KATHMANDU UNIVERSITY

DEPARTMENT OF CIVIL ENGINEERING

INTERNSHIP REPORT ON
SUPERMADI HYDROPOWER PROJECT (44 MW)
REPORT PREPAREDARED BY:
Anup Gautam REG: 022511-17
Arbin Kc REG:022514-17
UNG, Civil engineering 4th year

REPORT SUBMITTED TO:

BIRAJ BHANDARI(SITE SUPERVISOR)
SUDIP BAJAGAIN(INTERNAL SUPERVISOR)
DEPARTMENT OF CIVIL ENGINEERING ,KU
SUPERMADI HYDROPOWER LTD,KATHMANDU

Date: 2021/11/17
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ACKNOWLEDGEMENT
First we would like to express our sincere gratitude to the Department of Civil Engineering, Kathmandu
University for providing us this opportunity to seek and grab practical knowledge from site and making
us familiar with expected futuristic condition.
We would like to thank Supermadi hydropower ltd and ER Padam Pokhrel for giving us the opportunity
to do an internship within the organization. We also would like all the people at the camp that worked
along with us with their patience and openness. It is indeed with a great sense of pleasure and immense
sense of gratitude that we acknowledge the supervision of Er. Biraj Bhandari at the hydropower site.
We would also like to thank Er. Sudip Bajagain for his supervision throughout our internship. We
would like to thank Er. Santosh Chaudhary, College internship coordinator for his support and advices
to get and complete internship in above said organization and for assisting us with all the necessary
details and documents. We extremely great full to my destaff members and friends who helped me in
successful completion of this internship. Finally, we are extremely great full to all technical and non-
technical members related to this venture directly or indirectly and helping us through our internship.

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SYMBOLS & ABBREVIATIONS
Amsl Above mean sea level
d/s Downstream
EIA Environmental Impact Assessment
GPS Global positioning system
HRT Head Race Tunnel
HW Head Works
km Kilo meters
m Meters
MW Megawatt
NEA Nepal Electricity Authority
PH Powerhouse
RoR Run of River
SMHEP Super Madi Hydroelectric Project

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Contents
1. INTRODUCTION .................................................................................................................................1
1.1 BACKGROUND .............................................................................................................................1
1.2 OBJECTIVES ..................................................................................................................................1
1.3 SCOPE .............................................................................................................................................1
1.4 ABOUT PROJECT..........................................................................................................................1
1.5 LOCATION AND ACCESIBILITY ...............................................................................................2
2. LITERATURE REVIEW ......................................................................................................................9
2.1 HEADWORKS ................................................................................................................................9
2.1.1 Weir ..........................................................................................................................................9
2.1.2 Undersluice ...............................................................................................................................9
2.1.3 Fish Ladder .............................................................................................................................10
2.1.4 Intake Structure.......................................................................................................................10
2.1.5 Gravel Trap .............................................................................................................................10
2.2UNDERGROUND WORKS ..........................................................................................................10
2.2.1 Head Race Tunnel (HRT) .......................................................................................................10
2.2.2Settling Basin...........................................................................................................................11
2.2.3Adit-I .......................................................................................................................................11
2.2.4Adit-II ......................................................................................................................................12
2.2.5Surge shaft ...................................................................................................................................12
2.3 Penstock .........................................................................................................................................12
2.5 Powerhouse ....................................................................................................................................12
2.6 TUNNELING ................................................................................................................................13
2.6.1 NORWEGIAN METHOD OF TUNNELING (NMT) ...........................................................13
2.6.2 ROCK MASS CLASSIFICATION AND ROCK SUPPORT ...............................................13
3 DETAIL OF INTERNSHIP PROJECT ACTIVITY............................................................................16
3.1 SADDLE SUPPORT .....................................................................................................................16
3.2TUNNEL EXCAVATION CYCLE ...............................................................................................18
3.2.1Drilling.....................................................................................................................................18
3.2.2 Loading and blasting ..............................................................................................................19
3.2.3 Dislodging ..............................................................................................................................20
3.2.4 Geological mapping ................................................................................................................20
3.2.5 Support Works ........................................................................................................................20
3.3 ROCK SUPPORTS IN TUNNEL OF SMHEP .............................................................................20
3.3.1. Rockbolts ...............................................................................................................................20
3.3.2 Shotcrete .................................................................................................................................21

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 3.3.3 Steel ribs .................................................................................................................................22
3.3.4 Spilling....................................................................................................................................22
3.4 LABROTARY WORKS ...............................................................................................................25
3.4.1 Concrete Mix design/ trial mix ...............................................................................................25
3.4.2 Slump test ...............................................................................................................................25
3.4.3 Compressive strength test .......................................................................................................25
3.5 CALCULATION OF CONCRETE QUANTITY AND FORM WORK REQUIRED IN
SADDLE SUPPORT ...........................................................................................................................26
3.6 WORK PROGRESS DURING INTERNSHIP .............................................................................27
4 CONCLUSION ....................................................................................................................................28
5 BIBLIOGRAPHY ................................................................................................................................29
6 APPENDICES ......................................................................................................................................30

