懸臂式斗輪堆取料機(jī)安裝技術(shù)條件及調(diào)試、試驗(yàn)規(guī)程

1、第一篇 概述Chapter 1:General IntroductionDQ1200/2500.40懸臂式斗輪堆取料機(jī)是由長春發(fā)電設(shè)備總廠為越南沿海一期火力發(fā)電廠項(xiàng)目開發(fā)、設(shè)計(jì)、制造的一種大型、連續(xù)、高效的散狀、粒狀物料堆取作業(yè)的設(shè)備。DQ1200/2500.40 Boom type bucket wheel stacker reclaimer (BWSR is a kind of large, continuous and efficient bulk cargo stacking & reclaiming equipment, developed/ designed and man

2、ufactured by Changchun Generating Equipment Co., Ltd, China for DUYEN HAI 1 THERMAL POWER PLANT Project.第一節(jié) 設(shè)備簡介Section 1 Brief Introduction of the equipment 越南沿海一期火力發(fā)電廠項(xiàng)目共二臺(tái)斗輪堆取料機(jī),為整體俯仰,頭部分流固定單尾車。詳見總圖(圖號(hào)DQ9721.0ST。Two sets Boom Bucket Wheel Stacker Reclaimer will be supplied by CGE for DUYEN HAI 1

3、THERMAL POWER PLANT Project, the luffing of each equipment is integral luffing, and the single tripper car is coal flow branching. Details refer to general drawing (Drawing No: DQ9721.0ST.斗輪堆取料機(jī)由斗輪機(jī)構(gòu)、上部金屬結(jié)構(gòu)、懸臂膠帶機(jī)、主機(jī)梯子平臺(tái)、俯仰裝置及系統(tǒng)、行走機(jī)構(gòu)、門座、中部料斗、緩沖托架、回轉(zhuǎn)機(jī)構(gòu)、集中潤滑裝置、限位裝置、檢測裝置、尾車、尾車梯子平臺(tái)、電氣室、電氣系統(tǒng)、司機(jī)室及支架、廠牌、配重組

4、、灑水裝置、動(dòng)力電纜卷筒裝置、控制電纜卷筒裝置、水纜卷筒、轉(zhuǎn)盤、支承鉸座、基礎(chǔ)布置及載荷等組成;司機(jī)室安裝在門柱下部;裝有斗輪機(jī)構(gòu)、懸臂膠帶機(jī)、司機(jī)室、配重組等變幅部分的上部金屬結(jié)構(gòu)圍繞變幅鉸點(diǎn)變幅;尾車上裝有動(dòng)力電纜卷筒、控制電纜卷筒、水纜卷筒、電氣室及灑水系統(tǒng)的水源裝置。Bucket Wheel Stacker Reclaimer consists of bucket-wheel mechanism, super steelstructure, boom conveyor, walkway/access stairs and platforms of the main machine, l

5、uffing unit and system, long travel, portal, centre chute, buffer bracket, slew unit, central lubrication system, limited switches, detector, tripper car, walkway/access stairs and platforms of tripper car, electric room and electrical system, operators cabin and brackets, nameplate, counterweight a

6、ssembly, dust suppression system, power cable reel drum, control cable reel drum, water cable reel drum, slew deck, supporting pivot block, foundational layout and load etc. Operators cabin is installed on the upper part of the pylon. The super steel structure on which bucket-wheel mechanism, boom c

7、onveyor, operators cabin, counterweight etc. luffing parts are installed will be luffing around the luffing pivot point. Power cable reel, control cable reel drum, water cable reel drum, electric room and water source device of dust suppression system are installed on the tripper car.第二節(jié) 工作原理Section

8、 2: Working Principle本設(shè)備能夠采用手動(dòng)、手動(dòng)聯(lián)鎖、半自動(dòng)進(jìn)行堆料和取料作業(yè)。This equipment can select to use manual, manual interlocking as well as semi-automatic stacking and reclaiming operation.堆料作業(yè)時(shí),中部料斗分流板處于堆料狀態(tài),系統(tǒng)膠帶機(jī)送來的物料經(jīng)尾車(系統(tǒng)膠帶機(jī)、尾車頭部落料斗轉(zhuǎn)運(yùn)到中部料斗,再輸送到懸臂膠帶機(jī)上,然后拋向儲(chǔ)煤場。臂架的上仰和下俯可實(shí)現(xiàn)高、低位的堆料;臂架回轉(zhuǎn)實(shí)現(xiàn)左右料場及料場寬度的堆料;大車行走則實(shí)現(xiàn)軌道長度方向的堆料。D

