Development of Packaging and Integration of Sensors for On-Line Use in Harsh Environments

A number of sensors and control systems have been developed for use within power systems; however the effects of high temperature, corrosive/oxidizing atmospheres, and abrasive media have limited their use in gas turbine engines, boilers, solid oxide fuel cells and other harsh environments. Improved sensor packaging and encapsulation is needed to enable on-line sensing for component sensing & diagnostics and structural heath monitoring. The inability to monitor the actual component in real time leads to higher operating and maintenance costs and decreases equipment availability which directly affects the reliability of the US electric supply. Sensors will also provide enhanced control enhancements and enable more efficient turbine operation which will decrease emissions and reduce fuel costs. New sensor packaging concepts are proposed to (1) encapsulate low profile temperature and strain gages with moisture-corrosion barrier coatings and (2) to improve lead-wire connections to sensors using Direct Write processes to enable robust sensor routing and attachment, and (3) to attach fiber optic sensors to components using Direct Write processing for use in ultra supercritical boilers. Commercial applications and other benefits: High temperature sensors are in high demand, spanning a range of industries including power generation, commercial and military aviation, aerospace structures and transportation. Steam turbines, gas turbines, and boilers used in the power generation industry are examples of critical equipment that must operate at top performance to provide the low cost electricity that drives the U.S. economy. Sensors are critical for accurate life prediction models and to operate power systems efficiently with fewer emissions.