cleaning method for gas turbine engine

专利摘要:
CLEANING METHOD FOR JET ENGINE. Turbines and associated equipment are normally cleaned with pressure washing of water or chemicals through a mist, sprinkler system. However, these systems fail to reach depth through the gas path to remove fouling materials. Various embodiments of the present invention pertain to apparatus and methods that use existing water and chemicals to generate a foam. Foam can be introduced into the inlet of the equipment's gas path, where it contacts the stages and internal surfaces, to contact, exfoliate, transport and remove dirt out of the equipment to restore performance.
公开号:BR112016007366B1
申请号:R112016007366-5
申请日:2014-10-02
公开日:2021-05-18
发明作者:Jorge Ivan Saenz
申请人:Aerocore Technologies Llc；
IPC主号:

专利说明:

REFERENCE TO THE RELATED DEPOSIT REQUEST
[001] This application claims priority over the priority benefit over US Provisional Patent Application Serial Numbers 61/885,777, filed October 2, 2013 and 61/900,749, filed November 6, 2013, incorporated herein, by way of reference. FIELD OF THE INVENTION
[002] Various embodiments of the present invention relate to apparatus and methods for cleaning devices that include the gas path including a combustion chamber and, in particular, to apparatus and methods for cleaning a gas turbine engine. BACKGROUND
[003] Turbine engines extract energy to deliver power across a wide range of platforms. Energy can range from steam to fuel combustion. The extracted power is then used for electricity, propulsion, or general power. Turbines work by transforming the flow of fluids and gases into usable energy for helicopters, planes, tanks, power plants, ships, special vehicles, cities, etc. Upon use, the gas path of these devices becomes contaminated with residues and contaminants such as minerals, sand, dust, soot, carbon, etc. When dirty, equipment performance deteriorates, requiring maintenance and cleaning.
[004] It is well known that turbines come in many forms, such as jet engines, industrial turbines, or ship-based and land-based aero-derived units. The internal surfaces of equipment, such as that of an airplane or helicopter engine, accumulate the dirt material, deteriorating the airflow through the engine and decreasing performance.
[005] Correlated to this trend, fuel consumption increases, engine life decreases, and available power decreases. The simplest and most economical means to maintain engine health and restore performance is to properly clean an engine. There are several methods available, such as mist, sprinkler and steam systems. However, all fail because they do not reach deep or along the entire gas path of the engine.
[006] Engine telemetry or diagnostic tools have become routine functions to monitor engine health. However, the use of such tools to monitor, trigger or quantify improved foam engine cleanliness has not been used in the past.
[007] Various embodiments of the present invention provide novel and non-obvious methods and apparatus for cleaning such engines. SUMMARY OF THE INVENTION
[008] The foam material is introduced into the inlet of the turbine equipment's gas path while offline. The foam will coat and contact internal surfaces, scrubbing, removing and transporting dirt material away from the equipment.
[009] One aspect of the present invention relates to an apparatus for foaming a cleaning agent. Some embodiments include an enclosure that defines an internal flow path that has a first, second, and third flow portions, a gas inlet, a liquid inlet for the cleaning agent, and a foam outlet. The first flow portion includes a gas filled space that is adapted and configured to receive gas under pressure from the gas inlet and including a plurality of openings, the filled space and the interior of the housing forming a mixing region that provides a first foam of liquid and gas. The second flow portion receives the first foam and flows the first foam past a foam growth matrix adapted and configured to provide a surface area for cell attachment and fusion. The third portion of the stream flows the second foam through a 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. It is understood that still other embodiments of the present invention contemplate an enclosure having only a first portion; or a first and a second portion; or just a first and third portion in various other nucleation devices.
[010] Another aspect of the present invention relates to a method for foaming a liquid cleaning agent. Some embodiments include mixing the liquid cleaning agent and a pressurized gas to form a first foam. Other embodiments include flowing the first foam over a member or matrix and increasing the cell size of the first foam to form a second foam. Still other embodiments include flowing the second foam through a structure such as a web or one or more apertured plates and decreasing the cell size of the second foam to form a third foam.
[011] Yet another aspect of the present invention relates to a system for providing an air foamed liquid cleaning agent. Other embodiments include an air pump or pressurized gas reservoir supplying air or gas at a pressure greater than ambient pressure, and a liquid pump supplying the liquid at pressure. Still other embodiments include a nucleating device that receives pressurized air, a liquid inlet that receives pressurized liquid, and a foam outlet, the nucleating device turbulently mixing pressurized air and liquid to create a foam. Still other embodiments include a nozzle which receives the foam through a foam conduit, the internal passages of the nozzle and conduit being adapted and configured not to increase foam turbulence, the nozzle being adapted and configured to deliver a low velocity stream. of the foam.
[012] Yet another aspect pertains to a method for providing a foamed liquid cleaning agent with air to the inlet of a jet engine installed in an aircraft. Some embodiments include providing a source of a pressurized liquid cleaning agent, an air pump, a turbulent mixing chamber and a non-atomizing supply port. Other modalities include mixing pressurized air with pressurized liquid in the mixing chamber and creating a supply of foam. Still other arrangements include flowing the foam supply to the installed motor, either through the inlet or through various tubes connected to the motor from the opening.
[013] Yet another aspect of the present invention relates to an apparatus for foaming a water-soluble liquid cleaning agent. Some embodiments include means for mixing a gas under pressure with a flowing water-soluble liquid to create a foam. Other embodiments include means for increasing foam cell size and means for reducing the size of cultured cells.
[014] In various embodiments of the invention, the effluent after a cleaning operation is collected and evaluated. This assessment may include an on-site analysis of the effluent content, including whether or not particular metals or compounds are present in the effluent. Based on the results of this assessment, a decision is made as to whether or not additional cleaning is appropriate.
[015] Still other embodiments of the present invention relate to a method in which the effect of a cleaning operation is assessed, and that assessment is used to assess the terms of a contract. As an example, the contract may relate to the terms of the engine warranty provided by the engine manufacturer to the operator or owner of the aircraft. In still other modalities, the evaluation can be used to evaluate the terms of a contract referring to the cleaning operation of the engine itself. In still other modalities the evaluation of the cleaning effect on the engine can be used to evaluate the engine in relation to the establishment of FFA maintenance standards for the engine.
[016] In one modality, the assessment method includes running an engine in a commercial flight environment for more than about a month. It is expected that in some modalities this operation may include several flights per day, and the use of the aircraft for up to seven days a week. The method further includes operating the engine used and establishing a baseline characteristic. In some embodiments, the baseline characteristic may be specific fuel consumption at a given pressure level, engine pressure rating, or rotor speed. In some alternatives, the method includes correcting this baseline data for the characteristics of ambient atmospheric conditions. In still other modes, the baseline parameter could be the time taken to start a motor from zero rpm to the idle position. Still in other modalities, the evaluation of the used engine's baseline includes the evaluation of the engine starting time as follows: performing a first engine start; turn off the engine; motorize the engine at start (without fuel combustion) for a predetermined period of time; and after motorization, perform a second engine start, and use the second engine start time as the baseline start time.
[017] The method also includes cleaning the engine. This engine cleaning can include one or more successive cleaning cycles. After the engine is cleaned, the baseline test method is repeated. These results from the second test (from the clean engine) are compared with the results from the baseline test (from the engine used, as received); and changes in engine characteristics are evaluated against a contractual guarantee. As an example, the cleaning equipment operator may have offered contractual terms to the aircraft owner or operator regarding the improvement to be made by the cleaning method. In still other modalities, the delta improvement provided by the cleaning method (or, alternatively, the clean engine test results considered by themselves) can be compared to a contractual guarantee between the engine manufacturer (or the apparatus that performed the previous engine review, or the engine licensee) to assess whether or not the clean engine meets these contractual conditions.
[018] In yet other embodiments, there is a cleaning method in which a baseline test is performed on a used engine; the engine is clean; and the baseline test is performed a second time. Comparison of the baseline test to the clean engine test can be used for any reason.
[019] In yet other embodiments, the cleaning method includes a process in which the engine is operated in a cleaning cycle and that cleaning cycle (or a different cleaning cycle) is subsequently applied to the engine. Preferably, cleaning chemicals are supplied to the engine at relatively low rotational speeds, and preferably less than about half the typical idle speed for that engine.
[020] In still other embodiments, such as those on engines supported substantially vertically, the cleaning chemical can be applied to the engine when the engine is static (ie, zero rpm). After a sufficient amount of chemicals has been applied, the engine can then be run at any speed, and the cleaning chemicals subsequently discarded.
[021] Still other embodiments of the present invention relate to methods for cleaning an engine that include manipulating the temperature of the cleaning chemicals and/or manipulating the temperature of the engine being cleaned. In one embodiment, the cleaning system includes a heater that is adapted and configured to heat the cleaning chemicals prior to creating a cleaning foam. In yet other embodiments, the method includes a heater to heat the air being used to foam the cleaning liquids. In yet other embodiments, the cleaning apparatus includes one or more air fans that provide a source of heated ambient air (similar to "alligator" space heaters used on construction sites). These hot air blowers can be positioned at the inlet of the engine, and the engine can be powered (ie, run on the starter, without fuel combustion) for any one of a predetermined period of time (which can be done with based on ambient conditions), or motorized until thermocouples or other temperature measuring devices in the hot section of the engine have reached a predetermined temperature. In still other modalities, the engine temperature, before the introduction of the cleaning foam, can be raised by starting the engine and running the engine in idle conditions for a predetermined period of time and subsequently shutting down the engine before introducing the foam cleaning. In yet other embodiments, the engine can be motorized after shutting down from idle and before introducing chemicals to further achieve a consistent baseline temperature condition prior to introducing foam. Still other embodiments of the present invention contemplate any combination of preheated liquid chemicals, preheated compressed air used for foaming, externally heated engines, and engines "heated" for one or more recent periods of operation.
[022] In yet other embodiments of the present invention, the cleaning foam can be heated by providing a heating element within the device used to mix and create the cleaning foam.
[023] It will be appreciated that the various apparatus and methods described in this summary section, as well as elsewhere in this application, may be expressed as a large number of different combinations and subcombinations. All such useful, innovative and inventive combinations and sub-combinations are contemplated herein, it being recognized that explicit expression of each of these combinations is unnecessary.
[024] BRIEF DESCRIPTION OF THE DRAWINGS
[025] Some of the figures presented in this document may include dimensions. In addition, some of the figures presented in this document may have been created from scaled drawings or from photographs that are scalable. It is understood that such dimensions, or the relative dimensioning within a figure, are by way of example, and should not be interpreted as limiting.
[026] FIG. 1 is a schematic representation of a gas turbine engine.
[027] FIG. 2 is a schematic representation of a cleaning apparatus in accordance with an embodiment of the present invention.
[028] FIG. 3A is a photographic representation of some of the apparatus of FIG. 2. FIG. 3B is a photographic representation of some of the apparatus of FIG. 2, shown providing foam into the inlet of an installed engine.
[029] FIG. 3C is a photographic representation of a nozzle in accordance with an embodiment of the present invention in front of an engine inlet.
[030] FIG. 3D is a photographic representation of a nozzle according to another embodiment of the present invention in front of an engine inlet.
[031] FIG. 4 is a photographic representation of the structure of a foam in accordance with an embodiment of the present invention.
[032] FIG. 5 [Intentionally left blank]
[033] FIG. 6 are photographic representations of portions of the exhaust structure of an engine before and after being flushed in accordance with an embodiment of the present invention.
[034] FIG. 7 is a graphical representation of an improvement in engine start time for a washed engine in accordance with an embodiment of the present invention.
[035] FIG. 8 is a photographic representation of an engine being washed on an engine test stand in accordance with an embodiment of the present invention.
[036] FIG. 9 is a photographic representation of a portion of the apparatus of FIG. 8.
[037] FIG. 10 is a graphical representation of a parametric improvement of a washed engine in accordance with an embodiment of the present invention.
[038] FIG. 11 is a graphical representation of a parametric improvement of a washed engine in accordance with an embodiment of the present invention.
[039] FIG. 12A is a schematic representation of a cleaning system in accordance with an embodiment of the present invention.
[040] FIG. 12B is a schematic representation of a cleaning system in accordance with another embodiment of the present invention.
[041] FIGS. 13A, 13B and 13C are photographic representations of one embodiment of a portion of the apparatus of FIG. 12A.
[042] FIGS. 14A, 14B, 14C and 14D are enlarged photographic representations of portions of the apparatus of FIGS. 13.
[043] FIGS. 15A, 15B, 15C and 15D are photographic representations of the interior of the cabinet of FIGS. 13.
[044] FIGS. 16A, 16B, 16C, 16D, 16E and 16F are photographic representations of a component shown in FIG. 15B.
[045] FIG. 17 [Intentionally left blank]
[046] FIGS. 18A-18R are schematic cross-sectional representations of a nucleation chamber in accordance with various embodiments of the present invention.
[047] FIGS. 18L-18R show several schematic representations of a nucleation chamber in accordance with an embodiment of the present invention. FIG. 18L is the AA cross-sectional view of a 1260 nucleation chamber.
[048] FIG. 18M is an end view of nucleation chamber 1260 as seen from 18M-18M of FIG. 18L
[049] FIG. 18N is an enlargement of a portion of the apparatus of FIG. 18L
[050] FIGS. 18O, 18P, 18Q and 18R are enlarged schematic representations of portions of the apparatus of FIGS. 18L.
[051] FIGS. 19A, 19B and 19C are pictorial representations of an aircraft engine being cleaned with a system in accordance with an embodiment of the present invention.
[052] FIG. 19D is a CAD representation of an aircraft with installed engines being foamed.
[053] FIG. 19E is a CAD representation of a plurality of effluent collectors in accordance with various embodiments of the present invention.
[054] FIG. 2-1A, 2-1B are pictorial representations of an aircraft engine being cleaned with a system in accordance with an embodiment of the present invention.
[055] FIG. 2-2 is a pictorial representation of an aircraft engine being cleaned with a system in accordance with an embodiment of the present invention, and with an embodiment of the effluent capture device.
[056] FIG. 2-3 is a pictorial representation of an aircraft engine being cleaned with a system in accordance with an embodiment of the present invention, and with an embodiment of the effluent capture system; according to an aircraft scenario.
[057] FIG. 2-4 is a pictorial representation of an aircraft engine being cleaned with a system in accordance with an embodiment of the present invention, with a variable foam effluent capture system.
[058] FIG. 2-5 is an artistic schematic and photographic representation of aircraft engines being cleaned with a system in accordance with an embodiment of the present invention.
[059] FIG. 2-6 [Intentionally left blank]
[060] FIG. 2-7 is a schematic representation of a cleaning process in accordance with the present invention.
[061] FIG. 2-8A, 8B are schematic representations of an engine illustrating a foam injection system in accordance with an embodiment of the present invention.
[062] FIG. 2-9A is a schematic representation of a cross-sectional and internal view of the engine illustrating a foam connection system in accordance with an embodiment of the present invention.
[063] FIG. 2-9B is a schematic representation of a cross-section of the engine with external and internal components illustrating a foam connection system in accordance with an embodiment of the present invention.
[064] FIG. 2-10 is a graphical representation of an engine cleaning cycle prescription in accordance with an embodiment/method of the present invention.
[065] FIG. 2-11 is a graphical representation of a method for engine monitoring and benefit quantification in accordance with an embodiment/method of the present invention.
[066] FIG. 2-12A is a photographic representation of an effluent collector in accordance with an embodiment of the present invention.
[067] FIG. 2-12B is a front view looking behind the apparatus of FIG. 2-12A.
[068] FIG. 2-12C is a rear view looking forward of the apparatus of FIG. 2-12A.
[069] NUMBER OF ELEMENTS
[070] The following is a list of element numbers and at least one noun used to describe that element. It is understood that none of the embodiments described herein are limited to these nouns, and these element numbers may further include other words that would be understood by a person of ordinary skill in reading and reviewing this disclosure in its entirety.



