金槍魚TCN124P-M012-GY03軸系安裝工藝(含主機定位)

1、1.概述：General:1.1本工藝描述了57000DWT散貨船軸系各主要部件安裝以及主機定位的技術要求。ThisproceduredescribedthetechnicalrequirementofshaftcomponentsinstallationandM/Elocatingof57000DWTBC.1.2軸系主要部件包含有，4葉定距螺旋槳一支(直徑6000mm，重約16,347kg),螺旋槳軸1根(4500>6505,10211kg)，中間軸1根(4420>6006,7159kg),艇管裝置1套(3839kg),中間軸承一套(645kg)，艇軸首尾密封裝置，軸接地裝置一套

2、。Maincomponentsofshaftincludethefollowingparts,onefixedpitchpropellerwithfourblades(diameter6000mm,weight16,347kg),onepropellershaft(4500>6505,10211kg),oneintermediateshaft(420>6006,7159kg),sterntubeunitoneset(3839kg),intermediateshaftbearingoneset(645kg),foreandaft.shaftsealassembly,shaftgrou

3、ndingunit.1.3軸系的安裝工藝流程ShaftsystemInstallationsequence拉線T(照光)管定位澆注環(huán)氧T主機底角螺栓孔定位T裝螺旋槳軸T裝艄1尾軸密封裝置T安裝無鍵螺旋槳T安放中間軸、主機。船下水后按軸系校中計算法定位軸系及主機。Pullingwire(Shaftsight)-Locatingsterntubeandchockfast-locatingM/EholdingdownboltsTnstallpropellershaft-installshaftsealassembly-installpropeller-PutintermediateshaftandM

4、/E.AftervessellaunchinginstallandconnecttheshaftandM/Eaccordingtotheshaftalignmentcalculation.注：船下水時，軸和主機作臨時固定，防止螺旋槳軸轉動。具體見“下水封槳封舵工藝”。Note:BeforelaunchingfixtheshaftandM/Etemporarily,avoidturningofpropellershaft.DetailseeProcedureforfixrudderandpropellerduringlaunching”.1.4所有軸系零件均為外購成品，尺寸加工到位，在吊運、安裝

5、過程中要注意保護。在進行吊裝前應仔細檢查吊運工具，如吊索、眼板、卸扣等應安全可靠。Allthecomponentsofshaftisfinishedproduction,pleasepaymoreattentionduringhoistingandinstallation.Checkcarefullyhandlingtoolbeforeshafthoist,suchashalyard,eyeplate,shackleshouldbesafeandreliable.2.適用范圍：Rangeofapplication:本工藝適用與12#57000DWT散貨船軸系安裝及主機定位施工。Thisproc

6、edureistobeappliedforinstructtheshaftinstallationandM/Elocatingfor12#57000DWTbulkcarrier.3.親資料：Referencedocuments:SC4439(ZS)G3-400-04機艙布置圖E/RArrangementdrawingSC4439(ZS)G3-425-01推進軸系布置圖ShaftarrangementdrawingSC4439(ZS)G3-230-02舵系布置圖RudderarrangementdrawingSC4439(ZS)-425-002-00艇軸管總圖Generaldrawingofst

7、erntubeSC4439(ZS)-420-001-00主機安裝圖InstallationdrawingforM/ESC4439(ZS)-107-001螺旋槳圖PropellerdrawingCB/T4000-2005中國造船質量標準ChinaShipbuildingQualityStandard4. 工裝設備FrockEquipment激光經緯儀、拉線架4套、鉛錘1只、重錘1只（25kg）、琴鋼絲（O0.5mm）、鋼直尺、50m卷尺、常用鉗工工具等。Laserinstrument、4drawlineframes、1plumb、aheavy（25kg）、O0.5mmsteelwire、stee

8、lruler、50mtaperuler、normallocksmithtoolsetc.5. 軸系精拉線條件：Shaftfinaldrawwirepreconditions:5.1機艙前壁（FR35）以后，主甲板以下主要結構焊接工作已完成，火工矯正工作結束。機艙內部的船體艙、柜的焊接打磨密性試驗交驗完畢。Weldingjobofstructuresthatafterforebulkhead（FR35）ofE/Randbelowmaindeckalmostfinished,andthefirecorrectionjobfinished.ThestructuretanksinE/Rwelding、

