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View Full Version : OT: simple repair of bearing and seal



tlfamm
12-10-2014, 10:20 AM
So, your tunnel boring machine is stuck underground in Seattle, Washington with a blown main bearing and seal: whacha gonna do?

NYTimes article:
http://www.nytimes.com/2014/08/02/us/reanimating-bertha-the-mechanical-behemoth-stuck-under-seattle.html

Brief pictorial overview of repair:
http://www.wsdot.wa.gov/Projects/Viaduct/Media/Default/Documents/Brochures%20%28fact%20sheets%29/Repair_FORWEB.pdf

Detailed Repair plan (41 pages, takes some time to load)
http://www.wsdot.wa.gov/Projects/Viaduct/Media/Default/Documents/STP_Repair_Plan061614.pdf

bob_s
12-10-2014, 11:28 AM
So, your tunnel boring machine is stuck underground in Seattle, Washington with a blown main bearing and seal: whacha gonna do?

Bill the city for all repair costs plus reasonable rate of return on capital and working costs!

lakeside53
12-10-2014, 11:35 AM
It was still under warranty (just...) when it died. Luckily it stopped when you COULD dig a vertical access shaft. If it was under the freeway or buildings (most of its dig), we'd still be scratching heads.

The vertical access shaft dig required extensive de-watering of the area; nearby buildings and the freeway have sunk 1 inch in a month. Expect more delays while this is "studied".

If we have an earthquake....lol...

Stepside
12-10-2014, 01:50 PM
Lakeside

You forgot to mention the Viaduct above it and the Seawall just a bit beside it. They have already spent 1 billion of the 1.44 billion of their budget. We don't even want to mention that WASDOT does not have even a hint of what to do if the "repair" does not work. At least when the Viaduct falls down there will be better views of Puget Sound.

tlfamm
03-25-2015, 10:50 AM
Updates on repair of TBM "Bertha"
-----------------------------------------

Feb/early March 2015:

TBM bores through the access pit wall:
https://www.youtube.com/watch?v=uwguAPEaRcQ

TBM moves into the access pit:
https://www.youtube.com/watch?v=LS52u6Y_tXU




TBM Component lifts through the access pit, beginning March 18, 2015:

1'st lift:
http://www.wsdot.wa.gov/Projects/Viaduct/Contents/Item/Display/2190
https://www.youtube.com/watch?v=pCyuRXMOYPM&feature=youtu.be


2'nd lift (no pix?)


3'rd lift:
http://www.wsdot.wa.gov/Projects/Viaduct/Contents/Item/Display/2204


4'th lift (yet to come: cutter head and main drive assembly)





Some overview/coverage of TBM repair:
http://www.tunneltalk.com/Seattle-Alaskan-Way-12Feb2015-Technical-management-for-TBM-repair.php

Detailed repair discussion and animations:
https://www.youtube.com/watch?v=mfdITDPt6nI&feature=youtu.be


And a precious viewers comment from the previous:

"We begin by tying a string to Bertha's tooth. The other end is then tied to the knob of a door. When the time is right we will then slam the door shut extracting the bad tooth. Upon completion of the removal of said tooth we will then place it under Bertha's pillow. Hopefully by morning the tooth fairy will pay a visit and leave $195,000,000.00 to help pay for the procedure."


General project page:

http://www.wsdot.wa.gov/Projects/Viaduct

sch
03-25-2015, 11:29 PM
Interesting they are using a Japanese machine when the Robbins Co, maker of TBMs, is in Kent WA.

vpt
03-26-2015, 08:32 AM
So guess they tried some lucas oil additive to see if that would quiet the bearing down before going threw the work of changing it?

Mcostello
03-26-2015, 10:04 PM
STP for the old timers.

vpt
03-27-2015, 08:10 AM
Richard Petty would say so.

