Environmental Management Plan Construction Methodology

CISMHE

16
CONSTRUCTION METHODOLOGY
16.1 INTRODUCTION Hirong Hydro Electric Project is located on river Siyom in West Siang district of Arunachal Pradesh. The Project envisages construction of a concrete gravity dam 133.5 m high, a 9.2 km long Head Race Tunnel, a 15 m diameter Surge Shaft, two underground pressure shaft bifurcating into four near an underground Powerhouse to generate 500 MW. Considering the seasonal variation, the working season of seven months starting from mid October to mid May every year has been considered while preparing the construction programme especially for the project works in the open. Underground works have, however, been considered as continuous even during the monsoon season though with a slow rate of progress on account of practical problems in movement of heavy machinery and vehicles carrying men and material. Construction Programme and selection of methodology with the planning for equipment has, as such, been worked out keeping above site constraints in view. The project has been planned to be commissioned in a period of six and half years (78 months) including period for completion of infrastructure development works.

16.2

COMMON EQUIPMENT For construction of this project, main common equipments are Aggregate Processing

Plant, Batching Plant and Concrete cooling arrangement. These are common for all civil works. In addition to this, diesel captive power is also amongst common facility. However, this has been dealt with in Infrastructure chapter because diesel generating capacity is designed not only for civil works but also for garage and workshops etc.

16.2.1 Aggregate Processing Plant (APP) Important aspects related to setting up of an APP inter-alia include the following: i). Capacity and production schedule of aggregates; ii) Location of plant; iii) Type of Plants; iv) Location of quarry areas and method of extraction of river bed materials (RBM) or quarrying rock, as the case may be.
Hirong H.E. Project, Arunachal Pradesh 16-1

Environmental Management Plan Construction Methodology

CISMHE

The total quantity of concrete to be placed is estimated to be approximately 11.39 Lac cubic meters for Dam and Intake, 12150 cubic meter in Sitten Nallah, 1.56 Lac cubic meters for HRT, 34763 cubic meter for Diversion Tunnel and Coffer Dams and 79274 cubic meters for Powerhouse. For construction of this project, Aggregate Processing Plants (APP) are proposed at three locations and Concrete Batching Plants (CBP) at six locations. From location 1 of APP (APP-1) at dam site, aggregate shall be supplied for concreting of Dam, Sitten Nallah and Intake. From Second location (APP-2) at Powerhouse site near MAT portal, aggregate shall be supplied for concreting of the lining of part of HRT, Surge Shaft and Powerhouse Complex. From 3rd location (APP-3) near diversion tunnel portal, aggregate shall be supplied for concreting of Diversion Tunnel and concrete lining of part of HRT.

As worked out above the APP having capacities of 500 TPH on left bank located at dam site, 100 TPH APP will be located at Powerhouse site near MAT portal and 60 TPH APP will be located near Diversion Tunnel portal. FE Loader 3 cum Dozer (180 HP) : : 5 (2 at Quarry + 3 at APP) 5 (2 at Quarry + 3 at APP) 2 (at Quarry) 2 (at Quarry) 14 (6 at Quarry + 8 at APPs)

Crawler drill IRCM 341 : Compressor @ 450 cfm : 20 tonne capacity dumper :

16.2.1.1 Batching Plant Important aspects related to setting up of an Batching Plant inter-alia include the following: i). Capacity and production schedule of aggregates; ii). Location of plant; iii). Type and layout The maximum concreting in a month for all structures as per the construction program is 86,576 cum for Location-1 and 16,000 cum for Location-2 and 10,000 cum for Location-3. The maximum concrete requirement per month for Location-1 is 82660cum. Also about 10,000 cum per month concrete is required for Location-3.

Three CBPs (CBP1, CBP2, CBP3) and CBP6 will be required to match with the APP-1 and APP3. For APP-1 works, three CBPs, (CBP-1, 2 and 6), one of 300 cum/hr, second of 30 cum/hr and third 30 cum/hr capacity will be deployed. For APP-3 works one CBP-2 of 30 cum/hr
Hirong H.E. Project, Arunachal Pradesh 16-2

Environmental Management Plan Construction Methodology

CISMHE

shall be deployed. For APP-2 works two CBPs one 30 cum/hr (CBP-4) and second 60 cum/hr (CBP-5) capacity CBP will be deployed. The location of the CBPs are given here in below: 16.3 300 cum/hr capacity CBP-1. 30 cum/hr capacity CBP-2 30 cum/hr capacity CBP-3 30 cum/hr capacity CBP-6 30 cum/hr capacity CBP-4 60 cum/hr capacity CBP-5

DIVERSION ARRANGEMENT The Hirong HE Project envisages construction of a Concrete Gravity dam having its

anticipated deepest foundation at 1225m with top of dam at 1358.50m. Thus the height of dam from the deepest foundation level is 133.50m. Diversion arrangement for construction of concrete gravity Dam of Hirong HE Project comprises of: i). A Diversion Tunnel 10.15m dia Horse-shoe (modified) shaped, concrete lined and 473m long. ii). iii) iv) An Adit D-shaped 7m diameter and 280 m long. An Upstream concrete coffer dam with top at 1251m, 65.6m long at top. A Downstream concrete coffer dam with top at 1242m, 50.4m long at top.

In view of the better geology on the right bank of river Siyom, the diversion arrangement has been planned on the right bank. The left bank is readily accessible and to have access to right bank, a bridge on river Siyom along with access roads will be needed. However to take up the construction of adit and DT, the equipment will be taken on the right bank in dismantled condition by barges and by the time the excavation has been done, the access to this bank would be established.

16.3.1 Sequence of Construction of Diversion Arrangement Thus the sequence of construction shall be as below : i) ii). Excavation of adit after establishing its portal Establishment of junction of Adit and DT such that the invert of adit at the tunnel grade is at 1239.659 i.e. the benching level of DT. iii) Excavation of heading of DT both towards u/s and d/s side and leaving a rock plug at both the u/s and d/s portal ends.
Hirong H.E. Project, Arunachal Pradesh 16-3

Environmental Management Plan Construction Methodology

CISMHE

iv)

Regarding of adit invert in a length of about 36m to meet the invert of DT at the junction i.e. 1236.609 m elevation

v) vi)

Invert excavation both on upstream and downstream side. The structures at the inlet and outlet of DT to be established along with the activity 1 above during non-monsoon period after making ring bunds

vii) viii) ix) x).

Overt and invert lining of DT after activity 5 above followed by grouting. Removal of u/s and d/s plugs in DT, which were left earlier. Erection of H.M. equipment. Construction of plug at the junction of DT and adit (before diverting river water into the DT)

16.3.2 Underground Excavation of 7.0 m D-shaped Adit The excavation of 7.0 m D-shaped (finished) Adit to Diversion Tunnel would be taken up by drill/blast method tackling full face excavation, as soon as the portal is established. The drilling shall be done by Two-Boom Hydraulic Jumbo and removal of excavated material shall be done by a combination of 2.5 cum side dump loader and 20 ton capacity rear dumpers. The excavated area of 7 m, D-shaped Adit to DT is 48.67 sq m at minimum excavation line. Assuming twenty (20) working hours in a day and twenty five (25) working days in a month, the monthly progress of 7.0 m D-shaped Adit works out to about 85 m.

16.3.3 Junction between Adit and DT: After the Adit excavation, construction at the junction of Adit and DT will be completed. This will involve widening of Adit just before it joins the DT and installation of shotcrete, rock bolts and rib supports. Adjoining the junction the section of DT shall be kept marginally wider than the regular size of Diversion Tunnel, to adequately support the Rib-arches in the Haunches. After the junction area of Diversion Tunnel is excavated and adequately supported, excavation of DT in the upstream and downstream of the junction will be taken up.

