優(yōu)質文檔m02軸系校中及主機裝置工藝

1、（圖號：SNS-TECH-M02）編制（Designed） 2010年月日校對（Checked） 2010年月日審核(Verified ) 2010年月日批準 (Approved) 2010年月日山東省新船重工有限公司1 概述 overview1.1 本系列船軸系和主機在船舶下水后，采用合理校中法進行安裝。 After launching the ship, install the shafting and main engine with proper alignment. 1.2 主機底座采用環(huán)氧樹脂墊片，中間軸承采用鋼質墊片。The main engine base adopts epo

2、xy resin gasket, and the intermediate bearing adopts steel gasket.2 圖紙和技術文件Drawing and Technical Documents軸系布置圖 shafting arrangement drawing主機安裝圖 the drawing of main engine installation主機頂撐布置圖 arrangement of the main engine top-up軸系校中計算書 calculation of shaft alignment檢驗項目表 inspection item list MAN B

3、&W主機安裝工藝文件 MAN B&W main engine installation document3 工藝流程 Technological process主機軸系校中包括三個階段，其主要工作如下： Alignment of Shafting and Installation of the Main Engine include three steps. Main works as follows:3.1 連接軸系螺栓前Before connecting the shafting bolta主機輸出端法蘭和中間軸法蘭螺栓孔鉸孔Reaming for the flange of the ma

4、in engine output end and flange bolt hole of the intermediate shaftb軸系校中，調整法蘭的偏移（SAG）和曲折（GAP）Align the shafting and adjust the SAG and GAP of flangesc 檢查主機機座水平撓度Check the horizontal deflection of the main engine base.d 檢查曲軸甩檔Check the crank shaft deflectione冷凍法安裝軸系鉸制螺栓Install shafting reamer bolt wi

5、th freezing method3.2 連接軸系螺栓后，澆注環(huán)氧前(主機定位)After connecting the shafting bolt and before pouring the epoxy（main engine fix）a中間軸承臨時定位、固定Provisional positioning and fixation of the intermediate shaftb檢查軸系負荷（艉管前軸系、中間軸承、主機最后兩道主軸承）Check the shafting loading(the fore shafting and the intermediate shaft of t

6、he stern tube and the last two main bearings of the main engine)c檢查曲軸甩檔和最后兩道主軸承間隙Check the crank shaft deflection and the space of the last two main bearingsd澆注環(huán)氧Pouring Epoxy3.3 澆注環(huán)氧后After Pouring Epoxya主機底腳螺栓安裝Install the anchor bolt of the main engine b檢查曲軸甩檔check the crank shaft deflectionc中間軸承安

7、裝（墊片拂配、間隙測量）和檢查軸系負荷（艉管前軸系、中間軸承、主機最后兩道主軸承）Install the intermediate bearing (gasket coordination and clearance measurement) and Check the shafting loading(the fore shafting and intermediate shaft of the stern tube and the last two main bearings of the main engine)d主機側向支撐、端部支撐和頂撐安裝The installation of t

8、he main engine side direction support、end support and top-up.4 工藝過程Technological process連接軸系螺栓前Before connecting the shafting boltThe processing of the main engine base and the Lifting of the Main Engine主機吊裝前準備 Prepare for the lifting of the Main Enginea根據軸系（拉線）照光結果和主機安裝圖，劃出主機基座上的底腳螺栓孔位置。然后，進行鉆孔作業(yè)。詳

9、見主機安裝圖（SC4475(WH1)-420-01-0）Draw out the position of anchor bolt hole of the main engine base according to the optical alignment result of the shafting(wire drawing ) and The Installation Drawing of Main Engine, then begin to drill. See drawing Main engine installation （SC4475(WH1)-420-01-0）b 核對主機油底

10、殼與圖紙的正確性，進行主機回油管的開孔。見圖主機安裝圖（SC4475(WH1)-420-01-0）Check the correctness of the main engine oil pan and the drawing, and make hole in the oil return tube of the main engine. See drawing Main engine installation （SC4475(WH1)-420-01-0）c 按照圖紙要求焊裝環(huán)氧內擋板，規(guī)格為50mmX3mm,L20m。Weld the epoxy inner baffle accordin

