阅读说明：本技术 一种水轮机机组转桨改造方法 (Hydraulic turbine set rotor transformation method ) 是由 刘建波 于 2021-01-04 设计创作，主要内容包括：本发明公开了一种水轮机机组转桨改造方法,包括以下步骤：S1、转桨改定桨桨叶的分析,利用水轮机通用的计算公式进行水轮机额定工况的计算确定,并根据真机试验桨叶角度校核计算角度,S2、现有转轮叶片操作的结构分析,在步骤S1完成后,通过现场试验来确定叶片在某一角度时,活塞在接力器缸中的具体位置,并以此作为基准,对叶片进行角度定位。本发明有益效果是：采用该种改造方法,在原转轮的基础上进行现场改造,优点是实施简单、工期短、费用低,能够有效的解决漏油问题、清除油污染的问题,同时将原来单一的轴流转桨式机组改为轴流转浆和轴流定桨式机组组合方式,进一步优化电站运行模式,适应不同水位运行要求。(The invention discloses a method for modifying a rotating blade of a water turbine set, which comprises the following steps: s1, analyzing the paddle of the rotating paddle changing and fixing paddle, calculating and determining the rated working condition of the water turbine by using a general calculation formula of the water turbine, checking and calculating the angle according to the angle of the paddle in a real machine test, S2, analyzing the structure of the operation of the existing runner blade, determining the specific position of a piston in a servomotor cylinder when the blade is at a certain angle through a field test after the step S1 is finished, and positioning the angle of the blade by taking the specific position as a reference. The invention has the beneficial effects that: the method for reconstructing the axial flow propeller type rotating machine has the advantages of being simple to implement, short in construction period, low in cost, capable of effectively solving the problems of oil leakage and oil pollution removal, and meanwhile, the original single axial flow propeller type rotating machine set is changed into a combined mode of axial flow propeller type rotating machine set and axial flow propeller type fixed machine set, the operation mode of a power station is further optimized, and the method is suitable for operation requirements of different water levels.)

1. A method for modifying a rotating blade of a hydraulic turbine unit is characterized by comprising the following steps:

s1, analyzing the paddle changing and fixing blade, calculating and determining the rated working condition of the water turbine by using a general calculation formula of the water turbine, and checking and calculating the angle according to the angle of the blade tested by a real machine;

s2, structural analysis of the operation of the existing runner blade, after the step S1 is completed, the specific position of the piston in the servomotor cylinder is determined through field tests when the blade is at a certain angle, and the blade is positioned angularly by taking the specific position as a reference;

s3, positioning and analyzing the angle of the blade of the rotor of the variable propeller, determining the angle of the variable propeller blade according to hydraulic calculation and analysis and a field test, wherein the positioning of the angle is determined according to the position of the servomotor piston measured in the test before the transformation and the angle of the blade determined by adopting a measuring tool;

s4, material selection preparation, namely selecting various materials required by blade welding;

s5, preparing before blade welding, after S4 is completed, pumping water by a lower pump in a tail water cofferdam of a channel head power station, setting up a unit runner chamber working platform, detaching a through valve beside a unit, cutting a flange, installing a new bypass valve, welding the flange, adjusting the blade angle to 14 degrees by using 1MPa oil pressure, driving a wedge plate at the tail of the blade for fixing, increasing the pressure to 2MPa, unlocking and locking, and reducing the pressure to 1MPa after fully opening a guide blade;

s6, blade welding, namely measuring on the spot of a runner working platform, manufacturing a U-shaped welding part template by using a paperboard, automatically gas-cutting an iron plate with the thickness of 100mm by using laser, processing the U-shaped welding part, preparing round steels with different diameters, plug-welding the round steels with different diameters on the water inlet side of the runner, welding the U-shaped welding part after plug-welding, trimming the welding part into a streamline by using gas cutting and an angle grinder, and measuring the opening size of the blade;

s7, modifying the speed regulator, namely modifying the speed regulator properly after the step S6 is completed, and changing the double-regulation speed regulator into a single-regulation speed regulator;

s8, modifying a speed measuring device, namely removing a bearing bush of the oil feeding device after the step S7 is completed, removing a permanent magnet machine spline, mounting a set of fluted disc speed measuring device on a small shaft, and sending a speed measuring signal into an LCU (lower control Unit) to monitor the unit in real time;

