CH. Karnchang (Lao) Company LimitedBy Mr. Thamnoon Surarat & Mr. Weerayot Chalermnon

Xayaburi Hydroelectric project

How The Design

Implement to The Construction

Objective:

•To exchange on “How to make Project Planning?”

•To exchange on “Design Phylosophy of the Xayaburi HPP”

•To exchange on “Construction of Xayaburi HPP”

Content:

• Introduction to the Project: • The Potential on Lower Mekong

• Project configuration

• Project Time line

•Project Planning:• Construction Sequences

• Quantities of works

• Sources of Materials

• Construction Facilities

• Project Design Philosophy:• Key hydraulic information• Seismic design• Geology and Geotechnical• Physical Model test

• Construction of XHPP:• First phase construction• Intermediate block• First Stage Cofferdam• Spillway• Navigation Locks• River Closure and Diversion

• Conclusion

Introduction to the Project: Mekong Basin

CountryCatchment area

(Km2)%

China 165,000 21

Myanmar 24,000 3

Laos 202,000 25

Thailand 184,000 23

Cambodia 155,000 20

Vietnam 65,000 8

Total 795,000 100

Source* : MRC

Potential on Lower Mekong Basin and Xayaburi HPP

1 2

3

4

5

6

7

8

9

10

11

Project

Capacity (MW.)

Constructi

onPlanned

1. Pak Beng 1,230

2. Luang

Prabang1,410

3. Xayaburi 1,285

4. Pak Lay 1,320

5. Sanakham 570

6. Pak Chom 1,079

7. Ban Khoum 2,000

8. Lat Sua 800

9. Don Sahong 360

10. Stung Treng 980

11. Sambor 460

Total 1,285 10,209

XHPP locates at 1931 km upstream from Mekong River delta and 103 km downstream of Luang Prabang

Upper Mekong Development

MengSong

600 MW

Ganlanba

150 MW

JingHong 1500 MW

Nuozhadu 5500 MW

DaChaoShan1350 MW

ManWan 1500 MW

Xiaowan 4200 MW

GongGuoQiao 750 MW

China

Viet nam

Lao PDR

Myanmar

Thailand

8 Dams in China

- Completed (6) 14,800 MW.

- Planned (2) 750 MW.

- Total 15,550 MW.

Hydropower development in China

Completed

Planned

Canceled

Project timeline and cost

A. EPC 1. Civil Works 63%

2. Hydro-Mechanical Works 14%

3. Electro-Mechanical Works 18%

4. Transmission 5%

76,000 MB

2012 2013 2014 2015 2016 2017 2018

EPC Contract Signed 29 Oct 2011

2019

COD Oct 2019

1st stage Construction 2nd stage Construction

Project Configuration

Project General InformationHydroelectric power plant run-of-river concrete barrage

Installed Generating CapacityAnnual Production

1,285 MW (7x175 and 1x60 )7,370 GWh. (4.5%)

Average Flow (46 year record 1952-2007)

3,971 cms

Normal Operating Water Level 275 m.asl

River Pondage Area 49 sq.km

Barrage height 80 m.

Total Barrage Length 820 m.

Design Flood (PMF) 47,500 cms

Design Flow through Turbine 4,900 + 242 cms

Rated Net Head 28.5 m9

10

Type 2-steps NLs, with u/s and d/s approach channels for accommodating boats up to 2X 500 DTW.

Head Water Levels for navigation

265.90 – 275.00 m asl

Tailwater Level for Navigation

236.00 -260.00 m asl

Length 144 m for upper lock)154 m for lower lockTotal length: 724.5 m

Width 12 m

Min Water Depth

4 m

Navigation Locks

Spillways

12

Spillways

13

Spillway surface gate

•A structure where separating the spillway from the power intake - powerhouse complex ; and housing the powerhouse

• It is composed with unloading - erection bay, the diesel building, and part of the fish passing facilities.

Intermediate Block

Fish Passing Facilities

Facilities for upstream migration

•Fish collection gallery at powerhouse tailrace, auxiliary collection point at the spillway , The fish passing facilities situated on the left river bank is a pool type fish ladder, 800 m long and 10 m wide , pumping facilities for water supply in dry season , gravity water supply in wet season.

