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Muck transport in an open system Muck pumping systems The accessories – pipelines, sluices, damping systems ... clean and safe muck transport for modern tunnelling and mining methods Boundary layer lubricant injection nozzle This reduces the pressure significantly and thus protects the pump. This means less costs, since both pipeline and pump can be reduced in size. In addition there is an approximately 50 % reduction in the energy requirement. Stiff materials are conveyed over large distances at low pressure. The boundary layer lubricant injection nozzle reduces wear in the pump and pipeline The “power damper” ensures that delivery is even and continuous The POS controls and monitors the complete muck-removal installation ZX delivery lines are eminently suitable for conveying muck over long distances Control systems The Putzmeister POS operating system enables the user to control and monitor all parameters automatically. It functions independently or as an integral component of the tunnelling machine’s central control system. Hydraulically controlled pressure valves (HMC-S) MPT muck pump for the open system When pumping at high pressure material sometimes flows back during switchover. This is prevented by a valve fitted downstream. The open system Such an installation generally consists of: The open system is used where the muck is moved by excavators or where the material has to be crushed or mixed before being pumped. ■ a double-piston pump ■ a hydraulic aggregate ■ a mixing trough HMC-S valves are used for fine-grain or pasty material. The valve seats are particularly resistant, guaranteeing a hermetically sealed system. In addition they prevent nozzle wear. The muck has to be made pumpable. Crushers or mixers are attached to the system for this purpose. Alternatively complete muck pump systems are used. Examples of this are the MPT 16 and MPT 40 “muck pump tunnel” installations. The “processed” muck is then conveyed openly to the pump, which delivers the material above ground. The extremely compact MPT 16, for example, is eminently suitable for use in small pipes from ND 1400 upwards. The HMC-S valve effectively prevents the back-flow of muck into the pump Putzmeister Products and Services Concrete Pumps · Industrial Technology PIT · Telebelt · Mörtelmaschinen GmbH · Dynajet High Pressure Cleaners · Services · Concrete Project Division CPD · Consulting and Data Technology · Academy Putzmeister AG Max-Eyth-Str. 10 · D-72631 Aichtal P.O.Box 2152 · D-72629 Aichtal Tel. +49 (7127) 599-0 Fax +49 (7127) 599-520 www.putzmeister.com E-mail: [email protected] Very good pumpable material from a EPB tunnel boring machine TS 2616-2 GB TS 2616-2 GB TS 2616-2 GB Right to make technical amendments reserved · © by Putzmeister AG 2007 · All rights reserved · Printed in Germany (10704RR) The process – clean and economical transport by pipeline Muck transport in a closed system Muck transport to the surface Two muck transport methods Tunnelling produces excavated muck which has to be transported from the tunnelling machine’s discharge system through the tunnel to the surface. File under: A 1.00, A 4.00, IP 4.05 Which process is used depends upon the geological and logistical conditions, and also upon the space available in the tunnel. ■ Muck delivery in a closed system ... ■ ... and in an open system A system of this type will generally consist of the following components: The closed system ■ A KOS double-piston pump to convey the material to the surface and maintain the earth pressure ■ An electronic control unit for pump and tunnelling machine to ensure the reliable operation of both units ■ A hydraulic power pack to drive the KOS ■ A stone trap to detect blockages in the pipeline and protect the pump ■ Flexible pipeline systems comprising hose lines or pipe scissors Here the muck pumps are connected pressure sealed directly behind the outlet of the screw conveyor of the tunnelling machine. Care must be taken that the material to be transported is readily pumpable. Delivery by pipeline with high-performance piston pumps is becoming increasingly popular. The advantages are obvious: ■ Space-saving, e.g. for driving pipelines in a small tunnel ■ The clean and safe transport of excavated muck over long distances ■ High output ■ Addition of water rarely or not at all necessary ■ Simple logistics – no muck cars needed ■ Operational safety ■ Continuous delivery guaranteed, even with pressure locks There are two applied methods of delivering excavated muck using pipelines: In a closed system the existing earth pressure is maintained throughout the pump. This prevents water and mud penetrating the tunnel unchecked. The pumps transport the soil through the pipeline to the surface. The muck can be treated either naturally or with bentonite and polymers. Example – the Størebelt Tunnel in Denmark ■ The earth and water pressure of up to 0.8 MPa (116 psi) had to be maintained in order to prevent the inflow of groundwater ■ The rocks mixed with groundwater were then conveyed from the screw conveyor to the muck cars … ■ … and unloaded above ground under atmospheric pressure Flanged-on muck decompression pump The pump system A KOS double-piston pump is generally used for muck delivery. This type of pump is particularly suitable for coarsegrain material with a high solids content. It produces pressures of up to 20 MPa (2900 psi) and outputs of up to 500 m3/h. The hydraulic power pack Pumping of stiff muck through a pressure lock Putzmeister high-density pumps are hydraulically driven. This type of drive enables the system to respond to virtually any practical situation with great versatility and flexibility. Double pumps supply a performance of up to 250 m3/h per pump unit. This means that by using double pumps, tunnel machines can be equipped with diameters of up to 14 metres. Numerous operations in Asia and also in Europe (e.g. Botlek Tunnel in the Netherlands) demonstrate the strengths of this method compared to the transport of the soil by centrifuged pumps or via conveyor belts. KOS S-tube piston pump All important data, such as oil temperature and pressure and the degree of filter contamination, are displayed for greater operating precision. ■ Servicing is infrequent and wear is minimal since the KOS has few moving parts ■ Because of