A large cutter suction dredger deck pump single pump construction modification method

Abstract

The application discloses a large-scale cutter suction ship deck pump single-pump construction reconstruction method and belongs to the technical field of dredging engineering. The large-scale cutter suction ship deck pump single-pump construction reconstruction method comprises the following steps: S1, adding a gate valve system and optimizing a signal; S2, optimizing a pipeline and controlling water sealing; and S3, reconstructing an electrical control logic. The gate valve system adding operation of the step S1 is specifically as follows: workers first organize to disassemble mud pipes connected before and after the underwater pump, disassemble the underwater pump body and the gear box, and leave space for the subsequent installation of the gate valve system. The technical reconstruction effectively improves the single-pump construction efficiency, guarantees the service life of the equipment, eliminates the risk of pump failure, effectively prevents the situation that the underwater pump cannot be used and the single-deck pump cannot be constructed before technical reconstruction, the ship is stopped and production is stopped, and the situation is not conducive, thereby ensuring that the overall project development is good.

Description

Technical Field

[0001] This invention relates to the field of dredging engineering technology, and in particular to a method for the construction and modification of a single pump on a large cutter suction dredger deck pump. Background Technology

[0002] In existing technologies, cutter suction dredgers typically employ a 3-pump system (dual-deck mud pumps + submersible mud pump) for dredging operations. The choice between 3-pump or dual-pump operation depends on the blow distance. However, single-pump operation on cutter suction dredgers primarily utilizes a single submersible pump. In this mode, the submersible pump is submerged below the waterline, allowing for both mud and sand intake and discharge. But under specific conditions (such as in shallow water, low-intensity dredging, or when the submersible pump fails), it is necessary to switch to a single-deck pump operation mode.

[0003] Traditional deck single-pump construction has the following drawbacks: 1. Insufficient suction: When using a single deck pump, the distance between the pump and the suction port is too far, resulting in insufficient suction during startup and inability to effectively pump out mud and sand; 2. Cavitation and vibration: The distance and height of the pump from the suction port make it prone to cavitation and failure to pump water, as well as causing cavitation and abnormal vibration in the mud pump, shortening the equipment's lifespan; 3. Low efficiency: There is a lack of standardized technical modification solutions, temporary modifications are time-consuming, and pipeline connections are unstable, affecting the continuity of construction; 4. Signal control defects: The gate valve opening and closing signal feedback is incompatible with the hydraulic system, resulting in a high risk of pump start-up failure. Summary of the Invention

[0004] The purpose of this invention is to solve the problems existing in the prior art and to propose a method for the construction and modification of a single pump for a large cutter suction dredger deck pump.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for modifying a single-pump deck pump on a large cutter suction dredger includes the following steps:

[0007] S1: Gate valve system installation and signal optimization;

[0008] S2: Pipeline optimization and water seal control;

[0009] S3: Electrical control logic reconfiguration.

[0010] Preferably, the specific operation for installing the gate valve system described in step S1 is as follows:

[0011] The staff first organized the disassembly of the mud pipes connecting the front and rear of the underwater pump, and removed the underwater pump body and gearbox (the underwater pump gearbox was damaged and needed to be repaired) to make room for the subsequent installation of the gate valve system;

[0012] A gate valve system was added to the front end of the original underwater pump. The distance from the gate valve system to the suction port of the dredging pipeline was 15m, ensuring that the gate valve could be submerged below the waterline after the bridge was lowered. The gate valve operation switch was extended to the control platform.

[0013] Remove the deck intake water supply valve from the ship and use it as an intake valve.

[0014] Preferably, the specific operation of signal optimization in step S1 is: signal feedback improvement;

[0015] The 4-core signal line of the original suction gate valve at the tail end of the bridge is extended to the gate valve system. The opening and closing signal feedback is realized by using a PNP proximity switch, and the status is displayed by the indicator light on the driver's cab.

