SEMINAR TOPIC ON

TUNNEL BORING MACHINE

SUBMITTED BY:

AJAY.G.RAJAN
ROLL NO: 03 M3 S5

INTRODUCTION
Tunnel Boring Machine (TBM) also known as MOLE. It is used to excavate tunnels with a circular cross section. It can bore through anything from hard rock to sand. Different types of TBMs are used for different geotechnology. Used as an alternative to drilling and blasting (D&B) methods and conventional 'hand mining' in soil Limits the disturbance to the surrounding ground and produces a smooth tunnel wall. Suitable to use in heavily urbanized areas.
continues.
2

 TBMs is also a complete single unit moving factory Only little finishing work has to be done after using TBMs as this single unit can do DRILLING SYSTEMS CONCREATE SPRAYING SEGMENTAL LINING ROCK SUPPORTING PIPE JACKING CONVEYANCE OF EXCAVATED MATERIAL

GEOTECHNOLOGY
The geological and hydraulic information about the soil forms the basis for planning and executing tunnelling and pipe jacking projects. Provide the basic data for selecting tunnelling methods and cutting wheel tools that will cut through the native ground efficiently and economically.

The most important ground or rock-mechanical parameters for designing a tunnel boring machine are:
-grading curve -ground water penetration -consistency limits -rock/clay mineralogy -quality of the rock -hardness of the rock

General parts AND SYSTEMS

CUTTING ROLLS
Cutting rolls are used to tear of the soil and rock from tunnel face. They are mounted on the cutting heads. Different types of materials are used for different ground condition. They are placed radially, so as to have maximum efficiency. They can revolve themselves in full 360 degree. They can be replaced periodically. They presses the tunnel face with a force of 26 tons.
6

CUTTING BLADES
Cutting blades are used as a supporting tools to shear through hard and moist ground. They are mounted on cutter head radially and in periphery.

Cutting blade are of different geometry.

The geometry of the cutting blade is decided by the ground moisture content.
7

CUTTer heads
Cutter heads is the part of the TBM which faces the ground to be tunneled.
It will revolve in speed of 1 to 10 rpm Cutting rolls and cutting blades are mounted here.

Cutter head can revolve 360 degree

They are also provided with openings called muck buckets for extracting excavated materials (chips) to the conveyor.

GRIPPER
Grippers are also called supporting arms of TBMs. All TBMs have at least a pair of grippers. Grippers provide a radial thrust to the tunnel walls with the help of hydraulic press. Grippers are used only when cutter head moves forward against the tunnel face.

CONVEYORS
The chips are carried out off the tunnel from the tunnel face via many methods,

-Mechanical transportation Auger conveyor

Conveyor belts

Muck cars
-Hydraulic transportation (slurry circuit)

Continues.

10

conveyors
This conveyor system travels in full length of the tunnel.
Chips are then dumped on disposal plant. This keeps the workspace clean and easy to work

11

TUNNEL SECURING WORKS

Tunnel walls are secured soon after the boring finishes a length. They are done so as to avoid rock or soil slide. For this 4 different accessories are used: -Anchor drills

-Mesh placing machine

-Steel arch segments -Short concrete sprayer

12

Anchor drills
Anchor drills are used for drilling holes in tunnel walls. These holes are used to anchor steel meshes or steel arc linings used to support tunnel face. Also used to inject chemical adhesives to have a bond between layers of earth. They can rotate all around 360 degree making tunnel face secure. They are made of high quality aluminum alloy.
13

Continues

The property of drill material vary for each project. These drills are accommodated with settings to flush water for easy drilling. These drills are controlled by computer aided positioning system.

14

Steel arc segments AND MESH PLACING

These are done for providing support for tunnel walls. Either steel arc segmenting or mesh placing is done according to project site. They are done soon after the boring and drilling section finishes their work. Mesh placing is done only on the upper section.

Steel arc segmenting is done at 360 degree round the tunnel wall with equal spacing between each lining.

15

Continues

This provide minimum chance of wall collapse, providing safer work space for workers. Only after this drilled holes are anchored using screws by professionals. These are picked up by remote controlled gibbet and moved into position by erectors.

16

Concrete sprayer and blocks

In steel arc segmenting, concrete readymade blocks are placed inbetween each. While in meshing, concrete is sprayed at high pressure by concrete sprayers. The concrete sprayer is operated automatically, so that it provide even finishing everywhere. Concrete sprayers are fitted behind the gripper section. Concrete blocks are placed manually with help of machineries only after the tunneling process is finished.
17

Press frames

Press frames are hydraulic piston cylinder arrangement. The cutter heads are moved forward due to the extension of pistons. The processes stops when the cylinder piston reaches maximum.
18

METAL SHIELDS
This is a large metal cylinder used to brace the machine against the wall tunnels.
The number of shields depending on the TBM type and type of soil to be excavated.

Rock type soils can be excavated with a one-shield machine.

Sand soil digging requires a two-shield TBM.
19

The control containers are the place which occupies all the latest technologies for accurate boring. They are used to control depth of boring, cutter roll weariness, soil dampness, UNS (Universal Navigation System), depth monitors, etc. Control unit consists of a control panel, a computer unit and, for graphic displays, a monitor.

