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Selling documentation:
CMC: TBM / Backup System
Page 1 / 41
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1
2
3
4
5
6
7
8
Performance Specifications ............................................................................................................ 3
Cutterhead D = 9.7 meters ............................................................................................................. 4
2.1
Cutterhead description ........................................................................................................... 4
2.2
Available Cutter Inventory ...................................................................................................... 5
TBM: Robbins 253-309 ................................................................................................................... 5
3.1
Dimensions / Technical Specifications................................................................................... 5
3.2
TBM Operation ....................................................................................................................... 7
3.3
Revised Parts of TBM ............................................................................................................ 9
3.4
History of TBM........................................................................................................................ 9
Backup System for a Diameter of 9.73 Meters ............................................................................... 9
4.1
Towing System..................................................................................................................... 11
4.2
Conveyor Belt Installation .................................................................................................... 12
4.2.1
Preface ........................................................................................................................ 12
4.2.2
Machine Belt................................................................................................................ 12
4.2.3
Backup System Belt .................................................................................................... 13
4.2.4
Attachment Mounting Station for Tunnel Belt.............................................................. 13
4.2.5
Pillar Slewing Crane .................................................................................................... 14
4.2.6
Discharge belt.............................................................................................................. 14
4.2.7
Coarse Grit Precipitation ............................................................................................. 15
4.3
Securing / Rockbolting ......................................................................................................... 16
4.3.1
Rockbolting System L1................................................................................................ 18
4.3.2
Rockbolting Carriages ................................................................................................. 19
4.3.3
Rockbolting System L2................................................................................................ 19
4.3.4
Probe Drilling System .................................................................................................. 19
4.3.5
Logging of Probe Drilling ............................................................................................. 19
4.3.6
Ring Beam Erector ...................................................................................................... 19
4.4
Shotcrete Carriage ............................................................................................................... 19
4.4.1
Shotcrete Robot........................................................................................................... 20
4.4.2
Suprema ...................................................................................................................... 21
4.4.3
Secatol......................................................................................................................... 22
Cranes for Flow of Material........................................................................................................... 22
5.1
Monorail below TBM ............................................................................................................ 23
5.2
Crane on TBM ...................................................................................................................... 24
5.3
Crane TBM-BS ..................................................................................................................... 25
5.4
Surface Carrier BS1 ............................................................................................................. 25
5.5
Suspended platform (BS2)................................................................................................... 26
5.6
Monorail Overhead Crane (BS2).......................................................................................... 27
Ventilation System ........................................................................................................................ 28
6.1
Preface ................................................................................................................................. 28
6.2
Secondary Ventilator AL 12-550 .......................................................................................... 28
6.3
Dry-type Dedusting System HTKS 1/1000........................................................................... 29
6.4
Wet-type Deduster HCN 400/1 ............................................................................................ 30
Electrical Installations ................................................................................................................... 31
7.1
Electrical Main Data and Functions...................................................................................... 31
7.2
TBM and NL Schematics ..................................................................................................... 32
7.3
Frequency Converter ........................................................................................................... 34
7.4
Cutterhead Drive .................................................................................................................. 36
7.4.1
Cutterhead Motors....................................................................................................... 36
7.4.2
Cutterhead Planetary Gearbox.................................................................................... 37
7.5
High Voltage Cable Drum .................................................................................................... 37
7.6
Transformers ........................................................................................................................ 38
7.7
Emergency Lighting ............................................................................................................. 38
7.8
Default Lighting .................................................................................................................... 38
7.9
Emergency Backup Generator............................................................................................. 39
Miscellaneous ............................................................................................................................... 39
8.1
Rescue Container ................................................................................................................ 39
8.2
Duct Storage Unit ................................................................................................................. 39
8.3
Industrial Water Installation.................................................................................................. 40
8.4
Compressed Air.................................................................................................................... 41
8.5
Replacement Parts............................................................................................................... 41
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1 Performance Specifications
The TBM Robbins TBM 253-309 was fully revised under close surveillance of Robbins prior to its
operation (2300 meters) by the consortium CMC.
Power consumption of cutterhead:
Power consumption of backup system:
Rotation speed:
Torque:
Thrust force max.:*
Stroke:
Electrical motors:
Built in:
Revised in:
3000 kW
approx. 1650kW
0-4.6 rpm, field weakening capability: up to 8.3 rpm
approx. 6275 kNm at 0-4.6 rpm
approx. 3490 kNm at 8.3 rpm
20.6 MN
1.87 m
10 x 300 kW
2003
2007
Cutterhead diameter 9.7 meters built by Robbins in 2007.
