CN115890132A - Method for eliminating cracks of runner of water turbine - Google Patents
Method for eliminating cracks of runner of water turbine Download PDFInfo
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- CN115890132A CN115890132A CN202211193233.9A CN202211193233A CN115890132A CN 115890132 A CN115890132 A CN 115890132A CN 202211193233 A CN202211193233 A CN 202211193233A CN 115890132 A CN115890132 A CN 115890132A
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 105
- 238000000034 method Methods 0.000 title claims abstract description 36
- 238000003466 welding Methods 0.000 claims abstract description 130
- 238000005520 cutting process Methods 0.000 claims abstract description 79
- 230000004048 modification Effects 0.000 claims abstract description 13
- 238000012986 modification Methods 0.000 claims abstract description 13
- 238000007689 inspection Methods 0.000 claims abstract description 10
- 238000005498 polishing Methods 0.000 claims description 40
- 238000001514 detection method Methods 0.000 claims description 29
- 230000007547 defect Effects 0.000 claims description 19
- 230000008859 change Effects 0.000 claims description 16
- 238000012544 monitoring process Methods 0.000 claims description 13
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 10
- 229910052799 carbon Inorganic materials 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 9
- 229910052786 argon Inorganic materials 0.000 claims description 6
- 230000008569 process Effects 0.000 claims description 6
- 238000009966 trimming Methods 0.000 claims description 6
- 239000010953 base metal Substances 0.000 claims description 5
- 239000011324 bead Substances 0.000 claims description 5
- 230000003746 surface roughness Effects 0.000 claims description 5
- 238000005496 tempering Methods 0.000 claims description 4
- 238000004146 energy storage Methods 0.000 claims description 3
- 229910000831 Steel Inorganic materials 0.000 abstract description 4
- 239000010959 steel Substances 0.000 abstract description 4
- 230000007704 transition Effects 0.000 abstract description 4
- 230000036541 health Effects 0.000 abstract description 2
- 239000007769 metal material Substances 0.000 abstract description 2
- 239000002184 metal Substances 0.000 description 8
- 239000010410 layer Substances 0.000 description 7
- 238000005336 cracking Methods 0.000 description 5
- 230000003014 reinforcing effect Effects 0.000 description 5
- 230000008439 repair process Effects 0.000 description 4
- 230000037452 priming Effects 0.000 description 3
- 239000000306 component Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000003449 preventive effect Effects 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/20—Hydro energy
Abstract
The invention relates to a method for eliminating cracks of a runner of a hydraulic turbine, belonging to the technical field of hydraulic turbines. The method comprises the steps of blade water outlet edge end face modification, replacement area cutting and replacement, size inspection and the like. According to the invention, according to the 3D model of the blade, the water outlet edge of the runner blade is integrally cut short and polished, so that the thickness and the fatigue resistance of the water outlet edge are increased; cutting off the metal material of the heat affected zone at the connecting part of the water outlet edge of the runner blade and the lower ring; and welding high-quality forged steel which has the same size as the cut area of the blade at the stress concentration part, and performing fillet transition on the water outlet edge. The invention solves the problem of the crack of the water turbine runner, improves the health level of the water turbine generator set, effectively guarantees the operation safety, stability and reliability of the power plant, and is easy to popularize and apply.
Description
Technical Field
The invention belongs to the technical field of water turbines, and particularly relates to a method for eliminating cracks of a runner of a water turbine.
Background
The runner is a core component of the water turbine, if the unit continues to operate after the blades of the runner of the water turbine have cracks, the crack defects are continuously developed, so that the friction between the rotating part and the fixed part of the unit is increased, the swing of the water turbine is increased, the cracks of the blades are staggered and staggered, and even the blades fall off, the unplanned shutdown of the unit is caused, the service life of the runner of the water turbine is shortened, and the operation safety of the unit is seriously endangered.
At present, the method for eliminating the cracks of the water turbine runner at home and abroad mainly comprises the following steps: after repair welding is carried out on the cracking defect of the runner blade, a triangular reinforcing block is added at the connecting part of the blade and the water outlet edge, as shown in figure 1; the structure of the francis turbine runner is shown in figure 2. Although the method improves the fatigue resistance of the blade to a certain degree, the problem of fatigue damage of metal parts in the original blade cracking area and the welding heat affected area is not solved, metal defects of related areas still exist, and cracks of the turbine runner cannot be eliminated fundamentally.
