Combustion staging system

Abstract

A combustion staging system has a splitting unit receiving and splitting metered fuel flow into out-going pilot and mains flows; pilot and mains fuel manifolds receiving the pilot and mains flows; and parallel mains flow scheduling valves distributing the mains flow. The mains flow scheduling valves pass the pilot fuel flow to injector pilot discharge orifices. Each mains flow scheduling valve has a chamber containing a piston, the chamber to a piston pilot side communicating with the pilot fuel manifold and the chamber to a mains side of the piston communicating with the mains fuel manifold. The piston is biased towards a closed pilot-only position preventing flow out of the chamber mains side to the injector mains discharge orifice. The piston is movable under increased pressure in the mains fuel manifold to an open pilot-and-mains position allowing flow out of the chamber mains side to the injector mains discharge orifice.

Claims

1. A combustion staging system for fuel injectors of a multi-stage combustor of a gas turbine engine, the system having: a splitting unit which receives a metered fuel flow and controllably splits the metered fuel flow into out-going pilot and mains fuel flows to perform pilot-only and pilot-and-mains staging control of the combustor; pilot and mains fuel manifolds which respectively receive the pilot and mains fuel flows; and a plurality of parallel mains flow scheduling valves which distribute the mains fuel flow from the mains manifold to mains discharge orifices of respective injectors of the combustor and which also pass the pilot fuel flow from the pilot manifold to pilot discharge orifices of the respective injectors; wherein each mains flow scheduling valve has a chamber containing a movable piston, the chamber to a pilot side of the piston being in fluid communication with the pilot fuel manifold and the chamber to a mains side of the piston being in fluid communication with the mains fuel manifold, the piston being biased towards a closed pilot-only position which prevents flow out of the mains side of the chamber to the mains discharge orifice of the respective injector, and the piston being movable under an increase in pressure in the mains fuel manifold to an open pilot-and-mains position which allows flow out of the mains side of the chamber to the mains discharge orifice of the respective injector, and wherein the mains flow scheduling valves are configured such that the pilot fuel flow from the pilot manifold to the pilot discharge orifices of the respective injectors passes through the respective chambers on the pilot sides of the pistons, and wherein the pilot side of the piston and the main side of the piston are on opposing sides of the piston.

2. The combustion staging system according to claim 1, wherein each mains flow scheduling valve further has a cooling flow bypass line providing fluid communication between the mains and pilot sides of its chamber, and the splitting unit is configured to allow a cooling flow through the mains fuel manifold when the mains flow scheduling valves are in their pilot-only positions, wherein the cooling flow passes through the bypass lines to cool the mains fuel manifold during pilot-only operation.

3. The combustion staging system according to claim 2, wherein the piston shuts off the bypass line when the piston is in its pilot-and-mains position.

4. The combustion staging system according to claim 1, wherein the splitting unit sends a cooling flow to the mains fuel manifold during pilot-only operation; and wherein the system further has a mains cooling valve which, during pilot-only operation, opens a bypass connection between the mains and pilot fuel manifolds such that the cooling flow passes from the mains fuel manifold to the pilot fuel manifold.

5. The combustion staging system according to claim 4, wherein the mains cooling valve closes the bypass connection during pilot-and-mains operation.

6. The combustion staging system according to claim 4, wherein the mains cooling valve reduces the flow area of the bypass connection during pilot-and-mains operation, allowing a leakage flow to pass from the mains fuel manifold to the pilot fuel manifold.

7. The combustion staging system according to claim 4, wherein each mains flow scheduling valve provides a leak-tight seal between the pilot and mains sides of the chamber when its piston is in its pilot-only position, and a reduced seal between the pilot and mains sides of the chamber when the piston is in its pilot-and-mains position.

8. The combustion staging system according to claim 4, wherein the mains manifold is configured such that flow through the mains manifold passes in series across respective entrances to the mains flow scheduling valves, the bypass connection between the mains and pilot fuel manifolds comprising parallel first and second fuel lines, the first fuel line extending from the mains to the pilot fuel manifold from an upstream side of the last entrance, the second fuel line extending from the mains to the pilot fuel manifold from a downstream side of the last entrance, and the first and second lines being in fluid communication in the mains cooling valve such that during pilot-and-mains operation fuel circulates around the first and second fuel lines.

9. The combustion staging system according to claim 4, wherein the mains manifold is configured such that flow through the mains manifold splits into a first fraction which passes in series across respective entrances to a first portion of the mains flow scheduling valves, and a second fraction which passes in second series across respective entrances to a remaining second portion of the mains flow scheduling valves, the bypass connection between the mains and pilot fuel manifolds comprising a fuel line extending from the mains manifold from a location on the mains manifold which is downstream of the last entrances of the first and second portions of the mains flow scheduling valves.

10. The combustion staging system according to claim 1, wherein the system further has control means for setting a constant pressure differential between the metered fuel flow received by the splitting unit and the pilot fuel flow out of the splitting unit.

11. The combustion staging system according to claim 10, wherein the splitting unit has a flow splitting valve having a spool whose position is controllable to control the split of the metered fuel flow between the pilot and mains fuel flows, and wherein the control means comprises: a pressure sensor to measure the pressure differential between the metered fuel flow received by the splitter valve and the pilot fuel flow out of the splitter valve, and/or a further pressure sensor to measure the pressure differential between the metered fuel flow received by the splitter valve and the mains fuel flow out of the splitter valve; and a device to measure the position of the spool.

