Abu Dhabi Presentation2 - VMT GmbH

Examining New trends in
Microtunnelling - Automatic
Navigation and Monitoring
Systems For Curved
Microtunnelling
Nod Clarke-Hackston
International Sales Manager
VMT GmbH
Promoting Trenchless Technology in the Middle East
9 th –11 th November 2009, Abu Dhabi

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 2
www.vmt-gmbh.de
Geographical Profile - Europipe
project

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 3
Railway Embankment
(Made Ground)
STW
Site
Horden Pipejack Shaft Option
Lower Cohesive
Glacial Till
(Boulder Clay)
Pipejack 60m Long
diameter 1,5m
Gravity Sewer 350m Long
1m diameter
Upper Cohesive
Glacial Till
(Boulder Clay)
Drop Shaft 6m diameter
45m deep
Existing Ground Level
Top of Cliff
45,2m AOD
Tunnel 150m Long
diameter 2m
Made Ground
(Colliery Spoil)
5m AOD
Middle Magnesian
Limestone
www.vmt-gmbh.de
Agricultural Land S.S.S.I Horden Beach North Sea
Middle Glacial Sands
Middle Magnesian
Limestone
Predicted 60 Year
Erosion Profile
Beach Deposits
Sea Level
Outfall Constructed Using a 150m Long
12m Deep Cofferdam

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 4
4 No. 300 tonne
Push Cylinders
Horden Curved Pipejack Option
Launch Shaft
IJS 5 IJS 4
Rear Reference
Prism
IJS 3
IJS 2
95m 95m 95m
Tunnel Length 553m
www.vmt-gmbh.de
Vertical Curve r = 1200m
Laser Station
Reference Prisms
IJS 1
Laser Beam
Push-off
Station
TBM
95m 50m 9.3m

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 5
River Adige Crossing - Italy
www.vmt-gmbh.de
Reception Shaft R. Adige
Launch Shaft
897m

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 6
Typical Current European
Pipejack Project
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 7
Rhine Siphon Tunnel.
Ludwigshaven -Mannheim
744m
Construction Period April - December 1982
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 8
www.vmt-gmbh.de
Sewer Outfall:Sayreville NJ - USA

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 9
Complex curved alignment
pipejacking project
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 10
Seo Cho Project–200m Radius
Curve
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 11
‘S’ Curve 300m Radius
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 12
General Alignment For
Anckelmannplatz Project
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 13
Overall Scheme For
Anckelmannplatz Project
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 14
Underground
Parking
Start Shaft
Anckelmannplatz Alignment
Total Length 545m
Canal Metro Lines Main Road Underground
Bunker
Interjack Station
Type II
Interjack Station Station
Type II
R = ∞R R=589m = ∞
Interjack Station
Type I
Control Shaft 1 Control Shaft 2
R = 300m
Interjack Station
Type I
R = ∞
Municipal
Building
R = 300m)
www.vmt-gmbh.de
Interjack Station
Type II
Service Shaft
151.43m 44.23m 65.36m 80.5m 14m 116.46m 73.02m
Reception Reception Shaft
R = ∞

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 15
Anckelmannplatz Proximity To
Existing Sewer
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 16
www.vmt-gmbh.de
Anckelmannplatz Parts List For
Pipes

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 17
www.vmt-gmbh.de
Line & Level and Angular Tolerances
Joint deflection OK
Tolerance Centre Line
Deflection failure
Tolerance Centre Line

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 18
www.vmt-gmbh.de
Total length of drives guided by VMT Pipejacking Guidance systems: - 6/05/2009 = 232,666 m
Distribution of advanced meters according to inside diameters of pipes
Total sum of meters for drives up to ID 1000mm: 7,495 m
Total sum of meters for drives from ID 1000mm up to ID 1200mm: 24,813 m
Total sum of meters for drives from ID 1200mm up to ID 1400mm: 5,965 m
Total sum of meters for drives from ID 1400mm up to ID 1600mm: 36,757 m
Total sum of meters for drives from ID 1600mm up to ID 2000mm: 61,210 m
Total sum of meters for drives from ID 2000mm up to ID 2500mm: 64,384 m
Total sum of meters for drives from ID 2500mm up to ID 3000mm: 31,162 m
Mix Shield TBM
Open Face Shield (excavators, roadheaders ...)
others
Reference List Overview
Total sum of meters for drives over ID 3000mm:
Distribution of advanced meters according to TBM Types
AVN-style TBM
EPB-style TBM
880 m
79,034 m
27,883
10,224
4,460
6,817
m
m
m
m

