悬臂式斗轮堆取料机安装技术条件及调试、试验规程

1、第一篇 概述Chapter 1:General IntroductionDQ1200/2500.40悬臂式斗轮堆取料机是由长春发电设备总厂为越南沿海一期火力发电厂项目开发、设计、制造的一种大型、连续、高效的散状、粒状物料堆取作业的设备。DQ1200/2500.40 Boom type bucket wheel stacker reclaimer (BWSR is a kind of large, continuous and efficient bulk cargo stacking & reclaiming equipment, developed/ designed and man

2、ufactured by Changchun Generating Equipment Co., Ltd, China for DUYEN HAI 1 THERMAL POWER PLANT Project.第一节 设备简介Section 1 Brief Introduction of the equipment 越南沿海一期火力发电厂项目共二台斗轮堆取料机,为整体俯仰,头部分流固定单尾车。详见总图(图号DQ9721.0ST。Two sets Boom Bucket Wheel Stacker Reclaimer will be supplied by CGE for DUYEN HAI 1

3、THERMAL POWER PLANT Project, the luffing of each equipment is integral luffing, and the single tripper car is coal flow branching. Details refer to general drawing (Drawing No: DQ9721.0ST.斗轮堆取料机由斗轮机构、上部金属结构、悬臂胶带机、主机梯子平台、俯仰装置及系统、行走机构、门座、中部料斗、缓冲托架、回转机构、集中润滑装置、限位装置、检测装置、尾车、尾车梯子平台、电气室、电气系统、司机室及支架、厂牌、配重组

4、、洒水装置、动力电缆卷筒装置、控制电缆卷筒装置、水缆卷筒、转盘、支承铰座、基础布置及载荷等组成;司机室安装在门柱下部;装有斗轮机构、悬臂胶带机、司机室、配重组等变幅部分的上部金属结构围绕变幅铰点变幅;尾车上装有动力电缆卷筒、控制电缆卷筒、水缆卷筒、电气室及洒水系统的水源装置。Bucket Wheel Stacker Reclaimer consists of bucket-wheel mechanism, super steelstructure, boom conveyor, walkway/access stairs and platforms of the main machine, l

5、uffing unit and system, long travel, portal, centre chute, buffer bracket, slew unit, central lubrication system, limited switches, detector, tripper car, walkway/access stairs and platforms of tripper car, electric room and electrical system, operators cabin and brackets, nameplate, counterweight a

6、ssembly, dust suppression system, power cable reel drum, control cable reel drum, water cable reel drum, slew deck, supporting pivot block, foundational layout and load etc. Operators cabin is installed on the upper part of the pylon. The super steel structure on which bucket-wheel mechanism, boom c

7、onveyor, operators cabin, counterweight etc. luffing parts are installed will be luffing around the luffing pivot point. Power cable reel, control cable reel drum, water cable reel drum, electric room and water source device of dust suppression system are installed on the tripper car.第二节 工作原理Section

8、 2: Working Principle本设备能够采用手动、手动联锁、半自动进行堆料和取料作业。This equipment can select to use manual, manual interlocking as well as semi-automatic stacking and reclaiming operation.堆料作业时,中部料斗分流板处于堆料状态,系统胶带机送来的物料经尾车(系统胶带机、尾车头部落料斗转运到中部料斗,再输送到悬臂胶带机上,然后抛向储煤场。臂架的上仰和下俯可实现高、低位的堆料;臂架回转实现左右料场及料场宽度的堆料;大车行走则实现轨道长度方向的堆料。D

9、uring stacking operation, the centre chute branching plate should be in stacking state, the material transferred from yard-conveyor via tripper car conveyor, head hopper of the tripper car to centre chute and then feeding to boom conveyor, at last stacking onto stockpiles. Boom luffing can realize h

10、igh & low level stacking; Bucket wheel boom slewing can reach left-right stockyard and stockyard width stacking, Long Travel Drive can realize stacking along the track length.取料作业是按分层取料的工艺进行的 ,必要时也可以进行斜坡取料。斗轮机构上的斗子挖取上来的煤卸至悬臂胶带机上,再由悬臂胶带机抛向中部料斗,经系统胶带机输出。臂架的上仰和下俯可实现高、低位的取料;臂架回转实现左右料场及料场宽度的取料;禁止只靠大车

11、行走取料。Reclaiming operation is carried out according to layer reclaiming process as well as bevel reclaiming if necessary. Discharge the coal excavated and reclaimed by the hopper of the bucket wheel mechanism to boom conveyor- then through boom conveyor drop into centre chute, via yard conveyor trans

