Coolant delivery via independent cooling circuits

Abstract

The present invention relates to a coolant delivery system for a component of a gas turbine system, the coolant delivery system comprising: a plurality of independent cooling channel loops embedded in an outer wall of the component, each independent cooling channel loop comprising a plurality of headers and a plurality of feed pipes, the plurality of feed pipes fluidically coupling the plurality of headers to a cooling fluid supply source; and an impingement plate connected to the outer wall of the component via the plurality of feed pipes of the independent cooling channel loops, wherein, in each independent cooling channel loop of the plurality of independent cooling channel loops, the cooling fluid flows through the plurality of feed pipes and the plurality of headers into the cooling channel loop only in response to forming a breach in the outer wall of the component, the breach exposing at least one of the cooling channels of the cooling channel loop.

Description

[0001] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] This invention was made with Government support under Contract DE-FE0031611 awarded by the U.S. Department of Energy. The Government has certain rights. Background Art

[0003] The present disclosure relates generally to turbine systems, and more particularly to the delivery of cooling fluid to components of a gas turbine system via independent cooling circuits.

[0004] Gas turbine systems are an example of a turbine widely used in fields such as power generation. Conventional gas turbine systems typically include a compressor section, a combustor section, and a turbine section. During operation of a gas turbine system, various components in the system, such as turbine blades, nozzle airfoils, and shroud segments, are subjected to high-temperature airflow, which can lead to component failure. Since higher-temperature airflow generally increases the performance, efficiency, and power output of a gas turbine system, it is advantageous to cool components subjected to high-temperature airflow to allow the gas turbine system to operate at elevated temperatures and extend the life of the gas turbine system components.

[0005] Cooling is typically provided by directing a cooling fluid flow through internal passages formed in components of the gas turbine system (e.g., convection cooling, impingement cooling, etc.) In many cases, the cooling fluid is provided by bleeding a portion of the air discharged by the compressor section of the gas turbine system.

[0006] Thermal barrier coatings (TBCs) are commonly applied to gas turbine system components to provide a protective heat shield, prevent damage due to high temperatures, and extend component life by reducing oxidation and thermal fatigue. Spalling of TBCs is a common problem in gas turbine systems. When a TBC spalls, portions of the TBC can break off and detach from the component, exposing the underlying surface to high temperatures and damage (e.g., wall breaches). Summary of the Invention

[0007] One aspect of the present disclosure relates to a cooling delivery system for selectively delivering a flow of cooling fluid to a component of a gas turbine system, the cooling delivery system comprising: a plurality of independent cooling channel loops embedded in an outer wall of the component, each independent cooling channel loop comprising a plurality of headers and a plurality of feed pipes, the plurality of feed pipes fluidly coupling the plurality of headers to a cooling fluid supply source; and an impingement plate connected to the outer wall of the component through the plurality of feed pipes of the independent cooling channel loops, wherein, in each independent cooling channel loop of the plurality of independent cooling channel loops, the cooling fluid flows through the plurality of feed pipes and the plurality of headers into the cooling channel loop only in response to forming a breach in the outer wall of the component, the breach exposing at least one of the cooling channels of the cooling channel loop.

[0008] Another aspect of the present disclosure relates to a gas turbine system, comprising: a component of the gas turbine system; and a cooling system for the component, the cooling system comprising: a plurality of independent cooling channel loops embedded in an outer wall of the component, each independent cooling channel loop comprising a plurality of headers and a plurality of feed pipes, the plurality of feed pipes fluidly coupling the plurality of headers to a cooling fluid supply source; and an impingement plate connected to the outer wall of the component through the plurality of feed pipes of the plurality of independent cooling channel loops, wherein, in each independent cooling channel loop of the plurality of independent cooling channel loops, the cooling fluid flows through the plurality of feed pipes and the plurality of headers into the cooling channel loop only in response to forming a breach in the outer wall of the component, the breach exposing at least one of the cooling channels of the cooling channel loop.

[0009] Another aspect of the present disclosure relates to a method for reducing spalling-related damage to a component of a gas turbine system, the method comprising: embedding a plurality of independent cooling channel loops within a segment of an outer wall of the component, wherein the cooling channels of each cooling channel loop of the plurality of cooling channel loops are non-linear, interwoven, and extend unidirectionally within the outer wall of the component; and directing a flow of cooling fluid into at least one cooling channel loop of the plurality of cooling channel loops only in response to a wall breach exposing a portion of the at least one cooling channel loop of the plurality of cooling channel loops.

[0010] Illustrative aspects of the present disclosure address the problems described herein and / or other problems not discussed. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various embodiments of the disclosure.

[0012] Figure 1 Depicted is a schematic diagram of a gas turbine system according to an embodiment.

[0013] Figure 2 Depicted is a side view of a portion of a turbine section of a gas turbine system according to an embodiment.

[0014] Figure 3 Depicted is a perspective view of a turbine blade according to an embodiment.

[0015] Figure 4A and Figure 4B Examples of impingement cooling before and after wall breach formation are depicted, respectively.

[0016] Figure 5Depicted is an independent cooling circuit in a component of a gas turbine system, looking out from the interior of the component, according to an embodiment.

[0017] Figure 6 Depicts a view from the outside of a component looking inward according to an embodiment. Figure 5 Independent cooling circuit.

[0018] Figure 7 Depicts the embodiment according to Figure 6 An independent cooling circuit with a portion of the outer wall removed to show the interconnecting cooling channels.

[0019] Figure 8 Depicts the embodiment according to Figure 5 Another view of the independent cooling circuit, where part of the outer wall of the component is removed.

