越南松绑4水电站工程机电设备安装转子组装方案(中英文对照版).doc

越南松绑4水电站工程机电设备安装发电机转子组装方案批准：罗春华审核：张文红编制：谢荣新广东省源天工程公司 松绑4水电站项目部 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 Hydropower Station Project DepartmentNovember 20th, 2013目 录Contents1结构说明 Structure Instructions32施工组织机构及人员安排 Construction Organization43施工准备 Preparation43.1施工技术准备 Technical43.2施工设备工器具准备 Preparation of Erection Tools53.3 施工其它措施准备 Other preparation74主要技术标准和规范 The main technical standards and norms85施工程序及方法Construction Program85.1 发电机转子组装程序Generator Rotor Assembly Procedure85.2 转子支架与主轴的热套Assembly of rotor spider with shaft by heating.95.3 磁轭组装Rotor rim assembly115.4 转子绕组组装Rotor winding assembly165.5 主要部件安装的质量控制Quality Control of Critical Components Installation186施工工期 Construction Period227质量管理措施Quality Management Measures228安全文明施工 Safety & Environment-Friendly Manner239卫生环境保护 Health Environmental Protection2610 附件Appendix281结构说明 Structure Instructions1. 大轴下端通过法兰与水轮机轴连接，镜板通过热套方式与大轴连接，磁极引线从转子支架上部进入大轴引线槽内，并与集电环连接。 Connect main bearing bottom with turbine bearing by flange, runner plate with main bearing by hot shrinkage, pole lead with collecting ring.2. 轮毂包括转子支架、风扇等，通过热套方式与大轴固定。 Wheel hub consists of rotor support and fan. The wheel hub is fixed with main bearing by hot shrinkage.3. 磁轭由磁轭冲片，上压板、下压板、磁轭键、制动环等组成现场叠片 Magnet yoke consists of magnet yoke stamping, upper press board, lower press board, magnet yoke key and stop ring.4. 磁极由线圈、磁极铁芯、阻尼环、阻尼条、磁极引线、磁极连线等组成，24个磁极在现场挂装。 Pole consists of coil, iron core, damping ring, damping bar, pole lead and cables. 24 poles are hanging garmented on site.2施工组织机构及人员安排 Construction Organization现场负责人：李艺Site leader: Li Yi技术负责人：谢荣新Engineer : Xie RongXin安全员：陈涛记EHS: Chen TaoJi质检员：潘键强Quality controller: Pan JianQiang现场翻译/协调：陆昌龙Site translator: Lu ChangLong起重人员: 2人lifting worker: 2 机械安装人员：6人Mechanical worker: 63施工准备 Preparation 3.1施工技术准备 Technical 1施工前熟悉厂家图纸、安装规程、规范和技术文件；Read drawings carefully before installation, also should know well with installation stand and technical documents.2由项目总工程师组织安装人员进行详细审核设计图纸，并作好审图、澄清问题以及设计技术交底记录；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统计和核对设备和主要材料清单，制定到货计划和材料采购计划；Check the main equipment and material list then make a delivery and purchase plan.4制定重要设备安装和关键工序的安装方案和技术措施；Formulate the installation program and key process for main equipment. 5注意图纸提出的施工要求，设备部件的特殊安装工艺及对环境的特殊要求；Give more attention about technical request form the drawings, some parts have special technics request as well as environment. 6机组安装前机坑已清理干净，满足安装条件。Work surface have been clean well before installation and meet the request of erection.7安装前所需的设备及零、部件已到货齐全并检查合格。Check the elements needed which should be arrived site and the quality must be meet the drawings before installation.8安装所需的工器具满足要求，厂家提供的专用工具已到货。Erection tools must be meet the request and special tools form supplier have arrived site.3.2施工设备工器具准备 Preparation of Erection Tools 1备齐常用的起重吊具、绳索和安装工器具。Preparation of lifting, wire-rope, erection tools.2对所有的工具器具进行彻底检查和维护、保养，确保其工况良好，使用安全。起重设备的选择能满足设备最大起重量，达到吊装的安全要求。Check and maintenance carefully all 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指定有关安全负责人，检查安装用防护用品的配备是否齐全、到位。