CN113605346B

CN113605346B - Non-navigation-stop maintenance method for large drain valve

Info

Publication number: CN113605346B
Application number: CN202110889871.3A
Authority: CN
Inventors: 朱立新; 刘宇; 周友志; 贾宝良; 严俊; 胡佳琦; 诸惠红
Original assignee: No2 Engineering Co ltd Of Cccc Third Harbor Engineering Co ltd
Current assignee: No2 Engineering Co ltd Of Cccc Third Harbor Engineering Co ltd
Priority date: 2021-08-04
Filing date: 2021-08-04
Publication date: 2022-08-12
Anticipated expiration: 2041-08-04
Also published as: CN113605346A

Abstract

The invention discloses a non-navigation maintenance method for a large drain valve, which comprises the following steps of firstly, transporting materials; step two, manufacturing a bracket; step three, material transporting; step four, erecting a bracket; fifthly, shifting the rack; step six, integrally hoisting the oil cylinder and the gate; step seven, dismantling the fault oil cylinder; step eight, installing a new oil cylinder; step nine, debugging a drain valve; the method can well overhaul the drain valve under the condition of ensuring that the ship lock does not stop sailing, particularly can ensure the installation precision, greatly reduces the sailing stoppage caused by the overhaul of the drain valve, has quite high benefit, and greatly reduces the influence caused by the sailing stoppage of the gate; meanwhile, the problems of complex working procedures, difficult maintenance and influence on social life and economy caused by non-navigation construction of the drain valve are well solved, the technical standards of design, operation and maintenance units are met, the maintenance requirements are met, and the drain valve has good social benefits.

Description

Non-navigation-stop maintenance method for large drain valve

Technical Field

The invention relates to the technical field of maintenance of drain valves in ship lock engineering, in particular to a non-navigation maintenance method for a large drain valve.

Background

The gate valve is ubiquitous in ship lock engineering, the opening and closing mechanism of the gate valve can be divided into a mechanical transmission type opening and closing machine structure and a hydraulic type opening and closing machine structure, the hydraulic type opening and closing machine structure is simple in structural form, stable in operation, and the like, and is widely used, in the ship lock engineering, the drain valve is generally positioned at the head position of the gate in synchronization with a working gate, and is positioned at the bank side of the head position of the gate, greening is additionally arranged, stone slabs are paved or a command center is arranged, and when the drain valve is overhauled, the gate ship lock needs to be maintained, and is stopped in navigation for maintenance, and the greening and paving are easily damaged; therefore, the invention of a non-stop maintenance method for the large drain valve is very necessary at the present stage.

Disclosure of Invention

The invention aims to provide a non-stop maintenance method for a large drain valve, and aims to solve the problems of non-stop maintenance, easy damage to green pavement, complex construction process and difficult maintenance in the background technology.

In order to achieve the purpose, the invention provides the following technical scheme: a large-scale trap non-stop maintenance method comprises the steps of firstly, transporting materials; step two, manufacturing a bracket; step three, material transporting; step four, erecting a bracket; fifthly, shifting the rack; step six, integrally hoisting the oil cylinder and the gate; step seven, dismantling the fault oil cylinder; step eight, installing a new oil cylinder; step nine, debugging a drain valve;

in the first step, materials and equipment are transported to the lower part of a gate shaft platform through a truck crane and a manual hydraulic vehicle, then the materials and the equipment are hoisted to the platform by using a support crane, and finally the materials and the equipment are transported to the position near a drainage valve for construction by using a manual vehicle;

in the second step, the support manufacturing comprises the following steps:

1) the method comprises the steps of processing section steel, firstly, placing H-shaped steel on a gas cutting platform, firstly, using a gas cutting fire meter to unfold and preheat a cutting part, wherein the preheating temperature is 190-230 ℃, then, using a gas cutting machine to perform gas cutting on the H-shaped steel, firstly, respectively cutting flange plates from two sides of the flange plates during formal gas cutting, keeping the positions of webs not to be cut, after the upper flange plate and the lower flange plate are cut, horizontally placing the H-shaped steel, cutting an H-shaped steel web according to a required size, and finally, cutting the residual parts in the centers of the upper flange plate and the lower flange plate, wherein the method for blanking the H-shaped steel through gas cutting by using a single-foot bar I-shaped steel is the same as the blanking method for the H-shaped steel, and when the gas cutting is completed, the length error of the cut section steel is-3 mm, the flatness of the cutting surface is 0-2 mm, and the depth of a local gap is 0-1 mm;

2) processing a steel plate, namely blanking a main beam stiffening plate and a single-foot handle rod stiffening plate by a shearing mode of a plate shearing machine, drawing a shearing line on the steel plate according to the width of the stiffening plate and the required size, shearing a flat steel bar by the plate shearing machine according to the shearing line, drawing the length of the stiffening plate on the flat steel bar, shearing the stiffening plate by the plate shearing machine, checking the size of the stiffening plate after shearing is finished, and ensuring that the length and the width error of the stiffening plate are-3 mm;

3) processing a main lifting lug under a main beam and a single-foot handle rod lifting lug, wherein the lifting lug is blanked in a manual gas cutting mode after steel plate lofting, a middle lifting lug hole is processed in a boring mode, one single-foot handle rod lifting lug is manufactured, and two main lifting lugs under the main beam are manufactured; when the lifting lug is manufactured, the shape error is controlled to be-3 mm, the deviation of the position of the lifting lug hole is 0-1 mm, and the deviation of the diameter of the lifting lug hole is 0-1 mm;

4) processing a stand column, wherein the blanking mode of a stand column bottom plate adopts semi-automatic gas cutting blanking, the X-Y axis position and the bolt hole position of the stand column bottom plate are marked on the stand column bottom plate according to the required size, the punching central point position is knocked out by a awl on the bolt hole position, the bolt hole of the stand column bottom plate is processed by a bench drill, the axis position is marked on a wing plate and a web plate of the H-shaped steel which is blanked, the stand column bottom plate is placed on a welding platform and then the H-shaped steel is assembled with the stand column bottom plate, the alignment of the X-Y axis of the H-shaped steel and the marked X-Y axis of the stand column bottom plate is ensured during the assembly, the H-shaped steel and the stand column bottom plate are welded firmly after the alignment of the axes is checked, full welding is carried out on all stand columns and the bottom plate after the assembly welding of all the four stand columns is finished, and the welding seam is in the form of an angle welding seam;

5) processing a main beam, symmetrically adding stiffening plates on a stress structure of an H-shaped steel main beam, welding a main beam lower main lifting lug at the lower part of the main beam, marking the central position of the H-shaped steel by using a ruler, measuring the positions of the reinforcing plates from the central position to two sides respectively, drawing marks on upper and lower flange plates of the main beam by using a marking pen, assembling the stiffening plates according to the marks, fixing the stiffening plates by electric welding during installation, rechecking the installation position and the verticality of the stiffening plates and the close contact condition of the edges of the stiffening plates and the H-shaped steel after the installation is finished, welding the reinforcing plates after the confirmation is correct, fully welding the reinforcing plates and the H-shaped steel during welding, wherein the welding seam is an angle welding seam;

6) processing a single-foot handle rod, wherein the single-foot handle rod is mainly used for installing and dismantling a fault oil cylinder and a rack, a cantilever arm is manufactured at the top of the handle rod, a single-foot handle rod lifting lug is arranged at the lower part of the cantilever arm, a rib plate is additionally arranged on the main rod at the position corresponding to a stress structure of a wing plate of the cantilever arm, the rib plate is additionally arranged on the cantilever arm at the position corresponding to the stress structure of the lifting lug, and when the cantilever arm is welded with the main rod, 45-degree grooves are formed on an upper wing plate, a lower wing plate and a web plate for welding;

in the third step, for the transfer work of the main beam of the bracket with larger weight and the hydraulic oil cylinder, a hydraulic vehicle is adopted for transferring, in the transferring process, the hydraulic vehicle is used for conveying the construction material to the position below the drain valve platform, when the hydraulic vehicle passes through a stone slab paving road section, a whole block of wood formwork is additionally paved on the pavement, then a full-rotation small crane is adopted for hoisting the construction material and the equipment to the drain valve platform, and then the hydraulic vehicle is used for conveying the equipment to the position near the drain valve well;

in the fourth step, the support erection comprises the following steps:

1) measuring and setting out, namely setting out the axis position of the column foot of the support on the ground by using a level meter and a ruler and taking the center of the top shaft of the drain valve oil cylinder as a setting-out center according to the principle that the axis is parallel to the edge of the gate well and the axis is vertical to each other, and setting out the hole opening position of the expansion bolt of the column foot by using the level meter and the ruler again according to the axis position of the column foot;

2) punching an expansion bolt hole, selecting an impact drill bit with the same diameter as the expansion pipe of the expansion bolt, and punching the positioned installation position of the expansion bolt, wherein the punching depth is the same as the length of the expansion bolt or slightly larger than the length of the expansion bolt;

