阿雷水轮发电机安装说明书英文版.doc

1 General1.1 The installation manual is only used for the installation,debugging and testing of SF85-18/5850 vertical shaft hydroelectric generator supplied by Dong Fang Electrical Machinery Co.,Ltd（here in after referred as DEC）on the project site.1.2 The installation manual primarily describes the general installation procedure and requirement for hydroelectric generator. It is not intended to describe the detailed installation procedure for each individual part. 1.3 Installation for all parts should be performed under the direction of the DEC site Technical Director according to the requirement of the technical documents accompanying the unit.1.4 According to actual installation condition on site, the DEC site Technical Director will modify installation procedure or requirement for some part by technical requisition, so that the installation would be done smoothly. 1.5 Without the agreement of the DEC site Technical Director, no adding, canceling or altering the requirement of the technical documents sent along with unit.1.6 Before comprehend the method and procedure of the installation manual or technical requirement of the other technical documents sent along with unit, Installation Contractor should not start the installation, in order to avoid reworking.1.7 If somebody can not understand completely the installation manual or have some different view for the installation manual, please consult with the DEC site Technical Director. 1.8 For some part, if there is not special requirement in the installation manual or the other technical documents sent along with unit, the installation must accord withspecification installation of hydraulic turbine generator units(GB/T8564-2003); and if the requirement is different between technical documents sent along with unit, Installation Contractor should report to Supervisor or Customer and consult with the DEC site Technical Director to deal with.1.9 After finishing each installation procedure, the installation records must be filled in the QCR, and submit the QCR to the DEC site Technical Director in time. at the time, Installation Contractor should be in charge of truthness and precision of records, and only after the records are confirmed and signed by the DEC site Technical Director, the next procedure can be done.1.10 In the course of debugging and trial run for the unit, Installation Contractor should record the data of test and trial run detailly. After trial run has been finished, Customer shall submit the whole installation, debugging and trial run records to the DEC site Technical Director, which will be used as basis of inspecting and accepting for the unit.2 Acceptance and storage 2.1 Acceptance2.1.1 After the equipment has been transported to the delivery site, check and acceptance for the equipment should be taken in term of the contract in time.2.1.2 Before unload the equipment, Customer should check whether the packing cases of the equipment are in good condition, if find there is any loss and damage occurred during transportation, Customer should contact immediately with the transportation agent and the Insurance Agent, mark down and record it in visual image, and inform in time. at the same time, Customer should offer the certificate proved by the transportation agent and the Insurance Agent to Produce Contractor, in order that Produce Contractor supply again and claim for compensation.2.1.3 After receiving cargo, Customer should convene the relative units to check and accept according to the delivery list and packing list offered by Produce Contractor within the stated time of contract, and make the summary of check and acceptance, and the representatives of both parties of Customer and Produce Contractor must sign the summary of check and acceptance. Before both parties of Customer and Produce Contractor perform check and acceptance together, Customer should not open the packing cases privately. Under the special condition, Customer should contact with Produce Contractor in advance, and get the agreement of Produce Contractor, Customer can open the packing cases by oneself.2.1.4 Antirust material on the finish surface of parts should not be removed before installation. When check and acceptance, if find there is dent on the finish surface of parts or antirust material on the finish surface of parts has fallen off, remaining antirust material should be got rid of with organic solvent, then recoat antirust material again, and forbid using scraper or sandpaper, etc which would damage the finish surface of parts to get rid of antirust material on the finish surface of parts. Before taking any action for any finish part, Customer must consult with the representative of DEC.2.1.5 For the assembled parts, If find its some components had been lacked or damaged when check and acceptance, Produce Contractor should be in charge of dealing with, and if the components had been lacked or damaged because of improper storage or transit, Customer should be in charge of, and Produce Contractor should help to deal with.2.2 Storage2.2.1 The storehouses are classified into four classes: the first class is out of doors covered with waterproof cloth; the second class is open place withroofing; the third class is permanent storehouses; the forth class is constant temperature storehouses.2.2.2 After all parts have been checked and accepted, all parts should be stored in storehouses immediately according to the following table 1.table 1:classname of main parts1Embedded pipe, bare parts, huge and heavy parts2the upper bracket arm and hub, ladder, the rotor arm, the rotor hub, air baffle, outer shroud, the