CN1103341A - Process for installation of in-situ welded large-size disc type water-wheel generator rotor support - Google Patents
Process for installation of in-situ welded large-size disc type water-wheel generator rotor support Download PDFInfo
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Abstract
The welding technology for in-situ installation of disk-type water-wheel generator rotor supporter features use of CO2-gas protection welding and development of a complete set of welding steps, sequence and manner to control the relationship between welding parameters. The rotor supporter with diameter over 10 m and steel plate thickness over 30 mm may be successfully welded at once without high environmental requirements and monitoring meters.
Description
The invention belongs to what disc type water-wheel generator rotor support welding procedure, be specifically related to the welding technique of large-size disc type water-wheel generator rotor support in the erecting bed.
What disc type water-wheel generator adopted in the past is wheel arm composite fabricated rotor support, promptly takes turns between arm and the centerbody to be connected by bolt, and this connected mode rigidity is low, can not satisfy the requirement of large capacity hydroelectric generator packet size increase.At present, though large-sized water turbine generator adopts the disc rotor supporting structure to satisfy the requirement of rigidity, but it is big by the what volume, transportation is inconvenient, and transportation the time causes the distortion of disk plane easily, therefore centerbody and some fan-shaped outer rings are made with the large-size disc type water-wheel generator rotor support bulk-breaking by manufactory, are transported to the erecting bed, and assembly welding one-tenth is whole at the scene by installation unit.
At present, large-size disc type water-wheel generator rotor support assembly welding at the scene also belongs to the starting stage, by the diameter of what large-size disc type water-wheel generator rotor support generally more than 10 meters, fan-shaped outer ring steel plate thickness is more than 30 millimeters, under the situation about working under hard conditions in the erecting bed, work brings difficulty to assembly welding.If adopt manual electric arc welding, the weld seam first-time qualification rate is low, and welding interval is long, amount of contraction is big, and each secter pat amount of contraction is wayward, produces excessive deformation if the improper meeting of control causes centerbody and integral support, each sector that causes disk consequently can not use not in a plane.For preventing that manual arc is welded in the excessive deformation that produces in the welding process, to load onto hundred instrument monitorings during a support welding, the surveillance and control measure complexity, manpower and materials consumption is big, even if like this, can not satisfy quality requirement.If use CO
2Gas shielded arc welding generally also can only weld the flat thin steel plate.Will use steel hundreds of ton to steel plate thickness at the large-size disc type water-wheel generator rotor support more than 30 millimeters, make the distortion of rotor field spider disk excessive by the what assembly welding method is improper, so that can not use, this problem does not also have fine solution at present.Therefore, how to weld large-size disc type water-wheel generator rotor support in the erecting bed, making it once successfully is current a great problem.
The object of the present invention is to provide a kind of in the erecting bed, the welding large-size disc type water-wheel generator rotor support process.Require this method can solve diameter more than 10 meters, fan-shaped outer ring steel plate thickness is in the welding of the large-size disc type water-wheel generator rotor support more than 30 millimeters.And solve under the situation about working under hard conditions in the erecting bed, do not establish a large amount of dial plate monitoring, reduce post welding distortion, satisfy the design size requirement, and can once weld a successful difficult problem.
Main points of the present invention are: adopted the CO that makes the weldment contraction distortion little
2Gas shielded arc welding.On welding procedure, again according to the disc holder shape, promptly circularly formulated complete welding step in all directions characteristics of symmetry all, the whole weldering of some postwelding earlier earlier is fixed together each parts with spot welding, control distortion easily during therefore whole weldering.When spot welding or seam weldering, take left and right intersection weldering, from the centre alternately skip welding up and down of weld seam, segmentation regresses and welds, and positive and negative is the multiple form that is symmetrically welded of weldering alternately, and the contraction of weldment on all directions is compensated at any time, simultaneously, the control welding parameter strengthens with the welding process.Owing to adopted above-mentioned various measure, can control the unlikely generation excessive deformation of weldment like this.
