Thermal Barrier Sensor CoatingsThermal Barrier Sensor Coatingsfor Gas Turbine Applicationsfor Gas Turbine Applications

Southside ThermalSciences (STS) Limited

Power Generation Power Generation Aircraft Aircraft

July 10, CAME-GT 2003Brussels

Jörg P Feist

OutlineOutline

• Background STS Ltd.

• “Sensor” Coating technology

• Applications and User benefits

• Further development

• Summary, Questions

• 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

S T S

Condition Monitoring Hot SectionCondition Monitoring Hot Section

Current temperature measurement hot sectionØat compressor discharge and exhaust

Øno measurement in between

Ømost costly and hazardous part of turbine

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

...maintenance scheduled on conservative design practices

….. temperatures in hot gas path can vary by up to 100°F”

DoE Press Release, Energy Technology Lab, Dec. 2000

“Sensor” Coating Technology“Sensor” Coating Technology

• Standard TBC plus dopant = Sensor Coating

• UV light ⇒⇒ coating “phosphoresces”

• Data on coating & components

Non Destructive Evaluation

Condition Monitoring

0 1000 2000 3000 4000 5000

2000

4000

6000

8000

10000

at 600 Celsius

at 500 celsius

at 380 Celsius

Time / microsec onds

Doped layersStandard coating

UV light

Measured Variables

ErosionDegradationTemperatureImage

0 1000 2000 3000 4000 5000

2000

4000

6000

8000

10000

at 600 Celsius

at 500 celsius

at 380 Celsius

Time / microseconds

Temperature MeasurementTemperature Measurement11stst Method: Phosphor Lifetime Decay Method: Phosphor Lifetime Decay

Shorter decay times at higher temperatures

Standard PhosphorsStandard Phosphors

0 200 400 600 800 1000 1200 1400 16001

10

100

1000

YAG: Dy (paint)

YAG: Tb

YAG: Dy(powder)Y

2O

2S: Sm

YSZ: Eu(powder)

Y2O

3: Eu

(paint)

Y2O

2S: Pr

τ ( µ

s )

Temperature ( oC )

0 100 200 300 400 500 600 700 8001

10

100

1000

10mol% coating

1 atomic % 0.005 mol%

ττ ( µµ

s)

Temperature (Celsius)

3 mol%0.005mol%

Response of YSZ: Dy powderResponse of YSZ: Dy powder• Lifetime decay changes with concentration

Smart TBC ResponseSmart TBC Response

0 100 200 300 400 500 600 700 800 9001

10

100

1000

YSZ single coating YSZ dual coating

τ (

µs )

Temperature ( oC )

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

0 200 400 600 800 1000 1200300

400

500

600

700

800τ

(µs)

Temperature (Celsius)

Novel YSZ based composition: Temperature limit higher than 1130 Celsius

0.0007 0.0008 0.0009 0.0010 0.0011 0.0012

-0.6

-0.4

-0.2

0.0

0.2

0.4

900 K1100 K1250 K 1000 K

Slope: ∆E=1490 cm-1

ln (

ratio

)

Temperature-1( K-1 )440 450 460 470 480 490 500 5100

250

500

750

1000

1250

1500

1100 C1050 C

1000 C

900 C

800 C

700 C

600 C

400 C

206 C

26 C and 76 C

Inte

nsity

( a.

u. )

Wavelength ( nm )Wavelength (nm)

Temperature Measurement Temperature Measurement22ndnd Method: Phosphor Intensity Ratio Method: Phosphor Intensity Ratio•Spectrum changes with temperature; example: •Potential temperature distribution measurements using

Application: Combustor MeasurementsApplication: Combustor Measurements

Measurementregion

Measurementregion

Y2O3:Eu

Crack in window

•Lifetime decay•Y2O3: Eu•Looking through flame

Combustor Surface TemperatureCombustor Surface TemperatureDistributionDistribution

0 1 2 3 4 5 6 78

7

6

5

4

3

2

1

Dow

n st

ream

Horizontal axis

Ver

tical

axi

s

584.2 -- 610.0 558.3 -- 584.2 532.5 -- 558.3 506.7 -- 532.5 480.8 -- 506.7 455.0 -- 480.8 429.2 -- 455.0 403.3 -- 429.2 377.5 -- 403.3 351.7 -- 377.5 325.8 -- 351.7 300.0 -- 325.8

• Point measurements• Scanned surface (8 x 7.5 mm2)

• cooling holes visible

DegradationDegradationMaterial Phase MeasurementMaterial Phase Measurement

560 580 600 620 640 660

EACVD Powder

Inte

nsi

ty (

a.u

. )

Wavelength ( nm )

ESAVD

• Indications that changes in the material are reflected inchanges in phosphorescence• example YSZ: Eu

heat treatedno heat treatment

Erosion MeasurementErosion Measurement

Missing dopant layers allow detection ofcoating erosion and spallation

0 1000 2000 3000 4000 5000

2000

4000

6000

8000

10000

at 600 Celsius

at 500 celsius

at 380 Celsius

Ti m e / m i cr o se co nd s

Doped layers

UV light

Applications inApplications inCondition MonitoringCondition Monitoring

• Lifetime prediction for coatings and bladeØ Spallation, erosion, degradation, avoid overheating

• Operation at optimum efficiency level, full/part loadØOn-line temperature measurement

• Development tool for new designsØ Shorter development times

User BenefitsUser Benefits

“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

0 1000 2000 3000 4000 5000

2000

4000

6000

8000

10000

at 600 Celsius

at 500 celsius

at 380 Celsius

Time / microseconds

Technology DevelopmentTechnology Development

STS

OEMs

Users

licence to OEMs

integrate in existing systems

1 2 3 4 5 Year

Aircraft Sector Power Generation

Development

Co-operation in development

SummarySummary

• Enabling Technology for data collection

• Development is required until ready for application

• Integration in existing O&M systems

• Contact:Jörg P Feist13 Prince’s GateLondon, SW7 1NAUnited KingdomTel.: (+44) 0207 / 594 3564j.feist@imperial.ac.uk

The Wall Street Journal EuropeNovember 22nd 2002

European Innovations Award 2002

“Winner Base Technology/Materials”

Southside ThermalSciences (STS) Limited