[0016] Preferably, the pipeline optimization operation steps in step S2 are as follows:

[0017] Design the dredging pipeline route, install new mud pipes to connect the gate valve system to the deck pump, make good use of the existing mud pipes, and adjust the position of the mud pipe route by adding elbows and cutting the mud pipes to adjust the welding flanges to connect the deck pump to the suction port.

[0018] The water sealing control operation steps described in step S2 are as follows:

[0019] The workers lowered the cutter head to a depth of 5 meters below the waterline;

[0020] Close the gate valve, notify the mud pump to seal the water, and add sealing water into the mud pipe for 30 minutes. At this time, the front end of the deck pump is full of water.

[0021] Workers operate the deck pump to start it, and then open the gate valve within 2-3 seconds to complete the pump start-up operation, after which dredging can be carried out.

[0022] Preferably, the electrical control logic reconfiguration step in step S3 is as follows:

[0023] Connect the signal line of the hydraulic vacuum release valve to the solenoid valve of the bridge gate valve, and control the gate valve action through the linkage of the oil cylinder.

[0024] A manual short-circuit switch was added to resolve pump start-up failures caused by signal conflicts.

[0025] Preferably, the dredging pipeline includes several interconnected pipes, which are sequentially configured as a sludge suction pipe, a variable flange connecting steel pipe, a new steel sludge pipe, a bent steel pipe fitting, an armored climbing hose (because the armored hose has a steel ring inside, using the armored hose will not cause excessive suction during construction, and the hose will not collapse or deform, resulting in a smaller suction port), and a deck steel pipe. The end of the deck steel pipe away from the armored climbing hose is connected to the deck pump. The bent steel pipe fitting consists of two 25-degree bent steel pipes and one 15-degree bent steel pipe. The gate valve system is set between the variable flange connecting steel pipe and the bent steel pipe fitting. The gate valve system includes a gate valve body. The vacuum release valve is set at the suction port end of the sludge suction pipe.

[0026] Preferably, pipe positioning brackets are installed at both ends of the mud suction pipe, the variable flange connecting steel pipe, the new steel mud pipe, the bent steel pipe fitting, the armored climbing hose, the deck steel pipe, and the gate valve body to prevent vibration displacement during construction.

[0027] Preferably, both ends of the mud suction pipe, the variable flange connecting steel pipe, the new steel mud pipe, the bent steel pipe fitting, the armored climbing hose, the deck steel pipe, and the gate valve body are respectively provided with a first flange and a second flange. Both the first flange and the second flange are provided with annular grooves, and sealing gaskets are provided in the annular grooves. Each first flange is provided with a positioning part for positioning its adjacent second flange.

[0028] Preferably, the positioning part includes an electric push rod fixed on the first flange, an annular plate disposed at the movable end of the electric push rod, a plurality of side plates evenly disposed on the outer side of the annular plate in a circular pattern, a rotating rod rotatably connected to the side plates, and an abutment plate disposed at the end of the rotating rod away from the side plates. The abutment plate abuts against the second flange. The first flange is fixed with a positioning rod, and the second flange is provided with a positioning hole that cooperates with the positioning rod.

[0029] Preferably, a fixing pipe is fixedly provided on the outer side of the first flange, a guide block is fixedly provided on the inner side wall of the fixing pipe, and a track groove is provided on the rotating rod to slide with the guide block. The track groove includes a spiral groove and a straight groove that are interconnected.

[0030] Compared with the prior art, the present invention provides a method for the construction and modification of a single pump on a large cutter suction dredger deck pump, which has the following beneficial effects:

[0031] 1. This method for upgrading a large cutter suction dredger deck pump to a single pump, through the addition and signal optimization of the gate valve system, pipeline optimization and water sealing control, and electrical control logic reconstruction, can improve the suction and discharge efficiency of the deck pump in single pump mode, ensuring controllable mud concentration; reduce cavitation and equipment vibration, extending the service life of key components; establish a standardized technical upgrade process, shortening emergency upgrade time; solve the compatibility problem between the gate valve signal feedback and the control system, ensuring construction safety; thereby preventing the adverse situation of ship shutdown and production stoppage caused by the inability to use underwater pumps or the inability to construct single deck pumps before the technical upgrade, ensuring the overall smooth operation of the project.

