Post on 02-Mar-2016
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ECRS/METALOCK
Tom Durbin Professional Engineer Mechanical Engineering
Louisiana State University
President
Engineered Casting Repair Services, Inc. and
Metalock Corporation, Inc.
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The Technology Leaders in the Crack Repair Industry
Specializing in
Casting Repair & Restoration
Including
Failure Analysis
Casting Design & Redesign
Repair of Cracked & Damaged Castings
and
Field & Shop Machining
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Utilizing
Our Proven METALOCK Mechanical Repair Techniques.
State of the Art Engineering and Metallurgy.
Finite Element Computer Modeling and Stress Analysis.
Over 150 Years of Combined Experience.
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Examples
Repair of Cracked Pintel on Large Dragline.
Repair of Trunnion/Head on a Ball Mill.
Repair of Ball Mill Trunnion at Gold Mine.
Cracked Gear Case on Coal Pulverizer.
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Repair of Cracked Pintel on
Large Dragline
The Pintel of this dragline was found to
be cracked circumferentially around a
line immediately above the floor of the
pan of the dragline. The cracking
extended approximately 1/3rd around
the circumference of the Pintel and
completely thru the 7 wall thickness.
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This Dragline had a cracked Pintel
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Access Hole to the Pintel Area
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View Thru Access Hole to the Dragline Base
Sliding Base
Rotating Floor White Tennis Shoes ??
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Repaired Pintel Cracking Right Side
MASTERLOCKS
METALOCKS
Pintel
Stationary Base
Rotating Floor
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Repaired Pintel Cracking Middle Area
MASTERLOCKS
METALOCKS
Pintel
Stationary Base
Rotating Floor
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Repaired Pintel Cracking Left Side
MASTERLOCKS
METALOCKS
Pintel
Stationary Base
Rotating Floor
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Repair of Trunnion/Head on a
Ball Mill
The Trunnion and Head on this Mill was a one piece
casting. It became badly eroded when product leaked
behind the trunnion liner and raced around the I.D.
until it eroded nearly thru the 5 thickness of the trunnion wall. When the remaining thickness reached
, the trunnion broke completely off. Our repair consisted of converting the one piece trunnion/head
design to a two piece configuration. The head was
machined to receive the new trunnion which was
attached with METALOCK and METALACE and with
a series of high strength custom bolts.
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Broken off Trunnion
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Mill Head
Trunnion Stub
Remaining Thickness
Heavily Eroded Area
Close up of Head Where Trunnion Broke off
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Mill Head
New Trunnion
Rough Machined
METALOCK& METALACE
New Trunnion Positioned on Head
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METALOCK and METALACE Installation
Mill Head
New Trunnion
Rough Machined
METALOCKS Being Installed
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Close Up of METALOCK Installation
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Bolting Installed in Inner Flange
I.D. of New Trunnion
Inward Flange of New Trunnion
High Strength Bolts
Installed from Mill Head Side
Mill Head
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Mill Head
New Trunnion
Rough Machined
METALOCK& METALACE
New Trunnion Installation Nearly Complete
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Finish Machining of Trunnion After Installation
Trunnion Machining
Mill Head
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Completed Head/Trunnion Ready for Installation on the Mill
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Inside View of Stress Analysis Model
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New Trunnion
Mill Head
Bolts Installed Here
METALOCKS and METALACE
Installed Here
Cross Section of New Trunnion/Head Design
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New Trunnion
Mill Head
Bolts Installed Here
METALOCKS and METALACE
Installed Here
Close Up of Cross Section of New
Trunnion/Head Design
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The Trunnion on this Ball Mill became
severely eroded by product racing
around the I.D. of the Trunnion in the
same manner as the the Mill Presented
above. In this case the trunnion was
cracked but was not broken off. Due to
time constraints the Customer chose a
temporary repair option.
Repair of Ball Mill Trunnion
at a Gold Mine
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Mill Head
Trunnion
Eroded Area
Cracking
Cross Section of Head/Trunnion
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Cracking
Cross Section of Trunnion Area
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Cracking
O.D. of the Trunnion Journal Cracked Area
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METALOCKS
Heavily Eroded Surface
METALACE
I.D. Surface Showing
The Cracked Area
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Reinforcing Sleeve
Nordback Epoxy Filler
Pumped in after Sleeve
Had been Installed.
Repaired Crack Location
Temporary Repair Option with a
Reinforcing Sleeve Insert
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New Trunnion
Head Machined to Receive New Trunnion
Optional Permanent Trunnion
Replacement
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High Spots being ground to clear O.D. of Sleeve Insert
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Sleeve Fitted in Place
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Holes being Drilled from Inside Head
And Tapped into the New Sleeve.
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Angle Bolts Installed
Angled Holes being Drilled
Thru the Sleeve and into Head
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Installation of the New
Reinforcing Sleeve is
Complete and the Mill
Is Ready for the Liner
To be installed and the
Mill Returned to Service.
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Cracked Gear Case on Coal
Pulverizer The Gear Cases on Combustion
Engineering Raymond Type Bowl Mills
(RP3 Models) with bowl sizes of 80 or more are highly subject to cracking.
These cracks occur At 2 specific locations
as described in the following slides. The
cracking in these gear cases can be
readily repaired during a normal overhaul
outage with the techniques shown below.
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Input Side of the Mill Gear Case
Cracked Area
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Outboard Side on the Mill Gear Case
Cracked Area
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Cross Section of the Bowl Mill Case
Cracked Area Cracked Area
Input End Outboard End
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View of Inside of the Mill Gear Case
Input Side Outboard Side
Cracking
Cracking
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View of Outboard Side Cracking
Cracking
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Layout of MASTERLOCKS on Outboard Side
MASTERLOCKS Cracking
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MASTERLOCK on the Top Surface Outboard Side
MASTERLOCK
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Finished Repairs on the Outboard Side
MASTERLOCKS
METALOCKS
Stud Hole Bushing
Stop Drill Stud
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MASTELOCK Layout on Outside of Outboard Side
MASTERLOCKS
Crack End
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MASTERLOCKS Being Installed on Outside
MASTERLOCKS
METALOCKS
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Cracking on the Input Side
Cracking
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MASTERLOCK Layout on the Input Side
MASTERLOCK Layout
METALOCK Positions
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MASTERLOCK Being Installed on Input Side
MASTERLOCK
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Finished Repair on Input Side
MASTERLOCK
Stud Hole Bushing
METALOCKS
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Repair Techniques and
Components
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METALOCK & Metalace
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MASTERLOCK
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ANGLELOCK
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PRELOADED
MASTERLOCK
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KEYLOCK
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TIELOCK
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ECRS/METALOCK
Any Crack
Any Where
Any Time