Turbine combustion chamber and system with an effusion plate

Abstract

Turbine combustion chamber (14), comprising: a combustion chamber (42); a head end portion (48); and an effusion plate (40) placed between the combustion chamber (42) and the head end section (48), comprising: a proximal side (106); a distal side (108); and one or more channels (80) extending between the proximal side (106) and the distal side (108), wherein the one or more channels (80) have a serpentine or tortuous cross-sectional geometry, the cross-section being taken along a plane extending between the proximal side (106) and the distal side (108).

Description

NOTE ON GOVERNMENT-FUNDED RESEARCH & DEVELOPMENT

[0001] This invention was made under U.S. Department of Energy Contract DE-FC26-05NT42643 with support from the U.S. Government. The government is granted certain rights in this invention. GENERAL STATE OF THE ART

[0002] The subject matter disclosed herein relates generally to turbine combustion chambers and, more particularly, to a structure adapted to provide cooling within turbine combustion chambers.

[0003] A gas turbine burns a fuel-air mixture in a combustion chamber of a turbine combustor and then drives one or more turbines with the resulting hot combustion gas. In such systems, the combustor generates a significant amount of heat. This heat can cause thermal expansion and lead to wear or possible damage to various components within the system. In some gas turbines, a combustion chamber head end contains one or more fuel nozzles that provide fuel and air for combustion in a combustion chamber. Unfortunately, the high combustion temperatures can cause thermal expansion of sections of the combustion chamber, including the fuel nozzles. This thermal expansion can lead to power degradation, stress, cracking, and other problems.

[0004] US 2011 / 0 016 874 A1 discloses an effusion plate for a gas turbine with effusion holes extending through the effusion plate from the proximal surface to the distal surface. The effusion holes are each straight along the entire extension between the proximal and distal surfaces and are arranged parallel to each other and at an angle other than 90° with respect to the proximal and distal surfaces.

[0005] DE 10 2004 032 093 A1 discloses a component manufactured by selective laser melting (SLM) with at least one flow channel penetrating the interior of the component. A turbulence element is arranged in the region of the flow channel, which, in one embodiment, is formed by an annular constriction of the flow cross-section of the flow channel. In another embodiment, the turbulence element is formed by a sintered spiral-shaped flow channel section. BRIEF DESCRIPTION OF THE INVENTION

[0006] The present invention provides a turbine combustion chamber and a system having the features of independent claims 1 and 2, as well as a turbine combustion chamber and a system having the features of independent claims 6 and 7. Particularly preferred embodiments of the invention are specified in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other features, aspects and advantages of the present invention will be better understood from the following detailed description with reference to the accompanying drawings, in which like reference numerals represent like parts throughout the drawings, in which: Fig. 1 is a simplified illustration of one embodiment of a gas turbine system; Fig. 2 a cross-sectional view and side view of the turbine combustion chamber of Fig. 1, which illustrates an embodiment of an effusion plate placed adjacent to a combustion chamber; Fig. 3 is a front view of an embodiment of the effusion plate of FIG. 1 made according to the present disclosure. Fig. 2, which has a plurality of cooling holes; Fig. 4 is a cross-sectional view and side view of an embodiment of the effusion plate of FIG. 1 constructed in accordance with the present disclosure. Fig. 2 with curved channels; Fig. 5 a simplified side view of an embodiment of an outlet opening of the channels of Fig. 4 is within the range 5-5; Fig. 6 is a cross-sectional and side view of an embodiment of the effusion plate with curved channels placed circumferentially around fuel nozzles; Fig. 7 is a simplified plan view of the curved channel embodiment of Fig. 6 is within 7-7; Fig. 8 a cross-sectional view and side view of an embodiment of the effusion plate of Fig. 2 having a tapered channel with a plurality of turbulators placed in the channel; Fig. 9 a cross-sectional view and side view of the tapered channel of Fig. 8 is within 9-9, in which the plurality of turbulators in the channel is shown; and Fig. 10 is a flow diagram illustrating one embodiment of a material-adding manufacturing method for manufacturing the effusion plate according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0008] One or more specific embodiments of the present invention are described below. In order to succinctly describe these embodiments, not all features of an actual implementation may be described in the description. It should be recognized that in developing such an actual implementation, as with any engineering or design project, numerous implementation-specific decisions must be made to achieve the designers' specific goals, such as meeting system and business requirements that may differ from one implementation to the next. It should further be recognized that this development effort could be complex and time-consuming for one skilled in the art having the benefit of this disclosure, but would nevertheless be routine in design, manufacture, and production.