Specified full-time security staff to check all the tools needed to ensure safety during erection.4. 验收设备包含在施工设备工器具列表内Acceptance equipments are included in the list of construction equipments & tools.Tools Nameunitquantityremark钢琴线piano wire卷Reel1红外线焊条烘干箱 infrared ray weld rod heating box台set1焊条保温筒 electrode dryer个pcs2交流电焊机 AC arc welder台set1直流电焊机 DC arc welder台 set1磁力钻 Magnetic drill machine台set1千斤顶 Jack根据实际情况配备足够as needed手拉葫芦 Chain hoist根据实际情况配备足够as needed角磨机 angle grinder台set2磨光机 Grinding machine台set1加热保温棚 Heating tentpcs1加热器 Heaterspcs1（厂家提供）Provided by manufacture无接头吊带Round endless slingspcs4塑料锤Plastic hammerpcs5风动扳手Impact wrenchpcs2液压拉伸器Hydraulic press cylinderpcs8液压泵Hydraulic pumppcs1测圆架Roundness measuring devicePcs1百分表Dial indicatorPcs2力矩扳手Torque wrench 套set1内径千分尺（规格：L=3m） Inside caliper套set1框式水平仪 Square level个pcs1level-off直尺Straight edgePcs1塞尺Filler gauge把pcs1M2472专用扳手 Special spanner套set2活动扳手 Adjustable wrench套set1梅花扳手 Box spanner套set1卷尺 Measuring tape把pcs2水准仪Optical level部set1厂家提供的专用工具 Special tools套set13.3 施工其它措施准备 Other preparation 1施工平台准备 Platform转子组装前搭设组装平台Working face construction before rotor assembly.2施工用电准备 Power supply在安装间或设备安装现场适当位置布置开关箱约3个，电焊机、磨光机、照明等施工设备用电取自各开关箱上。Three electrical distribution box were set off on erection bay and work area. Tools like as weld machine, grinding machine, lighting take power from the reasonable box.3施工消防准备 Fire fighting 在安装现场各适当位置布置手提式干粉灭火器约3个。Three hand dry powder fire extinguisher lay on suitable position.4施工通信准备Communication安装现场配备对讲机约2对，保证安装现场通信。Prepare two talkie-talkies for site communication smoothly.4主要技术标准和规范 The main technical standards and norms1厂家资料Distributor assembly 2国家标准、部颁或行业标准National standards and industry standards3按合同规定的标准和要求Fulfill the requirements of relative standards and specifications.5施工程序及方法Construction Program5.1 发电机转子组装程序Generator Rotor Assembly Procedure预埋安装间转子组装场地埋件Embedding the Embedded Parts of Rotor Assembly at Erection-bay转子组装准备Preliminaries for Rotor Assembly转子支架的加热The heating of rotor spider 转子支架与主轴的热套Assembly of spider and shaft转子测圆架的安装Erection rotor compass转子磁轭叠装及预压Rotor rim stacking & prepressing转子磁轭片清洗分类Rotor Rim Sheet Cleaning and Classing转子清扫、耐压Rotor Cleaning, Voltage-withstanding Test挂装后单个磁极试验Test for Single Pole After Assembly转子吊具安装Installing Rotor Lifting Tool 转子引线和极间连线连接Rotor lead and Pole Connections Assembly转子磁极挂装Rotor Poles Assembly磁轭的收尾工作The Others Work for Rim转子清扫、喷漆Rotor Cleaning, Painting转子磁轭叠装及最终压紧Rotor rim stacking & final pressing单个磁极试验Test for Single Pole5.2 转子支架与主轴的热套Assembly of rotor spider with shaft by heating. 1. 核算并确定转子支架需要升高的温度。Checking calculate and determine the temperature of rotor spider should be heated.2. 转子支架加热的温度应使其膨胀后与主轴的间隙不小于1mm.The clearance of rotor spider with shaft should be more than 1mm after heating expanding.3. 清理主轴并直立于转子安装间基础上。Clean and erect the shaft on the foundation of rotor erection bay.4. 清理转子支架并根据图纸在安装间内立于加热工具上。试吊转子支架，调整吊具长度，确保吊起过程中上法兰面处于水平状态。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 upper flange.5. 在转子支架上安装加热保温棚。Install heating tent on rotor spider.6. 