懸臂式斗輪堆取料機安裝技術條件及調試、試驗規(guī)程

1、第一篇概述Chapter 1:Ge neral In troduct ionDQ1200/2500.40懸臂式斗輪堆取料機是由長春發(fā)電設備總廠為越南沿海一期 火力發(fā)電廠項目開發(fā)、設計、制造的一種大型、連續(xù)、高效的散狀、粒狀物料堆取 作業(yè)的設備。DQ1200/2500.40 Boom type bucket wheel stacker reclaimer (BWSR is a kind of large, con ti nu ous and efficie nt bulk cargo stack ing & reclai ming equipme nt, developed/ desig

2、 ned and manu factured by Chan gchu n Gen erati ng Equipme nt Co., Ltd, China for DUYEN HAI 1 THERMAL POWER PLANT Project.第一節(jié)設備簡介Section 1 Brief In troduction of the equipme nt 越南沿海一期火力發(fā)電廠項目共二臺斗輪堆取料機，為整體俯仰,頭部分流固定單尾車。詳見總圖(圖號DQ9721.0ST。Two sets Boom Bucket Wheel Stacker Reclaimer will be supplied by C

3、GE for DUYEN HAI 1 THERMAL POWER PLANT Project, the luffi ng of each equipme nt is in tegral luffi ng, and the si ngle tripper car is coal flow bran chi ng. Details refer to general drawi ng (Drawi ng No: DQ9721.0ST.斗輪堆取料機由斗輪機構、上部金屬結構、懸臂膠帶機、主機梯子平臺、俯仰 裝置及系統(tǒng)、行走機構、門座、中部料斗、緩沖托架、回轉機構、集中潤滑裝置、 限位裝置、檢測裝置、尾車

4、、尾車梯子平臺、電氣室、電氣系統(tǒng)、司機室及支架、 廠牌、配重組、灑水裝置、動力電纜卷筒裝置、控制電纜卷筒裝置、水纜卷筒、轉 盤、支承鉸座、基礎布置及載荷等組成；司機室安裝在門柱下部；裝有斗輪機構、懸 臂膠帶機、司機室、配重組等變幅部分的上部金屬結構圍繞變幅鉸點變幅；尾車上裝有動力電纜卷筒、控制電纜卷筒、水纜卷筒、電氣室及灑水系統(tǒng)的水源裝置。Bucket Wheel Stacker Reclaimer con sists of bucket-wheel mecha ni sm, super steelstructure, boom con veyor, walkway/access stairs

5、 and platforms of the mai n mach ine, luffing unit and system, long travel, portal, centre chute, buffer bracket, slew un it, cen tral lubricati on system, limited switches, detector, tripper car, walkway/access stairs and platforms of tripper car, electric room and electrical system, operator'

6、s cab in andn ameplate, coun terweight assembly, dust suppressi on system, power cable reel drum, con trol cable reel drum, water cable reel drum, slew deck, support ing pivot block, foun dati on al layout and load etc. Operator' s cab in is in stalled on the upper part of thepyl on. The super s

7、teel structure on which bucket-wheel mecha ni sm, boom conv eyor, operator ' s cab in, coun terweight etc. luffi ng parts are in stalled will be luffing around the luffing pivot point. Power cable reel, control cable reel drum, water cable reel drum, electric room and water source device of dust

8、 suppressi on system are in stalled on the tripper car.第二節(jié)工作原理Secti on 2: Worki ng Prin ciple本設備能夠采用手動、手動聯(lián)鎖、半自動進行堆料和取料作業(yè)。This equipme nt can select to use manu al, manual in terlock ing as well as semiautomatic stacking and reclaiming operation.堆料作業(yè)時，中部料斗分流板處于堆料狀態(tài)，系統(tǒng)膠帶機送來的物料經尾車（系統(tǒng) 膠帶機、尾車頭部落料斗轉運到中部料斗

9、，再輸送到懸臂膠帶機上，然后拋向儲煤 場。臂架的上仰和下俯可實現(xiàn)高、低位的堆料；臂架回轉實現(xiàn)左右料場及料場寬度 的堆料;大車行走則實現(xiàn)軌道長度方向的堆料。During stack ing operati on, the centre chute branching plate should be in stack ing state, the material tran sferred from yard-c onv eyor via tripper car con veyor, head hopper of the tripper car to centre chute and then f

