Turbine stator vane and/or turbine rotor vane with a cooling flow adjustment feature and corresponding method of adapting a vane

Abstract

A turbine stator vane or turbine rotor vane has a body, a channel being adapted for leading a cooling fluid through the body, and a flow adaption feature protruding from the body to the channel in such a manner as to reduce a cross-sectional area of the channel.

Claims

1. A method of manufacturing a vane, the vane comprising a root part, an aerofoil and a cooling channel extending through at least the root part, the cooling channel is defined by a wall and comprises a flow adaption feature, the method comprising: determining a first desired coolant mass flow for the cooling channel that is suitable for operation of the vane at a first operating level in a gas turbine engine, determining an oversized flow area of the cooling channel that is 105% to 200% greater than a flow area of the cooling channel required to achieve the first desired coolant mass flow, forming the vane comprising the cooling channel comprising the oversized flow area and comprising the flow adaption feature as an inlet of the cooling channel, wherein the inlet is disposed within the root part, and wherein the flow adaption feature partly occludes an inlet opening of the cooling channel to an initial and nominal flow area (Ai) which is less than the flow area of the cooling channel required to achieve the first desired coolant mass flow, testing a mass flow rate of coolant passing through the cooling channel to find an actual mass flow, determining an increase in area of the flow adaption feature needed to achieve the first desired coolant mass flow based on the actual mass flow, and machining the flow adaption feature to increase the inlet opening to achieve the first desired coolant mass flow.

2. The method of manufacturing a vane as claimed in claim 1, wherein the initial and nominal flow area (Ai) of the flow adaption feature is between 75% and 98% of the flow area required to achieve the first desired coolant mass flow.

3. The method of manufacturing a vane as claimed claim 1, wherein the determining step comprises calibrating the vane to find a relationship between the initial and nominal flow area (Ai) of the inlet opening and a setting value, by supplying coolant through the cooling channel by varying the setting value, and measuring an observation value and comparing the observation value to a target value, wherein the setting value is a mass flow through the cooling channel and the observation value is a seed pressure at the inlet opening of the cooling channel or the setting value is the seed pressure at the inlet opening of the cooling channel and the observation value is the mass flow through the cooling channel.

4. The method of manufacturing a vane as claimed in claim 1, further comprising: wherein the determining step comprises calibrating the vane to find a relationship between the initial and nominal flow area (Ai) of the inlet opening and a setting value, by supplying coolant through the cooling channel by varying the setting value, measuring an observation value and comparing the observation value to a target value, removing part or all of the flow adaption feature so as to enlarge a cross-sectional area of the inlet opening, and repeating the steps until the observation value corresponds to the first desired coolant mass flow, wherein the setting value is a mass flow through the cooling channel and the observation value is a seed pressure at the inlet opening of the cooling channel or the setting value is the seed pressure at the inlet opening of the cooling channel and the observation value is the mass flow through the cooling channel.

5. The method of manufacturing a vane as claimed in claim 1, wherein the vane comprises a nominal thermal-life greater than a nominal corrosion-life, the nominal thermal-life comprising the flow area required to achieve the first desired coolant mass flow, the method further comprising: forming the initial and nominal area (Ai) of the inlet opening between 50% and 90% of the flow area required to achieve the first desired coolant mass flow.

6. A vane for a gas turbine engine, the vane comprising: a root part, an aerofoil, and a cooling channel extending through at least the root part, wherein the cooling channel is defined by a wall and comprises a flow area that is 105% to 200% greater than a flow area required to achieve a first desired coolant mass flow and a flow adaption feature as an inlet of the cooling channel, wherein the inlet is disposed within the root part, and wherein the flow adaption feature partly occludes an inlet opening of the cooling channel to an initial and nominal flow area (Ai) and which is less the flow area required to achieve a first desired coolant mass flow in the cooling channel that is suitable for operation of the vane in the gas turbine engine.

7. The vane as claimed in claim 6, wherein the initial and nominal flow area (Ai) of the flow adaption feature is between 75% and 98% of the flow area required to achieve the first desired coolant mass flow.

8. The vane as claimed in claim 6, further comprising: a platform between the root part and the aerofoil, wherein the platform and/or the aerofoil comprise cooling passages which extend from the cooling channel.

9. The vane as claimed in claim 6, wherein the root part comprises a root base surface and the inlet opening is formed in the root base surface.

10. The vane as claimed in claim 6, wherein the flow adaption feature is integrally formed with the vane during initial casting, sintering or deposition forming.

