越南松綁4水電站工程機電設備安裝轉子組裝方案(中英文對照版)

1、越南松綁4水電站工程機電設備安裝發(fā)電機轉子組裝方案批準：羅春華審核：張文紅編制：謝榮新廣東省源天工程公司 松綁4水電站項目部 二0一三年十一月二十日VIETNAM SONGBUNG 4 HYDROPOWER STATION E&M EQUIPMENTS INSTALLATIONGenerator Rotor Assembly Program Approver: LUOCHUNHUA Inspector: ZHANG WENHONG Prepared by: XIE RONGXINGuangdong Yuantian Engineering Company Song Bung 4 Hydropo

2、wer Station Project DepartmentNovember 20th, 201328 / 29文檔可自由編輯打印目 錄Contents1結構說明 Structure Instructions32施工組織機構及人員安排 Construction Organization43施工準備 Preparation43.1施工技術準備 Technical43.2施工設備工器具準備 Preparation of Erection Tools53.3 施工其它措施準備 Other preparation74主要技術標準和規(guī)范 The main technical standards and

3、norms85施工程序及方法Construction Program85.1 發(fā)電機轉子組裝程序Generator Rotor Assembly Procedure85.2 轉子支架與主軸的熱套Assembly of rotor spider with shaft by heating.95.3 磁軛組裝Rotor rim assembly115.4 轉子繞組組裝Rotor winding assembly165.5 主要部件安裝的質量控制Quality Control of Critical Components Installation186施工工期 Construction Period

4、227質量管理措施Quality Management Measures228安全文明施工 Safety & Environment-Friendly Manner239衛(wèi)生環(huán)境保護 Health Environmental Protection2610 附件Appendix281結構說明 Structure Instructions1. 大軸下端通過法蘭與水輪機軸連接，鏡板通過熱套方式與大軸連接，磁極引線從轉子支架上部進入大軸引線槽內，并與集電環(huán)連接。 Connect main bearing bottom with turbine bearing by flange, runner pla

5、te with main bearing by hot shrinkage, pole lead with collecting ring.2. 輪轂包括轉子支架、風扇等，通過熱套方式與大軸固定。 Wheel hub consists of rotor support and fan. The wheel hub is fixed with main bearing by hot shrinkage.3. 磁軛由磁軛沖片，上壓板、下壓板、磁軛鍵、制動環(huán)等組成現場疊片 Magnet yoke consists of magnet yoke stamping, upper press board,

6、 lower press board, magnet yoke key and stop ring.4. 磁極由線圈、磁極鐵芯、阻尼環(huán)、阻尼條、磁極引線、磁極連線等組成，24個磁極在現場掛裝。 Pole consists of coil, iron core, damping ring, damping bar, pole lead and cables. 24 poles are hanging garmented on site.2施工組織機構及人員安排 Construction Organization現場負責人：李藝Site leader: Li Yi技術負責人：謝榮新Engineer

7、 : Xie RongXin安全員：陳濤記EHS: Chen TaoJi質檢員：潘鍵強Quality controller: Pan JianQiang現場翻譯/協(xié)調：陸昌龍Site translator: Lu ChangLong起重人員: 2人lifting worker: 2 機械安裝人員：6人Mechanical worker: 63施工準備 Preparation 3.1施工技術準備 Technical 1施工前熟悉廠家圖紙、安裝規(guī)程、規(guī)范和技術文件；Read drawings carefully before installation, also should know well

8、with installation stand and technical documents.2由項目總工程師組織安裝人員進行詳細審核設計圖紙，并作好審圖、澄清問題以及設計技術交底記錄；The general engineer should arrange the works check drawings and clairfy questions which raised by works, make statement of installation and keep the record. 3統(tǒng)計和核對設備和主要材料清單，制定到貨計劃和材料采購計劃；Check the main equ

