F 85353ee5307eb87f

180 MW Kali Gandaki Koban Hydroelectric Project
EPC Tender Documents: Volume II: Technical
Section 7 Method Statement
SINOHYDRO CORPORATION LIMITED
EPC Tender Documents: Volume II: Technical
Method Statement
of Kali Gandaki Koban Hydroelectric Project
Content
1.
Project Description .......................................................................................................................1
2.
Project Execution Organization and Main Construction Equipment ............................................. 2

2.1 Project Execution Organization ..............................................................................................2
2.1 Main Construction Equipment ................................................................................................3
3.
General Construction Layout ........................................................................................................7

3.1 Principles for General Construction Layout ............................................................................7
3.2 General...................................................................................................................................7
3.3 Camp & Office Building ..........................................................................................................8
3.4 Access Road .......................................................................................................................... 9
3.5 Air Compressing System for Site Works.................................................................................9
3.6 Power Supply ....................................................................................................................... 10
3.7 Water Supply ........................................................................................................................11
3.8 Communication System........................................................................................................12
3.9 Construction Auxiliary Facilities ............................................................................................12
4. Main construction methodology .................................................................................................... 15

4.1 Open Excavation Works .......................................................................................................15
4.2 Dam Embankments ..............................................................................................................16
4.3 Underground Works .............................................................................................................19
4.4 Grouting Work ...................................................................................................................... 23
4.5 River diversion ...................................................................................................................... 23
4.6 Concrete works ....................................................................................................................24
4.7 Turbine equipment installation ..............................................................................................28
4.8 Generator Installation ........................................................................................................... 39
4.9 Penstock manufacturing and installation ..............................................................................46
4.10 Steel gate and trash rack installation ..................................................................................53
5. Project Preliminary Schedule.......................................................................................................59
5.1 Milestone and Critical path ...................................................................................................59
5.2 Construction Rate at Peak ....................................................................................................60
1.
EPC Tender Documents: Tender Schedules
Project Description
Kali Gandaki Koban Hydroelectric Project (KGK HEP) with proposed installed capacity of 180MW, is a
high head hydropower plant. Its Headworks is located at Dhampu and the underground PowerStation at
Ghasa in Lete VDC of Mustang District. The project is a run of river type development having storage
capacity for peaking operation.
The general scope of works envisaged includes but is not restricted to the following:
(a) Design and Construction of all civil works, civil structures including:
Concrete Face Rockfill Dam (CFRD), Spillways & Undersluices, Intake Structures, Control Building
at Headworks,
Sediment Bypass Tunnel and its Guiding Structures including Overflow Weir and Side Channel
Spillway,
Headrace Tunnel, Surge Tunnel, Valve Chamber, Drop Shaft with trifurcation, Access Tunnel to
PowerStation, Tailrace Tunnel (a portion of which is expected to be in soft soil),
(b) Design, procurement, fabrication, testing and installation of all electrical, mechanical, hydromechanical, electromechanical, hydraulic steel structures including but not limited to operate and
maintain the plant in a manner that conform to the Contract Documents.
Hydraulic and Hydro-Mechanical steel structures (gates & stoplogs, cranes, valves, trash racks &
cleaning system, liners, manifold, trifurcation pipes).
Electromechanical, electrical, instrumentation & control equipments required at the powerhouse and
other structures. These include turbine, generators & transformers with its auxiliaries, cable and
cable ducts, Control System, GIS Switchyard and Outgoing Gantry, monitoring equipment, cooling
system, compressed air, hydraulic systems, fire fighting, ventilation, illumination in the Power House
and elsewhere, for construction/ operation/ maintenance of the plant.
(c) Design, procurement, testing and installation of a GIS (including cable head). Ducts and all civil
works for such switchyard to complete the Outgoing Gantry are also included.
(d) Design, rehabilitation/realignment, construction and maintenance of Beni Jomsom Road from Ghasa
to Larjung and all internal access roads required for construction works.
(e) Design and construction of all required Adits as indicated or approved by the Employer.
(f) Care of water
Dewatering in open excavation as well as in underground works,
River Diversion and flood control
(g) Design and Installation of temporary and permanent protection/support measures for all excavation
and civil works.
(h) Design and installation of fencing, gates, guard house, sentry post, landscaping, illumination as
indicated or as approved by the Employer.
(i) Bidders obligations towards health and safety as well as environmental mitigation plans are also
included.
(j) Commissioning, testing and rectification of defects to the extent and duration as provided in the
contract.
(k) Training of manpower for operation and maintenance.
Page 1 of 60
The main quantities to be used in this project are shown in the following table.
No.
Items
Earth
Exca.
Rock
Open
Exca.
Rock
Tunnel
Excavation
Concrete
Filling
Grouting
Rock
Bolt
Unit
Kg
Roadworks
Cofferdam
Bypass Tunnel
Guiding Structure
CFRD Dam &

Headworks
Head Race Tunnel
Pressure shaft
324,219
38,872
98,072
116,600
56,496
120,398
25,237
70,201
26,122
21,213
212,042
134,286
370,938
58,381
224,324
579,018
81,201
2,873,255
13,349
275,455
46,366
2,407,589
111,000
8,708
3,951
186,483
21,300
Power station access

tunnel
66,697
7,904
189,131
13,500
Tairace tunnel
68,900
12,704
10
Power station
33,766
8,050
11
Transformer cavern
10,800
520
584,724
184,326
Total
2.
23,730
645,306
516,158
24,021
300,000
8,540
501
534,438
6,535,476
273,412
Project Execution Organization and Main Construction Equipment
2.1 Project Execution Organization

Sinohydro is the leading company in the world in the field of engineering, procurement and construction
of the hydropower project, and has also practices and experiences working in Nepal, would like to have
further cooperation with AEHPL and make more contributions and benefits to Nepal.
Once Sinohydro has the opportunity to get the Project, we shall set up an efficient organization, and
select experienced staff in management, engineering, construction and installation, dispatch specialized
construction teams, and complete this project per the schedule.
Our head office will also establish a team to provide full supports and helps in technical and
management.
The staff and labor number at the peak will be about 1200, preliminary Organization Chart is shown
below:
Page 2 of 60
Head Office
Expert Team
Project Manager
Commercial
Manager
Chief Engineer
Construction
Manager
M&E Manager
Construction Department
M&E Department
Purchase Department
Quality Safety
Department
Design Department
Laboratory
Survey Department
Technical Department
Contract Department
Accounting Department
General Affairs
Department
General Office
Machinery Repair Plant
Aggregate Processing Plant

Concrete Batch Plant
Comprehensive Processing
plant
M&E Installation Section
Guiding Structure & Dam Section
Bypass Tunnel Section
Intake Structure Section
HRT Adit-1 Section
HRT Adit-2 Section
HRT Adit-3/4 Section
Underground PowerStation
Section
Tailrace Tunnel Section
Road Works Section
2.1 Main Construction Equipment
Hydraulic Drilling DX700
DX700
Down-in-Hole Drill 89mm
YQ100B
10
Rotary disk drill
JP100
Pneumatic Drill
YT27
120
ZFY2.0/LM400
XY-2
Exploration Drill
SGZ-III(A)
Air Compressor
Atlas
27m3/h
Air Compressor
Atlas
20m3/h
Air Compressor
Atlas
12/m3
Air Compressor
VFY-3/7
3m3/h
Air Compressor
2V-0.6/7
0.6m3/h
Raise Boring Machine

Geological Drilling
Page 3 of 60
Mortar Mixing Machine
NJ2000
Wet Jet Machine
TK500
5m3/h
10
Wet Jet Machine
Spritz CSS-3
30m3/h
BW-250/50
GJY-III
10
Backhoe
CAT330
1.6m3
Backhoe
PC220
1.0m3
Backhoe
CAT312D2
0.53m3
Hydraulic Hammer
KCB250
2.8t
Loader
WA380
3.5m3
Wheel Loader
ZL50
3m3
Loader
ZL30
1m3
JCB
Bulldozer
JCB3CX
D85
175KW
Dozer
HP220
220KW
Grader
GR100
75Kw
XZJ5110GLQ
100Kw
Asphalt Distributor
Dump Truck
20t
Dump Truck
15t
10
Dump Truck
5t
10
Dump Truck
8~10t
20
Heavy Duty Lorry
EQ1141G
8t
Heavy Duty Lorry
EQ1108G
5t
Platform Trailer
EQ4260G
40t
Flat Truck
EQ1208G
10t
EQ3208GZY
10t
Axial flow Fan
2*75Kw
150KW
Axial flow Fan
2*55KW
110KW
Axial flow Fan
2*37KW
74KW
Axial flow Fan
2*30KW
60KW
200t/h
90m3/h
Explosive Vehicle
KXP-1
Grouting Recorder
Inclinometer
Grouting Pump
Aggregate Production System

Concrete Batching Plant
HZS90
Page 4 of 60
JS1000
60m3/h
JS500
25m3/h
Ready-mix Concrete Truck
EQ5242GJB
6m3
Concrete Extruding Machine
BJY40
45Kw
Concrete belt feeder
800mm
70m
Concrete Bucket
LG1
1m3
Concrete Bucket
LG1.5
1.5m3
Concrete Pump
30m3/h
Concrete Pump
60m3/h
Steel mould trolley
10m
Truck Crane
QY50K
50t
Truck Crane
QY25VF
25t
Truck Crane
QY16E
16t
5t
Truck crane
Electric Winch
JM5
5t
Tower Crane
SHENYANG7050
25t
gantry crane
20t
20t
gantry crane
10t
10t
Vibratory Roller
SR18M
18t
Vibratory Roller
XS262J
26t
Vibratory Roller
LTC6
6t
Vibratory Roller
BW75S
1.5t
Hand Vibratory Roller
DX-70
0.7t
Electric Rammer
GVR200Y
Diesel Generator
500kw
Diesel Generator
300kw
Diesel Generator
250kw
Diesel Generator
200kw
Diesel Generator
100kw
Inverse DC arc welder
ZX7-500
Welding rod oven
ZYH-60
2 set
Page 5 of 60
Ultrasonic detector
CTS-22
X-ray detector
XX2505
Magnetic powder detector
XDYY-III
Ring welding trolley
HGK-20
Three-roller plate roll
W11S-503000
Submerged arc automatic welder
MZ-1-1250
Contravariant AC welding machine
ZX7-500
15
Facing machine
SKF-20
CG1-30B
Auto-flux dry oven
NZHG
Welding rod thermostat
101-
semi-auto cutting machine
Caterpillar infrared heater
LCD64-220
Ultrasonic Detector
MFDS-350
Air compressor
6m3/min
Air compressor
0.6m3/min
Windlass
JJMW3-10t
Windlass
JJMW3-5t
10
HY4030
Y32-2000KN
Hawking welding stress eliminator

Presses
Fueling Vehicle
EQ5141GJY
132kw
SGZ5141GSS
8t
Submerged Pump
65QW30-40
7.5kw,30m3/h
Submerged Pump
QW40-15-30
7.5kw,15m3/h
Submerged Pump
50WQ20-40-7.5
7.5kw,20m3/h
Submerged Pump
65QW35-60
15kw,35m3/h
Submerged Pump
QW200-400-30
55kw,400m3/h
Submerged Pump
QW150-200-30
37kw,200m3/h
Centrifugal Pump
IS125-100-200
45kw,200m3/h
Centrifugal Pump
QS40-30/2-55
5.5kw,40m3/h
Centrifugal Pump
IS100-80-125
15kw,100m3/h
2PW
7.5kw,43m3/h
16
Sprinkler
Sewage Pump
Equipment Maintenance Machine
1 Set
Laboratory Equipment
1 Set
Survey Instruments
5 Set
Page 6 of 60
3.
General Construction Layout
3.1 Principles for General Construction Layout

