One-time installation and positioning process for a water turbine water guide mechanism with a runner

Abstract

The present invention discloses a one-time installation and positioning process for a water pump, water turbine, generator motor, and water guide mechanism with a runner. This process eliminates the need for pre-installation of the conventional water guide mechanism. The one-time installation and positioning process for the water guide mechanism with a runner represents an innovation in turbine installation methods. The present invention's one-time installation and positioning process for the water guide mechanism with a runner features high installation accuracy, reduced construction difficulty, accelerated construction schedules, energy conservation, and emission reductions. It also avoids the construction safety hazards associated with repeated assembly, disassembly, and hoisting of large turbine components, resulting in significant economic and social benefits and significant value for widespread application.

Description

Technical Field

[0001] The invention relates to a one-time installation and positioning process for a water turbine water guide mechanism with a runner, and belongs to the technical field of installation of a water turbine generator set and a water pump and water turbine generator motor set. Background Art

[0002] During the installation of the pump-turbine water guide mechanism, conventional installation requires a pre-installation of the guide mechanism before formal installation. Due to the small size of the upper opening of the pump-turbine generator pit lining, the top cover must be hoisted into the pit in sections for assembly. The movable guide vanes must be hoisted through the center hole of the top cover after the top cover is assembled and hoisted above the pit. Conventionally, the water guide mechanism is pre-installed first. Once the pre-installation is qualified, the top cover is re-hoisted and suspended above the pit to remove the movable guide vanes. Temporary support piers are then installed, and the top cover is lowered onto the piers for removal and hoisted out of the pit in sections. During formal installation of the water guide mechanism, the runner is hoisted into the pit, installed, adjusted, and secured, and then the upper stop ring is hoisted in. The pre-installation steps for the water guide mechanism are followed, completing the steps of hoisting the sectioned top cover into the pit, assembling and hanging it, installing the movable guide vanes, and finally installing the top cover. The installation process of conventional water-guiding mechanisms is cumbersome, the top cover needs to be installed and disassembled twice, the turbine pit space is small, and the installation and disassembly of large top covers is difficult, time-consuming and labor-intensive, posing a high safety hazard in construction. Summary of the Invention

[0003] In order to solve the above technical problems, the present invention provides a one-time installation and positioning process for a water guide mechanism with a runner, which improves work efficiency, reduces the installation period of the water guide mechanism, and saves construction costs.

[0004] The technical solution of the present invention comprises the following steps:

[0005] 1) After the turbine seat ring is processed and cleaned on site, the bottom ring is installed. The bottom ring is adjusted concentrically with the seat ring center as the reference. The orientation of the bottom ring is adjusted to be consistent with the orientation of the seat ring. After the center and orientation are adjusted to meet the requirements, it is fixed with bolts to the seat ring;

[0006] 2) After the bottom ring is installed and fixed, the cone pipe is installed and the second phase of concrete pouring and grouting is carried out. The center of the cone pipe is adjusted to be concentric with the center of the bottom ring as the reference, and the orientation of the cone pipe is adjusted to be consistent with the orientation of the seat ring. The gap between the upper and lower annular seams of the cone pipe is adjusted to the design requirements and the external gap of the annular seam is sealed. After the upper annular seam of the cone pipe is welded, the second phase of concrete pouring and grouting is carried out. The lower annular seam of the cone pipe is welded after the second phase of concrete pouring and grouting.

[0007] 3) After the cone tube and the second phase concrete pouring and grouting are completed, the lower leak-proof ring is installed. The lower leak-proof ring is adjusted concentrically with the center of the bottom ring as the reference. The orientation of the lower leak-proof ring is adjusted to be consistent with the orientation of the bottom ring. After the center and orientation are adjusted to meet the requirements, it is fixed with bolts to the bottom ring;

[0008] 4) The unit installation center calibration is the core of the one-time installation and positioning technology of the water guide mechanism with the runner. The unit installation center calibration is to use the lower leak ring as the center reference, and then guide the center reference to the position of the pit lining and the bottom ring discharge ring for marking to complete the center conversion;

[0009] 5) After the unit center is calibrated, the runner is hoisted into the pit for adjustment and fixation. Before the runner is hoisted, the temporary installation elevation of the runner is determined based on the sum of the turbine shaft and generator shaft stop sizes and the coupling clearance. The runner center is adjusted concentrically based on the unit installation center calibration. After the runner center and elevation adjustments are qualified and the runner is securely fixed, the upper leak-proof ring is hoisted and placed on the runner;

[0010] 6) After the top cover is cleaned in the powerhouse installation room, the split top cover is hoisted into the machine pit for assembly and hoisting. The split top cover is hoisted into a whole with combination bolts and then installed with a leak-proof ring. The top cover is then hoisted using the powerhouse bridge crane and hung above the turbine room using special tools to complete the installation of bearings in all movable guide vanes.

