The subject matter herein relates to fuel nozzles for gas turbine engines. More particularly, the disclosed subject matter relates to elimination of flashback and flame holding in conjunction with fuel nozzles.
A gas turbine engine combusts a mixture of fuel and air to generate hot combustion gases, which in turn drive one or more turbines. In particular, the hot combustion gases force turbine blades to rotate, thereby driving a shaft to rotate one or more loads, e.g., electrical generator. As appreciated, a flame develops in a combustion zone having a combustible mixture of fuel and air. Unfortunately, the flame can potentially propagate upstream from the combustion zone into the fuel nozzle, which can result in damage due to the heat of combustion. This phenomenon is generally referred to as flashback. Likewise, the flame can sometimes develop on or near surfaces, which can also result in damage due to the heat of combustion. This phenomenon is generally referred to as flame holding. For example, the flame holding may occur on or near a fuel nozzle in a low velocity region. In particular, an injection of a fuel flow into an air flow may cause a low velocity region near the injection point of the fuel flow, which can lead to flame holding.
Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a system includes a turbine combustor fuel nozzle, comprising a swirl vane, and an injection hole configured to inject fluid in a downstream region of the swirl vane in response to detection of a condition indicative of a flame inside the turbine combustor fuel nozzle.
In a second embodiment, a system includes a turbine combustor fuel nozzle, comprising an air path, a fuel path, a fuel-air mixture region receiving air from the air path and receiving fuel from the fuel path, and an fluid injection hole configured to inject fluid in the fuel-air mixture region in response to detection of a condition indicative of a flame inside the turbine combustor fuel nozzle.
In a third embodiment, a system includes a fuel nozzle flame sensor configured to detect a condition indicative of a flame inside a turbine combustor fuel nozzle, and a fuel nozzle flame controller configured to control an injection of a fluid into the turbine combustor fuel nozzle in response to a signal from the fuel nozzle flame sensor indicative of the condition.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
In certain embodiments, as discussed in detail below, a gas turbine engine includes one or more fuel nozzles with fluid injection holes (e.g., injection holes) to resist thermal damage associated with flashback and/or flame holding. In particular, each fuel nozzle may include a fuel-air premixer having a plurality of swirl vanes disposed in a circumferential arrangement in an air flow path. The fuel nozzles may also include fluid injection holes (e.g., air injection holes) in a crossflow or angled flow relative to the longitudinal axis of the fuel nozzle and direction of main air flow through the fuel nozzle. For example, the fluid (e.g., air) injection holes may be located on the center body (e.g., hub) and the outer wall (e.g., shroud) of the fuel nozzle such that the holes direct air radially inward and radially outward relative to the longitudinal axis. Furthermore, the injection holes may be located immediately before each swirl vane trailing edge in the fuel nozzle. The injection holes improve the flame holding margin and reduce the possibility of flashback by blowing the flame out whether it anchors on the trailing edge of the swirl vane or behind the fuel outlet. This may be performed by steady air injection or modulation of air passing through the injection holes. Each method may disturb the entire flame stabilized behind the fuel hole by dividing the flame into at least two regions at the vane trailing edge or by fluttering it. Therefore, the injected air may detach the flame by weakening its energy and, thus, stabilizing the flame at the combustor. Also, the injected air may reduce the temperature in flame holding regions to eliminate the possibility of the re-ignition at those locations. The injection of fluid may reduce low velocity regions, that is, stagnant regions where flame may occur, through high velocity injection of fluids into the low velocity region. This may create a high velocity region where flame is not likely to occur and/or remain.
Turning now to the drawings and referring first to
Air supply 31 may route air via conduits to air intake 32, which then routes the air into compressor 28. Compressor 28 includes a plurality of blades drivingly coupled to shaft 26, thereby compressing air from air intake 32 and routing it to fuel nozzles 12 and combustor 20, via air supply 16. At this juncture, diluent may also be routed to fuel nozzles 12 from the diluent source 18. The diluent may be, for example, an inert gas such as nitrogen that may aid in reducing undesirable emissions during combustion of the air/fuel mixture, or may aid in generating proper pressure levels for combustion in the combustor. Alternatively, the diluent may be water or another fluid. Fuel nozzle 12 may then mix the pressurized air and fuel (as well as the diluent, if needed), to produce an optimal mix ratio for combustion, e.g., a combustion that causes the fuel to more completely burn so as not to waste fuel or cause excess emissions. As a result of this combustion, exhaust gasses are generated that pass through turbine 24 and exit the system 10 at exhaust outlet 33. As discussed in detail below, an embodiment of the fuel nozzles 12 include at least one fluid injection hole (e.g., air injection hole) configured to inject fluid (e.g., air) in a downstream region of the swirl vane in response to detection of a condition indicative of a flame inside the turbine combustor fuel nozzle 12.
