闸门与启闭机安装

1、12 闸门与启闭机安装12 INSTALLATION OF GATES AND HOISTS12.1 安装场地布置及要求12.1 Layout and Requirement of Installing Area本项目闸门安装分为进水口拦污栅、进水口快速闸门、进水口检修闸门、灌溉孔进水口事故闸门与尾水检修闸门安装，安装场地较为分散。拦污栅安装场地包括自身的工作面与上游导水槽处，导水槽可以作为堆放设备与吊装的场地使用；进水口闸门安装场地主要布置于114高程的检修平台处，届时闸门的拼装、吊放下闸与吊装门槽都在此处工作；尾水检修闸门安装场地主要布置于孔口下游与尾水检修平台（包含平台两边的平地）处，孔

2、口下游主要作为门槽吊装场地。The installed gates of this project include intake trash racks, intake stop gates, intake bulkhead gates, intake emergency gates for irrigation holes and tail bulkhead gates, with dispersed installing areas. Installing area of trash racks includes its working surface and upper head rac

3、e channel; head race channel can be used as place for equipment and hoisting; installing area for intake gates is located at the service platform which is 114 height and where the work of gates assembly, gates hoisting and placement and gate slot hoisting will be executed; installing area for tailra

4、ce bulkhead gates is mainly located at the downstream of orifice and service platform of tailrace (including areas around the platform); the downstream of orifice is mainly used as hoisting area for gate slots.安装前场地要求：Field requirement before installation:1、安装工作面与安装场地中的残余模板、废弃物与障碍物应清除干净；1. Remaining

5、 formwork, wastes and obstacles at installing working surface and installing area shall be removed;2、书面移交安装基准高程点与门槽、孔口中心线；2. Elevation point of installing datum and centerline of gate slots and orifices shall be handed over in written form;3、保证安装场地的施工用电与机械设施；3. Power supply for construction and mech

6、anical facilities shall be ensured at installing area; 4、保证安装场地与外围道路的畅通，运输车辆与汽车吊能自由通行。4. Installing area and peripheral channel shall be clear to ensure transport vehicle and mobile cranes can pass freely.12.2 闸门的安装程序12.2 Installing Procedure of Gates1埋件安装程序1. Installation procedure of embedded part

7、s底坎安装 主轨安装反轨侧轨安装门楣安装埋件的复测二期混凝土浇筑复测。Bottom sill installation mail guide installation reversed guide and side guide installation lintel installation retesting of embedded parts second stage concreting retesting.2.门体安装程序：2. Installing procedure of gates门体外形及配合尺寸复测检查门槽清理、检查单节运输、吊装、焊接焊接变形处理安装焊缝防腐水封安装及与水封

8、座板间密封情况检查、处理，其他配件安装启闭试验验收Retesting and checking of gate shape and dimension cleanliness and checking of gate slot single section transportation, hoisting and welding treatment of welding deformation anti-corrosion of weld seam sealing, seal checking and treatment of bottom plate for sealing, other a

9、ccessories installation hoisting test acceptance.12.3 闸门的运输和吊装方案12.3. Transportation and Hoisting Scheme of Gates1、运输1. Transportation闸门从国内打包运至现场后暂时存放于现场的制作车间内，待安装条件成熟后再二次倒运至安装场地。现场的运输、倒运和吊装主要由缅方负责。Gates will be transported from China to the construction site after packed, then temporarily stored in

10、 the fabrication workshop at site; when conditions permitting, secondarily transport gates to installing place. Myanmar Party will be in charge of site transportation, handling and hoisting.闸门的门叶、门槽采用裸运，宜采取临时加固措施防止变形及滑落，工作面与加工面应加以保护。叠放时设备之间应有木板相隔，防止运输时因振动互相碰伤。止水橡皮应妥善包装、运输。Gate leaves and gate slots

