Presentation on Advances in Hydraulic Structures, Rubber Dam-A way forward by Dr I Satyanarayan Raju, Former Chief Engineers, CDO, GOAP at #33NCCE 33rd National Convention of Civil Engineers at #IEIGSC

1. Advances in Hydraulic Structures, Rubber Dam-A way forward
Dr. I Satyanarayana Raju, MTech,MBA,Mphil,BL,FIE,PhD,
Former Chief Engineer,CDO(WRD) & Expert, State Dam
Safety Inspection Team & Member TAC-WRD,GoAP;
Imm Past Chairman, IEI, Telangana State centre &
Past Chairman IEI, AP State Centre,Hyderabad-500082(TS).
Contact:indukuriraju8@gmail.com; +91 9676686158

2. WELCOME
TO
Dignitories,Invited Speakers,Technical Paper Presenters,Delegates &Organisors,
Of
National Convention of Civil Engineers-IEI,
Seminar
On
Recent Advances in Structural Engineering
September 2-3rd
,2017
By
Gujarat State Centre,Ahmadabad
Institution of Engineers(India)

3. Presntation… Contains
• Back ground
• Issues related to Dams in India
• Rubber Dam- A way Forward
• Janjavathi Rubber Dam, Andhra Pradesh
• Conclusions

4. Water In India
 India’s land resource is 2.45 % of that of
World’s
 India has only 4 % of the world’s water
resource but supporting 17 % of the World’s
population.
 76 % of the total precipitation occurs in just
4 months, some times even 50 % of the
precipitation occurs in just 15 days and
<100 hrs.
 Of the 4000 BCM annual precipitation, 3000
BCM occurs during monsoon months(4).
 Average annual flow is 1953 BCM but 1122
BCM is utilizable.
4

5. Position of India in world scenario
• Land Resources ----------- 2.45%
• Renewable Water Resources - 4%
• Population ----------------- 17%
5

6. Water in India
Total utilizable water resourcesTotal utilizable water resources
1123 BCM1123 BCM
Ground WaterGround Water
433 BCM433 BCM
Surface waterSurface water
690 BCM690 BCM
Current utilizationCurrent utilization
450 BCM ( 65% )450 BCM ( 65% )
Current utilizationCurrent utilization
243 BCM (58%)243 BCM (58%)
Total water availabilityTotal water availability
1869 BCM1869 BCM
Total PrecipitationTotal Precipitation
4000 BCM4000 BCM
6

7. Scenario of Irrigation development in India
• Geographical Area
328.73 Mha
• Total Cultivable Land:
181.98 Mha
• Ultimate Irrigation Potential:
139.89 Mha
• Potential Created (as available Statistics):
113.53 Mha
• Major & Medium:
47.97 Mha
7

8. Annual Average Rainfall
Rainfall in mm
Average 1,170
Max. 11,000
Mawsynram,
Meghalaya
Min. 100 Western Rajasthan
8

9. Water use priorities
•1.Drinking water
•2.Irrigation water
•3.Hydro power
•4.Ecology
•5. Agro-industries and non-agricultural
industries.
• 6. Navigation and other uses .

10. Storage Capacity in Dams of India (BCM)
Large Dams in India – 4857 Nos.
10

11. Future demands of water
Year
WaterDemandinBCM(km3
)
11

12. Water Availability Per Capita in Cum.
12

13. WATER STRESS
 As per existing water resources per capita availability of
water varies from 300 to 13754 (Cum).
 National annual average per capita availability in 2001 is
1829 Cum.
 By 2021 this national average is expected to reach 1557
Cum ( Water Stress).
 By 2050 it may further reduce to 1168 Cum(Water
Scarce)
13

14. Actions to be Initiated for Water Conservation
• Water Availability
• Per Capita Availability – 1545 Cum against stress condition
being 1700 Cum
 Irrigation Development
• 113 Mha. potential created against ultimate potential
of 140 Mha
• 88 Mha potential utilised against 113 Mha created
potential
 Storage Creation
• Creation of 253 BCM Storage against desired
potential of 450 BCM
• Efficiency in Irrigation
• Surface Water – presently at about 40% against possibility of
60%
• Ground Water – presently at about 70% against possibility of
75%
14

