PRESENTATION

SUBMARINE GAS TRANSMISSION PIPELINE

ACROSS WEST JURONG CHANNEL

ED. ZBLIN AG, SINGAPORE BRANCH

24th May 2012

HISTORY OF THE PROJECT

WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

2
History of the Company
Ed Zublin AG

1898 Founded in Strasbourg/Alsace by

the Swiss engineer Eduard Zblin

1912 Production of first Concrete Pipes

1950 Production of first Jacking Pipes

and Start Pipe Jacking Projects

1997 Established Ed Zublin AG,

Singapore Branch

2007 Factory for the production of

precast concrete segment and
R.C. Pipe established in Thailand

History of the Company

Pipe Jacking Experience

Pipe Jacking Experience (Until end of 2011)

369 km Around the World

21 km Singapore

4
History of the Company
Completed Projects in Singapore

MRT North-East Line Contract 706 (1997 2000)

DTSS T-06 Queensway Tunnel (2000 2005)

DTSS Upper Thomson Link Sewers (2003 2005)

DTSS Kranji Link Sewer (2006 2007)

Pasir Ris / Tampines Package (2009 2011)

Submarine Gas Pipeline (2010 2011)

History of the Project

Adopted Concept and Open-Tender Issued

6
History of the Project
Transmission Pipeline Across West Jurong Channel

CONVENTIONAL METHOD
(Trenching + Pipelaying + Backfilling)

VS

PIPE JACKING METHOD

Reference Projects
Service Duct, Kieler Frde, Germany

Reception shaft

Jacking shaft
Technical Data:

Length: 1,368m
Internal Diameter: 4.10m
External Diameter: 5.00m
Slope: max 10%
Depth under Water level: max 37.46m

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Reference Projects
Gautami Godavari River Crossing, India

Technical Data:

Max. Drive Length: 1,303m

Total Length: 2,438m
Internal Diameter: 2.40m
External Diameter: 2.86m
Slope: max 6%
Depth: max 32.0m

Reference Projects
Southern Seawater Desalination Plant, Australia
NORTHERN INTAKE
TUNNEL

LAUNCHING
RECEIVING PITS
SHAFT

OUTFALL TUNNEL

SOUTHERN INTAKE
TUNNEL

Technical Data:
Max. Drive Length: 950m
Total Length: 2,670m
Internal Diameter: 2.00m/2.40m
External Diameter: 2.45m/2.86m
Slope: max 4.8%
Depth: max 35.2m
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 HISTORY OF THE PROJECT
WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

11

Working Shafts
Shafts Design: D-Wall

Why did we choose Circular D-Wall?

Close proximity to the sea

Geotechnical profile (sandy ground with water content)

Swift and safe construction

Tidy and spacious working environment for follow-up works.

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Working Shafts
Jacking Shaft

LAUNCHING SEAL 1.0 M

JACKING STATION 4.5 M

WALL THICKNESS = 1.0 M

WALL THICKNESS = 1.0 M

2 JACKING PIPES
INSTALLATION 7.0 M

MIN. SHAFT DIAMETER REQUIRED

SHAFT DEPTH = 30.8 M

FOR PIPE JACKING WORK = 12.5 M

JACKING STATION 4.5 M

LAUNCHING SEAL 1.0 M

2 JACKING PIPES
INSTALLATION 7.0 M

PLAN

SHAFT DIAMETER REQUIRED FOR PIPE JACKING WORK 12.5 M

~ 9.2 M
SHAFT DIAMETER REQUIRED FOR GAS PIPELINE INSTALLATION 13.5 M

PROPOSED JACKING SHAFT DIAMETRER 14.0 M ELEVATION

13

Working Shafts
Receiving Shaft

TBM CAN NO.1 = 5.8 M

WALL THICKNESS = 1.0 M

WALL THICKNESS = 1.0 M

SHAFT DEPTH = 29.3 M

MIN. SHAFT DIAMETER REQUIRED FOR

TBM RECOVERY = 7.2 M

TBM CAN NO.1 = 5.8 M

PLAN
~ 10.7 M

SHAFT DIAMETER REQUIRED FOR TBM RECOVERY 7.2 M

PROPOSED RECEIVING SHAFT DIAMETRER 7.5 M ELEVATION

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Working Shafts
Good Subcontractor: Bachy Soletanche

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Working Shafts
Praying Ceremony Good Praying!

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 HISTORY OF THE PROJECT
WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

17

Modification of TBM
Dual Mode Pipe Jacking Machine M-1182M

8 9 11 12 13
5 6 7
1 3 24

15 10
14
1 Cutting Wheel 6 Screw Conveyor 11 Power Pack
2 Drive Motor 7 Stone Crusher 12 Jacking Station
3 Steering Cylinder 8 Gate Valve 13 Winch
4 Articulation Joint 9 Belt Conveyor 14 Flushing Box
5 Gyro Target 10 Compressed Air Lock 15 Bypass
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Modification of TBM
Fire Box (Stone Crusher)

EXISTING FIRE BOX MODIFIED FIRE BOX

19

Modification of TBM
High Voltage System

High voltage system to be install behind the TBM

On-ground

Step up transformer: 400V => 10kV

Behind the TBM

Step down transformer: 10kV => 960V

10kV => 400V

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Modification of TBM
Stand Alone Power Pack for IJS

