Please click on the images to enlarge.
The clip below shows the rotation box in motion and boring away after the repairs.
Rotation gearbox MT5
47 Meters into the bore at The Lodden the rotation gearbox became very noisy. the two hydraulic motors that drive had a distinct bearing rumble and even with no load there was a grinding sound. The rotation box was removed and stripped. We found that the main thrust bearings in the gearbox had suffered water corrosion at some time and the last few days work had just aggravated the problem. Also the hydraulic motors had also suffered bearing damage, causing the seals to start leaking excessively. Parts were no problem and the motors were Rexroth , the gearbox bearings were available. Two days later the rotation box was assembled and fitted to the giant jacking frame that it belonged to. The photos show the size and weight of the parts in question.
Please click on the images to enlarge.
The clip below shows the rotation box in motion and boring away after the repairs.
Please click on the images to enlarge.
The clip below shows the rotation box in motion and boring away after the repairs.
Power Pack blow out.
The large 3000 cfm Vacuum Power Pack driven by a large Big Cam Cummins motor decided to take a rest. After working hard for days in the summer heat the control valve assembly started leaking badly. Little notice was taken at the start of the leak , in fact some hoped that it would just go away. This assembly controls the oil flow to the large Roots Vacuum Blower seen in the photo below. Drive by very high oil pressures and with oil temperature reaching the top end of the scale we were forced to shut down and repair the valve block. Confined to a 6m shipping contained this job was cramped , awkward , and very sweaty. The Rexroth hydraulic pumps and there associated parts are a pleasure to work on. With the faulty seals replaced and a good service all was up and going again.
Lesson learned : A stitch in time saves nine. Yes had we been informed when the leak started much expense and time could have been spared.
Please click on any of the photo's to enlarge.
Power pack with Cummins Big Cam motor crambed into 6m shipping container.
Rexroth hydraulic pumps - two banks of two pumps each = 4 pumps.
3000 cfm Roots vacuum blower - great stuff!
The faulty valve bank that created great expense.
All that was needed , these o rings and much time could have been saved.
Lesson learned : A stitch in time saves nine. Yes had we been informed when the leak started much expense and time could have been spared.
Please click on any of the photo's to enlarge.
Power pack with Cummins Big Cam motor crambed into 6m shipping container.
Rexroth hydraulic pumps - two banks of two pumps each = 4 pumps.
3000 cfm Roots vacuum blower - great stuff!
The faulty valve bank that created great expense.
All that was needed , these o rings and much time could have been saved.
MT5 980mm Microtunneling Machine Control Box.
While Sub-contracting for Leed Engineering on their large tunneling project on the bendigo mains water line the control box on the largest micro tunneling machines gave up. Power drivers that control the steering and camera failed. After stripping down and blowing all the dust out of the circuit boards the problem power transistors were identified. Replaceing did not realy last long as they blew again. Much time was spent tracing the fault down to a Milspec coupling that had been damaged by a bit of rough handling. After this was replaced , along with a new set of power transistors we were back in action.
Lesson learned : Although we work with heavy and large equipment , there are parts that need to be treated delicately and with much care.
Control box shut down - notice the gaping hole which we covered up to stop dust form getting into the electronics.
4 Silver and 4 Black power transistors that were replaced.
Faulty Milspec coupling that started all the problems
Control box ready for action - dust problem also solved.
Lesson learned : Although we work with heavy and large equipment , there are parts that need to be treated delicately and with much care.
Control box shut down - notice the gaping hole which we covered up to stop dust form getting into the electronics.
4 Silver and 4 Black power transistors that were replaced.
Faulty Milspec coupling that started all the problems
Control box ready for action - dust problem also solved.
Dream Occupation.
Some men want to go to the moon , others was to race a Formula F1 racing car , and some men just want to fish.
Well this man would realy love to work with a company that builds and operates MAIN BEAM TBM machines.
Imagine being part of a team that repairs and maintains machines that worm there way through the earth , going where no man can see.
A step up from micro tunneling , this industry takes a giant leap into mammoth type machines. Click the photo below and see for yourself.
