Combustor head flange assembly for combustor and associated combustor system

Abstract

A combustor (30) includes a combustor body extending from first and second combustor ends (32, 34) with an axis extending (A) along the body between the ends (32, 34). A combustion chamber (36) is defined within the body between the ends (32, 34). A combustor head flange assembly (48) positioned at the first combustor end (32) includes a flange body (50) having front and back sides (52, 54), with the front side (52) defining a main fuel channel (58) and the flange body (50) defining main fuel holes (86) between the channel (58) and the chamber (36). The assembly (48) includes fuel nozzles (188) disposed at least partially in the main fuel holes (86). A swirler (90) positioned on the back side (54) has swirler projections (92) defining swirler channels (94), with the nozzles (188) having fuel outlet holes (116) to direct a fuel into the swirler channels (94). Each nozzle (188) cooperates with the flange body (50) to prevent each nozzle (188) from moving radially relative to the axis (A) and to align the fuel outlet holes 116) with the swirler channels (94).

Description

COMBUSTOR HEAD FLANGE ASSEMBLY FOR COMBUSTOR ANDASSOCIATED COMBUSTOR SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and all the benefits of U.S. Provisional Patent Application No. 63 / 712,655, filed on October 28, 2024, the contents of which are hereby expressly incorporated herein by reference in their entirety.FIELD OF THE DISCLOSURE

[0002] The present application generally relates to a combustor and, more specifically, to a combustor head flange assembly for a combustor and associated combustor system.BACKGROUND OF DISCLOSURE

[0003] Combustors can be used with power-generating gas turbines in combustion systems for improving the efficiency of such systems for converting chemical energy in fuel to electrical energy. The combustor is configured to receive a fuel and an oxidizing agent into a combustion chamber at a first combustor end and expel exhaust gas from the combustion chamber at a second combustor end with the expelled gas being directed, ultimately, toward a turbine wheel coupled to an electric machine.SUMMARY OF THE DISCLOSURE

[0004] A combustor configured to receive a fuel and an oxidizing agent and expel an exhaust gas includes a combustor body extending from a first combustor end to a second combustor end with an axis extending along the combustor body between the first combustor end and the second combustor end. A combustion chamber is defined within the combustor body1Docket No. DKT24099 / 065757.01395between the first combustor end and the second combustor end with the combustion chamber configured to receive the fuel and the oxidizing agent at the first combustor end and expel the exhaust gas at the second combustor end. The combustor also includes a combustor head flange assembly positioned at the first combustor end. The assembly includes a flange body extending along the axis and having a front side facing a first direction and a back side facing a second direction opposite the first direction. The front side of the flange body defines a pilot fuel channel circumferentially about the axis for receiving fuel and initiating combustion in the combustion chamber, and the front side of the flange body also defines a main fuel channel circumferentially about the axis spaced from the pilot fuel channel for receiving the fuel and maintaining combustion in the combustion chamber. The assembly also includes a plurality of main fuel holes defined in the flange body between the front side and the back side for fluid communication between the main fuel channel and the combustion chamber. The assembly also includes a plurality of fuel nozzles with one of the plurality of fuel nozzles disposed at least partially in a respective one of the plurality of main fuel holes. The assembly also includes a swirler positioned on the back side of the combustor head flange assembly, with the swirler having a plurality of swirler projections extending away from the back side of the combustor in the combustion chamber and with the plurality of swirler projections defining a plurality of swirler channels extending between adjacent swirler projections. Each one of the plurality of fuel nozzles extends from the back side of the flange body and into a respective one of the swirler channels to direct the fuel from a fuel outlet hole of each of the plurality of fuel nozzles into each of the plurality of swirler channels for combustion, wherein a length of each one of the fuel nozzles extends from the back side of the flange body towards the second combustor end to define a nozzle axis. In addition, each of the plurality of fuel nozzles is configured to cooperate with the flange body to prevent each of the2Docket No. DKT24099 / 065757.01395plurality of fuel nozzles from rotating about the nozzle axis and to align the fuel outlet holes with the swirler channels during installation and subsequent use.

[0005] A combustor system includes the combustor as described above. In addition, the combustor system includes a turbine wheel in fluid communication with the combustion chamber and configured to rotate upon receiving the expelled exhaust gas. Still further, the combustor system includes a shaft rotatable with the turbine wheel and an electric machine coupled to the shaft and configured to convert rotational motion of the shaft to electrical energy.

[0006] The subject disclosure also discloses a combustor head flange assembly as described above.

[0007] The use of the fuel nozzles in accordance with the subject disclosure provides advantages over conventional fuel nozzles. The fuel nozzles cooperate with the combustor head flange assembly according to poka-yoke principles to ensure that the fuel nozzle of each respective one of the plurality of fuel nozzles is insertable in only a single orientation and to ensure that the fuel outlet holes are consistently aligned in a single orientation into each of the swirler channels for combustion. Still further, the fuel nozzles are configured such that they cannot rotate, or twist about any axis and cannot move radially, axially or circumferentially, thus maintaining the alignment of the fuel outlet holes on the fuel nozzles in a single orientation relative to the swirler channel during the installation process. Manual orientation of each fuel nozzle in accordance with the prior art, such as before welding, with the fuel nozzle in accordance with the subject disclosure is thus unnecessary to ensure that the outlet holes of the fuel nozzles are properly aligned with one of the swirler channels. Still further, the fuel nozzles are configured such that they cannot rotate, or twist about any axis and cannot move radially, axially or circumferentially during use, thus maintaining the alignment of the fuel outlet holes on the fuel nozzles in a single orientation relative3Docket No. DKT24099 / 065757.01395to the swirler channels for consistent fuel output from the outlet holes in a particular spray orientation within and relative to the respective swirler channel to maintain consistent combustion within the combustion chamber.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other advantages of the present disclosure will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0009] Figure 1 A is a schematic illustration of a combustor system including a combustor, a compressor wheel, a turbine wheel, and an electric machine;

[0010] Figure IB is a schematic illustration of a combustor system including a combustor, a first compressor wheel, a second compressor wheel, a first turbine wheel, a second turbine wheel, a third turbine wheel, and a first and second electric machine;

[0011] Figure 2 is a partially schematic illustration of a combustor having a combustor head flange assembly at a first combustor end of the combustor;

[0012] Figure 3 is a perspective view partially in cross-section of a rotating detonation combustor extending between a first combustor end and a second combustor end;

[0013] Figure 4 is a perspective view of a front side of the flange body of the combustor head flange assembly with first and second ring covers according to the prior art;

[0014] Figure 5 is a perspective view of the front side of the flange body of the combustor head flange assembly, with the combustor head flange assembly defining a pilot fuel channel and a main fuel channel;

[0015] Figure 6 is an exploded view from a front side of the combustor head flange assembly according to the prior art;4Docket No. DKT24099 / 065757.01395

[0016] Figure ? is a cross-sectional view of the combustor head flange assembly according to the prior art;

[0017] Figure 8 is an exploded view from a back side of the combustor head flange assembly according to the prior art;

[0018] Figure 9 is a cross-sectional view of the combustor head flange assembly according to the prior art;

[0019] Figure 10 is a perspective view of the front side of the combustor head flange assembly with a one-piece plate cover;

[0020] Figure 11 is a cross-sectional view of a portion of the combustor head flange assembly of Figure 10;

[0021] Figure 12 is a perspective view of the front side of the combustor head flange assembly of Figure 10, with the combustor head flange assembly defining the pilot fuel channel and the main fuel channel and with the one-piece plate cover removed;

[0022] Figure 13 is an exploded view from the front side of the combustor head flange assembly;

[0023] Figure 14 is a perspective view of a fuel nozzle shown in Figures 11 and 13;

[0024] Figure 15 is a perspective view of the fuel nozzle of Figure 14 attached to the front side of the flange body of a portion of the combustor head flange assembly;

[0025] Figure 16 is an exploded view from the back side of the flange body of the combustor head flange assembly;

[0026] Figure 17 is another cross-sectional view of the combustor head flange assembly;

[0027] Figure 18 is an enlarged rearward perspective view of a portion of Figure 17;

[0028] Figure 19 is an enlarged rearward perspective view of another portion of Figure 17;5Docket No. DKT24099 / 065757.01395

[0029] Figure 20 is a cross-sectional view of a combustor head flange assembly which includes the first and second ring cover and the plurality of fuel nozzles of Figure 14;

[0030] Figure 21 is a perspective view of a fuel nozzle according to another exemplary embodiment;

[0031] Figure 22 is a perspective view of the fuel nozzle of Figure 21 attached to the front side of the flange body of a portion of the combustor head flange assembly;

[0032] Figure 23 is a blown-up view of Figure 22 within circle 23;

[0033] Figure 24 is a perspective view of a fuel nozzle according to yet another exemplary embodiment;

[0034] Figure 25 is front view of the front side of the flange body of the combustor head flange assembly illustrating a plurality of non-circular shaped main fuel holes each fluidically coupled to a main fuel channel;

[0035] Figure 26 is a perspective view of the fuel nozzle of Figure 23 attached to the front side of the flange body of a portion of the combustor head flange assembly of Figure 24.DETAILED DESCRIPTION OF THE DISCLOSURE

[0036] With reference to the Figures, wherein like numerals indicate like parts throughout the several views, an exemplary combustor configured for use in a combustor system 25 is depicted by reference numeral 30 in Figures 1A, IB and 2. The combustor 30 extends along an axis A between a first combustor end 32 and a second combustor end 34. The combustor 30 also defines a combustion chamber 36. The combustor 30 is configured to receive a fuel and an oxidizing agent (represented by arrows 42 and 44 in Figures 2 and 3) into the combustion chamber 36 at the first combustor end 32 and expel exhaust gas (represented by arrow 46 in Figures 2 and 3) from the6Docket No. DKT24099 / 065757.01395combustion chamber 36 at the second combustor end 34. The oxidizing agent 44 may alternatively be referred to as an oxidizer.

