风机整体安装流程.doc

4 Erection procedure/安装流程 4.1 Foundation/基础 The foundation is supplied ready to mount, including duct work, load spreading plate (LSP), and grouting mortar. The wiring through the foundation can also be already installed. The grouting mortar must have been processed at least 24 hours in advance. The project supervisor/site manager must check the Acceptance Report I202_031_A01 before the erection work begins and approve the foundation for the erection. 基础已准备好安装,包括管道工作,装载扩散盘(LSP),和水泥灌浆.经过基础中的电缆已经安装.水泥灌浆工作要至少提前24小时开展. 项目主管/现场经理必须在安装工作开始前检查验证报告I202_031_A01并批准基础可以使用. Before the tower is brought into place, prepare the foundation as follows: 在塔筒到位之前,准备基础工作如下所示: Examine the foundation for any signs of damage. 检验基础上一切损害迹象。 Mark the position at which the tower door will later be located (90 from main wind direction). 标出塔筒门稍后将处于的位置(主风向的90)。 Clean the load spreading plate thoroughly. Sweep out the interstices with a broom and clean the LSP if necessary with other cleaning aids. 彻底清洁载荷分布板. 用扫帚清除间隙和清洁LSP-如有需要-使用其他的清洁工具。 Clean the thread of the anchor bolts with a wire brush and grease all the anchor bolts completely with Molykote G-Rapid Plus (more than in the picture below). 使用钢丝刷清洁地锚螺栓的螺纹并使用二硫化钼润滑剂给所有的铁锚螺栓进行全面涂脂(超出图中所显示的)。 Apply Sikaflex against penetrating water onto the load spreading plate (white lines, 1 circle Sikaflex around the exposed bolts (not shown in the picture) and to the joints of the LSP). 应用Sikaflex阻止水渗入载荷扩散盘(白线, 用一圈Sikaflex围绕在暴露的螺栓(图中没有显示的)和LSP的连接处。 Erection Instructions Erection of the turbine 风机安装技术说明 Doc. No.:I202_850_ZH Revision: 5 Date: 2007-03-07 Department responsible/负责部门 Replaces/替换 Classification/分类 Central Engineering/PDE 工程部 SC Partner Confidential Created/创建 Checked/检验 Released/公布 Status/状态 M. Artmann M. Hofmann G. Steininger FI Final Place the washers and nuts close to hand. In all towers, as a principle, spherical washers are used (cone washer/ball washer). 垫圈和螺母预先放置。在所有塔筒里,根据规定使用球状垫圈(圆锥体垫圈/球芯垫圈)。 Fig. 4 Prepared foundation and spherical washers准备好的基础和球形垫圈4.2 Erection of the lower tower segment/安装底层塔段 Make sure all tower segments are complete and not damaged. Spot check the platform fastenings and metal sheets for secure attachment. 确保所有塔筒的部分都完整无损。 为了安全添加,当场应检查平台的紧固和金属板的安全。 4.2.1 Transformer in the tower/塔筒内的变压器 If the transformer is installed in the tower, the transformer must be placed on the foundation before the first tower segment is brought into place. Follow the instructions in the handbook Transformer in the Tower. 如果塔筒内安装了变压器,那么变压器需要在第一节塔筒到位前放置在基础上.遵循手册”塔筒变压器”的使用说明. Mark the position of the transformer on the foundation, starting from the position of the door.在基础上标出变压器的位置,从门开始. If the transformer is an oil-immersed transformer, place and position the drip basin on the foundation first. 如果变压器属于油浸式, 要在基础上先放置一个脸盆. Fasten the transformer with shackles and chain slings to the hoisting ring and position it on the foundation (if it is an oil-immersed transformer: into the drip basin). Align the transformer. 用锚链和链式吊索将变压器固定在起重环上并将它放置在基础上(如果是油浸式变压器,要放在滴水盆中),对齐变压器 After the lowest tower segment is in place, you must first position the medium voltage (MV) switching system # on the lowest platform. 当最低部分的塔筒到位时, 必须将中压转换系统放在最低的平台上. Remove from the upper platforms the corresponding metal sheets. 1202_850_ZH_R05_Erection of the turbine_class-07_Type: Nordex S70, S77.doc Nordex AG/Nordex Energy GmbH, Bornbarch 2, D-22848 Norderstedt All rights reserved. Observe protection note ISO 16016. 