View metadata, citation and similar papers at core.ac.uk brought to you by CORE provided by PORTO@iris (Publications Open Repository TOrino - Politecnico di Torino) POLITECNICO DI TORINO Repository ISTITUZIONALE Prediction of performance and cutter wear in rock TBM: Application to Koralm tunnel project Original Prediction of performance and cutter wear in rock TBM: Application to Koralm tunnel project / Brino, Gabriele; Peila, Daniele; Steidl, Arnold; Fasching, Florian. - In: GEAM. GEOINGEGNERIA AMBIENTALE E MINERARIA. - ISSN 1121- 9041. - 145:2(2015), pp. 37-58. Availability: This version is available at: 11583/2642312 since: 2016-09-29T11:28:53Z Publisher: Patron Editore S.r.l. Published DOI: Terms of use: openAccess This article is made available under terms and conditions as specified in the corresponding bibliographic description in the repository Publisher copyright (Article begins on next page) 04 August 2020 GEOINGEGNERIA E ATTIVITÀ ESTRATTIVA Gabriele Brino* Prediction of performance Daniele Peila* Arnold Steidl** and cutter wear in rock TBM: Florian Fasching** application to Koralm tunnel * DIATI, Politecnico di Torino **3G Gruppe Geotechnik Graz project 1. Introduction Excavation by Tunnel Boring Machines is the tunnelling method most frequently used nowadays in long infrastructural projects, in a wide range of geological conditions. In the last 40 years, many predic- Tunnel Boring Machines are tion models were developed to estimate TBM performance and cutter wear, using as input geological parameters. The research gives an overview of the existing penetration models for hard rock TBMs, nowadays a common and fruitful identifies the most frequently used input parameters and summarizes the characteristics of the da- option a tunnel designer can adopt, tasets on which the models are based on. Theoretical background is tested through the example of and technological advancements Koralm tunnel project, a 32.9-km-long base tunnel in Austria, in a 1000-m-long portion of the South allowed using them in a wide range tube in the construction lot KAT 2. The outcomes shows that the estimation of the penetration is of geological conditions, from hard reasonably accurate when applying models that are based on a database consistent with the project rock to loose soil. data, especially in terms of geology and typology of machine used in the excavation. The article pro- From the adoption of disc cutter poses a design method for a system of TBM data analysis and prediction at the construction stage, based on a back-analysis process about machine data in different geological conditions. The method- tools by James Robbins in 1956, TBM ology can be applied in any other project and the system is particularly useful in long tunnels, in which productivity improved year by year. a continuous improvement of the ability of prediction can have an effective impact on time and costs. Today peaks of advance rate per day Keywords: TBM, penetration, wear, utilization, prediction can go over 100 m/day, but, in adverse geologic conditions, a production of Previsione delle prestazioni e dell’usura degli utensili di una TBM da roccia: applica- less than 50 m/month may be experi- zione al progetto del Koralm tunnel. Lo scavo con Tunnel Boring Machine (TBM) è il metodo di enced (Barla and Pelizza, 2000). scavo più utilizzato per grandi progetti infrastrutturali al giorno d’oggi, in un’ampia varietà di condizio- ni geologiche. Negli ultimi 40 anni molti modelli predittivi sono stati sviluppati per stimare le presta- In the last 40 years, several au- zioni della TBM e l’usura degli utensili, usando come input i parametri geologici. Questa ricerca forni- thors (Cassinelli et al., 1982; In- sce una panoramica dei modelli esistenti per la stima della penetrazione degli utensili per una TBM in naurato et al., 1990; Rostami and roccia, identifica i parametri di ingresso più frequentemente utilizzati e sintetizza le caratteristiche dei Ozdemir, 1993; Gehring, 1995; Al- database da cui sono stati ricavati i modelli. I modelli teorici sono stati testati attraverso il caso studio ber, 1996; Bruland, 1998; Alvarez del progetto del Koralm Tunnel, una galleria di base lunga 32.9 km in costruzione in Austria, in una Grima et al., 2000; Barton, 2000; porzione della canna Sud di lunghezza 1000 m, facente parte del lotto KAT 2. I risultati mostrano che Ribacchi and Lembo Fazio, 2005; la stima è ragionevolmente accurata se si applicano modelli che su fondano su una base di dati con Yagiz, 2008; Gong and Zhao, 2009; caratteristiche simili a quelle del progetto, specialmente in termini di geologia e tipologia di macchina usato per lo scavo. L’articolo propone un metodo di progetto per la creazione di un sistema di analisi Hamidi et al., 2010; Hassanpour et dei dati della TBM e di previsione in fase costruttiva, basata su un processo di back-analysis di dati al., 2011; Farrokh et al., 2012) pro- macchina raccolti in