9000dwt 襟翼舵安装工艺-ok

'无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页9000DWTSTEERINGCHEMICALTANKER9000吨不锈钢化学品/成品油船襟翼舵FLAPRUDDER安装使用说明书INSTALLATIONANDOPERATIONMANUAL无锡市东舟船舶附件有限公司WuxiDongzhouMarineFittingsCo.,Ltd 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页目录CONTENTSLIST套筒组件安装……………………………………3Installationofruddertrunk舵杆安装…………………………………………6Installationofrudderstock舵杆与舵叶安装…………………………………9Installationofrudderstockandrudderblade舵销与舵叶安装…………………………………12Installationofrudderpintleandrudderblade液压泵与液压螺母使用说明……………………15Instructionofhydraulicpumpandhydraulicnut传动机构安装……………………………………21Installationoflinkdevice止跳块与保险处理………………………………23Anti-jumpingblockandinsuranceprocess日常使用维护………………………………………24Maintenance 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页套筒组件安装Installationofruddertrunkunits一、拉线定位Positioningbyrunningline1．在0＃肋位，根据船体设计要求，确定舵杆的中心线位置；Accordingtodesignrequirementsofvessel,thecentrallineofrudderstockistobeconfirmed.2．在舵机平台和船底板上根据舵套筒的外形尺寸割孔；Tocutofftheholesonthesteeringgearplatformandbottomplatingaccordingtotheexternalsizeofruddertrunk.3．拉出舵杆中心线，要求舵杆中心线的定位偏差：Todrawthecentrallineofrudderstock,requirementsfortheorientationdeviationofthecentrallineofrudderstockasfollows:(1.)位置偏差：<0.5mm；Deviationfortherequiredpositionsinthedrawings：＜0.5mm(2.)垂直度偏差：<1mm。Verticalitydeviation：＜1mm二、在0＃肋位船底开孔，开孔直径约800mm；Toperforateattheship’sbottomofzeroposition,cutopening:φ800mm.三、在0＃肋位舵机平台甲板开孔，开孔直径约800mm；Toperforateatthedeckofsteeringgearplatformofzeroposition,cutopening:φ800mm四、在船体上安装连接套筒（见图一）；Toinstallconnectingsleeveonthevessel(seethefigure1) 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页1.将连接套筒从开的孔内吊至连接套筒上板下边缘距BL10314mm,即与舵机平台甲板等高，点焊固定；Tolifttheconnectingsleevefromtheopenedholetothelowerplaneoftheupperplateofconnectingsleeve,thedistanceisBL10314mm.Ithasthesameheightwithsteeringgearplatformdeck,tobeweldedasfixed.2.将舵套筒上与假舵相连接的两水平板与假舵底板相焊接（焊接前根据假舵底板的线型修整）。焊接后焊缝做探伤处理。（见图二）Thetwohorizontalplatesconnectwithruddertrunkandartificialrudderandthebottomplateofartificialrudderaretobewelded.Betrimmedaccordingtothelineshapeofthebottomplateoftheartificialrudder.Crackdetectionistobecarriedoutfortheweldingseam.(Seebelowfigure)3.将舵套筒的中间连接套筒与船体相焊接。焊接完毕后焊缝做探伤处理。Thecenterconnectingsleevesofruddertrunkaretobeweldedwithvessels.Crackdetectionistobecarriedoutfortheweldingseam.4.将套筒上的四条纵筋板与船体进行焊接。Fourverticalstiffenersonsleevesaretobeweldedwithvessel.二、将假舵与连接套筒按船体设计要求进行焊接，确保无气孔现象。焊接完毕后，焊缝应做探伤试验。Accordingtothedesignrequestofvessel,theartificialrudderaretobeweldedwiththeconnectingsleeves.Toinsurenoairvent.Crackdetectionistobecarriedoutfortheweldingseam. 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页图一图二 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页舵杆安装Rudderstockinstallation安装前，应检查不锈钢衬套和下舵承内是否干净，并在不锈钢衬套上涂上一层润滑油。