dfc-zwi-1045639_dfb001861_小型塔筒电缆在机舱内的预安装连接

1、小型塔筒电缆在机舱内的预安装连接DFC- ZWI-1045639ECN：DFB0018612016 年 12 月W6000 风力发电机组 DFC-ZWI-1045639小型塔筒电缆在机舱内的预安装连接 共 1 页 第 1 页 编 制 ： 黄 超 日 期 ： 2017.1.11 校 对 ： 晋 秋 明 日 期 ： 2017.1.11 审 核 ： 陈 健 日 期 ： 2017.1.11 W6000 风力发电机组 DFC-ZWI-1045639小型塔筒电缆在机舱内的预安装连接 共 1 页 第 1 页 更改页 ECN更改位置 更改内容描述 签字 日期 目录1234修订历史2引言3参考文件4预安装带连接

2、器和电缆的基础板54.1 在基础板上安装连接器54.2 安装偏航安全停止开关电缆6安装带信号线的基础板7安装基础板7电缆路径7将电缆与控制柜接通86连接接地电缆91 / 10操作手册： 小型塔筒电缆在机舱内的预安装连接文件编号：ZWI 1045639作者：Henrik Lund stergaard版次：1发电机组：D6检查表参见：ZCH 1046970ECN 编号：DFB001861 日期：2015-07-07修订历史12 / 10版次 日期 ECN 编号 变更描述 编制 12015-07-07200891新文件，首次官方发布 Henrik Lund stergaard2

3、引 言目的本操作手册描述了使用基础板和小电缆插头，从塔筒底部向 机舱预安装小型电缆的方法 操作时必须填写相应的检查表，以确保是按照操作说明实施 的。 要求的能力水平技术员必须满足以下涉及文件的能力要求以及特殊作业所要 求的额外证书。 Pro 12.19：“上海电气风电技术人员能力框架”Pro 12.12：“承包商技术人员能力框架”个人安全根据健康与安全基本准则（SI 545781），所有人员必须穿戴个人防护装备。 所有的操作必须根据健康与安全基本准则（SI 545781）来进行。 如果超过上海电气安全要求的范围（特殊项目），必须执行补充的本地和项目特殊规则。 特殊作业的已经由危险注意事项的象形

4、图阐述说明。整个操作中会涉及到的将在操作指南的顶部作出说明。作业时的特殊部分所包含的危险将在危险出现时进行说明。 风险评估所有操作必须根据风险评估来实施，参见第 3 章参考文件“风险评估”。 开始作业前，所有人员必须阅读列出的风险评估。电气安全电气作业必须根据PRO 18914：“有害能源的控制”来进行。只有上海电气相关人员和有电气相关的合格证书以及上海电气授权人员能够进行安装、检查、测试和修理电气装置和设备。 3 / 103 参考文件除了已有的文件，还需要以下文件：安全：SI 545781“健康与安全基本准则”。ZWI 1040332 “发电机组特殊安全说明”风险评估RAZWI 104563

5、9：小型塔筒电缆在机舱内的预安装风险评估。 检查表ZCH 1045970：小型塔筒电缆在机舱内的预安装检查表能力要求Pro 12.19：“上海电气风电技术人员能力框架”Pro 12.12：“承包商技术人员能力框架”螺栓力矩值参考 ZWI 517905“螺栓紧固扭矩与张力”。材料安全数据表根据化学制品管理，PRO 18811“化学制品管理进程”，参考上海电气 内部网的 SDS 数据基础，或联系特殊材料/物质供应商。 4 / 10预安装带连接器和电缆的基础板45 / 104.1 在基础板上安装连接器 以下信号线必须安装在基架 AA3 柜和机舱楼梯的插头之间。 -K1-AA3-W5-W56： 3G1

6、.5mm2LIHCH 塔筒内偏航安全停止开关 -K1-AA3-W5-W79： 12G1.5 mm2LIHCH 230V UPS 供 电 至 AA26-K1-AA3-W5-W89： 25G1 mm2LIHCH 24V 至 AA26 的互联信号线 图 1A：电缆-K1-AA3-W5-W56 的插座外壳B：电缆-K1-AA3-W5-W79 的插座外壳C：电缆-K1-AA3-W5-W89 的插座外壳 1. 按图中所示，用电缆密封盖板在基础板上安装连接器外壳。 6 / 104.2 安装偏航安全停止开关电缆 图 2图 31. 割开 10cm 长的电缆外部绝缘，留下 2cm 电缆屏蔽层。 2. 在电缆屏蔽层

