懸臂式斗輪堆取料機安裝技術條件及調(diào)試、試驗規(guī)程

1、第一篇 概述Chapter 1:General IntroductionDQ1200/2500.40懸臂式斗輪堆取料機是由長春發(fā)電設備總廠為越南沿海一期火力發(fā)電廠項目開發(fā)、設計、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) 設備簡介Section 1 Brief Introduction of the equipment 越南沿海一期火力發(fā)電廠項目共二臺斗輪堆取料機,為整體俯仰,頭部分流固定單尾車。詳見總圖(圖號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.斗輪堆取料機由斗輪機構、上部金屬結構、懸臂膠帶機、主機梯子平臺、俯仰裝置及系統(tǒng)、行走機構、門座、中部料斗、緩沖托架、回轉機構、集中潤滑裝置、限位裝置、檢測裝置、尾車、尾車梯子平臺、電氣室、電氣系統(tǒng)、司機室及支架、廠牌、配重組

4、、灑水裝置、動力電纜卷筒裝置、控制電纜卷筒裝置、水纜卷筒、轉盤、支承鉸座、基礎布置及載荷等組成;司機室安裝在門柱下部;裝有斗輪機構、懸臂膠帶機、司機室、配重組等變幅部分的上部金屬結構圍繞變幅鉸點變幅;尾車上裝有動力電纜卷筒、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本設備能夠采用手動、手動聯(lián)鎖、半自動進行堆料和取料作業(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,中部料斗分流板處于堆料狀態(tài),系統(tǒng)膠帶機送來的物料經(jīng)尾車(系統(tǒng)膠帶機、尾車頭部落料斗轉運到中部料斗,再輸送到懸臂膠帶機上,然后拋向儲煤場。臂架的上仰和下俯可實現(xiàn)高、低位的堆料;臂架回轉實現(xiàn)左右料場及料場寬度的堆料;大車行走則實現(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行的 ,必要時也可以進行斜坡取料。斗輪機構上的斗子挖取上來的煤卸至懸臂膠帶機上,再由懸臂膠帶機拋向中部料斗,經(jīng)系統(tǒng)膠帶機輸出。臂架的上仰和下俯可實現(xiàn)高、低位的取料;臂架回轉實現(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)膠帶機送來的煤經(jīng)尾車膠帶機(系統(tǒng)膠帶機、尾車頭部落料斗,一部分經(jīng)分流料斗轉運到

13、中部料斗卸至緩沖托架、經(jīng)系統(tǒng)膠帶機輸出。另一部分輸送到懸臂膠帶機上,然后拋向儲煤場。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.詳細結構說明請參見本機的使用、維護說明書。(Detailed structure and instruction, refer to “Operation and maintenance instruction” of this machine.第三節(jié) 設備的性能參數(shù)、基礎載荷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 reclaiming13.5 m above rail and 1.5 m below rail4 斗輪轉速Rpm. of the Bucket wheelBelt speedSlew

16、ing radius of Bucket wheelboom40m 7回轉角度Slewing angle ±110° 8 回轉速度Slewing speedTraveling 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 總裝機容量Total installed capacity430kW12 電源:Power 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, frequen

17、cy: 50HzPower supply mode: cable reel drum13 風壓:Wind pressure 最大工作風壓250N/m2、最大非工作風壓1850N/m2 Max. Working wind pressure: 250N/m2,Max. non- working wind pressure:1850N/m2.本安裝技術條件和調(diào)試、試驗規(guī)程適用于越南沿海一期火力發(fā)電廠項目DQ1200/2500.40懸臂式斗輪堆取料機,并作為斗輪堆取料機安裝要求及安裝質量標準和安裝完畢進行調(diào)試、試驗、驗收質量標準的依據(jù)。其中主要內(nèi)容如下:各部件或設備的維修說明及維修質量標準;各部件或設

18、備的調(diào)試、試驗規(guī)程;安裝要求及安裝質量標準。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. It is also as a standard for installation requirements and installa

19、tion 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 component or equipment- Regulations on commissioning and test of each

20、component or equipment- Installation requirements and installation quality standard第二篇 安裝技術條件Chapter 2: Technical Conditions of Installation第一節(jié) 總則Section 1: General Principles1 斗輪堆取料機必須按規(guī)定程序批準的圖樣及技術條件的要求進行安裝。Bucket wheel stacker reclaimer must be installed according to the drawings approvedby specif

21、ied program and technical requirements.2 待安裝的零部件必須是檢驗合格的產(chǎn)品,外購機電產(chǎn)品應具有出廠合格證、使用、維護說明書。The spare parts and components installed must be conformable products through inspection, the bought-in mechanical and electrical products should have ex-work quality certificate and operation & maintenance specif

22、ications.3 安裝中的消耗材料(焊條、緊固件、潤滑脂、機械油、液壓油等必須具有出廠合格證,符合國家(或行業(yè)標準。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 be in accordance with national (or industry standards.4 安裝工作應由專業(yè)部門負責

