HERRENKNECHT state of the art tunnel boring machines

HERRENKNECHT State of the Art Tunnel Boring Machines

27th June 2013

W i l m S c h a u b

H E R R E N K N E C H T A S I A H E A D Q U A R T E R S

H E R R E N K N E C H T A S I A H E A D Q U A R T E R S | T R A F F I C T U N N E L L I N G

Wilm Schaub Slide 2 17 June 2013

Population growth

Rapidly advancing urbanization

New high-capacity infrastructures to keep people, goods, and resources on the move

Refurbishment and extension of existing underground infrastructure

Congested arrangement of structure in the urban underground

Building of new and extension of existing high-speed train networks

Hydropower Projects

Fresh Water Supply

Irrigation and Sewage

GLOBAL TRENDS



Longer Drives

Larger Profiles

Capability to handle high pressure

Capability to excavate in heterogeneous ground conditions

Special reference projects

Answer and Questions

AGENDA : TUNNELLING REQUIREMENTS



1985: HERA 5.95m

1996: Sydney 10.70m

1997: Hamburg 14.20m

2011 St. Petersburg

19.25m

2006: Shanghai 15.43m

MIX-Shields

LONGER DRIVES & LARGER PROFILES

DEVELOPMENT OF DIAMETER



S-317/318 CHANGJIANG UNDER RIVER TUNNEL | SHANGHAI | CHINA



Connection between Pudong and Changxing

Geology consisting of Sand & Clay

2 Double-deck road tunnels:

Upper level: 3 lanes

Lower level: service +safety

Segment OD: 15.00 m

Segment ID: 13.70 m

Tunnel length: 7.170 km each

Yangtze River Crossing: Maximum overburden above tunnel axis: 65m

S-317/318 │THE PROJECT DETAILS



MIX-Shield®

Shield = 15.43m

Cutter Head accessible under atmospheric conditions from the arms

Main drive = 7.6m with total power of 15x250kW = 3750kW

Back-Up with installation equipment for road element

Total machine length 130m

S-317/318 │THE MACHINE DETAILS



S-317/318 │CUTTER HEAD DESIGN



S-317/318 BACK-UP SYSTEM FOR ROAD ELEMENT INSTALLATION



CHONGMING UNDER RIVER TUNNEL PROJECT

MIXSHIELD S-317/318

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37 41 45 49 1 5 9 13 17 21 25 29 33 37 41 45 49 1 5 9 13 17 21 25

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weekly advance

2006

S-317 Shanghai

2008

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S-318 Shanghai



May 28, 2008 September 5, 2008

BREAKTHROUGH OF THE WORLD‘S LARGEST TUNNEL BORING

MACHINES.

ABOUT 1 YEAR AHEAD OF TIME.



Tunnel Length = 3.6 km

Ø = 11.61m MIX Shield

Total Thrust Force: 123000 kN

Max. Op. Pressure: 7.5 bar

Smallest accessible chamber cutter head for tool exchange under atmospheric conditions

Main Drive Power: 2750 kW

S-668 NANJING METRO LINE 10 LOT 3

H E R R E N K N E C H T A G | U T I L I T Y T U N N E L L I N G | T R A F F I C T U N N E L L I N G


S-762 ISTANBUL STRAIT CROSSING

Trakya Formation (sandstone/mudstone/dykes)

Transition Zones (rock, soil, gravel, cobbles)

Marine Deposits (sand + clay)



Bore Diameter 13,690 mm

Shield Diameter 13,660 mm

SHIELD CONCEPT.



SHIELD DIAMETER CONCEPT.

Main Dimensions

Bore Diameter 13,690 mm

Front Shield Diameter 13,660 mm

Tailskin Diameter 13,620 mm

Outer Lining Diameter 13,200 mm

Ring building clearance

(Deflector strip) = 2 x 45 mm

New features

Camera units 5 No. (transfer chamber & cutter chamber)



ISTANBUL STRAIT ROAD CROSSING | MIXSHIELD WITH ACCESSIBLE

CUTTING WHEEL.