Therefore, how to overcome the defects of the prior art is a problem which needs to be solved urgently in the technical field of the water turbine at present.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, fundamentally eliminate the cracks of the runner of the water turbine, ensure the safe and stable operation of the unit and provide a method for eliminating the cracks of the runner of the water turbine.
In order to realize the purpose, the technical scheme adopted by the invention is as follows:
a method for eliminating cracks of a runner of a hydraulic turbine comprises the following steps:
step (1), the rotating wheel is lifted out of the foundation pit, the lower ring is placed on a support, and the large shaft handle of the rotating wheel is adjusted to be horizontal;
step (2), marking a new water outlet side end surface line on the blade by using a marking template and taking the end surface of the water outlet side of the blade as a reference, marking a position 49-51mm away from the new water outlet side end surface on a horizontal line to be used as a rotating wheel blade opening detection point, and recording the current opening between the blades to be used as the opening of the blades before modification;
step (3), uniformly arranging a plurality of dial indicators at the position of the leakage-stopping ring along the circumferential direction, and assembling bracing ribs at the positions of the water outlet edges of the blades, which are 145-155mm away from the end surface line of the old water outlet edge;
step (4), numbering the blades; cutting blades according to the end surface line of the new water outlet side, reserving 3-5mm polishing allowance during cutting, cutting by adopting grouping symmetry, polishing, and monitoring the variable value change of the dial indicator during the cutting process; then PT flaw detection is carried out on the new water outlet side profile within the range of 90-110 mm;
step (5), marking the position of a replacement block on the blade processed in the step (4), and reserving a grinding allowance of 5mm as a cutting line; then, cutting the replacement block, cutting by adopting grouping symmetry, and monitoring the variable value change of the dial indicator in the cutting process; polishing a cutting surface, and performing PT flaw detection; assembling the replacement block to the position of the blade cutting notch for welding;
and (6) removing the supporting ribs, wherein the base metal is not allowed to be damaged during removal, a 3-5mm polishing allowance is reserved, and PT flaw detection is performed after polishing.
Further, in the step (1), preferably, the large shaft of the rotating wheel is adjusted to be combined to be horizontal, and the levelness is 0.05mm/m.
Further, it is preferable that, when the replacement block is fitted to the blade cutting notch position in the step (5), the replacement block and the blade profile line position are checked for acceptance by the sample plate.
Further, in the step (4) and the step (5), it is preferable that the cutting is performed by a carbon arc gouging.
Further, in the step (5), it is preferable that the welding electrode is AWS E316L during welding; in the welding process, a welding rod with the diameter of 3.2mm is used for priming, and then a welding rod with the diameter of 1.2 mm is used for welding, wherein the welding speed is 6-20cm/min.
Further, preferably, 2 sections of tack welds are arranged at the positions of the replacement block and the lower ring weld, 3 sections of tack welds are arranged at the positions of the replacement block and the blade weld, the length of each section of tack weld is not less than 30mm, the thickness of each section of tack weld is at least 10mm or half of the groove depth, and the tack welds are arranged on the positive pressure side of the blade.
Further, preferably, the whole runner should be welded symmetrically according to the position of the blade;
welding each blade in a welding sequence from inside to outside;
the welding sequence of the single welding seam is as follows: firstly welding a negative pressure surface, fully welding 2/3 of the negative pressure surface from inside to outside, carrying out carbon arc gouging back gouging, and welding a positive pressure side and a negative pressure side to finish filling welding passes after VT inspection confirms no defect; welding a layer after the welding seam is fully welded, and taking the layer as a tempering welding bead;
if the deformation of a certain point of the excircle of the lower leakage-stopping ring exceeds 1.5mm, stopping welding;
and polishing the welding line, performing UT + PT flaw detection according to the standard, and repairing the surface defects by argon arc welding until the surface defects are qualified.
