Fuel Nozzle Flange Orifice Insert for Gas Turbine Assembly
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Solution Overview
Problem
The existing fuel nozzle assemblies in gas turbines require complete flow testing of the endcover, including the fuel nozzle, to ensure proper fuel flow, which is inefficient and necessitates creating matched sets, complicating the assembly process.
Innovation Solution
A fuel nozzle assembly with a flange body and an insert that includes an orifice within the base portion, allowing for fluid communication from the fuel circuit outlet to the fuel plenum, reducing the need for full endcover testing and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-orifice inserts are installed strictly in the endcover, then fuel flow metering is achieved, but complete endcover flow testing is required which reduces productivity and increases assembly complexity
Solution Approach 1:
The fuel nozzle assembly is segmented into modular components: the endcover, the fuel nozzle assembly with flange body, and the insert with orifice. The insert is separated from the endcover and integrated into the fuel nozzle assembly, allowing independent testing and assembly of these components. This segmentation eliminates the requirement to flow test the complete endcover assembly, thereby improving productivity while maintaining fuel flow metering reliability.
Solution Approach 2:
The flange body acts as an intermediary component that connects the endcover to the fuel nozzle assembly. It includes an aperture that receives the insert with the orifice, creating a fluid communication path from the fuel circuit outlet through the insert to the fuel plenum. This intermediary structure enables the insert to be positioned downstream in the fuel flow path while maintaining proper fuel metering, eliminating the need for complete endcover flow testing.
2Reliability
If complete endcover flow testing is performed, then proper fuel flow is ensured, but the testing process becomes time-consuming and requires creating matched sets
Solution Approach 1:
The testing process is segmented by allowing the insert to be independently installed in the fuel nozzle assembly. This enables the insert to be tested and verified separately from the endcover, eliminating the need for time-consuming complete endcover flow testing and matched set creation, while still ensuring proper fuel flow through the orifice.
3Reliability
If the insert is positioned upstream in the endcover, then fuel metering is achieved, but assembly complexity increases due to matched set requirements
Solution Approach 1:
The insert is extracted from the endcover and repositioned within the fuel nozzle assembly. The flange body provides a mounting structure with an aperture that receives the insert, allowing the orifice to be positioned in the fuel flow path downstream from the fuel circuit outlet. This extraction eliminates the complexity of assembling and testing matched sets of endcovers with pre-orifice inserts, while maintaining proper fuel metering function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration simplifies the testing and assembly process by ensuring proper fuel flow without requiring complete endcover flow testing, improving the efficiency and reliability of gas turbine operations.
Implementation Method 1
The orifice is in fluid communication with the fuel flow passage and provides for fluid communication from the first fuel circuit outlet to the fuel plenum of the first nozzle segment
Data Source
AI summary
A fuel nozzle assembly includes a flange body. The flange body includes a base portion that defines an aperture. The flange body is connected to a conduit. The flange body and the conduit define a fuel flow passage to a fuel plenum of the fuel nozzle assembly. The fuel nozzle assembly further includes an insert that is partially disposed within the aperture of the base portion. The insert includes an orifice disposed within the aperture of the base portion and a forward portion of the insert extends axially outwardly from the aperture. The orifice is in fluid communication with the fuel flow passage.