Water Power and Dam Construction

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32 MAY 2009 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

60TH ANNIVERSARY

IPING

UANG

, S

ENIOR

YDROPO WER

EOTECH NICAL

NGINEE R

, P

ROJECT

ANAGER

The largest hydro power project in the

world – Three Gorges – has been devel-

oped in China. However, modern hydro

development in China started back in 1984

when the government decided to us e a

World Bank loan to construct the Lubuge

hydro power project on the Huangli River,

southwest China. The project was the first

in the country to call for international bids

for construction work – specifically on the

headrace tunnel. A Japanese com pany,

Taisei Corporation, won the bid and com-

pleted the project successfully, five months

ahead of schedule. Norwegian and

Australian consultants also worked on the

underground powerhouse and the dam.

The foreign contractor and consultants

brought new con cepts of project

Management to the construction sector in

China. In the 1980’s, the experience gained

at Lubuge contributed greatly to China’s

deeper reform and open policy.

China was on its way to modernization,

and the construction of the Ertan hydro

power project is a great milestone in this

process. Ertan was the largest hydro pro-

ject com pleted in the 20th century in

China. The project has an installed capac-

ity of 3300MW, and features a 240m

double-curvature concrete arch dam and

a 280m(L) x 25.2m (W) x 65m (H) under-

ground powerhouse. Construction began

in 199 1 and the fir st generator com-

menced operation in August 1998. It was

well planed, designed and constructed. A

US$930M World Bank loan was used for

construction and thu s international con-

struction and suppliers were involved.

Over the relatively long constructi on

period, Chines e engineers were educ ated

in international m ethods of construction

work, including competitive bidding, con-

struction management based on FIDIC

contract conditions, and advanced c on-

struction technology, inc luding under-

ground engineering.

The Three Gorges project is so far the

largest hydro power project in the world,

and has probably experienced the heaviest

disputes internationally. The total installed

capacity of the project is 22,400MW with

annual production of ab out 100TWh.

Construction began in 19 93, with a

planned schedule of 17 years. The dam

reached it s designed height of 185m in

May 2006, approximately one year ahead

of schedule. This project is a great engi-

neering achievement in hydro industry.

Email: ziping.huang@norconsult.com

. S

IEGBERT

TTER

CTO

AND

ÜRGEN

EHNBRU CH

CMO OF

OITH

YDRO

One of the most significant changes of the last 50 to 60 years was

the formation of contractors capable of providing electrical and

mechanical turnkey solutions for hydro power plants. Half a cen-

tury ago, this spectrum was covered by a multitude of different

sized companies; then the business experienced two waves of con-

solidation in the 1960s and just before the turn of the Millennium.

Nowadays there are less, but therefore economically and techni-

cally strong global players serving the worldwide hydro market.

Voith Hydro, the joint venture of Voith (65% share) and Siemens

(

35% share), is one of them. We joined forces in order to supply

complete hydro power plant solutions, and to offer moderniza-

tion and services from one source.

In the 1950s, 60s, and 70s, the markets in South America and

Asia became sensitized for hydro power, and namely Brazil was

one of the first countries in that area showing an interest in devel-

oping its tremendous hydro power potential. Japanese companies

focused especiall y on Asian market s, including India and the

Pacific region. It was not until the Chinese market started to open

up that Western companies were able to participate in major pro-

jects there, such as Three Gorges. In the meantime, mature hydro

power markets offer large potential for modernization projects.

Quite a n umber of large new pr ojects ar e planned in emerg ing

markets who need to meet their increasing energy needs, and, at

the same time, cope with issues of low-carbon energy generation.

A major issue that has had quite an impact on the hydro busi-

ness is the importanc e of sustainabl e energ y generation. I n the

public perception, eco-friendly power generation is becoming more

and more important, including hydro power and especially small

hydro power, so many manufacturers have intensified their efforts.

