DESIGN AND CONSTRUCTION OF TAIL RACE SYSTEM OF

SJVNS RAMPUR HYDRO ELECTRIC PROJECT (412 MW)

Er. Revati Raman, Er. Vivek Chand

SJVN Limited, Shimla, India

Abstract: Hydropower projects in Himalayan regions, present geological and construction

challenges. The tectonic influences, the intense jointing and continued deformation, the
contrasting rock types, the clay-filled fault zones, all combine to test the ingenuity of the
designer. This paper focuses on design and construction of Tail Race System of Rampur
Hydro-electric Project (412 MW) in the weak rock zone of sheared carbonaceous Phyllites.
Tail race system of Rampur HEP is located under a shallow rock cover of 7m in carbonaceous
phyllites. The paper illustrates how the nature and quality of the available rock information
changed during design and construction, and how the design techniques and construction
methodology were adapted accordingly.

1.0 GENERAL DESCRIPTIPON OF RAMPUR HYDROELECTRIC PROJECT

Rampur Hydroelectric Project (412 MW), commissioned during 2015 is located on Himalayan
River Sutlej in Shimla and Kullu Districts of Himachal Pradesh, (India). This project is a
downstream development of Nathpa Jhakri Hydro Power Station (1500 MW) commissioned
during 2003 utilizing 383.88 cumecs of design discharge available at tail race outfall of NJHPS.
Both the projects are successfully working in tandem. Rampur Hydroelectric Project (RHEP) is
economically attractive as discharge of Nathpa Jhakri Hydro Power Station (NJHPS) outfall is
diverted through the Intake structure already constructed for this purpose thus saving the cost of
independent desilting and major diversion arrangement.

Figure 1: Layout of NJHPS (1500MW) and RHPS (412 MW) in Tandem

Operation

The upstream NJHPS has been constructed on the left bank of the river while the downstream
Rampur HPS is located on right bank of the river (Figure-1).The water from Rampur intake
structure is conveyed to the right bank through 10.5m dia Head Race Tunnel. The length of
HRT on left bank is 484m before it crosses the river Sutlej with 43.2m long river crossing
section. At the end of HRT, restricted orifice type surge shaft, 38 m diameter and 156 m in
height, is located. The water further enters into 3 underground pressure shafts, surface valve
house. After that water is conveyed through 3 surface penstocks of 5.4m diameter each,
bifurcating into six branches of 3.8m diameter to feed the six generating units in Surface
Powerhouse equipped with Francis turbines each having generating capacity of 68.67 MW. The
discharge from the turbines is fed through draft tube tunnels to a 179m long tail Race tunnel
system leading back to river Sutlej.

2.0 TAIL RACE SYSTEM:

Most of the hydroelectric projects with surface powerhouse discharge the water from draft tube
directly in to the river. However in order to gain additional head and to provide safety to the
powerhouse and tail channel from floods in Sutlej River, the water from RHEP power house is
discharged through draft tube tunnels to a 179m long Tail Race Tunnel (TRT) system. The
system comprises of 6 no. draft tube tunnels, 112m long D-shaped collection gallery (8 to 10 m
in diameter), 67m long horse shoe shape tail race tunnel (10.50m dia) including 23.90 m
transition( from 10m D-shape to 10.5 m dia. horseshoe shape). In this arrangement water from
6 nos draft tube tunnel is fed into collection gallery which further directs the water through
TRT and Tail Race outfall to tail race channel in to the river. The tail race system was divided
in to two parts namely Tail Race Tunnel system (Draft tube tube tunnel, Collection gallery and
TRT) and Tail Race Outfall (Outfall pond, Gate structure and Tail Race Channel). The overall
arrangement of tail race system is shown in figure 2.