Equipped with 59 disc cutters
4 pcs. center cutters:
55 pcs. face and und caliber cutters:
17“
19“
The ROWA backup system (BS) built in 2007 was designed and built specifically for the CMC
operation with an excavation diameter of 9.7 meters and a tunnel length of 2300 meters:
Curve radius:
Working area L1:
Working area L2:
Ventilation:
Air duct diameter on BS:
Logistics in:
Logistics out:
Average daily advance
(unsecured excavation):
Max. technical daily advance (BS):
Max. advance per hour:
Max. capacity of conveyor belt
Installation for excavated material:
Coarse grit precipitation:
Page 3 / 41
approx. 1000 meters
(enveloping circle of 8.4 meters)
rockbolts, ring beams, mash, shotcrete, probe drillings
rockbolts, shotcrete, probe drillings
blowing fresh air to TBM
1200 mm
by truck
conveyor belt 800 mm
27 meters by 18 hrs./day
54 meters by 18 hrs./day
2.25 meters
800 to/h
250 by 250 by 300 mm
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2 Cutterhead D = 9.7 meters
2.1 Cutterhead description
Diameter:
Equipped with 57 disc cutters:
4 center cutters:
53 face and caliber cutters:
Page 4 / 41
9.73 meters
17“
19“
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2.2 Available Cutter Inventory
The available cutter material consists of the following components:
- ½ set(s) of used cutters (Robbins)
- 25 pcs. 19“ single disc cutters Palmieri (new)
3 TBM: Robbins 253-309
3.1 Dimensions / Technical Specifications
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Technical Specifications
Cutterhead
drive configuration:
power consumption:
rotation speed:
torque:
max. thrust force*:
stroke:
electrical motors:
Contact force:
Hydraulic system, max. pressure:
Capacity of hydraulic system:
Transformers of cutterhead drive:
Transformers of backup and hydraulics:
Auxiliary drives and backup:
Spoil ridding capacity:
Belt speed:
Engine voltage:
Lighting system:
Electrical control:
Weight of TBM:
revolution-controlled electrical motors, gearbox
3000 kW
max. 8.3 rpm
3490 kNm at 8.3 rpm
6275 kNm at 4.62 rpm
20.6 MN (2100 to)
1.87 m
10 x 300 kW
18.6 MN (1900 to)
345 bar (feed cylinders: 285 bar)
150 kW (400 V)
2x2000 kVA (16/0.69kV)
1x1000 kVA (16/0.4 kV)
400/230 V 50 Hz
18.4 m3/h
122 m /min.
3 x 690 V, 3-phase
220 V, 50 Hz
24 V
approx. 800 to
*At normal operation
3.2 TBM Operation
A cabin has been fitted to the left side of the TBM, which houses the operation center of the machine.
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3.3 Revised Parts of TBM
The TBM was revised in 2007 under supervision of Robbins. Amongst others the following
components were revised by according specialists, respectively checked thoroughly:
Electrical motors:
Planetary gearbox:
Gripper cylinders:
Conveyer belt:
Hydraulic system:
Main bearings/kelly:
Adjustment of gripper plate:
Adjustment primary tension:
Robbins USA
Robbins USA
checked by Robbins Europe
revised by Robbins Europe
revised by Robbins USA
checked by SKF Italy via Robbins
retrofitted by Robbins
retrofitted Robbins
3.4 History of TBM
Operations to date:
Karahnjukar Iceland (Impregilo)
Switzerland, Sigirino TI
2003
March 2008 – Oct. 2008
Operating hours meter reading to date:
6315 h
14.6 km with D = 7.63 m
2.3 km with D = 9.7 m
4 Backup System for a Diameter of 9.73 Meters
The new backup system was specifically designed by ROWA AG in August 2007 to meet the following
requirements:
Tunnel length:
Bore diameter:
Curve radius:
Working area L1:
Working area L2:
Ventilation:
Air duct diameter:
Logistics in:
Logistics out:
Advance rail length:
Average daily advance:
Max. daily advance:
Max. advance per hour:
Max. capacity of conveyor belt installation
for excavated material:
Weight of backup system:
Page 9 / 41
2300 meters
9.73 meters
approx. 1000 meters
rockbolts, ring beam, mash, shotcrete, probe drillings
rockbolts, shotcrete, probe drillings
blowing fresh air to TBM
1200 mm
trucks
conveyor belt
5 meters
27 meters by 18 hrs./day
54 meters by 18 hrs./day
3.6 meters
800 to/h
approx. 450 to
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4.1 Towing System
The towing system consists of towing brackets and the according towing cylinders, which are fitted to
the rear end of the TBM. The towing system secures the towing connection between TBM and the
backup system. The hydraulic cylinders move the BS forward after each stroke of the TBM.