local packing parts, pipeline, cover plate, sole plate, pedal3all kinds of shafts, air cooler, rim punching, tensing screw, brake and braking shoe, thrust cone, thrust bearing seat, all kinds of pumps and valves, field pole, handrail, components packed in cases, stuffing34the guide bearing, the guide bearing segment, thrust bearing support or pad, motor, equipped stator or split stator inserted in manufactory, stator lamination, equipped rotor, seal material, varnish or glue and so on4Automatization element, lead, meter, instrument, stator winding(bar),the thrust ring, collecting ring, carbon brush, conducting component, mica taprefrigerator2.2.3 Storage condition 2.2.3.1 Within twenty meters of store area, there are not residence and welding or forging workshop. The special vanish, dangerous goods and flammable goods should be far from storage area; the fire fighting and lightning protector should be set within the storage area.2.2.3.2 Storehouses should locate at higher situation, and its groundsill should be firm, there is enough drain to discharge around the storage area and no seeper in the storage area. the doors and windows of storehouses should be in good condition, which can not only air but also be airtight.2.2.3.3 Keeping the storage area clean, and preventing mice and white ants from damaging, and there is no weed, seeper and dirt on the ground of storehouses.2.2.3.4 The shed frame should be firm in order to bear local annual wind, rain, thunder and lightning, the ground of the shed frame should be firm, smooth and dry, and the ground of the shed frame should be no lower than outer horizon.2.2.3.5 The thermometers and hygrometers should be set in the heat preservation storehouses or the storehouses where the precision components have been stored; the storehouses should be coldproof,dampproof, dustproof, fireproof, the indoor temperature must within -5+40, the indoor difference in temperature should not be over 10 in the day and night, relative humidity of indoor air should not be over 75%.2.2.4 Maintenance2.2.4.1 Inspecting the storehouses termly, if find the packing has been damaged or parts have been rust, report to the charge department to deal with in time.2.2.4.2 The packing cases can be opened only after 24 hours which had been handled in storehouse in winter, in order to avoid condensing to lead the surface of parts to being rust.2.2.4.3 For the baddish storehouses, parts can be stored in primary packing case, but primary stuffing in packing case should be taken away, then lay some dampproof paper and put some drier into packing case. For big packing cases, the inspecting gate should be set up.2.2.4.4 If the relative humidity in storehouses is greater than that of outside, the storehouses should be aired by opening the doors or windows.2.2.4.5 The mark on all parts should be kept completely, the label for small parts should be given to indicate, if the parts are stored by packing, there should be packing list for every case.2.2.4.6 Parts stored out of doors and in open shed or non-woodiness floor should be blocked up. For parts stored out of doors, which should be upraised upwards of 200mm, and there is no seeper around it, and its period of storage should be restricted; for parts stored in open shed, which should be upraised upwards of 100mm; for parts stored in permanent storehouse, which should be upraised upwards of 50mm.2.2.4.7 The finish surface of parts should not be as supporting point. The correct supporting procedure should be taken in the course of storage for the main shaft, the upper shaft,stator,rotor,thrust ring,thrust cone,etc.In order to prevent them from deforming, the important parts should not be superposed.2.2.4.8 Electrical equipment should be stored in constant temperature storehouse, which can be stored in primary packing case, and avoid being superposed. The insulation and DC resistance of electrical equipment shall be spot-checked according to 10 every other month ,any obvious drop in resistance shall be investigated; The rubber and plastic should be placed away from heat or high temperature, and prevent them being shined or being contaminated by oil.2.2.4.9 Supports of shafts cant be placed under journal surface, and which should not contact the shaft directly, the protection shall be provided at the contact point, and the shaft should be turned 180 every three months during storage.2.2.4.10 There should not be rust and nick on the surface of finish parts, and not be flaw and shell on the surface of bearing segment. The anticorrosive material spread on the surface of bearing segment should be inspected every three months during storage, if metamorphosing, which should be replaced in time.2.2.4.11 Special materials should be consigned in term of actual installation progress. Installation Contractor should inform in writing Customer the installation time of maerials in term of actual installation progress ahead of two monthes, and Customer should notify in writing DEC the consigning time of materials ahead of two monthes, DEC will consign materials to Customer in term of the Customers requirement in order to avoid that materials will have been expired or delaying the installation progress.2.2.4.12 In order to prevent from confusing, the parts belonging to one unit should be preserved together and make obvious mark, which should not be combined with that of the other unit.3 Essential requirement for erection 3.1 Before starting the installation, the installation personnel must be familiar with the installation manual,drawings and the other documents sent along with unit, if there are some questions, please consult with the DEC site Technical Director.3.2 The installation personnel must be familiar with performance and the operating specification for special tools supplied by DEC. Some important tools can be operated by experienced workers who were trained and accepted specially by DEC.3.3 The mounting field should be windproof,rainproof and kept clean , and there should be enough illumination.The ambient temperature should not be lower than 5, relative humidity of air shall not be over 75 %.3.4 Before installation, the equipment should been clean completely and should be got rid of burr, rust, local spot, oil smear, etc. the main dimensions and fit tolerance of important parts should be checked, in order to regulate or deal with in term of actual condition when installation. 