中英文对照版立式水轮发电机组安装工艺分解

立式水轮发电机组安装工艺

Vertical hydro-generating installation process

主轴转轮的联接The connection of the main shaft runner 准备工作Preparations 导水机构安装Distributor installation 尾水管里衬安装Draft tube liner installation 浇二期砼Place stage 2nd concrete座环安装Stay ring installation 蜗壳安装Spiral casing installation 机坑里衬、接力器里衬安装Pit liner, servomotor liner installation 浇二期砼Place stage 2nd concrete 下机架埋件及下机架的安装Lower bracket embedment and lower bracket installation 浇二期砼Place stage 2nd concrete 转轮检查Runner inspection 定子基础板及定子安装Stator foundation plate and stator installation 浇二期砼Place stage 2nd concrete 上机架安装定位、盖板安装Upper bracket installation localization, cover plate installation 空气冷却器安装Air 吊开上机架及盖板Lift away upper bracket and cover plate cooler installation 启动试运行Start 水轮机转轮整体吊入Turbine runner integrally lifted in commissioning 转子整体吊入Rotor lifted in integrally 充水试验、参数整定Filling water test, parameter adjusting 上机架吊装、复位Upper bracket lifting, reset 导轴承、推力轴承安装Guide bearing, thrust bearing installation 清扫、加油Clean, oil filling 发电机轴线找正Generator axial line 导轴瓦间隙调整及油槽装配Guide bearing pad gap adjustment and oil slot assembly 机组复装Unit fit back 联轴Coupling 推力瓦受力调整Thrust pad loading adjustment 机组轴线找正Unit axial line centering

1 水轮机安装工艺措施

Turbine installation technological measure 1.1 尾水管安装

Draft tube installation

尾水管里衬是水轮机最下部的埋设部件。尾水管预埋件的安装工作，要密切配合土建施工进度进行安装。安装前应先检查预留基坑底部高程，一般要求与设计值误差不超过+5～-15mm。同时检查尾水管里衬的几何尺寸，并进行校正，然后根据上管口的圆度来确定里衬的中心位置。同时按图纸要求，在里衬上管口标定X、Y轴线的位置，然后将尾水管里衬按X、Y标志吊入机坑，进行调整。其管口直径，上管口中心及方位、高程达到设计要求后，进行加固工作，最后交土建浇砼。

Draft tube liner is the embedded component at the lowest part of the turbine. The installation of the draft tube embedded part should closely accord with civil construction schedule. Before installation, check the height of the reserved foundation pit bottom, and the design value error should be not more than +5～-15mm. Check the physical dimension of the draft tube liner, adjust at the same time. Then determine the center position of the liner according to the upper pipe orifice roundness. As the requirement of the drawing, sign the X,Y axial line position on the liner upper pipe orifice, then lift the draft tube liner into the pit as X,Y sign, adjust as need. Reinforce after pipe orifice diameter, upper pipe orifice center and position, height meet the design requirement. Then civil engineering places the concrete. 1.2 座环、蜗壳安装

The installation of the stay ring and spiral casing

蜗壳为分瓣结构，在工地现场完成各节的拼装与焊接。先进行座环安装，后进行蜗壳挂装、焊接。

The spiral casing is split structure, assemble and weld on site. Install the stay ring first, then hang and weld the spiral casing.

座环、蜗壳安装前应进行清扫检查，各部分尺寸均应符合设计及规范要求，特别是过流面，不应有错牙。在座环支墩垫板上较均布的放上三对楔子板或千斤顶，其高程应使座环放上后，座环上法兰平面的高程基本与设计值相符。

Clean and check the stay ring and spiral casing before installation. All dimensions should follow the design and specification requirement, especially the flow surface, unevenness should not exist. Uniformly distribute 3 pairs of wedge plates or jacks on stay ring buttress base plate, and the height of the stay ring upper flange plane should accord with the design value after put on the stay ring.