3) the method comprises the steps of installing a stand column, firstly, drawing marks on the center line of the front side and the side surface of the stand column, aligning a bolt hole on a bottom plate of the stand column with a punched expansion bolt installation hole when the stand column is installed, adjusting the position of the bottom plate of the stand column to align the X-Y direction center line position of the bottom plate of the stand column with a ground lofting axis position and enable the bolt hole of the bottom plate of the stand column to correspond to the position of the expansion bolt hole, putting expansion bolt kits into the bolt hole together, lightly knocking the head part of the expansion bolt by a hammer, then adjusting the verticality of the stand column by adopting a level gauge, supporting the bottom plate of the stand column and a concrete platform by using steel base plates with different thicknesses, adjusting the installation height of the stand column, measuring the elevation of the top of the stand column by using the level gauge after the installation of the stand column is finished, controlling the elevation error of the top of the stand column to be-5-3 mm and controlling the verticality of the stand column to be 0-10 mm;

4) the method comprises the following steps of installing a main beam, measuring the installation positions of the main beam and an upright post by using a straight ruler and a square ruler, marking the axis X and the axis Y of the main beam at the installation positions of the main beam and the upright post by using a pen, lifting the main beam to the top of the upright post, aligning the marked X-Y axis position of the main beam with the X-Y axis position of the upright post by fine adjustment of a base plate, welding the upright post and the main beam after the two main beams are installed and checked to be correct, and ensuring full welding and foot-attached welding seam during welding;

5) mounting the connecting beam, marking the mounting position of the connecting beam on the end parts of the four I-shaped steels respectively, marking the mounting position of the connecting beam on the upright post and the main beam respectively, aligning the marking position of the connecting beam with the marking positions of the upright post and the main beam when the connecting beam is mounted, and welding the connecting beam with the upright post and the main beam after the connecting beam is checked to be error-free;

6) the method comprises the steps that a single-foot handle rod is installed, the installation position of the single-foot handle rod is marked in the middle of a main beam on one side, an X-Y axis symmetric axis is marked at the foot of the single-foot handle rod, the welding positions of three stabilizer bars are marked in the middle of the single-foot handle rod, the welding positions of the stabilizer bars are marked on the end portion of the main beam and an equipment well edge angle steel, a single-foot handle rod column base is placed in the middle of the marked main beam, the position of the single-foot handle rod column base is adjusted, the mark of the main beam is aligned with the X-Y axis symmetric axis of the single-foot handle rod, the verticality of the single-foot handle rod is checked, the three stabilizer bars are installed on the single-foot handle rod, the verticality of the single-foot handle rod is controlled from two vertical directions by a level gauge in the process of installing the single-foot handle rod, the verticality is controlled to be 0-10 mm, and an angle welding seam is fully welded between the root of the suspender and the main beam site;

in the fifth step, the rack shifting comprises the following steps:

1) the chain block is arranged on the single-foot handle rod, the chain block is hung at a single-foot handle rod lifting lug of the single-foot handle rod, the closing condition of a safety presser foot of a lifting hook is checked after the chain block is hung on the lifting lug, a lifting chain and a chain pull of the chain block are smoothed, when the chain block is hung, a worker stands on a safe and stable platform, the chain block checks the closing condition of the presser foot of the hook after the hanging is finished, the safety of the chain block in the hoisting process is ensured, the chain block checks a lifting chain and a chain pull of the chain block before the hoisting, the chain is ensured to be smooth, the chain pull is repeatedly pulled for multiple times, and the phenomenon that the chain pull is not blocked is ensured;

2) the piston head of the oil cylinder is temporarily fixed, the piston head of the oil cylinder is bound by a rope, one end of the rope is bound on the piston head of the oil cylinder to be detached and firmly bound, and the other end of the rope is bound on a main beam of the temporary hanging bracket;

3) dismantling an oil pipe, closing an oil pumping station before dismantling the oil pipe, dismantling the oil pipe by using a wrench, tightly wrapping an oil pipe joint by using a dry towel after dismantling the oil pipe, and placing the oil pipe joint on one side of a gate well;

4) dismantling a pin shaft of an oil cylinder piston, dismantling a shaft cover bolt of the pin shaft of the oil cylinder piston by using a spanner, after the mounting bolts of a single-side shaft cover are completely dismantled, manually removing the pin shaft cover, cleaning by using special oil stain cleaning liquid, uniformly spraying the oil stain cleaning liquid on the pin shaft, lightly wiping the pin shaft by using soft towel until all grease and sundries on the pin shaft are completely wiped off, dismantling the bottom mounting bolt of a pin shaft bracket by using the spanner, then removing the pin shaft bracket from a main beam of a rack, in the process of dismantling the pin shaft bracket, using hands to hold the end part of the pin shaft, removing the pin shaft sleeve after the pin shaft bracket at one side is removed, repeating the actions to dismantle the shaft sleeve and the shaft bracket at the other side of the pin shaft, holding the pin shaft by using two hands, slowly pushing the pin shaft to push the pin shaft out of a rod head of the oil cylinder piston, and tightly jacking the pin shaft side by using a copper rod when the pin shaft is blocked, tapping the copper bar by using a rubber hammer until the pin shaft is knocked out;

5) the frame is shifted, when the frame is moved, the chain block of the chain block is pulled, the lifting hook of the chain block is lowered to the upper position of the frame by a handle, one end of the chain block is bound on the pin shaft hole of the rod head of the oil cylinder piston rod, the other end of the chain block is bound on the lifting hook of the electric block, the chain block of the chain block is pulled, the lifting hook of the chain block is slowly lifted, when the lifting hook of the chain block is completely tightened, the bound rope is released, the binding point at the upper end is loosened, the hand chain block hand zipper is reversely pulled to slowly lower the lifting hook until the uppermost position of the oil cylinder piston rod is lower than the plane of the frame mounting platform, the upper end of the rope bypasses the frame from one side of the frame and is bound on the temporary support main beam, when the rope is bound, the rope is tightened, the lifting hook of the upper chain block is loosened, the lower ends of the two ropes are respectively hung on the lifting point of the frame, the upper end of the frame is hung on a lifting hook of a chain block, a manual wrench is used for removing a frame mounting bolt, the removed mounting bolt is neatly placed on a tablecloth arranged on a maintenance well platform and is separately placed with other removed parts, a chain pull chain of the chain block is pulled, the lifting hook of the chain block is slowly lifted, when the lifting height of the frame enables the frame to be completely separated from a frame embedded part and continuously lifted by about 50mm, a worker slowly pulls the frame from the side away from the initial position of the frame by a cable wind rope, the frame deviates from the original position by 250mm, then the worker continuously pulls the cable wind rope to keep the horizontal position of the frame unchanged, and meanwhile, the lifting hook of the chain block is slowly lowered until the frame stably falls to the ground, the frame displacement is completed, and the original mounting plane position of the frame is removed by 400 mm;

in the sixth step, the integral hoisting of the oil cylinder and the gate comprises the following steps:

1) the electric hoist hook is used for hanging an electric hoist at a main beam lower main lifting lug below the temporary hanger main beam, and the closing condition of a lifting hook safety clamp is checked after the electric hoist is hung on the lifting lug, so that a lifting chain of the electric hoist is smoothed, a junction box is prepared, and a power supply is switched on;

2) manufacturing a lifting appliance, namely adopting a horseshoe-shaped lifting appliance according to actual conditions, processing a round hole with the diameter of 50mm on the lifting appliance, and pressing the horseshoe-shaped lifting appliance and an oil cylinder body by transverse tension when a rope passes through the round hole;

3) preparing a lifting appliance, namely respectively penetrating two ends of a rope into a horseshoe-shaped lifting appliance, making ropes at the two ends into annular rope heads, firmly binding the rope and the horseshoe-shaped lifting appliance by using a cable rope, and releasing a rope ring and the lifting appliance to the maximum as possible;

4) the process that the lifting appliance is automatically buckled on the flange of the oil cylinder cover, two rope ends of a rope are connected by an omega-shaped shackle, the shackle is hung on a lifting hook of an electric hoist, the electric hoist is slowly lifted to hook the electric hoist, in the lifting process, the rope is firstly tightened because the U-shaped lifting appliance is heavy, an internal opening of the U-shaped lifting appliance hoops a cylinder body of the hydraulic oil cylinder under the tensile force of the rope, an arc-shaped part of the U-shaped lifting appliance inclines downwards under the action of gravity, the corresponding opening direction of the U-shaped lifting appliance inclines upwards under the tensile force of the rope, the electric hoist is continuously and stably lifted, when steel plates at two ends of the U-shaped opening part touch the flange of the oil cylinder cover, according to the lever principle, an end point of the steel plate at the opening part can form a fulcrum of the lever, the arc-shaped part of the U-shaped lifting appliance inclines upwards under the tensile force of the rope until the upper surface of the U-shaped lifting appliance is tightly attached to the flange of the oil cylinder cover, in the process, the rear part of the opening of the horseshoe-shaped lifting appliance is continuously pressed on a sleeve of the oil cylinder under the action of transverse tension of the rope, and at the moment, the placement process of the lifting appliance is finished;

