MANIFOLD FOR TURBINE BLADE OF GAS TURBINE ENGINE

A turbine blade includes a platform, a blade airfoil attached to one side of the platform, a blade root attached to the other side of the platform, a manifold attached to the blade root. The blade root defines a first cooling passage and a second cooling passage. The manifold includes an outer wall, a first compartment having a first flow area defined by a first aperture formed at the outer wall, and a second compartment having a second flow area defined by a second aperture formed at the outer wall. The first compartment meters a non-zero first flow of cooling air to the first cooling passage through the first flow area. The second compartment meters a non-zero second flow of cooling air to the second cooling passage through the second flow area that is different than the first flow area.

BACKGROUND

A gas turbine engine typically includes a compressor section, a turbine section, and a combustion section disposed therebetween. The compressor section includes multiple stages of rotating compressor blades and stationary compressor vanes. The combustion section typically includes a plurality of combustors. The turbine section includes multiple stages of rotating turbine blades and stationary turbine vanes. Turbine blades and turbine vanes often operate in a high temperature environment and are internally cooled.

BRIEF SUMMARY

In one aspect, a turbine blade includes a platform defining a first side and a second side. The turbine blade also includes a blade airfoil attached to the first side of the platform, the blade airfoil includes a pressure side wall and a suction side wall defining a blade airfoil interior. The turbine blade also includes a blade root attached to the second side of the platform, the blade root including a blade root leading edge and a blade root trailing edge with respect to a flow direction of a working flow, the blade root defining a first cooling passage and a second cooling passage that are in flow communication with the blade airfoil interior. The turbine blade also includes a manifold attached to the blade root, the manifold being non-planar, the manifold includes an outer wall, a first compartment having a first flow area defined by a first aperture, the first aperture being formed at the outer wall and open to the first compartment, the first compartment metering a non-zero first flow of cooling air to the first cooling passage through the first flow area, and a second compartment having a second flow area defined by a second aperture, the second aperture being formed at the outer wall and open to the second compartment, the second compartment metering a non-zero second flow of cooling air to the second cooling passage through the second flow area that is different than the first flow area.

In one aspect, a manifold for use with a turbine blade, the manifold includes a first side plate, a second side plate, an outer plate that extends between the first side plate and the second side plate, a forward plate attached to the first side plate, the second side plate, and the outer plate at one end, an aft plate attached to the first side plate, the second side plate, and the outer plate at the other side that is opposite to the one end, a first compartment having a first flow area defined by a first aperture, the first aperture being formed at the first side plate and open to the first compartment, a second compartment having a second flow area defined by a second aperture, the second aperture being formed at the first side plate and open to the second compartment, the second flow area being different than the first flow area.

In one aspect, a manifold for use with a turbine blade, the manifold includes a first compartment having a first compartment outer wall, the first compartment outer wall defining a first aperture that is open to the first compartment, the first aperture defining a first flow area, and a second compartment having a second compartment outer wall, the second compartment outer wall defining a second aperture that is open to the second compartment, the second aperture defining a second flow area that is different than the first flow area.

DETAILED DESCRIPTION

Various technologies that pertain to systems and methods will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present application will be described with reference to exemplary non-limiting embodiments.

Also, it should be understood that the words or phrases used herein should be construed broadly, unless expressly limited in some examples. For example, the terms “including”, “having”, and “comprising”, as well as derivatives thereof, mean inclusion without limitation. The singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. The term “or” is inclusive, meaning and/or, unless the context clearly indicates otherwise. The phrases “associated with” and “associated therewith” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like. Furthermore, while multiple embodiments or constructions may be described herein, any features, methods, steps, components, etc. described with regard to one embodiment are equally applicable to other embodiments absent a specific statement to the contrary.

Also, although the terms “first”, “second”, “third” and so forth may be used herein to refer to various elements, information, functions, or acts, these elements, information, functions, or acts should not be limited by these terms. Rather these numeral adjectives are used to distinguish different elements, information, functions or acts from each other. For example, a first element, information, function, or act could be termed a second element, information, function, or act, and, similarly, a second element, information, function, or act could be termed a first element, information, function, or act, without departing from the scope of the present disclosure.

