水发连轴及调整施工技术措施

三峡地下电站机电设备安装与调试工程合同编号：TGP/ME-UG/JA-200901HEC水发大轴连接与调整施工技术措施编制：审核：审批：葛洲坝集团三峡地下电站机电安装工程施工项目部二〇一〇年十月三峡地下电站机电设备安装与调试工程HEC水发大轴连接与调整施工技术措施葛洲坝集团三峡地下电站机电设备安装工程施工项目部第１页共8页１目录1.概述·············································································································································11.1主要结构······························································································································11.2主要内容······························································································································11.3编制依据······························································································································12.施工工艺流程·····························································································································13.施工准备·····································································································································14.施工措施···································································································································44.1水轮机大轴调整··················································································································44.2水发大轴临时连接··············································································································54.3水发大轴整体调整··············································································································55.质量检查与验收·························································································································65.1质量标准······························································································································65.2质量控制措施······················································································································66.安全技术措施·····························································································································66.1安全技术细节说明··············································································································67.文明施工与环境保护·················································································································78.进度计划与劳动力投入············································································································7三峡地下电站机电设备安装与调试工程HEC水发大轴连接与调整施工技术措施葛洲坝集团三峡地下电站机电设备安装工程施工项目部第1页共8页11.概述鉴于水发大轴采用销套定位的结构特殊性，并且涉及水发大轴同镗销套孔的工艺过程，水发大轴连接采用坑外施工的方式。