[071] DESCRIPTION OF THE PREFERRED MODALITY
[072] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe them. However, it will be understood that no limitation on the scope of the invention is thus conceived, such changes and other modifications in the illustrated device, and other applications of the principles of the invention as illustrated herein being contemplated as would normally occur to a person skilled in the art to which the invention relates. At least one embodiment of the present invention will be described and illustrated, and that application may present and/or describe other embodiments of the present invention.
[073] It is understood that any reference to "the invention" is a reference to an embodiment of a family of inventions, with no single embodiment including an apparatus, process or composition that should be included in all embodiments unless explicitly otherwise indicated. Additionally, while there may be discussion regarding the "advantages" provided by some embodiments of the present invention, it is understood that still other embodiments may not include those same advantages, or may even include different advantages. Any advantages described herein are not to be construed as limiting any of the claims. The use of words indicating preference, such as “preferred”, refers to features and aspects that are present in at least one modality, but that are optional for some modality.
[074] The use of an N-series prefix for an element number (NXX.XX) refers to an element that is the same as the element without a prefix (XX.XX), except as shown and described. As an example, a 1020.1 element would be the same as a 20.1 element, except for the different features of the 1020.1 element shown and described. In addition, common elements and common features of related elements can be drawn in the same way on the different figures and/or use the same symbology on the different figures. As such, it is not necessary to describe the features of 1020.1 and 20.1 which are the same, as these common features are evident to a person skilled in the art in the related area of technology. In addition, it is understood that features 1020.1 and 20.1 may be compatible, such that a feature (NXX.XX) may include features compatible with other various modalities (MXX.XX), as would be understood by those skilled in the art. This convention of description also applies to the use of element numbers suffixed with prime (’), double prime (“) and triple prime (”’). Therefore, it is not necessary to describe the features of 20.1, 20.1’, 20.1" and 20.1"’ which are the same, as these common features are evident to persons skilled in the art in the related area of technology.
[075] Although several specific quantities (spatial dimensions, temperatures, pressures, times, force, resistance, current, voltage, concentrations, wavelengths, frequencies, heat transfer coefficients, dimensionless parameters, etc.) can be stated here, these specific quantities are given as examples only, and additionally, unless explicitly noted to the contrary, are approximate values, and should be considered as if the word “about” preceded each quantity. Additionally, with the discussion relating to a specific composition of matter, such description is for example only, and does not limit the applicability of other species of said composition, nor does it limit the applicability of other compositions unrelated to the cited composition.
[076] The following are paragraphs expressing particular embodiments of the present invention. In these following paragraphs, some element numbers are prefixed with an “X” indicating that the expression refers to any of the similar features shown in the drawings or described in the text.
[077] What will be presented and described here, along with various embodiments of the present invention, is the discussion of one or more tests that were performed. It is understood that such examples are by way of example only, and are not to be construed as being limitations on any embodiment of the present invention. Additionally, it is understood that the embodiments of the present invention are not necessarily limited to or described by the mathematical analysis presented herein.
[078] Several references can be made to one or more processes, algorithms, operating methods, or logic, accompanied by a diagram showing them arranged in a particular sequence. It is understood that the order of such a sequence is for example only, and is not intended to limit any embodiment of the invention.
[079] Various references can be made to one or more manufacturing methods. It is understood that these are by way of example only, and various embodiments of the invention can be manufactured in a wide variety of ways, such as casting, centering, welding, electrodischarge machining, milling, as examples. In addition, various other modalities can be manufactured by any of several additive manufacturing methods, some of which are referred to for 3-D printing.
[080] This document may use different words to describe the same element number, or to refer to a number of elements in a specific family of features (NXX.XX). It is understood that such multiple usage is not intended to provide a redefinition of any language herein. It is understood that such words demonstrate that the specific resource can be considered in several linguistic forms, as forms not necessarily being additive or exclusive.
[081] What will be shown and described here are one or more functional relationships between the variables. Specific nomenclature for the variables can be provided, although some relationships may include variables that will be recognized by those skilled in the art for their meaning. For example, “t” could be representative of temperature or time, as would be easily evident from its use. However, it is also recognized that such functional relationships can be expressed in a variety of equivalents using standard techniques of mathematical analysis (for example, the relationship F = ma is equivalent to the relationship F/a = m). Additionally, in those modalities where the functional relationships are implemented in an algorithm or computer software, it is understood that an algorithm-implemented variable may correspond to a variable shown in this document, with this correspondence including a system gain scale factor control, noise filter, or the like.
[082] A wide variety of methods have been used to clean gas turbine engines. Some users use water sprayed into the engine inlet, others use a cleaning fluid sprayed into the engine inlet, and additional users provide solid wear material for the engine inlet, such as nutshells.
[083] These methods allow to achieve varying degrees of success, and still create various degrees of problems. For example, some cleaning agents that are strong enough to clean the hot section of the engine and are chemically acceptable in hot section materials are chemically unacceptable in the material used in the cold section of the engine. Water washes are gentle enough to be used on any materials in the engine, but they are also not particularly effective in removing stubborn deposits, and even more can leave silica deposits in some compressor stages. A number of water soluble cleaning agents are recognized in MIL-PRF-85704 C, but many users of these cleaning agents consider them to be marginally successful in restoring an engine operating parameter, and still other users. noted that simple washes with these MIL cleaning agents can degrade some operational parameters.
[084] Therefore, many aircraft operators are suspicious of the claims made with regard to some liquid cleaning methods, as to how the liquids will be effective in engine restoration performance. There are expenses incurred for liquid washing an engine, including the cost of liquid washing and the amount of time the air vehicle is removed from operation. Often, the benefits of liquid washing do not outweigh the costs incurred, or provide only a negligible commercial benefit.
[085] Various embodiments of the present invention indicate a significant commercial benefit to be obtained by washing gas turbine engines with a foam. As will be shown here, foam cleaning of an engine can provide significant improvements in operating parameters, including improvements that cannot be achieved with liquid washing. The reason for the substantial improvement made by foam washing is not fully understood. Successive engine tests have been carried out on the same specific engine, with the introduction of atomized liquid into the inlet, followed by the introduction of a foam of that same liquid into the inlet. In all cases, it was observed that the liquid (or foam) in the exhaust section of the engine, indicating that the liquid (or foam) appears to be wetting the entire gas path.
[086] However, using a foam version of a liquid provides significant improvements over and above any liquid wash improvements in important operating parameters such as engine start times, specific fuel consumption, and turbine temperatures needed to achieve a particular power output.
[087] Some embodiments of the present invention relate to a system for producing a foam from a water-soluble cleaning agent. It has been found that there are differences in the apparatus and methods of creating an acceptable foam with a water-soluble chemical, or a non-water-soluble chemical. Various embodiments of the present invention pertain to systems including nucleation chambers provided with pressurized liquid and pressurized air as well.
[088] It has been found that the injection of this foam into an engine inlet through conditional atomizing nozzles can reduce the foam cleaning effectiveness. Still further, any piping, tubing or hoses that deliver foam from the nucleation chamber to the nozzle must generally be smooth, and substantially free of turbulence-generating features in the flow path (such as sharp turns, sharp reductions in the flow area of the foam flow path, or delivery nozzles having sections with excessive convergence, such as toe-in to increase foam velocity).
[089] It is useful in various embodiments of the present invention to provide a flow path for the generated foam that maintains the highest energy state of the foam, and does not dissipate that energy prior to delivery. FIG. 3B shows foam being delivered in accordance with an embodiment of the present invention. It can be noted that the nozzle 30 provides a foam stream that has substantially the same diameter. There is little or no apparent convergence in the picture in FIG. 3B and no flow current divergence. In addition, ripples or "smooth masses" in the foam flow stream are indicative of a low speed release system, with the disturbance imparted to the foam stream when it impacts the rotator visibly passes upstream towards the nozzle. The amplitude of the “formless masses” in the foam flow path can be seen to be of higher magnitude closer to the impact of the foam with the rotator, and of lesser magnitude in a direction towards the outlet nozzle 30. The outgoing foam nozzle 30 has a substantially constant diameter, and preferably exits at a speed of less than about 15 feet per second.
[090] Various embodiments of the present invention are also assisted by the introduction of gas (including air, nitrogen, carbon dioxide, or any other gas) in a pressurized state into a flow of cleaning liquid. Preferably, the air is pressurized to more than about 5 psig and less than about 120 psig, and supplied by a pressurized pump or reservoir. While some embodiments of the present invention do not include the use of airflow eductors that can entrain ambient air, still other embodiments that utilize pressurized air have been found to provide improved results.
[091] Still other embodiments of the present invention relate to the commercial use of foam cleaning with aviation engines. As discussed above, the mechanism by which a foam cleaning agent provides superior results to a non-foaming cleaning agent is not well understood. Conversely, many experts in the field of jet engine maintenance initially believe that a foam cleaning agent will provide the same disappointing results as a non-foaming cleaning agent would. Therefore, as the use of a foam cleaning agent becomes better understood, the effect of improved foam cleaning on financial considerations in supporting an engine family will be better understood. Some of these improvements may be readily evident, such as improvements in operating temperature, specific fuel consumption, and start times indicated by the test documented here. Still other impacts on the use of foam cleaning agents can additionally impact the design of other life-limited components in the engine.
[092] For example, engines are currently designed with limited life parts (such as those based on hours of use, time at temperature, number of engine cycles, or others) and inspections of these components can be scheduled at times that coincide with washing the engine liquid. However, the use of foam washing can generally increase the time an engine can be installed in the aircraft, since foam washing will restore the used engine to a better level of performance than liquid washing would. However, an increase in time between foam washes (increased compared to the interval between liquid washes) could be increased as a foam wash no longer coincides with inspection of a limited life part. Under these conditions, it can be financially rewarding to design the part with limited life for a slightly longer cycle. The increased cost of the longer life-limited component may be more than offset by the increased time the foam-cleaned engine can remain on the wing.
[093] In such embodiments, there may be a paradigm shift in engine washing, inspection, and maintenance intervals, resulting at least from the improved cleanliness resulting from foam washing. In some modes, the effect of foam washing on an engine performance parameter (such as starting time, temperature at maximum rated energy, specific fuel consumption, carbon emission, nitrogen emission oxides, normal operating speeds of the engine at cruise and take-off, etc.) can be quantified. This quantification can take place within a family of engines, but in some cases it can be applied between different families. As a specific engine within this family is operated in an aircraft, the aircraft operator will observe some change in an operating parameter that can be correlated with an improvement to be gained by a foam wash of that particular engine. This information taken by the aircraft operator is passed on to the engine owner (which could be the US government, an engine manufacturer, or an engine rental company), and that owner determines when to schedule a foam cleaning for that particular engine. .
[094] It has been found experimentally that various embodiments of the foam washing methods and apparatus described herein are more effective in removing contaminants from a used engine than by cleaning by spraying a liquid cleaning agent. In some cases, the effluent collected in the turbine after foam cleaning has been compared to the effluent collected in the turbine after a liquid wash, with the liquid wash having preceded the foam wash. In these cases, it has been found that the foam effluent has contained substantial amounts of dirt and deposits which were not removed by liquid washing.
