金枪鱼TCN124P-M012-GY03轴系安装工艺(含主机定位)

轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 2 页 1 1 概述 概述 General General 1 1 本工艺描述了 57000DWT 散货船轴系各主要部件安装以及主机定位的技术要求 This procedure described the technical requirement of shaft components installation and M E locating of 57000DWT BC 1 2 轴系主要部件包含有 4 叶定距螺旋桨一支 直径 6000mm 重约 16 347kg 螺 旋桨轴 1 根 500 6505 10211kg 中间轴 1 根 420 6006 7159kg 艉管装置 1 套 3839kg 中间轴承一套 645kg 艉轴首尾密封装置 轴接地 装置一套 Main components of shaft include the following parts one fixed pitch propeller with four blades diameter 6000mm weight 16 347kg one propeller shaft 500 6505 10211kg one intermediate shaft 420 6006 7159kg stern tube unit one set 3839kg intermediate shaft bearing one set 645kg fore and aft shaft seal assembly shaft grounding unit 1 3 轴系的安装工艺流程 Shaft system Installation sequence 拉线 照光 艉管定位浇注环氧 主机底角螺栓孔定位 装螺旋桨轴 装 艏艉轴密封装置 安装无键螺旋桨 安放中间轴 主机 船下水后按轴系校中 计算法定位轴系及主机 Pulling wire Shaft sight Locating stern tube and chock fast Locating M E holding down bolts Install propeller shaft Install shaft seal assembly Install propeller Put intermediate shaft and M E After vessel launching install and connect the shaft and M E according to the shaft alignment calculation 注 船下水时 轴和主机作临时固定 防止螺旋桨轴转动 具体见注 船下水时 轴和主机作临时固定 防止螺旋桨轴转动 具体见 下水封桨下水封桨 封舵工艺封舵工艺 Note Note BeforeBefore launchinglaunching fixfix thethe shaftshaft andand M EM E temporarily temporarily avoidavoid turningturning ofof propellerpropeller shaft shaft DetailDetail seesee ProcedureProcedure forfor fixfix rudderrudder andand propellerpropeller duringduring launchinglaunching 1 4 所有轴系零件均为外购成品 尺寸加工到位 在吊运 安装过程中要注意保护 在进行吊装前应仔细检查吊运工具 如吊索 眼板 卸扣等应安全可靠 All the components of shaft is finished production please pay more attention during hoisting and installation Check carefully handling tool before shaft hoist such as halyard eye plate shackle should be safe and reliable 2 2 适用范围适用范围 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 3 页 RangeRange ofof application application 本工艺适用与 12 57000DWT 散货船轴系安装及主机定位施工 This procedure is to be applied for instruct the shaft installation and M E locating for 12 57000DWT bulk carrier 3 3 参考资料参考资料 ReferenceReference documents documents SC4439 ZS G3 400 04 机舱布置图 E R Arrangement drawing SC4439 ZS G3 425 01 推进轴系布置图 Shaft arrangement drawing SC4439 ZS G3 230 02 舵系布置图 Rudder arrangement drawing SC4439 ZS 425 002 00 艉轴管总图 General drawing of stern tube SC4439 ZS 420 001 00 主机安装图 Installation drawing for M E SC4439 ZS 107 001 螺旋桨图 Propeller drawing CB T 4000 2005 中国造船质量标准 China Shipbuilding Quality Standard 4 4 工装设备工装设备 FrockFrock EquipmentEquipment 激光经纬仪 拉线架 4 套 铅锤 1 只 重锤 1 只 25kg 琴钢丝 0 5mm 钢直尺 50m 卷尺 常用钳工工具等 Laser instrument 4 draw line frames 1 plumb a heavy 25kg 0 5mm steel wire steel ruler 50m tape ruler normal locksmith tools etc 5 5 轴系精拉线条件 轴系精拉线条件 ShaftShaft finalfinal drawdraw wirewire preconditions preconditions 5 1 机舱前壁 FR35 以后 主甲板以下主要结构焊接工作已完成 火工矫正工作结 束 机舱内部的船体舱 柜的焊接打磨密性试验交验完毕 Welding job of structures that after fore bulkhead FR35 of E R and below main deck almost finished and the fire correction job finished The structure tanks in E R welding grinding job and tightness test finished 5 2 轴系区域内主要辅机机座装焊完成 除主机及舵机以外的大型设备 3t 及以上 及底部单元等进舱就位 In the area around shaft line the auxiliary engine seat to be welded completely all the big equipments over 3 ton and assembly units on position except M E steering gear 5 3 船体垫墩 支柱受力均匀 稳定牢固 不允许随意移动 Frusta and support