This invention relates generally to gas turbine engines, and more specifically, to methods and apparatuses for reducing nozzle stress in a gas turbine engine.
A gas turbine engine generally includes in serial flow communication a compressor, a combustor, and a turbine. The compressor provides compressed airflow to the combustor wherein the airflow is mixed with fuel and ignited, which creates combustion gases. The combustion gases flow to the turbine which extracts energy therefrom.
The turbine includes one or more stages, with each stage having an annular turbine nozzle set for channeling the combustion gases to a plurality of rotor blades. The turbine nozzle set includes a plurality of circumferentially spaced nozzles fixedly joined at their roots and tips to a radially inner sidewall and a radially outer sidewall, respectively. Each individual nozzle has an airfoil cross-section and includes a leading edge, a trailing edge, and pressure and suction sides extending therebetween. Exposure to changing temperatures, in combination with the load on each nozzle can lead to undesirable stress which may reduce a useful life of the nozzle. Typically, the leading edge and trailing edge are the most common areas where cracks appear.
One aspect of the disclosed technology relates to a turbine nozzle segment having a radially-inner endwall, a radially-outer endwall, and a pair of airfoil-shaped vanes extending between the radially-inner endwall and the radially-outer endwall, wherein a back face of the radially-inner endwall and/or a back face of the radially-outer endwall has a pocket formed therein in an area between the pressure sidewall of the first vane and the suction sidewall of the second vane to enhance stiffness distribution between the second vane and the radially-inner endwall and/or radially-outer endwall.
One exemplary but nonlimiting aspect of the disclosed technology relates to a nozzle segment for a gas turbine comprising: a radially-inner endwall, the radially-inner endwall having a flowpath face exposed to combustion gases of the gas turbine and a back face opposed to the flowpath face; a radially-outer endwall, the radially-outer endwall having a flowpath face exposed to the combustion gases and a back face opposed to the flowpath face of the radially-outer endwall; a first airfoil-shaped vane extending between the radially-inner endwall and the radially-outer endwall, the first vane having a leading edge facing in an upstream direction, a trailing edge facing in a downstream direction and opposing pressure and section sidewalls extending in span between the radially-inner endwall and the radially-outer endwall and in chord between the leading edge and the trailing edge; and a second airfoil-shaped vane extending between the radially-inner endwall and the radially-outer endwall, the second vane having a leading edge facing in the upstream direction, a trailing edge facing in the downstream direction and opposing pressure and section sidewalls extending in span between the radially-inner endwall and the radially-outer endwall and in chord between the leading edge and the trailing edge, wherein the back face of the radially-inner endwall and/or the back face of the radially-outer endwall has a pocket formed therein in an area between the pressure sidewall of the first vane and the suction sidewall of the second vane to enhance stiffness distribution between the second vane and the radially-inner endwall and/or the radially-outer endwall, and wherein each said pocket includes a recess, a thickness of the radially-inner endwall in a respective recess and/or a thickness of the radially-outer endwall in a respective recess being in the range of 0.3 to 2.1 times a thickness of the pressure sidewall of the second vane.
Another exemplary but nonlimiting aspect of the disclosed technology relates to a method of enhancing stiffness distribution in a nozzle segment of a gas turbine, the method, comprising: 1) providing a nozzle segment comprising: a radially-inner endwall, the radially-inner endwall having a flowpath face exposed to combustion gases of the gas turbine and a back face opposed to the flowpath face; a radially-outer endwall, the radially-outer endwall having a flowpath face exposed to the combustion gases and a back face opposed to the flowpath face of the radially-outer endwall; a first airfoil-shaped vane extending between the radially-inner endwall and the radially-outer endwall, the first vane having a leading edge facing in an upstream direction, a trailing edge facing in a downstream direction and opposing pressure and section sidewalls extending in span between the radially-inner endwall and the radially-outer endwall and in chord between the leading edge and the trailing edge; and a second airfoil-shaped vane extending between the radially-inner endwall and the radially-outer endwall, the second vane having a leading edge facing in the upstream direction, a trailing edge facing in the downstream direction and opposing pressure and section sidewalls extending in span between the radially-inner endwall and the radially-outer endwall and in chord between the leading edge and the trailing edge; and 2) forming a pocket in the back face of the radially-inner endwall and/or the back face of the radially-outer endwall in an area between the pressure sidewall of the first vane and the suction sidewall of the second vane to enhance stiffness distribution between the second vane and the radially-inner endwall and/or radially-outer endwall, wherein each said pocket includes a recess, a thickness of the radially-inner endwall in a respective recess and/or a thickness of the radially-outer endwall in a respective recess being in the range of 0.3 to 2.1 times a thickness of the pressure sidewall of the second vane.