The detection of a condition indicative of a flame inside the turbine combustor fuel nozzle 12 may be registered by a flame monitor 34 connected to one or more sensors 36, (e.g., flame sensors). The sensors 36 may be pressure sensors for detecting changes in pressure inside of the fuel nozzles 12, thermal sensors for detecting changes in temperature in the fuel nozzles 12, and/or optical sensors for detecting changes in light in the fuel nozzles 12. In this manner, the sensors 36 may sense conditions indicative of either flashback or flame holding in the fuel nozzles 12. The sensors 36 may transmit signals to flame monitor 34 in response to the conditions of flame to the flame monitor 34.
Flame monitor 34 may be, for example, an application specific integrated circuit (ASIC) or other detection device that may receive the signals from the sensors 36 and may generate an indication that a flame has been detected in the fuel nozzles 12. This indication may be transmitted to a controller 38. The controller 38 may receive the indication of a detected flame in the fuel nozzles 12 from the flame monitor 34. The controller 38 may, for example, be a processor or an ASIC. In one embodiment, the flame monitor 34 and the controller 38 may be parts of a single processor. The controller 38 may, for example, operate to change conditions that affect the fuel nozzle 12. For example, the controller 38 may operate to increase or decrease the fuel supplied to the fuel nozzles 12 via adjustment of fuel supply 14, increase or decrease the air supplied to the fuel nozzles 12 via adjusting the air supply 16, and/or increase or decrease the diluent supplied to the fuel nozzles 12 via adjustment of the diluents source 18. By adjusting the components mixed in the fuel nozzle, the controller 38 may change the combustion conditions in the combustor 20, thus causing the extinguishment of the flame detected in one or more of the fuel nozzles 12. Furthermore, the controller 38 may selectively control one or more fluid injection holes (e.g., air, fuel, diluent, etc.) specifically oriented to reduce or eliminate conditions conducive to flashback or flame holding, or an actual event of flashback or flame holding. For example, as discussed below, the controller 38 may selectively activate and/or modulate fluid flow through these fluid injection holes to eliminate low velocity regions, create a crossflow, or generally disturb and blow out in flame inside the fuel nozzle 12.
During this process, a flame generated via the combustion in the combustion chamber 50 may flashback, (e.g., the flame may propagate from the combustion chamber 50 into one or more of the fuel nozzles 12. To aid in the removal of this flame from the fuel nozzles, the controller 38 may be utilized in conjunction with fluid (e.g., air, fuel, water, diluent, etc.) injection holes to reduce or eliminate the conditions conductive to flashback and flame holding in the fuel nozzle 12. That is, the fluid injection holes may, for example, reduce low velocity regions where flame may occur through high velocity injection of fluids into the low velocity region to create a high velocity region where flame is not likely to be sustained.
As illustrated, the nozzle 12 may include one or more swirl vanes 72. Each swirl vane 72 may be a hollow body, e.g., a hollow airfoil shaped body, which may induce a swirling flow within the fuel nozzle 12. Thus, the fuel nozzle 12 may be described as a swozzle in view of this swirl feature. It should be noted that various aspects of the fuel nozzle 12 may be described with reference to an axial direction or axis 73, a radial direction or axis 74, and a circumferential direction or axis 75. For example, the axis 73 corresponds to a longitudinal centerline or lengthwise direction, the axis 74 corresponds to a crosswise or radial direction relative to the longitudinal centerline, and the axis 75 corresponds to the circumferential direction about the longitudinal centerline.
The fuel may flow axially 73 through the fuel passage 70 until it abuts wall 76 in the fuel passage 70. Upon abutting wall 76, the fuel may radially 74 flow into a fuel compartment 78 of the hollow swirl vane 72 and may exit the fuel compartment 78 via fuel holes 80 (e.g., fuel injection hole) into a mixing region surrounding the swirl vane 72. In this mixing region, the fuel interacts with compressed air routed from the air supply 16 moving along directional arrow 81. As described above, this fuel-air mixture may be swirled by the swirl vane 72 to aid in mixing of the fuel and air for proper combustion.
