PROYECTO HIDROELECTRICO ALTO MAIPO

INGENIERIA BASICA

TUNNELLING AND ROCK SUPPORT

BASIC DESIGN

19-12-08

PARA LICITACION

EMISION

FECHA

PROPOSITO DE LA EMISION

PREPARA

REVISO

COORDINADOR
GENERAL
APROBO

D. PROYECTO
/ D. ADJUNTO
APROBO

GERENTE DE
PROYECTO
APROBO

SUBGERENTE
DE INGENIERIA
APROBO

REVISION

0
N: 600-TU-CDD-001

600-TU-CDD-001
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INDEX
ITEM

CONTENTS

1.

Executive summary ..............................................................................................1

PG.

1.1

Introduction...........................................................................................................1

1.2

Las Lajas ..............................................................................................................1

1.2.1

Upstream portion to connection with Alfalfal II tailrace ..........................................1

1.2.2

From connection with Alfalfal II tailrace to Las Lajas powerhouse ........................1

1.2.3

Las Lajas Pressure shaft ......................................................................................1

1.2.4

Las Lajas Powerhouse .........................................................................................2

1.2.5

Cable shaft and cable tunnel ................................................................................2

1.2.6

Las Lajas tailrace tunnel .......................................................................................3

1.3

Alfalfal II ...............................................................................................................4

1.3.1

Basic considerations decisive for layout ...............................................................4

1.3.2

From upstream end of the headrace tunnel (VA4) to top of the pressure shaft (A9)
.............................................................................................................................4

1.3.3

Alfalfal II Pressure Shaft .......................................................................................5

1.3.4

Alfalfal II Powerhouse ...........................................................................................5

1.3.5

Alfalfal II Tailrace tunnel .......................................................................................6

1.4

Tunnel Volcn ......................................................................................................7

2.

Las Lajas - Description of layout ..........................................................................8

2.1

Las Lajas Access tunnel .......................................................................................8

2.2

Las Lajas Powerhouse Area .................................................................................8

2.3

Las Lajas Headrace tunnel .................................................................................10

2.4

Surge system .....................................................................................................10

2.5

Pressure shaft ....................................................................................................11

2.6

Transition zone and valve chamber ....................................................................11

2.7

Las Lajas Tailrace tunnel....................................................................................11

2.7.1

General ..............................................................................................................11

2.7.2

Tunnel outlet.......................................................................................................12

2.7.3

Alternative with use of TBM for part of the Las Lajas Tailrace Tunnel.................12

2.8

Las Lajas Cable tunnel (Bio Bio).........................................................................12

2.8.1

600-TU-CDD-001
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Tunnel dimension ...............................................................................................12

2.8.2

Cable tunnel (Bo Bo) entrance..........................................................................13

3.

Alfalfal II description of layout ..........................................................................13

3.1

Basis for alignment of tunnels.............................................................................13

3.2

Alfalfal Access tunnel..........................................................................................14

3.3

Alfalfal Powerhouse area....................................................................................14

3.4

Tailrace tunnel....................................................................................................16

3.5

Pressure shaft ....................................................................................................16

3.6

Transition zone and valve chamber ....................................................................17

3.7

Surge shaft and surge chamber..........................................................................17

3.8

Headrace Tunnel Alfalfal II. ................................................................................17

3.8.1

General ..............................................................................................................17

3.8.2

Tunnel portion excavated by TBM ......................................................................18

3.8.3

Tunnel portion excavated from the upstream end ...............................................18

4.

Tunnel EL Volcn ...............................................................................................18

4.1

Basis for alignment .............................................................................................19

4.2

Tunnel portion excavated by TBM ......................................................................19

4.3

Tunnel portion excavated by D&B.......................................................................19

5.

Electrical equipment ...........................................................................................20

5.1

Background ........................................................................................................20

5.2

Evacuation..........................................................................................................20

5.3

Separate transformer hall ...................................................................................20

5.4

Generator breaker ..............................................................................................21

5.5

Generator and transformer .................................................................................21

5.6

Outdoor breakers................................................................................................22

5.7

230 kV Cable......................................................................................................22

5.8

Auxiliary supply...................................................................................................22

5.9

Control and Supervisory Control and Data Acquisition (SCADA) System ...........23

5.10

Protection ...........................................................................................................24

6.

Mechanical equipment........................................................................................24
6.1

General ..............................................................................................................24

6.2

Alfalfal II .............................................................................................................24

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Turbines .............................................................................................................24

6.2.2

Spherical valves .................................................................................................25

6.2.3

Cooling water system .........................................................................................25

6.2.4

Machine hall crane .............................................................................................26

6.2.5

Penstock steel lining...........................................................................................27

6.3

Las Lajas ............................................................................................................27

6.3.1

Turbines .............................................................................................................27

6.3.2

Spherical valves .................................................................................................27

6.3.3

Cooling water system .........................................................................................28

6.3.4

Machine hall crane .............................................................................................29

6.3.5

Penstock steel lining...........................................................................................29

7.

Engineering geology in basic design...................................................................30

7.1

General layout ....................................................................................................30

7.2

Geological information ........................................................................................30

7.3

Design of underground openings........................................................................30

7.3.1

General ..............................................................................................................30

7.3.2

Rock Mass Classification....................................................................................31

7.3.3

Plastic deformation .............................................................................................32

7.3.4

Water Leakage (WL) ..........................................................................................33

7.3.5

Rock support as function of classification ...........................................................33

7.3.6

Design of pressurized waterways .......................................................................35

7.3.7

Rock mass permeability......................................................................................35

7.4

Tunnelling conditions for selected alignments.....................................................36

7.4.1

General ..............................................................................................................36

7.4.2

Las Lajas project ................................................................................................36

7.4.3

Alfalfal II project ..................................................................................................37

7.4.4

Volcn tunnel......................................................................................................39

7.4.5

Rock support methods........................................................................................40

8.

Tunnel and shaft excavation methods ................................................................40

8.1

General ..............................................................................................................40

8.2

Drill and blast tunnelling......................................................................................42

8.3

TBM tunnelling....................................................................................................43

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General on Tunnel Boring Machine (TBM) for hard rock.....................................43

8.3.2

Open TBM ..........................................................................................................44

8.3.3

Double Shield TBM (DS TBM) ............................................................................44

8.3.4

Assembly of TBM and Backup System ...............................................................45

8.4

Shaft excavation .................................................................................................45

8.4.1

Raise Boring Machines (RBM)............................................................................45

8.4.2

Raise drill and slash ...........................................................................................46

8.4.3

Inclined TBM shaft excavation ............................................................................46

9.

Evaluation of use of TBM for tunnel excavation at the Alto Maipo project ...........47
9.1

General ..............................................................................................................47

9.2

Evaluation of TBM concept .................................................................................47

9.2.1

Open hard rock TBM (gripper type) ....................................................................48

9.2.2

Double shield machine .......................................................................................48

9.3

Selection of TBM for the various tunnels at the Alto Maipo project .....................49

9.3.1

Las Lajas tailrace tunnel .....................................................................................49

9.3.2

The Alfalfal II headrace tunnel - downstream portion ..........................................50

9.3.3

TBM for Tunnel Volcn .......................................................................................50

9.4

Summary of TBM requirements/ configuration....................................................51

9.4.1

Machine requirements ........................................................................................51

9.4.2

Backup special requirements..............................................................................51

9.4.3

Site operation requirements................................................................................51

LIST OF TABLES
Table 1-1:

Main technical data - Las Lajas ............................................................................3

Table 1-2:

Main technical data - Alfalfal II and Tunnel Volcn................................................6

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1.

EXECUTIVE SUMMARY
1.1

Introduction

This report presents the Basic Design of the Alto Maipo Hydroelectric Project
underground works.
Reference is made to the Drawings 600-TU-PLA-001, 610-TU-PLA-003, 620-TUPLA-003 and 630-TU-PLA-003 where the alignments are shown in plan and longitudinal profile,
and to Drawings 620-TU-PLA-004 and 630-TU-PLA-004 showing proposed layout and
arrangement of the powerhouses.
All dimensions and quantities given in this text are intended for general reference
only. Precise values are given in pertinent documents (drawings and general and particular
specifications).
1.2
1.2.1

Las Lajas
Upstream portion to connection with Alfalfal II tailrace

The flow from the existing Alfalfal power plant will be directed into a Cmara de
Carga, that will be located 500 m downstream of the Alfalfal tailrace outlet. The flow from
Cmara de Carga, including also the existing flow at Maitenes intake, will be conducted under
moderate pressure through a concrete culvert that will enter the upper end of Las Lajas
headrace tunnel approximately 2 km downstream of the Alfalfal tailrace outlet, at point VL8. The
culvert and tunnel will be dimensioned for a maximum flow of 38 m3/s.
The tunnel continues for 5.8 km to point L10, where the Alfalfal II tailrace tunnel
joins the Las Lajas headrace tunnel.
A construction adit of length 230 m will be located at VL7 (adit el Trescientos),
some 1.8 km downstream of the upper end of the tunnel (VL8).
1.2.2

From connection with Alfalfal II tailrace to Las Lajas powerhouse

The tunnel from the connection with Alfalfal II tailrace at point L10 to point L9 at
top of the pressure shaft will have a length of 3.7 km, and a design flow of 65 m3/s.
1.2.3

Las Lajas Pressure shaft

A vertical pressure shaft of some 160 m length leads to the Las Lajas
powerhouse. Steel lining with diameter 3.7 m has been assumed.

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The access tunnel to the top of the pressure shaft, from the switchyard area (VL5)
will connect to an inclined cable shaft, and serve as cable tunnel in the operational phase.
The final evaluation of whether extent of steel lining could be reduced or must be
increased will be made when results from in situ investigations of the underground rock
conditions are available.
No spherical valve will be installed at top of the pressure shaft, but preparations
will be made to allow for such installation later, if experience from operation deems it necessary.
1.2.4

Las Lajas Powerhouse

Refer Drawings 630-TU-PLA-004 and 630-TU-PLA-005

The Las Lajas powerhouse is located south west of Estero Aucayes, on the south
side of ro Colorado, (Point LPS).
The access tunnel will start at point VL4, and have a length of some 2050 m at
slope of 9%.
The Las Lajas powerhouse will have gross head of 483 m and an installation of
2 x 135 MW, in two 6 jet Pelton turbines with a speed of 300 rpm.
Two three-phase transformers will be installed. They will be located in niches in a
separate cavern running parallel with the main cavern, and connected to the latter with two
busbar tunnels.
1.2.5

Cable shaft and cable tunnel

A short horizontal tunnel will connect the transformer hall with the foot of an
inclined cable shaft.
The cable shaft will have 3.4 m diameter and approximate length of 210 m, joining
the access tunnel to the top of the pressure shaft. This tunnel leads to point VL5 close to the
new Alto Maipo Substation.
Drainage from the steel cone area at top of the pressure shaft will be conducted
via the cable shaft to the end of the transformer hall, and further to the tailrace tunnel via holes
drilled for this purpose.

