Created on:2021-07-30 10:50

Hydraulic fault diagnosis and maintenance of hydropower equipment_ Reform and maintenance of hoist

水电设备液压故障诊断与维修_ 启闭机改造维修
Hydraulic fault diagnosis and maintenance of hydropower equipment_ Reform and maintenance of hoist

(1)启闭机改造和维修措施
(1) Hoist transformation and maintenance measures

    针对启闭机存在的系统泄漏和液压缸内泄漏问题,采用了增设液压缸专用液压锁的方法来解决,并提高启闭机安全性;又更换了的所有密封,并对液压缸进行了必要的、适当的维修,以解决内泄漏问题。
Aiming at the problems of system leakage and hydraulic cylinder leakage of the hoist, the method of adding a special hydraulic lock for the hydraulic cylinder is adopted to solve the problem and improve the safety of the hoist; In order to solve the problem of internal leakage, all seals of the hydraulic cylinder were replaced and necessary and proper maintenance was carried out.

    ①增设液压锁液压锁定单元增设在每台液压缸外壁尾部进油管处。该锁定单元为液控全自动工作,当要提升闸门时,压力油自动打开液压锁,进入液压缸的有杆下腔,提升闸门;当闸门运行至设定的工作高位时,液压系统停止供油,液压锁自动闭锁液压缸的有杆下腔油道,保证液压缸的有杆下腔压力油不外泄,解决了启闭机系统泄漏问题,同时可保证液压缸之外的管网处于非高压状态,改善管网的运行环境。此时若管网出现损坏,由于液压锁的保护作用,液压缸有杆下腔的液压油也不会外泄,闸门亦不会下滑,大大提高了启闭机和闸门的可靠性和安全性。
① A hydraulic lock is added, and a hydraulic locking unit is added at the oil inlet pipe at the tail of the outer wall of each hydraulic cylinder. When the gate is to be lifted, the pressure oil will automatically open the hydraulic lock, enter the lower chamber of the hydraulic cylinder and lift the gate; When the gate runs to the set working high position, the hydraulic system stops supplying oil, and the hydraulic lock automatically locks the oil passage in the lower chamber of the hydraulic cylinder, so as to ensure that the pressure oil in the lower chamber of the hydraulic cylinder does not leak out, which solves the leakage problem of the hoist system, and ensures that the pipe network outside the hydraulic cylinder is in a non high pressure state, so as to improve the operation environment of the pipe network. At this time, if the pipe network is damaged, due to the protection of the hydraulic lock, the hydraulic oil in the lower chamber of the hydraulic cylinder rod will not leak out, and the gate will not slide down, which greatly improves the reliability and safety of the hoist and gate.

    ②液压缸内泄漏的处理措施针对前面分析的造成液压缸内泄漏的三种主要原因,采取了多种处理措施。
② In view of the three main causes of the leakage in the hydraulic cylinder, a variety of treatment measures are taken.

    a. 更换密封。更换液压缸所有活塞和活塞杆动密封和端面固定密封;在原有密封的基础上,增补了一道尾端固定密封,以防止雨水进入液压缸形成尾部缸内锈蚀。
a. Replace the seal. Replace all piston and piston rod dynamic seal and end face fixed seal of hydraulic cylinder; On the basis of the original seal, a tail end fixed seal is added to prevent rainwater from entering the hydraulic cylinder and forming corrosion in the tail cylinder.

    b.缸筒内壁拉伤处理措施。采用专用设备在现场对所有液压缸缸筒内壁进行研磨,彻底消除缸筒内壁拉痕,并除锈除污。该工艺为专有技术,需要有专用设备和相应技术、经验的人员才能进行,使用不当会造成缸筒内壁失圆、形成锥度等不可挽回的损坏;另外研磨量控制要根据每个液压缸的具体情况确定,研磨量过大会造成缸筒内径配合尺寸超差,过小又不能解决问题,因此使用该工艺一定要慎重。
b. Treatment measures for cylinder wall strain. Special equipment is used to grind the inner wall of all hydraulic cylinders on site to completely eliminate the pulling marks on the inner wall of the cylinder and remove rust and dirt. The process is a proprietary technology, which needs special equipment and relevant technical and experienced personnel to carry out. Improper use will cause irreparable damage to the inner wall of the cylinder, such as out of round, taper and so on; In addition, the grinding amount control should be determined according to the specific situation of each hydraulic cylinder. If the grinding amount is too large, the matching size of cylinder inner diameter will be out of tolerance. If the grinding amount is too small, it can not solve the problem. Therefore, the process must be used carefully.