9、uring stacking operation, the centre chute branching plate should be in stacking state, the material transferred from yard-conveyor via tripper car conveyor, head hopper of the tripper car to centre chute and then feeding to boom conveyor, at last stacking onto stockpiles. Boom luffing can realize h

10、igh & low level stacking; Bucket wheel boom slewing can reach left-right stockyard and stockyard width stacking, Long Travel Drive can realize stacking along the track length.取料作業(yè)是按分層取料的工藝進(jìn)行的 ,必要時(shí)也可以進(jìn)行斜坡取料。斗輪機(jī)構(gòu)上的斗子挖取上來的煤卸至懸臂膠帶機(jī)上,再由懸臂膠帶機(jī)拋向中部料斗,經(jīng)系統(tǒng)膠帶機(jī)輸出。臂架的上仰和下俯可實(shí)現(xiàn)高、低位的取料;臂架回轉(zhuǎn)實(shí)現(xiàn)左右料場及料場寬度的取料;禁止只靠大車

11、行走取料。Reclaiming operation is carried out according to layer reclaiming process as well as bevel reclaiming if necessary. Discharge the coal excavated and reclaimed by the hopper of the bucket wheel mechanism to boom conveyor- then through boom conveyor drop into centre chute, via yard conveyor trans

12、port out. Bucket wheel boom luffing can realize high & low level reclaiming; Bucket wheel boom slewing can reach left-right stockyard and stockyard width reclaiming; Forbidden to reclaim the material only depending on long travel mechanism traveling.分流作業(yè)是系統(tǒng)膠帶機(jī)送來的煤經(jīng)尾車膠帶機(jī)(系統(tǒng)膠帶機(jī)、尾車頭部落料斗,一部分經(jīng)分流料斗轉(zhuǎn)運(yùn)到

13、中部料斗卸至緩沖托架、經(jīng)系統(tǒng)膠帶機(jī)輸出。另一部分輸送到懸臂膠帶機(jī)上,然后拋向儲(chǔ)煤場。Branching operation is such a process that the coals, from yard conveyor, go through tripper car conveyor (yard conveyor and tripper car head hopper, part of coals go through branching hopper, transported to centre chute and discharged at buffer bracket, out

14、put by yard conveyor; the other part of coals transported on boom conveyor and discharged at stockpile.詳細(xì)結(jié)構(gòu)說明請參見本機(jī)的使用、維護(hù)說明書。(Detailed structure and instruction, refer to “Operation and maintenance instruction” of this machine.第三節(jié) 設(shè)備的性能參數(shù)、基礎(chǔ)載荷Section 3: Performance Parameter and foundational arrangem

15、ent load of the Equipment1 堆料能力Stacking capacity2500t/h(額定 3000t/h(額定 2500 t/h (rated 3000t/h (rated 2 取料能力Reclaiming capacity1200t/h(額定 1440t/h(額定 1200 t/h (rated 1440t/h(rated 3 堆取高度 Height of stacking and reclaiming軌上13.5m 、軌下1.5m13.5 m above rail and 1.5 m below rail4 斗輪轉(zhuǎn)速Rpm. of the Bucket whee

16、l6.86r/min 5 膠帶速度Belt speed3.15m/s 6 臂架回轉(zhuǎn)半徑Slewing radius of Bucket wheelboom40m 7回轉(zhuǎn)角度Slewing angle ±110° 8 回轉(zhuǎn)速度Slewing speed0.0320.116r/min 9 走行速度Traveling speed 工作速度7.5m/min 、調(diào)車速度30m/min Working speed: 7.5 m/min,commissioning speed: 30m/min10 總裝機(jī)容量Total installed capacity430kW12 電源:Power

