蝶阀安装方案(中英文对照版).doc

越南松绑4水电站工程机电设备安装蝶阀安装方案批准：罗春华审核：张文红编制：谢荣新广东省源天工程公司 松绑4水电站项目部 二0一三年十一月十二日VIETNAM SONGBUNG 4 HYDROPOWER STATION E&M EQUIPMENTS INSTALLATIONInstallation Scheme of Main Inlet Valve (MIV) Approver: LUOCHUNHUA Inspector: ZHANG WENHONG Prepared by: XIE RONGXINGuangdong Yuantian Engineering Company Song Bung 4 Hydropower Station Project DepartmentNovember 12th, 2013- 2 -目 录Contents1结构说明 General description02施工组织机构及人员安排 construction organization13施工准备 Preparation23.1施工技术准备 technical23.2施工设备工器具准备 Preparation of erection tools33.3 施工其它措施准备 other preparation44主要技术标准和规范The main technical standards and norms55施工程序及方法Construction Program65.1 安装准备 Prepare for install65.2 安装工艺流程 Installation Program75.3 安装过程 Installation process85.4 蝶阀全关位置校准Adjust the full close position of butterfly valve125.5 液压系统安装Hydraulic System Installation135.6 电气系统安装 Installation of electrical systems145.7 进水阀系统调试155.8主要部件安装的质量控制点15Main Components Installation Quality Control Points156施工工期 Construction Period167质量管理措施Quality Management Measures178安全文明施工 Safety & Environment-Friendly Manner189卫生环境保护 Health Environmental Protection2110 附件 accessory221结构说明 General description1 蝶阀：包括阀体、蝶板、轴、连接头、重锤、主油缸组成，阀体和蝶板采用Q345A材料制作，重锤和主油缸通过连接头转动轴的角度来控制蝶板的开关。阀体上部安装有旁通管路、旁通阀、空气阀、压差传感器等Butterfly valve consists of valve body, butterfly plate, bearing, connecting joint, counterweight and main oil tank. Valve body and butterfly plate are made of Q345A material. Control the switch of butterfly plate by the connecting joint rotating bearing angel of counterweight and main oil tank. Set by pass pipeline, by pass valve, air valve and pressure differential sensors on upper of valve body.2 阀前短管和阀后短管：分阀前短管和阀后短管，均采用Q345A材料制作。阀前短管上游侧与压力钢管焊接，下游侧与蝶阀体采用法兰面把合联接。阀后短管上游侧采用法兰面与伸缩节把合联接，下游侧与蜗壳进口钢管焊接。 Nozzle stub made of Q345A material consists of nozzle stubs in front and below the valve. Upstream side of nozzle stub in front of valve is welded with penstock, and the downstream side is welded with butterfly by flange surface. Upstream side of nozzle stub below the valve is connected with expansion joint by flange surface, and the downstream side is welded with spiral case inlet steel pipe.3 伸缩节：包括伸缩法兰、短管、压板，T型密封等组成，采用法兰把合方式与蝶阀体、阀后短管连接，伸缩节调节范围为360400mm。 Expansion joint consists of expansion flanges, nozzle stub, pressing plate and T type sealing. The expansion joint is connected with butterfly and nozzle stub below valve by flange surface, the adjustable range of expansion joint is 360400mm.4 液压控制系统：由液压集成油站、控制管路、自动化元件等组成。 Hydraulic control system consists of hydraulic oil plant, control pipeline and automatic elements.5 旁通管路与旁通阀：包括手动半球阀、液压针型阀、DN350旁通管组成。 By pass pipeline and valve consist of manual half ball valve, hydraulic needle type valve and DN350 by pass pipe.2施工组织机构及人员安排 construction organization现场负责人：李艺Site leader: Li Yi技术负责人：谢荣新Engineer : Xie RongXin安全员：陈涛记EHS: Chen TaoJi质检员：潘键强Quality controller: Pan JianQiang现场翻译/协调：陆昌龙Site translator: Lu ChangLong起重人员: 2人lifting worker: 2 机械安装人员：4人Mechanical worker: 43施工准备 Preparation 3.1施工技术准备 technical 1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 should 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 program 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 technics 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 erection.