Figure 2: General Arrangement of Tail Race System

3.0 TAIL RACE TUNNEL SYSTEM

3.1 Design and Construction Methodology

As per geological investigation and the rock exposed around Power House building and bank of
the river the rock in the TRT area was mainly phyllite and carbonaceous phyllites. In general,
the rock observed was thinly foliated and weak in nature. The joints/foliations joints recorded
on the surface were tight in nature and occasionally coated with clay in phyllites. The foliations
joints were rough smooth undulating in nature. Complete TRT system comprising of 6 nos.
draft tube tunnel, collection gallery and tail race tunnel was planned to be constructed
completely underground. Whole system was passing underneath the shallow rock cover of 7m
having very low rock mass strength and was designed to be supported with steel ribs, rock
anchors and shotcrete. Junction of collection gallery with large openings of draft tube tunnels
was designed to be supported with built up steel main rib spanning across the draft tube tunnel
taking whole load of steel supports of collection gallery in junction area. An RCC flood
protection wall was earlier constructed close to the TRT System to protect the surface power
house from flood in the river.

3.2 Changes in Design

Excavation of tail race tunnel and draft tube tunnels was done sucessfully with designed
support measures like steel ribs, rock anchors and shotcrete. During excavation of collection
gallery, collapse of crown of collection galllery occured in front of Draft tube tunnel -1 and
Draft tube tunnel-2 resulting in day lighting of this zone and partial hanging of base of Flood
protection wall (figure 3). The rock encountered in this area was carbonaceous phyllite with
interbands of crushed quartize. The rock mass was thinly foiliated, fragile and saturated. Due to
saturation of the rock mass, alteration of mica formed clay along the structural plane. These
foliation joints were dipping towards hill side and strike of the foliation joints was sub parallel
to alignment of collection gallery. After occurance of collapse of collection gallery detailed
deliberations on geology and project construction schedule were made and it was decided to
design and construct the complete collection gallery as RCC cut and cover tunnel. Depth of
open cut to be made for cut and cover section was 22m. It was decided to remove the entire
rock mass under which the tail race system was originally passing.

Figure 3: Collapse of Collection gallery (View from TRT Side and Draft tube tunnel 6 side)

3.3 Design and Construction of Cut and Cover Tunnel

3.3.1 Design loads and Analysis
Cut and cover section of collection gallery was analysed and designed in following steps:
Step1: The cross section (figure 4) of collection gallery at non draft tube tunnel area was
analysed in 1st step. The section near unit 1 which was biggest cross section of collection
gallery (10m dia) was analysed per unit meter length. The analysis was done in STAAD Pro by
applying all the external loads i.e. the loads of fill materials, self-weight, side pressure and
uplift pressures. Load on top of the section was 475kN/m, side pressure was 50 to 175 kN/m,
and load from bottom was 577kN/m. The roof slab (top curved portion) and side walls are
designed as per the analysis results obtained in this step.
 Figure 4: Cross Section of Collection Gallery used for analysis

Step2: The Bottom base slab of collection gallery in junction area where draft tube tunnel
connects with collection gallery was modelled as plate elements and analysed in STAAD Pro
by applying the reactions obtained due to the vertical loads in step1.
Step3: An inbuilt arch beam (figure 4) was provided to take the load from crown portion of
collection gallery towards the draft tube tunnel. Reaction of 2785.73kN obtained at springing
level of collection gallery in step1 was applied as uniformly distributed load on arch beam.

Figure 5: 3-D Model of collection gallery analysed in ANSYS

Step4: Complete collection gallery with draft tube tunnels (figure 5) was analysed in ANSYS
by applying all external loads.