Abner
03-27-2015, 09:02 AM
Building 'Bertha'

Engineer #1: So what happens if the main bearing goes out while it is underground?
Engineer #2: You dig it up and fix it.
Engineer #1: But what if you can't because it is under a 40 story building or under a bay.
Engineer #3: You don't want to think about that.
Engineer #2: Yeah, you don't want to think about that.

Am I the only one wondering why you wouldn't have rear access to sorta important parts like main bearings? Is this common?

Edit: Maybe I'm jumping here and this was easier than rear removal.

lakeside53
03-27-2015, 12:07 PM
The machine is ahead of the concrete that forms the tunnel - you can't back up the machine or get to the bearing or front from the rear. It has to seal the hydrostatic pressure ahead also.

This machine is huge - the largest in the world. A couple of slightly smaller machine also boring tunnels in Seattle are doing fine; one just finished its tunnel and the other will be done in week or two.

Abner
03-27-2015, 12:43 PM
Wow, so if it fails then you have no choice but to dig it out to fix it.

tlfamm
03-27-2015, 12:50 PM
Turns out TBM Bertha isn't the first of her kind to need a subsurface main bearing replacement. In 1993, TBM 'Excalibore' went kerput on the job at Sarnia, Ontario, on a bore under the St. Clair river:

http://www.oil-electric.com/2014/03/tale-of-two-tunnels-st-clair-river.html


The above is a detailed, lengthy history of railroading between Michigan and Ontario via the St. Clair river (surface and subsurface). It's worth a read if you've got the time.

lakeside53
03-27-2015, 01:04 PM
Wow, so if it fails then you have no choice but to dig it out to fix it.

Or... bury in place, and make a new tunnel. There are many place under Seattle where it wouldn't be possible to access it. Luckily it failed early in the dig.

lakeside53
03-28-2015, 01:26 AM
Btw..... the cutter head alone is 2000 tons... They figure 16 hours to lift it up the 120 foot access shaft and place on the ground. Should happen real soon.

Abner
03-28-2015, 07:36 AM
Lucky they had access. I'm certainly not an engineer nor a tunneling machine maker but what a risk to not have rear access. I get the part about having 2 different radius with the concrete getting formed behind, but still, there is no other way?
From wiki it would appear this is the machines first tunnel. 800' and its broken?
Ouch!

vpt
03-28-2015, 08:39 AM
I wonder if there was casting material left in the bearing from manufacturing. Don't they know you are supposed to dismantle, clean, and put in good new lube in any import machines. Jeez that has been covered how many times here?

tlfamm
04-02-2015, 08:26 PM
Video of Bertha's front-end being lifted to the surface: 2000 (not 200) tons of cutter-head, main bearing & seal, support structure and drive assembly. The lift was done Monday evening, March 30:

https://www.youtube.com/watch?v=La9cc6XS2Gs





Current (updating) views of the TBM front end in its parking cradle: see clickable images entitled "access pit #1" and "access pit #2", (upper right image, and lefthand image one row down) in the image array:

http://www.wsdot.wa.gov/projects/viaduct/Traffic/ConstructionCam

Views #1 and #2 are on opposite sides of the lifting crane. In the foreground of view #1 can be seen a second parking cradle. Apparently that will be used to reassemble the front end using new parts shipped from Japan (*) and used parts removed from the old front-end on the first parking cradle.

* Notably including a new bearing and seal



12-image photo coverage of the front-end lift:
http://www.equipmentworld.com/photos-big-berthas-2000-ton-front-end-lifted-to-the-surface-heres-how-the-crews-did-it/




Some technical detail on the TBM can be found here:

http://www.tunneltalk.com/TunnelTech-Dec12-Technical-parameters-of-the-SR99-Alaskan-Way-mega-EPBM-for-Seattle.php

Abner
04-03-2015, 08:40 AM
The scale of that machine is mind bending.
I still think it is not a good idea to not have the thing serviceable from the rear.
Suppose it gets 1/2 way there and is under water, what then?
Build another one and drill from the other side and then cut them both up for scrap?
Crazy!

