Indian Society of Engineering Geology Engineering Geology, Geotechniques & Geohazards – A quest for Excellence

10-11 July, 2014, Kolkata, India

CONSTRUCTION OF CHUTAK HE PROJECT – CHALLENGING TASK IN ADVERSE

CLIMATIC CONDITION

B.D.Patni * Arindom Chakraborty Ashwani Jain

Chief (Geology) Deputy Manager (Geology) Deputy Manager (Geology)
NHPC Limited, Sector-33, Faridabad-121003, *bdpatni@rediffmail.com
,
ABSTRACT: The 44 MW Chutak Power Station of NHPC is located in the far flank Kargil District of
J&K. Under this project water from River Suru, a tributary of River Indus is utilized to generate power for
meeting out the electricity requirement of highly remote Kargil District dependent on diesel generated
power. In this run of the river scheme, a net head of 52m is utilized for generating 44 MW of power. A
small reservoir has been created as an operating pool. The major project components comprise of a barrage
across river Suru, a 5.9m dia, 4.7km long, HRT, an underground powerhouse to accommodate four units
each of 11 MW capacity and a 65m long tail race tunnel.
Geologically, the power station is located in Trans Himalyan belt of Ladakh region comprising of
metavolcanics and granitic gneiss.
After comprehensive investigations, the DPR of the Project was submitted by NHPC in January, 2004 and
the construction was started in the year 2005.
Construction of a hydro project at an altitude of 8500 ft was indeed a challenging job. Due to high altitude
and absence of vegetation, less percent of oxygen had reduced the efficiency of man and machinery
considerably. Besides, due to adverse temperature conditions with minimum temperature as low as -32
coupled with heavy snow fall between November and March, the surface work at the project site practically
used to come to a halt. Thus, total working season limited to only seven months. Timely completion of the
project in such limited working session was thus a challenge. But, due to efficient construction management
and whole sole efforts of NHPC and contactors the project finally achieved all the targets and successfully
commissioned in January, 2013.
The present paper is an effort to document the gamut of geological works carried out in the project right
from inception to the commissioning of the project which includes geological investigations performed at
FR, DPR and pre construction stages, the geological problems faced during construction of various project
components and remedial measures adopted to tackle those problems.

1.0 INTRODUCTION
The 44 MW Chutak H.E. Project is located in Kargil District of J&K State. The energy requirement of
Kargil district is being made through diesel sets. To cater to the electricity requirement of the area, the 44
MW Chuak HE Project was conceived on river Suru, a tributary of Indus River.
The project is a run of the river scheme which generates 239.3 MU in a 90% dependable year, utilizing a
net head of approximately 52m developed by construction of a 15m high barrage with foundation level at
El. 2767M.
Geologically, the project is located in Trans-Himalayan belt of Laddakh region and forms part of Zanskar
mountains. Structurally, the project area falls in Indus Suture Zone which is a highly tectonised belt
sandwiched between the Indian plate in South and the Eurasian plate in North, comprising of Metavolcanics
and granitic gneiss of the Indus Flysch belonging to Cretaceous age. The barrage is founded on overburden,
generally constituted by riverine material and comprising boulder to pebble of granite gneiss, quartzite,
metavolcanics etc in a sandy matrix.
Owing to adverse temperature conditions with minimum temperature as low as -32 in winters, low oxygen
level (65-70% of normal) and heavy snow fall, the project faced severe constraints during construction The
severe cold put a serious limitation on performance of men and machineries thus it was almost impossible
to carry out concreting and grouting works. The timely completion of the project was thus a challenge.
Efficient project/construction management through advance planning of work, close interaction between
project and corporate Design & Geology team as well as Civil Contractor leads to successful completion of
the project.
The present paper describes investigation, preconstruction and construction stage geological studies carried
out at various project components.
2.0 GEOLOGY OF THE PROJECT AREA
The project area is located in Trans-Himalayan belt of Laddakh region and forms part of Zanskar
Mountains. Structurally, the project area falls in Indus Suture Zone which is a highly tectonised belt
sandwiched between the Indian plate in South and the Eurasian plate in North). The basaltic to andesitic

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Drass volcanic follow the zone of the Indus Suture and represent an Island arc that was active between Late
Jurassic and Late Cretaceous. There are reported local occurrences of pillow lava, rhyolite and other
volcanogenic products. The volcanic rocks are light grayish brown & comprise a thick complex of
greenstones and serpentines containing beds of pyroclastic material. The rocks trend in NW-SE direction
with dips ranging from 400 to 650 towards south west and are intruded by hornblende granite which is
grayish white, coarse grained and exposed around Kargil area.