Today, the planning and construction of large projects is pro-

ceeding with an increased sensitivity of environmental and social

impacts. Voith Hydro and the Hydropower Equipment

Association (HEA) strongly support the Sustainability Guidelines

and the ongoing Hydropower Sustainability Assessment Forum

process of the International Hydropower Association (IHA).

We have long been involved in dialogue w ith conservation

groups and NGOs. In conjunction with an Indian customer and a

respected global environmental protection agency, a specific hydro

power project has, for the first time, been assessed on a trial basis

on the grounds of the current Sustainability Assessment Protocol

of the IHA. It was not our first, but certainly a very important step

on the way to reconcile impacts of hydro power with new criteria

for sustainability and help to grow awareness of these issues.

As for the most important technical developments of the last 60

years, it is almost impossible to refer to only one advancement.

The development of the output capacity as shown in the figures

above, however, is proof of the many R&D developments which

have taken place to technically support such a tremendous increase

in the output capacity of a single turbine-generator unit. And this

doesn´t seem to be the end; the not-too-distant future will bring

us the 1000MW unit which again will be a tremendous historical

step. Of course we are proud to have written this history ourselves

many times and we will continue to do so in the future

IWP&DC has observed and accompanied all of these develop-

ments over the last 60 years. Happy birthday, IWP&DC!

www.voithhydro.com

900

800

700

600

500

400

300

200

Rating (MW)

1960 19801970 2000 20101990

Year

Itaipu

(Brazil/Paraguay)

Three

Gorges

(China)

Longtan (China)

Xiao Wan (China)

Guangzhou II

(China)

Ilha Solteira (Brazil)

Itaparica (Brazil)

Bath County (USA)

Gordon

(Australia)

Paulo

Afonso II

(Brazil)

Gokcekaya

(Turkey)

Dworshak

(USA)

Xi Luo Du

(China)

Ingula

(South

frica)

Limberg II

(Austria)

urbines

ump-turbines

1890 1930 19501910 1990 20101970

Year

1000

900

800

700

600

500

400

300

Rating (MVA)

Water cooled

Air cooled

Motor-generators

taipu

(Brazil/Paraguay)

Guri II

(

Venezuela)

Three Gorges (China)

Paulo Afonso IV (Brazil)

Helms(USA)

Samrangjin (South Korea)

Wehr (Germany)

Rotlau/Malta (Austria)

Vianden (Luxembourg)

El Chocon (Argentina)

Furnas (Brazil)

Suiho (China)

Herdecke (Germany)

Necaxa (Mexico)

ath County (USA)

Raccoon Mountain (USA)

ADVERTISEMENT FEATURE

Since 1956 when Krøll Cranes A/S was established it has been

involved in hydro power plants including some of the larges hydro

power plants in the world. In the early 60’ Krøll tower cranes model

K60 and K80 wor ked on the construction of Itaipu on the border

etween Brazil and Paraguay, at that time 60 and 80 ton-meter tower

cranes was considered to be heavy tower cranes. In the mid 80’ Krøll

Cranes supplied two K550 for the larges hydro power plant in New

Zealand at Clyde, one K550 was working on the powerhouse where

the other K550 was engages on the concrete dam, the capacity of

the Clyde hydro power plant is 432 MW. On the North American con-

tinent Krøll has been involved in a number of power plant project

including Ontario Hydro in Canada here a number of K200 and K400

was supplied. Naturally when the China become more concrete in

the design and planning, in the early 80’, of the 3 Gorges Dam, Krøll

Cranes was asked for advices and suggestions with respect to lifting

and crane solutions. For a period of almost 15 years Krøll was deeply

involved in the detailed planning of concrete placing and heavy lift-

ing on the 3 Gorges dam, K1800 with a maximum capacity of 60

tons has been engages during the construction. Krøll Cranes, as the

most experienced company in heavy lifting tower cranes, is a obvious

choice for heavy lifting solutions for hydro power dams as well as any

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are essential for the completion of the project.