9、grindingjobandtightnesstestfinished.5.2軸系區(qū)域內主要輔機機座裝焊完成，除主機及舵機以外的大型設備（3t及以上）及底部單元等進艙就位。Intheareaaroundshaftline,theauxiliaryengineseattobeweldedcompletely,allthebigequipments（over3ton）andassemblyunitsonpositionexceptM/E、steeringgear.5.3船體墊墩、支柱受力均勻、穩(wěn)定牢固，不允許隨意移動。Frustaandsupportbelowstructurebearevenst

10、rength.Mustbesuretheyaresteadyandwithoutmovement.5.4軸系精拉線要求在不受陽光曝曬及無急劇溫度變化情況下進行，一般在晚間或陰天時進行，以避免船體變形影響軸系中心線的正確性。Shaftdrawwirejobshouldbecarriedoutontheconditionofwithoutsunshineandthetemperaturesharpchange.Usuallyshouldcarryoutineveningorcloudlyday,avoidhulldeflectionimpacttheshaftcenterlineposition.

11、5.5停止引起振動的作業(yè)與有嚴重噪聲干擾的作業(yè)。Stopthevabriationandloudjob.5.6定位所用的激光經緯儀以及測量工具應經相應檢驗部門校驗合格。Thelaserinstrumentandallthemeasuretoolstobecheckedoutbyinspectdept.6. 軸系精拉線前的準備：Preparationofshaftfinaldrawwire:6.1實船基準線的確定Baselinedetermine6.1.1測量龍骨變形量，計算龍骨平均高度點，作為船體實船基線。Measurethedeformationofkeelcalculatetheevenh

12、eightofkeelasthebaselineheight.6.1.2測量實船中心線偏差量，并在尾封板及機艙前橫艙壁的區(qū)域塢底平面上勘劃出實船中線面的投影線，作為軸線在塢底平面的投影線。MeasuretheactualcenterlineandmarkthecenterlineprojectionlineonthedrydockbelowE/Rarea,thelineisshaftlineprojectionline.6.2軸系中心線的確定Shaftcenterlinedetermine6.2.1船體尾部理論軸中心面的確定Sternpartshaftcenterprofiledetermin

13、ea,以中心線在塢底的延伸點為基準，調整激光經緯儀”1”的軸線直至與船中心線重合。TakethecenterlineprojectionlineondockfloorasbenchmarkadjustlasermachineryNo.1untiltheaxiallineoflasercrossedwithbenchmark.b,將激光經緯儀“1”射出的光點延伸到尾部拉線架“B”上，并在垂直方向向上平移，同時測量此光點到塢底的垂直距離，當測定的距離等丁船體軸線到船臺的距離時（即：軸系中心線的高度為3300+外板厚度+塢墩高度），則此點為軸系中心線上一點。以此點作為參考點并打好樣沖點，同時將激光經

14、緯儀旋轉180。將光點投射到后艇管支撐套后端面上，并打好樣沖，這樣就可初步確定軸系尾部理論面。B"andmovethelaserExtendthelaserfromNo.1machineonthewireframepointup,meantimemeasuretheverticaldistanceformdockbottomtothelaserpoint,duringthedistancesameasshaftcenterlinetodockbottomheightstopmovement,wecanconfirmthatthispointonthetheoryshaftcenter

15、line.Takethispointasbenchmarkandpunchitonframe.Turnlasherhead1800andpunchthelasherpointonsternbossingaft.face,atpresentthesternshaftprofilehasbeendetermined.6.2.2機艙內軸系中心線的確定ShaftcenterlinedetermineinE/Ra, 在機艙Fr21附近位置設立一激光經緯儀”2”，將光點延伸到船體外部的拉線架“B：使之與拉線架上的樣沖點重合。Arrangeonelasermachine2”aroundFr21inE/R,e

