Crossover Ser ies

October 16, 2015

Presented By: Lok Home

AFTES Seminar

Dual -Mode Machines

Agenda

Today’s Presentat ion

- Introduction to Crossover

- Why Crossover Machines?

- Machine Design: Grosvenor Case

Study

- Key Takeaways

Introduction to Crossover TBMs

• Flexibility to switch from one mode to another

• Based on ground conditions

• Three main types of Crossover TBMs

- Hard Rock/EPB

- Open or Closed Mode

- Hard Rock or Soft Ground

- Screw Conveyor

- Slurry/EPB

- Equipped with screw

conveyor and slurry

system

- Hard Rock/Slurry Shield

- Highly adaptable to variety

of ground conditions

Crossover Introduction

Why Crossover

Machines?

Why Crossover Machines?

Today, Crossover Machines are required to excavate different types of ground

efficiently with one machine.

A Crossover machine may be considered if your tunnel includes a combination

of these elements:

• You want to excavate self supporting ground Open Mode (hard rock)

• You want to excavate self supporting ground but want to mitigate

underground water ingress Closed Mode (Compressed air, Slurry,

EPB, etc.)

• You want to excavate unstable ground Closed Mode (Compressed

air, Slurry, EPB, etc.)

Considerat ions for Crossover

Machines

• General

In most cases an intervention into cutter chamber is not undertaken

• Geological information

– To decide when and where to convert, reliable geological information will be required

– Adequate probe drilling is essential to determine the ground conditions ahead of a Crossover TBM

• Cost

– Up-front costs may be somewhat higher, but significant savings in the long-run

– Durability: savings in repair costs

– Dual-Mode: multiple project usage

• Safety

Conversion work should be carried out in a “save haven”

• Schedule

Conversion works can be time-consuming, so a detailed plan must be in

place

Defining Characterist ics

• Two-speed gearbox

• Crossover cutterhead

• Single-directional

• Convertible

• Tools for different

types of ground

• Improved probe drilling

• Completely customizable

2 S p e e d To r q u e C u r ve s - B o t h w i t h 1 2 6 0 kw

Diff icult Ground Busting Features

• Designed to excavate in open or closed mode

• Hard rock and/or soft, relatively permeable ground including fault zones

• Less well suited to permeable ground conditions such as sand and

pebbles, though additives/polymer can be used to stabilize these

conditions

• Typically proposed for mixed face conditions

Ground Condit ions

Crossover XRE TBM

Crossover XRE

Case Study

Grosvenor Decline Mining Project

• Queensland, Australia; 1,000km north of Brisbane

• Metallurgical Coal Project owned by Anglo American

• 2 Decline Tunnels for access to the 130m deep seam:

Conveyor Drift

Man and Material Drift

• TBM methodology for drift construction

Grosvenor – Project Overview

Crossover XRE TBM

• Soft Ground section (0-300m): sand, sand/clay, clay and conglomerate

• Mixed Face/Rock Section (300-1,000m): siltstone, coal, sandstone and

basalt (UCS=20-120MPa)

• Methane gas in intermediate coal layer and at pit bottom

Grosvenor – Dri f t Geology

Crossover XRE TBM

“Purpose-built” TBM to:

• Cope with mixed-face conditions

Crossover/Dual Mode TBM

• Operate safely in the coal mine environment

EPB mode

Double Screw conveyor

ERZ/NERZ compliance

• Build multiple decline tunnels

Quick de-mobilization/re-mobilization

Grosvenor – TBM Design

Crossover XRE TBM

General: 8.0m diameter Crossover (XRE) TBM capable of conversion from EPB mode to non-pressurized single shield mode

Back-loading Cutterhead designed for:

• Use with knife bits & scrapers (EPB mode - mixing chamber)

• 17” disc cutters & bucket lips (open mode - radial loading plates & extendable hopper and screw)

EPB Mode

Bi-directional

Rock Mode

Single direction Mixed Ground Mode

Bi-directional

Grosvenor – TBM Design

Crossover XRE TBM

EPB Mode Rock Mode

Grosvenor – TBM Design

Crossover XRE TBM

Double screw conveyor (front and rear) mounted in series and with

independent drives.