11、will be transported unpacked; temporary reinforcement measure will be taken to prevent them from deformation and slide; working surface and processing surface shall be protected. There shall be wood board to separate it when equipment is piled up to avoid damage by vibration during transport.门槽埋件、门叶

12、主要采用汽车运输，大件设备用平板车运输。由于现场道路都为泥沙路又不平坦，局部路段为下坡路；最大闸门（尾水检修闸门）门叶的外形尺寸为4280mm×11888mm，重约28.22t，因此运输时应特别小心，建议有前导车带路，指挥引导其它车辆规避。Motors are mainly adopted for transport of embedded parts of gate slots and gate leaves, while trucks are adopted for large equipment transport. Because the site road is sandy

13、 and unevenness with some downhill sections, the dimension of the largest gate leafs (tail bulkhead gates) is 4280mm×11888mm, with weight about 28.22t, special caution shall be exercised during transport. It is commenced that a guide-car shall adopt to lead the way for other vehicle.2、吊装2. Hois

14、ting闸门的门槽、门叶等构件在现场安装时主要用50吨汽车吊与相应的启闭设备进行吊装。吊装设备时指定一人统一指挥，做到人员、设备的绝对安全。During installation, components like gate slots and gate leaves are mainly adopted 50T mobile crane and corresponding hoisting device for hoisting. When hoisting equipment, a person shall be arranged to command so as to ensure the

15、 absolute safety of personnel and equipment.拦污栅的栅槽与栅叶（2.8t×4=11.3t）的吊装场地选取在上游导水槽处，吊装半径约9m，地面高程大约在90m，栅槽顶端高程为96m。Hoisting place for trash rack slot and trash rack leaves (2.8t×4=11.3t) shall be at the upper head race channel, with hoisting radius about 9m, ground elevation is about 90m, top

16、 elevation of trash rack slot is 96m.进水口闸门与埋件主要是通过汽车由公路桥运至进水口检修平台。然后，直接用汽车吊来吊装门槽，门槽安装完后，进水口快速闸门与检修闸门的门叶可直接在门槽上进行拼装（较为方便）亦可在平地上先进行组拼，门体重量分别为18.4t与16.4t，外形尺寸为5530mm×6250mm。门槽底部至检修平台的高度约为31m，吊放门叶时直接用启闭机进行吊放。Intake gates and embedded parts are transported to intake service platform by road-bridge w

17、ith motor cars; then hoisting gate slots with mobile crane; after installation of gate slots, leaves of intake stop gates and bulkhead gates can be directly assembled on gate slots (more convenient), or pre-assembled on ground. The weight of gates is 18.4t and 16.4t respectively, the dimension is 55

18、30mm×6250mm, the height from bottom of gate slot to service platform is about 31m. Directly adopt hoist for gate leaves hoisting.尾水闸门的重量较为重（28.22t），体积也较为庞大（4280mm×11888mm），吊装条件也相对困难，汽车吊无法在检修平台上摆腿，因此在吊放闸门时只有通过尾水闸门启闭机来下闸，但是需通过汽车吊把闸门从尾水检修平台靠近安装间这端吊运至检修平台上来，再由启闭机吊运至门槽。门槽的吊装则可直接在下游导水渠的位置进行。Beca

19、use the tail gate is heavy (28.22t) and the volume is large (4280mm×11888mm), conditions for hoisting is relatively difficult, mobile crane can not swing its arm on service platform. Gates can only be placed by tail gate hoist for gates hoisting. Use mobile crane to convey gates from the end of

20、 tail service platform near erection bay to service platform, then conveyed by gate hoist to gate slot. Hoisting of gate slots can be directly operated at the lower head race channel.12.4 安装前的准备工作12.4 Preparation Work before Installation按闸门的出厂验收记录，仔细了解其尺寸误差。制造质量应符合规范要求。According to the delivery acce