Also, in the description, the terms “axial” or “axially” refer to a direction along a longitudinal axis of a gas turbine engine. The terms “radial” or “radially” refer to a direction perpendicular to the longitudinal axis of the gas turbine engine. The terms “downstream” or “aft” refer to a direction along a flow direction. The terms “upstream” or “forward” refer to a direction against the flow direction.

In addition, the term “adjacent to” may mean that an element is relatively near to but not in contact with a further element; or that the element is in contact with the further portion, unless the context clearly indicates otherwise. Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Terms “about” or “substantially” or like terms are intended to cover variations in a value that are within normal industry manufacturing tolerances for that dimension. If no industry standard is available, a variation of twenty percent would fall within the meaning of these terms unless otherwise stated.

FIG.1illustrates an example of a gas turbine engine100including a compressor section102, a combustion section104, and a turbine section106arranged along a central axis112. The compressor section102includes a plurality of compressor stages114with each compressor stage114including a set of stationary compressor vanes116or adjustable guide vanes and a set of rotating compressor blades118. A rotor134supports the rotating compressor blades118for rotation about the central axis112during operation. In some constructions, a single one-piece rotor134extends the length of the gas turbine engine100and is supported for rotation by a bearing at either end. In other constructions, the rotor134is assembled from several separate spools that are attached to one another or may include multiple disk sections that are attached via a bolt or plurality of bolts.

The compressor section102is in fluid communication with an inlet section108to allow the gas turbine engine100to draw atmospheric air into the compressor section102. During operation of the gas turbine engine100, the compressor section102draws in atmospheric air and compresses that air for delivery to the combustion section104. The illustrated compressor section102is an example of one compressor section102with other arrangements and designs being possible.

In the illustrated construction, the combustion section104includes a plurality of separate combustors120that each operate to mix a flow of fuel with the compressed air from the compressor section102and to combust that air-fuel mixture to produce a flow of high temperature, high pressure combustion gases or exhaust gas122. Of course, many other arrangements of the combustion section104are possible.

The turbine section106includes a plurality of turbine stages124with each turbine stage124including a number of stationary turbine vanes126and a number of rotating turbine blades128. The turbine stages124are arranged to receive the exhaust gas122from the combustion section104at a turbine inlet130and expand that gas to convert thermal and pressure energy into rotating or mechanical work. The turbine section106is connected to the compressor section102to drive the compressor section102. For gas turbine engines100used for power generation or as prime movers, the turbine section106is also connected to a generator, pump, or other device to be driven. As with the compressor section102, other designs and arrangements of the turbine section106are possible.

An exhaust portion110is positioned downstream of the turbine section106and is arranged to receive the expanded flow of exhaust gas122from the final turbine stage124in the turbine section106. The exhaust portion110is arranged to efficiently direct the exhaust gas122away from the turbine section106to assure efficient operation of the turbine section106. Many variations and design differences are possible in the exhaust portion110. As such, the illustrated exhaust portion110is but one example of those variations.

A control system132is coupled to the gas turbine engine100and operates to monitor various operating parameters and to control various operations of the gas turbine engine100. In preferred constructions the control system132is typically micro-processor based and includes memory devices and data storage devices for collecting, analyzing, and storing data. In addition, the control system132provides output data to various devices including monitors, printers, indicators, and the like that allow users to interface with the control system132to provide inputs or adjustments. In the example of a power generation system, a user may input a power output set point and the control system132may adjust the various control inputs to achieve that power output in an efficient manner.

The control system132can control various operating parameters including, but not limited to variable inlet guide vane positions, fuel flow rates and pressures, engine speed, valve positions, generator load, and generator excitation. Of course, other applications may have fewer or more controllable devices. The control system132also monitors various parameters to assure that the gas turbine engine100is operating properly. Some parameters that are monitored may include inlet air temperature, compressor outlet temperature and pressure, combustor outlet temperature, fuel flow rate, generator power output, bearing temperature, and the like. Many of these measurements are displayed for the user and are logged for later review should such a review be necessary.

