COMBUSTION STAGING SYSTEM
20170241346 · 2017-08-24
Assignee
Inventors
Cpc classification
F02C7/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C9/26
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/301
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/228
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F05D2270/31
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/224
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02C7/228
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/224
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A combustion staging system includes a splitting unit receiving a metered fuel flow and controllably splitting the received flow into pilot and mains flows. Pilot and mains fuel manifolds distribute fuel. A cooling flow recirculation line provides a cooling flow to the mains manifold during pilot-only operation, and a return section to collect mains manifold cooling flow. The cooling flow enters a delivery section and exits the return section. A fuel recirculating control valve on the delivery section has an open position so that the cooling flow enters the delivery section during pilot-only operation; a shut off position prevents the cooling flow entering the delivery section through the cooling flow orifice during pilot and mains operation. A supplementary valve bleeds or feeds cooling flow. The mains manifold cooling flow pressure is determined by the cooling flow and pressure raising orifices flow numbers, and a control setting of the supplementary valve.
Claims
1. A combustion staging system for fuel injectors of a multi-stage combustor of a gas turbine engine, the system including: a splitting unit which receives a metered fuel flow and controllably splits the received fuel flow into pilot and mains flows for injecting respectively at pilot and mains fuel stages of the injectors to perform staging control of the combustor; and pilot and mains fuel manifolds respectively distributing fuel from the splitting unit to the pilot and mains stages; wherein the splitting unit is operable to select the pilot manifold and deselect the mains manifold for pilot-only operation in which there is a pilot flow but no mains flow from the splitting unit, and is operable to select both the pilot and mains manifolds for pilot and mains operation in which there are pilot and mains flows from the splitting unit; wherein the system further includes a cooling flow recirculation line having a delivery section arranged to provide a cooling flow of fuel to the mains manifold when it is deselected during pilot-only operation so that the deselected mains manifold remains primed with relatively cool fuel, and a return section arranged to collect the cooling flow from the mains manifold; wherein the cooling flow enters the delivery section from a high pressure fuel zone of the engine at a cooling flow orifice and exits the return section to a low pressure fuel zone of the engine at a pressure raising orifice; wherein the system further includes a fuel recirculating control valve on the delivery section adjacent the cooling flow orifice, the fuel recirculating control valve having an open position so that the cooling flow enters the delivery section at the cooling flow orifice during pilot-only operation, and a shut off position which prevents the cooling flow entering the delivery section through the cooling flow orifice during pilot and mains operation; wherein the system further includes a supplementary valve which is controllable to bleed cooling flow from the recirculation line or feed additional cooling flow into the recirculation line; and wherein the pressure of the cooling flow in the mains manifold is determined by the respective flow numbers of the cooling flow orifice and the pressure raising orifice, and a control setting of the supplementary valve.
2. A combustion staging system according to claim 1, further including a controller which controls the setting of the supplementary valve to meet a target fuel pressure in the mains manifold.
3. A combustion staging system according to claim 2, wherein the controller selects a target pressure which ensures that the mains manifold fuel pressure remains above gas pressure in the combustor.
4. A combustion staging system according to claim 2, further including a pressure sensor which measures the mains manifold fuel pressure, the controller performing feedback control based on the measured pressure to meet the target fuel pressure.
5. A combustion staging system according to claim 1, wherein the supplementary valve is a servo-valve which is configured to bleed/feed continuously variable amounts of cooling flow.
6. A combustion staging system according to claim 1, wherein the supplementary valve bleeds/feeds cooling flow from/into the recirculation line adjacent the pressure raising orifice.
7. A combustion staging system according to claim 1, wherein the supplementary valve is integrated with the splitting unit.
8. A combustion staging system according to claim 1, further including a recirculating flow return valve on the return section adjacent the pressure raising orifice, the recirculating flow return valve having an open position so that the cooling flow exits the return section at the pressure raising orifice during pilot-only operation, and a shut off position which prevents the cooling flow exiting the return section through the pressure raising orifice during pilot and mains operation.
9. A combustion staging system according to claim 1, wherein the splitting unit is configured to divert a portion of the mains flow into the delivery section during pilot and mains operation, the diverted portion re-joining the rest of the mains flow in the mains fuel stages of the injectors.