The mechanical engineering that goes into this type of machine is mind blowing. Dealing with forces and pressure that baffle the everyday man's mind , these machines cut and force there way through the earth devouring all that lies ahead. Take a look at the technoligy squeezed in behind this TBM head.
Please click on the photo to enlarge.
As the giant MAIN BEAM TBM moves forward imagine all the people working together as they edge forward to their goal. Boilermakers , Carpenters , Concrete Engineers , Electricians , Engineers , First Aid Workers , Fitters , Geologists , Hydraulic Engineers , Laser technicians , Mechanics , Machine Operators , Quantity Surveyors , Safety Officers ,Shutter Hands , Civil Surveyors , Steel Fixes , Structural Engineers , Ventilation Engineers , Welders , just to name a few. In the photo below try and picture the teamwork needed to get this machine to this stage of the project - and we have not started to tunnel yet!!
Please click on the photo to see more detail.
What is more they steer there way with laser guided precision. A company specalising in guidance systems that make it possible to navigate underground and steer tunneling machines up , down , and arround corners is VMT. Based in Denmark their team consists of engineers in Germany, Spain and China. For more than 10 years VMT technology has provided successful and reliable navigation of tunnel boring machines and they have completed many projects worldwide. It was a great pleaseure to meet Alexander Seilert at the Colorado School of Mines in the USA and also in Sydney Australia at the No-Dig Conference. His enthusiasm and passion to over-come the challanges in tunnelling has motivated me not to loose sight of my dream carreer. Please click here to browse the VMT site
Each of the BIG tunnel companies have slogans of their own. They represent the attitude needed to succeed in the tunneling world. Every day I remind myself of there mission statements , one day I will be part of a team!
As the mighty ROBBINS COMPANY say's "Our job is not finished until your tunnel is"
The photo below was taken on a project associated with the 15.4km long Ceneri Tunnel. A milestone was celebrated on November 6th, 2008, when the 9.7m diameter Robbins TBM excavating the 2.4 km long Sigirino access adit broke through.
Please click on the photo to enlarge.
Giants in tunneling HERRENKNECHT state the facts "SOLUTIONS. EVERYWHERE."
Trude, the world´s largest tunnel boring machines (TBMs) with a diameter of 14.2m, excavated the 4th pipe Elbe Tunnel in Hamburg, Germany. It took two years and five months to drill the 2,561 metres underground tunnel.
The German tunnelling company, Herrenknecht AG, responsible for this achievement is now applying a new technique with space origin in order to be able to drill tunnels even better. The German company Astro- und Feinwerktechnik Adlershof GmbH has produced a new transmitter for Herrenknecht AG based upon their know-how gained from their work for ESA on the Cassini-Huygens spacecraft.
A number of these transmitters are now mounted on a TBM and provides a look into the ground in front of the TDB. Every second the transmitters send sound waves into the ground, microphones receive the reflecting signals which are data processed and visualizes important geologic changes up to 40 m in front of the rotary shear blade.
This photo is a must to enlarge!
If you want to know more about these enormous beasts, here is a really good site all about the tunneling industry: The City of Ember Underground site. There are many more sites that are just totally wacko - one alleging that the US has had nuclear powered tunneling machines that have been boring their way across America by using fusion to melt the rock into a smooth glassy opening, and others alleging that America is criss-crossed by these high speed tunnels in which travel trains traveling at over 14,000 miles/hr (thanks to EYE of the Fish for the intriguingly fantastically weird links).
I would wet my rods should I ever get to see a nuclear powered TBM. To actually work on a nuclear-powered, rock-melting TBM (called NTBMs or Subterrenes) would blow my mind! Don't think it will happen in my lifetime as I am not to sure Australian's would like to travel through a Nuclear melted tunnel with the chance of us containing ourselves with some left-over radio-active by product.
My adage is simple "never , ever , give-up" Yes one day my dream will come true!
Well this man would realy love to work with a company that builds and operates MAIN BEAM TBM machines.
Imagine being part of a team that repairs and maintains machines that worm there way through the earth , going where no man can see.
A step up from micro tunneling , this industry takes a giant leap into mammoth type machines. Click the photo below and see for yourself.