11. The vane as claimed in claim 9, wherein the root base surface comprises a radially inward root base surface.

12. The method of manufacturing a vane as claimed in claim 1, wherein the first operating level is at least base engine design.

13. A method of manufacturing a vane assembly comprising a plurality of vanes, each vane comprising a root part, an aerofoil and a cooling channel extending through at least the root part, wherein the cooling channel is defined by a wall and comprises a flow adaption feature, the method comprising: determining an average first desired coolant mass flow for each vane of the plurality of vanes that is suitable for operation of the plurality of vanes at a first operating level in a gas turbine engine, determining for each vane an oversized flow area of the cooling channel that is 105% to 200% greater than a flow area of the cooling channel required to achieve the average first desired coolant mass flow, forming each vane comprising the cooling channel comprising the oversized flow area and comprising the flow adaption feature as an inlet of the cooling channel, wherein the inlet is disposed within the root part, and, wherein the flow adaption feature partly occludes an inlet opening of the cooling channel to an initial and nominal flow area (Ai) which is less than the flow area of the cooling channel required to achieve the average first desired coolant mass flow, testing a mass flow rate of coolant passing through the plurality of vanes to find an actual mass flow, determining an average machining requirement of each flow adaption feature needed to achieve the average first desired coolant mass flow based on the actual mass flow, and machining each flow adaption feature to increase the inlet opening to achieve the average first desired coolant mass flow.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows part of a turbine engine in a sectional view and in which the present invention is incorporated,

(2) FIG. 2 illustrates a cross-sectional view of a lower part of a turbine rotor vane including a root part of the body at which flow adjustment features are formed,

(3) FIG. 3 illustrates a cross-sectional view of a lower part of a further embodiment of a turbine rotor vane with further flow adjustment features,

(4) FIG. 4 illustrates a view on arrow A in FIG. 2 and shows the root base surface and extent of the flow adaption feature,

(5) FIG. 5 illustrates a similar view on arrow A in FIG. 2, but instead shows a second embodiment of the flow adaption feature,

(6) FIG. 6 illustrates a similar view on arrow A in FIG. 2, but instead shows a second embodiment of the flow adaption feature, and

(7) FIG. 7 illustrates an embodiment of a method for adapting a turbine stator vane or turbine rotor vane.

DETAILED DESCRIPTION OF INVENTION

(8) Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views.

(9) FIG. 1 shows an example of a gas turbine engine 110 in a sectional view. The gas turbine engine 110 comprises, in flow series, an inlet 112, a compressor section 114, a combustor section 116 and a turbine section 118 which are generally arranged in flow series and generally about and in the direction of a longitudinal or rotational axis 120. The gas turbine engine 110 further comprises a shaft 122 which is rotatable about the rotational axis 120 and which extends longitudinally through the gas turbine engine 110. The shaft 122 drivingly connects the turbine section 118 to the compressor section 114.

(10) In operation of the gas turbine engine 110, air 124, which is taken in through the air inlet 112 is compressed by the compressor section 114 and delivered to the combustion section or burner section 116. The burner section 116 comprises a burner plenum 126, one or more combustion chambers 128 and at least one burner 130 fixed to each combustion chamber 128. The combustion chambers 128 and the burners 130 are located inside the burner plenum 126. The compressed air passing through the compressor 114 enters a diffuser 132 and is discharged from the diffuser 132 into the burner plenum 126 from where a portion of the air enters the burner 130 and is mixed with a gaseous or liquid fuel. The air/fuel mixture is then burned and the combustion gas 134 or working gas from the combustion is channelled through the combustion chamber 128 to the turbine section 118 via a transition duct 117.

(11) This exemplary gas turbine engine 110 has a cannular combustor section arrangement 116, which is constituted by an annular array of combustor cans 119 each having the burner 130 and the combustion chamber 128, the transition duct 117 has a generally circular inlet that interfaces with the combustion chamber 128 and an outlet in the form of an annular segment. An annular array of transition duct outlets form an annulus for channelling the combustion gases to the turbine section 118.

(12) The turbine section 118 comprises a number of blade carrying discs 136 attached to the shaft 122. In the present example, two discs 136 each carry an annular array of turbine blades 138. However, the number of blade carrying discs could be different, i.e. only one disc or more than two discs. In addition, guiding vanes 140, which are fixed to a stator 142 of the gas turbine engine 110, are disposed between the stages of annular arrays of turbine blades 138. Between the exit of the combustion chamber 128 and the leading turbine blades 138 inlet guiding vanes 144 are provided and turn the flow of working gas onto the turbine blades 138.

