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With data present from the first drive, a new rock cutter head was custom ordered from Europe to handle these treacherous ground conditions. Although design, manufacture and delivery of this new head delayed the project by at least six months, there was no other alternative. This led to more idling of the whole rest of the equipment which just added to the overall project costs.To assure the success of the drive, SONAR system was used to confirm the river depth and it was found to be deeper compared to the drawings. This was useful information since it required extra precision in machine handling on part of machine operator and addition of a special bentonite polymer to avoid possibility of ground collapse near the deepest point.During this drive also, steel parts were found in the slurry in parts of the drive. The nature of these steel parts (eg, iron sausages, etc.) suggested the machine had encountered railway steel bridge structure which was damaged and buried at the location in the 60’s during heavy flooding of the Teesta River.Although the new cutter head was able to negotiate these small parts, it then encountered the whole railway bridge foundation. Result was the whole drilling operation came to a standstill. Experts atthe site concluded that since it was not possible to drill through this foundation, cutter head had to be pushed without drilling around this obstacle.This method resulted in huge damage to not only the cutter head (since it was not rotated) but also the whole jacking system because of the magnitude of loads. But in the end, the equipment was safely navigated around this obstruction.Other than this, there were issues with the microtunnel opening alignment with the previous opening in the intermediate shaft. To counter this, at the end of whole tunneling operation, a cold bend in the carrier pipe had to be given in the intermediate shaft.
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