发电机穿转子作业指导书

1、目 录Content目 录1Content11.编制依据 Basis of Compilation12.工程概况、工程量 Engineering Situation and Quantity13.施工作业进度及人员、材料准备2Construction Schedule, Personnel and Material Preparation23.1技术资料准备 Preparation for Technical Data23.2作业人员配置 Personnel Allocation23.3作业工机具准备 Machine Preparation23.4安全设备准备 Safety Equipment

2、 Preparation23.5其他准备 Other Preparation34施工作业流程及施工方法、步骤34.1 施工作业流程 Construction Process34.2发电机穿转子Generator Rotor Installation35施工质量要求及保证措施8Quality Requirements and Assurance Measure85.1质量要求Quality Requirements85.2质量保证措施 Quality Assurance Measure96施工安全注意事项 Safety Consideration During Construction96.1一

3、般要求 General Requirements106.2.施工用电及照明 Construction Electricity and Lighting106.3.防火 Fire Protection106.4.设备起吊 Equipment lifting116.5工器具使用 Facilities Using117.文明施工 Civilized construction128.ITP检验试验项目 Inspection and Test Plan (ITP) 12131.编制依据 Basis of Compilation 1.1印尼ADIPALA工程机组安装施工组织设计Construction O

4、rganization Design on Adipala Unit Installation, Indonesia.1.2 上海电气电站设备有限公司上海发电机厂家图纸、产品证明文件、产品说明书、安装手册。转子穿装方法。Shanghai generator Drawing, product certificate, product specification, installation notebook supplied from Shanghai electric power generation equipment CO., LTD.“METHOD OF INSTALLING ROTOR,

5、 DWG. NO.: AD/YQ0D412.064.01”1.3 阿迪帕拉电站EPC合同 EPC Contract for PLTU 2, Adipala1.4 IEC 60034 2.工程概况、工程量 Engineering Situation and Quantity 印尼ADIPALA工程安装一台由上海电气电站设备有限公司上海发电机厂家生产的QFSN-660-2型、静止励磁、三相交流隐极式同步发电机，额定功率660MW。发电机纵向布置在汽机间13.70m运行平台上，其纵向中心距A轴15300mm，距B轴15300mm。横向中心位于34线之间，转子中心标高为14770mm，其汽侧朝向扩建端

6、。This unit for Adipala Power Plant, Indonesia is static excitation, three-phase AC synchronous generator and made by Shanghai electric power generation equipment CO., LTD. Its rated power is 660MW and type is QFSN-660-2. Generator shall be vertically arranged on ele.13.7m operation platform in turbi

7、ne house. The distance from longitudinal center to axial is 15300mm; the distance from longitudinal center to axial is 15300mm also; the horizontal center is located at the center of line 3-4. The central elevation of rotor is 14770mm and steam side face the extended end. 发电机出线盒、氢冷却器、已安装完毕，定子单独风压已试验

8、完，具备转子穿装条件。Outlet box of generator, hydrogen cooler already been installed. Air test to stator already completed. Its ready for rotor installation.3.施工作业进度及人员、材料准备Construction Schedule, Personnel and Material Preparation 3.1技术资料准备 Preparation for Technical Data 3.1.1发电机厂家产品证明文件、技术资料及安装图齐全。Product ce

9、rtification, technical data and installation drawing from generator factory are complete. 3.1.2施工图纸审核完。The examination of construction drawing is completed. 3.1.3施工用料准备齐全。Construction material is prepared completely.3.2作业人员配置 Personnel Allocation 名称Name 数量Quantity 名称Name 数量Quantity 施工负责人Construction

10、 principal 1 person技术负责人Technical principal 1 person钳工Fitter 2 person起重工Lifting work 2 person吊车司机Crane driver 1 person力工Normal Workers 4 person3.3作业工机具准备 Machine Preparation 名称Name 数量Quantity名称Name数量Quantity5吨倒链Chain block, 5t2 set转子穿装专用工具Special tools for Rotor Installation1 set抬轴工具Spectial tools f

11、or Rotor uprising2 set3.4安全设备准备 Safety Equipment Preparation 名称Name 数量Quantity 名称Name数量Quantity灭火器Fire extinguisher 2瓶安全带Safety belt 5条跳板Spring board 10块安全帽Helmet 10个连体工作服Labor suit 5套5 units安全警戒绳Safety cordon 100米m3.5其他准备 Other Preparation 3.5.1转子开箱验收合格，通风试验合格。Rotor is qualified for the box opening

