TBM Specifications

24 November 2013

Mr. Alexandre Jonard

Package Manager, Riyadh Metro Transit Consultants (RMTC)

Smart Building, 2nd

Floor

Suliman Al Hamdan Street, Olaya District

P.O. Box 1174

Riyadh, 11431 Kingdom of Saudi Arabia

Subject: Riyadh Metro Project, Package 1

Tunnel Boring Machines (TBM) Specification and

References: N/A

Dear Mr. Jonard,

We have initiated the procurement process of four TBMs in parallel to finalizing decision on the

tunneling execution strategy. We enclose for your information the TBM technical specification

(as Attachment 1) and the TBM recommended

We will keep RMTC informed as we progress the tendering cycle.

Respectfully,

Dr. Amjad Bangash

Authorized BACS Consortium Representative

Reply Requested: No

Attachments: 1) TBM technical specification (

2) TBM recommended bidders’ list for TBMs (1 page)

Our Ref: BACS-Letter

, Riyadh Metro Transit Consultants (RMTC)

Olaya District

Kingdom of Saudi Arabia

Riyadh Metro Project, Package 1

Tunnel Boring Machines (TBM) Specification and Recommended Bidders’ List

the procurement process of four TBMs in parallel to finalizing decision on the


recommended bidders’ list (as Attachment 2).

TC informed as we progress the tendering cycle.

Authorized BACS Consortium Representative

TBM technical specification (44 pages)

ecommended bidders’ list for TBMs (1 page)

Receipt Acknowledged: ______________________

Letter-000017

Bidders’ List

the procurement process of four TBMs in parallel to finalizing decision on the


Receipt Acknowledged: ______________________

____________________________________________________________________________________________ Rev 0 dtd 12Nov13 Purchase Order No.: 0304-CWJV-000-ETM-VR-00001

RIYADH METRO PROJECT – PACKAGE 1

LINE 1 / BLUE LINE (OLAYA-KING FAISAL-BATHA CORRIDOR)

LINE 2 / GREEN LINE (KING ABDULLAH ROAD)

PURCHASE ORDER NO. 0304-CWJV-000-ETM-VR-00001 Rev.: 0

Dated: 12 November 2013

TUNNEL BORING MACHINES TECHNICAL SPECIFICATION

RIYADH METRO PROJECT


Purchase Order Number: 0304-CWJV-000-ETM-VR-00001 Rev.: 0

Rev 0 dtd 12Nov13 Page 1/43

1 INTRODUCTION ............................................................................................................ 4

1.1 General ................................................................................................................... 4

1.2 Scope of Supply ...................................................................................................... 5

2 DESIGN, MANUFACTURE AND SITE SUPPORT ......................................................... 5

2.1 Design and Manufacture ......................................................................................... 5

2.2 Health and Safety .................................................................................................... 6

2.3 Energy Efficiency .................................................................................................... 6

2.4 Site Support ............................................................................................................ 7

3 TBM DESIGN PARAMETERS ........................................................................................ 7

3.1 General Description ................................................................................................. 7

3.2 Ground Settlement .................................................................................................. 8

3.3 Materials Supply and Spoil Removal ....................................................................... 8

3.4 Design Methods and Checking ................................................................................ 8

3.5 The TBM Shield ...................................................................................................... 9

3.6 The TBM Cutter Head ............................................................................................. 9

3.7 TBM Launching ....................................................................................................... 9

3.8 Passage through Intermediate Stations ................................................................. 10

3.9 TBM Removal ....................................................................................................... 10

4 SPECIFICATION OF THE TBMs .................................................................................. 10

4.1 General Requirements .......................................................................................... 10

4.2 Shield Configuration .............................................................................................. 10

4.2.1 Front Shield .................................................................................................... 11

4.2.2 Main Shield .................................................................................................... 11

4.2.3 Tail Shield ...................................................................................................... 12

4.3 Cutterhead Main Bearing and Sealing System ...................................................... 13

4.3.1 Cutterhead ..................................................................................................... 13

4.3.2 Main Bearing .................................................................................................. 14

4.3.3 Drive Train ..................................................................................................... 14

4.3.4 Main Bearing Sealing System ........................................................................ 15

4.4 Removal of Excavated Material ............................................................................. 15

4.4.1 Face Conveyor ............................................................................................... 15

4.4.2 TBM Transfer Belt Conveyor .......................................................................... 15

4.5 Segment Erector ................................................................................................... 16

4.6 Erector Bridge ....................................................................................................... 18

4.7 Segment Magazine ............................................................................................... 18

4.8 TBM Operation ...................................................................................................... 19

4.8.1 TBM (sub-surface) Control Cabin ................................................................... 19





4.8.2 TBM (Surface) Control Room ......................................................................... 19

4.8.3 Conveyor operation ........................................................................................ 19

4.9 Belt weighing, conveyor and weigher parameters. ................................................ 19

4.9.1 Requirements for accurate and repeatable belt weighing. .............................. 19

4.9.2 Conveyor Structure ........................................................................................ 20

4.9.3 Conveyor Belt................................................................................................. 20

4.9.4 Idlers .............................................................................................................. 21

4.9.5 Weigh Quality Idler Roll Specification ............................................................. 21

4.9.6 Weigh Quality Idler Frame Specification ......................................................... 21

4.9.7 Belt Tension control – Gravity Take-Up Unit. .................................................. 21

4.9.8 Weight processing electronics ........................................................................ 22

4.9.9 Tachometers / Odometers .............................................................................. 22

4.9.10 Belt and Drum Cleanliness ............................................................................. 22

4.9.11 Other Considerations ..................................................................................... 22

4.9.12 Material Testing .............................................................................................. 22

5 CONTROL AND MONITORING ................................................................................... 22

5.1 Cutter Head ........................................................................................................... 25

5.2 Front Shield ........................................................................................................... 25

5.3 Main Shield ........................................................................................................... 25

5.4 Rear Shield ........................................................................................................... 25

5.5 Belt Conveyors ...................................................................................................... 25

5.6 Segment Erector ................................................................................................... 25

5.7 Erector Bridge ....................................................................................................... 26

5.8 Guidance and Control System ............................................................................... 26

5.9 Environmental Conditions. ..................................................................................... 27

5.10 Intrusive ground investigation ................................................................................ 28

5.11 Grouting Check ..................................................................................................... 28

5.12 Format of data ....................................................................................................... 28

5.13 Frequency ............................................................................................................. 28

6 BACK UP SYSTEM ...................................................................................................... 28

7 GROUTING SYSTEM. ................................................................................................. 30

7.1 Principal Equipment. ............................................................................................. 30

7.2 Grouting Process. ................................................................................................. 31

8 ELECTRICAL SPECIFICATION ................................................................................... 31

8.1 Standards .............................................................................................................. 31

8.2 Electrical System ................................................................................................... 31

8.3 Electrical Equipment .............................................................................................. 33

8.4 Control System ...................................................................................................... 34





8.5 Cabling .................................................................................................................. 35

8.6 Motors ................................................................................................................... 35

8.7 Emissions .............................................................................................................. 35

9 HYDRAULIC SPECIFICATION .................................................................................... 35

9.1 Main Hydraulic Drive Systems. .............................................................................. 35

9.2 Hydraulic Oil .......................................................................................................... 36

9.3 Particular Requirements ........................................................................................ 36

9.4 Articulation ............................................................................................................ 36

9.5 Shove Rams.......................................................................................................... 36

10 SAFETY.................................................................................................................... 37

10.1 Regulations ........................................................................................................... 37

10.2 Fire prevention ...................................................................................................... 39

10.3 BUYER Control and Interlocks .............................................................................. 40

10.3.1 TBM ............................................................................................................... 40

10.3.2 Shove Rams and Erector. .............................................................................. 40

10.3.3 Interlocks ........................................................................................................ 41

11 QUALITY ASSURANCE REQUIREMENTS .............................................................. 41

12 PERFORMANCE REQUIREMENTS ........................................................................ 42

12.1 Boring Rates of Advance ....................................................................................... 42

12.2 Shove Ram Retraction .......................................................................................... 42

12.3 Tunnel Lining Supply and Erection ........................................................................ 42

12.4 Rates of Advance - Performance - Monitoring ....................................................... 42

12.5 Machine Availability ............................................................................................... 43

13 OPTIONAL SUPPORT EQUIPMENT ....................................................................... 43





1 INTRODUCTION

1.1 General

This document sets out the Minimum Requirements for the supply of four (4) Tunnel Boring Machines (TBMs) with the characteristics as set out in this document. The base-case machine type for the purposes of this specification is a single-shield, rock TBM, with the ability to seal the face via guillotines/doors on the face conveyor port/access hatches. The doors and bulkhead/shield shall be designed to resist the anticipated ground and groundwater loads. Ports through the bulkhead/shield/cutterhead will be fitted with glands and shut-off valves to allow for probing/ground treatment to be performed whilst maintaining a seal against water ingress..

The general geological conditions and geotechnical data are provided for information in Appendix A. The conceptual arrangement for the segmental lining to be installed at the rear of the shield is illustrated on drawings included in Appendix B. The current alignment drawings are included in Appendix C. Finally, the current concept re driving strategy, along with tender-phase concepts for site layouts at TBM launch locations are included in Appendix D.

The TBM SELLER should note that:

• Additional ground investigations are currently being procured by BUYER. These will be made available, along with BUYER sponsored geotechnical reports, when completed.

• The segmental lining geometry and related details provided by BUYER are subject to design refinement.

• The driving strategy and site layouts are subject to refinement/in development.

o The SELLER should provide requirements, in terms of minimum areas and arrangements, for the delivery, assembly, disassembly and removal of TBMs from the site.

In addition to the required base proposal, the SELLER is encouraged to recommend alternatively suitable TBMs to achieve corresponding tunnelling scope, performance and schedule. The SELLER should note that deeper soil is currently inferred in the area south of Station 1E2, and that this material, should the current vertical alignment remain unchanged, may be encountered in the tunnel crown. To cover for this eventuality the SELLER is encouraged to consider whether dual mode earth-pressure balance/rock TBM of the type described in RMP WP3.2.2.1-P1L0-Design_MetTunnel_V2 (copy included in Appendix A; i.e. with two base configurations – i) screw conveyor for EPB-mode or open mode; or ii) face-conveyor for open-mode); or a more conventional dual-mode earth pressure balance machine (with screw conveyor only), would be a viable option for cost-effective means of achieving the desired rates of advance.

The TBM SELLER is expected to engage with BUYER’s engineering representative in an open, constructive manner aimed at refining the TBM design to accommodate Riyadh Metro machine requirements; and to enable the TBMs to address the anticipated ground conditions.

These Tunnel Boring Machines shall be supplied new; or refurbished like new such that all major components carry the same warranty as for new equipment by the original supplier. TBMs shall be state-of-the-art. SELLER shall supply the TBMs in accordance with all applicable and relevant British and European Regulations and Standards. The TBMs shall be suitable for the ground conditions to be encountered





and shall incorporate provisions for necessary spoil conditioning; and for probing and ground treatment ahead of the face.

The TBMs shall, as a minimum, meet the requirements set out in this document. Where considered necessary, the TBM SELLER shall incorporate elements with capacities/capabilities superior to the minimum requirements listed in this document in order to achieve the required TBM performance.

This document is arranged such that requirements for machine design, construction, operation and performance are outlined element-by-element. The SELLER shall adhere to particular requirements specific to the base-case machine-type as appropriate. Where an alternative machine type is being proposed, the SELLER is invited to propose appropriate details to meet or exceed the high-level performance requirements set out in this document for the base case machine type.

