Herrenknecht AG公司介绍.doc

Jinping Drainage Tunnel Project P.R. of China Single Gripper Hard Rock TBM 6,000mmTechn. Doc. No. A-2312-00 11. S-271 TBM history and reference Page 57 08.12.06 N.Zuber/zh 57 / 58 Herrenknecht AG Schlehenweg 2 _ D-77963 Schwanau I:GM_ProjectsAsiaChinaJinpingA_Offer_PhaseOffer_Drainage_Tunnel00_01.DOC1. Company introductionHerrenknecht AG was founded by Martin Herrenknecht in 1977. In 1980, anoffice and a workshop were established in Schwanau - southern Germany,near the French and Swiss borders. The headquarters in Schwanau arelocated near the airports of Stuttgart, Strasbourg (France) and Basle(Switzerland).Today, the company has more than 1,800 employees world-wide of which1,200 work in Schwanau.The manufacturing and assembly area has grown to 69,800m andcomprises ultra-modern production plants and office facilities.Herrenknecht AG facilities in Schwanau GermanyAs a manufacturer of tunnelling machines, Herrenknecht AG is unique inthe sense that it covers the complete range of tunnelling machines in termsof size and suitability to geological conditions._ from large diameter from 4,000mm up to 15,470mm used for road andrailway, metro and water tunnels down to the smallest 100mm outsidediameter fully automatic microtunnelling machine, house connectionmachines and HDD-Equipment,_ from soft, water bearing non-cohesive soils to hard rock up to 300MPacompressive strength.In total, Herrenknecht AG has supplied more than 1,300 tunnellingmachines worldwide.1.1 Production facilitiesThe headquarters at Schwanau comprises the following facilities:Production facilitiesAssembly of large diameter machines 32,500mEngineering and Administration 6,500mAssembly microtunnelling machines 16,800mProduction plant TBM components 10,000mApprentice training area 600mEquipment storage / parking 24,000mLifting facilities cranes80 tons capacity 4No.64 tons capacity 6No.50 tons capacity 1No.32 tons capacity 26No.20 tons capacity 3No.16 tons capacity 17No.10 tons capacity 4No.6.3 tons capacity 3No.5 tons capacity 5No.Portal crane2 x 2 x 80tons capacity 1No.1 x 80tons capacity 2No.1.2 Herrenknecht facilities in ChinaFollowing the dynamic market development in the Asian region,Herrenknecht AG has been building up its structures in the Asian areasystematically in the past few years.The services include among others, the engineering and supervision of themanufacturing of TBM, the assembly on site, the training of site crew /personnel and the project management with Chinese and internationalHerrenknecht staff.Tunnelling projects in China will be supported by the technical assistance ofHerrenknechts Asian facilities in Guangzhou, Beijing and Singapore:_ Service workshop in Guangzhou, Beijing, Shanghai and Singapore_ Approx. 100 field service engineers and technicians in Asia_ High efficiency and fast TBM technical support_ Spare parts management_ Construction and geotechnical engineering_ Very good knowledge of the Asian geological conditions (pleaserefer to our reference projects in Singapore, Hong Kong,Guangzhou, Chongqing, Beijing, Tianjin, Nanjing, Bangkok, NewDelhi, etc.).In Guangzhou, P.R. of China, Herrenknecht AG has the following assemblycapacity:_ Main hall 150m long x 32m wide_ Height under hook 14m_ Crane capacity 64 tons and 100 tons_ Possibility to assemble a TBM with a weight up to 2,000 tons in thefront of the hall (with mobile cranes).Herrenknecht AG has worked with different major Chinese steelconstruction companies to manufacture TBMs in China (e.g. STEC, DalianHeavy Industries, Wuhan Heavy Tool Machines, Guangzhou HeavyIndustries, Shougang Corporation, ZMPC, Hudong Shipyard-Shanghai).Reference list for TBMs produced in China:_ Metro Guangzhou: 10 TBMs (S-179/ S-180, S-181/ S-182; S-242/S-243; S-244/ S-245; S-266/ S-267)_ Circle Line Singapore: 2 TBMs (S-262/ S-263)_ Metro Beijing: 3 TBMs (S-254 / S-294 / S-282)_ Metro Tianjin: 2 TBMs (S-283 / S-284)_ Xinjiang Daban Water Diversion Project: 1 TBM (S-301)_ Singapore Metro: 5 TBMs (S-307/ S-308, S-310, S-311, S-312)_ Chongming Motorway, Shanghai: 2 TBMs (S-317/ S-318)1.3 Herrenknecht Group world-wideAs well as group headquarters, design and manufacturing facilities inSchwanau, there are subsidiaries in:Herrenknecht AG world-wideAsia_ Herrenknecht Asia-Pacific Pte. Ltd. Singapore_ Herrenknecht Asia Headquarters Pte. Ltd. Singapore_ Herrenknecht AG Beijing Office. China_ Herrenknecht (Guangzhou) Tunneling Equipment Co. Ltd. China_ Guangzhou Herrenknecht Tunnelling Machinery Co., Ltd. China_ Herrenknecht (Shanghai) Tunneling Equipment Co. Ltd. China_ Herrenknecht (Chengdu) Tunneling Equipment Co. Ltd. China_ Herrenknecht Malaysia Sdn Bhd_ Herrenknecht ASIA Ltd. ThailandMiddle East_ Herrenknecht AG Iran_ Herrenknecht AG DubaiUSA_ Herrenknecht Tunnelling Systems (HTS) - Washington StateAustralia_ Herrenknecht (Australia) Ltd. PerthEurope_ Herrenknecht Ibrica S.A. Spain_ Herrenknecht France S.A.R.L. France_ Herrenknecht International Ltd. Great Britain_ Herrenknecht Nederland B.V. The Netherlands_ Herrenknecht Schweiz AG Switzerland_ Herrenknecht Tunnelling Service Russia RussiaIn addition to these subsidiaries an extensive network of representativesguarantees close proximity to customers all over the world.1.4 Full service providerThrough its different subsidiaries and highly qualified partners,Herrenknecht AG can offer a wide range of tunnelling equipment such as:_ Slurry circuits and tunnel belt conveyor_ Segment moulds_ Gantry crane_ Rolling stock incl. locomotives_ Ventilation equipment_ Transformer station_ Separation plant (up to an output of 2,800m/h)_ Grout mixing equipment_ Cooling systems_ Compressed air plantsThrough this, Herrenknecht AG has established itself on the market as afull service provider with high quality products.The group today also comprises the following six independent companies: Bohrtec GmbHA well known specialist in the production of auger drilling machines. H + E Logistik GmbHExperts for continuous belt conveyor systems and logistic services. VMT GmbHA provider of a full package of tunnelling guidance systems, segmental ringsequence calculation, documentation and data transmission (www.vmtgmbh. ANAKON GmbHExperts in TBM static designs and finite element analysis. Euroform and Herrenknecht d.o.o.SloveniaSpecialist for the planning and delivery of turnkey manufacturing plants onsite for segment fabrication. Provision of segment design and theappropriate layout of the reinforcement. Maschinen- und Stahlbau DresdenSpecialist for the planning, manufacturing and delivery of special steelconstruction for tunnelling and rolling stock.2. General project descriptionThe project is located at the Jinping river bend of the Yalong River, SichuanProvince. The project includes a road access tunnel for Jinping secondaryhydropower station; 4.7km were already excavated with drill&blast method,the remaining 6km will be excavated with TBM method with outsidediameter of 6m.The main geology is marble and sandstone.The project goes through Karsts. Main possible hazards include: highground stress, rock burst, water inflow, gas, unstable face and faults.3. General concept3.1 General Description of a Gripper TBMThe Gripper TBM is the typical TBM (Tunnel Boring Machine), whichoperates in Hard Rock Tunnelling project with medium to hard, competentrock.The Herrenknecht Gripper TBM is a single and floating gripper TBM typeand incorporates the following features: CUTTERHEAD: A cutterhead design with centre and outer segments.The quantity of muck entering the muck handling system is limited inaccordance with the buckets design in order to prevent from plugging.Grill bars between buckets limit large blocks from entering the muckchute. CUTTERS: Herrenknecht high duty cutters to keep the cutterconsumption on an economical level while ensuring a high penetrationrate. MAIN BEARING: A three-axis roller bearing to match the high thrustcapacity of the machine. The main bearing is protected by a specific sealsystem. MAIN DRIVE: Water-cooled electric motors, frequency driven withplanetary gear reducers to drive a common internal hardened ringgear. GRIPPER SYSTEM: The floating gripper system allows steering whileboring. THRUST SYSTEM: The thrust system is dimensioned in accordance tothe cutterhead design and the expected shield friction MAIN BEAM: The main beam is the central structure of the GripperTBM, which interconnects the major TBM parts and auxiliary parts. REAR SUPPORT: To support the TBM during the resetting process. CUTTERHEAD SHIELD: using its hydraulically activated roof shield andside supports, the cutterhead