12、 inspection. Venting test is qualified.3.5.2各机械器具检查完确认无异常情况，各种量具已检定合格，并在有效期内。All mechanical appliances are checked and passed examination and is in force. 3.5.3施工电源已接好,施工现场采光良好。Construction power is connected well and lighting is good. 3.5.4施工人员到位,并对施工任务及程序清楚明了。Constructors are familiar with constru

13、ction task and procedure and are arrived. 4施工作业流程及施工方法、步骤 Construction Process and Construction Procedure 4.1 施工作业流程 Construction Process 转子就位前准备工作转子开始穿装转子进入定子内部桥吊缓钩倒链牵引抬轴工具安装轴瓦就位抬轴工具拆卸转子就位Preliminary Preparation-Rotor Installation- Rotor Erected to Inside Stator-Overhead Crane Loose Hook-Cooperatio

14、n with Chain Block-Install Axis ToolsBearing Pad in Position-Remove Axis Tools-Rotor in Position4.2发电机穿转子Generator Rotor Installation 4.2.1转子穿入定子前必备条件Essential Condition Before Rotor Installation a. 发电机定子、转子相关电气试验已完成；发电机转子气密试验合格；转子绕组通风孔检查试验合格；定子绕组水路气密性试验合格。The related electric tests for generator ro

15、tor and stator should be finished. The detail for these tests refer to “Test procedure for generator” which code is “UO-131028-CNTIC -028-IAP-ADPL-CI-028”.Seal test for generator rotor is qualified. Ventilation test for rotor winding vent is qualified. The air-tight test for stator winding waterway

16、also is qualified. b. 穿转子的各项专用工具清点、清扫完毕。Special tools used for rotor installation shall be counted and cleaned completed. c. 发电机定子拉钢丝调整中心结束。The alignment of steel wire used for rotor lifting should be completed. d. 发电机转子穿装工作，必须在完成机务、电气与热工仪表的各项工作后，电气专业人员对定子与转子进行最后清扫检查，确信其内部清洁无任何杂物并经签证后方可进行。 All works

17、 of maintenance, electric & thermal instruments are completed, and the final cleaning & checking for stator and rotor were worked by electrical professional, make sure inner is clean without any sundries, then signing certificate. The installation of generator rotor will be carrying out.4.2.2 转子穿入定子

18、前的准备工作 Preparation Work a. 测量轴颈的椭圆度、不柱度并记录，检查联轴器法兰面、集电环表面、护环表面应完好无损，平衡块应锁定无松动。Check and record the ovality and non-column degree of journal. Coupling flange surface, collecting ring surface, retaining ring surface are in perfect condition. Balance block shall lock without loose.b. 将转子槽楔通风孔的塞堵物全部摘除并切

19、记不能遗留。The “blockage” of rotor groove carving vent, is used to protect and test, shall be removed and ensure there is no missing. c. 将汽、励端端盖内端盖把合到机座的把合面上；将两端下半外端盖把合到机座的把合面上。Inner cover of Turbine and excitation end cover will be tied on occlusal surface of engine base; outer cover of two lower ends w

20、ill be tied on occlusal surface. d. 再一次用大功率吸尘器仔细清理定子内部及转子表面的杂物及灰尘；再次检查定子绝缘引水管有无弯折及损伤现象。Use Dust collector to clean the stator inner and rotor surface dust & sundries once again；Redo the visual inspection for stator isolating aqueduct (bending or damaged phenomenon)4.2.3 穿转子步骤Procedure for Rotor Inst

21、allation 穿转子步骤见附图。在穿转子前必须将汽、励两端的下半内端盖装配就位，下半端盖下沉450mm，以不妨碍转子的穿入，并要将励端基础平台平面用钢板下垫枕木的方法延伸到足够长度。Please see the attachment about rotor installation procedure. Before rotor installation, lower inner cover of steam & excitation ends should be located, and it should be moved down 450mm (than drawing), in o

22、rder to avoid rotor installation. Working platform of excitation end, sleeper underlays the steel plate, shall extend to enough length. a. 将转子保护用橡胶板用绳绑扎在转子本体上挂吊索处。将联轴器滑块把合在汽端联轴器上,应检查其高度是否小于本体滑块处的高度12mm。将转子托架把合在励端轴径上并布置好调整垫块及其外滑板。Rubber plate, used to protect rotor, shall be used rope to tie on lifti

23、ng position of rotor proper. Coupling slider shall be installed on coupling at steam end , and its height should be lower than that of rotor proper about 1-2mm. rotor support shall be tied on excitation shaft diameter and adjust iron pad and its outer sliding plate. b. 将定子铁芯保护板及弧形钢滑板先后铺在定子铁芯上。注意定子铁芯

