Modular Gas Turbine Exhaust Diffuser Lip Design
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Solution Overview
Problem
Industrial gas turbine exhaust systems face challenges in balancing aerodynamic efficiency, structural longevity, and cost-effectiveness, particularly when adapting to changes in turbine blade designs, as existing designs often require costly re-optimization and replacement of entire systems rather than modular upgrades.
Innovation Solution
A modular drop-in single-piece exhaust system with a turbine exhaust case and manifold, featuring splined and area-ruled cross sections, modular stiffening rings, and constant thickness strut collars, allowing for easy replacement and reconfiguration to optimize airflow and structural integrity without necessitating new castings or extensive redesign.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional aero-optimized exhaust system design is used, then aerodynamic efficiency is improved, but adaptability to changes in turbine blade designs deteriorates
Solution Approach 1:
The exhaust system is divided into modular components including a turbine exhaust case, turbine exhaust manifold, support struts, and collars that can be independently replaced. This segmentation allows the system to maintain aerodynamic optimization for current blade designs while enabling easy adaptation to future blade design changes through component replacement rather than complete system redesign.
Solution Approach 2:
The exhaust system incorporates replaceable modular components that can be dynamically updated over time. The support struts with collars and the manifold sections can be swapped to match changing turbine blade designs, providing dynamic adaptability while maintaining the aero-optimized geometry of the exhaust path.
2Adaptability or versatility
If the entire exhaust system is replaced to accommodate new turbine blade designs, then adaptability is improved, but manufacturing cost and downtime increase
Solution Approach 1:
The exhaust system is segmented into replaceable modules including the turbine exhaust case, manifold, support struts, and collars. This allows only the necessary components to be replaced rather than the entire system, reducing manufacturing costs and minimizing downtime during upgrades.
Solution Approach 2:
The modular design enables selective replacement of worn or obsolete components while retaining functional parts. Components can be discarded when needed and recovered when still serviceable, optimizing the balance between adaptability and cost-effectiveness.
3Ease of manufacture
If sharp angular changes are used in the exhaust case construction, then ease of manufacture is improved, but aerodynamic performance deteriorates
Solution Approach 1:
The exhaust system incorporates curved transitions and rounded fillets at critical flow paths, particularly at the diffuser sections and strut interfaces. These curved geometries reduce flow separation and turbulence while remaining compatible with standard manufacturing processes, balancing aerodynamic performance with ease of manufacture.
Data Source
AI summary
An integrated single-piece exhaust system (SPEX) with modular construction that facilitates design changes for enhanced aerodynamics, structural integrity or serviceability. The SPEX defines splined or curved exhaust path surfaces, such as a series of cylindrical and frusto-conical sections that mimic curves. The constructed sections may include: (i) a tail cone assembly fabricated from conical sections that taper downstream to a reduced diameter; or (ii) an area-ruled cross section axially aligned with one or more rows of turbine struts; or both features. Modular inner and outer diameter inlet lips enhance transitional flow between the last row blades and the SPEX, as well as enhance structural integrity. Modular strut collars have large radius profiles between the SPEX annular inner diameter and outer diameter flow surfaces, for enhanced airflow and constant thickness walls for uniform heat transfer and thermal expansion. Scalloped mounting flanges enhance structural integrity and longevity.