12. The combustion staging system according to claim 10, wherein the control means comprises a pressure drop throttle valve located between the splitting unit and the pilot manifold to controllably throttle the pilot fuel flow and/or between the splitting unit and the mains manifold to controllably throttle the mains fuel flow.

13. The combustion staging system according to claim 10, wherein the control means comprises: a flow sensing valve located between the splitting unit and the pilot manifold to measure the flow rate of the pilot fuel flow through the flow sensing valve, or a flow sensing valve located between the splitting unit and the mains manifold to measure the flow rate of the mains fuel flow through the flow sensing valve.

14. The combustion staging system according to claim 1, further having a plurality of pilot flow scheduling valves, each receiving the pilot fuel flow passed by a respective one of the mains flow scheduling valve, the pilot flow scheduling valves distributing the received pilot fuel flow to their respective pilot discharge orifices when the pilot fuel flow exceeds a cracking pressure set by the pilot flow scheduling valves.

15. A gas turbine engine having the combustion staging system according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:

(2) FIG. 1 shows a longitudinal cross-section through a ducted fan gas turbine engine;

(3) FIG. 2 shows schematically a staging system for fuel injectors of the combustor of the engine of FIG. 1 in pilot-only operating mode;

(4) FIG. 3 shows schematically the staging system of FIG. 2 in pilot-and-mains operating mode;

(5) FIG. 4 shows schematically a variant of the staging system of FIG. 2 in pilot-only operating mode;

(6) FIG. 5 shows schematically the variant staging system of FIG. 4 in pilot-and-mains operating mode;

(7) FIG. 6 shows schematically another variant of the staging system of FIG. 2 in pilot-only operating mode;

(8) FIG. 7 shows a plot of sector over-fuelling ratio (one mains flow scheduling valve failed fully open) against total burner flow under a conventional staging system;

(9) FIG. 8 shows a plot of sector over-fuelling ratio (one mains flow scheduling valve failed fully open) against total burner flow under a staging system of the present invention;

(10) FIG. 9 shows schematically another staging system for fuel injectors of the combustor of the engine of FIG. 1 in pilot-only operating mode;

(11) FIG. 10 shows schematically an injector of the system of FIG. 9 in pilot-only operating mode;

(12) FIG. 11 shows schematically an injector of the system of FIG. 9 in pilot-and-mains operating mode;

(13) FIG. 12 shows schematically a configuration for routing cooling flow through mains and pilot manifolds in pilot-only operating mode;

(14) FIG. 13 shows schematically the configuration of FIG. 12 in pilot-and-mains operating mode;

(15) FIG. 14 shows schematically a variant configuration for routing cooling flow through mains and pilot manifolds in pilot-only operating mode; and

(16) FIG. 15 shows schematically the variant configuration of FIG. 14 in pilot-and-mains operating mode.

DETAILED DESCRIPTION AND FURTHER OPTIONAL FEATURES

(17) With reference to FIG. 1, a ducted fan gas turbine engine incorporating the invention is generally indicated at 10 and has a principal and rotational axis X-X. The engine comprises, in axial flow series, an air intake 11, a propulsive fan 12, an intermediate pressure compressor 13, a high-pressure compressor 14, combustion equipment 15, a high-pressure turbine 16, an intermediate pressure turbine 17, a low-pressure turbine 18 and a core engine exhaust nozzle 19. A nacelle 21 generally surrounds the engine 10 and defines the intake 11, a bypass duct 22 and a bypass exhaust nozzle 23. A fan case 24 surrounds the fan 12 at the inner side of the nacelle.

(18) 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.

(19) 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.

(20) The engine has a pumping unit comprising a low pressure (LP) pumping stage which draws fuel from a fuel tank of the aircraft 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.

(21) 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 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 A 2339147 (which is hereby incorporated by reference).

(22) An engine electronic controller (EEC) commands the HMU fuel metering valve to supply fuel to fuel injectors 34 of the combustor 15 at a given flow rate. The metered fuel flow leaves the HMU and arrives at a staging system at a pressure P.sub.fmu.

(23) Staging SystemEmbodiment 1

(24) A first embodiment of the staging system 30 is shown schematically in FIGS. 2 and 3. The staging system splits the fuel under the control of the EEC (not shown) into two flows: one at a pressure PB.sub.p1 for first 31 and second 32 pilot manifolds and the other at a pressure P.sub.fsv for a mains manifold 33. The first pilot manifold feeds pilot discharge orifices of a subset of the fuel injectors. The second pilot manifold feeds pilot discharge orifices of the rest of the fuel injectors. The mains manifold feeds mains discharge orifices of all the fuel injectors. Mains fuel flow scheduling valves (FSVs) 40 at the injectors prevent combustion chamber gases entering the respective manifolds and also provide a drip tight seal between the mains manifold and the injectors when mains is de-staged. By varying the fuel split between the manifolds, the EEC can thus perform staging control of the engine.

