Abstract: A method of repairing a generator blower hub assembly (12) and rotor blade (10) removed from the generator blower hub assembly (12) where the rotor blade (10) has fatigued material in threads of a threaded blade root (14). The method may include removing (32) at least a portion of the fatigued material to form the blade root (14) to a first or new diameter. Threads may be formed (36) on the diameter of the blade root (14) using a roll forming process. A collar (20) may be secured within a threaded hole (16) formed in the generator blower hub assembly (12) where the collar (20) includes internal threads (35) for receiving the threads formed on the diameter of the blade root (14), which may be threaded into the collar (20). Collar (20) may be fabricated of steel alloy and include relief groove (40) for improving the fatigue resistance of the threaded blade root (14) when reassembled into the generator blower hub assembly (12).

Abstract: An online method, system, and computer-readable code for remotely monitoring radiant energy emitted from a turbine blade (106), which may be undergoing an incipient degradation, such as a crack, in a relatively low-temperature, and saturated steam environment of the low pressure stage of a steam turbine. The method and system provide sufficient temporal and spatial resolution to obtain high quality infrared images of the blade areas of interest enabling the system to identify the crack at any of those areas of the blade prior to such a crack growing to a critical length.

Abstract: A ground detection apparatus for use in a power generating system including an excitation circuit and a driven rotatable shaft. A ground detector ring is disposed on the rotatable shaft of the power generating system. A ground detection transmitter is mounted on the ground detector ring and in electrical communication with the excitation circuit of the power generating system. The ground detection transmitter is utilized to detect ground faults in the excitation circuit of the power generating system and to send a signal associated with ground faults detected by the ground detection transmitter. A ground detection receiver is associated with a stationary portion of the power generation system and is in communication with the ground detection transmitter for receiving the signal associated with ground faults detected and sent by the ground detection transmitter.

Abstract: A conformable layer (14) for inhibiting electrical discharge between vent tubes (16) and strands (12) in an inner-cooled coil (5). The conformable layer comprises a resistive inner core (24) and a conductive strip (20) wrapped in a conductive outer wrap (26). The conductive strip (20) is electrically connected to the strands (12) at one end of the coil (5) and left to electrically float at the other end. In this configuration, the conformable layer (14) reduces voltage buildup between the vent tubes (16) and the strands (12) to help prevent electrical damage to the coil (5).

Abstract: A phased array ultrasonic testing system is for examining turbine disc bores and blade attachments for discontinuities, such as stress corrosion cracking. The system is particularly suited to perform an accurate and efficient inspection of components despite their having a relatively complex geometry, such as axial entry blade attachments and bores of associated discs. The system includes a control system with a computer and a controller for programming, emitting, and steering an ultrasonic beam via at least one two-dimensional phased array probe, thereby precisely inspecting the area of interest while simultaneously accommodating the aforementioned complex geometry of the disc or blade attachment. Computer control of the beam permits the number of inspection locations and the number of different probe wedges to be reduced providing for an efficient, timely inspection. Methods of profiling and examining turbine components of known and unknown geometries, are also disclosed.

Abstract: In one embodiment the present invention provides for a method for checking the alignment of a stator core that comprises placing a laser source 14 and a target 18 a given distance apart on a stator core 10 and activating the laser such that the laser strikes the target. Then measuring on the target where the laser strikes, and interpreting the measurement to determine any misalignment of the stator core in the given distance.

Abstract: High voltage coils (40) having an insulated coil surface that includes a composite tape (32) bonded to a secondary conductive layer (34) in a half lap manner. The composite layer comprising a glass conductive tape bonded to a layer of mica paper tape in an edge lap manner.

Abstract: A winding for use in a superconducting electric generator having a rotating rotor assembly surrounded by a non-rotating stator assembly is provided. The winding comprises at least one conductor structure associated with a component in the superconducting electric generator. The conductor structure comprises a plurality of conductive elements formed from a high temperature superconductive material. At least a portion of the conductive elements is arranged in a transposed relationship. A protective shell is positioned about the conductive elements and formed from a high strength alloy suitable for cryogenic temperatures.

Abstract: A gas turbine combustor (23) includes a catalytic combustion stage (22) receiving a first portion (18) of a total oxidizer flow (16) and a first portion (30) of a total fuel flow (29) and discharging a partially oxidized fuel/oxidizer mixture (40) into a post catalytic combustion stage (24) defined by a combustion liner (58). The combustor further includes an injector scoop (54) having an injector scoop inlet (56) in fluid communication with an opening (56) in the combustion liner for receiving a second portion (20) of the oxidizer flow. A fuel outlet (e.g. 64) selectively supplies a second portion (42) of the total fuel flow into the second portion of the oxidizer flow.

Abstract: An improved turbine spring clip seal for directing gases to be mixed with fuel in a combustor basket. The turbine spring clip seal may include an inner housing and an outer housing. The inner housing or the outer housing, or both, may be shortened relative to conventional clips and may include a cooling channel proximate to a point of attachment to the combustor basket.

