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Collected by : BEHTA MIRJANY, STC Co.

Thermal Barrier Sensor Coatings


for Gas Turbine Applications
July 10, CAME-GT 2003
Brussels
Power Generation

Southside Thermal
Sciences (STS) Limited

Aircraft

Jrg P Feist

Collected by : BEHTA MIRJANY, STC Co.

Outline

Background STS Ltd.


Sensor Coating technology
Applications and User benefits
Further development
Summary, Questions

Collected by : BEHTA MIRJANY, STC Co.

STS

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

Condition Monitoring Hot Section


no current way to assess wear of components in real time,

Collected by : BEHTA MIRJANY, STC Co.

...maintenance scheduled on conservative design practices


.. temperatures in hot gas path can vary by up to 100F
DoE Press Release, Energy Technology Lab, Dec. 2000

Current temperature measurement hot section


at compressor discharge and exhaust
no measurement in between
most costly and hazardous part of turbine

Sensor Coating Technology

Collected by : BEHTA MIRJANY, STC Co.

Standard TBC plus dopant = Sensor Coating


UV light coating phosphoresces

UV light
10000

8000

at 380 Celsius

6000

at 500 celsius
4000
at 600 Celsius
2000

Data on coating & components

Measured Variables
Erosion
Degradation
Temperature
Image

1000

2000

3000

4000

5000

Ti me / mi crosec onds

Standard coating Doped layers


Non Destructive Evaluation
Condition Monitoring

Temperature Measurement
1st Method: Phosphor Lifetime Decay

Collected by : BEHTA MIRJANY, STC Co.

10000

8000

Shorter decay times at


higher temperatures
at 380 Celsius

6000

at 500 celsius
4000
at 600 Celsius
2000

1000

2000

3000

4000

Time / microseconds

5000

Standard Phosphors
YAG: Tb

( s )

Collected by : BEHTA MIRJANY, STC Co.

1000
YAG: Dy
(paint)

100
YSZ: Eu
(powder)

10
1

Y2O2 S: Pr

200

YAG: Dy
Y2O3: Eu
(paint) Y2O2S: Sm (powder)
400

600

800

1000 1200 1400 1600


o

Temperature ( C )

Response of YSZ: Dy powder


Lifetime decay changes with concentration

100

(s)

Collected by : BEHTA MIRJANY, STC Co.

1000

10mol% coating
10

3 mol%
0.005mol%

1 atomic %
0.005 mol%

1
0

100

200

300

400

500

Temperature (Celsius)

600

700

800

Smart TBC Response


Lifetime decay response of the YSZ: Eu coating
Subsurface temperature measurements

100

( s )

Collected by : BEHTA MIRJANY, STC Co.

1000

10
YSZ single coating
YSZ dual coating
1
0

100

200

300

400

500

600
o

Temperature ( C )

700

800

900

Novel YSZ based composition:


Temperature limit higher than 1130 Celsius
800

(s)

Collected by : BEHTA MIRJANY, STC Co.

700
600
500
400
300
0

200

400

600

800

Temperature (Celsius)

1000

1200

Temperature Measurement
2nd Method: Phosphor Intensity Ratio

0.4
1100 C
1050 C

0.2

1500

Slope: E=1490 cm-1

1000 C

1250
1000

0.0

ln (ratio)

Intensity ( a.u. )

Collected by : BEHTA MIRJANY, STC Co.

Spectrum changes with temperature; example:


Potential temperature distribution measurements using

900 C
800 C

750

700 C
600 C

500
250

-0.2
-0.4

400 C

-0.6

206 C
26 C and 76 C

0
440 450 460 470 480 490 500 510

Wavelength
Wavelength ((nm)
nm )

1250 K 1100 K

1000 K

900 K

0.0007 0.0008 0.0009 0.0010 0.0011 0.0012


-1 -1

Temperature ( K )

Collected by : BEHTA MIRJANY, STC Co.

Application: Combustor Measurements

Lifetime decay
Y2O3: Eu
Looking through flame

Measurement
region

Crack in window

Measurement
region

Y2O3:Eu

Combustor Surface Temperature


Distribution
1

Point measurements

Vertical axis

Down stream

Collected by : BEHTA MIRJANY, STC Co.

Scanned surface
(8 x 7.5 mm2)
cooling holes visible3
4

584.2
558.3
532.5
506.7
480.8
455.0
429.2
403.3
377.5
351.7
325.8
300.0

8
0

Horizontal axis

-------------

610.0
584.2
558.3
532.5
506.7
480.8
455.0
429.2
403.3
377.5
351.7
325.8

Degradation
Material Phase Measurement

Intensity ( a.u. )

Collected by : BEHTA MIRJANY, STC Co.

Indications that changes in the material are reflected in


changes in phosphorescence
example YSZ: Eu

ESAVD
heat
EACVDtreated
Powder
no heat treatment

560

580

600

620

Wavelength ( nm )

640

660

Erosion Measurement

Collected by : BEHTA MIRJANY, STC Co.

Missing dopant layers allow detection of


coating erosion and spallation
UV light
10000

8000
at380Celsius

6000

at500celsius
4000
at600Celsius
2000

1000

2000

3000

4000

Ti me / mi cro se co nd s

Doped layers

5000

Applications in
Condition Monitoring

Collected by : BEHTA MIRJANY, STC Co.

Lifetime prediction for coatings and blade


Spallation, erosion, degradation, avoid overheating
Operation at optimum efficiency level, full/part load
On-line temperature measurement
Development tool for new designs
Shorter development times

User Benefits

Collected by : BEHTA MIRJANY, STC Co.

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
10000
8000
at 380 Celsius

6000

at 500 celsius
4000
at 600 Celsius
2000

1000

2000

3000

4000

Ti me / microseconds

5000

Technology Development

Collected by : BEHTA MIRJANY, STC Co.

Co-operation in
development
Users

STS

OEMs

licence to OEMs
integrate in
existing systems

1
2
3
4
5
Year
Development
Power Generation
Aircraft Sector

Collected by : BEHTA MIRJANY, STC Co.

Summary
Enabling Technology for data collection
Development is required until ready for application
Integration in existing O&M systems
Contact:
Jrg P Feist
13 Princes Gate
London, SW7 1NA
United Kingdom
Tel.: (+44) 0207 / 594 3564
j.feist@imperial.ac.uk

The Wall Street Journal Europe


November 22nd 2002

Collected by : BEHTA MIRJANY, STC Co.

European Innovations Award 2002

Southside Thermal
Sciences (STS) Limited

Winner Base Technology/Materials

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