Method for producing burner, method for producing combustor, and method for producing gas turbine

Abstract

This method is for producing a burner including a plate that has formed therein a mixed gas formation section including at least one mixing passage which is configured to allow air to be supplied to the inside thereof and which extends along the axial direction, at least one fuel injection hole that is configured to inject fuel into the at least one corresponding mixing passage, and a fuel passage that is formed in the plate and that is for supplying fuel to the at least one fuel injection hole. The method comprises a manufacturing step for forming, by additive manufacturing, a component including the plate, the mixed gas formation section, the at least one fuel injection hole, and the fuel passage, a step for mounting, on the component, a protective device that is capable of blocking the at least one fuel injection hole, and a first machining step for machining the mixed gas formation section in a state where the at least one fuel injection hole is blocked by the protective device.

Description

Method for manufacturing a burner, method for manufacturing a combustor, and method for manufacturing a gas turbine

[0001] The present disclosure relates to a method for manufacturing a burner, a method for manufacturing a combustor, and a method for manufacturing a gas turbine. This application claims priority based on Japanese Patent Application No. 2024-232614 filed with the Japan Patent Office on December 27, 2024, the content of which is incorporated herein by reference.

[0002] As a burner of a combustor such as a gas turbine, a burner including one or more mixing flow paths (holes) extending along the axial direction of the burner and configured to mix air supplied to each mixing flow path with fuel injected into the mixing flow path and eject the mixture into a combustion chamber may be used.

[0003] Patent Document 1 describes a burner including a plurality of mixing flow paths to which air is supplied, a plurality of fuel nozzles for injecting fuel, and a plurality of support portions that respectively connect the plurality of fuel nozzles and the flow path walls of the mixing flow paths. The plurality of fuel nozzles are provided such that the central axis of each fuel nozzle coincides with the central axis of the mixing flow path. In the mixing flow path, fuel ejected from the fuel nozzle and air are mixed, and the air-fuel mixture flow formed thereby is ejected from the mixing flow path into the combustion chamber of the combustor.

[0004] Japanese Unexamined Patent Application Publication No. 2021-173190

[0005] By the way, a burner may be manufactured by additive manufacturing. For a burner formed by additive manufacturing, machining may be performed for the purpose of adjusting the shape or surface properties of the flow path or forming holes. During machining, chips, grinding powder, etc. are generated. If these foreign substances enter the fuel flow path, it may lead to combustion failure or equipment malfunction during operation.

[0006] In view of the above circumstances, at least one embodiment of the present invention aims to provide a method for manufacturing a burner, a method for manufacturing a combustor, and a method for manufacturing a gas turbine that can suppress the intrusion of foreign substances into the fuel flow path during machining.

[0007] A method for manufacturing a burner according to at least one embodiment of the present invention comprises: a plate having a mixture forming section formed therein, which is configured to supply air to the interior and includes at least one mixing passage extending along the axial direction; at least one fuel injection hole, each configured to inject fuel into the at least one mixing passage; and a fuel passage formed in the plate for supplying fuel to the at least one fuel injection hole, the method for manufacturing a burner comprising: a molding step of forming a component including the plate, the mixture forming section, the at least one fuel injection hole, and the fuel passage by additive molding; a step of attaching a protective device to the component that can block the at least one fuel injection hole; and a first machining step of machining the mixture forming section with the at least one fuel injection hole blocked by the protective device.

[0008] Furthermore, a method for manufacturing a combustor according to at least one embodiment of the present invention comprises the steps of: manufacturing a burner by the method described above; and installing a combustion cylinder downstream of the burner.

[0009] Furthermore, a method for manufacturing a gas turbine according to at least one embodiment of the present invention comprises the steps of: manufacturing a combustor by the method described above; and installing a turbine so as to be driven by combustion gas from the combustor.

[0010] According to at least one embodiment of the present invention, a method for manufacturing a burner, a method for manufacturing a combustor, and a method for manufacturing a gas turbine are provided that can suppress the intrusion of foreign matter into the fuel passage during machining.

[0011] This is a schematic diagram of a gas turbine according to one embodiment. This is a schematic cross-sectional view showing the combustor of a gas turbine according to one embodiment. This is a schematic cross-sectional view along the axial direction of a burner according to one embodiment. This is a diagram showing a cross-section perpendicular to the axial direction of the burner shown in Figure 3. This is a schematic cross-sectional view along the axial direction of a burner according to one embodiment. This is a flowchart of the method for manufacturing a burner according to one embodiment. This is a diagram for explaining the method for manufacturing the burner shown in Figure 3. This is a diagram for explaining the method for manufacturing the burner shown in Figure 5.

[0012] Hereinafter, several embodiments of the present invention will be described with reference to the attached drawings. However, the dimensions, materials, shapes, relative arrangements, etc., of the components described as embodiments or shown in the drawings are not intended to limit the scope of the present invention, but are merely illustrative examples.

[0013] (Gas Turbine Configuration) First, a gas turbine, which is an example of an application for burners and combustors according to several embodiments, will be described with reference to Figure 1. Figure 1 is a schematic configuration diagram of a gas turbine according to one embodiment. As shown in Figure 1, the gas turbine 100 includes a compressor 2 for generating compressed air, a combustor 4 for generating combustion gas using compressed air and fuel, and a turbine 6 configured to be rotationally driven by the combustion gas. In the case of a gas turbine 100 for power generation, a generator (not shown) is connected to the turbine 6.