3.0 INVESTIGATIONS CARRIED OUT BY NHPC

The Project was conceived by JKPDC and they identified three alternative dam sites and carried out
investigations. After the Project was handed over to NHPC in the year 2000, the investigations carried out
by JKPDC were reviewed and further investigations were carried out. Based on the investigations results,
the right bank initial scheme was partially modified and the barrage was shifted 1km downstream of village
Sarzhe, where as the underground powerhouse is located 500m upstream of village Chutak at right bank of
river Suru. After successful completion of requisite investigation at barrage and power house site the DPR
was submitted in January 2004. Following geological investigations were conducted for various project
components;

3.1 BARRAGE
3.1.1 Surface and Subsurface explorations
The river at the barrage site flows due northeast through a U-Shaped valley. The barrage, site has been
explored by geological mapping, drilling, drifting and rock mechanic testing to evaluate the subsurface
geology around the area.
3.1.1.1 Geological mapping
The stretch of approximately 2 sq km, extending from 300 m upstream to 300 m downstream of the dam
axis has been geologically mapped on 1:1000 scale with 1m contour interval (Figure 1).
At the barrage site, the Suru river bed is covered by riverine deposits consisting of an assemblage of
boulders, pebbles & gravel in a sandy matrix. The boulders in the river bed are rounded to sub-rounded,
angular and sub-angular of granites and volcanic rocks. These range in size from 0.5m to 2.5m. Till terrace
level, the banks are covered by fluvioglacial debris after which the slopes are covered dominantly by scree
material. Occasional and isolated rock blocks are found within the terraces & in the river course. The
spread of the overburden is greater in the left bank, whereas on the right bank it is concealed under the
younger scree debris. Higher up both the flanks are constituted by fluvioglacial deposits partly reworked by
river Suru & partly by the tributary nallahs. These fluvioglacial deposits are covered by slope wash deposits
and debris material brought from the higher elevation. On the right bank, the alluvial debris terminates
abruptly against an escarpment face of gneissose granite. In marked contrast, the left bank initially rises up
sharply at 30-400, thereafter, the profile levels out in the form of a river terrace till EL 2795M. At this level,
the riverine material is overlain by nallah debris in the form of a vast alluvial fan of Ganduche nallah
comprising of large granite rock blocks, which continues to the left flank of the valley and abuts against the
mountain ranges comprising of exposures of gneissose granite on the left bank.
3.1.1.2 Drilling and Drifting
To investigate the sub surface conditions, of river bed, two number holes were drilled at Barrage axis. As
expected, bed rock was not intercepted in either of the drill holes. The right bank of the river has been
explored by a drift of 20m length in rock. to evaluate rock mass characteristics of the intake tunnel.
Analysis of drift data reveals that, the right bank is constituted by hard, compact and moderately strong to
strong gneissose hornblende granite. Five prominent discontinuity sets, apart from foliation have been
deciphered. The initial 10-12m depth reveals considerable shearing with several minor shear seams of upto
15 mm width, visible both in crown and walls. Quartz mineralization is occasionally observed along S4 set
which is sometimes sheared. Rock mass ratings evaluated, reveals class III with RMR value 52 for the
initial reach of 10-12 m and thereafter indicating class II (good rock) with rating of 72.

