CN116117429A - Online repairing equipment and method for sealing surface of valve seat of safety valve - Google Patents
Online repairing equipment and method for sealing surface of valve seat of safety valve Download PDFInfo
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- CN116117429A CN116117429A CN202211092683.9A CN202211092683A CN116117429A CN 116117429 A CN116117429 A CN 116117429A CN 202211092683 A CN202211092683 A CN 202211092683A CN 116117429 A CN116117429 A CN 116117429A
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- 238000007789 sealing Methods 0.000 title claims abstract description 145
- 238000000034 method Methods 0.000 title claims abstract description 32
- 230000007246 mechanism Effects 0.000 claims abstract description 160
- 230000005540 biological transmission Effects 0.000 claims abstract description 104
- 239000000956 alloy Substances 0.000 claims abstract description 9
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 9
- 238000003466 welding Methods 0.000 claims description 166
- 238000010438 heat treatment Methods 0.000 claims description 25
- 238000007689 inspection Methods 0.000 claims description 17
- 230000008569 process Effects 0.000 claims description 16
- 238000012806 monitoring device Methods 0.000 claims description 13
- 230000008439 repair process Effects 0.000 claims description 13
- 230000002265 prevention Effects 0.000 claims description 7
- 239000000463 material Substances 0.000 claims description 6
- 238000007639 printing Methods 0.000 claims description 6
- 230000000903 blocking effect Effects 0.000 claims description 3
- 230000013011 mating Effects 0.000 claims 1
- 238000012544 monitoring process Methods 0.000 abstract description 6
- 238000012423 maintenance Methods 0.000 abstract description 5
- 230000007547 defect Effects 0.000 description 13
- 238000010586 diagram Methods 0.000 description 9
- 238000012360 testing method Methods 0.000 description 4
- 238000011056 performance test Methods 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009659 non-destructive testing Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000005493 welding type Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P6/00—Restoring or reconditioning objects
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- 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
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E30/00—Energy generation of nuclear origin
- Y02E30/30—Nuclear fission reactors
Abstract
The disclosure belongs to the technical field of nuclear power, and particularly relates to safety valve seat sealing surface on-line repairing equipment and method. The online cutting device can be integrally installed in the safety valve through the first connecting plate, so that the online cutting device is convenient to install and detach; the space position of the cutter in the safety valve can be adjusted through the Z-axis transmission mechanism, the Y-axis transmission mechanism and the X-axis transmission mechanism, and the positions of the cutter and the sealing surface can be finely adjusted through the cutter transmission mechanism, so that the safety valve can adapt to safety valves with various types and sizes, and any position of the sealing surface can be turned, the application is wide, and the purchase and replacement cost of spare parts of the whole valve is effectively reduced; the turning of the alloy layer of the sealing surface of the valve seat can be completed through the first control device and the first camera in a remote monitoring control manner, so that the field irradiation dose of maintenance personnel is effectively reduced.
Description
Technical Field
The invention belongs to the technical field of nuclear power, and particularly relates to equipment and a method for repairing a sealing surface of a valve seat of a safety valve on line.
Background
At present, the defect of the sealing surface of the safety valve is generally maintained in a grinding mode, but when the defect of the sealing surface of the safety valve is large or has a penetrating crack defect, the defect of the sealing surface of the safety valve cannot be maintained in a grinding mode. In addition, if a defect appears on the valve core sealing surface, the defect can be eliminated by replacing the valve core, and if the defect appears on the valve seat sealing surface, the valve can only be replaced by the whole valve. The replacement operation of the safety valve in a valve core or flange connection mode is relatively simple, but the replacement operation of the welding type safety valve is very complicated. In particular to a large-caliber nuclear-grade safety valve, which requires a great deal of manpower, material resources and financial resources for preparation and implementation.
Aiming at the analysis from actual field work, the whole valve replacement work of the welded safety valve has larger defects and uncertain factors. For a welded nuclear-grade large-caliber safety valve, firstly, preparing a whole valve spare part in advance; secondly, confirming technical requirements of welding, installation, test and the like required by the replacement of the whole valve through a design institute; thirdly, confirming the field implementation environment, and preparing a special tool according to the technical requirement; finally, the whole valve replacement work is completed on site and verified through experiments. In the process, the preparation period of spare parts is long, the cost is high, uncertainty exists, the implementation technical conditions need to be confirmed after the spare parts are implemented, special tools are prepared according to the technical conditions by writing the implementation technical scheme, and simulation exercise is carried out by combining the actual conditions of the site. And finally, performing field implementation, nondestructive testing and hydrostatic testing. All links must strictly control the quality or the planned work of the whole unit is seriously affected. If the sudden valve seat sealing surface cannot repair the defect, the maintenance work can be very passive or even can not be completed.
Regardless of the known or unknown defect of the sealing surface of the valve seat of the safety valve, the efficiency of defect eliminating work is improved, and the cost of defect eliminating work is reduced.
Disclosure of Invention
In order to overcome the problems in the related art, the online repairing equipment and the online repairing method for the sealing surface of the valve seat of the safety valve are provided.
