ISTANBUL STRAIT ROAD TUNNEL ... Herrenknecht. Pioneering Underground Technologies Istanbul Strait Road

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  • ISTANBUL STRAIT ROAD TUNNEL CROSSING

    Werner Burger, Herrenknecht AG, Schwanau.

    AFTES Journées Techniques, Lyon, October 16, 2015

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Road Tunnel

    Project Location

  • Herrenknecht. Pioneering Underground Technologies

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    Istanbul Strait Road Tunnel

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Road Tunnel

    Tunnel Design

     Single Tube, twin deck double track for light vehicles only

     Inner diameter 12 m, Segment thickness 0,6 m

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Road Tunnel

    Project Key Requirements

     Restricted access from above  most of the tunnel alignment below the

    Bosporus Strait

     Very large TBM diameter  13,71 m

     Variable, mixed ground conditions  full face rock – marine deposits, boulders

    – transition zones

     Very high face pressure  >10 bar

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Road Tunnel

    Project Requirements – Past Experience (State of Art)

     4. Tune Elbetunnel  very large diameter14,2 m; mixed

    ground conditions; face pressure 5,5bar

     Westerschelde  large diameter 11,4 m; long distance

    tunnel; face pressure 7,5bar; saturation diving

     Chongming  very large diameter 15,4 m; long distance

    tunnel; face pressure 7bar

     Lake Mead  full face rock, soft ground; very high face

    pressure 14 bar

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Road Tunnel

    Selected TBM Concept

     Mixschild, for variable ground

    conditions with very high face pressure

     Accessible cutterhead for atmospheric

    maintenance on primary cutter sets

     Full equipment for „conventional“

    chamber access up to 4 – 5 bar

     Full equipment and preparation for

    saturation diving at higher face

    pressures (shuttle transfer)

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Road Tunnel - TBM Design Target

    Minimization of The Necessity of Chamber Interventions

    Integration of all features of the Herrenknecht „Non – Exposure – Maintenance“

    development program

    Monitoring / Sensor Systems

     Fully articulated cutterhead for real time load measurement and control of cutting

    unit

     Electronic disc cutter monitoring system for real time monitoring of individual disc

    cutter condition

     Mechanic wear monitoring system for each disc cutter

     Multiple level mechanic wear monitoring system for cutterhead structure

     Pre-determined locations an process for remote ultrasonic checks of structural

    cutterhead plates

     Permanent installed excavation chamber camera system

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Road Tunnel - TBM Design Target

    Minimization of The Necessity of Chamber Interventions

    Integration of all features of the Herrenknecht „Non – Exposure – Maintenance“

    development program

     Maintenance

     Submerged wall gate for atmospheric crusher maintenance

     Accessible cutterhead for atmospheric cutter change for a full face disc cutter

    and soft ground tool coverage ( primary cutter sets)

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Crossing TBM

    Cutterhead Features

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    main spoke, atmospheric accessible

    auxiliary spoke, conventional

    19” twin disc cutter, atmospheric exchange

    with monitoring system

    scraper tools, atmospheric exchange

    scraper tools, conventional

    bucket lips, conventional

    multi level sectorized wear detection loops

  • Herrenknecht. Pioneering Underground Technologies

    Access down into cutting

    arm spoke.

    Operator undertakes

    maintenance in free air

    without the risk of having

    to work at the tunnel

    face.

    Back loading

    cutting tools.

    Non - Exposure Maintenance Solutions

    Accessible Cutterhead for “Atmospheric Cutterchange”

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  • Herrenknecht. Pioneering Underground Technologies

    Non - Exposure Maintenance Solutions “Atmospheric Cutter Change”

    System for large diameter Mixshields with

    accessible cutter head structure

     First use in 1996 (Elbetunnel)

     Full face disc cutters 17” or 19”

     Full face for disc cutters and soft ground tools

     Individual tool condition and wear sensors

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    Cutterhead Elbetunnel, now in front of the

    Museum of Work in Hamburg

  • Herrenknecht. Pioneering Underground Technologies

    19“ Disc cutter fixture for atmospheric

    cutter change

    Scraper tool fixture for atmospheric

    cutter change

    Cutter head spoke structure, accessible from

    inside

    Non - Exposure Maintenance Solutions

    Accessible Cutterhead for Eurasia Tunnel TBM Istanbul, Turkey

    13

  • Herrenknecht. Pioneering Underground Technologies

    Transport of disc cutter

    cartridge inside

    cutterhead

    Installing cutter cartridge

    in outer housing

    Opening of frontgate and

    push cutter cartridge in

    working position

    Atmospheric Cutter Change

    Shop Test and Training in the Factory

  • Herrenknecht. Pioneering Underground Technologies

    Non - Exposure Maintenance Solutions

    On-Site Cutter Change Eurasia Tunnel TBM Istanbul, Turkey

    15

  • Herrenknecht. Pioneering Underground Technologies

    Disc Cutter Monitoring System

    Mixshield-TBM with Accessible Cutterhead

    IPC

    Monitoring-unit

    Control cabin

    Data line Receiver

    Sensor-unit

    Radio

    signals

     Individual monitoring-unit for each disc cutter

     Radio transmission to repeater / receiver

     Data transfer from receiver to IPC

     Data analysis + status display (control cabin)

    Battery

    CS

  • Herrenknecht. Pioneering Underground Technologies

    Status indication of disc cutter

    with temporary no rotation

    Status indication of

    critical values

    Disc Cutter Monitoring System

    Data processing and visualization

  • Herrenknecht. Pioneering Underground Technologies

    Shuttle transport through

    tunnel on MSV

    Hydraulic lift to

    upper gantry deck

    Motorized shuttle

    transport through gantry

    Front lifting table to

    docking position for

    transport shuttle

    Permanent airlock Transport shuttle

    in docking position

    Saturation Process

    Crew Shuttle Transfer Through Trailing Gear At The Eurasia Tunnel TBM,

    Istanbul

    18

  • Herrenknecht. Pioneering Underground Technologies

    Hydraulic lifting system

    from MSV to gantry

    middle deck

    Motorized transfer

    through gantry

    Hydraulic lifting system to

    docking flange at shield

    airlock

    Saturation Process

    Crew Shuttle Transfer Through Trailing Gear At The Eurasia Tunnel TBM,

    Istanbul

  • Herrenknecht. Pioneering Underground Technologies

    “Non – Exposure – Maintenance” Solutions

    Mixshield Submerged Wall Gate for Crusher Maintenance

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    Submerged wall gate open Submerged wall gate closed

  • Herrenknecht. Pioneering Underground Technologies

    21

    Istanbul Strait Road Tunnel

    Crusher Maintenance

    Diver at 9 bar pressure cleaning invert in

    preparation for gate closure

    Work on crusher and suction grid under

    free air conditions

  • Herrenknecht. Pioneering Underground Technologies

    Istanbul Strait Crossing TBM

    Face Pressure Along The Drive

    22

    25.4.2014 22.8.2015

  • Herrenknecht. Pioneering Underground Technologies

    THANK YOU FOR YOUR ATTENTION.

    burger.werner@herrenknecht.de

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