(25) In more detail, the staging system 30 has a fuel flow splitting valve (FFSV) 35, which 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 46, the position of the spool determining the outgoing flow split between a pilot connection pipe 36 which delivers fuel to the first 31 and second 32 pilot manifolds and a mains connection pipe 37 which delivers fuel to the mains manifold 33. The spool can be positioned so that the mains stage is deselected, with the entire metered flow going to the pilot stage. An LVDT 38 provides feedback on the position of the spool to the EEC, which in turn controls staging by control of the servo valve.

(26) The pilot discharge orifices are divided into two groups by the first 31 and second 32 pilot manifolds in order to provide lean blow out protection. More particularly, the second pilot manifold connects to the pilot connection pipe 36 via a further connection pipe 39 (at a PB.sub.p2) and a lean blow out protection valve 41. This is operable to terminate or substantially reduce the supply of fuel to the second pilot manifold and associated pilot discharge orifices, when desired, so as to increase the flow of fuel to the first pilot manifold and associated discharge orifices under low fuel conditions for a given metered flow from the HMU. In the arrangement illustrated, the valve 41 is controlled by way of a solenoid operated control valve 42, although other forms of control are possible, such as by a servo-type valve (for example an electro hydraulic servo valve). In this way, under low fuel conditions the flow of fuel to the pilot discharge orifices may be directed preferentially to the discharge orifices served by the first pilot manifold, whereby the risk of a lean blow out condition arising can be reduced. Further details of such lean blow out protection are described in EP A 2469057.

(27) The part of the staging system 30 comprising the FFSV 35, servo valve 46, lean blow out protection valve 41 and control valve 42 is mounted to the fan case 24. The connection pipes 36, 37, 39 then extend across the bypass duct 22 to the manifolds 31, 32, 33, which wrap around the core engine in proximity to the injectors 34.

(28) In the staging system described in EP A 2469057, each injector has a pilot FSV and a mains FSV for respectively the flows from pilot and mains manifolds. In contrast, in the staging system shown in FIGS. 2 and 3, pilot FSVs are not provided, and instead pilot flow is routed through modified mains FSVs 40 with negligible restriction: the mains FSVs 40 distribute the mains flow from the mains manifold 33 to the mains discharge orifices in the injectors 34, while the pilot flow is passed through the mains FSVs for valve cooling purposes. These FSVs each have a chamber containing a movable, spring-biased piston, with the chamber to a pilot (spring) side of the piston being in fluid communication with the respective pilot fuel manifold 31, 32 and the chamber to a mains (non-spring) side of the piston being in fluid communication with the mains fuel manifold 33. In this way, the FSVs 40 have a reduced cracking pressure with the pilot (spring) side of the FSVs being referenced to pilot manifold pressure (PB.sub.p1 or PB.sub.p2) rather than the lower pressure downstream of the FSVs (as is the case with the system of EP A 2469057). With the low cracking pressure, the pressures on either side of each piston (P.sub.fsv and PB.sub.p) are approximately equal during the pilot-only operating mode (FIG. 2) such that the FSV springs maintain the FSVs 40 in a closed position (i.e. no flow from the mains manifold 33 through the FSVs to the mains discharge orifices of the injectors 34).

(29) In this pilot-only operating mode, the position of the FFSV 35, controlled by the servo valve 46, is such that there is a large flow number opening between the HMU supply and the pilot connection pipe 36, such that P.sub.fmu=PB.sub.p1=f.sub.fsv). Any difference between the metered fuel pressure (P.sub.fmu) from the HMU supply and the pilot manifold pressures (PB.sub.p1 and PB.sub.p2) is generally less than 10 psid (69 kPa). This is insufficient to open the FSVs 40, which may have a cracking pressure of typically 30 paid (207 kPa). In the pilot-only mode there can be a small opening in the FFSV between the HMU supply and the mains connection pipe 37 to allow for thermal expansion of fuel in the mains manifold 33 (i.e. to prevent a trapped volume in the mains manifold). The mains manifold remains fully primed in pilot-only mode, such that there is no hazardous failure to meet acceleration requirements when mains staging is selected. When mains staging is selected the FFSV 35 (controlled by the servo-valve 46) moves to increase the opening between the HMU supply and the mains connection pipe 37. This reduces PB.sub.p1 and PB.sub.p2 relative to P.sub.fsv, resulting in fuel flow to the mains discharge orifices of the injectors 34 (FIG. 3).

(30) If one of the FSVs 40 fails such that it opens in pilot-and-mains mode, fuel flows from the HMU supply through the FFSV 35 to the mains manifold 33 and thence through the open port in the failed FSV to the mains discharge orifice of the respective injector 34. However, as the FSVs have a relatively low cracking pressure, only a marginal increase in pressure in the mains manifold, resulting from flow through the port in the failed FSV, causes the other FSVs to open. This then leads to a relatively even distribution of fuel flow injection around the combustor. Thus, by ensuring that the other FSVs open before a severe level of fuel flow through the failed FSV is reached (i.e. a level that results in hot streaks and turbine damage), the staging system 30 can mitigate the potentially hazardous mal-distribution issues associated with failed open mains FSVs in the system of EP A 2469057 which incorporates high cracking pressure FSVs. Further, with a relatively low pressure differential acting across the FSV pistons, the FSVs 40 are less susceptible to incorrect opening due to pump ripple in pilot-only mode if the pressure ripples either side of the FSV piston are in phase.