11、g to the drawing, and the specification is 50mmX3mm, L20m.d 基座平面打磨清潔，抹上油脂。Polish the surface of the base and apply grease to it.e 主機吊裝前，核實機艙各甲板開口尺寸，拆去碰撞物。Before lifting the main engine, check the open dimension of all decks of the cabin, and dismantle objects that may lead to collision.f根據軸系（拉線）照光時確

12、定的主機墊片高度，調整主機頂升螺栓的高度。Adjust the jacking bolt height of the main engine according to the main engine gasket height confirmed by the optical alignment of the shafting.主機輸出端法蘭和中間軸法蘭螺栓孔鏜孔Hole boring of the main engine output end flange and the intermediate shaft flange bolt holea 法蘭校中：調整兩個法蘭外圓同軸度，要求兩法蘭偏

13、移量不大于，平面貼和值不大于。應用臨時螺栓和定位銷（交錯）將兩法蘭連接。The alignment of flanges: adjust the excircles of the two flanges to coaxiality. The offset of the two flanges is not more than 0.03mm, and the surface fit value is not more than 0.03mm. connect the two flanges with provisional bolts and fixable pin (interlacement

14、)。b 按相應的圖紙要求進行鏜孔，結束后，用內徑分厘卡測量孔的上下，左右兩個方向以及孔長度方向數值，并記錄。測量結束后，隨機打上螺孔編號。Bore holes according to the corresponding drawing. After that, measure the holes value ( length, width and height) with inner diameter micrometer and report. After the measurement, print the screw hole number at random. c 根據鉸孔數據，加工

15、緊配螺栓，并按照技術要求進行無損探傷。過盈量Process the close-fitting bolts according to the quantity and data of reaming. Carry out the nondestructive inspection according to the technical requirement. Press-fit interferencemm. See drawing: PROPULSION SHAFTINGARRANGEMENT軸系校中（連接軸系螺栓前） The Alignment of the Shafting (befor

16、e connecting the shafting bolts).1 校中條件The Conditions of Alignmenta 船舶下水后,校中過程中尾尖艙、淡水艙必須注滿水，第3底壓載(P/S)注水調節(jié)吃水。首艉吃水差不超過5M，保證艉吃水。 After launching the ship, During shaft alignment peak TK and FW TK must to be filled. NO.3BWTK(P/S) to be filled adjusting draft.The draft difference is be exceeded 5m betwe

17、en AFT draft and FORE draft. Ensure AFT draft is 5.5M .b校中時，船上無較大的振動作業(yè)，避開大量的加水、加油，船舶的吃水、壓載狀態(tài)基本不變。During the alignment, there is no strong vibration, and try to avoid large sums of watering and oiling. The draught and ballast condition of the ship should remain the same.c 主機及附件安裝完整，所有主機結構件螺栓全部上緊。 Ins

18、tall the main engine and all accessories, and all main engine structure bolts are screwed down.d 檢查和放對艉軸位置，使主機、軸系各法蘭之間留有滿足軸系校中的測量間隙（一般為1-2mm）Check and align the position of stern shaft, and leave necessary space between the main engine and flanges of shafting for the shafting alignment. (usually 1-2

19、mm)e 按照圖1軸系校中模型所示位置裝兩只可調臨時支撐1和2，臨時支撐的架設必須有足夠的強度。Install two adjustable provisional support 1 and 2 according to the position in the shafting aligning model. The provisional support must have enough intensity.f 按照軸系校中計算書有油泵在螺旋槳軸法蘭后220mm處上方施加一個垂直向下的附加力3000Kg（圖1）。According to Calculation Sheet of Shaft

20、 Alignment , the oil pump applies a vertical downward additional pressure 3000Kg to the upward side of AFT the propeller shaft flange220mm.(picture1) 圖1.2調整SAG，GAP Adjusting SAG, GAP a 校中依據圖2和表1 Align according to picture 3 and chart 1 圖2代號SAG1（飛輪處）GAP1(飛輪處)SAG2GAP2數值（螺旋槳浸沒50%）mmmmm數值（螺旋槳浸沒75%）數值（螺旋

21、槳浸沒100%）表1 數據表b 調整中間軸臨時支撐的高度，使中間軸艉法蘭與螺旋槳軸法蘭的“曲折”（GAP1）和“偏移”（SAG1）滿足圖2的要求，并使（GAP1）和（SAG1）的公差為；左右偏差為，并記錄數據。Adjust the provisional support height of the intermediate shaft, and make GAP1 and SAG1of the intermediate shaft flange and propeller shaft flange meet the need of picture 2. Make the tolerance o

