M02轴系校中及主机安装工艺.doc

92500DWT轴系校中及主机安装工艺 第17 页 共 16页SN333-336轴系校中及主机安装工艺（图号：SNS-TECH-M02）编制（Designed） 2010年 月 日 校对（Checked） 2010年 月 日审核 (Verified ) 2010年 月 日 批准 (Approved) 2010年 月 日山东省新船重工有限公司1 概述 overview1.1 本系列船轴系和主机在船舶下水后，采用合理校中法进行安装。 After launching the ship, install the shafting and main engine with proper alignment. 1.2 主机底座采用环氧树脂垫片，中间轴承采用钢质垫片。The main engine base adopts epoxy resin gasket, and the intermediate bearing adopts steel gasket.2 图纸和技术文件Drawing and Technical Documents 轴系布置图 shafting arrangement drawing 主机安装图 the drawing of main engine installation 主机顶撑布置图 arrangement of the main engine top-up 轴系校中计算书 calculation of shaft alignment 检验项目表 inspection item list MAN B&W主机安装工艺文件 MAN B&W main engine installation document3 工艺流程 Technological process 主机轴系校中包括三个阶段，其主要工作如下： Alignment of Shafting and Installation of the Main Engine include three steps. Main works as follows:3.1 连接轴系螺栓前Before connecting the shafting bolta主机输出端法兰和中间轴法兰螺栓孔铰孔Reaming for the flange of the main engine output end and flange bolt hole of the intermediate shaftb轴系校中，调整法兰的偏移（SAG）和曲折（GAP）Align the shafting and adjust the SAG and GAP of flangesc 检查主机机座水平挠度Check the horizontal deflection of the main engine base.d 检查曲轴甩档Check the crank shaft deflectione冷冻法安装轴系铰制螺栓Install shafting reamer bolt with freezing method3.2 连接轴系螺栓后，浇注环氧前(主机定位)After connecting the shafting bolt and before pouring the epoxy（main engine fix）a中间轴承临时定位、固定Provisional positioning and fixation of the intermediate shaftb检查轴系负荷（艉管前轴系、中间轴承、主机最后两道主轴承）Check the shafting loading(the fore shafting and the intermediate shaft of the stern tube and the last two main bearings of the main engine)c检查曲轴甩档和最后两道主轴承间隙Check the crank shaft deflection and the space of the last two main bearingsd浇注环氧Pouring Epoxy3.3 浇注环氧后After Pouring Epoxya主机底脚螺栓安装Install the anchor bolt of the main engine b检查曲轴甩档check the crank shaft deflectionc中间轴承安装（垫片拂配、间隙测量）和检查轴系负荷（艉管前轴系、中间轴承、主机最后两道主轴承）Install the intermediate bearing (gasket coordination and clearance measurement) and Check the shafting loading(the fore shafting and intermediate shaft of the stern tube and the last two main bearings of the main engine)d主机侧向支撑、端部支撑和顶撑安装The installation of the main engine side direction support、end support and top-up.4 工艺过程Technological process4.1连接轴系螺栓前Before connecting the shafting boltThe processing of the main engine base and the Lifting of the Main Engine4.1.1主机吊装前准备 Prepare for the lifting of the Main Enginea根据轴系（拉线）照光结果和主机安装图，划出主机基座上的底脚螺栓孔位置。然后，进行钻孔作业。详见主机安装图（SC4475(WH1)-420-01-0）Draw out the position of anchor bolt hole of the main engine base according to the optical alignment result of the shafting(wire drawing ) and The Installation Drawing of Main Engine, then begin to drill. See drawing Main engine installation （SC4475(WH1)-420-01-0）b 核对主机油底壳与图纸的正确性，进行主机回油管的开孔。见图主机安装图（SC4475(WH1)-420-01-0）Check the correctness of the main engine oil pan and the drawing, and make hole in the oil return tube of the main engine. See drawing Main engine installation （SC4475(WH1)-420-01-0）c 按照图纸要求焊装环氧内挡板，规格为50mmX3mm, L20m。Weld the epoxy inner baffle according to the drawing, and the specification is 50mmX3mm, L20m.d 基座平面打磨清洁，抹上油脂。Polish the surface of the base and apply grease to it.e 主机吊装前，核实机舱各甲板开口尺寸，拆去碰撞物。