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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