Method for repairing deformation of in-service down-hole radial gate panel

Abstract

The invention provides a method for repairing deformation of an in-service down-hole radial gate panel, and solves the problem that the correction effect is difficult to achieve when conventional machinery and flame are directly adopted for correction under the condition that the radial gate panel is not disassembled. According to the method, through on-site repair practice, the deformation fold line of the radial gate panel is creatively slotted, the calibration plate is subjected to spot welding, and the auxiliary groove is adopted in the deformation fold line, so that during correction, the thickness of the plate at the deformation fold line can be reduced, the deformation fold line is easier to deform, the correction difficulty is reduced, and the correction efficiency is improved. And the expansion allowance is provided for thermal expansion and cold contraction of the plate in the deformation area during subsequent flame heating. The calibration plate can guide the mechanical correction value during mechanical correction, the purpose of guiding rapid completion of preliminary mechanical calibration is achieved, and a successful method is provided for repairing of a down-hole and large-thickness deformed radial gate panel.

Description

Technical Field

[0001] This invention relates to the field of arc-shaped gate panel repair technology, and in particular to a method for repairing deformation of in-service downhole arc-shaped gate panels. Background Technology

[0002] If a certain arc-shaped gate panel bulges and deforms in a local area, it will result in poor water-stopping performance when the gate is closed, causing jetting or vibration in the gaps.

[0003] Current maintenance techniques for curved gate panels mostly involve disassembling them and then performing mechanical and flame straightening on tooling. However, considering the narrow space inside the tunnel and the thickness of the curved gate panels to be repaired, disassembling and assembling the curved gate panels is quite troublesome, and sometimes impossible. This makes it impossible for existing straightening techniques to straighten in-service curved gate panels without disassembly. At the same time, when mechanical and flame straightening is applied directly to the curved gate panels, the large size and thickness of the panels, as well as the numerous stiffeners at the side water seal seat plates, make it difficult to achieve the desired straightening effect using conventional flame and mechanical straightening methods. Summary of the Invention

[0004] To address the problem in the background art that conventional mechanical and flame straightening methods are insufficient to achieve the desired correction effect without removing the arc-shaped gate panel, this invention proposes a method for repairing deformation of in-service downhole arc-shaped gate panels.

[0005] The technical solution of this invention is: a method for repairing the deformation of an in-service downhole arc-shaped gate panel, comprising the following steps:

[0006] S1, lift the arc-shaped gate panel upward to the maximum opening, ensuring that both sides of the gate leaf of the arc-shaped gate panel are detached from the water-stop embedded parts;

[0007] S2, Gouge the curved gate panel with air to create an auxiliary groove. The depth of the auxiliary groove is less than the thickness of the curved gate panel.

[0008] S3. Along the extension direction of the deformation fold line, several calibration plates are welded at intervals on the arc-shaped gate panel, which are arranged perpendicular to the deformation fold line. The welding point of the calibration plate and the arc-shaped gate panel is located in the deformation area. The length of the calibration plate covers the undeformed area and extends above the deformation area. There is a gap between the side of the calibration plate facing the arc-shaped gate panel and the deformation area to guide the correction amount of the arc-shaped gate panel.

[0009] S4, brackets are installed on both the backwater side and the water-facing side of the deformation zone of the arc-shaped gate panel, and a jacking device is installed on the brackets. One end of the jacking device on the water-facing side is pressed against the calibration plate, and one end of the jacking device on the backwater side is pressed against the backwater side of the arc-shaped gate panel.

[0010] S5, flame heating is applied to the auxiliary groove and deformation area. The heating temperature is lower than the phase change temperature of the plate of the arc gate panel. At the same time, according to the gap thickness between the calibration plate and the deformation area, the deformation area is mechanically corrected by the pushing device on both sides of the arc gate panel so that the calibration plate and the deformation area are in contact.

[0011] S6. Measure the deformation of the corrected arc-shaped gate panel. If the deformation is greater than the normal usage deformation range, continue mechanical correction until the deformation is within the normal usage deformation range. Once the deformation correction is complete, remove the calibration plate.

