The hottest Shanghai heavy challenges world-class

2022-08-16
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Shanghai heavy challenges the world's first-class high-end nuclear power manufacturing technology

Shanghai heavy challenges the world's first-class high-end nuclear power manufacturing technology

China Construction machinery information

Guide: from smelting, forging, heat treatment to cold processing, and finally passing the appraisal, it is linked together. Any link goes wrong, but it can still burn rapidly and cause fire problems with a strong and continuous fire source. The whole trial production will start again. In the peripheral area far away from the center of Shanghai and close to Minhang Development Zone, Shanghai Heavy Machinery Factory Co., Ltd. (hereinafter referred to as Shangzhong) has clearly

from smelting, forging, heat treatment to cold processing, and finally passing the appraisal, it is linked together. If there is a problem in any link, the whole trial production will start again. Far away from the center of Shanghai and close to the peripheral area of Minhang Development Zone, Shanghai Heavy Machinery Co., Ltd. (hereinafter referred to as "Shangzhong") has clearly launched a challenge to the world-class high-end manufacturing industry - for most of the past six years, it has been committed to developing scrap steel and pig iron according to the design drawings of the main equipment of the AP1000 nuclear island, and finally turning the drawings into real large forgings for nuclear power equipment

more importantly, shangchong achieved success

on July 15 this year, with the approval of the national expert group, it became the first enterprise in China with the ability to produce AP1000 core forging equipment in complete sets, which also means that the "hardest puzzle" of China's nuclear power equipment manufacturing has been completed, and the heavy forging products will also be used in the construction of Zhejiang Sanmen Nuclear Power Plant, the world's first AP1000 nuclear power plant

AP1000, developed and designed by Westinghouse Electric Company of the United States, is one of the most advanced third-generation nuclear power technologies in the world. In 2006, AP1000, which only stayed on the drawing, was introduced into China through bidding. Since then, Shangzhong has started the localization research and development of AP1000 large forgings

before heavy industry, only Japan Steel Institute, Doosan Heavy Industry and other no more than 10 first-class manufacturing enterprises in the world can achieve the ability to turn a complete set of nuclear power forgings from drawings to reality. Most nuclear power plants in China can be built, powered and operated only with imported nuclear power equipment

but this time, the world's nuclear power equipment manufacturing pattern has also changed with heavy strides

many nuclear power experts said in an interview that the breakthrough will bring some changes to the localization of China's nuclear power equipment, which makes China master the core technology of high-end equipment manufacturing industry closely related to the development of nuclear power industry

on September 11, I walked into the Shangzhong plant at No. 1800, Jiangchuan Road, Minhang District, Shanghai, and tried to find the answer behind the breakthrough

according to our investigation, this is more like a real-life "soldier assault", behind which is the epitome of China's high-end manufacturing industry in the face of adversity. In addition to time and pressure, considering the characteristics of the industry and market-oriented factors, successful challenges do not necessarily mean complete victory, which is where the future of China's high-end equipment manufacturing industry lies

from pig iron to machine

unlike Shanghai Baosteel Group Co., Ltd., China's largest steel manufacturer, Shangzhong, a subsidiary of Shanghai Electric Group, produces metallurgical steel rolling and other equipment for Baosteel

Shangzhong also manufactures hundreds of tons, such as thermal power rotors and giant ship crankshafts, giant machine parts that can only be produced by a few domestic manufacturing enterprises. In the R & D process of AP1000, Shangzhong plays a role more like the mother of machines, and even the equipment needed to manufacture AP1000 core forgings is also manufactured by Shangzhong itself

facing the AP1000 design drawings, what we can do is to start with the selection of scrap steel and pig iron

graphene, which was built in 1958 and covers an area of 960000 square meters, equivalent to the area of more than 130 football fields, has basically no cytotoxicity. In the heavy plant area, the selected scrap steel and pig iron will be smelted, forged and heat treated, and will eventually become a part of the large forgings for AP1000 equipment after a span of about one year

the so-called large forgings include all the core main equipment in the nuclear reactor, and can best reflect the characteristics of AP1000 third-generation nuclear power technology - in order to be more safe, including fixing and wrapping the nuclear reactor pressure vessel, steam generator, reactor internals, main piping, etc., are built using modular technology

compared with the past, AP1000 heavy forgings are also larger, heavier and more complex due to modularization, which is an unprecedented world problem for manufacturing enterprises

