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Bheri Babai Diversion Multipurpose Project (BBDMP)

Presented by Jim Clark, Projects Manager IndiaThe Robbins Company

• More than 50 years of innovation and experience,

• More than 900 Employees worldwide

• Annual sales exceeding $300 million

• We hold almost 90% of TBM tunneling world production records

Company Facts

THE ROBBINS COMPANY

Front of office building

SOLON, OHIO, USA

Solon, Ohio, USA

Facilities include:

• Administration

• USA Equipment production

• Engineering staff

• Field service staff

Headquarters

THE ROBBINS COMPANY

• Robbins Europa -- Italy

• Roboretec -- Romania

• Robbins China -- Shanghai

• Robbins China -- Guangzhou

• Robbins Asia Pacific

• Hong Kong

• Brisbane

• Robbins GmbH -- Germany

• Robbins India – New Delhi

• Robbins España – Madrid

• Robbins Mexico – Mexico City

• Robbins TBM Korea – Seoul

• Representatives in

35 countries

Facilities in 11 Countries Worldwide

THE ROBBINS COMPANY

Robbins Experience in

India

• Almost 70 km of tunnels bored to date

• Metro

• Water Transfer

• Hydro Electric Power

• 300 Employees

• 25 expats

ROBBINS EXPERIENCE IN INDIA

AMR Water tunnel


• 2 x 10.0 m Diameter double shield TBMs

• Length 43.5 km.

• Longest tunnel in the world without intermediate access.

• Granite & Quartzite, UCS up to 300 MPa

• Robbins responsible for all TBM related activities

Alimineti Madhava Reddy Water Tunnel

Mumbai Water tunnel


• Tunnel length 8.3 Km

• 6.25 m Open Gripper machine

• Shaft depth 109 m

• Continuous conveyor system

• Vertical conveyor system

Mumbai Water tunnel


Mumbai Water tunnel

• Bored over 8 km in 18 months

• Over 60 m bored in 24 hours

• Indian record of 870 meters in a month

Jaipur Metro


Jaipur Metro

• TBM’s bored beneath heritage structures

• Only 5 m of cover

• Robbins provided key personnel & operators

• Took full responsibility for boring beneath the gate


Chandpole gate

• Foundations made up of irregular size stone blocks

• Limited resistance to settlement

• Lime mortar joints in poor condition

• Riddled with cavities

• Contract limit of 4 mm settlement


Jaipur Metro “whoever destroys, injures, mutilates, defaces, alters, removes,

disperses, misuses, imperils or allows to fall into decay a

protected monument, or removes from a protected monument

any sculpture, carving image, bas-relief, inscription or other like

object, shall be punishable with imprisonment for a term which

may extend to six months with a fine which may extend to five

thousand rupees or with both”

BBDMP TBM Selection

TBM SELECTION

Geology and overburden

• Mostly sandstone & Mudstone

• Some conglomerate

• Two thrust/shear zones

• Babai thrust (100m from portal)

• Bheri thrust (5,800m from portal)

• Up to 800m overburden

• Shielded machine best suited to geology

TBM SELECTION

Construction Schedule

• Necessity to finish the project in 54 months

• Absence of intermediate adits

• boring and lining must proceed concurrently

• High Performance Double Shield TBM is required

TBM SELECTION

Benefits of Double shield TBM

• Rapid tunnel and lining progress

• Secure the immediate stabilization of the tunnel walls

• Act as a final lining, not requiring any further working phase

• Immediately reducing any water inflow into the tunnel

TBM SELECTION

TBM Specifications

TBM Manufacturing, Delivery and Assembly

TBM MANUFACTURING, DELIVERY & ASSEMBLY

Manufacturing & Assembly

• Critical components are manufactured in the USA and Europe

• Shipped to Robbins facility in Shanghai for assembly

TBM MANUFACTURING , DELIVERY & ASSEMBLY

Testing, Disassembly & Shipping

• Full factory testing of machine (FAT)

• Machine then disassembled and shipped by sea to Kolkata

• Then 1,300 km overland from Kolkata to the project site


Site Assembly

• Machine arrived on site the first week of September 2017

• Assembly of the TBM commenced 10th September

• 6 weeks taken to complete assembly, commissioning and push machine to the face of the starter tunnel


Site Assembly

Production to Date

Learning curve

PRODUCTION TO DATE

• A learning curve is factored into all production predictions for TBM driven tunnels.

