In the accompanying drawings:
Referring to
The variable-vane turbine nozzle 40 incorporates one or more variable nozzle vanes 52 that control the direction at which the exhaust gases 38 discharging therefrom impinge on the blades 14′ of the power turbine 14, wherein this direction is controlled by controlling the corresponding rotational position 54 of each of the one or more variable nozzle vanes 52. During normal operation of the gas-turbine engine 12, the rotational positions 54 of each of the one or more variable nozzle vanes 52 are controlled—typically in synchronism, typically uniformly—by an associated variable-vane actuator 56 via an associated nozzle-vane-angle control mechanism 58 that operatively couples the variable-vane actuator 56 to each of the one or more variable nozzle vanes 52, so as to provide for adjusting the associated rotational positions 54 of the one or more variable nozzle vanes 52 responsive to the particular operating conditions of the gas-turbine engine 12, and responsive to the associated user control input(s) 34, so as to generate with the power turbine 14 a corresponding appropriate level of shaft torque or shaft power that is applied to, and absorbed by, the load 42.
During operation of the gas-turbine engine 12/Auxiliary Power Unit (APU) 44, if the power demanded by the load 42 is reduced—particularly if reduced suddenly—thereby reducing or suddenly reducing the shaft torque transmitted to the load 42 by the power turbine 14, the exhaust gases 38 impinging on the blades 14′ of the power turbine 14 will accelerate the power turbine 14, which absent further action may result in excessive rotational speed of the power turbine 14, i.e. an associated overspeed condition. In one set of embodiments, this overspeed condition can be avoided by quickly reconfiguring the rotational positions 54 of the one or more variable nozzle vanes 52 of the variable-vane turbine nozzle 40—each associated rotational position 54 referred to herein as an “overspeed-mitigating rotational position”—so as to redirect the stream of exhaust gases 38 impinging on the blades 14′ of the power turbine 14 so as to either provide for reducing the magnitude of the torque generated by the impingement of exhaust gases 38 on the blades 14′ of the power turbine 14, and/or to provide for generating a reverse torque on—and a resulting deceleration of—the power turbine 14.
In accordance with a first aspect 10.1 of the gas-turbine-engine overspeed protection system 10, 10.1, one or more of the variable-vane actuator 56, nozzle-vane-angle control mechanism 58, and the associated one or more variable nozzle vanes 52 of the variable-vane turbine nozzle 40 are configured by a variable-vane actuator 56 with sufficient authority to sufficiently-quickly reposition each of the associated one or more variable nozzle vanes 52 to an overspeed-mitigating rotational position so as to prevent an associated overspeed condition of the power turbine 14, responsive to the rotational speed of the power turbine 14, for example, responsive to a rotational speed signal 60 from a rotational speed sensor 62 operatively associated with the power turbine 14, and operatively coupled to the controller 32.
In accordance with a second aspect 10.2 of a gas-turbine-engine overspeed protection system 10, 10.2, each of the one or more variable nozzle vanes 52, 52′ of the variable-vane turbine nozzle 40 are configured to be inherently biased towards the associated overspeed-mitigating rotational position by action of the exhaust gases 38 impinging thereon. For example, in one set of embodiments, variable nozzle vanes 52, 52′ are configured to swing about an axis of rotation 64 that is approximately normal to the flow of exhaust gases 38, with each variable nozzle vane 52, 52′ shaped and positioned relative to the corresponding axis of rotation 64 so that the resulting center of pressure acts to rotate the variable nozzle vane 52, 52′ towards the associated overspeed-mitigating rotational position, the latter of which may be defined by an associated rotational-position-limiting mechanical stop. For example, in one set of embodiments, the rotational-position-limiting mechanical stop provides for each of the one or more variable nozzle vanes 52, 52′ to be rotated by the flow of the exhaust gases 38 to a relatively open position as the overspeed-mitigating rotational position, which limits the associated work that can be done by the power turbine 14, so as to prevent an overspeed thereof.
In accordance with a third aspect 10.3, the gas-turbine-engine overspeed protection system 10, 10.3 incorporates a biasing element 66 operatively coupled to the one or more variable nozzle vanes 52—for example, via the associated nozzle-vane-angle control mechanism 58—that provides for biasing each of the one or more variable nozzle vanes 52 towards a corresponding associated overspeed-mitigating rotational position, wherein the variable-vane actuator 56 has sufficient authority to overcome the associated biasing force—and thereby control the rotational positions of the one or more variable nozzle vanes 52—during normal operation of an associated gas-turbine engine 12 that is not experiencing an associated overspeed condition. For example, in one set of embodiments, the associated biasing force is generated by a spring 68 operative between the nozzle-vane-angle control mechanism 58 and a fixed portion of the gas-turbine engine 12, i.e. a mechanical ground. As another example, in another set of embodiments, the associated biasing force is generated by a fluid-powered actuator 70 for example, either a pneumatic cylinder 70.1 or a hydraulic cylinder 70.2, operative between the nozzle-vane-angle control mechanism 58 and the mechanical ground.
