Patent Application
20150037133
The present invention relates generally to gas turbine engines and, more particularly, to an apparatus for passively controlling the axial position of an inner casing within the compressor or turbine section of a gas turbine engine based on flowpath pressures during different modes of engine operation as well as using this method of control to advantageously adjusting a gap clearance between adjacent rotating and non-rotating components.
As one of ordinary skill in the art will appreciate, the efficiency of a gas turbine engine is dependent upon many factors, one of which is the radial clearance between adjacent rotating and non-rotating components, such as, for example, the rotor blade tips and the casing shroud surrounding the outer tips of the rotor blades. If the clearance is too great, an unacceptable degree of working fluid leakage will occur with a resultant loss in efficiency. If the clearance is too little, there is a risk that under certain conditions contact will occur between the components and cause damage thereto.
The potential for contact between rotating and non-rotating components may be present over a range of engine operating conditions. For example, one such condition is when the engine rotational speed is changing, either increasing or decreasing, since temperature differentials across the engine frequently result in the rotating and non-rotating components radially expanding and contracting at different rates. For instance, upon engine accelerations, thermal growth of the rotor typically lags behind that of the casing. During steady-state operation, the growth of the casing ordinarily matches more closely that of the rotor. Upon engine decelerations, the casing contracts more rapidly than the rotor. These type of issues are also present during both startup and shutdown procedures, as it is often difficult to match the casing to rotor thermal growths during these operations.
Control mechanisms, usually mechanically or thermally actuated, have been proposed in the prior art to maintain or reduce blade tip clearance so that leakage is minimized. However, none represent an optimized or efficient design. Specifically, active control systems require feedback loops, control systems, extra components and, thereby, add cost to the machine. It will be appreciated that, if passive systems could provide similar results, they would be desirable due to their more simplified activation strategy, which typically requires fewer parts, less cost, and greater robustness. Consequently, a need still remains for an improved mechanism for clearance control that maintains a narrow tip-shroud clearance through the operational range of the engine so to improve engine performance and reduce fuel consumption. Additionally, it will be appreciated that conventional methods and systems for axially positioning the inner casings typically are present through the compressor and turbine sections of the engine are similarly deficient, and that there would be commercial demand for improved methods and systems for controlling the axial position of these structures. As will be appreciated, such methods of control, if made cost-effective, robust and efficient, may be put to other uses than the specific exemplary ones described herein.
The present application thus describes a system for passively varying an axial position of an inner casing of a gas turbine pursuant to changing pressure in the engine's flowpath during transient engine operation. The system may include: a connection assembly slidably connecting the inner casing to the outer casing for axial movement of the inner casing between a first position and a second position; means for pressurizing the annulus relative to a flowpath pressure; biasing means for axially preloading the inner casing toward the first position; and an inner casing receiving surface configured to receive a pressure in the annulus for axially loading the inner casing in opposition to the axial preload of the biasing means.
The application further describes a method of passively varying an axial position of an inner casing relative to the flowpath based on pressure differential between an axially spaced first and second flowpath regions, the method including the steps of: slidably connecting the inner casing to the outer casing for axial movement between a first axial position and a second axial position; axially loading the inner casing with a static preload directed toward the first axial position; dividing the annulus into a first annulus and a second annulus for maintaining a pressure differential therebetween; pressurizing the first annulus relative to a pressure at the first flowpath region, and pressurizing the second annulus relative to a pressure at the second flowpath region; configuring the inner casing with opposing receiving surfaces, a first receiving surface disposed in the first annulus and a second receiving surface disposed in the second annulus. The opposing receiving surfaces may be configured to axially load the inner casing with a dynamic pressure load directive toward the second axial position. The dynamic pressure load may be based upon an amount by which a pressure in the first annulus exceeds a pressure in the second annulus.
The application further describes a method of passively varying an axial position of the inner casing between an upstream location and a downstream location based upon modes of engine operation, the method including the steps of: slidably connecting the inner casing to the outer casing for axial movement between a downstream position and an upstream position; forming a high-pressure region and a low pressure region in the annulus by extracting working fluid from axially spaced pressure regions in the flowpath; configuring the inner casing with opposing receiving surfaces, a first receiving surface disposed in the high-pressure region and a second receiving surface disposed in the low-pressure region of the annulus, for axially loading the inner casing toward the upstream position relative to an amount by which a pressure in the high-pressure region exceeds a pressure in the low-pressure region of the annulus.
