Ultrasonic Scanning Device Fluid Pad In-Situ Turbine Inspection
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Solution Overview
Problem
Current ultrasonic testing methods for turbine components require removal and transportation to a laboratory for immersion testing, leading to delays in inspecting operational turbines.
Innovation Solution
An ultrasonic scanning device with a moveable fluid distribution block and fluid pad forming a channel between the ultrasonic transducer and the turbine component, allowing for in-situ fluid column formation to facilitate ultrasonic energy transmission, combined with a control module and encoder for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional immersion testing is used to ensure accurate ultrasonic energy transmission, then measurement precision is improved, but the component must be removed and transported to a laboratory, causing loss of time
Solution Approach 1:
A fluid distribution block with fluid outlets and a fluid pad are introduced as intermediary components between the ultrasonic transducer and the turbine component. These components deliver fluid to form a fluid column that couples the ultrasonic energy, enabling accurate transmission without requiring complete immersion or component removal. The fluid pad specifically acts as a mediator to maintain consistent fluid coupling at the inspection interface.
Solution Approach 2:
The fluid delivery system is segmented into a fluid distribution block with multiple fluid outlets and a separate fluid pad. This segmentation allows the fluid to be delivered precisely to the inspection area and maintains a controlled fluid column between the transducer and component, achieving laboratory-quality coupling in field conditions without requiring the entire component to be immersed.
2Measurement precision
If a fluid column is formed between the ultrasonic transducer and the turbine component, then ultrasonic energy transmission is facilitated, but additional fluid delivery components are required
Solution Approach 1:
The fluid distribution block serves multiple functions: it distributes fluid from a single source through multiple outlets to create the fluid column, provides structural support for the ultrasonic transducer, and integrates with the fluid pad to maintain coupling. This multi-functionality reduces the need for separate components while achieving the required ultrasonic transmission capability.
3Productivity
If the turbine component remains installed in the operational turbine, then productivity is improved by avoiding removal and transportation, but the component cannot be immersed in a water tank for traditional testing
Solution Approach 1:
The inspection system is made dynamic and adaptable through the moveable fluid distribution block and fluid pad assembly that can be positioned and adjusted at various inspection locations on the turbine component. This dynamic configuration allows the system to adapt to different inspection points while keeping the component installed, maintaining both productivity and testing versatility.
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 on-site, portable ultrasonic inspections of turbine components, reducing inspection delays by allowing for immediate testing without the need for removal and transportation.
Implementation Method 1
Fluid received in the channel forms a fluid column between the ultrasonic transducer and the object that facilitates transmission of ultrasonic energy generated by the ultrasonic transducer
Data Source
AI summary
An ultrasonic scanning device for scanning a turbine component. The device includes an ultrasonic transducer attached to a moveable fluid distribution block, wherein the block includes a block opening and an internal passageway for receiving a fluid. The device also includes a fluid pad having a fluid pad opening that is in fluid communication with the block opening, wherein the fluid pad and block openings form a channel that extends between the ultrasonic transducer and the turbine component. Fluid received by the internal passageway moves to the channel and forms a fluid column between the ultrasonic transducer and the turbine component that facilitates transmission of ultrasonic energy generated by the ultrasonic transducer. In addition, the device includes a control module for controlling operation of the ultrasonic transducer and an encoder for providing travel information to the control module for determining a position of the device relative to the turbine component.