Segmented Turbine Cover Assembly for Maintenance Access
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Solution Overview
Problem
Existing gas turbine engine cover plate assemblies are complex to install and maintain, requiring removal of multiple cover plates for access, which delays turbine operation and increases maintenance costs due to the need for complicated machining and field customization.
Innovation Solution
A segmented cover assembly for a turbine rotor with circumferentially mounted cover segments, featuring first and second lips that fit into radially offset grooves, and fasteners that secure the cover body to the rotor or blades, allowing for easy installation and removal without disturbing other segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional cover plate assemblies are used to shield the turbine rotor from hot combustion gases, then the rotor is protected from thermal damage, but the assembly requires complicated machining and customization that increases manufacturing complexity and cost
Solution Approach 1:
The cover plate is divided into multiple segments that can be individually installed and removed. Each segment is a simplified component that can be manufactured with standard machining processes, eliminating the need for complex custom machining of a single large cover plate while still providing complete protection when assembled.
Solution Approach 2:
The cover segments are designed to fit together in a nested arrangement around the turbine rotor, with each segment containing features like lips that fit into grooves and receptacles for fasteners. This nested structure provides complete coverage through simple individual components.
2Object-affected harmful factors
If multiple cover plates are used to provide complete coverage, then the rotor is fully protected, but removal of multiple cover plates is required for maintenance and replacement, thereby delaying turbine operation and increasing maintenance costs
Solution Approach 1:
The cover assembly is segmented into multiple independent sections that can be accessed and removed individually. This allows maintenance personnel to remove only the specific segment that needs service rather than disassembling the entire cover assembly, significantly reducing maintenance time while maintaining complete coverage when all segments are installed.
Solution Approach 2:
Each cover segment is designed with specific local features (lips, grooves, fastener receptacles) tailored to its position and function, allowing localized maintenance and replacement without affecting other segments, thus enabling targeted maintenance operations.
3Object-affected harmful factors
If cover plates are customized in the field for installation, then fit and protection are improved, but the complexity of installation and the need for field customization increases
Solution Approach 1:
The cover is divided into standardized segments with pre-designed fitting features that simplify field installation. Each segment includes integrated lips that fit into corresponding grooves and receptacles for fasteners, eliminating the need for complex field customization while ensuring proper fit and protection.
Solution Approach 2:
The cover segments are designed with self-aligning and self-securing features, where the lips automatically fit into the grooves and the fasteners engage with the receptacles, reducing the skill level and time required for field installation without compromising fit quality.
Data Source
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AI summary
A system includes a turbine having a turbine rotor (54), a plurality of blades (48), and a segmented cover assembly. The turbine rotor (54) includes a blade mounting region (58) with a plurality of blade mounts (50) disposed circumferentially about a rotational axis (68) of the turbine rotor (54), and first and second grooves (64,66) extending circumferentially along the blade mounting region (58) at a radial offset from one another relative to the rotational axis (68). The plurality of blades (48) is disposed in the plurality of blade mounts (50). The segmented cover assembly includes a plurality of cover segments (74) configured to mount in the first and second grooves (64,66) circumferentially along the blade mounting region (58). Each cover segment (74) includes a cover body (70) and at least one fastener (72). The cover body (74) has first and first and second lips (94,98) extending along first and second circumferential portions (96,100) of the cover body (70), wherein the first lip (94) is configured to mount circumferentially along the first groove (64) and the second lip (98) is configured to mount circumferentially along the second groove (66). The at least one fastener (72) is configured to retain the cover body (70) to the turbine rotor (54) or one of the plurality of blades (48). A corresponding method of mounting the cover segment is als provided