Facilities for downstream migration

•Fish collection gallery at the power intakes, fish delivery channel and chute in the spillway – powerhouse separating block.

Powerhouse

18

19

EGAT EdL

No. of Generating Units 7 1

Turbine• Type• Rated Output• Rated Discharge (per unit)• Governor

Vertical axis Kaplan175 MW700 m3/s

Digital & Hydraulic

Vertical axis Kaplan60 MW

242 m3/sDigital & Hydraulic

Generators• Type• Rated Apparent Power• Power Factor

• Rated Frequency

3-phase synchronous220 MVA0.85 lagging and 0.95 lagging according to EGAT Grid Code50 Hz

Powerhouse

Transmission System

20

EGAT EdL

Transformer• Capacity• Phase• Location

7 x 220 MVA3

Outdoor

1 x 72 MWA3

Outdoor

Transmission Line• Destination

• Length• Voltage• Tower• Conductor

Switchyard to Thali Substation

200 km500 kV

Steel TowerAluminum Conductor Steel

Reinforce

Switchyard to XayaburiSubstation

16.4 km115 kV

Steel TowerAluminum Conductor Steel

Reinforce

Intermediate Block

Left Bank U/S Migration Fish

Passage

Fish Friendly TurbinesD/S Fish PassageD/S Fish Migration

U/S Fish Passage U/S Fish Passage

Original Design of Fish Passing Systems

ค ำถำมประเทศสมำชกิ MRC จำกกำรประชุม PNPCAProcedures for Notification, Prior Consultation and AgreementPrior Consultation for the Proposed Xayaburi Dam Project24th March 2011

1. เรอืเดนิขึน้และลงอยา่งไร

2. ตะกอนเกดิผลกระทบและแกไ้ขอยา่งไร

3. ปลาอพยพขึน้และลงอยา่งใร

4. ผลกระทบตอ่คณุภาพน ้าระหวา่งกอ่สรา้งและหลังการกอ่สรา้ง

5. ผลกระทบดา้นสงัคม

Modify Design by Government of Laos Engineers.August 2011

There are 3-Majors issues have to consider and modified as following;

1.Spillway: Replaced ogee type radial gate to bottom outlet for sediment flushing.

2.Navigation Lock: Modify and add fish passage into Navigation lock.

3.Fish Passing Facilities: Additional study on local fish behavior, swimming performance resulted to Lowering gradient in fish passing facilities.

Replace 3 radial gates with 4 low level outlet gates.

Modified design for sediment flushing

Modified design for fish passage during construction• Additional feeding system in Navigation Locks for attract the fish

Section

Additional feeding system in Navigation Locks for attract the fish

Modified design for fish passage during construction

Fish Lock

D/S Fish Passage

Pump 2 for D/S Fish

Migration

Pump 1 and Gravity pond

for U/S Fish Passage

U/S Fish Passage

U/S Fish Passage

Upper channel

Fish Ladder

D/S Exit

Switchyard AreaUpstream Reservoir

Modified Design of Fish passing facilities.

Introduced fish lock to fish ladder

Social Arrangement

RS 1

RS 2

RS 3

RS 4

RS 5

RS 6

RS-7RS-8

RSH-3

RSH-4

RSH-1

RSH-2

Project

CITY

Resettlement Site

Relocation Site

HouaySouy

93

98

164

55

68

24

3

3

4955

66

3

12

Paknoen

KhokYai

HouayDeua

Talan

76

62

Completed

Thadeua

PakkhonPakphai

Houaykheua

Pakhao

Khoktom

Hatxaykham

Pakmon

Paklan

Phonsavanh

Ongoing

• 612 household in 15 affected villages6 villages in Xayaburi side9 villages in Luang Prabang side

• Total 2,986 pp affected

• Social ArrangementSIA, RAP - Approved by GOL7 villages - Resettlement8 villages - Relocation684 new houses with InfrastructureCompensationCommunity Development ProgramLivelihoods Restoration ProgramIncome Generation Monitoring

How to design? How to build?

• We are not the first one who design and construct.

