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Abstract: The history of hydropower development in the Himalaya indicates that many tunnels have suffered from cost over-
runs and delays. These issues are directly dependent on the quality of rock mass and the permanent rock support applied in
underground excavation. Right judgment and proper evaluation of the self supporting capability of the rock mass and the use
of optimum rock support systems help considerably in reducing construction cost and delays. This paper examines such issues
as geological conditions in the Himalayas and varying approaches and costs in tunnel construction. An assessment is made
regarding the exclusion of permanent concrete lining in the headrace tunnel of the 72MW Middle Marsyangdi Hydroelectric
Project in Nepal. The project has 5.2 km fully concrete lined headrace tunnel that passes through fair to poor rock mass.
The evaluation is based on the use of actually recorded rock mass quality of the headrace tunnel during construction and
rock support principle used at the comparable Khimti Hydro Project headrace tunnel. The evaluation includes calculation of
equivalent tunnel section for similar headloss, stability analysis, assessment of possible water leakage, and required injection
grouting measures. We conclude that the headrace tunnel without permanent concrete lining was possible and would have
been equally stable, at considerable financial savings.
Key words: Equivalent tunnel section, squeezing, tunnel lining, stability analysis, leakage control, hydropower, Nepal
Case Description
shaft and about 1.5 km tailrace tunnel. The turbine system Equivalent cross section for MMHEP headrace
in Khimti is pelton wheel. The performance test carried out Due to closeness of the sloping topography, the relatively
to measure the hydraulic efficiency of the waterways found higher water pressure and the surge shaft location, it is
satisfactory. assumed that full concrete lining at the downstream end of
The length of the waterway from tunnel inlet to pelton headrace tunnel was needed. Therefore, out of the 5114 m
turbine center is 1003.60 +7888.00+11.60 = 8903.20 m. headrace tunnel, 214 m downstream end near surge shaft is
Considering all possible minor headloss, the Manning's assumed to be fully concrete lined and the remaining 4900 m
number (M) of the shotcrete lined tunnel of Khimti-I was may be left without full concrete lining. The headrace tunnel
back calculated and found to be M = 35.7. shape will then be an inverted D shaped with a base width B
The excavation methods in both headrace tunnels were as shown in the Figure 4 (left and middle). The permanent
conventional drilling and blast. The average round length of rock support will be systematic bolting, invert concrete lining,
the drilling and blasting, however, was more in Khimti than shotcreting and pre-injection grouting. For the calculation of
in MMHEP. The average round
Table 1. Waterway System and Manning’s Number at Khimti-I.
depth (pull length) in MMHEP is
1.64 m (Shrestha 2009), while the Mean Diam- Manning
Waterways Length
average round depth (pull length) eter/ Area Number
in Khimti is about 2.25m. From Steel Lined Penstock and Bifurcation Section
this we can say that the value of M Upper pressure shaft 439.95 m 1.94 m 80
obtained in Khimti could safely be Intermediate horizontal section & lower pressure shaft 563.65 m 1.80 m 80
used as reference M for MMHEP
Bifurcation penstock pipe 11.60 m 1.53 m 80
headrace tunnel without concrete
Headrace tunnel concrete lined section (Inverted ‘D’ shaped)
lining. Hence, this M value is used
to calculate the equivalent cross Downstream concrete lined section 418.00 m 9.1 m2 60
section with same headloss, as that Shotcrete lined or Unlined section (Inverted ‘D’ shaped)
is the case for fully concrete lined Headrace tunnel excavated from Adit-3 (Section-1) 1005.00 m 13.50 m2 ’M’ to be
headrace tunnel at MMHEP. calculated
Remaining shotcrete lined section (Section-2) 6465.00 m 11.60 m2
Figure 4. Proposed shortcrete lined and concrete line sections (left and middle) and existing concerete line section (right)
Figure 6b. Correlation of Specific Leakage to Joint Parameter and hstatic (Panthi Figure 6c. Specific Grout Consumption at Khimti Headrace Tunnel (Panthi 2006).
2006).
