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Chapter-9 Construction Methdology PDF
Chapter-9 Construction Methdology PDF
Hydroelectric Project
CHAPTER - 9
CONSTRUCTION METHODOLOGY
9.1 GENERAL
The project envisages construction of barrage, a head regulator, Feeder
Channel, desilting chamber, collection pool & intake, Head race tunnel, surge
shaft, pressure shaft, underground power house, tail race tunnel and all
infrastructure works. The construction methodology and equipment planning
for various works is based on the site conditions prevailing in the project area.
Construction activities are planned in such a way that the project will be
completed in the shortest possible time period. The following assumptions
have been made for construction methodology and equipment planning of the
project.
All the pre-construction activities like land acquisition, infrastructure works
and government approvals are completed before the start of construction
works on main components of the project. All civil, hydro-mechanical and
electro-mechanical works are executed in following main packages :
CIVIL WORKS
Package I : Barrage and Desilting works
Package II : Head Race Tunnel from RD-0.00m to
RD-8,400.00m
Package III : Head Race Tunnel from RD-8,400.00m
to RD-16,875.00m
Package IV : Head Race Tunnel from RD-
16,875.00m to RD-23,450.00 m
Package V : Civil works for Surge Shaft and
Pressure Shaft
Package VI : Civil works for Power House,
Transformer Cavern, Tail Race Tunnel
and Switch Yard.
HYDRO-MECHANICAL WORKS
Package VII : Hydro Mechanical works comprising of
gates, hoists and Pressure Shafts steel
liner
Electro-Mechanical Works
Package VIII : Generating Units (Turbine &
Generator), Cooling Water System,
Drainage/ Dewatering System, Unit
Control & Automation, Bus duct.
Package IX : Valves-MIV& BFV
Package X : EOT Crane,
Package XI : Air Conditioning, Ventilation etc.
Package XII : Fire Fighting,
Package XIII : Transformers(Generator Transformer),
for the planning of equipments. Basic assumptions made for the planning of
equipment for various construction activities are enumerated below:
9.7.1 Working hours of equipment
All works are proposed to be done in two shifts and the scheduled working
hours have been taken as 20 hours per day. 26 days/month have been
considered on an average in a month.
9.7.2 Densities of Materials
The calculations have been based on capacity of hauling units without
considering the densities of different types of materials for excavation and the
fill material.
9.7.3 Earth Volume conversion factor
Suitable standard norms have been adopted for conversion of volumes in
natural, loose and compacted state.
9.7.4 Operating Efficiency
The operating efficiency of different types of equipment has been taken as 50
min per hour.
9.7.5 Muck Dumping Lead
A lead of 15 km has been considered for dumping of muck that would be
generated from Head Race Tunnel and a lead of 5 km is assumed for the
dumping of muck that would be generated from Power House, TRT,
Transformer Cavern, Barrage, Feeder Channel, Desilting Chamber and
Collection Pool works. A lead of 10 km is assumed for the muck dumping of the
material generated from Surge Shaft and Pressure Shaft works.
9.7.6 Concreting Lead
A lead of 10 km is considered for the concrete works in Head Race Tunnel and
5 km is assumed for the concrete works in Power House, TRT, Transformer
Cavern, Barrage, Feeder Channel, Desilting Chamber, Collection Pool, Surge
Shaft and Pressure Shaft works.
Phase-I
Construction of 5 bays of Spillway, Undersluice and Head Regulator will be
taken up in the first phase of Barrage works. Total of 3.0 lacs cum of
earthwork is involved in these structures and by providing 3 Nos of Hydraulic
Excavators of 1.5 m3 capacity working round the clock (with stand bye
equipment) and fleet of dumpers, daily progress of 3,000 m3 is expected.