[095] It is believed that in some engine families the use of a foam wash will provide an improvement in the cleanliness of the burner liner. It is well known that combustor linings include complex arrangements of cooling holes, these cooling holes being designed to not only maintain a safe temperature for the lining itself, but also to reduce gas path temperatures and thus limit the formation of nitrogen oxides. It is anticipated that various embodiments of the present invention will demonstrate reductions in emission from a clean engine of nitrogen oxides.
[096] FIGS. 1 to 4 show various representations of a washing or cleaning system 20 in accordance with an embodiment of the present invention. While what will be shown and described is a washing system 20 applied to cleaning a gas turbine engine, it is understood that various embodiments of the present invention contemplate cleaning any object.
[097] FIGS. 1 and 2 schematically represent a system 20 being used to clean a gas turbine engine 10. The engine 10 typically includes a cold section including an inlet 11, a fan 12 and one or more compressors 13. Compressed air is supplied to the hot section of the engine 10, including the combustor 14, one or more turbines 15, and an exhaust system 16, the latter including as examples simple convergence nozzles, noise reduction nozzles (as will be seen in FIG. 6), and nozzles cooled (such as those used after afterburners and including converging and diverging sections).
[098] FIG. 2 schematically shows a system 20 being used to clean the gas turbine engine 10 with a foam. System 20 typically includes a supply 26 of gas, a supply 24 of water and a supply 22 of cleaning chemicals, all of which are supplied to a foaming system 40. The foaming system 40 accepts these constituents and provides a foam outlet 28 to a nozzle 30 which supplies the foam to the inlet 11 of the gas turbine engine 10. However, still other embodiments contemplate locating nozzles 30 so that the foam is supplied first to the compressor section 13, or in some embodiments provided first for still other components of the gas turbine engine 10. The system 20 preferably includes an effluent manifold 32 placed behind the exhaust 16 of the gas turbine engine 10, so to collect spent foam, chemicals, water, and particulate matter removed from the gas turbine engine within it 10.
[099] FIGS. 3A and 3B illustrate a wash system 20 during operation. In one embodiment, the foaming system 40 is provided within a cabinet 42. The cabinet 42 preferably includes a variety of equipment that is used to create foam 28, including the nucleation chamber, pumps and various valves and piping (which will be shown and described with reference to FIG. 15). Cabinet 42 preferably includes a variety of flow meters or peristaltic pumps 44, pressure gauges 46 and pressure regulators 48 (which will be described with reference to FIGs. 12 through 14).
[100] FIG. 3B is a photographic representation of a nozzle 30 that injects foam 28 into the inlet 11 of an engine. FIG. 4 is an enlarged photographic representation of a foam 28 in accordance with an embodiment of the present invention.
[101] FIGS. 3C and 3D show nozzles 30 in front of inlets 10 in accordance with other embodiments of the present invention. It may be noted that some modes utilize a pair of foam-generating nozzles for an inlet from substantially the same location and space, except on opposite sides of the engine centerline. Generally, nozzles in some embodiments have non-atomizing nozzles that deliver the foam stream under ambient conditions. As can be seen from FIGs. 3C and 3D, the cross-sectional area of the nozzle apparatus 30 generally increases from a central, unitary distribution tube to a pair of side-by-side outlet nozzles, each of which is of substantially the same cross-sectional area. Therefore, the cross-sectional area as a function of length along the flow path of the apparatus 30 is relatively constant for the center section, but then increases as the center section splits into two side-winged nozzles.
[102] FIGS. 6 to 11 refer to various tests performed with different embodiments of the present invention. FIG. 6 provides views of a corrugated perimeter noise suppression exhaust nozzle 16 both after a wash in accordance with existing procedures, and also after a wash performed in accordance with an embodiment of the present invention. When comparing the left and right photographs, it can be seen that, after a wash performed in accordance with an embodiment of the present invention (right photograph), the exhaust nozzle 16 was cleaned beyond the cleaning level previously achieved after of a standard washing procedure (photo on the left).
[103] FIG. 7 provides a pictorial representation of improvements in engine start time, including results after a standard wash, and after a wash in accordance with an embodiment of the present invention. It can be noted that the standard wash shortened the specific engine start time by 3 seconds, from 69 seconds to 66 seconds. However, a subsequent wash of that same engine with an inventive wash system provided an additional reduction in start-up time of about 9 seconds, thus showing that a cleaning method according to an embodiment of the present invention is capable of improving the flow dynamics of the engine's gas path plus the improvement achieved with a standard flush (such as those methods where a spray of atomized cleaning fluid is supplied into an engine inlet).
[104] FIGS. 8 through 11 illustrate tests and test results performed on a helicopter engine. FIGS. 8 and 9 show the gas turbine engine 10 being cleaned with the effluent foam 28 exiting the dual exhaust nozzles. FIG. 10 shows the results of various starting tests performed on a helicopter engine. It can be seen that the starting time of a used engine has been reduced by about 5 percent using an existing washing technique. However, cleaning that same engine with a cleaning system in accordance with an embodiment of the present invention provided even greater gains and a decrease in starting time (compared to the original engine used) of more than 22 percent.
[105] FIG. 11 pictorially represents exhaust gas temperature margin improvements for a helicopter engine operating at full power before and after cleaning. It can be seen that the use of an existing engine cleaning system did not provide any measurable improvement in the EGT margin. However, the same engine experienced an increase in the EGT margin (ie, the ability to run the cooler) of more than 30 degrees C after being cleaned with a system and method according to an embodiment of the present invention.
[106] FIGS. 12A and 12B depict in schematic format washing systems 20 and 120 in accordance with various embodiments of the present invention. Many of the components schematically represented in FIGs. 12A and 12B (including pressure gauges, flow meters, pressure reducing valves, pumps, check valves, nucleation chambers, and other valves and piping) are preferably housed within a cabinet 42, which can be seen in the FIGs. 13, 14 and 15.
[107] FIGS. 13A, 13B and 13C are photographic representations of the exterior of an enclosure 42 of a foaming system 40 in accordance with an embodiment of the present invention. The various inlets, shutoff valves, flow meters, pressure gauges and connections can be seen in these photographic representations. In addition, the representations in FIGs. 13, 14, and 15 are of the same flow system 40, and the various interconnections seen in FIGs. 15 can be traced to the exterior of the cabinet shown in FIGs. 13 and 14.
[108] FIGS. 14 are enlarged representations of portions of the flow cabinet 42 of FIG. 13. FIG. 14B shows that in one embodiment chemical A is preferably supplied at about 7 gallons per hour, and chemical B is supplied at about 19 gallons per hour. FIG. 14C shows that the airflow into the nucleation chamber was between about 13 to 14 standard cubic feet per minute, and the water flow (after the pump) used to create the foam was between about 7 and 8 gallons per minute. FIG. 14D shows water flow as measured before the pump is at about 7 gallons per minute. The pressure gauges in FIG. 14D indicates an operating pressure of air, water, and foam in the range of about 18 to 20 psig. These specific settings are by way of example only, and should not be construed as limiting. Additionally, these configurations were used with a mode flowing a chemical A from Zok27 and/or chemical B from Turco 5884. Similarly, according to engine manuals, combinations of approved products and basic ingredients (ie, kerosene , isopropyl alcohol, petroleum solvents) can be used. As a point of reference, qualified product listings or approvals are associated through the FAA or by Naval Air Systems Command approvals. Such gas path approval reports are determined by documentation MIL-PRF-85704 for the industry to follow.
[109] FIG. 15 illustrates the components and piping housed within cabinet 42 and are consistent with FIGs. 13, 14 and 16.
[110] FIGS. 16 and 18 show various embodiments of X60 nucleation chambers in accordance with various embodiments of the present invention. Many of these modalities include an X61 housing that includes an X62 inlet for gas, an X63 inlet for one or more liquids, and an X64 outlet that provides the foam outlet 28 for an X30 nozzle. In some embodiments, an X66 gas chamber receives gas under pressure from inlet X62. Gas chamber X66 is preferably enclosed within housing X61, and arranged such that portions of gas chamber X66 are in contact with the fluid from inlet X63 within housing X61. Various embodiments include X66 gas chambers that have one or more openings or other X70 features that provide fluid communication from the internal passage of the X66 chamber and the fluid within the X61 housing.
[111] The introduction of gas through the X70 openings is adapted and configured to create a foam, with the cleaning liquid within an X65 nucleation zone. Preferably, the foam is created by the nucleation of pre-certified aviation chemicals with proper arrangement of high velocity air jets, diffuser sections, growth spikes and/or centrifugal sheering of the chemicals, any of which can be used. to create foam that is a shorter life state with higher energy than more stable unfoamed liquid chemical. The resulting foam is supplied to the X64 output for introduction into the input of the device to be cleaned.
[112] In some embodiments, the X60 chamber further includes an X74 cell growth section in which there is material or apparatus that encourages the fusion of smaller foam cells into a larger foam cell. In yet other embodiments, the nucleation chamber X60 may include an X78 cell structuring section that includes material or apparatus for improving the homogeneity of the foam material. Still other embodiments of chamber X60 include a laminar flow section X82 in which the foam material 28 is made less turbulent so as to increase the longevity of the foam cells and thus increase the number of foam cells delivered to inlet 11 of product 10 being cleaned.
[113] Some of the X60 nucleation chambers include nucleation zones, growth sections, and structuring sections that are arranged in series within the foam flow path. In still other embodiments these zones and sections are arranged concentrically, with the foam being created first near the centerline of the flow path. In still other modalities the zones and sections are arranged concentrically with the foam being created on the periphery of the flow path, with the cells being cultivated and progressively structured towards the center of the flow path.
[114] Some of the described X60 nucleation chambers include nucleation zones, growth sections, and structuring sections that are arranged within a single filled space.
[115] However, it is understood that still other modalities include a modular arrangement for the nucleation chamber. For example, the nucleation zone can be a separate component that is bolted to a structuring zone, or a laminar flow zone. For example, the various sections can be connected to each other by flanges and fasteners, threaded fittings, or the like. Furthermore, X20 systems are described herein to include a single nucleation chamber. However, it is understood that the cleaning system can include multiple nucleation chambers. As an example, a plurality of chambers can be fed from collectors that supply the liquids and gas. The parallel flow arrangement can provide a foam outlet that is similarly piped together with a single X28 nozzle or a plurality of nozzles arranged in a pattern to best match the geometry of the engine inlet.
[116] The various X20 washing systems discussed here may include a mixture of liquids (such as water, chemical A and chemical B) that are supplied to the inlet of the nucleation chamber, into which the gas is injected so as to create a foam from the liquid mixture. However, the present invention is not so limited, and further includes embodiments in which liquids can be foamed separately. For example, a cleaning system in accordance with another embodiment of the present invention may include a first nucleation chamber for chemical A, and a second nucleation chamber for a mixture of chemical B and water. The two resulting foams can then be supplied to a single X28 nozzle, or they can be supplied to separate X28 nozzles.
[117] The various descriptions below refer to a variety of modalities of X60 nucleation chambers that incorporate many differences and many similarities. It is understood that each of these is presented as an example only, and are not intended to place limits on the general ideas expressed herein. As yet another example, the present invention contemplates an embodiment in which liquid product is supplied to an inlet X63 and flows within a flow path surrounded by a circumferential gas chamber X66. In such embodiments, gas chamber X66 defines an annular flow space and delivers gas under pressure from an inlet X62 into liquid product flowing within the ring.
[118] FIGS. 18A and 18B show a nucleation chamber 60 in accordance with an embodiment of the present invention. The housing 61 includes a gas inlet 62, a liquid inlet 63 and a foam outlet 64 with a foaming passage located between the inlets and the outlet. Generally contained within housing 61 is a cylindrical gas tube 66 which receives gas under pressure from inlet 62. Although gas chamber 66 has been described as a cylindrical tube, still other embodiments of the present invention contemplate internal gas chambers. of any size and shape adapted and configured to provide a gas flow in a liquid flow so that it results in a foam.
[119] The gas tube 66 is situated generally concentrically within the housing 61 (although a concentric location is not necessary), so that liquid from the inlet 63 generally flows around the outer surface of the tube 66. The tube 66 includes a plurality of openings 70 that are adapted and configured for the flow of gas from within tube 66 generally into the interior of the foaming passage of housing 61. As shown in Figure 18A, openings 70 are generally located. along the length of tube 66, and preferably surrounding the circumference of tube 66. However, still other embodiments of the present invention contemplate openings 70 that have locations limited to certain selection portions of tube 66, such as toward the inlet, toward at the exit, usually in the middle, or any combination thereof.