Combining the scale, features, construction environment and conditions of the project, the principles for
the general layout of the construction shall be scheduled to be as follows:
(1) The temporary facilities of construction campsite and site and the access road shall be planned and
laid out in the confirmation area according to the site survey and the conditions.
(2) The scale and volume of all the temporary life and production facilities and auxiliary plants for the
construction shall be planned and designed according to the total construction schedule and
intensity in an effort to reach compact, reasonable and convenient layout.
(3) In the underground construction, whether the layout of temporary projects including air, water and
electricity supply and ventilation and drainage in the tunnel is reasonable or not has a great effect on
the construction safety, schedule and investment, so such factors as the construction procedures,
traffic, safety, excavation explosion effect and balancing construction intensity shall be
comprehensively taken into account in the layout.
(4) All the construction campsites and sites shall be equipped with enough reliable environment
protection facilities and firefighting equipment according to related requirements to avoid the
impairment on the public interests.
3.2 General
In view of the topography and landform nearby the Site acknowledged by the site investigation, the
temporary facilities and auxiliary construction plant in each construction area, along with the access road
will be arranged in accordance with the Tender Documents and conditions provided by the Employer
within the expropriation range. Overall planning will be carried out with reference to the detailed location,
landform feature and current status described in the Tender Documents.
The temporary facilities include camps, offices, workshops, stores and yards and so on. The exact
location of all temporary facilities to be constructed will be agreed by the Engineer after commencement.
Generally, the following items are considered:
Contractors Main office and Camps
Clinic and First-aid station
Sub Offices
Construction Access Roads
Water-supply and Sewage system
Air supply system for construction
Power Supply and Lighting system
Communication system
Machinery Repair Plant
Comprehensive Processing Plant
Metalwork Structure Fabricating Plant
Disposal area
Explosive magazine
Page 7 of 60
Fuel station and Storage

Laboratory
Aggregate processing Plant
Concrete Batch Plant
3.3 Camp & Office Building

a) Contractors Offices and Residences.
Several camps shall be set up to meet the requirements of construction and living, the camp scales are
shown in the following table:
No.
AREA
m2
Came Name
Building
Area m2
Dam Section Labor Camp
8000
855
Dam Section Office and Camp
11000
1900
Adit-2 Site Camp
2000
470
Adit-3/4 Section Camp
6000
1070
PowerStation Section Labor Camp
6000
1900
PowerStation Section Main Camp
18000
1865
Tailrace Section Camp
8000
830
According to the construction progress and intensity, it is preliminarily estimated that about 1200 labors
and staffs will be required in the peak construction period of this project
b) Clinic and First-Aid Station
The Contractor will make arrangements which are satisfactory to the Government Medical Authority for
provision of free accident and emergency services for all labors and staffs on the Works.
The Contractor will provide at the site of the Permanent Works an ambulance and two staffed, furnished
and equipped first-aid hut, one to be located at the main camp and one to be moved from one location to
another with the Contractor field office.
Planning of Clinic & First Aid Facilities:
No.
Description
Building Area
Land Area
Remarks
Clinic and First Aid Station
25m2
200m2
Fixed
First-Aid Hut
10m2
25 m2
Movable
roads and parking
500m2
green areas and planting
500m2
Total
35m2
1225m2
c) Living camps and office facilities for Contractors

Living camps and office facilities for Contractors are mainly located in DAM and Power Station area.
Page 8 of 60
3.4 Access Road

3.4.1 External Access Road
The project site can be reached by a blacktopped road from Pokhara to Beni and by an earthen and
gravel road from Beni to Jomsom about 320 km by road north-west of the capital city Kathmandu of
Nepal.
3.4.2 Construction Access Roads
Total nine site access roads shall be constructed to access to different working sites, the parameters for
the access roads are listed below:
Construction Access Road Parameters
Name
Start - End
length
km
Road surface
Remark
Ghasa - Kalopani
10.0
6m wide, asphalt
maintenance
1# road
Existing road Employers camp
1.20
6m wide, gravel
new
2# road
Existing road tailrace outlet
0.35
6m wide, gravel
new
3# road
Existing road adit-3
4.5
6m wide, gravel
new
4# road
0.2
6m wide, gravel
new
5# road
Existing road 2# disposal area
0.95
6m wide, gravel
new
6# road
Existing road quarry site
0.85
6m wide, gravel
new
7# road
1.8
6m wide, gravel
new
8# road
Left abutment - CFRD
1.7
6m wide, gravel
new
9# road
Kalopani
7.0
6m wide, gravel
new
External road
Larjung
Total
28.55
3.5 Air Compressing System for Site Works

Compressing Air will be produced by movable compressors and conveyed to the various working faces
through pipelines.
Features for Compressor air supply system
Model
Capacity
m3/min
Quantity
Main Pipe
Sub-pipe
Bypass Tunnel
Atlas
27
DN108/2000m
DN50/800m
Headrace
Inlet
Atlas
20
DN108/300m
DN50/100m
Adit-1
Atlas
27
DN108/2500m
DN50/1000m
Adit-2
Atlas
27
DN108/5400m
DN50/2000m
Adit-3
Atlas
27
DN108/2700m
DN50/1000m
Location
Tunnel
Page 9 of 60
Adit-4
Atlas
20
DN108/900m
DN50/500m
Power House
Atlas
27
DN108/1500m
DN50/600m
Tailrace Tunnel
Atlas
20
DN108/1700m
DN50/100m
Concrete
system
Atlas
11
DN108/200m
Mixing
Total
10
3.6 Power Supply

According to the bidding documents and field investigation the 11 Kv power lines pass through the
construction area, it shall be used in the camp area. To ensure the continuity of site construction, some
Diesel generators should be provided at each working site.
Diesel Generator List
Power Equipment
Location
Capacity
Generator
Dam Site
Generator
Dam Section Auxiliary Factories
Generator
Camp of Dam Section
Generator
Dam Section Labour Camp
Generator
Dam Concrete System
Generator
Aggregate Proceeding System
Generator
Adit-1
500
Generator
Adit-2
500
Generator
Adit-3
500
Generator
Adit-4
250
Generator
Powerhouse Site
1000
Generator
Powerhouse Concrete System
300
Generator
Powerhouse Section Chinese Camp
Generator
Powerhouse Section Labour Camp
Generator
Powerhouse Section Auxiliary Factories
Generator
Generator
Tailrace Adit
KW)
500
300
500
500
250
Total
5100
Page 10 of 60
3.7 Water Supply

Water supply will be carried out by water pipe from stream, whose water will be conveyed to the
headwork site through the main pipelines ( 108-159 steel pipes) and then to the storage basins of all
construction sites and living camps via pipes of different diameters. An automatic control system will be
provided across the water supply system for its automatic operation.
The water transferred to the living camps will only be used after being purified in the purification basin.
Water tanks will be arranged above the tunnels and camps along the rivers to satisfy water demands for
camps and construction. Water will be diverted to these tanks from the stream of seti khola, lete khola
etc. at right mountain near the access road. Using high-lift pump to lift water from the khola, pool floor
elevation should be higher than the highest elevation above the vault inside the cave, 30m, to meet the
drill pipe inside the water pressure is greater than 0.3Mp, the pool water through the pipe to the
construction of D108 points and camps. Water pipe inside the tunnel to the cave operations using
surface water, set along the water, fork and valves, water pipes along the tunnel wall hanging, from the
ground 50cm, laid in the lower part of the tunnel side wall. There will be an elevation difference of 30m
between tunnel crown and water tank bottom, which could maintain water pressure as 0.3Mp for drill
machine and water supply pipes. Water will be distributed to every construction area and camps through
D108 steel pipes. In the tunnels, water distribution pipes will be suspended 50cm high along the walls
together with valves and distributors.
Water Pump
Capacity
Location
Rate
Lift
Power
m3/h
KW
Model
m3/d
Dam
100
65QW30-40
30
40
7.5
Bypass Tunnel
50
QW40-15-30
15
40
7.5
Adit-1
100
65QW30-40
30
40
7.5
Adit-2
100
65QW30-40
30
40
7.5
Adit-3
100
65QW30-40
30
40
7.5
Adit-4
50
QW40-15-30
15
40
7.5
Powerhouse
150
65QW35-60
35
60
15
Tailrace Tunnel
50
50WQ20-40-7.5
20
40
7.5
Camp of Dam Section
60
65QW35-60
35
60
15
Dam Section Auxiliary Factories
100
Dam Section Labour Camp
30
50WQ20-40-7.5
20
40
7.5
Site Camp in Concrete System
50
50WQ20-40-7.5
20
40
7.5
Dam Concrete System
1,000
QW200-400-30
400
30
55
Aggregate Proceeding System
1,000
Site Camp in Adit-2
30
QW40-15-30
15
40
7.5
Powerhouse Concrete System
800
QW150-200-30
200
30
37
Page 11 of 60
Powerhouse Section Labour Camp
50
65QW35-60
35
60
15
60
65QW35-60
35
60
15
30
QW40-15-30
15
40
7.5
Top of Surge Tunnel
400
65QW35-60
35
60
15
Powerhouse
Camp
Powerhouse
Factories
Section
Chinese
Section
Auxiliary
200
3.8 Communication System

3.8.1 Exterior Communication
The Contractor shall request the local communication company to establish a communication station
inside the Project area. Before the station is put into operation, communication with outside shall by
satellite communication system.
3.8.2 Communication on Site
The Contractor will maintain 60 hand-held two-way radios with a range of up to 5~30km, and all
necessary equipment to ensure that the radios operate safely.
3.9 Construction Auxiliary Facilities

Auxiliary Facilities will be established dispersedly near Dam camp and Powerhouse camp, which are
marked in layout drawing.
3.9.1 Storehouse
The total land area of storehouse is about 4000m2. It includes 10 rooms for store metal materials,
equipment parts, pipe parts, tools, protection goods, reinforcement steel bar and other purchase
materials.
Planning Table of Storage
S.No
Name of Storehouse
Building
Area (m2)
Storehouse for small equipment, tools and

devices
100
Storehouse for hardware parts
80
Storehouse for labor protection gears
60
Material storehouse
100
Management room
40
Guard room
20
Open goods yard
Total
Occupation
of land (m2)
Remark
4000
400
4000
Page 12 of 60
3.9.2 Machinery Repair Plant and Parking Areas
The Contractor plans to establish a machinery and equipment repairing plant in the Contractors works
area.
Planning of Machinery & Equipment Repairing Workshop
S.No
.
Content
Unit
area
Building Area
m2
200
Shed building
m2
200
Occupation area
m2
10000
Remark
3.9.3 Comprehensive Processing Plant
According to construction schedule of this project, during the peak period of construction, the mean
monthly intensity of reinforcement steel process will be about 350t per month, and mean daily intensity of
rebar processing will be about 12t.
Two rebar cutting machine, three rebar bending machine and 1 mobile crane with capacity of 16t will be
equipped in processing plant. Non-standard steel and wooden formworks will also be made here.
Planning of Steel & Formworks Processing Plant
Technical index
S.No.
Name of the program
Unit
Rebar processing shop
Formwork
processing shop
Capacity of production
shift
12t
20m2
Working system
Shift/day
Building area
m2
40
40
Shed
m2
200
60
Occupation of land
m2
2000
500
Equipment & Tools in Steel & Formworks Processing Plant

