Hydraulic propulsion sliding construction method for large generator stator

Abstract

The invention relates to the technical field of large-scale generator stator construction, in particular to a large-scale generator stator hydraulic propulsion sliding construction method which comprises the following steps: step 1, equipment arrival inspection and acceptance; step 2, unloading the stator; 3, a hoisting platform and a sliding way are manufactured and laid; step 4, stator trial hoisting and hoisting in place; step 5, stator slippage; and step 6, falling back the stator. Compared with a traditional construction method, safety control is more targeted, and major safety accidents such as stator collision, structural instability and hoisting overturning can be effectively avoided. According to the method, the implementation efficiency is improved through procedure connection optimization and equipment comprehensive design. The hauling platform and the slideways are built in a modularized mode, the slideways are assembled according to the specifications of 5 m, 9 m and the like to be matched with construction paths, and waste caused by field cutting is avoided; the hoisting and sliding processes are linked through trial hoisting and trial sliding, industrial vaseline or lithium-based butter is selected as a lubricant, the friction uniformity is verified, and the repeated adjustment time is shortened; and corollary equipment forms a comprehensive system.

Description

Technical Field

[0001] This invention relates to the field of large generator stator construction technology, and in particular to a hydraulic propulsion and sliding construction method for large generator stators. Background Technology

[0002] In large thermal power plants, the turbine generator stator, as a core component, is typically characterized by its large weight and size. Its weight often far exceeds the rated lifting capacity of conventional overhead cranes within the plant, posing a significant challenge to its hoisting and positioning. Currently, the industry primarily employs traditional hoisting or simple sliding methods for positioning such overweight stators. However, these methods have significant drawbacks in practical applications, as detailed below: First, the structural bearing risk is high: In traditional construction, if the stator is directly slid on the turbine operating floor, the concentrated weight of the stator can easily act directly on the turbine island frame beams and floor slabs, causing the local structural stress to far exceed the design bearing limit, resulting in safety hazards such as structural deformation and cracking.

[0003] Second, the construction efficiency is low and the construction period is long: existing solutions mostly rely on large hoisting equipment to operate for a long time, or adopt segmented sliding with poor connection between each link.

[0004] On the one hand, the rental cost of large hoisting equipment is high, the occupation period is long, and it is subject to great site restrictions; on the other hand, the laying accuracy of the sliding track is insufficient, the propulsion method is rudimentary, and problems such as stator deviation and jamming are prone to occur, requiring repeated adjustments, which leads to the delay in construction progress and makes it difficult to meet the project schedule requirements.

[0005] Therefore, there is an urgent need for a method for the installation of large generator stators that can achieve uniform load distribution and improve construction efficiency and safety, in order to overcome the shortcomings of existing technologies. Summary of the Invention

[0006] To solve one of the aforementioned technical problems, the present invention provides a method for hydraulic propulsion and sliding construction of a large generator stator, comprising the following steps: Step 1, Equipment arrival inspection and acceptance: Inspect the appearance and internal condition of the generator stator to confirm that there are no bumps or water ingress, the coils and paint inside the stator cavity are intact, the copper busbars at the bottom outlet are undamaged, and the surface of the stator plate is flat without scratches or rust.

[0007] Step 2, stator unloading: Use a 650-ton truck crane, control the lifting span to ≤9 meters, lift the stator to a height of 100mm, and after stabilization, move the transport vehicle away and slowly lower the stator.

[0008] Step 3, Construction and installation of hoisting platform and slide rails: Erect a towing platform 3-4 spans outside row A. The platform consists of ∅32510mm steel pipe main support columns, I-beam slide rails and channel steel connectors. The bottom of the support columns is fixed with 20mm thick steel plates. Multiple sets of slide rail beams are laid in the workshop to ensure consistent elevation and a 10-20mm gap with the ground. The middle is supported by ∅32510mm steel pipes, and the slide rail joints are smooth.

[0009] Step 4, Stator Trial Lifting and Positioning: A 650-ton truck crane is used to lift the stator. After checking for any abnormalities during lifting and lowering, the bottom blank is cleaned, lubricant is applied to the contact parts, and the stator is lifted onto the transport platform slide.

[0010] Step 5, stator sliding: Using an 80-ton hydraulic thruster, the stator is pushed and moved with the support of the slide rail baffle. First, it is pushed along the AB row direction, then slid along the longitudinal axis of the steam generator to the transverse position of the foundation, and finally pushed transversely to the top of the foundation.

[0011] Step 6, stator lowering: After reinforcing the crane, use the crane's main hook and lifting mechanism to lift the stator 20cm, and use a chain hoist to pull out the bottom blank and slide rail to complete the positioning.

[0012] Based on any of the above technical solutions, the following optimizations are made: In step 1, the inspection is carried out using a combination of visual inspection and tool testing. The focus is on checking the integrity of the coil inside the stator cavity and the quality of the paint adhesion. The copper busbar at the bottom outlet needs to be checked point by point to ensure that there are no bumps or deformations. The flatness of the stator plate surface is measured with a straightedge to ensure that there are no scratches or rust marks. After the inspection is completed, a written record is made, and any minor defects are marked and reported to the equipment manufacturer in a timely manner.

[0013] Based on any of the above technical solutions, the following further optimizations are made: In step 3, the elevation deviation of the towing platform is strictly controlled within 10mm; the main support columns are reinforced with a mesh connection using 20 channel steel or φ219*4.5mm steel pipe; the top of the slide beam is fixed by horizontal welding of 20 channel steel; the bottom steel plate of the support column is tightly fitted to the compacted ground; the gap between the plates is filled with shims and then welded for reinforcement; after the platform is erected, the elevation is checked point by point along the entire length of the slide using a level.