16、xtendlaseronthewireframeB,untilthelaserpointjustsuperposedwiththepunchmark.b, 調整激光經緯儀2的位置，使之既能與船體尾柱上的樣沖點的連線相交，同時也能投影到艇部拉線架上的樣沖點上，然后將經緯儀的位置固定。Adjustlaserhead(2)positionuntilthelaserpointcrossedwiththeconnectlinebetweenpunchmarkonsternbossingaft.face,andthelaserpointalsosuperposedwiththepunchmarkonfra

17、meB,fixthelasermachineposition.6.2.3軸系中心線的延伸Extendtheshaftcenterlinea,將激光經緯儀2調轉1800，將光點延伸并投影在機艙FR31拉線架上，并確定光點位置，打好樣沖點，這點與艇部拉線架上的樣沖點的連線即為理論軸線。Turnlasherhead(2)1800extendlasherpointonFR31frameA,andpunchit.ThenconnectionlinebetweenthepunchpointonframeA&Bisthetheoryshaftcenterline.6.3根據船舶設計理論軸系中心線，在

18、軸系冗首月尾端確定基準點，拉線時以此為基準?；鶞庶c坐標分別為：艄點A(Fr31,CL也，BL+3300)，艇點B(Fr-5-2000,CL也,BL+3300),見附圖。各基準點在現(xiàn)場確定后報驗船東船檢。Accordingtothetheoryshaftlinepositiondeterminetheforeandafterdatummark.Thecoordinateoftwodatummarksis:ForepointA(Fr31,CL也，BL+3300),Aft.pointB(Fr-5-2000,CL也，BL+3300),seeattacheddrawing.Twodatummarkspo

19、intpositionshouldbeconfirmedbyownerandsurveyor.6.4通過冗首艇基準點拉線，檢查FR13#艙壁艇管孔的直徑理論值應為4900,并根據軸系理論中心線檢查此開孔的偏心情況，在艙壁靠船首面劃出41130的檢驗圓以及圓孔的正交十字線，用洋沖標記。Throughthetwodatummarkpointspullsteelwireasshaftcenterline.AccordingtothislinecheckthesterntubeholeonFR13#bulkhead,thetheorydiameteris4900,checkeccentricityof

20、thehole,drawa(|)1130referenceroundandthecrosslinewithpunchmark.6.5在軸系基準點A后端，設立拉線架平臺，用來安放儀器和人員站立。AfterthetargetAarrangeoneplatformforthewireframe.6.6艇管裝置在車間平臺時應找正前后端面圓孔的中心，并劃十字線標記。前后艇管端面十字線交義點的連線即為艇管的理論中心線。完成后需交船東船檢認可。Findthecenterofforeandafterholeofsterntube,andmakecrosslinemarkontheendsurface.Thet

21、wocenterpointconnectlineisthetheorycenterlineofsterntube.Thecenterpointshouldconfirmedbyownerandsurveyor.6.7B管就位Installthesterntube6.7.1按“艇管總圖(425-02-00)”將八只艇管調整螺栓預先布置到相應位置處，其中四只在月尾柱中，另外四只安裝在FR13#艙壁船尾側。Accordingtogeneraldrawingofsterntube(425-02-00),previouslyplaceeightsterntubeadjustableboltstorela

22、tiveposition.Theafterfourboltsinsternbossing,theotherfourinstalledontheaft.sideofFR13#bulkhead.6.7.2按“艇管總圖(425-02-00)”焊好后艇柱上的兩個透氣管及一個注入管.注入管及透氣管均采用427X2.5無縫鋼管.鋼管上應無任何油漆，油污等。Accordingtogeneraldrawingofsterntube(425-02-00),weldtwoventpipesonaftsterntubesupportcoverandoneimmittube.Immitandventtubeallad

23、opt427X2.5seamlesssteelpipe.Noanypaintanddirtyonsteelpipe.6.7.3栓查艇管活潔，艇柱內表面及艇管外表面等與環(huán)氧樹脂接觸處(含澆注孔，透氣孔內表面)均需活除鐵銹、油污、毛刺、焊渣、油漆和灰塵等。提交環(huán)氧服務工程師及船東檢查活潔度。Checksterntubecleanness.Contactpartofsterntubefront&aftsupportcoverinnerfaceandsterntubeoutsidefacewithepoxyresin(includesprayinghole,ventholeinnerface)

