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Tunnel Boring Machine Brief Information
Tunnel Boring Machine Brief Information
Overall introduction
The oceans to be crossd, the distant brought near,
The lands to be welded together
(Walt Whitman)
English for Mechanical Engineering and Materials Science 2 is essential for technical students
in Hanoi University of Science and Technology, especially those who are currently enrolling
their studies in English. This course gives students chances to find themselves in a world of
knowledge.
The reason for our choosing this topic: Tunnel Boring Machine was that Tunneling has
already had a long lasting history. It was seen as a major breakthrough in tunneling
technology during the last century as tunnel boring machine was born. However, as the
demand of using this machine is growing in Vietnam as the transportation grows while people
lack awareness about this.
This report is our final result from what we have learned and achieved from the course. The
goal of this report is to give other students an understanding of what is a TBM, what makes a
TBM and how it works. The report explains in the first part some brief information, the
history of TBM machines and various types of TBMs. The second part describes the main
components of a typical TBM while the last one reveals its working mechanism.
Introducing this topic, we hope to provide students in the school with fundamental knowledge
about TBM.
Table of Content
Overall introduction ................................................................................................................................ 1
Week 1 TBM introduction .................................................................................................................... 4
I.
II.
III.
Classification ........................................................................................................................... 9
1.
2.
II.
2.
3.
III.
1.
2.
Slurry Line............................................................................................................................. 25
IV.
1.
2.
3.
I.
1.
2.
II.
III.
1.
Grouting ................................................................................................................................ 37
2.
3.
Maintenance .......................................................................................................................... 39
IV.
1.
2.
3.
Week 1
TBM introduction
During this section, we would like to let the audience go through a very brief introduction over the
machine and things around it.
CONTENT:
I.
II.
III.
I.
II.
The first successful tunneling machine which is commonly regarded as the forerunner of the
tunnel boring machine was developed by Marc Isambard Brunel to excavate the Rotherhithe
tunnel under the Thames in 1825 (Humber River, 2005). However, this was only the
invention of the shield concept and did not involve the construction of a complete tunnel
boring machine, the digging still having to be accomplished by the then standard excavation
methods using miners to dig under the shield and behind them bricklayers built the lining.
Although the concept was successful eventually it was not at all an easy project. The tunnel
suffered five floods in all. It is also noteworthy that Marc Brunels son who was the site
engineer went on to become what is generally thought of as Britains greatest engineer,
Isambard Kingdom Brunel. (Excavating rock by tunnel boring machine, 1985).
Improvements on this concept were used to build all of the early deep railway tunnels under
London in the early 20th century and lead to the name tube which is the nickname all
Londoners call their metropolitan railway and gave tunnels made by this method their
characteristic round shape.( Humber River, 1956).
6
In other countries tunnel boring machines were being designed to tunnel through rocks. The
very first actual boring machine ever reported to have been built is thought to be HenriJoseph Maus' Mountain Slicers design in 1845 dig the Frjus Rail Tunnel between France
and Italy through the Alps, Maus had it built in 1846 in an arm factory near Turin. It
basically consisted of more than 100 percussion drills mounted in the front of a locomotivesized machine, mechanically power-driven from the entrance of the tunnel however it was
not used, and the tunnel was finally built using conventional methods.
According to BBC News, In the United States, the first boring machine was used in 1853
during the construction of the Hoosac Tunnel. Made of cast iron, it was known as Wilson's
Patented Stone-Cutting Machine, after its inventor Charles Wilson. It drilled 10 feet into the
rock before breaking down and the tunnel was completed many years later, using less
ambitious methods.
We need to move on nearly 100 years when James S. Robbins built a machine to dig through
what was the most difficult shale to excavate at that time, the Pierre Shale.(Orrichela, 1972).
Robbins built a machine that was able to cut 160 feet in 24 hours in the shale, which was ten
times faster than any other digging speed at that time.
According to TARP (1967), the modern breakthrough that made tunnel boring machines
efficient and reliable was the invention of the rotating head, conceptually based on the same
principle as the percussion drill head of the Mountain Slicer of Henri-Joseph Maus, but
improving its efficiency by reducing the number of grinding elements while making them to
spin as a whole against the soil front. Initially, Robbins' tunnel boring machine used strong
spikes rotating in a circular motion to dig out of the excavation front, but he quickly
discovered that these spikes, no matter how strong they were, had to be changed frequently
as they broke or tore off. By replacing these grinding spikes with longer lasting cutting
wheels this problem was significantly reduced. Since then, all successful modern tunnel
boring machines use rotating grinding heads with cutting wheels for boring through rock.
III.
Classification
Based on the working environment, TBMs can be classified into 3 main types: Hard rock
TBM, Soft ground TBM and Dual mode TBM. While Hard rock and Soft ground TBMs are
appropriate for respective working environment, Dual mode ones can work in both ground
conditions.
Hard rock TBMs excavate rock using disc cutters mounted in the cutter head. The spinning
cutter head is pressed again the tunnel face to create high pressure on the rocks. The rocks
under high pressure are broken into pieces and chipped away by the disc cutters.
Depend on the diameter and the hardness of the rocks, Hard rock TBMs can be further
divided into three types: Single shield TBMs, Double shield TBMs and Gripper TBMs. There
are some differences in the structure of these machines.
a.
Single shield TBMs protect the machine from broken rock until the tunnel lining can be safely
installed. The body of the machine is enclosed in a shield that is smaller than the diameter of
the tunnel. The front of the TBM is a rotating cutter head that matches the diameter of the
tunnel. As the cutter head turns, a ring of hydraulic cylinders provides forward thrust through
shoes that push against last segment ring installed. However, due to this process, the TBM
have to stop to install new segment after digging a short distance. This process takes time and
results in the slow boring speed. Another disadvantage of this type is that it cannot reach high
performances in hard rock and is sensitive to squeezing ground and face instabilities
(Grandori, 2006)
1. Cutter head
2. Shield
3. Belt conveyor
4. Excavated material
removal trolley
b.
