ABB电机安装指导手册
NanJing Iron & Steel Co., Ltd.
NISCO Main Drive
Technical Specification
for
Erection Guidance for Twin Motor
REVISION
Description Date Dept./Init. Rev. ind. Page (P)
Chapt. (C)
A All Issued for NISCO Main Drive project 1/24/2013
PMC / Hu Dun
TABLE OF CONTENTS
1.Introduction (5)
1.1General information (5)
2.Minimum site conditions for ABB motor final installation
(5)
2.1Civil engineering and lay-out requirements (5)
2.2Engineering and common requirements (5)
3.Installation and alignment (6)
3.1Preparation for installation (6)
3.1.1Pre-caution for installation (6)
3.1.1.1List of recommended Installation Tools
(6)
3.1.1.2List of recommended installation materials
(7)
3.1.1.3Preparation for lifting works (8)
3.1.1.4Recommended man resource from erection
company (9)
3.1.1.5Opening package and check (9)
3.1.1.6Pouring oil into the bearings (10)
3.1.1.7General tightening torques (11)
3.1.2Check of foundation (11)
3.1.2.1Combination of support pads (14)
3.2Installation and alignment (14)
3.2.1Installation of the grouting moulds (16)
3.2.2Insertion of anchor bolts (16)
3.2.3Lifting and pre-alignment of bed plate (17)
3.2.4Pre-install the D-end and the N-end bearing base
(18)
3.2.5Remove the protection cover of stator (22)
3.2.5.1Grouting the bed plate (in case of limited space)
(22)
3.2.6Lifting the stator (23)
3.2.7Insertion of the rotor into the stator (24)
3.2.8Mounting the lower bearing housings (28)
3.2.9Lowering the motor onto the bed plate (28)
3.2.10Bearing assembly (29)
3.2.11Alignment of the rotor towards the mechanics (35)
3.2.12Alignment of the stator towards the rotor (37)
3.2.13Assembly and alignment of the intermediate shaft
(40)
3.2.14Mounting of covers under the shaft line (41)
3.2.15Grouting of bed plate (41)
3.2.16Checking the alignment, air gap and tightening of fixing bolts
(43)
3.2.17Clean and check the inner parts of motor
(44)
3.2.18Mount the covers, coolers and lubrication units.
(44)
Install the coolers. (44)
Install the lubrication units. (45)
3.2.19Install the encoder. (46)
3.2.20LU – commissioning and function check (47)
3.2.21Insulation resistance test and check (47)
3.3Final inspection and installation (48)
3.3.1Covers and enclosures (48)
3.4Install the top of main motor (48)
4.Mechanical and electrical connections (48)
1. Introduction
1.1 General information
This document is guidance for install twin drive motor.
The following pictures from User’ s manual and other reference project.
The actual erection should be according to User’ s manual from ABB Oy/Machine and guidance of the engineer from ABB to do. If have any questions, please with engineer from ABB to communication.
ABB ABB ABB
All of the information in this document just only for us reference.
2. Minimum site conditions for ABB motor final installation
2.1 Civil engineering and lay-out requirements
Big enough and correct located doors or wall openings for motor or motor parts entering to building.
Correct dimensioned hauling or lifting ways from transportation device to assembly place.
Lay-out drawing(s) of installation site to be sent to ABB in advance.
ABB
2.2 Engineering and common requirements
Strong enough (see ABB weight specifications for each motor part) overhead or mobile crane which can reach all needed areas on installation area for motor or motor parts handling during installation.
( ABB )
Alignment references for motor, gearbox, coupling flange or centrelines and accent values of mill mechanics.
Good overall lightning for safety working.
Electrical supply (110-240 V) for installation tools available.
(110-240V)
Dry, clean compressed air (min 5 bar.) available.
( 5 )
3. Installation and alignment
3.1 Preparation for installation
3.1.1 Pre-caution for installation
Good planning and preparation results in correct installation, assures safe running conditions and maximum accessibility.
During installation, general as well as local safety instructions must be followed.
NOTE: Install anti-condensation heaters to keep the machine interior dry when there is a risk of condensation.
NOTE: Protect the machine against dust and rain.