[0014] The compressor 2 includes a plurality of stationary vanes 16 fixed to the compressor casing 10 side, and a plurality of rotor blades 18 mounted on the rotor 8 so as to be alternately arranged with respect to the stationary vanes 16. Air taken in from the air intake 12 is supplied to the compressor 2, and this air is compressed by passing through the plurality of stationary vanes 16 and the plurality of rotor blades 18 to become high-temperature, high-pressure compressed air.

[0015] The combustor 4 is supplied with fuel and compressed air generated by the compressor 2. In the combustor 4, the fuel is burned, and combustion gas, which is the working fluid for the turbine 6, is generated. As shown in Figure 1, the gas turbine 100 has a plurality of combustors 4 arranged circumferentially around the central axis O of the rotor 8 within the casing 20.

[0016] The turbine 6 includes a plurality of stator blades 24 and rotor blades 26 provided in the combustion gas passage formed by the turbine casing 22. The stator blades 24 and rotor blades 26 of the turbine 6 are located downstream of the combustor 4 with respect to the flow of combustion gases. The stator blades 24 are fixed to the turbine casing 22 side, and a plurality of stator blades 24 arranged along the circumferential direction of the rotor 8 constitute a stator blade row. The rotor blades 26 are embedded in the rotor 8, and a plurality of rotor blades 26 arranged along the circumferential direction of the rotor 8 constitute a rotor blade row. The stator blade row and the rotor blade row are arranged alternately in the axial direction of the rotor 8.

[0017] In the turbine 6, combustion gas from the combustor 4 flows into the combustion gas passage and passes through multiple stationary blades 24 and multiple rotor blades 26, thereby driving the rotor 8 to rotate. This drives a generator connected to the rotor 8, generating electricity. After driving the turbine 6, the combustion gas is discharged to the outside through the exhaust chamber 30.

[0018] Figure 2 is a schematic cross-sectional view showing a combustor 4 of a gas turbine 100 according to one embodiment. As shown in Figure 2, the combustor 4 includes a burner 48 for burning fuel and a combustion cylinder 36 provided downstream of the burner 48 (i.e., closer to the turbine 6 than the burner 48).

[0019] The burner 48 includes a cylindrical member 34 provided along the axial direction (the direction of the central axis Q of the burner 48 or the combustion cylinder 36), a plate 50 supported by the cylindrical member 34 and having a plurality of mixing passages 56 formed inside, and a plurality of fuel nozzles 60 for injecting fuel into the plurality of mixing passages 56. The cylindrical member 34 is supported by the casing 20 by a support member 46 provided around the cylindrical member 34. The plurality of mixing passages 56 constitute a mixture forming section 90 for forming a mixture of air and fuel.

[0020] The plate 50 has an upstream end face 52 and a downstream end face 54, which are both ends in the axial direction. Each of the multiple mixing channels 56 is provided so as to extend axially through the interior of the plate 50. The upstream and downstream sides in the axial direction of the burner 48 refer to the upstream and downstream sides, respectively, in the direction of airflow through the multiple mixing channels 56 provided in the plate 50.

[0021] An air chamber 35 is formed between the casing 20 and the plate 50 in the axial direction, and compressed air from the compressor 2 is supplied to a plurality of mixing channels 56 through an inlet opening provided on the upstream end face 52 of the plate 50, via an air passage 40 and the air chamber 35 formed on the outer circumference of the cylindrical member 34.

[0022] Inside each mixing channel 56, air supplied from the compressor 2 and fuel ejected from the fuel nozzle 60 are mixed as they flow downstream (i.e., toward the combustion cylinder 36), generating a premixed gas. The premixed gas generated in each mixing channel 56 is injected from an outlet opening provided on the downstream end face 54 of the plate 50 into the combustion chamber 38 formed by the combustion cylinder 36, where it is ignited by a pilot light (not shown) and combusted. Fuel may also be supplied to each fuel nozzle 60 from the fuel port 44.

[0023] (Burner Configuration) Next, a burner 48 manufactured by a manufacturing method according to several embodiments will be described in more detail. The burner 48 described below is applied, for example, to the gas turbine 100 and combustor 4 described above.

[0024] Figure 3 is a schematic cross-sectional view of a burner 48 according to one embodiment, along the axial direction. Figure 4 is a cross-sectional view of the burner 48 shown in Figure 3, perpendicular to the axial direction. Note that Figure 3 corresponds to the A-A cross-section in Figure 5. Figure 5 is a schematic cross-sectional view of a burner 48 according to another embodiment, along the axial direction.

[0025] As shown in Figures 3 to 5, a burner 48 according to several embodiments comprises a plate 50 on which a mixture forming section 90 including at least one mixing passage 56 extending along the axial direction is formed, at least one fuel injection hole 78 each configured to inject fuel into at least one mixing passage 56, and a fuel passage 72 formed within the plate 50. The burner 48 may also include a mixture forming section 90 including a plurality of mixing passages 56, and a plurality of fuel injection holes 78 each configured to inject fuel into the plurality of mixing passages 56.

