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Instrumentation and Monitoring during Construction of the Ingula Power

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Conference Paper · July 2011

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Proceedings of the 15th African Regional Conference on Soil Mechanics and Geotechnical Engineering 605
C. Quadros and S.W. Jacobsz (Eds.)
IOS Press, 2011
© 2011 The authors and IOS Press. All rights reserved.
doi:10.3233/978-1-60750-778-9-605

Instrumentation and Monitoring during

Construction of the Ingula Power Caverns
G. J. KEYTER, M. KELLAWAY and D. TAYLOR
a
Braamhoek Consultants Joint Venture, South Africa

Abstract. An extensive programme of instrumentation and monitoring was carried

out during construction of the Ingula hydro power caverns given the size of these
excavations in Karoo mudrocks, for validation of assumptions made during design.
In this paper, some of the monitoring results are compared to predicted
convergence and an incident is reviewed where excessive overbreak in one of the
side headings of the machine hall top heading resulted, locally, in undue roof
deformation which necessitated remedial action to stabilize this part of the crown.

Keywords. Cavern, hydro, instrumentation, monitoring

Introduction

The Ingula pumped storage scheme is being constructed in the Drakensberg escarpment
between the Free State and KwaZulu Natal provinces, South Africa. The powerhouse
complex comprises two main caverns as well as other galleries, tunnels and shafts.
This paper provides details of instrumentation and monitoring work carried out in
the power caverns during construction and monitoring results are compared with those
predicted during design. Excessive overbreak in a side heading when excavating the
machine hall crown resulted locally, in undue roof deformation. Remedial actions
taken to stabilize the excavation in this area are discussed.

1. Powerhouse Location and Description

The high pressure waterways and underground powerhouse lie under a prominent
mountain ridge off the escarpment. The main power caverns are located at a depth of
almost 400 m below ground level, about halfway between the two reservoirs.
The machine hall is approximately 184 m long with a span of 26 m. The crown,
23.5 m above operating floor level, has a double curvature profile with a relatively low
span : height ratio of 2.5. The cavern width reduces to 24.6 m below crane beam level.
The turbine pits extend another 27 m below operating floor level.
The adjacent transformer hall has a 19 m span, a height of 21 m and a length of
approximately 176 m, with a cable and pipe gallery on one side running the length of
the cavern and extending another 6 m below operating floor level.
606 G.J. Keyter et al. / Instrumentation and Monitoring During Construction of Ingula Power Caverns

2. Geology

The powerhouse is being constructed in horizontally bedded siltstones, mudstones and

carbonaceous mudstones of the Volksrust Formation of the Ecca Group, Karoo
Supergroup. The power caverns are located some 25 m below a 40 m thick dolerite
sill. Intact rock properties derived from field and laboratory testing are presented
schematically in Figure 1 in relation to the powerhouse. A decreasing trend in intact
rock strength and stiffness with depth below the dolerite sill is evident in Figure 1.
This can be attributed to induration effects given the proximity of the sill above as well
as changes in mudrock composition with depth. The durability of mudstones at and
above cavern roof level was classified [1] as ‘good’ to ‘excellent’ and at lower
elevations, further away from the influence of the dolerite sill, as ‘poor’ to ‘fair’.

Figure 1. Rock material properties in relation to the power caverns

Faults in the project area generally trend E-W and ESE-WNW with a further two
sets of small displacement faults striking NW-SE and NE-SW. A sub-vertical, sheared
and faulted dolerite dyke with strike orientation NNW-SSE intersects the power
caverns and main access tunnel at an oblique angle. A normal fault zone comprising
slickensided, striated joints, infilled with calcite and mylonitic material, was intersected
in access tunnels near the powerhouse with a few of these fault planes intersecting the
far eastern end of the transformer hall. A number of bedding parallel shears have also
been identified in boreholes and underground excavations in the powerhouse area and
surrounds, three of which are located in and above the machine hall crown. However,
there are no known seismically active faults in the immediate project area. The Tugela
Fault which follows the boundary between the Kaapvaal Craton and the Namaqua
Province in this region, is located some 50 km to the south.
 G.J. Keyter et al. / Instrumentation and Monitoring During Construction of Ingula Power Caverns 607

In situ ground stress was measured in hydrofracture tests in boreholes and in a

small number of overcoring tests. The minimum horizontal stress is orientated
NNW-SSE. The major horizontal stress is greater, and the minor horizontal stress
slightly lower, than the estimated vertical overburden stress. Hydrofracture tests at
cavern level gave a horizontal / vertical stress ratio (K-ratio) of between 0.5 and 0.9
while overcoring tests indicated a K-ratio of approximately 1.0 in the powerhouse area.
Time dependent deformation of the rock mass was noted during construction of the
access tunnels to the powerhouse [2]. Taking into account scale effects given the size
of the main power caverns compared to that of the tunnels constructed earlier, most of
this time dependent deformation in the power caverns are expected to occur within
6 months to a year following excavation down to operating floor level and for about a
year in the turbine pits after turbine floor level has been reached.
The rock mass at powerhouse level is characterized by closed joints with a
resultant low rock mass permeability. Virtually no groundwater has been encountered
at cavern level during excavations carried out to date.

