Gas Turbine Compressor Run-In Layer Repair
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Solution Overview
Problem
The existing methods for repairing worn inlet layers in gas turbine compressors require dismantling the engine, leading to costly downtime, power loss, and potential engine damage due to uncontrolled vibrations and blade cracks, necessitating the development of a more efficient and cost-effective repair solution.
Innovation Solution
A method that uses a boroscope to analyze and repair the worn running-in layers without disassembling the gas turbine, employing a curable aluminum oxide-based repair medium applied via an air pressure brush, cured with heat, and processed mechanically to match the original coating's properties, allowing for multi-layer application and minimization of mechanical reworking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gas turbine is dismantled for repair of the running-in layer, then the repair can be carried out with proper equipment, but the downtime and costs increase significantly
Solution Approach 1:
The patent extracts the essential repair functions (material removal, cleaning, coating application, curing) from the workshop environment and implements them via portable tools that can be inserted through existing access openings in the gas turbine, eliminating the need for complete dismantling while maintaining repair quality
Solution Approach 2:
The patent uses a boroscope as an intermediary tool to guide and deliver repair equipment through access openings to the running-in layer, enabling repair operations in the non-dismantled state by mediating between the external repair equipment and the internal repair area
2Ease of repair
If the gas turbine is dismantled for repair, then the running-in layer can be properly repaired, but the complexity of the repair process increases
Solution Approach 1:
The patent employs a multi-functional tool system that combines boroscope guidance, material removal, cleaning, coating application, and curing capabilities in a single integrated approach, allowing one tool to perform multiple repair functions without requiring separate complex equipment for each operation
Solution Approach 2:
The repair system uses the gas turbine's own structure (access openings, rotor positioning) to facilitate the repair process, requiring minimal additional equipment while leveraging the existing turbine configuration to enable repair operations
3Productivity
If the worn running-in layer is not repaired, then the engine continues to operate, but compressor efficiency deteriorates and vibrations increase leading to blade cracks
Solution Approach 1:
The patent enables preliminary repair action to be taken while the engine is still in service or during minimal downtime, addressing the worn running-in layer before it causes catastrophic failure, thus maintaining both operational continuity and reliability
Solution Approach 2:
The patent maintains the compressor's useful action (efficient gas compression) by continuously or periodically restoring the running-in layer, ensuring the compressor operates at optimal efficiency throughout its service life rather than allowing degradation to occur
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables on-site repair of gas turbine compressors, reducing downtime and costs by avoiding engine removal and replacement, maintaining compressor efficiency, and preventing further damage through precise application and curing of the repair medium.
Implementation Method 1
A curable, aluminum oxide-based repair medium is applied to the area to be repaired using a type of air pressure brush
Implementation Method 2
A curable, aluminum oxide-based repair medium is applied to the area to be repaired using a type of air pressure brush and then cured
Data Source
AI summary
The invention relates to a method for repairing a run-in layer (1, 2) of a compressor for a gas turbine, in which a worn run-in layer (1, 2) is repaired. An analysis and/or a selection of areas of the run-in layer (1, 2) to be repaired is performed by means of a boroscope with the gas turbine in non-dismounted condition. A tool is applied through at least one boroscopy opening in the gas turbine to the area to be repaired and the worn run-in layer (1, 2) is removed at least in part, and the removed material is extracted by suction. The area of the run-in layer (1, 2) to be repaired is cleaned and/or prepared for the application of a repair medium (23). A hardenable repair medium (23) based on aluminium oxide is applied by means of a type of air pressure brush to the area to be repaired and subsequently hardened, and the area furnished with the repair medium is subsequently mechanically machined.