To prevent the towing along of the backup system during cutting advance of the TBM, the towing
cylinders are set to a pressure-less state.
Technical specifications
Towing force:
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approx. ??? to
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4.2 Conveyor Belt Installation
4.2.1 Preface
The conveyor belt installation consists of the machine belt of the TBM, the belt of the backup system
(full length of BS), the discharge belt and the attachment mounting station of the tunnel belt.
In order reduce the development of dust, the attachment mounting stations “machine belt to BS belt”
and “BS belt to tunnel belt” are equipped with spraying nozzles.
The belts are partly monitored by the TBM operator via cameras.
4.2.2 Machine Belt
The machine belt takes the excavation cuttings on from the cutterhead and passes them on to the BS
belt. It runs within the TBM.
Technical Specifications
Belt length:
Belt width:
Power output:
Max. conveyor capacity:
Weight:
Speed:
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approx. 26 m
1000 mm
5.5 kW (hydraulic drive)
18.4 m3/min.
2.5 to
122 m/min.
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4.2.3 Backup System Belt
The excavation material is being transported from the machine belt on the BS belt to the coarse grit
precipitation on the BS3. The hand-over point between machine and BS belts are monitored via video
camera. The backup system belt is designed to handle grit sizes up to 250 x 250 x 300 mm off the
machine belt. 90% of the cuttings mustn’t exceed a size of 150 x 150 x 150 mm.
Spray nozzles (water) after the deflector of the coarse grit precipitator.
Spray nozzles (water) only at hand-over points.
Technical Specifications
Belt length:
Belt width:
Belt type:
Belt speed:
Max. conveyor capacity:
Drive:
Tensioning device:
Belt monitoring:
100 m
1000 mm
Metaltrans M630 ITA V 8S+3
2.0 m/sec.
800 to/h
bevel gear drive block SK9082.1, 55 kW, 400 V
Lifting/tensioning cylinders, 2000 mm,
with hydraulic unit
by sensor
4.2.4 Attachment Mounting Station for Tunnel Belt
The attachment mounting station extends the tunnel belt during the excavation advance.
Technical Specifications
Dimensions of lifting cylinders:
Lifting range:
Type of manual pump:
Operating pressure:
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32/18 mm
250 mm
PS25+VS
160 bar
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4.2.5 Pillar Slewing Crane
The parts of the conveyor belt installation are lifted to the upper deck of BS3 using a hand crane.
Technical Specifications
Working range:
Type of chain hoist:
Load capacity:
Lifting elevation:
Lifting speed:
Power output:
360°
ST 0502-8/2 2/1
500 kg
8m
1/4 m/min.
0.1/0.4 kW, 400 V
4.2.6 Discharge belt
A shunting switch at the coarse grit precipitation allows the discharging of excavation material via a
conveyor belt to allow ground floor fitting. A control cabinet at the belt is used to control this
installation.
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Technical Specifications
Belt length:
Belt width:
Belt type:
Conveyor capacity:
Belt speed:
Drive:
Power consumption:
17 m
800 mm
EP500/3 5:3 VT
max. 600 to/h
2.6 m/sec.
Block SK 9042.1
15 kW, 400 V
4.2.7 Coarse Grit Precipitation
A vibrator chute with a bar screen (the coarse grit size cannot be fully controlled by the bar screening)
is used for the coarse discharge on the BS3. The coarse grit is transported via chute to a trough. The
trough is moved along on rollers on the floor.
The dust suppression is handled via water nozzles.
Technical Specifications
Year of construction:
Type:
Make:
2007
VSR1400/2580Ass-UVK79W
AVITEQ Vibrationstechnik GmbH
Bar Screen
Max. throughput:
800 to/h
Max. grit size of excavation material off TBM belt: 300 mm
Dispersion of grit sized up to 150 x 150 x 150 mm: 90%,
Selectivity:
150 mm
Trough length:
2500 mm
Trough width:
1400 mm
Unbalance motor power output:
2x 7 kW, 400 V, 50 Hz
Hydraulics unit:
approx. 50 bar, 2.2 kW
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4.3 Securing / Rockbolting
2 drilling carriages can be hydraulically positioned via roll-over on a ring beam.