1.2 Scope of Supply

Supply of the tunnel boring machines shall include the following elements:

a) Design of the tunnel boring machine (TBM) and backup equipment; and on-going input during design and manufacture.

b) Manufacturing and supply of the machines and their back-up equipment. c) Performance of required tests to confirm design assumptions. d) Performance of assembly and preliminary tests in the factory, including the grout

and ground conditioning system. e) Factory testing of TBM equipment. SELLER shall allow for attendance of the

BUYER’s and ENGINEER’s personnel during all Factory Testing as required by BUYER. Factory Testing to be scheduled with a 30 day advance notice to BUYER allowing for BUYER to notify the ENGINEER in due time.

f) Operation and maintenance manuals in English, provided electronically together with 4 paper copies.

g) Provision of technical assistance during TBMs assembly at the job site. h) Commissioning and tests as required at the job site. i) Provision of technical assistance by SELLER during the tunnel start-up until the

specified performance is achieved. j) Provision of technical assistance as necessary after start up to assist the BUYER in

achieving the required performance throughout the tunnelling operations. SELLER shall provide necessary details in the proposal of its means of meeting this requirement.

k) Training of the BUYER’s operation and maintenance personnel. l) The supply and management of spare, consumable and wear parts. m) Provision of technical assistance during the dismantling operations.

2 DESIGN, MANUFACTURE AND SITE SUPPORT

2.1 Design and Manufacture

The SELLER shall provide the following:

a) The designs, calculations, drawings and specifications of the TBMs and Back-up System, and the related method statements, to demonstrate compliance to this Minimum Requirements document. The TBM SELLER shall submit to the BUYER for approval a schedule of design submissions, which shall include all information necessary to demonstrate compliance with this Minimum Requirements document.





b) A detailed programme for the design and manufacture of the TBM’s. The programme shall highlight dates at which critical decisions regarding the finalization of the TBM design are required. The TBM SELLER shall attend regular meetings with the BUYER to monitor the design and manufacture of the TBM to the Purchase Order Scope and Schedule.

2.2 Health and Safety

The SELLER shall design and manufacture the TBMs in such a way to minimise the risks to the health, safety and welfare of personnel who manufacture, install and commission, operate, maintain and decommission them, in accordance with the Construction (Design and Management) Regulations 2007 and all other applicable legislation relating to health and safety.

A hazard and risk assessment shall be developed as part of the design and submitted to the BUYER addressing all risks related to the TBMs. As a minimum, the following elements of the TBMs shall be addressed:

a) The TBM electrical system (e.g. electrical shock and fire, electrical equipment fault and damage, loss of power supplies, fire suppression systems etc.).

b) The TBM Back-up system (e.g. leakage of high pressure fluids, close locations to heat and electrical sources, occurrence of naked flame, danger from moving machinery etc.)

c) The entry and exit points from the TBM and the Back-up system (e.g. means of escape during an emergency, including clear access for a stretcher from the air lock to the pit-bottom).

d) Segment transport and erection (e.g. moving of tunnel lining segments through TBM back-up onto segment erector, moving of tunnel lining segment on the segment erector, dangers to personnel arising from the segment erector, access for bolting segments). Particular attention shall be paid to the tunnel ring assembly area to ensure clear line of site for erector operations and foot trapping where tunnel segments are being assembled.

e) Start and operation of cutter head. f) Operation and maintenance of the TBM including surveying (e.g. provision of safe

working platforms). g) Man entry into the mixing chamber and safe working methods for maintenance of

the cutter head. h) The grouting system. i) TBM Assembly, Repair, Servicing & Dismantling. Lifting systems including all

necessary anchor points shall be provided for all equipment that may need replacement during the tunnel drives which cannot be safely manually handled.

j) The operation of the TBM in normal, degraded, accident and emergency modes. The design and operation of the TBM shall comply with BS6164.

k) Installation and maintenance of the spoil removal system and tunnel services for logistical support of the TBM. It should be noted that a decision regarding the form of the spoil removal system behind the TBM has not as yet been made.

l) Gas detection system and alarms. The SELLER should note that a number of potential sources of hydrocarbons are apparent along the rail corridor.

2.3 Energy Efficiency

The TBM SELLER shall endeavour to minimise the energy usage of the TBM during operation. The SELLER shall provide evidence to the BUYER that reasonable





measures to minimise energy consumption during tunnel operations have been incorporated into the TBM design.

2.4 Site Support

The TBM SELLER shall provide:

a) Essential support to the BUYER during erection and commissioning of the TBMs and during the start-up of the tunnel drives until the specified performance is achieved.

b) Checking and calibrating of measuring instruments that are directly related to tunnelling

c) A training programme for the BUYER’s TBM operation and maintenance staff including TBM driving, hydraulic and electrical maintenance and specialist training for the TBM computer systems to include operation of the TBM in normal, degraded, accident and emergency modes.

d) Spares in accordance with a list of recommended consignment spares that the BUYER retains on Site. The list shall be derived from a risk assessment undertaken jointly by the TBM SELLER and the BUYER based on their direct experience of using similar machines in similar ground conditions. The risk assessment shall identify which parts are likely to wear out, anticipated life-span of the parts, their ease of replacement and level of appropriate spares required on Site. The SELLER shall maintain the spares on site in support of the TBM operations at the agreed per cent (%) availability.

e) As built drawings of the TBM, technical documentation and details of planned maintenance requirements prior to commencing TBM’s operations including updated operational and maintenance manuals.

f) Support to the BUYER during TBM decommissioning and removal g) SELLER job site requirements for receiving, assembly, testing and commission of

the TBMs. SELLER shall include in sufficient details its required supporting equipment, utilities, personnel and provide site dimensions and other specification for its site requirements.

3 TBM DESIGN PARAMETERS

3.1 General Description

The specific details of the tunnels are (all details subject to refinement during detailed design):

a) Minimum radius of alignment: 300m horizontal; 1000m vertical. b) Minimum correction radius for steering purposes: 200m. c) Maximum vertical gradient: +/-1:27. d) Lining type: precast concrete e) Lining internal diameter: 9.20 m. f) Lining thickness: See drawings included in Appendix B. g) Segment Width: See drawings included in Appendix B. h) Segments: See drawings included in Appendix B.. i) Lining Type: Steel and polypropylene fibre reinforced concrete segments. j) Lining Gaskets EPDM with combined Hydrophilic gaskets complying with BS

2494 Type D, IRHD between 60 and 75. k) Cross Joint Fastening: Spear bolts. l) Circle Joint Fastening: Self Gripping Dowels.





3.2 Ground Settlement

The Project is located in an urban area. The operation and control features of the TBM shall be designed to minimise sub-surface and ground level settlement. Ground loss arising from the TBM boring and tunnel construction operations shall be limited to a maximum of 1% of the excavated volume.

The operating principles shall incorporate the following non-exhaustive methods:

a) Belt weighers that shall automatically measure and log the excavated muck per unit of advance and compare it with the actual advance to prevent operator error leading to over excavation and settlement.

b) A method of automatically measuring and logging the pressure and volume of grout continuously injected per tunnel ring of advance.

c) A method of measuring any voids exceeding 100mm maximum dimension in the grout beyond the tail skin, at or near tunnel crown real time by non-intrusive means (radar or similar device).

d) A method of injecting, measuring and logging the volume and pressure of support fluid in the annulus between the shield body and cut bore, to mitigate the risk of settlement.

Ground surface will be instrumented above the tunnel drives to ensure that sufficient ground control is achieved in accordance with the Works Information and this Minimum Requirements document.

Settlement-related driving parameters shall be continuously logged and provided in real-time to the TBM operator in a form that can be rapidly interpreted to allow optimum control of ground movements.

3.3 Materials Supply and Spoil Removal

The SELLER shall provide a TBM transfer belt conveyor through the TBM back-up complete with two belt weighers (to measure the weight of excavated material per unit of advance and volume per unit of advance).

This transfer belt conveyor shall be specifically designed to incorporate the belt-weighing functions, mounted on the full length of the backup and discharge onto the main tunnel conveyor belt or other system to be developed for transporting material from the tunnel to the portal.

For the belt weigh stations at least three (3) sets of independent material test results which confirm working to the specified measurement level at other similarly or higher rated applications shall be submitted to the BUYER prior to placing the order for the TBM.

3.4 Design Methods and Checking

The TBM structure shall be designed in accordance with the non-exhaustive requirements described below.

• The design of the structures of the shield body and other important members including back-up shall be supported by Finite Element Method calculations. The SELLER shall submit these calculations to the BUYER.





• The calculations shall be undertaken by suitably competent personnel with previous experience of designing TBMs.

• The CVs of these competent individuals shall be submitted to the BUYER for approval prior to the commencement of the design calculations.

• The calculations shall include a Design Statement agreed before calculations are commenced, including assumptions and loading conditions.

• The input and output of the calculations shall be presented together with graphical output fully annotated.

• An independent design check shall be carried out on critical elements by a competent Engineer independent of the TBM SELLER, and subject to the approval of the BUYER.

3.5 The TBM Shield

The shield shall be designed to withstand all loads and forces imposed by the overburden and all loads and forces arising from operating the TBM, both in normal, degraded, accidental and emergency modes.

Particular consideration shall be given to the loads and forces arising from operations to correct misalignment.

The deformation of the shield under all loading conditions shall be limited to allow the lining to be built to the correct geometry.

The shield shall be designed to withstand all overburden loads during dismantling; where propping may be required this shall be designed as part of the dismantling procedure and supplied with the TBM.

3.6 The TBM Cutter Head

The cutter head structure and bearing with its support system shall be rated to absorb the maximum forces envisaged in operation. These forces shall be included within the finite element analysis of the shield body structures. This shall include normal operation and ultimate load condition where the full power may need to be used in the event the TBM becomes stuck, resulting in maximum shove loading and maximum torque.

3.7 TBM Launching

The TBMs shall be designed to suit the constraints of the launch site. TBM launching locations are as follows:

• Drive A: Purple TBM tunnelling section

• Drive B: Blue TBM tunnelling section

• Drive C: Orange TBM tunnelling section

• Drive D: Brown TBM tunnelling section

The size of the launch shafts shall be taken into consideration in the design of the TBM and the assembly method. The concepts for launch site layouts are shown on the drawings included in Appendix C. The SELLER should provide requirements, in terms of minimum areas and arrangements, for the delivery, assembly, disassembly and removal of TBMs from the site.





3.8 Passage through Intermediate Stations

Structures for a number of intermediate stations will be completed prior to the TBM delivery and receipt on-site. These will include GRP reinforced wall structures, and sprayed concrete lining tunnels.

The TBM design and supply shall enable break in to / break out of these structures where they include GRP reinforcement. Any steel reinforcement will be broken out prior to TBM delivery and receipt on-site.

The TBM design shall enable the TBM to be moved through the station structures from the break in (reception) location to the break out (re-launch) location.

The TBM SELLER shall offer equipment for the support of the TBM and its back up systems for rapid transportation through the intermediate stations and for the subsequent launching of the TBM’s to continue the tunnel drivers.

3.9 TBM Removal

The TBMs shall be designed for dismantling at the end of their tunnel drives

The TBM will be received into a shaft, station structure or reception chamber and subsequently removed by cranage through construction shafts. The TBM may need to be transited to the shaft location.

4 SPECIFICATION OF THE TBMs

4.1 General Requirements

The TBMs shall be single-shield, rock TBMs. The machines shall be a conventional machine configured for cutting rock, with material removed from the front of the machine via rock buckets and a conveyor. The machine will have the facility to act as a pressure vessel, with the ability to seal the face via guillotines/doors on the face conveyor port/access hatches. The doors and bulkhead/shield shall be designed to resist the anticipated ground and groundwater loads. Ports through the bulkhead/shield/cutterhead will be fitted with glands and shut-off valves to allow for probing/ground treatment to be performed whilst maintaining a seal against water ingress Shield components shall be designed to facilitate transport, assembly and dismantling operations, including in-tunnel removal and abandonment of the body (skin) for ground support where required by the construction sequence. TBMs shall generally be of welded construction and the sacrificial skin will be the body and tail skin of the machine.

4.2 Shield Configuration

The TBM and back-up System will be divided into sections for transport, site lifting and assembly, taking cognisance of any site specific constraints and traffic/transport routes.

The SELLER shall submit piece sizes and weights of major components and the transport, assembly and removal procedures to the BUYER for agreement before commencing manufacture.





4.2.1 Front Shield

The front shield shall incorporate:

• A bulkhead designed to act as a pressure vessel end, to withstand the expected hydrostatic working pressures of 3 bar, plus any additional machine induced pressures during normal operations and exceptional high pressure working.

• A sufficient number of sleeves fitted with shut off valves spaced around the periphery for angular ground treatment. The arrangement of the sleeves shall allow for the formation of a treated zone of sufficient diameter at a suitable distance in front of the TBM cutter head face to enable head intervention for inspection and maintenance.