vpt
04-03-2015, 09:09 AM
Video of Bertha's front-end being lifted to the surface: 200 tons of cutter-head, main bearing & seal, support structure and drive assembly. The lift was done Monday evening, March 30:

https://www.youtube.com/watch?v=La9cc6XS2Gs


haha, I like the guy in the white shirt (like many of them it seems) that wasted the entire day away leaning on the fence and crane jack.

lakeside53
04-03-2015, 01:33 PM
The local guys report the cutter head as 2000 tons, not 200. One of them is right :)

I'd like to get the old bearing, but I doubt my Lille pickup would carry it. lol

tlfamm
04-03-2015, 02:31 PM
The local guys report the cutter had as 2000 tons, not 200. One of them is right :)

I'd like to get the old bearing, but I doubt my Lille pickup would carry it. lol

200 versus 2000 tons:

I've seen both figures used, as well as a stipulated 240-ton limit for the lifting crane. Ergo, I went with the smaller figure. The situation is muddied by the fact that the cutting head (and attached 'stuff') is actually the last of four individual pieces of the TBM front end that were lifted separately. Do those four parts add up to 2000 tons?

tlfamm
04-03-2015, 02:46 PM
The Mammoet folks say a single 2200 ton lift for the "front end":

http://www.mammoet.com/en/News/MM-USA-to-rescue-Bertha/


And Engineering News Record specifies a 2425 ton load-limit for the Mammoet modular lift tower crane that raised Bertha's "front end":

http://enr.construction.com/opinions/blogs/newcomb.asp?plckController=Blog&plckBlogPage=BlogViewPost&newspaperUserId=eb35b65e-9814-4559-9e19-584a5fb39113&plckPostId=Blog%3aeb35b65e-9814-4559-9e19-584a5fb39113Post%3a9b063347-1941-4d01-94f2-b566c5bc0de3&plckScript=blogScript&plckElementId=blogDest

boslab
04-03-2015, 08:22 PM
If it's a 2000 ton cutter head it's a hell of a big tunnel!
I somehow think neither figure is right, I'm guessing more than 200 and less than 2000, I've seen a crane lifting 1500 tons close up and personal and it was amazing, mammoet have a 3600 ton beast, that's ginormous, whatever it is it's quite a feat lifting the end off a TBM anyway, very slick but as has been said very expensive, they've come on a lot since the original tunnel shield.
I suppose these TBMs will only get bigger.
Mark

lakeside53
04-03-2015, 08:27 PM
It is a big tunnel... 57 feet diameter bore, and this is the world's largest TBM

The cutter head alone is head is 4 million lbs (sounds so much bigger than 2000 tons!).

http://gizmodo.com/the-worlds-largest-tunneling-machine-is-finally-getti-1694864222

http://q13fox.com/2015/03/30/berthas-back-front-end-of-broken-seattle-tunnel-machine-lifted-out-of-ground/

boslab
04-03-2015, 08:35 PM
Bloody hell that's a motorway over here!
Thanks
Mark

tlfamm
04-03-2015, 09:17 PM
Here's a good image of the cutter-head assembly hovering over the parking cradle. Two kilo-tons, eh?

http://sitelife.construction.com/ver1.0/Content/images/store/9/12/f9695831-6421-4538-9c45-4230870a264d.Full.jpg

Abner
04-03-2015, 11:31 PM
I found it on page 1,847 of the McMaster/Carr catalog.

Item # 24z235680

"Main bearing and seal for 2,000 Ton TBM"

call for pricing

lakeside53
04-03-2015, 11:39 PM
Bloody hell that's a motorway over here!
Thanks
Mark

It's for a double deck motorway here!

Catshooter
04-06-2015, 01:27 AM
What I love is the road it is supposed to be replacing is four lanes each direction. Last time I drove it, ten years ago it would pile up with traffic two three times a day.