Li Xiang, chief engineer of Shangzhong nuclear power products, said that due to the improvement of AP1000 power generation and safety factor, and the large forgings are in the nuclear radiation area, both the internal purity, mechanical performance and even the degree of integration have higher requirements than previous nuclear power equipment

for a pig iron, it is not only necessary to smelt and refine it into a large high-quality steel ingot that meets the standard, and then send it to the forging workshop for forging and forming, but also to correct the metal properties in the heat treatment workshop, and then polish it by machine tool workers, and finally form it. This is not enough, because it has to pass the joint witness inspection of the nuclear power plant owner, the project builder, the equipment manufacturer, the National Nuclear Safety Administration and other parties before it can finally achieve positive results

in the smelting workshop, which is 30 meters high, 300 meters long and 70 meters wide, a pipe nozzle with a diameter of about 20 cm facing the cylindrical ladle is emitting blue flames

"this is to prepare for steel-making at night", Li Xiang said that due to the high energy consumption of smelting, steel-making is generally carried out at night. The pipes with blue flames are gas pipelines, and the gas is also self-made by factories. China's plastic machinery enterprises have increased the development of emerging markets for extruders in recent years, and a ladle can hold more than 100 tons of molten steel

take the integrated top cover with the most representative complexity and weight in the AP1000 equipment as an example. It requires 400 ton large ingots to manufacture, and 5 ladles to be poured together in the smelting process

"since the whole smelting process takes more than 12 hours, many dynamic interfaces such as pouring temperature, composition ratio, holding time and so on need attention." Li Xiang said, "small changes in some elements may have a great impact on the performance of subsequent products."

therefore, the smelting of 400 ton steel ingots has become one of the key processes in the manufacturing process of AP1000 heavy forgings

Li Xiang said that at present, there are only three enterprises in China that have the ingot technology required to produce AP1000 extra large forgings. When the ingot is poured and solidified, it will be transported to the forging workshop and forged and formed in the forging workshop

at the gate of the forging workshop, you can see two giant machines rising from the ground. According to Li Xiang, the one on the left is China's first 10000 ton hydraulic press, which was installed in 1961 and put into use in 1962

in 1965, Edgar Snow of the United States visited China and visited Shangzhong. When he saw the gray steel giant in front of him, snow asked, "what's the meaning of having so much effort to build such a big machine?" Then he saw a cylindrical ingot pressed into a round cake in less than a minute. It is this hydraulic press that made it possible for China to manufacture heavy industrial equipment such as aerospace, military and shipping more than 50 years ago

today, there is another giant thing here, which is designed and independently manufactured by Shanghai Heavy Industry Corporation. It was officially put into operation in 2009, with two 16500 ton oil presses, the first in the world. Compared with the 10000 ton hydraulic press, it has higher precision and greater strength

it's like a blacksmith holding steel and hitting it repeatedly with a hammer. Next to the oil press, a machine with a manipulator, called an operator, will clamp the reheated high-temperature steel ingot and stretch it into the oil press to forge it into shape

the history is so similar. This oil press equipped with 630 ton · meter (torque unit) operator makes it possible to forge AP1000 large forgings of fourorfive ton large ingots. After forging and rough machining, AP1000 large forgings will be sent to the heat treatment workshop for final performance treatment

"just like the chef's grasp of the heat when cooking, different raw materials need to have different heat, so as to cook a more suitable taste." Li Xiang described heat treatment as cook cooking. Because of the dynamic factors of the experimental standard in the preliminary process: gb/t 13542.4 (2) 009, the forging state during performance heat treatment will not be exactly the same, so it is necessary to use different heat treatment parameters to adjust the performance of forgings to make all performance indicators reach the optimal state

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