A Double Shield TBM consists of a rotating cutter head mounted to the cutter head support,
followed by three shields: a telescopic shield (a smaller diameter inner shield which slides
within the larger outer shield), a gripper shield and a tail shield. The telescopic shield extends
as the machine advances keeping everything in the machine under cover and protected from
the ground surrounding it. The gripper shield remains stationary during boring. A segment
erector is fixed to the gripper shield allowing pre-cast concrete tunnel lining segments to be
positioned while the machine bores. The segments are positioned within the tail shield. The
ability to erect the tunnel lining simultaneously with boring that allows it to achieve such high
performance rates. The completely enclosed shielded design provides protection for the crews
and the machine. Double shield TBM can achieve very good performance in good to fair rock.
However, this type of TBM is sensitive to squeezing ground and to face instabilities (Grandori,
2006)
10
1. Cutter head
2. Shields
2a Gripper shield
2b Telescopic shield
2c Tail shield
3. Belt conveyor
4. Excavated material
removal trolley
Double shield TBM (NFM technologies)
c.
Gripper TBM
Gripper TBM uses shoes and presses radially against the walls of the excavated tunnel.
Contrary to shielded hard rock TBM, this tunnel boring machine does not rest against the
lining. The force exerted by the grippers must be very high to prevent the thrust applied to the
head from causing shield recoil.
However, gripper TBM is too sensitive to poor rock conditions especially in large diameter
range (Grandori, 2006)
1. Cutter head
2. Front shield
3. Main beam
4. Gripper trolley
5. thrust cylinders
6. Belt conveyor
7. Ring beam erector structure
8. Shortcret
Gripper TBM (NFL Technologies)
11
2.
According to EFNARC (2005), the infrastructure project (subways, sewers, water supply,)
often takes place in the soft ground under urban area, it poses the high risk of damage to the
above structures. Whether the ground is soft-solid (earth pressure) or unstably soft (mud
pressure), we can flexibly choose between earth pressure TBM or Slurry TBM. The Slurry
Shield and the Earth Pressure Balanced shield (EPBS) have been developed in the recent
decades for managing the instability of the excavation profile in unfavorable geotechnical and
hydro-geological conditions, with challenge external constraints.
a.
Slurry TBM
In the website of NFM technologies, Slurry TBM is used for tunnel-boring in highly
permeable unstable terrain, or under civilian structures sensitive to ground disturbances.
EFNARC (2005) defined the slurry and bentonite as below:
Bentonite is a form of clay mineral which extends its volume when dissolved in water.
Because the bentonite slurry is stored in the excavation chamber at the tunnel front, it required
a conveyance via pipes system: the slurry feeding pipe (suction line) and in the slurry
discharge pipe. EFNARC (2005) continued that the bentonite slurry together with one airfilled part help to maintain an even over-pressure in front of the TBM cutter head and also
acts as an aid to soil transportation by pumping.
b.
13
From the finding above, the comparison of EPBM and Slurry machine can be summarized in
the table below:
EPB Machines
Slurry Machines
Soil
condition
permeability
permeability
Example
Clay, silt,
Similarity in
structure
Supporting
liquid/ slurry
face
transportation by pumping
Difference in
structure
pressure
pressurize slurry
c.
Dual-Mode TBM
14
A dual-mode tunnel-boring machine, in the website of NFM technologies, can dig through
very different geologies, earth and rock for example. In this case, the tunnel-boring machine is
developed to receive two types of removal equipment, each one corresponding to a given type
of ground.
15
Week 2
The Structure
In this section, we went further into the structure of a specific boring machine: Earth Pressure
Boring Machine, or EPBM. The reason why it was chosen was that this machine utilizes a Tunnel
Boring Machine that allow for installations in unstable ground.
CONTENT:
I.
II.
III.
DISCHARGE SYSTEM
IV.
16
The machine is capable of operating under a wide range of ground from soft soils to
weathered rock. This is useful when the projects is implemented in an urban environment and
ground surface subsidence cannot be tolerated (The Robbins Company)
The ground at the cutting face is supported by earth pressure by balancing the advancement
of the tunnel with the discharge rate of the excavated soil
EPBM is used widely in the construction of rail tunnels, metropolitan subway systems,
highways tunnels, and other projects where the tunnel will be constructed either partly or
completely in soft soil beneath a water surface (Poor Ground, Tough Machine , 2013)
17
I.
The Shield has the function of protecting and containing all the subcomponents in it. The
most important part in the shield is rotary cutting wheel, or cutting head. This wheel is a
complicated structure containing a number of parts such as cutting discs, tungsten carbide
cutting bits, injection systems, sensors and hydraulic motors. The reason why cutting wheel is
called the most important one is because this component is responsible for excavating the soil.
The tool which directly contacts with the soil is cutting disc. (Herrenknecht tunneling
systems)
Attached to the rotary cutting head are several components which can be mentioned as cutting
disc, cutting bits, injection system, sensors,
The cutting knifes or discs are tools which provide the transmission of energy generated by
the machine to the rock in order to cause fragmentation (M. Cigla, 2001)
Sensors are attached at the tips of some tools on the surface of the cutting wheel and function
as a kind of alarm when wear is reached, so that the mechanics can replace the cutting tools
(EPB Shield)
The injection system works on the cutting wheel as a support for the excavating especially
when the machine goes through the hard layer of rock
18
II.
Hydraulic Jack
A hydraulic cylinder (also called a linear hydraulic motor) is a mechanical actuator used to
give a unidirectional force through a unidirectional stroke. (The Free dictionary, 2013). It has
many applications, notably in construction equipment (engineering vehicles), manufacturing
machinery, and civil engineering.
