Hydro Turbine Runner Inspection via ROV
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Solution Overview
Problem
Current methods for inspecting hydro turbine runners require extensive downtime for dewatering and transportation, leading to long intervals between inspections and potential missed detection of defects like cavitation damage and cracks.
Innovation Solution
A remote-operated vehicle (ROV) or autonomous underwater vehicle (AUV) equipped with cameras and scanners, capable of performing thorough surface inspections, generating 3D representations, and providing defect characterization, allowing for in-situ detection and potential repair without dismantling the turbine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inspection methods are used (dewatering and transporting runner to workshop), then thorough inspection can be performed, but inspection time and downtime increase significantly
Solution Approach 1:
An inspection device is introduced as an intermediary tool that can operate within the turbine hall without requiring dewatering or removal of the runner. The device includes a movable platform with inspection equipment that can access the runner in-situ, eliminating the need for traditional workshop-based inspection methods while maintaining inspection quality
Solution Approach 2:
The patent replaces the mechanical system of physically removing and transporting the heavy runner with an automated inspection device that moves along rails within the turbine hall. This substitution uses automated positioning and data acquisition systems to achieve thorough inspection without the time-consuming mechanical removal process
2Reliability
If inspection frequency is increased to detect defects early, then reliability improves, but downtime and operational disruption increase
Solution Approach 1:
The inspection device can operate while the turbine remains in place and potentially during partial operational conditions, allowing for more frequent inspections without complete shutdown. The system enables continuous or near-continuous inspection capability, transforming periodic disruptive inspections into a more continuous monitoring process
Solution Approach 2:
The inspection system is self-contained with its own power supply, positioning mechanism, and data processing capabilities, allowing it to operate independently without requiring plant shutdown or external support systems. This self-sufficiency enables frequent inspections with minimal operational disruption
3Productivity
If the runner remains installed for continuous power generation, then productivity is maintained, but access for inspection becomes difficult
Solution Approach 1:
The inspection device is divided into modular components including a movable platform, inspection equipment module, and control system. This segmentation allows the inspection system to navigate tight spaces between runner blades and access difficult-to-reach areas while the runner remains installed, maintaining both productivity and inspection accessibility
Solution Approach 2:
The inspection platform is designed to be movable along rails and adjustable in position, allowing dynamic access to different areas of the runner. The system can move in and out of position as needed, providing easy access for inspection while minimizing interference with power generation operations
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
Enables frequent and efficient inspection of hydro turbine runners, detecting defects at an early stage, reducing downtime and allowing for immediate repair, thereby enhancing maintenance efficiency and preventing catastrophic failures.
Implementation Method 1
The scanner can be a laser scanner or an ultrasound or an active infrared scanner
Implementation Method 2
The scanner can be a laser scanner or an ultrasound or an active infrared scanner
Implementation Method 3
The scanner can be a laser scanner or an ultrasound or an active infrared scanner
Data Source
AI summary
The invention relates to a device (1) for inspecting a cavitation damage or a crack of a runner (7) of a hydro turbine, comprising a remote operated vehicle (20) or an autonomous underwater vehicle, comprising at least one camera and/or scanner, and means (24) for processing images from said camera and/or scanner to generate at least one 3D view and/or IR thermal view of at least a part of a surface, or of a subsurface, of said runner comprising said cavitation damage or crack, said device further comprising means to reconstruct a 3D view by photogrammetry and/or means for locally heating, for example by induction or by a laser or by a heated water jet, said at least one part of a surface of said runner comprising said cavitation or crack.