Opposing-Rotation Dual-Nozzle Sludge Lance for Steam Generator Cleaning

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Solution Overview

Problem

Existing sludge lances for steam generators face challenges with small access openings, requiring multiple jets that increase fluid demand and reaction forces, leading to inefficiencies and reduced cleaning effectiveness.

Innovation Solution

A dual nozzle sludge lance system with a cantilever configuration and synchronized nozzle rotation, supported by an index drive and oscillator assembly, allows for reduced lancing time and fluid requirements, while maintaining accuracy and minimizing deflection through opposing jet forces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple jets are used to clean through small access openings, then cleaning coverage is improved, but fluid demand and reaction forces increase

Engineering Contradiction:
Improvecleaning coverageVSAvoidfluid demand
Core Design Contradiction:
Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The lance is divided into multiple segments or sections along its length, with nozzles distributed at different positions. This segmentation allows the cleaning function to be distributed across multiple locations, achieving comprehensive cleaning coverage through a single lance rather than requiring multiple concentrated jets, thereby reducing overall fluid demand and reaction forces.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The lance extends in the longitudinal dimension along the tube lane, transforming the cleaning approach from a concentrated point source to a distributed linear source. This dimensional change allows cleaning coverage to be achieved along the length of the tube bundle rather than requiring multiple jets at a single access point, reducing fluid requirements.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If multiple jets are used to clean through small access openings, then cleaning coverage is improved, but reaction forces increase

Engineering Contradiction:
Improvecleaning coverageVSAvoidreaction forces
Core Design Contradiction:
Manufacturing precisionVSForce

Solution Approach 1:

The nozzle configuration employs asymmetric positioning and orientation of nozzles along the lance, with nozzles arranged to direct fluid at specific angles relative to the tube bundle geometry. This asymmetric arrangement optimizes cleaning coverage while distributing reaction forces more favorably, preventing excessive cumulative forces that would occur with symmetric multiple-jet configurations.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

Instead of directing all cleaning jets in the same direction, the lance configuration uses nozzles pointing in opposite directions along its length. This inversion of jet direction creates opposing reaction forces that cancel each other out, significantly reducing the net reaction force on the lance structure while maintaining comprehensive cleaning coverage.

Inventive Principle:
Principle #13The other way round (Inversion)

3Manufacturing precision

If synchronized nozzle rotation is implemented, then cleaning effectiveness is improved, but device complexity increases

Engineering Contradiction:
Improvecleaning effectivenessVSAvoiddevice complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

Multiple nozzles are merged into a single integrated lance structure with unified rotation capability. Rather than rotating individual nozzles or nozzle groups separately, the entire lance assembly rotates as one unit, synchronizing all nozzle movements. This merging approach achieves comprehensive cleaning coverage through coordinated rotation while minimizing device complexity by eliminating the need for multiple independent rotation mechanisms.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The oscillating lance serves multiple functions: it provides longitudinal cleaning coverage through its extended structure, achieves angular coverage through synchronized rotation of all nozzles, and maintains structural integrity as a single supportable unit. This multi-functionality is accomplished with a single rotation mechanism rather than requiring separate mechanisms for each nozzle, reducing overall device complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

4Ease of operation

If cantilever configuration is used, then access through small openings is improved, but structural deflection increases

Engineering Contradiction:
Improveaccess through openingsVSAvoidstructural deflection
Core Design Contradiction:
Ease of operationVSStability of the object's composition

Solution Approach 1:

The lance is segmented into multiple sections along its length, with support features distributed at regular intervals. This segmentation reduces the effective cantilever length of each section, minimizing deflection while maintaining the overall extended configuration needed for access through small openings and along the tube lane.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The lance employs composite construction with high-strength, low-density materials that provide sufficient structural rigidity to resist deflection under operating conditions. This allows the cantilever configuration to extend far enough to access tube lanes through small openings while maintaining adequate structural stability through material properties rather than increased cross-sectional dimensions.

Inventive Principle:
Principle #40Composite materials

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 reduces lancing time and fluid demand by approximately 50% and improves cleaning efficiency by canceling horizontal forces, allowing precise alignment and compact envelope maintenance.

Implementation Method 1

The first nozzle body is rotatable relative to the body portion about a first longitudinal axis in a first direction in response to a rotation of the rotary output shaft of the oscillator assembly. The second nozzle body is positioned on a second lateral side of the body portion opposite the first lateral side. The second nozzle body is rotatable relative to the body portion about a second longitudinal axis in a second direction opposite the first direction... the first flow paths and the second flow paths are mirrored about a central vertical plane of the distal head

Methodology Applied
Scientific EffectReaction force cancellation: Reaction (physics)

Data Source

PatentUS20250251202A1Sludge lance for cleaning a steam generator
Publication Date: 2025.08.07 WESTINGHOUSE ELECTRIC CORP
  • US20250251202A1 patent drawing
  • US20250251202A1 patent drawing
  • US20250251202A1 patent drawing

AI summary

A sludge lance system for cleaning a tube bundle of a steam generator is disclosed. The sludge lance system comprises a mount, an index drive, and a sludge lance comprising a longitudinal rail, a manifold, an oscillator assembly, and a distal head. The oscillator assembly comprises a rotary output shaft. The distal head comprises a body portion, a first nozzle body on a first side of the distal head, and a second nozzle body on a second side of the distal head opposite the first side. The first nozzle body is rotatable relative to the body portion about a first longitudinal axis in a first direction in response to a rotation of the rotary output shaft. The second nozzle body is rotatable relative to the body portion about a second longitudinal axis in a second direction opposite the first direction in response to the rotation of the rotary output shaft.