[0032] 2. The single-pump construction and modification method for the large cutter suction dredger deck pump uses a positioning part on the first flange to position the adjacent second flange, replacing the method of fixing the two flanges by tightening multiple bolts. This method is simple and quick to operate, avoids the phenomenon of bolt loosening during long-term use, which leads to unstable connection between flanges, and improves pipeline connection efficiency and stability between flanges. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the dredging pipeline of the present invention;

[0034] Figure 2 This is a schematic diagram of the connection structure between the first flange and the second flange of the present invention;

[0035] Figure 3 This is a cross-sectional structural diagram of the first flange and the second flange of the present invention;

[0036] Figure 4 For the present invention Figure 3 Enlarged structural diagram of section A in the middle;

[0037] Figure 5 This is a schematic diagram of the external structure of the first flange of the present invention;

[0038] Figure 6 This is a schematic diagram of the rotating rod of the present invention.

[0039] In the diagram: 1. Dredging pipeline; 101. Sediment suction pipe; 1011. Vacuum release valve; 102. Variable flange connecting steel pipe; 103. New steel mud pipe; 104. Bent steel pipe fitting; 105. Armored climbing hose; 106. Deck steel pipe; 107. Gate valve body; 108. Pipe positioning bracket; 2. First flange; 201. Positioning rod; 3. Second flange; 301. Positioning hole; 4. Annular groove; 401. Sealing gasket; 5. Electric push rod; 501. Annular plate; 502. Side plate; 503. Rotating rod; 504. Abutment plate; 6. Fixed pipe; 601. Guide block; 7. Track groove; 701. Spiral groove; 702. Straight groove. Detailed Implementation

[0040] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0041] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0042] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0043] Example: Refer to Figure 1 A method for constructing and modifying a single-pump deck pump on a large cutter suction dredger includes the following steps:

[0044] S1: Gate valve system installation and signal optimization;

[0045] S2: Pipeline optimization and water seal control;

[0046] S3: Electrical control logic reconfiguration.

[0047] Furthermore, the specific operation for installing the gate valve system described in step S1 is as follows:

[0048] First, the staff organized the disassembly of the mud pipes connecting the front and rear of the underwater pump, and removed the underwater pump body and gearbox to leave space for the subsequent installation of the gate valve system.

[0049] 2. Install a gate valve system at the front end of the original underwater pump. The distance from the gate valve system to the suction port of dredging pipeline 1 is 15m. Ensure that the gate valve can be submerged below the waterline after the bridge is lowered. Extend the gate valve operation switch to the control platform.

[0050] 3. Remove the deck intake water supply valve from the ship and use it as an intake valve to prevent the intake pipe from running dry.

[0051] Furthermore, the specific operation of signal optimization described in step S1 is: signal feedback improvement;

[0052] The 4-core signal line of the original suction gate valve at the tail end of the bridge is extended to the gate valve system. A PNP proximity switch is used to realize the opening and closing signal feedback. Watertightness is ensured, and the opening and closing signal of the gate valve is displayed through the indicator light on the control panel.

[0053] Furthermore, the pipeline optimization operation steps described in step S2 are as follows:

[0054] Design the dredging pipeline route 1, install new mud pipes to connect the gate valve system to the deck pump, make good use of the existing mud pipes, and adjust the position of the mud pipe route by adding elbows and cutting the mud pipes to adjust the welding flanges, so as to connect the path from the deck pump to the suction port. On-site use of ramp hoses allows for flexible adjustment of the mud pipe route.

