Integrated Combustor Cap Insert Design
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Solution Overview
Problem
Current combustor cap assembly designs are complex, requiring multiple components and complex manufacturing and assembly techniques, leading to increased cycle fatigue, labor costs, and outage times due to the complexity of assembly and disassembly.
Innovation Solution
A cap insert for a combustor fuel nozzle cap assembly featuring a cap plate with an upstream peripheral edge contiguous with the downstream end of an impingement plate, which includes an axially extending annular sleeve and radially outer portion, reducing the number of components and simplifying assembly through a connecting sleeve that allows for axial separation, thereby decreasing the complexity and cost of manufacturing and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current cap assembly designs with multiple complex components are used, then structural support and flow path definition are achieved, but device complexity and manufacturing/assembly complexity increase
Solution Approach 1:
The patent combines multiple separate components (cap plate, impingement plate, connecting sleeve, cooling passages) into a single integrated cap insert assembly. The cap plate defines the fuel nozzle passage, the impingement plate provides structural support with integrated cooling passages, and the connecting sleeve couples them together, eliminating the need for multiple separate cap assembly components while maintaining all necessary functions.
2Strength
If multiple connection points such as weld joints or brazed joints are used, then structural integrity is maintained, but cycle fatigue increases and component life is limited
Solution Approach 1:
By integrating the cap plate, impingement plate, and cooling passages into a single monolithic cap insert, the invention eliminates multiple weld joints and brazed connections that would create stress concentration points and reduce fatigue life. The unified structure maintains structural integrity without the weaknesses introduced by multiple connection points.
3Reliability
If complex cap assembly designs are used, then functional requirements are met, but assembly and repair time increases
Solution Approach 1:
The cap insert is designed as a removable, segmented unit that can be easily detached from the combustor as a single piece. This segmentation allows the entire cap insert assembly to be quickly removed and replaced without requiring disassembly of multiple individual components, significantly reducing maintenance and repair time while maintaining all necessary cooling and structural functions.
4Adaptability or versatility
If multiple components are used in cap assembly, then design flexibility is achieved, but manufacturing cost and labor cost increase
Solution Approach 1:
The invention consolidates multiple separately manufactured components into a single cap insert that can be manufactured as one integrated piece using additive manufacturing or other suitable processes. This merging reduces the total number of parts, eliminates multiple assembly operations, and decreases both manufacturing complexity and labor costs while maintaining design flexibility through the integrated structure.
Data Source
AI summary
One embodiment of the present invention is a cap insert for a combustor fuel nozzle cap assembly. The cap insert generally includes a cap plate that defines a fuel nozzle passage and may have an upstream peripheral edge. An impingement plate having a body may generally define an axially extending annular sleeve and a radially outer portion that circumferentially surrounds the body. The radially outer portion may include an upstream end axially separated from a downstream end. The axially extending annular sleeve may define an annular passage through the body. The cap plate upstream peripheral edge may be contiguous with the downstream end of the impingement plate body radially outer portion.