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 Preparation of erection tools 1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 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.4. 验收设备包含在施工设备工器具列表内Acceptance equipments are included in the list of construction equipments & tools.Tools Nameunitquantityremark钢琴线piano wire卷Reel1红外线焊条烘干箱 infrared ray weld rod heating box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磁力钻 Magnetic drill machine台set1千斤顶 Jackas needed手拉葫芦 Chain hoistas needed角磨机 Angle Grinder台set2磨光机 Grinding machine台set1框式水平仪 Square level个pcs1level-off塞尺（规格：L=300mm）Filler gauge把pcs1M2472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经纬仪Theodolite部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 platform安装前搭设安装平台。 Erection bay construction before the installation.2施工用电准备 power supply在设备安装现场适当位置布置开关箱约2个，电焊机、磨光机、照明等施工设备用电取自各开关箱上。Set 2 switchgears, a welding machine, a polishing machine and lighting equipments on installation site. The power is supplied by each switchgear.3施工消防准备 Fire fighting 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The main technical standards and norms1厂家资料MIV System general layout VNSB4-B1-14-001/Rev.BMIV Figure for overall shape VNSB4-B1-14-002/Rev.BHydraulic system diagram VNSB4-B1-14-004/Rev.BHydraulic system figure for overall shape VNSB4-B1-14-005/Rev.BUpstream penstock VNSB4-B1-14-013/Rev.BDownstream penstock VNSB4-B1-14-014/Rev.BDismantling joint VNSB4-B1-14-015/Rev.BVelve body VNSB4-B1-14-016/Rev.BMain inlet valve Dsic VNSB4-B1-14-017/Rev.BElectric principle diagram 1/4 of the butterfly valveVNSB4-B1-14-020/Rev.BElectric principle diagram 2/4 of the butterfly valveVNSB4-B1-14-021/Rev.BElectric principle diagram 3/4 of the butterfly valveVNSB4-B1-14-022/Rev.BElectric principle diagram 4/4 of the butterfly valveVNSB4-B1-14-023/Rev.BElectric wiring diagram 1/1 of the butterfly valveVNSB4-B1-14-024/Rev.BInstallation instructions of MIV VNSB4-B1-14-028/Rev.ATest and Inspection program of MIV VNSB4-B1-14-029/Rev.A2国家标准、部颁或行业标准 Standards and Specifications按合同规定的规程和要求 Fulfill the requirements of relative standards and specifications.5施工程序及方法Construction Program5.1 安装准备 Prepare for install1. 安装前应核对铭牌上各参数是否符合使用要求。Check each parameter on the name plate and confirm whether it is suitable for the operation requirement or not before the installation.2. 清洗阀体内膛及蝶板，检查各部分有无损坏现象，各联接部分螺栓，螺母是否松动，松动的应拧紧。Wash the inside of valve body and valve disc, check each part if it is damaged or not, and check the joint bolts and nuts if it is loose or not. If there is, please fasten it.3. 土建部位交面后，对工作部位进行清扫、测量放点，对进水阀的基础支墩及接力器支墩进行复测，复测进水阀阀体、上游延伸管、伸缩节各部分尺寸并记录。 Do cleaning and measuring works after the civil works completed. 4. 在进水阀安装部位上、下游侧布置上游延伸管和伸缩节就位时的临时支撑。 Set temporary supporter for extension tube and expansion joint located on upstream and downstream side of intake valve installation position.5. 