below structure bear even strength Must be sure they are steady and without movement 5 4 轴系精拉线要求在不受阳光曝晒及无急剧温度变化情况下进行 一般在晚间或阴 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 4 页 天时进行 以避免船体变形影响轴系中心线的正确性 Shaft draw wire job should be carried out on the condition of without sunshine and the temperature sharp change Usually should carry out in evening or cloudly day avoid hull deflection impact the shaft center line position 5 5 停止引起振动的作业与有严重噪声干扰的作业 Stop the vabriation and loud job 5 6 定位所用的激光经纬仪以及测量工具应经相应检验部门校验合格 The laser instrument and all the measure tools to be checked out by inspect dept 6 6 轴系精拉线前的准备 轴系精拉线前的准备 PreparationPreparation ofof shaftshaft finalfinal drawdraw wire wire 6 1 实船基准线的确定 Base line determine 6 1 1 测量龙骨变形量 计算龙骨平均高度点 作为船体实船基线 Measure the deformation of keel calculate the even height of keel as the base line height 6 1 2 测量实船中心线偏差量 并在尾封板及机舱前横舱壁的区域坞底平面上勘划 出实船中线面的投影线 作为轴线在坞底平面的投影线 Measure the actual center line and mark the center line projection line on the dry dock below E R area the line is shaft line projection line 6 2 轴系中心线的确定 Shaft center line determine 6 2 1 船体尾部理论轴中心面的确定 Stern part shaft center profile determine a 以中心线在坞底的延伸点为基准 调整激光经纬仪 1 的轴线直至与船中心线 重合 Take the center line projection line on dock floor as benchmark adjust laser machinery No 1 until the axial line of laser crossed with benchmark 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 5 页 b 将激光经纬仪 1 射出的光点延伸到尾部拉线架 B 上 并在垂直方向向上 平移 同时测量此光点到坞底的垂直距离 当测定的距离等于船体轴线到船台的 距离时 即 轴系中心线的高度为 3300 外板厚度 坞墩高度 则此点为轴系中 心线上一点 以此点作为参考点并打好样冲点 同时将激光经纬仪旋转 180 将 光点投射到后艉管支撑套后端面上 并打好样冲 这样就可初步确定轴系尾部理 论面 Extend the laser from No 1 machine on the wire frame B and move the laser point up meantime measure the vertical distance form dock bottom to the laser point during the distance same as shaft center line to dock bottom height stop movement we can confirm that this point on the theory shaft center line Take this point as benchmark and punch it on frame Turn lasher head 180 and punch the lasher point on stern bossing aft face at present the stern shaft profile has been determined 6 2 2 机舱内轴系中心线的确定 Shaft center line determine in E R a 在机舱 Fr21 附近位置设立一激光经纬仪 2 将光点延伸到船体外部的拉线架 B 使之与拉线架上的样冲点重合 Arrange one laser machine 2 around Fr21 in E R extend laser on the wire frame B until the laser point just superposed with the punch mark b 调整激光经纬仪 2 的位置 使之既能与船体尾柱上的样冲点的连线相交 同时 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 6 页 也能投影到艉部拉线架上的样冲点上 然后将经纬仪的位置固定 Adjust laser head 2 position until the laser point crossed with the connect line between punch mark on stern bossing aft face and the laser point also superposed with the punch mark on frame B fix the laser machine position 6 2 3 轴系中心线的延伸 Extend the shaft center line a 将激光经纬仪 2 调转 1800 将光点延伸并投影在机舱 FR31 拉线架上 并确定 光点位置 打好样冲点 这点与艉部拉线架上的样冲点的连线即为理论轴线 Turn lasher head 2 1800 extend lasher point on FR31 frame A and punch it Then connection line between the punch point on frame A B is the theory shaft center line 6 3 根据船舶设计理论轴系中心线 在轴系艏艉端确定基准点 拉线时以此为基准 基准点坐标分别为 艏点 A Fr31 CL 0 BL 3300 艉点 B Fr 5 2000 CL 0 BL 3300 见附图 各基准点在现场确定后报验船东船检 According to the theory shaft line position determine the fore and after datum mark The coordinate of two datum marks is Fore point A Fr31 CL 0 BL 3300 Aft point B Fr 5 2000 CL 0 BL 3300 see attached drawing Two datum marks point position should be confirmed by owner and surveyor 6 4 通过艏艉基准点拉线 检查 FR13 