3. Cavern Support Design

Initial estimates of the support required in the Ingula power caverns were based on
precedent experience. The final support design was based on a detailed evaluation of
all available geological and geotechnical information followed by numerical modelling
using UDEC, Phase2 version 7 and FLAC3D [3, 4]. The convergence of different
points located on the crown and sidewalls of the main power caverns was estimated on
the basis of the results of this modelling work, for the anticipated excavation sequence
as well as specified timing of support installation.

4. Instrumentation and Monitoring Design

Instrumentation monitoring arrays were designed to monitor ground displacements as

well as ground anchor loads during construction of the power caverns and adjacent
excavations. This was critical for validation of design assumptions and analyses and to
timely detect unanticipated cavern convergence and loads in ground anchorages.
Instrument arrays typically comprised multiple point borehole extensometers
(MPBX), rock anchor load cells and optical convergence targets, with array layouts
optimized on site during installation to suit actual conditions. Figure 2 shows one of
the main MPBX arrays installed at one of the turbine pits. Most of this instrumentation
will become redundant after construction with only a limited number of instruments to
be maintained during scheme operation to monitor longer term effects.
Limits were set on cavern convergence and anchor loads in terms of so-called
trigger levels as follows, to allow a rapid but appropriate response to actual monitoring
data: A baseline level on which the support design is based, with observed excavation
convergence and anchor loads falling within expected limits in line with that predicted
during design; a warning level, which is approached when convergence and anchor
loads exceed the baseline level; and an alarm level, which is approached when
convergence and loads exceed the warning level.
608 G.J. Keyter et al. / Instrumentation and Monitoring During Construction of Ingula Power Caverns

50m

40m
50m
50m

25m
25m 25m

25m
25m 20m
20m 20m

13m
13m 13m
45°

13m 20m
20m
13m
6.5m
6.5m 6.5m 10m
6.5m 10m 10m
45°
6.5m 10m 10m
25m 25m 5m
5m 5m
13m 13m 5m 5m
6.5m 6.5m
10° 20m 20m
10m 10m
5m 5m

25m 13m 6.5m 6.5m 13m 25m 10°

20m 10m 5m 5m 10m 20m

Transformer
Machine Hall Hall 5m 10m 20m

25m 13m 6.5m 6.5m 13m 20m 25m 10m 5m

0 1m 2 5 10 15

Figure 2. Multiple point borehole extensometer array in power caverns

Baseline convergence is satisfied where measured increases in working load in an

anchor is projected not to exceed 50% of the yield capacity of the anchor on cavern
completion [5]. The warning level is reached where the anchor load is projected to
exceed 50% of the yield capacity of the anchor and the alarm level when the anchor
load is projected to surpass 62.5% of the anchor’s yield capacity on cavern completion.
Given the number of instruments installed in the power caverns and adjacent
excavations, a system was adopted whereby two flags were assigned to each instrument
installation, with the flag status indicated on an instrumentation plan of the powerhouse
complex as follows: (1) A first (or left) flag looking at ‘total convergence’ with a green
flag designating convergence within the baseline; an orange flag convergence
approaching the warning level; and a red flag indicating convergence approaching the
alarm level; and (2) a second (or right) flag looking at ‘rate of convergence’ with a
green flag indicating the excavation is stabilizing; an orange flag that creep
deformation is noted; a magenta flag indicating blasting nearby; and a red flag
accelerating convergence.
An extract from this summary with instrumentation flags is shown in Figure 3 for
that part of the machine hall where the dolerite dyke was intersected. This system of
flags allowed for a quick and easy, high level overview of cavern convergence and
support performance in different parts of the cavern. For example, in Figure 3, all the
instruments in the area of the dyke indicate total convergence within the baseline level
(i.e. all the ‘left flags’ are green). However, note that all the instruments on the western
side of the dyke are showing time dependent creep deformation (all the ‘right flags’ on
this side of the dyke are orange) whereas instruments on the eastern side of the dyke are
showing an excavation that is stabilizing (i.e. all the ‘right flags’ on this side of the
dyke are green).
 G.J. Keyter et al. / Instrumentation and Monitoring During Construction of Ingula Power Caverns 609