Grosvenor – TBM Design

Crossover XRE TBM

• EPB mode to maintain a positive

face pressure and contain the

methane;

• Double screw conveyor made with

spark resistant materials, forming a

sealed chamber with the mixing

chamber and capable of creating a

plug;

• Foam/additive injection ports also

along the screw conveyors to

prevent sparks;

• Snuffing box at the conveyor

discharge for suction and removal of

methane from the screw.

TBM Design for Compliance Crossover XRE TBM

Requirements:

• TBM to be disassembled in a blind heading, without large disassembly

chamber, without hot works and without work under exposed rock;

• TBM to be retracted quickly on the steep gradient to access the coal seam for

development works;

• TBM to begin excavation of the second drift.

Quick Removal System:

• CH – inner/outer bolted construction;

• FWD and REAR shields – inner/outer bolted construction;

• CHS, Bridge and Back-Up – able to be retracted as a self-propelled single unit

by a walking dolly system.

TBM Design for Mult iple Tunnels

Crossover XRE TBM

Cutterhead - Inner/Outer Bolted Connection

TBM Design for Mult iple Tunnels

Crossover XRE TBM

CH Segments

CH core

Inner Shield

Outer Shield CHS

CHS Dolly

Front Dolly Bridge Dolly

Sliding

Track

Segment Erector Bridge

Screw Conveyor

5.8m

Lift Jacks

Inner Shield

Grosvenor – Walk ing Dol ly System

Crossover XRE TBM

• Tight schedule Onsite First-Time Assembly: July-October 2013

• Walk-in, Tests, Compliance Dossier and Acceptance: November-December

2013

• Boring Started: December 20, 2013

Grosvenor - OFTA & Conveyor Drif t

Construct ion

Crossover XRE TBM

• Completion of Conveyor Drift at half face in coal: May 13, 2014 (798m in 20

weeks)

• Machine availability: 75-90% after week 8 up to 85m/week

• Last 6 weeks affected by more extensive presence of gas routine

implementation of procedures for mitigation and management (TARP)

Grosvenor - OFTA & Conveyor Drif t

Construct ion

Crossover XRE TBM

• Boring started on November 11, 2014

• Completion at full face in coal: February 9, 2015 (988m in 13.5 weeks)

• Machine availability: always above 60%; often between 80 and 90% up to

110m/week

Grosvenor – Transport Dri f t

Construct ion

Crossover XRE TBM

Grosvenor Mine – Achievements And

Conclus ions

• First time for a TBM to be fully compliant

to one of the most advanced coal mine

legislations

• More than 10 times faster advance rate

compared to a roadheader in the same

ground conditions

• Improved health conditions for workers

(no exposure to unsupported rock or

gas/fumes at any stage of the tunnel

construction)

• Crossover TBM was highly successful in

mixed ground conditions with methane

gas

• Custom Robbins Quick Removal System

was highly successful

3 New Crossover's in Manufacture

• Dovel Hydroelectric in Albania

• Geredes Rescue machine in Turkey

• Rondout New York City water supply tunnel

Devol – TBM Design

CROSSOVER TBM DESIGN

Devol – TBM Design

CROSSOVER TBM DESIGN

Rondout – TBM Design

CROSSOVER TBM DESIGN

Rondout – TBM Design

CROSSOVER TBM DESIGN

Gerede Cutterhead Assembly

CROSSOVER TBM DESIGN

Gerede – TBM Design CROSSOVER TBM DESIGN

Gerede

Gerede

Key Takeaways

Key Takeaways

• “Crossover” meets a growing demand: more complex projects are

being taken on as the world’s simple tunnels have been completed

already.

• Balanced design between two different modes

– Most efficient performance in variable project conditions

– Design is only as accurate as geological info provided

• Design is informed by over 60 years of TBM experience and

extensive research and development

• Consider total cost of ownership: saves cost of machine

modifications because machine already has necessary features

Questions?

(but no d i f f icu l t ones, p lease)