[0012] S7. Fill and weld the gap in the auxiliary groove until it is flush with its surface to complete the deformation repair.

[0013] Preferably, step S6 includes the following detailed steps:

[0014] S6.1 A suspended scanning platform is installed on the side wall of the backwater side or the water-facing side of the arc-shaped gate panel. A total station scanner is installed on both the upper and lower sides of the scanning platform so that the total station scanners on the upper and lower sides can work together to complete a full scan of the arc-shaped gate panel.

[0015] S6.2, a total station scanner is used to scan and process the arc-shaped gate panel to obtain the overall point cloud data of the arc-shaped gate panel;

[0016] S6.3, Based on the overall point cloud data of the arc-shaped gate panel, establish a deformation analysis coordinate system and perform deformation analysis to obtain the deformation of the arc-shaped gate panel;

[0017] S6.4 Compare the deformation amount obtained in step S6.3 with the normal usage deformation range value. If the deformation amount obtained in step S6.3 is greater than the normal usage deformation range value, continue mechanical correction until the deformation amount is within the normal usage deformation range value, complete the deformation correction, and remove the calibration plate.

[0018] Preferably, in step S6.4, when continuing the mechanical correction operation,

[0019] First, the deformation area is divided by marking lines to obtain several small deformation areas;

[0020] Then, during the repair process, a small deformed area after being divided is first heated with a flame, and then mechanically corrected. After the correction is completed, the point cloud of the small deformed area is rescanned for deformation analysis. If the deformation is greater than the normal range, the flame temperature, flame heating atmosphere, and the force point of the jacking device are adjusted, and the repair continues until the small deformed area is repaired. Then, other small deformed areas are repaired in sequence, and finally the overall deformation repair of the arc gate panel is completed.

[0021] Preferably, the deformation amount is the lateral straightness, and the normal use deformation range is the lateral straightness range of 0 to 7 mm.

[0022] Preferably, the flame heating is performed longitudinally on the water-facing side of the arc-shaped gate panel, and the flame temperature is between 500℃ and 700℃. During heating, a temperature monitoring device is used to monitor the temperature of the heating area of ​​the arc-shaped gate panel in real time.

[0023] Preferably, when using a full-station scanner, the scanning resolution is 1mm to 5mm.

[0024] Preferably, the arc-shaped gate panel and the calibration plate are connected by spot welding, and the spot welding position is located in the undeformed area.

[0025] Preferably, in step S7, before repairing the auxiliary groove, a plate of the same material as the curved panel is first filled into the auxiliary groove, and then the filled plate is welded to the curved panel.

[0026] Preferably, when performing flame heating in step S5, heating marks are first made at the deformed position of the arc-shaped gate panel to determine the flame heating position and heating shape; then, within the determined flame heating position, a small-scale medium- and high-temperature linear heating is first performed, and lateral oscillation is added while moving in a straight line to form a heating band of a certain width. After natural cooling, the correction is checked; finally, after confirming that the small-scale flame correction and mechanical correction have a corrective effect, the flame correction range is gradually increased, and multiple mechanical correction points are added within the correction range to straighten the gate edge.

[0027] Advantages of this invention: Through on-site repair practice, this invention creatively grooves and spot-welds calibration plates at the deformation fold lines of the arc-shaped gate panel. The auxiliary grooves at the deformation fold lines not only reduce the plate thickness at these points, making deformation easier and reducing the difficulty of correction, but also provide allowance for thermal expansion and contraction of the plate in the deformation zone during subsequent flame heating. The calibration plates can guide the mechanical correction amount during mechanical correction, achieving the goal of quickly completing the initial mechanical calibration.

[0028] By using a full-station scanner to scan and measure the point cloud model of the curved gate panel, we can obtain a more comprehensive picture of the deformation of the curved gate panel and guide the repair process.