[0014] Based on any of the above technical solutions, the following further optimizations are made: In step 3, the lengths of slides 1, 2, and 5 are 5m, 9m, and 5m respectively, with 2 of each; slide 3 is 4.6m long, with 2 of each; slide 4 is 9m long, with 4 of each; and slide 6 is 2.6m long, with 2 of each. All slide cross-sections are compatible, and the joints are fully welded with steel plates with a thickness of not less than 10mm. After welding, the joints are ground smooth with an angle grinder to ensure a smooth transition without steps. The height difference at the joints is measured with a feeler gauge and does not exceed 0.5mm.

[0015] Based on any of the above technical solutions, the following optimization is made: In step 4, four baffles are symmetrically welded to the front and rear ends of the stator blank. The baffles are made of 16mm thick steel plates, and the inner side is ground with a grinding wheel to a smooth chamfer of R3-R5 and evenly coated with grease. The spacing between the baffles is 20mm±2mm wider than the outer side of the slide. The hoisting radius is controlled between 12-16 meters, and the lifting height is adjusted according to the height of the A row column opening and the platform position to ensure that the stator passes through the opening smoothly.

[0016] Based on any of the above technical solutions, the following optimization is made: In step 4, industrial petroleum jelly or lithium-based grease is selected as the lubricant and is evenly applied to the entire stress-bearing surface in contact with the stator blank and the slide. The coating thickness is 2-3mm. Before coating, rust and impurities on the contact surface of the blank and the slide must be cleaned. After coating, the stator is pushed by hand to test the slide. Only after confirming that the frictional resistance is uniform can it be officially hoisted.

[0017] Based on any of the above technical solutions, the following optimization is made: In step 5, during the sliding process, two dedicated personnel are arranged to monitor the gap between the bottom positioning block and both sides of the slide, and the gap deviation is controlled within 3mm. The pressure of the thruster is adjusted by the hydraulic pump to ensure that the speed of movement on both sides is synchronized. The rear end of the thruster abuts against the steel baffle welded to the slide, the thickness of the baffle is not less than 20mm, and it is fully welded and fixed to the slide beam.

[0018] Based on any of the above technical solutions, the following further optimization is made: the self-made trolley for reinforcing and installing the crane in step 6 has cast steel wheels with a deviation of no more than 2mm. The small workshop is made of 10 channel steel and 8mm thick steel plate welded into an integral frame. The winch is fixed to the support plate welded to the frame by bolts. During hoisting, the center distance between the hoisting points is measured by a tape measure and precisely controlled to be 3.3m±5mm.

[0019] Based on any of the above technical solutions, the following optimization is made: In step 6, the support beam of the lifting mechanism is made of I63a I-beams, with a 20mm thick 500×500mm steel plate welded to the bottom. This steel plate is fully welded to the steel plate of the same specification pre-embedded in the ground, and the weld height is not less than the thickness of the steel plate. The top of the support beam is symmetrically tightened and fixed by two chain hoists with a rated load of not less than 60t. One end of the chain hoist is connected to the support beam, and the other end is fixed to the pre-embedded parts in the factory building.

[0020] Based on any of the above technical solutions, the following further optimizations are made: In the construction equipment, the ZX7-400 electric welding machine is used for welding operations on the slide and supporting structure, with the welding current adjusted to 180-220A, and the weld seam needs to be visually inspected; 60t jacks are used to assist in leveling the slide, with one jack installed at each end and in the middle of each slide beam; a hydraulic jacking device is used to fine-tune the elevation during the stator sliding process; and a J2 level instrument is used to check the track flatness every 2 meters and record the test data.

[0021] Based on any of the above technical solutions, the following further optimizations are made: After the slide rail is installed, the lateral levelness must be less than 1 / 100 (mm / m) of the rail width when tested with a J2 level instrument; the height difference between adjacent slide rail joints must be ≤1mm when tested with a feeler gauge with an accuracy of 0.02mm / m; the rail top elevation along the entire track is measured by setting a test point every 3 meters along the slide rail, and the maximum deviation is calculated after multiple measurements to ensure that it is controlled within 10mm; the surface welds are ground with an angle grinder until they are flush with the rail surface and there are no protruding burrs.

[0022] Based on any of the above technical solutions, the following further optimizations are made: A full-load test lift before stator hoisting must last 10-15 minutes, with a test lift weight of 1.2 times the actual weight of the stator. The focus is on verifying the reliability of the traction brake, the stability of the motor operation, and the sensitivity of the contactor engagement. The test lift height is 200mm ± 20mm, and the stress on each lifting point is checked during the suspension period. Hoisting and sliding operations are strictly prohibited in winds of level six or above, rain, snow, or when visibility is below 10m.

[0023] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention achieves this effect through a comprehensive safety management design encompassing equipment inspection, structural reinforcement, and process monitoring. Upon equipment arrival, a combination of visual and tool-based inspections is conducted and documented, proactively eliminating potential initial defects. During structural construction, seamless steel pipe support columns with a diameter of 325mm and a wall thickness of 10mm are reinforced with a mesh connection. Slide joints are fully welded and ground, with height differences controlled to ≤0.5mm. After reinforcement, the crane's load-bearing capacity is increased to over 160t, constructing a rigid load-bearing system. During operation, measures such as 1.2 times full-load stepped trial lifting, dual-person monitoring of sliding gaps (deviation ≤3mm), and prohibitions against strong winds exceeding level six comprehensively cover three risk categories: equipment, structure, and operation. Compared to traditional construction methods, its safety management is more targeted, effectively avoiding major safety accidents such as stator collisions, structural instability, and hoisting overturning. 2. The sliding track installation utilizes a J2-type level instrument to check the elevation every 3 meters, controlling the lateral levelness within 1 / 100 (mm / m) of the track width. Leveling is achieved through three-point jacks and fine-tuning with a hydraulic lifting device to ensure the geometric accuracy of the sliding track. During hoisting, the center-to-center distance of the hoisting points is precisely controlled at 3.3m ± 5mm, the stator base plate spacing deviation is ± 2mm, and the lubricant thickness is 2-3mm. Quantitative analysis of these detailed parameters ensures balanced stress distribution. During the sliding phase, the hydraulic pump adjusts the propulsion speed synchronously, and a chain hoist corrects the verticality of the support beam, ultimately achieving full-process controllable stator posture from unloading to foundation placement. This precision control avoids problems such as uneven stress on the internal coils of the stator and poor platform fit, ensuring the operational stability of the equipment after installation.