Hydro Power plants

and Krøll Cranes

34 MAY 2009 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

60TH ANNIVERSARY

Dam good celebrations

IWP&DC invited member countries of ICOLD to join in with our 60th anniversar y

edition, and help celebrate the international construction of dams over the

past 60 years. So which dam did the following ICOLD committees believe

to be their country’s most important since 1949?

The Sellrain-Silz hydro power scheme is sit-

uated in the Austr ian province of Ty rol,

40km west of the capital Innsbruck. It was

constructed in 1977-1981 fo r Tiroler

Wasserkr aft AG (TIWAG), who designed

the scheme, produced the plans and super-

vised the works.

The main structure of the complex is the

150m high Finstertal embankment dam,

located at an altitude of 2325m asl, which

creates a seasonal water reservoir with an

active storage capacity of 60 Mm³. The

rockfill dam was built from 1977-80.

Difficult climatic conditions, at an altitude

of over 2300m, meant that construction

work was only possible on around 100

days in the year.

Of the dam types investigated for the

site, including concrete wall designs, a

rockfill dam with an asphaltic concrete

core membrane and steep slopes (1:1.5 on

the water side and 1:1.3 on the air side)

proved to be the most cost-effective solu-

tion. Such a design also blends in well with

the mountain scenery and with the nearby

winter tourism centre of Kühtai.

More than two-thirds of the foundation

contact area of the dam was only thin cov-

ered bedrock, while the re maining area

(especially the left upstream abutment) was

covered wi th an ov erburden of moraine

material up to 20m thickness. On the basis

of large-scale laboratory tests, conducted to

improve the key between the rockfill and

the smooth bedrock polished by the abra-

sion of the glaciers , notches were blasted

into the r ock with an averag e depth of

70cm over an area of 20,000m².

Thanks to its favourable situation on the

projecting rock, the core membrane only

needs to be 96m high. The thickness of the

core membrane that inclines to the air side

is 50-70cm. The design moreover ensures

that the core membrane receives addition-

al support from the shoulders, so that there

is little risk of undesirable deformation

occurring.

The total dam volume amounts to

4.6Mm³. Seven fill zones of the dam mainly

consist of blasted material (granodiorite

gneiss); only 20% of the dam volume is

moraine material from the overburden of

the quarry area. In order t o optimise the

compaction of the material deposited, the

height o f the layers was limited to 7 5cm,

the material was kept moist and vibrating

roller compactors were used.

The dam surveillance system comprises a

total of 793 measuring points for monitor-

ing external and internal deformations,

pore water pressure, earth pressure, tem-

perature, response acceleration and seepage

water losses. An unusual feature for an

embankment dam is the construction of an

accessible shaft, which permits monitoring

of the core and surrounding a r e a s . It was

constructed of precast conc rete rings,

embedded independently of each other in

the fill in two staggered sections to take

account of the inclination of the core mem-

brane. This shaft accommodates two pre-

cision plumb-lines, permitting continuous

telemetering of crest and centre zone deflec-

tions and the orderly routing and arrange-

ment of all lines and cables to the

monitoring chamber. Besides typical instru-

ments (fluid level settlement devices, exten-

someters etc.), a new type of magnetic

deformation gauge for measuring the thick-

ness of the asphaltic core me mbrane was

also installed in the shaft.

The Finstertal dam has operated without

a hitch over 28 years – an obvious confir-

mation o f the soundness of t h e principles

on which i t has been des igned. Surface

deformations, with maximum settlements

of 38cm and maximum horizontal deflec-

tions of 19cm, are of a magnitude that

would hardly have been considered possi-

ble with earlier rockfill dams of such a

height. Total seepage water losses through

the 37,000m² core membrane surface were

only 9l/sec on first filling, and declined to

1.5l/sec by the end of 2008.