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LIST OF FIGURE
Figure 1 Madi river ....................................................................................................................................2
Figure 2 Watershed mapping of project ....................................................................................................3
Figure 3 Hydropower Camp ......................................................................................................................3
Figure 4:Headworks ..................................................................................................................................9
Figure 5 Fish ladder .................................................................................................................................10
Figure 6 Headrace tunnel .........................................................................................................................11
Figure 7 Penstock pipe ............................................................................................................................12
Figure 8 Preparation of cube ...................................................................................................................16
Figure 9 Compressive test .......................................................................................................................17
Figure 10 Use of vibrator in saddle support ............................................................................................17
Figure 11 Tunneling ................................................................................................................................18
Figure 12 Blasting pattern .......................................................................................................................19
Figure 13 Rock bolt .................................................................................................................................21
Figure 14 Steel ribs ..................................................................................................................................22
Figure 15 Tunnel support type.................................................................................................................24
Figure 16 Calculation of concrete quantity .............................................................................................26
Figure 17 Campsite ..................................................................................................................................30
Figure 18 Outletportal HRT ....................................................................................................................31
Figure 20 Batching plant .........................................................................................................................31
Figure 19 Crane .......................................................................................................................................31
Figure 21 Tailrace cannel ........................................................................................................................31
Figure 22 Construction of powerhouse ...................................................................................................32
Figure 23 Installation of formwork in surge tank ....................................................................................33
Figure 24 Saddle support .........................................................................................................................34
Figure 25 Anchor block ...........................................................................................................................35
Figure 26 Steel fibre used in shotcreting .................................................................................................35

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1. INTRODUCTION
1.1 BACKGROUND
During the eighth semester of engineering and science academic programs, Kathmandu University offers
internships at various locations. Students in Civil Engineering (Hydropower Specialization) are required
to complete a 6-week (45-day) internship at a hydropower site as per convenience of the students. The
internship carry 3 credits of 8th semester academic evaluation which shall be carried out by the
department of Civil Engineering in association with intern host company and external supervisors. The
main objective of internship is to make the students of hydropower to be submersion into the professional
world of hydropower company, acknowledge the goals set by company in its processes and application
of the knowledge acquired during the university years
1.2 OBJECTIVES
As per “Guidelines for Conducting Internship and Final Project Work-2013”
• To expose the interns with engineering duties and responsibilities.
• To develop the proficiency to function in diverse engineering and managerial settings based on
core knowledge, skills, attitudes and aptitudes acquired during the in-campus Semester.
• To make the interns aware of engineering norms, values and ethical practices.
• To acquaint the interns on how to educate and motivate clients about the activities of Host
• Organization.
1.3 SCOPE
As per “Guidelines for Conducting Internship and Final Project Work-2013”
• To be involved in the day-to-day work as instructed by the supervisor from the Host Organization.
• To document the day-to-day activities in a weekly format.
• To assist the supervisor and to be in consistent communication with the supervisor to accomplish
the objectives he/she may put forward within the period of internship.
• To utilize all the theoretical and practical knowledge gained by interns in order to solve the
problems faced by the Host Organization under the instruction provided by the supervisors.
• To accomplish engineering and managerial tasks required by the supervisors under engineering
norms, values and ethical practices.
• To demonstrate that the intern has the attitude and aptitude to grasp all necessary fundamentals
to become a fully well-groomed professional

1.4 ABOUT PROJECT

Super Madi Hydroelectric Project (SMHEP) is a Run-of-River (RoR) type project located in Madi River
at Kaski District of Madi Rural Municipality, Gandaki Province, Nepal. The entire project components
are located along the left bank of Madi River within Madi Rural Municipality (Previously Parche and
Namarjun Village Development Committees) of Kaski district
Diversion weir with undersluice, intake arrangement, subterranean settling basing, headrace tunnel, surge
shaft, surface penstock, surface powerhouse, and tailrace are among the project's components..The
generated electricity will be evacuated via a 10-kilometer 132-kV transmission line from the SMHEP
powerhouse to the Upper Madi Project's switchyard region. The power will then be evacuated through a
double circuit line built from the Upper Madi Project to the Integrated Nepal Power System (INPS) at
Lekhnath substation.

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 The installed capacity of the project will be 44 MW utilizing its design discharge of 18.00m3/s and gross
head of 295.76. The net annual energy production will be 242.649 GWh with 37.756 GWh as dry energy
and 204.893 GWh as wet energy as per PPA documents.
The main Civil works construction of SMHEP has started from Jestha 25, 2075 (June 08, 2018, agreed
commencement date). Its required commercial operation date (RCOD) is in Jestha 28, 2078 (June 11,
2021). Sanima Hydro and Engineering (P.) Ltd. has been appointed as the Engineer (Consultant) for
construction management and construction supervision of SMHEP.
The institutional arrangement to accomplish the project is as follows:
• The Employer/Owner: Super Madi Hydropower Ltd.
• The Engineer/Consultant: Sanima Hydro and Engineering (P.) Ltd.
• The Contractor (Civil Construction): Fewa Construction Ltd.

Figure 1 Madi river

1.5 LOCATION AND ACCESIBILITY

Geographically the project area is located within latitude of 28° 19' 02" N to 28° 21' 39" N and Longitude
of 84° 04' 45" E to 84° 08' 34" E. The Project area lies about 23 km north-east of Pokhara Metropolitan
City. The project road is earthen and gravel type and is about 15 km from Chasu (Madi River crossing
point) to Headworks area.

