Foam Cleaning System for Gas Turbine Engine Maintenance
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Solution Overview
Problem
Current methods for cleaning gas turbine engines, such as mist, sprays, and vapor systems, fail to effectively reach and remove deep-seated contaminants from the entire engine 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 material, using a system that mixes pressurized gas with a cleaning agent to create a foam that is then structured to optimize its cleaning efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional liquid washing methods (mist, sprays, vapor systems) are used to clean gas turbine engines, then the cleaning process is simple to operate, but the cleaning effectiveness is insufficient and cannot reach deep-seated contaminants
Solution Approach 1:
The patent changes the physical state of the cleaning agent from liquid to foam by controlling parameters such as gas-to-liquid ratio, pressure, and temperature. This parameter transformation enables the cleaning agent to penetrate deep into the engine gas-path while maintaining ease of operation
Solution Approach 2:
The invention creates a composite cleaning medium by combining gas (air or inert gas) with liquid cleaning agent to form foam. This composite structure allows the cleaning system to achieve both deep penetration capability and thorough cleaning effectiveness without significantly increasing operational complexity
2Reliability
If foam is introduced to achieve thorough cleaning of internal surfaces, then cleaning effectiveness improves, but the device complexity increases due to additional components
Solution Approach 1:
The foam generation system is divided into separate functional modules: a foam generator that creates the foam, a delivery system that transports it, and a collection system that recovers it. This segmentation allows each component to be optimized independently while maintaining overall system manageability
Solution Approach 2:
The foam acts as an intermediary medium between the liquid cleaning agent and the engine surfaces. It provides the benefits of both liquid (chemical cleaning action) and gas (deep penetration and coverage), achieving thorough cleaning without requiring complex application equipment
3Productivity
If conventional cleaning methods are used, then the system is simple to operate, but fuel consumption increases and engine life shortens due to inadequate cleaning
Solution Approach 1:
The foam cleaning system performs preliminary deep cleaning of the engine gas-path before normal operation resumes. By thoroughly removing contaminants in advance, it prevents performance deterioration, reduces fuel consumption, and extends engine life, making the additional system complexity worthwhile
Solution Approach 2:
The system changes the physical parameters of the cleaning agent (transforming liquid to foam) to achieve better penetration and coverage. This parameter change enables the cleaning system to effectively remove deep-seated contaminants that conventional methods miss, thereby improving engine performance and reducing operational costs
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 reducing fuel consumption, extending engine life, and providing a more thorough cleaning than traditional liquid washing methods, with measurable improvements in start times and fuel efficiency.
Implementation Method 1
The first flow portion includes a gas plenum that is adapted and configured for receiving gas under pressure from the gas inlet and including a plurality of apertures, the plenum and the interior of the housing forming a mixing region that provides a first foam of the liquid and the gas
Implementation Method 2
The second flow portion receives the first foam and flows the first foam past a foam growth matrix adapted and configured to provide surface area for attachment and merging of the cells
Implementation Method 3
The third flow portion flows the second foam through a foam structuring member downstream of either the first portion or the second portion adapted and configured to reduce the size of at least some of the cells
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C~3D
AI summary
An apparatus for foaming a water soluble liquid cleaning agent, which includes a housing (61) defining an internal flowpath, the flowpath having first (65), second (74), and third (78) flow portions arranged sequentially. The housing (61) has a gas inlet (62), a liquid inlet (63) for the water soluble cleaning agent, and a foam outlet (64). The first flow portion (65) includes a gas plenum (66) that is adapted and configured for receiving gas under pressure from the gas inlet (62) and includes a plurality of apertures (70). The plenum (66) and the interior of said housing (61) cooperate to form a mixing region receiving liquid from the liquid inlet (63) and receiving gas expelled from the apertures (70). The first portion (65) provides a first foam of the liquid and the gas into the internal flowpath. The second flow portion (74) receives the first foam and flows the first foam past a foam growth member (75) adapted and configured to provide surface area for attachment and merging of cells of the first foam to create a second foam. The third flow portion (78) receives the second foam and flows the second foam through a foam structuring member (79) adapted and configured to reduce the size of at least some of the cells of the second foam to create a third foam provided to the foam outlet (64).