23、進行。Installing work should be responsible by professional departments.第二節(jié) 安裝前的準備工作Section 2: Preparations before installation1 斗輪堆取料機各零部件及構架等運到現(xiàn)場卸車時應避免扭、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 Wheel Stacker Reclaimer will avoid distortion, bend , collision, corro

24、sion; etc accident, while unloading after they arrive at the jobsite. Therefore, the following rules must be observed:1.1 起吊時構件至少應捆扎兩處,捆扎處須有襯墊物,并捆扎在有筋板等加強節(jié)點處,一般應盡可能捆扎在構件的兩端,不宜捆扎在非節(jié)點部位或構件的外伸部。The components must be lifted with being enlaced at least two points where there must be gaskets, and they sh

25、ould 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 搬運時應將構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 components should be placed on trucks or flatcars while transported. It

26、is forbidden to roll or pull them directly on the ground.1.3 存放時應安置平穩(wěn),用枕木墊實放平,枕木應對稱放置,地面也必須選擇結實平整完好處,以防日久下沉以致構件變形。They should be stored on stationary crossties, and the crossties should be placed in symmetry. The ground must be solid, smooth and intact, thus avoiding deforming of the components due

27、to ground falling as time passes.1.4 零(部件如需露天存放的,應遮蓋好,對存放日期長或露天存放的件安裝前應檢查銹蝕情況,清除污漬,必要時重新涂油組裝,使各轉動部分靈活,并檢查各聯(lián)接部分的牢固性。存放期間應定期保養(yǎng),注意防潮、防銹和通風。If some parts and components need be stored outdoor, they should be well covered. Those that will be stored for a long time or outdoor should be inspected their rus

28、t 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 maintained regularly, prevented from moisture, rusting and ventilati

29、on.2 安裝前應組織安裝人員認真熟悉圖樣,根據(jù)要求詳細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 requirements of drawings should be modified.3 按附錄A復核查驗斗輪堆取料機軌道精度。Recheck and

30、inspect the rail accuracy of Bucket Wheel Stacker Reclaimer according to appendix A.4 安裝位置應選在錨定位置為宜(如在非錨定位置安裝,則應在車輪下塞進“鐵靴”以防大風刮跑。The installation position should be selected to anchoring point (if in non-anchoring point, wedge block assembly should be stuffed under the wheel to avoid blowing away by

31、 storm.第三節(jié) 安裝Section 3: Installation1 現(xiàn)場連接Connection on the jobsite1.1 所有連接應根據(jù)圖樣及有關連接技術要求進行。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,嚴禁強制裝配。It is unallowable to have additional force during connection; it is strictly prohibited to

32、 assemble forcibly.1.3 為減少高空作業(yè)量,應盡量在地面上連接。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 connection1.4.1 安裝焊接工作應由合格焊工進行。Site welding should be completed by qualified welders.1.4.2 重要構件的連接接口處應開坡口。The connection of the main comp

33、onents should be made bevel.1.4.3 焊接材料的型號、規(guī)格應符合設計圖樣及焊接工藝要求,一般Q235-A鋼制造的構件采用E4303焊條,16Mn制造的構件采用E5015焊條。異種材料構件之間的焊接,一般按強度較強的金屬基體選用焊條。本機除平臺以外全部工地現(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. Norm

34、ally, E4303 electrodesapply 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

35、site installation of this equipment should adopt E5015 electrodes.1.4.4 焊條使用前應根據(jù)使用說明書參照表1-1規(guī)定烘干。烘干的焊條應存放于在100150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 containe

36、r on the jobsite for taking electrode for use at any time of welding. 表1-1 Table 1-1焊條牌號Electrode brand 烘干溫度Baking temperature烘干Baking timeE4303 1502502小時2 hoursE5015 35040023小時23 hours1.4.5 烘干的焊條置于空氣中超過四小時應重新烘干,但烘干次數(shù)超過二次的焊條僅能作為次要件焊接使用。After the baked electrodes being placed in the open air for more

37、 than 4 hours, they must be re-baked in the heating oven, Those electrodes rebaked more than twice can only be used as secondary welding.1.4.6 所有焊縫焊前必須徹底清除邊緣(不小于10mm的水跡、油污、鐵銹、油漆、氧化等雜物,直至露出金屬光澤。Edges of all welding seams ( 10mm must be cleaned completely e.g. water stain, oil stain, rust, paint and o

38、xides, etc. until the surfaces expose the metallic gloss.1.4.7 不準在非焊接部位上引弧和試電流,焊縫藥皮應清理干凈,焊瘤要鏟除。It is not permitted to strike the arc and test electric current on non-welding position,flux on the welding seam should be removed and the weld beading shall be removed.1.4.8 露天施焊時,凡遇雨、雪、大霧等特殊氣候,無安全措施不允許焊接

39、。If it rains, snows or fogs while welded outdoors, it is unallowable to weld without safety precautions.1.4.9 焊縫檢查Inspection for weld seama.焊縫高度應符合圖樣要求。The height of the weld seam should be in accordance with the requirements of the drawings.b.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