• We make technical visit to the on going project and successful project to overview what is the difficulty, problem, constraint, etcand adopt to our XHPP.

Technical Visit Xiangjaiba Dam, China.

Technical Visit Wulong Dam, China.

Technical Visit Tongzhilin HPP, China

Technical Visit St Stephen, SC, USA.

Technical Visit, Vattenfall - Geesthacht, Germany

Technical Visit, E.ON – Kachlet, Germany

Project Organization structure rev 01

Project Director Project Manager

Axillaries section support to the Project Manager

High Level Manager

FrontLinestaffs

Financial and Administration

ConstructionEngineering

Project control

ler

Construction Planning:

Project Planning

Rainy Season 2011July 11 – Oct 11

Qty = 1,010,000 m3

252,500 m3 /month

Rainy Season 2011July 11 – Oct 11

Qty = 1,034,000 m3Aug 11 = 318,000 m3

Sep 11 = 350,000 m3

Oct 11 = 366,000 m3

Dry Season 2012Nov 11 – May 12

Qty = 3,447,00 m3

NL = 32,600 m3

Nov 11 = 446,000 m3

Dec 11 = 566,000 m3

Jan 12 = 645,000 m3

Feb 12 = 653,000 m3

Mar 12 = 481,000 m3

Apr 12 = 316,000 m3

May 12 = 340,000 m3

Rainy Season 2012June 12 – Oct 12

Qty = 630,000 m3

June 12 = 104,000 m3

July 12 = 99,000 m3

Aug 12 = 141,000 m3

Sep 12 = 130,000 m3

Oct 12 = 156,000 m3

Dry Season 2013Nov 12 – May 13

Qty = 2,286,000 m3

IB = 360,000 m3

SW = 100,000 m3

NV = 143,000 m3

Nov 12 = 305,000 m3

Dec 12 = 440,000 m3

Jan 13 = 434,000 m3

Feb 13 = 414,000 m3

Mar 13 = 320,000 m3

Apr 13 = 210,000 m3

May 13 = 163,000 m3

Rainy Season 2013June 13 – Oct 13

SW = 173,000 m3

NV = 165,000 m3

Dry Season 2014Nov 13 – May 14

NV = 169,000 m3

SW = 158,000 m3

IB = 752,000 m3

Nov 13 = 10,000 m3

Dec 13 = 60,000 m3

Jan 14 = 60,000 m3

Feb 14 = 30,000 m3

Mar 14 = 14,000 m3

Qty = 174,000 m3

Rainy Season 2014June 14 – Oct 14

IB = 516,000 m3

Oct 14 = 100,000 m3

Dry Season 2015Nov 14 – May 15

Rainy Season 2015June 15 – Oct 15

June 15 = 150,000 m3

July 15 = 120,000 m3

Aug 15 = 100,000 m3

Sep 15 = 54,000 m3

Qty = 424,000 m3

Season 2016 ~ 2018

Excavation Schedule

Excavation Planning

Excavation Planning

Excavation Planning

Excavation Planning

Spoil area planning

Equipment planning

Construction Schedule

Navigation locks

(Sample)

Navigation Locks Construction

Working Group Arrangement

Manpower planning

Manpower Planning

Material planning•Concrete Peak Production = 170,000 cu.m. per month

•Aggregate Peak Production = 230,000 tons per month

•Crush sand production = 112,000 tons per month

•Cement delivery = 33,000 tons per month

•Fly ash delivery = 13,500 tons per month

Material planning

• Aggregate demand = 230,000 tons per month = Crushing plant capacity = 660 tons per hours (26 working day per month, production 8 hours per day, night shift for maintenance).

• Concrete demand = 170,000 cu.m. per month, = batching capacity = 330 cu.m. per hour (26 working day per month, operate 20 hours per day) plus peak variable 20% = 396 cu.m. per hour => select 120x4 cu.m. per hour. (1-mixer under maintenance).

• Peak period maintained 1-year.

Material planning

• Water usage for concrete at dry season = 92,000 cu.m. (5 month dry season).

• Aggregate Shade stockpile = 12 days at peak month.

• Cement Silo = 6000 tons = 8 days at peak month.

