Composite Wedge Alignment for Deep HRSG Tube Cleaning
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Solution Overview
Problem
Existing cleaning methods for boiler tubes in heat recovery steam generators (HRSGs) are inefficient, often damaging the tubes due to the use of metallic wedges and limited to cleaning only the first few rows, and require costly and heavy equipment that cannot effectively clean hard deposits.
Innovation Solution
A deep cleaning alignment equipment using a composite wedge to spread tubes and form a channel, combined with wands that can spray liquids or gases at various angles, minimizing tube damage and ensuring thorough cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional metallic wedges are used to create access lanes between tubes, then the tubes can be spread to allow cleaning, but the tubes and fins are at risk of damage due to the hard material
Solution Approach 1:
The patent applies composite materials by using a wedge made of composite material instead of traditional metallic materials. This composite wedge maintains the ability to spread tubes for cleaning access while being softer and less abrasive, thereby reducing damage risk to the tubes and fins.
Solution Approach 2:
The patent changes the material parameter of the wedge from hard metal to softer composite material. This parameter change allows the wedge to perform its spreading function while minimizing harmful effects on the tubes and fins through reduced hardness and abrasiveness.
2Ease of operation
If traditional pointed lance wedges are used, then access lanes can be created, but the stress concentration at the contact point increases
Solution Approach 1:
The patent applies curvature by designing the wedge with a curved or rounded contact surface instead of a sharp pointed lance shape. This curved geometry distributes the contact stress over a larger area, reducing stress concentration on the tubes while still enabling access lane creation.
3Productivity
If traditional air spraying wands are used, then some tube lanes can be cleaned, but hard deposits cannot be effectively removed
Solution Approach 1:
The patent changes the cleaning parameter by switching from air spraying to liquid or gas spraying. This parameter change enables effective removal of hard deposits that cannot be cleaned by air alone, while maintaining the ability to clean tube lanes.
4Reliability
If wands are inserted into each row of tubes to clean the entire HRSG, then thorough cleaning is achieved, but the time and complexity increase
Solution Approach 1:
The patent applies preliminary action by using the composite wedge to pre-create access lanes and spread the tubes before cleaning. This preliminary preparation allows the cleaning wand to access and clean multiple tube rows more efficiently, reducing the overall cleaning time while maintaining thoroughness.
Solution Approach 2:
The patent applies multi-functionality by designing a cleaning system that can clean multiple tube rows through a single access lane. The universal wedge and wand design allows one access point to serve multiple cleaning functions across different tube rows, reducing the need to insert wands into each row individually.
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 equipment effectively cleans all boiler tubes while minimizing stress on the tubes and fins, allowing for efficient and thorough removal of deposits using composite materials and angled spray techniques.
Implementation Method 1
The elongate wedge is configured to contact the tubes and fins about an extended surface area. In turn, this minimizes a stress force between the wedge and the tubes.
Implementation Method 2
a wand configured to spray one of a liquid or a gas about the heat recovery steam generator system
Data Source
Figure 1
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AI summary
Systems and methods for cleaning a heat recovery steam generator system including tubes and fins associated therewith using deep cleaning alignment equipment are described. The deep cleaning alignment equipment primarily includes at least one wedge and at least one wand. The wedge may be an elongate wedge configured to maximize the surface area that contacts the tubes and fins, which in turn minimizes the amount of stress about any specific point of the tubes or the fins. Additionally, the wedge may be made of a variety of different materials. The wedge may be releasably secured to a plate to improve ease with which the wedge may be driven into tubes and fins. The wedge may also include wedge halves that are movable between expanded and collapsed positions.