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VENTILATION SYSTEM AND LOGISTICS
IN LONG TUNNELS DURING
CONSTRUCTION
ITA-AITES WORLD TUNNEL CONGRESS 2008
Agra, India 19 September 2008
Andreas Busslinger, HBI Haerter Ltd
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CONTENT
Introduction (Long Tunnels, Logistics, Ventilation, Safety)
Construction Logistics - Main Principles
Construction Ventilation - Main Principles
Case Studies
Conclusion
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
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LONG TUNNELS
What are long Tunnels?
Longer than typical existing Road, Rail Tunnels (>10 km)
Increased Challenges in Construction and Operation
Poor Experience (only a few in Operation)
Many Projects ahead
Some Examples
In Operation: Channel Tunnel (49.9 km, F/GB), Seikan Tunnel
(53.9 km, J ), Lrdal Tunnel (24.5 km, N), Guadarrama Tunnel
(28.3 km, E), Loetschberg Base Tunnel (34.6 km, CH)
Projects: Base Tunnels LyonTurin (52.0 km, F/I), Brenner
(55.0 km, A/I), Gotthard (57,1 km, CH), Pajares (24.7 km, E),
Koralm Tunnel (32.8 km, A)
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
LYON TURIN
BASE TUNNEL
BRENNER
BASE TUNNEL
LOETSCHBERG
BASE TUNNEL
GOTTHARD
BASE TUNNEL
DOK_2008-06-24_WTC2008_Figures.ppt
LYON TURIN
BASE TUNNEL
BRENNER
BASE TUNNEL
LOETSCHBERG
BASE TUNNEL
GOTTHARD
BASE TUNNEL
DOK_2008-06-24_WTC2008_Figures.ppt
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LOGISTICS, VENTILATION AND SAFETY
Yesterday
Lowly mechanised Construction
Slow and expensive Tunnel Construction Process
Poor Health Protection and Safety Conditions
Many Injuries and Fatalities
Example: Simplon Tunnel (Switzerland 19.8 km, 1898-1906)
Today
Highly mechanised Construction
Fast and Cost optimised Tunnel Construction Process
High Standard in Health Protection and Safety Conditions
Massif Reduction of Injuries and Fatalities
Crucial Need of sophisticated Logistics and Ventilation
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
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MAJOR CHALLENGES IN LONG TUNNELS
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Hugh Amount of Material (Excavation, Concrete, etc.)
Big Quantity of Staff and Machinery
Big Traffic Volume (Transport)
Variable and growing Tunnel System
Long Access Routes
Limited Access (via Portals)
Long Evacuation and Intervention Routes
High Rock Temperatures (due to high Overburden)
Big Heat and Pollution Loads (Concrete, Diesel Engines, etc.)
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LOGISTICS MAIN TASKS
Transport (Staff, Material, Excavation)
Lodging (Staff) and Storage (Material)
Handling of Material
Coordination of the Working Process (Procedures)
Elaboration of the Construction Schedule
Health Protection
Elaboration and Implementation of Safety Concept
Energy, Water and fresh Air Supply
Communication
Outline and Operation of Installation Areas inside/outside Tunnel
Maintenance and Cleaning
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
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Health Protection: Sufficient Climatic Conditions according to
Guidelines of occupational Medicine & Authorities (e.g. maximum
pollution concentrations at work sites)
Safety Support in Emergency (Self Rescue, Evacuation and Fire
Fighting, e.g. Reduction of Smoke Propagation & Removal of
Smoke)
No major Impact on Construction Process
Intensive Coordination with Logistics (Space, Power Supply,
Communication Requirements, etc.)