A hydraulic cylinder jack in TBM is a jack that uses a liquid to push against a piston and it is
placed behind the chamber. (Richard C. Milton, 1999)
Cylinder barrel
The main function of cylinder barrel is to hold cylinder pressure. The cylinder barrel is mostly
made from a seamless tube. The cylinder barrel is ground and/or honed internally with a
typical surface finish of 4 to 16 micro-inched. Normally hoop stress is calculated to optimize
the barrel size. (A.Lexis, 2010)
19
The main function of the cap is to enclose the pressure chamber at one end. The cap is
connected to the body by means of welding, threading, bolts, or tie rod. Caps also perform as
cylinder mounting components [cap flange, cap trunnion, cap clevis]. Cap size is determined
based on the bending stress. A static seal / o-ring is used in between cap and barrel (except
welded construction).
Cylinder head
The main function of the head is to enclose the pressure chamber from the other end. The
head contains an integrated rod sealing arrangement or the option to accept a seal gland. The
head is connected to the body by means of threading, bolts, or tie rod. A static seal / o-ring is
used in between head and barrel. (C.S Harris, 1997)
Piston
The main function of the piston is to separate the pressure zones inside the barrel. The piston
is machined with grooves to fit elastomeric or metal seals and bearing elements. These seals
can be single acting or double acting. The difference in pressure between the two sides of the
piston causes the cylinder to extend and retract. The piston is attached with the piston rod by
means of threads, bolts, or nuts to transfer the linear motion. (Thomasnet, 2012)
Piston rod
The piston rod is typically a hard chrome-plated piece of cold-rolled steel which attaches to
the piston and extends from the cylinder through the rod-end head. In double rod-end
cylinders, the actuator has a rod extending from both sides of the piston and out both ends of
the barrel. The piston rod connects the hydraulic actuator to the machine component doing the
work. This connection can be in the form of a machine thread or a mounting attachment....
Seal gland
The cylinder head is fitted with seals to prevent the pressurized oil from leaking past the
interface between the rod and the head. This area is called the seal gland. The advantage of a
seal gland is easy removal and seal replacement. The seal gland contains a primary seal, a
secondary seal / buffer seal, bearing elements, wiper / scraper and static seal. In some cases,
especially in small hydraulic cylinders, the rod gland and the bearing elements are made from
a single integral machined part.
Seals
20
The seals are considered / designed as per the cylinder working pressure, cylinder speed,
operation temperature, working medium and application. Piston seals are dynamic ones, and
they can be single acting or double acting. Generally speaking, Elastomer seals made
from nitrile rubber, Polyurethane or other materials are the best in lower temperature
environments, while seals made of Fluorocarbon Viton are better for higher temperatures.
Metallic seals are also available and commonly use cast iron for the seal material. Rod seals
are dynamic seals and generally are single acting.
a.
The hydraulic pressure in these cylinders is in the form of hydraulic fuels that are stored under
pressure in these cylinders. The energy stored in these oils is converted into motion. In a
complete hydraulic system, a hydraulic motor consists of one or more hydraulic cylinders. A
pump regulates the oil-flow in the hydraulic system. The pump is a part of the generator of a
hydraulic system. The hydraulic cylinders initiate the pressure of the oil, which cannot be
more
than
that
required
by
the
load.
(H.
Boelter,
2010)
A hydraulic cylinder consists of a cylindrical barrel, piston, and a piston rod. The piston that
is placed within the barrel is connected to the piston rod. The cylinder bottom, and the
cylinder head, closes the bottom and the head of the barrel respectively. The cylinder head is
the side from where the piston rod exits the cylinder.
A Cylinder
21
The cylinder bottom and the piston rod are mounted with mounting brackets or clevises. The
piston in the hydraulic cylinder consists of sliding rings and seals. The piston rod chamber
and the bottom chamber are the two chambers within the cylinder.
The piston rod starts moving outwards, as the hydraulic fluid is pumped into the bottom side
of the hydraulic cylinder. In the reverse process, the hydraulic fluid is pushed back into the
reservoir by the piston. The pressure in the cylinder is the ratio of unit force per unit piston
area.
The pressure generated in the piston rod chamber is the ratio of the unit load per the
difference in the unit piston area and unit piston rod area. This calculation is used when the
hydraulic fluid is let into the piston rod chamber as well as the fluid flows smoothly (without
pressure) from the piston area to the reservoir. In this way, the expansion and retraction (push
and pull) action of the hydraulic cylinder is generated.
b.
The characteristics of the hydraulic piping system in Tunnel Boring Machine (TBM) are large
slenderness ratio, high fluid pressure and low flow velocity. With the work conditions of
TBM, the beam model of long straight pipe was established. Under consideration of fluid
structure interaction (FSI) and simple supported conditions, oscillation equation of piping
system was solved by vibration formation decomposition. Having analyzed the effect of
piping system parameters on the first order inherent frequency by the method of sensitivity
analysis, pipe length was the most significant effective factor on inherent frequency of pipe
system. Considering the relation between fluid pressure wave frequency and pipe inherent
frequency, oscillation criteria based on the first order inherent frequency was put forward.
Finally, optimized design was given for piping system design.
22
III.
Discharge Systems
There are some types of mud discharge systems for TBMs. For example, the open-type TBM uses
conveyor belt, the Slurry has the pipe system or the shield TBM and the EBPM extract the excavated
material by using screw conveyor. In this report, we will go thru some kinds of discharge systems,
which are the most popular and significant ones.
1. Cutter head
2. Shield
3. Belt conveyor
4. Excavated material
removal trolley
1. Cutter head
2. Shield
3. Bentonite injection
4. Air regulation
5. Air bubble
6. Extraction of slurry with
soil
The pipe system in Slurry machine (NFM technologies)
23
1. Screw Conveyor
In the single shield TBM or the EBPM, the excavated material is removed from the
excavation chamber by a screw conveyor. The screw conveyor conveys the excavated
material to one of the ends of an open conveyor belts (Federal Highway Administration 2011).
