伸缩全回转推进器安装工艺

1、图纸履历 PLAN HISTORY日期DATE标记REV.NO简 述DESCRIPTION设绘DWN审核REVD批准APPDA版供 认 可FOR APPROVEO版供 施 工FOR WORKING技术设计相关图号生 产 设 计PRODUCTION DESIGNGBH307-40-02伸缩全回转推进器安装工艺Installation procedure for retractable azimuth propulsion thruster本图适用于号船SUITABLE FOR NO.标记MARK数量QTY修改单号REV.SH.NO签字SIGN日期DATE 重量,kgWEIGHT比例SCALE面积

2、,m2AREA2.94设 计DESIGNED共 49 页TOTAL SHEETS 49第 1 页SHEET 1校 对CHECKED审 核REVIEWED渤海船舶重工有限责任公司BOHAI SHIPBUILDING HEAVY INDUSTRY CO.，LTD标 检STAN.REV批 准APPROVED全回转推进器安装工艺 第 PAGE 50 页共 NUMPAGES 50 页SHEET PAGE 50TOTAL SHEETS NUMPAGES 50GBH307-40-021. 前言为了方便船厂安装伸缩全回转推进器AR100-Compact，编制了该工艺。注意：确保施工人员可以使用该文件。为了获得

3、最好的安装效果，根据该工艺一步一步执行。为了推进器的正确对中，焊接工作按正确的顺序进行。推进器单元和回转单元按两部分发货。我方担保条件要求Brunvoll服务人员现场指导船厂最后回转单元对中和推进器单元与回转单元的安装。GeneralThis introduction is written for the shipyard with the intention of easing the installation of Brunvoll Retractable Azimuth Thruster AR100-Compact.NOTE! Make sure this instruction alw

4、ays is available for personnel carrying out the installation.To obtain the best result, follow this instruction step by step.In order to ensure correct alignment of the thruster installation all welding must be done in correct sequence.The thruster unit (propeller with nozzle) and the azimuth unit a

5、re delivered in two separate parts.Our guarantee requires that Brunvolls service technician supervises the Yards final alignment of the installation of the azimuth unit and the mounting of the thruster unit to the azimuth unit. 2. 伸缩全回转推进器部件重量推进器单元带喷嘴14500 kg，全回转单元，28300 kg。Weight of thruster compon

6、entsThruster unit with nozzle 14500 kg; azimuth unit complete 28300 kg.3. 伸缩全回转推进器组成部件 伸缩全回转推进器组成如下图。 推进器单元，全回转单元，电机，液压单元。Thruster componentsThis retractable azimuth propulsion thruster comprises all parts as illustrated in the figure below. The thruster unit, azimuth unit, electric motor, azimuth u

7、nit, hydraulic power unit HPU电机全回转单元液压单元推进器单元4工具，密封剂和螺栓船厂应确保下列工具，密封剂，螺栓在安装前准备好：1乐凯2432乐凯Master Gasket 5743乐凯5734Molycote G-n plus5耐盐水型油脂ZDM 26，或类似6力矩扳手7焊条，焊接不锈钢AISI 316-TI与船体A级板（E 309L或类似，由船级社批准）Tools, sealants and fastenersThe yard must make sure that the following tools, sealant, fasteners, etc. a

8、re available before the installation:1. Loctite 2432. Loctite Master Gasket 5743. Loctite Form-A-Gasket Permatex no. 34. Molycote G-n plus5. Grease, salt water resistant type ZDM 26, or equal.6. Torque wrench7. Welding electrode for welding of stainless steel AISI 316-TI toShip steel Grade A: (E 309

9、L or equal, with class approval)5安装后简图该图显示了一个伸缩全回转推进器，伸缩全回转推进器通过螺栓和导向支撑确保其可以全部提升到船舱内以便维修服务。View of a finished installationThe view shows a finished installation of the Brunvoll retractable azimuth thruster. This unit has bolted and guided connections that enable it to be lifted into the ship for ser