24、保护板下层为钢板纸，上层为橡皮纸。弧形钢滑板上表面涂少量、均匀的黄干油后置于保护板上，注意不要碰撞气隙隔板。定子绕组端部必须用布遮蔽，严防杂物落在绕组上。Protective board used for stator core and arc sliding plate will be laying on stator core one by another. For protective board, lower layer is steel sheet and up is rubber sheet. Arc sliding plate upper surface shall be app

25、lied a few oil and then laid on protective board to avoid touching air gas clapboard. Stator winding head must cover by cloth to avoid sundried dropping on wiring. c. 将本体滑块预先置放在机座励端内定子绕组端部与下半端盖之间。前后两端分别系上足够长度的尼龙绳，且要系牢、伸出汽端及励端机座外，以备滑入和抽出时牵引用。Rotor proper slider shall be laid between rotor winding end

26、 and lower cover. The two ends shall be tied fasten with long enough nylon rope, extend to outside of steam and excitation base in case slip and extract. d. 用100T桥吊及专用吊索吊起转子，调整位置使转子保持水平。调整好高度之后缓缓将其汽端对准励端铁芯中心。向前移动转子，至能将联轴器滑块落在滑板上。然后使转子向汽端平稳移动，直到吊索要碰到机座端板为止。（见附图1）The rotor will be lifting with 100T cr

27、ane and special lifting piece, then adjust the rotors position to make it leveling. Adjust the height, steam end shall be slowly directed at center of excitation end core. Move rotor forward, until coupling slider may lay on sliding plate. Then the rotor shall move smooth to steam end until lifting

28、piece will be touched engine base plate. Refer to attachment sketch 1e. 下降转子直到由联轴器滑块和励端转子托架支撑转子重量为止，并调整励端转子托架底部钢板的高度，使转子励端要高于铁芯中心5mm，将转子托架底脚固定紧。去除吊索。在励端安装工具梁用于两台5t导链牵引转子。Put rotor down until it supports by coupling slider and rotor support, and adjust the height of steel plate below rotor support mu

29、st be higher than core center about 5mm, fasten firmly footing of rotor support. Remove lifting piece. Instrument bridge will install at excitation end used for two 10t chain blocks. f. 将吊索移到励端轴颈处，起吊转子励端，使励端转子托架处与地面虚接触。通过两台5t导链使转子前进到护环进入铁芯一段距离，能放入本体滑块为止（图2）。将励端转子吊起约15mm，注意不要碰伤气隙隔环。垫入本体滑块并拉到紧靠汽端护环上。注

30、意要仔细校正本体滑块的轴向位置，如果在牵引转子前进时，汽端联轴器开始转动，则表示滑块位置不合适或转子拉力方向与转子中心线不在一条线上。其中任何一种情况都可能引起转子从滑块中滚落，并可能碰伤铁芯。随后继续移动转子，使本体滑块与转子同步向汽端滑动。本体滑块后端牵引绳索必须保证始终留在励端机座外，以便抽出本体滑块时使用。由于本体滑块的外径大于轴颈滑块的外径1-2mm，所以在装入本体滑块之后的移动过程中，转子的重荷全部由本体滑块及转子托架承载。Move lifting piece to excitation end axle journal, lift rotor excitation end, an

31、d rotor support and ground will not connect. With two 10t chain blocks, rotor will move to protective ring and stator core until rotor slider can put into (sketch map 2). Rotor will be lifting about 15mm and pay attention not to damage spacer ring of air gap. Fill up proper slider and drag rotor to

32、protective ring that next to steam end. Pay attention on axial position of rotor slider. If coupling at steam end is starting rotating during rotor going forward, it means slider position is improper or tension direction and rotor central line are not in a line. Either of above condition will cause

33、rotor falling down from slider, and may damage core. Then keep on moving rotor, slider and rotor will be slipping to steam end together. The rear rope of slider shall be stay outside excitation end turbine base, in order to drag proper slider out. The external diameter of rotor slider is greater tha

34、n that of axle journal about 1-2mm, so all the load of rotor will be supported by rotor slider and rotor support during the moving process. g. 当转子滑到汽端联轴器露出机座210mm时停止滑动。将吊索移挂在汽端轴径处，吊起转子汽端约15mm，注意不要碰撞气隙隔环。从汽端联轴器上解下本体滑块前端牵引绳，用后端牵引绳从励端将其抽出。然后下落转子至水平位置，继续用导链向前牵引转子，使其到达最终位置。拆下联轴器滑块。（见附图3）When rotor slips

