Apparatus for vibration support in combustors and method for forming apparatus   

Abstract: A sleeve component assembly for a combustor, and a method for forming the sleeve component assembly for the combustor, are disclosed. The sleeve component assembly includes a sleeve component, the sleeve component comprising one of an inner sleeve component or an outer sleeve component. The sleeve component assembly further includes at least one support feature extending from the sleeve component, the at least one support feature configured to contact and provide vibratory support to an adjacent sleeve component. The at least one support feature is integral with the sleeve component.

FIELD OF THE INVENTION

The subject matter disclosed herein relates generally to turbine systems, and more particularly to apparatus for reducing vibrations in combustors of turbine systems and methods for forming the apparatus.

BACKGROUND OF THE INVENTION

Turbine systems are widely utilized in fields such as power generation. For example, a conventional gas turbine system includes a compressor, a combustor, and a turbine. During operation of the turbine system, various components in the system may be subjected to high temperature flows, which can cause the components to fail. Since higher temperature flows generally result in increased performance, efficiency, and power output of the gas turbine system, the components that are subjected to high temperature flows must be cooled to allow the gas turbine system to operate at increased temperatures.

During operation of a turbine system, many components of the system may be subject to significant structural vibrations. These vibrations can stress the components and eventually cause the components to fail. For example, in gas turbine systems, the combustor impingement sleeves are particularly vulnerable to structural vibrations.

Previous attempts to reduce structural vibrations in impingement sleeves have involved thickening the walls of the impingement sleeves or adding ribs or gussets to the impingement sleeves. Thickening the walls, however, may make the impingement sleeves undesirably heavy, and may further make the impingement sleeves more expensive and difficult to manufacture. The addition of ribs or gussets may also make the impingement sleeves more expensive and difficult to manufacture, and may potentially add failure points to the system.

Thus, an improved apparatus for reducing structural vibrations in a combustor of a turbine system, and a method for forming the apparatus, would be desired in the art. For example, a method and apparatus that provide support features that are integral with an existing combustor component would be advantageous. Further, a method and apparatus that provide support features that may be configured for optimal vibratory and heat transfer capabilities would be desired.

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one embodiment, a sleeve component assembly for a combustor is disclosed. The sleeve component assembly includes a sleeve component, the sleeve component comprising one of an inner sleeve component or an outer sleeve component. The sleeve component assembly further includes at least one support feature extending from the sleeve component, the at least one support feature configured to contact and provide vibratory support to an adjacent sleeve component. The at least one support feature is integral with the sleeve component.

In another embodiment, a method for forming a sleeve component assembly for a combustor is disclosed. The method includes flowing a sleeve component substrate into a mold through at least one gate, the mold comprising the at least one gate and at least one shell configured to form a sleeve component therein, the sleeve component comprising one of an inner sleeve component or an outer sleeve component. The method further includes solidifying the sleeve component substrate in the mold to form the sleeve component assembly, the sleeve component assembly comprising the sleeve component and at least one support feature, the at least one support feature integral with the sleeve component and disposed in the at least one gate. The method further includes removing the sleeve component assembly from the mold, and adjusting a height of the at least one support feature such that the at least one support feature is configured to contact and provide vibratory support to an adjacent sleeve component.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 is a schematic illustration of a gas turbine system;

FIG. 2 is a side cutaway view of one embodiment of various components of the gas turbine system of the present disclosure;

FIG. 3 is a side view of one embodiment of a sleeve component assembly of the present disclosure; and

FIG. 4 is a cross-sectional view of one embodiment of a mold for a sleeve component assembly of the present disclosure.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 is a schematic diagram of a gas turbine system 10. The system 10 may include a compressor 12, a combustor 14, and a turbine 16. Further, the system 10 may include a plurality of compressors 12, combustors 14, and turbines 16. The compressors 12 and turbines 16 may be coupled by a shaft 18. The shaft 18 may be a single shaft or a plurality of shaft segments coupled together to form shaft 18.

As illustrated in FIG. 2, the combustor 14 is generally fluidly coupled to the compressor 12 and the turbine 16. The compressor 12 may include a diffuser 20 and a discharge plenum 22 that are coupled to each other in fluid communication, so as to facilitate the channeling of a working fluid 24 to the combustor 14. For example, after being compressed in the compressor 12, working fluid 24 may flow through the diffuser 20 and be provided to the discharge plenum 22. The working fluid 24 may then flow from the discharge plenum 22 to the combustor 14, wherein the working fluid 24 is combined with fuel from fuel nozzles 26. After mixing with the fuel, the working fluid 24/fuel mixture may be ignited within combustion chamber 28 to create hot gas flow 30. The hot gas flow 30 may be channeled through the combustion chamber 28 along a hot gas path 32 into a transition piece cavity 34 and through a turbine nozzle 36 to the turbine 16.