[0009] When elements of various embodiments of the present invention are presented, the terms "a," "an," "the," "the," and "the" are intended to mean that one or more of the elements are present. The terms "comprising," "containing," and "having" are intended to be inclusive and mean that additional elements may be present besides those listed.

[0010] Gas turbines may include an effusion plate for cooling in the combustion chamber, e.g., in a cover between a head end and a combustion chamber of the combustor. Such effusion plates may be arranged to provide effusion cooling, which involves flowing cooling air through a plurality of closely spaced, relatively small holes. Some effusion plates may have holes therein to improve cooling (e.g., in the head end, such as the cover) and to reduce thermal damage resulting from the combustion of gases in the combustion chamber. The holes may be made by drilling into the effusion plate; thus, the holes are restricted to a straight geometry. Unfortunately, holes made in this way have limited cooling effectiveness and may therefore be inadequate.The present disclosure thus provides embodiments of an effusion plate manufactured using material-adding manufacturing processes. Using such processes, the effusion plates thus manufactured may include one or more design features configured to provide enhanced cooling. Examples of such design features include, but are not limited to, curved cooling channels, tapered cooling channel inlet and outlet openings, or turbulators within cooling channels. An effusion plate having the design features described herein may require less air to adequately cool the system, which in turn may provide various benefits such as lower emissions and more efficient combustion. For example, the disclosed design features may increase the surface area of ​​the effusion plate, increase its residence time, and enhance its overall cooling capacity.

[0011] Effusion plates of the present disclosure can be manufactured using material-adding manufacturing processes. Such processes generally allow complex solids to be constructed from computer models without difficult machining steps. Material-adding processes generally involve directing an energy source, such as a laser or electron beam, onto deposited powder layers to create a part with a specific shape and features.

[0012] With reference to the drawings, Fig. 1 illustrates a block diagram of one embodiment of a gas turbine system 10 that may include an effusion plate according to the present embodiments. The system 10 includes a compressor 12, a turbine combustor 14, and a turbine 16. The turbine combustors 14 may include one or more fuel nozzles 18 configured to receive a liquid fuel and / or gaseous fuel 20, such as natural gas or syngas.

[0013] A fuel-air mixture is ignited and burned in the turbine combustion chambers 14, and then hot, pressurized combustion gases 22 (e.g., exhaust gases) are directed into the turbine 16. Turbine blades are coupled to a shaft 24, which is also coupled to several other components throughout the turbine system 10. As the combustion gases 22 flow through the turbine blades in the turbine 16, the turbine 16 is rotated, causing the shaft 24 to rotate. The combustion gases 22 ultimately flow out of the turbine system 10 through an exhaust outlet 26. The shaft 24 may further be coupled to a load 28 that is driven via the rotation of the shaft 24. The load 28 may, for example, be any suitable device that can generate energy via the rotational power of the turbine system 10, for example an electric generator, an aircraft propeller, and so on.

[0014] Compressor blades may be included as components of compressor 12. The blades in compressor 12 are coupled to shaft 24 and rotate when shaft 24 is rotated by turbine 16, as previously described. An inlet 30 supplies air 32 to compressor 12, and the rotation of the blades in compressor 12 compresses the air 32 to generate compressed air 34. The compressed air 34 is then delivered to the fuel nozzles 18 of the turbine combustion chambers 14.