16.3.4 Excavation of 10.15 m dia Modified Horse-Shoe Shaped Diversion Tunnel The excavation of DT will be done by heading and benching. The heading will be kept 7.5m such that bottom level of heading is at 1239.659 m and benching at 3.45m. The 10.15m diameter Modified Horse-shoe shaped Diversion Tunnel having a length of about 473m would largely be excavated in rocks of varying quality. The excavation of DT is to be done by using Drill and Blast method (DBM). The Diversion Tunnel will have a lining thickness of 400mm,
Hirong H.E. Project, Arunachal Pradesh 16-4

Environmental Management Plan Construction Methodology

CISMHE

accordingly the minimum excavated dia as well as excavated vertical dimension will be 10.95m with 8.0m base width. The excavation and lining of diversion tunnel will require about 12 months as such at least one monsoon season resulting in high water levels / flows in the river Siyom has to be faced by the under construction diversion arrangement. The drilling of holes will be done by Two Boom Hydraulic Jumbos. Haulage of excavated material shall be done by a combination of 2.5 cum side dump loader and 20 ton capacity rear dumpers.

16.3.5 Ventilation At the time of excavation of tunnels, adequate provision for proper ventilation is absolutely essential, therefore an effective ventilation arrangement has been planned during execution of Adit and DT. It is proposed to provide two fans ZVN-1-14-110/4 in series with a circular ventilation duct of 1.4 dia. As soon as the tunnel is through, ventilation will not be required. Following criterion have been adopted for provision of ventilation arrangement.

16.3.6 Concrete Lining of DT After the excavation in heading followed by benching is completed, the invert of the Diversion Tunnel will be properly dressed and a 100mm thick layer of lean concrete (PCC M10) shall be laid to form the level base at the requisite invert slope to be maintained in the Diversion Tunnel in downstream. Suitable shuttering will be done and lining concrete of 400mm thick shall then be paced at invert base and on sides, up to 2m height.

While the overt lining for the downstream reach is in progress, simultaneously the invert laying in the upstream reach would be carried out. After the completion of overt lining on the downstream side the shutter would be moved from downstream side to the upstream side, where the invert would have been laid by then for the length of the reach such that it can accommodate the shutter easily. At the time of execution of Diversion Arrangement, it is planned to set up a Concrete Batching Plant of 30 m3/hr capacity and to cater for the requirement of Aggregate, an Aggregate Processing Plant of 60 TPH (APP-3) shall be provided nearby CBP (CBP-2). At the time of construction of Diversion Arrangement, an weighted average lead of about 1.2 km has been considered from CBP-2 to the Portal of Adit to Diversion tunnel.

16.3.7 Removal of Rock Plugs When the contact grouting on the upstream side is being carried out, rock plug on the downstream side will be removed by excavation in heading and benching and adequately
Hirong H.E. Project, Arunachal Pradesh 16-5

Environmental Management Plan Construction Methodology

CISMHE

supported with the help of rock bolts / ribs as the case may be. Then the invert for this reach would be laid. While the shutter for the lining in the reach occupied by the downstream rock plug is being erected, the upstream rock plug would be removed by excavation in heading and benching.

16.3.8 Inlet and Outlet Structures During the time when all the above cited activities viz. excavation of Adit and DT, establishment of Adit portal, raising of small ring dykes and concreting lining of DT are going on, following activities will also be carried out concurrently in the sequence given below: i). Removal of overburden material and excavation for Portals at the Inlet and Outlet ends of DT ii). iii). Concreting for structure of portals at the Inlet and Outlet Raising of 4m high earthen ring dyke for the inlet structure and 3.5m high for the outlet structure. iv). Reinforcement and Concreting for the walls of the Box RCC structure duly fixing the first stage embedment of gates v). vi). vii) viii) ix). x). xi) xii) Excavation of toe wall Concreting of toe wall Reinforcement and concreting of roof of the inlet and outlet structures Laying of CC Blocks in front and on sides of inlet and outlet structures Invert of the inlet and outlet structures Second stage concreting for gates in the groves etc. Lowering of gates and installation of HM equipments. Removal of earthen dykes.

16.3.9 Methodology for Erection of Main H.M. Equipment Following shall be the typical erection sequence of Vertical fixed wheel gate components:i) ii). Erection of the first stage embedment (anchor bolts) in the blockout left in the RCC walls. Each set of guides, and seal seat arrangements shall be assembled in the respective blockouts, secured in place by anchorages. iii). iv). Placement of second stage concrete in blockout Gate/Stoplog units transported in sub-assemblies by trailer and shall be assembled and erected by suitable mobile crane
Hirong H.E. Project, Arunachal Pradesh 16-6

Environmental Management Plan Construction Methodology

CISMHE

v). vi).

Rubber seals shall be fitted with gate to make it leak proof. Suitable Hoisting arrangement shall be installed at 1262 m. for Inlet and 1253m for Outlet.

16.3.10 Plugging of Adit The Diversion Tunnel has to be ready for diverting the river water along with plugging of Adit before the Earthen dykes for concreting of closure of coffer dams is taken up. At the same time the last few activities in the diversion tunnel which are removal of rock plugs, concrete lining of the respective reaches upstream and downstream along with contact / consolidation grouting have to be completed prior to commencement of work on the construction of earthen dykes. These earthen dykes would be constructed for closure of coffer dam only after the diversion tunnel is fully ready for passing of the diverted water of the river i.e. the Diversion Tunnel is complete in all respects and the Adit has been plugged.

16.3.11 Coffer dams Diversion of river water shall be carried out for taking up the construction of main dam. The upstream cofferdam shall be founded at 1234m and downstream cofferdam shall be founded at 1231m depending upon availability of rock. The u/s and d/s coffer dams are planned to be constructed using pumped concrete of grade M15A20/A40 and are likely to have maximum heights of 17-18m and 09-10m, respectively. On completion of all the works related to DT, plugging of Adit and removal of earthen dykes provided at the Inlet and Outlet structures will be taken up so that the river water gets diverted to DT and raising of earthen dykes for the coffer dams can be taken up.

For the closure of the coffer dams, earthen dykes would need to be constructed. From the water availability series evolved for the Hirong HE Project it is seen that maximum 10-daily inflows during the Jan, Feb and March months are 94.60, 125.42 and 102.34 cumecs. As such the closure of the coffer dams has to be planned during the months from January to March.

16.4

DAM AND INTAKE The construction methodology for the main dam mainly consists of (a) excavation of bed

up to sound rock profile (b) Treatment of shear zones, if any (c) Laying of concrete in lifts of 2.0 m thickness (d) Consolidation grouting (e) Curtain grouting (f) Drainage holes (g) Laying of spillway bridge (h) Erection of hydro mechanical equipments.