[0055] Furthermore, the water sealing control operation steps described in step S2 are as follows:

[0056] 1. The staff lowered the cutter head to a depth of 5 meters below the waterline;

[0057] 2. Close the gate valve, notify the mud pump to seal the water, and add sealing water into the mud pipe for 30 minutes. At this time, the front end of the deck pump is full of water. The sealing water system is a protection system of the cutter suction dredger to prevent mud and sand from entering the mud pump shaft and other key components during the construction process, which would cause wear.

[0058] 3. The staff will start the deck pump and open the gate valve within 2-3 seconds. After the pump is started, the dredging operation can be carried out.

[0059] Furthermore, the electrical control logic reconfiguration step described in step S3 is as follows:

[0060] Connect the signal line of the hydraulic vacuum release valve 1011 to the solenoid valve of the bridge gate valve, and connect the gate valve oil pipe to the cylinder for opening and closing the gate valve. Control the gate valve action through the linkage of the cylinder. The control system of the vacuum release valve 1011 is temporarily used on the driver's cab to control the closing of the gate valve.

[0061] A manual short-circuit switch was added to resolve pump start-up failures caused by signal conflicts.

[0062] Specifically, through the above-mentioned technical improvements, the present invention achieves the following significant effects:

[0063] 1. Improved efficiency: The single-pump construction efficiency reaches 70% of the dual-pump mode, the discharge pressure is stable within 0.8MPa, and the mud concentration can be controlled at 20-25%.

[0064] 2. Equipment protection: Cavitation rate reduced by 90%, mud pump vibration value reduced from 4.8 mm / s to 3.2 mm / s.

[0065] 3. Cost savings: The technical upgrade time has been shortened from 10 days to 3 days, and fuel consumption has been reduced by 20% (0.8L / m). 3 ).

[0066] 4. Enhanced safety: The success rate of gate valve signal feedback is increased to 100%, eliminating the risk of pump start-up failure.

[0067] Most importantly, it is crucial to prevent adverse situations such as ship shutdowns and production stoppages caused by the inability to use underwater pumps or the inability to construct single-deck pumps before the technical upgrade, and to ensure the overall smooth progress and operation of the project.

[0068] However, the following points should be noted: 1. Overload operation is strictly prohibited: In single pump mode, the continuous power should be ≤85% of the rated power to avoid motor burnout; 2. Soil adaptability limitations: Single pumps are not suitable for soil layers containing large-diameter stones (>10cm) or high-cohesion soil layers; 3. Cooperative operation: Coordinate with positioning anchor boats to reduce the impact of ship lateral resistance on the pump.

[0069] Reference Figure 1 As a preferred technical solution of the present invention, the dredging pipeline 1 includes several interconnected pipes, which are sequentially configured as a sludge suction pipe 101, a variable flange connecting steel pipe 102, a newly calibrated steel sludge pipe 103, a bent steel pipe fitting 104, an armored climbing hose 105, and a deck steel pipe 106. The end of the deck steel pipe 106 away from the armored climbing hose 105 is connected to the deck pump. The bent steel pipe fitting 104 consists of two 25-degree bent steel pipes and one 15-degree bent steel pipe. A gate valve system is set between the variable flange connecting steel pipe 102 and the bent steel pipe fitting 104. The gate valve system includes a gate valve body 107. The gate valve needs to be newly installed and calibrated inlet and outlet gate valve sealing pipes to prevent sludge from wearing the shaft seal rubber ring. A vacuum release valve 1011 is set at the suction end of the sludge suction pipe 101.

[0070] Reference Figure 1 As a preferred technical solution of the present invention, pipe positioning brackets 108 are installed at both ends of the mud suction pipe 101, the variable flange connecting steel pipe 102, the new steel mud pipe 103, the bent steel pipe fitting 104, the armored climbing hose 105, the deck steel pipe 106, and the gate valve body 107 to prevent pipeline vibration and displacement during construction.