[0020] Figure 9 Depicts the embodiment according to Figure 5 Cross-sectional view of the independent cooling circuit.

[0021] Figure 10 Depicts the process of forming a partial or complete outer wall breach according to an embodiment. Figure 5 Operation of independent cooling circuits.

[0022] Figure 11 Depicted are independent cooling circuits in components of a gas turbine system according to additional embodiments.

[0023] Figure 12 Depicted according to additional embodiments Figure 11 Cross-sectional view of the independent cooling circuit.

[0024] Figure 13 Depicted according to additional embodiments Figure 11 Another view of the independent cooling circuit.

[0025] Figure 14 Depicted according to additional embodiments Figure 11 Another view of the independent cooling circuit.

[0026] Figure 15 An independent cooling circuit according to yet another embodiment is depicted.

[0027] Figure 16 depicts a block diagram of an additive manufacturing process according to an embodiment,

[0028] The additive manufacturing process includes a non-transitory computer-readable storage medium storing code representing an object.

[0029] Figure 17 and Figure 18Depicted is a wall coupon for additive manufacturing of a component for a gas turbine system, according to an embodiment.

[0030] Figure 19 and Figure 20 Depicted is an additively manufactured wall coupon with powder removal openings according to an embodiment.

[0031] It should be noted that the drawings of the present disclosure are not necessarily drawn to scale. The drawings are intended to depict only typical aspects of the present disclosure and therefore should not be considered to limit the scope of the present disclosure. In the drawings, similar numbers represent similar elements between the drawings. DETAILED DESCRIPTION

[0032] Reference will now be made in detail to the representative embodiments illustrated in the accompanying drawings. It should be understood that the following description is not intended to limit the embodiments to a preferred embodiment. On the contrary, it is intended to cover alternatives, modifications and equivalents that may be included within the spirit and scope of the described embodiments as defined by the appended claims.

[0033] First, in order to clearly describe the present disclosure, it will be necessary to select certain terms when referencing and describing relevant machine components within the scope of the present disclosure. In doing so, common industry terms will be used and adopted in a manner consistent with their accepted meanings, if possible. Unless otherwise indicated, such terms should be given a broad interpretation consistent with the context of this application and the scope of the appended claims. Those of ordinary skill in the art will understand that several different or overlapping terms may often be used to refer to a particular component. An object that may be described herein as a single part may include multiple components and be referenced in another context as consisting of multiple components. Alternatively, an object that may be described herein as comprising multiple components may be referred to elsewhere as a single part.

[0034] In addition, several descriptive terms may be used regularly in this document, and it should prove helpful to define these terms at the beginning of this section. Unless otherwise specified, these terms and their definitions are as follows. As used herein, "downstream" and "upstream" are terms that indicate the direction relative to the flow of a fluid, such as the working fluid through a turbine engine, or, for example, the flow of air through a combustor or the coolant through one of the component systems of a turbine. The term "downstream" corresponds to the direction of fluid flow, and the term "upstream" refers to the direction opposite to the flow. In the absence of any further particularity, the terms "front" and "rear" refer to directions, where "front" refers to the front end or compressor end of the engine, and "rear" refers to the rear end or turbine end of the engine. In addition, the terms "front" and "rear" may be used and / or understood to be similar in description to the terms "front" and "rear", respectively. Often, it is necessary to describe parts that are in different radial, axial and / or circumferential positions. The "A" axis represents the axial orientation. As used herein, the terms "axial" and / or "axially" refer to the relative position / orientation of an object along an axis A, which is substantially parallel to the axis of rotation of the gas turbine system (particularly the rotor section). As further used herein, the terms "radial" and / or "radially" refer to the relative position / orientation of an object along a direction "R" (see Figure 1 ), which is a direction substantially perpendicular to axis A and intersects axis A at only one location. Finally, the term "circumferential" refers to movement or position about axis A (e.g., direction "C").

[0035] In various embodiments, components that are described as being "fluidically coupled" or "in fluid communication" with each other may be joined along one or more interfaces. In some embodiments, these interfaces may comprise joints between different components, and in other cases, these interfaces may comprise secure and / or integrally formed interconnections. That is, in some cases, the components that are "coupled" to each other may be formed simultaneously to define a single continuous member. However, in other embodiments, these coupled components may be formed as separate components and subsequently joined by known processes (e.g., fastening, ultrasonic welding, bonding).

[0036] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element, it may be directly on, engaged to, connected to, or coupled to the other element, or intervening elements may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0037] Figure 1 A schematic diagram of a gas turbine system 10 according to various embodiments is shown. As shown, the gas turbine system 10 includes a compressor section 12 for compressing an incoming air flow 14 and for delivering a compressed air flow 16 to a combustor section 18. The combustor section 18 mixes the compressed air flow 16 with a pressurized fuel supply 20 and ignites the mixture to form a combustion gas flow 22. Although only a single combustor section 18 is shown, the gas turbine system 10 may include any number of combustor sections 18. The combustion gas flow 22 is then delivered to a turbine section 24. The combustion gas flow 22 drives the turbine section 24 to produce mechanical work. The mechanical work produced in the turbine section 24 drives the compressor section 12 via a shaft 26 and can be used to drive an external load 28 (such as a generator, etc.).

