Foam Cleaning System for Jet Engine Gas Path Fouling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for cleaning gas turbine engines, such as mist, sprays, and vapor systems, fail to effectively reach and remove fouling materials from the entire gas-path, leading to performance deterioration and increased maintenance costs.
Innovation Solution
Introducing a foam material at the gas-path entry of turbine equipment, which coats and scrubs internal surfaces to remove fouling materials, using a system that mixes a cleaning agent with pressurized gas to create a foam that is then structured to optimize its cleaning effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mist, sprays, or vapor systems are used for cleaning, then the cleaning process can be applied, but the cleaning effectiveness is insufficient as they fail to reach deep or across the entire engine gas-path
Solution Approach 1:
The patent changes the physical state and properties of the cleaning agent by converting liquid cleaning solution into foam through aeration and mixing with compressed air. This parameter change allows the cleaning medium to penetrate deeper into the engine gas-path and reach areas that traditional spray or mist systems cannot access, thereby improving cleaning effectiveness and coverage without increasing system complexity
Solution Approach 2:
The patent utilizes phase transition by transforming the cleaning agent from liquid to foam state through the injection of compressed air and mechanical agitation in the foam generator. This phase transition enables the cleaning medium to better adhere to and penetrate the engine internal surfaces, improving both the depth and breadth of cleaning coverage throughout the gas-path
2Ease of manufacture
If traditional cleaning methods are used, then the process is simple to implement, but fuel consumption increases and engine life shortens due to insufficient fouling removal
Solution Approach 1:
The patent modifies the physical parameters of the cleaning agent by creating foam with specific cell structures and densities through controlled aeration. This parameter optimization enhances the cleaning agent's ability to penetrate and remove fouling materials, thereby reducing residual contaminants that would otherwise increase fuel consumption and shorten engine life, all while maintaining procedural simplicity
3Reliability
If foam is introduced to improve cleaning coverage, then deep and comprehensive cleaning is achieved, but the foam generation and structuring process adds system complexity
Solution Approach 1:
The foam generator serves multiple functions simultaneously: it mixes the cleaning solution with compressed air, generates foam through aeration, and structures the foam cells through controlled flow paths. This multi-functionality consolidates what could be separate complex subsystems into a single integrated component, achieving deep and comprehensive cleaning coverage without proportionally increasing overall system complexity
Solution Approach 2:
The patent employs pneumatic principles by using compressed air injection to generate and structure the foam. The compressed air not only creates the foam bubbles but also provides the driving force for foam circulation through the engine gas-path. This pneumatic approach simplifies the system by using readily available compressed air infrastructure rather than requiring complex mechanical foam pumping or circulation systems
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 foam cleaning method significantly improves engine performance by removing contaminants, reducing fuel consumption, and extending engine life, with measurable improvements in start times and fuel efficiency.
Implementation Method 1
The foam will coat and contact the internal surfaces, scrubbing, removing, and carrying fouling material away from equipment
Implementation Method 2
The foam will coat and contact the internal surfaces, scrubbing, removing, and carrying fouling material away from equipment
Data Source
AI summary
Turbines and associated equipment are normally cleaned via water or chemical pressure washing via a mist, spray systems. However, these systems fail to reach deep across the gas path to remove fouling materials. Various embodiments herein pertain to apparatus and methods that utilize the water and exiting chemicals to generate a foam. The foam can be introduced at that gas-path entrance of the equipment, where it contacts the stages and internal surfaces. In one embodiment, the method can include: forming a first foam with a liquid cleaning agent and pressurized gas; flowing the first foam over a member or matrix and increasing the size of the cells of the first foam to form a second foam; and flowing the second foam through a structure such as a mesh or one or more apertured plates and decreasing the size of the cells of the second foam to form a third foam.