controlling risks of large tunnels

Controlling Risks of Large Tunnels – Alfred Moergeli (www.moergeli.com), European Tunneling Seminar No. 8, 09/25/2012 1

Controlling Risks of Large Tunnels - An International Approach

How Do You Control The Risks of Your Large Tunnels …? … Apply Best Risk Management Practices

Alfred MOERGELI Certificated Civil Engineer FH, EUR ING SWISS Safety & Health Engineer EigV/BSV http://www.moergeli.com

European Tunneling Seminar # 8, Sept. 25, 2012 @ Strasbourg Hilton

www.drklug.com

http://www.moergeli.com/

http://www.drklug.com/



Controlling Risks of Large Tunnels An International Approach - Overview

1. US – CH … Similarities & Intercultural Differences

2. Risk Management – Best Practices

3. How Risk Management Really Helps You? Project Insides From - Gotthard Base Tunnel (GBT), southern lots - Ceneri Base Tunnel (CBT)

4. Questions / Answers


How Do You Control The Risks of Your Large Tunnels? - Summary

1. Risk Management (RM) – Do It By The Book 2. Start With RM As Early As Possible 3. Carry RM Through To Commissioning 4. Follow Best International RM Practices 5. Learn From Other Large Projects & Tunnels

6. Share Your Lessons Learned With The Industry - Thank You David R. Klug & Associates!

www.drklug.com


http://www.drklug.com/



SWITZERLAND In The Heart Of Europe - Paradise for Tunnel Builders

Switzerland (CH) A country in the heart of Europe

Population: 7.95 Mio (admin.ch, 31.12.11)

> 2,500 Tunnel-KM (FGU, 2010)

= 0.31 Tunnel-Meter/CH-Citizen

Graph, courtesy of beos-elektronik.de, Sept. 13, 2012

TBM-m3 by D > 10m worldwide: CH 45% Versus the US: 25% (Kovari/Fechtig/Amstad,1991)

A Paradise for (TBM) Tunnel Builders! Graph, courtesy of http://www.swisstunnel.ch, 12.09.12

http://www.swisstunnel.ch/


Switzerland’s Tunnels Graphs, courtesy of http://www.swisstunnel.ch, Sept. 12, 2012

http://www.swisstunnel.ch/


USA – Switzerland Similarities … Or Intercultural Differences …?

Internet, 13.09.12

Do we have bigger differences than money … and tax systems …?

Yes, you can bet on …


USA – Switzerland Facts & Figures 2012 UBS, CH in Figures 2012, internet, Sept. 12, 2012


USA – Switzerland Professional Similarities … Intercultural Differences

USA Dispute Resolution Boards

(DRB‘s) Escrow Bid Documents Geotechnical Baseline

Reports (GBR‘s) NRTL … (Machinery Safety) ISO 13849-1/2 Risk Management

„Rest of the world“ … Dispute Resolution Boards (DRB‘s) Escrow Bid Documents Geotechnical Doc‘s & Reports CEM (CE Marking) ISO 13849-1/2 (Control Systems) Risk Management (ISO 31000, iec 62198)

After crossing the North Atlantic > 70 times, we feel at home in both worlds!


Risk Management (RM) Do it by the book – Avoid proprietary solutions ISO 31000:2009 / ITIG Code

International Standards

Generic basics

True & tried, internationally acknowledged approach


So, How Do You Select An Appropriate Method? Use ISO Guides As A Starter Kit

Order & download all ISO documents online immediately from

Basic documents for a well-known, world-wide accepted risk management method: Risk management definitions ISO GUIDE 73:2009

Application to Safety & Health ISO GUIDE 51:1999

http://www.iso.ch


What Are Your Basics? Understand The Definitions

E.g. by ISO GUIDE 73:2009

E.g. by ISO GUIDE 51:1999


How Does Risk Management Really Work? Are My Residual Risks Tolerable?

1 Identified hazard...

3 ... Implement a solution

2 ... Risk Assessment

4 ... Check Residual Risks


How Do I Get A Risk Register …? Begin With A Risk Shortlist


1. Definition of your System’s Limits (“Context”)

How Does Risk Management Really Help You? Higher Productivity & Safety with Lower Costs

2. Register of all your relevant hazards 3. System Safety by a Safety System

4. Optimization of your processes 5. Higher productivity & safety, lower costs 6. Comprehensible communication of your Residual Risks 7. Transparent documentation 8. Win legal compliance, your liability remains limited 9. Rest well (again) at the end of the day!


