Variable Density TBMs

Variable Density TBMs
Geotechnical and Mechanical Principles
Dr. Ruben Duhme, Herrenknecht AG
TUCSS Seminar 13. April 2018

Agenda
1. Mechanics of Tunnel Face Support and Support Pressure Regulation

1. EPB and Mixshield Principle
2. Difficult Geological Settings – Low Overburden, Cavities
3. Variable Density Principle
4. High Density Support Media
2. Variable Density TBM Technology
1. Variants and Options of Variable Density TBMs
2. VD TBM without HDSM
3. VD TBM with HDSM
4. Mucking Systems & Conversion
5. Performance Aspects
Herrenknecht Variable DensityTBMs

Slide 2 Dr. Ruben Duhme
Different Geology Requires Different Face Support

What is a “Multimode Machine”?
 Different Types of Face Support  Different Types of Extraction from

Chamber (Primary Mucking)
 No Active Support
 Belt Conveyoer
 Compressed Air Support
 Slurry Support  Screw Conveyor
 Pumping
 High Density Slurry Support
 Earth Pressure Support
 Different Types of Mucking on TBM

(Secondary Mucking)
 Belt Conveyoer
 Slurry Circuit

EPB Principle for Face Support
 Formation of “plug” in screw conveyor holds pressure

 Transfer of face support pressure by conditioned muck
 Balance of screw conveyor extraction rate and advance rate to control pressure
 Full chamber leads to high torque and wear

EPB Standard Machine - Operation Modes
Closed Mode – EPB

• active face support
• Max. 6 to 8 bar, depending on soil and
conditioning.
Closed Mode – Compressed Air

• Non-standard application
• Control of water inflow
• Max. 2.5 bar, depending on soil and
conditioning.
Open Mode
• Stable tunnel face
• Excavation chamber without pressure
• Quick isolation of excavation chamber is
possible
• Min. filling grade required

Limits of EPB Pressure Control
 Excess water permeability prevents pressure control

 Full Chamber of abrasive rock leads to excessive wear
 Rock chips cannot transfer support pressure to face
 Interventions in mixed ground not possible without pressure loss and water inflow
 Annular gap grout washed out due to lack of pressure control
Image Source:
Prof. Markus Thewes
DTSS Stage 1 T05

Face Support with Bentonite Filter Cake

Slurry Shield Support Pressure Control
Pressure area
Atmospheric area
Legend:
1. Tunnel face 5. Man lock
5
3 2. Cutting wheel 6. Support pressure
2 3. Excavation chamber 7. Regulation of
support pressure
4. Pressure bulkhead 8. Support medium
4 7
(slurry)
1
Slurry feed line
6
8
Slurry discharge line
 Regulation of support pressure by flow of feed and discharge pump (Big & Heavy Parts!!)
 No room for rock crusher at suction pipe
 Mainly used in microtunneling applications and Japanese TBMs
Mixshield Support Pressure Control
 Slurry Mixshield ® system

 Support pressure regulated by air cushion
 More accurate face pressure control
 Minimized the risk of settlements

Limits of Mixshield Pressure Control
 Suspension loss due to blowouts and cavities known in karst formations

 Clogging must be addressed, influence on mucking, advance rate and pressures
 In low overburden, blowout possible if wrong support pressure and medium
 Separation plant must be sufficient, especially for fines

Variable Density TBM Principle
 Seamless transition between EPB and Mixshield mode (and everything in between)
 Additional High Density Support Medium (HDSM) possible

Blowout Prevention in Low Overburden
Pressure gradient with LDSM (γld ) pSL – γld x h
Slurry pressure pSL

earth pressure
Pressure gradient with HDSM (γhd ) pSL – γhd x h
water pressure
FS _LDSM = FS_ HDSM

Page 13

Determination of Required Support Medium Density
Hydrostatic height of the supporting liquid
39,00
38,00
37,00
36,00
Paxis= 4.55 bars
35,00 Upper
34,00 level
33,00 gel.
Height [m]
32,00 GW level
31,00
30,00
29,00
28,00
27,00
Covering: 30.00 m
26,00
Groundwater level 28.00 m
25,00
Water pressure (TBM axis) 314.0 kPa
24,00
Face support pressure
23,00 415.0 kPa
(axis)
22,00
21,00
Pressure fluctuations ± 20.00 kPa
20,00
10,00 10,50 11,00 11,50 12,00 12,50 13,00 13,50 14,00 14,50 15,00 15,50 16,00 16,50
Support medium density [kN/m³]

