环氧浇注及中心线的确定

1、图 纸 履 历 PLAN HISTORY日 期DATE版 本REV.标 记MARK简 述DESCRIPTION依据BY设 绘DRAWN审 核CHKD审 定APPDJINGJIANG JIANGSU CHINATel:+86-523-4209842Fax:+86-523-42113424250TEU集装箱船4250TEU container vessel工艺设计PROCEDURE DESIGN船号：0242001/002/003/004设绘Designed顾熀兴轴系中心线确定及环氧浇注工艺Procedure of centerline Deciding for Shaftline and cho

2、cking图号：DWG.NO.校对Checked重量MASS比例SCALE面积AREA审核Reviewed共 页TOTAL SHEETS第 1 页SHEET版本REV.审定Approved江苏新世纪造船股份有限公司 NEW CENTURY SHIPBUILDIONG CO.,LTD.1. 轴系中心线的确定 Decide the centerline of the shaftline.1）采用工具 Tools and instrument激光经纬仪、光靶。Laser theodolite and optical target.2）轴系中心线的确定的条件Decided condition the

3、centerline of the shaftline.轴系中心线的确定应根据季节温度变化来进行，夏天一般在晚上8-9点进行,冬天一般在下午5点左右进行, 或在阴天进行，在轴系中心线的确定过程中，船上不应有能够导致船体变形的工作在进行。从机舱前壁到船的尾部，从机舱二甲板到双层底舱的主船体结构焊接及火工矫正工作全部结束。两根中间轴必须吊运至机舱临时固定，同时主机主体必须根据轴系布置图上的尺寸位置大致就位。主机就位前必须初步确定轴系中心线，然后根据确定的轴系中心线在主机凹槽后端面和尾管前端面之间设置两个临时支架，把FR59肋位上光点引到临时支架上并打硬记。This step should be d

4、one according to temperature change of the season of a year , in the estival season , this work should be done at evening 8-9 clock, and in the winterly season, this work should be done at afternoon 5 clock ,or in the cloudy day, and any work that can bring hull deformation should be stopped. all th

5、e welding and the fire rectification work from fore bulkhead of engine room to stern and from engine room second deck to double bottom must be finished. two intermediate shaft must be lifted to engine room and located temporary . and the M/E main body must be located in accordance with the shaft arr

6、angement drawing. we must decide the shaft line in advance ,then set two temporary support between M/E groove end and the fore surface of stern tube according to the centerline of the shaft line .leading the mark on the FR59 to the temporary support and making hard marks on it . 2. 船体尾部理论轴中心面的确定。Dec

7、ide the center plan of shaft line outer of E/R. 以中心线在船台上的延伸点为基准，调整激光经纬仪“1”的轴线直至与船中心线重合。Adjust No.1 laser theodolite centerline overlap with hull C.L. basing on hull C.L. 将激光经纬仪“1”射出的光点延伸到船台尾部光靶“3”上，根据机舱区域舱底龙骨平整度数据平均值为基线高度并在垂直方向向上平移轴系高度+船体板厚，则此点为轴系轴线上一点。以此点作为参考点并打好样冲点，同时将激光经纬仪旋转180°将光点投射到尾柱上，并打好

8、样冲，这样就可初步确定轴系尾部理论面。Extend the laser from No.1 theodolite to No.3 target, then according to the mean valve of flexibility of the keel under the ring of groove for main engine as datum high move No.1 theodolite up and down in vertical plan and measure the height of shaft line and thickness of armor pl

9、ate, the point as a datum point in the shaft line,a laser point can be found in stern boss by turning No.1 theodolite 180°, and another mark will be made as the point. In this way, we can decide shaft center plan outer of E/R firstly.2） 机舱内轴系中心线的确定 Decide the shaft line in E/R. 在机舱与尾管平面适当位置设立一激

10、光经纬仪“2”，将光点延伸到船体外部的光靶“3”，使之与光靶“3”上的样冲点重合。Put No.2 theodolite to fit at Fr15. Its laser beam to be extended to No.3 target and to be kept superposition with that mark made on No.3 target. 调整激光经纬仪“2”的位置，使之既能与船体尾柱上的样冲点的连线相交，同时也能投影到光靶“3”上的样冲点上，调整经纬仪高度与光靶“3”上的样冲点重合，然后将经纬仪“2”的位置固定。Move No.2 theodolite, an