Before lifting the main engine, check the open dimension of all decks of the cabin, and dismantle objects that may lead to collision.f根据轴系（拉线）照光时确定的主机垫片高度，调整主机顶升螺栓的高度。Adjust the jacking bolt height of the main engine according to the main engine gasket height confirmed by the optical alignment of the shafting.4.1.2 主机输出端法兰和中间轴法兰螺栓孔镗孔Hole boring of the main engine output end flange and the intermediate shaft flange bolt holea 法兰校中：调整两个法兰外圆同轴度，要求两法兰偏移量不大于0.03mm，平面贴和值不大于0.03mm。应用临时螺栓和定位销（交错）将两法兰连接。The alignment of flanges: adjust the excircles of the two flanges to coaxiality. The offset of the two flanges is not more than 0.03mm, and the surface fit value is not more than 0.03mm. connect the two flanges with provisional bolts and fixable pin (interlacement)。b 按相应的图纸要求进行镗孔，结束后，用内径分厘卡测量孔的上下，左右两个方向以及孔长度方向数值，并记录。测量结束后，随机打上螺孔编号。Bore holes according to the corresponding drawing. After that, measure the holes value ( length, width and height) with inner diameter micrometer and report. After the measurement, print the screw hole number at random. c 根据铰孔数据，加工紧配螺栓，并按照技术要求进行无损探伤。过盈量0.002-0.015mmProcess the close-fitting bolts according to the quantity and data of reaming. Carry out the nondestructive inspection according to the technical requirement. Press-fit interference 0.0020.015mm. See drawing : PROPULSION SHAFTING ARRANGEMENT4.1.3 轴系校中（连接轴系螺栓前） The Alignment of the Shafting (before connecting the shafting bolts)4.1.3.1 校中条件The Conditions of Alignmenta 船舶下水后,校中过程中尾尖舱、淡水舱必须注满水，第3底压载(P/S)注水调节吃水。首艉吃水差不超过5M，保证艉吃水5.5M。 After launching the ship, During shaft alignment peak TK and FW TK must to be filled. NO.3BWTK(P/S) to be filled adjusting draft. The draft difference is be exceeded 5m between AFT draft and FORE draft. Ensure AFT draft is 5.5M .b校中时，船上无较大的振动作业，避开大量的加水、加油，船舶的吃水、压载状态基本不变。During the alignment, there is no strong vibration, and try to avoid large sums of watering and oiling. The draught and ballast condition of the ship should remain the same.c 主机及附件安装完整，所有主机结构件螺栓全部上紧。 Install the main engine and all accessories, and all main engine structure bolts are screwed down.d 检查和放对艉轴位置，使主机、轴系各法兰之间留有满足轴系校中的测量间隙（一般为1-2mm）Check and align the position of stern shaft, and leave necessary space between the main engine and flanges of shafting for the shafting alignment. (usually 1-2mm)e 按照图1轴系校中模型所示位置装两只可调临时支撑1和2，临时支撑的架设必须有足够的强度。Install two adjustable provisional support 1 and 2 according to the position in the shafting aligning model. The provisional support must have enough intensity.f 按照轴系校中计算书有油泵在螺旋桨轴法兰后220mm处上方施加一个垂直向下的附加力3000Kg（图1）。According to Calculation Sheet of Shaft Alignment , the oil pump applies a vertical downward additional pressure 3000Kg to the upward side of AFT the propeller shaft flange220mm.(picture1) 图14.1.3.2调整SAG，GAP Adjusting SAG, GAP a 校中依据图2和表1 Align according to picture 3 and chart 1 图2 代 号SAG1（飞轮处）GAP1(飞轮处) SAG2 GAP2数值（螺旋桨浸没50%）0.38mm0.14mm0.71mm0.10mm数值（螺旋桨浸没75%）0.38mm0.14mm0.72mm0.09mm数值（螺旋桨浸没100%）0.38mm0.14mm0.73mm0.08mm 表1 数据表b 调整中间轴临时支撑的高度，使中间轴艉法兰与螺旋桨轴法兰的“曲折”（GAP1）和“偏移”（SAG1）满足图2的要求，并使（GAP1）和（SAG1）的公差为0.08mm；左右偏差为0.08mm，并记录数据。Adjust the provisional support height of the intermediate shaft, and make GAP1 and SAG1of the intermediate shaft flange and propeller shaft flange meet the need of picture 2. Make the tolerance of GAP1 and SAG1 0.08mm, the deviation of left and right is 0.08mm and report the data.c 调整主机的位置，使中间轴法兰与主机输入端法兰的“曲折”（GAP2）和“偏移”（SAG2）满足图2的要求，并使（GAP2）和（SAG2）的公差为0.08mm；左右偏差为0.08mm，并记录数据。