[0029] Practice has shown that the repair process proposed in this invention, which combines "air gouging, preliminary correction guidance with calibration plate, flame correction, fine guidance with three-dimensional point cloud scanning and mechanical correction," provides a successful method for repairing deformed arc-shaped gate panels with downhole holes and large thicknesses, and can provide technical reference for similar repair work in future water conservancy projects. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram showing the layout and orientation of the jacking device during the repair of the arc-shaped gate panel in Example 1;

[0032] Figure 2 This is a schematic diagram showing the location of the auxiliary groove and the welding position of the calibration plate on the arc-shaped gate panel in Example 1;

[0033] In the diagram, 1. Side wall, 2. Concrete mounting platform, 3. Hinge seat, 4. Main support arm, 5. Hydraulic rod, 6. Auxiliary support arm, 7. Arc-shaped gate panel, 701. Deformation zone, 702. Deformation zigzag line, 703. Auxiliary groove, 8. Horizontal brace plate, 9. Calibration plate, 10. Handle, 11. Wall tie plate, 12. Connecting frame, 13. Pushing device. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Example 1: This example uses an eccentric hinged arc-shaped gate panel with dimensions of 4.8×5.4-140 (m), a radius of curvature of 9.0m, a thickness of 40.0mm, and made of Q355B material. The gate is operated by two hydraulic hoists: a main hoist (3800kN / 1000kN) operates the gate's opening and closing; and a secondary hoist (3000kN / 1000kN) operates the eccentric hinge to press or release the gate from the main water-stop rubber. The gate exhibits a localized bulge deformation on both sides towards the downstream side, with a maximum deformation of 33.0mm, as illustrated in the example. The connection structure of the arc-shaped gate panel 7 is as follows: Figure 1As shown, concrete mounting platforms 2 are fixedly installed on both side walls 1. A hinged seat 3 is installed on the water-facing side of the concrete mounting platform 2, and a main support arm 4 is hinged to the hinged seat 3. The other end of the main support arm 4 is fixedly connected to the backwater side of the arc-shaped gate panel 7. Multiple auxiliary support arms 6 are fixedly connected between the main support arm 4 and the arc-shaped gate panel 7. A hydraulic rod 5 is rotatably connected to the side wall 1, and the other end of the hydraulic rod 5 is hinged to the main support arm 4. A cross brace 8 is fixedly connected between the main support arm 4 and the auxiliary support arms 6 on both sides.

[0036] A method for repairing deformation of the panel of an in-service downhole arc-shaped gate includes the following steps:

[0037] S1, raise the arc-shaped gate panel 7 to its maximum opening, ensuring that both sides of the gate leaf of the arc-shaped gate panel 7 are detached from the water-stop embedded parts. The lower half of the arc-shaped gate panel is located below the scanning platform at an elevation of 146.50m, and the distance from the upstream breast wall is 0.4 to 1.3m.

[0038] S2, along the deformation fold line 702 of the arc-shaped gate panel 7, use an air gouging machine to perform air gouging grooves (e.g., Figure 2 As shown), an auxiliary groove 703 is obtained. The depth of the auxiliary groove 703 is less than the thickness of the arc gate panel. The depth of the auxiliary groove 703 is 50% to 80% of the thickness of the arc gate panel 7. In this embodiment, the depth of the auxiliary groove 703 is 20mm. The grooving is carried out in sections and multiple times. After each section is grooved, the deformation correction in that area is completed before the next section is grooved.

[0039] In this embodiment, the auxiliary groove 703 has an isosceles trapezoidal groove structure with a wide opening and a narrow bottom. This isosceles trapezoidal groove structure can provide a larger deformation allowance at the auxiliary groove 703 during deformation repair, while minimizing damage to the structural strength of the original plate of the arc-shaped gate panel 7.

[0040] Grooving is used at the deformation fold line 702. During the correction process, this not only reduces the thickness of the sheet material at the deformation fold line 702, making it easier for deformation to occur at the deformation fold line 702 and reducing the difficulty of correction, but also provides deformable amount for the thermal expansion and contraction of the sheet material in the deformation zone and mechanical correction.

