Gas Turbine Hot Gas Path Insert Element for Thermal and Acoustic Management
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Solution Overview
Problem
Existing gas turbines face challenges in achieving high operational efficiency and reducing emissions due to complex and costly manufacturing processes for double-walled cooling systems, as well as difficulties in controlling thermo-acoustic pulsations, which lead to mechanical vibrations and limited manufacturing precision.
Innovation Solution
A modular, prefabricated insert element with a plate-like body providing thermal resistance, cooling, and acoustic damping functions, made from high-temperature super alloys, which can be inserted into existing gas turbine components to enhance heat resistance, cooling efficiency, and reduce pulsations, allowing for retrofitting and improved operational behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If double-walled hollow core structures are cast for near wall cooling, then cooling efficiency is improved, but manufacturing complexity increases resulting in high scrap rate and cost
Solution Approach 1:
The insert element is divided into multiple functional layer-systems (first layer-system for heat resistance, second layer-system for cooling, third layer-system for acoustic damping) that can be manufactured separately and then assembled together. This segmentation allows each layer to be optimized independently and simplifies the overall manufacturing process compared to casting a complex double-walled hollow core structure as a single piece.
Solution Approach 2:
The insert element uses composite construction with multiple layer-systems made of different materials optimized for specific functions. The first layer-system uses heat resistant materials for thermal barrier, the second layer-system uses materials suitable for cooling channels, and the third layer-system uses materials for acoustic damping. This composite approach achieves superior performance while simplifying manufacturing compared to monolithic casting.
2Object-affected harmful factors
If Helmholtz dampers are added to absorb pulsations, then acoustic damping is improved, but device complexity increases
Solution Approach 1:
The acoustic damping function is merged with the insert element that is already required for heat resistance and cooling. The third layer-system providing acoustic damping is integrated into the same component structure, eliminating the need for separate damper assemblies. The circumferential edge of the insert element defines a gap that forms the Helmholtz damper, combining multiple functions in a single element.
Solution Approach 2:
The insert element is designed as a multi-functional component that simultaneously provides heat resistance (first layer-system), cooling (second layer-system), and acoustic damping (third layer-system). This universal design eliminates the need for multiple separate components, reducing overall device complexity while achieving all required functions.
3Manufacturing precision
If precision casting is used for double-wall structures, then manufacturing precision is improved, but lead-time for design modification increases significantly
Solution Approach 1:
By segmenting the insert element into separate layer-systems that can be manufactured using additive manufacturing or other rapid fabrication methods, design modifications can be made quickly by updating only the affected layers rather than re-casting the entire complex double-walled structure. This significantly reduces lead-time for design changes while maintaining manufacturing precision.
Solution Approach 2:
The insert element design allows for preliminary fabrication of individual layer-systems that can be stored and quickly assembled. This enables rapid response to design changes by preparing components in advance and making modifications only where needed, reducing overall lead-time compared to traditional precision casting of complete assemblies.
4Temperature
If cooling air is emitted into the hot gas path, then wall cooling is improved, but emissions increase
Solution Approach 1:
The cooling function is extracted from the hot gas path by providing cooling channels within the insert element itself (second layer-system). Cooling air is supplied through these internal channels to cool the hot gas path component walls from the inside, eliminating the need to emit cooling air into the hot gas path. This reduces emissions while maintaining effective wall cooling.
Solution Approach 2:
The insert element acts as an intermediary between the cooling air supply and the hot gas path component walls. Instead of directly emitting cooling air into the hot gas path, the cooling air flows through the second layer-system channels within the insert element, which then conducts heat away from the component walls. This indirect cooling mechanism reduces emissions while achieving the required wall cooling.
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
The insert element effectively enhances heat resistance and cooling efficiency while reducing acoustic pulsations, enabling reliable operation and maintenance of gas turbines, even in existing systems, by providing a customizable and cost-effective solution for thermal and mechanical stress management.
Implementation Method 1
a first functional layer-system, having at least one layer made of heat resistant material and defining the first area of the surface
Implementation Method 2
a second functional layer-system, being in direct or indirect flatly contact to said first layer-system at a side facing away from the first area and includes means for cooling the first layer-system
Implementation Method 3
means for cooling the first layer-system
Implementation Method 4
a third layer-system being in direct or indirect flatly contact to said second layer-system at a side facing from the first layer-system and including means for acoustical damping having at least one acoustic access to the hot gas path
Data Source
Figure 1a~1d
Figure 2a~3
AI summary
The invention refers an insert element (1) for closing an opening (2) inside a wall of a hot gas path component (3) of a gas turbine, the insert (1) comprising: a plate like body with an opening sided surface, said surface provides at least one first area (4) which projects beyond at least one second area (5) of said surface which surrounds the at least one first area (4) frame-like, the at least one first area (4) is encompassed by a circumferential edge (6) corresponding in form and size to said opening (2) such that the circumferential edge (6) and the opening contour limit a gap (7) at least in some areas while the at least one second area (5) contacts directly or indirectly the wall of the hot gas path component (3) at a rear side (8) facing away from the hot gas path (9), and the plate like body provides at least a first functional layer-system (10), providing at least one layer made of heat resistant material, defining the first area (4) of the surface (S).