Turbine Blade-Anchored Service Tool for In-Situ Flowpath Maintenance
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Solution Overview
Problem
Existing rotary machine inspection and repair methods, such as borescope inspections, struggle to access all locations within the machine, particularly non-rotating components, and often require partial disassembly for maintenance, leading to increased downtime and costs due to limited accessibility and unmitigated damage detection.
Innovation Solution
An insertion apparatus and service apparatus system that allows precise positioning of the service apparatus within the primary flowpath of rotary machines, using a steering interface and guide apparatus to access difficult-to-reach areas, enabling inspection and repair of rotating and stationary components without full disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If borescope inspection is used to inspect rotary machine components, then inspection capability is provided, but accessibility to all locations is limited
Solution Approach 1:
The service apparatus is divided into multiple functional modules including inspection module, repair module, and positioning module that can be independently operated or combined, allowing flexible access to different locations within the rotary machine
Solution Approach 2:
The service apparatus acts as an intermediary tool that bridges the gap between external inspection equipment and internal hard-to-reach components, providing both inspection and repair capabilities in locations previously inaccessible to borescopes
2Ease of repair
If rotary machine is disassembled for repair, then component repair is enabled, but maintenance time and downtime increase
Solution Approach 1:
The service apparatus enables self-service repair capabilities by providing integrated inspection, repair, and positioning functions that can be operated within the rotary machine without complete disassembly, allowing maintenance personnel to perform repairs in-situ
Solution Approach 2:
The service apparatus combines multiple functions including inspection, repair, and positioning into a single universal tool that can service multiple components across different locations, eliminating the need for separate disassembly and repair procedures
3Measurement precision
If damage is detected during inspection, then component condition is assessed, but damage mitigation is delayed until disassembly
Solution Approach 1:
The service apparatus performs preliminary repair actions immediately after damage detection by providing integrated repair modules that can address detected issues in-situ without waiting for disassembly, thus mitigating damage progression
Solution Approach 2:
The service apparatus maintains continuous useful action by seamlessly transitioning from inspection mode to repair mode within the same operational session, eliminating the interruption and delay that occurs when damage must wait for scheduled disassembly
Data Source
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AI summary
A system for use in maintaining a turbine assembly (100) includes a plurality of blades (122, 125) and a plurality of vanes (123, 124). The system includes an insertion apparatus (128) including an insertion end (130), a steering end (132) opposite the insertion end, and a body (162) extending from the insertion end to the steering end. The insertion end is positionable proximate at least one blade of the plurality of blades using a steering interface (138). The system also includes a service apparatus (101) for use in maintaining the turbine assembly. The service apparatus includes at least one maintenance device (180) and an anchoring feature (178). The service apparatus is proximate the insertion end of the insertion apparatus and is positionable in a plurality of orientations via the steering interface. The anchoring feature is configured to releasably couple the service apparatus to at least one blade of the plurality of blades.