[0041] S3, along the extension direction of the deformation fold line 702, several calibration plates 9 are welded at intervals on the arc-shaped gate panel 7, which are perpendicular to the deformation fold line and connected to the cloth by spot welding. The spot welding position is located on one side of the undeformed area of ​​the arc-shaped gate panel 7 near the auxiliary groove 703.

[0042] like Figure 1As shown, the length of the calibration plate 9 covers the undeformed area and extends above the deformed area 701. There is a gap between the side of the calibration plate 9 facing the arc-shaped gate panel 7 and the deformed area 701 to guide the correction amount of the arc-shaped gate panel 7.

[0043] S4, brackets are installed on both the backwater side and the frontwater side of the deformation zone 701 of the arc-shaped gate panel 7, such as Figure 1 As shown, in this embodiment, the front support uses a wall-connecting plate 11 connected to the side wall 1, and the rear support uses a connecting frame 12 mounted on the cross brace 8. Three jacking devices 13 are longitudinally installed along the deformation fold line between the wall-connecting plate 11 and the calibration plate 9, and between the connecting frame 12 and the arc-shaped gate panel 7. In this embodiment, the jacking devices 13 are 50T hydraulic jacks, and each hydraulic jack is 300mm laterally from the edge of the arc-shaped gate panel 7. The placement of each jack is related to the area to be repaired and the auxiliary tooling.

[0044] S5, flame heating is applied to the auxiliary groove 703 and the deformation zone 701. The heating temperature is lower than the phase change temperature of the plate of the arc gate panel 7. During flame heating, longitudinal heating is performed on the water-facing side of the arc gate panel 7. The flame temperature is between 500℃ and 700℃. During heating, a temperature monitoring device is used to monitor the temperature of the heating area of ​​the arc gate panel in real time. The flame temperature must not exceed 720℃. Repeated heating at the same location is not allowed.

[0045] Simultaneously, when performing flame heating, first mark the deformation position on the arc-shaped gate panel 7 to determine the flame heating position and shape; then, within the determined flame heating position, first perform a small-scale medium- and high-temperature linear heating, while moving in a straight line and adding lateral oscillation to form a heating band of a certain width. Do not repeatedly heat in the same position, and do not use water cooling. Check the correction after natural cooling; finally, after confirming that the small-scale flame correction and mechanical correction have a corrective effect, gradually increase the flame correction range. The deformation of the gate edge varies, and multiple mechanical correction points can be added within the correction range to make the edge of the arc-shaped gate panel 7 as straight as possible.

[0046] Meanwhile, based on the gap thickness between the calibration plate 9 and the deformation zone 701, the deformation zone 701 is mechanically corrected by the pushing devices 13 on both sides of the arc-shaped gate panel 7, so that the calibration plate 9 and the deformation zone 701 fit together.

[0047] S6. Measure the deformation of the corrected arc-shaped gate panel 7. If the deformation is greater than the normal usage deformation range, continue mechanical correction until the deformation is within the normal usage deformation range, then complete the deformation correction and remove the calibration plate. In this embodiment, the deformation is the lateral straightness, and the normal usage deformation range is the lateral straightness range of 0 to 7 mm.

[0048] Specifically, in this embodiment, step S6 includes the following detailed steps:

[0049] S6.1 A suspended scanning platform is installed on the side wall of the backwater side or the water-facing side of the arc gate panel 7. A Leica Nova MS60 total station scanner is installed on both the upper and lower sides of the scanning platform so that the total station scanners on the upper and lower sides can work together to complete a full scan of the arc gate panel 7.

[0050] S6.2, a total station scanner is used to scan the arc gate panel 7 with a scanning resolution of 1mm to 5mm. The scanning resolution of the water-stopping part of the arc gate panel 7 is 1.0mm. After obtaining point cloud data from multiple stations, the overall point cloud data of the arc gate panel 7 is obtained through registration, filtering, and cropping operations.

[0051] S6.3, Based on the overall point cloud data of the arc-shaped gate panel 7, establish a deformation analysis coordinate system and perform deformation analysis to obtain the deformation position and deformation amount of the arc-shaped gate panel;

[0052] S6.4 Compare the deformation amount obtained in step S6.3 with the normal usage deformation range value. If the deformation amount obtained in step S6.3 is greater than the normal usage deformation range value, continue mechanical correction until the deformation amount is within the normal usage deformation range value, complete the deformation correction, and remove the calibration plate.