Is Your Risk Mitigation Complete? Use a Safety System to Achieve System Safety

Use a Safety System (STOP) 1 Substitution System / Strategy 2 Technology 3 Organizational / Personal Measures (Administrative Controls) To end up with System Safety => US Military Standard 882 D, 02/10/2000, Appendix A, A 4.3.3, i. requires: You must not use behavior oriented measures only

if hazards can cause an irrecoverable outcome!


How Does A Risk Assessment Really Work? Apply A Safety System – Achieve System Safety

1 2 3 4 5 6 7 8 9


How Do I Keep Track Of All My Risks? Visualize Your Risks – Before And After Mitigation

Are your risks tolerable? Use a Risk Map (“Before” & “After”) as a graphic decision tool.


What IS My Value At Risk? Use Quantitative Risk Management For Your Costs With RIAAT – Tool Of RiskCon

1. Start-up screen

2. Cost Element

3. Report

Courtesy of RiskCon, www.riskcon.at

http://www.riskcon.at/

http://www.tat-ti.ch/


Courtesy of ATG, http://www.alptransit.ch

The Gotthard Base Tunnel Subject of Already Numerous Publications

New Railway Lines in Switzerland Transalpine Connections Cross Switzerland


The Gotthard Base Tunnel Four Herrenknecht Open Hard Rock TBMs

Courtesy of HK


Controlling Risks of Large Tunnels Gotthard Base Base Tunnel (GBT)

High(er than expected) rock temperatures High sophisticated ventilation & cooling required

Continuous TBM cutterhead maintenance & cutter change Rock bursting and micro earthquakes @ Faido

Large deformations block TBM Backup

Substantial invert heave => Revamp tunnel section

Shotcrete operations at the TBM face

Dust control

Extreme long logistic & communication lines Final Lining behind advancing TBMs

ID/Badge based Access Control


Risk Management in Action - Tunnel Bodio High Speed Tunneling in Hard Rock

Courtesy of TAT


Risk Assessment in Action CE Conformity of Hard Rock Tunneling Systems

Gotthard Base Tunnel (GBT) Courtesy of Consorzio TAT

http://www.tat-ti.ch

Four TBMs with Trailing Back-up

D = 8.83 / 9.53 m

> 400 m long

> 4,000 to, > 4,000 KW

> 110 Mio USD

Courtesy of AGN http://www.agn-amsteg.ch



http://www.agn-amsteg.ch/

http://www.agn-amsteg.ch/


> 11km

Inner Lining Hard Rock Excavation

> 14km

7 6 5 3

1 4

2

< 3 km

Risk Management in Action – GBT, Tunnel Bodio 7 Construction Sites in 2 Tunnels, Simultaneously

... Simultaneously ...

Gotthard Base Tunnel (GBT) - Courtesy of Consorzio TAT http://www.tat-ti.ch




1,400 m3 Shotcrete & Concrete

6,000 m3 Muck, 12,000 to

45 Locomotives, 260 Cars = Train > 3 km

216 Train Movements in the Tunnels

180 Switches, 55 km Rails

Risk Management in Action GBT, Tunnel Bodio Logistics – The Key To Success

Logistics per Working Day ...

As per May 2006 ...

Gotthard Base Tunnel (GBT) Courtesy of Consorzio TAT





Risk Management in Action - Tunnel Bodio Pouring the Final Lining

Courtesy of TAT


Lessons Learned Contractor’s “Go for Safety” Campaign

Courtesy of ATG

From The Owner‘s Request ...

... And the Contractor‘s Experience ...