Hirong H.E. Project, Arunachal Pradesh

16-7

Environmental Management Plan Construction Methodology

CISMHE

16.4.1 The Sequence of Construction The quantities of main items i.e. excavation and concrete to be executed in these structures are as below: Dam Blocks: 1. 2. Open excavation in gravels and boulders Rock excavation 1,19,733 m3 1,74,003 m3 1,02,114 m3 1,06,652 m3 88,985 m3 1,04,461 m3 30,402 m3 36,074 m3 3,41,235 m3 4,21,191 m3 3,762 m3 11,964 m3 11,16,093 m3 1,300 m3 11,17,393 m3 20,277 m3

Trajectory impact pit 1. 2. Open excavation in gravels and boulders Rock excavation

Left Bank excavation between dam blocks and trajectory impact pit 1. 2. Open excavation in gravels and boulders Rock excavation

Excavation for Road between dam blocks and trajectory pit on left and right bank 1. 2. Open excavation in gravels and boulders Rock excavation

Total quantities of excavation in dam blocks are as below: 1. 2. Open excavation in gravels and boulders Rock excavation

Total quantities of excavation in intake structure are as below: 1. 2. Open excavation in gravels and boulders Rock excavation

Total quantities of concrete are as below: (1) (a) In Dam Blocks (b) In CC Blocks d/s of dam Total Total quantity of concrete in intake

The civil works for Main Dam and Intake are planned to be executed in five working seasons. i) ii) iv) iv) v) First Working Season (16th Oct 2012 to 15th May 2013) Second Working Season (16th Oct 2013 to 15th May 2014) Third Working Season (16th Oct 2014 to 15th May 2015) Fourth Working Season (16th Oct 2015 to 15th Oct 2016) : Fifth Working Season (16th Oct 2016 to 15th Sep 2017)

Hirong H.E. Project, Arunachal Pradesh

16-8

Environmental Management Plan Construction Methodology

CISMHE

16.4.2 Excavation Methodology For excavation in overburden material, combination of Ex-400 hydraulic excavator (2 cum bucket) and dumpers shall be used. For rock excavation, drilling and blasting shall be done with crawler drills (with compressors). In addition, rock drills with or without pusher legs will also be used. The loading and haulage equipment will be same as for excavation in overburden material. The excavators shall be assisted by Dozers as needed. The type and number of equipment required has been worked out in paragraphs on equipments.

16.4.3 Methodology for Concrete Placement The concerting of dam blocks essentially consists of three main activities viz. manufacture of concrete which includes Aggregate Processing Plant for production of Aggregate, Batch and Mixing Plant and Ice Plant for production of ice. Aggregate processing plant and Batch/Mixing Plants shall produce concrete for Dam, Intake as well as for other components of the project such as HRT lining components of the project. The maximum concrete requirement for placement of concrete in Dam Blocks is 200 m3/ hour. The Aggregate Processing Plant of 500 t/hr capacity shall be installed for production of aggregate and Batch/ Mixing plant of capacity 300 cum/hr shall be installed for production of concrete (Refer Chapter on Common works). The ice plant of 90 t/hr capacity shall be installed so that required quantity of ice may replace the water to be mixed in concrete to bring the production temperature of concrete to 10C. The placement temperature of concrete as worked out by thermal studies is 12C. It has been assumed that the temperature of concrete will rise by 2C by the time it reaches from batch mixing plant to the placement location. 16.4.4 Equipment Required for Works of Dam and Intake List of equipment required for works of Dam and Intake Structure is as below

i). ii) iii) iv) v) vi) vii) viii) ix)

Ex-400 Hydraulic excavator/equivalent 20 t capacity dumpers Crawler/ wagon drills IRCM-341 Compressor 450 cfm Compressor 1000 cfm Dozers 180 HP/equivalent JCB Back Hoe Radial Cable Cranes (9 m3 capacity) Concrete buckets (9 m3 capacity)

2 Nos. 9 Nos. 4 Nos. 4 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 4 Nos.

16-9

Hirong H.E. Project, Arunachal Pradesh

Environmental Management Plan Construction Methodology

CISMHE

x) xi) xii) xiii) xiv) xv) xvi) xvii)

Silo Buses Concrete pump 38cum/ hr Transit Mixers (6 cum capacity) Needle Vibrators (65 mm dia. Needle) 150 mm dia Needle Vibrators with frequency changers Mobile crane (Hydra) 8/10 capacity Air water Jet Blaster Sand Blasting Equipment at 1.5 N/mm2 pressure

10 Nos. 2 Nos. 3 Nos. 6 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos.

xviii). Grout Pump SURFEX with capacity of 50 lit/min

xix) xx) xxi).

Drilling machines Diamec 262 Dozers D-50 (wheel Mounted) Dry shotcrete Machine 4/6 m per hour
3

2 Nos. 2 Nos. 2 Nos.

16.5

HEAD RACE TUNNEL The total length of the 7.5 m dia (finished) circular shape Head Race Tunnel, aligned on

right bank of river Siyom is 9202 m. Tunnel with a circular shape will be concrete lined having a finished diameter of 7.5 m. The alignment of tunnel has been fixed in such a way that adequate lateral and vertical rock cover is available at any particular location.

16.5.1 Infrastructure In order to access the work sites on right bank from the BRO road on the left the following basic infrastructure is required to be in place before taking up the tunnel excavation. Two no. bridges of approximately 60 m and 80 m span shall be needed to access the Adit locations. One steel girder bridge of 80 m span is proposed to be erected on river Siyom near Powerhouse location at an Elevation of 1040 m. A suitable diversion road from existing BRO road will be provided to connect the bridge location which will provide access to Adit near Surge Shaft and Intermediate Adit no.-2. Second bridge of 60 m span across Siyom river is proposed to be erected upstream of junction of Sitten Nallah with Siyom river. The bridge will provide access to Inlet adit and Intermediate Adit no.-1.

16.5.2 Construction Methodology and Equipment Planning The excavation of HRT will be done by using Drill and Blast Method (DBM). The excavation of HRT shall be done by using four Adits of 7.0 m D-shaped i.e. Inlet Adit,
Hirong H.E. Project, Arunachal Pradesh 16-10

Environmental Management Plan Construction Methodology

CISMHE

Intermediate Adit-1 and 2 and Adit to HRT near Surge Shaft. The above Adits meet the HRT at chainage 596.12 m, 3029.228 m, 5876.828 m and 9097.974 m respectively. Thus eight faces are available for excavation of HRT.

16.5.2.1 Excavation After jungle clearance and construction of roads and bridges, the excavation of Adit portals will be taken up. The overburden will be removed with the help of Excavator and Dozer whereas open excavation at portal face will be carried out by conventional Drill Blast Method with the help of Jack hammers and portable compressor. The mucking will be done by Excavator and Dumpers. The rock above the portal face will be excavated in a stabilized slope.

Four no. Adits (7.0 m D-shaped) will be provided for excavating HRT having total length of 9202 m. The location of Adits has been fixed keeping in view the geological and topographical conditions as well as construction convenience. The size of Adits has been kept as 7.0 m D-shaped keeping in view the easy movement of mucking equipment. The slope of various adits has also been kept mild in order not to stress the loaded equipment unnecessarily. A positive slope to all the adits has been provided in order to make them self draining. The excavation of Adits has been planned to be carried out full face by normal Drill and Blast Method as soon as the portals are established. The drilling operation for excavation of Adits is proposed to be carried out by deploying two-boom drilling jumbos and mucking will be done with the help of side tilting loader (2.5 cum) and 20 T capacity dumpers.

16.5.2.2 Head Race Tunnel (Heading) The excavation of heading will be carried out in following operations. i). ii). Survey and marking of profile Drilling operation Drilling will be done by using two boom hydraulic drilling Jumbos, which can theoretically drill up to 2 m per minute say 100 m per hour of 50 minutes working) iii). Charging and Blasting (The holes drilled will be loaded by Powergel or equivalent. Nonelectric detonators with millisecond delay are proposed to be used. iv). Defuming (At the time of excavation of tunnels, adequate provision for proper ventilation is absolutely essential; therefore an effective ventilation arrangement has been planned during excavation of tunnels).

