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PDM & METHOD STATEMENT

AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP


FOR FIXING TURBINE FOR UNIT 3

OWNER : DA AFGHANISTAN BRESHNA SHERKAT


CONSULTANT : HILL INTERNATIONAL
CONTRACTOR : AIPL-HUNAN ALLONWARD JV
REHABILITATION OF GERESHK HPP (3 x 1.62 MW)

Drawn VKS
Checked AK
Approved SSJ

Rev. Modification Date Checked Date Approved


MFF 0026 Energy Sector Development Investment Program Project No. 3
Gereshk Electricity Services Improvement Project
Contract ICB No.
PLANT: 3 x 1.62 MW GERESHK HYDRO POWER PLANT ICB-DABS/Gereshk HPP 012/2010

Docket No. AIPL-GSK-MS (TURUT3)


PDM & METHOD STATEMENT FOR Pages : 29 Rev. 0
FIXING TURBINE FOR UNIT NO. 3

THIS DOCUMENT IS A PROPERTY OF AIPL-HUNAN ALLONWARD JV AND MUST NEITHER BE COPIED NOR USED IN ANY WAY EXCEPT UNDER THE
OFFICIAL CONSENT OF DABS FOR AND ALL PURPOSE RELATED TO THE GERESHK PROJECT HPP. INFRINGEMENT WILL LEAD TO
PROSECUTION. OBSERVE THE PROTECTION ISSUE ISO 16016.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CONTENTS
CHAPTER 1 : EXECUTIVE SUMMARY ............................................................................................................. 3

CHAPTER 2 : INTRODUCTION ........................................................................................................................ 6

CHAPTER 3: METHOD STATEMENT ............................................................................................................... 8

1 PREPARATION OF SURFACE .................................................................................................. 9

2 SEALING THE CRACKS IN EXISTING CONCRETE ................................................................... 11

3 APPLYING BONDING COAT TO EXPOSED REINFORCEMENT & EXISTING CONCRETE ......... 12

4 FIXING ANCHOR FASTENERS............................................................................................... 13

5 SHUTTERING & PLACING DRAFT TUBE IN POSITION .......................................................... 14

6 CONCRETING AND CURING ................................................................................................ 14

7 SHELF LIFE OF CHEMICALS.................................................................................................. 15

CHAPTER 4: ESSENTIAL PARAMETERS FOR REPAIR MATERIAL ................................................................... 16

CHAPTER 5: DRAWINGS .............................................................................................................................. 21

CHAPTER 6: LITERATURE ............................................................................................................................. 23

CHAPTER 7: LOAD CALCULATIONS AND DESIGN LOADS............................................................................. 24

CHAPTER 8: CONCLUSION ........................................................................................................................... 27


PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 1 : EXECUTIVE SUMMARY


PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

EXECUTIVE SUMMARY

General: Gereshk town is situated in Helmand Province in South-Western Afghanistan.


Electrical power supply to the town and some of the adjoining villages is predominately
supplied from Gereshk Hydro Power Project (HPP). HPP constructed on Boghra Irrigation Canal
is located at about 2.5 km north-east of Gereshk District Business Centre, Gereshk Town on
Kandahar-Herat National Highway. HPP coordinates are 31o4936N Latitude and 64o3530E
Longitude at EL 826.

Boghra Irrigation Canal draws water from Helmand River at a gated Diversion Structure 4.35 km
upstream of the HPP. River catchment area at this location is about 58,00 km 2. The source of
Helmand River and its tributaries rests in Hindu Kush Mountains of Afghanistan. Canal runs past
but outside of the Gereshk town.

HPP has installed generation capacity of 2.4 MW from two Turbine units. HPP has a spare
available bay for third unit. It is understood that HPP is not generating to its full installed
capacity.

HPP was designed in late 1940 and constructed in the 1950s to American Code of Pracitice.
Construction was completed in July 1958. Plant was run at partial output from 1961 to 1964
due frequent breakdown and teething troubles but was eventually made fully operational and
commissioned in 1965. Subsequently, also the Plant could not be run continuously and was
damaged in 1973 due to armed conflict with Mujahedeen. Damage is evident even today. Plant
remained shut down from 1973 to 1993. Plant was repaired under the resources of the local
population and has remained operational since, but at a much reduced power output than its
installed capacity. Project can be approached by roads at both banks of Boghra Canal and is
connected to Kabul Herat National Highway.

