Removable Lapping Tool for Gas Turbine Fitting Seal Repair
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Solution Overview
Problem
The existing methods for repairing damaged sealing surfaces in gas turbine fittings are costly and time-consuming, involving replacement and welding, which requires specialized personnel and equipment, and often result in fuel leaks due to misalignment and material damage.
Innovation Solution
A lapping tool with removable inserts that correspond to the shape of the sealing surfaces, allowing for manual lapping with abrasive compounds to smooth out damaged areas, eliminating the need for replacement and welding by aligning and smoothing the surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If welding replacement is used to repair damaged sealing surfaces, then the fitting can be restored, but the process requires specialized personnel, equipment, and time
Solution Approach 1:
The patent employs disposable abrasive inserts that can be easily replaced after use. These inserts contain abrasive material that wears down during the lapping process, and when depleted, they are discarded and replaced with fresh inserts. This eliminates the need for complex welding equipment and specialized personnel, as the repair process becomes a simple mechanical lapping operation using replaceable consumable inserts.
Solution Approach 2:
The patent changes the repair approach from thermal welding to mechanical lapping by altering the physical state and properties of the repair process. Instead of using heat and specialized welding procedures, the invention uses abrasive mechanical removal of material through lapping with replaceable inserts, fundamentally changing the repair parameters from thermal to mechanical.
2Ease of repair
If welding replacement is used to repair damaged sealing surfaces, then the fitting can be restored, but the process is time-consuming
Solution Approach 1:
The disposable abrasive inserts enable rapid repair by eliminating the lengthy welding process. The inserts are pre-loaded into simple holders that can be quickly attached to a lapping tool, allowing the repair operation to proceed immediately without waiting for welding equipment setup, qualified welders, or post-weld inspection procedures.
Solution Approach 2:
The patent extracts the time-consuming elements (welding process, x-ray inspection, specialized personnel coordination) from the repair procedure and replaces them with a simplified mechanical lapping process using removable inserts, thereby dramatically reducing the overall repair time while maintaining repair capability.
3Ease of repair
If welding is performed to replace damaged fittings, then replacement is achieved, but misalignment and material damage occur resulting in fuel leaks
Solution Approach 1:
The patent changes the repair mechanism from thermal welding (which causes distortion and misalignment) to mechanical lapping (which preserves alignment and surface integrity). The lapping process using abrasive inserts gently removes high spots and smooths surfaces without generating the thermal distortion that leads to misalignment, thereby maintaining sealing integrity and preventing fuel leaks.
Solution Approach 2:
The patent converts the harmful effect of damaged surfaces into a beneficial process by using the damaged areas themselves as the target for controlled abrasive removal. The lapping process with replaceable inserts systematically removes the damaged material and smooths the surfaces, turning the previously harmful irregularities into a benefit by creating fresh, smooth sealing surfaces that ensure proper alignment and prevent leaks.
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
The tool effectively repairs damaged sealing surfaces, preventing fuel leaks and reducing costs and time by allowing on-site smoothing of surfaces without the need for specialized welding or personnel, ensuring a reliable seal.
Implementation Method 1
manual lapping with abrasive compounds to smooth out damaged areas
Data Source
AI summary
A lapping tool for lapping sealing surfaces of a fitting used in a gas turbine. The tool includes a shaft having first and second ends and a longitudinal axis. A removable handle is attached to the first end and is oriented in a direction transverse to the axis. The tool also includes a removable lapping insert having an outwardly extending attachment portion that is attached to the second end of the shaft. The lapping insert includes a lapping surface which corresponds to the shape of a sealing surface of the fitting. In one embodiment, the lapping insert includes a cavity for receiving a cone portion of a fitting. Alternatively, the lapping insert includes a projection for insertion into a receptacle portion of a fitting.