Project area

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 Catchment area=282km2

Figure 2 Watershed mapping of project

Figure 3 Hydropower Camp

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General Project Overview
SALIENT FEATURES (as per PDR)

GENERAL
Name of the Project Super Madi Hydroelectric Project
Developer Super Madi Hydropower Ltd.
Name of the River Madi River
Type of Scheme Run-of-River
Project Location Madi Rural Municipality
District Kaski
Province Province-04
Latitude 28°19’ 02” N to 28°21’ 39” N
Longitude 84° 04’ 45” E to 84° 08’ 34” E
Nearest Town Pokhara
Gross Head 295.76 m
Rated Net Head 278.59 m
Normal Operating Headwater Level 1344.00m amsl
Tailrace water level 1048.24 m amsl

WEIR
Weir Crest Level 1344.00 m amsl
Type of Weir Concrete ogee shaped weir
Length of overflow weir 44.00 m
Lowest River Bed Level at Weir Axis 1335.00 m amsl
100 Years Flood 1508 m3/s

INTAKE
Catchment Area at Intake site 282.843 km2
Design Flow 18.00 m3/s
Riparian Release 1.52 m3/s
Intake Type Side intake
Intake orifice number/size 4 Nos./ 3.6 m wide x 2.0 m high

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UNDERSLUICE
No., Dimension (length x breadth) 2 nos., 4.0 x 4.0 m
Under-sluice Invert level at gate EL 1336.00 m amsl

GRAVEL TRAP
Length (effective) 20.0 m
Width 8.0 m
Height 9m
Particle size to settle 5 mm (at 85% efficiency)

UNDERGROUND SETTLING BASIN

Type Double Chamber, Intermittent Flushing Type
Settling Criteria 90%, ≥ 0.20 mm
Number of Chambers 2
Inlet Transition Length (m) 28.0 m
Settling Basin Size (uniform section) 124 m long x 12.30 m wide and 13.05 m high each
Flushing System Intermittent
Size of Flushing Channel 1.00 m x 1.5 m (B x H), slope 1:50

Headrace Tunnel (HRT)

Type of Flow Low Pressure Tunnel
Shape of Tunnel Inverted D
Length (excluding settling basin and Kalbandi 5270.95 m
Kholsi crossing )
Excavation Size 4.2 m x 4.2 m (B x H)
Support Type Concrete/ Shotcrete/Rockbolt
Tunnel inlet portal invert level before settling 1337 m amsl
basin (finish)
55.50 m
Length of Kalbandi Level crossing
2.7 m
Diameter of Pipe in Crossing

Adit-I (to HRT)

Type Inverted “D” Type, Shotcrete lined
Total length of Adit (excluding flushing tunnel) 237.16 m
Excavation Size 4.2 m x 4.2 m (B x H)
Adit portal invert level (excavation) 1324.02 m amsl

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Surge Shaft
Type Cylindrical
Diameter - upper section 8.0 m
Height - upper section 45.60 m
Diameter (excavation) – bottom restricted 4.0 m
section
Height – bottom restricted section 31.68 m
77.28 m
Total Height EL 1287.72 m amsl
Invert Level

Penstock Pipe
Type Exposed steel lined
Length (from HRT outlet portal) 562 m (center), 90 m (left branch), 66.7 m (right
branch)
2.70 m dia. / 14-40 mm thick, 2.2 m dia 32 mm
Diameter/Thickness
thick, 1.6 m dia 28 mm thick of E-350 Grade Steel
or Equivalent

Adit-II (Bagalethar adit)

Type Inverted “D” Type, Shotcrete lined
Total length of Adit 254.36 m
Excavation Size 4.2 m x 4.2 m (B x H)
Adit portal invert level (excavation) 1300 m amsl

Powerhouse
PH dimension (L X B X H) 46.00 x 16.0 m x 28.5 m
Turbine Axis Level EI 1045.65 m amsl
PH Access Floor Level EL 1052.90 m amsl

Tailrace
Type Concrete box culvert
Size 3.2 m x 3.0 m (B x H)
Length of Tailrace 195 m
Slope 1 in 500
Invert Level of Tailrace outlet 1045.43 m amsl

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Turbine
Type Vertical Axis Francis Turbine
Number of Unit 3 (Three)
Rated Capacity per Unit 15.28 MW
Discharge per Unit 6.0 m3/s
Turbine Axis Elevation 1045.65 m amsl
Tail water level 1048.24 m amsl
Turbine efficiency 93.5 %

Generator
Type of Generators Three phase, Synchronous, Brushless
Number of Unit 3 (Three)
Rated Output 17260 kVA
Generation Voltage 11.0 kV
Frequency 50 Hz
Power Factor 0.85
Generator efficiency 97 %

Transformers
Type Three Phase, Oil immersed
Number of Units 3
Frequency 50 Hz
Transformer Efficiency 99.0%
Rated capacity per unit 17,500 kVA
Primary (LV Side) 11 kV
Secondary (HV Side) 132 kV

Transmission Line
Transmission Voltage (kV) 132 kV
Length (km) 10 km Upto Upper Madi Powerhouse (under
study)Single Circuit
Type of Circuit
ACSR (Bear)
Line Conductor
132 kV NEA Substation at Lekhnath via Upper Madi
Proposed Interconnection Point
Transmission line(Proposed)

Power and Energy

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Installed Capacity 44 MW
Deemed / Contract Energy 242.65 GWh
Wet Saleable Energy 204.893 GWh
Dry Saleable Energy 37.756 GWh

Construction Time and Key dates

Development and Construction Time 1 year (access road) + 3 years
Power Purchase Agreement with NEA February 09, 2017 (Magh 27, 2073)
Generation licence issued date and validity March 30, 2017 (Chaitra 17, 2073) 35 years
Required Commercial Operation Date (RCOD) June 11, 2021 (Jestha 28, 2078)

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2. LITERATURE REVIEW
2.1 HEADWORKS
Supermadi Hydro Electric Project (SMHEP)-44 MW is an ongoing project whose
headworks consist of following hydraulic structures.
1. Weir
2. Undersluice
3. Fish Ladder
4. Intake structure
5. Gravel Trap