Further, it is preferable that the method further includes a step (7) of checking a size:
the dimension inspection specifically comprises:
checking the opening degree of the blade according to the measuring point; measuring the opening degree of the blade before and after modification at the same position, wherein the relative variation of the opening degree of a single blade after modification is required to be less than +/-2%; relative change amount = [ (average opening of vane-single opening of vane)/single opening of vane ] × 100%);
according to the requirements of GB _ T10969-2008 water turbine, energy storage pump and pump turbine through-flow component technical conditions, the end surface of the water outlet edge of the blade, the molded line of the water outlet edge trimming area and the molded line of the replacement block area are inspected;
checking the surface roughness of the repaired area; the surface is required to be flush with the base material, and the roughness is not lower than the original surface;
and (3) checking the roundness of the lower ring leakage-stopping ring by adopting a sample plate, allowing a local area to be concave inwards, and polishing and transiting an area, which protrudes outwards and exceeds 1mm, of the local area.
Further, preferably, the material of the replacement block is X3CrNiMo13-4.
The method of the invention thoroughly solves the problem of fatigue damage of metal parts in the original blade cracking area and the welding heat affected area by trimming the molded line of the blade of the turbine runner, cutting off the heat affected area at the intersection of the water outlet edge of the blade and the lower ring and replacing the heat affected area by a high-quality forged steel replacement block, improves the fatigue strength of the runner and fundamentally eliminates the cracks of the turbine runner.
In step (1) of the present invention, the support is not particularly limited, and is preferably a buttress.
The marking template adopted in the step (2) is the existing template.
In the step (3), when the supporting ribs are assembled, two ends of each supporting rib are connected with adjacent blades
In the step (4), the numbering is to facilitate grouping and symmetrical cutting, all the blades are numbered in sequence, and then the circumference is correspondingly cut. The purpose of monitoring the variable value change of the dial indicator is to monitor the amplitude of thermal deformation in the cutting process; specifically, the magnitude of the thermal deformation is controlled within 1 mm.
In the step (5), when the sample plate is used for checking whether the positions of the replacement block and the blade profile line are qualified or not, the adopted sample plate is the existing sample plate, and comparison checking is carried out.
In the step (7), when the roundness of the lower ring leakage-stopping ring is checked by adopting a sample plate, the adopted sample plate is the existing sample plate, and comparison checking is carried out.
The key points of the invention are as follows:
1. cutting and grinding the water outlet edge of the water turbine runner blade: according to the 3D model of the blade, the water outlet edge of the runner blade is integrally cut and polished, so that the thickness and the fatigue resistance of the water outlet edge are increased;
2. cutting off the metal material of the heat affected zone at the connecting part of the water outlet edge of the runner blade and the lower ring;
welding high-quality forged steel with the size identical to that of the cut area of the blade at the stress concentration part, and performing fillet transition on the water outlet edge.
Compared with the prior art, the invention has the beneficial effects that:
1. the invention provides a method for eliminating cracks of a water turbine runner, which solves the problem of cracks of the water turbine runner, improves the health level of a water turbine generator set, and effectively guarantees the operation safety, stability and reliability of a power plant.
2. The method can be widely applied to various hydraulic power plants with cracks on the runner of the water turbine, can also be applied to hydraulic power plants planning to increase the fatigue resistance of the water turbine, has strong reproducibility and popularization, and can effectively eliminate the cracks on the runner of the water turbine.
3. In the prior art, repair welding is carried out on a crack of a runner blade, and a triangular reinforcing block is added at the connecting part of a water outlet edge and a lower ring of the blade. Although the fatigue resistance of the blade is improved to a certain extent, the problem of fatigue damage of metal parts in an original blade cracking area and a welding heat influence area is not solved, metal defects of related areas still exist, and cracks of a turbine runner cannot be eliminated fundamentally. After crack treatment is carried out on the turbine runner by using the method in 2015, cracks do not appear on the turbine runner treated till now.
Drawings
FIG. 1 is a view of the prior art in which a triangular reinforcing block is added to the water outlet edge of a blade;
FIG. 2 is a schematic structural view of a francis turbine runner;
FIG. 3 is a schematic view of the placement of the runner;
FIG. 4 is a schematic diagram of a new water outlet side line;
FIG. 5 is a schematic view of a detecting point of the opening of a runner blade;
FIG. 6 is a schematic diagram of a dial indicator layout;
FIG. 7 is a schematic view of a brace bar;
FIG. 8 is a schematic view of an alternate block position;
FIG. 9 is a schematic view of tack welding;
FIG. 10 is a schematic view of a blade welding sequence;
FIG. 11 is a schematic view of a weld welding sequence.
