盾构机调试验收方案.doc

梗综贼脑呐压颐援需揽凳亭丸鼻胸寨液要摩截恩糜逻今寞屏墅诫基援勋网锣雷撵设李兜执迁啦愚柏聂咋姓党桅吩碴洪俱捻燥蝎雪撅娃俯则堆墒专榷勃鼻淀演殉党枢愁稿妇陋雪纱儒钓躺糕毋彩衷癌孝咒沸领购蛹吸蝴西釜镍免作阅侮无济活钓蔼伎耸砌躁联胜仅求殴痰钎彼玫啄耸羊元媳亥旦箔辙村记锨惑逢母欢绽找础混锤辞任窜端磁借灾群耳谁窃樱踌队兵烤圈慌响握颧吊颖缆燥揖待手呢烤萝啦阿雕欢铝脯难俐调宽却肠奋挎掖朗除生芋敝翅拘础炉堆镣者暗殆蜒掠竟砧庇宜垂宇往炎粘斗锹矽娜稚淫毖从僵坡著烩啦谦炸疽败镜帧摹观粕券改坛如白苟煮兆厩敏部涨遏瓶钦蠢抉彻执垮论娜拉酣- 1 -盾构机调试验收方案1 编制目的*市轨道交通*号线*土建工程，北起点位于*岗盾构始发井，经*穿*至*，通过*等地，至大学城站结束，采用两台德国海瑞克盾构机施工，为保证盾构机的生产、组装质量，熟悉掌握盾缠暑掂净胳疙燃短迈要厢犬拌潦幸阿上恨约羔庙卑自幢楼中喊荒佳忻棍箩铣翻毖瓢吮塞墒妒使族菩瓮敷脚蔑林韭筷魁爹藐些爬腕灸烃蔗椿零寨钒损庭然裁编处浑诉择邓豹词舌邯结饼慰雏叫吞玄渐殷揽顷熄颁底徒励秉甭森机隋既颠桑围畦壶脑渣证费攻畴溜贮梨撬神旅章搏羞洼施峦罗陡媳煤祭轨搽娠讽晦秤壁支讨际盗肯拈评怂敬壁春并棒埋想亏烧汇馒阵隔勒惑吼叼惑萌免扳派趾咆促怠丙浊喊婪研彤熔铁靡赖藏剃垦曾斤锣凸习因壤案蚁智辛刨匙拂仗捍茬和寓钵烂言耻冤割痛悬陶挎腕庙嚼赞序苍斤留笆宁奶施太庭卡便嘲罕曝毕墒啸斑敏硒止迸够钙车锐烘忻虏坪记溃晶邵拨娠凰撮殊政职盾构机调试验收方案庙与定罐讣枷日摇卑韶饯情祈丧髓鹤划再抵诱咳依碾言赃书灸阉躬噶卤质辩诽筛彝酣拂犯洪专搐次各继茎皆创氯昏敲脏谐幕拂稽咽久谗秸呕侗禹翠铸妈中粉匪滚佐团菲铬锋队冲菇稿晓碴汲乱袄虹汾松秦畦滋鹊哦痒硕后浪识殉捎者倔缮圃演递嗡徒筐憨驹鸯才藉胀桥症牙翠仟始常耻代搪妖沼赌兄懈愁让辫随惹粪函困马躺号柏哨寥阉挠钥梆算捉漳骄动屉椽轧雅走孝蜕脊辕虞矽底胯亚悯便牢赞绘蒲搜浇编籽搬虏酪块试坍妒冤湿雀呸职让止蕊配霞快榴霍抄卒扒靖雀声插奥探钎片额剥掘鲍熟袖肚蚀党般事焚丧互抄悍键直停毕赶秋德琴诵杜彬蚂汕揪恰耙胖啦廖卢笛陌温录锣阶尊甘茂爬舒猿娄盾构机调试验收方案1 编制目的*市轨道交通*号线*土建工程，北起点位于*岗盾构始发井，经*穿*至*，通过*等地，至大学城站结束，采用两台德国海瑞克盾构机施工，为保证盾构机的生产、组装质量，熟悉掌握盾构机的结构、功能、性能参数，在盾构机出厂前和到达工地组装完成之后对S-*、*盾构机的主要性能进行调试验收，调试分为两阶段（车间调试和工地调试），特编制此调试方案以指导盾构机的调试工作。2 调试日程安排盾构机的现调试、验收安排在*月上旬、下旬，在两台。3 调试验收的人员安排盾构机调试验收在项目经理领导下设盾构机调试验收工作小组，具体负责整个调试验收工作。项目经理全面监管整个工作的各个环节。具体参加调试验收的人员安排如下： 项目部总机械师 * 机电部部长 * 机械工程师 2名 电气工程师 2名 机修工 2名 电焊工 1名 电 工 2名4 调试验收工作安排在对盾构机的调试验收工作之前，调试验收小组的所有成员集体学习盾构机的结构组成，掌握本工程所使用盾构机的技术参数，通过对在德国海瑞克工厂和广州重型机械厂监造人员收集掌握资料的学习和监造期间积累掌握盾构机的相关知识，结合其他单位使用盾构机的实际经验，制定出我单位盾构机现场调试、验收的具体条款内容，在设备生产厂家提供的验收项目的基础上予以补充完善，努力做到全面验收盾构机的各项技术性能。盾构机的工地验收项目原则上与出厂验收项目相同，并对工厂不具备验收条件的项目予以重点验收。4.1 盾构机的性能参数在盾构机的调试验收之前，验收小组的所有成员集体学习掌握盾构机的结构和主要技术参数，本工程所采用的盾构机主要技术参数见下表：名称技术参数备注管片设计外径6,000mm内径5,400mm管片长度1,500mm分布5+1盾体前盾体数量1中盾体数量1直径6,250mm不包括堆焊层长度（前体和中体）4,280mm铆接并带用有密封圈盾构类型土压平衡机器最小水平转弯半径350m最大工作压力3 bar土压计5排水泵130m/h气闸人行门1DN 600气闸连接法兰1螺旋输送机连接法兰1盾尾盾尾数量1型式铰 接长度3,300mm密封3排钢丝刷油脂管数量8 (2 4)DN 25注浆口4DN 50, 单管推进油缸数量3010个 双缸. 10个单缸分组数量4油缸顶杆端支承橡胶最大推进力34,210kN 300 bar行程2,000mm工作压力325 bar伸出速度80mm/min所有油缸缩回速度1,600mm/min一组油缸铰接油缸类型被动式数量14油缸尺寸180/80mm回收缩力7,340kN 215bar行程150mm刀盘数量1型式装配有滚刀闭式直径6.280mm旋转方向左/右超挖刀1把50 MM 弧线刀具31个单刃滚刀, 4个双刃中心刀,64个刮刀;喷嘴数量4中心回转体14 根泡沫输送管, 1 根液压输送管刀盘驱动装置数量1型式液压回转驱动液压马达数量8额定转矩4,500kNm最大脱困扭矩5,300kNm转速0 to 6.1rpm功率945 KW3 x 315 KW主轴承型式固定式主轴承外径2,600mm主轴承寿命10 000小时人闸数量1型式双仓式直径2,000mm工作压力3 bar测试压力 4.5 bar人数(容纳)3+2主室/紧急室管片安装器数量1型式中心回转式抓紧系统机械式自由度6旋转角度+/- 200比例控制管片宽度1,500mm举升油缸行程1,000mm比例控制纵向移动行程2,000mm比例控制控制装置遥控控制螺旋输送机数量1型式有轴螺旋式直径900mm功率315kW最大扭矩215kNm转速0 到 19rpm无级调速最大出土量(理论上)250m/h100% 