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 19
Geology
Requirements on
Navigation Systems
Specification of
the Tender
Type of Machine
Advance Technique
Technical
Requirements
Navigation System
Alignment
Geometry
Economical
Requirements
www.vmt-gmbh.de
Diameter
Customer
Requirements

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 20
Different Navigation Systems
Navigation Systems can be grouped in different
categories:
Laser-Target Systems
Laser-Total Station-Systems with Active Target
Gyro Systems with Hydro Level
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 21
Active
Laser
Target
www.vmt-gmbh.de
The Basic Package contains essential hardware components
System PC including
Navigation Module
SLS-Microtunnelling L
Cabling for 400m
Advance
System Description
Length
Measuring
System
Tunnel Laser
(optional)
Central Communication
Unit

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 22
The Basic Package with the implementable Navigation
Modules
SLS-Microtunnelling HL
System Description
SLS-Microtunnelling G
SLS-
Microtunnelling
Basis Package
www.vmt-gmbh.de
SLS-Microtunnelling LT
SLS-Microtunnelling
LT plus

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 23
Navigation Systems
SLS-Microtunnelling HL – Hydro level
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 24
Navigation Systems
SLS-Microtunnelling L - Laser
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 25
Navigation Systems
SLS-Microtunnelling LT – Laser Total Station
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 26
Navigation Systems
SLS-Microtunnelling G - Gyro
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 27
Navigation Systems
Display of TBM Position
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 28
Operating Principle of SLS-LT
www.vmt-gmbh.de
Laser based system working to an active target
Motorized Laser Total Station enables frequent,
automatic measurement cycles to all system points
Basic philosophy at the heart of the SLS-LT system “the
pipes will follow the hole made by the machine”
Position of Laser Station and Backsight Target is
determined in order to the recorded reference line of
pipes
Inclinometers are mounted in the system for roll
correction
Laser Total Station mounted on a self-levelling platform
Periodic control surveys are necessary to replace the
recorded reference line

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 29
Start Shaft Backsight Target
Target Length
Survey Prism
Measurement
System
Laser Station
SLS-LT Phase 1
TBM
Design Tunnel Axis
Control Cabin
Plan Section
Laser Station
www.vmt-gmbh.de
Target
TBM

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 30
SLS-LT Phase 2
Start Shaft Backsight Target Left Reference Prism Target Length
Survey Prism
Measurement
System
Laser Station Right Reference Prism TBM Design Tunnel Axis
Laser Station Reference pipe
www.vmt-gmbh.de
Control Cabin
Plan Section
Target
TBM

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 31
Start Shaft Backsight Target Left Reference Prism Target Length
Survey Prism
Measurement
System
Plan
SLS-LT Phase 3
Section
www.vmt-gmbh.de
Control Cabin
Laser Station Right Reference Prism TBM Design Tunnel Axis
Backsight Target
Survey Prism
Laser Station Reference pipe
Target
TBM

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 32
Survey Pillar In Shaft
Temporary Protection
for Laser Theodolite
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 33
Laser Station in 1800mm Pipe
Vertical
Tunnel Axis
200
532
195
617 592
1068
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 34
Total Station Clearance at
Maximum Roll of AD-12
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 35
www.vmt-gmbh.de
Various Laser Station mounting
options

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 36
Guidance System for Diameters
from 800mm to 4.0m
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 37
Target Types
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 38
ELS Target Support Bracket
www.vmt-gmbh.de
Target Support Bracket

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 39
Reference Prisms Mounted on
Clamping Ring
Prism
Clamping Ring
Prism
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 40
Backsight Prism
Backsight Inclinometer
www.vmt-gmbh.de
Backsight Prism and Inclinometer

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 41
Measurement Cycle
www.vmt-gmbh.de
1. Read values from LMS to determine chainage of Laser
Station.
2. Read inclinometers values.
3. Point Laser Total Station at the backsight target (BT) and
carry out distance measurement to determine the chainage
of the BT.
4. Point Laser Total Station at left reference target and record
values.
5. Point Laser Total Station at right reference target and
record values.
6. Point Laser Total Station at prism on the ALTU target and
record values.
7. Point Laser Total Station at centre of ALTU target and
record values.
8. Monitor reading of ALTU Target values.
9. Carry out calculations for the co-ordination of the new
reference point and TBM position in ALTU target plane and
cutter head.
10. Save data and values to file.
11. Display new measured and calculated values on operators
display.