35、to steam end coupling and exceeds base about 210mm, it should stop slipping. Remove lifting piece and hang to axle journal, lift steam end of rotor about 15mm, and pay attention not to hit the damage space ring of air gap. Disentangle former rope from steam end coupling, use rear rope to drag rotor

36、slider out from excitation end. Put rotor down to horizontal position, then use chain block to drag rotor to finial position. Then dismantle coupling slider. Refer to attachment 3h. 将汽端转子支架安装在汽端下半端盖上，落下转子使其汽端由转子支架上的顶丝支撑，顶丝与轴之间接触面须垫入轴颈保护用铜带。Rotor support at steam end will be installed on lower cover.

37、 Put down rotor and let the top rope will be supporting at steam end. The connection surface between top rope and axle shall be covered with protective cooper belt. i. 取下吊索，在汽端安装轴承座，用装轴瓦工具将下半轴瓦放到轴颈上并滚入就位。调节顶丝将转子汽端降落在轴承上。拆下汽端转子支架。Take down lifting piece and install bearing pedestal at steam end. With

38、 journal bearing tools, lower journal bearing will be put on axle journal and located. Adjust the top rope to let rotor down on steam end bearing. Dismantle rotor support at steam end. j. 将吊索挂在励端联轴器法兰上，吊起转子励端，注意严禁压碰气隙隔板，拆下转子托架，抽出弧形滑板及定子铁芯保护工具，注意仔细检查定子铁芯保护工具，确认其没有被铁芯撕下碎片或脱开。将励端转子支架安装在励端下半端盖上，落下转子使其励端

39、由转子支架上的顶丝支撑，顶丝与轴的接触面须垫入轴颈保护铜带。（见附图4）Hang lifting piece on excitation end coupling flange, lift rotor and pay attention not to hit the air gap diaphragm, and then dismantle rotor support at excitation end. Draw out arc sliding plate and protective tools of stator core, check carefully about protectiv

40、e tools for stator core, and make sure there is no fragment ripped by core or loose phenomenon. Rotor support at excitation end will be installed on lower cover. Put down rotor and let the top rope will be supporting at excitation end. The connection surface between top rope and axle shall be covere

41、d with protective cooper belt. Refer to attachment 4k. 取下吊索，在励端安装轴承座，用专用工具将下半轴瓦放到轴颈上并滚入就位。然后调节顶丝将转子励端落在轴承上。拆下励端转子支架。Take down lifting piece and install bearing pedestal at excitation end. With journal bearing tools, lower journal bearing will be put on axle journal and located. Adjust the top rope t

42、o let rotor down on excitation end bearing. Dismantle rotor support at excitation end.至此，穿转子的工作基本结束。At this point, the work of rotor installation is completed basically. 5施工质量要求及保证措施Quality Requirements and Assurance Measure5.1质量要求Quality Requirements5.1.1为隔绝发电机、励磁机轴电流的各项绝缘部件应光洁、无翘曲及缺陷，厚度应均匀并有良好的绝缘性

43、能，安装后一律用1000V绝缘电阻表测量，其绝缘电阻应符合要求，一般应0.5M。Each insulated parts used to insulate generator and exciter shaft shall be bright, clean, no warping and on defect. The thickness shall be uniform and have a good insulation performance. After installation, the insulation resistance of insulated parts, checked

44、 by 1000V insulation resistance meter, shall be not less than 0.5M in general situation 5.1.2 进入定子内的工作人员，应穿无纽扣、无口袋的专用工作服和不带钉子的软底布鞋，对必须带入的物件应进行登记，工作完毕应认真清点核对，保证全数拿出。在端盖敞开的情况下，无人施工时，应用苫布将定子妥善盖好，防止灰尘或其他杂物落入内部。The workers who enter into the stator shall wear special clothing without buttons and pocket a

45、nd soft shoes without nails. The things that must be brought into shall be register. After work, these things must be taking out and checking carefully to ensure no leaving. When end cover is opening and there is no construction, stator shall be covered well by tarpaulin to avoid dust or other sundr

46、ies dropping into the internal. 5.2质量保证措施 Quality Assurance Measure5.2.1发电机在安装、检查、试验时必须按照制造厂提供的有关图纸及技术文件进行。安装过程中的每项检查、试验的结果都必须有详细正式的记录。The generator installation, inspection and test shall be carrying out as manufactory drawing and technical data. During installation, all the inspecting results shal