10、eeding to boom conveyor, at last stacking onto stockpiles. Boom luffing can realize high & low level stacking; Bucket wheel boomslewi ng can reach left-right stockyard and stockyard width stack ing. Long Travel Drive can realize stack ing along the track len gth.取料作業(yè)是按分層取料的工藝進行的，必要時也可以進行斜坡取料。斗輪機

11、構 上的斗子挖取上來的煤卸至懸臂膠帶機上，再由懸臂膠帶機拋向中部料斗，經系統(tǒng)膠 帶機輸出。臂架的上仰和下俯可實現(xiàn)高、低位的取料；臂架回轉實現(xiàn)左右料場及料場寬度的取料;禁止只靠大車行走取料。Reclai ming operati on is carried out accord ing to layer reclai ming process as well as bevel reclai ming if n ecessary. Discharge the coal excavated and reclaimed by the hopper of the bucket wheel mecha n

12、ism to boom conv eyor- the n through boom conv eyor drop into centre chute, via yard con veyor tran sport out. Bucket wheel boom luffing can realize high & low level reclaimi ng; Bucket wheel boom slewi ng can reach left-right stockyard and stockyard width reclaiming; Forbidden to reclaim the ma

13、terial only depending on long travel mecha nism traveli ng.分流作業(yè)是系統(tǒng)膠帶機送來的煤經尾車膠帶機(系統(tǒng)膠帶機、尾車頭部落料斗， 一部分經分流料斗轉運到中部料斗卸至緩沖托架、經系統(tǒng)膠帶機輸出。另一部分輸 送到懸臂膠帶機上，然后拋向儲煤場。Branching operati on is such a process that the coals, from yard conv eyor, go through tripper car con veyor (yard conv eyor and tripper car head hoppe

14、r, part of coals go through branching hopper, tran sported to centre chute and discharged at buffer bracket, output by yard conv eyor; the other part of coals tran sported on boom conv eyor and discharged at stockpile.詳細結構說明請參見本機的使用、維護說明書。(Detailed structure and in structi on, refer to“ Operatio n a

15、nd maintenance in structio nof this mach ine.第三節(jié)設備的性能參數、基礎載荷Secti on 3: Performa nee Parameter and foun datio nal arran geme nt load of the Equipme nt1堆料能力Stack ing capacity2500t/h(額定 3000t/h(額定 2500 t/h (rated 3000t/h (rated 2取料能力Reclai ming capacity1200t/h(額定 1440t/h(額定 1200 t/h (rated 1440t/h(rat

16、ed 3堆取高度 Height of stack ing and reclai ming軌上13.5m、軌下1.5m13.5 m above rail and 1.5 m below rail4斗輪轉速Rpm. of the Bucket wheel6.86r/min 5膠帶速度Belt speed3.15m/s 6臂架回轉半徑Slewi ng radius of Bucket wheelboom40m 7回轉角度Slewing angle 110° 8回轉速度Slew ing speed0.0320.116r/min 9 走行速度Traveling speed工作速度 7.5m/m

17、in、調車速度 30m/min Working speed: 7.5 m/mi n,commissi oning speed: 30m/m in10總裝機容量Total in stalled capacity430kW12電源：Power Supply供電電壓6.6kV、供電頻率50Hz、供電方式為電纜卷筒 Power voltage: 6.6 kV, freque ncy: 50HzPower supply mode: cable reel drum13風壓：Wind pressure最大工作風壓250N/m2、最大非工作風壓 1850N/m2 Max. Worki ng wi nd pre

18、ssure: 250N/m2,Max. non- work ing wind pressure:1850N/m2.本安裝技術條件和調試、試驗規(guī)程適用于越南沿海一期火力發(fā)電廠項目 DQ1200/2500.40懸臂式斗輪堆取料機，并作為斗輪堆取料機安裝要求及安裝質量標 準和安裝完畢進行調試、試驗、驗收質量標準的依據。其中主要內容如下：各部件或設備的維修說明及維修質量標準；各部件或設備的調試、試驗規(guī)程；安裝要求及安 裝質量標準。 This “ In stallatio n Tech ni cal Con diti ons & Regulati ons on Commissio ning an