• Prediction for this tunnel was a learning curve of 3 months at 250m production per month (750m total)

• Boring commenced Early November 2017

• TBM completed 330m of boring in November

• By Mid December after only 6 weeks of tunneling the TBM passed the 750m in 3 months learning curve target.

• Excellent achievement by any standards.

First 6 months

PRODUCTION TO DATE

• The machine has completed almost 4 km during the first 6 months of boring

• Best 24 hours 52.9m

• Best week 285m

• Best month/30 day period

1057 m

Challenges Ahead ?

Main Areas of Concern

CHALLENGES AHEAD

• Squeezing ground

• Slabbing/Spalling ground

• Jointed and blocky rock

• Water ingress

• Bheri thrust/shear zone estimated to be 400m wide

Inundation

CHALLENGES AHEAD

Probe Drilling/Ground Treatment

PROBE DRILLING/GROUND TREATMENT

Probe Drill

• The probe drill is used for probe and grout holes

• It can also be used to relieve hydrostatic pressure at the face

• By drilling relief holes through the segmental lining behind the machine


Grout Packers

• Mechanical packer

Can be inserted to approx 4-5m. May not be long enough to prevent grout return into bored tunnel in fractured rock

• Inflatable packer

Can be extended and inserted up to 10m+. Can be placed ahead of the tunnel face to prevent grout return.


• Primary holes drilled first

• Packers inserted into holes

• Pressure gauge is connected to the packer in any hole thatshows water ingress.

• Water pressure is measured

• Injections begins from lowest holes

• Injection pressure is dictated by hydrostatic pressure

Operations carried out in 2 separate phases


• Secondary or control holes drilled.

• Experienced geologist must monitor the drilling

• Observe the effects of the primary injection

• Packers inserted in selected holes if required

• Injection sequence repeated

Secondary phase begins once primary phase completed

Squeezing Ground

SQUEEZING GROUND

TBM Shields becoming trapped

• CHD Diameter 5,060 mm -Diameter of Front/ Telescopic Shield 4,990 mm (70 mm clearance)

• Diameter of Gripper Shield/ Tail Shield 4,910 mm (80 mm clearance)

• 35 mm of radial overcut is also available

SQUEEZING GROUND

TBM Shields becoming trapped

• Single shield mode

• TBM gripper shoes are retracted

• Main thrust cylinders closed up

• Auxiliary thrust cylinders are utilized to push machine

• By thrusting off the segmental lining

• 40% additional thrust

• 38,475 kN

Bursting and Spalling Ground

BURSTING and SPALLING GROUND

Shield Design

• Designed to deal with bursting or spalling ground

• Cope with extreme loading

• Protect the tunnel personnel

• Provide support to the ground continually

• Up until erection of segmental lining

BURSTING and SPALLING GROUND

Cutterhead design

• Low profile muck buckets

• Reduce possibility of “pulling in” loose rock

• Large capacity and smooth throat

• Able to handle the large amount of broken rock produced in high speed production.

BBDMP Summary

SUMMARY

• Selected correct Machine for the Job

• Initial 500m excavated by Robbins plus training

• Experienced contractor

• Good site set up

• Experienced project team

• Production to date is very good

• Caution required when approaching Bheri thrust Zone

• First TBM project in Nepal has exceeded target

• Now expected to be huge success

• TBM can be refurbished and utilized on other projects.

Questions?