Tunnel Cleaning - systemair.com · The TBM drilling method normally uses a deduster, which is...

Tunnel CleaningDry Dedusters

Tunnel Fans

Tunnels during construction, mining, or whatever activity is going on below ground generates a remarkable amount of dust, therefore one of the major requirements is for the control and collection of dust. European Directives impose stringent exposure limits, to a finite particles, so as to reduce the risk to the worker’s health, reduce social costs, and increase safety.

Systemair, backed up by its experience in tunnel ventilation, is always sensitive to such human and environmental issues and has specifically designed a filtration system leading to an advance in technology for dry deduster equipment.

The range of DS dedusters provides the technical answer that can be used to filter the polluted air and bring it in line with the legally permitted atmosphere present in the tunnel. These can be either hydro, road, rail or metro and also the activities during tunnel refurbishing activities.

DS dedusters are required, even to a greater extent, by the World Health Organization (WHO), especially when silicon dioxide (quartz) or asbestos are present in the rocks that are being excavated. The high efficiency is especially suitable for fine dust (PM2.5) that is particularly unhealthy for the personnel working in the tunnel.

Underground space “today” and for the “future”

Several application of use are possible for our range of DS deduster units. Mechanical tunnel construction executed by using Tunnel Boring Machine (TBM), road headers or even in the crush/mucking operations.

These are the most typical situations where the dust present in the tunnel will be of the largest amount so, in order to be in line with legal legislations, a dust collection and reduction system must be adopted.

The TBM drilling method normally uses a deduster, which is positioned in the TBM’s back up and should be limited in its dimensions.

Main fan

The units have been tested by the German Labora-tory DMT in accordance to IKO DN 70 and VDI 2066, with a load of 2000 mg/m3 (3.58 kg/h) in order to determine the MAK value for quartz (≤ 0.15 mg/m3). The efficiency is over 99.99%.

Tests in Germany!

Humanity is searching for new living spaces and also the ability to have fast mobility facilities. One solution is to use the sub-surface and create habitable spaces and a travel infrastructure network underground.

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Underground space “today” and for the “future”

Our particular design using the vertical cartridge is the most suitable one, since it requires just for filter removal, a side space of 500 mm that can provide easy access for assembly and removal for maintenance purposes. Our design is also suitable to accept modifications of the overall dimensions, particularly where TBM’s are being used for small tunnel diameters, where the height can interfere with the maximum allowable contour, a shaped external side can be accommodated. Special slimmer and more compact DS dedusters suitable for use with TBM’s are available and can be customized in accordance to customer’s needs.

The sturdy construction of the DS deduster allows it to be used in the harsh environments encountered in tunnels. The airtight structure, which is manufactured in galvanized metal sheets which are then powder coated, with modular construction so as to allow flexibility in order to meet the demand of the technical specifications. The air volume range varies from 2 m3/s up to 30 m3/s; larger air volumes are possible with proper planning and on the basis of

the available space agreed with the customer, units mounted in parallel can also be used.

Inside the tunnel the DS deduster is installed so that it follows the drilling operation, therefore the DS Dedusters movement must be easy and flexible. It is normally mounted on a stable sled, but it can be also installed on a truck, on a railway flatbed or in a tailor made movable arrangement.

Dust conveyance/collection is standard via a cochlea conveyor but alternative solutions like multi cochlea, redler conveyor, water or dust bags etc. can be adopted and the dust is collected in a hopper. Dust discharge can be customized with a roto-valve, pneumatic, alternative valve, pumps or water etc. and then discharged for disposal. Cleaning of the filters is automatically controlled and it is normally set up for the clogged

Inside the tunnel the DS deduster is installed so that it follows the drilling operation, therefore the DS Dedusters movement must be easy and flexible. It is normally mounted on a stable sled, but it can be also installed on a truck, on a railway flatbed or in a tailor made movable arrangement.

filter pressure drop or fixed time, then an automatic cleaning cycle, with a counter flow compressed air system, at 5.5 to 6 bar is activated; other solutions available on request. The compressed air device can be included in the DS deduster or sourced from facilities that are available on site. The Fan section is normally assembled and mounted on the clean air outlet and it is dimensioned in accordance to the pressure losses required. The complete operating cycle is fully automatic and controlled by a PLC, it includes the fans start up, all electronic and electrical equipment is encased in a control cabinet with a suitable mechanical IP protection, options such as inverters, remote controls, are available on request.