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1.2.6

Las Lajas tailrace tunnel

The Las Lajas tailrace tunnel is a free flow tunnel of mild slope, 1.1 m per km,
13 km long. It will cross under ro Colorado some 200 m below the riverbed which is at elevation
approx. 1030 masl.
The entire tunnel can be excavated by D&B by constructing an intermediate adit
to the tailrace tunnel, adit Las Puertas at VL2. Alternatively, the downstream portion of the
tailrace tunnel, some 9000 m, can be excavated by TBM. In this case, the adit Las Puertas can
be omitted.
Table 1-1:
Main technical data - Las Lajas
Las Lajas power plant. Main data
Intake Cmara de Carga
Highest operation level, Cmara de Carga
masl
Lowest operation level, Cmara de Carga
masl
Exceptional high level at Cmara de Carga
masl
Live volume of Cmara de Carga
m3
Power conduit system
Pressure concrete culvert from Cmara Carga to headrace
tunnel, designed for 37 m3/s
Headrace tunnel, total length to top pressure shaft.
Tunnel excavation method
Tunnel cross section (varies - one part designed for 38
m3/s, one part for 65 m3/s )
Elevation at top of pressure shaft
Vertical, drilled steel lined pressure shaft
Drilled diameter
Internal diameter of steel penstock
Tailrace tunnel, free flow, Cross-section 36 m2
Surge shaft diameter (vertical)
Surge chamber diameter
Underground powerhouse
Length x Width
Number of units (Pelton)
Design flow per unit
Rated capacity per unit
Speed
Elevation of runner
Max gross head
Generators
Capacity, each
Power Factor
Transformers, 3-phase
Capacity, each
Transmission voltage

1 323.0
1 318.0
1 324.0
300 000

m
m

1 160
9 480
Drill &
Blast

m2
masl
m
m
m
m

21/31
1000
160
4.7
3.7
12950

m
m

m
no
m3/s
MW
rpm
masl
m
no
MVA
no
MVA
kV

5.0
10

62.6x18.2
2
32.5
134
300
840
468,5
2
144
0,92
2
158
110

Access tunnel, length

Cable shaft, inclined
Cable tunnel , from top of shaft
1.3

m
m
m

600-TU-CDD-001
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1930
213
580

Alfalfal II
1.3.1

Basic considerations decisive for layout

Alfalfal II will have a maximum gross head of 1156 m and a headrace tunnel 14.8

km long.
Location of the headrace tunnel alignment and the powerhouse at an area
somewhat to the west of Estero Aucayes has been selected taking into account the geological
conditions and their impact on tunnelling and rock support measures. It has been an aim to
reduce the magnitude of the overburden, which still is very high, and more than 1000 m at
places.
For the present layout it has been assumed that steel lining will be needed in the
pressure shaft below elevation 1950 masl, i.e. for pressures above 550 m. This assumption
determines the location of the top of the pressure shaft, and thereby several other key elements
of the layout, such as powerhouse location and location of adits/access tunnels in the
powerhouse/pressure shaft area.
A surge chamber will be located in the Aucayes Valley, connected to the
headrace tunnel via a shaft/tunnel.
The tailrace of Alfalfal II will empty into the headrace tunnel for Las Lajas Power
plant at L10.
1.3.2

From upstream end of the headrace tunnel (VA4) to top of the pressure shaft
(A9)

(Reference is made to the drawings and to the list of coordinates, Table 1-2, for
location and data for the key points of the tunnel system).
No intermediate adit will be available for the Alfalfal II headrace tunnel, and the
following method has been selected for excavation in Basic Design:
A Tunnel Boring Machine (TBM) will be used for excavation from the downstream
end (A9) in the upstream direction, for an estimated length of 8500 m, to point A10.
Conventional excavation by drill and blast (D&B) will be used for excavation from
the upstream end in the downstream direction, for an estimated length of 6250 m, to point A10.

600-TU-CDD-001
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The downstream access to the headrace tunnel by the TBM will be located at
point VA2, south west of Estero Aucayes. The length of this access, from VA2 to A9, will be
2000 m. It has been assumed that this access tunnel also will be excavated by TBM for its
entire length.
A surge system will be located near the downstream end of the headrace tunnel,
connecting to the tunnel some 250 m upstream of the pressure shaft. The system will comprise:
An inclined shaft that will be excavated by TBM from the headrace tunnel to
elevation 2400 masl. A tunnel on milder slope from elevation 2430 masl to the surge chamber,
will also be excavated by the TBM.
For Basic design it has been assumed that the TBM will be transported back
through the surge tunnel/shaft to the headrace tunnel and further through the tunnel A9-VA2, but
it is for the Contractor to decide wether the TBM can alternatively be withdrawn at the Aucayes
pond, where a 7.5 km road would have to be constructed to access the Aucayes pond.
The TBM is the same that will excavate the pressure shaft for Alfalfal II.
1.3.3

Alfalfal II Pressure Shaft

An inclined, steel lined pressure shaft has been selected for Alfalfal II. Relative to
a vertical shaft this solution will reduce the length of the access tunnel by 600 m, giving a
reduction in critical construction time for the project.
The final evaluation of whether extent of steel lining could be reduced or must be
increased will be made when results from in situ investigations of the underground rock
conditions are available.
No spherical valve will be installed at top of the pressure shaft, but preparations
will be made to allow for such installation later, if experience from operation deems it necessary.
1.3.4

Alfalfal II Powerhouse
Refer Drawings 620-TU-PLA-003, 620-TU-PLA-004 and 620-TU-PLA-005

Alfalfal II powerhouse is located south west of Estero Aucayes, on the south side
of ro Colorado, (Point APS).
Two generating units with Pelton type turbines of 500 rpm with 4 jets will be
installed, for a maximum capacity of 2 x 132 MW.
Two three-phase transformers will be installed, located in niches in a tunnel
parallel to the main cavern, connected to the main cavern via busbar tunnels.

600-TU-CDD-001
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The access tunnel will start at point VA1, and have a length of some 2500 m at
slope of 8%.
Cables will be conveyed out via the access tunnel. The topography and
overburden in the powerhouse area is such that a separate cable tunnel, or a combination of
cable shaft and cable tunnel, is not feasible.
1.3.5

Alfalfal II Tailrace tunnel

The Alfalfal II tailrace tunnel will be 3.1 km long, and will end in the Las Lajas
headrace tunnel.
Decisive for design and dimensioning of the tailrace tunnel, and for the elevation
of the Pelton runners at Alfalfal II, is the situation when Las Lajas power plant stops operating
while Alfalfal II continues. The Alfalfal tailrace system will then be a part of the Las Lajas surge
system, experiencing water surface fluctuations before the surface stabilizes at a higher level,
when the Alfalfal II flow is directed to the Cmara de Carga of Las Lajas.
As result of hydraulic analysis of the system, the elevation of the Pelton runner at
Alfalfal II has been set to 1341 masl.
The Alfalfal II tailrace will be ventilated via a shaft excavated to surface (A1A)
located 1420 m downstream of the foot pressure shaft (FPS).
Table 1-2:
Main technical data - Alfalfal II and Tunnel Volcn
Alfalfal II power plant. Main data.
Tunnel Volcn
Total length, Tunnel Volcn. ( No intermediate adits)
Excavation by TBM from the downstream end (V6). Estimated
maximum length by TBM
Excavation by D&B from the upstream end (V1) towards
downstream. Estimated minimum length intermediate adits.
Tunnel Inlet elevation
Tunnel outlet elevation
Design flow, tunnel Volcn
TBM diameter, estimated minimum
Tunnel cross section for D&B

14105

7000

m
masl
masl
m3/s
m
m2

7105
2494.1
2 480
12
4.1
14

Power tunnel system Alfalfal II

Headrace tunnel, length from VA4 A9
Additional length from A9 to inlet cone of steel lining

m
m

14789
100

TBM diameter ( wheel bound), on ascending slope 7%

Estimated length of tunnel by TBM
Minimum area of D&B tunnel from upstream

m
m
m2

4.5
8540
13

600-TU-CDD-001
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Estimated length of tunnel by D&B, on variable descending
slope
Elevation at top of pressure shaft
Shaft for penstock 45 slope, excavated by TBM
Drilled diameter
Internal diameter of steel penstock
Tailrace tunnel, to Las Lajas headrace tunnel. Part free flow,
part pressure tunnel
Cross section of major part of tailrace tunnel
Diameter of inclined surge shaft, by TBM
Length of inclined surge shaft, to reservoir
Underground powerhouse
Length x Width of theoretical contour line at machine floor level
Number of units (Pelton)
Design flow per unit
Rated capacity per unit
Speed
Runner diameter
Elevation of runner
Max gross head
Generators
Capacity, each
Power Factor
Transmission voltage
Transformers, 3-phase
Capacity, each
Machine hall crane capacity, estimated
Access tunnel, cross section
Access tunnel, length

1.4

m
masl
m
m
m
m
m2
m
m

m
no
m3/s
MW
rpm
m
masl
m
no
MVA
kV
no
MVA
t
m2
m

6245
1950,5
860
3.4
2.4
3055
21
3.4
912

57.5 x 16.4
2
13.5
132
500
2.72
1 341
1 159
2
144
0,92
220
2
161
180/10
35
2456

Tunnel Volcn

Tunnel Volcn will conduct the flow collected from the ro Volcn catchment and
transfer it to entrance of the El Yeso siphon system (Pozo de Toma) that will take the
Yeso/Volcn flow into the Alfalfal II headrace tunnel. Design flow for Tunnel Volcn will be
12 m3/s and the size will be determined from construction requirements. The tunnel will be
14.1 km long, with no intermediate adits.
Available information on geology in the area indicates that at some distance along
the tunnel, some 5 - 7 km upstream of V6, conditions could cease to be suitable for excavation
by TBM due to the high magnitude of rock overburden, with corresponding high risk of spalling
and squeezing.
For Basic design it has been assumed that tunnel Volcn will be excavated by
TBM from the downstream end, at Point V6, in the upstream direction for an estimated maximum
of 7 km. After removal of the TBM, the excavation will continue with D&B.

600-TU-CDD-001
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The upstream portion of the tunnel will be excavated by D&B from point V1.

2.

LAS LAJAS - DESCRIPTION OF LAYOUT

Reference is made to drawings 630-TU-PLA-001, 630-TU-PLA-002, 630-TU-PLA003, 630-TU-PLA-004, 630-TU-PLA-005 and 630-ME-PLA-006.

2.1

Las Lajas Access tunnel

The entrance for the access tunnel will be at point VL4 near the Colorado river
and the main road along the valley, at elevation 1025 masl. Length of the access tunnel will
have some 2050 m, with slope 8.5%.
The access tunnel has been designed with an excavated cross section of 35 m2.
This size has been selected with basis in the estimated space needed for transport of the
transformer. If this size is not sufficient for transport of the bifurcation for the 3.7 m dia penstock,
the bifurcation must be transported in parts and assembled inside.
Las Lajas will have a separate cable shaft/cable tunnel, and the cables from the
transformers will not be led out of the access tunnel.
It has been decided to supply ventilation air via the access tunnel, and evacuate
air via the tailrace tunnel and a shaft drilled to the surface at point L5A.
2.2

Las Lajas Powerhouse Area

Location of the powerhouse inside the rock massif east of Estero El Sauce is
determined by the location of the top of pressure shaft, point L9, at elevation 1000 masl.
The direction of the longitudinal axis of the powerhouse cavern has been
preliminarily determined from what appears the optimum with respect to the geological
conditions, based on information from geological mapping available at the time of basic design.
Final orientation of the powerhouse, and hence the final arrangement of the tunnel system in the
powerhouse area will be determined when sufficient information on the in situ rock conditions
has been obtained.
The Las Lajas powerhouse will have a gross head of 469 m and an installation of
2 x 132 MW, in two Pelton type turbines with speed of 300 rpm and 6 jets.
The elevation of the Pelton runners is 840 masl.

600-TU-CDD-001
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Elevation of the main machine hall floor will be at 852 masl.
The dimension of the powerhouse is determined chiefly by the dimensions of the
turbines and generators selected.
The width between the upstream and downstream walls of the power station is
15.2 m. Adding 0.3 m wall thickness and 1.2 m between wall and rock on each side it gives a
total cavern width of 18.2 m.
The generator will have a diameter of approx. 8.2 m, and inner dimensions of the
generator room are 10 x 10 m.
The distance between units is estimated to 21.2 m.
The height of the station is determined by the height of the generator rotor with
shaft, and the need to be able to lift it above the machine hall floor. The height from turbine
centre level to crane rail level is approximately 21 m.
Cooling water tanks and tanks for fire water are located in a tunnel excavated as
extension of the cavern top heading.
The dimensions of the powerhouse have been determined with basis in the
dimensions of the turbines and generators selected. The dimensions of the equipment actually
supplied may deviate from this design basis, which could imply minor adjustment of powerhouse
dimensions.
Two three-phase transformers will be located in niches in a tunnel parallel to the
main cavern, connected to the cavern via busbar tunnels.
The cables will be conveyed out via a separate cable shaft, 210 m long, inclined
45, continuing in a cable tunnel of 685m length to the point VL5, at elevation 1080 masl, from
there it will be laid in cable trays up to new Alto Maipo substation, where the cables will be
connected to the GIS plant.
The cable tunnel continues from top of the cable shaft to top of the pressure shaft.
Leakage from the cable tunnel and from downstream of the steel cone area will be conducted
via the cable shaft to the tailrace tunnel, via one ore two holes drilled from the transformer tunnel
to the tailrace.
A transport tunnel to the area at the foot of the pressure shaft branches off from
the main access near the powerhouse cavern. Dimensioning for the size, alignment and curve
radius for this tunnel, and for necessary space in the area at the foot of the pressure shaft, and
the lower penstock area with bifurcation, will be the space needed for transport and assembly of
the downstream portion of the penstock steel lining with bifurcation. If necessary due to space

600-TU-CDD-001
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limitation in the access tunnel, the bifurcation must be transported in parts and assembled
inside.
A transport tunnel connects the access tunnel with the tailrace tunnel. The tunnel
will be used for excavation of part of the tailrace tunnel and to ensure air supply to the free flow
tailrace tunnel. A tunnel cross section of 36 m2 has been assumed for basic design.
The resulting layout and dimension of the transport tunnel and associated area,
as well as need for additional transport tunnels and space in the powerhouse area, will be
determined by the contractor.
2.3

Las Lajas Headrace tunnel

Flow from Alfalfal and ro Colorado, maximum 37 m3/s, is conveyed into the
headrace tunnel at point VL8, some 2 km downstream of the Alfalfal I tailrace outlet, by means
of a concrete culvert from Cmara de Carga. The tunnel alignment follows the points VL8 - L15
- L14-L13- L12-L11- L10 to the top of the pressure shaft at L9. The minimum tunnel cross
section from VL8 to L10 is 21 m2. The tunnel invert will have concrete pavement.
An adit to the headrace tunnel, Los Trescientos, starts at point VL7.
A shaft drilled from the surface will connect canal Aucayes with the headrace
tunnel.
Flow from Alfalfal II, 27 m3/s, is introduced at L10.
From L10 to L9 the total maximum design flow is 65 m3/s. The minimum cross
section at this stretch is 30 m2. The tunnel invert will have concrete pavement.
2.4

Surge system

The surge system comprises a vertical shaft excavated from the surface by raise
boring down to the headrace tunnel close to point L9, near the top of the pressure shaft. A shaft
diameter of 5 m, has been selected, the same diameter as the pressure shaft. The diameter is
enlarged to 10 m by slashing, between elevations 1275 masl and 1335 masl.
It is estimated that the heaviest pieces of the drilling equipment will have a weight
of 6-8 tons, exceeding the capacity of a helicopter. Suitable access to the surface of the shaft is
needed for transport of these elements.