According to an aspect of the embodiments of the present disclosure, there is provided an on-line relief valve seat sealing surface repairing apparatus including: the online cutting device, the online cutting device includes: the device comprises a first rotating mechanism, a Z-axis transmission mechanism, a Y-axis transmission mechanism, an X-axis transmission mechanism, a first rack, a first connecting plate, a first main shaft, a cutter transmission mechanism, a cutter, a first control device, a first monitoring device, a first camera and a cutter head;
the first connecting plate can be connected to the upper end of the valve body of the safety valve, and is respectively connected with the first rotating mechanism, the Z-axis transmission mechanism, the Y-axis transmission mechanism and the X-axis transmission mechanism through the first rack;
the upper end of the first main shaft is respectively connected with the first rotating mechanism, the Z-axis transmission mechanism, the Y-axis transmission mechanism and the X-axis transmission mechanism, the lower end of the first main shaft is connected with the cutter head, and the lower end of the cutter head is connected with the cutter through the cutter transmission mechanism;
the first control device can control the Z-axis transmission mechanism to drive the cutter to move along the radial direction, control the Y-axis transmission mechanism to drive the cutter to move along the horizontal first direction, control the X-axis transmission mechanism to drive the cutter to move along the horizontal second direction, and control the cutter transmission mechanism to drive the cutter to move along the radius of the lower surface of the cutter disc, wherein the first direction is perpendicular to the second direction;
the axis of the cutter disc is coincident with the axis of the safety valve seat, and the first control device can control the first rotating mechanism to drive the cutter to rotate around the axis of the first main shaft under the condition that the cutter contacts the sealing surface of the valve seat, so that the cutter turns the sealing surface;
the first camera is connected to the lower end of the cutter head and used for shooting images of the cutter and surrounding environment of the cutter, and the first monitoring device is used for acquiring and displaying the images acquired by the first camera in real time.
In one possible implementation, the in-line cutting device includes a plurality of first connection plates, each of which is detachably mountable in the in-line cutting device, and a different second connection plate is mountable in a matching manner with a flange in a safety valve body of a different size.
In one possible implementation, the in-line cutting device includes a plurality of cutterheads, each cutterhead being removably mountable in the in-line cutting device, the diameter of the different cutterheads matching the diameter of the different kinds of valve seats.
In one possible implementation manner, the safety valve seat sealing surface online repairing device further includes: an online build-up device, the online build-up device comprising: the welding machine comprises a wire feeder, a welding machine, a second frame, a second connecting plate, a second main shaft, a rotating disc, a welding gun transmission mechanism, a welding gun, a second camera, a second monitoring device, a second control device, a second rotating mechanism, an arc length electric sliding frame, a yaw electric sliding frame and a longitudinal swing electric sliding frame;
the second connecting plate is connected to the upper end of the valve body of the safety valve, the wire feeder and the welding machine are connected with the second connecting plate, and the second connecting plate is respectively connected with the second rotating mechanism, the arc length electric sliding frame, the yaw electric sliding frame and the pitch electric sliding frame through the second rack;
the upper end of the second main shaft is respectively connected with the second rotating mechanism, the arc length electric sliding frame, the yaw electric sliding frame and the pitch electric sliding frame, the lower end of the second main shaft is connected with the rotating disc, the lower end of the rotating disc is connected with the welding gun through the welding gun transmission mechanism, and the welding gun is connected with the welding machine;
the second control device can control the arc length electric sliding frame to drive the welding gun to move along the radial direction, control the yaw electric sliding frame to drive the welding gun to move along the horizontal first direction, control the longitudinal swing electric sliding frame to drive the welding gun to move along the horizontal second direction, and control the welding gun transmission mechanism to drive the welding gun to move along the radius of the lower surface of the cutterhead;
under the condition that the welding gun is located right above the sealing surface by a preset distance, the second control device controls the wire feeder and the welding machine to start working, and controls the second rotating mechanism to drive the welding gun to rotate around the axis of the second main shaft, so that the welding gun moves along the annular upper surface of the sealing surface for surfacing;
the second camera is connected to the lower end of the rotating disc and used for shooting the welding gun and images of surrounding environments of the welding gun, and the second monitoring device is used for acquiring and displaying the images acquired by the second camera in real time.
In one possible implementation, the online build-up device includes a plurality of second connection plates, each second connection plate being removably mountable in the online build-up device, different second connection plates being mountable in a matching manner with flanges in safety valve bodies of different sizes.
In one possible implementation, the online build-up device includes a plurality of rotating disks, each of which is removably mountable in the online build-up device, the diameter of the different rotating disks matching the diameter of the different kinds of valve seats.
In one possible implementation manner, the online repairing device for the sealing surface of the valve seat of the safety valve further comprises a plurality of foreign matter prevention devices, wherein positions, close to the valve seat, of an inlet and an outlet of the safety valve, on which the plurality of foreign matter prevention devices are installed are used for blocking the debris splashed in the process of repairing the valve seat from entering the inlet and the outlet of the safety valve.
According to another aspect of the embodiments of the present disclosure, there is provided an online repairing method for a sealing surface of a seat of a relief valve, the method including:
step 100, disassembling the safety valve from the pipeline system, and determining a repairing process according to the structural size of the safety valve and the materials of the valve seat body and the sealing surface of the safety valve;
step 101, installing an online cutting device in a safety valve;
102, under the condition that the wire cutting device is safe, controlling a Z-axis transmission mechanism, a Y-axis transmission mechanism and an X-axis transmission mechanism to adjust the position of a cutter through a first control device, so that the axis of a cutter disc is coincident with the axis of a valve seat of a safety valve, and the cutter is opposite to and contacts with the upper surface of a sealing surface;
step 103, after step 102, controlling a first rotating mechanism to drive a cutter to rotate by a first control device so as to perform online turning on a sealing surface;
104, performing PT inspection on the sealing surface after the sealing surface is turned;
step 105, after the PT inspection in step 104 is passed, the online cutting device is detached from the safety valve, a heat treatment device is arranged around the sealing surface, and the sealing surface is subjected to pre-welding heat treatment;
step 106, after the pre-welding heat treatment is finished, the heat treatment device is disassembled, and an online build-up welding device is installed in the safety valve;
step 107, under the condition that the online build-up welding device is installed, controlling an arc length electric sliding frame, a yaw electric sliding frame and a longitudinal swing electric sliding frame to adjust the position of a welding gun through a second control device, so that the axis of a rotating disc is overlapped with the axis of a safety valve seat, and the welding gun is positioned at a position right above a sealing surface by a preset distance;
step 108, after step 107, controlling the wire feeder and the welding machine to be started through a second control device, and controlling a second rotating mechanism to drive the welding gun to rotate, so that the welding gun moves along the annular upper surface of the sealing surface for surfacing welding;
step 109, after the surface overlaying on the sealing surface is finished, the online butt welding device is detached from the safety valve, a heat treatment device is arranged around the top end of the valve seat, and postweld heat treatment is carried out;
step 110, after the postweld heat treatment is finished, the heat treatment device is disassembled from the safety valve, and an online cutting device is arranged in the safety valve;
step 111, after the linear cutting device is installed, controlling a Z-axis transmission mechanism, a Y-axis transmission mechanism and an X-axis transmission mechanism to adjust the position of a cutter through a first control device, and under the condition that the axis of a cutter disc is coincident with the axis of a safety valve seat, controlling the cutter transmission mechanism to enable the cutter to be positioned on the upper surface of a sealing surface surfacing layer, controlling a first rotation mechanism to drive the cutter to rotate so as to turn the upper surface of the surfacing layer, controlling the cutter transmission mechanism to enable the cutter to be positioned on the inner side of the sealing surface surfacing layer, controlling the first rotation mechanism to drive the cutter to rotate so as to turn the inner side surface of the surfacing layer, and controlling the cutter transmission mechanism to enable the cutter to be positioned on the outer side of the sealing surface surfacing layer, and controlling the first rotation mechanism to drive the cutter to rotate so as to turn the outer side surface of the surfacing layer;
step 112, after turning the outer surface of the build-up welding layer, detaching the online cutting device from the safety valve, and performing PT inspection on the sealing surface of the valve seat;
step 113, grinding the valve seat sealing surface and performing color printing inspection after PT inspection on the valve seat sealing surface is passed;
step 114, after finishing grinding and color printing inspection of the valve seat sealing surface, the safety valve is returned to the pipeline system.
