steve smading - the robbins company - unique tbm design unleashed at the grosvenor tunnel project
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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
Agenda
Today’s Presentation
- Introduction to Crossover
- Why Crossover Machines?
- Machine Design: Grosvenor
Case Study
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
Crossover Introduction
Why Crossover
Machines?
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.)
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
• 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
Crossover XRE
Case Study
Grosvenor Decline Mining Project
• 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
• 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
“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
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
EPB Mode Rock Mode
Grosvenor – TBM Design
Crossover XRE TBM
Double screw conveyor (front and rear) mounted in series and
with independent drives.
Grosvenor – TBM Design
Crossover XRE TBM
• 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
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
• 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
• 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
• 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
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
Questions?
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