Ventilation, Cooling 28C Temperature
Ventilation 1.5 m
3
/min/Person Air Flow / Manpower
Ventilation 4 m
3
/min/kW (Full Load)
2 m
3
/min/kW (Part Load)
Air Flow / Diesel
Power
Measure Limit Requirement
Ventilation, Cooling 28C Temperature
Ventilation 1.5 m
3
/min/Person Air Flow / Manpower
Ventilation 4 m
3
/min/kW (Full Load)
2 m
3
/min/kW (Part Load)
Air Flow / Diesel
Power
Measure Limit Requirement
VENTILATION MAIN TASKS
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
REQUIREMENTS
OF LOGISTICS
(Schedule, Staff, Engines,
Space, etc.)
GUIDELINES OF
OCCUPATIONAL MEDICINE
(Air Volume Rate,
Temperature, etc.)
CALCULATION OF
REQUIRED
FRESH AIR SUPPLY
CALCULATION OF
REQUIRED
COOLING POWER
DESIGN OF
COOLING
ELEMENTS
DESIGN OF
VENTILATION
ELEMENTS
a
b
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a
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g
ig
k
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it
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n
_
b
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l
f
t
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g
.
p
p
t
REQUIREMENTS
OF LOGISTICS
(Schedule, Staff, Engines,
Space, etc.)
GUIDELINES OF
OCCUPATIONAL MEDICINE
(Air Volume Rate,
Temperature, etc.)
CALCULATION OF
REQUIRED
FRESH AIR SUPPLY
CALCULATION OF
REQUIRED
COOLING POWER
DESIGN OF
COOLING
ELEMENTS
DESIGN OF
VENTILATION
ELEMENTS
a
b
h
a
e
n
g
ig
k
e
it
e
n
_
b
a
u
l
f
t
u
n
g
.
p
p
t
REQUIREMENTS
OF LOGISTICS
(Schedule, Staff, Engines,
Space, etc.)
GUIDELINES OF
OCCUPATIONAL MEDICINE
(Air Volume Rate,
Temperature, etc.)
CALCULATION OF
REQUIRED
FRESH AIR SUPPLY
CALCULATION OF
REQUIRED
COOLING POWER
DESIGN OF
COOLING
ELEMENTS
DESIGN OF
VENTILATION
ELEMENTS
a
b
h
a
e
n
g
ig
k
e
it
e
n
_
b
a
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l
f
t
u
n
g
.
p
p
t
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Overview Base Tunnels in Europe
LYON TURIN
BASE TUNNEL
BRENNER
BASE TUNNEL
LOETSCHBERG
BASE TUNNEL
GOTTHARD
BASE TUNNEL
DOK_2008-06-24_WTC2008_Figures.ppt
LYON TURIN
BASE TUNNEL
BRENNER
BASE TUNNEL
LOETSCHBERG
BASE TUNNEL
GOTTHARD
BASE TUNNEL
DOK_2008-06-24_WTC2008_Figures.ppt
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Base Tunnel System
North Portal
Innsbruck
South Portal
Franzensfeste
Connection Tunnel
Bypass
Innsbruck
Service Tunnel
Rescue Station
Innsbruck
Rescue Station
Steinach
Rescue Station
Wiesen
2 x 55 km single track tunnels
174 cross passages
2 connection tunnels
6 crossovers
2 passing tunnels
3 access tunnels
5
5

k
m
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huge amount of excavation
(~18 Mio m
3
)
long distances
heat input from rock,
transport, machinery
emissions
permanently changing
locations / activities
fire safety
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
CASE STUDY: BRENNER BASE TUNNEL
Major challenges of excavation phase
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Construction Schedule
8 Ventilation Sections
21 Ventilation Phases
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Ventilation Concept, Normal Operation
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Ventilation Concept, Emergency Operation
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Cooling Concept
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Cooling Concept, Design Calculations
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CASE STUDY: BRENNER BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Main Results
Demanding Construction Schedule (up to 6 synchronous Main
Tunnel Excavation Heads)
Demanding Deposit Planning
Huge Space Requirements in Access Tunnels (Air Ducts, Cooling
Pipes)
Extension of planned Tunnels & Caverns (Air Ducts, Cooling
Installations)
Additional Ventilation Tunnels & Caverns (Air Supply, Ventilation
Central)
Additional Excavation in Pilot Tunnel (Intermediate Fans, etc.)
