Compressor Wash System Using Spheroid Injection
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Solution Overview
Problem
Existing compressor cleaning systems for gas turbine engines are ineffective in cleaning middle and later stages, as the cleaning solution is degraded or vaporized, and nozzles often become plugged, leading to reduced cleaning effectiveness and airflow restrictions.
Innovation Solution
A compressor cleaning system that includes a wash nozzle and a spheroid injection port to inject malleable and mildly abrasive spheroids into the compressor, combined with a cleaning fluid, which rotates with the compressor to scour and clean all stages, and the spheroids are recoverable and reusable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water wash systems are used to clean compressor blades and vanes, then early compressor stages are effectively cleaned, but middle and later compressor stages show reduced or no cleaning effectiveness
Solution Approach 1:
The cleaning system is segmented into multiple injection ports positioned at different locations (bellmouth and downstream stages) to address different compressor sections. This allows targeted cleaning of early, middle, and later stages with appropriately positioned nozzles and spheroid injection points, resolving the coverage limitation of single-location water wash systems.
Solution Approach 2:
Malleable and mildly abrasive spheroids are introduced as an intermediary cleaning medium that enhances the cleaning action. These spheroids physically scour the blades and vanes while being carried by the cleaning solution, providing mechanical cleaning action that maintains effectiveness throughout all compressor stages rather than degrading like pure liquid spray.
2Manufacturing precision
If cleaning solution is injected about the bellmouth, then cleaning action is provided at the front end, but the cleaning solution is degraded or vaporized by the time it reaches later stages
Solution Approach 1:
The cleaning solution injection is segmented into multiple locations along the compressor length. By placing injection ports at the bellmouth and additional ports at downstream locations, fresh cleaning solution is supplied to each section, preventing degradation and vaporization that occurs with single-point injection over long distances.
Solution Approach 2:
The system performs preliminary cleaning action with spheroids and cleaning solution at each compressor stage before the solution degrades. The segmented injection ensures that cleaning action is renewed at each location, maintaining effectiveness throughout the entire compressor length without relying on solution that has traveled from the bellmouth.
3Productivity
If traditional water wash nozzles are used, then cleaning solution can be delivered, but nozzles become plugged reducing cleaning effectiveness and producing undesirable spray pattern variations
Solution Approach 1:
Malleable and mildly abrasive spheroids serve as a mediator that flows through the injection system with the cleaning solution. These spheroids help prevent nozzle plugging by maintaining fluid movement and providing mechanical clearing action, while their controlled abrasiveness allows them to pass through without causing damage. This maintains consistent spray patterns and reliable nozzle performance.
Solution Approach 2:
The system changes the physical parameters of the cleaning medium by adding spheroids to the water-based solution. This creates a two-phase flow that maintains better fluid dynamics through the nozzles, preventing plugging while the spheroids themselves provide enhanced cleaning action. The parameter change from pure liquid to liquid-solid mixture improves reliability.
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 system provides thorough cleaning of all compressor stages, reduces nozzle plugging, and minimizes compressor blade erosion, enhancing gas turbine engine performance and efficiency by ensuring consistent and effective cleaning without the need for frequent manual cleaning.
Implementation Method 1
a spheroid injection port to inject a number of malleable and mildly abrasive spheroids therein
Implementation Method 2
The cleaning solution may be degraded or vaporized by the time the solution reaches the later stages
Data Source
AI summary
The present application thus provides a cleaning system for use with a compressor of a turbine engine. The cleaning system may include a wash nozzle positioned about the compressor and a spheroid injection port to inject a number of spheroids therein.