Narrative 1: Construction of Inlet portal of Sanjen(Upper) Hydroelectric Project

CE1.1) Introduction
Bajra Guru Construction Company Pvt Ltd, Nepal was awarded the tender to construct
the civil works at Sanjen (Upper) Hydroelectric Project (SUHP). This run of rover
scheme project generates 14.8MW during peak discharge from Sanjen and Chilime River
Basin, which falls under Rasuwa district, 161 km north of the capital of Nepal. The civil
works is located approximately 6km upstream of the headworks of the Chilime station.
The powerhouse and the headwork of the project are almost 29kms and 25kms from
Syaphrubesi. The designed location of headwork site is Tiloche which is 1.5km upstream
from the confluence of Chhuphcung Khola and Sanjen River. The water from sanjen river
is diverted in to the powerhouse from a 1.4kms long headrace channel. My Tenure as
civil engineer at Bajra Guru Construction Company started on 1st May 2013 and I worked
till 30th June 2014

CE1.2) Background:
Bajraguru Construction Company Pvt Ltd is one of the leading construction companies in
Nepal and is registered with Ministry of physical planning and works, Government of
Nepal. Bajraguru has a massive experience in delivery of infrastructural projects such
road, bridges, irrigation, transmission lines and hydropower. Bajraguru has successfully
completed numerous civil projects and specializes in construction of civil and mechanical
works of hydroelectric projects.

Address of the Organization:

Bajra Guru Construction Company Private Limited
Talchhikhel, Satdobato, Lalitpur, Nepal
Tel no: +977-1-5520192, +977-1-5524509
Email: ecibajra@gmail.com

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 Organizational Structure and chart
“Construction of Inlet Portal of Sanjen (Upper) Hydroelectric Project”
Sanjen Jalavidyut Company Ltd
Ministry of Energy, Water Resources and Irrigation
Nepal Electricity Authority
(Client)

Bajraguru Construction Company Pty Nepal Electricity Authority SMEC

Ltd (Project Manager) (Design Consultant)
(Contractor)

Project Manager (Bajraguru Construction Company Pty

Ltd)

Mechanical Engineer Geotechnical Engineer Civil/ Site Engineer Electrical Engineer Geologist

Civil Overseer

Surveyor/Sub overseer/Supervisors/Staffs

CE 1.3) Objectives of the work

The major objective was the safely construction of following components
i. Peaking Pond
ii. Head works
iii. Headrace Tunnel
iv. Surge Tank
v. Penstock
vi. Powerhouse
vii. Tailrace and Outlet Structure
CE 1.4) Statement of my duties
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 At Bajraguru construction my major duties were planning, formulation and
implementation of diversion tunnel excavation works, drilling and blasting works,
surveying and documentation, material quantification and co-ordination between
different stake holders of the project. Similarly, my major duty was to review, implement
the earthworks as per design drawings and reports. I supervised and monitored all the
daily work of the tunnel excavation.

CE 1.5) Duties and Responsibilities

Because I was engineer incharge of the tunneling works I was also responsible for
administrative works besides providing technical hand to everyday engineering issues
using mathematical and analytical techniques. Because I had a very good knowledge of
softwares like Civil CAD 3D, Microsoft suite, LAN development and primavera I easily
able to perform the tasks assigned to me. Following were the works I performed in the
project:

 Review bid documents; contract documents and Environmental impact assessment

(EIA) reports and implement environmental protection activities and contractual
drawings.
 Implementing, supervising and controlling tunnel excavation works as per the
contract drawings and specifications.
 Prepare daily site diaries and report daily civil works to the project manager and co-
ordinate for meetings with Nepal Army, Client, consultant, subcontractors, assets
owners and other principals.
 Prepare Inspection test and plans (ITP), review quality assurance documents and
prepare quality assurance plans.
 Perform and update site safety plans, emergency evacuation plans, site management
plans, emergency drills, toolbox talks and incident registers.
 Monthly cost tracking and measuring financial performance of the project to avoid
cost and time overrun.
 Work as a team leader by effectively communicating with technical and non-technical
staffs and allocating daily tasks.
 Reviewing project drawings, specifications and reports and implement it as per the
project reports.
 Material quantification, surveying works as executed and preparing monthly payment
claims and payment certificates
 Making requests for information (RFI), claiming for extension of time, measuring and
preparation of variation documents and correspondence of official letters
 Because tunneling works were executed in different shifts, I had to assign
responsibilities and rosters and supervise junior technical staffs and report
performance rating to the project manager
CE 1.6) Workplace Activity

