Beruflich Dokumente
Kultur Dokumente
12
CONSTRUCTION METHODOLOGY
12.1 INTRODUCTION
The construction of Lower Siang project shall be carried out in two phases. In the first
phase, the works on the left bank will be constructed while the river flow is confined on the right
bank deep river channel. In phase-I four blocks of spillway, five units consisting of Power
Dam, Power House (1500 MW) along with the Erection bays, Approach Channel, D/s channel,
Switchyard and Protection wall will be constructed. Hydromechanical and electromechanical
works along with embedments, erection and commissioning for the same shall be taken up
concurrently during the first phase as per requirement.
In the IInd phase, the works on the right bank will be taken up after construction of u/s
and d/s Coffer dam. The phase-II works consist of construction of four right bank Spillway
blocks and remaining four units (4x300 MW) of power dam and power house (two units each on
the left and right sides of Spillways) would be taken up.
Construction methodology and equipment has been planned with the aim to commission
the first phase of the project with total capacity of 1500 MW (5x300MW) at the end of 74th
Month & second phase of the project with total capacity of 1200MW (4 x 300 MW) at the end
of 114 months.
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The river will divert in the Diversion sluices at El. 155.0m provided in one of the left
bank spillway blocks by launching diversion dyke.
Construction of u/s and d/s Coffer Dams along with Jet grouting.
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The excavation on the abutment up to El. 220m will be taken up before launching of
diversion dyke and below El. 220m up to river bed will be taken up after completion of (ii)
above.
Concreting of Spillway blocks, Power Dam - Power House blocks along with Erection
bay.
First stage embedment for Hydro-mechanical works to be taken up concurrently with (iv)
above
Erection of HM equipment related to sluice gates to be taken up after completion of
concrete in spillway block up to El. 208.0m.
Erection of trunnion girder for ogee radial gates to be taken up after completion of pier up
to El. 216.488m.
Erection of HM equipments related to ogee spillway radial gates to be taken up after
completion of spillway blocks up to top including bridges.
Erection of HM equipment related to d/s stoplog gates after completion of extended
portion of piers.
Erection of HM equipment related to Power Dam – Power House blocks such as trash
rack, hydraulic gates & hoist, bulkhead gate and gantry, Draft Tube gate etc. shall be taken up
after completion of these blocks except Penstock and first stage embedment which will be fixed
concurrently with concrete.
Erection of items related to E&M works up to pit free such as DT liner, DT Cone, Spiral
casing etc. will be done along with the concreting of Power House. Erection of remaining E&M
works will be taken up after completion of Power house concreting i.e. pit free.
The construction methodology for different components of project under Phase-I and II
are as follows:-
12.3 EXCAVATION
The total excavation (bank) involved is 20,542,815 cum. This excavation require about
33 months. The total excavation area is 800m long (average) along the river flow and the width
varies from 400m at the centre to about 250m at the ends. This area can permit deployment of
required number of sets of excavation equipment each of which shall consists of (i) Excavator (ii)
Dozer (iii) Dumper (iv) Drilling and Miscellaneous equipment along with arrangement to provide
adequate compressed air. It is proposed to deploy eight such set to tackle the area of excavation
with a view to complete it in the stipulated time frame.
The excavation shall be tackled concurrently from the left bank hill side as well as from
the edge on the right bank. The slope stabilization work, mainly consisting of shotcrete and rock
bolts shall be carried concurrently with the excavation on the slopes.
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12.3.3 Excavation for Left Spillway Blocks (S1 to S5), Power Dam – Power House (P-1 and
P-5) along with Erection bay E1 & E2
12.3.3.1 Method Statement
Four Spillway blocks, five Power Dam - Power House blocks and two Erection bays are
located on the left bank of river Siang. All the above structures are located in hilly area at left
bank of river and no diversion is required for Ist phase construction. The excavation of all these
structures will be done simultaneously and will be taken up from top in benches at three metre
interval in heights, tackling both the overburden and the rock strata, as encountered. Temporary
roads shall be established for access to berms at various levels.
As the excavation proceeds, the slope treatment works consists of mechanical rock bolts,
anchors, welded wire mesh and shotcrete will be provided. The drilling for rockbolts will be done
by wagon drill and shotcrete by dry shotcrete machines. If any shear zone will be encountered
during the excavation and same shall be treated accordingly. Treatment mainly consists of
plugging the shear zone with concrete cladding on hill slopes as well as on benches. The concrete
plug is tied by rockbolts to the rock. Pressure relief hole shall also been provided for the
drainage of water to reduce pore water pressure on slopes.
The common excavation shall be carried out by Ex-600 and Ex-400 Hydraulic Excavator
in combination with fifty and twenty five tonne capacity Dumpers. However, JCB Back Hoe
shall be provided for preparation and clean up of foundations. For rock excavation, drilling will
be done with wagon drill and dozing will be done with D-155/D-65 dozers.
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Excavator in combination with fifty tonne capacity Dumpers. However, one JCB Back Hoe shall
be provided for preparation and clean up of foundations. For rock excavation, drilling will be
done with Wagon Drills and dozing will be done with D-155 dozers. The open excavation for
the Downstream Channel shall start in 21st month and shall be completed by the 36th month.
