Turboengine water wash system
09708928 ยท 2017-07-18
Assignee
Inventors
Cpc classification
F01D25/002
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B08B3/003
PERFORMING OPERATIONS; TRANSPORTING
B05B7/26
PERFORMING OPERATIONS; TRANSPORTING
B05B7/166
PERFORMING OPERATIONS; TRANSPORTING
B08B3/10
PERFORMING OPERATIONS; TRANSPORTING
F05D2220/323
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60S3/044
PERFORMING OPERATIONS; TRANSPORTING
B08B9/00
PERFORMING OPERATIONS; TRANSPORTING
B08B3/026
PERFORMING OPERATIONS; TRANSPORTING
B05B7/0093
PERFORMING OPERATIONS; TRANSPORTING
B08B3/08
PERFORMING OPERATIONS; TRANSPORTING
B08B3/02
PERFORMING OPERATIONS; TRANSPORTING
International classification
B08B9/093
PERFORMING OPERATIONS; TRANSPORTING
B08B9/00
PERFORMING OPERATIONS; TRANSPORTING
B05B12/00
PERFORMING OPERATIONS; TRANSPORTING
B05B7/26
PERFORMING OPERATIONS; TRANSPORTING
B05B7/16
PERFORMING OPERATIONS; TRANSPORTING
B05B7/00
PERFORMING OPERATIONS; TRANSPORTING
B08B3/00
PERFORMING OPERATIONS; TRANSPORTING
F01D25/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B08B3/10
PERFORMING OPERATIONS; TRANSPORTING
B08B3/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A system for cleaning gas turbine engines is described. More specifically, methods and apparatuses for cleaning stationary gas turbines and on-wing turbofan engines found on aircraft are disclosed that includes a trailer-mounted, automated low-pressure water delivery system, additive and detergent injection system, nozzle and manifold technology, and active waste water effluent collector system. The system will deliver the liquid cleaning medium at a specific pressure, temperature, and flow rate to optimize the atomization that occurs at the nozzles.
Claims
1. A method of cleaning a gas turbine engine, the method comprising: pressurizing a wash fluid; incorporating additives and/or detergents into the wash fluid by injection of additives and/or detergents into the wash fluid; delivering wash fluid into the gas turbine engine at a low pressure, finely divided spray at about 200 psi to about 725 psi and a delivery rate of about 1 gallon per minute to about 50 gallons per minute to clean the gas turbine engine; and dispersing, simultaneously, a first low pressure, finely divided spray in a first spray pattern, and a second low pressure, finely divided spray in a second spray pattern different from the first spray pattern.
2. The method of claim 1 wherein pressurizing the wash fluid includes heating and maintaining a temperature of the wash fluid to a range from about 150 degrees to about 200 degrees Fahrenheit.
3. The method of claim 2 wherein the wash fluid is heated using any of tank band heaters, immersion heaters or panels.
4. The method of claim 1 wherein said additives and/or detergents are selected from a group consisting of cleaning solutions, foaming agents, detergents, freeze depressants, emulsifiers, corrosion inhibitors, and anti-static additives.
5. The method of claim 1 wherein the first and second sprays are dispersed through a plurality of nozzles, each having unique characteristics as to droplet size, flowrate, and dispersion spray pattern.
6. The method of claim 1 wherein delivering wash fluid further includes pumping the wash fluid using a wash delivery pump.
7. The method of claim 6, and further comprising: purging the wash fluid from the wash delivery pump.
8. The method of claim 7 wherein purging the wash fluid comprises activating a compressed air source to flush the wash fluid from the wash delivery pump at the end of the wash cycle.
9. The method of claim 6, and further comprising: powering the wash delivery pump using a portable power generator.
10. The method of claim 1, wherein wash fluid is delivered into the gas turbine engine through a manifold and injection nozzle assembly, having a plurality of nozzles mounted on a moveable manifold that is fluidly connected to a source of the wash fluid; and wherein the manifold is positioned directly in front of an air inlet of a gas turbine engine for delivering the wash fluid into the air inlet of the gas turbine engine and connectable to the gas turbine engine.
11. The method of claim 10, and further comprising: dispersing the wash fluid through the plurality of nozzles in the multiple, different spray patterns, each having unique characteristics as to droplet size, flowrate, and dispersion spray pattern.