It was also found that the excavated material is conveyed on this reversible conveyor from
which the transportation structure in the backup areas is loaded. And then the excavated
material is removed from the tunnel by mud car, train or conveyor system.
The amount of material removed is controlled by the speed of the screw conveyor driver.
24
During the excavation process, the ground material or excavated soil move thru the cutter face
to the working chamber. Inside the chamber, the mud is pressurized. The different pressure
between the chamber and the screw conveyor forces the excavated material to the screw
conveyor.
A TBM operator can control the pressure in the chamber continuously (TheRobbinsCo 2010).
The pressure in the excavation chamber is controlled by balancing the rate of advance of the
machine and the rate of extraction of the excavated material by the screw conveyor.
TheRobbinsCo (2010) showed that in order to raise pressure, the operator can either increase
the machine raise of advance or decrease the rotation of the screw conveyor. To lower the
pressure, the operator does the opposite. It decreases the machine raise of advance or increase
the rotation of the screw conveyor.
2.
Slurry Line
This type of muck discharge system is used in the Slurry TBM. The treated slurry is fed into the
working chamber thru slurry feed pipe and the excavated material is taken out thru the discharge pipe
(EFNARC 2005). The excavated ground material and suspension liquid is mixed by hydraulic
conveyance via tubes with separation of the two materials.
25
IV.
Tunnel lining is highly mechanized process. The purpose of this process is to support the
exposed ground, providing and maintaining the required operational cross-section and provide
a barrier against liquids. There are many types of lining system. However, as automatic
processes is applied more and more in TBM, many TBMs now using fully automatic system
such as The Fully Automated System for shield tunneling under Integrated Control (FASTIC).
FASTIC (Ohno, Kazama, Higashide, & Tomioka, 1996) comprises an automatic lining
system, which in turn, consist of three most important components:
1.
The system provides full automation of the segment conveying operation without manual
labor.
26
Automatic Segment Conveying System (Ohno, Kazama, Higashide, & Tomioka, 1996)
a.
AGV System
b.
The segment handling equipment uses a suction pad to hold the segments conveyed by the
AGV system and deliver them to the segment feeder.
27
Automatic segment erection robot (Ohno, Kazama, Higashide, & Tomioka, 1996)
a.
Segment Feeder
Segment feeder transports the segments received from the handling equipment. The segments
are slowly delivered on a conveyor to the segment erector system.
b.
Segment Erector
The segment erector is a rotating ring type erector. Attached to the rotating ring is a crane
arm. The crane arm is equipped with vacuum pads to pick up the segments from the segment
feeder and build up the ring using precise sensor.
28
3.
The purpose of this robot, unlike the systems and robot described above that were developed
for automation of the main shield tunneling tasks, is to perform shield construction incidental
work such as retightening of segment bolts or the laying of sleepers and rails.
Multi - Function Ancillary Robot (Ohno, Kazama, Higashide, & Tomioka, 1996)
29
Week 3
Working Method
In this section, we mainly focused on the working method of Earth Pressure Boring Machine (EPBM).
Some notable projects which have used Tunnel Boring Machine as an useful tool will be mentioned as
well.
CONTENT:
I.
MACHINE ASSEMBLY
II.
WORKING METHOD
III.
BACKUP SYSTEM
IV.
NOTABLE PROJECTS
30
I.
Assembly
TBM assembly is a very sophisticate process which requires a great amount of time and
human force. To assemble a TBMs components, a large assembly site has to be prepared as
the size of the TBM and the assembly equipment are very large. Second, a crane system is
required to lift the components up. The crane system must be strong enough to carry the
heavy weight of the components. Assembly operations must be carried out under the
supervision of skilled technicians including those from the supplier of the machines (Roby &
Willis, 2010)
1.
Traditionally, the delivery of Tunnel Boring Machines started by the full assembly and
testing of the TBM at the manufacturers facility before dismantling and shipping to site. The
tradition method of assembly consists of 6 steps:
Factory assembly
No-load testing
Dismantle
Assemble
Test run
Once the assembly and the cold testing are completed the TBM is ready for the hot testing,
that is the checking of the TBM during the excavation of a tunnel length agreeing with the
TBM supplier. The phase of assembly can last up to three months. (Roby & Willis, 2010)
31
2.
In order to shorten overall delivery time to supply these machines some suppliers have
recently introduced the so called OFTA (Onsite First Time Assembly), consisting of
only one direct assembly at site. This procedure, allowing the saving of several weeks, clearly
increases the risks of possible problems arising during the testing (Roby & Willis, 2010)
II.
Tunneling phase
In the tunneling phase, the cutting wheel rotates, and then it is pressed against the tunnel face
by means of hydraulic cylinders. The cutting wheel is driven by 24 hydraulic motors via a
gear ram. The high strength steel disc cutters and the cutting knifes loosen the material of the
tunnel face quickly.
The soil can be conditioned with water, bentonite, or foam through the injection system. After
which, the soil is pressed into the excavation chamber and then transported from the bottom
of the chamber to a belt conveyor by a screw conveyor.
Each completed tunnel ring consists of several segments: 2 later elements and the key
segment which is installed last. The position of the segments always follows the same routine.
The erector lifts the stone from the segment feeder, the hydraulic cylinder are then retracted
from the corresponding installation point
The segment is then positioned precisely, holding side contact next to the previous installed
ring using a remote control. Now the hydraulic cylinders are extended again to secure the
segment and its position
Again, the next tunnel ring can start. The tunneling phase and the ring building phase alternate
continuously. In this way, the tunnel grows ring by ring
36
III.
1.
Backup System
Grouting
EFNARC (2005) stated that during the segment lining process, all parts of the machine and
segment rings are protected inside the shield against pressure or ground heave. Backfill
grouting is the grouting work to fill the annular (ring-shaped) void (a completely empty
space) between segments and the ground.