Instrument position ‘Right flag’ FLAG KEY

Total Convergence Rate of Convergence
Within expected Stable
Within expected Creep
Within expected Blasting nearby / Accelerating
Approaching warning level Stable
Approaching warning level Creep

‘Left flag’ Approaching warning level Blasting nearby / Accelerating

Approaching alarm level Stable
Approaching alarm level Creep
Approaching alarm level Blasting nearby / Accelerating

N Decreasing convergence

Dolerite dyke

Figure 3. Instrumentation flags in part of the machine hall cavern

5. Actual Cavern Convergence and Support Performance

Less than expected convergence has been noted to date on cavern centre line, possibly
due to permanent ground anchorages in the roof being installed closer to the face than
originally designed. Convergence measured in the cavern side headings are nearer to
that predicted during design as shown in Figure 4. However, in October 2009,
overbreak occurred along a bedding shear plane in one of the machine hall side
headings, see Figure 5. The overbreak developed over 3 days in as many blast rounds
in this heading and increased to more than 2 m beyond the theoretical excavation line
by the third blast. Increases in anchor loads were noted in load cells and a jump in
convergence was noted in MPBX readings in the cavern crown. By then, cracking of
shotcrete developed in the ‘brow’ in the roof as shown in Figure 4. With primary
support rock bolts already installed up to the face of the side heading at that point in
time, all blasting work in this heading was stopped and the following remedial action
taken in the affected area: All rock bolts already installed were full column grouted; all
cable bolts were installed up to the face and grouted up; a layer of steel fibre reinforced
shotcrete was applied over the area of cracked shotcrete followed by a layer of
weldmesh reinforced shotcrete; permanent cable anchors were installed closer to the
side heading face; and voids behind the cracked shotcrete were grouted to ensure good
contact between the shotcrete and the rock substrate. The monitoring frequency was
also increased to check the adequacy or otherwise of the above remedial measures;
these measures successfully stabilized the roof in this area.

6. Acknowledgements

This paper could not have been published without permission from the client, ESKOM,
and the support of the Braamhoek Consultants Joint Venture (BCJV). The monitoring
results presented in this paper are based on regular readings of instruments and
presentation of data as prepared by the main contractor for construction of the
underground works, CMI JV, as submitted to the BCJV site supervision team.
 610 G.J. Keyter et al. / Instrumentation and Monitoring During Construction of Ingula Power Caverns

150 1220
WARNING LEVEL
ALARM LEVEL
Machine Hall Side Heading Convergence (mm)

135 MPBX E4-N1 1214

Excavated Cavern Invert Level (masls))

MPBX E4-S1
120 MPBX E4-N2 1208
MPBX E4-S2
105 MPBX E4-N3 1202
MPBX E4-S3
90 Excavated invert level (masl) 1196

75 1190

60 1184

45 1178

30 1172
Expected
15 Convergence 1166

0 1160
First bench excavated

Sixth bench excavated

Side headings excavated

Long term creep deformation

Second bench excavated
Central heading excavated

Fourth bench excavated

Fifth bench excavated

Third bench excavated

Turbine pits excavated

Drainage gallery excavated

Figure 4. Measured convergence in machine hall side headings

As-built profile

Bedding shear

Extent of cracked shotcrete

Theoretical excavation line

Figure 5. Overbreak on bedding shear in machine hall side heading

References

[1] H. J. Olivier, A new engineering-geological rock durability classification, Engineering Geology, Vol. 14
(1979), 255–279.
[2] G. J. Keyter, M. Ridgway and P. M. Varley, Rock engineering aspects of the Ingula powerhouse caverns,
6th International Symposium on Ground Support in Mining and Civil Engineering Construction,
SAIMM (2008), 409-445.
[3] G. J. Keyter and P. M. Varley, Design of the Ingula powerhouse caverns: General design considerations,
SANCOT Seminar, SAIMM, Ladysmith, South Africa, 2008.
[4] G. J. Keyter and P. M. Varley, Ingula pumped storage scheme: Excavation and support of the main
powerhouse caverns, Braamhoek Consultants Joint Venture, Construction design brief – Main
underground works, 2010.
[5] Civil Engineering and Building Structures Standards Policy Committee, British Standard Code of
Practice for Ground Anchorages, British Standards Institution, London, 1989.

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