Decoupled Pilot Cone Assembly for Gas Turbine Burners
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Solution Overview
Problem
The existing burner systems in gas turbines face reduced cyclic service life due to inhibited thermal expansion of the pilot cone and mounting insert, leading to high stresses and component damage from permanent welded joints.
Innovation Solution
The pilot cone is constructed as a decoupled assembly with additional sides that allow for thermal expansion, including a screw-fixed axial seating side and a parallel side with a gap to accommodate thermal growth, reducing stresses and enabling longer service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the pilot cone is permanently welded to the mounting insert, then the structural strength and stability are improved, but the thermal expansion is inhibited leading to high stresses and reduced service life
Solution Approach 1:
The pilot cone assembly is segmented into multiple components: the pilot cone itself, a mounting insert, and a retaining ring. This segmentation allows the pilot cone to expand thermally independently while maintaining structural integrity through the retaining ring that secures the assembly to the mounting insert.
Solution Approach 2:
The connection method is changed from permanent welding to a mechanical retention system using a retaining ring. This parameter change allows for thermal expansion while maintaining structural strength, as the retaining ring accommodates dimensional changes without creating stress concentrations.
2Stability of the object's composition
If the pilot cone is permanently welded to the mounting insert, then the assembly stability is improved, but the thermal stresses cause component damage and reduced cyclic service life
Solution Approach 1:
The assembly is divided into separable components (pilot cone, mounting insert, retaining ring) that can expand independently during thermal cycles, preventing the stress accumulation that would otherwise occur in a permanently welded configuration.
Solution Approach 2:
The retaining ring acts as an intermediary element between the pilot cone and mounting insert. It provides mechanical retention while accommodating thermal expansion, serving as a mediator that maintains assembly stability without transmitting damaging thermal stresses.
3Duration of action of stationary object
If the pilot cone is constructed as a decoupled assembly with gaps, then the thermal expansion is accommodated and service life is extended, but the device complexity increases
Solution Approach 1:
The pilot cone assembly is segmented into discrete components (cone, mounting insert, retaining ring) connected with intentional gaps. This segmentation enables thermal expansion accommodation while maintaining relatively simple individual component geometries and assembly procedures.
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 decoupled pilot cone assembly significantly increases the service life of the components by allowing thermal expansion and reducing stresses, while also simplifying assembly and potentially reducing material costs through the use of a sealing ring.
Implementation Method 1
During operation, thermal expansions occur. These are the different thermal expansions of the various components, and also by the radial thermal expansion of the pilot cone.
Data Source
Figure 1
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AI summary
A burner incorporating a pilot cone and a mounting insert is provided. The pilot cone is constructed as a pilot cone assembly which is decoupled from the mounting insert. Further, an operating method for increasing the service life of a burner which incorporates a pilot cone assembly and a mounting insert is provided. The pilot cone assembly has a cone side and incorporates at least one further side where the further side is arranged to be essentially parallel to one of the sides of the mounting insert and spaced apart from it, so that between the further side and the side of the mounting insert there is a defined gap. In an operation of the burner, the gap is significantly reduced by the thermal expansion in at least at one point of contact between the further side and the side of the mounting insert. Finally, an assembly method is provided.