The mechanical engineering that goes into this type of machine is mind blowing. Dealing with forces and pressure that baffle the everyday man's mind , these machines cut and force there way through the earth devouring all that lies ahead. Take a look at the technoligy squeezed in behind this TBM head.
Please click on the photo to enlarge.
As the giant MAIN BEAM TBM moves forward imagine all the people working together as they edge forward to their goal. Boilermakers , Carpenters , Concrete Engineers , Electricians , Engineers , First Aid Workers , Fitters , Geologists , Hydraulic Engineers , Laser technicians , Mechanics , Machine Operators , Quantity Surveyors , Safety Officers ,Shutter Hands , Civil Surveyors , Steel Fixes , Structural Engineers , Ventilation Engineers , Welders , just to name a few. In the photo below try and picture the teamwork needed to get this machine to this stage of the project - and we have not started to tunnel yet!!
Please click on the photo to see more detail.
What is more they steer there way with laser guided precision. A company specalising in guidance systems that make it possible to navigate underground and steer tunneling machines up , down , and arround corners is VMT. Based in Denmark their team consists of engineers in Germany, Spain and China. For more than 10 years VMT technology has provided successful and reliable navigation of tunnel boring machines and they have completed many projects worldwide. It was a great pleaseure to meet Alexander Seilert at the Colorado School of Mines in the USA and also in Sydney Australia at the No-Dig Conference. His enthusiasm and passion to over-come the challanges in tunnelling has motivated me not to loose sight of my dream carreer. Please click here to browse the VMT site
Each of the BIG tunnel companies have slogans of their own. They represent the attitude needed to succeed in the tunneling world. Every day I remind myself of there mission statements , one day I will be part of a team!
As the mighty ROBBINS COMPANY say's "Our job is not finished until your tunnel is"
The photo below was taken on a project associated with the 15.4km long Ceneri Tunnel. A milestone was celebrated on November 6th, 2008, when the 9.7m diameter Robbins TBM excavating the 2.4 km long Sigirino access adit broke through.
Please click on the photo to enlarge.
Giants in tunneling HERRENKNECHT state the facts "SOLUTIONS. EVERYWHERE."
Trude, the world´s largest tunnel boring machines (TBMs) with a diameter of 14.2m, excavated the 4th pipe Elbe Tunnel in Hamburg, Germany. It took two years and five months to drill the 2,561 metres underground tunnel.
The German tunnelling company, Herrenknecht AG, responsible for this achievement is now applying a new technique with space origin in order to be able to drill tunnels even better. The German company Astro- und Feinwerktechnik Adlershof GmbH has produced a new transmitter for Herrenknecht AG based upon their know-how gained from their work for ESA on the Cassini-Huygens spacecraft.
A number of these transmitters are now mounted on a TBM and provides a look into the ground in front of the TDB. Every second the transmitters send sound waves into the ground, microphones receive the reflecting signals which are data processed and visualizes important geologic changes up to 40 m in front of the rotary shear blade.
This photo is a must to enlarge!
If you want to know more about these enormous beasts, here is a really good site all about the tunneling industry: The City of Ember Underground site. There are many more sites that are just totally wacko - one alleging that the US has had nuclear powered tunneling machines that have been boring their way across America by using fusion to melt the rock into a smooth glassy opening, and others alleging that America is criss-crossed by these high speed tunnels in which travel trains traveling at over 14,000 miles/hr (thanks to EYE of the Fish for the intriguingly fantastically weird links).
I would wet my rods should I ever get to see a nuclear powered TBM. To actually work on a nuclear-powered, rock-melting TBM (called NTBMs or Subterrenes) would blow my mind! Don't think it will happen in my lifetime as I am not to sure Australian's would like to travel through a Nuclear melted tunnel with the chance of us containing ourselves with some left-over radio-active by product.
My adage is simple "never , ever , give-up" Yes one day my dream will come true!
1200mm Bores Head TBM
Preparation for a bore with this 1200mm Bores Head along with the Brivinni Pipe Jacking Station. All controls and gearboxes checked. Hydraulic cylinders extended and retracted - pressure tested and jacking tonnage calculated.The photos of the Bores Head below show the head after pipe jacking was completed. The Brivinni jacking station is cleaned up and ready for sale to Leed Engineering.
