Rowa Customers Day. Gotthard Base Tunnel Sedrun, Lot 360. Speaker: Heinz Jenni 07 September 2004

Transcription

1 Rowa Customers Day Gotthard Base Tunnel Sedrun, Lot 360 Speaker: Heinz Jenni 07 September 2004 Highly mechanized heading installation for full excavation with large convergences in Tavetscher intermediate massifs

2 List of Contents List of Contents Special Requirements Special Structural Requirements Special Requirements to Heading Installation Special safety engineering requirements Feasibility study / order Construction sequences Multifunctional Heading Installation Overall system Roadway support machine High-performance heavy lift crane Suspended platform Infrastructure train with supply devices Waste train loading equipment Rotary Tipper Rowa ROTARY III Rowa strengths in the Sedrun Project...21 D Vortrag-HJ-Sedrun-englisch doc Seite 2 von 21

3 1 Special Requirements 1.1 Special Structural Requirements Special system of excavation support with steel TH profiles Radial system anchoring Heading face anchoring Shotcrete hull after deformation phase Due to its large cross-section and difficult geology, the Sedrun parcel places high demands on the tunneler and the system constructor. The convergences in the interference zones represent a great challenge. To be able to control the deformations of up to 0.7 m radial, a massive steel integration with two interleaved rings with a glide connection is used, which takes up these convergences. No tunnel has been opened in this manner and in these dimensions. As an additional heading-face safety measure, large quantities of radial and working face anchors are staggered. After the deformation phase (ca. 70 m), when the steel-installation glide path has been exhausted, the shotcrete hull is placed during the so-called resistance phase. These requirements demand special measures from the machine engineering aspect also; a tailor-made general system. 1.2 Special Requirements to Heading Installation Consequent mechanization of the excavation support devices Performance and safety Supply to and removal from the work areas Aeration Cooling Due to the large cross-section and the great amounts of excavation support devices such as steel arches, anchors, wet concrete and shotcrete, a persistent mechanization of excavation safety is necessary. Only by using a high degree of mechanization is it possible to achieve the high requirements placed on performance and industrial safety. Supply and removal must supply the work places with the correct quantities at the correct time using a well thought-out logistics concept. The same also applies to the guaranteeing of climatically humanized work areas that is, ventilation and cooling. D Vortrag-HJ-Sedrun-englisch doc Seite 3 von 21

4 1.3 Special safety engineering requirements Hazard analysis Action plan Implementation Training Documentation Compliance with the current industrial safety regulations is standard nowadays. The developer, project planning engineer, and the executive company, together with its suppliers, take care to prevent any possible industrial accidents in all phases. All technical equipment is to be reviewed for possible weak spots and injury potential using a hazard analysis. Through suitable protective measures, the risks are reduced to an acceptable remaining risk. Subsequently, intensive training of the cadre and heading teams is carried out and correspondingly documented. 2 Feasibility study / order Even before and during the submission phase, Rowa intensively grappled with the peculiarities of the Sedrun project. An overall system for heading the special tunnel was developed. After the contract award for the contract section 360 Sedrun to Arge Transco Sedrun (Batigroup, Frutiger, Bilfinger and Berger, Pizarotti), the heading installation was developed further in close collaboration with Arge Transco. On 23 April 2003, Rowa was able to accept the order from Arge Transco-Sedrun for the development, fabrication, supply, assembly, and start-up of 4 multifunctional heading installations. Furthermore, Rowa was commissioned with the fabrication, supply, and assembly of 3 rotary tipplers, Rowa Rotary III. D Vortrag-HJ-Sedrun-englisch doc Seite 4 von 21

