Risk Management - TBM Manufacturer s Perspective II

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Lauren Shelton
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1 November 14-16, 2016 Risk Management - TBM Manufacturer s Perspective II

2 History of LOVSUNS 350 TBMs Built to Date

3 History of Risk Management Techniques Developed in the Late 60 s by NASA during the Apollo Mission In 1974, US Navy Adopted it in the Weapons Program In the Late 1970 s the Automotive Industries was Driven by Liability Cost to Use FMEA and Later Required Suppliers to do the Same

4 Types of Risk Assessment System Risk Assessment Highest Level Risk Assessment and Focus on System Related Deficiencies such as Safety System, System Interfaces or Integration between Subsystems to Humans and/or Environment. Design Risk Assessment Focuses on Product Design with Emphasis on Minimizing Design Risk and Ensuring Product Operation is Safe and Reliable During Equipment life. Process Risk Assessment Focuses on Operation or Assembly Process with Emphasis on how Process Risk can be Minimized to Ensure the Product is Built to Design Requirement in a Safe Manner with Minimal Downtime, Waste and Rework.

5 Types of Risk Assessment 1.0 RME257SE EPB TBM 1.1 Cuttinghead System 1.2 Main Drive System 1.3 Main Drive Sealing System 1.4 RFJ System 1.5 Active Articulation System 1.6 Passive Articulation System 1.7 Airlock System 1.8 Propulsion System Propulsion Cylinders Propulsion Pump Propulsion Manifolds Propulsion Pads 1.9 Screw Conveyor System System Level Item Identification Design Level Item Identification

Conducting Risk Assessment Analysis Risk Management Process should be Part of your Project Management Plan and should Start at the Project Planning

6 Conducting Risk Assessment Analysis Risk Management Process should be Part of your Project Management Plan and should Start at the Project Planning Stage:- Key Inputs Required - Project Charter - Project Management Plan - Stakeholder Register - Enterprise Environmental factors - Organizational Process Assets

Conducting Risk Assessment Analysis Tips - Break it Down (by System, by Function, by Process) - Agreed on a Scaling System First - Draw From Past Successes and Failures -

7 Conducting Risk Assessment Analysis Tips - Break it Down (by System, by Function, by Process) - Agreed on a Scaling System First - Draw From Past Successes and Failures - Involve the Right People (SME) - Do it in Multiple Sessions - Take a Course in Conflict Resolution and How to Manage a Meeting The Process Does Get Easier the Third Time Around!!!

8 TBM Supplier s Perspective on Risk Management

9 TBM Supplier Risk Management TBM Manufacturer s Roles in Project Risk Management Solution provider - Types of TBM - Features on TBM - Technical Assistance - Spare Parts Support

10 TBM Supplier s Risk Management - GBR and Tunnel Alignment - Equipment Specification and Performance - Equipment Delivery - Operation and Maintenance - Contract Terms Needed to provide the right tools for the Project!!!

11 GBR and Tunnel Alignment Detail Geotechnical Baseline Report containing at a minimum:- - Quantity and Depth of Bore Hole Analysis - Groundwater Condition (Expected Inflow and Pressure) - Grain Size Distribution - Rock Strength and RMR - Boulders, Faults, Obstacles along Alignment - Operating and Maximum EPB Pressure - Presence of Hazardous Gas Alignment Details Containing at a minimum:- - Tunnel Lengths and Shaft/Portal details - Maximum Vertical Slope and Minimum Horizontal Radius - Segment Details

Equipment Specification and Performance - Owner s

Regulatory Standards and Requirement - Contractor s

Manufacturer s Past Experience and Internal

12 Equipment Specification and Performance - Owner s requirement Typically very Descriptive - Local Regulatory Standards and Requirement - Contractor s Equipment Requirement and Performance Expectation - Manufacturer s Past Experience and Internal Standards - Transportation, Assembly and Disassembly Restrictions

13 Equipment Specification and Performance EPB TBM Features that can assist to Mitigate Risks - Cuttinghead Design - Tool Selection - Airlock - EPB Sensors - Ground Conditioning - Probe Drilling - Emergency Inflatable Seal - Data logging

opening as 50% to Reduce clogging in the

14 Cuttinghead Design 14mm thick CrC on Cuttinghead Face 19mm thick CrC on Cuttinghead Rim 5 No. injection ports on Cuttinghead face 1 No. Injection ports on Cuttinghead Gauge Cuttinghead opening 32%~35% Center opening as 50% to Reduce clogging in the center Interchangeable Rippers and Disc Cutters Wear detection on face of Cuttinghead

15 Tool Selection Disc Cutters Single tip and Twin tip type disc cutters used for mixed ground conditions containing boulders & hard rock. Different disc cutter tip spacing are used to cut the rock efficiently. Lovsuns Tunneling provides 12.0,13.0,15.0, 15.5 & 17 Single tip, Twin tip and Center cutters with replaceable rings.