s9, recovering the unit rush-repair treatment, detaching the tail water pipe platform after the step S8 is completed, closing the volute, the tail water pipe manhole door and the tail water pipe emptying valve, and lifting the overhaul gate and the tail water gate;

s10, other structural components recover to recover the generator outgoing line and related equipment, and impurities in the water diversion system are cleaned;

s11, checking, after the step S10 is finished, checking the water diversion system, filling water after the water diversion system is qualified, checking related structures and equipment of the generator, and confirming whether the unit, the oil system, the water system and the wind system are normal or not;

s12, starting the test, and after the water diversion system, the generator related structure and the water turbine set are all detected to be qualified, quickly opening the gate to start the test.

2. The method for modifying the rotor of the hydraulic turbine set according to claim 1, wherein the method comprises the following steps: the general formula of the water turbine in the step S1 is as follows:

energy equation of the water turbine: n is a radical of_h＝9.81×Q_ixHxη H (kw) or

N_h＝9.81×Q₁ ¹×H^1.5×D¹²×ηh(kw)；

Efficiency correction formula: Δ η 2/3 ═ 1- (1/η)_mmax)^0.2〕；

Specific rotation speed: n is_s＝3.13×n₁ ¹×(Q₁₁*η)^0.5；

Unit rotating speed: n is₁ ¹＝n*D₁/(Hi)^0.5；

Unit flow rate: q₁₁＝Q_i/D₁ ²/(Hi)^0.5；

Sucking out elevation: h_S＝10-(Ⅴ/900)-K_σ×σ×H。

3. The method for modifying the rotor of the hydraulic turbine set according to claim 1, wherein the method comprises the following steps: in step S4, the runner blade is made of ZG1Cr13 cast steel, the runner body is made of ZG25 ii cast steel, the ZG1Cr13 cast steel is martensitic stainless steel, and the welding rod is made of E5516 welding rod or E1-30-9 stainless steel welding rod.

4. The method for modifying the rotor of the hydraulic turbine set according to claim 1, wherein the method comprises the following steps: in the step S6, during welding, the U-shaped block and the welding rod are weighed to ensure equal weight after welding, heavy-current manual arc welding is adopted, a symmetrical, stepping-back, multilayer and multi-pass welding process is adopted, after welding, the U-shaped block is further trimmed by gas cutting to ensure that the overcurrent resistance is small, and during welding, the volute inlet hole and the tail water inlet hole are opened for natural ventilation.

5. The method for modifying the rotor of the hydraulic turbine set according to claim 1, wherein the method comprises the following steps: while the step S6 is performed, the following operations are performed:

firstly, a pressure oil pipe and an oil return pipe on an oil supply head drain oil and are disassembled, and an oil port is plugged by a blind plate;

removing the part above the end cover of the unit, and removing three copper tiles of the permanent magnet machine spline and the oil receiver;

the speed regulator is withdrawn in a tandem way, and a blade adjusting plate, a proportional valve plug, a button and an indicator light are disconnected;

fourthly, the part above the end cover is installed again, the permanent magnet machine is in place, and a fluted disc speed measuring device is installed;

measuring the size of a gate slot by the tail gate of the unit, adjusting the reverse support of the gate, and installing a tail water gauge.

Plugging the volute and tail water inlet hole of the unit, and filling new oil into water.

6. The method for modifying the rotor of the hydraulic turbine set according to claim 1, wherein the method comprises the following steps: in step S7, the modification points of the governor are as follows:

in the hydraulic servo system, an oil way of a blade oil receiver in a pressure distribution valve shell is cut off, and a main pressure distribution valve bushing, an auxiliary piston and the like of the blade at the improved part are arranged;

cutting off power supply of the blade in the electric loop;

the method comprises the following steps that the cooperation relation between guide vanes and blades is changed in electrical cooperation part software of the PLC;

cutting off a pressure oil source entering the oil receiver and plugging the pressure oil source by using a blind plate;

removing the paddle operation oil pipe and plugging the oil port by using a blind plate;

removing a stroke pointer and a blade sensor of the blade servomotor, and removing a feedback connection wire of the blades of the electric tilt cabinet;

removing the copper tiles and the return bearing of the rotating oil basin and the oil receiver;

pulling down a paddle operation plate plug and a paddle proportion electromagnetic valve plug of the machine adjusting cabinet;

removing a wire of an indicator light of a paddle of the mechanical adjustment cabinet, manually and automatically switching the paddle of the mechanical adjustment cabinet, and connecting the wire by an electric manual button;

and (3) controlling the blades of the mechanical adjustment cabinet to be mechanical and manual, removing the door handles of the oil way switching valves of the blades, and removing mechanical and manual operating rods.