安装时，如现场起吊设备能满足座环一次吊装就位的则可将座环直接吊到预先放在混凝土支墩上的楔子板或千斤顶上，拉好控制座环中心、标高的测量基准线，根据基准中心线，按环形部件的特点，进行中心调整、水平以及圆度的测定调整。

During installation, if the site lifting device is able to lift the stay ring into position in one time, lift the stay ring on the wedge plate or jack prepared on the concrete buttress, tie well the control stay ring center, height measurement datum line, as the datum center line and ring part features to adjust the center, level and roundness.

座环是整台水轮发电机组的基准，对座环的中心、高程、水平的安装质量要求高，误差小，尤其是座环的水平误差，务必严格控制。全面调整座环，各控制尺寸经质检部门和监理工程师检查符合设计及规范要求并签证后立即加固，电焊固定时应对称进行，以防变形和位移，调整工具也要点焊加固，在加固过程中，用框架水平仪和千分表配合进行监视。安装基础环与尾水管里衬上管口之间的凑合节，该凑合节暂不与尾水管焊接，接缝修好焊接破口后在其外面点焊一圈宽50mm左右的薄钢板围带。

Stay ring is the benchmark of the whole hydro-generator, so the

installation quality requirement of the stay ring center, height and level should be high, especially the stay ring level error should be strictly controlled. Adjust the stay ring, the control size should be checked by the Quality Control Department and supervising engineer. After certificating, reinforce at once. Symmetrically fix it by electric welding to prevent the deformation and movement. Adjustment tool should be also spot-welding to reinforce, during the reinforcement, monitor with the frame type level and dial indicator. The expansion joint between the installation foundation ring and draft tube liner upper pipe opening does not weld with the draft tube temporarily. After repairing the joint and welding the cleavage, spot weld around a sheet steel shroud ring about 50mm.

座环安装固定后，按设计图纸及工艺要求进行蜗壳挂装并进行焊接，首先吊装蜗壳进口段定位节，调整其中心、高程以及与座环上下环板的位置，最远点半径等应合格，并焊接固定。然后依次吊装其它各节，其断面中心高程及各部分间隙应合格。最后吊装凑合节，调整间隙合格后固定。然后对蜗壳进行总体检查应符合有关的技术文件要求，并符合《水轮发电机组安装技术规范》GB8564的规定。

After the fixation of the stay ring installation, carry out the spiral casing hanging and welding as the drawing and process requirement. Hang spiral casing inlet orientation section, adjust the center, height and the position of the stay ring upper and lower ring plate, the furthest point radius should be qualified, and weld to fix. Then hang the sections in turn, the section center height and gaps in all parts should be qualified. At last, hang expansion joint, adjust the gap and fix. Check the spiral casing, which should follow related technical document requirement, and the requirement of GB8564 in Turbine and generator installation technical specifications.

蜗壳与座环的焊接严格按制造厂家有关“焊接工艺”要求进行，首先焊接蜗壳组合环缝，然后再进行蜗壳上下环板的焊接。蜗壳与座环环板焊接时应上下同时对称分段退步焊接，并在水准仪的监视下测量座环的水平，如有超出，应调整焊接的顺序，使座环在焊接过程中始终处于受控状态。焊接完经超声波探伤合格后由质检人员和监理工程师检查签证后交土建单位回填二期砼和浇座环支墩砼。

The weld of the spiral casing and stay ring should follow the manufacturer welding technology. Weld the spiral casing joint first, then weld the spiral casing upper and lower ring plate. During welding the spiral casing and stay ring ring plate, adopt the symmetrical segmentation setback welding with upper and lower parts welded at the same time. Measure the level of the stay ring with the monitor of the level device, if necessary, adjust the sequence of the welding, to control the whole stay ring welding process. After welding and passing the ultrasonic flaw detection, checked and certificated by quality inspection personnel and supervision engineer, civil engineering would start the stage 2 concrete and stay ring pier concrete placing.

待浇筑座环砼养护好之后焊接凑合节与尾水管之间的接缝。

After maintenance of the stay ring concrete, weld the joint line between the expansion joint and draft tube.

