Operation and maintenance of Hydro tunnels

13th December 2018

Kathmandu, Nepal
Lessons learnt from previous accidents
during operation
Philippe Lazaro

Lombardi SA
Contents of presentation

1. Repair works of Estí headrace tunnel (Panamá)

2. Repair works of Pucará headrace tunnel (Ecuador)

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
1. Rehabilitation of Estí pressure tunnel (Panamá)

Estí HPP
120 MW
610 GWh/year

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
1. Estí pressure tunnel (Panamá)
General layout of Estí HPP

Canjillones
• Tunnel length: 4.8 km 2 Francis units (120
MW)
• Construction period: 2001-2002
• Year of collapse: 2010
• Period of repair works: 2011-2012
• Rehabilitation costs: ~60 Mio. USD
Operation & Maintenance of hydro tunnels
13 December 2018; Kathmandu, Nepal
1. Estí pressure tunnel (Panamá)
Typical cross section

• Horseshoe cross section

• Area: ~67 m2
• Internal diameter: 8.80 m
• Lining type: shotcrete and
grouted bolts

• Design flow: 180 m3/s

• Max. head: 180 m

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
1. Estí Power tunnel (Panamá)
Geological setting in the main collapse zone

Main collapse probably due to a

combination of:
• sub-vertical faults and
• horizontal water-sensitive rock
layers

Main collapse estimated dimensions:

Length: ≥ 40 m
Width: 23 m
Height: ≥ 15 m

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
1. Estí Power tunnel (Panamá)
Main tunnel collapse in 2010 (after 7 years of regular operation)

Huge rock blocks in the main collapse zone

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
1. Estí Power tunnel (Panamá)
Main tunnel collapse in 2010

Collapses in tunnel roof controlled by rock-mass stratification. Sub- Collapses at tunnel walls probably occurred in the dewatering
horizontal rock layers were separated by water-sensitive mudstone operation consequent to the main collapse.
layers. Maximum collapses height: 5 m.

Lining (shotcrete) detachments probably occurred in the Complete obstruction of the tunnel section due to a collapse
dewatering phase
Operation & Maintenance of hydro tunnels
13 December 2018; Kathmandu, Nepal
 1. Estí Power tunnel (Panamá)
Repair solutions – Main collapse

Operation sequence:
1. Partial void filling using boreholes from the surface
with cement mortar;
2. Formation of a concrete “cap” over the collapsed
material;
3. Systematic injection of the collapsed material with
cement mortar;
4. Realization of forepolings and front face
consolidations;
5. Excavation of the collapsed material with advance
techniques typical for soils of very weak rocks.

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
 1. Estí Power tunnel (Panamá)
Repair solutions – Main collapse

Cement mortar pumping from the Main collapse crossing works. Main collapse crossing works. Is possible
surface to partially fill the void. to see the installation of the forepoling
umbrellas.

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
 1. Estí Power tunnel (Panamá)
Repair solutions – Minor collapses

Operation sequence:
1. Installation of steel ribs (HEB140 – spacing 0.75 -1.00 m) and Bernold plates to form a shield for workers and a
formwork for the void filling;
2. Partial filling of the voids with pumped concrete in order to form a “cap” of concrete over the ribs;
3. Completion of the void filling;
4. Realization of contact grouting in order to assure the contact between the filling material and the rock-mass.
Operation & Maintenance of hydro tunnels
13 December 2018; Kathmandu, Nepal
 1 Estí Power tunnel (Panamá)
Repair solutions – Minor collapses

Steel ribs installation phase Steel ribs completion phase Preparation of the void filling phase with
pumped concrete

Final result of the

repair process
Operation & Maintenance of hydro tunnels
13 December 2018; Kathmandu, Nepal
 1. Estí Power tunnel (Panamá)
Final lining to improve HRT efficiency, safety and durability

Realization of the final lining with cast in place concrete. Realization of a flat invert. Minimum thickness = 30 cm.
Minimum thickness = 30 cm
Reinforced with steel ribs (minimum dosage 35 kg/m3)

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará pressure tunnel (Ecuador)
Rehabilitation of Pucará pressure tunnel (Ecuador)