7. The method for modifying the rotor of the hydraulic turbine set according to claim 1, wherein the method comprises the following steps: in step S8, the fluted disc is fixed at the return bearing, and the fluted disc speed measuring device is installed.

8. The method for modifying the rotor of the hydraulic turbine set according to claim 1, wherein the method comprises the following steps: in step S11, each system and structure is inspected to ensure that each unit and system can work normally after the emergency repair and reconstruction, so as to ensure the completion effect of the emergency repair work.

Technical Field

The invention relates to the technical field of paddle changing into fixed paddles, in particular to a method for changing the paddles of a water turbine set.

Background

The water turbine is a power machine for converting water flow energy into rotary mechanical energy, belongs to a turbine machine in fluid machinery, is an important hydroelectric device, is an essential component in the hydroelectric power industry, is an important device for fully utilizing clean renewable energy to realize energy conservation and emission reduction and reduce environmental pollution, and has the defects of runner oil leakage, oil pipe operation oil circuit series cavity and the like in the operation process of a water turbine unit. Because urban water has higher and higher requirements on water quality, the axial-flow Kaplan turbine often leaks oil due to abrasion of a Kaplan sealing mechanism or other faults, and water source pollution is easily caused. Therefore, a method for modifying the rotating blade of the hydraulic turbine set is provided.

Disclosure of Invention

The invention mainly aims to provide a method for modifying a rotating blade of a water turbine set, which can effectively solve the problems in the background technology.

In order to achieve the purpose, the invention adopts the technical scheme that:

a method for modifying the rotating blade of a hydraulic turbine set comprises the following steps:

s1, analyzing the paddle changing and fixing blade, calculating and determining the rated working condition of the water turbine by using a general calculation formula of the water turbine, and checking and calculating the angle according to the angle of the blade tested by a real machine;

s2, structural analysis of the operation of the existing runner blade, after the step S1 is completed, the specific position of the piston in the servomotor cylinder is determined through field tests when the blade is at a certain angle, and the blade is positioned angularly by taking the specific position as a reference;

s3, positioning and analyzing the angle of the blade of the rotor of the variable propeller, determining the angle of the variable propeller blade according to hydraulic calculation and analysis and a field test, wherein the positioning of the angle is determined according to the position of the servomotor piston measured in the test before the transformation and the angle of the blade determined by adopting a measuring tool;

s4, material selection preparation, namely selecting various materials required by blade welding;

s5, preparing before blade welding, after S4 is completed, pumping water by a lower pump in a tail water cofferdam of a channel head power station, setting up a unit runner chamber working platform, detaching a through valve beside a unit, cutting a flange, installing a new bypass valve, welding the flange, adjusting the blade angle to 14 degrees by using 1MPa oil pressure, driving a wedge plate at the tail of the blade for fixing, increasing the pressure to 2MPa, unlocking and locking, and reducing the pressure to 1MPa after fully opening a guide blade;

s6, blade welding, namely measuring on the spot of a runner working platform, manufacturing a U-shaped welding part template by using a paperboard, automatically gas-cutting an iron plate with the thickness of 100mm by using laser, processing the U-shaped welding part, preparing round steels with different diameters, plug-welding the round steels with different diameters on the water inlet side of the runner, welding the U-shaped welding part after plug-welding, trimming the welding part into a streamline by using gas cutting and an angle grinder, and measuring the opening size of the blade;

s7, modifying the speed regulator, namely modifying the speed regulator properly after the step S6 is completed, and changing the double-regulation speed regulator into a single-regulation speed regulator;