Figure 4:Headworks

2.1.1 Weir
A diversion weir is a hydraulic structure placed over a water channel, such as a river or a stream, to divert
river flow to a certain point. A diversion weir diverts water flow from a water channel to supply water
to the intake in hydropower operations.
In SMHEP, the diversion weir is proposed across madi river. The proposed type of weir is Concrete ogee
shaped weir and is 44meters in length with horizontal floor stilling basin. Lowest river bed level at weir
axis is 1335.00 m amsl.
2.1.2 Undersluice
Under Sluices are gates controlled openings in the weir with crest at low level. They are located on the
same side as off-take canal. If two canal take off on either side of the river, it would be necessary to
provide undersluices on either side.
There are 2 under suice of dimension 4.0*4.0 on the left side of the diversion weir beside intake for
conventional hydraulic flushing of bed load.

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2.1.3 Fish Ladder
River obstructions such as dams, culverts, and waterfalls have the potential to slow or stop fish migration.
Indeed, these impediments to fish migration are often implicated in the decline of certain fish stocks.A
fish ladder, also known as a fishway, provides a detour route for migrating fish past a particular
obstruction on the river.

Figure 5 Fish ladder

2.1.4 Intake Structure

A intake is structure to obtain the required quantity of water from river or reservoir .Intake structure
divert water into a conduit leading to power plant. They are used to control the flow of water.
In SMHEP there is a side intake structure with 3 no of orifice. The flow from the intake structures shall
be controlled by 2 vertical gates. The intake have 4 orifices each3.6 m wide and 2.0 m high .the design
discharge at intake is 18m3/s and catchment area at intake is 282.843 km2.
2.1.5 Gravel Trap
The gravel trap is a device that permits coarse material to flush out while keeping it out of the approach
canal. These can come in a variety of shapes and structures.
In SMHEP,the dimension of gravel trap is 20m length,8 m width and 9m height. The gravel trap allows
to trap coarse particles greater than 5mm with 85 percent efficiency.

2.2UNDERGROUND WORKS
2.2.1 Head Race Tunnel (HRT)
Headrace tunnel takes water from connecting channels and convey it to the fore bay or directly to the
penstock provided with surge shaft depending upon the project and site requirements some times also
known as power tunnel.
The HRT in SMHEP IS D shaped tunnel with dimension of 4.2m breadth *4.2m height . It starts from
RL of 1337 and the length of HRT is 5270.95 m excluding settling basin and kalbandi crossing. Rock
Quality Designation (RQD) value ranges from 25 – 45 which indicate poor to fair rock. Q value ranges
from 0.025 to 0.075 which indicates rock support class IV to V.

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Figure 6 Headrace tunnel

2.2.2Settling Basin
Settling basin is a large hydraulic structure whose main objective is to settle down the finer sediments
present in the approaching water and not trapped in either gravel trap. Settling basin may contain a unit
or multiple chambers with varying slope. The main principle is to deduce the velocity of approaching
sediment laden water due to having large area and allows the sediments to settle down and let the
sediment free water towards the headrace canal.
In SMHEP there are 2 intermediate flushing type underground settling basin . Each chamber is 124m
in length, 12.3 m in width and 14.03m height. The flushing system in settling basin is intermediate and
size flushing channel is 1.00 m x 1.5 m (B x H), with slope of 1:50.
The excavated rock in settling mass is grey coloured, medium grained, foliated, moderately weathered
to weathered weak to medium strong, banded gneiss. Rock Quality Designation (RQD) value ranges
from 35-45 which indicates poor rock. Q value ranges from 0.028 – 0.063 indicates rock support class
IV to V.
2.2.3Adit-I
Adit-1 tunnel has distance of 237.16m. It is also an inverted D tunnel with finished dimension of
4.2m*4.2m and is at RL 1324.02m from amsl .The excavated rock mass in this tunnel is grey colored,
medium grained, foliated, moderately weathered to highly weathered, banded gneiss with schist partings.
Rock Quality Designation (RQD) value ranges from 50 – 55 which indicates fair rock. Q value ranges
from 0.028-0.031 indicates rock support class V.

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2.2.4Adit-II
Adit-1 tunnel has distance of 254.36m. It is also an inverted D tunnel with finished dimension of
4.2m*4.2m and is at RL 1300m from amsl. Rock Quality Designation (RQD) value ranges from 40– 75
which indicate fair rock. Q value ranges from 1.25 - 0.11 which indicates rock support class II and IV.
2.2.5Surge shaft
There is provision of cylindrical surge shaft of 77.28m height in SMHEP . the diameter of surge shaft
ranges from 8m (upper section ) to 4m (lower section).the surge shaft is located at 1287.72m from amsl.
Rock Quality Designation (RQD) value ranges from 40– 65 which indicates poor to fair rock. Q value
ranges from 0.8125 - 0.0563 which indicates rock support class II to IV.
2.3 Penstock
The water from outlet of HRT is conveyed by a steel pipe of 2.70 m in diameter and 14-40 mm thickness
to machine inside powerhouse. There are 7 bends in penstock pipe with stiffeners. The alignment has 7
anchor blocks and Saddle Supports provided in the pipe alignment to facilitate easy installation and
control of alignment.

Figure 7 Penstock pipe

2.5 Powerhouse
Semi-underground type of powerhouse is proposed with three units of Francis turbines installed in
vertical axis. The size of powerhouse building shall be 46m long, 16m wide and 28.5 m high from the
deepest foundation level.