The object of the present invention is achieved like this: when large-size disc type water-wheel generator rotor support is assembled in the erecting bed, mainly with centerbody, the fan-shaped outer ring that is connected with centerbody, and be uniformly distributed along the circumference be fixed on the main stud secondary stud assembly welding together, the process of welding is to adopt CO
2Gas shielded arc welding, the step of welding, in proper order, mode, CO
2The parameter selection and the concrete measure of gas shielded arc welding are as follows:
One, Han Jie step, in proper order, mode:
A. Han Jie step is as follows:
(1) begins to carry out spot welding.With the preliminary assembly welding of each parts together, to the weld seam of form of the same race, the solder joint number is identical, under the situation of position symmetry, uses CO
2The identical parameters of gas shielded arc welding is carried out spot welding in the same way;
(2) formally weld disc holder.On the basis of spot welding, all should select symmetric position to the weld seam of form of the same race, take same mode to weld, the CO of usefulness
2Each parameter of gas shielded arc welding all should be identical, every weld seam is all combined by N layer layer, and every layer is adopted the welding of M bar arrow path, and each layer arrow path divides the position of segment interface interleaved between levels, every weld seam is backing welding between, two layer all, checks and continues welding again after errorless;
(3) weld secondary stud.To join and dig between the good secondary stud and main stud, make progress, replace spot welding downwards from the centre, spot welding is highly identical, then in the regress mode of weldering of segmentation, carrying out integral body according to the order of intersecting about from bottom to top welds, at last the countersunk bolt on through hole on the secondary stud and the main stud is carried out plug welding, welding hockets upwards, downwards from secondary stud centre.
B. Han Jie order is: the upright seam of weldering is earlier all taked in the formal welding of spot welding and disc holder, and the weld-ring that continues seam welds radial slot at last.
C. the welding manner of three kinds of weld seams is:
Upright seam: take skip welding to two ends respectively from the middle part of upright seam, and alternately weldering of positive and negative;
Circumferential weld: every section circumferential weld is taked segmentation room for manoeuvre skip welding mode, earlier in the middle of the weldering, more respectively to the both sides skip welding; Radial slot: ground floor is taked the skip welding mode, and respectively to the two ends welding, each layer taked the mode that segmentation regresses and welds later on from the centre, and the principal direction of welding is carried out from the center of circle to circumferencial direction or from circumferential center of circle direction intersection;
Two. the relation of each parameter during welding:
A. speed of welding and bonding power increase according to upright seam, circumferential weld, the welding sequence of radial slot and the welding bead of every weld seam, are adjusted toward big by little;
B. under the fixing situation of core diameter and weldingvoltage, generally change CO by regulating welding current
2The flow of gas, the welding current value is adjusted toward big by little according to the increase of throat depth of the same race.
Three. some concrete measures during welding:
A. to the welding at position, plane:, take single face welding and double face shaping at the reeded ceramic substrate of the back side of welding position, plane adhesive surface;
The control of environment temperature when B. welding: when environment temperature is lower than 5 ℃, should be heated to Celsius more than 80 ℃.In each layer welding process, temperature difference between strict key-course should little what 150 ℃.
C. use CO
2The crator that need not remove spot welding during gas shielded arc welding can directly carry out tack welding on crator.
The invention has the advantages that:
1. hydrogenerator is the visual plant in power station, and the quality of level is installed, directly influence operation generating.The installation of large-sized water turbine generator, especially disc rotor support, because of its diameter more than 10 meters, size is huge, welds the bad distortion that is easy to generate.If can not meet design requirement, can not the once mounting success, will influence construction speed, the influence generating duration, cause tremendous economic loss.Therefore can large-size disc type water-wheel generator rotor support once weld success, and hydroelectric generation is had very important influence.The present invention uses CO
2Gas shielded arc welding technology is once welded success in the erecting bed, solved a great problem in the installation, and this is to the installation of large-size disc type water-wheel generator rotor support from now on, and especially the installation to the Three Gorges Projects generating set provides effective method.
2. do not have at the scene can adopt CO under the situation of mounting platform
2Gas shielded arc welding without complex device, is not established dial plate, need not monitor, and one time assembly welding is successful, has solved the technology difficult problem of large-size disc type water-wheel generator rotor support building site assembly welding.
3. take a series of assembly welding measures by what,, intersect weldering such as balanced welding, skip welding, it is little that disc face is shunk, and be out of shape for a short time, and welding stress is little, misaligns heart body and exerts an influence, and satisfies the design size requirement, so has improved the welding first-time qualification rate.
4. adopt CO
2Gas shielded arc welding can be realized single face welding and double face shaping, and welding efficiency improves more than 2 times than manual electric arc welding.
The invention will be described further below in conjunction with accompanying drawing:
Accompanying drawing 1: large-size disc type water-wheel generator rotor support plane;
Accompanying drawing 2: large-size disc type water-wheel generator rotor support elevation;
Accompanying drawing 3: large-size disc type water-wheel generator rotor support weld seam distribution plane;
Accompanying drawing 4: upright seam spot welding schematic diagram;
Accompanying drawing 5: circumferential weld spot welding schematic diagram;
Accompanying drawing 6: radial slot spot welding schematic diagram;
Accompanying drawing 7: upright seam welding artwork;
Accompanying drawing 8: girth welding artwork;
Accompanying drawing 9: radial slot welding procedure figure;
Accompanying drawing 10: secondary stud welding procedure figure;
Embodiment 1:
The step of welding, in proper order, mode is as follows:
1. begin to carry out spot welding.For the control welding deformation, at first assembly is carried out spot welding, with the preliminary assembly welding of each parts together, and then formally weld disc holder and the secondary stud of welding.The order of welding is: the upright seam of weldering earlier, the weld-ring that continues seam welds radial slot at last.