Hirong H.E. Project, Arunachal Pradesh

16-11

Environmental Management Plan Construction Methodology

CISMHE

v).

Scaling (The scaling is proposed to be carried out manually with help of scissors platform.

vi). vii)

Mucking Rock Support Measures (Shotcreting shall be carried out up to excavated face after each blast whereas rock bolting shall be provided about 2 pulls behind the excavated face).

16.5.2.3 Head Race Tunnel (Benching) After heading operations are complete between two Adits, the benching of 1.2 m will be carried out by conventional bench blasting method. The progress targeted for benching operations is 20 m per day i.e. a monthly progress of 500 m. Same equipment as provided for heading excavation shall cater for benching operations as well.

16.6

EQUIPMENT PLANNING FOR TUNNEL EXCAVATION The planning of equipment has been carried out based on following data. 49.94 m2

i). ii). iii). iv). v). vi). vii).

Excavated Tunnel Area at minimum excavation line (heading)

Excavated Tunnel Area including payline and 5% over excavation (heading)52.44 m2 Blast Hole diameter Empty hole diameter Advance per pull Drilling Equipment Theoretical rate of penetration or 100 m / hour 41 mm 102 mm 3m Two boom hydraulic drilling Jumbos 2 m / minute

viii). ix). x). xi). xii). xiii).

Actual anticipated rate of drilling Swell Factor Estimated loose muck per pull No. of drill holes Depth of drilling for each hole Total drilling involved

80 m / hour 1.5 235.98 m3 110 3.5 m 385 m

16.7

CONCRETE LINING OF HRT The concrete lining in HRT is proposed to be carried out after completion of benching.

The lining is proposed to be carried out by using three set of shutters (each set containing two shutters and one traveler). The sequence of concrete lining operations in overt will be as follows:

Hirong H.E. Project, Arunachal Pradesh

16-12

Environmental Management Plan Construction Methodology

CISMHE

i).

One set of shutter will be installed at chainage 0.0 m. This shutter will move towards Inlet Adit (Ch. 596.12). After completion of this reach the above set of shutter will be dismantled and installed at chainage 3029.228 m. This shutter will move towards the Inlet Adit. For supply of concrete 30 cum/hr capacity CBP installed at Inlet Adit will be used.

ii).

Second set of shutter will be installed at chainage 5876.828 m and lining will proceed towards Intermediate Adit-1. The 30 cum/hr capacity CBP installed at the portal of Intermediate Adit-1 will be used for concrete placement.

iii).

Third set of shutter will be installed at upstream end of Surge Shaft at chainage 9202 m and lining will proceed towards Adit to Surge Shaft i.e. 9097.974 m. The concrete during this reach will be supplied from CBP of 30 cum/hr capacity installed at portal of Adit to Surge Shaft. After completion of lining from chainage 9202 m to Ch. 9097.974 m the above set of shutter will be installed at chainage 9097.974 m and the lining between the two chainages i.e. 5876.828 m and 9097.974 m will be completed and concrete will be supplied from 30 cum/hr capacity CBP installed at portal of Intermediate Adit-2.

16.7.1 Grouting 16.7.1.1 Contact Grouting Contact grouting in the tunnel is proposed to be carried out after 30 days of placement of concrete in tunnel invert. After this the contact grouting will progress simultaneously with lining activity of tunnel. Contact grouting is provided to fill any gap, especially at crown level, which has been left during concreting activity between rock and concrete lining. For this purpose grout holes of 38 mm diameter will be drilled 300 mm inside the rock and grouting will be done at a low pressure of about 1 to 1.5 kg/cm2. The water cement ratio in the beginning will be kept leaner and the same will be thickened as grouting progresses.

16.7.1.2 Consolidation Grouting The same holes as utilized for contact grouting will be re-drilled up to a depth of 6m for consolidation grouting. The consolidation grouting will be done at a pressure ranging from 5 kg/cm2 to 7 kg/cm2. The consolidation grouting in this case will also be carried out till refusal.

16.7.1.3 Plugging of Adits Once the grouting operations in the tunnel as well as all other activities in adjacent components i.e. Surge Shaft and Intake are completed the Adits will be plugged with concrete. For this purpose adequate no. of Shear keys will be provided. To fill any gap between rock and
Hirong H.E. Project, Arunachal Pradesh 16-13

Environmental Management Plan Construction Methodology

CISMHE

concrete plug the consolidation grouting will be carried out after plugging operations have been completed. Two no. adits i.e. Adit near Surge Shaft and Inlet Adit are proposed to be provided with a vehicular access each.

16.7.1.4 Cleaning of HRT After completion of all activities the tunnel is to be thoroughly inspected for any foreign material left inside during construction. This will ensure that no 16.7.2 Construction Equipment for HRT The summary of equipment is given below
Sl. No A. i). ii). iii). iv). B. v). vi). vii). C viii). ix). x). xi). xii). xiii). xix). xv). xvi). D xvii). xviii). E xix). xx). xxi). xxii) xxiii). xxiv). xv). Construction Equipment Quantity Drilling and Blasting Equipment Portable Compressors 1000 cfm 6 Two boom drilling Jumbos 6 Crawler drill IRCM 341 along with 450 cfm compressors 4 Jack Hammer with Pusher legs 12 Mucking Equipment Wheel mounted Dozer (180 HP) 3 3 Loader 2.5 m bucket capacity side Dump Loader 6 Dumper (20 T) 30 Concrete Production and Placement Aggregate Processing Plant 500 t/hr Capacity 1 Aggregate Processing Plant 100 t/hr Capacity 1 Aggregate Processing Plant 60 t/hr Capacity 1 Concrete Batching Plant - 30 cum/hr Capacity 4 Tunnel Shutters with Vibrators Complete (each of 12 m length)6 (with 3 travelers) Needle Vibrator - 65mm diameter with flexible shaft. 10 Transit Mixers - 6 cum Capacity 9 Concrete Pump (38 cum/hr.) 3 Surge Hopper 3 Shotcrete, Drilling and Grouting Wet Shotcrete Machine with Telescopic Arm 4 Grouting Pump (Surfex / Mai) 4 Support Equipment for Underground Works Ventilation Fans 1400mm dia Impeller 13 Ducting 1400mm dia 10718 Scissors Platform 4 Rib Erector 4 Rib Bending Machine with Jack etc. Complete 1 Alignment Lazer 6 Profiler 6 16-14

Hirong H.E. Project, Arunachal Pradesh

Environmental Management Plan Construction Methodology

CISMHE

16.8

SURGE SHAFT The Head Race Tunnel terminating in a 15.0m finished dia and 140.25 m high Surge

Shaft at RD 9217.53 m. The excavated dia of surge shaft is 17.20m (including 1000 mm thk lining and 100 mm thk shotcrete) from 1277.75 m to 1388.00 m and 18.10 m (including 1450 mm thk lining and 100 mm thk shotcrete) from. 1388.00 m to 1418.00 m. The location of Surge Shaft has been so planned that sufficient cover is available on all side of Surge Shaft. Sufficient space has also been ensured for working of a gantry crane at top to facilitate widening of pilot shaft and supply of concrete for concreting operations.

16.8.1 Construction Methodology 16.8.1.1 Excavation An independent road to Surge Shaft has been provided which will be completed after twenty months from start date of project. A bench is proposed to be excavated at 1418 m. The surge shaft is connected at its bottom through an adit which is connecting HRT, valve chamber and adit to top of penstocks. Excavation of Surge Shaft will be carried out in two stages i.e. Pilot Shaft and widening.

