Created on:2021-07-30 10:50

Hydraulic fault diagnosis and maintenance of hydropower equipment_ Analysis and treatment of hydraulic failure of hoist

水电设备液压故障诊断与维修_ 启闭机液压故障分析处理
Hydraulic fault diagnosis and maintenance of hydropower equipment_ Analysis and treatment of hydraulic failure of hoist

(1)常规故障分析及处理
(1) Analysis and treatment of common faults

    ①启门时,一缸动作,一缸不动,偏差超过正常范围,系统被迫停机。原因:长期不运行,调速阀中的各单向阀、单向节流阀发卡,打不开。处理:首先将闸门落至底坎,可纯手动操作(自动操作已失效),即手动启动软启动器,电机启动,这时PLC内程序不执行任何指令,电机处于空载运行状态;其次用工具(钟表起)先后顶动DT5、DT6阀芯,手动执行落门动作,直至闸门全关至零位;拆洗及,回装后启门正常。
① When the valve is opened, one cylinder acts, and the other cylinder does not move. The deviation exceeds the normal range, and the system is forced to stop. Cause: long term non operation, speed control valve in the one-way valve, one-way throttle card, can not open. Treatment: first, the gate is lowered to the bottom sill, which can be operated manually (the automatic operation is invalid), that is, the soft starter is started manually, and the motor is started. At this time, the PLC program does not execute any instructions, and the motor is in no-load operation state; Secondly, the DT5 and dT6 valve cores are pushed successively with tools (clock start), and the door is manually lowered until the gate is fully closed to zero position; The door is opened normally after disassembly, washing and reassembly.

    ②闸门全关后,一侧液压缸行程已至零位,另一侧还有局部开度。原因:纠偏不灵或瞬间失效。处理:将闸门重新提起小开度后再落。
② After the gate is fully closed, the stroke of hydraulic cylinder on one side has reached the zero position, and there is local opening on the other side. Cause: ineffective correction or instant failure. Treatment: lift the gate up again and lower it after a small opening.

    ③左右缸下腔压差大,某一缸下腔的压力值已达到系统低压报警值,但此时闸门并不存在较大不同步。原因:由于负载的变化,使作用在某一缸上的力较大,而另一缸的力较小,液压缸下腔压力瞬对达到低压报警值。处理:在保证设备正常运行.的前提下重新调整压力继电器动作值,根据现场实际分别整定各闸门的低压报警值,保证两缸同步。
③ When the pressure difference between the left and right lower chambers is large, the pressure value of one lower chamber has reached the low pressure alarm value of the system, but there is no large asynchrony of the gate at this time. Cause: due to the change of load, the force acting on one cylinder is larger, while the force acting on the other cylinder is smaller, and the pressure in the lower chamber of the hydraulic cylinder reaches the low pressure alarm value instantly. Treatment: on the premise of ensuring the normal operation of the equipment, readjust the action value of the pressure relay, and set the low-pressure alarm value of each gate according to the actual situation on site to ensure the synchronization of the two cylinders.

    ④液压缸下滑。原因:液控单向阀阀芯上的密封圈损坏。处理:闸门在全关位时拆除液控单向阀阀芯,更换密封圈。
④ The hydraulic cylinder slides down. Cause: the sealing ring on the spool of hydraulic control check valve is damaged. Treatment: when the gate is in the fully closed position, remove the hydraulic control check valve spool and replace the sealing ring.

(2)现场故障分析
(2) On site fault analysis

    某时刻,远方全关5号表孔闸门,当闸门关到46.4%时,CCS报警:5号表孔启闭机左管破裂被检测到;5号表孔启闭机l号、2号液压泵故障;表孔闸门命令失效发生;5号表孔闸门开度测量值故障被检测到。现场检查为闸门左右缸行程不同步,偏差大,经处理后远方全关5号表孔正常。
At a certain time, the gate of No. 5 meter hole was fully closed in the distance. When the gate was closed to 46.4%, CCS alarm: the left pipe rupture of No. 5 meter hole hoist was detected; No.1 and No.2 hydraulic pumps of No.5 surface hole hoist are faulty; The command failure of surface outlet gate occurred; The failure of gate opening measurement value of No.5 meter hole was detected. The on-site inspection showed that the stroke of the left and right cylinders of the gate was not synchronous, and the deviation was large. After treatment, the No. 5 surface hole was fully closed in the distance, which was normal.

    ①现场现象 5号表孔闸门垒关操作过程中出现左缸开度4626,右缸开度4600,1号,2号液压泵故障。
① On site phenomenon: during the barrier closing operation of No.5 surface outlet gate, the opening of left cylinder was 4626, the opening of right cylinder was 4600, and the faults of No.1 and No.2 hydraulic pumps occurred.

    ②分析 闸门下落时,由于主油路左缸下腔出流的流量较小,左缸下落较慢,纠偏回路开始工作,但纠偏回路节流阀开度过大,导致下腔压力下降过快、左缸下腔压力过低,报警停机,CCS显示为左管破裂、故障、表孔闸门命令失效、开度测量值故障。现场手动启动液压泵,手动调整,减小纠偏回路左腔节流阀开度,使两缸丽步,再联系中控室远方落门,闸门关闭正常。
② During the analysis of the gate falling, due to the small flow of the lower chamber of the left cylinder in the main oil circuit and the slow falling of the left cylinder, the deviation correction circuit began to work, but the throttle valve of the deviation correction circuit was too large, which led to the rapid drop of the lower chamber pressure and the low pressure of the lower chamber of the left cylinder, and the alarm shutdown. CCS showed that the left pipe was broken, the fault, the command failure of the surface hole gate, and the measured value of the opening failure. Start the hydraulic pump manually on site, adjust it manually, reduce the opening of the throttle valve in the left chamber of the deviation correction circuit, make the two cylinders walk quickly, then contact the central control room to drop the door remotely, and the gate is closed normally.

    ③结论 通过现场调整流量解决异步,说明在闸门下落过程中两缸负载与无水试验时有较大差别,半年前表孔无水动门试验时一切正常,但有水落门时却因闸门两缸负载不:同而出现故障。
③ Conclusion by adjusting the flow rate on site to solve the problem of asynchrony, it shows that there is a big difference between the two cylinder load in the process of gate falling and the water free test. Half a year ago, when the surface hole water free moving door test, everything is normal, but when there is water falling, the two cylinder load of the gate is different, which causes the failure.

④预防措 施每年汛前设备大检查中进行表孔闸门无水试验,调整纠偏回路流量,保证无水情况下闸门运行正常。在汛期第一次操作闸门时,现场监视闸门运行情况,必要时调整纠偏回路调节阀,保证汛期闸门正常启闭。
④ Preventive measures: during the annual equipment inspection before flood season, the waterless test of surface outlet gate is carried out, and the flow of deviation correction circuit is adjusted to ensure the normal operation of gate under waterless condition. When the gate is operated for the first time in the flood season, the operation of the gate shall be monitored on site, and the regulating valve of the deviation correction circuit shall be adjusted if necessary to ensure the normal opening and closing of the gate in the flood season.
④ Preventive measures: during the annual equipment inspection before flood season, the waterless test of surface outlet gate is carried out, and the flow of deviation correction circuit is adjusted to ensure the normal operation of gate under waterless condition. When the gate is operated for the first time in the flood season, the operation of the gate shall be monitored on site, and the regulating valve of the deviation correction circuit shall be adjusted if necessary to ensure the normal opening and closing of the gate in the flood season.

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