[0011] 7) Clean the movable guide vanes before installation. The movable guide vanes are hoisted into the machine pit one by one using special tools for guide vanes and installed in place. The seals should be installed before the movable guide vanes are installed in place;

[0012] 8) After all the movable guide vanes are installed in place, use the powerhouse bridge crane to hoist the top cover into place, then install, adjust, and secure it. The center of the top cover is calibrated with the center of the unit as the reference for concentricity adjustment. The orientation of the top cover is adjusted to be consistent with the orientation of the seat ring. After the top cover is adjusted to pass, use a feeler gauge to check that the total clearance of each movable guide vane end face meets the design requirements. After the top cover is inspected and passed, install the top cover and seat ring and tighten the bolts.

[0013] 9) After the top cover is installed and qualified, the movable guide vane bearings are installed. After all the guide vane bearings are installed, the guide vane end face clearance is checked again to ensure it is qualified. The flexibility of the movable guide vanes is checked using a hand hoist, a dynamometer and special tools to check the opening torque of each guide vane. After the guide vane bearings are installed and checked, the top cover and bearing pins are drilled and positioned;

[0014] 10) After the guide vane bearing is installed, install other parts of the water guide mechanism.

[0015] Furthermore, the bottom ring axis orientation is required to be adjusted to coincide with the seat ring axis orientation, and the orientation deviation should be ≤1mm; the concentricity deviation should be ≤0.05mm; and the bottom ring radial horizontality deviation should be ≤0.02mm / m.

[0016] Furthermore, the concentricity deviation between the lower stop ring and the bottom ring should be ≤0.05mm; the difference between the radius of each step of the stop ring and the average radius should not exceed ±10% of the design gap of the stop ring.

[0017] Furthermore, the unit installation center calibration deviation should be ≤0.05mm.

[0018] Furthermore, the center deviation of the wheel should be ≤0.05mm, and the horizontal deviation of the wheel should be ≤0.02mm / m; eight copper wedge plates are used to tighten and fix the wheel to the bottom ring. During the tightening process of the wedge plates, a dial indicator should be used to monitor that the wheel does not move, and a feeler gauge should be used to check the wheel clearance at the eight wedge plate positions and record them.

[0019] Furthermore, after the top cover is installed, the center difference should be ≤0.05mm, the orientation deviation of the top cover should be ≤1mm, and the clearance between the large and small end faces of the movable guide vane should be checked to see if there is any regular tilt.

[0020] Furthermore, it is preferred that the torsional force of a single movable guide vane is no greater than 60% of the average torsional force of all movable guide vanes.

[0021] Beneficial effects of the present invention:

[0022] 1. The lower stop ring serves as the unit installation center reference component. A one-time installation and positioning process using a water guide mechanism and a runner is employed. After the runner is hoisted into the pit, it shields the lower stop ring. Unit center calibration involves transferring the lower stop ring center reference to the pit lining and bottom ring discharge surface, facilitating subsequent component installation and center positioning. This invention transfers the center reference to two locations, creating a "primary and backup" system, or more appropriately, a "primary and calibration" system. This ensures reliable centering after the transfer.

[0023] 2. Lifting the split roof into the pit is difficult, and the large number of bolts on the roof joints complicates assembly. This also means the roof assembly process takes a long time. Using a one-time installation and positioning process with a water guide mechanism and a rotating wheel eliminates the need for secondary disassembly and lifting the roof in and out. This greatly simplifies the installation process, reduces construction difficulty, and saves time for unit assembly.