5 Main arms (atmospheric accessible)

Center (Main atmospheric access)

5 Side arms (Chamber access)



ISTANBUL STRAIT ROAD CROSSING | MIXSHIELD WITH ACCESSIBLE

CUTTING WHEEL.

Cutters 35 No. x 19”

Twin disc Monobloc.

Pressure compensated

Spacing 100 mm

(120 mm center)

Scrapers 32 No. x 250 mm

Atmospheric accessible

Scrapers 90 No. x 220 mm

Buckets 2 x 10 No.

Flushing

outlets 7 No.

Sizers 800 mm

(max. 1,200 mm)



1991: Taipei 6.26m

2000: Madrid 9.33m

2003: Barcelona 12.06m

2010: Sparvo 15.50m

2006: Madrid 15.20m

EPB-Shields

DEVELOPMENT OF DIAMETER



DEVELOPMENT OF TORQUE IN MIXSHIELD AND EPB TUNNELLING

Diameter [m]

Torq

ue [

kN

m]



S-574 GALLERIA SPARVO = 15.615M – HERRENKNECHT EPB SHIELD.



Torque: 94.800kNm

Breakout Torque : 125.000kNm

MAIN DRIVE

Power: 12.000kW

Speed: 2,16 rpm



12 electric motors with 1.000 kW each

50 hydraulic motors with a torque of 2.387 Nm each

50 planetary gearboxes with transmission ratio of 51,42

Creating a max. total cutterhead torque of: 125.268 kNm

CUTTERHEAD DRIVE.



315.000kN @ 400bar

THRUST FORCE



CAPABILITY TO HANDLE HIGH PRESSURE

DEVELOPMENT OF OPERATION PRESSURE



S-502 Lake Mead, Intake No. 3 | Las Vegas | USA

Dual-Mode TBM - Hard

Rock /Mixshield

Diameter: 7,180mm

Tunnel length: 4,800m

Cutterhead power: 2,800kW

Geology: Basalt, sandstone,

amphibolite, conglomerate

S-502 │LAKE MEAD, USA



Sedimentary and volcanic geology

Depth of the tunnel

Potential for high groundwater inflows and high hydrostatic pressures

CHALLENGES IN MECHANIZED TUNNELLING.

GROUNDWATER PRESSURE.



CAPABILITY TO EXCAVATE IN HETEROGENEOUS GROUND CONDITIONS



SINGAPORE – CUSTOMIZED SOLUTIONS FOR CHALLENGING PROJECTS



• The Mixshield is an improvement of the original slurry techniques

• Invented by HERRENKNECHT and WAYSS & FREYTAG in the 1980’s

• Designed for a more accurate face pressure control and thus to minimise the risk of settlements

MIXSHIELD TECHNOLOGY



SLURRY SHIELD - MIXSHIELD

Hydraulic

transport cycle

Bulk head

Air bubble

Bentonite

suspension

Bulk head

Hydraulic

transport cycle

Slurry Shield Mixshield

without air bubble with air bubble

Bentonite

suspension



MIXSHIELD - ACCURATE FACE PRESSURE CONTROL



1. Cutting Wheel

2. Bulkhead

3. Air – Cushion

4. Submerged Wall

5. Slurry Line

6. Stone-crusher

7. Feed Line

8. Erector

MIX – SHIELD

1

2

3

4

5 6

7

8



PRESSURE REGULATION ACCURACY

0

1

2

3

0 10 20 30 40 50

time [sec]

Support Pressure MIX Shield - Double Chamber

Reference Pressure Support Pressure Slurry Shield - Single Chamber



TBM DESIGN



Optimized design in terms of machine length

Customized design for various operation pressures

Thrust Cylinder arrangement solutions for 5+1 and 7+1 segment lining

SHIELD



Dual man lock design 2 x (3+2)

Operating pressure: 7 bar

Complies to CENEN12110 regulations

Fully equipped for compressed air works

Manufactured and tested in Germany

Oxygen Decompression System

SHIELD – MAN LOCK



Independent Lock for transfer of cutting tools from and to the excavation chamber

No obstruction in air lock

Safe for workers

SHIELD – MATERIAL LOCK



SHIELD – SLURRY CIRCUIT

Injection Lines for bentonite on various positions of pressure wall and submerged wall

Discharge line in shield invert

Heavy duty hydraulic driven ball valves for operation from the control cabin

Chamber flushing

Clogging prevention

Crusher flushing

Pipe bends made of extra wear resistant material



If the geology bears an increased risk of clogging, the submerged wall gate opening could cake up gradually and eventually be completely closed. This could lead to a pressure rise in the excavation chamber.