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 42
System Editor
The system editor for entering of the system
parameters
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 43
Reference Line Editor
www.vmt-gmbh.de
The Reference Line Editor shows the as-built position of
the pipes

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 44
3D Model
www.vmt-gmbh.de
3-dimensional display of the as-built situation of the
pipeline

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 45
2D Position Plan
2-dimensional display of the as-built position in
relation to the surface
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 46
Data Viewer
Creates an advance report file
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 47
Internet Viewer
www.vmt-gmbh.de
Online Visualization and Remote Control Solutions

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 48
www.vmt-gmbh.de
Tunnel and Underground
Integrated Software structure
Online Visualization and Remote Control Solutions
separation plant
compression plant
PLC
user
photos
control cabin
manual
input
documents
user
PDA
user
user
TUnIS Server
manual
input
documents
email
SMS
MMS

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 49
Extension Modules
www.vmt-gmbh.de
The extension modules of VMT cover all requirements that appear
more and more in tenders for pipe jacking construction regarding
the documentation and data recording around all advance
processes.
We provide the sensors for the recording, automation, monitoring
and documentation. All extension modules can be integrated in
the system structure and will be recorded together with the data
of the Guidance System.

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 50
www.vmt-gmbh.de
Extension Module Data Recording
Length encoder and pressure
sensor at the steering
cylinders
Length encoder at the
interjack station

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 51
www.vmt-gmbh.de
Extension Module Heading Face
Distance
A non-contact distance meter is mounted in the cutting head of
an open face shield and measures continuously the distance to
the heading face. As soon as a pre-defined limit is exceeded a
warning will be shown on the system monitor. The measured
distance will be recorded in a file for documentation.

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 52
The Inclinometer Chain System INCS determines the vertical
position of the tunnelling machine. An evaluation of the
measuring data such as pitch and roll affords the precise and
continuous determination
This system can be used as an alternative to the electronic
www.vmt-gmbh.de
INCS Inclinometer Chain System
hydrostatic level, as a stand alone system or as an extension of
the electronic hydrostatic level for advance with great variations in
elevation.
Precise and continuous determination of the vertical position
Alternative to the electronic hydrostatic level
After installation it requires no supervision

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 53
GMS Gap Measurement System
www.vmt-gmbh.de
Gap Measurement System to record the joint gaps of
pipes

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 54
www.vmt-gmbh.de
AICS Automatic Interjack Control
System
The Automatic Interjack Control System AICS is intelligent
software that coordinates and monitors the opening and closing
of the interjack stations. During the advance, the interjack stations
can be activated individually or as a group.
Automatic interjack control during the advance
Optimize the advance process on long distance drives
Enables the machine to continue the advance independently
of the following pipeline
Assistance for the machine operator

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 55
MoVi Monitoring Video System
www.vmt-gmbh.de
A desired number of cameras can be placed in various locations in
the pipe line or on the surface to monitor and record interjack
stations, pumps or the separation plant.
The images recorded by the network cameras can be displayed on
the guidance system or on a external monitor and as file with
supplement information such as date, time and positioning.
Real-time visualization of dangerous places on site
Stand Alone System or as integrated version in a VMT
Navigation System
Optional recording of the images in defined intervals

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 56
Lubrication with Bentonite
www.vmt-gmbh.de
Filling of the annular gap created by the overcut
Reduction of the friction between pipe and ground
Reduction of jacking forces
Lower stress on jacking pipes
Avoiding of pipe damages
Enables longer drives
Enables curved drives
Successful completion of project

