卧式水轮发电机组安装工艺.doc

卧式水轮发电机组安装工艺
Horizontal hydro-generating unit installation process
卧式水轮发电机组的安装分为预埋部份（管路）、导水机构（主机）、轴承部份、基础部份、发电机部份、辅助设备。
The installation of the horizontal hydro-generating unit is divided into embedded part(piping), distributor ( main unit), bearing part, foundation part, generator part, auxiliary part.
一、 水轮发电机组埋件预埋
Hydro-generating unit embedded part
根据工程进度的要求与土建配合对所需的油、气、水管路进行预埋，对所有埋设的管路的管口进行封堵，防止异物进入。
Embed the needed oil, gas, water piping according to the project process and civil engineering. Plug all the pipe orifices of the piping embedded to keep foreign matters from getting into.
二、 测点放样
Measuring point layout
根据按甲方提供的高程按设计图纸来确定机组的三维坐标，方法可用水准仪或钢琴线连通器原理来保证机组中心、高程与X、Y坐标。
According to the height provided by owner and the design drawing to determine the unit three-dimension coordinate, and the unit center, height and X、Y coordinate can be guaranteed with balance level or the law of piano line connected vessels.
三、 进水部份的安装
The installation of the water inlet part
把阀门、伸缩节和进水弯管依次吊入预留的机坑内，用法兰连接，即阀门与伸缩节连接，伸缩节与进水弯管连接，并校正前后左右位置和安装高程，下部加临时支撑固定，用水准仪吊线法校正进水弯管法兰面高度和中心线位置，主要是校正进水弯管的水平、垂直度和中心高。
Successively lift valve, expansion joint, water inlet elbow into the reserved pit. Use flange to connect valve and expansion joint, expansion joint and water inlet elbow, then adjust the position and installation height, temporary supports are fixed at the bottom. Balance level plumbing method is adopted to check the water inlet elbow flange surface height and center line position, mainly to check the level, verticality and center height.
蝶阀在没安装凑合节前做好蝶阀静态的全开、全关调整工作，并检查在关闭状态的密封情况，在全开时阀门是否在中间位置，必要时给予适当的调整。
Before butterfly valve installed with the expansion joint, carry out the all open, all closed adjustment work at the static state, check the seal situation at the closed state, check whether valve is in the middle position at the all open state, then adjust if necessary.
四、 导水机构的安装（蜗壳）
The installation of distribution(spiral casing)
金属蜗壳的安装是卧轴混流式水轮机安装中的一个重要环节，由于导水机构是整机出厂，所以可以整体同时安装。将蜗壳吊装就位后，蜗壳进水口与进水法兰面对好，加石棉橡胶垫套上螺栓拧紧，并穿上地脚螺栓，加临时支撑，为了保证蜗壳的位置正确必须做到以下三点：（1）蜗壳整体中心高程（2）蜗壳整体水平（3）蜗壳整体X、Y垂直度。
The metallic spiral casing installation is the important part during horizontal Francis turbine installation. Install the distributor integrally, since distributor is out of factory in one piece. When the spiral casing is lifted into position, check spiral casing water inlet and water inlet flange face, pad the asbestos rubber gasket and tighten the bolts, fix with foundational bolt, use temporary support. In order to ensure the accuracy of the spiral casing position, the following three points should be fulfilled: One, the unity center height of the spiral casing. Two: spiral casing unity level. Three: spiral casing unity X、Y verticality.
两台蜗壳就位后将采用橡胶水平器、钢琴线、框式水平仪吊线法等工艺，使精度达到优良标准。同时检查导水机构、导水叶的开口，立面间隙、端面间隙，做好静态手动开关机的调整，运动时无卡阻现象，并加以调整，完成上述工作后，点焊牢固，准备二期混凝土浇灌。
When the two spiral casings are put into position, use rubber level device, piano line, frame type level suspension method to make the accuracy meet the excellent standard. Check the distributor, the opening of the guide vane, vertical face gap, end face gap, adjust the manual start and shutdown at the static state, non- obstruction in operation. After the above adjustment, spot-weld tightly, and prepare the stage 2 concrete placing.
五、 基础底板的埋设与调整
The embedment and adjustment of the foundational base plate
根据两台导水机构中心以及机组X、Y十字线基准点来确定基础板位置，调整高程、水平，用垫片、楔子板来保证。
Determine the foundational plate position as the center of the two distributors and the unit X、Y reticle benchmark, adjust the height and level, use gaskets, wedge board to ensure.
以转轮室中心为基准，来定位定子基础板中心、高程以及X、Y坐标。方法为基础底板中心线与钢琴线重合，用角尺测量基础板与钢琴线的高程，要求比设计值略低0·5~1mm，用调整铁调整达到要求后，用电焊牢固基础板，固定地脚螺栓，拧上螺母。再按上述方法复查中心、高程、水平有无变化，必要时再作调整，直到符合要求。
Consider the benchmark as the runner room to locate the state foundation plate center, height and X、Y coordinate. The method is coincide the foundation base plate center line and piano line, measure the height of the foundation plate and piano line with angle rule, the value should be lower 0·5~1mm than design value. After adjusting with adjustable iron to meet the requirement weld the foundation plate with electrical welding, fix the foundation bolt, fix the nut. Recheck the center, height and level as above method, adjust if necessary.