Excavation of approach road on the right bank offtaking from State PWD road from
Rottung to Pengin would be taken first. The construction roads for excavation will offtake from
this road to reach the Power Dam blocks and Spillway blocks area and the Tail Race area.
In addition, by the time works of right bank are taken up a bridge (70R capacity) d/s of
the dam at a proper location connecting the left and right bank would also be available for
interconnectivity of the left bank and right bank works.
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12.3.7 Excavation for Right Spillway Blocks (S6 to S10), Power Dam – Power House (P-6 to
P-9) along with Erection Bay
12.3.7.1 Method Statement
Spillway blocks, Power Dam - Power House and Erection bay are located on the right
bank of river Siang. Since all these structures are located at right bank of river, excavation of
Spillway and Power Dam - Power House would be done simultaneous after construction of
Coffer Dams. The excavation of all these structures will be done simultaneously and will be
taken up from top in benches at three metre interval in heights, tackling both the overburden and
the rock strata, as encountered. Temporary roads shall be established for access to berms at
various levels.
The common excavation shall be carried out by Ex-600 and Ex-400 Hydraulic Excavator
in combination with fifty and twenty five tonne capacity Dumpers. However, JCB Back Hoe
shall be provided for preparation and clean up of foundations. For rock excavation, drilling will
be done with Wagon Drills and dozing will be done with D-155/D-65 dozers. As the excavation
proceeds, the slope treatment by way of mechanical rock bolts, anchors, welded wiremesh and
shotcrete will be provided.
12.4 CONCRETING
Total works of concreting consists of (i) spillway blocks along energy dissipation
arrangement (ii) Power Dam along Intake and Penstocks and (iii) Power House at the toe of the
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Power Dam along with Tail Race Channel. According to diversion scheme, first four spillway
blocks on the left bank side and five Power dam – Power House blocks along with two erection
bays are to be constructed during first phase of construction. Rest of the four spillway blocks and
four Power Dam and Power House blocks along with right bank erection bay are to be
constructed in the second phase of works. Quarry for the material and space for installation of
APP and CBP are available only on the left bank side which will serve for the works of both the
phases. Therefore, after considering various alternatives, it is proposed to use two parallel Cable
ways which will run on the left and right bank and feeding arrangement will be from left bank
side. These Cable ways will cater for both phases of works. Both the Cable ways are proposed to
run in tandem. Because of the hill cutting limitations specially on the right bank and also looking
to the requirement of pouring rate, it is proposed that Cable ways will be able to cater for only the
main works i.e. spillway blocks, Power Dam and Power House blocks. In the mass concrete
portions of spillway and Power Dam, the peak pouring rate during some periods exceeds the
pouring capacity of two Cable ways. To cater for this situation it is proposed to deploy two tower
crane on the u/s side and two on the d/s side running parallel to dam axis which will cover about
30m area from u/s and d/s sides. The area left in between the two tower cranes will be concreted
by Cable ways. Concreting of stilling basin d/s of Spillway blocks and Tail Race Channel d/s of
the Power House will be done by Creter cranes which will approach the work from d/s side.
Two numbers of 750 TPH and 250 TPH will be installed on left bank to cater for left
bank works. In addition, one 250 TPH will be installed on right bank to cater for right bank
stilling basin and Tail Race channel.
Two numbers of (360 cum/hr and 120 cum/hr) CBP will be installed on left bank to cater
for left bank works. In addition, one 120 cum/hr capacity will be installed on right bank to cater
for right bank works.
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S. No. Description
12.4.1.2 Sequence of Construction of Power Dam – Power House along with Erection bay
Once the excavation of power house completed, the concreting of power house will be
taken up. Sequence of concreting in Power Dam, Power House including erection bay is
described here in below:-
i) Foundation preparation and covering concrete in Power House area will be done
followed by the consolidation grouting.
ii) The construction of columns and beams.
iii) The construction of spiral casing pedestals followed by erection of spiral casing and
concreting.
iv) Concreting of columns and beams of machine hall, concreting of draft tube piers, walls
and slab.
v) The construction of power dam will be started after the first stage concreting in Power
House. The power dam will be constructed up to EL 190.50 m for erection of penstock
and once the penstock will be erected the concrete up to top will be done.
vi) The concreting of erection bay and power dam upstream of central Erection bay will
starts after completion of excavation followed by the concreting of column and beams for
unloading bay.
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Concrete to the Cable ways will be fed on the left bank from 360 cum/hr Batching plant
which is proposed to be located. Concrete from the batching plant will be brought by silo buses
with 9 cum capacity which unload concrete into buckets placed on the platform. The loaded
bucket will be lifted by the crab and taken to the desired location of placement.
The maximum spillway blocks and Power Dam blocks width in all blocks are 25m and
36m respectively. The sequence of pours for raising the Block by 1.5m lift in three pours each of
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0.5m height is shown below. In this scheme of pouring, it has been ensured that there is no
formation of cold joints with the envisaged rate of pouring.