5) lifting the gate, wherein the gate needs to be lifted twice after the lifting appliance is installed, when the stroke of a first electric hoist is used up, the first lifting is completed, then the gate is symmetrically installed at the oil cylinder installation lifting lug by using a rope and a shackle, the other end of the rope is hung on a lifting hook of a second electric hoist, the second electric hoist is slowly lifted, the lifting hook of the first electric hoist is gradually loosened, when the lifting hook of the first electric hoist does not bear lifting tension completely, the lifting hook of the first electric hoist is loosened, and the second electric hoist continues to lift;

6) the cushion block is placed, when the fault oil cylinder is removed, the gate is in a stable state, the wedge block hoisting point is hoisted by using the single-foot rod hoisting hook, and the falling state of the wedge block is the same as the gate direction in the length direction; when the position of the wedge control lever is level with the elevation 5.5m, the control lever is rotated for 90 degrees; the operating rod is used for keeping the falling direction of the wedge block, and the wedge block continues to fall until the wedge block is sufficiently supported; stopping dropping the wedge block, binding a wedge block control handle by using temporary facilities, and finishing the stop work of the wedge block; repeating the above steps, and putting down the subsequent second and third wedges; after the wedge blocks are placed, the gates are symmetrically and slowly dropped until the gates are stably supported on the wedge blocks, the gates are dropped on the wedge blocks, and at the moment, the lifting hooks of the two electric hoists are not loosened to serve as safety ropes of the gates;

7) welding lifting lugs, removing sludge on the top of the gate, and wiping muddy water on the top of the gate with a dry towel; positioning a lug welding position by using a straight ruler and a triangular ruler, wherein the lug welding position is in the length direction of the gate, selecting the position of a vertical main rib of the gate, marking a lug installation position on the upper surface of the gate by using a marking pen and the straight ruler, wherein the central position of the lug installation is the center of the thickness direction of the gate, polishing away anticorrosive paint at the position where the lug needs to be welded by using a polishing machine, and adopting penetration welding when welding the lug;

8) changing the lifting point of the electric hoist, after the cushion block is placed and the lifting lugs are welded, transferring the main lifting hook lifting point of the electric hoist to the welded lifting lugs in a single time, and starting the electric hoist to tighten the hoisting zipper of the electric hoist after the two lifting points are transferred;

after the gate is placed on the cushion block, and no abnormity is detected, the fault oil cylinder begins to be dismantled, two suspension ladder stands are firstly installed, when the ladder stands are installed, the ladder stands are firmly fixed on the wall of the gate well, then transverse springboards are installed on the two suspension ladder stands and used as an operation platform for worker construction, then the fault oil cylinder is fixed by using the single-foot handle rod and the electric hoist on the temporary support, then a professional oil cylinder dismantling person uses a professional tool to dismantle the flange bolt of the fault oil cylinder, then the fault oil cylinder is hoisted by using the electric hoist on the single-foot handle rod, the fault oil cylinder is rotated by 90 degrees in the air, and finally the springboard of the upper support is erected, and the fault oil cylinder is manually pushed to be transported away from the gate well;

wherein in the above step eight, installing the new oil cylinder comprises the following steps:

1) lifting a new oil cylinder, conveying the new oil cylinder to the well edge of the drain valve by using a hydraulic handle, adjusting the position of the new oil cylinder to enable the bottom of the new oil cylinder to penetrate into the temporary support, then hanging an electric hoist on a single-foot handle rod, hanging a lifting hook of the electric hoist on an installation lifting lug of the new oil cylinder, finally slowly pulling up a lifting hook of the electric hoist, and simultaneously pushing a flat hydraulic car forward to enable the new oil cylinder to be gradually lifted until the new oil cylinder is in a vertical state;

2) installing a new oil cylinder on the drain valve, slowly descending a main hook of the electric hoist to enable the bottom of the new oil cylinder to descend to a position about 10cm away from the top of the drain valve, then climbing down from the temporary crawling ladder and standing on the top of the drain valve, lightly holding the new oil cylinder by an installer to enable the bottom of the new oil cylinder to be aligned with an oil cylinder installation hole of the drain valve, then continuing descending the electric hoist to enable an installation flange of the new oil cylinder to lightly touch an oil cylinder installation flange of the drain valve, then positioning the angle and the plane position of the installation flange of the new oil cylinder by three punching nails, symmetrically installing high-strength bolts in three directions, preliminarily pre-tightening the installed high-strength bolts, then pulling out the three punching nails, pulling out bolt holes of the punching nails to penetrate the high-strength bolts, and finally screwing all the high-strength bolts;

3) the frame is restored, the two electric hoists are slowly and symmetrically lifted, the height of the electric hoists is 15cm, cushion blocks at the bottoms of the three drain valves are removed from the sides of the drain valve wells, the two electric hoists are synchronously descended, the two electric hoists are stopped to descend until the highest point of the new oil cylinder is about 10cm lower than the frame mounting platform, the frame is manually moved back to the original frame mounting position, then mounting bolts of the frame are inserted into frame mounting bolt holes and tightened, the two electric hoists are synchronously lifted, so that a plunger top shaft pin hole of the new oil cylinder is aligned with a shaft frame pin shaft hole on the frame, a pin shaft is inserted, a pin shaft cover is mounted, shaft frame bolt holes are mounted, all the bolts are tightened, oil pipes of the new oil cylinder are mounted, main hooks of the two electric hoists are loosened, and the new oil cylinder is debugged under the condition that the two electric hoists are not unhooked;

in the ninth step, the debugging of the oil cylinder comprises the following steps:

1) debugging preparation, namely confirming that the frame, the oil cylinder and a gate are fastened by related mounting and fixing screws through a spanner, confirming that a high-pressure oil pipe of a rodless cavity of a rod cavity of a valve oil cylinder is correctly connected, loosening a cover cap of an exhaust pressure measuring connector of the oil cylinder, confirming that ball valves at all positions on the whole oil path of the valve oil cylinder are opened, ensuring that the filtering precision of a hydraulic medium is not lower than a design rule, all air of a hydraulic system is exhausted, and checking that pressure-resistant elements of the valve and a pipeline have no leakage;

2) debugging an oil cylinder, manually opening and closing a valve on one side, clicking a valve opening button through a touch screen, popping up a confirmation window, starting a motor of a hydraulic station after clicking confirmation, opening the valve, observing whether the door opening speed and the state of a gate are normal or not at the moment, preparing to stop the machine at any time when abnormal conditions exist in all parts, clicking a self-falling valve button through the touch screen, popping up the confirmation window, automatically falling the valve after clicking confirmation, observing whether the door closing speed and the state of the gate are normal or not at the moment, preparing to stop the machine at any time when abnormal conditions exist in all parts, repeatedly operating the machine for several times, and ensuring that the air in the oil cylinder is completely discharged; the valve is opened and closed at two sides, a valve opening button is clicked through a touch screen, a confirmation window is popped out, after confirmation is clicked, motors of left and right hydraulic stations at the upstream side are started, the valve is opened, when synchronous deviation rectifying actions of the left and right valves are normal, the stroke difference value of the two valves in the whole stroke process is 0-10 mm, the opening time is about 280S, the newly replaced oil cylinder is qualified in opening and debugging, then a self-falling valve button is clicked through the touch screen, the confirmation window is popped out, after confirmation is clicked,

the valves automatically fall, and when the synchronous deviation rectifying action of the left and right valves is normal, the stroke difference of the two valves in the whole stroke process is 0-10 mm, and the valve self-falling closing time is about 180S, the newly changed oil cylinder is qualified in debugging; after the rope sensor is installed again, the normal reading is confirmed; observing whether the opening pressure of the newly replaced oil cylinder is normal or not in the opening and closing process; and observing whether external leakage exists when the new oil cylinder is replaced and the door is opened in the opening and closing process.

Preferably, in the second step 4), after the upright plate bolt hole of the upright post base plate is punched, the center point position of the bolt hole is checked, the deviation is controlled to be-1 mm, after the assembly welding is finished, the axis alignment condition of the H-shaped steel and the upright post base plate is checked, the error is controlled to be-3 mm, the height deviation of the upright post is checked by using a ruler, the error is controlled to be-3 mm, the residual height deviation of the welding line of the welding foot is checked to be 0-3 mm, and the height deviation of the welding foot is controlled to be 0-3 mm.

Preferably, in the second step 5), after the H-shaped steel girder is welded, the length deviation of the H-shaped steel girder is checked to be controlled to be minus 3-3 mm by using a ruler, the lateral bending deviation is controlled to be minus 1.5-1.5 mm, the straightness is controlled to be 0-3 mm, the residual height deviation of the detected fillet weld is controlled to be 0-3 mm, and the height deviation of the fillet weld is controlled to be 0-3 mm.

Preferably, in the second step 6), after the welding of the single-foot handle rod is finished, the length deviation of a main beam is checked by using a ruler and is controlled to be-3 mm, the lateral bending deviation is controlled to be-1.5 mm, the straightness is controlled to be 0-3 mm, the residual height deviation of a detected foot-attaching welding seam is controlled to be 0-3 mm, and the height deviation of the foot-attaching welding seam is controlled to be 0-3 mm.

