CN111889958A - Abrasion repairing method for movable guide vane of water turbine - Google Patents
Abrasion repairing method for movable guide vane of water turbine Download PDFInfo
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- CN111889958A CN111889958A CN202010749276.5A CN202010749276A CN111889958A CN 111889958 A CN111889958 A CN 111889958A CN 202010749276 A CN202010749276 A CN 202010749276A CN 111889958 A CN111889958 A CN 111889958A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
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Abstract
The invention provides a method for repairing abrasion of movable guide vanes of a water turbine, which comprises the following steps: s1) welding the guide vane shaft neck; s2) grinding and shape-adjusting guide vane wing-shaped and R-angle areas; s3) inlaying a stainless steel end face and a stainless steel sleeve; s4) carrying out metal machining on the guide vane repair welding area and the stainless steel sleeve; s5) guide vane repair inspection; s6) assembling the guide vane after the flow surface of the guide vane is sprayed. The invention has the advantages that: and the device is put into installation and use again, and does not need to be manufactured again, so that the operation and maintenance cost of the power station is reduced, and social resources are saved.
Description
Technical Field
The invention relates to the technical field of mechanical part repair, in particular to an abrasion repair method for a movable guide vane of a water turbine.
Background
For a sandy hydropower station, the movable guide vane of the water turbine can cause abrasion due to silt, the comprehensive performance of the water turbine can be reduced when the movable guide vane continuously operates, and even the safe operation of the water turbine is damaged. Because the movable guide vane is a finely processed long shaft neck part, if a repair method of performing repair welding and post-processing on a large number of conventional movable guide vanes is adopted, the part is easy to deform, residual stress cannot be effectively released, and the condition that the joint cannot be installed due to improper size matching is caused. Even if the repaired component can be reinstalled and put into service, the plant overhaul period is reduced due to the reduced performance of the repaired component; and when the hydropower station is overhauled, the flow passage components such as the movable guide vanes are replaced, so that the large remanufacturing cost is required to be invested. The repaired movable guide vane can be installed and used again, the performance of the repaired movable guide vane is approximately equivalent to that of a newly manufactured flow component, the conventional overhaul period of a power station is achieved, material resources can be saved, the operation and maintenance cost of the power station is reduced, and benefits are brought to the power station.
Disclosure of Invention
The invention aims to provide a method for repairing the abrasion of the movable guide vane of the water turbine, which can be installed and used again, does not need to be manufactured again, reduces the operation and maintenance cost of a power station and saves social resources.
In order to achieve the purpose, the invention is realized by the following technical scheme:
a method for repairing abrasion of movable guide vanes of a water turbine comprises the following steps:
s1) repairing and welding guide vane shaft neck
By taking the major axis and the minor axis of the guide vane as the reference, the wing-shaped central line of the guide vane is defined, and the references of two end surfaces of the wing-shaped central line are determined; polishing corners of the wear area, carrying out PT flaw detection on the wear area, and immersing the shaft neck into water for repair welding;
s2) guide vane wing shape and R angle area grinding shape adjustment
Grinding the guide vane airfoil and the R-angle area according to the requirements of a repair drawing; detecting flaws of the guide vane airfoil and the R-angle area PT; turning and shape-adjusting the guide vane;
s3) embedding stainless steel end face and stainless steel sleeve
The upper end surface of the guide vane is exposed, the lower end surface of the guide vane is turned, and a stainless steel plate is embedded on the lower end surface of the guide vane; turning a boss part of the shaft diameter of the guide vane, turning a boss part of the shaft diameter of the guide vane lower shaft, and thermally sleeving a stainless steel sleeve on the boss parts of the shaft diameter of the guide vane and the shaft diameter of the guide vane lower shaft;
s4) carrying out gold processing on the guide vane repair welding area
Roughly turning a guide vane shaft neck, a sealing groove and an airfoil end face; carrying out PT flaw detection on the repair welding area; finely turning guide vane journals, sealing grooves, wing-shaped end faces and minor axis outer edge sizes; machining the size of a meshing surface by a milling machine;
s5) guide vane repair inspection
Drilling an exhaust hole on the lower shaft diameter negative pressure side of the guide vane; carrying out flaw detection on the whole PT of the guide vane repair welding area;
s6) guide vane flow surface spraying post-assembly
Spraying the guide vane flow surface; and pre-assembling the guide vanes with the top cover and the bottom ring.
Further, in the step S1), two guide vanes are simultaneously placed into an iron bucket filled with 2/3 water by gas shielded welding for repair welding of the guide vane journals.