Tocheckthecleannessforthestainlesssteelbushandthelowerrudderbearing,coatthelubeoilonthestainlesssteelbush.1、将上舵承轴承座预先固定在套筒上顶部，J型有骨架密封圈安装到位；Thebearingseatofupperrudderbearingshouldbefixedontopofthesleeves.Jtypebonesealingshallbefittedinplace.2、将舵杆吊起，从下伸入连接套筒、上舵承内，在上舵承处应相当小心，以防止舵杆损伤J型有骨架密封圈；Liftrudderstock,extendtheconnectingsleeveandtheupperrudderbearingfromthebottom,becarefulwiththeupperrudderbearing,preventrudderstockfromdamagingJtypebonesealing.3、固定高度，将调心滚子轴承安装到位，然后安装卡环；Fixtheheight,installtheself-aligingrollerbearinginplace,andinstallthekeyingring.4、放松吊舵系统，使卡环承重；Loosehangedruddersystem,thekeyingringisusedforloadbearing.5、安装轴承上端盖；Installtheuppercoverofbearing.6、将下油封组件中的J型有骨架密封圈、油封挡圈，从舵杆下套入就位， 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页旋紧螺栓；Jtypebonesealingandoilseallockingringfromtheloweroilseaunits,tobefittedinplaceofthebottomoftherudderstock,screwbolt. 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页舵杆与舵叶的连接Connectionbetweenrudderstockandrudderblade一、安装前注意事项：Notebeforeinstallation:1.在安装的过程中，舵杆和舵叶必须在同一温度下进行；Rudderstockandrudderbladeshouldbefittedunderthesametemperatureduringtheinstallation.2.安装和拆卸时，均不可加热舵叶上的铸钢件，只能用油压膨胀。Donotheatthesteelcastingofrudderbladeinprocessofinstallationandremoving,onlytobeexpandedbyoilpressure.二、装配步骤：Assemblingsteps:1.把舵叶放在0位；Setrudderbladetothezeroposition2.用液压泵用油脂清洁舵杆承座与舵杆的锥面；Cleanconesurfacesofrudderstockhubandrudderstockbyhydraulicpumpandgrease.3.将O型圈，密封圈挡圈套在舵杆上，O型圈在安装前，应先在密封圈槽内涂抹油脂，避免在安装时滑出。Theo-ringandsealingringaretobefittedonrudderstock,andputO-ringintogroovewithgrease,toavoidslidingoutduringinstallation.4.通过吊舵叶装置提升舵叶，并移动至舵杆下面，确保舵机、舵杆、舵叶襟翼在0位；Connecttherudderbladetoliftinggearsandmoveitintopositionbelowtherudderstock.Ensurethatthesteeringgear,therudderstock,therudderbladeandtheflapareinzeropositionasshownondrawing. 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页1.向上提升舵叶，直至与舵杆连成一体，保证O型圈在密封槽内；Liftrudderbladeuntilconnectingwithrudderstockwhole.EnsurethattheO-ringinplaceofsealinggroove.2.旋上液压螺母，并用专用扳手施加一定的预紧力；Screwonthehydraulicnutandimposeacertaindegreepreload.3.松开吊舵装置，并将其移开；Lowermountingdeviceandremoveit.4.检查手动液压泵、连接体油管接口处螺纹的清洁，将液压泵分别接到液压螺母及舵杆承座上；Checkthehydraulicpumpbyhandandthethreadsinpositionoftheconnectoroilpipelineinterfaceforclearness.Connectthehydraulicpumptohydraulicnutandtherudderstockbearing.1.连接体的最大压力：60MpaMaxpressureofconnector2.液压螺母的最大压力：65MpaMaxpressureofhydraulicnut5.轴向推进距离一旦达到要求，释放径向压力，断开舵杆承座上的液压管(此时液压螺母的液压泵不断开)，将泵移开，此时不能封闭连接口，因为舵杆承座内的液压油会在压力的作用下向外流，大约15分钟后，再释放液压螺母的压力，两连接口用旋塞堵住，并搪好水泥；Oncetherequiredaxialpushupisreached,relaxthewideningpressure,disconnectthehydraulichosefromtherudderstockbearing(bythistimethehydraulicpumpofhydraulicnutdonotdisconnect)andremovethepump.Don’tclosetheconnectionopeningyetsothattheoilstillpresentinthebearingcanleakout.After15minutesabout,thenrelaxthepressureofhydraulicnut.Twoconnectorsaretobepluggedupwithfaucet,andbefilledwithconcert.6.用专用扳手将液压螺母旋紧,并装妥防松装置（见图一） 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页Screwonthehydraulicnutbyspecialwrenches,thelockingdevicetobesetforbolts.1.最后将安装液压螺母用的开孔，用封板按图二所示焊接，焊缝应平整,无气孔，夹渣现象。