CN112417733A - Comprehensive evaluation method for remaining life of over-service water turbine generator set - Google Patents
Comprehensive evaluation method for remaining life of over-service water turbine generator set Download PDFInfo
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Abstract
The invention provides a comprehensive evaluation method for the residual life of an overdue service hydroelectric generating set, which comprises the following steps: determining key components of the hydroelectric generating set according to the appearance state of the hydroelectric generating set, and giving an on-site appearance inspection evaluation coefficient S according to the appearance state of the hydroelectric generating set1A numerical value; carrying out test detection on key components of the hydroelectric generating set and endowing a test detection coefficient S according to a detection result2A numerical value; obtaining the calculated service life of each key component through the fatigue numerical value calculation analysis of the key components, and obtaining the fatigue calculated service life of the out-of-service hydroelectric generating set after weight distribution and weighted summation are carried out on each key component; acquiring out-of-service hydroelectric generating setYear of operation N2(ii) a And calculating the residual service life N of the super-service water-turbine generator set according to a formula. The invention can accurately evaluate the residual service life of the water-turbine generator set.
Description
Technical Field
The invention relates to the technical field of water conservancy and hydropower engineering, in particular to a comprehensive evaluation method for the residual life of an overdue service hydroelectric generating set.
Background
Since the last 30 s, hydropower, as a renewable energy source, has begun to be developed in disputes in countries around the world. About 220 hydropower stations (installed with more than 25 MW) built and built in 20 th century in China exist, and a batch of hydropower stations built before 80 years run for more than 40 years so far, which plays a great promoting role in the development of national economy in China. According to the regulations of relevant specifications, the life expectancy of the axial flow type water turbine and the bulb type water turbine is 25-50 years, the life expectancy of the mixed flow type water turbine is 30-50 years, and the life expectancy of the generator and relevant electrical equipment is 25-40 years. According to the relevant requirements of the national energy agency, the enterprises with the overdue service units are provided with the requirements of life prolonging modification and safety evaluation and the guidance suggestions of relevant policies and the like, and the relevant enterprises are required to handle permission change in time according to the regulations, and the enterprises which reach the design service life, plan shutdown but do not apply for continuous operation in time according to the regulations or do not apply for the units which do not pass through are not required to handle the permission of change.
For a batch of hydropower stations built in the 80 s of China and before, the hydro-turbo generator set and the electrical and mechanical accessory equipment thereof basically reach the design life of the equipment, and corresponding over-period service safety evaluation must be carried out according to the national regulations, otherwise the normal operation of the hydropower stations must be influenced.
The service life evaluation of the hydroelectric generating set is a complex system engineering, large-scale equipment such as a generator, a water turbine and the like runs for tens of thousands of hours, and actually is a long-term heat treatment or high-strength load test, and the problems of material aging, fatigue damage, insulating medium loss, increase of local discharge amount and the like are inevitable results of long-term action of high temperature, high pressure and pulsating pressure. Especially for the water turbine generator set which is partially out of service, the aging problem is increasingly prominent, the service basis is insufficient for randomly prolonging the service life, and the risk is very high. Therefore, how to scientifically evaluate the residual service life of the water-turbine generator set in service for exceeding the service life and ensure the continuous safe operation of the water-turbine generator set equipment in service for exceeding the service life is a key problem to be solved urgently
Disclosure of Invention
The invention aims to provide a comprehensive evaluation method for the residual life of a water-turbine generator set in an over-service period, aiming at the defects of the prior art, and the method can accurately evaluate the residual life of the water-turbine generator set.
The invention provides a comprehensive evaluation method for the residual life of an overdue service hydroelectric generating set, which is characterized by comprising the following steps of:
a. determining key components of the hydroelectric generating set according to the appearance state of the hydroelectric generating set, and giving an on-site appearance inspection evaluation coefficient S according to the appearance state of the hydroelectric generating set1A numerical value;
b. carrying out test detection on key components of the hydroelectric generating set and endowing a test detection coefficient S according to a detection result2A numerical value;
c. obtaining the calculated service life of each key component through the fatigue numerical value calculation analysis of the key components, and obtaining the fatigue calculated service life of the out-of-service hydroelectric generating set after the weight distribution and the weighted summation are carried out on each key component
d. Obtaining the production period N of the super-service hydroelectric generating set2；
f. Calculating the residual service life N of the overdue hydroelectric generating set according to the following formula:
in the above technical solution, in the step a and the step b, the field appearance inspection evaluation coefficient S1And test detection coefficient S2The numerical values are assigned to corresponding evaluation coefficient ranges according to four grades of excellence, good, qualified and unqualified. The production period N2 of the super-service water-turbine generator set is obtained by looking up the production operation data of the power station generator set
In the technical scheme, in the step a, the appearance state of the water-turbine generator set is evaluated through field inspection and reference data of equipment of the water-turbine generator set; the data to be consulted mainly comprises equipment facility design, manufacture and installation data, operation records, overhaul and maintenance records, test and analysis reports, major repair reports, equipment overhaul ledgers, regular work records, operation reports, equipment defect records, fault accident records and technical modification data; wherein, the problem description and treatment suggestion are given to the equipment facilities with problems, and the related special detection is carried out to the equipment facilities which lack related test and detection data and cannot explain the current situation; and performing current state description on equipment with better conditions.
In the above technical scheme, in the step a, the appearance inspection of the water turbine part mainly comprises a water turbine runner, a water turbine guide bearing, a servomotor, a top cover, a bottom ring, a guide vane, a main shaft, an oil receiver, a volute, a draft tube entrance door, a speed regulator, a top cover drainage device, unit operation condition distribution and water turbine abrasion; the appearance inspection of the main parts of the generator mainly comprises an upper generator frame and a base of the generator, a rotor bracket of the generator, a thrust bracket, oil grooves of bearings of the generator, a brake of the generator, an anti-runaway protection device of the generator, an excitation system of the generator and a fire-fighting system of the generator; evaluating each sub item according to four grades of excellence, good, qualified and unqualified, and giving an on-site appearance inspection evaluation coefficient S according to the evaluation result of each sub item1Numerical values.