21、ptance record of gates, know their detailed dimension tolerance. Fabrication quality shall be conformity with specification.闸门及其埋件运到工地后，按发货单及图纸清算数量，按图纸对闸门外形尺寸，相配尺寸进行复核，轴、销等进行试装检查。检查构件变形情况，不应超过规范或图纸要求，否则应在安装前进行处理。进行外观检查，有否碰损，变形等异常现象，如发现异常应及时汇同监理，研究处理方案。After the arrival of gates and its embedded part

22、s, check the quantity, gates shape and dimension and matching dimension as per dispatch list and drawings, take trial assembly for shaft and bearing etc. Deformation of components shall not exceed the requirement of specification and drawings, or treatment measures shall be taken before installation

23、. Do the visual examination to check whether there is clash, breakage and deformation, if abnormal situation is found, reported to supervisor and work out treatment measures.对到货的闸门及其零部件应妥善存放，保管。闸门应平放，不得堆叠，加工面应予保护。止水橡皮应平放室内，不得盘折。小型零部件，开箱后分类，编号入库保管。Arrived gates and their components shall be well stor

24、ed and kept. Gates shall be kept flat, never piled up; processing surface shall be protected. Water stop rubber shall be kept indoor flat and never folded. Small components shall be classified open-box and numbered before putting in to storage.闸门安装前应具备的资料：Documents provided before gates installation

25、:1设计图纸和安装必须的技术文件。1. Technology documents necessitated for design drawings and installation.2闸门出厂合格证。2. Gate Testing Certificate.3闸门验收资料和材质证书。3. Gate examination documents and Material Certificate.4发货清单。4. Shipping list.5. 安装用控制点位置图。5. Control Plot for installation.12.5 预埋件的埋设方案及质量控制措施12.5 Embedded P

26、rogram and Quality Control Measures for Embedded Parts1安装顺序：1. Installation sequence:1）门槽检查，清理；1) Gate slots checking and cleaning;2）复查确认安装基准点；2) Recheck and verification of installation datum point;3）由安装基准点放安装控制点、线；3) Set installation control point and line from installation datum point;4）埋件安装前检查及变

27、形处理；4) Check and deformation treatment before embedded parts installation;5）埋件吊装、调整、加固；5) Embedded parts hoisting, adjustment and reinforcement;6）校核复测、验收、移交浇筑二期砼；6) Check, retesting, acceptance and handover to deposit second-stage concrete; 7）二期砼浇筑完后再进行复测，必要时进行局部处理。7) Retest after the second-stage c

28、oncrete deposit, doing local processing if necessary.2控制点设置：2. Setting control point 基准点由测量部门提供，提供位置应尽量接近安装部位，交接有书面凭证，并经监理确认，施工过程中应妥善保护。控制点由基准点引入，一般距安装构件100200mm，控制点设置应牢固、可靠、正确、并经复核。Datum points are provided by measurements department with written confirmation and supervisors verification which shal

29、l be well kept during construction; provided places shall be as near the installation places as possible. Control point which is 100-200mm from installation components is led by datum point; setting of control points shall be fixed, secured, correct and rechecked.3底坎安装：3. Bottom sill installation:底坎

30、吊装前，将预埋插筋焊成支架，支架依底坎结构而定。其架面高程低于底坎构件底面1050mm，以便底坎就位后，留有调整的裕度。利用门槽两侧放好的样点，拉一水平钢丝线，找正底坎的高程及水平。每隔0.5m测量一点，调整至合格。同时用水准仪配合测量检查底坎高程。底坎中心的调整是利用已设置的闸孔纵横中心线来控制。中心偏差不超过±5mm，倾斜不超过1mm，底坎左右两头相对高程不超过3mm。 因为底坎是门槽构件的安装基础，装好后必须支撑加固牢靠，以防二期砼浇筑，振捣时走样。Before bottom sill hoisting, embedded steel dowels shall be welde

31、d to brackets which will depend upon the structure of bottom sill. Height of bracket surface shall be 10-50mm lower than the bottom of sill components so that the sill gets some adjusting space after being in place. Use the sampling points on both sides of gate slots to verify the height and level o

