PROJECT REPORT

About THDC India limited

The Tehri Dam Project, the fourth highest Dam in the world is under construction. It
has suffered enormous time and cost over runs The issues were attended to by the
Govt.of India and several committees were appointed to help in the solution of the
problems.

THDC India Limited is a Joint Venture of Govt. of India and Govt. of

Uttar Pradesh. The Equity is shared in the ratio of 75:25 between GoI and
GoUP. The Company was incorporated in July’ 88 to develop, operate & maintain the
2400 MW Tehri Hydro Power Complex and other hydro projects. The Company has
an authorised share capital of ` 4000 cr. THDCIL is a Mini Ratna Category-I and
Schedule ‘A’ CPSE. The initial ma ndate of THDCIL was to develop, operate and
maintain the 2,400 MW Tehri Hydro Power Complex (comprising of 1000 MW Tehri
Dam & HPP, 1000 MW Tehri Pumped Storage Plant & 400 MW Koteshwar HEP) HEP)
and other Hydro Projects.
 THERI PUMP STORAGE PLANT (4* 250MW)

1.0 BACKGROUND
Govt. of India approved the implementation of Tehri Dam & HPP (1000
MW) in March, 1994 along with committed works of Koteshwar HEP
and essential works of Tehri PSP, as Stage-I of Tehri Hydro Power
Complex.

Tehri Dam & HPP (1000 MW) located at 1.2 km downstream of the
confluence of River Bhagirathi & Bhilangana, comprises a 260.5 M
high Earth & Rock fill dam which is one of the highest dams of its type
in the world, a Spillway System designed for PMF of 15540 Cumecs
and a drop of 220m, having one Chute Spillway and four Shaft
Spillways and an underground Power House housing four Turbine/
Generator sets of 250 MW each, designed to operate with a head
variation of 90 m.

HPP Project was commissioned in 2006-07 since then all

four machines of Tehri Power Station are under commercial
operation. Besides providing much needed power to the
Northern Grid, the command area is availing irrigation
benefits from the Project and drinking water is being supplied
to Delhi and UP.

Koteshwar Hydro-Electric Project (400 MW), located 22 km

downstream of Tehri, is an integral part of Tehri Power
Complex comprising of Tehri Dam & HPP (1000 MW), Tehri
PSP (1000MW) and Koteshwar HEP (400MW) to develop
Hydro-electric potential of river Bhagirathi. It will facilitate the
functioning of Tehri Power Complex as a major peaking
station in Northern grid as reservoir created by Koteshwar
Dam having a live storage capacity of 35.0 MCM will function
as lower (balancing) reservoir for Tehri PSP. This project is
also regulating water releases from Tehri reservoir for
irrigation purpose. The Koteshwar HEP was commissioned

in 2011-2012.

The essential works of Tehri PSP have already been completed along
with Tehri Dam & HPP Stage-I.

Tehri PSP comprising of four reversible pump turbine units of 250 MW

each, involves construction of an Underground Machine Hall on the left
bank of river Bhagirathi. The main feature of the Project is the large
variation of about 90 m between the maximum and minimum head,
under which the reversible units shall operate. The operation of Tehri
PSP is based on the concept of recycling of water discharged between
upper reservoir and lower reservoir. The Tehri Dam reservoir shall
function as the upper reservoir and Koteshwar reservoir as the lower
balancing reservoir. On completion, additional generating capacity of
1000 MW, peaking power, will be added to the Northern Region
(annual generation of 1268 million units).

For pumping operation of reversible units during off-peak hours, the

energy requirement will be of the order of 1712 MU limited to maximum
of 1000 MW during off-peak hours. With the construction of Tehri PSP,
Tehri Hydro power Complex shall function as a major peaking station
having an installed capacity of 2400mw
2.0 PROJECT APPROVAL

Govt. of India approved the execution of Pumped Storage Plant (4X250

MW) in July-2006, at a cost of Rs.1657.60 Cr. including IDC of Rs.
81.64 Cr. at Dec.’05 price level with debt equity ratio of 70:30.