Preferably, in the step four 1), the support lofting sequence is that support axis lofting is prior to column base axis lofting and is prior to bolt hole lofting, the length and width deviation of the center point of the stand column of the measurement and dimension of the measurement and pay-off is checked after the measurement and pay-off is finished, the control deviation is-4 mm, the diagonal deviation of the center point of the stand column is controlled to be 0-6 mm, the lofting of the bolt hole position is detected in a mode of a bottom plate hole of the stand column, and the hole position deviation is controlled to be 0-2 mm.

Preferably, in step four 2), the drill bit is repeatedly pushed and pulled from top to bottom several times after the expansion bolt is punched to clear up the downthehole piece that punches, and the bolt hole plane position is examined with square and ruler after the expansion bolt hole is punched, and plane positional deviation control is at 0 ~ 1mm, penetrates the bolt hole that has been beaten with the expansion bolt expansion pipe, guarantees in the expansion pipe can penetrate the hole smoothly.

Preferably, in step four 4), measure the elevation of girder with spirit level and ruler after the installation is accomplished, guarantee that the elevation error is 0 ~ 10mm, measure two girder diagonal lengths with the ruler, guarantee that diagonal length deviation is 0 ~ 6mm, the surplus height deviation control of inspection butt welding seam is at 0 ~ 3mm, and butt welding seam leg height deviation control is at 0 ~ 3 mm.

Preferably, in the step four 5), after the connection beam, the upright post and the main beam are aligned, the distance and the length of the connection beam are measured by using a ruler, the length deviation of the connection beam is controlled to be-10 mm, and the height deviation of two ends of the connection beam is controlled to be 0-15 mm.

Preferably, in the fifth step 4), in the process of removing the shaft cover, the pin shaft seat and the shaft sleeve, in the process of unloading the parts, the bolts and the like, the parts and the bolts are placed on the cloth liner and are sequentially placed in a subarea manner, the number of the parts is counted, and the parts are prevented from being lost in the process of removing the parts; before the pin shaft is dismantled, the pin shaft is cleaned by a soft towel and a special cleaning oil sludge spray, and when the pin shaft is jammed in the dismantling process, the pin shaft is knocked and dismantled by a copper bar matched with a rubber hammer.

Preferably, step six 6), use the cushion to place on the rectangular shape funnel structure of the gate shaft lower part of trap valve, the cushion lower part sets up the corner cut of laminating each other with gate shaft funnel structure and is used for guaranteeing stably, and the cushion middle part sets up the lug, and the right side sets up the manipulation pole, and three are placed altogether to the cushion, and two of them are main load cushion, and one is as the insurance cushion.

Compared with the prior art, the invention has the beneficial effects that: the method is safe and reliable, the installation process is reasonably arranged, the operation process is annularly fastened, the temporary support is reasonably designed, the proper equipment type selection is realized, the influence of adverse working conditions can be overcome, and the maintenance work of the drain valve is completed under the condition that no large-scale hoisting equipment is provided; through a reasonable installation process and a detection method, the success rate and the quality of oil cylinder replacement can be effectively ensured; by using the method, the installation quality of each procedure is ensured, and the process guarantee is provided for the final installation quality by accurately measuring and checking the operation quality of each procedure in time and adjusting and correcting construction errors in time; the installation procedure and the quality of the drain valve can be checked through debugging work after the new oil cylinder is installed; through the detection of debugging the water valve, various equipment parameters after the drain valve operates can be effectively controlled, so that the drain valve meets the requirements of design and owners, and the operation performance of the equipment is effectively detected; the method can well overhaul the drain valve under the condition of ensuring that the ship lock does not stop sailing, particularly can ensure the installation precision, greatly reduces the sailing stoppage caused by the overhaul of the drain valve, has quite high benefit, and greatly reduces the influence caused by the sailing stoppage of the gate; meanwhile, the problems of complex working procedures, difficult maintenance and influence on social life and economy caused by non-navigation construction of the drain valve are well solved, the technical standards of design, operation and maintenance units are met, the maintenance requirements are met, and the drain valve has good social benefits.

Drawings

FIG. 1 is a schematic structural view of a main lifting lug under a main beam of the invention;

FIG. 2 is a schematic front view of the single-foot handle lifting lug of the present invention;

FIG. 3 is a schematic view of the assembly of the H-shaped steel and the column bottom plate according to the present invention;

FIG. 4 is a position diagram of the girder rib plates and lifting lugs of the present invention;

FIG. 5 is a view of the assembly welding of the single-foot handle bar of the present invention;

FIG. 6 is a schematic view of a main beam mounting structure of the present invention;

FIG. 7 is a schematic view of the attachment beam mounting structure of the present invention;

FIG. 8 is a schematic view of a front view of the mounting structure of the single-foot handlebar of the present invention;

FIG. 9 is a side view of the mounting structure of the single foot bar of the present invention;

FIG. 10 is a schematic front view of the horseshoe-shaped hanger of the present invention;

FIG. 11 is a schematic front view of the spreader of the present invention with the ropes compressed against the horseshoe spreader during the lifting process;

fig. 12 is a schematic side view of the spreader of the present invention with the ropes compressed against the horseshoe spreader during hoisting;

FIG. 13 is a schematic side view of the first lift of the gate of the present invention;

FIG. 14 is a schematic structural view of the first lifting of the gate of the present invention;

FIG. 15 is a schematic side view of the second lift of the gate of the present invention;

FIG. 16 is a schematic structural view of the second time of lifting the gate according to the present invention;

FIG. 17 is a schematic side view of the wedge arrangement of the present invention;

FIG. 18 is a front view of the wedge arrangement of the present invention;

FIG. 19 is a flow chart of a method of the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.

Referring to fig. 1-19, an embodiment of the present invention is shown: a large-scale trap non-stop maintenance method comprises the steps of firstly, transporting materials; step two, manufacturing a bracket; step three, material transporting; step four, erecting a bracket; fifthly, shifting the rack; step six, integrally hoisting the oil cylinder and the gate; step seven, dismantling the fault oil cylinder; step eight, installing a new oil cylinder; step nine, debugging a drain valve;

in the second step, the support manufacturing comprises the following steps:

3) processing a main lifting lug under a main beam and a lifting lug of a single-foot handle rod, and referring to fig. 1 and 2, blanking the lifting lug in a manual gas cutting mode after lofting a steel plate, processing a middle lifting lug hole in a boring mode, manufacturing one lifting lug at 2t, and manufacturing two lifting lugs at 10 t; when the lifting lug is manufactured, the shape error is controlled to be-3 mm, the deviation of the position of the lifting lug hole is 0-1 mm, and the deviation of the diameter of the lifting lug hole is 0-1 mm;

4) processing the upright posts, referring to fig. 3, blanking the upright post bottom plate by adopting semi-automatic gas cutting, marking the X-Y axis position and the bolt hole position of the upright post bottom plate on the upright post bottom plate according to the required size, knocking out the punching central point position on the bolt hole position by using a awl, processing bolt holes on the bolt holes of the upright post bottom plate by using a bench drill, marking the axis positions on wing plates and web plates of the H-shaped steel which is already blanked, placing the upright post bottom plate on a welding platform, then assembling the H-shaped steel and the upright post bottom plate together, ensuring that the X-Y axis of the H-shaped steel is aligned with the marked X-Y axis of the upright post bottom plate during assembly, electrically welding the H-shaped steel and the upright post bottom plate firmly after the axes are aligned, fully welding all the upright posts and the bottom plate after the assembly welding of all the four upright posts is finished, wherein the welding line is an angle welding line, and checking the central point positions of the bolt holes of the upright post bottom plate after the upright post bottom plate is punched, the deviation is controlled to be-1 mm, the axis alignment condition of the H-shaped steel and the upright post bottom plate is checked after assembly welding is completed, the error is controlled to be-3 mm, the height deviation of the upright post is checked by using a ruler, the error is controlled to be-3 mm, the residual height deviation of a fillet welding seam is checked to be 0-3 mm after the upright post bottom plate and the H-shaped steel are welded, and the height deviation of the fillet welding seam is controlled to be 0-3 mm;

5) processing a main beam, referring to fig. 4, symmetrically adding stiffening plates on a stress structure of an H-shaped steel main beam, welding a 10t lifting lug at the lower part of the main beam, firstly marking the central position of the H-shaped steel by using a ruler, then respectively measuring the positions of rib plates from the central position to two sides, drawing marks on upper and lower flange plates of the main beam by using a marking pen, assembling the stiffening plates according to the marks, fixing the stiffening plates by electric welding when installing, rechecking the installation position and the verticality of the stiffening plates and the close contact condition of the edges of the stiffening plates and the H-shaped steel after the installation is finished, welding the rib plates after the correctness is confirmed, fully welding the rib plates and the H-shaped steel when welding, wherein the welding seam is a fillet welding seam, after the welding of the H-shaped steel main beam is finished, checking the length deviation of the main beam by using the ruler is controlled to be-3 mm, the lateral bending deviation is controlled to be-1.5 mm, and the straightness is controlled to be 0-3 mm, checking that the residual height deviation of the fillet weld is controlled to be 0-3 mm, and the height deviation of the fillet weld is controlled to be 0-3 mm;