During spot welding, to the spot welding position of the weld seam of form of the same race in 180 degree direction symmetries.The solder joint number is identical, and solder joint length 80-100MM, upright seam, circumferential weld welded spot pitch be apart from 400MM, throat depth 6-8MM, radial slot spot welding spacing 200MM, solder joint height 6-8MM.Upright seam weldering 6 points, circumferential weld welds 4 points at each support, radial slot spot welding 6 points.During welding, the welder uses CO on symmetric position
2The identical parameters of gas shielded arc welding is carried out simultaneously.Welding current 110-130 ampere; Voltage 21-24 volt; Speed of welding 140-160 mm/min.
The spot welding mode of three kinds of weld seams:
The 1st from the middle part of upright seam welds the 2nd point to two ends respectively, the 3rd point ..., carry out in the skip welding mode, as shown in Figure 4.
Circumferential weld is to weld the every mid point 1 that sector is connected with centerbody earlier, and then welds the 2nd point, the 3rd point of both sides respectively with the skip welding mode ..., as shown in Figure 5.
Radial slot is first spot welding intermediate point 1, then spot welding point 2, point 3, point 4 ..., as shown in Figure 6.
2. formally weld disc holder; On the basis of spot welding, the upright seam of weldering earlier by 5 welders, is symmetrically welded simultaneously, along upright seam short transverse, take the skip welding mode to two ends respectively by the middle part, and the positive and negative welding that hockets, weld 6 layer of 11 road welding bead, as shown in Figure 7, all identical to the welding manner of the upright seam of each bar.
With CO
2Each parameter of gas shielded arc welding is also all identical.
After upright seam has welded, the weld-ring seam.Select the bigger weld seam of circumferential weld outer ring assembly deviation earlier, on symmetry direction,,, take the technology of single face welding and double face shaping, can make root of weld penetration like this at the reeded ceramic substrate 7 of the back side of weld seam adhesive surface by 5 welders welding up and down simultaneously.On every section circumferential weld, take segmentation room for manoeuvre skip welding mode, in the middle of the weldering, more respectively to the both sides skip welding, weld 6 layer of 10 road welding bead altogether, the minimum 30-50MM that staggers of welding line joint between each layer earlier.The welding manner of all circumferential welds is all identical, sees Fig. 8.
During the weldering radial slot, weld simultaneously up and down in symmetric position by 4 welders, ground floor is taked the skip welding mode, and respectively to the two ends welding, each layer taked the mode that segmentation regresses and welds later on from the centre, the principal direction of welding is that the second layer welds to circumferencial direction from the center of circle, the 3rd layer is that so each layer intersection carried out, and welds 5 layers altogether from the welding of circumferential center of circle direction, 10 road welding beads, as shown in Figure 9.
3. weld secondary stud at last.As shown in figure 10, join according to the size of main stud 8 and to dig secondary stud, be fixed by bolts on the main stud, and last digging 20 good secondary studs, in, down and between spot welding 10 places, every place's spot welding 100MM, by the centre make progress, alternately spot welding downwards, weld high 5-6MM.Be evenly distributed on symmetrical welding on the circumference by five welders then, with segmentation regress weldering mode from bottom to top, from left to right chi sequence carries out integral body and welds, every segment length 200MM, solder joint height is identical.Afterwards plug welding is carried out in the slit between the countersunk bolt on through hole on the secondary stud and the main stud, in the middle of secondary stud, made progress the welding that hockets, weld seam section length 200MM, welding current 90-100A, voltage 24-26V downwards.
The relation of each parameter during welding:
A. speed of welding and bonding power are according to upright seam, and circumferential weld, the welding sequence of radial slot and the welding bead of every weld seam increase by little to be adjusted toward big, and the variation of each parameter sees following table for details:
B. be under the situation of 1.2MM and weldingvoltage 22-24V at core diameter, general by regulating welding current change CO
2The flow of gas, the welding current value is adjusted toward big by little according to the increase of throat depth of the same race, is example to weld upright seam, full weld thickness 30MM, each parameter changes as follows:
Radial slot, the parameter situation of change of circumferential weld and last same.
The temperature that will control environment during welding when environment temperature is lower than 5 ℃, should be heated to more than 80 ℃ in each layer welding process, and the little what of temperature difference is 150 ℃ between strict key-course.