FIG.2illustrates a perspective view of a turbine blade200that can be used in the gas turbine engine100inFIG.1. A plurality of the turbine blades200may replace the rotating turbine blades128or combine with the rotating turbine blades128.

The turbine blade200includes a platform202, a blade airfoil204, and a blade root206. The platform202has a first side208that faces away from the rotor134and a second side210that is opposite to the first side208and faces toward the rotor134.

The blade airfoil204is attached to the platform202at the first side208. The blade airfoil204has a pressure side wall212and a suction side wall214. The pressure side wall212and the suction side wall214meet at a blade airfoil leading edge216and a blade airfoil trailing edge218with respect to a flow direction of a working flow234. The working flow234may be the exhaust gas122from the combustion section104. The pressure side wall212and the suction side wall214define a blade airfoil interior220.

The blade root206is attached to the platform202at the second side210. The blade root206has a blade root leading edge236and a blade root trailing edge238with respect to the flow direction of the working flow234. The blade root206includes a plurality of cooling passages that are defined within the blade root206. In the construction illustrated inFIG.2, the blade root206includes six cooling passages including, from the blade root leading edge236to the blade root trailing edge238, a first leading cooling passage222, a second leading cooling passage224, a first mid cooling passage226, a second mid cooling passage228, a first trailing cooling passage230, and a second trailing cooling passage232. The cooling passages extend to the platform202and are in flow communication with the blade airfoil interior220to provide cooling air to the plurality of cooling channels of the blade airfoil204. In other constructions, the blade root206may have more or less than six cooling passages.

The turbine blade200includes a manifold300that is attached to the blade root206at a side facing to the rotor134. The manifold300is non-planar and meters or controls the quantity of cooling air that flows to each cooling passage of the plurality of cooling passages or blocks the cooling air from entering at least one of the cooling passages.

FIG.3illustrates the manifold300for use with the turbine blade200ofFIG.2. The manifold300includes an outer wall328that can be made up of one or more features, walls, or plates, which define the non-planar manifold300. In the construction illustrated inFIG.3, the outer wall328is made up of a first side plate302, a second side plate304, an outer plate306, a forward plate308, and an aft plate310. The outer plate306is solid and extends between the first side plate302and the second side plate304. The forward plate308is positioned at an upstream side with respect to the flow direction of the working flow234. The forward plate308is perpendicular to the outer plate306. The aft plate310is positioned at a downstream side with respect to the flow direction of the working flow234. The aft plate310is perpendicular to the outer plate306. The first side plate302, the second side plate304, the outer plate306, the forward plate308, and the aft plate310define a plenum therein. The forward plate308, the aft plate310, and the outer plate306are solid. A side that is opposite to the outer plate306is open and defines a perimeter having a planar surface that is attached to the blade root206. The forward plate308is disposed at the blade root leading edge236and the aft plate310is disposed at the blade root trailing edge238once the manifold300is attached to the blade root206.

The manifold300includes a plurality of divider plates312that divide the manifold300into a plurality of compartments. Each divider plate312of the plurality of divider plates312is solid and perpendicular to the outer plate306. In the construction illustrated inFIG.3, the manifold300includes five divider plates312that divide the manifold300into six compartments including, with respect to the flow direction of the exhaust gas122, a first leading compartment314, a second leading compartment316, a first mid compartment318, a second mid compartment320, a first trailing compartment322, and a second trailing compartment324. In other constructions, the manifold300may have more or less than six compartments.