[0071] Reference Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 5 and Figure 6As a preferred technical solution of the present invention, the mud suction pipe 101, the variable flange connecting steel pipe 102, the new steel mud pipe 103, the bent steel pipe fitting 104, the armored climbing hose 105, the deck steel pipe 106, and the gate valve body 107 are respectively provided with a first flange 2 and a second flange 3 at both ends. The first flange 2 and the second flange 3 are each provided with an annular groove 4, and a sealing gasket 401 is provided in the annular groove 4. Each first flange 2 is provided with a positioning part for positioning the adjacent second flange 3.

[0072] Furthermore, the positioning part includes an electric push rod 5 fixed on the first flange 2, an annular plate 501 disposed at the movable end of the electric push rod 5, a plurality of side plates 502 evenly disposed on the outer side of the annular plate 501, a rotating rod 503 rotatably connected to the side plates 502, and an abutment plate 504 disposed at the end of the rotating rod 503 away from the side plates 502. The abutment plate 504 abuts against the second flange 3. A positioning rod 201 is fixed on the first flange 2, and a positioning hole 301 that cooperates with the positioning rod 201 is opened on the second flange 3.

[0073] Furthermore, a fixed pipe 6 is fixedly provided on the outer side of the first flange 2, and a guide block 601 is fixedly provided on the inner side wall of the fixed pipe 6. A track groove 7 is provided on the rotating rod 503 to slide and cooperate with the guide block 601. The track groove 7 includes a spiral groove 701 and a straight groove 702 that are interconnected.

[0074] Specifically, when two adjacent pipes of the dredging pipeline 1 are connected, the end of the abutment plate 504 is far from the central axis of the first flange 2, which facilitates the abutment of the second flange 3 with the first flange 2 and prevents the abutment plate 504 from blocking the second flange 3 from approaching the first flange 2. Then, the positioning rod 201 of the first flange 2 is inserted into the positioning hole 301 of the second flange 3 to prevent misalignment when the first flange 2 and the second flange 3 are assembled and connected. Then, the electric push rod 5 is controlled to move, so that the movable end of the electric push rod 5 drives the annular plate 501 to move away from the first flange 2 and the second flange 3. The movable end of the electric push rod 5 drives the rotating rod 503 and the abutment plate 504 to move through the side plate 502, so that the abutment plate 504 moves closer to the first flange 2 and the second flange 3. During this period, the track groove 7 on the rotating rod 503 and the fixed pipe 6 are connected. The guide block 601 cooperates with the rotating rod 503 to drive the abutment plate 504 to rotate relative to the side plate 502, thereby rotating the abutment plate 504 to a position close to the central axis of the second flange 3. At this time, the guide block 601 is placed in the straight groove 702, and the rotating rod 503 no longer rotates. With the continuous operation of the electric push rod 5, the abutment plate 504 finally abuts against the side of the second flange 3 away from the first flange 2. The sealing gaskets 401 of the first flange 2 and the second flange 3 are squeezed and deformed, realizing the rapid assembly of the first flange 2 and the second flange 3. This replaces the method of fixing the two flanges by tightening multiple bolts. The operation is simple and quick, avoiding the phenomenon of bolt loosening during long-term use, which leads to unstable connection between flanges. This improves the efficiency of pipeline connection and the stability between flanges.