土建在浇座环蜗壳二期砼时，要求土建单位严格按施工措施规定控制砼浇捣速度，做到对称均匀下料，分层进行浇捣。

During civil engineer placing stay ring stage 2 concrete, control the placing speed as construction measures, uniformly placing and pouring by layers.

1.3 水轮机机坑里村的安装

The installation of the turbine pit liner

安装时，在机坑外先调整好里衬的椭圆度，符合规范要求后，在里衬内部进行加固，然后吊入机坑，按座环上管口至里衬法兰的距离，来调整其中心位置，

符合要求后，将机坑里衬焊接固定在座环上。

During the installation, adjust the ovality of the liner outside the pit, after meeting the requirement, reinforce inside of the liner, then lift into the pit. As the distance from stay ring upper pipe opening to liner flange to adjust the center position, after meeting the requirement, weld and fix the pit liner on the stay ring. 1.4 机坑检查交接，座环的中心、水平精密测定记录

Pit check and handover, make measurement record of the stay ring center, level accuracy

水轮机部件在安装前与土建施工单位进行机坑检查交接：土建工程临时设施是否全部撤出；安装工作面是否整洁。检查已埋部件是否符合规定要求，基础混凝土浇捣是否产生变形。对不符合要求的经处理合格后，开始机组的安装。

Pit check and handover with civil engineering construction department before the installation of the turbine parts: whether all the civil engineering temporary services have been moved, whether the installation work surface is clean. Check whether embedded parts follow the require requirement, and whether foundation concrete pouring has be deformed. Start the unit installation after repaired the unqualified ones.

为了保证水轮发电机组安装基准正确，进行座环的中心、水平精密的测定、记录。

In order to ensure the accuracy of the hydro-generator installation benchmark, precisely measure and make record for the stay ring center and level. 1.5 导水机构的预装

The pre-assembly of the distributor

导水机构要进行预装，导叶预装数量应在总数50%以上。预装前对座环上平面高程、水平镗口圆度复测：并通过调整顶盖和底环的中心，使导叶上、下各轴瓦同心，预装导叶端部、立面的间隙要符合规范和设计要求且导叶转动灵活。顶盖吊出前及时作好标记。

Pre-assemble the distributor. The guide vane pre-assembly quantity should be morn than 50% of the total qty. Before the preassembly, recheck the stay ring upper plane height, horizontal boring roundness. Adjust the center of the head cap and the bottom ring to achieve the concentricity of the guide vane upper and lower bearing pads. The preassembly of the guide vane end, vertical gap should follow the requirement of the specification and design, and the rotation of the guide vanes should be flexible. Make mark before lifting the head cap. 1.6 接力器里衬安装

Servomotor liner installation

接力器安装前应分解、清洗、检查，装配后活塞移动应平稳、灵活，各配合间隙、活塞行程应符合设计要求。接力器安装应做严密性耐压试验，试验压力为6MP，时间为30分钟无渗透漏现象，根据设计高程与角度安装接力器。安装接力器水平偏差不大于0.1mm/m，接力器压紧行程值应符合设计和规范要求的规定，两个活塞实际行程的相互偏差不应大于1mm。

Disassemble, clean and check servomotor before installing. After assembly, the piston movement should be stable and flexible. The gap and piston stroke should meet the design requirement. Precise pressure withstanding test should be carried out for the servomotor installation, the test pressure is 6MP，lasting for 30min with no leak. According to the design height and angle to install the servomotor. Installation servomotor horizontal error should be not more than 0.1mm/m，servomotor pressure stroke value should follow the requirement of the design and specification. The mutual deviation of two pistons real travel should be not more than 1mm. 1.7 主轴与转轮的连接及安装

The connection and installation of the main shaft and runner

在主轴与转轮连接前，先对主轴、转轮、连接螺栓、螺母进行彻底清扫干净。连接螺栓与螺母的丝扣部分，用细油石、什锦挫进行修磨，并涂以二硫化钼进行预装配。

Before the connection of the main shaft and runner, clean the main

shaft, runner, connection bolt, nut. The thread part of the connection bolt and nut should be grinded by fine oil stone, needled file, then pre-assemble by coating molybdenium disulfide.