[0026] The mixture forming section 90 has an upstream end 90a that opens to the upstream end face 52 of the plate 50 and a downstream end 90b that opens to the downstream end face 54 of the plate 50. At least one mixing channel 56 constitutes at least a part of the mixture forming section 90. When the burner 48 is in operation, air is supplied to the inside of the mixture forming section 90, which includes at least one mixing channel 56, through the upstream end 90a of the mixture forming section 90.

[0027] In the exemplary embodiment shown in Figures 3 and 4, the mixture forming section 90 includes a groove 80 provided in the plate 50 so as to be recessed in the axial direction from the upstream end face 52 of the plate 50, and a plurality of mixing channels 56 located downstream of the groove 80 in the axial direction. The groove 80 has an upstream end 80a that opens to the upstream end face 52 of the plate 50, a bottom surface 84 that extends along a plane intersecting in the axial direction, and an inner wall surface 82 that extends along the axial direction. The upstream end 56a of each of the plurality of mixing channels 56 opens to the bottom surface 84 of the groove 80. The downstream end 56b of each of the plurality of mixing channels 56 opens to the downstream end face 54 of the plate 50. The upstream end 90a of the mixture forming section 90 coincides with the upstream end 80a of the groove 80, and the downstream end 90b of the mixture forming section 90 coincides with the downstream end 56b of the plurality of mixing channels 56.

[0028] As shown in Figure 4, the multiple mixing channels 56 may be arranged circumferentially with respect to a center line P that extends along the direction of the central axis Q of the burner 48. In this case, the groove 80 is provided to extend along the circumferential direction. The groove 80 may be a circumferential groove extending within a certain angular range around the center line P, or it may be an annular groove extending around the entire circumference of the center line P.

[0029] In the exemplary embodiment shown in Figure 5, the mixture forming section 90 includes at least one mixing channel 56 having an upstream end 56a that opens to the upstream end face 52 of the plate 50 and a downstream end 56b that opens to the downstream end face 54 of the plate 50. The upstream end 90a of the mixture forming section 90 coincides with the upstream end 56a of the at least one mixing channel 56, and the downstream end 90b of the mixture forming section 90 coincides with the downstream end 56b of the at least one mixing channel 56.

[0030] The fuel injection port 78 is configured to inject fuel from the fuel passage 72 formed inside the plate 50 into the mixing passage 56.

[0031] In some embodiments, the fuel injection port 78 may be provided in a fuel nozzle 60 for injecting fuel into the mixing passage 56.

[0032] In the exemplary embodiments shown in Figures 3 and 4, the burner 48 includes a plurality of fuel nozzles 60 for injecting fuel into at least one mixing channel 56, each fuel nozzle 60 being provided with a fuel injection hole 78.

[0033] As shown in Figures 3 and 4, the fuel nozzle 60 may be provided coaxially with the mixing channel 56 in which the fuel nozzle 60 is located (i.e., the central axis of the fuel nozzle 60 coincides with the central axis of the mixing channel 56). The fuel injection hole 78 may be provided so as to extend axially through the inside of the fuel nozzle 60. The fuel injection hole 78 may have an injection port 78a that opens at the tip of the fuel nozzle 60.

[0034] As shown in Figure 3, the fuel injection port 78 provided in the fuel nozzle 60 may be provided with a flow rate adjustment section 79 for adjusting the flow rate of fuel ejected from the fuel injection port 78. The flow rate adjustment section 79 may include an orifice with a narrowed diameter.

[0035] In the exemplary embodiments shown in Figures 3 and 4, the fuel nozzle 60 is supported on the plate 50 via a support portion 62. As shown in Figures 3 and 4, the support portion 62 may include a strut connecting the fuel nozzle 60 and the plate 50. The strut may be provided to extend radially with respect to the central axis of the mixing passage 56.

[0036] As shown in Figures 3 and 4, the strut (support portion 62) may be provided to connect the inner wall surface 82 of the groove 80 (inner wall surface 82a or outer wall surface 82b; outer wall surface 82b in Figures 3 and 4) with the fuel nozzle 60.

[0037] Alternatively, although not specifically shown, in some embodiments, the strut (support portion 62) may be provided to connect the inner wall surface 57 of the mixing passage 56 to the fuel nozzle 60. For example, in some embodiments, the mixture forming section 90 may include at least one mixing passage 56 (i.e., a mixing passage 56 having an upstream end 56a opening to the upstream end surface 52 and a downstream end 56b opening to the downstream end surface 54) that extends axially between the upstream end surface 52 and the downstream end surface 54 of the plate 50. A fuel nozzle 60 is provided corresponding to each mixing passage 56, and each fuel nozzle 60 may be supported on the plate 50 via a strut (support portion 62) connecting the fuel nozzle 60 to the inner wall surface 57 of the mixing passage 56.

[0038] As described above, in a burner 48 equipped with a fuel nozzle 60 supported on a plate 50 via a support portion 62, fuel from the fuel port 44 (see Figure 2) is supplied to the fuel injection hole 78 via a fuel flow path 72 including an axial passage 74 extending axially through the inside of the plate 50, and a passage 76 formed inside the support portion 62, and is ejected into the mixing flow path 56 through an injection port 78a located at the tip of the fuel nozzle 60.

