Abstract: The temporary fastening system for joining upper and lower shell casings of a turbine to one another for maintenance purposes includes a stud/nut tensioning system employed in lieu of the conventional studs and nuts. Once the turbine is opened up and the inner shell and rotor removed, the upper and lower shell casings are temporarily secured to one another using studs received in registering openings in the horizontal flanges of the upper and lower shell casings and retainer plates serving as a stop for the stud/nut tensioning system. The tensioning system is hydraulically operated and avoids torsional force on the temporary studs. Once measurements are made, the turbine is again reopened and reassembled using the initially removed bolts or a third set of bolts to secure the upper and lower shell casings to one another.

Abstract: A self indexing portable automated tenon peening device including: a peening machine in operable communication with a mounting arm; a circumferential slide assembly including a circumferential rail in operable communication with the mounting arm; an axial slide assembly including a axial slide rail in operable communication with the circumferential slide assembly; a base in operable communication with the axial slide assembly; and a programmable logic controller for controlling a position of the circumferential slide assembly and the axial slide assembly.

Abstract: Bucket tip tenons requiring refurbishment are removed from the bucket tips by grinding. Groups of buckets are clamped on a rotatable table in positions adjacent an induction heating coil and a robotic welding arm, respectively. While one group is preheated, the other group of buckets is in a welding location, enabling the welding head on the robotic arm to sequentially apply weld buildup material to the bucket tips. After applying weld buildup material in multiple passes and sequentially to the bucket tips, the buckets are removed, stress-relieved and the weld buildup material machined to provide refurbished tenons. Upon removal of the buckets from the table, the table is rotated to locate the preheated buckets in welding locations and additional buckets are clamped to the table for preheating.

Abstract: A system and method for easily separating upper and lower turbine shells involves forming elongated access pockets vertically aligned across the upper and lower turbine shells and at multiple locations on the turbine shells. Telescoping hydraulic rams are placed into elongated access pockets at each of the multiple locations for lifting the upper shell off of the lower shell. The telescoping hydraulic rams are connected to a controller for controlling each of the rams to operate in parallel with the other rams. Once the turbine shells are separated the upper turbine shell can be removed by conventional block and rigging.

Abstract: Bucket tip tenons requiring refurbishment are removed from the bucket tips by grinding. Groups of buckets are clamped on a rotatable table in positions adjacent an induction heating coil and a robotic welding arm, respectively. While one group is preheated, the other group of buckets is in a welding location, enabling the welding head on the robotic arm to sequentially apply weld buildup material to the bucket tips. After applying weld buildup material in multiple passes and sequentially to the bucket tips, the buckets are removed, stress-relieved and the weld buildup material machined to provide refurbished tenons. Upon removal of the buckets from the table, the table is rotated to locate the preheated buckets in welding locations and additional buckets are clamped to the table for preheating.

Abstract: A machining apparatus is provided. The machining apparatus includes a discharge machining head assembly and a slide assembly supporting the head assembly. The machining apparatus also includes an electromagnet configured to support the slide assembly in a position on a work piece to machine an area. The slide assembly permits linear displacement of the head assembly generally parallel to the supporting work piece surface.

Abstract: A system and method for securing an integral closure bucket to a rotor wheel assembly. The integral closure bucket is inserted in a direction coincident with a radius of the rotor wheel assembly, where the remaining buckets have been previously inserted in a direction parallel to the axis of the turbine rotor wheel. The closure bucket has an integral shroud and is connected to a turbine rotor wheel assembly in which the remaining buckets have been previously inserted in an axial direction. The buckets adjacent the closure bucket are spread apart both tangentially and axially to provide sufficient clearance for the radial insertion of the integral closure bucket. To prevent axial movement of the closure bucket and adjacent buckets, twist locks are utilized in channels provided in the bottom of the female dovetails in the rotor wheel.

Abstract: A system and method for securing an integral closure bucket to a rotor wheel assembly. The integral closure bucket is inserted in a direction coincident with a radius of the rotor wheel assembly, where the remaining buckets have been previously inserted in a direction parallel to the axis of the turbine rotor wheel. The closure bucket has an integral shroud and is connected to a turbine rotor wheel assembly in which the remaining buckets have been previously inserted in an axial direction. The buckets adjacent the closure bucket are spread apart both tangentially and axially to provide sufficient clearance for the radial insertion of the integral closure bucket. To prevent axial movement of the closure bucket and adjacent buckets, twist locks are utilized in channels provided in the bottom of the female dovetails in the rotor wheel.

Abstract: A method has been developed for removing turbine buckets that have become stuck to a turbine rotor wheel. This method includes making two or more first cuts to the base of a female dovetail of the turbine bucket. Two or more second cuts are also made to a lower neck of the female dovetail. The blade of the bucket is broken off at the first cut, which breakage also splits the base of the dovetail into two sections. These sections are pressed down along the second cuts so that they may be removed from the wheel.

Abstract: A method of reducing the formation of burrs during machining of turbine bucket covers of a turbine assembly includes the steps of inserting a filler material in a gap formed between adjacent bucket covers of a turbine assembly, machining the bucket covers to produce a desired profile for the bucket covers, and removing the filler material.