Abstract: A circuitry adapted to operate in a high-temperature environment of a turbine engine is provided. A relatively high-gain differential amplifier (102) may have an input terminal coupled to receive a voltage indicative of a sensed parameter of a component (20) of the turbine engine. A hybrid load circuitry may be coupled to the differential amplifier. A voltage regulator circuitry (244) may be coupled to power the differential amplifier. The differential amplifier, the hybrid load circuitry and the voltage regulator circuitry may each be disposed in the high-temperature environment of the turbine engine.

Abstract: A method for predicting the remaining useful life of an engine (10) having components (18, 19, 22, 23) that are instrumented with sensors (50) that generate electronic data signals indicative of an operating condition of the component comprises identifying (52) one or more components and at least one failure mode for each component that limit an operating life of the components and engine (10). The method further comprises acquiring (62) and storing data relative to current operating conditions of the components associated with the identified failure mode; and, then determining (68) a remaining useful life of the component based on the data relative to current operating condition of the components, the data relative to historical data of the operating condition associated with the failure mode and a predicted failure mode rate.

Abstract: In a telemetry system for use in an engine, a circuit structure (34) affixed to a moving part (20) of the engine is disposed for amplifying information sensed about a condition of the part and transmitting the sensed information to a receiver external to the engine. The circuit structure is adapted for the high temperature environment of the engine and includes a differential amplifier (102, 111) having an input for receiving a signal from a sensor (101, 110) disposed on the part. A voltage controlled oscillator (104, 115) with an input coupled to the output of the amplifier produces an oscillatory signal having a frequency representative of the sensed condition. A buffer (105, 116) with an input coupled to the output of the oscillator buffers the oscillatory signal, which is then coupled to an antenna (26) for transmitting the information to the receiver.

Abstract: A bracket assembly is used to mount a wireless telemetry component proximate a rotating component of a combustion turbine engine (10), wherein the wireless telemetry component includes an RF transparent ceramic cover (128). The bracket assembly comprises a first mounting bracket (125) on a surface proximate the rotating component that includes a first (138) and second (139) bracket member spaced apart from one another. The first (138) and second (139) bracket members are disposed generally perpendicular to a direction of centrifugal forces generated by the rotating component. At least one of the first (138) or second bracket (139) members is inclined toward the other bracket member and disposed at an acute angle relative to the surface (141) proximate the rotating component.

Abstract: A telemetry system for use in a combustion turbine engine (10) having a compressor (12), a combustor and a turbine (16) and includes a sensor (118) in connection with a turbine blade (111) or vane (23). A transmitter assembly (117) includes a telemetry transmitter circuit/transceiver may be affixed on a turbine blade (111) or seal plate (115) proximate the turbine blade with a first connecting material (119) deposited on the turbine blade (111) for routing electronic data signals, indicative of a condition of the turbine blade (111), from the sensor (118) to the telemetry transmitter circuit/transceiver. An induction power system for powering the telemetry transmitter circuit/transceiver may include a rotating data antenna (116) affixed to the seal plate (115) with an electrical connection (122) between the telemetry transmitting circuit/transceiver for routing electronic data signals from the telemetry transmitter circuit/transceiver to the rotating data antenna (119).

Abstract: A circuit assembly (34) affixed to a moving part (20) of a turbine for receiving information about a condition of the part and transmitting this information external to the engine. The circuit assembly includes a high-temperature resistant package (34A) that attaches to the part. A high temperature resistant PC board (42) supports both active and passive components of the circuit, wherein a first group of the passive components are fabricated with zero temperature coefficient of resistance and a second group of the passive components are fabricated with a positive temperature coefficient of resistance. The active components are fabricated with high temperature metallization. Connectors (40) attached to the PC board pass through a wall of the package (34A) for communication with sensors (30) on the part and with an antenna (26) for transmitting data about the condition of the part to outside the turbine.

