ISTANBUL STRAIT ROAD TUNNEL CROSSING Werner Burger, Herrenknecht AG, Schwanau. AFTES Journées Techniques, Lyon, October 16, 2015
Istanbul Strait Road Tunnel Project Location
Istanbul Strait Road Tunnel 3
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
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 Very high face pressure >10 bar transition zones
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
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)
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
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)
Istanbul Strait Crossing TBM Cutterhead Features main spoke, atmospheric accessible auxiliary spoke, conventional 19 twin disc cutter, atmospheric exchange with monitoring system scraper tools, atmospheric exchange scraper tools, conventional multi level sectorized wear detection loops bucket lips, conventional 10
Non - Exposure Maintenance Solutions Accessible Cutterhead for Atmospheric Cutterchange 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. 11
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 Cutterhead Elbetunnel, now in front of the Museum of Work in Hamburg Individual tool condition and wear sensors 12
Non - Exposure Maintenance Solutions Accessible Cutterhead for Eurasia Tunnel TBM Istanbul, Turkey 19 Disc cutter fixture for atmospheric cutter change Scraper tool fixture for atmospheric cutter change Cutter head spoke structure, accessible from inside 13
Atmospheric Cutter Change Shop Test and Training in the Factory Transport of disc cutter cartridge inside cutterhead Installing cutter cartridge in outer housing Opening of frontgate and push cutter cartridge in working position
Non - Exposure Maintenance Solutions On-Site Cutter Change Eurasia Tunnel TBM Istanbul, Turkey 15
Disc Cutter Monitoring System Mixshield-TBM with Accessible Cutterhead Sensor-unit Control cabin Monitoring-unit Radio signals Battery IPC CS Receiver Data line Individual monitoring-unit for each disc cutter Radio transmission to repeater / receiver Data transfer from receiver to IPC Data analysis + status display (control cabin)
Disc Cutter Monitoring System Data processing and visualization Status indication of disc cutter with temporary no rotation Status indication of critical values
Saturation Process Crew Shuttle Transfer Through Trailing Gear At The Eurasia Tunnel TBM, Istanbul Permanent airlock Transport shuttle in docking position Front lifting table to Motorized shuttle Hydraulic lift to Shuttle transport through docking position for transport through gantry upper gantry deck tunnel on MSV transport shuttle 18
Saturation Process Crew Shuttle Transfer Through Trailing Gear At The Eurasia Tunnel TBM, Istanbul Hydraulic lifting system from MSV to gantry middle deck Motorized transfer through gantry Hydraulic lifting system to docking flange at shield airlock
Non Exposure Maintenance Solutions Mixshield Submerged Wall Gate for Crusher Maintenance Submerged wall gate open Submerged wall gate closed 20
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 21
Istanbul Strait Crossing TBM Face Pressure Along The Drive 22.8.2015 25.4.2014 22
THANK YOU FOR YOUR ATTENTION. burger.werner@herrenknecht.de 23