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KEYNOTE LECTURE
Oscar M. Bandeira *
Abstract. The project is developed by Norte Energia S.A. The consortium is controlled
by the state-owned power company Eletrobras, which directly and through its
subsidiaries Eletronorte and Chesf controls a 49.98% stake in the consortium. Others
important partners are stakeholders of the consortium. The Belo Monte project on the
Xingu River is in the middle of the Amazonia jungle, in the State of Pará, in Brazil´s
north side, some 40 km downstream from the cities of Altamira and Vitoria do Xingu,
and 800 km away in a straight line from Belém, the capital city of the state. The plant is
about 3000 km from several major Brazilian cities, such us São Paulo, Rio de Janeiro,
Brasilia and Belo Horizonte. It is the largest completely Brazilian hydroelectric power
plant in installed capacity and the largest hydro project under construction in the
country. When completed in December 2019, it will be the world´s fourth largest hydro
project in installed capacity.
This paper deals with the construction of the Belo Monte hydropower complex, as well as
it comprises the project design with its considerations, the construction logistic, the
phases of the construction with its challenges, and the construction methods. The main
objective of the project is power generation, with an installed capacity of 11,233.1 MW
and an average 4571 MW of firm energy, Belo Monte has been also the solution to
generate the clean, renewable energy, which is required for the development of Brazil.
With a flooded area of 478 km2, it is a run-of-river plant, with only 0,04 km2/MW
installed. The project is modern and fully committed to the principles of technical and
economical feasible, low social and environmental impact. The arrangement of the
project is different from any other one already built in Brazil or abroad, with six earth-
fill and rockfill dams, thirty dikes (some really big dams), a channel with capacity of
13,950m3/s considered the largest artificial one in the world, two powerhouses with 24
generators units being 6 with horizontal Kaplan Bulb turbines, 18 Francis turbines, and
a spillway with eighteen radial gates with a flow capacity of 62,000m3/s.
To achieve large production rates, was needed to build an urban complex to house the
workers and the first work on the cofferdams in 2011 was the kickoff of the construction
of the Belo Monte Power Plant. The construction of a vast hydropower plant in the
middle of the Amazon jungle was a very challenging project. From December to June,
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heavy rains and floods occur, with an average rainfall of 2200 mm per year, increasing
the difficulties and logistical problems, most of the suppliers of materials, equipments
and processed food where located in other regions, mainly in Southeast of Brazil.
Simultaneously to the work´s progress, it was necessary to improve river access by
building a port, the regional highway network was also improved and expanded. More
than at other brazilian hydro projects was necessary to attract and hold workers, by
offering both direct and indirect extra benefits, mainly, by building a village with
complete and standard educational, health and leisure facilities. With a need to produce
high production rates, with schedule constraints, at the peak of the construction were
reached world records of excavation and earth-fill and rockfill, for that it was necessary
four different construction sites, with distance among them up to 40 km, as well as
mobilize an impressive quantity of 35,000 workers and 2500 heavy equipments, provide
maintenance and handle the complex logistics of supply and movement of the materials
on the job site. The civil works needed to allow the start of the filling of the main and
intermediate reservoirs were accomplished in a record time of 4.2 years.
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1 INTRODUCTION
The Belo Monte is a run-of-river plant, with a complex of dams, 02 powerhouses, 02
reservoirs, 01 Spillway, numerous dykes, power canal and a series of canals to supply
two different power stations with water, located in two sites Pimental and Belo Monte 40
km far away, (In Annex 1 the main characteristics of the hydroelectric complex).
It was under study since late 1970s. Throughout this period, the original concept, has
undergone several modifications, so that all necessary measures could be taken to
mitigate its impacts. This was made to maintain the living conditions of indigenous
groups and communities who live in the area surrounding the plant, known as big bend of
the Xingu River.
To comply with strong environmental constraints, Belo Monte was planned to operate
as a run-of-river plant, resulting in a significant reduction in the size of the reservoir and
consequently the area to be flooded.
The area of the reservoir was reduced by 60 per cent compared with the initial Project.
As a comparison, while the Brazilian average flooded area for hydropower is 0.49 km2
per installed MW, the ratio for Belo Monte is only 0.04 per installed MW, the second
lowest ratio in Brazil. In addition, of the 478 km2 of flooded area, about 228 km2 or 47.7
per cent correspond to the original riverbed.
It can thus be concluded that the Belo Monte hydropower scheme was continuously
optimized to reduce environmental impacts, as compared with other hydropower, which
leads to improved sustainability and represents good practice for a hydro project.
The Project took the necessary steps to avoid flooding Indian lands, which remain
untouched by the dam, construction sites, access roads and other engineering structures
required for the project.