(13) The combustion gas from the combustion chamber 128 enters the turbine section 118 and drives the turbine blades 138 which in turn rotate the shaft 122. The guiding vanes 140, 144 serve to optimise the angle of the combustion or working gas on the turbine blades 138.

(14) The turbine section 118 drives the compressor section 114. The compressor section 114 comprises an axial series of vane stages 46 and rotor blade stages 48. The rotor blade stages 48 comprise a rotor disc supporting an annular array of blades. The compressor section 114 also comprises a casing 50 that surrounds the rotor blade stages 48 and supports the vane stages 46. The guide vane stages include an annular array of radially extending vanes that are mounted to the casing 50. The vanes are provided to present gas flow at an optimal angle for the blades at a given engine operational point. Some of the guide vane stages have variable vanes, where the angle of the vanes, about their own longitudinal axis, can be adjusted for angle according to air flow characteristics that can occur at different engine operations conditions.

(15) The casing 50 defines a radially outer surface 152 of the passage 156 of the compressor 114. A radially inner surface 154 of the passage 156 is at least partly defined by a rotor drum 153 of the rotor which is partly defined by the annular array of blades.

(16) The present invention is described with reference to the above exemplary turbine engine having a single shaft or spool connecting a single, multi-stage compressor and a single, one or more stage turbine. However, it should be appreciated that the present invention is equally applicable to two or three shaft engines and which can be used for industrial, aero or marine applications.

(17) The terms upstream and downstream refer to the flow direction of the airflow and/or working gas flow through the engine unless otherwise stated. The terms forward and rearward refer to the general flow of gas through the engine. The terms axial, radial and circumferential are made with reference to the rotational axis 120 of the engine.

(18) FIG. 2 illustrates an embodiment of a turbine rotor vane or turbine stator vane, referred to as vane 61 and which may be any one or more of the vanes 144, 140 or blades 138 described with reference to FIG. 1. Vane 61 has a root part 62 and a body or aerofoil 74 through which a channel 63 for cooling vane 61 extends. From the root part 62, flow adaption features 64 protrude into the channel 63 in such a manner as to reduce a cross-sectional area of channel 63. In particular, the flow adaption feature(s) 64 protrude at an inlet opening 73 of channel 63 so as to reduce the cross-sectional area of the inlet opening 73. The protrusions 64 are formed as integral parts of the root part 62, enlarging a root base surface 65 of root part 62 in a direction occluding the inlet opening 73 of channel 63. The vane 61 has a platform 75 situated between the root part 62 and the aerofoil 74.

(19) Due to the arrangement of the protrusions at the inlet opening 73 of channel 63, the flow adaption feature 64 is easily reachable for a calibration and machining of vane 61 by partly or entirely removing the flow adaption feature 64, e.g. by machining. Thus the flow adaption feature 64 allows an easy calibration of vane 61, in particular in view of a cooling demand e.g. in view of an intended firing or operating temperature, a type of turbine or field of application in which vane 61 is to be used. Thus, cooling fluid use is minimised and an engine's overall efficiency is maximized, while prescribed temperature conditions are met.

(20) FIG. 3 illustrates a further embodiment of root part 62 of vane 61, wherein the flow adaption features 64 are formed of a material specifically adapted for a selective removal. Thus, vane 61 may be easily adapted in view of varying cooling demands. The flow adaption feature 64 is in the form of a disc having a generally rectangular cross-sectional shape as shown. Other cross-sectional shapes are possible. The radially outer edge or surface of the disc integrally blends into the channel walls 76 and the radially inner edge or surface defines the inlet opening 73 and its area Ai. The channel 63 has an area Ac such that complete removal of the flow adaption feature 64, Ac=Ai. The flow adaption feature 64 extends a distance d from the channel wall 76. In this embodiment the flow adaption feature 64 has an initially-manufactured constant extension d from the channel wall 76.

(21) The term initially manufactured means the cast shape of the vane or where other manufacturing methods are used such as laser sintering or laser deposition, it is the vane's shape formed by that process. It is possible that the initially-manufactured form of the vane may comprise a dressing process to remove casting or laser forming irregularities or imperfections such as sharp edges, pips and dimples as known in the art. A plate welded on to the vane is a step after initial manufacturing. Similarly, in this context the term integral or integrally formed means that the flow adaption feature is formed during the initial manufacturing process and is part of the casting, sintering or laser deposition process of the vane.

