istanbul strait road tunnel crossing...herrenknecht. pioneering underground technologies istanbul...
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ISTANBUL STRAIT ROAD TUNNEL CROSSING
Werner Burger, Herrenknecht AG, Schwanau.
AFTES Journées Techniques, Lyon, October 16, 2015
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Road Tunnel
Tunnel Design
Single Tube, twin deck double track for light vehicles only
Inner diameter 12 m, Segment thickness 0,6 m
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Road Tunnel
Project Key Requirements
Restricted access from above most of the tunnel alignment below the
Bosporus Strait
Very large TBM diameter 13,71 m
Variable, mixed ground conditions full face rock – marine deposits, boulders
– transition zones
Very high face pressure >10 bar
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Road Tunnel
Project Requirements – Past Experience (State of Art)
4. Tune Elbetunnel very large diameter14,2 m; mixed
ground conditions; face pressure 5,5bar
Westerschelde large diameter 11,4 m; long distance
tunnel; face pressure 7,5bar; saturation diving
Chongming very large diameter 15,4 m; long distance
tunnel; face pressure 7bar
Lake Mead full face rock, soft ground; very high face
pressure 14 bar
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Road Tunnel
Selected TBM Concept
Mixschild, for variable ground
conditions with very high face pressure
Accessible cutterhead for atmospheric
maintenance on primary cutter sets
Full equipment for „conventional“
chamber access up to 4 – 5 bar
Full equipment and preparation for
saturation diving at higher face
pressures (shuttle transfer)
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Road Tunnel - TBM Design Target
Minimization of The Necessity of Chamber Interventions
Integration of all features of the Herrenknecht „Non – Exposure – Maintenance“
development program
Monitoring / Sensor Systems
Fully articulated cutterhead for real time load measurement and control of cutting
unit
Electronic disc cutter monitoring system for real time monitoring of individual disc
cutter condition
Mechanic wear monitoring system for each disc cutter
Multiple level mechanic wear monitoring system for cutterhead structure
Pre-determined locations an process for remote ultrasonic checks of structural
cutterhead plates
Permanent installed excavation chamber camera system
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Road Tunnel - TBM Design Target
Minimization of The Necessity of Chamber Interventions
Integration of all features of the Herrenknecht „Non – Exposure – Maintenance“
development program
Maintenance
Submerged wall gate for atmospheric crusher maintenance
Accessible cutterhead for atmospheric cutter change for a full face disc cutter
and soft ground tool coverage ( primary cutter sets)
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Crossing TBM
Cutterhead Features
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main spoke, atmospheric accessible
auxiliary spoke, conventional
19” twin disc cutter, atmospheric exchange
with monitoring system
scraper tools, atmospheric exchange
scraper tools, conventional
bucket lips, conventional
multi level sectorized wear detection loops
Herrenknecht. Pioneering Underground Technologies
Access down into cutting
arm spoke.
Operator undertakes
maintenance in free air
without the risk of having
to work at the tunnel
face.
Back loading
cutting tools.
Non - Exposure Maintenance Solutions
Accessible Cutterhead for “Atmospheric Cutterchange”
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Herrenknecht. Pioneering Underground Technologies
Non - Exposure Maintenance Solutions “Atmospheric Cutter Change”
System for large diameter Mixshields with
accessible cutter head structure
First use in 1996 (Elbetunnel)
Full face disc cutters 17” or 19”
Full face for disc cutters and soft ground tools
Individual tool condition and wear sensors
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Cutterhead Elbetunnel, now in front of the
Museum of Work in Hamburg
Herrenknecht. Pioneering Underground Technologies
19“ Disc cutter fixture for atmospheric
cutter change
Scraper tool fixture for atmospheric
cutter change
Cutter head spoke structure, accessible from
inside
Non - Exposure Maintenance Solutions
Accessible Cutterhead for Eurasia Tunnel TBM Istanbul, Turkey
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Herrenknecht. Pioneering Underground Technologies
Transport of disc cutter
cartridge inside
cutterhead
Installing cutter cartridge
in outer housing
Opening of frontgate and
push cutter cartridge in
working position
Atmospheric Cutter Change
Shop Test and Training in the Factory
Herrenknecht. Pioneering Underground Technologies
Non - Exposure Maintenance Solutions
On-Site Cutter Change Eurasia Tunnel TBM Istanbul, Turkey
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Herrenknecht. Pioneering Underground Technologies
Disc Cutter Monitoring System
Mixshield-TBM with Accessible Cutterhead
IPC
Monitoring-unit
Control cabin
Data line Receiver
Sensor-unit
Radio
signals
Individual monitoring-unit for each disc cutter
Radio transmission to repeater / receiver
Data transfer from receiver to IPC
Data analysis + status display (control cabin)
Battery
CS
Herrenknecht. Pioneering Underground Technologies
Status indication of disc cutter
with temporary no rotation
Status indication of
critical values
Disc Cutter Monitoring System
Data processing and visualization
Herrenknecht. Pioneering Underground Technologies
Shuttle transport through
tunnel on MSV
Hydraulic lift to
upper gantry deck
Motorized shuttle
transport through gantry
Front lifting table to
docking position for
transport shuttle
Permanent airlock Transport shuttle
in docking position
Saturation Process
Crew Shuttle Transfer Through Trailing Gear At The Eurasia Tunnel TBM,
Istanbul
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Herrenknecht. Pioneering Underground Technologies
Hydraulic lifting system
from MSV to gantry
middle deck
Motorized transfer
through gantry
Hydraulic lifting system to
docking flange at shield
airlock
Saturation Process
Crew Shuttle Transfer Through Trailing Gear At The Eurasia Tunnel TBM,
Istanbul
Herrenknecht. Pioneering Underground Technologies
“Non – Exposure – Maintenance” Solutions
Mixshield Submerged Wall Gate for Crusher Maintenance
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Submerged wall gate open Submerged wall gate closed
Herrenknecht. Pioneering Underground Technologies
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Istanbul Strait Road Tunnel
Crusher Maintenance
Diver at 9 bar pressure cleaning invert in
preparation for gate closure
Work on crusher and suction grid under
free air conditions
Herrenknecht. Pioneering Underground Technologies
Istanbul Strait Crossing TBM
Face Pressure Along The Drive
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25.4.2014 22.8.2015
Herrenknecht. Pioneering Underground Technologies
THANK YOU FOR YOUR ATTENTION.
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