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CONSTRUCTION METHODOLOGY
12.1 INTRODUCTION The construction of Lower Siang project shall be carried out in two phases. In the first phase, the works on the left bank will be constructed while the river flow is confined on the right bank deep river channel. In phase-I four blocks of spillway, five units consisting of Power Dam, Power House (1500 MW) along with the Erection bays, Approach Channel, D/s channel, Switchyard and Protection wall will be constructed. Hydromechanical and electromechanical works along with embedments, erection and commissioning for the same shall be taken up concurrently during the first phase as per requirement. In the IInd phase, the works on the right bank will be taken up after construction of u/s and d/s Coffer dam. The phase-II works consist of construction of four right bank Spillway blocks and remaining four units (4x300 MW) of power dam and power house (two units each on the left and right sides of Spillways) would be taken up. Construction methodology and equipment has been planned with the aim to commission the first phase of the project with total capacity of 1500 MW (5x300MW) at the end of 74th Month & second phase of the project with total capacity of 1200MW (4 x 300 MW) at the end of 114 months. 12.2 THE CONSTRUCTION METHODOLOGIES FOR DIFFERENT PHASES OF PROJECT ARE AS FOLLOWS: 12.2.1 Sequence of Construction 12.2.1.1 First Phase Construction Activities The construction of Protection Wall, four blocks of Spillways, five units of Power Dam Power House (1500 MW), two Erection bays, Approach Channel, D/s Channel and Switchyard will be taken up during the first phase. The sequence of construction will be as follows.

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The excavation as well as concreting of Protection wall. Excavation of left spillways blocks and five units of Power Dam - Power House along with two erection bays. Concreting of Spillway blocks, Power Dam Power House blocks and Erection bays. The concrete of Power Dam and spillway block portion will be done after raising the concrete in Power House portion up to El. 149.00m. Excavation of Approach Channel as well as D/s Channel to be taken up after (ii) above. First stage embedment for Hydro-mechanical works to be taken up concurrently with (iii) above Erection of HM equipment related to sluice gates to be taken up after completion of concrete in spillway block up to El. 208.00m. Erection of trunnion girder for ogee radial gates to be taken up after completion of pier up to El. 216.488 m. Erection of HM equipments related to ogee spillway radial gates to be taken up after completion of spillway blocks up to top including bridges. Erection of HM equipment related to d/s stoplog gates after completion of extended portion of piers. Erection of HM equipment related to Power Dam Power House blocks such as trash rack, hydraulic gates & hoist, bulkhead gate and gantry, Draft Tube gate etc. shall be taken up after completion of these blocks except Penstock and first stage embedment which will be fixed concurrently with concrete. Erection of items related to E&M works up to pit free such as DT liner, DT Cone, Spiral casing etc. will be done along with the concreting of Power House. Erection of remaining E&M works will be taken up after completion of Power house concreting i.e. after pit free. 12.2.1.2 Second Phase Construction Activities The construction of four blocks of Spillway, four units of Power Dam - Power House (two on the right abutment and two on the right side of the protection wall)) (1200 MW) and Erection bay on right abutment will be taken up during the second phase. The sequence of construction will be as follows. The river will divert in the Diversion sluices at El. 155.0m provided in one of the left bank spillway blocks by launching diversion dyke. Construction of u/s and d/s Coffer Dams along with Jet grouting.
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The excavation on the abutment up to El. 220m will be taken up before launching of diversion dyke and below El. 220m up to river bed will be taken up after completion of (ii) above. Concreting of Spillway blocks, Power Dam - Power House blocks along with Erection bay. First stage embedment for Hydro-mechanical works to be taken up concurrently with (iv) above Erection of HM equipment related to sluice gates to be taken up after completion of concrete in spillway block up to El. 208.0m. Erection of trunnion girder for ogee radial gates to be taken up after completion of pier up to El. 216.488m. Erection of HM equipments related to ogee spillway radial gates to be taken up after completion of spillway blocks up to top including bridges. Erection of HM equipment related to d/s stoplog gates after completion of extended portion of piers. Erection of HM equipment related to Power Dam Power House blocks such as trash rack, hydraulic gates & hoist, bulkhead gate and gantry, Draft Tube gate etc. shall be taken up after completion of these blocks except Penstock and first stage embedment which will be fixed concurrently with concrete. Erection of items related to E&M works up to pit free such as DT liner, DT Cone, Spiral casing etc. will be done along with the concreting of Power House. Erection of remaining E&M works will be taken up after completion of Power house concreting i.e. pit free. The construction methodology for different components of project under Phase-I and II are as follows:12.3 EXCAVATION 12.3.1 Left Bank Works (Phase-I Works) As per the stages of construction adopted, the excavation for the first stage consists of excavation for the left bank works up to El. 168.0m on the upstream of dam; up to El. 158/145.0m under the Spillway blocks and up to El. 125.30 m under the Power House the Tail Race portion with appropriate slopes. However rock ledge with top elevation of 200.00 m on the upstream side and at El. 190.00m on the downstream side will be left in position to protect

