In dam and hydroelectric power plant (HEPP) facilities, water intakes become clogged over time due to debris, branches, leaves, garbage, and similar foreign substances carried by the water. This situation disrupts the flow regime and significantly reduces system efficiency. Trashrake cleaning machines, which ensure the regular cleaning of the trashracks used to prevent such issues, are of great importance for the safe and continuous operation of the facility.
Trashrake cleaning machines are among the most reliable and efficient cleaning systems used in dam and HEPP structures today, eliminating the labor requirements, time loss, and occupational health and safety risks created by manual cleaning methods. These systems, which can operate fully automatically or semi-automatically, offer high operational efficiency that recovers investment costs in a short time. Enermak Steel Energy Machinery and Engineering manufactures qualified trashracks and hydraulic trashrakes that automatically clean solid waste at water intakes used in dam and HEPP facilities.
What are Trashracks and Hydraulic Trashrake Cleaning Machines?
Trashracks and hydraulic trashrake cleaning machines are equipment used primarily in dam and HEPP facilities, as well as water treatment plants and various industrial processes. These machines mechanically clean solid waste, such as leaves, plastic, or debris, that gets caught in the trashracks located at the water intakes of dams and HEPPs.
Thanks to their continuous or periodic operation, they prevent the clogging of trashracks and ensure uninterrupted water flow. Hydraulic trashrake cleaning machines perform this process automatically and more powerfully with hydraulic systems. They collect waste using chain, bucket, or wire systems and transfer it to a waste pool or conveyor. Thus, both the need for labor is reduced and the efficiency of dam and HEPP facilities is increased.
How Do Trashrake Cleaning Machines Work?
Hydraulic trashrake cleaning machines operate using hydromechanical systems to effectively clean the trashrack surface at the water intake structure. The basic operating principle is summarized as follows:
- The telescopic boom and cleaning bucket are lowered into the water using a hydraulic system and directed toward the trashrack surface.
- Thanks to hydraulic cylinders, the boom applies controlled and balanced pressure to the trashrack surface.
- The cleaning bucket collects solid waste accumulated on the trashrack surface by scraping it upward.
- When the bucket is moved away from the trashrack, the collected waste is safely discharged outside the intake structure.
- This cycle is repeated regularly and uninterruptedly depending on time intervals set by the automation system or data received from sensors.
What are the Advantages of Trashracks and Trashrake Cleaning Machines?
Trashrake cleaning machines have a flexible structure that can be applied to existing facilities as well as integrated into dam and HEPP projects in the design stage. A special system design is carried out for each facility by considering the geometry of the intake structure, trashrack slope, and flow rate values. This system offers the following advantages:
Continuous and Safe Cleaning: Trashrake cleaning machines are designed to operate 24/7 without interruption. Thanks to the heating elements within the system, safe and trouble-free operation is ensured even at low temperatures and in environmental conditions with a risk of freezing. With the advanced automation infrastructure, the machine's automatic start and stop processes can be controlled based on timing or operating conditions.
High Flow Efficiency: Continuously ensuring the cleanliness of the trashracks reduces hydraulic losses in the intake structure and directly increases the operational efficiency of the power plant. In this way, energy production capacity is maintained, and performance drops and unplanned downtimes are minimized.
Occupational Health and Safety: By eliminating the need for manual cleaning, these systems prevent personnel from working in slippery and risky areas near water, significantly reducing the probability of industrial accidents and providing a safer operating environment.
Easy Maintenance and Safe Access: All main mechanical and hydraulic components of the trashrake cleaning machines are positioned above the water level. This allows inspection, periodic maintenance, and spare part replacement procedures to be carried out more safely and quickly; maintenance times and operational interruptions are reduced.
Suitable Design for Every Slope and Surface: The cleaning system is designed to effectively carry solid waste accumulated on vertical, inclined, or specially geometered surfaces upward, independent of the trashrack slope, and adapts to different facility conditions.
Flexible Hydraulic Design: The machines are designed to be placed at the upper elevation of the water intake structure. Thanks to this layout, personnel access, walking platforms, and waste discharge areas can be planned ergonomically and safely.
Replaceable Cleaning Brushes: The brushes used in the cleaning buckets are long-lasting, replaceable, and have high wear resistance. This feature simplifies maintenance processes and lowers operating costs.
Remote and Wired Control: Trashrake cleaning machines can be controlled both via a wired connection and remotely through the electrical control panel. Monitoring and control from the plant control center are possible with PLC and SCADA integration.
Overload Protection: The system is equipped with safety valves, pressure limiters, and protection circuits against hydraulic and electrical overloads, ensuring equipment and operational safety.
How are Integrated Solutions Provided with Conveyor Systems?
Depending on investor demands, heavy-duty belt conveyor systems can be integrated into the trashrake cleaning machines. This allows the solid waste collected from the front of the trashrack to be transferred fully automatically to:
- A designated waste discharge area,
- A container,
- Or mobile transport vehicles.
This integration makes the cleaning and waste discharge process completely automatic, bringing operational continuity and efficiency to the highest level.
How is the Manufacturing and Installation Process Managed?
The manufacturing of trashracks and hydraulic trashrake cleaning machines is carried out by taking into account project calculations, hydraulic loads, flow values, and environmental conditions. During the installation phase, full compatibility of the system with the intake structure, mechanical axis alignments, and automation integration are meticulously checked, and the machine is commissioned ready for operation.
How are the Prices of Trashracks and Hydraulic Trashrake Cleaning Machines Determined?
The prices of trashracks and hydraulic trashrake cleaning machines are determined according to the dimensions of the intake structure, trashrack type and slope, design flow rate, hydraulic system capacity, automation level, and additional equipment (conveyor, remote control, special coatings, etc.). Furthermore, project-based engineering, manufacturing quality, and installation scope directly affect the total cost.
Enermak Prioritizes Quality, Durability, and Operational Safety
Enermak bases the production of trashracks and hydraulic trashrake cleaning machines on national and international quality standards. It manufactures by evaluating engineering calculations and field conditions together. Quality, durability, and operational safety are prioritized throughout the design, production, and installation processes. It develops its products specifically for facilities to be long-lasting and high-performing.