Cutopeningwithinstallationofhydraulicnutaretobeweldedbyclosingplatedetailsonfigure2.Weldbeadtobeleveloff,outofairholeandslaginclusion.2.焊接结束后,应对焊缝进行探伤处理。Crackdetectionistobecarriedoutfortheweldingseam.图一图二 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页舵销与舵叶的连接Connectionbetweenrudderpinlteandrudderblade一、安装前注意事项：Notebeforeinstallation:1.在安装的过程中，舵销和舵叶必须在同一温度下进行；Rudderpintleandrudderbladeshouldbefittedunderthesametemperatureduringtheinstallation.2.安装和拆卸时，均不可加热舵叶上的铸钢件，只能用油压膨胀。Donotheatthesteelcastingofrudderbladeinprocessofinstallationandremoving,onlytobeexpandedbyoilpressure.二、装配步骤：Assemblingsteps:1.把舵叶放在0位；Setrudderbladetothezeroposition2.用液压泵用油脂清洁舵销承座与舵销的锥面；Cleanconesurfacesofrudderpintlebearingandrudderpintlebyhydraulicpumpandgrease.3.将O型圈，密封圈挡圈套在舵销上，O型圈在安装前，应先在密封圈槽内涂抹油脂，避免在安装时滑出。Theo-ringandsealingringaretobefittedonrudderpintle,andputO-ringintogroovewithgrease,toavoidslidingoutduringinstallation.4.将舵销从舵叶开口处移动至挂舵臂铸件上方，确保舵销、舵叶襟翼在0位；Moverudderpintlefromcutopeningofrudderbladetouppositionofrudderarmcastings.Ensurethatthetherudderpintle,therudderbladeandtheflapareinzeropositionasshownondrawing. 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页1.将舵销放入舵销承座，直至与舵销承座连成一体，保证O型圈在密封槽内；Takerudderpintleintorudderpintlebearinguntilconnectingwithrudderpintlebearingwhole.EnsurethattheO-ringinplaceofsealinggroove.2.旋上液压螺母，并用专用扳手施加一定的预紧力；Screwonthehydraulicnutandimposeacertaindegreepreload.3.检查手动液压泵、连接体油管接口处螺纹的清洁，将液压泵分别接到液压螺母及舵销承座上；Checkthehydraulicpumpbyhandandthethreadsinpositionoftheconnectoroilpipelineinterfaceforclearness.Connectthehydraulicpumptohydraulicnutandtherudderpintlebearing.1.连接体的最大压力：60MpaMaxpressureofconnector2.液压螺母的最大压力：65MpaMaxpressureofhydraulicnut4.轴向推进距离一旦达到要求，释放径向压力，断开舵销承座上的液压管(此时液压螺母的液压泵不断开)，将泵移开，此时不能封闭连接口，因为舵销承座内的液压油会在压力的作用下向外流，大约15分钟后，再释放液压螺母的压力，两连接口用旋塞堵住，并搪好水泥；Oncetherequiredaxialpushupisreached,relaxthewideningpressure,disconnectthehydraulichosefromtherudderpintlebearing(bythistimethehydraulicpumpofhydraulicnutdonotdisconnect)andremovethepump.Don’tclosetheconnectionopeningyetsothattheoilstillpresentinthebearingcanleakout.After15minutesabout,thenrelaxthepressureofhydraulicnut.Twoconnectorsaretobepluggedupwithfaucet,andbefilledwithconcert.5.用专用扳手将液压螺母旋紧,并装妥防松装置（见图一）Screwonthehydraulicnutbyspecialwrenches,,thelockingdevicetobesetfor 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页bolts.1.最后将安装液压螺母用的开孔，用封板按图二所示焊接，焊缝应平整,无气孔，夹渣现象。Cutopeningwithinstallationofhydraulicnutaretobeweldedbyclosingplatedetailsonfigure2.Weldbeadtobeleveloff,outofairholeandslaginclusion.2.焊接结束后,应对焊缝进行探伤处理。Crackdetectionistobecarriedoutfortheweldingseam.图一图二 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页液压泵及液压螺母的使用说明Instructionofhydraulicpumpandhydraulicnut一、操作说明：Operationinstruction1.