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2.6 TUNNELING
Underground excavation as specified hereunder shall include all excavation performed by conventional
"drill and blast" tunneling method. Excavation shall be made to the lines, grades and dimensions as
shown on the drawings or as directed by the Engineer. The general dimensions, arrangements and details
of the typical sections of the tunnel and shaft are shown on the drawings. The type of section to be
excavated at any location shall be confirmed in written by the Engineer. Temporary (initial) and
permanent (final) support shall be furnished and installed if so required or as directed the Engineer.
During construction, tunnel and other underground structures shall be drained, lighted and ventilated as
specified here in under. If any particular operation or activities necessary for the proper performance of
the work has not specifically been mentioned, it shall be deemed to have been included in the unit prices
for underground excavation. The term tunnel or tunneling shall, depending on the contest, refer to tunnels
including adits, shaft, caverns or other type of underground structures or underground excavation.
2.6.1 NORWEGIAN METHOD OF TUNNELING (NMT)
Tunnel excavation and tunnel support shall follow the Norwegian Method of tunneling using Barton's
Q method of rock mass classification or equivalent. In the subsequent section NMT has been used to
describe the specification for tunneling works. The NMT is based on two closely related guiding
principles for underground excavation. Safety Cost efficiency . NMT is based on the principle that
utilizes utmost advantage of the rock mass quality and its self-supporting capability. After excavation in
the rock mass, the in-situ stresses are re- distributed. A careful measure and deliberate guidance of re-
distributed in-situ stress is the key principle in NMT. The rock mass capable to withstand re-distributed
stresses if rock support measures such as shotcrete and rock bolts are used immediately after excavation
and before progressive loosening in the rock mass. In jointed rock mass, the shotcrete shall be reinforced
using either steel wire mesh or steel fibre and length and number of rock bolts shall be increased. In fault
zones and water bearing zones it may become necessary to use pre-injection grouting, spilling or fore
poling, steel arch ribs or lattice girder or reinforced ribs of shotcrete, bolting and shotcrete. The
application of NMT requires high safety and careful deformation monitoring by using extensometer and
or survey equipment.
2.6.2 ROCK MASS CLASSIFICATION AND ROCK SUPPORT
The rock mass classification and tunnel mapping and/ or logging shall be carried out after each and
every round of blasting during tunnel excavation. The rock mass classification sha be carried out using
rock mass quality index "Q" and this value shall be correlated with the Rock Mass Rating (RMR), Rock
Mass index (RMI) and NATM. The rock mass classification and tunnel logging shall be submitted to the
Engineer after each blast. The initial as well as permanent rock support shall be decided at site on the
basis of Q-value and as per the instruction of the Engineer. The type of rock support may vary depending
upon the rock mass quality and quality index "Q". Depending upon the rock mass quality, combination
of rock support such as shotcrete with wire mesh or steel fibre, systematic bolting, spilling, steel arch
ribs or lattice girder or ribs of shotcrete and pre-injection grouting shall be used. In tunnel sections with
extremely weak rock mass condition, a reinforced concrete lining (with or without steel lining as
required) shall be used as a permanent support.

13
 A. CLASSIFICATION PARAMETERS AND THEIR RATINGS
PARAMETER Range of values // ratings
For this low range
Strength Point-load strength
> 10 MPa 4 - 10 MPa 2 - 4 MPa 1 - 2 MPa uniaxial compr. strength is
of intact index preferred
1 rock Uniaxial com- 5 - 25 1-5 <1
material > 250 MPa 100 - 250 MPa 50 - 100 MPa 25 - 50 MPa
pressive strength MPa MPa MPa
RATING 15 12 7 4 2 1 0
Drill core quality RQD 90 - 100% 75 - 90% 50 - 75% 25 - 50% < 25%
2
RATING 20 17 13 8 5
Spacing of discontinuities >2m 0.6 - 2 m 200 - 600 mm 60 - 200 mm < 60 mm
3
RATING 20 15 10 8 5
Length, persistence <1m 1-3m 3 - 10 m 10 - 20 m > 20 m
Rating 6 4 2 1 0
Separation none < 0.1 mm 0.1 - 1 mm 1 - 5 mm > 5 mm
Rating 6 5 4 1 0
Condition Roughness very rough rough slightly rough smooth slickensided
4 of discon- Rating 6 5 3 1 0
tinuities none Hard filling Soft filling
Infilling (gouge)
- < 5 mm > 5 mm < 5 mm > 5 mm
Rating 6 4 2 2 0
Weathering unweathered slightly w. moderately w. highly w. decomposed
Rating 6 5 3 1 0
Inflow per 10 m
none < 10 litres/min 10 - 25 litres/min 25 - 125 litres/min > 125 litres /min
tunnel length
Ground
pw / s1 0 0 - 0.1 0.1 - 0.2 0.2 - 0.5 > 0.5
5 water
General conditions completely dry damp wet dripping flowing
RATING 15 10 7 4 0
pw = joint water pressure; s1 = major principal stress

B. RATING ADJUSTMENT FOR DISCONTINUITY ORIENTATIONS

Very favourable Favourable Fair Unfavourable Very unfavourable

Tunnels 0 -2 -5 -10 -12

RATINGS Foundations 0 -2 -7 -15 -25
Slopes 0 -5 -25 -50 -60

C. ROCK MASS CLASSES DETERMINED FROM TOTAL RATINGS

Rating 100 - 81 80 - 61 60 - 41 40 - 21 < 20
Class No. I II III IV V
Description VERY GOOD GOOD FAIR POOR VERY POOR