In one possible implementation, when the on-line cutting device is used for turning, the first control device controls the Z-axis transmission mechanism to step by taking a preset step size as a unit, and the alloy layer of the sealing surface of the valve seat is turned on line.
In one possible implementation, the preset step is between 0.15 and 0.25 mm.
In one possible implementation, step 108 further includes:
after step 107, the wire feeder and the welding machine are controlled to be started by the second control device, the second rotating mechanism is controlled to drive the welding gun to rotate, and the welding gun driving mechanism is controlled to drive the welding gun to move back and forth between the outer ring edge and the inner ring edge of the sealing surface, so that the welding gun moves along the fold line or curve of the annular upper surface of the sealing surface to build up welding.
In a possible implementation manner, step 108 further includes, after step 107, controlling, by the second control device, the wire feeder and the welding machine to be turned on, and repeating the following steps with different temporary distances until the welding gun overlay covers the entire upper surface of the sealing surface, where the temporary distances are between the radius of the inner ring of the valve seat and the radius of the outer ring of the valve seat:
and after the welding gun transmission mechanism is controlled to drive the welding gun to be separated from the axis of the rotating disc by a temporary distance, the welding gun is controlled to drive the welding gun to rotate by the second welding mechanism, so that the welding gun is enabled to build up welding along the sealing surface.
In one possible implementation, after step 108, the welding gun driving mechanism is controlled to drive the welding gun to horizontally move to a position opposite to the outer edge of the sealing surface, and then the welding second rotating mechanism is controlled to drive the welding gun to rotate, so that the welding gun is overlaid along the edge of the sealing surface.
In one possible implementation, step 111 further includes: in the process of turning the upper surface of the surfacing layer of the sealing surface, the second control device monitors the flatness of the upper surface of the surfacing layer in real time and the distance from the upper surface of the surfacing layer to the flange in the safety valve, and when the distance from the upper surface of the surfacing layer, which is flat and has no pits, to the flange in the safety valve is judged to be the repairing distance, the turning of the upper surface of the surfacing layer is stopped.
The beneficial effects of the present disclosure are: the online cutting device can be integrally installed in the safety valve through the first connecting plate, so that the online cutting device is convenient to install and detach; the space position of the cutter in the safety valve can be adjusted through the Z-axis transmission mechanism, the Y-axis transmission mechanism and the X-axis transmission mechanism, and the positions of the cutter and the sealing surface can be finely adjusted through the cutter transmission mechanism, so that the safety valve can adapt to safety valves with various types and sizes, and any position of the sealing surface can be turned, the application is wide, and the purchase and replacement cost of spare parts of the whole valve is effectively reduced; the turning of the alloy layer of the sealing surface of the valve seat can be completed through the first control device and the first camera in a remote monitoring control manner, so that the field irradiation dose of maintenance personnel is effectively reduced.
Drawings
Fig. 1 is a schematic view of an in-line cutting apparatus according to an exemplary embodiment.
FIG. 2 is a schematic diagram of an online build-up device, according to an exemplary embodiment.
Fig. 3 is a schematic view illustrating a foreign matter prevention device according to an exemplary embodiment.
FIG. 4 is a schematic diagram illustrating a valve seat sealing surface prior to turning, according to an exemplary embodiment.
FIG. 5 is a schematic diagram illustrating a valve seat sealing surface turned according to an exemplary embodiment.
Fig. 6 is a schematic diagram illustrating a heat treatment apparatus according to an exemplary embodiment.
FIG. 7 is a schematic diagram illustrating a valve seat sealing surface weld overlay according to an example embodiment.
FIG. 8 is a schematic diagram illustrating a weld gun motion trajectory during a valve seat sealing surface build-up process, according to an example embodiment.
FIG. 9 is a schematic illustration of a valve seat sealing surface weld overlay finish without a turning process, according to an example embodiment.
FIG. 10 is a schematic diagram illustrating a valve seat sealing surface weld overlay turned according to an exemplary embodiment.
Fig. 11 is a schematic diagram illustrating a relief valve size according to an exemplary embodiment.
