The present invention relates generally to gas turbine engines having centrifugal compressors and, more specifically, to control of clearances between an impeller and a shroud of a centrifugal compressor.
Conventional gas turbine engines having centrifugal compressors typically have an axial cold clearance between the impeller and the impeller shroud set such that a rub between them will not occur at the operating conditions that will cause the highest clearance closure which is typically a cold burst. Active clearance control systems have been developed to control radial turbine clearances between tips of axial flow radially extending turbine and compressor blades and shrouds surrounding the blades. Typically, these active clearance control systems are thermally activated and use relatively cold or hot air or a combination of both from the fan, different compressor stages, or compressor discharge air to thermally cool or heat turbine or compressor shrouds or shroud support structures or casings in order to reduce the operating radial clearances. Controlling radial turbine clearances between tips of axial flow radially extending turbine and compressor blades and shrouds surrounding the blades increases fuel efficiency and reduces wear on the blades due to rubs.
It is known in the art to minimize clearance between the blade tips of an impeller rotating within a gas turbine engine and a surrounding blade tip shroud to reduce leakage of a working fluid around the blade tips of centrifugal compressor stages. Several actuation systems for adjusting blade tip clearance during engine operation have been developed. These systems often include complicated linkages, contribute significant weight, and/or require a significant amount of power to operate. Thus, there continues to be a demand for advancements in blade clearance technology to decrease impeller tip clearance thus causing an increase in overall compressor efficiency.
A gas turbine engine centrifugal compressor and active control system assembly includes a centrifugal compressor having a plurality of centrifugal compressor blades mounted on an annular centrifugal compressor impeller, an annular blade tip shroud adjacent to blade tips of the blades, a substantially sealed annular cavity bounded in part by the annular blade tip shroud, and an active control system for controlling an annular blade tip clearance between the annular blade tip shroud and the blade tips by controlling a cavity pressure in the cavity.
An exemplary embodiment of the assembly includes valving controlled by an electronic controller for pressurizing and depressurizing the cavity. The valving is operably connected to a source of compressor discharge pressure air for pressurizing the cavity and may include a control pressure valve for pressurizing the cavity and depressurizing the cavity. The control pressure valve may be connected to the source of compressor discharge pressure air and to a vent line. An electronic controller may be controllably connected to the control pressure valve. The electronic controller may be operable for pulsing a solenoid of the control pressure valve many times a second for rapidly cycling the valves between open and closed states using pulse width modulation.
The assembly may further include one or more pressure sensors positioned for measuring the cavity pressure, one or more clearance sensors positioned for measuring the blade tip clearance, and the pressure and clearance sensors in signal supply communication with the electronic controller.
The assembly may further include the shroud supported by radially spaced apart annular impeller shroud radially outer and inner supports connected to a casing, the cavity bounded by the outer and inner supports and the annular blade tip shroud, and the radially outer and inner supports attached to radially outer and inner ends of the shroud respectively. The radially outer and inner supports may be connected to the casing by a bolted joint.
The assembly may further include axial stop pads extending radially outwardly from the radially outer end of and distributed circumferentially about the shroud of the stop pads.
An alternative embodiment of the active control system assembly includes a control pressure valve for pressurizing the cavity and a blow off pressure valve for depressurizing the cavity. The control and blow off pressure valves may be inline and connected to a pressure line extending between the cavity and the source of compressor discharge pressure air. An electronic controller may be controllably connected to the control and blow off pressure valves. The electronic controller may be operable for pulsing solenoids of the control and blow off pressure valves many times a second for rapidly cycling the valves between open and closed states using pulse width modulation.
A method for controlling the annular blade tip clearance includes controlling the cavity pressure with the active control system. The method may further include valving a source of compressor discharge pressure air for increasing the cavity pressure in the cavity and using a control pressure valve for the increasing of the cavity pressure in the cavity and for decreasing the cavity pressure in the cavity. The electronic controller may be used for controlling the control pressure valve for the controlling of the cavity pressure by opening and closing the control pressure valve for pressurizing the cavity with the source of compressor discharge pressure air and alternatively closing the control pressure valve for depressurizing the cavity with a pressure sink.