12.4.1.6 Shuttering
Steel shuttering correct to the lines, levels and grades, as per concrete outlines shown in
the approved drawings, shall be used. The surface of the shuttering shall be kept free from
protrusions and shall be properly oiled.
12.4.1.7 Curing
Curing of concrete shall be accomplished by continuous wetting of the concrete surface
by circulating water through perforated steel pipes fixed along the top of Dam blocks and
covering the concrete surface with gunny bags wherever required and possible.
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concreting exceeds the Cable ways capacity, the Tower cranes along with lay down buckets and
Creter cranes will be used to cater for the exceeded rate. The abstract of equipment deployed for
both phases is given herein below :
Cable ways 28 t capacity - 2nos.
Tower crane 10T @ 30m radius - 4nos.
Creter Crane - 1no.
Concrete pumps - 2 nos.
Silo Buses - 10nos.
Hi-boys - 5 nos.
Transit mixers (with one pump) - 4 nos.
Lay down bucket 3 cum capacity - 8 nos.
Air Water Jet Blaster - 2 nos.
Sand Blasting Equipment - 2 nos.
Mobile Cranes 10 T capacity - 2 nos.
Needle Vibrators 65 mm dia - 4 nos.
Vibrators 150 mm dia with frequency changers - 2 nos.
Group Pump Surfex make - 2 nos.
Drilling Machine Diamac 262 - 2 nos.
At the location of the dam axis, valley width is about 641 m. The cross section of the river
shows that river is confined by steeply rising hill on the right bank side and a gradually rising hill
on the bank. This necessitates that the works are split up in two phases. In the phase-I, the works
on the left bank consisting of four spillway blocks and five Power Hour / Power Dam blocks
along with two erection bay and the protection wall will be constructed. In phase-II, the works on
right bank consisting of four spillway blocks and four Power House / Power Dam blocks along
with erection bay would be constructed.
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while ensuring that its foundation level is not lower than about El. 170.0 will be constructed. The
protection wall will be in two portion i.e. u/s of works and d/s of works and these two portions
will abut against u/s and d/s face of the erection bay which is located at the right edge of the left
bank terrace which will serve three Power House units of the phase-I and two of the phase-II.
Stage-II (Filling of Cofferdams up to top) : After the construction of dyke, the filling in
u/s and d/s Coffer dam up to top El. 226.0m and El.201.0m respectively have been done leaving
35m wide platform at El.183.0m and El. 173.0m in d/s of u/s and d/s Coffer dam for Jet grouting.
Stage-III (Jet Grouting) : The Jet grouting from El. 183.0m and El. 173.0m upto 1m below
rock level will be done for both u/s and d/s Coffer dams.
Stage-IV : Filling over Jet grouting for both the dams will be done from El. 183.0m to El.
200 m for u/s and from El. 173.0m to El. 178.0m for d/s Coffer dam.
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The rock fill and transition material shall be available from the excavation at Dam site
which will be stacked at Dumping sites and impervious clay shall be available from quarry
designated as LSC-3 to 6. Hydraulic Excavator (Ex-600) and fifty tonne capacity Dumpers shall
be used for excavation, loading and transportation of materials. For pushing the material. D-155
Dozers will be used. The rock layers shall be compacted with IR Vibratory compactors.
Equipment requirement has been worked out assuming twenty five working days per month and
twenty working hours per day with 1.2 as a peaking factor.
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Second Stage concreting around Sill Beam, Wall Plates and Lintel Beam.
Erection of Bottom Gate Element.
Erection of Arm-Trunnion Connector.
Erection of Bottom Arms.
Erection of balance gate elements.
Final welding of elements, arms etc..
Erection of Cylinder Support Structure.
Erection of Cylinder and Connecting with Gate.
Second Stage Concreting of the Cylinder Support Structure.
Placement of Power Packs and Control Panels in the Control Room/Hoist Gallery.
Installation of Hydraulic Pipings between Power Pack and Cylinders.
Fixing of Limit switches and Electrical cabling.
Filling of Hydraulic Oil in the Cylinders and Power pack.
Fixing of Rubber Seals on gate and on Lintel Beam.
Fixing of Side Guide Rollers on Gate.
Protective coating and touch up paint.
Trial testing/Dry testing and commissioning of Gate.
The gate segments shall be lowered by Cable Crane. The gate segments shall also be
lowered by mobile cranes of suitable capacity from upstream road bridge. Tower cranes
travelling on upstream road bridge shall also be provided for handling the lighter gate
components up to 10T weight.
The erection sequence of the gate components shall be similar to erection sequence of
radial gates.
The E.P.’s, Intake Stoplogs and Intake Gates shall be erected using Mobile Cranes
travelling on road bridge. The tower cranes shall also be used for the erection of these items.
The segments shall be pulled at desired location using winches & derricks. The suitable
number of hydraulic/mechanical jacks shall be used for final alignment with the adjoining
segment. After ensuring correct line and grade of the segments, the welding between segments
will be completed. After completing the welding, the concreting shall be completed.
The grouting below the bottom liner shall be completed through various grout holes.
After erection, concrete back filling and grouting, all temporary fixtures/appurtenances,
debris etc. inside the steel liner shall be carefully removed.
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