Types of Oil, Greases, and Consumption Rates for Tunnel Boring Machines

BULLETINS Title: Types of oil, greases and Consumption rate used on Tunnel Boring Machines (TBM s) Sensitivity: LNT Construction Internal Use

Types of oil and greases and Consumption rate used on Tunnel Boring Machines (TBM s) The following guide is based upon a 10mts Hard Rock TBM negotiating a total length of the 10.5 km (10,500 mtrs, We will advise on the typical consumption rates of materials based on manufacturers instructions and best practise. Always best to confirm actual rates of usage with the TBM manufacturer or material supplier Sensitivity: LNT Construction Internal Use

Types of oil and greases and Consumption rate used on (TBMs) Per unit consumption Consumption Per Tunnel consumption per project Descriptions Remarks Cutter Head 1.1 ltrs for 2 mtrs of tunnel per one cutter, total length of the project 10.5 km (10500 mtrs/2 mtrs = 5250 times, 5250 X 1.1 ltrs = 5775 ltrs and initial stage 50 cutters required each 1.1 lts of oil i.e 55 lts, total 5830 ltrs of oil required for one tunnel 1.1 ltrs for 2 mtrs per one cutter Cutter Oil (19'' Cutters), Mobile SHC 630 Front shield 5830 ltrs 11660 ltrs Per tunnel 6176 rings(10,500 mtrs(tunnel length)/1.7 mtrs(ring length) = 6176 rings), per Ring 8.25 Kg HBW grease consuption(Total HBW grease = 6176 rings X 8.25 kg = 50952/tunnel) Grease flow 126.0 cm /min, Average excavation speed 50 mm/min Tunnel length 8,400 m, Additional greasing time 15%, *Greasing outside excavation time Total greasing time 3,220 h Theoritical quantity necessary to fill up main drive system lubrication system. It is common practice to make a complete refill after TBM commissioning / or after rebuilding when leap- froffing over a station or after the first 500m of excavation. (3500 ltrs x 2 times = 7300 ltrs) HBW Grease (Inner & Outer seals) CONDAT HBW 8.25 Kg per every ring 50952 KG 101904 kg EP2 Grease (Inner, Outer Seals & Lubrication system), CONDAT GR130 / GR217 Grease flow 126.0 cm /min 22396 Kg 44792 kg 2500 Ltrs(Tank) + 150 ltrs(Oil quantity In system) per TBM 3650 ltrs 7300 ltrs 14600 Ltrs Main Drive Oil, (Shell Omala F 320) first Fill Main bearing oil Top Up(Leakage) 200 ltrs every 1000 hrs of cutterhead running .CHD total 3088 hrs running for 6176 rings( 6176 rings X 30 min(advance time) = 3088 hrs).(3088 hrs/1000 hrs = 3 times, 3 X 200 ltrs = 600 ltrs) 200 ltrs per every 1000 hrs Main Drive Oil, Due to leakage Top Up (Shell Omala F 320) 600 Ltrs 1200 Ltrs Theoritical quantity necessary to fill up gearbox lubrication tank. It is common practice to make a complete refill after TBM commissioning or after the first 500m of excavation. (25 ltrs x 10 No's x 2 Times = 500 ltrs. 25 ltrs per each Drive motor gear box, Total 10 No's gearbox CH Drive Motor Gear Box Oil (Shell Omala 320F) 500 Ltrs 1000 ltrs Every 2500hrs need to change CHD motor gear box oil. CHD total 4632 hrs running for 6176 rings( 6176 rings X 30 min(advance time) = 3088 hrs). ( Total 3088 hrs/2500 hrs = 1.2 times, 1.2 X 10 motors X 25 ltrs = 300 ltrs required for one Tunnel) capacity/motor is 25 ltrs 25 ltrs per each Drive motor for every 2500 hrs 300 Ltrs CH Drive Motor Gear Box Oil (Shell Omala 320F) 600 ltrs Sensitivity: LNT Construction Internal Use