600-TU-CDD-001
11
2.5

Pressure shaft

A vertical pressure shaft has been selected for Las Lajas. Steel lining has been
assumed up to elevation 1000 masl, i.e. for pressures exceeding approx. 320 m. This gives the
criterion for the proposed location of the steel cone shortly upstream of the pressure shaft, near
point L9.
The final decision on location of the steel cone will be made when results are
available from in situ observations and tests, including hydraulic fracturing tests.
The vertical shaft is approx. 160 m long, and will be excavated by drilling a pilot
hole from the top and reaming to the desired diameter of 4.7 m. The steel lining with diameter
3.7 m will be embedded in concrete.
2.6

Transition zone and valve chamber

The transition between the headrace tunnel and the steel lined pressure shaft will

comprise:

An expanded section of the tunnel, with sand trap, for a length of approx.
90 m.

The steel cone followed by a 25 m long section of steel tube embedded in

concrete.

A horizontal section through a potential, future valve chamber. No valve will

be installed at the time of construction.

The dimension of a valve will be such that it would be necessary to produce the
valve in parts and assemble it in the valve chamber. The dimensions of the chamber will be
designed with this in mind. Any concrete structures necessary for valve assembly will be
constructed later when and if needed.
2.7
2.7.1

Las Lajas Tailrace tunnel

General

Total length of the Las Lajas tailrace tunnel measured from the outlet at ro Maipo
to the point where the tunnel meets the tailrace branches from each unit is 13.0 km.
Elevation of the tunnel invert at the outlet is governed by the criterion that
sufficient free space must be provided between the tunnel roof and the water surface when the
power plant is operating at maximum design flood level in ro Maipo. This criterion, combined
with the selected slope of 0.011% slope for the free flow tailrace tunnel, has been used when

600-TU-CDD-001
12
optimizing the tunnel size and determining the elevation of the Pelton runner in Las Lajas
powerhouse.
Minimum tunnel cross section for a D&B tunnel has been set to 36 m2, with a
theoretical width of 6.1 m. In order to reduce friction, the invert will be concreted along its entire
length and a 5 cm layer of sprayed concrete will be applied on all parts of the tunnel wall where
concrete lining or sprayed concrete has not already been applied for reasons of rock support.
2.7.2

Tunnel outlet

The Las Lajas tailrace tunnel outlet at ro Maipo, point VL1, will be located
approximately 1950 m downstream of Estero El Manzano.
The elevation of the invert floor at the tunnel outlet has been selected to release
the flow to the Maipo River at the natural flow elevation of the River itself.
The tunnel will pass under the public road into the rock massif. Rock topography
is unknown in the area under the public road. One cannot exclude the possibility that the Maipo
river previously had its course in this area, implying that soil could be encountered at tunnel
level.
Crossing of this area with the tailrace tunnel and establishing a tunnel cut in rock
will be at the Contractors design. He will also be responsible for all necessary permits, contact
with road authorities, arrangements to ensure that traffic on the road can be maintained
according to authorities requirements etc.
2.7.3

Alternative with use of TBM for part of the Las Lajas Tailrace Tunnel

An alternative for excavation of the Las Lajas tailrace tunnel would be by TBM
from the downstream end, for a length of approx. 9 km. In this case, the adit Las Puertas could
be omitted.
If a TBM is selected, the initial 1.5 km of the downstream end of the tailrace tunnel
could be excavated by D&B during the lead time for the TBM.
2.8

Las Lajas Cable tunnel (Bio Bio)

2.8.1

Tunnel dimension
The tunnel from point VL5 at the switchyard will serve several purposes:

Construction adit for excavation of the headrace tunnel

600-TU-CDD-001
13

Transport tunnel for the elements of the 3.7 m diameter penstock

Cable tunnel.

Dimensioning for tunnel size has been the 3.7 m diameter penstock elements. A
tunnel with minimum width 5.1 m and height minimum 6.0 m2, cross section 28.1 m2, has been
selected for the Cable tunnel. Measurements refer to the theoretical contour line.
2.8.2

Cable tunnel (Bo Bo) entrance

The location of VL5 near the plateau for the switchyard has been selected
considering needs for the road down to the plateau and switchyard requirements. The tunnel
will cross under the public road. There will be excavation in a certain amount of soil before
reaching tunnel cut in rock. Design of this part of the tunnel/cut and arrangements for
maintaining traffic on the road according to requirements, including contact with authorities,
permits etc is the responsibility of the contractor. The road is exposed to traffic by heavy trucks.

3.

ALFALFAL II DESCRIPTION OF LAYOUT

3.1

Basis for alignment of tunnels

Evaluation of the geology in the area for the Alfalfal II headrace tunnel, from its
upstream end to the powerhouse area, has been basis for the selection of the tunnel alignment.
It has been decided not to include an intermediate adit for the tunnel.
In order to complete the 14.8 km long Alfalfal II headrace tunnel within a
reasonable time, alternatives with TBMs and combining TBM with D&B have been analysed.
The following method has been selected for Basic Design:

Excavation by a TBM from the downstream end, A9, at an ascending slope

of 7%, for approx 8 km to point A10. The cross section of this tunnel will be
dictated from constructive reasons, and a minimum TBM diameter of 4.5 m
has been assumed.

Excavation by D&B, with rail bound equipment, from point VA4 in direction
of A11 with a minimum tunnel cross section of 13 m2, on descending slope
for 6250 m to point A10.

The tunnel from VA4 to A11, a stretch of 200 m, will be expanded to a cross
section of minimum 26.2 m2 in order to give room for the 3.1 m dia steel tube transferring flow
from the Volcn/Yeso system to the headrace tunnel and passage of vehicles for future
inspection of the tunnel. At the transition between steel tube and tunnel, a concrete plug with a

600-TU-CDD-001
14
steel bulkhead will be located. Dimensions of the gate will be W x H = 2.7 x 2.7 m, to permit
passage of vehicles for inspection of the tunnel.
The Yeso/Volcan steel tube will have a high point at the entrance to the headrace
tunnel, at VA4. An aeration arrangement will be connected to the steel tube at the high point.
A particular investigation and laboratory test program regarding rock
characteristics has been done in order to determine specifications for the TBM. (Ref. 600-GEINF-005)
3.2

Alfalfal Access tunnel

The access tunnel portal has been selected at point VA1 where the tunnel for the
access road along Estero Aucayes starts, at elevation 1507 masl. The length of the tunnel will
be approx. 2500 m. The length is subject to adjustment following decision on exact location and
orientation of the powerhouse.
The minimum cross section of the tunnel has been determined from the space
needed for transport of the transformer, and has been estimated to 35 m2.
The cables from the transformers will be located on cable trays fixed to the tunnel
walls out to the entrance from where they will be installed in a cable trench to the small
switchgear just outside the portal.
Three niches for phase revolvement of the cables shall be provided along the
access tunnel.
Ventilation air will be supplied from the access tunnel and evacuated via a vertical
shaft to the surface from the tailrace tunnel.
3.3

Alfalfal Powerhouse area

Ref. Drawings 620-TU-PLA-003, 620-TU-PLA-004 and 620-TU-PLA-005 for

arrangements and main dimensions of the powerhouse.
Location of the powerhouse inside the rock massif south-west of Estero Aucayes
is determined by the location of top the pressure shaft, point TPS, and the decision on
constructing a 45 inclined pressure shaft.
The direction of the longitudinal axis of the powerhouse cavern has been
preliminarily determined from what appears the optimum with respect to the geological
conditions, based on information from geological mapping available at the time of basic design.
Final orientation of the powerhouse, and hence the final arrangement of the tunnel system in the

600-TU-CDD-001
15
powerhouse area will be determined when sufficient information on the in situ rock conditions
has been obtained.
The elevation of the Pelton runners has been set at elevation 1341 masl. The
criterion for determining the elevation of the Pelton runners at Alfalfal II is that they shall be
located sufficiently high above the tailrace water surface also in the situation that Las Lajas
closes and the Alfalfal II flow is conducted to Cmara de Carga, at the upper end of the Las
Lajas headrace tunnel.
The width between the upstream and downstream walls of the station is 13.4 m.
Adding 0.3 m wall thickness and 1.2 m between wall and rock on each side it gives a total
cavern width of 16.4 m.
The inner dimensions of the generator room have been set to 8.9 m x 8.9 m in
Basic Design.
The distance between units is estimated at 19.6 m.
The height of the station is determined by the height of the generator rotor with
shaft, and the need to be able to lift it above the machine hall floor. The height from turbine
centre level to crane rail level is approximately 22 m.
Cooling water tanks are located in a tunnel excavated as extension of the cavern
top heading.
Additional cooling water volume for emergency cases will be provided by
excavating the inner part of the tailrace tunnels/turbine pits to a lower level.
The dimensions of the powerhouse have been determined with basis in the
dimensions of the turbines and generators selected. The dimensions of the equipment actually
supplied may deviate from this design basis, which could imply adjustment of powerhouse
dimensions.
Transformers will be located in niches in a tunnel parallel to the powerhouse
cavern and connected to the cavern by busbar tunnels.
A transport tunnel to the area at the foot of the pressure shaft branches off from
the main access tunnel some distance from the powerhouse cavern. Dimensioning for the size,
alignment and curve radius for this tunnel, and for necessary space in the area at the foot of the
pressure shaft, and the lower penstock area with bifurcation, will be:

The space needed for transport and assembling of the TBM to be used for
excavation of the pressure shaft.

600-TU-CDD-001
16

The space needed for transport and assembly of the downstream portion of
the penstock steel lining with bifurcation.

The resulting layout and dimension of the transport tunnel and associated area,
as well as need for additional transport tunnels in the powerhouse area, will be determined by
the contractor.
3.4

Tailrace tunnel

The tailrace tunnel from Alfalfal II connects to point L10 of the Las Lajas headrace
tunnel at elevation 1250 masl. The tunnel length is approx. 3055 m and its cross section 21 m2,
as determined from hydraulic needs.
The upstream part of the tailrace tunnel will be a free flow tunnel at mild slope,
while the lower part, connecting to L10, will have a slope of 10%.
The tunnel cross section will be expanded in the transition zone between mild and
steep slope of the tunnel.
A construction tunnel connects the tailrace tunnel with the access tunnel a short
distance downstream of the powerhouse.
A ventilation shaft will be drilled from the surface to connect with the free flow
section of the access tunnel, some 950 m upstream of A1.
3.5

Pressure shaft

The maximum gross head for Alfalfal II will be 1160 m. From interpretation of the
available data, and also with reference to the experience from Alfalfal, it has been assumed that
steel lining would be needed up to elevation 1950 masl, i.e. for pressures higher than approx.
550 m.
The pressure shaft could be vertical or inclined. An inclined shaft has been
selected by the Gener, as this will shorten the length of the access tunnel and tailrace tunnel by
600 m and thereby reduce critical construction time for the powerhouse complex.
The shaft will be steel lined, with an internal liner diameter of 2.4 m. The shaft will
be excavated by a TBM with diameter 3.4 m, i.e. with theoretical space 0.5 m between the steel
lining and rock. The steel lining will be embedded in concrete.
After reaching the top of the pressure shaft, the TBM will be partly dismantled and
moved a distance upstream in the headrace tunnel where it will be reassembled and used for
excavation of the surge shaft and tunnel.

600-TU-CDD-001
17
3.6

Transition zone and valve chamber

The transition between the headrace tunnel and the steel lined pressure shaft will

comprise:

An expanded section of the tunnel, with sand trap, for a length of approx.
90 m.

The steel cone followed by a 30 m long section of steel tube embedded in

concrete.