3.0 REVISED COST ESTIMATE

The RCE-II proposal has been examined in CEA/CWC and cost of the
project has been vetted for an amount of Rs. 4401.90 Cr. (including
IDC & FC Rs. 897.82 Cr.) at January 2017 price level.

4.0 SALIENT FEATURES:

1. Upstream Reservoir Tehri Dam Reservoir (Alread

commissioned)

2. Downstream Reservoir Koteshwar Dam Reservoir (Alread

commissioned)

3. Head Water Levels

Maximum 830 m

Minimum 740 m

4. Head Race Tunnels Two Nos. concrete lined HRTs (HRT

& HRT-4) Already constructed.

Diameter 8.5 M
 Length HRT-3 932 m

Length HRT–4 1060 m

5. Upstream Surge Shaft

Location End of HRT

Type Restricted Orifice

Numbers 02 Nos.

Diameter Approx. 20.92 m

Penstock Bifurcation At the base of surge shaft

6. Penstocks

Numbers 04

Diameter 6.0 m

Type Steel lined

7. Power House

Type Underground

Size of Machine hall

Max. width 25.4 m + lining

Height 55 m

Length 203 m

Location Left Bank

Rated unit capacity 250 MW

 Installed capacity 1000 MW

Number of units 04 nos.

Type of Machine Variable speed vertical Francis typ

reversible Turbine.

Turbine Net Head Range 120.4m to 219.4 m

Pump 130.5m to 229.5 m

delivery Head Range

Design Head 188 m

Rotational Speed Variable speed

Distributor axis Approx. EL 568 M

Submergence Approx. 38 m

8. Output

-Nominal value 278 MVA

-Maximum capacity 306 MVA

Rated electrical power output 250 M W at about 18

WC of rated net Head

9. Downstream Surge Shaft

Numbers 02

Diameter Approx. 18.44 m

Height Approx. 80 m

10. Tail Race Tunnels

Numbers 02

Diameter 9.0 m

Length

TRT-3 1151 m

TRT-4 1255 m

11. Tail Water Levels

Maximum 612.5 m
 Minimum (in pump mode) 606 m

Minimum (in turbine mode) 603 m

How does pump storage plant

work?

.There's another type of hydropower plant, called the pumped-storage

plant. In a conventional hydropower plant, the water from the reservoir
flows through the plant, exits and is carried down stream. A pumped-
storage plant has two reservoirs:

Upper reservoir - Like a conventional hydropower plant, a dam creates a

reservoir. The water in this reservoir flows through the hydropower plant
to create electricity.

Lower reservoir - Water exiting the hydropower plant flows into a lower
reservoir rather than re-entering the river and flowing downstream.

Using a reversible turbine, the plant can pump water back to the upper
reservoir. This is done in off-peak hours. Essentially, the second reservoir
refills the upper reservoir. By pumping water back to the upper reservoir,
the plant has more water to generate electricity during periods of peak
consumption.

The Generator

The heart of the hydroelectric power plant is the generator. Most

hydropower plants have several of these generators.

The generator, as you might have guessed, generates the electricity. The
basic process of generating electricity in this manner is to rotate a series
of magnets inside coils of wire. This process moves electrons, which
produces electrical current.

The Hoover Dam has a total of 17 generators, each of which can generate
up to 133 megawatts. The total capacity of the Hoover Dam hydropower
plant is 2,074 megawatts. Each generator is made of certain basic parts:

Shaft
Excitor

Rotor

Stator

As the turbine turns, the excitor sends an electrical current to the rotor.
The rotor is a series of large electromagnets that spins inside a tightly-
wound coil of copper wire, called the stator. The magnetic field between
the coil and the magnets creates an electric current.

In the Hoover Dam, a current of 16,500 amps moves from the generator
to the transformer, where the current ramps up to 230,000 amps before
being transmitted.

