27th June 2013
HERRENKNECHT State of the Art Tunnel Boring Machines
Wilm Schaub HERRENKNECHT ASIA HEADQUARTERS
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
GLOBAL TRENDS Population growth Rapidly advancing urbanization New high-capacity infrastructures to keep people, goods, and resources on the move Refurbishment and extension of existing underground infrastructure Congested arrangement of structure in the urban underground Building of new and extension of existing high-speed train networks Hydropower Projects Fresh Water Supply Irrigation and Sewage 17 June 2013
Slide 2
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
AGENDA : TUNNELLING REQUIREMENTS
Longer Drives Larger Profiles Capability to handle high pressure Capability to excavate in heterogeneous ground conditions Special reference projects Answer and Questions
17 June 2013
Slide 3
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
LONGER DRIVES & LARGER PROFILES DEVELOPMENT OF DIAMETER
MIX-Shields
1997: Hamburg 14.20m
1985: HERA 5.95m
17 June 2013
1996: Sydney 10.70m
2006: Shanghai 15.43m
Slide 4
2011 St. Petersburg 19.25m
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-317/318 CHANGJIANG UNDER RIVER TUNNEL | SHANGHAI | CHINA
17 June 2013
Slide 5
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-317/318 │THE PROJECT DETAILS
Connection between Pudong and Changxing Geology consisting of Sand & Clay 2 Double-deck road tunnels: Upper level: 3 lanes Lower level: service +safety Segment OD: 15.00 m Segment ID: 13.70 m Tunnel length: 7.170 km each Yangtze River Crossing: Maximum overburden above tunnel axis: 65m
17 June 2013
Slide 6
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-317/318 │THE MACHINE DETAILS
MIX-Shield® Shield = 15.43m Cutter Head accessible under atmospheric conditions from the arms Main drive = 7.6m with total power of 15x250kW = 3750kW Back-Up with installation equipment for road element Total machine length 130m
17 June 2013
Slide 7
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-317/318 │CUTTER HEAD DESIGN
17 June 2013
Slide 8
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-317/318 BACK-UP SYSTEM FOR ROAD ELEMENT INSTALLATION
17 June 2013
Slide 9
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CHONGMING UNDER RIVER TUNNEL PROJECT MIXSHIELD S-317/318
S-317 Shanghai
180 160 140 120 100 80 60 40 20 0
S-318 Shanghai weekly advance 37 41 45 49 1 5 9 13 17 21 25 29 33 37 41 45 49 1 5 9 13 17 21 25
2006
2007
week
2008 meter
meter
weekly advance
180 160 140 120 100 80 60 40 20 0 2
7 12 17 22 27 32 37 42 47 52 5 10 15 20 25 30 35 40 45 50
2007 17 June 2013
Slide 10
week
2008 Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
BREAKTHROUGH OF THE WORLD‘S LARGEST TUNNEL BORING MACHINES. ABOUT 1 YEAR AHEAD OF TIME.
May 28, 2008 17 June 2013
September 5, 2008 Slide 11
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-668 NANJING METRO LINE 10 LOT 3
Tunnel Length = 3.6 km Ø = 11.61m MIX Shield Total Thrust Force: 123000 kN Max. Op. Pressure: 7.5 bar Smallest accessible chamber cutter head for tool exchange under atmospheric conditions Main Drive Power: 2750 kW
17 June 2013
Slide 12
Wilm Schaub
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
S-762 ISTANBUL STRAIT CROSSING
Trakya Formation (sandstone/mudstone/dykes)
Marine Deposits (sand + clay)
Transition Zones (rock, soil, gravel, cobbles) 17 June 2013
Slide 13
Wilm Schaub
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
SHIELD CONCEPT.
Bore Diameter 13,690 mm Shield Diameter 13,660 mm
17 June 2013
Slide 14
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SHIELD DIAMETER CONCEPT.
Main Dimensions Bore Diameter
New features 13,690 mm
Camera units 5 No. (transfer chamber & cutter chamber)
Front Shield Diameter
13,660 mm
Tailskin Diameter
13,620 mm
Outer Lining Diameter
13,200 mm
Ring building clearance (Deflector strip) = 2 x 45 mm 17 June 2013
Slide 15
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
ISTANBUL STRAIT ROAD CROSSING | MIXSHIELD WITH ACCESSIBLE CUTTING WHEEL.
17 June 2013
Slide 16
5 Main arms (atmospheric accessible)
Center (Main atmospheric access)
5 Side arms (Chamber access)
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
ISTANBUL STRAIT ROAD CROSSING | MIXSHIELD WITH ACCESSIBLE CUTTING WHEEL. Cutters
35 No. x 19” Twin disc Monobloc. Pressure compensated
Spacing
100 mm (120 mm center)
Scrapers
32 No. x 250 mm Atmospheric accessible
Scrapers
90 No. x 220 mm
Buckets
2 x 10 No.
