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distance pipe jacking

Long

distance pipe jacking , experience in PR

Chia

Yu Bin Qian, Senior Engineer , GX Tunnel, gxtunnel*@gmail.com, David Cheng tunnelcon@gmail.com,Technical advisor

1204-YU long

distance pipe jacking

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distance pipe jacking

Index 0 1 2 3 4 5 6 Abstract The life of the machine Grouting and grouting technology Soil disposal Intermediate jacking Measurements Power and ventilation station Pg 2 4 6 12 16 21 25

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Abstract Long Distance Pipe Jacking Discussions on Problems and prospective The definition of long-distance pipe jacking /pipe jacking technology continues to change. In the past, usually 100m length for such work was considered long-distance pipe jacking. However, with the development of increasingly sophisticated pipe jacking machines with the improvement in jacking accuracy especially with the improvement of the Grouting lubricating materials and grouting technology, regardless of the size of the pipe diameter, a continuous jacking 100m seems to have become an easy task, therefore, now long distance jacking is now used to describe jacking distances 300m to 1000m length .For length > 1000m length the term ultra-long distance pipe jacking may be used . Long distance pipe jacking required to master the following techniques and to solve the following problems: 1, the service life of the pipe jacking machine 2, grouting lubricating materials and grouting technology 3, Soil conveyance and disposal ; 4, the use of the relay/Intermediate jacking stations; 5, the tolerance and measurement technique ; 6, power supply and ventilation The paper describe the challenges involved in such long distance works recently in China
Abstract Long Distance Pipe Jacking Discussions on Problems and prospective The definition of long-distance pipe jacking /pipe jacking technology continues to change. In the past, usually 100m length for such work was considered long-distance pipe jacking. However, with the development of increasingly sophisticated pipe jacking machines with the improvement in jacking accuracy especially with the improvement of the Grouting lubricating materials and grouting technology, regardless of the size of the pipe diameter, a continuous jacking 100m seems to have become an easy task, therefore, now long jacking is now used to describe
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distance

jacking distances 300m to 1000m

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length .For length > 1000m length the may be used .

term ultra-long distance pipe jacking

Long distance pipe jacking required to master the following techniques and to solve the following problems: 1, the service life of the pipe jacking machine 2, grouting lubricating materials and grouting technology 3, Soil conveyance and disposal ; 4, the use of the relay/Intermediate jacking 5, the tolerance and measurement technique ; 6, power supply and ventilation The paper describe the challenges involved in such long distance works recently in China stations;

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1) The life of the machine Long-distance pipe jacking slurry pipe jacking machine or earth pressure balance pipe jacking machine, its life is mainly reflected in two aspects : that of the life of the cutter and shaft seal. The life of the cutter depend on the wear and are recommended : tear of the cutter. To solve the problem of good wear resistance of the cutter, the following considerations

The first is designed to grasp the speed of the cutter. Speed is too fast, the wear of the cutter will increase; too slow, the pace of jacking affected. Generally peripheral line of the knife plate at the speed of 10m/min to 15m/min. At the same time, VVVF speed control to adjust speed of the cutter. Jacking in the sandy soil can knife plate to reduce speed; jacking in clay in a can knife disk speed increase. Mother is to minimize the wear of the cutter. Followed in the selection of the cutter material, have a good wear resistance. Meanwhile, the local heap is easy to wear in the cutter body to wear welding. Once again, in the selection of the cutter, cutting tool materials, pay attention to the election only to have better wear resistance at the same time must also have good toughness, and only prefer to use this material cutter cutting tool. Is usually the better the wear resistance of cutting tool materials, their brittleness also increased. If you prefer to use this material, in the event of stones, the cutter may be crashing, but reduces the life of the cutter. The service life of the shaft seal is the key to distance pipe jacking. Usually the life of a long spindle seal in two forms: one is a variety of styles, multi-channel ring a combination of a shaft seal; the other is continuously injected to the spindle seals lithium Grease, lithium Grease along the annular gap between the spindle and spindle extrusion, to prevent the intrusion of muddy water, sediment. Former life of 1000-1500 hours, the latter useful life of more than 2000 hours.