1200mm Bores Head
Inside view
Control System Veiw
Brivinni Jacking Frame ready for delivery.
1200mm Bores Head
Inside view
Control System Veiw
Brivinni Jacking Frame ready for delivery.
SOMERSBY BORE
After completing the bores for Leed Engineering in Bendigo we were invited to work on a future project that had a limited time frame. This bore would would new to conform to the following customer spec.
"Installation by accurate ‘pipe jacking’ from the new inlet location, downhill, at approx 6.5% grade, 37 units (2.32m each), approx 86m of 1500mm internal diameter concrete Class 4 Humes “J” Series jacking pipe (supplied by the RTA) transversely under the F3 at Somersby, NSW at depth ranging from 7m to 14m below the Freeway."
To accomplish this challenge a Tunnel Boring Machine would be needed. Leed Engineering had put aside a certain amount of the project money to build a TBM. The TBM would be called ELNA 1800.
Ground conditions were favourable , sandy clay , the customer was the RTA in NSW , and we had 90 days to build a TBM and complete the bore. This included pushing 86m of concrete pipe behind a TBM.
The photo below shows the location of the bore in Somerby , NSW.
After some earnest discussion with senior management at Leed Engineering it was decided to kick-start the planning stage with all haste. A basic design was sketched up for a 1.8m external diameter TBM. Parts were sought and priced. Included in these was a new type of rock and stone cutter. This type of cutter is also known as Twin Headers or RoadHeaders or Rock Grinders. This Rock Cutter is the first of it's kind in Australia, and this piece of equipment goes well beyond the conventional,great speed and very maintenance friendly.
Below is the RoadHeader we had priced and specked up for the job.
Next was the design for the TBM itself. A large steel rolling company was located and were prepared to roll the 1.8m outer shells for the TBM. Planning was well on it's way with hydraulics ans electronic control systems all taking shape realy fast. A large Brivinni pipe jacking station was to be used to push allomg the 86m of concrete pipe. Although not new to TBM design, this would be our first go at using vacuum extraction technology. A gigantic vacuum plant with interceptors would be used to carry away the waste and dispose of it to EPA standards.
In reality we would be building a TBM that was a combination of the Herrenknecht pipe jacking TBM ,a Herrenknecht shaft sinking machine which works with a sweeping action and the giant TBM machine in India. See the pictures below , and CLICK HERE to see the animation of a pipe jacking TBM.
Engineering drawings were drawnup and the computer generated workings of the TBM were simulated to make sure all worked in harmony. Below is a structural drawing of Elna.
good.JPG)
The TBM would be assisted during the boring stage with a expanding and retractable jacking station inserted right behind the TBM head. The clip below illustrates the principal.
During a brainstorming session one evening we realized that it was going to be very risky to commit to the deadline requested by the client. Senior management at Leed Engineering made the right decision and informed the client the next day that we would not be able to meet there timeline. Although immensely disappointed, we all accepted and respected the solid decision.
What did we learn?
1) Respect for the client's timeline and his project is very important for future relations and projects.
2) If you can imagine it , you can build it!
3) Teamwork makes the world go round, or in this cases helps make the right decision.
I thank Leed Engineering for the opportunity to work and learn from them and hope that someday we will tunnel together.
Robbie Ashton from tunnel Bore Australia accepted the project and completed it in record time.
"Installation by accurate ‘pipe jacking’ from the new inlet location, downhill, at approx 6.5% grade, 37 units (2.32m each), approx 86m of 1500mm internal diameter concrete Class 4 Humes “J” Series jacking pipe (supplied by the RTA) transversely under the F3 at Somersby, NSW at depth ranging from 7m to 14m below the Freeway."
To accomplish this challenge a Tunnel Boring Machine would be needed. Leed Engineering had put aside a certain amount of the project money to build a TBM. The TBM would be called ELNA 1800.
Ground conditions were favourable , sandy clay , the customer was the RTA in NSW , and we had 90 days to build a TBM and complete the bore. This included pushing 86m of concrete pipe behind a TBM.
