Author Archives: 光明路

Advantage of Brightway Slurry Separation Plant

To meet the growing requirements of micro-tunneling projects worldwide, Brighway developed the slurry separation system, so called BWSP or Brightway slurry separation plant system, are specially designed for micro-tunneling separation with slurry mud conveyance in various ground condition, which is an important factor of every successful micro-tunneling operation.

BWSP slurry separation plant

BWSP slurry separation plant

Depending on the tunneling diameter, the excavation rate, the viscosity slurry rate, and geological conditions, Brightway offers efficient separation solutions.

In below introduction, we illustrate the operation of Brightway BWSP system, suitable for the wide range of geological conditions from very coarse to ultra fine.

The basic BWSP250 system is consisted of primary screen separation and secondary vacuum assisted cyclones for fine solids removal down to 60 microns/ 20 microns. The equipment are mounted on the 20′ standard container that operates as the storage tank. The tank is divided into  2 compartments. The slurry is pumped from the TBM / PIPE JACKING MACHINE to BWSP primary linear shaker, utilizing the High G force to allow the efficient conveyance of solids in the minimal foot print.

The high-G shaker is addressed with 3 wire woven stainless steel panels given the total screen area of 2.5 m². The screen separate the coarse material from the fluids and convey to the disposal. The screened slurry flow into the 1st compartment of the storage tank.

From here, the slurry fluids is pumped to the secondary vacuum assisted hydra-cyclones for secondary separation down to 60 microns. The fluids inside the body of the cyclones creates the centrifugal force.

The conical section increase the force and causes the large particles to settle. Solids accumulates at the bottom,when the weight of he solids exceeds the elastic force of the cyclone underflow, the solids dumps. Clean fluids and smaller particles are caught as the spiral and exit the vortex finder into the overflow pipe. Rather than small diameter, high pressure cyclones, the BWSP system utilizes the large diameter low pressure hydra-cyclones, the vacuum assisted cyclones separate the solids at low pressure, minimizing the share of effect that creates finer solids in the slurry which is more difficult to remove. The cyclone operates continuously without plug in.

The solids underflow exits to the high G force linear motion shaker screen for dewatering.

This dewatering  screen deck utilizes the ultra fine wire woven stainless steel screen technology, dewaters and removes he ultra fine solids. The lighter material that smaller than 60 micro exits through the fluids overflow and discharged to the 2nd compartment of the storage tank.

Now BWSP system removes the most of solids bigger than 60 microns.

For geography conditions mainly with coarse and sandy materials, the above solution is capable to keep the slurry for operation. As the geography charges for finer silts and clays, further separation is required.

With the additional BWLW365G decanter centrifuge and BWVC vertical clarifier, it is possible to clean the slurry to 2 microns and maintain a close slurry circuit. In this case, the slurry containing the particles smaller than 60 microns is pumped from the 2nd compartment of the storage tank to the BWVC clarifier.

decanter centrifuge

decanter centrifuge

Prior to the slurry entering into the clarifier, the polymer flocculant is introduced by the means of BWFU flocculant unit. The treated slurry enters the charmber of the clarifier and flocked solids sinks to the conical bottom, and the clearer water rises up to overflow to return to the clean water storage tank. The flocked ultra fine solids accumulated and is pumped to the decanter centrifuge for dewatering.

The sludge enters the centrifuge though the feed tube. The BWLW365G decanter centrifuge is specially designed for the BWSP system. The centrifuge creates the high G force to increase the speed of the solids settling. and separate the sludge into the liquid and the solids phase.

The solids  phase is mechanically extracted with the internal scroll and disposed. The liquid phase is discharged to the clean water storage tank from where it is finally transfered to the return tank.

The use of BWSP separation system ensures the operation of the TBM/ Micro-tunneling or pipe jacking  and reduces both the environment impact and the disposal cost. The modular design provides flexibility in the limited work space for the large range of geography conditions and performance rate.

The use of combination of high G force shaker and conjunction of fine screen technology and consequently large open screen makes the BWSP solution as the efficient plan for the micro-tunneling industry.

Beijing No Dig Exhibition

The 34th CSTT Exhibition ( China international trenchless technology conference and exhibition ) has concluded successfully in Beijing on Oct 12, 2016.