Other aspects, features, and advantages of this technology will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of this invention.
The accompanying drawings facilitate an understanding of the various examples of this technology. In such drawings:
Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views,
The turbine 10 includes a first stage nozzle 12 which comprises a plurality of circumferentially spaced airfoil-shaped hollow first stage vanes 14 that are supported between an arcuate, segmented first stage outer band 16 and an arcuate, segmented first stage inner band 18. The first stage vanes 14, first stage outer band 16 and first stage inner band 18 are arranged into a plurality of circumferentially adjoining nozzle segments that collectively form a complete 360° assembly. The first stage outer and inner bands 16 and 18 define the outer and inner radial flowpath boundaries, respectively, for the hot gas stream flowing through the first stage nozzle 12. The first stage vanes 14 are configured so as to optimally direct the combustion gases to a first stage rotor wheel 20.
The first stage rotor 20 wheel includes an array of airfoil-shaped first stage turbine blades 22 extending outwardly from a first stage disk 24 that rotates about the centerline axis of the engine. A segmented, arcuate first stage shroud 26 is arranged so as to closely surround the first stage turbine blades 22 and thereby define the outer radial flowpath boundary for the hot gas stream flowing through the first stage rotor wheel 20.
A second stage nozzle 28 is positioned downstream of the first stage rotor wheel 20, and comprises a plurality of circumferentially spaced airfoil-shaped hollow second stage vanes 30 that are supported between an arcuate, segmented second stage outer band 32 and an arcuate, segmented second stage inner band 34. The second stage vanes 30, second stage outer band 32 and second stage inner band 34 are arranged into a plurality of circumferentially adjoining nozzle segments that collectively form a complete 360° assembly. The second stage outer and inner bands 32 and 34 define the outer and inner radial flowpath boundaries, respectively, for the hot gas stream flowing through the second stage turbine nozzle 34. The second stage vanes 30 are configured so as to optimally direct the combustion gases to a second stage rotor wheel 38.
The second stage rotor wheel 38 includes a radial array of airfoil-shaped second stage turbine blades 40 extending radially outwardly from a second stage disk 42 that rotates about the centerline axis of the engine. A segmented arcuate second stage shroud 44 is arranged so as to closely surround the second stage turbine blades 40 and thereby define the outer radial flowpath boundary for the hot gas stream flowing through the second stage rotor wheel 38.
The radially-inner endwall 110 has a flowpath face 112 that is exposed to the stream of combustion gases and a back face 114 opposed to the flowpath face 112. The radially-outer endwall 120 has a flowpath face 122 that is exposed to the stream of combustion gases and a back face 124 (cold side of endwall 120) opposed to the flowpath face 124.
In this exemplary embodiment, a first vane or airfoil 160 and a second vane or airfoil 170 extend radially (in span) between the flowpath face 112 of the radially-inner endwall 110 and the flowpath face 122 of the radially-outer endwall 120, as shown in
Still referring to
An anti-rotation lug 140 protrudes radially outward from the back face 124 of the radially-outer endwall 120, as shown in
The radially-outer endwall 120 has a thickness that is greater than a thickness of the suction sidewall 173 of the second vane 170. Thus, in conventional nozzle segments, this arrangement results in a non-uniform stiffness distribution that concentrates peak stress on the suction sidewall 173 near the connection with the radially-outer endwall 120. Like the radially-outer endwall 120, the radially-inner endwall 110 may also have a thickness that is greater than a thickness of the suction sidewall 173, which also may result in non-uniform stiffness distribution.
In accordance with an example of the disclosed technology, a pocket 130 is formed in the back face 124 of the radially-outer endwall 120 to reduce the thickness of the endwall in an area immediately adjacent the suction sidewall 173, as shown in
It is also noted that a pocket may be formed in the back face 114 of the radially-inner endwall 110 to reduce the thickness of the endwall in an area immediately adjacent the suction sidewall 173 to reduce peak stress in the second vane 170 and the adjacent portions of the radially-inner endwall 110.
Those skilled in the art will understand that a pocket may be formed in either the radially-inner endwall 110 or the radially-outer endwall 120, or alternatively, in both the radially-inner endwall 110 and the radially-outer endwall 120. The pockets in the radially-inner endwall 110 and the radially-outer endwall 120 may have the same structure. Only the pocket 130 in the radially-outer endwall 120 will be described in detail.
The pocket is particularly effective on nozzle segments which are supported in a cantilevered configuration since the endwalls tend to be much thicker than the airfoils, which causes the stress to concentrate in the airfoil.