24、needcleanrust,oildirty,burr,weldingdregs,paintinganddust.Submitepoxyserviceengineerandownertocheckcleannessandcansatisfytherequirement.6.7.4將艇管吊起送入艇柱中并向艄移動，在移動過程中注意保持艇管外表面和艇柱內表面活潔，并用丙酮活洗?，F(xiàn)場需由環(huán)氧服務工程師及船東監(jiān)控，當到達艇管裝置圖中所示位置時，重新檢查艇管外表面和艇柱內表面活潔度，提交環(huán)氧服務工程師及船東檢查活潔度。Hoistingthesterntubeandmoveittoforwardinster

25、nbossing,duringthetransportpleasekeepthesurfacecleannessandcleanituseacetone.Thechockfastserviceengineerandownerinspectonsite,duringthesterntubeonpositionrecheckthecleannessandsubmittoserviceengineerandownercheck.6.7.5擰入艄艇處的調節(jié)螺栓將艇管撐起，撤去起吊艇管所用的輔助工具。Sterntubewillberaisedbyscrewingadjustmentboltofforea

26、ndafter,andremoveallauxiliarytoolsthatslingsterntube.7. 拉線調整定位艇管：Drawwireandadjustthepositionofsterntube:7.1在理論軸線前后端拉線架上用40.5mm琴鋼絲穿過前后艇軸管拉出理論軸線，鋼絲自由端掛25kg重錘。Pullshaftlineonwireframeuse（|）0.5mmsteelwire,attheaft.sidehanga25kgheavy.7.2調節(jié)鋼絲線位置，使其穿過A和B兩個基準點，檢查確定后報驗船東船檢。Adjustthesteelwireuntilitthroughth

27、etwobenchmarkAandB,thensubmittedtoshipownerandsurveyorforapproval.7.3用為首艇調整螺栓精調艇管位置，使前后端艇管中心均在軸系理論中心線上（考慮撓度值）。并且調整艇管后端面距艇柱后端面距離為75mm，允許誤差±2mm。擰緊頂絲螺栓，固定艇管，報驗船東船檢。Adjustthesterntubepositionusetheadjustbolts,untilthesterntubetargetcenterontheshaftcenterline.Andadjustthedistancebetweensterntubeafte

28、rendtosternbossingend,thedistanceshouldbe75mm,theallowabletoleranceis坦mm.Fixthesterntubebytheadjustbolts,submittoownerandsurveyorcheck.琴鋼絲撓度計算公式如下：Thedeflectionformulaasfollowing,Y=qX(L-X)/(0.99*2G)式中：Y一鋼絲線上X一點撓度(m)Intheformula:Y-theflexibilityofpointXonthesteelwire(m).q一鋼絲線單位長度重量q/m,0.5mm鋼絲線取1.59g/

29、mq-unitlengthweightofsteelwireq/m,1.59g.mper0.5mmsteelwire.X一所求撓度點到基準點距離(m)X-distancebetweencalculationpointtothebenchmark(m)L一鋼絲兩基準點間的距離(m)L-thedistancebetweenthebenchmarkonsteelwire(m).G一鋼絲拉力(kg)G-pullstrengthonsteelwire(kg).7.4檢查艇管與艇柱之間的最小間隙，采用動力泵澆注環(huán)氧最小允許間隙為3mm.Checktheclearancebetweensterntubean

30、dsternbossing,adoptthepumppouringchockfasttheminimumclearanceis3mm.7.5檢查軸系中心線到主機基座面板的高度，此高度實際測量值應在1135mm左右,檢查主機基座兩側的偏中情況，中心線到基座邊緣的距離應為1095mm,若以上尺寸實測偏差過大需及時通知技術部門核對。ChecktheverticaldistancebetweenshaftcenterlinetoM/Efoundationtop,measureddistanceshouldaround1135mm.CheckthewidthfromshaftcenterlinetoM/

31、Efoundationside,thewidthshouldbe1095mm.Iime.7.6吊舵系中心線，檢查舵線與軸線的相交情況，以及舵線到艇管末端的距離，尺寸應滿足TCN124P-M012-GY01軸舵系初拉線工藝”中第10.3的要求。Hangtheruddercenterline,checktherelativepositionbetweenruddercenterlineandshaftcenterline,andthedistancebetweenrudderli

