Patent Application
20130149120
The present invention relates to gas turbine engines and, more particularly, to structures for providing thermal protection to limit heating of the outer case of a gas turbine engine.
A gas turbine engine generally includes a compressor section, a combustor section, a turbine section and an exhaust section. In operation, the compressor section may induct ambient air and compress it. The compressed air from the compressor section enters one or more combustors in the combustor section. The compressed air is mixed with the fuel in the combustors, and the air-fuel mixture can be burned in the combustors to form a hot working gas. The hot working gas is routed to the turbine section where it is expanded through alternating rows of stationary airfoils and rotating airfoils and used to generate power that can drive a rotor. The expanded gas exiting the turbine section may then be exhausted from the engine via the exhaust section.
In a typical gas turbine engine, bleed air comprising a portion of the compressed air obtained from one or more stages of the compressor may be used as cooling air for cooling components of the turbine section. Additional bleed air may also be supplied to portions of the exhaust section, such as to cool portions of the exhaust section and maintain a turbine exhaust case below a predetermined temperature through a forced convection air flow provided within an outer casing of the engine. Advancements in gas turbine engine technology have resulted in increasing temperatures, and associated outer case deformation due to thermal expansion. Case deformation may increase stresses in the case and in components supported on the case within the engine, such as bearing support struts. The additional stress, which may operate in combination with low cycle fatigue, may contribute to cracks, fractures or failures of the bearing support struts that are mounted to the casing for supporting an exhaust end bearing housing.
In accordance with an aspect of the present invention, a gas turbine engine is provided comprising an outer case defining a central longitudinal axis, and an outer case surface extending circumferentially around the central longitudinal axis. A thermal barrier/cooling system is provided for controlling a temperature of the outer case. The thermal barrier/cooling system includes an internal insulating layer supported on an inner case surface opposite the outer case surface, the internal insulating layer extending circumferentially along the inner case surface and providing a thermal resistance to radiated energy from structure located radially inwardly from the outer case. The thermal barrier/cooling system further includes a convective cooling channel defined by a panel structure located in radially spaced relation to the outer case surface and extending around the circumference of the outer case surface. The convective cooling channel is generally axially aligned with the internal insulating layer and forms a flow path for an ambient air flow cooling the outer case surface.
In accordance with further aspects of the invention, the convective cooling channel may include a cooling air supply inlet at a first circumferential location, and an exhaust air outlet at a second circumferential location diametrically opposite from the first circumferential location. The axis of the outer case may extend in a generally horizontal direction, and the air supply inlet may be located at a bottom-dead-center location of the outer case and the exhaust air outlet may be located at a top-dead-center location of the outer case. Auxiliary air inlets may be located about midway between the first and second circumferential locations on opposing sides of the outer case, and cover plates may be located over the auxiliary air inlets, the cover plates being displaceable from the auxiliary air inlets to permit entry of ambient air into the cooling channel through one or more of the auxiliary air inlets. Further, an external insulating layer may be provided supported on and covering the panel structure.
The panel structure may comprise a plurality of circumferentially located panel segments joined at axially extending joints, the air flow through the cooling channel may create a pressure lower than an ambient air pressure such that any air leakage through the joints may comprise leakage of ambient air into the cooling structure.
The internal insulating layer may comprise a plurality of circumferentially located separately mounted insulating layer segments.
The outer case may comprise a turbine exhaust case, and may include an exhaust diffuser defining the structure located radially inwardly from the outer case at the axial location of the internal insulating layer.
In accordance with another aspect of the invention, a gas turbine engine is provided comprising an outer case comprising a turbine exhaust case defining a central longitudinal axis extending in a generally horizontal direction, and an outer case surface extending circumferentially around the central longitudinal axis. A thermal barrier/cooling system is provided for controlling a temperature of the outer case. The thermal barrier/cooling system includes an internal insulating layer supported on an inner case surface opposite the outer case surface, the internal insulating layer extending circumferentially along the inner case surface and providing a thermal resistance to radiated energy from an exhaust diffuser located radially inwardly from the outer case. The thermal barrier/cooling system further includes a convective cooling channel including at least a first portion defined by a panel structure located in radially spaced relation to the outer case surface and extending around the circumference of the outer case surface. The convective cooling channel is generally axially aligned with the internal insulating layer and forms a flow path for directing an ambient non-forced air flow in an upward direction to cool the outer case surface.