A horizontal section through a potential, future valve chamber. No valve will

be installed at the time of construction.

The dimension of such a valve will be such that it could be necessary to produce
the valve in parts and assemble it in the valve chamber. The dimensions of the chamber will be
designed with this in mind. Any concrete structures necessary for valve assembly will be
constructed later when and if needed.
3.7

Surge shaft and surge chamber.

The surge system for Alfalfal II comprises a 45 inclined shaft, approx. 685 m
long, excavated by 3.4 m dia TBM used for the headrace tunnel, followed by a tunnel on
minimum slope of approx. 250 m length, also excavated by the TBM, ending in an upper surge
chamber on the surface. The surge chamber will be excavated in rock as an open pit in the
Aucayes valley.
For Basic design it has been assumed that the TBM will be dismantled and
withdrawn back through the surge tunnel/shaft to the headrace tunnel and further through the
tunnel A9-VA2 and the spoils from the excavation of the surge chamber, some 50 000 m3, will
also have to be transported out via this tunnel system. It is for the Contractor to decide wether
the TBM can alternatively be withdrawn through the surface at the Aucayes pond, where approx.
7.5 km of road would have to be constructed in order to access the Aucayes pond.
3.8

Headrace Tunnel Alfalfal II.

Reference is made to Drawings 620-TU-PLA-001, 620-TU-PLA-002 and 620-TU-

PLA-003
3.8.1

General

The length of the headrace tunnel, from point A9 shortly upstream of the top of
the pressure shaft via A10 to VA4 at the upstream end will be 14.8 km. Access to point A9 will

600-TU-CDD-001
18
be via a 2000 m long tunnel excavated from point VA2. Basis for the selected alignment A9A10-A11 is evaluation of the topography and indications for tunnelling conditions in the area to
be traversed. The bend at A10 is recommended in order to reduce the rock cover above the
tunnel to an acceptable level.
It has been assumed for Basic Design that the tunnel will be excavated by TBM
from the downstream end and by D&B from the upstream end.
3.8.2

Tunnel portion excavated by TBM

The TBM will start at point VA2, excavating 2 km at approx. 6.7% slope before
reaching the headrace tunnel at point A9. From this point, the TBM will continue at approx 5.6%
slope towards A10 and further in the direction of A11 until it meets the D&B excavation from the
upstream end. Point A10 has been assumed as meeting point.
Due to the slope requirements, the secondary transport system must be on
wheels. The minimum diameter of the TBM has been set to 4.5 m. in Basic Design.
3.8.3

Tunnel portion excavated from the upstream end

The upstream portion of the headrace tunnel will start at VA4, and will be by D&B
at ascending slope, initially 1.5%, then 0.15% until meeting the TBM excavating from the
downstream end.
The cross section will be minimum 13 m2, and rail mounted excavation equipment
is anticipated. The contractor will be permitted to suggest larger cross section.
The cross section of the initial 200 m of the tunnel from VA4 will be expanded to
26.3 m in order to accommodate the 3.1 m diameter steel tube transferring the Volcn-Yeso
flow into the Alfalfal II headrace tunnel and passage of vehicles for future tunnel inspections. A
concrete plug with a gated steel bulkhead will be installed at the transition between the steel
tube and the headrace tunnel. Gate opening will be W x H = 2.7 x 2.7 m to allow entrance of
vehicles for tunnel inspection.
2

4.

TUNNEL EL VOLCN
Reference is made to the Drawings 610-TU-PLA-001, 610-TU-PLA-002 and 610-

TU-PLA-003.

600-TU-CDD-001
19
4.1

Basis for alignment

Basis for the design is that the tunnel will start at point V1, which is the ending
point of the upstream flow collecting system, and point V6, at starting point for the conduit
crossing ro Yeso with the Yeso/Volcn flow. The alignment has been selected based on the
geological information as described in Chapter 7. Total tunnel length is approximately 14.1 km.
The tunnel elevation and slope is determined from the aim to obtain a pressurized
tunnel system from the upstream end of Tunnel El Volcn, and to utilize the volume of tunnel
Volcn for reservoir purposes. This implies that the tunnel will be excavated on mild slope of
0.1%.
For Basic Design it has been assumed that a TBM will be used for excavation in
the upstream direction from V6. D&B will be used from the upstream end.
The design flow for Tunnel El Volcan is 12,8 m3/s. The minimum cross section of
the tunnel will be determined from constructional needs.
4.2

Tunnel portion excavated by TBM

The geological conditions described in Chapter 7 indicate that the risk of

encountering spalling and squeezing rock, due to the high overburden, becomes very high at
5-7 km upstream of point V6. This must be considered by the contractor when selecting type of
TBM and when estimating the length of tunnel that can be expected to be excavated by the
TBM. A TBM diameter of 4.1 m has been assumed for basic design. The TBM will excavate on
ascending slope 0.1%.
4.3

Tunnel portion excavated by D&B

For Basic Design it has been assumed that the TBM will have to be withdrawn
after 7 km, and that excavation continues in the upstream direction with D&B.
The tunnel starting in the upstream end near V1 will excavate on descending
slope of 0.1%, until meeting the TBM excavating from downstream.
A minimum cross section of 14 m2 has been assumed for the D&B tunnel in Basic
Design.

600-TU-CDD-001
20
5.

ELECTRICAL EQUIPMENT
5.1

Background

The basic design for the electrical works in the two new power stations is defined
in the following documents:

Proposed single line diagrams for Alfalfal II and Las Lajas Power Station.

Proposed topological diagram for the control of the Alto Maipo Complex.

Proposed arrangement drawings for Alfalfal II and Las Lajas Power Station.

Proposed general specifications.

Proposed general technical specifications.

Proposed project specific data.

This section supplements the documents mentioned above and addresses some
basic design considerations not immediately evident in the design documents.
The overruling design basis is that the stations should be designed for reliable
unmanned operation, long lifetime as well as low and easy maintenance. Special attention is
given to the matter of safety for personnel and equipment.
The detailed engineering shall be based on Chilean and international accepted
standards (in particular IEC standards) and well proven solutions adapted to local conditions.
Special attention will be paid to the seismic requirements in the region.
5.2

Evacuation

The powerhouses, and Alfalfal II in particular, are located far underground with
only one fully functional evacuation route. Should this route be blocked by smoke, escape would
be difficult even with smoke diving equipment. In line with modern health and safety practice,
the station is, therefore, designed with a centrally located safe room with air storage, storage of
smoke diver equipment, first aid equipment and direct voice communication to the outside.
5.3

Separate transformer hall

Each of the two power stations in the Alto Maipo project will have units in the
range of 150 MVA which is quite sizable. The rated current will be in the range of 7 kA and the
sub-transient short circuit current in the range of 100 kA.

600-TU-CDD-001
21
This means that the amount of energy stored in the system is large. If a fault
occurs, the destruction can therefore be considerable provided the fault is not confined to a
limited space and time.
Transformer faults are very rare but the consequences are often dramatic. A fire
in the transformer normally results in development of heavy smoke that can damage nearby
equipment and be quite hazardous for personnel. Hence, recent trends have been to erect the
transformers in a separate cavern which can be sealed off from the main machine hall. A fire
may then be extinguished faster due to lack of oxygen, smoke will not penetrate to the rest of the
station, personnel will be able to evacuate to smoke-free locations and possible oil mist
explosions will be relieved into empty space. Such location also offers advantages for operation
as the transformer is more accessible for inspection and maintenance.
An arrangement with transformers in niches in a separate cavern has been
assumed.
5.4

Generator breaker

The rotational energy stored in large generator units will continue to be pumped
into a fault until the generator is disconnected or de-energised. A generator breaker will remove
the energy supply from a transformer or cable fault within milliseconds, thus reducing the
consequences of a fault. Without a generator breaker it will take seconds before the fault
current stops flowing. A generator breaker is indicated as an option on the drawings. The
Gener will make the decision on whether to include this item, based on considerations of cost,
risks and insurance policy.
5.5

Generator and transformer

The rating of the generator is governed by the rating of the turbine. For Alfalfal II,
the 600 r.p.m turbine alternative was discarded due to the high runaway speed given by a Pelton
turbine. No references have been found for generators with this combination of speed and
power. A generator meeting the pertaining runaway requirements could most likely be designed
by more reputable manufacturers but will be relatively costly. A more conservative approach
with 500 r.p.m. has been chosen. Bidders could be invited to present costs for 600 r.p.m as a
separate option.
The design is based on erection in the pit. Extra room for floor erection or for
unloading will be considered in the detailed design. The waterways are relatively stable and no
extra moment of inertia above the natural design values are considered necessary.
Considering that a certain degree of reactive power capacity gives some room for
overproduction and some temperature margins, a power factor of 0.9 has been selected. The
generator will be designed to run at full MVA rating at power factor 1.0.

600-TU-CDD-001
22
The transformer rating follows the generator rating. Three phase transformers are
selected, as the transport roads can reportedly can be prepared for such loads. Approximate
transport weight of one transformer is 120 tons.
5.6

Outdoor breakers

The portal of the Las Lajas cable tunnel is located close to the new Alto Maipo
Substation and the cables will be terminated in the proposed GIS switchgear here. This means
that each of the Las Lajas power transformers will have a normal HV transformer breaker. Care
must be taken in coordinating the protection and control as Las Lajas and Alto Maipo belong to
separate contracts.
For Alfalfal II the nearest substation is far away and the connection has to be on a
double overhead line passing rather difficult terrain. This means that the chances for short
circuits (temporary and permanent) are not to be neglected. If no breaker is accommodated
between the cable and the overhead line the trip signal has to be transmitted up to the nearest
substation which is a substantial distance for conveying trip signals. Anyhow, fault currents will
be fed from the generator and stress the cable and transformer until the generator breaker trips
or the generator is de-energized. If no generator breaker is installed this can take seconds.
It is possible to have a simplified substation just outside the portal. It is therefore
proposed to have a simplified possibility to disconnect the line from the cable. This is in order to
have a backup in the event of faults and to have a safe isolation point for work on the line. Such
disconnection point could easily be arranged by using the modern combined circuit
breakers/isolators/ earth switches.
5.7

230 kV Cable

The main 230 kV cable will be of solid PEX design. In Alfalfal II the cables are
proposed to be installed in cable trays in the access tunnel. In Las Lajas a separate cable
tunnel is proposed. In the inclined part of this tunnel the supplier will be requested to present a
reinforcement, fastening and monitoring system assuring that no creep will develop over the
lifetime of the cable.
5.8

Auxiliary supply

The auxiliary supply is proposed to be based on the unit transformer system

where each running unit is supplied by its own auxiliary transformer. If this supply is unavailable,
the supply will be switched to the other unit. If both auxiliary transformers are unavailable, the
supply is taken from the outside 12 kV line. If that line is down, the emergency generator in the
portal building will start.

600-TU-CDD-001
23
The distance from the portal building to the machine hall is so long that the
transmission must be based on medium voltage level. It is therefore proposed to combine the
cable from the outside 12 kV connection and for the emergency generator by a switch over
arrangement in the portal building. The cable must be designed for emergency operation (fire
proof) and disconnection of non priority loads will be done by contactor operation in the motor
control centres.
Low voltage switchgear can be built for up to 50 kA short circuit current but a
more modest requirement of 32 kA gives a smaller and less expensive board. Provisionally, a
short circuit limiting reactor is planned but the final short circuit calculations will determine
whether such reactor will be necessary.
5.9

Control and Supervisory Control and Data Acquisition (SCADA) System

The local control system will be based on distributed control with intelligent
input/output units close to the main components. The basic intention should be to interact and
control the equipment as close to the process as possible. Internal communication will be by bus
communication, most likely with fibre optic cables.
Each independent system (Unit 1, Unit 2, Auxiliary Systems, Water Management
etc. will have an independent control computer (object computer). The object computer must be
autonomous, assuring safe operation of the unit if communication with overlaying system fails or
the control system for another system fails. The principle of the system is shown in the
topological control diagram.
If the Gener would wish a conventional back up control cubicle for each unit, such
will work through the object computer.
The three stations (Alfalfal II, Las Lajas and Alto Maipo Substations) will work
independently with full control functionality from the respective control rooms. Local data will be
stored and dealt with as close to the process as possible.
For normal operation these control rooms will be unmanned and all three stations
together with the existing Alfallfal will be controlled from a SCADA system in the central control
room located in the Alfalfal administrative building. Communication to the grid companys
dispatch centre is foreseen to be performed from this main control centre and is outside the
scope for this contract but necessary data will be available in the SCADA system.
The main connection with the power stations will be on a fibre optic earth wire on
the transmission line (OPGW). As OPGW is lacking on the old transmission lines, a ring cannot
be closed. A separate backup should be considered (Power Line Carrier or microwave or
similar).