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Set Average Spacing Aperture Condition

No. Orientation

S1 2770/800 20-60cm In general filled with quartz vein (1-5 mm) Rough undulatory

S2 1510/820 20-60 cm Tight to 5mm open Rough planner

S3 0410/210 6-20 cm -do- Rough undulatory
S4 2080/280 60-200 cm -do- -do-
S5 0970/880 60-200 cm -do- -do-

Figure-1 Geological Plan of Barrage

3.1.1.3 Rock Mechanic Testing

At Barrage Axis- River Bed, the Modulus of deformation (MPa) by Plate Load Test was determined which
comes out to be 15.26 to 16.44 MPa and 12.21 to 16.73 MPa for dry and saturated samples respectively.
The geotechnical parameters of two soil samples from barrage area were also determined. The results are as
follows:

Test Description Sample PLT01 Sample PLT02

Unit Weight gm/cum 1.63 1.95
Dry density gm/cum 1.43 1.73
Void ratio 0.9 0.62
Specific gravity 2.72 2.80
Cohesion kg/sqcm 0.04 0.15
Angle of internal friction in degree 37 35

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3.2 HEAD RACE TUNNEL

The 5.9m dia horse shoe shaped, 4.78Km long HRT was driven on the right bank of the river Suru. The
design discharge of the tunnel is 96.20cumec with a velocity of 3.33m/s.

3.2.1 Geological mapping

The HRT was geological mapped on 1:5000 scale and discontinuity survey was conducted all along the
tunnel alignment. It is noted that except for some initial portion being accommodated in granitic terrain
major portion of HRT would be excavated in metavolcanic rocks.
The terrain along the tunnel was extremely rugged with towering rock escarpments projecting sub vertically
out of a scree covered profile. The scree covered slopes rest at angles of 50 0-550 against the foot of the cliffs
and attain a gentle profile near the river bed. The rock profiles are interrupted occasionally by both seasonal
and perennial nallahs mostly cutting through weak features in the rock and sculpturing gullies in the
otherwise steep topography. A major stream, the cheskor nallah, bisects the tunnel alignment in the vicinity
and upstream of the powerhouse location. Downstream of village Stikchey, the profile becomes almost
horizontal as a consequence of a wide, thinly foliated and sheared band of volcanics at this location. The
differential weathering of this band has resulted in a depression in the otherwise steep topography.

The further stretch of the proposed tunnel alignment displays on the surface, relatively thick overburden
cover of fluvioglacial debris/scree concealing bedrock of black meta-volcanics. The Scree deposits
comprising of colluvial debris are generated by weathering of weak zones within the volcanics and granites
and are constituted by pebble to boulder grade rock blocks (Devoid of fines) brought down by gravity
transport.

3.3 POWER HOUSE

A 83m long, 15.5m wide and 34.5m high underground power house with the installed capacity of 44MW
and foundation level at EL. 2702M. The power house has been investigated with the aid of geological
mapping, exploratory drifting and rock mechanic testing.

3.3.1 Geological Mapping

The power house has been geologically mapped on 1:1000 scale. The structure is confined in a hill on the
right bank of the Suru River. At this location hill slope rises steeply from the river bed at an angle of 450-
500 till El 2810M, being constituted by bare rock exposures. Thereafter, the hill slope attains a gentle
profile of 300, generally being overburden covered till El 2900M, where the overburden abuts against steep
rocky escarpment. The overburden generally comprises of loose scree debris generated by frost action and
brought down by gravity. The scree is assessed to range from 5-15m in depth at this location.
Apart from foliation, two other prominent discontinuity sets have been identified within the rock mass. The
discontinuity characteristics are briefly described below

Sl No. Orientation Spacing Aperture Roughness

S1 014/810 <6cm 3-4 mm open Smooth Undulatory
S2 109/25-300 <6cm 3-4mm open Smooth Undulatory
S3 255/720 20-60 cm 2-3cm wide quartz vein Smooth Undulatory

3.3.2 Drifting
One drift of 85m length has been excavated to evaluate the subsurface geology of the powerhouse area. The
drift has been excavated in rocks of Dras volcanics and extended by cross cuts along the longer axis of
powerhouse cavern. RMR values assessed from the drift geology reveals rock mass rating mainly varying
from 42 to 58 indicating fair rock condition with a few minor bands of RMR less than 40 and also some
percentage of good rock with RMR value of 61-64. In view of the prominent NW/SE trending foliation with
steep NE dips, the longer axis of the powerhouse structure is aligned at 65 o across the prevalent strike for
maximum stability.