16 Tool Selection Rippers Used in Soft Ground Three Styles for different grounds (Clay, Weak Rock and Abrasive soil) Main Excavation tool for EPB Pressurized Oil Circuit

17 EPB Sensors Additional EPB Cells on top of Forward Shell 2 No. EPB Cells Inside Screw Conveyors 6 No. EPB Cells Inside Cuttinghead Chamber

18 GROUND CONDITIONING When a ground type does not have the ideal characteristics of fluidity and plasticity, ground conditioning can be used to modified & improve its ability to transmit the confinement pressure.

19 GROUND CONDITIONING SYSTEM

20 Probe Drill or Polarization Ground Detection Technique

21 Probe Drill or Polarization Ground Detection Technique

22 Emergency Inflatable Seal

23 TBM DATA LOGGING Web Edition Surface (Site Location) Tunnel TBM System Parameters PLC / Data Acquisition Module Cutterhead Speed, Torque, Direction, Hours, Flood Door Opening Site LAN (Local Area Network for TBM) Hosting of Data Tunnel Media Articulation Extension, Cylinder Pressure, Total Thrust, Center of Thrust/Offset Firewall Windows Server (SQL) Propulsion Main Drive Forward Shell Extension, Cylinder Pressure, Total Thrust, Center of Thrust/Offset Main Bearing Lube Flow, Sealing Systems Flow and Pressures Chamber Earth Pressures Hosting of Data InterNet Optional End User Supplied Hardware Remote Client Connection(s) Remote Client Connection(s) LOVAT Supplied Hardware HMI / Operators Interface LOVAT Supplied Hardware Note: The EtherNet within the TBM, wireless and plug in both can facilitate the connections of PC s/laptops to support the hosting of data. Screw Conveyor Speed, Torque, Earth Pressures, Guillotine Gate Position Remote (Off Site) Remote (Off Site) Trailing Belt Conveyor Excavation Rate, Excavated Material Totalizer LAN Edition Ground Conditioning System Output Totals, Injection Pressures and Flow Rates Surface (Site Location) Generic Workstation Tunnel TBM PLC / Data Acquisition Module Grout System Injection Pressures and Accumulated Volumes, Rate Site LAN (Local Area Network for TBM) Hosting of Data Tunnel Media Environmental Methane and Toxic Gases Windows Server (SQL) Hydraulic Systems Electrical Systems Oil Temperatures, System Pressures Motor Current Loads, TBM Power Monitoring (kva, kw, PF, Amps and Volts) Optional End User Supplied Hardware Notes: 1. This package can operate standalone, as delivered 2. Connection of Client Workstations rely on the infrastructure provided by the client. LOVAT Supplied Hardware HMI / Operators Interface LOVAT Supplied Hardware Note: The EtherNet within the TBM, wireless and plug in both can facilitate the connections of PC s/laptops to support the hosting of data. Remote (Off Site) Remote (Off Site)

24 Additional Features Other TBM Features that can help Mitigate Risks - Emergency Bentonite System - Enhanced De-watering System - Explosion Proof Design - Internal Disassembly or Bearing Replacement Design

25 Equipment Delivery TBM Delivery is often on the Project s Critical Path Currently there are two type of Equipment Procurement Model - Owner Procured - Contractor Procured Delivery Risk for TBM Supplier - Major Component Delivery (i.e. MD Bearing, Gear boxes) - Workshop Capacity - Project Management