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Technical Specifications
Drill hammers Tamrock:
Page 17 / 41
type 560S C/W2
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4.3.1 Rockbolting System L1
TAMROCK Rockbolting Equipment L1
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Equipment per side (left/right):
1 pc. drill hammer Tamrock 560S C/W2
1 pc. radio remote control unit
4.3.2 Rockbolting Carriages
Both carriages are attached to a ring beam, which allows securing along a 360° radius.
4.3.3 Rockbolting System L2
System anchoring (adhesion) is executed by a Tamrock Commando, which is mounted on coach 3 of
the BS.
It is equipped with openings, in order to allow rockbolting along an approximately 230° radius in the
overhead area.
4.3.4 Probe Drilling System
The drilling equipment in L1 can also be used to perform forward investigation probe drillings. The
kinematics of this assembly is designed to allow drilling in a flat angle above the cutterhead.
4.3.5 Logging of Probe Drilling
To allow electronic logging of excavation data, the hydraulic supplies of the following functions are
equipped with electronic pressure gauges: blow pressure, rotation pressure, advance pressure, rinse
pressure and advance oil flow. All data can be further processes on a PC.
4.3.6 Ring Beam Erector
A ring beam erector is mounted in front of the L1 which allows exact positioning of ring beams in a
360° radius.
4.4 Shotcrete Carriage
A spray robot allows shotcrete application in L2.
Longitudinal mobility of extruder lance:
Longitudinal mobility of carriage:
Longitudinal spraying area:
Max. radial spraying area:
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2m
4m
6m
220°
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4.4.1 Shotcrete Robot
Conceptual drawing:
Remote Control Unit:
Technical Specifications
Shotcrete platform:
Longitudinal traverse path:
Longitudinal running speed:
Lateral traverse path:
Lateral running speed:
Spray head:
7150 mm (weight: approx.10 to)
4m
0.3 m/sec.2
220°
0.15 m/sec..
Swivel longitudinal and lateral, extruder head
rotation, nutation extruder head
Hydraulic Unit:
Power output:
Operating pressure:
Throughput capacity:
Power consumption:
Capacity of oil tank:
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22 kW
210 bar
54 l/min.
3 x 400 V
225 l
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4.4.2 Suprema
The shotcrete pump is mounted on a platform at the end of the backup system. It can be charged by
skip (e.g., Secatol) or directly by truck mixer (e.g., Dieci F7000).
Technical Data:
Designation:
Overall width:
Overall length:
Overall height:
Feed hopper capacity:
Filling height:
Outlet:
Total weight:
Electrical motor:
Nominal conveyor capacity:
Conveyor distance/height:
Conveying line/jet size:
Page 21 / 41
Suprema
1520 mm
2500 mm
1950 mm
250 l
1100 mm
100 mm
2.2 to
3 x 400 V/50 Hz, 30 kW
2-14 or 3-20 m3/h
300/100 m
50, 65, 80, 100 mm
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4.4.3 Secatol
Technical Specifications
Year of construction:
Type:
Capacity:
Drive:
Dead weight.
Lifting capacity:
Allowable gross weight:
2003
RHV, 7 m3
7000l
Electrical hydraulic (15 kW)
4100 kg
approx. 1990 mm
19100 kg
5 Cranes for Flow of Material
The flow of material is carried out via several cranes from TBM cutterhead to the rear end of the BS.
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5.1 Monorail below TBM
Technical Specifications
Type of chain hoist (converted)
Bearing load of winch (2.5 to):
Max. lifting height:
Longitudinal traverse path:
Main lifting speeds:
Max. longitudinal friction wheel running speed:
Longitudinal sprocket wheel running speed:
Operating voltage:
Output of lifting motors:
Output of friction wheel motors:
Output of sprocket motors:
Weight (excl. rails)
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SH 5025- 8/2 1/1
25 kN
3.0 m
approx. 16 m
8.0 / 2.0 m/min.
50 m/min.
20.0 / 5.0 m/min.