The application further describes a method for passively controlling an axial position of the inner casing, the method including the steps of: slidably connecting the inner casing to the outer casing for axial movement between a first axial position in the converging direction and a second axial position in the diverging direction; using a static load derived from a mechanical biasing means to axially preload the inner casing toward the first axial position; extracting working fluid from a high-pressure extraction point and a low-pressure extraction point from the flowpath; and in the annulus, axially loading opposing receiving surfaces on the inner casing with a pressure derived from the extracted working fluid so to oppose the mechanical biasing means with a dynamic pressure load, the dynamic pressure load configured to directly relate to a current pressure differential between the high-pressure extraction point and the low-pressure extraction point.
These and other features of the present application will become apparent upon review of the following detailed description of the preferred embodiments when taken in conjunction with the drawings and the appended claims.
These and other features of this invention will be more completely understood and appreciated by careful study of the following more detailed description of exemplary embodiments of the invention taken in conjunction with the accompanying drawings, in which:
The following description provides examples of both conventional technology and the present invention, as well as, in the case of the present invention, several exemplary implementations and explanatory embodiments. It will be appreciated that the following examples are not intended to be exhaustive as to all possible applications of the invention. While the following examples may be presented in relation to a certain type of turbine engine, the technology of the present invention may be applicable to other types of turbine engines, as would the understood by a person of ordinary skill in the relevant technological arts.
Certain terminology has been selected to describe the present invention in the text that follows. To the extent possible, these terms have been chosen based on the terminology common to the technology field. Still, it will be appreciate that such terms often are subject to differing interpretations. For example, what may be referred to herein as a single component, may be referenced elsewhere as consisting of multiple components, or, what may be referenced herein as including multiple components, may be referred to elsewhere as being a single component. In understanding the scope of the present invention, attention should not only be paid to the particular terminology used, but also to the accompanying description and context, as well as the structure, configuration, function, and/or usage of the component being referenced and described, including the manner in which the term relates to the several figures, as well as, of course, the precise usage of the terminology in the appended claims.
Because several descriptive terms are regularly used in describing the components and systems within turbine engines, it should prove beneficial to define these terms at the onset of this section. Accordingly, these terms and their definitions, unless specifically stated otherwise, are as follows. The terms “forward” and “aft”, without further specificity, refer to directions relative to the orientation of the gas turbine. That is, “forward” refers to the forward or compressor end of the engine, and “aft” refers to the aft or turbine end of the engine. It will be appreciated that each of these terms may be used to indicate movement or relative position within the engine. The terms “downstream” and “upstream” are used to indicate position within a specified conduit relative to the general direction of flow moving through it. The term “downstream” refers to the direction in which the fluid is flowing through the specified conduit, while “upstream” refers to the direction opposite that.
Thus, for example, the primary flow of fluid through a turbine engine, which consists of air through the compressor and then becomes the combustion gases within the combustor, may be described as beginning from an upstream location at an upstream end of the compressor and terminating at an downstream location at a downstream end of the turbine. In regard to describing the direction of flow within a common type of combustor, as discussed in more detail below, it will be appreciated that compressor discharge air typically enters the combustor through impingement ports that are concentrated toward the aft end of the combustor (relative to the combustors longitudinal axis and the aforementioned compressor/turbine positioning defining forward/aft distinctions). Once in the combustor, the compressed air is guided by a flow annulus formed about an interior chamber toward the forward end of the combustor, where the air flow enters the interior chamber and, reversing it direction of flow, travels toward the aft end of the combustor. Coolant flows through cooling passages may be treated in the same manner.
Given the configuration of compressor and turbine about a central common axis as well as the cylindrical configuration common to certain combustor types, terms describing position relative to an axis will be used. In this regard, it will be appreciated that the term “radial” refers to movement or position perpendicular to an axis. Related to this, it may be required to describe relative distance from the central axis. In this case, if a first component resides closer to the central axis than a second component, it will be described as being either “radially inward” or “inboard” of the second component. If, on the other hand, the first component resides further from the central axis than the second component, it will be described herein as being either “radially outward” or “outboard” of the second component. Additionally, it will be appreciated that the term “axial” refers to movement or position parallel to an axis. Finally, the term “circumferential” refers to movement or position around an axis. As mentioned, while these terms may be applied in relation to the common central axis that extends through the compressor and turbine sections of the engine, these terms also may be used in relation to other components or sub-systems of the engine. For example, in the case of a cylindrically shaped combustor, which is common to many machines, the axis which gives these terms relative meaning is the longitudinal central axis that extends through the center of the cross-sectional shape, which is initially cylindrical, but transitions to a more annular profile as it nears the turbine.
