Inlet Ball Valve Pivot Bushing Replacement in Confined Maintenance Space
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Solution Overview
Problem
The existing methods for replacing the bushing and seal of an inlet ball valve disc pivot in hydropower stations are cumbersome, labor-intensive, and require significant space, posing safety risks due to potential water leakage and equipment damage.
Innovation Solution
A tool comprising a support frame with adjustable rings and support assemblies, a support shaft, and a driving ring for rapid replacement of the bushing and seal, reducing the space requirement and improving operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional chain hoist with support plate is used for replacing bushing and seal, then the replacement process can be performed, but the operating space required is large and the selection of support points is restrictive
Solution Approach 1:
The tool is divided into multiple functional modules: a support frame with adjustable support points, a driving ring for bushing removal, and a seal removal mechanism. This segmentation allows each component to perform its specific function independently, enabling the tool to operate in confined spaces while maintaining ease of replacement operation.
Solution Approach 2:
The support frame incorporates adjustable support points that can be dynamically positioned according to the valve body geometry. The connecting rods can be adjusted in length and position, allowing the tool to adapt to different operating environments and maintain ease of operation regardless of the specific valve configuration or available space.
2Productivity
If traditional manual disassembly method is used for replacing bushing and seal, then the replacement can be performed, but the operation is cumbersome, time-consuming, and labor-intensive
Solution Approach 1:
The tool combines multiple functions into a single integrated device: the support frame provides structural support and positioning, the driving ring enables bushing removal, and the seal removal mechanism facilitates seal replacement. This merging of functions eliminates the need for multiple separate tools and manual disassembly steps, significantly reducing replacement time and improving maintenance efficiency.
Solution Approach 2:
The driving ring acts as an intermediary mechanism between the operator and the bushing, providing a mechanical advantage that simplifies the removal process. The tool includes intermediate components such as connecting rods and support assemblies that mediate the force application, making the disassembly process less labor-intensive and more efficient compared to direct manual manipulation.
3Reliability
If traditional replacement method is used, then the bushing and seal can be replaced, but the operation is labor-intensive and poses safety risks due to potential water leakage
Solution Approach 1:
The tool incorporates safety features that prevent water leakage during the replacement process. The support frame provides stable positioning and support throughout the operation, preventing accidental displacement of components. The driving ring and connecting rods are designed with secure engagement mechanisms that eliminate the risk of sudden component failure, thereby cushioning against potential safety hazards while maintaining operational simplicity.
Data Source
AI summary
A tool for replacing a bushing and seal of an inlet ball valve disc pivot and a method thereof, relating to the technical field of installation and maintenance of hydropower station equipment. The tool for replacing the bushing and seal of the inlet ball valve disc pivot comprises a support frame, a driving ring, a support shaft, a first support assembly and a second support assembly; the support frame includes a first ring, a second ring provided in parallel, and a plurality of connecting rods connected between the first ring and the second ring; the first ring is used for connecting to the ball valve body; the driving ring is provided between the first ring and the second ring in an adjustable position; the driving ring is used for detachable connection with the bushing; the support shaft is used for coaxial connection with the pivot.