The excavation of pilot for Surge Shaft is proposed to be carried out from Adit to HRT near the Surge Shaft bottom. For this purpose an Alimak raise climber will be installed at the bottom and a pilot of 2.6 m diameter will be excavated with the help of raise climber. If needed the temporary rock support by way of spot rock bolts of 2 to 2.5 m length shall be provided in the pilot shaft.

A temporary winch of 10 T capacity will be installed for carrying out the sinking operations. A Tripod will be erected over top of pilot shaft from where the sinking operations will be carried out. Mucking in this case will have to be carried out manually. In case rock is very much shattered in top reaches the shaft will be supported by providing temporary steel supports. A 30 T capacity gantry crane will be installed at top of surge shaft for lowering and lifting excavation equipments, men and material as the excavation for widening proceeds. Widening operations shall be taken up proceeding from top to bottom by drill and blast method for 1.0 m depth at a time. The muck generated after blast will be dozed of by a small dozer upto pilot shaft and will be collected at bottom of surge shaft from where it will be hauled to nearest dumping site. The above sequence shall be repeated until the entire depth of the Surge Shaft is excavated. Total depth of Surge Shaft to be excavated in this manner is around 140.25 m. Normal benching operation shall be followed while widening of surge shaft.
Hirong H.E. Project, Arunachal Pradesh 16-15

Environmental Management Plan Construction Methodology

CISMHE

In the initial reach of about 30 m from the top the widened Surge Shaft is proposed to be supported by composite steel section of ISMB 300 x 140.25 with plates of 16 mm welded on both flanges and concrete. The ISMB will be completely embedded in concrete with a cover of 150 mm on its front face.

16.8.2 Equipment Planning 16.8.2.1 Open Excavation at Surge Shaft Top Open excavation to the extent of 12740 cum is to be carried out for which three month time has been provided in construction schedule. The excavation will be carried out by using Jack Hammers and a portable compressor of 500 cfm. A loader will be used to load dumpers of 20 T capacity. Since muck generated is only 13.6 cum/hour which is almost equal to carrying capacity of one 20 T dumper as such only one loader and dumper are sufficient to meet with the requirement. In addition one Crawler Dozer 180 HP shall be provided for dozing and collection of muck at the excavation site.

16.8.2.2 2.60 m dia pilot Shaft from Bottom Pilot shaft of 2.6 m diameter is to be excavated by deploying one no. Alimak raise climber at bottom of Surge Shaft. A progress of 1 m per day will be achieved by raise climber. As such four months time period has been provided in the construction schedule for this purpose. Since the muck generated per day is only of the order of 8.31 cum after considering a swell factor of 1.5 for loading and haulage of this muck a loader and a 20T dumper will be provided at bottom of Surge Shaft.

16.8.2.3 Side Slashing / Widening of Surge Shaft Widening of surge shaft is to done after completion of pilot shaft with the progress of 10 m / month in top 30 m and 15 m/month in remaining portion for which 11 months time has been provided. The Drilling will be carried out by wagon drill and a portable compressor of 500 cfm. A small dozer for dozing and loader will be used to load dumpers of 20 T capacity.

16.8.3 Concreting The concreting of Surge Shaft is proposed to be carried out by deploying a slip form shutter. The installation time for slip form shutter will be about two months. Concrete mix shall be transported from batching and mixing plant installed at adit to HRT near Surge Shaft through transit mixers feeding 40 cum concrete pumps for concrete lining up to 30 m height from bottom
Hirong H.E. Project, Arunachal Pradesh 16-16

Environmental Management Plan Construction Methodology

CISMHE

of Surge shaft. Concrete lining in rest of the Surge Shaft shall be done from top of Surge Shaft. Shutter vibrators and needle vibrators shall be used for vibration of concrete. The progress with slip form shutter will be of the order of 15 m / month and it will take about 9 months to complete the operation of concrete lining of 138 m deep Surge Shaft. For providing reinforcement a separate platform will be erected which will move ahead of concrete lining.

16.8.4 Grouting 16.8.4.1 Contact Grouting The contact grouting is to ensure proper contact of concrete with rock and consequent load transfer. For this purpose periphery holes will be drilled 300 mm deep into rock and grouting carried out at low pressure of 1 to 1.5 kg/cm2. The water cement ratio of the grout mix will be kept leaner in the beginning and thickened consequently. The contact grouting is to be carried out till refusal of the grout intake.

16.8.4.2 Consolidation Grouting In order to prevent any loss of water through shear seams and open joints it is necessary, especially in reach where rock cover is limited, to carry out consolidation grouting. For this purpose the holes drilled for contact grouting will be redrilled up to 8 m depth and consolidation grouting carried out through these holes at a pressure ranging from 5 kg/cm2 to 7 kg/cm2. The grouting in this case also is to be carried out till refusal. Total requirement of equipment for concreting in surge shaft are as under: The important equipment required are Transit Mixer 6 cum (Nos. 3), Concrete Pump (1), Needle vibrator (4), Batching and mixing plant 30 m3 cap

(1), Grout pump (1) and Slip form shutter 1.1 height (1).

16.9

PRESSURE SHAFT AND VALVE CHAMBER

16.9.1 Construction Methodology For the excavation of Pressure Shafts two Adits, namely Adit to Bottom of Penstock and Adit to Top of Pressure Shaft have been provided. Bottom Adit off takes from MAT at 1020.00 m. The Adit invert has been kept at 1005.275 m so as to match centre line of penstock with centre line of unit. The Adit to Top of Pressure Shaft bifurcates from Adit to HRT near bottom of surge shaft at 1269.756 m further this adit extend to valve house chamber, designated as adit to top of valve chamber. Thus, the top horizontal reach of Pressure Shafts will be approached by Adit to top of Pressure Shafts and the bottom horizontal reach by Adit to bottom of Pressure

Hirong H.E. Project, Arunachal Pradesh

16-17

Environmental Management Plan Construction Methodology

CISMHE

Shafts. For approaching vertical portion of Pressure Shafts all the two approaches will be utilized.

16.9.1.1 Excavation Methodology (Pressure Shafts) After completion of excavation of Adit to bottom of Pressure Shaft, bottom horizontal reach from u/s of Adit to bottom vertical bend of Pressure Shafts will be excavated. About 5 to 6 m of vertical portion of Pressure Shaft will be excavated from bottom horizontal reach by conventional drill and blast method. The Alimak raise climber will then be installed / erected at the bottom of Pressure Shaft-1 and Pressure Shaft-2 simultaneously. This activity will take about one month. The Alimak will land on a raised platform about 3 m from invert of bottom horizontal reach. The mono rail will be fixed in vertical reach manually. After this the Pilot Shaft of vertical portion will be excavated through Alimak raise climber and monorail extended after each blast. The size of Pilot Shaft will be 2.6 m i.e. the size of Alimak Platform. The progress of 1 m per day will be achieved for excavating the Pilot Shaft. Following this sequence the pilot shaft will be excavated from bottom to top. The methodology adopted remain same in both Pressure Shafts.

For widening of Pressure Shaft an 15 tonne winch shall be provided in Top Adit to Penstock. Platform will be lowered in the vertical reach of Pressure Shaft from where men and material will be taken inside the widened portion of Shaft. A progress of 1 m will be achieved for widening the Pressure Shaft to its full dimensions.

