05new Bournes LOVAT 01

ITA/AITES
ITA/AITES – Training Course

TUNNEL ENGINEERING
MECHANIZED FULL FACE TUNNELLING

RELEVANT EXAMPLES
Prepared by “Rick P. LOVAT, P.Eng, President & CEO – LOVAT Inc.”
Seoul, 2006
April 19, 2006 1/97

Index
1
Introduction
2
Chapter 1 – Pougues Run Upgrade, Indiannapolis, USA
3
Chapter 2 – Docklands Light Rail Extension, London, UK
4
Chapter 3 – Krolsky Railway Tunnel, Kraznoyarsk, Russia
5 Conclusions and references
MECHANIZED FULL FACE TUNNELLING

RELEVANT EXAMPLES 2/97
INTRODUCTION Chapter 1
1
Sections: Pougues Run RME167SE
Project, TBM Specifications, Special Features
2
DLR Extension – ME238SE
3
Krolosky Railway Tunnel RMP375SE
4
Conclusions
5
Questions
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Chapter 2
Consolidation of Pogues Run CSO

Outfalls 034 & 035
Indianapolis, USA
LOVAT RME167SE
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Consolidation of Pogues Run Chapter 2
1
• Location: Marion County
2 Indianapolis, USA
• Owner: City of Indianapolis
3 Department of Public Works
• Consultant: Clark Dietz Inc.
4 Christopher Burke Eng. Ltd.
• Contractor: Super Excavators Inc.
5
• Purpose: Combined Sewer Outfall
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1
• Length: 500 m
2 • Maximum Depth: 14.6 m
• Minimum Depth: 6.7 m
• Water Pressure: 0.8 bar
3 • Estimated EPB Pressure: 1.5 bar
• Tunnel Lining:
4 – Inside Diameter: 3.66 m
– Outside Diameter: 4.11 m
–
5 Length: 1.5 m
– Configuration: 6 Piece Universal Ring
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1
• Geology:
– Fill
2
– Glacial outwash sands and gravels
– Glacial Till
3 – High presence of cobbles and boulders
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LOVAT RME167SE Chapter 2
1
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TBM Specifications Chapter 2
1
• Shield Diameter: 4229 mm
2 • Cut Diameter: 4267 mm
• Length: 9.0 m
• Overall Length: 50 m
3 • Overall Weight: 206 tonne
• Total Installed Thrust: 1840 tonne
4 • Propulsion Stroke: 2250 mm
• Total installed power: 1043 kW
5
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1
• Forward and Rear Articulation Joints
2 • Independent control of propulsion cylinders
• Class 1 Division 2 Electrical System for
operation in “Potentially Gasey Environments”
3 • High Voltage Cable Tray – 300m capacity
• A/B Component Grout Injection System
4 – 2 No. Injection Points
– 10m3/hr injection capacity
• Trailing Belt Conveyor
5
• Trailing Gantry
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Cuttinghead Chapter 2
1
• Mixed Face Design
2 • Incorporates either Ripper Teeth and/or Disc
Cutters
• Four Spoke Layout
3 • Face Isolation Doors
• 5 No. Independent Injection Ports
4 • Chromium Carbide Plating
• Grizzly Bars Across Cuttinghead Openings
5
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Cuttinghead Layout Chapter 2
1
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Main Drive Design Chapter 2
1
• Ring Gear on Extrados of Main Bearing
2
• Use of fewer but higher capacity gear reducers
(resulting in larger teeth on the ring gear)
3
• Use of large diameter rollers in the bearing to
4 achieve required load capacity and life
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1
• The use of a VDF for the benefit of higher
overall efficiency
2
– 90% for VFD vs. 72% for Hydraulic Drive
– ie: 540 kW at the Cuttinghead face requires 600 kW
3 input in a VFD drive vs 750 kW on a hydraulic
drive
• Additional power is lost due to mechanical and
4 volumetric inefficiencies in the hydraulic
pumps and motors
5 • This is the seventh LOVAT TBM to be
equipped with VF Drives
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• Variable Frequency Electric Drive
2 • Installed Power: 600 kW
• Maximum Torque: 265 t•m
• Maximum Speed: 4.8 rpm
3 • Torque at maximum speed: 106 t•m
• Peak Starting Torque: 314 t•m
4 • Torque vs Face Area: 18.8 t•m / m2
• External Ring Gear on Main Drive Bearing
5
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Main Drive Layout Chapter 2
1
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Main Drive Layout Chapter 2
1
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1
Screw Conveyor Design Chapter 2
• Located at invert of cuttinghead chamber
• Primary and secondary drives
2 • Two independent auger sections capable of
varying speeds between the two sections
• Multiple injection ports for lubrication and
3 ground conditioning
• Length of screw to allow for pressure
dissipation, maintaining of clean working area
4 for segment erection
• Emergency Closure System
5
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1
• Total Length of 30m
2 • 610mm Nominal Diameter
• Installed power of 200kW
• Both drives are variable speed and reversible
3 • Total installed torque for Rear Drive of 3.3t•m
• Total installed torque for Front Drive of 3.0t•m
4 • Discharge capacity of 100m3/hr
• Maximum Speed of 22 rpm
5 • Maximum boulder size of 188 mm
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Screw Conveyor Layout Chapter 2
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Segment Erector Chapter 2
1
• Bulkhead Mounted
– Ease of access to TBM
2
• Mechanical Pick-Up System
– Ball and Cup
3 • Hydraulic Controls from fixed stations
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TBM Assembly Chapter 2
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BREAK THROUGH! Chapter 2
1
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Chapter 3
Docklands Light Rail Extension