Use CO
2The crator that need not remove spot welding during gas shielded arc welding can directly carry out tack welding on crator.
Each bar weld seam all carries out backing welding when welding one, two layer, after the passed examination, down carry out again.After all having welded, check according to a conventional method, meet code requirement.Construction results is: the weld seam first-time qualification rate is 95.3%, and the weld seam contraction distortion is 1-3MM.
Embodiment 2: disc type water-wheel generator rotor support is made up of centerbody and 8 fan-shaped outer rings, adopts CO
2Gas shielded arc welding, the step of welding, in proper order, mode, parameter control and concrete measure are identical with example one, weld seam first-time qualification rate 97% consequently, radius maximum collapse value 3MM, average 2MM.Welding stress does not cause the change of centerbody flange form and position tolerance.
Claims (1)
- When 1, large-size disc type water-wheel generator rotor support is assembled in the erecting bed, mainly with centerbody, the fan-shaped outer ring that is connected with centerbody, and be uniformly distributed along the circumference be fixed on the main stud secondary stud assembly welding together, the process of welding is characterised in that and adopts CO 2Gas shielded arc welding, the step of welding, in proper order, mode, CO 2The parameter selection and the concrete measure of gas shielded arc welding are as follows:One. the step of welding, in proper order, mode:A. Han Jie step is as follows:(1) begin to carry out spot welding, identical to the weld seam solder joint number of form of the same race with the preliminary assembly welding of each parts together, under the situation of position symmetry, use CO 2The identical parameters of gas shielded arc welding is carried out spot welding in the same way;(2) formally weld disc holder, on the basis of spot welding, all should select symmetric position, take same mode to weld, the CO of usefulness the weld seam of form of the same race 2Each parameter of gas shielded arc welding all should be identical, and every weld seam is all combined by N layer layer, and every layer is adopted the welding of M bar arrow path, each layer arrow path divides the position of segment interface interleaved between levels, every weld seam backing welding between, two layer is checked and is continued welding again after errorless;(3) weld secondary stud, to join and dig between the good secondary stud and main stud, make progress, replace spot welding downwards from the centre, spot welding is highly identical, then in the regress mode of weldering of segmentation, carry out integral body weldering according to the order of intersecting about from bottom to top, at last the countersunk bolt on the through hole on the secondary stud and the main stud is carried out plug welding, make progress from secondary stud centre, welding hockets downwards;B. Han Jie order is: the upright seam of weldering is earlier all taked in the formal welding of spot welding and disc holder, and the weld-ring that continues seam welds radial slot at last;C. the welding manner of two kinds of weld seams is:Upright seam: take skip welding to two ends respectively from the middle part of upright seam, and alternately weldering of positive and negative;Circumferential weld: every section circumferential weld is taked segmentation room for manoeuvre skip welding mode, earlier in the middle of the weldering, more respectively to the both sides skip welding;Radial slot: ground floor is taked the skip welding mode, and respectively to the two ends welding, each layer taked the mode that segmentation regresses and welds later on from the centre, and the principal direction of welding is carried out from the center of circle to circumferencial direction or from circumferential center of circle direction intersection;Two. the relation of each parameter during welding:A. speed of welding and bonding power stitch according to upright, circumferential weld, and the welding sequence of radial slot and the welding bead of every weld seam increase, and are adjusted toward big by little;B. under the fixing situation of core diameter and weldingvoltage, generally change CO by regulating welding current 2The flow of gas, the welding current value is adjusted toward big by little according to the increase of throat depth of the same race;Three. some concrete measures during welding:A. to the welding at position, plane:, take single face welding and double face shaping at the reeded ceramic substrate of the back side of welding position, plane adhesive surface;The control of environment temperature when B. welding: when environment temperature is lower than 5 ℃, should be heated to more than 80 ℃, in each layer welding process, temperature difference between strict key-course, 150 ℃ of little whatsC. use CO 2The crator that need not remove spot welding during gas shielded arc welding can directly carry out tack welding on crator.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN94114847A CN1042107C (en) | 1994-08-13 | 1994-08-13 | Process for installation of in-situ welded large-size disc type water-wheel generator rotor support |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN94114847A CN1042107C (en) | 1994-08-13 | 1994-08-13 | Process for installation of in-situ welded large-size disc type water-wheel generator rotor support |
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| Publication Number | Publication Date |
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| CN1103341A true CN1103341A (en) | 1995-06-07 |
| CN1042107C CN1042107C (en) | 1999-02-17 |
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|---|---|---|---|
| CN94114847A Expired - Fee Related CN1042107C (en) | 1994-08-13 | 1994-08-13 | Process for installation of in-situ welded large-size disc type water-wheel generator rotor support |
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