Detailed Description
The present invention will be described in further detail with reference to examples.
It will be appreciated by those skilled in the art that the following examples are illustrative of the invention only and should not be taken as limiting the scope of the invention. The examples do not specify particular techniques or conditions, and are performed according to the techniques or conditions described in the literature in the art or according to the product specifications. The materials or equipment used are not indicated by manufacturers, and all are conventional products available by purchase.
Example 1
A method for eliminating cracks of a water turbine runner comprises the following steps:
step (1), the rotating wheel is lifted out of the foundation pit, the lower ring is placed on a support, and the large shaft of the rotating wheel is adjusted to be level;
step (2), marking a new water outlet side end surface line on the blade by using a marking template and taking the end surface of the water outlet side of the blade as a reference, marking a position 50mm away from the new water outlet side end surface on a horizontal line to be used as a rotating wheel blade opening detection point, and recording the current inter-blade opening as the opening of the blade before modification;
step (3), uniformly distributing a plurality of dial indicators at the position of the leakage-stopping ring along the circumferential direction, and assembling supporting ribs at the position of the blade water outlet edge, which is 150mm away from the end surface line of the old water outlet edge;
step (4), numbering the blades; cutting blades according to the end surface line of the new water outlet side, reserving 3-5mm polishing allowance during cutting, cutting by adopting grouping symmetry, polishing, and monitoring the variable value change of the dial indicator during the cutting process; then PT flaw detection is carried out on the new water outlet side profile within the range of 100 mm;
step (5), marking the position of a replacement block on the blade processed in the step (4), and reserving 5mm grinding allowance to be used as a cutting line; then, cutting a replacement block, cutting by adopting grouping symmetry, and monitoring the variable value change of the dial indicator in the cutting process; polishing a cutting surface, and performing PT flaw detection; assembling the replacement block to the position of the blade cutting notch for welding;
and (6) removing the supporting ribs, wherein the base metal is not allowed to be damaged during removal, a 3-5mm polishing allowance is reserved, and PT flaw detection is performed after polishing.
Example 2
A method for eliminating cracks of a water turbine runner comprises the following steps:
step (1), the rotating wheel is lifted out of the foundation pit, the lower ring is placed on a support, and the large shaft handle of the rotating wheel is adjusted to be horizontal;
step (2), marking a new water outlet side end surface line on the blade by using a marking template and taking the end surface of the water outlet side of the blade as a reference, marking a position 49mm away from the new water outlet side end surface on a horizontal line to be used as a rotating wheel blade opening detection point, and recording the current inter-blade opening as the opening of the blade before modification;
step (3), uniformly arranging a plurality of dial indicators at the position of the leakage-stopping ring along the circumferential direction, and assembling support ribs at the position of the water outlet edge of the blade, which is 145mm away from the end surface line of the old water outlet edge;
step (4), numbering the blades; cutting blades according to the end surface line of the new water outlet side, reserving 3-5mm polishing allowance during cutting, cutting by adopting grouping symmetry, polishing, and monitoring the variable value change of the dial indicator during the cutting process; then PT flaw detection is carried out on the new water outlet side profile within the range of 90 mm;
step (5), marking the position of a replacement block on the blade processed in the step (4), and reserving a grinding allowance of 5mm as a cutting line; then, cutting the replacement block, cutting by adopting grouping symmetry, and monitoring the variable value change of the dial indicator in the cutting process; polishing a cutting surface, and performing PT flaw detection; assembling the replacement block to the position of the blade cutting notch for welding;
and (6) removing the supporting ribs, wherein the base metal is not allowed to be damaged during removal, a 3-5mm polishing allowance is reserved, and PT flaw detection is performed after polishing.
In the step (1), the large shaft of the rotating wheel is adjusted to be level, and the levelness is 0.05mm/m.