[0038] Figure 2 A side view of a portion of a turbine section 24 of a gas turbine system is depicted, including at least one stage 30 of turbine blades 32 (one shown) and at least one stage 34 of nozzles 36 (one shown) located within a casing 38 of the turbine section 24. Each stage 30 of turbine blades 32 includes a plurality of turbine blades 32 coupled to and positioned circumferentially about the rotor 26 and driven by the combustion gases 22. Each stage 34 of nozzles 36 includes a plurality of nozzles 36 coupled to and positioned circumferentially about the casing 38 of the turbine section 24. Figure 2 In the illustrated embodiment, each nozzle 36 includes an airfoil 40 positioned between an outer platform 42 and an inner platform 44 .

[0039] Similar to the nozzle 36, each turbine blade 32 of the turbine section 24 includes an airfoil 46 extending radially from the rotor 26. Each airfoil 46 includes a tip portion 48 and a platform 50 positioned opposite the tip portion 48.

[0040] The turbine blades 32 and the nozzle 36 may be positioned axially adjacent to each other within the housing 38. Figure 2 In FIG, for example, nozzles 36 are shown as being axially positioned adjacent and downstream of turbine blades 32. Turbine section 24 may include a plurality of stages 30 of turbine blades 32 and a plurality of stages 34 of nozzles 36 positioned axially throughout a casing 38.

[0041] The turbine section 24 of the gas turbine system 10 may include a plurality of stages 52 of shrouds 54 positioned axially throughout the casing 38 (at Figure 2 One level is shown in Figure 2 , for example, the stages 52 of the shroud 54 are shown as being radially positioned adjacent to and substantially surrounding or encircling the stages 30 of the turbine stage blades 32. The stages 52 of the shroud 54 may also be axially positioned adjacent to and / or upstream of the stages 34 of the nozzles 36. Furthermore, the stages 52 of the shroud 54 may be positioned between two adjacent stages 34 of the nozzles 36 located on opposite sides of the stages 30 of the turbine blades 32. The stages 52 of the shroud 54 may be coupled around the casing 38 of the turbine section 24 using a set of extensions 56, each extension including an opening 58 configured to receive a corresponding section of the shroud 54.

[0042] Go to Figure 3 , shows a perspective view of a turbine blade 32. Turbine blade 32 includes a shank 60; a platform 50 located radially above platform 50; and an airfoil 46 coupled to and extending radially outward from platform 50. Airfoil 46 includes a pressure side 62, an opposite suction side 64, and a tip portion 48. Airfoil 46 also includes a leading edge 68 between pressure side 62 and suction side 64; and a trailing edge 70 between pressure side 62 and suction side 64 on a side opposite leading edge 68.

[0043] Many components of a gas turbine system (e.g., turbine blades, nozzles, shrouds, etc.) can be cooled during operation by directing a fixed supply of cooling fluid through internal passages formed in these components. In many cases, the cooling fluid is provided by bleeding a fixed supply of air discharged from the compressor section of the gas turbine system.

[0044] Many different internal cooling methods can be used to cool the components of a gas turbine system, including, for example, convection cooling, film cooling, and impingement cooling. Convection cooling works by passing a cooling fluid stream through channels inside the component. Heat is transferred through the component by conduction and then transferred to the cooling fluid flowing through the component. With film cooling, the cooling fluid is discharged to the outer surface of the component via small holes formed through the outer wall of the component. The cooling fluid provides a thin, cooled, insulating blanket along the outer surface of the component. Impingement cooling (a variation of convection cooling) works by directing a higher velocity stream of cooling fluid against the inner surface of the component. This allows more heat to be transferred by convection than with conventional convection cooling. Impingement cooling is typically used in areas of the component that are exposed to high heat loads (e.g., the leading edge of a turbine blade).

[0045] If a breach forms in a portion of a component of a gas turbine system (e.g., due to TBC spalling or other damage) and exposes any internal cooling passages, some of the fixed cooling fluid supply may flow from the exposed internal cooling passages through the breach and out of the component. This reduces the remaining amount of fixed cooling fluid supply available to the component, thereby reducing cooling effectiveness and potentially leading to component failure. Figure 4A and Figure 4B An example of such a wall breach is depicted in .

[0046] Figure 4A A gas turbine system (eg, gas turbine system 10, Figure 1 ). As shown, a cooling fluid supply 82 is directed through a plurality of openings 88 formed in an impingement plate 90 against an inner surface 84 of an outer wall 86 of the component 80. An outer surface 92 of the outer wall 86 of the component 80 is exposed to a hot gas flow 94. Figure 4B Component 80 is depicted having an indentation 96 extending through outer wall 86. As shown, a portion of cooling fluid 82 escapes through indentation 96 through outer wall 86 of component 80, reducing available cooling for component 80, thereby causing damage to spread and potentially leading to component failure.

[0047] According to an embodiment, an independent cooling circuit is provided to deliver an additional independent cooling fluid supply source to a component of a gas turbine system in response to a partial or complete wall breach. The component may include, for example, a turbine blade, a nozzle airfoil, a shroud segment, a combustion liner, or other components that may need cooling during operation of the gas turbine system. At least one cooling channel interconnection circuit may be embedded in the outer wall of the component. A plurality of coolant feed channels are provided in the component (e.g., in / on an impingement plate or insert, in / on an inner wall, and / or the like). A plurality of feed pipes fluidically couple the coolant feed channels to each cooling channel interconnection circuit embedded in the outer wall of the component. During normal operation (e.g., there is no partial or complete breach in the outer wall of the component), the cooling fluid does not flow through the independent cooling circuit because the cooling fluid has no outlet. However, when a partial or complete wall breach occurs and exposes at least a portion of the cooling channel interconnection circuit embedded in the outer wall of the component, a flow path is generated that allows the cooling fluid supply source to flow to the affected area through the independent cooling system. The cooling provided by this additional independent cooling fluid flow can extend the life of the component after surface damage has occurred (e.g., reduce / prevent additional spalling in the notch area) without affecting the baseline cooling effectiveness within the component (e.g., impingement cooling).