[0024] 3. This invention improves implementation efficiency through optimized process connections and integrated equipment design. The towing platform and sliding track are modularly constructed, with tracks assembled in 5m and 9m sizes to suit different construction paths, avoiding on-site cutting waste. The hoisting and sliding processes are connected through trial hoisting and trial sliding; industrial petroleum jelly or lithium-based grease is used as lubricant, and friction uniformity is verified to reduce repeated adjustment time. Supporting equipment forms a comprehensive system; a ZX7-400 welding machine performs precise welding with 180-220A current parameters, and a 60t jack combined with a level instrument enables rapid leveling of the sliding track. Simultaneously, the selection of materials allows for flexibility (such as Q235 steel or equivalent strength materials), and construction parameters can be adjusted according to on-site conditions (such as adjusting the lifting height to match the opening size), enabling the solution to adapt to different factory layouts and equipment specifications. Compared to fixed-process construction methods, the construction period can be shortened by 15%-20%, significantly improving adaptability. Detailed Implementation

[0025] The embodiments of the technical solution of the present invention will be described in detail below. These embodiments are only used to illustrate the technical solution of the present invention more clearly, and are therefore merely examples and should not be used to limit the scope of protection of the present invention.

[0026] Example 1: A method for hydraulic propulsion and sliding construction of a large generator stator, comprising the following steps: Step 1, Equipment arrival inspection and acceptance: Inspect the appearance and internal condition of the generator stator to confirm that there are no bumps or water ingress, the coils and paint inside the stator cavity are intact, the copper busbars at the bottom outlet are undamaged, and the surface of the stator plate is flat without scratches or rust.

[0027] By conducting a comprehensive inspection of the appearance and condition of key components of the generator stator, we can control the initial quality of the equipment from the source and avoid affecting the stability of subsequent construction and operation due to defects in the equipment itself. It covers core components such as stator appearance, internal coils, paint, copper busbars, and platform, with comprehensive inspection dimensions, which can detect potential problems in advance and reduce the risk of rework after construction. The above steps complete the initial quality inspection after the equipment arrives, providing a qualified basic equipment guarantee for the smooth progress of subsequent construction processes. In the early stages of generator stator construction, this inspection step is not only a simple quality confirmation, but also provides benchmark status data for subsequent high-precision operations such as hoisting and sliding. It avoids hidden problems such as uneven stator stress and damaged insulation performance during construction due to initial defects, and ensures equipment safety throughout the entire construction process.

[0028] Step 2, stator unloading: Use a 650-ton truck crane, control the lifting span to ≤9 meters, lift the stator to a height of 100mm, and after stabilization, move the transport vehicle away and slowly lower the stator.

[0029] Using the rated load and controllable lifting parameters of a 650-ton truck crane, the stator is safely transferred from the transport vehicle to the designated location, and the lifting is ensured to be stable by controlling the span and lifting height. By clearly selecting a large-tonnage truck crane to match the stator weight, and limiting the lifting span to ≤9 meters and the lifting height to 100mm, the torque and stability during the lifting process can be effectively controlled, reducing the risk of overturning. The above steps complete the transformation of the stator from its transportation state to its initial placement state during construction, creating conditions for the subsequent hoisting and positioning process after the hoisting platform and slide rail are fabricated. During the unloading process, the 100mm lifting height setting is not chosen arbitrarily. It can meet the space requirements for moving the transport vehicle, minimize the risk of the stator being suspended in the air, and provide an initial basis for adjusting the equipment posture for subsequent trial lifting operations, so as to achieve a smooth transition between unloading and subsequent processes.

[0030] Step 3, Construction and installation of hoisting platform and slide rails: Erect a towing platform 3-4 spans outside row A. The platform consists of ∅32510mm steel pipe main support columns, I-beam slide rails and channel steel connectors. The bottom of the support columns is fixed with 20mm thick steel plates. Multiple sets of slide rail beams are laid in the workshop to ensure consistent elevation and a 10-20mm gap with the ground. The middle is supported by ∅32510mm steel pipes, and the slide rail joints are smooth.

[0031] The main support column is made of 325mm thick steel pipe with a wall thickness of 10mm. The towing platform is built with I-beam slide rails and channel steel connectors. The support column is fixed by the bottom steel plate. The internal slide rail beam is supported by steel pipes and the elevation and gap are controlled to ensure that the platform and slide rail form a stable bearing and sliding foundation. High-strength steel pipe support columns and I-beam slide rails are selected, and the overall structure is enhanced by channel steel connectors. Thick steel plates are added to the bottom of the support columns to increase the stress area. The slide rail beams are reserved with gaps and additional supports, which can effectively distribute the weight of the stator and avoid excessive local stress that could lead to structural deformation. The slide rail joints are required to be smooth to reduce sliding resistance. This step provides a rigid load-bearing structure for the hoisting and positioning of the stator and subsequent sliding operations, ensuring that the stator remains on a stable support surface throughout the transfer process, and enabling the orderly movement of the stator in different construction areas. The 10-20mm gap between the slide beam and the ground not only provides space for the installation of the support column, but also avoids the impact of uneven ground on the slide elevation during the sliding process. At the same time, the deformation of the slide under stress can be observed through this gap, and potential structural problems can be detected in time. The smooth joint design not only reduces friction, but also prevents the stator blank from generating impact loads due to joint protrusions during the sliding process, thus protecting the stator bottom structure.

[0032] Step 4, Stator Trial Lifting and Positioning: A 650-ton truck crane is used to lift the stator. After checking for any abnormalities during lifting and lowering, the bottom blank is cleaned, lubricant is applied to the contact parts, and the stator is lifted onto the transport platform slide.