19、d Test ” will be applicable for DUYEN HAI 1 THERMAL POWER PLANT Project DQ1200/2500 40 Boom Bucket Wheel Stacker cum Reclaimer. It is also as a sta ndard for in stallati on requireme nts and in stallati on quality as well as a basis for quality of commissioning/ test, also as a standard for quality

20、acceptance after installation. Main contents will be as follows:-Maintenance in structio n and maintenance quality sta ndard of each comp onent or equipme nt-Regulati ons on commissi oning and test of each comp onent or equipme nt-Installation requirements and installation quality standard第二篇安裝技術條件C

21、hapter 2: Technical Conditions of Installation第一節(jié)總則Secti on 1: Gen eral Prin ciples1斗輪堆取料機必須按規(guī)定程序批準的圖樣及技術條件的要求進行安裝。Bucket wheel stacker reclaimer must be in stalled accordi ng to the draw ings approvedby specified program and tech ni cal requireme nts.2待安裝的零部件必須是檢驗合格的產品，外購機電產品應具有出廠合格證、使 用、維護說明書。The

22、spare parts and comp onents in stalled must be con formable products through in specti on, the bought-i n mecha ni cal and electrical products should have ex-work quality certificate and operation & maintenance specifications.3安裝中的消耗材料(焊條、緊固件、潤滑脂、機械油、液壓油等必須具有出 廠合格證，符合國家(或行業(yè)標準。The con sumable mat

23、erial of in stallatio n (such as electrodes, faste ners, lubricati ng grease, mach ine oil, and hydraulic oil etc must have an Ex-work certificate, and should be in accorda nee with n ati onal (or in dustry sta ndards.4安裝工作應由專業(yè)部門負責進行。In stalli ng work should be resp on sible by professi onal departm

24、e nts.第二節(jié)安裝前的準備工作Section 2: Preparations before installation1斗輪堆取料機各零部件及構架等運到現(xiàn)場卸車時應避免扭、彎、撞擊、腐蝕 等事故的發(fā)生，為此必須遵守以下規(guī)定：All parts and comp onents as well as frames of Bucket Wheel Stacker Reclaimer will avoid distortio n, bend , collisi on, corrosi on; etc accide nt, while uni oadi ng after they arrive at

25、the jobsite. Therefore, the following rules must be observed:1.1起吊時構件至少應捆扎兩處，捆扎處須有襯墊物，并捆扎在有筋板等加強節(jié)點 處一般應盡可能捆扎在構件的兩端，不宜捆扎在非節(jié)點部位或構件的外伸部。The comp onents must be lifted with being enl aced at least two points where there must be gaskets, and they should be enl aced at the stiffe ner no des of stiffe ner,

26、 no rmally, the comp onents should be enl aced at the two en ds, it is improper to enl ace them at places without no des or exte nsional part.1.2搬運時應將構件擱置在載重汽車或平板車上，禁止直接在地面上放滾拖移The comp onents should be placed on trucks or flatcars while tran sported. It is forbidde n to roll or pull them directly o

27、n the ground.1.3存放時應安置平穩(wěn)，用枕木墊實放平，枕木應對稱放置，地面也必須選擇結實 平整完好處，以防日久下沉以致構件變形。They should be stored on stati onary crossties, and the crossties should be placed in symmetry. The ground must be solid, smooth and in tact, thus avoid ing deform ing of the components due to ground falling as time passes.1.4零（部件

28、如需露天存放的，應遮蓋好，對存放日期長或露天存放的件安裝前應 檢查銹蝕情況，清除污漬，必要時重新涂油組裝，使各轉動部分靈活，并檢查各聯(lián)接部分 的牢固性。存放期間應定期保養(yǎng)，注意防潮、防銹和通風。If some parts and comp onents n eed be stored outdoor, they should be well covered. Those that will be stored for a long time or outdoor should be inspected their rust situati ons before in stallati on a