The combustor 14 may comprise a hollow annular wall configured to facilitate working fluid 24. For example, the combustor 14 may include a combustor liner 40 disposed within a flow sleeve 42. The arrangement of the combustor liner 40 and the flow sleeve 42, as shown in FIG. 2, is generally concentric and may define an annular passage or flow path 44 therebetween. In certain embodiments, the flow sleeve 42 and the combustor liner 40 may define a first or upstream hollow annular wall of the combustor 14. The flow sleeve 42 may include a plurality of inlets 46, which provide a flow path for at least a portion of the working fluid 24 from the compressor 12 through the discharge plenum 22 into the flow path 44. In other words, the flow sleeve 42 may be perforated with a pattern of openings to define a perforated annular wall. The interior of the combustor liner 40 may define the substantially cylindrical or annular combustion chamber 28 and at least partially define the hot gas path 32 through which hot gas flow 30 may be directed.

Downstream from the combustor liner 40 and the flow sleeve 42, an impingement sleeve 50 may be coupled to the flow sleeve 42. The flow sleeve 42 may include a mounting flange 52 configured to receive a mounting member 54 of the impingement sleeve 50. A transition piece 56 may be disposed within the impingement sleeve 50, such that the impingement sleeve 50 surrounds the transition piece 56. A concentric arrangement of the impingement sleeve 50 and the transition piece 56 may define an annular passage or flow path 58 therebetween. The impingement sleeve 50 may include a plurality of inlets 60, which may provide a flow path for at least a portion of the working fluid 24 from the compressor 12 through the discharge plenum 22 into the flow path 58. In other words, the impingement sleeve 50 may be perforated with a pattern of openings to define a perforated annular wall. Interior cavity 34 of the transition piece 56 may further define hot gas path 32 through which hot gas flow 30 from the combustion chamber 28 may be directed into the turbine 16.

As shown, the flow path 58 is fluidly coupled to the flow path 44. Thus, together, the flow paths 44 and 58 define a flow path configured to provide working fluid 24 from the compressor 12 and the discharge plenum 22 to the fuel nozzles 26, while also cooling the combustor 14.

As discussed above, the turbine system 10, in operation, may intake working fluid 24 and provide the working fluid 24 to the compressor 12. The compressor 12, which is driven by the shaft 18, may rotate and compress the working fluid 24. The compressed working fluid 24 may then be discharged into the diffuser 20. The majority of the compressed working fluid 24 may then be discharged from the compressor 12, by way of the diffuser 20, through the discharge plenum 22 and into the combustor 14. Additionally, a small portion (not shown) of the compressed working fluid 24 may be channeled downstream for cooling of other components of the turbine engine 10.

A portion of the compressed working fluid 24 within the discharge plenum 22 may enter the flow path 58 by way of the inlets 60. The working fluid 24 in the flow path 58 may then be channeled upstream through flow path 44, such that the working fluid 24 is directed over the combustor liner 34. Thus, a flow path is defined in the upstream direction by flow path 58 (formed by impingement sleeve 50 and transition piece 56) and flow path 44 (formed by flow sleeve 42 and combustor liner 40). Accordingly, flow path 44 may receive working fluid 24 from both flow path 58 and inlets 46. The working fluid 24 through the flow path 44 may then be channeled upstream towards the fuel nozzles 26, as discussed above.

Thus, the combustor liner 40, transition piece 56, flow sleeve 42, and impingement sleeve 50 are all sleeve components for the combustor 14. As shown in FIG. 2, both the combustor liner 40 and the transition piece 56 are inner sleeve components 100 configured to at least partially provide a flow boundary in the combustor 14. In general, an inner sleeve component 100 according to the present disclosure may be configured to provide a flow boundary by providing a physical boundary between various flows or directions of flow in the combustor 14. In some embodiments, the various flows or directions of flow may have different temperatures, and the inner sleeve component 100 may thus further provide a temperature boundary in the combustor 14.

For example, the combustor liner 40 and the transition piece 56 provide a flow boundary between the flow of working fluid 24 and the hot gas flow 30, as discussed above. Further, the working fluid 24 is generally cooler than the hot gas flow 30, and is used to cool the combustor liner 40 and the transition piece 56. Thus, the combustor liner 40 and transition piece 56 further provide a temperature boundary.

