Staged Compressor Wash Nozzle System for Erosion Control
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Solution Overview
Problem
Compressor wash systems face challenges in effectively cleaning compressor air flow paths due to large mass flow, high compression ratios, and erosion concerns, requiring a rugged and compact design that balances fluid injection for efficient cleaning while avoiding combustion instability and flame out issues.
Innovation Solution
A staged compressor wash system with multiple fluid delivery lines and nozzle sets, each connected to a control valve, allowing for selective fluid supply and varying droplet sizes to target specific areas of the compressor, ensuring efficient cleaning while minimizing erosion and maintaining a stable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high concentrations of fluid are injected into the compressor to aid cleaning effectiveness, then cleaning efficiency is improved, but combustion instability and flame out occur
Solution Approach 1:
The compressor inlet is divided into multiple stages with separate fluid injection points. Instead of injecting all fluid at one location, the system segments the injection into multiple zones (first stage, second stage, etc.), allowing controlled fluid distribution that prevents combustion instability while maintaining cleaning effectiveness.
Solution Approach 2:
Different fluid concentrations are applied to different locations within the compressor inlet. The system varies fluid injection quantities and droplet sizes based on local conditions at each stage, optimizing cleaning in high-velocity regions while avoiding excessive fluid concentration in areas that could cause combustion issues.
2Area of stationary object
If multiple water injection points are used to cover rotating and non-rotating blades, then cleaning coverage is improved, but device complexity increases
Solution Approach 1:
The fluid injection system is designed to serve multiple functions through a unified multi-stage structure. The same injection infrastructure addresses both rotating and non-rotating blades across multiple compressor stages, reducing overall system complexity compared to separate injection systems for each blade type.
Solution Approach 2:
The system adds the dimension of staged fluid injection, transitioning from a single-plane injection approach to a multi-stage three-dimensional injection strategy. This allows comprehensive blade coverage through vertical and radial staging of injection points without proportionally increasing horizontal complexity.
3Productivity
If large water droplets are used for cleaning, then cleaning effectiveness is improved, but blade erosion increases
Solution Approach 1:
The system dynamically changes droplet size parameters based on injection stage and location. Large droplets are used in specific stages where cleaning effectiveness is prioritized, while smaller droplets are used in other stages to minimize erosion. This parameter variation allows optimization of the cleaning-to-erosion ratio across different compressor zones.
Solution Approach 2:
The multi-stage injection system creates periodic action patterns where different droplet sizes are introduced at different stages. This periodic variation in droplet characteristics allows the system to alternate between aggressive cleaning modes (large droplets) and protective modes (small droplets), achieving effective cleaning while controlling erosion over time.
4Manufacturing precision
If fluid is injected in high velocity areas to clean blade tips, then line of sight to blade tips is achieved, but fluid is directed towards blade root causing concentrated erosion
Solution Approach 1:
The system applies different fluid injection characteristics to different radial locations. High-velocity area injection points are specifically designed to target blade tips with appropriate droplet sizes and angles, while separate low-velocity area injection points serve the blade root region. This local differentiation prevents cross-contamination of fluid streams and eliminates the erosion problem at blade roots.
Solution Approach 2:
The injection system segments the compressor inlet into distinct radial zones with dedicated injection points for each zone. This segmentation isolates the high-velocity blade tip cleaning function from the low-velocity blade root region, allowing optimized fluid delivery to each area without adverse interactions between zones.
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 achieves effective cleaning of compressor blades by varying fluid droplet sizes and trajectories, reducing erosion and maintaining compressor efficiency, even at high compression ratios, with a rugged design suitable for industrial environments.
Implementation Method 1
each nozzle positioned in an opening on an inlet of the compressor or on an inlet cone of the compressor, with the nozzle extending into an inlet air flow path of the compressor within the line of sight of compressor blades
Implementation Method 2
a pump for supplying fluid, fluid delivery lines connected at one end to an output of the pump
Implementation Method 3
a control valve for selectively supplying fluid from the pump, each connected to a corresponding fluid delivery line between the pump and corresponding nozzle set
Data Source
AI summary
A compressor wash system for compressor washing includes stages of fluid delivery lines coupled at one end to a pump output and at the other end to a corresponding nozzle set. A control valve is connected to the fluid delivery line between the pump and the nozzle set, selectively supplying fluid between the pump and the nozzle set. Each nozzle of a nozzle set is positioned on an inlet of the compressor to allow the stages to wash a portion of the compressor. Nozzle sets are positioned around a bellmouth assembly and/or around an inlet cone of the compressor inlet, with a nozzle spray tip of each nozzle extending into an inlet air flow path of the compressor. Fluid may be directed to one or more of the stages in a sequencing pattern determined and configured to wash the compressor. Templates and installation guides are utilized to position the nozzles.