Summary report of electromechanical operation management of Yellow River Diversion Project

XX year operation management work summary report
I. Overview
The Wanjiazhai Yellow River Diversion Project is a water diversion project with a large scale across the basin. The operation, maintenance and overhaul of the first and second pumping stations of the main dry three and south main line are undertaken by the Wanjiazhai Yellow River Diversion Project Department of the Tenth Engineering Bureau of China Water Resources and Hydropower. With the help of the support from the Yellow River Head Office, the Operation Branch Office, the Dispatch Center, and the Lower Territory and Yantou Temple Management Offices, our project department completed three ground pumps from July 20, XX to December 31, XX. The operation of the station and the elimination of equipment, maintenance and repair, equipment commissioning, preventive testing, and the task of eliminating fires.
Because of its long water transmission line, high pump lift and advanced equipment, Wanjiazhai Yellow River Project has high technical requirements for operation. For this reason, my project department has invested a large number of comrades with excellent skills, strong sense of responsibility and high education. Finish the running work.
Second, a brief description of the completion of the operation
Although the electromechanical equipment of the three ground pump stations of GM3, SM1 and SM2 was installed by our bureau, the various supporting equipment and facilities outside the plant were undertaken by the civil contractor. Although the equipment handover was carried out at the initial stage of operation, there was no shortage of various construction materials and At the same time, the equipment handed over has a large number of defects, and it is difficult to meet the requirements of safe operation. For this reason, the Ministry invested a lot of manpower and material resources to eliminate and repair the equipment outside the fire protection system, the water system and the living system. jobs. In August, our department found that there was a serious shortage of flow in the clean water system of the Nangan secondary pumping station, which was difficult to meet the requirements of operation. Our department promptly reported to the operation branch. This problem was solved by the operation of the branch office, the leadership of the Pinglu branch and the care and support of the branch office biotechnology department until the end of August. In the meantime, according to the work arrangement of the Yellow River Dispatching Center and the Operation Sub-bureau on the third-stage trial operation, the Ministry of Firepower completed the fire prevention inspection and the rectification of fire hazards, the verification of the protection device and the automatic device, and the dust removal in the electrical panel before operation. The series work ensures that the third phase of the trial operation can be carried out smoothly.
From September 9th to September 26th, under the unified command of the Yellow River Dispatching Center, the three ground pumping stations operated by our department started the single-machine 72-hour and double-machine 6-hour trial operation, due to the defects and design of the equipment itself. The shortcomings and the failure of the SCADA system resulted in multiple accidental shutdowns of the pump motor units of the three pumping stations. Since it can be discovered and processed in time, it does not cause equipment and personal accidents, and achieves the purpose of safe operation. At the same time, it also discovers some defects of the equipment and records and analyzes the defects, so as to reduce the future work. Laid a certain foundation.
With the end of the trial operation, our department cooperated with the Australian company to carry out the test of the automatic control system of three ground pumping stations and carried out the annual preventive test of the antifreeze insulation and electrical primary equipment of the three ground pumping stations. Relay protection setting check and switch transmission test and drainage work of front pool, hard shaft, technical water supply system, pump station water strength measurement system. At the same time as the completion of the dispatch center and the operation of the branch office, the Ministry of the Department assigned a special person to carry out various technical training and assessments for the operators of the two branch offices of the operation branch and the operators of the department. And in the unified arrangement of the branch biotechnology department, the auditing of the running account and the finishing of the equipment number were carried out. However, due to the error of the equipment number and the design reasons, the work was slow and could not be completed quickly. And delays the operation of the operation of the branch and the modification of the operating procedures.
Third, the operation of equipment defects and processing
1. In the trial operation stage, the self-control valve is not working properly due to the damage of the valve disc and the valve core of the self-control valve of the clean water system, and each time the pump is operated, manual operation is required. To this end, our department worked with the manufacturer to repair and control the self-control valves in the GM3, SM1, and SM2 pressurized pump rooms, so that the equipment can operate safely.
2. The main dry three-stage pumping station overhauls the leaking collecting wells. Due to the failure of the civil construction unit to clean up, there are a large number of woven bags, cement blocks and silt, which often cause the two collecting well pumps to fail to operate normally. In response to this situation, the Ministry of Mines, with the support of the Yantou Temple Management Office, thoroughly cleaned the two collection wells and maintained the inspection of the pump impeller.