10、vice/maintenance.电机推进器单元全回转单元锁紧单元支架焊接锁紧单元螺栓连接锁紧单元将伸缩式回转推进器固定在船上。锁紧单元支架与船体采用螺栓连接，与锁紧单元采用焊接。锁紧单元支架与船体采用螺栓连接的目的是锁紧单元支架可以拆卸。当服务操作期间，把整个回转推进器单元吊入船舱时，锁紧单元支架影响吊装需要拆卸。The locking units lock the azimuth thruster to the ship. Brackets for the locking mechanism have a bolted connection to the hull and are weld

11、ed to the locking units. The purpose of the bolted connection is to be able to remove the bracket. This is required because it obstructs the path when lifting the complete azimuth thruster unit into the ship during service operation.喷嘴导向塑料垫板船体盖板筋板在伸缩时，两侧两个塑料垫板导向喷嘴。安装期间推进器船体盖板的加强筋板需要焊接。Two plastic li

12、ners guide the nozzle during retracting. The ribs on the nozzle/thruster unit have to be adapted and welded to the hull cover plate during installation.舱顶全回单元转法兰液压缸底端与固定在船体上的座圈连接推进器海水箱内导向液压缸推进器室的导杆导杆的上端与固定在船体上的伸缩管连接为了确保放下和收回全回转推进器操作时的刚度，我们用导向杆控制其运动。In order to lower or retract the azimuth thruster u

13、nit we have guidings to control the movement and ensure stiffness during operation.起升液压缸的控制杆筋板座圈起升液压缸的控制杆在船体上的导槽推进器海水箱：液压缸底端用带加强板的座圈支撑。液压缸带控制杆，放下和收回全回转推进器操作时，焊接在船体上的导槽控制其运动。Sea chest: The hydraulic cylinder lower ends are supported by a ring with connecting ribs. A steering connected to the hydrauli

14、c cylinder and a guide welded to the hull controls the movement during lifting and lowering of the complete azimuth thruster unit.基座板推进器室: 4个伸缩管连接导管到船体结构。注意在这个方案中，2个伸缩管连接到锁紧单元的支架上。Thruster room: Telescopic tubes (4x) connect the guides to the ship structure/foundation plates.Please note that in this

15、 proposal two of the telescopic tube arrangements are attached to the bracket for the locking units.焊接块定位销透气和观察孔基座板舱顶全回转法兰用带橡胶垫的螺栓连接。在推进器法兰四个角上，每个角上焊接两个挡块，防止推进器在水平面内移动。定位销保证正确对中。注意安装法兰时的透气，在吊装操作过程中，可以用观察孔透气。The tank-top azimuth flange connection is a bolted type with a rubber gasket. Two welding blo

16、cks in each corner secure the plate from movement in horizontal direction.Guide pins secure correct alignment. Also note the location of the flange for air bleeding. This can also be used for camera inspection during the lifting operation of the complete unit.6推进器安装前船体结构加工 Hull prefabrication before

17、 azimuth installation推进器安装前，几个零件必须或可以预加工。零件预加工可以使安装过程容易和加快。有些零件的预加工不紧急，可以在下一阶段安装。Before the installation of the azimuth several features must or can be prefabricated. To prefabricate can ease and speed up the installation process. Some of the features may not be critical to prefabricate and can be m

18、ounted at a later stage in the installation.舱顶区域：准备一个法兰带加工余量在船体结构的加强筋上，加强筋上带螺栓空间槽，详见推进器海水箱顶法兰。Tank top area: Prepare a flange (green) with machining allowance in a stiff rib construction and with access for a bolted connection. See drawing: “Top flange thruster sea chest”.海水箱区域：两个座圈与舱顶的顶法兰对正，并与筋板连接。

19、准备在底板上加工一个推进器通过的开孔和喷嘴导向的结构。用割下的板作为船体盖板，推荐底板厚度20毫米或更厚。船体盖板将在推进器安装时调整和安装。详见船体开孔和布置图。Sea chest area: The two rings (green) to be aligned with the top flange in the tank top and connected to ribs. Prepare a cut out in the hull bottom and structure for the nozzle guides. Use the plate in red colour as a

