定子安装方案(中英文对照版终稿).doc

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1、越南SONGBUNG4水电站机电设备安装工程VIETNAM SONGBUNG4 HYDROPOWER STATIONE&M EQUIPMENT INSTALLATION PROJECT水轮发电机定子安装方案Hydro-generator Stator Installation Program批准：李艺Approved by Mr. LiYi审核：张文红Checked by Ms. ZhangWenhong编制：谢荣新Written by Mr. XieRongxin广东省源天工程公司越南SONGBUNG4水电站项目部二一三年十月Guangdong Yuantian Engineering Co

2、mpanyVietnam SONGBUNG4 Hydropower Project DepartmentOct. 2013目 录Content1结构说明GENERAL DESCRIPTION22施工组织机构及人员安排CONSTRUCTION ORGANIZATION23施工准备 CONSTRUCTION PREPARATION33.1施工技术准备 Technical Preparation33.2施工设备工器具准备 Construction Equipment Preparation33.3 施工其它措施准备 Other Preparation64主要技术标准和规范MAIN TECHNICAL

3、 STANDARDS AND NORMS65施工程序及方法 CONSTRUCTION PROCEDURE AND METHODS65.1发电机定子组装程序图 Generator Stator Assembly Procedure Chart65.2定子组装 Stator Assembly85.3 定子的最终安装Final installation of stator215.4主要部件安装的质量控制点Main Components Installation Quality Control Points236施工工期 CONSTRUCTION PERIOD327质量管理措施QUALITY MANA

4、GEMENT MEASURES338安全文明施工 SAFETY & ENVIRONMENT-FRIENDLY MANNER349卫生环境保护 HEALTH ENVIRONMENTAL PROTECTION3610验收 ACCEPTANCE3838 / 391结构说明General Description定子由机座、铁心、线圈、基础板等部件组成。定子装配分3瓣结构，在厂内铁芯叠片、绕组下线。分瓣运输到工地，进行3瓣定子的组圆、现场下合缝线。定子机座由6个支脚、外环设置6组空气冷却器。Stator is made up of engine base, iron core, coil and sol

5、e plate, etc. Stator assembles divides into 3 clacks, while laminating iron core and winding inserting coil in the workshop, setting 3 clack-stator to a circle and inserting coil to the seams at site. Stator engine base is made up of 6 supporting feet, 6 sets of air coolers at outer ring.2施工组织机构及人员安

6、排Construction Organization现场负责人：李艺Site leader: Li Yi技术负责人：谢荣新Technical director: Xie Rongxin安全员：陈涛记EHS: Chen Taoji质检员：潘健强Quality inspector: Pan Jianqiang现场翻译/协调：陆昌龙Site translator/coordinator: Lu Changlong电气人员：3人Electric workers：3电气试验人员：2人Electric testers：2起重人员: 2人Lifting workers: 2 机械安装人员：4人Mechani

7、cal installation workers: 43施工准备 Construction Preparation 3.1施工技术准备 Technical Preparation1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 shoul

8、d 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 prog

9、ram 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 techniques request as well as environment. 6机组安装前机坑已清理干净，满足安装条件。Workface have been clean well before installation and meet the request of e

10、rection.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 Construction Equipme

11、nt Preparation1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

12、 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.名称 Tools Name单位 unit数量 quantity备注 remark耐压试验装置Withstand voltage testing apparatus套Set1感应器Inductor套Set1绝缘测试装置Insulation

13、 tester套Set1套液压设备Hydraulic press equipment套Set1分瓣定子吊具Lifting tools for stator section套Set4经纬仪或水准仪Theodolite or Optical level套Set1搅拌设备Mixing equipment套Set1套绕线设备Round packing device套Set1套高精度天平Precision scale 0 10 kg套Set1套灭火器Fire extinguisher套Set4清洁设备C lean Zone equipment套Set4线棒缠绕设备1pcs Round packing d

14、evice套Set1彩笔Coloured pencil套Set2上胶工具Paint gluer套Set1环形吊带Round endless slings套Set2木线棒及临时固定楔) Wood bars and temporary fitting wedges套Set1加热设备Heating equipment套Set1木榔头或塑料榔头 Wood hammer or plastic hammer套Set调整工具Alignment tools套Set2中频铜焊机Medium frequency brazing unit套Set1铜焊感应线圈Brazing inductor套Set2力矩扳手Tor