3.3.2 Design
RCC structure of cut and cover section was designed for maximum forces obtained in the
analysis. The reinforcement was designed for maximum bending moments, shear forces and
axial loading by limit state methods as per IS: 456 (Latest Revision)

3.3.3 Construction
Before Excavation of cut and cover section, the existing flood protection wall was dismantled
and a new flood protection wall was constructed away from construction zone, close to river to
protect working area from flooding. A cement grout curtain was provided between river and
proposed cut and cover tunnel to prevent seepage of water during excavation. Due to
excavation of 22m deep open cut in very poor rock, it was planned to carry out the excavation
and concreting of a zone covering two draft tube tunnel junctions at a time. Excavation of this
zone was carried out in vertical steps of 2.5m in a length of 10m at a time and simultaneously
support was provided on the slopes. Elevation difference of 5m was maintained between two
patches of 10m. Excavation of collection gallery was done mechanically with excavator and
was taken up from two fronts; one from TRT side and other from draft tube tunnel no. 6 side.
After completing the excavation, concreting of bottom raft was taken up initially, followed by
concreting of walls and overt simultaneously with excavation of next zone. After completion of
construction of whole collection gallery, the excavated material was back filled over the
section. The construction activities of cut and cover tunnel were completed within the
scheduled time.

Figure 6: Excavation for Cut and Cover Figure 7: Reinforcement and Concreting
tunnel

4.0 TAIL RACE OUTFALL (CUT AND COVER SECTION)

Tailrace outfall structure (figure 8) is a RCC cut and cover structure. Total length of tail race
outfall measured from the exit portal of tail race tunnel is 133.199 m. The cut and cover section
is 37.05 m long and it terminates at gate structure. The floor of this structure has been provided
with reverse slope of 1V:4.8H up to STA.24.60 m and 1V:2H up to STA. 37.05 m. Transition
modified horse shoe to rectangular section has been provided from STA.0.00 m to STA.5.00 m.

Figure 8: Plan of Outfall Structure

 Two number piers (1 m thick) from the gate structure are extended up to STA.5.00 m where 1
m thick RCC wall has been provided. Finished level of floor changes from EL.850.65 m at
STA.0.00 m to EL.862.00 m at STA.37.05 m which is the crest level of gates. A 1500 mm
thick RCC slab has been provided at EL.873.50 m.

4.1 Design and Construction Methodology

As per geological investigations, tail race outfall structure comprising tail race pond, 3 number
gates and outfall channel, was planned to be constructed open to air with side slopes of
1horizontal: 7 vertical forming an angle of approximately 80 degree with the horizontal. This
involved open excavation to the extent of almost 30 m at the deepest part of the pond. The
stability of cut slopes was intended to be achieved by installation of rock bolts, wire mesh
reinforced shotcrete and RCC lining. The channel slopes were planned to be protected with
RCC lining.

4.2 Changes in Design

During the excavation of approach road to TRT excavation (figure 9) indicated the presence of
carbonaceous phyllites which was very poor rock mass, fragile and sheared. Laboratory tests of

Road to TRT Very Poor

Rock Mass

Figure 9: Rock exposed in Outfall Area

the rock gave very low UCS value of 0.28 MPa. The C & values as reported were 0.14 MPa
and 23 respectively. The rock encountered was thinly foliated and was expected to lose its
strength further under saturated conditions. In such geological conditions, rock supporting
measures such as rock anchor, shotcrete and cladding may not be able to provide intended
support strength during life of the project and caving in of slopes in saturated conditions may
occur. After observing the rock exposed in the excavated portion and stability problems being
encountered, it was proposed to construct the outfall pond in the form of RCC cut and cover
tunnel. Since the channel portion, which was about 20m deep involved lesser excavation and the
rock encountered was better than that found in the pond reach, it was decided to construct it as
open channel, as originally proposed.

4.3 Design and Construction of Cut and Cover Portion

4.3.1 Design loads and Analysis:
A number of sections at different intervals (figure 10 showing typical section) were analysed for
loading conditions. The analysis was done in STAAD Pro by applying all the external loads i.e.
earth pressure from hill side, water pressure from river side, load on top during maximum flood
comprising of load due to water and debris during flood, self-weight, and uplift pressures. Load
on top of the section was 122 kN/m, side pressure was 240 to 995 kN/m, and load from bottom
was 712 to 1010 kN/m. The top slab, side walls and bottom raft are designed as per the analysis
results obtained.