12. The method of claim 10 wherein a first of the nozzles provides finely-divided spray to a core of the gas turbine engine located remote from the first of the nozzles, and wherein a second of the nozzles provides direct impingement of the wash fluid on bypass blades of the gas turbine engine located in close proximity to the second of the nozzles.
13. The method of claim 10, and further comprising: purging the wash fluid from the manifold array and nozzles.
14. The method of claim 13 wherein purging the wash fluid comprises activating a compressed air source to flush the wash fluid from the manifold array and nozzles at the end of the wash cycle.
15. The method of claim 1, and further comprising: collecting the wash fluid delivered into the gas turbine engine through a manifold and injection nozzle assembly, wherein the step of collecting the wash fluid comprises: expelling waste wash fluid from the gas turbine engine; separating the waste wash fluid from air flow; and collecting the waste wash fluid in a container.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention, and, together with the description, serve to explain the principles of the invention. In the drawings:
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(13) It is to be noted that the drawings illustrate only typical embodiments of the invention and are therefore not to be considered limiting of its scope, for the invention will admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
(14) In general, the present invention relates to methods and apparatuses for cleaning gas turbine engines. More specifically, the invention relates to methods and apparatuses for cleaning on-wing turbofan engines found on aircraft that includes, among other things, a trailer-mounted, automated low-pressure water delivery system, additive and detergent injection system, nozzle and manifold technology, and active waste water effluent collector system.
(15) Turning now to
(16) The trailer 10 is a street-legal, enclosed, steel-framed trailer such as those made available from Pace American of Middlebury, Ind., one of the largest manufacturers of enclosed cargo and auto trailers in the world. Depending upon the size of the components, the trailer can range in size from about 4 wide6 long to about 8.5 wide53 in length, and can be enclosed, partially enclosed, or not enclosed at all. In addition, the trailer can include factory-installed options and accessories such as air conditioning units, living quarters, awnings, heaters, winches, TVs and sound systems, refrigerators, and other such items. Here, the trailer 10 is about 20 feet in length and includes a trailer hitch 12, one or more access or side doors 14, modular tires 16, and ramp door 18. While the components and machinery are all shown in one trailer, the separate components can be mounted on separate trailers (or grouped in different configurations and then mounted on different trailers) to allow for user versatility. Likewise, one or more of the components can be skid mounted. In addition, rather than using a trailer towed by a vehicle with a towing hitch, the components of the present invention could be mounted inside a tractor trailer rig. The use of a trailer is only necessary when the invention is to be portable. In those applications where portability is not required, a permanent fixed platform may be utilized.
(17) The clean water tank 20 is a square, 316 stainless steel IBC tank capable of holding from about 50 to about 300 gallons of water, preferably 250 gallons. If desired, the tank may be of welded steel construction with its internal surfaces treated, as for example by tinning, to resist corrosion. As is known in the art, there are many available shapes for stainless steel tanks or totes including round, elliptical, conical, cylindrical, cone-topped, truncated, and square. In addition, single and double wall tanks, stackable tanks, and tanks made of different materials (such as aluminum or plastic) are also available and can be used in the present invention. The tank can also be outfitted with emergency vents, pumps, meters, and level indicators. To prevent jostling of liquids, the tank may be baffled. The clean water tank 20 has a closable filler aperture 23 near its roof whereby a supply of water may be filled into said tank. The tank is also provided with one or more drain plugs with sloped bottoms to allow for virtually complete drainage of the transported liquid. If desired, the clean water tank 20 may include banded or immersion heaters or panels (and sufficient tank insulation) to keep the water at proper operating temperatures, preferably from about 150 to about 200 degrees Fahrenheit, most preferably 180 degrees Fahrenheit, or as otherwise required by the appropriate Aircraft Maintenance Manual or turbine engine manufacturer. As described in more detail below, the clean water tank 20 is filled with ultra pure water with less than 0.1 parts per million Total Dissolved Solids (TDS) and near 18 MegaOhm resistivity
(18) The grey water tank 30 is also a square, 316 stainless steel IBC tank capable of holding from about 50 to about 300 gallons of water, preferably 250 gallons. It has the same characteristics of the clean water tank, with a closable filler aperture 33, one or more drain plugs, and baffles to prevent jostling of liquids. The grey water tank 30 is designed to hold the waste water effluent directed from the effluent collector 60 described below. In fact, the collector 60 may have a sump dewatering pump at its lower trough.
