MECHANIZED TRENCHLESS

INSTALLATIONS FOR SMALLER

DIAMETERS

MICROTUNNELLING . PIPE JACKING.

DIRECT PIPE . PIPE THRUSTER . PIPE EXPRESS

Dr. Gerhard Lang. Herrenknecht AG

Herrenknecht Headquarter in Schwanau/Germany.

HK Product range.

Influence of geology and hydrogeology.

design of machine

means and method

Success

of project

Geology and

Hydrology

influences manner

and extent of

Tunnel alignment, gradient

Type of machine (shielded, non shielded)

Face support (Slurry, Mix, EPB)

Cutting wheel design (opening ratio etc.)

Cutting tools: selection and arrangement

Cutting tools: inspection procedure

Soil conditioning and soil stabilisation

Soil removal (pipes, muck cars, belt

conveyors)

Potential of obstacles and removals

Slurry mode: composition of the slurry

EPB: Foam injection capabilites

Rock TBM: Rock stabilization (anchoring etc.)

….

Machine: Open Shield with

roadheader

Outer diameter: 3.480mm, (11,4ft)

Tunnel length: approx. 4.000m (2,5 mi)

Geology: Gravel, conglomerate,

clay

Contractor: Municipality Munich

Customer: Bilfinger & Berger AG

Hofoldinger Stollen in Munich.

Herrenknecht open-face machines

Part-face excavation.

MH Box Machine – non-circular Tunnels –

with precast liner.

MH Box Machine – non-circular Tunnels

with in situ cast liner.

Herrenknecht. Solutions for all geologies.

Utility Tunnelling.

Cobbles

Coarse gravel

Medium gravel

Fine gravel

Coarse sand

Medium sand

Fine sand

Sandy, Silty clay

Silt

Clay

–– 10

–– 1

–– 10 - 1

–– 10 - 2

–– 10 - 3

–– 10 - 4

–– 10 - 5

–– 10 - 6

–– 10 - 7

–– 10 - 8

–– 10 - 9

–– 10 - 10

–– 10 - 11

–– 10 - 12

Perm

eabili

ty F

acto

r k (

m/s

)

SLURRY

EPB

Herrenknecht Slurry microtunnelling / pipejacking

equipment.

Suited for all geologies and challenging conditions.

1 Submerged wall

2 Pressure wall

3 Working face chamber

4 Pressure chamber

5 Communication pipe

6 Slurry line

7 Extraction line pressure chamber

8 Supply line pressure chamber

9 Slupply line working face chamber

10 Air pressure supply and discharge

11 Working face chamber

Ventilation

12 Air pressure-cushion

13 Suction screen

Slurry Mode (AVN) AVND Mode System

Slurry microtunnelling. Mode of operation.

AVND.

Slurry microtunnelling.

AVND Mode system.

Diagr. Drucksensor Türe

time [sec.]

wo

rkin

g face p

ressu

re

[bar]

0 10 20 30 40 50

0

1

2

3

working face pressure

slurry shield

working face pressure

hydro shield

Reduced fluctuation of the working face pressure using Hydro mode

(= Mixed-shield mode; D-mode; Bentonite-shield mode)

Slurry microtunnelling.

AVND Mode system.

Adjustment of the rheological properties of the slurry.

Marsch funnel – kugelharfe (ball-harp).

Slurry microtunnelling. Long distance pipejacking.

Intermediate Jacking Stations IJS.

Slurry microtunnelling. Long distance pipejacking.

Intermediate Jacking Stations IJS. Additional thrust.

Long Distance Pipe jacking – Europipe

MTBM OD 149 ” (3.8 m), pipe ID 120” (3,0 m)

Drive length 8,317 ft (2.535 m)

Launch shaft Receiving shaft

Levee Levee Accumersieler

Balje

Sand

0m

-5m

-10m

-15m

-20m

TBM

Automated bentonite lubrication system

- minimum friction along the pipe

- maximizing jacking distance

New development:

Automated bentonite lubrication system

ajusting to soil conditions – optimum lubrication.

• Volume controlled distribution of the bentonite along the tunnel

• Adjustable bentonite volumes for different ground conditions

• Minimizing jacking loads

• Increasing jacking distance without the use of IJS‘s

• Complete data logging

Long distance mtbm. Face access.

AVN-Series (Slurry).

AVND-Series (Hydroshield).

Long distance mtbm. Face access.

Airlock system for hyperbaric interventions.

PARALLEL CHAMBER SYSTEM IN LINE CHAMBER SYSTEM

• Can follow the ideal alignment (streets, existing lines, etc.)

• Amount of shafts and manholes can be minimized

• Amount of start and receiving shafts are reduced

• Construction time and traffic interruptions minimized

• Overall time and costs reduced (social costs, etc.)