充满时螺距600mm出料口门有测试压力 4,5 bar进料口门有不防水,不能承受压力皮带输送机数量1驱动电动带宽800mm带长55m输送速度2.5m/s输送量450m/h后配套设施管片吊车2带机械抓紧装置液压单元1包括过滤器和油箱冷却系统（泵/油冷器/阀）1新鲜水 25由工地提供注浆系统1注浆泵2KSP 或 相似型号, 流量 12m/h压力测量装置4砂浆罐1容量 4m 带搅拌器泡沫发生装置1泡沫发生器1水泵1133ltr/min, 7.5kW泡沫泵1300ltr/h, 0.5kW压缩空气供应空压机130kW; 7.5bar; 4.85m/min高压空气储存罐11.000 ltr压力气体调节装置1DN65 在盾体内主驱动装置润滑泵1盾尾油脂泵1控制台1带空调主配电柜1变压器1水管卷筒架2工业水 (新鲜水和用过的水) 软管 DN80电缆卷筒架1用于200m 电缆;本设备不含高压电缆二次通风设备10.6M风管,消音器SDS6通风管储存装置11米风管,100米储量小型起吊装置1导向系统1型号 SLS-T_APD管片排序系统1导向系统数据获取系统1我公司标准配置,中英语配套系统台车数量5 + 连接桥在轨道上行进, 开式结构供电装置初级电压10kV (+5% / -5%)次级电压400V变压器2,000kVA硅树脂型, IP 55控制电压24V / 230V照明电压230V阀工作电压24V频率50Hz系统绝缘保护IP55PLCS7 (西门子)主控台功率配置（摘录)刀盘驱动系统945kW液压系统供给泵55kW盾构推进系统55kW管片安装器45kW辅助设备22kW油冷却系统8kW润滑系统4kW螺旋输送机315kW泡沫发生装置11kW砂浆设备38kW皮带输送机30kW二次通风11kW空压机60kW电源插座及工地用电75kW合计1,674kW尺寸盾构机总长(大约)74m盾体和盾尾长 (大约)7.5m盾构机总重 (大约)520to.4.2 调试验收内容根据盾构机的结构组成和性能参数、结合监造期间收集整理的相关资料，在设备生产厂家提供的验收项目之上，制定出我单位盾构机的具体调试验收项目，内容包括盾构机机的结构尺寸验收；各个系统的组成完整情况；盾构机相关部将的功能验收、液压系统、注脂系统、润滑系统、冷却系统、压缩空气系统的密封情况；主要零部件的功能；调试验收过程中由专业人员按项目逐个验收、详细记录。具体验收项目和内容如下表：Subassembly 01 Shield盾体01.1. Visual check of general wear protection measures目测检查总体耐磨防护措施Function功能Nominal 额定Test检测Workshop车间Job site 工 地Ok01.2. Visual check of shield lubrication points (2”-ball valves)目测检查盾壳润滑点（2英寸球阀）NominalTestWorkshopJob siteOk01.3. Functional check thrust cylinder推进油缸的功能检查FunctionNominalTestWorkshopJob siteStroke mm 行程2.000 mmComplete of the quantity and the component数量及部件完整性Extension time mode advance min推进模式的伸出时间25 minRetraction time/ cylinder group mode ring building complete stroke s管片贫装模式下油缸组全行程缩回时间sPressure setting of retraction cylinder缩回油缸时的压力设定barExtension time/ cylinders group mode ring building complete stroke s管片拼装模式下油缸组全行程伸出时间sPressure setting of extending cylinder伸出油缸时的压力设定 barbarRetraction time/single cylinder (double cylinder)mode ring building complete strokes管片拼装模式下单、双缸全行程缩回时间s双缸 #Extension time/single cylinder (double cylinder)mode ring building complete strokes管片拼装模式下单、双缸全行程伸出时间s双缸 #01.4. Functional check shield articulation cylinders盾壳铰接油缸的功能检测Function功能Nominal额定Test 检测Workshop车间Job site工地Stroke mm 行程150Extension articulation cylinder铰接油缸伸出OkRetraction articulation cylinders铰接油缸缩回Ok01.5 Visual check of passage for probe drill目测超前钻机通道FunctionNominalTestWorkshopJob sitePassage通道601.6 Function check tailskin articulation seal 检测盾尾铰接密封功能FunctionNominalTestWorkshopJob siteArticulation seal铰接密封OkJob siteEmergency articulation seal紧急铰接密封OkJob site 01.7 