6) processing the single-foot handle rod, referring to fig. 5, the single-foot handle rod mainly has the main functions of installing and removing a fault oil cylinder and a machine frame, a cantilever arm is manufactured at the top of the handle rod and used for providing enough operation space for a chain block in the lifting process, a 2t lifting lug is arranged at the lower part of the cantilever arm, a rib plate is additionally arranged at the position, corresponding to a stress structure, of a wing plate of the cantilever arm on the main rod, a rib plate is additionally arranged at the position, corresponding to the stress structure, of the lifting lug on the cantilever arm, 45-degree beveling welding is carried out on an upper wing plate, a lower wing plate and a web plate when the cantilever arm is welded with the main rod, after the welding of the single-foot handle rod is completed, the length deviation of the main beam is detected by a ruler and controlled to be-3 mm, the lateral bending deviation is controlled to be-1.5 mm, the straightness is controlled to be 0-3 mm, the residual height deviation of a foot welding seam is detected to be 0-3 mm, and the height deviation of the foot welding seam is controlled to be 0-3 mm;

in the fourth step, the support erection comprises the following steps:

1) measuring and setting out, namely lofting the axis position of a support column base on the ground by using a level meter and a ruler and taking the center of a top shaft of a drain valve oil cylinder as a setting-out center according to the principle that the axis is parallel to the edge of a gate well and the axis is vertical to each other, then lofting the hole opening position of a column base expansion bolt by using the level meter and the ruler according to the axis position of the column base, wherein the lofting sequence of the support is that the lofting of the support axis is prior to the lofting of the column base axis and is prior to the lofting of a bolt hole, the length and width deviation of the center point of an upright column is detected after the measurement and setting-out are finished, the control deviation is-4 mm, the diagonal deviation of the center point of the upright column is controlled to be 0-6 mm, the lofting of the bolt hole position is detected by adopting an upright column bottom plate hole mode, and the hole position deviation is controlled to be 0-2 mm;

2) punching an expansion bolt hole, selecting an impact drill bit with the same diameter as that of an expansion pipe of the expansion bolt, punching at the positioned installation position of the expansion bolt, wherein the punching depth is the same as the length of the expansion bolt or slightly larger than the length of the expansion bolt, repeatedly pushing and pulling the drill bit up and down for several times after the punching of the expansion bolt is finished so as to clean punched scraps in the hole, checking the plane position of the bolt hole by using a square ruler and a straight ruler after the punching of the expansion bolt hole is finished, controlling the plane position deviation to be 0-1 mm, and penetrating the punched bolt hole by using the expansion pipe of the expansion bolt to ensure that the expansion pipe can smoothly penetrate into the hole;

3) installing a vertical column, firstly drawing marks on central lines of the front surface and the side surface of the vertical column, aligning a bolt hole on a bottom plate of the vertical column with a drilled expansion bolt installation hole when the vertical column is installed, adjusting the position of the bottom plate of the vertical column to ensure that the X-Y direction central line position of the bottom plate of the vertical column is aligned with the ground lofting axis position and the bolt hole of the bottom plate of the vertical column corresponds to the expansion bolt hole position, putting an expansion bolt sleeve into the bolt hole together, lightly tapping the head part of the expansion bolt by a hammer, screwing a nut on the expansion bolt when the expansion bolt is installed to prevent the bolt from falling into the hole and being difficult to remove, then adjusting the verticality of the vertical column by adopting a level gauge, supporting a steel pad with different thicknesses between the bottom plate of the vertical column and a concrete platform, adjusting the installation height of the vertical column, measuring the elevation of the top of the vertical column by the level gauge after the installation of the vertical column is finished, and controlling the elevation of the top of the vertical column to be-5-3 mm, controlling the verticality of the stand column to be 0-10 mm;

4) mounting a main beam, referring to fig. 6, measuring the mounting positions of the main beam and an upright post by using a straight ruler and a square ruler, marking the X axis and the Y axis of the main beam at the mounting positions of the main beam and the upright post by using a pen, lifting the main beam to the top of the upright post, aligning the marked X-Y axis of the main beam with the X-Y axis of the upright post by fine tuning a base plate, welding the upright post and the main beam after the two main beams are mounted and checked to be correct, ensuring full welding and foot-pasting welding seams during welding, measuring the elevation of the main beam by using a level meter and the straight ruler after mounting is finished, ensuring that the error of the elevation is 0-10 mm, measuring the length of diagonal lines of the two main beams by using the straight ruler, ensuring that the deviation of the length of the diagonal lines is 0-6 mm, checking that the deviation of the residual height of the foot-pasting welding seams is controlled to be 0-3 mm, and controlling the deviation of the height of the foot-pasting welding seams to be 0-3 mm;

5) mounting the connecting beam, referring to fig. 7, marking the mounting positions of the connecting beam on the end parts of the four i-beams respectively, marking the mounting positions of the connecting beam on the upright post and the main beam respectively, aligning the marking positions of the connecting beam with the marking positions of the upright post and the main beam when the connecting beam is mounted, welding the connecting beam with the upright post and the main beam after checking that the connecting beam is correct, measuring the distance and the length of the connecting beam by using a ruler after the connecting beam, the upright post and the main beam are aligned, controlling the length deviation of the connecting beam to be-10 mm, and controlling the height deviation of two ends of the connecting beam to be 0-15 mm;

6) mounting the single-foot handle bars, referring to fig. 8-9, marking the mounting positions of the single-foot handle bars at the middle of a main beam on one side, marking X-Y axis symmetry axes at the feet of the single-foot handle bars, marking the welding positions of the three stabilizer bars in the middle of the single-foot handle bars, marking the welding positions of the stabilizer bars on the end parts of the main beam and on edge angle steel of an equipment well, placing the column feet of the single-foot handle bars in the middle of the marked main beam, adjusting the positions of the column feet of the single-foot handle bars to align the marks of the main beam with the X-Y axis symmetry of the single-foot handle bars, checking the verticality of the single-foot handle bars, mounting the three stabilizer bars on the single-foot handle bars, controlling the verticality of the handle bars from two vertical directions by using a level gauge in the process of mounting the single-foot handle bars, controlling the verticality to be 0-10 mm, and fully welding angle welding seams between the roots of the hanger bars and the main beam field;

in the fifth step, the rack shifting comprises the following steps:

1) the chain block is arranged on the single-foot handle rod, the chain block is hung at the 2t lifting lug of the single-foot handle rod, the closing condition of a safety presser foot of a lifting hook is checked after the chain block is hung on the lifting lug, a lifting chain and a chain pull chain of the chain block are smoothed, when the 2t chain block is hung, a worker stands on a safe and stable platform, the 2t chain block checks the closing condition of the presser foot of the hook after the hanging is finished, the safety of the chain block in the hoisting process is ensured, the chain block checks a hoisting chain and a chain pull chain of the chain block before the hoisting, the chain is ensured to be smooth, the chain pull is repeatedly pulled for multiple times, and the phenomenon that the chain pull chain is not blocked is ensured;

2) the piston head of the oil cylinder is temporarily fixed, a rope is used for binding the piston head of the oil cylinder, one end of the rope is bound to the head of the oil cylinder piston to be removed firmly, the other end of the rope is bound to a main beam of the temporary hanging bracket, the purpose of binding and fixing the piston head of the oil cylinder by the rope is to prevent the oil cylinder from freely falling due to no pressure after a hydraulic oil pipe is removed by a fault oil cylinder to cause secondary damage to the cylinder body of the oil cylinder, the binding rope on the piston head of the oil cylinder can also be used as a guide rope, the piston position can be successfully found when the piston head falls into water, and a special lifting appliance can be smoothly hung;

3) removing an oil pipe, closing an oil pumping station before removing the oil pipe, removing the oil pipe by using a wrench, tightly wrapping an oil pipe joint by using a dry towel after removing the oil pipe, placing the oil pipe at one side of a gate well, connecting two oil nozzles of an oil cylinder piston by using an oil pipe with a joint when removing the oil pipe so as to prevent hydraulic oil from flowing into the gate well in the oil pipe removing process, and tightly wrapping the oil pipe joint by using the dry towel so as to prevent impurities and dust from entering the oil pipe by accessing the other end of the oil pipe into a waste oil cylinder;

4) dismantling a pin shaft of an oil cylinder piston, dismantling a shaft cover bolt of the pin shaft of the oil cylinder piston by using a spanner, after the mounting bolts of a single-side shaft cover are completely dismantled, manually removing the pin shaft cover, cleaning by using special oil stain cleaning liquid, uniformly spraying the oil stain cleaning liquid on the pin shaft, lightly wiping the pin shaft by using soft towel until all grease and sundries on the pin shaft are completely wiped off, dismantling the bottom mounting bolt of a pin shaft bracket by using the spanner, then removing the pin shaft bracket from a main beam of a rack, in the process of dismantling the pin shaft bracket, using hands to hold the end part of the pin shaft, removing the pin shaft sleeve after the pin shaft bracket at one side is removed, repeating the actions to dismantle the shaft sleeve and the shaft bracket at the other side of the pin shaft, holding the pin shaft by using two hands, slowly pushing the pin shaft to push the pin shaft out of a rod head of the oil cylinder piston, and tightly jacking the pin shaft side by using a copper rod when the pin shaft is blocked, the copper bar is tapped by a rubber hammer until the pin shaft is tapped, the parts and the bolts are placed on the cloth liner in the process of dismounting the shaft cover, the pin shaft seat and the shaft sleeve and in the process of dismounting the parts, the bolts and the like, the parts and the bolts are placed in a partition mode in sequence, the number of the parts is counted, and the parts are prevented from being lost in the process of dismounting; before the pin shaft is dismantled, a soft towel and a special cleaning oil sludge spray are used for cleaning the pin shaft, so that the situation that the pin shaft cannot be dismantled due to the fact that the pin shaft is jammed in the dismantling process is avoided, when the jamming phenomenon occurs in the pin shaft dismantling process, a copper bar is used for being matched with a rubber hammer to tap for dismantling, and a steel hammer is forbidden to be used for hard knocking for dismantling, so that the pin shaft is prevented from being damaged;