详细校中计算见（SA-0917-NB295）Adjust the position of the main engine, and make GAP2 and SAG2 of intermediate shaft flange and main engine input end flange meet the need of picture 2. Make the tolerance of GAP2 and SAG2 0.08mm, the deviation of left and right is 0.08mmand report the data.The detailed calculation of the alignment can refer to（SA-0917-NB295）d考虑到主机所浇注的环氧树脂垫片在固话过程中约有1/1000Xmm（-环氧垫片厚度）。The epoxy resin gasket poured by the main engine is about 1/1000Xmm during the solidification.4.1.4 参照MAN B&W的相关技术文件，调整主机基座的水平挠度Adjust the horizontal deflection of the main engine base referring to the relevant technical documents of MAN B&W.4.1.5 测量并调整曲轴曲柄差（验收标准见主机制造厂推荐数据）。Measure and adjust the crank shaft subtraction (The acceptance standard can refer to the recommendable data of main engine plant.)4.1.6 轴系铰制螺栓安装The installation of shaft reaming bolts a 铰制螺栓必须先行提交验收。 Inspection and acceptance of the reaming bolts must be submitted at first.b 清洁螺栓、螺孔，螺栓放入液氮冷冻箱。Clean bolts and screw hole, and put the bolts into the liquid nitrogen freezer. c 应用冷冻安装工艺将合格的铰制螺栓（连接前需喷涂二硫化钼）分别连接主机和中间轴的法兰、中间轴与螺旋桨轴法兰。Put the qualified reaming bolts (spray molybdic sulfide before the connection)to the flange that links the main engine and the intermediate shaft and the flange that links the intermediate shaft and the propeller shaft respectively with freezing installation technology.d 48小时后，用扳手拧紧螺帽，螺母平面与法兰平面应紧密接触，接触面75%周长应插不进0.05mm塞尺。装上开口销After 48 hours, fasten the screw cap with a wrench, and the screw surface should contact closely with the flange surface. 0.05mm feeler gauge should not insert into 75% of circumference of the contact surface. Fit on the cotter.4.2 连接轴系螺栓后，浇注环氧前(主机定位)After connecting the shafting bolt and before pouring the epoxy（main engine fix）4.2.1 轴承负荷测量 Measuring the Bearing Load4.2.1.1轴承负荷测量的条件The Conditions for Measuring the Bearing Loada拆除螺旋桨轴法兰处的附加力F和中间轴上的临时支撑1和2.Dismantle the additional pressure F in the flange of the propeller and the provisional support 1 and 2 of the intermediate shaft.b初步确定中间轴承垫片厚度，利用4只顶升螺栓使中间轴承处于正确的位置，中间轴承用夹持工具紧固。Make sure the thickness of intermediate bearing gasket preliminarily. Use 4 jacking bolts to make intermediate bearing in a proper position, and fasten the intermediate shaft with clamping device. c 测量时应停止一切振动作业。Stop all vibration operation during the measurement. 4.2.1.2轴承负荷测量的方法。The Methods for Measuring the Bearing Loada 按照轴系校中计算书所示的位置，安装千斤顶，检查千斤顶座架是否牢固.Install the lifting jack according to the position indicated the Shaft Alignment Calculation Sheet, and check if the base of lifting jack is fastened.b 在千斤顶所对应的轴颈上，放置一个百分表，并检查百分表的支架是否牢固。Put a dial indicator on the shaft neck corresponding to the lifting jack, and check if the bracket of the dial indicator is fastened.c 掀开油泵从而顶升中间轴，要求油压每升高2.0MPa,记录对应的百分表读数（即轴上升量），直到压力上升不大但轴颈抬高较快为止。Open the oil pump to jack the intermediate shaft. Report the corresponding indication on the dial indicator (the rising volume of shaft) every time the oil pressure is up 2.0 Mpa, till the rising of the pressure is not big and the elevation of the shaft neck is rather fast. d 慢慢地泻放油压，每降2.0 MPa，记录对应的百分表读数（即轴下降量），直至油压完全释放。