• The system will allow for 360-degree coverage ahead of the machine as a provision for ground treatment to deal with any large solution cavities detected.

• Man entry to the cutting/mixing chamber through a lockable sealable door fitted with observation window.

• Materials door with provision for mechanical handling and transport of tools, cutters, etc through the TBM and into mounting position. This is to be demonstrated in the factory commissioning.

• Penetrations through the bulkhead for de-watering the mixing chamber at the capacity expected for the ground conditions and permeability.

• A minimum of eight (8) spoil conditioner injection nozzles at the cutter head positioned and arranged to maximise the ability of the spoil conditioners to mix with the excavated material. Each injection nozzle to have individual fluid supply and designed to allow for high pressure cleaning, clearing blockages and monitoring of the delivery spoil conditioning fluids.

• Penetrations for essential services of electricity, hydraulics, water H.P. compressed air, grout and pumped concrete

• Provision for fluid transfer (oil and spoil conditioner) to the cutter head.

• Provision for minimum four probe drilling points through the cutter head, and minimum ten peripheral positions during open or closed mode working to include a gland and shut off valve and facilities for pre-support ground treatment. The probing points shall be located in a suitable position to mount the probe drilling equipment, which will allow for 360-degree coverage of the tunnel profile.

• Earth/water pressure measuring devices positioned as follows: 2nr in the crown; 2nr at the shoulders; 2nr at axis and 2nr at knee levels. These shall be capable of replacement from the rear face of the bulkhead (when full and pressurised) and manual calibration to check face pressure.

• L.P. Compressed air pipes to assist with spoil conditioning/de-watering. This shall include a port close to the crown of the tunnel to vent free air into the cutting/mixing chamber while dewatering.

• Machines are to incorporate rock buckets that can be closed in order to seal the face.

4.2.2 Main Shield

The main shield shall incorporate:

a) Shove Rams - Total installed shove force of a minimum of 65,000KN @ 350 bar maximum pressure. It is the responsibility of the TBM SELLER to determine ram thrust capabilities to match the anticipated geological conditions. The number and ram forces shall be provided to the BUYER to confirm compatibility with the tunnel





lining design such that individual shove ram shoes do not overlap segments. Four (4) rams at or close to the 45 degree axis to have linear transducer measuring for link to steering and guidance computers. Shove ram shoes shall be fitted with flexible rubber or similar material sweepers to displace hands and feet away from entrapment below axis level.

b) Reversible cutter to control the machine roll. The TBM roll shall be controlled to ±50mm measured across the axis. The shove ram controls shall include a sequential relax feature to prevent high bending moments transferring into the shove ram rods and bearings due to cutter head torque reaction during each stroke. The maximum torque to be applied to the tunnel lining shall be compatible with the tunnel lining and joint fastener design.

c) Provision for angular displacement of shove rams in groups to correct TBM roll. d) 12-ports through the skin for the injection of anti-friction lubricants, non-active

grouts or mortars (i.e. bentonite or similar) into the annulus between the TBM and the ground. These shall be linked to a monitoring system to measure both volume and pressure over time. They shall be fully linked into a manifold supply system that shall be shop function tested.

e) The design shall incorporate passive or active type tail skin articulation rams. f) Passive articulation shall be rated to absorb a minimum of 25% of the max shove

force under normal hydraulic working and 35% of max shove force under exceptional mechanical working in the event of the tail becoming fixed. Active articulation shall be rated to absorb a minimum of 80% of the max shove force.

g) Each articulation joint shall be fitted with a sealing system rated for the maximum hydrostatic and any machine induced pressures. The system shall be grease lubricated and purged with the ability to replace the front seal in-situ as a minimum.

h) De-watering pumps and pipes to remove a minimum water flow of 50 litres/second. i) Lighting to be a minimum of 300 lux in working areas. The SELLER shall ensure

that there is sufficient lighting in all areas. j) Safe access for operatives and maintenance personnel. k) A voice communications system linking the proposed work stations within the TBM

and back-up; and the surface. l) Fixed and hard wired gas detection along the TBM inputting to the TBM or Tunnel

Data logging system. SELLER shall include an airflow monitor to measure the airflow from the tunnel ventilation.

4.2.3 Tail Shield

The tail shield shall incorporate:

a) Provision of a proven (ETAC or similar ) constant continuous pressure grouting system for the annulus of the tunnel linings with quick setting gel grout utilising “A” & “B” mixtures through ports in the tail skin. 2 working and 2 reserve ports shall be provided at shoulder level equally spaced about the vertical centre line.

b) 2 working and 2 reserve ports shall be provided at knee level equally spaced about the vertical centre line. The grout ports shall have a minimum cross sectional area of 30 cm2 each. The design of the ports shall allow mixture of the “B” accelerator to join the cement slurry filler “A” mixture at the point of exit from the tail ports. The “B” mixture injector shall be retractable for cleaning purposes and to self-clean at the end of each grout cycle. The tail skin grout tubes shall have a full bore valve in front of the wire brush protection ring to allow jetting out; when the jetting nozzle is retracted the valve can be closed to prevent material travelling back down the cleaned tube into the tail skin. Interlocking systems shall be installed that prevent





moving the shove cylinders (and/or cutter head turning) when the grouting system is not functioning.

c) The design of the tail skin grout system shall ensure that both pressure and flow of grout to each port are controlled, monitored and logged continuously. Each grout port is to be serviced by an individual pump.

d) A tail seal system with 3-rows of seals each rated to withstand a hydrostatic pressure of 3 bar. The inner 2 rows of seals shall be wire brush type supported by membrane and spring steel leafs. The outer seal shall be multiple spring steel leaves forming and durable barrier against the ingress of grout. The tail seal system shall include suitable seals to prevent grout travelling forward over the TBM tail skin.

e) A tail seal greasing system to distribute tail seal grease with independent flow through a minimum of 10 ports of 12 cm² cross section each per chamber between seal rows. The design shall facilitate their maintenance and replacement.

4.3 Cutterhead Main Bearing and Sealing System

4.3.1 Cutterhead

The cutterhead shall be a substantial structure, which provides the necessary mechanical support to the tunnel face. It shall incorporate the necessary abrasion protection features to enable the shield to be able to complete excavation of the tunnels through all the expected geological conditions.

The cutter head shall incorporate:

a) Cutting tools appropriate for the expected geological conditions. Electronic or similar cutter wear indicators shall be fitted to the cutters, and they shall alarm in the TBM control cabin and duplicate in the above ground monitoring station. The cutter head should include disc cutters to deal with the rock formations anticipated and ground treatment zones that may be required.

b) A sufficient number of injection nozzles (minimum 10nr) with sufficient capacity for tunnel face spoil conditioning in all expected geological conditions. They shall be arranged to condition all parts of the tunnel face. Each injection nozzle to have individual fluid supply to allow for high pressure cleaning and the monitoring the delivery spoil conditioning fluids.

c) Rotary fluid coupling for transfer of hydraulic and spoil conditioning fluids. d) All cutting tools shall be designed to be replaced from the rear face of the cutter

head with access from the plenum chamber. A mechanical handling system shall be provided to transport the tools and other equipment through the TBM, material door and into position within the plenum chamber. Interlocks shall be provided in accordance with Section 10.3.1 of this document.

e) Wear protection shall take the form of replaceable wear protection plates and/or weld on tools arranged in a pattern for the entrapment of spoil to protect the cutter head structure.

f) An indexing facility to allow probe and ground treatment drilling through the apertures within the cutter head. Coverage to be 360-degree ahead of the face to allow for the treatment of large cavities that may encountered in any location with respect to the tunnel profile.

g) Bi-directional cutting. h) Provision to retract the cutter head from the face for tool inspection/replacement.

Retraction shall move either the cutter head or the cutter head and front shield. Rearward movement of the rear shield/tail shall not be permitted.





i) A cutter head of the open type to suit the expected ground conditions and flow of excavated spoil shall be provided. It shall afford adequate ground support and incorporate good spoil flow features. The SELLER shall submit full details of the cutter head to the BUYER. The apertures shall be fitted with face board retaining brackets, and a full set of face boards shall be available on site, to allow manual face boarding of all apertures in the event of a prolonged stop. The SELLER should note that the head will need to be configured to deal with boulders that are present with the limestone breccia encountered at the site.

j) Fixed gauge cutting shall be with disk cutters. The design shall incorporate a minimum of six (6) passes of gauge & semi gauge cutters and reserve long life cutters.

k) A method of pre-setting the cutter head to index cutter head arms into the desired tool change position without the need to open the air lock entry door.

4.3.2 Main Bearing

The main bearing shall have a rating of not less than 10,000 hours B10 life based upon the assumed loadings defined by the SELLER. The bearing shall be a 3- row axial, radial and counter axial roller bearing with integral drive gear. The SELLER shall submit to the BUYER lifecycle calculations for the main bearing and drive pinions against the given load cases.

SELLER shall submit their proposed bearing Supplier and shall indicate the delivery time and possible program delivery mitigations (reserving forgings etc).

The lubrication circuit for the bearing raceways and gear drives shall be provided with a facility for monitoring lubricant contamination, and alarming to the operator and above ground monitoring station.

Sampling points for all lubricants shall be provided.

The bearing shall be removable rearward from the front bulkhead with the minimum of disturbance to the other components, in the event of the need for replacement. A replacement main bearing should be available within 12 weeks should replacement be required.

The SELLER shall submit a method statement to the BUYER demonstrating that the design will facilitate main bearing removal and replacement in the event of bearing failure during tunnelling operations.

4.3.3 Drive Train

The drive train shall meet the minimum requirements defined below (to be amended as required by the SELLER to cope with the anticipated conditions):

a) The installed power to the cutter head shall be a minimum of 3,600 kW provided by variable speed electric drive motors with a cutter head speed range of 0 to 4.5 rpm.

b) The torque / speed graph shall be submitted to the BUYER as part of the Proposal. c) Main drive gearboxes and motors shall have a rating of not less than 10,000 hours

B10 life for the given load cases selected for the main bearing by the SELLER. d) Indirect water cooling of the main drive motors and gearboxes through outer jackets

shall be provided. The SELLER shall submit the design of the circuits and details of the components to the BUYER.

e) To mitigate any risk of gearbox or drive pinion failure causing damage to the main bearing gear final drive pinions meshing with the main gear shall have bearing





supports on each side of the pinion to remove bending moments. The SELLER shall submit the details of the gearbox drive pinions and support bearings to the BUYER.

f) It is the responsibility of the TBM SELLER to arrange/determine the drive capabilities to match the anticipated geological conditions.

4.3.4 Main Bearing Sealing System

The main bearing sealing systems shall meet the minimum requirements defined below:

a) The outer and inner main bearing sealing systems shall be of a proven design capable of protecting the bearing for life of 10,000 working hours. The sealing system shall comprise a series of labyrinths and multiple lip seals that have been proven competent for the duties required. They shall be rated to withstand the potential hydrostatic pressure of up to 3 bar and any machine-induced pressures in excess of this taking into account the expected wear during the working life. The design shall accommodate this pressure drop through the outer and inner sealing systems.

b) The design shall provide for exchanging both inner and outer sealing systems from within the tunnel should failure of the seals occur.

c) The sealing system shall have facilities to monitor its performance. In the case where total loss grease is used for lubrication, cooling and support of the seals, and a means of adequate sampling shall be provided. In the case where oil is used to lubricate, cool and support the seals, the SELLER shall incorporate a circuit to filter (including filtering water), cool and sample the oil.

d) Flushing of all component parts prior to assembly and flushing of the full system. Flushing sample analysis shall be included in the TBM commissioning documentation.

e) The design of the sealing system shall be proven in service in similar conditions. Details of where the system has previously been used, the tunnel drive lengths and the pressures encountered shall be submitted to the BUYER for approval prior to manufacture.

4.4 Removal of Excavated Material

The tunnelling machines shall be designed to permit removal of spoil from the face by belt conveyor.

4.4.1 Face Conveyor

The face conveyor shall conform to the requirements set out for the transfer belt in the following section. No weighing mechanisms are however required for the face conveyor. The face conveyor shall be configured to discharge to the transfer belt. The face conveyor shall be configured such that it will enter into the plenum through a bulkhead door during operation and be retractable from the plenum when not in use.