S.No
Description
Model
Number
Power (KW)
Rebar cutting machine
GQ40
Rebar bending machine
GW40
Mobile crane
YQ 16
Carpenters circular saw
MJ109
7.5
Carpenters circular saw
MJR154
4.0
Carpenters planning machine
MB104
5.0
Carpenter's flat plane
MBG502
4.5
Tenoner
MX2115
3.0
Carpenters drilling machine
MK515
2.5
Remark
Page 13 of 60
3.9.4 Metalwork Plant
A metalwork plant will be set up to process some minor metalwork structure, the occupation of land will
be of about 8,000m2.
Planning of Metalwork Plant
S.No
Content
Unit
Building
area
Tool room
m2
20
Examining & repairing shop
m2
50
Storeroom
m2
40
Processing plant
m2
300
Storage yard
m2
Total
m2
Occupation
of land
Remark
shelf
8000
350
8000
3.9.5 Explosive Magazine
Temporary explosive magazine will be established on site to meet the requirement of blasting materials
during construction. The design storage capacity of temporary explosive magazine will be about 30t,
which can meet the requirement of site rock excavation works for
days during the peak construction
period. The temporary explosive magazine will be located on the right bank of river, with building area of
200m2 and occupation of land of 500 m 2. The designing, constructing and management of the temporary
explosive magazine will be carried out according to related laws of Nepal.
3.9.6 Fuel Station
In order to ensure the continuity of construction, the storage capacity of the fuel depot will be designed
as 100t. One fuel depot will be located at the right bank of dam and another one will be located near
powerhouse camp. The fuel depot will be designed, constructed and built by Contractor with two oil tanks.
Two tank trucks with capacity of 50 tons each will be provided on site to provide fuel for all machines and
vehicles.
Planning of Fuel Depot for the Project
No
Content
Unit
Fuel Depot
Storage capacity
100
Oil tank with capacity of 50t
Nos.
Occupation of land
m2
2000
Control room
m2
20
Construction of fuel depot (reinforced concrete

structure)
m3
210
Surrounding fencing (including gate)
260
3.9.7 Aggregate Processing Plant
The aggregate processing plant will be established adjacent to quarry site for production of concrete
aggregates, bedding materials and transition materials.
Page 14 of 60
In accordance with the analysis of demand quantity of graded aggregate used in the construction of dam,
access road and concrete placement in the peak period of construction, it is estimated that the
production capacity of sand/aggregates processing plant will be about160t/h, and the designed
processing capability of this system will be 200t/h.
Main Technical Parameter of Sand/aggregate Processing Plant
3.9.8 Concrete Batch Plant
According to the preliminary calculation and technical statistics, there are about 180,000m3 concrete to
be placed in this project, the average intensity of concrete placement during the peak time of
construction will be 11000m3/month, the concrete batching & mixing system will be designed and
planned accordingly.
One batch plant (u/s batch plant) with a design capacity of 90m3/h will be set up near the dam, another
batch pant (d/s batch plant) with a design capacity of 60m3/h will be set up near switchyard. Several
minor batch plants shall be established near the adits portal to provide some shotcrete.
Main Equipment Proposed for Concrete Mixing System
Serial No.
Items
Model
Quantity
Remark
Concrete mixing plant
HZ90-2F1500
90m3/h
Concrete mixing plant
HZ50-2F1000
60m3/h
Bulk cement silo
100t
Single-compartment silo pump
CP2.0
Air tank
3m3
Air compressor
DY-6/7
Bag-type dust collector
QMC24
Screw conveyor
GX300
3.9.9 Precast Production Yard
The precast concrete yard is set up near u/s concrete batch plant, the area is about 2000m2.
3.9.10 Laboratory
In order to meet the needs of inspecting and testing of raw material, semi-finished products and final
products used in the construction of this work, the central laboratory will be built up near the concrete
batch plant .Building area of the central laboratory is 120m2 with occupation of land of 1000m2.
4. Main construction methodology

4.1 Open Excavation Works
Open excavation shall follow the following procedures:
(1) Construction surveying
Page 15 of 60
According to the requirements for different terrains, landforms and accuracy, the proper equipment and
different sampling methods shall be selected for construction surveying, with all the sampling work
conducted under the supervision of the engineer.
(2) Overburden excavation
The excavation of the overburden shall be executed by excavator. The layering excavation from top to
bottom shall be conducted according to the survey, with the bench height of 4 to 5m. The excavation
construction at the same level shall be subject to the order of first earth excavation, rock excavation and
slope support. The excavated materials are loaded onto 15~20t dump truck with the excavator to the
designated area.
(3) Rock excavation
The rock excavation is conducted after the overburden layer and the weathered rock are removed
completely. The rock excavation shall be subject to the bench blasting, the permanent inclined slope is
formed by presplitting blasting, the horizontal foundation formation is formed by the horizontal presplitting
blasting, for the narrow areas the protection layer will be preserved and excavated with control blasting.
Bench blasting hole making is mainly subject to the ROCD7 hydraulic drill and YQ-100B down-in-hole
drill; the YT27 hand drill is used for hole making in the narrow parts.
The construction procedures of presplitting blasting: operation instruction issuing---surveying and hole
distributing---drilling machine in place (with angle corrected) ---drilling hole---hole inspection---charging
and blastingentering the next cycle.
Excavated material transportation shall be loaded with excavator, unused materials are transported with
the 20t dump truck to the designated disposal areas, and utilizable materials for the dam to the
designated filling place.
4.2 Dam Embankments

Backfill and filling construction of soil and rock works in this Contract consist of: backfill and filling at
Guiding Structure, backfill and filling of Concrete Faced Rockfill Dam (CFRD).
Main quantities of backfill and filling project are showed as below:
Main quantities of backfill of soil and rock
No.
1
Description
Rockfill
Unit
Quantity
Remark
212320
Guiding Structure
17920
Guiding Structure
Boulder Rip Rap
Coarse Filter (Rockfill)
m3
150000
CFRD Zone 0-600mm
Medium Filter(Rockfill)
90000
CFRD Zone 0-400mm
6000
CFRD Zone 0-60 mm
2600
CFRD Zone 50- 400 mm
4
5
Filter in Transition
Downstream Slop Drainage
m3
4.2.1 Dam Filling Material Classification
CFRD dam filling materials consists of rockfill materials, transition materials, and downstream slope dry
boulder pitching. Guiding Dam filling materials consists of sand and gravel material, upstream face
bedding material and downstream face dry boulder pitching.
Page 16 of 60
Rockfill materials shall be obtained from the excavated materials of the spillway/under sluice and tunnel
excavation material, sand and gravel from river beach, and other bedding materials and transition
materials shall be gained from aggregate processing system.
4.2.2 On-site Filling and Compaction Test
Dam material compaction test is made up of the tests of bedding materials, transition materials, main
rockfill materials, and secondary rockfill materials.
4.2.3 Unit Division and Construction Procedures for Dam Filling
(1) Division and Cycling of Filling Unit of Working Face

It is proper that the area of each unit is within 3000 to 5000 m2.
The principle for unit cycling is that: the material spreading and leveling in the first unit, sprinkling water
and rolling in the second unit, and the quality inspection and acceptance in the third unit, which goes in
circles.
(2) Construction procedures for dam filling
Plane surveying of filling unit
Material side line surveying of

the areas, scattering lime
Foundation face acceptance
To next filling unit
Feeding and unloading
Excavation and loading of

filling material
Extra-diameter rock treatment
Control of leveling materials and

layer thickness
Sprinkling water
Rolling
Inspection of compaction quality
NO
Unit acceptance
(3) Order of zonal embankment of dam materials

The order of the filling operation of the dam plane is subject to the filling of one-layer 80cm-thick main
rockfill materials followed by filling of two layers of 40cm-thick transition materials, ensure that different
filling materials are always kept at the same level. The excavator is used to clear away the oversize
stone; the junction rolling shall be conducted at the joint of main rock material and transition material to
guarantee the compaction degree.
Page 17 of 60
4.2.4 Dam Filling Construction Technology and Method
1.
Dam materials transportation and downloading
(1) Dam materials transportation

The 15~20t dump truck is used to transport the dam materials with the sign boards on such vehicles to
distinguish the different materials areas. The cleaning should be kept for the carriage and tyres of the
transportation vehicles.
(2) Dam materials downloading
The frontward downloading method is applied to the main rockfill materials, and the backward
downloading method of downloading to the transition materials.
3.
Spreading materials
The thickness of spreading materials in each layer is 2 to 10 cm filling more than the compacted
thickness to reach the layer thickness of the technical requirements after being rolled. The layer
thickness of spreading materials in the areas of the dam shall be finally determined through the site test.
The bulldozer is used to level the fill materials. The elevation is controlled with the leveling instrument in
the material spreading to avoid big error.
4.
Oversize rock treatment
When oversize rocks arise in the main rockfill materials, the hydraulic breaker shall be used to crash
them, or the excavator is used to clear away them.
5. Dam material watering
To improve the compaction effect, water will be added to the filling materials outside the dam and on the
dam is applied.
(1) Water adding outside the dam: before the dam materials to the dam, water is added through the
watering station, and then delivered to the filling working face. The watering station is managed by
specially-assigned person and automatically controlled.
(2) Water adding on the dam surface: the method of combining watering cart sprinkling and the water
hose on the dam surface sprinkling is applied. Main water pipe is arranged at the upstream, connect
hose to add water on the dam surface.
6.
Material filling construction in the different area of the dam
(1) Filling of dam transition materials area

Transition materials are subjected to the 3 m3 loader for loading and the 15t dump truck for transportation
with the downloading subject to the backward method, T220 for spreading, 18t roller for compaction
In order to ensure the compaction degree and protect the u/s dam face, concrete extruding side wall may
be placed prior to the transition materials spreading, the side wall will be cast with extruding machine and
have a height of about 40cm for each lift.
(2) Filling of dam rockfill materials
The dam rockfill materials are from the excavated materials of the spillway and the tunnels, the 2 m3
excavator is used for loading and the 20t dump truck for transportation, downloading is subject to the
frontward method, and the T320 bulldozer is used to level materials. When spreading materials, the
levelling instrument is employed to control the thickness by the specially-assigned person to command
the leveling of the bulldozer.
Rockfill material watering control is determined through test, with the watering by combining the watering
outside the dam and on the dam.
Page 18 of 60
4.2.5 Construction of stone pitching behind the dam
The downstream stone pitching shall be placed layer by layer with the rise of the dam by excavator and.
4.3 Underground Works

4.3.1 Scope of Work
The underground works includes the excavation and support of the Bypass Tunnel, Headrace Tunnel,
Adit-1\2\3\4, Surge Tunnel, Drop Shaft, Underground Powerhouse, and Cavern for Transformers,
Tailrace Tunnel, PS Access Tunnel etc. The total excavation volume will be 490,000m3, with the rock
bolt of 253,000m, the shotcrete of 28,800m3.
4.3.2 Construction plan
1. Headrace tunnel
Four adits (adit-1 at chainage of 0+415, adit-2 at chainage of 4+177, adit-3 at chainage of 6+970, adit-4
at middle of connection tunnel of 2 shafts) shall be arranged to use as the access to carry out the
headrace tunnel excavation, each adit will provides two heading faces, and total eight heading faces will
be available.
New Austrian Tunneling Method will be adopted, micro-second delay-detonators and perimeter smooth
blasting will also be employed. Pneumatic drills (on a quick-fabricated platform) will be used for the hole
drilling, 0.5m3 excavator for muck loading and 10t dumper for transportation.
2. Sediment tunnel
Sediment tunnel shall be excavated from the intake and outlet simultaneously. New Austrian Tunneling
Method will be adopted, micro-second delay-detonators and perimeter smooth blasting will also be
employed. Pneumatic drills (on a self-making trolley) will be used for the hole drilling, 3m3 side-dump
loader for muck loading and 10t dumper for haulage.
3. Surge tunnel
After the headrace tunnel stretch 6+970~4+177 is completed, surge tunnel excavation will commence,
adit-3 will be the access. New Austrian Tunneling Method will be adopted, micro-second delaydetonators and perimeter smooth blasting will also be employed. Pneumatic drills (on a quick-fabricated
platform) will be used for the hole drilling, since the tunnel slope is little steep, 3m3 loader will be used to
load and transport the muck to the junction with the headrace, and load 10t dumper for transportation.
4. Drop shaft excavation
There are 2 shafts with the upper one having a height of 240m and the lower one having a height of
290m. Adit-3, adit-4 and access tunnel will be used as the access to transport the machine and the muck.
Raise boring machine shall be employed for the shaft excavation, firstly a pilot shaft with a diameter of
1.4m shall be drilled with raise boring machine, then enlarge the pilot shaft to the design line from top to
bottom by drilling & blasting method.
5. Access tunnel excavation
Excavation method is same as Sediment tunnel.
6. Power station excavation
Page 19 of 60
Power station has a dimension of 85m*15m*30m (L*W*H), the access tunnel will be access for the
excavation construction. Excavation shall be carried out from top to bottom in layer wise, New Austrian
Tunneling Method will be adopted, micro-second delay-detonators and perimeter smooth blasting and
pre-splitting blasting will be employed
1st layer: EL1932~EL1921
Normally full-section smooth blasting method will be adopted. If the rock condition is not satisfied, central
part shall be excavated firstly, after the primary arch support, both side parts shall be excavated
accordingly. Pneumatic drills (on a self-making trolley) will be used for the hole drilling, excavator and
loader for muck loading, 20t dumper for muck haulage.
2nd layer: EL1921~EL1914
Pre-splitting balsting shall be conducted firstly, then execute bench blasting section by section from
inside to outside, hole drilling by D7 hydraulic drill, muck loading by excavator and muck haulage by 20t
dumper.
3rd layer: EL1914~EL1910
inside to outside, hole drilling by D7 hydraulic drill, muck loading by excavator and much haulage by 20t
dumper. Some muck will be hauled by 10t dumper through 1# manifold tunnel (the section has to be
extended to meet the dumper dimension) and access tunnel.
4th layer: EL1910~EL1905
inside to outside, hole drilling by D7 hydraulic drill, muck loading by excavator and muck haulage by 10t
dumper, the access is 1# manifold tunnel and access tunnel.
5th layer: EL1905~EL1902
Pre-splitting balsting shall be conducted firstly,, hole drilling by pneumatic drill, muck loading by
excavator and loader, muck haulage by 10t dumper, the access is 1# manifold tunnel and access tunnel.
6. Transformer Cavern excavation
Access tunnel will be used as the access, exaction method is same as 1st layer of power station.
7. Tailrace tunnel excavation
Tailrace tunnel excavation shall be carried out from outlet to upstream, execution method is same as the
headrace tunnel.
For the first 150m stretch which is located in the river borne material, special attention shall be paid
during excavation. Leading consolidation grouting and leading anchor shall be proposed to stabilize the
unstable rock, the principle of short footage and weak blasting shall be followed. Shotcrete and steel rib
support shall be applied immediately as soon as current footage excavation is completed.
Deformation of surrounding rock shall be monitored at all the time.
4.3.2 Tunnel excavation measure
General tunnel excavation procedures are shown in the following chart:
Page 20 of 60
When necessary
Excavation preparation
Setting out
Locally pilot rock bolt
Drilling holes
Explosive charging and blast
Ventilation and water spraying
Safety monitoring
Safe treatment
Primary support
Mucking
Extending air, water and power