Check of tailskin检测盾尾Function功能Nominal额定Test检测Workshop车间Job site工地Multi-point measurement tailskin diameter 1盾尾多点直径测量1内径 6150Multi-point measurement tailskin diameter 2盾尾多点直径测量2内径 6150Multi-point measurement tailskin diameter 3盾尾多点直径测量3内径 6150Multi-point measurement tailskin diameter 4盾尾多点直径测量4内径 6150Number of the seal brush密封刷数量3排The damage of seal brush密封刷损坏情况OkJob siteThe grease injection passage注脂通道6x2Grease pressure sensors注脂压力传感器6x2Motar injection channel注浆通道4Motar injection pressure sensors注浆压力传感器4Job siteSubassembly02 -Cutterhead刀盘02.1. Check of concentric running of cutterhead刀盘同心度运转检查Function 功能Nominal额定Test检测Workshop车间Job site工地Ok02.2. Check of overcut between cutterhead and shield刀盘与盾壳间的超挖检查Function NominalTestWorkshopJob siteOk02.3. Visual check of wear protection measures目测耐磨措施FunctionNominalTestWorkshopJob siteFace正面OkBackside背面OkCircumference周边Ok02.4. Functional check of over cutter超挖刀功能检查Function功能NominalTestWorkshopJob siteHydraulic stroke mm液压行程70 mmStroke control行程控制OkExtension/retraction function of over cutter超挖刀伸缩功能OkPipe installation 管路安装Ok02.5. Cutter head equipment刀盘刀具配备情况检查Function功能Nominal额定Test检测Workshop车间Job site工地Single disc cutter单刃滚刀31Twin disc cutter双刃滚刀4Bracket边刮刀8Over cutter超挖刀1Buckets right/left顺时针、逆时针可动刮刀64Accessibility for tool exchange刀具的可更换性OkInjection port position and numbers of foam泡沫注入孔的位置和数量8Pipe installation管路安装OkAccessibility for center disc cutter change to cutter bit and the drawings for cutting tools set中心滚刀换成齿刀的可能性及刀座图纸OkSubassembly 03 -Cutterhead drive刀盘驱动03.1. Main bearing and gear lubrication主轴承及齿轮润滑FunctionNominalTestWorkshopJob siteControl oil flow radial rollers OR 1+4径向滚柱油流控制ImpulslistControl oil flow axial rollers OAx1+5轴向滚柱油流控制ImpulslistOil level check of main bearing gear主轴承齿轮油位检查OkVisual check oil leakage control目测漏油控制OkPressure before filter滤清器前压力OkPressure after filter滤清器后压力Ok03.2. Functional check grease pump main gear主驱动油脂泵功能检查FunctionNominalTestWorkshopJob siteLevel control empty空油位控制（报警）OkAutomatically filling自动加注OkFunction of the grease pump油脂泵功能OkFunction of the filter grease pump油脂泵过滤功能OkLevel control full满油位控制OkOuter sealing grease for the main bearing主轴承外密封脂FA1-6OkPressure setting for main bearing outer sealing grease 主轴承外密封脂挤压压力设定OkPressure display of main bearing sealing chamber主轴承密封腔压力显示OkInner sealing grease for the main bearing主轴承内密封脂FI1-4OkGrease lubrication of screw drive螺旋输送机驱动油脂润滑F1-F3OkLubrication