[0033] The stator was test-lifted using a 650-ton truck crane to verify the reliability of the lifting equipment and operation. The bottom blank was cleaned and lubricant was applied to reduce slippage and friction. The stator was then precisely lifted onto the transport platform slide. Trial lifting can detect hoisting equipment malfunctions or operational problems in advance, avoiding risks during formal hoisting; applying lubricant can reduce frictional resistance during sliding and protect the contact surfaces. This step involves transferring the stator from its placement position to the transport platform slide, preparing it for subsequent sliding operations, and verifying the safety of the hoisting system. Trial lifting is not only an inspection of the lifting equipment, but also a pre-adjustment of the stator's lifting posture. By observing the lifting and lowering movements, we can see if there are any tilting or jamming issues with the stator, providing a basis for precise control during the formal lifting and positioning. The timing of applying lubricant is chosen after the trial lifting is normal, which can avoid impurities from contaminating the lubrication surface during the trial lifting process and ensure the stability of the lubrication effect.

[0034] Step 5, stator sliding: Using an 80-ton hydraulic thruster, the stator is pushed and moved with the support of the slide rail baffle. First, it is pushed along the AB row direction, then slid along the longitudinal axis of the steam generator to the transverse position of the foundation, and finally pushed transversely to the top of the foundation.

[0035] Using the linear thrust provided by the 80-ton hydraulic thruster, and with the slide baffle as the support point, the stator is driven to slide gradually along a preset path (AB row direction → steam generator longitudinal axis → foundation transverse direction) to directly above the foundation. The hydraulic thruster has a large and controllable thrust, which can achieve smooth propulsion of the stator; the phased sliding path design conforms to the construction site layout, can avoid obstacles, and accurately reach the target position. The complete spatial transfer of the stator from the transport platform slide to directly above the foundation is one of the core procedures of the entire construction method, which determines the final positioning accuracy of the stator. The phased sliding path design is not only to adapt to the site, but also to adjust the stator attitude at each stage. For example, it can correct lateral offset when advancing in the AB row direction and adjust the longitudinal position when sliding along the longitudinal axis. The final precise positioning is achieved through step-by-step adjustments. The thrust of the hydraulic thruster is applied to the slide baffle, which can evenly transfer the thrust to the stator and avoid excessive local stress on the stator, which could lead to structural damage.

[0036] Step 6, stator lowering: After reinforcing the crane, use the crane's main hook and lifting mechanism to lift the stator 20cm, and use a chain hoist to pull out the bottom blank and slide rail to complete the positioning.

[0037] First, reinforce the crane to increase its load-bearing capacity. Then, use the crane's main hook and lifting mechanism to lift the stator to a certain height, leaving space to remove the base blank and slide rail. Finally, allow the stator to fall smoothly back onto the foundation to complete its placement. The crane reinforcement ensures the safety of hoisting, and the dual-mechanism integrated lifting can distribute the force evenly. The 20cm lifting height can meet the space requirements for removing the base blank from the slide, and reduce the risk of suspension. The final transformation of the stator from the sliding state to the foundation in place is a key step in the construction process. The integrated lifting of the main hook and the lifting mechanism is not a simple superposition of forces, but a horizontal lifting of the stator achieved through synchronous control, which avoids the internal coils from shifting due to the stator tilting during the lifting process; the 20cm lifting height design can not only ensure the smooth extraction of the base blank and slide, but also shorten the stator suspension time and reduce the risk of positioning deviation caused by sudden shaking.

[0038] Based on any of the above technical solutions, the following optimizations are made: In step 1, the inspection is carried out using a combination of visual inspection and tool testing. The focus is on checking the integrity of the coil inside the stator cavity and the quality of the paint adhesion. The copper busbar at the bottom outlet needs to be checked point by point to ensure that there are no bumps or deformations. The flatness of the stator plate surface is measured with a straightedge to ensure that there are no scratches or rust marks. After the inspection is completed, a written record is made, and any minor defects are marked and reported to the equipment manufacturer in a timely manner.

[0039] By combining the intuitiveness of visual observation with the precision of tool inspection, targeted checks are conducted on key parts of the stator. Inspection indicators are quantified using tools such as straightedges, and written records are created to achieve quality traceability and timely feedback and handling of defects. A combined visual inspection and tool-based testing approach is adopted to balance efficiency and accuracy; key inspection areas and testing tools are clearly defined, and specific testing standards are established; written records and defect feedback are required to form a complete quality control closed loop. Improve the accuracy and comprehensiveness of equipment arrival inspections to ensure that defects are traceable and manageable, and further guarantee that the initial quality of the stator meets construction requirements. Written records are not only quality certification documents, but also a reference for equipment protection during subsequent construction. For example, for minor defects marked on the equipment, targeted protective measures can be taken during hoisting and sliding. Reporting defects to the manufacturer can provide professional handling guidance before equipment installation, avoiding damage to equipment performance due to handling defects on your own, and reflecting the comprehensive quality control of construction and equipment production.

[0040] Based on any of the above technical solutions, the following further optimizations are made: In step 3, the elevation deviation of the towing platform is strictly controlled within 10mm; the main support columns are reinforced with a mesh connection using 20 channel steel or φ219*4.5mm steel pipe; the top of the slide beam is fixed by horizontal welding of 20 channel steel; the bottom steel plate of the support column is tightly fitted to the compacted ground; the gap between the plates is filled with shims and then welded for reinforcement; after the platform is erected, the elevation is checked point by point along the entire length of the slide using a level.

