Integrated Tip Clearance Control Panel for Turbine Casing
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Solution Overview
Problem
Conventional tip clearance control (TCC) systems for turbomachines suffer from air leakages, complex designs, and inefficiencies due to separate impingement and distribution chambers, leading to reduced cooling effectiveness and increased fuel consumption.
Innovation Solution
A self-supporting panel system integrating both air distribution and impingement chambers with perforations, allowing for relative movement and optimized air flow, eliminating the need for separate securing elements and reducing weight and volume, while using existing casing access points for sensor passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate impingement chambers and distribution ducts are used, then the system can be secured to the casing, but the device complexity increases and weight increases
Solution Approach 1:
The patent combines the distribution duct and impingement chamber into a single integrated panel structure. The distribution duct is formed as a channel within the panel, and the impingement chamber is created by a cavity in the same panel, eliminating the need for separate components and their associated securing elements. This merging reduces device complexity while maintaining securing reliability through the self-supporting panel design that utilizes the casing itself for support.
Solution Approach 2:
The integrated panel serves multiple functions simultaneously: it acts as the distribution duct for conveying cooling air, forms the impingement chamber for air accumulation, provides the perforated surface for air release, and functions as a self-supporting structure secured to the casing. This multi-functionality eliminates the need for separate components, reducing overall system complexity while maintaining reliability.
2Reliability
If separate impingement chambers and distribution ducts are used, then the system can be secured to the casing, but the weight increases
Solution Approach 1:
The patent merges the distribution duct and impingement chamber into a single panel structure, eliminating the weight of separate components. The integrated design removes the need for additional securing elements for separate chambers, reducing overall weight while maintaining securing reliability through the self-supporting panel that uses the casing for support.
Solution Approach 2:
The patent extracts the securing function from separate mounting elements and integrates it into the panel's self-supporting design. The panel is designed to be self-supporting and secured directly to the casing through its own structure, eliminating the need for separate securing elements and reducing weight.
3Reliability
If separate impingement chambers and distribution ducts are used, then the system can be secured to the casing, but the volume increases
Solution Approach 1:
The patent combines the distribution duct and impingement chamber into a single integrated panel, significantly reducing the overall volume. The distribution duct is formed as a channel within the panel thickness, and the impingement chamber is created by a cavity in the same panel, eliminating the volume that would be occupied by separate components and their securing elements.
Solution Approach 2:
The patent applies nesting by placing the distribution duct channel and impingement chamber cavity within the same panel structure. The distribution duct is nested within the panel body, and the impingement chamber is nested as a cavity in the same panel, creating a compact integrated structure that reduces volume while maintaining functionality.
4Ease of operation
If air is conveyed through long paths in separate ducts, then the air can reach the impingement chambers, but pressure drops increase
Solution Approach 1:
The patent merges the distribution duct and impingement chamber into a single integrated panel, dramatically shortening the air flow path. Air is conveyed through a channel within the panel and impinges directly through perforations in the same panel, eliminating the long paths and multiple bends associated with separate ducts. This reduces pressure drops while maintaining ease of operation.
Solution Approach 2:
The integrated panel acts as an intermediary structure that directly connects the air source to the impingement surface through a short, direct path. The panel's channel and perforations provide a minimal resistance pathway, reducing pressure drops compared to separate ducts with multiple bends and connections.
5Ease of operation
If cut-outs are provided in impingement chambers for sensor passage, then sensors can access the casing, but shadow regions increase and efficiency decreases
Solution Approach 1:
The patent incorporates sensor passage holes in the panel structure during manufacturing, before the panel is installed on the casing. This preliminary action allows sensors to be positioned in optimal locations for monitoring without requiring cut-outs in the impingement chamber that would create shadow regions. The panel design integrates sensor access functionality without compromising cooling efficiency.
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 integrated panel system enhances air impingement efficiency, reduces pressure drops, and minimizes air leakages, achieving a 35% reduction in weight and volume, with improved cooling uniformity and reduced hot spots, resulting in increased system efficiency and reduced fuel consumption.
Implementation Method 1
By means of perforations on the lower face thereof, the one facing the casing, this recirculated air is accelerated by the Venturi effect, causing it to accelerate and impinge on the casing
Implementation Method 2
cooling the cover thereof (which can reach more than 800° C.) and causing its shrinkage
Implementation Method 3
a system for supporting these panels on the casing is proposed, enabling relative movement between them with thermal expansion of the casing
Data Source
AI summary
The present invention relates to a panel for tip clearance control formed by: a first perforated sheet adapted for being seated on the turbine casing; a second sheet arranged on said first sheet and configured for being attached to the first sheet leaving a gap between both sheets; and a third sheet arranged between both first sheet and second sheet such that respective spaces in fluid connection by at least one hole are configured: a distribution chamber and an impingement chamber, both chambers extending from one end of the panel to the other. The panel further comprises a closure element together with a sealing element at one of its lateral ends for allowing the passage of fluid with another adjacent panel, whereas the sealing element is configured for allowing relative movement between both adjoining panels.