29、nd derust ing, and repa in ted and reassembled if n ecessaryto make sure smooth running of every rotati ng part. The fast ness of every lin ked part should be also in spected. During storage they should be maintained regularly, preve nted from moisture, rusting and ventilation.2安裝前應組織安裝人員認真熟悉圖樣，根據要求

30、詳細檢查部件的安裝尺寸，不 符合圖樣要求的需校正。It is necessary to organize personnel to read the drawings carefully, inspect the in stallati on dime nsion of all spare parts and comp onen ts, the parts which can not meet the requireme nts of draw ings should be modified.3按附錄A復核查驗斗輪堆取料機軌道精度。Recheck and in spect the rail a

31、ccuracy of Bucket Wheel Stacker Reclaimer accordi ng to appe ndix A.4安裝位置應選在錨定位置為宜(如在非錨定位置安裝，則應在車輪下塞進鐵 靴”以防大風刮跑。The installation position should be selected to anchoring point (if in non-anchoring point, wedge block assembly should be stuffed un der the wheel to avoid blow ing away by storm.第三節(jié)安裝Sec

32、tion 3: Installation1現(xiàn)場連接Conn ecti on on the jobsite1.1所有連接應根據圖樣及有關連接技術要求進行。All connections should be carried out accord ing to draw in gs a nd related tech ni cal requireme nts.1.2連接中不允許存在附加力，嚴禁強制裝配。It is unallowable to have additional force during connection; it is strictly prohibited to assemble

33、forcibly.1.3為減少高空作業(yè)量，應盡量在地面上連接。Conn ecti on should be done on the ground in order to reduce work high above the ground.1.4焊接連接要求Requireme nts for weldi ng connection安裝焊接工作應由合格焊工進行。Site welding should be completed by qualified welders.142重要構件的連接接口處應開坡口。The connection of the main comp onents should be

34、 made bevel.143焊接材料的型號、規(guī)格應符合設計圖樣及焊接工藝要求，一般Q235-A鋼制造的構件采用E4303焊條,16Mn制造的構件采用E5015焊條。異種材料構件之間的焊 接，一般按強度較強的金屬基體選用焊條。本機除平臺以外全部工地現(xiàn)場安裝焊條采用 E5015焊條。The type and specification of the welding material should be in accordance with thedesig n draw ings and requireme nts of weldi ng procedure. Normally, E4303 e

35、lectrodesapply to the comp onents made of Q235-A steel, E5015 electrodes apply to those madeof 16Mn steel. Weld ing betwee n differe nt material comp onen ts, electrode should usuallybe selected according to the metal with larger hardness. Except the platform, all welding electrodes used for site in

36、stallation of this equipment should adopt E5015 electrodes.144焊條使用前應根據使用說明書參照表1-1規(guī)定烘干。烘干的焊條應存放于在100150C保溫箱中，隨用隨取Electrode should be baked before being used accordi ng to refere nee of table 1-1 in the “ operat ing in struct ion” . The baked electrodes should be stored in a 100150thermal container on

37、 the jobsite for taking electrode for use at any time of welding表 11 Table 1-1焊條牌號Electrode brand烘干溫度Bak ing temperature烘干Bak ing timeE4303 150250C 2 小時 2 hoursE5015 350400C 23小時 23 hours烘干的焊條置于空氣中超過四小時應重新烘干，但烘干次數超過二次的焊條僅能作為次要件焊接使用。After the baked electrodes being placed in the open air for more tha

38、n 4 hours, they must be re-baked in the heating oven, Those electrodes rebaked more than twice can only be used as sec on dary weldi ng.所有焊縫焊前必須徹底清除邊緣（不小于10mm的水跡、油污、鐵銹、油 漆、氧化等雜物，直至露出金屬光澤。Edges of all weld ing seams (> 10mm must be clea ned completely e.g. water sta in.oil sta in, rust, paint and