9、ipment and material list then make a delivery and purchase plan.4制定重要設備安裝和關鍵工序的安裝方案和技術措施；Formulate the installation program and key process for main equipment. 5注意圖紙?zhí)岢龅氖┕ひ螅O備部件的特殊安裝工藝及對環(huán)境的特殊要求；Give more attention about technical request form the drawings, some parts have special technics request as

10、 well as environment. 6機組安裝前機坑已清理干凈，滿足安裝條件。Work surface have been clean well before installation and meet the request of erection.7安裝前所需的設備及零、部件已到貨齊全并檢查合格。Check the elements needed which should be arrived site and the quality must be meet the drawings before installation.8安裝所需的工器具滿足要求，廠家提供的專用工具已到貨。E

11、rection tools must be meet the request and special tools form supplier have arrived site.3.2施工設備工器具準備 Preparation of Erection Tools 1備齊常用的起重吊具、繩索和安裝工器具。Preparation of lifting, wire-rope, erection tools.2對所有的工具器具進行徹底檢查和維護、保養(yǎng)，確保其工況良好，使用安全。起重設備的選擇能滿足設備最大起重量，達到吊裝的安全要求。Check and maintenance carefully all

12、 the tools to ensure them in good behavior and safety for use, the lifting equipment capacity should cover the maximum weight of part of the equipment which to be erected.3指定有關安全負責人，檢查安裝用防護用品的配備是否齊全、到位。Specified full-time security staff to check all the tools needed to ensure safety during erection.

13、4. 驗收設備包含在施工設備工器具列表內Acceptance equipments are included in the list of construction equipments & tools.Tools Nameunitquantityremark鋼琴線piano wire卷Reel1紅外線焊條烘干箱 infrared ray weld rod heating box臺set1焊條保溫筒 electrode dryer個pcs2交流電焊機 AC arc welder臺set1直流電焊機 DC arc welder臺 set1磁力鉆 Magnetic drill machine臺se

14、t1千斤頂 Jack根據實際情況配備足夠as needed手拉葫蘆 Chain hoist根據實際情況配備足夠as needed角磨機 angle grinder臺set2磨光機 Grinding machine臺set1加熱保溫棚 Heating tentpcs1加熱器 Heaterspcs1（廠家提供）Provided by manufacture無接頭吊帶Round endless slingspcs4塑料錘Plastic hammerpcs5風動扳手Impact wrenchpcs2液壓拉伸器Hydraulic press cylinderpcs8液壓泵Hydraulic pumppc

15、s1測圓架Roundness measuring devicePcs1百分表Dial indicatorPcs2力矩扳手Torque wrench 套set1內徑千分尺（規(guī)格：L=3m） Inside caliper套set1框式水平儀 Square level個pcs1level-off直尺Straight edgePcs1塞尺Filler gauge把pcs1M2472專用扳手 Special spanner套set2活動扳手 Adjustable wrench套set1梅花扳手 Box spanner套set1卷尺 Measuring tape把pcs2水準儀Optical level部

16、set1廠家提供的專用工具 Special tools套set13.3 施工其它措施準備 Other preparation 1施工平臺準備 Platform轉子組裝前搭設組裝平臺Working face construction before rotor assembly.2施工用電準備 Power supply在安裝間或設備安裝現場適當位置布置開關箱約3個，電焊機、磨光機、照明等施工設備用電取自各開關箱上。Three electrical distribution box were set off on erection bay and work area. Tools like as w

17、eld machine, grinding machine, lighting take power from the reasonable box.3施工消防準備 Fire fighting 在安裝現場各適當位置布置手提式干粉滅火器約3個。Three hand dry powder fire extinguisher lay on suitable position.4施工通信準備Communication安裝現場配備對講機約2對，保證安裝現場通信。Prepare two talkie-talkies for site communication smoothly.4主要技術標準和規(guī)范 Th

18、e main technical standards and norms1廠家資料Distributor assembly 2國家標準、部頒或行業(yè)標準National standards and industry standards3按合同規(guī)定的標準和要求Fulfill the requirements of relative standards and specifications.5施工程序及方法Construction Program5.1 發(fā)電機轉子組裝程序Generator Rotor Assembly Procedure預埋安裝間轉子組裝場地埋件Embedding the Embe