And (5) when the replacement block is assembled at the position of the blade cutting notch, checking whether the positions of the replacement block and the blade profile line are qualified or not by using a sample plate.
In the step (4) and the step (5), the cutting is carried out by adopting a carbon arc gouging.
In the step (5), during welding, the welding rod is AWS E316L; in the welding process, a welding rod with the diameter of 3.2mm is used for priming, and then a welding rod with the diameter of 1.2 mm is used for welding, wherein the welding speed is 6-20cm/min.
And 2 sections of tack welds at the positions of the replacement block and the lower ring weld, 3 sections of tack welds at the positions of the replacement block and the blade weld, wherein the length of each section of tack weld is not less than 30mm, the thickness of each section of tack weld is at least 10mm or half of the depth of a groove, and the tack welds are positioned on the positive pressure side of the blade.
Example 3
A method for eliminating cracks of a runner of a hydraulic turbine comprises the following steps:
step (1), the rotating wheel is lifted out of the foundation pit, the lower ring is placed on a support, and the large shaft of the rotating wheel is adjusted to be level;
step (2), marking a new water outlet side end surface line on the blade by using a marking template and taking the end surface of the water outlet side of the blade as a reference, marking a position 51mm away from the new water outlet side end surface on a horizontal line to be used as a rotating wheel blade opening detection point, and recording the current inter-blade opening as the opening of the blade before modification;
step (3), uniformly arranging a plurality of dial indicators at the position of the leakage-stopping ring along the circumferential direction, and assembling support ribs at the position of the water outlet edge of the blade, which is 155mm away from the end surface line of the old water outlet edge;
step (4), numbering the blades; cutting blades according to the end surface line of the new water outlet side, reserving 3-5mm polishing allowance during cutting, cutting by adopting grouping symmetry, polishing, and monitoring the variable value change of the dial indicator during the cutting process; then PT flaw detection is carried out on the new water outlet side profile within the range of 110 mm;
step (5), marking the position of a replacement block on the blade processed in the step (4), and reserving a grinding allowance of 5mm as a cutting line; then, cutting a replacement block, cutting by adopting grouping symmetry, and monitoring the variable value change of the dial indicator in the cutting process; polishing a cutting surface, and performing PT flaw detection; assembling the replacement block to the position of the blade cutting notch for welding;
and (6) removing the supporting ribs, wherein the base metal is not allowed to be damaged during removal, a 3-5mm polishing allowance is reserved, and PT flaw detection is performed after polishing.
In the step (1), the large shaft of the rotating wheel is adjusted to be level, and the levelness is 0.05mm/m.
And (5) when the replacement block is assembled at the position of the blade cutting notch, checking whether the positions of the replacement block and the blade profile line are qualified or not by using a sample plate.
In the step (4) and the step (5), the cutting is carried out by adopting a carbon arc gouging.
In the step (5), during welding, the welding rod is AWS E316L; in the welding process, a welding rod with the diameter of 3.2mm is used for bottoming, then a welding rod with the diameter of 1.2 mm is used for welding, and the welding speed is 6-20cm/min.
And 2 sections of tack welds at the positions of the replacement block and the lower ring weld, 3 sections of tack welds at the positions of the replacement block and the blade weld, wherein the length of each section of tack weld is not less than 30mm, the thickness of each section of tack weld is at least 10mm or half of the depth of a groove, and the tack welds are positioned on the positive pressure side of the blade.
The whole runner is welded symmetrically according to the positions of the blades;
welding each blade in a welding sequence from inside to outside;
the welding sequence of the single welding seam is as follows: firstly welding a negative pressure surface, fully welding 2/3 of the negative pressure surface from inside to outside, carrying out carbon arc gouging back chipping, and welding a positive pressure side and a negative pressure side to finish a filling weld bead after VT inspection confirms no defect; welding a layer after the welding seam is fully welded, and taking the layer as a tempering welding bead;
if the deformation of a certain point of the excircle of the lower leakage-stopping ring exceeds 1.5mm, stopping welding;
and polishing the welding line, performing UT + PT flaw detection according to the standard, and repairing the surface defects by argon arc welding until the surface defects are qualified.
