Principles for Tunnel Design. 20th to 21st April 2017 Kuala Lumpur

Transcription

1 20th to 21st April 2017 Kuala Lumpur Mechanized Tunneling (TBM and Support Systems) Thorsten Tatzki Herrenknecht Asia Headquarters Pte. Ltd.

2 Introduction: General Overview Shield Machines and Tunnel Boring Machines EPB Shield Slurry Shield/Mixshield Multi-mode TBM Single Shield TBM Double Shield TBM Gripper TBM 2

3 Outline of Lecture Selection of Tunnelling Machines DAUB Classification Scheme Geotechnics Lining / Support Influencing Aspects Key Elements of Machine Design Mechanized Tunnelling for Soil Conditions Earth Pressure Balance Shield Machines Slurry Shield Machine / Mixshield Machines Multi Mode Machines Important Technical Trends Literature / Links Mechanized Tunnelling for Rock Gripper Single Shield Double Shield 3

4 Selection of Tunnelling Machines 4

5 Selection of Tunnelling Machines - DAUB Classification Scheme according DAUB for all Type of Tunnelling Machines Rock Deutscher Ausschuss fuer unterirdisches Bauen: DAUB Established in December 1972, the German Tunnelling Committee works on the development and standardization of techniques in underground construction. Source: DAUB Recommendations for the Selection of Tunnel Boring Machines ( ) Soil/ soft ground 5

6 Selection of Tunnelling Machines - Geotechnics General information: Geological longitudinal profile with vertical alignment of the tunnel (max./min. gradient) and borehole locations Layer structure & Groundwater conditions (max./min. groundwater pressure during construction) Horizontal alignment (max./min. radius) of the tunnel with borehole locations Details about the soil layers: Grain size distribution curves Specific weights / Shear parameters:, c, c u Permeability k In case of fine soil: clay mineralogy and consistency (Atterberg Limits) In case of granular soil: Quartz content Modulus of elasticity E s Possible existence of boulders: rock type, expected amount, expected sizes, UCS, quartz content, CAI In situ stress situation: Earth pressure coefficient K 0 6

7 Selection of Tunnelling Machines Lining / Support Possible types of lining in shield tunnelling Source: Mechanised Shield Tunnelling Methods of supporting the ground and holding water at the face Source: Mechanised Shield Tunnelling 7

8 Selection of Tunnelling Machines Key Elements of Machine Design GEOLOGY + HYDROGEOLOGY Design of shield structure Torque calculation GEOTECHNICS Thrust force calculation Support pressure calculation Wear prognosis 8

9 Selection of Tunnelling Machines Key Elements of Machine Design Interface Ground & TBM: support pressure Some important questions: Where is highest overburden? Where is highest water level above crown? Where are the highest surface loads? Lowest inner friction angle? GOK z 1 SILO Lowest cohesion? GW b t Foundation loads? z 2 t w p(t) ERDKEIL R G SCHILD p LP S D p(t) F G K 90 R G E E R F+K 9

10 Selection of Tunnelling Machines Key Elements of Machine Design Interface Ground & TBM Shield Loads External loads: Water and earth pressure Rock burst, Swelling pressure, Squeezing pressure Steering movements Vertical earth pressure (crown) Vertical water pressure (crown) Horizotal water pressure Buoyancy Internal loads: Pressure on bulk head k = 6 MN/m 3 G Thrust forces Erector and ring built Weight of the components (drive, bridge ) Grease pressure (tail skin sealing) Vertical earth pressure (invert) Vertical earth pressure (invert) Horizontal earth pressure 10

11 Selection of Tunnelling Machines Key Elements of Machine Design Interface Ground & TBM Thrust Force Friction of the shield coat W 2 r l 0,5 M V H Thrust resistance of cutting edge Wsch 2 r p sch t Cutterhead thrust WBA maximum tool thrust or thrust of displacement cylinders Drag force tailskin seal FSSW D Tübbing * P s F SP W M Drag force back-up system FNL empirical value Support pressure FSP support pressure calculation W BA G W NL Force of thrust cylinders W W M W Sch W BA F S F NL F SP 11

12 Selection of Tunnelling Machines Key Elements of Machine Design Interface Ground & Wear and Performance Weak rock: High penetration Large crushing zone with low thrust and small angle Hard rock: Low penetration Small crushing zone with high thrust and large angle 12