[0039] In some embodiments, the fuel injection port 78 may be provided on the plate 50.

[0040] In the exemplary embodiment shown in Figure 5, the burner 48 includes a fuel injection hole 78 provided on the plate 50, having an injection port 78a that opens into the inner wall surface 57 of the mixing passage 56. As shown in Figure 5, the fuel injection hole 78 may be provided to connect the mixing passage 56 with a fuel cavity 64 provided inside the plate 50. The fuel cavity 64 functions as a fuel passage 72 formed inside the plate 50. As shown in Figure 5, a plurality of fuel injection holes 78 may be provided for a single mixing passage 56. The plurality of fuel injection holes 78 may be spaced apart in the circumferential direction with respect to the central axis of the mixing passage 56.

[0041] As described above, in a burner 48 equipped with a fuel injection hole 78 having an injection port 78a that opens into the inner wall surface 57 of the mixing passage 56, fuel from the fuel port 44 (see Figure 2) is supplied to the fuel injection hole 78, for example, via the fuel passage 72 including the fuel cavity 64, and is injected into the interior of the mixing passage 56 through the injection port 78a.

[0042] As shown in Figure 5, the fuel injection port 78 provided in the plate 50 may be provided with a flow rate adjustment unit 79 for adjusting the flow rate of fuel injected from the fuel injection port 78. In the exemplary embodiment shown in Figure 5, the fuel injection port 78 functions as the flow rate adjustment unit 79.

[0043] The fuel supplied to the fuel nozzle 60 may be, for example, a gaseous fuel containing hydrocarbons, hydrogen, ammonia, or carbon monoxide (including, for example, natural gas or coal gasification gas).

[0044] In some embodiments, as shown in FIGS. 3 and 5 for example, the air-fuel mixture formation part 90 includes a downstream part 90D located on the downstream side in the axial direction (or on the downstream side of the injection port 78a of the fuel injection hole 78) with respect to the fuel injection hole 78, and an upstream part 90U located on the upstream side of the downstream part 90D in the axial direction. And the surface roughness of the inner wall surface 91D of the downstream part 90D is smaller than the surface roughness of the inner wall surface 91U of the upstream part 90U. In FIGS. 3 and 5, the region occupied by the downstream part 90D in the axial direction is indicated by R1, and the region occupied by the upstream part 90U is indicated by R2.

[0045] In the exemplary embodiments shown in FIGS. 3 and 5, the downstream part 90D includes a part of the downstream side of the mixing flow path 56. Also, in the exemplary embodiment shown in FIG. 3, the upstream part 90U includes a part of the upstream side of the mixing flow path 56 and the groove 80. In the exemplary embodiment shown in FIG. 5, the upstream part 90U includes a part of the upstream side of the mixing flow path 56.

[0046] Thus, by making the surface roughness of the downstream part 90D located on the downstream side of the fuel injection hole 78 relatively small among the air-fuel mixture formation part 90 formed in the burner 48, a decrease in the flow velocity near the wall surface at the outlet part of the mixing flow path 56 (that is, the outlet part of the air-fuel mixture formation part 90) is suppressed. Therefore, the occurrence of flashback in the burner 48 can be suppressed.

[0047] In some embodiments, as shown in FIGS. 3 and 5 for example, the burner 48 includes a chamfer part 93 provided at the inlet opening part (the part including the upstream end 90a) of the air-fuel mixture formation part 90 formed in the plate 50.

[0048] Thus, by providing the chamfer part 93 at the inlet opening part of the air-fuel mixture formation part 90 formed in the burner 48, the disturbance of the air flow flowing into the air-fuel mixture formation part can be suppressed.

[0049] (Method for manufacturing the burner) Next, the method for manufacturing the above-described burner 48 will be described. FIG. 6 is a flowchart of the method for manufacturing the burner 48 according to an embodiment. FIGS. 7 and 8 are diagrams for explaining the method for manufacturing the burner 48 shown in FIGS. 3 and 5 respectively.

[0050] As shown in Figure 6, in one embodiment, first, a component 102 including a plate 50, a mixture forming section 90, a fuel passage 72 formed inside the plate 50, and at least one fuel injection hole 78 is formed as an integral additive product by additive manufacturing (S2; see Figures 7 and 8). The surface of the component 102 formed by additive manufacturing in step S2 is an additively manufactured surface with relatively high surface roughness.

[0051] As shown in Figure 7, in step S2, the part 102, which includes the plate 50, groove 80 and mixing passage 56 (mixture forming section 90), fuel passage 72 including the axial passage 74, fuel injection hole 78, fuel nozzle 60, support section 62 and passage 76, may be formed as an integral additive product by additive manufacturing.

[0052] As shown in Figure 8, in step S2, the part 102, which includes the plate 50, the mixing channel 56 (mixture forming section 90), the fuel channel 72 including the fuel cavity 64, and the fuel injection holes 78 opening into the inner wall surface 57 of the mixing channel 56, may be formed as an integral additive product by additive manufacturing.