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the working area from the river flows which are confined to the right bank deep river channel during this phase of construction. The total excavation (bank) involved is 20,542,815 cum. This excavation require about 33 months. The total excavation area is 800m long (average) along the river flow and the width varies from 400m at the centre to about 250m at the ends. This area can permit deployment of required number of sets of excavation equipment each of which shall consists of (i) Excavator (ii) Dozer (iii) Dumper (iv) Drilling and Miscellaneous equipment along with arrangement to provide adequate compressed air. It is proposed to deploy eight such set to tackle the area of excavation with a view to complete it in the stipulated time frame. The excavation shall be tackled concurrently from the left bank hill side as well as from the edge on the right bank. The slope stabilization work, mainly consisting of shotcrete and rock bolts shall be carried concurrently with the excavation on the slopes. 12.3.2 Excavation for Protection Wall 12.3.2.1 Method Statement The excavation of Protection wall will be done simultaneously with the excavation of Spillway and Power House. The excavation for the Protection wall will require approximately 4 months. The common excavation shall be carried out by Ex-600 Hydraulic Excavator in combination with fifty tonne capacity Dumpers. One JCB Back Hoe shall be deployed for preparation and clean up of foundations. Rock excavation, drilling will be done with Wagon Drills and dozing will be done with D-155 dozers. 12.3.2.2 Equipment Planning The excavation of Protection wall will continue during monsoon season. Thus out of the total four months only three will be considered for the equipment planning. The planning of equipment has been done assuming 25 working days / month, 20 working hours / day and considering 20% peak factor. Following equipment is required for protection wall excavation :Ex-600 Hydraulic Excavators Fifty tonne capacity Dumpers
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1 no. 9 nos.
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Crawler Drills Compressors 450 cfm Dozers D-65 JCB Backhoe

2 nos. 2 nos. 1 no. 1 no.

12.3.3 Excavation for Left Spillway Blocks (S1 to S5), Power Dam Power House (P-1 and P-5) along with Erection bay E1 & E2 12.3.3.1 Method Statement Four Spillway blocks, five Power Dam - Power House blocks and two Erection bays are located on the left bank of river Siang. All the above structures are located in hilly area at left bank of river and no diversion is required for Ist phase construction. The excavation of all these structures will be done simultaneously and will be taken up from top in benches at three metre interval in heights, tackling both the overburden and the rock strata, as encountered. Temporary roads shall be established for access to berms at various levels. As the excavation proceeds, the slope treatment works consists of mechanical rock bolts, anchors, welded wire mesh and shotcrete will be provided. The drilling for rockbolts will be done by wagon drill and shotcrete by dry shotcrete machines. If any shear zone will be encountered during the excavation and same shall be treated accordingly. Treatment mainly consists of plugging the shear zone with concrete cladding on hill slopes as well as on benches. The concrete plug is tied by rockbolts to the rock. Pressure relief hole shall also been provided for the drainage of water to reduce pore water pressure on slopes. The common excavation shall be carried out by Ex-600 and Ex-400 Hydraulic Excavator in combination with fifty and twenty five tonne capacity Dumpers. However, JCB Back Hoe shall be provided for preparation and clean up of foundations. For rock excavation, drilling will be done with wagon drill and dozing will be done with D-155/D-65 dozers. 12.3.3.2 Equipment Planning The excavation of above structures will continue during monsoon seasons. Thus out of the total 17 workings months only 16 month will be considered for equipment planning. The planning of equipment has been done assuming 25 working days / month, 20 working hours / day and considering 20% peak factor.