Abstract: In a telemetry system for use in an engine, a circuit structure (34) affixed to a moving part (20) of the engine is disposed for amplifying information sensed about a condition of the part and transmitting the sensed information to a receiver external to the engine. The circuit structure is adapted for the high temperature environment of the engine and includes a differential amplifier (102, 111) having an input for receiving a signal from a sensor (101, 110) disposed on the part. A voltage controlled oscillator (104, 115) with an input coupled to the output of the amplifier produces an oscillatory signal having a frequency representative of the sensed condition. A buffer (105, 116) with an input coupled to the output of the oscillator buffers the oscillatory signal, which is then coupled to an antenna (26) for transmitting the information to the receiver.

Abstract: A diagnostic system and method for monitoring operating conditions of turbine machine components (18, 19, 22, 23) that comprise one or more non-contact sensors (24, 31) that detect an operating condition of a turbine component (18, 19, 22, 23) over a defined region of the component. In addition, point sensors (50) are provided that detect and monitor the same operating condition within the defined region. Data generated from the point sensor (50) is used to calibrate the non-contact sensor (24, 31) and the data generated by the non-contact sensor (24, 31).

Abstract: A wear sensor (30, 50, 60) installed on a surface area (24) of a component (20, 21) subject to wear from an opposing surface (74, 75). The sensor has a proximal portion (32A, 52A, 62A) and a distal portion (32C, 52C, 62C) relative to a wear starting position (26). An electrical circuit (40) measures an electrical characteristic such as resistance of the sensor, which changes with progressive reduction of the sensor from the proximal portion to the distal portion during a widening reduction wear of the surface from the starting position. The measuring circuit quantifies the electrical changes to derive a wear depth based on a known geometry of the wear depth per wear width. In this manner, wear depth may be measured with a surface mounted sensor.

Abstract: A structure and method for instrumenting a component for monitoring wear in a coating. The method includes depositing a first thin layer of electrically insulating material, depositing a thin electrically conductive layer over the first electrically insulating layer, depositing a second thin layer of electrically insulating material over the electrically conductive layer. An overlying thickness of the coating material is deposited over the second thin layer of electrically insulating material. The thicknesses of the insulating and conducting layers is controlled to be small enough such that the overlying coating surface exposed to mechanical wear retains a desired degree of smoothness without the necessity for a separate planarization step.

Abstract: A circuit assembly (34) resistant to high-temperature and high g centrifugal force is disclosed. A printed circuit board (42) is first fabricated from alumina and has conductive traces of said circuit formed thereon by the use of a thick film gold paste. Active and passive components of the circuit assembly are attached to the printed circuit board by means of gold powder diffused under high temperature. Gold wire is used for bonding between the circuit traces and the active components in order to complete the circuit assembly (34). Also, a method for manufacturing a circuit assembly resistant to elevated temperature is disclosed.

Abstract: A circuit assembly (34) resistant to high-temperature and high g centrifugal force is disclosed. A printed circuit board (42) is first fabricated from alumina and has conductive traces of said circuit formed thereon by the use of a thick film gold paste. Active and passive components of the circuit assembly are attached to the printed circuit board by means of gold powder diffused under high temperature. Gold wire is used for bonding between the circuit traces and the active components in order to complete the circuit assembly (34). Also, a method for manufacturing a circuit assembly resistant to elevated temperature is disclosed.

Abstract: A circuit affixed to a moving part of an engine for sensing and processing the temperature of the part. The circuit generates a signal representative of the temperature sensed by a thermocouple (110) and amplified by an amplifier (112). A square wave oscillator (113) with a temperature sensitive capacitor (C8) varies its frequency in response to changes of a local temperature of the circuit. A chopper (114, J27) converts the output of the amplifier into an alternating current signal. The chopper is gated by the square wave oscillator and a second input is coupled to an output of the amplifier. Thus, the chopper has an output signal having a frequency representative of the local temperature and an amplitude representative of the thermocouple temperature, whereby the combined signals represent the true temperature of the part.

Abstract: A printed circuit board (PCB 22) capable of withstanding ultra high G forces and ultra high temperature as in a gas turbine (11). The PCB includes a substrate having a plurality of cavities (30A, 36A) formed therein for receiving components of a circuit, and conductors embedded in the PCB for electrically connecting the components together to complete the circuit. Each of the cavities has a wall (36A?) upstream of the G-forces which supports the respective component in direct contact in order to prevent the development of tensile loads in a bonding layer (37A). When the component is an integrated circuit (50), titanium conductors (63) are coupled between exposed ends of the embedded conductors and contact pads on the integrated circuit. A gold paste (51) may be inserted into interstitial gaps between the integrated circuit and the upstream wall.

