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煤立磨在线堆焊再制造的典范——记北京嘉克在贵港电厂的堆焊再制造工程
  Published:2007-11-26 15:48:14  Author:北京嘉克
Beijing ARC   http://www.arceq.com


    2007年10月,嘉克在中国华电集团贵港发电有限公司一期2X600MW机组工程的6台磨煤机磨辊辊套和衬板同时进行了在线堆焊施工,10天时间堆焊了7.5吨焊丝,创造了国内煤磨同时在线施焊台数最多的典范。

    贵港电厂一期2X600MW机组6台磨煤机投入运行仅半年时间,但是由于煤质差,硅、铁等杂质含量多,致使磨煤机磨辊、磨盘磨损严重,磨辊出现磨损不均匀、局部大坑等现象,如果不及时更换备件或进行堆焊修复,很可能面临磨辊断裂的风险。
 
    煤立磨是在电力行业和水泥行业的粉磨系统中被广泛应用的设备之一。行内人士都知道,煤磨内的狭小空间是在线堆焊再制造施工不得不面临的难题。应用于本项目的磨辊/盘瓦在线堆焊再制造技术由嘉克公司在2000年首创,并获得了国家发明专利,是至今仍受到法律保护的专利技术。基于本技术的“管内壁及磨辊/盘瓦电弧熔覆机器人”项目还获得了国家技术创新基金支持,其先进性和技术领先程度远远超过同类产品。
 
    从2000年以来,嘉克的磨辊/盘瓦在线堆焊再制造技术已经为国内电力系统和水泥行业的200多家企业的粉磨设备耐磨件提供了堆焊再制造服务,不仅满足了生产的需要,更为企业和社会创造了可观的经济效益。
 
    为了完满完成贵港电厂磨煤机的堆焊再制造项目,嘉克安排了10台设备、18个具有在线焊丰富施工经验的工人,只用10天的时间,堆焊修复了18只磨辊和6套磨盘。不仅工期满足了电厂的生产需求,为电厂节约了宝贵的时间,而且堆焊施工的质量和服务水平也得到甲方的高度认可,工程被甲方有关人员评价为:“解决了我们原以为不能实现的难题”。

    嘉克现在有40套设备、12个工程队长期在外进行磨辊/盘瓦在线堆焊再制造施工,在国家各大发电集团的多个下属企业拥有良好的工程实例。
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  1、Online/offline overlaying remanufacturing service
1、Overlaying remanufacturing service for the rollers/segments of the cement mill.
2、overlaying remanufacturing for the coal grinding roller/segment
3、overlaying remanufacturing for the rollers of roller press
4、overlaying remanufacturing for the steel and iron slag rollers and segments.
5、overlaying remanufacturing for the wear plate

2、Overlaying the mill roller/segment
1、composite overlaying remanufacturing for LM grinding roller/segment
2、composite overlaying remanufacturing for MPS grinding roller/segment
3、composite overlaying remanufacturing for ATOX grinding roller/segment
4、Overlaying remanufacturing for Polysius compound roller/segment
5、Overlaying remanufacturing for UBE compound roller/segment
6、Overlaying remanufacturing for MPS、MLS compound roller/segment
7、Overlaying remanufacturing for HP、RP compound roller/segment
8、Overlaying remanufacturing for HRM compound roller/segment
9、Overlaying compound remanufacturing for TRM roller/segment
10、Overlaying compound remanufacturing for ZGM roller/segment
11、Overlaying compound remanufacturing for CITIC roller/segment

3、Self-protective wear -resistant flux cored wire
1、ARCFCW1001 self-protective wear resistant flux cored wire
2、ARCFCW1006 self-protective wear -resistant flux cored wire
3、ARCFCW1016 self-protective wear -resistant flux cored wire
4、ARCFCW9018self-protective wear -resistant flux cored wire
5、ARCFCW9061self-protective wear -resistant flux cored wire
6、ARCFCW9993 self-protective wear -resistant flux cored wire
7、ARCFCW9996 self-protective wear -resistant flux cored wire
8、ARCFCW9998self-protective wear -resistant flux cored wire
9、ARCFCW9991 self-protective wear -resistant flux cored wire

4、Arc Spraying
1、Arc Spraying Technology

5、Automatic over-laying welding equipment
1、off-line automatic open-arc overlaying equipment for mill roller/segment
2、on-line automatic open-arc overlaying equipment for mill roller/segment
3、 automatic repairing system for roller press
4、Open-arc automatic welding machine for Inner pipe
5、strip surfacing machine
6、Automatic open-arc overlaying welding machine for wear plate
7、Automatic overlaing robot for the inner bend pipe
8、Automatic Overlaying welding machine for the inner side of small-diameter straight pipe.
9、water cooling hot wire TIG overlaying equipment

6、Specialized automatic welding machine
1、Automatic welding machine for the u-shape ones
2、Round bead operation machine
3、Antomatic welding machine for flange/steel ring channel/intersection line
4、Arc deposited formed machine
5、Antomatic welding machine for the ball-shape /horizontal /vertical workpiece
6、Automatic cutting machine for saddle-shape workpiece
7、Automatic submerged welding machine for saddle-shape workpiece
8、Automatic gas protective welding machines for saddle-shape workpiece

7、Automatic welding equipment
1、Automatic submerged welding machine for narrow-gap workpiece
2、Automatic Submerged arc welding machine(handling frame style or carriage wheel style)
3、Automatic gas-protective welding machine(operation frame style and carriage wheel style)
4、All position automatic welding machine for the pipe
5、Automatic welding machine for the steel cylinder
6、Automatic welding machine for the metal strip

8、welding equipment for railway construction
1、Arc deposited robot for the train hook tongue
2、induction-heated furnace for the rivet.
3、Automatic welding production line for box girder

9、Welding Auxiliary Machines
1、Welding manipulator
2、Welding positioner
3、Welding turning roller
4、fixture
5、 Oscillator/sensor
6、Dust discharger/interconnecting cables/water-cooled torch
7、Hydraulic double bracing positioner

10、Frequency Converse Rectifier
1、Frequency converse rectifier(automatic welding power source/carbon arc air gouging power
2、Hand arc frequency converse rectifier
3、Frequency converse rectifier type argon tungsten-hand arc welding machine
4、Frequency converse rectifier type Self-protective/gas protective welding machine
5、Frequency converse rectifier type heat sensor power source

 
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