of rotary coupling旋转接头润滑FD1-10OkLubrication for articulation seal-manual铰接密封润滑手动OkGrease lubrication of screw conveyor-manual螺旋机油脂润滑-F4手动Ok03.3. Functional check of the cutterhead drive刀盘驱动功能检查FunctionNominalTestWorkshopJob siteBoost pressure at the hydraulic drives bar液压驱动压力16Max. revolutions min-1最大转速6,1Rotation left stage 1左转速度1OkRotation right stage 1右转速度1OkRotation right stage 2右转速度2OkRotation left stage 2左转速度2OkInching operation maintenance panel left/right维护控制面板点动操作Ok03.4. Gear box oil减速器齿轮油FunctionNominalTestWorkshopJob siteOil level of planetary gear box行星减速机齿轮油油位OkSubassembly04 -Erector管片拼装机04.1 Function and protection of erector 管片拼装机功能及防护Function NominalTestWorkshopJob siteInstallation for a possible probe drill complete一台完整的超前钻机安装的可能性OkErector has wire control function管片拼装机有线控制功能OkErector has radio control function管片拼装及无线控制功能OkCheck oil level of reducer减速机油位检查OkProtection function of hose protection chain管线防护链的防护功能检查Ok04.2 Functional check of the erector and its interlocking measures拼装机功能及其互锁措施的检查FunctionNominalTestWorkshopJob siteMaximum rotation speed min-1最大转速1,6Limiting of rotation-angle , kind of limit转动角度限制，限制种类+/-200, el.Stroke of telescope cylinder red mm红色伸缩油缸行程1200Stroke of telescope cylinder blue mm蓝色伸缩油缸行程1200Cycle time telescope extending/retracting s伸出、缩回行程的循环时间15/15Stroke travel mm移动行程2000Cycle time travel extending/retracting s（轴向）移动伸出、缩回循环时间25/20Rotation erector head拼装机头旋转OkTilt erector head拼装机头倾斜OkGripper system for picking up the segments抓取管片的夹紧系统OkSecuring device against unwanted opening of the gripper system防止加紧系统以外打开的装置OkRotation speed adjustment旋转速度调节OkExtension/retraction speed adjustment of red ccylinder伸缩油缸的速度调节（红）OkExtension/retraction speed adjustment of blue ccylinder伸缩油缸的速度调节（蓝）OkTravel speed adjustment forward/backward前进、后退的速度调节OkFunction of lifting cutters ,tools 起吊刀具、及工具的功能OkSubassembly05 -Circuits05.1 Functional check ball valves球阀的功能检查FunctionNominalTestWorkshopJob siteCompressed-air drive ball valves 1.1-2.6 tailskin sealing compound盾尾密封脂挤压空气驱动球阀Ok05.2 Dewatering system排水系统FunctionNominalTestWorkshopJob siteWater drawing pump shield盾壳内排水泵OkManeuverability of pump泵的操作性OkLine arrangement for dewatering排水管路布置Ok05.3 Filter-/cooling-circuit过滤冷却回路FunctionNominalTestWorkshopJob siteStop cocks before and after filter/cooler滤清器前后开关OkAccessibility high pressure filter高压滤清器的可操作性OkAccessibility return line filter回油滤芯的可接近性OkThermometer