As the expert in the mud recycling system and equipment manufacturer, Brightway welcomed the customers at home and abroad.

trechless exhibation

trechless exhibation

beijing no dig exhibation

beijing no dig exhibation

During the exhibition, Enrico Boi,the chairman of Association for international trenchless technology seminar,came to visit Brightway No.38 Booth. All sales of Brightway extended a warm welcome to the arrival of the chairman. With the booming construction market trend domestic and overseas,  Brightway believe that we can contribute our efforts to our customers’ projects-tunneling, micro-tunneling, pipe jacking, piling, HDD etc.

TRENCHLESS CASE

TRENCHLESS CASE

NO DIG

NO DIG

Beijing No Dig Exhibitation

Beijing No Dig Exhibition on Oct 10-12,2016, another show for Brightway for trenchless industry.
I wrote the company brief for exhibition several times.
This time is different, I’d like to show more about my understanding for trenchless application as below.

Xi’an Brightway Energy Machinery Equipment Co. Ltd is a professional manufacturer which design, develop, and manufacture the solids control equipment and the mud recycling system.
Our products are environmentally friendly high-tech products which is used for the separation of the solid particles from the slurry liquid and the recycling of the clean fluids..
Brightway products are wildly used in different applications and industries such as oil and gas drilling, CBM drilling, drilling waste management, and the modern trenchless infrastructure construction.
In trenchless construction industry, the concerned applications include tunneling, micro-tunneling, pipe-jacking, bored piles construction,piling construction and diaphragm wall construction, etc
BRIGHTWAY solids control system and slurry separation plant is the necessary equipment in the above applications, which can control the slurry parameter, improve the quality and efficiency of hole forming, shorten the quality of hole cleaning time, and reduce the construction cost , the sticking accidents the pollution of the environment.

I like the X-frame design for this exhibition, and would like to share here.

NO DIG

NO DIG

TRENCHLESS CASE

TRENCHLESS CASE

What is pipe jacking?

Brightway slurry separation plant is widely used in the pipe jacking, then what is pipe jacking?

The below layout is the typical job site for pipe-jacking.

Mirco-tunneling slurry job site

Mirco-tunneling slurry job site

1. The virgin ground is being excavated to create a manhole pit, and the hydraulic jack is placed at a strategic spot. The size and depth of the manhole pit varies, depending on the specification requirements.

2. The pipes strings are stringed together piece by peice using the hydraulic jacking machine. Each unit of pipe are being lifted down into the manhole pit by a crane. The jacking of pipes towards the destined direction is done from the launch shaft to the target shaft.

3. Brightway Slurry Separation System is essential in different soil with different ground water levels. In the cutter head, the excavated spoil is mixed with water and then transported to the surface, where water and spoil are separated by the separation plant and the clean water then remains in the slurry circle.
Brightway unique separation plant can operate in different models depending on the ground condition.

4.Lastly, once the string of pipes are done, the crane will then, remove the cutter head from the manhole pit at the target shaft, and replace the gap with a connecting pipe inside. Both manhole pits will be sealed with cement seamlessly.

Slurry treatment system

Slurry treatment system

 

Pipe Jacking

Brightway provide the full range of slurry separation plant for pipe jacking project.

  • What is pipe jacking?

From the below picture, let’s know pipe jacking briefly.

pipe jacking layout

pipe jacking layout

1. The virgin ground is being excavated to create a manhole pit, and the hydraulic jack is placed at a strategic spot. The size and depth of the manhole pit varies, depending on the specification requirements.
2. The pipes strings are stringed together piece by peice using the hydraulic jacking machine. Each unit of pipe are being lifted down into the manhole pit by a crane. The jacking of pipes towars the destined direction is done from the launch shaft to the target shaft.
3.Lastly, once the string of pipes are done, the crane will then, remove the cutter head froom the manhole pit at the target shaft, and replace the gap with a connecting pipe inside. Both manhole pits will be sealed with cement seamlessly.

slurry separation plant

slurry separation plant

The technology used to separate and remove undesirable materials from a fluid

– Maximize drilled/excavated solids removal

– Minimize fluid lost with the discarded cuttings

– Minimize commercial solids lost with cuttings ƒ Maintain fluid properties for a clean, healthy slurry ƒ

The result is lower mud cost and manageable waste volume for efficient control of well costs.