In the figure:
1. a valve body; 2. a valve seat; 3. sealing surfaces; 4. a middle flange; 5. a first rotation mechanism; 6. a Z-axis transmission mechanism; 7. a Y-axis transmission mechanism; 8. an X-axis transmission mechanism; 9. a first frame; 10. a first connection plate; 11. a first spindle; 12. a cutter transmission mechanism; 13. a cutter; 14. a first control device; 15. a first monitoring device; 16. a first camera; 17. a cutterhead; 18. a water tank; 19. a second frame; 20. a second connecting plate; 21. arc length electric carriage; 22. a second rotation mechanism; 23. a second spindle; 25. a rotating disc; 26. a second camera; 27. a welding gun transmission mechanism; 28. a welding gun; 29. a second monitoring; 30. a second control device; 37. a wire feeder; 38. welding machine; 52. yaw electric carriage; 53. a pitch electric carriage; 54. a foreign matter prevention device.
Detailed Description
The invention will be described in further detail with reference to the accompanying drawings and specific examples.
Fig. 1 is a schematic view of an in-line cutting apparatus according to an exemplary embodiment. As shown in fig. 1, the on-line repair device for the sealing surface of the valve seat of the safety valve comprises: the online cutting device, the online cutting device includes: the device comprises a first rotating mechanism 5, a Z-axis transmission mechanism 6, a Y-axis transmission mechanism 7, an X-axis transmission mechanism 8, a first rack 9, a first connecting plate 10, a first main shaft 11, a cutter transmission mechanism 12, a cutter 13, a first control device 14, a first monitoring device 15, a first camera 16 and a cutter disc 17;
the first connecting plate 10 can be connected to the upper end of the valve body 1 of the safety valve, and the first connecting plate 10 is respectively connected with the first rotating mechanism 5, the Z-axis transmission mechanism 6, the Y-axis transmission mechanism 7 and the X-axis transmission mechanism 8 through the first rack 9;
the upper end of the first main shaft 11 is respectively connected with the first rotating mechanism 5, the Z-axis transmission mechanism 6, the Y-axis transmission mechanism 7 and the X-axis transmission mechanism 8, the lower end of the first main shaft 11 is connected with the cutter disc 17, and the lower end of the cutter disc 17 is connected with the cutter 13 through the cutter transmission mechanism 12;
the first control device 14 can control the Z-axis transmission mechanism 6 to drive the cutter 13 to move along a radial direction, control the Y-axis transmission mechanism 7 to drive the cutter 13 to move along a horizontal first direction, control the X-axis transmission mechanism 8 to drive the cutter 13 to move along a horizontal second direction, and control the cutter transmission mechanism 12 to drive the cutter 13 to move along a radius of the lower surface of the cutter disc 17, wherein the first direction is perpendicular to the second direction;
the axis of the cutter disc 17 coincides with the axis of the valve seat 2, and the first control device 14 can control the first rotating mechanism 5 to drive the cutter 13 to rotate around the axis of the first main shaft 11 under the condition that the cutter 13 contacts the sealing surface 3, so that the cutter 13 turns the sealing surface 3;
the first camera 16 is connected to the lower end of the cutter head 17, and is configured to capture images of the cutter 13 and an environment surrounding the cutter 13, and the first monitoring device 15 is configured to acquire and display images acquired by the first camera 16 in real time.
The online cutting device can be integrally installed in the safety valve through the first connecting plate, so that the online cutting device is convenient to install and detach; the space position of the cutter in the safety valve can be adjusted through the Z-axis transmission mechanism, the Y-axis transmission mechanism and the X-axis transmission mechanism, and the positions of the cutter and the sealing surface can be finely adjusted through the cutter transmission mechanism, so that the safety valve can adapt to safety valves with various types and sizes, and any position of the sealing surface can be turned, the application is wide, and the purchase and replacement cost of spare parts of the whole valve is effectively reduced; the turning of the alloy layer of the sealing surface of the valve seat can be completed through the first control device and the first camera in a remote monitoring control manner, so that the field irradiation dose of maintenance personnel is effectively reduced.
In one possible implementation, the in-line cutting device comprises a plurality of first connection plates 10, each first connection plate 10 being detachably mountable in the in-line cutting device, different first connection plates 10 being mountable in match with flanges 4 in safety valve bodies 1 of different sizes. In this way, the in-line cutting device can be installed in a safety valve of a different size by exchanging the in-line cutting device for a first connection plate of a different size.
In one possible implementation, the in-line cutting device comprises a plurality of cutterheads 17, each cutterhead 17 being removably mountable in the in-line cutting device, the diameter of the different cutterheads 17 being matched to the diameter of the different kinds of valve seats 2. Therefore, turning of valve seats with different sizes can be realized by replacing cutterheads with different sizes.
FIG. 2 is a schematic diagram of an online build-up device, according to an exemplary embodiment. As shown in fig. 2, the on-line repairing device for the sealing surface of the valve seat of the safety valve further comprises: an online build-up device, the online build-up device comprising: wire feeder 37, welding machine 38, second frame 19, second connecting plate 20, second main shaft 23, rotary disk 25, welding gun transmission mechanism 27, welding gun 28, second camera 26, second monitoring device 29, second control device 30, second rotary mechanism 22, arc length electric carriage 21, yaw electric carriage 52, pitch electric carriage 53;
the second connecting plate 20 is connected to the upper end of the valve body 1 of the safety valve, the wire feeder 37 and the welding machine 38 are connected to the second connecting plate 20, and the second connecting plate 20 is respectively connected to the second rotating mechanism 22, the arc length electric carriage 21, the yaw electric carriage 52 and the pitch electric carriage 53 through the second frame 19;
the upper end of the second main shaft 23 is respectively connected with the second rotating mechanism 22, the arc length electric sliding frame 21, the yaw electric sliding frame 52 and the pitch electric sliding frame 53, the lower end of the second main shaft 23 is connected with the rotating disc 25, the lower end of the rotating disc 25 is connected with the welding gun 28 through the welding gun transmission mechanism 27, and the welding gun 28 is connected with the welding machine 38;
the second control device 30 can control the arc length electric sliding frame 21 to drive the welding gun 28 to move along the radial direction, control the yaw electric sliding frame 52 to drive the welding gun 28 to move along the horizontal first direction, control the pitch electric sliding frame 53 to drive the welding gun 28 to move along the horizontal second direction, and control the welding gun transmission mechanism 27 to drive the welding gun 28 to move along the radius of the lower surface of the cutter disc 17;
when the welding gun 28 is located right above the sealing surface 3 by a preset distance, the second control device 30 controls the wire feeder 37 and the welding machine 38 to start working, and controls the second rotating mechanism 22 to drive the welding gun 28 to rotate around the axis of the second main shaft 23, so that the welding gun 28 moves along the annular upper surface of the sealing surface 3 for surfacing;
the second camera 26 is connected to the lower end of the rotating disc 25, and is configured to capture images of the welding gun 28 and an environment surrounding the welding gun 28, and the second monitoring device 29 is configured to acquire and display images acquired by the second camera 26 in real time.