Abstract: A thin-film thermocouple (12) is disclosed for use with a gas turbine component. The thermocouple may be formed on a non-planar substrate (22) having formed thereon an electrically insulating layer (34) capable of maintaining its insulating properties at gas turbine operating temperatures. A first thermocouple leg (26) made of pure platinum is then deposited on the dielectric layer (34). A second thermocouple leg (28) made of another pure metal or a transparent ceramic oxide is also formed on the dielectric layer (34) wherein the first and second thermocouple legs make ohmic contact at a first end of each leg to form a hot junction (30) for conversion of heat into an electrical signal. The thermocouple may be deposited on a surface of a thermal barrier coating or between a thermal barrier coating and an underlying metal substrate.

Abstract: A circuit assembly (34) resistant to high-temperature and high g centrifugal force is disclosed. A printed circuit board (42) is first fabricated from alumina and has conductive traces of said circuit formed thereon by the use of a thick film gold paste. Active and passive components of the circuit assembly are attached to the printed circuit board by means of gold powder diffused under high temperature. Gold wire is used for bonding between the circuit traces and the active components in order to complete the circuit assembly (34). Also, a method for manufacturing a circuit assembly resistant to elevated temperature is disclosed.

Abstract: The present invention provides for steam generation replacing natural gas with a selected refined product of a feedstock of bitumen, asphaltenes or heavy oil using locally produced surplus bitumen, asphaltene or heavy oil, separating the asphaltenes and other components of the feedstock for use in providing a liquid fuel for steam generation. The lighter products from the separation equipment not used for liquid fuel may be blended into the produced bitumen, asphaltenes or heavy oil, to increase its API gravity and reduce the diluent required for transportation. This technology may be employed in open pit mining operations for the generation of steam and power. The refined components of the feedstock used to provide liquid fuel are selected to optimize energy output balancing planned energy demand against the value of the components of the feedstock used.

Abstract: A gas turbine component (49) may be instrumented to provide a plurality of signals indicative of thermal measurements in a high temperature combustion environment of the gas turbine. A thermocouple arrangement may include a first thermocouple leg (50) disposed within a thickness of the component. At least two or more thermocouple legs (52, 53, 54) is each electrically connected to the first leg to form individual thermocouple junctions (56, 57, 58, 59) along the first leg for conversion of respective thermal gradients to respective electrical signals, such as electromotive force (emf) based voltages. The thermocouple arrangement may be used in combination with a thermographic system (70) to calculate heat flux over a region of the turbine component.

Abstract: An instrumented component (18, 19) for use in various operating environments such as the hot gas path section of a combustion turbine engine (10). The component (18, 19) may have a substrate, a sensor (50, 204, 210) connected with the substrate for sensing a condition of the component (18, 19) within the casing during operation of the combustion turbine (10) and a connector (52, 202) attached to the substrate and in communication with the sensor (50, 204, 210) for routing a data signal from the sensor (50, 204, 210) to a termination location (53). The component (18, 19) may include a wireless telemetry device (54, 202) in communication with the connector (52, 202) for wirelessly transmitting the data signal outside the casing. A transceiver (56) may be located outside the casing for receiving the data signal and transmitting it to a processing module (30) for developing information with respect to a condition of the component (18, 19) or a coating (26) deposited on the component (18, 19).

Abstract: A component including a surface subject to wear by an electrically conductive wear counterface (50). The component comprises a substrate (10); one or more material layers (32) overlying the substrate (10); a wear surface layer (16) overlying the one or more material layers (32); a first pair of spaced apart and electrically open wear sensor conductors (12/14) disposed in the substrate (10), in the one or more material layers (32), or in the wear surface layer (16); a first wear warning electrical circuit (68/69/70/74) for communicating with the first pair of conductors (12/14) for providing a first wear warning; and wherein when the wear counterface (50) has worn overlying layers, the wear counterface (50) interconnects the first pair of conductors (12/14) to activate the first wear warning circuit (68/69/70/74).