In accordance with additional aspects of the invention, the insulating layer segments may comprise a plurality of circumferentially located separately mounted insulating layer segments, and may each comprise a pair of sheet metal layers and a thermal blanket layer located between the sheet metal layers, the thermal blanket layer having a lower thermal conductivity, i.e., a higher thermal resistance, than the sheet metal layers.
Bearing support struts may extend from the outer case, and through the internal insulating layer and the exhaust diffuser.
The internal insulating layer may have a thermal conductivity of about 0.15 W/m·K or less.
The exhaust case may include an exhaust case flange, and the gas turbine engine may further include a spool structure having a spool structure flange forming a joint to the exhaust case flange. The thermal barrier/cooling system may comprise a second internal insulating layer supported on an inner surface of the spool structure, the internal insulating layer extending circumferentially along the inner surface of the spool structure and providing a thermal resistance to radiated energy from the exhaust diffuser. The panel structure of the thermal barrier/cooling system may extend past the joint between the exhaust case flange and the spool structure flange to form a second portion of the convective cooling channel extending around the circumference of the spool structure, and the further convective cooling channel may be generally axially aligned with the second internal insulating layer and form a second flow path for directing an ambient non forced air flow in an upward direction to cool the spool structure surface.
While the specification concludes with claims particularly pointing out and distinctly claiming the present invention, it is believed that the present invention will be better understood from the following description in conjunction with the accompanying Drawing Figures, in which like reference numerals identify like elements, and wherein:
In the following detailed description of the preferred embodiment, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, and not by way of limitation, a specific preferred embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the spirit and scope of the present invention.
Referring to
The exhaust case 14 includes a downstream exhaust case flange 18 that extends radially outwardly of a downstream end the exhaust case 14, and the spool structure 16 includes an upstream spool structure flange 20 that extends radially outwardly of the spool structure 16. The downstream exhaust case flange 18 and upstream spool structure flange 20 abut each other at a joint 22, and may be held together in a conventional manner, such as by bolts (not shown). In addition, an upstream exhaust case flange 21 extends radially outwardly from an upstream end of the exhaust case 14 and may be bolted to a radially extending flange 23 of the turbine section 12 for supporting the exhaust case 14 to the turbine section 12.
The exhaust case 14 comprises a relatively thick wall forming a structural member or frame for supporting an exhaust end bearing housing 24 and for supporting at least a portion of an exhaust diffuser 26. The exhaust end bearing housing 24 is located for supporting an end of a rotor 25 for the gas turbine engine.
The diffuser 26 comprises an inner wall 28 and an outer wall 30 defining an annular passage for conveying hot exhaust gas from the turbine section 12. The bearing housing 24 is supported by a plurality of strut structures 32. Each of the strut structures 32 include a strut 34 extending from a connection 36 on the exhaust case 14, through the diffuser 26, to a connection 38 on the bearing housing 24 for supporting and maintaining the bearing housing 24 at a centered location within the exhaust case 14. The strut structures 32 may additionally include a fairing 40 surrounding the strut 34 for isolating the strut 34 from the hot exhaust gases passing through the diffuser 26, see also
As a result of the hot exhaust gases passing through the diffuser 26, the outer wall 30 of the diffuser 26 radiates heat radially outwardly toward an inner case surface 42 of the exhaust case 14. As discussed above, conventional designs for cooling a turbine exhaust section may provide bleed air supplied from a compressor section of the engine to the exhaust section to provide a flow of cooling air between the diffuser and the exhaust case in order to control or reduce the temperature of the exhaust case through forced convection. In accordance with an aspect of the invention, a thermal barrier/cooling system 44 is provided to reduce and/or eliminate the use of compressor bleed air to control the temperature of the exhaust case 14 and spool structure 16.