14
 D. MEANING OF ROCK MASS CLASSES
Class No. I II III IV V
10 years for 6 months for 1 week for 10 hours for 30 minutes for
Average stand-up time
15 m span 8 m span 5 m span 2.5 m span 1 m span
Cohesion of the rock mass > 400 kPa 300 - 400 kPa 200 - 300 kPa 100 - 200 kPa < 100 kPa
Friction angle of the rock mass < 45o 35 - 45o 25 - 35o 15 - 25o < 15o

Support
Rock Rock bolts
Excavation (20 mm diam., fully Shotcrete Steel sets
mass class
bonded)
1. Very good rock Full face: Generally no support required except for occasional spot bolting
RMR: 81-100 3 m advance
2. Good rock Full face: Locally bolts in crown, 3 m 50 mm in crown None
RMR: 61-80 1.0-1.5 m advance; Complete long, spaced 2.5 m with where required
support 20 m from face occasional wire mesh
3. Fair rock Top heading and bench: Systematic bolts 4 m long, 50-100 mm in None
RMR: 41-60 1.5-3 m advance in top spaced 1.5-2 m in crown crown, and 30
heading; and walls with wire mesh mm in sides
Commence support after in crown
each blast;
Commence support 10 m
from face
4. Poor rock Top heading and bench: 1.0- Systematic bolts 4-5 m 100-150 mm in Light ribs spaced
RMR: 21-40 1.5 m advance in top long, spaced 1-1.5 m in crown and 100 1.5 m where
heading; crown and walls with wire mm in sides required
Install support concurrently mesh
with excavation - 10 m from
face
5. Very poor rock Multiple drifts: Systematic bolts 5-6 m 150-200 mm in Medium to heavy ribs
RMR < 21 0.5-1.5 m advance in top long, spaced 1-1.5 m in crown, 150 mm spaced 0.75 m with
heading; crown and walls with wire in sides, and 50 steel lagging and
Install support concurrently with mesh. Bolt invert mm on face forepoling if
excavation; shotcrete as soon as required. Close invert
possible after blasting

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3 DETAIL OF INTERNSHIP PROJECT ACTIVITY

First we arrived at the hydropower campsite on 26th September. Our supervisor Er. Biraj Bhandari
introduced us to the member of staffs and his colleagues in hydropower and introduced to the
surroundings of the camp site . They briefly explained about general feature of the project, work
progress till now and future working plan of project.
3.1 SADDLE SUPPORT
For preparation of saddle support excavation was done . Then for concreting including rebar,
formwork was completed.
Procedure for Concreting:
1. Preparation of C25 at batching plant:
2. Transferring pumpable concrete from concrete pump:
Now the concrete in transit mixture travelled from the batching plant is then poured on concrete
pump through machine which control the volume of concrete that is needed at the concreting site.
The drum of transit mixture should rotate in order to keep flat spots from being worn in to the ring
and rollers.
3. Test at site:
Slump test was carried out at each concreting works to maintain the workability of concrete.
Similary, 9-12 concrete cubes were casted for single batching which were taken to quality control
lab for carrying out compressive strength test at 3 days, 7 days and 28 days.

Figure 8 Preparation of cube

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Figure 9 Compressive test

4. Use of vibrator:
Concrete vibrator is used so as to spread the concrete uniformly and removing air voids in between
and fill the gaps.

Figure 10 Use of vibrator in saddle support

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5. Curing of concrete:
The objective of curing is to prevent loss of moisture and maintain a favorable temperature to
support continued hydration. Without an adequate supply of moisture, the concrete won’t set
properly which might lead to crack formation. Moist Jute bags were laid above the raft to prevent
the loss of moisture.

3.2TUNNEL EXCAVATION CYCLE

The details of the SMHEP tunnel excavation cycle are provided here. For tunnel boring, the drill
and blast method was used, and it was used at all tunnel boring sites, including HRT, adits, and
the Penstock tunnel. The excavation was followed by the placement of support
structuresimmediately afterward at weak rock condition.

Figure 11 Tunneling

3.2.1Drilling
During this phase, drilling of holes is done on the tunnel face. It is done by boomer or by jack
hammer.Drilling IN SMHEP is done by boomer .Drilling is always carried out in a predetermined
pattern which is recommended by the geologist after face map reading. The drilling pattern
guarantees that the explosive is distributed evenly throughout the rock and that the intended

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blasting result is achieved. When constructing the drilling pattern, several aspects must be
considered, including the type of explosives used, blast vibration constraints, and the blasted wall's
accuracy requirements, among others.

Figure 12 Blasting pattern

3.2.2 Loading and blasting

The drill holes are now filled with explosives, detonators are attached to the explosive devices and
the individual explosive devices are connected to one another. The holes are blasted in a proper
sequence, from the center outward, one after the other. Although more than 100 explosions may
be set off, one after the other, the blast sequence is completed in several seconds. The devices
should not explode at the same time, but rather one after the other at specified intervals. Only when
the blast master has ensured that nobody is left in the danger zone can the explosion be triggered
by the blasting machine. On average each explosives in about 200gm with a diameter of 32mm
and length of 200mm.
Blast pattern wedge cut and burn cut are the two most common forms. The center holes in a wedge
cut, also known as a V-cut, are drilled in a v shape and extra explosives are placed in these holes
to form a wedge. As the wedge forms, rock masses from subsequent delayed blasts merge in the
wedge, blasting the whole tunnel face. In a burn cut, more explosives are utilized in each hole than
in a wedge cut. To allow the rock mass to move after the blast, a few of holes in the middle are not
loaded. Burn cuts have a longer pull length than wedge cuts, however they can't be employed in
weak rock masses.