25Erection Instructions Erection of the turbine 风机安装技术说明 Doc. No.:I202_850_ZH Revision: 5 Date: 2007-03-07 Department responsible/负责部门 Replaces/替换 Classification/分类 Central Engineering/PDE 工程部 SC Partner Confidential Created/创建 Checked/检验 Released/公布 Status/状态 M. Artmann M. Hofmann G. Steininger FI Final 要将上部的平台上相对应的金属板移开. Lower the MV switching system onto the lowest platform using the crane. 使用吊车将中压转换系统调低到最低的平台上 Afterwards, install the cover $ for the transformer compartment and the metal sheets in the platform where the control cabinet will be located. 之后,安装盖子在变压器的间隔层,放置在控制箱平台的金属板上 Mount a hood from outside to the lower tower access at the air outlet of the fan在外部安装一个风帽到底部塔筒风扇通风入口处Fig. 5 Transformer position Medium voltage transformer in the tower 变压器位置 塔筒内中压变压器 1 MV switching system中压转换系统 2 Cover盖子 3 Transformer变压器 4.2.2 Preparing and fastening the lower tower segment/底部塔筒段准备和加固 The tower segments are delivered on lorries. In most cases, transport does not permit lifting the tower segments directly down. 塔筒分段由卡车运输.在大多数情况下,运输不允许起吊塔筒段直接向下. Preparing the tower塔筒准备工作 The upper end of the tower segment must be set down as follows: 塔筒上端必须按照以下规定放下: Lower the upper end of the tower onto a firmly secure surface. To prevent any damage to the paint finish, place a layer of clean carpeting or an equivalent material between the tower and 1202_850_ZH_R05_Erection of the turbine_class-07_Type: Nordex S70, S77.doc Nordex AG/Nordex Energy GmbH, Bornbarch 2, D-22848 Norderstedt All rights reserved. Observe protection note ISO 16016. 26Erection Instructions Erection of the turbine 风机安装技术说明 Doc. No.:I202_850_ZH Revision: 5 Date: 2007-03-07 Department responsible/负责部门 Replaces/替换 Classification/分类 Central Engineering/PDE 工程部 SC Partner Confidential Created/创建 Checked/检验 Released/公布 Status/状态 M. Artmann M. Hofmann G. Steininger FI Final the supporting surface. 将塔筒上端放在一个牢固而安全的表面.为了阻止任何在完成油漆时带来的损坏,要在塔筒和支持表面中间铺放一层干净的毛毯或其他相关的材料. Lower the upper end of the tower onto the supporting surface and disconnect it from the tractor. 将塔筒上端放在辅助表面并且将其与拖拉机断开 You can now repair any damage to the paint or clean the tower, if required. 如果需要的话,可以修复所有油漆损坏处或是清洁塔筒. To lower the control cabinet into the tower from above later, you must disassemble the steel sheeting in the upper platform and the platform under it to permit passage, if not done yet. They are hoisted later on. 要使控制柜从上面进入塔筒,如果没有完成的话必须拆卸上平台上的钢板及支撑以保证通过.他们将随后吊起. Visually inspect the ladder and the ascent protection rail. At the upper end of the rail, a rail connector must be fitted as a stopper. The rail can now be released by an expert as long as the tower segment is still in horizontal position. 检验爬梯和上升的保护滑轨.在滑轨的上端,必须安装一个连接器用来当作制动器.这条滑轨可以被资深专家批准使用当塔筒段处于水平位置时. Fig. 6 Attaching and lowering the tower Check the vertical access ladder 安装和降下塔筒 检查梯子垂直入口 Attaching the tower segment连接塔筒段 Attach the large crane to the upper end of the tower segment. Attach the lifting tackle in the circle of holes, to the left and right, in the middle (on the diameter, see sketch). 连接大型起重机到塔筒上端. 安装吊具到孔的周围,放在左面右面和中间(在直径上,见草图) 1202_850_ZH_R05_Erection of the turbine_class-07_Type: Nordex S70, S77.doc Nordex AG/Nordex Energy GmbH, Bornbarch 2, D-22848 Norderstedt All rights reserved. Observe protection note ISO 16016. 27To do this, lay a spirit level vertically on the flange and mark the middle bore. 