Microtunnelling – South korea – AVND 2400. Benefits of curved drives.

Target alignment

Slurry microtunnelling – long distance pipejacking. steering operation.

Camera system

provides insight in the excavation chamber.

• Suitable for UT machines DN 1600-3000

• Camera protected by wear-resistant glass

• Additional LEDs for lighting

• Monitor installed in control panel

• Hard disc recorder

• Cleaning system for camera and lighting

• either compressed air jet

• and/or water jet

(e.g. from slurry feed line)

• Cleaning automatic or via push button in

control panel

Camera system

The features.

Camera system

Demo movies.

• Permanent monitoring and recording

• Check the cutting-wheel and the slurry flow

• Visual inspection of the cutting-tools and wear and tear

• Movies are saved for later use

• Work safety

• Evaluation of the tunnel face stability before man entry into excavation chamber

• Monitoring of working personnel in the excavation chamber

Camera system inside excavation chamber.

The benefits.

Pipe Thruster technology – key innovation

• PIPE ASSIST TOOL FOR HDD DURING PIPE PULL-IN (For long pipelines, large diameters or difficult geological conditions).

• RECOVERY OF STUCK OR DAMAGED PIPELINE.

• INSERTION OF PRODUCT PIPELINE IN EXISTING TUNNEL.

• DIRECT PIPE®

• PIPE EXPRESS®

Pipe Thruster as pipe assist tool.

For long or difficult crossings.

HDD-RIG ON

RIG-SIDE PIPE THRUSTER ON

PIPE-SIDE

Pipe Thruster: Pipe installation in existing tunnels.

Ems River Project: 2,5mi. (4km), 48” Between Germany & The Netherlands - under Ems River.

The pipe is pushed into flooded tunnel - with

gravel bed on bottom.

Direct Pipe® Microtunnelling

The Direct Pipe® method. Advantages.

• Applicable in all geological conditions.

• Borehole is supported at all times.

• One pass installation from one side.

• Slurry discharge through the pipeline.

• High alignment accuracy compared to HDD.

• Minimum ’frac-out’ risk.

• …

Direct Pipe®: minimum frac-out risk.

DIRECT PIPE® HDD

Opportunity to pullback the machine.

Step 1: Pipeline installation

Step 2: Pipeline Retraction for e.g. tool change – Borehole is stabilized with Bentonite

Use of 2 Pipe Thruster – additional pull or push force.

2 x 500 tons (HK500PT) or 2 x 750 tons (HK750PT).

Used in the USA for pipe pull-in.

Used in the Netherlands for Direct Pipe.

The Pipe Thruster – 3 different models.

HK300PT HK500PT HK750PT

Max. push/pullforce (kN) 3,000 5,000 7,500

Stroke 4m 5m 5m

Max. clamping diameter 36“ 48“ 60“

Weight (to.) 37 45 85

Shearing angle 0°-15° Pipeline coating protection

Direct Pipe® - navigation system.

Direct Pipe® - supply lines inside the pipeline.

SLURRY FEED AND DISCHARGE LINE.

HANGERS FOR CABLES, PIPES AND HOSES

(SERVICE LINES).

RUBBER ROLLERS FOR THE EASY ASSEMBLY

AND PROTECTION OF THE INTERNAL COATING.

Target side: simple recovery of the Direct Pipe - machine.

Operator vehicle Launch pit

with Pipe Thruster

Excavation unit

Pipe Express® . Equipment Components.

Pipe Express® . Equipment Components.

Excavation unit.

Pipeline installation methods.

Projects with special requirements:

• Environmentally sensitive areas

• Swampy areas with high groundwater level

• Areas with unstable ground conditions

• Areas with water-bearing layers

Pipe Express® . Fields of application.

conventional 100%

Pipe Express® ~30%

Pipe Express® . Fields of application.

Tight pipeline corridors.

• Drive length: up to 2,000m

• Pipeline diameter: 30“- 60“

• Overburden: 0.5 – 2.5m

• Advance rates of up to: 1.2m/min | 500 – 1,000m/day

Pipe Express® . Current application range.

48“ Gas pipeline in the Netherlands, Length: 500m; Advance speed: 1,2m/min

Pipe Express® . Pilot project.

Bauma innovation award for Pipe Express®

Munich, April 2013.

Winner of the ISTT

NO DIG AWARD

2008

at the NO DIG 2008

in Moscow.

Top 5 nominée for the

HERMES AWARD 2008

at Hannover Fair.

Thank You!

WINNER OF THE

TECHNOLOGIE AWARD AT

THE IPLOCA CONVENTION

2009 IN SAN FRANCISCO.

Winner of the

NSTT NO DIG AWARD

2010

in the Netherlands.