Furthermore, the guide vane long shaft head position digital display dial indicator monitors the welding deformation condition, the periphery of the surface of the guide vane repair welding area is protected by wet cloth, and the temperature between welding seam layers does not exceed 100 ℃ during welding.
Furthermore, the welding is carried out in a small-scale multi-layer and multi-channel skip welding subsection mode, and a small air shovel or a hammer is adopted to hammer a repair welding area after each layer of welding is finished.
Further, in the step S2), two guide vanes are simultaneously placed into an iron bucket filled with 2/3 of water by gas shielded welding for repair welding of the wing profile and the R-corner region of the guide vanes, and the bottoms of the guide vanes are leveled and tamped by wood.
Furthermore, the guide vane long and short shaft bracket dial indicator monitors welding deformation, turns over the front and the back in turn according to the abrasion conditions of the R corner area of the positive and negative pressure side and the shaft neck boss, and performs repair welding, wherein the R corner area of the pressure side and the periphery of the shaft neck boss of the repair welding area are protected by wet cloth, and the temperature between welding seam layers is not more than 100 ℃ during welding.
Furthermore, the welding is carried out in small specifications, multiple layers and multiple paths of skip welding are carried out in a segmented mode, and a small pneumatic shovel or a hammer is used for hammering a repair welding area after each layer of welding is finished. Gas shielded arc welding
Compared with the prior art, the invention has the following advantages:
the invention discloses an abrasion repair method for movable guide vanes of a water turbine, and provides a repair method for controlling repair welding deformation of the movable guide vanes and finally achieving the purposes of roughly equivalent performance to that of newly manufactured movable guide vanes and unchanged installation fit size.
Drawings
Fig. 1 is a schematic view of an assembly structure of a movable guide vane of a water turbine.
Fig. 2 is a schematic view of the whole structure of the movable guide vane of the water turbine.
FIG. 3 is a schematic structural view of a hot jacket stainless steel sleeve and a lower end surface welded stainless steel plate of a movable guide vane of a water turbine according to the present invention.
Fig. 4 is a schematic sectional view a-a of a movable guide vane of a water turbine according to the present invention.
Fig. 5 is a schematic view of the main wear parts of the movable guide vane of the water turbine.
FIG. 6 is a schematic view of a repairing welding operation of a guide vane shaft neck of the abrasion repairing method for the movable guide vane of the water turbine.
FIG. 7 is a schematic view of a repair welding area of a guide vane shaft neck of the abrasion repairing method for the movable guide vane of the water turbine.
FIG. 8 is a schematic view of the guide vane airfoil profile and the R-angle repair welding operation of the method for repairing the movable guide vane of the water turbine in the present invention.
FIG. 9 is a schematic view of a guide vane airfoil profile and an R-angle repair welding area of the method for repairing the movable guide vane of the water turbine in an abrasion manner.
Detailed Description
Embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.
As shown in fig. 1, the installation position of the movable guide vane 1 of the water turbine on the water turbine is shown, and as shown in fig. 2, the overall structure of the movable guide vane 1 is shown, according to the operating principle of the water turbine and the position of the water turbine where the movable guide vane 1 is located, the main wear part of the movable guide vane 1 shown in fig. 5 can be obtained, and the main wear part is an R-angle wear region, that is, A, B, C.
The invention relates to an abrasion repair method for a movable guide vane of a water turbine, which adopts repair welding, stainless steel end surface embedding, stainless steel sleeve embedding, polishing, turning and PT nondestructive inspection repair methods. The purpose of repair welding is to eliminate deeper pits and fill the worn part of the movable guide vane 1; the purpose of inlaying the stainless steel sleeve end face and inlaying the stainless steel sleeve is to reduce the repair welding amount and prevent the repair welding deformation; the purpose of polishing is to smooth the flow surface of the movable guide vane 1; the purpose of turning is to make the repaired movable guide vane 1 meet the requirements of drawing metalworking, meet the requirements of performance and installation; the aim of PT nondestructive inspection is to carry out nondestructive inspection and verification on the repaired position of the movable guide vane 1 and prevent defects.
In order to avoid the deformation caused by a large amount of repair welding, the repair welding is required to be reduced as much as possible, and the deformation is controlled by adopting a proper process. During the repair process, attention is paid to the protection of all the finish machining parts.
