TBM (Tunnel Boring Machine) mounting and debugging method under limited site

Abstract

The invention discloses a TBM installing and debugging method under a limited site, and aims to solve the technical problems that in the prior art, the TBM equipment assembling site is limited, parts are difficult to place, the construction period is long, and the safety risk is high. The TBM installing and debugging method comprises the following steps that S1, a truck crane enters a site, and a stepping system exits the site to be unloaded and installed; s2, the TBM is assembled, and then fluid system installation and electrical circuit connection are conducted on all systems under the condition that stepping is not affected; s3, after the TBM is assembled, no-load debugging and load debugging are carried out on all systems of the TBM; and S4, the TBM is assembled and is stepped to the tunnel face, the continuous belt conveyor is assembled and debugged, and finally, the TBM starts tunneling. By assembling and debugging the TBM in a limited site, the problems that the TBM assembling site is small and components are difficult to place are effectively solved, the construction efficiency can be improved, the construction period can be shortened, and the safety risk in the TBM construction process can be reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of tunnel construction, and in particular to a TBM installation and debugging method in a limited site. Background Art

[0002] The full-face tunnel boring machine (TBM) is a large-scale special equipment that relies on the rotation of hard rock cutter discs to break rocks and advance, and tunnel support and slag discharge are carried out simultaneously, and the full section of the tunnel is formed at one time. It adopts high-tech achievements in the fields of machinery, electricity and hydraulics, uses computer control, closed-circuit television monitoring, and factory operation. It is a complete set of equipment integrating excavation, support, slag discharge and transportation. TBM equipment is mainly composed of main machine, equipment bridge, rear supporting trailer and other parts, and plays a vital role in underground tunnel engineering. Since the total length of TBM equipment is generally 100m to 400m according to the diameter of the cutter disc, for such a large and complex equipment system, each component is transported from the factory to the construction site for assembly, which requires a sufficiently spacious assembly site. However, most tunnel projects are located between mountains, with steep terrain, greatly affected by rainfall, snowmelt, etc., and the surface slopes and grooves are alternating, which results in narrow assembly sites outside the tunnel and cannot meet the TBM assembly space requirements.

[0003] The inventor knows a method for fast assembly of TBM in a narrow site outside the tunnel (CN115788455A), which includes the following steps S1: preparatory tunnel excavation and filling of the assembly site outside the tunnel; S2: assembly, debugging, and stepping in the first stage; S3: assembly, debugging, and stepping in the 1+R stage, where R is a non-zero natural number, where R≥1; S4: overall stepping to the starting tunnel and excavation. According to the TBM assembly sequence, the assembly site is scientifically planned to ensure the installation sequence, avoid large and medium-sized secondary transportation, shorten the installation time, and effectively ensure the orderly installation of TBM in a narrow assembly site. However, in the process of realizing the technical solution in the embodiment of the present application, the inventor of the present application found that the above technology has at least the following technical problems: although the problems existing in each functional area of ​​the TBM can be found through "segmented assembly and segmented debugging", so that the quality during the installation process is guaranteed, it is difficult to debug the entire TBM equipment after installation, and thus it is difficult to effectively solve the technical problem of high safety risks during the construction of TBM equipment.

[0004] The information disclosed in this background technology section is only used to deepen the understanding of the background technology of the present disclosure, and should not be regarded as acknowledging or suggesting in any form that the information constitutes the prior art known to those skilled in the art. Summary of the invention

[0005] Through research, the inventors found that TBM equipment is large and complex, and construction sites are mostly located between mountains or urban buildings. The equipment assembly site is limited, which leads to technical problems such as difficult assembly and debugging of TBM parts, long construction period, and high safety risks.

[0006] In view of at least one of the above technical problems, the present disclosure provides a TBM installation and commissioning method in a limited site, which assembles and commissions the TBM through reasonable and efficient process coordination, effectively solving the technical problems of small TBM assembly site, long construction period and high safety risk.

[0007] The present application discloses a TBM installation and commissioning method in a limited site, comprising the following steps: S1. The crane enters the site, and the stepping system arrives to unload and install; S2. First, assemble the TBM host system. After the host assembly is completed, step forward until the host part completely enters the pilot tunnel opening, and then assemble the connecting bridge and the rear supporting trailer simultaneously. Then, install the fluid system and connect the electrical lines of each system without affecting the stepping; S3. After the TBM is assembled, firstly, each system of the TBM is debugged without load to ensure that the TBM has working capacity, and then each system of the TBM is debugged with load to check the load capacity of various pipelines and seals; S4. After the TBM is assembled and moves to the face, the continuous belt conveyor is assembled and debugged. When the continuous belt structure is not assembled, the single system is debugged. When the continuous belt structure is assembled, the whole machine is debugged. Finally, the TBM starts excavation.

[0008] In some embodiments of the present disclosure, in step S2, the TBM main engine system includes support shoes, a bottom shield, a main drive installed above the bottom shield, a side shield installed on the outside of the main drive, a main beam 1 installed at one end of the main drive, a main beam 2 connected to the main beam 1, a rear support installed at one end of the main beam 2, a cutter disc installed at the other end of the main drive, and a top shield installed above the main drive.