s8, modifying a speed measuring device, namely removing a bearing bush of the oil feeding device after the step S7 is completed, removing a permanent magnet machine spline, mounting a set of fluted disc speed measuring device on a small shaft, and sending a speed measuring signal into an LCU (lower control Unit) to monitor the unit in real time;

s9, recovering the unit rush-repair treatment, detaching the tail water pipe platform after the step S8 is completed, closing the volute, the tail water pipe manhole door and the tail water pipe emptying valve, and lifting the overhaul gate and the tail water gate;

s10, other structural components recover to recover the generator outgoing line and related equipment, and impurities in the water diversion system are cleaned;

s11, checking, after the step S10 is finished, checking the water diversion system, filling water after the water diversion system is qualified, checking related structures and equipment of the generator, and confirming whether the unit, the oil system, the water system and the wind system are normal or not;

s12, starting the test, and after the water diversion system, the generator related structure and the water turbine set are all detected to be qualified, quickly opening the gate to start the test.

Preferably, in step S1, the general formula of the water turbine is as follows:

energy equation of the water turbine: n is a radical of_h＝9.81×Q_ixHxη H (kw) or

N_h＝9.81×Q₁ ¹×H^1.5×D¹²×ηh(kw)；

Efficiency correction formula: Δ η 2/3 ═ 1- (1/η)_mmax)^0.2〕；

Specific rotation speed: n is_s＝3.13×n₁ ¹×(Q₁₁*η)^0.5；

Unit rotating speed: n is₁ ¹＝n*D₁/(Hi)^0.5；

Unit flow rate: q₁₁＝Q_i/D₁ ²/(Hi)^0.5；

Sucking out elevation: h_S＝10-(Ⅴ/900)-K_σ×σ×H。

Preferably, in step S4, the material of the runner blade is ZG1Cr13 cast steel, the material of the runner body is ZG25 ii cast steel, the ZG1Cr13 cast steel is martensitic stainless steel, and the welding rod is an E5516 welding rod or an E1-30-9 stainless steel welding rod.

Preferably, in step S6, during welding, the U-shaped block and the welding rod are weighed to ensure equal weight after welding, heavy-current manual arc welding is adopted, a symmetrical, stepping-back, multi-layer and multi-pass welding process is adopted, after welding, the U-shaped block is further trimmed by gas cutting to make the overcurrent resistance smaller, and during welding, the volute inlet hole and the tail water inlet hole are opened for natural ventilation.

Preferably, the step S6 is performed simultaneously with the following steps:

firstly, a pressure oil pipe and an oil return pipe on an oil supply head drain oil and are disassembled, and an oil port is plugged by a blind plate;

removing the part above the end cover of the unit, and removing three copper tiles of the permanent magnet machine spline and the oil receiver;

the speed regulator is withdrawn in a tandem way, and a blade adjusting plate, a proportional valve plug, a button and an indicator light are disconnected;

fourthly, the part above the end cover is installed again, the permanent magnet machine is in place, and a fluted disc speed measuring device is installed;

measuring the size of a gate slot by the tail gate of the unit, adjusting the reverse support of the gate, and installing a tail water gauge.

Plugging the volute and tail water inlet hole of the unit, and filling new oil into water.

Preferably, in step S7, the modifying positions of the speed governor are as follows:

in the hydraulic servo system, an oil way of a blade oil receiver in a pressure distribution valve shell is cut off, and a main pressure distribution valve bushing, an auxiliary piston and the like of the blade at the improved part are arranged;

cutting off power supply of the blade in the electric loop;

the method comprises the following steps that the cooperation relation between guide vanes and blades is changed in electrical cooperation part software of the PLC;

cutting off a pressure oil source entering the oil receiver and plugging the pressure oil source by using a blind plate;

removing the paddle operation oil pipe and plugging the oil port by using a blind plate;

removing a stroke pointer and a blade sensor of the blade servomotor, and removing a feedback connection wire of the blades of the electric tilt cabinet;

removing the copper tiles and the return bearing of the rotating oil basin and the oil receiver;

pulling down a paddle operation plate plug and a paddle proportion electromagnetic valve plug of the machine adjusting cabinet;

removing a wire of an indicator light of a paddle of the mechanical adjustment cabinet, manually and automatically switching the paddle of the mechanical adjustment cabinet, and connecting the wire by an electric manual button;

and (3) controlling the blades of the mechanical adjustment cabinet to be mechanical and manual, removing the door handles of the oil way switching valves of the blades, and removing mechanical and manual operating rods.