[0024] 3. The top cover is hung above the pit, resulting in a narrow space in the pit. The movable guide vane is hoisted into place from the center hole of the top cover. Hoisting the guide vane into place is difficult and time-consuming. The one-time installation and positioning process of the water guide mechanism with a runner avoids the movable guide vane from being hoisted in and out twice, simplifies the installation process of the water guide mechanism, and reduces the difficulty of construction.

[0025] 4. The centers of the turbine runner and top cover are adjusted based on the unit center calibration point, and the center deviation of the two components is consistent with the unit center calibration reference deviation, eliminating the error after the center conversion of the lower leak-proof ring.

[0026] 5. The one-time installation and positioning process of the water guide mechanism with the runner adopts the method of measuring the guide vane opening torque to check the flexibility of the movable guide vane. The torque force of the guide vane opening can be read intuitively, which is conducive to analyzing whether there is a jamming phenomenon in the guide vane and ensuring the installation quality of the water guide mechanism.

[0027] 6. The one-time installation and positioning process of the water guide mechanism with the runner has high requirements for the installation center deviation of each component, which is conducive to improving the overall installation accuracy of the water guide mechanism and ensuring the stable operation of the unit in the later stage.

[0028] 7. The one-time installation and positioning process of the water guide mechanism with the runner greatly simplifies the installation process of the water guide mechanism, reduces the construction difficulty, improves work efficiency, saves construction costs, and adds a new process for the installation of the turbine water guide mechanism. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the embodiments of the present invention, the drawings required for describing the embodiments or the prior art will be briefly described below.

[0030] Figure 1 This is a process flow chart for one-time installation and positioning of the water guide mechanism with a rotating wheel according to the present invention.

[0031] Figure 2 This is a cross-sectional view of the one-time installation and positioning of the water guide mechanism with the runner of the present invention.

[0032] Figure 3 It is a plan view of embedded parts of the turbine equipment of the present invention.

[0033] Figure 2 In the middle, 10-seat ring, 11-bottom ring, 12-cone tube, 13-lower anti-leakage ring, 14-runner, 15-upper anti-leakage ring, 16-movable guide vane, 17-top cover, 18-movable guide vane middle sleeve, 19-movable guide vane upper sleeve, 20-machine pit lining, 21-bottom ring discharge surface, S4-Ⅰ-machine pit lining center mark point Ⅰ, S4-Ⅱ-bottom ring discharge surface center mark point Ⅱ.

[0034] Figure 3 In the figure, 10-seat ring, 20-pit lining, 21-bottom ring discharge surface, 101-seat ring X axis, 102-seat ring Y axis, S4-Ⅰ (1)-point 1 of the center mark point Ⅰ of the pit lining, S4-Ⅰ (2)-point 2 of the center mark point Ⅰ of the pit lining, S4-Ⅰ (3)-point 3 of the center mark point Ⅰ of the pit lining, S4-Ⅰ (4)-point 4 of the center mark point Ⅰ of the pit lining, S4-Ⅱ (1)-point 1 of the center mark point Ⅱ of the bottom ring discharge surface, S4-Ⅱ (2)-point 2 of the center mark point Ⅱ of the bottom ring discharge surface, S4-Ⅱ (3)-point 3 of the center mark point Ⅱ of the bottom ring discharge surface, S4-Ⅱ (4)-point 4 of the center mark point Ⅱ of the bottom ring discharge surface. DETAILED DESCRIPTION

[0035] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention. It should be noted that although the functional modules are divided in the process flow chart and the logical order is shown in the flow chart, in some cases, the steps shown or described can be performed in the order of different process flow module divisions or flow charts.

[0036] The following is combined with Figure 1 , Attachment Figure 2 , Attachment Figure 3 , further elaborating on the embodiments of the present invention.

[0037] Reference Figure 1 A process flow chart for one-time installation and positioning of a water guide mechanism with a rotating wheel is provided for one embodiment of the present invention. The process includes but is not limited to the following steps:

[0038] 1) After the turbine seat ring is processed and cleaned on site, the bottom ring 11 is installed. The bottom ring 11 is adjusted concentrically with the center of the seat ring 10 as the reference. The orientation of the bottom ring 11 is adjusted to be consistent with the orientation of the seat ring 10. After the center and orientation of the bottom ring are adjusted to meet the requirements, it is fixed with bolts to the seat ring 10.