[0015] The fuel nozzles 18 mix the pressurized air 34 and the fuel 20 to create a suitable mixture ratio for combustion (e.g., combustion that causes the fuel to burn more completely) so as not to waste fuel or cause excessive emissions. In particular, certain gas turbine systems may include a plurality of separate premix tubes configured to receive and mix the fuel 20 and the pressurized air 34. In some embodiments, these premix tubes may be housed within the fuel nozzle 18, although in some systems, the premix tubes may be used in place of the fuel nozzle 18. In other words, each premix tube may be independently suspended in a headend chamber and not housed within a fuel nozzle 18 or arranged as a group.

[0016] Fig. Figure 2 is a simplified illustration of an embodiment of the turbine combustion chamber 14 of Fig. 1, which shows an effusion plate 40 placed adjacent to a combustion chamber 42. As previously described, the compressor 12 receives the air 32 from the air inlet 30, compresses the air, and generates a stream of compressed air 34 for use in the combustion process within the turbine combustion chamber 14. As shown in the illustrated embodiment, the compressed air 34 is received from a compressor outlet 44 that is operatively coupled to the turbine combustion chamber 14. As indicated by arrows 46, the compressed air 34 flows from the compressor outlet 44 toward a head end 48 of the turbine combustion chamber 14. Specifically, the compressed air 34 flows through an annular space 50 between a liner 52 and a baffle 54 of the turbine combustion chamber 14 and then reaches the head end 48.

[0017] In certain embodiments, the head end 48 includes an end plate 56 that defines the one or more Fig. 1. In addition, a fuel supply 58 may be coupled to the end plate 56 and supply the fuel nozzles 18 with fuel 20. Pressurized air 34 from the annular space 50 of the turbine combustion chamber 14 may also be supplied to the fuel nozzles 18, and the fuel 20 may be combined with the compressed air 34 in the fuel nozzles 18 to produce a fuel-air mixture. After the fuel and air are mixed, the fuel-air mixture flows downstream from the head end 48 into the combustion chamber 42, where the fuel-air mixture is ignited and burned to produce combustion gases (e.g., exhaust gases). The combustion gases flow in a direction 60 toward a transition portion 62 of the turbine combustion chamber 14.The combustion gases flow through the transition part 62, as indicated by the arrow 64, towards the turbine 16, where the combustion gases cause the blades in the turbine 16 to rotate.

[0018] As previously noted, the combustion of the fuel-air mixture results in high temperatures in the combustion chamber 42 compared to other portions of the gas turbine 10. For example, the combustion may cause temperatures to reach from approximately 1093°C to 1649°C (2000°F to 3000°F) or more degrees Celsius. The effusion plate 40 fabricated according to the present disclosure may, in turn, be used to protect the head end 48 (e.g., including the fuel nozzles 18) from heat generated in the combustion chamber 42. The effusion plate 40 may be configured to provide cooling within the combustion chamber 14 through the use of one or more channels or elements having a geometry that provides a relatively large internal surface area for enhanced convection cooling compared to substantially straight channels.

[0019] The effusion plate 40 of the present disclosure may generally separate the head end 48 from the combustion chamber 42. More specifically, the effusion plate 40 may be located on or within a cover assembly 72 adjacent the combustion chamber 42. In some embodiments, the effusion plate 40 may be a stand-alone structure located adjacent the combustion chamber 42. The effusion plate 40 may generally be configured to at least partially surround and / or support the downstream end of the fuel nozzles 18, thereby facilitating the flow of the fuel-air mixture from the fuel nozzles 18 into the combustion chamber 42. The effusion plate 40 described herein may additionally be disposed within, integrated with, or extend along a wall of one of the components of the combustion system.Thus, in some embodiments, material-added manufacturing processes may be used to construct the effusion plate 40 and / or the various cooling elements described below (e.g., cooling channels with various curvatures, angled inlet and outlet openings, and so on) on or within various other components or surfaces of the combustion system to provide cooling. In some embodiments, the effusion plate 40 and / or the cooling elements (e.g., cooling channels and the like) may be constructed on or within the combustor cover, the fuel nozzle, the turbine blade, the combustor liner, the transition piece, and so on. In some embodiments, a combustor cover, a combustor wall, the fuel nozzle, a turbine vane, a turbine shroud, or any combination thereof may be configured to include or be coupled to the effusion plate 40.