为了达到此目的,要将一个水平仪垂直地安置上以标记中间孔.Fig. 7 Attaching the tower连接塔筒 Firmly attach the lifting tackle using 3 screws, washers and hexagon nuts on each side. For flanges bores for M42 screws you must insert sleeves into the bores (see arrow). Check in advance if the sleeves smoothly fit into the bores, if necessary, file off edge. 将吊具用三个螺栓,垫圈和六角螺母紧固在每一边.关于使用M42螺栓的法兰孔,必须将套筒嵌入在孔里(参见箭头). 检查套筒是否可以流畅进入孔中，如有必要, 打磨边缘. The screw connections of the lifting tackle must only be tightened with a wrench by hand! 吊具的螺纹连接必须只能通过手动扳手拧紧. Since the pan-head screws are special screws only used for fastening the lifting tackle, make sure during assembly that the load-bearing heads of the screws lie flat against the lifting tackle to prevent any inclination or tilting of the screws. 由于平头螺栓是专门用来紧固起重工具的,因此要确保在安装过程中螺栓的载荷轴承正面要紧靠起重工具,防止任何倾斜或螺栓的摆动. Fasten the large crane using 2 chain slings (each with a load-bearing capacity of 40t) and 2 shackles (each with a load-bearing capacity of 35t) to the lifting tackle. 使用两根链条吊索(每根承载力40吨)和起重索具上的两根锚链(每根承载力35吨)来加固大型起重机。 Fasten the small crane to the lower end of the tower segment at the highest point in the circle of holes (Fig. 7). 要使小型起重机拧紧在塔筒底段的位置：整圈孔的最高点（图7）。 Attach the lifting tackle with 3 pan-head screws, washers and hexagon nuts.使用平头螺栓、垫圈和六角螺母连接吊具 Fasten the small crane using 2 chain slings (load-bearing capacity of 40t) and 1 shackle (load-bearing capacity of 35t) to the lifting tackle. 将小吊车用两条吊链（额定负载40t）和一个锁扣（额定负载35t）固定在升降滑具上。 Once the small crane is bearing the load, you can release the rear part of the tank platform from the tower segment and repair any final damage to the paint. 一旦小吊车起吊后,将塔筒段平台里的积水释放,并且将受损的地方补上油漆。 4.2.3 Erection of the lower tower segment/安装底部塔筒 DANGER危险 The area underneath the tower is OFFLIMITS TO PERSONNEL while the tower is being rotated. Loose objects in the tower could fall out 当塔筒在进行吊装时,塔筒下方不允许一切人员停留。以防不牢固的物体从塔筒坠落。 Both cranes lift the load now, whereby the small crane lifts only a bit and then follows with the lower end of the tower. 当两个吊车同时开始起吊时，小吊车吊起少量后接着移动塔筒的底部。 When the tower hangs vertically, you must detach the smaller crane. 当塔筒垂直悬挂时必须将小吊车分离。 If the transformer is installed in the tower, guide the tower segment over the previously positioned transformer. Rotate the tower in such a manner that the entrance door is positioned appropriately for the transformer and duct work, and the access entrance. 如果在塔筒内安装了变压器，要将塔身超过之前标注的变压器位置。塔筒通过该方式进行吊装后，入口门要放在变压器，管道工作以及方便通过的适当位置。 2 fitters are in the bolt circle to guide the tower from inside as well. Lower the tower until it is just above the anchor bolts. 塔筒内部使用螺圈中的两个卡具用来防止安装地锚时塔筒直接碰撞在锚定螺栓上。降低塔筒直到正好处于地锚螺栓的上部。 Continue to lower the tower into the appropriate position slowly and very carefully until it rests on the load spreading plate. 继续将塔筒缓慢地放到适当的位置并且非常小心的将其塔筒放在载荷分布板上。Fig. 8 Positioning the tower Placing the spherical washers 图表8 安装塔架 置入球形垫圈 Place the spherical HV washers on the anchor bolts, each 1 receiving a cone washer (concave shaped) and a ball washer on top. Also lubricate the upper side of the ball washer (nut bearing surface). Then screw 1 nut onto each. 将球形HV垫圈置入铁锚螺栓里，每个垫圈上都装一个圆锥体垫圈（凹形）和顶部一个球形垫片。同时在球形垫片朝上一面涂上润滑油(螺母受力面)。然后用螺母把每个都拧紧。 Use an impact wrench to apply preload torque to all the anchor bolts. 使用一个电动扳手将压载力矩应用到所有的地锚螺栓上。 CAUTION小心 It is imperative to wear ear protection and safety helmet for any work in the tower using an impact wrench! This applies to all staff in the tower 在塔筒内使用电动扳手工作时必须佩戴听力保护装置和安全头盔，此规定适用于塔筒内所有的人员。 The site manager must attach a sign to the ladder stating that safety ropes must be used until the safety rail has been inspected and approved. In this case, the fitters must be secured by 2 safety ropes. 