3.1.1.1 List of recommended Installation Tools
Suitable materials for set-up and shimming as well as other auxiliary tools for installation are normally not included in the ABB delivery.
ABB
Auxiliary tools for installation are to be supplied by the customer.
The following should be available on site if required:
attachments for gauges, extension brackets and other alignment tools
other auxiliary tools and materials for the installation, such as hydraulic jacks and bracket plates with adjusting screws
for suitable oil qualities, see Chapter 7.5.1, Lubrication.
7.5.1
1
2
3
4
5
6
7
8 ( 130mm )
9 a lever
for turning the rotor
10 some hydraulic jacks
11 bracket plates with adjusting screws
12
3.1.1.2 List of recommended installation materials
1 sealant
2 thread glue
3.1.1.3 Preparation for lifting works
Before lifting stator and rotor
1. Check the weight of every parts of main motor and total weight.
2. Check the capacity of overhead crane 70 ton . 70
3. Check the capacity of lifting beam.
4. Check the capacity of lifting strip.
3.1.1.4
Recommended man resource from erection company
The recommended team number is about 12 15 mechanical worker and 3 4 electrician later, normally working 8-10 hour per day no shift.
12~15 3~4 8~10 3.1.1.5
Opening package and check
Unpacking and OPI were done by XXXX, (no remarks of missing or damaged material). Check the every parts of main motor arrived site according to installation drawings.
Package of Stator
Package for rotor
3.1.1.6 Pouring oil into the bearings
Before turning the rotor, suitable bearing oil must be filtered through a 10 micrometer mesh, and poured into the bearings.
10 To pour oil into the bearings:
1. Turn the rotor using a lever.
2. Pour oil continuously into the bearings at both ends of the machine while turning the
rotor.
see Figure 3-1, Pouring oil into the bearings.
Figure 3-1 Pouring oil into the bearings
3.1.1.7 General tightening torques
General tightening torques for screws are given in Chapter 7.4.1, The tightness of fastenings. Use these values if no specific tightening torques are given in this manual or in the mechanical and electrical drawings (see Section 4, Mechanical Drawings and Section 5, Electrical Drawings).
7.4.1
4 5
3.1.2 Check of foundation
The structural design of the foundation is not included in the ABB scope, and the customer or a third party is therefore responsible for this.
ABB
The machine is anchored to the concrete foundation using anchor bolts, sole plates, or a bed plate, see Section 4, Mechanical Drawings. They are available from ABB as an optional accessory set.
4 ABB
The grouting operation is not included in the ABB scope and responsibility, unless formally included in the agreement.
ABB
The installation of the machine should be planned as early as possible. Before lifting the machine onto the foundation:
Check that the position of the anchoring or fixing holes and the height of the foundation are in agreement with corresponding measurements on outline and foundation drawings in Section 4, Mechanical Drawings.
4
Section View
Top View
Check that the foundation is flat. If any inclination has been agreed upon, the permissible inclination must be stated on the installation drawing.
Sweep or vacuum-clean the foundation some days before testing.
Make sure that the foundation is made of non-shrinking concrete.
Wash and rinse the grouting holes. Walls of the grouting holes must have rough surfaces and be free from debris to give a good grip. Remove oil or grease by chipping away slices of the concrete surfaces.
Foundations were checked before installation to clarify dimensions and condition of foundation.
3.1.2.1 Combination of support pads
The supporting pads must be forced into the concrete and level using a spirit level (Sensitivity 0.1mm/m)
3.2 Installation and alignment
Check that the axial center line has been marked on the site permanently.
NOTE: For top-forward twin drive, the lower motor with the intermediate shaft must be aligned before the top motor is grouted.
