The legend of millions of kilowatts uniter

Accurately design precision manufacturing fine installation of Baihetan engineering builders together work together to build boutique units

From 700,000 or 850,000 to 1 million, the number is a very simple progressive relationship, but it is actually very difficult. It is not a simple "85+15 = 100", but a new breakthrough from 0 to 100.

The successful application of a million kilowatt units of 800 MPa high -strength steel has made China get rid of important raw materials such as high -strength steel plates to rely on imports for a long time.

The total mass of the right -shore unit of the Baihetan Hydropower Station reached 338 tons. "Zero -matching" means that we can use a finger to dial this 338 -ton weighing big guy, which put forward very high requirements for manufacturing and processing accuracy.

There are a million kilowatt units with a diameter of more than 16 meters and a weighing more than 2000 tons. The cylindrical accuracy after the assembly is completed reaches the degree of unimaginable ordinary people -0.7 mm.

Overlooking Baihetan Hydropower Photography: Huang Zhengping

On May 20, 2022, the assembly work of Unit 9 Baihetan Hydropower Station was completed and entered the debugging stage. It marked that the assembly work of the 16 million kilowatt water wheel generator sets of the Baihetan Hydropower Station was completed.

From the 2006 Three Gorges Group's relevant units launched the research and development of millions of kilowatts of units, to November 2019 Baihetan Hydropower Station's millions of kilowatts into the installation stage, and then the first batch of crews were put into production and power generation on June 28, 2021. All the installation work of the monthly unit was completed, and a sword was grinded in 16 years. The R & D and application of the Millions of Million KW Hydropower Station in the Baihetan Hydropower Station has promoted the upgrading of the entire industry chain of major equipment manufacturing technology in China, and consolidated the status of my country as the leader of the world's hydropower development.

In the past 16 years, in order to fulfill the million kilowatt units, the Three Gorges Group has a scientific and rigorous work attitude with the design, manufacturing, and construction units. First -class boutique.

Accurate design to consolidate the base of the major power

Starting from the construction of the Three Gorges Project, my country has independently developed and manufactured water -wheel generator sets in 7 years, and successfully achieved a historic leap from 300,000 kilowatts to 700,000 kilowatts of water electricity units. Construction, the capacity of domestic hydropower units was successfully increased to 850,000 kilowatts. At this time, the design and manufacturing millions of kilowatt units have been tentative.

"From 700,000, 850,000, to 1 million, the number is a very simple progressive relationship, but it is actually very difficult. After all, the research and development, manufacturing and installation of millions of kilowatts of units is the 'uninhabited in the world's hydropower industry. 'There is no ancient. There is no experience in the design stage to learn from, so it is not a simple '85+15 = 100', but a new breakthrough from 0 to 100. " Deputy Director Jin Kun said.

Since 2006, the Three Gorges Group and East China Survey and Design Research Institute, the Yangtze River Survey and Planning and Design Research Institute, Oriental Electric Group, Harbin Electric Group, etc. have jointly carried out the overall design, water conservancy design and related technologies of millions of kilowatts of water electricity units.

"We target the key core issues of millions of kilowatt units, 'card necks' issues, and conduct scientific and technological research and research. For example, for water conservancy design and raw material issues, we have done very deep and comprehensive research in the early period of scientific research." The Three Gorges. "The Three Gorges." Li Hajun, deputy director of the Group's Mechanical and Electrical Technology Center.

Speaking of the "stuck neck" problem, Li Haijun tells a story about the Three Gorges right -shore units. During the installation stage of the Three Gorges right -shore units that year, 600 MPa snail steel plates could not be produced in China, and all steel was imported from abroad. Because people have me, they are often passive. "It was really angry at the time, and it was too uncomfortable by others 'stuck neck'!" Li Haijun said.

Since then, the Three Gorges Group has led domestic large -scale steel enterprises in China to carry out scientific research research, achieving independent research and development and production of 600 MPa steel.

Entering the design stage of a million kilowatt units in Baihetan, facing the challenges of higher water heads, faster speed, and greater external loads in the face of millions of kilowatt units. Essence Will it continue to design and use 600 MPa steel plates, or continue to innovate to break through to a higher level of 800 MPa steel plate, and the Three Gorges Group decisively chose the latter.

Baihetan Hydropower Station left bank No. 5 Snail Welding Construction Photography: Zhao Yang

During the design and research and development process, the Three Gorges Group gave full play to the leading role of the owner and adhered to the full process management of the design link. Li Haijun said: "Everyone proposes to apply innovative things, we will conduct research and review around it, safe and reliable talent to apply. We recommend the design and connection meeting and review the design plan. Inspection and censorship. At the same time, design review must be carried out. Is there any omissions in the process of repeated inspection and completely avoid the problems found. "

On December 12, 2018, the world's first one million -kilowatt water rotor generator set began installation. On May 29, 2020, the installation of 16 million kilowatt units of Baihe Beach was completed. The successful application of the 800 MPAR high -strength steel of the Baihetan Million kilowatt units not only optimizes the construction technology, saves construction costs, and has high quality quality, but also makes China get rid of important raw materials such as high -strength steel plates to rely on imports for a long time.