For the indigenous communities, and those who use the Xingu River for fishing or
transport, the Belo Monte project created solutions to enable boats to pass through, also
to allow fishes to pass the dam.
As well in the construction of the main dam of Belo Monte, in Pimental site, a stretch
of approximately 100km, downstream of the dam, the so-called big bend of the Xingu
river, has an ecological hydrograph consensus with the purpose of generation of energy
and the adoption of a hydrography that meets the maintenance and continuity of
ecological processes (terrestrial and aquatic ecosystems) and navigability and life of
riparian and indigenous communities for the maintenance of biodiversity, navigability
and the living conditions of the populations of the Stretch of Reduced Flow (SRF).
Currently, the civil works are concentrated in the placement of the secondary concrete
for assembling of the remaining generating units. By August 2018, the civil works
amount 98.1% and the installed capacity of 6344.2 MW with 16 generating units, 06
Bulb and 10 Francis turbines, what represents 56,5% of the total of the installed capacity.
The first turbines went online on April 2016. The power station is planned to be
completed by end of 2019. The plant is also responsible for supplying electricity for the
interconnection among the systems in the North/Northeast, South/Southeast and Centre-
West regions.
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2 GENERAL ARRANGEMENT
The general arrangement of Belo Monte hydroelectric complex, which is a run-of-river
plant, is characterized to be one of the largest diverse powerplant in the world, it presents
four distinct construction sites distant to each other, from the main dam structures, with
approximately 7 km of extension in the actual stretch of the Xingu River. From the site
called Pimental, to the site Belo Monte, where the main Powerhouse of the project is
currently in generation and under construction, the distance is approximately 40 km
away, in which they are interconnected by the largest Power Canal of the World (For
more details, see Ref. [1]), approximately 16 km long and 0.3 km wide, and the
Intermediate Reservoir, an artificial reservoir with 28 large dykes, like Dike 13,
approximately 2000 m in length, 53 m of height and volume of 5,7 million m³, as well as
by small dikes, like Dike 1, with 80 m of length, 6 m of height and volume of 5 thousand
m³, forming a maximum abrupt drop of 94.12m (See Figure 1).
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construction times and ensuring the safe start of reservoir filling and power generation,
without the need to complete all structures in one first step. After reservoir filling the
cofferdam was incorporated and the dam was completed.
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2.1.4 SPILLWAY
The spillway is located on the right of the Complementary powerhouse and it was
designed to discharge 62,000 m3 / s, with the reservoir at El. 97,50 (Full Supply Water
Level level). There are 18 spans with 20.00 m of width each and ogee crest in El. 76.00.
Its flow is controlled by segment type floodgates, and upstream and downstream are
provided stop-logs for maintenance. The energy dissipation of the discharged flows is
made by means of a short dissipation stilling basin. The Spillway has two service
bridges, one upstream with crest in the El. 100 m and another downstream with the crest
in the El. 98 m.
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was removed when the water level inside of the Canal was approximately the same of the
water level of the lake in Pimental site. A bridge located 13.5 km from entrance of the
Canal links both sides of the access roads.
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have access roads at the elevation 100 m, which delimits the edge of the channel (line A)
distant 179.50 m from the axis. At elevations 84.00 m and 93.00 m, the slopes have
intermediate berms which, for a soil excavation configuration (Figure 3A), are 6.00 m
wide. This configuration of section excavated in soil (or conformed by earth-fill)
constitutes the typical section where the top of the rock is above the bottom floor of the
channel (Figure 3B), the slopes are excavated with inclination of 0, 5H: 1.0V with the
width of the rock-carved shoulders widened in order to maintain the excavation of the
typical section in soil.
As can be seen in Figure 3C, soil or earth-fill embankments are lined with a 0.6 m-
thick 5D rockfill material applied over a transition layer of 0.20 m in thickness. This
material has a grain size greater than the 5D ‘material (applied to the bottom floor), it
was obtained directly from the mandatory excavations of the channel.
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Figure 14- 16 steps of filling of Power Canal and Intermediate reservoir in 45 days
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The Left Dam Closure has the crest at the EL. 100.00 m, maximum height of 88 m and
extension of 1100.00 m with a volume 7.790.326. The Right Dam Closure has the crest at
the EL. 100.00 m, maximum height of 54.00 m and extension of 780.00m, with a volume
of materials of The Santo Antônio Dam, is located to the left of the Power Intake in a
position close to the Left Dam Closure. The dam crest at the EL. 100.00 m with the
lowest elevation of the foundation being located in approximately EL. 30.00 m, which
results in a structure with a height of 70.00 m. The crest has a width of 7 m and an
extension of the order of 1,310.00 m totaling 6,222,390 m³ of earth-fill.