加热转子支架Heating the rotor spider. （1）投入电源对转子支架进行加温，控制温升在610/小时内，大约需要2030小时完成加热。Turn on the power, control the heating speed between 610/h, about need 2030 hours for heating.（2）加热到规定温度，每30分钟记录一次温度，包括内、外侧的上、中、下各部，以及转子支架的顶面及底面，在圆周方向测八点。Heat 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）检查转子支架的膨胀情况，内孔应均匀、缓慢膨胀，直到比主轴直径大1mm。Check the state of rotor spider expanding; the expanding of rotor spider should be equally and slowly, till the diameter of spider is bigger 1mm than shaft.（4）控制转子支架的加热温差不能超过10度，否则应通过开关柜进行调节。Control the deviation of rim temperature is less than 10 degrees; otherwise adjusted it by power boxes. 7. 在主轴上套装转子支架。Assembly of rotor spider to shaft.（1）转子支架吊起后检查并调整水平。Check and adjust level of spider, when lift rotor spider up.（2）吊起后应尽快套在主轴上，接近主轴时检查转子支架的温度，如果温度太低应重新进行加热。After lifting rotor spider, install on shaft as soon as possible, check the temperature of rotor spider when spider is near the shaft.（3）吊装前确定好主轴与转子支架的+Y、+X线及其相对位置。Confirm and mark the +Y and +X axis, and relative position of shaft and rotor spider before lifting the rotor spider.8. 自然冷却转子支架。Cooling rotor spider naturally.（1）关闭加热电源。Turn off the power.（2）慢慢降低转子支架温度直至室温，每30分钟记录一次温度，包括转子支架内、外侧的上、中、下各部，以及转子支架的顶面及底面，在圆周方向测八点。Cooling the temperature of rotor spider 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）转子支架冷却到室温的时间至少要30小时。The duration of cooling down the rotor spider to room temperature must be at least 30 hours. 5.3 磁轭组装Rotor rim assembly1. 安装并调整测圆架Install and align roundness measuring device.（1）测圆架必须调到与转子中心基准面同心，同心度应小于0.05mm。The roundness-measuring device must be aligned exactly concentric to the rotor hub reference surfaces. The deviation of concentricity should be less than 0.05mm.（2）测圆架的旋转一周的测量偏差小于0.02mm。The measuring deviation of arm turing one cycle should be less thang 0.02mm.2. 在安装间, 用粉笔标注转子磁轭支撑的位置Mark the position for the rotor rim supports with chalk on the erection bay.3. 最终安装磁轭键。Final installation of wedges. （1）用卡兰临时把磁轭主键与两个副键固定在一起，以便进行磁轭的叠装。The two auxiliary wedges must be fixed together with main wedge using clamps, for rim stacking.（2）转子磁轭叠片叠至120mm高度。Stack rotor rim up to a height of 120mm.（3）按照图纸检查磁轭叠片错开距离是否正确。Check for correct interlacing of the rim sheets according to the drawing.（4）用塑料锤轻击磁轭叠片使其穿过叠片销。Drive rim sheets with plastic hammer over the stacking pins.4. 按照图纸进行转子磁轭叠片，直至第一次压紧高度。Stack rotor rim according to the drawing until you reach the height for the first pre-pressing.（1）按照图纸检查磁轭叠片的错开距离是否正确。Check for correct interlacing of the rim sheets according to the drawing.（2）用塑料锤轻击磁轭叠片使其穿过叠片销。Drive rim sheets with plastic hammer over the stacking pins.（3）根据磁轭叠片测量结果加补偿片。Equalize rim according to the measured rim sheet.（4）一旦叠片销不能起到调整磁轭叠片的作用，就要向上拉长叠片销。Pull up the long stacking pins as soon as the alignment of the rim sheets is not guaranteed. （5）补偿片的压紧螺栓孔位置要与磁轭压紧螺栓孔位置对齐。Align the equalizing segments exactly to the holes for the rim press bolts.（6）不要移动下端的短叠片销，这些叠片销使磁轭叠片成为一个牢固的整环。Do not move the short stacking pins on the DE side. These stacking pins hold the rim sheets to a solid ring together.（7）拉出叠片销（长叠片销）末端的伸出长度应不超过200mm。