[0009] In some embodiments of the present disclosure, in step S2, after the TBM main machine part completely steps to the entrance of the guide tunnel, the first and second sections of the connecting bridge are assembled, and after the assembly is completed, they are hoisted, the stepping system is debugged, and stepping begins, and at the same time, the third section of the connecting bridge and the subsequent supporting trailer are assembled.

[0010] In some embodiments of the present disclosure, in step S4, the main structural parts of the continuous belt conveyor are first assembled, including the main drive of the belt conveyor, the belt storage bin, the unloading device, the tensioning device and the belt conveyor bracket, and then the rollers, belt threading and vulcanized belts are installed, and the electrical system is installed simultaneously for tensioning and debugging.

[0011] In some embodiments of the present disclosure, in step S4, assembly and debugging of the continuous belt conveyor are carried out simultaneously. When the continuous belt structural parts are not completely assembled, single system debugging is carried out; when the continuous belt structural parts are completely assembled, the belt conveyor systems and control systems are jointly debugged as a whole.

[0012] One or more technical solutions provided in the embodiments of the present application have at least any of the following technical effects or advantages: 1. Rationally set the installation steps to assemble the TBM equipment, and match the site layout according to the equipment shape characteristics before assembly to shorten the equipment assembly time, improve construction efficiency, reduce construction costs, and realize the scientific and orderly installation of TBM in a limited site.

[0013] 2. The installation principles of "assembling while entering the site" and "assembling while moving forward" are adopted to effectively solve the technical problems of small TBM assembly site and difficulty in placing large items on site, shorten the project construction period, and realize the transportation of TBM on narrow roads and rapid assembly in limited sites.

[0014] 3. During the assembly process, no-load and load debugging are performed on each TBM system at the corresponding stages. While ensuring that the TBM has working capacity, the load capacity of various pipelines and seals can be checked at the same time. By performing single system debugging and whole machine joint debugging on the TBM, problems existing in the operation of each TBM system can be discovered in time, ensuring stable and reliable system operation, effectively reducing the safety risks of TBM equipment during use, and improving the construction efficiency of TBM equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a layout diagram of the TBM assembly site in one embodiment of the present application.

[0016] Figure 2 Schematic diagram of a TBM stepping device in one embodiment of the present application.

[0017] Figure 3 This is a schematic diagram of the assembly of the connecting bridge in one embodiment of the present application.

[0018] Figure 4 This is a schematic diagram of the rear-end trailer hoisting in one embodiment of the present application.

[0019] Figure 5 This is a flow chart of the installation of a continuous belt conveyor in one embodiment of the present application.

[0020] In the above figures, 1 is the driving road, 2 is the TBM assembly area, 3 is the tunnel entrance, 4 is the truck crane, 5 is the TBM component placement area, 501 is the stepping base plate, 502 is the bottom shield, 503 is the main drive, 504 is the main beam one, 505 is the main beam two, 506 is the side shield, 507 is the top shield, 508 is the rear support, 509 is the cutter head, 510 is the propulsion and support shoe cylinder, 511 is the connecting bridge one, 512 is the connecting bridge two, 513 is the connecting bridge three, and 514 is the rear supporting trailer. DETAILED DESCRIPTION

[0021] In the description of the present application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "top", "bottom", "inside", "outside", "vertical", "horizontal", "clockwise", "counterclockwise", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application. The terms "first", "second", etc. involved in the present application are used to distinguish the objects described and do not have any order or technical meaning. The terms "connection" and "connection" involved in the present application, unless otherwise specified, include direct and indirect connections (connections).

[0022] In order to better understand the technical solution of the present application, the above technical solution will be described in detail below in conjunction with the accompanying drawings and specific implementation methods. It should be understood that the specific implementation methods described herein are only used to explain the present invention and do not limit the scope of the present invention in any way.

[0023] The present application discloses a TBM installation and debugging method in a limited space. First, the TBM equipment is assembled according to a reasonably set installation step. After the TBM is assembled, no-load debugging and load debugging are performed on each system of the TBM. Then, after the TBM is assembled and stepped to the face, the continuous belt conveyor is assembled and debugged synchronously. Finally, the TBM starts excavation.

[0024] Application Example 1: Detailed explanation based on a cave exploration project 1. Project Overview: The entrance elevation of a cave project is about 2730m. It extends into the mountain along the slope, deflects upstream at an elevation of 2738m, and ends at a certain inclined shaft. The terminal elevation is 2800m. The total length of the cave is 5.366km (K0+091.3~K5+458, starting at K0+091.3). The first 330m is constructed by drilling and blasting, and the remaining sections are constructed by open TBM. The excavation diameter is 4.75m. The tunnel is excavated on a positive slope with a slope ratio of 0.3% and a turning radius of 600m.

[0025] 2. Limited TBM assembly site: The project is located in a national forest reserve with limited construction sites, and it is impossible to requisition additional land to expand the TBM assembly site. The available area of ​​the TBM equipment assembly site is 44m long and 56m wide, which is too small for assembling TBMs. It is difficult to place large TBM parts on site, and a crane unloading area of ​​about 20m long must be reserved. Therefore, the longitudinal available length of the entire assembly area is only about 30m. Before assembly, the site was planned and divided into unloading area, storage area, hoisting and assembly area. The assembly follows the principle of assembling while entering the site, but the cutter head, main drive, stepping mechanism, shield, main beam, etc. need to be brought to the site in advance, and the placement of large parts has been carefully and scientifically planned and arranged.