3. Since the SM1 and SM2 technical water supply systems are flooded from the front pool side, a large amount of sediment and gravel are stored in the original buried pipeline, which causes the pump to issue cards several times during the operation and cause downtime accidents. A comprehensive inspection and overhaul of the technical water supply pumps of the two ground pumping stations SM1 and SM2 was carried out.
4. The SFC one-way check valve of the main dry three-stage pumping station, the cooling water inlet and the drainage wedge-shaped stop valve on the SM1 and SM2 motor pits are all found to have cracks and water seepage and water leakage during operation. Toshiba supplies, Ouhai Valve Co., Ltd. produces. Our department timely reported to the management office and the branch office, and at the same time, negotiated with the Japanese field service personnel, and asked the Japanese personnel to handle or replace all the valves found to have problems. Toshiba purchased the valves and the company replaced them. After the treatment, the working condition was normal and there was no leakage.
5. The SM1 pumping station 6# machine has many times of over-standard and alarm phenomenon during the operation. After observation and comprehensive analysis of various data, the Ministry believes that this defect is caused by the unreasonable deviation of the motor rotor weight. Since the Japanese equipment has not been handed over, the Ministry has no right to deal with this defect.
Because the three ground pump stations in our department have many defects in the equipment found during the operation, they cannot be introduced in detail, and only some of the most representative defects can be introduced.
Fourth, safe and civilized production and operation
1. Full operation management organization


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2. Main safety management measures and systems
(1) Conscientiously implement the relevant safety regulations, laws and decrees promulgated by the State, and implement various operational and operational procedures issued by the Yellow River Operation Sub-bureau;
(2) When operating personnel enter the factory area, they should wear helmets and use relevant labor protection articles;
(3) Where the operating personnel should be neat and tidy, there must be no wearing or slipping;
(4) All equipment and areas that are vulnerable to electric shock or lightning strikes are assigned to be responsible for inspections;
(5) Warning signs shall be set in the live areas of the equipment and in the maintenance and repair areas, and corresponding effective fire protection facilities or equipment shall be arranged;
(6) There are sufficient lighting in the operation area to prevent accidents such as misoperation due to insufficient brightness. The temporary power supply voltage arranged in the maintenance and repair area does not exceed 36V, so as to avoid leakage accidents;
(7) All the running areas and operating equipment are hoisted with signboards to prevent accidental operation and cause operational accidents;
(8) All personnel entering the factory shall be registered in detail to prevent unrelated personnel from entering the operation area and causing safety accidents;
(9) All operating personnel should learn safety knowledge and safety regulations, and pass the examinations of the project department before they can be allowed to work;
(10) Hold safety councils on a regular basis, summarize the problems in the safe operation, and arrange solutions and methods;
(11) Establish a safety award and a fine system to link safe operation work with personal benefits;
(12) Establish special accident handling and maintenance agencies, each with their own responsibilities and perform their duties;
(13) Find problems in time during operation, report them at the first time, make records, and process them after receiving the instructions of the dispatching center, and report the processing measures and processing results;
(14) The processed equipment should be inspected and confirmed without any error, and the equipment can be put into operation after replying.
V. Operation management system

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Due to its high technical content and advanced automation control system, the Yellow River Pumping Station has high requirements for the quality of the operating personnel. In response to this situation, the project department has specially formulated the operation patrol system, the long running value system, the operating main value system, and the operation. A series of internal management systems and incentive mechanisms, such as the duty officer system, effectively manage the operational personnel so that each employee knows what his or her duties are at runtime and how to fulfill his or her responsibilities and obligations.
6. Important defects and suggestions for operating equipment
(1) Thinking and discussion on technical water supply system
The technical control system of the technical and water supply system of the Nangan No.1 and No.2 pumping stations of our Ministry is designed to rotate the technical water supply pump once every hour. In actual operation, due to the corrosion of the hot standby water outlet electric valve and the failure of the opening, the hot standby water supply pump cannot be started, and the running water supply pump has stopped running. Under this circumstance, after the unit water supply system and the SFC lose the cooling water for a certain period of time, the pump group in operation will automatically stop, resulting in loss of water in the front pool. This defect must be modified from the PLC program so that after the standby pump is started, the water outlet sluice action sends a water signal to stop the running water pump, so that the technical water supply can guarantee the technical water supply regardless of whether the technical water supply pump rotates successfully during the rotation process. The normal supply, and in the program to design a signal that the rotation is successful, once the rotation is unsuccessful, a pumping signal is sent to the pumping station manager for immediate processing.
