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    科學技術論文

    超大直徑盾構機工地組裝流程及關鍵技術

    時間:2019年07月02日 所屬分類:科學技術論文 點擊次數:

    [摘要]本文結合施工實例,針對超大直徑盾構機工地組裝所面臨的重點、難點問題進行分析,重點研究了超大直徑盾構機工地組裝過程中超大尺寸、超重及關鍵部件的組裝關鍵技術,同時介紹了組裝的工序、注意事項等。本文可為今后類似工程提供相關的技術指導及參考

      [摘要]本文結合施工實例,針對超大直徑盾構機工地組裝所面臨的重點、難點問題進行分析,重點研究了超大直徑盾構機工地組裝過程中超大尺寸、超重及關鍵部件的組裝關鍵技術,同時介紹了組裝的工序、注意事項等。本文可為今后類似工程提供相關的技術指導及參考,具有較大的借鑒意義。

      [關鍵詞]盾構機;工地組裝;流程;關鍵技術

    建筑技術

      盾構機常在工廠進行初步組裝并完成調試驗收后,再運輸到施工工地進行組裝,經始發調試等進入工作狀態。超大型盾構機的一些超大尺寸、超重部件由于加工制造技術、運輸、成本等限制,無法一次成型或者整體加工,需采用分塊加工后再進行整體組裝;并且在工廠內無法完全組裝而需預留到工地組裝,否則無法分塊運輸或者需要進行破壞性拆分而造成設備損壞。工地組裝受場地大小、吊裝條件、裝機效率、成本及安全等因素影響,組裝難度巨大。本文結合中鐵306號超大直徑盾構機工地組裝相關流程、關鍵技術進行論述。

      1裝機準備及吊裝設備選型

      組裝前熟悉盾構機的主要參數,結合場地條件選取所需使用的大型設備,同時做好物資設備等的準備工作。

      1.1盾構機概況

      中鐵306號盾構機開挖直徑15.03m,主機長約15m,整機長約135m。整機重約4300t,其中主機重約2700t,后配套重約1600t,最重單件刀盤570t(含刀具、吊具)。后配套系統由1#-5#拖車、1節連接橋及輔助平臺組成。

      1.2組裝場地概況

      隧道始發段設計主、副2個設備吊裝井口進行同步作業以保證工期、工序。主井口尺寸為18×18×21m(長×寬×深),副井口尺寸為14×12.5×15m(長×寬×深)。主、副井口間有效間距153m,井口結構尺寸滿足盾構機刀盤、盾體、拖車等大件的井下組裝。

      1.3吊裝設備選型

      吊裝設備須滿足起重負載要求,并具備安全系數。根據場地條件,主井口采用龍門式起重機進行刀盤等尺寸、重量大的部件吊裝;副井口采用履帶起重機進行連接橋及2#-5#拖車的吊裝。鋼絲繩、卸扣等吊裝工具根據最大載荷按照安全系數選取合格的標準產品即可。下面以龍門式起重機、履帶起重機在最大負載情況進行選型計算,其它所需用到的起重設備可參照選型。

      1.3.1龍門式起重機選型

      綜合施工場地吊裝井口尺寸及吊裝部件的相關參數,對龍門式起重機進行選型,龍門式起重機必須滿足:起重能力wmin≥Gmax×δ;起重機跨度Smin≥max(Lmax,Lj)。

      式中wmin——龍門式起重機最小起重能力,t;Gmax——最重單件刀盤重量,570t;δ——起重機安全系數,取1.1;Smin——龍門式起重機最小跨距尺寸,m;Lmax——最大單件尺寸,15.03m;Lj——起重機軌道方向地連墻間距,19m。計算得出Wmin≥627t;Smin≥19m。據安全經濟性原則,通用型起重能力650t雙鉤龍門式起重機,跨距22~28m可調,滿足最大尺寸、最重部件的起吊要求。

      1.3.2履帶起重機選型

      履帶起重機進行副井口的設備吊裝,配合龍門式起重機在刀盤焊接完成后將其平抬及翻轉,平抬刀盤時履帶起重機負載最大。履帶起重機必須滿足:Qmin≥G1×δ×η;G1=Gmax×h2/(h1+h2)。式中Qmin——履帶起重機最小起起重能力要求,t;G1——履帶起重機最大受力,t;Gmax——最重單件刀盤重量,570t;δ——不平衡系數,取1.1;η——動載系數,取1.1;h1——履帶起重機吊耳到刀盤重心距離,6.36m;h2——龍門式起重機吊耳到刀盤重心距離,7.62m。計算得出G1=310.7t;Qmin≥376t。根據安全經濟性原則,選取通用型400t履帶起重機,滿足起吊半徑范圍內的吊裝安全要求。

      1.4物資準備

      盾構機工地組裝作業量大、難度高、周期長,需要提前做好所需材料、設備、工具的準備工作。組裝過程中易變形、易損壞件存放需要使用臨時支撐、固定裝置及工裝等保持設備不損壞、不變形。此外,組裝時所需要的水、電、氣等條件必須保證。