CONTROL CONTAINERS & navigation system

20

Continues..

Via the computer unit, all data - e.g. hydraulics oil pressure, strokes of individual hydraulic cylinders - can be measured and displayed.

These prevents faults and saves the data on each bore operation for analysis later. In other words, any bore operation can be reconstructed at any time.
They provide an accuracy of knife edge precision.

For example, after traveling 14km through the mountain complex, the two Herrenknecht Gripper-TBMs on the southern side of the Gotthard Base Tunnel arrived at their destination with a horizontal deviation of 5cm and a vertical deviation of 2cm. This can be compared with a marksman hitting a 21 1 Euro coin from a distance of 2km.

Separation plant
Separation is an important, sensitive and integral component of tunneling systems. System is placed away from the tunnel.

Its purpose is to separate the solid from the fluid components in the excavated material, so that the slurry water can be returned to the circuit after depositing the excavated soil. Separation in the separation plant takes place in several stages - dependent on the granular size of the loose rock - and is based on mechanically generated centrifugal forces and screening technology.
Modern screening technology, hydro vacuum cyclones, vertical separators and centrifuges form a closed recycling concept and ensure that the critical fine particles are removed.
22

Powerful treatment and reuse of bentonite suspensions of up to 2,800m3/h.

MACHINE TECHNOLOGY
For tunneling project different kind of TBMs are used. Type of TBM varies with ground condition. Soft ground type -EPB technology -Slurryshield -Mixshield Hard ground type -Single shield TBM -Double shield TBM

23

EPB Technology

EPB is used in soft ground type with less than 7 bar of pressure Uses combination of tungsten carbide cutting bits, carbide disc cutters, and/or hard rock disc cutters. The EPB gets its name because it is capable of holding up soft ground by maintaining a balance between earth and pressure.
Also additives such as bentonite, polymers and foam are injected into the ground to further stabilize it. Auger conveyor is used to remove chips.
24

SLURRYSHIELD &MIXSHIELD

In soft ground with very high water pressure and large amounts of ground water, Slurry Shield TBMs are needed. Offers a completely enclosed working environment. Soils are mixed with bentonite slurry, which must be removed from the tunnel through a system of slurry tubes that exit the tunnel. Large slurry separation plants are needed on the surface for this process, which separate the dirt from the slurry so it can be recycled back into the tunnel. For recycling separation plants are used.
Continues
25

26

SINGLE SHIELD TBM

Single shield TBMs have no shield as that of in soft ground type. Excavation is done by cutter rolls transferred through openings in the cutter head to a belt conveyor, and then to muck cars or conveyor belt. There is no excavation chambers as chips are of solid and not as slurry. The cutter head torque depends largely on the degree of penetration of the disks and their contact pressure. More smoother tunnel walls can be created using single shield TBMs.
27

Double shield TBMs

These are the most technically sophisticated tunnel boring machines in use.
This type of machine is ideally suited for drilling long tunnels in hard rock where geological fault zones occur.

Its main feature is an extendable front shield in the front part of the machine, which allows the cutterhead to be extended.
On completion of a thrust stroke, the gripper shoes are retracted and the rear section of the machine is pushed against the front shield by the 28 auxiliary thrust cylinders. This changeover lasts a few minute only.

External features
1) ADVANTAGES -Is mainly suitable for urban tunneling. -Less time for completion.

-Total expense is less than any other process.

-Less manual effort is needed. -Risk factors like explosion, rock slide, etc are less.

2) DISADVANTAGES
-High initial expense. -Difficult to transport machines. -Need many skilled technicians.

29

Continues.

PROJECTS COMPLETED -Alimineti Madhava Reddy (AMR) project -Veligonda project -Parbati hydro electric project -Dulhasti hydro electric project -Onsite First Time Assembly (OFTA) part of Sleemanabad carrier canal project FUTURE PROJECTS -Delhi Metro Project Phase-1(65km) & Phase-2 (124.63) -Bangalore Metro Project (8.822km) under city railway station, vidhana soudha, majestic & city market area. -Chennai Metro Project Phase-1 washermenpet to saidapet(14.3km), Phase-2 Chennai Central to Anna Nagar 2nd Avenue. -Hyderabad Metro Project (70km). -Jaipur Metro Project from Mansarovar to Chandpol.
30

CONCLUSTION
For a fast developing country like INDIA, it is very important to have traffic free transport facilities, underground water supply canal, etc. As these thinks have major part in boosting our economics by foreign investments. The tough task is that to have all this in highly densed metros like Delhi, Mumbai, Bangalore, Chennai, etc. its not possible to build flyovers at all places to as it leads to traffic conjunctions till the project finishes. Also when it come to have transportation across hilly areas time taken and risk factors are more. To over come this and to provide safe and comfortable transportation in all terrains TUNNELING is the best way to it provide easy tunneling even under huge buildings, tough terrains, under river beds too. It is the best suitable method for a fast developing nation.
31

REFERENCES

GOOGLE (www.google.com)

WIKIPEDIA (en.wikipedia.org )
YOU TUBE (www.youtube.com ) HERRENKNECHT TUNNEL SYSTEMS (www.herrenknecht.com) THE ROBBINS COMPANY (www.robbinstbm.com) THE MASTERBUILDER construction magazine

32