32、netosterntubeend.Thedimensionshouldwithinthetoleranceofitem10.3inTCN124P-M012-GY01Preliminaryalignmentprocedureforshaft&rudder7.7檢查軸線到中間軸承基座面板的ft直高度(不包含墊塊高度)，理論值為500mm,為保證活動墊塊的厚度A50mm(按照設備說明書要求),垂直高度應500mm且小515mm。Checktheverticalheightbetweenshaftcenterlinetointermediatebearingseatfaceplate(noti

33、ncludepadheight)theoryvalueshouldbe500mm.Inordertokeepthemoveablepadthickness50mm(accordingtoequipmentspec.requirement),theverticalheightshould藝00mmand奇15mm.7.8按照附圖尺寸確定主機滑油回油孔的開孔位置，開孔前應檢查到貨主機油底殼上開孔尺寸是否與圖紙相符，確定無誤后方能開孔。AccordingtotheattacheddrawingdimensiondeterminetheM/ELOreturnholeposition,beforeope

34、nholechecktheholedimensiononM/Efollowattacheddrawing,afterconfirmeddothecutjob.8. 安裝艇管總成加強板：Installthesterntubereinforcementplate:8.1艇管總成吊裝上船以后，先按照艇管總圖(SC4439(ZS)-425-02-00)將加強板(SC4439(ZS)-425-02-14)焊在艇管總成前端艇管座上Aftersterntubeonposition,accordingtosterntubegeneraldrawing(SC4439(ZS)-425-02-00)weldrein

35、forcementplateonsterntubeforwardbossing.8.2按照圖紙將加強板與FR13艙壁焊接，按右圖所示，分段、對稱施焊。在焊接過程中必須打表隨時監(jiān)測焊接的變形情況，使得焊接完成時艇管艄1尾部的中心仍在軸系中心線上，允許偏差V0.50mm。AccordingtothedrawingweldthereinforcementplateontheFR13#bulkhead,symmetricweldastherightpicture.Checkandcontrolthedeformationduringwelding,keepthesterntubecenterstill

36、ontheshaftcenterlineafterweld,allowabledeflection司.50mm.9. 艇管總成的環(huán)氧澆鑄：Chockfastofsterntube:見艇管環(huán)氧澆注工藝。Seesterntubechockfastprocedure.環(huán)氧澆注24h后，復核艇管總成的位置，將測量結果填入下檢驗表中24hoursafterchockfastrecheckthepositionofsterntube,filltheresultinthebelowlist.差方向Direction位置Position上up下Down左left右right尾管前中心Sterntubefore

37、center尾管后中心Sterntubeaft.center10.主機底角螺栓孔定位開孔:LocatingofM/Eholdingdownbolts:10.1以A,B兩點為基準，用0.5mm鋼絲拉出軸系理論中心線，A點掛重25kg。AccordingtotheA&Bdatummarkspull0.5mmsteelwireastheshaftcenterline,atApointhunga25kgheavy.10.2在主機座槽中裝焊臨時支架，將軸系中心線引至臨時支架上平面，并以此為基準按照主機安裝圖中的尺寸，在兩側基座面板上劃出兩列主機地腳螺栓孔的中心連線，如下圖所示。Installth

38、etemporarysupportinM/Eseatgrooveasbelowdrawing,marktheshaftcenterlineprojectiononthesupport.Accordingtothemarkedwiredrawtwoarrangelineofholdingdownboltscenterconnectline.AsbelowFACEPLATEOFENGINEFOUNDATIONdrawing.10.3以艇管后端面為基準確定主機第6缸中心位置，沿鋼絲線向前測量，艇管后端面到6缶工中心的理論距離為12325土mm(該尺寸為理論值，實際尺寸待螺旋槳與螺旋槳軸在車間預壓后確

39、定)，采用吊線錘的方法找出主機第6缸中心投影點，在臨時支架上穿過此點劃出與船中線的垂線，并延長與兩列主機地腳螺栓孔的中心連線相交。DeterminetheNo.6cyl.centerpositionmeasuredfromsterntubeafterendside,thetheorydistanceshouldbe12325ddmm(theactualdistancedecidebythepropellerandpropellershaftpre-installationtestresultinworkshop),usetheplumbfindouttheprojectionpointofNo

