Construction Process of Water Selectable Intake

1. Process of Construction
The construction process of the water level selectable intake is as shown the Figure 2.1 and
below.
(l) Excavation of the vertical shaft
The vertical shaft with diameter of 25 cm is excavated up to the EL. 60.0. Before the vertical
shaft excavation, the open cut excavation up to EL.95.0 above the shaft excavation should
be carried out together with the access road to the shaft, and before reaching the bottom
elevation the next work of connecting tunnel is to be commenced at around EL.64.
(2) Excavation of connecting tunnel
The connecting tunnel with diameter of 3.7 m and length of 43 m is excavated from the
vertical shaft at the elevation of EL. 64 to the diversion tunnel, which is used for the
existing intake. However, the last 3 m to the diversion tunnel is left unexcavated.
(3) Lining of connecting with concrete
The lining of connecting tunnel with concrete is conducted from the vertical shaft except for the
last 3 m of joint part with the diversion tunnel.
(4) Concreting and installation of water Level selectable Intake
The concreting and installation of metalwork are carried out from the bottom of 8L.60 to top of
EL. 106. The metalwork is installed step by step and followed by concreting of tower.
(5) Closing the bulkhead gate of existing intake and draining the water from the diversion
tunnel
In order to construct the joint part of connecting tunnel with the diversion tunnel, the supplying
water through the existing intake should be interrupted. At first the valve at the power station
and control gate of the existing intake are closed, secondarily the bulkhead gate at the
entrance of existing intake is closed, and thirdly the valve and control gate are opened so
that the inside of the tunnels can be dried up.
(6) Construction of joint part of connecting tunnel with diversion tunnel
The last 3 m of connecting tunnel which is joint part with the diversion tunnel is excavated and
demolishing existing tunnel lining, concrete lining, consolidation grouting are conducted. The
construction period of this work should be shortened as much as possible because of interruption
of water supply.
(7) Filling water into the vertical shaft and existing intake and commencement of water
supply through the existing intake.
Since the bulkhead gate is already closed in the process (6), the valve and control gate are closed
and the water is filled into the vertical shaft and existing intake up to the reservoir water level,
then the bulkhead can be opened, after that the valve of the power station is opened so that the
water supply through the existing intake can be commenced.

(8) Excavation of the remaining part between the reservoir and the vertical shaft
The excavation of the remaining part between the reservoir and the vertical shaft is conducted.
Since the lowest level of excavation is EL. 70.0, the water level is to be lowered until this level
to avoid submerged excavation in accordance with the reservoir operation curve.
(9) Constructing operation house
The operation house is constructed and the new intake operation facilities are installed.
2. Construction Access Road
The work space for intake tower construction for such as mucking of vertical shaft excavation,
concreting and installation of siphon etc. is to be prepared at EL. 95.0. The access road from the
top of dam with EL,106.0 to the work space and hauling road for open cut excavation above the
vertical shaft is required.
The major design criteria of construction road are as follows:
Width of lane
: 3.0 m with 0.5 m of shoulder at both sides
Maximum longitudinal gradient
: 12 %
Minimum curvature radius
: 12 m
Design speed
: 20 km/h
3. Surface Excavation of Vertical Shaft
Although the excavation of the intake tower is to be carried out by vertical shaft method,
since the ground material is common soil and soft rock from ground surface to EL. 95.0,
the open cut excavation should be applied. The access road is to be excavated together with the
surface excavation of vertical shaft.
The excavation material for surface excavation of vertical shaft ranges from common soil to soft
rock II (CM class), therefore the excavation method is determined for each material as shown
below. The excavation of soft rock II is carried out with ripping and partly blasting.
The disposal area at present forms a kind of shallow pond, so that the excavated material is to be
just dumped there without any bulldozer works such as grading and compaction.
4. Vertical Shaft Excavation
The vertical shaft is located in the hard rock (class CH or B) so that the blasting method should
be applied. The process of excavation is as follows:
l) Drilling blasting hole by crawler drill and charging explosive.
2) Blasting
3) Breaking rock boulder into small pieces by breaker
4) Mucking and loading by backhoe into bucket
5) Lifting bucket by crawler crane to dump truck
6) Transportation of excavated material to disposal area by dump truck
5. Connecting Tunnel
The connecting tunnel is constructed between the intake tower and the diversion tunnel, which is
used as the existing intake facilities. The inside diameter of tunnel is 3.7 m and the length of it is
about 43 m, and main part of it is diagonal tunnel with the inclination of about 20O.

The excavation of tunnel is to be carefully planned so that the excavation causes no damage to
the existing structures especially the existing diversion including joint part with the tunnel.
The tunnel is to be excavated by normal method using explosive except the joint part 3 m with
the diversion tunnel. The joint part is excavated by SD (Slot Drilling) method without explosive.
The last 8 m of the normal section is excavated by the limited blasting method.
6. Concreting of Intake Tower
The total concrete volume of intake tower is about 8,000 m 3. Considering the volume and
construction period, the concrete placing is to be conducted by concrete pump and purchase of
ready mixed concrete. The installation of metal work is carried out before concreting of a lift at
each level.
7. CSG Protection
The excavation of the intake is composed of vertical shaft excavation and open cut excavation.
The slope of open cut excavation should be transferred to that of vertical shaft. In order to protect
the excavation surface of vertical shaft, the vertical wall is covered with CSG retaining wall with
slope of 1: 0.3 and l.5 m berm in every height of 5 m and the slope of retaining wall is to be
connected with the open cut slope of l : 0.3. The top of CSG protection is used as an access road
from the ground to the intake tower. The surface of CSG work is covered with concrete wall.
8. Open Cut at Front Yard of Intake
The open cut excavation at front yard of intake should be conducted following the falling of the
reservoir water level. However, since the lowest part of excavation reaches to EL.70.0, the
reservoir water level should be lowered to EL.70.0 according to the reservoir operation curve in
order to avoid submerged excavation.
The water level record in the past l0 years is as shown in the Figure. The blue broken line shows
the average reservoir water level excluding the first two years data because in which years the
water levels are extremely high. According to the Figure, the excavation more than EL. 87.0
which is average water level up to September can be done following the natural falling of water
level. However it seems to be impossible for the excavation less than EL. 87,0. The compulsory
lowering of water level is necessary to excavate up to the EL.70.0 keeping water level over the
operation rule curve shown in the red line. The compulsory water level lowering is as shown in
the orange line. During I month from September l, the water level can be lowered with discharge
of about 37 m3/sec. The lowest water level of EL. 70.0 is to be maintained about one month.
The compulsory water level line is over the reservoir operation rule curve so that the influence to
the downstream water users seems not to be so much.
9. Metal Work
The work flow of installation is as shown in the Figure 9.2 and the details of installation plan are
as shown in the Figure 9.3 - Figure 9,5.