The online surfacing device can be integrally installed in the safety valve through the second connecting plate, so that the online surfacing device is convenient to install and detach; the space position of the welding gun in the safety valve can be adjusted through the arc length electric sliding frame, the yaw electric sliding frame and the longitudinal swing electric sliding frame, and the positions of the welding gun and the sealing surface can be finely adjusted through the welding gun transmission mechanism, so that the safety valve can adapt to safety valves with various types and sizes, any position of the sealing surface can be subjected to surfacing, the application is wide, and the purchase and replacement cost of spare parts of the whole valve is effectively reduced; the turning of the alloy layer of the sealing surface of the valve seat can be completed through remote monitoring control by the second control device and the second camera, so that the field irradiation dose of maintenance personnel is effectively reduced.
It should be noted that the first control device and the second control device may be represented as intelligent electronic devices capable of executing program to process data, and the first control device and the second control device may be, for example, a computer, an intelligent mobile terminal, etc., and the types of the first control device and the second control device are not limited in this disclosure.
The first control device and the second control device may be integrated in the same device, or may be two different devices, and the specific forms of the first control device and the second control device are not limited in this disclosure.
In one possible implementation, the online build-up device includes a plurality of second connection plates 20, each second connection plate 20 being removably mountable in the online build-up device, different second connection plates 20 being mountable to match the flange 4 in the differently sized relief valve body 1. In this way, the online build-up welding device can be installed in safety valves of different sizes by replacing the online cutting device with a second connecting plate of different sizes.
In one possible implementation, the online build-up device comprises a plurality of rotating disks 25, each rotating disk 25 being removably mountable in the online build-up device, the diameter of a different rotating disk 25 matching the diameter of a different kind of valve seat 2. Therefore, build-up welding of valve seats with different sizes can be realized by replacing rotating discs with different sizes.
In one possible implementation manner, the safety valve seat sealing surface online repairing device further comprises a plurality of foreign matter prevention devices 54, wherein positions, close to the valve seat 2, of an inlet and an outlet of the safety valve, on which the plurality of foreign matter prevention devices 54 are installed are used for blocking the debris splashed during the repairing of the valve seat 2 from entering the inlet and the outlet of the safety valve.
In one possible implementation manner, there is provided an online repairing method for a sealing surface of a valve seat of a safety valve, the method including:
step 100, disassembling the safety valve from the pipeline system, and determining a repairing process according to the structural size of the safety valve and the materials of the valve seat body and the sealing surface of the safety valve;
in step 100, the structural dimensions of the relief valve may be measured, as shown in fig. 11, and A, B, C, H dimensions may be obtained. The materials of the safety valve seat body and the sealing surface can be obtained, and the repair process can be determined conveniently.
In step 101, an in-line cutting device is installed in the safety valve, as shown in fig. 4, and a defective old build-up alloy layer exists on the sealing surface of the valve seat before treatment.
102, under the condition that the wire cutting device is safe, controlling a Z-axis transmission mechanism, a Y-axis transmission mechanism and an X-axis transmission mechanism to adjust the position of a cutter through a first control device, so that the axis of a cutter disc is coincident with the axis of a valve seat of a safety valve, and the cutter is opposite to and contacts with the upper surface of a sealing surface;
step 103, after step 102, the first control device controls the first rotating mechanism to drive the cutter to rotate to perform online turning on the sealing surface, as shown in fig. 5, and after the old build-up welding alloy layer is removed, turning work can be finished.
And 104, performing PT inspection on the sealing surface after the sealing surface turning is finished, and confirming that the material of the valve seat sealing surface body has no defects such as cracks.
Step 105, after the PT check in step 104 is passed, the wire cutting device is detached from the safety valve, and as shown in fig. 6, a heat treatment device is installed around the sealing surface, and the sealing surface is subjected to pre-welding heat treatment;
step 106, after the pre-welding heat treatment is finished, the heat treatment device is disassembled, and an online build-up welding device is installed in the safety valve;
step 107, under the condition that the online build-up welding device is installed, controlling the arc length electric sliding frame, the yaw electric sliding frame and the pitch electric sliding frame to adjust the position of the welding gun through a second control device, wherein as shown in fig. 7, the axis of the rotating disc is overlapped with the axis of the safety valve seat, and the welding gun is positioned at a position right above the sealing surface by a preset distance;
step 108, after step 107, controlling the wire feeder and the welding machine to be started through a second control device, and controlling a second rotating mechanism to drive the welding gun to rotate, so that the welding gun moves along the annular upper surface of the sealing surface for surfacing welding;
step 109, after the surface overlaying on the sealing surface is finished, the online butt welding device is detached from the safety valve, a heat treatment device is arranged around the top end of the valve seat, and postweld heat treatment is carried out;
step 110, after the postweld heat treatment is finished, the heat treatment device is disassembled from the safety valve, and an online cutting device is arranged in the safety valve;
in step 110, as shown in fig. 9, the surface of the build-up layer on the sealing surface after the build-up process is irregular, and there is a sagging around, and turning process is required by using an online cutting device.