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Following equipment is required for above works :Ex-600 Hydraulic Excavator Ex-400 Hydraulic Excavator Fifty tonne capacity Dumpers Twenty five tonne capacity Dumpers Wagon Drills along with its compressor Dozers D-155 Dry Shotcrete machine 12.3.4 Excavation for Approach Channel 12.3.4.1 Method Statement The excavation of Approach Channel will be done after completion of excavation of Spillway and Power House. The common excavation shall be carried out by Ex-600 Hydraulic Excavator in combination with fifty tonne capacity Dumpers. However, one JCB Back Hoe shall be provided for preparation and clean up of foundations. For rock excavation, drilling will be done with Wagon Drills and dozing will be done with D-155 dozers. The open excavation for the Approach Channel shall start in 21st month and shall be completed by the 36th month. 12.3.4.2 Equipment Planning The excavation of Approach Channel will continue during monsoon season. Thus out of the total sixteen months only fifteen will be considered for the equipment planning. and considering 20% peak factor. Following equipment is required for above works :Ex-600 Hydraulic Excavators Ex-200 Hydraulic Excavators Fifty tonne capacity Dumpers Twenty five tonne capacity Dumpers Wagon Drills along with its compressor Dozer D-65 Dozers D-155 JCB Backhoe Dry Shotcrete machine - 4nos. - 2nos. - 44nos. - 28nos. - 5nos. - 1no. - 4 nos. - 1no. - 2nos. The planning of equipment has been done assuming 25 working days / month, 20 working hours / day 7nos. 3nos. 77nos. 42nos. 10nos. 8nos. 3nos.

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12.3.5

Excavation for Downstream Channel The excavation of Downstream Channel will be done after completion of excavation of

12.3.5.1 Method Statement Spillway and Power House. The common excavation shall be carried out by Ex-600 Hydraulic Excavator in combination with fifty tonne capacity Dumpers. However, one JCB Back Hoe shall be provided for preparation and clean up of foundations. For rock excavation, drilling will be done with Wagon Drills and dozing will be done with D-155 dozers. The open excavation for the Downstream Channel shall start in 21st month and shall be completed by the 36th month. 12.3.5.2 Equipment Planning The excavation of Downstream Channel will continue during monsoon season. Thus out of the total sixteen months only fifteen months will be considered for the equipment planning. The planning of equipment has been done assuming 25 working days / month, 20 working hours/ day and considering 20% peak factor. Following equipment is required for above works :Ex-600 Hydraulic Excavators Ex-400 Hydraulic Excavators Fifty tonne capacity Dumpers Twenty five tonne capacity Dumpers Wagon Drills along with its compressor Dozers D-155 JCB Backhoe Dry Shotcrete machine 12.3.6 Right Bank Works (Phase-II Works) Right bank works are to be taken up in phase-II after completion of the left bank works and diversion of river over the completed left bank works by constructing u/s and d/s coffer dam to isolate right bank works. For this phase of works excavation is involved for four spillway blocks, four Power Dam Power house blocks (2 on the right bank abutment and 2 on the right side of protection wall), along with the Erection bay on the right bank abutment. Excavation of approach road on the right bank off taking from State PWD road from Rottung to Pengin would be taken first. The construction roads for excavation will offtake from this road to reach the Power Dam blocks and Spillway blocks area and the Tail Race area.
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In addition, by the time works of right bank are taken up a bridge (70R capacity) d/s of the dam at a proper location connecting the left and right bank would also be available for interconnectivity of the left bank and right bank works. 12.3.7 Excavation for Right Spillway Blocks (S6 to S10), Power Dam Power House (P-6 to P-9) along with Erection Bay 12.3.7.1 Method Statement Spillway blocks, Power Dam - Power House and Erection bay are located on the right bank of river Siang. Since all these structures are located at right bank of river, excavation of Spillway and Power Dam - Power House would be done simultaneous after construction of Coffer Dams. The excavation of all these structures will be done simultaneously and will be taken up from top in benches at three metre interval in heights, tackling both the overburden and the rock strata, as encountered. Temporary roads shall be established for access to berms at various levels. The common excavation shall be carried out by Ex-600 and Ex-400 Hydraulic Excavator in combination with fifty and twenty five tonne capacity Dumpers. However, JCB Back Hoe shall be provided for preparation and clean up of foundations. For rock excavation, drilling will be done with Wagon Drills and dozing will be done with D-155/D-65 dozers. As the excavation proceeds, the slope treatment by way of mechanical rock bolts, anchors, welded wiremesh and shotcrete will be provided. 12.3.7.2 Equipment Planning The excavation of above structures will continue during monsoon seasons. Thus out of the total 10 workings months only eight month will be considered for equipment planning. The planning of equipment has been done assuming 25 working days / month, 20 working hours / day and considering 20% peak factor. Following equipment is required for above works :Ex-600 Hydraulic Excavator Ex-400 Hydraulic Excavator Fifty tonne capacity Dumpers Twenty five tonne capacity Dumpers Wagon Drill along with its compressor Dozers D-155 Dry Shotcrete machine
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4nos. 1no. 44nos. 14nos. 4nos. 4nos. 2nos.