13 Mechanized Tunnelling for Rock 13

14 Selection of Tunnelling Machines Mechanized Tunnelling for Rock Gripper Functional Principle Thrust cylinders Cutterhead Roof shield Probe drilling unit Gripper shoes Muck ring Buckets Roof bolting unit Machine support Ring beam erector Machine belt 14

15 Selection of Tunnelling Machines Mechanized Tunnelling for Rock Single Gripper TBM: S-155 Tscharner, 9.53m Double Gripper TBM: S-96 TBM 3000, 3.00m Shielded TBM with articulation joint: S- 163 Sörenberg, 4.56m Double Shield TBM: S-153 La Réunion, 3.80m Overview of the various machine systems of TBM with full face excavation Source: Hardrock Tunnel Boring Machines,

16 Selection of Tunnelling Machines Gripper Cutterhead 2. Cutterhead support 3. Ring erector 4. Anchor drilling devices 5. Wire mesh erector 6. Gripper plates 7. Automatic shotcrete robot 16

17 Selection of Tunnelling Machines Gripper / Mucking 17

18 Selection of Tunnelling Machines Gripper / Cutting Wheel Wear protection measures on cutterhead for blocky face conditions Heavy bucket lips Hardox-plates on entire surface Protection blocks for cutter discs Overcutting with shifting Gauge Cutter Grain size limiters for buckets 18

19 Selection of Tunnelling Machines Gripper / Tunnel Support 19

20 Selection of Tunnelling Machines Gripper / Probe Drilling Gripper TBM. Tunnel support in working area L1 Exploration Drilling Drainage and Injection Core Sampling Geological Investigations 20

21 Selection of Tunnelling Machines Gripper / Ring Beam Installation 21

22 Selection of Tunnelling Machines Gripper / Wire Mesh Installation 22

23 Selection of Tunnelling Machines Gripper / L2 Area (Shotcrete Robot) Rock drills Shotcrete robot 23

24 Selection of Tunnelling Machines Gripper / Performance Gripper TBM Rock Conditions vs TBM Performance Rock support The performance of the Gripper TBM depends mainly on the rock and support classes Source: Schmid L.: Einsatz großer Tunnelbohrmaschinen verschiedener Bauart in der Schweiz Leistungen und Wirtschaftlichkeit. In: Forschung + Praxis 29.,

25 Selection of Tunnelling Machines Mechanized Tunnelling for Rock Single Shield Functional Principle Buckets Shield skin Thrust cylinders Backfilling Muck ring Cutterhead Machine belt Erector 25

26 Selection of Tunnelling Machines Single Shield / Swiss Double Lining Swiss Double Lining System With Thrust Ring. 1. Withdrawal of the thrust ring and placing of the bottom segments. 2. Placing of the left and right tunnel side wall segments. 3. Placing of the crown segment and Spreading of the bottom segments 4. Placing of the key stone and Pushing forward of the thrust ring 26

27 Selection of Tunnelling Machines Single Shield / Special Design Swing support roller Single Shield TBM with Thrust Ring. Thrust ring 27

28 Selection of Tunnelling Machines Mechanized Tunnelling for Rock Double Shield Functional Principle Front shield Stabilizers Telescopic shield Gripper shield Gripper shoes Cutterhead Muck ring Machine belt Erector Torque cylinders Main thrust cylinders Auxiliary thrust cylinders 28

29 Selection of Tunnelling Machines Double Shield / Telescopic Shield Thrust cylinders Open telescope 29

30 Selection of Tunnelling Machines Double Shield / Logistic Double Shield TBM / Single Shield TBM Logistics DOUBLE-SHIELD Tunnelling Ring-building Moving of machine SINGLE-SHIELD Tunnelling Ring-building 30

31 Mechanized Tunnelling for Soil 31

32 Selection of Tunnelling Machines Mechanised Tunnelling for Soil Conditions Thrust cylinders Tailskin Backfilling Air lock Tunnel lining Bulkhead Earth Pressure Balance Shield (EPB) Functional Principle. Cutting wheel Mixing arms Erector Excavation chamber Screw conveyor Belt conveyor 32

33 Selection of Tunnelling Machines EPB / Application Range (1): Typical range for EPB with 30% fines (<0.06mm) (2): permeability k < 10-5 m/s k ~ d10 2 = 0.03mm 2 = 10-5 m/s (3): not under water pressure Source: Mechanised Shield Tunnelling B. Maidl, M. Herrenknecht, L. Anheuser 33