[0026] 3. Engineering Difficulties (1) Dynamically adjust the length of the drilling and blasting section and the layout of the continuous belt conveyor The original design of the step hole length of the drilling and blasting section was 150m, the TBM assembly site was 60m, and the total length was 210m; the length of the TBM before transformation was 315m, the continuous belt length was 149m, and the total length was 464m. The original design of the assembly site plus the step hole length could not guarantee the installation of the TBM and the continuous belt conveyor. The length of the step hole in the drilling and blasting section needs to be adjusted according to the length of the TBM continuous belt conveyor and the TBM equipment.

[0027] (2) Dynamically control the drilling and blasting construction progress to match the TBM assembly progress The drilling and blasting construction progress is dynamically adjusted according to the TBM assembly progress. The construction of the drilling and blasting section must meet the requirements of TBM installation and stepping. The drilling and blasting excavation end mileage and the invert construction progress are controlled in combination with the progress of TBM transportation and assembly.

[0028] (3) Batch storage and assembly of TBM equipment in limited assembly sites The available area of ​​the TBM equipment assembly site is 44m long and 56m wide, which is too small for assembling TBMs. It is difficult to place large TBM parts on the site, and a crane unloading area of ​​about 20m must be reserved. The entire assembly area is only about 30m.

[0029] (4) Determination of the time and space relationship between the lifting of the main parts of the TBM equipment, the storage of the supporting equipment and the drilling and blasting construction The lifting of the main parts of the TBM equipment and the storage of supporting equipment require the assembly site at the tunnel entrance. The planned time for TBM transportation is 10 days. The installation of the TBM main machine starts from the second day after transportation, and it takes a total of 10 days for the TBM main machine to step into the tunnel for the first time to block the tunnel entrance. The drilling and blasting section bottom laying construction is planned to be completed 7 days after the end of excavation. Taking into account the 1-day civilized construction time in the tunnel, that is, the drilling and blasting excavation and bottom laying pouring have spatial overlap with the TBM transportation and assembly. Construction vehicles are all operating at the tunnel entrance and the first-floor platform of the industrial square, and cross-operation is carried out.

[0030] (5) Efficient assembly and commissioning of TBM within a limited time The main lifting work content of TBM includes: unloading and turning over the cutterhead and main drive; lifting of main beam, shield, support shoe propulsion cylinder, rear support, connecting bridge, rear supporting trolley and other components.

[0031] The unloading of the main drive, cutterhead and main beam 2 is done by a 130t truck crane (45 tons of counterweight) and a 100t truck crane (40 tons of counterweight). The hoisting of the main beam 2 is also done by two cranes.

[0032] 4. The TBM installation and commissioning method under limited site includes the following steps: S1. The truck crane enters the site, and the stepping system arrives to unload and install (see Figure 1 ); S1.1. Construction process of mobile crane The construction process of the mobile crane includes the entry of the mobile crane, lifting briefing, installation of the mobile crane, lifting operations, and the departure of the mobile crane.

[0033] (1) Truck crane entry According to the on-site construction schedule, contact the lessor of the mobile crane 4 in advance, collect the information of the personnel and vehicles entering the site, go through the entry procedures, and sign a safety agreement with the lessor. The on-site safety personnel will supervise to ensure that the mobile crane 4 entering the site is in good condition and meets the use requirements. After entering the site, introduce the relevant management regulations related to the on-site construction to the relevant personnel, and carry out necessary safety training and explanations. Pay attention to road driving safety when the mobile crane 4 enters the site, and provide guides to enter the site when necessary.

[0034] (2) Lifting briefing Before the lifting begins, technical explanations are given again to the personnel involved in the lifting operation, and confirmation and communication are carried out on the lifting items, lifting methods, lifting environment and lifting requirements to ensure the smooth progress of the lifting operation.

[0035] (3) Truck crane support According to the requirements of the lifting operation, the truck crane 4 is parked at the designated location for support, and the support surface of the outriggers is required to have sufficient strength to comply with the safety management regulations for on-site lifting operations. The counterweight is installed as required, and a cordon is set up around the lifting operation area.

[0036] (4) Lifting operation Perform the hoisting operation according to the hoisting steps planned in advance. During the hoisting operation, pay close attention to the wind level on site to ensure hoisting safety.

[0037] (5) The truck crane leaves the site After the lifting was completed, the surrounding cordon was removed and the truck crane 4 left the site in an orderly manner.

[0038] S1.2. TBM lifting process TBM hoisting mainly includes main machine hoisting, connecting bridge hoisting and rear supporting hoisting.

[0039] Large TBM parts are transported by truck from the Paizhen transfer point to the assembly platform in the production area. Special personnel are arranged to check on site that the vehicles used for the secondary transportation are in good condition before transportation. It is forbidden to operate vehicles with defects. Large parts are unloaded by 130t truck cranes and 100t truck cranes are used in conjunction with unloading. When unloading, strictly follow the lifting specifications, lift large parts horizontally, and slowly lower them after the transport vehicle leaves to avoid collisions or safety accidents. When placing the cutter head 509, sufficient space should be reserved for the subsequent lifting of the cutter head 509. After the TBM mainframe components arrive at the site, they must be placed on the assembly platform in a reasonable orientation, and the bare TBM parts should be placed on the sleepers to avoid direct contact with the ground.