Concretely, the abrasion repairing method for the movable guide vane of the water turbine comprises the following steps:
s1) repairing and welding guide vane shaft neck
As shown in fig. 2, the guide vane includes a guide vane wing shape 11, a guide vane upper shaft diameter 12, a guide vane middle shaft diameter 13, a guide vane lower shaft diameter 14, a guide vane journal 16 and an R-angle region 15, wherein bosses are arranged at the guide vane journal 16 on both sides, that is, a boss part of the guide vane upper shaft diameter 13 and a boss part of the guide vane lower shaft diameter 14.
The method comprises the following steps of (1) defining the center line of a guide vane wing-shaped 11 by taking the major axis and the minor axis of a guide vane as a reference, and determining the references of two end surfaces of the wing-shaped; polishing edges and corners of the abrasion area, carrying out PT flaw detection on the abrasion area, and immersing the guide vane shaft neck into water for repair welding;
s2) grinding and shaping guide vane wing-shaped 11 and R-angle area 15
Polishing and repair-welding the guide vane airfoil 11 according to the requirements of a repair drawing, properly performing repair welding on the worn part of the R corner region 15 on the positive pressure side of the guide vane, and paying attention to control welding deformation during repair welding; carrying out PT flaw detection on the guide vane airfoil 11 and the R-angle area 15; and after repair welding, turning and adjusting the shape or polishing for smooth transition.
S3) Embedded stainless Steel plate 5 and stainless Steel Sleeve 6
As shown in fig. 3, the upper end surface 17 of the movable guide vane is exposed, the lower end surface 18 of the movable guide vane is turned, a stainless steel plate 5 (S135) or the like with a proper thickness is insert-welded to the lower end surface 18 of the guide vane, the boss part of the center shaft diameter 13 of the guide vane is turned, the boss part of the lower shaft diameter 14 of the guide vane is turned, and then the boss parts of the center shaft diameter 13 and the lower shaft diameter 14 of the guide vane are sleeved with a stainless steel sleeve 6 (S135) or the like.
S4) carrying out gold processing on the guide vane repair welding area
Roughly turning a guide vane shaft neck, a sealing groove and an airfoil end face; carrying out PT flaw detection on the repair welding area; finely turning guide vane journals, sealing grooves, wing-shaped end faces and minor axis outer edge sizes; machining the size of a meshing surface by a milling machine;
s5) guide vane repair inspection
Drilling an exhaust hole on the lower shaft diameter negative pressure side of the guide vane; carrying out flaw detection on the whole PT of the guide vane repair welding area;
s6) guide vane flow surface spraying post-assembly
Spraying the guide vane flow surface; the movable guide vane 1 is preassembled with the top cover 2 and the bottom ring 3.
Further, in the step S1), as shown in fig. 6 and 7, the two movable guide vanes 1 are simultaneously placed into an iron bucket filled with 2/3 of water by gas shielded welding for guide vane journal repair welding, and the argon arc welding is adopted to control the heat input to be small, so that a half area of the guide vane shaft head must be ensured to be immersed in water. The guide vane long shaft head position digital display dial indicator 4 monitors the welding deformation condition, the periphery of the surface of the guide vane repair welding area is protected by wet cloth to control the temperature, the temperature between welding seam layers does not exceed 100 ℃ during welding, and the welding deformation condition is monitored. The welding is carried out in a small-scale multi-layer and multi-channel skip welding segmented mode, a small air shovel or a hammer is adopted to hammer a repair welding area after each layer of welding is finished, and shrinkage deformation caused by stress concentration is reduced.
Further, in the step S2), as shown in fig. 8 and 9, the two movable guide vanes 1 are simultaneously placed into an iron bucket filled with 2/3 of water by gas shielded welding to repair the wing sections 11 of the guide vanes and the R-corner regions 15, the controllable heat input by argon arc welding is small, half regions of the whole movable guide vanes 1 must be immersed in water, and the bottoms of the guide vanes are leveled and solidly cushioned by wood heads. The guide vane long and short shaft bracket digital display dial indicator 4 monitors the welding deformation condition, turns over in turn in a positive and negative mode in sequence according to the abrasion conditions of bosses at the R corner area 15 of the positive and negative pressure side and the guide vane shaft neck 16 to perform repair welding and control the welding deformation, wet cloth is adopted at the peripheries of the bosses at the R corner area 15 of the pressure side and the guide vane shaft neck 16 of the repair welding area to protect the bosses so as to control the temperature, the temperature between welding seam layers does not exceed 100 ℃ during welding, and the welding deformation condition is monitored. The welding is carried out in a small-scale multi-layer and multi-channel skip welding segmented mode, a small air shovel or a hammer is adopted to hammer a repair welding area after each layer of welding is finished, and shrinkage deformation caused by stress concentration is reduced.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and improvements can be made without departing from the spirit of the present invention, and these modifications and improvements should also be considered as within the scope of the present invention.