舱壁艉管孔的直径理论值应为 900 并根据 轴系理论中心线检查此开孔的偏心情况 在舱壁靠船首面划出 1130 的检验圆 以及圆孔的正交十字线 用洋冲标记 Through the two datum mark points pull steel wire as shaft center line According to this line check the stern tube hole on FR13 bulkhead the theory diameter is 900 check eccentricity of the hole draw a 1130 reference round and the cross line with punch mark 6 5 在轴系基准点 A 后端 设立拉线架平台 用来安放仪器和人员站立 After the target A arrange one platform for the wire frame 6 6 艉管装置在车间平台时应找正前后端面圆孔的中心 并划十字线标记 前后艉管 端面十字线交叉点的连线即为艉管的理论中心线 完成后需交船东船检认可 Find the center of fore and after hole of stern tube and make cross line mark on the end surface The two center point connect line is the theory center line of stern tube The center point should confirmed by owner and surveyor 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 7 页 6 7 艉管就位 Install the stern tube 6 7 1 按 艉管总图 425 02 00 将八只艉管调整螺栓预先布置到相应位置处 其中四只在艉柱中 另外四只安装在 FR13 舱壁船尾侧 According to general drawing of stern tube 425 02 00 previously place eight stern tube adjustable bolts to relative position The after four bolts in stern bossing the other four installed on the aft side of FR13 bulkhead 6 7 2 按 艉管总图 425 02 00 焊好后艉柱上的两个透气管及一个注入管 注 入管及透气管均采用 27X2 5 无缝钢管 钢管上应无任何油漆 油污等 According to general drawing of stern tube 425 02 00 weld two vent pipes on aft stern tube support cover and one immit tube Immit and vent tube all adopt 27X2 5 seamless steel pipe No any paint and dirty on steel pipe 6 7 3 栓查艉管清洁 艉柱内表面及艉管外表面等与环氧树脂接触处 含浇注孔 透气孔内表面 均需清除铁锈 油污 毛刺 焊渣 油漆和灰尘等 提交环 氧服务工程师及船东检查清洁度 Check stern tube cleanness Contact part of stern tube front aft support cover inner face and stern tube outside face with epoxy resin include spraying hole vent hole inner face need clean rust oil dirty burr welding dregs painting and dust Submit epoxy service engineer and owner to check cleanness and can satisfy the requirement 6 7 4 将艉管吊起送入艉柱中并向艏移动 在移动过程中注意保持艉管外表面和艉 柱内表面清洁 并用丙酮清洗 现场需由环氧服务工程师及船东监控 当 到达艉管装置图中所示位置时 重新检查艉管外表面和艉柱内表面清洁度 提交环氧服务工程师及船东检查清洁度 Hoisting the stern tube and move it to forward in stern bossing during the transport please keep the surface cleanness and clean it use acetone The chock fast service engineer and owner inspect on site during the stern tube on position recheck the cleanness and submit to service engineer and owner check 6 7 5 拧入艏艉处的调节螺栓将艉管撑起 撤去起吊艉管所用的辅助工具 Stern tube will be raised by screwing adjustment bolt of fore and after and remove all auxiliary tools that sling stern tube 7 7 拉线调整定位艉管 拉线调整定位艉管 DrawDraw wirewire andand adjustadjust thethe positionposition ofof sternstern tube tube 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 8 页 7 1 在理论轴线前后端拉线架上用 0 5mm 琴钢丝穿过前后艉轴管拉出理论轴线 钢丝自由端挂 25kg 重锤 Pull shaft line on wire frame use 0 5mm steel wire at the aft side hang a 25kg heavy 7 2 调节钢丝线位置 使其穿过 A 和 B 两个基准点 检查确定后报验船东船检 Adjust the steel wire until it through the two benchmark A and B then submitted to ship owner and surveyor for approval 7 3 用艏艉调整螺栓精调艉管位置 使前后端艉管中心均在轴系理论中心线上 考 虑挠度值 并且调整艉管后端面距艉柱后端面距离为 75mm 允许误差 2mm 拧紧顶丝螺栓 固定艉管 报验船东船检 Adjust the stern tube position use the adjust bolts until the stern tube target center on the shaft center line And adjust the distance between stern tube after end to stern bossing end the distance should be 75mm the allowable tolerance is 2mm Fix the stern tube by the adjust bolts submit to owner and surveyor check 琴钢丝挠度计算公式如下 The deflection formula as following Y q X L X 0 99 2G 式中 Y 钢丝线上 X 一点挠度 m In