And 111, after the linear cutting device is installed, controlling a Z-axis transmission mechanism, a Y-axis transmission mechanism and an X-axis transmission mechanism to adjust the position of a cutter through a first control device, controlling the cutter transmission mechanism to enable the cutter to be positioned on the upper surface of a sealing surface surfacing layer under the condition that the axis of the cutter disc is coincident with the axis of a safety valve seat, controlling a first rotation mechanism to drive the cutter to rotate so as to turn the upper surface of the surfacing layer, controlling the cutter transmission mechanism to enable the cutter to be positioned on the inner side of the sealing surface surfacing layer, controlling the first rotation mechanism to drive the cutter to rotate so as to turn the inner side surface of the surfacing layer, controlling the cutter transmission mechanism to enable the cutter to be positioned on the outer side of the sealing surface surfacing layer, and finally obtaining the surfacing layer with the repaired surfacing layer shown in fig. 10.
Step 112, after turning the outer surface of the build-up welding layer, detaching the online cutting device from the safety valve, and performing PT inspection on the sealing surface of the valve seat;
step 113, grinding the valve seat sealing surface and performing color printing inspection after PT inspection on the valve seat sealing surface is passed;
step 114, after finishing grinding and color printing inspection of the valve seat sealing surface, the safety valve is returned to the pipeline system.
In one possible implementation, when the on-line cutting device is used for turning, the first control device controls the Z-axis transmission mechanism to step by taking a preset step size as a unit, and the alloy layer of the sealing surface of the valve seat is turned on line. For example, the preset step size is between 0.15 mm and 0.25 mm.
In one possible implementation, step 108 further includes:
after step 107, the wire feeder and the welding machine are controlled to be started by the second control device, the second rotating mechanism is controlled to drive the welding gun to rotate, and the welding gun driving mechanism is controlled to drive the welding gun to move back and forth between the outer ring edge and the inner ring edge of the sealing surface, as shown in fig. 8, so that the welding gun moves along the fold line or curve of the annular upper surface of the sealing surface to build up welding.
In a possible implementation manner, step 108 further includes, after step 107, controlling, by the second control device, the wire feeder and the welding machine to be turned on, and repeating the following steps with different temporary distances until the welding gun overlay covers the entire upper surface of the sealing surface, where the temporary distances are between the radius of the inner ring of the valve seat and the radius of the outer ring of the valve seat: and after the welding gun transmission mechanism is controlled to drive the welding gun to be separated from the axis of the rotating disc by a temporary distance, the welding gun is controlled to drive the welding gun to rotate by the second welding mechanism, so that the welding gun is enabled to build up welding along the sealing surface.
Therefore, the coverage of a wider sealing surface can be automatically realized through the surfacing paths of curves, fold lines or multiple circles, the repair quality is improved, personnel monitoring and measurement are not needed in the surfacing process, high-efficiency and accurate surfacing operation is realized, human error is reduced, and personnel radiation dose is reduced.
In one possible implementation, after step 108, the welding gun driving mechanism is controlled to drive the welding gun to horizontally move to a position opposite to the outer edge of the sealing surface, and then the welding second rotating mechanism is controlled to drive the welding gun to rotate, so that the welding gun is overlaid along the edge of the sealing surface. Therefore, the phenomenon of edge collapse of the build-up welding layer can be effectively prevented.
In one possible implementation, step 111 further includes: in the process of turning the upper surface of the surfacing layer of the sealing surface, the second control device monitors the flatness of the upper surface of the surfacing layer in real time (for example, the first control device can judge whether the flatness of the upper surface of the surfacing layer meets the preset flatness requirement through image recognition through a graph acquired by the first camera, so that dependence on personnel experience is reduced, whether the flatness of the upper surface of the surfacing layer meets the requirement can be automatically judged in the turning process), and the distance from the upper surface of the surfacing layer to the flange in the safety valve (for example, a distance sensor can be arranged at a position, which is close to a cutter, below the cutter disc and is used for detecting the distance between the lower surface of the cutter disc and the sealing surface, the first control device can acquire distance data acquired by the distance sensor in real time, and can calculate the distance from the flange to the surface of the surfacing layer in real time by combining thickness information of the first main shaft and the cutter disc, so that the dependence on experience of personnel is reduced, and whether the height of the upper surface of the surfacing layer reaches the requirement can be automatically judged in the turning process.
Finally, the sealing performance test and the setting pressure check can be carried out on the safety valve with the repaired sealing surface of the valve seat, the relevant test is confirmed to be qualified, and if the test is not qualified, the disassembly valve is used for grinding the sealing surface again until the sealing performance test and the setting pressure check are qualified
The foregoing description of the embodiments of the present disclosure has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the various embodiments described. The terminology used herein was chosen in order to best explain the principles of the embodiments, the practical application, or the technical improvement of the technology in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
Claims (14)
1. The utility model provides a relief valve disk seat sealing surface on-line repair equipment which characterized in that, relief valve disk seat sealing surface on-line repair equipment includes: the online cutting device, the online cutting device includes: the device comprises a first rotating mechanism, a Z-axis transmission mechanism, a Y-axis transmission mechanism, an X-axis transmission mechanism, a first rack, a first connecting plate, a first main shaft, a cutter transmission mechanism, a cutter, a first control device, a first monitoring device, a first camera and a cutter head;
the first connecting plate can be connected to the upper end of the valve body of the safety valve, and is respectively connected with the first rotating mechanism, the Z-axis transmission mechanism, the Y-axis transmission mechanism and the X-axis transmission mechanism through the first rack;
the upper end of the first main shaft is respectively connected with the first rotating mechanism, the Z-axis transmission mechanism, the Y-axis transmission mechanism and the X-axis transmission mechanism, the lower end of the first main shaft is connected with the cutter head, and the lower end of the cutter head is connected with the cutter through the cutter transmission mechanism;
the first control device can control the Z-axis transmission mechanism to drive the cutter to move along the radial direction, control the Y-axis transmission mechanism to drive the cutter to move along the horizontal first direction, control the X-axis transmission mechanism to drive the cutter to move along the horizontal second direction, and control the cutter transmission mechanism to drive the cutter to move along the radius of the lower surface of the cutter disc, wherein the first direction is perpendicular to the second direction;
the axis of the cutter disc is coincident with the axis of the safety valve seat, and the first control device can control the first rotating mechanism to drive the cutter to rotate around the axis of the first main shaft under the condition that the cutter contacts the sealing surface of the valve seat, so that the cutter turns the sealing surface;
the first camera is connected to the lower end of the cutter head and used for shooting images of the cutter and surrounding environment of the cutter, and the first monitoring device is used for acquiring and displaying the images acquired by the first camera in real time.