20、hull-cover. We recommend a thickness of the bottom-plate to be 20 mm or thicker. The hull-cover will be adjusted and assembled during the installation of the thruster unit. See drawing: “Cut away in hull” and “arrangement drawing”顶法兰和两个座圈根据图纸加工：推进器海水箱顶法兰图和船体开孔图。顶法兰和两个座圈的加工在推进器安装前必须完成。建议先加工顶法兰，然后参考顶法

21、兰加工座圈。The flange on top and the two rings marked in yellow must be machined according to drawings: “Top flange thruster sea chest” and “Cut away in hull”. This must be done before installation of the azimuth. We recommend machining the flange first and then machining the two rings using the flange a

22、s a reference.座圈加工后装入轴套导管座安装推进器时最后加工余量螺栓安装通道锁紧单元支架锁紧单元支架和导管座可以在安装前准备，安装推进器前拆下锁紧单元支架，因为锁紧单元支架影响顶法兰的安装。在安装回转单元时，根据锁紧单元加工锁紧单元支架。回转单元水平外形尺寸3500 x 3300 mm 。在吊装单元时，保证与船体之间有间隙。注意安装螺栓的通道也很重要。The brackets for the locking unit and foundations for the upper guiding can be prepared before installation. Remove t

23、he brackets before installing the azimuth. This must be done because the brackets will obstruct the assembly of the tank-top flange connection. The final adaption of the bracket against the locking unit must be done during the installation of the azimuth unit. The outer horizontal dimensions of the

24、tank-top flange on the azimuth unit are 3500 x 3300 mm. It is important to have clearance to the hull during lifting operations of the unit. Please note that access for the bolted connections is important.7. 吊装回转单元和推进器单元到机舱Lifting azimuth and thruster unit into hull.吊装前拆除运输支撑吊点，用两个吊车使回转单元由水平位置竖立注意不要

25、吊装回转单元舱顶法兰，以免舱顶法兰内密封和轴承损坏。双套吊点垂直位置吊点推进器单元吊点 8吊装全回转单元到最后舱顶位置的准备工作注意在安装和焊接过程中，保护所有部件和滑动表面。检查液压缸导向和安装在液压缸底部的调整圆锥。当全回转单元的舱顶法兰接近舱顶开孔时需要特别小心，为了避免舱顶法兰变形，舱顶法兰不能与一侧相碰。控制测量：见布置图，控制纵向和横向位置，另外测量基线到舱顶底部的距离。Preparations before lifting the azimuth to its final position on tank top.NOTE! Protect all components and

26、sliding surfaces during installation / welding process.1） Check that the hydraulic cylinder guide and the steering cone is attached to the lower end of the lifting cylinders.2）Be careful when the Tank Top plate of the azimuth is approaching the tank top cut-out, so that it does not hang up on one si

27、de, to avoid deformation of the plate.Control measurement: See “Arrangement drawing” and control longitudinal and transverse position, and additionally measure the dimension from the underside of Tank top plate to base line (BL).9初次伸出推进器的准备工作从立柱上拆下保护包装（轴壳，液压缸和上导杆）清洁和在立柱上涂一层薄润滑油润滑立柱确认液压缸导杆轴承座圈清洁安装上导杆

28、在伸出和缩回操作时，用电动机架上的吊装板Preparations for initial lowering of the thruster1）Remove protective packing from the columns (stem housing, cylinders and upper guiding column).2）Clean and lubricate the columns with a thin layer of grease.3）Make sure that the guide bearing housings for the cylinders also are cl

29、ean4）Assemble the upper guiding columnsUse lifting pads on top of motor frame during lowering and retracting operation.10海水箱内液压缸对中安装全回转单元，在舱顶的两法兰之间放入垫片全回转在低位定位对中全回转单元轴和液压缸安装定位销在安装过程中，安装几个螺栓固定全回转单元Alignment hydraulic cylinders in sea chest1) Mount the azimuth, and insert washers placed between the tw