4.4.2 TBM Transfer Belt Conveyor

The TBM transfer belt conveyor shall meet the minimum requirements defined below.





• This conveyor shall be sufficient to remove a minimum of 2000 tonne/hour of cut spoil from the screw conveyor/face conveyor in open mode or closed mode working; or convertible rock-mode.

• The conveyor shall have the following features:

i) A loading hopper which accepts spoil from the screw conveyor / face conveyor and contains and prevents spillage.

ii) A sump below the hopper to gather water, with facilities for pumping away.

iii) Be provided with variable speed and reversible feature. Reverse running should only be used in exceptional circumstances to clear a blockage. The belt weighing shall be configured to eliminate errors resulting from repeated weighing when the belt is reversed.

iv) Deliver and transfer the spoil onto the main tunnel belt conveyor or other spoil removal system via the TBM Transfer belt conveyor. The design of this feature shall be integrated with the design of the back-up system.

v) Have adequate belt cleaners (both sides of the bottom belt) that deposit the scraped muck back into the system.

vi) Have muck treatment system to prevent spoil from packing and hardening under the given ambient conditions.

vii) Be fitted with a Gravity Tension Unit to maintain a constant tension.

viii) The main rollers are fitted with waterproof bearing systems and adequate lubrication system. The bearings shall be rated for 10,000 hours.

ix) Be designed to facilitate maintenance and replacement.

x) The TBM Transfer conveyor shall be fitted with two real time spoil belt weighing devices. These shall have a proven accuracy of +/- 0.5% and shall comply with Section 4.9;

xi) The TBM Transfer conveyor shall be fitted with the necessary guards, emergency stops and trip wires.

xii) Both top and bottom rollers shall be adjustable to allow belt tracking, except for the 10 top strand weighing quality idlers associate with each belt weigher, which shall be rigidly locked in place and not be available for belt tracking purposes.

xiii) Drive drums should have ceramic or similar long life lagging.

xiv) Easily removed bottom guards to allow access for cleaning.

4.5 Segment Erector

The segment erector shall meet the minimum requirements defined below.

a) The segment erector shall be equipped with a single pick up head of semi-rotary type. It shall have axial movement sufficient to allow pick up from the segment feed magazine and allow dismantling of previously built tunnel rings for tail seal repair / maintenance.

b) The segment erector shall have the following features:

i) The erector head shall be provided with a vacuum pick up pad for the lifting of the segments with positive engagement interlock. A factor of





safety 3 for lifting the heaviest segment shall be applied assuming 0.8 of absolute vacuum. This shall be applied to all vacuum devices.

ii) The erector head shall have a single or double tapered shear pin to locate into the central grout socket(s), within the segments. The pin shall be designed to impart the necessary cross joint closing force and shall be designed to transmit this force into the central section of the segment by a replaceable plastic sleeve to prevent damage to the segment.

iii) The erector driver shall be provided with a means of accurately locating the erector shear pin(s) into the segment with a clear indication of engagement. Laser pencils shall be provided to locate into (2) dimples cast into the trailing edge of the tunnel segments.

iv) The segment erector system shall avoid the need for personnel to enter the build area in selecting the correct ring taper and orientation. The system shall be linked to laser measurement of tail gap between the tail skin and segment extrados. Manual override shall be provided.

v) The erector shall be provided with a clockwise and anti-clockwise rotational movements of sufficient angular rotation (minimum +/- 190 degrees) spaced equally about the invert of the tunnel.

vi) The erector will be provided with a means of safe transfer of power cables and hoses from static to rotation section by reel.

vii) The erector will be provided with proportional control of main movements.

viii) The erector shall be provided with a pick up head with the ability to move the segment in all directions and rotations sufficient to properly erect the segments.

ix) The erector shall have a radio remote control to provide clear visibility to the operator of all erector movements. The control shall be fitted with dual enabling buttons to prevent inadvertent operation. The control shall include selection and control of individual shove rams for use during the segment erection. Indexing of segments forward on the magazine shall be controlled by the erector driver during the segment erection and by the crane driver during excavation. Individual remote controls shall be equipped with a unique isolation system such that only one (1) control shall be operable in the case of maintenance / replacement of the remote controllers.

x) The erector will be provided with sufficient torque to generate the required force to achieve closure of the segment radial joint gasket, when operated against the mass of the segment.

xi) The rotational speed shall be capable of being varied in the range of 0-3 rpm.

xii) The erector shall be equipped with an integral bearing and sealed drive system rated for 10,000 hours.

xiii) The design shall provide a means of safe access for the operatives to reach the segment bolting positions.

xiv) As part of the safety interlocks, the erector shall be provided with a transfer switch to release control of the shove rams from the main operation station to the erector driver.





4.6 Erector Bridge

The erector bridge shall meet the minimum requirements defined below.

a) The length of the bridge shall be determined to ensure the annulus grout will have gained sufficient strength to support the tunnel lining and bridge support.

b) The bridge shall have the following features:

i) It shall extend from the rear of the TBM and run on support rails fixed onto the tunnel linings or polyurethane tyre hydraulically steerable bogies running tangentially onto the tunnel lining. The bridge will transfer all services including electricity, hydraulic hoses/pipes, ventilation air, cooling fluids, de-watering pipes, spoil conditioning fluids and control services to the TBM and act as the towing beam for the back-up system.

ii) It shall be provided with an articulated towing connection to the TBM with load indicating and interlocked features. These features shall include a link to the shove rams which will stop the shove should excessive loads be transmitted to the towing connection with a minimum factor of safety equal to 3.

4.7 Segment Magazine

The segment magazine shall meet the minimum requirements defined below.

a) The invert-mounted magazine will receive tunnel-lining segments from the transfer crane and index them forward to the pick-up position of the segment erector.

b) The magazine shall have the following features:

i) A minimum capacity for one ring of segments.

ii) Be fitted with an indexing system to present individual segments to the erector without any damage to the segments or the sealing gaskets.

iii) Be provided with a system for removal and replacement of damaged segments from the erector area not relying on vacuum.

iv) Have a means of propulsion either from the erector bridge or independently. The magazine shall bear on the tunnel lining segments and be supported on wheels or skates. The individual weight per support shall take account of the building and grout time and the rate of gain of the grout strength.

v) The base of the magazine shall be constructed to allow access for grouting to the tunnel invert.

vi) The base structure shall be equipped with a clear access walkway to TBM tail area.

vii) Control of the magazine functions shall be by the erector driver during ring building and the crane driver during excavation. In all cases the drivers shall have clear sight of movements.





4.8 TBM Operation

4.8.1 TBM (sub-surface) Control Cabin

• The TBM shall be equipped with an air-conditioned control cabin at the front end of the back-up system from which the TBM shall be driven. This shall contain all remote controls and visual displays necessary for the safe operation of the TBM and its environment.

• The operation control cabin shall have space for a minimum of four (4) persons. The controls shall monitor and record the operational parameters of the TBM and its systems and shall transmit copies of these records via secure high capacity data cable to a remote station on the surface and from there to the secure Project Underground Construction Instrumentation and Monitoring System.

• The cabin shall be equipped with video cameras to observe as a minimum:

i) The tunnel lining build area.

ii) The transfer of spoil from screw/ face conveyor to the belt conveyors (camera provided at all transfer points).

iii) The segment supply magazine.

iv) The level of spoil in the plenum.

v) Train / gantry interface area.

• All video feeds shall be recorded and transmitted to the surface control room.

4.8.2 TBM (Surface) Control Room

A separate above-ground monitoring facility shall be provided for each TBM that will duplicate all the remote controls and visual displays within the respective (sub-surface) Control Cabin. Multiple facilities may be provided in a single, air-conditioned room.

The room shall have direct links with the BUYER’s Instrumentation and Monitoring System. In addition to the video feed identified in 4.8.1 additional video cameras shall monitor the discharge from the main tunnel conveyor or other method of spoil removal. Visual displays shall be provided to enable constant review of the excavated volume, soil conditioning, and grout volume and ground movement. The control room shall be supervised at all times during TBM operation.

4.8.3 Conveyor operation

An Interlock between primary TBM conveyor belt and the main tunnel conveyor belt shall be provided to prevent operation of the TBM conveyor in the event of main tunnel conveyor failure. There should be feedback to the TBM operator to confirm that the main tunnel conveyor is running.

4.9 Belt weighing, conveyor and weigher parameters.

4.9.1 Requirements for accurate and repeatable belt weighing.

The belt weighing equipment shall comply with Organisation Internationale de Métrologie Légale (OIML) Document OIML R 50-1 (Continuous totalizing automatic instruments (belt weigher) Part 1: Metrological and technical requirements – Tests (1997)), Accuracy Class 0.5. Copies of this publication are available from www.oiml.org.





The requirements for accuracy and repeatability of the belt weighers are as follows:

• Maximum permissible error as a percentage of the mass of the totalised load in Initial verification: 0.25%

• Maximum permissible error as a percentage of the mass of the totalised load In- service: 0.5%

• Flow range: 100 – 20%

• Repeatability: 90 days

The belt weighing equipment shall have full approval against OIML R 50-1 (1997). The supplier shall provide the BUYER with approval certificates that the belt weighing equipment meets these standards. These shall include:

• Current certificate of approval

• Full copy of Laboratory and Commissioning Reports

The BUYER will require three separate sets of independent proof of the proposed belt weighing instruments, working to the specified standard of measurement, at similar (or higher) rated capacities, prior to placing the order with the TBM SELLER.

The SELLER is to regard the conveyor through the belt weigher as part of the weighing machine and design the conveyor to suit not just materials handling duty, but also high specification continuous belt weighing purposes, as an integral item.

4.9.2 Conveyor Structure

Good performance of a belt weigher requires that it is mounted on a solid conveyor structure, designed to limit lateral and vertical deflections to a practicable minimum at the point of installation of the weigher.

On conveyors, modifications may be necessary to achieve a rigid structure e.g. stringer joints may be required to be welded so that no movement can take place between different parts of the weighers, and additional supports may need to be fitted at the conveyor stringers to minimise deflection.

Deflection at the belt weigher installations (and for three idler sets either side of the weighbridges) shall be restricted to a maximum of 1mm arising from the full scale material load.

In order to fit the weighers it may be necessary to lower the return strand of the belt by snubbing it down using the return strand rolls. In some instances these rolls may not be robust enough for this duty in which case suitable rolls shall be supplied by the SELLER. Typically the return strand needs to be at least 200mm below the top of the conveyor stringer structure, with the return idlers below the belting.

4.9.3 Conveyor Belt

The conveyor belting shall meet the following requirements:

• It shall be without mechanical joints. (i.e. vulcanised joint required)

• It shall be as flexible as practicable for the application.

• It shall be of a consistent type and thickness throughout its length.

• It shall be resistant to moisture absorption.

• It shall be fire resistant in compliance with section 10.2 of this Minimum Requirements document.





4.9.4 Idlers

Weigh quality idler sets shall be fitted at the weigh area and shall comply with Organisation Internationale de Métrologie Légale (OIML) Document OIML R 50-1 (1997).

There shall be a minimum of three (3) sets before each belt weigher, a minimum of four (4) sets on each belt weigher, and a minimum of three (3) sets after each belt weigher.

In summary this will equate to not less than ten (10) sets of balanced weighing quality idlers per belt weigher.

Weigh Quality Idler Roll and Weigh Quality Idler Frame specifications, are provided below.

4.9.5 Weigh Quality Idler Roll Specification

Idler Rolls shall meet the following requirements:

• They shall be fitted with totally enclosed, grease lubricated, sealed-for-life bearing assemblies having a design rated life of 10,000 hours minimum.

• They shall be free running. The SELLER is to ensure that the rolls would turn freely under normal "Empty - Belt" conditions, for the duty given on the roll detail drawing.

• Diameter: The difference in diameter between any two rolls shall not exceed 1.0mm.

• Concentricity: The maximum Total Indicated Run-out (TIR) on diameter at any point along roll face length shall not exceed 0.25mm.

• Balance: The maximum out of balance of the roller shell shall not exceed 14 grammes.

• They shall be suitably protected against corrosion.

