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1.3 SCOPE
Depending on the requirements of the or with modification. Typically major or core components of
individual future project (e.g. tunnel length or The basic philosophy behind the machines (e.g. main drive, bearing and seal
anticipated duration of use, geological Remanufacturing process is to establish a full systems, shield structure etc.), or ground
conditions) different options for equipment new life cycle for the product with sufficient life condition related components (e.g. cutter
specification are available. to complete the new project. head, rock support installation etc.) are
Equipment can be specified to be all new or specified as new and specifically built for
Note: Remanufacturing is typically applicable
rebuilt equipment could be an alternative with the project in a list of “mandatory new”
for projects without special challenges where
corresponding benefits for schedule or components, as listed in the contract
full component lifetime and a “state of the art”
economics. specification or supply offer for a machine.
set of requirements for the machinery exist.
It may not be necessary to specify highest and Note: New means components are of new
therefore most expensive level of rebuild. Common practice in the industry is also to
manufacture and have never previously been
For that reason two levels of the rebuild combine the allowance for the use of
used. This can also include new components
process are established going back to different remanufactured equipment with the
of older manufacture taken from the spare
stages of the product life cycle (Figure 1): requirement of new condition for a limited
part stock of previous projects. For new
number of clearly specified subassemblies or
• Remanufacturing components from stock that are subject to
components of a TBM or MTBM.
• Refurbishment aging (e.g. seals, hydraulic hoses etc.) the
In many cases the components or
remaining life span should be a minimum of
subassemblies with such “mandatory new”
The minimum requirements for each of these two times the anticipated project duration.
requirement are defined by the project owner,
rebuild levels are given within the guideline.
designer or the buyer of the equipment. Also
Individual manufacturers or rebuilders may offer 2.1.1 The remanufacturing process
TBM suppliers may offer such combined
additional measures in order to achieve a
options for projects allowing remanufactured
specific warranty. The general remanufacturing process consists
equipment.
of five major process steps (Figure 2)
Note: Such combined configurations are accompanied by a defined quality assurance
2.1 REMANUFACTURING typically applicable for “high profile” projects procedure. The remanufacturing process is in
where extended component lifetime is needed most aspects, similar to the original process of
Systems or subassemblies are employed at a and a special set of requirements for the first manufacturing.
different project in the original configuration machinery exists.
Waste
Figure 1: part of the full life cycle process covered by this guideline (full line, black). Figure 2: Remanufacturing process steps
REFURBISHMENT REMANUFACTURING
Visual inspection
Hoses Replacement when exceeding New
lifetime limit or damaged
Oil reservoirs Visual inspection, cleaning Disassembly, cleaning, new seals, reassembly
Hydraulic motors > 150 cm³ displacement Disassembly, new seals, new wear parts,
Visual inspection, functional test
volume reassembly, bench test
Hydraulic motors < 150 cm³ displacement volume Visual inspection, functional test Visual inspection, bench test
Hydraulic pumps > 100 cm³ displacement Disassembly, new seals, new wear parts,
Visual inspection, functional test
volume reassembly, bench test
hydraulic pumps < 100 cm³ displacement volume Visual inspection, functional test Visual inspection, bench test
REFURBISHMENT REMANUFACTURING
Cables > 1000 V Visual inspection, insulation test Visual inspection, insulation test
Cables < 1000 V Visual inspection, insulation test Visual inspection, insulation test
Cable drums > 1000 V Visual inspection Disassembly, cleaning, electrical test
High voltage switchgear Visual inspection Disassembly, cleaning, electrical test
Low voltage switchgear Visual inspection Disassembly, cleaning, electrical test
Transformers Disassembly, cleaning, electrical test Disassembly, cleaning, electrical test
Electrical motors Visual inspection, electrical test Disassembly, new bearings, electrical test
PLC hardware Functional test Replace obsolete parts, functional test
PLC software Functional test New, newest update
Sensors Functional test Functional test
Safety related parts Functional test New, functional test
However due to the fact that the majority of Parts and subassemblies of TBMs that are
main bearings do not come close to reaching primary elements of the TBM – ground 4.5 DOCUMENTATION
the limit of their design life in their first interaction, excavation and primary muck
application, multiple use of a main bearing is transport are highly project specific elements In addition to the QA documentation
acceptable given the following requirements: with a high exposure to wear. Therefor such accompanying the rebuild and testing process
•T
he operating hours of the main bearing elements are less suitable for multiple uses for structures and major components as
have not yet reached an estimated 50% of on different projects. described in chapter 4.1 to 4.4 documentation
the original design life of the bearing. should be provided about the previous
•C
utter tools are considered to be
serviclife history or previous projects.
5.2 WARRANTY
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