Abstract: A method for welding superalloy components at ambient temperature conditions while reducing the propensity of the superalloy material to crack as a result of the weld. A root pass region of the weld is formed using a filler material that exhibits ductility that is higher than that of the base superalloy material. The ductile material mitigates stress in the root region, thereby preventing the formation of cracks. A remaining portion of the weld is formed using a filler material that essentially matches the base superalloy material. The method may utilize a pre-weld heat treatment to grow a gamma prime precipitate phase in the superalloy material, a chill fixture to remove heat during welding, a relief cut to reduce stress in the root region, and a conventional post-weld heat treatment.

Abstract: A method and system for directly measuring the compression of a ripple spring (23) in a dynamoelectric machine through a corresponding wedge (27). A compression-assessment tool (3) is provided that includes a carriage (32) for supporting a proximity sensor (34). The carriage (32) enables the proximity sensor (34) to be passed over the length of the ripple spring (23), which produces an output signal that is representative of the compression of the ripple spring (23).

Abstract: A cooling system for a turbine blade of a turbine engine having a leading edge impingement cooling channel in series with one or more pressure and suction side impingement cooling channels. The turbine blade may include a double outer wall with impingement cooling channels positioned between the walls. The impingement cooling channels may be adapted to match heat localized loads and hot side gas pressures across the turbine blade to maximize the efficiency of the cooling system.

Abstract: A fastening system has at least one peripheral spring and at least one peripherally expandable bushing, with the peripheral spring being at least partially enclosed within the peripherally expandable bushing. The peripheral spring and peripherally expandable bushing each contain axial openings for receiving an elongated fastening member to secure two dissimilar structures together. The peripheral spring can be a spring bushing. The spring bushing can comprise a series of radially outwardly bowed ribs joined at one end by a fixed hoop. The axial spring can be a spring washer. The peripherally expandable bushing can be a split bushing.

Abstract: A braze material (10) including nano-sized filler material particles (14). The nano-sized particles will melt at a temperature significantly lower than the micron-sized particles used in prior art braze materials, thereby eliminating or reducing the need for the addition of temperature depressant materials such as boron or silicon. The resulting braze joint is substantially free of detrimental boride and suicides phases, thereby improving the material properties of the joint, eliminating the need for a separate post-braze diffusion heat treatment, and permitting a subsequent welding operation with reduced risk of cracking. The braze heat treatment may also function as a solution heat treatment, a pre-weld heat treatment or a post-weld heat treatment.

Abstract: Aspects of the invention are directed to an acoustic resonator with improved impingement cooling effectiveness. The resonator includes a plate with an inside face and an outside face. A plurality of passages extend through the plate. The resonator includes a side wall that extends from and about the plate. A plurality of cooling tubes are attached to the resonator plate such that an inner passage of each cooling tube is in fluid communication with a respective passage in the resonator plate. The resonator can be secured to a surface of a turbine engine combustor component to define a closed cavity. The ends of the cooling tubes are spaced from the surface. Thus, a coolant can enter the passages in the plate and can be directed to the surface so as to impingement cool the surface. The cooling tubes can minimize coolant loss by dispersion in the cavity.

Abstract: A cooling system for a turbine blade of a turbine engine having a bifurcated mid-chord cooling chamber for reducing the temperature of the blade. The bifurcated mid-chord cooling chamber may be formed from a pressure side serpentine cooling channel and a suction side serpentine cooling channel. The pressure side and suction side serpentine cooling channels may flow counter to each other, thereby yielding a more uniform temperature distribution than conventional serpentine cooling channels.

Abstract: A composite material (10) formed of a ceramic matrix composite (CMC) material (12) protected by a ceramic insulating material (14). The constituent parts of the insulating material are selected to avoid degradation of the CMC material when the two layers are co-processed. The CMC material is processed to a predetermined state of shrinkage before wet insulating material is applied against the CMC material. The two materials are then co-fired together, with the relative amount of shrinkage between the two materials during the firing step being affected by the amount of pre-shrinkage of the CMC material during the bisque firing step. The shrinkage of the two materials during the co-firing step may be matched to minimize shrinkage stresses, or a predetermined amount of prestress between the materials may be achieved. An aluminum hydroxyl chloride binder material (24) may be used in the insulating material in order to avoid degradation of the fabric (28) of the CMC material during the co-firing step.

Abstract: A ceramic thermal barrier coating material (10) containing nano-sized features is predicted to exhibit improved high temperature performance than a comparable material containing fewer of such features. In a coating deposited by an APS process, the nano-sized features may be intersplat columns (32). In a coating deposited by an EB-PVD process, the nano-sized features may be a mixed oxide layer (22) formed of nano-sized mixed oxide particles, or nano-sized alumina projections (24) extending across the interface from the mixed oxide layer into the insulating material layer (20). Alternatively, the nano-sized features may be secondary columnar grains (36) extending laterally from primary columnar grains (34) in a columnar-grained ceramic material.

Abstract: A generator monitoring system and method includes a plurality of sensors (12) disposed within a generator enclosure (18) to sense health conditions of a generator (10) housed within the enclosure. The sensors are interconnected to provide a single communication path (14) for allowing communication with the plurality of sensors. A monitoring device (16) outside the generator enclosure receives health condition information from each of the plurality of sensors via the single communication path. A sensor may be disposed within the generator enclosure to detect particulates emitted from a monitored portion (e.g., 52) of the generator housed within the enclosure. A sensor may be disposed proximate a bus bar connection (130) of the generator to sense a health condition of the bus bar connection and generate corresponding health condition information provided to the monitoring device.