[120] As an example, the nucleation jets 70 are adapted and configured to have a total flow area that is approximately equal to the cross-sectional flow area of housing 61 or less than that cross-sectional area. As an example, jets 70 have orifice diameters from about one-eighth of an inch to about one-sixteenth of an inch.
[121] The foam within nucleation chamber 60 is first created within a nucleation zone 65 which includes initial mixing of the gas and liquid streams as discussed above. As the foam leaves this zone, it flows into a downstream growth section 74 and passes over a corresponding growth material 75. Material 75 is adapted and configured to provide structural surface area over which foam cells Individuals can attach or combine with other foam cells to split into more foam cells. Material 75 includes a plurality of features that cause larger, more energized cells to divide into a number of smaller cells. In some embodiments, material 75 is a web preferably formed from a metallic material. Plastic materials can also be replaced, as long as the organic material can withstand exposure to the liquids used for cleaning. It is contemplated by yet other embodiments that material 75 may be materials other than a web.
[122] As the more split foam cells exit the growth section 74, they enter a cell structuring section 78 that preferably includes a material 79 within the inner foam passage of housing 61. The material 79 of the cell structuring section 78 is adapted and configured to receive a first varying foam cell size distribution from section 74, and provide for output 64 a smaller and narrower second cell size distribution. In some embodiments, the scaffolding material 79 includes a web formed from a metal, with the web cell size of section 78 being smaller than the web size of the growth section 74.
[123] After the fused cells (more abundant cells) and structured cells (improved homogeneity) exit section 78, they enter a portion of the flow path, parts of which may be within envelope 61, and parts of which may being outside the housing 61, wherein the flow path is adapted and configured to provide a laminar flow of the foam 28. Therefore, the cross sectional area of the laminar flow section 82 is preferably larger than the cross sectional areas of flow representative of nucleation section 65, growth section 74, or structuring section 78. Flow section 82 encourages laminar flow and also discourages turbulence that would otherwise reduce foam quantity or quality. Still additionally, the outlet section of the apparatus 60, together with the flow passages that extend to the nozzle 30, are generally smooth, and with the turn radii smooth enough to further encourage laminar flow and discourage turbulence.
[124] FIG. 16 shows a nucleation chamber 260 in accordance with an embodiment of the present invention. Housing 261 includes a gas inlet 262, a liquid inlet 263, and a foam outlet 264 with a foaming passage located between the inlets and the outlet.
[125] Generally contained within cylindrical housing 261 is a cylindrical gas tube 266 which receives gas under pressure from inlet 262. Although gas chamber 266 has been described as a cylindrical tube, still other embodiments of the present invention contemplate internal gas chambers of any size and shape adapted and configured to provide a flow of gas in a flow of liquid so that a foam results.
[126] The gas tube 266 is situated generally concentrically within the housing 261 (although a concentric location is not required), so that liquid from the inlet 263 flows generally around the outer surface of the tube 266. The tube 266 includes a plurality of regularly spaced openings 270 that are adapted and configured for gas flow from within tube 266 generally into the interior of the foaming passage of housing 261. As shown in Figure 16A, openings 270 are located generally along the length of tube 266, and preferably encircling the circumference of tube 266.
[127] The zones of nucleation, growth, and cell structuring (272, 274, and 278, respectively) are concentrically arranged. Nucleation zone 272 is created between the outer periphery of tube or tubing 266. Metal wire web 275 material of growth section 274 surrounds the outer periphery of tube 266, as best seen in FIG. 16F (where shown held in place by three electrical connection straps). Nucleation section 271 is created between the outer surface of tubing 266 and the innermost surfaces of growth material 275. As gas bubbles are emitted from openings 270 and pass through nucleation zone 272, the foam is created and the foam cells pass through one or more generally concentric layers of web material 275. As the larger foam cells exit material 275 of growth section 274, the larger cells then pass into a annularly arranged tissue metal material 279 comprising the cell structuring and homogenizing section 278 (as best seen with reference to Figs. 16C and 16F). Referring to FIG. 16E, it can be noted that material 279 of homogenizing section 278 in one embodiment tapers towards the centerline of nucleation chamber 260. Foam cells are created by mixing liquid and gas, increased in size, and homogenized in a manner discussed above.
[128] After the fused (cultured) cells and structured cells (improved homogeneity) exit section 278, they enter a portion of the flow path, parts of which may be inside envelope 261, and parts of which may be outside of housing 261, wherein the flow path is adapted and configured to encourage laminar flow of the foam 228. 16E, 15A and 15B). It can be seen that the outside diameter of the flow path from outlet 264 to outlet 228-1 mounted on cabinet 42 (as best seen in FIGS. 13B and 15A) is substantially the same size as the outside diameter of the flow chamber. nucleation 260. However, the cross-section of nucleation chamber 260 (which can be viewed from FIGS. 16A and 16F) has a cross-sectional flow area that is less than the cross-flow area of the downstream pipeline. of outlet 264 (as best seen in FIG. 15A), the cross-sectional flow area of the flow path within chamber 260 being partially blocked by materials 275 and 279. Flow section 282 (as best seen in Figures 15A and 15B) stimulates laminar flow and also discourages turbulence which would otherwise reduce foam quantity or quality. Still additionally, the outlet section of the apparatus 260, together with the flow passages that extend to the nozzle 230, are generally smooth, and with the turn radii smooth enough to further encourage laminar flow and discourage turbulence.
[129] FIG. 18C shows a nucleation chamber 360 in accordance with an embodiment of the present invention. The housing 361 includes a gas inlet 362, a liquid inlet 363 and a foam outlet 364 with a foaming passage located between the inlets and the outlet.
[130] Generally contained within housing 361 is a cylindrical gas tube 366 which receives gas under pressure from inlet 362. Although gas chamber 366 has been described as a cylindrical tube, still other embodiments of the present invention contemplate chambers. internal gas valves of any size and shape adapted and configured to provide a flow of gas in a flow of liquid in such a way as to result in a foam.
[131] The gas tube 366 is situated generally concentrically within the housing 361 (although a concentric location is not required), so that liquid from the inlet 363 flows generally around the outer surface of the tube 366. The tube 366 includes a plurality of openings 370 that are adapted and configured for gas flow from within tube 366 generally into the interior of the foaming passage of housing 361. As shown in Figure 18C, openings 370 are generally located. along the length of tube 366, and preferably surrounding the circumference of tube 366.
[132] Nucleation zone 365 includes jets or perforations 370 that are disposed in a plurality of subzones, the jets within such subzones 372 introducing gas into the liquid flowing at different angles of attack. A first nucleation zone 372a is located upstream of a second intermediate nucleation zone 372b, which is followed by a third nucleation zone 372c (each of which is situated longitudinally and spaced apart along the length of the chamber. gas 366). As indicated in FIG. 18C, zone 372b overlaps both zones 372a and 372c, although other embodiments of the present invention contemplate more or less overlap, including no overlap.
[133] The jets or perforations 370a within zone 372a are preferably adapted and configured to have an angle of attack that is generally opposite (or against) the predominant flow of liquid (which flows from left to right, as seen in FIG. 18C). As an example, the centerline of these jets 370a are at about 3040 degrees from a line extending perpendicular to the centerline of the foam flow path within chamber 360 (i.e., forming an angle of 60-50 degrees with the center line). Therefore, air exiting perforations 370a within zone 372a transmits energy to the surrounding liquid flow which acts to decelerate the liquid (i.e., a velocity vector for gas exiting a nozzle 370a has a component that is opposite to the velocity vector of the liquid flowing from left to right within FIG. 18C of chamber 360).
[134] The nucleation jets 370 in a zone 372b are angled so as to impart a rotational swirl for the fluid within the foam flow path. In one embodiment, the 370b nucleation jets are angled at about 30-40 degrees from a perpendicular line extending from the centerline of the flow path, in a direction to impart hurricane-like rotation within the flow chamber. nucleation 360.
[135] A third nucleation zone 372c includes a plurality of jets 370C that are at an angle of approximately 30-40 degrees in a direction so as to propel liquid generally in the general direction of flow within the foam flow path (i.e. is, left to right, and generally opposite the angular orientation of jets 370a).
[136] It is further understood that perforations or nucleation jets 372 within a zone 370 may have angles of attack as described above in their entirety among all jets or only partially in some of the jets. Still other embodiments of the present invention contemplate zones 372a, 372b, 372c, in which only some of the jets 370a, 370b or 370c, respectively, are angled as described above, with the remainder of the jets 370a, 370b, or 370C, respectively, being oriented in a different way. Still additionally, although what has been shown and described is a first zone A, with an angle of attack opposite that of fluid flow and followed by a second zone of section B, having jets with angles of attack oriented to impart eddy, and, then followed by a third zone of section C with jets with an angle of attack oriented so as to push the foam towards the outlet, it is understood that various embodiments of the present invention contemplate even more arrangements of angled jets. As an example, still other modalities contemplate a fluid eddy section located either at the beginning or at the end of the nucleation zone. As yet another example, still other embodiments contemplate a counterflow section (previously described as zone 372a) located toward the most distal end of the nucleation zone (i.e., oriented closer toward growth section 374). In still other embodiments, there are nucleation zones that comprise less than all three zones A, B, and C, including embodiments that have holes arranged with only one of the features of the previously described zones A, B, and C.
[137] FIG. 18D shows a nucleation chamber 460 in accordance with an embodiment of the present invention. The housing 461 includes a gas inlet 462, a liquid inlet 463 and a foam outlet 464 with a foaming passage located between the inlets and the outlet.
[138] Generally contained within housing 461 is a cylindrical gas tube 466 which receives gas under pressure from inlet 462. Although gas chamber 466 has been described as a cylindrical tube, still other embodiments of the present invention contemplate chambers. internal gas valves of any size and shape adapted and configured to provide a flow of gas in a flow of liquid in such a way as to result in a foam.
[139] Gas tube 466 is situated generally concentrically within housing 461 (although a concentric location is not required), so that liquid from inlet 463 flows generally around the outer surface of tube 466. Tube 466 includes a plurality of openings 470 that are adapted and configured for gas flow from within tube 466 generally into the interior of the shell foaming passage 461. As shown in Figure 18D, openings 470 are generally located. randomly along the length of tube 466, and preferably surrounding the circumference of tube 466. However, still other embodiments of the present invention contemplate openings 470 that have locations limited to certain selection portions of tube 466, such as toward the inlet, at towards the exit, usually in the middle, or any combination thereof.
[140] FIG. 18E shows a nucleation chamber 560 in accordance with an embodiment of the present invention. The housing 561 includes a gas inlet 562, a liquid inlet 563 and a foam outlet 564 with a foaming passage located between the inlets and the outlet.
[141] Generally contained within housing 561 is a gas chamber or filled space 566 that receives gas under pressure from inlet 562. Although gas chamber 566 has been described as a cylindrical tube, still other embodiments of the present The invention contemplates internal gas chambers of any size and shape adapted and configured to provide a gas flow in a liquid flow in such a way as to result in a foam.
[142] Gas tube 566 is situated generally concentrically within housing 561 (although a concentric location is not required), so that liquid from inlet 563 flows generally around the outer surface of tube 566. Tube 566 includes a plurality of openings 570 that are adapted and configured for gas flow from within tube 566 generally into the interior of the foaming passage of housing 561. As shown in Figure 18E, openings 570 are generally located. along the length of tube 566, and preferably surrounding the circumference of tube 566. However, still other embodiments of the present invention contemplate openings 570 that have locations limited to certain selection portions of tube 566, such as toward the inlet, toward at the exit, usually in the middle, or any combination thereof.
[143] The openings within zones 572a, 572b and 572c are arranged generally as previously described with respect to nucleation chamber 560. FIG. 18E includes an inset drawing showing a single nucleation jet 570a having an angle of attack 571a. Outlet gas jet velocity vector 570a includes a velocity component that is adverse (i.e., upstream) to the overall flow direction of the foam flow path from inlets 562 and 563 to outlet 564.
[144] FIG. 18F shows a nucleation chamber 660 in accordance with an embodiment of the present invention. The housing 661 includes a gas inlet 662, a liquid inlet 663 and a foam outlet 664 with a foaming passage located between the inlets and the outlet.