600-TU-CDD-001
24
An emergency stop system acting directly on the units will be included, allowing
emergency stop and disconnection from the mains by activating centrally located pushbuttons in
the machine hall and the portal building.
Company proprietary communication protocols have up to recent years been a
great hindrance for mixing of makes within a system. The development of international
standards (in particular the IEC 60817 standards and newer IEC standards) has solved this
problem and use of such protocols should therefore be demanded.
Communication to the critical intake reservoirs (Las Lajas intake and Alfalfal II
reservoir) should be given special attention in the detailed design phase. The measurements
are simple and communication capacity requirements small but the importance of the
measurements is high.
5.10

Protection

Protection is achieved with multi-functional numeric protection units. The detailed

protection scheme will be worked out as part of the technical specifications. The basis will be to
have selectivity avoiding total blackout, and safety in the form of at least two independent
systems for detection of short circuit and earth fault.
Selective protection of short lines has up to now been difficult. New technology
has expanded the differential protection technology by using the fibre optic cable for
communication of the differential currents. Such system is strongly recommended in this case.

6.

MECHANICAL EQUIPMENT
6.1

General

Data for the main mechanical equipment and the steel penstock are described
below, and will be further detailed in the general and particular specifications to be elaborated.
The following is supplementary information on basis for the decisions made.
6.2
6.2.1

Alfalfal II
Turbines
Two vertical Pelton turbines will be installed, with the following main data;

600-TU-CDD-001
25

Item
Gross head
Net head
Nominal capacity
Number of jets
Speed
Runner diameter

Data
1156 m
1118
132 MW
4
500
2.72 m

An alternative with 5 jets and a speed of 600 rpm is possible from the point of
view of the turbine, and has been analyzed. It has the advantage of giving a smaller and less
expensive turbine, but the combination of output and speed is problematic for the generator due
to the high runaway speed. Although such a generator could be technically feasible, generators
with this combination of output and speed have not yet been constructed. This alternative has,
therefore been discarded for basic design.
6.2.2

Spherical valves
Each turbine will be equipped with a spherical valve.

Opening will be by oil pressure. Closing by counterweight is proposed. Used

originally mostly for smaller units, this method is increasingly used also for large spherical
valves. A recent reference is the 200 MW Pelton turbines with 1 100 m head at Tyin power
station in Norway.
Alternatively, closing by water pressure (as for Alfalfal I) is possible, but a
counterweight solution will eliminate problems related to the quality of the water.
6.2.3

Cooling water system

An open circuit cooling system has been selected. Pumps will take water from a
cooling water sump in the tailrace, pumping it up to a cooling water tank. The cooling water is
then distributed to the different consumers:

Generator air coolers

Turbine and Generator bearings

Bearing coolers and governor cooler

Turbine Governor

Transformer coolers

600-TU-CDD-001
26
The pumps will be either long shafted units with the motor located at the turbine
cellar level, or submersible pumps. The latter solution is increasingly used. Automatic
back-flushing strainers will be provided, located in the pump room.
The tank is double to permit cleaning of one section while the other is in
operation.
Preliminary data for the cooling water system:
Total cooling water consumption (units and
transformers

210 l/s

Number and capacity of pumps:

4 pumps - 70 l/s

Total volume of tank:

300 m3

One pump is spare, 3 pumps are normally on duty. One spare plus two pumps on
duty is an option, but a total of 4 pumps is preferred as it reduces the size and power of the
units, and reduces the frequency of start and stop of the pumps. Start and stop of the pumps
will be by level switches between defined levels in the tank.
6.2.4

Machine hall crane

One machine hall crane will be installed, with sufficient capacity to lift the
generator rotor. Estimated weight of the rotor is 180 ton. The crane will also have an auxiliary
hoist with a capacity in the range of 20 ton.
The spherical valve will be installed through hatches in the machine hall floor and
the generator floor.
The turbine runner will be installed and removed by means of a platform with rails
to a position below hatches on the downstream side of the station, and lifted by the machine hall
crane.
The inlet tube to the valve has an angle of 60 relative to the longitudinal axis of
the powerhouse. This arrangement allows bringing the valve farther in, thus reducing the width
requirement of the powerhouse on the upstream side.
Cooling water piping to the units will be routed in the space between the upstream
wall and the rock, from where it will be distributed to the respective units. A common outlet pipe
from the units will be routed to the outlet channel of the unit on the downstream side of the
station.

600-TU-CDD-001
27
6.2.5

Penstock steel lining

A steel quality with denomination 460 (Steel grade: P460NL1 acc. to EN

10 028-3) is now frequently used for this kind of application, and has been assumed for basic
design.
The figure 460 is the yield strength in MPa for smaller thicknesses. The yield
strength is slightly reduced as the thickness increases. For thickness above 40 mm, the yield
strength is 440 MPa. For simplicity at the present stage, 440 MPa yield strength has been
assumed for all the elements of the lining.
Calculation of thickness with empty pipe submitted to outer pressure has been
performed according to Amstutz, assuming generally accepted material and load factors.
Design of the penstocks has been based on a maximum velocity of 6.0 m/s.
6.3
6.3.1

Las Lajas
Turbines
Two vertical Pelton turbines will be installed, with the following main data;
Item

Data

Gross head

483 m

Net head

468 m

Nominal capacity
Number of jets
Speed
Runner diameter

134 mw
6
300 rpm
2.91 m

Opinions vary between suppliers concerning the question of whether a six jet
turbine would be more sensitive to sand erosion than a five jet turbine, and whether there is a
reduction of the efficiency at full load. The natural choice of speed for a five jet turbine would be
250 rpm. The main conclusion is that the influence of these two aspects will be marginal and will
not justify the significant increase in total equipment cost that would result from reducing the
speed to 250 rpm.
6.3.2

Spherical valves
Each turbine will be equipped with a spherical valve.

Opening will be by oil pressure. Closing by counterweight is proposed. Used

originally mostly for smaller units, this method is increasingly used for large spherical valves. A

600-TU-CDD-001
28
recent reference is the 200 MW Pelton turbines with 1 100 m head at Tyin power station in
Norway.
Alternatively, closing by water pressure (as for Alfalfal) is possible, but a
counterweight solution will eliminate any problems related to the quality of the water.
6.3.3

Cooling water system

An open circuit cooling system has been selected. Pumps will take water from a
cooling water sump in the tailrace, pumping it up to a cooling water tank. The cooling water is
then distributed to the different consumers:

Generator air coolers.

Turbine and Generator bearings

Bearing coolers and governor cooler.

Turbine Governor

Transformer coolers.

The pumps will be either long shafted units with the motor located at the turbine
cellar level, or submersible pumps. The latter solution is increasingly used. Automatic backflushing strainers will be provided, located in the pump room.
The tank is double to permit cleaning of one section while the other is in
operation.
Preliminary data for the cooling water system:
Total cooling water consumption (units and
210 l/s
transformers
Number and capacity of pumps:

4 pumps - 70 l/s

Total volume of tank:

300 m3

One pump is spare, 3 pumps are normally on duty. One spare plus two pumps on
duty is an option, but a total of 4 pumps is preferred as it reduces the size and power of the
units, and reduces the frequency of start and stop of the pumps. Start and stop of the pumps
will be by level switches between defined levels in the tank.

600-TU-CDD-001
29
6.3.4

Machine hall crane

One machine hall crane will be installed, with sufficient capacity to lift the
generator rotor. Estimated weight of the rotor is 200 tons. The crane will also have an auxiliary
hoist with a capacity in the range of 20 tons.
The spherical valve will be installed through hatches in the machine hall floor and
the generator floor.
The turbine runner will be installed and removed by means of a platform with rails
to a position below hatches on the downstream side of the station, and lifted by the machine hall
crane.
The inlet tube to the valve has an angle of 60 relative to the longitudinal axis of
the powerhouse. This arrangement allows bringing the valve farther in, thus reducing the width
requirement of the powerhouse on the upstream side.
Cooling water piping to the units will be routed in the space between the upstream
wall and the rock, from where it will be distributed to the respective units. A common outlet pipe
from the units will be routed to the outlet channel of the unit on the downstream side of the
station.
6.3.5

Penstock steel lining

A steel quality with denomination 460 is now frequently used for this kind of
application, and has been assumed for preliminary dimensioning and cost estimates.
The figure 460 is the yield strength in MPa for smaller thicknesses. The yield
strength is slightly reduced as the thickness increases. For thickness above 40 mm, the yield
strength is 440 MPa. For simplicity at the present stage, 440 MPa yield strength has been
assumed for all the elements of the lining.
Calculation of thickness with empty pipe submitted to outer pressure has been
performed according to Amstutz, assuming generally accepted material and load factors.
Economic optimisation of the penstock results in velocities that are considered
unfavourably high in practice. Design of the penstocks has been based on a maximum velocity
of 6.0 m/s.

600-TU-CDD-001
30
7.

ENGINEERING GEOLOGY IN BASIC DESIGN

7.1

General layout

Drawing 600-TU-PLA-001 shows the general arrangement of the Alto Maipo

Hydroelectric Project. For the Alfalfal II power station the ca 14 km long Volcn transfer tunnel
combines with flow from the Yeso reservoir into the ca 15 km long headrace tunnel to the top of
the pressure shaft. The inclined pressure shaft, 860 m long, is planned as steel lined shaft. The
remaining 530 m of head is accommodated in an unlined pressure tunnel.
From Alfalfal II the ca 3 km long tailrace tunnel meets the ca 6 km long tunnel
taking the flow from Alfalfal and the combined flow is taken by a ca 3 km long pressure tunnel to
the top of the vertical, 160 m long pressure shaft of the Las Lajas power station. The remaining
about 280 m of head is accommodated in the pressure tunnel. From the Las Lajas power
station, a ca 13 km free flow tailrace tunnel leads to the outlet in ro Maipo downstream of El
Manzano.
The layout outlined above is a result of a process where technical requirements
from the hydropower engineering have been mated with geological constraints and construction
aspects.
7.2

Geological information

Available geological information for the basic design has been the investigations
performed for the concept studies, feasibility study and the geological mapping done for the
basic design. The interpretation of this information is documented in the reports N 601-GE-INF001, 610-GE-INF-001, 620-GE-INF-001 y 630-GE-INF-001, with geological maps and profiles.
7.3
7.3.1

Design of underground openings

General

Design criteria for underground openings are linked to functionality. One basic
requirement is that the design shall ensure the integrity of the opening during the construction
phase and during the operational phase, limited to the design life expectancy of the opening.
The integrity of the opening relates to the rock mass quality and thereby the amount of rock
support required in order to provide this integrity.
For pressurized waterways without impermeable lining, the requirement to global
stability is that the minimum principal stress in the rock mass shall exceed the internal pressure.
The consequence of deficiency is hydraulic jacking and uncontrollable leakage from the system.
For pressurized waterways permeability is also a case to consider. Acceptable
leakage from the waterways during operation is negligible. The significance of this is that areas

600-TU-CDD-001
31
with unacceptable permeability must be identified and appropriate rectifying measures
undertaken.
7.3.2

Rock Mass Classification

The classification system used for this project is an empirical system based on
practical experience from underground construction during the last 25 years. Several projects in
the Andes Region in South America form part of this practical experience. Factors as lithology,
discontinuities, faults, hydrothermal alteration, rock stress and groundwater and leakage are
considered in the process of assigning a quality class to the rock mass. Seismicity is not directly
included as a factor in the classification because general experience is that only surface
structures as portals are at risk during earthquakes. A possible exemption from this would be
active faults or reactivation of secondary faults. The classification system divides rock mass
quality into 5 classes. A description of the geological conditions related to each class is given
below.
q1 Very Good
Massive to low joint frequency, Jv < 5/m3. Tight joints, unaltered strong rock and
insignificant stress slabbing.

q2 Good
Low to moderate joint frequency, 5< Jv < 10. Strong rock with no or insignificant
alteration and some joints with coating. Low to moderate intensity stress
slabbing.

q3 Fair
Moderate to high joint frequency, 10< Jv < 20. Moderately strong to strong rock
generally with coated joints and with some seams and some minor weakness
zones. The rock mass may be slightly weathered. Also applies to q1 and q2
class with moderate to high intensity stress slabbing; and to medium to low
strength rock subjected to low to medium stresses causing plastic deformations.

q4 Poor
High joint frequency, Jv > 20, clay seams (fault zones, swelling clays) in
moderately strong rock. Also applies to moderately weathered strong rock and to
high to very high intensity stress slabbing in q1 and q2 class rock mass; and to
medium to low strength rock subjected to swelling and/or medium to high stresses
causing plastic deformation.

600-TU-CDD-001
32
q5 Extremely Poor
Completely crushed rock containing a significant amount of secondary clay
minerals as in major fault zones. Smectite clays may lead to significant swelling
and squeezing. Also applies to highly weathered rock and to low strength rock
mass subjected to swelling and/or high stresses causing plastic deformation.