3.3.3 Rock Mechanic Tests

In order to determine engineering properties of the rock types, in-situ rock mechanic testing at powerhouse
drift has been conducted on metavolcanics at RD 72 , 75, 76.5 and 83 for determination of in-situ stresses.

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The plate load test indicates Modulus of Elasticity – 3.46 to 6.36 GPa (Vertical), Modulus of Deformation –
2.09 to 5.09 GPa (Vertical), Modulus of Elasticity – 2 .00 to 5.94 GPa (Horizontal), Modulus of
Deformation – 1.87 to 4.14 GPa (Horizontal) where as in-situ stress and stress ratio by Flat Jack Test
indicates average Horizontal Stress – 21.42 kg/sqcm, average Vertical Stress – 16.25 kg/sqcm, and average
Stress Ratio – 1.32.

4.0 CONSTRUCTION STAGE GEOTECHNICAL ASSESSMENT OF PROJECT STRUCTURES

4.1 INTAKE TUNNEL
The intake tunnels are constructed in fresh to slightly weathered, very strong to extremely strong granite
having spacing up to 250mm with 3 sets of prominent joints and random joints, RMR of these tunnels
derived from Geomechanical Classification of rock mass falls under 65-72 which means Class II, Good
rock. The excavation of these tunnels was carefully carried out by taking care of the Kul (water supply of
local) passing just above the tunnel. The controlled blasting along with line drilling was taken up to avoid
any damages and to sustain the Kul.

4.2 HEAD RACE TUNNEL

The 4.78Km long, 5.9m dia horse shoe shaped HRT was driven on the right bank of the river Suru. The
design discharge of the tunnel is 96.20cumec with a velocity of 3.33m/s. The tunnel is aligned at N0370 for
a distance of initial 665m, thereafter from RD 700m its direction is N0500 then from RD3213m it is N0450
till 4042m and then finally from RD4584m the curve starts from N0400 to N0070 till the end of HRT. The
bends in the tunnel alignment have been provided to ensure adequate lateral and top cover over the tunnel.
The maximum cover over the tunnel is 450m near RD 520m and the minimum cover is 80m near
RD3600m. (Figure 2). The HRT has been encountered with fresh to slightly weathered, very strong to
extremely strong granite and strong to very strong, thinly to moderately foliated Metavolcanics with 3 sets
of prominent joints and random joints. The discontinuity characteristics of HRT are as follows:-

Average Spacing
Set No. Aperture Condition
Orientation (in mm)
S1 065/700 150-300 Tight to 5 mm Rough Undulatory
S2 320/600 200-250 -do- Rough Undulatory
S3 165/650 200-300 -do- Rough Undulatory
RJ 140/300 60-300 Tight to 1mm Rough Undulatory
The comparative chart of Predicted and Encountered rock class in HRT (in meter & in %) is as follows:-
Rock Class Rock Class Encountered Rock Class Anticipated

(in m) (in %) (in m) (in %)

Class I 14 0.3 0 0
Class II 3696 77.9 1910.4 45
Class III 988 20.2 1910.4 40
Class IV 78 1.6 716.4 10
Class V 0 0 238.8 5

Figure 2- Geological Section of HRT

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During the excavation of HRT, at few places cavities were formed due to wedge formation which was
completely filled during the concreting and at few places some loose fall occurs in the Class IV area of
HRT which was supported by installing ribs and backfill concrete.

4.2.1 Construction Methodology of HRT

To facilitate construction activity the HRT was divided into six faces with the help of 3 adits. Face 1 and
Face 2 from adit-1, Face-3 and Face-4 from adit-2 (Figure-3) and Face-5 and Face-6 from adit-3.

Figure 3- Portal of Adit II to HRT

The excavation of HRT started from Face V & VI. The wedge cut drilling & blasting pattern was used for
excavation. Defuming was carried out through 1.5m diameter air duct. In Class II rock 50mm shotcrete
and rock bolts were installed, however in Class III rock 100mm shotcrete with wiremesh and rockbolt were
provided. The Class IV & V portion of the HRT was supported by Class III support followed by steel rib
support and concrete backfill. The excavation of HRT was completed on 25.07.09. After excavation of
HRT 300mm thick concrete lining was provided with the help of 15m long gantry (Figure-4). The low
cover area, heavy seepage zone, and class IV & V portion of HRT was considered for consolidation
grouting.