[0053] In step S6.4 above, when continuing the mechanical correction operation, firstly, the deformation area 701 is divided into several small deformation areas by marking lines.

[0054] Then, during the repair process, an iterative repair method is adopted. First, a small deformed area after being divided is heated by flame, and then mechanical correction is performed. After the correction is completed, the point cloud of the small deformed area is re-scanned for deformation analysis. If the deformation is greater than the normal deformation range, the flame temperature, flame heating atmosphere, and the force point of the jacking device are adjusted to continue the repair until the small deformed area is repaired. Then, other small deformed areas are repaired in sequence to finally complete the overall deformation repair of the arc gate panel 7.

[0055] S7. When repairing the gap at the auxiliary groove 703, first fill the auxiliary groove 703 with a plate of the same material as the arc gate panel 7, and then weld the filled plate to the arc gate panel 7 until it is flush with its surface. Welding should be done in small batches and multiple times. After welding, it should be allowed to cool naturally before the next welding can be carried out to avoid excessive stress concentration and reduce the amount of deformation until the deformation repair is completed.

[0056] Based on the above repair method, a total of two repairs were performed. After each repair, the arc-shaped gate panel 7 was scanned and measured to obtain the deformation of the arc-shaped gate panel 7 after repair. The specific test results are shown in the table below:

[0057] Serial Number Repair process Maximum deformation (mm) 1 Repair the front arc gate panel 33.0 2 After the first repair 10.0 3 After the second repair 2.0

[0058] After two repairs, the maximum deformation of the arc-shaped gate panel 7 was reduced from 33.0 mm to 2.0 mm. Operational testing confirmed that the water-stopping requirements were met, and the repair work achieved its intended objectives.

[0059] This invention, through field repair practice, yielded a method for repairing the panel of an in-service downhole arc gate. It innovatively involves slotting at the deformation fold line 702 of the arc gate panel 7 and spot-welding a calibration plate 9 to guide rapid preliminary mechanical calibration, reducing the number of corrections and the error range after preliminary calibration. Then, a point cloud model of the arc gate panel 7 is obtained through total-station scanning measurement to more comprehensively understand the deformation of the arc gate panel and guide the repair process. Practice shows that the repair process proposed in this invention, combining "air gouging, preliminary calibration plate guidance, flame correction, and detailed guidance from 3D point cloud scanning with mechanical correction," provides a successful method for repairing deformed arc gate panels with downhole holes and significant thickness, and can provide technical reference for similar repair work in future water conservancy projects.

[0060] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims and not by the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A method for repairing deformation of the panel of an in-service submersible arc-shaped gate, characterized in that, The steps include: S1, raising the arc-shaped gate panel to its maximum opening, ensuring that both sides of the gate leaf of the arc-shaped gate panel are detached from the water-stop embedded parts; S2, Gouge the curved gate panel with air to create an auxiliary groove. The depth of the auxiliary groove is less than the thickness of the curved gate panel. S3, along the extension direction of the deformation fold line, several calibration plates are welded at intervals on the arc-shaped gate panel, which are arranged perpendicular to the deformation fold line. The length of the calibration plate covers the undeformed area and extends to the top of the deformed area. There is a gap between the side of the calibration plate facing the arc-shaped gate panel and the deformed area. S4, brackets are installed on both the backwater side and the water-facing side of the deformation zone of the arc-shaped gate panel, and a jacking device is installed on the brackets. One end of the jacking device on the water-facing side is pressed against the calibration plate, and one end of the jacking device on the backwater side is pressed against the backwater side of the arc-shaped gate panel. S5, flame heating is applied to the auxiliary groove and deformation area. The heating temperature is lower than the phase change temperature of the plate of the arc gate panel. At the same time, according to the gap thickness between the calibration plate and the deformation area, the deformation area is mechanically corrected by the pushing device on both sides of the arc gate panel so that the calibration plate and the deformation area are in contact. S6. Measure the deformation of the corrected arc-shaped gate panel. If the deformation is greater than the normal usage deformation range, continue mechanical correction until the deformation is within the normal usage deformation range. Once the deformation correction is complete, remove the calibration plate. S7. Fill and weld the gap in the auxiliary groove until it is flush with its surface to complete the deformation repair.