[0020] The effusion plate 40 described herein may be made from any of a variety of materials. In some embodiments, the effusion plate 40 may be made from a corrosion-resistant metal alloy, such as a nickel-based alloy or a chromium-based alloy. More specifically, in some embodiments, the effusion plate may be made from INCONEL 617 or INCONEL 718 (nickel-based alloys manufactured by Special Metals Corporation), cobalt-chromium, or other similar alloys. In addition, any other materials that can be built up and formed using a material-added manufacturing process may be used. For example, stainless steel and titanium may be used in the construction of the effusion plate 40 because these materials are available as powders (e.g.,These materials are available (either commercially or after treatment) and can be processed into specific structures using material-adding manufacturing processes. As further examples, various ceramic materials and composite materials can be used in the construction of the effusion plate 40. Various material combinations are also conceivable for the structure of the effusion plate 40.

[0021] Fig. 3 is a front view of one embodiment of the effusion plate 40 according to the present disclosure. The effusion plate 40 may be generally circular, although any shape is presently contemplated. As illustrated, the effusion plate 40 may include one or more openings 78 for receiving a downstream end of a corresponding number of fuel nozzles 18, and the fuel nozzles 18 may extend through the openings 78 of the effusion plate 40 into the combustion chamber 42. In the illustrated embodiment, the effusion plate 40 surrounds and / or supports five fuel nozzles 18, although the effusion plate 40 may be configured to accommodate any number of fuel nozzles 18.

[0022] As previously noted, the effusion plates 40 of the present disclosure may alternatively be configured to be incorporated into premix turbine systems having one or more premix tubes extending through the one or more fuel nozzles 18 (e.g., there may be 2 to 1000 tubes extending through a fuel nozzle). Each premix tube may, for example, receive both fuel 20 and air 22 and premix the fuel 20 and air 22 in the respective mixing tube. Each mixing tube may further have a diameter of approximately 0.25 to 5, 0.5 to 4, 0.75 to 3, or 1 to 2 centimeters. The effusion plates 40 described herein may alternatively be incorporated into various systems having one or more separate premix tubes extending between the end plate 56 and the combustion chamber 42 ( Fig. 2). In these premixing systems, the plurality of openings 78 in the effusion plate 40 may be configured (e.g., sized and shaped) to receive a downstream end of a corresponding number of premixing tubes. The effusion plate 40 may generally surround and / or retain an end of each premixing tube, thereby allowing the fuel-air mixture to be introduced into the combustion chamber 42 at a suitable ratio for optimal combustion, emissions, fuel consumption, and power output.

[0023] According to the present disclosure, material-added manufacturing processes may be used to construct the effusion plate 40, which has openings 78 for receiving fuel nozzles and / or premix tubes and additionally has one or more channels 80 disposed in an area 82 around and between the openings 78 to promote cooling during combustion of gases in the adjacent combustion chamber 42. In some embodiments, the channels 80 may receive a portion of the pressurized air 34 from the head end 48 and / or cooling air supplied via a separate inlet opening in the combustion chamber and / or exhaust gases to effectively cool the effusion plate 40. The channels 80 may be arranged in various ways within the effusion plate. For example, the channels 80 may be evenly or substantially evenly distributed throughout the effusion plate 40, as shown in Fig. 3. However, in some embodiments, the channels 80 may be concentrated in a central portion of the effusion plate 40 or any area of ​​the effusion plate 40 that may be subject to relatively high temperatures. As another example, the channels 80 may be grouped or concentrated around each of the openings 78.

