Quick Troubleshooting and Diagnosis of Common Faults in the Three Major Systems of Rotary Drilling Rigs

    Rotary drilling rigs operate continuously under high load in foundation construction, and various faults are prone to occur in the hydraulic, electrical, and power systems. Quickly locating problems and accurately troubleshooting can not only reduce downtime but also prevent minor faults from expanding into damage to core components.

1. Troubleshooting of the hydraulic system

    The hydraulic system is the power core of the rotary drilling rig, and faults are mostly manifested as slow movement, weakness, abnormal noise, leakage, and abnormal oil temperature.

    If the movement is weak or there is no movement, priority should be given to checking the hydraulic oil level and oil quality. Insufficient oil level and deteriorated oil will directly lead to insufficient pressure. At the same time, check whether the oil suction pipeline is taking in air and whether the filter element is blocked.

    In case of movement jamming and abnormal noise, it is mostly due to wear of the hydraulic pump, pressure imbalance of the relief valve, or jamming of the valve core. The status of the pump body and valve group can be judged by testing the system pressure, and the faulty valve parts should be cleaned or replaced in time.

        For hydraulic leakage, focus on pipeline joints, seals, and cylinder piston rods. High temperature and vibration can easily cause seal aging. Once leakage is found, fasten or replace the seals immediately to avoid hydraulic oil loss and pollution.

    If the oil temperature is too high, check the cleanliness of the radiator and the working status of the cooling fan, reduce long-term high-load pressure-holding operations, and keep the hydraulic system's heat dissipation unobstructed.

II. Troubleshooting of Electrical System

    The electrical system is responsible for equipment control and signal transmission. Common faults include no display on the instrument, no response to actions, sensor failure, and line short circuits.

    If there is no power to the entire machine or partial power outage, first check the main power switch, battery terminals, and fuses to rule out poor contact or burnout issues, then check if the battery voltage meets the standard.

    For unresponsive controls and abnormal signals, focus on checking the operating handle, controller, and wiring harness interfaces. Dust and mud in the construction environment can easily cause line oxidation, short circuits, or loose connectors; clean and fasten the lines in a timely manner.

Sensor failures can lead to distorted data display and false protection actions, which are common in pressure, angle, and speed sensors. Whether they are damaged can be determined by comparing parameters and replacement tests to avoid misoperations caused by signal errors.

III. Troubleshooting of Power System

    The power system is mostly a diesel engine, with faults concentrated in difficult starting, reduced power, unstable idle speed, and abnormal exhaust smoke.

    For difficult starting, first check the fuel quantity, whether the oil circuit is intake or blocked, replace the diesel filter, then check the battery power, starter motor, and preheating system. In low-temperature environments, focus on checking the preheating device.

    Insufficient engine power and unstable idle speed are mostly caused by clogged air filters, poor atomization of fuel injectors, and insufficient fuel supply pressure. Regularly clean or replace the filters and calibrate the fuel injectors to ensure sufficient fuel combustion.

    Abnormal exhaust smoke can directly indicate faults: black smoke is mostly due to insufficient combustion or excessive load; blue smoke is due to oil burning; white smoke is due to water in the fuel or cylinder faults. When abnormalities are found, stop the machine immediately for inspection to prevent serious faults such as engine cylinder scuffing and bearing seizure.

The troubleshooting of rotary drilling rigs follows the principle of starting with the easy and then the difficult, and starting with the external and then the internal. Doing a good job in daily maintenance and inspection can greatly reduce the probability of faults in the hydraulic, electrical, and power systems, ensuring efficient and stable construction operations.