Types of oil and greases and Consumption rate used on (TBMs) Middle Shield Greasing required for every 6 months( total duration of the tunnel 26.25 months(per month production was 400 mtrs, tunnel length 10,500 mtrs/400 mtrs = 26.25 months), 26.25 months/6 months = 4.37 times, 4.375 X 1.14 kg X 10 = 49.875 kg per tunnel) Gear oil filters need to change for evry 1000 hrs of cutterhead running .Total running hrs of CHD was 3088 hrs for 6176 rings ( 6176 rings X 30 min(advance time) = 3088 hrs).(3088 hrs/1000 hrs = 3 times, 3 times X 3 No's.of filters = 9 filters per TBM) 1.14 kg per motor for every 6 months 8 CH Drive Motor Bearing Grease (Kluberplex bem 41 - 132) 49.875 Kg 99.75 kg 3 no of filters per every 1000 hrs 9 Gear Oil Filters 9 No's 18 No's 8 no of filters change per 1000hrs .Tunnel completion duration was 18900hrs(10,500mtrs/400mtrs = 26.25months, 26.25months X 30days X 24hrs = 18900hrs).(18900hrs/1000hrs = 18.9times, 18.9 X 8no.of filters = 151 filters per TBM) Grease filters need to change for evry 1000 hrs of CHD total 3088 hrs running for 6176 rings.( 3088 rings X 30 min(advance time) = 3088 hrs).(3088 hrs/1000 hrs = 3 times, 3 X 1 filter = 3 filters per TBM) 8 no of filters per every 1000hrs 10 Hydraulic Filters for valve block. 151 No's 302 No's 1 filters per every 1000hrs 11 Grease Filters Tail skin Shield 3 No's 6 No's 12 Tail skin brush(initial stage) 4rows 4rows 8rows Per TBM, initial stage 4 rows of tail skin brushes required. Tail skin brushes required to change every 5km once, per tunnel need to change 2 times(10,500mtrs/5000mtrs = 2 times). (2times X 4rows required to change per tunnel) Tail skinn grease need to fill three times at iniatial(starting) time of the TBM. Tail Skin Grease 430532kg required per tunnel( 7.8mtrs(inner dia of segment) + 0.9mtrs(segment width 2 X 0.45mtrs) = 8.7mtrs, 8.7mtrs X 3.142(pi value) = 27.33sq.mtrs, 27.33sq.mtrs X 10,500mtrs(length of the TBM01 tunnel) = 2,87,021.7 sq.mtrs. 2,87,021.7 X 1.5kg(grease per sq.mtr) =430532kg required per TBM01 tunnel) 13 Tail skin brush 4 row brushes 2 times 400 kg per 4 layer for one time filling 2 times 4 times 14 Tail skin Grease first fill (CONDAT WR 90) 1200 Kg 2400 Kg 15 Tail Skin Shield Grease (CONDAT WR 89) Erector 1.5 kg per sq.mtr 430532 kg 861065 kg Erector vaccume Rubber seal need to change for every 100mtrs( 10,500mtrs / 100mtrs = 105 times, 105 X 5mtrs = 525mtrs of erector vaccume seal required for one tunnel) 20 ltrs of vaccume oil required per tunnel(10,500mtrs/1000mtrs = 10 times, 10 times X 2 ltrs = 20 ltrs) Capacity 2 ltrs Erector Lubrication EP2 grease 1.04kg required for 1 ring .Total 6176 rings per tunnel(10,500mtrs(tunnel length)/1.7mtrs(ring length) = 6176rings) (6176 X 1.04kg = 6423kgs of grease required per Tunnel) 5mtrs seal per every 100 mtrs 15 Erector Vaccum pad (Rupper Seal) 525 mtrs 1050 mtrs 16 Erector Vaccume oil (Becker Lube M 100 mineral Oil) 2 ltrs per every 1000 mtrs 20 ltrs 40 ltrs 17 Erector Lubrication EP2 Grease CONDAT GR130 / GR217 1.04 kg per every ring 6423 Kg 12846 Kg Sensitivity: LNT Construction Internal Use

Types of oil and greases and Consumption rate used on (TBMs) Segment Feeder Every 4000 hrs need to replace with new Tefflon pad, Tunnel completion duration was 18900hrs(10,500mtrs/400mtrs = 26.25months, 26.25months X 30days X 24hrs = 18900hrs),(18900/4000 = 5times, 5 X 14 Pads = 70 Tefflon pads per tunnel 14 no of pads per Every 4000 hrs. 18 Segment Feeder Tefflon Pad Segment Crane 70 No's 140 No's Need change 9 ltrs of oil for every 1000 hrs, Tunnel completion duration hrs was 18900 hrs(10,500 mtrs/400 mtrs = 26.25 months, 26.25 months X 30 days X 24 hrs = 18900 hrs).(18900 hrs/1000 hrs = 18.9 times, 18.9 X9 ltrs = 170 ltrs per tunnel) 19 Segment Transfer Crane Gear Box Oil (Ltr) 9 ltrs per 1000hrs 170 ltrs 340 ltrs Segment crane vaccume Rubber seal need to change for every 100 mtrs( 10,500 mtrs / 100 mtrs = 105 times, 105 X 5 mtrs = 525 mtrs of erector vaccume seal required for one tunnel) 5 mtrs seal per every 100 mtrs 20 Segment Transfer Crane Vaccum Pad(Rupper Seal) 525 mtrs 1050 mtrs Segment crane Vaccume oil (Becker Lube M 100 mineral Oil) Hydraulic Tank 20 ltrs of vaccume oil required per tunnel(10,500 mtrs/1000 mtrs = 10 times, 10 times X 2 ltrs = 20 ltrs) 21 2 ltrs per every 1000 mtrs 20 ltrs 40 ltrs First fill tank capacity 5500 ltrs + 1650 Ltr(Oil quantity TBM system) toal 7150 ltrs Theoritical quantity necessary to fill up hydraulic tank and system. It is common practice to make a complete refill after TBM commissioning or after the first 500 mtrs of excavation.Initially fill Hydralic Oil 7150 Ltr x 2 times = 14300 ltrs per TBM 22 Hydraulic Oil (Initial fill) CONDAT D46/68 7150 ltrs 14300 ltrs Hydraulic oil tank completely fill with new oil due to contamination, 14300 ltrs required per tunnel(10,500mtrs/5000mtrs = 2 times, 2times X 7150 ltrs = 14300 ltrs) 200 ltrs Hydraulic Oil need to fill in Tank for every 100mtrs( 10,500mtrs / 100mtrs = 105 times, 105 X 200lts = 21000 lts of hydraulic oil required for top up, 12 filters need to change for every 100 mtrs( 10,500 mtrs / 100 mtrs = 105 times, 105 X 12 No's= 1260 No's filters required for one tunnel) 1 times per every 5000 mtrs(tank capacity 7150 ltrs) 23 Hydraulic oil (allowance for full tank oil change) 14300 ltrs 28600 ltrs 200 ltrs top up per every 100 mtrs 24 Hydraulic Oil top up due to leakage 21000 ltrs 42000 ltrs Sensitivity: LNT Construction Internal Use 12 filter per every 100 mtrs 25 Hyd Tank, Pumps pressure and return Filters 1260 No's 2520 No's