5 3 Construction sequences The concept is based on a compilation of installations, construction equipment, and construction machinery. The proportion of supplies from Rowa basically consists of the roadway support machine, heavy lift crane, suspension rails, suspended platform, and the infrastructure train. All construction equipment, construction machinery, track systems, rolling stock, concrete pumps incl. pan mixer, power lines, energy supplies (electricity, water, compressed air), cooling plants, flush fans, dewatering, suspension adapters for the chain suspension rails, and communications equipment are being provided by Arge Transco. The work processes 1 7 described in the following result, which can be carried out with the corresponding machinery equipment. Drill workface: (possibly loosening blasts) with jumbo drill. Blast mobile, telescope shovel dredger and additional machinery equipment are parked on the rock-fill work stratum. The roadway support machine work-baskets can be called upon to support the work (e.g. for loading). 5 flat wagons are planned on the infrastructure train for consumable materials. The heavy lift crane supplies the consumable-materials working face either directly from the supply train or from the in-process storage on the 5 flat wagons. Working face exploitation: The working face exploitation is carried out mechanically with a heavy duty tunnel excavator CAT. Through a special jib, every area in the required excavation cross-section can be reached during this, even behind the last set support. Possible supplementary tools with quick adapters are hydraulic hammers, detachment teeth, manipulation adapters for steel arch supports, possibly gearheads and buckets. Debris: Debris is removed with a TORO loading shovel from the heading face into the skips. The installed loading equipment enables an efficient loading of the excavation material into the dump wagon without any great loss of material. The initial heading-face and ridge safeguards with shotcrete (sealing) is carried out with a shotcrete manipulator adapted to a roadway support machine work-basket. The shotcrete is supplied through a shotcrete transport. Supply of the shotcrete: The delivery of the pan mixer from the supply train directly to the shotcrete transport is managed with a heavy lift crane. Steel structure including covering matting: Roadway support machines with 20 kn roof timber supports, with two work baskets, and a manipulator arm as well as a special excavator with a manipulation adapter are used. The roof timber supports are suitable for the simultaneous placement and setting of up to a maximum of 3 preassembled steel-arch roof timbers (consisting of 3 elements each) in one circular cross-section with a diameter of max. 13m. The machine is so conceived that the ridge timber room is exactly positioned and can be placed in one work sequence; its load-bearing value amounts to 20 kn. Through that, the underlying work area is protected within the permissible loads. The remaining assembly of the segments up to the ring closure is then carried out using the manipulator arm and the work baskets. For acceleration, the telescope shovel dredger with a manipulation adapter is additionally used. D Vortrag-HJ-Sedrun-englisch doc Seite 5 von 21

6 The high performance heavy-lift crane brings the support arch for the steel support to the heading face. The preassembled arches are then mounted with the roadway support machine. The ring closure is carried out with the aid of the working baskets. The high performance heavy lift crane also guarantees the continual material flow from L3 into all areas of L2, in case the drive track is interrupted or obstructed through the monitoring and adjusting of the expansion ring lock. Consolidation of the advance: The heading face and expansion consolidation are carried out with shotcrete manipulator, adapted to one of both work baskets. The mobile concrete pump vehicle is loaded directly via the pan mixer. Radial anchoring: Radial anchors are set with the jumbo drill. All other devices are parked during this time. Anticyclical working face anchoring: During working face anchoring with a jumbo drill, the stratum in areas L2 / L3 can be exposed at the same time in order to monitor the steel support arches for applying the necessary shotcrete. Likewise, possible rework, for instance additional steel installations or additional anchoring can be carried out. This process is only used in every 6-9 advances. D Vortrag-HJ-Sedrun-englisch doc Seite 6 von 21

7 4 Multifunctional Heading Installation 4.1 Overall system The heading installation basically consists of the roadway support machine with workbaskets, shift arms, spray robots, a 20 ton heavy lift crane for supplying the work areas, a suspension platform with installations for aeration, cooling, etc. an infrastructure train with supply installations and the loading system for loading the waste trains. As well as construction equipment and construction machinery (loading shovel, jumbo drill, excavator, spray-mobile, etc.) The Suspended Installation concept was selected mainly for the following reasons: Creation of two work levels Rational direct supply of the work areas through a suspended heavy lift crane Performance and safety Heading installation layout D Vortrag-HJ-Sedrun-englisch doc Seite 7 von 21