5) the frame is shifted, when the frame is moved, the chain block of the 2t chain block is pulled, the lifting hook of the chain block is lowered to the upper part of the frame by a handle, one end of the chain block is bound on the pin hole of the rod head of the oil cylinder piston rod, the other end of the chain block is bound on the lifting hook of the 2t electric block, the chain block of the 2t chain block is pulled to slowly lift the lifting hook of the chain block, when the lifting hook of the chain block is completely tightened, the bound rope is released, the binding point at the upper end is loosened, the chain block hand zipper is reversely pulled to slowly lower the lifting hook until the uppermost part of the oil cylinder piston rod is lower than the plane of the frame mounting platform, the upper end of the rope bypasses the frame from one side of the frame and then is bound on the temporary support main beam, when the rope is bound, the rope is tightly collected, the lifting hook of the 2t chain block is loosened, the lower ends of the two ropes are respectively hung on the frame hanging points, the upper end of the frame is hung on a lifting hook of a 2t chain block, a manual wrench is used for dismantling a frame mounting bolt, the dismantled mounting bolt is neatly placed on a tablecloth arranged on a maintenance well platform and is separately placed with other dismantling parts, a chain pull of the 2t chain block is pulled, the lifting hook of the chain block is slowly hoisted, when the hoisting height of the frame is higher, the frame is completely separated from a frame embedded part and is continuously hoisted for about 50mm, a worker slowly pulls the frame away from the initial position of the frame from the side by using a cable rope, the frame is deviated from the original position by 250mm, then the worker continuously pulls the cable rope to keep the horizontal position of the frame unchanged, and simultaneously slowly descends the 2t chain block lifting hook until the frame stably lands, the frame displacement is completed, and the original mounting plane position of the frame is removed by 400 mm;

1) the electric hoist hook is used for hanging a 10t electric hoist at a 10t lifting lug below the temporary hanger main beam, checking the closing condition of a lifting hook safety clamp after the electric hoist is hung on the lifting lug, smoothening a lifting chain of the electric hoist, preparing a junction box and switching on a power supply;

2) the method comprises the following steps of manufacturing a lifting appliance, referring to fig. 10, as no existing lifting point exists on a gate, and an oil cylinder plays a role of lifting the gate, the lifting point during the lifting at this time is selected on the position of a front cover of the oil cylinder, a special lifting appliance is utilized to lift together with a drain valve, according to actual conditions, a horseshoe-shaped lifting appliance is adopted, the lifting appliance is conveniently guided to a specified flange position by itself, a circular hole with the diameter of 50 is processed on the lifting appliance, and the horseshoe-shaped lifting appliance and an oil cylinder body are tightly pressed by transverse tension when a rope passes through the circular hole;

3) preparing a lifting appliance, referring to fig. 11, respectively penetrating two ends of a rope into a horseshoe-shaped lifting appliance, making the ropes at the two ends into annular rope heads, respectively and firmly binding the ropes and the horseshoe-shaped lifting appliance by using a guy rope, so that a rope ring and the lifting appliance are released to the maximum extent, sleeving the rope ring of the lifting appliance on an oil cylinder when the rope ring is formed by the lifting appliance and the ropes below, continuously dropping the lifting appliance to the bottom of the lifting appliance, dropping the lifting appliance on the upper surface of a drain valve, and lowering the lifting appliance to the mounting flange of the oil cylinder and the valve;

4) referring to fig. 12, two rope ends of a rope are connected by a 12t omega-shaped shackle, the shackle is hung on a lifting hook of a 10t electric hoist, the electric hoist is lifted slowly to hook the electric hoist, in the lifting process, the rope is firstly tightened due to the fact that the horseshoe-shaped sling is heavy, an inner opening of the horseshoe-shaped sling hoops a cylinder body of a hydraulic oil cylinder under the tensile force of the rope, a horseshoe-shaped arc-shaped part inclines downwards under the action of gravity, the corresponding horseshoe-shaped opening direction inclines upwards under the tensile force of the rope, the 10t electric hoist is continuously and stably lifted, when steel plates at two ends of the horseshoe-shaped opening part touch the flange of the oil cylinder cover, according to the lever principle, end points of the steel plates at the opening part can form supporting points of the lever, the horseshoe-shaped sling arc-shaped part inclines upwards under the tensile force of the rope until the upper surface of the horseshoe-shaped sling is tightly attached to the flange of the oil cylinder cover, in the process, the rear part of the opening of the horseshoe-shaped lifting appliance is continuously pressed on a sleeve of the oil cylinder under the action of transverse tension of the rope, and at the moment, the placement process of the lifting appliance is finished;

5) lifting the gate, referring to fig. 13-16, after the installation of the lifting appliance is completed, the gate needs to be lifted twice, after the stroke of the first electric hoist is used up, the first lifting is completed, then the gate is symmetrically installed at the oil cylinder installation lifting lug by using a rope and shackles, the other end of the rope is hung on a lifting hook of the second electric hoist, the second electric hoist is slowly lifted, the lifting hook for lifting the first electric hoist is gradually released, when the lifting hook of the first electric hoist does not bear the lifting tension completely, the lifting hook of the first electric hoist is released, and the second electric hoist continues to lift;

6) placing the cushion blocks, referring to fig. 17-18, when the fault oil cylinder is dismounted, the gate is in a stable state, the single-foot rod lifting hook is used for lifting the wedge block hoisting point, and the falling state of the wedge block is the same as the gate direction in the length direction; when the position of the wedge control lever is level with the elevation 5.5m, the control lever is rotated for 90 degrees; the operating rod is used for keeping the falling direction of the wedge block, and the wedge block continues to fall until the wedge block is sufficiently supported; stopping dropping the wedge block, and binding a wedge block control handle by using a temporary facility to complete the stop work of the wedge block; repeating the above steps, and putting down the subsequent second and third wedges; after the wedge blocks are placed, the gates are symmetrically and slowly dropped until the gates are stably supported on the wedge blocks, the gates are dropped on the wedge blocks, and at the moment, the lifting hooks of the two 10t electric hoists are not loosened to serve as safety ropes of the gates; the wedge-shaped cushion blocks are placed on the long strip-shaped funnel structure at the lower part of the gate well of the drain valve and placed at the position for placing the gate, the cushion blocks can fix the gate and keep the gate at the stable position at the elevation, the lower parts of the wedge-shaped cushion blocks are provided with cut angles which are mutually attached to the gate well funnel structure to ensure stability, the middle parts of the wedge-shaped cushion blocks are provided with lifting lugs, the right sides of the wedge-shaped cushion blocks are provided with operating rods, the wedge-shaped cushion blocks are totally placed into three blocks, two of the wedge-shaped cushion blocks are main bearing cushion blocks, and one of the wedge-shaped cushion blocks is used as a safety cushion;

8) changing a lifting point of the electric hoist, transferring a main lifting hook lifting point of the 10t electric hoist to the welded lifting lug in a single time after the cushion block is placed and the lifting lug is welded, starting the electric hoist to tighten a lifting zipper of the electric hoist after the two lifting points are transferred, wherein the purpose of transferring the lifting points of the two 10t electric hoists to the drain valve is a necessary step for subsequently installing a new oil cylinder, and the two 10t electric hoists can be used as placing insurance of the other drain valve;

after the gate is placed on the cushion block, and no abnormity is detected, the fault oil cylinder begins to be dismantled, two suspension ladder stands are firstly installed, when the ladder stands are installed, the ladder stands are firmly fixed on the wall of the gate well, then transverse springboards are installed on the two suspension ladder stands and used as an operation platform for worker construction, then the fault oil cylinder is fixed by using a single-foot handle rod and a 2t electric hoist on a temporary support, then a professional oil cylinder dismantling person uses a professional tool to dismantle a flange bolt of the fault oil cylinder, then the fault oil cylinder is hoisted by using the 2t electric hoist on the single-foot handle rod, the fault oil cylinder is turned for 90 degrees in the air, and finally the springboard of an upper support is erected, and the fault oil cylinder is manually pushed to be transported away from the gate well;