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 My technical and project management skills helped me get appointed as the site engineer
and tunneling works in charge of the hydropower project. The site location being very
remote and limited access to resources was one of the major challenges I felt. Luckily my
project manager was a very experienced and helping personality. Geologists,
geotechnical engineers, contract documents, drawings and codes helped me understand
the dynamics of the tunnels.

CE 1.7) Desk Study

I organize and compiled EIA report, Contract documents, civil and structural drawings,
explosives schedule, civil specifications, explosive specifications, and safety data sheets,
detailed cost estimation for the blasting works, Work health and safety documentations,
contract security and insurance documents. I carried out a detail study of these documents
which a major focus to geological and geotechnical reports. After a detailed study of all
the reports I sort of found out that water table of a small portion of the inlet portal
alignment was high and there was a major chance of flooding during blasting works. I
proposed a review of the alignment of the inlet portal. My proposal of the alignment shift
was very carefully considered and there were multiple meetings between the concerned
stake holders. However the review panel decided that there will be major cost
implications and decided not to change the alignment but opt for preparation of pumping
schedule.

CE 1.8) Reconnaissance, Survey and Excavation:

Before we started the tunneling works the prime responsibility assigned to us was
comparison of the design DTM and existing surface. To start with we were given a set of
control points. The socio-political condition of the site location wasn’t very good. Local
people were not happy with the land acquisition procedure specifically contesting the
land compensation rate provided to them. Because of these scenarios, some of the local
destroyed the existing control points around the site area. I arranged for a meeting with
the stake holders, local political parties, and surveyors of department of survey control.
With the understanding between all the stake holders, I convinced the survey department
to provide us the nearest established benchmark. Because the geographic terrain of the
site area was very remote and due to dense forest GPS functioning was very limited.
Thus, I opted using closed traversing method of transferring co-ordinates and hence,
along with mu junior engineer I established enough control points with the help of total
station. Because the blasting works was to be highly precise, I had to be careful and make
sure that we eliminated line of site error and height axis error prior to start of works and
least square method to confirm the tolerance precision of the traversing. During the
traversing method we used total station, Auto CAD and SOFTWEL.

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CE 1.9) Construction, Monitoring and Supervision of Blasting, Excavation and Rock
Supporting Works:

After surveying works my next job was site clearance, excavation and rock supporting
works. There were many trees and stumps in the alignment of the inlet portal. As per the
EIA report for the trees clearing works, I had to co-ordinate with the clearing
subcontractor and ecologist. During blasting works I had to co-ordinate with Nepal army
and the blasting team for a schedule. After the confirmation of blasting date, I had to
stake out the central, bottom and side RLs of the channel (3.75m x 3.5m) with the help of
Total Station within a tolerance of 5mm. After the controlled blasting of the tunnel I had
to inspect the blasted materials and use rock mass classification system to classify the
type of the rock and record the quantity of rock. The rock mass classification would
automatically recommend the rock support system. During the supervision works I
referred codes such as IS 15026 Tunneling Methods in Rock Masses, IS 5878 Code of
Practice for Construction of Tunnels and IS 4756 Safety Code of Tunneling Works. I
prepared rebar schedule and shop drawings of the tunnel. I used NBC 111: 1994, IS 800:
2007 for Steel, NBC 110: 1994 and IS 456: 2000 for Plain and Reinforced Concrete. I
frequently used Ms-Excel and Auto CAD for drafting and calculation purposes. While
placing the rock bolts, steel ribs and shotcrete I had to refer my course books and IS
codes regarding drainage system in tunnels within water charged rock, identification of
weak zone, strength and strength of shotcrete mix, type, spacing and capacity of roof
bolts, steel ribs and plates in different types of joints. I developed casting schedule for
installation of A-continuous steel ribs (3.75m x 3.5m) and D rib wall and post and
shotcreting schedules. During the tunnel construction works I also consulted with geo
technical engineers, geologists and my project managers.