7、上安装热缩管。 3. 根据电气回路图纸，在外壳内安装有内置连接其的 24V 信号线K1-AA2-W5-W894. 放置支架，并根据电气回路图纸放入连接器外壳内。 5. 装配连接器，用小的电缆扎带将电缆编号标签安装在电缆上。 4.5 检查插头外形配置 图 81. 将测试用的连接器与基础板上的连接器连接，以此来确定连接器已被正确安装。 安装带信号线的基础板57 / 105.1 安装基础板 图 9A：边缘保护。 1. 在机舱楼梯的左手边安装基础板。 2. 在上缘安装边缘保护，已放置电缆被锐利边缘割伤。 5.2 电缆路径 图 10图 11A：急停按钮电缆B：AA3 柜旁的方形平板 3. 通过机舱楼梯左

8、手侧的电缆槽放置至机舱的信号线。 4. 沿着急停按钮的电缆放置电缆，并用小的电缆扎带进行固定。 8 / 10图 12图 13A：移走方形平台后A：AA3 柜下的电缆槽 5. 为了将电缆放进电缆槽，临时将 AA3 柜旁的方形平板拆除。 6. 通过电缆槽，在基架左侧的 AA3 柜下方放置电缆。 5.3 将电缆与控制柜接通 电气危险 根据电路图纸中的说明，将柜子断电，并测量检查零能量状 态。 图 14 A：电缆入口 B：电缆编号标签C：接地夹 1. 通过柜下方的电缆入口，将信号线放置进柜内。 2. 用小的电缆扎带安装电缆编号标签。 3. 用接地夹将电缆屏蔽与接地母排进行连接。 4. 根据电路图纸将电

9、缆进行端接。 连接接地电缆69 / 10图 15图 161. 在地线上安装电缆接头和热缩管。 2. 在插头的基础板上紧固地线。 3. 通过机舱楼梯左侧的电缆槽，放置从塔筒到机舱的地线。 图 17图 18A：接地电缆的电缆槽 1. 沿着电缆槽横穿机舱放置电缆。 2. 用电缆扎带将电缆固定在电缆槽上。 10 / 10图 19图 20A：接地线的安装点。B：机械偏航锁 3. 在左侧变流器前打开平台，接近接地线的安装点。 4. 沿着基架，将电缆放至在基架上的机械偏航锁旁安装点。 5. 为了合适的长度缩短电缆并安装电缆接头。 6. 用干净的布将安装点擦拭干净。 7. 将电缆接头固定在基架上。 Table

10、 ofContents1234Revision history2Introduction3Referenced documents4Premounting base plate with connectors and cables4.44.5Mounting connectors on baseplate5Mounting cable for yaw safety stop switch6Mounting cable for 230 V UPS supply to AA266Mounting cable for 24 V signals to AA267Verificati

11、on of plug configuration75Mounting base plate with signal cablesMounting baseplate8Routing cable8Connecting cables in control cabinet96Connecting grounding cables101 / 11Work Instruction:Premounting connnectors in nacelle for small tower cablesDocument no.:ZWI 1045639Author:Henrik Lund ste

12、rgaardVersion:1Turbine:D6Checklist reference:ZCH 1045970ECN No.:DFB001861Date:2015-07-071Revision history2 / 11VersionDateECN no.Change descriptionAuthor12015-07-07200891New document, first official release.Henrik Lund stergaard2IntroductionObject:This work instruction describes how to premount the

13、small cables with base plate and plugs which is used to connect the small cables from the bottom of the tower to the nacelle.The corresponding checklist must be filled in during the work to confirm that the work is carried out in accordance with the work instruction.Training level requiredTechnician

14、s must fulfill the training requirements given in the below mentioned documents as well as additional certifications if required by the specific task.Pro 12.19: “SEWPG Project Wind Technician Competency Framework”Pro 12.20: “Subcontractor Wind Technician Competency Framework”Personal safetyAll perso

15、nnel must wear personal protective equipment according to Basic Health and Safety Rules (SI 545781).All work must be carried out in accordance with Basic Health and Safety Rules (SI 545781).Supplementary local and project-specific regulations must be followed if they exceed SEWPG safety requirements

16、 (project specific).Task-specific hazards are illustrated by a pictogram together with a detailed description of the hazard and required actions. Hazards which apply to the entire duration of a work task is described in the top of the section of the work instruction. Hazards which apply to a specifi

17、c part a work task is described when the hazard occurs.Risk AssessmentAll work must be carried out in accordance with the Risk Assessments listed under chapter 3. Referenced documents: Risk Assessments.All personnel must read the listed Risk Assessments prior to starting the work.Electrical safetyEl

18、ectrical work should be carried out in accordance with PRO 18914: “Control of Hazardous Energies”.Only personnel instructed by SEWPG and with a valid relevant electrical safety certificate and with authorization from SEWPG Senior Authorized Person (SAP) are permitted to carry out installation, inspe