32、f bottom sill with a horizontal steel wire. Measure a point in every 0.5m, adjusting to conformity, measuring and checking the height of bottom sill with water level gauge. The adjustment of sill center is controlled by the located crossed centerline of gate hole. The center deviation shall not exce

33、ed ±5mm, the inclination shall not exceed 1mm, relative height on both ends of bottom sill shall not exceed 3mm. Because bottom sill is the installation foundation for components of gate slot, it shall be reinforced after installation to avoid deformation of second-stage concrete deposit during

34、 vibration. 4主轨安装：4. Main guide installation:主轨安装前，在已安好的底坎上定出中心位置，根据底坎的中心位置定出主轨的位置，将主轨吊入门槽，底部落在底坎上，同时对准定在底坎上的中心位置。上端焊上两个调整螺栓，松钩后，在主轨前面100mm左右焊上两套重力线锤，侧面再挂一套线锤。调整从下端开始，逐步向上进行，每隔0.5m测量一次。若轨道有里弯或外凸，可用千斤顶调整。符合要求后，电焊加固。接头错牙用砂轮机打磨平滑。Before main guide installation, fix the center on the installed bottom si

35、ll; then fix the position of main guide, hoist the main guide into gate slot with its bottom on the sill, aiming at the center on the bottom sill. Weld on two adjusting bolts on the upper end; after loosing the hook, weld on two sets of plumb bobs about 100mm in front of main guide, hang a set of pl

36、umb bobs on the side surface. Adjust from lower end to upper end, measuring once in every 0.5m. If the guide cambers inwards or outwards, a jack can be used for adjustment, then reinforce by welding after conforming to requirement. Unevenness of joints shall be grinded to smooth by grinding machine.

37、5反轨安装：5. Reverse guide installation:安装方法与主轨相同，安装允许误差应符合图纸及规范规定。Installation procedure is the same with that of main guide. Allowable tolerance of installation shall be conformity with drawings and specification.6门楣安装：6. Lintel installation:门楣吊装就位前，预先在轨道面上定出门楣的横向中心高度线。并在两主轨道的内侧固定两个托架。将门楣吊落在托架上。沿门楣水封中

38、心拉一钢丝，调整不平度和中心高程。Before lintel hoisting, fix the height of lateral centerline of lintel on the guide surface. Fix two brackets at the inner side of two main guides, then hoist lintel on the brackets. Set a steel wire along the seal center of lintel to adjust unevenness and center height.门楣的倾斜度检查，可以在

39、止水面前上下拉两道钢丝，测量两读数误差小于1mm。Set two lines of steel wire on the top and bottom of seal for inclination examination of lintel. The deviation of measuring data shall be less than 1mm.7埋件的复测：7. Recheck of embedded parts:埋件安装完，经检查合格，应尽快浇筑二期混凝土。混凝土一次浇筑高度不宜超过5米，浇筑捣实混凝土时，应注意防止碰撞。After qualified inspection of e

40、mbedded parts installation, deposit the second-stage concrete as soon as possible. The height of the first-stage concrete deposit shall not exceed 5m. During concrete deposit and compaction, measures shall be taken to avoid crash.二期混凝土拆模后对埋件进行复测，并作记录。如有超差应预处理。拆模后应要求土建施工单位检查二期混凝土面的尺寸，清除遗留的钢筋和杂物，以免影响闸

41、门启闭；如遇有鼓曲情况，应将其凿平。After the shuttering demolition of the second-stage concrete, retest the embedded parts and make records, if out-of-tolerance is found, pre-treatment shall be taken; require the civil construction company to check the surface dimension of the second-stage concrete, to remove remain

42、ing steel bars and sundries so that it will not impact gate lifting; if there are cambers, smooth them.工程挡水前，应对全部门槽进行试槽。Before water retaining, all gate slots shall be tested.12.6 闸门的安装方案及质量控制措施12.6 Installation Method and Quality Control Measures of Gates1.门体安装顺序：1. Installation sequence of gate:1）