15. Issues Related to Dams in India
• The states could construct Gigantic dams like Bhakra-Nangal,
Hirakhud,Srisailam,Nagarjuna-Sagar etc. as Land Acquisition (LA) is very much
within regulatory control of respective Governments
• Only financial compensation used to be paid to land and habitation losers.
• But in present scenario, Land Acquisition and R&R are major constraints in taking
up any new Dam.
• The Rehabilitation and Resettlement (R&R) has become a major issue for
conceiving and completing new Dams under prevailing LA & RR Acts in India.
• The Land Acquisition (LA) for the submergible lands of larger extents under dams
including land required for Dam construction.
• LA Process is very critical and a delayed process to take up any Dam in Indian
democratic Scenario.
• The implementation of provisions of latest R&R and LA Acts have become
cumbersome and time consuming.
• The Interstate River Basin issues for implementing Dams by respective states in
India either as joint project or in individual states stands unresolved for decades
together.
 For Immediate benefit of Creating Irrigation Potential,Rubber dam is alternate
with out submersion issues.

16. Rubber Dam –A Way Forward

17. Rubber Dam
• Inflated Rubber dams are cylindrical rubber fabrics placed across channels,
streams and weir or Dam crests to raise the upstream water level when
inflated.
• The membrane is a multi-layer fabric made of synthetic fiber (Usually Nylon)
and rubberized on one or both sides.
• The fabric is quite flexible and yet exhibits good wear resistance
characteristics.
• A layer of stainless steel mesh or ceramic chips can be embedded in the
surface layer to reduce or prevent vandal damage.
• The Technology was developed in early 1950s.
• They are installed in stream and river beds, generally being bolted into a
concrete foundation and used to divert water for irrigation, temporarily
raising existing dams, flood control, water retention for aquifer recharge.
• They also used for reducing or preventing salt water intrusion in to fresh
water areas, protecting low lying coastal areas from tidal flooding, enabling
fish passage over diversion works, by deflation, and for sewage
retention/separation during flood events.

18. Rubber Dam
• The Inflatable dams can be filled with water, air or both. The
typical length of these Dams will be 100-200Mts with specially
made fabric membranes and for heights upto 5Mts.
• Usually but can be laid to 10Mts in special cases.
• The membranes are deflated to for large overflows but allow
small spillages over the inflated Dam.
• During overflows greater than 20% over topping, vibrations
might result from fluid structure interactions and instabilities
might damage or destroy the rubber membrane (mostly on
downstream face).
• In practice a deflector (a fin) is installed on the downstream face
of Rubber Dam to project the nappe away from membrane to
prevent rubber membrane vibrations

20. Advantages of Rubber Dam over Conventional diversion weir
• A flexible weir structure, allowing through-flow of flood water.
• Stable seamless control of reservoir level (+/- 1, 0 cm).
• Safe flood relief-excess flood water automatically triggers
lowering of barrier tube without the need for mechanical help.
• Ideal for damming wide expanses of water in sections of upwards
of 50 metres each.
• Easy renovation of existing weir structures, regardless of shape
and configuration.
• Absence of mechanical components eliminates corrosion risk.
• No lubricants needed-protects the environment.
• Low maintenance cost.
• Low operational costs due to minimal energy requirements.
• Flexible rubber dam is advantageous than gated conventional
gated weir for damming rivers since easy to operate during floods.
• Life span of rubber dam is 40 years and can re-deploy in between
as per exigency.

21. Hydro-construct Rubber Dam System
• M/S HYDRO-CONSTRUCT, Austria specially developed water
filled rubber dam to damming heights ranging 30cm to 500cm as
asymmetrical weirs with horizontally and vertically curved
configurations.
• The tube material is highly elastic, restraint to abrasion, corrosion
free and robustly withstands the age factor too.
• The synthetic rubber material of 12mm thick with 3 layers of
nylon to with stand 750KN/m and confirms to ISO-9001.
• The regulation of upstream water level will be maintained by means
of a probe controlled system of pumps and sluice gates.
• An automatic vat-discharge will be installed for emergency
release. The regulating system consists of 4 shafts and their
corresponding equipment.
• All steel components are properly protected against corrosion; the
piping is made of PVC, and all screws and bolts of stainless steel.
• The control of Rubber dam will be coordinated by central switch
board, housed in a weather tight panel enclosure.

