Unique TBM Des ign Unleashed

at the Grosvenor Tunnel Pro ject

October 14, 2015

Presented By: Steve Smading

General Manager Asia Pacific

Agenda

Today’s Presentation

- Introduction to Crossover

- Why Crossover Machines?

- Machine Design: Grosvenor

Case Study

Introduction to Crossover TBMs

• Flexibility to switch from one mode to another

• Based on ground conditions

• Three main types of Crossover TBMs

- Hard Rock/EPB

- Open or Closed Mode

- Hard Rock or Soft

Ground

- Screw Conveyor

- Slurry/EPB

- Equipped with screw

conveyor and slurry

system

- Hard Rock/Slurry

Shield

- Highly adaptable to

variety of ground

conditions

Crossover Introduction

Why Crossover

Machines?

Why Crossover Machines?

Today, Crossover Machines are required to excavate different types of

ground efficiently with one machine.

A Crossover machine may be considered if your tunnel includes a

combination of these elements:

• You want to excavate self supporting ground Open Mode

(hard rock)

• You want to excavate self supporting ground but want to

mitigate underground water ingress Closed Mode

(Compressed air, Slurry, EPB, etc.)

• You want to excavate unstable ground Closed Mode

(Compressed air, Slurry, EPB, etc.)

Considerations for Crossover

Machines• Safety

Conversion work should be carried out in a confined space

• Schedule

Conversion works can be time-consuming, so a detailed plan must

be in place

• Geological information

– To decide when and where to convert, reliable geological

information will be required

– Adequate probe drilling is essential to determine the ground

conditions ahead of a Crossover TBM

• Cost

– Up-front costs may be high, but significant savings in the long-run

– Durability: savings in repair costs

– Dual-Mode: multiple project usage

• Designed to excavate in open or closed mode

• Hard rock and/or soft, relatively impermeable ground including

fault zones

• Less well suited to permeable ground conditions such as sand and

pebbles, though additives/polymer can be used to stabilize these

conditions

• Typically proposed for mixed face conditions

Ground Conditions

Crossover XRE TBM

Crossover XRE

Case Study

Grosvenor Decline Mining Project

• Queensland, Australia; 1,000km north of Brisbane

• Metallurgical Coal Project owned by Anglo American

• 2 Decline Tunnels for access to the 130m deep seam:

Conveyor Drift

Man and Material Drift

• TBM methodology for drift construction

Grosvenor – Project Overview

Crossover XRE TBM

• Soft Ground section (0-300m): sand, sand/clay, clay and

conglomerate

• Mixed Face/Rock Section (300-1,000m): siltstone, coal, sandstone

and basalt (UCS=20-120MPa)

• Methane gas in intermediate coal layer and at pit bottom

Grosvenor – Drift Geology

Crossover XRE TBM

“Purpose-built” TBM to:

• Cope with mixed-face conditions

Crossover/Dual Mode TBM

• Operate safely in the coal mine environment

EPB mode

Double Screw conveyor

ERZ/NERZ compliance

• Build multiple decline tunnels

Quick de-mobilization/re-mobilization

Grosvenor – TBM Design

Crossover XRE TBM

General: 8.0m diameter Crossover (XRE) TBM capable of conversion from EPB mode to non-pressurized single shield mode

Back-loading Cutterhead designed for:

• Use with knife bits & scrapers (EPB mode - mixing chamber)

• 17” disc cutters & bucket lips (open mode - radial loading plates & extendable hopper and screw)

EPB Mode

Bi-directional

Rock Mode

Single direction

Mixed Ground Mode

Bi-directional

Grosvenor – TBM Design

Crossover XRE TBM

EPB Mode Rock Mode

Grosvenor – TBM Design

Crossover XRE TBM

Double screw conveyor (front and rear) mounted in series and

with independent drives.

Grosvenor – TBM Design

Crossover XRE TBM

• EPB mode to maintain a positive

face pressure and contain the

methane;

• Double screw conveyor made

with spark resistant materials,

forming a sealed chamber with

the mixing chamber and

capable of creating a plug;

• Foam/additive injection ports

also along the screw conveyors

to prevent sparks;

• Snuffing box at the conveyor

discharge for suction and

removal of methane from the

screw.

TBM Design for ComplianceCrossover XRE TBM

CH Segments

CH core

Inner Shield

Outer ShieldCHS

CHS Dolly

Front Dolly Bridge Dolly

Sliding

Track

Segment ErectorBridge

Screw Conveyor

5.8m

Lift Jacks

Inner Shield

Grosvenor – Walking Dolly System

Crossover XRE TBM

• Tight schedule Onsite First-Time Assembly: July-October 2013

• Walk-in, Tests, Compliance Dossier and Acceptance: November-

December 2013

• Boring Started: December 20, 2013

Grosvenor - OFTA & Conveyor

Drift Construction

Crossover XRE TBM

• Completion of Conveyor Drift at half face in coal: May 13, 2014 (798m

in 20 weeks)

• Machine availability: 75-90% after week 8 up to 85m/week

• Last 6 weeks affected by more extensive presence of gas routine

implementation of procedures for mitigation and management

(TARP)

Grosvenor - OFTA & Conveyor

Drift Construction

Crossover XRE TBM

• Boring started on November 11, 2014

• Completion at full face in coal: February 9, 2015 (988m in 13.5 weeks)

• Machine availability: always above 60%; often between 80 and 90%

up to 110m/week

Grosvenor – Transport Drift

Construction

Crossover XRE TBM

Grosvenor Mine – Achievements And

Conclusions

• First time for a TBM to be fully

compliant to one of the most

advanced coal mine legislations

• More than 10 times faster advance

rate compared to a roadheader in

the same ground conditions

• Improved health conditions for

workers (no exposure to

unsupported rock or gas/fumes at

any stage of the tunnel

construction)

• Crossover TBM was highly

successful in mixed ground

conditions with methane gas

• Quick Removal System was highly

successful

Questions?