heads <NUM> and associated sensor cables <NUM> may be fabricated within the circumferential track <NUM>.

Technical effects of the disclosed embodiments include providing an aeromechanics measurement system that may be rapidly deployed on a gas turbine engine for acquiring baseline data for validating an operation of a gas turbine engine. The measurement system may collect the data independent of a control system for the gas turbine engine. The measurement system includes a sensor assembly having multiple sensors coupled to it. The sensor assembly may be inserted into and subsequently withdrawn (e.g., via the same port) from a cavity or space defined between a circumferential track embedded within an inner surface of a casing and the inner surface of the casing. The sensor assembly may be inserted and removed without having to disassemble the gas turbine engine. This enables the baseline data to be gathered without having to utilize a slip ring or telemetry. The measurement system is adaptable for use with gas turbine engines of different sizes and from different manufacturers. In addition, the measurement system may reduce costs and time associated with testing and validating the gas turbine engine.

Claim 1:
A system comprising:
a gas turbine engine (<NUM>), comprising:
a compressor (<NUM>) comprising a compressor casing (<NUM>) having an inner diameter;
a combustor (<NUM>) downstream of the compressor (<NUM>);
a turbine (<NUM>) downstream of the combustor (<NUM>);
characterized by comprising
a circumferential track (<NUM>, <NUM>) embedded within an inner surface of the compressor casing (<NUM>), wherein the circumferential track (<NUM>, <NUM>, <NUM>) extends about at least a portion of the inner diameter of the compressor casing (<NUM>) in a circumferential direction (<NUM>) relative to a longitudinal axis (<NUM>) of the gas turbine engine (<NUM>); and
a measurement system (<NUM>), comprising:
a sensor assembly (<NUM>); and
a plurality of sensors (<NUM>) coupled to the sensor assembly (<NUM>), wherein the sensor assembly (<NUM>) is configured to be removably inserted within the circumferential track (<NUM>, <NUM>, <NUM>) without having to disassemble the compressor casing (<NUM>).