2. An in-line repair apparatus for a sealing surface of a seat of a safety valve according to claim 1, wherein the in-line cutting device comprises a plurality of first webs, each of the first webs being removably mountable in the in-line cutting device and a second, different web being mountable in a mating relationship with a flange in a valve body of a safety valve of different sizes.
3. The safety valve seat sealing surface on-line repair apparatus according to claim 1, wherein the on-line cutting device includes a plurality of cutterheads, each cutterhead being detachably mountable in the on-line cutting device, the diameters of the different cutterheads being matched to the diameters of the different kinds of valve seats.
4. The safety valve seat sealing surface online repair apparatus according to claim 1, further comprising: an online build-up device, the online build-up device comprising: the welding machine comprises a wire feeder, a welding machine, a second frame, a second connecting plate, a second main shaft, a rotating disc, a welding gun transmission mechanism, a welding gun, a second camera, a second monitoring device, a second control device, a second rotating mechanism, an arc length electric sliding frame, a yaw electric sliding frame and a longitudinal swing electric sliding frame;
the second connecting plate is connected to the upper end of the valve body of the safety valve, the wire feeder and the welding machine are connected with the second connecting plate, and the second connecting plate is respectively connected with the second rotating mechanism, the arc length electric sliding frame, the yaw electric sliding frame and the pitch electric sliding frame through the second rack;
the upper end of the second main shaft is respectively connected with the second rotating mechanism, the arc length electric sliding frame, the yaw electric sliding frame and the pitch electric sliding frame, the lower end of the second main shaft is connected with the rotating disc, the lower end of the rotating disc is connected with the welding gun through the welding gun transmission mechanism, and the welding gun is connected with the welding machine;
the second control device can control the arc length electric sliding frame to drive the welding gun to move along the radial direction, control the yaw electric sliding frame to drive the welding gun to move along the horizontal first direction, control the longitudinal swing electric sliding frame to drive the welding gun to move along the horizontal second direction, and control the welding gun transmission mechanism to drive the welding gun to move along the radius of the lower surface of the cutterhead;
under the condition that the welding gun is located right above the sealing surface by a preset distance, the second control device controls the wire feeder and the welding machine to start working, and controls the second rotating mechanism to drive the welding gun to rotate around the axis of the second main shaft, so that the welding gun moves along the annular upper surface of the sealing surface for surfacing;
the second camera is connected to the lower end of the rotating disc and used for shooting the welding gun and images of surrounding environments of the welding gun, and the second monitoring device is used for acquiring and displaying the images acquired by the second camera in real time.
5. The safety valve seat sealing surface on-line repair apparatus of claim 1, wherein the on-line overlay device comprises a plurality of second connection plates, each second connection plate being removably mountable in the on-line overlay device, a different second connection plate being mountable to match a flange in a safety valve body of a different size.
6. The safety valve seat sealing surface on-line repair apparatus according to claim 1, wherein the on-line build-up welding device includes a plurality of rotating disks, each of which is detachably mountable in the on-line build-up welding device, the diameter of the different rotating disks being matched with the diameter of the different kinds of valve seats.
7. An in-line repair apparatus for a seat sealing surface of a safety valve according to any one of claims 1 to 6, further comprising a plurality of foreign matter prevention devices installed at positions near the seat in the inlet and outlet of the safety valve for blocking debris splashed during repair of the seat from entering the inlet and outlet of the safety valve.
8. An online repairing method for a sealing surface of a valve seat of a safety valve, which is characterized by comprising the following steps:
step 100, disassembling the safety valve from the pipeline system, and determining a repairing process according to the structural size of the safety valve and the materials of the valve seat body and the sealing surface of the safety valve;
step 101, installing an online cutting device in a safety valve;
102, under the condition that the wire cutting device is safe, controlling a Z-axis transmission mechanism, a Y-axis transmission mechanism and an X-axis transmission mechanism to adjust the position of a cutter through a first control device, so that the axis of a cutter disc is coincident with the axis of a valve seat of a safety valve, and the cutter is opposite to and contacts with the upper surface of a sealing surface;
step 103, after step 102, controlling a first rotating mechanism to drive a cutter to rotate by a first control device so as to perform online turning on a sealing surface;
104, performing PT inspection on the sealing surface after the sealing surface is turned;
step 105, after the PT inspection in step 104 is passed, the online cutting device is detached from the safety valve, a heat treatment device is arranged around the sealing surface, and the sealing surface is subjected to pre-welding heat treatment;
step 106, after the pre-welding heat treatment is finished, the heat treatment device is disassembled, and an online build-up welding device is installed in the safety valve;
step 107, under the condition that the online build-up welding device is installed, controlling an arc length electric sliding frame, a yaw electric sliding frame and a longitudinal swing electric sliding frame to adjust the position of a welding gun through a second control device, so that the axis of a rotating disc is overlapped with the axis of a safety valve seat, and the welding gun is positioned at a position right above a sealing surface by a preset distance;
step 108, after step 107, controlling the wire feeder and the welding machine to be started through a second control device, and controlling a second rotating mechanism to drive the welding gun to rotate, so that the welding gun moves along the annular upper surface of the sealing surface for surfacing welding;
step 109, after the surface overlaying on the sealing surface is finished, the online butt welding device is detached from the safety valve, a heat treatment device is arranged around the top end of the valve seat, and postweld heat treatment is carried out;
step 110, after the postweld heat treatment is finished, the heat treatment device is disassembled from the safety valve, and an online cutting device is arranged in the safety valve;
step 111, after the linear cutting device is installed, controlling a Z-axis transmission mechanism, a Y-axis transmission mechanism and an X-axis transmission mechanism to adjust the position of a cutter through a first control device, and under the condition that the axis of a cutter disc is coincident with the axis of a safety valve seat, controlling the cutter transmission mechanism to enable the cutter to be positioned on the upper surface of a sealing surface surfacing layer, controlling a first rotation mechanism to drive the cutter to rotate so as to turn the upper surface of the surfacing layer, controlling the cutter transmission mechanism to enable the cutter to be positioned on the inner side of the sealing surface surfacing layer, controlling the first rotation mechanism to drive the cutter to rotate so as to turn the inner side surface of the surfacing layer, and controlling the cutter transmission mechanism to enable the cutter to be positioned on the outer side of the sealing surface surfacing layer, and controlling the first rotation mechanism to drive the cutter to rotate so as to turn the outer side surface of the surfacing layer;
step 112, after turning the outer surface of the build-up welding layer, detaching the online cutting device from the safety valve, and performing PT inspection on the sealing surface of the valve seat;
step 113, grinding the valve seat sealing surface and performing color printing inspection after PT inspection on the valve seat sealing surface is passed;
step 114, after finishing grinding and color printing inspection of the valve seat sealing surface, the safety valve is returned to the pipeline system.