10. A combustion staging system according to claim 9, wherein the splitting unit has a slidable spool, the position of the spool determining the flow split between an outlet of the splitting unit to the pilot manifold, an outlet of the splitting unit to the mains manifold, and an outlet of the splitting unit to the delivery section of the cooling flow recirculation line.
11. A combustion staging system according to claim 1, wherein the delivery section includes a delivery manifold which distributes the cooling flow to the injectors en route to the mains manifold.
12. A combustion staging system according to claim 1, wherein the fuel injectors have integrated mains check valves which are arranged to open when the fuel pressure within the mains manifold exceeds a predetermined fuel pressure relative to gas pressure in the combustor.
13. A combustion staging system according to claim 1, wherein the pilot manifold includes a segment restrictable by a lean blow out protection valve to decrease the proportion of a pilot fuel flow delivered to the injectors fed by the segment relative to the total pilot fuel flow delivered to all the injectors of the combustor.
14. A gas turbine engine having the combustion staging system according to claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:
[0042]
[0043]
[0044]
[0045]
[0046]
[0047]
[0048]
DETAILED DESCRIPTION AND FURTHER OPTIONAL FEATURES
[0049] With reference to
[0050] During operation, air entering the intake 11 is accelerated by the fan 12 to produce two air flows: a first air flow A into the intermediate-pressure compressor 13 and a second air flow B which passes through the bypass duct 22 to provide propulsive thrust. The intermediate-pressure compressor 13 compresses the air flow A directed into it before delivering that air to the high-pressure compressor 14 where further compression takes place.
[0051] The compressed air exhausted from the high-pressure compressor 14 is directed into the combustion equipment 15 where it is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the high, intermediate and low-pressure turbines 16, 17, 18 before being exhausted through the nozzle 19 to provide additional propulsive thrust. The high, intermediate and low-pressure turbines respectively drive the high and intermediate-pressure compressors 14, 13 and the fan 12 by suitable interconnecting shafts.
[0052] The engine has a pumping unit comprising a low pressure (LP) pumping stage which draws fuel from a fuel tank of the aircraft and and supplies the fuel at boosted pressure to the inlet of a high pressure (HP) pumping stage. The LP stage typically comprises a centrifugal impeller pump while the HP pumping stage may comprise one or more positive displacement pumps, e.g. in the form of twin pinion gear pumps. The LP and HP stages are typically connected to a common drive input, which is driven by the engine HP or IP shaft via an engine accessory gearbox.
[0053] A fuel supply system then accepts fuel from the HP pumping stage for feeds to the combustor 15 of the engine 10. This system typically has a hydro-mechanical unit (HMU) comprising a fuel metering valve operable to control the rate at which fuel is allowed to flow to the combustor. The HMU further typically comprises: a pressure drop control arrangement (such as a spill valve and a pressure drop control valve) which is operable to maintain a substantially constant pressure drop across the metering valve, and a pressure raising and shut-off valve at the fuel exit of the HMU which ensures that a predetermined minimum pressure level is maintained upstream thereof for correct operation of any fuel pressure operated auxiliary devices (such as variable inlet guide vane or variable stator vane actuators) that receive fuel under pressure from the HMU. Further details of such an HMU are described in EP 2339147 A.
[0054] An engine electronic controller (EEC) commands the HMU fuel metering valve to supply fuel to the combustor at a given flow rate. The metered fuel flow leaves the HMU and arrives at a staging system 30, shown schematically in
[0055] The staging system 30 splits the fuel into two flows: one at a pressure P.sub.p for first 31a and second 31b segments of a pilot manifold and the other at a pressure P.sub.m for a mains manifold 32. Fuel injectors 33 of a combustor of the engine are split into two groups. The injectors of one group are connected to the first pilot manifold segment 31a, while the injectors of the other group are connected to the second pilot manifold segment 31b. The mains manifold feeds secondary nozzles of the fuel injectors. Pilot weight distributor valves (WDVs—discussed in more detail below) 39 at the injectors improve injector-to-injector fuel distribution by compensating for the pilot manifold pressure head, while mains flow scheduling valve (FSVs) 40 at the injectors retain a primed mains manifold when de-staged and at shut-down.