Austrian National Committee on

Large Dams

AUSTRIA - F

INSTERTAL DAM

The Finstertal dam is the main structure of

the Sellrain-Silz-hydro power scheme in

Austria. This embankment dam, nearby the

Kühta i tourism centre, will be one destina-

tion of the technical excursions during the

8th ICOLD European Club Symposium (21–24

September 2010 in Innsbruck, Austria)

60TH ANNIVERSARY

WWW.WATERPOWERMAGAZINE.COM MAY 2009 35

Owned by Dwr Cy mru/Welsh Water and

completed in 1972, the 91m high Brianne

dam is the highest dam in the UK. It has a

rugged appearance that blends well with

the rocky valleys in this part of Wales and

the true beauty of the dam lies in the sim-

plicity of its design – a symmetrical central

rolled clay core supported by shoulders of

compacted rockfill.

The Towy Scheme was selected to pro-

ide a major water supply for Swansea and

the rapidl y expanding industrial area of

South Wales. Direct supply reservoirs were

then out of favour and a large river reg u -

lating re servoir was required in the head-

waters of the River Towy to support the

abstraction for the scheme at the tidal limit

of the rive r downstre am. The site of

Brianne dam was a rock gorge but the left

abutment was intersected by a major fault

plane and a rockfill embankment dam was

selected as the most appropriate structure.

The dam has a number of unique features.

The rock in the area is highly cleaved

slatey muds tone of Silurian Age. Such a

rock type had not previously been used in

high rockfill embankments. The core was

to be formed of boulder clay which would

be placed in wet conditions and would be

highly deformable within the stiff rockfill

shoulders of the embankment.

In l968, when the dam was being

designed, embankment dams were being

analysed by the semi-empirical method of

limit state design. Essentially this assumed

failure surfaces through the embankment,

as signed shear stre ngth to the materials ,

assumed equal strain and sought to estab-

lish factors of safety against failure. With

widely differing materials, usually having

non-linear stress/strain relat ionships, it

was not possible to predict the emb ank-

ment deformation when fully loaded by

the reservoi r water. It was found e mpir i-

cally that, with factors of safety usually in

excess of 1.4, the deformation w ould be

acceptable.

The designer, Bill Carlyle of Binn ie &

Partners, felt that it was unsatisfactory

that such a large and potentially danger -

ous structure should be constructed when

it s deformation under fully applied load

could not be predicted. Thus Brianne dam

was equipped with a unique array of

instruments to measure stress and strain

within the embankme nt during construc-

tion and subsequent reservoir filling. The

data from these instruments has been pub-

lished and widely used in the development

of finite element analysis methods for

emban kment dams and is now rou tinely

used in design.

The contract for construction provided

for the design engineers to retain full con-

trol of the embankment fill operation, spec-

ifying the compaction control and fill mois-

ture content and operating the on-site lab-

oratory to do so.

The dam has proved to be entirely satis-

factory in operation for its first 37 years of

life. The design and construction of Brianne

reservoir demonstrated that a major dam

can be engineered without compl ex solu-

tions to provide a durable and re liable

structure t hat will benefit the people of

Wales for many decades by provid ing

water, power and a popular amenity.

British Dam Society

WALES – B

RIANNE DAM

The Al Wahda dam is in many respects the

pride of the Kingdom of Morocco in the

mobilisation of water resources. This 88m

high, 2600 m long dam has a storage

volume of 3800Mm

Since swinging int o full operation in

1997 the dam has fulfilled its functions of:

• Protecting the rich and vast plain of the

Gharb against floods which occur on aver-

age every two years.

• Producin g 400GWh of hydro power,

especially during peak hours.

• Supplying drinking water for the sur-

rounding cities.

• Contributing towards national solidarity

by transferring water to the deficit south-

ern basins.

The Al Wahda dam symbolises the

efforts of the late King Hassan II to

mobilise water and aid agricultural devel-

opment within the country. It represents

the culmination of the country’s dam

policy undertaken since the mid 1960s. It

must also be remembered that the dam was

completed successfully during a period

characterised by an unfavourable attitude

to the financing and construction of inter-

national dams.