With a communicating pipe, the bentonite which is pumped into the excavation chamber can flow via the communicating tube and thus prevent a sudden pressure rise in the excavation chamber.

SHIELD – SLURRY CIRCUIT – COMMUNICATING PIPE

[1] Excavation chamber [2] Working chamber [3] Communicating tube [4] Feed line [5] Slurry line [6] Clogged submerged wall door



= 700mm crushing size

Wiping mode for clogging prevention in softground

Optimized hydraulic connection lines

Independent hydraulic power pack

Grid in front of discharge line to prevent large obstacles from entering the slurry circuit.

STONE CRUSHER



2 x high performance rock drills mounted on 360° drill rig

Inclined probe holes through TBM shield

Horizontal probe holes through TBM shield and cutting wheel

1 x adjustable center probe drill hole

PROBE DRILLING



PROBE DRILLING – DRILLING PATTERN

Inclined probe drill lines



Horizontal probe drill lines


Center inclined probe drill lines



Combined drilling pattern




Blow out preventer Equipped with rotating seal, pressure relieve valve, mechanical clamping and manual ball valve

PROBE DRILLING – BLOW OUT PREVENTER



Heavy Duty Robust Structure

Adaptation of proven solutions

Implementation of experience gained from former Herrenknecht projects with MIX-Shields in Rock and Mixed Face conditions.

FE Analysis to meet the requirements of the project

CUTTING WHEEL - STRUCTURE



19” center disc cutter

19” face and gauge disc cutter

Scrapers

Bucket lips



CUTTING WHEEL – SHIFTING OF GAUGE DISCS

Shifting of Gauge

Discs by C-Piece with

full load capacity for

overcut in curve



Durable heavy duty mounting system for rock application

Load transfer through the housing into the steel structure of the cutting wheel

Wedge to fix the cutter axis

CUTTING WHEEL – WEDGE LOCK MOUNTING



CUTTING WHEEL – PRESSURE COMPENSATING DISCS- FOR HIGH

OPERATION PRESSURE

For a standard disc cutter, there is no pressure compensation. Under high pressure (>3.5bar), the external pressure is higher than the internal pressure.

For non P.C unit, high pressure (>3.5bar) can result in slurry and muck pressing against seal sets and contaminating inside of disc cutters

Damage of the seal sets reduces the lifetime of the cutter and higher cost of refurbishment of cutters



Herrenknecht pressure compensating discs use a bladder design that is installed into the shaft. The balance of the pressure is through the compensating bore in the shaft

P.C unit is balancing the pressure difference at the seal sets

The bladder is easy to change and maintain

P.C cutters ensure a higher lifetime, reduce risk of bearing failure and reduce refurbishment cost of cutters

Project references:

S502 Lake Mead

S536 Hong Kong Lai Chi Kok

S548/549 Singapore DTL2

S602/603/604/605/617 Singapore DTL2

CUTTING WHEEL – PRESSURE COMPENSATING DISCS- FOR HIGH

OPERATION PRESSURE





Hydraulic Wear detectors for Disc Cutter

Hydraulic Wear detector for Steel Structure

Circumferential GRILL BARS Hardox 400 – HRC 40

Circumferential welded Hardfacing on shield edge. HRC 56

VAUTID Plates on front surface HRC 60

CUTTING WHEEL – WEAR DETECTION&PROTECTION

GRILL BARS Hardox 400 HRC 40

HARDFACING On shield edge HRC 56

VAUTID PLATES 100 x 100 mm HRC 60

Wear detector For cutting wheel structure

Wear detector For disc cutter



Down to the present day, this is the only TBM‘s of this kind. Especially it is developed to handle the karstic geology of Kuala Lumpur.