4.9.6 Weigh Quality Idler Frame Specification

Idler Frames shall meet the following requirements:

• Roll frames shall be of the in-line type, not skewed or staggered.

• Roll frames shall be designed and manufactured such that deflection due to live load is limited to one (1) mm maximum.

• There shall be no use of flat surfaces for transoms, to avoid product build up.

• The deviation in dimensions of the frame profile from frame to frame shall not exceed 0.5mm. Roll frames shall be suitably protected against corrosion.

• The maximum trough angle shall be 30 degrees.

4.9.7 Belt Tension control – Gravity Take-Up Unit.

The belt tension control Gravity Take-up Unit shall be:

• Located as near to the tail drum as possible.

• Of the minimum mass whilst providing the optimum operation of the conveyor.

• Suitable for easy servicing to ensure free movement is readily achieved and maintained.

• Screw or winch tension control is not acceptable.





4.9.8 Weight processing electronics

Each belt weigher shall have two (2) sets of weight processing electronics, thus providing on each TBM four (4) sets of belt weigher measurements.

4.9.9 Tachometers / Odometers

The tachometers / odometers (devices for measuring belt speed / belt travel), 4 number in total, shall be mounted as follows:

• 2 on tail drum.

• 2 on drive snubbing drum.

4.9.10 Belt and Drum Cleanliness

Suitable belt scraping shall be employed to remove any material attempting to adhere to the belt. Scraper “blades” shall also be used to limit any product build up on drums carrying tachometers.

4.9.11 Other Considerations

Belt tracking idlers shall not be employed in the area of the weighers. There shall be no magnetic separators in close proximity to the weighers. Built-in full-size calibration weights are required for each belt weigher.

The use of a lagged drive drum is beneficial as it results in a lower belt tension.

Material feed on through “pig trough” feed on arrangements (with low friction slider plate impact section) shall be considered.

4.9.12 Material Testing

The minimum material test load size is expected to be 14 tonne.

5 CONTROL AND MONITORING

The SELLER shall incorporate a TBM operational control and monitoring data acquisition system. The system shall be compatible with the BUYER requirements for the project-wide Underground Construction Instrumentation and Monitoring System (UCIMS). The monitoring system shall record and report the key information that will ensure the reliable and safe operation of the TBM.

The monitoring system shall also record all necessary parameters to ensure that ground movements are kept within the specified limits.

The monitoring system shall record and report all of the parameters listed in Table 1. The system shall also allow pre-programming of target values of TBM control parameters and monitor adherence to those values.





Table 1 - Table of TBM parameters

Parameter Units

Progress

Ring No. N

Start Excavation dd/mm/yy hh:mm

Finish Excavation dd/mm/yy hh:mm

Net Stroke Mm

Instantaneous Advance rate mm/min

Position (easting, northing, elevation to Project Datum)

M

Station M

Horizontal alignment control mm from design

Vertical alignment control mm from design

Shield

Face Pressure MPa

Overbreak Ram Earth Pressure MPa

Overbreak Ram extension mm

Earth/water pressure at crown, shoulder, axis & knee

MPa

Thrust Ram Pressure MPa

Thrust Ram Stroke MPa

Thrust Ram Speed mm/min

Copy cutter Stroke mm

Copy cutter position °

Articulation Ram Stroke (all rams) mm

Articulation angle (vertical) °

Articulation angle (horizontal) °

Pitch °

Roll °

Cutter Rotation speed rpm

Cutter Rotation direction CW/CCW

Cutter Torque kNm

Power Used Kw

Temperature of Drive Motors Degrees C





Parameter Units

Bulkhead gate Open / Closed

Discharge gate Open / Closed

Environmental Monitoring

Oxygen/ oxygen deficiency %

Carbon Monoxide Ppm

Carbon Dioxide %

CH4 %LEL

Hydrogen sulphide (H2S) Ppm

Sulphur Dioxide (SO2) Ppm

NO2 & NO Ppm

Humidity %RH

Dust mg/m³

Temperature deg C

Ventilation air flow m³/minute

Face treatment

Volume of air m³

Volume of solution m³

Additive / Conditioning Flow l/minute

Foam Solution Flow l/minute

Polymer flow l/minute

Grouting System B

Volume in tank m³

Tail grout injection pressure (all ports) MPa

Tail grout injection volume (individual ports and total)

m³

Tail grout annulus pressure MPa

Conveyor System

Spoil flow weight tonne/min

Total spoil mass for ring Tonne

Total spoil volume for ring m3





5.1 Cutter Head

a) Position of cutter head in project coordinate system b) Control of rotational direction, speed and index position. c) Cumulative record of operating hours. d) Condition monitoring of the main bearing and its sealing system to include oil flow,

oil pressure, oil temperature including filter analysis and the measurement of metal parts per million & ground contamination on a regular basis to allow monitoring of the bearing and sealing system to detect contamination and wear. An interlock with the cutter head movement shall be provided to prevent use should contamination occur.

e) Power and torque monitoring. f) Interlocking of torque to shove rams. g) Monitoring volume, pressure and control of spoil conditioning fluids. h) Isolation of drive for interventions to the cutter head. i) Cutter tool wear indicators & alarms.

5.2 Front Shield

a) Control and monitoring of the articulation system. b) Control and monitoring of spoil conditioning fluids. c) Steering control and link to guidance system. d) Control and monitoring of the air lock and systems.

5.3 Main Shield

• Shove ram monitoring for stroke and guidance systems.

• Shove ram control and selection with proportional pressure feature when shoving.

• Fast retraction or extension of individual or groups of rams when ring building.

• Control and monitoring of shield roll.

• Interlock and transfer to erect mode.

5.4 Rear Shield

• Monitoring of tail sealer grease delivery, indicating distribution, pressure and warnings.

• Monitoring and alarming of grout volume and pressure delivery interlocked with advance rate / shove rams.

• Automatic measurement of the tail to segment extrados gap for ring position.

• Non-destructive grouting checks i.e. infra-red, radar or similar device to prove void filling.

5.5 Belt Conveyors

• Monitoring of speed and forward/reverse operation.

• Monitoring belt weighing and scanning technology to compare weight and volume excavated per ring with theoretical volume of excavation (for transfer belt only).

• Interlock to alarm when difference reaches +/- 5% by weight.

• Interlock with main tunnel conveyor belt or other spoil clearance system to be developed.

5.6 Segment Erector

• Number of ring





• Position of leading edge of ring in project coordinate system

• Interlock to allow individual or group operation of shove rams when segment erecting.

• Safe lifting alarms.

• Vacuum monitoring for segment lifting.

• Return to pick up segment position and automatic location and pick up of segments.

• Automatic segment identification to position the key / ring interlocked with tail to segment extrados measurement.

5.7 Erector Bridge

• Monitoring of the back-up towing forces with alarm for high pressure and cut-out of shove rams for excessive pressure.

• Primary and secondary belt conveyor monitoring.

• Compressed air monitoring and control for tunnel face pressure.

• Non-intrusive measurement of the annulus between segment extrados and the ground to check any voids due to over-break or lack of grouting.

5.8 Guidance and Control System

The SELLER shall provide the TBM guidance and control system.

The system shall provide for but not be limited to the following functions:

• The guidance system shall incorporate an independent Non-Manual check of the correct position of the TBM cutter head and tail position at hourly intervals. An additional Non-Manual check should be initiated at the commencement of each shift. The system shall alarm when the tunnel alignment is predicted to go out of tolerance.

• TBM position relevant to surface topography shall be shown on a monitor.

• The guidance system shall be self-checking, with redundancy in essential components, and shall generate and record appropriate status messages for delivery when remotely or locally interrogated and to alert the operator to fault conditions immediately they occur.

• The guidance system shall have an uninterrupted power supply system to prevent data loss in the event of loss of primary power,

• During forward movement of the shield or TBM, the guidance system shall provide as a minimum the following real-time data for the TBM, with reference to the designed tunnel alignment at the machine head:

i) Station (chainage).

ii) Horizontal / line displacement.

iii) Vertical / level / grade displacement.

iv) Left or right lead / yaw at axis level.

v) Overhang or look-up / pitch at axis level.

vi) Main axis rotation (roll).

vii) This information shall be presented in numerical and graphical form, refreshed every 20 seconds or faster. The precision of each measurement shall be as stated in Table 2.

Table 2 Precision of Position Measurements





DATA ACCURACY

Station ( chainage) +/- 5mm.

Horizontal displacement +/- 2mm.

Vertical displacement +/- 2mm.

Left or right lead +/- 0.1mm/m

Overhang or look-up +/- 0.1mm/m

Main axis rotation (Roll) +/- 0.1mm/m

• The data shall be presented on displays in the TBM operator’s cabin and the above ground monitoring station in the offices of both the SELLER and the BUYER. The BUYER shall be provided with access to the above ground monitoring station and shall be trained by the SELLER in the use of the system. The data shall be automatically transferred to the Project Underground Construction Instrumentation and Monitoring System.

• The format shall be agreed with the BUYER and provided with paper print out.

• Data shall be recorded in a medium unaffected by primary power loss in a store of sufficient capacity to hold the entire tunnels production records.

• The guidance system shall, throughout the forward movement of the TBM, compute the correction curve which returns the TBM tangentially to the designed tunnel alignment and compute and display the necessary corrections to attitude to be applied during the course of forward movement. The correction curve re-alignment shall be designed in accordance with BUYER alignment standard. This computed data may be used directly as input into the control mechanism of the TBM as approved by the BUYER.

• The guidance system shall facilitate construction of the tunnel lining so that it follows, and does not bind into, the TBM tail skin. The system shall provide data defining the plane of the circumferential joint of the leading edge of the tunnel lining with respect to the Designed Tunnel Alignment (DTA) and actual TBM axis. To assist in understanding steering requirements, the guidance system shall predict the horizontal and vertical displacement of the TBM at interval of 5, 10, 15 & 20min front of the TBM. Laser measurement of the tail skin to segment extrados gap shall be input into the guidance system.

5.9 Environmental Conditions.

Control and monitoring of environmental conditions to include but not be limited to:

• Gas detection system for oxygen deficiency, CO2, CO, H2S, NO, NO2, SO2 and CH4. The data acquisition unit shall include provision for the monitoring of tunnel gas alarms throughout the tunnel to provide early warning to the TBM operator of potential gas danger.

• Fire protection systems.

• CCTV monitoring of work areas.

• Electrical power.

• Temperature

• Humidity

• Dust monitoring

• Inundation of the cutter head chamber

• Ventilation air supply (including failure).





All control and monitoring of environmental conditions will be supported by an uninterrupted power supply system and resilient communications capable of relaying data under all operational modes (normal, degraded, accident and emergency) to surface operators.

5.10 Intrusive ground investigation

The TBM shall be equipped with drilling equipment that allows pre-probing of up to 30m ahead of the TBM cutter head in at least four (4) positions where; also angled drilling of up to 15o outlook angle can be carried out. The same equipment may also be used for ground treatment drilling ahead of the tunnel face.

5.11 Grouting Check

The TBM shall trail non-destructive infrared, ground radar or similar system to confirm that the annulus around the rings; five (5) rings back from the last ring built has been filled with grout. A permanent record of the measurements shall be captured on the TBM database.

5.12 Format of data

The data recorded for each parameter or system shall be uniquely identified in time and space to allow comparison with other project monitoring systems.

The data shall be formatted for immediate automatic transfer into the Project Underground Construction Instrumentation and Monitoring System.

The format of the data shall be agreed with the BUYER and shall generally comply with the AGS Format as defined in ‘Electronic Transfer of Geotechnical and Geo-environmental Data (Edition3.1) including addendum May 2005’. The specification is available from the AGS website: http://www.ags.org.uk.

The data shall provide full details of all measured parameters together with commentary on variations in the parameters and the performance of the TBM. The data shall be formatted to be unique to each ring advance and referenced in 3-D coordinates to the Project grid and datum.

5.13 Frequency

All the parameters shall be recorded at the same regular time interval or station.

6 BACK UP SYSTEM

The Manufacturer shall provide the design of the back-up system and rail transport system. The design of the back-up system and its availability shall match the performance specified for the TBM.

