Installation Process of a Hydraulic Elevator Dam

1. Preparatory Phase

1. Design Disclosure and Plan Validation

   Coordinate technical briefings involving design, construction, and supervision entities to define critical parameters: dam water-retaining height, load-bearing capacity, hydraulic system pressure rating, and installation accuracy thresholds (e.g., guide rail verticality tolerance ≤3mm per 10m). Develop a detailed construction blueprint encompassing hoisting strategies and safety protocols.
2. Site Survey and Preparation

   Assess on-site geological attributes (e.g., foundation bearing capacity must meet or exceed design specifications), nearby utility access points, and transportation routes. Clear debris, level the terrain, and establish temporary facilities such as material storage zones and interim power distribution stations.
3. Inspection of Incoming Materials and Equipment

   Validate certifications and technical specifications for core components: water-retaining panels (steel components require weld flaw detection reports), hydraulic cylinders (seal types, cylinder pressure test records), guide rails (straightness deviations), and PLC control cabinets to ensure alignment with design criteria.

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2. Foundation and Support Structure Construction

1. Foundation Pit Excavation and Ground Stabilization

   Excavate the foundation pit per design drawings. For soft soil substrates, implement replacement (e.g., graded sand-gravel mixtures) or pile reinforcement (e.g., CFG piles) to restrict annual foundation settlement to ≤5mm.
2. Reinforced Concrete Foundation Casting

   Assemble foundation rebars (protective layer thickness ≥50mm), install formwork, and pour concrete (typically C30-C40). Embed fixtures (e.g., anchor bolts for guide rails and hydraulic cylinder supports) with positional accuracy controlled within ±2mm. Conduct curing for a minimum of 14 days to achieve 80% of the design concrete strength.

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3. Guide Rail System Installation

1. Guide Rail Positioning and Securing

   Utilize total stations for guide rail alignment (vertical/horizontal spacing as per design). Secure rails to embedded fixtures via bolts, adjusting verticality with shims (allowable deviation ≤1mm/m).
2. Guide Rail Connection and Calibration

   Weld or bolt rail segments (welds must pass ultrasonic flaw detection). Post-installation, perform comprehensive calibration to ensure rail surface smoothness (roughness ≤Ra12.5μm) and consistent spacing between paired rails (tolerance ≤2mm).

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4. Hydraulic System Installation

1. Hydraulic Cylinder Mounting

   Hoist hydraulic cylinders to support bases, aligning their axes with the design centerline (coaxiality tolerance ≤0.1mm/m). Secure with high-strength bolts (preload torque per specifications). Install cylinder rod end connectors (e.g., hinges) to ensure unimpeded rotation.
2. Pump Station and Pipeline Layout

   Position the hydraulic pump station (comprising motor, pump, and oil tank) on a level concrete platform. Lay oil pipes (preferably seamless steel) with a bending radius ≥10 times the pipe diameter; flange connections must use gaskets for sealing (avoid over-tightening to prevent deformation).
3. Pipeline Flushing and Pressure Testing

   Flush pipes with clean hydraulic oil (contamination level ≤NAS 8) until no particulate matter is detected. Conduct a pressure test: sustain 1.5 times the working pressure for 30 minutes with no leakage and pressure drop ≤5%.

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5. Water-Retaining Panel (Gate Leaf) Installation

1. Panel Hoisting and Positioning

   Use cranes to lift the panel (steel or reinforced concrete) into the guide rail frame, ensuring centering between rails (side clearance 5-10mm). Temporarily secure to prevent tilting during adjustments.
2. Connection to Hydraulic Cylinders

   Link the panel’s lifting lugs to cylinder rod ends via pins or hinges, ensuring uniform force distribution (verify all cylinder rods are at the same elevation, tolerance ≤3mm).

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6. Control System Installation

1. Electrical Wiring and PLC Cabinet Setup

   Install the PLC control cabinet in a waterproof, dustproof enclosure. Connect wires (power lines, signal lines) with clear labeling; signal lines must be shielded to avoid interference.
2. Sensor Installation

   Mount water level sensors (accuracy ±10mm), pressure sensors (range 1.2 times working pressure), and position sensors (e.g., linear encoders, resolution ≤0.5mm) at designated locations. Calibrate sensors to ensure data accuracy.

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7. Commissioning and Testing

1. Individual Component Testing

   Test hydraulic pump operation (no abnormal noise, flow meets design), cylinder extension/retraction (smooth movement, no jamming), and sensor responsiveness (real-time data transmission to the control system).
2. Integrated Operation Testing

   Perform lifting tests: cycle the panel through full stroke (0 to maximum height) 5-10 times, recording speed (deviation ≤10% of design) and positional accuracy (tolerance ≤5mm). Test emergency stop functionality (system shutdown within 2 seconds when activated).
3. Water Pressure Testing

   Fill the upstream to 80% of the design water level, inspect for leaks at panel seals (allowable leakage ≤0.1L/(m·h)) and structural deformation (maximum deflection ≤L/500, where L is panel span).

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8. Acceptance and Handover

1. Documentation Compilation and Review

   Organize installation records (e.g., material certificates, test reports, calibration data) and submit to the supervision unit for verification.
2. On-Site Acceptance

   A joint inspection team (design, construction, supervision, and client entities) verifies compliance with design requirements and national standards. Re-test key metrics (e.g., hydraulic system pressure, panel positioning) if discrepancies arise.
3. Handover and Training

   Provide operation manuals and maintenance guidelines to the client. Train operators on system startup/shutdown, fault resolution, and daily inspections (e.g., oil level checks, seal wear assessments) to ensure proper post-installation operation.

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