From the website of Colcrete Eurodrill, grout is the important link between the surroundings
(soil or rock) and the structure (pre-cast segments). Its the composition of Cement, Water and
some other Additives.
The reasons for using grout can be summarized as follows (EFNARC 2005):
There are 2 types of grout inlets. The grout may be pumped into position either through the
tail shield or through holes in the segments (EFNARC 2005). The type of grout inlet in each
TBM will be chosen depended on the required shape and size of the grouted body as well as
the type of grout.
In the case of segmental TBMs, the lining and its backfill grouting are inseparable from the
operation of the machine (Colcrete Eurodrill). Because of their interfaces with the machine,
they must be designed in parallel and in interdependence with the TBM.
The backup system is required in the TBM, which accommodates all the facilities required
such as hydraulic power unit, pump, controlling cabinet, ventilation, laser instrumentation,
storage containers, (Central Subway 2011).
38
The whole system is set in a wheel house. With each advance movement of the machine, the
backup is pull ahead. Also the logistic structures for excavated material discharge system and
the delivery of the lining process are here (Central Subway, 2011). As in the previous part
such as belt storage system, soil containers or mine car line.
According to Central Subway (2011), controlling cabinet can be seen as the brain of the
machine. All important, up-to-date information and diagrams are gathered in the central
control cabin. There, they are visualized on monitor, make available for the machine operator.
The operator can control the processes and interfere if necessary.
3.
Maintenance
In the Central Subway s video (2011), the cutting tool must be maintained or replaced in
regular depended on the hardness and the abrasiveness of the geology. Sensor is attached to
the tips of some tools which send the signal to the control cabin when a certain degree of wear
happens. The tool must be replaced. The excavation chamber is partially emptied. At the same
time the cavity of the chamber is supplied with compressed if necessary to stabilize the tunnel
face. Then the excavation chamber can be mannerly accessed to maintenance work such as
disc cutter tools or sensor replacement.
39
IV.
1.
Notable Projects
TBM is the most modern machine applied in digging tunnel. Reported in 2012, in a document
of American technology center, researchers listed the list of top 5 longest and largest tunnel
using TBM on the world. This is a great achieve in the development of technology and
intelligence of human being:
1.1- Gotthard Tunnel
1.2- Channel Tunnel
1.3- Seikan Tunnel
1.4- Channel Tunnel
1.5- Guadarrama Tunnel
2.
This tunnel is a typical one with cross section, a service tunnel between twin rail tunnels.
Shown linking the rail tunnels is a piston relief duct, necessary to manage pressure changes
due to the movement of trains
Tunneling between England and France was a major engineering challenge, with the only
precedent being the undersea Seikan Tunnel in Japan. A serious risk with underwater tunnels
is major water inflow due to the water pressure from the sea above under weak ground
40
conditions. The Channel Tunnel also had the challenge of timebeing privately funded, early
financial return was paramount.
According to Channel Project, JJennifer Rosenberg (2005) reported that: Precast segmental
linings in the main TBM drives were used, but different solutions were used on the English
and French sides. On the French side, neoprene and grout sealed bolted linings made of cast
iron or high-strength reinforced concrete were used. On the English side, the main
requirement was for speed and bolting of cast-iron lining segments was only carried out in
areas of poor geology. In the UK rail tunnels, eight lining segments plus a key segment were
used; on the French side, five segments plus a key segment. On the French side, a 55-metre
(180 ft) diameter 75-metre (246 ft) deep grout-curtained shaft at Sangatte was used for access.
On the English side, a marshalling area was 140 meters (459 ft) below the top of Shakespeare
Cliff, and the New Austrian Tunneling method (NATM) was first applied in the chalk marl
here. On the English side, the land tunnels were driven from Shakespeare Cliff, the same
place as the marine tunnels, not from Folkston. (UK News, 2010). The platform at the base of
the cliff was not large enough for all of the drives and, despite environmental objection,
tunnel spoil was placed behind a reinforced concrete seawall, on condition of placing the
chalk in an enclosed lagoon to avoid wide dispersal of chalk fines. Owing to limited space,
the precast lining factory was on the Isle of Grain in the Thames estuary.
On the French side, owing to the greater permeability to water, earth pressure balance TBMs
with open and closed modes was used. (Jennifer Rosenberg, 2009). The TBMs were of a
closed nature during the initial 5 kilometers (3 mi), but then operated as open, boring through
the chalk marl stratum. This minimized the impact to the ground and allowed high water
pressures to be withstood, and it also alleviated the need to grout ahead of the tunnel. The
French effort required five TBMs: two main marine machines, one main land machine (the
short land drives of 3 km allowed one TBM to complete the first drive then reverse direction
and complete the other), and two service tunnel machines. On the English side, the simpler
geology allowed faster open-faced TBMs. Six machines were used, all commenced digging
from Shakespeare Cliff, three marine-bound and three for the land tunnels. Towards the
completion of the undersea drives, the UK TBMs were driven steeply downwards and buried
clear of the tunnel. These buried TBMs were then used to provide an electrical earth. The
French TBMs then completed the tunnel and were dismantled. A 900 mm gauge railway was
used on the English side during construction.
41
3.
According to the newest information from Amanda Foley, a famous American journalist, the
largest TBM on the world- Bertha the world largest TBM is ready to be shipped to Seattle.
Following testing at Hitachi Zosens manufacturing plant in Osaka, Japan; Bertha the
worlds largest-diameter TBM to date is ready to be shipped to Elliot Bay, in Seattle,
Washington. The 57ft (17.5m) EPB machine will begin excavation of Washington State
Department of Transportations (WSDOT) US$1.35bn (State Route-99) Alaskan Way tunnel,
beneath downtown Seattle, this summer.