7.3.3

Plastic deformation

Plastic deformation of the rock mass around an opening is a function of strength

of the material and the stress. The strength of the rock mass depends on the strength of the
matrix and joint frequency. This means that the strength of a jointed rock will be less than for a
massive rock given identical matrix strength. Occurrence of secondary minerals in the rock
mass will further reduce strength. The rock mass will respond elastically up to a stress level
where new fractures start to form.
There are failure criteria that based on assumptions regarding strength and joint
frequency for rock mass makes it possible to calculate critical stress at failure. One such
criterion is the Hoek-Brown criterion. The problem is that failure will affect material strength that
in turn will affect stress distribution, thus creating a loop. The criterion will, however, indicate in
a qualitative way the onset of failure.
Not surprisingly, the criterion indicates that strong matrix and moderate joint
frequency will result in failure at opening surface for overburden in the 500 1000 m range, but
that moderate support pressure will contain the problem. For weak rock, massive failure will
take place at 500 m overburden. The criterion gives no clue to time scale. A Lauffer diagram for
prediction of stand up time is used in the RMR classification system, but rock stress is not
considered in the RMR system.
In the Q-system the ratio of tangential stress over compressive strength of rock
mass is used as indicator. Ratio in the 1 5 range is supposed to result in mild plastic
deformation (squeezing), more than 5 to heavy squeezing. A medium strong rock (25 50 MPa)
with a volumetric joint number of 10 will have Rmi (rock mass index) rating of about 5 MPa.
Overburden of 1000 m results in a theoretical vertical stress of about 25 MPa and tangential
stress at least twice this figure.
The conclusion that may be drawn is that plastic deformation will occur in the
tunnels on the project where the weaker rock types are encountered at depth. On the Volcan
tunnel where effective overburden may reach as much as 2000 m, plastic deformation is
expected to be a significant factor in design.

600-TU-CDD-001
33
7.3.4

Water Leakage (WL)

Water leakage is treated separately from rock mass quality classification. It is

presupposed that minor seeps or drips will have no practical significance on rock mass quality.
It is, however, recognized that the application of sprayed concrete is hampered by wet
conditions. Below are listed two classes of leakage that will require grouting and sealing.
WL 1 Moderate
Water leakage of less than 2000 l/min. at moderate pressure occurring in medium
strong to strong rock. Applies also to low water flow in medium to low strength
rock, and to relatively dry (drips and seeps) but poor to extremely poor rock
masses.

WL 2 Major
Water leakage larger than 2000 l/min. at moderate to high pressure, encountered
in medium strong to strong rock. Applies also to medium to high water flow in
medium to low strength rock and to low water flow in poor to extremely poor rock
masses.

It is recognized that neither the presence of erodible materials nor the full effects
of high pressures are covered by the above classes, but they do still form an acceptable basis
for scheduling and costing.

7.3.5

Rock support as function of classification

The required rock support for an opening is a function of the rock mass quality
and the size of the opening. In order to calculate support quantities, construction time and
construction costs, the rock mass quality is combined with the appropriate rock support for the
relevant category and opening size. The basic support resources (RS) used for each rock mass
category (q) are listed as follows:
q1 => RS 1:

Scaling and spot bolts.

TBM: Scaling and spot bolts.

q2 => RS 2:

Scaling. Spot bolting for smaller cross-sections. Pattern bolting

and spot applied fibre reinforced sprayed concrete for larger crosssections.
TBM: Scaling and spot bolts.

q3 => RS 3:

600-TU-CDD-001
34
Scaling. Pattern bolting and minimum one layer of fibre reinforced
sprayed concrete in crown and walls for smaller cross-section.
Number/length of bolts and thickness of sprayed concrete depend
on the cross-section.
TBM: Scaling, spot bolts and use of fibre reinforced sprayed
concrete.

q4 => RS 4:

Pattern bolting and a minimum of two layers of fibre reinforced

sprayed concrete in crown and walls for smaller cross-section.
Occasionally (i.e. on 10 - 20% of the length) reinforced ribs of
lattice girders and sprayed concrete or concrete lining.
Occasionally concreting of the invert at face. Number/length of
bolts and thickness of sprayed concrete depend on the crosssection. Also applies to short blasting rounds and subdivision of
rounds depending on cross-section.
TBM: No use of concrete lining at the face, segmental lining may
come into use.

q5 => RS 5:

Pattern bolting and spiling bolts. When stand up time is short

reinforced ribs of lattice girders and sprayed concrete is applied at
the face. Additional fibre reinforced sprayed concrete or concrete
lining is applied behind the face. Reinforced ribs may be deleted if
concrete lining is cast at the face. Concreting of the invert at face.
Number/length of bolts and the thickness of sprayed concrete as
well as the distance between the lattice girders depend on the
cross-section. Also applies to systematic short rounds for small
cross-sections and subdivided rounds or multiple drifts for larger
cross-sections.
TBM: No use of concrete lining at the face, segmental lining may
come into use.

The basic treatment of rock mass with water ingress by exploration drilling and
grouting (EG) for each water leakage category (WL) is listed as follows:
WL1 => EG 1: Exploratory drilling, 2 - 4 holes of 12 - 30 m length ahead of the
face. Minimum overlap between exploratory drilling is two blast
rounds. Also applies to grouting, 5 - 10 fan shaped drillholes of
12 - 20 m length ahead of the face. Also applies to 3 - 6 drillholes
for control of the grouting result.
WL2 => EG 2: Exploratory drilling, 3 - 6 holes of 12 - 30 m length ahead of the
face. Minimum overlap between exploratory drilling is three blast

600-TU-CDD-001
35
rounds. Also applies to extensive grouting, 10 - 30 fan shaped
drillholes of 12 - 25 m length ahead of the face. Also applies to
5 - 15 drillholes for control of the grouting result.
The rock support described in the RS categories above is the total support
installed, and include both support installed at the excavation front and later in the construction
process. This means that all types of support materials used must meet the requirements to
quality. Design life requirement for all materials used for rock support is presupposed to be a
minimum of 50 years.
7.3.6

Design of pressurized waterways

Global stability of unlined waterways is dependent on a minimum principal stress

in the rock mass that is higher than the internal water pressure. Standard design charts have
been used for preliminary design. The charts are based on theoretical calculation of stress in
the rock mass by means of numerical plain strain analysis. In addition to this, the practical
experience obtained during construction of the unlined tunnels at the Alfalfal I project has been
considered.
Verification of stress assumption for the power station areas was planned for by
means of hydraulic jacking in drill holes in the vicinity of the planned pressure shafts. These
jacking tests were, however, inconclusive. Further testing is planned at a later stage as
described in Chapter 11 in order to confirm or adjust design. For the Alfalfal II power station the
most likely adjustment, if any, is considered to be extension of horizontal parts of the steel lined
tunnels.
For the Las Lajas power station steel lining of the vertical shaft has been
assumed for basic design. Considering the comparatively low hydraulic head for this power
station it may be an option to omit shaft lining pending conclusive results from testing of stress
and permeability.
Further verification of stresses in the rock mass and fine-tuning of design, if
required, is assumed to be performed from the tunnels during excavation.
7.3.7

Rock mass permeability

Empty underground openings will act as sinks regardless of position relative to

phreatic level. A filled tunnel will act as sink if the internal pressure is less than the groundwater
pressure in the formation. A filled tunnel will function as a source if internal pressure is higher
than the natural groundwater pressure.
During construction the underground opening will drain the rock mass. A
recharging of the rock mass takes place when the tunnel system is filled with water. If the filled
tunnel is a sink, as will probably be the case for transfer tunnels and headrace tunnels that

600-TU-CDD-001
36
operate on low heads, the process may take a relatively short time and the volume of water
involved is comparatively small. If the tunnel acts a source, the volume of water required for
establishing a new phreatic level will be significant and the time required before a steady state
leakage is established, may be long. The source scenario is relevant for the parts of the
pressure tunnels with the highest pressure and especially the tunnel from the top of the pressure
shaft at Alfalfal II.
Flow in rock mass is directly proportional with permeability. A permeability
coefficient. k < 110exp 7 m/s may be acceptable for a rock mass subjected to pressure
comparable to the pressure tunnel in Alfalfal II. This permeability may be found in fresh rock
with moderate to high joint frequency. At present only a few permeability measurements from
relevant formations are available, showing low to moderate permeability. Further testing is
planned at later design phases and during the construction phase.
The design basis for the alignment has been to ensure a vertical cover equal to
static head and a side cover of minimum 3 times static head or more if geological structures are
especially unfavourable. In potentially critical areas it has been assumed that pre-grouting will
be done from the tunnel front during excavation.
7.4
7.4.1

Tunnelling conditions for selected alignments

General

This chapter gives an overview of the geological conditions along the

recommended tunnel alignment. The rock types in the formations crossed by the tunnels are
treated in a general form based on the available geological information. Factors influencing the
tunnelling like alteration of the host rock near to intrusions, major faults, low strength rock types,
anticipated water problems and high overburden are discussed. Also mentioned are some
general aspects of rock support and additional investigations required for optimisation and
geological risk reduction. Evaluation of tunnelling conditions for the present projects is based on
information mentioned above coupled with information from the excavation and support used in
comparable formations on the Alfalfal I project.
7.4.2

Las Lajas project

The whole tunnel including the power station will be situated in the Formacin
Abanico Occidental (Tia) with a possible exception for the younger caldera El Manzano. The
geological maps 630-GE-PLA-001 and -002 and section shown on 630-GE-PLA-003 present the
interpretation of available information.
The headrace tunnel, the power station complex and the upper about 2 km of the
tailrace tunnel will cross units of the oldest part of the formation, the Tia A. The units crossed in
Tia A consist of benches, often massive, of volcanoclastic breccia in addition to volcanoclastic
sandstones and tuff. The strata form a gentle anticline meaning that the units will appear sub-

600-TU-CDD-001
37
horizontal in the tunnels. Some minor intrusive sills are exposed at the surface and similar
intrusions will probably be encountered in the tunnels.
The escarpment to the east of the Ro Colorado is formed by normal faulting. The
old tunnel to the Maitenes power plant is not directly affected by the faults, indicating that the
planned headrace tunnel also will be unaffected. A normal faulting regime may, however, be
negative for tunnel stability and permeability due to low horizontal stress (3).
The tailrace tunnel will pass through about 3 km of Tia B units starting from about
2 km downstream of the power station. The units consist of tuff, sandstones and breccias, all of
volcanoclastic origin. The units will appear mostly sub-horizontal in the tunnel.
About 6 km of the tailrace tunnel will be located in the caldera El Manzano. The
dominant rock types are volcanoclastic consisting of breccia and ignimbrite. The transition
between breccia and ignimbrite appears gradual in exposures, and it is not clear which type will
dominate at tunnel level. A granodiorite intrusion outcrops a short distance to the north of the
tunnel in the caldera. Some intrusive dikes and possible effects caused by the larger
granodiorite body may be expected.
The last part of the tailrace tunnel and the section near the outlet in ro Maipo will
be located in massive and strong andesite.
The vertical overburden on the Las Lajas tunnels typically varies between a few
hundred and up to 800 metres. Effective overburden may be marginally higher on part of the
tailrace tunnel, but serious problems with stress spalling and large-scale plastic deformation are
not anticipated on the Las Lajas project.
The aforementioned normal faulting regime may have a negative effect on
permeability. The first hole drilled in the area indicates a low to moderate permeability. This
should be further verified in later design phases and during construction.
For the present stage of design, steel lining of the pressure shaft as been
assumed as basis.
7.4.3

Alfalfal II project

The tunnel system, from tailrace tunnel through the power station to upstream end
is located in the Abanico formation (Tia). The geological map 620-GE-PLA-001 and section on
620-GE-PLA-002, present the interpretation of available information. It should be noted that
verification of photogeological interpretation and information from other sources has been partly
difficult, partly impossible due to snow cover at higher altitudes. This affects the headrace tunnel
and surge shaft area.

