Real-Time Corrosive Detection for Turbomachine Compressor Wash Control
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Solution Overview
Problem
Turbomachines face performance and heat-rate issues due to compressor fouling from corrosion, which is exacerbated by ambient conditions, and existing systems require offsite analysis to determine when to initiate mitigation, leading to delayed action.
Innovation Solution
A real-time corrosion detection system that separates and analyzes corrosives in the airstream, determining the need for mitigating actions and controlling an on-line water wash system to reduce corrosion levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If offsite analysis is used to determine corrosive levels, then analysis accuracy may be maintained, but response time is delayed and mitigation efforts are postponed
Solution Approach 1:
The patent replaces offline mechanical/chemical analysis systems with an online analytical instrument that continuously monitors corrosives in real-time. This substitution enables immediate detection and response while maintaining measurement accuracy through automated sampling and analysis capabilities integrated directly into the compressor system.
Solution Approach 2:
The patent introduces an intermediary automated sampling and analysis system that bridges the gap between corrosive presence in the airstream and mitigation action. The system includes automated sample collection, filtration, and analysis components that continuously provide corrosive level data to the control system, enabling real-time decision-making without manual intervention.
2Device complexity
If de-mineralized water is used for cleaning, then system simplicity is maintained, but cleaning effectiveness is insufficient for strong corrosives
Solution Approach 1:
The patent implements a dynamic water wash system that automatically adjusts cleaning parameters based on real-time corrosive levels. The control system modulates water flow rate, wash cycle frequency, and chemical additive injection based on the severity of corrosive contamination detected by the online analyzer, optimizing both effectiveness and resource usage.
Solution Approach 2:
The patent changes the parameters of the water wash system from fixed to variable, adjusting water chemistry, temperature, and flow characteristics based on detected corrosive types and concentrations. The system can switch between different cleaning regimens (e.g., water-only, water with mild chemicals, water with strong chemicals) depending on the analyzed corrosive profile.
3Productivity
If continuous monitoring is implemented, then real-time mitigation is achieved, but system complexity and cost increase
Solution Approach 1:
The patent segments the monitoring and mitigation system into modular functional units: aerosol sampling module, particle filtration module, chemical analysis module, control decision module, and water wash execution module. Each module performs a specific function and can be independently maintained or replaced, reducing overall system complexity while enabling continuous monitoring.
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 effectively reduces compressor corrosion by initiating targeted water washes in real-time, linking corrosive analysis with on-line water wash operations to prevent fouling and maintain turbomachine performance.
Implementation Method 1
separating at least one corrosive from a sample of an airstream entering the compressor
Implementation Method 2
separating at least one corrosive from a sample of an airstream
Implementation Method 3
determining a level of the at least one corrosive
Implementation Method 4
determining a level of the at least one corrosive
Implementation Method 5
reducing the level of the at least one corrosive, if the mitigating action is desired
Data Source
AI summary
An embodiment of the present invention measures a sample of the airstream, in real time, for a corrosive, before the airstream enters the compressor. An embodiment of the present invention may then initiate an on-line water wash system to reduce the level of the at least one corrosive on the compressor. An embodiment of the present invention also provides an on-line water wash system that may mix a cleaning fluid with at least one chemical agent to form a cleaning solution. The cleaning solution reduces the level of corrosives on components of a turbomachine compressor. The cleaning solution may be an acidic solution to reduce corrosion of a caustic nature. Alternatively, the cleaning solution may be a basic solution to reduce corrosion of an acidic nature.