• Owner: Corporación Eléctrica del

Ecuador (CELEC EP)
• Plant located about 160 km
South East of Quito, in the
province of Tungurahua
• Construction: 1972-1977
Pisayambo
HPP • First main plant of Ecuador’s
power supply system
• Installed capacity: 75 MW
• Average annual energy
production: 230 GWh

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
General layout of Pisayambo HPP
• Rockfill dam: H=41.20 m
• Crest elevation: 3’569.20 m asl
• Storage volume: 90 Mio. m3
• Embedded intake structure
• Headrace tunnel: L=5.5 km, D=2.60 m
with concrete lining
• Surge shaft: H=117 m, D=5.00 m
• Pressure shaft with steel lining:
L=685 m, D=2.20-1.90 m
• Underground powerhouse at 3’086 m asl
2 Pelton units, gross head: 479 m,
installed capacity: 75 MW
• Tailrace tunnel and channel between
powerhouse and Yanayacu river
Operation & Maintenance of hydro tunnels
13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
General layout of Pucará headrace tunnel

• Tunnel length: 5’475 m

• Internal diameter: 2.60 m
• Concrete lining with reinforcement at
final part (higher pressures and lower
coverage)
• Design discharge: 18.6 m3/s
• Max. head: 65 m (at surge tank)

Pucará headrace tunnel in the damaged zone (2011)

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
Landslide and damages of concrete lining occurred in 2011

• After 34 years of operation a landslide

occurred in 2011 at the final part of
headrace tunnel
• Very complex geology contest with
many faults, discontinuities an open
fissures
• Zone with high seismic activity called
“Pisayambo Seismic Nest”
• After tunnel dewatering and
inspection damages in the concrete
lining were observed

Landslide occurred in September 2011

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
Collapse of concrete lining in 2011

• Location and shape of the fissures

indicate tensile stresses caused by
internal water pressure

• Fissure propagation
destroyed/affected arch effect
in the concrete lining
• Compression of semi-
circumferential concrete parts
• Rock spalling at the tunnel
roof

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
 2. Rehabilitation of Pucará headrace tunnel
Lateral and vertical rock coverage

• Position of the affected headrace tunnel

not adequate with respect to the distance
to slope surface

• Lateral and vertical rock thickness not

sufficient to ensure long term stability

• Rock mass characteristics progressively

reduced due to water circulation

→ Construction of a bypass tunnel to the damaged section

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
 2. Rehabilitation of Pucará headrace tunnel
New bypass tunnel

• Bypass tunnel displaced some 70 m into the mountain (L=519 m, D=2.70 m)

• Access tunnel (380 m) to allow safe bypass excavation
• Drainage holes from the existing tunnel to drain the nearby rock slope
Operation & Maintenance of hydro tunnels
13 December 2018; Kathmandu, Nepal
 2. Rehabilitation of Pucará headrace tunnel
Geotechnical investigations in the project area

vertical boreholes from the surface (70-100 m)

sub-horizontal (10°) boreholes from the existing tunnel (15, 30, 55, 60 m)
sub-vertical (30°) boreholes from the existing tunnel (12 m)
boreholes from the bypass during construction
Operation & Maintenance of hydro tunnels
13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
Geotechnical characterisation of the project area

UG Class Tunnel length

UG3 III 23 m 4%
UG4 IV 251 m 48%
UG5 IV 120 m 23%
UG6 IV-V 112 m 22%
UG7 V-VI 14 m 3%

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
Typical cross section of the new bypass tunnel

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
Construction works

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
2. Rehabilitation of Pucará headrace tunnel
Temporary service of the existing tunnel
• Duration of repair works (plant
shutdown): 2011-2013
• Rehabilitation costs: 22 Mio USD
• Support measures of the most
strongly damaged tunnel section
(70 m) with circumferential steel
ribs and 15 cm of shotcrete with
steel mesh reinforcement
• Installation of a GRP pipe DN1600
in the existing tunnel
• Operation 24 h/day of one unit
(36.5 MW, 9.3 m3/s) for 8 months,
during bypass construction

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
 THANK YOU FOR YOUR
ATTENTION
Philippe Lazaro

Operation & Maintenance of hydro tunnels

13 December 2018; Kathmandu, Nepal
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