Further, as shown in FIG. 2, both the flow sleeve 42 and impingement sleeve 50 are outer sleeve components 102. In general, an outer sleeve component 102 is a component of the combustor 14 is disposed adjacent an inner sleeve component 100. The outer sleeve component 102 may act as an outer sleeve or casing for the inner sleeve component 100, and may provide an outer boundary for flows flowing past the inner sleeve component 100. For example, the flow sleeve 42 and impingement sleeve 50 are outer sleeve components 102 for the combustor liner 40 and the transition piece 56, respectively.

During operation of the turbine system, the outer sleeve component 102 according to the present disclosure may vibrate undesirably. Thus, devices and apparatus are needed to provide vibratory support to the outer sleeve component 102 in order to reduce or eliminate the vibration of the outer sleeve component 102. Thus, the present disclosure is further directed to a sleeve component assembly 104 for the turbine system 10.

As shown in FIGS. 2 and 3, the sleeve component assembly 104 may include a sleeve component. The sleeve component may in exemplary embodiments be an inner sleeve component 100, or alternatively may be an outer sleeve component 102. For example, in exemplary embodiments, as discussed above, the sleeve component may be a transition piece 56.

The sleeve component assembly 104 further includes at least one support feature 110. In exemplary embodiments, the sleeve component assembly 104 includes a plurality of support features 110. Each support feature 110 extends from the sleeve component, such as the inner sleeve component 100 or outer sleeve component 102. For example, each support feature 110 may extend from a surface 112 of the sleeve component that faces an adjacent sleeve component, which may be the other of the inner sleeve component 100 or the outer sleeve component 102. In exemplary embodiments wherein the sleeve component 100 is a transition piece 56, the support features 110 may extend from the surface 112 of the transition piece 56 facing the adjacent impingement sleeve 50.

The support features 110 may be configured to contact and provide vibratory support to the adjacent sleeve component. In some embodiments, for example, the support features 110 may be configured to generally continuously contact and provide vibratory support to the adjacent sleeve component. The support features 110 may thus interact with the adjacent sleeve component to support the component and reduce the structural vibrations of the component.

For example, the support features 110 may each define a height 114. As shown in FIG. 3, the height 114 of each support feature 110 may allow the support feature 110 to contact and interact with the adjacent sleeve component, such as the adjacent outer sleeve component 102, to provide the required vibratory support. As discussed below, the height 114 of each support feature 110 may be adjusted as desired to ensure that the support feature 110 properly supports the adjacent sleeve component.

In some embodiments, the height 114 may be adjusted such that the support features 110 generally continuously contact and provide vibratory support to the adjacent sleeve component. In these embodiments, the height 114 may be such that when the turbine system 10 is non-operational, the adjacent sleeve component and the support features 110 are in contact. It should be understood, however, that during operation, vibrations may cause the generally continuously contacting support features 110 and adjacent sleeve component to occasionally separate, and that this vibrational movement of the support features 110 and adjacent sleeve component relative to one another is within the scope and spirit of the generally continuously contacting support features 110 and adjacent sleeve component.

In other embodiments, the height 114 may be adjusted such that the support features 110 contact and provide vibratory support to the adjacent sleeve component during operation of the system 10. In these embodiments, the height 114 may be such that when the turbine system 10 is non-operational, the adjacent sleeve component and the support features 110 are not in contact. During operation, vibrations may cause the generally continuously contacting support features 110 and adjacent sleeve component to occasionally contact, and the support features 110 may thus contact and provide vibratory support to the adjacent sleeve component.

Each support feature 110 according to the present disclosure is integral with the sleeve component, such as with the inner sleeve component 100 or outer sleeve component 102. Thus, the sleeve component and the support features 110 extending therefrom may be formed from the same materials, and may be formed together as a singular unit. The sleeve component and the support features 110 may in exemplary embodiments be formed from a nickel or cobalt based alloy or super alloy. Alternatively, the sleeve component and the support features 110 may be formed from any materials suitable for use in a combustor 14.

Further, in exemplary embodiments, the support features 110 may be formed during casting of the sleeve component. For example, in some embodiments, the mold shells for casting the sleeve component assembly 104 therein, as discussed below, may be designed and configured to form a sleeve component assembly 104 including the sleeve component and at least one support feature 110. In other exemplary embodiments, as discussed below, the gates utilized during casting to flow a sleeve component substrate therethrough into the mold shells may form the support features 110. The support features 110 may be formed by the gates during casting of the sleeve component. The sleeve component assembly 104 may thus be formed as an integral unit during casting.