(31) The staging system 30 also allows complex cooling recirculation architectures to be avoided, which avoids the hazards that can result from combustion gases leaking past mains FSVs and thence to the low pressure side of the fuel system.

(32) Cooling of the FSVs 40 can be provided by the pilot flow that is continuously routed through the FSVs. If necessary, however, further cooling arrangements can be provided for the pilot manifolds 31, 32 and particularly the mains 33 manifold, e.g. by using a small portion of the air flow B through the bypass duct 22.

(33) The pilot/mains flow split is achieved via movement of the spool within the FFSV 35. However, an accurate spilt (which may be otherwise by affected by FSV tolerances, variation and friction) can be promoted by either measuring the FFSV pressure differentials or by setting a constant pressure differential P.sub.fmuPB.sub.p1 across the FFSV 35 inflow and outflow metering ports. This can be achieved in a number of ways. For example, the system 30 can have pressure sensors to measure P.sub.fmuPB.sub.p1 and/or P.sub.fmuP.sub.fsv. Combined with the spool position feedback provided by the LVDT 38, knowledge of the pressure drop(s) across the pilot/mains metering ports in the FFSV can allow the EEC to compute the pilot and mains flows, driving the FFSV via the servo valve 46 to set the required pilot/mains flow split. As another example, a pressure drop throttle valve located on the pilot connection pipe 36 can sense the pressure drop P.sub.fmuPB.sub.p1 and throttle the pilot flow to maintain a constant P.sub.fmuPB.sub.p1 pressure differential. With this pressure differential nominally constant, the pilot flow can be set as a function of spool position with position measurement provided by the LVDT 38.

(34) As yet another example, a flow sensing valve can be located on the pilot connection pipe 36 or the mains connection pipe 37. Such an example is illustrated in the variant staging system 30 shown in FIGS. 4 and 5, the system having a mains fuel flow sensing valve (MFFSV) 43 on the mains connection pipe 37. The position of the FFSV 35 is controlled via the servo valve 46 using the position feedback signal from the LVDT 44 attached to the MFFSV 43 to give accurate flow control in the connection pipes 36 and 37. In particular, the position feedback signal that is input to the staging control logic in the EEC is taken from an LVDT 44 measuring a spool position of the MFFSV rather than the FFSV. In such an arrangement, MFFSV spool position is a measure of the mains flow.

(35) In the variant staging system 30 of FIGS. 4 and 5, cooling flow orifices are incorporated into the FSVs 40. In each FSV, these orifices form flow-restrictions in a bypass line 45 providing fluid communication between the mains and pilot sides of the chamber. In the pilot-only operating mode (see FIG. 4) these orifices are open resulting in a continuous flow of fuel through the mains manifold 33 to the pilot discharge orifices of the injectors 34, which maintains cooling in the mains manifold and the lines from the mains manifold to the FSVs. This cooling flow is sensed by the MFFSV 43 and the feedback signal from the MFFSV LVDT 44 to the EEC is used to adjust the spool position of the FFSV 35 (via the servo valve 46) if the cooling flow needs to be altered. In the pilot-only operating mode the pressure drop across the FSV piston (P.sub.fsvPB.sub.p) is typically low, e.g. <5 psid (34 kPa). A typical cooling flow of 10 imperial gallons per hour (45 litres per hour) through a total cooling orifice of 9 igph/sqrt(psi) (4.33 cc/s/sqrt(kPa)) flow number gives (P.sub.fsvPB.sub.p)=1.24 psid (8.55 kPa). This is insufficient to open the FSVs which typically require 30 psid (207 kPa) for cracking and 27 psid (186 kPa) to lift the piston off its stop.

(36) When the pilot-and-mains operating mode is selected (see FIG. 5), the spool position of the FFSV 35 is altered to increase the opening of the mains port of the FFSV and reduce the opening of the pilot port of the FFSV, which increases the pressure differential P.sub.fmuPB.sub.p1 across the pilot port, thus producing a rise in the pressure P.sub.fsv relative to PB.sub.p1 and PB.sub.p2. This results in the pistons of the FSVs 40 opening against their respective spring forces, and fuel flowing through the FSV to the mains discharge orifices of the injectors 34. In addition, the opening of the FSV pistons closes off the cooling flow orifices in the FSVs to shut off the bypass lines 45. The MFFSV now senses the flow to the mains discharge orifices of the injectors and the feedback signal from the LVDT 44 is used to adjust the FFSV spool position via the EEC and FFSV servo valve 46 to set the correct pilot/mains flow split.

(37) Thus inclusion of the MFFSV 43 on the mains connection pipe 37 enables accurate control of the pilot/mains split irrespective of FSV tolerances, variation and friction. The MFFSV position from the LVDT 44 is a measure of mains manifold cooling flow during pilot-only operation, and total mains burnt flow during pilot-and-mains operation. This flow measurement signal is sent to and used by the EEC control logic to provide an MFFSV position demand signal that is used to drive the FFSV servo valve 46 to move the FFSV 35 to set the correct pilot/mains flow split (during pilot-and-mains operation) or the correct mains cooling flow (during pilot-only operation).

(38) FIG. 6 shows schematically another variant of the staging system 30, in pilot-only operating mode. This variant is similar to that shown in FIG. 4. However, each injector 34 now also includes an optional pilot FSV 47 located between its mains FSV 40 and its pilot discharge orifice.

