Research on the Development of a Specialized Non-Destructive Extraction Tool and Process Optimization for the Lower Guide Bushing of Hydraulic Turbines

Aiming at the technical challenge of safely and efficiently removing the lower bushing of the runner guide vanes due to interference fit during turbine maintenance, this paper systematically elaborates on the development background, structural design, operational methods, and engineering application effects of a new specialized extraction tool. Using the A-level maintenance of the 161.25 MW Francis bulb turbine at Yinpan Power Station as a practical case, the study demonstrates the implementation of a non-destructive and rapid removal process for the lower bushing. By replacing traditional hot welding techniques with a mechanical clamping mechanism developed by an innovation team, the new tool significantly reduces risks associated with high-altitude edge work, shortens maintenance cycles, minimizes bushing damage, and lowers maintenance costs. Comparative analysis reveals the tool's advantages in operational safety, efficiency, bushing integrity, and overall cost-effectiveness, providing a more secure and efficient technical solution for hydroelectric equipment maintenance.