11、d keep its height same as the mark on No.3 target and make the beam pass through the center of marks on stern boss, then fix No.2 theodolite.3） 轴系中心线的延伸 Extending the centerline of the shafting.将激光经纬仪“2”旋转180°，将光点延伸并投影在机舱设置的临时支架上，并确定光点位置，打好样冲点，这点与光靶“3”上的样冲点的连线即为初步确定的理论轴线。Turn No.2 theodolite 18

12、0°, the laser beam can be extended to the temporary support on the M/E groove, make the mark again. Now we can say that the line decided by this point mark and that one on No.3 target is shaft line.Following is the general operation procedure for the sterntube installation with Epocast 36:- EPO

13、CAST 36 环氧树脂在应用于艉管安装时的操作程序主要如下：3. Main Points To Be Noted In Advance 施工前应注意的要点(1) Ensure that appropriate Classification Society has been informed of the proposed application of EPOCAST 36 and written approval has been obtained where necessary.确保EPOCAST 36 环氧树脂垫块浇注的已通知有关船级社，并且必要时相应图纸应获得其书面认可(2) Ensu

14、re the EPOCAST 36 chocking for sterntube installation will be carried out by the service engineer from WILLTRUST PTE LTD. 确保EPOCAST 36 环氧树脂垫块在应用于艉管安装的浇注由新加坡维信有限公司的服务工程师实施。(3) EPOCAST 36 consists of 2 liquid components, the resin and the hardener, which should be stored protected against freeze. Shel

15、f life of EPOCAST 36 is 18 months. EPOCAST 36 包括两种液体材料：环氧树脂和固化剂。它们的储藏应防止冰冻。其有效期为出厂后18 个月。(4) Due to the special designed filling pump, this will not effect the EPOCAST 36 installation as long as the minimum gap is at least 3 mm. 由于采用特殊设计的浇注泵进行压力式浇注，所以对艉管环氧树脂垫块其允许的最小厚度为3mm 。4. Material And Tools Requ

16、ired 材料和工具(1) EPOCAST 36 of sufficient quantity: 70 sets (Supplied by WILLTRUST). 足够用量的EPOCAST 36 环氧树脂材料：70 套(维信公司提供)。(2) Damming material for moulding the chocking arrangement according to the drawings approved by the Classification Society; 足够的按照船级社认可的环氧树脂垫块布置图制作模框的材料，具体如下: 1 (a) Damming foam: 4 p

17、cs (Supplied by WILLTRUST) 泡沫条：4 根（维信公司提供）；1 (b) Flange damming steel plate: 18(W)x 1.52.5(Th)x9000(L) mm (Supplied by S/Y); 1 宽度约18mm，1.52.5mm 厚的铁皮条：约9m（船厂提供）；1 (c) “2-Half ring plates” with thickness 6 mm: 4 pairs, 1 pairs will be welded on the outside surface of sterntube, other 1 pairs will be w

18、elded on the inside surface of the stern frame boss. the other 2 pairs will be installed after sterntube assembly. please see the Drawing No.1 & 2 for its position and dimensions (Supplied by S/Y); 1 6mm 厚的2-half 密封压板：4 对, 其中2对预先焊接在艉管外表面(焊接好后把密封条直接粘在尾管上)，另外两对将在尾管装配后安装(根据附图1的尺寸在尾管内装上密封压板,然后用支撑杆固定

19、在船体结构上)。其位置与尺寸详见附图一、附图二（船厂提供）；1 (d) Sealing compound: 4 kg (Supplied by WILLTRUST); 1 密封胶泥：4 公斤（维信公司提供）；1 (e) Sufficient wooden bolt plugs for sealing the bolt holes on stern-tube flange. Diameter: bolt hole diameter + 23mm; Length: (flange thickness + EPOCAST 36 Thickness)x1.5; Quantity: = bolt hol