The photo below shows the location of the bore in Somerby , NSW.
After some earnest discussion with senior management at Leed Engineering it was decided to kick-start the planning stage with all haste. A basic design was sketched up for a 1.8m external diameter TBM. Parts were sought and priced. Included in these was a new type of rock and stone cutter. This type of cutter is also known as Twin Headers or RoadHeaders or Rock Grinders. This Rock Cutter is the first of it's kind in Australia, and this piece of equipment goes well beyond the conventional,great speed and very maintenance friendly.
Below is the RoadHeader we had priced and specked up for the job.
Next was the design for the TBM itself. A large steel rolling company was located and were prepared to roll the 1.8m outer shells for the TBM. Planning was well on it's way with hydraulics ans electronic control systems all taking shape realy fast. A large Brivinni pipe jacking station was to be used to push allomg the 86m of concrete pipe. Although not new to TBM design, this would be our first go at using vacuum extraction technology. A gigantic vacuum plant with interceptors would be used to carry away the waste and dispose of it to EPA standards.
In reality we would be building a TBM that was a combination of the Herrenknecht pipe jacking TBM ,a Herrenknecht shaft sinking machine which works with a sweeping action and the giant TBM machine in India. See the pictures below , and CLICK HERE to see the animation of a pipe jacking TBM.
Engineering drawings were drawnup and the computer generated workings of the TBM were simulated to make sure all worked in harmony. Below is a structural drawing of Elna.
good.JPG)
The TBM would be assisted during the boring stage with a expanding and retractable jacking station inserted right behind the TBM head. The clip below illustrates the principal.
During a brainstorming session one evening we realized that it was going to be very risky to commit to the deadline requested by the client. Senior management at Leed Engineering made the right decision and informed the client the next day that we would not be able to meet there timeline. Although immensely disappointed, we all accepted and respected the solid decision.
What did we learn?
1) Respect for the client's timeline and his project is very important for future relations and projects.
2) If you can imagine it , you can build it!
3) Teamwork makes the world go round, or in this cases helps make the right decision.
I thank Leed Engineering for the opportunity to work and learn from them and hope that someday we will tunnel together.
Robbie Ashton from tunnel Bore Australia accepted the project and completed it in record time.
Colorado School of Mines > USA
In early February 2008 I made a trip to Denver Colorado , USA. The learned town of Golden just outside Denver is where the most prestigious University of Mining is situated. Under the tutorship of Tim Cross and his Instructors the short course on Microtunnelling brought the science of tunnelling to new life. Amazing new technological developments were introduced that have been used successfully and accurately in parts of Europe. Much food for thought was left as to how we here in Australia could adopt and evolve this technology to our advantage. The opportunity to meet with these creative Engineers and share there enthusiasm was extremely motivating. Great doors of opportunity lie ahead in developing this art and we look forward to sharing in it.
Brisbane > Ipswitch Highway.
Another bore for SEQUID , in Brisbane on the Ipswitch Highway . Larger vacuum tunnelling machine used here , 520mm diameter bore. Mixed ground conditions with floaters (river bed rocks) along with a tight time shedule made this a challenging exercise. Special cutter were prepared for the soil conditions. Here steel sleeve was pushed along as we bored.
Special cutter made for clay bore , notice the outside teeth can collapse to allow the cutter and head to be withdrawn from the steel sleeve should things go wrong.
Steel sleeve being lowered into position on jacking frame.
Boring underway.
Special cutter made for clay bore , notice the outside teeth can collapse to allow the cutter and head to be withdrawn from the steel sleeve should things go wrong.
Steel sleeve being lowered into position on jacking frame.
Boring underway.
Microtunnelling Project in Port Melbourne
Back-filled with anything possible many years ago , not to mention the old pier rafters still in place this microtunnelling job had it's challenges. This was also a free bore with the sewer pipe being pulled in after the bores were drilled. Average length of the bores was 46m. Pipe diameter 300mm. All 256m of tunneling was completed in record time for MIRVAC. Photos show ground conditions.
All bores were for sewer and were spot on for line and grade.
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