(39) The plot of FIG. 7 relates to a conventional staging system such as that described in EP A 2469057 where high cracking pressure main FSVs are required to ensure that they do not open during pilot-only operation when the cooing manifold is operational. More particularly, in such a system the flow in the cooling manifold returns to an LP (gear pump inlet pressure) sink and, because LP can be high relative to combustion chamber pressure P30, a high FSV spring load is required to ensure the mains FSVs stay closed. The plot considers the level of overfuelling that can occur during pilot-only operation through a single mains injector when its associated mains FSV has failed fully open. The plot shows sector over-fuelling ratio against total burner flow. The high cracking pressure of about 170 psid (1.2 MPa) for the mains FSVs results in unacceptable over-fuelling across the entire operating range. Because the FSVs have a high cracking pressure, the flow through the failed open FSV can reach a high level before the other FSVs open. Thus, a high degree of mains flow mal-distribution is possible and this can result in turbine torching and subsequent damage. In contrast. FIG. 8 shows a plot of sector over-fuelling ratio (one mains flow scheduling valve failed fully open) against total burner flow under a staging system of the present invention. In this case, except for very low flows (i.e. a single over-fuelling point), the maximum over-fuelling is acceptable. This is because the flow through the failed open mains FSV does not reach a high level before sufficient pressure is generated to crack open the other FSVs. Thus, the degree of mains flow mal-distribution does not reach a high level for most operating conditions. This is a benefit of using low cracking pressure main FSVs, facilitated by referencing the spring side of the main FSVs to pilot manifold pressure. At low flow conditions, and particularly at high pilot/mains splits (i.e. above 40% pilot) there is still a risk of unacceptable overfuelling, albeit a lower risk than on a conventional staging system; the low mains flow means that normally operating FSVs operate at a low travel, accentuating the difference between flow through a failed open FSV (e.g. providing a 19.9 igph/sqrt(psi) (9.57 cc/s/sqrt(kPa) flow number)) and an active FSV.

(40) Staging SystemEmbodiment 2

(41) A second embodiment of the staging system 30 is shown schematically in FIG. 9. The staging system splits the fuel under the control of the EEC (not shown) into two flows: one at a pressure PB.sub.p1 for first 31 and second 32 pilot manifolds and the other at a pressure P.sub.fsv for a mains manifold 33. The first pilot manifold feeds pilot discharge orifices of a subset of the fuel injectors. The second pilot manifold feeds pilot discharge orifices of the rest of the fuel injectors. The mains manifold feeds mains discharge orifices of all the fuel injectors. Mains fuel flow scheduling valves (FSVs) 40 at the injectors prevent combustion chamber gases entering the respective manifolds and also provide a drip tight seal between the mains manifold and the injectors when mains is de-staged. By varying the fuel split between the manifolds, the EEC can thus perform staging control of the engine.

(42) In more detail, the staging system 30 has a fuel flow splitting valve (FFSV) 35, which 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 46, the position of the spool determining the outgoing flow split between a pilot connection pipe 36 which delivers fuel to the first 31 and second 32 pilot manifolds and a mains connection pipe 37 which delivers fuel to the mains manifold 33. The spool can be positioned so that the mains stage is deselected, with the entire metered flow going to the pilot stage (except that a cooling flow is sent to the mains manifold during pilot-only operation, as discussed in more detail below). An LVDT (not shown) can provide feedback on the position of the spool to the EEC, which in turn controls staging by control of the servo valve 46.

(43) The pilot discharge orifices are divided into two groups by the first 31 and second 32 pilot manifolds in order to provide lean blow out protection. More particularly, the second pilot manifold connects to the pilot connection pipe 36 via a further connection pipe 39 (at a PB.sub.p2) and a lean blow out protection valve 41. This is operable to terminate or substantially reduce the supply of fuel to the second pilot manifold and associated pilot discharge orifices, when desired, so as to increase the flow of fuel to the first pilot manifold and associated discharge orifices under low fuel conditions for a given metered flow from the HMU. In the arrangement illustrated, the valve 41 is controlled by way of a solenoid operated control valve 42, although other forms of control are possible, such as by a servo-type valve (for example an electro hydraulic servo valve). In this way, under low fuel conditions the flow of fuel to the pilot discharge orifices may be directed preferentially via the first pilot manifold, whereby the risk of a lean blow out condition arising can be reduced. Further details of such lean blow out protection are described in EP A 2469057.

(44) The part of the staging system 30 comprising the FFSV 35, servo valve 46, lean blow out protection valve 41 and control valve 42 is mounted to the fan case 24. The connection pipes 36, 37, 39 then extend across the bypass duct 22 to the manifolds 31, 32, 33, which wrap around the core engine in proximity to the injectors 34.