12、port out. Bucket wheel boom luffing can realize high & low level reclaiming; Bucket wheel boom slewing can reach left-right stockyard and stockyard width reclaiming; Forbidden to reclaim the material only depending on long travel mechanism traveling.分流作业是系统胶带机送来的煤经尾车胶带机(系统胶带机、尾车头部落料斗,一部分经分流料斗转运到

13、中部料斗卸至缓冲托架、经系统胶带机输出。另一部分输送到悬臂胶带机上,然后抛向储煤场。Branching operation is such a process that the coals, from yard conveyor, go through tripper car conveyor (yard conveyor and tripper car head hopper, part of coals go through branching hopper, transported to centre chute and discharged at buffer bracket, out

14、put by yard conveyor; the other part of coals transported on boom conveyor and discharged at stockpile.详细结构说明请参见本机的使用、维护说明书。(Detailed structure and instruction, refer to “Operation and maintenance instruction” of this machine.第三节 设备的性能参数、基础载荷Section 3: Performance Parameter and foundational arrangem

15、ent load of the Equipment1 堆料能力Stacking capacity2500t/h(额定 3000t/h(额定 2500 t/h (rated 3000t/h (rated 2 取料能力Reclaiming capacity1200t/h(额定 1440t/h(额定 1200 t/h (rated 1440t/h(rated 3 堆取高度 Height of stacking and reclaiming轨上13.5m 、轨下1.5m13.5 m above rail and 1.5 m below rail4 斗轮转速Rpm. of the Bucket whee

16、l6.86r/min 5 胶带速度Belt speed3.15m/s 6 臂架回转半径Slewing radius of Bucket wheelboom40m 7回转角度Slewing angle ±110° 8 回转速度Slewing speed0.0320.116r/min 9 走行速度Traveling speed 工作速度7.5m/min 、调车速度30m/min Working speed: 7.5 m/min,commissioning speed: 30m/min10 总装机容量Total installed capacity430kW12 电源:Power

17、 Supply 供电电压6.6kV 、供电频率50Hz 、供电方式为电缆卷筒 Power voltage: 6.6 kV, frequency: 50HzPower supply mode: cable reel drum13 风压:Wind pressure 最大工作风压250N/m2、最大非工作风压1850N/m2 Max. Working wind pressure: 250N/m2,Max. non- working wind pressure:1850N/m2.本安装技术条件和调试、试验规程适用于越南沿海一期火力发电厂项目DQ1200/2500.40悬臂式斗轮堆取料机,并作为斗轮堆取

18、料机安装要求及安装质量标准和安装完毕进行调试、试验、验收质量标准的依据。其中主要内容如下:各部件或设备的维修说明及维修质量标准;各部件或设备的调试、试验规程;安装要求及安装质量标准。This “Installation Technical Conditions & Regulations on Commissioning and Test” will be applicable for DUYEN HAI 1 THERMAL POWER PLANT Project - DQ1200/2500·40 Boom Bucket Wheel Stacker cum Reclaimer

19、. It is also as a standard for installation requirements and installation quality as well as a basis for quality of commissioning/ test, also as a standard for quality acceptance after installation. Main contents will be as follows:- Maintenance instruction and maintenance quality standard of each c

20、omponent or equipment- Regulations on commissioning and test of each component or equipment- Installation requirements and installation quality standard第二篇 安装技术条件Chapter 2: Technical Conditions of Installation第一节 总则Section 1: General Principles1 斗轮堆取料机必须按规定程序批准的图样及技术条件的要求进行安装。Bucket wheel stacker re

21、claimer must be installed according to the drawings approvedby specified program and technical requirements.2 待安装的零部件必须是检验合格的产品,外购机电产品应具有出厂合格证、使用、维护说明书。The spare parts and components installed must be conformable products through inspection, the bought-in mechanical and electrical products should ha

22、ve ex-work quality certificate and operation & maintenance specifications.3 安装中的消耗材料(焊条、紧固件、润滑脂、机械油、液压油等必须具有出厂合格证,符合国家(或行业标准。The consumable material of installation (such as electrodes, fasteners, lubricating grease, machine oil, and hydraulic oil etc must have an Ex-work certificate, and should

23、 be in accordance with national (or industry standards.4 安装工作应由专业部门负责进行。Installing work should be responsible by professional departments.第二节 安装前的准备工作Section 2: Preparations before installation1 斗轮堆取料机各零部件及构架等运到现场卸车时应避免扭、弯、撞击、腐蚀等事故的发生,为此必须遵守以下规定:All parts and components as well as frames of Bucket W