Woolwich Aresenal to
King George V
London, UK
LOVAT ME2383SE
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DLR Extension Chapter 3
1
• Location: London, UK
2 • Owner: Woolwich Aresenal Rail
Enterprise (WARE)
3 • Contractor: AMEC
• Purpose: Light Rail Line
4
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• Length: 2 x 1830 m
2 • Maximum Depth: 30 m
• Minimum Depth: 7m
3 • Estimated EPB Pressure: 3.5 bar
• Tunnel Lining:
4 – Inside Diameter: 5.3 m
– Outside Diameter: 5.8 m
–
5 Length: 1.5 m
– Configuration: 8 Piece Trapezoidal
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1
• Geology:
– Fill
2
– Alluvium
– Terrace Gravels
3 – Chalk c/w Flints
– Thanet Sand
– Bullhead Clays
4
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• Length: 9.0 m
5
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• ‘CE’ Certification
• HSE Approval and Certification
3 • A/B Component Grout Injection System
– 2 No. Injection Points
4 – 10m3/hr injection capacity
• Trailing Belt Conveyor discharge to tunnel
conveyor
5
• Trailing Gantry
• Computer Tunnel Guidance System
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LOVAT ME238SE Chapter 3
1
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LOVAT ME238SE Chapter 3
1
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• Soft Ground Cuttinghead
2 • Independently Operated Face Isolation Doors
• 6 No. Independent Injection Ports
• Lovat Scraper Teeth
3 • Grizzly Bars
• Lovat Ripper TeethLovat Center Nose Cutter
4 • 5 No. Secondary Opening ports – Additional
openings at Cuttinghead center when required
5
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• Variable Frequency Electric Drive
2 • Installed Power: 1020 kW
3 • Torque at maximum speed: 243 t•m
• Peak Starting Torque: 671 t•m
4 • Torque vs Face Area: 18.7 t•m / m2
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Main Drive Chapter 3
1
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1
• Located at invert of cuttinghead chamber
• Peripheral Drive
2 • Multiple injection ports for lubrication and
ground conditioning
• Two Discharge Options:
3 – Discharge to trailing belt and tunnel conveyor
– Closed Discharge to Muck Pump
• Boulder Catcher for Muck Pump Discharge
4 • Emergency Closure System
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1
• Total Length of 14m
2 • 790mm Nominal Diameter
• Installed power of 188kW
• Discharge capacity of 300m3/hr
3 • Maximum Speed of 22 rpm
• Maximum boulder size of 250 mm
4
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Screw Conveyor Chapter 3
1
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Trailing Gantry Chapter 3
1
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Chapter 4
KROLSKY Railway Tunnel