Crews in Japan began disassembling the five-story-tall, US$80 million machine last week. By
mid-month, Bertha which is owned by Seattle Tunnel Partners (STP), the Washington State
Department of Transportations contractor for the project will be loaded aboard the Jumbo
Fairpartner in 41 pieces.
The ship will leave Japan in mid-March and arrive in Seattle by the end of the month, if the
weather cooperates. Were entering an exciting stage of this project, said Linea Laird,
WSDOTs administrator for the Alaskan Way Viaduct Replacement Program. While we
have a lot of work to do once Bertha arrives, we cant wait to introduce her to the people of
Washington.
42
STP is responsible for ensuring the TBM functions properly at all times. Accordingly, shes
been put through a succession of rigorous tests at the Sakai Works factory in Osaka, where
manufacturer Hitachi Zosen Corporation built the machine. One of the tests revealed a
problem with the machines main drive unit, and crews made appropriate repairs.
Bertha has since passed all of her tests, and will officially become the property of STP once
shes tunneled approximately 1,000ft (300m) without any issues. Construction is going well,
both in Japan and in Seattle, said Chris Dixon, Seattle Tunnel Partners project manager.
Were on track to open the tunnel in late 2015.
Crews in Seattle are about 80% finished with the launch pit where Bertha will start her
journey and are currently preparing the surrounding site for tunneling. That work includes
strengthening the soil and building protected areas along the initial section of the tunnel route
so crews can perform scheduled inspections of the machine before it begins tunneling beneath
the city. Work is also under way near the north end of the Battery Street Tunnel to prepare the
area where Bertha will emerge at the end of tunneling.
Berthas 41 pieces the largest weighing up to 900 tons are being loaded on a single ship.
Once she arrives in Seattle, crews will unload the pieces and transport them a few hundred
yards to the 80ft (25m) deep launch pit, where she will be reassembled and launched this
summer.
43
Reference
44
Xie Jinghua Tian Ke Key Laboratory of Modern Complex Equipment Design and Extreme
manufacturing, Central South University, Ministry of Education, Changsha, China Yang
Dawei . (2010). The effect of TBM hydraulic piping system parameters on FSI vibration.
Pages 363-371 .
Xie Jinghua, Tian Ke Yang Dawei. (2010). The effect of TBM hydraulic piping system
parameters on FSI vibration. Retrieved April 2, 2013, from Digital Library.
Foley, A. (2013, March 7). Bertha the worlds largest TBM is ready to be shipped to
Seattle. Retrieved 5 15, 2013, from tunneling journal.
Grandori, R. (2006). Abdalajis East railway tunnel (Spain)- Double shield universal TBMs.
Hard Rock Shield, Tunnel Boring Machine (TBM). (n.d.). Retrieved February 10, 2013,
from Attiko Metro S.A.
Jenkins, C. ( 2011, Apr 13). The 17 Longest Tunnels In The World. Retrieved April 8, 2013,
from Business Insider .
Kelly, L. (2013, April 04). 7 record-breaking tunnels from around the world. Retrieved 04
16, 2013, from FoxNews.com.
Michael Spencer, Zurich London (Chairman) . (2009). Tunnel Boring Machines.
Ohno, H., Kazama, K., Higashide, A., & Tomioka, A. (1996). Fully automated system for
shield tunnelling under integrated control. OBAYASHI CORP.
Roby, J., & Willis, D. (2010). Onsite, First Time Assembly of TBMs: Merging 3D Digital .
Washington.
Rosenberg, J. (May 6, 1994). The Channel Tunnel.
Single Shield TBM. (n.d.). Retrieved March 2013, from The Robbins Company Website:
http://www.therobbinscompany.com/our-products/tunnel-boring-machines/singleshield/
The British Tunnelling Society and The Institution of Civil Engineers. (2004). Tunnel
lining design guide. London: Thomas Telford Publishing.
To raise a tunnel boring machine. (2013 , Jaunuary 29). Retrieved April 2013, from OCH
Magazine: http://www.ochmagazine.com/features/to-raise-a-tunnel-boring-machine/
Tunnelling & Pipelines. (n.d.). Retrieved April 2012, from Herrenknecht AG Website:
http://www.herrenknecht.com/products/tunnel-boring-machines.html
Tunnelling by EPB Tunnel Boring Machine in DMRC. (2012, June). Retrieved febrary 15,
2013, from NBM Media.
Central Subway (2011) TBM/Tunneling Video. [video file]. Retrieved from
http://www.youtube.com/watch?v=qx_EjMlLgqY
45
ITA-WG14 (2000) Recommendations and Guidelines for Tunnel Boring Machines (TBMs).
International Tunnelling Association, Working Group No. 14 - Mechanized Tunnelling.
NFM technologies. Underground work. Retrieved March 10, 2013 from http://www.nfmtechnologies.com
Nguyen D. Toan (2006) TBM and Lining Essential Interfaces. Retrieved March 10, 2013
from http://www.itaaites.org/fileadmin/filemounts/general/pdf/ItaAssociation/ProductAndPublication/Th
esis/ThesisToan.pdf
TheRobbinsCo (2010) Robbins EPB TBM Excavation with Screw Conveyor [video file].
Retrieved from http://www.youtube.com/watch?v=g4XGQ9H2YP4
Federal Highway Administration (2011) Technical Manual for Design and Construction
of Road Tunnels - Civil Elements. Retrieved March 10, 2013 from
http://www.fhwa.dot.gov/bridge/tunnel/pubs/nhi09010/appd.cfm
46
Appendix
47
Digging by hand
Using explosives
Using excavating machine
All the above choices
Answer: D
a. screw conveyor
c. pipe system
49
50
No-load testing
Test run
Deliver components to site
Dismantle
Factory assembly
Assemble
Answer: _e_>_a_>_d_>_c_>_f_>_b_
2. OFTA process
a. Test run
b. Assemble
c. Deliver components to site
Answer: _c_>_b_>_a_
Part 2: Fill the words into order to make a process of the tunneling phase of EPBM
1.Soil is transported to belt conveyor
2.Soil is pressed into excavation chamber
3.The cutting wheel rotates
4.Disc cutters and cutting knifes loosen the material
Answer: 3421
51
52
Glossary of terms
53
No.