In exemplary embodiments, each support feature 110 may be configured to provide a desired vibratory characteristic. For example, each support feature 110 may be individually tailored to impart a desired vibratory characteristic onto the adjacent sleeve component, such as the adjacent outer sleeve component 102, that the support feature 110 is providing vibratory support to. Each support feature 110 may be formed with a desired shape, size, and/or height 114, and/or the location of the support feature 110 may be individually tailored, and/or the spacing between various support features 110 may be tailored, to provide the desired vibratory characteristic. In exemplary embodiments, the desired vibratory characteristic may be the natural frequency of the adjacent sleeve component, such as the adjacent outer sleeve component 102. Each support feature 110 may be configured to raise or lower the natural frequency of the adjacent sleeve component or to cause the adjacent sleeve component to have a certain desired natural frequency. For example, the height 114 of the support features 110 may be raised to raise the natural frequency of the adjacent sleeve component or lowered to lower the natural frequency of the adjacent sleeve component.

It should be understood, however, that the present disclosure is not limited to adjusting the above characteristics of the support features 110 to adjust the natural frequency of the adjacent sleeve component. Rather, the adjustment of any suitable characteristics of the support features 110 to adjust any suitable vibratory characteristics of the adjacent sleeve component are within the scope and spirit of the present disclosure.

In exemplary embodiments, each support feature 110 may be configured to provide a desired heat transfer characteristic. As discussed above, the sleeve component, such as in exemplary embodiments the inner sleeve component 102, may provide a temperature boundary between, for example, a relatively hotter flow and a relatively cooler flow. In embodiments wherein the sleeve component is a transition piece 56, for example, the sleeve component may provide a temperature boundary between a hot gas flow 30 and a working fluid 24. The support features 110 may thus be utilized to provide desired heat transfer characteristics for the sleeve component. Each support feature 110 may be formed with a desired shape, size, and/or height 114, and/or the location of the support feature 110 may be individually tailored, and/or the spacing between various support features 110 may be tailored, to provide the desired heat transfer characteristic. For example, it may be desirable that the heat exchange through the sleeve component is relatively uniform. Thus, various support features 110 may be formed as relatively thick support features 110, and may thus act as insulators to heat cold spots on the sleeve component, while other support features 110 may be formed as relatively thin support features 110, and may thus act as fins to cool hot spots on the sleeve component. The support features 110 may thus assist in providing a relatively uniform heat exchange through the sleeve component.

It should be understood, however, that the present disclosure is not limited to adjusting the above characteristics of the support features 110 to provide uniform heat exchange through the sleeve component. Rather, the adjustment of any suitable characteristics of the support features 110 to adjust any suitable heat transfer characteristic of the sleeve component assembly 104 or adjacent sleeve component are within the scope and spirit of the present disclosure.

The present disclosure is further directed to a method for forming a sleeve component assembly 104 for a combustor 14. The sleeve component assembly 104, as discussed above, includes a sleeve component, such as an inner sleeve component 100 or an outer sleeve component 102, and at least one support feature 110 or a plurality of support features 110. Further, the sleeve component in exemplary embodiments is a transition piece 56.

As shown in FIG. 4, the method includes, for example, flowing a sleeve component substrate 200 into a mold 202 through at least one gate 204, or through a plurality of gates 204. The mold 202 may comprise the gates 204 and at least one shell configured to form the sleeve component 100. For example, in some embodiments as shown in FIG. 4, the mold 202 may include at least one inner shell 206, or a plurality of inner shells 206, and at least one outer shell 208, or a plurality of outer shells 208. The inner and outer shells 206, 208 may fit together to form an interior molding area 210 therein for the sleeve component 100. The gates 204 may provide access points through the outer shells 208 and/or the inner shells 206 for the sleeve component substrate 200 to flow into the interior molding area 210.

The mold 202 in some embodiments may further include a pour spout 212 or a plurality of pour spouts 212, a sprue 214 or a plurality of sprues 214, and a runner 216 or a plurality of runners 216. The pour spouts 212 may be provided as inlets to the mold for the sleeve component substrate 200. Thus, the component substrate 200 may be flowed through the pour spouts 212 into the mold 202 in general. The sprues 214 and runners 216 may provide a network of channels for the sleeve component substrate 200 to flow through before flowing into the interior molding area 210. Thus, the sprues 214 and runners 216 may distribute the sleeve component substrate 200 through the mold 202, such that the sleeve component substrate 200 enters the interior molding area 210 relatively evenly and is allowed to solidify relatively evenly. As discussed above, the gates 204 provide access points through the outer shells 208 and/or the inner shells 206 for the sleeve component substrate 200 to flow into the interior molding area 210. Thus, the sprues 214 and/or runners 216 may be in fluid communication with the gates 204, such that the sleeve component substrate 200 flows from the sprues 214 and/or runners 216 through the gates 204 and generally into the interior molding area 210.

