Company & Application

STRABAG UK’s tunnelling project, based in North Yorkshire, UK, is being constructing as the world’s longest conveyor tunnel, known as the Mineral Transport System, as part of the Woodsmith mine development. This project will see transportation of tens of millions of tonnes of Polyhalite, a naturally occurring mineral substance and subsequently when crushed, POLY4, a multi-nutrient fertiliser used worldwide.

The project began launching a Tunnel Boring Machine to commence a 36.7km long tunnel, which was constructed using a single shield machine. This length of tunnel is expected to be a new world record with the tunnel fit out, including a new full length conveyor system.

The Challenge

The project demonstrates the scale of the tunnelling and underground construction capabilities in the UK, also highlighting the need for focus on innovation and social responsibility throughout all processes. The 380 m-deep shafts were constructed using the blind-bore method, not only with the aim of reducing carbon emissions, but also to improve general on-site safety. Extensive air quality monitoring was required throughout the entire project and, notably, Trolex systems were fitted to ensure reliable and accurate monitoring is available and maintained throughout the entire project.

The Trolex plan

A range of Trolex real-time solutions have been identified for use in the STRABAG project for the detection of hazardous gases and dusts in this tunnelling project. 236 devices, including SENTRO 8 Gas detector, SENTRO single Gas detectors and AIR X real-time Particulate Monitors have been fitted across multiple systems with a total of 824 individual sensors for both gas detection and dust monitoring.

As well as particulate ranges from PM2.5 to PM10 being constantly monitored, logic systems constantly watch for key gases such as CH₄, CO, NO, H₂S, SO₂ and O₂. Local emergency Audio/Visual alarms, Trolex Flow Sensors and Intrinsically Safe Battery Back-Up units have been added to back up the system and add intelligent data to the data all powered by intrinsically safe battery back-up units.

The Trolex solution

Alongside the systems being implemented across the tunnelling project, the Tunnel Boring Machine itself has also been fitted with multiple gas detectors, as well as Audio/Visual alarms and sensors.

Due to the nature of tunnelling projects, with fast paced demolition, excavation and drilling processes, cutting, concrete spraying and transportation generates fine dust and particulates as a by-product of natural materials like rock and sand being disturbed, increasing risk of lung diseases and respirable health issues.

The recognised risk of using combustion engines and diesel-powered equipment often produces carbon monoxide and Diesel Particulate Matter is something the project was increasingly aware of, something the system will flag through data indicators across its broad range of sensors.

Gas sensors are already actively working as the mining machine hits pockets of hydrocarbons which set the unit into alarm, and where necessary lower down the mining machine to avoid risk of explosion.

What it meant moving forward

Providing this pioneering safety technology to STRABAG meant the project has joined a long-standing reputation of safety instrumentation being supplied to workers by Trolex in some of the most challenging environments over the last 65 years.

Like many other underground industry leaders across the globe, STRABAG made the decision to deploy multiple Trolex detectors, monitoring equipment, sensors and alarms demonstrating to their workers that health and safety is a priority on this project, and a superior approach, not only for producing the highest quality throughout the tunnelling project, but also with a conscious effort on the effects relating to the workforce wellbeing and the wider society.

Company & Application 

Since 1976, Timeco have been working in the field of tunnelling, particularly in tunnel boring machine (TBM) excavation and environmental monitoring systems. For almost 50 years, Timeco’s expertise have spanned from major TBM excavation projects to involvement in significant piling and foundations works. 

The Challenge 

Given that underground and tunnelling environments are recognised as hazardous areas (ATEX), TBM workers are consistently exposed to various flammable and hazardous gases throughout their working day, like combustible dust and high levels of RCS, therefore accurate and reliable monitoring of gases and air quality is essential. 

Thanks to experience accrued, the wide spectrum of projects completed and the long-standing partnership with Trolex, Timeco are proud to support and assist customers from the initial design of complex air and/or gas monitoring systems in ATEX areas to the implementation stages during operations, to protect workers from various risks. 

The AIR X plan 

Timeco supply a variety of Trolex gas monitoring systems, including TX9165 Sentro 8 and TX6351-2 Sentro 1 Universal Gas Detector designed to perform in the most hazardous working environments, as well as the highly robust TX6383 Flammable Gas Detector. 

To protect workers from a range of hazardous dusts, Timeco supply ground-breaking Trolex particulate monitors, such as the AIR XD Group I IS Dust Monitor, designed to monitor all types of dust in ATEX atmospheres, and the AIR XS Silica Monitor, which detects levels of RCS in tunnelling environments. 

The AIR X solution 

As an official Trolex partner and dealer in the Italian market, Timeco offers on-site commissioning services and can supply all the required spare parts. A Timeco spokesperson said about supplying Trolex solutions to tunnelling environments: 

Norilsk Nickel is a major mining corporation in the world market, and the system was bought for their Anhydrite mine, up on the Arctic Circle in the city of Norilsk.  

The Challenge 

Most mines collect water from the surrounding strata, and this must be carefully monitored. Failure to monitor the water levels and control the pumps in a timely way can lead to tragedy, with loss of life and economic ruin for the mine and can force equipment and whole workings to be abandoned. Water pump out (AKA mine de-watering) is critical to both operation and safety in the mine. 

The plan 

The system which combines our TX2100 Commander, TX6649 Power Supplies, TX2071/5 Temperature Probes, TX5637 Vibration Sensors, TX6114 Pressure Sensors, TX6001 Insertion Flow Switches and TX5814 Submersible Level Sensors, along with a suite of bespoke software and system building by Promtex, controls a set of 3 mine pumps and a complex of valves in the pipework around them. These are located in the bottom of the mine and pump out any water accumulating in the mine. 

The solution 

Our TX2100 Commander, along with special communications protocols developed by us and a flexible programming platform installed by Promtex, provides the combination of speed of reaction and reliability essential to this key application. The system offers a range of operating modes to the operator working at the pump station and also includes a remote control from the mine supervisory level on the surface linked via Ethernet.  

What it meant moving forward? 

Reliability in the sensing and controller hardware is essential to the success of the application and the Trolex platform was selected as it provides a flexible and cost-effective basis for any mine-critical system in the next few years.