[0037] In one embodiment as shown in Figure 2, the combustion of the fuel 42 and the oxidizing agent 44 in the combustion chamber 36 occurs at subsonic speeds and may be characterized as deflagration. In this embodiment, the combustion chamber 36 of the combustor 30 may be cylindrical. However, in another embodiment as shown in Figure 3, the combustor 30 may be further defined as a rotating detonation combustor (RDC) 30’ having an outer wall 38 extending along and circumferentially about the axis A and an inner wall 40 extending along and circumferentially about the axis. The inner wall 40 is spaced radially inward relative to the outer wall 38 such that the combustion chamber 36 is further defined between the outer wall 38 and the inner wall 40. In this embodiment, the combustion of the fuel 42 and the oxidizing agent 44 in the combustion chamber 36 occurs at supersonic speeds and may be characterized as detonation. Other configurations of the combustor 30 are contemplated.

[0038] Unless otherwise specified, the description of a combustor 30 is equally applicable to the description of a rotating detonation combustor 30’, and thus the use of combustor 30 below is meant to include the RDC 30’ unless otherwise specified. In addition, the description of a combustor system 25 for a combustor 30 herein is equally applicable to the description of combustor system for an RDC 30’ unless otherwise specified and is referred to simply as system 25 below.

[0039] Referring back to Figure 1A, the system 25 in accordance with one configuration also includes a turbine wheel 26 in fluid communication with the combustion chamber 36. The turbine wheel 26 is configured to rotate upon receiving the exhaust gas 46 from the combustor 30. The system 25 further includes a shaft 27 rotatable with the turbine wheel 26 and an electric7Docket No. DKT24099 / 065757.01395machine 28 rotatable with the shaft 27. The electric machine 28 is configured to convert at least one of rotational motion of the shaft 27 to electrical energy and electrical energy from the electric machine 28 to rotational motion of the shaft 27.

[0040] Accordingly, the system 25 is able to convert chemical energy in fuel 42 to electrical energy through combustion of the fuel 42 in the combustion chamber 36 through expulsion of the exhaust gas 46 to rotate the turbine wheel 26 and the shaft 27. and through conversion of rotational motion of the shaft 27 to electrical energy by the electric machine 28.

[0041] In certain embodiments, the system 25 further includes a compressor wheel 29 rotatable with the shaft 27. The compressor wheel 29 is in fluid communication with the combustion chamber 36 and is configured to deliver compressed oxidizing agent 44 to the combustion chamber 36. Accordingly, the system 25 is also able to rotate the shaft 27 and hence rotate the compressor wheel 29. ensuring the adequate flow rate and pressure of the oxidizing agent 44 is delivered by the compressor wheel 29 to the combustion chamber 36. Ensuring adequate flow rate and pressure of the oxidizing agent 44 to the combustion chamber 36 through use of the electric machine 28 is advantageous during periods of operation of the combustor 30 (or of the rotational detonation combustor 30’) when the flow of exhaust gas 46 to the turbine wheel 26 cannot alone rotate the compressor wheel 29 with sufficient force to supply the combustion chamber 36 with an adequate flow rate and pressure of the oxidizing agent 44. such as during startup of the combustor 30.

[0042] In an alternative configuration to the system 25 of Figure 1A, as shown in Figure IB, the system 25 includes where the oxidizing agent 44 passes through a first compressor wheel 29A on a low pressure turbo and then passes through a second compressor wheel 29B on a high pressure turbo before being delivered to the combustion chamber 36 of the combustor 30. After8Docket No. DKT24099 / 065757.01395the combustor 30, the heated exhaust gas 46 goes through a first turbine wheel 26A on a high pressure turbo and then goes through a second turbine wheel 26B on a low pressure turbo. A first electric machine 28A is connected via shafts 27A between the first turbine wheel 26A and the second compressor wheel 29B, while a second electric machine 28B is connected via shafts 27B between the second turbine wheel 26B and the first compressor wheel 29 A. Finally, the exhaust gas 46 may go through a third turbine wheel 26C after passing through the second turbine wheel 26B.

[0043] Although not required, the system 25 of either Figure 1A or IB may also include a pump 31 and a fuel line 33 in fluid communication with the combustion chamber 36. The pump 31 is configured to direct the fuel 42 through the fuel line 33 to the combustion chamber 36. The system 25 may also include a control unit 35 configured to operate the pump 31 to either direct fuel 42 through the fuel line 33 to the combustion chamber 36. or to refrain from directing fuel 42 through the fuel line 33 to the combustion chamber 36. The control unit 35 may also be configured to control operation of the electric machine 28, and the control unit 35 may further be configured to control operation of the combustor 30, for example, by controlling an ignition process which determines when the combustor 30 ignites. The ignition process may be designed to promote transition from deflagration to detonation. The system 25 may further include a power grid 37 incorporating a battery and a direct current converter to supply power to the control unit 35. It is to be appreciated that the power grid 37 may be powered by the electric machine 28, and thus the system 25 requires no external power source.

[0044] Although not required, the combustor 30 may be used in combination with a recuperator (shown schematically as box 55 in Figure 2) disposed about the axis A. Generally, the recuperator 55 is a heat exchanger configured to recover waste heat generated from the combustion9Docket No. DKT24099 / 065757.01395of the fuel and the oxidizing agent 44. More specifically, the recuperator 55 may include a plurality of heat exchange cells that extract heat from downstream of the last turbine stage and transfer the heat to the oxidizer 44 immediately prior to addition of fuel 42 in the combustor 30. The heat added to the oxidizer 44 by the recuperator 55 can improve overall efficiency of the system 25.

[0045] As noted above, and referring back to Figures 1A. IB and 2, the system 25 includes the combustor 30. The combustor 30 includes a combustor head flange assembly 48 at the first combustor end 32 of the combustor 30. It is to be appreciated that the combustor head flange assembly 48 may be referred to as a combustor head flange 48 and used interchangeably therewith herein. As shown throughout Figures 4-13 and 15-19, the combustor head flange assembly 48 includes a flange body 50 having a front side 52 facing away from the second combustor end 34 of the combustor 30 and a back side 54 facing toward the second combustor end 34 of the combustor 30. The front side 52 of the flange body 50 of the combustor head flange assembly 48 defines a pilot fuel channel 56 circumferentially about the axis A for receiving the fuel 42 with the received fuel 42 used for initiating combustion in the combustion chamber 36. The front side 52 of the flange body 50 of the combustor head flange assembly 48 also defines a main fuel channel 58 circumferentially about the axis A for receiving the fuel 42 with the received fuel 42 used for maintaining combustion in the combustion chamber 36.

[0046] As illustrated in the Figures, the pilot fuel channel 56 is disposed radially inward relative to the main fuel channel 58. In other words, the pilot fuel channel 56 may be disposed radially between the main fuel channel 58 and the axis A. However, although not shown, it is to be appreciated that the main fuel channel 58 may instead be disposed radially inward relative to the pilot fuel channel 56. In other words, the main fuel channel 58 may be disposed radially between the pilot fuel channel 56 and the axis A.10Docket No. DKT24099 / 065757.01395

[0047] It is to be appreciated that the pilot fuel channel 56 need not extend completely circumferentially about the axis A. The pilot fuel channel 56 may be defined to include two separate ends 60, 62, particularly to accommodate an ignitor 108 between the two separate ends 60, 62 and outside the pilot fuel channel 56. Moreover, it is also to be appreciated that the main fuel channel 58 need not extend completely circumferentially about the axis A. In certain embodiments, the main fuel channel 58 may also be defined as having two separate ends.Prior Art

[0048] In accordance with the prior art, as shown in Figures 4 and 6-9, the combustor head flange assembly 48 includes a first ring cover 68 coveringdelimiting) the pilot fuel channel 56. The combustor head flange assembly 48 may define first notches on one or both sides of the pilot fuel channel 56 to seat the first ring cover 68. The combustor head flange assembly 48 also includes a second ring cover 72 covering the main fuel channel 58. The combustor head flange assembly 48 typically further define second notches on one or both sides of the main fuel channel 58 to seat the second ring cover 72.

