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An improved, closed-loop control system was designed, utilising state-of-the-art electro-magnetic flow meters, and inverter controlled electric pumps. As the system was critical to the tunnelling operation, a three-level control fall-back methodology was employed and 3D Solid Modelling used to ensure that the equipment would fit effectively into a very constrained space envelope, whilst still allowing the pumps to be easily maintained. The whole project was completed in 6 weeks from inception to delivery, and ensured the 3.6m diameter 5Km long tunnel drive was completed ahead of schedule, by preventing delays due to grout quality issues or breakdowns.
A major tunnelling contractor had operational problems with filling the void behind tunnel segment rings using a cementitious grout and setting accelerator. Their existing equipment employed two eccentric screw pumps, one supplying grout and the other accelerator, operating on a fixed speed ratio between the two. However, this open-loop control resulted in a large variability of the filling material proportions due to back-pressure and pump wear, resulting in quality control delays to the tunneling operation.