装舵叶操作程序：Operatingprocedureforinstallationofrudderblade:a)将组装好的舵杆系统悬吊于“套筒组件”内，舵叶放置于0位，使之处于待命状态；Hanging-uptheassembledrudderstocksystemintoruddertrunk.Ensurethattherudderbladeisinthezeropositionandonstandby.b)清洁舵杆承座和舵杆的锥面；Cleanconesurfacesofrudderstockbearingandrudderstock.c)舵杆与舵杆承座上的“O”型密封圈安装时要在密封槽内抹上油脂，以免在安装过程中滑出；Theo-ringsfromrudderstockandrudderstockbearingaretobeputintogroovewithgrease,toavoidslidingoutduringinstallation.d)用清洁的液压油润滑两个锥面；Lubricatetwoconesurfacesbycleanlyhydraulicoil.e)将舵杆伸入舵杆承座中（要保证“O”型密封圈不要滑出槽外）；Extendrudderstockintorudderstockbearing.(insuretheO-ringinplaceofsealinggroove)f)旋上液压螺母，并用专用扳手施加一定的预紧力；Screwonhydraulicnutandimposeacertaindegreepreload.g)检查接头螺纹的清洁，将两只液压泵分别接到连接体和液压螺母上；Checktheplugthreadsforclearness,connecttwohydraulicpumptoconnectorandhydraulicnut.h)将压力表分别接到舵杆承座和液压螺母上；Putthepressureindicatortorudderstockbearingandhydraulicnut.i)增加液压螺母内的压力，使舵杆上的标记线（0位标记线）应与舵叶 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页上顶板上口平，以此标记线为起始值计算推入量；Increasethepressureinthenut,untilzeropositionmarkonstocklinerisinlinewiththeupperplatesideofdistanceblock.Andthentocalculatethepushuplengthfromthezeropostionmarkline.a)在舵叶水平隔板上安装一磁力座千分表（千分表的上端通过简单装置顶住液压螺母下底面）；Installamagneticstanddialgaugeonlevelingboardofrudderblade.(Bottomsideofhydraulicnutistobeholdoutagainsttheupperdialgaugebysimpledevice.)b)操作与液压螺母相连接的手摇泵（增加轴向力），直到千分表显示0.5mm的推入量,停止增压，并记录轴向压力；Operatethehandpumpconnectedwithhydraulicnutuntilabt0.5mmpushuplengthisshownonthedialgauge.Thenstopandnotetheliftingpressure.c)操作连接体相连接的手摇泵（增加径向压力），增加到工作压力的10％，使舵叶连接体膨胀；Operatehandpumpconnectedwithconnector(increasewideningpressure)untilthepressurereaches10%ofthewideningpressuretoexpandtherudderbladeconnector.d)增加轴向压力，当千分表显示0.5mm时记录轴向、径向压力；Increaseliftingpressureuntil0.5mmlengthisshownonthedialgauge,noteliftingpressureandwideningpressure.e)继续增加轴向、径向压力，直到实现工作推入量（4~6mm）并按下表格记录中间过程的轴向、径向压力值（见附表一）。在安装的过程中，，以主要考核推入量，其余压力为非考核参数；Keeponincreasingliftingandwideningpressureuntiltocarryouttheworkpushuppressure(4~6mm).Andnotetheliftingandwideningpressureduring 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页intermediateprocessesaccordingtothefollowingsheet.(seeattachedform1)Duringtheinstallation,otherpressuresarenotassessedexceptpushuppressures.a)一旦满足推入量要求，即释放径向压力，拆下连接体上的泵。但不装闷头，使液压油流出。约等15分钟后，再释放液压螺母压，待液压油流出后装闷头；Ifpushuppressurereachesthedesignedone,thenrelaxwideningpressureanddismountthepumpfromconnector.Donotmountthebulkheadsothatthehydraulicoilcanleakout.Afterabout15minutes,relaxthepressureofhydraulicnutsothattheoilcanleakoutandthenmountthebulkhead.b)将舵叶连接体上的密封圈压圈与连接体用螺栓连接,螺栓应均匀旋紧；Sealingring(snapring)ofrudderbladeconnectorandconnectorshouldbecombinedwithbolt.Boltsshouldbetightenedenevly.c)用液压螺母专用扳手将液压螺母旋紧（必要时可敲打专用扳手）；Screwonthehydraulicnutbystrickkey.(hitthestrickkeyifnecessary)d)将防松机构焊妥；Anti-loosedevicetobewidedcorrectly.e)装两侧封板(参考舵杆与舵叶连接10、11、12条)。Installbothsideblankingplates. 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页一、拆舵，使舵叶—舵杆分离:Rudderbladeanfrudderstockshouldbeseparatedbydismountingrudder.1.拆舵叶前,应用钢缆使舵叶与起吊装置相连接,并保证舵叶可以下降15~20mm；Beforedismountingrudderblade,bladeandliftingdevicearetobeconnectedbywirerope.Ensurethatrudderbladecanfall15~20mm.2.