[0053] In step S2, the mixture forming section 90 may be formed by adding material to the above-mentioned part 102 such that the downstream portion 90D includes an excess material portion 94 with a smaller inner diameter than the upstream portion 90U. In the burner shown in Figures 7 and 8, an excess material portion 94 is provided in the region R1 corresponding to the downstream portion 90D, in which the flow path wall is thicker (i.e., has a smaller inner diameter) than in the region R1 corresponding to the upstream portion 90U.

[0054] In Figures 7 and 8, the downstream portion 90D in the state where the excess material portion 94 is provided has an inner wall surface 91D'.

[0055] Next, a protective device 96 capable of blocking the fuel injection hole 78 is attached to the part 102 obtained by additive manufacturing in step S2 (S4). The protective device 96 may include a plug inserted into the fuel injection hole 78, or a cap or cover provided to cover the opening (injection port 78a) of the fuel injection hole 78.

[0056] As shown in Figure 7, in step S4, a cap 97 covering the injection port 78a may be attached to the tip of the fuel nozzle 60.

[0057] As shown in Figure 8, in step S4, a cover 98 may be installed inside the mixing channel 56 so as to cover the area of ​​the inner wall surface 57 of the mixing channel 56 that includes the injection port 78a.

[0058] Next, with the protective device 96 (such as a cap 97 or cover 98) attached to the part 102 (i.e., with the fuel injection hole 78 blocked by the protective device 96), machining of the mixture forming section 90 is performed (S6).

[0059] In one embodiment, in step S6, the excess material 94 provided in the region R1 corresponding to the downstream portion 90D of the mixture forming section 90 may be removed by machining (cutting or grinding, etc.). Here, the downstream portion 90D may be machined so that the inner wall surface 91U of the upstream portion 90U and the inner wall surface 91D of the downstream portion 90D are flush (or so that the inner wall surface 91U of the upstream portion 90U and the inner wall surface 91D of the downstream portion 90D are smoothly connected). In Figures 7 and 8, the position of the inner wall surface 91D of the downstream portion 90D after the excess material 94 has been removed in step S6 is shown by a dashed line.

[0060] The inner wall surface 91U of the upstream portion 90U of the burner 48 obtained in this way is an additively formed surface (a surface obtained by additive forming), and the inner wall surface 91D of the downstream portion 90D is a machined surface (a machined surface) with a surface roughness smaller than that of the additively formed surface.

[0061] Alternatively, in one embodiment, in step S6, the inlet opening of the mixture forming section 90 may be chamfered (cut or grind, etc.) to form a chamfered section 93. In Figures 7 and 8, the position of the chamfered section 93 after it has been formed in step S6 is shown by a dashed line. The chamfered section 93 formed in step S6 may have an R-chamfer or C-chamfer shape.

[0062] According to the method of the above embodiment, with respect to a part including a plate formed by additive molding, a mixture forming section 90, a fuel injection hole 78, and a fuel passage 72, the mixture forming section 90 is machined with the fuel injection hole 78 blocked by a protective device 96, thereby suppressing the intrusion of foreign matter (such as chips and grinding dust) generated during machining into the fuel injection hole 78 and the fuel passage 72.

[0063] Furthermore, by machining the mixture forming section 90 with a cap 97 (Figure 7) or cover 98 (Figure 8) attached as a protective device 96 covering the area including the injection port 78a of the fuel injection hole 78, it is possible to suppress the intrusion of foreign matter (such as metal shavings) generated during machining into the fuel injection hole 78 and the fuel passage 72, and to suppress the formation of dents on the tip of the fuel nozzle 60 or the inner wall surface 57 of the mixture passage 56 due to collision with the tool or the like.

[0064] Generally, additive-formed parts have a rougher surface than machined parts. If a burner 48 including a mixing channel 56 is used as is after being formed by additive molding, the roughness of the inner wall surface 57 of the mixing channel 56 will be high, which will tend to lower the flow velocity of air or the mixture near this wall surface. When the flow velocity near the wall surface of the mixing channel 56 decreases, it is thought that flashback (backflow of flame along the inner wall surface of the mixing tube, or backfire) is more likely to occur.

[0065] In this regard, as described above, by making the surface roughness of the downstream portion 90D, which is located downstream of the fuel injection hole 78 in the mixture forming section 90, smaller than the surface roughness of the upstream portion 90U, the decrease in flow velocity near the wall surface at the outlet of the mixing channel 56 is suppressed. Therefore, the occurrence of flashback can be effectively suppressed in the burner 48 formed by additive molding.

[0066] Furthermore, the arithmetic mean roughness Ra of the inner wall surface 91D of the downstream portion 90D may be 1 / 2, 1 / 3, or 1 / 4 of the arithmetic mean roughness Ra of the inner wall surface 91U of the upstream portion 90U. Alternatively, the arithmetic mean roughness Ra of the inner wall surface 91D of the downstream portion 90D may be 1.6 μm or less. Alternatively, the arithmetic mean roughness Ra of the inner wall surface 91U of the upstream portion 90U may be 10 μm or more.

[0067] The arithmetic mean roughness Ra can be calculated using the method defined in JIS B 0601.

[0068] Next, in one embodiment, once the machining in step S6 is complete, the protective device 96 is removed from the part 102 (S8).