[145] Generally contained within housing 661 is a cylindrical gas tube 666 which receives gas under pressure from inlet 662. Although the gas chamber 666 has been described as a cylindrical tube, still other embodiments of the present invention contemplate chambers. internal gas valves of any size and shape adapted and configured to provide a flow of gas in a flow of liquid in such a way as to result in a foam.
[146] Gas tube 666 is situated generally concentrically within housing 661 (although a concentric location is not required), so that liquid from inlet 663 flows generally around the outer surface of tube 666. Tube 666 includes a plurality of openings 670 that are adapted and configured for gas flow from within tube 666 generally into the interior of the foaming passage of housing 661. As shown in FIG. 18F, apertures 670 are located generally along the length of tube 666, and preferably encircle the circumference of tube 666. However, still other embodiments of the present invention contemplate apertures 670 having locations limited to certain selection portions of tube 666. as towards the entrance, towards the exit, usually in the middle, or any combination thereof.
[147] The foam within nucleation chamber 660 is first created within a nucleation zone 665 which includes initial mixing of the gas and liquid streams as discussed above. As the foam leaves this zone, it flows into a downstream growth section 674 and passes over and around a 675 ultrasonic transducer. In one embodiment, the 675 transducer is a rod (as shown), though in yet other embodiments it is understood that the ultrasonic transducer is adapted and configured to provide sonic excitation for the foam exiting nucleation zone 665, and may be of any shape. For example, still other embodiments of the present invention contemplate a transducer that is generally cylindrical in shape such that the foam passes through the inside diameter of the cylinder, and in some embodiments where the transducer is smaller than the inside diameter of the path. of flow 661, the foam also passes over the outside diameter of the transducer. Furthermore, although one modality includes a transducer that is excited with ultrasonic frequencies, it is understood that other modality still contemplates sensors that vibrate and transmit vibrations to the nucleated foam at any frequency, including sonic frequencies and subsonic frequencies.
[148] With reference to the smaller inset figure of FIG. 18F, transducer 675 is preferably excited by an external, electronic source. In one embodiment, the source provides an oscillating output voltage that excites a piezoelectric element within transducer 675. The use of a vibration transducer has been found to be effective in converting a substantial amount of the supplied liquid into foam. Various embodiments of the present invention contemplate excitation vibrations in transducer 675 with any oscillating type input, including one or more individual frequencies, frequency sweeps over a range, or random frequency inputs over a frequency range. In one test, a transducer supplied by Sharpertek was excited at frequencies above 25 kHz. Although a generally cylindrical transducer rod is shown, still other embodiments contemplate vibration transducers of any shape, including side mounted transducers, which can be used in a rectangular-shaped chamber so that liquids and gas within the chamber flow closely together. to the transducers for an improved effect. Still further, it is understood that electronic excitation of transducer 675 is contemplated in some embodiments, while in other embodiments transducer 675 may be excited by other mechanical means, including hydraulic or pneumatic inputs. Still further, still other embodiments contemplate the use of a vibrating table within cabinet 42 in order to physically shake the nucleation chamber. In such modalities, the inlets and outlets of the nucleation chamber are coupled to other piping inside the cabinet by flexible accessories.
[149] As the larger foam cells exit growth section 674, they enter a cell structuring section 678 which preferably includes a material 679 within the inner foam passage of housing 661. Material 679 of cell structuring section 678 is adapted and configured to receive a larger first foam cell size distribution from section 674, and provide for output 664 a smaller and narrower second cell size distribution. In some embodiments, framing material 679 includes a web.
[150] FIG. 18G shows a nucleation chamber 760 in accordance with an embodiment of the present invention. The housing 761 includes a gas inlet 762, a liquid inlet 763 and a foam outlet 764 with a foaming passage located between the inlets and the outlet.
[151] Generally contained within housing 761 is a cylindrical gas tube 766 which receives gas under pressure from inlet 762. Although gas chamber 766 has been described as a cylindrical tube, still other embodiments of the present invention contemplate chambers. internal gas valves of any size and shape adapted and configured to provide a flow of gas in a flow of liquid in such a way as to result in a foam.
[152] Gas tube 766 is situated generally concentrically within housing 761 (although a concentric location is not required), so that liquid from inlet 763 flows generally around the outer surface of tube 766. Tube 766 preferably includes a plurality of nucleation devices 770, each of which includes a plurality of small holes for the passage of air. As shown in the insert figure of FIG. 18G, in one embodiment the 770 device is a porous metal filter silencer, such as those made by Alwitco of North Royalton, Ohio. These devices include a porous metal member attached to a threaded member. Air is supplied through the threaded member to the porous material, which in one embodiment includes a variety of holes around the periphery and end of the porous member, the holes being anywhere from about ten to one hundred microns in diameter. Still other modalities contemplate the use of porous metal respirator ventilation filters, such as those supplied by Alwitco. Still other modalities contemplate 770 devices including gas outflow paths similar to those of Alwitco's miniatures and mini-silencers.
[153] More generally, device 770 includes an internal flow path that receives gas under pressure from within chamber 766. One end of device 770 includes a plurality of holes (obtained by using porous metal, or achieved by drilling, stamping, chemical grinding, photoengraving, electro-discharge machining, or the like) in a pattern (random or ordered) so that gas from the internal passage of device 770 flows into the surrounding mixture of liquids and creates foam. As best seen in FIG. 18G, in some embodiments the porous end of device 770 is cylindrical and extends into the liquid flow path, while in still other embodiments, the porous end is generally purged, and yet in other embodiments it may be of any shape. In some embodiments, device 770 has a porosity that is directionally oriented so that the protruding end of the device is generally non-porous on the upstream side and the downstream side of the device is porous. In such embodiments, foam is created following the liquids as they pass over the protruding body of device 770. As shown in FIG. 18G, in some embodiments, there are a plurality of devices 770 located along the length of and around the circumference (or otherwise extending from) of the gas chamber 766.
[154] Still further embodiments contemplate a gas chamber 766, which is fabricated from a porous metal such as the porous metal discussed above. In such embodiments, gas escapes from the chamber and into the liquid flow path along the entire length of the porous structure. Still further, some embodiments contemplate gas chambers that are constructed from a material that includes a plurality of holes (formed by punching, stamping, chemical grinding, photoengraving, electro-discharging machine, or the like).
[155] FIG. 18H shows a nucleation chamber 860 in accordance with an embodiment of the present invention. The housing 861 includes a gas inlet 862, a liquid inlet 863 and a foam outlet 864 with a foaming passage located between the inlets and the outlet.
[156] Generally contained within housing 861 is a cylindrical gas tube 866 which receives gas under pressure from inlet 862. Although gas chamber 866 has been described as a cylindrical tube, still other embodiments of the present invention contemplate chambers internal gas valves of any size and shape adapted and configured to provide a flow of gas in a flow of liquid in such a way as to result in a foam.
[157] Gas tube 866 is situated generally concentrically within housing 861 (although a concentric location is not required), so that liquid from inlet 863 flows generally around the outer surface of tube 866. Tube 866 preferably includes a plurality of devices 870 similar to the nucleation jets 770 described above.
[158] The foam within nucleation chamber 860 is first created within a nucleation zone 872 that includes initial mixing of the gas and liquid streams as discussed above. As the foam leaves this zone, it flows into a downstream growth section 874 and passes over a corresponding growth material 875. In some embodiments, the material 875 is a web preferably formed from a material metallic. Plastic materials can also be replaced, as long as the organic material can withstand exposure to the 822 liquids used for cleaning. It is contemplated by yet other embodiments that material 875 may be materials other than a web.
[159] As the larger foam cells exit the growth section 874, they enter a cell structuring section 878 that preferably includes a material 879 within the inner foam passage of the casing 861. The material 879 of the cell structuring section 878 is adapted and configured to receive a larger first foam cell size distribution from section 874, and provide for output 864 a smaller and narrower second cell size distribution. In some embodiments, scaffolding material 879 includes a web formed from a metal, with the web cell size of section 878 being smaller than the web size of growth section 874. In one test, a device 860 was successful in converting most liquids to foam.
[160] FIG. 18I shows a nucleation chamber 960 in accordance with an embodiment of the present invention. The housing 961 includes a gas inlet 962, a liquid inlet 963 and a foam outlet 964 with a foaming passage located between the inlets and the outlet.
[161] Generally contained within housing 961 is a cylindrical chamber 966 which receives gas under pressure from inlet 962.
[162] Chamber 966 is situated generally within the foam flow path of chamber 960 so that liquid from inlet 963 generally flows around the outer surfaces of chamber 966. In one embodiment and as illustrated in Figure insertion of FIG. 18I, chamber 966 comprises a plurality of radiator-like structures within the foam flow path. Each structure includes one or more 966.1 main feed lines that supply gas from inlet 962 to one or more 966.2 cross tubes that extend along the foam flow path. Each of these transverse pipes 966.2 includes a plurality of nucleation jets 970 through which gas exits into the circulating liquid. In one embodiment, the cross tubes 966.2 are generally in close contact with a plurality of fin-like members 975, which generally extend through some or all of the cross tubes 966.2. This chamber 966 therefore combines the nucleation zone 972 and the growth and/or homogenization sections 974 and 978, respectively, in a single device. The result is that liquids enter the upstream side of device 966, and a foam exits the downstream side of device 966. In one embodiment, device 966 is similar to a computer chip cooling radiator and heat sink.
[163] FIG. 18J shows a nucleation chamber 1060 in accordance with an embodiment of the present invention. The housing 1061 includes a gas inlet 1062, a liquid inlet 1063 and a foam outlet 1064 with a foaming passage located between the inlets and the outlet. Generally contained within housing 1061 is a gas chamber 1066 which receives gas under pressure from inlet 1062.
[164] In one embodiment, chamber 1066 includes a supply-filled space 1066.1 that is in fluid communication with a plurality of longitudinally extending tubes 1066.2. Preferably, tubes 1066.1 and 1066.2 each extend within the flow path of nucleation chamber 1060 and additionally incorporate a plurality of nucleation jets 1070. As seen in FIG. 18J, in some embodiments, tubes 1066.2 are disposed longitudinally so that liquid flows generally along the length of tubes 1066.2. However, in other embodiments tubes 1066.2 may still be arranged orthogonally, in a similar manner to tubes 966.2 described with respect to nucleation chamber 960.
[165] FIG. 18K shows a nucleation chamber 1160 in accordance with an embodiment of the present invention. Housing 1161 includes a gas inlet 1162, a liquid inlet 1163 and a foam outlet 1164 with a foaming passage located between the inlets and the outlet. Contained within housing 1161 is a nucleation zone 1172 that includes both filled space 1166 for releasing gas to the foam flow path and a powered mixing device that includes a propeller 1186 driven by a motor 1184. In one embodiment, the impeller 1186 includes one or more curved stirring paddles connected to a shaft, and similar to a paint mixing device. Gas from an outlet tube of chamber 1166 is supplied upstream of the agitation blades. Foam created in this way has been found to be acceptable, albeit with a wide variation in the size of the foam cells. Still other embodiments include a cell structuring section 1178 (not shown) located downstream of nucleation section 1172. Still other examples of the stirring member are shown in the insert to Fig. 18K, including devices 1186-1 and 1186-2 . In one application, the 1186-1 nucleation device is similar to a coiled spring helix, similar to those sold by McMaster Carr. In yet another embodiment, the device 1186-2 is similar to the configuration for the propeller of a hair dryer. In some embodiments, the foam prepared in chamber 1160 is preferably made with liquids 1163 provided at relatively low flow rates.
[166] FIGs. 18L, 18M, 18N, 180, 18P, 18Q and 18R illustrate a nucleation chamber 1260 in accordance with another embodiment of the present invention. These drawings show various angular relationships and other geometric relationships among the various components of a nucleation device 1260. FIG. 180 shows that the first nucleation zone 1272a may include jets that have a negative angle of attack, meaning that there may be a component of the velocity of air leaving the gas-filled space that is opposite to the general flow direction of the liquid that flows inside the nucleation device. FIGs. 18P and 18Q show that downstream nucleation zones 1272b and 1272c can include injection angles into the air that include a velocity component in the same direction as the flow of liquid (which is partially foamed, having already passed through the first zone 1272a ). FIG. 18R further shows a nucleation jet 1270 which is oriented to provide swirl for the foam mixture (i.e., rotation about the central axis of the nucleation device). It is further understood that multiple nucleation jets may have a combination of swirl angle as shown in FIG. 18R with any of the alpha, beta, or Rho angles shown in FIGS. 180, 18P or 18Q, respectively.
