CN101053926A - Axial-flow rotary propeller type water turbine runner blade crackle treating method - Google Patents
Axial-flow rotary propeller type water turbine runner blade crackle treating method Download PDFInfo
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- CN101053926A CN101053926A CN 200710049214 CN200710049214A CN101053926A CN 101053926 A CN101053926 A CN 101053926A CN 200710049214 CN200710049214 CN 200710049214 CN 200710049214 A CN200710049214 A CN 200710049214A CN 101053926 A CN101053926 A CN 101053926A
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Abstract
The invention discloses a crack treating method for an axial turning blade hydro-turbine runner, wherein the runner can be repaired in situ without being hoisted out from a runner chamber. 'R' value of round corner of one front side of the blade on exit edge which is connected with a root flange is enlarged intentionally; crack arrest holes are drilled on end part of crack, with different shaped groove for different crack, and the preheat, patch weld and heat preservation are carried out based on predetermined process order. The invention has the following advantages: construction on-the-spot, restoration in short period, avoided miscellaneous disassembly and assembly work, saved transportation cost, good weld restoration strength and stiffness, strong crack resistance, thus the invention can satisfy the work requirement of the axial turning blade hydro-turbine runner after repairing the crack.
Description
Affiliated field
The present invention relates to crackle processing method, particularly axial-flow rotary propeller type water turbine runner blade crackle treating method.
Background technology
Movable propeller turbine, by long use, blade will produce crackle in various degree.The reason that crackle produces mainly comprises following aspect: the one, because the long-term underload of unit, excess load or, make runner bucket under the alternate stress effect, produce the crack or aggravated the development of crackle in the bad vibrating area operation of operating mode; The 2nd, because the kaplan turbine runner blade is a cantilever force, crackle appears in blade variable cross-section root if no transition arc or amount of transition hour easy generation stress is concentrated.Cantilever runner bucket Root Stress in the unit operation is concentrated, the suffered basic stress of blade is higher, and the dynamic stress the during synergy of various load is bigger in addition, and the suffered alternation dynamic stress of blade has been aggravated fatigue of materials, produce fatigue rupture, cause runner bucket to crack.
Summary of the invention
Purpose of the present invention promptly is to overcome the shortcoming of prior art, provides a kind of repair process at the scene, the axial-flow rotary propeller type water turbine runner blade crackle treating method that the cycle is short, expense is low.
Purpose of the present invention is achieved through the following technical solutions: axial-flow rotary propeller type water turbine runner blade crackle treating method, runner without lifting goes out runner envelope, repair at the scene, have a mind to strengthen " R " value that face of blade goes out the excessive fillet that waterside one side is connected with the root flange with the method for built-up welding; Afterbody at crackle bores stop hole, and different crackles is adopted difform groove, in accordance with regulations process sequence preheating, repair welding and insulation, and it may further comprise the steps:
(1) preparation
(a) blade is beaten to fully open position, simultaneously to blade just, back side crackle handles;
(b) set up workbench;
(c) pull down the pivot sealing;
(d) blade and runner envelope are fixed, added suitable support fixation simultaneously between blade and web, it is stressed to reduce the blade axle journal;
(2) removing of crackle
(a) check sharf neck position front and back with PT flaw detection comprehensively and go out the waterside positive and make the visible marking;
(b) remove preceding the beating of crackle and only prolong the hole, bore the diameter that only prolongs the hole and be about 8mm, the big 4～6mm of hole depth rate crack depth in the line tail bit of crackle;
(c) rooting out of crackle adopts carbon arc air gouging to exclude, before removing crack site is reached near the 200mm scope with 80 ℃～100 ℃ of oxy-acetylene preheatings, the carbon arc air gouging direction should be removed to direction of check from stop hole, and till crackle was peace and quiet, carbon arc air gouging must be interrupted use;
(d) leave the repair welding groove during carbon arc air gouging simultaneously.
(e) after defective is thoroughly removed totally, the case-carbonizing oxide layer of groove is polished with mushroom hair style abrasive machine;
(f) confirm that with PT flaw detection crackle treats repair welding after thoroughly peace and quiet.
(3) welding
(a) welding rod must be dried 2h before using under 350 ℃ of temperature, is incubated under 100 ℃ of constant temperature.
(b) before weldering, rejected region is carried out integral body or local preheating, runner envelope environment temperature integral body is heated to 30～40 ℃, to adopting oxy-acetylene flame local preheating in repair welding position and near the 200mm scope, temperature rise speed is advisable with 8～10 ℃/h, temperature is controlled at 80-120 ℃, and preheat temperature reaches after the requirement again that constant temperature 2～4h can weld.
