Sealed Enclosure Argon Replenishment for Turbine Coating
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Solution Overview
Problem
The existing coating process for gas turbine components is inefficient in preventing oxidation during storage, leading to high argon gas consumption due to continuous flow in unsealed purge tanks.
Innovation Solution
A controlled environment enclosure with a purge tank system that uses an oxygen sensor and controller to maintain a sealed environment, allowing argon gas to be replenished only when necessary, reducing gas loss and oxidation risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous argon gas flow is used in an unsealed purge tank to prevent oxidation, then oxidation protection is improved, but argon gas consumption increases
Solution Approach 1:
The patent uses argon gas to create an inert atmosphere environment inside the sealed tank, preventing oxidation of the metal part during storage and transport. The inert atmosphere is maintained by sealing the tank and replenishing argon only when the level drops, rather than continuous flow.
Solution Approach 2:
The patent employs an oxygen sensor that continuously monitors the oxygen level inside the sealed tank and provides feedback to the control system. When oxygen is detected (indicating argon level is low), the system automatically triggers argon replenishment, creating a closed-loop control system that maintains protection while minimizing gas consumption.
2Loss of substance
If a sealed enclosure with oxygen sensing is used, then argon gas consumption is reduced, but system complexity increases
Solution Approach 1:
The system is designed to be self-regulating through the oxygen sensor and control logic. Once configured, the system automatically monitors oxygen levels and triggers argon replenishment when needed, reducing the need for continuous manual monitoring or complex control systems.
Solution Approach 2:
The oxygen sensor acts as an intermediary device that indirectly monitors argon levels by detecting oxygen presence. This simpler indirect measurement approach replaces the need for direct argon level sensors or complex flow control systems.
3Ease of operation
If the tank is kept open for easy access, then ease of operation is improved, but oxidation risk increases
Solution Approach 1:
The metal part is cleaned and prepared beforehand, then immediately placed in the sealed tank with argon atmosphere. This preliminary preparation followed by immediate sealing prevents oxidation from the start, eliminating the need to keep the tank open for extended periods.
Solution Approach 2:
The sealed tank maintains an inert argon atmosphere that protects the metal part from oxidation during storage and transport. The part can be easily accessed by opening the seal when needed, and the inert atmosphere is quickly re-established after opening, minimizing oxidation risk during brief access periods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces argon gas consumption, achieving annual savings of over thirty-six thousand dollars while effectively preventing oxidation of turbine components during storage and coating processes.
Implementation Method 1
oxygen is less dense than the filling fluid; and a controller operatively connected to the oxygen sensor
Data Source
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AI summary
A method of coating a part is disclosed, comprising cleaning the part; storing the part in a controlled environment enclosure (10), wherein the enclosure controls a first parameter of the environment in the enclosure to prevent contamination of the cleaned part by sensing a second parameter in the tank and adjusting the environment within the tank; maintaining the environment in the enclosure; removing the part from the enclosure; and applying a coating to the part.