浇筑进水阀基础支墩混凝土时，按照设计图纸要求埋设相应的基础垫板，基础垫板的平面度及空间位置应符合有关规范及图纸要求。 Embed base plate as design required while concreting the base supporter of intake valve.6. 进水阀系统具备安装条件后，清扫阀坑，检查蜗壳延伸管进口断面与压力钢管出口断面的轴线中心及高差，分析测量数据，确定进水阀实际安装中心与高程。 Clean valve pit, measure axis center and altitude difference, and ensure the center and elevation of intake valve while installing.操作系统安装控制系统安装蝶阀系统调试旁通管、旁通阀及其他附件安装基础垫板埋设压力钢管、蜗壳管口测量确定蝶阀安装中心和基础板位置阀体吊入阀坑调整均分36点测上游连接管长度、配割上游压力钢管均分36点测阀体下游法兰面至蜗壳上游管口距离、配制下游连接管配制尺寸复核，阀体吊出阀坑上、下游连接管吊装阀体吊装伸缩节吊装阀体、伸缩节及上下游连接管组合成整体上下游短管与钢管或蜗壳安装环缝焊接装配伸缩节与下游短管组合缝密封件5.2 安装工艺流程 Installation ProgramOperating SystemControlling SystemButterfly System CommissioningBy pass Pipe and Valve Installation Embed Base PlateEnsure Center and Base Plate Position Lift Valve BodyConnecting Pipe Length MeasurementDistance from Flange Surface to Spiral Case Outlet Lift Valve out of Pit Connecting Pipe Erection Valve Body Lifting Expansion Joint LiftingAssemble Valve Body, Expansion Joint and Connecting PipeWeld Nozzle Stub with Spiral Case Erection RingSealing of Expansion and Nozzle Stub5.3 安装过程 Installation process1. 根据液控蝶阀成套安装图及外形图，确定驱动装置的位置及拐臂的倒向。According to VNSB4-B1-14-001 MIV general layout and VNSB4-B1-14-002 MIV figure for overall shape, make sure where is the correct position and direction for drive unit and the connecting level.2. 将阀门吊入蝶阀室并放在基础上。Lift MIV into the valve room and put it on the foundation.3. 蝶阀安装在基础上应校正水平，使水平安装的阀轴不倾斜，法兰平面应与基础水平面垂直，水平度和垂直度允许误差是0.5mm/m.The butterfly valve shall be horizontal after installation and without inclination of valve shaft, which makes the horizontal valve shaft dont incline and the flange plane be vertical with the horizontal plane, The allowable tolerance for levelness and verticality is 0.5mm/m.4. 调整好蝶阀地脚螺孔与螺栓的间隙，并尽量使间隙均匀留在地脚螺栓的两侧，便于蝶阀以后装拆时既能向上游压力钢管侧移动，也能向下游蜗壳侧移动。Adjust the clearance between foundation bolts and hole of butterfly valve. Try to keep the clearance wellproportion on the two sides of foundation bolts. When the valve is disassembled, it is convenient for the valve move to the side that is with upstream pressure pipe or opposite direction.5. 将油缸、拐臂及连接件安装到位并固定好所有的连接螺栓(重锤，基础螺栓除外)。Installed Oil cylinder (servomotor), connecting level, and fasten all connecting bolts exception hammer and the foundation bolts.6. 根据液控蝶阀成套安装图，在进水蝶阀出水侧，即水轮机侧安装主伸缩节、下游出水短管及连接螺栓，安装时伸缩节的内外套管间隙应调整均匀，不应有卡阻现象。伸缩节与内外套管的伸缩距离应在两侧预留并且作适当的分配。According to VNSB4-B1-14-001 MIV general layout to Install the main expansion joint 、outlet pipe and connecting bolts on the outlet side of inlet valve .The clearance between the inner sleeve and outer sleeve of expansion joint should be adjusted evenly, without blockage during the period of installation. The stretching distance of the expansion joint should be remain in two sides and allocate properly. 7. 根据液控蝶阀密封结构图，在进水蝶阀进水侧分别安装上游进水短管、紧固连接螺栓及导向杆等,具体安装步骤如下：As per VNSB4-B1-14-008 Working Seal and maintenance Seal Assembly Drawing. Install inlet pipe(up stream)、connecting bolts and guide rods at the inlet side of MIV, The specific installation steps are as follows:（1) 在确定阀体不再移动的情况下,拆除支撑环上2根运输固定螺杆；Under the condition of making sure that the valve body cant be moved, remove the two bolts which is used in fixing the support ring for transporting （2）将上游短管吊装就位；安装上游短管时，上游短管与支撑法兰骑缝销应该对准。