In the above technical solution, in the step b, the test and detection of the water turbine part of the water turbine generator set of the water turbine set are divided into the performance detection of the start-up and shut-down state of the water turbine, the energy characteristic detection of the water turbine, the stability test detection of the water turbine, and the response of the key components of the water turbineForce detection and analysis, and nondestructive inspection detection and analysis of key components of the water turbine; the test and detection of the generator part are divided into main generator parameter detection and analysis, generator ventilation test, generator temperature rise test, stress detection and analysis of generator key components and nondestructive flaw detection and analysis of generator key components; evaluating each sub item, and classifying the sub items into four grades of excellence, good, qualified and unqualified; giving a test detection coefficient S according to the evaluation result of each subentry2Numerical values.
And each subentry refers to the scoring system of the national grid enterprise standard Q/GDW11713-2017, and according to the assessment standard of each subentry, the subentry is given four grades of excellence, good, qualified and unqualified.
The appearance detection (or test detection) refers to the quality grade evaluation standards of unit engineering, expanded unit engineering and subsection engineering in the unit engineering quality grade evaluation standard of 'DLT 5113.3-2012 hydropower basic construction engineering part 3 hydroelectric generating set installation engineering (attached text)', for example, all the items in the appearance detection are qualified, more than 90% of the items are excellent, and all the key items are excellent, namely, the total item of the appearance detection is evaluated as excellent; all the items are qualified, more than 89-89% of the items are good and above, and all the key items are good and above, namely the total item of the appearance detection can be evaluated as good; all the sub-items are qualified, and most key sub-items are good and above, namely the total item of the appearance detection is judged to be qualified. The evaluation criteria can be referred to in the following table.
In the technical scheme, the key parts comprise equipment which cannot master the performance condition of the key parts or has defects in the step a and equipment which has important influence on the service life of the water-turbine generator set; wherein hydroelectric set life-span has equipment of important influence and corresponds the detection content and includes: the water turbine evaluates stress distribution and crack conditions of the rotating wheel, the top cover and the large shaft according to cavitation erosion of the rotating wheel and the guide vane, and the generator evaluates stress distribution and crack conditions of the stator, the rotor and the support according to insulation aging of the winding.
In the above technical solution, the step c specifically includes the following steps: by researching the start-stop rule, the operation condition and the structure and the material of each key component of the hydroelectric generating set in the hydropower station, constructing a mathematical model by combining the key components of the hydroelectric generating set and boundary conditions by adopting a finite element method, analyzing the stress and deformation conditions, the rigidity and the strength of the key components of the water turbine and the generator by numerical simulation calculation, and estimating the fatigue life of each key component of the hydroelectric generating set.
The invention can effectively and scientifically evaluate the running safety and the residual service life of the water-turbine generator set which is in service for a long time, and can accurately judge whether the water-turbine generator set equipment which is in service for a long time can continuously and safely run according to the evaluation result, thereby improving the economic benefit of the water-turbine generator set, and being widely applied to the technical field of water conservancy and hydropower engineering.
Drawings
Fig. 1 is a schematic flow chart of a method for evaluating the residual life of an overdue water-turbine generator set.
Detailed Description
The invention will be further described in detail with reference to the following drawings and specific examples, which are not intended to limit the invention, but are for clear understanding.
The invention evaluates the safety and the service life of the water-turbine generator set according to the characteristics of the water-turbine generator set, and mainly evaluates and detects important key components and equipment which are difficult to replace of the water-turbine generator set of a hydropower station, wherein the water turbine comprises key system components such as a rotating wheel, a guide vane, a guide bearing, a large shaft, a volute, a draft tube, a speed regulating system and the like and pre-embedded components thereof, and the generator comprises a stator, a rotor, a thrust bearing, a guide bearing, a large shaft, an excitation system and the like. The invention provides a comprehensive life evaluation method combining field safety appearance inspection evaluation, structural component detection, field comprehensive performance test, three-dimensional modeling finite element rigidity strength calculation analysis and fatigue calculation analysis of key components of the water-turbine generator set, aiming at safety evaluation and residual service life prediction of the water-turbine generator set in the long-term service. The method comprises four stages, namely field appearance inspection evaluation, test detection, numerical calculation (critical component fatigue numerical calculation analysis) and comprehensive evaluation.
As shown in FIG. 1, the invention provides a comprehensive evaluation method for the residual life of an overdue water-turbine generator set, which is characterized by comprising the following steps:
a. determining key components of the hydroelectric generating set according to the appearance state of the hydroelectric generating set, and giving an on-site appearance inspection evaluation coefficient S according to the appearance state of the hydroelectric generating set1A numerical value;
b. carrying out test detection on key components of the hydroelectric generating set and endowing a test detection coefficient S according to a detection result2A numerical value;
c. obtaining the calculated service life of each key component through the fatigue numerical value calculation analysis of the key components, and obtaining the fatigue calculated service life of the out-of-service hydroelectric generating set after the weight distribution and the weighted summation are carried out on each key component
d. Obtaining the production period N of the super-service hydroelectric generating set2；
f. Calculating the residual service life N of the overdue hydroelectric generating set according to the following formula:
the step a is a process of on-site appearance inspection and evaluation:
the field appearance inspection evaluation is mainly carried out by two methods of field inspection of the equipment and relevant data review. The data to be consulted mainly includes equipment and facilities design, manufacture and installation data, operation records, overhaul and maintenance records, test and analysis reports, major repair reports, equipment overhaul accounts, regular work records, operation reports, equipment defect records, fault accident records, technical improvement data and the like. Wherein problem description and treatment suggestions are given to the problematic equipment facilities; the equipment which lacks relevant test and detection data and cannot explain the current situation needs to be recommended to carry out relevant special detection; the necessary status quo description is also needed for other better-performing devices.
1) Hydraulic turbine section (taking axial flow hydraulic turbine as an example)
The appearance inspection of the water turbine part mainly comprises a water turbine runner, a water turbine guide bearing, a servomotor, a top cover, a bottom ring, a guide vane, a main shaft, an oil receiver (if any), a volute, a draft tube inlet door of a draft tube, a speed regulator, a top cover drainage device, the distribution of the operation working conditions of a unit, the abrasion condition of the water turbine and the like. The main method of inspection combines field inspection and data verification. And evaluating each sub item, and classifying the sub items into four grades of excellence, good, qualified and unqualified. The specific examination content and criteria are as follows:
water turbine runner
Checking whether the rotating wheel and the rotating wheel chamber of the water turbine are stable or not; whether cracks and cavitation exist; whether the surface coating falls off or not; whether the sealing is good or not, and no oil leakage or water inflow exist; whether the transmission of the blade servomotor leaks oil (if so); whether the transmission part moves flexibly and does not have the situation of jam and the like and whether the unit keeps good A-C repair record; whether cavitation erosion and shedding are timely repaired, and the like.