The first side plate302and the second side plate304define a plurality of apertures326. In the construction shown inFIG.3, the first side plate302defines three apertures326that are open to the first leading compartment314. The second side plate304defines three apertures326that are open to the first leading compartment314. The six apertures326in the first leading compartment314equally contribute to a flow area of the first leading compartment314. The first side plate302defines one aperture326that is open to the second leading compartment316. The second side plate304defines one aperture326that is open to the second leading compartment316. The two apertures326in the second leading compartment316equally contribute a flow area of the second leading compartment316. The first side plate302defines one aperture326that is open to the first mid compartment318. The second side plate304defines one aperture326that is open to the first mid compartment318. The two apertures326in the first mid compartment318equally contribute a flow area of the first mid compartment318. The first side plate302defines six apertures326that are open to the second mid compartment320. The second side plate304defines six apertures326that are open to the second mid compartment320. The twelve apertures326in the second mid compartment320equally contribute a flow area of the second mid compartment320. The first side plate302and the second side plate304in the first trailing compartment322includes no apertures326. The first side plate302defines five apertures326that are open to the second trailing compartment324. The second side plate304defines five apertures326that are open to the second trailing compartment324. The ten apertures326in the second trailing compartment324equally contribute a flow area of the second trailing compartment324. The flow areas of the compartments may be different from each other. In general, the flow areas of the compartments at the blade root leading edge236is larger than the flow areas of the compartments at the blade root trailing edge238. Other constructions could include apertures326that extend through the outer wall328in any direction desired. For example, the apertures326may pass through the outer plate306.

In the construction shown inFIG.3, the flow area of the second leading compartment316is larger than the flow area of the first leading compartment314, the flow area of the first mid compartment318, the flow area of the second mid compartment320, and the flow area of the second trailing compartment324. The flow area of the first mid compartment318is larger than the flow area of the first leading compartment314, the flow area of the second mid compartment320, and the flow area of the second mid second trailing compartment324. The flow area of the first leading compartment314is larger than the flow area of the second mid compartment320and the flow area of the second trailing compartment324. The flow area of the second mid compartment320is larger than the flow area of the second trailing compartment324.

In other constructions, each compartment may have different numbers of apertures326than the manifold300shown inFIG.3. The flow area of each compartment may be different than the manifold300shown inFIG.3. The geometries of the apertures326may be different than the geometries of the apertures326shown inFIG.3.

FIG.4illustrates a perspective exploded view of the manifold300shown inFIG.3. A plurality of gaps402are formed in the first side plate302and the second side plate304. The first side plate302, the second side plate304, and the outer plate306each have a generally rectangular shape. The first side plate302and the second side plate304perpendicularly extend from two sides of the outer plate306. Each of the first side plate302, the second side plate304, and the outer plate306has rounded edges. The first side plate302, the second side plate304, and the outer plate306are formed as a single piece. In other constructions, the first side plate302, the second side plate304, and the outer plate306may be formed as separated pieces and assembled together.

The forward plate308has a general square shape having rounded edges. The forward plate308is perpendicularly welded or brazed to the first side plate302, second side plate304, and the outer plate306.

The aft plate310has a general square shape having rounded edges. The aft plate310is perpendicularly welded or brazed to the first side plate302, second side plate304, and the outer plate306. The aft plate310is thicker than the forward plate308. In other constructions, the aft plate310may be thinner or equal to the forward plate308.

Each divider plate312has a general square shape having rounded edges. Each divider plates312has a cutout404to engage with the outer plate306. Each divider plate312is inserted into one of the gaps402and welded or brazed to the first side plate302, the second side plate304, and the outer plate306.

FIG.5illustrates a perspective view of a manifold500suitable for use with the turbine blade200shown inFIG.2. The manifold500may replace the manifold300shown inFIG.2.

In the construction shown inFIG.5, the forward plate308and the divider plate312are oblique to the outer plate306. It is also possible that the aft plate310is oblique to the outer plate306. It is also possible that is oblique to the outer plate306. The manifold500may be manufactured as a single piece using methods, such as additive manufacture. The manifold500otherwise has the similar configuration as the manifold300.

FIG.6illustrates a perspective view of a manifold600suitable for use with the turbine blade200shown inFIG.2. The manifold600may replace the manifold300shown inFIG.2.

In the construction shown inFIG.6, the apertures326are formed at the outer plate306and the forward plate308. It is also possible that the apertures326are formed at the aft plate310. The manifold500otherwise has the similar configuration as the manifold300.

FIG.7illustrates a portion of a perspective view of the turbine blade200shown inFIG.2that better illustrates the blade root206and the manifold300. The manifold300is aligned with the blade root206with a position pin702that is inserted into the blade root206. The position pin702is inserted into the blade root206through the first trailing compartment322. The manifold300is perimeter welded to a blade root end surface706all around, using, for example, a fillet weld. The outer plate306is spaced a non-zero distance away from the blade root end surface706.