the formula Y the flexibility of point X on the steel wire m q 钢丝线单位长度重量 q m 0 5mm 钢丝线取 1 59g m q unit length weight of steel wire q m 1 59g m per 0 5mm steel wire X 所求挠度点到基准点距离 m X distance between calculation point to the benchmark m L 钢丝两基准点间的距离 m L the distance between the benchmark on steel wire m 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 9 页 G 钢丝拉力 kg G pull strength on steel wire kg 7 4 检查艉管与艉柱之间的最小间隙 采用动力泵浇注环氧最小允许间隙为 3mm Check the clearance between stern tube and stern bossing adopt the pump pouring chock fast the minimum clearance is 3mm 7 5 检查轴系中心线到主机基座面板的高度 此高度实际测量值应在 1135mm 左右 检查主机基座两侧的偏中情况 中心线到基座边缘的距离应为 1095mm 若以上尺 寸实测偏差过大需及时通知技术部门核对 Check the vertical distance between shaft center line to M E foundation top measured distance should around 1135mm Check the width from shaft center line to M E foundation side the width should be 1095mm If the above result with big deviation please inform technical dept in time 7 6 吊舵系中心线 检查舵线与轴线的相交情况 以及舵线到艉管末端的距离 尺 寸应满足 TCN124P M012 GY01 轴舵系初拉线工艺 中第 10 3 的要求 Hang the rudder center line check the relative position between rudder center line and shaft center line and the distance between rudder line to stern tube end The dimension should within the tolerance of item 10 3 in TCN124P M012 GY01 Preliminary alignment procedure for shaft rudder 7 7 检查轴线到中间轴承基座面板的垂直高度 不包含垫块高度 理论值为 500mm 为保证活动垫块的厚度 50mm 按照设备说明书要求 垂直高度应 500mm 且小 515mm Check the vertical height between shaft center line to intermediate bearing seat face plate not include pad height theory value should be 500mm In order to keep the moveable pad thickness 50mm according to equipment spec requirement the vertical height should 500mm and 515mm 7 8 按照附图尺寸确定主机滑油回油孔的开孔位置 开孔前应检查到货主机油底壳 上开孔尺寸是否与图纸相符 确定无误后方能开孔 According to the attached drawing dimension determine the M E LO return hole position before open hole check the hole dimension on M E follow attached drawing after confirmed do the cut job 8 8 安装艉管总成加强板 安装艉管总成加强板 InstallInstall thethe sternstern tubetube reinforcementreinforcement plate plate 8 1 艉管总成吊装上船以后 先按照艉管总图 SC4439 ZS 425 02 00 将加强板 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 10 页 SC4439 ZS 425 02 14 焊在艉管总成前端艉管座上 After stern tube on position according to stern tube general drawing SC4439 ZS 425 02 00 weld reinforcement plate on stern tube forward bossing 8 2 按照图纸将加强板与 FR13 舱壁焊接 按右图所示 分段 对称施焊 在焊接过 程中必须打表随时监测焊接的变形情况 使得焊接完成时艉管艏艉部的中心仍 在轴系中心线上 允许偏差 0 50mm According to the drawing weld the reinforcement plate on the FR13 bulkhead symmetric weld as the right picture Check and control the deformation during welding keep the stern tube center still on the shaft center line after weld allowable deflection 0 50mm 9 9 艉管总成的环氧浇铸 艉管总成的环氧浇铸 ChockChock fastfast ofof sternstern tube tube 见艉管环氧浇注工艺 See stern tube chock fast procedure 环氧浇注 24h 后 复核艉管总成的位置 将测量结果填入下检验表中 24 hours after chock fast recheck the position of stern tube fill the result in the below list 10 10 主机底角螺栓孔定位开孔 主机底角螺栓孔定位开孔 LocatingLocating ofof M EM E holdingholding downdown bolts bolts 10 1 以 A B 两点为基准 用 0 5mm 钢丝拉出轴系理论中心线 A 点挂重 25kg According to the A B datum marks pull 0 5mm steel wire as the shaft center line at A point hung a 25kg heavy 10 2 在主机座槽中装焊临时支架 将轴系中心线引至临时支架上平面 并以此为基 准按照主机安装图中的尺寸 在两侧基座面板上划出两列主机地脚螺栓孔的中 心连线 如下图所示 Install the temporary support in M E seat groove as below drawing mark the shaft center line projection on the support According to 偏差方向 