Referring to
The internal insulating layer 46 is preferably formed by a plurality of insulating layer segments 46a (
Referring further to
The construction of the insulating layer segments 46a may comprise a pair of opposing sheet metal layers 58, 60, and a thermal blanket layer 62 located between the sheet metal layers 58, 60 and having a substantially lower thermal conductivity than the sheet metal layers 58, 60. A plurality of metal bushings 64 may extend through the sheet metal layers 58, 60 and the thermal blanket layer 62 at mounting points for the insulating layer segments 46a. In particular, each of the metal bushings 64 comprise a rigid structure defining a predetermined spacing between the sheet metal layers 58, 60, and are adapted to receive a fastener structure, such as a standoff 66 (
The insulating layer segments 46a may be provided with slots 65 extending from the trailing edge 52 to a rear row of the bushings 64 to facilitate assembly of the insulating layer segments 46a to the exhaust case 14. In particular, the slots 65 facilitate movement of the insulating layer segments 46a onto the studs 67 during assembly by permitting a degree of axial movement of the rear row of bushings 64 onto a corresponding row of studs 67 at a rear portion of the exhaust case 14 where there is a minimal space between the exhaust case 14 and the diffuser 26.
It may be noted that a limited spacing may be provided between adjacent insulating layer segments 46a at particular locations around the inner case surface 42. For example, at the locations of the connections 36 where the struts 34 extend inwardly from the inner case surface 42 a spacing or gap may be provided between adjacent insulating layer segments 46a located adjacent to either side of each strut 34. Similarly, a limited gap may be present between the insulating layer segments 46a that are directly adjacent to structure forming the horizontal joints 92. It may be noted that an alternative configuration of the insulating layer segments 46a may be provided to reduce gaps at these locations. For example, the insulating layer segments 46a may be configured to include portions that extend closely around the struts 34 and thereby reduce gap areas that may expose the inner case surface 42 to radiated heat.
Provision of multiple insulating layer segments 46a facilitates assembly of the internal insulating layer 46 to the engine case 14, and further enables repair of a select portion of the internal insulating layer 46. For example, in the event of damage to a portion of the internal insulating layer 46, the configuration of the internal insulating layer 46 permits removal and replacement of individual ones of the insulating layer segments 46a that may have damage, without requiring replacement of the entire internal insulating layer 46.
It should be understood that although a particular construction of the insulating layer segments 46a has been described, other materials and constructions for the insulating layer segments 46a may be provided. For example, the insulating layer segments 46a may be formed of a known ceramic insulating material configured to provide a thermal resistance for surfaces, such as the inner case surface 42.
Referring to
Referring to
As seen in
The panel structure 72 comprises individual panel sections 72a that may be formed of sheet metal, i.e., relatively thin compared to the outer case 11. The panel sections 72a are curved to match the curvature of the outer case 11, and extend downwardly from the side portions 94 toward the main air inlet 84, and extend upwardly from the side portions 94 toward the air outlet 86. The panel sections 72a are formed as generally rectangular sections extending between the upstream and downstream locations 74, 76 on the exhaust section 10, and preferably engage or abut each other, as well as the side portions 94 at shiplap joints 98 along axially extending edges of the panel sections 72a. The panel sections 72a and side portions 94 may be attached to the exhaust section outer case 11 by any conventional means, and are preferably attached as removable components by fasteners, such as bolts or screws. It should be understood that although the enlarged side portions 94 are depicted as box sections, this portion of the panel structure 72 need not be limited to a particular shape and may be any configuration to facilitate passage of air flow past the horizontal joints 92, which typically comprise enlarged and radially outwardly extending flange portions of the exhaust section outer case 11. Further, it should be noted that the main air inlet 84 and the air outlet 86 may incorporated into respective panel sections 72a at respective bottom-dead-center and top-dead-center locations around the panel structure 72.
Referring to
In accordance with an aspect of the invention, the convective cooling channel 48 receives a non-forced ambient air through the main air supply inlet 84. That is, air may be provided to the convective cooling channel 48 without a driving or pressure force at the air inlet 84 to convey air in a convective main air supply flow 114 from a location outside the gas turbine engine through the main air supply inlet 84. The main air supply inlet 84 may be sized with a diameter to extend across at least a portion of each of the first and second channel portions 78, 82, such that a portion of the main supply air flow 114 may pass directly into each of the channel portions 78, 82.