As indicated above, flashback may occur in the fuel nozzle 12, specifically in the downstream portion 82 of the fuel nozzle 12. To reduce the occurrence of flashback, fluid injection holes 84 (e.g., air injection holes) may be utilized to inject fluid (e.g., air) into the downstream portion 82 of the fuel nozzle 12. These injection holes 84 may, for example, have a diameter of approximately less 80, 70, 60, 50, 40, 30, 20, or 10 percent the diameter of the fuel holes 80. The fluid injection holes 84 may be included in a fluid compartment 86 of the swirl vane 72, in the plenum 62, and/or in the center body 68 of the fuel nozzle 12. The fluid (e.g., air) injected from these holes 84 may be angled or crosswise with respect to directional flow line 81. It should be noted that the holes 84 may inject, for example, air into the fuel nozzle 12. Alternatively, other fluids such as nitrogen, water, and/or fuel may be utilized in place of or in conjunction with the air injected via holes 84. Thus, the fluid injected from immediately prior to swirl vane trailing edge on concave face and from center body and outer wall may enter the downstream portion 82 of the nozzle 12 at an angle of approximately less than 20 degrees and 30 to 90 degrees relative to the directional flow 81 of the main air along directional arrow 81. In an embodiment, the fluid may enter the downstream portion 82 of the nozzle 12 at an angle of approximately less than 20 degrees or approximately between 30 to 90 degrees relative to the directional flow 81 of the main air along directional arrow 81. As may be seen, air delivery to the holes 84 on the center body 68, (e.g., hub), may be through the fluid compartment 86 of the vane 72, while the plenum 62 may provide air to the holes 84 on the outer wall 88 (e.g., annular wall) of the fuel nozzle 12. It should be noted that the center body 68 and the outer wall 88 may be coaxial or concentric with one another. The holes 84 on the center body 68 may receive fluid via the diluent travelling along directional line 67. Furthermore, air delivery to the holes 84 on the center body 68 may be coupled to a delivery tube, which is connected to an air delivery tube of the outer wall 88 holes 84. In one embodiment, an adjustable valve may lie between the delivery tubes that may be controlled by the controller 38 to adjust the fluid flow (e.g., airflow) rate for each delivery tube upon reception of an indication from the flame monitor 34 that a flame has been detected in the fuel nozzles 12. The controller 38 may also operate a main air valve 90 to control the air flow into both the upstream portion 66 of the fuel nozzle 12 as well as the air (or fluid) passed to the plenum 62 for transmission to the holes 84.
It should be noted that the fluid (or air) may be continuously flowing through the holes 84, or the air may be modulated, (e.g., pulsed). Alternatively, the fluid may be in an “off” state, and then turned “on” when a flame is detected. If the fluid is continuously flowing through the holes 84, it may be increased when a high velocity jet is required to extinguish a flame. For example, the velocity of the flow through the jets may be increased to approximately 1.25, 1.3, 1.5, 1.75, 2, 2.5, 3, 3.5, or greater times the speed of the main air flow along directional line 81. Similarly, if the fluid is introduced through the holes 84 when previously not flowing, the fluid may flow at a velocity of approximately 1.05 or greater times the speed of the main air flow along directional line 81.
If the fluid from the holes 84 is pulsed, it may be modulated at a frequency of approximately less than 20 Hz. The modulation of the fluid exiting the holes 84 may be approximately less than 10 Hz. In other embodiments, the modulation of the fluid exiting the holes 84 may be approximately 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 Hz. This modulation may be sufficient to change the flame conditions in the nozzle to detach any flame from the downstream region 82 of the fuel nozzle, for example, downstream of the vane 72. It should also be noted that the speed of the fluid exiting the holes, in either a continuous or modulated manner, may be approximately 1.25, 1.3, 1.5, 1.75, 2, 2.5, 3, 3.5, or greater times the speed of the of the main air flow. Additionally, the speed of the fluid exiting the holes, in either a continuous or modulated manner, may be approximately 1.3 to 3 times the speed of the of the main air flow.