Flushing outlets
7 No.
Sizers
800 mm (max. 1,200 mm)
17 June 2013
Slide 17
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
DEVELOPMENT OF DIAMETER
EPB-Shields
2010: Sparvo 15.50m
1991: Taipei 6.26m
17 June 2013
2000: Madrid 9.33m
2003: Barcelona 12.06m
Slide 18
2006: Madrid 15.20m
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
Torque [kNm]
DEVELOPMENT OF TORQUE IN MIXSHIELD AND EPB TUNNELLING
Diameter [m] 17 June 2013
Slide 19
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-574 GALLERIA SPARVO = 15.615M – HERRENKNECHT EPB SHIELD.
17 June 2013
Slide 20
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
MAIN DRIVE
Torque: 94.800kNm Breakout Torque : 125.000kNm
17 June 2013
Slide 21
Power: 12.000kW Speed: 2,16 rpm
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CUTTERHEAD DRIVE.
12 electric motors with 1.000 kW each 50 hydraulic motors with a torque of 2.387 Nm each 50 planetary gearboxes with transmission ratio of 51,42 Creating a max. total cutterhead torque of: 125.268 kNm
17 June 2013
Slide 22
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
THRUST FORCE
17 June 2013
Slide 23
315.000kN @ 400bar
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CAPABILITY TO HANDLE HIGH PRESSURE DEVELOPMENT OF OPERATION PRESSURE
17 June 2013
Slide 24
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-502 │LAKE MEAD, USA
S-502 Lake Mead, Intake No. 3 | Las Vegas | USA Dual-Mode TBM - Hard
Cutterhead power: 2,800kW
Rock /Mixshield
Geology: Basalt, sandstone,
Diameter: 7,180mm
amphibolite, conglomerate
Tunnel length: 4,800m 17 June 2013
Slide 25
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CHALLENGES IN MECHANIZED TUNNELLING. GROUNDWATER PRESSURE.
Sedimentary and volcanic geology Depth of the tunnel Potential for high groundwater inflows and high hydrostatic pressures
17 June 2013
Slide 26
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CAPABILITY TO EXCAVATE IN HETEROGENEOUS GROUND CONDITIONS
17 June 2013
Slide 27
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SINGAPORE – CUSTOMIZED SOLUTIONS FOR CHALLENGING PROJECTS
17 June 2013
Slide 28
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
MIXSHIELD TECHNOLOGY
•
The Mixshield is an improvement of the original slurry techniques
•
Invented by HERRENKNECHT and WAYSS & FREYTAG in the 1980’s
•
Designed for a more accurate face pressure control and thus to minimise the risk of settlements
17 June 2013
Slide 29
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SLURRY SHIELD - MIXSHIELD
Bentonite suspension
Bentonite suspension
Bulk head
Bulk head
Air bubble Hydraulic transport cycle
without air bubble
with air bubble
Slurry Shield 17 June 2013
Hydraulic transport cycle
Mixshield Slide 30
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
MIXSHIELD - ACCURATE FACE PRESSURE CONTROL
17 June 2013
Slide 31
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
MIX – SHIELD
1.
Cutting Wheel
2.
Bulkhead
3.
Air – Cushion
4.
Submerged Wall
5.
Slurry Line
6.
Stone-crusher
7.
Feed Line
8.
1
3 2 4
8
7
Erector 6
17 June 2013
Slide 32
5
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
PRESSURE REGULATION ACCURACY
3
2
1 Support Pressure MIX Shield - Double Chamber
Reference Pressure
Support Pressure Slurry Shield - Single Chamber
0 0 17 June 2013
10
20 30 time [sec] Slide 33
40
50 Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
TBM DESIGN
17 June 2013
Slide 34
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SHIELD
17 June 2013
Slide 35
Optimized design in terms of machine length Customized design for various operation pressures Thrust Cylinder arrangement solutions for 5+1 and 7+1 segment lining
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SHIELD – MAN LOCK
Dual man lock design 2 x (3+2) Operating pressure: 7 bar Complies to CENEN12110 regulations Fully equipped for compressed air works Manufactured and tested in Germany Oxygen Decompression System
17 June 2013
Slide 36
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SHIELD – MATERIAL LOCK
Independent Lock for transfer of cutting tools from and to the excavation chamber No obstruction in air lock Safe for workers
17 June 2013
Slide 37
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SHIELD – SLURRY CIRCUIT
Injection Lines for bentonite on various positions of pressure wall and submerged wall Discharge line in shield invert Heavy duty hydraulic driven ball valves for operation from the control cabin Chamber flushing Clogging prevention Crusher flushing Pipe bends made of extra wear resistant material
17 June 2013
Slide 38
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SHIELD – SLURRY CIRCUIT – COMMUNICATING PIPE If the geology bears an increased risk of clogging, the submerged wall gate opening could cake up gradually and eventually be completely closed. This could lead to a pressure rise in the excavation chamber. With a communicating pipe, the bentonite which is pumped into the excavation chamber can flow via the communicating tube and thus prevent a sudden pressure rise in the excavation chamber.