Predicted Volume
Description Unit Percentage
Volume Executed
Earth and Rockfill m3 60.867.964 60.857.734 100,0%
RCC
m3 689.009 689.009 100,0%
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5 CONSTRUCTION METHODOLOGY
The most relevant construction methods employed in the concrete structures of the
Belo Monte site were the Roller Compacted Concrete- RCC at the Intake of the Belo
Monte site, using the sloped layer method of placing.
As well the construction method with pre-assembled steel bars, the use of slip forming
with pumped concrete in the concrete structures of the Intake, Powerhouse and Spillway
speed up the construction in the Belo Monte and Pimental site.
6 PEAKS OF OUTPUT
The Belo Monte HPP, a national pride, was built in Brazil by more than 35 thousand
workers, breaking several output records of common and rock excavation, as well as in
earth fill and rock fill services.
- Peak of monthly output of structural concrete: 110,000 m³ on September 2014;
- Peak of monthly output of common excavation: 6,600,000 m³ on July 2015;
- Peak of monthly rock excavation: 2,500,000 m³ on July 2015;
- Peak of monthly output earth-fill and rock-fill: 6,280,000 m³ on July 2015.
7 ACKNOWLEDGEMENT
The author is grateful to the Board of Norte Energia and particularly to his engineering
team who have worked together since the beginning of the project and for all 35.000
workers who have worked in this huge Project,
8 REFERENCES
[1] IEP – Consórcio Projetista. Projeto Básico Consolidado da UHE Belo Monte. 2012.
[2] IEP – Consórcio Projetista. Projeto Executivo da UHE Belo Monte. 2012-2016.
[3] CCBM – Consórcio Construtor Belo Monte. Relatório Mensal de Progresso. 2016.
[4] CBDB- Revista Brasileira de Barragens- A CONSTRUÇÃO DO COMPLEXO
HIDRELÉTRICO DE BELO MONTE QUARTA MAIOR DO MUNDO EM
CAPACIDADE INSTALADA- MAIO 2017- BIAGIONI J.M, BANDEIRA O.M., AND
LEITE D.T.
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ANNEX 1 - MAIN CHARACTERISTICS – BELO MONTE HPP
Pimental Site
Geradores
River Xingu Nominal Power: 40,90 MVA
Installed Capacity: 233,10 MW Rotation Speed: 100,00 rpm
Firm Energy: 145,72 MW Tensão Nominal: 13,8 kV
Flooded Area 373 km2 Rendimento Máximo: 97,00 %
Quantities: Power Factor: 0,95
Common Excavation: 4,269,205 m3 Total Weight per Unit: 2.700 kN
Rock Excavation: 1,946,811 m3 Spillway
Earthfill and Rockfill: 11,676.030 m3 Type: Floor Sill
Concrete: 666,687 m3 Maximum Flow: 62.000 m3/s
Power Intake Sill Elevation: 76 m
Type: Gravity Total Length: 445.50 m
Total length: 114,30 m Number of Spans: 18
Gates Width: 20 m
Type: Stop-Logs Gates
Width: 5.64 m Type: Segment
Height: 17.33 m Width: 20 m
Complementary Powerhouse Height: 22 m
Type: Surface Right Channel Dam
Generators Units: 6 Type: Rockfill
Width of the Blocks: 67.15 m Material: Soil and Rock
Total Length: 114.30 m Total Length: 1100 m
Turbines Height: 34 m
Type: Horizontal Kaplan- Bulb Width of Crest: 9,00 m
Nominal Power: 38.85 MW Elevation of Crest: 100,00 m
Rotation Speed: 100 rpm Lateral Left Dam
Nominal Head 11.40 m Type: Earth-fill
Nominal turbinable flow: 380 m3/s Total Crest Length: 5100 m
Rendimento Máximo: 94.5 % Height: 14 m
Total Weight per Unit: 8.200 kN Crest Elevation: 100,00 m
[5]
Power Canal
Minimum Width of the Bottom: 210 m Common Excavation: 86.957.163 m3
Total Length Excavated: 20,181 m Rock Excavation: 24.537.929 m3
Total Length after Impounding: 16,200 m Fund coating (Agr. Crushed): 2.704.765 m3
Maximum flow depth: 22.50 m Embankment: 8.942.544 m3
Maximum Flow: 13,950 m3/s Concreto: 38.152 m3
[6]
Intermediate Reservoir
Dam: 1 Common Excavation: 21.508.433 m3
Dikes: 28 Excavation in Rock: 690.141 m3
Transposition Channels: 7 Fund Coating (Broken Rock): 1.005.925 m3
Filling Channels: 3 Embankment: 30.380.351 m3
Flooded Area (NA Max. Maximorum):: 120 km2 Concrete: 44.272 m3