1.
Term
Abrader
Explanation
Vietnamese
equivalent
Mi
Abreuvoir
Mch ni kn
with mortar
3.
Accelerant
Cht xc tc
accelerate setting.
4.
5.
Accurate
Additive
Tnh chnh xc
Ph gia
Adit
Li v o m
Adjustment
or improve it
8.
Adsorbent
Cht ht, bm
liquids
9.
Advance
S ti n l n
10.
Aelotropy
Tnh d hng
11.
Ancillary
Cht l m d
hng
ph tr
or operation of an organization
12.
Annular
ring-shape
hnh tr n
13.
Arch
Khung t v
14.
Backfill
V t li u lp
15.
Backup system
H thng ph tr
54
Band
Bng
Bar
Thanh
Barrel
Barrel
Bearing
tr c
21.
Bentonite
Bits
S t bentonit (loi
t s t c gi tr
dissolved in water.
d thm nc)
M i khoan
TBM
22.
Bolt
cht
23.
Bolt hole/pocket
cht
Boring
Qu trnh khoan
Boulder
cui
26.
Bricklayer
Th n
Buckle
Lm cong
55
Bulkhead
C ngn, vch
ngn
Buttress
tr tng
Bypass
ng ni v ng
Cable tunnel
Hm cp
communications cables.
32.
Cantilever
Dm cha
support.
33.
Carriage
gi chuy n ch
Casing
V khoan
35.
Cast Iron
Gang
36.
Cavern
A cave
Hang ng
37.
CCTV
Truyn hnh
mch kn
38.
Cement
39.
Chamber
Chip
41.
Compaction
m ln
manipulation.
42.
Concrete
B tng
56
Cone crusher
my nghin kiu
cn
Construction
Xy d ng
Conventional
o hm kiu
tunneling
truyn thng
machines
46.
Conveyor
Thi t b t i truyn
Conveyor system
H thng bng t i
Corrosion
S xi mn
Cracks
V t nt
Crane arm
Tay cu
51.
Crown
nh v m
Cutter Head
u kho t
Cutting plane
Mt phng ct
process
54.
Cylinder head
u xi lanh
Data logger
my ghi d li u
57
DCRM
H thng gim
st u kho t
Debris
v n
or destroyed
58.
Deform
to change shape
Bi n dng
59.
Dereliction
S sao nhng
60.
Disc Cutter
a ct
Dismantle
Tho d
separate pieces
62.
Diurnal
63.
Double shield TBM A TBM with a full-face cutter head and two sets of
thrust rams that react against either the tunnel walls
Mt ng y m
My khoan hm
hai khi n o
(radial gripper)
64.
Dowels
Cht
Drift
Hm ph
66.
Drill
Khoan
holes
67.
Drive
Li hng
Dual-mode TBM
My khoan hm
a nng
69.
Duct
ng
58
Dynamite
Thuc n
71.
Earth Pressure
My khoan hm
Balanced
pressurized soil.
a p
b k
Machines (EPBM)
72.
Embankment
Erector
Tay lp rp
Excavation
S o bi
Excavation
Expander
B ph n gin
Face
Mt hm
in a tunnel
78.
FASTIC
H thng o
hm t ng tch
hp iu khin
79.
Fault
A fracture in rocks.
Li
80.
Flexible
Un c, linh
damage.
hot
81.
Flotation
S ni l n, li l n
82.
Flow meters
Lu lng k
Foam
B t xp
Foaming Solution
Dung dch b t
85.
Geotechnical
Thuc a k
thu t
86.
Granular
Dng ht
87.
Grinding
Mi
Grippers
B k p
excavated tunnel.
89.
Ground arch
V m hm
Grout
Va
Grouting
Cht va
Guidance system
H thng d n
ng
Hand excavation
o b ng tay
Hoop
Dng ai
95.
Hydraulic jack
ng c thy l c
Hydraulically
H tr d n ng
actuated supports
thy l c
centered.
60
Hydraulics
Thy l c
99.
Thuc a cht
thy vn
Hydrophilic/Hydrot
Ho nc
ite
Hydro-geological
100. Idlers
Bnh xe d n
hng
101. Impact
L c xung
My o
nghing
gravity
103. Invert
y hm
Kch
Phun ra
106. Joint
Khp ni
structure
107. Key segment
on kha
108. Lagoon
Thi t b nh
hng laze
61
V hm
111. Load
T i tr ng
112. Lubricate
Bi trn
bi chnh
C m kch chnh
is often called
jacking frame (pipe jacking)
C th ti p c n
Mt li
T u i n
118. Metropolitan
th
region.
119. Mole (TBM)
My o hm
circular cross-section
120. Monitoring and
control
Theo d i v iu
khin
t tp
X bn
Xe gong
V b n
R ng buc mi
trng
Lp t ti ch
127. Overcut
Kho ng thong
diameter of
the shield skin or pipe string
128. Percussion
B g
another;
forcible collision, esp. such as gives a sound or report
129. Permeability
thm
material
130. Pig
D ng c no
Cn piston
a mine or a quarry
Hm m
133. Polyethylene
Poli-etylen
Ca hm
tunnel.
135. pressure gauges
p k
63
c tng p,
n n
conditions
137. Radial joint
Mi ni hng
tm
Kh Radon
Ba my p thy
l c
B tng cn l c
L i li
entrance pit.