Morroccan Committee on large

Dams

MOROCCO – A

AHDA DAM

Photo by Aled Hughes

36 MAY 2009 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

60TH ANNIVERSARY

The Menta dam is located on the river

Menta in the Calabria region of Italy. The

90m high, zoned earthfill dam has a bitu-

minous concrete multilayer membrane on

the upstream face.

Constructed in 1998 its main purpose is

to supply dr inking water to the town of

Reggio Calabria. It also has a hydro power

capacity of 22 .5MW. The hydro produc-

tion is connected to the high available head

between the reservoir, the treatment plant

and the supply zones.

Menta dam was built within the slopes

f the Aspromonte of the Cabride Complex

inside the Aspromonte Na tional Park, in

order to assuage the chronic shortage of

water of the Calabrian peninsula.

The works for the dam were completed

in spite of many technical and economic

difficulties. The ancillary works, namely all

he diversion and distribution works, were

delayed due to political and economic dif-

ficulties. Now, at last, all those are nearing

the completion, and in a few months it will

be able to supply Reggio Calabria with a

first phase of 250 litre/sec of drinking water,

and shortly after, all the scheme will be fully

operational.

Comitato Italiano Grandi Dighe

ITALY - M

ENTA DAM

Wolwedans dam is a 70m h igh RCC

arch/gravity dam situated on the Great

Brak river near Mossel Bay in the Southern

Cape, So uth Africa . The dam, owned by

the Department of Water Affairs and

Forestry ( D WAF) , was designed and con-

structed in-house by DWAF and completed

in 1989. The dam provides water for indus-

trial use.

This was the world’s first arch-gravity

RCC dam . Other unique features include

groutable joints and a stepped spillway

with a relative short apron (the latter was

confirmed with model studies at the time).

The dam was instrumented quite exten-

sively to monitor temperatures and defor-

mation pattern across all the joints.

With a downstream slope of 0.5H:1V the

dam has to rely on arch-action for stabili-

ty. Shrinkage of the RCC and the associat-

ed cracks would therefore pose serious

problems especi ally with respect to a rch-

action if they are not grouted. A groutable

system of induced crack joints was devel-

oped by engineers of DWAF to overcome

the problem.

South African National Committee

on Large Dams

SOUTH AFRICA - W

OLWEDANS DAM

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38 MAY 2009 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

60TH ANNIVERSARY

IWP&DC would like to thank the above member countries of ICOLD for their contribution to this feature

Switzerland participated in the foundation

of the International Commission on Large

Dams in 1928 in Paris. It was represented

by the Swiss Commission o n Dams, a

board of five famous Swiss engineers; pio-

neers in the design and construction of large

concrete dams.

Contractors, dam owners and operators

joined the dam experts of the Commission

in order to found the Swiss Nat ional

ommittee on Large Dams in 1948 . The

Committee wa s constituted as a profes-

sional as s o c i at i o n , which is still its actual

status. In 2000, the Committee changed its

name to Swiss Committee on Dams,

expressing its interest to not only focus on

large dams, but on all aspects related to all

size of dams and their reservoirs.

There are 205 large dams in operation in

Switzerland according to ICOLD criteria.

Forty-eight of them exceed 60m height and

25 are more that 100m high.

Grande Dixence dam was completed in

1961. It is the highest dam in Europe and

the highest concrete gravity dam in the

world. This dam, with a crest elevation of

2365m asl in the Alps, is the key structure

of a huge hydro power scheme including

more than 100km of water transfer tunnels,

75 intakes on mountain streams, four other

dams for water transfer, four underground

powerhouses with a total installed capaci-

ty of 2100MW and five pumping stations.

Mauvoisin, Luzzone and Co ntra arch

dams are more than 200m high. Mauvoisin

and Luzz o n e arch dam were b o t h height-

ened in the 1990s in order to increase their

reservoir volume.