In one example of operation, the rotation of compressor rotor blades 14 within the axial compressor 11 may compress a flow of air. In the combustor 12, energy may be released when the compressed air is mixed with a fuel and ignited. The resulting flow of hot gases from the combustor 12, which may be referred to as the working fluid, is then directed over the turbine rotor blades 16, the flow of working fluid inducing the rotation of the turbine rotor blades 16 about the shaft. Thereby, the energy of the flow of working fluid is transformed into the mechanical energy of the rotating blades and, because of the connection between the rotor blades 61 and the shaft, the rotating shaft. The mechanical energy of the shaft may then be used to drive the rotation of the compressor rotor blades 14, such that the necessary supply of compressed air is produced, and also, for example, a generator to produce electricity.
Turning now to
As illustrated, the connection assembly 75 may be configured to slidably connect the inner casing 51 to the outer casing 52 for axial movement. As part of the connection assembly 75 a biasing structure, such as a spring 79, may be used for axially preloading the inner casing 51 in the converging direction 72. In a preferred embodiment, the biasing structure may include a Belleville washer or compression spring 79 (which also may be known as a disk spring). In other embodiments, other biasing means may be used, such as leaf springs or metal foam or other type of spring or system that includes magnetic biasing.
The annulus 53 may include an extraction passage 66 that fluidly communicates with an extraction point in the flowpath 54. In this manner, a pressure in the annulus 53 may be achieved that directly relates or is proportional to a pressure in the flowpath 54. As illustrated, in a preferred embodiment, the connection assembly 75 is configured to divide the annulus 53 into a first or downstream annulus 57, which in this case corresponds to the converging direction 72, and a second or upstream annulus 58, which in this case corresponds to the diverging direction 71. The connection assembly 75 may include a seal 80 that is configured to fluidly seal the downstream annulus 57 from the upstream annulus 58 so to maintain a pressure differential therebetween. The seal 80 may be any conventional type of seal that achieves the purpose and functionality described herein. It will be appreciated that the seal 80 may be incorporated into the connection assembly 75, as illustrated, or it may be a separate component.
The downstream annulus 57 may include an extraction passage 66 that fluidly communicates with a first extraction point on the flowpath 54. In this manner a pressure may be created in the downstream annulus 57 that directly relates to or is proportional to a pressure at a particular location in the flowpath 54. The upstream annulus 58 may include an extraction passage 66 that fluidly communicates with a second extraction point on the flowpath 54. In this manner, a pressure may be created in the upstream annulus 58 that directly relates to or is proportional to a pressure at a second particular location on the flowpath 54. As illustrated, the two extraction locations may be axial spaced along the flowpath 54. In a preferred embodiment, the extraction points are positioned to each side of the row of rotor blades 61. It will be appreciated that the wide axially spacing of the extraction points may be used to purposefully create materially different levels of pressure within each of the upstream annulus 58 and the downstream annulus 57, as pressure differentials between two points on the flowpath 54 generally increase as the distance between the increases. It will be appreciated that, within a combustor 11, the downstream annulus 57 will have a higher pressure than that of the upstream annulus 58 given that its extraction point is further downstream.