Preferably, in step S8, the fluted disc is fixed at the return bearing, and the fluted disc speed measuring device is installed.

Preferably, in step S11, each system and structure is inspected to ensure that each unit and system can normally work after the emergency repair and reconstruction, so as to ensure the completion effect of the emergency repair work.

Compared with the prior art, the invention has the following beneficial effects: the method for reconstructing the axial flow propeller type rotating machine has the advantages of being simple to implement, short in construction period, low in cost, capable of effectively solving the problems of oil leakage and oil pollution removal, and meanwhile, the original single axial flow propeller type rotating machine set is changed into a combined mode of axial flow propeller type rotating machine set and axial flow propeller type fixed machine set, the operation mode of a power station is further optimized, and the method is suitable for operation requirements of different water levels.

Detailed Description

In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further described with the specific embodiments.

A method for modifying the rotating blade of a hydraulic turbine set comprises the following steps:

s1, analyzing the paddle changing and fixing blade, calculating and determining the rated working condition of the water turbine by using a general calculation formula of the water turbine, and checking and calculating the angle according to the angle of the blade tested by a real machine;

s2, structural analysis of the operation of the existing runner blade, after the step S1 is completed, the specific position of the piston in the servomotor cylinder is determined through field tests when the blade is at a certain angle, and the blade is positioned angularly by taking the specific position as a reference;

s3, positioning and analyzing the angle of the blade of the rotor of the variable propeller, determining the angle of the variable propeller blade according to hydraulic calculation and analysis and a field test, wherein the positioning of the angle is determined according to the position of the servomotor piston measured in the test before the transformation and the angle of the blade determined by adopting a measuring tool;

s4, material selection preparation, namely selecting various materials required by blade welding;

s5, preparing before blade welding, after S4 is completed, pumping water by a lower pump in a tail water cofferdam of a channel head power station, setting up a unit runner chamber working platform, detaching a through valve beside a unit, cutting a flange, installing a new bypass valve, welding the flange, adjusting the blade angle to 14 degrees by using 1MPa oil pressure, driving a wedge plate at the tail of the blade for fixing, increasing the pressure to 2MPa, unlocking and locking, and reducing the pressure to 1MPa after fully opening a guide blade;

s6, blade welding, namely measuring on the spot of a runner working platform, manufacturing a U-shaped welding part template by using a paperboard, automatically gas-cutting an iron plate with the thickness of 100mm by using laser, processing the U-shaped welding part, preparing round steels with different diameters, plug-welding the round steels with different diameters on the water inlet side of the runner, welding the U-shaped welding part after plug-welding, trimming the welding part into a streamline by using gas cutting and an angle grinder, and measuring the opening size of the blade;

s7, modifying the speed regulator, namely modifying the speed regulator properly after the step S6 is completed, and changing the double-regulation speed regulator into a single-regulation speed regulator;

s8, modifying a speed measuring device, namely removing a bearing bush of the oil feeding device after the step S7 is completed, removing a permanent magnet machine spline, mounting a set of fluted disc speed measuring device on a small shaft, and sending a speed measuring signal into an LCU (lower control Unit) to monitor the unit in real time;

s9, recovering the unit rush-repair treatment, detaching the tail water pipe platform after the step S8 is completed, closing the volute, the tail water pipe manhole door and the tail water pipe emptying valve, and lifting the overhaul gate and the tail water gate;

s10, other structural components recover to recover the generator outgoing line and related equipment, and impurities in the water diversion system are cleaned;

s11, checking, after the step S10 is finished, checking the water diversion system, filling water after the water diversion system is qualified, checking related structures and equipment of the generator, and confirming whether the unit, the oil system, the water system and the wind system are normal or not;

s12, starting the test, and after the water diversion system, the generator related structure and the water turbine set are all detected to be qualified, quickly opening the gate to start the test.