(45) In the staging system described in EP A 2469057, each injector has a pilot FSV and a mains FSV for respectively the flows from pilot and mains manifolds. In contrast, in the staging system shown in FIG. 9, pilot FSVs are not necessary (although optional pilot FSVs can be located between the mains FSVs 40 and the pilot discharge orifices), and instead pilot flow is routed through modified mains FSVs 40 with negligible restriction: the mains FSVs 40 distribute the mains flow from the mains manifold 33 to the mains discharge orifices in the injectors 34, while the pilot flow is passed through the mains FSVs for valve cooling purposes. These FSVs each have a chamber containing a movable, spring-biased piston, with the chamber to a pilot (spring) side of the piston being in fluid communication with the respective pilot fuel manifold 31, 32 and the chamber to a mains (non-spring) side of the piston being in fluid communication with the mains fuel manifold 33. In this way, the FSVs 40 have a reduced cracking pressure with the pilot (spring) side of the FSVs being referenced to pilot manifold pressure (PB.sub.p1 or PB.sub.p2) rather than the lower pressure downstream of the FSVs (as is the case with the system of EP A 2469057). With the low cracking pressure, the pressures on either side of each piston (P.sub.fsv and PB.sub.p) are approximately equal during the pilot-only operating mode such that the FSV springs maintain the FSVs 40 in a closed position (i.e. no flow from the mains manifold 33 through the FSVs to the mains discharge orifices of the injectors 34).

(46) In this pilot-only operating mode, the position of the FFSV 35, controlled by the servo valve 46, is such that there is a large flow number opening between the HMU supply and the pilot connection pipe 36, such that P.sub.fmuPB.sub.p1P.sub.fsv. Any difference between the metered fuel pressure (P.sub.fmu) from the HMU supply and the pilot manifold pressures (PB.sub.p1 and PB.sub.p2) is generally less than 10 psid (69 kPa). This is insufficient to open the FSVs 40, which may have a cracking pressure of typically 30 psid (207 kPa). In the pilot-only mode there is a small opening in the FFSV between the HMU supply and the mains connection pipe 37 to allow for the cooling flow in the mains manifold 33. The mains manifold remains fully primed in pilot-only mode, such that there is no hazardous failure to meet acceleration requirements when mains staging is selected. When mains staging is selected the FFSV 35 (controlled by the servo-valve 46) moves to increase the opening between the HMU supply and the mains connection pipe 37. This reduces PB.sub.p1 and PB.sub.p2 relative to P.sub.fsv, resulting in fuel flow to the mains discharge orifices of the injectors 34.

(47) If one of the FSVs 40 falls such that it opens in pilot-and-mains mode, fuel flows from the HMU supply through the FFSV 35 to the mains manifold 33 and thence through the open port in the failed FSV to the mains discharge orifice of the respective injector 34. However, as the FSVs have a relatively low cracking pressure, only a marginal increase in pressure in the mains manifold, resulting from flow through the port in the failed FSV, causes the other FSVs to open. This then leads to a relatively even distribution of fuel flow injection around the combustor. Thus, by ensuring that the other FSVs open before a severe level of fuel flow through the failed FSV is reached (i.e. a level that results in hot streaks and turbine damage), the staging system 30 can mitigate the potentially hazardous mal-distribution issues associated with failed open mains FSVs in the system of EP A 2469057 which incorporates high cracking pressure FSVs.

(48) The staging system 30 also allows complex cooling recirculation architectures to be avoided, which avoids the hazards that can result from combustion gases leaking past mains FSVs and thence to the low pressure side of the fuel system of the system.

(49) Cooling of the FSVs 40 can be provided by the pilot flow that is continuously routed through the FSVs. Cooling arrangements can be provided for the pilot manifolds 31, 32 and the mains 33 manifold, e.g. by using a small portion of the air flow B through the bypass duct 22, and for the mains manifold in pilot-only operation using the cooling flow discussed below.

(50) The pilot/mains flow split is achieved via movement of the spool within the FFSV 35. However, an accurate split (which may be otherwise by affected by FSV tolerances, variation and friction) can be promoted by either measuring the FFSV pressure differentials or by setting a constant pressure differential P.sub.fmuPB.sub.p1 across the FFSV 35 inflow and outflow metering ports. This can be achieved in a number of ways. For example, the system 30 can have pressure sensors to measure P.sub.fmuPB.sub.p1 and/or P.sub.fmuP.sub.m (where P.sub.m is the pressure in mains connection pipe 37). Combined with the spool position feedback provided by an LVDT, knowledge of the pressure drop(s) across the pilot/mains metering ports in the FFSV can allow the EEC to compute the pilot and mains flows, driving the FFSV via the servo valve 46 to set the required pilot/mains flow split. As another example, a pressure drop throttle valve located on the pilot connection pipe 36 can sense the pressure drop P.sub.fmuPB.sub.p1 and throttle the pilot flow to maintain a constant P.sub.fmuPB.sub.p1 pressure differential. With this pressure differential nominally constant, the plot flow can be set as a function of spool position with position measurement provided by an LVDT.

(51) As yet another example, a flow sensing valve can be located on the pilot connection pipe 36 or the mains connection pipe 37. Such an example is illustrated in FIG. 9, the system having a mains fuel flow sensing valve (MFFSV) 43 on the mains connection pipe 37. The FFSV 35 then provides a coarse split and the MFFSV trims to the required accuracy. The position of the FFSV 35 is controlled via the servo valve 46 using the position feedback signal from the LVDT 44 attached to the MFFSV 43 to give accurate flow control in the connection pipes 36 and 37. In particular, the position feedback signal that is input to the staging control logic in the EEC is taken from an LVDT 44 measuring a spool position of the MFFSV rather than a spool position of the FFSV. In such an arrangement, MFFSV spool position is a measure of the mains flow.