[0040] S2. First, assemble the TBM host system. After the host assembly is completed, step forward until the host part completely enters the pilot tunnel opening, and then assemble the connecting bridge and the rear supporting trailer simultaneously. Then, install the fluid system and connect the electrical lines of each system without affecting the stepping; S2.1. Preparation before lifting (1) Technical briefing and training on assembly work; (2) Arrangement of the assembly site to ensure smooth lifting; (3) Inventory of assembly tools, and the Equipment and Materials Department shall appoint a dedicated person to be responsible for their safekeeping; (4) All bolts and seals are counted, cleaned and kept by a designated person; (5) Assemblers must be familiar with the installation drawings of their respective parts and assemble in strict accordance with technical requirements; (6) Before installation, all joint surfaces of components must be cleaned to remove burrs and edges; for relatively rough joint surfaces, use emery cloth or an angle grinder to remove rust and paint, collision marks, and local protrusions and grind them flat; for precise joint surfaces, bolt holes, etc., use a cleaning agent to scrub repeatedly to remove dirt; (7) Lifting must be carried out strictly in accordance with lifting specifications; (8) Use supporting tools correctly and reasonably, and it is strictly forbidden to use them beyond the range; for special tools, they are only allowed to be operated after passing the formal training in accordance with safety regulations; (9) Clarify the tightening method and tightening torque of all bolts and mark them properly. Apply Loctite glue or bolt lubricant to special bolts with special requirements according to technical requirements; (10) During the assembly period, each shift will have a handover, which includes but is not limited to the progress of the shift, items to be completed, preparations, precautions, etc. The construction log filled out by each shift will be handed over to the next team; (11) When a crane is lifting a fully loaded object, it should be lifted 20-50cm off the ground and kept still for at least 1 minute to check the crane's stability, the reliability of the brakes and the firmness of the lashing, and whether the outrigger pads have sunk. Only after confirmation can the crane be lifted; (12) The lifting operation of a truck crane with 4 double cranes must be coordinated by a full-time commander, and the lifting operation must not be directed arbitrarily.

[0041] S2.2. Host large parts lifting (1) Installation of bottom shield: The bottom shield 502 is installed by four Ф25×3000mm steel wire ropes. The bottom shield 502 is placed on the stepping device trolley 501. The horizontal axis is adjusted and fixed before unhooking. After the installation is completed, the bottom shield 502 is welded to the stepping device trolley 501.

[0042] (2) Main drive hoisting: The main drive 503 contains the main bearing, main bearing lip seal, cutter head adapter ring, and large gear ring. The drive motor is not installed when entering the site. When unloading, two cranes are used for lifting at the same time, under the command of a dedicated person. After lifting, the main drive 503 is lifted 20cm away from the transport vehicle and kept stationary for 1 minute for trial lifting. Only after observing that there are no problems can the lifting be continued. After lifting, the transport vehicle leaves immediately and moves the main drive 503 to the target position. The components must not be dragged. The main drive 503 is placed horizontally on the floor, and sleepers are laid on the floor. The total weight of the main drive 503 is 70t (75t including tooling). It is turned over and hoisted by 130t and 100t truck cranes 4. Two steel wire ropes of Ф60×4000mm and two steel wire ropes of Ф50×3000mm are used, and six 55t shackles are used. Under the command of a special person, after hoisting to a suitable height, the hook of the 100t truck crane 4 is slowly lowered. Before it is about to touch the ground, the two hooks are lifted at the same time. This operation is repeated until the 100t truck crane 4 is no longer under stress. The hook and tooling are removed to make the main drive 503 in a vertical position, and then lowered to touch the ground. The 100t truck crane 4 lifts the top tooling, and supports are added at the bottom to place the main drive 503 stably. The hook of the 130t truck crane 4 is slowly lowered, and then two steel wire ropes are passed through and hoisted. Then the tooling and support are removed, the 100t hook is removed, and the main drive 503 is slowly moved until it is stably placed on the bottom shield 502. Note that both lifting and stopping actions must be performed steadily and slowly, and the next action can be performed after one action is completed and stopped steadily. Before the main drive 503 and the bottom shield 502 are installed, the wedge block, the side shield cylinder, and the torque sensor cylinder are installed on the main drive 503, and the connecting pin at the ear seat at the fixed end of the main drive 503 needs to be tightened and fixed with the clamping plate bolt, and the other end is fixed when the side shield 506 is installed.

[0043] (3) Main beam 1 hoisting: The main beam 1 504 is hoisted with four Ф50×3200mm steel wire ropes as the main hoisting ropes for the front section of the main beam. Two 20t hand chain hoists are used to adjust the position of the front section of the main beam. The hand chain hoists are connected to the hooks through a 1m long steel wire rope. Two spare 55t bow shackles are used for hoisting adjustment. After the main beam 1 504 is hoisted in place and the flange bolts of the main drive 503 are initially tightened, the tail end of the main beam 1 504 is temporarily tightened with two 50t jacks or a combination of supporting piers and pads.

[0044] (4) Side shield hoisting: The side shield 506 is hoisted using two Ф25×3000mm steel wire ropes as the main hoist of the side shield 506, and two 5T hand hoists are used to adjust the pin posture of the side shield 506.