(c) welding adopts thin layer, segmentation, room for manoeuvre solder technology;
(d) in the welding process except that bottom and superficial layer every layer adopt hammering method to eliminate stress;
(e) use the slow cooling of asbestos cloth covering and heat insulating after the repair welding immediately;
(4) cleaning, polishing
Postwelding is removed welding slag, is splashed, with the slick and sly into treatment sites of the suitable vane type line reconditioning of emery wheel;
(5) PT flaw detection and inspection
Into treatment sites and hot shadow zone are carried out " PT " defect detecting test, and qualified back is removed and is supported, and inspection distortion situation and polishing are supported spot welding place to slyness.
Leave the repair welding groove during carbon arc air gouging simultaneously, the form of groove is mainly according to crackle situation, position with root out and weld and convenient decide, all crackles that does not penetrate, the degree of depth at 30mm with interior opening " V " shape groove, the degree of depth opening more than 30mm " U " shape groove is near employing " V " the shape groove of root; All crackles that penetrates, the degree of depth at 40mm with interior opening " X " shape groove, near root open " K " shape groove, the need of thickness more than 40mm are opened " U " shape groove, near root open " K " shape groove, the groove root repairs suitable fillet R.
Welding adopts Austria 307 and G232 stainless steel electrode during welding, welding rod specification Φ 3.2, Φ 4, and 307 stainless steel electrodes wherein difficult to understand are used for bottom and intermediate layer, and the G232 stainless steel electrode is used for capping and built-up welding R part.
Welding adopts thin layer, segmentation, room for manoeuvre solder technology, long weld seam is taked the segmentation weldering, every segment length 100～150mm, the above not chemistry of 300mm is taked segmentation room for manoeuvre weldering, can be below the 300mm by the centre to outside weld, the sectionalizing joint place should successively overlap, and weld seam takes turns to weld just on the contrary, to the groove of the degree of depth more than 40mm, should use bilateral fringing welding technology; To the degree of depth below 40mm and by the then available one-sided fringing welding technology of groove of root of blade, should behind its face bonding 2--3 road weld seam, root out the overlap of groove bottom again with pneumatic shovel at its back side to through wall flaw, begin welding when waiting to expose new weld seam again, in the crackle repair welding, under which floor adopts little electric current as far as possible and lacks electric arc (general 2～2.5mm) with the welding rod of diameter 3.2mm and under the situation that guarantees through welding, and the control interlayer temperature must not be greater than 120 ℃, welding order should first repair welding axle journal middle part, and repair welding goes out the position, waterside again.
By top narration as can be seen, the present invention has the following advantages: site operation, repairing efficiency is short, avoided numerous and diverse disassemble and assemble work, saved cost of transportation, REPAIR WELDING place intensity, stiffness are good, and crack resistance is strong, can satisfy the job requirement of axial-flow rotary propeller type water turbine runner blade after the crackle reparation.
The specific embodiment
The present invention will be further described below in conjunction with the specific embodiment, position, shape, the length of the crackle through turbine runner blade is checked out and the direction that may continue to develop have been carried out comprehensive analysis, take the specific aim measure that the blade crackle is repaired, strictness is carried out recovery scenario and is observed welding procedure when blade is repaired.Runner without lifting goes out runner envelope, repairs at the scene, is the intensity of reinforced blade root, has a mind to strengthen " R " value that face of blade goes out the excessive fillet that waterside one side is connected with the root flange with the method for built-up welding; Afterbody at crackle bores stop hole, and different crackles is adopted difform groove, in accordance with regulations process sequence preheating, repair welding and insulation, and it may further comprise the steps:
(1) preparation
(a) blade is beaten to fully open position, be beneficial to can be simultaneously to blade just, back side crackle handles.
(b) set up workbench, be advisable with handled easily and assurance safety.
(c) pull down the pivot sealing, sealing strip damages in the process of patch weld to avoid.
(d) blade and runner envelope are fixed,, do not welded, in processing procedure, do not change to guarantee runner and runner envelope gap only with blade and runner envelope gap jam-pack.It is stressed to reduce the blade axle journal to add simultaneously suitable support fixation between blade and web.
(e) in-situ processing should specifically confer with the power station and get ready before processing with instrument, equipment and material.
(2) removing of crackle
(a) check sharf neck position (front and back) with PT flaw detection comprehensively and go out the waterside positive and make the visible marking.
(b) because the afterbody internal stress of crackle near the ultimate strength of material, also can continue to extend under the influence of external force or thermal stress, therefore, before removing crackle, need beat and only prolong the hole, stop the extension of crackle to block crackle in the line tail bit of crackle.Boring the diameter that only prolongs the hole is 8mm, the general big 4～6mm of hole depth rate crack depth.
