Tunnelling Process Innovation

Transcription

1 Ram Hari Sharma Nepal Tunnelling Association (NTA) 5 7 January 2018, Kathmandu Nepal Tunnelling Process Innovation

2 A Collaborative Initiative of Nepalese Institutions Knowledge Holding International (KHInt) Nepal Tunneling Association (NTA) Independent Power Producers Association, Nepal (IPPAN) Youth Community for Nepalese Contractors (YCNC) Acknowledgement on Hands on Knowledge Er. Shiv Kumar Basnet, Project Director, BBDMP

3 Problem: Slow / Time consuming Hydropower Tunnelling High Cost for Short Tunnel Length for TBM Innovative Solution: Accelerated Construction Completing Projects Faster & Cheaper

4 Idea to Innovation Idea / Analogy Making Hole on Wall Hole Drilling Machine (HDM) Multiple Hole on Wall by 1 HDM Tunnel Boring Machine (TBM) Multiple Tunnel by 1 TBM Innovation Application of Idea on Making Tunnel for Hydropower Plant Not that easy!

5 Key Determining Factors: Single TBM for Multiple Hydropower Projects 1. Inventory of Tunnel based projects 2. Geology along tunnel alignment 3. Tunnel Size (diameter) 4. Collaboration / Coordination IPPs (Cost Distribution & Benefit Sharing) 5. Construction Timing > Sequencing 6. Transportation of TBM

6 Key Determining Factors:

7 Key Determining Factors:

8 Preliminary Identification: HPPs at Marsyangdi Basin S. Hydropower Project Tunnel Size Tunnel Geological Condition No (Dia) Length 1 Marsyangdi - 7 (85MW) 4.5m 6.0km Tibetan Tethys Sedimentary zone; above the MCT 2 Manang Marsyangdi (280MW) 5.2m 7.0km 3 Lower Manang Marsyangdi (140MW) 5.0m 5.0km 4 Upper Marsyangdi - 2 (600MW) 6.5m 9.5km 5 Upper Marsyangdi - 1 (138MW) 6.5m 6.5km 6 Marsyangdi Besi (50MW) 6.5m 6.0km Higher Himalayan Gneiss, Granitic gneiss, fine to coarse grain Schistose Gneiss, Paragneiss, Ortho Gneiss content of Quartz Feldspar Chlorite, Muscovite Biotite Total Capacity of Six HPPs 1,293MW Total Tunnel Length 40.0km

9 TuPIN in Reality: Marsyangdi Basin Traditional Excavation Process Cost Excavation for six Tunnels Support cost for six Tunnels Time Conventional construction time Risk Cost overrun / Variation Time overrun / Production loss Environmental Health & Safety Other Associated Risk IPPs are Independent in Construction TuPIN - TBM Cost Procurement / Lease Transportation & Erecting Operation including Energy Re-dismentaiing & Transportation Re-erection & Operation Time Fast & Finished in single run Risk Various Associated Sequencing & Timing Conflict between Multiple Developers Collaboration with Multiple IPPs Needed

10 Further Workout TuPIN in Reality LET US COMPARE Bucket-1 Tunnel Projects Cost (Drill and Blast Tunnelling Method) Total excavation cost of six Tunnels Total support cost of six Tunnels Allocated construction time Cost overrun/variation risk Time overrun/ production loss risk Environmental risk in cost Health and safety risk in cost Other associated risk in cost Bucket-2 TBM Cost, Operation and Associated Cost (TBM Tunnelling Method) Procurement cost of TBM Transportation cost of TBM Erection cost of TBM at site Power required for TBM operation Operation cost of TBM Cost of disc cutter changing Cost of consumable and spares parts Cost of re-disentailing and transport Cost of re-erection and operation Cost of repair, minor modification Construction sequence of projects Various Associated Risk

11 Further Workout TuPIN in Reality LET US COMPARE Bucket-1 Tunnel Projects Cost (Drill and Blast Tunnelling Method) Cost of 5m dia 40 km tunnel is tentatively calculated 230 million USD (5.75 million $/km) by Drill and Blast method Construction time 4 to 5 years for each Project Bucket-2 TBM, Operation and Associated Cost (TBM Tunnelling Method) Cost of 5m dia Gripper TBM/Open TBM is about 12 million USD Per km Cost of TBM is 0.3 million USD Tunnel Advance Rate 15km/year Overall Cost, Risk and Construction Time COLLABORATION Overall Cost, Risk and Construction Time

12 TuPIN in Reality: Marsyangdi Basin Status & Issues: TuPIN Sufficient: Tunnel based HPPs Easy: Other Issues to Resolve High Value: To Independent Developers High Potential: for other River basins Evidence & Strategy to Overcome Issues Six (6) Projects only in Marsyangdi basin Tunnel diameter 4.5m to 6.5m Potential to optimize with total length of tunnel 40km Similar geology along entire length Collaborations with six different developers Stage of project: start of construction Sequencing of construction Mode of project construction & procurement Re-assessment of geology 20% Cheaper 2.5 times early construction 3-5 times better progress rate highly Safe & Environmentally friendly (based on BBMDP, may vary with the set of HPPs) In addition to Marsyangdi River basin, the TuPIN Expert Team had Identified potential other basins; namely Tamakoshi-Sunkoshi, Tamor and Arun valley, Trishuli, Kaligandali, Budhigandaki, Dudhkoshi, Bheri, Karnali, Seti etc.

13 Concluding Message Preliminary assessment Tunneling for Multiple Hydropower Projects with Single TBM is Technically & Financially Now Possible in Nepal There exists Sufficient number of Projects Resolving other issues is not Major Challenge TuPIN is expected to Happen Soon As an example of Collaborative Innovation Expected to Replicated rapidly (as one set of project starts) Applicable to Transport, Utilities, Storage & Many more purposes)

14 Thank you!!! TuPIN: A Collaborative Initiative Shashi Bhattarai Knowledge Holding International (KHInt) Sandip Shah, Subas Chandra Sunuwar & Ram Hari Sharma Nepal Tunneling Association (NTA) Khadga Bahadur Bisht & Sailendra Guraghai Independent Power Producers Association, Nepal (IPPAN) Birendra Raj Pandey Youth Community for Nepalese Contractors (YCNC) Acknowledgement for Handson Knowledge Shiv Kumar Basnet, Project Director, BBDMP