15、que wrench 套Set2焊接设备Welding equipment套Set1气焊装置Gas welding units 套Set2夹紧装置Clamping device套Set1球心器、中心架、水平梁及钢琴线等Centering tools, center frame, horizontal beam, piano line 件pc1红外线焊条烘干箱Infrared ray drying box of welding rod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

16、钻 Magnetic drill machine台set1千斤顶Jack根据实际情况配备足够Qty should be in accordance with the practical situation手拉葫芦 Chain hoist根据实际情况配备足够Qty should be in accordance with the practical situation角磨机Angle Grinder台set2磨光机Grinding machine台set1内径千分尺（规格：L=3m） Inside caliper套set1框式水平仪 Square level个pcs1调水平Adjust to l

17、evel塞尺（规格：L=300mm）Filler gauge 把pcs1M2442专用扳手 Special spanner套set2活动扳手 Adjustable wrench套set1梅花扳手 Box spanner套set15m卷尺 Measuring tape把pcs2水准仪Optical level 部set1打压泵 pressure pump台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 Construction platform preparation 定子安装前搭设防护棚。 Prot

18、ective shed should be prepared before stator installation.2施工用电准备 Construction power supply preparation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

19、 the reasonable box.3施工消防准备 Fire fighting preparation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 preparation安装现场配备对讲机约2对，保证安装现场通信。Prepare two walkie-talkies for site communication smoothly.4主要技术标准和规范Main Technical Standards and Norms1

20、厂家资料 Manufacture Data定子装配Stator Assembly H757300MKB100000FTB定子机座Stator Frame H757300MKB110000FTB定子铁芯Stator Core H757300MKB120000FTB定子接线图Stator Winding Drawing H757300MKB100000FTB铜环引线Stator Parllel Ring H757300MKB130000FTB定子起吊工具Stator Lifting Tool H757300MKB820100FTB2国家标准、部颁或行业标准National Standards or

21、 Industrial Standards根据合同规定的规范 Be in accordance with the contract.5施工程序及方法 Construction Procedure and Methods5.1发电机定子组装程序图 Generator Stator Assembly Procedure Chart进行定子组装准备Preparing for the stator assembly 将定子基础板把紧在机座脚板上Bolting the stator foundation on stator frame feet搭设定子下线平台Preparing for stator w

22、ingding patform下层定子线棒安装Inserting the bottom bars下层定子线棒试验High-voltage test for bottom bars下层定子线棒绑扎Wrapping for sator bottom bars上层定子线棒和槽楔的安装Inserting the top bars and wedging the slot wedges定子端箍的涂漆、注胶Painting and injecting for surge rings分瓣定子在安装间进行组圆Assemble the stator sections to circle in erection

23、bay上层定子线棒绑扎Wrapping for stator top bars上、下层定子线棒试验High-voltage test for bottom bars and top bars in stator joints把地脚螺栓装在定子基础板上install anchor bolts on the stator foundation plates将定子吊入机坑lifting stator into pit 定子总体试验High-voltage test for stator winding定子总体喷漆The whole stator painting焊接引线、装配定子绝缘盒Brazing

24、 joints and assemble insulation caps 安装汇流环Brazing and assemble connections定子绕组的干燥Drying for stator winding调整定子的中心和高程Adjust the center and elevation of stator to unit base points5.2定子组装 Stator Assembly1.进行定子支腿固定螺栓拉伸试验。Carry out bolt tensioning test on stator foot bolts.（1）清扫定子支腿表面，表面必须洁净，无损伤，由于碰撞引起的损

25、伤要用锉刀修复。Clean stator foot surface. The surfaces must be clean and free of damage. Damage caused by impacts must be removed with a file.（2）安装4个支腿螺栓、垫片和8个圆螺母。Install shims with four (4) stator foot bolts and eight (8) round nuts on the stator foot.（3）根据图纸用液压装置对4个支腿螺栓进行预紧。Pre-stress the four (4) stator