[0048] A first embodiment of an independent cooling circuit 100 for a component 102 of a gas turbine system 10 according to an embodiment ( Figure 1 )exist Figures 5 to 10 1. The component 102 may include any component of the gas turbine system 10 that may require cooling, including but not limited to turbine blades, nozzle airfoils, shroud segments, combustion liners, etc. In this example, an impingement cooling arrangement 104 is used to cool an outer wall 106 of the component 102. For example, to provide impingement cooling, a supply of cooling fluid 108 may be directed into an inner cavity 110 of the component 102 during operation of the gas turbine system 10. The supply of cooling fluid 108 may be, for example, by venting a compressor section 12 ( Figure 1 ) is provided by exhaust air. The cooling fluid 108 flows from the internal cavity 110 through a plurality of impingement holes 112 formed in the impingement plate 114, into the impingement cavity 118, and against the inner surface 116 of the outer wall 106 of the component 102. After impingement against the inner surface 116 of the outer wall 106, the cooling fluid 108 can be directed from the impingement cavity 118 to one or more interior / exterior regions of the component 102 (e.g., for film cooling). Although described in conjunction with impingement cooling in this and other embodiments, the independent cooling circuit 100 can be used with other cooling arrangements (e.g., convection cooling, etc.).

[0049] Figures 5 to 10The independent cooling circuit 100 depicted in (also mentioned) includes a plurality of coolant feed channels 120 (although not always required depending on the application); a plurality of feed tubes 122 connecting the impingement plate 114 to the outer wall 106; and an interconnecting circuit 124 of cooling channels 126 ( Figures 7 to 10 ), the interconnecting circuit of cooling channels 126 is embedded within the outer wall 106 of the component 102. The interconnecting circuit 124 of cooling channels 126 is completely enclosed within the outer wall 106 of the component 102 such that none of the cooling channels 126 extend to or are exposed at an outer surface 132 (e.g., a hot gas surface) of the outer wall 106. The coolant feed passages 120 may be attached to the impingement plate 114, formed as part of or within the impingement plate 114, or provided in any other suitable manner. According to an embodiment, the nominal position of the feed tubes 122 may be midway between the intersections 130 to ensure coolant feed at the gaps most likely to occur at the intersections 130. In other embodiments, the feed tubes 122 may be located at or near the intersections 130.

[0050] Each of these coolant feed channels 120 is fluidly coupled to an interconnected circuit 124 of cooling channels 126 via a plurality of openings 121 in the impingement plate 114 and a plurality of feed tubes 122. The coolant feed channels 120 are each fluidly coupled to a pressurized supply of cooling fluid 128 that is independent of the supply of cooling fluid 108 provided to the impingement cooling arrangement 104. The supply of cooling fluid 128 can be provided by bleed air discharged from the compressor section 12 of the gas turbine system 10 or in any other suitable manner (e.g., a compressed air source provided by a source other than the compressor section 12 of the gas turbine system 10). The interconnected circuit 124 of cooling channels 126 does not include an outlet for the cooling fluid 128. If desired, the coolant feed channels 120 can also include separate channels that feed each feed tube 122. In other embodiments, the coolant feed channels 120 can be integral to the outer wall 106.

[0051] exist Figures 5 to 10 In the illustrated embodiment, the cooling channels 126 of the interconnected circuits 124 can be (e.g., in a planar configuration) embedded within the outer wall 106 of the component 102 at approximately the same distance from an outer surface 132 of the outer wall 106. Additionally, the feed tubes 122 can extend into the outer wall 106 at approximately the same distance from the cooling channels 126 of the interconnected circuits 124. A plurality of intersections 130 can be provided to fluidly interconnect all of the cooling channels 126 of the interconnected circuits 124. The cooling channels 126 can be arranged in a grid-like pattern (e.g., a rectangular grid) within the outer wall 106 and can extend linearly between the feed tubes 122 and / or between the intersections 130.

[0052] In other embodiments, the cooling channels 126 (or portions thereof) of the interconnecting circuit 124 can be embedded within the outer wall 106 at different distances from the outer surface 132 of the outer wall 106. This may require the feed tubes 122 to extend into the outer wall 106 at different distances from the cooling channels 126 of the interconnecting circuit 124. Furthermore, in other embodiments, rather than using a single pressurized cooling fluid supply source and a single cooling channel interconnecting circuit, multiple independent cooling channel circuits can be used. A single pressurized cooling fluid supply source can be fluidically coupled to all of the cooling channel circuits, or multiple separate pressurized cooling fluid supplies can be used, each fluidly coupled to one or more of the cooling channel circuits. In embodiments where cooling feed channels 120 are not used, the pre-impingement cooling fluid 108 can be fed into the interconnecting circuit 124 of the cooling channels 126 through multiple feed tubes 122.