The controller 38 may operate to prevent or actively eliminate flame in the nozzle 12. For example, in the event of flashback or flame holding in the fuel nozzle 12 detected by the flame monitor 34, the controller 38 may adjust air flowing through the injection holes 84 via one or more valves, as previously discussed. The injection holes 84 may provide an extinguishing force that may operate as a corrective measure to eliminate the flashback or flame holding. In particular, thermal damage may occur at the downstream end portion 96 (e.g., downstream tip) of the swirl vane 72. Thus, by locating the injection holes 84 proximate to this end portion 96, the thermal damage to of the swirl vane 72 may be reduced or eliminated and the possibility of any further damage to the fuel nozzle 12 (e.g., further upstream 66) may also be reduced.
In the illustrated embodiment, the premixer 92 includes eight swirl vanes 72 equally spaced at 45 degree increments about the circumference 75 of the nozzle center body 68. In certain embodiments, the premixer 92 may include any number of swirl vanes 72 (e.g., 8 or 10) disposed at equal or different increments about the circumference 75 of the nozzle center body 68. The swirl vanes 72 are configured to swirl the flow, and thus induce fuel-air mixing. As illustrated, each swirl vane 72 bends or curves from the upstream end portion 98 to the downstream end portion 96. In particular the upstream end portion 98 is generally oriented in an axial direction along the axis 73, whereas the downstream end portion 96 is generally angled, curved, or directed away from the axial direction along the axis 73. For example, the downstream end portion 96 may be angled relative to the upstream end portion 98 by an angle of approximately 5 to 60 degrees, or approximately 10 to 45 degrees. As a result, the downstream end portion 96 of each swirl vane 72 biases or guides the flow into a rotational path about the axis 73 (e.g., swirling flow). This swirling flow enhances fuel-air mixing within the fuel nozzle 12 prior to delivery into the combustor 20.
Additionally, one or more injection holes 84 may be disposed on the vanes 72 at the downstream end portion 96, as well as on the center body 68 and/or outer wall 88. For example, these injection holes 84 may be approximately 40 mil diameter (for example, 80% of 50 mil diameter fuel hole), 45, or 50 mils in diameter. Each swirl vane 72 may include 1, 2, 3, or more injection holes 84 and in the case of 10 swirl vanes there may be 10 on the vane trailing edge or more injection holes 84 on the center body 68 and or on the outer wall 88 (for example, inside of the plenum 62 and along the outer wall 88).
Furthermore, each injection hole 84 may be oriented in an axial direction along the axis 73, and/or in a radial direction along the axis 74. In other words, each injection hole 84 may have a simple or compound angle relative to a surface of the swirl vane 72 and/or the center body 68 and outer wall 88. For example, the injection holes 84 may cause the air to flow into the premixer 92 at an angle of approximately less than 20 degrees and 30 to 90 degrees with respect to the directional flow of the main air 81. Angling the injection holes 84 in this manner may allow for more complete extinguishing of any flames in the premixer 92. Thus the injection of fluid via the injection holes 84 may be parallel to the main fuel-air flow, or crosswise relative to the longitudinal axis and to the main fuel-air flow. In this manner, the holes 84 may reduce or eliminate conditions conducive to flashback and flame holding (e.g., low velocity regions) via injection of air, water, nitrogen, fuel, or another fluid into the nozzle 12.
As such, holes 84 may inject fluid such as air, diluent (e.g., water, nitrogen, etc.), and/or fuel in a substantially parallel or in a longitudinally crosswise manner to the direction of the main fuel-air flow through the nozzle. The injection may occur from the center body 68, the vanes 72, and/or the outer wall 88 (e.g., in the plenum 62). The fluid may, for example, be directed radially inward, radially outward, axially, or at a particular angle relative to the longitudinal axis of the fuel nozzle 12. Additionally, the controller 38 may trigger the injection only when flames are detected in particular regions of the fuel nozzle 12 and/or the injection may always be occurring and may be increased in velocity when flames in those regions are detected. That is, the controller may increase the flow through the holes at a baseline flow rate, (e.g., increase the velocity of the fluid injected through the holes 84 by approximately 50%, 100%, 150%, 200%, or more), or the controller may control the modulation (e.g., pulsing) of the fluid flow through the holes 84.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
This invention was made with Government support under contract number DE-FC26-05NT42643 awarded by the Department of Energy. The Government has certain rights in the invention.