Figure-4- View of a Lined HRT

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Total no. of holes done for grouting in HRT 5648 nos.

Total consumption of cement for grouting in HRT 4389.3 tons
Consumption of cement per meter in HRT 138.293 kg

The total excavated quantity of HRT was approximately 2.1 lacs cubic meters.

4.2.2 Rock Support

The rock mass in the HRT was supported by shotcreting along with wiremesh and rock bolting as per
design drawing.
Class-I Spot bolting.
Class-II 3m long rock bolt 25mm dia @ 2m c/c, with 50mm shotcrete.
Class III 3m long rock bolt 25mm dia @ 1.5 m c/c with 100mm shotcrete and wiremesh.
Class IV 3m long rock bolt 25mm dia @ 1.5m c/c with 100mm shotcrete, wiremesh and Steel Rib @ 1m
c/c with backfill concrete.

4.3 SURGE SHAFT

The orifice type, 19m dia & 59m deep underground surge shaft, with the top level at El 2802.5M is located
on a spur constituted by thinly to moderately foliated, slightly to moderately weathered, strong to very
strong, dry to damp metavolcanics. A few shear seams are also observed in the rock mass with clay or
quartz filling. The geological log with discontinuity data is shown in Figure 5.

Figure-5 Geological Log of Surge Shaft

4.3.1 Geology of Surge Shaft

The surge shaft is accommodated in thinly to moderately foliated, slightly to moderately weathered, strong
to very strong, dry to damp metavolcanics. The rock mass in surge shaft is intersected by three sets of
discontinuities inclusive of foliation and random joint. These are summarized as below:-

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Set No. Average Spacing Aperture Condition

Orientation In mm
SS1 015/750 60-200 Tight to 2 mm Rough Undulatory
SS2
280/700 100-300 Tight to 1 mm open -do-
SS3 120/350 100-200 Tight to 0.1 mm open -do-
RJ 325/500 100-200 Tight to 0.1 mm open -do-

4.3.2 Construction Methodology for Surge Shaft

The excavation of 59m deep surge shaft was carried out by full face sinking method. The excavation of
surge shaft was carried out by drilling of 3m deep drill holes in ring pattern. After blasting and defuming
the muck was removed with the help of loader or excavators of 72CK. A gantry crane of capacity 12.5 tons
was installed at the top of surge shaft for lifting muck and machines.
The drilling of surge shaft was carried out through ROC machine/Jack hammer. Drill holes of length up to
3m are drilled throughout the surge shaft diameter for blasting purpose. After completion of mucking the
excavated wall of surge shaft was supported by 150mm shotcrete along with wiremesh and rock bolt. After
completion of support, concrete lining of 750mm was carried out. The consolidation grouting was carried
out with the help of 6m deep drill holes. The total excavated quantity in surge shaft was approximately
18910 cubic meters. During the excavation of surge shaft no geological problems were encountered.

4.3.3 Rock Support

The rock mass of surge shaft was supported by 9m long rock bolt 32mm dia @ 1.5m c/c, and 7.5m long
rock bolt 32mm dia @ 1.5m c/c with 150mm shotcrete along with wiremesh. The crown portion of the
surge shaft was supported by 12m long rock bolt of 32mm dia @1.5m c/c with 200mm shotcrete along with
double layer of wiremesh. During progressive excavation the surge shaft was supported by pre-grouting
throughout the total length.

4.4 PRESSURE SHAFT

The two number 124m and 107m long Pressure Shaft, with finished dia 4m has been excavated by full face
sinking method and drilling and blasting method.
Pressure Shaft-1: The pressure shaft 1 consists of 70m upper horizontal pressure shaft, 30m vertical
pressure shaft and 24m lower horizontal pressure shaft.
Pressure Shaft-2: The pressure shaft 2 consists of 53m upper horizontal pressure shaft, 30m vertical
pressure shaft and 24m lower horizontal pressure shaft.

