Generator installation procedure 柴油发电机安装工艺

配布栏 经营部 生产部 技术部 安监部 质量部 船体车间 机电车间 涂装车间 物资部 资产部 项目组 ERP 会签栏 日期 DATE 版 本 REV 描 述 DESCRIPTION 修 改 单 编 号 MODIFIED NOTICE 工程名称 PROJECT 东安吉东安吉 2 2 A2SEAA2SEA NBNB 002002 图 号 DWG NO 工 程 号 JOB NO 设 计 阶 段 DESIGN STAGE 生产设计 PRODUCT DESIGN图纸名称 TITLE Generator installation procedure 柴油发电机的安装工艺 申 请 人 DESIGNED 日期 DATE 比 例 SCALE 船级社 CLASS DNV 船 号 SHIP NO N488 校 对 CHECKED 日期 DATE 版 本 REV 1 审 核 REVIEWED 日期 DATE 图 幅 SIZE A4 南通中远船务工程有限公司 COSCO NANTONG SHIPYARD CO LTD 批 准 APPROVED 日期 DATE 页 数 PAGE 1 7 1 范围 Scope 本规范规定了船用发电机安装工艺的安装准备 人员 工艺要求 工艺过 程 安装后的检验 The procedure contained the preparation work list the worker certification the sequence of the procedure the requirements and survey after installation of generator 2 工艺准备 Preparation 2 1 了解并掌握发电机安装的所有设计图样及产品安装使用说明书等技术文件 必须按技术文件要求进行安装 Every related drawing and installation manual should be kept and checked over before installation 2 2 库领机电产品必须严格检查 设备附件应完整 产品名称 规格 型号 数量必须与设计图样要求一致 Check the integrality of the accessories and spare parts prior to get the equipment from warehouse Compare the name the type the model the quantity and the other related information with the drawing 2 3 检查产品外观是否有碰 擦伤 油漆剥落 零部件缺损及杂物污染等现象 Observe any damage and feed back to vendor at first time 2 4 检查所有管口 螺纹接头 道门及其他平面连接处的清洁和防锈封堵状态 对有疑问的必须及时报告并采取措施 Keep those interfaces away from any pollution and rust such as flanges bolts for installation and contact surface and etc 2 5 对检查完毕的配套设备必须有相应的保洁 防潮 防擦伤等安全措施 After checking over a mean shall be carried out to avoid any pollution and collision 2 6 对基座 垫块 薄垫片等零部件必须按图纸等有关文件进行核对 Check the foundation the welding plates shim plates and the other related accessories according to installation drawings 3 人员 Worker certification 3 1 安装人员及检验人员应具备专业知识并经过专业培训 经考核取得相应专 业合格证书具有相应专业知识方可上岗 The workers to attend the installation should be trained or study the installation procedure maker s installation guide before the working on site 3 2 安装人员和检验人员应熟悉本规范要求 并严格遵守工艺纪律和现场安全 操作规程 Everybody to attend the installation should comply with the approved installation procedure and Safety Requirement 4 工艺要求 Tech Requirement 发电机的安装状态符合图纸或厂家说明书要求 The final status shall comply with the approved drawings and vendor s manual 5 工艺过程 Procedure 5 1 基座安装 Install foundation 5 1 1 定位 安装人员首先找对设备的安装部位 即按图样标出发电机距甲板 平台 肋骨 船舯或船体相关结构定位 Orientation Look for the installation position on site and marked on deck by center line frame or other related structure according to the drawings 5 1 2 将预制的基座吊至定位位置 并检查基座位置必须符合图样要求 Lift the foundation to the position and check the fabrication accordingly 5 1 3 检查基座下平面与结构吻合状态 当出现缝隙过大时必须进行修正 直 至缝隙符合规定 方可进行焊接 焊接时注意焊接工艺程序以减少变形 Observer the gap between deck and foundation adjust the gap if needed Weld the foundation according to prior WPS Hull standard 5 1 4 焊接完工后 检查焊缝质量符合要求 Check the quality after welding according to yard standards 5 1 5 检查基座安装效果 用水平尺测量安装表面 保证基座面板水平 平面 度标准规范 2mm m 允许极限 5mm m Measure the flatness of foundation by flat ruler or laser instrument Keep the surface flatting limited with 2mm m the permission terminal is to be 5mm m at a few points 5 2 焊接垫块安装 Welding plates installation 5 2 1 待发电机基座分段合拢后 根据图纸在发电机基座上划出每块焊接垫片 的位置 通过模板来检查发电机基座每块焊接垫片位置的平面度 保证 焊接垫片与发电机基座至少有 50 的接触面积 Line out the position of each welding plate according to the drawing after the block erection Ensure the contact area between welding plate and foundation not less than 50 the surface under the welding plates can be ground suitably