lines and shifting to next cycle
1) Setting out: Measurement and setting out will be performed before construction according to the blast
design. The total station and laser directional instrument will be used for the setting out.
2) Drilling operation: Pneumatic drill YT-27 will be used for the hole drilling. When the tunnel section is
more than dia.6m, a drilling trolley will be equipped, several drills can work on the trolley at the
same time. When the tunnel section is smaller, a quick-fabricated platform will be equipped, the
platform will be dismantled while the mucking commences. Perimeter smooth blasting holes shall be
controlled strictly to ensure the excavation line meets the design.
3) Explosive charging and blast: No.2 rock blasting explosive or emulsion explosive will be used.
Different explosive cartridges will be adopted for different holes. The method of explosive charging
and blasting process refer to the following table.
Charging method and ignition order
Location of Hole
Explosive Cartridge
Remarks
Cut hole
32
35mm
Successive charging
Breaking hole
32
35mm
Successive charging
Perimeter hole
22 mm
Interval charging
The sequence of millisecond delay blasting is:

cut hole
breaking hole
perimeter hole.
4) Ventilation and smoke extraction: heavy duty propeller fan will be adopted to supply the forced
ventilation after blasting. Fresh air will be blown to the working face through the air duct.
Page 21 of 60
5) Safe-handling: After blasting, the safety staff and worker will firstly investigate and handle the
potential safety hazard of heading face and arch. After the mucking, the heading face shall also be
inspected and treated by safety personnel.
6) Mucking: WA380 side-dump loader and excavator will be adopted to load the muck, and 10~20t
dumper for haulage. Excavated material for reuse shall be placed directly in its final position, if
possible. Otherwise it may be stockpiled or deposited on site. Unused materials shall be deposit to
spoil area. For the truck crossing, passing bays will be established with a space of about 400m, to
allow turning of transport vehicles.
4.3.5 Support construction
constructions of bolt (anchor)
Anchor bolt construction shall be generally carried out after initial shotcreting is finished on excavation
face. For the excavation face with relatively poor stability, temporary support anchor bolt can be first
installed and then shotcreting can be conducted.
The installation position of anchor bolt shall be determined according to the design drawing or site
designation by the engineer or safety requirement. Measuring personnel shall mark the drilling position.
Hand pneumatic drill and anchor jumbo drill shall be used to drill according to the design hole position,
angle and hole depth. After drilling, the hole shall be cleaned. Injection pipe shall be used to inject grout
outward from the hole bottom, and then anchor bolt shall be inserted into the hole. After anchor bolt is
fixed with steel wedge, mortar mixed with accelerator shall be used to fill the orifice solidly.
Construction procedure: initial shotcreting
setting out
inserting anchor bolt fixing orifice treating orifice.
drilling
cleaning the hole
grouting
As to the anchor bolt for emergency support, ordinary grout might not be injected into bolt hole, and
special injection gun can be used to inject the composite containing accelerator into bolt hole, so as to
make anchor bolt and composite grout quickly solidified with certain strength. Therefore, the surrounding
rock can be reinforced fast.
2
Constructions of shotcrete
Shotcreting shall be organized and carried out after excavation face is made. When the geological
section is poor, shotcreting shall be conducted immediately after excavation. The construction shall be
carried out according to instructions of the engineer. The distance between shotcreting face and
excavation working face shall ensure no influence of blasting vibration on concrete solidification.
According to site conditions, wet shotcreting or dry shotcreting can be adopted. For wet shotcreting,
concrete shall be first mixed in batching station and then be transported to the working point; concrete
shall be put into concrete sprayer manually, and liquid accelerator shall be added at the sprayer head.
Before shotcreting, rock surface shall be treated to make it clean and wet. Shotcreting shall be
conducted symmetrically from bottom to top in layers. The shotcreting thickness of each layer is about 50
mm. For relatively large shotcreting face, operating platform shall be erected. After shotcreting, wet
curing shall be carried out until the design strength is reached.
Construction procedure: construction preparation
quality inspection curing.
3
rock surface treatment
setting out
shotcreting
I-Steel Support
For the surrounding rock sections with relatively poor geological conditions, in order to ensure stability of
surrounding rock during tunnel excavation and surrounding rock of excavated section, and according to
analysis of observation data of surrounding rock displacement, for the tunnel section which still shows
the sign of instability after shotcreting anchorage, steel support will be adopted to strengthen support, so
as to ensure stability of tunnel excavation.
I-shaped steel is generally adopted to process steel support, which is designed according to the tunnel
section and processed in segments in comprehensive processing plant. After steel supports are
transported to the construction site, they shall be assembled, and bolts or welding will be adopted to
connect segments.
Construction process of steel support: cleaning excavation face
anchor bolt installation of steel support shotcreting
initial shotcreting
installation of
Page 22 of 60
4.4 Grouting Work

4.4.1 Tunnel surrounding rock consolidation grouting
According to design drawing, use pneumatic drill to drill grouting holes. In order to avoid drilling holes
encountering rebar in lining concrete, it is proposed to embed steel pipe or PVC casing based on design
during concrete lining construction, and then carry out drilling from embedded pipe.
After drilling, use pressure water to wash the hole repeatedly and carry out water pressure test.
According to parameter gained from water pressure test, adjust grouting pressure and grout mix
proportion. During process of grouting in sequence, adjust grout mix proportion level by level according
to grout-take volume, until it reaches designed standard to stop grouting. If it does not reach the standard
for a long time, report to engineer to analyze the reason and figure out dealing measures together. When
grouting is finished, seal the hole and cut off the embedded pipe exposed on the concrete surface.
4.4.2 Curtain grouting
The dam curtain grouting construction will be done on plinth.

Grouting shall be carried out in stages, 'B' line holes shall be drilled and grouted prior to drilling of 'A' line
holes. No holes of subsequent series shall be drilled until grouting has been completed to full depth in
adjacent holes of the previous series.
Before construction, conduct grouting test to investigate grout-take capacity of underground rock. At the
time of grouting through a single hole, based on fracture degree of surface rock, determine to conduct
sectional grouting from top to bottom or from bottom to top. If foundation rock is fractured, it is suggested
to conduct downstage grouting.
Based on designed hole-depth, XY-2 rotary geological drill with carbide bit or artificial diamond bit shall
be selected for drilling of curtain grouting. After drilling, rinse the hole and conduct water pressure test
selectively to get reference information for adjustment of grout mix proportion. As construction area of
curtain grouting is kind of centralized, grout preparation station may be set in neighbor area to supply
grout. Use grouting pipe to deliver grout to pumps. During the whole course, use automatic recorder to
record and print the grouting data which will be used as the original date for calculation of grouting work
volume and the reference of following grouting.
4.5 River diversion

4.5.1 Plan
As per the project scale and the local hydrology, 20-year return period flood standard shall be
adopted to make the design, the respective flow is 500m3/s, stage diversions shall be arranged, please
refer to the river diversion plan drawing.
Stage 1 cofferdam for Guiding structure: build u/s transversal cofferdam, d/s transversal cofferdam
and longitudinal cofferdam to enclose the structures at the right abutment, and construct the headrace
intake and the spillway and the side channel, river flow will run in the original river bed.
Stage 2 cofferdam for Guiding structure: After the sediment bypass tunnel is ready, build the u/s
cofferdam, and construct the guiding structure, the river flow will run in the bypass tunnel. River diversion
shall be carried at the beginning of the dry season.
Cofferdam for CFRD: After stage 2 cofferdam for guiding structure is completed, the river flow will
run in the bypass tunnel, at this time to build cofferdam at CFRD d/s, then construct the CFRD and the
structures at the right abutment.
Power station and switch yard are at higher level, no cofferdam is required.
4.5.2 Structures for river diversion
Cofferdam shall use earth and rock embankment, Geo-membrance and high-pressure-jet cutoff for
anti-seepage.
When building Stage 1 cofferdam for Guiding structure, the river water level will be about EL2508m,
the cofferdam crest will be set at EL2509m. The cofferdam will have a height of 4m with the crest width
of 4m, the cofferdam side slope is 1:2~1:2.5.
Page 23 of 60
When building Stage 2 cofferdam for Guiding structure, the river water level will be about EL2511m,
the cofferdam crest will be set at EL2513m. The cofferdam will have a height of 5m with the crest width
of 4m, the cofferdam side slope is 1:2~1:2.5.
When building CFRD d/s cofferdam, the river water level will be about EL2506m, the cofferdam crest will
be set at EL2507m. The cofferdam will have a height of 5m with the crest width of 4m, the cofferdam
side slope is 1:2~1:2.5.
4.5.3 Cofferdam construction
Since the river diversion will be carried out at the dry season, the river flow is limited, so the river
diversion will be easier. The closure dike shall progress from one side to the other side, excavator for the
earth and rock loading, dump truck for hauling, and dozer for pushing and leveling.
After the closure dike is completed, use rotary drill to drill hole and high-pressure jet trolley to make
the cutoff, then increase and widen the dike to the design section
.4.5.4 Foundation pit drainage
After the cofferdam is ready, several sump pits shall be made, and pump out the water (seepage
water, rain water and construction waste water) and keep the construction in dry condition.
4.6 Concrete works

4.6.1 Dam concrete construction
4.6.1.1 Concrete construction of plinth

1.
Plinth concreting procedure
As shown in the following flow chart:
Cleaning
Install
water stop
Concreting
2.
Erect steel
bar
Drill anchor
bar
Embed
anchor bar
Measure
template
Embedded
parts
washing
acceptance
inspection
Concrete curing
Concrete placing
The concrete is mixed by the concrete mixing station, transported by 6 m3 mixer truck, and delivered to
the place by chute or concrete pump. The general plinth concrete is vibrated by Foshan 100 vibrator,
and it adopts 50 vibrator for the concretes in parts with intensive waterstop, embedded parts and
reinforcing steel bars.
3. Waterstop protection
After removing the formwork of plinth, waterstop shall be protected in time by wooden boxes. The placing
close to waterstop will be undertaken by specially assigned personnel by small vibrator to prevent from
the deformation of the waterstop. The placing layer shall be controlled at about 30cm. When placing the
plinth in abutment slope, it shall start from the lower area, and keep the placing surface horizontal.
4.2.3.2 Concrete face slab construction
1. Face slab concreting procedure
Page 24 of 60
Trackless sliding formwork shall be employed to construct the face slab. The procedure of concrete face
slab construction is shown in the following chart.
Set out
Apply mortar at joints
Set copper waterstop
Install winch
Set joint bar
Install. transport trolley
Install. reinforcing
Remove the trolley
Install chute
Install side form
place slip form
Manual
operation
Crane hosting
Face slab concreting process
Install side form
Concreting
Surface finishing
Dismantle side form