Release the oil pressure slowly and report corresponding indication on the dial indicator ( the descending volume of shaft) for falling of every 2.0MPa, till the oil pressure is completely released.e 根据记录的数据，在坐标纸上绘制出压力与位移的曲线，按照附注中的计算公式（*），计算轴承负荷。According to reported data, draw the curve of pressure and displacement on the coordinate paper. Calculate the bearing load referring to the computational formula （*）in the annotation. f 每一轴承测力完毕后，应将轴旋转180oC。重新测量。比较两次数据。 After measure every bearing load, turning shaft 180oC. measure shaft load again and compare the data 4.2.1.3艉管前轴承、中间轴承负荷测量Measure the load of fore bearing and intermediate bearing of the stern tube.a 按照4.1.2所述的轴承负荷检测方法，对艉管前轴承、中间轴承负荷进行检测，并记录相关数据。根据记录的数据，在坐标轴纸上绘制出压力与位移的曲线。According to the test methods of the bearing load mentioned in 4.3.6.1, detect the load of fore bearing and intermediate bearing of the stern tube, and report the relative data. According to the data, draw the curve of the pressure and displacement on the paper of coordinate axis.b 按照公式（*）计算轴承负荷，要求轴承计算结果与轴系校中计算书计算值误差在20%之内，则本次校中合格。Calculate the bearing load according to formula（*）, the error between the result of the bearing calculation and the calculated value in the Calculation Sheet of the Shaft Alignment is within 20%, then the alignment is qualified. 4.2.1.4 主机推力轴承、最后道主轴承负荷测量load measurement for the thrust bearing of the main engine and the main bearinga 参照MAN B&W的相关技术文件，测量主机推力轴承、最后道主轴承（7#、8#轴承）负荷，并记录相关数据。根据记录的数据，在坐标轴纸上绘制出压力与位移的曲线。Measure the load of main engine thrust bearing and the main bearings (bearings7# and 8#) referring to the relevant technological document of MAN B&W, and report relative data. Draw the curve of pressure and displacement on the paper of coordinate axis according to the reported data. b 按照公式（*）计算轴承负荷，并按照MAN B&W推荐数据对主机轴承负荷进行验收，如果测量负荷不满足要求，可适当调节中间轴承或主机高度。Calculate the bearing load according to the formula(*). Check and accept the bearing load of the main engine according to the recommendable data of MAN B&W. If the measured load can not meet the requirements, adjust the intermediate bearing or the height of the main engine appropriately.4.2.1.5 轴承负荷和预升系数 Bearing Load and Pre-rising Coefficient轴承负荷和预升系数依据表2：The bearing load and pre-rising coefficient can refer to picture 2. Cold condition (75 % IMMERSION) 表2 数据表 Picture 2 4.2.2 检查曲柄差和最后两道主轴承间隙，通过调整顶丝调整接近出厂时数值。第一缸和第六缸最大偏差不大于0.56mm,其它不大于0.21mm。Check the crank subtraction and the space of the last two main bearings. and slightly adjusting it with adjusting screw as possible as near value of test in workshop. First and last cylinder the max deflection within 0.56mm. Others no more than 0.21mm.4.2.3参照MAN B&W的相关技术文件，调整主机基座的水平挠度,每道支撑允许0.08mm.总误差0.15mm每10mAdjust the horizontal deflection of the main engine base referring to the relevant technical documents of MAN B&W. The max deflection within 0.08mm between one support. The total deflection within 0.15mm pre 10m.4.2.4 浇注主机环氧垫片 Pour the Epoxy Gasket of Main Enginea轴负荷、曲柄差、主机水平均合格后浇灌环氧 After bearing load、crank subtraction and the horizontal deflection of the main engine base be checked out Pour the Epoxy Gasket b 按主机安装图要求，装焊6只测量销，并记录主机与各测量销之间的间隙，并作好记录。 