[0039] 2) After the base ring 11 is installed and secured, the cone 12 is installed and the second phase of concrete pouring and grouting is carried out. The center of the cone 12 is aligned with the center of the base ring 11, and the orientation of the cone 12 is aligned with the orientation of the seat ring 10. The upper and lower annular gaps of the cone 12 are adjusted to the design requirements, and the outer gaps of the annular gaps are sealed. The upper annular gap of the cone 12 is welded before the second phase of concrete pouring and grouting. The lower annular gap of the cone 12 is welded after the second phase of concrete pouring and grouting.

[0040] 3) After the cone tube 12 and the second phase concrete pouring and grouting are completed, the lower leak-proof ring 13 is installed. The lower leak-proof ring 13 is adjusted concentrically with the center of the bottom ring 11 as the reference. The orientation of the lower leak-proof ring 13 is adjusted to be consistent with the orientation of the bottom ring 11. After the center and orientation are adjusted to be qualified, it is fixed with bolts to the bottom ring 11.

[0041] 4) Unit installation center calibration S4 is the technical core of the one-time installation and positioning of the water guide mechanism with the impeller. Before the unit installation center calibration, the measuring points are marked on the pit lining 20 wall and the bottom ring discharge surface 21. The method is as follows: make four measuring point marks S4-Ⅰ (1), S4-Ⅰ (2), S4-Ⅰ (3), S4-Ⅰ (4) on the same elevation surface of the pit lining 20 wall. The marking point S4-Ⅰ should be higher than the upper plane of the top cover 17. The four measuring point marks are recommended to be in the direction of the seat ring X axis 101 and the seat ring Y axis 102; use the same method to make another four marking points S4-Ⅱ (1), S4-Ⅱ (2), S4-Ⅱ (3), S4-Ⅱ (4) on the same elevation surface at the appropriate position of the bottom ring discharge surface 21. The four measuring point marks should be consistent with the orientation of the marking points on the pit lining wall. With the lower stop ring 13 as the center reference, the center of the lower stop ring is transferred to the marking points S4-Ⅰ and S4-Ⅱ on the wall of the pit lining 20 and the bottom ring discharge surface 21 and marked.

[0042] 5) After the unit center is calibrated, the runner 14 is hoisted into the pit for adjustment and fixation. Before the runner 14 is hoisted, the temporary installation elevation of the runner 14 is determined based on the sum of the stop sizes of the turbine shaft and the generator shaft and the coupling clearance. The center of the runner 14 is adjusted concentrically based on the unit installation center calibration S4-Ⅰ. After the runner center and elevation are adjusted to meet the requirements and the runner is securely fixed, the upper leak-proof ring 15 is hoisted and placed on the runner 14.

[0043] 6) After the top cover 17 is cleaned, the petal top cover is hoisted into the machine pit for assembly and hoisting. The top cover 17 is hoisted into the machine pit and assembled into a whole with combination bolts, and then the leak-proof ring 15 is installed. Then, the top cover 17 is hoisted by the factory bridge crane and hung above the water turbine room with special tools to complete the installation of the shaft sleeves 18 of all movable guide vanes.

[0044] 7) Clean the movable guide vanes 16 before installation. The movable guide vanes 16 are hoisted one by one into the machine pit from the center hole of the top cover 17 using a special tool for guide vanes and installed in place. The seals should be installed before the movable guide vanes 16 are installed in place.

[0045] 8) After the movable guide vanes 16 are fully installed, use the plant bridge crane to hoist the top cover 17 into place, then adjust and fix the top cover. The center of the top cover 17 is adjusted concentrically with the unit center calibration S4-Ⅰ as the reference. The orientation of the top cover 17 is adjusted to be consistent with the orientation of the seat ring 10. After the top cover 17 is adjusted to be qualified, use a feeler gauge to check whether the total clearance of each movable guide vane 16 end face meets the design requirements. After the top cover 17 is checked and qualified, install the top cover and the seat ring 10, bolt them together and tighten them.

[0046] 9) After the top cover 17 has been installed, the upper sleeves 19 for the movable guide vanes are installed. Once all sleeves 19 are installed, the guide vane end face clearance is rechecked for compliance. Each movable guide vane is tested for flexibility (S91) using a hand chain hoist, a dynamometer, and specialized tools. The flexibility of the guide vane is primarily determined by the torsional force required to open it. After the guide vane flexibility test (S91) is complete, the top cover 17 and the upper sleeves 19 for the movable guide vanes are positioned by pin drilling (S92).