Convertible between 4 different advance mode

LATEST DEVELOPMENT: VARIABLE DENSITY TBM



EPB – Mode

Support medium pasty earth cake

EPB – Mode with bentonite support

Support medium pasty – liquid earthcake

2

Mixshield – Mode

Thin suspension (bentonite suspension)

1 4

HDSM – Mode

Thick suspension (bentonite suspension with

filter)

3

WORKING MODES WITH THE DIFFERENT SUPPORT MEDIA.



VARIABLE DENSITY SYSTEM.

Excavation & Working chamber

Air bubble

Screw conveyor

Flushing box

with the crusher

High density

slurry

Slurry pump

Feed line

Slurry circuit

Slurry line



Apart from tunnel face support, material transport can also be changed in line with the respective geology. The system can switch from hydraulic transportation via pipeline to solid transportation via belt conveyor or muck car haulage.

MUCK TRANSPORTATION



SPECIAL REFERENCE PROJECTS



Convertible EPB / Single Shield

Shield = 10.02 m

Operating Pressure 3.0bar

Tunnel Length 2 x 3860m

Convertible Cutter Head

Simultaneous installation of screw conveyor and conveyor belt in shield for quick conversion

S-670 │CONVERTIBLE EPB / SINGLE SHIELD



S-670 │CONVERTIBLE EPB / SINGLE SHIELD



S-575 | Linth Limmern | Switzerland

Gripper-TBM

Diameter: 5,200mm

Tunnel length: 2 x 1,000m

Cutterhead power: 2,205kW

Geology: limestone

Incline: 85% 40°

Customer: Marti Tunnelbau

40° INCLINE TUNNEL FOR HYDROELECTRIC POWER.



PUMPED STORAGE HEPP LIMMERN / SWITZERLAND.

TRANSPORT TO THE JOBSITE BY CABLE-CAR.





Machine type: Gripper TBM

Diameter: 5,200mm

Tunnelling length: 1,045m

Gradient: 40.3°

Commissioning: 24.06.2010

Breakthrough: 14.10.2011

Best daily performance: 28.8m

Best weekly performance: 132.6m

PUMPED STORAGE HEPP LIMMERN / SWITZERLAND.

BREAKTHROUGH FIRST TUNNEL ON OCTOBER 14, 2011.



Mechanized enlargement of existing railway tunnels

Maintains route availability with relatively little reconstruction work

RAILWAY TUNNEL ENLARGEMENT – RESEARCH AND DEVELOPMENT


Wilm Schaub Slide 66 17 June 2013 Page 66

Tunnelling projects all over the world are demanding TBM technology with permanently higher requirements on the TBM design especially in regards of:

settlement control

operation effeciency

labour safety

operating loads (water pressure, overburden)

adaptability to multiple kinds of geology (Multi Purpose TBM)

cost efficiency

SUMMARY- PERSPECTIVES


Wilm Schaub Slide 67 17 June 2013 Page 67

As a supplier of Tunnel Boring Machines, Herrenknecht is continuously striving to optimize and extend the TBM product portfolio .

A few exemplary development steps are:

Cutting Wheel geometry closely adapted to project geology (Custom made)

More wear resistant cutting tools and wear parts

Spherical- and displacable main drives

Accessable Cutting Wheels (smallest Diameter= 11,62m, S-668 Nanjing), extended application range

Improved tailskin sealing systems

Double Screw Conveyor (mainly Chinese market)

More accurate Muck control systems

Geology exploration systems

Data monitoring/ recording systems

SUMMARY- PERSPECTIVES

THINK POSITIV.

TOGETHER WE BUILD THE FUTURE.

Thanks for your attention. THANKS FOR YOUR ATTENTION!

Wilm Schaub Herrenknecht Asia Pte. Ltd. +65 92995899 [email protected]

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HERRENKNECHT state of the art tunnel boring machines