Transcript
Page 1: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Risk Management - TBM Manufacturer’s

Perspective II

November 14-16, 2016

Page 2: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

History of LOVSUNS

350 TBMs Built to Date

Page 3: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

History of Risk Management Techniques

Developed in the Late 60’s by NASA

during the Apollo Mission

In 1974, US Navy Adopted it in the

Weapons Program

In the Late 1970’s the Automotive

Industries was Driven by Liability Cost

to Use FMEA and Later Required

Suppliers to do the Same

Page 4: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Types of Risk Assessment

System Risk Assessment

Highest Level Risk Assessment and Focus on System Related Deficiencies

such as Safety System, System Interfaces or Integration between

Subsystems to Humans and/or Environment.

Design Risk Assessment

Focuses on Product Design with Emphasis on Minimizing Design Risk and

Ensuring Product Operation is Safe and Reliable During Equipment life.

Process Risk Assessment

Focuses on Operation or Assembly Process with Emphasis on how

Process Risk can be Minimized to Ensure the Product is Built to Design

Requirement in a Safe Manner with Minimal Downtime, Waste and Rework.

Page 5: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Types of Risk Assessment

1.0 RME257SE EPB TBM

1.1 Cuttinghead System

1.2 Main Drive System

1.3 Main Drive Sealing System

1.4 RFJ System

1.5 Active Articulation System

1.6 Passive Articulation System

1.7 Airlock System

1.8 Propulsion System

1.8.1 Propulsion Cylinders

1.8.2 Propulsion Pump

1.8.3 Propulsion Manifolds

1.8.4 Propulsion Pads

1.9 Screw Conveyor System

System Level Item

Identification

Design Level Item

Identification

Page 6: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Conducting Risk Assessment Analysis

Risk Management Process should be Part of your Project Management

Plan and should Start at the Project Planning Stage:-

Key Inputs Required

- Project Charter

- Project Management Plan

- Stakeholder Register

- Enterprise Environmental factors

- Organizational Process Assets

Page 7: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Tips

- Break it Down (by System, by Function, by Process)

- Agreed on a Scaling System First

- Draw From Past Successes and Failures

- Involve the Right People (SME)

- Do it in Multiple Sessions

- Take a Course in Conflict Resolution and How to Manage a Meeting

The Process Does Get Easier the Third Time Around!!!

Conducting Risk Assessment Analysis

Page 8: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

TBM Supplier’s Perspective on Risk

Management

Page 9: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

TBM Supplier Risk Management

TBM Manufacturer’s Roles in Project Risk Management

Solution provider

- Types of TBM

- Features on TBM

- Technical Assistance

- Spare Parts Support

Page 10: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

TBM Supplier’s Risk Management

- GBR and Tunnel Alignment

- Equipment Specification and Performance

- Equipment Delivery

- Operation and Maintenance

- Contract Terms

Needed to provide the right tools for

the Project!!!

Page 11: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

GBR and Tunnel Alignment

Detail Geotechnical Baseline Report containing at a minimum:-

- Quantity and Depth of Bore Hole Analysis

- Groundwater Condition (Expected Inflow and Pressure)

- Grain Size Distribution

- Rock Strength and RMR

- Boulders, Faults, Obstacles along Alignment

- Operating and Maximum EPB Pressure

- Presence of Hazardous Gas

Alignment Details Containing at a minimum:-

- Tunnel Lengths and Shaft/Portal details

- Maximum Vertical Slope and Minimum Horizontal Radius

- Segment Details

Page 12: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Equipment Specification and Performance

- Owner’s requirement – Typically very Descriptive

- Local Regulatory Standards and Requirement

- Contractor’s Equipment Requirement and Performance

Expectation

- Manufacturer’s Past Experience and Internal Standards

- Transportation, Assembly and Disassembly Restrictions

Page 13: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

EPB TBM Features that can assist to Mitigate Risks

- Cuttinghead Design

- Tool Selection

- Airlock

- EPB Sensors

- Ground Conditioning

- Probe Drilling

- Emergency Inflatable Seal

- Data logging

Equipment Specification and Performance

Page 14: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

•14mm thick CrC on Cuttinghead Face

•19mm thick CrC on Cuttinghead Rim

•5 No. injection ports on Cuttinghead face

•1 No. Injection ports on Cuttinghead Gauge

•Interchangeable Rippers and Disc Cutters

•Wear detection on face of Cuttinghead

•Cuttinghead opening

32%~35%

•Center opening as 50% to

Reduce clogging in the

center

Cuttinghead Design

Page 15: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Disc Cutters

Single tip and Twin tip type disc cutters used for mixed ground conditions containing

boulders & hard rock.

Different disc cutter tip spacing are used to cut the rock efficiently.

Lovsuns Tunneling provides 12.0”,13.0”,15.0”, 15.5” & 17” Single tip, Twin tip and

Center cutters with replaceable rings.

