Lubrication and Sealing System Overview for Tunnel Boring Machines

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Understanding the importance of proper lubrication and sealing systems is crucial for the efficient operation of tunnel boring machines. This module covers the use of various greases and gear oils to protect critical components such as tail seals and main bearings. Failure in maintaining these systems can lead to catastrophic failures, emphasizing the need for proper maintenance and periodic sampling. Tail Skin Grease, HBW Grease, EP2 Grease, and Gear Oil are discussed in detail, highlighting their specific applications and benefits.

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Module Number : Module:-2 Module Title : TBM Basics and Operation Procedure TBM Operation Chapter : Lubrication and Sealing System

Module 2 Lubrication and Sealing System Introduction Lubrication and sealing system This module will highlight the very important activity of understating the importance of the initial installation (tail seal grease for e.g.), cooling, sealing and periodic sampling of the TBM system (bearing oil for e.g ). And how failure with this system can result in catastrophic failure of major components Tail Skin Grease(TSG) : Protection of the wire brushes and tightness of the tail seal are essential in tunnel excavation. Tail sealants, are viscous, resistant to wash-out, and adhere to any damp surface. HBW Grease : The protection of the main bearing of the cutting head is ensured by the simultaneous injection of a sealing paste resistant to wash-out. EP2 Grease: EP Grease represents Extreme Pressure. Under high weight or stun stacking, typical oil can be compacted to the degree that the defensive film breaks and the lubed parts come into physical contact, causing grinding and wear. In almost applications, EP Grease is used where an AP(All Purpose) or MP(Multi-Purpose) oil is called for. Gear Oil: Gear oil is a lubricant made specifically for transmissions, transfer cases and main Bearing of TBM. It is of a high viscosity and usually contains organosulfur compounds.

Module 2 Lubrication and Sealing System Contents Chapter 1: Tail Skin Grease(TSG) Chapter 2: HBW Grease Chapter 3: EP2 Grease Chapter 4: Gear Oil

Module 2 Lubrication and Sealing System Chapter 1: Tail Skin Grease(TSG)

Module 2 Lubrication and Sealing System Chapter 1: Tail Skin Grease(TSG) Protection of the wire brushes and tightness of the tail seal are essential in tunnel excavation. Tail sealants, are viscous, resistant to wash-out, and adhere to any damp surface. Pumped continuously as the tunnel boring machine advances, CONDAT sealing compounds for tail seals allow for good filling of the inter brush chambers to: Act as a barrier to water, mortar, and soil fines Offer controlled consumption Brushes thus protected by WR New Generation or SL 89 New Generation sealants show greater flexibility and greater durability. Injection of the tail seal greases takes place in 2 steps: At the start-up phase As the tunnel boring machine advances

Module 2 Lubrication and Sealing System Chapter 1: Tail Skin Greasing area(TSG) (Video)

Module 2 Lubrication and Sealing System Chapter 1: Tail Skin Grease(TSG) start-up phase : Before starting to bore, it is imperative that a first filling of the brushes should be carried out. The first-filling sealant WR 90 New Generation must be injected deep into the brushes until reflux on brush surfaces. All the brushes must be prepared in this way to ensure an uninterrupted sealing of the tail brushes . The consistency and adherence of the first-filling sealant ensures protection during the entire lifetime of the brushes. Tunnel Boring Machine advances : As the tunnel boring machine advances, another seal grease is pumped continuously between the rows of brushes to complete the tightness of the tail seal: WR 89 New Generation. The latter ensures good filling of the chambers, extends the brushes' lifetime and it is perfectly compatible with the WR 90 New Generation. Through its performance, it guarantees a good pressure control and therefore optimal safety for the personnel and the equipment.

Module 2 Lubrication and Sealing System Chapter 1 : TSG Grease Front 03 Front 01 Front 02 TSG Grease Pump with barrel TSG Grease Distributor- Front Port Front 06 Front 04 Front 05 Rear 01 Rear 03 Rear 02 TSG Grease Pump with barrel TSG Distributor Rear Port TSG Grease Pump with barrel Rear 05 Rear 04 Rear 06

Module 2 Lubrication and Sealing System Chapter 2: HBW Grease

Module 2 Lubrication and Sealing System Chapter 2: HBW Grease The protection of the main bearing of the cutting head is ensured by the simultaneous injection of a sealing paste resistant to wash-out. The sealing paste is injected continuously as the machine advances in the labyrinth(a complicated irregular network of passages or paths) by flushing downstream of the lip seals. The grease is injected to outside of the outerseal.

Module 2 Lubrication and Sealing System Chapter 2 : HBW Grease HBW Grease Pump with barrel Inter-seal chambers

Module 2 Lubrication and Sealing System Chapter 3: EP2 Grease

Module 2 Lubrication and Sealing System Chapter 3: EP2 Grease EP Grease represents Extreme Pressure. Under high weight or stun stacking, typical oil can be compacted to the degree that the defensive film breaks and the lubed parts come into physical contact, causing grinding and wear. In almost applications, EP Grease is used where an AP(All Purpose) or MP(Multi-Purpose) oil is called for. The protection of the rotary Coupling, sealing chamber front, main drive Articulation Front/Rear, Screw conveyor sealing and feeder.

Module 2 Lubrication and Sealing System Chapter 3 : EP2 Grease Rotary Coupling Erector Lubrication EP2 Grease Pump with barrel Automatic Grease Lubrication System

Module 2 Lubrication and Sealing System Chapter 4: Gear Oil

Module 2 Lubrication and Sealing System Bearing side view (Video)

Module 2 Lubrication and Sealing System Chapter 4: Gear Oil Gear oil is a lubricant made specifically for transmissions, transfer cases and main Bearing of TBM. It is of a high viscosity and usually contains organosulfur compounds. Some modern automatic transaxles (integrated transmission and differential) do not use a heavy oil at all but lubricate with the lower viscosity hydraulic fluid, which is available at pressure within the automatic transmission. Gear oils account for about 20% of the lubricant market. Gear Oil Selection Criteria In order to choose the best lubricant for a gear set, the following criteria must be addressed: Viscosity Often referred to as the most important property of a lubricating oil(TBM Gear Oil-320F). Additives The additive package used in the lubricant will determine the lubricant s general category and affects various key performance properties under operating conditions. Base Oil Type The type of base oil used should be determined by the operating conditions, gear type and other factors.

Module 2 Lubrication and Sealing System Chapter 4 : Gear Oil 7.5KW Distribution main Bearing Distribution Pinion Bearing Front 4KW Distribution Pinion Distribution Pinion Bearing Rear