IMPACT OF DRILL SOLIDS (CONTAMINANTS). ƒ

Increased hydrostatic head ƒ Interference with bit/formation interface ƒ Increase viscosity causing:

– Reduced efficiency of all SCE Coarser screens use Hindrance of accelerated settling (stokes law)

– Higher chemical and dilution costs – Higher disposal costs

ƒ Excess abrasion affects:

– Pumps and expendables

– SCE equipment Screens and screen supports/ Hydrocyclones Centrifuge rotating assembly

– Slurry separation plant drill bits

– Piping

ƒ Increase tunneling operating costs

Brightway slurry separation plant on the Qatar Post

Brightway slurry separation plant is compact in design, easy for operation.

The good technology does not need to be complicated, but to make the life easier, as Brightway design durable but easy for operation.

Brightway 180 m3/h slurry separation plant has commissioned in Qatar and customer used the Herrenknecht micro-tunneling machine as below picture.

brightway separation plant

brightway separation plant

Brightway separation plant with the below separation process:

The separation effect can be 60 um or 20 um according to customer requirement.

Brightway separation plant separation process

Brightway separation plant separation process

Brightway Separation Plant has demonstrated its high-performance capalilities at many job sites worldwide.
It is available in different sizes, so you can always find the optimal Brightway separation plant to meet your requirements.
Brightway separation plant outstanding design will be apparent in transport. All of the required components, such as the screen, cyclones, pumps and the control system are located inside a container to minimizes shipping expenses and protects the components during transport.
To set up Brightway Separation Plant, simply lift the screen-cyclone frame out of the container, you can place the frame in position to suite the job site conditions. After mounting all connections, the plant is ready for operation.
The machine is very easy to operate. And with the wear resistant components, it minimizes cost for maintenance and repairs.

Herrenknecht Separation Plant

Herrenknecht is a respectable enterprise.

I am lucky to join the 2016 Bauma Exhibation on Apr 11-17, 2016, and have a close contact with Herrenknecht culture, people and product.

As the slurry separation plant manufacturer, always pay great attention to the leaders in this industry worldwide.  Here is demo of Herrenknecht typical separation plant design.

Slurry separation plant

Slurry separation plant

slurry separation plant

slurry separation plant

To know the separation plant  processing flow, the below diagram for your reference.

Herrenknecht separation plant flow chart

Herrenknecht separation plant flow chart

The slurry from the discharge pump goes to the coarse screen firstly, then go to the 1st compartment of the tank, the 1st gravel pump takes the slurry from the 1st compartment to the desander for further separation with the cut point reaching 60 um, and the cleaner fluids goes to the 2nd tank compartment. The 2nd gravel pump has the slurry go to the desilter processing from the 2nd compartment, reaching the cut point 20 um, and the cleaner fluids go to the 3rd compartment, which can be used for the pipe jacking machine by the charging pump.

 

Brightway Separation Plant Flowchart

For the well-known brands in the slurry separation plant industry-Schauenburg, Herrenknecht, Bauer, etc, they are the respectable manufacturer.

Brightway is the growing company in the separation plant industry for the micro-tunneling( pipe-jacking) and TBM( Tunneling Bore Machine) projects, and I’d like to introduce our processing flow of Brightway separation plant as below.

Separation Plant Operation Flowchart

Separation Plant Operation Flowchart

Slurry charged with soil is conveyed to the plant through the supply line (1) and let out onto a vibrating coarse sieve (2) which removes particles exceeding 5 mm in size.
The sieved slurry processed by the second fine shaker and drops into a trough and passes through a pipe into the main reservoir (3) of the desanding module from where it is pumped (4) to the two main cyclones (5) which separate out sand from the slurry.

The sand pours out through the underflow outlets (6) of the cyclones and drops onto a vibrating fine sieve to be dewatered and removed (7) from the process.

The treated slurry leaving the cyclones through the overflow outlets pours into an intermediate tank (8) from where it passes to a storage tank (9).

A further refinement of the slurry can be achieved by pumping (10) already

Brightway Slurry Separation Plant

Brightway Slurry Separation Plant

I will update the processing flow of Herrenknecht , Bauer, Schauenburg in the follow weeks.