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JCB Back hoe 12.4 CONCRETING

2nos.

Total works of concreting consists of (i) spillway blocks along energy dissipation arrangement (ii) Power Dam along Intake and Penstocks and (iii) Power House at the toe of the Power Dam along with Tail Race Channel. According to diversion scheme, first four spillway blocks on the left bank side and five Power dam Power House blocks along with two erection bays are to be constructed during first phase of construction. Rest of the four spillway blocks and four Power Dam and Power House blocks along with right bank erection bay are to be constructed in the second phase of works. Quarry for the material and space for installation of APP and CBP are available only on the left bank side which will serve for the works of both the phases. Therefore, after considering various alternatives, it is proposed to use two parallel Cable ways which will run on the left and right bank and feeding arrangement will be from left bank side. These Cable ways will cater for both phases of works. Both the Cable ways are proposed to run in tandem. Because of the hill cutting limitations specially on the right bank and also looking to the requirement of pouring rate, it is proposed that Cable ways will be able to cater for only the main works i.e. spillway blocks, Power Dam and Power House blocks. In the mass concrete portions of spillway and Power Dam, the peak pouring rate during some periods exceeds the pouring capacity of two Cable ways. To cater for this situation it is proposed to deploy two tower crane on the u/s side and two on the d/s side running parallel to dam axis which will cover about 30m area from u/s and d/s sides. The area left in between the two tower cranes will be concreted by Cable ways. Concreting of stilling basin d/s of Spillway blocks and Tail Race Channel d/s of the Power House will be done by Creter cranes which will approach the work from d/s side. Two numbers of 750 TPH and 250 TPH will be installed on left bank to cater for left bank works. In addition, one 250 TPH will be installed on right bank to cater for right bank stilling basin and Tail Race channel. Two numbers of (360 cum/hr and 120 cum/hr) CBP will be installed on left bank to cater for left bank works. In addition, one 120 cum/hr capacity will be installed on right bank to cater for right bank works.

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12.4.1 Concreting for Phase-I works (Left bank) (Method Statement) 12.4.1.1 Sequence of Construction of Spillway blocks As soon as the excavation of Spillway blocks is completed, the concreting of Spillway blocks will be taken up. The sequence of concreting as generally proposed for the Spillway block is given below:
S. No. 1 2 3 4 5 6 7 8 9 10 Description Concreting from foundation (El. 158/145) to El. 160/147m Consolidation grouting from EL 160/147m Concreting from El. 160/147 to El. 166/155m Erection of steel liner in sluices at El. 168.0m Concreting from El. 168.0m to El. 208 m including 1st stage EPs Grouting around steel liner Concreting from El. 208.0m to El. 235.0m including 1st stage EPs D/s Bridge at El. 205.00m Bridge at El. 235m after completion of piers.