Prevention of Support Pressure Loss in Karst
 Thicker support medium less likely to be lost into cavities due to viscosity
 Lost bentonite can be replenished from HDSM tanks on gantry immediately
 HDSM tanks can be refilled from surface HDSM plant directly
Slurry mixing plants Separation plant
Buffer tank Slurry line
HDSM
Buffer tank LDSM HDSM

muck yard
Compressed-air LDSM Mixer Mixer Transfer pump
plant HDSM
Feed line
Buffer tank
LDSM
Feedline
HDSM
1. LDSM = bentonite suspension

2. HDSM Density 1.30 ... 1.70 t/m³
Tank for
TBM HDSM LDSM = Low Density Support Medium

HDSM = High Density Support Medium

Measurement and Precise Control of Support Density
 Measuring circuit for precise control of support medium density is installed in the shield
 Permanent evaluation of support density and adjustment of operation parameters
Density Measurement
Circuit

Efficient and Safe Hydromechanical Mucking
Submerged Bulk head

wall
Hong Kong Shatin Central Link
Bulkhead
Comminication Submerged
pipe wall
Pipeline
HD Medium
Circuit for Slurry circuit for

the face muck transportation
support Feed line
Discharge line
Slurryfier
box

Measurement and Precise Control of Support Density

Precise Slurry Face Stability in Highly Permeable Ground
 HDSM Suspension is able to transfer support pressure in highly permeable ground where
LDSM would be lost and EPB would not allow building up of support pressure

Development of HDSM Suspension – Base Minerals
Baryte Limestone Powder
Baryte
Limestone powder
Heavy spar/ Baryte (BaSO4) Limestone powder from source Istein

Dealer: Well filter engineering Efringen – Kirchen (Germany)
Particle density 4.70 to/m³ Particle density 2.70 to/m³
Bulk density 1.8 to/m³
Grain size 0 ... 75 µm Grain size 0 ... 200 µm
Carrier liquid: 5% - bentonite suspension

Bentonite B1 from IBECO , dry bulk density 2.65 to/m³

Testing of HDSM Suspension

HDSM Mixing Plant Unit
Tank
mixer 1 limestone
limestone
limestone
bentonite
limestone
Tank
mixer 2

Options for Face Support Medium
 Variable Density TBM allows full control of the support medium properties. The full range of
densities between 1.05t/m³ and 2t/m³ in the excavation chamber can be achieved.
Additionally the viscosity can be controlled. Support pressure can always be regulated by air
bubble.
 Mucking method depends on liquidity of excavated material and bentonite

 EPB Muck
 EPB Muck + LDSM (any mixing ratio)
 EPB Muck + LDSM + HDSM (any mixing ratio)
 LDSM
 LDSM + HDSM
 EPB Muck + HDSM

Variable Density TBM ® (Possible Operation Modes )
MODE 1 MODE 2 MODE 3 MODE 4

EPB – closed mode EPB – closed mode with Mixshield mode with LDSM HDSM - Mode
additional bentonite (bentonite slurry )
support
FACE SUPPORT
EPB - TBM Mixshield – TBM
Variable Density - TBM
TRANSPORT OF EXCAVATED MATERIAL
DRY MUCKING
HYDRAULIC Transportation possible HYDRAULIC Transportation required

The variable Density TBM® Concept – EPB  Slurry
 Conversion from EPB mode to slurry mode without modification works and compressed air
interventions.
 Safe control of the support pressure during the conversion process.