Concrete curing
Remove slide form
2. Lifting of the sliding formwork and arrangement of the chute

After installing the side formwork and reinforcing mattress, it can install the sliding formwork. After
fabricating at the dam heel, lift the sliding formwork onto the side formwork by crane. Trail sliding has to
be executed prior to the formal placing.
Installation of the chute: after the sliding formwork is in position, it can install chutes on the reinforcing
mattress. The chutes are tied to the reinforcing mattress to guarantee the safety. It can arrange two to
three pieces of chutes for one slab.
3. Concrete pouring and Formwork lifting
The concrete is mixed by the concrete mixing station, transported by 6 m3 transit mixer truck.
Upon the completion of the inspection and acceptance, concrete can be poured. Concrete shall be
placed horizontally in lift wise with the lift thickness of 25 30cm. Conduct vibration after the whole layer
Page 25 of 60
concrete surface is even and flat. It will be vibrated by immersion vibrator with diameter less than 50mm.
During the construction, it shall pay attention to the vibration at the waterstop, for which it shall use
smaller vibrator.
When sliding up, it shall stably and synchronically lift both ends with uniform speed. It will slide up one
time for 25-30cm after one lifts concrete pouring finished. The average pouring speed with the sliding
formwork shall be controlled at about 1m/h, and the maximum speed shall be no larger than 2.5m/h. it
shall timely conduct manual finishing to the concrete surface with steel trowel after the formwork is slid
up.
Concrete curing shall be applied in time curing to the concrete face, special-assigned personnel shall
record the whole process of curing.
4.6.2 Spillway and Undersluice construction
1.
Concreting procedure
Concrete shall be placed in lift wise with each lift height of about 3m. In general, the concrete placement
procures:
Foundation clearing (construction joint clearing)
Inspection of prepared foundation surface
setting out
Erecting formwork & reinforcement & embedded parts
Clearing off the debris
Inspecting & acceptance
for Placing Concrete
Concrete mixing and transport
Concrete placing and vibrating
Removing of
formwork and concrete curing
2.
Concreting measures
(1) Checking before concreting

After completion of treatment of foundation surface and trimming of construction joint surface, the treated
surface upon which concrete will be placed shall be cleared by manpower and flushed with high-pressure
water, followed by draining off all of collecting water. The construction joint surface shall be green-cut in due
course except for some narrow locations where the construction joint surface shall be roughened by the
manpower. Thereafter, all of debris, foreign matters and other materials shall be washed off.
The points, lines, grades and elevations shall be precisely surveyed and set out by using a total station. The
markings of points, lines and levels shall be clear and visible for easy measuring.
(2) Steel bar processing and fixing

Technicians shall fill in the rebar request sheet in accordance with the shop-drawings and technical
specification, and submit the request sheet to rebar processing workshop where the re-bars will be cut and
bended as per the aforesaid sheet. The identification label shall be attached to each bundle of rebar to avoid
any confusion. The fabricated rebar shall be hauled to the site with flat-bed trucks and installed by the
manpower. The installation of reinforcement shall conform to the requirements of construction drawing and
specification.
(3) Installing Formwork

Steel and wooden formwork shall be used. The formworks shall be transported and installed in a safe and
protective manner to prevent them from deformation and damage. The formwork should be elected by tower
crane or mobile crane in coordination with the manpower. Every time, removal of dust from the formworks
should be carried out before they are erected, and the surface of formworks shall be applied with a layer of
formwork stripping agent. The formwork should be erected at the exact location and level, and shall be
securely tied and supported, to ensure the levels and the dimensions of concrete in conformity with the
requirements of design and specification. The embedded parts and waterstop will also be firmly fixed.
After completion of installation of formwork, surveying and correction of formwork shall be carried out carefully,
then water stop shall be installed. Finally, the pouring block shall be cleared and washed by high-pressure
Page 26 of 60
water gun to remove all the debris, chippings, garbage and other foreign matter out of the block.
(4) Concreting
Prior to the starting of each concrete placement in a pouring block, the technicians along with the Quality
Controller and the Engineer shall carry out a careful inspection to the pouring blocks and issue the Release
Order for Concrete Placement.
Concrete will be mixed in u/s concrete batch plant, transported with 6m3 concrete mixer truck or dump truck,
lifted and deposited by tower/mobile crane and bucket, conveyance belt and chute and concrete distributing
belt could be used where the site condition is permitted.
The concrete shall be deposited as nearly as possible in its final position without re-handling or segregation
and in such a manner as to avoid displacement of the reinforcement, other embedded items or the formwork.
(5) Curing
After completion of each concrete placement, it should be covered with straw mat for curing till the initial
setting of concrete is achieved. Then, the concrete can be cured by spraying some water up to the expiry of
aging.
(6) Removing Formwork

When the concrete reaches the condition to possibly remove the formwork, formworks shall be stripped off by
using crane in combination with manpower. After removal of formworks, the concrete surface shall be carefully
inspected. If any defect is found, and suitable measures to repair the defect shall be taken.
For the tunnel intake and outlet, similar method and procedure shall be taken for the concrete placing.
4.6.3 Tunnel concrete lining
In the headrace tunnel, when the class-5 surrounding rock is encountered, whole section concrete lining
will be applied.
Firstly the invert concrete slab shall be placed, then install side-wall and arch steel mould trolley, to cast
the side-wall and arch. Concrete is mixed in u/s concrete batch plant, transported by 6m3 mixer truck,
and deposited to the place with concrete pump.
Concrete lining shall be carried out in section wise with each section length of about 10m, the mould
trolley will move on the steel rail driven by loader or excavator. Before the mould trolley is to be in
position, the steel bar fixing and embeddd parts and water stop installation should be ready.
Floor concrete shall be placed ahead of the side-wall and arch by several blocks, floor surface shape
shall be controlled by template frame.
4.6.3 Drop shaft lining
Shaft will be lined with penstock and concrete. Upon the completion the excavation and support, Lining
can be carried out. Lining shall be executed from bottom to top in section wise with each section height
of about 10m.
First the penstock pipe will be lowered from top with wench and steel cable, then positioned and welded.
After the pipe the welding seam are inspected and detected, concrete can commence.
Concrete shall be mixed in d/s batch plant, transported to shaft top by 6m3 mixer truck. Concrete
conveyance from top to the place by Dia.200 steel pipe equipped with buffer box at every 10m height, to
guarantee no segregation will happen.
At the Dia.250 pipe bottom, a rotatable distributing pipe is connected to distribute the concrete to the
place evenly, concrete leveled by manpower and vibrated by flexible-shaft vibrator.
Page 27 of 60
4.6.3 Power station concrete
Power station has a dimension of 85*15*30m (L*W*H), the concrete volume is about 8000m3. Access
tunnel will be the access for concrete placing.
Concrete shall be placed in lift wise with each lift height of 1.5m to 3m, combined steel formwork and
scaffold pipe and tie bar shall be used.
Concrete shall be mixed in d/s batch plant, transported by 6m3 mixer truck, conveyance belt, concrete
distributing belt, chute shall be used to deposit concrete to the place. At some higher locations, concrete
pump shall be used to pump concrete to the casting place.
Flexible-shaft vibrator shall be used to compact the concrete, flat-vibrator shall be used for the floor
concrete compaction. During the concreting, attention shall be paid to the embedded parts and water
stop, special staff shall be designated to supervise this work, no deformation or movement shall happen
to these items.
4.7 Turbine equipment installation

4.7.1 General Installation Procedure
Preparatory works
Embedded of base plate and pipes installed
Installation of turbine housing and maintenance platform
Installation of distributor parts
Installation of pit liner
Second stage concrete
Installation of turbine shaft
Installation of turbine guide
Installation of water passage shield
Installation of generator foundation
Installation of installation of generator
Installation of nozzle assemblies
Page 28 of 60
Installation of runner
Installation of nozzle assemblies
Coupling of turbine & generator shafts
Adjustment of axis
Adjusting centerline of rotating parts
Installation of main shaft seal
Dry test
Commissioning
4.7.2 Embedding of base plate and pipes
1) First stage concrete finished

2) Base plates for distributor and turbine housing installed
3) First stage embedded pipes installed
Page 29 of 60
4.7.3 Install turbine housing and maintenance platform
1) Installation of turbine housing

2) Installation of maintenance platform
3) Adjustment of the parts
4.7.4 Install distributor parts
1) Installation of distributor parts

2) Alignment of distributor parts
3) Welding of distributor parts
Page 30 of 60
4) Welding of connections to turbine housing

5) Installation of piping
6) Application of pressure test devices
7) Pressure test
(Touch-up painting if applicable)
4.7.5 Install pit liner
1) Alignment of pit line on turbine housing

2) Weld on pit liner on turbine housing
3) Touch-up painting if applicable
4) Apply stiffeners if applicable
Page 31 of 60
4.7.6 Secondary stage concrete
1) Concreting of up to generator floor

2) Distributor pipe shall be concreted under pressure
3) Remove stiffeners if applicable
4) Closing of openings for concreting
5) Touch up painting if applicable
Page 32 of 60
4.7.7 Install turbine shaft
1) Installation of bearing support on turbine housing

2) Lifting in of turbine shaft
3) Installation of temporary support for turbine shaft (bearing cover)
4) Shaft alignment
5) Shaft free
Page 33 of 60
4.7.8 Install turbine guide bearing
Installation of remaining bearing parts (pads, cooler, covers, etc.)

4.7.9 Install water passage shield
Lifting up and install the water passage shield.
Page 34 of 60
4.7.10 Install generator foundation
May be done after 2nd stage concreting
Page 35 of 60
4.7.11 INSTALLATION OF GENERATOR
Generator installation may be started immediately after shaft free (in coordination with turbine supplier)
Page 36 of 60
4.7.12 INSTALLATION OF NOZZLE ASSEMBLIES
1) Modification of passflange for nozzles - justify with dummy nozzle and dummy
2) runner
3) Bring in nozzle with transportation cart to maintenance platform
4) Install lifting devices (chain hoists) on turbine housing
5) Lift up and install nozzles to distributor pipe (include passflange)
6) Install oil piping
7) Install water piping
Page 37 of 60
4.7.13 INSTALLATION OR RUNNER
1) Using Lifting cylinder in turbine shaft:

2) Bring in runner by transport cart to maintenance platform
3) Lower hydraulic lifting cylinder and connect to runner
4) Lift up runner
5) Couple runner to shaft
6) Install cover for coupling bolts
4.7.14 INSTALLATION OF REMAINING PARTS
Installation of remaining parts such as piping, instruments, smaller parts as well as auxiliary systems
such as governor, inlet valve, cooling water system (as far as applicable) can be done in parallel with
other works.
Page 38 of 60
4.7.15 COMMISSIONING AND FIELD TESTS
Commissioning of the unit including dry & wet tests, in coordination with the generator supplier.
Field tests according to the contract.
4.8 Generator Installation

The Section shall describe the installation of stator, rotor, thrust bearing and guide bearing, upper and
lower brackets, slip ring and brush, cooling water system, lubrication system, brake system, fire fighting
system, relay and instrument etc.
4.8.1 General Installation flowchart for generator
Preparation works
Embeding soleplate
Assembly the stator
Preassembly the lower

and upper bracket
Lifting the upper bracket out of pit
Lifting the lower bracket out of pit bracket

Put the elevation
f
Lowering the turbine parts
Installing the lower bracket
Erecting the rotor hub
The rotor assembly
Installing the upper bracket

Installing the trust bearing
Shrinking the thrust cone on
Coupling the main shaft and the turbine shaft
Installing the collecting ring
Installing the upper

Align the axial line of unit
Installing the oil
adjusting the gap of the guide

bearing segments
water pipeline
Installing the other parts of unit
Cleaning and checking the unit
Starting up and trial run
Completion
Page 39 of 60
4.8.2 Embedding soleplate
4.8.3 Lowering the stator
Page 40 of 60
4.8.4 Assembly of stator
4.8.5 Preassembly the lower bracket
Page 41 of 60
4.8.6 Preassembly the upper bracket
4.8.7 Assembly of the lower bracket
Page 42 of 60
4.8.8 Rotor assembly
4.8.9 Rotor pole turning over
Page 43 of 60
4.8.10 Lowering the rotor
4.8.11 Installing the upper bracket
Page 44 of 60
4.8.12 Installing the other parts of unit
4.8.13 Demolition flowchart for generator overhaul