The length of projection of the pulled up stacking pin ends (long stacking pins) should not be more than 200 mm.5. 用风动扳手压紧转子磁轭。Pre-press rotor rim with impact wrenches according to the instruction.（1）用风动搬手按照图纸要求压紧螺栓。Pre-stress the bolts according to the drawing with impact wrenches.（2）重复压紧顺序直到拧紧所有螺栓，按对称交错的原则进行。Repeat the pre-stress sequence until all the bolts are tight by principle of cross and interlacing.6. 重复以上步骤，按照图纸进行转子磁轭叠片，直至最后一次压紧高度。Repeat above steps, stack rotor rim according to the drawing until you reach the height for the final pressing. （1）按照图纸检查磁轭叠片的错开距离是否正确。Check for correct interlacing of the rim sheets according to the drawing.（2）用塑料锤轻击磁轭叠片使其穿过叠片销。Drive rim sheets with plastic hammer over the stacking pins.（3）根据磁轭叠片第三次压紧测量的结果加补偿片。Equalize rim according to the measurements taken at the third pre-pressing（4）一旦叠片销不能起到调整磁轭叠片的作用，就要向上拉长叠片销。Pull up the long stacking pins as soon as the alignment of the rim sheets is not guaranteed. （5）补偿片的压紧螺栓孔位置要与磁轭压紧螺栓孔位置对齐。Align the equalizing segments exactly to the holes for the rim press bolts.（6）不要移走下端的短叠片销，这些叠片销使磁轭叠片成为一个牢固的整环。Do not move the short stacking pins on the DE side. These stacking pins hold the rim sheets to a solid ring together.（7）拉出叠片销（长叠片销）末端的伸出长度应不超过200mm。The length of projection of the pulled up stacking pin ends (long stacking pins) should not be more than 200 mm.7. 按照手册用液压工具对转子磁轭进行最终压紧。首先用风动扳手对每隔一个螺栓进行预压紧，用液压工具压紧所有的螺栓。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 cylinders.（1）按照手册压紧螺栓。逐步增加拧紧压力直至达到最终压力。大约进行三步压紧后，才能达到最终压力。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）安装前压紧螺栓和螺纹涂润滑脂。The press bolts and the treads must be greased prior to the installation.（3）重复压紧程序直到所有螺栓达到最终压紧值。Repeat the pre-stress sequence until all the bolts have reached the final pre-stress（4）为了防止在磁轭叠片之间移动，最初2圈不要用最终压力压紧螺栓，每次压紧的量应不超过两个圈。Do not pre-stress the bolts with the final pressure the first two turns in order to prevent movements between the rim sheets. Not more than two turns every pressing step.8. 检查最终压紧好的磁轭。Check final pre-stressed rim.（1）用拉伸检查装置抽查10%的压紧螺栓的拉伸值。如果没有达到规定的拉伸值，再次压紧所有的压紧螺栓。Check elongation on 10% of the press bolts with the elongation control device. Pre-stress all press bolts again, if the specified elongation were not achieved.（2）在磁轭的内、外径用钢卷尺测量磁轭的高度。在圆周上测量每张磁轭的高度。记录结果。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）用直尺和塞尺检查上、下压板的径向平面度，并记录结果。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）用精密水平仪和带有百分表的测圆架检查下压板的水平度。Check the level of the DE press plates by using a precision level and the roundness-measuring device with a dial indicator.（5）用测圆架测量并记录磁轭直径和同心度。Measure and record the concentricity and diameter of the rim with the roundness-measuring device.（6）按图纸安装制动环瓦及相应的垫片。Install all brake ring segments with the corresponding spacer sheets according to the drawing. （7）在检验表上记录制动环的平面度。Record flatness of the brake ring segments on the test sheet.9. 沿转子转动方向制动环必须平滑或连续，制动一环后一块不能高出前一块。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 转子绕组组装Rotor winding assembly1. 检查转子磁轭及磁极表面的所有沟槽Check all pole slots in the rotor rim and rotor rim surface.（1）检查磁极沟槽。磁极沟槽的表面必须清洁且无油渍无损伤。若有必要，清洁表面。Check pol