if necessary and checked by a model plate 5 2 2 通过经纬仪来测量水平状态下发电机基座的平面度 计算出每块焊接垫 块的厚度 在车间统一机加工焊接垫片 并编好号 同时 将焊接垫块 按照图纸打孔攻丝 Measure the flatness of the foundation by laser instrument and calculate the thickness of each welding plate Fabricate and number the welding plates in workshop Drilling and tapping on the welding plates according to installation drawings at the same time 5 2 3焊接垫块加工后 按照编号摆到发电机基座上的相应位置 测量焊接垫 块的平面度 平面度须控制在 2 毫米以内 对不符合要求的点进行修正 Put each welding plate on the foundation according to drawings Measure the flatness of welding plates surface Ensure the flatness not more than 2mm modify the points which are not according to requirement 5 3 发电机吊运及安装 Generator lifting and installation 5 3 1 拆除易发生触碰损伤附件 妥善保管 按照图纸 将弹性脚安装到位 螺栓打好扭力 扭力值为 150 N M Dismantle any branch part which would be in risk of broken during lifting and installation Store them in proper way Mount rubber rails on the base frame of generator with bolts and washers according to drawings The torque of the bolts shall be 150 N M 5 3 2 合理安排发电机进舱时间 核实机舱吊运通道 清除吊运途中的障碍物 Make the plan of the lifting procedure and ensure there have enough space for lifting 5 3 3 按厂家建议方案进行吊运 吊运过程中应采取防碰措施 Lifting the engine accordingly and keep away from any collision during lifting 5 3 4 发电机吊入舱后 根据图纸位置 将发电机定好位 用顶推工装顶起发 电机 根据发电机位置定位焊接垫块 Jack up the engine above the foundation with jacking tool after position of generator according to drawings Then position the welding plates below the bonded rubber rails by screwing in the hexagon bolts by two thread turns 5 3 5 根据图纸要求烧焊焊接垫块 为了保护弹性垫的橡皮 在烧焊时要保证 焊接垫块与弹性脚之间有 5mm 左右的间隙 Weld welding plates onto the foundation keep a distance of 5mm between welding plates and bonded rubber rails to protect the rubber from heat 5 3 6 焊接垫块烧焊完成后 将发电机水平放下 直至焊接垫块的最高点与发 电机的弹性脚相接触 焊接垫块与弹性脚之间有间隙的 通过塞薄垫片来进行 调整 调整时将焊接垫块上的螺栓拆除 然后在焊接垫块与弹性脚之间塞入薄 垫片 垫片厚度为 0 5mm 1 0mm 2 0mm 调整结束后 将发电机放下 拆除顶 升工装 使发电机完全坐落在底座上 Lower the generator evenly until the highest welding plate touches the according bonded rubber rail Remove hexagon bolts from the welding plates Fit shims between welding plates and bonded rubber rails where necessary to fill the gaps the shims thickness can be 0 5mm 1 0mm or 2 0mm Lower the generator more after all gaps adjusted until it set on the foundation wholly then dismantle the jacking tool 5 3 7 48 小时后测量各个弹性垫的压缩量 将测量报告发送给厂家确认 根据 厂家的计算报告 对不满足要求的点进行修正 The exact compress clearance of the hold downs is to be measured and sent to vendor to confirm after setting of elastic elements About 48 hours after installation of the engine Adjust the points which are not according to the vendor s calculation report 5 3 8 在确认所有弹性脚的压缩量符合要求后 将焊接垫块与弹性脚用螺栓安 装好 并依次上好扭力 扭力值为 180N M Screw the bonded rubber rails on the welding plates with hexagon bolts and washers after all elastic elements compress clearance are according to requirement Torque all bolts with 150 N M according to drawings 5 5 止推块的安装 end stoppers Installation 5 5 1 为了防止发电机的过幅振动 在发电机四角处分别安装 X 方向与 Y 方向 的止推块 To avoid over swing of the engine when running two stoppers should be installed in X and Y direction at each corner of the base 5 5 2 按照安装图纸要求 定位止推块 定位时要确保发电机处于自由状态 顶 升工装及吊装工具要拆除 然后根据要求 焊接止推块 Position the end stoppers and weld them to the top plate according to drawings Be sure that the generator is free on the bonded rubber rails jacking tools and lifting devices removed 6 检验 Verify 6 1 基座检验 Foundation installation quality verify 6 1 1 质检部门对发电机的位置定位状态进行检查 Verify the orientation of