The demolition of oil and water pipe
The demolition of
guiding pads
The demolition of oil pipes and water pipes
The demolition of temperature

lines
The demolition of Carbon brush and cooler
The demolition of cover Collection slip ring
The demolition of upper bracket
The demolition of upper axis
The demolition of rotor
The demolition of axis
The demolition of lower bracket
Page 45 of 60
4.9 Penstock manufacturing and installation

4.9.1 Flow chart of penstock manufacturing and installation
Preparations for penstock manufacturing
Preparing purchasing plan for raw material

Compiling the instruction of
ti
Purchasing raw material
Test of evaluating welding process
Compiling welding process
Compiling welding process of

penstock
Test of evaluating painting process
Compiling painting process
Inspection, acceptance check and test of raw

material
Compiling process workflow at

penstock shop workshop
Assembling and welding of penstock section

Cutting of rolling sheet
Assembling and welding accessories and

penstocks
Assembling and welding of the

i
Derusting and painting of penstock section
Assembling and welding of penstock section

Inspection & acceptance check of single-section
t k
Inspection & acceptance check of penstock section
Transportation of penstock
Preparations for penstock

installation
Assembling and welding of penstock
Concrete backfilling of penstock
Grouting treatment for penstock
Closure welding for grouting holes
Derusting and painting of the welding gaps
Clean, inspection and acceptance check of

penstock
Page 46 of 60
4.9.2 Penstock manufacturing
4.9.2.1 Field arrangement of penstock manufacturing

Workshop for penstock manufacturing shall be set up at site, the main arranged equipments for penstock
manufacturing are: 20t weight, 24m-span gantry crane (1 Pc.), which is used for the hoisting of loading/
unloading , blanking, circular, installing and welding of the finished steel sheet and penstock, W11STNC50
3000 3-roll rolling machine (1 Pc.), 10t weight, 8m-span hoisting gantry crane (1 Pc.) is used for the
rolling of penstock tile, roll-welding trolley (1 Pc.) is used for circular seam welding of penstock sew.
Steel sheet are stacked orderly and leaving from ground in different kinds and thickness, and they are
marked clearly.
Welding material: welding wire and welding rod should be put in storeroom, welding liquid should be put
in dry container, and welding wire and welding rod should be kept clean and dry.
4.9.2.2 Manufacturing Flow Chart of Penstock
Marking and cutting of steel plate
Steel tube attachment marking and
Weldingbutt joint of steel plate
Assembling of steel tube attachments
Steel plate rolling
Welding of steel tube
Assembling sections of steel tube
Butt inspection of steel tube
Welding the longitudinal joints of steel
Back chipping of internal longitudinal
Welding the external longitudinal of
Assembling sections of the steel tube
Penetrating inspection on longitudinal
Welding the interal circular joints
Assembling and welding of steel tube
Back chipping of internal circular joints
Welding inspection
Welding of external circular joints
Derusting and painting of tube
Installation the interanal supports of
Inspection of size shape
Single section of tube leave factory
Girth welding flaw detection
Derusting and anti-corrosion of
Inspection of size shape
Large section of steel tube leave
Page 47 of 60
4.9.2.3 Blanking and machining of steel sheet

1) Steel sheet blanking
(1) Steel sheet blanking base on the real width of steel sheet, the ordered width of steel sheet is 2m,
2 sections make a bigger segment, and the size of the bigger segment is 4m.
(2) After scoring steel sheet, mark the number of machine, segment, block, water flow direction, the
centering line in horizontal and vertical, the location of grouting hole, the angle of groove, the cutting line
and so on.
(3) The steel sheet cutting and the preparing groove is made by semi-auto-cutting machine. The
slag, burr of cutting side and the gap made through cutting should be rubbed out by grinding wheel. After
cutting, the limited deviation of groove size should follow the requirements in related technical
specifications or design.
(4) After machining the groove, then paint the anti-rust paint which is hazard-free and not affect the
welding capability and quality.
2) Rolling sheet
Single-segment penstock could be machined into two (2) penstock tiles, firstly should weld the steel
sheet into entirety as per markings, then roll to tile shape. When rolling steel sheet, make sure the
direction of rolling-sheet should be the same with the press forging direction. Measuring and rectifying
sheet by sample while rolling, in order to ensure the radian following requirements. When rolling the
sheet, dont hammer the sheet, and keep the sheet form appearing any scar.
Before rolling penstock, should clean the attached horn wire, oxidations and so on, and carry out
cleaning during rolling operation accordingly.
3) Fabrication of penstock
(1) Penstock circular is made in circular platform. Should imagine and measure if the up and down
nozzle is even, the even degree of nozzle shouldnt more than 2mm.
(2) The penstocks perimeter, vertical, clearance and assembly tolerance should comply with the
specifications.
(3) After welding the longitudinal seam, should arrange the supporting which have the adjusting
functions inside the penstock, which can reach the requirements of the different requirements on
maximum and minimum diameter of penstock.
Circling support of penstock
Stiffening support of penstock
Page 48 of 60
(4) The installation of the bigger segment shall be completed through the bigger-segment assembly
trolley. Hang the penstock segment and put it on the trolley, move the penstock to a correct installing
direction, using the combination of strainer and chain jack, then conduct seam-pressing and spot-welding
symmetrically by seam-pressing machine after measure the two opening perimeter and the averagelydistributed displacement.
(5) Penstocks longitudinal jointing and circular jointing should adopt automatic submerged arc
welding, and the circular welding should be conducted on the roll-welding trolley.
(6) Never harm the substrate when welding and dismantle accessories as fixture tools and lifting lug
at penstock segment for the requirements of assembly, transportation and installation, and the place of
welding should be ensured of no harm to penstock and produce over-stress while lifting. If there is no
bad influence to the following procedures, the accessories can not be dismantled.
(7) Installation of stiffening ring
After conduct longitudinal welding to the penstock and pass non destructive inspection, can use the
adjusting inner circling support at welding place of stiffening ring, and weld stiffening ring and penstocks
stabilizer. The butt weld of stiffening ring and longitudinal seam should be misplacement more than
100mm as required, and the inner radian should be checked by sample with the string is 1.5m, and
check clearance shouldnt over 2.5mm.
The welding of stiffening ring and penstock should adopt manual electric arc welding.
4) Manufacturing of manifold penstock and bending penstock
When making manifold penstock, should adjust the rolling machines upper roller to a leaning angle,
then roll according to the mean line of big and small border radian. Check two pieces of different radial
sample sheet in plane position while rolling. When a piece of steel sheet is in finished, should continue to
roll the steel sheet to next mean line, after the manifold penstock is in finished form, some part of radian
may bigger or smaller, should correct radian of the manifold penstock using flame. After the radian
correction, should fix two sides of the nozzle by temporary supporting. When the sections of manifold
penstock are machined, should conduct preassembly at machining spot. The manufacturing way of
bending penstock and reducing penstock are the same as manifold penstock.
The forked penstock should be installed and welded entirely on-site, and every size of welding
should comply with the specifications of the design drawings.
4.9.3 Transportation of penstock
(1) The finished penstock should be transported to the spot by a 40t trailer. When transporting,
penstock should be placed in side direction and level. Interior can be fixed by movable supporting, the
space between penstock and trailer can be supported by arc-pallet, and fastened by steel wire.
(2) Should pre-embed two 40t flukes on the top of the construction lateral tunnel which is the cross
between the construction lateral tunnel and every penstock tunnel, and should dispose a 10t hoisting
machine inside the construction lateral tunnel. After transported penstock into the tunnel, should hang
penstock in four sides horizontally by hoisting machine and pulley block, then the trailer retreat from the
tunnel. Hoist the upper flat tunnel and the inclined straight section to the track directly, then back
transport to the installation position. Hoist the down flat section penstock to the penstock trolley, and tow
to the installation position by hoisting machine and install.
Page 49 of 60
(3) The transportation of inclined straight sections and upper flat sections. Dispose a 5t hoisting
machine and a 10t hoisting machine in the upstream of the construction lateral tunnel. After penstock is
transported from construction lateral tunnel to the penstock tunnel, should utilize the pre-embedded fluke,
then unload penstock to the track by hoisting machine and pulley block. Tow the penstock to upper
bending penstock by 5t hoisting machine and pulley block,
then slide penstock to the installation position by 10t hoisting
Preparation
machine and pulley block and install.

4.9.4 Installation of penstock
Hoisting to installation
(1) Penstock transportation access: adit-3 for stretch of

upper shaft, adit-4 for stretch between 2 shafts and lower
Butt joint of penstock
shaft, access tunnel for stretch of d/s of lower shaft.

(2) Penstock will be put in the position by winch and
position, they will be jacked up by jack through arc pallet,

then readjust penstocks orderly. When seam-pressing and
welding the penstock, the inside and outside of penstock can
be fixed in upper opening by removable working platform to
Repeat in this order
trolley and penstock stabilizer. After the penstocks are in
Circular welding
Detection of defects
Stiffening and cleaning
make sure the builders safety.

(3) The installing of penstock and the concrete pouring
Check and acceptance
can be alternately made in segment, the installing and

pouring length of every section is 10~12m, as the right
Concrete pouring
flowchart of penstock installation is showed, installation by

pouring one after one. After finishing a section of pouring,
should make a whole checking and adjusting, and fix the
Grouting
penstock to the steel dowel on the tunnel wall by junction

pieces (strainer and round steel) etc. according to the
Finishing painting
designing requirements. The junction pieces should weld to

the
penstocks
stiffening
ring,
fix
tightly
and
avoid
final acceptance
displacement when pouring. Before pouring, should meet

inspector for pilotscale inspection, the mileage, highness and installation centers deviation of penstock
should comply with the specifications.
(4) Should keep the stiffening support inside the penstock until the pouring is finished, and can be
removed only until certain intensity is reached. Should consider the turnover quantity of the stiffening
support
4.9.5 Welding of penstock
Before welding, should prepare the technical specifications following the approved Welding
Technology Reviewing Report, combined with the reality of this project, and report to the inspector then
weld after approved.
Page 50 of 60
The welding of penstock longitudinal jointing should adopt automatic submerged arc welding; the
longitudinal jointing of penstock after tiles butting and the circular jointing of penstock after installing the
bigger segment should be welded on the roll-welding trolley; the circular jointing, stiffening ring and other
accessories of the bending penstock should be welded by manual electric-arc welding.
4.9.5.1 Cleaning before welding
Before welding, should clean impurities such as oxidized surface, rust, oil dirt and so on which are
in the all welding surfaces and the two sides of groove at the range of 50 ~ 100mm, and clean at once
after one section welding finished, then continue welding after checking qualified.
4.9.5.2 Tack weld
The project need to be welded should be assembled and tack welded by means of the approved
methods. All welding work including tack welding and temporary welding should follow the welding
procedure strictly. The preheating temperature of tack welding seam should higher 20 ~30 than the
preheating temperature of main welding seam, and should maintain the preheating temperature during
the welding, the interlayer temperature shouldnt lower than the preheating temperature and should less
than 230 ,
4.9.5.3 Welding
(1) The welding of longitudinal seam and circular seam in manufacturing factory should be
conducted in an ease work shed via automatic welding. The welding of stiffening ring should be
conducted in the open air.
(2) The welding of penstock in tunnel should be weld via manual electric-arc welding, every weld
seam should be welded by 6 welders symmetrically via DC Inverter Welding Machine.
(3) Before welding, should check the installation of main parts, if there is any deviation, should
correct in time.
(4) Adopt multi-layer and multi-pass welding for the seam. The bedding joint of multilayer welding
should be staggered. Every seam should be welded continuously, if the welding is interrupted by
accident, should take proper measure to prevent cracking, and keep warm in time. Before welding
restarted, should clean the surface and make sure no crack then continue to weld according to the same
technical process. After welding, should burnish the welding scar to be flush with the substrate.
(5) After welding, the welder should check by himself, then put on steel mark nearby the qualified
weld seam which is Type I and Type II, and record properly.
4.9.5.4 Treatment of stress relief and hydrogen relief after welding
During the welding, should conduct the treatment of stress relief and hydrogen relief to the welded
part on each layer by using Haokeneng Welding Stress Relief Machine, so as to relief the stress.
4.9.5.5 Remedy of defects on penstock surface
After finished the welding, should check the situation of penstocks inside/ outside faces and the
welding places totally, burnish the bulging on inside face. If there is pit which is deeper than 10% of the
surface thickness, should make repairing welding and recheck as per the approved measures by
inspector.
4.9.6 Check of weld seam
4.9.6.1 Classification of weld seam