The ambient air flow into the convective cooling channel 48 provides a decreased thermal gradient around the circumference of the exhaust section 10 to reduce or minimize thermal stresses that may occur with a non-uniform temperature distribution about the exhaust section 10. In particular, stresses related to differential thermal expansion of the exhaust case 14, and transmitted to the struts 34, may be decreased by the increased uniformity of the cooling flow provided by the convective cooling channel 48. Further, the operating temperature of the exhaust case 14 may be maintained below the material creep limit to avoid associated case creep deformation that may cause an increase in strut stresses.
A multiport cooling configuration may be provided for the convective cooling channel 48 by displacing or removing one or more of the cover plates 108, 110 of the auxiliary air inlet structure 102 to increase the number of convective cooling air supply locations. Hence, the amount of cooling provided to the channel portions 78, 82 may be adjusted on turbine engines located in the field to increase or decrease cooling by removal or replacement of the cover plates 108, 110. For example, it may be desirable to provide an increase in the cooling air flow by removing one or more of the cover plates 108, 110, or it may be desirable to provide a decrease in air flow by replacing one or more of the cover plates 108, 110 to prevent or decrease the auxiliary air flow 116, depending on increases or decreases in the ambient air temperature. Further, the cover plates 108, 110 may be used optimize the temperature of the exhaust case 14 and spool structure 16 to minimize any thermal mismatch between adjacent hardware and components.
The exhaust air outlet 86 is located at the top of the convective cooling channel 48, such that the heated exhaust air 118 may flow by convection out of the convective cooling channel 48. The exhaust air outlet 86 may be sized with a diameter to extend across at least a portion of each of the first and second channel portions 78, 82, such that the heated air exhausting from the convective cooling channel 48 may be conveyed directly to the exhaust air outlet 86 from each of the channel portions 78, 82. Subsequently, the heated air passing out of the exhaust air outlet 86 may be exhausted out of existing louver structure (not shown) currently provided for existing gas turbine engine units.
It should be understood that the convective air flow through the convective cooling channel 48 comprises a cooling air flow that may be substantially driven by a convective force produced by air heated along the outer case surface 68 and outer surface 80 of the spool structure 16. The heated air within the convective cooling channel 48 rises by natural convection and is guided toward the exhaust air outlet 86. As the air rises within the convective cooling channel 48, it draws ambient air into the channel 48 through the main cooling air supply inlet 84, effectively providing a driving force for a continuous flow of cooling air upwardly around the outer surface of the outer case 11. Similarly, when either or both of the auxiliary air inlet openings 104, 106 on the sides of the panel structure 72 are opened, natural convection will draw the air upwardly around the channel 48 through the auxiliary air inlet structure 102 to the exhaust air outlet 86.
It may be noted that as the cooling air flows upwardly as a convection air flow 48, a lower pressure will be created within the convective cooling channel 48 than the ambient air pressure outside the convective cooling channel 48. Hence, any leakage at the panel joints 98, or the joints 97, 99 (
Optionally, as is illustrated diagrammatically in
The convective cooling channel 48 may further be provided with an external insulating layer 122, as seen in
Referring to
As described above, the thermal barrier/cooling system 44 provides a system wherein the internal insulating layer 46 substantially reduces the amount of thermal energy transferred to the outer case 11 of the exhaust section 10, and thereby reduces the cooling requirement for maintaining the material of the outer case 11 below its creep limit. Hence, the external cooling configuration provided by the convective cooling channel 48 provides adequate cooling to the outer case 11 with a convective air flow, with an accompanying reduction or elimination of the need for forced air cooling provided to the interior of the outer case 11. Elimination of forced air cooling to the interior of the outer case 11, i.e., by maintaining supply and exhaust of cooling air external to the outer case 11, avoids problems associated with thermal mismatch or thermal gradients between components within the outer case 11.
Additionally, since the air supply for cooling the outer case 11 does not draw on compressor bleed air or otherwise directly depend on a supply of the air from the gas turbine engine, the present thermal barrier/cooling system 44 does not reduce turbine power, such as may occur with systems drawing compressor bleed air, and the cooling effectiveness of the present system operates substantially independently of the engine operating conditions. Hence, the present invention may be implemented without drawing on the secondary cooling air of the gas turbine engine, and may provide a reduced requirement for usage of secondary cooling air with an associated increase in overall efficiency in the operation of the gas turbine engine.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