Some of the important term

. 1.wire mesh
Welded wire mesh, or welded wire fabric, or "weldmesh"
is an electric fusion welded prefabricated joined grid
consisting of a series of parallel longitudinal wires with
accurate spacing welded to cross wires at the
requireBACKGROUND
2.ROCK BOLT

A rock bolt is a long anchor bolt, for stabilizing rock

excavations, which may be used in tunnels or rock cuts. It
transfers load from the unstable exterior to the confined (and
much stronger) interior of the rock mass.

Rock bolts were first used in mining in the 1890s, with

systematic use documented at the St Joseph Lead Mine in the
U.S. in the 1920s. Rock bolts were applied to civil tunneling
support in the U.S. and in Australia starting in the late 1940s

3.RESIN CAPSULES
RESIN CAPSULA resin capsule is a permeable container for resin
beads designed for multiple/combinatorial solid-phase organic
synthesis. Resin capsules consist of a high density polyethylene
ring sealed with peek mesh on both sides. The cylindrical shape
of resin capsules enabled space-saving packing into plastic
column-like reaction vessels commonly used for solid-phase
organic synthesis. Resin capsules have been evaluated for their
use in combinatorial synthesis, and a set of model compounds
with excellent purity was preparedE

S.
4.STEEL ROD - Basically a cylindrical piece of steel.
Steel Rod's have many wonderful uses. Can be used as simple
set prop, whereby you place it leaning against a wall, or can be
used more appropriately as a form of beaver crowd control,
whereby constant hard hits to the head of a pananian marsh
beaver (beaverus ignoramus) will result in the suppression of
all unwanted acts by the creature. Excess striking will result in
brain damage or possible death

5.CEMENT CAPSULES.

Quick Setting Cement Capsules are manufactured by us are free from lime, chlorine
or toxic chemicals and generate very less heat for safety and durability. For its
efficient and consisting performance Cement Capsule is used mainly in roof bolting
in mines. It has also proved to be of much use in checking the leakages in the
pipeline and filling the cracks on the wall.
 STATUS ON EXECUTION
Essential works of Tehri PSP already completed along
with the execution of Tehri Stage-I are as follows:

 Two Headrace Tunnels for PSP

 Intakes for Headrace Tunnels of PSP
 Transformer Hall constructed under Tehri Stage-I has
been planned to accommodate Generator
Transformers for the PSP also.
 Main Cable Gallery
 Interface Facility civil work
A.Advance actions taken

Works executed prior to award of EPC contract

are as under:

 The excavation and stabilization of Adit-6 & 6c

(total length 857 m) up to Machine Hall.

 The protection wall in front of TRT outlet

raised up to the required level of El. 622.0 M.

 Excavation of Adit-8 (Total length- 604.0 RM)

leading to bottom of D/S Surge Shaft and Tail
Race Tunnels.

 Excavation of Adit-7A leading to crown of

Machine-Hall cavern.
 Excavation of Adit-9 leading to top of D/S
Surge.

 Excavation of Link Adit 8-9 to isolate approach of

Tehri Power Station from PSP construction traffic.

6. Award of Major Works:

Major works of the Tehri Pump Storage Plant (PSP – 4x250 MW) projec
executed through a single EPC contract. The work has
been awarded to Consortium of Alstom Hydro-France
(AHF), Hindustan Construction Co. Ltd. and Alstom
Project India Ltd, vide Agreement No.
THDC/RKSH/CD-262/OA dated 23.07.2011.

The consortium and THDCIL having agreed that the project shall be exe
co-ordinate basis through 05 separate agreements
under the Umbrella agreement as mentioned above ,
each signed by the partners of the consortium
directly responsible for the respective portion of
supplies, services or works. Description of the work
and detail of the agreements is as under:-
DESCRIPTION OF SEPARATE AGREEMENT UNDER OVERAAL
AGREEMENT:

Contract No. THDC/RKSH/CD- Planning, Design and Engineering of 4x 250 MW

262/AG/01 Pumped Storage Plant

Contractor M/S Hindustan Construction Company Ltd. And

Alstom Hydro France

Contract Price €5,117,283.00 and INR 30,000,000.00 Plus appl

Service tax €8,482.00 and INR 35,740,936.00

Contract No-THDC/RKSH/ Civil Works of 4x 250 MW Tehri Pumped Storage P

CD-262/AG/02

Contractor M/S Hindustan Construction Company Ltd.