现场经理必须将一个安全标志贴在爬梯上并且标明在安全轨道经过检查并认可之前必须使用安全绳索。在这种情况下，卡具要用两条安全绳索固定。 Connect the plugs to the corresponding power supply cables of the tower and to the junctionbox of the diesel generator (pictures bottom left). 将电源插头连接在塔筒相应的电源接口并接在柴油发动机的连接盒上（底部左边的图片）。 Detach the tower segment from the crane. 将塔身段与吊车分离。 Next, connect the 4 foundation earth connections to the bushings of the tower wall (each separated by a 90 angle, M12, 100Nm). 随后，连接4个接地基础到塔内墙壁的套管上（每个都已90角度隔开，M12, 100Nm）。 Connect the tower wall to the equipotential bonding rail in the base of the tower. Figure 9 shows the equipotential bonding bar with a transformer in the tower. 将塔筒的墙壁与塔筒底部的等电势铜排连接。图9显示了塔筒内带有变压器的等电势铜排。Fig. 9 Junction box连接盒 Equipotential bonding bar in the tower等电势铜排 Then, mount the access stairs. 然后，安装入口梯子。 4.2.4 Determining the position of the tower/塔筒的定位 After erecting the tower and the complete WT you must determine the towers degree of inclination. 在塔架和风机安装完成之后必须决定塔筒倾斜的角度。 If the load spreading plate is not level, the degree of inclination should be established directly after the first segment has been erected. 如载荷分布板不平，那么应在第一段塔筒安装之后直接确定倾斜度。 NOTE注意The theodolite must be set to measure in GON. 必须设定经纬仪的测量单位为GON。 Follow the operating instructions for the theodolite (included in the case of the instrument). 必须遵守有关经纬仪的使用说明(包括相关器械说明)。 To check the position of the tower you require 2 locations at a distance of approx. 50-80 meters from the tower and whose position in relation to each other forms a roughly 90 angle with the tower at its vertex. The conditions at the site and the degree of light are crucial when making the measurement. The towers position must not be measured in the dark. 为了检查塔筒的位置，需要找两个距离塔筒大约5080米的位置，并且他们与塔筒顶部形成大约90的角度。现场条件和灯光强度是进行测量的关键。塔筒的位置不能在黑暗中测量。 Position yourself such as the border of the entrance door is not within the measurement area. There are 2 options for the position of the entrance door shown in the sketch. 选择的位置应使门框不在测量区域内。入口门有两个可选的位置，见草图。Fig. 10 Measuring positions测量位置 Measuring points on the tower塔筒上测量点 The sketch on the right side shows the measuring points. Points 1, 4 and 5 share the same elevation, the same is true of points 2 and 3. 在右图中显示的是测量点。点1，4，5在同一高度，点2和3在同一高度。 First take a bearing on point 1, the left, lower edge of the tower. 先取测量点1，左边的位置，塔筒底边。 Set the horizontal angle to 0 and note the vertical angleMeasure the points 2 to 5 in sequence and note the individual angles, vertical and horizontal, in the table of the Erection Report. 按顺序从点2到点5进行测量，在安装报告上标明单个的垂直和水平角度。 Check whether point 1 and 5 agree. The deviation of the horizontal angle should not be greater than 0.001 GON, otherwise the measurement must be repeated. 检查点1到5是否符合。水平角度的偏差不允许超过0.001 GON，否则必须重新测量。 Enter the results (both sites) in millimetres into the erection report. 将结果（两个位置）以毫米的形式记入安装报告中。 4.2.5 Installation of the control cabinet in the lowest tower segment/底段塔筒内控制柜的安装 Leave the sheet over the cabinet until the nacelle has been fitted. Avoid jerky movements. 在机舱安装好之前不要拆掉控制柜上的包装。防止猛烈移动。 Attach shackles and chain slings (chains) to the transport beams of the cabinet (top). Caution: Angle of lift 60. 将锚链和吊装绳索系在顶部控制箱的运输横梁上。注意：吊挂角度小于60。Fig. 11 Correctly attached control cabinet准确吊起控制箱 Base plates for platforms平台的基地平板The fitters on the platform must be secured with their safety ropes + shock absorbers to the safety bolts. 平台上的卡具和安全螺栓的减震器必须使用安全绳索固定。 