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.

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

Access Hole to the Pintel Area

View Thru Access Hole to the Dragline Base

Sliding Base

Rotating Floor

White Tennis Shoes ??

Repaired Pintel Cracking Right Side

Rotating Floor

Pintel

METALOCKS MASTERLOCKS

Stationary Base

Repaired Pintel Cracking Middle Area

Rotating Floor

Pintel

METALOCKS Stationary Base MASTERLOCKS

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Repaired Pintel Cracking Left Side

Rotating Floor Pintel

METALOCKS MASTERLOCKS Stationary Base

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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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Close up of Head Where Trunnion Broke off

Mill Head

Heavily Eroded Area Trunnion Stub

Remaining Thickness

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New Trunnion Positioned on Head

New Trunnion Rough Machined

METALOCK& METALACE Mill Head

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METALOCK and METALACE Installation

New Trunnion Rough Machined

METALOCKS Being Installed

Mill Head

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Close Up of METALOCK Installation

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Bolting Installed in Inner Flange

Mill Head High Strength Bolts Installed from Mill Head Side Inward Flange of New Trunnion I.D. of New Trunnion

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New Trunnion Installation Nearly Complete

New Trunnion Rough Machined

METALOCK& METALACE Mill Head

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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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Cross Section of New Trunnion/Head Design

Bolts Installed Here

New Trunnion METALOCKS and METALACE Installed Here

Mill Head

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Close Up of Cross Section of New Trunnion/Head Design

Bolts Installed Here

New Trunnion

Mill Head

METALOCKS and METALACE Installed Here

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Repair of Ball Mill Trunnion at a Gold Mine

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.
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Cross Section of Head/Trunnion

Mill Head

Trunnion Cracking

Eroded Area

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Cross Section of Trunnion Area

Cracking

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O.D. of the Trunnion Journal Cracked Area

Cracking

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I.D. Surface Showing The Cracked Area

METALACE

METALOCKS

Heavily Eroded Surface

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Temporary Repair Option with a Reinforcing Sleeve Insert

Repaired Crack Location

Reinforcing Sleeve

Nordback Epoxy Filler Pumped in after Sleeve Had been Installed.

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Optional Permanent Trunnion Replacement

Head Machined to Receive New Trunnion

New Trunnion

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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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Angled Holes being Drilled Thru the Sleeve and into Head

Angle Bolts Installed

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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

Outboard End

Input End
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View of Inside of the Mill Gear Case

Input Side Cracking

Outboard Side

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

Stud Hole Bushing

MASTERLOCKS

METALOCKS

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

METALOCKS

MASTERLOCKS

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Cracking on the Input Side

Cracking

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MASTERLOCK Layout on the Input Side

METALOCK Positions MASTERLOCK Layout

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MASTERLOCK Being Installed on Input Side

MASTERLOCK

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Finished Repair on Input Side

MASTERLOCK METALOCKS

Stud Hole Bushing

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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

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