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Bheri Babai Diversion Multipurpose Project (BBDMP)
Presented by Jim Clark, Projects Manager IndiaThe Robbins Company
• More than 50 years of innovation and experience,
• More than 900 Employees worldwide
• Annual sales exceeding $300 million
• We hold almost 90% of TBM tunneling world production records
Company Facts
THE ROBBINS COMPANY
Front of office building
SOLON, OHIO, USA
Solon, Ohio, USA
Facilities include:
• Administration
• USA Equipment production
• Engineering staff
• Field service staff
Headquarters
THE ROBBINS COMPANY
• Robbins Europa -- Italy
• Roboretec -- Romania
• Robbins China -- Shanghai
• Robbins China -- Guangzhou
• Robbins Asia Pacific
• Hong Kong
• Brisbane
• Robbins GmbH -- Germany
• Robbins India – New Delhi
• Robbins España – Madrid
• Robbins Mexico – Mexico City
• Robbins TBM Korea – Seoul
• Representatives in
35 countries
Facilities in 11 Countries Worldwide
THE ROBBINS COMPANY
Robbins Experience in
India
• Almost 70 km of tunnels bored to date
• Metro
• Water Transfer
• Hydro Electric Power
• 300 Employees
• 25 expats
ROBBINS EXPERIENCE IN INDIA
AMR Water tunnel
ROBBINS EXPERIENCE IN INDIA
• 2 x 10.0 m Diameter double shield TBMs
• Length 43.5 km.
• Longest tunnel in the world without intermediate access.
• Granite & Quartzite, UCS up to 300 MPa
• Robbins responsible for all TBM related activities
Alimineti Madhava Reddy Water Tunnel
Mumbai Water tunnel
ROBBINS EXPERIENCE IN INDIA
• Tunnel length 8.3 Km
• 6.25 m Open Gripper machine
• Shaft depth 109 m
• Continuous conveyor system
• Vertical conveyor system
Mumbai Water tunnel
ROBBINS EXPERIENCE IN INDIA
Mumbai Water tunnel
• Bored over 8 km in 18 months
• Over 60 m bored in 24 hours
• Indian record of 870 meters in a month
Jaipur Metro
ROBBINS EXPERIENCE IN INDIA
Jaipur Metro
• TBM’s bored beneath heritage structures
• Only 5 m of cover
• Robbins provided key personnel & operators
• Took full responsibility for boring beneath the gate
ROBBINS EXPERIENCE IN INDIA
Chandpole gate
• Foundations made up of irregular size stone blocks
• Limited resistance to settlement
• Lime mortar joints in poor condition
• Riddled with cavities
• Contract limit of 4 mm settlement
ROBBINS EXPERIENCE IN INDIA
Jaipur Metro “whoever destroys, injures, mutilates, defaces, alters, removes,
disperses, misuses, imperils or allows to fall into decay a
protected monument, or removes from a protected monument
any sculpture, carving image, bas-relief, inscription or other like
object, shall be punishable with imprisonment for a term which
may extend to six months with a fine which may extend to five
thousand rupees or with both”
BBDMP TBM Selection
TBM SELECTION
Geology and overburden
• Mostly sandstone & Mudstone
• Some conglomerate
• Two thrust/shear zones
• Babai thrust (100m from portal)
• Bheri thrust (5,800m from portal)
• Up to 800m overburden
• Shielded machine best suited to geology
TBM SELECTION
Construction Schedule
• Necessity to finish the project in 54 months
• Absence of intermediate adits
• boring and lining must proceed concurrently
• High Performance Double Shield TBM is required
TBM SELECTION
Benefits of Double shield TBM
• Rapid tunnel and lining progress
• Secure the immediate stabilization of the tunnel walls
• Act as a final lining, not requiring any further working phase
• Immediately reducing any water inflow into the tunnel
TBM SELECTION
TBM Specifications
TBM Manufacturing, Delivery and Assembly
TBM MANUFACTURING, DELIVERY & ASSEMBLY
Manufacturing & Assembly
• Critical components are manufactured in the USA and Europe
• Shipped to Robbins facility in Shanghai for assembly
TBM MANUFACTURING , DELIVERY & ASSEMBLY
Testing, Disassembly & Shipping
• Full factory testing of machine (FAT)
• Machine then disassembled and shipped by sea to Kolkata
• Then 1,300 km overland from Kolkata to the project site
TBM MANUFACTURING , DELIVERY & ASSEMBLY
Site Assembly
• Machine arrived on site the first week of September 2017
• Assembly of the TBM commenced 10th September
• 6 weeks taken to complete assembly, commissioning and push machine to the face of the starter tunnel
TBM MANUFACTURING , DELIVERY & ASSEMBLY
Site Assembly
Production to Date
Learning curve
PRODUCTION TO DATE
• A learning curve is factored into all production predictions for TBM driven tunnels.