40、and slag etc defects on the welding seam andheat-affected surface.c.焊縫咬邊當板厚小于10mm時,不得大于0.5mm,當板厚大于10mm時,不得大于1mm,咬邊連續(xù)長度不大于100mm。二側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; the undercut of the welding seam is not greater than 1mm,

41、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.焊縫應呈圓滑過渡至母材的幾何形狀,焊縫轉角處應飽滿。Weld should be smooth transition to base metal geometry in

42、 shape, the corner ofweld should be fullness.1.5 高強度螺栓連接Connection with high strength bolt1.5.1 鋼結構用高強度螺栓連接方式Connection mode of high strength bolt for steel structure1.5.1.1 連接面的處理Treatment of connection surface1.5.1.1.1 連接前,必須清理連接表面的污物、油漆、油污及氧化皮等減少摩擦系數(shù)的雜物,并用鋼絲刷刷去浮銹,不準用砂輪打磨。Contaminations, paint, oi

43、l and oxide skin etc that can reduce friction 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.1.5.1.1.2安裝高強度螺栓時,嚴禁強行穿入螺栓(如用錘敲打。如不能自由穿入時,該孔應用鉸刀進行修整,修整后孔的最大直徑應小于1.2倍螺栓直徑。修孔時,為了防止鐵屑落入板

44、迭縫中,鉸孔前將四周螺栓全部擰緊,使板迭緊密貼后再進行。嚴禁氣割擴孔。While installation high strength bolt, bolts are not permitted to infix withadditional force (e.g. with hammer. If can not infix smoothly, fraise should be used to repair, the diameter of holes should be smaller than that of 1.2 bolt after repairing. Before startin

45、g 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.1.5.1.1.3安裝高強度螺栓時,構件的摩擦面應保持干燥,不得在雨中作業(yè)。While installing high strength bolts, friction surface of components should bedry, installation is n

46、ot permitted in rain.1.5.1.1.4大六角頭高強度螺栓施工所用的扭矩扳手,扳前必須校正,其扭矩誤差不得大于±5%,合格后方準使用。校正用的扭矩扳手,其扭矩誤差不得大于±3%。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 o

47、f wrench for correction is not more than ±3%.1.5.1.1.5大六角頭高強度螺栓的擰緊應分為初擰、終擰。對于大型節(jié)點應分為初擰、復擰、終擰。初擰扭矩為施工扭矩的50%左右,復擰扭矩等于初擰扭矩。初擰或復擰后高強度螺栓應用顏色在螺母上涂上標記,然后按施工扭矩值進行終擰。終擰后的高強度螺栓應用另一種顏色在螺母上涂上標記。Tightening for hexagon head high strength bolt is divided into pre-tighteningand final tightening, tightening for

48、 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 of first tightening. High strength bolts should be marked with color on the nut after first and second tightening

49、, then make final tightening according to operating torque. High strength bolts should be marked with different color.1.5.1.1.6大六角頭高強度螺栓擰緊時,只準在螺母上施加扭矩。高強度螺栓在初擰、復擰和終擰時,連接處的螺栓應按一定順序施擰,一般應由螺栓群中央順序向外擰緊。高強度螺栓的初擰、復擰、終擰應同一天完成。During tightening hexagon head high strength bolts, torque only on nuts. Bolts on

50、 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.1.5.1.2 緊固方法及預緊力Tightening method and pretightening forceHigh strength bolts must be tightened with torque wrench

51、 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 torque will be decided by the following formula:M=K Dg. dDg-預緊力M22高強螺栓Dg=210×10³NDg-pretightening force: M22 high strength bo

52、lt Dg=210×103N注:K值以生產(chǎn)高強螺栓的廠家提供的合格證為準。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裝備手段(起吊作業(yè)機具等和安裝現(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、質量的前提下,進行空間與時間的合理交叉,以達到縮短安裝周期的目的。Since the technical equipmen

53、ts and instruments (lifting 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

54、period. The following installation order is recommended.3 裝配與安裝技術要求:Technical Requirements for Assembly and Installation斗輪堆取料機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 行走機構Long Travel mechanism3.1.1 行走車輪安裝精度Installing precision of the

55、traveling wheel for long travela同側軌道上各車輪滾動圓的中心應在同一平面上,其同位差應符合表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同一臺車架的兩

56、個車輪Two wheels of the same bogie2mm同一支腿下的三個以上車輪 Over three wheels under the same support leg3mm同側軌道上的全部車輪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 horizont

57、al deflection ax shall not be more than 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相反,且上邊應向外偏,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 deflecti

58、on of the wheel ay shall not be more than one four-hundredth of the measured length L (figure 3 圖3 figure 33.1.2行走機構安裝精度應符合表1-3及圖4的規(guī)定。Installation accuracy for long travel drive should be in accordance with table1-3 and figure 4表1-3 Table1-3檢測項目測量點允許公差Inspection item Measuring point permissible tolerance 輪距W 兩鉸軸中心±5mm Wheel gauge W Center of two pivot shafts ±5mm軌距 S 輪距中心兩側之間±5mmRail gauge S Between two sides of thewheel gauge center ±5mm對角線A、B 臺車中心點15mmDiagonal A-B Cente