With the large crane, carefully lift the cabinet from above into the lowest tower segment and lower it onto the lower platform. 使用大吊车将控制柜小心的从上面移入底段塔筒并且将其放置在底部平台上面。 Position the cabinet and connect it to the platform with screws. 将控制柜移正，并用螺栓固定在平台上。 Earth the bottom box by connecting it to the equipotential bonding bar. 将底箱与等电势铜排相连。 Disassemble the transport beams as they must be returned to the manufacturer by Nordex! 拆卸运输横梁，由恩德将它们返回制造商。 Seal the openings in the upper platforms of the lower tower segment with the provided base plates. 用提供的底板将底部塔筒的上部平台密封。 4.2.6 Erection of additional tower segments Preparations/其它部分塔架的安装准备 Bring all the tools, screws, washers and nuts to connect the tower flange, tower earth cable, crimping sleeves, shrink hose and other required materials up to the top platform of the already standing segment. For this purpose there is a suitable transport container available which can be transported up by crane. 将连接塔筒法兰、塔筒地缆、压缩套筒、收缩管和其他材料的所有工具、螺栓、垫圈和螺母连接在已经立好塔架的上部平台。因此，需要准备一个可以由吊车运输的集装箱。Fig. 12 Prepared screw box correctly attached to the crane将备好的螺母箱连接在吊车上 Arrange the screws, washers and nuts with washers on the platform such that they are easy to pick up. 将螺栓，垫圈和带有垫圈的螺母排列在平台上，使它们可以很容易的被拣起。 NOTE注意 Consult section 3.2.3 regarding the type, quantity and length of the screws, washers and nuts which you need for the screw connections of the individual tower segments. 参阅章节3.2.3有关垫圈和螺母的种类，数量和螺栓的长度,用来进行塔架单独部分的螺栓连接。 For the screw connection of the tower you need关于塔筒的螺栓连接需要: one impact wrench with attachment, wrench size (WS) 60 and 70 配有附件的电动扳手，尺寸60、70。 one open-end wrench to provide counter-pressure, WS 60 and 70 一个开口扳手提供背压，WS 60/70。 2 guide pins to adjust the tower segments 使用两个导向销调整塔对正。 one silicone gun with sufficient silicone cartridges 使用装满硅胶的硅树脂枪。 For the impact wrench the towers power supply must be connected. 对于电动扳手，必须连接上塔筒的电源。 To prevent rain water from penetrating between the screwed flanges, you must apply a continuous, 3mm thick bead of silicon sealant to the flange. 为了避免雨水渗透到拧紧的法兰缝隙中，必须将一条连续3mm厚的硅质密封胶粘在法兰上。 It must be approx. 3cm from the outer edge (immediately at the bores). 必须确保距离外部边缘大约3cm，靠近孔附近。 Fix the connection piece of the ladder to the pre-installed ladder using the square profile. Keep the 2 other square profiles in reach for the connection of the next segment.将爬梯用方形套管连接，保证两个方形套管可以与另一段梯子连接。Fig. 13 Tower sealing塔架密封 Ladder connection爬梯接口 Erection of the second tower segment 安装第二节塔架 The second segment is unloaded and assembled in a manner similar to the first segment. 第二节塔架的卸载和安装与第一节相似。 Visually inspect the ladder and the ascent protection rail. At the upper end of the rail there must be a rail connector fitted as a stopper. 检查爬梯和上升保护滑轨。在滑轨的上部应有一个连接器用作阻挡器。 Fit the screw box with the screws that belong to the each flange plus tools, crimping sleeves and shrink hoses for the cables etc 将连接相应法兰的螺栓和相关工具、压缩套筒和电缆收缩管等放入螺栓盒子。 Move the screw box, which contains the screws for this flange, close to the upper end of the tower segment until the tower segment could also be attached. 将装有法兰螺栓的螺栓盒移动到接近塔架上部的位置，直到塔身可以被连接上为止。 Set the screw box down, remove it and then attach the tower segment. 放下螺栓盒，移开并连接塔架。 DANGER危险 Never perform any work underneath the suspended screw box. 在悬挂螺栓盒的下方不能从事任何工作 Only now reattach the screw box to the crane. The chains must be as long as required for safely hanging the screw box in front of the tower without causing any damage to neither platform nor flange nor ladder.只有在此时可以重新将螺栓接到吊车上。吊绳必须保证足够长，以致于可以安全的将螺栓盒悬吊在塔筒前而不会导致对法兰、平台或爬