steve smading - the robbins company - unique tbm design unleashed at the grosvenor tunnel project
TRANSCRIPT
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Unique TBM Des ign Unleashed
at the Grosvenor Tunnel Pro ject
October 14, 2015
Presented By: Steve Smading
General Manager Asia Pacific
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Agenda
Today’s Presentation
- Introduction to Crossover
- Why Crossover Machines?
- Machine Design: Grosvenor
Case Study
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Introduction to Crossover TBMs
• Flexibility to switch from one mode to another
• Based on ground conditions
• Three main types of Crossover TBMs
- Hard Rock/EPB
- Open or Closed Mode
- Hard Rock or Soft
Ground
- Screw Conveyor
- Slurry/EPB
- Equipped with screw
conveyor and slurry
system
- Hard Rock/Slurry
Shield
- Highly adaptable to
variety of ground
conditions
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Crossover Introduction
Why Crossover
Machines?
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Why Crossover Machines?
Today, Crossover Machines are required to excavate different types of
ground efficiently with one machine.
A Crossover machine may be considered if your tunnel includes a
combination of these elements:
• You want to excavate self supporting ground Open Mode
(hard rock)
• You want to excavate self supporting ground but want to
mitigate underground water ingress Closed Mode
(Compressed air, Slurry, EPB, etc.)
• You want to excavate unstable ground Closed Mode
(Compressed air, Slurry, EPB, etc.)
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Considerations for Crossover
Machines• Safety
Conversion work should be carried out in a confined space
• Schedule
Conversion works can be time-consuming, so a detailed plan must
be in place
• Geological information
– To decide when and where to convert, reliable geological
information will be required
– Adequate probe drilling is essential to determine the ground
conditions ahead of a Crossover TBM
• Cost
– Up-front costs may be high, but significant savings in the long-run
– Durability: savings in repair costs
– Dual-Mode: multiple project usage
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• Designed to excavate in open or closed mode
• Hard rock and/or soft, relatively impermeable ground including
fault zones
• Less well suited to permeable ground conditions such as sand and
pebbles, though additives/polymer can be used to stabilize these
conditions
• Typically proposed for mixed face conditions
Ground Conditions
Crossover XRE TBM
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Crossover XRE
Case Study
Grosvenor Decline Mining Project
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• Queensland, Australia; 1,000km north of Brisbane
• Metallurgical Coal Project owned by Anglo American
• 2 Decline Tunnels for access to the 130m deep seam:
Conveyor Drift
Man and Material Drift
• TBM methodology for drift construction
Grosvenor – Project Overview
Crossover XRE TBM
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• Soft Ground section (0-300m): sand, sand/clay, clay and
conglomerate
• Mixed Face/Rock Section (300-1,000m): siltstone, coal, sandstone
and basalt (UCS=20-120MPa)
• Methane gas in intermediate coal layer and at pit bottom
Grosvenor – Drift Geology
Crossover XRE TBM
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“Purpose-built” TBM to:
• Cope with mixed-face conditions
Crossover/Dual Mode TBM
• Operate safely in the coal mine environment
EPB mode
Double Screw conveyor
ERZ/NERZ compliance
• Build multiple decline tunnels
Quick de-mobilization/re-mobilization
Grosvenor – TBM Design
Crossover XRE TBM
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General: 8.0m diameter Crossover (XRE) TBM capable of conversion from EPB mode to non-pressurized single shield mode
Back-loading Cutterhead designed for:
• Use with knife bits & scrapers (EPB mode - mixing chamber)
• 17” disc cutters & bucket lips (open mode - radial loading plates & extendable hopper and screw)
EPB Mode
Bi-directional
Rock Mode
Single direction
Mixed Ground Mode
Bi-directional
Grosvenor – TBM Design
Crossover XRE TBM
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EPB Mode Rock Mode
Grosvenor – TBM Design
Crossover XRE TBM
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Double screw conveyor (front and rear) mounted in series and
with independent drives.
Grosvenor – TBM Design
Crossover XRE TBM
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• EPB mode to maintain a positive
face pressure and contain the
methane;
• Double screw conveyor made
with spark resistant materials,
forming a sealed chamber with
the mixing chamber and
capable of creating a plug;
• Foam/additive injection ports
also along the screw conveyors
to prevent sparks;
• Snuffing box at the conveyor
discharge for suction and
removal of methane from the
screw.
TBM Design for ComplianceCrossover XRE TBM
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CH Segments
CH core
Inner Shield
Outer ShieldCHS
CHS Dolly
Front Dolly Bridge Dolly
Sliding
Track
Segment ErectorBridge
Screw Conveyor
5.8m
Lift Jacks
Inner Shield
Grosvenor – Walking Dolly System
Crossover XRE TBM
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• Tight schedule Onsite First-Time Assembly: July-October 2013
• Walk-in, Tests, Compliance Dossier and Acceptance: November-
December 2013
• Boring Started: December 20, 2013
Grosvenor - OFTA & Conveyor
Drift Construction
Crossover XRE TBM
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• Completion of Conveyor Drift at half face in coal: May 13, 2014 (798m
in 20 weeks)
• Machine availability: 75-90% after week 8 up to 85m/week
• Last 6 weeks affected by more extensive presence of gas routine
implementation of procedures for mitigation and management
(TARP)
Grosvenor - OFTA & Conveyor
Drift Construction
Crossover XRE TBM
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• Boring started on November 11, 2014
• Completion at full face in coal: February 9, 2015 (988m in 13.5 weeks)
• Machine availability: always above 60%; often between 80 and 90%
up to 110m/week
Grosvenor – Transport Drift
Construction
Crossover XRE TBM
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Grosvenor Mine – Achievements And
Conclusions
• First time for a TBM to be fully
compliant to one of the most
advanced coal mine legislations
• More than 10 times faster advance
rate compared to a roadheader in
the same ground conditions
• Improved health conditions for
workers (no exposure to
unsupported rock or gas/fumes at
any stage of the tunnel
construction)
• Crossover TBM was highly
successful in mixed ground
conditions with methane gas
• Quick Removal System was highly
successful
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Questions?