26、 foot bolts with the hydraulic press equipment according to the drawing.（4）用外径千分尺测量支腿固定螺栓的长度，并把测量结果记录在表格上。Measure the length of the stator foot bolts with an outside micrometer gauge and record the measurements on the test sheet.（5）用液压装置松弛4个支腿固定螺栓。Loosen the four （4） stator foot bolts with the hydra

27、ulic press equipment.（6）用外径千分尺测量支腿螺栓长度，并填在记录表格上。根据（4），（6）测量的结果计算螺栓的伸长值。定子支腿螺栓所受力不允许超过屈服限的90%。Measure the length of the stator foot bolts with an outside micrometer gauge and record the measurements on the test sheet. Calculate the elongation for each bolt with the measurements taken under point 4 an

28、d 6. Do not pre-stress stator foot bolts above 90% of the yield strength.2. 在定子支腿上安装基础板。Install stator foundation plates on the stator feet.（1）清洁基础板表面和定子支腿表面，表面必须洁净且无损伤，由于碰撞引起的损伤要用锉刀修理。Clean foundation plate surface and stator foot surface，The surfaces must be clean and free of damages，Damages cause

29、d by impacts must be removed with a file.（2）在定子支腿和基础板之间加装垫片，垫片必须洁净完好，垫片表面稍许润滑。Install stator foundation plate shims, between Stator foundation plate and stator foot, on the stator foot. The shims must be clean and free of damages. Install shims with slightly lubricated surfaces.（3）安装定位销、双头螺栓、圆螺母。Ins

30、tall dowel-pins, studs and round nuts.（4）根据1.条确定的预紧力或油压值，用液压装置按预紧压力以对称方式预压支腿螺栓，将预紧压力值记录在表格中。Pre-stress stator foot bolts crosswise with the pre-stress pressure, determined under point 1. Use the hydraulic press equipment to pre-stress stator foot bolts. Record tightening pressure on the test sheet.（

31、5）在基础板上安装水平调整螺栓。Install leveling bolts in the stator foundation plate.（6）用厂房桥机提升分瓣定子，根据图纸在定子基础板上安装地脚螺栓。Raise stator sections with the power house crane and install anchor bolts on the stator foundation plates according to the drawing.（7）在安装间组装分瓣定子，将把合和调整块的定位销、螺栓装好，并用液压工个紧固螺栓。Assemble the stator sect

32、ions to circle in erection bay. Install dowel-screws in the clamping and alignment devices for the stator frame and torque screws with hydraulic tools.（8）在分瓣定子组装后测量合缝处的间隙，根据图纸的要求配制垫片。对于间隙大于0.5mm的位置相应加垫上胶Nomex纸。Measuring the gaps of joint after stator sections adjusted to circle, make the shims accor

33、ding to drawing. For the gap is bigger than 0.5mm, add the fit Nomex papers.（9）松开把合螺栓，将预制的垫片垫入铁芯内，按图纸要求把合螺栓。Loose the bolts of stator frame put the shim into stator core and tightening the bolts of stator. 3. 下线准备工作Preparation for winding installation（1）安装脚手架Install scaffold for stator winding insta

34、llation. （2）根据验收和试验计划，安装前先检查线槽的清洁及损伤情况。Check core slots for cleanliness and damages prior to the winding installation according to the inspection and test plan.（3）线棒制作（“缠绕”）工作空间（作业区的）准备Preparation of the working area for bar preparation (“Round Packing”). （4）确定硅胶的厚度。Determine the thickness of the si

35、licone compound. 测量线槽的宽度Bn 和线棒的宽度Bb。Measure the slot width Bn and bar width Bb.从Bn和Bb的差值得到线棒和槽壁间的间隙。The difference Bn and Bb gives the clearance between the bar and the slot wall.对折的裹包带厚度是0.22mm。双边的厚度是0.44mm。A double-layer folded round packing tape has a thickness of 0.22mm. The total thickness (bot

36、h sides) is 0.44mm.（5）硅胶的重量配比为树脂与固化剂9:1。树脂与固化剂应彻底搅拌。搅拌后硅胶在23环境下的使用时间为2小时。当在混合前后进行冷处理，可以延长此时间。The rate of resin and hardener is 9:1 by weight. Thoroughly mix the resin and hardener in the mixing equipment. The potlife of the compound is 2 hours at a temperature of 23. This period can be prolonged by