24、heel Stacker Reclaimer will avoid distortion, bend , collision, corrosion; etc accident, while unloading after they arrive at the jobsite. Therefore, the following rules must be observed:1.1 起吊时构件至少应捆扎两处,捆扎处须有衬垫物,并捆扎在有筋板等加强节点处,一般应尽可能捆扎在构件的两端,不宜捆扎在非节点部位或构件的外伸部。The components must be lifted with being

25、 enlaced at least two points where there must be gaskets, and they should be enlaced at the stiffener nodes of stiffener, normally, the components should be enlaced at the two ends, it is improper to enlace them at places without nodes or extensional part.1.2 搬运时应将构件搁置在载重汽车或平板车上,禁止直接在地面上放滚拖移。The com

26、ponents should be placed on trucks or flatcars while transported. It is forbidden to roll or pull them directly on the ground.1.3 存放时应安置平稳,用枕木垫实放平,枕木应对称放置,地面也必须选择结实平整完好处,以防日久下沉以致构件变形。They should be stored on stationary crossties, and the crossties should be placed in symmetry. The ground must be sol

27、id, smooth and intact, thus avoiding deforming of the components due to ground falling as time passes.1.4 零(部件如需露天存放的,应遮盖好,对存放日期长或露天存放的件安装前应检查锈蚀情况,清除污渍,必要时重新涂油组装,使各转动部分灵活,并检查各联接部分的牢固性。存放期间应定期保养,注意防潮、防锈和通风。If some parts and components need be stored outdoor, they should be well covered. Those that wi

28、ll be stored for a long time or outdoor should be inspected their rust situations before installation and derusting, and repainted and reassembled if necessaryto make sure smooth running of every rotating part. The fastness of every linked part should be also inspected. During storage they should be

29、 maintained regularly, prevented from moisture, rusting and ventilation.2 安装前应组织安装人员认真熟悉图样,根据要求详细检查部件的安装尺寸,不符合图样要求的需校正。It is necessary to organize personnel to read the drawings carefully, inspect the installation dimension of all spare parts and components, the parts which can not meet the requirem

30、ents of drawings should be modified.3 按附录A复核查验斗轮堆取料机轨道精度。Recheck and inspect the rail accuracy of Bucket Wheel Stacker Reclaimer according to appendix A.4 安装位置应选在锚定位置为宜(如在非锚定位置安装,则应在车轮下塞进“铁靴”以防大风刮跑。The installation position should be selected to anchoring point (if in non-anchoring point, wedge bloc

31、k assembly should be stuffed under the wheel to avoid blowing away by storm.第三节 安装Section 3: Installation1 现场连接Connection on the jobsite1.1 所有连接应根据图样及有关连接技术要求进行。All connections should be carried out according to drawings and related technical requirements.1.2 连接中不允许存在附加力,严禁强制装配。It is unallowable to

32、have additional force during connection; it is strictly prohibited to assemble forcibly.1.3 为减少高空作业量,应尽量在地面上连接。Connection should be done on the ground in order to reduce work high above the ground.1.4 焊接连接要求Requirements for welding connection1.4.1 安装焊接工作应由合格焊工进行。Site welding should be completed by q

33、ualified welders.1.4.2 重要构件的连接接口处应开坡口。The connection of the main components should be made bevel.1.4.3 焊接材料的型号、规格应符合设计图样及焊接工艺要求,一般Q235-A钢制造的构件采用E4303焊条,16Mn制造的构件采用E5015焊条。异种材料构件之间的焊接,一般按强度较强的金属基体选用焊条。本机除平台以外全部工地现场安装焊条采用E5015焊条。The type and specification of the welding material should be in accordanc

34、e with thedesign drawings and requirements of welding procedure. Normally, E4303 electrodesapply to the components made of Q235-A steel, E5015 electrodes apply to those madeof 16Mn steel. Welding between different material components, electrode should usuallybe selected according to the metal with l

35、arger hardness. Except the platform, all welding electrodes used for site installation of this equipment should adopt E5015 electrodes.1.4.4 焊条使用前应根据使用说明书参照表1-1规定烘干。烘干的焊条应存放于在100150保温箱中,随用随取。Electrode should be baked before being used according to reference of table 1-1 in the “operating instruction