(19) The wash pump 40 is a stainless steel axial piston pump such as those manufactured by Danfoss. This pump is specifically designed for high-purity water applications and is a stainless steel, high efficiency axial piston pump with high recirculating capability. The pump is designed to deliver from about 1 to about 50 gallons per minute of wash water at a pressure of from about 200 to about 725 psi. The pump's operating parameters may be adjusted by a variable-frequency drive attached to the pump's electric motor. As is known in the art, a variable-frequency drive is an electronic controller that adjusts the speed of the electric motor by modulating the power being delivered. Variable-frequency drives provide continuous control, matching motor speed to the specific demands of the work being performed. Variable-frequency drives enable pumps to accommodate fluctuating demand, running pumps at lower speeds and drawing less energy while still meeting pumping needs.
(20) One or more additive/detergent tanks 50 can be in fluid communication with the clean water tank. These tanks are preferably 10-50 gallon stainless steel square tanks or totes with large fill openings and output ports for piping. The typical detergents, freeze depressants, corrosion inhibitors, and other additives used in this process can be obtained from manufacturers such as ZOK International Group. Preferably, these chemicals are non-flammable, environmentally friendly, and biodegradable.
(21) Rather than being expelled directly onto the underlying surface (such as the hangar floor), the wash water and engine effluent is collected for treatment with a waste water effluent collector 60. As described in more detail below, the waste water effluent collector 60 is a mobile device that is placed under and behind the aircraft engine 160. The device captures the contaminated wash water as it exits the engine and separates the waste wash water from the air flow of the engine. The contaminated wash water is collected in a collection base pan 61 and pumped to the grey water tank 30 for later processing.
(22) In some operating environments, the present invention will also need a power generation system 70 to power the various components discussed above. For example, if airport power is not available, a power source will be provided on the trailer 10 to run, among other things, (a) the heater for the clean water tank, (b) the water pump for the spraying steps, (c) the air purge system, (d) the active fan for the air mist eliminator, (e) the additive injector pumps, (f) the automation panel and related electronics, (g) the effluent collector bilge pump, and (h) the external lighting for night-time or low-light level operations. A suitable power generation system can include a 480 volt, 3 phase, 60 Hertz diesel engine-driven generator unit from such suppliers as Caterpillar, Honda, or Kubota. For non-US systems, the power generation system may be a different voltage, phase and frequency.
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(25) For the nozzles directed towards the engine core, the liquid is finely-divided to a degree such that when the liquid is sprayed against and through the object, the liquid particles will follow the same routes as those earlier taken by the air-borne contaminants through the object. The engine is running during the actual cleaning process, i.e. is rotated with the aid of its start motor, for instance; this provides the air flow that is needed for the finely-divided liquid particles to follow the same route as the air-borne particles and therewith reach contamination coatings throughout the engine.
(26) For the nozzles directed towards the bypass blades, the liquid is dispersed so as to directly impinge upon the pressure and suction side of the bypass blades.
(27) In practice, the pressure for injecting the liquid through the spray nozzles 108 is from about 200 to about 725 psi, preferably 700 psi, with a delivery quantity of from about 1 to about 50 gallons per minute of wash water, with the exact flow rate to be determined by the requirements and specifications of the turbine manufacturer or Aircraft Maintenance Manual. The nozzle orifices are fixed at sizes ranging from 0.05 mm to 1.3 mm. The number of nozzles and radial displacement of each nozzle employed can be varied to provide the desired volume of liquid for the engine and the wash solution droplet size and spray pattern for the engine component the nozzle is targeting.
(28) As is known in the art, the manifold and nozzle apparatus is releasably connected to the leading edge of the gas turbine engine for dispersing the cleaning or rinsing fluid to the air intake area of the engine and on into the engine's internal air flow path.