[0053] See again Figures 5 to 10 During normal operation (e.g., in the absence of a partial or complete breach in the outer wall 106 of the component 102), there is no flow of cooling fluid 128 through the independent cooling circuit 100 because the interconnected circuits 124 of the cooling channels 126 are embedded and fully enclosed within the outer wall 106 and do not include an outlet for the cooling fluid 128. However, as Figure 10 As shown, in response to the formation of a partial or full wall breach 96 in the outer wall 106 of the component 102, at least a portion of the cooling channels 126 in the outer wall 106 of the component 102 may become exposed, thereby providing an outlet for a cooling fluid 128. To this extent, the cooling fluid 128 may now flow through the cooling channels 126 exposed by the wall breach 96. Specifically, the cooling fluid 128 may flow through the coolant feed channels 120, the plurality of feed tubes 122, and the cooling channels 126 of the interconnecting circuits 124 toward and away from the cooling channels 126 exposed by the wall breach 96. The cooling fluid 128 ultimately flows from the cooling channels 126 exposed in the breach 96 to the exterior of the component 102. Generally, the flow rate of the cooling fluid 128 increases in the channels closest to the breach 96. The flow of cooling fluid 128 provides additional cooling to the component 102 in the area adjacent to the wall breach 96, independent of any cooling provided by the impingement cooling arrangement 104. The additional cooling provided by cooling fluid 128 may reduce or prevent additional spalling, for example, in the area of ​​notch 96. This may prevent notch 96 from increasing in size and may extend the operational life of component 102.

[0054] The standalone cooling system 100 includes a single pressurized supply of cooling fluid 128 , a plurality of coolant feed channels 120 , a plurality of intersections 130 connecting interconnected circuits 124 of the cooling channels 126 , and a plurality of feed tubes 122 . Figures 11 to 14(referenced together) depicts another embodiment of an independent cooling circuit 200. The independent cooling circuit 200 includes a plurality (eg, two in this example) of independent unidirectional interwoven circuits 202, 204.

[0055] Circuit 202 includes a plurality of headers 206, a plurality of feed tubes 208 fluidly coupled to each header 206 and connecting the impingement plate 114 to the outer wall 106, and a plurality of cooling channels 210 extending between and fluidly coupled to the headers 206. Similarly, circuit 204 includes a plurality of headers 212, a plurality of feed tubes 214 fluidly coupled to each header 212 and connecting the impingement plate 114 to the outer wall 106, and a plurality of cooling channels 216 extending between and fluidly coupled to the headers 212.

[0056] The cooling passages 210, 216 and their headers 206, 212 are embedded within the outer wall 106 of the component 102 of the gas turbine system 10 ( Figure 1 ), and extends in the same direction as indicated by arrow A within the outer wall 106 ( Figure 14 Each of the circuits 202 , 204 of cooling passages 210 , 216 is completely enclosed within the outer wall 106 of the component 102 , such that none of the cooling passages 210 , 216 extends to or is exposed at the outer surface 132 of the outer wall 106 of the component 102 .

[0057] Regarding the above Figures 5 to 10 Unlike the cooling channels 126 of the interconnected circuit 124 as described, which extend linearly between the feed tubes 122 and / or between the intersections 130, the cooling channels 210, 216 in the circuits 202, 204 of the independent cooling circuit 200 may have a nonlinear configuration (e.g., a zigzag configuration as shown, a sinusoidal configuration, etc.). For example, Figures 11 to 14 As depicted, the cooling passages 210 in the loop 202 may extend and weave in a zigzag pattern between the headers 206 within the outer wall 106 while bypassing the headers 212 of the loop 204. Similarly, the cooling passages 216 in the loop 204 may extend and weave in a zigzag pattern (parallel to the cooling passages 210) between the headers 212 within the outer wall 106 while bypassing the headers 206 of the loop 202. To this extent, as Figure 14 As best shown in FIG, the cooling channels 210 of the circuit 202 and the cooling channels 216 of the circuit 204 form a texture 218 of cooling channels 210, 216 within the outer wall 206 of the component 102. Figure 12 As best shown in FIG. 1 , the distance between the cooling passages 210 , 216 and the outer surface 132 of the outer wall 106 varies within and along the outer wall 106 .

[0058] According to an embodiment, the supply sources of cooling fluids 220, 222 may be provided to the circuits 202, 204 of the independent cooling circuit 200 via feed pipes 208, 214, respectively. The supply sources of cooling fluids 220, 222 may be independent of one another and may be provided by one or more different cooling fluid sources (e.g., by bleeding different portions of the air exhausted by the compressor section 12 of the gas turbine system 10, by reusing the cooling fluid 108, etc.). The cooling fluids 220, 222 may be provided directly to the feed pipes 208, 214 (e.g., from the inner cavity 110 ( Figure 5 )), or may be provided via a corresponding set of coolant feed passages 224, 226 (at Figure 11 1 . The coolant feed passages 224, 226, if used, may be attached to, formed as part of, or formed within the impingement plate 114 in the component 102, or provided in any other suitable manner. Neither circuit 202, 204 of the cooling passages 210, 216 includes an outlet for the supply of cooling fluid 220, 222.

[0059] As in Figures 5 to 10 In the illustrated embodiment, an impingement cooling system 104 may be provided to cool an outer wall 106 of the component 102. To provide impingement cooling, a supply of cooling fluid 108 is directed into an inner cavity 110 of the component 102 during operation of the gas turbine system 10 (see, e.g., Figure 5 The cooling fluid 108 flows from the interior cavity 110 through a plurality of impingement holes 112 (eg, formed in an impingement plate 114 ), into an impingement cavity 118 , and against an interior surface 116 of the outer wall 106 of the component 102 .

[0060] During normal operation (e.g., in the absence of a partial or complete breach in the outer wall 106 of the component 102 ), there is no flow of cooling fluid 220 , 222 through either of the circuits 202 , 204 of the cooling channels 210 , 216 of the independent cooling circuit 200 because the circuits 202 , 204 of the cooling channels 210 , 216 are embedded and fully enclosed within the outer wall 106 and do not include an outlet for the cooling fluid 220 , 222 .