Table 4. Specific Leakages Based on Tokheim and Janbu (1984) and Panthi ( 2006)
Specific Leakage (l/min/tm) Specific grout consumption (kg/m) Total Grout
Methods
Average Max Min St.dev Average Max Min St.dev ( tons)
Tokheim and Janbu (1984) 14.06 24.38 2.94 7.07 785.03 1718.53 146.33 502.15 3980.81
Panthi ( 2006) 5.98 13.95 3.16 2.23 324.58 572.94 121.20 134.37 1694.54
Figure 7a. Specific Leakage at HRT, MMHEP . Figure 7b. Grout Intake in HRT, MMHEP (Shrestha 2009).
Table 6. Cost of Pre-Injection Grouting to Control Leakage Calculated for both Approaches
Total Grout Consumption and Grouting Cost References
Description Tokheim & Janbu
Khimti-I Approach Barton, N., 2001, Water and
Approach
Total Cement Consumption (tones) 3,981 1,695 stress are fundamental to rock mass
mill NRs. 139.3 59.3 characterization and classification,
Total Cost of pre-injection
mill USD 1.74 0.74
grouting(NRs. 35.00/ kg) ISRM News Journal (letter to the
mill NOK 11.76 5.00
NRs. 27245 11,597 editor, December).
Injection grouting average cost per
USD 341 145 Bell, F.G., 2007, Engineering
meter tunnel
NOK 2299 1,718
Deduction for 214 m mill NRs. 5.8 2.5 Geology (2nd ed.), Amsterdam:
Total cost of grouting mill NRs. 133.5 56.8 Elsevier.
Benson, R.P., 1989, Design of
unlined and lined pressure tunnels,
Table 7. Cost of Concrete Lining for MMHEP Headrace Tunnel. Tunnelling and Underground Space
Cost of concrete lining Technology, 4, pp.155-170.
Description and Quantity
Rate NRs. Amount NRs. Amount USD Amount NOK
Concrete cost for 4900 m 11,431x6.9 =
Brady, B.H.G. and E.T.
tm 386,482,600 4,831,033 32,609,469
length considered 78,874 Brown, 1985, Rock Mechanics for
Cost per m tunnel tm 78,874 78,874 986 6,655 Underground Mining. Boston: Allen
*tm = tunnel meter & Unwin.
Broch, E., 1982, The development
Table 8. Cost Comparison Between Headrace Tunnel of unlined pressure shafts and
With and Without Final Concrete Lining. tunnels in Norway, pp.545-554 in
Tokheim and Janbu Panthi Approach W. Wkttke, ed., Rock Mechanics:
Cost items
Approach (M. NRs) (M. NRs)
Cost of injection grouting 133.5 56.8 Caverns and Pressure Shafts,
Extra cost of excavation and support 146.3 146.3 Rotterdam: Balkema.
A
Total extra cost for tunnel without final Hoek, E., 1998, Practical Rock
279.8 203.1
concrete lining
Engineering (2000 ed.), Hoeknotes,
B Cost of concrete 386.5 386.5
Toronto: Rocsciences; URL:
C Differences 106.7 183.4
www.rocscience.com/roc/hoek/
D % saving 27.6 47.5
hoeknotes2000.html.
Hoek, E. and E.T. Brown, 1980,
to Tunnelling in Himalayan Rock Mass Conditions’ in Underground Excavation in Rock, London: Institute of
2006 from NTNU. He completed his MSc in Hydropower Mining and Netallurgy.
Development in 1998 and MSc in Civil Engineering in Hoek, E., and Marinos, P., 2000, Predicting tunnel
1992. He is the author of many scientific papers related squeezing problem in weak heterogeneous rock masses,
to tunnelling, rock slope engineering and hydropower. Tunnels and Tunnelling International, Part 1 &2 (Nov-Dec)..
He has over 15 years of experience in design, construction Karlsrud, K., 2002, Control of Water Leakage when
and planning of tunnelling and hydropower projects in the Tunneling under Urban Areas in the Oslo Region,
Himalaya (Nepal and India). Publication No. 12, Oslo: Norwegian Tunelling Society.
Corresponding Address: krishna.panthi@ntnu.no Nilsen, B. and Thidemann, A., 1993, Rock Engineering,
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