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(34) Of course, the use of ultra pure water necessitates the use of high-purity water pipe, fittings, and valves. For best results, the ultra pure water is added to the clean water tank 20 no more than about four hours before the washing process takes place. In addition, a resistivity meter or conductivity probe 25 can be used to monitor the purity of the wash water. The clean water tank 20 may include banded or immersion heaters or panels 27 (and sufficient tank insulation) to keep the water at proper operating temperatures.
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(36) The additive or detergent used depends upon the amount and type of fouling found in the engines, the operating environment of use, and the degree of cleaning required. For example, one or more cleaning solutions or detergents can be added to the wash water to assist in the efficacy and efficiency of the cleaning process. Any conventional cleaning solution appropriate for removal of the specific contaminants in the compressor section, typically oils, greases, dust, and entrapped particulates may be employed. Those skilled in the art are adept at selecting, preparing, and producing such solutions in the desired consistency. Moreover, water alone can be used only when certain environmental conditions are met. In particular, when ambient temperatures are below 45 degrees Fahrenheit, there is a strong likelihood that the water will freeze, thereby creating ice formations that can damage the compressor and associated inlet guide vanes, which are expensive to manufacture and replace. In an attempt to increase the temperature range within which water can be used, freeze depressant additives can be mixed with the water to lower its freezing point.
(37) In certain situations it may be necessary to employ a corrosion resistance additive if the engine will not be utilized for a specified length of time.
(38) If desired, other additives can be injected into the engine to facilitate reducing a rate of formation of particulate matter within the gas turbine engine. More specifically, an anti-static liquid that coats compressor blades within the gas turbine engine to facilitate suppressing static charges from developing within the compressor blades can be employed.
(39) As seen in
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(43) The procedures for washing engines are specified by the turbine manufacturers or the Aircraft Maintenance Manual. In general, the cleaning composition is applied to the deposits on the turbofan blades and internal engine components by spraying into the engine from about 30 seconds to about 5 minutes, preferably three one minute intervals. The engine may be turned by hand (windmilled) or run using the starter motor alone during application to further promote uniform distribution of the cleaning composition within the engine. The cleaning composition is allowed to soak into the deposits for about 2 to 5 minutes, which allows surface reactions to occur. To properly clean an aircraft engine, about 3 to 5 such application and soak steps are cyclically repeated to assure adequate dislodging of the deposits from the engine components. Of course, the method of application and number of application and soak steps will vary depending on the engine type, severity of deposit accumulation, and resistance to removal. In non-aircraft applications, the procedures for on-line and off-line washing of the turbine compressor outlined by the turbine manufacturers are followed.
(44) Rinsing may be required to remove both the cleaning composition and loosened deposits from the engine. A rinse solution may be applied in a similar cyclic application and soak pattern. Using water as the preferred rinsing agent, a 30 second application, while windmilling, followed by soaking for 1 minutes and then repeating for about 3 to 8 cycles will provide adequate rinsing. As will be understood by those skilled in the art, any rinsing means which sufficiently removes residual cleaning composition and loosened deposits from the engine may be used.
(45) The present invention will allow for the introduction of certain additives into the wash solution by injection into the suction input plumbing or high pressure output of the main wash delivery pump. Additives required will be injected in precise operator-specified quantities and flow rates for specific time durations controlled by the system automation devices.
(46) The present invention will use a feed-back automation system with electronic controllers to adjust the pressure, flow rate, temperature, and duration of the water wash system. The wash procedure needed for each engine type and for specific applications will be specified in a proprietary computer program running on the system. The operator will input the necessary information and the system will begin operation according to the required parameters. Of course, manual override and emergency stop procedures will be allowed.
(47) While not required, sampling of the resulting effluent liquid may be periodically conducted during the cleaning operation for analysis of suspected contaminants. Upon determining that the concentration of one or more selected contaminants in the effluent has dropped below predetermined values, the cleaning operation can be modified. The constituent contaminants, the degree of contamination, the selected solvents, the concentration thereof, and the operating temperature all affect the cleaning time and efficacy.
(48) After the cleaning and rinsing steps are completed, and the waste water effluent collected, the manifold and nozzles are then removed and stowed in the trailer, and the engine prepared for operation utilizing the instrument air purge. The engine is then run-dried as per the specifications and requirements of the turboengine manufacturer or the Aircraft Maintenance Manual
(49) Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations could be made herein without departing from the spirit and scope of the invention as defined by the appended claims.