(c) the employing speed of the rooting out carbon arc air gouging fast, easy and simple to handle of crackle is excluded.Before removing crack site is reached near the 200mm scope with 80～100 ℃ of oxy-acetylene preheatings.For preventing that when excluding crackle because of the extension of the former crackle of temperature effect, the carbon arc air gouging direction should be removed to direction of check from stop hole, till crackle is peace and quiet.Cause the expansion of deformable blade and crackle for preventing that blade is overheated, carbon arc air gouging must be interrupted use.
(d) leave the repair welding groove during carbon arc air gouging simultaneously, the form of groove is mainly according to crackle situation, position with root out and weld and conveniently decide.All crackles that does not penetrate, the degree of depth at 30mm with interior opening " V " shape groove; The degree of depth opening more than 30mm " U " shape groove; Employing " V " shape groove near root.All crackles that penetrates, the degree of depth at 40mm with interior opening " X " shape groove; Open " K ", shape groove near root; The need of thickness more than 40mm are opened " U " shape groove; Open " K " shape groove near root.The groove root repairs suitable fillet R.
(e) after defective is thoroughly removed totally, the case-carbonizing oxide layer of groove is polished with mushroom hair style abrasive machine, grind off the metallic luster that oxide layer is exposed mother metal.
(f) confirm that with PT flaw detection crackle treats repair welding after thoroughly peace and quiet.
(3) welding
(a) be the solderability requirement of guaranteeing intensity, rigidity and the material of repair place, welding employing good mechanical property, crack resistance is strong, plasticity is big Austria 307 and G232 stainless steel electrode, welding rod specification 3.2,4.307 stainless steel electrodes wherein difficult to understand are big because of plasticity, crack resistance is used for bottom and intermediate layer by force; The G232 stainless steel electrode is used for capping and built-up welding R part because of intensity height, erosion resistant.Welding rod must be dried 2h before using under 350 ℃ of temperature, be incubated under 100 ℃ of constant temperature.
(b) concentrate and improve the metallographic structure of weld seam for the stress that reduces the repair welding district, the particularly heat affecting of weld seam and base material transition region, prevent to crack once more, before weldering, rejected region is carried out integral body or local preheating, the runner envelope environment temperature is heated to 30 ℃～40 ℃ with electric stove integral, to adopting oxy-acetylene flame local preheating in repair welding position and near the 200mm scope, temperature rise speed is advisable with 8～10 ℃/h, temperature is controlled at 80-120 ℃, and preheat temperature reaches after the requirement again that constant temperature 2～4h can weld.
(c) weld employing thin layer, segmentation, room for manoeuvre solder technology, long weld seam is taked the segmentation weldering, every segment length 100～150mm, and the above not chemistry of 300mm takes the segmentation room for manoeuvre to weld, can be by the centre to outside weld below the 300mm.Notice preventing to weld that the starting the arc and current interruption crack in the repair process.For preventing the concordant weldquality that influences in joint, the sectionalizing joint place should successively overlap, and weld seam takes turns to weld just on the contrary.To the groove of the degree of depth more than 40mm, should use bilateral fringing welding technology; Below 40mm and by the then available one-sided fringing welding technology of groove of root of blade, should behind its face bonding 2--3 road weld seam, root out the overlap of groove bottom again with pneumatic shovel at its back side to the degree of depth, begin welding when waiting to expose new weld seam again through wall flaw.In the crackle repair welding, beneath which floor adopt little electric current and short electric arc (general 2～2.5mm), and the control interlayer temperature must not be greater than 120 with the welding rod of diameter 3.2mm and under the situation that guarantees through welding as far as possible.Welding order should first repair welding axle journal middle part, and repair welding goes out the position, waterside again.
(d) in the welding process except that bottom and superficial layer every layer adopt hammering method to eliminate stress.
(e) use the slow cooling of asbestos cloth covering and heat insulating after the repair welding immediately.
Note in the processing procedure covering protection being carried out at other positions, weld seam is coated with on every side and prevents splash agent.
(4) cleaning, polishing
Postwelding is removed welding slag, is splashed, with the slick and sly into treatment sites of the suitable vane type line reconditioning of emery wheel.
(5) PT flaw detection and inspection
Into treatment sites and hot shadow zone are carried out PT defect detecting test, and qualified back is removed and is supported, and inspection distortion situation and polishing are supported spot welding place to slyness.