22. Rubber Components, Dam Foundation
• Weir plate foundation side walls, piers and regulating shafts made of reinforced concrete.
• In the weir plate the anchor rails are fixed including anchor bolts for later fixing the membrane
and all the filling-emptying pipes are laid.
• The rubber foils body with layers of fabric, fixed with special clamping rails.
• Shaft equipment, installed in the regulation shafts-pumps, valves, flaps, motors and safety
equipment.
• Control Shaft System consists of 4 Chambers, viz. Pump shaft, filling shaft, Control shaft, and
Drainage shaft.
• The electrical system for operating pumps depends on height of rubber dam and 3 phase
connection is compulsory for operating these pumps. Control of the rubber dam will be
coordinated by central switchboard, housed in a weather tight panel enclosure.
Dam Foundation
• The foundations of Rubber dam in the River portion will constructed in cement concrete upto
one metre below dam crest and this one metre top to be carried out in Reinforced cement
Concrete (RCC) embodying two pipe lines meant for Rubber dam over this RCC crest. One pipe
line is meant for filling water in to rubber dam and other one for draining water from Rubber
Dam to delete.
• Over the RCC crest the rubber dam foils of designed height will fixed to clamps embodied in RCC
and side pipes constructed at spacing as decided of each bay of rubber dam and number of spans
separated by RCC pier to rubber dam height.
• The rubber foil of dam on either side of each span will be fixed to clamps embedded in piers.

23. Rubber-Dam ,Operation and Maintenance
• The operation principle water filled rubber dam is basically by pumping water via a
shaft system to the inside of rubber membrane to rise up under hydrostatic pressure
and also a standing rubber dam can be sinked by deflation of the filled in water with
motorized valves or flaps.
• The inlet pumps are to be operated from control shaft to lift rubber dam by pumping
water duly ensuing care that the minimum water level in upstream of dam is 50cm fro
top of rubber dam.
• In control room the rubber dam level and water level will automatically screened and
regulated accordingly.
• If the inflows are lean, proper time should be taken to pool up the water on upstream
side and rubber dam is to be raised to the maximum height duly observing water level
not less than 50cm.
• For lowering the dam, the drainage pipe to be operated. During floods when water
level exceeds 50cm over and above rubber foil and tail automatically be lowered down.
The drainage pipe can be operated both manually and electrically to facilitate lower
down the rubber foil during floods.
• In case of power failure and emergency case, deflating is possible by manual sluice
between control shaft and drainage shaft. This shall be done during turning switch from
Service Automatic to Service with display of “service mode activated

40. Existing Rubber Dams Across Globe

53. Janjavati Irrigation Project, Andhra Pradesh (AP)
• Jhanjavati Reservoir ,a Medium Irrigation Project was taken up by Andhra
Pradesh way back in 1976 at an estimated cost of Rs.15.15 crores to benefit
10,000,Ha in most backward region of Vizianagaram dist of North Coast.
• Classification of Projects:Major Project(>10000,Ha.); Medium Project
(2000Ha-10000Ha);Minor(<2000Ha)
• The Janjhavathi Reservoir Project situated across Janjhavatjhi River, a
tributary of Nagavali River near Rajyalaxmipuram (V) Komarada Mandal of
Vizianagaram District of AP to benefit 75 villages, bordering to Odisha State.
• Janjavati Scheme was an Interstate Project since River originates in Odisha
State and Project was conceived in State of AP.
• An Inter State Agreement was entered into between State of Andhra
Pradesh and Odisha Government for Utilizing 50% of yield i.e., 4TMC of
water in the Year during 1976-78 after series of meetings between two
States.
• It was further agreed to carry out the project works except in river gap
portion ( River Gorge) until amicable settlement of land acquisition to the
extent of submersion lying in Odisha territory in the fore shore of Dam.

54. ANDHRA
PRADESH
JANJHAVATHI
RIVER
RUBBER DAM
LOCATION MAP OF JANJHAVATHI RUBBER DAM

55. Dam Salient Features
• Catchment area…………………………….325 Sq.Miles.
• Max. Flood Discharge……………………..2,18,953 Cusecs.
• Gross storage Capacity……………………3.40TMC.
• Live Storage………………………………….2.774TMC.
• F.R.L……………………………………………+146.20M.
• MWL…………………………………………….+146.20M.
• Free Board……………………………………..3.00M.
• Spill Way Length……………………………..89.50M.
• Spillway Gates……………………………6Nos.-12MX11M(Radial).
• Dam Length……………………………………4.07Km.
• NOF…………………………………………….154M.
• Rubber Dam crest………………………… +122.50M.
• Height of Rubber Dam………………………03.2M.
• Lift Height for Canal Pump with Rubber Dam-17M;
• Pumps-3Nosof 650HP.