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2) Grouting and Grouting Technology

The use of lubricating slurry to reduce the frictional resistance of the jacking pipe surrounding one of the most economical means of long distance pipe jacking construction. At present, there are three types of lubrication slurry material: The first completely synthetic polymer materials. The second category is a natural bentonite-based, appropriate to add some auxiliary materials, the process is carried out entirely in the factory, just watered can be used. Lubrication pulp properties of the materials are relatively stable, but the gap between each product must be carefully screened. The third category is the bentonite plus tackifier, dispersant at the construction site from the deployment. Lubrication slurry performance the most unstable, the indicators are not easy to control. The first synthetic polymer grouting material is characterized by relatively simple modulation, tune into relatively large particles, it is suitable for pipe jacking in the gravel. However, its high price, and so far the country has not finished products for sale. Mineralogical name of the bentonite called montmorillonite is composed of nanoscale particles (10-11 ~ 10-9m), it is also known as a natural nano-materials. We Recommend lubrication slurry material. Sodium bentonite and calcium bentonite . The two major categories of natural bentonite can be classified according to chemical composition. Sodium bentonite is superior to many physical and chemical properties or process performance than calcium bentonite due to the following reasons : 1.An absorbent future expansion in multiples of: sodium bentonite can absorb five times its own weight of water, swelling up to 15 times its own volume. Calcium bentonite expansion is only about three times its own volume. 2, high cation exchange capacity. 3, good dispersion in aqueous media. 4 glial highest bid. 5, heating and good stability. Sources : Xuanhua, Zhangjiakou, Jinxi, Montenegro, nine, Xinyang, Toksun, abundance,
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Jinchang, Xing, Yasuaki, Yushan, Jixi, Liyang, Yuhang, Linan and other hundreds of mining in our country, which 90% calcium bentonite. Zhejiang Linan Hirayama is a natural high quality sodium bentonite ore producing areas of China's rare. Pipe jacking lubrication slurry grouting with bentonite must be a natural sodium bentonite, rigorous drying, crushing, drying, milling, sifting, plus process, processed into semi-finished products. Then, based on different usage requirements, add a variety of supporting material. Finally, the product of a series of experiments, only qualified after the packaging for the finished product. There are many producing areas of the mine is not a natural sodium bentonite mine, but calcium-based bentonite mine. So, take the approach of artificial sodium calcium bentonite to exchange with sodium ions. Na sodium carbonate plus a certain amount of water, to have sufficient exchange of free sodium ions with calcium bentonite mixed evenly, and then apply some pressure. Round grind extrusion, double-screw extruder, extrusion, etc., in order to increase the contact area of the sodium and calcium bentonite on the stick, accelerate the sodium ion exchange in this process of calcium. At the same time, make bentonite temperature in the mechanical extrusion process, thereby speeding up the rate of movement of sodium ions, to expand the scope of the movement of sodium ions, resulting in accelerated sodium calcium exchange. After artificial sodium after calcium bentonite slurry rate can only reach about 18.00m3 / t. The easiest way to distinguish the pros and cons of the pipe jacking lubrication slurry grouting with bentonite material is to take the same weight of material, blended with 10 times the water, after full mixing, expansion, and measured their funnel viscosity, large better. Funnel viscosity should generally be small and 38 seconds. The serous modulation is a dire need to pay attention to. Modulation of the slurry, after full mixing. Stirring mechanical force can also be water. But any kind should be noted that the uniform mixing. Modulated serous place for some time, insert a wooden pencil, pencil self-reliance in the slurry does not fall, means that the slurry can be used. longimportant. The grouting process in the long-distance pipe jacking is also very important
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First of all, in fine sand and sand jacking, grouting hole with a one-way valve. If no check valve, when the grouting is stopped, the tube outside the silt along the grouting pipe flow of pipe, and settle down, the grouting pipe plug. The quality of the grouting effect and not one-way valve has a great relationship. Secondly , the Grouting procedures should attract attention. In general, the sections of pipe jacking machine should note enough lubrication paste it well to form a complete set of pulp. Note foot tube lubrication pulp slurry is designed to complement plasma sets intact. If there is a long time stopped jacking, as long as this section of the top tube is not over, and grouting work can not stop every three to four hours across the board meeting note a lubricating slurry. Third, the injection pump screw pump is good, because the slurry screw pump output ripple, easy to form a slurry sets. Slurry piston pump output ripple, the effect will be relatively poor. Fourth, in theory, the grouting pressure is generally only need to slightly higher than the ground water pressure a little can. However, this depends on soil. If the clay is the leakage coefficient is small, injection pressure, some can also be. But if it is sand, the leakage coefficient, the grouting pressure should also be larger, and lubrication slurry should be adjusted thick some. Only in this way, lubrication slurry to form a parcel in the tube of the appearance of plasma sets. Fifth, the grouting, the pulp need to have the person responsible. Moreover, each class of the grouting pressure, grouting the amount of grouting process should have a complete record.