The Swiss Committee on Dams is strong-

ly represented in ICOLD Technical

Committees with highly skilled experts in

all domains of dam engineering and man-

agement. It has also established several

working groups with the aim to summarise

and to describe the state of the art of the

Swiss experience on the behaviour, surveil-

lance and maintenance of dams.

Presently, dam construction act ivity is

limited in Switzerland as in most Alpine

countries. However, severa l projects of

rehabilitation, upgrading and heightening

of existing dams are currently being stud-

ied and will be implemented in the future.

The evol ution of the E uropean

Interconnected Electricity Market and the

fast growth of wind energy may also lead

to a new age of hydropower construction

in Sw itzerland with a focus on pump ed

storage for the coming decades.

Swiss Committee on Dams

WITZERLAND – G

RANDE

IXENCE

Grande Dixence gravity dam with a height of 285m (pictures by Heinz Preisig)

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ts 60th and Muhr its 50th

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congratulate on the 60th anniversary!

2009 – year of anniversaries!

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ADVERTISEMENT FEATURE

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Renewable Energy from Treated Effluent

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Design of the Floating Surface Collector

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As a condition of its new license for the Swift No. 1 Hydroelectric

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determine that the powerhouse intake channel would be the most

attractive to migrating salmonids.

The Swift FSC will be an all-welded steel structure, 170 feet long

with a 60-foot beam, 28-feet tall and an operating draft of 22 feet.

On-board pumps will generate flows to attract fish into a channel

leading into three zones: a primary screening area, a secondary

screening area and a sorting and sampling area. The structure will

be fabricated as a series of modules for transportation to the

planned assembly site near the head of Swift Reservoir.

Innovative Surge-Shaft Liner Installed Under Water

The Middle Fork Surge Shaft Rehabilitation Project used an

innovative approach solution for the cracked concrete lining of a

10-foot-diameter surge shaft without dewatering the shaft. The

600-foot-deep surge shaft of the Middle Fork American River

Hydroelectric Project had longitudinal cracks in its original non

reinforced liner.

The project is owned and operated by Placer County Water

Agency (PCWA). Pacific Gas & Electric Company partnered with

PCWA as financer and power purchaser for the project. Leakage,

coupled with intense rainfall in January 1997, contributed to the

mobilization of a debris flow that ran down the adjacent hillside

into the river and filled the Middle Fork Interbay with sediment,

making the turbine/generator units inoperable.

The liner was successfully constructed in 2007 and has reduced

groundwater levels around the shaft to natural pre-project

elevations. Key to the success of this project was the effective

collaboration among Black & Veatch, project designer; Kiewit

Pacific Company, project constructor; PG&E, project financier and

power purchaser; and PWCA, project owner.

For additional information about this project, please see the

related feature in the June issue of this publication.

Merwin Dam Fish Collection Facilities

In accordance with the Lewis River Hydroelectric Projects FERC

licenses, anadromous fish runs were reestablished upstream of

the Merwin, Yale, and Swift Dams on the Lewis River, owned and

operated by PacifiCorp. Because Merwin Dam is the most

downstream project on the river, the design of efficient adult fish

passage facilities were essential for successful reestablishment of

the fish runs.

To achieve a high fish-attraction efficiency, the design team

strategically relocated fish entrances, determined the optimum

fish attraction flow ranges and optimized trap entrance geometry

and hydraulics to produce a strong discharge jet to attract

migrating fish.

Goals of the new fish passage system improvements included

higher attraction flows at the fishway entrance, the ability to

operate the system under an expanded flow range and automation

of fish loading into an elevator system for relocation.

CONTACT: Carlos E. Araoz, Vice President, Hydropower and

Hydraulic Structures Director, araozc@bv.com, (1) 916-858-

2433 (www.bv.com)

Black & Veatch Hydropower & Hydraulic Structures:

A History of Success and a Hand in the Future

Water Power and Dam Construction - Issue May 2009

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