22、f GAP1 and SAG1 0.08mm, the deviation of left and right is 0.08mm and report the data.c 調整主機的位置，使中間軸法蘭與主機輸入端法蘭的“曲折”（GAP2）和“偏移”（SAG2）滿足圖2的要求，并使（GAP2）和（SAG2）的公差為；左右偏差為，并記錄數據。詳細校中計算見（SA-0917-NB295）Adjust the position of the main engine, and make GAP2 and SAG2 of intermediate shaft flange and main engin

23、e input end flange meet the need of picture 2. Make the tolerance of GAP2 and SAG2 0.08mm, the deviation of left and right is 0.08mmand report the data.The detailed calculation of the alignment can refer to（SA-0917-NB295）d考慮到主機所澆注的環(huán)氧樹脂墊片在固話過程中約有1/1000Xmm（-環(huán)氧墊片厚度）。The epoxy resin gasket poured by the

24、 main engine is about 1/1000Xmm during the solidification.參照MAN B&W的相關技術文件，調整主機基座的水平撓度Adjust the horizontal deflection of the main engine base referring to the relevant technical documents of MAN B&W.測量并調整曲軸曲柄差（驗收標準見主機制造廠推薦數據）。Measure and adjust the crank shaft subtraction (The acceptance standard c

25、an refer to the recommendable data of main engine plant.).6軸系鉸制螺栓安裝The installation of shaft reaming bolts a 鉸制螺栓必須先行提交驗收。Inspection and acceptance of the reaming bolts must be submitted at first.b 清潔螺栓、螺孔，螺栓放入液氮冷凍箱。Clean bolts and screw hole, and put the bolts into the liquid nitrogen freezer. c 應用

26、冷凍安裝工藝將合格的鉸制螺栓（連接前需噴涂二硫化鉬）分別連接主機和中間軸的法蘭、中間軸與螺旋槳軸法蘭。Put the qualified reaming bolts (spray molybdic sulfide before the connection)to the flange that links the main engine and the intermediate shaft and the flange that links the intermediate shaft and the propeller shaft respectively with freezing ins

27、tallation technology.d 48小時后，用扳手擰緊螺帽，螺母平面與法蘭平面應緊密接觸，接觸面75%周長應插不進塞尺。裝上開口銷After 48 hours, fasten the screw cap with a wrench, and the screw surface should contact closely with the flange surface. 0.05mm feeler gauge should not insert into 75% of circumference of the contact surface. Fit on the cotter.

28、4.2 連接軸系螺栓后，澆注環(huán)氧前(主機定位)After connecting the shafting bolt and before pouring the epoxy（main engine fix）軸承負荷測量 Measuring the Bearing Load.1軸承負荷測量的條件The Conditions for Measuring the Bearing Loada拆除螺旋槳軸法蘭處的附加力F和中間軸上的臨時支撐1和2.Dismantle the additional pressure F in the flange of the propeller and the prov

29、isional support 1 and 2 of the intermediate shaft.b初步確定中間軸承墊片厚度，利用4只頂升螺栓使中間軸承處于正確的位置，中間軸承用夾持工具緊固。Make sure the thickness of intermediate bearing gasket preliminarily. Use 4 jacking bolts to make intermediate bearing in a proper position, and fasten the intermediate shaft with clamping device. c 測量時應

30、停止一切振動作業(yè)。Stop all vibration operation during the measurement. .2軸承負荷測量的方法。The Methods for Measuring the Bearing Loada 按照軸系校中計算書所示的位置，安裝千斤頂，檢查千斤頂座架是否牢固.Install the lifting jack according to the position indicated the Shaft Alignment Calculation Sheet, and check if the base of lifting jack is fastened

31、.b 在千斤頂所對應的軸頸上，放置一個百分表，并檢查百分表的支架是否牢固。Put a dial indicator on the shaft neck corresponding to the lifting jack, and check if the bracket of the dial indicator is fastened.c 掀開油泵從而頂升中間軸，要求油壓每升高2.0MPa,記錄對應的百分表讀數（即軸上升量），直到壓力上升不大但軸頸抬高較快為止。Open the oil pump to jack the intermediate shaft. Report the corre