Tool Selection

Page 16: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Tool Selection

Rippers

Used in Soft Ground

Three Styles for different grounds (Clay, Weak Rock and Abrasive soil)

Main Excavation tool for EPB

Pressurized Oil Circuit

Page 17: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

EPB Sensors

Additional EPB Cells

on top of Forward Shell

6 No. EPB Cells Inside

Cuttinghead Chamber

2 No. EPB Cells Inside

Screw Conveyors

Page 18: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

GROUND CONDITIONINGWhen a ground type does not have the ideal characteristics of fluidity

and plasticity, ground conditioning can be used to modified &

improve its ability to transmit the confinement pressure.

Page 19: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

GROUND CONDITIONING SYSTEM

Page 20: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Probe Drill or Polarization Ground Detection

Technique

Page 21: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Probe Drill or Polarization Ground Detection

Technique

Page 22: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Emergency Inflatable Seal

Page 23: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

TBM DATA LOGGING

Web Edition

Windows

Server

(SQL)

Tunnel TBMSurface (Site Location)

Tunnel Media

LOVAT Supplied Hardware LOVAT Supplied HardwareHMI / Operators Interface

PLC / Data Acquisition Module

Firewall

InterNet

Remote (Off Site)

Site LAN

(Local Area Network for TBM)

Remote (Off Site)

Hosting of Data

Optional End User Supplied Hardware

Remote Client Connection(s) Remote Client Connection(s)

Hosting of Data

Note:

The EtherNet within the TBM, wireless and plug in both can

facilitate the connections of PC’s/Laptops to support the hosting of

data.

LAN Edition

Windows

Server

(SQL)

Tunnel TBMSurface (Site Location)

Tunnel Media

LOVAT Supplied Hardware LOVAT Supplied HardwareHMI / Operators Interface

PLC / Data Acquisition Module

Remote (Off Site)

Site LAN

(Local Area Network for TBM)

Remote (Off Site)

Hosting of Data

Optional End User Supplied Hardware

Note:

The EtherNet within the TBM, wireless and plug in both can

facilitate the connections of PC’s/Laptops to support the hosting of

data.

Generic

Workstation

Notes:

1. This package can operate “standalone”, as delivered

2. Connection of Client Workstations rely on the infrastructure provided by the client.

System Parameters

Cutterhead Speed, Torque, Direction, Hours, Flood Door

Opening

Articulation Extension, Cylinder Pressure, Total Thrust,

Center of Thrust/Offset

Propulsion Extension, Cylinder Pressure, Total Thrust,

Center of Thrust/Offset

Main Drive Main Bearing Lube Flow, Sealing Systems Flow

and Pressures

Forward Shell Chamber Earth Pressures

Screw

Conveyor

Speed, Torque, Earth Pressures, Guillotine Gate

Position

Trailing Belt

Conveyor

Excavation Rate, Excavated Material Totalizer

Ground

Conditioning

System Output Totals, Injection Pressures and

Flow Rates

Grout System Injection Pressures and Accumulated Volumes,

Rate

Environmental Methane and Toxic Gases

Hydraulic

Systems

Oil Temperatures, System Pressures

Electrical

Systems

Motor Current Loads, TBM Power Monitoring

(kVA, kW, PF, Amps and Volts)

Page 24: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Additional Features

Other TBM Features that can help Mitigate Risks

- Emergency Bentonite System

- Enhanced De-watering System

- Explosion Proof Design

- Internal Disassembly or Bearing Replacement Design

Page 25: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Equipment Delivery

TBM Delivery is often on the Project’s Critical Path

Currently there are two type of Equipment Procurement Model

- Owner Procured

- Contractor Procured

Delivery Risk for TBM Supplier

- Major Component Delivery (i.e. MD Bearing, Gear boxes)

- Workshop Capacity

- Project Management

Page 26: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Major Components Supplier ListS/N KEY TBM COMPONENTS MANUFACTURER REMARKS

1

MAIN DRIVE

(ELECTRIC MAIN DRIVE)

MAIN BEARING SKF / ROTEK FRANCE / USA

2 GEAR REDUCER REXROTH /MITSUI MIIKE GERMANY / JAPAN

3 VFD MOTORS SIEMENS (LOHER) GERMANY

4 VFD DRIVE ABB ABB CHINA

5 GREASE PUMPS GRACO USA

6 MAIN BEARING SEALS MERKEL GERMANY

7

MAIN DRIVE

(HYDRAULIC MAIN DRIVE)