The inner casing 51 includes an outboard surface that defines a boundary of the annulus 53. As illustrated, the inner casing 51 may be configured such that it includes a surface area or receiving surface exposed to both the downstream annulus 57 and the upstream annulus 58. Configured in this way, it will be appreciated that the surface of the inner casing 51 receives the pressure within each annulus 57, 58, and that this results in the application of a force to the inner casing 51 that is proportional to the level of this pressure in each annulus 57, 58. Given the orientation of some of the surface areas of the inner casing, it will be appreciated that this force or load includes an axially directed component. The axially directed component of this resulting load may be referred to herein as a “pressure load”. It will be further appreciated that each of the upstream annulus 58 and the downstream annulus 57 loads the inner casing 51 in this manner so to create axial pressure loads that oppose each other. Because the pressure in the downstream annulus 57 is greater than that of the upstream annulus 58, the system of the present invention is configured so that a net force or pressure load is applied to the inner casing in the diverging direction 71. Furthermore, the system of the present invention may be configured such that this resulting pressure load is a dynamic one, which is based upon or proportional to an amount by which the pressure in the downstream annulus 57 exceeds the pressure in the upstream annulus 58. Because the pressure in each annulus 57, 58 directly relates to a pressure at a specific region on the flowpath 54, it will be appreciated that the resulting axial pressure load on the inner casing 51 may be configured to directly relate or be proportional to a pressure differential between specific locations of the flowpath 54 (i.e., the pressure differential between the two extraction points). Accordingly, the arrangement of the present invention enables engine operators to take advantage of passive controls that react to certain pressure load levels on the inner casing 51 because such load levels reflect pressure differentials in the flowpath 54, which, in turn, reflect certain modes of engine operation.
In one preferred embodiment, the outboard boundary 55 of the flowpath includes a configuration in which axial movement of the inner casing 51 results in a narrowing of a leakage path. In this instance, the system may be configured such that the mode of engine operation that produces a predetermined threshold pressure load that initiates axial movement of the inner casing is also a mode of operation in which the leakage path is wide. As illustrated, pursuant to aspects of the present invention, a sloping or axially tilted outboard boundary 55 is a flowpath configuration that may be used to narrow a leakage path (such as the gap clearance 65) by axially moving the inner casing 51 in the diverging or upstream direction. Further aspects of this axial tilt are discussed in more detail below.
As shown, in one preferred embodiment, the connection assembly 75 includes a radially interlocking structure in which an inner casing flange 77, which also may be referred to as an axial thrust collar, engages a slot formed between two outer casing flanges 78, though it will be appreciated that other configurations are possible. As illustrated, the width of the slot may be oversized relative to the axial width of the inner casing flange 77. In this manner, the opposing sidewalls of the slot define limits or a range for the axial movement of the inner casing 51. The opposing sidewalls of the slot provide mechanical stops beyond which axial movement of the inner casing is prevented. The axial range of movement may depend upon several factors including the type of turbine engine, flowpath architecture, and operating conditions. According to a particular preferred embodiment, the axial range of the axial movement of the inner casing 51 is between 0.15 and 0.35 inches. In certain embodiments, the connection assembly 75 includes a compression spring 79 that is used to bias the inner casing 51 toward an initial position. In this case, the compression spring 79 forces the flange 77 toward the converging or downstream sidewall of the slot. As illustrated, in a preferred embodiment, the compression spring 79 has a first end that engages the flange 77 and a second end that engages the diverging or upstream sidewall of the slot.
As further illustrated, the outer casing upstream flange 78 and the compression spring 79 may include a threaded connection 85, which allows for the adjustment of the preload compression of the spring 79. In this manner, the static load of the compression spring may be very such that the axial movement of the inner casing 51 occurs at a particular operating mode, i.e., the operating mode that provides a pressure differential in the flowpath 54 that overcomes the preloading of the spring 79 to initiate axial movement of the inner casing 51. More specifically, the axial preload of the compression spring 79 may be configured at a threshold such that: a) during a first mode of engine operation, the axial preload exceeds the axial pressure loading of the inner casing 51 receiving surface so that the inner casing 51 remains in an initial position; and b) during a second mode of engine operation, the axial pressure loading of the inner casing 51 receiving surface exceeds the axial preload such that axial movement to a second position is initiated. As illustrated, the threaded connection 85 is configured such that an upstream end of the compression spring 79 is threadably received by the upstream outer casing flange 78 such that rotational adjustment axially displaces that end of the compression spring 79.