[0056] A fuel flow splitting valve (FFSV) 34 receives the metered fuel flow from the HMU at pressure P.sub.fmu. A spool is slidable within the FFSV under the control of a servo-valve 35, the position of the spool determining the outgoing flow split between outlets to, respectively, a pilot connection pipe 36 which delivers fuel to the pilot manifold segments 31a, b, a mains connection pipe 37 which delivers fuel to the mains manifold 32, and a delivery pipe 41 of a recirculation line (discussed below). The spool can be positioned (as shown in
[0057] Between the FFSV 34 and the second pilot manifold segment 31b, the pilot connection pipe 36 communicates with a lean blow out protection valve 50 which controls communication between the pilot connection pipe 36 and the second pilot manifold segment 31b. The lean blow out protection valve is spring biased towards an open position. A solenoid operated control valve 52 is operable to apply a control pressure to the valve member of the lean blow out protection valve to move it against the action of the spring biasing to a closed position, restricting the communication between the pilot connection pipe 36 and the second pilot manifold segment 31b, when required.
[0058] The recirculation line provides the mains manifold 32 with a cooling flow of fuel when the mains manifold is deselected in pilot-only operation mode (as shown in
[0059] In addition, the recirculation line has a return section which collects the returning cooling flow from the mains manifold 32. The return section is formed by a portion of the mains connection pipe 37 and a branch pipe 44 from the mains connection pipe, the branch pipe extending to a recirculating flow return valve (RFRV) 45 from whence the cooling flow exits the recirculation line through a pressure raising orifice (PRO) 47.
[0060] At entry to the CFO 46, the cooling flow for the recirculation line (obtained from the HMU) is at a high pressure HP.sub.f, and after exiting from the PRO 47 is returned to the pumping unit at a lower pressure LP for re-pressurisation by the HP pumping stage. Between the CFO and the PRO, the cooling flow in the mains manifold 32 is at an intermediate pressure, measured by a pressure sensor 58. Fine control of this pressure is performed by a supplementary valve 57 termed a mains manifold pressure control valve (MMPCV), the control of which is discussed in more detail below. A check valve 48 accommodates expansion of fuel trapped in the mains system during shutdown. The FRCV 42 and the RFRV 45 are operated under the control of the EEC. The HMU also supplies fuel at pressure HP.sub.f for operation of the servo-valve 35 and the RFRV 45.
[0061] During pilot-only operation (
[0062] If one of the mains FSVs 40 fails open, the FRCV 42 can be closed so that no fuel is directed through the recirculation manifold 43. Thus there is no leakage through the failed valve into the combustion chamber during pilot-only operation, although the cooling effect of the recirculation manifold is therefore sacrificed.
[0063] In a windmill relight situation the FRCV 42 can also be closed so that no fuel is directed through the recirculation manifold 43 during pilot-only operation. Instead all the flow is directed through the segments 31a, b of the pilot manifold, which increases the available fuel for relight.
[0064] A failure mode associated with the system of
[0065] Advantageously, in the system of
[0066] The pilot WDVs 39 have a relatively low crack pressure and open fully at a low fuel flow, so that the difference between a failed open WDV and a correctly-functioning WDV is small. If one fails open it still works the same as an FSV in that as one is taking most of the flow, the flow through the others is reduced. However, as the WDVs are fully open at a much lower flow rate than FSVs it is possible to re-open the other WDVs more quickly, thereby avoiding hot streaks.
[0067] The staging system 30 has a balancing pressure check valve (BPCV) 54 on the pilot connection pipe 36. The BPCV maintains a pressure balance relative to the pressure in the mains manifold 32 for improved split control of the received fuel flow by the FFSV 34. More particularly, adopting the pilot WDVs 39 changes the fuel flow restriction to the injectors, potentially affecting the fuel flow split control. However, the BPCV cooperates with the mains FSVs 40 to maintain the necessary pressure balance, for example, during the pilot and mains operating mode illustrated in
[0068] Locating the BPCV 54 upstream of the lean blow out protection valve 50 provides a flatter over-fuelling ratio to the injectors of the first pilot manifold segment 31a in the event of a lean bow out, making the engine more robust to engine flame-out during slam decelerations.
[0069] The BPCV 54 can also accommodate back-purge of the pilot manifold segments 31a, b via a back purge non-return valve 56 (although, alternatively, a direct line to a dump valve of the HMU and thence to a drains tank may be used).