IG.8illustrates a perspective view of a manifold800suitable for use with the turbine blade200shown inFIG.2.

In the construction shown inFIG.8, the manifold800includes a base plate802. The base plate802is one single piece. The first leading compartment314, the second leading compartment316, the first mid compartment318, the second mid compartment320, the first trailing compartment322, and the second trailing compartment324are formed at the base plate802and extend out from the base plate802.

Each of the compartments has a compartment outer wall804. The compartment outer wall804may have a compartment outer plate806that is spaced a non-zero distance away from the base plate802. Apertures326are defined at the compartment outer wall804. As illustrated inFIG.8, the second mid compartment320has at least one aperture326that is formed at the compartment outer wall804of the second mid compartment320. The first trailing compartment322has at least one aperture326that is formed at the compartment outer wall804of the first trailing compartment322. The second trailing compartment324has at least one aperture326that is formed at the compartment outer wall804of the second trailing compartment324. The apertures326are formed at the side plates of the compartment outer wall804. The compartment outer walls804of the first leading compartment314, the second leading compartment316, and the first mid compartment318are solid.

In other constructions, the first leading compartment314, the second leading compartment316, and the first mid compartment318may have at least one aperture326that is formed at the compartment outer wall804of the respective first leading compartment314, the second leading compartment316, and the first mid compartment318. It is also possible that the second mid compartment320, the first trailing compartment322, and the second trailing compartment324are solid. It is also possible that the apertures326are formed at the compartment outer plate806.

FIG.9illustrates a perspective view of a manifold900suitable for use with the turbine blade200shown inFIG.2.

The manifold900has a plurality of base plates. The plurality of base plates are separated pieces from each other. Each of the first leading compartment314, the second leading compartment316, the first mid compartment318, the second mid compartment320, the first trailing compartment322, and the second trailing compartment324is formed at one of the plurality of base plates and extends out from the respective base plate.

For example, in the construction shown inFIG.9, the manifold900has a first base plate902, a second base plate904, and a third base plate906. The first base plate902, the second base plate904, and the third base plate906are separated pieces. The second base plate904is disposed between the first base plate902and the third base plate906. The second base plate904has an arm908that extends out from the second base plate904and engages with a recess910of the third base plate906. In other constructions, the third base plate906may have an arm that extends out from the third base plate906and engages with a recess of the second base plate904. It is also possible that the first base plate902has an arm that extends out from the first base plate902and engages with a recess of the second base plate904, or vise verse.

The first leading compartment314is formed at the first base plate902and extends out from the first base plate902. The second leading compartment316is formed at the second base plate904and extends out from the second base plate904. The first mid compartment318is formed at the third base plate906and extends out from the third base plate906. The first leading compartment314has at least one aperture326that is formed at the compartment outer wall804of the first leading compartment314. The second leading compartment316has at least one aperture326that is formed at the compartment outer wall804of the second leading compartment316. The first mid compartment318has at least one aperture326that is formed at the compartment outer wall804of the first mid compartment318.

Further compartments, such as the second mid compartment320, the first trailing compartment322, and the second trailing compartment324may be each formed at a further base plate. It is possible that at least one of the compartment outer walls804is solid.

FIG.10illustrates a portion of a perspective view of the turbine blade200shown inFIG.2that better illustrates the blade root206and the manifold800.

In the construction shown inFIG.10, the base plate802is attached to the blade root206. The first leading compartment314is inserted into the first leading cooling passage222. The second leading compartment316is inserted into the second leading cooling passage224. The first mid compartment318is inserted into the first mid cooling passage226. The second mid compartment320is inserted into the second mid cooling passage228. The first trailing compartment322is inserted into the first trailing cooling passage230. The second trailing compartment324is inserted into the second trailing cooling passage232. The compartment outer plate806is spaced a non-zero distance away from the blade root end surface706.