• Fly ash Silo = 3200 tons = 10 days at peak month.

EPC Cost Estimateand

Financial planning

Cost Estimate Structure:

• SA1

• SA2

• SA3

• E&M

• Process Material plants

• Engineering

• Indirect cost, Admin cost

Cost Estimate assumption

• Working time = 26 days per month and 2-shifts of 8+3 hours.

• E&M provide equipments, machine, etc with rental rate as shown in attached rental fee with condition.

• The Site Agent who use equipment must pay the rental fee to E&M. The fuel shall pay by Site Agent who use the equipments or machine.

• Fuel cost exclude tax 34 THB/liter.

• Reinforcement steel include transport 25,180 THB/ton.

• Rental fee ,operator ,maintenance ,workshop operation is include rental rate. (exception hydraulic crawler drill and vehicles )

Cost Estimate assumption (con.)

•Equipment rental rate ,transportation ,aggregate ,plant operation ,admixture ,cement is include concrete unit rate .

•Equipment rental rate ,plant operation is include aggregate unit rate .

•Development cost is not consider.

•Escalation Factor is not consider.

•Permanent Camp is exclude.

•Hauling distance consider as same as Nam Ngum 2.

•Staff compensation is exclude.

Scope of Works

•SA1 Scope of works:- Construction Facilities (Earth Work)

- Access, Hauling, Permanent Road

- Quarry works

- Common and Rock Excavation

- Slope Stabilization works

- Embankment, Rock backfill works

- Concrete leveling, Dental concrete, anchoring works

- Foundation treatment works (Sub-contractor)

- Grouting works (Sub-contractor)

- Instrumentation works (Sub-contractor)

Scope of Works

•SA2 Scope of works:- Temporary works; i.e. construction camp, workshop,

plants foundation, Yards construction, etc. (Structure Work)

- Concrete works, reinforcements, form works, water stop,

and others incidental works.

- Concrete back fill works.

- RCC

- Concrete works associated with the equipment and

system works. Installation of 1st stage embedded in

the first stage concrete. All second stage concrete.

- All required ladder, hand rail, fences, gate, all

architectural works.

Scope of Works

•SA3 Scope of works:- Supervision on Packages contractors.

- Supply and installation of cable duct, conduits, all

piping required, all pipes conveying from the different

powerhouse floors toward the drainage pits or to the

sewage treatment plant.

- Water supply, Water maker, waste water treatment

and its system

- Dewatering

- Construction area lighting service.

- All supply and installation on Electrical & Mechanical works

which not in scope of Packages contractors.

Scope of Works

•E&M Scope of works:- Supply and maintenance for all heavy equipments,machinery

(except batching plants, crushing plants, conveyor belts).

- Supply and maintenance for all light vehicles.

- Manage and control CSA contract i.e. Metro, Altas copco,

Italthai.

- Manage control use of spare part, lubricant, etc.

- Supply all equipments, machinery, vehicles, operators.

- Manage and control all heavy equipments, vehicles

investment.

- Transportation all equipments and production plant from NN2

Scope of Works

•Process Material Scope of works:- Process and supply concrete and shotcrete

aggregates.

- Process and supply nature sand.

- Transport concrete to pouring location by transit truck

mixer, conveyor belt, 10-wheel trucks, tower crane

use for concrete pouring, etc.

- Control quality of concrete, shotcrete.

- Operate and maintenance crushing plants, batching

plant, wet belt, ice plant, conveyor belt, truck mixer,sand dragging, etc.

Scope of Works

•Engineering:- Development on civil works design, drawings, shop drawings, as-built drawings, bar-bending, etc.

- Development and supervision on packages contractor design, drawings, shop drawings, as-built drawing, testing certificate,installation drawings, etc.

- Civil & Packages design interfaces works, interface drawings, combine drawings.

- Geological and geotechnical works.

- Survey works.

- Laboratory and material testing works, material submission.

- Information and Technology service., ERP, License

- Develop and Supervision on concrete mix design

Scope of Works

•Indirect cost, Admin cost- All staff salary (range higher than headman).

- All office expenses.

- All temporary construction expenses.

