Turbine Blade Carrier Repairs

Performed at Metalock Engineering Dammam Industrial City II – KSA

Daily Log for 30 dayshifts duration

This project was completed within our company workshop facility in Damman Saudi Arabia under the guidance of engineers from the OEM.

The J seals were supplied and fitted by the OEM technicians then finished machined in situ by the Metalock team.

The new blade shrouds were supplied by the OEM. They were drilled and fitted to 10 rows of blades (upper and lower half casings) and then finished machined by the Metalock team to OEM specifications.

The entire project was completed over 30 dayshifts duration using portable in situ machining equipment.

Day 1

Blade Carrier #1 – Upper Half - J-Seal Machining – in progress

Blade Carrier #2 – Upper Half Joint Blade Machining in progress / Lower Half Joint Blade Pin Locking – in progress

Day 2

Blade Carrier #2 – Upper Half Joint Blade Machining - complete / Lower Half Joint Blade Pin Locking – complete

Blade Carrier #1 - Upper Half J-Seal Machining – complete

Blade Carrier #2 – Lower Half Joint Blade Machining Setup - in progress

New Shroud Banding Inspection and Blue Dye for Layout – complete

Shroud Banding Layout and Setup for Drilling – in progress

Day 3

Blade Carrier #2 – Lower Half Joint Blade Machining – complete

Blade Carrier #2 - Upper Half Joint Blade Pin Locking – complete

Stage 20 Lower Half Shroud Band Drilling – in progress

Blade Carrier #2 - Upper Half – Boring Bar Setup for J-Seal Machining – in Progress

Day 4

Blade Carrier #2 Upper Blade Carrier #2 Lower Half – Stage 20 Shroud Band Fit and Installed w/ Hot Peening – complete

Blade Carrier #2 Lower Half – Stage 20 Shroud Band Fit and Installed w/ Hot Peening – complete

Stage 20 and 21 Shroud Band Drilling – in progress w/ Multiple Setups in use

Day 5

Shroud Band Drilling – continues

Blade Carrier #2 - Setup for Seal Strip machining – in progress

Shroud Band Drilling Layout – continues for all remaining stage

Shrouds 20 and 21 installed w/hot peening in Blade Carrier #2 Upper and Lower haves

Day 6

Blade Carrier #2 - Upper Half – Seat Strip Machining - completed

Blade Carrier #2 – Lower Half – Shroud banding Installation w/Hot Peening – continues

Shroud Band Drilling – continues

Fixture Mfg. and Machine Modifications for Shroud Joint Angle machining – in progress

Day 7

Blade Carrier #2 Upper Half – Shroud Band Installation – continues

Shroud Drilling – continued

Blade Carrier #2 Lower Half – setting up for Shroud Joint Machining

Day 8

Blade Carrier #2 Lower Half – Shroud Band Joint Machining – in progress

Blade Carrier #2 Upper Half – Shroud Band Installation – complete

Layout for Shroud Banding Joint Machining – completed

Blade Carrier #1 – Stage 12 Upper and Lower - Shroud Band Installation - complete

Day 9

Blade Carrier #2 Upper Half – Shroud Band Joint Machining – in progress

Day 10

Blade Carrier #2 Upper Half – Shroud Band Joint Machining – complete

Lower Half – in progress

Day 11

Blade Carrier #2 Lower Half – Shroud Band Joint Machining – complete

Blade Carrier #2 Upper Half – Boring Bar Setup and Shroud Band Machining – commenced

Blade Carrier #1 Upper Half – Milling Machine Setup and Shroud Band Joint Machining – in progress

Blade Carrier #1 Lower Half – Remaining Seal Strips Needed – Installation - in progress

Day 12

Blade Carrier #2 Upper Half – Boring Bar Setup and Shroud Band Machining – continues

Blade Carrier #1 – Seal Strip Installation – complete pending machining

Day 13

Blade Carrier #2 Upper Half – Boring Bar Setup and Shroud Band Machining – continues

Day 14

Blade Carrier #2 Upper Half – Boring Bar Setup and Shroud Band Machining – continues

Day 15

Blade Carrier #2 Upper Half – Shroud Band Machining continues – rough cutting complete on 8 of 10 stages

Day 16

Blade Carrier #2 Upper Half – Shroud Band Machining continues – finish machining in progress

Day 17

Blade Carrier #2 Upper Half – Shroud Band Machining continues – finish machining in continues

Day 18

Blade Carrier #2 Upper Half – Shroud Machining Complete – boring bar transfer to Lower Half - in progress

Day 19

Blade Carrier #2 Upper Half – Shroud Machining Complete – cleaning and deburring - in progress

Blade Carrier #2 Lower Half – Shroud Band Machining – Axial Face Machining - in progress

Day 20

Blade Carrier #1 – Upper Half Joint Shroud Angle Machining - in progress

Blade Carrier #2 Lower Half – Shroud Band Machining – Axial Face Machining – continues

Day 21

Blade Carrier #1 – Upper Half Joint Shroud Angle Machining – complete

Lower Half Joint Shroud Angle Machining – in progress

Blade Carrier #2 - Lower Half – Shroud Band Machining – Axial Face Machining – complete

Beginning Setup and Rough Cut Machining of Diameters

Day 22

Blade Carrier #2 Lower Half – Shroud Band Machining – Rough Cut Machining of Diameters continues

Blade Carrier #1 – Joint Blade Cold Straightening and Hand Blending - complete

Day 23

Blade Carrier #2 Lower Half – Shroud Band – Rough Machining complete – Setup and Final Machining begins

Day 24

Carrier #2 Lower Half – Shroud Band Final Machining – in progress

Day 25

Blade Carrier #2 Lower Half – Shroud Band Final Machining – continues

Day 26

Blade Carrier #2 Lower Half – Shroud Band Final Machining – complete

Boring Bar Disassembled from Blade Carrier #2 and transferred to Blade Carrier #1 Lower Half

Blade Carrier #1 Lower Half – Setup & Shroud Band and Integral Blade Cover Machining – underway

Day 27

Blade Carrier #1 Lower Half – Seal Strip Machining – complete - Blade Shroud Machining – in progress

Day 28

Blade Carrier #1 Lower Half – Blade Shroud Machining complete on 12th stage – 1st & 2nd machining continues

Blade Carrier #2 Upper & Lower Halves – Cleaning and Deburring – complete

Awaiting Test Assembly to verify Shroud Band Joint Gaps

Day 29

Blade Carrier #1 Lower Half – Blade Shroud Machining complete – Deburr and Cleaning – in progress

Boring Bar Transferred to Blade Carrier #1 Upper Half – Setup complete – machining in progress

Day 30

Blade Carrier #1 Upper Half – Shroud Machining – in progress

Blade Carrier #1 Lower Half – Blade Shroud Machining complete – Deburr and Cleaning – continued

Casing Lifting Device Mfg. is in progress

Day 31

Blade Carrier #1 Upper Half – Shroud Machining – complete

Cleaning, Deburring, Shroud Butt Gap adjusting and prep to ship – in progress