The second and third aspect gas-turbine-engine overspeed protection systems 10, 10.2, 10.3 further incorporate a decoupling mechanism 72 that provides for decoupling the variable-vane actuator 56 from the one or more variable nozzle vanes 52—for example, by providing for decoupling the variable-vane actuator 56 from the associated nozzle-vane-angle control mechanism 58 interposed therebetween—so as to provide for each of the one or more variable nozzle vanes 52 to be rotated to the associated overspeed-mitigating rotational position responsive to the above-described biasing element 66 following a decoupling of the variable-vane actuator 56 responsive to the detection of an associated overspeed condition of the power turbine 14. For example, in one set of embodiments, the decoupling mechanism 72 incorporates a decouplable spline-shaft-driven gear mechanism 74—incorporating at least one spline coupling 76—that is mechanically actuated, i.e. decoupled, by an associated mechanically-actuated trigger system 78 that is inherently responsive to the rotational speed 80 of either the power turbine 14 or a shaft operatively coupled thereto. As another example, in accordance with another set of embodiments, the decoupling mechanism 72 incorporates a releasable mechanical clutch 82, for example, rotationally in series with a drive shaft of the variable-vane actuator 56 and actuated either responsive to an associated mechanically-actuated trigger system 78, the latter of which is inherently responsive to the rotational speed 80 of either the power turbine 14 or a shaft operatively coupled thereto, or responsive to a solenoid-actuated trigger system 78′, the latter of which may be actuated responsive to a rotational-speed actuated switch responsive to the rotational speed 80 of either the power turbine 14 or a shaft operatively coupled thereto, or responsive to a rotational speed signal 60 from the rotational speed sensor 62. As yet another example, in accordance with yet another set of embodiments, the decoupling mechanism 72 incorporates a releasable electro-mechanical clutch 84, for example, rotationally in series with a drive shaft of the variable-vane actuator 56, and actuated responsive to an associated mechanically-actuated trigger system 78, the latter of which may be responsive to the rotational speed signal 60 from the rotational speed sensor 62, either under direct control or via an associated actuation signal 86 from the controller 32. For example, in one set of embodiments, the releasable electro-mechanical clutch 84, 84′ is engaged responsive to a holding current in one or more associated coils, and disengaged when that holding current is interrupted. As another example, in another set of embodiments, the releasable electro-mechanical clutch 84, 84″ is normally held in engagement by one or more permanent magnets incorporated therein, and disengaged responsive to a current applied to one or more coils that provide for canceling the magnetic field(s) of the associated one or more permanent magnets. As yet another example, in accordance with yet another set of embodiments, the decoupling mechanism 72 incorporates at least one frangible link 88—for example, either rotationally in series with the variable-vane actuator 56, or axially in series with a link driven thereby—that, when severed, for example, responsive to actuation of a corresponding associated at least one pyrotechnic device 90, provides for decoupling the variable-vane actuator 56 from the one or more variable nozzle vanes 52.
Accordingly, under normal operation of the gas-turbine engine 12 with the power turbine 14 not subject to an overspeed condition, the variable-vane actuator 56 provides for controlling the rotational position of each of the one or more variable nozzle vanes 52, 52′ of the variable-vane turbine nozzle 40, so as to provide for controlling the direction and/or flow rate of the associated exhaust gases 38 from the gasifier spool 16, thereby providing for generating sufficient power to drive the associated load 42, 42′. However, if the load 42, 42′ becomes suddenly reduced or disconnected from the power turbine 14,—for example, as a result of a sudden reduction of load current from an associated main electrical generator 42′, for example, as a result of a break in the associated load circuit or an associated equipment failure,—if the controller 32 cannot respond sufficiently quickly to reduce the flow of fuel 28 to the gas-turbine engine 12, the exhaust gases 38 that continue to be generated by the gasifier spool 16 will tend to drive the power turbine 14 towards an overspeed condition, responsive to which, upon detection of the overspeed condition, the associated decoupling mechanism 72 is actuated so as to decouple the variable-vane actuator 56 from the associated one or more variable nozzle vanes 52, 52′, and thereby provide for each of the associated one or more variable nozzle vanes 52, 52′ to be biased towards the corresponding associated overspeed-mitigating rotational position either responsive to aerodynamic forces from the exhaust gases 38 acting on the one or more variable nozzle vanes 52, 52′ in accordance with the second aspect gas-turbine-engine overspeed protection system 10, 10.2; or responsive to the associated biasing element 66 acting on the one or more variable nozzle vanes 52, 52′, either directly, or via the associated nozzle-vane-angle control mechanism 58, in accordance with the third aspect gas-turbine-engine overspeed protection system 10, 10.3.