先将转轮吊入在稳固的平台上，并调好水平，在对称方向穿上两只销钉螺栓作为导向。然后将主轴平稳吊起并调好水平，用细白布、酒精等彻底清扫主轴和转轮的法兰面，按螺孔编号的对应方向，主轴徐徐落在转轮上。按编号穿入所有的连接螺栓。按设计要求打紧螺栓并测量其伸长值。

Lift the runner on the stable stand, and adjust to be horizontal, thread two pit blots on the symmetrical direction as guide. Then stably lift the main shaft and adjust the level, use the canequim、alcohol to clean the main shaft and runner flange surface. Slowly fall down the main shaft on the runner as corresponding direction of the screw hole. Thread into all the connection bolts as number. As design requirement, hit tightly the bolts and measure the elongation.

在主轴转轮吊入前，在底下按十字方向放上四组楔子板。各楔子板的高程应一致，且使水轮机的轴头高程比设计值低，大约2～6mm。

Before lifting the main shaft runner, put 4 groups of wedge boards as cross direction at the bottom. The height of the wedge boards should be the same, and the turbine shaft head height should be lower than the design value, about 2～6mm.

主轴转轮起吊后，作2～3次升降试验。然后调整水轮机轴头的水平在0.5mm以内，慢慢吊入机坑。

After the lifting of the main shaft runner, do 2-3 times up and-down test. And adjust the turbine shaft head level in the range of 0.5mm, then lift into the pit slowly. 1.8 水轮机总装程序

Turbine general assembly program

经过预装、试验合格的水轮机各部件，按总装程序底环、导水机构、转轮、

顶盖等部件逐一吊入机坑，都应按照设计图纸要求，进行仔细的检测、调整、固定。安装每一工序环节均应详尽的记录。

The turbine parts through pre-assembly and teat qualified should be lifted into pit by the general assembly sequence: bottom ring, distributor, runner, head cap. As the design drawn requirement to check, adjust and fix carefully. Each process part in the installation should be made record. 1.9 水轮机其它部件的安装

The installation of the turbine other parts

调速控制环的位置确定是按导叶全关的位置进行。为避免单向承受荷载过大而产生烧瓦，水导轴承的间隙的调整将考虑到盘车时的水轮机轴线摆度。主轴密封应按有规范关要求进行安装、试验。

The position of the speed regulation control ring is determined by the guide vane all close position. In order to prevent pad burning due to single side supporting too much loading, turbine axial line run out during turning should be considered when adjusting water guide bearing gap. Install and test the main shaft seal as related specification. 2 水轮发电机安装工艺措施

Hydro-generator installation process 2.1 发电机预埋件安装

Generator embedded parts installation

根据发电机的实际结构尺寸，以座环面作为高程基准面，对下风罩的基础件、下机架及定子基础垫板等进行预埋，要控制预埋件的水平、高程、中心满足规范要求。

According to the generator real structure size, and consider the stay ring surface as elevation datum plane, embed the fan cover foundational piece, lower bracket and stator foundation base plate, and the level, height and center of the embedded parts should be controlled to meet the requirement.

2.2 转子装配及安装

Rotor assembly and installation

磁极挂装：挂装磁极前，测量磁轭圆度。各半径与平均半径之差不应大于0.36mm，检查磁轭平直度并作适当的修磨。磁极开箱后，进行全面的清扫。逐个检查磁极的绝缘电阻，其值不应低于5MΩ，否则应予以处理。对每一个磁极进行交流耐压试验和交流阻抗测试，试验通过后方可挂装磁极。按照制造厂编号挂装磁极。根据第1#与第20#磁极挂装位置要与转于引线的位置相对应。在磁极挂装时，应合理选择调整垫片，一方面可使磁极线圈与磁轭接触良好，另一方面可调整转子圆度。以转子中心体下法兰面的实际高程并参考定子铁芯的实际高程定出磁极铁芯高度。应保证机组总装后转子磁极铁芯中心平均高程比定子铁芯中心线平均高程低1.5—3mm；同时，各磁极中心线挂装高程与平均高程之差不应大于±lmm。插入磁极键并用大锤打紧。按图纸要求焊好鸽尾挡块。检查转子圆度，各半径与平均半径之差不应大于0.36mm。测量单个磁极线圈的交流阻抗值，其相互间不应有显著差别。试验所加电压不应大于额定励磁电压。