Twin drive motors are delivered in pieces. To install the machine:
1. Install the grouting moulds.
2. Insert the anchor bolts.
3. Lift and pre-align the bed plates with the bearings.
3A. Pre-install the D-end and the N-end bearing housing (so as to final align the bed plate, then remove them totally). ( )
3B. Remove the protection cover of stator
3C. Grout the bed plate (in case of limited space)
3D. Remove the protection cover of rotor
3E. Lift the rotor to assigned position
4. Lift the stator.
5. Insert the rotor into the stator.
6. Mount the lower bearing halves.
7. Lower the motor onto the bed plate.
8. Assemble the bearings.
9. Align the rotors towards the mechanics, (Bearing housing alignment and level check
10. Align the stators towards the rotors.
11. Assemble and align the intermediate shaft (bottom motor).
12. Mount the covers under the shaft line.
13. Grout the bed plate.
14. Check the alignment and tighten the fixing bolts. (Air Gap Check and adjustment, final
tightening of stator fastening bolts)
15. Clean and check the inner parts of the motor.( Brush gear adjustments)
16. Mount the covers, coolers and lubrication units.
17. Install the encoder.
18. LU – commissioning and function check.
19. Insulation resistance check (Windings and bearings)
3.2.1 Installation of the grouting moulds
The embedded parts to be installed into the structural concrete are supplied well in advance before the main equipment delivery. Only the grouting moulds (integral part including anchor plate and sleeve) will be delivered at an early phase. T-head anchor bolts, nuts, washers, jacking screws, lifting hooks etc. will not be needed before installation of the motor.
( ) T
To install the grouting moulds:
1. Locate the grouting moulds for the motor foundation bolts in relation to the mechanical
machinery by using the plant layout drawings. Note the possible different types of double and single grouting moulds.
2. Check the position of each grouting mould with dimension drawings of the motors.
3. Weld the grouting moulds, which are located close to each other, together with a
sufficient number of iron bars. Check the correct distances between single and/or double grouting moulds according to the dimension drawings. Weld these sets and the
other separate grouting moulds to a sufficient number of concrete reinforcing bars so
that the distances and elevations of the grouting moulds will remain according to the dimension drawings.
4. Make sure that the grouting moulds are correctly aligned and reliably welded to the
concrete reinforcing bars, so that casting and vibrating the concrete will not move the
grouting moulds.
5. Cast the concrete up to the level of the base casting surface.
3.2.2 Insertion of anchor bolts
To install the anchor bolts:
1. Make sure that the grouting moulds are clean and that there are no foreign particles
inside the moulds.
2. Insert the T-head anchor bolts into the grouting moulds with the lifting hooks. The
lifting hook (eye bolt) at the upper end of the bolt is used for lifting the bolt. T
3. Lower the bolts through the holes in the anchor plate. The anchor plate and the T-
head prevent the bolt from turning during tightening.
T
4. Place plastic sleeves around the anchor bolts on top of the concrete. The sleeves
prevent this part of the bolts from getting stuck in the concrete, and thus allow the bolts
to elongate during tightening. The plastic sleeves are delivered with the anchor bolts.
NOTE: These polyurethane sealing material is used to avoid any leak of grout to sleeve.
3.2.3 Lifting and pre-alignment of bed plate
To lift and pre-align the bed plate:
1. Lift the bed plate onto the concrete (see Section 4, Mechanical drawings).
( 4 )
2. Let the bed plate rest on the jacking screws and pre-align it using the machined
bearing surfaces and the permanent axial center line as reference. The bed plate was lifted to foundation on the base plates (double conical wedges) and fine level tuning done by adjusting above wedges.
The anchor bolts were tightened by final torque 6450 Nm pre-tensioning tool. 6450 Nm
The bed plate was aligned according of given reference point`s (accuracy 0.2mm). ( 0.2mm)
3.2.4 Pre-install the D-end and the N-end bearing base
The bearing housing bottom surface were cleaned very well before lowering these for bed plate cause of insulation sheets (multilayer structure 2 layer of insulation sheets- copper plate-2 layer of insulation sheets) are very sensitive and to avoid any damage and insulation resistance problem on future.
( 2 )
Bearing housings are pre-adjusted in the factory when the tapered holes for pins are spot on housing standing in right place.
Please pay attention to each parts of motor and understand each parts will install to which location before installation.
The following pictures is insulation sheets and normally sheets, each insulation sheets and normally sheets have No. by themselves, please install them according to manual.
The following picture is pins for bearing, which have insulation material.
When we install the bearing’s bolt, we can see the length thread at both side is different. We should keep the long one at top