Like 800 MPa high -strength steel plates, the Baihetan millions of kilowatts use a large number of new technologies, new processes, and new materials. The unit hydraulic design, electromagnetic design, ventilation and cooling and other technologies have reached the world's leading level. The leading position of technology has improved China's core competitiveness. Precision manufacturing presents a big country of heavy weapons

On January 18, 2020, the third one million kilowatt unit of the Baihetan Hydropower Station on the right bank realized the "zero -match weight" and successfully passed the expert acceptance. This is the world's first giant long and short blade water wheel generator set to pass the "zero -match weight".

The rotor is the "heart" of the water wheel generator set. It is the key component of the stability and energy conversion of the unit. In the process of turntable manufacturing, quality bias is common. If it is not treated, it will cause the unit to generate additional centrifugal force during operation. If this centrifugal force is too large, hydropower is imbalanced in the rotor, which will affect the safe and stable operation of the unit.

Baihetan Hydropower Station, Unit 14, Rotary Ship Rotor Factory Hanging Information Picture

"The total mass of the right -shore unit rotor reaches 338 tons, nearly 4 meters in height, and a diameter of 8.8 meters. 'Zero -match weight" means that we can use a finger to mobilize this 338 -ton big guy. The accuracy of processing is very high requirements. "Li Haijun introduced that the right -shore unit of the Baihetan Hydropower Station is not only heavy, but also a large number of parts. There are flaws in the way of Taoism, which will cause the quality of the rotor to imbalance, and this imbalance cannot be repaired later. Therefore, the "zero weight" of giant turntables has always been the ultimate goal of hydropower people.

"In order to achieve this goal, the Three Gorges Group organized experts to refine and quantify the inspection standards of production and manufacturing, and formulated a very strict management system. From each major part to Quantitative quality control. This 'boutique standard' is higher than the national standard and industry standards. "Jin Kun said.

The preparation of boutique crew manufacturing standards is an innovation of the Three Gorges Group in the Baihetan project. This standard is not only aimed at host manufacturers, but also suppliers of host manufacturers to ensure that the quality of supply equipment is controlled.

"We extend the management chain to the supplier of the host manufacturer and incorporate the full process management. Each component must be controlled and traceable." Processing and re -inspection will never be allowed to leave the factory with doubt.

In order to ensure the perfect presentation of millions of kilowatt units, the Three Gorges Group is improving and continuously trying to refresh the upper limit of product quality in practice.

"There is a chromium in the chemical composition of the stainless steel used in our rotor, which can play a role in anti-corrosion and rust. There are some parts of rust. Our research believes that it should improve the chromium content and further increase its rust -proof ability. Later, the lower limit of this standard was increased to 12.5%. "Li Haijun said Manufacturers are not easy to.

The host manufacturer strictly implements the technical standards proposed by the Three Gorges Group. All 16 rotary wheels meet the fine standards, of which 4 of them have achieved "zero -match weight". "In order to make the performance of the rotor more reliable, the host manufacturer has accepted the higher requirements. In order to build a million kilowatt units, the opinions of each participating unit are highly uniform." Li Haijun said deeply, saying, saying that Unity and collaboration, the masses of the minds are one of the connotations of the Three Gorges spirit.

The world's second largest hydropower station, the Baihetan Hydropower Station, has a very obvious role in promoting the China Hydropower Equipment Manufacturing Industry. After completing the manufacturing task of the Baihetan Water Wheel Unit, more and more major technical equipment products participated in the manufacturers manufactured by the host manufacturing are increasing, and the technical level and management capabilities have been greatly improved. "After completing the Baihetan manufacturing task, they also assumed many challenging pumping projects. They transplanted the management system of Baihetan, and they were handy." Li Haijun said.

There is stress to have motivation, and the motivation will create real boutiques. The "boutique crew" manufacturing standards compiled by the Three Gorges Group not only create a boutique unit, ensure the efficient and stable operation of the unit, but also drive the upgrading of the entire industrial chain of China's hydropower and equipment, and make important contributions to the creation of an upgraded version of China.

Fine installation and casting the peak of world hydropower

The single unit of the Baihetan Hydropower Station is more than 50 meters high, more than 8,000 tons, and more than one million large and small parts. It is not easy to assemble such a complex big guy.