Guide bearing of hydraulic turbine
Checking whether an oil groove of a guide bearing of the water turbine leaks oil or throws the oil; whether the oil supply amount and the water supply amount of the bearing cooling system are normal or not; whether the bearing bush is complete and whether the bearing bush clearance meets the requirements, and the like.
Hydraulic turbine servomotor
Checking whether the servomotor piston is jammed, jumped or in other abnormal states when the guide vane is opened or closed; whether the crank arm has cracks or deformation; whether the shearing device and the annunciator are intact and whether the action is reliable; whether the locking device can be normally put in and cut off; the support cover has no crack or deformation.
Top cover, bottom ring and guide vane
Checking whether the top cover is seriously deformed; whether cavitation erosion and abrasion conditions exist on the bottom ring flow surface; whether the guide vane has a cavitation wear condition; whether the end surfaces of the guide vanes, the vertical surface gaps and the sealing devices are good or not, and the like.
Inlet door of volute and draft tube
And checking whether the connecting bolts of the volute, the taper pipe and the draft tube inlet door are loosened, and the like.
Speed regulator for water turbine
Checking whether an oil collecting groove, an oil pressing tank and accessories of the speed regulator leak oil or seep oil; whether the oil temperature is within an allowable range; whether the oil pump and the motor operate normally or not has abnormal vibration and overheating phenomena; whether the safety valve is normally opened or closed or not; whether the oil level of the oil pressure device is within a prescribed range, indicating whether it is correct; whether the automatic air supply device and the oil level transmitting device of the oil collecting tank act correctly and reliably; whether the mechanical part of the speed regulator is rusted and jammed or not; whether the startup and shutdown time of the speed regulator meets the design requirements or not.
Seventh, water turbine top cover drainage
Checking whether the working water pump and the standby water pump are in normal and reliable operation; whether the water level control system and the signal device of the drainage system are normal, and the like.
Distribution of operating conditions of the generator set
And carrying out statistical analysis on the distribution condition of the unit operation condition, and drawing a distribution condition graph of the operation condition on the prototype operation characteristic curve graph of the water turbine. Observing whether the operation working conditions are all in the operation range, whether the operation working conditions are far away from the boundary of the small-load vibration area, whether the operation working conditions are basically in a large-load and optimal working condition area, whether most of the operation points are in a high-efficiency area, whether the operation points exceed a front cavitation primary line of a blade inlet, a back cavitation primary line of the blade inlet and the like, and judging whether the operation working conditions of the water turbine are reasonable and efficient according to the operation working conditions.
(ninthly) abrasion of water turbine
Whether the silt content and the particle size of the water turbine exceed the standards or not is analyzed, and the large abrasion of a water turbine flow passage component is avoided. The main parts of the abrasion of the water turbine flow passage component are a runner chamber, blades, a water guide mechanism, a main shaft seal and the like, whether the abrasion amount of the water turbine generator set exceeds a specified value or not, whether the structure is improved or not (such as adding a skirt edge on the outer edge of the blade, improving the blade seal and the like) or not, whether an anti-abrasion material (such as adopting a non-metal coating, a tungsten carbide coating and laser remelting of the blade and the like) is applied and researched or not) and the like are observed, so that the phenomena of vibration and noise increase, efficiency reduction, even possible accidents, influence on the economic and safe operation of the generator set and the like of the water turbine are avoided.
2) Generator part
The appearance inspection of the main parts of the generator mainly comprises an upper frame and a base of the generator, a rotor bracket (comprising a magnetic pole and a magnetic yoke) of the generator, a thrust bracket (if any), oil grooves of bearings of the generator, a generator brake, an anti-runaway protection device of the generator, an excitation system of the generator, a fire-fighting system of the generator and the like. The main method of inspection combines field inspection and data verification. And evaluating each sub item, and classifying the sub items into four grades of excellence, good, qualified and unqualified. The specific examination content and criteria are as follows:
fastening bolt for upper frame and base
Checking whether the fastening of the upper frame fixing bolt is good or not and whether anti-loosening measures exist or not; whether the fastening of the stator foundation bolt is good or not, whether anti-loosening measures exist or not, and the like.
Bracket for rotor
Checking whether the appearances of the rotor bracket body, the welding seam and the like are defective or not and whether the anti-loosening measures of all fasteners are intact or not; whether the fixed keys of each magnetic pole of the rotor are loosened or not; whether the hanging elevation deviation value of the magnetic pole meets the requirement or not; whether the air gap meets the requirements, etc.
Thrust support (if any) of generator and lower frame
Inspecting the defects, welding seams and cracks of the thrust support (or the lower frame) body; whether the elastic oil tank has leakage, whether the welding line has cracks, and the like.
Oil groove of each bearing of generator
Checking whether the positions of the running oil level and the static oil level of each bearing oil groove of a thrust bearing, a guide bearing and the like of the generator meet the requirements or not; the oil level and flow indication can be truly displayed; thrust, whether the upper guide bearing oil groove leaks oil, spills oil and the like.
Generator brake
Checking whether a generator brake can jack up the rotor smoothly and reset automatically, and whether the generator brake can be accurately put into braking and reset automatically when the generator is stopped; the specified brake test items are carried out according to the requirements; whether all the found problems are processed; whether the clearance between the brake and the brake ring meets the requirement or not; whether the braking surface is complete; whether the leakage phenomenon exists in the brake system pipeline valve and the like; whether the brake block and the brake plate are firmly fixed, and the like.
Runaway-proof protector for generator
Checking whether the generator is provided with an anti-runaway protection device; the runaway device protects whether the constant value and the action are normal, etc.