3.5 The elevation deviation of the setting plates should not exceed 0-5mm while embedding, the deviation of distributing position should not be over 10mm,the level deviation should not be over 1mm/m.3.6 Wedge plates for adjusting shall be used in pairs and the length lapped shall be more than two-thirds. Which should be fitting before mounting to assure the contacting area of all working face is more than 70,and to assure the pressure stress of contacting area is not over 30Mpa.3.7 Before grouting concrete, the embedded parts should be reinforced to avoid displacing and deforming when grouting. The foundation bolt, jack, tension tool, wedge plate, sole plate, etc should be fixed by short welding, round steel and anchor should possibly been lap welding with reinforcing steel bar when embedded. There should not be oil smear and rust on the surface of embedded parts.3.8 While grouting concrete, making the proper grouting speed and grouting method to avoid displacing and deforming of the embedded parts, measuring the deformation of the embedded parts during grouting concrete, and concrete should adhere tightly to the surface of the embedded parts.3.9 Installation should be begun only after the concrete strength has come to 70% of design strength, the second stage concrete for foundation should be thick and rigid.3.10 The combined surface should be clean, smooth and no burr. After combining, the partial clearance can be existed, inspecting with 0.10mm feeler gauge, the depth of inserting should not exceed one-third width of the combined surface, the total length of gap should not exceed 20 percent of the perimeter of joint plate; and with 0.05mm feeler gauge to inspect the joint gap, which should not be penetrated; no gap shall be allowed around the bolts and pins.3.11 Before assembling, all bolts and nuts should been clean and be inspected. For fine thread and upward of M56 coarse thread, which should be pre-fitted before used, and lubricating agent should be applied on the thread when pre-fitted and tightened. For the bolts distributed at equal interval on a circumference, tightening should be uniformly done in diagonal positions step by step. For the coupling bolts that the elongation has been required, the elongation of the bolts should be measured when tightened, the elongation deviation of each bolt compared with the designing value should not exceed 10 %. Bolts, nuts and pins should be locked or been spot-welding tightly according to the requirement on drawing.3.12 The measuring deviation of datum point of unit should not exceed 1mm.the diameter of plumb wire for measuring shall be within 0.300.40mm, the tension stress shall be more than 1200Mpa, and strong air current and strong magnetic field shall be avoided while using plumb wire.3.13 While installation, pay attention to the fit marks. When more units are being installed at the same time, each unit shall be assembled with parts which there are the same serial number, otherwise, inform the DEC site Technical Director to identify.3.14 If seal made with the rubber packing at job site, the dimension of seal should be suitable for the packing groove, and the bonding cuts of the rubber packing should be straight. Before installing, the dimension of the packing groove and diameter of the rubber packing should be measured according to drawing.3.15 Before start-up of unit, all bolts and nuts of rotating part should be inspected completely, and prevent any bolts,nuts and other foreign material from being lost in the unit.3.16 No welding should be done to the rotating part of unit after the bearing segments have been installed unless the ground terminal is securely attached to the part being welded, and necessary saftguard should be taken to prevent the bearing segments from being scathed or to prevent the welding slag from splashing into the bearing.4 Prime parameter and installation flowchart for generator 4.1 Prime parameter for generator4.1.1 Type SF85-18/58504.1.2 Rated capacity 100 MVA4.1.3 Rated output 85 MW4.1.4 Rated voltage 13.8kV4.1.5 Rated current 4183.7 A4.1.6 Rated power factor 0.85（lagged）4.1.7 Number of phase 34.1.8 Rated speed 333.3 r/min4.1.9 Maximum run away speed 585.4r/min4.1.10 Rated frequency 50 Hz4.1.11 Direction of rotation clockwise viewed from top4.1.12 Cooling style air cooling4.1.13 Type of excitation static SCR4.1.14 Insulation class Class F4.1.15 Rated excitation current 1225 A4.1.16 Rated excitation voltage 215 V4.1.17 Rated Load on the thrust bearing 2500kn4.2 The installation flowchart for generatorThe flowchart is the basic procedure for installation of SF85-18/5850. Generally, the following flowchart has been proven to be the best. However, the DEC site Technical Director will modify the flowchart in special condition so as to carry out the installation smoothly. The installation flowchart for generatorEmbedding sol