Complete Report Of Nelum Jehlum Hydro Electric Project

[ ]
Submitted to :- Submitted by:-
Chief Engineer Mohammad Emad
&
Project Director 2k13 – Civil – 13UET70
Swedish college of Engineering
UET Taxila wah cantt
Internship Report

Acknowledgement
A special gratitude of respected Engineers who’s contribution in stimulating
suggestions and encouragement and the persons who have helped me during in the
internship.
With grateful heart I would like to thanks of Mr. Abdul Qayyum, Director of
civil Engineering for providing me a big opportunity to do internship and project with
in NJHPC.

Project layout..................................................................................................................................5
Summary.........................................................................................................................................6
Client Contractor Consultant........................................................................................................7
Design and operation...................................................................................................................10
Basic information.........................................................................................................................11
About the project .........................................................................................................................15
Dam ...............................................................................................................................................18
Gravity dam.............................................. ....................................................................19
Rock fill dam.................................................................................................................20
Coffer dam.....................................................................................................................................23
Debris Chanel...............................................................................................................................23
Spillway.........................................................................................................................................24
Stilling basin.................................................................................................................................24
Divide pier.....................................................................................................................................25
Intake structure............................................................................................................................26
Left end wall..................................................................................................................................27
Access gallery.......................... ................................................................................…................27
Sedimentation basin....................................................................................................................28
Collecting canal...........................................................................................................................28
RCC (Roller Compacted Concrete)……......................................................................................29
Tunnel...................................................................................................................................... 30-31
Batching plant...............................................................................................................................31
Crush plant....................................................................................................................................32
Laboratory...............................................................................................................................32-33

SUMMARY
This Report is about our internship of the NEELUM - JHELUM
HYDROELECTRIC PROJECT at NAUSERI about 41 km upstream of
MUZAFFAEABAD on 15 July to 14 of August, 2016
.
In this Report there is some basic information about the project. Like
who is the contractor of the project, who is the client, who is design and consultant
engineer etc. After that there is some background information about of this project.
Like when it was started, its cost, its expected completion date, the reason of delay,
the expected and extension in the project.
Then proceeding further is the detail about our visit to site that days.
Time was short so because of this we couldn’t get much knowledge. But as they say,
Knowledge is a Sea. So it’s never enough. Well still we learnt a lot of things there
like the construction of dam and then RCC and concrete on them. And further we
learnt about the construction of a Tunnel and also grouting and lining of tunnel. And
further Detail of these things is given below

Client :-
WAPDA :- (water and power development authority)
First time it’s a big and diverse nature project is implemented in azad Kashmir,
Pakistan to meet energy crisis project initiated in 2008 and expected completion date
is June 2017 estimated power generation is 969MW.
Consultants:-
To ensure quality of project, NJC is consultant
NJC (Nelum Jhelum Consultants) is basically a joint venture of different national and
international companies NJC is joint venture.
Five firms in which three belongs to Pakistan like ACE, NESPAK, NDC and one from
Norway which is NORPLAN and one from America which MWH
Contractors:-
CGGC and CMEC are contractors of NJHEP
both firms belongs to china CGGC is executing civil works at site and CMEC is
working for the mechanical and electrical works .

DESIGN AND OPERATION
The Neelum–Jhelum Dam will be a 60 m height. It will with hold Gross
Storage Capacity10.0 million m3 and Live Storage Capacity 2.8 million m3.
The dam diverts up to 280 m3
/s (9,888 cu ft/s) of the Neelum southeast
into a 28.5 km (18 mi) long head-race tunnel; the first 19.5 km twin tunnel of the
head-race is two tunnels which later meet into one. The tunnel passes 380 m
(1,247 ft) below the Jhelum River and through its bend.
At the terminus of the tunnel, the water reaches the surge
chamber which contains a 353 m tall surge shaft (to prevent water hammer) and a
820 m long surge tunnel. Diameter of Surge tunnel is 9.5m
From the surge chamber, the water is split into four
different penstocks which feed each of the four 242.25 MW Francis turbine-
generators in the underground power house.
After being used to generate electricity, the water is discharged
southeast back into the Jhelum River at 34°10′29″N 73°29′34″E through a 3.5 km
(2 mi) long tail-race tunnel. The drop in elevation between the dam and power station
afford an average hydraulic head of 420 m (1,378 ft)

