Disk Stack Repair Insert for Restoring Steam Flow Passages
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Solution Overview
Problem
Disk stacks in power plants, used to dissipate steam pressure and heat, often suffer damage from high-pressure fluids, necessitating entire stack replacement rather than repair.
Innovation Solution
A disk stack repair insert comprising replacement disk segments with matching groove patterns is inserted into the damaged area, restoring fluid passageways and maintaining the disk stack's functionality without full replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire disk stack is replaced to ensure proper operation after damage, then the reliability of the valve system is improved, but the loss of time and increase in maintenance costs worsen
Solution Approach 1:
The disk stack is divided into multiple individual disks that can be independently replaced. When damage occurs, only the affected disk or segment needs to be removed and replaced, rather than replacing the entire stack. This segmentation allows for targeted repair of damaged portions while preserving functional disks, significantly reducing maintenance time and resource consumption.
Solution Approach 2:
The damaged disk or disk segment is extracted from the stack for replacement. The repair process involves removing only the specific damaged component from the assembled disk stack, replacing it with a new or refurbished disk, and reassembling the stack. This extraction approach eliminates the need to disassemble and replace the entire disk stack, reducing maintenance time and operational disruption.
2Reliability
If the entire disk stack is replaced to ensure proper operation after damage, then the reliability of the valve system is improved, but the maintenance costs increase
Solution Approach 1:
The disk stack is divided into multiple individual disks that can be independently replaced. When damage occurs, only the affected disk or segment needs to be removed and replaced, rather than replacing the entire stack. This segmentation allows for targeted repair of damaged portions while preserving functional disks, significantly reducing maintenance time and resource consumption.
3Ease of manufacture
If traditional disk stacks are used without repair capability, then the manufacturing process is simple, but the adaptability to extend service life worsens
Solution Approach 1:
The disk stack is divided into multiple individual disks that can be independently replaced. When damage occurs, only the affected disk or segment needs to be removed and replaced, rather than replacing the entire stack. This segmentation allows for targeted repair of damaged portions while preserving functional disks, significantly reducing maintenance time and resource consumption.
Solution Approach 2:
Damaged disks or disk segments are discarded and replaced with new or refurbished components, while the remaining functional disks are recovered and retained in the stack. This approach allows for partial replacement and repair, extending the service life of the disk stack by maintaining usable components rather than discarding the entire assembly.
Data Source
AI summary
Example aspects of a disk stack repair insert, a repaired disk stack, and a method for repairing a disk stack are disclosed. The disk stack repair insert can comprise a first replacement disk segment defining a first groove pattern comprising first grooves; and a second replacement disk segment defining a second groove pattern comprising second grooves, the first replacement disk segment coupled to the second replacement disk segment, wherein the first groove pattern and the second groove pattern define a fluid passageway therebetween.