[0049] The combustor head flange assembly 48 as shown in Figures 4 and 6-7 typically includes a pilot fuel fitting 76 coupled to the first ring cover 68. The pilot fuel fitting 76 is configured to be in fluid communication with a fuel source to provide the pilot fuel channel 56 with fuel 42. The combustor head flange assembly 48 includes the flange body 50 defining one or more pilot fuel inlet channels 78 (also referred to interchangeably as one or more pilot fuel holes 78 or one or more pilot fuel bores 78) in fluid communication with the pilot fuel channel 56 and the combustion chamber 36 to provide the combustion chamber 36 with fuel 42 from the pilot fuel channel 56. Although not required, the pilot fuel fitting 76 may be coupled to the first ring cover 68 through a pilot fuel pipe 80. In other words, the pilot fuel pipe 80 may be directly affixed to the11Docket No. DKT24099 / 065757.01395first ring cover 68 and the pilot fuel pipe 80 may be directly affixed to the pilot fuel fitting 76. The first ring cover 68 may define a pilot fuel fitting inlet hole 73 such that fuel 42 may flow through the pilot fuel fitting 76, the pilot fuel pipe 80, and the pilot fuel fitting inlet hole 73 into the pilot fuel channel 56.

[0050] The combustor head flange assembly 48 as shown in Figures 4 and 6-7 typically further includes a main fuel fitting 84 coupled to the second ring cover 72. The main fuel fitting 84 is configured to be in fluid communication with the fuel source to provide the main fuel channel 58 with fuel 42. The flange body 50 of the combustor head flange assembly 48 further defines one or more main fuel inlet channels 86 (also referred to interchangeably hereinafter as one or more main fuel holes 86 or one or more main fuel bores 86) extending between the main fuel channel 58 and the combustion chamber 36. Although not required, the main fuel fitting 84 may be coupled to the second ring cover 72 through a main fuel pipe 85. In other words, the main fuel pipe 85 may be directly affixed to the second ring cover 72 and the main fuel pipe 85 may be directly affixed to the main fuel fitting 84. The second ring cover 72 typically defines a main fuel fitting inlet hole 82 such that fuel 42 may flow through the main fuel fitting 84, the main fuel pipe 85, and the main fuel fitting inlet hole 82 into the main fuel channel 58.

[0051] The combustor head flange assembly 48 as shown in Figures 4 and 6-8 typically further includes the ignitor 108. The ignitor 108 may produce a spark or other means of igniting and / or detonating the fuel 42 in the combustion chamber 36. The ignitor 108 includes an ignitor fitting 110 fixed, such as by welding, to the flange body 50 of the combustor head flange assembly 48. It is to be appreciated that the ignitor 108 may be adjacent to the pilot fuel channel 56 so that the ignitor 108 may ignite and / or detonate fuel 42 which is passing, or has passed, through the pilot fuel channel 56.12Docket No. DKT24099 / 065757.01395

[0052] As shown in Figures 5 and 8, the flange body 50 of the combustor head flange assembly 48 defines one or more main fuel holes 86. As shown in Figures 6-9, the combustor head flange assembly 48 further includes a plurality of fuel nozzles 88 each disposed at least partially in a respective one of the plurality of main fuel holes 86. Accordingly, the fuel nozzles 88 disposed in the main fuel holes 86 provide the combustion chamber 36 with fuel 42 from the main fuel channel 58 and are therefore in fluid communication with each of the main fuel channel 58 and the combustion chamber 36. Further, the main fuel fitting 84 is in fluid communication with each one of the one or more main fuel holes 86 through the main fuel channel 58.

[0053] As best shown in Figure 8, the back side 54 of the flange body 50 of the combustor head flange assembly 48 includes a swirler 90 having a plurality of swirler projections 92 extending toward the second combustor end 34 of the combustor 30 and defining a plurality of swirler channels 94 between adjacent swirler projections 92. The plurality of fuel nozzles 88 extend from the back side 54 of the flange body 50 of the combustor head flange assembly 48 toward the second combustor end 34 of the combustor 30 and define at least one outlet hole 116 (alternatively referred to hereinafter in certain instances as outlet holes 116 or more than one outlet hole 116 in embodiments having multiple outlet holes 116 per nozzle 88) through which fuel 42 may be expelled. Each of the plurality of fuel nozzles 88 are aligned with one of the swirler channels 94 to direct fuel 42 from the at least one outlet hole 116 of the fuel nozzle 88 through one of the swirler channels 94. Each of the plurality of fuel nozzles 88 are configured with one of the respective fuel nozzles 88 to be inserted into a respective one of the plurality of main fuel holes 86 and fixed to align the at least one outlet hole 116 with one of the swirler channels 94.

[0054] A method of forming the combustor head flange assembly 48 according to the prior art typically includes welding the first ring cover 68 to the flange body 50 of the combustor head13Docket No. DKT24099 / 065757.01395flange assembly 48 to cover the pilot fuel channel 56 and typically includes welding the second ring cover 72 to the flange body 50 of the combustor head flange assembly 48 to cover the main fuel channel 58. Welding the first and second ring covers 68, 72 includes producing a weld line circumferentially about the axis A between the radially outermost segment and the radially innermost segments for the first and second ring covers 68, 72 and the flange body 50 of the combustor head flange assembly 48. The method typically includes fixing (such as by welding) the pilot fuel fitting 76 to the pilot fuel pipe 80 and fixing (such as by welding) the pilot fuel pipe 80 to the first ring cover 68. The method may also further include fixing (such as by welding) the main fuel fitting 84 to the main fuel pipe 85 and fixing (such as by welding) the main fuel pipe 85 to the second ring cover 72. The method further typically includes inserting the plurality of fuel nozzles 88 in the plurality of main fuel holes 86 and manually or otherwise adjusting the fuel nozzles 88 such that the outlet holes 116 are properly aligned within the swirler channels 94 and to prevent the fuel nozzle 88 from twisting. The method typically further includes fixing (such as by welding) the plurality of fuel nozzles 88 to the back side 54 of the flange body 50 of the combustor head flange assembly 48 such that the at least one outlet hole 116 of each of the plurality of fuel nozzles 88 remains aligned with one of the swirler channels 94.Embodiments of the Subject Disclosure

[0055] The subject disclosure provides three embodiments below (a first embodiment and a second embodiment and a third embodiment that combines aspects of the first and second embodiment) as shown in Figures 10-20, which can be included alone or in combination with each other, and which can be included with certain components, or replace or improve certain components, of the combustor head flange assembly 48 of the combustor system 25 described above in Figures 4 and 6-9. For ease of description, like components are identified by the same14Docket No. DKT24099 / 065757.01395description and reference numbers in Figures 10-20 as provided in Figures 4 and 6-9 where appropriate.

[0056] In the first embodiment, as shown throughout Figures 10-19, the combustor head flange assembly 48 includes a one-piece plate cover 100 (i.e., a single plate cover 100, a unitary plate cover, or a single, unitary plate cover 100) coupled to the front side 52 of the flange body 50 of the combustor head flange assembly 48 with the one-piece plate cover 100 covering both the pilot fuel channel 56 and the main fuel channel 58 that replaces the first and second ring covers 68, 72 of the prior art such as illustrated in Figures 4 and 6-9 above. In the embodiments where the main fuel channel 58 is disposed radially outward relative to the pilot fuel channel 56, the front side 52 of the flange body 50 of the combustor head flange assembly 48 may define a notch 101 on the radially outermost side of the main fuel channel 58 to seat the one-piece plate cover 100. In the embodiments where the pilot fuel channel 56 is disposed radially outward relative to the main fuel channel 58, the front side 52 of the flange body 50 of the combustor head flange assembly 48 may define a notch on the radially outermost side of the pilot fuel channel 56 to seat the one-piece plate cover 100. In certain embodiments, such as shown in Figures 10-13 and 15-19, the one- piece plate cover 100 has an outer circumference with a continuous diameter extending from one end of the outer circumference to another end of the outer circumference. Stated another way, the one-piece plate cover 100 shown in Figures 10-13 and 15-19 is circular.