9. The method of claim 8, wherein the first control device controls the Z-axis drive mechanism to step in units of a preset step size to perform on-line turning of the valve seat sealing surface alloy layer when turning is performed using the on-line cutting device.
10. The method of claim 9, wherein the predetermined step size is between 0.15 mm and 0.25 mm.
11. The method of claim 8, wherein step 108 further comprises:
after step 107, the wire feeder and the welding machine are controlled to be started by the second control device, the second rotating mechanism is controlled to drive the welding gun to rotate, and the welding gun driving mechanism is controlled to drive the welding gun to move back and forth between the outer ring edge and the inner ring edge of the sealing surface, so that the welding gun moves along the fold line or curve of the annular upper surface of the sealing surface to build up welding.
12. The method of claim 8, wherein step 108 further comprises, after step 107, controlling the wire feeder and the welder to turn on by the second control device, repeating the following steps with different temporary distances until the weld gun build-up covers the entire upper surface of the sealing surface, the temporary distances being between the valve seat inner radius and the valve seat outer radius:
and after the welding gun transmission mechanism is controlled to drive the welding gun to be separated from the axis of the rotating disc by a temporary distance, the welding gun is controlled to drive the welding gun to rotate by the second welding mechanism, so that the welding gun is enabled to build up welding along the sealing surface.
13. The method of claim 8 wherein after step 108, the welding gun driving mechanism is controlled to drive the welding gun to move horizontally to a position opposite to the outer edge of the sealing surface, and the welding second rotating mechanism is controlled to drive the welding gun to rotate, so that the welding gun is deposited along the edge of the sealing surface.
14. The method of claim 8, wherein step 111 further comprises: in the process of turning the upper surface of the surfacing layer of the sealing surface, the second control device monitors the flatness of the upper surface of the surfacing layer in real time and the distance from the upper surface of the surfacing layer to the flange in the safety valve, and when the distance from the upper surface of the surfacing layer, which is flat and has no pits, to the flange in the safety valve is judged to be the repairing distance, the turning of the upper surface of the surfacing layer is stopped.
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| CN202211092683.9A CN116117429A (en) | 2022-09-08 | 2022-09-08 | Online repairing equipment and method for sealing surface of valve seat of safety valve |
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| CN202211092683.9A CN116117429A (en) | 2022-09-08 | 2022-09-08 | Online repairing equipment and method for sealing surface of valve seat of safety valve |
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| JPS58112656A (en) * | 1981-12-26 | 1983-07-05 | Okano Valve Seizo Kk | Automatic valve-sheet build-up welding device for y type main vapor isolating valve for nuclear power facility |
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| CN110744258A (en) * | 2019-11-18 | 2020-02-04 | 中核核电运行管理有限公司 | Online repairing method for valve seat sealing ring of nuclear-grade gate valve |
| CN110814410A (en) * | 2019-11-12 | 2020-02-21 | 中核核电运行管理有限公司 | Be used for nuclear level gate valve disk seat sealing ring to restore automatic cutout device on line |
| CN110935995A (en) * | 2019-11-19 | 2020-03-31 | 中核核电运行管理有限公司 | Online repair automatic welding device and method for valve seat sealing ring of nuclear-grade gate valve |
| CN111375985A (en) * | 2018-12-27 | 2020-07-07 | 中核核电运行管理有限公司 | Main steam safety valve seat defect on-site processing device and method |
| WO2021164421A1 (en) * | 2020-02-21 | 2021-08-26 | 苏州纽威阀门股份有限公司 | Gate valve processing and assembling production line |
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- 2022-09-08 CN CN202211092683.9A patent/CN116117429A/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS58112656A (en) * | 1981-12-26 | 1983-07-05 | Okano Valve Seizo Kk | Automatic valve-sheet build-up welding device for y type main vapor isolating valve for nuclear power facility |
| CN208050933U (en) * | 2018-04-10 | 2018-11-06 | 河南华豫盛达特种设备检测技术有限公司 | A kind of online truning fixture of sealing surface of safety valve |
| CN111375985A (en) * | 2018-12-27 | 2020-07-07 | 中核核电运行管理有限公司 | Main steam safety valve seat defect on-site processing device and method |
| CN110814410A (en) * | 2019-11-12 | 2020-02-21 | 中核核电运行管理有限公司 | Be used for nuclear level gate valve disk seat sealing ring to restore automatic cutout device on line |
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