In-Situ Stator Blade Removal Tool for Compressor Maintenance
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Solution Overview
Problem
Current methods for repairing or upgrading compressors require the costly and risky removal of the rotor to change stator blade counts, which is impractical and poses ergonomic hazards due to limited access and high risk of damage to components.
Innovation Solution
A tool with a skid, vibrator, and jaws that can engage and remove stator airfoils in situ, allowing for blade count adjustments without rotor removal, utilizing a power supply and sliding along a groove in the compressor case to facilitate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If rotor removal is performed to change stator blade counts, then blade count adjustment is possible, but cost increases and operational risk increases
Solution Approach 1:
The invention divides the stator assembly into individually removable airfoils that can be removed separately from the rotor assembly. Each airfoil can be independently accessed and removed through the access opening, allowing blade count changes without requiring complete disassembly of the compressor assembly.
Solution Approach 2:
The invention extracts the airfoil removal operation from the rotor removal process. By providing dedicated removal tools that access airfoils through an opening in the rotor assembly, the method separates the stator modification task from the rotor disassembly task, eliminating the need to remove the heavy rotor.
2Adaptability or versatility
If rotor removal is performed to change stator blade counts, then blade count adjustment is possible, but downtime and cost increase
Solution Approach 1:
The stator assembly is segmented into individually removable airfoils that can be accessed and removed through an opening in the rotor assembly. This segmentation allows selective removal of only the necessary airfoils without requiring complete disassembly of the compressor, significantly reducing maintenance downtime.
Solution Approach 2:
The method enables preliminary preparation of replacement airfoils before entering the compressor. Since airfoils can be removed and installed through the access opening, all necessary components can be prepared in advance, and the actual airfoil replacement can be completed quickly during the maintenance window.
3Ease of repair
If traditional removal methods are used, then airfoils can be removed, but ergonomic hazards and operator injury risk increase
Solution Approach 1:
The invention introduces intermediary removal tools that bridge the gap between the operator and the airfoils. These tools are inserted through the access opening to engage and remove airfoils, eliminating the need for operators to reach into the confined space under the rotor where ergonomic hazards exist.
Solution Approach 2:
The invention replaces manual mechanical manipulation of airfoils with specialized removal tools that can be operated from outside the compressor assembly. The tools provide mechanical advantage and controlled force application, substituting the dangerous manual reaching and pulling operations with safe, tool-assisted removal.
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 efficient and safe in-situ removal of stator blades, reducing downtime and costs by allowing compressor modifications without rotor removal, thereby improving operational safety and efficiency.
Implementation Method 1
The tool includes a skid for mounting tool components, a vibrator attached to the skid
Data Source
AI summary
A tool is provided for use in removing at least one airfoil. The tool includes a skid for mounting tool components, a vibrator attached to the skid, at least one jaw connected to a jaw activator. The jaw is configured to engage the airfoil. Power supply means are provided for powering the tool.