shield stabilizes the Gripper whileexcavating. The roof support is equipped with a finger shield to protectthe TBM operators. ROCK SAFETY EQUIPMENT: Equipment to carry out the necessaryrock safety/ improvements, e.g. steel ring erector, roof-bolting drill, probedrill.3.2 Gripper TBM operation modeThe basic principle is that the machine braces itself with the gripper shoesradial to the rock while tunnelling. The thrust cylinders will provide thenecessary thrust force for the Cutterhead to excavate the rock and to pushforward the Cutterhead Shield. Once the thrust cylinders have reached theirfull stroke, the boring process is stopped. The rear support is extended tokeep the TBM supported while the gripper shoes are released and thegripper assembly is reset.With the Herrenknecht floating Gripper design, it is possible to carry outcorrection curve/ Steering operation during the excavation process to limitthe steps while excavating (depending on the TBM operators skill and rockhardness) and so achieve a good tunnel wall surface.Gripper cylindersGripper shoesThrust cylindersRear support3.3 Rock support conceptAccording to the rock type and the designer requirements, specific rocksafety measures as roof bolting, mesh wire installation, steel arch settingmay be required. According to Herrenknecht Gripper Design, such roofsupports is carried directly in the zone L1 behind the gripper shield withinthe finder shield area to ensure adequate protection to the TBM operators.The space allocated for the rock bolting, mesh wire installation is large andindependent from the boring process through the chosen wide workingrange.Rock support on Gotthard projects3.4 Back up system logisticThe logistic concept of the proposed Back up system and its interface tothe tunnel logistic are based on the maximal advance rate specified in thetender document with sufficient safety. The Back up system logistic mostlycomprises the transportation and storage of rock support material, TBMconsumable (by tunnel train) and removal of excavated material (by tunnelconveyor belt).During design period, we will study in co-operation with the End-user theworkplaces ergonomic to improve the working efficiency. Most of theoptimization can be done in the Back up system as the interfaces betweenthe parties involved in large. Such optimization can lead to importantincrease of productivity and of advance rate mostly in complex system aslarge TBMs.3.5 Specific water protection measuresHerrenknecht AG has foreseen specific water protection concept to handleingress water.Gripper area:As the gripper TBM/ bridge section shall be kept open to carry out rocksupport works, Herrenknecht AG proposes to have high Index of protectionfor the electric equipment in zone L1/ L2 as: Main drive motors: IP 67 Other electric or electronic devices: IP 55In the back up area: The back up system height was optimized to height level leavingroom to be kept out of the water. Electric cabinets are located in fully closed electrical container Complete housing of the hydraulic power pack on the tunnel side Specific protection for the transformer All equipment have minimum IP 553.6 Specific Design TBM performancesThe S-271 TBM was designed for following performances:Max. advance rate : 100mm/min. or 6m/hDaily TBM capacity : 20 circles/ dayAverage advance speed: 700m/monthMax performance : 1000m/month3.7 Herrenknecht past Hard Rock experiencesPlease refer to attached list4. Technical specifications4.1 Technical Data SheetPlease see the following pages.4.2 Torque curvePlease see the following page.4.3 Basic data calculationPlease see the following page.5. Technical description5.1 Cutterhead5.1.1 GeneralAccording to the geological conditions, the cutterhead has been speciallydesigned as a closed drum type cutterhead.The steel quality of the cutterhead is S355J2G3. There is a robust steelcenter with flange plate which serves as a connecting flange with the maindrive.The machined outside surfaces of the cutterhead center serve asreceptacle for the outer segments.The outer segments are welded structures and for reduction of wear andfriction they are equipped with grill bars which are made from hard andwear resistant steel.For tunneling operations, the outer segments are bolted and weldedtogether with the cutterhead