Swirler Spray Nozzle for Compressor Cleaning Adaptability
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Solution Overview
Problem
Conventional nozzle systems are inadequate for both on-line and off-line compressor cleaning in gas turbines, as they fail to operate effectively across a range of pressures and flows, leading to inefficiencies, wastage of cleaning fluids, and increased hardware costs due to the need for separate nozzle arrangements for different cleaning modes.
Innovation Solution
A spray nozzle with a side-spray configuration and a swirler head that creates a swirling turbulent flow, allowing for a wide range of fluid pressures and droplet sizes, and enabling the use of a single nozzle body with multiple outlets of varying geometry to adapt to different turbine configurations, thus facilitating efficient cleaning and rinsing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single nozzle system is used for both on-line and off-line cleaning, then hardware costs are reduced, but the nozzle must operate effectively across a wide range of pressures and flows which is technically challenging
Solution Approach 1:
The nozzle is designed with a universal structure that can perform both on-line cleaning (at high pressures of 1000-2000 PSIG) and off-line cleaning (at low pressures of 100-150 PSIG) functions. The swirler head with its specific geometry and the adjustable orifice plate enable the same nozzle to operate effectively across this wide pressure range, eliminating the need for separate nozzle systems for different cleaning modes.
Solution Approach 2:
The nozzle incorporates an adjustable orifice plate that can be positioned at different locations within the flow path. This dynamic adjustment capability allows the nozzle to adapt its flow characteristics to match the required operating conditions - using smaller effective orifice areas for high-pressure on-line cleaning and larger effective areas for low-pressure off-line cleaning, thus maintaining versatility across different pressure regimes.
2Productivity
If high pressure injection is used for off-line cleaning, then cleaning effectiveness is improved, but the system becomes unsuitable for on-line washing due to thermal shock and blade erosion risks
Solution Approach 1:
The nozzle design enables precise control of operating parameters including pressure, flow rate, and droplet size. For off-line cleaning, the system can be configured to deliver high pressure (1000-2000 PSIG) with appropriate droplet sizing to achieve effective cleaning. For on-line cleaning, the same nozzle delivers lower pressure (100-150 PSIG) with fine mist droplets that avoid thermal shock and erosion while maintaining cleaning effectiveness through prolonged chemical contact time.
Solution Approach 2:
The adjustable orifice plate allows dynamic control of the pressure-droplet size relationship. By adjusting the orifice position, the system can optimize droplet characteristics for each cleaning mode - producing larger droplets acceptable for off-line high-pressure cleaning while producing fine mist for on-line low-pressure cleaning, thus preventing harmful effects in both operating modes.
3Loss of time
If cleaning solution is injected over a short period, then the process is faster, but fluid wastage increases and chemical contact time is insufficient
Solution Approach 1:
The nozzle enables operation at reduced flow rates by adjusting the orifice plate position to create smaller effective flow areas. This allows the cleaning solution to be injected over extended periods (10-15 minutes or more) at lower flow rates, increasing chemical contact time with deposits while reducing the total volume of fluid required and minimizing wastage to the combustion system.
4Reliability
If multiple separate nozzle arrangements are used for different cleaning modes, then each mode can be optimized, but hardware costs and installation complexity increase
Solution Approach 1:
The nozzle incorporates multiple functional capabilities within a single device. The swirler head design with adjustable orifice plate enables the same nozzle to deliver appropriate spray patterns and droplet sizes for both on-line and off-line cleaning modes, eliminating the need for separate nozzle arrangements and reducing hardware complexity while maintaining mode-specific optimization.
Solution Approach 2:
The nozzle function is segmented into controllable parameters (pressure, flow rate, droplet size, spray pattern) that can be independently adjusted via the orifice plate position. This segmentation allows each cleaning mode to be optimized by adjusting specific parameters rather than requiring completely different nozzle hardware, achieving mode-specific optimization with a single versatile device.
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 nozzle design reduces fluid wastage, increases chemical contact time, and allows for effective post-wash rinsing, achieving better cleaning results while reducing hardware costs by accommodating various pressure and flow rates, and enabling adaptability to different turbine configurations.
Implementation Method 1
The swirler head creates a swirling turbulent flow for the fluid passing through and about the head
Implementation Method 2
The swirler head includes a reduced diameter neck portion about which the fluid is introduced, allowing the fluid full circumferential contact with and passage through and about the swirler
Data Source
AI summary
A spray nozzle, particularly well adapted for use in compressor spray cleaning systems, has a nozzle body with a right angle fluid delivery bore having a first passageway section extending longitudinally and at least one connected transverse nozzle bore section terminating in a reduced diameter spray bore at a sidewall of the nozzle body. A swirler is mounted in the nozzle bore section, and has a head section with a plurality of passageways formed between swirl vanes arranged about a periphery of the head section to pass fluid to the spray bore and an adjacent neck section of a reduced diameter. The neck forms an annulus between the neck and the nozzle body in fluid-passing contact with the first passageway section and head section to direct fluid from the first passageway through the head passageway for exit through the spray bore. The nozzle can be used in spray systems over a wide range of fluid delivery volumes and pressures.