19、dded Parts of Rotor Assembly at Erection-bay轉子組裝準備Preliminaries for Rotor Assembly轉子支架的加熱The heating of rotor spider 轉子支架與主軸的熱套Assembly of spider and shaft轉子測圓架的安裝Erection rotor compass轉子磁軛疊裝及預壓Rotor rim stacking & prepressing轉子磁軛片清洗分類Rotor Rim Sheet Cleaning and Classing轉子清掃、耐壓Rotor Cleaning, Volta

20、ge-withstanding Test掛裝后單個磁極試驗Test for Single Pole After Assembly轉子吊具安裝Installing Rotor Lifting Tool 轉子引線和極間連線連接Rotor lead and Pole Connections Assembly轉子磁極掛裝Rotor Poles Assembly磁軛的收尾工作The Others Work for Rim轉子清掃、噴漆Rotor Cleaning, Painting轉子磁軛疊裝及最終壓緊Rotor rim stacking & final pressing單個磁極試驗Test for S

21、ingle Pole5.2 轉子支架與主軸的熱套Assembly of rotor spider with shaft by heating. 1. 核算并確定轉子支架需要升高的溫度。Checking calculate and determine the temperature of rotor spider should be heated.2. 轉子支架加熱的溫度應使其膨脹后與主軸的間隙不小于1mm.The clearance of rotor spider with shaft should be more than 1mm after heating expanding.3. 清理主

22、軸并直立于轉子安裝間基礎上。Clean and erect the shaft on the foundation of rotor erection bay.4. 清理轉子支架并根據圖紙在安裝間內立于加熱工具上。試吊轉子支架，調整吊具長度，確保吊起過程中上法蘭面處于水平狀態(tài)。Clean and erect the rotor spider on the heating tool in erection bay. Lift the rotor spider, adjust the length of lifting tap, guarantee the level of spider uppe

23、r flange.5. 在轉子支架上安裝加熱保溫棚。Install heating tent on rotor spider.6. 加熱轉子支架Heating the rotor spider. （1）投入電源對轉子支架進行加溫，控制溫升在610/小時內，大約需要2030小時完成加熱。Turn on the power, control the heating speed between 610/h, about need 2030 hours for heating.（2）加熱到規(guī)定溫度，每30分鐘記錄一次溫度，包括內、外側的上、中、下各部，以及轉子支架的頂面及底面，在圓周方向測八點。Hea

24、t rotor spider up to the specified temperature. Record temperature all 30 minutes. Include the top, middle, bottom for spider inside and outside, and top, bottom surface for rotor spider, measure point in eight points on circle direction. （3）檢查轉子支架的膨脹情況，內孔應均勻、緩慢膨脹，直到比主軸直徑大1mm。Check the state of roto

25、r spider expanding; the expanding of rotor spider should be equally and slowly, till the diameter of spider is bigger 1mm than shaft.（4）控制轉子支架的加熱溫差不能超過10度，否則應通過開關柜進行調節(jié)。Control the deviation of rim temperature is less than 10 degrees; otherwise adjusted it by power boxes. 7. 在主軸上套裝轉子支架。Assembly of ro

26、tor spider to shaft.（1）轉子支架吊起后檢查并調整水平。Check and adjust level of spider, when lift rotor spider up.（2）吊起后應盡快套在主軸上，接近主軸時檢查轉子支架的溫度，如果溫度太低應重新進行加熱。After lifting rotor spider, install on shaft as soon as possible, check the temperature of rotor spider when spider is near the shaft.（3）吊裝前確定好主軸與轉子支架的+Y、+X線及