center. On the cutterhead periphery and facethere are buckets and muck chutes to pick up the excavated rock and guideit to the central conveyor belt.5.1.2 Cutting toolsThe tools used are discs and bucket lips. The tool arrangement is adaptedto hard rock geological conditions and reflects the latest experience ofHerrenknecht in hard rock conditions.The tool arrangement is designed for one direction of rotation. The toolsupports are integrated into the cutterhead structure; the tool itself is theonly component sitting forward of the cutterhead front plate. Change of thetools is possible from inside the cutterhead (back loading type). Thepersonnel are always behind the steel structure and protected from evenpotential tunnel face collapse.5.1.3 Steel constructionThe multi-component structure of the cutterhead is a heavy steelfabrication. The steel used is S355J2G3. The plate thicknesses and sizesof weld seams take into account the high dynamic loading of roller cutters.All the connecting flanges are machined, and connected together with M36grade 10.9 bolts. The flanges are secured with shear pins.The massive central section forms the connection to the cutterhead drive.Its heavy construction and stability ensure a uniform passage of cutterheadthrust into the main bearing.The outer segments are flanged on to the structure of the centralcomponent, and with diagonal flanges connected to each other and weldedon site.The combination of high individual cutter loading, optimal cutter spacing,proper selection of the cutter profile and correct pattern guarantees a highpenetration rate at long cutter life.The size and shape of the buckets are optimized to ensure perfect muckingdue to a high advance rate and low wear in the gauge area.The cutter head is equipped with several spray nozzles for dustsuppression. The water is supplied by a central rotary connection.5.1.4 Hard rock cutter assembliesThe TBM is equipped with state of the art, 432mm (17”) diameter disccutters.High capacity bearings allow loading of an individual cutter with up to267kN resulting again in higher performance.The shrink fitted rings allow an easy replacement of worn rings on the sitescutter shop. Several rings maybe used on one hub assembly before hubmaintenance is required, an important fact when considering the cuttercosts.The cutter housings are heavy steel bodies. The housings are aligned inour works using a template to locate them within tight tolerances in theoptimum position before welding.All functionally important parts of the housings and related parts are locatedin the inner part of the cutterhead to protect them from wear.The cutter fixing system is of the wedge lock type.5.1.5 Bucket lipsThe proposed cutterhead design employs bucket lips to pick up the muckand for clearing spoil from the periphery of the excavation.The front faces of the bolt on bucket lips are hard faced over the cuttingedges, whilst the rears of the tools are protected by carbide inserts. Themounting of the lip elements to the cutterhead is a bolted configurationusing a threaded insert in the cutterhead which can be exchanged in caseof damage.The bucket lips at the flat face are of the cutterhead are mechanicallyadjustable in three steps regarding the distance to the face.5.1.6 Changing cuttersAll cutter assemblies and bucket lips can be changed from inside thecutterhead. Cutter assemblies are transported through the center of thecutterhead.The necessary crane tracks and lifting gear are installed.All necessary special tools and fixtures are included in the scope of supply.5.1.7 Muck handling and conveyorBuckets, integrated in the cutterhead collect the muck up from the bottomof the tunnel. While rotating the cutterhead the muck moves through themuck chutes and is loaded on the machine conveyor through a hopperintegrated in the cutterhead support. The conveyor transfers the muck frominside the cutterhead back to the rear end of the machine. There the muckis transferred to the muck handling equipment on the back-up.5.2 Cutterhead support, main beam and front TBM supportThe cutterhead support is one rigid (resistant to twisting and torsion) andheavy welded steel structure on which the main drive unit, the front, sideand roof supports are mounted on. The side and roof supports arehydraulically driven.Th