[167] In some embodiments of the present invention, the total flow area of all nucleation jets is in the range from about 50 percent of the cross-sectional flow area N of the gas-filled space to about three times the total cross-sectional flow area N of the glass-filled space. In order to achieve this ratio of the total nucleation jet area to the total cross-sectional area of the full space, the length NL can be adjusted accordingly. In still other embodiments, the ratio of the cross-sectional area O of the inner diameter of the nucleation device to the area N of the gas-filled space chamber should be less than about five.
[168] FIG. 19 provides pictorial representations of cleaning aero engines in accordance with various embodiments of the present invention. FIG. 19A shows a vehicle 21 parked between the wing and engine of an aircraft in the DC-9 family. FIGs. 19B and 19C show a vehicle 21 that uses a scrubbing system 20 to clean the right engine of a type DC-10 aircraft. The vehicle 21 includes a washing system 20. A nozzle 30 is supported from an extendable lance 23 near the inlet 11 of the gas turbine engine mounted on the fuselage 10. An effluent collector 32 is located near the exhaust 16 of the gas turbine engine 10. Manifold 32 in one embodiment includes a housing 33 coupled to support member 34. Support member 34 in some embodiments is coupled to vehicle 21 (or, alternatively, to tarmarc or other suitable restraint ) in order to maintain the location of the manifold 32 behind the gas turbine engine 10 during the cleaning process. In some embodiments, the housing 33 is inflatable with air, in a manner similar to large outdoor play equipment. In such embodiments, vehicle 21 further includes a fan for supplying pressurized air to an enclosure 33.
[169] Foam from the nozzle 20 supported by the lance 23 is supplied into the inlet of the gas turbine engine 10, preferably as the gas turbine engine 10 is rotated by its start. Foam 28 is injected into inlet 11 as the gas turbine engine 10 is rotated on startup. In some embodiments, typical starter operation results in a maximum (ie, non-operating) engine motor speed, which is typically less than the engine's idle (ie, running) speed. However, in some embodiments, the method of use system 20 preferably includes rotating the engine at a speed of rotation less than the typical engine speed. With such lower speed operation, the components in the cold section of the gas turbine engine 10 are less likely to reduce the quality or quantity of foam before it is supplied to the hot section of the engine. In one embodiment, the preferred rotational speed during cleaning is from about 25 percent of the drive speed to less than about 75 percent of the drive speed.
[170] FIGs. 2-1A and 2-1B depict various representations of a washing or cleaning system 20 in accordance with an embodiment of the present invention. A washing system 20 applied to cleaning a gas turbine engine is illustrated, while it is understood that various embodiments of the present invention contemplate cleaning any object. Wash system 20 may be incorporated within vehicle 21. Vehicle 21 may also take the form of a trailer, compact car or dolly so that it can be rolled like vehicle 21 to a desired location that varies in capacity. .
[171] FIG. 2-1A pictorially represents a rear-side view of a gas turbine engine 10 being cleaned or aircraft wing 90 in an airport configuration. Vehicle 21 contains flushing system 20 for delivering sponge cleaning product to gas turbine engine 10 through hose 33 handled by gas turbine engine 10 by the bracket. It has already been contemplated that vehicle 21 may provide a support 34 as well as a boom 23 (seen later in Fig. 2-2).
[172] FIG. 2-1B pictorially represents the front view of a washing system 20 being used to clean a gas turbine engine 10. System 20 typically includes a gas supply 26 (not shown), a water supply 24, a supply 22 of cleaning chemicals and a supply of electricity (not shown) all of which are supplied to a foaming system 40. The foaming system 40 accepts these input constituents and provides a foam output 28 (not shown ) through a nozzle 30 to the inlet 11 of the gas turbine engine 10.
[173] FIGs. 2-2, 2-3, and 2-4 pictorially represent various modalities of an effluent collector 32 and positioning of vehicle 21. Effluent collector 32 is designed to collect foam and effluent for post-processing, recycling (processing unit 80 , seen later in FIG. 2-7) or for disposal.
[174] FIG. 2-2 pictorially represents the effluent collector 32. The effluent collector 32 can be inflated, similar to outdoor recreational equipment, or similar to an aircraft emergency ramp or life raft. The effluent collector 32 in one mode is safe and gentle to the aircraft and structurally supporting to contain foam, liquids and solid particles.
[175] In addition, vehicle 21 may contain a lance 23 to support nozzle 30 (more about nozzle 30 in FIG. 2-8). The lance 23 allows for the positioning of the nozzle 30 by introducing foam into the gas turbine engine 10. The lance 23 can have a combination or range of degrees of freedom in space, in addition. but not limited to stretching, rotation and/or angles.
[176] FIG. 2-3 pictorially represents the effluent collector 32 (similar to FIG. 2-2) in a very large gas turbine engine. Vehicle 21 may be positioned ahead of the engine but is not limited to this mode. For example, the gas turbine engine 10 at the upper rear of aircraft 90 is high enough that the position of vehicle 21 and boom 23 would not reach the entrance (such as in Figs. 8). In such a comparative scenario, the effluent collector 32 can be lifted by another vehicle 21 with the lance 23 or by a support 34 (as in FIG. 2-1).
[177] FIG. 2-4 pictorially represents an embodiment of the effluent collector 32. The collector 32 may be a floor pad with the containment wall 37. In one example, the containment wall 37 has been contemplated to be supported with brackets or to be inflatable. The effluent manifold 32 can be a variation of sizes and dimensions to encompass one or fewer gas turbine engines 10 during the cleaning process.
[178] FIG. 2-5 is an artistic schematic and photographic representation of aircraft engines 10 being cleaned with a system in accordance with an embodiment of the present invention. The gas turbine engines 10 are assembled in accordance with the aircraft design 90; where the illustrations show a twin rotor helicopter (Bell) with engines 10 horizontally mounted towards the rear, and the other design has engines 10 mounted on the wing side and pivots between the vertical and horizontal (V22 Osprey). Vehicle 21 shown in this photographic representation incorporates a trailer. The orientation of the gas turbine engine 10 over the V22 aircraft is vertical, where the hose 33 directs the foam cleaner to the nozzle 30 at the inlet of the engine 11. The cleaning or flushing engine 10 in this format allows for the prescription of the motor (more in FIG. 2-10) to possibly alternate the core components of the reciprocating motor 10 or to rotate, or be stationary, or both. It has been contemplated that foam cleaners can cascade downward without shaking/rotation. The effluent would then exit at the bottom of the gas turbine engine 10, to be captured (similar to FIG. 2-4), or allowed to enter the sewer.
[179] FIG. 2-7 is a schematic representation of a cleaning process/method in accordance with an embodiment of the present invention. As demonstrated in all previous figures, the apparatus and method of the invention can allow for versatility in the field. The diagram shows the trajectory of the method of process steps for cleaning the gas turbine engine 10. For purposes of explanation, the process starts on vehicle 21, which contains the washing system 20. The washing system provides the Foam cleaners to clean the 10 gas turbine engine where dirt, contaminants, liquids and foam; effluent exits the gas turbine engine 10. Because field condition and regulations vary (ie, airports, private land, or military zones) the method and design of the invention contemplates incorporating modular flexibility into the vehicle 21. For example , the effluent has three method routes that can take, the trajectory A, B or C. First, the trajectory A, the effluent can go directly to the sewage or soil. Second, because of the effluent collector system 32, the foam, liquids, and dirt material can be recycled and/or processed by processing unit 80, shown by Trajectory B or C. Vehicle 21 can accommodate one unit Processing unit 80, as shown in trajectory B. While, in trajectory C, processing unit 80 can be treated separately from vehicles 21. Processing unit 80 can be a pre-built module similar to those sold by AXEON Water Technologies.
[180] FIGs. 2-8A, 2-8B are similar schematic representations of an engine illustrating a foam injection system in accordance with an embodiment of the present invention. The schematic shows a closer view ahead of the gas turbine engine 10 with inlet 11 from the fan and compressor section. The two figures are shown to clarify the perspective view particularly for the nozzle 30 in relation to the gas turbine engine 10. The nozzle 30 may be a plurality of nozzles, and/or nozzles which pivot in position, angle and /or rotation. For example, point A in both figures illustrates an articulating nozzle (ie robot or monitor sold by Task Force Tips, remotely controlled monitor Y2-E11 A) with an elongated tube (not limited in size) where the foam cleaning product can reach and direct the compressor inlet 11 of the gas turbine engine 10. Similarly, point B in both figures illustrates the hinge nozzle having a nozzle outlet in the form of a “Y” (but not limited in design), positioned along the axis of rotation of the gas turbine engine core 10 from where the nozzle 30 can rotate axially along the compressor inlet zone 11.
[181] FIG. 2-9A is a schematic representation of a sectional and interior view illustrating a foam connection system 41 in accordance with an embodiment of the present invention. The gas turbine engine 10 typically includes a cold section including an inlet 11, a fan 12 (not shown) and one or more compressors 13. Compressed air is supplied to the hot section of the gas turbine engine 10, including the combustor 14, one or more turbines 15, and an exhaust system 16. Because different engines exhibit variations in wear and tear due to clogging of the gas turbine engine 10 manufacturers have 42 dedicated tubes, fittings or passages designed for flushing procedures with water. Because the present invention shows that the foam cleaning system has improvements, with reference to FIG. 2-5, the nozzle 30 or hose 33 can also connect directly to one or many of the foam connection points (dotted line) 41, specifically targeting some or all sections of the engine.
[182] As an example, some sections of the compressor are known to include one or more manifolds or pipes that carry compressed air, such as to supply bleed air to the aircraft or to supply relatively cool compressed air for cooling the hot section of the engine. In some embodiments, the cleaning foam is supplied to the engine through these manifolds or tubes. This foam can be supplied while the engine is running or when the engine is static. In addition, engine hot sections are known to include pipes or manifolds that receive the coldest compressed air for hot section cooling purposes and uncovered ports used for borescope inspections or other purposes. Still other embodiments of the present invention contemplate introducing foam into such pipes and ports, either in a static engine or a rotating engine.
[183] FIG. 2-9B is a schematic representation of a cross-section of the engine with external and internal components illustrating a foam connection system in accordance with an embodiment of the present invention. Similar to FIG. 2-9A, the gas turbine engine section 10 has an inlet 11, a fan 12, a compressor section 13, a combustion section 14, a turbine section 15 and an exhaust section 16. The tubes 43, passageways , fittings, existing or not in future engine manufacturing engineering, can be used to release foam for cleaning the gas turbine engine sections 10. Referring to FIG. 2-1B, because hoses 33 are intended to connect to nozzle 30, alternatively hose 33 can connect directly to gas turbine engine 10 at one or iterations of connections 41.
[184] FIG. 2-10 is a graphical representation of a rotational engine cleaning cycle prescription in accordance with an embodiment/method of the present invention. As demonstrated in most of the previous figures, the gas turbine engines 10 can be mounted in many ways (ie, horizontal, vertical) and the engines come in many shapes and sizes. With this in mind, the foam cleaning procedure can work most effectively at the prescribed gas turbine engine core speeds 10 (the compressor sections 13, and the turbine sections 15). By way of example, this graphical representation has three types of core speeds (three individual - compressor 13 for turbine 15 connected via an axis) shown as N1, N2 and N3. The y-axis is the maximum allowable rotational speed (actual values not shown, scaling for example). The x-axis represents time (not to scale, only example). The purpose of the engine cleaning prescription is to rotate and agitate the foam that has flooded the gas path inside the 10 gas turbine engine. The foam will contact, scrub, and remove scale. Foam has different fluid dynamic properties at different speeds of rotation (agitation). Thus, by cycling the gas turbine engine 10 at various variable speeds, cleaning effectiveness can be achieved. The graph shows that the gas turbine engine 10 is fired 3 times (3 cycles) but is not limited to this frequency. When evaluating the first cycle, it is evident that N1, N2 and N3 behave according to the amount of inertia. At time zero, N1, N2, N3 is zero, when the motor is driven to drive, N1, N2, N3 reaches a maximum limit of about 10.5%, 8.5%, 5.8% respectively. The foam product flooded inside the gas turbine engine 10 forces N3 to stop faster through hydrodynamic friction, while comparatively, N1 can sustain rotation longer. It is preferred to cycle one or many times in the prescription, but the gas turbine engine 10 can also be cleaned without rotation by injecting and flooding the gas path, as discussed in FIG. 2-5.
[185] The foam temperature is useful for the frequency and amplitude of the cycle prescription. Vehicle 21 may house a heater 38 to regulate and positively impact the effectiveness of the cleaning prescription.