The four branch penstocks from bottom adit towards Powerhouse end shall be excavated 10 m short of upstream Powerhouse wall. The 10 m reach of branch Penstocks shall be excavated after Powerhouse excavation reaches that level. The excavation in penstock branches (i.e. bifurcation) will be taken up one after the other. The drilling will be done by 2-boom Hydraulic Jumbo and haulage of excavated muck will be done by loader, dumper combination. The excavation shall be done full face with conventional drilling/blasting method.

The excavation of Top horizontal reach both upstream and downstream of Valve House Chamber shall be carried out after completion of excavation of Valve House. For excavation of Valve House Chamber, adit to top of Penstock will be further extended to reach top of Valve House Chamber. The overt of this adit shall match with overt of Valve House Chamber. A central gullet 6.5 m wide and 6.5 m deep shall be excavated (Activity-I). The central Gullet so excavated shall be widened to its full width before carrying out the benching down operations
Hirong H.E. Project, Arunachal Pradesh 16-18

Environmental Management Plan Construction Methodology

CISMHE

(Activity-II). The benching down shall be carried out by providing a ramp in a slope of 1:12 to meet with top of adit to bottom of valve chamber at 1277.00 m (Activity-III). The haulage of excavated muck shall be carried out from Adit to top of valve chamber. After the completion of Activity-III the Valve Chamber will be excavated up to 1282.00 m on one side and 1277 on other side. The ramp removal shall be done from Adit to bottom of valve chamber. The excavation of rest portion of Valve Chamber will be done by making ramp in a upward slope of 1:12 and the haulage of excavated muck will be carried out via Adit to bottom of Penstocks. Thus after completion of this activity i.e. Activity-IV, further benching down up to invert level of Valve Chamber will be carried out (Activity-V).

The penstock work involves fabrication of steel liners of 4.25.0m and 3.0 m dia, thus before the fabrication work, exact number and size of each ferrule shall be planned talking into account the vertical and horizontal bend reaches. For this purpose, a well equipped Ferrule Fabrication Workshop will be established at site, with the state-of-the-art plant and equipment. The erection of ferrules shall be started from Adit to bottom of penstock. The erection of bottom vertical bend shall be carried out first of all. The stepped concrete pedestals (stairs) shall be provided to facilitate alignment of various pieces of vertical bend. The vertical bend will be erected in 18 pieces.

After erection of the bottom vertical bend the 5 m vertical pieces of ferrules will be lowered in the Pressure Shaft with help of 15 tonne winch provided in Adit to top of Penstock. Backing strip will be welded with upper face of ferrule. The strip will help in proper alignment of next ferrule. A clear gap of 3 mm will be provided between bevelled edges of two ferrules. The circumferential welding will then be carried out. The welding flux will be contained with help of backing strip.

After circumferential welding is completed Ultrasonic Tests will be conducted before carrying out backfill concrete and erection of another ferrule. After completion of vertical reach in this fashion the top horizontal bend will be erected in similar manner as bottom horizontal bend. Erection of ferrules in top horizontal reach upstream of Valve House is an independent activity and can be carried out after fabrication of ferrules is over whereas, erection downstream of Valve Chamber shall be carried out after erection of top horizontal bend.

Hirong H.E. Project, Arunachal Pradesh

16-19

Environmental Management Plan Construction Methodology

CISMHE

Erection of ferrules in bottom horizontal reach up to upstream face of bottom adit to Pressure Shaft will be carried out after bottom bend is erected. The erection of Y-piece and its testing will be done after this activity is over and ferrules for branch Penstocks will be erected after their excavation from Powerhouse end is over.

16.9.2 Equipment Planning Total requirement of equipment for open Excavation, Pilot Shaft and Side Slashing is given below.

S.No. Equipment Description

Pilot Shafts

Side Slashing 2 1 1 1 2 2 1* 3 1* 1 2

Optimum requirement 4 1 4 1 1 2 2

1. Heavy duty 120 cfm jack hammer (auto feed) 2. 2.5 cum capacity bucket loader (80 m3/hr) 3. Dumper 20 T capacity 4. Air compressor capacity 1000 cfm 5. Wet Shotcrete machine 6. Alimak Raise Climber 7. Winch 15 T capacity

16.9.3 Concreting The backfill concrete behind Steel Liner (ferrules) will be carried out once a ferrule of 5 m length is erected at site. The backfill concrete in vertical reach of Pressure Shaft will be carried out from top with help of a concrete pump. Similarly in horizontal reaches also the backfill concreting will be carried out after erection of each ferrule is over.

16.9.3.1 Concreting Equipment Planning The concrete shall be transported in transit mixers of 6.0 cum capacity. In three shifts working, total erection time including backfill concrete for a 5.0 m long single ferule is 6 days. Assuming one shift i.e. 8 hr is dedicated for backfill concrete.
Total backfill concrete behind single ferule Working hours Hourly concreting program = = = = Handling losses (5 %) = = Concrete production rate per hour Hirong H.E. Project, Arunachal Pradesh = 45.71 cum 8 hr 45.71 / 8 5.71 cum 5.71 x 1.05 5.99 6.0 cum 16-20 Say 6.0 cum

Environmental Management Plan Construction Methodology Weighted Average Lead = 1.2 KM

CISMHE

Hauling time (12.5 km/hr (average), transit mixer speed) = = Spotting and waiting time at the CBP Loading time at the CBP Turning, Spotting and Unloading time Total cycle time Nos of trip of transit mixer per hr of 50 min Concrete quantity carried per hour (assuming 66% efficiency of Transit Mixer) Transit mixer required = = = = = = = = = Total = 2 x 1.2 x 60 /12.5 12 min 7.6 min 6.6 min 4.95 min 31.15 min 50/31.15 = 1.61 x 6 x 0.66 6.38 cum 6/6.38 0.94 no. Say 1 no. 1 No. 1.61

Hence, only 1 No. pump 38 cum/hr is sufficient for placing the backfill concrete in penstocks.

16.9.4 Grouting Contact grouting shall be carried out once the backfill concreting operations are over. This will be carried out from holes left in steel Penstocks for this purpose. Drilling will be carried out from these holes up to 300 mm inside the rock and contact grouting at a pressure of 1 to 1.5 kg/cm2 shall be carried out. Total requirement of equipment for backfill concrete in penstock are as under: S. No. 1 2 3 4 5 Equipments Description Transit Mixer 6.0 cum Concrete pump (38 m /hr) Needle vibrator Batching and mixing plant 30 m /hr cap Grout pump
3 3

No. 1 1 2 1 1

16.10 POWER HOUSE COMPLEX The Power House Complex comprises of two parallel underground caverns having a clear rock cover of 41m between them. The Power House Cavern is 130m (L) x 22m (W) x 46m (H)
Hirong H.E. Project, Arunachal Pradesh 16-21

Environmental Management Plan Construction Methodology

CISMHE

and houses the Erection bay, Machine Hall and Control Block. The Transformer Hall Cavern is on the downstream side of the Power House Cavern and is 118m (L) x 15m (W) x 26m (H) and houses the Generator Transformers and GIS. The 76m (L) x 7m (W) x 10m (H) D.T. Gate Operating Gallery is located on the downstream side of the Transformer Hall Cavern with a clear intervening rock cover of 21.50m. The Power House (PH) and the Transformer Hall (TH) caverns are connected by four nos. Bus Duct Galleries spaced 17m apart from each other. Four no. Draft Tube tunnels off-take from the bottom of the P.H. Cavern and go up to the bottom of D.T. gate shaft and further merges into a Collection Gallery forming the TRT for discharging water into the river. The excavation of the two major caverns i.e. Power House and Transformer Hall could be done only after establishing of the Approach Adits, viz. 7.5m D-shaped Main Access Tunnel, a branch Adit (6.5m D-shaped and 158.65m long) off-takes from MAT at RD 255m and meets the bottom of Transformer Hall at 1020m, Another branch Adit (7.5 D-shaped and 147.25m long), 6.5m D-shaped Adit to top of T.H. Cavern cum Ventilation Tunnel, a branch Adit (6.5m D-shaped and 95.62m long), 7.5m Dia. Construction Adit cum Surge Gallery, 390m long with Portal at 1040m

