Relying on a pair of hands, a measuring tape, a leather hammer, and a flashlight, it took only 8 years to reach the skill level that other technicians can only achieve in 15 years. For more than 20 years, Zhang Guoyun has practiced precise winding skills with dedication and diligence, and has solved problems for many key projects.
● Jing Shuangshan / text
China in the lights is inseparable from many people who are unknown and work hard.
On March 1, the release ceremony of the 2023 "Great Country Craftsman of the Year" jointly recorded by the All-China Federation of Trade Unions and China Central Radio and Television was broadcast on CCTV. Zhang Guoyun, a national technical expert, a model worker in the autonomous region and a leader of the Talent Craftsman Studio, won the title of "Great Country Craftsman of the Year".
Zhang Guoyun is carefully checking the coil structure. Chen Dan/photo
At the launch event, Zhang Guoyun wore blue overalls and was full of spirit. A song dedicated to all ordinary laborers "Extraordinary Light" sounded, the hot melody and sonorous singing voice infected everyone at the scene to follow the rhythm with applause, "carve the mountains and rivers in the heart, polish the color of dreams, thousands of scenes, paint the heaven and earth in the heart, fight the waves in the sea, and the road to rejuvenation has craftsmen and craftsmen......"
Solve the problem of "power Everest" wire welding
Zhang Guoyun, 46 years old, graduated from Karamay Vocational and Technical College in 1999 and joined TBEA Co., Ltd. as a winder.
The coil is the "heart" of the transformer, the key component to achieve voltage conversion, and determines the quality, performance and service life of the entire transformer. Since the types and structures of large transformers vary, coil winding must be carried out manually.
"The internal structure of the transformer is extremely complex, and the coil winding seems simple and boring, but in fact, it requires continuous innovation and research. Since joining the work in 1999, Zhang Guoyun has participated in the winding of tens of thousands of coils, with a total length of 40,000 kilometers, which can circle the earth for a whole time. In the 25 years since he took root in the production workshop, Zhang Guoyun has completed the transformation from an apprentice to a core technician of transformer winding, and then to the world's first product winding expert and senior technician, and finally became a craftsman of a great country.
As a key project of the national "West-to-East Power Transmission" strategy, the Changji-Guquan ± 1100 kV UHVDC transmission project, known as "Power Everest", has created the highest voltage level, the largest transmission capacity, the farthest transmission distance, and the most advanced technology level in the world.
In 2018, during the accelerated construction phase of the project, the winding of the transformer coil ushered in a problem: due to the complex structure of the ± 1100 kV converter transformer, the coils of many different types of wires needed to be welded. Prior to this, there was no precedent for the use of this technology, and for a while, how to weld quickly and well stumped everyone.
"There are so many details, such as the transposition of the insulating paper wrapping, if there is one less layer, it will cause the insulation breakdown of this part, and in serious cases, it will cause the paralysis of the power grid system. Zhang Guoyun said that the ± 1100 thousand volt converter transformer used for the project has a complex structure, and the products that can be wound with a whole wire in the past need to weld a variety of different types of wires, with thousands of solder joints.
In the face of hundreds of wire cores, Zhang Guoyun sampled and analyzed the materials one by one, carried out welding tests, and finally used high-frequency welding technology to achieve contactless operation to avoid damage to the wire.
"During the high-frequency current welding process, the welder needs to control the wire temperature at about 700 degrees, the welding torch is 1 to 2 mm away from the weldment, and each solder joint must be completed in one go in a few seconds. Zhang Guoyun said. With many years of experience, he finally successfully completed the wire welding, so that the ± 1100 kV converter transformer was successfully put into operation. The ± 1100 kV DC transmission equipment development and engineering application project also won the China Machinery Industry Science and Technology Award and the Special Prize of Science and Technology Progress Award.
Cultivate a skilled winding backbone team
Coil winding may seem simple, but it's not. Take an 800 thousand volt transformer as an example, its wire is more than 60,000 meters long, it needs to be wound more than 6,000 times, the error value of the amplitude and axial direction must be controlled within 1 mm, and each hammering force, each insulator can not be added, and the package of each insulating paper can not have the slightest deviation.
Zhang Guoyun's apprentice Wenwu always gushes about the story of his master: "Whenever the coil winding is completed and ready to go off the assembly line, my master will take out his mobile phone to take pictures of the structure and details of the coil in detail, and study every detail, which provides an important reference for future technical improvement." For more than 20 years, hundreds of thousands of these pictures have been stored in Zhang Guoyun's computer. He has compiled the relevant research results into a database for the workshop workers to learn. "Master Zhang's database is an authoritative database. Colleague Sun Yinnian said, "Problems encountered in work can always be solved in the database." ”
The development of advanced manufacturing industry is inseparable from a team of highly skilled and high-quality workers. TBEA's "Zhang Guoyun Model Worker and Craftsman Talent Innovation Studio" has been established for 8 years, Zhang Guoyun and his workers have overcome one technical problem after another, not only built a good platform for technological innovation and exchange, but also cultivated a backbone team with high technical level and strong innovation ability for the core process of Xinjiang power transmission and transformation production and manufacturing.
"Master always reminds us to put craftsmanship and quality first. Zhang Guoyun's apprentice, Yu Cunshi, the leader of the winding team of the 750 production center of Xinjiang Transformer Factory, said. Zhang Guoyun's innovative training materials shortened the training cycle of mature winders from two years to half a year, and made outstanding contributions to further consolidating the mainland's dominant position in the field of UHV.
In addition, innovative projects such as "small reform and small innovation" and "quality golden ideas" proposed by Zhang Guoyun have improved production efficiency by a total of 20,000 hours. More than 60% of the winders in the 750 production center were trained by Zhang Guoyun.
Overcome illness and pursue life ideals
"West-to-East Power Transmission" is the world's largest power transmission project, with the world's most advanced UHV power transmission and transformation technology, and UHV transformer is one of the core equipment of this technology.
At the beginning of March, the Xinjiang transformer factory was extremely busy, and 6 transformers that will be used in the Ruoqiang 750 kV substation entered the test stage, and the construction period of 400 kV transformer products exported to Morocco is approaching...... After returning from Beijing, Zhang Guoyun plunged headlong into the work of quality control, follow-up of key products and training of relevant personnel.
It's hard to imagine that he was once a leukemia patient. In 360 days, he underwent 2 surgeries, 9 chemotherapy treatments, 10 bone punctures, and 6 lumbar punctures...... Recalling that "darkest moment", Zhang Guoyun was more grateful in his heart, "Because of that illness, the blood in my body was equivalent to three or four times, and the blood transfusion at that time relied on the help of my workers." "In 2019, the last bone piercing showed that he had overcome the disease!
"The first thing I did when I was discharged from the hospital was to go back to work and finish what I didn't finish. Zhang Guoyun couldn't wait to apply to return to the production workshop.
In June 2019, Zhang Guoyun honorably joined the Communist Party of China and has been rated as an outstanding Communist Party member for consecutive years. Now, under his leadership, the workshop process experience has gradually been transformed into research results that drive digital development, especially in the large-scale automatic vacuum oil injection project of power transformer, which has achieved 100% traceability of key process process parameters and quality management. At the same time, the intelligent environmental online monitoring system of the workshop also realizes the automatic detection of the production environment data of the workshop.
"I love this job, it's my life's work, and whenever I get results, I always reap spiritual enrichment. Zhang Guoyun said.