(22) The inlet opening 73 has an initial and nominal flow area Ai and which is less than a flow area for a first desired coolant mass flow. When designing the vane its cooling system, typically comprising cooling passages in the aerofoil and/or platform, is designed to transport a design or desired coolant mass flow to keep the vane's temperature to acceptable levels. However, for the present vane 61, the inlet opening 73 is initially manufactured with a smaller flow area Ai than a design or desired flow area and therefore all or a high percentage of all vanes will require the inlet opening 73 machining to increase its flow area to allow the design mass flow to pass into the vane. For a low percentage of initially manufactured vanes, manufacturing tolerances may mean that these few vanes will not require the inlet opening 73 machining.

(23) In the present exemplary embodiment, the vane is initially manufactured such that the initial and nominal flow area Ai of the flow adaption feature 64 is between 75% and 98% of the flow area required for the first desired or design coolant mass flow. Thus, in nominal terms a high percentage, e.g. 98% of the vanes will have their inlet opening area increased before use. Not only does this ensure that the minimum amount of coolant is used, but also that the scrap rate of vanes is also reduced because initially manufactured vanes having worst-case tolerances can be remedied by significant increases in the inlet opening area Ai to increase coolant flow to the design mass flow rate or even higher to ensure all the vane is adequately cooled.

(24) In a further embodiment, the cooling channel 63 is initially manufactured having a flow area Ac which is greater than the flow area for the first desired or design coolant mass flow. In particular the initially manufactured flow area Ac is between 105% and 200% the flow area for the first desired or design coolant mass flow. Thereby, the vane is capable of being used in second condition which can be either a hotter environment, such as a different gas turbine engine or an upgraded gas turbine engine, or where the life improvement is desired.

(25) Yet further, in a circumstance where the life of the vane is limited by corrosion e.g. sulphate attack, then the mass coolant flow can be minimised such that the thermal degradation or thermal-life is also relaxed to the corrosion-life whereby the coolant mass flow is reduced from the coolant mass flow based on the vane's nominal thermal-life expectancy. In other words, the corrosion-life limited vane has less coolant and operates at a higher metal temperature. This reduces the thermal-life of the vane, but only to the extent of the corrosion life of the vane. In this case the initial manufacture of the flow adaption feature 64 has an initial and nominal inlet opening up to 50% of the design or desired area for a coolant mass flow of based on a nominal thermal-life.

(26) FIG. 4 is a view on arrow A in FIG. 2 and shows the root part's 62 base surface 65. The inlet opening 73 is shown here as a general oval shape, but could be any other shape. The flow adaption feature 64 has a constant extent d into the aperture formed by the inlet opening 73. The wall 76 of the cooling channel 63 is shown in dashed lines.

(27) In FIG. 5 is a similar view to FIG. 4 and shows a third embodiment of the flow adaption feature 64. However, here the flow adaption feature 64 does not have a constant extent d into the cooling channel and forming the inlet opening 73. At the forward part or left hand side the flow adaption feature 64 has a greater extent d2 than elsewhere indicated by d1.

(28) FIG. 6 is a similar view to FIG. 4 and shows a fourth embodiment of the flow adaption feature 64. However, the flow adaption feature 64 does not have a constant extent d into the aperture formed by the inlet opening 73. Instead there are two separate sections to the flow adaption feature indicated by 64a and 64b. Here the generally oval cooling channel 63 has an inlet opening 73 formed partly by the channel wall 76 itself and partly by the fore and aft flow adaption feature regions 64a, 64b. The fore flow adaption feature 64a is show on the left hand side of the figure. The fore and aft flow adaption features 64a, 64b need not be the same size and nor do they necessarily require the same machining when the inlet area Ai is increased.

(29) In FIG. 7, an embodiment of a method for adapting a vane, e.g. vane 61, is illustrated. The method has optional steps, illustrated by dashed rectangles, and a mandatory step, illustrated by a continuous rectangle.

(30) After a beginning 6 of the method, a target turbine may be determined at 7 for vane 61, e.g. a turbine in which vane 61 is intended to be mounted. At 8, a target cross-sectional area of the channel may be determined in accordance with a cooling demand, which cooling demand may depend on a firing temperature of the target turbine, a life requirement of the vane or target turbine and/or on an intended field of application. At 9, the flow adaption feature 64 is partly or entirely removed so as to enlarge the cross-sectional area of the inlet opening of cooling channel 63. In particular, the removing may be performed such that the cross-sectional area of the inlet opening of channel 63 may essentially correspond to the target cross-sectional area of channel 63 as determined at 8. At 10, vane 61 may be mounted in the target turbine as determined at 7. At 11, a cooling fluid may be supplied through cooling channel 63 e.g. by varying a setting value. Further, an observation value may be measured and compared to a target value. Depending on a result of the comparison, the method may end at 12 if a sufficient calibration of vane 61 has been achieved, or may be continued e.g. by repeating steps 7 to 11.