39、oxides, etc. un til the surfaces expose the metallic gloss.147不準在非焊接部位上引弧和試電流，焊縫藥皮應清理干凈，焊瘤要鏟除。It is not permitted to strike the arc and test electric current on non-welding positi on ,flux on the weld ing seam should be removed and the weld bead ing shall be removed.148露天施焊時，凡遇雨、雪、大霧等特殊氣候，無安全措施不允許焊接

40、。If it rains, snows or fogs while welded outdoors, it is unallowable to weld without safety precauti ons.149焊縫檢查In spect ion for weld seama. 焊縫高度應符合圖樣要求。The height of the weld seam should be in accorda nee with the requireme nts of the draw in gs.b. 焊縫及熱影響表面不得有裂紋、氣孔、弧坑和夾渣等缺陷。No cracks, pores, arc cr

41、aters and slag etc defects on the weld ing seam and heat-affected surface.c. 焊縫咬邊當板厚小于10mm時，不得大于0.5mm,當板厚大于10mm時,不得大于1mm,咬邊連續(xù)長度不大于100mm。二側咬邊總長不得超過焊縫總長的10%。The un dercut of the weld seam is not more tha n 0.5mm, if the plate thick ness is less tha n 10mm; the un dercut of the weldi ng seam is not gre

42、ater tha n 1mm, if the plate thick ness is more tha n 10mm; and the continu ous len gth of the un dercut will not more than 100mm. The total le ngth of the bilateral un dercut shall not exceed 10% of the total len gth of the weldi ng seam.d. 焊縫應呈圓滑過渡至母材的幾何形狀，焊縫轉角處應飽滿。Weld should be smooth tran siti

43、on to base metal geometry in shape, the corner ofweld should be full ness.1.5高強度螺栓連接Conn ecti on with high stre ngth bolt鋼結構用高強度螺栓連接方式Conn ecti on mode of high stre ngth bolt for steel structure連接面的處理Treatme nt of connection surface連接前，必須清理連接表面的污物、油漆、油污及氧化皮等減少摩擦系 數的雜物，并用鋼絲刷刷去浮銹，不準用砂輪打磨。Con tam in at

44、io ns, paint, oil and oxide skin etc that can reduce frict ion factor on the conn ecti on surface must be removed before conn ecti on. Steel brush should be used for getting rid of the rust on the face rust and without grinding wheel.安裝高強度螺栓時 嚴禁強行穿入螺栓(如用錘敲打。如不能自由穿入 時，該孔應用鉸刀進行修整，修整后孔的最大直徑應小于1.2倍螺栓直徑。

45、修孔時，為 了防止鐵屑落入板迭縫中，鉸孔前將四周螺栓全部擰緊，使板迭緊密貼后再進行。嚴 禁氣割擴孔。 While installation high strength bolt, bolts are not permitted to infix withadditional force (e.g. with hammer. If can not infix smoothly, fraise should be used to repair, the diameter of holes should be smaller tha n that of 1.2 bolt after repairi

46、ng. Before starting to repair, all the bolts around the hole are tightened and plates are put closely in order to avoid iron chips falling. Gas cutting for bearizing is prohibited.安裝高強度螺栓時，構件的摩擦面應保持干燥，不得在雨中作業(yè)。While installing high strength bolts, friction surface of components should bedry, installa

47、tion is not permitted in rain.大六角頭高強度螺栓施工所用的扭矩扳手，扳前必須校正，其扭矩誤差 不得大于±%,合格后方準使用。校正用的扭矩扳手，其扭矩誤差不得大于±3%。Torque wrench for hexag on head high stre ngth bolts must be corrected before using, torque error percentage is not more than5%, it is used after qualification; torque error perce ntage of wr

48、ench for correcti on is not more tha n 3%.±大六角頭高強度螺栓的擰緊應分為初擰、終擰。對于大型節(jié)點應分為 初擰、復擰、終擰。初擰扭矩為施工扭矩的50%左右，復擰扭矩等于初擰扭矩。初擰或復擰后高強度螺栓應用顏色在螺母上涂上標記，然后按施工扭矩值進行終擰。 終擰后的高強度螺栓應用另一種顏色在螺母上涂上標記。Tighte ning for hexag on head high stre ngth bolt is divided into pre-tighte ningand final tighte ning, tighte ning for bi