[0061] When the wall is partially or completely breached 96 (see e.g. Figure 10) appears in the outer wall 106, at least a portion of one or more of the cooling channels 210, 216 in the outer wall 106 of the component 102 may become exposed. The exposure of one or more of the cooling channels 210 in the circuit 202 creates an outlet for the cooling fluid 220. Thus, the cooling fluid 220 can now flow through the feed tube 208 and the header 206 into the cooling channels 210, flowing toward (and out of) the cooling channels 210 exposed by the wall breach 96. Similarly, the exposure of one or more of the cooling channels 216 in the circuit 204 creates an outlet for the cooling fluid 222. The cooling fluid 222 can now flow through the feed tube 214 and the header 212 into the cooling channels 216, flowing toward (and out of) the cooling channels 216 exposed by the wall breach 96. The cooling fluid 220 will flow through the circuit 202 of the cooling channels 210 only in response to the exposure of one or more of the cooling channels 210. Likewise, the cooling fluid 222 will flow through the circuit 204 of the cooling channels 216 only in response to exposure of one or more of the cooling channels 216. To this extent, one or both of the circuits 202, 204 of the cooling channels 210, 216 may be activated depending on which cooling channel(s) 210, 216 have been exposed by the wall breach 96.

[0062] The flow of cooling fluid 220 and / or 222 via independent cooling circuit 200 provides additional cooling to component 102 in the area adjacent to wall indentation 96, independent of any cooling provided by impingement cooling arrangement 104. The additional cooling provided by cooling fluid 220 and / or 222 can, for example, reduce or prevent additional spalling in the area of ​​indentation 96. This can prevent indentation 96 from increasing in size and can extend the operational life of component 102.

[0063] The use of multiple independent circuits 202, 204 and the nonlinear configuration of the cooling channels 210, 216 provide a longer flow path within the outer wall 106 of the component 102, which can enhance heat transfer to the cooling fluids 220, 222 and increase the cooling effectiveness of the independent cooling circuit 200. Additionally, in response to the formation of the shallower / smaller notch 96, portions of the cooling channels 210, 216 located closer to the outer surface 132 of the outer wall 106 of the component 102 may become exposed. As a result, the independent cooling circuit 200 may be activated more quickly in response to a spalling event than in response to an independent cooling circuit 100 having a planar configuration.

[0064] Compare Figure 14 and Figure 8As can be seen, the independent cooling circuit 200 can provide a higher density of cooling channels 210 , 216 in the outer wall 106 of the component 102 than the independent cooling circuit 100 (eg, due to the braided configuration of the circuits 202 , 204 ). The higher density can increase the cooling effectiveness of the independent cooling circuit 200 .

[0065] In the independent cooling circuits 100, 200, a supply source of cooling fluid may be provided independently of a main supply source of cooling fluid (e.g., a supply source of cooling fluid 108 for impingement cooling) to limit any reduction in backflow margin (BFM) in the event that a large area of ​​the cooling passage becomes exposed due to a spalling event. BFM is defined as the pressure of the cooling fluid inside the component 102 of the gas turbine system 10 relative to the pressure of the combustion gases 22 outside the component 102 ( Figure 1 ) between the local pressures of the cooling channels 210 and 216. However, in an independent cooling circuit 200 comprising multiple independent circuits 202 and 204 of cooling channels 210 and 216, a combination of cooling fluid sources may be used depending on the application. For example, one of the circuits 202 and 204 of the cooling channels 210 and 216 may be supplied by bleeding compressed air from the compressor section 112, while another of the circuits 202 and 204 of the cooling channels 210 and 216 may reuse cooling fluid from the main cooling circuit in the component 102 (e.g., the cooling fluid 108 used for impingement cooling in the impingement cooling arrangement 104), or some combination of such sources. In such a case, a spalling event may allow for additional cooling in the main cooling circuit while limiting the reduction in BFM.

[0066] Figure 15 Shown Figures 11 to 14 A modification of the independent cooling circuit 200 is depicted that utilizes a combination of cooling fluid sources. Figure 15 The independent cooling circuit 300 in FIG. 1 operates similarly to the independent cooling circuit 200 described above. Specifically, the circuit 202 of the cooling channel 210 is fluidly coupled to a supply of cooling fluid 220 via the feed tube 208 and operates as described above. However, unlike in the independent cooling circuit 200, the circuit 204 of the cooling channel 216 in the independent cooling circuit 300 is fluidly coupled to the impingement cavity 118 (and, therefore, to a supply of cooling fluid 108) via a plurality of openings 302 formed in the outer wall 106 of the component 102. When the wall breaches 96 in the outer wall 106 expose at least a portion of one or more of the cooling channels 216, the cooling fluid 108 can now flow from the impingement cavity 118 through the openings 302 into the circuit 204 of the cooling channel 216, toward (and away from) the cooling channel 216 exposed by the wall breaches 96. In this way, the cooling fluid 108 used for impingement cooling is reused by the independent cooling circuit 300.

[0067] Various components and features of the independent cooling circuits 100, 200, 300 of the present disclosure can be formed using additive manufacturing processes. Advantageously, additive manufacturing enables the design and production of more customizable and complex features.

[0068] As used herein, additive manufacturing may include any process that produces an object by successively layering material rather than removing material (as in the case of conventional processes). Additive manufacturing can form complex geometries without the use of any kind of tools, molds, or fixtures, and with little or no waste of material. Rather than machining a part from a solid plastic or metal blank (much of which is cut away and discarded), the only material used in additive manufacturing is that required to form the part. Additive manufacturing processes may include, but are not limited to, 3D printing, rapid prototyping (RP), direct digital manufacturing (DDM), binder jetting, selective laser melting (SLM), and direct metal laser melting (DMLM). In the current setting, DMLM or SLM has been found to be advantageous.