(52) To provide the cooling flow in the mains manifold 33 during pilot-only operation, the system 30 has a single-stage solenoid-operated mains cooling valve 47 which in pilot-only operation opens a bypass connection between the mains 33 and second pilot 32 fuel manifolds, allowing the cooling flow to pass from the mains fuel manifold to the pilot fuel manifold, and thence onwards for burning at the pilot orifices of the injectors 34. The mains cooling valve 47 closes during pilot-and-mains operation. The cooling flow in the bypass connection has a relatively large orifice size compared to possible alternative cooling arrangements such as distributed cooling orifices in the mains FSVs 40, and thus is relatively insensitive to contamination and ice build-up. The mains cooling valve 47 may be located in a relatively hot engine zone close to the injectors 34 to simplify pipework. The circumferential position of the valve on the engine can affect the amount of engine heat soak-back into the valve, and thus the resultant valve temperature. Accordingly, a location at the base of the engine is generally preferred.

(53) More particularly, in the plot-only operating mode the cooling flow of fuel passes continuously from the mains manifold 33 to the second pilot fuel manifold 32, which maintains cooling in the mains manifold. This cooling flow is sensed by the MFFSV 43 and the feedback signal from the MFFSV LVDT 44 to the EEC is used to adjust the spool position of the FFSV 35 (via the servo valve 46) if the cooling flow needs to be altered. In the pilot-only operating mode, even with the cooling flow the pressure drop across each FSV piston (P.sub.fsvPB.sub.p) is typically low, e.g. <5 psid (34 kPa). This is insufficient to open the FSVs which typically require 30 psid (207 kPa) for cracking and 27 psid (186 kPa) to lift the piston off its stop.

(54) When the pilot-and-mains operating mode is selected, the spool position of the FFSV 35 is altered to increase the opening of the mains port of the FFSV and reduce the opening of the pilot port of the FFSV, which increases the pressure differential P.sub.fmuPB.sub.p1 across the pilot port, thus producing a rise in pressure P.sub.fsv relative to PB.sub.p1 and PB.sub.p2. This results in the pistons of the FSVs 40 opening against their respective spring forces, and fuel flowing through the FSV to the mains discharge orifices of the injectors 34. The MFFSV now senses the flow to the mains discharge orifices of the injectors and the feedback signal from the LVDT 44 is used to adjust the FFSV spool position via the EEC and FFSV servo valve 46 to set the correct pilot/mains flow split.

(55) Thus inclusion of the MFFSV 43 on the mains connection pipe 37 enables accurate control of the pilot/mains split irrespective of FSV tolerances, variation and friction. The MFFSV position from the LVDT 44 is a measure of mains manifold cooling flow during pilot-only operation, and total mains burnt flow during pilot-and-mains operation. This flow measurement signal is sent to and used by the EEC control logic to provide an MFFSV position demand signal that is used to drive the FFSV servo valve 46 to move the FFSV 35 to set the correct pilot/mains flow split (during pilot-and-mains operation) or the correct mains cooling flow (during pilot-only operation).

(56) The MFFSV 43 also provides the ability to independently close off the cooling flow to the mains manifold 33. This can assist with a health monitoring determination of whether the mains FSVs 40 are failed open. More particularly, since the MFFSV provides a means of indicating the flow in the mains connection pipe 37, the MFFSV can identify deviations of cooling flow in pilot-only mode flow from expected values. For example, if the mains cooling valve 47 is shut initially when mains is de-staged, a flow registered by the MFFSV would indicate either that the valve 47 has not closed (when it should be closed) or that one or more of the mains FSVs 40 is open, when they should be closed.

(57) FIGS. 10 and 11 show schematically an injector 34 of the system 30 of FIG. 9 in respectively pilot-only and pilot-and-mains operating modes. In the pilot-only position (FIG. 10), the piston 48 of the mains FSV 40 of the injector is dual face-sealed in the chamber 49 by seals 50 at both ends of the piston, such that there is substantially no leakage across the piston from P.sub.fsv or PB.sub.p to the engine combustion chamber. In the pilot-and-mains position (FIG. 11), however, the sealing is broken such that some fuel may leak from PB.sub.p to the mains flow line via clearance between the FSV piston 48 and the wall of the chamber 49. However, by avoiding dynamic sealing between the piston 40 and the chamber wall there is a lower level of friction between these components and little or no variation in the level of friction as the piston moves, which in turn reduces variation in operation of the mains FSVs 40. The benefit of consistency of valve movement as a result of lower, more consistent levels of friction between the piston and chamber wall outweighs any detrimental impact of the leakage on splitting accuracy.