[0024] Effusion plates 40 manufactured according to the material-adding manufacturing methods of the present disclosure may include various cooling elements having a curved or asymmetrically shaped geometry, and examples of these elements are described in more detail below. Fig. 4 illustrates a cross-section of one embodiment of the effusion plate 40 having curved channels 80 (e.g., up-and-down, wave-like, or generally arcuate channels) that may be formed via a material-adding manufacturing process. The curved channels 80 may have 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more curved sections, such as top and bottom bends. The channels 80 may also have zigzag-shaped or angled sections. In particular, the effusion plate 40 may be configured to include one or more curved channels 80 having an inlet opening 102 and / or an outlet opening 104. In some embodiments, approximately 10, 100, 1000, 2000, 3000, or more curved channels 80 may be placed in the effusion plate 40.In some embodiments, the walls defining the arcuate channels 82 may be annular, forming substantially cylindrically shaped arcuate channels 80 extending between a proximal side 106 and a distal side 108 of the effusion plate 40. The arcuate channels 80 may be generally serpentine or tortuous, as in the embodiment of FIG. Fig. 4. For example, the channels 80 may have a curved cross-sectional geometry 106 when a cross-section 108 is created along a plane extending between a proximal side and a distal side of the effusion plate 40. The curved channels 80 may further include curves or bends aligned in one or more planes within the effusion plate. Fig. 4 is illustrated in the context of curved channels 80, any geometry may be suitable for the channels 80. Various other geometries are contemplated, including designs that provide increased surface area within the channels 80 to enhance heat transfer between the pressurized air 34 and the effusion plate 40 as the pressurized air 34 or exhaust gases flow through the channels 80. While any size or geometry is presently contemplated, a diameter 110 of interior portions of the channels 80 may generally range from about 0.01 centimeters to about 0.5 or more centimeters. However, in some embodiments, the diameter 110 may range from about 0.02 to about 0.3 or about 0.1 to about 0.2 centimeters. Further, as discussed below, the diameter 110 may vary along the length of the channels 80 to provide a tapered geometry.

[0025] Material-adding manufacturing techniques may also enable the construction of a relatively strong effusion plate 40, enabling better protection and cooling. A relatively strong effusion plate may generally enable each channel 80 to have a longer length and / or a higher length-to-diameter (L / D) ratio, allowing more heat to be transferred through the increased surface area within the channel 80. Therefore, in some embodiments, material-adding manufacturing techniques may be used to construct relatively strong effusion plates having channels 80 with high L / D values ​​and an increased surface area for heat transfer. In particular, the effusion plate 40 of the present disclosure may generally have a thickness of about 0.1 to about 1 or more centimeters.In some embodiments, the effusion plate 40 may have a thickness of about 0.1 to about 0.8, or from about 0.3 to about 0.7, or from about 0.4 to about 0.6 centimeters. The channels 80 may generally run between the distal side 108 and the proximal side 106 of the effusion plate 40, or in other words, the channels 80 may generally run across the thickness of the effusion plate 40. Additionally, curved channels 80 are possible with material-adding manufacturing techniques such that the length of the channels 80 is longer than the thickness t of the effusion plate 40. For example, the length of the channels 80 may be at least 1%, 10%, 20%, 50%, or more longer than the thickness t. In particular, the channels 80 may be between 10% and 500% longer, 20% to 400% longer, 25% to 300% longer, or any suitable percentage longer than the thickness t of the effusion plate 40.

[0026] In some embodiments, it is also possible for the inlet opening 102 and / or outlet opening 104 to be designed quite differently by means of material-adding manufacturing processes. With reference to Fig. 5, which is an enlarged view of the inlet openings 102 and the outlet openings 104 of the effusion plate 40, the inlet openings 102 and / or outlet openings 104 may be circular, square, elliptical, or any other suitable shape. For example, in some embodiments, one or more channels 80 are configured to flare radially outward (e.g., diverge) at the inlet opening 102 and / or the outlet opening 104 such that the diameter of the inlet opening 102 and / or the outlet opening 104 is larger than the diameter of an inner portion of the channel 80 in the effusion plate 40. An expanded outlet opening 104 such as that shown in Fig. The outlet opening 104 shown in Figure 5 can, for example, provide stronger film cooling. As shown in Fig. 4, such a tapered geometry may enhance the airflow illustrated by curved arrows 112 along the distal side 108 of the effusion plate 40. Although any suitable size is presently contemplated, the diameter of the inlet openings 102 or outlet openings 104 may generally range from about 0.02 to about 1 or more centimeters. However, in some embodiments, the diameter of the inlet openings and outlet openings may range from about 0.05 to about 0.8 or about 0.1 to about 0.5 centimeters.