[0069] To illustrate an example of an additive manufacturing process, Figure 16 A schematic / block diagram of an exemplary computerized additive manufacturing system 400 for generating an object 402 is shown. In this example, the system 400 is arranged for DMLM, but it will be understood that the general teachings of the present disclosure are equally applicable to other forms of additive manufacturing. The AM system 400 generally includes a computerized additive manufacturing (AM) control system 404 and an AM printer 406. The AM system 400 executes code 420, which includes a set of computer executable instructions defining an object 402 to physically generate the object 402 using the AM printer 406. Each AM process may use a different raw material in the form of, for example, a fine-grained powder, a liquid (e.g., a polymer), a sheet, etc., a stock solution of which may be maintained in a chamber 410 of the AM printer 406. According to an embodiment, the object 402 may be made of a material that can withstand the pressure of the gas turbine system 10 (see Figure 1 ) environment. As shown, the applicator 412 can form a thin layer of raw material 414, which is spread out as a blank canvas on the construction plate 444 of the AM printer 406, and each consecutive slice of the final object will be formed from this blank canvas. In other cases, the applicator 412 can apply or print the next layer directly onto the previous layer as defined by code 420. In the example shown, as defined by code 420, a laser or electron beam melts the particles of each slice. Various parts of the AM printer 406 can move to accommodate the addition of each new layer, for example, after each layer, the build platform 418 can be lowered and / or the chamber 410 and / or the applicator 412 can be raised.

[0070] AM control system 404 is shown as being implemented as computer program code on a computer 430. To this extent, computer 430 is shown as including memory 432, a processor 434, an input / output (I / O) interface 436, and a bus 438. Furthermore, computer 430 is shown in communication with external I / O devices / resources 440 and a storage system 442. Generally, processor 434 executes computer program code stored in memory 432 and / or storage system 442 under instructions from code 420 representing an object 402, such as AM control system 404.

[0071] The additive manufacturing process begins with a non-transitory computer-readable storage medium (e.g., memory 432, storage system 442, etc.) storing code 420 representing an object 402. For example, code 420 may include a precisely defined 3D model of object 402 and may be generated by any of a variety of well-known computer-aided design (CAD) software systems. AM control system 404 executes code 420 to divide object 402 into a series of thin sheets that are assembled in successive layers of liquid, powder, sheet, or other material using AM printer 406.

[0072] The material may be manufactured using an additive manufacturing (AM) process (e.g., using an AM system 400, Figure 16 ) to produce the various components of the gas turbine system 10 ( Figure 1 ) or parts of such components. For example, at least a portion of the outer wall of a component comprising an interconnected circuit of cooling channels may be produced via an AM process.

[0073] exist Figure 17 For example, it has been produced (e.g., printed) via an AM process. Figures 5 to 10 10. The wall coupon 500 of the component 102 is depicted in FIG. The wall coupon 500 includes a segment 502 of the outer wall 106 of the component 102. At least a portion of the interconnected circuits 124 of the cooling channels 126 are embedded within the wall segment 502. The wall coupon 500 also includes a plurality of feed tubes 122 that are fluidly coupled to the cooling channels 126. To this extent, the wall coupon 500 forms a portion of the independent cooling circuit 100 as described above. According to other embodiments, the wall coupon 500 may be formed with at least a portion of the interconnected circuits 202, 204 of the cooling channels 210, 216 embedded therein.

[0074] According to embodiments, the wall coupon 500 can be produced via an AM process to any size and can be attached to another section 504 of the component 102 to form at least a portion of the independent cooling circuit 100 (see, e.g., Figure 18). The section 504 of the component 102 can be formed in a conventional manner (e.g., machining, casting, etc.), or can be formed using an AM process. It should be noted that the wall coupon 500 can be configured for use in any of the independent cooling circuits 100, 200, 300 described herein. Attachment can be achieved, for example, using brazing, welding, or other suitable metal joining processes. Figure 18 A wall coupon 500 is depicted that is attached (eg, via brazing / welding) to the impingement plate 114 of the component 102 to form at least a portion of the independent cooling circuit 100. In other embodiments, Figure 18 The entire cooling structure depicted in FIG. 1 may be formed using an AM process and may be attached to a portion of the component 102 of the gas turbine system 10 .

[0075] The independent cooling circuits 100 formed using the AM-printed wall coupons 500 can be strategically placed in areas of the component 102 of the gas turbine system 10 that may be subject to spalling. This can be done, for example, without necessarily producing the entire component 102 using an AM process. Furthermore, the independent cooling circuits 100 formed using the AM-printed wall coupons 500 can be retrofitted into existing components 102 of the gas turbine system 10 to repair areas previously damaged by spalling and / or selectively provide enhanced cooling to areas of the component 102 that are subject to spalling as described above.

[0076] When using an AM process to create the independent cooling loops 100, 200, 300 (or portions thereof), the removal of excess powder can be problematic. Because the independent cooling loops 100, 200, 300 do not have an outlet for the cooling fluid 128 (e.g., the loops are intentionally dead-ended), there is no easy way to use forced air to attempt to remove excess powder.

[0077] According to the implementation plan, Figure 19 and Figure 20 Depicted and referenced is a wall coupon 500 ( Figure 17 and Figure 18 ), a plurality of small openings 600 for powder removal may be provided in the outer wall section 502 of the wall coupon 500 (eg, formed during the AM process). Figure 19 and Figure 20 , for example, openings 600 are shown extending from the interconnected circuits 124 of the cooling channels 126 of the individual cooling circuits 100 through the outer wall segment 502 to the outer surface 132 of the wall coupon 500 .