Page 51 of 60
Type I: including weld seam received main stress, for example, longitudinal seam in penstock wall,
circular seam in joining section, butt welding seam of stiffening accessories (including supporting ring)
and combined weld seam between the penstock walls.
Type II: including weld seam received secondary stress, for example circular seam in penstock wall,
butt weld seam of strengthening ring and combined weld seam between penstock walls.
Type III: including weld seam of accessories which are weld seam received minor stress, and will not
cause to stop generating electricity and water supply when make repairing weld.
4.9.6.2 Radiographic Examination
All the weld joints in the pipe shells and bifurcation shall be radiographed at the rate of the followings:
(a) Longitudinal weld joints : 100% of weld line in length including T-joints
(b) Girth weld joints: More than 20% of weld line in length including T joints.
Radiographs shall be in accordance with the requirements in the Specification.
Weld defect detected shall be repaired in accordance with the following procedures:
(1) 30 cm length weld lines of both sides of the defect portion shall be radiographed to examine
whether there is the objectionable defect therein or not.
(2) If there is the defect therein, all weld lines of concerned joint shall be radiographed and defective
welds discovered shall be repaired.
(3) If there is not the defect therein, the defect portion only shall be repaired.
(4) Objectionable defects in welds shall be chipped or flame or arc gauged to show sound metal and
the defects rewelded. Welds that have been repaired shall be 100 per cent radiographed again.
The Contractor shall furnish all equipment, films and labour necessary to perform the radiographic
tests. All original films of the radiographs shall become the property of the Employer.
The Contractor shall provide proper storage for his radiographs and shall store and preserve all
radiographs of welding, whether the welding is accepted or rejected. All radiographs shall be identified
and a identification drawing prepared.
The Contractor shall submit the radiographic inspection procedure for approval to the Engineer and
shall obtain Employer's approval before the inspection is made. The Employer shall have the right to add
further radiographic inspection of the welded lines when needed.
4.9.7 Treatment of welding defect
The inside defects of weld seam should be removed completely by pneumatic digger or burnishing
machine, and burnish it with grinding wheel to a flute which is easy to be welded. Before repairing,
should check strictly and make sure defects are removed. The defects which belong to crack, should
check by magnetic powder firstly, then make repairing weld after the crack is removed.
After welding, should recheck defects by ray detection and ultrasonic wave detection. The repairing weld
in the same location shouldnt be more than 2 times. If the repairing is more than 2 times, make reliable
technical measure, and ask for approval from supervisory Engineer, only then can the repairing been
done, the repairing shall be recorded in writing as well.
Page 52 of 60
4.9.8 Test of water pressure
The water pressure test is not advised for this project because that the diameter of penstock in the
project is relatively big, and the construction is conducted inside the tunnel. Hence, it is very important to
control strictly in every step of the welding procedures including flaw detection so as to meet the
requirements of specification and quality.
4.9.9 Painting
Before painting, should do the technical test according to the requirement of drawing and the rule of
painting factory. Do the test strictly as the ratio of dope, the way of preparing, and the interval of painting
ordered. The result of test should be reported to the Engineer and the painting shall only be carried on
after the test result being approved.
The painting should adopt high-pressure airless spraying technology. It is required even painting, without
bubbler, cavity and impurity, and no phenomenon of separation. After finishing paint, should check if
there are defects like sagging, wrinkling, pinhole, crack and blistering, and make sure the surface is good,
the color is consistent. The testing of inside quality should follow the requirements of drawing and
specifications. The test of coating thickness and the binding ability should follow the requirements of
drawing and specifications. After painting, make joint inspection with the Engineer participated in to
check and make acceptance to the quality of the penstock painting surface, and report the testing result
to the Engineer.
4.10 Steel gate and trash rack installation

4.10.1 Plain Gates and Embedded parts
4.10.1.1 Manufacture of Plain Gate & Embedded Parts

The embedded frames and parts for the gate are composed of sill, main guide, auxiliary guides, reverse
guides, lintel and the like. The manufacture procedure is shown in the following:
Inspection and correction of sectional steel
Measuring & cutting of section steel
Setting out
Welding
Correcting after welding
Machining & planning of metal parts
De-rusting & painting
Inspection for quality. The fabrication method and procedure is described as the following:
4.10.1.2 Fabrication of Gate Leaf

1 Gate leaf is composed of the faceplate, main beam, side beam, small horizontal beam, longitudinal
separating plate, clamping plate, lifting eye, main wheel, reverse wheels, and side wheels. The
fabrication procedure include cutting of steel plate, assembling, non-destructive test for the welding seam,
pre-assembly of gate body, inspection and correction, de-rusting and painting, and so forth.
2
Technical requirement for fabrication and assembly of gate leaf
a. The bearing pad of slide channel of fate shall be adjusted by referring to the surface of rubber seal
seat. All the slide channels shall be on the same plane with allowance not more than 1.0mm. Minimum
one point one either end of slide channel shall be surveyed.
b. the bearing pad face of slide channel shall be parallel with reference surface of rubber seal seat, with
allowable difference not more than 0.5mm. The difference in height between the joints of adjoining slide
channel shall not exceed 0.5mm.
c. The allowable deviation of span between the bearing pads of slide channel shall be 2.0mm and the
central line of same slide channel shall not deviates from the design value by more than 2.0mm.
d. On the same profile, the allowable difference from the bearing pad face to the rubber seal seat shall
be 1.5mm.
Page 53 of 60
4.10.1.3 Quality Control in Fabrication of Gates

The welding seam of gate leaf shall be symmetrical on both sides, that is, welding shall be performed
simultaneously by even welders on both sides of gate leaf. Welding shall be done from center towards
outside, following such a sequence: Butt seam
Vertical welding seam
Flat-filled weld seam
Flange plate overhead welding seam. Welding shall be done in sections and in backing direction by the
welders who shall use the same technical parameter in respect of welding. The beams and faceplate
shall be welded by using CO2 protective welding method.
The welding seam shall be of multi-layer and multi-pass welding joint, with thickness of each layer not
more than the diameter of welding rod. During the welding operation, care shall be taken to prevent any
deformation of welding plates.
No-destructive test for the welding seam shall be carried out to ensure no any defects appearing on the
steel works.
4.10.1.4 Requirement on the welding operation

Prior to the starting of welding works, the specification and method for the welding works shall be
prepared, which shall be abided by during the period of performing the welding works. At the same time,
it is allowed to timely correct some parameters when doing the welding works, to avoid any deformation
arising from the welding.
The welder who is going to participate in the welding of welding seams Class I and Class II shall obtain
the valid qualification certificate issued by the appropriate authority.
4.10.1.5 Hauling
Prior to the starting of transportation of gate leaf, temporary bracing and supporting works shall be
provided to them by using the some I beam and/or channel steel as necessary. The embedded parts,
such as guides, lintels, sills and so on, shall be packed in bundles, with square timber or straw mats put
beneath them, all to avoid colliding with each other and deforming during the hauling period.
4.10.2 Trash-rack
4.10.2.1 Fabrication of Trash-rack
The trash-rack is composed of side beam, horizontal beam, vertical beam and lifting eyes, etc.
1 Fabrication of trash-rack bar: Steel plate Settling out
shape of bars
Matching
Welding
Correcting
Cutting of steel plate
Correcting the
Assembling: Setting out

Positioning of the horizontal beam Positioning of the vertical beam
Positioning of the side beam Installation of bars Installation of lifting eye Examination of the
dimension
3
Welding: Welding of vertical seam
Welding of butt seam of flange plate
4 Inspection and correction: all the dimension and size shall be carefully inspected in strict accordance
with the design drawing and specification. Any dimension found not in compliance with the design shall
be rectified immediately.
5
No-destructive test of welding seam
4.10.2.2 Technical Requirement for Fabrication and Assembling of Trashrack

1 the deviation of height and width from the specified ones shall be not more than 4mm, and that of
thickness from the design one shall be not more than 3mm.
2
the difference between the diagonal line of the trash-rack shall be not more than 4.0mm, and the
distortion allowance shall not exceed 3.0mm.

Page 54 of 60
3 All the bars shall be parallel with each other, and the apart space between the bars shall not
deviate from the design one by 5%.
4.10.3 Radial gate and embedded parts
4.10.3.1 Process measures for radial gate of spillway
The embedded parts of radial gate include bottom sill, side rail and anchor bolt of hinged support and so
forth, which shall be manufactured segmentally as per the design and drawings. The production methods
used are the same to those applied to embedded parts of plain gate.
4.10.3.2 Flow chart of radial gate manufacturing
Technology documents
Staff and equipments
Lofting
Positioner supporting
Blanking
Material rechecking
Castings and forgings
Casting and
machining
Number of goods
Antiseptic treatment
Acceptance checks
Holistic splicing
Package and
transportation
Quality control
Non-destructive examination
Assembling
Bought-in components
Machining of other components
Machining of hinge
Machining of fixed hinge
Machining of acting hinge
Manufacturing of miscellaneous
parts
Manufacturing of gate flap
Manufacturing of supporting arm
Calibration
Purchasing of standard parts
Preparatory work
drawings
4.10.3.3 Manufacturing of gate flap