Country Pakistan
Location Muzaffarabad
Coordinates
34°23′34″N 73°43′08″ECoordinates: 34°23′34″N 73°43′08″E
Status Under construction
Construction began 2008
Opening date Feb 2018
Construction cost Rs. 404.32 Billion ($4.03 billion)
Owner(s) Water and Power Development Authority
Dam and spillways
Type of dam Concrete gravity & Rock fill
Impounds Neelum River
Height 60 m
Length 160 m
Dam volume 156,000 m3
(204,040 cu yd)[1]
Reservoir
Total capacity 8,000,000 m3
(6,486 acre·ft)
Power station

Name Neelum-Jhelum Hydropower Plant
Coordinates 34°11′54″N 73°30′41″E
Commission date December 2017
Type Conventional, diversion
Hydraulic head 420 m (1,378 ft)
Turbines 4 x 242 MW Francis-type
Installed capacity 999 MW
Annual generation 5,150 GWh

About the project: -
The project is running through Neelum Jhelum Hydro Power Company
(NJHPC) WAPDA, headed by a board of directors (BOD), the chairman of BOD is
chairman WAPDA.
Neelum Jhelum Hydroelectric Project (NJHEP) is located in the
Muzaffarabad (AJ&K).It envisages the diversion of Neelum River water through a
tunnel out falling into Jhelum River the intake Neelum Jhelum is at Nauseri.
The Power House is being constructed at Chattar kalas. After passing
through the turbine water will be released into Jhelum River. The generation power
of (NJHEP) is 969 MW.
The Neelum Jhelum hydroelectric project is divided into 3 sites
 NAUSERI (C1)
 MAJHOI /THOTA (C2)
 CHATTER KALAS (C3)
Financial Status Local
(Rs. Million)
FEC
(Rs. Million)
Total
(Rs. Million)
Original PC-I Cost 7,794 7,218.00 15,012.00
1st
Revised PC-I Cost 37,834.56 46,667.70 84,502.26
2nd
Revised PC-I Cost (04.07.2013) 116,515.40 158,367.18 274,882.59
3rd Revised PC-I (approved by ECNEC
on 19-12-2015)
224,978.50 179,342.60 404,321.10
3rd
Revised PC-I (without including IDC) 165,430.33 179,342.56 344,772.88
PSDP Allocation Fy 2015-16 5,500.00 5,500.00 11,000.00
Introduction to the project

It is the main site of this project. It has 60m high composite
(gravity+ rock fill dam) diversion dam. Before starting the construction of diversion
dam a diversion tunnel is dug out having length 500m to change the direction of
water.
NAUSERI C1

MAJHOI/THOTA ( C2 )
The headrace tunnel is 28.5km long including twin
tunnel and conveys the water from the intake area at Nauseri to the power house
area near Chattar kalas .the tunnel crosses under high mountains and also cross the
Muzaffarabad fault zone. A 19.5km stretch of the tunnel from the Nauseri
constructed as a twin tunnel system.
CHATTER KALAS AREA (C3)
The headrace tunnel will feed four vertical
shafts Francis turbine with an install capacity of 969MW house in an underground
powerhouse. The water is discharge back in to the Jhelum river near Zamainabad
through 3.54 km trail race tunnel. Associated facilities include
D A M
Any artificial barrier, together with appurtenant works, that does or may
impound or divert water, and that either
(a) 25 feet or more in height from the natural bed of the stream or watercourse at
the downstream toe of the barrier (or from the lowest elevation of the outside limit of
the barrier if it is not across a stream channel or watercourse) to the maximum
possible water storage elevation
(b) Has an impounding capacity of 50 acre-feet or more.
Types
 COMPOSITE DAM
 GRAVITY DAM
 ROCKFILL DAM
 COFFER DAM

Diversion dam has following parts:
 DABRIS CHANNEL
 SPILLWAY
 STILLING BASIN
 DIVIDE PIER
 INTAKE STRUTURE
 ACCESS GALLERY
 SEDIMENTATION BASIN
 COLLECTING CANAL
 RCC(ROLLER COMPACTED CONCRETE)
 TUNNEL
GRAVITY DAM
Gravity dams are dams which resist the horizontal thrust of the
water entirely by their own weight.
 They use their weight to hold back the water in the reservoir.
 This dam can be made of earth or rock fill or concrete.
 In gravity dam here the intake structure, spillways and divide pier.
In here the debris channel divide pier, spillway and intake structure
are acting like gravity dam.
ldgjd