Screen installation for slurry separation plant

I am studying the Schauenburg product, and in 2016 BAUMA exhibation, I visited their booth, and impressed by their 3D experienced video to understand their slurry plant structure. The Below is the screen installation for their slurry separation plant.

Bring spring chairs at the support construction into the provided position and arrange it horizontal. The higher spring chairs were installed at the discharge side. Place helical compression springs at the spring chairs. Hoist of the dewatering screen basically with 4 ropes, which are fixed via clevis mechanical stop grommets. Use pulling harnesses to avoid damages via bevelled ongoing ropes at the painting resp. at the bonnets or splash guard.   Manoeuvring and sinking with caution of the dewatering screen over the spring to the spring chairs. Thereby check out that the centring pipes slide into the springs. Check out, if all springs are in the prescribed positions, before the holding ropes are full released. Remove clevis from the mechanical stop grommets.  Check downward deflection of the dewatering screen to constancy. Connect exciters preferable above the provided cable lashes electrically upside the dewatering screen lobbying water proofed branching point. In case that new cables should conducted up to the motor connection box, absolutely seeing that the junction box is closed water proofed again. (See for this separate installation indications special for exciters). The cable to the motors should so hang up, that they do not rubber during the operation to the vibrating parts. The exciters should electrically so locked together, that at a black out of one motor the second motor is automatically stop. The motors must rotate in the opposite direction, rotating direction see indication in the machine operating manual. Check out and make sure, that the distance between the vibrating parts and other construction parts is not less then 50 mm.

Brightway slurry separation plant with the classifying screen and dewatering screen, while fixed by wedge on the screen desck.

slurry separation plant

slurry separation plant

Brief Introduction about the Micro-tunneling Pipe Jacking Method

Brief Introduction about the Micro-tunneling Pipe Jacking Method

Micro-tunneling technology for trenchless installation of supply and disposal tunnels by pipe jacking method, ID200-ID3000
The main object is to find a balance between customer requirements and the requirements of nature and the environment.
The technologically advanced products allow us to make life easier for many people all over the world and use trenchless technology to conserve resource and focus on sustainability.
Machines that fit customer needs!
General speaking, there are 4 kids of micro-tunneling systems:
1. AugerPro system
2. Slurry System
3. EPB System
4. Hard rock system

Mirco-tunneling Grain layout

Mirco-tunneling Grain layout

microtunneling methold

microtunneling methold

AugerPro System is an economic micro-tunnelling solution for soft soil( sand, silt, clay) without boulders and with a very low groundwater level. It is suitable for small to medium diameters, and short to medium jacking lengths. The excavated soil is transported via Auger train to the start shaft; a spoil treatment is not necessary. The pipes are pushed in directly after the cutter head. The machine is easily operated from the control container on the surface. As a result of the laser -based guidance system, it can achieve a very high level of accuracy.

AUGERPRO SYSTEM

Micro-tunneling methold-AUGERPRO SYSTEM

Slurry System is essential in difficult soil with high ground water levels. It is suitable for very long distances and large diameters. In the cutter head, the excavated spoil is mixed with water and then transported to the surface, where water and spoil are separated again; the water then remains in the slurry circle.

Mirco-tunneling slurry job site

Mirco-tunneling slurry job site

1)Pipe
2)Control Container
3)Charge Pump
4)Mud Tank
5)Separation Plant
6)Start Shaft
7)Laser
8)Jacking Station
9)Discharge Pump
10)Intermediate Jacking Station
11)Steering Head
12)Trailer With Power Pack
13)Target Shaft
14)Flow Meter
15)Bentonite Pump
16)Generator

EPB system( Earth pressure balance shields) is that all non-stable ground require a support pressure to balance the earth pressure that is acting on the cuter disc. The excavated soil accumulates in the excavation chamber and , together with the driving force of the machine, builds the supports pressure. The spoil is transported out of the excavation chamber by a screw conveyor and is then brought to the launching shaft by conveyor belts or lorries.

EPB system

Micro-tunneling methold-EPB system

Hard rock system can be used in fractured and unfractured rock. In stable ground conditions, the machine is equipped with a gripper station to grip against the tunnel wall to move forward. In factured rock, the unstable tunnel wall is supported by pipes or segments.