1) Manufacturing process of gate flap comprises the following steps: machining of faceplate, machining
of main beam, machining of side beam, machining of minor crossbeam, longitudinal baffle, watertight
platen, machining of lifting lug and side wheel, articulatory assembly, articulatory welding, articulatory
calibration, non-destructive testing of welding seam, holistic preassembly, testing and calibrating and so
on. Following is the detailed information of the manufacturing process:
Page 55 of 60
A: Machining of faceplate: plate leveling, scribing, cutting, plate rolling, fitting up, welding, testing,
calibrating.
B: Machining of main beam: plate leveling, scribing, cutting, non-shrinking flange, fitting up, welding,
calibrating.
C: Machining of minor crossbeam: calibrating, scribing, cutting, fitting up, calibrating.
D: Articulatory assembly: faceplate in position, scribing and fitting up, main beam in position, minor
crossbeam in position, baffle in position, side beam in position, fitting up the stiffening plate, testing of
geometrical size.
E: Welding: butt welding of the rear edge plate, vertical seam welding, flat fillet seam.
F: Testing and calibrating: testing as per the design drawings and acceptance specifications, and
calibrating the places where mismatching the specifications.
G: Machining of watertight platen: plate leveling, scribing, cutting, calibrating, scribing on the faceplate,
drilling on the basis of actual measure, testing.
H: Non-destructive testing of welding seam: adopt ray or ultrasonic wave to test as per the percentage of
detection specified in DL/T5018-94 criteria. Infiltration or magnetic powder will be used for testing the
surface.
I: Holistic preassembly: using the crane to carry through preassembly on cambered workbench and
ensure the consistency between geometrical size and criteria; distinguishing marks and serial numbers
should be plotted onto the welding position and locking plates be welded when assembling.
4.10.3.4 Manufacturing of supporting arm
1) Manufacturing process of supporting arm comprises the following steps: machining of main beam,
machining of supporting montant, machining of supporting diagonal brace, holistic assembly, welding,
calibrating, non-destructive testing of welding seam, descaling and spray painting. Following is the
detailed information of the manufacturing process:
A: Machining of main beam and supporting montant and diagonal brace: plate leveling, scribing, cutting,
non-shrinking flange, fitting up, welding, testing, calibrating.
B: Holistic assembly: lofting on the platform at the ratio of 1:1, main beam be filled in position, adjusted
and fastened. Afterwards miscellaneous parts are filled in position and fit up. The opening size of
supporting arm should be controlled strictly.
C: Welding: vertical seam, butt welding of flange plate.
D: Calibrating: check the dimensions of each parts after welding and calibrate the greatly-deformed
places with flame correcting method.
4.10.3.5 Machining of supporting hinge:
The castings and jointed-shaft materials used in supporting hinge should conform to the requirements of
specifications.
4.10.3.6 Installation technical measures of radial gate
Generally, the installation of radial gate can be divided into three sections:
The first section is the installation of embedded parts for trunnion beam, bottom sill, side rail and door
head and so forth.
The second section is the installation of radial gate body, which comprises the installation of hinge
support, support leg, gate leaf and watertight rubber and so forth.
Page 56 of 60
The third section is the installation of hoist, which comprises the installation of hoist body, coupling shaft,
pulley block and distribution equipment and so forth.
Generally the installation of gate wont start unless the civil works are basically finished and will be
carried through on the basis of civil works, therefore, the installation of gate and civil works are closely
related. The former is both restricted and closely coordinated by the latter.
1) Processes and methods of the installation of gate
(1) Setting out
Setting out consists of the following steps: setting out the axis of sluice chamber, trimming the side line,
setting out the bottom sill and the speedometer cable of trunnion beam; setting out the uniform altitude
traverse and radius line of side rail, capturing the central coordinate of supporting hinge axis, etc.
(2) Installation of bottom sill and trunnion beam
Installation of bottom sill and trunnion beam. Recheck and clear the bottom sill and trunnion beam prior
to their installation to find out the manufactured central line and axis. Attach sufficient importance to the
perching of bottom sill, or domino effect and unimaginable destructive consequence will be caused for its
fundamental status among the whole installation work and possible imperceptible changes of axis,
speedometer cable and elevation. Therefore each size should be captured accurately during the
perching course. Use the lifting jack and reversible bolt to adjust horizontal position during work progress,
and the level gauge to control elevation by dint of multipoint and repeated measurement, The concrete
placing in Phase II cannot be carried through unless the specified standard are reached.
Ascertain the central point of hinge axis prior to the hoisting of trunnion beam to facilitate wire drawing
and the adjusting of concentricity. The concrete steps are as following: make two calibrating plates
applicable to hinge axis and fasten the plates respectively onto the dowel bars of preformed holes at
bilateral walls with about two-thirds of the plates above the central altitude traverse of trunnion beam.
Also the central perpendicular of faceplate and the perpendicular at speedometer cable of hinge axis
coincide, whereafter gouge along the coincident line by hacksaw with the depth reaching altitude
traverse to make the bottom sill the central point of hinge axis. Link the central points at two terminals by
fine steel wire as both the axis of pivot shaft and working baseline for adjusting trunnion beam.
Calibrating the trunnion beam and fixing hinge support simultaneously as per specific conditions, which
requires install the fixing hinge support onto beam prior to the hoisting of trunnion beam and position the
nether margin of trunnion beam onto the designed coordinate point during hoisting. Calibrate pivot shaft
to achieve the gradient. Hitherto, the hoisting work is completed. According to worksites actual situations,
hoisting will be fulfilled with hoist or horizontal bar or door-shaped hanger.
Some trunnion beams have integral structures while others are divided into two parts. The latter should
be respectively hoisted with the central lines of hinge axis are collinear. Moreover the strengthening
welding should not be carried out unless concentricity on the left and right sides is captured. Tools such
as lifting jack, chain block or tightening bolt should be used during temporary fastening prior to welding
so that welding deformation can be avoided. Constant measurement and calibrating of concentricity of
two hinges should be carried out during fastening until the welding is finished. In the Phase II concrete
placing, instrument detecting is still needed to avoid displacement and ensure the installation quality.
2) Installation of hoist
In order to accelerate the process of the project, save cost and keep the construction site in good order,
if possible, install the hoist during the process of installing the trunnion beam and bottom sill. Setting out
and elevation-measuring is also needed prior to the installation of hoist. Also, the axes of hoist and sluice
chamber must coincide. Rinse and check each part of the equipment, mend the disfigurement and
prepare all the accessories.
Page 57 of 60
Accurate locating, smooth positioning and stable bedplate are required for installing the radial gate hoist,
therefore the anchor bolt in the bedplate should be manufactured as per the drawings. If the locations of
preformed holes of the anchor bolts are inaccurate, modify them to prevent the expansion of screw holes.
Moreover, after concrete placing in Phase II, the embedded bolts should not be tightened until the
concrete strength reaches specified value.
3) Installation of head sill of gate
Some head sills have integral structures while others are divided into two parts. We will take the latter as
an example to illustrate its installation methods. Merge two main body parts and weld them firmly after
they are checked. Please note dislocation is not allowed. Hoist them onto the designed height by hoist,
and repeatedly measure and calibrate their mileage, elevation and gradient. Weld and fix them with
dowel bars on parapet after all requirements are met. Meanwhile, weld them with the side rail after the
latter is further adjusted. Finally assemble the first watertight rubber and place the cover plate. As there
will be replacement of watertight rubber in subsequent operations, the cover plate should not be welded
with the side rail. In this case, there will be a gap between the cover plate ends and the side rail, which
will lead to water leakage if handle improperly. The best method is to add a 1.5mm rubber pad of the
same shape as the surface of the cover plate.
4) Installation of support leg and gate leaf
Put the support leg and gate leaf in place, erect the gate leaf and cut off the extra part of the support leg
and assemble movable trunnion; measure the compatibility between trunnion axis and the hole and
modify defects if any; then hoist the support leg and assemble the trunnion axis. Lubricate the axle hole
with machine oil prior to hoisting. The assembling of support leg and gate leaf will be carried out after the
assembling of trunnion axis. The following steps should be followed: hoist the support leg to a certain
height and lean the gate leaf against the lower end of the support leg; measure the radius of the gate leaf
and make sure the central line of the gate leaf and the axis of sluice chamber coincide before the
welding of the support leg and the pressure-reducing plate. Please note the position alignment. Ensure
the lower margin is about 23mm shorter than the upper margin when measuring the radius of the gate
leaf for the smooth hoisting of radial gate and reducing the friction of top watertight; finally fasten the
pressure-reducing plate and gate leaf with bolts. After the procedures above are finished, hoist the radial
gate and perform tracking measurement for vibration or abnormal situation of the central line of gate leaf.
Timely proper handle of problems is required until the flexible and agonic hoisting is achieved.
5) Installation and adjustment of side rail
The welding of side rail was mentioned in the illustration of installation of head sill. In actual practice the
side rail parts should be hoisted with hoist after the completion of hoist installation. Then fasten the side
rail onto the prepared steel bars with reversible bolts as per the radius of side rail. As the bottom sill is
already setup, the nether margin of side rail and bottom sill can be first welded as long as the
measurement of the side rails radius is accurate. After the gate leaf is well adjusted, utilize the hoist of
gate leaf to further adjust the side rail. Specifically, measure the distance between the working surface of
the stainless steel side rail and the plate of the gate leaf., and adjust the upper and lower gap according
to design requirements with the pre-fixed reversible bolt and lifting jack. Measure a point every 500mm
and make a record, or carry out adjustment through the hoisting of radial gate. Further strengthening
welding should be carried out for the adjusted section.
6) Installation of watertight rubber
Make suitable space and cut the watertight rubber as per the dimensions stipulated by the drawing.
Afterwards assemble the watertight rubber as the following sequence: first bottom watertight, then side
watertight and finally the top watertight.
Installation of bottom watertight: fasten the bolts one by one from central to two ends, and save 23
bolts on both ends respectively unfastened to facilitate the connection with side watertight rubber.
Page 58 of 60
Installation of side watertight: fasten the bolts from top to bottom and overlap joint the side and bottom
watertight rubber; bind the lap joint with stick in prison(adhesive); cut off extra parts and fasten all the
bolts.
Similar to the bottom watertight, carry out the installation of top watertight from central to two ends and
cut off extra parts; fasten bolts with suitable strength and over-tight fastening may lead to the
deformation of P-type watertight rubber and affects the waterproof effect.
7)Concrete placing in Phase II
The concrete placing, including side rail and head jamb, is the final working procedure of the whole
installation of radial gate. It has a decisive effect to the fixing and protection of embedded parts, therefore
it should be taken seriously. To ensure construction quality, all the performed grooves in concrete
placing in Phase II must be surface roughened and cleaned as per the required specifications. Proper
proportion of concrete mixture is required and no disturbance is allowed in the placing process.
8) Trial running
After all the assembling works are finished, trial running of the gate is required to check the overall effect
of installation. Clean the gate leaf, especially the watertight rubber prior to trial running. Continuously
pour cold water onto the watertight rubber during the hoisting course for cooling and lubrication to avoid
the damage of watertight rubber. Trial running should achieve effects such as flexible hoisting, rigorous
watertight, with no abnormal voice and vibration.
5. Project Preliminary Schedule

According to the requirement of 42 months duration and the data depicted in the bidding documents, the
preliminary schedule is developed with P6 software and attached herein.
5.1 Milestone and Critical path

(1) Milestone:
Work commencement: 1 January 2014
Civil design completion: 28 September 2014
Sediment tunnel cons. Completion: 14 October 2015
Guiding structure cons. Completion: 5 September 2016
CFRD cons. Completion: 5 September 20 June 2017
Headrace tunnel cons. Completion: 8 June 2017
Power station M&E install. Completion: 17 April 2017
Work completion: 30 June 2017
(2) Critical path:

Mobilization
Access tunnel excavation & support
station concreting
Turbine & generator install.
Power station excavation & support
Power
Turbine & generator commissioning
Since the float time for the CFRD and the headrace tunnel adit-2 working face is very few, so great
attention should also be paid to these work.
Page 59 of 60
5.2 Construction Rate at Peak

Earth and rock fill monthly peak: 86222m3/month, in May 2016
Rock open excavation peak: 55634m3/month, in December 2015
Tunnel excavation peak: 28889m3/month, in October 2014
Concrete placing peak: 10960m3/month, in July 2016
Page 60 of 60

F 85353ee5307eb87f

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

F 85353ee5307eb87f

Uploaded by

Copyright:

Available Formats

180 MW Kali Gandaki Koban Hydroelectric Project

EPC Tender Documents: Volume II: Technical

Section 7 Method Statement

SINOHYDRO CORPORATION LIMITED

EPC Tender Documents: Volume II: Technical

180 MW Kali Gandaki Koban Hydroelectric Project

Project Description .......................................................................................................................1

Project Execution Organization and Main Construction Equipment ............................................. 2

General Construction Layout ........................................................................................................7

4. Main construction methodology .................................................................................................... 15

180 MW Kali Gandaki Koban Hydroelectric Project

EPC Tender Documents: Tender Schedules

EPC Tender Documents: Tender Schedules

180 MW Kali Gandaki Koban Hydroelectric Project

CFRD Dam &

Head Race Tunnel

Power station access

Project Execution Organization and Main Construction Equipment

2.1 Project Execution Organization

SINOHYDRO CORPORATION LIMITED

EPC Tender Documents: Tender Schedules

180 MW Kali Gandaki Koban Hydroelectric Project

Machinery Repair Plant

Aggregate Processing Plant

M&E Installation Section

Guiding Structure & Dam Section

Bypass Tunnel Section

Intake Structure Section

HRT Adit-1 Section

HRT Adit-2 Section

HRT Adit-3/4 Section

Tailrace Tunnel Section

Road Works Section

2.1 Main Construction Equipment

Hydraulic Drilling DX700

Down-in-Hole Drill 89mm

Rotary disk drill

Raise Boring Machine

SINOHYDRO CORPORATION LIMITED

EPC Tender Documents: Tender Schedules

180 MW Kali Gandaki Koban Hydroelectric Project

Mortar Mixing Machine

Wet Jet Machine

Wet Jet Machine

Heavy Duty Lorry

Heavy Duty Lorry

Axial flow Fan

Axial flow Fan

Axial flow Fan

Axial flow Fan

Aggregate Production System

SINOHYDRO CORPORATION LIMITED

EPC Tender Documents: Tender Schedules

180 MW Kali Gandaki Koban Hydroelectric Project

Concrete Batching Plant

Concrete Batching Plant

Ready-mix Concrete Truck

Concrete Extruding Machine

Concrete belt feeder

Steel mould trolley

Hand Vibratory Roller

Inverse DC arc welder