    c. 支承环磨损处理措施。对现场所有支承环和活塞进行选配,挑选出配合公差合理的组配直接使用。对超差不严重的支承环,采用对活塞镀铜的工艺来补偿尺寸偏差,使配合公差在合理范围内。对尺寸损失量特大的支承环,要重新加工活塞来保证其配合尺寸,满足使用要求。
c. Wear treatment measures of support ring. All the supporting rings and pistons on site are selected, and the assembly with reasonable fit tolerance is selected for direct use. For the support ring with less over tolerance, the piston copper plating process is used to compensate the dimensional deviation, so that the fit tolerance is within a reasonable range. For the support ring with large size loss, the piston should be reprocessed to ensure its fit size and meet the use requirements.

    d.组的处理。更换所有损坏件和密封件,重点保证其换向功能,而不追求其不可靠的液压锁定功能。
d. Group processing. Replace all the damaged parts and seals, focus on ensuring the reversing function instead of pursuing the unreliable hydraulic locking function.

    e.其他部分处理。其他部分均按常规工艺处理。
e. Other parts of the treatment. Other parts were treated by conventional process.

(2)改造维修后的使用效果
(2) Application effect after modification and maintenance

改造维修后启闭机能正常启、闭闸门,启门、闭门运行平稳;闸门48h、60h高位锁定下滑量远远小于国标中48h不大于200mm的要求,见下表。
After renovation and maintenance, the gate can be opened and closed normally with stable operation; The sliding amount of 48h and 60H high position lock of the gate is far less than the requirement of no more than 200 mm for 48h in the national standard, as shown in the table below.

 

启闭机改造维修后阀门下滑量/mm
Valve sliding amount after hoist modification and maintenance / mm

闸门编号
Gate number

48h下滑量

60h下滑量

表孔1

9

-

表孔2

-

20

表孔3

-

9

表孔4

-

18

底孔

85

-

 

    启闭机已完全恢复了原有工作性能,维修质量好。
The hoist has completely recovered its original working performance and good maintenance quality.

(3)小结
(3) Summary

    ①液压启闭机启升闸门后闸门下滑量大是因泄漏引起的,液压缸内泄漏为主要原因。液压缸内泄漏发展严重时,启闭机会出现开闸后闸门下滑量大、闸门无法高位锁定而直接下滑,甚至无法开启闸门的故障。
① After the gate is lifted by the hydraulic hoist, the large sliding amount of the gate is caused by leakage, and the leakage in the hydraulic cylinder is the main reason. When the leakage in the hydraulic cylinder develops seriously, the gate will slide down a lot after opening, the gate will not be able to be locked in high position, and even the gate will not be able to be opened.

    ②液压启闭机维修复杂、工期长,汛期无法组织应急修理,必须于汛期前完成。
② The maintenance of hydraulic hoist is complex and the construction period is long. It is impossible to organize emergency repair in flood season, so it must be completed before flood season.

    ③液压启闭机属精密设备,维修前必须制定详细的维修方案,准备充足的设备、工装。维修时做到轻吊轻放、轻拆轻装,千万不得使用大锤之类的工具强行拆装,做好文明施工。
③ Hydraulic hoist is a kind of precision equipment. Before maintenance, detailed maintenance plan must be made and sufficient equipment and tooling must be prepared. During the maintenance, it is necessary to lift, dismantle and install with care, never use tools such as sledgehammer to forcibly dismantle and assemble, and do a good job in civilized construction.

Home    Article    Hydraulic fault diagnosis and maintenance of hydropower equipment_ Reform and maintenance of hoist