[0057] The one-piece cover plate 100 requires less welding than the separate first and second ring covers 68, 72. As such, the one-piece cover plate 100 may be less costly to manufacture than the first and second ring covers 68, 72. Moreover, reducing the amount of welding between the cover plate 100 and the flange body 50 reduces the possibility of failure at the welds (e.g., failures caused by pressure and / or temperature fatigue).15Docket No. DKT24099 / 065757.01395

[0058] The combustor head flange assembly 48 further includes the pilot fuel fitting 76 coupled to the one-piece plate cover 100. The pilot fuel fitting 76 is configured to be in fluid communication with a fuel source to provide the pilot fuel channel 56 with fuel 42. The flange body 50 of the combustor head flange assembly 48 further defines one or more pilot fuel holes 78 extending from the pilot fuel channel 56 through the back side 54 of the flange body 50. Accordingly, the pilot fuel channel 56 is in fluid communication with the pilot fuel channel 56 and the combustion chamber 36 to provide the combustion chamber 36 with fuel 42 from the pilot fuel channel 56. Due in part to the large surface area of the one-piece plate cover 100, the pilot fuel fitting 76 may be directly affixed to the one-piece plate cover 100. In other words, the pilot fuel fitting 76 does not necessarily require a pilot fuel pipe 80 directly affixed to both the pilot fuel fitting 76 and directly affixed to the one-piece plate cover 100, although such a construction is contemplated herein. The one-piece plate cover 100 may define a main fuel fitting inlet hole 106 such that fuel 42 may flow through the pilot fuel fitting 76, optionally the pilot fuel pipe 80 if present, and the main fuel fitting inlet hole 106 into the pilot fuel channel 56.

[0059] The combustor head flange assembly 48 further includes the main fuel fitting 84 coupled to the one-piece plate cover 100. The main fuel fitting 84 may be configured to be in fluid communication with the fuel source to provide the main fuel channel 58 with fuel 42. The flange body 50 of the combustor head flange assembly 48 further defines one or more main fuel holes 86 extending from the main fuel channel 58 through the back side 54 of the flange body 50.

[0060] Due in part to the large surface area of the one-piece plate cover 100, the main fuel fitting 84 may be directly affixed to the one-piece plate cover 100. In other words, the main fuel fitting 84 does not necessarily require a main fuel pipe 85 directly affixed to both the main fuel fitting 84 and directly affixed to the one-piece plate cover 100, although such a construction is16Docket No. DKT24099 / 065757.01395contemplated herein. The one-piece plate cover 100 may define the main fuel fitting inlet hole 106 such that fuel 42 may flow through the main fuel fitting 84, optionally the main fuel pipe 85 if present, and the main fuel fitting inlet hole 106 into the main fuel channel 58.

[0061] The combustor head flange assembly 48 includes an ignitor 108. The ignitor 108 may produce a spark or other means of igniting and / or detonating the fuel 42 in the combustion chamber 36. The ignitor 108 may include an ignitor fitting 110 fixed, such as by welding, to either the flange body 50 of the combustor head flange assembly 48 or to the one-piece plate cover 100. The one-piece plate cover 100 may define an ignitor fitting inlet hole 112 such that the spark or other means of igniting and / or detonation the fuel 42 is not impeded by the one-piece plate cover 100. It is to be appreciated that the ignitor 108 may be adjacent to the pilot fuel channel 56 so that the ignitor 108 may ignite and / or detonate fuel 42 which is passing, or has passed, through the pilot fuel channel 56.

[0062] The back side 54 of the flange body 50 of the combustor head flange assembly 48 as shown in Figures 13, 16, 18 and 19 includes the swirler 90 having a plurality of swirler projections 92 extending toward the second combustor end 34 of the combustor and defining a plurality of swirler channels 94 between adjacent swirler projections 92. The plurality of fuel nozzles 188 extend from the back side 54 of the flange body 50 of the combustor head flange assembly 48 toward the second combustor end 34 of the combustor and define at least one outlet hole 116 (alternatively referred to hereinafter in certain instances as outlet holes 116 or more than one outlet hole 116 in embodiments having multiple outlet holes 116 per nozzle 188) through which fuel 42 may be expelled. Each of the plurality of fuel nozzles 188 are aligned with one of the swirler channels 94 to direct fuel 42 from the at least one outlet hole 116 of the fuel nozzle 188 through one of the swirler channels 94.17Docket No. DKT24099 / 065757.01395

[0063] The swirler 90 may be a single, unitary component (z.e., the swirler 90 may be a unitary structure) or may be separate components. In a non-limiting example such as shown in Figures 13 and 16-19, the swirler 90 may have a backing ring 98 extending circumferentially about the axis A, and the swirler projections 92 may extend from the backing ring 98 toward the second combustor end 34 of the combustor 30. The swirler channels 94 may be defined by adjacent swirler projections 92 such that the swirler channels 94 direct fuel 42 both radially inward and circumferentially about the axis A. In other words, the swirler 90 may be configured to swirl fuel 42 circumferentially about the axis A as the fuel 42 is fed radially inward toward the combustion chamber 36 and combined with the oxidizing agent 44 for combustion. The swirler projections 92 may approximate a triangular shape, although not required. The back side 54 of the flange body 50 of the combustor head flange assembly 48 may define a swirler seating notch to seat the back plate of the swirler 90. Although not required, the back plate (or backing ring 98) of the swirler 90 may be fixed to the back side 54 of the flange body 50 of the combustor head flange assembly 48, such as by welding or by fasteners 99 including, but not limited to, studs 99 (see Figure 15). The fasteners 99, such as the studs 99, may extend through the swirler projections 92 and the swirler back plate and into the back side 54 of the flange body 50 of the combustor head flange assembly 48.

[0064] In a second embodiment of the subject disclosure, as shown in Figures 11 and 13- 19, the combustor head flange assembly 48 further includes a plurality of fuel nozzles 188 different than the fuel nozzles 88 described above with respect to prior art as shown in Figures 6-9 in terms of their shape and coupling to the flange body 50, as described further below. The fuel nozzles 188 of Figures 11 and 13-19 are each disposed at least partially in one of the plurality of main fuel18Docket No. DKT24099 / 065757.01395holes 86. The fuel nozzles 188 disposed in the main fuel holes 86 are thus in fluid communication between the main fuel channel 58 and the combustion chamber 36.

[0065] In the second embodiment and as best illustrated in Figures 11 and 13-17 but also present in each of Figures 10-19, each of the plurality of fuel nozzles 188 include a nozzle body 114 extending along the axis A. The nozzle body 114 is disposed at least partially in the main fuel hole 86 and extends at least partially away from the back side 54 of the flange body 50 of the combustor head flange assembly 48 toward the second combustor end 34 of the combustor 30. The nozzle body 114 may define the at least one outlet hole 116 not disposed within the main fuel hole 86 and open to the combustion chamber between the flange body 50 and the second combustor end 34. Although not required, the nozzle body 114 may define one, two, three, four, five, or more than five spaced apart outlet holes 116.

[0066] As best shown in Figure 14, each of the plurality of fuel nozzles 188 further includes a nozzle head 118 adjacent to the nozzle body 114 to seat the fuel nozzle 188 in the main fuel hole 86. The nozzle head 118 may extend radially further away than the nozzle body 114 (z.e., the nozzle head 118 may be wider than the nozzle body 114). The nozzle head 118 include a nozzle projection 120 extending radially away from the nozzle head 118. Although not required, the nozzle projection 120 may extend radially away from the axis A. As best shown in Figure 17, the nozzle projection 120 may cooperate with the combustor head flange assembly 48 to align the at least one outlet hole 116 with one of the swirler channels 94 when the nozzle body 114 is inserted in the main fuel channel 58. More specifically, the front side 52 of the flange body 50 of the combustor head flange assembly 48 may define an indentation 113 to seat the nozzle projection 120. The nozzle projection 120 may be disposed at least partially in the indentation 113. In this way, the nozzle projection 120 and the indentation 113 may cooperate according to poka-yoke19Docket No. DKT24099 / 065757.01395principles to ensure that the fuel nozzle 188 is insertable in only a single orientation to ensure that the at least one outlet hole 116 is aligned with one of the swirler channels 94. Manual orientation of the fuel nozzle 88 in accordance with the prior art and as illustrated in Figures 6-9, such as before welding, is not necessary with the fuel nozzle 188 as best illustrated in Figure 17 to ensure that the at least one outlet hole 116 of a fuel nozzle 188 is properly aligned with the respective one of the swirler channels 94 and to prevent the nozzle 188 from twisting (and in particular to prevent the nozzle body 114 from twisting (z.e., rotating about a nozzle axis NA defined along a length of the fuel nozzle 188 extending away from the back side 54 of the flange body 50 of the combustor head flange assembly 48 toward the second combustor end 34 (see Figures 14 and 17)) during installation. The nozzle axis NA may be further defined as extending along a length of the nozzle body 114 (also as shown in Figures 14 and 17) not contained in the main fuel hole 86 and extending within the combustion chamber 38 between the back side 54 of the flange body 50 and the second combustor end 34, and the fuel nozzle 188 of Figure 17 ensures that the at least one outlet hole 116 extending along the length of the nozzle body 114 is properly and consistently aligned in a single and consistent orientation with the respective one of the swirler channels 94, and prevents the nozzle body 114 from twisting or otherwise rotating about the nozzle axis NA to misalign the outlet holes 116 relative to the respective swirler channel 94, during installation. As a result, assembly times for the fuel nozzles 188 into the flange 50 may be decreased. It is also to be appreciated that the nozzle projection 120 of the fuel nozzle 188 of Figure 17 also prevents the fuel nozzle 188 from moving radially toward or away from the axis A, and from moving axially in embodiments where the fuel nozzle 188 is press-fit to the flange body 50, and the nozzle projection 120 prevents the fuel nozzle 188 from moving circumferentially relative to the axis A.Further as a result, the consistent installation of the fuel nozzles 188 with the outlet holes 11620Docket No. DKT24099 / 065757.01395aligned in a single and consistent orientation within and relative to the respective swirler channel 94, without allowing the fuel nozzle 188 in general and the nozzle body 114 from rotating about the nozzle axis NA or moving radially, circumferentially or axially relative to the axis A, results in a consistent flow of fuel 42 out of the outlet holes 116 and into the combustion chamber 36 within a corresponding one swirler channel 94 to ensure proper and consistent combustion within the combustion chamber 36 during subsequent use.