 Seamless transition of face support mode
 Different Variants and Configurations

Variants and Configurations

Variable Density TBM ® (mechanical conversion)
 Phase 1 – TBM with slurry circuit installation
 Phase 2 - Dismantling slurryfier-box and crusher. Placing at the park – position

Parking position
 Phase 3 – Extension of the belt conveyor

Variable Density TBM ® (fully equipped)

Options for Rock Crushers
 Adaption of rock crushing technology and slurrifier box to geology
Roller Crusher Jaw Crusher

S-600
Miami Port
Tunnel

S-600 USA – Miami Port Tunnel
 Variable Density, Ø 12,860mm

 Total Tunnel Length: 2338 m
 Min. Overburden: 5 m
 Max. Overburden: 14 m
 Max. Compressive Strength: 41 Mpa
 Convertible Mucking, No HDSM Mode
 Geology:
Cemented sand and shell,
sand with conclusions and interbedded
zones of weakly cemented sandstones
cemented limestone,
sand with interbedded zones of limestone
 Max. Op. Pressure: 4 bar
 Final breakthrough May 6, 2013
 Tunnel commissioning mid-2014

Miami Port Tunnel, USA
 Used some of the functional principles of Variable Density TBMs

 Single screw conveyor paired with slurryfier-box and rotary crusher.
 Crusher / slurryfier- box to be moved to parking position prior to use of screw conveyor.

S-989
Hong Kong
SCL 1128

Hong Kong SCL 1128 Geology and Challenges
 Eastern tunnel drive mainly in backfill area with very low overburden (min 3.7m)
 Sensitive area regarding to settlement required attention
 TBM technology required to control
 Accurate control and adaption of support medium density
 Precise control of tunnel face pressure
 Sections of hard granite required suitable crushing mechanism
Trunk Min. Overburden

Sewers Ca. 3.7m

TBM Solution S-989 Hong Kong SCL 1128
 Variable Density TBM

 Only Slurry Mucking, no conversion possible
 Jaw crusher for hard granite
 Shield ∅ = 7.41m
 Tunnel Length = 675m
 Start = 15. April 2016
 Breakthrough = 28th November 2016
 Client Dragages Bouygues

Stone Crusher Slurry Circuit

 Workshop Acceptance: 15. April 2016
 Launch: 27. August 2016
 Best Daily Performance: 22.5m

 Best Weekly Performance:106.5m

D-778
Cairo Metro
Line 3

D-778 Cairo Metro Phase 3
Variable Density
EPB TBMs
Mixshield TBMs

D-778 Cairo Metro Phase 3 - VD TBMs in Clay and Sand
 May 2015: Request to modify existing ∅9.5m EPB into Variable Density TBM
 Geology: Clay, Sand, first 500m in full clay
 With variable density technology, better advance rate was expected than EPB or Slurry TBM
 Performance of EPB and Slurry known from past projects

D-778 Modification of EPB TBM into Variable Density Machine
 Addition of Slurry Circuit

 Addition of Air Bubble Chamber
 Addition of Compressed Air Pressure Control System
 Installation of Crusher and Slurrifier Box

D-778 Main Slurry Circuit Lines
Q_f Feed Line Flow

Q_e Excavation Feed Flow
Q_b Bubble Chamber Flow
Q_c Cutter Face Flow
Q_m Mixing Box Flow
Q_g Geology Volume Flow
Q_s = G_g + Q_e Screw Conveyor Flow
Q_d = Q_s + Q_m Discharge Line Flow

D-778 Study of Operating Parameters for Machine Type Selection
Comparison of Slurry TBM and VD TBM
 Tunneling in: SAND Slurry TBM VD TBM

Slurry Circuit Parameters
 Higher penetration with VD TBM possible Q_f [m³/h] 1500 1500
than with Slurry TBM in previous project. Q_e [m³/h] 1500 1040
Q_b [m³/h] 0 140
 VD mode needs less energy and leads to Q_c [m³/h] 1500 900
less tool wear. Q_m [m³/h] 0 460
Q_g [m³/h] 318 318
75mm/min Q_s [m³/h] 1818 1358
Q_d [m³/h] 1818 1818
Operation Parameters
CH Rotation Speed [rpm] 1.6 1.1 - 1.3
Penetration [mm/rot] 47 60-70
Exc. Duration [min] 20 20
CH Rotations / Ring [rot] 32 22 - 26
Energetic Parameters
Spec. Energy [MJ/m³] 11 9
Flushing [kWh] ⇨ ⇧
Separation [kWh] ⇨ ⇨
Tool Wear [kWh] ⇧ ⇨