CE 1.10) Detail estimation of works and resources:

I estimated for various civil works and checked the manpower, materials and equipment
required by dedicated excel sheets to complete various jobs for the smooth maintenance
of work schedule as per the contract document. I used to check the day to day record
made by the supervisors in the field. I used resource leveling techniques maintained the
number of labors, quantity of materials stocked and used and the type and condition of
equipment used in the site. I used the district rate and norms provided by the department
of urban development and building construction. I planned for the detail requirement of
pump, manpower, mixture machines, vibrator, admixture, fabricated ply boards and other
for concreting.

CE 1.11) Issued faced and Solutions provided:

i) The major issues I faced were determining the type of rock support required. This had
two implications. The first one was determining the rock type and establishing the
necessary rock support system and second was cost implications of the respective support
system used. We had predefined rock support systems but deciding which one to use was
a challenge. I arranged a meeting between the geologist, client engineer we developed a

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three-stage solution using IS 4756, IS 5878, IS 15026 and Building codes and excel
sheets:

a) Calculation sheet of Q Method of rock mass classification to record mass quality with
the help of joint sets, roughness, alternation and rock mass stress situation

A 1 = Very Good Q>40: Massive to low joint frequency, Jv< 5/m3. Tight joints,
unaltered strong rock and insignificant stress slabbing.
A 2 = Good 10<Q<40: Low to moderate joint frequency, 5<Jv< 10. Strong rock with
none or insignificant alteration and with coating on some joints. Low to moderate
stress slabbing.
A 3 = Fair 4<Q<10: Moderate to high joint frequency, 10<Jv< 20. Moderately strong
to strong rock generally with coated joints
A 4 = Poor1<Q<4: High joint frequency, Jv> 20, clay seams (fault zones, swelling
clays) in moderately strong rock.
A 5 = Extremely PoorQ<1: Completely crushed rock containing a significant amount
of secondary clay minerals as in major fault zones.

Where, Q = RQD/Jn × Jr/Ja × Jw/SRF

RQD = given as the value for this parameter
Jn = ratings for the number of joint sets
Jr = ratings for the joint roughness
Ja = ratings for the joint alteration
Jw = ratings for the joint or ground water,
SRF = ratings for the rockmass stress situation

b) Stockpiling excavated rocks as per the Q System. Doing survey pick up of the
stockpiles. Maintaining tip sheets and run sheets of the dump trucks to calculate the
approximate volume and match it with the stock pile volume.

c) Rock Support (RS) used for each rock class (A) to be as per follows:

A1 => RS 1: Scaling and spot bolts.

A2 => RS 2: Scaling, Spot bolting for smaller cross-sections. Pattern bolting and spot
applied fibre reinforced sprayed concrete for larger cross-sections.
A3 => RS 3: Scaling. Pattern bolting and minimum one layer of fibre reinforced
sprayed concrete in crown and walls for smaller cross-section. For larger cross-
sections number/length of bolts and thickness of 70mm sprayed concrete
A4 => RS 4: Pattern bolting and a minimum of two layers of fibre reinforced sprayed
concrete in crown and walls for smaller cross-section. Reinforced ribs of rebars and
sprayed concrete. For larger cross-sections number/length of bolts and 100mm spray
thickness.
A5 => RS 5: Pattern bolting and spiling bolts. Fibre reinforced shotcrete when short
stand up time and application of Steel Ribs and 150mm sprayed concrete at the face
and concrete lining behind the face.