MAIN BEARING SKF / ROTEK FRANCE

8 HYDRAULIC MOTORS SAUER DANFOSS / REXROTH GERMANY

9 GEAR REDUCER REXROTH /MITSUI MIIKE GERMANY/ JAPAN

10 HYDRAULIC PUMPS PARKER USA

11 ELECTRIC MOTORS SIEMENS (LOHER) GERMANY

12 HYDRAULIC VALVES PARKER / REXROTH etc. USA / GERMANY

13 GREASE PUMPS GRACO USA

14 MAIN BEARING SEALS MERKEL GERMANY

15

Screw Conveyor

DRIVE MOTORS SAUER DANFOSS / REXROTH GERMANY

16 GEAR REDUCERBONFIGLIOLI / REGGIANNA

RIDUTTORI ITALY

17

PROPULSION SYSTEM

PROPULSION CYLINDERS JIANGSU HENGLI /SHANGHAI

LONGGONG CHINA18 ARTICULATION CYLINDERS

19 HYDRAULIC VALVES PARKER / REXROTH etc. USA / GERMANY

20

ELECTRICAL PARTS

TRANSFORMER SCHNEIDER SCHNEIDER CHINA

21 POWER COMPENSATION

EATON / CUTTLER-HAMER / ABB

USA / GERMANY22

DISTRIBUTION CABINENTS

COMPONENTS

23 PLC COMPONENTS ABB USA

24 GROUT SYSTEM INJECTION PUMPS WATSON MARLOW /SUG USA / GERMANY

25

SEGMENT ERECTOR

GEAR REDUCERBONFIGLIOLI / REGGIANNA

RIDUTTORI ITALY

26 HYDRAULIC MOTORS PARKER / REXROTH USA / GERMANY

27 HYDRAULIC COMPONENTS PARKER / REXROTH / HAWE etc. USA / GERMANY

28 GUIDANCE SYSTEM TOTAL STATION TACS GERMANY

29 OPERATING SYSTEM OPERATING COMPUTER DELL USA / CHINA

30 COMPRESSED AIR SYSTEM AIR COMPRESSOR ATLAS COPCO ATLAS COPCO CHINA

31 GROUND CONDITIONING SYSTEM FOAM PUMP SEEPEX / MOYNO SEEPEX / MONYO CHINA

NOTE: FINAL SUPPLIER SUBJECT TO CONTRACTUAL TBM DESIGN SPECIFICATION AND AVAILABILITY

Page 27: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Liaoyang Facility, China

Key Purchased &

Manufactured Components

Engineering

Project Management

Production Support

Manufactured Components

Page 28: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Project Management

Project Management and Project Planning

• Follows PMOK Methodologies.

• Develop the Project Charter

• Identification of Work Breakdown Structures

• High Level Planning with Control Team

• Identify high level critical path

Page 29: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Project Planning• Detailed Planning – over 2000 activities per project

• Network Diagrams – establish activity relationships

• Validation Sessions

• Setting the Baseline

• Establish Controlling Paths

Page 30: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Project Monitoring

• Weekly control cycle to monitor progress Issues addressed immediately

Maintain continuous team focus on target completion date

• Reporting activity status via Web Based Updates

• Accountability – people responsible are reporting

Page 31: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Project Control

• Weekly Control Meetings

Successes & Current Events

Controlling Paths

Start & Finish On-Time Metrics

Project Variance

Near Term Critical Activities

Status of Critical Purchased Items

Financial Review

Review of Old Action Items

Creation of New Action Items

• Status Memo - Company Wide

• Compression Sessions

• Senior Management Reviews

Page 32: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Project Closure – Post Mortem

Page 33: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Traditional TBM Technical Support Model

- Factory Training

- Support on TBM Assembly led by Manufacturer’s

Technicians

- Technical Support on Initial 200m drive led by

Manufacturer’s Technicians

- Remote troubleshooting

TBM Operation and Maintenance

Page 34: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Current TBM Support Model to Increase Risk mitigation

TBM Supplier to Train, Assist and Conduct TBM Preventative

Maintenance to ensure Maximum Productivity and Minimize

Downtime

Support TBM until Performance Requirement is met or until

Tunnel Completion

Field Service Technician dispatch to jobsite with 24 hours

notice for emergency troubleshooting

TBM Operation and Maintenance

Page 35: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Consignment Parts

- On site (Critical Spare parts, Job Stoppers)

- In Factory (Main Drive Bearing, Gear boxes)

Establish Local Repair and Supply for Long Term support

TBM Operation and Maintenance

Page 36: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

TBM Contracts

Contract has the Potential to Create Many Risks that are often

overlook

Trend is to Transfer more Risk Downstream to TBM Supplier.

- Increase Total Liability to Equipment Supplier

- Collateral Warranty to allow Project Owner to claim against

TBM supplier

- APG, LCs

- Performance Guarantee

TBM Supplier is working with Contractors much Sooner in their

tender Process.

Page 37: Risk Management - TBM Manufacturer’sundergroundriskmanagement.com/pdfs/2016-presentations/pres-21.pdf · Risk Management - TBM Manufacturer’s ... 1.8 Propulsion System ... TBM

Lovsuns Tunneling Canada Ltd.

Thank You


Recommended