ROCK FILL DAM
If the depth of water to be retained by the embankment of
cofferdam that is of order of 18 to 30 in stone or rubble is used for the embankment.
In purpose of rockfill dam the foundation of rockfill dam desgin
weak because like earthquake occur in 2005 produced fault line to weaker the rock
fill dam and they don’t destroy or damage our gravity dam (intake and spilway
structure)
In rock fill dam first we drilling and (MBT treatment ) its maintain our foundation
weak. And then foundation core.
The rockfill dam is divided in zone
 Zone 1 ( Clay Material)
 Zone 2 (fine filter) (0-4mm)
 Zone 2a (coarse filter) (5-8mm and 19mm)
 Zone 3 (Rocks) (Green Stone)
 On the left of debris channel there is rock fill dam.
 Length of rock fill dam is 65m.
 Rock fill dam is composed of different layers of green stones.
 Rock Fill dam is on the fault line
 i.e. Murree and Punjal Rock Fill dam is constructed to reduce the settlement along
the fault line To reduce earthquake thirst that may damage dam structure

COFFER DAM
Temporary structures (sheet-pile, water-tight) that allow
construction operations and diverts flow from construction areas until work
completed.

DEBRIS CHANNEL
At the left side of spillway there is dabris channel. There are
two flap gates on the top of debris channel. Woods and other flaoting materials can
be removed through debris channel.
B20 concrete is used in debris channel. 63mm aggregate size are
used.And Pumping concrete are used at the side walls.In pumping concrete 19mm
aggregate was used.
E50 used where water directly intract with structure.

DEBRIS CHANNEL
SPILLWAYS
At the left side of dividing pier there is spillway section. Length of
spillway is 103m, height is 60m and width along flow is 80.25m.
Spillways consist of three radial gates, each gate has dimension 12x15m. A spillway
has four numbers of pears and E-50 concrete is use for the lining of piers. It has
three bays from which water will flow when we will open the radial gates. Radial
gates are operated through hydraulic system (pressure).These radial gates remain
closed but in case of flood or any emergency Gates will open. Piers are stressed
together vertically and horizontally by using cables. At the back side of spillway there
are 4 triennium blocks.
Spillway

Radial Gates (Spillway)
STILLING BASIN :-
In front of spillways there is stilling basin the purpose of
stilling basin is to decrease the speed of water and also don’t erosion occur.
STILLING BASIN

DIVIDE PIER
It divide the intake section from spill way.
INTAKE STRUCTURE
At the right side of dividing pier there is intake section.
Length of intake section is 88m.Height of intake section is 38m.Capacity of intake
section is 280 cumecs.

Intake Structure are divided in four blocks.
 Block 0
 Block 1
 Block 2
 Block 3
In intake structure in each block there is two gates and total gates are
six gates in intake section. The main purpose of gates is to stop the water and there
is some issue or clean or something else of sedimentation basin or collecting canal
then the gates are closed and work easily.
Gates in intake blocks
And in front of intake section and every block there is fitted trash racks
he purpose of trash racks is they don’t allow debris or larger than 4mm dia material.

Trash racks
At the bottom of intake section there is flushing gallery which all the dust
particles are which enter in under sluice flushing gallery and then forward to river.
Flushing gallery

LEFT END WALL :-
It divide sedimentation basin to the stilling basin. At that
place sliding was occur that’s why we constructed left end wall.
LEFT END WALL

ACCESS GALLERY:-
Access gallery is used for entrance purpose inside the
spillway and intake section one can reach through access gallery.
And also grouting to the foundation of spillway and intake structure
below about the 44m depth by grouting Gallery and Consolidation.
And here we used curtain grouting. The purpose of the grout curtain is
restrict seepage to such an amount that it does not cause too much loss of storage,
and does not dislodge the foundation downstream or erode the base of the dam
The maintenance work is through access gallery
Access gallery In Intake Structure
SEDIMENTATION BASIN
In middle of intake and collecting canal there is
sedimentation basin the intake gates are opened to the sedimentation basin and the
water passes through the sedimentation basin into collecting canal then tunnel the
purpose of sedimentation basin are to settle down the sediments and throughout the
flushing gallery in collecting canal.

All the water which will come from intake collected at
collecting canal. There will be 3 blocks at collecting canal and each block contains 4
gates. There will be 12 gates at collecting canal. These gates will be use to stops the
sediments and pure water will flow through headrace tunnel For Flashing or drainage
gallery all the sediments and dust particles are removed through these gates to
gallery and then to river. The length of collecting canal is 88.26m.E-50 concrete is
used at collecting canal and temperature of concrete was less than 20 degree
centigrade.
COLLECTING CANAL