[0045] (5) Lifting of the second main beam assembly: The second main beam assembly includes the second main beam 505, 2 saddle frame connection blocks, 4 torque cylinders, 2 support shoe cylinders, 2 single-sided saddle frames, and 1 cross pin assembly, with a total weight of about 78 tons. The wire ropes are 4 Ф50×3000mm ring ropes, 8 55t shackles, and 4 10t auxiliary guide chains for posture adjustment. Four wire ropes and a special tooling are used as the main lifting equipment for the middle section of the main beam. Four 10t hand winches are used for the pitch adjustment of the front and rear position of the middle section of the main beam. During the lifting, the saddle frame is fixed to the main beam through a limit device to determine the lifting center of the middle section of the main beam.

[0046] (6) Rear support hoisting: The rear support 508 is hoisted with four steel wire ropes and two 10t hand hoists as the main hoist. Four Ф25×2000mm steel wire ropes and shackles are connected to the rear support 508 lifting ears. The hoist guide chain and the main machine belt conveyor are also used to adjust the posture of the rear support 508.

[0047] (7) Lifting of the gantry shoe: The lifting of the gantry shoe 510 uses two Ф25×2000mm steel wire ropes as the main lifting and two 10t hand hoists for posture adjustment.

[0048] (8) Cutterhead hoisting: Four 60×3000mm steel wire ropes are used for hoisting the cutterhead 509. When unloading, two cranes 4 are used for lifting at the same time, under the command of a dedicated person. After lifting, the cutterhead 509 is lifted 20cm away from the transport vehicle and kept stationary for 1 minute for trial lifting. Only when no problems are observed can the lifting be continued. After lifting, the transport vehicle leaves immediately, and the cutterhead 509 is moved to the target position. The components must not be dragged, and the cutterhead 509 is placed on the ground paved with square timber. The cutter disc 509 needs to be turned over in three dimensions before installation. Under the command of a special person, two cranes 4 lift the cutter disc 509 to a suitable height, and then slowly lower the hook of the 100t truck crane 4. Before it is about to touch the ground, the two hooks lift at the same time. Repeat this operation until the 100t truck crane 4 is no longer under stress. Remove the hooks to make the cutter disc 509 in a vertical position, and then slowly move it to the front of the main drive 503. After cleaning the two connecting surfaces, slowly press them together. The cutter disc 509 is installed to the positioning pin and fixed, and then the bolts are connected. Note that the lifting and stopping actions must be performed steadily and slowly, and the next action can be performed after one action is completed and stopped. Use two truck cranes 4 to perform the turning operation, and then perform the three-dimensional installation.

[0049] (9) Lifting of top shield assembly: The top shield assembly includes top shield 507 and two overlapping shields, with a total weight of 16t. Before lifting, the plug plate at the connection between top shield 507 and overlapping shields is welded, and then the assembly is carried out after welding. Four Ф25×2000mm steel wire ropes and four 10t shackles are used for lifting. After the lifting is completed, the connection between top shield 507 and the left and right overlapping shields is cut to enable relative rotation.

[0050] S2.3. After the host is assembled, step After the main machine is assembled, it needs to step 30m until the main machine is completely in the hole, and then install the connecting bridge. Figure 2 .

[0051] (1) Preparation before stepping (a) Install the saddle support frame and connect it rigidly to the base of the stepping trolley 501.

[0052] (b) Weld the shield lifting cylinder and ensure proper grounding during welding.

[0053] (c) The main engine, connecting bridge and No. 1 trailer are assembled.

[0054] (d) The stepping device is supplied with oil by an independent pump station, which uses the anchor drilling rig pump and the stepping pump station frame and oil tank to supply energy for the stepping device. When stepping, the pump station is installed in front of the second injection-mixing trolley of the connecting bridge. The pump station is connected to the rear support telescopic cylinder, the stepping propulsion cylinder, and the jacking cylinder.

[0055] (e) A lubricating oil tank is placed below the propulsion cylinder for lubrication of the propulsion system.

[0056] (f) Cut off the bottom shield 502 and the stop blocks of the sliding trolley and the base.

[0057] (j) Apply grease to the trolley rails. Place the manual grease injection device on the trolley base to manually inject grease to lubricate the trolley during the stepping process.

[0058] (h) Confirm that the thrust cylinder is fully retracted and in a floating position.

[0059] (2) Stepping: When stepping, the top shield 507 can be fully retracted, but the two side shields 506 must be extended to simulate an excavation section with a diameter of 4750 mm. The stepping system is supplied with oil by an independent pump station. The control valve group and pipeline of the stepping device are delivered together with the TBM and installed on site.

[0060] (a) Stepping process - pushing forward: First retract the lifting cylinder and the rear support cylinder to a position where they do not interfere with the ground before extending the stepping cylinder. When the stepping cylinder is extended by 1.8m, the main machine moves forward by 1.8m. At this time, the pushing cylinder extends the single-side saddle frame and moves backward by 1.8m.

[0061] (b) Stepping process - step change: After the advancement is completed, the lifting cylinder and the rear support cylinder extend to lift the TBM main machine. The lifting height is determined by the flatness of the ground and non-interference. The smaller the lifting height, the better, which is convenient for rapid stepping. When the main machine is lifted, the stepping cylinder can be retracted to return the sliding trolley to the initial position. The reset cylinder and the rear support cylinder are retracted to start the second stepping cycle.