Claims (4)
1, axial-flow rotary propeller type water turbine runner blade crackle treating method is characterized in that runner without lifting goes out runner envelope, repairs at the scene, has a mind to strengthen " R " value that face of blade goes out the excessive fillet that waterside one side is connected with the root flange with the method for built-up welding; Afterbody at crackle bores stop hole, and different crackles is adopted difform groove, in accordance with regulations process sequence preheating, repair welding and insulation, and it may further comprise the steps:
(1) preparation
(a) blade is beaten to fully open position, simultaneously to blade just, back side crackle handles;
(b) set up workbench;
(c) pull down the pivot sealing;
(d) blade and runner envelope are fixed, added suitable support fixation simultaneously between blade and web, it is stressed to reduce the blade axle journal;
(2) removing of crackle
(a) check sharf neck position front and back with PT flaw detection comprehensively and go out the waterside positive and make the visible marking;
(b) remove preceding the beating of crackle and only prolong the hole, bore the diameter that only prolongs the hole and be about 8mm, the big 4～6mm of hole depth rate crack depth in the line tail bit of crackle;
(c) rooting out of crackle adopts carbon arc air gouging to exclude, before removing crack site is reached near the 200mm scope with 80 ℃～100 ℃ of oxy-acetylene preheatings, the carbon arc air gouging direction should be removed to direction of check from stop hole, and till crackle was peace and quiet, carbon arc air gouging must be interrupted use;
(d) leave the repair welding groove during carbon arc air gouging simultaneously;
(e) after defective is thoroughly removed totally, the case-carbonizing oxide layer of groove is polished with mushroom hair style abrasive machine;
(f) confirm that with PT flaw detection crackle treats repair welding after thoroughly peace and quiet;
(3) welding
(a) welding rod must be dried 2h before using under 350 ℃ of temperature, is incubated under 100 ℃ of constant temperature;
(b) before weldering, rejected region is carried out integral body or local preheating, runner envelope environment temperature integral body is heated to 30～40 ℃, to adopting oxy-acetylene flame local preheating in repair welding position and near the 200mm scope, temperature rise speed is advisable with 8～10 ℃/h, temperature is controlled at 80-120 ℃, and preheat temperature reaches after the requirement again that constant temperature 2～4h can weld;
(c) welding adopts thin layer, segmentation, room for manoeuvre solder technology;
(d) in the welding process except that bottom and superficial layer every layer adopt hammering method to eliminate stress;
(e) use the slow cooling of asbestos cloth covering and heat insulating after the repair welding immediately;
(4) cleaning, polishing
Postwelding is removed welding slag, is splashed, with the slick and sly into treatment sites of the suitable vane type line reconditioning of emery wheel;
(5) PT flaw detection and inspection
Into treatment sites and hot shadow zone are carried out " PT " defect detecting test, and qualified back is removed and is supported, and inspection distortion situation and polishing are supported spot welding place to slyness.
2, axial-flow rotary propeller type water turbine runner blade crackle treating method according to claim 1, it is characterized in that, leave the repair welding groove during carbon arc air gouging simultaneously, the form of groove is mainly according to crackle situation, position with root out and weld and convenient decide, all crackles that does not penetrate, with interior opening " V " shape groove, the degree of depth opening more than 30mm " U " shape groove is near employing " V " the shape groove of root at 30mm for the degree of depth; All crackles that penetrates, the degree of depth at 40mm with interior opening " X " shape groove, near root open " K " shape groove, the need of thickness more than 40mm are opened " U " shape groove, near root open " K " shape groove, the groove root repairs suitable fillet R.
3, axial-flow rotary propeller type water turbine runner blade crackle treating method according to claim 1, it is characterized in that, welding adopts Austria 307 and G232 stainless steel electrode during welding, welding rod specification Φ 3.2, Φ 4,307 stainless steel electrodes wherein difficult to understand are used for bottom and intermediate layer, and the G232 stainless steel electrode is used for capping and built-up welding R part.
4, axial-flow rotary propeller type water turbine runner blade crackle treating method according to claim 1, it is characterized in that, welding adopts thin layer, segmentation, room for manoeuvre solder technology, and long weld seam is taked segmentation weldering, every segment length 100～150mm, the above not chemistry of 300mm is taked segmentation room for manoeuvre weldering, can be below the 300mm by the centre to outside weld, the sectionalizing joint place should successively overlap, and weld seam takes turns to weld just on the contrary, to the groove of the degree of depth more than 40mm, should use bilateral fringing welding technology; To the degree of depth below 40mm and by the then available one-sided fringing welding technology of groove of root of blade, should behind its face bonding 2--3 road weld seam, root out the overlap of groove bottom again with pneumatic shovel at its back side to through wall flaw, begin welding when waiting to expose new weld seam again, in the crackle repair welding, under which floor adopts little electric current as far as possible and lacks electric arc (general 2～2.5mm) with the welding rod of diameter 3.2mm and under the situation that guarantees through welding, and the control interlayer temperature must not be greater than 120 ℃, welding order should first repair welding axle journal middle part, and repair welding goes out the position, waterside again.
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