[0069] Then, with the protective device 96 removed from the part 102, the flow rate adjustment section 79 of the fuel injection hole 78 is machined while supplying a fluid at a pressure higher than atmospheric pressure (for example, air or an inert gas) to the fuel passage 72 (S10).

[0070] The order in which steps S6 (machining of the mixture forming section 90) and S10 (machining of the flow rate adjustment section 79) are performed is not limited. In some embodiments, the mixture forming section 90 may be machined (step S6), then the protective device 96 may be removed from the part 102 (step S8), and then the flow rate adjustment section 79 may be machined (step S10). In other embodiments, the flow rate adjustment section 79 may be machined (step S10) first, then the protective device 96 may be attached to the part 102 (step S4), and then the mixture forming section 90 may be machined (step S6).

[0071] In one embodiment, in step S10, while supplying a fluid at a pressure higher than atmospheric pressure to the fuel passage 72 (including the axial passage 74), an orifice (flow rate adjustment section 79; see Figures 3 and 7) provided inside the fuel nozzle 60 or a fuel injection hole 78 (flow rate adjustment section 79; see Figures 5 and 8) provided in the plate 50 is formed by machining. In Figure 7, the position of the orifice formed by machining in step S10 is indicated by a dashed line.

[0072] As described above, when machining the inside of the fuel injection hole 78, it is necessary to remove the protective device 96 that is blocking the fuel injection hole 78. According to the embodiment described above, since the flow rate adjustment section 79 of the fuel injection hole 78 is machined while supplying high-pressure fluid to the fuel passage 72 with the protective device 96 removed, it is possible to suppress the intrusion of foreign matter into the fuel passage 72 and its retention inside the fuel injection hole 78 that occurs during this machining.

[0073] The contents described in each of the above embodiments can be understood, for example, as follows:

[0074] [1] A method for manufacturing a burner (48) according to at least one embodiment of the present invention comprises: a plate (50) having a mixture forming section (90) formed thereon, which includes at least one mixing passage (56) configured to supply air inside and extending along the axial direction; at least one fuel injection hole (78) configured to inject fuel into the at least one mixing passage; and a fuel passage (72) formed in the plate for supplying fuel to the at least one fuel injection hole, the method for manufacturing a burner comprising: a molding step (S2) of forming a component (102) including the plate, the mixture forming section, the at least one fuel injection hole, and the fuel passage by additive molding; a step (S4) of attaching a protective device (96) capable of blocking the at least one fuel injection hole to the component; and a first processing step (S6) of machining the mixture forming section with the at least one fuel injection hole blocked by the protective device.

[0075] According to the method described in [1] above, with respect to the part including the plate, mixture forming section, fuel injection hole, and fuel passage formed by additive molding, the mixture forming section is machined with the fuel injection hole blocked by a protective device, thereby suppressing the entry of foreign matter (such as metal shavings) generated during machining into the fuel injection hole and fuel passage.

[0076] [2] In some embodiments, the method of [1] above includes a second machining step in which, with the protective device removed from the component, the flow rate adjustment section (79) of the at least one fuel injection hole is machined while a fluid at a pressure higher than atmospheric pressure is supplied to the fuel passage.

[0077] When machining the inside of a fuel injection hole, it is necessary to remove the protective device that is blocking the fuel injection hole. According to the method in [2] above, the flow rate adjustment part of the fuel injection hole is machined while supplying high-pressure fluid to the fuel passage with the protective device removed, so that foreign matter generated during this machining does not enter the fuel passage or remain inside the fuel injection hole.

[0078] [3] In some embodiments, in the method of [1] or [2] above, the mixture forming portion includes a downstream portion (90D) located downstream of the fuel injection hole in the axial direction, and an upstream portion (90U) located upstream of the downstream portion in the axial direction, and in the molding step, the part is formed by additive molding such that the downstream portion includes an excess material portion (94) having a smaller inner diameter than the upstream portion.

[0079] In the method described in [3] above, when additive manufacturing of the part, an excess material with a relatively small inner diameter is formed in the downstream portion of the mixture forming section located downstream of the fuel injection hole. Therefore, in the first processing step, by removing the excess material by machining while the fuel injection hole is blocked with a protective device, the intrusion of foreign matter generated during machining into the fuel injection hole and fuel passage can be suppressed, while the surface roughness of the inner wall surface of the downstream portion can be made smaller than the surface roughness of the inner wall surface of the upstream portion (the inner wall surface formed by additive manufacturing). Therefore, in a burner formed by additive manufacturing, the intrusion of foreign matter into the fuel injection hole and fuel passage can be suppressed, while the occurrence of flashback can be suppressed.

[0080] [4] In some embodiments, in the method of [3] above, the first processing step is to remove the excess material by machining.

[0081] According to the method described in [4] above, the excess material formed during the additive manufacturing of the part is removed by machining while the fuel injection holes are blocked with protective equipment. This suppresses the intrusion of foreign matter into the fuel injection holes and fuel passages generated during machining, while making the surface roughness of the inner wall surface of the downstream portion smaller than that of the inner wall surface of the upstream portion (the inner wall surface formed by additive manufacturing). Therefore, in a burner formed by additive manufacturing, the intrusion of foreign matter into the fuel injection holes and fuel passages can be suppressed while suppressing the occurrence of flashback.