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3) Soil disposal Slurry pipe jacking spoil and add material into the mud and then discharge it with a pump, there are no problems in this long-distance pipe jacking, if the distance increases by simply adding the middle of the water, mud pump can a. Earth pressure balance pipe jacking spoil transport within the tube to solve many kinds: one is to spoil soil bucket load of electric vehicles shipped out of the other is to spoil modulation into the muddy water with the pump discharge suffering from a soil sand pump directly to the spoil discharge. The merits of the battery car earthmoving spoil can be mounted directly on the truck moved away, the drawback is that the spoil in the pipe can not be continuous conveyor, reducing the efficiency. Spoil modulation advantage of the mud pump discharge spoil in the pipe can continuously transport, improve efficiency, but the drawback is the only transport in the mud to be precipitation or separated, the cost is too high. Discharge the spoil soil sand pump directly to the best of both worlds.

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Yangzhou wide Xin successfully developed patented products - soil sand pump dump. Action principle see Figure -1 to -4.

1 ,-1 Soil sand pump appearance (except tubing)

2 ,-2 Sleeve stretch (soil)

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3 , -3 Sleeve stretch in place after the piston extension (Pressure soil)

4 , Figure -4 piston extension in place, the sleeve and piston retraction The sleeve and the piston in place with the retraction end of the loop (as shown in Figure -4), the next cycle begins. Patent application number: 2007200679060. -5, -6 Is the situation when the soil sand pump the 400m lose soil test.
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5 400m ,Dump status -5 soil sand pump 400m lost to soil test

6 400m figure -6 soil sand pump 400m lose soil test pipe and elbow site

4 The use of intermediate jacking stations

Relay between the structure of steel pipe and reinforced concrete works two kinds, much the same structure. Reinforced concrete pipes for the relay structure with -7 as shown, which consists of 13 parts:

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7 1 2 3 6

4 5

7 8 9 10 11 12 Figure -7 1, the first concrete pipe, concrete pipe interface ring, wood pad ring 4, before the fuel tank mounting flange 5, the relay between the fuel tank 6, the fuel tank mounting flange 7, with inflatable sealing ring 8, repair inflatable sealing ring 9, before the shell 10, after the shell, wood pad ring 12, the concrete pipe interface ring 13, after the concrete pipe 13

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Before and after the concrete pipe, concrete pipe joints seals, wood pad ring is exactly the same with the top tube. Before and after the fuel tank mounting flange is used to install the fuel tank between the fixed relay, the flange is reusable. Both ends of the cylinder in the relay mounting plate, the plate at the same time as the front and rear flange of the connecting plate, which makes installation and removal of the fuel tank in the relay are very convenient. Work after the inflatable sealing ring placed in the relay must be inflated in order to avoid leakage. During use, it must also always been in the inflated state. When there is leakage between the relay, to supplement its inflatable. Relay between the inflatable sealing ring wear ring affixed to the first shell and wear rings inflatable pouch. If the wear ring wear can be replaced. Repair of the inflatable sealing ring is usually not inflated only when the work with inflatable sealing ring wear ring wear and normal use of the need to replace the wear rings when their inflatable. Sufficient gas in the airbag of the inflatable sealing ring repair first before replacing the wear ring, then let go of the inflatable sealing ring airbag gas, and then remove the flange can be replaced. In general, when the fuel tank of the main roof about 70% of the total thrust, must be placed relay. Such as the fuel tank design of the main roof thrust of 800t (31.5MPa), then, when the fuel tanks of the main roof thrust of 560t (about 22MPa) must be placed in the relay. When the main top cylinder is about 80% of the total thrust, it must be enabled relay. Such as the total thrust of the main top of the fuel tank design for the 800t (31.5MPa), then, when the cylinder of the main roof thrust of 640t (about 25MPa) must be enabled relay. Be sure to leave room for about 20% to prevent the process of jacking thrust changes. The factory relay is assembled as a whole, but the sealing ring and inflated. Between placed relay must be shown as placed in the anteroposterior direction must not be put out antiRelay placement should work after a good inflatable with inflatable sealing ring 7, the inflation pressure of 0.4 MPa. Inflatable work can be completed with the ordinary pump. Relay cylinder is a plunger-type single-acting cylinder: it can only be stretched out, not their own retraction to retraction only relied on the back of the fuel
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tanks of the main roof or relied on the back of a relay between into the top of the fuel tank. Relay cylinder stroke of 300mm. Relay between the fuel tank tubing in parallel in an Explorer, open the pump relay, then through the manual valve this root Explorer relay between the pump inlet connection, then to the relay The fuel tank will be stretched out. When they reached out to the 300mm, you should immediately make the reversing valve, that is, this root Explorer and relay the tank back to the oil port. At this time, if the main top of the fuel tank forward into the top, the relay between the fuel tank slowly retracting place. Continue to repeat the process until the tube top into place. The next can be a relay between the fuel tank removed, and then around the fuel tank mounting flange removed and let the relay close.