400 V, 50 Hz
3.8 kW
2 x 3.0 kW
0.3 kW
ca. 1.5 to
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5.2 Crane on TBM
A crane on top of the TBM allows lifting of mashes, rockbolts and other resources from the ground to
the TBM platform.
Technical Specifications
1 pc. PM crane type 5022
- Load category 5mt
- Bearing load of 680 kg at an overhang of 6.80 m
- Working range 360 degrees
- HAWE control valve
- Hetronic remote control linear, 24 V
- Recharger for radio unit 24 V or 220 V
- Load holding valve and load moment limiter
- Winch P6E, tensile force 800 kg in direct pull
- CE standard
- Dead weight approx. 800 kg
- Mounting material
- blue finishing
1 pc. hydraulic unit SA75
- Hydraulic tank, steel 75 ltr.
- Electrical motor, 10 kW, 1500 rpm, 400 V
- Hydraulic pump 20 l/min., 270 bar
- Return line filter F10 100/1
- Funnel
- Level indicator
- Pressure connection
- Leak oil connection
- Unit has been completely disassembled and thoroughly checked.
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5.3 Crane TBM-BS
A crane is mounted on the top deck of BS1, which allows lifting material from the tween deck to the top
deck. The crane is operated by radio control unit.
Technical Specifications
Year of construction:
Type:
Bearing load:
Lift moment:
Max. reach:
Working range:
Weight:
Hydraulic system:
Power consumption:
2007
PM5023
440 kg at an overhang of 8.2 m
5 mt
11m
360°
approx. 840 kg
operating pressure 270 bar, conveyor capacity
20 l/min., voltage 400V/50Hz,
10 kW
5.4 Surface Carrier BS1
The surface carrier ensures the link between the monorail beneath the TBM and the monorail beneath
the BS3. This carrier is used to install the rails underneath the BS1.
The overhead crane BS1 moves along two rails, which are mounted underneath the lower deck. The
traverse drive consists of two friction drive units. The carrier is operated by radio control unit.
Technical Specifications
Rail:
Track width:
Weight:
Longitudinal traverse path:
Max. longitudinal running speed:
Output of longitudinal drive motors:
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I140E
2800 mm
approx. 4 to
55 m
40 m/min.
4 x 5.5 kW
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Lifting Units 1 + 2:
Bearing load per chain hoist:
Lifting height:
Lifting speed:
Output of lifting motors:
3200 kg
3m
4 and 1 m/min.
2 x 2.44/0.61 kW
Lateral Carriage:
Lateral traverse path:
Max. lateral running speed:
Output of lateral drive motors:
1.8 m
12 m/min.
2 x 0.25 kW
Handover Crane:
Type of electric chain hoist:
Bearing load:
Lifting height:
Lifting speed:
Output lifting motors:
GCHO1000/2NF
1600 kg
3m
4 and 1 m/min.
2 x 2.44/0.61 kW
Auxiliary Rail Cranes:
Type of electric chain hoist:
Bearing load:
Lifting height:
Lifting speed:
Output lifting motors:
GCHO1000/1NF
1000 kg
3m
8 and 2 m/min.
2 x 1.45/0.36 kW
5.5 Suspended platform (BS2)
The rear end of the “backup system infrastructure” is linked to a suspended platform (BS2).
The suspended platform bridges the ground floor construction site. The walkable platform supports the
conducts (energy, air, etc.), the BS conveyor belt and the monorail overhead crane.
The platform is hung by periodically displaced rockbolts in the tunnel top slab.
The material handling crane – in the form of a monorail overhead crane – is intended to move material
from a transport vehicle to the rear end of the BS1.
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Technical Specifications „BS2“
Suspended platform
Platfrom segments:
System length of platform segments:
Suspension rail incl. chain and shackles:
Rail length:
Distance between the two rows of rockbolts:
Bearing load of rockbolts nominal:
Test load of rockbolts:
18 pcs.
3m
2 x 20 pcs.
3m
4.700 m
35 kN
70 kN
5.6 Monorail Overhead Crane (BS2)
The monorail overhead crane moves along a rail, which is attached to the underside of the suspended
platform. The traverse drive consists of two friction drive units. The crane is operated by radio control
unit.
Technical Specifications
Rails:
Weight:
Longitudinal carriage:
Max. longitudinal speed:
Output of longitudinal drive motor:
I140E
2.7 to
approx. 46 m
60 m/min.
