RECOVERY OF

TUNNEL BORING MACHINE

TVHPP (EVENT-1)

TBM EVENT-1
Introduction:
Excavation of HRT through TBM was stopped at Ch. 3016.5 m on
24th Dec 2009 due to falling of huge rock mass over front shield
and water ingress to the tune of 700 lps.
Preliminary investigations such as water testing to ascertain the
source of water, use of probe camera to locate the ingress of
water and assess the geological conditions around, visit to the
local water bodies/lakes to ascertain any connection etc. were
carried out to finalize future course of action.

Preventive measures such as grouting in the affected area,

supports to the distressed segmental rings, regular measurement
of movement in segmental rings, cleaning of slush from TBM
gantries etc were taken immediately.

With the help of information gathered and exploring all other

possibilities and risks, NTPC decided to construct bypass tunnel
(BPT) for retrieval & restart of TBM.

Partial backup units were removed by 20th April 2010 and entry
portal for BPT was constructed till 13th May 2010 and finally
excavation of bypass tunnel was started on 14th May 2010.

Ingress of water at Ring No

Ring No 1903
1905
Broken Segment
No 1905

Probe drill
Segment Erector

Dec
2009

Glimpses
Water Ingress
observed at face

Water ingress

Dec
2009

Dec 2009

Rock blockGlimpses
at segment feeder
Rock block

Dec
2009

Precast segment

Dec 2009

Glimpses
Debris over
segment feeder
Segment Erecter

Rock block

Dec
2009

Glimpses
Ingress of
water at Bridge
Gantry

Water from the top of bridge gantry

Dec
2009

Water ingress at gantry 1

Debris below ring no 1905

Ring No 1902
Broken segment No 1905
Probe drill

Dec
2009

Jan 2010

Ingress of water in TBM Gantry

Dec
2009

Jan 2010

Ingress of water at TBM portal

Dec
2009

Jan 2010

Construction of Bypass Tunnel

Length of bypass tunnel including cavern over TBM cutterhead was around 170
m.
Till excavation of 1st Niche i.e. upto Ch. 28.5 m, progress of bypass tunnel was
very slow due to space constraint.
Excavation of bypass tunnel upto Ch. 98.5 m was completed on 06th September
2011, after which it was stopped for exploratory drilling from 2nd Niche.
With the geological information gathered during excavation of BPT and
exploratory drilling, length of BPT was shortened to 143 m and cavern over TBM
cutterhead was eliminated.

Layout of BPT (Old & New Alignment)

Major Activities involved in Resumption works

Exploratory drilling from HRT with Preventer
Construction of Bypass Tunnel
Diversion of water
Cavity
Treatment
Repair of TBM

Restart of TBM

Expat supervision &

General support services

Marking of BPT Portal

BPT face

Dec
2009

April 2010

Grouting Process at BPT Portal

Dec
2009

May
2010

BPT Portal
BPT
face

Circular arc support

Dec
2009

May 2010

Rock stabilization process

Shotcrete in progress

Dec
2009

June 2010

Niche #1 Junction

Niche # 1

Dec
2009

BPT face

July 2010

Probe drilling activity at BPT

Face RD 53.3m

Probe Hole 2
24m

Dec
2009

Probe Hole 1
24m

July 2010

TBM-BPT Junction

BPT face

Dec
2009

TBM face

Aug 2010

Ingress of water after removal

of broken segment 1905

Dec
2009

Sept 2010

Rock mass above ring No 1906

Crevasse above ring no 1906 on top side

Dec
2009

Sept 2010

Rock mass above ring No 1906

Water flowing through crevasse

Dec
2009

Sept 2010

Rock mass above Ring no 1906

Large Crevasse

Dec
2009

Sept 2010

Exploratory Core Drilling

Niche No 2

BPT face
BH5

BH6

BH3

BH4

Exploratory Core
Drilling machine

Dec
2009

Sept 2010

Niche #2 Junction

BPT face

Water tank
For drilling

Niche # 2

Drilling
rods
Exploratory Core
Drilling machine

Dec
2009

Sept 2010

Exploratory Core Drilling with

Preventer
BPT face RD98.7

Preventer

BH-1

Dec
2009

Nov 2010

Consolidation grouting between

BPT&TBM
Drilling for Grouting
by Boomer

Dec
2009

Nov 2010

Location of drift at Niche # 2

BH6
BH4

BH5

BH7

Drift face before blast

Start date of Drift : 28th Nov 2010

Dec
2009

Nov 2010

First blast of drift

Drift Face
BH5

BH7

Start date of Drift : 28th Nov 2010

Dec
2009

Nov 2010

Niche #2 Junction

BPT face
Drift

Dec
2009

Dec 2010

Water Diversion from the drift

Diverted water in the drift

End date of Drift : 19th Dec 2010

Dec
2009

Dec 2010

Pipe roofing from TBM above

1906

Self drilling Pipe roofing

Ring No 1907

Dec
2009

Jan 2011

Rock condition just before TBM

get exposed
BPT face

TBM location

Dec
2009

Jan 2011

First glimpse of trapped TBM

Pipes
Self drilling pipe

Grout holes

BPT face

Cutter head

Dec
2009

TBM

Jan 2011

Glimpse of trapped TBM

Dent
Inner telescopic Shield
Cutter head

Stabilizer

Outer telescopic Shield

Dec
2009

Feb 2011

New outer telescopic shield

Dec
2009

Feb 2011

Outer telescopic shield repaired

Dec
2009

Feb 2011

Dec
2009

March 2011