Rotor Slot Modification Drill Assembly for Gas Turbine Maintenance
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Solution Overview
Problem
The existing methods for modifying rotors in gas turbines require substantial disassembly of the compressor and associated equipment, leading to increased costs and downtime due to the need for complete removal of the casing and surrounding structures, which limits the frequency of blade removal and re-staking.
Innovation Solution
A system and method that uses a drill assembly to create a cavity in the rotor slot without requiring complete disassembly, utilizing a drill positioned in the radial space previously occupied by a removed blade, with sliding and pivotal connections for precise manipulation within the confined space, allowing for repeated blade removal and re-staking without extensive disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a drill is used to create a recess in the bottom of the slot with complete disassembly of the compressor and surrounding structures, then the blade can be removed and re-staked multiple times, but the disassembly and staging is expensive to perform, extends the time needed for the rotor modification, and increases the outage associated with the modification
Solution Approach 1:
The invention divides the modification process into segments by removing only the specific blade requiring modification rather than disassembling the entire compressor. The drill assembly is then positioned through the opening created by blade removal, allowing targeted modification of the slot without affecting other components. This segmentation approach reduces outage time while maintaining the ability to perform multiple blade removals and re-stakings.
Solution Approach 2:
The invention extracts only the necessary components for the modification process - specifically removing the target blade and positioning the drill assembly through the resulting opening. This extraction approach avoids the need to disassemble the entire compressor casing and surrounding structures, thereby reducing the time and cost associated with the modification while still enabling repeated blade removals.
2Ease of manufacture
If complete disassembly of the compressor and surrounding structures is performed to access the rotor, then the slot can be modified, but the disassembly and staging is expensive to perform
Solution Approach 1:
The invention applies segmentation by isolating the modification task to only the necessary components - removing the target blade and accessing the slot through the resulting opening. This avoids the complexity of disassembling the entire compressor and surrounding structures, reducing both cost and device complexity while maintaining slot modification capability.
Solution Approach 2:
The drill assembly serves as an intermediary tool that can be positioned through the opening created by blade removal. This intermediary approach allows slot modification without requiring complete disassembly of the compressor and surrounding structures, thereby reducing the complexity and cost of the modification process.
3Ease of operation
If scaffolding and cranes are used to support equipment and personnel for rotor modification, then the slot can be modified, but the amount of disassembly and staging increases
Solution Approach 1:
The invention segments the access requirement by creating a localized opening through blade removal rather than requiring complete disassembly. This segmented approach allows the drill assembly to be positioned and operated without the need for extensive scaffolding and cranes, reducing device complexity while maintaining ease of operation for the specific modification task.
Solution Approach 2:
The blade root itself serves as a natural access pathway when removed, eliminating the need for external scaffolding and staging structures. The opening created by blade removal provides direct access to the slot for the drill assembly, allowing the system to service itself without requiring additional complex support equipment.
Data Source
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AI summary
A system (40) for modifying a slot (24) in a rotor (18) includes a drill (42), a clamp (80) connected to the drill (42) and configured to engage with an interior surface of the slot (24), and means for supporting the drill (42) from a stationary platform adjacent to the rotor (18). A method for modifying a slot (24) in a rotor (18) includes connecting a coupling (100) to a stationary platform adjacent to the rotor (18), connecting a drill (42) to the coupling (100), and locating the drill (42) proximate to the slot (24). The method further includes inserting a clamp (80) into the slot (24), engaging the clamp (80) with an interior surface of the slot (24), and operating the drill (42) to create a cavity in the slot (24).