32、sponding indication on the dial indicator (the rising volume of shaft) every time the oil pressure is up 2.0 Mpa, till the rising of the pressure is not big and the elevation of the shaft neck is rather fast. d 慢慢地瀉放油壓，每降2.0 MPa，記錄對應的百分表讀數（即軸下降量），直至油壓完全釋放。Release the oil pressure slowly and report c

33、orresponding indication on the dial indicator ( the descending volume of shaft) for falling of every 2.0MPa, till the oil pressure is completely released.e 根據記錄的數據，在坐標紙上繪制出壓力與位移的曲線，按照附注中的計算公式（*），計算軸承負荷。According to reported data, draw the curve of pressure and displacement on the coordinate paper. C

34、alculate the bearing load referring to the computational formula （*）in the annotation.f 每一軸承測力完畢后，應將軸旋轉180oC。重新測量。比較兩次數據。 After measure every bearing load, turning shaft 180oC. measure shaft load again and compare the data .3艉管前軸承、中間軸承負荷測量Measure the load of fore bearing and intermediate bearing of

35、the stern tube.a 按照所述的軸承負荷檢測方法，對艉管前軸承、中間軸承負荷進行檢測，并記錄相關數據。根據記錄的數據，在坐標軸紙上繪制出壓力與位移的曲線。According to the test methods of the bearing load mentioned in .1, detect the load of fore bearing and intermediate bearing of the stern tube, and report the relative data. According to the data, draw the curve of the

36、 pressure and displacement on the paper of coordinate axis.b 按照公式（*）計算軸承負荷，要求軸承計算結果與軸系校中計算書計算值誤差在20%之內，則本次校中合格。Calculate the bearing load according to formula（*）, the error between the result of the bearing calculation and the calculated value in the Calculation Sheet of the Shaft Alignment is withi

37、n 20%, then the alignment is qualified. .4 主機推力軸承、最后道主軸承負荷測量load measurement for the thrust bearing of the main engine and the main bearinga 參照MAN B&W的相關技術文件，測量主機推力軸承、最后道主軸承（7#、8#軸承）負荷，并記錄相關數據。根據記錄的數據，在坐標軸紙上繪制出壓力與位移的曲線。Measure the load of main engine thrust bearing and the main bearings (bearings7#

38、and 8#) referring to the relevant technological document of MAN B&W, and report relative data. Draw the curve of pressure and displacement on the paper of coordinate axis according to the reported data. b 按照公式（*）計算軸承負荷，并按照MAN B&W推薦數據對主機軸承負荷進行驗收，如果測量負荷不滿足要求，可適當調節(jié)中間軸承或主機高度。Calculate the bearing load a

39、ccording to the formula(*). Check and accept the bearing load of the main engine according to the recommendable data of MAN B&W. If the measured load can not meet the requirements, adjust the intermediate bearing or the height of the main engine appropriately.5 軸承負荷和預升系數Bearing Load and Pre-rising C

40、oefficient軸承負荷和預升系數依據表2：The bearing load and pre-rising coefficient can refer to picture 2.Cold condition (75 % IMMERSION)表2 數據表 Picture 2檢查曲柄差和最后兩道主軸承間隙，通過調整頂絲調整接近出廠時數值。第一缸和第六缸最大偏差不大于0.56mm,其它不大于。Check the crank subtraction and the space of the last two main bearings. and slightly adjusting it with

41、 adjusting screw as possible as near value of test in workshop. First and last cylinder the max deflection within 0.56mm. Others no more than 0.21mm.參照MAN B&W的相關技術文件，調整主機基座的水平撓度,每道支撐允許0.08mm.總誤差每10mAdjust the horizontal deflection of the main engine base referring to the relevant technical documents

42、 of MAN B&W. The max deflection within 0.08mm between one support. The total deflection within 0.15mm pre 10m.澆注主機環(huán)氧墊片 Pour the Epoxy Gasket of Main Enginea軸負荷、曲柄差、主機水平均合格后澆灌環(huán)氧 After bearing load、crank subtraction and the horizontal deflection of the main engine base be checked out Pour the Epoxy Ga

43、sket b 按主機安裝圖要求，裝焊6只測量銷，并記錄主機與各測量銷之間的間隙，并作好記錄。 Weld six measuring pins according to the requirement of layout drawing for the main engine, and report the space between the main engine and the measuring pins.c 澆注前應仔細清潔機座底板平面和基座面板平面。Before pouring, clean the baseplate surface of the engine base and th