[0067] The nozzle projection 120 is adjacent to the nozzle body 114 and has a proximal end 122 spaced apart from a distal end 124. The distal end 124 of the nozzle projection 120 includes a nozzle spacer 126 extending axially away from the distal end 124 of the nozzle projection 120. More specifically, the nozzle spacer 126 extends axially away from the second combustor end 34 of the combustor 30. As can be seen in Figure 15, the distal end 124 of the nozzle projection 120 is flush with the main fuel channel 58. The nozzle spacer 126 extending axially away from the distal end 124 of the nozzle projection 120 is flush with the notch 101 (see Figure 17) used to seat the one-piece plate cover 100. Once the one-piece plate cover 100 is fixed to the front side 52 of the flange body 50 of the combustor head flange assembly 48, as also best shown in Figure 17, the nozzle spacer 126 may contact, and in alternative embodiments be welded to, the one-piece plate cover 100 and is prevented from moving axially along the axis A. Said differently, the fuel nozzle 188 is fixed in space relative to the other components of the combustor head flange assembly 48 once the one-piece plate cover 100 is seated in the notch 101 and fixed to the front side 52 of the flange body 50 of the combustor head flange assembly 48. In this way, the fuel nozzles 188 in accordance with the second embodiment as shown in Figures 10-19 need not be welded to the combustor head flange assembly 48, further increasing the efficiency of manufacture. However, it is to be appreciated that the fuel nozzle 188 in the second embodiment21Docket No. DKT24099 / 065757.01395as shown in Figures 10-19 may nonetheless be welded, such as to the flange body 50 of the combustor head flange assembly 48 and / or to the one-piece plate cover 100. The fuel nozzle 188 may be press-fit into at least one chosen from the main fuel hole 86, the indentation 113, and the notch 101.

[0068] Although not required, and as best shown in Figure 14, the proximal end 122 of the nozzle projection 120 may be semi-circular in shape. In addition, as best shown in Figure 15, the nozzle spacer 126 may be semi-circular in shape. However, it is to be appreciated that the proximal end 122 of the nozzle projection 120, and the nozzle spacer 126 in particular, may have any shape. The indentation 113 (see Figure 17) in the flange body 50 used to seat the proximal end 122 of the nozzle projection 120, and used to seat the nozzle spacer 126, may also have any shape, such as that corresponding to the shape of the nozzle projection 120 and / or corresponding to the shape of the nozzle spacer 126.

[0069] It should be appreciated that the fuel nozzles 188 of this second embodiment may also be incorporated into the combustor head flange assembly 48 of combustors 30 and combustor systems 25 in which the first and second ring covers 68, 72 are utilized to cover the pilot fuel channel 56 and main fuel channel 58, respectively, instead of through the use of a single, unitary plate cover 100. In the third embodiment as illustrated in Figure 20, the fuel nozzles 188 are positioned within the main fuel hole 86 as described above, and the nozzle spacer 126 contacts, and in alternative embodiments may be welded to. the second ring cover 72 to retain the nozzle 188 within the main fuel hole 86 with the fuel outlet holes 116 positioned properly relative to the respective swirler channel 94 when the second ring cover 72 is welded to the flange body 50 to cover the main fuel channel 58. To accommodate these fuel nozzles 188, the main fuel channel58 includes the indentation 113 and includes where the nozzle projection 120 is seated at least22Docket No. DKT24099 / 065757.01395partially in the indentation 113 to assist in prevention of the axial and radial movement of the fuel nozzles 188 and further to assist in preventing the fuel nozzles 188 from twisting during installation and during use to maintain the alignment of the outlet holes 116 relative to the swirler channels 94 in the same manner as described above with respect to Figures 10-19.

[0070] A method of forming the combustor head flange assembly 48 for the second embodiment of Figures 10-19 includes welding the one-piece plate cover 100 to the flange body 50 of the combustor head flange assembly 48 to cover the pilot fuel channel 56 and cover the main fuel channel 58. The method may also include seating the one-piece plate cover 100 in the notch adjacent to the main fuel channel 58 and / or the pilot fuel channel 56 prior to welding. Welding the one-piece plate cover 100 includes producing a weld line circumferentially about the axis A between the radially outermost segment of the one-piece plate cover 100 and the flange body 50 of the combustor head flange assembly 48. The method further includes fixing (such as by welding) the pilot fuel fitting 76 to the one-piece plate cover 100. The method further includes fixing (such as by welding) the ignitor 108 to the one-piece plate cover 100 and / or to the flange body 50 of the combustor head flange assembly 48. It is to be appreciated that the method of forming the combustor head flange assembly 48 with the one-piece plate cover 100 (i.e., the one-piece plate cover 100 is a unitary structure) is simplified relative to the method of forming the combustor head flange assembly 48 with the first and second ring cover 68, 72. More specifically, the method of forming the combustor head flange assembly 48 with the first and second ring cover 68.72 requires four weld lines circumferentially about the axis A, and the method of forming the combustor head flange assembly 48 with the one-piece plate cover 100 only requires a single weld line circumferentially about the axis A. The method of forming a combustor head flange assembly 48 with the one-piece plate cover 100 also eliminates the close proximity of weld lines associated23Docket No. DKT24099 / 065757.01395with the first and second ring cover 68, 72 which may result from the method of forming the combustor head flange assembly 48. With the reduction in weld lines, it can be appreciated that a corresponding reduction in fuel 42 leakage at weld lines may be reduced through the use of a single one-piece plate cover 100 with a single weld as compared with the use of the first and second ring cover 68, 72 with four welds.

[0071] It is further to be appreciated that the combustor head flange assembly 48 with the one-piece plate cover 100 as in Figures 10-19 reduces the number of component parts required. More specifically, the one-piece plate cover 100 is a single component and functionally replaces the two separate first and second ring covers 68, 72. The reduction of component parts required provided of the combustor head flange assembly 48 also reduces the costs of the component parts and thus reduces the cost of the combustor head flange assembly 48. Moreover, because only the one-piece plate cover 100 requires aligning, the assembly process of the combustor head flange assembly 48 is simplified relative to assembly process of aligning both the first ring cover 68 and the second ring cover 72 of the combustor head flange assembly 48. Parts handling is thus also simplified relative to combustor head flanges 48 including both the first ring cover 68 and the second ring cover 72 of the combustor head flange assembly 48. Moreover, through reduction in number of component parts and / or reduction in number of weld lines required, the number of defects inadvertently formed is reduced in this embodiment of the combustor head flange assembly 48 including the one-piece plate cover 100.

[0072] The method associated with Figures 10-19 and 20 further includes fixing the swirler 90 to the back side 54 of the flange body 50 of the combustor head flange assembly 48. Fixing the swirler 90 to the back side 54 of the flange body 50 of the combustor head flange assembly 48 includes welding the swirler 90 to the back side 54 of the flange body 50 of the combustor head24Docket No. DKT24099 / 065757.01395flange assembly 48 or includes disposing fasteners 99 through the swirler 90 and into the back side 54 of the flange body 50 of the combustor head flange assembly 48. The method associated with Figures 10-19 and 20 further includes inserting, such as through press-fitting, each of the plurality of fuel nozzles 188 into one of the plurality of main fuel holes 86 in a single orientation to align the at least one outlet hole 116 with one of the swirler channels 94. More specifically, the method includes disposing of the nozzle body 114 at least partially in the main fuel hole 86 such that the nozzle body 114 extends at least partially away from the back side 54 of the flange body 50 of the combustor head flange assembly 48 toward the second combustor end 34 of the combustor 30. The method further includes positioning the nozzle projection 120 at least partially in the indentation 113.

[0073] The method associated with Figures 10-19 and 20 includes disposing of the fuel nozzle 188 in the main fuel channel 58 such that the proximal end 122 of the nozzle projection 120 is disposed within the indentation 113 of the main fuel channel 58 and the distal end 124 is flush with the main fuel channel 58. The method associated with Figures 10-19 also includes disposing of the fuel nozzle 188 in the main fuel hole 86 such that the nozzle spacer 126 is flush with the notch 101 used to seat the one-piece plate cover 100. The method associated with Figures 10-19 further includes fixing the one-piece plate cover 100 to the front side 52 of the flange body 50 of the combustor head flange assembly 48 to prevent the nozzle spacer 126 from moving axially along the axis A.