Figure 10: Cross Section of Outfall at STA. 20.00

4.3.2 Design
RCC structure of cut and cover section was designed for maximum forces obtained in the
analysis. The reinforcement was designed for maximum bending moments, shear forces and
axial loading by limit state methods as per IS: 456 (Latest Revision)

4.3.3 Construction
Excavation of Tail race outfall was planned open excavation. It was required to excavate a
maximum depth of 31.35 m. Initially a portion of 27.5 m length of was excavated at a slope
angle of 1horizontal: 2.5 Vertical. Intermediate bench of 3 m width was provided 10 m below
the top. Excavated slope was supported with rock anchors, shotcrete with wire mesh. Drainage
holes were also provided to relive the water pressure. After completing the excavation,
concreting of bottom raft was taken up initially, followed by concreting of walls and top slab
simultaneously with excavation of next 13 m portion of outfall. After completion of
construction of whole structure, the excavated material was back filled over the section. The
construction activities of cut and cover tunnel were completed within the scheduled time.

5. CONCLUSION
Tunnel construction in the Himalayas presents various challenges in the form of unexpected
geology, challenging sites and unprecedented working conditions. In view of these, it becomes
imperative for the design as well as construction engineers to adopt techniques and
methodologies which are both flexible and efficient to ensure successful and timely completion
of projects. Large diameter hydropower tunnels passing through regions of low rock cover
 present typical case studies of tunnel construction in the Himalayan Mountains. Tail race
system of 412 MW Rampur HEP presented conditions which required thorough assessment and
detailed analysis in respect of time, cost and technical implications. The construction of these
major civil structures is a good example of thorough construction planning, proactive action to
modify design as per construction requirement and best coordinated effort by construction &
design engineers. Today Rampur HPS 412 MW is successfully running in tandem with NJHPS
1500 MW and providing valuable power to the grid. The experience gained in dealing with
above mentioned issues can be utilized in other projects with similar conditions.

REFERENCES
[1]Design and Construction Report of Rampur Hydropower Project (412MW), SJVN Limited,
India.(2014)
[2]Design and construction of TRT System and under River Crossing of Head Race Tunnel
with specific reference to SJVNs Rampur Hydro Electric Project (412 MW)-India-Revati
Raman, Vivek Chand & R.K. Sharma, 13th International Conference on Underground
Construction held at Prague, Czech Republic.
THE AUTHORS:
Revati Raman He holds M. Tech. degree in Structural Engineering from IIT, Delhi and a
Masters in Business Administration from IGNOU, in addition to Bachelor Degree in Civil
Engineering from university of Pune. He was associated in the design of Rampur HEP from start
to commissioning. He is specialized in design of various component of hydroelectric project. He
is currently working as Dy. Manager and 252 MW Devsari Hydroelectric Project, 60 MW
Naitwar Mori Hydroelectric Project and 44 MW Jakhol Sankhri Hydroelectric Project in
Uttrakhand along with civil design related issue of Nathpa-Jhakri Hydro power station and
Rampur Hydro Power station. He presented a technical paper at International conference on
Underground construction at Prague, Czech Republic.

Vivek Chand graduated in Civil Engineering from Thapar University. He was associated in the
design of various component of Rampur HEP. He is specialized in design of various component
of hydroelectric project. He is currently working as Senior Engineer and looking after designs of
252 MW Devsari Hydroelectric Project, 60 MW Naitwar Mori Hydroelectric Project and 44 MW
Jakhol Sankhri Hydroelectric Project in Uttrakhand along with civil design related issue of
Nathpa-Jhakri Hydro power station and Rampur Hydro Power station. He was awarded with
Promising Young Executive award at the India Power Awards 2016, organized by the Council
of Power Utilities.