Contract Price INR 6,61,46,91,866.00

Contract No.THDC/RKSH/ Supply of Electro-Mechanical plant & machiner

CD-262/AG/03 Hydro-Mechanical plant& machinery (Off-
Component) of 4x250 MW Tehri Pumped Storage

Contractor M/S Alstom Hydro France

Contract Price € 82,841,152.00 (EM Supply € 62,923,012.00 an

supply € 19,918,140.00)

Contract No.THDC/RKSH/ Supply of Electro-Mechanical plant & machiner

CD-262/AG/04 Hydro-Mechanical plant & machinery (On-
Component)
of 4x250 MW Tehri Pumped Storage Plant.

Contractor M/S Alstom Projects India Limited (Reconstitut

Alstom India Limited)

Contract Price INR 5,134,863,955.00 plus applicable State

112,367,579.00

Contract No.THDC/RKSH/ Transportation, Insurance, Custom clearance, Sto

CD-262/AG/05 Erection, Testing and Commissioning of the El
Mechanical plant & machinery and Hydro-Mech
plant& machinery (Onshore services)of 4x250
Tehri Pumped Storage Plant
 Contractor M/S Alstom Projects India Limited (Reconstitut
Alstom India Limited)

Contract Price € 798,000.00 and INR 719,408,038.00 plus appl

Service Tax € 82,200.00 and INR 74,099,034.00

7. PRESENT STATUS

The work was awarded to Consortium of Alstom – HCC on

Turnkey Basis under a Common Programme/MCN. The
work of PSP started on 27th July 2011 (commencement date
as per the contract). As per contract, planned completion of
ACTIVITY PLANNED FINISH STATUS
As per Contract As per Revised
Schedule
Letter of award 23-June-11 23-June-11 Complete

Signing of 27-July-11 27-July-11 Complete

contract
agreement
Commencement 27-July-11 27-July-11 Complete
of works(zero
date)
Taking over 1st 26-July-15 10-Oct-2020 Under prevailing
unit circumstances,
Taking over 2nd 26-Sep-15 04-Nov-2020 commissioning of all four
unit units is expected in
Taking over 26-Nov-15 29-Nov-2020 May’2021.
rd
3 unit

Taking over 4th 26-Jan-16 24-Dec-2020

unit

the work was 26th Jan’2016. As per revised schedule,

planned completion date of the project is 24.12.2020
B. Downstream Wall :
Sl. Detail of Level Total Activity Completed
No Cable Anchor Planned Pad Drilling Install. Groutin St
Installation Conc. g g
1 Ist Row 721.5 M 39 (Inc. 39 37 37 37 37
upward)
 2 IInd Row 719.5 M 39 (Inc. 38 35 35 35 32
upward)
3 IIIrd Row 717.75 M 39(Horizontal 38 38 38 38 38
)
4 IVth Row 716.50 M 39 14 0 0 0 0
(Horizontal)
5 Vth Row 715.25 M 39 26 0 0 0 0
(Horizontal)

.
STATUS WITH RESPECT TO WORKS:

(i) Construction of approach adits and drainage galleries:

 Underground excavation of all 14 approach adits has been completed.