34 Selection of Tunnelling Machines Functional Principle EPB Ideal application on soils with: High plasticity Low inner friction Low permeability Aim is to maintain conditions with: Good homogeneous pressure distribution & pressure variation Low torque for low energy consumption Low wear 34

35 Selection of Tunnelling Machines Functional Principle EPB 6 1. Cutting Wheel 2. Main Drive Excavation Chamber Screw Conveyor 5. Erector 6. Shield 7. Thrust Cylinders Belt Conveyor 9. Segment Feeder 7 10.Man lock 11.Backup Gantries / Bridge 12.Tunnel Wall 35

36 Selection of Tunnelling Machines Functional Principle EPB Support pressure regulation Advance speed (thrust cylinders) Rotation speed screw conveyor 36

37 Selection of Tunnelling Machines Functional Principle EPB Support pressure regulation Closed Mode To avoid groundwater inflow For unstable tunnel face Settlement control 37

38 Selection of Tunnelling Machines Mechanised Tunnelling for Soil Conditions Tailskin Bulkhead Air lock Thrust cylinders Backfilling or grouting Air cushion Mixshield Cutting wheel Functional Principle. Submerged wall Jaw crusher Slurry circuit Erector 38

39 Selection of Tunnelling Machines Mixshield / Application Range Source: Mechanised Shield Tunnelling B. Maidl, M. Herrenknecht, L. Anheuser 39

40 Selection of Tunnelling Machines Mixshield / Filter Cake Trial: Muck Cake under compressed air Face with Muck Cake / Geology Sand and Gravel Source: Pictures from Project S- 321 / Arge Nordsued Stadtbahn Koeln 40

41 Selection of Tunnelling Machines Slurry Shield Principal 6 Legend: 1 2 Pressure area 1. Tunnel face 5. Man lock 3 8 Atmospheric area 2. Cutting wheel 6. Support pressure Slurry feed line 3. Excavation chamber 7. Regulation of support pressure 4. Pressure bulkhead 8. Support medium (slurry) Slurry discharge line One chamber system Regulation and control of support pressure by flow of feed and discharge pump Control of support pressure by pressure sensors Closed type cutting wheel System is typical for Japan due to geology Partly clay suspension as support medium Further development for cohesive soils led to principle of EPB-Shield 41

42 Selection of Tunnelling Machines Mixshield Principal Pressure area Atmospheric area Legende: Tunnel face 2. Cutting wheel 3. Excavation chamber Submerged wall 1 5. Excavation chamber 9 6. Air bubble 5 11 Slurry feed line Slurry discharge line 7. Pressure bulkhead 8. Man lock 9. Support pressure 10. Regulation of support pressure 11. Support medium 42

43 Selection of Tunnelling Machines Mixshield / Support Pressure 3 Pressure to be adjusted 2 1 Regulation of support pressure by air bubble (Mixshield) Regulation of support pressure by pumps (Slurry shield) Time (s) 43

44 Selection of Tunnelling Machines Mixshield / Slurry Cycle Slurry = Support of tunnel face and transport medium Compressor station (Bentonite) slurry Mixing plant Separation plant Muck discharge Slurry discharge line Slurry feed line TBM Compressed air regulation Slurry circuit 44

45 Selection of Tunnelling Machines Mixshield Design 1. Cutting Wheel 2. Bulkhead Air Cushion 4. Submerged Wall 5. Slurry Line Stone-crusher 8 7. Feed Line 8. Erector

46 Selection of Tunnelling Machines Multi Mode Machines Open Mode Single Shield TBM Conversion integrated modular Slurry Shield EPB Shield Closed Mode 46

47 Selection of Tunnelling Machines Convertible Machines Modular system: Exchange of subassemblies or specific modules conversion in shaft Integrated system: Dual systems on Board conversion in tunnel 47

48 Selection of Tunnelling Machines EPB / Open Mode Integrated Concept Closed Mode - EPB Screw conveyor in extended position (maximum capacity) Center belt conveyor and muck ring retracted. Cutter head muck chutes partly dismantled. Open Mode Screw conveyor in retracted position (reduced capacity) Center belt conveyor and muck ring in working position. Cutter head muck chutes completely installed 48

49 Selection of Tunnelling Machines Slurry / Open Mode Integrated Concept Special Variant Hallandsas Closed Mode Open Mode 49