The back-up system shall have the following minimum features and capabilities:

• Portal wagons running on rail track fixed to the tunnel segments using purpose made support brackets or polyurethane tyre hydraulically steerable bogies running tangentially onto the tunnel lining. The portals shall accommodate the





construction railway, to include segment off loading, loco run around switches and, where required, single track working.

• Forward bridge portal / portals running on rail track fixed to the tunnel segments using purpose made support brackets or polyurethane tyre hydraulically steerable bogies running tangentially onto the tunnel lining. Wheel loading shall take account of the rate of gain of the grout strength to ensure there is no segment damage.

• Rail lifting and transfer facility for installing the construction track in the invert of the bridge area.

• Cranes for the vacuum unloading and transfer of the tunnel lining segments from the delivery wagons to the segment supply magazine. The travelling and operation of the cranes shall provide the operator with clear sight at all times.

• Designated walkways with sufficient clearance outside the tunnel rolling stock swept envelope. These walkways are to be unobstructed and fenced off from the rolling stock.

• Soil conditioning systems and equipment for the required additives.

• Settling tanks for dewatering unless pumping systems are provided to eject suspended solids to the surface.

• Continuous 2 part gel grouting system with a minimum of 15m3 of grout available in the tank / mixer within the back-up.

• Tail sealer grease mechanical handling and pumping system.

• Provision for the extension of all surface connected services to include: Ventilation, Communication systems, de-watering pipes, mains power, compressed air and cooling water. The Design shall incorporate service extensions of:

i) Electricity 250-metre capacity reel.

ii) Ventilation air flexible ducting, a minimum diameter of 1.5 metre and a minimum cassette capacity of 100 metres. The assembly shall include a TBM boost fan at the interface between the tunnel ventilation cassette and TBM back-up. There shall be a powered lifting mechanism for the ventilation cassette, There shall be a suitable and long enough platform behind the cassette for man access hanging the ducting, there shall be a platform in front of the ventilation cassette to drill and fix the ventilation suspension wire.

iii) De-watering pipes of 100 mm dia x a minimum of 6 metres long.

iv) Compressed air pipes.

v) Transmission cable reels a minimum of 100 metres capacity.

vi) Cooling / clean water pipes of 100mm dia x a minimum of 6 metres long.

vii) High capacity data cable

• TBM transfer belt conveyor loading onto the main tunnel belt conveyor.

• A towing station for the tail end of the extendible in main tunnel belt conveyor and space provision throughout the back-up for assembly and support of the tunnel conveyor

• An assembly station for the addition of support brackets and conveyor rollers for the in tunnel conveyor.

• Welfare and toilet facilities to include; drinking water stations, toilets, clean washing water and mess room.





• A safety device shall be provided at the outby end of the railing area which shall be linked to a signal and should prevent the possibility of rolling stock overrun or runaway from entering the railing and ring erection areas. The device shall be designed to take account of the impact loading.

• A towed crossing designed and supplied by the SELLER. The crossing can be either linked to the rear of back-up or moved independently.

• Maintenance area fitted with workshop and bench facilities.

• Routing of all services through the back-up shall be segregated and colour coded. They shall conform to the Health and Safety (Safety signs and Signals) Regulations 1996 or other equivalent standard as appropriate.

• Dual communications systems shall be fitted at strategic points throughout the TBM and back- up.

• A traffic light system shall be incorporated within the TBM back-up to control train entry/exit movements.

The SELLER shall undertake a hazard risk assessment and provide a refuge chamber sufficient to accommodate the number of persons identified to be at risk of fire or smoke hazards in the tunnel including the entire TBM crew, loco drivers, surveyors, fitters, electricians and six (6) other persons. The chamber shall comply with the requirements of BS6164, the ITA guidelines for provision of refuge chambers in tunnels under construction and other relevant standards.

7 GROUTING SYSTEM.

7.1 Principal Equipment.

An ETAC or similar gel grouting system shall be installed on the upper level of the back-up system. It will comprise:

• 1nr 25m3 “A” mixture holding tank fitted with appropriate agitators with means of rapidly emptying the tank back to grout car when delay occurs, Tank shaped so as not to allow a build-up of grout as the agitator rotates.

• 2nr 2m3 “B” mixture holding tanks.

• A dedicated grouting station out with the TBM control cabin where the grout operator has visibility and control of the operation and all flows, pressures etc displayed and duplicated in the TBM control cabin.

• 6nr peristaltic pumps each with a capacity of 250 l/min for the supply of liquid “A” grout to the tail skin injection ports.

• 6nr peristaltic pumps each with a capacity of 25 l/min for the supply of liquid “B” grout to the tail skin injection ports.

• 50 mm diameter supply line for liquid “A” grout. g) 25 mm diameter supply line for liquid “B” grout. h) 4nr flow meters for liquid “A” grout.

• 6nr flow meters for liquid “B” grout

• 6nr pressure meters for liquid “A” grout k) 4nr automatic injection units.

• 2nr pumps for the rapid transfer of liquids “A” & “B” from rolling stock transport into the holding tanks.

• 1nr bentonite tank and pump to flush grout from tail skin lines during stoppage periods.

• 1nr high pressure (Harben or similar) pump 300bar, 30l/min with ring main and connection points to allow cleaning/unblocking of tail skin pipes and other areas requiring grout wash down/cleaning.





7.2 Grouting Process.

a) The annulus void between the tunnel lining extrados and the excavated ground shall be grouted by means of injection ports located within the tail skin of the TBM using a constant pressure grout injection system. There are to be eight (8) available injection ports in the tailskin in total located as follows: 4nr ports at shoulder level (1nr each side for use and 1nr each side spare); 4nr ports at knee level (1nr each side for use and 1nr each side spare).

b) The injection of grout liquid “A” starts at the beginning of the TBM excavation advance cycle. From the automatic injection unit, retarded grout liquid “A” will be pumped via the 50 mm supply line from the holding tank to the tail skin. After approximately 50 mm of excavation the accelerator grout liquid “B” will be pumped via the 25 mm supply line to the injection unit, the accelerator liquid “B” flows through a separate hose contained within the 50 mm injection port within the tail skin. Liquids “A” & “B” are only mixed together as they exit the rear of the tail skin port. Grouting through the advance stroke shall be carried out as a continuous process. At the end of the liquid “B” hose is an injection nozzle. Only in the area of the nozzle will the liquid “B” react with liquid “A” to form the gel grout mixture.

c) This nozzle is moved out of the injection pipe as the accelerator is pumped by the automatic injection unit. Approximately 50 mm before the end of the excavation cycle liquid “B” transfer is stopped and the nozzle is retracted away from liquid “A” mixture. Liquid “A” is injected for the remainder of the excavation cycle filling the tail void and cleaning the liquid “B” injection nozzle.

8 ELECTRICAL SPECIFICATION

8.1 Standards

All TBM electrical installations shall comply with all relevant Regulations and with all relevant British and European Standards. The SELLER shall always use the latest published version of any Regulation or Standard that relates to health and safety.

The following list of relevant Regulations and Standards is non-exhaustive:

a) BS6164 Code of Practice tunnelling. b) BSEN 12336:2005 Tunnelling Machines Safety Requirements. c) Electricity at Work Regulations 1989. d) BS 7671: 2008 Requirements for Electrical Installations. IEE Wiring Regulations

16th Edition. e) BS5304 and EN292 Safety of Machinery. f) BS 7430: 1998. Earthing. g) BSEN 60204 Safety of Machinery. h) BS 7375: 1996 Distribution of Electricity on Construction sites. i) BSEN 60529 1992 Degrees of Protection of Enclosures. j) BS6724: 1997 armoured cables for low emissions. k) BS5000-3:2006 Rotary Electrical Machines for particular applications. l) BSEN 60898 1991 Moulded case and miniature circuit breakers.

8.2 Electrical System

The SELLER shall provide the electrical system that incorporates the features and capabilities described below.





• The electrical system shall be operated with the maximum voltages as per Table 3

Table 3 Electrical system voltages

Power 415V 3 Phase 50 Hz

Control 110V/25V Single Phase 50 Hz

Lighting 110V Single Phase 50Hz

Tunnel Supply 3.3KV/11KV 3 Phase 50Hz

• For motors larger than 200kW higher voltages may be used where accepted by the BUYER.

• The TBM shall be equipped with sulphur hexaflouride (SF6) or vacuum high voltages disconnect switches and dual HV to 415V, dry type, air cooled or inert oil filled transformers, with primary adjustable tapings.

• Control equipment enclosures shall conform to BSEN 60529 IP65 and all control components shall be of the same manufacture wherever possible. Any Miniature Circuit Breaker (MCB’s) or Moulded Case Circuit Breaker (MCCB’s) used must conform to BS 60898 set with a safe fault trigger level that will not electrocute personnel.

• Motors shall be totally enclosed, water or fan cooled to BS 5000 and shall be equipped with conventional overload protection and thermistors embedded in the motor windings to be used for trip and alarms via the operator’s console. In the case of electrical main drive motors they shall be water-cooled.

• The motor starting methods shall be selected so as to ensure that large starting currents are avoided, and motors shall be equipped with lockable isolators where supplies are remote. Twin speed drives and soft start system shall be considered.

• The cables used for distribution around the machine shall have the following characteristics;

i) Low Smoke Zero Halogen (LSZH / LSOH). PVC cables are prohibited.

ii) High oxygen index

iii) Minimum acid and corrosive gas emission

iv) Good resistance to oil, abrasion and heat

v) Low smoke emissions.

• The use of these cables shall conform to BS 7375.

• The machines shall be equipped with a flexible trailing cable contained on a powered reeling drum capable of extending preferably up to a minimum of 250 m behind the rear of the backup. If there are space restrictions on the TBM or in the tunnel that make this length of cable extension impracticable, shorter lengths may be considered. The cable shall be fitted with bolted couplers and meet the following general specifications, BS 6360/6899/6469/6708. Pilot and earth monitoring of TBM supply cable is required.

• The TBMs shall be equipped with fixed lighting to provide a minimum of 30 lux in walkways and general access areas and a minimum of 300 lux in the working areas. A minimum of 15 lux emergency egress lighting shall also be provided of 3 hour minimum duration. At least 1 in 3 light fittings shall be emergency light





fittings. The SELLER shall ensure there is sufficient lighting to all areas particularly where there are work stations.

• Emergency lock off stop buttons is to be provided adjacent to moving parts.

• Means of connecting and disconnecting machine for cable extensions without causing loss of essential services required to maintain safety, i.e. twin supplies if necessary.

• All switchgear transformers and protection equipment including power on indication, power metering, and phase rotation indication shall be provided.

• Appropriate power factor correction equipment to ensure that the power factor of the entire electrical load for the construction works is not lower than 0.9 lagging.

• Good access must be provided for isolation and arrangements shall be made such that the main power can be cut off in an emergency.

• Main cable runs shall be segregated from control and communication cables.

• Main earthing system for the TBM must include all gantries. Means of monitoring the connection of the TBM to tunnel earth should be included.

• Where more than one transformer is utilised to supply the TBM, a means of transferring load under outage conditions shall be provided. The transformers shall therefore be sized accordingly.

• Audible and visual warnings shall be used at the start of all moving parts of the TBM equipment where deemed appropriate. This shall include but not be limited to:

i) TBM cutter head.

ii) TBM conveyors.

iii) TBM shove rams in excavation and ring building modes.

iv) Segment erector.

v) Segment magazine.

vi) Segment cranes.

vii) Rail or services cranes

viii) Tunnel train entry and exit from the TBM back-up

• A minimum of 30 minutes back-up power supply shall be available to the segment erector.

8.3 Electrical Equipment

• All enclosures shall be minimum IP65 (if not possible alternative arrangements must be made to provide secondary enclosure). The preferred IP rating for power transformers is IP65. If this is not practicable due to space restrictions, enclosures to a lower IP rating may be acceptable, provided that additional external measures are taken to adequately protect the transformer from the environmental conditions, including water ingress due to burst water hoses or washing down activities that might reasonably be expected in the area.

• Inert oil filled or air cooled transformers are permitted.

• Power transformers should be resin cast or equivalent and the windings arranged in segregated manner (mining standard) to minimise the possibility of short circuits between phases.





• Safety interlocks must be provided between power supply isolators and access to enclosures.