600-TU-CDD-001
38
The headrace tunnel is expected to be located in unit Tia C from the intake and
for about 12 km downstream. The rock types found in the unit are pyroclastic breccias, andesitic
breccias, andesite and sandstones. The unit forms a gentle syncline and the different benches
will appear sub-horizontal in the tunnel. The general tunnelling condition in this formation is
expected to be fair.
From about km 4.5 to km 7.5 a number of granodioritic dikes and prominent faults
are visible at the surface. An alternative interpretation of the geology is that an intrusive batholite
or extensive sills may exist at depth in this area. The overburden in this area is from 500 to
1000 m and no direct observation of geology is possible. This alternative interpretation has
been the basis for classification and calculation of support and rate of excavation. The
alternative interpretation also considers possible squeezing in poor ground on this section of the
headrace tunnel.
The syncline forms a saucer-like structure above the tunnel.
From a
hydrogeological point of view this is unfavourable because vertical permeable structures
intersecting the tunnel and the saucer above may result in drainage into the tunnel. The
probability of this effect has been incorporated in the classification.
The remaining 2 3 km stretch of headrace tunnel is expected to be situated in
the upper part of unit Tia B, consisting of volcanoclastic breccias, sandstone and tuff. The lower
part of the surge shaft will also be situated in this unit, the upper part of the shaft in unit Tia C
described under the first part of the headrace tunnel. Tunnelling conditions in the Tia B
formation is expected to be fair on the average.
In order to assess the conditions for TBM tunnelling, an extensive mapping and
sampling programme is required. Data on mineralogy and mechanical parameters are
mandatory for a realistic calculation of a TBM bid.
Sub-horizontal strata in the lower part of the pressurized part of the headrace
tunnel may give rise to pervious layers draining to the surface of the escarpment. Several
groundwater seeps are visible at the surface in this area. The horizontal distance from tunnel to
surface is in excess of 1 km, and the probability of leakage to the surface small, but a systematic
high pressure grouting of the tunnel in this area is incorporated in the design. Stress
measurements by hydraulic jacking and permeability measurements are needed in this area for
an improved detailed design.
The pressure shaft and the power station are located in unit Tia B, the lower part
of which also includes some pyroclastic breccias.
The general conditions for tunnel and shaft excavation are anticipated to be fair
on the average, but significant effective overburden in the power station area is expected to
have a negative impact on tunnelling conditions and requirement for rock support. This
assumption presupposes that effect of normal faulting on the stress situation does not affect the

600-TU-CDD-001
39
power station area. Stress spalling in the underground openings has been considered in the
classification and calculation of support, costing and scheduling.
The bedding in the formation is fairly flat with gentle folds. In the power station
area the dip is towards the East, which is favourable for stability for the pressure shaft and the
surge shaft. Some steeply dipping faults with strikes NE SW are indicated on the geological
map. A granodiorite SW of the planned power station may also have affected rock mass quality
in the area. When conclusive results from hydraulic jacking have been obtained, verification can
be obtained on the assumptions made regarding the in situ stress.

7.4.4

Volcn tunnel

From the intake ro Volcan the tunnel will cross the Formations ro Damas. Lo
Valdes, Colimapu and the youngest one, Abanico Oriental. The interpretation of available
geological information is presented on the map 610-GE-PLA-001 and in section on 610-GEPLA-002.
From the intake Volcan the tunnel will traverse about 600 m in the ro Damas
formation. The dominant rock types in this formation are conglomerates, sandstones and
siltstones. The benches are close to vertical and intersect the tunnel axis at an obtuse angle.
Next the tunnel will cross about 600 m in the Lo Valdes formation dominated by limestone,
claystone and carbonaceous sediments. The dip and strike relative to the tunnel are quite
similar to the ro Damas formation.
The tunnel then enters the Colimapu formation, a ca 4 km long and fairly
heterogeneous mixture of volcanic and sedimentary rocks. The largest part consists of andesite,
andesitic breccia and tuff, but members of limestone, red sandstone, red claystone are important
and so are lenses of gypsum and anhydrite. Some doleritic and andesitic dikes have intruded
the formation. The red claystone is expected to be fissile and mechanically weak.
The remaining about 9 km of the tunnel is located in the Abanico Oriental
formation. This formation is mainly made up of andesite and andesitic breccias while sandstone
and tuff are subordinate units.
Effective overburden along the tunnel is generally high. More than 2000 m
effective overburden is anticipated over a distance of about 1 km, but more than 1000 m
effective overburden will probably affect most of the tunnel. The significance of this is that stress
induced spalling will be an important factor for classification of rock mass quality. It is also
probable that where overburden is high relative to the strength of the rock mass, squeezing
(plastic deformation) will take place.

600-TU-CDD-001
40
The high overburden in general, the stretches with weak fissile claystone and the
occurrence of gypsum and anhydrite all contribute to an estimated high percentage of poor and
very poor rock mass quality for this tunnel.
7.4.5

Rock support methods

The rock support and ground treatment methods used are in principle similar to
what was used on the Alfalfal project and are considered well known. Regarding sprayed
concrete, the trend has been to use steel fibre reinforced concrete instead of the formerly used
mesh reinforced sprayed concrete. The main advantage of this is the increased production rate
achieved.
In extremely poor ground there are 2 alternative support methods available,
concrete lining at the face or the use of lattice girders in combination with thick, sprayed
concrete. The latter option is faster, but may be more costly than concrete lining. The fact that
accelerators, allowing very thick layers of sprayed concrete to be built up in one operation has
also contributed to limiting use of cast lining at the face.
Support in bored tunnels and shafts are in principle similar to drill and blast
tunnels. In a TBM tunnel it may be more convenient to use welded mesh in combination with
steel sets or lattice girders in order to relegate concrete spraying to the work platform further
back from the cutter head. Installation of conventional rock support in the poorer rock mass
qualities is cumbersome and slow in TBM tunnels.
In TBM tunnels it may be practical to use prefabricated concrete segments on the
invert as basis for rails or for rubber wheel transport. These concrete segments may form part of
the final tunnel.

8.

TUNNEL AND SHAFT EXCAVATION METHODS

8.1

General

The two tunnelling excavation methods available for use on this project are the
conventional drill and blast method and the use of a Tunnel Boring Machine (TBM).

For shaft excavation the alternatives are :

raise climber (ALIMAK)

reaming from a pilot hole

use of TBM

shaft sinking by drill and blast.

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For the Alto Maipo project, reaming from a pilot hole by use of a Raise Boring
Machine (RBM) is proposed for vertical pressure shafts and surge shafts, and any cable,
ventilating or emergency shaft, if such will be deemed necessary.
The drill and blast method for tunnels has advantages in flexibility and adaptability
also in adverse rock mass qualities. The method is considered well known.
Mechanical excavation by rotating cutter head is used in tunnelling and in shaft
excavation. In shaft excavation a pilot hole is drilled, a cutter head mounted on the string and
pulled back up the pilot hole. During the pilot hole drilling, stability and permeability is handled
by cement grouting and re-drilling. Permeability is important because drill chips are removed by
flushing, and loss off drilling fluid means clogging of hole. It is also necessary to be aware of the
fact that a pilot hole is an unlined pressure shaft and that hydraulic jacking due to stress
deficiency means loss of drilling fluid and termination of drilling. Access to the shaft during
reaming is limited. This means that the stability or stand up time of the shaft must be long
enough for safe installation of support after drilling is terminated. All support has to be done
from the top, working downwards for reason of safety.
For the Alfalfal II headrace and tunnel Volcn, cross sections are not governed by
the minimum hydraulic requirements, but have been selected as the minimum size that can be
reasonably and efficiently excavated by the relevant excavation method, taking into
consideration tunnel length, transport and ventilation aspects.
In these cases it is recommended to allow contractors to propose larger tunnel
sections, based on their own experiences with normal or special equipment and methods.
The main shafts proposed on the Alto Maipo project are long and of relatively
large diameters. All shafts are within the range of experience and available equipment, but
components are heavy, a fact that must be considered for access and transport.
Tunnel boring machines for hard rock (TBM) are either of the open type or the
shielded type. In a tunnel excavated by an open machine, the rock support installation is largely
similar to methods used in drill and blast tunnelling. A shielded machine propels itself forward by
pushing on an installed (segmental) lining. A double shield machine can operate both as an
open machine and as a shielded machine, but shifting is costly and time consuming.
A double shield TBM is the most versatile type, but also the most expensive to
buy and operate. An open machine is the most economical, but is a less versatile type if
tunnelling conditions become difficult. An open machine may be the best choice if the
percentage of very poor rock mass quality is small. Slow progress in bad ground may then be
compensated by high excavation rate in fair and good ground. An open machine would also be
preferable in heavily squeezing ground due to the short length of the cutter head, since the
ground may not deform fast enough to settle on the machine.

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A TBM works best in fair rock mass quality. Moderately jointed and moderately
strong rock (R3 R4) with little or no content of abrasive minerals result in the most economical
production. Strong, massive and abrasive rock and very poor rock (for an open machine) is
detrimental for progress and cost. The consequence of this is that in order to have a realistic bid
on a TBM alternative it is necessary to have reliable and fairly detailed geological information.
The level of information required for TBM tunnelling is higher than for traditional drill and blast
tunnelling. As a minimum, mineralogy and mechanical parameters should be available for all
relevant units crossing the tunnel alignment.
Each of the proposed methods listed have advantages and disadvantages as
discussed below.
8.2

Drill and blast tunnelling

The drill and blast method is flexible. With the same equipment it is possible to
excavate a variety of cross sections. Trackless equipment is also readily adaptable for slopes
up to 1: 5 on incline and 1:7 on decline. The flexibility makes it possible to excavate also under
adverse rock conditions when support at the face, short rounds and subdivision of cross section
are required. This makes drill and blast tunnelling the most versatile tunnelling method and the
method best suitable for tunnelling through extremely poor rock mass as in the q5 category.
The availability of trackless equipment is good and the set up time at site is short.
The availability of rail-bound equipment may be less favourable, at least when new rigs suitable
for high speed tunnelling is considered. The set up time at site is also longer for rail-bound than
for trackless equipment. For both types of equipment the unit sizes are small enough to allow
fairly unrestricted road transport.
The methods are sensitive to the skill of the contractor. This includes both the
organisation at site and the crew. Numerous examples prove that a well-organised contractor
with a skilled crew will produce more than the double of an average performer, geological
conditions and available equipment being equal. These aspects should be considered in a
bidding process where it may be difficult to distinguish the consistently good performer from the
average one.
The rate of tunnelling that may be achieved will limit the length of tunnel that may
be constructed within a set construction schedule. This governs the need for construction adits
necessary to meet the schedule and as a consequence imposes constraints on both the vertical
and horizontal alignment of the tunnel.
The drill and blast excavation produces a rough tunnel surface. In a water tunnel
this translates to head loss. The head loss may be compensated by application of concrete
lining, but this will be a trade off between the concrete cost and the excavation cost. Normally

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the marginal cost of excavation is less than the cost of concrete, which means that a larger
tunnel will be selected.
Excavation by blasting will necessarily lead to a certain fracture development in
the rock around the tunnel. This means that a certain part of the rock support needed for safe
working conditions is a consequence of the excavation method. This effect is significant in fair
or better rock mass quality, but not so important when support is needed to ensure the integrity
of the opening as is the case under adverse conditions.
8.3
8.3.1

TBM tunnelling
General on Tunnel Boring Machine (TBM) for hard rock

The main advantage of a TBM is its high excavation rate relative to D&B. In
conditions favourable for TBM, excavation rates of about the double of traditional drill and blast
tunnelling may be expected. The higher rate allows for long tunnels without intermediate
construction adits, a direct saving compared to drill and blast tunnelling.
The smooth TBM excavation reduces the need for rock support compared to a
drill and blast tunnel. In a drill and blast tunnel cracks and fissures from the blasting will
penetrate the periphery to a depth of at least 0.5 m and invariably lead to scaling and rock
support. The support reduction in a TBM tunnel is found in the rock mass quality classes Q1 to
Q3, or from very good to fair rock. In poor and extremely poor rock there is little or no difference
between a drill and blast tunnel and a TBM tunnel. The rock support classes RS1 and RS2
require scaling and some spot bolting only. Pattern bolting in an open system and partial use of
sprayed concrete will be the typical support in class RS3.
An exception to the above general rule is when the TBM tunnel is subjected to
stress induced spalling (popping rock). Because no blast induced cracks and fissures reduce
the elastic modulus of the rock at the periphery, the need for rock bolting and sprayed fibre
reinforced concrete will be the same as for a drill and blast tunnel.
The high cost of a TBM and the back up rig and the long lead-time on
procurement are important disadvantages. From the time a decision is made to use a TBM until
it is at the site, about 10-12 months may pass for a refurbished, used machine and some 12-15
months for a new machine. During this period, conventional tunnelling and preparation of a
launching chamber must be done.
A TBM is one complete machine. This means that a breakdown in one of the
main components, the main bearing, for example, will halt progress during the time taken by
repairs. In a drill and blast tunnel, reserve jumbo, loader and trucks will be available at short
notice.

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The probability of the TBM getting stuck in extremely poor rock mass cannot be
excluded. By selecting a versatile machine provided with equipment for probe drilling and
grouting ahead of the face, combined with careful observation of the rock mass quality at hand,
this probability may be significantly reduced.
For hard rock tunnelling there are three main types of machines:

the open type,

the shielded type

the hybrid, double shield type.