56. Janjavati Irrigation Project, Andhra Pradesh
• The submergible issue in Odisha state territory stands unresolved as on the
date even after lapse of 4 decades
• The project came to standstill for want of closure of River Gap,and left over
balance work since 40 years.
• The Odisha state is not agreeing for the financial compensation extended
by State of A.P and also not accepting in toto cost towards the R&R
package to be decided by Odisha state.
• The reasons are political, which Odisha ruling party feels to have an impact
on Vote bank, issues likely to raised by Opposition Parties of that State.
• As a result the Project investment made as of date has become in-
fructuous and about 10000 ha. ayacut getting starved for non-completion
of Dam even after 40 years of its commencement.
• The balance cost of project works now inflated to an order of Rs.150 crores
at current schedule of rates.
• No solution is emerging for completion of Dam in near future due to delay
of R&R issue in the state of Odisha.

57. The Way Forward
• The Irrigation experts of Water Resources Department of Andhra Pradesh
interacted with Global technocrats.
• A Technical solution by proposing a Rubber Dam of 3.2 M height in the
River Gap was evolved for immediate benefit of 10000 Ha of Irrigation.
• When once,Inter state Issue with Odisha settles, the original proposed can
be permanently raised in the River Gorge portion to its Full Reservoir
Level (FRL) originally contemplated with storage facility of 2TMC.
• This Rubber Dam is a diversion arrangement in River Gap and avoid
submersion in Odisha territory with facility of deflation at the time of
floods and can be inflated to a height of 3.2M in normal lean flows of
Janjavathi River.
• By this arrangement, partial gravity Irrigation and lift irrigation (Head of
-17M) benefit 10000 Ha.
• After original dam completion in river Gorge,the rubber Dam can
redeployed elsewhere for similar purpose.

59. Janajavati Rubber Dam
• Taken up by State of Andhra Pradesh in 2004-2005 has raised Non Over Flow
(NOF) Dam in the river gap for a length of 60 m up to +122.50m.
• Over NOF,Rubber Dam as diversion Wier was constructed.
• Water was divertd in to the canal through river sluice for irrigation of proposed
ayacut.
• Partial Gravity irrigation and small Lift with 17M head was also established to
pump into existing Canal System of rest ayacut.
• The RUBBER DAM of this project was dedicated to the Nation on 01.01.2006.
• The Rubber Dam is of two spans of 60m total length and 3.20Mts. height.
• The capital cost and post maintenance was of the order of Rs.10 crores.
• This capital investment had made a break even by irrigating about 5000 ha. for
the last 10 years contributing to food production.
• The interstate issue between the States of Andhra Pradesh and Odisha is still in
a stalemate.
• After resolution at a later date, the river Gap can be raised in concrete to
designed height for storing full capacity reservoir. FRL + 146.20M.
• In that contingency the existing Rubber Dam can be dismantled and re-
deployed elsewhere for the similar purpose maintaining same span and height

61. Conclusions
 The Rubber Dam is a recent advanced Technology of
Hydraulic Structures.
 Alternate solution as A diversion structures across
streams and rivers to mitigate foreshore submergence
and R&R issues of conventional Irrigation gravity Dams.
 Further they are reusable after its purpose elsewhere
in other needy places.
 The Life of Rubber Dam is 40 years and capital cost can
be recovered in 10 years of Irrigation facilities in terms
of productivity.
 In the light of engineering challenges in Knowledge Era,
Rubber Dam is an innovative solution as Alternate Head
works component of Irrigation dams.

62. Acknowledgements
• The Technical paper is written based on Author’s
involvement and experience enjoyed while working as
CE, Central Designs Organisation (GoAP), during 2004-
11 and also as Project Chief Engineer of Janjavathi
Project in AP, during Execution of Rubber Dam.
• Profound and deepest acknowledgements to all my
colleagues and Irrigation Engineers of erstwhile
combined AP State with whom the Author associated
over 35 years while in service.
• The Author acknowledges M/S HYDRO-CONSTRUCT, The
Rubber Dam Company, Austria Pioneers of technology and
executed rubber dams and enables to use specifications
and technology in this technical paper

64. THANKS from – Dr. I.S.N.Raju