Excitation system
Checking whether the equipment and elements forming the excitation power supply have enough safety reliability; when the generator is under the no-load rated voltage, whether the given end voltage step quantity is within the range of 70% -110% can be stably and smoothly regulated; when the generator is under the no-load rated voltage, the given terminal voltage step quantity is 10 percent and when the generator suddenly rises to zero, the respective terminal voltage overshoot, the swinging times and the adjusting time meet the requirements; whether the de-excitation switch is on, the tripping is off, the de-excitation performance is good, and the like.
Fire fighting system of generator
Checking whether the generator is provided with a reliable fire extinguishing device; whether the fire fighting water pressure is normal or not; whether the fire fighting pipe jet hole direction is correct, etc.
The step b is a test detection process:
the test detection comprises two conditions, wherein the performance conditions of important parts of the water turbine generator set can not be mastered or the equipment has defects in the field appearance inspection and evaluation stage, the water turbine generator set is subjected to special test detection by the discussion of a field inspection and evaluation expert group, the critical parts having important influence on the service life of the water turbine generator set are subjected to routine test detection, the water turbine part can be evaluated according to the cavitation erosion of a rotating wheel and a guide vane of the water turbine generator set, the stress distribution and cracks of the critical parts such as the rotating wheel, a top cover and a large shaft, and the power generator part can be evaluated according to the conditions such as the insulation aging of a winding, the stress distribution and cracks of the critical parts such as a stator, a.
Routine and special test detection work is carried out on equipment which needs to be tested and needs to be tested, performance conditions of equipment facilities are obtained by analyzing test detection data, and a basis is further provided for safety assessment and service life prediction of the water-turbine generator set which runs out of date.
1) Water turbine section
The partial test and detection of the water turbine are divided into the items of performance detection of the starting and stopping state of the water turbine, energy characteristic detection of the water turbine, stability test and detection of the water turbine, stress detection and analysis of key components of the water turbine, nondestructive flaw detection and analysis of key components of the water turbine and the like. And evaluating each sub item, and classifying the sub items into four grades of excellence, good, qualified and unqualified. The specific detection contents and standards are as follows:
detecting the performance of the water turbine in the starting and stopping state
Respectively acquiring transition process curves of parameters such as the rotating speed, the power, the swing degree of a main shaft (upper guide, lower guide, water guide and the like), the vibration, the pressure pulsation, the opening degree of guide vanes and blades (if any), noise and the like of a unit (upper frame, stator frame, support cover and the like) under two conditions of normal starting of the unit to synchronous rotating speed grid connection and normal stopping of the unit, analyzing a time domain oscillogram of the transition process curves, and further analyzing whether the guide vanes and the blades (if any) of a water turbine act according to a preset starting program or not in the starting and stopping process; whether the time domain waveform changes of the parameters such as main shaft throw, unit vibration, water pressure pulsation, noise and the like are normal or not.
Detection of energy characteristics of water turbine
By referring to the annual operation logs of the turbine set and the recent related energy characteristic and stability test reports of the turbine set, performing field test detection, comprehensively knowing the energy parameter and stability condition in the operation process of the water turbine, mastering the operation characteristic and state of the turbine set, analyzing whether the characteristics such as the efficiency of the water turbine generator set meet the original design requirements, analyzing whether the real machine comprehensive operation characteristic curve is consistent with the characteristic curve given by a manufacturer, analyzing whether the trend of the cooperation curve (if any) is consistent with the optimal cooperation curve, and the like, and further analyzing and evaluating the energy characteristic of the water turbine.
③ testing and detecting the stability of the water turbine
The stability test working conditions are divided into tests including a variable rotating speed test, a variable excitation test and a variable load test, and the test point arrangement, the measurement parameters and the used sensors are the same as those of the start-up and shut-down process test. The variable-speed test sequentially changes the rotation speed of the unit to be 40%, 60%, 80% and 100% of rated rotation speed, and after the rotation speed is stable, parameters such as vibration and swing of the unit are collected, wherein the collection time is about 2 minutes. After the collection is finished, the next working condition is carried out; the variable excitation test is to change the current output of an excitation regulator, so that the voltage at the generator terminal is 20% Ue, 40% Ue, 60% Ue, 80% Ue and 100% Ue in sequence, observe and acquire parameters such as vibration and swing of a unit after the excitation current is stable, the acquisition time is about 2 minutes, and then perform the next working condition after the acquisition is completed; the variable load test is carried out under the existing cooperative working condition, the load is adjusted from the minimum load to the full load, 10-15 working condition points are selected, and after the standby unit operates stably after adjustment once, parameters such as vibration and swing of the unit are acquired.
Respectively drawing a relation curve of the main shaft swing frequency mixing amplitude, the main shaft swing frequency and the active power of the unit; the relationship curve of the vibration mixing amplitude, the vibration dominant frequency and the active power of the machine set of the upper frame, the stator base and the supporting cover; and the pressure pulsation mixing amplitude, the pressure pulsation main frequency and the unit active power are in a relation curve.
And analyzing the field stability test detection, and analyzing whether the unit vibration, the swing degree, the pulsation, the noise, the vortex band and the like exceed the standard values under various working conditions, particularly under the small-load working condition, by combining stability test reports under various water heads and the cooperative working condition (if any), and evaluating the stability of the water turbine unit.
Stress detection and analysis of critical parts of water turbine
The stress detection and analysis of the key parts of the water turbine are divided into test detection and analysis of main shaft stress (torque), guide vane connecting rods, water thrust and the like, and the test working conditions comprise joint working conditions (if any) and transition process working conditions.
In test detection and analysis of main shaft stress (torque), water thrust and the like, a plurality of strain gauges are arranged on the surface of a main shaft and are respectively used for measuring the main shaft torque and the water thrust, a relation curve of the main shaft torque and load is made through calculation, whether the main shaft torque increases along with the increase of the load or not is analyzed to form a linear relation, and whether a measured value of the main shaft torque is matched with the calculated value or not is compared; whether the general trend of the axial water thrust is reduced along with the increase of the load is analyzed through calculation.
In the stress detection and analysis of the guide vane connecting rods, each unit selects two guide vanes (close to the servomotor and far from the servomotor), a strain gauge is attached to each guide vane connecting rod, the stress of the connecting rods is measured, and whether the strain of each connecting rod of the guide vanes is basically kept stable along with the increase of the load is observed.