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In accordance with one set of embodiments, the mechanical rotational-speed sensor 144 incorporates a spring-biased mass 148 that is radially biased within a first socket 150 in the output shaft 146 by a compression spring 152 operative within a second socket 154 in the output shaft 146, wherein the second socket 154 is radially opposed to the first socket 150, and the compression spring 152 is operative between the base of the second socket 154 and a spring retainer 156 on the end of a stem shaft portion 158 of the spring-biased mass 148 that extends through a bore 160 in a portion of the output shaft 146 between the first 150 and second 154 sockets. As the rotational speed of the power turbine 14 increases, the net centrifugal force on the spring-biased mass 148 increases, causing a radially-outboard displacement of the spring-biased mass 148 and an associated compression of the compression spring 152 until the associated compressive spring force balances the net centrifugal force. The components of the mechanical rotational-speed sensor 144 and the geometry and relative position of the mechanically-actuated trigger system 78 are configured so that when the rotational speed of the power turbine 14 increase to an associated overspeed condition, the radial displacement of the spring-biased mass 148 becomes sufficient to sufficiently engage the follower surface 138.2′ of the trigger latch 138 to cause the trigger latch 138 to rotate to the second rotational position 142 illustrated in
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Alternatively, the overspeed-mitigating rotational position of the one or more variable nozzle vanes 52 could be configured as a relatively-open condition, for example, as illustrated in
A method of controlling a variable-vane turbine nozzle upstream of a turbine of a gas-turbine engine may include: a) biasing a rotational position of at least one variable-vane of the variable-vane turbine nozzle towards a corresponding rotational position that will mitigate against an overspeed condition of the turbine during operation of the gas-turbine engine; b) during the operation of the gas-turbine engine and independent of the operation of biasing the rotational position of the at least one variable-vane, when the turbine is operating at a rotational speed that is less than an overspeed threshold, independently controlling the rotational position of the at least one variable-vane of the variable-vane turbine nozzle using a variable-vane actuator operatively coupled to the at least one variable-vane of the variable-vane turbine nozzle; and c) responsive to the rotational speed of the turbine in excess of the overspeed threshold, releasing the operative coupling of the variable-vane actuator to the at least one variable-vane of the variable-vane turbine nozzle so as to provide for the at least one variable-vane of the variable-vane turbine nozzle to be repositioned towards the corresponding rotational position that will mitigate against the rotational speed of the turbine otherwise exceeding the overspeed threshold responsive to the operation of biasing the rotational position of the at least one variable-vane. For example, the operation of biasing the rotational position of the at least one variable-vane may provide for either biasing the rotational position of the at least one variable-vane in a relatively-open rotational position; biasing the rotational position of the at least one variable-vane in a rotational position that provides for the turbine to generate either a reverse torque or a relatively-reduced positive torque sufficient to prevent the overspeed condition of the turbine during the operation of the gas-turbine engine; or biasing the rotational position of the at least one variable-vane in a relatively-closed rotational position. The variable-vane turbine nozzle may incorporate at least one mechanical stop that provides for limiting the rotational position of the at least one variable-vane responsive to the operation of biasing the rotational position of the at least one variable-vane. The operation of biasing the rotational position of the at least one variable-vane may be responsive to either a) a biasing force generated by a spring and operatively coupled to the at least one variable-vane, b) a biasing force generated by a fluid-powered actuator and operatively coupled to the at least one variable-vane, or c) an aerodynamic biasing force operating on the at least one variable-vane during operation of the gas-turbine engine. The variable-vane actuator may be operatively coupled to the at least one variable-vane either a) with a spline-shaft-driven gear mechanism, and the operation of releasing the operative coupling of the variable-vane actuator to the at least one variable-vane comprises disconnecting at least one spline coupling of the spline-shaft-driven gear mechanism; b) with a releasable mechanical clutch and the operation of releasing the operative coupling of the variable-vane actuator to the at least one variable-vane comprises disconnecting the releasable mechanical clutch; c) with a releasable electromechanical clutch by which the associated operative coupling is via an associated first magnetic field, for example, either i) generated responsive to a holding current in a corresponding at least one coil wherein the operation of releasing the operative coupling of the variable-vane actuator to the at least one variable-vane