(2) Coordination of automatic sewage system
There are two ways to discharge the automatic sewage system. The first one is differential pressure sewage, the second is timed sewage discharge, and the sewage discharge time is 3 minutes each time. The phenomenon that the two sewage modes are performed in actual operation always causes the water supply pipe pressure to decrease and the flow rate to decrease, causing the technical water supply alarm to cause downtime. For this problem, the sewage discharge time can be modified to 2 to 2.5 minutes. This can solve the accident shutdown caused by the time problem; the other method can be changed to when the water filter discharges, the backup technology water supply pump starts the water supply, and the technical water supply pump stops after the sewage discharge ends, which avoids the sewage discharge. Causes the disappearance of cooling water.
(3) Automatic restart of the water supply pump when the plant power is automatically switched
In the operation of the pumping station, the switchover of the plant's electricity supply is often occurred. When the power supply of the plant is cut off, the three-phase AC power supply of the main circuit on the soft start device of the water supply pump disappears, and the water supply pump will stop the pump abnormally. , thus losing the PLC start command before switching. When the plant is automatically powered on, the water supply pump running before switching the power supply cannot be restarted because there is no start-up order, so that the pump group in operation will be shut down due to the interruption of the cooling water. This phenomenon needs to be modified from the PLC and the control program. When the factory power supply self-injection switching power supply disappears, the pump should be stopped to the running water pump. After the plant power is input, the pump stop process is completed, and the standby pump is started. Water supply.
(4) The problem of the upper guide and drain wedge stop valve in the motor pit
The three ground pumping station pit stop valves operated by our department are produced by Guhai Valve Factory. During operation, these valves are often found to have cracks and water leakage, which is extremely detrimental to the safe operation of the motor. The analysis of such defects is considered to be due to the quality problem of the valve itself. Secondly, the heater is automatically activated by the heater in the pit after the motor is stopped. When the motor is running, the heater cuts off the cooling water and causes the valve to shrink due to the temperature drop. The long-term accumulation makes the valve gradually crack. According to this phenomenon, the valves in the pit should be replaced with stainless steel valves or intermediate transition tubes provided by equipment manufacturers.
The impact of domestic water systems on operations
Since the pumping station is relatively free of domestic water and construction water in the initial stage of construction, most of them are directly taken from the high water pool or the low water pool of the clean water system. The design of the pumping station clear water system is relatively high, and it is not allowed to be connected with other water systems. Now, due to the chaos of water intake, the pressurized water pump, deep well water pump and domestic water pump are damaged many times. If it continues, it will affect the safe operation of the pump. It is also possible that the water pump in operation will cause an emergency shutdown of the pump or damage the spindle seal, which will cause significant economic losses. At present, the Nangan secondary pumping station is particularly prominent. Therefore, it is necessary for the branch office to strengthen the coordination of the domestic water system to ensure the running water of the pump unit main shaft seal and the running water of the drainage pump in the plant.
Unreliable work on water level gauge outside the plant
The clean water system of the three ground pumping stations has not been able to be automatically controlled due to the unreliable work of the water level gauge. This water level meter is supplied by Shanghai Foxboro Co., Ltd., and the manufacturer is Xuzhou Kexun Automation Technology Co., Ltd. The construction unit is Hydropower Eleventh Bureau and Shanxi Provincial Water Works Bureau. Due to operational needs, it was handed over to our management in July XX. At the time of handover, a set of water level gauges and low water level gauges of the high level pool of the GM3 pumping station showed abnormality. The water level gauges of the SM1 high and low pools and the fire pool were not normal. SM2 pump station high level pool A set of water level gauge and fire pool water level gauge display is not normal. From August 27th to 29th, XX, our department cooperated with Xuzhou Kexun manufacturers to carry out replacement treatment and commissioning. After the treatment, the water level meter can only measure the water level except the relative water level value of the SM1 fire pool. After September 28, XX, a group of water levels in the SM1 fire pool, high and low water pools, and SM2 fire pools and high water pools have lost their normal display, which is difficult to meet the requirements of automation control.
The three wells outside the clear water system of the ground pumping station are supplied by Shanxi Tianhai Pump Co., Ltd. and handed over to our department for management in July XX. When the water level meter of SM2 new well cannot indicate the water level, the remaining water level gauges can It shows the relative water level of the deep well, but there is no 4-20mm analog output for automatic control, which is difficult to meet the requirements of automatic control.