此方式既避免了坑内联轴施工环境对其产生的干扰性，又节约了机组主体安装工期。1.1主要结构水发大轴均为中空结构。主轴长5900mm，最大外径Ø4000mm，内径Ø3765mm。其下端采用20颗螺栓与转轮连接，上端采用30颗M110X6螺栓与发电机下端轴连接。发电机大轴长5311mm，轴身外径Ø3100mm，上、下法兰端面外径分别为Ø3329和Ø4000mm，轴身内径Ø2650mm。水发大轴分别重约108.5T和110T。为防止大轴运输及长期存放产生过大形变，自制造厂发货前均在大轴内腔装设支撑工具，待工地施工时拆除。1.2主要内容水发大轴坑外连接在机组段吊物孔内进行。其主要内容包括：清扫水发大轴及其连接附件；检查大轴几何尺寸及连接面加工情况，不允许突出；吊装水轮机轴就位并作调整；吊装发电机主轴与水轮机大轴连接并作整体调整；调整合格后同镗联轴销套孔；安装销套及连轴螺栓，测量验收大轴各考核数据合格后，安装吊具准备吊装。1.3编制依据Z1a000166主轴Z1a000169主轴联轴装配Z1b000663转轴0EA.412.578三峡地下水电站水轮发电机安装说明书TGPS.JZ三峡水轮发电机机组安装规程2.施工工艺流程水发连轴及加工工艺流程见图2-1。3.施工准备1）工程施工前，根据厂家技术文件和相关的技术规范，编制详细施工措施并提交审查，获批准后才能施工。2）准备本工序必要的材料、工装与工器具，包括设备清扫消耗性材料、检查、安装、调整工具。制作求心梁和吊装销套的旋转支架。检查吊具螺栓外观锈蚀和磨损情况，检查焊缝、螺栓螺纹部分是否存在裂纹，必要时做吊具螺栓拉伸试验。施工工器具与工装见表3-1。3）对于机组段吊物孔67层设计有竖井位置，布置σ60mm大小为1.5mX1.5m的钢板封住井口。此钢板封堵坑洞的同时作为大轴调整支墩的基础。三峡地下电站机电设备安装与调试工程HEC水发大轴连接与调整施工技术措施葛洲坝集团三峡地下电站机电设备安装工程施工项目部第2页共8页2图2-1水发连轴及加工工艺流程4）按水轮机大轴下法兰断面直径，在67层机组段吊物孔位置均布4个高1950mm的支墩，其顶面放置4对楔子板并调平，待大轴落下前在楔子板与主轴法兰面间塞入铜皮。另外，轴线方向再布置2个高1.2m的支墩，以放置100T液压千斤顶调整大轴水平。工装布置与测量见图3-1。5）拆除大轴外包装及内支撑，仔细清洗法兰面和连接螺栓孔，清扫连轴螺栓、螺母、销套等附件，检查轴身及其附件外观有无缺陷，否则报请厂家和监理工程师，商议处理事宜。6）用深度尺和刀口平尺检查连轴法兰面相关几何尺寸和平面情况，要求止口深度满足图纸与安装要求，且法兰面应无高点、毛刺。7）在连轴法兰盘处找出厂家已标记好的水发大轴连接法兰面高低点（“H”、“L”点），并且做出明显标记。8）待大轴调整时，施工场地设置充足照明。水轮机轴就位调整大轴清扫吊具安装并立轴水发临时连轴大轴测量、调整合格水发大轴同镗销套孔搭设测量平台安装销套及连轴螺栓螺栓拉伸并测量拉伸值整体验收分段吊装三峡地下电站机电设备安装与调试工程HEC水发大轴连接与调整施工技术措施葛洲坝集团三峡地下电站机电设备安装工程施工项目部第3页共8页3图3-1水发大轴连接工装布置图三峡地下电站机电设备安装与调试工程HEC水发大轴连接与调整施工技术措施葛洲坝集团三峡地下电站机电设备安装工程施工项目部第4页共8页4表3-1水发连轴专用工器具与工装序号名称数量备注1大轴吊具1套立轴、吊装2刀口平尺1把3深度尺1把4水准仪1台5内径千分尺1套6耳机、电池1套含导线7角磨机1台8电焊机（含焊把线）1套9气动泵1台10M110x6拉伸器2套含油管11100T液压千斤顶2台12支墩4个13旋转架1个销套吊装142T导链1副15楔子板4对4.施工措施4.1水轮机大轴调整1)利用桥机安装大轴翻身工具及吊具，为保证各吊具螺栓受力均匀，其螺母应以相当压力把紧。在安装吊具销钉时，为便于销钉顺利安装，其周身涂抹润滑脂，同时可借助导链或液压千斤顶。2）缓慢起升桥机主钩将大轴竖立，当翻身工具即将离开地面时，停止主钩起升。松开翻身工具组合螺栓螺母。3）再次缓慢升起桥机主钩提起大轴离开地面至合适高度，走动桥机大车，将其吊至指定机组段吊物孔上方，落下桥机主钩，将水轮机主轴放置于先前摆放就位的支墩上，楔子板与大轴法兰间垫以铜皮保护法兰。4）拆除水轮机主轴吊具，并在大轴内膛搭设测量平台。5）利用“Cayere”方法测量法兰面水平，并根据所测得的数据，计算各相邻测点之间的高差，绘制各测量点高差分布曲线及拟和正弦曲线，从而确定法兰面实际水平。并通过下端支撑千斤顶调整其水平合格，要求0.02mm/m。6）用在主轴内膛挂钢琴线的方法测量大轴内止口4个轴线方向半径，计算大轴垂直度。7）项5）、6）调整完毕并经检验合格后，按照图纸要求安装主轴内中心补气管支架三峡地下电站机电设备安装与调试工程HEC水发大轴连接与调整施工技术措施葛洲坝集团三峡地下电站机电设备安装工程施工项目部第5页共8页5等附件。主轴调整的详细施工技术措施另见《主轴与水轮机连接及调整施工技术措施》4.2水发大轴临时连接1）利用厂家提供的发电机大轴翻身工具与吊具，将发电机下端轴竖立，松开下端吊具螺栓，卸下吊具。用刀口平尺检查下法兰平面情况，用油石和砂纸处理高点和毛刺，并用沾酒精的干净白布擦拭干净。2）将发电机大轴吊至水轮机大轴上方，点动桥机对正螺栓孔，并通过软带用人力旋转发电机下端轴，使其高点对应水轮机低点，慢速落钩。3)当发电机下端轴下落至距水轮机主轴上法兰面150mm高度时停止落钩，再次用干净白布沾酒精擦拭法兰面，并且在大轴止口位置涂上凡士林等润滑脂。4)将发电机下端轴落在水轮机轴上，通过连轴螺栓孔错牙情况，初步判断两轴相互位置，通过起落桥机再对发电机下端轴做旋转、位移调整。5)均匀对称的临时安装6根连轴螺栓，并用液压工具按设计压力对称拧紧。用塞尺检查组合面配合情况，要求无间隙。6)松开吊具螺栓，