Nondestructive inspection detection and analysis of key parts of water turbine
The nondestructive inspection and analysis of key parts are combined by ultrasonic inspection and magnetic powder inspection. The ultrasonic detection (UT) can detect the internal defects of the test piece in a larger thickness range, and the detection objects comprise a main shaft and a connecting bolt of the water turbine, a guide vane connecting rod, a support cover and a bolt thereof, a first-class welding seam, a second-class welding seam and the like; magnetic particle test (MT) can detect surface and near-surface cracks and defects, a test object comprises a support cover, a bolt and the like, whether cracks or other types of over-standard defects occur or not is observed, and whether the working state of a hydraulic turbine testing component is normal or not is further judged.
2) Generator part
The partial test and detection of the generator are divided into main parameter detection and analysis of the generator, ventilation test of the generator, temperature rise test of the generator, stress detection and analysis of key components of the generator, nondestructive flaw detection and analysis of key components of the generator and the like. And evaluating each sub item, and classifying the sub items into four grades of excellence, good, qualified and unqualified. The specific detection contents and standards are as follows:
detecting and analyzing main parameters of generator
Under the no-load and rated working conditions of the unit, main generator parameters such as rated apparent power, rated active power, rated stator current, rated stator voltage, rated exciting current, rated exciting voltage, power factor, no-load exciting voltage and no-load exciting current are respectively detected and recorded, and compared with in-plant monitoring data and original design data, whether the main generator parameters are normal or not is analyzed.
Ventilation test of generator
The method comprises the steps of measuring the total air volume at the air outlet of a cooler, the upper end part of a stator, the air inlet above an air cooler, the lower end part of the stator and the air inlet below the air cooler under the working conditions of idle running, no-load running, full-load running and the like of a generator, measuring the cold air temperature and the hot air temperature of the air cooler under the stable state of full-load running of the generator, calculating the temperature difference between the cold air and the hot air after the temperature is stable, calculating the windmilling loss of the generator under the full-load state, and analyzing whether the ventilation state of the generator is good or not and whether the loss of the generator is in a.
Thirdly generator temperature rise test
And measuring the temperature rise of the stator, the rotor winding and the stator core under the rated load and the rated working condition, and detecting whether the temperature rise value is in a normal range.
Stress detection and analysis of key parts of generator
The generator key component stress detection and analysis has test detection and analysis such as a generator thrust support, the test working condition comprises a cooperative working condition (if any) and a transition process working condition, measuring points can be arranged on two side surfaces of the thrust support (if any) close to the people entrance door, a relation curve of the strain of the measuring points of the thrust support and the load is made under the cooperative working condition (if any), a variation curve of strain values of the measuring points is made under the working condition of starting and stopping, and whether the strain variation of each measuring point is small or constant along with the increase of the load is analyzed, so that whether the stress working state of the thrust support (if any) is normal is indicated.
Nondestructive inspection detection and analysis of key parts of generator
The detection objects of ultrasonic detection (UT) comprise a generator main shaft and a connecting bolt, a rotor bracket I, a rotor bracket II, a rotor bracket fastening bolt, an upper end shaft fastening bolt, an upper bracket I, a stator base, a thrust bracket I, a thrust bracket II and a bolt; a thrust bracket (if any) is arranged on a magnetic particle test (MT) detection object, whether cracks or other types of standard exceeding defects occur or not is observed, and whether the working state of a generator testing component is normal or not is judged.
The step c is a numerical calculation process:
the fatigue damage and the fatigue life of key components of the water turbine generator set are determined by factors such as alternating stress, average stress (stable stress), the cycle characteristics of materials, the operation history and the operation conditions of the components and the like. By researching the start-stop rule, the operation condition and the structure and the material of each key component of the hydroelectric generating set of the hydropower station, adopting a finite element method, reasonably considering the key components and the boundary condition of the hydroelectric generating set for modeling, analyzing the stress and the deformation condition, the rigidity and the strength of the main components of the water turbine and the generator through numerical simulation calculation, and estimating the fatigue life of the key components of the hydroelectric generating set.
1) Water turbine section
Calculation of critical rotation speed of shafting
Calculating the critical rotating speed and torsional vibration frequency of the front 2 orders of a shafting of the unit, and checking whether the critical rotating speed of the shafting far exceeds the working rotating speed and the runaway rotating speed of the unit; whether the torsional natural frequency of the shafting avoids the rotating frequency and the possible excitation frequency thereof or not is judged, so that whether the shafting of the unit can safely and stably operate or not is judged, and whether the shafting of the unit has good dynamic characteristics or not is judged.
Calculation of stiffness and fatigue of critical parts of water turbine
The key parts of the water turbine comprise a thrust support (if any), a top cover, a supporting cover, a runner body, runner blades, a main shaft, a control ring, a servomotor, a tail water pipe disc valve, a volute entrance door, a runner chamber entrance door, a taper pipe entrance door and the like.
And respectively calculating the calculated stress of each key component under different working conditions, and judging whether the calculated stress meets allowable stress specified by a standard and is lower than the yield limit of the material, and whether the maximum equivalent stress appears in a local area and belongs to stress concentration, thereby judging whether the structural rigidity of each key component meets the design requirement.
And analyzing the fatigue life, and calculating the service life calculated value of the stress concentration position of each key part by considering the water pressure pulsation.
Thirdly, fatigue calculation of connection bolt of each key component
And the top cover handle bolt, the blade handle bolt and the main shaft handle bolt respectively calculate the bolt prestress, the bolt pre-tightening load and the residual clamping force of the connecting pair under the normal operation working condition and the emergency shutdown working condition. All parts such as the bolt, the screw rod, the connecting rod and the like are subjected to prestress treatment, the prestress of the parts cannot exceed 7/8 of the yield strength of the material, the load of the bolt is not less than 2 times of the design load of the connecting part, and the residual clamping force of the connecting pair is not less than 0.5 time of the design load of the bolt, so that whether all parameter indexes of the bolt meet the national standard requirements or not and whether the parameter indexes of the bolt are reliable or not is judged.
And analyzing the fatigue life, and respectively calculating the service life calculation value of each key part connecting bolt by counting accumulated damage.