44、e panel surface of the base carefully.d 在清潔機座、圍海綿、攪拌環(huán)氧及澆注過程中，主機周圍應無打磨、電焊、氣割等工作的進行。No polishing, electric welding and gas cutting are operated around the main engine during the process of cleaning the engine base, enclosing sponge, mixing epoxy and pouring.e 環(huán)氧墊片的大小、規(guī)格和布置，必須符合主機安裝圖的要求。The size, speci

45、fication and layout of epoxy gasket must conform with the Requirement for the Installation of the Main Engine.f 澆注時由環(huán)氧服務商負責。Epoxy service providers are responsible for the pouring.g 澆注時，在主機四角位置各取一試樣。 Get a sample from the quadrangle of the main engine respectively when pouring.h 待環(huán)氧48小時硬化后，檢查環(huán)氧墊片的硬度

46、。After 48-hour hardening of the epoxy, check the hardness of the epoxy gasket.4.3 環(huán)氧澆注后的工作 Works after Pouring Epoxy主機底座螺栓安裝。Installation for the Bolts of the Main Engine Basea 拆除主機頂升螺栓。Dismantle the jacking bolts of the main engine.b地腳螺栓涂上二硫化鉬，上螺母必須按照主機安裝圖進行調整。確保上、下螺母用圓螺母扳手扳緊。Apply molybdic sulfide

47、 to the anchor bolt, Adjust the upper bolt according to The Installation Drawing of The Main Engine. Make sure that the upper nut and the lower nut are fastened with round nut wrench圖3 picture 3c 安裝液壓拉伸工具，應確保液壓缸緊貼定距環(huán)并確保零部件要一起正確導向。Install the hydraulic stretching instrument, and make sure the hydraul

48、ic cylinder is appressed with the distance collar and make sure that the components are correctly orientedd分兩次緊固。Fasten at twice.施加壓力（液壓拉緊壓力：150MPa）用圓形螺母扳手緊固螺母釋放壓力到0在進行第二步前等待約2分鐘。施加壓力（液壓拉緊壓力：150MPa）將螺母緊固牢并釋放系統(tǒng)壓力到0.Exert pressure( hydraulic straining pressure:150MPa) Clamp nuts with round nut wrenchr

49、elease the pressure to zerobefore the second step, please wait for about 2 minutes. Exert pressure (hydraulic straining pressure: 150MPa) clamp the nut and release the system pressure to zero.e 擰緊順序The Sequence of Clamping將機座分隔為三個相等的部分：前部、中部和后部，按照圖3編號和箭頭的反向順序擰緊螺栓。The dropper base can be divided into

50、 three equivalent parts: the fore part, the middle and the rear. Clamp bolts according to the reverse sequence of number and arrowhead in the picture 3.擰緊順序： clamping sequence:在主機中部的截面上的螺栓在（1+2）兩側緊固；在主機前部的螺栓在（3+4）兩側緊固；最后端的螺栓在（5+6）兩側緊固；將主機中部截面上的螺栓在（7+8）兩側再次緊固。Clamp the bolts on the cross section of t

51、he middle of the main engine in the two sides of (1+2).Clamp the bolts in the front of the main engine in the two sides of (3+4).Clamp the final bolts of the final end in the two sides of (5+6).Re-clamp the bolts on the cross section of the middle main engine in the sides of (7+8).測量主機同各測量銷之間的間隙，對比主

52、機的下沉量。Measure the space between the main engine and measurement pins, and contrast the submergence volume of the main engine.測量曲軸曲柄差Measure the Crank Subtraction and report data.確定中間軸承墊片厚度，拂配、基座鉆孔并緊固，接觸面積70%（允許極限60%），塞尺允許插入深度不超過10mm.Make sure the thickness of middle bearing shim. Carry out the coord

53、ination, base drilling and fastening. The contact area70%( permissible limit value 60%) The permissible insertion depth is not beyond 10mm with 0.05mm feeler gauge.復測軸承負荷（艉管前軸承、中間軸承、主機最后兩道主軸承）。并記錄Retest the bearing load.( the fore bearing and middle bearing of the stern tube and the last two main bearings of the main engine) and report端部支撐安裝End Support Installationa楔入拂配端部支撐螺栓緊固安裝，