36、”. The baked electrodes should be stored in a 100150 thermal container on the jobsite for taking electrode for use at any time of welding. 表1-1 Table 1-1焊条牌号Electrode brand 烘干温度Baking temperature烘干Baking timeE4303 1502502小时2 hoursE5015 35040023小时23 hours1.4.5 烘干的焊条置于空气中超过四小时应重新烘干,但烘干次数超过二次的焊条仅能作为次要件

37、焊接使用。After the baked electrodes being placed in the open air for more than 4 hours, they must be re-baked in the heating oven, Those electrodes rebaked more than twice can only be used as secondary welding.1.4.6 所有焊缝焊前必须彻底清除边缘(不小于10mm的水迹、油污、铁锈、油漆、氧化等杂物,直至露出金属光泽。Edges of all welding seams ( 10mm must

38、 be cleaned completely e.g. water stain, oil stain, rust, paint and oxides, etc. until the surfaces expose the metallic gloss.1.4.7 不准在非焊接部位上引弧和试电流,焊缝药皮应清理干净,焊瘤要铲除。It is not permitted to strike the arc and test electric current on non-welding position,flux on the welding seam should be removed and t

39、he weld beading shall be removed.1.4.8 露天施焊时,凡遇雨、雪、大雾等特殊气候,无安全措施不允许焊接。If it rains, snows or fogs while welded outdoors, it is unallowable to weld without safety precautions.1.4.9 焊缝检查Inspection for weld seama.焊缝高度应符合图样要求。The height of the weld seam should be in accordance with the requirements of th

40、e drawings.b.焊缝及热影响表面不得有裂纹、气孔、弧坑和夹渣等缺陷。No cracks, pores, arc craters and slag etc defects on the welding seam andheat-affected surface.c.焊缝咬边当板厚小于10mm时,不得大于0.5mm,当板厚大于10mm时,不得大于1mm,咬边连续长度不大于100mm。二侧咬边总长不得超过焊缝总长的10%。The undercut of the weld seam is not more than 0.5mm, if the plate thickness is less

41、than 10mm; the undercut of the welding seam is not greater than 1mm, if the plate thickness is more than 10mm; and the continuous length of the undercut will not more than 100mm. The total length of the bilateral undercut shall not exceed 10% of the total length of the welding seam.d.焊缝应呈圆滑过渡至母材的几何形

42、状,焊缝转角处应饱满。Weld should be smooth transition to base metal geometry in shape, the corner ofweld should be fullness.1.5 高强度螺栓连接Connection with high strength bolt1.5.1 钢结构用高强度螺栓连接方式Connection mode of high strength bolt for steel structure1.5.1.1 连接面的处理Treatment of connection surface1.5.1.1.1 连接前,必须清理连接

43、表面的污物、油漆、油污及氧化皮等减少摩擦系数的杂物,并用钢丝刷刷去浮锈,不准用砂轮打磨。Contaminations, paint, oil and oxide skin etc that can reduce friction factor on the connection surface must be removed before connection. Steel brush should be used for getting rid of the rust on the face rust and without grinding wheel.1.5.1.1.2安装高强度螺栓时,

44、严禁强行穿入螺栓(如用锤敲打。如不能自由穿入时,该孔应用铰刀进行修整,修整后孔的最大直径应小于1.2倍螺栓直径。修孔时,为了防止铁屑落入板迭缝中,铰孔前将四周螺栓全部拧紧,使板迭紧密贴后再进行。严禁气割扩孔。While installation high strength bolt, bolts are not permitted to infix withadditional force (e.g. with hammer. If can not infix smoothly, fraise should be used to repair, the diameter of holes sh

45、ould be smaller than that of 1.2 bolt after repairing. Before starting to repair, all the bolts around the hole are tightened and plates are put closely in order to avoid iron chips falling. Gas cutting for bearizing is prohibited.1.5.1.1.3安装高强度螺栓时,构件的摩擦面应保持干燥,不得在雨中作业。While installing high strength

46、bolts, friction surface of components should bedry, installation is not permitted in rain.1.5.1.1.4大六角头高强度螺栓施工所用的扭矩扳手,扳前必须校正,其扭矩误差不得大于±5%,合格后方准使用。校正用的扭矩扳手,其扭矩误差不得大于±3%。Torque wrench for hexagon head high strength bolts must be corrected before using, torque error percentage is not more tha