4.4.1 Geology of Pressure Shaft

The pressure shaft consists of thinly to moderately foliated, slightly to moderately weathered and
moderately strong to strong metavolcanics with dry to damp water condition with quartz and clay filling
along joints at some places. The rock mass is intersected by three sets of discontinuities inclusive of
foliation and a random joint. These are summarized as below:-

Set No. Average Spacing Aperture Condition

Orientation In cm
S1 015/650 60-200 upto 1 mm Rough Undulatory
S2 300/350 100-300 -do- -do-
S3 140/350 100-300 -do- -do-
RJ 180/650 100-300 -do- -do-

4.4.2 Construction Methodology for Pressure Shafts

The two numbers pressure shaft of length 124m and 107m was excavated in three stages. These stages are
Upper horizontal pressure shaft, Vertical pressure shaft and Lower Horizontal Pressure shaft.

4.4.2.1 Upper Horizontal Pressure Shafts: - The two number upper horizontal pressure shafts were
excavated by drill and blast method. The wedge cut drilling and blasting pattern was adopted for
excavation. The excavated portion was supported by rock bolting, 50mm thick shotcrete along with
wiremesh.

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4.4.2.2 Vertical Pressure Shafts: - Two vertical pressure shafts of length 30m each were constructed by
full face sinking method. The excavation of pressure shaft was carried out by drilling of 3m deep drill holes
in ring pattern. These shafts were supported by 50mm shotcrete along with wiremesh and rock bolts. No
geological problems were encountered during excavation of shafts. During the construction of shaft no rock
fall was reported in both the shafts however a little seepage was observed.

4.4.2.3 Lower Horizontal Pressure Shafts: - The two number Lower horizontal pressure shafts were
constructed to connect to the penstocks. These shafts are excavated by drill and blast method. The wedge
cut blasting pattern used during the excavation. The excavated portions were supported by 50mm shotcrete
along with wiremesh and rock bolting. 600mm thick concrete lining was provided in both the pressure
shafts. The lower horizontal portions of the shafts were provided steel liners. The rock is supported by
contact and consolidation grouting.

4.4.3 Rock Support

The rock mass in pressure shaft is classified in class II and supported with 25mm dia, 3m long rock bolt @
2m c/c with 50mm shotcrete where as at junction of Horizontal Portion and Vertical portion 25mm dia, 4m
long rock bolt @ 2m c/c with 50mm shotcrete were provided. The steel liners were provided in the lower
horizontal shaft.

4.5 PENSTOCKS
4 nos penstocks with finished dia 2.3m and length 14m each were constructed.

4.5.1 Geology of Penstocks

The penstocks consists of thinly to moderately foliated, slightly to moderately weathered and moderately
strong to strong metavolcanics with dry to damp water condition and quartz and clay filling at some places.
The rock mass in penstocks is intersected by three sets of discontinuities inclusive of foliation and a random
joint. These are summarized as below:-

Set No. Average Spacing Aperture Condition

Orientation In cm
S1 015/650 60-200 upto 1 mm Rough Undulatory
S2 300/350 100-300 -do- -do-
S3 140/350 100-300 -do- -do-
RJ 180/650 100-300 -do- -do-

During the excavation of penstocks no geological problems were encountered.

4.5.2 Rock Support

The rock mass in penstocks is classified in class II and supported with 25mm diameter 3m long rock bolt @
2m c/c with 50mm shotcrete.

4.6 POWERHOUSE
A 83m long, 15.5m wide and 34.5m high underground power house with the installed capacity of 44MW is
housed in thinly to moderately foliated, slightly to moderately weathered and moderately strong to strong
metavolcanics with dry to wet water condition on the right bank of the river Suru near village Chutak.