[0062] (c) Dismantling of the stepping system: After stepping to the face, the stepping pump station will be dismantled and the anchor drilling rig pump station will be restored.

[0063] S2.4. Connection bridge assembly: After the mainframe is assembled, step into the hole until the mainframe is completely in place, and then start installing the connection bridge. The connection bridge is divided into three sections, which are connected in sequence from front to back (see Figure 3 ).

[0064] (1) Assembly of the first section of the connecting bridge: The first section of the connecting bridge 511 is hoisted by two truck cranes 4. After the installation of the first section of the connecting bridge 511 is completed, the rear matching towing cylinder can be installed between the rear support 508 and the first section of the connecting bridge 511, and the bolts of the clamping plate need to be tightened.

[0065] (2) Assembly of the second section of the connecting bridge: The second section 512 of the connecting bridge is hoisted by two truck cranes 4 in combination, and the second section 512 of the connecting bridge is installed on one side of the first section 511 of the connecting bridge.

[0066] (3) Assembly of the three sections of the connecting bridge: The three sections of the connecting bridge 513 are hoisted by two truck cranes 4. Before the installation of the three sections of the connecting bridge 513, the connecting bridge support, the connecting bridge walking mechanism and the three sections need to be assembled. Since the stepping device raises the bottom shield by 100mm, the bottom track of the connecting bridge also needs to be raised by 100mm. According to the design, the height of the upper surface of the track from the bottom of the tunnel during normal excavation of the TBM is 425mm. Therefore, the bottom of the connecting bridge and the rear supporting trailer bottom track needs to be raised by 100mm.

[0067] S2.5. Assembly of rear trailer: The rear trailer 514 is lifted by two truck cranes 4 (see Figure 4 ), the assembly sequence is as follows: (1) Install the trailer running track.

[0068] (2) The trailer is used for transport as a whole, so after unloading on site, it is directly hoisted onto the running track as a whole.

[0069] (3) Install the support workshop connecting plate.

[0070] (4) Install trailer upper equipment, air ducts, walkways, stairs, railings, etc.

[0071] S2.6. Fluid system installation: Equipment assembly is carried out in subsystems. After each system is installed, the pipelines are connected without affecting the steps.

[0072] S2.7. Electrical circuit connection: When assembling the electrical circuit connection on site, each sub-system, trailer circuit and junction box are connected first; after the main engine is connected to the rear supporting trailer, the power line of the frequency converter cabinet is laid forward and connected to the main motor; the main control room is radially laid forward and backward to connect to each sub-system.

[0073] S3. After the TBM is assembled, firstly, each system of the TBM is debugged without load to ensure that the TBM has working capacity, and then each system of the TBM is debugged with load to check the load capacity of various pipelines and seals; S3.1. No-load commissioning (1) First, conduct a comprehensive inspection of the electrical system, fluid system and the connection with the host system. After the inspection, the equipment is debugged, which includes all operating systems.

[0074] (2) Equipment debugging mainly tests the equipment's operating performance, reliability, safety performance, etc. Before debugging, the integrity and safety of the equipment installation must be checked to ensure that the debugging is safe and smooth.

[0075] S3.2. Load Debugging After the no-load debugging proves that the TBM has working capacity, the load debugging can be carried out. The main purpose of the load debugging is to check the load capacity of various pipelines and seals; to make the various working systems and auxiliary systems of the TBM reach the working state that meets the normal production requirements. Usually, the trial excavation time is the time for equipment load debugging. During the load debugging, strict technical and management measures will be taken to ensure the project safety, project quality and linear accuracy.

[0076] S4. After the TBM is assembled and moves to the face, the continuous belt conveyor is assembled and debugged. When the continuous belt structure is not assembled, the single system is debugged. When the continuous belt structure is assembled, the whole machine is debugged. Finally, the TBM starts excavation.

[0077] S4.1. Installation of continuous belt conveyor: After the TBM large materials enter the tunnel, the installation of the belt conveyor can be started; on the foundation cast in advance, the external support, drive device and unloading hopper, internal belt support, material receiving device and other equipment are installed in sequence. The overall installation process refers to the continuous belt conveyor.

[0078] After the TBM is assembled and starts to move, the continuous belt conveyor is installed. On the pre-cast foundation, the main drive, belt storage bin, unloading device, tensioning device and other equipment of the continuous belt conveyor are installed in sequence. At the same time, the belt conveyor chain and belt frame are installed. After the main structural parts are installed, the upper and lower rollers are installed, the lower return belt and the upper belt are passed, and finally the belt joints are vulcanized, the electrical system is installed simultaneously, and finally the tensioning and debugging are carried out. For the installation of the continuous belt conveyor, please refer to Figure 5 .

[0079] (1) Belt bin installation: According to the design drawings, determine the specific locations of the belt bin, winch and drive device, and accurately locate the embedded parts.

[0080] Install the belt bin base: Place the belt bin base in order from the inside to the outside. Use a level to accurately adjust the position of each base bracket so that the running slides on the upper part of each base bracket of the belt bin are tightly connected and maintain longitudinal and lateral smoothness.

[0081] Install the belt bin fixing roller: lift the roller into position and tighten the bearing seat fixing bolts according to the recommended torque, striving for accurate positioning and horizontal roller position.