26 Major Components Supplier List S/N KEY TBM COMPONENTS MANUFACTURER REMARKS 1 MAIN BEARING SKF / ROTEK FRANCE / USA 2 GEAR REDUCER REXROTH /MITSUI MIIKE GERMANY / JAPAN 3 MAIN DRIVE VFD MOTORS SIEMENS (LOHER) GERMANY 4 (ELECTRIC MAIN DRIVE) VFD DRIVE ABB ABB CHINA 5 GREASE PUMPS GRACO USA 6 MAIN BEARING SEALS MERKEL GERMANY 7 MAIN BEARING SKF / ROTEK FRANCE 8 HYDRAULIC MOTORS SAUER DANFOSS / REXROTH GERMANY 9 GEAR REDUCER REXROTH /MITSUI MIIKE GERMANY/ JAPAN 10 MAIN DRIVE HYDRAULIC PUMPS PARKER USA 11 (HYDRAULIC MAIN DRIVE) ELECTRIC MOTORS SIEMENS (LOHER) GERMANY 12 HYDRAULIC VALVES PARKER / REXROTH etc. USA / GERMANY 13 GREASE PUMPS GRACO USA 14 MAIN BEARING SEALS MERKEL GERMANY 15 DRIVE MOTORS SAUER DANFOSS / REXROTH GERMANY 16 Screw Conveyor BONFIGLIOLI / REGGIANNA GEAR REDUCER RIDUTTORI ITALY 17 PROPULSION CYLINDERS JIANGSU HENGLI /SHANGHAI 18 PROPULSION SYSTEM ARTICULATION CYLINDERS LONGGONG CHINA 19 HYDRAULIC VALVES PARKER / REXROTH etc. USA / GERMANY 20 TRANSFORMER SCHNEIDER SCHNEIDER CHINA 21 POWER COMPENSATION 22 ELECTRICAL PARTS DISTRIBUTION CABINENTS EATON / CUTTLER-HAMER / ABB COMPONENTS USA / GERMANY 23 PLC COMPONENTS ABB USA 24 GROUT SYSTEM INJECTION PUMPS WATSON MARLOW /SUG USA / GERMANY BONFIGLIOLI / REGGIANNA 25 GEAR REDUCER RIDUTTORI ITALY SEGMENT ERECTOR 26 HYDRAULIC MOTORS PARKER / REXROTH USA / GERMANY 27 HYDRAULIC COMPONENTS PARKER / REXROTH / HAWE etc. USA / GERMANY 28 GUIDANCE SYSTEM TOTAL STATION TACS GERMANY 29 OPERATING SYSTEM OPERATING COMPUTER DELL USA / CHINA 30 COMPRESSED AIR SYSTEM AIR COMPRESSOR ATLAS COPCO ATLAS COPCO CHINA 31 GROUND CONDITIONING SYSTEM FOAM PUMP SEEPEX / MOYNO SEEPEX / MONYO CHINA NOTE: FINAL SUPPLIER SUBJECT TO CONTRACTUAL TBM DESIGN SPECIFICATION AND AVAILABILITY

27 Key Purchased & Manufactured Components Engineering Project Management Production Support Liaoyang Facility, China Manufactured Components

28 Project Management Project Management and Project Planning Follows PMOK Methodologies. Develop the Project Charter Identification of Work Breakdown Structures High Level Planning with Control Team Identify high level critical path

29 Project Planning Detailed Planning over 2000 activities per project Network Diagrams establish activity relationships Validation Sessions Setting the Baseline Establish Controlling Paths

30 Project Monitoring Weekly control cycle to monitor progress Issues addressed immediately Maintain continuous team focus on target completion date Reporting activity status via Web Based Updates Accountability people responsible are reporting

31 Project Control Weekly Control Meetings Successes & Current Events Controlling Paths Start & Finish On-Time Metrics Project Variance Near Term Critical Activities Status of Critical Purchased Items Financial Review Review of Old Action Items Creation of New Action Items Status Memo - Company Wide Compression Sessions Senior Management Reviews

32 Project Closure Post Mortem

33 TBM Operation and Maintenance Traditional TBM Technical Support Model - Factory Training - Support on TBM Assembly led by Manufacturer s Technicians - Technical Support on Initial 200m drive led by Manufacturer s Technicians - Remote troubleshooting

Productivity and Minimize Downtime Support TBM until Performance Requirement is met or until

34 TBM Operation and Maintenance Current TBM Support Model to Increase Risk mitigation TBM Supplier to Train, Assist and Conduct TBM Preventative Maintenance to ensure Maximum Productivity and Minimize Downtime Support TBM until Performance Requirement is met or until Tunnel Completion Field Service Technician dispatch to jobsite with 24 hours notice for emergency troubleshooting

35 TBM Operation and Maintenance Consignment Parts - On site (Critical Spare parts, Job Stoppers) - In Factory (Main Drive Bearing, Gear boxes) Establish Local Repair and Supply for Long Term support

36 TBM Contracts Contract has the Potential to Create Many Risks that are often overlook Trend is to Transfer more Risk Downstream to TBM Supplier. - Increase Total Liability to Equipment Supplier - Collateral Warranty to allow Project Owner to claim against TBM supplier - APG, LCs - Performance Guarantee TBM Supplier is working with Contractors much Sooner in their tender Process.

37 Thank You

2 Technology of closed-face tunnelling machines

2 Technology of closed-face tunnelling machines 2.1 Machine types There are two basic types of pressurised closed-face tunnelling systems slurry tunnelling machines (STMs) and earth pressure balance machines