六、 轴承座的安装
The installation of the bearing seat
将所有轴承座吊放在基础板上并在组合面上按图纸规定加金属垫片及绝缘板，轴承座就位后进行调整，用水平仪、钢琴线调整检查，调整轴承使轴承与机组中心、水平、高程相对应。调整后紧固基础螺栓，以防移位。
Lift the bearing seat on the foundation plate, and pad with the metal spacer and insulation plate on the combination face. Adjust when bearing seat is in the position, check with level device and piano line. Adjust the bearing until it matches the unit center, level and height. By preliminary adjustment, fix the foundation bolt to prevent movement.
七、定子和转子的安装
The installation of the stator and rotor
1、将定子底座用方木垫高，并拆除发电机轴伸端的轴承座。
Raise the state bottom with square timber, then dismount the bearing seat on the generator shaft extension end.
2、将转子水平吊起，利用行车和手拉葫芦穿入定子，待转子法兰穿过定子后在转子两端轴头垫上方木。
Horizontally lift the rotor, penetrate the stator by travelling crane and chain block, and pad with square timber at two ends of the rotor after rotor flange penetrating into stator.
3、解下吊蝇，改吊转子两端轴头，穿入定子内孔，然后恢复拆去的轴承座。
Untie the lifting rope, lift two ends shaft heads of the rotor penetrate the stator inter hole, then lift into the bearing seat dismounted.
4、在定子上悬挂链式葫芦，将定转子同时吊起，起吊时在空气隙中塞入木条，防止定、转子相互碰擦，起吊后拆除方木，定子落于基架上，转子落于轴承座上。
Hang chain block on the stator, lift the stator and rotor at the same time. During lifting, insert wood slats in the air gaps to prevent the scraping of the stator and rotor. After the lifting, dismount the square timber, place the stator on the bracket, and put the rotor on the bearing seat.
八、轴瓦精刮和转轮间隙检查
Bearing pad fine scratching and runner gap check
为了使轴瓦与轴颈接触均匀，需要进行轴瓦的研刮工作，刮瓦工作是与转轮调整结合进行的，精刮工作需要完成下列工作：（1）检查和调整主轴的水平度和高度，当不符合要求时可用补偿法在轴承底下进行必要的调整，直至符合要求。（2）检查转轮室四周间隙，轴向位置，达到要求后将轴承座固定。（3）转动主轴，精刮轴瓦，使轴瓦与主轴接触点达到要求为止。
In order to make the bearing pad uniformly contact the bearing journal, bearing pad should be scraped. The pad scraping should be combined with runner adjustment, and the fine scraping should do following work:1. check and adjust the levelness and height of the main shaft, if not meet the requirement, compensation method should be adopted to adjust the bearing bottom until meeting the requirement. 2. check the gaps around the runner room, axial direction position, then fix the bearing seat until meeting the requirement. 3. rotate the main shaft, fine scrape the bearing pad, making the bearing pad and main shaft contact point meet the requirement.
九、整机复装
Whole machine fit back
卧式水轮发电机轴线的测量及调整是安装工作很重要的一个环节，将关系到机组振动、轴承温度。因此轴线调整的准确性，将直接影响机组转动部分是否在一条轴线上旋转。通过盘车测量数据进行调整，根据各轴线位置摆度值，放出轴瓦间隙。
The measurement and adjustment of the horizontal hydro generator axial line is the important part in the installation work, which is related to the unit vibration and bearing temperature. And the accuracy of the axial line adjustment is directly related to the unit rotation parts rotating in an axial line. Adjust according to the turning measurement data, and as the axial line throw value to adjust the bearing pad gap.
用桥机挂装尾水弯管、在水泥干燥期内进行所有水轮机的辅助设备复装、静态调试，包括对调速器的清洗、静态开关机时间的调整，紧急关机的调整，蝶阀在无水状态下开关机时间的调整。各方面检查均无问题，可交土建进行二期混凝土浇灌。
Hang the tail water elbow with bridge crane, fit back all the turbine auxiliary, static test, including the cleaning of the governor, the adjustment of the static unit start and shutdown, the adjustment of the emergency shutdown, the adjustment of the start and shutdown time when butterfly in the no-water state. Civil engineering starts the stage 2 concrete placing if no problems.十、精确调整
Accurate adjustment
由于浇灌混凝土时可能使机组产生部份位移，所以保养期满后应进行一次精调。
Part movement may occur due to concrete placing, so an accurate adjustment should be made after maintenance period.
拆下尾水弯管、转轮，打开各轴承上盖，检查主轴水平蜗壳垂直度、转轮四周各迷宫间隙，用红丹粉检查轴瓦接触点是否与原记录有变化，并进行全面调整，达到优良要求后全部复装待机组充水，做好最后静动态的机电联调工作。
Dismount the tail water elbow, runner, open all bearing upper covers, check main shaft horizontal spiral casing verticality, labyrinth gaps around the runners, check the bearing pad contact points with red lead powder, and carry out an overall adjustment. After meeting the requirement, fix back, and do electrical and mechanical alignment work at the static state when the unit filled with water.