- All utilities expenses (not include IT expenses).

- All premium and tax expenses.

- Manage control use of fuel.

- Etc.

Preliminary cost estimate

Interim payment

Design Philosophy:

General Design Code:

• The most commonly referenced guidelines include those published by the following United States agencies:• US Army Corps of Engineers (USACE): Engineering Manuals, Engineering Pamphlets,

Regulations, Engineering Technical Letters.• US Bureau of Reclamation (USBR): Design of Gravity Dams, other publications.• Federal Energy Regulatory Commission (FERC): Engineering Guidelines for the Evaluation

of Hydropower Projects, other publications.

• In addition, other general design codes, design manuals and specifications to be considered will include as applicable:• Canadian Dam Association: Dam Safety Guidelines• American Concrete Institute (ACI)

• Recommended Practices.• American Society for Testing and Materials (ASTM): testing specifications.• International Committee on Large Dams (ICOLD): guidelines and recommendations.

Hydrology:

River Runoff recorded 46 years 1960-2006

Frequency of Flood Recurrences:

Tail water Rating Curve

Seismic Design Parameter (Original)

• Seismic Design Parameters

• Based on the seismic hazard map in the Feasibility Study Report, the Peak Ground Acceleration (PGA) at the project site is adopted as follows:

• The seismic loadings are calculated using the seismic coefficient method(pseudo static method) with the following seismic coefficients being applied:

• OBE, kh = 2/3 x 0.16 = 0.11 for unusual loading condition

• MCE, kh =2/3x 0.31 = 0.21 for extreme loading condition

Seismic EventRecurrence

Earthquake Designation Horizontal

PGA

500-Year Operation Basis Earthquake (OBE)

0.16 g

10,000-Year Maximum Credible Earthquake

0.31 g

Seismic Design Criteria:

• Xayaburi dam and reservoir are classified as large project with large damage potential, the dam and safety-relevant elements are designed for the worst earthquake ground motion to be expected at the dam site.

• Safety Evaluation Earthquake (SEE) ground motion have employed to the project.

Seismic Hazard Risk Assessment:

• Dr. Pennung Warnitchai has been studied PROBABILISTIC SEISMIC HAZARD ASSESSMENT • 29th October 2010

• Dr. Noppadol, Dr. Panya, Dr. Supot as Seismic Hazard Risk Assessment Expert Team, have been reviewed and interpretation of aerial photos, satellite images, reports and papers with respect to crustal faults and active faults around Xayaburi dam site

• Field geologic and paleo-seismic investigation of the area and site verification of active faults by trenching and dating of young sediments around fault planes.

• Update deterministic seismic hazard analysis include hazard curves showing contributions of various earthquake sources and various periods, horizontal and vertical uniform hazard response spectra for various return periods such as 145, 475, 2475, and 10,000 years, and Acceleration Response Spectra with acceleration time histories• 30th Sep 2011/18th Oct 2012

Seismic Hazard Risk Assessment:

• Comparison between the DBP fault segments (red lines) delineated by the SHRA team and the modeled fault lines of DBP North, Central, and South sections (pink, green, and black lines, respectively). The Xayaburi project site is illustrated by a yellow pin.

• Based on Geographical Hazard Deaggregation(Harmsen and Frankel, 2001) for the project site, the earthquake scenario selected for Deterministic Seismic Hazard Analysis (DSHA) is set to an Mw 6.8 earthquake with a focal depth of 5 km at Nam Huang segment (about 8 km from the project siteใ

Comparison Seismic design Parameter.

Deterministic

Return Period PGA (g)

145 0.060

475 0.110

2475 0.240

10000 0.440

Deterministic (84th

percentile)

0.440

Original (Probabilistic)

Seismic EventRecurrence

Earthquake Designation Horizontal

PGA

500-Year Operation Basis Earthquake (OBE)

0.16 g

10,000-Year Maximum Credible Earthquake

0.31 g

Plant Safety Concept against Seismic

• Establish priorities structure taking into account the impact of failures during and after quaking events on the plant itself and on the public safety / environment, particularly downstream of the plant; and the possibility, difficulty and cost of damage, repair of structures and hydro/electro-mechanical components. • First Priority: Mainly to the Upstream part of structures.