"For millions of kilowatts of units, we always have a sense of learning attitude, and the whole process remains like a thin ice." Jin Kun said that the assembly of millions of kilowatts of units cannot be lost. "Once a problem occurs, you want to check which link is difficult, and the recurrence is very difficult, so you must do every step."

To do every step, you must fight for the slightest.

In the rotor lifting session of a million kilowatt unit, this large diameter of more than 16 meters and more than 2,000 tons. After the assembly is completed, the accuracy of the cylindricality reaches an unimaginable level.

Baihetan Hydropower Station on the right bank of the one million kilowatt water wheel generator set of rotor hanging information pictures

Previously, the standard of Xiangjiaba Hydropower Station was 0.9 mm, and the accuracy standard of Baihe Beach is now 0.7 mm. Li Haijun repeatedly emphasized that don't underestimate the "small standard" of 0.2 mm. For millions of kilowatts of unit rotor, if there is an extra 0.2 mm deviation, the influence of the unit's smooth operation and the degree of wear on parts will be enlarged many times.

0.2 mm, it can be said that the entire unit can be said to move the whole body, but for the on -site installation unit, it is not easy to increase the accuracy of such a huge rotor by 0.2 mm.

"I participated in the formulation of this standard, and the parties participating in the construction were repeatedly argued. Some of the construction units said that the Three Gorges Group's formulation of this standard was too harsh. At the beginning, I also doubted whether the standard was too high. However, we not only achieved 0.9 mm, but also reached a level of 0.6 mm and 0.7 mm in the construction of the Jiaba Hydropower Station. In the end, everyone agreed that it is feasible to set the standard at 0.7 mm. "Li Haijun said.

The standard at 0.7 mm seems to have no retreat, but this is also the incentive and supervision of the Three Gorges Group for manufacturing installation units. It turns out that the Three Gorges Group must strive for good results.

"At the scene, everyone could perform fine control through the processing size and on -site assembly. In fact, the final installation result was far less than 0.7 mm. The best unit reached 0.3 mm, which was basically controlled at about 0.4 mm. Meaning. "Li Haijun said happily.

Installation construction must be arguing, and the quality inspection is meticulous.

At the installation site of millions of kilowatts, the Three Gorges Group improved traditional quality inspection methods. Based on the "three inspection systems" of the quality inspection, quality inspection, and quality inspection department of the construction unit's single group, the inspection of the technical service personnel of the manufacturer and the project department, the participating unit, and the operation unit inspection were added. Each installation process can only enter the next construction link only through all inspections.

During the installation of GIS, the silver plating surface in the parent conductor was damaged during the inspection of the Three Gorges Group's electromechanical technicians, and the spray paint outside the bus also dropped a large piece due to transportation. The technician asked where the installer should handle it? Installing workers' answers are not standardized.

When Jin Kun heard the report of the technicians, he arrived at the scene as soon as possible. He asked to return to the factory to deal with the damage. He picked up Baijie cloth and demonstrated how to clean up the installation workers. He repeatedly told details such as wiper with waterless wine, sucking twice with a vacuum cleaner, and the cloth on the mouth.

"After returning to the factory, the manufacturer told me that after doing so many projects, I haven't encountered an owner like you, I can't rub a little sand in my eyes, and I don't let go of any small problems." Telling the quality story, Jin Kun is a few treasures. In the end, the installation and commissioning of GIS and the world's largest gap in GIL care and distribution equipment all set a number of new records, and achieved a one -time passing of electrical high -voltage tests.

Baihetan Hydropower Station GIS Room Photography: Zhang Yong

From November 2019 Baihetan's first unit of civil construction projects to the mechanical and electrical installation project, until May 20, 2022, all the installation work of the crew was completed. In two and a half years, the Three Gorges Group adheres 16 machine group installation and commissioning work. As of now, the nine aircraft groups that have been launched are stable in operation and excellent indicators.

"The success of the Baihetan million kilowatt units is not the credit of which link. Just like running a 4 × 100 meter relay race, designing, manufacturing, installation, and operation. Everyone must run for themselves. Good results. "Li Haijun compared the Fangdao image.

After all the 16 million kilowatts units of the Baihetan Hydropower Station are put into production and power generation, the annual power generation can meet the demand for domestic electricity for about 75 million people for a year, replacing the standard coal about 19.68 million tons, and about 52 million tons of carbon dioxide. Quality development provides a steady stream of green power.

Jin Kun introduced that the story of the Baihetan Hydropower Station of the Millions of Wish is far from over. Thousands of builders bring the technical accumulation and management experience of Baihetan Million KW Hydropower Units to participate in all parts of the country to participate in more engineering project construction , Create a new major country, create a new glory of China Hydropower. (Author: Sun Kai Cheng Lin)

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