19、ction, testing, and repair of electrical installations and equipment.3 / 113Referenced documentsThe following documents are required in addition to the present documents:Safety:SI545781 “Basic Health and Safety Rules”.ZWI1040332 “Turbine-specific safetyinstructions”.Risk assessment:RA_ZWI 1045639: R

20、isk assessment for: Premounting connnectors in nacelle for small tower cablesChecklist:ZCH 1045970: Checklist for: Premounting connnectors in nacelle for small tower cablesTraining requirements:Pro 12.19: “SEWPG Project Wind Technician CompetencyFramework” Pro 12.20: “Subcontractor Technician Compet

21、ency Framework”Bolt torque values:Refer to ZWI517095 “Bolt Tightening torque and tension”.Safety data sheets:Refer to SDS database on Shanghai Electric Wind Power Group Co.,Ltd. Intranet according to requirements in Chemical Management, PRO 18811- “Chemical Management Procedure”, or contact the supp

22、lier of the specific material/substance.4 / 115 / 114.1Mounting connectors onbaseplateFollowing signal cables must be routed between the AA3 cabinet in the bedframe and plugs at the nacelle stairs:-K1-AA3-W5-W56:3G1.5 mm2 LIHCHYaw safety stop switch in tower-K1-AA3-W5-W79:12G1.5 mm2 LIHCH230V UPS su

23、pply to AA26-K1-AA3-W5-W89:25G1 mm2 LIHCH24V signal interconnection to AA26BAFigure 1A: Plug housing for cable -K1-AA3-W5-W56 B: Plug housing for cable -K1-AA3-W5-W79 C: Plug housing for cable -K1-AA3-W5-W891.Mount the connector housings on the baseplate with the cable glands positioned as illustrat

24、ed in the picture4Premounting base plate with connectors andcables6 / 114.2Mounting cable for yaw safety stop switchFigure 2Figure 31. Strip 8 - 10 cm of the outer cable insulation and leave 2 cm of the cable shield.2. Fit heat shrink tubing at the cable shield.3. Mount the cable K1-AA3-W5-W56 for t

25、he yaw safety stop to the FEMALE connector according to the electrical diagram.4. Fit cable ID tag on the cable with small cable ties.4.3Mounting cable for 230 V UPS supply to AA26Figure 4Figure 5A: Connector for cable K1-AA3-W5-W791. Strip 10 cm of the outer cable insulation and leave 2 cm of the c

26、able shield.2. Fit terminal sleeves on the cable cores and heat shrink tubing at the cable shield.3. Mount the cable K1-AA3-W5-W79 for the 230V UPS supply to the terminals of the FEMALE insert according to the electrical circuit diagrams.4. Position the insert in the housing according to the electri

27、cal circuit diagrams.5. Assemble the plug and fit cable ID tag on the cable with small cable ties.7 / 114.4Mounting cable for 24 V signals to AA26Electrical hazardThe cable is mounted with modular inserts. The male and female inserts must be positioned exactly as instructed in order to avoid risk of

28、 live terminal pins when the plugs are disconnected.AFigure 6Figure 7A: Connector for cable K1-AA3-W5-W891. Strip 10 cm of the outer cable insulation and leave 2 cm of the cable shield.2. Fit heat shrink tubing at the cable shield.3. Mount the cable K1-AA3-W5-W89 for the 24V signals with connector i

29、nserts in the housing according to the electrical circuit diagrams.4. Place the frame and inserts in the connector housing according to the electrical circuit diagam.5. Assemble the connector and fit cable ID tag on the cable with small cable ties.4.5Verification of plugconfigurationFigure 81.Connec

30、t test connectors to the connectors on the baseplate to verify that the connectors has been assembled correctly.5Mounting base plate with signal cables8 / 115.1Mounting baseplateFigure 9A: Edge protection.1. Mount the base plate on the left-hand side of the stairs to the nacelle.2. Mount edge protec

31、tion on the upper edge to protect the cables against sharp edges.5.2Routing cableBFigure 10Figure 11A: Emergency stop button cablesB: Square platform next to AA3 cabinet.3. Route the signal cables to the nacelle via the cable tray on the left-hand side of the nacelle stairs.4. Position the cable alo

32、ng the cables for the emergency stop pushbutton and fasten it with small cable ties9 / 11AFigure 12Figure 13A: Square platform removed.A: Cable trays below AA3 cabinet.5. Dismantle the square platform next to theAA3 cabinet temporarily to access the cable tray.6. Route the cable further below the AA

33、3 cabinet in the left-hand side of the bed frame via the cable trays.5.3Connecting cables in control cabinetElectrical hazardDe-energize the cabinet and prove zero-energy state by measurement according to the instructions in the circuit diagram.CBAFigure 14A: Cable inletsB: Cable ID label. C: Earthing Clamp.1. Route the signal cables into the control part of the AA3 cabinet via the cable inlets in the bottom of the cabinet2. Fit th