• Upstream part of Navigation lock

• Spillway

• Power Intake structure

• Second Priority: Mainly to the downstream part of structures

• Third Priority: Mainly to the equipment unlikely to be in use during an earthquake.

Geology and Geological condition.

• Geotechnical design of the Xayaburi Hydropower Project, the geology has been divided into several rock mass classes and assigned geotechnical parameters. This classification is based on the classification by Marinos and Hoek (2000).

• Due to the high variability of each rock mass on site and for a simplified presentation of the geology, the rock masses are divided as follows: • Carbonate rock mass (muddy limestone, and crystalline Limestone )

• Coarse grain clastic dominated rock mass (Meta-sandstone)

• Fine grained dominant rock mass (Phyllite)

• Sheared rock-mass (Graphitic Phyllite)

Original exploratory holes

Geological Map of the Project

Geological Map of the Project

• Plan view Quartzite, Meta Siltstone, Meta Sandstone

Phylite and graphitic sheared

Volcanic rock

Phyllite schist

Crystalize limestone

Physical Model Test

Sample of tests.

Navigation Lock flow pattern LLO: Negative and flow condition test

Construction of XHPPFirst Stage Construction

Construction Schedule

1. Preparation phase2. 1st stage construction phase (complete in Jan 2015)3. 2nd stage construction phase (complete by end October 2019)

Preparation Phase.

Key Project Quantities

• Construction of access road 25 km.• 115kV transmission line and site

substation.• Camps, utilities, and community

facilities, • Procurement and installation of

Crushing Plant.• Procurement and installation of

Batching Plant.• Installation of plants and yards.

• Prepare lifting device; Tower crane

• Quarry Development

Access road 25 km

Previous DBST

Crushing Plant

Previous

2 Plants design capacity 660 tons/hr. each aggregate 63, 38, 19, 9.5 and artificial sand.

Batching Plants

Previous

Batching Plant equipped with wet belt aggregate cooling system, and ice/ ice water plant (2 plants/4 mixers, capacity of 240m3/h each)

Quarry Development and Operation

Construction Facilities

Rebar yard (Total area 18,950 sq.m)Carpenter yard (Total area 21,920 sq.m)

Construction Facilities

Equipment maintenance Workshop Precast yard

Camps and Facilities

Previous Camps for 11,000 persons.

Camps and Facilities

Emergency Medical Facility – 24 hour servicing first aid, stand-up ambulance Main Office

First Construction PhaseNovember 2012-January 2015

• Construction of the upstream and downstream first stage cofferdam , of the navigation facility , of the spillway , and of the part of the intermediate block on the right bank while the river will keep flowing in its natural dry season channel

Official Construction in the Mekong River

Ground Breaking ceremony 7th November 2012

Navigation Lock

Spillway

Spillway

Trouble and Solution:

• Late Start Construction resulted from Revised Design.• Acceleration plan, increase manpower and equipment

• Unforeseen Geological condition at Navigation lock excavation • Flatten excavation slope resulted to more excavation quantities.

• Dry Season Flood with more than 200 years recurrences' period on 17th

December 2013• Flood to Construction site resulted to pending on construction for 4 weeks.

• Unforeseen underwater Mekong Geology• Prepare alternative design and implement immediately.

• Difficulty on River Closure.• Prepare adequate stockpile for Big Riprap for River Closure.

Conclusion:

•The Project is able to modified the design to meet all requirements of the Owner.

•The Construction able to made accelerate to meet key date with short noticed.

Completion of the First Stage ConstructionRiver Diversion ceremony 26th January 2015

Conclusion:

2nd Construction Phase.

The 2nd stage will consist of completion of the intermediate block construction of the intake powerhouse complex, fish passing facilities and 500kV transmission line. This stage will start with the construction of upstream and downstream embankment cofferdam across the river once the navigation facilities and the spillway are ready for operation.

Construction Activities 2nd Stage Construction-initialJune 2015

Construction Activities 2nd Stage Construction before impoundingOctober 2018

Construction Activities Operation stageOctober 2019

Question?