[0041] The rigidity of the platform structure is enhanced by reinforcing the main support columns with a mesh connection, fixing the slide beams by horizontal welding, and addressing the gaps at the bottom of the support columns. The elevation is checked point by point using a level instrument to ensure that the platform meets the accuracy requirements for load-bearing and sliding. The mesh reinforcement structure can comprehensively improve the stability of the support columns, and the horizontal welding and fixing of the slide beam can ensure the overall straightness of the slide. The bottom gap treatment method can eliminate the impact of uneven ground on the platform. The level instrument can accurately control the elevation deviation within 10mm by checking each point. This step ensures both the structural strength and elevation accuracy of the towing platform, providing a reliable foundation for the stable placement and sliding of the stator on the platform. The mesh connection of 20 channel steel or φ219mm*4.5mm steel pipe not only strengthens the structure, but also evenly distributes the weight of the stator to each support column when the platform is under stress, avoiding single-point overload; the treatment of welding reinforcement after the shims are filled in creates a rigid support point at the bottom of the support column, preventing the platform from settling under long-term load or sliding impact, and ensuring long-term stability of elevation accuracy.

[0042] Based on any of the above technical solutions, the following further optimizations are made: In step 3, the lengths of slides 1, 2, and 5 are 5m, 9m, and 5m respectively, with 2 of each; slide 3 is 4.6m long, with 2 of each; slide 4 is 9m long, with 4 of each; and slide 6 is 2.6m long, with 2 of each. All slide cross-sections are compatible, and the joints are fully welded with steel plates with a thickness of not less than 10mm. After welding, the joints are ground smooth with an angle grinder to ensure a smooth transition without steps. The height difference at the joints is measured with a feeler gauge and does not exceed 0.5mm.

[0043] Based on the layout requirements of the construction area, different lengths of slide rails are designed. The continuity of sliding is ensured by cross-section adaptation. The joints are made of thick steel plates that are fully welded and ground. The height difference is controlled by feeler gauge detection to achieve seamless connection of the slide rails. The length and quantity of the slide rails are matched with the construction path, and the cross-section is adapted to avoid slippage and jamming; the full welding of thick steel plates ensures the joint strength, and grinding and height difference control (≤0.5mm) can minimize the slippage resistance and reduce the wear of the stator blank. Constructing a continuous and flat sliding track ensures smooth movement of the stator between different areas while protecting the stator blank and the sliding track itself from damage. The combination design of slides of different lengths is not a simple splicing, but a precise layout based on the needs of stator sliding, such as steering and load changes. For example, short slides are used in the steering area to facilitate direction adjustment; the 0.5mm height difference control standard is far higher than the requirements of conventional sliding projects, which can effectively avoid the vibration of the stator caused by the joint steps during the sliding process and protect the internal precision coil structure of the stator from impact.

[0044] Based on any of the above technical solutions, the following optimization is made: In step 4, four baffles are symmetrically welded to the front and rear ends of the stator blank. The baffles are made of 16mm thick steel plates, and the inner side is ground with a grinding wheel to a smooth chamfer of R3-R5 and evenly coated with grease. The spacing between the baffles is 20mm±2mm wider than the outer side of the slide. The hoisting radius is controlled between 12-16 meters, and the lifting height is adjusted according to the height of the A row column opening and the platform position to ensure that the stator passes through the opening smoothly.

[0045] Steel plate baffles with rounded chamfers are welded to the front and rear ends of the stator blank. A guide structure is formed by controlling the spacing of the baffles, and grease lubrication is used to reduce guide friction. The hoisting radius and lifting height are adjusted to allow the stator to pass smoothly through the corresponding opening size. The symmetrical arrangement of four baffles enables bidirectional guidance, and the rounded chamfers and grease application prevent the baffles from rubbing against the slide. The baffle spacing is precisely controlled (20mm ± 2mm wider than the outer side of the slide), which ensures both guiding effect and avoids jamming. The hoisting parameters can be adjusted according to the site structure, making it highly adaptable. The baffle provides lateral limiting and guidance during the stator's sliding process, preventing the stator from deviating from the slide rail; reasonable hoisting parameters ensure that the stator safely passes through the A-row column opening and is hoisted into place. The guiding function of the baffles is not only reflected in the straight sliding stage. When the stator is turning and sliding, the turning accuracy can be predicted by the change in the gap between the baffles on both sides and the slide, which makes it easy to adjust the propulsion force in time. The 20mm±2mm spacing design reserves space for the small deformation of the stator caused by the force during the sliding process, while strictly controlling the offset, avoiding stator shaking due to excessive gap or jamming due to insufficient gap.

[0046] Based on any of the above technical solutions, the following optimization is made: In step 4, industrial petroleum jelly or lithium-based grease is selected as the lubricant and is evenly applied to the entire stress-bearing surface in contact with the stator blank and the slide. The coating thickness is 2-3mm. Before coating, rust and impurities on the contact surface of the blank and the slide must be cleaned. After coating, the stator is pushed by hand to test the slide. Only after confirming that the frictional resistance is uniform can it be officially hoisted.

[0047] Select a suitable industrial lubricant and apply it evenly to the specified thickness on the cleaned contact surface. Verify the lubrication effect through trial sliding to ensure uniform frictional resistance during sliding. Industrial petroleum jelly or lithium-based grease has good lubricity and adhesion, making it suitable for metal contact surfaces; applying it to all stressed surfaces and controlling the thickness (2-3mm) ensures uniform and sufficient lubrication; the trial run allows for direct testing of the lubrication effect, avoiding localized poor lubrication. The friction coefficient between the stator blank and the slide is reduced, the sliding resistance is reduced, the contact surface is protected from wear, and the sliding process is ensured to be smooth and stable. A coating thickness of 2-3mm is not only for lubrication, but also forms a protective film on the contact surface to prevent metal debris generated during sliding from scratching the substrate or slide surface. Test sliding confirms uniform friction resistance, which can indirectly judge the flatness of the slide and the consistency of the stress surface of the substrate. If the resistance is uneven, it indicates that there are problems such as slide protrusion or substrate deformation, thus achieving the dual function of lubrication detection and equipment condition detection.

[0048] Based on any of the above technical solutions, the following optimization is made: In step 5, during the sliding process, two dedicated personnel are arranged to monitor the gap between the bottom positioning block and both sides of the slide, and the gap deviation is controlled within 3mm. The pressure of the thruster is adjusted by the hydraulic pump to ensure that the speed of movement on both sides is synchronized. The rear end of the thruster abuts against the steel baffle welded to the slide, the thickness of the baffle is not less than 20mm, and it is fully welded and fixed to the slide beam.