Further comprising the step (7) of checking the size:
the dimension inspection specifically comprises:
checking the opening degree of the blade according to the measuring point; measuring the opening degree of the blade before and after modification at the same position, wherein the relative variation of the opening degree of a single blade after modification is required to be less than +/-2%; relative change amount = [ (average opening of vane-single opening of vane)/single opening of vane ] × 100%);
according to the requirements of GB _ T10969-2008 water turbine, energy storage pump and pump turbine through-flow component technical conditions, the end surface of the water outlet edge of the blade, the molded line of the water outlet edge trimming area and the molded line of the replacement block area are checked;
checking the surface roughness of the repaired area; the surface is required to be flush with the base material, and the roughness is not lower than the original surface;
and (3) checking the roundness of the lower ring leakage-stopping ring by adopting a sample plate, allowing a local area to be concave inwards, and polishing and transiting an area, which protrudes outwards and exceeds 1mm, of the local area.
The material of the replacement block is X3CrNiMo13-4.
Examples of the applications
The water turbine runner repair mainly carries out water outlet edge cutting and short polishing, replacement area digging and removing and replacement block welding. Cutting and polishing the water outlet edge according to a 3D model of the blade, cutting 100mm at the maximum, cutting a replacement block reinforcing area, adopting high-quality forged steel as a replacement block, taking X3CrNiMo13-4 as a material, enabling the total size to be 400X 300mm, enabling the water outlet edge to be 20mm at the thinnest, and welding the water outlet edge at a stress concentration part near the lower ring to perform fillet transition. The main process flow is as follows:
1. end face trimming method for water outlet edge of blade
1. The runner is hoisted out of the foundation pit, and 6 buttresses are placed at the position of the lower ring, as shown in figure 3.
2. And a frame type level meter is used for adjusting the large shaft of the rotating wheel to level the joint surface, and the levelness is 0.05mm/m.
3. And (4) marking a new water outlet side end surface line on the blade by using the marking template and taking the water outlet side end surface of the blade as a reference, as shown in figure 4.
4. And marking the position 50mm away from the new water outlet edge end surface on the horizontal line as a rotating wheel blade opening degree detection point, as shown in figure 5. And recording the opening degree between the blades before processing.
5. A dial indicator is arranged at the position of the leakage stopping ring, and 8 dial indicators are uniformly distributed along the circumferential direction, as shown in figure 6.
6. And (3) assembling support ribs (in-situ assembling) at the position of the water outlet side of the blade, which is 150mm away from the end line of the water outlet side, and welding and fixing the support ribs as shown in the figure 7.
7. And carrying out blade numbering. And (3) cutting the blade by using a carbon arc gouging machine according to the scribing position, reserving 3-5mm of polishing allowance, cutting by adopting grouping symmetry, and monitoring the change value of the variable value of the dial indicator in the cutting process.
8. And polishing and shaping the water outlet edge, wherein the water outlet edge is polished to be smooth transition from the vortex water outlet edge of the anti-blocking door to the semicircular water outlet edge.
9. And carrying out PT flaw detection on the new water outlet side profile within the range of 100 mm.
2. Replacement area cutting and replacement
1. Alternate block locations are scribed on the blade in the position shown in fig. 8. And reserving grinding allowance of 5mm as a cutting line.
2. And (3) cutting the blade by using a carbon arc gouging according to the scribing position, cutting by adopting grouping symmetry, and monitoring the variable value change of the dial indicator in the cutting process.
3. And (5) polishing a cutting surface and carrying out PT flaw detection.
4. The replacement block is assembled to the blade cutting notch position, and the template is used for checking whether the replacement block and the blade profile line position are qualified.
5. Replacement block to blade welding
5.1. Welding was performed by manual arc welding with the electrode AWS E316L.
5.2. The welding parameters were performed as in table 1.
Table 1: welding parameters
5.3. General requirements for welding
The storage and use of the welding rod are executed according to JB/T3223.
And cleaning and removing impurities which are harmful to welding quality, such as flaw detection liquid, rust, oil stain and the like within a range of 50mm near the welding area. When the wind speed of the welding environment is higher than 10 m/s or the relative humidity is higher than 90%, if no effective preventive measures are taken, the welding is stopped.
Preheating range: the area to be welded and the vicinity thereof are 50mm.