2) Generator part
The key parts of the generator comprise a stator base, an upper frame, a magnetic pole, a magnetic yoke, a rotor bracket main shaft, a generator upper end shaft, a main shaft connecting bolt, an elastic oil tank and the like.
Firstly, calculating the rigidity and the fatigue of the stator base
And (3) calculating the front 3-order natural frequency of the stator base, and analyzing whether the electromagnetic excitation frequency of the unit is avoided or not, so as to judge whether the dynamic performance of the stator base is excellent or not and whether the poor vibration is generated due to the dynamic characteristics or not.
And respectively calculating the maximum stress under the rated working condition, the two-phase short-circuit working condition and the half magnetic pole short-circuit working condition to see whether the rigidity strength requirement is met.
And analyzing the fatigue life to obtain a service life calculated value of the stress concentration position of the stator frame.
Second, calculating the rigidity and fatigue of the upper frame
And (3) calculating the first 5-order natural frequency of the upper rack, and analyzing whether the natural frequency is far higher than the frequency corresponding to the unit rotating frequency and the unit runaway rotating speed or not, so as to judge whether the power performance of the upper rack is excellent or not and whether the upper rack generates bad vibration or not due to the power characteristics.
And respectively calculating the maximum stress under the rated working condition and the half magnetic pole short circuit working condition, and analyzing whether the rigidity strength requirement is met.
And analyzing the fatigue life to obtain a service life calculated value of the stress concentration position of the upper frame.
Calculating magnetic pole magnetic yoke rigidity and fatigue
And respectively calculating the maximum stress under the normal operation working condition and the runaway working condition, analyzing whether the allowable stress meets the standard regulation or not, whether the allowable stress is lower than the yield limit of the material or not, and whether the maximum equivalent stress appears in a local area or not and belongs to stress concentration or not, and judging whether the rigidity strength of the magnetic pole and magnetic yoke structure meets the design requirement or not.
And analyzing the fatigue life to obtain a service life calculated value of the magnetic pole and magnetic yoke stress concentration position.
Fourthly, calculating the rigidity and the strength of the rotor support and calculating the fatigue
And calculating the first 5-order natural frequency of the rotor support, and analyzing whether the electromagnetic excitation frequency of the unit is avoided or not, so as to judge whether the dynamic performance of the rotor support is excellent or not and whether the poor vibration is generated due to the dynamic characteristics or not.
And respectively calculating the maximum stress under the rated working condition, the runaway working condition and the key striking working condition, and analyzing whether the requirements on the rigidity strength and the dynamic characteristics are met.
And analyzing the fatigue life to obtain a service life calculated value of the stress concentration position of the rotor support.
Calculation of main shaft rigidity and fatigue
And the calculation is equivalent to the calculation of the rigidity and the fatigue of the main shaft of the water turbine.
Fatigue calculation for main shaft bolt
And the method is equivalent to the calculation of the fatigue of the main shaft bolt of the water turbine.
Seventhly, calculating the rigidity and the fatigue of the upper end shaft of the generator
And respectively calculating the maximum stress under the rated working condition and the half magnetic pole short circuit working condition, and analyzing whether the rigidity strength requirement is met.
And analyzing the fatigue life to obtain a service life calculated value of the stress concentration position of the upper end shaft.
Calculation of rigidity and fatigue of elastic oil tank
And (3) performing tests, fatigue tests, stress calculation and water thrust tests on the mechanical properties of the elastic oil tank material, and further evaluating the service life of the elastic oil tank.
And according to the results of field appearance inspection evaluation, detection tests and numerical calculation, carrying out comprehensive evaluation according to a relevant theory to calculate the continuous service life of the water-turbine generator set in service for the extended period. If the unit modifies part of the equipment, the sustainable operation time of the unit can be further prolonged, but the service life of the newly replaced equipment needs to take the influence of the environment into consideration.
In the field appearance inspection and evaluation, according to the condition of each subentry evaluation grade of the appearance detection of the water turbine part and the generator part, the water turbine generator set is summarized and evaluated at the stage of the appearance detection, and the evaluation coefficient ranges of the water turbine generator set are respectively provided with the evaluation coefficient ranges of 0.96-1.0, 0.86-0.95, 0.61-0.85 and 0-0.6, wherein the evaluation coefficient ranges are classified into four grades of excellence, good, qualified and unqualified.
In the test detection, the water turbine generator set is summarized and evaluated in the stage of field test detection according to the field test detection evaluation grade conditions of the water turbine part and the generator part, the evaluation grades are divided into four grades of excellence, good, qualified and unqualified, and the evaluation coefficient ranges of 0.96-1.0, 0.86-0.95, 0.61-0.85 and 0-0.6 are respectively given to the evaluation grades.
In the numerical calculation, the calculated service life of each key component is obtained through the calculation and analysis of the fatigue numerical value of the key component, the calculated service life of the whole overdimension water-turbine generator set is obtained through the weight distribution and the weighting summation of each key component, and the calculated service life of the whole overdimension water-turbine generator set is obtained by subtracting the production period from the production period.
The specific evaluation criteria of the process are further described by using a safety evaluation example of the residual life of a certain overdimensioned axial-flow Kaplan type hydroelectric generating set of a certain power station.
(1) In-situ visual inspection assessment
In the water turbine part, runner blades have slight cavitation erosion, no cracks, flexible rotation, no serious oil leakage, uniform runner chamber gaps, slight falling and cavitation erosion of an epoxy coating and repair; the water guide bearing has no oil leakage, no oil throwing, good cooling system, no shelling and cracking of the bearing bush, and single side of the clearance value of the bearing bush is 0.292-0.296 mm, thus meeting the requirements; the control ring is flexible, no jumping and jamming exist, the working state of the crank arm is good, no crack and deformation exist, the locking device can be normally put in and cut off, and the support cover does not have crack and deformation; the oil flow of the oil supply head is smooth, but oil throwing exists, the feedback indication of the blades is normal, the installation fit clearance of the floating tile and the operation oil pipe and the tile sleeve is normal, and the level of the oil supply head base and the concentricity of the operation oil pipe meet the requirement; the top cover has no serious deformation, the bottom ring epoxy coating has local falling, the guide vane has no cavitation erosion, the abrasion-resistant coating has falling, each gap of the guide vane is normal, and the guide vane is sealed and has no falling; the volute inlet door, the taper pipe and the draft pipe inlet door connecting bolt are not loosened; the oil collecting tank of the speed governor has no oil leakage, the oil temperature is normal, the pressure oil tank and the gas tank have no leak points, the oil pump and the motor run normally, the safety valve is normal, the oil level is in the specified range, the air supplementing device and the oil level transmitting device are reliable, the mechanical part of the speed governor has no corrosion and jam, and the on-off time of the speed governor reaches the design requirement; the top cover row works, the standby water pump is normally put in, and the monitoring signal is normally put in; the unit operates in a working condition, is far away from the boundary of a small-load vibration area, is basically in a large-load and optimal working condition area, has most of operating points in a 93 percent high-efficiency area and operating points not exceeding the cavitation primary lines of the front surface and the back surface of the blade inlet; the silt content and particle size of the machine-passing silt do not exceed the standard, the abrasion loss of the machine set does not exceed the specified value, the skirt edge is additionally arranged at the outer edge of the blade, the sealing of the blade is improved, and the blade and the runner chamber are both provided with non-metal coatings or tungsten carbide coatings.