U/G excavation in a length of total 3526.4 RM in all access adits and
drainage galleries (except drainage gallery around U/s Surge Shaft)
has been completed under the EPC contract.
 Excavation in drainage gallery around U/s Surge Shaft has been
completed in a length of 118.0 RM out of 350.0 RM.
(ii-a) U/S Surge Shaft (3 & 4):-
  Excavation of Pilot shaft HRT-4 was completed on 5th July’14 (total length of
151.0M).
 Excavation of Pilot shaft HRT-3 was completed on 31st Dec’2014.
 Benching in U/s Surge Shaft upper Chamber-3 was
completed on 12.05.2016.
 Benching in U/s Surge Shaft upper Chamber-4 was
completed on 13.12.2016.
 Casting of Collar beam has been completed in Upper
Chamber-3 and 4.
 Widening of U/s Surge shaft-3 has been completed in a
length of 11 RM out of 140 RM.
 Widening of U/s Surge shaft-4 has been completed in a
length of 09 RM out of 140 RM.
(ii- b) Grouting Gallery around U/s Surge shaft upper
chamber
 Grouting gallery around U/s Surge shaft upper chamber-3
has been Completed (Total length 176.0 M).
 Grouting gallery around U/s Surge shaft upper chamber-4
was completed on 07.11.2015
(iii) Butter Fly Valve Chamber (BVC):
 Excavation of pilot tunnel, geological investigation and crown
slashing was completed on 07.08.2014
 Benching in BVC has been completed up to EL 715m.
 Cable anchor box concreting, drilling, fixing and grouting
work are in progress as detailed below:
A. Upstream Wall:
Sl. Detail of Level Total Activity Completed
No Cable Anchor Planned Pad Drilling Install Groutin Stre
Installation Conc. . g
1 Ist Row 724 M 39(Inc. 39 39 39 39 39
 downward)
2 IInd Row 722.5 M 39(Inc. 39 39 39 39 39
downward)
3 IIIrd Row 721 M 39 39 39 39 39 39
(Horizontal)
4 IVth Row 719 M 39 39 39 39 39 39
(Horizontal)
5 Vth Row 717 M 39 39 25 22 22 22
(Horizontal)

(iv) Penstock Assembly Chamber (PAC):

 PAC crown slashing was completed on 8th April’14.
 Benching in PAC up to EL 716.6 m has been completed. Cable anchor box
concrete, drilling, fixing and grouting work is in progress.

(v) Lower penstock assembly chamber, lower horizontal

penstocks & vertical penstocks
 Excavation of Lower Penstock Chamber has already been
completed.
 Lower horizontal Penstocks (PS-5 to PS-8) have been
completed in length of 430.9M.
 Vertical Penstock -5(Pilot shaft) was completed on
26.08.2014.
 Vertical Penstock-6(Pilot Shaft) was completed on
11.06.2015.
 Vertical Penstock -7(Pilot shaft) was completed on
30.07.2015.
 Vertical Penstock -8(Pilot shaft) was completed on
30.11.2015.
(vi) Bus bar Cavern and Bus bars:-
 Excavation of Adit AA-10 (141RM) & AA10 R (108RM) to
Bus bar cavern was completed on 20th Nov’13.
 Excavation of Bus bar cavern (Total Length 92.0M) was
completed on 30th June’14.
 Excavation in bus bar-5 is under progress & completed up to
135.7 M out of 155.6 M.
 Excavation in bus bar-6 (total length 155.0 M) has been
completed.
 Excavation in bus bar-7 (total length 156.2 M) has been
completed.
 Excavation in bus bar-8 (total length 165.6 M) has been
completed.
 Lining in bus bar upper horizontal tunnel 8 has been
completed in a length of 87.3 RM out of total 113.1 Rm.
 Lining in bus bar upper horizontal tunnel 7 has been
completed in a length of 58.8 RM out of total 103.7 Rm.
(vii) Ventilation Tunnel:-
 Excavation of Ventilation tunnel is in progress. Out of total 581 RM,
excavation in a length of 468.0 RM has been completed so far.
(viii) Power House:-
 Crown slashing of Power house cavern (203 RM) was
completed on 29th July’13. Power house excavation up to EL
590m was completed on 15th Mar’14.
 Excavation of approach adit AA-7(386 RM) to bottom of Penstock & draft tube pits of
M/C Hall was completed on 2nd Aug’13.
 Excavation of approach Adit AA-9 to Control room and approach Adit AA-8 to Service
bay has been abandoned due to revision of layout of M/C hall. New approach Adit AA-
8R to Service Bay was completed 29th April’14.
 Construction of crane beam in service bay was completed on 30.08.2014.
 Construction of crane beam in Unit area was completed on 05.06.2015.
  Benching in PH service bay has been completed (EL580.0 m).
 Benching in PH control room area has been completed ( EL 568.95 m).
 Service bay raft concreting has been completed on 28.02.2016.
 Control room building work is in progress. Raft concrete at EL 570.45m was completed
on 06.05.2017. First slab at EL 574.65 of control room building was completed on
27.12.2017. 04 Nos. centre columns have been completed up to 579.60 m. 02 Nos.
columns b/w HVAC gallery and Cable access gallery have been completed up to
579.60m. U/s wall, D/s wall & Service bay side wall (RD : -31m) around control room
have been completed up to EL 578.30, 578.20 & 579.60 respectively. Remaining columns
have been completed up to EL 577.05 m and boundary wall at RD -53m have been
completed up to EL 577.15 m.
 Unit area benching is under progress. At present benching has been completed upto EL
558m, EL 558.5 m, EL 557.5 m and EL 557m in unit 5, 6, 7 & 8 respectively .
 Excavation of pipe access gallery below service bay (total length 53 m) was completed in
Nov.’2017.
 At U/s wall of Machine hall from El 578m to El 573m, all 31 cable anchors have been
completed in all respect. Description of which is as follows:
Sl.
Detail of Cable Anchor Installation Elevation Planned Completed
No
1 Ist Row EL 578m 10 10
2 IInd Row EL 576m 4 4
3 IIIrd Row EL 575.5 7 7
4 IVth Row EL 573 m 10 10