Therefore, the excavation gets completed in 4 months. Adequate dewatering
arrangements would be made during the excavation in foundation at Barrage
complex. Dynamic compaction will commence immediately after the necessary
excavation at Barrage site. The excavation for cut-off wall will commence
immediately after dynamic compaction/compacted backfill at Barrage site. The
deep excavation for cut-off wall will be done with Hydraulic Excavator BC-
30. Bentonite solution will be used during excavation of cut-off wall so as to
avoid the side wall collapses. The excavation of cut-off wall up to the required
level will be done and plastic concrete will be poured in the excavated trench
by using a tremmie. The concrete work for Barrage base slab and other
superstructure works will commence immediately after the completion of
plastic concrete in cut-off walls. Concreting in the river bed, pertaining to
under sluice, 5 bays of spillway and head regulator and adjacent structures will
be taken up on priority in full swing by 2 nos. 30 m3 Batching plant and 2
Stationery 1 m3 Capacity Mixers, placement of concrete is planned by Transit
mixers and Cranes with suitable Concrete Buckets. The concreting of under
sluice, 5 bays of spillway and head regulator up to sill level will be completed
in 2 months before onset of monsoon. The superstructure works of these
structures will commence immediately after the concreting of the base slab.
The Hydro-Mechanical works for these structures will be executed in parallel to
the civil works of these components. All civil and hydro mechanical works for
these components will get completed in 27 months after the start of work at
Barrage site.
During planning it is assumed that all the structures on the left bank that will
be affected by the river flow will be completed in two seasons. Structures like
floodwalls and the intake will be completed within the first eight months. The
upstream and downstream apron, stilling basin and the rip rap protections will
be completed within 27 months. After completing the First Phase works on the
left bank, the river will be diverted through under sluice and the construction
for Phase-II Barrage works will be taken up.
Phase-II
Construction of Earthen Dam and 6 bays Spillway will be taken up in this phase
of Barrage works. 1.2 lacs cum of earthwork is involved in these structures and
by providing 2 Nos. of Hydraulic Excavators of 1.5 cum capacity working round
the clock (with stand bye equipment) and fleet of dumpers, daily progress of
2,000 m3 is expected. Therefore, the excavation gets completed in 3 months.
Adequate dewatering arrangements would be made during the excavation in
foundation at Barrage complex. Dynamic compaction will commence
immediately after the necessary excavation at this phase of Barrage
construction. The excavation for cut-off wall will commence immediately after
dynamic compaction/compacted backfilling at this front. The deep excavation
for cut-off wall will be done with a Hydraulic Excavator BC-30 and Bentonite
solution will be used during excavation of cut-off wall so as to avoid the side
wall collapses. The excavation of cut-off wall up to the required level will be
done and plastic concrete will be poured in the excavated trench by using a
tremmie. The concrete / earth filling work for this phase will commence
immediately after the completion of plastic concrete in cut-off walls. Concreting
in the river bed, pertaining to remaining bays of spillway will be taken up after
necessary excavation / dynamic compaction. The concreting of remaining bays
of spillway up to sill level will be completed in 2 months. The superstructure
work of this structure will commence immediately after the concreting of the
base slab. All civil works for these components will get completed in 18
months.
The structures like Desilting Basin and Feeder channel can be constructed
throughout the year. The excavation of the Desilting Basin will commence
after the completion of flood wall beside the Desilting Basin. Work at Reservoir
just downstream of Desilting Basin would be taken up simultaneously with the
Desilting Basin. Excavation and backfilling at Desilting Basin, Reservoir and
Feeder Channel would be taken up with 4 Nos. of Hydraulic excavators of 5.0
lacs cum bucket capacity and sufficient nos of 20/25 T Dumpers. Therefore,
total earthwork of 5 lacs cum involved in these structures is planned to be
completed in 6 months. Adequate dewatering arrangements would be made
during the excavation at these fronts. The concrete work will commence
immediately after the completion of excavation/backfilling work at these
fronts. Concreting of the structures will be taken up on priority in full swing by
2 nos. 30 m3 Batching plant and 2 Stationery 1 m3 Capacity Mixers,
placement of concrete is planned by Transit mixers and Cranes with suitable
Concrete Buckets. The superstructure civil works for these structures will be
carried in parallel to hydro mechanical works. All civil and hydro mechanical
works for these components will get completed in 30 months after the start of
work at these fronts.
Equipments required for the construction of Coffer Dam, Earthen Dam,
Spillway, Under Sluice, Head Regulator, Feeder Channel, Desilting Chambers
and Collection Pool are shown in Annexure-14.1.