(58) Various configurations for routing the cooling flow through the mains 33 and second pilot 32 manifolds are possible. One such configuration is shown schematically in FIGS. 12 and 13 in respectively pilot-only and pilot-and-mains operating modes, arrows indicating directions of fuel flow. For simplicity, the first pilot manifold 31 is ignored, such that all the FSVs 40 are shown being fed by the second pilot manifold 32. The mains cooling valve 47 comprises a 2-way solenoid valve that falls to pilot mode. The mains manifold 33 is an end fed daisy chain such that flow through the mains manifold passes in series across respective entrances to the mains FSVs 40. Preferably any feeds from the mains manifold 33 to the mains FSVs are as short as possible to reduce the amount of stagnant fuel in these feeds in pilot-only operation. Indeed, as shown in FIGS. 9 to 11, the mains manifold may port directly to the mains sides of the chambers 49 of the FSVs, thus eliminating such feeds entirely. The pilot manifold 32 can have a split configuration (e.g. bottom fed to flow left and right), for example with pigtails joining the pilot manifold 32 to the FSVs 40. A section 54 of the pilot manifold 32 to one side of the split is within the mains cooling valve 47 such that half of the pilot fuel flow passes through the mains cooling valve for solenoid cooling purposes. By only routing a portion the pilot manifold fuel flow through the mains cooling valve 47, the size of the valve can be reduced. A flow path parallel to that of the section 54 is provided to allow a small portion of the pilot fuel flow into and out of the main valve cavity 51 thereby replenishing fuel in the cavity.

(59) In pilot-only operating mode (FIG. 12), mains cooling flow enters the ring of the mains manifold 33 from the FFSV 35 and the MFFSV 43, and passes across the mains FSVs 40 in turn before passing to the pilot manifold 32 via a bypass connection comprising parallel first 52 and second 53 fuel lines, and the open mains cooling valve 47. The first fuel line 52 extends from the mains fuel manifold from an upstream side of the last entrance, while the second fuel line 53 extends from the mains fuel manifold from a downstream side of the last entrance. The last FSV in the daisy chain thus receives only a portion of the cooling flow. However, the parallel fuel lines 52, 53 ensure that there is always fuel flowing through the lines to keep the lines and the mains cooling valve 47 cool. More particularly, in the pilot-and-mains operating mode (FIG. 13), the mains fuel flow enter the mains manifold ring from the FFSV 35 and the MFFSV 43 to feed all the FSVs 40 in series. However, the last FSV 40 in the daisy chain receives its flow from the mains manifold (clockwise) and also via circulation (anticlockwise) through the parallel fuel lines 52, 53 and a connection 55 between the lines in the (otherwise closed) mains cooling valve 47. The amount of circulating flow can be set by balancing the line losses.

(60) A variant routing configuration is shown schematically in FIGS. 14 and 15 in respectively pilot-only and pilot-and-mains operating modes, arrows again indicating directions of fuel flow. The mains manifold 33 is now a complete daisy chain fed from the bottom, with flow passing left and right, to allow cooling flow to pass across all the mains FSVs 40. The bypass connection between the mains 33 and pilot 32 fuel manifolds comprises a fuel line 56 extending from the top of the mains manifold to prevent a stagnant region at top-dead-centre. There is always flow in this region in all operating modes. As with the previous configuration, the pilot manifold 32 can have a split configuration with pigtails joining the pilot manifold 32 to the FSVs 40. Similarly, a section 54 of the pilot manifold 32 to one side of the split is within the mains cooling valve 47.

(61) In a pilot-only operating mode (FIG. 14), the cooling flow enters the mains manifold ring from the FFSV 35 and the MFFSV 43 and is split between the left and right potions of the ring to feed the FSVs 40 in respective left and right series. The fuel line 56 sends the cooling flow to the open mains cooling valve 47, and there it proceeds to the pilot manifold 32. In the pilot-and-mains operating mode (FIG. 15) the mains cooling valve 47 is closed, but a small leakage flow from mains to pilot can be set up in the mains cooling valve 47 by a bypass line 57 to cool and maintain flow in the fuel line 56. However, as a consequence control of the fuel splitting is less optimal than in the previous configuration because the leakage flow diverts some mains fuel flow to pilot.

SUMMARY

(62) The staging system of the present invention has mains FSVs 40 and optional pilot FSVs 47, which are typically located at the head of each injector. The mains FSVs close when mains is deselected and at shut down, and the optional pilot FSVs close at shut down, in order to: Retain a fully primed mains manifold 33 when the mains are staged out to facilitate rapid relight for go around cases. Provide a drip tight seal to avoid fuel degradation/lacquering/coking in the injector passageways when the mains is staged out. Provide a drip tight seal for both the pilot and mains discharge orifices at shut down to avoid injector coking/lacquering during soak back and to avoid fuel leaking into the combustor. They also help to achieve a uniform injector to injector flow distribution at low flow conditions. In particular, a narrow metering profile ensures that if one mains FSV 40 opens first, a small change in flow through it causes a large change in pressure sufficient to crack the other mains FSVs 40 so that the flow is evenly distributed.

(63) The system also addresses potentially hazardous failure modes and complexity associated with systems having complex recirculation architectures. To summarise: Pilot FSVs can be deleted to avoid a risk of pilot flow mal-distribution resulting in hot streaks and turbine damage. Referencing the mains FSV chamber to the pilot (spring) side of its piston to pilot manifold pressure, allows the cracking pressure of the mains FSVs to be reduced. This in turn means that if one mains FSV fails fully open, the resultant injector to injector flow mal-distribution is decreased so the threat of hot streaks and turbine damage is also reduced. By avoiding a complex recirculation architecture, the mains manifold pressure P.sub.fsv can be maintained above the combustion chamber pressure so that combustion gases cannot ingress into the fuel system. This also helps to ensure that the mains manifold remains fully primed at all conditions so that there is no hazardous risk of failing to meet engine acceleration requirements at a go around condition.

(64) 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.