Twinning
Kraznoyarsk, Russia
LOVAT RMP3753SE
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1
Krolsky Railway Tunnel Chapter 4
• Location: Kraznoyarsk, Russia
2 • Owner: Russian National Railways
• Contractor: OAO Bamtonnelstroy
3
• Purpose: Twinning of Railway Tunnel
Trans Siberian Railway
4
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1
• Length: 2252 m
2 • Maximum Depth: 80 m
• Minimum Depth: 5m
3 • Tunnel Lining:
– Inside Diameter: 8.4 m
4 – Outside Diameter: 9.2 m
– Length: 1.5 m
– Configuration: 6+Key Universal Ring
5
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1
• Geology:
– Eluvium (Slate Detritus)
2
– Slate [30-70 MPa]
– Limestone [50-100 MPa]
3 – Granite [60-100 MPa]
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1
• Length: 10 m
5
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1
• Single Component Grout Injection System
– 4 No. Injection Points
3 – 30 m3/hr injection capacity
• Trailing Belt Conveyor
4 • Trailing Gantry
• Auxiliary Ventilation System
5 • Computer Tunnel Guidance System
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1
• Rock Cuttinghead
2 • 15½” Replaceable Ring Disc Cutters
• Scraper Collector Tools
• Capable of Bi-Directional Operation
3 • 11 No. Face Injection Ports
• Grizzly Bars across openings
4 • 2 No. Access Ports to Face
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1
• Variable Speed Hydraulic Drive
2 • Total Cuttinghead Power: 2100 kW
• Minimum Torque: 675 t•m
3 • Peak Break Out Torque: 1959 t•m
4 • Speed at Maximum Torque: 1.4 rpm
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TBM Status Chapter 4
1
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Chapter 5
1
2
CONCLUSIONS
3 and
ACKNOWLEDGEMENTS
4
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Conclusions Chapter 2
1
• The design and manufacture of the TBM
provided numerous challenges
2
• The incorporation of new features on a TBM is
3 not something that occurs frequently in the
tunnelling industry.
4
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1
• There are numerous risks involved in putting
untested technology into a tunnel environment
2 that would prevent a contractor from allowing
experimentation.
3
• Therefore the commitment of the
manufacturers to push new technology is
4
required to keep the industry moving forward
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1
• ADVANCES IN TBM TECHNOLOGY
2 • Variable Frequency Electric Drive
• Higher Efficiency
• Ease of Maintenance
• Lower Operating Costs (less power loss to heat)
3 • Computer aided trouble shooting of problems
• Cooler and Quieter Operating Environment
•
4
No increase in capital costs over traditional hydraulic
drives
• High Torque Drives
5 • Ability to handle more difficult ground conditions
• Achievable due to advances in Gear Box, and Bearing
Technology
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1
• ADVANCES IN TBM TECHNOLOGY
2 • TBM Operation under High In-situ Pressures
• Long Screw Conveyors c/w multiple drives
• Muck Pumping direct from Screw Discharge
3 • Bulkhead Erectors on small diameter TBMs

• Better access for safety
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Acknowledgements Chapter 5
1
• Consolidation of Pogues Run CSO
– Super Excavators
2
– City of Indianapolis, USA
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1
• Docklands Light Rail Extension
– AMEC
2
– WARE (Woolrich Aresenal Rail Enterprises)
– City of London, UK
3
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• Krolsky Railway Tunnel Twining
– OAO Bamtonnelstroy
2
– Russian National Railways
– Region of Kraznoyarsk, Russia
3
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ITA/AITES
Clause de non-responsabilité pour les rapports des groupes de travail de l'AITES

L’Association Internationale des Travaux en Souterrain (AITES) publie ce rapport, conformément à ses Statuts, pour faciliter les échanges d’informations afin :
d’encourager l’utilisation du sous-sol au profit du grand public, de l’environnement et du développement durable;
de promouvoir les progrès dans la planification, le projet, la construction, l’entretien, la réhabilitation et la sécurité des tunnels et de l’espace souterrain en
rassemblant et confrontant les informations, ainsi qu’en étudiant les questions qui s’y rapportent.
Cependant, l’AITES décline toute responsabilité en ce qui concerne les informations publiées dans ce rapport.
Ces informations :
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ne constituent pas un avis professionnel or juridique (si vous avez besoin d’avis spécifiques, consultez toujours un professionnel dûment qualifié).
Disclaimer for the reports of ITA working groups

The International Tunnelling Association (ITA) publishes this report to, in accordance with its statutes, facilitate the exchange of information, in order:
to encourage planning of the subsurface for the benefit of the public, environment and sustainable development
to promote advances in planning, design, construction, maintenance and safety of tunnels and underground space, by bringing together information thereon and
by studying questions related thereto.
However ITA accepts no responsibility or liability whatsoever with regard to the material published in this report.
This material is:
information of a general nature only, which is not intended to address the specific circumstances of any particular individual or entity;
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ITA/AITES

ITA/AITES – Training Course

MECHANIZED FULL FACE TUNNELLING

April 19, 2006 1/97

5 Conclusions and references

MECHANIZED FULL FACE TUNNELLING

Consolidation of Pogues Run CSO

Docklands Light Rail Extension

KROLSKY Railway Tunnel

3 • Bulkhead Erectors on small diameter TBMs

Clause de non-responsabilité pour les rapports des groupes de travail de l'AITES

Disclaimer for the reports of ITA working groups

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