2. The method for repairing deformation of the panel of an in-service submerged arc-shaped gate as described in claim 1, characterized in that: S6 includes the following detailed steps. S6.1 A suspended scanning platform is installed on the side wall of the backwater side or the water-facing side of the arc-shaped gate panel. A total station scanner is installed on both the upper and lower sides of the scanning platform so that the total station scanners on the upper and lower sides can work together to complete a full scan of the arc-shaped gate panel. S6.2, a total station scanner is used to scan and process the arc-shaped gate panel to obtain the overall point cloud data of the arc-shaped gate panel; S6.3, Based on the overall point cloud data of the arc-shaped gate panel, establish a deformation analysis coordinate system and perform deformation analysis to obtain the deformation of the arc-shaped gate panel; S6.4 Compare the deformation amount obtained in step S6.3 with the normal usage deformation range value. If the deformation amount obtained in step S6.3 is greater than the normal usage deformation range value, continue mechanical correction until the deformation amount is within the normal usage deformation range value, complete the deformation correction, and remove the calibration plate.

3. The method for repairing deformation of the panel of an in-service submerged arc-shaped gate as described in claim 2, characterized in that: In step S6.4, when continuing the mechanical correction operation, First, the deformation area is divided by marking lines to obtain several small deformation areas; Then, during the repair process, a small deformed area after being divided is first heated with a flame, and then mechanically corrected. After the correction is completed, the point cloud of the small deformed area is rescanned for deformation analysis. If the deformation is greater than the normal range, the flame temperature, flame heating atmosphere, and the force point of the jacking device are adjusted, and the repair continues until the small deformed area is repaired. Then, other small deformed areas are repaired in sequence, and finally the overall deformation repair of the arc gate panel is completed.

4. A method for repairing deformation of the panel of an in-service submerged arc-shaped gate as described in any one of claims 1-3, characterized in that: The deformation amount is the lateral straightness, and the normal use deformation range is the lateral straightness range of 0 to 7 mm.

5. The method for repairing deformation of the panel of an in-service submerged arc-shaped gate as described in claim 1, characterized in that: During the flame heating process, longitudinal heating is performed on the water-facing side of the arc-shaped gate panel. The flame temperature is between 500℃ and 700℃. During heating, a temperature monitoring device is used to monitor the temperature of the heating area of ​​the arc-shaped gate panel in real time.

6. A method for repairing deformation of the panel of an in-service downhole arc-shaped gate as described in claim 2 or 3, characterized in that: When using a full-station scanner, the scanning resolution is 1mm to 5mm.

7. The method for repairing deformation of the panel of an in-service submerged arc-shaped gate as described in claim 1, characterized in that: The arc-shaped gate panel and the calibration plate are connected by spot welding, and the spot welding position is located in the undeformed area.

8. The method for repairing deformation of the panel of an in-service submerged arc-shaped gate as described in claim 1, characterized in that: In step S7, before repairing the auxiliary groove, first fill the auxiliary groove with a plate of the same material as the arc-shaped gate panel, and then weld the filled plate to the arc-shaped gate panel.

9. A method for repairing deformation of an in-service submerged arc-shaped gate panel as described in claim 1, characterized in that: When performing flame heating in step S5, first mark the deformation position of the arc-shaped gate panel to determine the flame heating position and shape; then, within the determined flame heating position, perform small-scale medium and high temperature linear heating, while moving in a straight line and adding lateral swing to form a heating band of a certain width. After natural cooling, check the correction situation; finally, after confirming that the small-scale flame correction and mechanical correction have a corrective effect, gradually increase the flame correction range and add multiple mechanical correction points within the correction range to straighten the gate edge.

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