In good quality rock masses, a double shielded machine works as an open face
machine. Grippers are used for propulsion and apart from a prefabricated invert segment, no
lining is placed. Access to the tunnel surface behind the head is limited compared to an open
machine and support has to be placed behind the tail of the shield.
8.3.2

Open TBM

Due to the geological setting on the Alto Maipo Project, an open TBM has been
selected for the Alto Maipo Project in basic design. It will be the Contractor who choose the type
of the TBM to use.
The open machine is described in more detail in Chapter 9.
8.3.3

Double Shield TBM (DS TBM)

General description

The double shield Tunnel Boring Machine is of a telescopic shield design and is
intended for work in hard to soft rock formations that may vary along the tunnel route. This
machine type is also capable of handling rock support for high rock stress with rock burst
problems. The rock mass may vary from competent rock not requiring any support, to rock
masses requiring immediate installation of a segmental lining.
The machine consists of four main structural assemblies; the cutter head, the
front shield with the cutter head support, the rear shield with the gripper and thrust assembly and
the conveyor assembly.
In poor ground, the mode of operation is changed to that of a shielded machine.
For reasons of logistics and rate of tunnel production, the minimum section length of lining is in
the order of 1000 m.

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The remaining part of the machine is the working or moving section. It is the part
of the machine that is actually powered and moved forward during a boring stroke.
Backup System
The backup system should be designed with a continuous conveyor mucking
system.
In addition, the backup consists of a series of rolling platforms with either a single
rail track for trains or arrangement for rubber tired vehicles for transport of personnel, segments
and materials. The choice depends on the slope of the tunnel. There is also adequate space for
mounting of various equipment and sub-systems to support the TBM and the other works.
Service vehicles
Continuous invert segments are recommended in on which the service vehicles
will be running for transport of personnel, segments and materials to the heading.
Vehicles on rubber tires are developed for such use. It consists of one module
with a driver cabin at each end of the vehicle and a loading platform. Several units can be
connected to constitute a wheel-bound train.
Muck Haulage
It is proposed to use continuous conveyor systems for haulage of the muck all the
way from the TBM headings to the dumpsite at surface near the tunnel portal.
8.3.4

Assembly of TBM and Backup System

The TBMs for the Alfalfal II and Volcn tunnels would be assembled outside of
the tunnel, beginning excavation from a start block at the tunnel entrance, VA2 and V6 for the
Alfalfal II tunnel and the Volcn tunnel, respectively.
8.4
8.4.1

Shaft excavation
Raise Boring Machines (RBM)

After drilling a pilot hole, reaming is done by pulling a rotating cutter head back up
by the drill string, thus enlarging the pilot hole. The number of reaming passes is determined by
the capacity of the rig and the final size of the shaft. For a long shaft in the 3 to 5 m diameter
range, 2 passes are normal. For large capacity rigs, 1 pass might suffice. All angles from subhorizontal to vertical may be drilled. Water flushing is used for spoil removal in the flatter shafts.
The maximum vertical shaft length for reaming could for planning purposes be set
to 600 m. Longer shafts will need an intermediate construction adit. The pilot hole will deviate

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46
from the theoretical line. This means that active guided drilling must be used or, as an
alternative, a certain flexibility in the tunnel alignment in the receiving end must be planned for.
Access to the shaft during drilling and reaming is not possible. The only practical
way to stabilise the opening is by pressure grouting in the pilot hole. This means that the
opening must have a stand up time equal to or longer than the total reaming period. In other
aspects the reamed shaft is quite similar to a TBM tunnel with regards to support requirements
and smoothness.
It is recommended that RBMs with sufficient reaming thrust and torque and with
min. 11 inch and 12 7/8 inch diameter drill pipes are used for boring of 3.5 m and 5.0 m
diameter raises respectively.
8.4.2

Raise drill and slash

For shafts of larger diameters, drilling and reaming followed by slashing is

recommended as the safest and most economical method. Slashing of the shafts would take
place from the top and downward by using a sinking plant comprising the necessary hoist and
stage winches and a sinking head frame equipped with rock drills for vertical drilling and
equipment for performing necessary rock support measures.
Drilling, reaming and subsequent slashing are recommended for the larger
sections of the surge shaft at Las Lajas.
8.4.3

Inclined TBM shaft excavation

In principle, shaft excavation by use of TBM is similar to tunnel excavation by

TBM. Advantages and disadvantages are to some extent the same. Some modifications as
installation of an extra pair of grippers and adapting operator and work platform to work at a
steep incline must be made.
Spoil removal is by gravity, supplemented with water flushing when required.
There is, however, limited project experience with use of TBMs for inclined shafts.
Minimum practical shaft diameter is about 3 m as spoil handling systems are
simpler than on a tunnel machine. Shafts longer than 1 kilometre have been bored and this is
clearly no limitation on possible shaft length. As for a tunnel machine, the lack of flexibility will
severely impair production in Q5 class rock mass. Even so, the use of TBM is considered a
robust shaft excavation method, technically feasible also for the Alto Maipo project.
The TBM for the inclined pressure shaft at Alfalfal II must be transported in parts
and assembled inside. The necessary additional excavation needed for such assembly, and for
bringing the TBM into position, must be designed by the contractor.

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9.

EVALUATION OF USE OF TBM FOR TUNNEL EXCAVATION AT THE ALTO MAIPO

PROJECT
9.1

General
The Alto Maipo project is characterized by:
1.

long tunnel fronts

2.

limited possibilities of intermediate access tunnels

3.

tunnel sections with high overburden

4.

tunnel sections with heavily fractured and/or soft rock formations

The two first aspects are in favour of applying TBM, while the latter may in more
extreme cases favour drill and blast method as the most suitable excavation method.
An overall evaluation of tunnel alignments and the available geological
information indicates that the following tunnel sections are deemed feasible for TBM application
as an alternative to conventional drill and blast methods:

9.2

1.

Tailrace tunnel of Las Lajas, excavated from the downstream end. Length
approx. 9000 m.

2.

Headrace tunnel of Alfalfal II, excavated from (VA2) the top of the penstock.
Length approx. 10.543 m.

3.

Inclined pressure shaft/surge shaft for Alfalfal II

4.

Transfer tunnel of El Volcan, excavated from the downstream side. Length

approx. 5000 7000 m depending on the encountered ground conditions.

Evaluation of TBM concept

Based upon available geological information at the present stage of planning, the
choice would be between two types of TBM concepts:
1.

open hard rock TBM (gripper type)

2.

double shield machine

The two concepts are presented in the following chapters.

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9.2.1

Open hard rock TBM (gripper type)

Advantages.

High performance in stable ground formations.

Easy operation.

Easy to observe actual rock condition.

Fairly easy to install rock support such as rock bolts, steel sets, wire mesh
and spiling bolts.

Fairly good access for probe drilling and grouting works ahead of tunnel
face.

Less risk of getting trapped in squeezing ground.

Disadvantages

Low progress rate in unstable ground.

Risk of getting trapped in heavily unstable ground.

Concrete lining, if needed, has to be done after boring is completed.

9.2.2

Double shield machine

Advantages

High performance in relatively soft and fractured rock.

Allows for installation of segmental (final) lining while boring.

Disadvantages

Limited access behind the cutter head for exploration, grouting and
conventional rock support works.

High risk of getting trapped in squeezing ground.

Generally a more expensive tunnelling method than the open hard rock
TBM.

The organization Deutscher Ausschu fr unterirdisches Bauen (DAUB), has

prepared the following table in order to indicate basic recommendations on selecting TBM
concept depending on rock mass characteristics.
Table: Recommendations for selecting and evaluating tunnel boring machines
Value

Open TBM

Shielded TBM

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Recommended

Possible

Recommended

Possible

300 50

50 5

50 5

300 50

25 5

5 0.5

5 - .05

25 5

RQD (%)

100 50

50 10

50 10

100 50

Fissure spacing

>2.0 0.6

0.6 0.06

0.6 0.06

>2.0 0.6

Compressive strength
(MN/m2)
Tensile strength (MN/m2)

The recommendation is to select an open hard rock type machine. The major
geological risk is assessed to be the risk of getting trapped in squeezing ground. However, by
using this type of machine in combination with overcutting and heavy rock support consisting of
rock bolts, steel sets and sprayed concrete, the risk of getting trapped could be reduced.
When applying a machine configuration as described further below, the boring
capacity would be expected to be relatively high over long portions of the tunnels.
9.3
9.3.1

Selection of TBM for the various tunnels at the Alto Maipo project
Las Lajas tailrace tunnel

The Las Lajas tailrace tunnel could be excavated by TBM from its downstream
end. The mobilisation area is assumed to be located near the downstream portal.
While the TBM and the backup system are under fabrication and transport, the
downstream portion of the tailrace tunnel, some 1-1.5 km, could be excavated by the
conventional drill and blast method. A starting chamber for the TBM could then be excavated at
a predetermined chainage. The size of this chamber will depend on the TBM diameter and
length (width x height x length = 12m x 10m x 40m). Upon arrival of TBM at site, the assembly
could take place outside the portal. The TBM is assembled on temporary dollies and pulled to
the starting chamber or alternatively on walking beams. The backup is assembled in sections
and transported into the tunnel on a low bedded truck.
Muck transportation out of the tunnel can be either by rail bound equipment or by
a continuous conveyor belt system.
The length of excavation by TBM should be kept flexible, depending on the actual
progress obtained.
After break-through the machine can be disassembled and transported partly
through the upstream drill and blast section and out via the access tunnel to the Las Lajas
powerhouse, and partly through the bored tunnel.

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The minimum size of a TBM for a free flow tailrace tunnel at Las Lajas has been
estimated to 6.9 m2.
9.3.2

The Alfalfal II headrace tunnel - downstream portion

The access to the headrace tunnel will be through a 2 km long tunnel from point
VA2 to A9. It is assumed for basic design that the TBM would start excavation at VA2. The
TBM will be assembled outside and begin excavation from a start block immediately inside the
tunnel.
The Alfalfal II headrace tunnel from A9 will be bored on an ascending slope of
approximately 7%, and rail bound transport will not be possible. Transport of materials, crew,
etc. will have to be done by means of rubber tired vehicles designed for such purpose. The
mucking out system will be on a continuous conveyor belt system, possibly in combination with
reloading onto trucks near A9 in order to maintain more flexibility for other transport.
From a practical point of view, the required diameter of TBM from the downstream
end is assessed to be =4.5 m. For this alternative, with conventional excavation from
upstream, the TBM would excavate an estimated length of approx. 8.5 km. in addition to the
2 km of access tunnel to the headrace.
9.3.3

TBM for Tunnel Volcn

A TBM for tunnel Volcn would start at the downstream end. Assembly of the
TBM could be performed in front of the portal and pushed into the launching chamber on
temporary dollies. Alternatively, the first portion of the tunnel could be excavated by
conventional means while waiting for the TBM, and a starting chamber could be established
inside the tunnel.
Mucking out from the tunnel can be either on a rail bound or on a continuous
conveyor belt system. The length of excavation that will be feasible with a TBM is difficult to
predict, due to possibility of squeezing ground. The first stretch of approx. 5 km would be
anticipated feasible for TBM. As the overburden increases, the risk for squeezing and adverse
spalling may become critical for the TBM operation and at some chainage it is assumed that the
boring would have to stop. This total length is assumed to be 7 km.
After boring is stopped, the TBM and the backup will have to be disassembled
and transported back to the downstream portal.
From a technical and practical point of view the required diameter of TBM for this
tunnel is assessed to be =4.1m. This has been set as the minimum diameter for the tunnel.

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9.4

Summary of TBM requirements/ configuration

9.4.1

Machine requirements

The technical requirements for the open TBM machines are recommended and
described as follows, and should be the same for all alternatives:

19 back loading cutters with up to 30 tonnes thrust/cutter.

High cutterhead power (torque). For 4.1-4.5 m => 2200 kW and for 7.16.6 m => 3000 kW.

Variable frequency drive.

Possibility for overcutting, min. 100 mm.

Drilling machines for installation of radial rock bolts (one on each side of the
main beam of TBM).

Possibility for boring and installing up to 8 m long spiling bolts from the
cutterhead support area, see above.

Ring beam erector behind head of TBM.

Rock drills for drilling ahead of the TBM for exploratory drilling and for
drilling for grouting works.

Sprayed concrete manipulator (robot-equipment) between TBM and back

up with collector buckets for rebound material.

Electronic device for continuous measuring of ground conditions ahead of

the TBM.

9.4.2

9.4.3

Backup special requirements

The backup should be designed for passing through the tunnel in case of
temporary rock support installed in front of back up system, up to a
thickness of 300 mm.

Mixers and pumps for grouting ahead of the tunnel face to be installed at
back up rig. Grouting pressure capacity up to 120 bars.

Site operation requirements

The TBM machines should be manned 7 days a week, 24 hours per day. This will
also reduce the risk for getting stuck in rock masses with slightly plastic behaviour.