The tunnel to "replace" it is three lanes one way, two the other.

What could go wrong? :)


Cat

tlfamm
10-08-2015, 02:23 PM
An Oct 7 update with video of repair progress on Big Bertha:

http://www.wsdot.wa.gov/Projects/Viaduct/Contents/Item/Display/2468

mattthemuppet
10-08-2015, 05:22 PM
wow, that's seriously non-trivial stuff! I loved that clip of the external trimming of the center section - I wonder how big those chips were?

boslab
10-08-2015, 05:42 PM
I should imagine they are big enough to brand you with the " mark of the beast" as one mill operator I knew called it, it was a 6 btw, quite funny at the time as it was on his arse, not behind his ear.
Mark

lakeside53
10-08-2015, 08:24 PM
$80 million so far to fix...

tlfamm
12-22-2015, 07:32 PM
Big Bertha on the move today (baby steps):

http://www.seattletimes.com/seattle-news/transportation/bertha-restarts-after-two-years-of-delays/

tlfamm
04-19-2016, 08:54 AM
(1) By January 7, Big Bertha had traveled 73 feet since the completion of repairs:

http://www.seattletimes.com/seattle-news/transportation/bertha-making-progress-tunnels-73-feet-since-repairs/


(2) On January 14, tunneling was stopped due to concerns about sinkholes forming above the TBM. Operations resumed February 23:

http://www.seattletimes.com/seattle-news/transportation/inslee-orders-bertha-tunneling-stopped-after-sinkhole-forms/


(3) On March 12, operations were stopped for scheduled TBM maintenance:

http://www.seattlepi.com/local/transportation/article/Bertha-stops-again-this-time-for-planned-6889648.php

It appears that operations have not yet resumed. When they do, the TBM will shortly be under the Alaskan Way Viaduct, forcing its closure for some weeks:

http://www.seattletimes.com/seattle-news/transportation/viaduct-closure-coming-once-berthas-ready-to-dig/




To-date, Bertha has traveled 1,560 of 9,270 feet.

lakeside53
04-19-2016, 11:18 AM
It in good shape... just waiting for the prep work to be completed for the boring beneath the viaduct starting NEXT Friday.. Lots of extra pilings driven, carbon fiber wrap applied on the concrete, and the butterflies in the WDOT engineers stomachs have to settle.. ;)

I work 100 feet from the viaduct. It's going to be glorious (quiet) to have no traffic on it, but a nightmare with traffic getting to work while closed. For those who don't know what I'm taking about, imagine shutting down a major freeway though your city for two weeks. lol

tlfamm
03-16-2017, 06:06 PM
Article devoted to Big Bertha on Popular Mechanics site:

http://www.popularmechanics.com/technology/infrastructure/news/a24895/seattle-big-bertha-tunnel-boring-machine/

The old gal is 556 feet away from the end ....

boslab
03-16-2017, 06:57 PM
Remarkable feat of engineering, difficult on the ground, down the bottom of a hole, amazing.
Just lining up the drive ring gear segments is difficult, we had a slew ring to change on a caster ladle turret some years ago, I've never clocked over 25 feet before, it was difficult and that was horizontal, can't imagine doing it vertical, the gas cage of 12 argon bottles sitting on top of it gave an impression of the scale, huge, they haven't repaired it they have remanufactured it, must have been like fixing a submarine on the bottom of the sea
Mark

lakeside53
03-16-2017, 07:45 PM
I like the "heat treating" of the inserts. lol

elf
03-16-2017, 08:43 PM
Remarkable feat of engineering,

Last week it was 10" offline. The Romans were better underground engineers:rolleyes:

tlfamm
04-05-2017, 09:15 AM
Bertha broke through into the disassembly pit yesterday at noon:

https://youtu.be/XESUja2hKEw

https://youtu.be/r5vQjry2NSc

http://www.wsdot.wa.gov/Projects/Viaduct/About/FollowBertha