The present method may further include solidifying, such as curing, the sleeve component substrate 200 in the mold 202 to form the sleeve component assembly 104. When the sleeve component substrate 200 is flowed into the mold 202, a portion of the substrate 200 may remain in the gates 204 rather than flow into the interior molding area 210. When the sleeve component substrate 200 solidifies, the substrate 200 in the gates 204 may thus form the support features 110 of the sleeve component assembly 104. Thus, the sleeve component assembly 104 may comprise the sleeve component and at least one support feature 110, and the support feature 110 may be integral with the sleeve component and disposed in the at least one gate 204.

The present method may further include removing the sleeve component assembly 104 from the mold 202. For example, the various shells 206, 208, gates 204, and other components of the mold 202 may be removed from the sleeve component assembly 104 using any suitable methods or devices.

The present method may further include adjusting the heights 114 of the support features 110. The heights 114 may be adjusted such that the support features 110 are configured to provide vibratory support in the turbine system 10. For example, the heights 114 may be adjusted such that the support features 110 are configured to contact and provide vibratory support to adjacent sleeve components. To adjust the heights 114, the support features 110 may be measured and trimmed, cut, sanded, or otherwise reduced as required so that the support features 110 contact and interact as desired with the adjacent sleeve components.

In some embodiments, the present method may include the step of, for example, designing the gates 204 such that the support features 110 provide a desired vibratory characteristic. For example, as discussed above, the support features 110 may be configured to provide a desired vibratory characteristic. Thus, each support feature 110 may be formed with, for example, a desired shape, size, and/or height 114, and/or the location of the support feature 110 may be individually tailored, and/or the spacing between various support features 110 may be tailored, to provide the desired vibratory characteristic. To form the support features 110 with these configurations in order to provide the desired vibratory characteristic, the gates 204 may be sized and positioned such that the support features 110 formed therein generally have these configurations.

In some embodiments, the present method may include the step of, for example, designing the gates 204 such that the support features 110 provide a desired heat transfer characteristic. For example, as discussed above, the support features 110 may be configured to provide a desired heat transfer characteristic. Thus, each support feature 110 may be formed with, for example, a desired shape, size, and/or height 114, and/or the location of the support feature 110 may be individually tailored, and/or the spacing between various support features 110 may be tailored, to provide the desired heat transfer characteristic. To form the support features 110 with these configurations in order to provide a desired heat transfer characteristic, the gates 204 may be sized and positioned such that the support features 110 formed therein generally have these configurations.

In some embodiments, the present method may include the step of, for example, modifying the support features 110 such that the support features 110 provide a desired vibratory characteristic. For example, after forming of the sleeve component assembly 104, the support features 110 may not have the appropriate configurations to provide a desired vibratory characteristic. Thus, various characteristics of various support features 110 such as the shape, size, and/or height 114 may be modified, and/or various support features 110 may be eliminated, and/or the various support features 110 may be otherwise modified, to provide the desired vibratory characteristic. To modify the support features 110, various portions of the support features 110 may be removed, or the support features 110 may be reshaped, or the support features 110 may be otherwise modified as desired.

In some embodiments, the present method may include the step of, for example, modifying the support features 110 such that the support features 110 provide a desired heat transfer characteristic. For example, after forming of the sleeve component assembly 104, the support features 110 may not have the appropriate configurations to provide a desired heat transfer characteristic. Thus, various characteristics of various support features 110 such as the shape, size, and/or height 114 may be modified, and/or various support features 110 may be eliminated, and/or the various support features 110 may be otherwise modified, to provide the desired heat transfer characteristic. To modify the support features 110, various portions of the support features 110 may be removed, or the support features 110 may be reshaped, or the support features 110 may be otherwise modified as desired.

In exemplary embodiments, the present disclosure thus advantageously utilizes the gates 204 of the mold 202 for forming the sleeve component to additionally form the support features 110. During the forming process, which may in exemplary embodiments be a casting process, it is generally advantageous to have a multitude of gates 204 to provide a variety of access points for a substrate to enter the mold. More gates 204 allow for better, more uniform solidifying of the substrate into the desired component. However, previously, the addition of gates 204 had to be weighed against the cost of removing the resulting protrusions from the desired component. The present disclosure reduces this cost by requiring that the resulting protrusions, rather than being removed, be configured to provide vibratory support in the combustor 14. Thus, more gates 204 may be advantageously utilized during the forming process according to the present disclosure. More gates 204 will provide for higher quality sleeve component assemblies 104 with more support features 110, which may provide improved vibratory support.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.