The manifold800may be replaced by the manifold900to be attached to the blade root206. Each separated base plate is attached to the blade root206and the compartment that is formed at the base plate is inserted into one of the cooling passages. For example, the first base plate902is attached to the blade root206and the first leading compartment314that is formed at the first base plate902is inserted into the first leading cooling passage222. The second base plate904is attached to the blade root206and the second leading compartment316that is formed at the first base plate902is inserted into the second leading cooling passage224. The third base plate906is attached to the blade root206and the first mid compartment318that is formed at the third base plate906is inserted into the first mid cooling passage226. Further base plates may be attached to the blade root206and further compartments each formed at one of the further base plates may be inserted into one of the second mid cooling passage228, the first trailing cooling passage230, and the second trailing cooling passage232.

In other constructions, the manifold800and manifold900may be attached to the blade root206in a way such that the compartments extend out a non-zero distance away from the cooling passages, respectively.

In operation, with reference toFIG.2throughFIG.10, the manifolds300, the manifold500, the manifold600, the manifold800, or the manifold900is attached to the blade root206with the forward plate308disposed at the blade root leading edge236and the aft plate310disposed at the blade root trailing edge238. Cooling air704enters the manifold and is throttled through the apertures326while entering. By placing the outer plate306or the compartment outer plate806away from the blade root end surface706with a non-zero distance, the cooling air704enters and is mixed in the first leading compartment314, the second leading compartment316, the first mid compartment318, the second mid compartment320, and the second trailing compartment324before entering the first leading cooling passage222, the second leading cooling passage224, the first mid cooling passage226, the second mid cooling passage228, and the second trailing cooling passage232, respectively. The compartments create a plenum for the cooling air704before flowing into the cooling passages. The manifold is thus functioned as a flow conditioner such that the inlets of the cooling passages are shielded from throttling disturbance that may be created by the various apertures326. The uniform and diffused cooling air704reduces asymmetric heat transfer.

The cooling air704enters the manifold300, or the manifold500from the first side plate302and the second side plate304which generate effective mixing before entering the cooling passages. The cooling air704turns 90 degrees in the compartments and flows into the cooling passages to reduce the cooling air704bias from the downstream side to the upstream side.

The first leading compartment314meters a non-zero first flow of cooling air704to the first leading cooling passage222through the flow area of the apertures326in the first leading compartment314. The second leading compartment316meters a non-zero second flow of cooling air704to the second leading cooling passage224through the flow area of the apertures326in the second leading compartment316. The first mid compartment318meters a non-zero third flow of cooling air704to the first mid cooling passage226through the flow area of the apertures326in the first mid compartment318. The second mid compartment320meters a non-zero fourth flow of cooling air704to the second mid cooling passage228through the flow area of the apertures326in the second mid compartment320. The first trailing compartment322has no apertures326so that the cooling air704is blocked from entering the first trailing cooling passage230. The second trailing compartment324meters a non-zero fifth flow of cooling air704to the second trailing cooling passage232through the apertures326in the second trailing compartment324. The non-zero first flow of cooling air704, the non-zero second flow of cooling air704, the non-zero third flow of cooling air704, the non-zero fourth flow of cooling air704, and the non-zero fifth flow of cooling air704rmay be different from each other.

Discrete throttling control (i.e., by selecting aperture flow areas) of the flow of cooling air704that flows to each cooling passage is achieved by different arrangements of the compartments. In general, the flow areas of the apertures326in the compartments at the blade root leading edge236is larger than the flow areas of the apertures326in the compartments at the blade root trailing edge238. For example, in manifold300and manifold500, the flow area of the apertures326in the second leading compartment316and the flow area of the apertures326in the first mid compartment318is larger than the flow area of the apertures326in the first leading compartment314, the flow area of the apertures326in the second mid compartment320, and the flow area of the apertures326in the second trailing compartment324. As such, the cooling air704is the least throttled in the second leading compartment316and the first mid compartment318than in the first leading compartment314, the second mid compartment320, and the second trailing compartment324. The first trailing compartment322has no apertures326such that the cooling air704is blocked from entering the first trailing cooling passage230.

The manifolds better controls the cooling air704flowing into the cooling passages which allows more accurate prediction for the life of the blade. In addition, the manifolds assist in reducing leakages of the cooling air704.