30、o flanges in the tank-top.2) Position the azimuth in the low position.3) Align the azimuth stem with the hydraulic cylinders.4) Mount the guide pins.5) Mount some bolts to secure the position of the azimuth plate during installation.对中全回转单元轴和液压缸两个定位销垫片（厚8mm）在该位置安装软管支架11液压缸尺寸检查液压缸的直线度和液压缸之间的距离应该在高度方向

31、控制三点，如下表和下图尺寸检验：在海水箱内，推进器轴和液压缸之间的正常距离：287.5 mm, 公差: +/- 0.3 mmDimension check: Hydraulic cylinder guidingThe linearity and distance between the hydraulic cylinders should be controlled at three heights along the cylinders, as shown in the table and in the principal figure below.Dimension check:The n

32、ominal distance between stem housing and hydraulic cylinders in sea chest for this azimuth thruster: 287.5 mm, Tolerance: +/- 0.3 mm控制位置Control position右舷SB side cyl. 左舷Port side cyl. mm mm接近舱顶near to tank topA1/A2液缸中间mid-point of cylinderB1/B2接近船体 near to hullC1/C2导向架推进器轴套液压缸导向架通过合成材料的滑动轴承连接液压缸，滑动轴

33、承与液压缸之间有小量的间隙。在推进器海水箱，液压缸的底部通过轴套与船体结构相连。The guiding yoke is connected to the hydraulic cylinders via sliding bearings of a synthetic material, and has just a slight clearance to the cylinder. The bottom-end of the cylinders is connected to the hull structure in the thruster sea-chest via bushings de

34、livered by Brunvoll.在整个行程中保持液压缸的平行度和直线度，对导向架在推进器的垂直移动中保持导向作用非常重要。To maintain the guidance of the guiding yoke during the vertical movement of the azimuth, it is of great importance that the parallelism and linearity of the lifting cylinders is maintained during the full stroke.除了控制缸底部，控制不锈钢轴套和船体结构同样

35、重要。当推进器完全伸出到操作位置，起落架应落在两个液压缸上，推进器的重量完全由接触面承担。在操作位置，导向架，液压缸导向和轴套以及推进器海水箱底部结构之间有间隙，最小间隙为25mm。舱顶法兰底部和不锈钢轴套之间的控制尺寸3690 +/- 5。In addition to controlling the horizontal position of the cylinder ends, it is also important to control the vertical position of the stainless steel bushes and the connecting str

36、ucture. When the thruster is fully lowered to the operating position, the lifting yoke shall land on top of the two lifting cylinders and the weight of the thruster shall be carried over this contact only. That is, in the operating position there shall be a clearance (min 25mm) between the guiding y

37、oke, hydraulic cylinder guide and the bushes as well as the sea chest bottom structures. The control dimension between underside of tank top flange and top of stainless steel bushing is 3690 +/- 5.推进器单元应该在整个伸缩过程中运行平稳，向下最后500 mm需特别注意，最大偏差在该位置发生。垂直行程3430 mm。The unit shall run smoothly over the full le

38、ngth of the stroke, with special attention to the last 500 mm towards the downwards position, where the largest deviation from nominal dimension are expected to occur. The vertical stroke is ca. 3430 mm.建议：安装推进器前和后，测试整个行程。要求船体基线到船坞地面的最下高度尺寸为3430mm。也可以在船坞上挖坑。Recommendation: The full stroke of this mo

39、vement shall be tested both prior to and preferably also after the installation of the thruster unit. This will require a minimum height below the ships base line to the dock floor of min 3430mm. The alternative is to have a pit on the dock floor.12安装液压单元液压单元安装到一个合适的基座上。为了推进器的初次伸缩，液压单元应安装。详见液压单元图。开始