8 900m Figure -8 intermediate jacking station Figure 8 is a relay into the top 900m of the application instance. The left rough pipe mud tubes, the right flat out blast pipe, and the left front of the relay between the pump station. In addition, the main push, relay and pit the main roof using the programmable logic controller (PLC) to control their individual has the action and order.

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5 Measurements Long-distance pipe jacking construction survey measurement of the tenders LPS laser guidance system. LPS laser guidance system is shown in Figure -9, it mainly consists of the laser transmitter (usually a laser theodolite or laser pointing instrument), laser electron receiving target (LPS) and the PC.

9 , 8 10mm 0.1mm

Figure 9 laser measurement Laser electronic receiver target in photoelectric sensors can distinguish between exposure to the laser electron receiving target panel, usually the center of gravity of 8 to 10mm diameter red laser beam relative to the panel between the centers, only a difference of 0.1mm the exact location. Laser transmitter is fixed in the pit of the work, and the red laser beam represents the design of the center axis of the laser electronic receiver target is installed in the pipe jacking machine, laser guidance system by LPS can be accurately measured top tube machine location and design of the central axis of the deviation. When LPS and PC connections, laser electron receiving target panel shows the PC display output interface is shown in Figure -10.

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10 LPS PC Figure -10 LPS and PC to connect the output of the interface LPS laser guidance system, the main parameters and technical indicators are as follows: External dimensions ---------- high 135mm wide 173mm deep 125mm with flange; high 113mm wide 173mm deep 125mm, without flange Protection class ---------- IP65, with reference to DIN40050 Weight -------------- 2 kg Operating Temperature ----------- 10 - 60 C Power -------------- 24 6VDC, 5W Output interface ---------- RS232, TTY, or PROFIBUS-DP Data Format ---------- ASCII code 20 ms transmission time, 9600 baud (RS232/TTY) Connector ------------ IP67 protection, 12-core plug-ins Measuring range ---------- 60 mm, 110 mm wide Measurement accuracy ---------- 1 mm Resolution ------------ 0.1 mm Laser wavelength range ---- 600 ~ 700 nm The laser sensitivity ------ a variety of continuous emission wavelength of the laser power of 5 mW Laser with LPS distance - 100 meters or more, depending on the specific circumstances in accordance with the performance of the laser transmitter. Laser theodolite selected the LT202 type, its effective range of the longest (at night) up to 1000m, jacking length of less than 800m, is straight top tube, the
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measurement is relatively simple. If more than 800m in the middle of a station. Pipe jacking machine, within the measurement target is symmetrical, so add a station is very convenient. At the construction site, but also to LPS laser-guided systems, transmission cables and RS232 interface to connect to the supervision of the Engineer's Office on a PC. And to the Office of the supervising engineer in real-time synchronous transfer all the data measured, this real-time monitoring to ensure that the supervising engineer.

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6 .Power and ventilation

Long-distance supply high voltage power supply, there is a certain risk, the proposed switch to SBW three-phase automatic compensating power voltage regulator to compensate for the long distance to send the electricity voltage drop. These products is the introduction and absorption of advanced technology in Western Europe, combined with China's national conditions, designed to stabilize the AC voltage, and can automatically maintain the stability of the output voltage when the external power supply network voltage fluctuations or load changes caused by voltage fluctuations. Is commonly used in 380V voltage available 380V leakage, electric shock protection devices. The series has the advantages of large capacity, high efficiency, no waveform distortion, stable voltage regulation, applicable to a wide range of load can withstand instantaneous overload, long-term continuous work, manual / automatic switch, equipped with overvoltage protection, phase loss, phase sequence protection and mechanical failure of automatic protection, as well as small size, light weight, easy installation, reliable operation.

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Figure 11 is the shape of the SBW three-phase automatic compensation power regulator, each set of two cabinets. Specifications shown in Table -1, SBW-F350K models can be selected in the tenders top tube.