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CE 1.12) Preparation and approval of Progress Report:
I prepared monthly progress report with the help of grant chart and s-curve which
recorded the ongoing activity progress, achieved milestones within the month and task
planned for the coming month. My monthly progress report also recorded the technical
and nontechnical delays in the month, reasons and lessons learnt from the delays and
extension of time claimed for the month. I used project management tools like Primavera
and Ms-project.

CE 1.13) Preparation of Monthly claims and Payment Certificates:

Preparation of running claims and payment certificates was undoubtedly very important
for running the job. I maintained regular record of survey pick-ups, schedule items
measurement books, calculation schedules of items measured, and abstract of costs to
prepare monthly claims. I also maintained a separate measurement book for non-schedule
and items deemed as variation as per public procurement act and regulation. During the
preparation of monthly payment schedule I made sure that I collected all the geotechnical
test reports, concrete strength repots, rock mass classification sheet and rock sheets. I also
collected all the compliance documents for quality control

CE 1.14) Safety Role and preparation of safety plan:

Safety is a very major underrated section in construction field of Nepal. Besides normal
safety requirements, tunneling has some extra safety requirements. I had to referred IS
4756 “Safety code for tunneling works” and prepared a safe working methodology which
included parameters like working under comfortable ventilation and night, noise
suppression, first aid arrangements, safe drilling and blasting arrangements, safe scaling
and mucking requirements. The methodology also included the recording the daily site
hazard reports, use of personal protective equipments, preparing and updating emergency
evacuation plans, preparing site sign plans and recording near miss and any incidents on
site. I also designed standard labor camps, rural pit latrine and initiated for filtration tank
of clean drinking water

CE 1.15) Inventory and quality control:

Inventory management and quality control was one my major duties. Inventory of
explosives and chemicals was a very risky task assigned to me. Stock of the explosive
and right handling was essential to achieve project milestones. Inspection of rock
surfaces, establishing chainages, recommendation of type of rock support system and
scaling works was my everyday task. Analysis and recording of rock mass and required
support system, rock scaling, rock bolting and grouting, shotcrete, hydraulic pull testing
were my quality control methods to record consistency, strength, porosity, expansion,
permeability and tensioning of the support system. Regular sampling including sieve
analysis of aggregate, cements, tensile strength of steel and compressive strength and
slump value of concrete were other methods of quality control. I drafted a whole set of
ITPs and checklist to make sure that all the hold points and witness points were recorded.

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 I referred International Standard ISO 2859-1 “Sampling procedures and tables for
inspection by attributes” for determining sampling requirement and test frequencies.

CE 1.16) Preparation of Working Drawings and Reports:

I prepared the working drawings and markups based on the design drawings. I also
prepared as-built drawings for the inlet portal for submission and approval. Preparation of
geological logging schedule, toxicity level reports, rock support system scheduling, rock
bolting schedule, shotcrete schedule, noise emission records, site diaries, construction
manuals and handbooks for supervisors and foremen along with fortnightly progress
report, explosive and chemical use schedules, drilling and blasting schedules, incident
reports, site prestart reports, toolbox talks and ITPs were my major tasks. I used
softwares such as Auto CAD civil 3D and Ms-excel. I involved my junior engineer while
recording the data and presented it to my project manager for approval.

CE 1.17) Participation in Workshops, Trainings and Seminars:

While at this project I frequently had to visit the capital city for meetings and workshops.
I participated in seminars, workshops and trainings regarding safety in tunneling,
geological mapping, hydropower scheme and project management software. I would take
all the power point prints and take it to the site to brief my co-workers.

Summary:
This site engineer role was a game changing position in my career which helped me
understand the basics of surveying, foundation engineering, soil mechanics, rock
slope engineering and dynamics of tunnelling. I also acquired the knowledge of
project formulation, planning, implementation and management. Moreover, quality
assurance and control, compliance to safety standards, effective communicating
skills, report writing, and presentations, team leading skills were other skills that
helped to logically reason and critically think to excel in my professional career. I
also learnt the effective use of computer aided software such as Civil CAD 3D,
primavera and SW-DTM.
.

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Site Meeting after the excavation of Inlet Portal Access

Detail of Inlet Portal

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