[0070] Returning to the control of the fuel pressure in the mains manifold 32 during pilot-only operation,
[0071] Between these two limits, in the flow rate range from zero to about 13000 pph (5900 kg/h), a preferred design space (corresponding approximately to the shaded grey triangle in
[0072]
[0073] The following considerations are used to determine the position of the MMPCV servo-valve 57. If 165 psid (1.14 MPa) is the minimum pressure at which the mains FSVs 40 will seal, then a maximum pressure (P.sub.manifold.sub._.sub.high) for the mains manifold fuel pressure can be set at:
P.sub.manifold.sub._.sub.high=P30 +165 psid−10%×P.sub.manifold.sub._.sub.high
whereby P.sub.manifold.sub._.sub.high=(P30 +165 psid)/110%
and a minimum pressure (P.sub.manifold.sub._.sub.low) for the mains manifold fuel pressure can be set at:
P.sub.manifold.sub._.sub.low=P30 +15%×P.sub.manifold.sub._.sub.low
whereby P.sub.manifold.sub._.sub.low=P30/85%
the 10% and 15% values being respectively the expected high and low system pressure ripple amplitude as a percentage of the pressure in the manifold. Accordingly, the exact percentages may vary between implementations. Similarly, different minimum pressures than 165 psid may be applicable for different FSVs. On
[0074] The MMPCV 57 can be controlled by the EEC, which selects the higher of P.sub.manifold.sub._.sub.high and P.sub.manifold.sub._.sub.low to ensure it meets the above requirements. Thus the EEC controls the MMPCV to operate such that the mains manifold fuel pressure follows the thick dashed line (P.sub.manifold.sub._.sub.high) until the lines cross at around 11000 pph (5000 kg/h), and thereafter follows the solid thick line (P.sub.manifold.sub._.sub.low). Below the LSL (triangular data points) there is a potential for combustion chamber gases to be ingested, which is a safety hazard. Above the USL (square data points) unmetered fuel can dribble into the combustion chamber, which increases coking and decreases component life but is not a safety hazard. Thus this control strategy avoids gas ingestion, even if at the expense of some dribble (e.g. at flow rates above about 13000 pph outside the preferred design space), but prevents dribble where possible.
[0075] Thus the EEC can calculate a respective flow number for the MMPCV 57 required for each operating condition based on the target pressure, the estimated HP and LP pressures, and the flow numbers of the CFO 46 and the PRO 47. The EEC then sets the servo-valve current of the MMPCV 57 based on its nominal characteristic to achieve that flow number. Moreover, the EEC can use feedback from the pressure sensor to compensate for variation in servo-valve characteristics, leakage through the FFSV 34, and variation in CFO and PRO characteristics by setting a trimming current. When there is a switch to pilots and mains operation (e.g. when there is no longer a need to control pressure in the mains manifold 32), the trim current can be stored for use when the system reverts to pilot-only operation. In
[0076] Advantageously, the variable orifices 60 of the MMPCV servo-valve 57 provide for precise control of the MMPCV flow number, and hence control of the pressure drop across the PRO 47. This tight control of the mains manifold pressure makes the selection of the CFO 46 and PRO and the manufacture of the FFSV 34 less critical. An option is to replace the servo-valve with e.g. a solenoid (switching) type valve. Such a device would not provide the variable pressure control of the servo-valve, but rather two-position fixed pressure switching. Another option is to replace the servo-valve with a modification to the FFSV 34 in which the FFSV spool is lengthened and provided with additional ports to the HP feed and the LP return that can be used to pressurise/depressurise the mains manifold 32. Thus according to this option, the supplementary valve which performs fine control of mains manifold pressure can be integrated into the FFSV.
[0077] An additional advantage of the MMPCV servo-valve 57 is that the servo-valve port can be selected so that, in the event of loss of power to the servo-valve, the valve tends to supply HP fuel into the mains manifold 32, preventing P30 gas ingestion. The PRO 47 can then be sized accounting for the minimum zero current flow (the minimum flow which can be delivered when there is zero control current supplied to the servo valve) to ensure the manifold pressure never falls below the LSL preventing P30 ingestion even in a failure case. Sizing the PRO in this way helps to maximise the used capacity of the MMPCV servo-valve, while ensuring the ingestion requirement is always met. Making the PRO any smaller, while raising the manifold pressure further, tends not to be beneficial as the MMPCV then has to be capable of bleeding more flow from the manifold at the maximum pressure conditions.
[0078] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
[0079] All references referred to above are hereby incorporated by reference.