Wherein, the general formula of the water turbine in the step S1 is as follows:

energy equation of the water turbine: n is a radical of_h＝9.81×Q_ixHxη H (kw) or

N_h＝9.81×Q₁ ¹×H^1.5×D¹²×ηh(kw)；

Efficiency correction formula: Δ η 2/3 ═ 1- (1/η)_mmax)^0.2〕；

Specific rotation speed: n is_s＝3.13×n₁ ¹×(Q₁₁*η)^0.5；

Unit rotating speed: n is₁ ¹＝n*D₁/(Hi)^0.5；

Unit flow rate: q₁₁＝Q_i/D₁ ²/(Hi)^0.5；

Sucking out elevation: h_S＝10-(Ⅴ/900)-K_σ×σ×H。

In step S4, the runner blade is cast steel ZG1Cr13, the runner body is cast steel ZG25 II, the cast steel ZG1Cr13 belongs to martensite stainless steel, and the welding rod is an E5516 welding rod or an E1-30-9 stainless steel welding rod.

In step S6, during welding, the U-shaped block and the welding rod are weighed to ensure equal weight after welding, heavy-current manual arc welding is adopted, a symmetrical, stepping-back, multilayer and multi-pass welding process is adopted, after welding, the U-shaped block is further trimmed by gas cutting to ensure small overcurrent resistance, and during welding, the volute inlet hole and the tail water inlet hole are opened for natural ventilation.

Meanwhile, step S6 performs the following operations:

firstly, a pressure oil pipe and an oil return pipe on an oil supply head drain oil and are disassembled, and an oil port is plugged by a blind plate;

removing the part above the end cover of the unit, and removing three copper tiles of the permanent magnet machine spline and the oil receiver;

the speed regulator is withdrawn in a tandem way, and a blade adjusting plate, a proportional valve plug, a button and an indicator light are disconnected;

fourthly, the part above the end cover is installed again, the permanent magnet machine is in place, and a fluted disc speed measuring device is installed;

measuring the size of a gate slot by the tail gate of the unit, adjusting the reverse support of the gate, and installing a tail water gauge.

Plugging the volute and tail water inlet hole of the unit, and filling new oil into water.

In step S7, the modification points of the speed governor are as follows:

in the hydraulic servo system, an oil way of a blade oil receiver in a pressure distribution valve shell is cut off, and a main pressure distribution valve bushing, an auxiliary piston and the like of the blade at the improved part are arranged;

cutting off power supply of the blade in the electric loop;

the method comprises the following steps that the cooperation relation between guide vanes and blades is changed in electrical cooperation part software of the PLC;

cutting off a pressure oil source entering the oil receiver and plugging the pressure oil source by using a blind plate;

removing the paddle operation oil pipe and plugging the oil port by using a blind plate;

removing a stroke pointer and a blade sensor of the blade servomotor, and removing a feedback connection wire of the blades of the electric tilt cabinet;

removing the copper tiles and the return bearing of the rotating oil basin and the oil receiver;

pulling down a paddle operation plate plug and a paddle proportion electromagnetic valve plug of the machine adjusting cabinet;

removing a wire of an indicator light of a paddle of the mechanical adjustment cabinet, manually and automatically switching the paddle of the mechanical adjustment cabinet, and connecting the wire by an electric manual button;

and (3) controlling the blades of the mechanical adjustment cabinet to be mechanical and manual, removing the door handles of the oil way switching valves of the blades, and removing mechanical and manual operating rods.

In step S8, the tooth disc is fixed at the return bearing, and the tooth disc speed measuring device is installed.

In step S11, each system and structure is inspected to ensure that each unit and system can work normally after rush repair modification, so as to ensure the completion effect of rush repair; the method for reconstructing the axial flow propeller type rotating machine has the advantages of being simple to implement, short in construction period, low in cost, capable of effectively solving the problems of oil leakage and oil pollution removal, and meanwhile, the original single axial flow propeller type rotating machine set is changed into a combined mode of axial flow propeller type rotating machine set and axial flow propeller type fixed machine set, the operation mode of a power station is further optimized, and the method is suitable for operation requirements of different water levels.

It should be understood that the above examples are only for clarity of illustration and are not intended to limit the embodiments. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. And obvious variations or modifications therefrom are within the scope of the invention.