• Each cable shall be securely glanded to enclosures ensuring positive earth continuity using appropriate seals to maintain the integrity of the IP rating of the enclosures.

• The TBM shall be an equipotential zone within which all exposed conductive parts and extraneous metalwork shall be maintained at substantially the same potential by bonding.

• Individual circuits must each be provided with, but not limited to, over current earth fault and short circuit protection.

• Equipment must be readily accessible but located out of danger from being damaged by moving machinery or materials being handled.

• Distribution boards should be well laid out and maintenance friendly, with segregation between bus-bars, outgoing cables etc. (Note: bus-bars to be shrouded).

• Where more than one transformer is to be used, interconnection with the bus- bars should be via a bus-section switch:

i) Interlocked in such a way that the two supplies cannot be paralleled i.e. only 2 of 3 switches can be closed.

ii) Fault rating of the bus-bar to be such as to deal with the worst case conditions.

• Provision shall be made to expand the system (i.e. spare circuit breakers to be provided). Circuit protection shall be simple and reliable.

• E/F supplies to be monitored with indication of failure.

• Grading of E/F protection

i) 750MA, 750MS - Main Distribution

ii) 300MA, 300MS - Sub Distribution

iii) 100MA, 100MS - Fixed Plant

iv) 30MA inst - Socket Outlet

• Every circuit breaker to have locking facility.

• Terminal shrouds to be fitted to all live terminals.

• Gland plates to be bottom entry preferably. Where side entry is used a water cover must be fitted. No top entry to be used.

• All socket outlets to have Residual Current Device (RCD) protection of 30 Milli- Ampere (MA) instantaneous.

• For power tools and lighting the voltage should not exceed 55volts to earth and in confined or damp locations should not exceed 25 volts to earth.

• Earth loop monitoring to be considered in design of circuits controlling the supply to low voltage socket outlets.

8.4 Control System

• All systems must be fail-safe and cater for accidental damage as well as abuse whilst in use. Careful attention should be paid to cabling to ensure damage does not cause inadvertent operation.

• The control systems shall comply with BSEN 292/ BSEN 60204

• Screened cores shall be used in cabling.





• 24v control circuits shall be used for moving equipment e.g. cranes.

• To be designed such that closing a circuit breaker does not start its motor.

• All control circuit trip relays shall be latch type (e.g. thermistors) or latch indication (e.g. overload).

• Relay banks and terminations shall be segregated from power supplies.

• Plant stop relays shall be fail safe design.

• Wire numbers shall be individual.

• Where possible all control circuits and components shall be standardised.

• Monitored pre-start alarms shall be installed for main plant systems.

• Programmable Logic Controller (PLC’s) shall be provided with clean segregated supplies.

• PLC software shall be fully protected from unauthorised access with enforced authorisation for change.

• Solenoid valves shall be sealed from oil and water ingress and be readily tested.

• Remote pendant controls shall incorporate ‘dead man’s’ facility.

• All safety critical functions shall be handled outside PLC’s.

8.5 Cabling

• Shall be designed to be Low Smoke Zero Halon (LSOH) type or equivalent.

• Power cables shall have earth cores and armouring.

• All flexible cables shall be screened.

• A cable handling system is required to ensure that flexible cables to the head of the TBM are supported without unnecessary slack in the cable.

• Cable runs shall be accessible but protected where possible.

8.6 Motors

• Shall be IP 65 rating and shall have 20% latitude above actual full load requirement and fitted with overload cut-outs and trips. Cable link boxes shall be readily accessible.

8.7 Emissions

The TBM SELLER shall arrange for the complete TBM and back-up systems to be tested for electrical emissions in conformance with “The Amended Consolidated EMC Directive reference EMC89/336/EEC” and issued with CE conformance certification.

9 HYDRAULIC SPECIFICATION

9.1 Main Hydraulic Drive Systems.

The main hydraulic drive systems of the TBM shall include but shall not be limited to:

• Cutter head auxiliary functions (e.g. copy cutters, flood doors).

• Articulating ram functions.

• Shove rams.

• Screw conveyor.

• Segment erector.

• Belt conveyors.





• Segment magazine.

• Auxiliary back up functions.

All hydraulic systems shall comply with ISO/DIN technical standards.

9.2 Hydraulic Oil

Only synthetic hydraulic fluids type HFDU shall be permitted within the TBMs hydraulic systems.

9.3 Particular Requirements

• All circuits shall be equipped with pressure test and gauge points. All circuits will be purged and sample tested for cleanliness prior to operation

• All hydraulic tanks shall be provided with automatic valves to allow instantaneous isolation of individual circuits in the event of substantial leakage. They shall also be provided with high and low level oil warnings and cut outs. All tanks shall have easily accessible removable manholes to allow cleaning of tanks. All tank breathers shall have filters.

• High temperature cut out (deemed to be in excess of 60 degrees centigrade).

• Oil containment trays shall be fitted under tanks.

• Each tank shall have Pressure and return line filters, the return lines 25 micron filtration the pressure lines shall have 10µsize. With an off line water separation, 3 micron filtration and or centrifuge package.

• Hydraulic tank filling will be via a filter.

• Water to oil cooling systems is preferred.

• All main hydraulic circuits shall be supplied with devices to monitor:

i) The pressure in the system.

ii) The oil temperature.

iii) The condition of pressure and return line filter elements.

• Wherever possible, hydraulic piping shall be rigid metal tubing and the use of flexible steel reinforced hose shall be kept to a minimum.

• Wherever possible, in hydraulic circuits, valves shall be provided to allow removal and repair of components without stopping the operation of the TBM.

9.4 Articulation

• Active type: oil pressure shall not exceed 350 bars in the form of intensification due to the cutting and pushing forces.

• Passive type: oil pressure shall not exceed 350 bars in the form of intensification from the towing forces.

9.5 Shove Rams

There shall be 3 modes of operation:

• Shove mode. In shove mode the maximum oil working pressure shall be 350 bars.

• Fast retract for ring building.





• Segment erection. In segment erection mode the working pressure shall be variable to balance the face pressure with 50 bars being the nominal maximum (this shall be an active pressure).

10 SAFETY

10.1 Regulations

The design and manufacture of the TBM and back-up systems shall comply with all applicable Legislation and Regulations, relevant Codes of Practice relating to safety and relevant British and European Standards including, but not limited to, those described below. The SELLER shall always use the latest published version of any Regulation or Standard that relates to health and safety.

1) Health and Safety at Work Act 1974. 2) The Health and Safety at Work etc. Act 1974 (Application to Environmentally

Hazardous Substances)(Amendment) Regulations 2009. 3) The Management of Health and Safety at Work Regulations 1999. 4) The Management of Health and Safety at Work (Amendment) Regulations 2006. 5) The Workplace (Health, Safety and Welfare) Regulations 1992. 6) The Health and Safety (Display Screen Equipment) Regulations 1992. 7) The Provision and Use of Work Equipment Regulations 1998. 8) The Lifting and Lifting Equipment Regulations 1998 9) The Work at Height Regulations 2005 (as amended) and The Work at Height

(Amendment) Regulations 2007 and Correction 4/11/11. 10) The Noise at Work Regulations 2005. 11) The Control of Vibration at Work Regulations 2005. 12) The Control of Noise at Work Regulations 2005. 13) The Health and Safety (Safety Signs and Signals) Regulations 1996. 14) The Dangerous Substances and Explosive Atmospheres Regulations 2002. 15) The Control of Substances Hazardous to Health Regulations 2002 including

Amendments of 2003, 2004. 16) BS EN 12336:2005+A1:2008 Tunnelling machines. Shield machines, thrust boring

machines, auger boring machines, lining erection equipment. Safety requirements. 17) BS EN 12110:2002+A1:2008 Tunnelling machines. Air locks. Safety requirements. 18) 10/30234293 DC BS EN 12110. Tunnelling machines. Air locks. Safety requirements

(the new specification under review). 19) BS 6164:2011 Code of practice for Safety in tunnelling in the construction

industry. 20) The Work in Compressed Air Regulations 1996. 21) BTS “Guide to the Work in Compressed Air Regulations 1996” of June 2012. 22) ITA Report No 10 Joint ITA / BTS CAWG “Guidelines for Good Working Practice in

High Pressure Compressed Air” ITA Working Group No5 Health & Safety in Works of Feb 2012.

23) The Construction (Design and Management) Regulations 2007. 24) The Personal Protective Equipment Regulations 2002. 25) The Regulatory Reform (Fire Safety) Order 2005. 26) The Regulatory Reform (Fire Safety) Subordinate Provisions Order 2006. 27) EH40/2005 Workplace exposure limits Second Edition 2011. 28) BS EN ISO 9000:2005 Quality management systems. Fundamentals and vocabulary,

and BS EN 9000:2008 Quality management systems. Requirements. 29) BS EN 60079 Electrical apparatus for potentially explosive atmospheres including

relevant sections of the following :





30) BS EN 60079-0:2012 Explosive Atmospheres. Equipment. General requirements. 31) BS EN 60079-1:2007 Explosive atmospheres. Equipment protection by flameproof

enclosures "d" including 11/30247086DC Explosive atmospheres. Part 1. Equipment protection by flameproof enclosures “d”.

32) BS EN 60079-2:2007 Explosive atmospheres. Equipment protection by pressurized enclosure "p".

33) BS EN 60079-5:2007 Explosive atmospheres. Equipment protection by powder filling "q" including 12/30267444DC Explosive atmospheres. Part 5. Equipment protection by powder filling 0Qq0R.

34) BS EN 60079-6:2007 Explosive atmospheres. Equipment protected by oil immersion "o".

35) BS EN 60079-7:2007 Explosive atmospheres. Equipment protection by increased safety "e".

36) BS EN 60079-10-1:2009 Explosive atmospheres. Classification of areas. Explosive gas atmospheres.

37) BS EN 60079-10-2:2009 Explosive atmospheres. Classification of areas. Combustible dust atmospheres.

38) BS EN 60079-11:2012 Explosive Atmospheres. Equipment protection by intrinsic safety “I” including 09/30212062DC Explosive atmospheres. Part 11. Equipment protection by intrinsic safety "i".

39) BS EN 60079-13:2010 Explosive atmospheres. Equipment protection by pressurized room "p".

40) BS EN 60079-14:2008 Explosive atmospheres. Electrical installations design, selection and erection including 12/30269297DC Explosive atmospheres. Electrical installations design, selection and erection.

41) BS EN 60079-15:2010 Explosive atmospheres. Equipment protection by type of protection "n".

42) BS EN 60079-17:2007 Explosive atmospheres. Electrical installations inspection and maintenance including 12/30268608 Explosive atmospheres. Electrical installations inspection and maintenance.

43) BS EN 60079-18:2009 Explosive atmospheres. Equipment protection by encapsulation "m".

44) BS EN 60079-19:2011 Explosive atmospheres. Equipment repair, overhaul and reclamation.

45) BS EN 60079-20-1:2010 Explosive atmospheres. Material characteristics for gas and vapour classification. Test methods and data.

46) BS EN 60079-25:2010 Explosive atmospheres. Intrinsically safe electrical systems. 47) BS EN 60079-26:2007 Explosive atmospheres. Equipment with equipment protection

level (EPL) Ga. 48) BS EN 60079-28:2007 Explosive atmospheres. Protection of equipment and

transmission systems using optical radiation. 49) BS EN 60079-29-1:2007 Explosive atmospheres. Gas detectors. Performance

requirements of detectors for flammable gases. 50) BS EN 60079-29-2:2007 Explosive atmospheres. Gas detectors. Selection,

installation, use and maintenance of detectors for flammable gases and oxygen. 51) BS EN 60079-29-3 Explosive atmospheres. Part 29-3. Gas detectors. Guidance on

functional safety of fixed gas detection systems including 12/30247700DC Explosive atmospheres. Part 29-3. Gas detectors. Guidance on functional safety of fixed gas detection systems.

52) BS EN 60079-29-4:2010 Explosive atmospheres. Gas detectors. Performance requirements of open path detectors for flammable gases.

53) BS EN 60079-30-1:2007 Explosive atmospheres. Electrical resistance trace heating. General and testing requirements.