In the welding process, a welding rod with the diameter of 3.2mm is needed to be used for priming; after the bottoming is finished, the phi 1.2 welding rod is replaced when formal welding is carried out.
The preheating mode is flame heating, and the preheating temperature is more than or equal to 100 ℃.
And (4) performing multi-layer and multi-pass welding at the welding speed of 6-20cm/min.
5.4. Tack welding
2 sections of tack welds at the positions of the replacement block and the lower ring weld, and 3 sections of tack welds at the positions of the replacement block and the blade weld, wherein the length of each section of tack weld is not less than 30mm, and the thickness of each section of tack weld is at least 10mm or half of the groove depth, as shown in figure 9. The tack welds are located on the positive pressure side of the blade. The replacement block position is checked again after tack welding.
5.5. Welding sequence
1) The whole runner should be welded symmetrically according to the position of the blade.
2) The welding sequence for each blade is performed in an inside-out welding sequence, as shown in fig. 10. The welding sequence is indicated by the serial number.
3) The welding sequence of the single welding seam is as follows: firstly welding a negative pressure surface, fully welding 2/3 of the negative pressure surface from inside to outside, carrying out carbon arc gouging back gouging, and welding a positive pressure side and a negative pressure side to finish filling welding passes after VT inspection confirms no defect. As shown in fig. 11. The welding sequence is indicated by the serial number.
4) And welding a layer after the welding seam is fully welded, and taking the layer as a tempering welding bead.
5.6. And if the deformation of a certain point of the excircle of the lower leakage-stopping ring exceeds 1.5mm, stopping welding.
5.7. Polishing the welding line, performing UT + PT flaw detection according to the standard, repairing the surface defects by argon arc welding until the surface defects are qualified, and performing argon arc welding according to the welding parameters shown in the table 2.
Table 2: welding parameters of argon arc welding
| Diameter of welding wire/mm | Polarity | Welding current/A | Welding voltage/V | Preheating temperature/. Degree.C | Interlayer temperature/. Degree.C |
| Φ2.4 | Direct current is connected positively | 70~130 | 8~15 | ≥80 | ≤200 |
5.8. Removing the support, not allowing the parent metal to be damaged, reserving a polishing allowance of 3-5mm, and performing PT flaw detection according to the standard after polishing.
5.9. The profile of the replacement block area is checked again.
3. Dimensional inspection
1) And checking the opening degree of the blade according to the measuring points.
2) And (5) inspecting the profile of the end face of the water outlet edge of the blade.
3) And (5) checking the molded line of the water outlet trimming area.
4) And (5) replacing the block region type line inspection.
5) And checking the surface roughness of the repaired area, wherein the surface roughness is required to be flush with the base material, and the roughness is not lower than the original surface.
6) And (3) checking the roundness of the lower ring leakage-stopping ring by adopting a sample plate, allowing a local area to be concave inwards, and polishing and transiting an area with the local area protruding outwards and exceeding 1 mm.
In the prior art, repair welding is carried out on a crack of a runner blade, and a triangular reinforcing block is added at the connecting part of a water outlet edge and a lower ring of the blade. Although the fatigue resistance of the blade is improved to a certain extent, the problem of fatigue damage of metal parts in the original blade cracking area and the welding heat affected area is not solved, metal defects of related areas still exist, and cracks of the turbine runner cannot be eliminated fundamentally. After crack treatment is carried out on the turbine runner by using the method in 2015, cracks do not appear on the turbine runner treated till now.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (9)
1. A method for eliminating cracks of a water turbine runner is characterized by comprising the following steps:
step (1), the rotating wheel is lifted out of the foundation pit, the lower ring is placed on a support, and the large shaft of the rotating wheel is adjusted to be level;
step (2), marking a new water outlet side end surface line on the blade by using a marking template and taking the end surface of the water outlet side of the blade as a reference, marking a position 49-51mm away from the new water outlet side end surface on a horizontal line to be used as a rotating wheel blade opening detection point, and recording the current opening between the blades to be used as the opening of the blades before modification;
step (3), uniformly distributing a plurality of dial indicators at the position of the leakage-stopping ring along the circumferential direction, and assembling support ribs at the position of the blade water outlet edge, which is 145-155mm away from the end face line of the old water outlet edge;
step (4), numbering the blades; cutting blades according to the end surface line of the new water outlet side, reserving 3-5mm polishing allowance during cutting, cutting by adopting grouping symmetry, polishing, and monitoring the variable value change of the dial indicator during the cutting process; then PT flaw detection is carried out on the new water outlet side profile within the range of 90-110 mm;
step (5), marking the position of a replacement block on the blade processed in the step (4), and reserving a grinding allowance of 5mm as a cutting line; then, cutting a replacement block, cutting by adopting grouping symmetry, and monitoring the variable value change of the dial indicator in the cutting process; polishing a cutting surface, and performing PT flaw detection; assembling the replacement block to the position of the blade cutting notch for welding;
and (6) removing the supporting ribs, wherein the base metal is not allowed to be damaged during removal, a 3-5mm polishing allowance is reserved, and PT flaw detection is performed after polishing.