8 D Vortrag-HJ-Sedrun-englisch doc Seite 8 von 21

9 The multi-functional advance installation during assembly D Vortrag-HJ-Sedrun-englisch doc Seite 9 von 21

10 4.2 Roadway support machine The roadway support machine concept has been being used in mining for a long time, but not in the dimensions as in the Sedrun Project. In cooperation with competent mining engineering technicians from the GTA Company, Rowa has further developed the roadway support machine for the Sedrun tunnel heading. The main tasks of the roadway support machine consist of: Steel arch installation placement in a safe and efficient manner Mechanized cutting of the heading face anchors from the work baskets Inclusion of the heading-facing seals (shotcrete) with spray robots at the work baskets D Vortrag-HJ-Sedrun-englisch doc Seite 10 von 21

11 Roadway support machine structure Steel-archway extension-placement operation Up to a maximum of three preassembled three-part roof cap elements are pre-mounted on the stratum and joined together on a removable day framework with a minimum clear interval of 33 cm into a headpiece roof. The roof cap elements are connected via clip bolts to the removable support framework during this. D Vortrag-HJ-Sedrun-englisch doc Seite 11 von 21

12 The thus pre-mounted headpiece roof is supported by the stratum via the roadway support machine manipulator. The gripper tongs firmly clamp into the corresponding pre-adjusted framework support during this. After acceptance of the pre-mounted headpiece roof by the manipulator, this is placed in the bogie-lift. After placing the complete headpiece roof into the lifting device, the roadway support construction machine is driven into the freed-up space at the heading face and arrested via the four bracing devices. The heading roof is lifted with the hoisting device, adjusted, and subsequently held in the roof. For adjusting, the hoisting device can be lifted, lowered, and telescoped. Furthermore, the mount table can also be longitudinally shifted, crossways shifted, and tilted. D Vortrag-HJ-Sedrun-englisch doc Seite 12 von 21

13 In the next step, the pre-mounted floor elbow (consisting of three individual segments) is taken up by the manipulator and positioned into the floor. The manipulator has all necessary degrees of freedom for this and is designed for this type of load with max 8 kn. The next operation is bringing both pre-mounted bench elbow pieces (consisting of two each individual segments) left and right and the attachment with the floor elbow piece. The work step is likewise carried out with the roadway support machine manipulator. To shorten the support steps, the excavator can be additionally equipped with a manipulation adapter. The bench elbows can then be attached parallel. D Vortrag-HJ-Sedrun-englisch doc Seite 13 von 21

14 Finally, the last two elbows (consisting of three individual elements each) are set and bolted left and right in the upper parament area. This operation can also be carried out in parallel with the roadway support machine manipulator and the excavator manipulation adapter. Procedure with the spray manipulator The spraying manipulator is mounted on the work-basket-2 side looking towards the middle of the route. In the unfolded working position, the entire cross-section with up to 13 m diameter can be coated with the spraying manipulator. D Vortrag-HJ-Sedrun-englisch doc Seite 14 von 21

15 Work test Special Machine for Rock Support An uncompromising mechanization, also in a conventional heading, increases performance, productivity and safety D Vortrag-HJ-Sedrun-englisch doc Seite 15 von 21

16 4.3 High-performance heavy lift crane The Rowa high-performance heavy lift crane supplies and clears the operations and the corresponding work areas directly from the supply train without intermediate unloading. All necessary material transport can be carried out due to the large amount of carrying capacity (20 t) of the crane. Take shotcrete for example: the pan mixers are unloaded from the supply train and brought directly to the spray-mobile or the mobile shotcrete pump. The heavy lift crane is driven to the same two suspended I140E special mounting rails on 8 leveled chassis per rail line just as is the roadway support machine. An ergonomically laid out driver s cage is set up on the crane. The entrance to the crane in the driver s cage is ensured via the suspended platform. The additionally installed diesel generator with builtin exhaust particulate filter supplies the crane with electrical power. The 2 hoisting winches are equipped with corresponding safeguards such as operations and overtravel limit switches. The longitudinal drive is carried out via 2 friction disc drives front and rear. Thus it is ensured that the crane is always drawn and pushed for the longitudinal displacement. The longitudinal drives are operated with a frequency converter to produce gentle acceleration and deceleration. Heavy duty crane: carrying force 20 tones D Vortrag-HJ-Sedrun-englisch doc Seite 16 von 21

