Guidelines for Troubleshooting Common Faults in Pressure-Induced Opening: A Comprehensive Analysis from the Hydraulic System to Seal FailureCarrying out hole-making operations while the pipeline is not in operation, with efficient and professional troubleshooting, is the cornerstone of safe operation. The pressure-bearing opening technology is an important process in modern pipeline maintenance. It enables the completion of branch connections, equipment installations, or maintenance and replacement work without affecting the normal operation of the pipeline. This technology is widely applied in fields such as petroleum, chemical industry and gas supply, and it is highly favored due to its characteristics of no production suspension and high efficiency and safety. However, during the process of pressure-bearing hole opening operations, equipment failures occur frequently. A scientific troubleshooting method not only enables the resumption of the operation promptly, but is also crucial for ensuring the safety of personnel and the integrity of the pipeline. Troubleshooting of the hydraulic system The hydraulic system is the power core of the pressure-opening machine, and its operating condition directly affects the success of the entire operation. The hydraulic motor is not functioning properly. The hydraulic motor operates normally without load, but the noise is slightly louder than usual. Once a load is applied, it experiences insufficient power or slow operation, which is typically a sign of internal leakage. · Cause analysis: The stator and rotor of the hydraulic motor are not properly matched, resulting in accelerated wear of the internal components. When the needle teeth inside the stator reach a certain limit of wear, it will cause the internal clearance of the stator's pairing to increase, and the oil sealing effect will no longer be normal. · Inspection method: Check the quality of the hydraulic oil. If the oil is of poor quality, it must be replaced immediately; Check whether there is internal leakage between the output shaft and the housing hole due to wear. · Solution: Replace the needle teeth with slightly larger diameters; if the internal part of the housing is severely worn and has formed grooves, then the housing needs to be replaced or the entire assembly needs to be reconfigured. Unstable rotational speed and crawling phenomenon When the pressurized hole-making machine exhibits unstable speed and crawling phenomenon at low rotational speed, the following aspects should be given particular attention: · Rotor inspection: Check whether the tooth surfaces of the rotor have any scratches or damages. The areas with scratches have a higher friction force, while the areas without scratches have a lower friction force. This uneven friction force can cause pulsations in rotational speed and torque. · Minimum rotational speed limit: The minimum rotational speed of the cycloidal motor should not be less than 10 r/min at all. This is an important parameter for ensuring low-speed stability. · Stator processing: In cases where the cylindrical pin wheels of the stator cannot rotate during operation, the thickness of the pin teeth can be adjusted to be slightly less than the thickness of the stator. Reduced rotational speed and insufficient output torque · Sealing line issue: When the contact surface between the rotor and the stator is affected by poor tooth shape accuracy, poor assembly quality, or scratches at the contact line, it will lead to an increase in internal leakage, resulting in a decrease in volumetric efficiency. In this case, the rotational speed and output torque will significantly decrease. · Inadequate flow distribution accuracy: The consistency of the relative positions of the meshing points between the rotor and stator, and the meshing points of the flow distribution axis and the body, has a significant impact on the output torque. If the corresponding relationship is mismatched, it will cause a significant reduction in the rotational speed and output torque. · Wear of the distribution shaft: Wear of the distribution shaft will cause significant internal leakage, which will affect the oil distribution accuracy; excessive clearance between the distribution sleeve and the motor body shell hole will also impact the oil distribution accuracy. Mechanical failure and knife jam handling Analysis of Hole Cutting Tool When making the hole, the drill pipe does not move, the hydraulic working pump station is struggling, and the feeling that the hole-making tool is not cutting is a common mechanical fault. Take the following immediate measures: Close the hydraulic valves of the hydraulic working pump station; Check if the sound of the gasoline engine hydraulic working pump station has returned to normal; Check if the fuel supply is sufficient. If the pumping station is operating normally but the pressure gauge reading is lower than the normal level and the sound is rather strenuous, the drilling should be reversed following the procedure for unsuccessful hole opening and re-drilling. The reasons for using a knife vary. There are many reasons for using a knife, mainly including: The saddle short sections used for pipeline welding were not up to standard, resulting in the center point of the pressure-bearing opening being displaced. 2. The opening points of the pipeline have an inherent eccentricity (commonly referred to as an elliptical pipeline) within the pipeline itself. During the operation of pressurized hole drilling, the cutting speed was too fast, which increased the friction between the pipe edge and the hole-drilling tool. SolutionRegarding the issue of knife sticking, the following solutions can be adopted: · Replace the large-power pumping station and increase the output power · Re-designed and welded the opening cutter, and increased the cutting and shaping of the pipe edges. · Stop the operation of pressurized hole drilling and reselect the location (this is costly and is generally not adopted) Troubleshooting of the sea