Stilling Basin including Divide wall (concreting will be done simultaneously with the Raising of Dam) 11 Sluice Radial gate after completion of concreting upto El. 208.0m 12 13 14 Ogee Radial Gate after completion of bridge at EL 235.0m. Sluice & Ogee stoplogs after completion of top concreting upto EL 235m. Stoplogs in D/s of sluices after completion of spillway pier in d/s at El. 205.0m

The above activities will be same for all the blocks. 12.4.1.2 Sequence of Construction of Power Dam Power House along with Erection bay Once the excavation of power house completed, the concreting of power house will be taken up. Sequence of concreting in Power Dam, Power House including erection bay is described here in below:i) ii) iii) iv) Foundation preparation and covering concrete in Power House area will be followed by the consolidation grouting. The construction of columns and beams. The construction of spiral casing pedestals followed by erection of spiral casing and concreting. Concreting of columns and beams of machine hall, concreting of draft tube piers, walls and slab.
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v)

The construction of power dam will be started after the first stage concreting in Power House. The power dam will be constructed up to EL 190.50 m for erection of penstock and once the penstock will be erected the concrete up to top will be done.

vi)

The concreting of erection bay and power dam upstream of central Erection bay will starts after completion of excavation followed by the concreting of column and beams for unloading bay.

12.4.1.3 Placement of Concrete The concrete placement is proposed to be done by three methods as explained herein below:i) Cable Ways The mass concrete of spillway, power dam and power house portion will be done using Cable ways. The A-frame and Guy rope of Cable ways will be installed on left bank and Right bank. Two parallel running Cable ways of 28 tonne capacity each will be used for concreting. Two Cable ways can place the concrete at the rate of 216 cum/hr. Concrete to the Cable ways will be fed on the left bank from 360 cum/hr Batching plant which is proposed to be located. Concrete from the batching plant will be brought by silo buses with 9 cum capacity which unload concrete into buckets placed on the platform. The loaded bucket will be lifted by the crab and taken to the desired location of placement. ii) Creter Crane Creter crane is a moving belt conveyor system in which maximum arms is 61 m from swing centerline. The maximum angle at which it will pour is 30. Therefore, maximum distance from the centre of the creter crane varies from 61m to 53.19m. For feeding concrete to the belt conveyor a surge hopper type arrangement is provided at the creter crane base. Concrete to this surge hopper is fed by hi-boys which will bring concrete from batching plant. The creter crane can cover the area in circular 53m to 61m radius. Whenever crane is to be place beyond this area, creter crane can move easily. This crane will also be used for concreting in spillway blocks and Power Dam blocks, where the rate of concreting will exceeds the pouring capacity of Cable ways. iii) Concrete Pump The concreting of columns, beams and slabs will be done using concrete pumps.

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12.4.1.4 Pouring of Concrete Lifts Pouring of mass concrete portion in the spillway blocks and Power Dam blocks will be done in such fashion that there is no formation of cold joints. The maximum spillway blocks and Power Dam blocks width in all blocks are 25m and 36m respectively. The sequence of pours for raising the Block by 1.5m lift in three pours each of 0.5m height is shown below. In this scheme of pouring, it has been ensured that there is no formation of cold joints with the envisaged rate of pouring. 12.4.1.5 Vibration and Lift Preparation Concrete shall be vibrated by using 150 mm dia immersion type needle vibrators with frequency changers along with 65 mm dia immersion type vibrators. As soon as the concrete surface has hardened, which will be in about six (6) to eight (8) hours after pouring concrete, the surface shall be green cut with the help of air-water jets to remove the laitance from the surface and to expose the coarse aggregates. The surface shall be thoroughly cleaned with air-water jets before placing the next layer of concrete. 12.4.1.6 Shuttering Steel shuttering correct to the lines, levels and grades, as per concrete outlines shown in the approved drawings, shall be used. The surface of the shuttering shall be kept free from protrusions and shall be properly oiled. 12.4.1.7 Curing Curing of concrete shall be accomplished by continuous wetting of the concrete surface by circulating water through perforated steel pipes fixed along the top of Dam blocks and covering the concrete surface with gunny bags wherever required and possible. 12.4.2 Ancillary Facilities required during Construction In order to ensure that concreting operations, as described herein above, are carried out with the desired efficiency and quality, the following ancillary facilities will be provided. Adequate arrangement of compressed air for operation of vibrators and surface preparation. Adequate lighting facilities during night.
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Adequate perforated piping and water supply for concrete curing. 12.4.2.1 Abstract of Equipment The concrete placement will be done by three methods, whereas, the construction will be done in two phases. Thus the two parallel traveling Cable ways having 28 tonne capacity along with silo buses will be common for both the phases. Creter crane along with Hi-boys will be deployed for concrete of Stilling Basin and Tail Race Channel. Where the rate required for concreting exceeds the Cable ways capacity, the Tower cranes along with lay down buckets and Creter cranes will be used to cater for the exceeded rate. The abstract of equipment deployed for both phases is given herein below : Cable ways 28 t capacity Tower crane 10T @ 30m radius Creter Crane Concrete pumps Silo Buses Hi-boys Transit mixers (with one pump) Lay down bucket 3 cum capacity Air Water Jet Blaster Sand Blasting Equipment Mobile Cranes 10 T capacity Needle Vibrators 65 mm dia Vibrators 150 mm dia with frequency changers Group Pump Surfex make Drilling Machine Diamac 262 12.5 DIVERSION ARRANGEMENT At the location of the dam axis, valley width is about 641 m. The cross section of the river shows that river is confined by steeply rising hill on the right bank side and a gradually rising hill on the bank. This necessitates that the works are split up in two phases. In the phase-I, the works on the left bank consisting of four spillway blocks and five Power Hour / Power Dam blocks along with two erection bay and the protection wall will be constructed. In phase-II, the works on 2nos. 4nos. 1no. 2 nos. 10nos. 5 nos. 4 nos. 8 nos. 2 nos. 2 nos. 2 nos. 4 nos. 2 nos. 2 nos. 2 nos.