20、e quantity; (Supplied by S/Y); 足够的木棒塞，用于艉管法兰面螺栓通孔的密封。其直径比螺栓通孔直径大23mm，长度应不小于法兰及法兰面环氧树脂的总厚度的1.5 倍，数量根据法兰面螺栓通孔的数量来确定（船厂提供）；(f) Foam rubber sealing ring: 2 pcs (Supplied by WILLTRUST);橡胶密封环：2 根（维信公司提供）。(3) Heavy duty hand drill with operation speed less than 500 rpm. (Supplied by S/Y) 转速不超过500rpm 的手提电钻2

21、 只，用于搅拌环氧树脂（船厂提供）。(4) Jiffy mixer: 2 pcs. (Supplied by WILLTRUST) 搅拌叶轮：2 只（维信公司提供）。(5) Filling pump: 1 set. (Supplied by WILLTRUST) 浇注泵：1 台（维信公司提供）。(6) 380 V / 50 Hz / 3 Phase power supply for filling pump. (Supplied by S/Y) 380 V / 50 Hz / 3 Phase 的电源，用于驱动浇注泵（船厂提供）。(7) 220 V / 50 Hz / 1 Phase power

22、 supply for mixing drill. (Supplied by S/Y) 220 V / 50 Hz / 1 Phase 的电源，用于驱动手提电钻（船厂提供）。(8) Portable temperature gauge: 1 pc. (Supplied by S/Y) 便携式温度计：1 只（船厂提供）。(9) Barcol hardness tester: 1 pc. (Supplied by WILLTRUST) 巴科硬度计：1 只，用于测量样块硬度（维信公司提供）。(9.1) 10 20 litres acetone and sufficient rags, for rem

23、oving grease, oil in the chocking area and cleaning the filling pump after the installation. (Supplied by S/Y) 1020 升丙酮和足够的抹布，用于清除环氧树脂浇注区域内的油污及清洗浇注泵（船厂提供）。(9.2) 6 10 men (including 1 welder) for the sterntube installation work. (Supplied by S/Y) 6 10 名工人（含1 名点焊工）进行施工配合（船厂提供）。(9.3) Sufficient 36V wor

24、k-lights in the chocking areas. (Supplied by S/Y) 如施工区域亮度不够或者在晚上施工，还需准备足够的36V 安全照明灯，并预拉到位（船厂提供）。(9.4) Stopping plate: 2 pcs, made by channel steal for preventing the movement along the shaft line after pushing the sterntube into the stern frame boss. Please see the Drawing No.3 for the detail. (Supp

25、lied by S/Y) 为防止艉管塞入艉柱后发生轴向的位移，需采用槽钢制作2 只法兰面压板，如附图三所示。其宽度应小于法兰面两相邻螺栓间的间距，长度比艉柱直径长约150mm；同时在艉柱上焊两只螺栓，用于紧固该法兰面压板（船厂提供）。(9.5) In winter or at below an ambient and / or steel temperature of 13°C, the additional preparation work must be carried out in advance as follows:- 在冬季或者环境温度过低（<13）时，还需准备下列

26、加热设备： (a) Sufficient electric heater for preheating the Epocast 36. (Supplied by S/Y) 足够的电烘箱或电加热器，用于预热环氧树脂（船厂提供）。(b) Sufficient electric hot air machine or heater to heat the sterntube area to at least 20°C after the Epocast 36 pumping to shorten the cure time. (Supplied by S/Y) 足够的热风机或电加热器，用于浇

27、注后加热环氧树脂浇注区域至20°C 以上，以促使并缩短固化时间（船厂提供）。5. Preparatory Work 准备工作1 (1)Prepare the EPOCAST 36 resin to the required temperature well ahead of time. (See the MIXING and POURING GUIDE ). The temperature of the pouring is 20at least to ensure suitable mixing and pouring viscosity. The hardener to be a

