Lovsuns Tunneling Canada Ltd.
Risk Management - TBM Manufacturer’s
Perspective II
November 14-16, 2016
Lovsuns Tunneling Canada Ltd.
History of LOVSUNS
350 TBMs Built to Date
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
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.
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
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
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
Lovsuns Tunneling Canada Ltd.
TBM Supplier’s Perspective on Risk
Management
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
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!!!
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
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
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
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
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
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
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
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.
Lovsuns Tunneling Canada Ltd.
GROUND CONDITIONING SYSTEM
Lovsuns Tunneling Canada Ltd.
Probe Drill or Polarization Ground Detection
Technique
Lovsuns Tunneling Canada Ltd.
Probe Drill or Polarization Ground Detection
Technique
Lovsuns Tunneling Canada Ltd.
Emergency Inflatable Seal
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)
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
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
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
Lovsuns Tunneling Canada Ltd.
Liaoyang Facility, China
Key Purchased &
Manufactured Components
Engineering
Project Management
Production Support
Manufactured Components
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
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
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
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
Lovsuns Tunneling Canada Ltd.
Project Closure – Post Mortem
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
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
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
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.
Lovsuns Tunneling Canada Ltd.
Thank You