43、门体外形及配合尺寸复测检查1) Recheck and Examination of gate shape and corresponding dimension2）门叶拼装、焊接及变形处理2) Assembly, welding and deformation treatment of gate leaves3）安装焊缝防腐3) Anti-corrosion of erection weld4）水封、侧轮等配件安装4) Accessories erection of water seal and side wheel5）启闭试验5) Hoisting test2.闸门门叶拼装2. Assem

44、bly of gate leaf拼装时先按厂内定位板的位置，用千斤顶，手拉葫芦等工具使其达到厂内预组装位置。 When assembly, place all components in pre-assembly places with tools like hoisting jack and hand winch. 对于分块制造的闸门，安装前必须进行工地拼装，拼装可采用在门槽顶部平台组装的方法或在门槽内直接组装：将第一块门叶吊入门槽落在门槽上下游之间设立的锁定梁上，门体分别用千斤顶或手拉葫芦临时固定，防止倾倒。For those sectioned fabricated gates, sit

45、e assembly is necessary before installation. The work of assembly can be operated on the platform of gate slot top or directly assembled in gate slot: hoist the first gate leaf in to gate slot, on the dogging beam fixed between the upper and lower gate slot; the gate shall be temporarily fixed with

46、hoisting jack or hand winch to avoid inclination.为控制门叶尺寸，通过面板、边梁位置挂三组铅锤，根据事先设在门叶上放出的控制点，调整门叶垂直度，使其倾斜和扭曲值均达到要求。合格后将已调整好的门体牢固地固定在门槽中，接着吊入第二块门叶落在第一块门叶上，其调整方法相同，直至整扇闸门组装完毕。几何尺寸检查合格后进行施焊作业。In order to control the dimension of gate leaf, hang three groups of plumb bobs based on the positions of panel and

47、side beam. According to the pre-set control points on gate leaf, adjust the verticality of gate leaf to make its inclination and distortion reach the requirement before firmly fix the well-adjusted gate in gate slot. Then hoist the second gate leaf on the first one with the same adjusting method unt

48、il all gates are assembled. Welding work can only be done after qualified inspection of dimension.门叶的现场拼装组合焊缝，是门叶组装中的一项重要工序，关键是如何防止焊接变形。为防止变形，一般先将组合焊缝全部点焊牢固，经检查，在门叶组装允许偏差范围内才进行焊接，先焊接纵梁腹板焊缝，次焊接面板焊缝，最后焊接其它焊缝。采用从门叶中部向四周施焊顺序，使其焊接应力能够自由向外消除。焊接过程中，各部位的焊接线能量应尽量保持一致。焊接电流、电压、焊接速度等工艺参数应相一致。焊工必须偶数对称施焊，步调统一，焊接方

49、向一致。为了控制焊接变形而改变焊接顺序时必须听从指挥人员统一指挥。施焊时采取对称、倒退、分段跳焊等方法，并且在施焊过程中加强检查，特别是第一道焊完后，必须进行检查，及时发现问题，采取对策进行挽救。The site assembly and composite welds of gate leaf is an important process for gate leaf assembly. The key point is to prevent the welding deformations. In order to prevent deformations, generally, all

50、composite welds shall be firmly fixed by spot welding and checked the deviation is in the allowable deviation of gate leaf assembly before welding. The weld of longitudinal beam web shall be welded firstly, then the weld of faceplate shall be welded, other welds shall be welded finally. Gate leaf sh

51、all be welded center out so that welding stress can be freely eliminated outwards. During welding, weld heat input of each position shall be consistent with each other. Technological parameters of welding current, voltage and welding speed shall be correspondent. Welding shall be executed in paralle