17、 Supply 供電電壓6.6kV 、供電頻率50Hz 、供電方式為電纜卷筒 Power voltage: 6.6 kV, frequency: 50HzPower supply mode: cable reel drum13 風(fēng)壓:Wind pressure 最大工作風(fēng)壓250N/m2、最大非工作風(fēng)壓1850N/m2 Max. Working wind pressure: 250N/m2,Max. non- working wind pressure:1850N/m2.本安裝技術(shù)條件和調(diào)試、試驗(yàn)規(guī)程適用于越南沿海一期火力發(fā)電廠項(xiàng)目DQ1200/2500.40懸臂式斗輪堆取料機(jī),并作為斗輪堆取

18、料機(jī)安裝要求及安裝質(zhì)量標(biāo)準(zhǔn)和安裝完畢進(jìn)行調(diào)試、試驗(yàn)、驗(yàn)收質(zhì)量標(biāo)準(zhǔn)的依據(jù)。其中主要內(nèi)容如下:各部件或設(shè)備的維修說明及維修質(zhì)量標(biāo)準(zhǔn);各部件或設(shè)備的調(diào)試、試驗(yàn)規(guī)程;安裝要求及安裝質(zhì)量標(biāo)準(zhǔn)。This “Installation Technical Conditions & Regulations on Commissioning and Test” will be applicable for DUYEN HAI 1 THERMAL POWER PLANT Project - DQ1200/2500·40 Boom Bucket Wheel Stacker cum Reclaimer

19、. It is also as a standard for installation requirements and installation quality as well as a basis for quality of commissioning/ test, also as a standard for quality acceptance after installation. Main contents will be as follows:- Maintenance instruction and maintenance quality standard of each c

20、omponent or equipment- Regulations on commissioning and test of each component or equipment- Installation requirements and installation quality standard第二篇 安裝技術(shù)條件Chapter 2: Technical Conditions of Installation第一節(jié) 總則Section 1: General Principles1 斗輪堆取料機(jī)必須按規(guī)定程序批準(zhǔn)的圖樣及技術(shù)條件的要求進(jìn)行安裝。Bucket wheel stacker re

21、claimer must be installed according to the drawings approvedby specified program and technical requirements.2 待安裝的零部件必須是檢驗(yàn)合格的產(chǎn)品,外購機(jī)電產(chǎn)品應(yīng)具有出廠合格證、使用、維護(hù)說明書。The spare parts and components installed must be conformable products through inspection, the bought-in mechanical and electrical products should ha

22、ve ex-work quality certificate and operation & maintenance specifications.3 安裝中的消耗材料(焊條、緊固件、潤滑脂、機(jī)械油、液壓油等必須具有出廠合格證,符合國家(或行業(yè)標(biāo)準(zhǔn)。The consumable material of installation (such as electrodes, fasteners, lubricating grease, machine oil, and hydraulic oil etc must have an Ex-work certificate, and should

23、 be in accordance with national (or industry standards.4 安裝工作應(yīng)由專業(yè)部門負(fù)責(zé)進(jìn)行。Installing work should be responsible by professional departments.第二節(jié) 安裝前的準(zhǔn)備工作Section 2: Preparations before installation1 斗輪堆取料機(jī)各零部件及構(gòu)架等運(yùn)到現(xiàn)場卸車時(shí)應(yīng)避免扭、彎、撞擊、腐蝕等事故的發(fā)生,為此必須遵守以下規(guī)定:All parts and components as well as frames of Bucket W

24、heel Stacker Reclaimer will avoid distortion, bend , collision, corrosion; etc accident, while unloading after they arrive at the jobsite. Therefore, the following rules must be observed:1.1 起吊時(shí)構(gòu)件至少應(yīng)捆扎兩處,捆扎處須有襯墊物,并捆扎在有筋板等加強(qiáng)節(jié)點(diǎn)處,一般應(yīng)盡可能捆扎在構(gòu)件的兩端,不宜捆扎在非節(jié)點(diǎn)部位或構(gòu)件的外伸部。The components must be lifted with being

25、 enlaced at least two points where there must be gaskets, and they should be enlaced at the stiffener nodes of stiffener, normally, the components should be enlaced at the two ends, it is improper to enlace them at places without nodes or extensional part.1.2 搬運(yùn)時(shí)應(yīng)將構(gòu)件擱置在載重汽車或平板車上,禁止直接在地面上放滾拖移。The com