16.10.1 Construction Methodology A Steel bridge of approx. span of 80m is proposed on river Siyom u/s of Powerhouse location at an Elevation of 1040 m for which a suitable diversion road from existing BRO road will connect the bridge location. This bridge will provide access to Portal of Main Access Tunnel, Ventilation Tunnel, Construction Adit cum Surge Gallery, TRT Outfall and Switch Yard. The proposed road to MAT portal will further extend to access the Concrete Batching Plant (CBP-5) of 60 cum/hr capacity located approx. 0.50Km from MAT Portal and Aggregate Processing Plant (APP-2) of 100TPH capacity located approx. 1.50KM from CBP-5. For timely completion of the project, it is necessary that the construction of approach roads leading to various adits from the bridge is started simultaneously with bridge construction for which necessary equipment.

16.10.1.1 Approach Adits Following adits have been provided for approaching various components in Power House Complex. i). ii). iii). 7.5m D-shaped Main Access Tunnel (MAT), 6.5m D-shaped Adit to bottom of Transformer Hall offtaking from MAT, 7.5m D-shaped Adit to bottom of Penstocks offtaking from MAT,
16-22

Hirong H.E. Project, Arunachal Pradesh

Environmental Management Plan Construction Methodology

CISMHE

iv). v). vi). vii).

6.5m D-shaped Ventilation Tunnel to Top of T.Hall, 6.5m D-shaped Adit to top of P.House offtaking from VT, 6.5m D-shaped Adit to DT Gate Operating Gallery offtaking from VT, 7.5m Dia. Construction Adit cum Surge Gallery

16.10.1.2 Excavation of Adits The excavation of Adits shall be taken up as soon as the portals are established. The drilling for excavation of adits shall be done by 2 boom hydraulic jumbo and by conventional drill and blast method using full face excavation methodology and the mucking will be done by a combination of Side dumping Loader (2.5cum) and 20T capacity Dumpers. As the excavation proceeds, suitable rock support by way of rock bolts, shotcrete, steel ribs and backfill concrete shall be provided as per prevalent geological conditions. Drilling for rock bolts shall also be carried out with two boom drill jumbos. An average progress of 85m for excavation of Adits has been assumed as per cycle time calculation shown in Appendix-1 of Chapter-3 for Diversion Arrangement. The size of MAT and VT has been kept as 7.5m D-shaped and 6.5m D-shaped respectively keeping in view the transportation of largest size of E-M equipment inside Power House and easy movement of mucking equipment. The slope of various Adits has also been kept mild so as not to stress the loaded Dumper/Trailer unnecessarily.

16.10.1.3 Power House cavern First of all, the roof of the powerhouse cavity will be excavated. This will be done through 6.5m D-shaped Adit to top of P.H. Cavern off-taking from the VT and meeting the powerhouse cavity gable end at its roof level on the Erection bay side. The excavated crown level of the powerhouse cavity is at 1042.60m which is same for 6.5m D-shaped Adit to top of PH where it meets the powerhouse cavity. For excavating the roof vault, a central gullet will first be excavated along the entire length of the powerhouse cavity and in line with the 6.5m D-shaped Adit. The central gullet will be 7.5m wide with roof having same profile as that of powerhouse cavity.

After completion of excavation for central gullet, 10m wide nitches along the profile of Powerhouse crown will be provided on both sides of central gullet. These nitches will be staggered by atleast 25 m along the length on both sides of gullet. This will ensure that full width of Powerhouse is not excavated in one go and part excavation and supporting is completed in 2/3rd portion along the crown before taking up remaining 1/3rd portion. This will ensure proper supporting of crown with least initial deformations. The widening of the central gullet to full
Hirong H.E. Project, Arunachal Pradesh 16-23

Environmental Management Plan Construction Methodology

CISMHE

width of the powerhouse roof vault in 22.20m width will be undertaken from the Erection bay end and proceed towards the Control block end.

After having excavated and supported the roof vault of the powerhouse cavity up to the 1035m, benching down operations up to the Erection bay level at 1019.7m will be taken up. Initially, the mucking during the benching down of the powerhouse cavern will necessarily have to be done through the 6.5m D-shaped Adit to top of P.House, as this will be the only access available. Benching down will be done in stages by making ramps and removing the same progressively.

In the next phase, i.e. under Stage-V the entire area of the powerhouse will be benched down to a elevation of .1019.70m which is same as required for the erection bay floor. In Stage-VII 7.5m wide ramp shall be excavated along upstream wall of the cavity with its elevation near the control block end being 1012m and that near the Unit Before the end of Stage-VII, the lower horizontal portions of the Unit Pressure Shafts would have been excavated up to the U/S wall of the powerhouse cavity. Stage-VIII will thus consist of removal of ramp and benching down of entire Power House Cavern beyond Erection bay to 1003.20m, which is the general excavated floor level in powerhouse cavity. Mucking of this portion shall be done through the lower horizontal portion of Unit pressure shaft-4. Before the end of Stage-VIII, the Draft tube tunnels will also get excavated through the collection gallery.

16.10.1.4 Transformer Hall Cavern The Transformer Hall Cavern (THC) is approached at the crown level through the 6.5m D-shaped Ventilation Tunnel. Another approach is also available through the 6.5m D-shaped Adit to bottom of Transformer Hall offtaking from MAT, which meets the THC at its invert at 1020m. Also, the Erection bay of P. House and the T. Hall are connected at 1020m by a 7.0m wide Connecting Gallery.

First of all, the roof of the Transformer Hall cavity will be excavated. This will be done through 6.5m D-shaped Ventilation Tunnel meeting the T.Hall cavity gable end at its roof level. The excavated crown level of the T.Hall cavity is at 1046m which is same for 6.5m D-shaped Adit to top of T. Hall where it meets the Transformer Hall cavity. After completion of excavation for central gullet, 10m wide nitches along the profile of T. Hall crown will be provided on both sides of central gullet. These nitches will be staggered by atleast 25 m along the length on both
Hirong H.E. Project, Arunachal Pradesh 16-24

Environmental Management Plan Construction Methodology

CISMHE

sides of gullet. This will ensure that full width of T. Hall is not excavated in one go and part excavation and supporting is completed in 2/3rd portion along the crown before taking up remaining 1/3rd portion. This will ensure proper supporting of crown with least initial deformations. The widening of the central gullet to full width of the T. Hall roof vault in 15.20m width will be then taken up and the supporting of the roof of the widened portion will also be done concurrently.