[0027] As in Fig. 4, one or more of the inlet ports 102 and / or outlet ports 104 may additionally be positioned at an angle α relative to the proximal side 106 or distal side 108 of the effusion plate 40 when using material-added manufacturing techniques. For example, the inlet ports 102 and / or outlet ports 104 may receive air or discharge it from the channels 80 at an angle of between approximately 90 degrees and 5 degrees, 80 degrees and 10 degrees, 70 degrees and 20 degrees, 60 degrees and 30 degrees, or 50 degrees and 40 degrees relative to the proximal side 106 or distal side 108. In some embodiments, the inlet openings 102 and / or outlet openings 103 may receive or discharge air from the channels 80 at an angle of approximately 90, 80, 70, 60, 50, 40, 30, and / or 20 degrees relative to the proximal side 106 or distal side 108.In another embodiment, the inlet openings 102 and / or outlet openings 104 may be arranged at an angle of approximately less than about 45 degrees relative to the proximal side 106 and distal side 108, respectively. Alternatively, each inlet opening 102 and / or outlet opening 104 may be arranged at an angle of approximately less than about 20 degrees relative to the proximal side 106 and distal side 108, respectively. The various inlet openings 102 and / or outlet openings 104 in the effusion plate 40 may further be placed at different angles to one another. In some embodiments, the inlet openings 102 and / or outlet openings 104 may be angled, for example, to create a converging or diverging airflow.

[0028] Additionally, in some embodiments, when the effusion plate 40 is formed using a material-added manufacturing process, the inner walls of the channels 80 may be substantially smooth, particularly compared to straight channels formed using laser or waterjet processes, which may leave burnt or roughened portions or unpredictable or irregular holes. However, in some embodiments, the inner walls of the channel 80 may be ridged. The ridges may be about 20 micrometers thick, although the ridges may range from about 5 micrometers to 30 micrometers. The ridges may also run longitudinally or circumferentially along the inner wall of the channels 80 and may be formed by compacting multiple layers of metal powder together during the material-added manufacturing process.

[0029] Fig. 6 and Fig. 7 illustrate an embodiment manufactured using material-adding manufacturing techniques in which annular channels 120 generally surround or wrap around a fuel nozzle 18 (e.g., a premix tube). As shown in Fig. 7, each of the channels 120 may be substantially spiral or coiled so that they are arranged circumferentially around the openings 78. In Fig. 6, each of the channels 120 is wrapped twice circumferentially around the fuel nozzle 18 (i.e., the orifice 78), although in other embodiments, the channels 120 may be wrapped 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more times around the fuel nozzle 18 between the proximal side 106 and the distal side 108 of the effusion plate 40. Further, additional bends, twists, and features may be included along the length of each of the annular channels 120. Although in Fig. 6, the channels 120 are shown surrounding a fuel nozzle 18 (e.g., a premix tube), in some premix systems, these annular channels 120 may in turn directly surround or wrap around a plurality of premix tubes. For example, the fuel nozzles 18 may have a diameter ranging from about 7 to about 20 centimeters, while the diameter of premix tubes may be smaller—from about 0.5 to about 2 centimeters. Thus, it is presently conceivable that the channels 120 may be conveniently configured to wrap around thicker fuel nozzles 18 or to surround thinner premix tubes (e.g., a single premix tube or a group of 2 to 100, 3 to 50, or 4 to 25 premix tubes).

[0030] Fig. Figure 8 illustrates an embodiment of the effusion plate 40, not per se within the claimed invention, manufactured according to the material-adding manufacturing method of the present disclosure. As shown, in certain embodiments, each channel 80 may taper generally between the proximal side 106 and the distal side 108 of the effusion plate 40. For example, the diameter at the inlet opening 102 may be larger than the diameter of an interior portion of the channel 80 in the effusion plate 40. This taper may be desirable for accelerating air through the channel 80, resulting in better heat transfer.In some embodiments, the channel 80 may gradually taper along the entire length of the channel 80 such that the inlet opening 102 has the largest diameter within the channel 80, while the outlet opening 104 has the smallest diameter within the channel 80. However, in other embodiments, as shown in FIG. Fig. 8, it may be desirable to taper the channel 80 from the inlet opening 102 to a location 124 (e.g., a midpoint location) within the channel 80 and also to provide a flared or radially expanded exit opening 104. In this way, the channel 80 may have a passageway in the form of a venturi tube. Some embodiments may have alternating tapered and radially expanded sections so that the cross-sectional diameter varies along the length of the channel 80. Other designs having various tapered sections and expanded sections along the length of the channel 80, as shown in dashed lines, are contemplated.

