Dry Detergent Particle Segmentation for Gas Turbine Cleaning
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Solution Overview
Problem
Environmental particulate accumulation on gas turbine engine components leads to reduced cooling effectiveness and corrosive reactions, resulting in premature distress and reduced engine life.
Innovation Solution
A dry detergent with varying-sized abrasive particles is injected into the gas turbine engine, where smaller particles clean cooling passageways and larger particles abrasively clean surfaces, providing simultaneous mechanical and chemical removal of particulate deposits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single-size abrasive detergent is used, then the cleaning process is simple, but it cannot effectively clean both cooling passageways and external surfaces simultaneously
Solution Approach 1:
The detergent is segmented into two distinct particle size sets: fine particles (3-10 microns) for cleaning cooling passageways and coarse particles (20-40 microns) for cleaning external surfaces. This segmentation allows each particle size to perform its specific cleaning function effectively, resolving the contradiction between cleaning effectiveness and detergent complexity.
Solution Approach 2:
Different particle sizes are distributed to different locations within the engine: fine particles are carried into and deposit on cooling passageway surfaces, while coarse particles remain on external surfaces. This local quality assignment ensures optimal cleaning performance in each specific area, addressing the need for simultaneous cleaning of different engine components.
2Productivity
If coarse abrasive particles are used for surface cleaning, then external surfaces are effectively cleaned, but cooling passageways cannot be reached
Solution Approach 1:
The detergent system is divided into two particle size segments that can access different areas: coarse particles (20-40 microns) for external surfaces and fine particles (3-10 microns) for internal cooling passageways. This segmentation enables both surface and internal cleaning without requiring separate cleaning operations.
Solution Approach 2:
Fine particles act as intermediaries that can penetrate into cooling passageways where coarse particles cannot reach. The fine particles are carried by airflow into the passageways and deposit on internal surfaces, while coarse particles handle external surface cleaning, creating a complementary cleaning system.
3Productivity
If fine particles are used for cooling passageway cleaning, then internal surfaces are cleaned, but external surfaces require separate treatment
Solution Approach 1:
The detergent combines both fine and coarse particles in a single composition, merging the functions of internal passageway cleaning and external surface cleaning into one unified cleaning operation. This eliminates the need for separate cleaning processes and reduces overall operational complexity.
Solution Approach 2:
The detergent achieves multi-functionality by incorporating dual particle size sets that can simultaneously clean both internal cooling passageways and external engine surfaces. This universal cleaning capability allows a single detergent application to address all cleaning needs, reducing the number of required cleaning steps.
4Reliability
If traditional cleaning methods are used, then thorough cleaning can be achieved, but the process requires disassembly and extensive time
Solution Approach 1:
The detergent system enables self-service cleaning where the engine cleans itself during normal operation or idle periods. The detergent is introduced into the engine and circulated through the existing airflow paths, allowing cleaning to occur without external intervention, disassembly, or specialized equipment, thus minimizing engine downtime.
Solution Approach 2:
The detergent performs preliminary cleaning action by depositing abrasive particles on surfaces during normal operation, removing particulate accumulation before it causes significant damage. This preventive cleaning approach maintains engine reliability without requiring extensive shutdowns for thorough cleaning operations.
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 method effectively cleans gas turbine engine components on-wing and off-site, improving durability and extending engine time by removing particulate deposits and preventing corrosive reactions without requiring a rinse step.
Implementation Method 1
a first set of particles having a median particle diameter within a first micron range... configured to deposit on surfaces of one or more cooling passageways
Implementation Method 2
a second set of particles having a median particle diameter within a second micron range... configured to abrasively clean the one or more components
Data Source
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AI summary
The present disclosure is directed to a method and detergent for in-situ (e.g. on-wing) cleaning one or more components of a gas turbine engine (10). The method includes injecting a dry detergent (84) into the gas turbine engine (10). Further, the dry detergent (84) contains a plurality of detergent particles having varying particle sizes. More specifically, the plurality of detergent particles includes a first set of particles having a median particle diameter within a first micron range and a second set of particles having a median particle diameter within a second micron range. Further, a median of the second micron range is larger than a median of the first micron range. In addition, the method includes circulating the dry detergent (84) through at least a portion of the gas turbine engine (10) so as to clean the one or more components thereof.