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3.2.3 Dislodging
Dislodging refers to the stripping away and removal of loose pieces of rock, which were not
completely released from the rock during the blasting procedure. This working step is completed
by a robust tunnel excavator.
3.2.4 Geological mapping
The working face is now freely accessible and the geologist has a few minutes to map it. In the
process, he determines what type of rock is present and how the rocks lie, i.e. whether they dip in
a flat or steep manner, whether they are folded or even broken.. At the same time, the strength of
the rock, the reaction of the rock mass to the excavation process and any mountain water
infiltration are also documented. The mapping report created from this with sketches and photos
serves as the basis for the selection of appropriate supporting measures.
3.2.5 Support Works
Support works in tunnel depends on the available rock class.If the rock class is good, a few rock
supports such as shotcrete and rock bolts may suffice; otherwise, for weak rock masses, additional
supports such as ribs and spills may be required. One of the biggest advantages of the drill and
blast approach is that it allows you to start a new cycle without completely finishing the previous
one.

3.3 ROCK SUPPORTS IN TUNNEL OF SMHEP

The basic functions of a tunnel support system are to keep the tunnel stable and to make the
opening usable Commonly used Rock supports in the tunnel of SKDHEP are as follows:
1. Rock Bolts
2. Shotcrete
3. Steel Ribs
4. Spilling
Rib protection is used if the rock is extremely weak, whereas rock bolting and shotcrete are used
if the rock is stable and less weak. A geologist recommends the type and amount of support.
3.3.1. Rockbolts
rock bolt, in tunneling is steel rod inserted in a hole drilled into the roof or walls of a rock formation
to provide support to the roof or sides of the cavity. Rock bolt reinforcement can be used in any
excavation geometry, is simple and quick to apply, and is relatively inexpensive. The installation
can be fully mechanized. The length of the bolts and their spacing can be varied, depending on the
reinforcement requirements. There are three major ways of anchoring the rock bolts: mechanical,
grouted, and friction. Rock bolts are almost always installed in a pattern, the design of which
depends on the rock quality designation and the type of excavation.

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In SMHEP, Rock bolts of 25mm and 20mm diameter and 2-2.5m long were used to provide
additional support to the tunnels. The holes of the rock bolt were driven by a standard jack hammer
and Boomer. After the installation of the rock bolt cement mortar mixed with some admixtures
were grouted into the hole inorder to keep the bolt intact.. If not grouted, the expansion-shell bolt
will not be recognised as a permanent bolt. The bolts shall be pre-tensioned immediately after the
installation as specified by the manufacturer. If this type of bolt is later grouted, grouting shall be
done without de-stressing the bolt. Grouting shall be done after installation to convert expansion-
shell bolt to a permanent bolt. For non-expansion type rock bolts, boreholes shall have diameters
minimum 10 mm larger than the diameter of the bolt and shall be thoroughly cleaned out by water
and/or air jets
Main purposes:
• reinforce loose rock or fractured in-situ rock to prevent caving in or spalling
• to assist the rock mass to form its own self-supporting structure

Figure 13 rock bolt

3.3.2 Shotcrete
Shotcrete is a method of applying concrete projected at high velocity primarily on to a vertical or
overhead surface. The impact created by the application consolidates the concrete. Although the
hardened properties of shotcrete are similar to those of conventional cast-in-place concrete, the
nature of the placement process results in an excellent bond with most substrates, and rapid or
instant capabilities, particularly on complex forms or shapes. The shotcrete process requires less
formwork and can be more economical than conventionally placed concrete. Shotcrete is applied

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using a wet- or dry-mix process. The wet-mix shotcrete process mixes all ingredients, including
water, before introduction into the delivery hose. The dry-mix shotcrete process adds water to the
mix at the nozzle
Shotcrete for rock support shall be used immediately after excavation. inSMHEP mainlt two type
of shorcreting was done:plain cement shotcrete and concrete mixed with steel fiber (Steelfiber
reinforced). Plain concrete shotcrete was done over portals and in between ribs where there is
wiremesh placed. For rock support on the inner lining of tunnels, steel fiber reinforced shotcrete
was done.Steel fibre, added in quantities of 8 to 13% by weight of cement, can allow shotcrete to
achieve compressive strengths which are double or triple the value of plain shotcrete mixes. The
result is an extremely strong, impermeable and durable shotcrete

3.3.3 Steel ribs

The underground excavation in the weak section shall be provided by the steel ribs or lattice girder.
Steel ribs are provided in exceptionally weak site condition during construction of tunnel. For the
rib protection ISHB 150 steel section is used. ISHB 150 is bent into arc shape and is connected
with nut and bolt. It is supported in wall with the help of anchor bars. Steel ribs are provided in the
site condition with Q value less than 0.03, i.e. V B and VI B support types. The steel ribs or lattice
girder shall be covered by at least 5 cm thick shotcrete lining. The steel ribs or lattice girder shall
be installed such that its surface contact with wail and crown is tight if not the gap shall be filled
with other appropriate materials and different lagging shall be provided depending upon the site
condition.

Figure 14;steel ribs

3.3.4 Spilling
Where spilling is employed to provide support for advancing the excavation, spiles shall be driven
into the ground or placed in pre-driven holes as required in the Contract. The embedded length
shall be not less than 1 m beyond the proposed advance of the excavation. The number, location
and angle of spiles shall be commensurate with the ground conditions. The angle shall not be less
than 10° and greater than 25° unless otherwise instructed by the Engineer The proposed excavation

22
length shall not be exceeded before further spiles are driven or other approved means of ground
support are employed or as instructed by the Engineer.
Rock support drawing for SMHEP
Rock supports in tunnel depends on the rock class obtained. For each rock class type the rock
supports vary accordingly. In SMHEP, drawings for each rock class were pre-defined. After each
blasting and mucking, geologist would observe the face and prepare face map and determine the
rock class and select the rock support accordingly.