4 x7.5 kW
Lifting Unit
Type:
Bearing load:
Lifting range:
Lifting speed:
Output lifting motors:
electric chain hoist: GCHO1600/2NF
3200 kg
5m
4 and 1 m/min.
2 x 2.44/0.61 kW
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5.3 Backup System for Supply and Disposal (BS3)
The backup system “supply and disposal” (BS) consists of the tailing portal carriages 5 and 6.
These portal carriages are supported by skids and rails.
The following functions are integrated in these carriages:
- Coarse grit extrusion: A grader extrudes the course grit. The course grit (approx. 150 – 300 mm) is
separated and deposed in a trough. The trough moves along with the BS3 (resp. is pulled along the
ground floor) and is exchanged by truck.
- A shunting switch below the normal-sized grit separator allows the diversion of the excavation
material to a truck below the installation (e.g., if the tunnel belt is out of order or to acquire filling
material to be used at the ground floor construction site.)
- A deposition point for the tunnel belt.
- An installation point for the tunnel belt. A raised platform with stairway access on the upper deck can
be used by the customer to mount an extension installation for the tunnel belt. A crane is used to
move parts of the installation to and from the platform. The max. tolerable tension on the tail pulley
installed by the customer is 54 kN.
- Units (pumps, reservoirs, etc.) of the water installation for industrial and mountain water are not
included in this submission. Space is provided at the rear of the BS to mount the hose drums of the
water supply to the backup system installation.
- A medium voltage cable drum is mounted on one of the tailing carriages. The emergency power
supply of the duct storage unit is used for electrical power during the coiling up of the cables
- A material-handling crane is used to exchange the duct storage units.
- A cooling unit of the tunnel air ventilation (Which was never installed, because it wasn’t required).
- An emergency power supply unit to supply above pumps, cable drums and emergency lighting.
- Secondary ventilation
6 Ventilation System
6.1 Preface
The tunnel airduct has a diameter of 2200 mm. The main ventilation unit is located at the tunnel
entrance. The fresh air is conducted via the airduct to the duct storage unit with diffuser, then to the
secondary ventilator with sound absorber and finally via the secondary air duct to the TBM.
6.2 Secondary Ventilator AL 12-550
Technical Specifications
Type:
Diameter:
Installation length:
Nominal rotation speed:
Nominal output:
Weight:
Sound absorber type:
Secondary airduct:
Startup:
Page 28 / 41
AL12-550
1200 mm
1350 mm
1500 rpm
55kW
approx. 1050 kg
SDS12
flat airducts D1400 and D1200 (approx. 110 m)
via soft starter
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6.3 Dry-type Dedusting System HTKS 1/1000
The dry-type deduster is mounted on the BS1. Dust is aspirated from the cutterhead via spiral airducts
leading through the main TBM body to the rear end. Dust in the TBM area is exhausted via a
branching in the airduct
Technical Specifications
Year of construction:
Aspiration capacity:
Air filter elements:
Filter material quality:
Filter surface:
Filter cleaning:
Operating pressure:
Filter resistance:
Pressurized air requirement:
Scraper discharge:
Fan station:
Page 29 / 41
2007
1000 m3/min.
128 pcs. compact-type
PHP (uncoated)
approx. 452 m2
Annular contact controller
4.5 bar
approx. 2500 Pa
approx. 2 m3/min.
0.75 kW
3x45 kW, incl. sound absorber,
star-delta security combination
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Wet discharge device for blended volumes:
approx. 200 l
Electric circuits for:
Control of all discharge units
Filter purification
Control of starting and stopping sequences of all units
6.4 Wet-type Deduster HCN 400/1
A wet-type dedusting system exhausts and cleans the air from the shotcrete robot area.
Technical Specifications
Year of construction:
Aspiration capacity:
Amount of water needed:
Water pressure:
Degree of efficiency:
Page 30 / 41
2007
400m3/min
approx. 0.1-0.2 l/m3 air (approx. 60 l/min.)
4 bar
approx. 99.5%
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Ventilator station with axial blower:
Stream volume:
Pressing:
Drive output:
Propeller diameter:
Rotation speed:
Voltage:
360 m3/min.
300 Pa at 360 m3/min.
2x15 kW
600 mm
3000 rpm
400 V, 50 Hz
Incl. control unit
7 Electrical Installations
7.1 Electrical Main Data and Functions
Connection voltage:
Operating frequency:
Connected load:
16 kV ± 2x2.5% (can be adapted by coiling up to 24 kV)
50 Hz
3 x 2000 kVA = 6000 kVA
Installed brands:
low voltage splitter and circuit elements: ABB
cutting motors: ELIN
frequency reduction: VACON
transformers SCAE
medium voltage switches SCAE
SPS: Mitsubishi
The machine is fed via a cable drum with 16 kV. Length of trailing cable: 350 m.