40、阶段，通常用软管连接液压单元和回转单元。一个软管连接液压单元的缩进口和回转单元上的软管架。软管架上的接头通过管路与液压缸的顶部相连。一个软管连接液压单元的伸出口和两个液压缸。两个液压缸通过舱顶法兰的三通连接。一个软管连接三通和回转单元上的软管架。一个软管连接液压单元的锁紧关闭口通过三通和两个软管到锁紧液压缸。一个软管连接液压单元的锁紧打开口通过三通和两个软管到锁紧液压缸。Installation of HPUThe hydraulic power unit (HPU) is to be installed on a suitable foundation (yard delivery).The

41、 HPU for the thruster should be installed and connected in order to ease the initial lowering and retraction of the thruster. See the Brunvoll drawing, “Hydraulic Power Unit”.At an early stage it is common to have a temporary solution when the HPU is connected together with the azimuth unit. Use hos

42、es for this solution:1 hose is connected between “Retraction” on the HPU and the hose bracket on the azimuth (see fig above). The coupling on this bracket is connected to the top of the hydraulic cylinders through pipes.1 hose is connected between “Lower” on the HPU and the two hydraulic cylinders.

43、The two cylinders have a common connection with a T-coupling which is located on the tank top plate.1 hose is connected between the same T-coupling and the hose bracket on the azimuth (pilot pressure).1 hose is connected to the HPU “Lock off” to a T-coupling with two hoses which are mounted to the l

44、ocking cylinders.1 hose is connected to the HPU “Lock on” to a T-coupling with two hoses which are mounted to the locking cylinders.加油（根据加油泄放指导） 连接伺服油泵控制箱（或临时连接电源，电源带启动和停止按钮）。 启动电机（从电机的非驱动看，顺时针），手动操作控制站上的阀“推进器收缩和伸出”。操作液压缸收缩和伸出几次（10-20次）排出空气。Fill with oil (see “Instruction for filling and drainage of

45、 oil”)Connect one of the motors to the respective starter cabinet for servo pumps. (Or temporary connected to power source, preferably with a start/stop switch on the cable.)Start the motor (Clockwise rotation seen from Electric motor Non-Driving End) and hand operate valve THRUSTER IN/OUT on the po

46、wer pack carefully.Operate the cylinders in and out several times (10-20 times) to bleed any air.负荷指示阀阀在液压单元上的位置如上图注意：液压单元上的负荷指示阀开始时保持关闭，限制液压缸的压力（压力不超过约35 bar），可以避免安装时液压缸的损坏。阀的位置在液压单元顶板上，有安装时正常打开，关闭标志。阀在液压单元上的位置如上图。注意：第一次伸出回转单元时，检查在吊装架上的锁紧支撑与锁紧机构不干涉。注意：伸出回转单元时，如果没有用液压缸的压力，为避免回转单元损坏，手拉葫芦必须逐渐下放。（也可以从下

47、面支撑单元）See figure above to locate the valve on the HPU.NOTE! Valves for load sensing on the HPU to be kept preliminary closed.This will limit the pressure supplied to the cylinder in order to avoid damages during installation. (Pressure will now not exceed approx. 35 bar).The location of the valves i

48、s on the HPUs top-plate and has the sign NORMALLY OPEN, CLOSED WHEN INSTALLING. For location of valve, see also figure above.NOTE! During lowering of the Azimuth Unit for the first time, it is important to check that the locking bracket on lifting yoke does not collide with the locking device.NOTE!

49、Take care when lowering the azimuth unit. If the lowering is carried out without using hydraulic pressure on the lifting cylinders, chain blocks have to be slackened gradually to avoid damaging the unit. (Alternatively, support the unit from underneath).13对正推进器导杆基座布置和切割示意图安装两对伸缩管，内管和外管有100200 mm重叠。焊

50、接两个支撑到船体结构，点焊伸缩管。检查回转单元平稳的滑动从下到上整个行程。如果需要调整导杆顶部的支撑伸缩管。对正结束后，满焊伸缩管。Alignment guiding columns in thruster roomBrunvoll drawing “Arrangement and cut-away in trunk”Assemble the two pairs of telescopic tubes. Obtain 100 200 mm overlap between inner and outer tube. Weld the two brackets to ship structure.