It is also noted that the angled surface 145 of the anti-rotation lug 140 represents a section of the second portion 144 of the lug that has been removed. The removal of a portion of the anti-rotation lug 140 adjacent the suction sidewall 173 also helps to create a more desirable stiffness distribution.
The nozzle segment 100 may be machined to remove material from the radially-outer endwall 120 and the anti-rotation lug to form the pocket 130 and the reduced-size anti-rotation lug 140. This process may be performed on nozzle segments 100 in the field in order to prevent early failure of these devices. Suitable techniques include milling and electron discharge machining (EDM), for example. Alternatively, the nozzle segments 100 may be cast with the pocket 130 and reduced-size anti-rotation lug formed therein, machined after casting, or a formed by a combination of such techniques.
A depth of the pocket 130 may vary across the radially-outer endwall 120 in order to optimize stiffness distribution and/or machining/fabrication. For example, the pocket may resemble rolling hills. However, in the illustrated example, the depth varies more gradually (
The pocket 130 is disposed between the suction sidewall 173 of the second vane 170 and the pressure sidewall 162 of the first vane 160, as shown in
Referring to
The first section 134 of the recess is disposed adjacent and downstream of the ramp 132 but upstream of the anti-rotation lug 140. The second section 136 of the recess is disposed downstream of the first section 134 and extends immediately adjacent the anti-rotation lug 140 between the anti-rotation lug and the suction sidewall 173 of the second vane 170. The third section 138 of the recess is disposed downstream of the second section 136 and downstream of the anti-rotation lug 140. A fillet 131 is formed around the pocket 130, as shown in
Turning to
The reduced thickness of the radially-outer endwall 120 in the pocket 130 brings the thickness of the radially-outer endwall closer to the thickness d2 of the suction sidewall 173 of the second vane 170, as shown in
Turning to
The anti-rotation lug 240 may be disposed adjacent an aft end of the nozzle segment at a location between the first vane 160 and the second vane 170, as shown in
The pocket 230 is disposed between the suction sidewall 173 of the second vane 170 and the pressure sidewall 162 of the first vane 160, as shown in
Referring to
The first section 233 of the recess is disposed adjacent and downstream of the ramp 232, as shown in
The depth of the second section 235 of the recess may be less than the depth of the first section 233. As mentioned above, the anti-rotation lug 240 adds stiffness to the second vane 170. Thus, the radially-outer endwall 120 may be relatively thicker in the second section 235 of the recess (as compared to the first section 233) to account for the higher stiffness of the anti-rotation lug 240.
The ramp 232 may be disposed at a most upstream portion of the pocket 230. In the illustrated example, the ramp 232 is inclined in two directions. That is, ramp 232 includes an inclined portion of the bottom surface 239 which transitions from the back face 124 to the first section 233 of the recess. Ramp 232 also slopes radially inward towards the pressure side wall 162 of the first vane 160. Thus, in viewing to
The second transition (e.g., step 234) is disposed between the first section 233 of the recess and the second section 235 of the recess as a step formed in the bottom surface 239 which transitions from the first section 233 to the second section 235, as best shown in
Turning to
Referring to
In an example, the thickness d2 of the pressure sidewall 173 of the second vane may be in the range of 0.2 to 0.4 inches (or 0.2 to 0.3 inches, or 0.3 to 0.4 inches, or 0.25 to 0.35 inches). The thickness d1 of the radially-outer endwall in the recess may be in the range of 0.3 to 2.1 (0.5 to 1.9, or 0.7 to 1.75, or 0.9 to 1.6, or 1.0 to 1.5, or 1.0 to 1.25, or 1.0 to 1.15) times the thickness d2. Thus, in an example, the thickness d2 of the pressure sidewall 173 may be 0.3 inches and the thickness d1 may be 0.09 to 0.63 inches (or 0.15 to 0.57 inches, or 0.21 to 0.525 inches, or 0.27 to 0.48 inches, or 0.3 to 0.45 inches, or 0.3 to 0.375 inches, or 0.3 to 0.345 inches). In other examples, d2 may be 0.2, 0.25, 0.35, or 0.4 inches, and d1 may relate to d2 as described above.
It is also noted that the reduced thickness of the radially-outer endwall 120 in the pocket 130 facilitates heat removal from the nozzle segment. In other words, there is less material to cool but the surface area remains the same; therefore, less work is required to cool the nozzle segment. This helps reduce the thermal load and increases longevity of the part.
While the invention has been described in connection with what is presently considered to be the most practical and preferred examples, it is to be understood that the invention is not to be limited to the disclosed examples, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
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Number | Date | Country | |
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20190040755 A1 | Feb 2019 | US |