[0082] Install and adjust the tail wheel pulley block: Assemble the pulley block smoothly and keep the pulley block running flexibly without interference.

[0083] Install and adjust the mobile roller section: The basic requirements are the same as above, the key is to ensure smooth installation and flexible movement.

[0084] Install and adjust the rack supports to ensure they are securely fastened and positioned correctly.

[0085] Install and adjust the middle section of the upper frame.

[0086] Install and adjust the carriage.

[0087] Install and adjust the belt separator: Before installation, confirm the quality of the roller inside the separator, and make sure it rotates flexibly without damage; the running rollers are not stuck; and it moves easily and flexibly on the slide.

[0088] Install and adjust wire rope winches.

[0089] Install the wire rope on the winch: Make sure the wire ropes are arranged in order inside the winch and are not tangled.

[0090] Install the separator chain: the chain connection is smooth, without twisting; the connection is reliable.

[0091] (2) Installation of the main belt drive: Install two drive rollers: ensure the position accuracy of the rollers themselves and the installation accuracy between the rollers. At the same time, fully check the lubrication condition of the supporting bearing seats at both ends of the rollers and fill them with sufficient grease.

[0092] Install the power equipment: insert the reduction box assembly into the drum drive shaft respectively, and after accurate positioning, tighten the fastening bolts on the drive shaft fixing pressure ring one by one and in batches in a clockwise direction, and finally tighten the reduction box anchor bolts.

[0093] Place the drive motor in place, connect the power line in the correct way in advance, carefully test and verify the motor direction by jogging, confirm that it is correct, and finally connect it tightly.

[0094] Through slight adjustments, it can be reliably and accurately connected to the coupling of the reduction box to ensure the height, concentricity and coaxiality of the connection direction. After the coupling connecting spring and related parts are inlaid, the protective cover can be installed.

[0095] Install and complete all other parts.

[0096] The inverter cabinet must be placed not too far from the drive device, and the effective distance must be kept within 30m to ensure the normal operation of the continuous belt conveyor. The foundation of the inverter cabinet itself must be raised to prevent water from entering the cabinet; the surrounding environment must be kept clean and dry, and necessary protective facilities must be installed; all belt operation monitoring sensors (deviation, belt speed, emergency pull line, etc.) must be installed, and wait for the final online test.

[0097] (3) Slag separator installation: Determine the specific location of the slag separator device according to the design drawing and accurately locate the embedded parts.

[0098] Install the power equipment: After the slag separator bracket is accurately positioned, install the bracket on the embedded parts, and then install the slag separator on the bracket. With the help of a level, make slight adjustments to ensure that the slag separator and the bracket are connected reliably and accurately, ensuring that the center of gravity of the slag separator coincides with the bracket, and there must be no center of gravity offset or skew.

[0099] Ensure the height, concentricity and coaxiality of the connection direction, and install the protective cover after the coupling spring and related parts are inlaid.

[0100] (4) Belt installation: Clamp one end of the belt with a splint and connect it reliably with the wire rope. Use a winch to pull the wire rope to start from the belt vulcanizing table in the correct direction of winding, and slowly pull the belt out through the belt bin. Then, the belt is led along the lower belt roller to the rear supporting tail drive roller of the TBM. Then, the belt is wound back from the upper belt roller, passed through the upper belt bracket of the belt bin, and returned to the vulcanizing table through the winding drive device. After the belt is threaded, it is vulcanized in sections.

[0101] S4.2. Belt conveyor system debugging: The belt conveyor system debugging shall firstly carry out single system debugging and then carry out joint debugging of the whole machine.

[0102] (1) Single system debugging (a) Debugging of the main engine and the supporting belt drive device and the continuous belt drive device, starting and debugging of the motor, and checking the running stability and operability; (b) Debugging of tensioning device, trial operation of electric tensioning device and debugging of auxiliary hydraulic system, and checking of tensioning stability; (c) Debugging of each driven roller and various types of rollers. Manually rotatable rollers should be manually checked one by one; (d) Debug the scraper and scraper plate. The scraper should fit tightly against the belt surface. (e) Check whether each grease injection port has been filled with grease; (f) Start the belt drive at low speed, check the belt operation, and adjust the belt if it deviates; (j) TBM tail end commissioning inspection and lubrication pipeline operation status; (h) Test the operation, stability and deviation of the transfer belt conveyor, and the speed is adjustable; (i) Test whether the emergency stop and deviation switches and pull rope switches can stop the belt operation in an emergency.

[0103] (2) Joint debugging of the whole machine: mainly to check the operation of each belt conveyor system and control system, whether the belt contacts the belt frame, whether the belt deviates, and whether the belt rollers are noisy or overheated. During the debugging of the whole machine, a specialized technician should be assigned to record the operating parameters of each belt system in detail as a reference for future excavation. If problems are found, they should be recorded, analyzed and solved in a timely manner.

[0104] The TBM main control room controls the continuous belt, the rear supporting belt, and the main machine belt to start and stop in sequence, test the speed adjustment capability and interlocking relationship, and ensure that the belt conveyor runs stably at the required speed for excavation for 30 minutes. The stability of each system is checked and any problems that arise are eliminated.