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right bank consisting of four spillway blocks and four Power House / Power Dam blocks along with erection bay would be constructed. i) First Stage Diversion With this concept, for phase-I construction diversion of the river will first be affected towards right bank to enable construction of works on left bank. In order to isolate the left bank area, it will be necessary to construct a isolation wall separating left and right banks of the river. Therefore a protection wall on the right side of left bank terrace, keeping at the farthest side while ensuring that its foundation level is not lower than about El. 170.0 will be constructed. The protection wall will be in two portion i.e. u/s of works and d/s of works and these two portions will abut against u/s and d/s face of the erection bay which is located at the right edge of the left bank terrace which will serve three Power House units of the phase-I and two of the phase-II. ii) Second Stage Diversion After completion of works as described herein above, stage-II diversion would be affected to isolate the right bank of the river section to enable construction of works located on the right bank side. This diversion will entail construction of u/s and d/s coffer dams. 12.5.1 Upstream and Downstream Coffer Dams 12.5.1.1 General These coffer dams are founded on river bed and is about 75.5 m (u/s) and 41.0 m (d/s) high respectively. The top level of u/s and d/s coffer dam is 229 m and 190 m respectively. 12.5.1.2 Method Statement The construction of u/s and d/s coffer dam will be done in four stages. Stage-I (Construction of Diversion Dyke) : After monsoon, diversion of river would be carried out in one month time by constructing diversion dyke on upstream side of u/s Coffer dam and on d/s side of d/s Coffer dam. Stage-II (Filling of Cofferdams up to top) : After the construction of dyke, the filling in u/s and d/s Coffer dam up to top El. 226.0m and El.201.0m respectively have been done leaving 35m wide platform at El.183.0m and El. 173.0m in d/s of u/s and d/s Coffer dam for Jet grouting.

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Stage-III (Jet Grouting) : The Jet grouting from El. 183.0m and El. 173.0m upto 1m below rock level will be done for both u/s and d/s Coffer dams. Stage-IV : Filling over Jet grouting for both the dams will be done from El. 183.0m to El. 200 m for u/s and from El. 173.0m to El. 178.0m for d/s Coffer dam. 12.5.1.3 Equipment Planning (u/s and d/s Coffer dam) Placement of fill material at site The rock fill and transition material shall be available from the excavation at Dam site which will be stacked at Dumping sites and impervious clay shall be available from quarry designated as LSC-3 to 6. Hydraulic Excavator (Ex-600) and fifty tonne capacity Dumpers shall be used for excavation, loading and transportation of materials. For pushing the material. D-155 Dozers will be used. The rock layers shall be compacted with IR Vibratory compactors. Equipment requirement has been worked out assuming twenty five working days per month and twenty working hours per day with 1.2 as a peaking factor. Abstract of Equipment both for u/s and d/s Coffer Dams The construction of Coffer dams will be done after completion of first phase works. The equipments required for Coffer dams construction is as below :
Equipment Dozer D-155 Ex-600 Hydraulic Excavator Fifty tonne capacity Dumpers Vibratory Compactors Sprinkler System u/s & d/s Coffer dams 7* 8*+1 79* 8 6 Equipment available from construction of first phase 8 8 86 -