26、ponents should be placed on trucks or flatcars while transported. It is forbidden to roll or pull them directly on the ground.1.3 存放時(shí)應(yīng)安置平穩(wěn),用枕木墊實(shí)放平,枕木應(yīng)對稱放置,地面也必須選擇結(jié)實(shí)平整完好處,以防日久下沉以致構(gòu)件變形。They should be stored on stationary crossties, and the crossties should be placed in symmetry. The ground must be sol

27、id, smooth and intact, thus avoiding deforming of the components due to ground falling as time passes.1.4 零(部件如需露天存放的,應(yīng)遮蓋好,對存放日期長或露天存放的件安裝前應(yīng)檢查銹蝕情況,清除污漬,必要時(shí)重新涂油組裝,使各轉(zhuǎn)動(dòng)部分靈活,并檢查各聯(lián)接部分的牢固性。存放期間應(yīng)定期保養(yǎng),注意防潮、防銹和通風(fēng)。If some parts and components need be stored outdoor, they should be well covered. Those that wi

28、ll be stored for a long time or outdoor should be inspected their rust situations before installation and derusting, and repainted and reassembled if necessaryto make sure smooth running of every rotating part. The fastness of every linked part should be also inspected. During storage they should be

29、 maintained regularly, prevented from moisture, rusting and ventilation.2 安裝前應(yīng)組織安裝人員認(rèn)真熟悉圖樣,根據(jù)要求詳細(xì)檢查部件的安裝尺寸,不符合圖樣要求的需校正。It is necessary to organize personnel to read the drawings carefully, inspect the installation dimension of all spare parts and components, the parts which can not meet the requirem

30、ents of drawings should be modified.3 按附錄A復(fù)核查驗(yàn)斗輪堆取料機(jī)軌道精度。Recheck and inspect the rail accuracy of Bucket Wheel Stacker Reclaimer according to appendix A.4 安裝位置應(yīng)選在錨定位置為宜(如在非錨定位置安裝,則應(yīng)在車輪下塞進(jìn)“鐵靴”以防大風(fēng)刮跑。The installation position should be selected to anchoring point (if in non-anchoring point, wedge bloc

31、k assembly should be stuffed under the wheel to avoid blowing away by storm.第三節(jié) 安裝Section 3: Installation1 現(xiàn)場連接Connection on the jobsite1.1 所有連接應(yīng)根據(jù)圖樣及有關(guān)連接技術(shù)要求進(jìn)行。All connections should be carried out according to drawings and related technical requirements.1.2 連接中不允許存在附加力,嚴(yán)禁強(qiáng)制裝配。It is unallowable to

32、have additional force during connection; it is strictly prohibited to assemble forcibly.1.3 為減少高空作業(yè)量,應(yīng)盡量在地面上連接。Connection should be done on the ground in order to reduce work high above the ground.1.4 焊接連接要求Requirements for welding connectionSite welding should be completed by qualified welders.The

33、connection of the main components should be made bevel.件采用E4303焊條,16Mn制造的構(gòu)件采用E5015焊條。異種材料構(gòu)件之間的焊接,一般按強(qiáng)度較強(qiáng)的金屬基體選用焊條。本機(jī)除平臺(tái)以外全部工地現(xiàn)場安裝焊條采用E5015焊條。The type and specification of the welding material should be in accordance with thedesign drawings and requirements of welding procedure. Normally, E4303 elect

34、rodesapply to the components made of Q235-A steel, E5015 electrodes apply to those madeof 16Mn steel. Welding between different material components, electrode should usuallybe selected according to the metal with larger hardness. Except the platform, all welding electrodes used for site installation

35、 of this equipment should adopt E5015 electrodes.150保溫箱中,隨用隨取。Electrode should be baked before being used according to reference of table 1-1 in the “operating instruction”. The baked electrodes should be stored in a 100150 thermal container on the jobsite for taking electrode for use at any time of

36、 welding. 表1-1 Table 1-1焊條牌號(hào)Electrode brand 烘干溫度Baking temperature烘干Baking timeE4303 1502502小時(shí)2 hoursE5015 35040023小時(shí)23 hours為次要件焊接使用。After the baked electrodes being placed in the open air for more than 4 hours, they must be re-baked in the heating oven, Those electrodes rebaked more than twice can