A medium voltage switchboard installation (max. 24 kV) feeds two transformers for the operation of the
cutterhead and one transformer for the auxiliary drives and the backup supply unit.
Two main transformers, 2000 kVA each, transform the 16 kV to 690 V. The transformers feed two
power converter cabinets with 5 frequency converters each. (brand: Vacon, Pn = 450 kW, watercooled).
These control the 10 continuously variable speed-controlled three phase squirrel cage motors
(brand: ELIN, On = 300 kW, water-cooled).
Up to 50 Hz the motors operate at nominal torque. From 50 Hz to the maximum operating frequency of
86 Hz, the motors operate within field weakening range.
The precise synchronization of all 10 drives is achieved by Mitsubishi-Melsec SPS.
A panel-mate operating software controls the revolution speed of the motors and therefore the
cutterhead.
A feed-in transformer (2000 kVA) transforms the 16 kV to 400/230 V. It feeds the machine hydraulic
system and the machine control unit (SPS), as well as the whole backup assembly such as conveyor
belt, dedusting system, pumps, compressors, rockbolting installation, shotcrete system, cranes,
lighting, etc.
The control voltage of the machine is 24 Vdc. A Mitsubishi-Melsec is used as control unit (SPS),
CC link.
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7.2 TBM and NL Schematics
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Main switchboard: 16 kV, 400 V:
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7.3 Frequency Converter
10 water-cooled frequency converters in 2 switchboard cabinet groups are located on BS1.
The rotation speed of the 10 cutter motors with 300 kW each is controlled by 2 cabinets containing
5 frequency converters each. The Frequency can be set by SPS from 0 Hz to 50 Hz, and up to
86.25 Hz.
The 6-pole gear-reduced electric motors rotate the cutterhead between 0 and 8.3 rpm.
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Technical Specifications
Stations I and II
Each contains:
- 1 main switch:
690 V, 2500 A
- 5 frequency converters:
VACON, SF
- Nominal power:
450 kW,
- Operating voltage:
3 x 525 V up to 690 V ± 10 %, 50/60 Hz
- Nominal output current:
456 A
- Output voltage:
0 up to 690 V (frequency-controlled)
- Water cooling system:
- Water temperature:
0 – 30° C
- Controlled by device net card, via CC link
- With keypad
- With power choke
- Cooling water pump
- Cooling Fan
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7.4 Cutterhead Drive
10 gear-reduced cutter motors with 300 kW each rotate the cutterhead at 0 to 8.3 rpm. The torque is
transmitted from motor to gearbox by safe set.
7.4.1 Cutterhead Motors
Technical Specifications
Three-phase squirrel cage motors ELIN/EBG:
- Nominal capacity:
300 kW S1
- Nominal rotation speed at 50 Hz:
989 rpm.
- Max. rotation speed:
1870 rpm at 95 Hz
- Nominal torque:
2900 Nm
- Torque at max. rotation speed:
1532 Nm
- Operating voltage:
3 x 690 V Y
- Nominal current:
330 A
- Build type:
IM B5 special
- Fuse type:
IP 66
- Insulation class:
F/H
Water-cooling system:
- Flow rate:
- Water temperature:
- 1 motor with hydraulic disc brake
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30 l/min.
0 – 30° C
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7.4.2 Cutterhead Planetary Gearbox
Gearboxes 1 to 10:
- Planetary gearbox:
- Nominal capacity:
- Input torque:
- Output torque:
- Max. coupling torque:
- Input rotation speed:
- Output rotation speed:
- Transmission:
Water cooling system:
- Flow rate:
- Water temperature
Lohman & Stolterfüht
315 kW
1671 Nm
31057 Nm
5100 Nm
1800 rpm
96.9 rpm
1 by 18.571
20 l/min.
0 – 30° C
7.5 High Voltage Cable Drum
Technical Specifications
Cable drum driven by electric motor:
- Max. operating voltage:
- Trailing cable:
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20 kV
350 m, 16 kV, highly flexible, 3 x 95 + 3 x 50 mm2
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7.6 Transformers
Technical Specifications
Main supply transformers of TBM.