(31) Steps 7 to 11 may be repeated until the observation value corresponds to a cooling demand. Thereby, an accurate adaption may be achieved, allowing to exactly determine the cooling flow for an intended application.

(32) In another embodiment of the present method of manufacturing the vane 61, the inlet opening 73 is formed having an initial and nominal flow area Ai and that is less than a flow area for first desired coolant mass flow. The vane is then tested for its mass flow rate of coolant passing through the cooling channel 63 to find an actual mass flow. From a calibration relationship, fluid flow theory or by retesting an increase in area of the flow adaption feature 64 is determined to achieve the desired coolant mass flow. The flow adaption feature 64 is then machined to increase the inlet opening 73 area to achieve the desired or design mass flow. The design mass flow may be based on achieving a certain initial thermal life of the vane or a second thermal life of the vane. In summary, the vane has a nominal thermal-life greater than a nominal corrosion-life, the nominal thermal-life having the flow area for first desired coolant mass flow, thus the method comprises the step of forming the initial and nominal area Ai of the inlet opening between 90% and 50% of the flow area for first desired coolant mass flow. Therefore, it is possible to operate the vane with only 50% of the coolant flow to limit the thermal life to that of the corrosion life. This can save a substantial amount of parasitic coolant that would otherwise be bled from a compressor.

(33) As mentioned before, the determining step comprises calibrating at least one vane 61 to find a relationship between the area of the inlet opening 73 and a setting value. This can be done of a vane-by-vane basis or on a batch of vanes and by statistical analysis with a high confidence limit of say 95%. Calibration can be done by supplying 10 the coolant through the channel 63 by varying a setting value, and measuring 11 an observation value and comparing the observation value to a target value. The setting value is a mass flow through the channel 63 or a seed pressure at the inlet of the channel 63. The observation value is a seed pressure at the inlet of the channel 63 or the mass flow through the channel 63.

(34) Repeating the method steps of supplying, measuring and removing until the observation value corresponds to the desired coolant mass flow gives the greatest accuracy. However, this is advantageously conducted for the calibration phase for each different design mass coolant flow or for occasional quality testing.

(35) A first desired coolant mass flow of a vane 61 is that suitable for a first operating condition and which could be for a base engine design. However, alternatively, the desired coolant mass flow can be a second desired coolant mass flow of a vane 61 suitable for a second operating condition which is at higher or longer operating level than the first operating level.

(36) As mentioned, the method is extended to manufacturing a vane assembly such as an array of stator vanes or a rotor stage of the turbine. Each vane of the plurality of vanes 61 is initially manufactured as described above except that the desired coolant mass flow is that of an average mass flow per vane 61 of the desired coolant mass flow of the plurality of vanes 61.

(37) Thus, a selective calibration of vane 61 in view of its cooling demand and cooling fluid consumption in its intended use in the target turbine and target field of application is achieved, minimizing a cooling fluid consumption while optimizing an overall efficiency.

(38) The embodiments of the present vane and its method of manufacture enable precise metering of coolant into each vane by virtue of machining the flow adaption feature. Vanes may be tested and calibrated individually to identify the amount of machining required to meet the desired coolant flow. Alternatively, an array of vanes may be tested and calibrated to identify an average machining requirement to meet the desired coolant flow for that array. Not only can the present vane and its method of manufacture be applied to an originally intended first engine application, but also a second engine application which operates at a higher turbine temperature. Here in-service vanes can be reworked or new vanes can be adjusted by further machining of the flow adaption feature to allow yet more coolant into the vane. Similarly, where in-service blades or new blades are required to have an increase in life, the vane can be remedied by further machining of the flow adaption feature to allow yet more coolant into the vane thereby reducing metal temperatures and thermal stresses. The present vane and its method of manufacture are also suited to yet further optimisation of coolant use. Where a vane's life is limited by corrosion for example its thermal life can also be reduced accordingly to that of the corrosion-life thus saving coolant and increasing overall efficiency. Here the flow adjustment feature has none or minimal machining.