37、 only be used as secondary welding.Edges of all welding seams ( 10mm must be cleaned completely e.g. water stain, oil stain, rust, paint and oxides, etc. until the surfaces expose the metallic gloss.It is not permitted to strike the arc and test electric current on non-welding position,flux on the w

38、elding seam should be removed and the weld beading shall be removed.If it rains, snows or fogs while welded outdoors, it is unallowable to weld without safety precautions.Inspection for weld seama.焊縫高度應(yīng)符合圖樣要求。The height of the weld seam should be in accordance with the requirements of the drawings.b

39、.焊縫及熱影響表面不得有裂紋、氣孔、弧坑和夾渣等缺陷。No cracks, pores, arc craters and slag etc defects on the welding seam andheat-affected surface.c.焊縫咬邊當(dāng)板厚小于10mm時(shí),不得大于0.5mm,當(dāng)板厚大于10mm時(shí),不得大于1mm,咬邊連續(xù)長度不大于100mm。二側(cè)咬邊總長不得超過焊縫總長的10%。The undercut of the weld seam is not more than 0.5mm, if the plate thickness is less than 10mm; t

40、he undercut of the welding seam is not greater than 1mm, if the plate thickness is more than 10mm; and the continuous length of the undercut will not more than 100mm. The total length of the bilateral undercut shall not exceed 10% of the total length of the welding seam.d.焊縫應(yīng)呈圓滑過渡至母材的幾何形狀,焊縫轉(zhuǎn)角處應(yīng)飽滿。W

41、eld should be smooth transition to base metal geometry in shape, the corner ofweld should be fullness.1.5 高強(qiáng)度螺栓連接Connection with high strength boltConnection mode of high strength bolt for steel structureTreatment of connection surfaceContaminations, paint, oil and oxide skin etc that can reduce fri

42、ction factor on the connection surface must be removed before connection. Steel brush should be used for getting rid of the rust on the face rust and without grinding wheel.additional force (e.g. with hammer. If can not infix smoothly, fraise should be used to repair, the diameter of holes should be

43、 smaller than that of 1.2 bolt after repairing. Before starting to repair, all the bolts around the hole are tightened and plates are put closely in order to avoid iron chips falling. Gas cutting for bearizing is prohibited.While installing high strength bolts, friction surface of components should

44、bedry, installation is not permitted in rain.Torque wrench for hexagon head high strength bolts must be corrected before using, torque error percentage is not more than ±5%, it is used after qualification; torque error percentage of wrench for correction is not more than ±3%.一種顏色在螺母上涂上標(biāo)記。T

45、ightening for hexagon head high strength bolt is divided into pre-tighteningand final tightening, tightening for big nodes is divided into first tightening, second tightening, final tightening. Torque for pre-tightening is 50% that of operating torque, torque for second tightening is equal to that o

46、f first tightening. High strength bolts should be marked with color on the nut after first and second tightening, then make final tightening according to operating torque. High strength bolts should be marked with different color.復(fù)擰和終擰時(shí),連接處的螺栓應(yīng)按一定順序施擰,一般應(yīng)由螺栓群中央順序向外擰緊。高強(qiáng)度螺栓的初擰、復(fù)擰、終擰應(yīng)同一天完成。During tigh

47、tening hexagon head high strength bolts, torque only on nuts. Bolts on the connection points should be tightened in sequence which from center to outside part during first, second and final tightening, these three process should be finished on the same day.Tightening method and pretightening force高強(qiáng)

48、度螺栓必須采用力矩搬手緊固,控制扭矩達(dá)到要求的預(yù)緊力。對本機(jī)采用的GB12281230-94標(biāo)準(zhǔn)大六角頭高強(qiáng)度螺栓,力矩板手扭矩值按下式確定: M=KDg.dHigh strength bolts must be tightened with torque wrench to control torque to reach the required pre-stress. Refer to the GB12281230-94 standard hexagon head high strength bolts that applies to this machine, the value of