49、g no des is divided in to first tighte ning, sec ond tightening, final tightening. Torque for pre-tightening is 50% that of operating torque, torque for second tightening is equal to that of first tightening. High strength bolts should be marked with color on the nut after first and second tightenin

50、g, then make final tightening according to operating torque. High strength bolts should be marked with differe nt color.大六角頭高強度螺栓擰緊時，只準在螺母上施加扭矩。高強度螺栓在初擰、復擰和終擰時，連接處的螺栓應按一定順序施擰，一般應由螺栓群中央順序向外 擰緊。高強度螺栓的初擰、復擰、終擰應同一天完成。During tightening hexagon head high strength bolts, torque only on nuts. Bolts on the c

51、onn ecti on points should be tighte ned in seque nee which from cen ter to outside part during first, second and final tightening, these three process should be finished on the same day.緊固方法及預緊力Tighte ning method and pretighte ning force高強度螺栓必須采用力矩搬手緊固，控制扭矩達到要求的預緊力。對本機采用 的GB12281230-94標準大六角頭高強度螺栓，力矩

52、板手扭矩值按下式確定： M=KDg.dHigh strength bolts must be tightened with torque wrench to control torque to reach the required pre-stress. Refer to the GB1228T230-94 sta ndard hexagon head high stre ngth bolts that applies to this machi ne, the value of torque will be decided by the following formula:M=K Dg. d

53、式中:K -扭矩系數(范圍值0.110-0.150K-torque coefficie nt (ran ge: 0.110-0.150Dg-預緊力 M22高強螺栓Dg=210Xl03NDg-pretighte ning force: M22 high stre ngth bolt Dg=210 103NXd -螺栓直徑M22高強螺栓d=0.022m d-diameter of the bolt M22 high stre ngth bolt d=0.022m 注:K值以生產高強螺栓的廠家提供的合格證為準。Note: K value is in accorda nee with the con

54、formity certificate offered by high stre ngth bolt manu facturer.2安裝順序Seque nee of in stallati on由于各安裝單位擁有的技術裝備手段(起吊作業(yè)機具等和安裝現(xiàn)場場地條件的 不同，允許有不同的安裝方案，但在保證安全、可靠、經濟、質量的前提下，進行空間 與時間的合理交叉，以達到縮短安裝周期的目的。Since the tech ni cal equipme nts and in strume nts (lifti ng mach ines etc. and the installation fields ar

55、e various, it is permitted to use different installation plans which, however, must base on safety, reliability, economy and quality, and logically cross in time and space, so as to realize the objective of shorten installation period. The following installation order is recommended.3裝配與安裝技術要求：Tech

56、ni cal Requireme nts for Assembly and In stallati on斗輪堆取料機對行走軌道的精度要求見附錄A oThe rail accuracy being required by Bucket Wheel Stacker Reclaimer refers to Appe ndix A:3.1行走機構Long Travel mecha nism 行走車輪安裝精度Installing precision of the traveling wheel for long travela同側軌道上各車輪滾動圓的中心應在同一平面上，其同位差應符合表1-2及圖1。Th

57、e centers of the rolling circles of all wheels on the same side of the rail should be on the same level, whose positi on deflect ion should be in accord with Table1- 2 and figure 1表 1-2 Table1-2測量部位 Measuring point偏差 Deflection同一臺車架的兩個車輪Two wheels of the same bogie< 2mm同一支腿下的三個以上車輪 Over three whe

58、els un der the same support leg< 3mm同側軌道上的全部車輪All wheels on the same side of the rail< 5mm圖 1 figure 1b同一軸線上一對車輪的水平偏斜方向應相反，其水平偏斜值ax不得大于測量 長度L的千分之一(圖2。The deviated direct ion of a pair of wheels on the same axis shall be opposite, the horiz on tal deflect ion ax shall not be more tha n millesimal of the measured len gth L(figure 2.figure 2c同一軸線上一對車輪的垂直偏斜方向應相反，且上邊應向外偏，車輪的垂直偏 斜值ay不得大于測量長度L的四百分之一(圖3。The deviated direct ion of a pair of wheel