the generous and free material flow the suction resistance is particularly low ■ The hydraulic circuit is kept well separated from the conveyed material London Heathrow tunnel Two Putzmeister single-piston decompression pumps removed 200 m3/h of untreated loamy soil from the shield area supported by compressed air. This prevented the ground from subsiding and the loamy soil was not contaminated by auxiliary fluids, such as bentonite or polymers. The stone trap The stone trap has sensors to detect blockages in the suction line. In such a case the pump shuts down. Any stones caught in the pipeline section of the stone trap can then be easily removed. Screw conveyor with two muck pumps type KOS 1480 TS 2616-2 GB TS 2616-2 GB Muck transport in an open system Muck pumping systems The accessories – pipelines, sluices, damping systems ... clean and safe muck transport for modern tunnelling and mining methods Boundary layer lubricant injection nozzle This reduces the pressure significantly and thus protects the pump. This means less costs, since both pipeline and pump can be reduced in size. In addition there is an approximately 50 % reduction in the energy requirement. Stiff materials are conveyed over large distances at low pressure. The boundary layer lubricant injection nozzle reduces wear in the pump and pipeline The “power damper” ensures that delivery is even and continuous The POS controls and monitors the complete muck-removal installation ZX delivery lines are eminently suitable for conveying muck over long distances Control systems The Putzmeister POS operating system enables the user to control and monitor all parameters automatically. It functions independently or as an integral component of the tunnelling machine’s central control system. Hydraulically controlled pressure valves (HMC-S) MPT muck pump for the open system When pumping at high pressure material sometimes flows back during switchover. This is prevented by a valve fitted downstream. The open system Such an installation generally consists of: The open system is used where the muck is moved by excavators or where the material has to be crushed or mixed before being pumped. ■ a double-piston pump ■ a hydraulic aggregate ■ a mixing trough HMC-S valves are used for fine-grain or pasty material. The valve seats are particularly resistant, guaranteeing a hermetically sealed system. In addition they prevent nozzle wear. The muck has to be made pumpable. Crushers or mixers are attached to the system for this purpose. Alternatively complete muck pump systems are used. Examples of this are the MPT 16 and MPT 40 “muck pump tunnel” installations. The “processed” muck is then conveyed openly to the pump, which delivers the material above ground. The extremely compact MPT 16, for example, is eminently suitable for use in small pipes from ND 1400 upwards. The HMC-S valve effectively prevents the back-flow of muck into the pump Putzmeister Products and Services Concrete Pumps · Industrial Technology PIT · Telebelt · Mörtelmaschinen GmbH · Dynajet High Pressure Cleaners · Services · Concrete Project Division CPD · Consulting and Data Technology · Academy Putzmeister AG Max-Eyth-Str. 10 · D-72631 Aichtal P.O.Box 2152 · D-72629 Aichtal Tel. +49 (7127) 599-0 Fax +49 (7127) 599-520 www.putzmeister.com E-mail: [email protected] Very good pumpable material from a EPB tunnel boring machine TS 2616-2 GB TS 2616-2 GB TS 2616-2 GB Right to make technical amendments reserved · © by Putzmeister AG 2007 · All rights reserved · Printed in Germany (10704RR) Muck transport in an open system Muck pumping systems The accessories – pipelines, sluices, damping systems ... clean and safe muck transport for modern tunnelling and mining methods Boundary layer lubricant injection nozzle This reduces the pressure significantly and thus protects the pump. This means less costs, since both pipeline and pump can be reduced in size. In addition there is an approximately 50 % reduction in the energy requirement. Stiff materials are conveyed over large distances at low pressure. The boundary layer lubricant injection nozzle reduces wear in the pump and pipeline The “power damper” ensures that delivery is even and continuous The POS controls and monitors the complete muck-removal installation ZX delivery lines are eminently suitable for conveying muck over long distances Control systems The Putzmeister POS operating system enables the user to control and monitor all parameters automatically. It functions independently or as an integral component of the tunnelling machine’s central control system. Hydraulically controlled pressure valves (HMC-S) MPT muck pump for the open system When pumping at high pressure material sometimes flows back during switchover. This is prevented by a valve fitted downstream. The open system Such an installation generally consists of: The open system is used where the muck is moved by excavators or where the material has to be crushed or mixed before being pumped. ■ a double-piston pump ■ a hydraulic aggregate ■ a mixing trough HMC-S valves are used for fine-grain or pasty material. The valve seats are particularly resistant, guaranteeing a hermetically sealed system. In addition they prevent nozzle wear. The muck has to be made pumpable. Crushers or mixers are attached to the system for this purpose. Alternatively complete muck pump systems are used. Examples of this are the MPT 16 and MPT 40 “muck pump tunnel” installations. The “processed” muck is then conveyed openly to the pump, which delivers the material above ground. The extremely compact MPT 16, for example, is eminently suitable for use in small pipes from ND 1400 upwards. The HMC-S valve effectively prevents the back-flow of muck into the pump Putzmeister Products and Services Concrete Pumps · Industrial Technology PIT · Telebelt · Mörtelmaschinen GmbH · Dynajet High Pressure Cleaners · Services · Concrete Project Division CPD · Consulting and Data Technology · Academy Putzmeister AG Max-Eyth-Str. 10 · D-72631 Aichtal P.O.Box 2152 · D-72629 Aichtal Tel. +49 (7127) 599-0 Fax +49 (7127) 599-520 www.putzmeister.com E-mail: [email protected] Very good pumpable material from a EPB tunnel boring machine TS 2616-2 GB TS 2616-2 GB TS 2616-2 GB Right to make technical amendments reserved · © by Putzmeister AG 2007 · All rights reserved · Printed in Germany (10704RR)