• Prediction for this tunnel was a learning curve of 3 months at 250m production per month (750m total)
• Boring commenced Early November 2017
• TBM completed 330m of boring in November
• By Mid December after only 6 weeks of tunneling the TBM passed the 750m in 3 months learning curve target.
• Excellent achievement by any standards.
First 6 months
PRODUCTION TO DATE
• The machine has completed almost 4 km during the first 6 months of boring
• Best 24 hours 52.9m
• Best week 285m
• Best month/30 day period
1057 m
Challenges Ahead ?
Main Areas of Concern
CHALLENGES AHEAD
• Squeezing ground
• Slabbing/Spalling ground
• Jointed and blocky rock
• Water ingress
• Bheri thrust/shear zone estimated to be 400m wide
Inundation
CHALLENGES AHEAD
Probe Drilling/Ground Treatment
PROBE DRILLING/GROUND TREATMENT
Probe Drill
• The probe drill is used for probe and grout holes
• It can also be used to relieve hydrostatic pressure at the face
• By drilling relief holes through the segmental lining behind the machine
PROBE DRILLING/GROUND TREATMENT
Grout Packers
• Mechanical packer
Can be inserted to approx 4-5m. May not be long enough to prevent grout return into bored tunnel in fractured rock
• Inflatable packer
Can be extended and inserted up to 10m+. Can be placed ahead of the tunnel face to prevent grout return.
PROBE DRILLING/GROUND TREATMENT
• Primary holes drilled first
• Packers inserted into holes
• Pressure gauge is connected to the packer in any hole thatshows water ingress.
• Water pressure is measured
• Injections begins from lowest holes
• Injection pressure is dictated by hydrostatic pressure
Operations carried out in 2 separate phases
PROBE DRILLING/GROUND TREATMENT
• Secondary or control holes drilled.
• Experienced geologist must monitor the drilling
• Observe the effects of the primary injection
• Packers inserted in selected holes if required
• Injection sequence repeated
Secondary phase begins once primary phase completed
Squeezing Ground
SQUEEZING GROUND
TBM Shields becoming trapped
• CHD Diameter 5,060 mm -Diameter of Front/ Telescopic Shield 4,990 mm (70 mm clearance)
• Diameter of Gripper Shield/ Tail Shield 4,910 mm (80 mm clearance)
• 35 mm of radial overcut is also available
SQUEEZING GROUND
TBM Shields becoming trapped
• Single shield mode
• TBM gripper shoes are retracted
• Main thrust cylinders closed up
• Auxiliary thrust cylinders are utilized to push machine
• By thrusting off the segmental lining
• 40% additional thrust
• 38,475 kN
Bursting and Spalling Ground
BURSTING and SPALLING GROUND
Shield Design
• Designed to deal with bursting or spalling ground
• Cope with extreme loading
• Protect the tunnel personnel
• Provide support to the ground continually
• Up until erection of segmental lining
BURSTING and SPALLING GROUND
Cutterhead design
• Low profile muck buckets
• Reduce possibility of “pulling in” loose rock
• Large capacity and smooth throat
• Able to handle the large amount of broken rock produced in high speed production.
BBDMP Summary
SUMMARY
• Selected correct Machine for the Job
• Initial 500m excavated by Robbins plus training
• Experienced contractor
• Good site set up
• Experienced project team
• Production to date is very good
• Caution required when approaching Bheri thrust Zone
• First TBM project in Nepal has exceeded target
• Now expected to be huge success
• TBM can be refurbished and utilized on other projects.
Questions?