Hoist the inlet pipe ( up stream ) to the appropriate location ; Istallation upstream penstock, the upstream penstock and support flange pipe should be aligned.（3）安装上游侧法兰连接螺栓但是不紧固；Install the connecting bolts but not fasten them.（4）将上游短管上的密封压盖连接螺栓拧松；Loosen the connecting bolts between gland cover and the inlet pipe (up stream) .（5）将导向杆两端装上垫圈、螺母、挡块位于两垫圈、螺母之间，插入上游凑合节，将导向杆拧入移动密封圈螺孔并拧紧密封压盖连接螺栓；Install gaskets and nuts at the both sides of guide rod. The fixing pedestal is between the two nuts. Insert it into flange of inlet pipe(up stream), let all the guide rods screw into the moveable sealing seat, then fasten the bolts of gland cover;（6）逐个将导向杆两端螺母拧紧于挡块上，采用手动拧固定座两侧螺母的方式将移动密封环移动至最外侧(即:使检修密封处于完全解除状态),然后将固定座两侧螺母锁紧在固定座上.Fasten all the nuts of guide rod to the fixing pedestal one by one, Screw the nut at both sides of the fixing pedestal to make the maintenance sealing seat extract at the ultimate left position (which means the maintenance seal released completely), then fasten all the nuts of guide rod to the fixing pedestal.（7）将上游侧法兰连接螺栓紧固一半.Connect the upstream side of the flange bolts in half.8. 将上、下游短管与对接的管道焊牢，焊缝要求表面无裂纹、夹渣和气孔等缺陷，且保证焊缝处无外泄漏，并按要求对焊缝做无损检测.Weld the inlet pipe(up stream)and the outlet pipe(down stream). To assure that there is no crack、no slag and no air hole in the surface of weld joint and zero leakage in the weld joint，required to make NDT testing of the weld.9. 把管道法兰螺栓全部拧松，消除安装内应力.All the pipe flange bolts to loosen and eliminate installation of internal stress.10. 重新拧紧整圈螺栓，必须全部拧紧，保证密封。(采用对称紧固方式紧固法兰螺栓)Retighten the bolts full circle, must all be tightened to ensure sealing.( Fasten all the flange bolts with Symmetrical fastening sequence.11. 对基础螺栓进行二次灌浆。紧固所有基础螺栓且确保进水阀能在基础上移动。Pour the second concrete for the foundation bolts.fasten all the foundation bolts and confirm that the MIV can slide on the foundation surface.12. 根据液控蝶阀安装结构图和旁通管路图，逐步安装重锤，旁通阀、旁通管、旁通伸缩节、排污(水)阀、空(排)气阀、差压控制器(控制阀前后压差)等。安装时必须保证各部件正确安装，各连接螺栓必须拧紧，以保证各连接处无外泄漏。安装时注意差压控制器的压力方向不得接反。According to VNSB4-B1-14-001 MIV general layout and VNSB4-B1-14-007 Bypass pipe drawings and part list, Install hammer 、 the bypass valve、bypass pipe、bypass expansion joint、drain valve、intake valve、pressure-balance switch(to control the pressure-balance between the pipe of before or after valve) step by step. You should make sure that each component have been installed correctly、all of the connecting bolts have been tightened and there is not leakage of each joint. When install the pressure-balance switch, you must make sure it is not reverse. 5.4 蝶阀全关位置校准Adjust the full close position of butterfly valve1. 将拐臂安装好，将蝶阀关闭，直到全关。全关定位方法如下：Install the arm. The butterfly valve closed, until close., Full Close the butterfly valve as the follow state:先将阀门关到全关位置，然后将手动销插入阀体销孔，直至手轮不能旋转操作；Close the valve near to the station of full close, , then the manual pin shall be inserting into the pin hole of body, Until the handwheel cant rotate;2. 