Claims (7)
1. A method for repairing abrasion of movable guide vanes of a water turbine is characterized by comprising the following steps:
s1) repairing and welding guide vane shaft neck
By taking the major axis and the minor axis of the guide vane as the reference, the wing-shaped central line of the guide vane is defined, and the references of two end surfaces of the wing-shaped central line are determined; polishing corners of the wear area, carrying out PT flaw detection on the wear area, and immersing the shaft neck into water for repair welding;
s2) guide vane wing shape and R angle area grinding shape adjustment
Grinding the guide vane airfoil and the R-angle area according to the requirements of a repair drawing; detecting flaws of the guide vane airfoil and the R-angle area PT; turning and shape-adjusting the guide vane;
s3) embedding stainless steel end face and stainless steel sleeve
The upper end surface of the guide vane is exposed, the lower end surface of the guide vane is turned, and a stainless steel plate is embedded on the lower end surface of the guide vane; turning a boss part of the shaft diameter of the guide vane, turning a boss part of the shaft diameter of the guide vane lower shaft, and thermally sleeving a stainless steel sleeve on the boss parts of the shaft diameter of the guide vane and the shaft diameter of the guide vane lower shaft;
s4) carrying out gold processing on the guide vane repair welding area
Roughly turning a guide vane shaft neck, a sealing groove and an airfoil end face; carrying out PT flaw detection on the repair welding area; finely turning guide vane journals, sealing grooves, wing-shaped end faces and minor axis outer edge sizes; machining the size of a meshing surface by a milling machine;
s5) guide vane repair inspection
Drilling an exhaust hole on the lower shaft diameter negative pressure side of the guide vane; carrying out flaw detection on the whole PT of the guide vane repair welding area;
s6) guide vane flow surface spraying post-assembly
Spraying the guide vane flow surface; and pre-assembling the guide vanes with the top cover and the bottom ring.
2. The abrasion repairing method for the movable guide vane of the water turbine as claimed in claim 1, wherein: and in the step S1), simultaneously putting two guide vanes into an iron bucket filled with 2/3 of water by adopting gas shielded welding to perform guide vane journal repair welding.
3. The abrasion repairing method for the movable guide vane of the water turbine as claimed in claim 2, wherein: the guide vane long shaft head position digital display dial indicator monitors the welding deformation condition, the periphery of the surface of a guide vane repair welding area is protected by wet cloth, and the temperature between welding seam layers does not exceed 100 ℃ during welding.
4. The abrasion repairing method for the movable guide vane of the water turbine as claimed in claim 3, wherein: and the welding is carried out in a small-scale multi-layer and multi-pass skip welding subsection mode, and a small pneumatic shovel or a hammer is adopted to hammer a repair welding area after each layer of welding is finished.
5. The abrasion repairing method for the movable guide vane of the water turbine as claimed in claim 1, wherein: and in the step S2), two guide vanes are simultaneously placed into an iron bucket filled with 2/3 of water by adopting gas shielded welding to perform repair welding on the wing profiles and the R-angle regions of the guide vanes, and the bottoms of the guide vanes are flatly and solidly cushioned by wood.
6. The abrasion repairing method for the movable guide vane of the water turbine as claimed in claim 5, wherein the abrasion repairing method comprises the following steps: the guide vane long and short shaft bracket dial indicator monitors welding deformation conditions, sequentially turns over the front and the back to repair welding according to the abrasion conditions of the R corner area of the positive and negative pressure side and the shaft neck boss, wet cloth is adopted to protect the R corner area of the pressure side and the shaft neck boss of the repair welding area, and the temperature between welding seam layers is not more than 100 ℃ during welding.
7. The abrasion repairing method for the movable guide vane of the water turbine as claimed in claim 6, wherein the abrasion repairing method comprises the following steps: the welding is carried out in small specifications, multiple layers and multiple paths of skip welding are carried out in a segmented mode, and a small pneumatic shovel or a hammer is adopted to hammer a repair welding area after each layer of welding is finished.
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| CN202010749276.5A CN111889958B (en) | 2020-07-30 | 2020-07-30 | Abrasion repairing method for movable guide vane of water turbine |
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| CN202010749276.5A CN111889958B (en) | 2020-07-30 | 2020-07-30 | Abrasion repairing method for movable guide vane of water turbine |
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