40、.6cyl.centerontemporarysupport.Throughthispointdrawtheverticallinewithshipcenterline,andprolongtheverticallinecrossedwithholdingdownboltscenterconnectline.10.4根據主機安裝圖，采用常規(guī)方法劃出主機全部地腳螺栓孔的中心位置，打硬記。然后對照主機安裝圖，采用縱向、橫向、以及對角測量的方法，反復校對，以確保全部地腳螺栓孔位置的準確無誤。Accordingtoengineinstallationdrawingdrawoutthecenterpos

41、itionofallengineholdingdownboltsholewithpunchmark.Thenfollowtheengineinstallationdrawing,measureeachdistancefromlongitudinal、transverseandcrosseddirection,inordertoensurethecorrectpositionofallholdingdownboltshole.10.5檢查艄、艇兩端螺栓孔中心對角間距，理論值應為6436mm，允許偏差±2mm。復核全部螺栓孔的縱、橫向尺寸，縱向兩孔間誤差土0.5mm,橫向兩孔間誤差土1m

42、m確保準確無誤，縱向累積誤差土2mm。Checktheforeandafterendboltscrossconnectlinelength,theorydistanceshouldbe6436mm,allowabletolerance坦mm.Recheckalltheholdingdownboltsposition,tolerancebetweentwoholesonlongitudinaldirection坦.5mm,onthetransversedirection土1mm,cumulatetoleranceonlongitudinaldirection坦mm.10.6根據已劃好的底腳螺栓孔

43、的中心點，戈仙全部地腳螺栓孔的加工圓線446mm、檢查圓線466mm,打硬記。Accordingtothemarkedcenterpointofholdingdownboltholes,drawthedrillinghole（|）46mmandreferenceround（|）66mmandmarkedonM/Eseat.10.7加工出全部（|）460+2.0mm的地腳螺栓孔，修除毛刺打磨光順。Drillalltheholdingdownboltshole（|）460+2.0mmandgrinding.10.8鉆孔作業(yè)后，須檢查主機機座下橫向加強板的位置，是否會影響螺栓螺母的安裝。消除反面毛刺

44、，以保證安裝時的良好貼合。AfterdrillingcheckthetransversereinforceplatebelowM/Eseatplate,confirmwhethertheplatewillimpactinstallboltsandnuts.Removetheburrontheoppositeside,ensurethenutsurfaceM/Eseatoppositesidewithgoodcontact.10.9回油管開孔時，應核對主機油底殼與圖紙的正確性。Beforeopenthereturnoilpipeholeonlubeoilcirculationtankmustco

45、nfirmtheopeningpositiononM/Esumpbottomsameasthedrawing.11.塞螺旋槳軸：Insertpropellershaft:11.1艇軸由機艙內向艇管塞入，在裝軸之前，根據螺旋槳軸后端的螺紋，制造一個螺紋連接的導向帽，以免在塞軸的時候碰壞軸承內的白合金。InsertthepropellershaftintosterntubeformE/R,duringinsertthepropellershafttheshaftendscrewshouldcoveredbyasmoothhat,avoidcrashedwithwhitemetalbearing.1

46、1.2尾軸安裝前，艇管內孔包括后軸承內表面應活潔，活潔程度要得到船東認可，裝入時應涂潤滑劑。Beforeinstallthepropellershaftcleantheshaftandbearinginnersideanddaublubeoil,thecleannessshouldconfirmedbyowner.11.3艇軸塞入時，首密封裝置及密封墊圈已套裝在尾軸上。Theforwardshaftsealandthegasketshouldbemoveonshaftbeforeinsertshaft.11.4如下圖，在艇軸法蘭后端面后200mm處設置艇軸臨時支撐，支撐上安裝的頂絲螺栓可以用來調節(jié)及固定艇軸位置。借助臨時支撐上的頂絲螺栓，調整艇軸位置，使得艇軸在軸系理論中心線上，且月尾軸法蘭后端面200mm處位置比理論高度低0.45mm。（軸系對中的基準，參考STX軸系校中計