In the generator part, an upper frame fixing bolt and a stator foundation bolt are well fastened and have anti-loosening measures; the rotor bracket body has no defect and no crack, is fastened by bolts and is provided with a stop piece; the fixed keys of the magnetic poles are not cracked, detached and loosened, the hanging elevation deviation of the magnetic poles is within 1.5mm, the requirements are met, and the average air gap value is 21.85 mm; the thrust support body has no crack, the elastic oil tank has no leakage phenomenon, and the welding line has no crack, but the service life is reached, and replacement is recommended; the oil surface position of each bearing oil groove meets the requirement, the oil level and flow indication is normal, and the oil groove has no oil leakage and oil spill; the brake is normal in rising and falling, no jamming exists, the air brake has no air blow-by, the gap between the brake and the brake ring meets the requirement, the brake ring is good, and the pipeline valve of the brake system has no air leakage and oil leakage; the generator is provided with an anti-runaway protection device, a protection constant value and normal action; the excitation regulator has the advantages that each power module and equipment elements are periodically subjected to C-repair inspection, safety and reliability are realized, excitation action is correct, a de-excitation switch and a resistor are good, and under no-load rated voltage, 10% of terminal voltage step quantity, overshoot and regulation time conditions meet requirements; the generator has reliable fire extinguishing device, fire-fighting water pressure of 0.51MPa and correct fire-fighting pipe jet hole direction.
(2) Test detection
In the water turbine part, in a performance detection test of the start-up and shut-down states of the water turbine, guide vanes and blades of the water turbine act according to a preset start-up program, and time domain waveform changes of parameters such as main shaft throw, unit vibration, water pressure pulsation, noise and the like are normal; in the energy characteristic detection test of the water turbine, the characteristics of the efficiency and the like of the water turbine generator set meet the original design requirements, the comprehensive operation characteristic curve of the real machine is basically consistent with the characteristic curve given by a manufacturer, the trend of the tandem curve is consistent with the trend of the optimal tandem curve, and the like; in stability test detection, the parameter values of unit vibration, swing, pulsation, noise, vortex band and the like under various working conditions, particularly under a small-load working condition, do not exceed the standard values, and the unit stability meets the requirements; in the stress detection and analysis of the key part of the water turbine, the torque of a main shaft is increased along with the increase of the load and has a linear relation, an actual measurement value is matched with a calculated value, the total trend of the axial water thrust is reduced along with the increase of the load, the abnormal vibration phenomenon is not found, and the strain of each connecting rod of the guide vane is basically kept stable along with the increase of the load; in the nondestructive flaw detection and analysis of the key components of the water turbine, ultrasonic detection is carried out on a main shaft and a connecting bolt of the water turbine, a guide vane connecting rod, a first class welding seam, a second class welding seam and a bolt of a support cover, cracks or other types of overproof defects are not found, magnetic powder detection is carried out on the support cover, cracks or other types of overproof defects are not found, and the working state of the components for testing the water turbine is normal.
In the generator part, main parameter data of the generator are synchronously recorded under no-load and rated working conditions of a unit in the detection and analysis of the main parameters of the generator, and a test measurement value is basically consistent with monitoring data; in a generator ventilation test, the average value of the temperature difference between cold air and hot air is calculated to be 13.56 ℃, the total air quantity Q is 144.3m3/s, the generator loss P is 2250.3kW, and the fact that the ventilation state of a generator is good and the generator loss is in a normal range is found through comparison with the previous operation condition of a power station; in the generator temperature rise test, the temperatures of the stator core and the stator coil are relatively close, the average temperature of the stator is measured to be 52.95 ℃, the cooling air temperature is deducted to be 24.63 ℃, and the stator temperature rise is about 28.3 ℃. The average temperature of the rotor is measured to be 53.19 ℃, the temperature of cooling air is deducted to be 24.63 ℃, the temperature of the rotor is raised to be 28.56 ℃, and the running state of the unit is normal; in the stress detection and analysis of key components of the generator, the change of the strain of each measuring point of the generator thrust support along with the increase of the load under the working condition of the unit linkage and the working condition of the transition process is small or constant, and the stress working state of the thrust support is normal; in nondestructive flaw detection and analysis of key components of the generator, ultrasonic detection is carried out on a main shaft and a connecting bolt of a water turbine, a welding seam and a connecting bolt of a rotor bracket, a fastening bolt of an upper end shaft, a welding seam of an upper frame, a welding seam of a stator base, a welding seam of a thrust bracket and the like, no crack or other types of standard exceeding defects are found, and the working state of the components tested by the generator is normal.
(3) Numerical calculation
In the calculation and analysis of the rigidity and the strength of the key component structure of the water turbine generator set, the rigidity and the strength of each key component of the water turbine and the generator meet the design requirements, the calculated service life of the whole overtime service water turbine generator set is obtained by weighting and summing the service life calculated value of the stress concentration position of the key components, the calculated service life is 138 years, the production service life is subtracted by 40 years, and the calculated value of the residual service life of the overtime service water turbine generator set is 98 years.