Headrace tunnel
6.2 m dia. Circular shaped, 23.450 km long Head Race Tunnel has been
proposed at the end of Collection pool for carrying water to the pressure
shafts. 300 mm thick concrete lining has been proposed all along the length of
the tunnel.
The headrace tunnel will be started from the thirteen faces as shown in Fig-
9.1. All the adits shall be completed before the start of excavation of headrace
tunnel. Construction of HRT Face-1 and Face-2 will be taken up from Adit-1 to
HRT. Similarly Face-3/Face-4, Face-5/Face-6, Face-7/Face-8, Face-9/Face-10,
Face-11/Face-12, and Face-13 will be taken up from Adit-2, Adit-3, Adit-4,
Adit-5, Adit-6, and Adit-7 respectively. The critical reach of HRT is about
5000m between Face-8 and Face-9, so special attention in terms of resources
is required at this front for completion of work in time schedule.
Figure-9.1
The tunnel will be excavated by conventional drill and blast method using
mechanised equipment. At each Adit, 3-Boom Drill Jumbo will be used for
drilling holes and robotic shotcrete machine will be used for temporary rock
support. After blasting, fresh air will be supplied at excavated face to remove
gas and dust produced during blasting by a duct. The excavated muck will be
loaded through one 1.5 cum bucket capacity hydraulic excavator and
transported by dump trucks of 20/25 T capacity to muck dumping area. After
excavation scaling will be done followed by the rock bolting and shotcreting.
Pre-splitting or smooth blasting technique shall also be adopted to avoid over
break. The proposed cycle time for the excavation and rock support of HRT
along with equipment planning is enclosed as Annexure-14.2.
Overt Lining
For overt lining it is proposed to take up more than half of upper portion of the
tunnel. The concrete will be placed in the overt by using 6m long shutter form.
Transit mixer of 6 cum capacity will be used for transportation of concrete from
batching plant to concreting site. Pouring of concrete in the overt will be done
through with 38 cum capacity truck mounted concrete pumps fitted with
hydraulically operated placing boom. With this arrangement and suitable
manipulation of boom, the concrete will be delivered from the pump.
Invert Lining
Invert lining will be taken up after the completion of overt lining of HRT in
various reaches. A progress of 300 m/month on average is assumed for this
activity.
Surge shaft
Construction of approach road to Adit to Surge Shaft bottom is planned to be
completed during pre-construction works. The construction of Adit to Surge Shaft
bottom would be taken up immediately after the start of Civil works. This Adit is
planned to be completed in 4 months. Thereafter, a pilot shaft (235m deep & 4m
dia.) would be constructed from bottom of Surge Shaft using Alimack Raise
Climber with sufficient nos. of jack hammers, one Dozer of 200 HP, one Hydraulic
Excavator of 1.5 cum capacity and sufficient nos. of 20/25 T Dumpers. This
activity is planned to be completed in 5 months time while excavation of horizontal
Pressure Shaft at EL-1940m would be in progress simultaneously. Once pilot shaft
is made through, slashing of Surge Shaft can be done from the top to bottom.
Pressure Shaft
Two number 3.3 m dia circular steel lined pressure shafts each bifurcating into
unit penstock of 2.0 m dia circular steel lined pressure shaft have been
provided for taking the water to six pelton machines in underground power
house. Each pressure shaft consists of horizontal and inclined portions. Adits to
Horizontal Pressure Shafts at EL-1571.4m, EL-1271.4m and EL-1051.4m would
be completed before the start of excavation work in Pressure Shafts. The
construction of horizontal pressure shafts at elevation of 1900.0 m shall be
taken up by full face drilling and blasting method. The adit used for reaching
the bottom of Surge Shaft will be used for construction of this portion of
pressure shaft. The excavation shall be taken up with one 3Boom Drill Jumbo,
one hydraulic excavator, one dozer (200HP) and sufficient nos of 10T/20T
dumpers.
Similarly the horizontal pressure shafts at El-1571.4m and EL-1271.4m shall
be taken up individually with separate set of equipments as deployed at upper
horizontal pressure shafts. Construction of horizontal pressure shaft at
elevation of El 1051.4 m will be undertaken from branch tunnel from Main
Access Tunnel to Power House.