142. Ring
v ng
rm hnh xuy n
Cn
Screw-shaped conveyor
Bng t i gung
xon, vt t i
Ca x bin
147. Seamless
c, khng c
next
mi h n (ng kim
loi)
148. Segment
on hnh vi n
64
phn
Tay lp v hm
segments
Bng t i v hm
segments
151. Segmental lining
152. Settlement
Lt v hm dng
concrete segments
tm
ln, bi n dng
Cng ngm
Khi n o
B tng l ng
156. Shove
y l n
157. Sidewall
Tng hm
158. Silt
Ph sa
diameter
159. Site
Cng trng
160. Sleepers
T v t
161. Slurry
B n qung
ng ng d n
b n
My khoan hm
65
Nn t y u
165. Specifications
c im k
thu t
Machine
Spike
t b n no v t
ln
casing is installed.
168. Squeezing rock
n n
iu hng
deviation
170. Stress
ng sut
171. Subsidence
S ln nn
structures
172. Subsoil
Tng t gc
Gic ht
S gim st
Th keo
H n ui
V sau
My khoan hm
180. Telescopic
cng
kiu ng lng
My kinh v
M men xon
183. Truss
b ng gi n, ko
tunnel body
hm
Khc hm
Khoan khng v
187. Underground
Di l ng t
level
o hm trong
khu th
67
ng thot kh
face or heading.
190. ventilation
H thng thong
gi
191. Vibration
Rung
192. viscosity
nht
194. Waling
Kho ng chng, l
rng, khe h
thanh ngang
gi ng c c
Giong
197. Wear
Gng nc, mt
nc ngm
Cn, mn
use
198. Weeper (Weep
hole)
L thot p sut
H n b ng b n
ch i kim loi
Bung l m vi c
68
Self-reflection
69
About Nguyen Trung Hieu: He is another good member of the team. He obeys the punctuality.
Overall he was doing fine with the team work except I felt that he was a little bit passive
during the meetings. It would be great if he spoke up his own voice instead of listening to
others. But we have come to the end together.
About Hoang Anh Thu: She was a creative student, always worrying about what the team is
doing. She was the one who solve the conflict between members. Except sometimes she was
passive with other members, which shouldnt be expressed, she was good. But finally we have
come to the end together.
Nguyen Trung Hieu
About you
I must say that you are a very caring and responsible teacher. You have helped us a lot when
issues come up and we find your instructions very useful. We learnt a lot from you.
About our group
Our group consist of 4 people, despite that we havent work with each other before and I
dont know much about Qun and Th, our group work surprising well.
About Qun
Qun is a responsible group leader. His teamwork ability is good, as the group leader,
he did a good job in orienting and distributing the work for members. He also helped
and encouraged other members a lot.
About Th
Th is a very hard working member of our group. She always get her part done
splendidly and contributed some very useful ideas to the group.
About Thu
Thu is an energetic member, she has taken part in the activities of group
enthusiastically and contributed a lot to ourt work.
About the subject
71
Firstly, its a difficult but interesting subject. Due to the complication of our topic, we faced a
lot of difficulties in research. However, we acquired a great amount of knowledge not only
from our research but from other groups research as well.
Hoang Anh Thu
Teamwork is a beautiful work; I would like to use team than group. That is the most
favorable time for one to find out the real personal characteristics of your teammate and
yourself. It is also a nice time for one to get new friends. In this subject, Im lucky to have
worked with new friends. However, due to this fact, I faced a lot of difficulties and I also
gained a lot.
About my teammates:
Hi u: The vice team leader. He understand deeply, work hard and do well. It is
pleasure to get to know and work with him.
Thu: I am very worried about her health; however, she is always very dynamic when
she appears, so I feel very comfortable. She always contribute her ideas.
Finally, I want to send my sincerely thanks to my teacher Nguyn Vn Khanh for being not
only an enthusiastic and dedicated teacher but also a friend.
Hoang Thi Thu
72
This course is an exciting and interesting experience, a long trip to get, to cultivate new and
necessary knowledge, valuable information, essential experiments. After about 5 months of
learning the subject, I have three opportunities to present our topic, 9 times to be listened
presentation of other groups, I feel comfortable and happy, especially, I express deeply this
subjects.
To do the success of the course, there are three key elements of which are: dedicated teachers,
the spirit of teamwork and efforts of each person.
First, we are really lucky and excited when received the guidance of our teacher - Nguyen
Thi Van Khanh. The first lesson is also the important lesson with us. In the first days of the
course, we are very worried and stressed with many questions such as: what we have to do?
What can we do? How to get high great results this subject? It is the teacher who helped
us to answer all questions. But the most important thing is that we feel comfortable and
interesting instead of worry or afraid gelatinous. Thanks for the stories about last experiment
students and his/ her achievements, we feel confident and motivating. By the way of telling
the stories, our teacher motivated sprit of our learning. In the first lesson, I especially express
with my teacher because she is very friendly, active and enthusiasm.
Many students said that she always has high requirements for her students. In fact, that is
true. She always highly demands from us but this focus on English skills because we are
foreign students. I am interested because it it is essential and important for us. We like the
way of scientific working as well as the way to arrange timeline for students in the whole
course. We love her comments and questions after our presentation. Her requires help us to
become more professional. Of course, we need understand our topic or my problem deeply
and widely so that we can present more perfect and efficient in next time.
We proud of our teacher and thank for her help. We are attracted by her method training and
her characteristic such as friendly, intelligent and psychological.
The second element which makes the success of the course is members of each group. I am
proud of working with members in my group. Working together in the long time, of course it
is so difficult to avoid controversy or even intense discussion. But the discussion bases on
responsibility of each member in the group and forward only one purpose: We understand
each other and try our best to do success of the team work.
The first member the most intelligent member - Mr Quan is leader of our group. He is
considered as our older brother because he is smart, logical, creative, and very hard. He is also
73
a person who responsible for connecting all members in the group, summarizing all comments
and dealing with any conflicts.
Mr Hieu is a smart and creative person. I express by the patience and his way of approach
problems
when we study new topic or get new information. Of course, I admire his