27、其相對位置。Confirm and mark the +Y and +X axis, and relative position of shaft and rotor spider before lifting the rotor spider.8. 自然冷卻轉子支架。Cooling rotor spider naturally.（1）關閉加熱電源。Turn off the power.（2）慢慢降低轉子支架溫度直至室溫，每30分鐘記錄一次溫度，包括轉子支架內、外側的上、中、下各部，以及轉子支架的頂面及底面，在圓周方向測八點。Cooling the temperature of rotor s

28、pider to room temperature slowly. Record temperature all 30 minutes. Include the top, middle, bottom for spider inside and outside, and top, bottom surface for rotor spider, measure point in eight points on circle direction. （3）轉子支架冷卻到室溫的時間至少要30小時。The duration of cooling down the rotor spider to roo

29、m temperature must be at least 30 hours. 5.3 磁軛組裝Rotor rim assembly1. 安裝并調整測圓架Install and align roundness measuring device.（1）測圓架必須調到與轉子中心基準面同心，同心度應小于0.05mm。The roundness-measuring device must be aligned exactly concentric to the rotor hub reference surfaces. The deviation of concentricity should be

30、 less than 0.05mm.（2）測圓架的旋轉一周的測量偏差小于0.02mm。The measuring deviation of arm turing one cycle should be less thang 0.02mm.2. 在安裝間, 用粉筆標注轉子磁軛支撐的位置Mark the position for the rotor rim supports with chalk on the erection bay.3. 最終安裝磁軛鍵。Final installation of wedges. （1）用卡蘭臨時把磁軛主鍵與兩個副鍵固定在一起，以便進行磁軛的疊裝。The two

31、 auxiliary wedges must be fixed together with main wedge using clamps, for rim stacking.（2）轉子磁軛疊片疊至120mm高度。Stack rotor rim up to a height of 120mm.（3）按照圖紙檢查磁軛疊片錯開距離是否正確。Check for correct interlacing of the rim sheets according to the drawing.（4）用塑料錘輕擊磁軛疊片使其穿過疊片銷。Drive rim sheets with plastic hammer

32、over the stacking pins.4. 按照圖紙進行轉子磁軛疊片，直至第一次壓緊高度。Stack rotor rim according to the drawing until you reach the height for the first pre-pressing.（1）按照圖紙檢查磁軛疊片的錯開距離是否正確。Check for correct interlacing of the rim sheets according to the drawing.（2）用塑料錘輕擊磁軛疊片使其穿過疊片銷。Drive rim sheets with plastic hammer ov

33、er the stacking pins.（3）根據磁軛疊片測量結果加補償片。Equalize rim according to the measured rim sheet.（4）一旦疊片銷不能起到調整磁軛疊片的作用，就要向上拉長疊片銷。Pull up the long stacking pins as soon as the alignment of the rim sheets is not guaranteed. （5）補償片的壓緊螺栓孔位置要與磁軛壓緊螺栓孔位置對齊。Align the equalizing segments exactly to the holes for the

34、rim press bolts.（6）不要移動下端的短疊片銷，這些疊片銷使磁軛疊片成為一個牢固的整環(huán)。Do not move the short stacking pins on the DE side. These stacking pins hold the rim sheets to a solid ring together.（7）拉出疊片銷（長疊片銷）末端的伸出長度應不超過200mm。The length of projection of the pulled up stacking pin ends (long stacking pins) should not be more t

35、han 200 mm.5. 用風動扳手壓緊轉子磁軛。Pre-press rotor rim with impact wrenches according to the instruction.（1）用風動搬手按照圖紙要求壓緊螺栓。Pre-stress the bolts according to the drawing with impact wrenches.（2）重復壓緊順序直到擰緊所有螺栓，按對稱交錯的原則進行。Repeat the pre-stress sequence until all the bolts are tight by principle of cross and in

36、terlacing.6. 重復以上步驟，按照圖紙進行轉子磁軛疊片，直至最后一次壓緊高度。Repeat above steps, stack rotor rim according to the drawing until you reach the height for the final pressing. （1）按照圖紙檢查磁軛疊片的錯開距離是否正確。Check for correct interlacing of the rim sheets according to the drawing.（2）用塑料錘輕擊磁軛疊片使其穿過疊片銷。Drive rim sheets with plast