11 SBW Figure -11S-BW-F three-phase sub-tuning automatic compensation power regulator SBW-F three-phase sub-tuning automatic compensation power regulator, SBW series product to be improved voltage regulator, suitable for three-phase voltage input unbalanced grid when the grid fluctuations or load current transformer, three phase The output can automatically balance and maintain a stable voltage regulation advantages. Product performance Input voltage: three-phase four-wire voltage 380V 20% 220 20% line voltage or phase voltage 220V 30% line voltage 380V 30% (orders need to explain) Output voltage: three-phase phase voltage 220V line voltage 380V Output accuracy of 2-5% (adjustable) Frequency: 50Hz/60Hz Efficiency: 95% (power level a 50KVA above) Response speed: 1.5S (10%) of the external voltage changes Ambient temperature: -10 - +40 Insulation resistance: 2M Electrical strength: power frequency sinusoidal voltage 2000V for 1 minute without breakdown and flashover
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Overload: two times the rated current for 1 minute Waveform distortion: no additional waveform distortion Protection function: over-voltage, over current, lack of phase, phase sequence protection and mechanical failure

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Table 1
Serial power (A) (A) Size (cm_ (cm) Weight (Kg) (kg) Packing size (cm) (cm)

PBW-F320K SBW-F350K SBW-F400K SBW-F450K

485 530 603 682

110145185 110145185 110145185 110145185

1100 1350 1450 1850

120155210 120155210 120155210 120155210

Because in the ultra-long top tube, even if the power supply transformer from the SBW-F series three-phase sub-tone automatic compensating power voltage regulator 1500m no problem. Therefore, the SBW-F three-phase sub-tone full-automatic compensating power voltage regulator can be easily installed in the machine pipe from the top 500m pipeline to solve the long-distance supply voltage drop too much contradiction. Ventilation in the long-distance pipe jacking construction can not be ignored, and its direct impact on the health of construction workers in the tube, can be a single drum or drum pumping a combination of ventilation systems. With the advancing distance increases, when advancing to a length of 150m, it is necessary to install ventilation device. 800m or less, in the form of ventilation can only use the CF-6-type axial-flow blower two series, the lookout has been drum reach the peak tube inside. When the advancing length of 800m above, in addition to the blast outside the DN3600 steel pipe from the hole 30m at the re-established a ventilation tube, the CF-5 axial flow exhaust fan ventilation to increase air flow in the steel pipe. Ventilation using long short drum pumping blast to the head at the series with two CF-6 blower, and then a CF-5 exhaust fan the lookout pipe is always located at a distance out of the hole 30m at ventilation, such The air in the pipe to form a cycle, smoke and harmful gases to discharge welding process.

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100m 100m 300m1000m >1000m 1 2 3 4 5 6

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10m/min 15m/min VVVF (WEAR RESISTance)(ductility) (lithium grease) 1000 1500 2000

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(10-1110-9m) 1 5 15 3 2 3 4 5 90
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18.03/
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4 200720067906056 400m

5 400m

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6 400m 7 13

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2 3 6

4 5

7 8 9 10 11 12 13 70% 800t(31.5MPa) 560t( 22MPa) 80% 800t(31.5MPa) 640t( 25MPa)

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20% 7 0.4 MPa 300mm 300mm

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8 8 900m PLC LPS LPS 9 LPS PC

8 10mm 0.1mm LPS

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LPS PC PC 10

10 LPS PC LPS ---------- 135mm 173mm, 125mm ; 113mm 173mm, 125mm ----------IP65 DIN40050 --------------2 ---------- -1060 --------------246VDC5W ----------RS232TTY PROFIBUS-DP ----------ASCII 20 9600 RS232/TTY
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------------IP67 12 ---------- 60 110 ----------1 ------------0.1 ----600~700 ------ 1~5 LPS ---100 LT202 1000m 800m 800m LPS RS232 PC

SBW 380V 380V

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/ 11 SBW 1 SBW-F350K

11 SBW-F SBW 22020% 380V20% 220V 30% 380V30%()

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220V 380V 2-5() :50Hz/60Hz 95%( 50KVA ) 1.5S( 10%) -10 +40 2M 2000V 1 1 1 (A) (cm) 110145 110145 SBWSBW-F320K 485 185 110145 SBW-F350K 530 185 SBW-F400K 606 110145 1450 1350 210 120155 1100 210 120155 (kg) (cm) 120155 120155

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185 110145 SBW-F450K 682 185 1850

210 120155 210

SBW-F 1500m SBW-F 500m 150m 800m CF-6 800m DN3600 30m CF-5 CF6 CF5 30m

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