将接力器安装好，接力器全关定位如下：The servomotor is installed, locate the following servomotor fully closed:（1）根据液控蝶阀基础载荷图，安放阀门及接力器地脚螺栓、基础垫板及其支撑螺栓，并初步调平；According to VNSB4-B1-14-003 Foundation Drawings & Embedded Parts，Install the valve and servomotor anchor bolts, base plate and its support bolts, and preliminary leveling；（2）调整阀门站脚基础垫板处的调整螺栓，保证以下4点：Adjust valve station at the foot base plate adjustment bolts, to ensure the following four points:a、使阀体中心线与管道中心线重合；Ensure that the body centerline coincides with the centerline of a pipeline;b、阀体法兰面与管道中心线垂直；Body flange surface and the vertical centerline of a pipeline;c、两阀轴中心线水平；Two horizontal centerline of the valve shaft;d、阀门站脚基础垫板处地脚螺栓处于螺栓孔的中心位置；Valve station at the foot base plate bolt in the center of the bolt hole;（3）调整接力器支座基础垫板处的调整螺栓，使接力器竖直，使活塞杆完全缩回到缸筒内（即油缸全关到位），直至调整螺栓无法调整，并校核接力器安装尺寸，并且让接力器基础垫板处地脚螺栓处于螺栓孔的中心位置。Adjust servomotor seat adjustment bolts at the base plate, the servomotor vertically, so that the piston rod is fully retracted into the cylinder barrel (cylinder fully closed position) until the adjusting bolt at B can not be adjusted, and check servomotor installation size, and let the servomotor base plate at the bolt in the center of the bolt hole.5.5 液压系统安装Hydraulic System Installation1. 液压系统采用二次安装方式，即：预安装酸洗 正式安装。Hydraulic system using secondary installation, Namely: Pre-Installation Pickling Formal Installation2. 预安装时，先将液压系统，液压缸及中间过渡块固在规定的基础上，然后根据图纸要求把液压系统的出油口用高压胶管连接。Pre-installation, the hydraulic system, hydraulic cylinders and intermediate solid block on the basis of the specified, According to VNSB4-B1-14-018 With a high pressure hose to the hydraulic system oil outlet connected.3. 管道的焊接采用对接焊。焊接前，焊接处应倒角，去毛刺，焊接时采用氩弧焊打底，电弧焊盖面。Butt welding pipe welding. Before welding, welding should chamfering, deburring, welding using welding backing, surface covered arc.4. 管道的酸洗工艺，建议采用循环冲洗形式对管道内表面进行处理.Pickling process pipeline, the proposed form of a rinse cycle pipe surface treatment.5. 安装前，要将各接口处擦洗干净。Before installation, the interface will be cleaned.6. 正式安装时，不准有砂粒，焊渣等污物进入管道内。管道安装完毕后，可在适当的位置上安装管夹，以防止管道震动。Formal installation, not allowed to have sand, welding slag and other contaminants into the duct. After pipe installation can be installed in place pipe clamps to prevent pipe vibration.7. 用可靠措施（如管路压力试验等）保证工地进行焊接的油管路至少承压24MPa 以上。With reliable measures (such as the line pressure test, etc.) to ensure the oil pipeline welding site at least pressure 24MPa or more. 5.6 电气系统安装 Installation of electrical systems1. 将电控箱打开，可见底板上螺钉孔，对应螺钉孔位置将电控箱装上固定。按照电气接线图，连接中控室与电控柜、液压站及蝶阀与电控柜之间的连接线。The electronic control box opens, showing the screw holes on the bottom, corresponding to the screw hole locations on the electrical control box mounted fixed. Accordance with the electrical wiring diagram, connect the control room and cabinet, hydraulic station and the connection between the valve and the control cabinet line.2. 连接好差压控制器、电动旁通阀与控制箱的电源、电气接线等，保证接线正确、连接可靠、信号稳定。Connect the differential pressure controlle