The calculated values of the service life of the stress concentration parts of the key parts of the hydroelectric generating set are shown as the following table:
(4) comprehensive evaluation
As can be seen from the examination conditions of all the sub-items of the field appearance examination evaluation, most of the examination items basically meet the relevant requirements, so the field appearance examination evaluation can be evaluated to be qualified through comprehensive evaluation, and the evaluation coefficient is 0.7.
In the test, the working state of the tested part is basically normal according to the field test of the water turbine part and the generator part, the test detection evaluation is evaluated to be qualified through comprehensive evaluation, and the evaluation coefficient is 0.7.
Therefore, comprehensive evaluation shows that the residual service life of the super-service water-turbine generator set is as follows:
N＝0.7×0.7×(138-40)＝48
namely, the super-service water turbine generator set can be operated for 48 years under normal working conditions. Meanwhile, in view of the problems of cavitation erosion, blade protective coating falling off and the like frequently seen in overhaul, the method recommends that when a unit is overhauled, the cavitation erosion and crack detection is carried out on the runner blade and the runner chamber; considering that the calculated value of the fatigue service life of the upper frame is small, the dynamic state of the upper frame is closely concerned when the hydraulic generator set is in delayed operation, and meanwhile, the calculated value of the fatigue strength service life of the elastic oil tank is also small, the elastic oil tank is recommended to be replaced in time, and the influence on the normal operation of the hydraulic generator set caused by the damage of the elastic oil tank is avoided. In addition, each key component of the water turbine generator set is subjected to nondestructive testing if necessary, and the defective part is timely and correspondingly treated, so that the operation risk and hidden danger are reduced.
Details not described in this specification are within the skill of the art that are well known to those skilled in the art.
Claims (7)
1. A comprehensive evaluation method for the residual life of an overdimension hydroelectric generating set is characterized by comprising the following steps:
a. determining key components of the hydroelectric generating set according to the appearance state of the hydroelectric generating set, and giving an on-site appearance inspection evaluation coefficient S according to the appearance state of the hydroelectric generating set1A numerical value;
b. aiming at a hydraulic generatorTesting key components of the group, and giving a test detection coefficient S according to the detection result2A numerical value;
c. obtaining the calculated service life of each key component through the fatigue numerical value calculation analysis of the key components, and obtaining the fatigue calculated service life of the out-of-service hydroelectric generating set after the weight distribution and the weighted summation are carried out on each key component
d. Obtaining the production period N of the super-service hydroelectric generating set2；
f. Calculating the residual service life N of the overdue hydroelectric generating set according to the following formula:
2. the method for comprehensively evaluating the residual life of the turbine generator set in extended service according to claim 1, wherein in the step a and the step b, the field appearance inspection evaluation coefficient S1And test detection coefficient S2The numerical values are assigned to corresponding evaluation coefficient ranges according to four grades of excellence, good, qualified and unqualified.
3. The comprehensive evaluation method for the remaining life of the turbine generator set in out-of-service according to claim 2, wherein in the step a, the appearance state of the turbine generator set is evaluated through field inspection and reference data of equipment of the turbine generator set; the data to be consulted mainly comprises equipment facility design, manufacture and installation data, operation records, overhaul and maintenance records, test and analysis reports, major repair reports, equipment overhaul ledgers, regular work records, operation reports, equipment defect records, fault accident records and technical modification data; wherein, the problem description and treatment suggestion are given to the equipment facilities with problems, and the related special detection is carried out to the equipment facilities which lack related test and detection data and cannot explain the current situation; and performing current state description on equipment with better conditions.
4. The method according to claim 3, wherein in the step a, the appearance inspection of the water turbine part mainly comprises a water turbine runner, a water turbine guide bearing, a servomotor, a top cover, a bottom ring, a guide vane, a main shaft, an oil receiver, a volute, a draft tube inlet door, a speed regulator, a top cover drainage device, the distribution of the operating conditions of the turbine and the abrasion condition of the water turbine; the appearance inspection of the main parts of the generator mainly comprises an upper generator frame and a base of the generator, a rotor bracket of the generator, a thrust bracket, oil grooves of bearings of the generator, a brake of the generator, an anti-runaway protection device of the generator, an excitation system of the generator and a fire-fighting system of the generator; evaluating each sub item according to four grades of excellence, good, qualified and unqualified, and giving an on-site appearance inspection evaluation coefficient S according to the evaluation result of each sub item1Numerical values.
5. The method for comprehensively evaluating the remaining life of the service-overtime hydroelectric generating set according to claim 1, wherein in the step b, the test and detection of the water turbine part of the hydroelectric generating set of the hydro turbine set are divided into the performance detection of the start-up and shutdown state of the water turbine, the energy characteristic detection of the water turbine, the stability test detection of the water turbine, the stress detection and analysis of the key components of the water turbine and the nondestructive flaw detection and analysis of the key components of the water turbine; the test and detection of the generator part are divided into main generator parameter detection and analysis, generator ventilation test, generator temperature rise test, stress detection and analysis of generator key components and nondestructive flaw detection and analysis of generator key components; evaluating each sub item, and classifying the sub items into four grades of excellence, good, qualified and unqualified; giving a test detection coefficient S according to the evaluation result of each subentry2Numerical values.
6. The comprehensive evaluation method for the remaining life of the turbine generator set in out-of-service according to claim 5, wherein the key components comprise equipment which cannot master the performance condition of the key components or has defects in the step a and equipment which has important influence on the life of the turbine generator set; wherein hydroelectric set life-span has equipment of important influence and corresponds the detection content and includes: the water turbine evaluates stress distribution and crack conditions of the rotating wheel, the top cover and the large shaft according to cavitation erosion of the rotating wheel and the guide vane, and the generator evaluates stress distribution and crack conditions of the stator, the rotor and the support according to insulation aging of the winding.
7. The comprehensive evaluation method for the residual life of the overdimensioned hydroelectric generating set according to claim 1, wherein the step c specifically comprises the following steps: by researching the start-stop rule, the operation condition and the structure and the material of each key component of the hydroelectric generating set in the hydropower station, constructing a mathematical model by combining the key components of the hydroelectric generating set and boundary conditions by adopting a finite element method, analyzing the stress and deformation conditions, the rigidity and the strength of the key components of the water turbine and the generator by numerical simulation calculation, and estimating the fatigue life of each key component of the hydroelectric generating set.
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