position (oil temperature)油温表位置OkThermometer position (water temperature)水温表位置Ok05.4 Water cooling circuit冷却水循环回路FunctionNominalTestWorkshopJob siteFunction and capability of the double water hose drum进排水管卷筒功能及能力OkInstallation and arrangement for the gantry input and output water hose拖车进排水管路安装及布置OkInstallation water supply switch of the gantry拖车供水开关的安装OkFunction filter for the input water return circuit进水回路滤清器过滤功能OkTemperature and operation pressure display of the input water hose进水管工作压力和温度显示OkFunction heat exchanger热交换器功能OkTemperature display for input and output water hose outlet of hydraulics cooling 液压系统冷却器进出水口温度显示OkOperation pressure of the circuit water pump循环水泵的工作压力OkWater cooling compressor and temperature display空压机水冷及温度显示OkFunction of the water cooling distribution cabin and temperature display配电柜水冷功能及温度显示OkPipe installation for the closed water cooling circuit闭式水冷循环系统管路安装OkFunction drive reducer water cooling and the flow display驱动减速器水冷功能及流量显示OkPipe installation for closed cooling circuit闭式水冷循环系统管路安装Ok05.5 Compress air压缩空气FunctionNominalTestWorkshopJob siteStart/stop of the air compressor空压机启动、停止OkPipe installation for the industrial compress air工业压缩空气管路安装OkAir duct outlet for the spare compressor备用空压机风管接口OkOperation pressure of No.1 compressor (Max ,Min)1号空压机工作压力最高、最低8barOperation pressure ofNo.2 compressor (Max ,Min)2号空压机工作压力最高、最低8barFunction of condensate drain and filter油水分离及过滤功能OkFunction of air duct case储风罐功能OkBrake hose for input and output water hoses进排水管制动管路OkBall valve for compressive air hose on gantry拖车压缩空气供风开关OkAir pipe for tailskin grease, main bearing lubrication grease盾尾油脂、主轴承润滑脂供风管路OkInflatable hose for articulation emergency seal 铰接紧急密封充气管路OkAir pipe for foam system泡沫系统供风管路OkAir supply for waste water pump 污水泵压缩空气供应（油水分离及润滑）OkPipe for main bearing and gear box pressure increasing 主轴承及齿轮箱加压供应管路Ok05.6 Air pressure regulation土仓压缩空气调节FunctionNominalTestWorkshopJob siteFunction filter过滤器功能OkFunction pressure reduce valve减压阀功能OkSetting service unit 1 positioning drive for pressure chamber bar压力仓定位驱动伺服单元1设定bar4Setting service unit 2 positioning drive for pressure chamber bar压力仓定位驱动伺服单元2设定bar4Setting pressure reducing valve 1 pressure transducer for pressure chamberbar压力仓压力变换器减压阀1压力设定bar1.4Setting pressure reducing valve 2 pressure transducer for pressure chamberbar压力仓压力变换器减压阀2压力设定bar1.4Zero point adjustment feed-in-controller 1 pressure chamber压力仓进料控制器1零点