Weld six measuring pins according to the requirement of layout drawing for the main engine, and report the space between the main engine and the measuring pins.c 浇注前应仔细清洁机座底板平面和基座面板平面。Before pouring, clean the baseplate surface of the engine base and the panel surface of the base carefully.d 在清洁机座、围海绵、搅拌环氧及浇注过程中，主机周围应无打磨、电焊、气割等工作的进行。No polishing, electric welding and gas cutting are operated around the main engine during the process of cleaning the engine base, enclosing sponge, mixing epoxy and pouring.e 环氧垫片的大小、规格和布置，必须符合主机安装图的要求。The size, specification and layout of epoxy gasket must conform with the Requirement for the Installation of the Main Engine.f 浇注时由环氧服务商负责。Epoxy service providers are responsible for the pouring.g 浇注时，在主机四角位置各取一试样。 Get a sample from the quadrangle of the main engine respectively when pouring.h 待环氧48小时硬化后，检查环氧垫片的硬度。After 48-hour hardening of the epoxy, check the hardness of the epoxy gasket.4.3 环氧浇注后的工作 Works after Pouring Epoxy4.3.1主机底座螺栓安装。Installation for the Bolts of the Main Engine Basea 拆除主机顶升螺栓。Dismantle the jacking bolts of the main engine.b地脚螺栓涂上二硫化钼，上螺母必须按照主机安装图进行调整。确保上、下螺母用圆螺母扳手扳紧。Apply molybdic sulfide to the anchor bolt, Adjust the upper bolt according to The Installation Drawing of The Main Engine. Make sure that the upper nut and the lower nut are fastened with round nut wrench 图3 picture 3c 安装液压拉伸工具，应确保液压缸紧贴定距环并确保零部件要一起正确导向。Install the hydraulic stretching instrument, and make sure the hydraulic cylinder is appressed with the distance collar and make sure that the components are correctly orientedd分两次紧固。Fasten at twice.施加压力（液压拉紧压力：150MPa）用圆形螺母扳手紧固螺母释放压力到0在进行第二步前等待约2分钟。施加压力（液压拉紧压力：150MPa）将螺母紧固牢并释放系统压力到0.Exert pressure( hydraulic straining pressure:150MPa) Clamp nuts with round nut wrenchrelease the pressure to zerobefore the second step, please wait for about 2 minutes. Exert pressure (hydraulic straining pressure: 150MPa) clamp the nut and release the system pressure to zero.e 拧紧顺序The Sequence of Clamping 将机座分隔为三个相等的部分：前部、中部和后部，按照图3编号和箭头的反向顺序拧紧螺栓。The dropper base can be divided into three equivalent parts: the fore part, the middle and the rear. Clamp bolts according to the reverse sequence of number and arrowhead in the picture 3. 拧紧顺序： clamping sequence:在主机中部的截面上的螺栓在（1+2）两侧紧固；在主机前部的螺栓在（3+4）两侧紧固；最后端的螺栓在（5+6）两侧紧固；将主机中部截面上的螺栓在（7+8）两侧再次紧固。Clamp the bolts on the cross section of the middle of the main engine in the two sides of (1+2).Clamp the bolts in the front of the main engine in the two sides of (3+4).Clamp the final bolts of the final end in the two sides of (5+6).Re-clamp the bolts on the cross section of the middle main engine in the sides of (7+8).4.3.2 测量主机同各测量销之间的间隙，对比主机的下沉量。Measure the space between the main engine and measurement pins, and contrast the submergence volume of the main engine.4.3.3 测量曲轴曲柄差Measure the Crank Subtraction and report data.4.3.4 确定中间轴承垫片厚度，拂配、基座钻孔并紧固，接触面积70%（允许极限60%），0.05mm塞尺允许插入深度不超过10mm.Make sure the thickness of middle bearing shim. Carry out the coordination, base drilling and fastening. The contact area70%( permissible limit value 60%) The permissible insertion depth is not beyond 10mm with 0.05mm feeler gauge.4.3.5 复测轴承负荷（艉管前轴承、中间轴承、主机最后两道主轴承）。并记录Retest the bearing load.( the fore bearing and middle bearing of the stern tube and the last two main bearings of the main engine) and report4.3.6 端部支撑安装End Support Installation