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Figure 15 tunnel support type

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3.4 LABROTARY WORKS
As the project is just started, laboratory is not completely set. Managing and set up of lab
equipment is going on and will be completed soon. Currently few test can be performed.

3.4.1 Concrete Mix design/ trial mix

Concrete mix design is the process of finding right proportions of cement, sand and aggregates for
concrete to achieve target strength in structures. This process is usually adopted for structures
which requires higher grades of concrete and above and large construction projects where quantity
of concrete consumption is huge. Benefits of concrete mix design is that it provides the right
proportions of materials, thus making the concrete construction economical in achieving required
strength of structural members.
After the sample is prepared, it is placed in six cubes of 15*15*15 cm dimension. The concrete in
these cube are tempered so that no voids are formed in between. Then these cubes are placed in
curing tank. Three cubes are taken for 7-day compression test and other three cubes are used in
28-day compression test.

3.4.2 Slump test

Slump test is carried out the calculate consistency and the water cement ratio in concrete. Concrete
prepared for casting cubes are placed in the conical frustum. It is placed in conical apparatus in
3stage with tampered to remove any void presence in it. After filing concrete, it is slowly removed.
Height of the slump from top is measured. It is measured taking reference of conical frustum.
After the concrete is placed, the cone is removed slowly and the height of slump from the top is
measured. If shear or collapsed slump is obtained, the concrete mix is prepared again with new
water cement ratio.

3.4.3 Compressive strength test

Compressive strength test is a mechanical test to measure the maximum amount of load concrete
can take before failure. Compression test is done by the help of UTM (Universal Testing Machine).
This test as the name specifies is used to measure the compressive strength of the concrete. In this
test, a concrete sample is kept in the UTM and the load is gradually increased. The load is increased
until the sample can take no more. The highest value of load the sample can take is its compressive
strength

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3.5 CALCULATION OF CONCRETE QUANTITY AND FORM WORK REQUIRED IN
SADDLE SUPPORT
During our stay we calculated the concrete quantity and formwork quantity for the saddle support
type 4, type 5A,type 5B,type 5C,type 5D,5E and anchor block 07 using the civil drawings.
Concrete Quantity Calculation

Saddle Support Total Surface area Volume Total actual Concrete Volume For formwork Note:
(sq. m) (Cubic m) (Total Volume-Volume of curved sector) Toal area(sq. m) Volume of curved sector= 2.17 (Calculated from the Autocad drawing)

Type 4 4.72 20.296 18.126 24.622

Type 5A 7.22 31.046 28.876 38.222

Type 5B 7.97 34.271 32.101 42.302

Type 5C 8.47 36.421 34.251 45.022

Type 5D 60.48 260.064 249.214 467.341

Type 5E 19.84 85.312 80.972 96.661

Figure 16;calculation of concrete quantity

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3.6 WORK PROGRESS DURING INTERNSHIP
During our stay at Super Madi Hydropower, we Observe various works of hydropower project.
Our observation and supervision however was mostly in the underground structures and
penstock. We observed and/or completed the following progress in site;
1. Obseration of Shuttering in Surge tank

2. Progression of ground excavation in HRT outlet and inlet.

3. Excavation of settling basin, intake structures and gravel trap

4. Observation of tunnel excavation cycle which includes drilling, loading, blasting,

mucking and scaling, surveying and face mapping and support works.
5. Observed the concreting in base of the saddle support type 4.

6. Observed the concreting in surge tank up to 3.4m.

7. Support works in outlet HRT which had weak rock condition and good rock condition.

8. Calculated the concrete quantity and formwork quantity for the saddle support type 4,
type 5A,5B,5C,5D,5E and anchor block 07.
9. Observed the installation of saddle plate on the saddle support.

10. Calculated the excavation quantity from given survey data.

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4 CONCLUSION
Our stay at Super Madi Hydropower was a wonderful experience. It was a great introduction to
our professional career in future as we learnt the duties and responsibilities of a site engineer,
learnt to bear responsibility to handle a project from its designs, workmanship, construction and
dealing with the unexpected problems encountered. We were able to learn about the structure
and working of manpower and resources at project site. We learnt about the working relationship
of Client, Consultant and Contractor in a project site. Observing the works done at Headworks,
powerhouse and tunnel which we had been studying in class lectures only was one of the key
knowledge we grasped at field. We are also given a tasks to learn the AutoCAD drawings of
powerhouse, anchor blocks and saddle supports and calculate the formworks needed and
concrete quantity needed for those structures. We got the opportunity to work and supervise in
fields regarding surveying works, civil construction, office works, reporting duties, quality
control, drawings and layout, tunnel cycle and many more which have grown our experience to a
new level

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5 BIBLIOGRAPHY
Progress report of SMHEP-44 MW (shrawan,2078)
Baral, S. (2016). Fundamentals of Hydropower Engineering. 3rd ed. Kathmandu: National Book
Center.

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6 APPENDICES

Figure 17 Campsite

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 Figure 18 Outletportal HRT
Figure 20 Batching plant

Figure 21 tailrace cannel Figure 19 crane

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Figure 22 construction of powerhouse

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Figure 23 Installation of formwork in surge tank

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Figure 24 Saddle support

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Figure 25 Anchor block

Figure 26 Steel fibre used in shotcreting

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