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)

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1、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 Hydropo

2、wer Station Project DepartmentNovember 20th, 2013 27 / 28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

3、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

4、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

5、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 p

6、ress 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 R

7、ongXin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 ins

8、tallation 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 a

9、nd 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

10、 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

11、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 too

12、ls 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

13、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 Ja

14、ck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Rou

15、ndness 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

16、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 mach

17、ine, 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 t

18、echnical 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 Par

19、ts 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-withs

20、tanding 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 Po

21、le5.2 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

22、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

23、.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

24、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

25、 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 spid

26、er 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。Co

27、nfirm 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

28、 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 temper

29、ature 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 th

30、an 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 auxilia

31、ry 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

32、 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 s

33、tacking 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 pres

34、s 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

35、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 interlacin

36、g.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 hamme

37、r 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 seg

38、ments 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

39、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

40、.（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

41、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 m

42、ovements 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

43、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

44、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

45、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.

46、 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 sur

47、face.（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 pole slots. The pole slot surfaces must be clean, free of paint and damages. Clean surfaces, if necessary.（2）检查磁轭表面。磁轭表面及磁极的受力区域必须清洁且无油漆滴、无损伤。若有必要， 清洁磁轭表面。Check rim surface. The rim surface must be clean and free of paint drops and damages in the pol

48、e bearing area. Clean rim surface, if necessary.2. 准备安装转子磁极Prepare rotor poles for installation.（1）外观检查转子磁极是否有损伤。Visual check of rotor pole for damages.（2）检查磁极。磁极必须清洁且无油渍、无损伤。必要的话，清洁磁极。Check pole claws. The pole claws must be clean, free of paint and damages. Clean pole claws, if necessary.（3）检查磁极受力

49、区域。该区域必须清洁且无油渍、无损伤。必要的话，清洁磁极受力区域。Check pole-bearing areas. The pole bearing areas must be clean and free of paint and damages. Clean pole-bearing areas if necessary.（4）检查磁极绕组接头表面。要保证其清洁且无损伤。必要的话，清洁表面。Check surfaces for the pole winding connections. The surfaces for the pole winding connections must

50、be clean and free of damages. Clean surfaces, if necessary.（5）检查阻尼绕组接头表面。要保证其清洁且无损伤。必要的话，清洁表面。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. 测量并记录磁极绕组的绝缘电阻，如不符合要求应对磁极进行烘干。Measure an

51、d record insulation resistance of the pole winding. If very low must bake pole.4. 确定转子磁极的放置位置。磁极沿转子圆周的分布时，应按磁极重量的偏差进行补偿。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 weights

52、 will be compensated. 5. 在进行转子磁极配重时要将磁极按图纸分成两组，两种磁极的位置不同，应按图纸进行区分。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. 先装的两个磁极确定的垫片厚度，挂装其它磁极。Install all poles with the shim thickness, defined duri

53、ng the installation of the first two rotor poles. 7. 转子磁极和磁轭要按No.2条所述做好安装准备。The rotor poles and the rim must be prepared for installation as described under point No.2.（1）安装前，检查磁极重量是否正确。Check for correct weight of the pole prior to the installation.（2）检查极性顺序是否正确。Check for correct polarity sequence.8

54、. 安装磁极和阻尼绕组接头的固定板，根据图纸在磁轭上定位。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绕组和磁极的连接头确定。Position of fixing plates is given from the damper winding and pole coil connections（2）所有接触面必须干净，无损伤All contact surfaces must be clea

55、n and free of damages.9. 根据图纸，安装励磁引线，并锁定螺栓。Install field leads and lock bolts according to the drawing.10. 按图纸要求安装上、下风扇。Install the upper and lower air fans according to drawing.11. 根据图纸，检查和试验计划测试转子。Test rotor according to the drawing and to the inspection and test plan12. 连接阻尼绕组以及上端磁极绕组接头的连线以便作试验。I

56、nterconnect damper winding as well as NDE pole winding connections for test 13. 根据图纸要求对转子进行喷漆。Painting the rotor according to drawing.5.5 主要部件安装的质量控制Quality Control of Critical Components Installation1 磁轭冲片宜在制造厂内称重分组，若制造厂内未对磁轭冲片按质量分组，应按下表要求过秤、分组，每组抽出3 张5 张测量厚度，堆放时正反面应一致； Magnet Yoke stamping shall b

57、e weighted and divided as required if the weighting and dividing works have not been done by manufacture. Draw out 3-5 pieces from each group for thickness measurement. 磁轭冲片质量分组Quality Group Unit:Kg每张磁轭冲片质量(t)Quality of Each Stamping转速(n)Speed(r/min)n100100n300n300t2020t40t400.30.40.50.20.30.40.10.2

58、0.32 磁轭全部压紧后，磁轭的平均高度不得低于磁轭设计高度。同一纵截面上的高度偏差不应大于5mm。沿圆周方向的高度相对于设计高度的偏差不超过下表的规定； Magnet yoke average height shall not be lower as designed after all stampings are impacted. Height tolerance of a same lengthwise section shall not be more than 5mm. The height tolerance of circumference direction shall be

59、 as follows:磁轭圆周方向各测点高度允许偏差 Height Tolerance Unit:mm磁轭高度Heighth10001000h15001500h20002000h2500h2500允许偏差Tolerance-1+5-1+7-1+80+100+113 按磁极号检查极性及装配质量，并按制造厂编号顺序挂装磁极。制造厂无规定时，应满足在磁极挂装后任意22.5 45角度范围内，对称方向不平衡质量不应超过下表的要求，配重时一般计入引线及附件的质量。 Check the polarity and assembly quality of poles, and hang the poles i

60、n order. The unbalanced quality in sym direction shall fulfill the following specifications:磁极挂装不平衡质量允许偏差 Unbalanced Mass Tolerance 磁轭与磁极的质量之和(t)Magnet yoke and pole, total weight不同转速（r/min）下的磁极挂装不平衡质量允许偏差(Kg)Unbalanced mass tolerance under different speed200200500500t200632200t400842400t6001053600t2.0 1.0 1.5 2.0 5. 磁极挂装后检查转子圆度，各半径与设计半径之差不应大于设计空气间隙值的 4。Check rotor roundness after hanging, the radius shall be not more than 4 as designed.6. 在工地组装的转子，其单个磁极及集电环、引线、刷架均应按下表规定的标准进行交流耐电压试验和绝缘电阻检查。 The rotor assembled on site shall conduct AC withstanding volta