Space Requirements at the Portals (Cooling Towers, Fans)
Adaptation of Construction Procedure (synchronous Main Tunnel
and Cross Passage Excavation)
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CASE STUDY: GOTTHARD BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Overview Base Tunnels in Europe
LYON TURIN
BASE TUNNEL
BRENNER
BASE TUNNEL
LOETSCHBERG
BASE TUNNEL
GOTTHARD
BASE TUNNEL
DOK_2008-06-24_WTC2008_Figures.ppt
LYON TURIN
BASE TUNNEL
BRENNER
BASE TUNNEL
LOETSCHBERG
BASE TUNNEL
GOTTHARD
BASE TUNNEL
DOK_2008-06-24_WTC2008_Figures.ppt
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2 x 57 km single track tunnels
178 cross passages
4 crossovers
3 access tunnels (1.5 to 3 km)
2 vertical shafts (800 m)
5
7

k
m
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
CASE STUDY: GOTTHARD BASE TUNNEL
Base Tunnel System
2008: 75 % of tunnels excavated
2017: Operation
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huge amount of material
(~500000 t)
long distances
heat input from rock,
transport, machinery
emissions
permanently changing
locations / activities
fire safety
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
CASE STUDY: GOTTHARD BASE TUNNEL
Major challenges of railway equipment installation
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More than 15 Phases of Ventilation & Cooling
1
Phase Erstfeld-Sedrun Sedrun-Faido S Faido-Bodio Sedrun-Faido N
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Years
1
2
3
4
5
6
7
Civil Construction
Installation of Railway Equipment
(Trackway, Catenary System,
Communication, etc.)
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Construction Schedule
CASE STUDY: GOTTHARD BASE TUNNEL
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INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Ventilation Concepts, Normal Operation
CASE STUDY: GOTTHARD BASE TUNNEL
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Key principles:
Separation of installation sections by air locks
All shafts / access tunnels used for air supply / removal
Smallest possible obstruction of installation (few air tubes)
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Ventilation Concept, Emergency
CASE STUDY: GOTTHARD BASE TUNNEL
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Key principles:
Local cooling by mobile air coolers at installation sites
Heat removal by cooling towers at portals
Pipes only in one tunnel (branch pipes through cross passages)
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Cooling Concept
CASE STUDY: GOTTHARD BASE TUNNEL
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Key principles:
Main control by temporary tunnel control centre
All elements of ventilation and cooling controlled and
monitored
Climate monitoring (air speed, immission, temperature, etc.)
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Control Concept
CASE STUDY: GOTTHARD BASE TUNNEL
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reversible axial fan 6 multifunctional station auxiliary fan
2 access tunnel
axial fan mounted on truck 2 portals mobile fan
6 cross passages
reversible axial fan 8 multifunctional station main fan
2
16
6
Number
2 km of flexible air duct access tunnel air duct
air tight walls tunnel air barrier
2 operated doors tunnel air lock
Specification Location Element
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Ventilation Design
CASE STUDY: GOTTHARD BASE TUNNEL
Total number of fans: 24
Maximum ventilation power: 8 MW
Maximum air flow: 700 m
3
/s
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primary water pump 6 portals water pump
pressure exchange
system
1 multifunctional station PES
twin pipe 300 mm 57 km tunnel
twin pipe 500 mm 6 km access tunnels water pipes
300 kW cooling power 30 tunnel side strip air cooler incl.
fan
3
6
Number
water re-cooling portals cooling tower
secondary water pump multifunctional station water pump
Specification Location Element
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Cooling Design
CASE STUDY: GOTTHARD BASE TUNNEL
Total number of air coolers: 30
Total length of water pipes: 130 km
Maximum cooling power: 9 MW
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CASE STUDY: GOTTHARD BASE TUNNEL
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Main Results
Demanding Construction Schedule (up to 6 synchronous
Installation Sites)
Demanding Ventilation Design (up to 15 different Concepts)
Flexible & modular Concepts required due to Time & Space
dependent Installation Process.