differenti condizioni geologiche. La metodologia può essere applicata in qualsiasi posed models that allow to predict altro progetto, e il sistema è particolarmente utile in tunnel di grande lunghezza, nei quali una miglio- TBM performance and cutter wear. ria continua dell’abilità di previsione può avere un impatto rilevante in termini di tempo e costi. The aim of the work is to under- Parole chiave: TBM, penetrazione, usura, utilizzazione, previsione stand if the quality of the prediction, obtained through the adoption of Prévision de la performance et de la consommation des molettes pour un tunnelier à roche dure : application au projet du tunnel du Koralm. Le creusement avec un tunnelier these models, can be influenced by à roche dure est désormais la méthode de construction plus utilisée dans les projets d'infrastructures the characteristics of the databases longues, sur une fourchette très large de conditions géologiques. Dans les derniers 40 ans, beaucoup models in literature are based on (Bot- de modèles prévisionnels pour l'estimation de la performance et de la consommation des molettes tero and Peila, 2005). Data analysed pour un tunnelier à roche dure ont été développés, utilisant les paramètres géologiques comme don- in the study has been recorded during nées d'entrée. La recherche donne une vision globale des modèles existants en matière de pénétra- the excavation of the Koralm tunnel, tion pour les tunneliers à roche dure, elle identifie les paramètres d'entrée plus utilisés et elle synthé- a railway tunnel excavated in hard tise les caractéristiques des séries de données à la base du modèle. Les hypothèses théoriques sont testées sur l'exemple du projet du tunnel du Koralm, un tunnel de base autrichien de 32,9 km de rock in the southern Austria. longueur, et notamment sur une section de 1000 m de longueur du tube sud du lot constructif KAT 2. In mechanized tunnelling by Les résultats montrent que l'estimation de la pénétration est raisonnablement précise quand le TBM, the process of rock fragmen- modèle appliqué est basé sur une base de données cohérente avec les paramètres du projet, spé- tation is guaranteed by cutters, steel cialement en terme de géologie et de type de tunnelier utilisé pour le creusement. discs that are capable of dealing with Geoingegneria Ambientale e Mineraria, Anno LII, n. 2, agosto 2015, 37-50 37 GEORESOURCES AND MINING L'article propose une méthode de conception pour un système d'analyse des données du tunnelier 1.1.1. Analytical models et de prévision en phase de construction, basé sur un procès d'analyse à rebours des données ma- chine en conditions géologiques différentes. La méthode peut être appliquée sur d'autres projets et le système est particulièrement utile pour Analytical performance predic- des longs tunnels, où l'amélioration continue de la capacité prévisionnelle peut avoir un retour effec- tion models are based on the study of tif sur les délais et sur les coûts. the rock fragmentation process with Mots-clés: TBM, pénétration, consommation, utilisation, prévision. mechanical tools. From the results of full-size laboratory tests, as linear the high cutter loads required for discs in the same position, due to cutting and punch penetration, the hard rock and keeping a constant cutterhead design. This solution is authors individuated forces acting production and high abrasion resist- used when the load applied to the on the cutter, and thrust, torque and ance. cutter and/or the time of applica- power requirement of the TBM are The thrust acting on a single tool tion of the force is not sufficient for obtained from a balance of forces. consists of two forces: a component the detachment of a complete chip Analytical models usually com- of the force normal to the face, FN, (Rostami and Ozdemir, 1993; Bru- bine intact rock characteristics and a force tangential to the face, land, 1998). (mainly uniaxial compressive and the rolling force FR. tensile strength, ıc and ıt) with in- Two different processes can cause formation about the cutter (e.g. cut- rock breakage, when the TBM is 1.1. Prediction models ter diameter Ɏdisc, spacing scutters, tip pressed against the face, respective- width wtip, and thrust per cutter). ly single pass and multiple cutting Prediction models produce fo- They do not take in deep account process. Single pass cutting process recast in terms of penetration rate rock mass characteristics that recent consists in the detachment of rock (PR), that is the penetration of the studies (Bruland 1998; Ramezanza- chips, due to the action of two disc cutterhead per revolution, utiliza- deh, 2006; Gong and Zhao, 2007) cutters and is the process that more tion factor (UF), i.e. percentage of proved to be very important to un- frequently can occur. time in which the machine is actual- derstand TBM performance, as joint The effect of cutters on the rock ly working, and tools wear (Peila and frequency and joint orientation.