Coking Sensor System for Gas Turbine Engine Fuel
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Solution Overview
Problem
Traditional systems for detecting coking in gas turbine engines, particularly those operating above fuel thermal stability limits, are unsuitable for aircraft due to size and weight constraints and provide unreliable data, failing to account for factors other than oxygen that contribute to coking.
Innovation Solution
A coking sensor system that includes heatable collecting elements configured to induce coking conditions upstream of high-temperature regions, equipped with sensors to detect physical build-ups or accumulation of deposits, and communicate signals to the engine control for timely maintenance and operation adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional oxygen removal systems are used, then oxygen concentration can be reduced, but system reliability decreases due to failure or miscalibration
Solution Approach 1:
The patent implements a feedback mechanism by using a coking sensor to detect deposit formation on heatable collecting elements and communicating this information back to the engine control. This allows the system to monitor the effectiveness of oxygen removal and adjust operations accordingly, improving reliability by providing continuous verification rather than relying solely on the oxygen removal system's performance.
Solution Approach 2:
The patent introduces an intermediary detection system (coking sensor with heatable collecting elements) that indirectly monitors oxygen removal effectiveness by detecting coking conditions. This intermediary approach provides a more reliable indication of system performance than direct oxygen measurement, as it detects the actual consequence of insufficient oxygen removal (coke deposit formation).
2Difficulty of detecting and measuring
If traditional coking detection systems are used, then detection capability is provided, but device complexity and weight increase making them unsuitable for aircraft
Solution Approach 1:
The patent uses heatable collecting elements that replicate the thermal conditions of high-temperature engine regions where coking occurs. By creating a simplified model (copy) of the coking environment upstream of the engine, the system can detect coking conditions without requiring complex instrumentation in the actual high-temperature zones, thus reducing device complexity and weight.
Solution Approach 2:
The patent extracts the coking detection function from the main engine system by positioning heatable collecting elements and sensors upstream of the high-temperature regions. This separation allows the detection system to operate in a more benign environment, simplifying the overall system design and reducing the complexity and weight of the detection apparatus.
3Temperature
If fuel is heated above thermal stability limit, then cooling performance is improved, but coking deposits increase
Solution Approach 1:
The patent implements preliminary action by detecting coking conditions upstream of the high-temperature regions before significant deposit formation occurs in the engine. The heatable collecting elements and sensors monitor the early stages of coking, allowing maintenance personnel to take preventive action (such as cleaning or adjusting oxygen removal) before harmful deposits accumulate in the engine, thus mitigating the harmful effect while maintaining the temperature benefit.
Solution Approach 2:
The system provides feedback about coking conditions to the engine control, which can then adjust fuel temperature or oxygen removal operations to prevent excessive deposit formation. This feedback loop allows the system to maintain fuel temperature above the thermal stability limit for cooling performance while actively managing coking deposits through control adjustments.
4Loss of time
If upstream detection is implemented, then maintenance timing is improved, but system accessibility decreases
Solution Approach 1:
The patent uses an intermediary detection system positioned upstream that indirectly monitors conditions in the high-temperature regions. This intermediary approach provides early maintenance warnings without requiring direct access to the difficult-to-reach high-temperature zones, thus maintaining ease of operation while improving maintenance timing.
Solution Approach 2:
The patent segments the detection function into separate components (heatable collecting elements and sensors) positioned upstream where they are more accessible. This segmentation allows the detection system to be maintained and serviced independently of the main engine, improving accessibility while still providing timely maintenance information through the upstream monitoring location.
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
The system provides accurate detection of coking, enhancing engine efficiency and reliability by allowing for proactive maintenance and reducing unwanted deposits, while being more accessible and maintainable than traditional systems.
Implementation Method 1
the at least one heatable collecting element is heated to a temperature that induces coking
Implementation Method 2
a sensor configured to detect an indication of coking on the at least one heatable collecting element
Data Source
AI summary
An improved system, apparatus and method may be configured for detecting coking in a gas turbine engine. The system may comprise one or more heatable collecting elements configured to be positioned in a fuel supply passage having an inlet and an outlet. The apparatus heatable collecting may be configured to generate heat at or over a fuel system temperature range to induce coking in at least one of the heatable collecting elements. The apparatus may also include a sensor configured to detect an indication of coking on the heatable collecting elements and, in response to the coking indication, communicate a coking condition signal to an engine control.