37、ic hammer over the stacking pins.（3）根據磁軛疊片第三次壓緊測量的結果加補償片。Equalize rim according to the measurements taken at the third pre-pressing（4）一旦疊片銷不能起到調整磁軛疊片的作用，就要向上拉長疊片銷。Pull up the long stacking pins as soon as the alignment of the rim sheets is not guaranteed. （5）補償片的壓緊螺栓孔位置要與磁軛壓緊螺栓孔位置對齊。Align the equali

38、zing segments exactly to the holes for the rim press bolts.（6）不要移走下端的短疊片銷，這些疊片銷使磁軛疊片成為一個牢固的整環(huán)。Do not move the short stacking pins on the DE side. These stacking pins hold the rim sheets to a solid ring together.（7）拉出疊片銷（長疊片銷）末端的伸出長度應不超過200mm。The length of projection of the pulled up stacking pin end

39、s (long stacking pins) should not be more than 200 mm.7. 按照手冊用液壓工具對轉子磁軛進行最終壓緊。首先用風動扳手對每隔一個螺栓進行預壓緊，用液壓工具壓緊所有的螺栓。Final pressing of rotor rim with hydraulic press-equipment according to the instruction. First pre-press every second bolt with impact wrench. Press the all bolts with the hydraulic press c

40、ylinders.（1）按照手冊壓緊螺栓。逐步增加擰緊壓力直至達到最終壓力。大約進行三步壓緊后，才能達到最終壓力。Pre-stress the bolts according to the instruction.Increase the tightening pressure in steps up to the final pressure. Make approximately three pressure steps until you pre-stress the bolts with the final pressure.（2）安裝前壓緊螺栓和螺紋涂潤滑脂。The press bo

41、lts and the treads must be greased prior to the installation.（3）重復壓緊程序直到所有螺栓達到最終壓緊值。Repeat the pre-stress sequence until all the bolts have reached the final pre-stress（4）為了防止在磁軛疊片之間移動，最初2圈不要用最終壓力壓緊螺栓，每次壓緊的量應不超過兩個圈。Do not pre-stress the bolts with the final pressure the first two turns in order to p

42、revent movements between the rim sheets. Not more than two turns every pressing step.8. 檢查最終壓緊好的磁軛。Check final pre-stressed rim.（1）用拉伸檢查裝置抽查10%的壓緊螺栓的拉伸值。如果沒有達到規(guī)定的拉伸值，再次壓緊所有的壓緊螺栓。Check elongation on 10% of the press bolts with the elongation control device. Pre-stress all press bolts again, if the sp

43、ecified elongation were not achieved.（2）在磁軛的內、外徑用鋼卷尺測量磁軛的高度。在圓周上測量每張磁軛的高度。記錄結果。Measure the rim height with a steel tape measure on the inside and the outside diameter of the rim. Measure the heights on every rim sheet at the circumference. Record the measurements on the test sheet.（3）用直尺和塞尺檢查上、下壓板的徑

44、向平面度，并記錄結果。Check radial flatness of the DE and NDE press plates with a straight edge and a feeler gauge. Record measurements on the test sheet.（4）用精密水平儀和帶有百分表的測圓架檢查下壓板的水平度。Check the level of the DE press plates by using a precision level and the roundness-measuring device with a dial indicator.（5）用測

45、圓架測量并記錄磁軛直徑和同心度。Measure and record the concentricity and diameter of the rim with the roundness-measuring device.（6）按圖紙安裝制動環(huán)瓦及相應的墊片。Install all brake ring segments with the corresponding spacer sheets according to the drawing. （7）在檢驗表上記錄制動環(huán)的平面度。Record flatness of the brake ring segments on the test