Transformer 1: Epoxy dry-type transformer
Output voltage: 2000 kVA, UO = 16 kV ? 2x2.5 %, UU = 690 V, Dyn11, Ksp 6.13 %,
m = 4450 kg. L = 3200 mm, B= 1500 mm, H= 2300 mm (gabarit), Cl F, AN cooling
with external fans 400 V, with self-extinguishers, in steel cabinet
Transformer 2: Epoxy dry-type transformer
Output voltage: 2000 kVA, UO = 16 kV ? 2x2.5 %, UU = 690 V, Yyn0, Ksp 5.99 %
m = 4560 kg. L = 3200 mm, B= 1500 mm, H= 2300 mm (gabarit), Cl F, AN cooling
with external fans 400 V, with self-extinguishers, in steel cabinet
Transformer 3: Epoxy dry-type transformer “Elettromeccanica de Marnate”
Output voltage: 2000 kVA, UO = 16 kV ± 0.5 kV, UU = 420 V, Dyn5, Ksp 6.39 %
m = 4450 kg. L = 4560 mm, B= 1500 mm, H= 2300 mm (gabarit),
with self-extinguishers, in steel cabinet
7.7 Emergency Lighting
10 battery-backed lamps are mounted on the backup system. These are integrated into the default
lighting circuit and serve as illumination during normal operations. In case of power failure they
automatically switch to emergency mode. As soon as the power returns they are reset to normal
mode. During an emergency power outage the lighthing can be maintained up to 1 hour.
7.8 Default Lighting
The lighting system consists of short fluorescent lamps 2 x 18 W (230 V, 50 Hz)
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7.9 Emergency Backup Generator
An emergency power installation for the supply of the pumps and lighting is mounted on BS3.
Technical Specifications
Year of construction:
Type:
Nominal capacity:
Effective power cosγ 0,8:
Continuous power:
Continuous effective power cosγ 0,8:
Nominal voltage:
Frequency:
Rotation speed:
2007
GEPK275HE
275 kVA
225 kW
250 kVA
200 kW
400/230 V
50 Hz
1500 G/1
8 Miscellaneous
8.1 Rescue Container
A rescue container with overpressure ventilation is mounted on carriage 2 of BS1.
Technical Specifications
Number of persons
Weight:
16
2 to
The air is supplied by an external compressor located at the tunnel entrance.
8.2 Duct Storage Unit
The duct system, the duct storage unit and the reserve cassette, as well as a handling installation for
the storage cassettes are mounted on the backup system. The tunnel airduct has a diameter of
2200 mm. There are a total of 2 duct storage units present.
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Technical Specifications
Airduct diameter:
Storage capacity:
Bearing load per chain hoist (2 pcs.):
Type:
Distance between fasteners:
Lifting height:
Lifting speed:
Control voltage:
Capacity:
Weight of both chain hoists: ca. 200kg
2200mm
100 m
3200 kg
STD 3016-8/2 4/2-2E
2200 mm
6m
¼ m/min.
48 VAC
2x 0.57/2.3 kW
8.3 Industrial Water Installation
A hose reel for the water conduit control is mounted on BS3. The industrial water ductwork leads from
the hose reel to the rear part of the TBM.
Technical Specifications
Nominal width of main conduit:
Overall length:
4“
approx. 450 m
Hose Reel
Type:
Outside diameter:
Coiling width:
Max. operating pressure:
Coiling up speed:
Motor output:
Weight incl. hose:
TALPA 6/A4
2200 mm
100 mm
10 bar
15 m/min.
0.55 kW
approx. 305 kg
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8.4 Compressed Air
2 Atlas Copco GA75FF compressors and one pressure tank are mounted on carriage 3 of the backup
system. The compressed air supply reaches from here to the TBM and the end of the backup system.
Technical Specifications
2 pcs. stat. compressor Atlas Copco GA75 FF
Type:
Capacity:
Compressed air connection:
Motor:
Normal operating pressure:
May. operating pressure:
Screw-type compressor
13.32 m3/min. at 7.5 bar
G21/2“
75 kW
7.0 bar
7.5 bar
Compressed Air Piping:
Rescue Container:
General appliances:
Shotcrete robot:
1“ (approx.110 m)
2“ (approx. 130 m)
3“ (approx. 60 m)
8.5 Replacement Parts
Check separate list.
Note: No responsibility is taken for the correctness of the information in this document.
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