[0074] A method of forming the combustor 30 includes fixing, such as by welding, the combustor head flange assembly 48 to the first combustor end 32 of the combustor 30. The flange body 50 of the combustor head flange assembly 48 may be fixed to the first combustor end 32 of the combustor 30 either before, after, or concurrently with welding either or both of the first and25Docket No. DKT24099 / 065757.01395second ring covers 72 to the flange body 50 of the combustor head flange assembly 48, as may be accomplished to form the first embodiment of the combustor head flange assembly 48. The flange body 50 of the combustor head flange assembly 48 associated with Figures 10-19 may be fixed to the first combustor end 32 of the combustor 30 either before, after, or concurrently with welding the one-piece plate cover 100 to the flange body 50 of the combustor head flange assembly 48, as may be accomplished to form the combustor head flange assembly 48 of Figures 10-19. It is also to be appreciated that gas tightness between any components welded together is ensured.

[0075] Any aspects of the first embodiment and the second combination may be combined to create the third embodiment as described in Figure 20 or to create other additional embodiments. In the non-limiting example of Figure 20, as noted above, the fuel nozzles 188 described with respect to Figures 10-19 and inserted into one of the plurality of main fuel holes 86 in a single orientation to align the at least one outlet hole 116 with one of the swirler channels 94 may be used in combination with the first and second ring covers 68, 72 covering the pilot fuel channel 56 and the main fuel channel 58. Moreover, in another non-limiting example, the fuel nozzles 188 of Figures 10-19 may instead be fixed to the back side 54 of the flange body 50 of the combustor head flange assembly 48, such as by welding, to align the at least one outlet hole 116 with one of the swirler channels 94, and may therefore be used in combination with either the single, unitary plate cover 100 or the first and second ring covers 68, 72 covering the pilot fuel channel 56 and the main fuel channel 58.

[0076] Referring next to Figures 21-26, two additional alternative designs of the fuel nozzles 188 of Figure 14 may also be used in the system 25 and in the combustor 30.

[0077] Referring first to Figures 21-23, a variation of the design of the fuel nozzle 188 ofFigure 14 is provided, in which the nozzle head 118 further defined as including a first nozzle head26Docket No. DKT24099 / 065757.01395portion 118 A adjacent to the nozzle body 114 to seat the fuel nozzle 188 in the main fuel hole 86 and a second nozzle head portion 118B extending from first nozzle head portion 118A that extends within the main fuel channel 58.

[0078] The outer side surface 119 of the first nozzle head portion 118A is circular and is disposed within the main fuel hole 86. The outer side surface 119 defines a diameter DI that corresponds to the diameter of the main fuel hole 86. The outer side surface 121 of the second nozzle head portion 118B includes a curved section 123 that defines a diameter D2, with the diameter D2 greater than the diameter DI of the outer side surface 119. In addition, a stepped surface 125 extends transverse to and connects the outer side surface 119 of the first nozzle head portion 118A and the outer side surface 121 of the second nozzle head portion 118B that is seated within the main fuel channel 58 adjacent to the main fuel hole 86, and in particular is seated within the indentation 113 in the main fuel channel 58 adjacent to the main fuel hole 86 (see Figure 23).

[0079] The fuel nozzle 188 also includes the nozzle projection 120 that extends radially away from the second nozzle head portion 118B. Although not required, the nozzle projection 120 may extend radially away from the axis A. The nozzle projection 120 includes a proximal end 122 that extends radially away from the second nozzle head portion 118B. The distal end 124 of the nozzle projection 120 opposite the proximal end 122 is positioned flush with the main fuel channel 58 and includes the nozzle spacer 126 extending axially away from the distal end 124 of the nozzle projection 120. More specifically, the nozzle spacer 126 extends axially away from the second combustor end 34 of the combustor 30. Similar to the embodiment of the fuel nozzle 188 of Figure14, and as shown best in Figure 22 and Figure 23, the nozzle spacer 126 may contact, and in certain embodiments be welded to, the one-piece plate cover 100 and is prevented from moving axially along the axis A. Said differently, the fuel nozzle 188 is fixed in space relative to the other27Docket No. DKT24099 / 065757.01395components of the combustor head flange assembly 48 once the one-piece plate cover 100 is seated in the notch 101 and fixed to the front side 52 of the flange body 50 of the combustor head flange assembly 48. In this way, the fuel nozzles 188 in accordance with the alternative embodiment shown in Figures 21-22 need not be welded to the combustor head flange assembly 48, further increasing the efficiency of manufacture. However, it is to be appreciated that the fuel nozzle 188 as shown in Figures 21-22 may nonetheless be welded, such as to the flange body 50 of the combustor head flange assembly 48 and / or to the one-piece plate cover 100. The fuel nozzle 188 of Figures 21-23 may be press-fit into at least one chosen from the main fuel hole 86, the indentation 113, and the notch 101.

[0080] The addition of the second nozzle head portion 118B as in Figures 21-23 may allow for an easier and precise aligning of the fuel nozzle 188 during the installation process in which the outlet holes 116 are properly aligned with and within the respective swirler channel 94. Similar to the embodiment of Figure 14, the shape of the fuel nozzle 188 prevents twisting or rotation of the fuel nozzle 188 about the nozzle axis NA, and in particular twisting or rotation of the nozzle body 114 about the nozzle axis NA, during installation and during subsequent use of the combustor 30.

[0081] Referring next to Figures 24-26, yet another alternative fuel nozzle 188 design is provided. In this alternative embodiment, the fuel nozzle 188 includes a non-circular nozzle head 131 that is positioned within a corresponding non-circular main fuel hole 186 (see Figure 25) that replaces the circular fuel hole 86 as illustrated in the embodiments of Figures 10-19, 20, and 21- 22.

[0082] As best shown in Figure 24, the outer side surface 133 of the non-circular nozzle head 131 includes a first curved section 135 and a second curved section 137. In addition, the28Docket No. DKT24099 / 065757.01395outer side surface 133 includes a pair of spaced apart opposing coupling sections 139, 141 that connect, respectively, the first curved section 135 to the second curved section 137. In certain embodiments, such as shown in Figures 24 and 26, each of the opposing coupling sections 139, 141 are flat surfaces. Accordingly, the outer side surface 133 of the non-circular nozzle head 131 is not circular but generally takes on a generally oval shape. In addition, the non-circular nozzle head 131 includes bottom surface 143 configured to be seated within the non-circular main fuel hole 186, as described further below.

[0083] Referring to Figure 25, the non-circular main fuel hole 186 includes a non-circular inner side surface 187 that preferably corresponds to the shape of the outer side surface 133 of the non-circular nozzle head 131. Accordingly, the non-circular inner side surface 187 includes a first curved section 195 and a second curved section 197 and a pair of spaced apart opposing coupling sections 199. 201 that connect, respectively, the first curved section 195 to the second curved section 197. In Figure 25, the first curved section 195 is disposed further radially outward from the axis A than the second curved section 197, although in alternative configurations the main fuel hole 186 may be configured such that the coupling section 199 is disposed further radially outward than the coupling section 201. The non-circular main fuel hole 186 also includes a top ledge surface 189 which defines a main fuel outlet hole 190 that extends to the back side 54 of the flange body 50.

[0084] As best shown in Figure 26. in the assembled state, the non-circular nozzle head 131 is inserted, such as press-fit, within the main fuel hole 186 such that the nozzle body 114 extends through the main fuel outlet hole 190 and within the combustion chamber 36 with the outlet holes 116 aligned within one of the swirler channels 94. In addition, the bottom surface 143 is seated onto the top ledge surface 189.29Docket No. DKT24099 / 065757.01395

[0085] In addition, the non-circular outer side surface 133 the non-circular nozzle head 131 is adjacent to, such as being press-fit against, the non-circular inner side surface 187 of the main fuel hole 186, with the bottom surface 146 seated adjacent to a top ledge 189. Accordingly, the first curved section 135 of the non-circular nozzle head 131 is aligned and adjacent to the first curved section 195 of the main fuel hole 186, while the second curved section 137 of the non- circular nozzle head 131 is aligned and adjacent to the second curved section 197 of the main fuel hole 186. In addition, the opposing coupling sections 139, 141 are aligned respectively with a corresponding one of opposing coupling sections 199, 201 of the main fuel hole 186.

[0086] In this configuration, and owing to the alignment of the non-circular outer side surface 133 with the non-circular inner side surface 187, the non-circular nozzle head 131 cannot rotate about the nozzle axis NA, and hence the at least one outlet hole 116 on the nozzle body 114 is maintained in a single orientation relative to the respective swirler channel 94 during the installation process, the nozzle body 114 cannot rotate about the nozzle axis NA, or move radially or circumferentially or axially relative to the axis A. In embodiments wherein the non-circular outer side surface 133 is press-fit with the non-circular inner side surface 187, Once in the assembled state, the non-circular nozzle head 131 is fixed to the flange body 50, such as by welding, to complete the installation process. Once assembled and fixed, the nozzle body 114 cannot rotate about the nozzle axis NA or move radially or circumferentially or axially relative to the axis A, similar to the other embodiments of the fuel nozzle 188 as in Figures 14 or 21 described above.