54) BS EN 60079-30-2:2007 Explosive atmospheres. Electrical resistance trace heating. Application guide for design, installation and maintenance.

55) BS EN 60079-31:2009 Explosive atmospheres. Equipment dust ignition protection by enclosure "t” including 12/30261858DC Explosive atmospheres. Equipment dust ignition protection by enclosure "t".

56) BS EN 60079-35-1:2011 Explosive atmospheres. Caplights for use in mines susceptible to firedamp. General requirements. Construction and testing in relation to the risk of explosion.

57) BS EN 60079-35-2:2012 Explosive atmospheres. Caplights for use in mines susceptible to firedamp. Performance and other safety-related matters.

58) BS EN 50402:2005+A1:2008 Electrical apparatus for the detection and measurement of combustible or toxic gases or vapours or of oxygen. Requirements on the functional safety of fixed gas detection systems.

59) The Supply of Machinery (Safety) Regulations 2008 and The Supply of Machinery (Safety) (Amendment) Regulations 2011.

60) BS EN 981:1996+A1:2008 Safety of machinery. System of auditory and visual danger and information signals.

61) BS EN 60034-9:2005 Rotating electrical machines. Noise limits. 62) BS EN ISO/IEC 17050-1:2010 Conformity assessment. Supplier's declaration of

conformity. General requirements. 63) BS EN 61310-1:2008 Safety of machinery. Indication, marking and actuation.

Requirements for visual, acoustic and tactile signals. 64) BS EN 1012-1:2010 Compressors and vacuum pumps. Safety requirements. Air

compressors. 65) BS EN 1012-2:1996+A1:2009 Compressors and vacuum pumps. Safety

requirements. Vacuum pumps. 66) BS EN ISO 1688-1:2009 Acoustics. Recommended practice for the design of low-

noise machinery and equipment. Planning. 67) BS EN ISO / TR 11688-2:2001 Acoustics. Recommended practice for the design of

low-noise machinery and equipment. Introduction to the physics of low-noise design. 68) BS EN 620:2002+A1:2010 Continuous handling equipment and systems. Safety and

EMC requirements for fixed belt conveyors for bulk materials.

10.2 Fire prevention

1) The SELLER and the TBM manufacturer shall jointly undertake a fire hazard assessment to identify and mitigate all potential fire sources. The assessment shall be included in the TBM Design Statement submitted to the Project Manager.

2) Subject to the conclusions of the hazard assessment, the TBM and back-up systems shall be provided with:

a. The fire suppression system which shall be suitable to mitigate the risks identified in the hazard assessment.

b. Emergency plunger buttons at suitable locations to activate a fire alarm. c. Electrical Cabinets and enclosures shall be fitted with automatic fire

suppression systems. d. The TBM shall be equipped with manual fire suppression systems in

areas identified to have a high fire risk. e. Hand held extinguishers provided with colour coded covers in suitable

locations. f. A means of rapidly shutting off fresh air ventilation to the tunnel face,

after the area has been evacuated.





g. Operation and training manuals for use by the SELLER. h. Conveyor belting, rubber covered rollers and other similar parts to

be manufactured in materials that reduce the fire risk, fire load, spread of flame and toxic fume risk.

i. Hydraulic hoses shall comply with BS EN 853 / ISO 1436. The hose covers shall be flame retardant and conform to the requirements of USMSHA. All hydraulic hoses shall be fitted with swaged end connections, re-usable fittings are not permitted.

j. Rubber covered rollers and other similar parts to be manufactured in materials that reduce the fire risk, fire load, spread of flame and toxic fume risk.

k. Gas monitoring for oxygen deficiency and gasses including CO2, CO, H2S, NO, NO2, SO2 and CH4..

l. Smoke detection and rate of temperature rise. m. Water mist screen shall be positioned at the rear of the back-up system. n. Low density foam generators shall be sited at high fire risk areas

with either automatic or manual operation in the event of fire. o. Spraying nozzles to be installed at the last sledge to create an anti-

smoke curtain in case of fire in the tunnel. 3) Essential services shall be protected in the event of a fire so that they remain

operable during all tunnelling operations for a period of 1 hour. The essential services are:

a) Emergency power supplies. b) All fire suppression systems c) TBM emergency lighting. d) Environmental monitoring systems e) All controls and tunnel communications. f) The security of the air supply and control systems to the man lock

shall remain operable in all emergencies including a fire.

10.3 BUYER Control and Interlocks

10.3.1 TBM

The TBM cutter head shall be prevented from moving at any point during any maintenance or entry. An interlock shall be provided between the control cabin and air lock so that direct inching of the cutter head for maintenance operation can be undertaken from the air lock. It will be the responsibility of the maintenance foreman to ensure that all personnel have evacuated the cutter head and front chamber before any movement is undertaken.

This provision is intended to assist cutter tool changes with local indexing of the cutter head. The cutter head drive shall have fail to safe braking to prevent inadvertent movement.

10.3.2 Shove Rams and Erector.

The shove rams shall be controlled from the main control cabin during the excavation cycle and from the erector control pendant during the ring building cycle. An interlock shall be provided between the TBM driver and segment erector operator such that operation is given by the TBM driver to the erector driver by switching to prevent duplicate operation of the shove rams. Transfer of control shall lie with the erector driver.





• Operation of any functions using the erector remote control (pendant) shall be achieved only by simultaneous dual switching of the enable button and the function button. The remote control shall incorporate the indexing of segments forward from the magazine during ring building. Control of the magazine shall be transferred to the crane driver during the excavation.

• All erector load-holding functions shall fail to safe. Rotational drives shall be fitted with fail safe brakes with appropriate systems for checking the brakes.

• The segment erector shall be fitted with the selection and audibility of safe lifting alarms.

• An interlock that prevents extension of the shove rams should grout delivery through the tail skin be interrupted or blocked. It shall incorporate a method of automatically data logging and measuring volume and pressure of grout injected per tunnel lining ring.

10.3.3 Interlocks

The status of interlocks shall be recorded in the control and monitoring system.

11 QUALITY ASSURANCE REQUIREMENTS

• The TBM SELLER shall operate an independently approved Quality Management system in accordance with the requirements of ISO9001. The Quality Management system shall provide procedures for design, manufacturing, testing, commissioning, and maintenance of the TBM. It shall provide documentary evidence that tests and inspections specified are undertaken and the specified standards have been achieved.

• Within four (4) weeks of award of the Purchase Order, the TBM SELLER shall submit a preliminary quality plan. The preliminary plan shall indicate the approach and structure that the detailed plan will take with respect to the design and supply of the TBMs and shall include but not limited to:

i) All quality assurance and quality control procedures which are to be use in the design, manufacturing, commissioning and maintenance of the TBM. The procedures shall cover, but not be limited to design checks, inspection and test plans, and details of steel plate identification and testing, weld testing and welding procedures.

ii) A list of all the Codes of Practice, Standards and Specifications that is proposed to apply where they may differ from or complement the requirements of this Minimum Requirements document or where the Purchase Order requires that they be proposed.

iii) Quality assurance audit proposals.

iv) A statement detailing the records that the SELLER proposes to keep and those that the SELLER proposes to supply, the time during which they will be prepared and the subsequent period and manner in which they will be stored.

v) Inspection and test plans for every activity requiring inspection. The plans shall identify the level of inspection required and who is responsible for releasing an activity from a “Hold Point”.

• Within 12 weeks of award of Purchase Order the SELLER shall provide a detailed quality plan to the BUYER.





• The SELLER shall update the detailed Quality Plan from time to time to incorporate all changes to the TBM related procedures.

• Periodically during the currency of the Purchase Order the BUYER will conduct compliance audits on the activities relating to the design and supply of the TBM, based on ISO 19011 ‘Guidelines for quality and/or environmental management systems auditing’. Throughout the audit process the SELLER shall provide suitably qualified staff to assist the audit team.

12 PERFORMANCE REQUIREMENTS

The TBM SELLER shall demonstrate that each TBM is capable of complying with the minimum performance factors described in this section.

12.1 Boring Rates of Advance

The instantaneous rate of advance corresponds to the boring of the width of the tunnel lining. The TBM shall be capable of achieving after six (6) weeks of learning curve or 200 m of completed tunnel:

• Open Mode: 22.5 minutes. (Instantaneous boring rate of 8 cm/min.

• Closed Mode: 30 minutes. (Instantaneous boring rate of 6 cm/min.

12.2 Shove Ram Retraction

Provision shall be made to fast retract and extend individual or groups of rams, to allow the starting of tunnel ring erection within 5 minutes of completing the shove stroke.

12.3 Tunnel Lining Supply and Erection

The duration for the building of one ring of segments is defined as the period from engagement of the first segment by the erector to release of the key segment and the tightening of bolts. This duration shall not be greater than 30 minutes.

12.4 Rates of Advance - Performance - Monitoring

• The average rates of advance shall be calculated by measuring the duration of time to advance twelve successive strokes. The time shall be measured from the beginning of the first boring stroke to the placement of the final segment. All auxiliary operations, including tunnel segment grouting, tail seal greasing, segment feeding and unloading shall be included within the performance monitoring.

• The maximum time to undertaken twelve strokes in succession for all ground conditions shall be (min. stroke 2500mm):

i) Open Mode: 12 hours.

ii) Closed Mode: 13hours.

The above performance shall be achieved within the first two (2) months of tunnel boring for each TBM, and shall be maintained thereafter.

A cyclogramme of tunnelling operations, including all operations connected with the tunnelling advance shall be submitted to the BUYER.





12.5 Machine Availability

• The TBMs shall be designed to achieve a minimum of 95% machine availability excluding planned maintenance periods.

• Availability shall be the time when the TBM and all its associated systems are ready for use and shall be expressed as: Availability A= [100 (T-P)] / T. Where T= the time period measured. P = the time the machine is unable to work.

• The TBM SELLER shall provide all service components and personnel to assist the BUYER in achieving the TBM performance and availability requirements throughout the duration of the tunnel drives. To maximise TBM availability and performance the TBM SELLER ensures that the following is provided to the BUYER:

i) Maintenance advice and supervision to the BUYER.

ii) Daily monitoring of equipment and early warning of maintenance requirements.

iii) Training of BUYER’s operatives and maintenance personnel.

iv) A maintenance manual detailing the design life of major components in order to establish a spare parts provision regime and to implement a preventative maintenance regime.

v) Consignment spares held on site or in a readily available location to ensure the TBM availability. They shall comprise project critical items of spare and wear parts.

13 OPTIONAL SUPPORT EQUIPMENT

SELLER is encouraged to provide alternative proposal(s) considering Optional Support Equipment for surface and or tunnel TBM related operations; that SELLER is capable to supply in addition to the TBMs.

A sample list of support equipment is provided below; however SELLER is encouraged to recommend additional support equipment as it deems applicable for the proposed TBMs.

BUYER shall consider alternative proposals with Optional equipment as its discretion.

• Tunnel belt conveyors to transport the spoil. Tunnel belt systems shall incorporate the following features:

• Capacity to match maximum capacity of TBM to produce spoil plus a suitable margin.

• Belt truss suspended from the tunnel lining.

• Alignment as per tunnel alignment.

• Basic requirements as per the conveying systems associated with the TBM (see Section 4.4).

• HACs (High Angle Conveyors) to transport the spoil from shaft bottom to surface, and

• Surface Conveyors to move the spoil to the chosen transportation position

• Gantry Cranes to service the tunnel

• Surface compressors to service the tunnel

• Ventilation and chiller systems to service the tunnel

• Cooling system for the water cooled equipment on the TBM

• Tunnel locomotives and rolling stock to service the tunnel and TBMs.

Recommended Bidders list - Tunnel Boring Machines Page 1 of 1


** CONFIDENTIAL **

RECOMMENDED BIDDERS LIST

TUNNEL BORING MACHINES

No. Bidder

Company Address City Country Contact Phone

1 Herrenknecht Schlehenweg 2 , 77963 Schwanau

Baden GERMANY Roy Slocombe +49 7824 3020

2 NFM Technologies

5, Place Jules Ferry, Le Lugdunum, 69006

Lyon FRANCE Frank Houcard +33426848745

3 Robbins Westheimer Street 34

Zell GERMANY Detlef Jordan +49 07164 14940 17

Documents

TBM Specifications