A row of stator blades 62 is positioned just downstream of the rotor blades 61 and attached to the inner casing 51. The stator blades 62 having inner tips 42 that oppose rotating structure that defines the inboard boundary 55 of the flowpath 54. An inner gap clearance 65 is defined between the inner tips 42 of the stator blades 62 and the inboard boundary 55 of the flowpath 54. In certain embodiments, the inboard boundary 55 of the flowpath 54 comprises an axial tilt. In preferred embodiments, the axial tilt of the inboard boundary 55 converges the flowpath 54 in the same direction as the axially tilted outboard boundary 65. It will be appreciated that, given the axial tilt of the outboard boundary 55, the gap clearance 65 between the rotor blades 61 and the inner casing 51 narrows as the inner casing 51 moves in the diverging direction, which, as stated, occurs when the biasing preload is overcome. As illustrated in
The present invention further describes methods and processes by which the mechanical systems described above may be employed. Pursuant to one exemplary embodiment, the present invention includes a method of passively varying an axial position of the inner casing 51 in a compressor 11 between an upstream location and a downstream location based upon modes of engine operation. The method may include the steps of: slidably connecting the inner casing 51 to the outer casing 52 for axial movement between a downstream position and an upstream position; forming a high-pressure region and a low pressure region in the annulus 53 by extracting working fluid from axially spaced pressure regions in the flowpath 54; configuring the inner casing 51 with opposing receiving surfaces, a first receiving surface disposed in the high-pressure region and a second receiving surface disposed in the low-pressure region of the annulus 53, for axially loading the inner casing 51 toward the upstream position relative to an amount by which a pressure in the high-pressure region exceeds a pressure in the low-pressure region of the annulus 53. The method may further include the step of configuring the outboard boundary 55 and an inboard boundary 55 of the flowpath 54 such that leakage paths between stationary and rotating structures are wider when the inner casing 51 occupies the first axial position and narrower when the inner casing 51 occupies the second axial position.
An alternative embodiment describes a method for passively controlling an axial position of an inner casing 51 of a compressor or a turbine. In this instance, the inner casing 51 defines an axially tilted outboard boundary 55 that, relative thereto, defines a converging direction in which the flowpath 54 converges and a diverging direction in which the flowpath 54 diverges. This embodiment may include the steps of: slidably connecting the inner casing 51 to the outer casing 52 for axial movement between a first axial position in the converging direction and a second axial position in the diverging direction; using a static load derived from a mechanical biasing means to axially preload the inner casing 51 toward the first axial position; extracting working fluid from a high-pressure extraction point and a low-pressure extraction point from the flowpath 54; and in the annulus 53, axially loading opposing receiving surfaces on the inner casing 51 with a pressure derived from the extracted working fluid so to oppose the mechanical biasing means with a dynamic pressure load, the dynamic pressure load configured to directly relate to a current pressure differential between the high-pressure extraction point and the low-pressure extraction point. As described above, the opposing receiving surfaces may include a first receiving surface and a second receiving surface, and the dynamic pressure load may be derived by axially loading the first receiving surface toward the diverging direction with a pressure derived from the working fluid extracted from the high-pressure extraction point, and axially loading the second receiving surface toward the converging direction with a pressure derived from the working fluid extracted from the low-pressure extraction point. The method may further include the steps of determining a first mode of engine operation in which the inner casing 51 is preferably located in the first axial position based on a leakage path clearance defined between opposing rotating and stationary structure, as well as determining a second mode of engine operation in which the inner casing 51 is preferably located in the second axial position based upon the leakage path clearance. Once this is complete, an engine operator and/or component designer may then determining an amount by which the dynamic pressure load of the second mode of engine operation exceeds the dynamic pressure load of the first mode of engine operation. This pressure load differential between operating modes then may be used to tune tuning the amount by which the mechanical biasing means axially preloads the inner casing 51 toward the first axial position. Specifically, the axial preload may be based upon the amount by which the dynamic pressure load of the second mode of engine operation exceeds the dynamic pressure load of the first mode of engine operation. The static preload may be set so that it is greater than the dynamic pressure load during the first mode of engine operation; and less than the dynamic pressure load during the second mode of engine operation.
As one of ordinary skill in the art will appreciate, the many varying features and configurations described above in relation to the several exemplary embodiments may be further selectively applied to form the other possible embodiments of the present invention. For the sake of brevity and taking into account the abilities of one of ordinary skill in the art, all of the possible iterations is not provided or discussed in detail, though all combinations and possible embodiments embraced by the several claims below or otherwise are intended to be part of the instant application. In addition, from the above description of several exemplary embodiments of the invention, those skilled in the art will perceive improvements, changes and modifications. Such improvements, changes and modifications within the skill of the art are also intended to be covered by the appended claims. Further, it should be apparent that the foregoing relates only to the described embodiments of the present application and that numerous changes and modifications may be made herein without departing from the spirit and scope of the application as defined by the following claims and the equivalents thereof.