The method may further include pulsing a solenoid in the control pressure valve for opening and closing the control pressure valve many times a second for rapidly cycling the valve between open and closed states for the controlling of the cavity pressure using pulse width modulation for the pulsing of the solenoid. The method may further include measuring the cavity pressure using one or more pressure sensors positioned for measuring the cavity pressure and in signal supply communication with the electronic controller, measuring the blade tip clearance using one or more clearance sensors positioned for measuring the blade tip clearance and in signal supply communication with the electronic controller, and using output from the pressure and clearance sensors to the electronic controller for further controlling the control pressure valve for the controlling of the cavity pressure.
An alternative method for controlling the annular blade tip clearance includes using a control pressure valve for increasing the cavity pressure in the cavity and using a blow off pressure valve for decreasing the cavity pressure in the cavity. The electronic controller may be used for controlling the control and blow off pressure valves for the controlling of the cavity pressure by opening and closing the control pressure valve for pressurizing the cavity with the source of compressor discharge pressure air and alternatively opening and closing the blow off pressure valve for depressurizing the cavity with a pressure sink.
The method may further include pulsing solenoids in the control and blow off pressure valves for opening and closing the control and blow off pressure valves many times a second for rapidly cycling the valves between open and closed states for the controlling of the cavity pressure using pulse width modulation for the pulsing of the solenoids. The method may further include measuring the cavity pressure using one or more pressure sensors positioned for measuring the cavity pressure and in signal supply communication with the electronic controller, measuring the blade tip clearance using one or more clearance sensors positioned for measuring the blade tip clearance and in signal supply communication with the electronic controller, and using output from the pressure and clearance sensors to the electronic controller for further controlling the control and blow off pressure valves for the controlling of the cavity pressure.
Illustrated in
In the exemplary embodiment illustrated herein, the compressor 14 is a five stage axial compressor 30 followed by the single stage centrifugal compressor 18 having an annular centrifugal compressor impeller 32. Outlet guide vanes 40 are disposed between the five stage axial compressor 30 and the single stage centrifugal compressor 18. Compressor discharge pressure (CDP) air 76 exits the impeller 32 and passes through a diffuser 42 and then through a deswirl cascade 44 into a combustion chamber 45 within the combustor 52 surrounded by a combustor casing 46 where it is conventionally mixed with fuel provided by a plurality of fuel nozzles 48 and ignited in an annular combustion zone 50 bounded by the combustor 52. Resulting hot combustion gases 54 flow through the turbine 16 causing rotation of the high pressure rotor 12 and continue downstream for further work extraction in a low pressure turbine (not shown) and final exhaust as is conventionally known. In the exemplary embodiment depicted herein, the high pressure turbine 16 includes, in downstream serial flow relationship, first and second high pressure turbine stages 55, 56 having first and second stage disks 60, 62. A forward shaft 64 connects the high pressure turbine 16 in rotational driving engagement to the impeller 32. First and second stage nozzles 66, 68 are directly upstream of the first and second high pressure turbine stages 55, 56, respectively. Disposed radially inwardly from inner wall 72 of combustor casing 46 is annular cavity 74 which extends radially from wall 72 to the forward shaft 64.
Referring to
Referring to
To this end, the active control system 34 was developed. The shroud 130 is supported by radially spaced apart annular impeller shroud radially outer and inner supports 132, 134 which are both connected by a bolted joint 136 to the aft casing 114. The radially outer and inner supports 132, 134 are attached such as by brazing to radially outer and inner ends 80, 82 of the shroud 130 respectively. A substantially sealed annular cavity 140 is thus formed between the shroud 130 and the radially outer and inner supports 132, 134. The radially outer support 132 is substantially thinner and more flexible than the radially inner support 134 and acts as a flexible element that allows the shroud 130 to flex or rotate about the bolted joint 136 and also seals the cavity 140. An annular stiffener 138 extending between and connected to the radially outer support 132 and the shroud 130 stiffens the assembly with respect to modal response and, therefore, prevents resonance of the shroud 130 during engine operation. Axial stop pads 90 extend radially outwardly from the radially outer end 80 of and are distributed circumferentially about the shroud 130. The axial stop pads 90 are designed to prevent accidental rubs between the shroud 130 and the impeller 32.