49、torque will be decided by the following formula:M=K Dg. d式中: K -扭矩系數(shù)(范圍值0.110-0.150K-torque coefficient (range: 0.110-0.150Dg-預(yù)緊力M22高強(qiáng)螺栓Dg=210×10³NDg-pretightening force: M22 high strength bolt Dg=210×103Nd -螺栓直徑M22高強(qiáng)螺栓 d=0.022md-diameter of the bolt M22 high strength bolt d=0.022m注:K

50、值以生產(chǎn)高強(qiáng)螺栓的廠家提供的合格證為準(zhǔn)。Note: K value is in accordance with the conformity certificate offered by high strength bolt manufacturer.2 安裝順序Sequence of installation由于各安裝單位擁有的技術(shù)裝備手段(起吊作業(yè)機(jī)具等和安裝現(xiàn)場場地條件的不同,允許有不同的安裝方案,但在保證安全、可靠、經(jīng)濟(jì)、質(zhì)量的前提下,進(jìn)行空間與時(shí)間的合理交叉,以達(dá)到縮短安裝周期的目的。Since the technical equipments and instruments (li

51、fting machines etc. and the installation fields are various, it is permitted to use different installation plans which, however, must base on safety, reliability, economy and quality, and logically cross in time and space, so as to realize the objective of shorten installation period. The following

52、installation order is recommended.3 裝配與安裝技術(shù)要求:Technical Requirements for Assembly and Installation斗輪堆取料機(jī)對行走軌道的精度要求見附錄A。The rail accuracy being required by Bucket Wheel Stacker Reclaimer refers to Appendix A:3.1 行走機(jī)構(gòu)Long Travel mechanismInstalling precision of the traveling wheel for long travela同側(cè)軌道

53、上各車輪滾動(dòng)圓的中心應(yīng)在同一平面上,其同位差應(yīng)符合表1-2及圖1。The centers of the rolling circles of all wheels on the same side of the rail should be on the same level, whose position deflection should be in accord with Table1- 2 and figure 1表1-2 Table1-2測量部位Measuring point偏差Deflection同一臺(tái)車架的兩個(gè)車輪Two wheels of the same bogie2mm同一

54、支腿下的三個(gè)以上車輪 Over three wheels under the same support leg3mm同側(cè)軌道上的全部車輪All wheels on the same side of the rail5mm 圖1 figure 1b 同一軸線上一對車輪的水平偏斜方向應(yīng)相反,其水平偏斜值ax 不得大于測量長度 L 的千分之一(圖2。The deviated direction of a pair of wheels on the same axis shall be opposite, the horizontal deflection ax shall not be more t

55、han millesimal of the measured length L (figure 2.figure 2c 同一軸線上一對車輪的垂直偏斜方向應(yīng)相反,且上邊應(yīng)向外偏,車輪的垂直偏斜值 ay 不得大于測量長度 L 的四百分之一(圖3。The deviated direction of a pair of wheels on the same axis shall be opposite, the upper side shall deviate outwards, and the vertical deflection of the wheel ay shall not be more

56、 than one four-hundredth of the measured length L (figure 3 圖3 figure 3Installation accuracy for long travel drive should be in accordance with table1-3 and figure 4表1-3 Table1-3檢測項(xiàng)目測量點(diǎn)允許公差I(lǐng)nspection item Measuring point permissible tolerance 輪距W 兩鉸軸中心±5mm Wheel gauge W Center of two pivot shaf

57、ts ±5mm軌距 S 輪距中心兩側(cè)之間±5mmRail gauge S Between two sides of thewheel gauge center ±5mm對角線A、B 臺(tái)車中心點(diǎn)15mmDiagonal A-B Center point of the wheelbogie15mm水平度C 鉸軸中心高低差±5mm Flatness C High-low difference of pivot ±5mm輪距距軌圖4 figure3.2 斗輪機(jī)構(gòu)Bucket Wheel mechanismThe clearance between ri

58、ng chute and inner circle of wheel should be 510mm.After installation, angle between bucket-wheel shaft and upper surface of theBucket wheel boom is 7°.3.3 回轉(zhuǎn)機(jī)構(gòu)Slew unitDuring installation, the quenching soft strip of the slewing support should beplaced on unloading area or unfrequent load area.High strength friction grip bolts should be used for installing slewing suppor