RCC ( Roller Compacted Concrete)
Roller compacted Concrete is be
composed of Portland Cement, slag, fine aggregate, coarse aggregate and
water, all well mixed and brought to the proper consistency. Chemical water
reducing and set retarding admixtures may be used with the Engineer’s mix design
express approval. The RCC mixes shall contain not less than 180 kg/m3 of
cementitious materials, which shall comprise at least 90 kg/m3 cement with the
balance made up slag. If blended cement is used, the proportion of slag in the
blended cement shall be counted as slag. The RCC shall have a Characteristic
Strength of not less than 17 MPa at an age of 91 days. The RCC shall have a
maximum size of aggregate (MSA) of between 38 and 50 mm. The aggregate
shall be batched from two or three sizes of coarse aggregate and one or
two sizes of fine aggregate.
The combined aggregate grading shall have a grading curve within the
limits given by the following formula: the fresh RCC shall be a cohesive
mixture which is not prone to segregation during transport or placement.
The compacted density of the RCC shall be not less than 98% of the
theoretical air free density

Installation of crack Directors, drainage voids and water-stops
The crack inducers shall be installed at the locations. Where crack
required to break a block in Any crack inducer plate showing after the formwork has
been removed shall be cut away. The crack director direct the crack into specified
way in order to retain the future flexural cracks.
Sampling and testing of RCC
Each layer of RCC shall be compacted with 12 passes of the
approved vibrating 15 tone roller or such other number of passes as the test
fill has above than 98% compaction.
Each layer of RCC is 30cm and there are two test used for this
specially
Compaction should be above than 98%
 FDT ( Sand replacement method )
 Ve Be Test ( 10-15 sec )

Advantage of RCC
 Low heat of hydration
 Speed of work maximum
 Roller compacted concrete is Comfortable for the large zone or Area
TUNNEL :- (Linear length of tunnel is 2.5 – 3.5 km tailrace tunnel)
A tunnel is an underground or underwater passageway,
dug through the surrounding and enclosed except for entrance and exit, commonly
at each end.
This tunnel is aqueducts to supply water for generation only for
hydroelectric station. Headrace tunnel start from Nauseri C1 and ends at Chattar
kalas C3. At outlet at Agar Nallah.
For movement purpose a tunnel is used called adit A1 or access
tunnel is at distance of 432m, And now in progress works in tunnel are lining and
grouting (contact grouting) and blasting.
The material for lining we collect material from batching plant which
near built from tunnel A1. And also for grouting and all the material are mixed
through max design which are standard.

Adit A1
The tunnel excavation has been completed by 86 per cent as 59-km
tunnel has been constructed. At the dam site, 72 per cent construction work has
been completed, including the construction of spillway up to level of 1019 meters,
wherein one hydraulic gate has been installed and the second one will also be in
place in next two months.
The tunnel boring machines (TBMs) have the target to excavate the
22.5-km tunnel out of which 13.5-km has been done. The official said the project was
earlier delayed by six months because of the rock burst at the site owing to which
three workers died and nine were injured.
. HRT PORTAL

CONCRETE BATCHING PLANT:
In batching plant there are two mixer used in batching plant. Capacity of mixer is 2
cubic meter per minute. 50 to 60 cubic meter storage of that plant.
There is different crusher used at batching plant.
In batching plant aggregate size ranges from 4.5 to 63mm. There are two hoppers in
which cement and slag is to be uploaded. In batching plant main problem is the
source of aggregate. Every day 600 to 700 m^3.Ice plant controlled the temperature
of concert.
BATCHING PLANT

Temperature of concrete for summer is 12 to 19 degree and ice is
used in concrete for summer days. Temperature of concrete for winter is 8 to 15
degree. Water reducing agent (liquid) increases the setting time of concrete.
Steel fiber and poly fiber are used in E50 concrete which is high
strength concrete used in tunnel.
Air entrained agent 3 to 5 % used in concrete to avoid cracking.
Whole the batching plant system is controlled in monitoring system in which all
concrete mixed design is fixed.
CRUSH PLANT
In the crush plant there is different size of aggregate
19mm
38mm
63mm
Also sand is

Laboratory Work
CEMENT TEST
 Cement Consistency Test
 Initial and Final Setting Time Test
 Soundness Test
 Specific Surface Area test
 Coasting cube
 Specific Surface Area test
 Coasting cube
 Fineness test
AGGREGATE TEST
 Loss Angles test (Absorption test )
 Sieve analysis test
 Soundness test
 Flakiness and elongation test
SLAG TEST

SOIL TEST
 Specific gravity
 Sieve analysis
 Hydrometer
 Alter burg limit
 CBR
 FDT
 Sand Cone
 Water replacement
 Moisture content (speedy)

Complete Report Of Nelum Jehlum Hydro Electric Project

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