[186] FIG. 2-11 is a graphical representation of a method of the present invention; for engine monitoring and benefit quantification. The positive effects and benefits of properly cleaning a gas turbine engine 10 can be further quantified for the invention. By using diagnostic or telemetry tools to obtain financial, operational, maintenance, environmental data (ie, carbon credits, time on the wing, fuel economy, etc.). Data analysis tools are scientific methods to improve the life and safety of the 10 gas turbine engine. As shown in FIG. 2-11, an embodiment of the present invention includes a method. For example, a gas turbine engine 10 in an aircraft or boat transmits information to a data center. Then, the engine operator or manufacturer through computer automation, either separately or in conjunction with a professional trained a person who requested a foam engine cleaning method. By following a foam cleaning method in conjunction with this method of monitoring, performance restoration metrics can record improvements. These quantified improvements can be collected for financial purposes, carbon credits, engine life extension and/or safety.
[187] FIG. 2-12 show various embodiments of a portable effluent collector in accordance with an embodiment of the present invention. The effluent collector includes a trailer 232.1 having a plurality of wheels supporting it from the ground, and preferably also including a trailer hitch for towing by another vehicle. The trailer includes a cargo compartment that can be adapted and configured to support and contain the foam effluent during an engine cleaning process. As shown in these figures, the cargo compartment is lined with a flexible, waterproof and waterproof plastic sheet to form a collection pool 232.2 generally supported by the wheels.
[188] The trailer preferably includes a plurality of collection devices that can be conveniently folded down into a compact format for transport. These devices can also be extended and supported in a vertical condition to collect foam during the cleaning process.
[189] FIG. 2-12 shows the trailer and collection devices in extended condition suitable for collecting foam during a cleaning process. An exhaust manifold 232.3 is formed of a flexible sheet that is waterproof and waterproof, and separated by a pair of spaced ribs 232.34. Each of the support ribs is located on opposite sides of the trailer, and each is pivotally coupled to the front end of the trailer 232.1.
[190] Preferably, the sheet is large enough, and also loosely enveloped in the ribs, so that in the vertically supported condition the sheet forms an envelope 32.31 which has an inlet 232.34 for collecting the foam coming out of the engine exhaust. Enclosure 232.31 forms a gravity-assisted flow path from the inlet to a drain that is located near pool 232.2. Any foam received at the inlet flows down into the enclosure and into the pool through the drain. A pair of 232.33 upright supports are provided on both sides of the housing. Each of the upright supports attaches at one end to one side of the trailer, and at the other end to a matching rib. The rib and corresponding vertical supports are locked together in the extended condition (as shown in FIG. 2-12), to keep the casing in an upright state. When the ribs and upright supports are unlocked, the ribs fold towards the rear of the trailer, and the upright supports can bend towards the front of the trailer, or be removed for transport purposes.
[191] The rear end of the 232.1 trailer includes a 232.4 manifold that is adapted and configured to capture flow from the flushed engine inlet, and also under the engine if the nacelle doors are open. Manifold 232.4 extends from the front end of trailer 232.2, and when supported by upright supports 232.43 presents an upward angle for the inlet of the engine to be cleaned. Any foam exiting the engine inlet or out of the engine nacelle falls onto the drain path created by supporting a sheet 232.41 between a pair of spaced substantially parallel support ribs 232.42. Each of these ribs is hingedly connected to the front end of the trailer. The upright supports 232.43 each attach to a rib, and make contact with the ground. Any foam falling onto the concave sheet drainage path 232.41 moves by gravity into pool 232.2.
[192] Several aspects of different embodiments of the present invention are expressed in paragraphs X1, X2, X3, X4, X5, X6 and X7 as follows:
[193] X1. One aspect of the present invention relates to an apparatus for foaming a water-soluble liquid cleaning agent comprising a housing having a plurality of sequentially disposed foam handling portions or regions, said housing having a gas inlet, a liquid inlet for the water-soluble cleaning agent, and a foam outlet; a region or portion includes a pressurized gas injection device having a plurality of openings, the interior of said housing forming a mixing region which receives liquid from the liquid inlet and which receives gas expelled from the openings and creating a foam of a first medium cell size and a first cell size range; another foam handling portion receives cells having a first distribution band and first average size, and flows them through a cell attachment and growth member that provides surface area for attachment and fusion of the cells to create a foam having a second larger average cell size; yet another foam handling region or portion receives the foam having a first cell size range and flows this foam through a foam structuring member adapted and configured to reduce the foam size range and provide a foam outlet. more homogeneous.
[194] X2. Another aspect of the present invention relates to a method for foaming a liquid, comprising mixing the liquid and a pressurized gas to form a foam; flow the foam over a limb and increase cell size; and subsequently flowing the foam through a plurality of openings or a grid to decrease cell size.
[195] X3. Yet another aspect of the present invention relates to a system for providing a water-soluble liquid cleaning agent foamed with air, comprising an air pump that delivers air at a pressure greater than ambient pressure; a liquid pump that delivers the water-soluble liquid at pressure; a nucleating device having an air inlet that receives air from the pump to air, a liquid inlet that receives liquid from the pump to liquid, and a foam outlet, said nucleating device turbulently mixing pressurized air and liquid to create a foam; and a nozzle receiving foam through a foam conduit, the internal passages of said nozzle and said conduit being adapted and configured to decrease foam turbulence, said nozzle being adapted and configured to deliver a low velocity foam stream. .
[196] X4. Yet another aspect of the present invention relates to a method of providing a water-soluble liquid cleaning agent foamed with air to the inlet of a gas turbine engine installed in an aircraft, comprising providing a source of a cleaning agent. water-soluble liquid, a pump for liquid, a pump for air, a turbulent mixing chamber and a non-atomizing nozzle; mixing pressurized air with pressurized liquid in the mixing chamber and creating a supply of foam; place the nozzle in front of the installed inlet; and flowing the foam supply into the inlet installed from the nozzle.
[197] X5. Another aspect of the present invention relates to an apparatus for foaming a water-soluble liquid cleaning agent, comprising means for mixing a pressurized gas with a circulating water-soluble liquid to create a foam; means for increasing the size of the foam cells; and means to reduce the size of cultured cells.
[198] X6. Yet another aspect of the present invention relates to a method for scheduling a foam cleaning of a gas turbine engine comprising quantifying an improvement range for an operating parameter of a family of gas turbine engines attainable by foam washing. of a family member; operate a family gas turbine engine installed in an aircraft for a period of time; measuring the performance of the gas turbine engine during said operation; determine that the gas turbine engine should be foam washed; and schedule a foam cleaning of the gas turbine engine.
[199] X7. Yet another aspect of the present invention relates to an apparatus for foam cleaning a gas turbine engine, comprising a multi-wheeled trailer having a cargo compartment, the compartment having an impermeable coating; an exhaust foam effluent manifold including a first sheet supported by a first pair of spaced apart ribs, the first ribs being pivotally coupled to one end of said trailer, the ribs and sheet cooperating to provide a closed flow path, one end the flow path having an inlet for receiving foam, the other end of the flow path having a drain adapted and configured to supply foam effluent to the liner; and an inlet foam manifold including a second sheet supported by a second pair of spaced apart ribs, the second ribs being pivotally connected to the other end of said trailer, the ribs and sheet cooperating to provide a drainage path for the liner.
[200] Still other modalities refer to any of the above statements X1, X2, X3, X4, X5, X6 or X7 that are combined with one or more of the other aspects below. It is also understood that any of the aforementioned X paragraphs include listings of individual resources that can be combined with individual resources of other X paragraphs
[201] Whereas the first flow portion, the second flow portion and the third flow portion have substantially the same flow area.
[202] Where the casing has an inner wall and an inner axis and the direction of the internal flow path is from the axis towards the inner wall.
[203] Where at least two of the first, second and third flow portions are concentric or the third flow portion is the outermost from the first and second portions, or the first flow portion is the most internal of the second or third servings.
[204] The first, second, and third flow portions being concentric, and the second flow portion being between the first portion and the third portion.
[205] Where the direction of the internal flow path is from the liquid inlet towards the foam outlet.
[206] Said growth member includes a wire mesh.
[207] The wire mesh having a first weft size and said structuring member includes a wire mesh having a second weft size smaller than the first weft size.
[208] Said web comprises a plastic material or a metallic material.
[209] Said structuring member including an aperture plate, lattice or fibrous matrix.
[210] Said first foam flow over a member increases the turbulence of the first foam.
[211] This further comprises flowing the third foam into a chamber having an inlet and an outlet, the chamber being adapted and configured to lessen the turbulence of the third foam.
[212] The chamber is adapted and configured to provide more laminar flow of the third foam between the inlet and outlet.
[213] Said mixture including flowing liquid in a first direction and injecting gas in a second direction having a velocity component at least partially opposite to the first direction.
[214] Said second foam flow being at one speed, and further comprising flowing the third foam at substantially the same speed over an object and cleaning the object.
[215] Said nozzle is adapted and configured to supply the foam stream to a bleed air duct of a gas turbine engine.
[216] Said nozzle is adapted and configured to supply the foam stream to a pipe mounted on a gas turbine engine.
[217] Since the chain has a substantially constant diameter.
[218] Since the nozzle has a first flow area, the conduit has a second flow area, and the first flow area is approximately the same as the second flow area.
[219] Since the foam outlet has a first flow area, the conduit has a second flow area, and the first flow area is approximately the same as the second flow area.
[220] Since the nozzle is one or more nozzles that have a full flow area, the foam outlet has an exit area and the exit area is approximately the same as the total flow area.
[221] Said nucleation device including a pressurized air filled space having a plurality of air flow openings and located within a chamber provided with a flow of liquid, the openings expelling air into the flowing liquid to create the foam.
[222] Whereas the air received by said nucleation device has a pressure greater than about ten psig and less than about one hundred and twenty psig, and the liquid received by said nucleation device has a pressure greater than about ten psig and less than about center and twenty psig.
[223] Since the fluid supply is at a velocity greater than about three feet per second and less than about fifteen feet per second.
[224] Since the fluid supply is a unit stream of substantially constant diameter.
[225] Said supply including a cell growth chamber downstream of the mixing chamber and further comprising foam cell size growth after said mixing and prior to said continuous flow.
[226] Said supply includes a turbulence reduction chamber downstream of the mixing chamber and further comprising reducing the turbulence of the mixed foam after said mixing and before said continuous flow.
[227] With the installed motor being substantially vertical in orientation and the continuous flow being into the installed inlet without motor rotation.
[228] Since said growing means includes a growing frame, said reducing means includes a reducing frame, and the frame size of the reduction frame is smaller than the frame size of the growing frame.
[229] Said growth media being adapted and configured to provide surface area for attachment and blending of foam cells from said mixing media.
[230] Said growth media including a plurality of first passages and said reducing means are adapted and configured to reduce the size of at least some of the cultured cells by passing the cultured cells through a plurality of smaller second passages than the first passages.
[231] Said mixing means are the injection of gas from inside a tube into the liquid in circulation.
[232] Said mixing means are by supplying pressurized gas into the circulating liquid through a porous metal filter.
[233] Said mixing means include a motorized rotating propeller.
[234] Said mixing means generate vortex in the liquid in circulation by the gas injection.
[235] Said growth medium is either a vibration rod, or an ultrasonic transducer.
[236] Which further comprises providing the measured performance of the gas turbine engine to the engine owner and said determination by the engine owner.
[237] Where the operating parameter is the start time.
[238] The operational parameter is the specific fuel consumption of the engine. The operational parameter is the carbon or nitrogen oxides emitted by the engine.
[239] Since said measurement is during the commercial passenger operation.
[240] Which further comprises a vertical support connected at one end to the trailer and at the other end to one of said first ribs, said vertical support keeping the flow path closed in a vertical condition to facilitate gravity-induced drainage to from the entrance to the drain.
[241] Which further comprises a vertical support connected at one end to the trailer and at the other end to one of said second ribs, said vertical support maintaining the flow path at an upward angle to facilitate gravity-induced flow in towards the coating.
[242] While the inventions have been illustrated and described in detail in the aforementioned drawings and description, they are to be considered as illustrative and not restrictive in character, it being understood that certain modalities have been shown and described and that it is desired to protect all changes and modifications that are within the spirit of the invention.