Types of oil and greases and Consumption rate used on (TBMs) Probe Drill Oil consumption/ hammer 0.6 L/h, Total pure TBM excavation time TBM 2,800 h, effective excavation time only, Number of probe drill 1 No. Percentage of use of probe drill 10%, Total time of use of probe drills 280 h. Total oil quantity * 168 L Oil consumption/ hammer = 0.6 L/h 26 Probe Drill lubrications Oil (Atlos copco ISO VG 68-150) Conveyor Belt 168 ltrs 336 ltrs For every 1000 hrs need to change 7.5 ltrs of Gear oil, Tunnel completion duration hrs was 18900 hrs 2 Gear box for TBM and tunnel conveyor system (10,500 mtrs/400 mtrs = 26.25 months, 26.25 months X 30 days X 24 hrs = 18900 hrs)(10,500 mtrs/400 mtrs = 26.25 months, 26.25 months X 30 days X 24 hrs = 18900 hrs), (18900 hrs/1000 hrs = 18.9 times, 18.9 X7.5 ltrs X 2 motors = 284 ltrs per tunnel) TBM Conveyor Belt and tunnel conveyor Gear Box Oil (RENOLIN PG 220) Tunnel Conveyor Belt Boosters 27 7.5 ltr per every 1000hrs 284 Ltr 568 Ltr For every 1000 hrs need to change 7.5 lltr of Gear Oil, Every 2 Km Booster was installed, (Booster 1 installed at 2 km of the tunnel, it will work untill 10.5 kmts of the tunnel i.e 8.5 km (10.5 km - 2 km = 8.5 km) The 8.5 km tunnel completion duration hrs was 15300 hrs, ( 8500 mtrs/400 mtrs=21.25 monthx30 days=637.5 days x 24 hrs=15300 hrs) (15300 hrs/1000= 15.3 times,X7.5 ltrX1 booster= 115 ltr per Booster 1 33 Booster No -1 Motor Gear Box Oil (RENOLIN PG 220) 7.5 ltr per every 1000hrs 115 Ltr 230 Ltr For every 1000 hrs need to change 7.5 lltr of Gear Oil, After 4 Km Booster-2 was installed, The tunnel completion duration hrs was 11700 hrs,(10.5 km - 4 km = 6.5 km, 6500 mtrs/400 mtrs =16.25 months X 30 days X 24 hrs = 11,700 hrs) (11700 hrs/1000 hrs= 11.7 times,X7.5 ltrX1= 88 ltr, For every 1000 hrs need to change 7.5lltr of Gear Oil, After 6 Km Booster-3 was installed, The tunnel completion duration hrs was 8100 hrs, (10.5 km - 6 km = 4.5 km, 4500 mtrs/400 mtrs =11.25 months X 30 days X 24 hrs = 8100 hrs) (8100 hrs/1000 hrs= 8.1 times,X7.5 ltrX1= 61 ltr, For every 1000 hrs need to change 7.5 lltr of Gear Oil, Every 8 Km Booster-4 was installed, The tunnel completion duration hrs was 4500 hrs, (10.5 km - 8 km = 2.5 km, 2500 mtrs/400 mtrs =6.25 months X 30 days X 24 hrs = 4500 hrs) (4500 hrs/1000 hrs= 4.5 times,X7.5 ltrX1= 34 ltr, 34 Booster No -2 Motor gear Box Oil 7.5 ltr per every 1000 hrs 88 Ltr 176 Ltr 35 Booster No -3 Motor gear Box Oil 7.5 ltr per every 1000 hrs 61 Ltr 122 Ltr 36 Booster No -4 Motor gear Box Oil 7.5 ltr per every 1000hrs 34ltr 68 Ltr Sensitivity: LNT Construction Internal Use

END Sensitivity: LNT Construction Internal Use