[0049] By having a dedicated person monitor the gap between the two sides to ensure that the stator does not deviate, adjusting the hydraulic pump pressure to achieve synchronous propulsion speed on both sides, and using high-strength steel baffles to provide reaction force support for the propeller, the sliding direction and speed are controllable. The dual-person monitoring system allows for real-time monitoring of stator offset, with a 3mm deviation control standard ensuring sliding accuracy. Pressure regulation enables speed synchronization, preventing stator torsion. Thick, fully welded steel plates withstand the propeller's reaction force, ensuring stable support. This step achieves directional correction and speed control during stator sliding, preventing the stator from deviating from the track or torsion, ensuring precise sliding path, and simultaneously guaranteeing the propeller's operational stability. The 3mm gap deviation control is far higher than the precision requirements of conventional sliding engineering, which can effectively prevent the copper busbar at the bottom of the stator from colliding with the surrounding structure due to the offset during the sliding process; the steel baffle is not only a support point for the reaction force, but its fully welded structure with the slide beam can also enhance the overall rigidity of the slide when it is subjected to sliding force, and prevent the slide from bending and deforming due to the thrust.

[0050] Based on any of the above technical solutions, the following further optimization is made: the self-made trolley for reinforcing and installing the crane in step 6 has cast steel wheels with a deviation of no more than 2mm. The small workshop is made of 10 channel steel and 8mm thick steel plate welded into an integral frame. The winch is fixed to the support plate welded to the frame by bolts. During hoisting, the center distance between the hoisting points is measured by a tape measure and precisely controlled to be 3.3m±5mm.

[0051] By adding a self-made trolley with cast steel wheels and reinforcing the trolley with an overall welded frame, the winch is reliably fixed, and the spacing between lifting points is precisely controlled to ensure that the trolley is subjected to balanced force and runs stably during the lifting process. The cast steel wheels have high strength and good wear resistance, and the skew amount is controlled (≤2mm) to ensure accurate running trajectory; the overall welded frame enhances the rigidity of the trolley, and the winch fixing method is reliable; the 3.3m±5mm lifting point spacing control ensures that the stator is subjected to symmetrical force. To improve the load-bearing capacity and operational accuracy of the crane, ensure the stability of the stator during the comprehensive lifting process, and provide equipment support for precise positioning.

[0052] The overall frame design of the self-made trolley not only enhances the load-bearing capacity of the trolley, but also, through the rigid constraint of the frame, evenly transmits the pulling force of the winch to the trolley beam, avoiding local stress concentration that could lead to beam deformation. The precise control of the lifting point spacing of 3.3m±5mm is the optimal parameter calculated based on the position of the stator's center of gravity. This ensures that the stator remains horizontal during lifting, preventing uneven stress on the internal coils due to center of gravity shift, and laying the foundation for precise alignment during subsequent lowering and positioning.

[0053] Based on any of the above technical solutions, the following optimization is made: In step 6, the support beam of the lifting mechanism is made of I63a I-beams, with a 20mm thick 500×500mm steel plate welded to the bottom. This steel plate is fully welded to the steel plate of the same specification pre-embedded in the ground, and the weld height is not less than the thickness of the steel plate. The top of the support beam is symmetrically tightened and fixed by two chain hoists with a rated load of not less than 60t. One end of the chain hoist is connected to the support beam, and the other end is fixed to the pre-embedded parts in the factory building.

[0054] Using high-strength I63a I-beams as the main supporting beams, vertical load-bearing and fixing are achieved through full welding connection between the bottom thick steel plate and the pre-embedded steel plate in the ground. The top is symmetrically tightened with chain hoists and connected to the pre-embedded parts of the factory building to achieve lateral stability, thus constructing a lifting mechanism support foundation that has both vertical load-bearing and lateral anti-overturning capabilities. The I63a I-beam has excellent mechanical properties and can withstand the huge load transmitted by the lifting mechanism; the double steel plates at the bottom are fully welded and the weld height requirements ensure the reliability of the vertical support; the double chain hoists at the top are symmetrically fixed, which can effectively counteract the horizontal force generated during the lifting process and prevent the support beam from tilting. To provide a stable and rigid support for the lifting mechanism, ensuring that the lifting mechanism does not shift or deform during the lifting of the stator, and ensuring that the lifting action is safe and controllable. The design of the 500×500mm thick steel plate at the bottom is not only to expand the load-bearing area, but also to form a rigid grounding structure by fully welding with the pre-embedded steel plate, so as to directly transfer the lifting load to the ground foundation and avoid settlement due to insufficient local ground bearing capacity. The symmetrical tensioning and fixing of the top chain hoist, in addition to the anti-overturning effect, can also correct the verticality of the support beam by finely adjusting the length of the chain hoist during the lifting process, so as to indirectly ensure that the load center of the lifting mechanism is aligned with the center of gravity of the stator.

[0055] Example 2: Compared with Example 1, this example also includes the following technical features: Based on any of the above technical solutions, the following further optimizations are made: In the construction equipment, the ZX7-400 electric welding machine is used for welding operations on the slide and supporting structure, with the welding current adjusted to 180-220A, and the weld seam needs to be visually inspected; 60t jacks are used to assist in leveling the slide, with one jack installed at each end and in the middle of each slide beam; a hydraulic jacking device is used to fine-tune the elevation during the stator sliding process; and a J2 level instrument is used to check the track flatness every 2 meters and record the test data.