2. The method for eliminating cracks on the runner of a water turbine as claimed in claim 1, wherein in the step (1), the large axis of the runner is adjusted to be horizontal and the levelness is adjusted to 0.05mm/m.
3. The method for eliminating cracks of a turbine runner according to claim 1, wherein in the step (5), when the replacement block is fitted to the blade cutting notch position, the position of the replacement block and the blade profile line is checked to be acceptable by using a sample plate.
4. The method for eliminating cracks on a water turbine runner according to claim 1, wherein in the step (4) and the step (5), the cutting is performed by carbon arc gouging.
5. The method for eliminating cracks on the runner of a water turbine as claimed in claim 1, wherein in the step (5), the welding rod is AWS E316L; in the welding process, a welding rod with the diameter of 3.2mm is used for bottoming, then a welding rod with the diameter of 1.2 mm is used for welding, and the welding speed is 6-20cm/min.
6. The method for eliminating cracks of a turbine runner according to claim 5, wherein the replacement block is welded with 2 sections of tack welds at the lower circumferential weld and 3 sections of tack welds at the weld of the replacement block and the blade, each section of tack weld has a length of not less than 30mm and a thickness of at least 10mm or a half of a groove depth, and the tack welds are located on the positive pressure side of the blade.
7. The method for eliminating cracks on a turbine runner of claim 5, wherein the entire runner is welded symmetrically according to the blade positions;
welding each blade in a welding sequence from inside to outside;
the welding sequence of the single welding seam is as follows: firstly welding a negative pressure surface, fully welding 2/3 of the negative pressure surface from inside to outside, carrying out carbon arc gouging back gouging, and welding a positive pressure side and a negative pressure side to finish filling welding passes after VT inspection confirms no defect; welding a layer after the welding seam is fully welded, and taking the layer as a tempering welding bead;
if the deformation of a certain point of the excircle of the lower leakage-stopping ring exceeds 1.5mm, stopping welding;
and polishing the welding line, performing UT + PT flaw detection according to the standard, and repairing the surface defects by argon arc welding until the surface defects are qualified.
8. The method for eliminating cracks in a turbine runner according to claim 1, further comprising the step (7) of checking the dimensions:
the dimension inspection specifically comprises:
checking the opening degree of the blade according to the measuring point; measuring the opening degree of the blade before and after modification at the same position, wherein the relative variation of the opening degree of a single blade after modification is required to be less than +/-2%; relative change amount = [ (average opening of vane-single opening of vane)/single opening of vane ] × 100%);
according to the requirements of GB _ T10969-2008 water turbine, energy storage pump and pump turbine through-flow component technical conditions, the end surface of the water outlet edge of the blade, the molded line of the water outlet edge trimming area and the molded line of the replacement block area are inspected;
checking the surface roughness of the repaired area; the surface is required to be flush with the base material, and the roughness is not lower than the original surface;
and (3) checking the roundness of the lower ring leakage-stopping ring by adopting a sample plate, allowing a local area to be concave inwards, and polishing and transiting an area, which protrudes outwards and exceeds 1mm, of the local area.
9. The method for eliminating cracks on a turbine runner of claim 1, wherein the material of the replacement block is X3CrNiMo13-4.
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