[0075] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for constructing and modifying a single-pump deck pump on a large cutter suction dredger, characterized in that, Includes the following steps: S1: Gate valve system installation and signal optimization; S2: Pipeline optimization and water seal control; S3: Electrical control logic reconfiguration; The specific operation for installing the gate valve system described in step S1 is as follows: The staff first organized the disassembly of the mud pipes connecting the front and rear of the underwater pump, and removed the underwater pump body and gearbox to make room for the subsequent installation of the gate valve system. A gate valve system was installed at the front end of the original underwater pump. The distance from the gate valve system to the suction port of the dredging pipeline (1) was 15m. This ensured that the gate valve could be submerged below the waterline after the bridge was lowered. The gate valve operation switch was extended to the control platform. Remove the deck intake water valve from the ship and use it as an intake valve; The electrical control logic reconfiguration steps described in step S3 are as follows: Connect the signal line of the hydraulic vacuum release valve (1011) to the solenoid valve of the bridge gate valve, and control the gate valve action through the linkage of the oil cylinder; A manual short-circuit switch was added to resolve pump start-up failures caused by signal conflicts; The dredging pipeline (1) includes several interconnected pipes, which are sequentially configured as a mud suction pipe (101), a variable flange connecting steel pipe (102), a new steel mud pipe (103), a bent steel pipe fitting (104), an armored climbing hose (105), and a deck steel pipe (106). The end of the deck steel pipe (106) away from the armored climbing hose (105) is connected to the deck pump. The bent steel pipe fitting (104) consists of two 25-degree bent steel pipes and one 15-degree bent steel pipe. The gate valve system is set between the variable flange connecting steel pipe (102) and the bent steel pipe fitting (104). The gate valve system includes a gate valve body (107). The vacuum release valve (1011) is set at the suction end of the mud suction pipe (101). The mud suction pipe (101), the variable flange connecting steel pipe (102), the new steel mud pipe (103), the bent steel pipe fitting (104), the armored climbing hose (105), the deck steel pipe (106), and the gate valve body (107) are all provided with a first flange (2) and a second flange (3) at both ends. The first flange (2) and the second flange (3) are all provided with an annular groove (4). A sealing gasket (401) is provided in the annular groove (4). Each first flange (2) is provided with a positioning part for positioning the adjacent second flange (3). The positioning part includes an electric push rod (5) fixed on the first flange (2), an annular plate (501) disposed at the movable end of the electric push rod (5), a number of side plates (502) evenly disposed on the outer side of the annular plate (501), a rotating rod (503) rotatably connected to the side plate (502), and an abutment plate (504) disposed at the end of the rotating rod (503) away from the side plate (502). The abutment plate (504) abuts against the second flange (3). A positioning rod (201) is fixed on the first flange (2), and a positioning hole (301) is opened on the second flange (3) to cooperate with the positioning rod (201).

2. The method for constructing and modifying a single pump on a large cutter suction dredger deck pump according to claim 1, characterized in that, The specific operation of signal optimization described in step S1 is: signal feedback improvement; The 4-core signal line of the original suction gate valve at the tail end of the bridge is extended to the gate valve system. The opening and closing signal feedback is realized by using a PNP proximity switch, and the status is displayed by the indicator light on the driver's cab.

3. The method for constructing and modifying a single pump on a large cutter suction dredger deck pump according to claim 1, characterized in that, The pipeline optimization operation steps described in step S2 are as follows: Design the dredging pipeline (1) route, install new mud pipes to connect the gate valve system to the deck pump, make good use of the existing mud pipes, and adjust the position of the mud pipe route by adding elbows and cutting the mud pipes to adjust the welding flanges to connect the deck pump to the suction port. The water sealing control operation steps described in step S2 are as follows: Workers lowered the cutter head to a depth of 5 meters below the waterline; Close the gate valve, notify the mud pump to seal the water, and add sealing water into the mud pipe for 30 minutes. At this time, the front end of the deck pump is full of water. Workers operate the deck pump to start it, and then open the gate valve within 2-3 seconds to complete the pump start-up operation, after which dredging can be carried out.

4. The method for constructing and modifying a single pump on a large cutter suction dredger deck pump according to claim 1, characterized in that, The mud suction pipe (101), the variable flange connecting steel pipe (102), the new steel mud pipe (103), the bent steel pipe fitting (104), the armored climbing hose (105), the deck steel pipe (106), and the gate valve body (107) are all equipped with pipe positioning brackets (108) at both ends.

5. The method for constructing and modifying a single pump on a large cutter suction dredger deck pump according to claim 1, characterized in that, A fixed pipe (6) is fixed on the outside of the first flange (2), and a guide block (601) is fixed on the inner wall of the fixed pipe (6). A track groove (7) that slides with the guide block (601) is opened on the rotating rod (503). The track groove (7) includes a spiral groove (701) and a straight groove (702) that are interconnected.

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