[0056] Specialized equipment was matched to meet the needs of each stage of construction. Welding operations were completed using a ZX7-400 welding machine under specific current parameters. A 60t jack was used for leveling the track, and a hydraulic jacking device was used to fine-tune the stator's sliding elevation. A J2 level was used to check the track flatness at fixed intervals and record the data, forming a comprehensive quality control system for equipment operation. The welding machine model and current parameters were clearly defined to meet the welding requirements of the track and support structure, ensuring weld quality. The three-point setting of the jacks allowed for precise adjustment of the track elevation. The hydraulic jacking device responded quickly, facilitating fine-tuning of the elevation. The level was used at 2-meter intervals to ensure no blind spots in track flatness detection. Through the specialized functions of the supporting equipment, the welding quality, slide rail accuracy, sliding elevation control, and track flatness are ensured respectively, providing equipment support for the quality and safety of each construction process. The precise control of welding current from 180 to 220A not only meets the requirements for welding formation, but also matches the welding characteristics of different materials such as ∅325mm steel pipes with a wall thickness of 10mm and I-beams. This avoids the base material from burning through due to excessive current or the weld from not fusing due to insufficient current. Each slide beam is equipped with jacks at three points, which can achieve linear leveling of the slide beam. Compared with single-point leveling, it can more accurately control the straightness of the slide, providing a prior guarantee for the stability of subsequent sliding.

[0057] Based on any of the above technical solutions, the following further optimizations are made: After the slide rail is installed, the lateral levelness must be less than 1 / 100 (mm / m) of the rail width when tested with a J2 level instrument; the height difference between adjacent slide rail joints must be ≤1mm when tested with a feeler gauge with an accuracy of 0.02mm / m; the rail top elevation along the entire track is measured by setting a test point every 3 meters along the slide rail, and the maximum deviation is calculated after multiple measurements to ensure that it is controlled within 10mm; the surface welds are ground with an angle grinder until they are flush with the rail surface and there are no protruding burrs.

[0058] High-precision testing equipment and methods were used to quantitatively test the installation quality of the slideway. The lateral levelness was tested with a J2 level instrument, the height difference of the joints was tested with a high-precision feeler gauge, the track top elevation deviation was calculated by setting test points at fixed intervals, and the surface welds were ground to ensure that all indicators of the slideway met the sliding requirements. The lateral levelness adopts a relative deviation standard (less than 1 / 100 (mm / m) of the rail width) to adapt to the inspection needs of different width slides; the feeler gauge accuracy is as high as 0.02mm / m, which can accurately identify the slight height difference of the joint; multi-point inspection of elevation and welding point grinding treatment further improve the flatness and consistency of the slide. The geometric accuracy and surface quality of the slide rail after installation are fully verified to ensure that the slide rail meets the requirements for stability, low resistance and directional controllability during stator sliding. The lateral levelness adopts a relative standard of 1 / 100 (mm / m) of the track width, rather than an absolute value, which reflects the adaptability of the inspection standard. The pass threshold can be dynamically adjusted according to the actual width of the slide, ensuring accuracy while avoiding over-testing. Elevation detection points are set every 3 meters and the maximum deviation is calculated, which can effectively identify the cumulative error of the slide and avoid slippage problems caused by local compliance but overall deviation exceeding the standard, providing accurate track data for subsequent slippage path planning.

[0059] Based on any of the above technical solutions, the following further optimizations are made: A full-load test lift before stator hoisting must last 10-15 minutes, with a test lift weight of 1.2 times the actual weight of the stator. The focus is on verifying the reliability of the traction brake, the stability of the motor operation, and the sensitivity of the contactor engagement. The test lift height is 200mm ± 20mm, and the stress on each lifting point is checked during the suspension period. Hoisting and sliding operations are strictly prohibited in winds of level six or above, rain, snow, or when visibility is below 10m.

[0060] By applying a load of 1.2 times the stator weight for a long-term full-load test, the performance and reliability of the core components of the lifting equipment are comprehensively tested. The lifting points are checked by suspending at a specific height. At the same time, the prohibition of operation in severe weather is clearly defined, so as to control the lifting safety from both the aspects of equipment performance and environmental conditions. A 1.2 times overload test lift and a duration of 10-15 minutes can fully expose potential defects in the lifting equipment; a reasonable test lift height facilitates inspection of the lifting points and reduces the risk of falls; clear weather prohibition standards can directly avoid operational risks in harsh environments. Verify the safety and stability of the lifting equipment under extreme working conditions, confirm the balance of force on the lifting points, eliminate environmental interference, and provide a safe prerequisite for formal lifting operations. The 1.2 times full load test not only tests the load-bearing capacity of the equipment, but also allows the various components of the equipment to be fully stressed by suspending for a long time, simulating the continuous load state during the actual hoisting, and discovering fatigue defects that are difficult to detect by static testing; the test hoisting height of 200mm±20mm, in addition to facilitating inspection, also provides reaction time and buffer space for emergency handling in the event of sudden braking failure, reducing accident losses.

[0061] It needs to be explained that: in step 3, the ∅32510mm steel pipe refers to a seamless steel pipe with a nominal outer diameter of 325mm and a wall thickness of 10mm, and the material conforms to the Q235 steel or equivalent strength level standard; the I-beam slide rail specifically selects I30c type I-beams, whose cross-sectional dimensions and mechanical properties meet the requirements of GB / T 706-2016 "Hot-rolled steel" standard.

[0062] Step 6 involves reinforcing the overhead crane by adding temporary supports under the main beam of the European-style bridge crane. The support columns are made of Φ325×10mm seamless steel pipes, with the top tightly fitted to the overhead crane beam by steel plates, and the bottom welded and fixed to the pre-embedded steel plates in the ground. The overall load-bearing capacity of the reinforced overhead crane must reach more than 160t.

[0063] The lifting mechanism consists of a winch (rated tension not less than 80t), a pulley block (no less than 4 movable pulleys) and a wire rope (637+1-φ65 model). The pulley block is fixed to the self-made trolley by a pin shaft. The pin shaft diameter is not less than 50mm and the material is 45 steel.

[0064] During the trial lifting, the actual weight of the stator shall be based on the weight indicated on the factory certificate of conformity provided by the equipment manufacturer. The loading method for the full-load trial lifting shall be gradual loading: first load to 50% of the rated weight and hold for 5 minutes, then load to 100% of the rated weight and hold for 5 minutes, and finally load to 120% of the rated weight to complete the trial lifting process.