4.6.1 Geology of Power House

The power house is accommodated in thinly to moderately foliated, slightly to moderately weathered and
moderately strong to strong metavolcanics with dry to wet water condition. The rock mass in Power house
is intersected by three sets of discontinuities inclusive of foliation and a random joint. These are
summarized as below:-

Set No. Average Spacing Aperture Condition

Orientation In cm
S1 015/650 60-200 Tight to hard filling upto 1 mm Rough Undulatory
S2 280/600 100-300 up to 5mm -do-
S3 140/350 150-300 upto 3mm -do-
RJ 100/650 100-300 upto 0.1mm -do-

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The 3-D Geological log of U/s and D/s wall of power house is enclosed in Plate 6A & 6B.

‘’

Figure-6a Geological Log D/S wall of Powerhouse Cavern

Figure-6b Geological Log U/S wall of Powerhouse Cavern

4.6.2 Construction Methodology for Power House

The 83m long, 15.5m wide and 34.5m high underground power house was constructed to accommodate
Control Block, Machine Hall and Service Bay to generate 44MW from four units each of 11MW. The
service bay of size 18m long and 15.5m wide at EL. 2720M in power house was accommodated between
RD 0 to 18m where as the control room of size 12m long and 15.5m wide from EL 2704.5M is between RD
71 to 83m of power house and the machine hall was accommodated in the remaining portion . The EOT
crane has been placed at an EL 2730M.
The power house excavation was started with the pilot tunnel of 6m diameter to the length of 83m from
ventilation tunnel side. The crown portion of the tunnel (at EL.±2736.5M) was supported by shotcrete along
with wire mesh and rock bolts as per design drawing. Widening of both sides of pilot tunnel was then

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carried out. Further the lowering of cavern was done by benching excavation and supported by permanent
support. (Figure-7).

Figure 7- Excavation of Power House Cavern

The right wall of the power house has accommodated four penstocks and drainage gallery where as four bus
ducts and four draft tubes were accommodated in the left wall of the power house from service bay side.
The invert level of the power house is at EL. 2702M. The total excavated quantity of power house executed
was approximately 52840 cum. No major geological problem encountered during excavation of power
house.

4.6.3 Rock Support

The power house cavern was supported by rock bolting with double layered wire mesh and shotcreting.
Necessary provisions have been kept for drainage arrangement on roof arch and walls.

The details of support system are given below:

1st Phase Central part excavation as per drawing
2nd Phase 8m long 32mm dia rock bolt @2000mm c/c in crown
3rd Phase U/s side balance excavation as per drawing
4th Phase 8m long 32mm dia rock bolt @2000mm c/c in crown and 8m long 32mm dia rock bolt @
1500mm c/c below crown.
5th Phase D/s side balance excavation as per drawing
6th Phase 8m long 32mm dia rock bolt @2000mm c/c in crown and 8m long 32mm dia rock bolt @
1500mm c/c below crown.
7th Phase 200mm thick shotcrete crown and below
8th Phase Relief holes in crown and below

4.6.4 Instrumentation
For monitoring of load, displacement or movement in the crown and wall portion of the power house cavern
Load Cells and Single & Multiple Point Borehole extensometers have been placed in the crown and wall of
Power house.

4.7 TRANSFORMER CAVERN

The 67m long, 12m wide and 10m high underground transformer cavern is located in just D/s of Power
house cavern with a lateral distance of 30m.

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4.7.1 Geology of Transformer Cavern

The transformer cavern consists of thinly to moderately foliated, slightly to moderately weathered and
moderately strong to strong metavolcanics with dry water condition. The rock mass in transformer cavern is
intersected by three sets of discontinuities inclusive of foliation joint. These are summarized as below:-

Set No. Average Spacing Aperture Condition

Orientation In cm
S1 015/650 60-200 Tight to hard filling upto 1 mm Rough Undulatory
S2 280/600 100-300 up to 5 mm -do-
S3 110/350 100-300 upto 3 mm -do-

4.7.2 Construction Methodology for Transformer Cavern

The transformer cavern excavation was started with the pilot tunnel of 6m diameter to the length of 67m
from main access tunnel side. The crown portion of the tunnel (at EL.±2729M) was supported by shotcrete
along with wiremesh and rock bolts as per design drawing. Widening of both sides of pilot tunnel was then
carried out. Further the lowering of cavern was done by benching excavation and supported by permanent
support.
Below transformer cavern a cable trench was constructed at an EL. 2716M to accommodate the cables from
Bust ducts and to carry them to switchyard through cable tunnel. The total excavated quantity of
transformer cavern executed was approximately 8745 cum.