The exemplary embodiment of the active control system 34 illustrated in
The control pressure valve 150 is used to increase and decrease the cavity pressure CP in the cavity 140 with pressure of the CDP air 76. The blow off pressure valve 152 is optional and is used blow off the cavity 140 in the event of an active control system 34 failure and is controlled independently. The control and blow off pressure valves 150, 152 illustrated herein are three way solenoid valves having three ports opened and closed by solenoid powered poppets. The ports are connected to the cavity 140 by the cavity line 148, to the pressure of the CDP air 76 in the combustor 52 by the pressure line 156, and to the ambient pressure by the vent line 154.
Operation of the control and blow off pressure valves 150, 152 are controlled by the electronic controller 146 which can be part of an electronic engine controller such as a full authority digital engine control (FADEC). The electronic controller 146 connected to the control and blow off pressure valves 150, 152 and operable for signalling valves to open and close. The electronic controller 146 may use input from one or more pressure sensors 160 positioned for measuring the cavity pressure CP and one or more clearance sensors 162 positioned for measuring the blade tip clearance 180 between the shroud 130 and the blade tips 127 of the blades 126. The control and blow off pressure valves 150, 152 may be electrically powered by solenoids 158 in the valves as illustrated herein.
The electronic controller 146 pulses the solenoid 158 of the control pressure valve 150 many times a second so as to rapidly cycle between open and closed positions or states. When the control pressure valve 150 is in the open position the cavity 140 is connected to the compressor discharge pressure CDP in the combustor 52. When the control pressure valve 150 is in the closed position the cavity 140 is connected through the vent line 154 to ambient pressure or some other low pressure source or sink.
Referring to
Referring back to
Thus, the active control system 34 using CDP air pressure will decrease the annular blade tip clearance 180 between the shroud 130 and the blade tips 127 from its non-pressure augmented amount. The non-pressure augmented amount is the amount of the blade tip clearance 180 when no pressure is either being supplied to or bled from the cavity 140 by the active control system 34. Alternatively, a secondary supply of pressure substantially lower than the impeller pressure 174 can be used to increase the annular blade tip clearance 180 between the shroud 130 and the blade tips 127 from its non-pressure augmented amount.
If a problem develops then the control pressure valve 150 is closed and the blow off pressure valve 152 is opened and the cavity 140 is depressurized. The pressure within the cavity pressure CP is lowered by blowing off or bleeding air out of the cavity 140 to a pressure sink or a low pressure source which may be located outside the compressor, typically ambient pressure, and depressurizing stops when the blow off pressure valve 152 is closed.
An alternative exemplary embodiment of the active control system 34 is illustrated in
Operation of the supply and blow off pressure valves 150, 152 are controlled by the electronic controller 146 which can be part of an electronic engine controller such as a full authority digital engine control (FADEC). The electronic controller 146 connected to the supply and blow off pressure valves 150, 152 and operable for signalling valves to open and close. The electronic controller 146 may use input from one or more pressure sensors 160 positioned for measuring the cavity pressure CP and one or more clearance sensors 162 positioned for measuring the blade tip clearance 180 between the shroud 130 and the blade tips 127 of the blades 126. The supply and blow off pressure valves 150, 152 may be electrically powered by solenoids 158 in the valves as illustrated herein. The electronic controller 146 pulses the solenoids 158 of the supply and blow off pressure valves 150, 152 many times a second so as to rapidly cycle between open and closed states. When the supply pressure valve 150 is open, the cavity 140 is pressurized and the pressure within the cavity pressure CP is increased using CDP air 76 pressure and pressurizing stops when the supply pressure valve 150 is closed. When blow off pressure valve 152 is open, the cavity 140 is depressurized and the pressure within the cavity pressure CP is lowered by blowing off or bleeding air out of the cavity 140 to a pressure sink or a low pressure source which may be located outside the compressor, typically ambient pressure, and depressurizing stops when the blow off pressure valve 152 is closed.
Referring to
While there have been described herein what are considered to be preferred and exemplary embodiments of the present invention, other modifications of the invention shall be apparent to those skilled in the art from the teachings herein and, it is therefore, desired to be secured in the appended claims all such modifications as fall within the true spirit and scope of the invention. Accordingly, what is desired to be secured by Letters Patent of the United States is the invention as defined and differentiated in the following claims.
The government may have rights in this invention pursuant to government contract W911W6-07-2-0002 awarded by the Department of Defense.