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 57
Manual Lubrication
www.vmt-gmbh.de
One worker goes frequently through the pipeline and
opens / closes the each valve by hand.
Additional manpower needed: long drives require
one person who is exclusively doing the lubrication
of the pipeline
One complete lubrication cycle takes a relatively
long time
The operator who sees directly the development of
the jacking forces has only limited influence on the
lubrication process
No documentation of bentonite consumption

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 58
Automatic Lubrication
www.vmt-gmbh.de
PC controlled pneumatic valves open and close automatically. Documentation
of consumption and pressure values.
The automatic procedure enables a continuous and reliable lubrication of the
whole pipeline
Enables shorter lubrication intervals
Faster and more effective lubrication of the pipeline
Operator controls lubrication process himself and can therefore react
immediately to changing jacking forces
The sequence of lubrication can easily be adapted, the lubrication can be
concentrated on critical areas, leaking areas e.g. near interjack stations can
be excluded
Clear and detailed documentation of the whole lubrication process including
consumption and pressure of bentonite as well as assignment to the
separate valves and cycles
No additional manpower necessary for the lubrication of the pipeline
especially in small diameter tunnels access to the tunnel is limited due to
safety regulations

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 59
Single Valve Lubrication
Ball Valve
Injection Nozzle
Electronic
Valve
Electronic
Valve
Electronic
Valve
www.vmt-gmbh.de
Concrete Pipe
Bentonite Coating
(annular
(annular gap)
gap)
Main Bentonite
Supply line
Ground

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 60
Ring Lubrication
Ball Valve
Injection Nozzle
Bentonite
Ring Line
Electronic
Valve
www.vmt-gmbh.de
Concrete Pipe
Bentonite Coating
(annular
(annular gap)
gap)
Main Bentonite
Supply line
Ground

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 61
www.vmt-gmbh.de
ABLS – Description of Hardware

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 62
www.vmt-gmbh.de
ABLS – Description of Software
Provides continuous and proper lubrication of the tunnel
Display of the already connected valves
Offers different lubrication methods
The user chooses the valves to be integrated in the
lubrication cycle
Lubrication time and max. lubrication pressure can be
defined for each single valve
The software allows the integration of the bentonite pump
itself – start/stop signals will then be given by the software
Data Recording:
consumption / pressure / lubrication time for each valve
total consumption, max. pressures, date, time, chainage

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 63
www.vmt-gmbh.de
ABLS – Description of Software
Integrated ABLS
The ABLS can easily be integrated to any existing navigation
system SLS-Microtunnelling
Uses the same cables and communication units as the
navigation systems
Software runs on the same PC
Stand-Alone ABLS
The ABLS can also be used independently from any
navigation system
Supports the operator also on short straight drives

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 64
Partner Valves
ball valve
injection
nozzle
combination of single
valve and partner valve
concrete pipe
www.vmt-gmbh.de
bentonite coating
(annular gap)
ground
main bentonite
supply line

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Slide 65
Analysis Tool
Graphical display of bentonite consumption per meter
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 66
www.vmt-gmbh.de
Hydraulic Joint by Jackcontrol ®
Real Time Monitoring System based on the
Hydraulic Joint

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 67
Loading of Pipes during the
Jacking Operation
Three Standard Cases
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 68
Deformation and Forces
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 69
The Hydraulic Joint
Idea
Principle of communicating Tubes / vessels:
Fluid pressure p = const.
www.vmt-gmbh.de
Complete Reversibility of the mechanical behavior of
non-compressible fluids
If a (f) = constant e = 0!
(a (f): specific contact area Pipe Face - Packer)

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 70
Compressed Hose Ring
q
=
pπ
⎡
⋅ ⎢d
+
2 ⎣
⎛ −
dp ⎞⎤
( δ − d ) ⋅⎜1
⎟⎥
⎝ 2k
⎠⎦
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 71
Cracking of the Concrete
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 72
www.vmt-gmbh.de
Spalling of the Concrete Cover

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 73
Sensor Unit
www.vmt-gmbh.de

Complex
Alignments
Navigation
System
System
Description
Extension
Modules
Page 74
The Hydraulic Joint
www.vmt-gmbh.de

Thank you for your attention
www.vmt-gmbh.de