      2盾構機工地組裝流程

      組裝工序是組裝效率、安全質量及經濟性的重要因素,根據井口凈空尺寸限制、吊裝設備與盾構各部件的尺寸、重量進行工序安排。

      2.1主機(主井口)組裝流程

      主井口主要進行刀盤、主機及1#拖車等部件的吊裝下井工作,以及與后配套的連接。

      2.2后配套(副井口)組裝流程

      副井口進行后配套系統的設備橋及2#-5#拖車吊裝下井工作。

      3工地組裝關鍵技術

      盾體、主驅動、刀盤等關鍵部件的工地組裝質量直接影響設備的整體性能甚至工程成敗,其組裝的關鍵技術尤為重要。

      3.1盾體組裝關鍵技術

      盾體外徑達14.98m,中前盾分為10塊,尾盾分為4塊,各分塊運到工地后再進行拼裝、焊接,形成由前中盾、尾盾組成的完整盾體。中前盾底塊6的調整定位、頂塊1的下井安裝,盾尾的調圓、焊接是需要掌握的關鍵技術難題。

      3.1.1前中盾底塊6安裝定位

      前中盾底塊6的下井組裝是盾構主機組裝的開始,后續組裝都以它為定位基準進行。底塊6中心需與隧道軸線對齊,盾體切口環與井口架構預留的距離X足夠滿足刀盤下井安裝。在底塊6避開切口環位置分前后2排布置4個調平油缸,通過油缸的升降來調整底塊6到合適位置與其左、右側的盾體塊5、7進行法蘭連接,并按要求安裝密封條及涂抹密封膠[1]。

      3.1.2前中盾頂塊1的安裝定位

      前中盾頂塊1在所有盾體塊中最后安裝,其兩側的法蘭面需同時與塊2、塊10的法蘭面傾斜貼合,安裝的空間較小,定位銷很難穿入塊2、塊10的銷孔,并容易將左右側盾體塊的密封擠壓損壞。因此塊1安裝時需要控制速度,最后利用千斤頂將塊1往下頂進迫使塊2、塊10張開,確保塊1安裝到位并插入定位銷。頂塊1安裝完成后,緊固整個中前盾連接螺栓。

      3.1.3尾盾組裝技術

      尾盾共分4塊下井安裝,盾尾底塊安裝時其中心線與前中盾的中心線對齊,其前端與前中盾尾部截面對齊,然后再依次將尾盾左塊、右塊及頂塊下井。盾尾安裝過程中需要在內部加強支撐,防止薄壁圓筒變形,并且使用全站儀測量尾盾放置的位置是否存在偏差。測量底塊內圓到中心線的距離,并根據情況及時調整,確保盾尾整體的圓度及與中前盾的同軸度。

      3.1.4盾體焊接技術

      前中盾焊接前需確保各分塊間的連接螺栓已打緊,分塊間錯臺≤0.1mm,并且要在氣墊倉保壓完成后進行;焊接時采用多層多道小規范,減小焊接溫度防止燒壞密封。測量調整盾尾與前中盾的中心線偏差≤3mm,測量調整盾尾半徑偏差≤±5mm;盾尾焊接時需要保留內部支撐工裝,先焊接盾尾分塊間的直焊縫,其次焊接盾尾與中盾處環焊縫,再焊接其他焊縫。盾體焊接后進行UT探傷。

      3.2主驅動吊裝關鍵技術

      3.2.1主驅動翻身吊裝技術

      主驅動運達工地后進行水平支撐放置,在地面完成防銹油漆清理和驅動電機、中心倉、伸縮環等的組裝工作,并在盾體下部5個分塊組裝完成后再進行吊裝。主驅動重約530t,直徑8.5m,采用650t龍門式起重機進行吊裝,并需配合專用吊裝、翻身工裝。翻身工裝端著地支撐,主驅動起吊工裝端起吊,吊鉤慢速抬升吊起工裝最終使主驅動整體垂直吊起,用龍門式起重機進行平移及下井吊裝,找準主驅動與中前盾的定位孔并進行緊固連接。

      3.2.2主驅動吊裝工裝安全校核

      使用SolidWorks建立起吊、翻身工裝的三維模型,再用ANSYS進行網格劃分、受力加載,分析主驅動吊裝過程中起吊、翻身工裝受力情況以進行安全校核。仿真分析顯示,翻身工裝最大應力發生在法蘭與筋板焊接處,最大應力值為55.5MPa;起吊工裝最大應力發生在法蘭板與筋板連接處,最大應力值為134MPa。仿真分析得知最大應力都在材料許可范圍內,滿足吊裝安全性要求。

      3.3刀盤組裝技術

      3.3.1刀盤拼接技術

      刀盤分為6個邊塊(含副梁)、1個中心塊,分塊運輸到工地后進行拼接組裝與焊接。刀盤拼裝時需要支撐起足夠的高度保證仰焊的操作性,拼裝完成后進行靜置觀察,調整各個分塊高度并進行刀盤平面度、圓度等重要參數測量,刀盤整體參數滿足設計要求,達到焊接條件后開始進行整體焊接。

      4結束語

      本文相關技術成功應用于超大直徑泥水盾構機工地組裝,避免了常見問題的出現,保證了施工安全與質量,同時兼顧了成本與效率,可為今后類似工程提供相關的技術指導及參考,具有較大的借鑒意義,但仍有許多未提及的知識及事項需要關注:(1)地面及結構井須滿足承載力要求,定期監測地表沉降;(2)吊裝時設備的安全防護;(3)吊裝設備、鋼絲繩、卸扣等的定期安全質量檢查;(4)遵守相關安全、質量、環保法規。

      [參考文獻]

      [1]劉智香.超大直徑盾構機的組裝技術[J].鐵道建筑技術,2009,4:60-64.

      [2]趙懷輝,葛兵,丁洪波.大型泥水盾構機主機裝配[J].理論研究,2012,4:42-43.

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