Ventilation with small Obstruction of Installation & service on
demand
Improvement of Safety & Reliability by Separation of Working Sites
by Air Locks
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CONCLUSIONS
Logistics & Ventilation are decisive Elements in Long Tunnel
Projects.
Health Protection & Safety have gained highest Priority in Tunnel
Construction.
Ventilation (incl. Cooling) is irreplaceable to support Health
Protection & Safety.
Cost & time efficient Projecting require additional Effort for Logistics
& Ventilation (Access Tunnels, Shafts, Caverns, etc.)
Expenses of Construction Ventilation in long Tunnels are often
bigger than Expenses of Operation Ventilation.
Transition Phases (Excavation-Equipment-Commissioning) must be
handled carefully and coordinated in Advance.
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
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Thank you for your attention!
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Requirements
respect the MAC values
pressure variation within
comfort and health limits
Temperature max: 35C
Humidity max: 70%
Normal Mode
respect the MAC values
pressure variation within
comfort and health limits
Temperature max: 35C
Humidity max: 70%
Emergency Mode
Maintenance Mode
support the self rescue
no smoke in safe areas
support the rescue team
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Equipment
Elements:
rescue platform
air extraction system
fresh air supply system
tunnel doors
Elements:
rescue platform
air extraction system
fresh air supply system
Elements:
rescue platform
air extraction system
Emergency station
The main tunnel ventilation
equipments
Elements:
rescue platform
Elements:
extraction fan: 250m
3
/s
reversible
air extraction point
air extraction point
supply fan: 200m
3
/s
air supply point
air supply point
rescue platform
rescue platform
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Equipment
INNSBRUCK
FORTEZZA
Railway tunnel
Auxiliary ventilation at tunnel
ends
Elements:
2 series of 2 jet fans per tube
and direction
w
e
s
t

t
u
b
e
e
a
s
t

t
u
b
e
FORTEZZA
INNSBRUCK
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Equipment
cross passage
Railway tunnel
Elements:
sliding doors
normal ventilation
air flap
supply fan
Cross passages
Secondary tunnel ventilation
system
Elements:
sliding doors
Elements: Elements:
sliding doors
normal ventilation
Elements:
sliding doors
normal ventilation
air flap
incident ventilation
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Concept, Normal Operation
natural air exchange
due to piston effect
normal mode
East tube
West tube
Innsbruck Fortezza
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Concept, Maintenance Operation
200 m
3
/s 200 m
3
/s
200 m
3
/s 200 m
3
/s
complete tube
East tube
West tube
Innsbruck Fortezza
maintenance work
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Concept, Emergency Operation
inside an emergency
station
East tube
West tube
Innsbruck Fortezza
250 m
3
/s 200 m
3
/s
200 m
3
/s 200 m
3
/s
Emergency: train fire
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
Analysis
Aerodynamic
Thermodynamic
Safety studies
Aerodynamic
Thermodynamic studies
Aerodynamic studies
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
AERODYNAMIC ISSUES: pressure load in tunnel and train
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OUTLOOK: VENTILATION DURING OPERATION
INTRO
LOGISTICS
VENTILATION
CASE STUDY
OUTLOOK
CONCLUSION
THERMODYNAMIC ISSUES: tunnel temperature and humidity
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Heat
sources
Heat sinks
INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Cooling Design, Heat Balance
CASE STUDY: GOTTHARD BASE TUNNEL
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INTRO
LOGISTICS
VENTILATION
CASE STUDY
CONCLUSION
Cooling Design, Temperature Prediction
CASE STUDY: GOTTHARD BASE TUNNEL