Once the crown of the THC has been excavated, a 6.5m wide ramp with a slope of 1(V) in 10(H), which is considered suitable for haulage equipment will be excavated first up to 1029.75m in a length of 87.5m. Further, the benching down of the remaining portion of T. Hall cavern on both sides of the ramp will be done up to 1029.75m leaving the 6.5m wide ramp for mucking through VT under Stage-III The rock bolting and shotcreting of the final exposed rock faces of the cavity walls will be done simultaneously. Under Stage-IV a 4.35m wide ramp shall be excavated from 1029.75m up to invert level of Connecting Gallery to P.House and 6.5m DShaped Adit to bottom of T. hall i.e. 1020 m along the D/S wall of T. Hall cavern. By the time this activity is over, the excavation of Connecting Gallery to P.House and 6.5m D-Shaped Adit to T.Hall bottom off-taking from MAT would have been completed and thus the same will be available for taking up further excavation and mucking operation. In the next phase, i.e. under Stage-V, the entire area of the T. Hall will be benched down to a horizontal elevation of1019.50m which is same as required for the Transformer Hall floor. The benching down operations for each stage shall be similar as adopted for Power House cavern. The mucking under this activity shall be done through Adit to bottom of T. Hall.

The excavation and support of niche for Oil separator sump along with balance portion of Drainage and Dewatering Tunnel between PHC and TH and TH and DT Gate Operating Gallery will be taken up next. The mucking under these activities shall also be done through Adit to bottom of T. Hall. The drilling for underground excavation shall be done by Two-Boom Hydraulic Jumbo adopting conventional drill/blast method for the excavation. Removal of excavated material shall be done by a combination of Excavator/Side Dump Loaders with Dumpers. As the excavation proceeds, rock supports system by way of rock bolts, shotcrete, steel ribs and back fill concrete shall be provided, as required. Drilling for rock bolts shall also be carried out with Two-Boom Drill Jumbos.

Hirong H.E. Project, Arunachal Pradesh

16-25

Environmental Management Plan Construction Methodology

CISMHE

16.10.1.5 Bus Duct Galleries Four no. Bus Ducts offtaking from the THC at 1020.00m meets the PH cavern at 1015.20 in a length of 41m each. The excavation of Bus Ducts for a length of 9m shall be taken up partly from the P.House cavern end as explained above.

16.10.1.6 Draft Tube Gate Operating Gallery The excavation of 76m (L) x 7.0m(W) x 10m(H) D.T. Gate Operating Gallery (GOG) shall be taken up as soon as the excavation of 6.5m D-Shaped Adit to DT GOG offtaking from VT is completed. The crown level of the Gate Operating Gallery is at 1042.10m whereas the crown level and invert level of Adit where it meets the GOG are at 1038.50 m and 1032.00 m respectively. The drilling for excavation will be done by 2-boom Hydraulic jumbo (Boomer) and the mucking of the excavated material will be done by a combination of Excavator/ Side dumping Loader (2.5cum) and Dumpers through VT. Due to limitation in available working height of 7.5m for Two-Boom Drill Jumbos, full face excavation of GOG will not be possible. The excavation of GOG shall be done in two stages

16.10.1.7 Draft Tube Gate Shafts After completion of excavation of GOG under Stage-II, the excavation for four no. D.T. Gate Shafts, shall be taken up. It is proposed to erect one no. 10T capacity winch for lowering of excavation equipments, men and materials for the excavation work. The excavation of Gate Shafts for Draft Tube-1 and 3 will be taken up first and shall be done in 2 stages each i.e. Stage-III and IV. The excavation of Gate Shafts for Draft Tube-2 and 4 will be done simultaneously later in StageV and VI each. Under Stage-III, Pilot Shafts each of two meter diameter shall be excavated from top i.e. at 1031.60m by conventional drill and blast method. After the Pilot shafts for Gate shaft 1 and 3 are completed, widening operations shall be taken up under Stage-IV, proceeding from top to bottom by drill and blast method for 1.0 m depth at a time. Similar operation is carried out for excavation of Gate shafts for Draft tubes 2 and 4 under Stage-V and VI.

16.10.1.8 Construction Adit cum Surge Gallery The excavation of 390m long Construction Adit cum Surge Gallery shall be taken up as soon as the portals are established. The drilling for excavation is proposed to be carried out by using two boom hydraulic drilling Jumbos which can safely drill up to a height of about 7.5m. The finished diameter of circular tunnel is 7.5m and will have maximum excavated height of

Hirong H.E. Project, Arunachal Pradesh

16-26

Environmental Management Plan Construction Methodology

CISMHE

8.25 m in normal reaches and 8.50 m in ribbed reaches. Keeping in view the limited reach of drilling Jumbo, It is proposed to carry out the excavation in 2 stages- heading and Benching.

16.10.1.9 Tail Race Tunnel, Collection Gallery, Draft Tube Tunnels and Outfall Structure. The length of Tail Race Tunnel is 210m long and has a circular section with finished diameter of 7.5m. The TRT is proposed to be excavated from Construction Adit cum Downstream Surge Gallery which is also of similar sectional profile. The Construction Adit meets the TRT at 10m D/S of junction of TRT with Collection Gallery.

16.10.1.10 Tail Race Tunnel The concrete lining in 7.5 m finished dia. circular shaped and 210m long Tail race Tunnel is to be carried out once the concreting works of D.T. Tunnels including D.T. Gate Shaft and Collection Gallery are completed. Concrete lining operation consists of Kerb laying, overt lining to be followed by invert lining. The overt lining shall be done using a 12m long hydraulically operated collapsible Gantry Shutter moving on rails. The rails shall be fixed on kerbs to facilitate movement of the shutter. The concreting of invert portion will be done after the overt lining is completed.

One no. 12m long Gantry shutter will be erected at d/s end of TRT near rock ledge. The lining operations in this case will be carried out in upstream direction towards junction with surge gallery. The concrete will be fed from 60 cum/hr capacity CBP-5 installed near MAT portal. The concrete behind the Shutter shall be placed by Concrete Pumps (38cum/hr capacity). A Surge Hopper shall be kept near the concrete pump to ensure uninterrupted supply of concrete to the Pump. Vibration of concrete shall be accomplished by surface vibrators mounted on the Shutter itself and needle vibrators inserted through inspection window in shutters. While the lining in this reach is in progress the kerb along with rail fixing will be extended in upstream reach and the shutter will be moved on rails. The overt concrete lining from up to junction with collection gallery is completed thus with a progress of 96m/month. The invert lining in TRT will be done after the overt lining in Surge Gallery is completed. The surface profile of the invert will be finished to shape by screeding with the help of a tailor made template.

16.11 CONSTRUCTION SCHEDULE Table 16.1 gives the construction schedule of Hirong H.E. Project

Hirong H.E. Project, Arunachal Pradesh

16-27

Environmental Management Plan Construction Methodology

CISMHE

Table 16.1 Construction Schedule of Hirong H.E. Project S. N. Description

i). Diversion Arrangement and River Diversion (including u/s and d/s coffer dams) ii). iii). iv). v). vi). vii) Main Dam (All four sluice gates erected) Intake Structure Reservoir Impounding Date HRT Surge Shaft (including gates) Valve Chamber (including erection of valves) 15.12.2017 15.05.2017 15.12.2017 15.07.2017 30.06.2017 15.03.2017 15.09.2016 31.05.2017 31.12.2016 30.04.2017 15.05.2017

Completion Date
15.01.2014

viii). Pressure Shafts ix). x). xi). Transformer Hall Surge Gallery TTR & Outfall Structure (including h/m works)

xii). Cable Tunnel & Switch Yard (including erec. & commissioning of e&m works) xiii) Power House a) b) c) d) e) Water Availability UNIT-1 - Testing & Commissioning UNIT-2 - Testing & Commissioning UNIT-3 - Testing & Commissioning UNIT-4 - Testing & Commissioning

31.12.2017 28.02.2018 30.04.2018 31.05.2018 30.06.2018

Hirong H.E. Project, Arunachal Pradesh

16-28