[0031] Fig. 9 is an enlarged view of an inner wall 130 of the channel 80 within lines 9-9 of Fig. 8. As illustrated, material-added manufacturing processes can be used to construct the inner wall 130 with various features designed to affect airflow through the channel 80. For example, one or more turbulators 132 can be placed at various locations on the inner wall 130. The turbulators 132 can have any design that affects airflow, such as random protrusions in one or more rows arranged axially along the length of the channel 80 or in one or more rows arranged circumferentially within the channel 80. The turbulators 132 can also be of any suitable size, and each channel 80 can have turbulators of one or more different sizes.As a non-exhaustive example, each turbulator 132 may independently have a cross-sectional geometry that is triangular, rectangular, square, semicircular, elliptical, or the like. These turbulators 132 may help increase the surface area for convective heat transfer (e.g., like small heat transfer fins) and / or the turbulators 132 may help create mixing or turbulent flow within the channels 80. The increased surface area and mixing, in turn, improve heat transfer and thus cooling.

[0032] The channels 80, which are manufactured using material-adding manufacturing processes, may also, in some embodiments, be differently shaped within the same effusion plate 40. For example, there may be one or more tapered channels 80 and one or more coiled channels 80, such as those shown in Fig. 7 may be integrated into the effusion plate 40. In other embodiments, one or more channels 80 may be connected inside the effusion plate 40. For example, two coiled channels 80 surrounding adjacent fuel nozzles 18 may intersect, allowing air to flow between the connected channels 80. In certain embodiments, one or more of the channels 80 may also be configured to branch or split between the proximal side 106 and distal side 108 of the effusion plate 40. In one embodiment, the channel 80 may branch into two or more different arms within the effusion plate 40, for example. The arms may be connected to two or more different exit ports 104 on the distal side 108 of the effusion plate 40, or alternatively, the arms may converge and connect to one exit port 104.

[0033] As previously noted, material-added manufacturing processes generally enable the construction of customized parts with complex geometries, curvatures, and features such as the cooling channels 80 discussed herein. Accordingly, material-added manufacturing can be used to construct effusion plates with different shapes and features such as the cooling channels 80 that are impractical or cannot be manufactured using conventional methods such as laser or waterjet machining processes.

[0034] Add-on manufacturing can be particularly useful in constructing an effusion plate 40 for a gas turbine system, as the effusion plate 40 can be constructed from high-strength materials that may be difficult to process or machine using conventional methods. Add-on manufacturing techniques also allow complex solid bodies to be constructed from computer models without difficult machining steps. Add-on manufacturing techniques generally involve directing a heat source, such as a laser or electron beam, onto deposited powder layers (e.g., layer upon layer) to create a part with a specific shape. Fig. 10 is a block diagram illustrating one embodiment of a method 138 for constructing an effusion plate (e.g., effusion plate 40) using material-added manufacturing techniques. The method 138 may be performed by a material-added manufacturing system, with the acts described herein being performed by a computer. The method 138 includes specifying a particular design (block 140). The design may be programmed into a material-added manufacturing system using, for example, a dedicated or general-purpose computer. In some embodiments, the template may be for an effusion plate (e.g., effusion plate 40) having a plurality of internal cooling channels (e.g., channels 80), each channel having a complex shape. The specified design may include any of the previously described shapes and features.The shape may, for example, be curved, circular / spiral-shaped, or it may be a radially expanded inlet opening 102 and / or exit opening 104. In step 142, a powder (e.g., a metal, ceramic, or composite powder) is deposited in a chamber, such as a vacuum chamber. Any of various materials may be used in any suitable combination, including those previously described in detail with reference to FIG. Fig.2. In step 144, an energy source, such as a laser or electron beam, is directed at the deposited metal powder. The laser or electron beam melts or otherwise densifies the powder into a layer having a cross-sectional shape 146 that conforms to the design specified in step 140. A computer or operator may determine in step 148 whether the part is incomplete or finished. If the part is incomplete, steps 142 and 144 are repeated to produce layers of densified powder having cross-sectional shapes 146 that conform to the specified shape or template until part build is complete. In other words, the energy source is applied to melt or otherwise densify each newly deposited layer of powder until the final product is complete and an effusion plate having the specified design is produced.