17 June 2013
Slide 39
[1] Excavation chamber [2] Working chamber [3] Communicating tube [4] Feed line [5] Slurry line [6] Clogged submerged wall door
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
STONE CRUSHER
= 700mm crushing size Wiping mode for clogging prevention in softground Optimized hydraulic connection lines Independent hydraulic power pack Grid in front of discharge line to prevent large obstacles from entering the slurry circuit.
17 June 2013
Slide 40
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
PROBE DRILLING
2 x high performance rock drills mounted on 360° drill rig Inclined probe holes through TBM shield Horizontal probe holes through TBM shield and cutting wheel 1 x adjustable center probe drill hole
17 June 2013
Slide 41
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
PROBE DRILLING – DRILLING PATTERN
Inclined probe drill lines
17 June 2013
Slide 42
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
PROBE DRILLING – DRILLING PATTERN
Horizontal probe drill lines
Center inclined probe drill lines
17 June 2013
Slide 43
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
PROBE DRILLING – DRILLING PATTERN
Combined drilling pattern
17 June 2013
Slide 44
Wilm Schaub
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
PROBE DRILLING – BLOW OUT PREVENTER
Blow out preventer Equipped with rotating seal, pressure relieve valve, mechanical clamping and manual ball valve
17 June 2013
Slide 45
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CUTTING WHEEL - STRUCTURE
Heavy Duty Robust Structure Adaptation of proven solutions Implementation of experience gained from former Herrenknecht projects with MIX-Shields in Rock and Mixed Face conditions. FE Analysis to meet the requirements of the project
17 June 2013
Slide 46
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
Bucket lips Scrapers
19” face and gauge disc cutter
19” center disc cutter 17 June 2013
Slide 47
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CUTTING WHEEL – SHIFTING OF GAUGE DISCS
Shifting of Gauge Discs by C-Piece with full load capacity for overcut in curve
17 June 2013
Slide 48
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CUTTING WHEEL – WEDGE LOCK MOUNTING
Durable heavy duty mounting system for rock application Load transfer through the housing into the steel structure of the cutting wheel Wedge to fix the cutter axis
17 June 2013
Slide 49
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CUTTING WHEEL – PRESSURE COMPENSATING DISCS- FOR HIGH OPERATION PRESSURE
For a standard disc cutter, there is no pressure compensation. Under high pressure (>3.5bar), the external pressure is higher than the internal pressure. For non P.C unit, high pressure (>3.5bar) can result in slurry and muck pressing against seal sets and contaminating inside of disc cutters Damage of the seal sets reduces the lifetime of the cutter and higher cost of refurbishment of cutters
17 June 2013
Slide 50
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CUTTING WHEEL – PRESSURE COMPENSATING DISCS- FOR HIGH OPERATION PRESSURE
Herrenknecht pressure compensating discs use a bladder design that is installed into the shaft. The balance of the pressure is through the compensating bore in the shaft P.C unit is balancing the pressure difference at the seal sets The bladder is easy to change and maintain P.C cutters ensure a higher lifetime, reduce risk of bearing failure and reduce refurbishment cost of cutters Project references: S502 Lake Mead S536 Hong Kong Lai Chi Kok S548/549 Singapore DTL2 S602/603/604/605/617 Singapore DTL2
17 June 2013
Slide 51
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
17 June 2013
Slide 52
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
CUTTING WHEEL – WEAR DETECTION&PROTECTION
Hydraulic Wear detectors for Disc Cutter Hydraulic Wear detector for Steel Structure
Circumferential GRILL BARS Hardox 400 – HRC 40 Circumferential welded Hardfacing on shield edge. HRC 56 VAUTID Plates on front surface HRC 60
17 June 2013
Slide 53
Wear detector For cutting wheel structure
Wear detector For disc cutter
HARDFACING On shield edge HRC 56
GRILL BARS Hardox 400 HRC 40
VAUTID PLATES 100 x 100 mm HRC 60
Wilm Schaub
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
LATEST DEVELOPMENT: VARIABLE DENSITY TBM
Down to the present day, this is the only TBM‘s of this kind. Especially it is developed to handle the karstic geology of Kuala Lumpur. Convertible between 4 different advance mode
17 June 2013
Slide 54
Wilm Schaub
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
WORKING MODES WITH THE DIFFERENT SUPPORT MEDIA.