[0087] The disclosure has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present disclosure30Docket No. DKT24099 / 065757.01395are possible in light of the above teachings, and the disclosure may be practiced otherwise than as specifically described.31Docket No. DKT24099 / 065757.01395

Claims

CLAIMSWhat is claimed is:

1. A combustor configured to receive a fuel and an oxidizing agent and expel an exhaust gas, said combustor comprising: a combustor body extending from a first combustor end to a second combustor end opposite said first combustor end with an axis extending along said combustor body between said first combustor end and said second combustor end, wherein a combustion chamber is defined within said combustor body between said first combustor end and said second combustor end with said combustion chamber configured to receive the fuel and the oxidizing agent at said first combustor end and expel the exhaust gas at said second combustor end; and a combustor head flange assembly positioned at said first combustor end, said combustor head flange assembly comprising: a flange body extending along said axis and having a front side facing a first direction and a back side facing a second direction opposite said first direction, wherein said front side of said flange body defines a pilot fuel channel circumferentially about said axis for receiving fuel and initiating combustion in said combustion chamber, and wherein said front side of said flange body also defines a main fuel channel circumferentially about said axis spaced from said pilot fuel channel for receiving the fuel and maintaining combustion in said combustion chamber; a plurality of main fuel holes defined in said flange body between said front side and said back side for fluid communication between said main fuel channel and said combustion chamber;32Docket No. DKT24099 / 065757.01395a plurality of fuel nozzles with one of said plurality of fuel nozzles disposed at least partially in a respective one of said plurality of main fuel holes; and a swirler positioned on said back side of said combustor head flange assembly, said swirler having a plurality of swirler projections extending away from said back side of said combustor in said combustion chamber, said plurality of swirler projections defining a plurality of swirler channels extending between adjacent swirler projections, wherein each one of said plurality of fuel nozzles extends from said back side of said flange body and into a respective one of said swirler channels to direct the fuel from a fuel outlet hole of each of said plurality of fuel nozzles into each of said plurality of swirler channels for combustion, wherein a length of each one of said plurality of fuel nozzles extends from said back side of said flange body towards said second combustor end to define a nozzle axis, and wherein each of said plurality of fuel nozzles is configured to cooperate with said flange body to prevent each of said plurality of fuel nozzles from rotating about said nozzle axis and to align said fuel outlet holes with said swirler channels.

2. The combustor of claim 1, wherein each one of said plurality of fuel nozzles includes a nozzle body at least partially disposed into said respective one of said plurality of main fuel holes and extending away from said back side toward said second combustor end, with said nozzle body of each respective one of said plurality of fuel nozzles further defining said fuel outlet hole and further defining said nozzle axis.

3. The combustor of claim 2, wherein each one of said plurality of fuel nozzles further comprises: a nozzle head adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of main fuel holes; and33Docket No. DKT24099 / 065757.01395a nozzle projection adjacent to said nozzle head and extending radially away from said axis, said nozzle projection cooperating with said combustor head flange assembly to align said fuel outlet hole of each one of said plurality of fuel nozzles with said respective one of said plurality of swirler channels.

4. The combustor of claim 3, wherein said nozzle projection of each one of said plurality of fuel nozzles includes: a distal end adjacent to said nozzle body and flush with said main fuel channel; a proximal end spaced from said distal end; and a nozzle spacer at said distal end extending axially away from said second combustor end.

5. The combustor of claim 2, wherein each one of said plurality of fuel nozzles further comprises: a nozzle head comprising: a first nozzle head portion adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of main fuel holes, said first nozzle head portion including an outer side surface defining a first diameter, and a second nozzle head portion extending from said first nozzle head portion and within said main fuel channel, said second nozzle head portion including an outer side surface having a curved section defining a second diameter with said second diameter greater than said first diameter, and a stepped surface extending transverse to and connecting said outer side surface of said first nozzle head portion and said outer side surface of said second nozzle head portion, with said stepped surface seated within said main fuel channel; and34Docket No. DKT24099 / 065757.01395a nozzle projection adjacent to said second nozzle head portion and extending radially away from said axis, said nozzle projection cooperating with said combustor head flange assembly to align said fuel outlet hole of each one of said plurality of fuel nozzles with said respective one of said plurality of swirler channels.

6. The combustor of claim 5, wherein said nozzle projection of each one of said plurality of fuel nozzles includes: a distal end adjacent to said nozzle body and flush with said main fuel channel; a proximal end spaced from said distal end; and a nozzle spacer at said distal end extending axially away from said second combustor end.

7. The combustor of claim 2, wherein each one of said plurality of main fuel holes comprises a non-circular main fuel hole, and wherein each one of said plurality of fuel nozzles further comprises a non-circular nozzle head adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of non-circular main fuel holes such that said nozzle body cannot rotate about said nozzle axis.

8. The combustor of any one preceding claim, wherein said swirler includes: a backing ring extending circumferentially about said axis; and a plurality of swirler projections extending from said backing ring towards said second combustor end, with one of said swirler channels defined by adjacent swirler projections.

9. The combustor of claim 8, wherein said backing ring is fixed to said back side of said flange body.35Docket No. DKT24099 / 065757.0139510. The combustor of one of claim 4 or claim 6 further comprising a one-piece plate cover coupled to said front side of said flange body and covering both of said pilot fuel channel and said main fuel channel, wherein said nozzle spacer of each one of said plurality of fuel nozzles contacts said one- piece plate cover covering said pilot fuel channel and said main fuel channel such that each one of said plurality of fuel nozzles is retained in said respective one of said plurality of main fuel holes.

11. The combustor of one of claim 4 or claim 6 further comprising: a first ring cover covering said pilot fuel channel; and a second ring cover covering said main fuel channel, wherein said nozzle spacer of each one of said plurality of fuel nozzles contacts said second ring cover covering said main fuel channel such that each one of said plurality of fuel nozzles is retained in a respective one of said plurality of main fuel holes.

12. The combustor of any one preceding claim, wherein said pilot fuel channel is disposed radially inward of said main fuel channel.

13. A combustor system comprising: a combustor body extending from a first combustor end to a second combustor end opposite said first combustor end with an axis extending along said combustor body between said first combustor end and said second combustor end, wherein a combustion chamber is defined within said combustor body between said first combustor end and said second combustor end with said combustion chamber configured to receive the fuel and the oxidizing agent at said first combustor end and expel the exhaust gas at said second combustor end; a combustor head flange assembly positioned at said first combustor end, said combustor head flange assembly comprising:36Docket No. DKT24099 / 065757.01395a flange body extending along said axis and having a front side facing a first direction and a back side facing a second direction opposite said first direction, wherein said front side of said flange body defines a pilot fuel channel circumferentially about said axis for receiving fuel and initiating combustion in said combustion chamber, and wherein said front side of said flange body also defines a main fuel channel circumferentially about said axis spaced from said pilot fuel channel for receiving the fuel and maintaining combustion in said combustion chamber; a plurality of main fuel holes defined in said flange body between said front side and said back side for fluid communication between said main fuel channel and said combustion chamber; a plurality of fuel nozzles with one of said plurality of fuel nozzles disposed at least partially in a respective one of said plurality of main fuel holes; and a swirler positioned on said back side of said combustor head flange assembly, said swirler having a plurality of swirler projections extending away from said back side of said combustor in said combustion chamber, said plurality of swirler projections defining a plurality of swirler channels extending between adjacent swirler projections; a turbine wheel in fluid communication with said combustion chamber and configured to rotate upon receiving the expelled exhaust gas; a shaft rotatable with said turbine wheel: and an electric machine coupled to said shaft and configured to convert rotational motion of said shaft to electrical energy, wherein each one of said plurality of fuel nozzles extends from said back side of said flange body and into a respective one of said swirler channels to direct the fuel from a fuel outlet hole of37Docket No. DKT24099 / 065757.01395each of said plurality of fuel nozzles into each of said plurality of swirler channels for combustion, wherein a length of each one of said plurality of fuel nozzles extends from said back side of said flange body towards said second combustor end to define a nozzle axis, and wherein each of said plurality of fuel nozzles is configured to cooperate with said flange body to prevent each of said plurality of fuel nozzles from rotating about said nozzle axis and to align said fuel outlet holes with said swirler channels.

14. The combustor system of claim 13, wherein each one of said plurality of fuel nozzles includes a nozzle body at least partially disposed into said respective one of said plurality of main fuel holes and extending away from said back side toward said second combustor end, with said nozzle body of each respective one of said plurality of fuel nozzles further defining said fuel outlet hole and further defining said nozzle axis.