[0105] 5. Construction results (1) After a series of hardships and unremitting efforts during the TBM assembly process, which lasted 40 days, on June 24, as the cutterhead was close to the tunnel face and the continuous belt transported the slag to the slag yard outside the tunnel, the TBM trial excavation was successful, indicating that the TBM equipment assembly work was finally successfully completed. The problems of small installation site, tight construction period, and adjustment of the construction length of the drilling and blasting section were solved.

[0106] (2) The construction length of the drilling and blasting section was reduced by 93 m, reducing the total loss by RMB 2,243,625, which reduced the pressure on the project funds and ensured the funds during the installation period.

[0107] 6. Project Summary (1) The length of the TBM assembly site is equal to the length of the TBM mainframe plus the length of the TBM No. 1 bridge, which can meet the requirements of the TBM split assembly. The length of the TBM assembly site (minimum for split assembly) = the length of the TBM mainframe + the length of the TBM No. 1 bridge.

[0108] (2) For high-fill rockfill at the TBM assembly site, in the rainy season, the deformation rate reaches the maximum within 7 days, and becomes stable after 7 days, and concrete hardening can be carried out. The latest completion time of the site hardening = TBM assembly start point - 14 days (concrete equal strength) - 7 days.

[0109] (3) TBM step hole length ≥ TBM continuous belt length - outside the hole continuous belt length + TBM length. TBM step hole length equals TBM continuous belt length minus outside the hole continuous belt length plus TBM length to meet construction requirements.

[0110] (4) Pay attention to the preliminary preparation work. Consider the optimal length of the drilling and blasting step-in hole from the time of TBM modification and transportation. According to the construction period, the time and space for site construction and installation of TBM ancillary facilities should be reversed to optimize the most favorable time nodes for equipment installation and drilling and blasting construction. One day is reserved for the completion node of the drilling and blasting step-in hole and the space time for TBM assembly and step-in plugging drilling and blasting operations to meet the construction requirements. The optimal construction length can be optimized and comprehensively allocated based on the cost comparison between the drilling and blasting section and the TBM excavation section.

[0111] (5) Plan and arrange the site in advance, arrange the storage location of TBM accessories and number them and the transportation time in advance, save the transportation time of TBM small site assembly, improve assembly efficiency, and meet the requirements of short-term assembly.

[0112] (6) In view of the large-scale lifting of small sites and the frequent cross-operations, targeted safety measures are adopted to avoid safety accidents during construction, which may cause the installation work to be stalled. Targeted technical measures are adopted to carry out early detection of the bearing capacity of the access road and the bottom plate of the isolated rock overhead section of the stepping hole and the contour of the stepping hole to ensure the smooth progress of the TBM stepping process.

[0113] Although some preferred embodiments of the present application have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present application.

[0114] Obviously, those skilled in the art can make various changes and modifications to the present application without departing from the spirit and scope of the inventive concept. Thus, if these modifications and variations of the present application fall within the scope of the claims of the present application and their equivalents, the present application is also intended to include these modifications and variations.

Claims

1. A TBM installation and commissioning method in a limited site, characterized in that: The steps include: S1, the crane enters the site, and the stepping system arrives to unload the truck and install; S2, first assemble the TBM host system. After the host assembly is completed, step forward until the host part completely enters the pilot tunnel entrance, and then assemble the connecting bridge and the rear supporting trailer simultaneously. Then, install the fluid system and connect the electrical lines of each system without affecting the stepping; S3, after the TBM is assembled, firstly, each system of the TBM is debugged without load to ensure that the TBM has working capacity, and then each system of the TBM is debugged with load to check the load capacity of various pipelines and seals; S4, the TBM is assembled and stepped to the face, the continuous belt conveyor is assembled and debugged, single system debugging is carried out when the continuous belt structure is not assembled, and the whole machine is debugged when the continuous belt structure is assembled. Finally, the TBM starts excavation.

2. The TBM installation and debugging method according to claim 1, characterized in that: In step S2, the TBM main engine system includes support shoes, a bottom shield, a main drive installed above the bottom shield, a side shield installed on the outside of the main drive, a main beam 1 installed at one end of the main drive, a main beam 2 connected to the main beam 1, a rear support installed at one end of the main beam 2, a cutter head installed at the other end of the main drive, and a top shield installed above the main drive.

3. The TBM installation and debugging method according to claim 2, characterized in that: In step S2, after the TBM main machine part completely steps to the entrance of the pilot tunnel, the first and second sections of the connecting bridge are assembled, and after the assembly is completed, they are hoisted, the stepping system is debugged, and stepping begins. At the same time, the third section of the connecting bridge and the subsequent supporting trailer are assembled.

4. The TBM installation and debugging method according to claim 1, characterized in that: In step S4, the main structural parts of the continuous belt conveyor are first assembled, including the main drive of the belt conveyor, the belt storage bin, the unloading device, the tensioning device and the belt conveyor bracket, and then the rollers, the belt threading and the vulcanized belt are installed, and the electrical system is installed simultaneously for tensioning and debugging.

5. The TBM installation and debugging method according to claim 4, characterized in that: In step S4, the assembly and debugging of the continuous belt conveyor are carried out simultaneously. When the continuous belt structural parts are not assembled, the single system debugging is carried out; when the continuous belt structural parts are assembled, the belt conveyor systems and the control system are jointly debugged as a whole.

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