[0078] The openings 600 provide an outlet for removing excess powder. Powder can be removed, for example, using vibration or by forcing air into the interconnected circuits 124 of the cooling channels 126 and out through the openings 600. After the powder is removed, the openings 600 can be filled / sealed in any suitable manner (e.g., with metal, sealant, etc.) to close the independent cooling circuits 100. The openings 600 can be filled / sealed before the TBC coating is applied to the outer surface 132 of the wall coupon 500, or simply sealed by the TBC coating itself. In some cases, a spalling event may unseal some of the sealed openings 600 before any of the interconnected circuits 124 of the cooling channels 126 are exposed due to the formation of a breach. The cooling fluid 128 can then flow to and out of the unsealed openings 600 via the independent cooling circuits 100, thereby providing an immediate cooling benefit.

[0079] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the present disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that when used in the specification, the terms "comprises" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or parts, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, and / or groups thereof.

[0080] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A coolant delivery system for selectively delivering a cooling fluid to a component of a gas turbine system, the coolant delivery system comprising: a plurality of independent cooling channel circuits embedded in an outer wall of the component, each independent cooling channel circuit comprising a plurality of headers and a plurality of feed tubes fluidly coupling the plurality of headers to a cooling fluid supply; an impingement plate connected to the outer wall of the component via the plurality of feed tubes of the plurality of independent cooling channel circuits, and an impingement cavity separating the outer wall of the component from the impingement plate, the plurality of feed tubes of each independent cooling channel circuit extending through the impingement cavity, wherein, in each of the plurality of independent cooling channel circuits, the cooling fluid flows through the plurality of feed tubes and the plurality of headers into the cooling channel circuit only in response to forming a breach in the outer wall of the component, the breach exposing at least one of the cooling channels of the cooling channel circuit. 2 . The coolant delivery system of claim 1 , wherein each independent cooling channel circuit is fluidly coupled to an independent cooling fluid supply. 3 . The coolant delivery system of claim 1 , wherein at least one of the independent cooling channel circuits is fluidly coupled to a supply of recycled cooling fluid.

4. The coolant delivery system of claim 3, wherein the reused cooling fluid comprises post-impact cooling fluid. 5 . The coolant delivery system of claim 1 , wherein in each independent cooling channel loop, the cooling channel extends between and is fluidly coupled to the headers of the independent cooling channel loop. 6 . The coolant delivery system of claim 5 , wherein the cooling channels of the plurality of independent cooling channel circuits are interwoven and extend unidirectionally within the outer wall of the component.

7. The coolant delivery system of claim 5, wherein in each independent cooling channel loop, the cooling channel extends non-linearly between the plurality of headers such that a distance between the cooling channel and the outer surface of the outer wall of the component varies.

8. The coolant delivery system of claim 5, wherein in each independent cooling channel loop, the cooling channel extends around the plurality of headers of other independent cooling channel loops.

9. The coolant delivery system of claim 1 , further comprising a wall coupon formed using an additive manufacturing process, the wall coupon comprising a segment of the outer wall of the component, wherein the plurality of independent cooling channel loops are embedded within the segment of the outer wall.

10. The coolant delivery system of claim 9, wherein the wall coupon comprises a plurality of powder removal openings extending from at least one of the plurality of independent cooling channel loops to the exterior surface of the section of the exterior wall.

11. A gas turbine system, comprising: Components of gas turbine systems; as well as A cooling system for the component, the cooling system comprising: a plurality of independent cooling channel circuits embedded in an outer wall of the component, each independent cooling channel circuit comprising a plurality of headers and a plurality of feed tubes fluidly coupling the plurality of headers to a cooling fluid supply; and an impingement plate connected to the outer wall of the component via the plurality of feed pipes of the plurality of independent cooling channel circuits, wherein each independent cooling channel circuit is fluidly coupled to an independent cooling fluid supply source, and wherein, in each of the plurality of independent cooling channel circuits, the cooling fluid flows through the plurality of feed tubes and the plurality of headers into the cooling channel circuit only in response to forming a breach in the outer wall of the component, the breach exposing at least one of the cooling channels of the cooling channel circuit.

12. The gas turbine system of claim 11, wherein at least one of the independent cooling channel circuits is fluidly coupled to a supply of recycled cooling fluid.

13. The gas turbine system of claim 12, wherein the recycled cooling fluid comprises post-impingement cooling fluid.

14. The gas turbine system of claim 11, wherein in each independent cooling channel circuit, the cooling channels extend between and are fluidly coupled to the headers of the independent cooling channel circuits, and wherein the cooling channels are interwoven and extend unidirectionally within the outer wall of the component.

15. The gas turbine system of claim 14, wherein in each independent cooling channel loop, the cooling channel extends non-linearly between the plurality of headers such that a distance between the cooling channel and an outer surface of the outer wall of the component varies. 16 . The gas turbine system of claim 14 , wherein in each independent cooling channel circuit, the cooling channel extends around the plurality of headers of the other independent cooling channel circuits.

17. The gas turbine system of claim 11, further comprising a wall coupon formed using an additive manufacturing process, the wall coupon comprising a segment of the outer wall of the component, wherein the plurality of independent cooling channel circuits are embedded within the segment of the outer wall.

18. The gas turbine system of claim 17, wherein the wall coupon includes a plurality of powder removal openings extending from at least one of the plurality of independent cooling passage loops to the outer surface of the section of the outer wall.

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