comprises interrupting the holding current, or ii) generated by a permanent magnet wherein the operation of releasing the operative coupling of the variable-vane actuator to the at least one variable-vane comprises at least partially opposing the associated first magnetic field generated by the permanent magnet, with a corresponding associated second magnetic field; or d) with at least one frangible link, and the operation of releasing the operative coupling of the variable-vane actuator to the at least one variable-vane comprises severing the at least one frangible link, for example, using an associated at least one pyrotechnic device. The determination of whether the rotational speed of the turbine is in excess of the overspeed threshold may be automatically responsive to mechanically sensing the rotational speed of the turbine, for example, by rotating a spring-biased mass operatively coupled to a shaft rotating at a rotational speed responsive to the rotational speed of the turbine, and activating a trigger mechanism responsive to a radial position of the spring-biased mass relative to a rotational axis of the shaft; or responsive to a measurement of a rotational speed responsive to the rotational speed of the turbine. In accordance with one set of embodiments, the operative coupling of the variable-vane actuator to the at least one variable-vane is resettable following a decoupling thereof responsive to the overspeed condition.
A gas-turbine-engine overspeed protection system may include a. a variable-vane turbine nozzle, wherein the variable-vane turbine nozzle incorporates a plurality of variable nozzle vanes; b. a nozzle-vane-angle control mechanism, wherein the nozzle-vane-angle control mechanism provides for controlling a corresponding rotational angle of each of the plurality of variable nozzle vanes; c. a variable-vane actuator, wherein in a first mode of operation, the variable-vane actuator is operatively coupled to the plurality of variable nozzle vanes via the nozzle-vane-angle control mechanism so as to provide for controlling the corresponding rotational angle of each of the plurality of variable nozzle vanes and thereby control a direction of a stream of exhaust gases exiting the variable-vane turbine nozzle and subsequently impinging on a turbine of the gas-turbine engine downstream of the variable-vane turbine nozzle, and in a second mode of operation, the variable-vane actuator is operatively decoupled from the plurality of variable nozzle vanes, and the corresponding rotational angle of each of the plurality of variable nozzle vanes is biased in a rotational direction that provides for mitigating against an overspeed condition of the turbine downstream of the variable-vane turbine nozzle, wherein a rotational position of at least one variable nozzle vane of the plurality of variable nozzle vanes is biased responsive to at least one biasing force selected from the group consisting of an aerodynamic force acting on the at least one variable nozzle vane responsive to a geometry of the at least one variable nozzle vane, a spring force acting on either the nozzle-vane-angle control mechanism or the at least one variable nozzle vane, and a fluid-powered force acting on either the nozzle-vane-angle control mechanism or the at least one variable nozzle vane; and d. a decoupling mechanism, wherein the decoupling mechanism provides for decoupling the variable-vane actuator from the plurality of variable nozzle vanes in accordance with the second mode of operation, and the decoupling mechanism is actuated when a rotational speed of or responsive to the turbine exceeds a corresponding overspeed threshold. For example, the at least one biasing force if otherwise unimpeded may act either a) in a direction that provides for relatively-opening the plurality of variable nozzle vanes; b) in a direction that provides for positioning the plurality of variable nozzle vanes to cause the turbine to generate either a reverse torque or a relatively-reduced positive torque sufficient to prevent the overspeed condition of the turbine during the operation of the gas-turbine engine; or c) in a direction that provides for relatively-closing the plurality of variable nozzle vanes. The gas-turbine-engine overspeed protection system may further include a mechanical stop that provides for defining a rotational position limit of the plurality of variable nozzle vanes responsive to the at least one biasing force. The gas-turbine-engine overspeed protection system may further include a biasing element is operative between the nozzle-vane-angle control mechanism and a mechanical ground, and wherein the biasing element either generates the spring force or generates the fluid-powered force. In accordance with one set of embodiments, at least one variable nozzle vane of the plurality of variable nozzle vanes is shaped and configured so that a center of aerodynamic pressure acting on the at least one variable nozzle vane in relation to a rotational axis of the at least one variable nozzle vane acts to rotate the at least one variable nozzle vane in a direction responsive to the at least one biasing force. In accordance with one set of embodiments, the turbine is a power turbine of the gas-turbine engine. The gas-turbine-engine overspeed protection system may be incorporated in a gas-turbine engine that further includes a gasifier spool incorporating a compressor and a gasifier turbine operatively coupled to one another by an associated spool