28、t the ambient temperature. Check the mixed temperature is within +/- 5 of the required temperature. In hot climates avoid leaving EPOCAST 36 in direct sunlight before use. 1 预先将环氧树脂预热到要求的温度 (参见搅拌、浇注温度表 )。浇注的温度需不低于20，以保证适宜的搅拌和浇注粘度。固化剂应保持室温，搅拌的温度应在要求的温度±5的范围内。在夏季，使用前EPOCAST 36 环氧树脂应防止阳光直晒。1 (2)Pr

29、e-drill following holes on the stern frame boss. Please see the Drawing No.1 & 4 for its position and dimensions:-1 预先在艉柱上开孔如下, 其位置与尺寸详见附图一、附图四：1 (a) 4 pcs holes for adjusting screws; 4 个调整螺栓孔，并攻丝；1 (b) 4 pcs air ventilation holes at the top of the stern frame boss; 2 pcs pump filling holes at t

30、he bottom of the stern frame boss. 1 4 个透气孔，2 个注入孔，并焊好注入管和透气管。注：调整螺栓的数量和位置仅供参考，船厂可根据船上的实际情况灵活调整。(3)Finish all hot work (for example: welding etc.) on chocking area. 所有能产生热量的工作均需完工，如焊接等。(4) Clean the stern frame boss and sterntube surfaces, including the inside surfaces of the filling and air ventila

31、tion holes & pipes, where it would be in contact with EPOCAST 36 resin. Remove all grease, oil, mill scale, rust, paint etc. 艉柱内表面及艉管外表面等与环氧树脂接触的表面(含浇注、透气孔/管内表面)均需清除铁锈、油污、毛刺、焊渣、油漆和灰尘等。(5)Recheck the clean of the boss and sterntube surfaces. And then push the sterntube into the stern frame boss.

32、待维信公司服务工程师检查清洁并满足要求后塞入艉管。注意塞入艉管的过程中应避免带入灰尘，油污等。A. Prepare at least 6 PCS chain blocks whose work load is 4.5 ton. 准备至少六只工作载荷为4.5吨的手拉葫芦. B. Put stern tube to the place shown on drawing7,adjust it along vertical direction as shafting arrangement drawing, and adjust the trolley until stern tube centerl

33、ine parallel with shaft theory centerline.将艉管放至图7中所示位置, 艉管上下方向需按轴系布置图摆正,调节小车上下水平 位置使得艉管中心线与轴理论中心线平行.C. Install lifting gourd on the inner structure above stern tube, check cleanness of stern tube. Clean the stern outer boss and stern tube surface where it would be in contact with EPOCAST 36, remove

34、all grease, oil, sharp edge, welding slag , rust and paint. Deliver to WILLTRUST SERVICE ENGINEER. 在尾管铸件内上部的结构安装起吊葫芦. 检查艉管清洁度. 艉管前后支撑套内表面及艉管外表面等与环氧树脂接触处(含浇注孔,透气孔内表面)均需清除铁锈,油污,毛刺,焊渣,油漆和灰尘等.提交维信服务工程师检查清洁并满足要求;D. MOVE TROLLEY TOWARD FWD SIDE TO THE PLACE SHOWN ON DRAWING 8, pull up the stern tube by ch

35、ain block, drop the trolley, carefully clean contact part between S/T and wood, and recheck cleanness of stern tube outer surface and stern boss inner surface and clean by ACETONE. Deliver to WILLTRUST SERVICE ENGINEER.将小车向艏移动,当到达图8中所示位置时，利用手拉葫芦将艉管拉起,将小车降低, 仔细清洗艉管与垫木接触处, 且重新检查艉管外表面和支撑套内表面清洁度且用丙酮清洗.