4.7.3 Rock Support

The transformer cavern was supported by shotcrete along with wire mesh and rock bolting. The transformer
cavern is supported by 32mm dia 6m long rock bolt @2000mm c/c with and 32mm dia 8m long rock bolt
@ 1500mm c/c with 150mm thick shotcrete with two layers of wire mesh in the crown portion where as the
wall portion of the transformer cavern was provided with 32mm dia 6m long rock bolts at 2000mm c/c both
ways staggered.
4.8 TAIL RACE TUNNEL & TRT OUTLET
To release the water from powerhouse to Suru River, a 5.9m dia, 56m long Tail Race Tunnel was excavated
in metavolcanic rock. The Tail Race Tunnel was followed by a 9m long cut and cover section.

4.8.1 Geology of Tail Race Tunnel

The tunnel consists of thinly to moderately foliated, slightly to moderately weathered and moderately strong
to strong metavolcanics with dry to damp water condition in the tunnel.
The rock mass in tail race tunnel is intersected by three sets of discontinuities inclusive of foliation and a
random joint. These are summarized as below:-

Set No. Average Spacing Aperture Condition

Orientation in cm
S1 015/650 100-150 upto 1 mm Rough Undulatory
S2 285/350 100-300 -do- -do-
S3 140/650 100-300 -do- -do-
RJ 120/300 100-300 -do- -do-

The TRT Outlet slope consist of thinly to moderately foliated, slightly to moderately weathered and
moderately strong to strong metavolcanics with dry to damp water condition (Figure-8).

4.8.2 Rock Support

The rock mass in TRT is classified in class II & III and supported with rock bolt, shotcrete along with
wiremesh.
Class-II 3m long rock bolt 25mm dia @ 2m c/c, with 50mm shotcrete
Class III 3m long rock bolt 25 mm dia @ 1.5 m c/c with100 mm shotcrete and wiremesh.

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Indian Society of Engineering Geology Engineering Geology, Geotechniques & Geohazards – A quest for Excellence
10-11 July, 2014, Kolkata, India

Figure-8 - Protection work at TRT Outlet

5.0 HINDRANCES FACED DURING CONSTRUCTION

Construction of a hydro project at an altitude of 9300 ft is indeed a challenging job. Due to high altitude and
absence of vegetation, % of oxygen in the atmosphere is also less (70% of normal) due to which efficiency
of man and machinery reduces as much as 30%. Besides, due to adverse temperature conditions with
minimum temperature as low as -32 coupled with heavy snow fall between November and March, the
surface work at the project site practically comes to a halt. Thus, total working season reduces to only seven
months. During winters no concerting work can be done and due to road blockades, transportation of steel,
cement and other equipments also stop. Besides, acute shortage of skilled and unskilled manpower in the
area due to very low population density coupled non availability of local workshops and fast moving spares
also put hindrance in fast progress of the project. Timely completion of the project in such reduced working
session was thus a challenge. But, due to efficient construction management and wholesole efforts of NHPC
and contactors the project was successfully commissioned in January, 2013.
6.0 CONCLUSION
The 44 MW Chutak HE Project is the first major hydropower project commissioned in cold desert of Kargil
area. Due to remoteness of the area and prevailing adverse climatic & temperature conditions, timely
construction of the project was a challenge. NHPC took up the work and carried out extensive
investigations and prepared DPR in 2003. Subsequently contract was awarded and despite various technical
and climatic hindrances, the project has been successfully commissioned in January, 2013. After successful
commissioning, the project is providing quality power in the strategically important Kargil area. Moreover,
the project has also given us the experience and confidence of construction in the high altitude terrain under
extreme weather condition.

ACKNOWLEDGEMENT
The authors express their sincere gratitude to NHPC management for granting permission to prepare the
present paper.

REFERENCES
[1] Feasibility Report : Chutak HE. Project, NHPC Ltd.
[2] Detailed Project Report (2004), Volume-I & IV: Chutak HE Project, NHPC Ltd.

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