[0047] 10) After the guide vane bearing is installed S9, other components of the water guide mechanism are installed. The installation of other components of the water guide mechanism is carried out according to the conventional water guide mechanism installation process, and the content of the present invention will not be repeated.

[0048] The above-mentioned bottom ring axis orientation is required to be adjusted to coincide with the seat ring axis orientation, and the orientation deviation should be ≤1mm; the concentricity deviation should be ≤0.05mm; the bottom ring radial horizontality deviation should be ≤0.02mm / m.

[0049] The concentricity deviation between the above-mentioned lower stop ring and the bottom ring should be ≤0.05mm; the difference between the radius of each step of the stop ring and the average radius should not exceed ±10% of the design gap of the stop ring.

[0050] The calibration deviation of the installation center of the above-mentioned unit should be ≤0.05mm. The four center mark points S4-I marked on the lining wall of the machine pit should be on the same elevation plane; the four center mark points S4-II marked on the bottom ring discharge surface should also be on the same elevation plane, and the positions of each point should be consistent with the upper and lower correspondence of S4-I.

[0051] The above-mentioned runner center deviation should be ≤0.05mm, and the runner horizontality deviation should be ≤0.02mm / m; eight copper wedge plates are used to tighten and fix the runner and the bottom ring. During the tightening process of the wedge plates, a dial indicator should be used to monitor the runner to ensure that it does not move. Use a feeler gauge to check the runner clearance at the eight wedge plate positions and make a record.

[0052] After the above-mentioned top cover is installed, the center difference should be ≤0.05mm, and the orientation deviation of the top cover should be ≤1mm. Check that there is no regular tilt in the gap between the large and small end faces of the movable guide vane.

[0053] The torsional force of the above-mentioned single movable guide vane should not be greater than 60% of the average torsional force of all movable guide vanes.

[0054] The present invention's one-step installation and positioning process for the water guide mechanism with the runner eliminates the need for secondary disassembly and assembly of components such as the top cover and guide vanes, significantly simplifying the installation process. This invention has been successfully applied to the installation of the water guide mechanisms of three pump-turbine units at the Yangjiang Pumped Storage Power Station in Guangdong Province, achieving excellent installation quality, eliminating construction safety hazards, reducing construction difficulty, and meeting energy conservation, emission reduction, and low-carbon environmental protection requirements, resulting in significant social and economic benefits.

[0055] The above is a specific description of the preferred implementation of the present invention, but the present invention is not limited to the above implementation. Those skilled in the art can make various equivalent modifications or substitutions without violating the spirit of the present invention. These equivalent modifications or substitutions are all included in the scope defined by the claims of the present invention.