... To Action: Go For Safety Campaign

Gotthard Base Tunnel (GBT) Courtesy of Consorzio TAT http://www.tat-ti.ch




Risk Management CBT

Courtesy of ATG


Controlling Risks of Large Tunnels Ceneri Base Tunnel (CBT) Courtesy of rowa

D&B Performance about 200 Tunnelmeters/Month * Face & increasing

Rowa Suspended System No. 20 plus New level of industrialized / mecanized (D&T) tunneling Efficient Ventilation & Cooling Concrete Batching Plant & Powder House both underground Control of traffic on two separate levels – safey (long) logistic lines

Safer lifting operations / devices Safe parallel construction operations unter gantry bridge

Excellent illumination Redundant COM – Cell Phone coverage ID/Badge based Access Control


Controlling Risks Of Large Tunnels CBT – Four Suspended Tunneling Systems by rowa

Courtesy of rowa www.rowa-ag.ch

http://www.rowa-ag.ch/



Controlling Risks Of Large Tunnels Ceneri Base Tunnel (CBT) – Protect The Crews

Videos: Ceneri Base Tunnel (CBT), Again – Thank you ROWA, www.rowa-ag.ch



2nd Level Risk Management Support for Caltrans Devil‘s Slide Tunnel, CA - USA

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Risk Management (RM) is not rocket science and does not take a wizard!

Conclusions Set Up Your Team And Get Started ... Today!

All you really have to do is …

Set up your team as early on as possible.

Select your team members with care. As multi-disciplinary as possible.

Under the leadership of an experienced Risk Manager. Start with a Preliminary Hazard Analysis (PHA).

Use a well known and accepted risk management method. Start controlling your risks – convince everyone by real added-value.

Controlling Risks of Large Tunnels – Alfred Moergeli (www.moergeli.com), European Tunneling Seminar No. 8, 09/25/2012

Risk Management – What’s In It For You? Pros & Cons

Pros Enhances your performance Cuts your costs Potential for innovative solutions Potential for process optimization Added value through team work

Legal Compliance – Your Liability remains limited

Cons

The earlier you can start with RM the bigger are your profits RM may bind valuable resources in critical project phases

RM needs additional time = money


Risk Management – If It Works Here … … It Will Work For You As Well

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Your value added based on our proven applications: 1. Priority on implementation of Risk Mitigation in situ 2. Closing the information loop by Risk Response Audits 3. Lessons Learned (Continuous Improvement by ISO 9001) 4. System Risk Management based on ISO 31000 5. More than 24 years of contractor experience underground 6. Project-independent Subject Matter Expert 7. Out-of-the-box thinking, independent Risk Manager 8. Latest state of the art technology background 9. US & international high-profile project experience


Risk Management – Making A Difference

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1 Review processes in situ

2 Preliminary Hazard Analysis

3 Risk Assessments 4 Risk Response Audits

5 Validate system improvement in situ

Picture courtesy of SMS Concast AG

Picture courtesy of SMS Concast AG

We Walk The Talk – Complete The Process


Your Consequences - What’s Your Next Step? Well, Let’s Just Begin With It - Now!

Risk Management is not rocket science and does not take a wizard!

We are here to assist you: http://www.moergeli.com All our tools are available for download from our website,

incl. this presentation (=> Download => Document Index)

Take care and stay safe! We need all of you to shape a safer & more economic world!

Just start it – and keep it going and current.



Thanks and Acknowledgements

The author thanks and acknowledges the very competent support and kind provision of detailed data by

http://www.alptransit.ch

http://www.herrenknecht.de http://www.rowa-ag.ch


http://www.alptransit.ch/

http://www.herrenknecht.de/





Thanks and Acknowledgements

Tunnel AlpTransit – Ticino Bodio Lotto 554 / Faido Lotto 452

25% 25% 25% 25%


Courtesy of TAT




Thanks And Acknowledgements Thank You For Having Me

However, the biggest thanks goes to all crews on site, safely managing the unforeseeable (= Risk Management in Action) as their daily routine.

Every day they move into places where no human being has ever been before. Therefore, always … “… That’s one small step for (a) man, one giant leap for mankind ...”

Neil Armstrong, 2:56 UTC on July 21, 1969 – First person to walk on the Moon Internet, Sept. 19, 2012 - Edited by mcllc/am

Controlling Risks of Large Tunnels – Alfred Moergeli (www.moergeli.com), European Tunneling Seminar No. 8, 09/25/2012

Your Questions…? … Our Answers –

Controlling Risks Of Large Tunnels Questions & Answers – Thank You!

Videos: Gotthard Base Tunnel (GBT) Again – Thank you TAT, www.tat-ti.ch

If Risk Management could help here … …. It will deliver value added for you as well !

Thank You!

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