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ISTANBUL STRAIT ROAD TUNNEL CROSSING

Werner Burger, Herrenknecht AG, Schwanau.

AFTES Journées Techniques, Lyon, October 16, 2015

Herrenknecht. Pioneering Underground Technologies

Istanbul Strait Road Tunnel

Project Location


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Tunnel Design

Single Tube, twin deck double track for light vehicles only

Inner diameter 12 m, Segment thickness 0,6 m



Project Key Requirements

Restricted access from above most of the tunnel alignment below the

Bosporus Strait

Very large TBM diameter 13,71 m

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

– transition zones

Very high face pressure >10 bar



Project Requirements – Past Experience (State of Art)

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

ground conditions; face pressure 5,5bar

Westerschelde large diameter 11,4 m; long distance

tunnel; face pressure 7,5bar; saturation diving

Chongming very large diameter 15,4 m; long distance

tunnel; face pressure 7bar

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

pressure 14 bar



Selected TBM Concept

Mixschild, for variable ground

conditions with very high face pressure

Accessible cutterhead for atmospheric

maintenance on primary cutter sets

Full equipment for „conventional“

chamber access up to 4 – 5 bar

Full equipment and preparation for

saturation diving at higher face

pressures (shuttle transfer)


Istanbul Strait Road Tunnel - TBM Design Target

Minimization of The Necessity of Chamber Interventions

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

development program

Monitoring / Sensor Systems

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

unit

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

cutter condition

Mechanic wear monitoring system for each disc cutter

Multiple level mechanic wear monitoring system for cutterhead structure

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

cutterhead plates

Permanent installed excavation chamber camera system


Istanbul Strait Road Tunnel - TBM Design Target

Minimization of The Necessity of Chamber Interventions

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

development program

Maintenance

Submerged wall gate for atmospheric crusher maintenance

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

and soft ground tool coverage ( primary cutter sets)


Istanbul Strait Crossing TBM

Cutterhead Features

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main spoke, atmospheric accessible

auxiliary spoke, conventional

19” twin disc cutter, atmospheric exchange

with monitoring system

scraper tools, atmospheric exchange

scraper tools, conventional

bucket lips, conventional

multi level sectorized wear detection loops


Access down into cutting

arm spoke.

Operator undertakes

maintenance in free air

without the risk of having

to work at the tunnel

face.

Back loading

cutting tools.

Non - Exposure Maintenance Solutions

Accessible Cutterhead for “Atmospheric Cutterchange”

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Non - Exposure Maintenance Solutions “Atmospheric Cutter Change”

System for large diameter Mixshields with

accessible cutter head structure

First use in 1996 (Elbetunnel)

Full face disc cutters 17” or 19”

Full face for disc cutters and soft ground tools

Individual tool condition and wear sensors

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Cutterhead Elbetunnel, now in front of the

Museum of Work in Hamburg


19“ Disc cutter fixture for atmospheric

cutter change

Scraper tool fixture for atmospheric

cutter change

Cutter head spoke structure, accessible from

inside


Accessible Cutterhead for Eurasia Tunnel TBM Istanbul, Turkey

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Transport of disc cutter

cartridge inside

cutterhead

Installing cutter cartridge

in outer housing

Opening of frontgate and

push cutter cartridge in

working position

Atmospheric Cutter Change

Shop Test and Training in the Factory



On-Site Cutter Change Eurasia Tunnel TBM Istanbul, Turkey

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Disc Cutter Monitoring System

Mixshield-TBM with Accessible Cutterhead

IPC

Monitoring-unit

Control cabin

Data line Receiver

Sensor-unit

Radio

signals

Individual monitoring-unit for each disc cutter

Radio transmission to repeater / receiver

Data transfer from receiver to IPC

Data analysis + status display (control cabin)

Battery

CS


Status indication of disc cutter

with temporary no rotation

Status indication of

critical values

Disc Cutter Monitoring System

Data processing and visualization


Shuttle transport through

tunnel on MSV

Hydraulic lift to

upper gantry deck

Motorized shuttle

transport through gantry

Front lifting table to

docking position for

transport shuttle

Permanent airlock Transport shuttle

in docking position

Saturation Process

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

Istanbul

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Hydraulic lifting system

from MSV to gantry

middle deck

Motorized transfer

through gantry

Hydraulic lifting system to

docking flange at shield

airlock

Saturation Process

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

Istanbul


“Non – Exposure – Maintenance” Solutions

Mixshield Submerged Wall Gate for Crusher Maintenance

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Submerged wall gate open Submerged wall gate closed


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Crusher Maintenance

Diver at 9 bar pressure cleaning invert in

preparation for gate closure

Work on crusher and suction grid under

free air conditions


Istanbul Strait Crossing TBM

Face Pressure Along The Drive

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25.4.2014 22.8.2015


THANK YOU FOR YOUR ATTENTION.

[email protected]

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