36、并提交维信服务工程师检查清洁并满足要求E. Remove stern tube to the place shown on “SHAFT ARRANGEMENT” by FWD AND AFT chain blocks. 利用艏艉手拉葫芦的配合将艉管移到“轴系布置图”中所示的位置.F. Hold up stern tube by FWD AND AFT adjusting bolts, and remove all auxiliary tools of lifting stern tube. 拧入艏艉处的调节螺栓将艉管支起, 撤去起吊艉管所有辅助工具.(6)Rotate the adjustm

37、ent screw for alignment. 调节调整螺栓，进行轴系安装定位、校中。 (6.1) 艉管校中的准备工艺 preparation of stern tube positioning 1） 将艉管布置于车间平台上保持水平。Place stern tube horizontal on platform in workshop.2） 根据艉管前后外圆中心线在艉管前后端面上的水平方向及垂直方向上划出水平和垂直线并打好洋冲眼，那么前后艉管端面的十字线的交点的连线即为艉管外圆的理论中心线。Draw a horizontal line and a vertical line accordin

38、g to the centerline of holes at stern tube fore and aft. End, and make a mark, so the line between the two intersection points stated above is the theory centerline of s/t outer circle, and should be approved by ship owner and survey-er. (6.2) 艉管校中 stern-tube alignment 1) Install separately one targ

39、et at fwd and aft655 hole, adjust optical target to make the center coincide with holes center, then the line between fwd and aft plug center is stern tube centerline.在艉管艏艉圆孔处各装一只光靶，调节光靶使得其中心与艉管外圆圆心重合，那么此时艏艉塞芯中心的连线即代表艉管的中心线。2) Adjusting bolts to make the fwd and aft optical target center coincide wi

40、th the beam projected by theodolite. Deliver to ship-owner and surveyer after finish. 调节艉管调整螺栓，使得艏艉光靶中心与经纬仪光点重合，则表明艉管中心线即为艉轴的轴中心线，完工后需要提船东船检认可。3） At the same time check the tolerance between the stern tube outer surface and the stern boss inner surface, the average tolerance should be 16-26mm 同时需检查艉

41、管外壁与支撑套内壁之间的间距,范围值应在16MM-26MM之间。(7)After taking the approval for the alignment, prepare the Epocast 36 damming work. 待轴系对中报验船东、船检结束后，对环氧树脂浇注区域各端面进行密封。(8) It is recommended to re-check the sterntube alignment readings before starting the Epocast 36 pumping work. 建议在搅拌、浇注EPOCAST 36 环氧树脂之前，再校验一下定位、对中读数

42、是否满足要求。6. Mixing And Pumping 搅拌和浇注(1) Add hardener into the EPOCAST 36 and power mix at speed not exceeding 500 rpm for 23 minutes to ensure homogenous mixture. Traverse side and bottom of the can to ensure complete mixing all resin and hardener. For quantity of hardener and temperature guides, plea

43、se see the MIXING and POURING GUIDE . 将固化剂加入EPOCAST 36 环氧树脂中，将搅拌叶轮安装到搅拌电钻，接通电源以不超过500rpm 的转速搅拌2 3 分钟，以保证搅拌均匀。转动搅拌叶轮，使罐底和边缘的环氧树脂也能与固化剂均匀混合。固化剂的用量以及搅拌温度请参阅搅拌、浇注温度表 。(2)Pour the mixed resin into the funnel located at the pump inlet without delay and with minimum free fall to avoid air entrapment. Do no

44、t scrap the residue out of the can. 搅拌好的环氧树脂与固化剂混合物应立即浇注，并应以细条状自由流入浇注泵进口处的漏斗中，以防止将空气带入。罐底残留的部分不要再倒出。(3)Start the pump and fill EPOCAST 36 into the gap between the sterntube and stern frame boss until it overflows at the air vents. 启动浇注泵，环氧树脂即被泵入艉管和艉柱间的空隙，直至环氧树脂从透气管冒出而无气泡溢出，即表明环氧树脂已全部充满。(4)Make the h

45、ardness test sample simultaneously. 在浇注的同时，制作硬度测试所需的样块。7. Final Works 浇注结束后的工作(1) The damming plates, filling hose and air ventilation hose, etc can be dismantled in advance after about 12 hours. But drilling of bolt holes must only be carried out after EPOCAST 36 has reached Barcol Hardness reading 40. EPOCAST 36 环氧树脂浇注结束后约12 小时，可以先拆除密封档板、浇注和透气软管等。但法兰处的安装孔必须在EPOCAST 36 环氧树脂的巴科硬度达到40 以后才能进行钻孔、攻丝等作业。(2) Allow EPOCAST 36 to cure