Upper drainage gallery around M/C Hall

 Excavation of upper drainage gallery (EL. 601 m) around

M/C Hall (468 RM) was completed on 19th Sept’13.
Lower Drainage gallery around M/c Hall

 Excavation of lower drainage gallery (EL. 559 m) around

M/C Hall (533 Rm) was completed on 30th July 2016.
(ix) Draft Tubes :
 Excavation of Draft Tube-5 has been completed (total length
42m).
  Excavation of Draft Tube-7 has been completed (total length
42m).
(x) D/S Surge Shafts 3 & 4:

 Pilot excavation in D/S Surge Shafts-3 & 4 was completed

on 19th July’13 and 4th Sept’13 respectively.
 D/S SS Upper chamber -3 (central gullet & side slashing)
was completed on 25.09.2015
 D/S SS Upper chamber -4 (central gullet & side slashing)
was completed on 14.12.2015.
 Benching in D/s SS Upper Chamber- 3 & 4 was completed on
31.01.2016.
 Casting of collar beam has been completed in D/s SS upper chamber-
3 & 4.
 Shaft widening of D/s Surge Shaft – 3 & 4 is under progress.
 In D/s Surge Shaft-4 excavation in 6.0 RM depth (out of total
75.0 RM) has been completed.
 In D/s Surge Shaft-3 excavation in 4.0 RM (out of total 75.0
RM) depth has been completed.
(xi) Drainage gallery around D/S Surge Shaft

 Excavation of drainage gallery (EL. 596 m) around D/S

Surge was completed on 31st Jan’14


(xii) Tail Race Tunnels:-
 Heading excavation of Tail Race Tunnel (TRT-3) is under
progress. Out of total 1151 RM, excavation in a length of
888.0 RM (full face + Drift ) has been achieved so far.
 Heading excavation of Tail Race Tunnel (TRT-4) is under
progress. Out of total 1255 RM, excavation in a length of
948.4 RM in full face has been achieved so far.
 Benching in TRT-3 in length of 188.5 RM out of 1151 RM
has been completed.
 Benching in TRT-4 in length of 422.5 RM out of 1255 RM
has been completed.
 TRT-3 U/s invert lining in the length of 108.4 RM and overt
lining in the length of 48 RM out of 148.5 RM has been
completed.
 TRT-4 U/s invert lining in the length of 156.0 RM out of 212.4
RM has been completed. Reinforcement work is in progress
for next invert.
(xiii) TRT Outlet Area
 River protection work and work of approach road are
under progress.
 Support installation for slope stabilization between EL
660m to EL 644m & El.644 m to El.632 m is under
progress.