15. The combustor system of claim 14, wherein each one of said plurality of fuel nozzles further comprises: a nozzle head adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of main fuel holes; and a nozzle projection adjacent to said nozzle head and extending radially away from said axis, said nozzle projection cooperating with said combustor head flange assembly to align said fuel outlet hole of each one of said plurality of fuel nozzles with said respective one of said plurality of swirler channels.

16. The combustor system of claim 15, wherein said nozzle projection of each one of said plurality of fuel nozzles includes: a distal end adjacent to said nozzle body and flush with said main fuel channel; a proximal end spaced from said distal end; and38Docket No. DKT24099 / 065757.01395a nozzle spacer at said distal end extending axially away from said second combustor end.

17. The combustor system of claim 14, wherein each one of said plurality of fuel nozzles further comprises: a nozzle head comprising: a first nozzle head portion adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of main fuel holes, said first nozzle head portion including an outer side surface defining a first diameter, and a second nozzle head portion extending from said first nozzle head portion and within said main fuel channel, said second nozzle head portion including an outer side surface having a curved section defining a second diameter with said second diameter greater than said first diameter, and a stepped surface extending transverse to and connecting said outer side surface of said first nozzle head portion and said outer side surface of said second nozzle head portion, with said stepped surface seated within said main fuel channel; and a nozzle projection adjacent to said second nozzle head portion and extending radially away from said axis, said nozzle projection cooperating with said combustor head flange assembly to align said fuel outlet hole of each one of said plurality of fuel nozzles with said respective one of said plurality of swirler channels.

18. The combustor system of claim 17, wherein said nozzle projection of each one of said plurality of fuel nozzles includes: a distal end adjacent to said nozzle body and flush with said main fuel channel; a proximal end spaced from said distal end; and a nozzle spacer at said distal end extending axially away from said second combustor end.39Docket No. DKT24099 / 065757.0139519. The combustor system of claim 14, wherein each one of said plurality of main fuel holes comprises a non-circular main fuel hole, and wherein each one of said plurality of fuel nozzles further comprises a non-circular nozzle head adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of non-circular main fuel holes such that said nozzle body cannot rotate about said nozzle axis.

20. The combustor system of any one of claims 13 to 19, wherein said swirler includes: a backing ring extending circumferentially about said axis; and a plurality of swirler projections extending from said backing ring towards said second combustor end, with one of said swirler channels defined by adjacent swirler projections.

21. The combustor system of claim 20, wherein said backing ring is fixed to said back side of said flange body.

22. The combustor system of one of claim 16 or claim 18 further comprising a one- piece plate cover coupled to said front side of said flange body and covering both of said pilot fuel channel and said main fuel channel, wherein said nozzle spacer of each one of said plurality of fuel nozzles contacts said one- piece plate cover covering said pilot fuel channel and said main fuel channel such that each one of said plurality of fuel nozzles is retained in said respective one of said plurality of main fuel holes.

23. The combustor system of one of claim 16 or claim 18 further comprising: a first ring cover covering said pilot fuel channel; and a second ring cover covering said main fuel channel,40Docket No. DKT24099 / 065757.01395wherein said nozzle spacer of each one of said plurality of fuel nozzles contacts said second ring cover covering said main fuel channel such that each one of said plurality of fuel nozzles is retained in a respective one of said plurality of main fuel holes.

24. The combustor system of any one of claims 13 to 23, wherein said pilot fuel channel is disposed radially inward of said main fuel channel.

25. A combustor head flange assembly for use in a combustor which defines a combustion chamber, said combustor head flange assembly comprising: a flange body extending along an axis and having a front side facing a first direction and a back side facing a second direction opposite said first direction, wherein said front side of said flange body defines a pilot fuel channel circumferentially about said axis for receiving fuel and initiating combustion in the combustion chamber, and wherein said front side of said flange body also defines a main fuel channel circumferentially about said axis spaced from said pilot fuel channel for receiving the fuel and maintaining combustion in the combustion chamber; a plurality of main fuel holes defined in said flange body between said front side and said back side for fluid communication between said main fuel channel and the combustion chamber; a plurality of fuel nozzles with one of said plurality of fuel nozzles disposed at least partially in a respective one of said plurality of main fuel holes; and a swirler positioned on said back side of said flange body, said swirler having a plurality of swirler projections extending away from said back side of said combustor in the combustion chamber, said plurality of swirler projections defining a plurality of swirler channels extending between adjacent swirler projections, wherein each one of said plurality of fuel nozzles extends from said back side of said flange body and into a respective one of said swirler channels to direct the fuel from a fuel outlet hole of41Docket No. DKT24099 / 065757.01395each of said plurality of fuel nozzles into each of said plurality of swirler channels for combustion, wherein a length of each one of said plurality of fuel nozzles extends from said back side of said flange body towards said second combustor end to define a nozzle axis, and wherein each of said plurality of fuel nozzles is configured to cooperate with said flange body to prevent each of said plurality of fuel nozzles from rotating about said nozzle axis and to align said fuel outlet holes with said swirler channels.

26. The combustor head flange assembly of claim 25, wherein each one of said plurality of fuel nozzles includes a nozzle body at least partially disposed into said respective one of said plurality of main fuel holes and extending away from said back side, with said nozzle body of each respective one of said plurality of fuel nozzles further defining said fuel outlet hole and further defining said nozzle axis.

27. The combustor head flange assembly of claim 26, wherein each one of said plurality of fuel nozzles further comprises: a nozzle head adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of main fuel holes; and a nozzle projection adjacent to said nozzle head and extending radially away from said axis, said nozzle projection cooperating with said combustor head flange assembly to align said fuel outlet hole of each one of said plurality of fuel nozzles with said respective one of said plurality of swirler channels.

28. The combustor head flange assembly of claim 27, wherein said nozzle projection of each one of said plurality of fuel nozzles includes: a distal end adjacent to said nozzle body and flush with said main fuel channel; a proximal end spaced from said distal end; and42Docket No. DKT24099 / 065757.01395a nozzle spacer at said distal end extending axially away from said second combustor end.

29. The combustor head flange assembly of claim 26, wherein each one of said plurality of fuel nozzles further comprises: a nozzle head comprising: a first nozzle head portion adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of main fuel holes, said first nozzle head portion including an outer side surface defining a first diameter, and a second nozzle head portion extending from said first nozzle head portion and within said main fuel channel, said second nozzle head portion including an outer side surface having a curved section defining a second diameter with said second diameter greater than said first diameter, and a stepped surface extending transverse to and connecting said outer side surface of said first nozzle head portion and said outer side surface of said second nozzle head portion, with said stepped surface seated within said main fuel channel; and a nozzle projection adjacent to said second nozzle head portion and extending radially away from said axis, said nozzle projection cooperating with said combustor head flange assembly to align said fuel outlet hole of each one of said plurality of fuel nozzles with said respective one of said plurality of swirler channels.

30. The combustor head flange assembly of claim 29, wherein said nozzle projection of each one of said plurality of fuel nozzles includes: a distal end adjacent to said nozzle body and flush with said main fuel channel; a proximal end spaced from said distal end; and a nozzle spacer at said distal end extending axially away from said second combustor end.43Docket No. DKT24099 / 065757.0139531. The combustor head flange assembly of claim 26, wherein each one of said plurality of main fuel holes comprises a non-circular main fuel hole, and wherein each one of said plurality of fuel nozzles further comprises a non-circular nozzle head adjacent to said nozzle body to seat each one of said plurality of fuel nozzles into said respective one of said plurality of non-circular main fuel holes such that said nozzle body cannot rotate about said nozzle axis.

32. The combustor head flange assembly of any one of claims 25 to 31, wherein said swirler includes: a backing ring extending circumferentially about said axis; and a plurality of swirler projections extending from said backing ring towards said second combustor end, with one of said swirler channels defined by adjacent swirler projections.

33. The combustor head flange assembly of claim 32, wherein said backing ring is fixed to said back side of said flange body.

34. The combustor head flange assembly of one of claim 28 or claim 30 further comprising a one-piece plate cover coupled to said front side of said flange body and covering both of said pilot fuel channel and said main fuel channel, wherein said nozzle spacer of each one of said plurality of fuel nozzles contacts said one- piece plate cover covering said pilot fuel channel and said main fuel channel such that each one of said plurality of fuel nozzles is retained in said respective one of said plurality of main fuel holes.

35. The combustor head flange assembly of one of claim 28 or claim 30 further comprising: a first ring cover covering said pilot fuel channel; and a second ring cover covering said main fuel channel,44Docket No. DKT24099 / 065757.01395wherein said nozzle spacer of each one of said plurality of fuel nozzles contacts said second ring cover covering said main fuel channel such that each one of said plurality of fuel nozzles is retained in a respective one of said plurality of main fuel holes.

36. The combustor head flange assembly of any one of claims 25 to 35, wherein said pilot fuel channel is disposed radially inward of said main fuel channel.45Docket No. DKT24099 / 065757.01395

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