1) lifting a new oil cylinder, transporting the new oil cylinder to the edge of a drain valve well by using a hydraulic vehicle, adjusting the position of the new oil cylinder to enable the bottom of the new oil cylinder to penetrate into the temporary support, then hanging a 2t electric hoist on a single-foot handle rod, hanging a lifting hook of the electric hoist on an installation lifting lug of the new oil cylinder, finally slowly pulling up a lifting hook of the 2t electric hoist, and simultaneously pushing a flat hydraulic vehicle forwards to enable the new oil cylinder to be gradually lifted until the new oil cylinder is in a vertical state;

2) installing a new oil cylinder on the drain valve, slowly descending a main hook of the 2t electric hoist to enable the bottom of the new oil cylinder to descend to a position about 10cm away from the top of the drain valve, then climbing down from the temporary crawling ladder and standing on the top of the drain valve, lightly holding the new oil cylinder by an installer to enable the bottom of the new oil cylinder to be aligned with an oil cylinder mounting hole of the drain valve, then continuously descending the 2t electric hoist to enable the mounting flange of the new oil cylinder to lightly touch an oil cylinder mounting flange of the drain valve, then positioning the mounting flange angle and the plane position of the new oil cylinder by using three punching nails, then symmetrically installing high-strength bolts in three directions, preliminarily pre-tightening the installed high-strength bolts, then pulling out the three punching nails, inserting the high-strength bolts into bolt holes for pulling out the punching nails, and finally screwing all the high-strength bolts;

3) the frame is recovered, the two 10t electric hoists are slowly and symmetrically lifted, the height of the electric hoist is 15cm, the cushion blocks at the bottoms of the three drain valves are removed from the sides of the drain valve wells, the two 10t electric hoists are synchronously descended until the highest point of the new oil cylinder is about 10cm lower than the rack mounting platform, the two 10t electric hoists are stopped to descend, the rack is manually moved to the original rack mounting position, then the mounting bolt of the frame is inserted into the mounting bolt hole of the frame and is screwed tightly, the two 10t electric hoists are synchronously lifted, aligning a pin hole at the top of a plunger of the new oil cylinder with a pin hole of a shaft bracket on a rack, inserting a pin shaft, installing a pin shaft cover, installing a bolt hole of the shaft bracket, screwing all bolts, installing an oil pipe of the new oil cylinder, loosening the main hooks of the two 10t electric hoists, and debugging the new oil cylinder under the condition that the two 10t electric hoists are not unhooked;

2) debugging an oil cylinder, manually opening and closing a valve on one side, clicking a valve opening button through a touch screen, popping up a confirmation window, starting a motor of a hydraulic station after clicking confirmation, opening the valve, observing whether the door opening speed and the state of a gate are normal or not at the moment, preparing to stop the machine at any time when abnormal conditions exist in all parts, clicking a self-falling valve button through the touch screen, popping up the confirmation window, automatically falling the valve after clicking confirmation, observing whether the door closing speed and the state of the gate are normal or not at the moment, preparing to stop the machine at any time when abnormal conditions exist in all parts, repeatedly operating the machine for several times, and ensuring that the air in the oil cylinder is completely discharged; the method comprises the steps that valves are opened and closed on two sides, a valve opening button is clicked through a touch screen, a confirmation window is popped out, after clicking confirmation, motors of left and right sides of an upstream hydraulic station are started, the valves are opened, when left and right sides of the valves synchronously correct the deviation and act normally, the stroke difference value of the two sides of the valves in the whole stroke process is 0-10 mm, the opening time is about 280S, a new oil cylinder is opened and debugged to be qualified, then a self-falling valve button is clicked through the touch screen, the confirmation window is popped out, after clicking confirmation, the valves automatically fall down, when left and right sides of the valves synchronously correct the deviation and act normally, the stroke difference value of the two sides of the valves in the whole stroke process is 0-10 mm, and the self-falling valve closing time is about 180S, the new oil cylinder is debugged to be qualified; after the rope sensor is installed again, the normal reading is confirmed; observing whether the opening pressure of the newly replaced oil cylinder is normal or not in the opening and closing process;

and observing whether external leakage exists when the new oil cylinder is replaced and the door is opened in the opening and closing process.

Based on the above, compared with the traditional overhauling method of the large drain valve, the overhauling method has the advantages that the installing process is reasonable, the operation process is performed by annularly fastening, and the overhauling work of the drain valve is completed under the condition of no large-scale hoisting equipment through the matched use of the temporary support, the electric hoist, the chain block and the lifting appliance, so that the overhauling method is convenient to use; through a reasonable installation process and a detection method, the success rate and the quality of oil cylinder replacement are effectively ensured; the quality of installation and maintenance is ensured by accurately measuring and checking the operation quality of each process in time and adjusting and correcting construction errors in time; the installation quality of the drain valve to be tested is further improved through the debugging work after the oil cylinder is replaced; by the method for overhauling the drain valve without stopping the navigation, the installation precision is ensured, the loss caused by the shutdown and the overhauling is reduced, the method has quite high benefit, and the influence caused by the shutdown of the gate is greatly reduced; meanwhile, the problems of complex working procedures, difficult maintenance and influence on social life and economy caused by non-navigation construction of the drain valve are well solved, and the drain valve is convenient to popularize and use.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.

Claims

1. A large-scale trap non-stop maintenance method comprises the steps of firstly, transporting materials; step two, manufacturing a bracket; step three, material transporting; step four, erecting a bracket; fifthly, shifting the rack; step six, integrally hoisting the oil cylinder and the gate; step seven, dismantling the fault oil cylinder; step eight, installing a new oil cylinder; step nine, debugging a drain valve; the method is characterized in that:

in the second step, the bracket manufacturing comprises the following steps:

4) processing a stand column, wherein the blanking mode of a stand column bottom plate adopts semi-automatic gas cutting blanking, the X-Y axis position and the bolt hole position of the stand column bottom plate are marked on the stand column bottom plate according to the required size, the punching central point position is knocked out by using an awl on the bolt hole position, a bolt hole is processed by using a bench drill on the bolt hole of the stand column bottom plate, the axis positions are marked on a wing plate and a web plate of the H-shaped steel which is already blanked, the stand column bottom plate is placed on a welding platform, then the H-shaped steel and the stand column bottom plate are assembled together, the alignment of the X-Y axis of the H-shaped steel and the marked X-Y axis of the stand column bottom plate is ensured during the assembly, the H-shaped steel and the stand column bottom plate are electrically welded firmly after the axes are aligned, all stand columns and the bottom plate are fully welded after the assembly welding of all the four stand columns is finished, and the welding seam is in the form of a welding seam angle;

in the fourth step, the support erection comprises the following steps:

4) the method comprises the following steps of (1) installing a main beam, measuring the installation positions of the main beam and an upright post by using a straight ruler and a square ruler, marking an X axis and a Y axis of the main beam at the installation positions of the main beam and the upright post by using a pen, lifting the main beam to the top of the upright post, aligning the marked X-Y axis position of the main beam with the X-Y axis position of the upright post by finely adjusting a base plate, welding the upright post and the main beam after the two main beams are installed and checked to be correct, and ensuring full welding and sticking a foot welding seam during welding;

6) the method comprises the following steps of installing single-foot handle rods, marking the installation positions of the single-foot handle rods in the middle of a main beam on one side, marking X-Y axis symmetry axes at the feet of the single-foot handle rods, marking the welding positions of three stabilizer bars in the middle of the single-foot handle rods, marking the welding positions of the stabilizer bars on the end parts of the main beam and equipment well edge angle steel, placing the column feet of the single-foot handle rods in the middle of the marked main beam, adjusting the column feet of the single-foot handle rods to enable the marks of the main beam to be aligned with the X-Y axis symmetry of the single-foot handle rods, checking the verticality of the single-foot handle rods, installing the three stabilizer bars on the single-foot handle rods, controlling the verticality of the handle rods from two vertical directions by using a level gauge in the process of installing the single-foot handle rods, controlling the verticality to be 0-10 mm, and fully welding angle welding seams between the roots of the hanger rods and the main beam fields;

in the fifth step, the rack shifting comprises the following steps:

5) the frame is shifted, when the frame is moved, the chain block of the chain block is pulled, the lifting hook of the chain block is lowered to the upper position of the frame by a handle, one end of the chain block is bound on the pin shaft hole of the rod head of the oil cylinder piston rod, the other end of the chain block is bound on the lifting hook of the electric block, the chain block of the chain block is pulled, the lifting hook of the chain block is slowly lifted, when the lifting hook of the chain block is completely tightened, the bound rope is released, the binding point at the upper end is loosened, the hand chain block hand zipper is reversely pulled to slowly lower the lifting hook until the uppermost position of the oil cylinder piston rod is lower than the plane of the frame mounting platform, the upper end of the rope bypasses the frame from one side of the frame and is bound on the temporary support main beam, when the rope is bound, the rope is tightened, the lifting hook of the upper chain block is loosened, the lower ends of the two ropes are respectively hung on the lifting point of the frame, hanging the upper end of the lifting hook on the lifting hook of the chain block, dismantling the rack mounting bolt by a manual wrench, neatly placing the dismantled mounting bolt on a tablecloth arranged on a maintenance well platform, separately placing the dismantling part and other dismantling parts, pulling the chain pull of the chain block, slowly lifting the lifting hook of the chain block, slowly pulling the rack away from the initial position of the rack by a cable wind rope from the side when the lifting height of the rack is about 50mm, deviating the rack from the original position by 250mm, continuously maintaining the horizontal position of the rack by the cable wind rope by a worker, and slowly descending the lifting hook of the chain block until the rack stably falls to the ground to complete the displacement of the rack, and removing the original mounting plane position by 400 mm;