[0082] [5] In some embodiments, in any of the methods [1] to [4] above, the first processing step involves chamfering the inlet opening of the mixture forming section.

[0083] According to the method described in [5] above, the chamfering of the inlet opening of the mixture forming section is performed with the fuel injection holes blocked by protective equipment. This suppresses the entry of foreign matter generated during machining into the fuel injection holes and fuel passages, while making the inlet opening of the mixture forming section a shape in which the flow area gradually changes. Therefore, it is possible to suppress turbulence in the airflow introduced into the mixture forming section while suppressing the entry of foreign matter into the fuel injection holes and fuel passages.

[0084] [6] In some embodiments, in any of the methods described in [1] to [5] above, the burner includes: at least one fuel nozzle (60) having at least one fuel injection hole and positioned along the central axis of the at least one mixing passage; and a support (62) for supporting the at least one fuel nozzle on the inner wall surface of the mixture forming section, wherein the molding step is to form the component including the at least one fuel nozzle and the support by additive molding.

[0085] According to the method described in [6] above, for a component which is an integrally molded part including a plate with a fuel mixture forming section and a fuel passage formed inside, a fuel nozzle, and a support section, the fuel mixture forming section is machined with the fuel injection hole covered by a protective device, thereby suppressing the entry of foreign matter (such as metal shavings) generated during machining into the fuel injection hole and fuel passage.

[0086] [7] In some embodiments, the method of [6] above, the protective device includes a cap (97) attached to the tip of at least one fuel nozzle.

[0087] According to the method described in [7] above, the fuel injection hole is sealed by attaching a cap to the tip of the fuel nozzle, and the mixture forming section is machined in this manner. This prevents foreign matter (such as metal shavings) generated during machining from entering the fuel injection hole and fuel passage, and also prevents the formation of dents on the fuel nozzle due to collisions with tools, etc.

[0088] [8] In some embodiments, the method of [6] or [7] above comprises a second machining step of machining the flow rate adjustment section of the at least one fuel injection hole while supplying a fluid at a pressure higher than atmospheric pressure to the fuel passage with the protective device removed from the component, the flow rate adjustment section includes an orifice provided inside the at least one fuel nozzle.

[0089] According to the method described in [8] above, for a component that is an integrally molded part including a plate with a mixture forming section and a fuel passage formed inside, a fuel nozzle, and a support section, the inside of the fuel nozzle is machined to form an orifice while supplying a fluid at a pressure higher than atmospheric pressure to the fuel passage with the protective device (cap, etc.) removed from the component. This makes it possible to suppress the intrusion of foreign matter into the fuel passage and its retention inside the fuel injection hole that occurs during this machining.

[0090] [9] In some embodiments, in any of the methods described in [1] to [5] above, the at least one fuel injection hole is formed in the plate such that it connects the fuel passage and the at least one mixing passage, and has an injection port (78a) formed on the inner wall surface (57) of the at least one mixing passage.

[0091] According to the method described in [9] above, for a component which is an integrally formed add-on part including a plate in which a mixing channel (mixture forming section) and a fuel channel are formed inside, and a fuel injection hole having an injection port formed on the inner wall surface of the mixing channel, the mixture forming section is machined with the fuel injection hole covered by a protective device, thereby suppressing the intrusion of foreign matter (such as metal shavings) generated during machining into the fuel injection hole and fuel channel.

[0092]

[10] In some embodiments, the method of [9] above, the protective device includes a cover (98) provided to cover the area of ​​the inner wall surface of the at least one mixing channel that includes the nozzle.

[0093] According to the method described in

[10] above, the fuel injection holes are covered by attaching a cover to the area of ​​the inner wall surface of the mixing passage that includes the injection port of the fuel injection hole, thereby machining the mixture forming section with the fuel injection holes blocked. This makes it possible to suppress the entry of foreign matter (such as metal shavings) generated during machining into the fuel injection holes and fuel passage, and also suppress the formation of dents on the inner wall surface of the mixing passage due to collision with the tool, etc.

[0094]

[11] A method for manufacturing a combustor according to at least one embodiment of the present invention comprises the steps of: manufacturing a burner by any of the methods described in [1] to

[10] above; and installing a combustion cylinder downstream of the burner.

[0095] According to the method described in

[11] above, with respect to the plate, fuel injection holes, and fuel passages formed by additive molding, the fuel mixture forming portion is machined with the fuel injection holes covered by protective equipment, thereby suppressing the entry of foreign matter (such as metal shavings) generated during machining into the fuel injection holes and fuel passages.

[0096]

[12] A method for manufacturing a gas turbine according to at least one embodiment of the present invention comprises the steps of: manufacturing a combustor by the method described in

[11] above; and installing a turbine so as to be driven by combustion gas from the combustor.

[0097] According to the method described in

[12] above, with respect to the part including the plate, fuel injection holes, and fuel passage formed by additive molding, the fuel mixture forming portion is machined with the fuel injection holes covered by a protective device, thereby suppressing the intrusion of foreign matter (such as metal shavings) generated during machining into the fuel injection holes and fuel passage.

[0098] Although embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and also includes modified forms of the embodiments described above, as well as forms that combine these forms as appropriate.