Operation of Slurry TBM in Clogging Risk Ground
Medium Strong
 Tunneling in: SAND / CLAY MIXED FACE Clogging Clogging
 Medium Clogging can lead to severe Q_f [m³/h] 1500 2000
performance reduction in tunneling in Q_e [m³/h] 1500 2000
clays with Slurry TBMs. Q_b [m³/h] 0 0
Q_c [m³/h] 1500 2000
Q_m [m³/h] 0 0
Q_g [m³/h] 71 <40
Q_s [m³/h] 0 0
Q_d [m³/h] 1571 <2040
CH Rotation Speed [rpm] 1.6 1.6
Penetration [mm/rot] 11 <6
Exc. Duration [h:min] 1:30 >2:30
Q_f CH Rotations / Ring [rot] 144 240
Q_d Spec. Energy [MJ/m³] 15 25
Flushing [kWh] ⇧ ⇧⇧
Separation [kWh] ⇧⇧⇧ ⇧⇧⇧
Tool Wear [kWh] ⇧⇧⇧ ⇧⇧⇧
Operation of Slurry TBM in Clogging Risk Ground
Medium Strong
 Tunneling in: SAND / CLAY MIXED FACE Clogging Clogging
 Variable Density TBMs can handle Q_f [m³/h] 1500 1500
clogging ground without as much Q_e [m³/h] 540 1040
problems and Slurry TBMs due to Q_b [m³/h] 140 0
Q_c [m³/h] 400 900
hydromechanical mucking mode.
Q_m [m³/h] 960 460
Q_g [m³/h] 318 193
Q_s [m³/h] 858 1233
Q_d [m³/h] 1818 1693
CH Rotation Speed [rpm] 1.1 – 1.3 0.9
Penetration [mm/rot] 60 – 70 50
Exc. Duration [h:min] 0:20 0:33
CH Rotations / Ring [rot] 22 – 26 30
Spec. Energy [MJ/m³] 9 15-18
Flushing [kWh] ⇨ ⇧
Separation [kWh] ⇨ ⇧
Tool Wear [kWh] ⇨ ⇨
D-778 Cairo Metro Operational Results
 Outstanding Advance Rates of 60-70 mm/min in clogging geology and sand / clay.
 Much higher advance rates than with Slurry TBMs and EPBs in the past in the same area
 Lower Energy Consumption
 Lower Wear and Tool Changes

New Project: S-1123-1125 Grand Paris Line 15

Conclusions

THANK YOU VERY MUCH
FOR YOUR ATTENTION!


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Variable Density TBMs

Geotechnical and Mechanical Principles

Dr. Ruben Duhme, Herrenknecht AG

TUCSS Seminar 13. April 2018

1. Mechanics of Tunnel Face Support and Support Pressure Regulation

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

 Different Types of Face Support  Different Types of Extraction from

 Different Types of Mucking on TBM

Herrenknecht Variable DensityTBMs

 Formation of “plug” in screw conveyor holds pressure

Herrenknecht Variable DensityTBMs

Closed Mode – EPB

Closed Mode – Compressed Air

Herrenknecht Variable DensityTBMs

 Excess water permeability prevents pressure control

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

Slurry discharge line

 Slurry Mixshield ® system

Herrenknecht Variable DensityTBMs

 Suspension loss due to blowouts and cavities known in karst formations

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

Pressure gradient with LDSM (γld ) pSL – γld x h

Slurry pressure pSL

FS _LDSM = FS_ HDSM

Herrenknecht Variable DensityTBMs

Hydrostatic height of the supporting liquid

Support medium density [kN/m³]

Herrenknecht Variable DensityTBMs

Buffer tank LDSM HDSM

1. LDSM = bentonite suspension

TBM HDSM LDSM = Low Density Support Medium

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

Submerged Bulk head

Circuit for Slurry circuit for

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

Baryte Limestone Powder

Heavy spar/ Baryte (BaSO4) Limestone powder from source Istein

Carrier liquid: 5% - bentonite suspension

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

Herrenknecht Variable DensityTBMs

 Mucking method depends on liquidity of excavated material and bentonite

 EPB Muck + LDSM (any mixing ratio)

 EPB Muck + LDSM + HDSM (any mixing ratio)

 EPB Muck + HDSM

Herrenknecht Variable DensityTBMs

MODE 1 MODE 2 MODE 3 MODE 4

EPB - TBM Mixshield – TBM