51、 Tacks weld the telescopic support tubes in their position. Then check that the Azimuth Unit is sliding smoothly over the whole stroke length from lower to the upper retracted position. If necessary adjust telescopic tubes supporting the top of the guiding columns. Full-weld, with care, the connecti

52、on between inner and outer tubes for the top support of the guiding columns when the alignment is satisfied.焊接14液压缸导杆回转单元与船体结构之间的正常间隙是5mm。Hydraulic cylinder guidingThe clearance between the hull part and the guiding on the azimuth is nominally 5mm.导向（船体零件）15安装舱顶密封和推进器单元拆下回转单元。用模板在舱顶法兰上钻孔。吊起推进器单元到海水箱

53、。安装垫片（带螺栓孔垫）。Installation of tank top sealing and thruster unitRemove the azimuth unit.Drill holes in the top flange using a template.Lift the thruster unit into the sea chest.Mount the gasket with washers.定位销：用定位销找正模板推进器单元螺栓孔垫片16安装回转单元吊装回转单元到船体结构。安装定位销，螺栓和在舱顶焊接挡块。在导管顶部安装伸缩管。Installation of azimuth

54、unitLift the azimuth unit into the hull.Mount guide pins, bolt connection and weld blocks in tank top.Assemble the telescopic tubes in the upper guiding.17推进器单元安装推进器单元安装前，全回转单元内部油必须泄放掉（工厂试验剩余）。拆下全回转单元回底部运输盖的螺塞，泄放掉约50-100升油。放置推进器单元在船下方与全回转单元对正。 向下移动全回转单元直到两加工后的安装法兰间隙约75 mm。推进器通过安装在两个法兰的螺栓M30 X 300-45

55、0 导向。确保两个法兰之间有较好的平行度。继续降低回转单元。当剩余45 mm时，转动螺旋桨（或在全回转单元的中间轴），同时慢慢降低回转单元。这样将确保推进器小齿轮和中间轴齿轮正确啮合。推进器齿轮箱顶法兰海水密封面外侧的O型圈必须彻底清洁并涂乐凯Master Gasket no. 574。回转单元和推进器本体的法兰之间M30 X 100螺栓，在螺纹表面和螺栓头下部涂Molycote并拧紧。 螺栓拧紧力矩M30 X 100：1050 Nm(107kpm)。按顺序安装法兰之间的两个对角螺栓。用不锈钢丝6固定螺栓，在螺栓头上用不锈钢焊条焊接。注意：焊机与一个螺栓接地非常重要。立柱单元法兰推进器单元法兰

56、螺栓Installation of thruster unitBefore installation of the thruster unit, oil has to be drained from azimuth unit (remnants from factory testing). The transport cover plug, at the lower end of the azimuth unit, to be removed and it maybe as much as approximately 50-100 liters of oil to be drained. Th

57、ruster unit is to be positioned under the ship, in line with the azimuth unit. Move the azimuth unit down until there is a remaining distance of approximately 75 mm between the two machined flanges.Guide the thruster unit by means of 2 studs M30 X 300-450 mounted in the holes in the two flanges. Ens

58、ure that there is good parallelism between the flanges.Continue lowering the azimuth unit. When there is approximately 45 mm left, it is necessary to rotate the propeller (or the intermediate shaft in azimuth unit), while at the same time lowering the azimuth unit. This to ensure engagement of the g

59、ear coupling halves on thruster unit pinion and the intermediate shaft.The sealing face towards seawater on top face of thruster unit gearbox flange outside the O-ring must be thoroughly cleaned and coated with Loctite Master Gasket no. 574. The bolts, M30 X 100 between the flanges (azimuth unit and

60、 thruster body) to be coated with Molycote on the threads and under the bolt head and tightened. Tightening torque for cylinder Headed screw M30X100:1050 Nm (107kpm).Assemble two opposite bolts in a sequence, in the holes between the flanges.Secure the bolts with corrosion-proof steel wire 6. place