Magnetic pole hanging: before hanging the magnetic pile, measure the rim roundness. The difference between each radius and the average radius should be not more than 0.36mm. Scrape the rim flatness if necessary. After opening the rim box, clean completely. Check the insulation resistance of the magnetic pole one by one, the value should be not lower than 5MΩ. Do the AC withstand voltage test and AC impedance test for each magnetic pole, after qualified, start hanging the magnetic pole. As the manufacturer's serial number to hang the magnetic pole. The hanging position of the 1# and the 20# magnetic pole should be corresponding with the rotor lead wire. During magnetic pole hanging, reasonably choose and adjust the spacer, in order to make the magnetic pole coil contact well with the rim, and also it would adjust the rotor roundness. Determine the magnetic pole iron core height by referring to the rotor center body lower flange face real height and the real height of the stator iron core. After

the general assembly, the average height of the magnetic pole iron core should be lower 1.5—3mm than that of the stator iron core center line average height. At the same time, the difference between the magnetic pole center line hanging height and average height should be not more than ±lmm. Insert the magnetic pile key and hit to tighten with hammer. Weld well the dove tail baffle plate. Check the rotor roundness, the difference between each radius and the average radius should be not more than 0.36m. check the alternating current impedance of single magnetic pole coil, marked difference should not occur. The test voltage should be not more than that of rated excitation voltage.

按图纸要求连接极间连线、阻尼环连接片和转子引线相应之径向方向的两磁极的连接件均先不相联。所有螺栓螺母均应固定牢靠。极间连接片接头螺栓把合处以0.05mm塞尺检查，塞入深度不应超过5mm。测量转子绕组绝缘电阻，其值不应超过0.5MΩ，否则应进行干燥处理。

Connect the inter-polar wire, two magnetic poles joint pieces in the radial direction of the damping ring joint piece and rotor lead wire should be not connected. All bolts and nuts should be fixed tightly. Check connection place of the inter-polar joint piece track bolt with 0.05mm feeler gauge, the inserting depth should be not more than 5mm. Measure the rotor winding insulation resistance, the value should be not than 0.5MΩ，or dry treatment.

转子绕组通电干燥前，应彻底清扫转子磁极及转子。在转子绕组中通电流，以不超过额定励磁电流的直流电流为准，在对转子绕组进行干燥时，线圈表面温度不应超过85℃，温度上升率不超过5℃/h。当线圈温度稳定6h左右后，即可降温停止干燥。当转子绕组温度降至40℃以下时，对绕组进行交流耐压试验。测量转子绕组直流电阻值，以便今后作比较。电气试验通过后，按图纸要求搭焊磁极键并将多余部分割去。

Before rotor winding energizing dry, clean the rotor magnetic pole and rotor. Pass the current on the rotor winding, and the direct current value should be not

more than that of rated excitation current. When drying the rotor winding, the coil surface temperature should be not more than 85℃，temperature rise rate should be not more than 5℃/h. After the coil temperature is stable for about 6h, decrease the temperature and stop drying. When the winding temperature decreases below 40℃, carry out the AC withstand voltage test for winding, measure the rotor winding direct current resistance value, for comparison in future. After the qualified of the electrical test, lap weld the magnetic pole as drawn and get rid off the rest part.

（2）转子安装：转子吊装是机组安装的重要环节，转子吊装应制订安全技术措施，成立专门机构，负责统一指挥。本电站转子吊装是由厂内50/10t桥式起重机完成的。

Rotor installation: rotor lifting is the important part in the unit installation. During rotor lifting, prepare safety technical measures, set up special agency for unified command. The rotor lifting in this power station is done by 50/10t bridge crane.