52、l with uniform steps and direction. The single command of the leader shall be obeyed when changing welding sequences to control welding deformation. 焊接完成，卸去千斤顶及支撑，检查闸门质量，合格后作出记录。When the welding is finished, remove the jack and support, check the gate quality, and then make record if qualified.3.闸门配

53、件组装3. Gate fittings assembly闸门配件主要是指水封、侧轮、滑块、充水阀等，在闸门启闭机投入使用时再进行安装。安装前先将水封与压板进行配孔，如压板是采取分段制造，则配孔前应校对压板与闸门水封座板的螺孔位置并作出标记。按图纸尺寸裁剪水封时应注意水封接头位置，尤其是转角位置，应裁成45°角贴密后用粘性胶水粘接。利用启闭机升、降闸门到适合安装水封的位置，从上至下安装水封。安装完后应检查水封的压缩量，一般压缩量在5mm左右， 并作透光性试验，如局部仍存在透光，应在透光位置加垫适当厚度的橡胶垫板。亦可通过在水封上涂抹黄油，然后起闭闸门观察水封的磨擦痕迹来检查水封的封闭性

54、。侧轮、滑块与充水阀的安装比较简单，直接利用启闭机将闸门起降到侧轮或滑块的安装位置，将侧轮与滑块装好后上紧螺栓，检查每组侧轮的跨距及相对位置即可。4.闸门启闭试验4. Gate hoisting test闸门安装检查合格后，用启闭机将闸门缓慢吊放入槽，观察充水阀是否起落自然，不产生偏移、倾斜现象；水封、侧轮、滑块等是否入槽顺畅。来回多次升、降闸门，如无任何卡阻，自然入槽则视为通过。闸门入槽时应用水浇注水封，防止水封干磨擦受损坏。如现场条件许可，最好做一次挡水试验。12.7 启闭机安装12.7 Hoist installation本项目闸门启闭机安装主要分为进水口快速闸门、灌溉孔事故门固定卷扬式

55、启闭机安装，进水口检修闸门移动卷扬式启闭机安装与尾水检修闸门电动葫芦安装。综合现场情况与设备的安装工艺认为：本项目的安装难点在于电动葫芦轨道安装。电动葫芦轨道属于悬挂式倒装，安装场地临近尾水又狭窄，吊装条件也比较困难，因此作为本项目的难点来考虑其安装措施。12.7.1 卷扬式启闭机安装12.7.1 Winch installation安装程序Installation process轨道安装（移动式）设备吊装前准备设备吊装就位设备调整穿绕钢丝绳设备试验Rails installation (mobile type) Preparation before equipments hoisting E

56、quipments hoisting and emplacement Equipments adjustment Steel wire winding Equipments test 1、轨道安装 1. Rail installation1）、轨道安装程序1）Rails installation process轨道安装Rails installation基础安装Foundation installation轨道吊装Rails hoisting轨道校直Rails alignment放线Wire measuring2）、轨道安装2) Rails installation（1）放线：根据给定的基准线

57、确定轨道中心线位置及给定的高程基准确定轨顶和垫板基面高程。利用经纬仪、钢卷尺，钢丝线等放出轨道中心线。(1) Line setting: the rail center line is fixed according to the given datum, rail crest and backing plate elevation is fixed according to the given elevation datum. The rail center line is set by theodolite, steel tape, steel wire, etc.（2）轨道检查及校直：安

58、装前对到货轨道端面，踏面及正侧弯等进行检查，确认轨道材质，规格型号，符合设计要求，端面应平齐，踏面应平滑无缺陷。用拉线法检查轨道的正弯、侧弯，应符合设计有关要求，对有超标缺陷的轨道，应会同监理部门研究处理方案，用压力校形及机械铣削端头等方法处理。(2) Rail inspection and straightening: before installation, the rail end, tread and positive side bending shall be checked, confirm the rail material, model; they shall meet the design requirements, end surface shall be flat, the tread surface shall be smooth and without any defects. The positive bending and side bending of rails shall be checked by pulling line and meet the design requirements; the rails with defects sha