shaft, wherein the power turbine provides for driving a load external of the gas-turbine engine, the variable-vane turbine nozzle is located downstream of the gasifier turbine, and the gasifier spool provides for driving or being driven by either a fluid machine or an electrical machine. In one set of embodiments, the variable-vane actuator may be operatively coupled to the at least one variable nozzle vane with a spline-shaft-driven gear mechanism, wherein the decoupling mechanism comprises at least one spline coupling of the spline-shaft-driven gear mechanism. In other sets of embodiments, the decoupling mechanism may incorporate either a) a releasable mechanical clutch; b) a releasable electromechanical clutch that provides for operatively coupling the variable-vane actuator to the plurality of variable nozzle vanes via an associated first magnetic field, wherein i) the releasable electromechanical clutch incorporates at least one coil that provides for generating the associated first magnetic field responsive to a holding current, and an interruption of the holding current provides for decoupling the variable-vane actuator from the plurality of variable nozzle vanes, or ii) the releasable electromechanical clutch incorporates at least one permanent magnet that provides for generating the associated first magnetic field, and the decoupling mechanism further incorporates at least one coil that provides for generating a second magnetic field in opposition to the first magnetic field, so as to provide for decoupling the variable-vane actuator from the plurality of variable nozzle vanes; c) at least one frangible link that provides for operatively coupling the variable-vane actuator to the plurality of variable nozzle vanes, and a severing of the at least one frangible link provides for decoupling the variable-vane actuator from the plurality of variable nozzle vanes, for example, responsive to activation of a corresponding associated at least one pyrotechnic device; d) a trigger system that is mechanically responsive to a rotational speed of the turbine, for example, wherein the trigger system incorporates a spring-biased mass operatively coupled to a shaft rotating at a rotational speed responsive to a rotational speed of the turbine during operation of the gas-turbine engine, and a trigger mechanism responsive to a radial position of the spring-biased mass relative to a rotational axis of the shaft; or a rotational speed sensor that generates a rotational speed signal responsive to a rotational speed of the turbine, and a controller operatively coupled to the rotational speed sensor, wherein the controller provides for generating a decoupling actuation signal responsive to a comparison of the rotational speed signal with a corresponding overspeed threshold, wherein the decoupling actuation signal provides for actuating the decoupling mechanism so as to provide for decoupling the variable-vane actuator from the plurality of variable nozzle vanes. In accordance with one set of embodiments, following an actuation thereof, the decoupling mechanism is resettable so as to provide for operating the gas-turbine engine to generate shaft power with the turbine.
While specific embodiments have been described in detail in the foregoing detailed description and illustrated in the accompanying drawings, those with ordinary skill in the art will appreciate that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. It should be understood, that any reference herein to the term “or” is intended to mean an “inclusive or” or what is also known as a “logical OR”, wherein when used as a logic statement, the expression “A or B” is true if either A or B is true, or if both A and B are true, and when used as a list of elements, the expression “A, B or C” is intended to include all combinations of the elements recited in the expression, for example, any of the elements selected from the group consisting of A, B, C, (A, B), (A, C), (B, C), and (A, B, C); and so on if additional elements are listed. Furthermore, it should also be understood that the indefinite articles “a” or “an”, and the corresponding associated definite articles “the” or “said”, are each intended to mean one or more unless otherwise stated, implied, or physically impossible. Yet further, it should be understood that the expressions “at least one of A and B, etc.”, “at least one of A or B, etc.”, “selected from A and B, etc.” and “selected from A or B, etc.” are each intended to mean either any recited element individually or any combination of two or more elements, for example, any of the elements from the group consisting of “A”, “B”, and “A AND B together”, etc. Yet further, it should be understood that the expressions “one of A and B, etc.” and “one of A or B, etc.” are each intended to mean any of the recited elements individually alone, for example, either A alone or B alone, etc., but not A AND B together. Furthermore, it should also be understood that unless indicated otherwise or unless physically impossible, that the above-described embodiments and aspects can be used in combination with one another and are not mutually exclusive. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims, and any and all equivalents thereof.
The instant application claims the benefit of prior U.S. Provisional Application Ser. No. 63/055,556 filed on 23 Jul. 2020, which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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63055556 | Jul 2020 | US |