Our department has contacted the electromechanical department and the equipment supplier several times, but it has still not been resolved. This problem will affect the safe and stable operation of the pump group in the future and should be given high priority.
Ultrasonic flowmeter display problem
The ultrasonic flowmeters of the three ground pumping stations are all supplied by Xuzhou Kexun Industrial Automation Technology Co., Ltd., and the GM3 and SM1 pumping station ultrasonic flowmeter display screens are all red. On August 28, XX, Xuzhou Kexun Company took back the processing and the display screen was still anti-red. The Ministry has repeatedly contacted Xuzhou Kexun Company for further processing, but it has not been processed yet.
Unreliable problem of self-control valve outside the factory
The three-ground pumping station outside the clear water system pressure pump automatic control valve are supplied by Changsha Industrial Pump General Factory, produced by Tianjin Guowei Valve Co., Ltd., Hydropower Eleventh Bureau, Shanxi Provincial Water Works Bureau, handed over to July XX Our department runs management. After the Ministry took over, the pressure pump self-control valve was inspected and repaired. However, since the self-control valve has been in operation for more than 2 years, some of the self-control valves cannot be operated after installation. Some of the self-control valves must be replaced due to wear of the valve plate. In October XX, our department cooperated with Tianjin Guowei Company and the maintenance center to carry out valve plate replacement treatment and debugging, but still could not meet the requirements of automatic control.
According to the long-term operation inspection and observation analysis of our department, the self-control valve can not meet the requirements of the automatic control of the system. First of all, the soft starter used in the system must be a no-load or light-load start-up process, that is, the pressure-starting process, otherwise the soft starter will maintain the maximum starting current, and an overload fault will be issued after the start-up time limit, and the startup fails. Our department has opened the outlet gate valve to 5-10% opening. Under the normal working condition of the automatic control valve, the pressure pump is started, and the soft starter still has an overload fault. Secondly, the opening pressure adjustment of the self-control valve can not meet the requirements. The soft starter pressure start-up process time is 10-20S, and the self-control valve opening process cannot meet the soft starter pressure-starting process. Since the pressure starting process is the highest pressure during the whole running process, the pressure at the highest pressure of the pressure is not enough to open the automatic control valve, that is, the automatic opening process of the automatic control valve cannot escape the pressure starting process of the soft starter.

, so the soft starter has an overload fault and the boot fails. At present, the operation of the system is to first close the outlet gate valve. After the pressure is started, the outlet manual valve is opened. After replacing the valve plate, part of the self-control valve can achieve the function of the check valve, but the work is still unreliable.
In order to achieve complete automatic control, our department believes that even if the Italian self-control valve is used, it can not meet the control requirements of the system. Therefore, our department recommends installing an electric butterfly valve on the water supply main pipe, and modifying the PLC control program to start the soft starter pressure generation. After the completion, the electric valve is automatically opened. When the pump is stopped, the electric valve is closed first, and then the pressure pump is stopped.
VII, XX year work prospects
Through the operation, maintenance and management of XX years, many defects and deficiencies have been discovered. In order to realize the safety and economy in the long-term operation of the pumping station, we need to constantly find problems in the operation and solve the problems in time. At the same time, we also need to continuously analyze and summarize, so that the operation and management of the pump station can be safer and more reliable.
In order to achieve long-term safe and stable operation of the pumping station, we must do the following work in XX years, and we need the support and assistance of the branch office and the two management offices.
1. Complete the water delivery task issued by the branch office.
2. Processing of equipment and design defects. Technical water supply and sewage discharge pressure and unqualified water level gauges and self-control valves outside the plant will be the most important factors affecting the safe and stable operation of the pump unit. Therefore, it is necessary for the branch to coordinate the design and solve the problem with the manufacturer.
3. Perfect work of double numbering of equipment. Mainly hydraulic machinery auxiliary equipment has numbering errors and no numbering problems.
4. Establish and improve the equipment technology account, operation technology account, operation rules, management system, and archives data management. An archives room and corresponding facilities are required.
5. Strengthen training and study. Fully mobilize the enthusiasm and initiative of employees, and implement the reward and punishment system. Focusing on self-study, focusing on theoretical and practical operation and maintenance training, on the basis of familiarity with the whole plant equipment, the maintenance and management of equipment will be carried out by specialization and sub-system.