[0065] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention. For those skilled in the art, any alternative improvements or transformations made to the implementation of the present invention fall within the protection scope of the present invention.

[0066] Any aspects of this invention not described in detail are well-known to those skilled in the art.

Claims

1. A method for hydraulic propulsion and sliding construction of a large generator stator, characterized in that, Includes the following steps: Step 1, Equipment arrival inspection and acceptance: Inspect the appearance and internal condition of the generator stator to confirm that there are no bumps or water ingress, the coils and paint inside the stator cavity are intact, the copper busbars at the bottom outlet are undamaged, and the surface of the stator plate is flat without scratches or rust. Step 2, stator unloading: Use a 650-ton truck crane, control the lifting span to ≤9 meters, lift the stator to a height of 100mm, and after stabilization, move the transport vehicle away and slowly lower the stator; Step 3, Construction and installation of hoisting platform and slide rails: Erect a towing platform 3-4 spans outside row A. The platform consists of ∅32510mm steel pipe main support columns, I-beam slide rails and channel steel connectors. The bottom of the support columns is fixed with 20mm thick steel plates. Multiple sets of slide rail beams are laid in the workshop to ensure consistent elevation and leave a 10-20mm gap with the ground. The middle is supported by ∅32510mm steel pipes, and the slide rail joints are smooth. Step 4, Stator Trial Lifting and Positioning: The 650-ton truck crane is used to lift the stator. After checking that there are no abnormalities during lifting and lowering, the bottom blank is cleaned, lubricant is applied to the contact parts, and the stator is lifted onto the transport platform slide. Step 5, stator sliding: Using an 80-ton hydraulic thruster, the stator is pushed and moved with the support of the slide rail baffle. First, it is pushed along the AB row direction, then slid along the longitudinal axis of the steam generator to the transverse position of the foundation, and finally pushed laterally to the top of the foundation. Step 6, stator lowering: After reinforcing the crane, use the crane's main hook and lifting mechanism to lift the stator 20cm, and use a chain hoist to pull out the bottom blank and slide rail to complete the positioning.

2. The method according to claim 1, characterized in that, Step 1 involves visual inspection combined with tool testing, focusing on checking the integrity of the coils inside the stator cavity and the quality of paint adhesion. The copper busbars at the bottom lead-out end need to be checked point by point for any bumps or deformations. The flatness of the stator plate surface is measured with a straightedge to ensure there are no scratches or rust marks. After the inspection is completed, a written record is made, and any minor defects are marked and reported to the equipment manufacturer in a timely manner.

3. The method according to claim 2, characterized in that, In step 3, the elevation deviation of the towing platform is strictly controlled within 10mm. The main support columns are reinforced by a mesh connection using 20 channel steel or φ219*4.5mm steel pipe. The top of the slide beam is fixed by horizontal welding of 20 channel steel. The steel plate at the bottom of the support column is tightly attached to the compacted ground. The gap between the attachments is filled with shims and then welded for reinforcement. After the platform is erected, the elevation is checked point by point along the entire length of the slide using a level.

4. The method according to claim 3, characterized in that, In step 3, slides 1, 2, and 5 are 5m, 9m, and 5m long respectively, with 2 of each; slide 3 is 4.6m long, with 2; slide 4 is 9m long, with 4; and slide 6 is 2.6m long, with 2. All slides have compatible cross-sections, and the joints are fully welded with steel plates with a thickness of not less than 10mm. After welding, the joints are ground smooth with an angle grinder to ensure a smooth transition without steps. The height difference at the joints is checked with a feeler gauge and does not exceed 0.5mm.

5. The method according to claim 4, characterized in that, In step 4, four baffles are symmetrically welded to the front and rear ends of the stator blank. The baffles are made of 16mm thick steel plates. The inner side is ground with a grinding wheel to a smooth chamfer of R3-R5 and evenly coated with grease. The spacing between the baffles is 20mm±2mm wider than the outer side of the slide. The hoisting radius is controlled between 12-16 meters. The lifting height is adjusted according to the height of the A row column opening and the platform position to ensure that the stator passes through the opening smoothly.

6. The method according to claim 5, characterized in that, In step 4, industrial petroleum jelly or lithium-based grease should be used as the lubricant. Apply it evenly to the entire stress-bearing surface where the stator blank and slide rail are in contact, with a thickness of 2-3 mm. Before applying, rust and impurities on the contact surface of the blank and slide rail should be cleaned. After application, push the stator by hand to test slide. Only after confirming that the frictional resistance is uniform can the formal hoisting proceed.

7. The method according to claim 6, characterized in that, In step 5, during the sliding process, two dedicated personnel are assigned to monitor the gap between the bottom positioning block and both sides of the slide. The gap deviation is controlled within 3mm. The pressure of the thruster is adjusted by the hydraulic pump to ensure that the speed of movement on both sides is synchronized. The rear end of the thruster abuts against the steel baffle welded to the slide. The baffle is not less than 20mm thick and is fully welded to the slide beam.

8. The method according to claim 7, characterized in that, In step 6, the self-made trolley used for reinforcing the crane has cast steel wheels with a deviation of no more than 2mm. The small workshop is made of 10 channel steel and 8mm thick steel plate welded into an integral frame. The winch is fixed to the support plate welded to the frame with bolts. During hoisting, the center distance between the hoisting points is measured with a tape measure and precisely controlled to be 3.3m±5mm.

9. The method according to claim 8, characterized in that, In step 6, the lifting mechanism support beam is made of I63a I-beams, with a 20mm thick 500×500mm steel plate welded to the bottom. This steel plate is fully welded to the steel plate of the same specification pre-embedded in the ground, and the weld height is not less than the thickness of the steel plate. The top of the support beam is symmetrically tightened and fixed by two chain hoists with a rated load of not less than 60t. One end of the chain hoist is connected to the support beam, and the other end is fixed to the pre-embedded parts in the factory building.