Repairable fuel nozzle

This Application claims priority to U.S. Provisional Application Ser. No. 61/044,116, filed Apr. 11, 2008, which is herein incorporated by reference in its entirety.

This invention relates generally to fuel nozzles used in gas turbine engines, and more specifically to repairable fuel nozzles, components and methods of repairing fuel nozzle components and assemblies.

Turbine engines typically include a plurality of fuel nozzles for supplying fuel to the combustor in the engine. The fuel is introduced at the front end of a burner in a highly atomized spray from a fuel nozzle. Compressed air flows around the fuel nozzle and mixes with the fuel to form a fuel-air mixture, which is ignited by the burner. Because of limited fuel pressure availability and a wide range of required fuel flow, many fuel injectors include pilot and main nozzles, with only the pilot nozzles being used during start-up, and both nozzles being used during higher power operation. The flow to the main nozzles is reduced or stopped during start-up and lower power operation. Such injectors can be more efficient and cleaner-burning than single nozzle fuel injectors, as the fuel flow can be more accurately controlled and the fuel spray more accurately directed for the particular combustor requirement. The pilot and main nozzles can be contained within the same nozzle assembly or can be supported in separate nozzle assemblies. These dual nozzle fuel injectors can also be constructed to allow further control of the fuel for dual combustors, providing even greater fuel efficiency and reduction of harmful emissions. The temperature of the ignited fuel-air mixture can reach an excess of 3500° F. (1920° C.). It is therefore important that the fuel supply conduits, flow passages and distribution systems are substantially leak free and are protected from the flames and heat.

Over time, continued exposure to high temperatures during turbine engine operations may induce thermal gradients and stresses in the conduits and fuel nozzle components which may damage the conduits or fuel nozzle components and may adversely affect the operation of the fuel nozzle. For example, thermal gradients may cause fuel flow reductions in the conduits and may lead to excessive fuel maldistribution within the turbine engine. Exposure of fuel flowing through the conduits and orifices in a fuel nozzle to high temperatures may lead to coking of the fuel and lead to blockages and non-uniform flow. To provide low emissions, modern fuel nozzles require numerous, complicated internal air and fuel circuits to create multiple, separate flame zones. Fuel circuits may require heat shields from the internal air to prevent coking, and certain fuel nozzle components may have to be cooled and shielded from combustion gases. Additional features may have to be provided in the fuel nozzle components to promote heat transfer and cooling. Furthermore, over time, continued operation with damaged fuel nozzles may result in decreased turbine efficiency, turbine component distress, and/or reduced engine exhaust gas temperature margin.

Improving the life cycle of fuel nozzles installed within the turbine engine may extend the longevity of the turbine engine. Known fuel nozzles include a delivery system, a mixing system, and a support system. The delivery system comprising conduits for transporting fluids delivers fuel to the turbine engine and is supported, and is shielded within the turbine engine, by the support system. More specifically, known support systems surround the delivery system, and as such are subjected to higher temperatures and have higher operating temperatures than delivery systems which are cooled by fluid flowing through the fuel nozzle. It may be possible to reduce the thermal stresses in the conduits and fuel nozzles by configuring their external and internal contours and thicknesses. Some known conventional fuel nozzles have 22 braze joints and 3 weld joints. Assembling and repairing such conventional fuel nozzles is time consuming, difficult and expensive.

Conventional gas turbine engine components such as, for example, fuel nozzles and their associated swirlers, conduits, distribution systems, venturis and mixing systems are generally expensive to fabricate and/or repair because the conventional fuel nozzle designs having complex swirlers, conduits and distribution circuits and venturis for transporting, distributing and mixing fuel with air include a complex assembly and joining of more than thirty components. More specifically, the use of braze joints can increase the time needed to fabricate such components and can also complicate the fabrication process for any of several reasons, including: the need for an adequate region to allow for braze alloy placement; the need for minimizing unwanted braze alloy flow; the need for an acceptable inspection technique to verify braze quality; and, the necessity of having several braze alloys available in order to prevent the re-melting of previous braze joints. Moreover, numerous braze joints may result in several braze runs, which may weaken the parent material of the component. Modern fuel nozzles such as the Twin Annular Pre Swirl (TAPS) nozzles have numerous components and braze joints in a tight envelope. The presence of numerous braze joints can undesirably increase the weight and the cost of repairing, assembling and inspection of the components and assemblies.

Repair of a damaged conventional fuel nozzle is usually difficult, involving disassembly of the fuel nozzle assembly components to remove the damaged component. Fuel nozzle assemblies usually have a number of braze joints and weld joints. A damaged fuel nozzle component, such as a heat shield, is conventionally repaired by welding excess metal into the damaged area and machining the metal to form the appropriate shape, or by cutting out the damaged area and replacing the cut out material by welding or bracing a new piece of material into the damaged area. However, such an approach is both expensive and results in reduced performance by introducing undesirable steps in the fuel wetted areas of nozzle component such as a venturi. Other known manufacturing methods such as laser cladding often result in imperfections and inclusions in the formed or repaired part resulting from incomplete fusion of the melted layers to the underlying substrate or previously welded material. These imperfections and inclusions are often associated with complex geometry of the formed or repaired part.

Accordingly, it would be desirable to have a repairable fuel nozzle having features for protecting the structures from heat for reducing undesirable effects from thermal exposure described earlier. It is desirable to have a repairable fuel nozzle assembly having features to reduce the cost and for ease of repair and re-assembly as well as providing protection from adverse thermal environment and for reducing potential leakage.

It is desirable to have a method of repair of components having complex three-dimensional geometries, such as, for example, a venturi with a heat shield, for use in repairable fuel nozzles having reduced potential for leakage in a gas turbine engine. It is desirable to have a method of repairing a component without having to disassemble the component from a fuel nozzle assembly. It is desirable to have a repair method that is economical and flexible.

The above-mentioned need or needs may be met by exemplary embodiments which provide a repairable fuel nozzle comprising an adaptor configured to direct a fuel flow from at least one flow passage in a fuel distributor to a pilot assembly comprising a fuel swirler.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding part of the specification. The invention, however, may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:

FIG. 1 is a partial cross-sectional view of exemplary repairable fuel nozzle according to an exemplary embodiment of the present invention.

FIG. 2 is an axial cross sectional view of the tip region of the exemplary repairable fuel nozzle shown in FIG. 1.

FIG. 3 is a flow chart showing an exemplary embodiment of a method for fabricating a unitary component according to an aspect of the present invention.

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