2012 –long distance pipe jacking -experience

7/29/2019 2012 long distance pipe jacking -experience

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1 1204-YU long distance pipe jacking

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Long distance pipe jacking , experience in PR Chia

Yu Bin Qian, Senior Engineer , GX Tunnel, gxtunnel*@gmail.com,

David Cheng [email protected],Technical advisor


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Index

0 Abstract Pg 2

1 The life of the machine 4

2 Grouting and grouting technology 6

3 Soil disposal 12

4 Intermediate jacking station 16

5 Measurements 21

6 Power and ventilation 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 longdistance 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 distance

jacking is now used to describe jacking distances 300m to 1000m


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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 tosolve 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 recentlyin China


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1) The life of the machine1) The life of the machine1) The life of the machine1) 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 thelife of the cutter and shaft seal.

The life of the cutter depend on the wear and tear of the cutter. To solve

the problem of good wear resistance of the cutter, the following considerations

are recommended :

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 inthe 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 Grouting2) Grouting and Grouting2) Grouting and Grouting2) Grouting and Grouting TechnologyTechnologyTechnologyTechnology

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 jackingconstruction.

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 theconstruction 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 bentonitemine, 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.

The grouting process in the longThe grouting process in the longThe grouting process in the longThe grouting process in the long----distance pipe jacking is also very importantdistance pipe jacking is also very importantdistance pipe jacking is also very importantdistance 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. Thequality 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 outputripple, 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 disposal3) Soil disposal3) Soil disposal3) 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 thedistance 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 pumpdischarge 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

4444 The use of intermediate jacking stationsThe use of intermediate jacking stationsThe use of intermediate jacking stationsThe 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

4 5 6

7 8 9

10 11 12 13

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


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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 isreusable.

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 shelland 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 anti-

Relay 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 pumprelay, 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 fueltank 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 Measurements5 Measurements5 Measurements5 Measurements

Long-distance pipe jacking construction survey measurement of the tenders

LPS laser guidance system. LPS laser guidance system is shown in Figure -9, itmainly 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 ventilation6 .Power and ventilation6 .Power and ventilation6 .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 voltageregulator 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 waveformdistortion, 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 regulatorSBW-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 sequenceprotection and mechanical failure


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Table 1

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

(A) (cm) (kg) (cm)

PBW-F320K 485 110145185 1100 120155210

SBW-F350K 530 110145185 1350 120155210

SBW-F400K 603 110145185 1450 120155210

SBW-F450K 682 110145185 1850 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

100m300m1000m

>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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,

1 4


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1

2


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30

3


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4

4

200720067906056 400m

5 400m


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6 400m

7 13

7


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1 2 3

4 5 6

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

LPSLPS

9

LPS PC

9

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

----------ASCII209600RS232/TTY


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------------IP6712

---------- 60 110

----------1

------------0.1

----600~700

------ 1~5

LPS ---100

LT202 1000m 800m

800m

LPSRS232

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) (kg) (cm)

SBWSBWSBWSBW----F320KF320KF320KF320K 485485485485

110110110110145145145145

185185185185

1100110011001100

120120120120155155155155

210210210210

SBW-F350K 530

110145

185

1350

120155

210

SBW-F400K 606 110145 1450 120155


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185 210

SBW-F450K 682

110145

185

1850

120155

210

SBW-F

1500m SBW-F

500m

150m 800m

CF-6

800m DN3600 30m

CF-5

CF6

CF5 30m

2012 –long distance pipe jacking -experience

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Transcript of 2012 –long distance pipe jacking -experience