21

HISTORY OF THE PROJECT

WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

22
Jacking Pipe
Pipe Factory in Thailand

23

Jacking Pipe
Production Line

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 HISTORY OF THE PROJECT
WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

25

Construction Techniques
Geology

RECEIVING SHAFT JACKING SHAFT

(Tuas Area) (Jurong Island)

CHART DATUM

SAND GRAVEL

CLAY CLAY

SAND
SILT
SILT

SAND

SAND
MUDSTONE

JACKING PIPE ID2000MM, LENGTH = 1550M

LEGENDS:

SILT SAND GRAVEL CLAY MUDSTONE

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Construction Techniques
High Water Pressures in Rock

Hyperbaric Lock Operator Training

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Construction Techniques
Universal Navigation System

Gyro Compass Hydrostatic Water Operators Monitor Laser

Leveling System

28
Construction Techniques
Control Survey
Final Result
H = 153mm
V = 28mm

29

Construction Techniques
Intermediate Jacking Station (IJS)

IJS No.1 IJS No.2

Main Jacks

IJS No.1 IJS No.2 Main Jacks

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Construction Techniques
Intermediate Jacking Station (IJS)

159m 156m 156m 189m

match line A-A

300 344 345 346 347 348 349 396 397 398 399 400 448 449 450 451 452 511 512 513

IJS no.7 IJS no.8 IJS no.9 MAIN

JACKING
STATION
match line B-B

match line A-A

159m 159m 159m

141 142 143 189 190 191 192 193 240 241 242 243 244 245 246 293 294 295 296 297 298 299

IJS no.4 IJS no.5 IJS no.6

match line B-B

105m 153m 156m

TBM 01 02 03 04 05 06 33 34 35 36 37 38 84 85 86 87 88 89 135 136 137 138 139 140

IJS no.1 IJS no.2 IJS no.3

Maximum 3 nos. of IJS used during pipe jacking operation.

Maximum Allowable Jacking Force 820 tons, Maximum used: 700 tons

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Construction Techniques
3 Points Lubrication System
Compressed

Bentonite Pump 1 Bentonite Pump 2 Bentonite Pump 3

Air

e Hoses
Bentonit

Cables
Control
Stand Alone

TBM

TBM

12m

12m

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 HISTORY OF THE PROJECT
WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
DANGERS, TROUBLES AND PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

33

Dangers and Troubles During Operation

Possible stoppages due to Break-Down are avoided due to;

Good Maintenance Plan

Extensive Consignment stock
Full Time presence of HK personnel

Stoppages avoided as a result of excessive friction by;

Using 3-Point Automatic Lubrication System

Continuous monitoring, and maintenance of lubrication system
No. of total Inter-jack stations used during operations

Stoppages avoided due to Steering;

Skilled / Experienced operators

34
Problems Faced During Operation

Surveyors Fault!

Gantry Crane Breakdown

Malfunction of High Voltage Transformer

High Skin Friction close to the end

35

HISTORY OF THE PROJECT

WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
DANGERS, TROUBLES AND PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

36
 Safety
Safety Records
Monthly Accident Frequency Rates

Feb-11 Mar-11 Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11

No. of Minor Accidents - - - - - - - - - - -

No. of Major Accidents - - - - - - - - - - -

No. of Manhours 3,300 10,070 11,860 14,215 17,289 15,714 16,204 19,208 18,084 22,200 24,192

Accident Frequency
- - - - - - - - - - -
Rate A
Accident Frequency
- - - - - - - - - - -
Rate B

Cumulative Accident Frequency Rates - Cumulative No. of:

Minor Accidents - - - - - - - - - - -

Major Accidents - - - - - - - - - - -

Manhours 3,300 13,370 25,230 39,445 56,734 72,448 88,652 107,860 125,944 148,144 173,272

Accident Frequency
- - - - - - - - - - -
Rate A
Accident Frequency
- - - - - - - - - - -
Rate B

37

Safety
Safety Drill / Training

38
 HISTORY OF THE PROJECT
WORKING SHAFTS
MODIFICATION OF TBM
JACKING PIPE
CONSTRUCTION TECHNIQUES
DANGERS, TROUBLES AND PROBLEMS FACED
SAFETY
PROGRESS & RECORDS

39

Progress and Records

Breakthrough 18.12.2011

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Progress and Records
Breakthrough 18.12.2011

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Progress and Records

Pipe Jacking Progress

Tunnelling Duration 123 calendar days

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Progress and Records
Records Around the World

Max. drive length Year of

Rank Country City / region Pipe ID
(m) completion

1 Germany Europipe 3000 2,535 1994

2 Germany Munich - Allacher Forst 2740 1,600 1988

3 Germany Bremen - Buergerpark 2600 1,600 1990

4 Russia Moscow 3000 1,600 2009

5 Singapore Jurong Island 2000 1,550 2011

6 Germany Berlin / Bewag 3000 1,536 1998

7 Germany Berlin 3000 1,530 2001

8 Germany Hamburg 1600 1,520 1992

9 Portugal Praia de Mira 2000 1,500 2008

10 Portugal Praia de Mira 2400 1,500 2008

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Thanks for your Attention 44