[0035] In this written description, examples are used to disclose the invention, including the best mode, and also to enable one skilled in the art to practice the invention, including making and using devices or systems and performing methods incorporated therein. The patentable scope of the invention is defined by the claims and may include other examples that occur to one skilled in the art. These other examples are intended to be within the scope of the claims if they include structural elements that do not depart from the precise language of the claims or if they include equivalent structural elements with insubstantial differences from the precise language of the claims.

[0036] Material-added manufacturing processes can be used to construct effusion plates. Such material-added manufacturing processes can include defining a design for an effusion plate with one or more internal cooling channels. The manufacturing processes can further include depositing a powder in a chamber, directing an energy source onto the deposited powder, and compacting the powder into a cross-sectional shape that conforms to the defined design. These processes can be performed to construct an effusion plate with one or more channels having a curved cross-sectional geometry.

Claims

[1] Turbine combustion chamber (14), comprising: a combustion chamber (42); a head end portion (48); and an effusion plate (40) placed between the combustion chamber (42) and the head end section (48), comprising: a proximal side (106); a distal side (108); and one or more channels (80) extending between the proximal side (106) and the distal side (108), wherein the one or more channels (80) have a serpentine or tortuous cross-sectional geometry, the cross-section being taken along a plane extending between the proximal side (106) and the distal side (108). [2] System comprising: an effusion plate (40) designed for mounting on a turbine combustion chamber, comprising: a proximal side (106); a distal side (108); and one or more channels (80) extending between the proximal side (106) and the distal side (108), wherein the one or more channels have a serpentine or tortuous cross-sectional geometry, the cross-section being taken along a plane extending between the proximal side (106) and the distal side (108). [3] Turbine combustor according to claim 1 or system according to claim 2, wherein the one or more channels (80) comprise a radially expanded exit opening (104) and / or a radially expanded inlet opening (102). [4] Turbine combustion chamber according to claim 1, wherein the one or more channels (80) comprise an inlet opening (102) and / or an outlet opening (104) oriented at an angle (α) less than 90° with respect to the proximal or distal side (106, 108). [5] Turbine combustor according to claim 1, wherein the effusion plate (40) has one or more openings (78) for receiving a downstream end of a corresponding number of fuel nozzles (18). [6] Turbine combustion chamber (14), comprising: a combustion chamber (42); a head end portion (48); and an effusion plate (40) placed between the combustion chamber (42) and the head end section (48), comprising: a proximal side (106); a distal side (108); one or more openings (78) extending through the effusion plate (40) from the proximal side (106) to the distal side (108), the one or more openings (78) each receiving a downstream end of a fuel nozzle (18), and one or more channels (120) extending between the proximal side (106) and the distal side (108), wherein the one or more channels (120) each have a spiral or coiled shape so that they each surround or are wrapped around one of the one or more openings (78) with the fuel nozzle (18) received therein. [7] System comprising: an effusion plate (40) designed for mounting on a turbine combustion chamber, comprising: a proximal side (106); a distal side (108); one or more openings (78) extending through the effusion plate (40) from the proximal side (106) to the distal side (108) for each receiving a downstream end of a fuel nozzle (18), and one or more channels (120) extending between the proximal side (106) and the distal side (108), the one or more channels (120) each having a spiral or coiled shape so as to each surround or wrap around one of the one or more openings (78).

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