47、n ±5%, it is used after qualification; torque error percentage of wrench for correction is not more than ±3%.1.5.1.1.5大六角头高强度螺栓的拧紧应分为初拧、终拧。对于大型节点应分为初拧、复拧、终拧。初拧扭矩为施工扭矩的50%左右,复拧扭矩等于初拧扭矩。初拧或复拧后高强度螺栓应用颜色在螺母上涂上标记,然后按施工扭矩值进行终拧。终拧后的高强度螺栓应用另一种颜色在螺母上涂上标记。Tightening for hexagon head high strength bo

48、lt is divided into pre-tighteningand final tightening, tightening for big nodes is divided into first tightening, second tightening, final tightening. Torque for pre-tightening is 50% that of operating torque, torque for second tightening is equal to that of first tightening. High strength bolts sho

49、uld be marked with color on the nut after first and second tightening, then make final tightening according to operating torque. High strength bolts should be marked with different color.1.5.1.1.6大六角头高强度螺栓拧紧时,只准在螺母上施加扭矩。高强度螺栓在初拧、复拧和终拧时,连接处的螺栓应按一定顺序施拧,一般应由螺栓群中央顺序向外拧紧。高强度螺栓的初拧、复拧、终拧应同一天完成。During tight

50、ening hexagon head high strength bolts, torque only on nuts. Bolts on the connection points should be tightened in sequence which from center to outside part during first, second and final tightening, these three process should be finished on the same day.1.5.1.2 紧固方法及预紧力Tightening method and pretig

51、htening force高强度螺栓必须采用力矩搬手紧固,控制扭矩达到要求的预紧力。对本机采用的GB12281230-94标准大六角头高强度螺栓,力矩板手扭矩值按下式确定: M=KDg.dHigh strength bolts must be tightened with torque wrench to control torque to reach the required pre-stress. Refer to the GB12281230-94 standard hexagon head high strength bolts that applies to this machine

52、, the value of torque will be decided by the following formula:M=K Dg. d式中: K -扭矩系数(范围值0.110-0.150K-torque coefficient (range: 0.110-0.150Dg-预紧力M22高强螺栓Dg=210×10³NDg-pretightening force: M22 high strength bolt Dg=210×103Nd -螺栓直径M22高强螺栓 d=0.022md-diameter of the bolt M22 high strength b

53、olt d=0.022m注:K值以生产高强螺栓的厂家提供的合格证为准。Note: K value is in accordance with the conformity certificate offered by high strength bolt manufacturer.2 安装顺序Sequence of installation由于各安装单位拥有的技术装备手段(起吊作业机具等和安装现场场地条件的不同,允许有不同的安装方案,但在保证安全、可靠、经济、质量的前提下,进行空间与时间的合理交叉,以达到缩短安装周期的目的。Since the technical equipments and

54、instruments (lifting machines etc. and the installation fields are various, it is permitted to use different installation plans which, however, must base on safety, reliability, economy and quality, and logically cross in time and space, so as to realize the objective of shorten installation period.

55、 The following installation order is recommended.3 装配与安装技术要求:Technical Requirements for Assembly and Installation斗轮堆取料机对行走轨道的精度要求见附录A。The rail accuracy being required by Bucket Wheel Stacker Reclaimer refers to Appendix A:3.1 行走机构Long Travel mechanism3.1.1 行走车轮安装精度Installing precision of the traveli

56、ng wheel for long travela同侧轨道上各车轮滚动圆的中心应在同一平面上,其同位差应符合表1-2及图1。The centers of the rolling circles of all wheels on the same side of the rail should be on the same level, whose position deflection should be in accord with Table1- 2 and figure 1表1-2 Table1-2测量部位Measuring point偏差Deflection同一台车架的两个车轮Two

57、wheels of the same bogie2mm同一支腿下的三个以上车轮 Over three wheels under the same support leg3mm同侧轨道上的全部车轮All wheels on the same side of the rail5mm 图1 figure 1b 同一轴线上一对车轮的水平偏斜方向应相反,其水平偏斜值ax 不得大于测量长度 L 的千分之一(图2。The deviated direction of a pair of wheels on the same axis shall be opposite, the horizontal defl

58、ection ax shall not be more than millesimal of the measured length L (figure 2.figure 2c 同一轴线上一对车轮的垂直偏斜方向应相反,且上边应向外偏,车轮的垂直偏斜值 ay 不得大于测量长度 L 的四百分之一(图3。The deviated direction of a pair of wheels on the same axis shall be opposite, the upper side shall deviate outwards, and the vertical deflection of the wheel ay shall not be more than one four-hundredth of the measured length L (figure 3 图3 figure 33.1.2行走机构安装精度应符合表1-3及图4的规定。Installation accuracy for long travel drive should be in accor