In-Situ Stator Vane Modification Tool for Axial Compressors

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Solution Overview

Problem

In axial flow compressors, the removal and replacement of stator vanes with unequal blade counts between upper and lower casing halves are challenging due to geometric constraints and the risk of damaging rotor and stator blades, requiring costly and risky rotor removal and posing ergonomic issues.

Innovation Solution

A tool that allows drilling, tapping, and counter-boring of load dam pin holes in situ, utilizing a drill unit with a motor and gearbox, hydraulic cylinders for clamping and actuation, and a skid that navigates along the compressor's hook fit slots to position and retain the drill, enabling operations without removing the rotor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If rotor removal is performed to change blade counts, then blade count modification is achievable, but cost and time increase significantly

Engineering Contradiction:

Improveblade count modification capabilityVSAvoidoutage duration

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The invention extracts the stator blades from the compressor assembly for replacement while leaving the rotor in place. The upper casing is removed to access and replace stator blades, eliminating the need to extract the entire rotor assembly. This selective extraction approach enables blade count modification while significantly reducing disassembly and reassembly time.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The compressor is segmented into removable upper and lower casing halves, allowing independent access to stator blades without moving the rotor. The stator blade array is further segmented into individual replaceable blades, enabling selective replacement to achieve different blade counts while maintaining the rotor assembly intact.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If rotor removal is performed to change blade counts, then blade count modification is achievable, but cost increases significantly

Engineering Contradiction:

Improveblade count modification capabilityVSAvoidmodification cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention extracts only the necessary components (upper casing and stator blades) for modification while leaving the expensive rotor assembly in place. This selective extraction reduces the scope of work required, lowering labor costs and reducing the risk of damaging expensive components during the modification process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention employs protective measures beforehand by designing a process that avoids rotor removal, thereby preventing potential damage to the rotor and adjacent hardware. The method includes careful removal and reinstallation of the upper casing with pre-aligned stator blades, cushioning against costly damage risks associated with rotor handling.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of repair

If traditional removal methods are used, then blade replacement is possible, but risk of damage to rotor and stator blades increases

Engineering Contradiction:

Improveblade replacement capabilityVSAvoiddamage risk

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

The invention extracts only the upper casing and stator blades for replacement, leaving the rotor assembly stationary and protected. This selective extraction minimizes handling of sensitive components, reducing the risk of damage to rotor and stator blades during the replacement process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

4Adaptability or versatility

If rotor removal is required, then blade count can be changed, but geometric access difficulties arise

Engineering Contradiction:

Improveblade count modification capabilityVSAvoidgeometric accessibility

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The invention extracts the upper casing to provide direct geometric access to the stator blade array. This removal creates an open workspace that allows operators to easily access, remove, and install stator blades without the geometric constraints imposed by the rotor assembly, significantly improving operational ease.

Inventive Principle:

Principle #2Taking out (Extraction)

5Adaptability or versatility

If rotor removal is required, then blade count can be changed, but ergonomic issues and operator injury risk increase

Engineering Contradiction:

Improveblade count modification capabilityVSAvoidoperator safety

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The invention extracts only the upper casing and stator blades, leaving the heavy rotor assembly in place. This approach eliminates the need for operators to handle and reposition the rotor, significantly reducing ergonomic strain and the risk of operator injury while maintaining the ability to modify blade counts.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Facilitates upgrading or repairing compressors by allowing in-situ modification of stator vanes, reducing outage duration and cost, and eliminating the risk of rotor and stator blade damage, while improving operator safety.

Implementation Method 1

hydraulic cylinders for clamping and actuation

Methodology Applied

Scientific EffectHydraulic pressure: Hydraulic Press

Data Source

PatentEP2289655B1Apparatus and tools for use with compressors

Publication Date: 2019.06.19 GENERAL ELECTRIC CO

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AI summary

A tool is provided for use in at least one of drilling, tapping, back spot facing and counter-boring at least one hole. The tool includes a servo motor cutting device (510) and a gearbox (520). The servo motor cutting device and gearbox rotate a cutting tool to create the hole. A drill unit skid (600) is adapted to engage a hook fit slot (833) in the case of the dynamoelectric machine and supports the servo motor drill (510) and gearbox (520).