* Shifted position of the equipment from one structure to other structure

12.6

METHODOLOGY FOR ERECTION OF MAIN H.M. EQUIPMENTS

12.6.1 Under Sluice Radial Gates and Stoplogs The gate shall be fabricated in various segments such that the weight of each segment or the heaviest piece does not exceed 25T to suit the capacity of cable crane.

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Following shall be the typical erection sequence of Radial gate components:Installation of Sluice Liner & Concreting. Casting of Trunnion Girder. Installation of Trunnion Assembly. Placement of Sill Beam. Placement of Side Seal Supports/Wall Plates. Placement of Lintel Supports. Second Stage concreting around Sill Beam, Wall Plates and Lintel Beam. Erection of Bottom Gate Element. Erection of Arm-Trunnion Connector. Erection of Bottom Arms. Erection of balance gate elements. Final welding of elements, arms etc.. Erection of Cylinder Support Structure. Erection of Cylinder and Connecting with Gate. Second Stage Concreting of the Cylinder Support Structure. Placement of Power Packs and Control Panels in the Control Room/Hoist Gallery. Installation of Hydraulic Piping between Power Pack and Cylinders. Fixing of Limit switches and Electrical cabling. Filling of Hydraulic Oil in the Cylinders and Power pack. Fixing of Rubber Seals on gate and on Lintel Beam. Fixing of Side Guide Rollers on Gate. Protective coating and touch up paint. Trial testing/Dry testing and commissioning of Gate. 12.6.2 Ogee Spillway Radial Gates and Stoplogs These Radial Gates shall also be made in various segments. The trunnion assembly shall be erected with the help of Mobile Cranes moving on bridge at El 235.0m or cable crane used for concreting. The gate segments shall be lowered by Cable Crane. The gate segments shall also be lowered by mobile cranes of suitable capacity from upstream road bridge. Tower cranes

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travelling on upstream road bridge shall also be provided for handling the lighter gate components up to 10T weight. The erection sequence of the gate components shall be similar to erection sequence of radial gates. 12.6.3 Intake Trash Racks, Intake Stoplogs and Intake Gates The second stage E.P.s and trashracks shall be erected using Tower Cranes travelling on top of pier El 235.0m. The E.P.s, Intake Stoplogs and Intake Gates shall be erected using Mobile Cranes travelling on road bridge. The tower cranes shall also be used for the erection of these items. 12.6.4 Draft Tube Gates The erection of second stage E.P.s shall be done from downstream end using winches and derricks. The gate shall be made in two units, each unit shall be in one piece. These units will be lowered in the chamber using Draft Tube Gantry Crane. 12.6.5 Erection of Sluice Liners The rectangular frame of sluice liners shall be fabricated in the length of 2.5m such that weight of each segment is limited to 25T. These segments shall be brought by cable crane and will be lowered on the rail track already erected & aligned to line and grade over the concrete floor. The erection shall be started from downstream end progressing towards upstream side. The segments shall be pulled at desired location using winches & derricks. The suitable number of hydraulic/mechanical jacks shall be used for final alignment with the adjoining segment. After ensuring correct line and grade of the segments, the welding between segments will be completed. After completing the welding, the concreting shall be completed. The grouting below the bottom liner shall be completed through various grout holes. 12.6.6 Erection of Penstock The transport of steel liner from workshop to Cable way shall be done by low bed trailers. The unloading of steel liner from trailer shall be done by 30 tonne capacity mobile crane. The 30 tonne capacity mobile crane unload the steel liner at the 20m wide road from where the crab of

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Cable way will lift it up and place it at the exact position. The weight of each piece of penstock steel liner will be kept below 25 tonne as the capacity of Cable way is 28 tonnes. After erection, concrete back filling and grouting, all temporary fixtures/appurtenances, debris etc. inside the steel liner shall be carefully removed.

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