Turbine blades are crucial components in aircraft engines, playing a critical role in converting the potential energy of the jet fuel into the kinetic energy that propels the aircraft. Due to the extreme environmental conditions that these components operate under, their production, repair, and maintenance processes must meet the highest standards of precision and quality.
One of our clients, a prominent turbine blade facility, specializes in the inspection and repair of turbine blades. These blades are often coated with coolants and lubricants during the manufacturing process. These substances reduce friction, dissipate heat, and protect the blades from wear and corrosion, ensuring their optimal performance and longevity.
The turbine blades were going to be subjected to Fluorescent Penetrant Inspection (FPI), a widely-used method of Non-Destructive Testing (NDT) that reveals surface-breaking defects by bleed-out of a fluorescent dye from the defect. The client needed Brulin’s team to design a cleaning process that ensured these coolants and lubricants were thoroughly removed beforehand.
The client was using an OMEGASONICS 33-gallon washing system to clean the turbine blades. However, due to less-than-ideal maintenance practices, the cleaning tank often developed a foul odor and had a shorter-than-expected operational lifespan.
Moreover, the cleaning process was not always successful in completely removing the coolants and lubricants, resulting in less-than-optimal preparation for the inspection and FPI processes.
Upon reviewing the client’s operations, our team of parts cleaning experts identified the core issue — a pressing need for an intensive tank de-scaling regimen. Understanding that the residue build-up and foul odor stemmed from improper and infrequent tank cleaning, our advisors proposed a strategic solution to not only address the present problem but also to prevent such issues from recurring in the future.
Our team recommended a rigorous and comprehensive tank de-scaling process designed to completely remove any scale, residue, or contaminants from the cleaning tanks. This process would involve the use of Brulin Descaler, a specialized cleaning agent specifically designed to safely and effectively dissolve scale and deposits.
The client was advised to begin the process by draining the tanks to remove all existing liquid and visible debris. Then, the de-scaling process would begin, which involves filling the tank with a solution of Brulin Descaler at a 25% concentration.
This de-scaling solution would need to be left in the tank for approximately 30 minutes. The relatively high concentration and longer exposure time would allow the de-scaler to penetrate and break down stubborn scale and residue thoroughly.
Following the de-scaling process, a thorough freshwater rinse would be needed to wash away the dissolved deposits and any remaining de-scaler. This step is crucial to ensure a completely clean and residue-free tank, ready for the next batch of turbine blades.
Our de-scaling recommendation aimed to address the root cause of the client’s issue. By implementing a comprehensive de-scaling regimen, we were confident that the client could eliminate the foul odor and residue build-up, extending the tank’s lifespan and improving the overall efficiency and effectiveness of the turbine blade cleaning process.
Once the de-scaling procedure was completed, it was crucial to restart the system using an optimized process that would ensure high-quality cleaning while minimizing the chances of future build-up. Our team provided a set of guidelines for the client to follow, drawing upon our extensive experience and proven expertise in the industry.
The first step was the selection of the right cleaning chemistry. Our team recommended AquaVantage® 815 GD, our top-tier, high-performance cleaning agent specifically designed for demanding applications like turbine blade cleaning.
Our team provided precise parameters for charging the 33-gallon wash tank. A concentration of 10% AquaVantage® 815 GD was suggested, offering the perfect balance, strong enough to effectively clean the turbine blades yet gentle enough to prevent unnecessary wear on the tank and its mechanical components.
The manufacturer was instructed to use a wash temperature of 145°F (63°C), providing the heat necessary for AquaVantage® 815 GD to penetrate and break down the coolants and lubricants on the turbine blades. The recommended cleaning time was set at 10 minutes, sufficient for thorough cleaning without causing any potential damage to the blades.
Once the wash cycle was complete, the turbine blades would undergo a short rinse cycle. The rinse temperature was set to ambient to avoid thermal shock to the components, which could potentially induce micro-cracking or other forms of damage. The rinse time was set to 1 minute, ensuring that all residues of the cleaning agent were effectively washed off.
These guidelines were designed to not only deliver superior cleaning performance but also promote better tank maintenance, ensuring an extended tank life and consistently high-quality output. Moreover, to avoid similar problems in the future, the client was advised to carry out regular tank maintenance, including tank titration, at least once per week.
After implementing our team’s process recommendations, the client immediately noticed considerable improvements.
The foul odor in the cleaning tank was completely removed, significantly improving the working conditions for the manufacturer and their employees. Furthermore, the tank life was considerably extended, reducing maintenance costs and downtime.
Most importantly, the turbine blades came out cleaner after the washing process. This resulted in a more efficient and effective inspection and repair procedure, as well as a more accurate FPI.
By adopting recommended process and maintenance practices designed by our team of dedicated parts cleaning advisors, this turbine blade facility significantly improved its cleaning process. The implementation of the newly designed process demonstrated that even minor changes to maintenance and cleaning protocols could lead to substantial improvements in operational efficiency and effectiveness.