[0099] In this specification, expressions describing relative or absolute arrangements such as "in a certain direction," "along a certain direction," "parallel," "orthogonal," "center," "concentric," or "coaxial" shall not only describe such arrangements strictly, but also describe states of relative displacement with tolerances or angles or distances sufficient to achieve the same function. For example, expressions describing things being in an equal state such as "identical," "equal," and "homogeneous" shall not only describe states of being strictly equal, but also describe states where tolerances or differences exist to the extent that the same function is achieved. Furthermore, in this specification, expressions describing shapes such as quadrilaterals or cylindrical shapes shall not only describe geometrically precise quadrilaterals or cylindrical shapes, but also describe shapes including concave and concave parts, chamfered parts, etc., to the extent that the same effect is achieved. In addition, in this specification, expressions such as "equipment," "includes," or "possesses" a component are not exclusive expressions that exclude the existence of other components.

[0100] 2 Compressor 4 Combustor 6 Turbine 8 Rotor 10 Compressor casing 12 Air intake 16 Stationary blades 18 Rotor blades 20 Casing 22 Turbine casing 24 Stationary blades 26 Rotor blades 30 Exhaust chamber 34 Cylindrical member 35 Air chamber 36 Combustion cylinder 38 Combustion chamber 40 Air passage 44 Fuel port 46 Support member 48 Burner 50 Plate 52 Upstream end face 54 Downstream end face 56 Mixing passage 56a Upstream end 56b Downstream end 57 Inner wall surface 60 Fuel nozzle 62 Support part 64 Fuel cavity 72 Fuel passage 74 Axial passage 76 Passage 78 Fuel injection hole 78a Injection port 79 Flow rate adjustment part 80 Groove 80a Upstream end 82 Inner wall surface 82a Inner wall surface 82b Outer wall surface 84 Bottom surface 90 Mixture forming section 90D Downstream section 90U Upstream section 90a Upstream end 90b Downstream end 91D Inner wall surface 91D' Inner wall surface 91U Inner wall surface 93 Chamfered section 94 Excess material 96 Protective device 97 Cap 98 Cover 100 Gas turbine 102 Parts O Center axis P Centerline Q Center axis R1 Area R2 Area

Claims

1. A method for manufacturing a burner comprising: a plate having a mixture forming section formed thereon, which includes at least one mixing channel configured to supply air to the interior and extending along the axial direction; at least one fuel injection hole configured to inject fuel into the at least one mixing channel; and a fuel channel formed in the plate for supplying fuel to the at least one fuel injection hole, the method comprising: a molding step of forming a component including the plate, the mixture forming section, the at least one fuel injection hole, and the fuel channel by additive molding; a step of attaching a protective device to the component that can block the at least one fuel injection hole; and a first machining step of machining the mixture forming section with the at least one fuel injection hole blocked by the protective device.

2. The method for manufacturing a burner according to claim 1, further comprising a second machining step of machining the flow rate adjustment portion of at least one fuel injection hole while supplying a fluid at a pressure higher than atmospheric pressure to the fuel passage with the protective device removed from the component.

3. The method for manufacturing a burner according to claim 1 or 2, wherein the mixture forming portion includes a downstream portion located downstream of the fuel injection hole in the axial direction, and an upstream portion located upstream of the downstream portion in the axial direction, and in the molding step, the part is formed by additive molding such that the downstream portion includes an excess material portion having a smaller inner diameter than the upstream portion.

4. The method for manufacturing a burner according to claim 3, wherein in the first processing step, the excess material is removed by machining.

5. The method for manufacturing a burner according to claim 1 or 2, wherein the first processing step involves chamfering the inlet opening of the mixture forming section.

6. The method for manufacturing a burner according to claim 1 or 2, wherein the burner includes at least one fuel nozzle having at least one fuel injection hole and arranged along the central axis of the at least one mixing passage, and a support portion for supporting the at least one fuel nozzle on the inner wall surface of the mixture forming portion, and in the molding step, the component including the at least one fuel nozzle and the support portion is formed by additive molding.

7. The method for manufacturing a burner according to claim 6, wherein the protective device includes a cap attached to the tip of at least one fuel nozzle.

8. A method for manufacturing a burner according to claim 6, comprising a second machining step of machining the flow rate adjustment section of at least one fuel injection hole while supplying a fluid at a pressure higher than atmospheric pressure to the fuel passage with the protective device removed from the component, wherein the flow rate adjustment section includes an orifice provided inside the at least one fuel nozzle.

9. The method for manufacturing a burner according to claim 1 or 2, wherein the at least one fuel injection hole is formed in the plate so as to connect the fuel passage and the at least one mixing passage, and has an injection port formed on the inner wall surface of the at least one mixing passage.

10. The method for manufacturing a burner according to claim 9, wherein the protective device includes a cover provided to cover the area of ​​the inner wall surface of the at least one mixing channel that includes the injection port.

11. A method for manufacturing a combustor, comprising the steps of: manufacturing a burner by the method described in claim 1 or 2; and installing a combustion cylinder downstream of the burner.

12. A method for manufacturing a gas turbine, comprising the steps of: manufacturing a combustor by the method described in claim 11; and installing a turbine so as to be driven by combustion gas from the combustor.

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