46、sheet.9. 沿轉子轉動方向制動環(huán)必須平滑或連續(xù)，制動一環(huán)后一塊不能高出前一塊。The passing between brake ring segments must be even or slide off against the direction of rotation. Outer surface of brake ring segments must touch the wedges.5.4 轉子繞組組裝Rotor winding assembly1. 檢查轉子磁軛及磁極表面的所有溝槽Check all pole slots in the rotor rim and rotor

47、 rim surface.（1）檢查磁極溝槽。磁極溝槽的表面必須清潔且無油漬無損傷。若有必要，清潔表面。Check pole slots. The pole slot surfaces must be clean, free of paint and damages. Clean surfaces, if necessary.（2）檢查磁軛表面。磁軛表面及磁極的受力區(qū)域必須清潔且無油漆滴、無損傷。若有必要， 清潔磁軛表面。Check rim surface. The rim surface must be clean and free of paint drops and damages in

48、 the pole bearing area. Clean rim surface, if necessary.2. 準備安裝轉子磁極Prepare rotor poles for installation.（1）外觀檢查轉子磁極是否有損傷。Visual check of rotor pole for damages.（2）檢查磁極。磁極必須清潔且無油漬、無損傷。必要的話，清潔磁極。Check pole claws. The pole claws must be clean, free of paint and damages. Clean pole claws, if necessary.（

49、3）檢查磁極受力區(qū)域。該區(qū)域必須清潔且無油漬、無損傷。必要的話，清潔磁極受力區(qū)域。Check pole-bearing areas. The pole bearing areas must be clean and free of paint and damages. Clean pole-bearing areas if necessary.（4）檢查磁極繞組接頭表面。要保證其清潔且無損傷。必要的話，清潔表面。Check surfaces for the pole winding connections. The surfaces for the pole winding connectio

50、ns must be clean and free of damages. Clean surfaces, if necessary.（5）檢查阻尼繞組接頭表面。要保證其清潔且無損傷。必要的話，清潔表面。Check surfaces for the damper winding connections. The surfaces for the damper winding connections must be clean and free of damages. Clean surfaces, if necessary.3. 測量并記錄磁極繞組的絕緣電阻，如不符合要求應對磁極進行烘干。Me

51、asure and record insulation resistance of the pole winding. If very low must bake pole.4. 確定轉子磁極的放置位置。磁極沿轉子圓周的分布時，應按磁極重量的偏差進行補償。Determine the locating place of the rotor poles. The poles must be distributed on the circumference of the rotor, that the tolerance of the pole weights and the field leads

52、 weights will be compensated. 5. 在進行轉子磁極配重時要將磁極按圖紙分成兩組，兩種磁極的位置不同，應按圖紙進行區(qū)分。When confirm poles location, should divide the poles to two groups, the location of two type poles is different, should pay more attention by the drawing.6. 先裝的兩個磁極確定的墊片厚度，掛裝其它磁極。Install all poles with the shim thickness, defi

53、ned during the installation of the first two rotor poles. 7. 轉子磁極和磁軛要按No.2條所述做好安裝準備。The rotor poles and the rim must be prepared for installation as described under point No.2.（1）安裝前，檢查磁極重量是否正確。Check for correct weight of the pole prior to the installation.（2）檢查極性順序是否正確。Check for correct polarity se

54、quence.8. 安裝磁極和阻尼繞組接頭的固定板，根據圖紙在磁軛上定位。Install pole and damper winding connection fixing plate, positioning according to the drawing in to the rotor rim.（1）固定板的位置由阻尼繞組和磁極的連接頭確定。Position of fixing plates is given from the damper winding and pole coil connections（2）所有接觸面必須干凈，無損傷All contact surfaces must be clean and free of damages.9. 根據圖紙，安裝勵磁引線，并鎖定螺栓。Install field leads and lock bolts according to the drawing.10. 按圖紙要求安裝上、下風扇。Install the upper and lower air fans according to drawing.11. 根據圖紙，檢查和試驗計劃測試轉子。Test rotor according to the