17 Heavy duty loader with suspension platform 4.4 Suspended platform The suspended platform serves as a carrier device for the aeration and cooling. The accessibility is ensured through an extendable stairway. The longitudinal displacement of the complete suspended platform and aeration lines is carried out using 2 hydraulic feed units. The exchangeable air hose reel is replaced with the 2 chain hoists. The extension of the suspension rails is carried out on the disassembly platform, which is attached overhung to the rear of the suspension platform. The suspension rails are conveyed to the floor on left and right tracks using an electric chain pulley. D Vortrag-HJ-Sedrun-englisch doc Seite 17 von 21

18 Suspension platform during assembly 4.5 Infrastructure train with supply devices The infrastructure train serves as a carrier device for the necessary supply devices. The components are constructed on 5.8 m flat wagons. The infrastructure train consists of the following units: Wagon 1 Wagon 2 Wagons 3-7 Wagons 8+9 Wagons Wagon 12 Transformer and electrical installation Compressed air plant Material storage Workshop and team container Escape container, toilette Medium voltage cable drum with emergency power generating set D Vortrag-HJ-Sedrun-englisch doc Seite 18 von 21

19 4.6 Waste train loading equipment The loading equipment has the task of ensuring efficient loading of the waste wagons with the TORO loading equipment. During loading, a hopper is lowered into the skips and thus prevents material losses during loading. D Vortrag-HJ-Sedrun-englisch doc Seite 19 von 21

20 5 Rotary Tipper Rowa ROTARY III In the 4 headings the material is loaded by mobile loaders by means of a loading installation into the tipper wagons with a capacity of 12 m 3 each. A lift takes 2 tipper wagons to the surface, where trains of 6 wagons each are put together again. From here the trains arrive at the unloading area, where 2 parallel material handling lines are located for the separation of the material into the excavated material classes A, B and Z. A rotary tipper with a loading bunker of 80 m 3 including an outlet conveyor and an impact crusher unit is installed on the line 1, taking care of the further processing of the material. On the line 2 there is a rotary tipper with a loading bunker of 80 m 3 including an outlet conveyor and an impact crusher unit for the subsequent processing, as well as another rotary tipper for the Z-material, which is removed by trucks. Every rotary tipper is able to unload simultaneously 2 tipper wagons with a total volume of 24 m3. Wagon release and fastening is carried out automatically. The entire tipping process is controlled by the engine driver, without this person needing to leave the locomotive. With the rotary tipper, the engine driver unloads a train with six wagons in less than ten minutes. Every rotary tipper is able to unload simultaneously 2 tipper wagons with a total volume of 24 m 3. D Vortrag-HJ-Sedrun-englisch doc Seite 20 von 21

21 6 Rowa strengths in the Sedrun Project Rowa strengths in the Sedrun Project The Sedrun project is an unusual construction project for all participants. New ideas in the planning phase practical, safe solutions in the implementation phase were and are asked for. Not all the systems supplied by Rowa are being used yet; the true test is still to come. Still, we are proud of our supplies and services for this project. The systems that was able to supply for ARGE Transco are an outstanding example of our abilities. Together with the customers, Rowa is in the position of being able to develop, projectplan, manufacture, and operate very demanding special systems for complex construction processes. They materialized under the following influences: The early inclusion of Rowa Rowa carried out extensive studies, variations, and feasibility studies already during the project planning phase. Through that, we were able to input our know-how including that of our partner (GTA Maschinensysteme GmbH) early on. Mutual development The multifunctional heading device, which you will see on-site, is part of a total system that was developed and optimized for the construction site requirements. The product is a mutual development by the customer and Rowa. Competence We lay claim to being competent, especially in the area of system construction for tunneling and in the area of project management. Regarding the matter in its entirety is our strength. However, we don t know everything better therefore we include external specialists and competences in the project for the benefit of the customer. Reliability Rowa has supplied, assembled, and tested all systems in Sedrun on time. Our customers can be sure they will have the required functions and services available on time. The systems are constructed for heavy-duty use in tunnels. Rowa offers a comprehensive services catalog Here in Sedrun you see 1:1 high performance heading installations for drill and blast special systems for rock safeguards rotary tippers Wangen, September 2004 D Vortrag-HJ-Sedrun-englisch doc Seite 21 von 21