50 Selection of Tunnelling Machines EPB/Slurry Variable Density System Screw conveyor and slurry circuit can be permanently installed Support mode can be gradually changed between EPB mode and Slurry Mode Mucking can be done with Belt Conveyor or Slurry Circuit Slurry Mode EPB Mode 50

51 Cutter Head Selection of Tunnelling Machines Variable Density System I. Tunnelling through heterogenous ground condition II. Combining Mixshield Mode and EPB Mode III. Variation of the support medium density IV. Variation of the muck transportation Excavation Chamber Working Chamber with air bubble Flushing box with drum crusher High density slurry Bentonite feed line Slurry discharge line Screw conveyor Slurry pump 51

52 Selection of Tunnelling Machines Slurry / EPB Application Range EPB / MIX Shield Range 100 Clay Fine Sieve Size Silt Sand Gravel Medium Coarse Fine Medium Coarse Fine Medium Coarse ,001 0,002 0,006 0,02 0,06 0,2 0,6 2,0 6, ,0 52

53 Selection of Tunnelling Machines 4 Operation Mode MODE 1 EPB closed mode MODE 2 EPB closed mode with additional bentonite support MODE 3 Mixshield mode with LDSM (bentonite slurry ) MODE 4 HDSM - Mode FACE SUPPORT EPB - TBM Mixshield TBM Variable Density - TBM TRANSPORT OF EXCAVATED MATERIAL DRY MUCKING HYDRAULIC Transportation possible HYDRAULIC Transportation required 53

54 Selection of Tunnelling Machines Mixed Face Conditions in the KL-limestone. Sinkhole! Collapsed cavity Cavity Surface Overhang GW Soft ground Hard rock 54

55 Selection of Tunnelling Machines Variation Of Support Medium Density. LDSM - low density support medium HDSM - high density support medium Ground level GW Pressure gradient with LDSM (γ ld ) p SL γ ld x h earth pressure Slurry pressure p SL (γ hd > γ ld ) Pressure gradient with HDSM (γ hd ) p SL γ hd x h water pressure h F S _LDSM = F S_ HDSM 55

56 Face Pressure [bar] Selection of Tunnelling Machines Important Technical Trends Multi Purpose Tunnels Multi Mode Machine Development Larger TBM Diameters 17,5 Higher Pressures 15,0 12,5 WESTERSCHELDE Mixshield, Ø 11.4m LAKE MEAD Mixshield, Ø 7.18m 14,0 HALLANDSAS Mixshield, Ø 10.53m ISTANBUL Mixshield, Ø 13.71m 10,0 MÜLHEIM Mixshield, Ø 6.9m HAMBURG 4TH ELBTUNNEL Mixshield, Ø 14.2m 11,0 11,0 7,5 GRAUHOLZ Mixshield, Ø 11.6m 7,5 5,0 HERA HAMBURG Mixshield, Ø 6.0m 3,5 3,5 SYDNEY Mixshield, Ø 10.4m 4,0 5,5 2,5 2, HERA 5.95m 1996 Sydney 10.70m 1997 Hamburg 14.20m 2006 Shanghai 15.43m 2013 Hong Kong 17.6m Concept St. Petersburg 19.25m 0,0 DIVERS ENGAGED 56

57 Literature / Links B. Maidl, M. Herrenknecht, U. Maidl, G. Wehrmeyer: Mechanised Shield Tunnelling; 2. Edition, 2011 B. Maidl, L. Schmid, W. Rotz, M. Herrenknecht: Hardrock Tunnel Boring Machines, 2008 Deutscher Ausschuss fuer unterirdisches Bauen (DAUB): Recommendations for selecting and evaluating tunnel boring, 1997 German-Czech Scientific Foundation: Mechanised Tunnelling and Segmental Lining, 2009 Schmid L.: Einsatz großer Tunnelbohrmaschinen verschiedener Bauart in der Schweiz Leistungen und Wirtschaftlichkeit. In: Forschung + Praxis 29., 1980 D. Kolymbas: Tunnelling and Tunnel Mechanics; 2. Edition,

58 20th to 21st April 2017 Kuala Lumpur Disclaimer a) The speakers are presenting their own personal views and are not expressing the view of the Foundation. b) Papers and documents displayed or handed out during the Event are copyrighted. The participants must observe and comply with all applicable law regulations concerning the copyright. 58