Powerhouse
An underground Power House has been proposed on the left bank of Nyamjang
Chhu River with the installed capacity of 780 MW comprising 6 units of 130
MW each. An underground excavation of 1.2 lacs cum is assessed in Power
House and is expected to be completed in 25 months with two shifts operating.
The construction of powerhouse involves co-ordination of civil works and
electromechanical works. The main civil works in the powerhouse consists of
excavation, rock support and concreting works.
The excavation of Power House would be taken up after the excavation of the
Adit to Power House Crown branching off from Main Access Tunnel to Service
Bay in the Power House. This Adit would be extended through the length of the
Power House and expanded sideways to the size of 20m x 7m. Power House
excavation would be carried out by constructing suitable ramps for benching
down. Movement of equipment would be carried through ramps. For
excavation from EL-1084.202m to EL-1077.20m mucking would be done
through adit to the crown of Power House including ramp removal. For
excavation from EL-1077.20m to EL-1070.20m mucking would be carried out
through Main Access Tunnel to Power House including Bus Duct Tunnels.
Mucking of Power House below Service Bay level would be carried out through
Main Access Tunnel as well as construction adit to Pressure Shaft and Tail Race
Tunnel. Benching down of Power House from EL-1070.20m to EL-1059.40m
would be carried out in two stages by making suitable ramps in each stage. For
excavation from EL-1059.40m to EL-1054.50 m mucking would be carried out
through pressure shaft Tunnels. The bottom of the Power House will be
excavated through Tail Race Tunnels.
The equipment required for underground excavation of power house are 3
boom drill jumbo, 1.5 cum hydraulic excavator, 20/25T dumpers, wagon
drills/crawler drills, jack hammers, shotcrete machine, grout pump, concrete
pump, vibrator, transit mixers etc. Batching and mixing plant (90 cum/hr), 180
TPH aggregate processing plant would meet the concreting requirement of
Power House. The installation of electromechanical equipment will be done in
close coordination with the civil contractor. Almost all of the civil structures
including the installation of overhead crane will be completed before the
installation of electromechanical equipment.
Transformer Cavern
The excavation Work for Transformer Cavern of size 173mx16.3mx23m
located on downstream of Power House Cavern will generate about 70,000
cum of excavated muck. The crown of this cavern would be accessed through
100 m long Adit branching off from adit to crown of Power House cavern. The
construction adit to Transformer Cavern crown would be extended to full
length of the Transformer Cavern. Thereafter, it would be enlarged sideways to
the full width of the Transformer Cavern. Transformer Cavern excavation
would be carried out by constructing suitable ramps for benching down.
Movement of equipment would be carried through ramps. For excavation from
EL-1085.675m to EL-1076.80m mucking would be carried out through adit to
crown of Transformer Cavern including ramp removal. Mucking of Transformer
Cavern at EL-1076.80m to EL-1070.20m would be carried out through the
access tunnel branching off from Main Access Tunnel.
The equipment required for this purpose are 3 boom drill jumbo.1.5 cum
hydraulic excavator, 20/25T multi axle rear dumpers, wagon drills/crawler
drills, jack hammers, shotcrete machine, grout pump, concrete pump, vibrator,
transit mixers etc. Batching and mixing plant (90 cum/hr), 180 TPH aggregate
processing plant would meet the concreting requirement of Transformer
Cavern.
Tailrace
7m dia. Circular shape, 1.965 km long Tail Race Tunnel has been proposed
from power house to discharge the water back to river. TRT will be concrete
lined. The construction of Tail Race tunnel will be done from outlet face of TRT
and from junction of the Main Access Tunnel with TRT. The tunnel will be
excavated by drill and blast method using mechanised equipment. 3-Boom
Drill Jumbo will be used for drill holes and robotic shotcrete machine will be
used for temporary lining. An advance of 95 m/month from each face is
proposed for the excavation of TRT.
Concrete Lining of TRT will commence immediately after the completion of
excavation work at respective faces. The lining of the tunnel is proposed to be
done in two stages i.e. overt concrete will be done firstly followed by invert
concrete lining. Two gantry shutters of 6m length are proposed to be used in
TRT so as to achieve a progress of 6m/day and 150m/month in this reach.