用碳弧气刨刨开舵叶上的液压螺母舱盖,并拆下防松机构；Openhydraulicnuthatchcoverofrudderbladebycarbonarcgouginganddismounttheanti-loosedevice.3.用专用扳手旋下液压螺母；Screwoffhydraulicnutbystrickkey.4.检查管接头螺纹的清洁，将液压泵接到连接体；Checktheconnectingthreadsforcleannessandconnectthehydraulicpumptoconnector.5.检查接头螺纹的清洁，将压力表接到连接体；Checktheconnectingthreadsforcleannessandconnectthepressuregagetoconnector.6.增加径向压力，直到舵杆与连接体分开为止；Increasewideningpressureuntilrudderstockandconnectoraretobedetached.7.释放径向压力，拆下泵，待油流出后装好闷头。Relaxwideningpressure,dismountpumpandinstallbulkheadaftertheoilleakout. 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页表一Sheet1舵杆液压螺母安装记录表Installlistofrudderstockhydraulicnut按照ABS规范要求液压螺母计算推进量：AccordingroABSspecification,calculatethepushuplength舵杆液压螺母工作推入量：Workingpushuplengthofrudderstockhydraulicnut推进量Pushuplength舵杆液压螺母轴向压力liftingperssure舵杆承座径向压力wideningpressureofstockbearing1mmMpaMpa2mmMpaMpa3mmMpaMpa3.5mmMpaMpa4mmMpaMpa4.5mmMpaMpa5mmMpaMpa5.5mmMpaMpa6mmMpaMpa签名（船厂代表）：日期：Signature（shipyard）签名（设备厂安装代表）：日期：Signature(supplier) 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页表二Sheet2舵销液压螺母安装记录表Installlistofrudderpintlehydraulicnut按照ABS规范要求液压螺母计算推进量：AccordingroABSspecification,calculatethepushuplength舵销液压螺母工作推入量：Workingpushuplengthofrudderpintlehydraulicnut推进量Pushuplength舵销液压螺母轴向压力Liftingpressure舵销承座径向压力Wideningpressureofbearing1mmMpaMpa2mmMpaMpa3mmMpaMpa3.5mmMpaMpa4mmMpaMpa4.5mmMpaMpa5mmMpaMpa5.5mmMpaMpa6mmMpaMpa签名（船厂代表）：日期：Signature（shipyard）签名（设备厂安装代表）：日期：Signature(supplier) 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页传动机构安装Installationoflinkdevice1.旋转主舵叶至45o（出厂时主付舵叶已经安装完毕）；Turntherudderblade45o2.在导杆衬套上均匀涂抹一层润滑油，将导杆从套筒前端伸入（见图一）。Applygreaseontheleaderbushingevenly.Inserttheleaderfromthefrontofsleeve.(seefigure1)3.将销轴穿过下销轴套筒、导杆前端孔至上销轴套筒。Extendthepintlefrombottompintlesleeveandthefrontholeofleadertoupperpintlesleeve.4.安装下销轴套筒封板；Installtheclosingplateonbottompintle图一 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页止跳块与保险处理Stopperandinsuranceprocess1.除液压螺母、销轴下端螺母和铰链螺栓设置保险外，还应该在以下几处设置保险：Thefollowingprovisionistobemadeforaneffectivelockingdevicetopreventtheaccidentlooseningofboltsexceptthehydraulicnut,bottompintlenutandhingedbolts.A:下油封密封圈挡圈的螺栓连接处的保险见图一；Boltsconnectionofbottomoil-sealringseefigure1B:放泄旋塞处的保险见图二；Drainageplugseefigure22.待舵机安装完毕后，安装止跳装置见图三；Installanti-jumpingdeviceafterinstallationofsteeringgearseefigure33.根据舵杆与舵叶连接体的连接情况，调整止跳块的高度，确保止跳块与下舵承套筒下端面的间隙小于等于2mm。Accordingtotheconnectionbetweenrudderstockandrudderblade,assembleheighthofanti-jumpingblockandadjustthediatancebetweenanti-jumpingblockandthebottomsurfaceofruddertrunkbearingisnotgreaterthan2mm. 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页 无锡市东舟船舶附件有限公司安装、使用说明书第24页共24页日常使用维护Maintenance1.由于本舵下舵承采用高分子自润滑合成材料。该材料具有水润滑、自润滑、油润滑。为了降低下舵承处的摩擦系数，下舵承处仍采用牌号：通用锂基润滑脂（GB7324-1994）进行油润滑。Lowerrudderbearingofoil2.当船进入码头或港口时，如船舶停留的时间超过七天，则每隔七天舵机操舵2-3次，即从左满舵至右满舵往复2-3次。防止海生物在传动机构上滋生。Turntherudder2~3timesperweekifnotinsailing.'