37、cooling the components before and after minxing.注意：平包间距为1-3mm，两端长出铁芯各15mm，用透明绝缘胶带固定两周，线棒进槽后低阻带的开口朝上。硅胶的固化需线棒在槽内静置5到10小时。如果只是在槽内移动困难，可用垫块垫上毛毡小心敲击进入。Notice: the distance of wrapping is 1-3mm, wrapping length is over two ends of stator core 15mm, fixing two rounds with scotch insulation tape, hatch of

38、semiconductor tape on the top after inserting slot. The bar must be left undisturbed in the slot for the hardening time of the silicone compound (5 to 10 hours). If the bar only goes into the slot with difficulty, it may be driven in by means of careful blows on a piece of plastic with a felt backin

39、g placed over the straight portion of the bar.（6）参照下图将带子包于线棒上。Wrap the tape around the bar as shown in the illustrations below.（7）准备“清洁区域”用于绕组的安装Prepare “Clean Zone” for winding installation.4. 安装合缝处下层线棒Installation of bottom bars in stator joints（1）测定（确定）硅胶的厚度。Determine the thickness of the silicon

40、e compound（2）下层线棒安装之前铜焊表面必须磨光，且清洁（无损伤、无灰尘、无油脂）。Brazing surfaces on the bottom bars must be polished and cleaned (free of damages, dust and grease) prior to the bottom bar installation.（3）用清洁的干布将线棒擦干净（不要划伤）。Use separate cloth for end winding and slot part, dont cover up conductive slot corona over hi

41、gh resistance surface of end winding。（4）用不同的布擦拭绕组端部和线槽， (不要将它们的擦拭物混杂)。Clean the bars with a clean and dry cloth (non abrasive). （5）检查线棒是否有明显损伤。（外部损伤情况）Check the bars for visible damages.（6）根据工作手册的要求，用封装胶带包裹（缠绕绑扎带）线棒。Wrap the round packing tape around the bar according to the working instruction.（7）用

42、彩笔在定子铁芯上端的线棒上标记，不要用导体（铅笔）、尖东西（圆珠笔）等，以防定子受损。Mark the NDE - end of the stator core on the bar with colored pencil.Do not use conductive (lead pencil) or pointed markers (Ball pen) to prevent damages on the stator bars.5. 上层线棒的安装Installation of the top bars（1）拆除木线棒及临时楔紧工具。Remove temporary wedging tool

43、and wood bars.（2）确定硅胶的厚度。Determine the thickness of the silicone compound.（3）在顶部线棒安装之前,要将顶部和底部线棒的表面打磨光并清理干净(无损,无尘及油脂) 。Brazing surfaces on the bottom and on the top bars must be polished and cleaned (free of damages, dust and grease) prior to the top bar installation.（4）用干净的干布清洁线棒(不能划伤)。 Clean the b

44、ars with a clean and dry cloth (non abrasive).（5）用不同的布擦拭绕组端部和线槽, (不要将它们擦试物混杂) 。Use separate cloth for end winding and slot part, dont cover up conductive slot corona over high resistance surface of end winding.（6）检查线棒有无外观损伤。Check the bars for visible damages.（7）根据手册用绑扎带缠绕线棒。Wrap the round packing ta

45、pe around the bar according to the working instruction.（8）在整个定子铁芯槽标识上层线棒位置顺序(用遮盖带和永久记号笔)。Mark bar position top layer sequence all around on stator core slots (use that for masking tape and permanent marker).（9）检查线槽的清洁度(必要的话用干风吹)。Check core slots for cleanliness (blow out with dry air pressure if nec

46、essary).（10）开始安装普通线棒，安装时，用电工胶带粘住定子线槽边角，以防损伤缠绕带。Start installation with normal top bars.Cover sharp slot edges of the stator core with electrical tape to pent damages on the round packing tape during installation. （11）用起吊装置安装上层线棒。Install top bars with crane. （12）拿掉电工胶带并且去除定子铁芯上多余的硅胶。Remove the electrical tape and the excessive silicone com