The DS deduster design can be fully customized to suit various customer needs and special units made of stainless steel EN 1.4301, EN 1.4404 can be supplied. Special electrical compliance to ATEX (incl. Group I M2), UL and UL/CSA.

Life Cycle Cost (LCC) aspects are becoming more important parameters. Therefore from an economic point of view it is important to consider all aspects from the preliminary stages to the maintenance, the operational

running costs, and the spare parts. The limited pressure drop of the filtration section (filters and plenum chamber) can be lowered by as much as 40% compared to other products of the same type, so that it makes the DS de-duster range most attractive. The operation of these units, when continuously working can have a high cost to the customer, therefore running costs are sensitive to savings. As a general guide for kW saving, with 8500 hours/year running time, at

a basic energy cost of € 0.15/kW, this would give an estimated saving of € 1275 per annum. Should we consider a typical air volume of 18 m3/s for a standard tunnel construction method (not TBM) the energy saving is ranging closer to 30 kW so the associated saving to annual running costs is € 38000 .The payback time is consequently shortened and positively influences the financial resources plan.

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The DS deduster is fully assembled in the factory, for larger dimensions it can be shipped in sections and locally assembled. The operational settings can be previously carried

out in the factory or on site. A full Technical Service is available so as to help the customer needs and for any personnel teaching or training that may be required.

Tunnel Construction Ventilation Systems – References*

Site Fans Year

BBT Brenner Base TunnelMules BolzanoItaly

2 of Dedusters DS-C16 16 m3/s V400/50/3 2018

South Africa 1 of Deduster DS3.5 V400/50/ 2018

Railway link Paris-Eole HSLFrance

2 of Dedusters DS80 V400/50/3 2018

Railway high speed Milan-GenoaCastagnola access window Italy

1 of Deduster-U 30 for asbestosATEX EX IM2 V400/50/3

2017

Angat ProjectPhilippines

1 of Deduster DS-MC4 4 m3/s V 400/50/3

2017

AtlantaUSA

1 of Deduster DS2.5-C 2.5 m3/sV 400/50/3

2017

Albula TunnelSwitzerland

2 of Deduster DS10-C 10 m3/s V400/50/3

2015

Salt MineNew Mexico (USA)

2 of Deduster DS24-C 24 m3/sV460/60/3

2015

Qingdao Metro Project Metro TunnelChina

2 of Deduster DS-R 8 – 8m3/s V400/50/3

2014

Shanxi Metro Project Metro TunnelChina

1of Deduster DS-R 3,3 – 3,3m3/s V400/50/3

2014

OTTAWA Metro Metro TunnelCanada

3 of Deduster DS-C 23 – 23 m3/s V460/60/3

2014

Birkikara-Msida-Gzira-Wiedis-Seweda Tunnels Hydraulic Tunnel Malta

1 of Deduster COMPACT DS2 C-R – 2 m3/s V400/50/3

2013

Minas Project EcuadorMine TunnelEcuator

1 of Deduster DS6-R6 - 6 m3/s WxHxL 850x2027x8394 mmV440/60/3

2013

Bormio Ring RoadRoad TunnelItaly

1 of Deduster DS16 – 16 m3/s V400/50/2

2013

Birkikara-Msida-Gzira-Wiedis-Seweda Tunnels Hydraulic Tunnel Malta

1 of Deduster DS4 – 4 m3/s V400/50/3

2013

* Extract of references. The full list of references is available on request.

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