Mixshield – Mode
4
EPB – Mode
Thin suspension (bentonite suspension)
HDSM – Mode
Support medium pasty earth cake
2 EPB – Mode with bentonite support
3
Thick suspension (bentonite suspension with filter) 17 June 2013
Support medium pasty – liquid earthcake Slide 55
Wilm Schaub
1
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
VARIABLE DENSITY SYSTEM.
Excavation & Working chamber
Air bubble
Flushing box with the crusher
High density slurry Feed line
Slurry circuit
Slurry pump
Screw conveyor
17 June 2013
Slide 56
Wilm Schaub
Slurry line
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
MUCK TRANSPORTATION
Apart from tunnel face support, material transport can also be changed in line with the respective geology. The system can switch from hydraulic transportation via pipeline to solid transportation via belt conveyor or muck car haulage. 17 June 2013
Slide 57
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
SPECIAL REFERENCE PROJECTS
17 June 2013
Slide 58
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-670 │CONVERTIBLE EPB / SINGLE SHIELD
Convertible EPB / Single Shield Shield = 10.02 m Operating Pressure 3.0bar Tunnel Length 2 x 3860m Convertible Cutter Head Simultaneous installation of screw conveyor and conveyor belt in shield for quick conversion
17 June 2013
Slide 59
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
S-670 │CONVERTIBLE EPB / SINGLE SHIELD
17 June 2013
Slide 60
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
40° INCLINE TUNNEL FOR HYDROELECTRIC POWER. S-575 | Linth Limmern | Switzerland Gripper-TBM Diameter: 5,200mm Tunnel length: 2 x 1,000m Cutterhead power: 2,205kW Geology: limestone Incline: 85% 40°
Customer: Marti Tunnelbau
17 June 2013
Slide 61
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
PUMPED STORAGE HEPP LIMMERN / SWITZERLAND. TRANSPORT TO THE JOBSITE BY CABLE-CAR.
17 June 2013
Slide 62
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
17 June 2013
Slide 63
Wilm Schaub
HERRENKNECHT ASIA HEADQUARTERS | TRAFFIC TUNNELLING
PUMPED STORAGE HEPP LIMMERN / SWITZERLAND. BREAKTHROUGH FIRST TUNNEL ON OCTOBER 14, 2011.
Machine type: Gripper TBM Diameter: 5,200mm Tunnelling length: 1,045m Gradient: 40.3° Commissioning: 24.06.2010 Breakthrough: 14.10.2011 Best daily performance: 28.8m Best weekly performance: 132.6m
17 June 2013
Slide 64
Wilm Schaub
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
RAILWAY TUNNEL ENLARGEMENT – RESEARCH AND DEVELOPMENT
Mechanized enlargement of existing railway tunnels Maintains route availability with relatively little reconstruction work
17 June 2013
Slide 65
Wilm Schaub
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
SUMMARY- PERSPECTIVES
Tunnelling projects all over the world are demanding TBM technology with permanently higher requirements on the TBM design especially in regards of: settlement control operation effeciency labour safety operating loads (water pressure, overburden) adaptability to multiple kinds of geology (Multi Purpose TBM) cost efficiency
17 June 2013
Slide 66
Wilm Schaub
Page 66
HERRENKNECHT AG | UTILITY TUNNELLING | TRAFFIC TUNNELLING
SUMMARY- PERSPECTIVES
As a supplier of Tunnel Boring Machines, Herrenknecht is continuously striving to optimize and extend the TBM product portfolio . A few exemplary development steps are: Cutting Wheel geometry closely adapted to project geology (Custom made) More wear resistant cutting tools and wear parts Spherical- and displacable main drives Accessable Cutting Wheels (smallest Diameter= 11,62m, S-668 Nanjing), extended application range Improved tailskin sealing systems Double Screw Conveyor (mainly Chinese market) More accurate Muck control systems Geology exploration systems Data monitoring/ recording systems
17 June 2013
Slide 67
Wilm Schaub
Page 67
THANKS Thanks for your FOR attention.YOUR ATTENTION!
THINK POSITIV.
Wilm Schaub Herrenknecht Asia Pte. Ltd. +65 92995899
TOGETHER WE BUILD THE FUTURE.
[email protected]