47、l have a completed formal record. 5.2.2 进入定子内的工作人员，应穿无纽扣、无口袋连体服和不带钉子的软底鞋。对必须带入的物件应进行登记，工作完毕后认真清点核对，保证全数拿出。在端盖敞开的情况下，无人施工时，应用苫布将定子妥善盖好，防止灰尘或其它杂物落入内部。The workers who enter into the stator shall wear special clothing without buttons and pocket and soft shoes without nails. The things that must be broug

48、ht into shall be register. After work, these things must be taking out and checking carefully to ensure no leaving. When end cover is opening and there is no construction, stator shall be covered well by tarpaulin to avoid dust or other sundries dropping into the internal. 5.2.3任何时候都不允许将任何种类的密封胶弄到密封

49、瓦、密封座的油孔里，以免堵塞。At any time, it is not allow putting various sealants into oil holes of sealing pad and sealing seat to avoid blocking. 5.2.4对轴承和密封瓦的巴氏合金进行着色探伤，以保证巴氏合金无夹渣、气孔、凹坑、裂纹或脱胎缺陷。汽、励两端轴封装置不能互换。PT test for Babbitt Metal of bearing and sealing pad shall be carrying out to ensure than Babbitt Meta

50、l has no defect such as slag inclusion, air hole, concave pit, crack or loosen etc. The shaft seal unit of steam and excitation end shall not be changed with each other. 5.2.5定子与转子磁力中心的偏差予留值按制造厂给定值予留。实际予留值与理论值偏差不大于1mm。空气间隙与磁中心调整结束后，进行发电机封闭工作并办理签证。Deviation reserve-value for magnetic center of stator

51、 and rotor shall be given as manufactory pointed value. The deviation between the actual value and theoretical value shall not be more than 1mm. after adjust air gap and magnetic center, the generator will be closed and applied a certificate. 5.2.6穿转子后定期检测定子绝缘值。发电机定子冷却水具备条件后尽快开始内部循环，以便于定子内部干燥。After

52、installation of rotor, Periodic test should be conform of the stator insulation value. When Cooling water system for generator stator is completed and the resource of water meets the requirement，start cooling water circulation as soon as possible for The stator internal drying.6施工安全注意事项 Safety Consi

53、deration During Construction 6.1一般要求 General Requirements 6.1.1贯彻执行“安全第一，预防为主”的安全生产方针。Stick to “safety first, precaution first” principle during construction.6.1.2现场所有施工人员必须全部接受安全教育，并经考试合格。All the site constructors must accept safety education and pass the test. 6.1.3施工现场的布置符合防火、卫生的有关规定。The arrangem

54、ent of construction site must meet the fireproofing and healthful related rules. 6.1.4施工现场及其周围的孔洞均应铺设与地面平齐的盖板或设置可靠的围栏、挡脚板及警告标志。Holes of construction site and around shall be laying cover board at the ground level or set reliable fencing, toe-boards and warming sign. 6.1.5进入施工现场的人员必须正确佩戴安全帽，严禁穿拖鞋、凉鞋、

55、高跟鞋或带钉的鞋。严禁酒后进入施工现场。Wear qualified safety protection clothes and helmet when enter into construction site. Slipper、sandal、high-heeled shoes or shoes with nails, short sleeve skirt or short trousers are forbidden to enter into site. No drunken into the construction site.6.2.施工用电及照明 Construction Elect

56、ricity and Lighting 6.2.1电气设备不得超铭牌使用，闸刀电源开关严禁带负荷开或关。Electric equipment should not use more than nameplate regulation. Knife power switch strictly prohibit opening and closing on load.6.2.2在光线不足及夜间工作的场所应有足够的照明，主要通道应装设路灯。It should have enough lighting that in insufficient light or night work place. Ma

57、in passageway should be equipped with streetlights.6.3.防火 Fire Protection 氧气、汽油、油漆、煤油等危险品仓库及乙炔站应有避雷及静电接地设施，屋面应采用轻型结构，并设置气窗及底窗，门窗应向外开。氧气瓶仓库的室温不得超过35。Dangerous goods store and acetylene station should be equipped with lightning protection and electrostatic grounding device. Roof should adopt light-typ

58、e structure and set transom window and bottom window. Open and windows should be open to the outside. The temperature of oxygen bottle store should not more than 35.6.4.设备起吊 Equipment lifting 6.4.1起吊物应绑牢。吊钩悬挂点应与吊物的重心在同一垂直线上，吊钩钢丝绳应保持垂直，严禁偏拉斜吊。落钩时应防止吊物局部着地引起吊绳偏斜。吊物未固定时严禁松钩。Lifting object should be tied. Hook suspension point and object Centre of gravity shoul