1) the electric hoist hook is used for hanging an electric hoist at a main beam lower main lifting lug below a temporary hanger main beam, checking the closing condition of a lifting hook safety clamp after the electric hoist is hung on the lifting lug, smoothening a lifting chain of the electric hoist, preparing a junction box and switching on a power supply;

6) the cushion block is placed, when the fault oil cylinder is removed, the gate is in a stable state, the wedge block hoisting point is hoisted by using the single-foot rod hoisting hook, and the falling state of the wedge block is the same as the gate direction in the length direction; when the position of the wedge control lever is level with the elevation 5.5m, the control lever is rotated for 90 degrees; the operating rod is used for keeping the falling direction of the wedge block, and the wedge block continues to fall until the wedge block is sufficiently supported; stopping dropping the wedge block, and binding a wedge block control handle by using a temporary facility to complete the stop work of the wedge block; repeating the above steps, and putting down the subsequent second and third wedges; after the wedge blocks are placed, the gates are symmetrically and slowly dropped until the gates are stably supported on the wedge blocks, the gates are dropped on the wedge blocks, and at the moment, the lifting hooks of the two electric hoists are not loosened to serve as safety ropes of the gates;

7) welding lifting lugs, removing sludge on the top of the gate, and wiping muddy water on the top of the gate with a dry towel; positioning a lug welding position by using a ruler and a triangular ruler, wherein the lug welding position is in the length direction of the gate, selecting the vertical main rib position of the gate, marking a lug installation position on the upper surface of the gate by using a marking pen and the ruler, wherein the central position of the lug installation is the center of the thickness direction of the gate, polishing off anticorrosive paint at the lug to be welded by using a polishing machine, and performing fusion penetration welding when welding the lug;

8) changing the lifting points of the electric hoist, after the cushion blocks are placed and the lifting lugs are welded, transferring the lifting points of the main lifting hook of the electric hoist to the welded lifting lugs in a single time, and after the two lifting points are transferred, starting the electric hoist and tightening a hoisting zipper of the electric hoist;

3) the frame recovers, two electric hoists are hoisted slowly and symmetrically, the height of the electric hoists is 15cm, cushion blocks at the bottoms of three drain valves are removed on the sides of drain valve wells, the two electric hoists are lowered synchronously, the two electric hoists are stopped to be lowered until the highest point of a new oil cylinder is about 10cm lower than a frame mounting platform, the frame is moved back to the original frame mounting position manually, then mounting bolts of the frame are inserted into frame mounting bolt holes and tightened, the two electric hoists are hoisted synchronously, so that shaft pin holes at the tops of plungers of the new oil cylinders are aligned with shaft holes of shaft brackets on the frame, pin shafts are inserted into the shaft brackets, pin shaft covers are mounted, the shaft bracket bolt holes are mounted, all bolts are tightened, oil pipes of the new oil cylinders are mounted, main hooks of the two electric hoists are loosened, and the new oil cylinders are debugged under the condition that the two electric hoists do not unhook;

2) debugging an oil cylinder, manually opening and closing a valve on one side, clicking a valve opening button through a touch screen, popping out a confirmation window, starting a motor of a hydraulic station after clicking confirmation, opening the valve, observing whether the opening speed and the state of a gate are normal or not at the moment, preparing to stop at any time if abnormal conditions exist in all parts, clicking a self-falling valve button through the touch screen, popping out the confirmation window, automatically falling the valve after clicking confirmation, observing whether the closing speed and the state of the gate are normal or not at the moment, preparing to stop at any time if abnormal conditions exist in all parts, repeatedly operating for several times, and ensuring that the air in the oil cylinder is completely exhausted; the method comprises the steps that valves are opened and closed on two sides, a valve opening button is clicked through a touch screen, a confirmation window is popped out, after clicking confirmation, motors of left and right sides of an upstream hydraulic station are started, the valves are opened, when left and right sides of the valves synchronously correct the deviation and act normally, the stroke difference value of the two sides of the valves in the whole stroke process is 0-10 mm, the opening time is about 280S, a new oil cylinder is opened and debugged to be qualified, then a self-falling valve button is clicked through the touch screen, the confirmation window is popped out, after clicking confirmation, the valves automatically fall down, when left and right sides of the valves synchronously correct the deviation and act normally, the stroke difference value of the two sides of the valves in the whole stroke process is 0-10 mm, and the self-falling valve closing time is about 180S, the new oil cylinder is debugged to be qualified; after the rope sensor is installed again, the normal reading is confirmed; observing whether the opening pressure of the newly replaced oil cylinder is normal or not in the opening and closing process; and observing whether external leakage exists when the new oil cylinder is replaced and the door is opened in the opening and closing process.

2. The non-stop maintenance method for the large drain valve according to claim 1, characterized in that: in the second step 4), the center point position of the bolt hole is checked after the upright plate bolt hole of the upright post bottom plate is punched, the deviation is controlled to be-1 mm, the axis alignment condition of H-shaped steel and the upright post bottom plate is checked after assembly welding is finished, the error is controlled to be-3 mm, the height deviation of the upright post is checked by using a ruler, the error is controlled to be-3 mm, the residual height deviation of the welding line of the welding pin is checked to be 0-3 mm after the upright post bottom plate and the H-shaped steel are welded, and the height deviation of the welding pin of the welding line of the welding pin is controlled to be 0-3 mm.

3. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: in the second step 5), after the H-shaped steel girder is welded, the length deviation of the girder is checked to be controlled to be-3 mm by using a ruler, the lateral bending deviation is controlled to be-1.5 mm, the straightness is controlled to be 0-3 mm, the residual height deviation of the welding line of the detected pin is controlled to be 0-3 mm, and the height deviation of the welding pin of the welding line of the pin is controlled to be 0-3 mm.

4. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: in the second step 6), after the welding of the single-foot handle rod is finished, the length deviation of a main beam is checked to be controlled to be-3 mm by using a ruler, the lateral bending deviation is controlled to be-1.5 mm, the straightness is controlled to be 0-3 mm, the residual height deviation of a detected foot-attaching welding seam is controlled to be 0-3 mm, and the height deviation of the foot-attaching welding seam is controlled to be 0-3 mm.

5. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: in the step four 1), the support lofting sequence is that support axis lofting is prior to column base axis lofting and is prior to bolt hole lofting, the length and width deviation of the center point of the stand column of the measurement dimension is checked after the measurement of the pay-off is finished, the control deviation is-4 mm, the diagonal deviation of the center point of the stand column is controlled to be 0-6 mm, the lofting of the bolt hole position is detected in a mode of a bottom plate hole of the stand column, and the hole position deviation is controlled to be 0-2 mm.

6. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: in step four 2), push-and-pull drill bit is repeated several times from top to bottom after the expansion bolt is punched and is accomplished in order to clear up the downthehole piece that punches, and the bolt hole plane position is examined with square and ruler after the expansion bolt hole is punched and is accomplished, and the plane positional deviation control is at 0 ~ 1mm, penetrates the bolt hole that has been beaten with the expansion bolt expansion pipe, guarantees that the expansion pipe can penetrate in the hole smoothly.

7. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: in step four 4), measure the elevation of girder with spirit level and ruler after the installation is accomplished, guarantee that the elevation error is 0 ~ 10mm, measure two girder diagonal lengths with the ruler, guarantee that diagonal length deviation is 0 ~ 6mm, the surplus height deviation control of inspection butt welding seam is at 0 ~ 3mm, and butt welding seam leg height deviation control is at 0 ~ 3 mm.

8. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: and in the step four 5), after the connection beam, the upright post and the main beam are aligned, measuring the distance and the length of the connection beam by using a ruler, controlling the length deviation of the connection beam to be-10 mm, and controlling the height deviation of two ends of the connection beam to be 0-15 mm.

9. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: in the fifth step 4), in the process of removing the shaft cover, the pin shaft seat and the shaft sleeve, in the process of unloading the parts, the bolts and the like, the parts and the bolts are placed on the cloth liner and are sequentially placed in a subarea manner, and the number of the parts is counted to prevent the parts from being lost in the process of removing the parts; before the pin shaft is dismantled, the pin shaft is cleaned by a soft towel and a special cleaning oil sludge spray, and when the pin shaft is jammed in the dismantling process, the pin shaft is knocked and dismantled by a copper bar matched with a rubber hammer.

10. The non-navigation maintenance method of the large drain valve according to claim 1, characterized in that: and step six 6), placing the cushion blocks on the strip-shaped funnel structure at the lower part of the gate well of the drain valve, arranging cut angles which are mutually attached to the drain funnel structure of the gate well at the lower parts of the cushion blocks to ensure stability, arranging lifting lugs at the middle parts of the cushion blocks, arranging a control rod on the right side, and placing three cushion blocks, wherein two cushion blocks are main bearing cushion blocks, and one cushion block is used as a safety cushion.