Direction 位置 Position 上 up 下 Down 左 left 右 right 尾管前中心 Stern tube fore center 尾管后中心 Stern tube aft center 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 11 页 the marked wire draw two arrange line of holding down bolts center connect line As below drawing 10 3 以艉管后端面为基准确定主机第 6 缸中心位置 沿钢丝线向前测量 艉管后端 面到 6 缸中心的理论距离为 12325 1mm 该尺寸为理论值 实际尺寸待螺旋桨 与螺旋桨轴在车间预压后确定 采用吊线锤的方法找出主机第 6 缸中心投影点 在临时支架上穿过此点划出与船中线的垂线 并延长与两列主机地脚螺栓孔的 中心连线相交 Determine the No 6 cyl center position measured from stern tube after end side the theory distance should be 12325 1mm the actual distance decide by the propeller and propeller shaft pre installation test result in workshop use the plumb find out the projection point of No 6 cyl center on temporary support Through this point draw the vertical line with ship center line and prolong the vertical line crossed with holding down bolts center connect line 10 4 根据主机安装图 采用常规方法划出主机全部地脚螺栓孔的中心位置 打硬记 然后对照主机安装图 采用纵向 横向 以及对角测量的方法 反复校对 以 确保全部地脚螺栓孔位置的准确无误 According to engine installation drawing draw out the center position of all engine holding down bolts hole with punch mark Then follow the engine installation drawing measure each distance from longitudinal transverse and crossed direction in order to ensure 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 12 页 the correct position of all holding down bolts hole 10 5 检查艏 艉两端螺栓孔中心对角间距 理论值应为 6436mm 允许偏差 2mm 复核全部螺栓孔的纵 横向尺寸 纵向两孔间误差 0 5mm 横向两孔间误差 1mm 确保准确无误 纵向累积误差 2mm Check the fore and after end bolts cross connect line length theory distance should be 6436mm allowable tolerance 2mm Recheck all the holding down bolts position tolerance between two holes on longitudinal direction 0 5mm on the transverse direction 1mm cumulate tolerance on longitudinal direction 2mm 10 6 根据已划好的底脚螺栓孔的中心点 划出全部地脚螺栓孔的加工圆线 46 mm 检查圆线 66mm 打硬记 According to the marked center point of holding down bolt holes draw the drilling hole 46 mm and reference round 66mm and marked on M E seat 10 7 加工出全部 460 2 0mm 的地脚螺栓孔 修除毛刺打磨光顺 Drill all the holding down bolts hole 460 2 0mm and grinding 10 8 钻孔作业后 须检查主机机座下横向加强板的位置 是否会影响螺栓螺母的安 装 消除反面毛刺 以保证安装时的良好贴合 After drilling check the transverse reinforce plate below M E seat plate confirm whether the plate will impact install bolts and nuts Remove the burr on the opposite side ensure the nut surface M E seat opposite side with good contact 10 9 回油管开孔时 应核对主机油底壳与图纸的正确性 Before open the return oil pipe hole on lube oil circulation tank must confirm the opening position on M E sump bottom same as the drawing 11 11 塞螺旋桨轴塞螺旋桨轴 InsertInsert propellerpropeller shaft shaft 11 1 艉轴由机舱内向艉管塞入 在装轴之前 根据螺旋桨轴后端的螺纹 制造一个 螺纹连接的导向帽 以免在塞轴的时候碰坏轴承内的白合金 Insert the propeller shaft into stern tube form E R during insert the propeller shaft the shaft end screw should covered by a smooth hat avoid crashed with white metal bearing 11 2 尾轴安装前 艉管内孔包括后轴承内表面应清洁 清洁程度要得到船东认可 装入时应涂润滑剂 Before install the propeller shaft clean the shaft and bearing inner side and daub lube oil the cleanness should confirmed by owner 11 3 艉轴塞入时 首密封装置及密封垫圈已套装在尾轴上 轴系安装工艺 Procedure for shaft installation TCN124P M012 GY03 共 14 页 第 13 页 The forward shaft seal and the gasket should be move on shaft before insert shaft 11 4 如下图 在艉轴法兰后端面后 200mm 处设置艉轴临时支撑 支撑上安装的顶 丝螺栓可以用来调节及固定艉轴位置 借助临时支撑上的顶丝螺栓 调整艉轴 位置 使得艉轴在轴系理论中心线上 且艉轴法兰后端面 200mm 处位置比理论 高度低 0 45mm 轴系对中的基准 参考 STX 轴系校中计算书 As the below drawing arrange one temporary support at 200mm back o