Claims

1. A one-time installation and positioning process for a water turbine guide mechanism with a runner, characterized by comprising the following steps: 1) After the turbine seat ring is processed and cleaned on site, the bottom ring is installed. The bottom ring is adjusted concentrically with the seat ring center as the reference. The orientation of the bottom ring is adjusted to be consistent with the orientation of the seat ring. After the center and orientation are adjusted to meet the requirements, it is fixed with bolts to the seat ring; 2) After the bottom ring is installed and fixed, the cone pipe is installed and the second phase of concrete pouring and grouting is carried out. The center of the cone pipe is adjusted to be concentric with the center of the bottom ring as the reference, and the orientation of the cone pipe is adjusted to be consistent with the orientation of the seat ring. The gap between the upper and lower annular seams of the cone pipe is adjusted to the design requirements and the external gap of the annular seam is sealed. After the upper annular seam of the cone pipe is welded, the second phase of concrete pouring and grouting is carried out. The lower annular seam of the cone pipe is welded after the second phase of concrete pouring and grouting. 3) After the cone tube and the second phase concrete pouring and grouting are completed, the lower leak-proof ring is installed. The lower leak-proof ring is adjusted concentrically with the center of the bottom ring as the reference. The orientation of the lower leak-proof ring is adjusted to be consistent with the orientation of the bottom ring. After the center and orientation are adjusted to meet the requirements, it is fixed with bolts to the bottom ring; 4) The unit installation center calibration is the core of the one-time installation and positioning technology of the water guide mechanism with the runner. The unit installation center calibration is to use the lower leak ring as the center reference, and then guide the center reference to the position of the pit lining and the bottom ring discharge ring for marking to complete the center conversion; 5) After the unit center is calibrated, the runner is hoisted into the pit for adjustment and fixation. Before the runner is hoisted, the temporary installation elevation of the runner is determined based on the sum of the turbine shaft and generator shaft stop sizes and the coupling clearance. The runner center is adjusted concentrically based on the unit installation center calibration. After the runner center and elevation adjustments are qualified and the runner is securely fixed, the upper leak-proof ring is hoisted and placed on the runner; 6) After the top cover is cleaned in the installation room of the powerhouse, it is hoisted into the machine pit for assembly and hoisting. The top cover is hoisted into the machine pit and assembled into a whole with combination bolts, and then a leak-proof ring is installed. Then, the top cover is hoisted by the powerhouse bridge crane and hung above the turbine room with special tools to complete the installation of the bearings in all movable guide vanes; 7) Clean the movable guide vanes before installation. The movable guide vanes are hoisted into the machine pit one by one using special tools for guide vanes and installed in place. The seals should be installed before the movable guide vanes are installed in place; 8) After all the movable guide vanes are installed in place, use the powerhouse bridge crane to hoist the top cover into place, then install, adjust, and secure it. The center of the top cover is calibrated with the center of the unit as the reference for concentricity adjustment. The orientation of the top cover is adjusted to be consistent with the orientation of the seat ring. After the top cover is adjusted to pass, use a feeler gauge to check that the total clearance of each movable guide vane end face meets the design requirements. After the top cover is inspected and passed, install the top cover and seat ring and tighten the bolts. 9) After the top cover is installed and qualified, the movable guide vane bearing is installed. After all the guide vane bearings are installed, the guide vane end face clearance is checked again to ensure it is qualified. The flexibility of the movable guide vane is checked using a hand hoist and a dynamometer, and the opening torque of each guide vane is checked. After the guide vane bearing installation is checked, the top cover and bearing pins are drilled and positioned; 10) After the guide vane bearing is installed, install other parts of the water guide mechanism.

2. The one-time installation and positioning process for the water turbine guide mechanism with the runner according to claim 1 is characterized in that: In step 1), the bottom ring axis orientation is required to be adjusted to coincide with the seat ring axis orientation, and the orientation deviation should be ≤1mm; the concentricity deviation should be ≤0.05mm; and the bottom ring radial levelness deviation should be ≤0.02mm / m.

3. The one-time installation and positioning process for the water turbine guide mechanism with the runner according to claim 1 is characterized in that: In step 2), the concentricity deviation between the lower stop ring and the bottom ring should be ≤0.05mm; the difference between the radius of each step of the stop ring and the average radius should not exceed ±10% of the design gap of the stop ring.

4. The one-time installation and positioning process for a water turbine guide mechanism with a runner according to claim 1 is characterized in that: In step 4), the unit installation center calibration deviation should be ≤0.05mm.

5. The one-time installation and positioning process for the water turbine guide mechanism with the runner according to claim 1 is characterized in that: In step 5), the runner center deviation should be ≤0.05mm, and the runner horizontality deviation should be ≤0.02mm / m; eight copper wedge plates are used to tighten and secure the runner to the bottom ring. During the wedge plate tightening process, a dial indicator should be used to monitor the runner to ensure that it does not move. Use a feeler gauge to check the runner clearance at the eight wedge plate positions and make a record to serve as a basis for rechecking the runner center during construction.

6. The one-time installation and positioning process for the water turbine guide mechanism with the runner according to claim 1 is characterized in that: In step 8), after the top cover is installed, the center deviation should be ≤0.05mm, and the top cover orientation deviation should be ≤1mm. Check that the clearance between the large and small end faces of the movable guide vanes does not show regular tilt.

7. The one-time installation and positioning process for a water turbine guide mechanism with a runner according to claim 1 is characterized in that: In step 9), the opening torque of a single movable guide vane is no greater than 60% of the average torque of all movable guide vanes.

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