权利要求:
Claims (17)
[0001]
1. Method for cleaning a gas turbine engine (10) installed in an aircraft, the gas turbine engine (10) having a starter, an inlet (11) and a compressor (13), characterized by comprises: providing a source of a water-soluble liquid cleaning agent (22), a liquid pump (50), an air pump or a pressurized gas reservoir (26), a turbulent mixing chamber (60) and a non-atomizing nozzle (30), mix in the mixing chamber pressurized air or gas of the air pump or pressurized gas reservoir (26) with pressurized liquid cleaning agent (22) pressurized by the liquid pump (50) and create a foam supply (28) by rotating the gas turbine engine (10) installed with the starter, and transmitting the foam supply (28) to the inlet (11) of the gas turbine engine (10) installed at from the non-atomizing nozzle (30) as the gas turbine engine (10) is rotated by the starter.
[0002]
Method according to claim 1, characterized in that the gas turbine engine (10) is rotated at a speed between 25% and 75% of its maximum engine speed of the gas turbine engine.
[0003]
Method according to claim 1, characterized in that the current supply is at a speed greater than 0.91 m/s (three feet per second) and less than 4.5 m/s (fifteen feet per second). second).
[0004]
Method according to claim 1, characterized in that the current supply is a unit current of constant diameter.
[0005]
A method according to any one of claims 1 to 4, further comprising providing a cell growth chamber (74) downstream of the mixing chamber (60) and increasing the size of the foam cells after said mixing and before transmission.
[0006]
A method according to any one of claims 1 to 5, further comprising providing a turbulence reduction chamber (28) downstream of the mixing chamber (60) and reducing the turbulence of the mixed foam after said mixing and before transmission.
[0007]
A method according to any one of claims 1 to 6, characterized in that it further comprises: rotating all the spools of the gas turbine engine (10) during said transmission; allowing an innermost spool to stop and maintaining said transmission after the innermost spool has stopped; and re-rotating all gas turbine engine spools (10) after the innermost spool has stopped.
[0008]
Method according to any one of claims 1 to 7, characterized in that it further comprises: improvements in operating temperature, fuel consumption and start times for an operating parameter of a family of gas turbine engines (10), achievable by washing foam from a family member; operating a family-specific (10) gas turbine engine installed in an aircraft for a period of time; measuring the specific gas turbine engine (10) parameter during said operation; determine that the specific gas turbine engine (10) should be foam washed; and scheduling a specific gas turbine engine (10) foam wash.
[0009]
Method according to claim 8, characterized in that the operating parameter is a start time or a specific fuel consumption of the gas turbine engine (10).
[0010]
A method according to any one of claims 1 to 9, characterized in that said nozzle (30) is adapted and configured to supply the supply of foam (28) to a gas turbine engine bleed air duct ( 10) or to a pipe manifold mounted on the gas turbine engine (10).
[0011]
A method according to any one of claims 1 to 10, characterized in that said mixing includes flowing the liquid (22) in a first direction and injecting the air or gas (26) in a second direction having a velocity component. at least partially opposite the first direction.
[0012]
A method according to any one of claims 1 to 11, characterized in that the air or gas received by said mixing chamber (60) has a pressure greater than 68.9 kilopascals (10 psig) and less than 827 kilopascals (120 psig) and the liquid (22) received by said mixing chamber (60) has a pressure greater than 68.9 kilopascals (10 psig) and less than 827 kilopascals (120 psig).
[0013]
A method according to any one of claims 1 to 12, characterized in that the mixing chamber (60) includes a pressurized plenum (66) for air or gas (26) with a plurality of outflow openings (65, 70) of air or gas (26) and located within a chamber provided with a flow of liquid (22), the openings (65, 70) expelling air or gas (26) into the flow liquid (22) to create the foam. .
[0014]
A method according to any one of claims 1 to 13, characterized in that mixing in the mixing chamber (60) comprises mixing the liquid cleaning agent (22) and the pressurized air or gas (26) to form a first foam. , creating a supply of foam (28) which comprises flowing the first foam over a member or matrix (75) and increasing the size of the cells of the first foam to form a second foam.
[0015]
The method of claim 14, characterized in that creating a supply of foam (28) further comprises flowing the second foam through an apertured structure (79) and decreasing the cell size of the second foam to form a third foam.
[0016]
16. Method for cleaning a gas turbine engine (10) installed in an aircraft while the gas turbine engine (10) is in a vertical orientation, the gas turbine engine (10) having an inlet (11) and a compressor (13), characterized in that it comprises: providing a source of a water-soluble liquid cleaning agent (22), a liquid pump (50), an air pump or a pressurized gas reservoir (26), a chamber of turbulent mixing (60) and a non-atomizing nozzle (30), mix in the mixing chamber pressurized air or gas of the air pump or pressurized gas reservoir (26) with pressurized liquid cleaning agent (22), pressurized by the liquid pump (50) and create a foam supply (28), transmit the foam supply to the inlet (11) of the vertical gas turbine engine (10) installed from the non-atomizing nozzle (30).
[0017]
The method of claim 16, characterized in that the gas turbine engine (10) comprises a starter, the method comprises rotating the gas turbine engine (10) installed with the starter. after transmission of a sufficient amount of foam (28) and subsequent washing of the cleaning agent.

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同族专利:

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公开号 | 公开日

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EP3052252A4|2017-05-17|

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US10364699B2|2019-07-30|

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KR102355641B1|2022-01-25|

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SG11201602591QA|2016-04-28|

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KR20220013016A|2022-02-04|

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BR112016007366A2|2017-08-01|

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JP6543636B2|2019-07-10|

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CA2963071A1|2015-04-09|

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KR20160088866A|2016-07-26|

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JP2019173757A|2019-10-10|

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JP2016535835A|2016-11-17|

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EP3052252A1|2016-08-10|

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US20160230592A1|2016-08-11|

---

MX2016004220A|2017-01-26|

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WO2015051146A1|2015-04-09|

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法律状态:
2019-12-24| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-09-08| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-03-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-05-18| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 02/10/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201361885777P| true| 2013-10-02|2013-10-02|

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US61/885,777|2013-10-02|

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US201361900749P| true| 2013-11-06|2013-11-06|

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US61/900,749|2013-11-06|

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PCT/US2014/058865|WO2015051146A1|2013-10-02|2014-10-02|Cleaning method for jet engine|

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