在安装间进行试吊，当转子起吊到离地约l00~200时，先升降一至两次，检查桥式起重机构运行情况是否良好，然后起升至一定高度，使转子处于垂直状态，检查转子垂直度，合格后，转子吊至机坑上空，先与定子初步对正，徐徐落下，当转子将要进入定子时，再仔细找正，为避免转子和定子相碰，需用8根木板条(约30—40mm宽，比磁极稍长，厚度为空气间隙的一半)均匀分布在定子、转子间隙内，每根木板条由一人提着，靠近磁极中部上下活动。在转子下落过程中发现木条卡住，说明在该方向间隙过小，立即告诉现场指挥，向相反方向移动转子。中心调控几次后，转子即可顺利下降，待其即将落在千斤项上时，要特别注意防止大轴相碰。

Trial hoisting in erection bay. When the rotor is lifted above ground l00~200, rising and falling one or two times, check the operation situation of the bridge crane mechanism, when the rotor is rose to certain height, check the rotor verticality, after qualified, lift the rotor to the above of the pit, preliminarily center with the rotor, fall slowly, when the rotor is going to be in the stator, check carefully, in order to avoid the collision between the rotor and stator, 8 wooden laths should be uniformly

distributed in the gaps between the stator and rotor. Each wooden lath should be carried by one man, and move up and down close the magnetic pole center. If wooden lath jamming occurs, tell the on scene commander as soon as possible, move the rotor to the opposite direction. Adjust some times until the rotor falls down successfully. When the rotor falls on the jack, pay attention not to collide with the large shaft. 2.3 发电机各部件预装定位

Pre-assembly position of the generator parts

下机架安装定位以机组座环的中心、高程作为依据；上机架与定子组合后两部件一起进行中心找正预装，经预装的上、下机架即钻饺销钉孔，配装销钉定位。预装过程需对机架内结构进行检查，抗重螺栓的灵活度应侧重检查。

The lower bracket installation position should be based on the center and height of the unit stay ring. After the combination of the upper bracket and stator, center and pre-install the two parts, then drill the pin hole on the upper and lower bracket which have been pre-assembled, and prepare pins to position. Check the structure in the bracket during pre-assembly process, and pay attention to the flexibility of the loading resistance bolts. 2.4发电机总装程序

Generator final assembly program

当水轮机总装完结束即组织发电机的总装，其总装程序为：下风罩吊装；下导轴承油盆、冷却器吊装；接下去是经预装过的下机架、定子吊装。下机架、定子的吊装过程应首先校核各部件实测尺寸，并按水轮机主轴法兰校核各部件安装高程。

After the final assembly of the turbine, start the generator final assembly. And the assembly schedule: lower fan cover lifting, lower guide bearing oil basin, cooler lifting, then the lower bracket been pre-assembled, stator lifting. The lifting of the lower bracket and stator should check the real parts demission, then check all parts assembly height as turbine main shaft flange.

当上述吊装工序结束即可组织吊装转子。吊入的转子可座落在预先调好的下机架

的风闸板上。接下去是进行上机架、推力头等部件的安装。

After finishing the above lifting schedule, start to lift rotor. The rotor should be placed on the air damper plate of the lower bracket. Then start the assembly of the upper bracket, thrust collar. 2.5机组轴线检查，推力轴承受力调整

Check the unit axial line, adjust the thrust bearing loading

水轮发电机大轴联轴经连接后，推力轴承即承受转动部分的总量。机组的轴线达不到要求时，可通过研刮镜板和推力瓦之间的绝缘垫进行调整，接着进行调整推力瓦的受力状况。调整好转轮间隙的同时测定转子间的空气间隙，使其满足规范和设计要求。

After the connection of the hydraulic generator big shaft coupling, the thrust bearing supports the total weight of the rotation part. If the unit axial line dose not meet the requirement, scrape the insulation pad between the thrust runner and thrust pad for adjustment, then adjust the loading situation of the thrust pad. Adjust the runner gap and measure the air gap between the rotors, to check whether they follow the specification and design requirement.

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