Gereshk town has an independent island electrical grid operating at 3.3 kV. Due to failure
synchronization equipment in the Plant, the distribution network has been split in to two, with
each generator feeding to one part of the grid.

Ministry of Energy and Water (MEW), Government of Islamic Republic of Afghanistan has
decided to rehabilitate HPP so as to fully utilize the water available in the Canal and meet the
increased requirement of electrical energy in the area. Funds for rehabilitation of HPP are being
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

provided by UK Department for International Development (DFIR), Danish Government and


Asian Development Bank. It is understood that associated power distribution network will also
be upgraded.

Geology and Seismicity: Review of the available Geological data of Southern Afghanistan
reveals that area has generally loose granular material. There is no evidence or reported
Geological problem in the HPP area.

Afghanistan is bounded by two major faults. However, there is no active fault so far reported or
recorded in Gereshk area. Consequently, it is safe to assume that there is relatively little risk of
earthquakes affecting the area.

Rehabilitation on Gereshk HPP: Rehabilitation of Gereshk HPP as per the scope of work
discussed in the succeeding Chapters can be distinct divided as follows:
a) Boghra Canal Intake Structure
b) Boghra Canal
c) Powerhouse Structure
d) Hydro Power Plant
e) Associated Civil Works

Environment and Social Aspects: Barring disposal of debris from Civil construction work and old
equipment removed from Plant rehabilitation areas, there is no major environment impact
expected. Due precautions will need to be taken during handling and use of POLs and
chemicals. Necessary disposal sites will need to be identified in consultation with Consultant
and/or Client.

Socially, the resultant benefits accruing from the rehabilitation of HPP outweigh the likely
minor social adverse impact. Increased electrical power supply will facilitate economic growth
and thus usher in local prosperity.

Security: Continuously dynamic volatile security in the Project region poses serious threat to
men and materials. General elections and withdrawal of NATO ISAF forces during 2014 further
compounds the already grim situation.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 2 : INTRODUCTION
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

INTRODUCTION

Da Afgahnistan Breshna Sherkat (DABS), Client has awarded Contract ICB No. ICB-
DABS/Gereshk HPP 012/2010 dated Feb. 06, 2012 (Contract) to AIPL-Hunan Allonward JV
(Contractor) for the Rehabilitation of Gereshk Hydro Power Plant (HPP), Helmand Province,
Afghanistan. Scope of work under the Contract covers Designing, Engineering, Manufacturing /
Procurement, Installation, Testing & Commissioning of certain Electro-mechanical & Hydro-
mechanical new equipment, Refurbishing certain existing Hydro-mechanical equipment and
Construction of certain Facilities pertaining to Civil works etc. for Gereshk Hydro Power Plant
situated on Boghra Irrigation Canal as enumerated in Volume 2 of the Contract.

DABS have appointed Hill International NV as Consultant for the Rehabilitation of Gereshk
Hydro Power Plant (HPP) Project.

This document has been prepared for fixing details of turbine for Unit No 3.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 3: METHOD STATEMENT


PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

METHOD STATEMENT
Existing two nos. Hydro Generators of Gereksh Hydro Power Plant (HPP) has been in
operational use over the last more than five decades. However, an opening was left for fixing
Unit 3 later.

Drawings have been developed for fixing turbine for Unit 3 based on vendor GA drawings. This
procedure has been developed for fixing of turbine for Unit 3. Following procedures are to be
adopted on the surfaces, where chemically anchored bars are to be provided.

1 PREPARATION OF SURFACE
The appropriate surface preparation and crack sealing as per site requirements shall be completed,
which may sequentially cover one or more of the following items of work.

1.1 Removal of existing surface plaster


Existing plaster to be to be identified for removal by tapping all areas and its boundary shall be marked
with a color marking.

Make a cut normal to the surface all along the boundaries with power driven cutters. The depth of cut
shall not exceed the thickness of plaster.

Remove the plaster manually with the help of chisel and hammers to completely expose the parent
concrete surface, so as not to have any traces of such plaster left behind.

1.2 Chipping unsound/weak concrete material


Unsound or weak areas of concrete shall be identified.

Mark the area to be repaired using straight lines between corners. The marked area shall have 90o
corners with the sides parallel or normal to the direction of the reinforcement. The marked boundaries
for the repair area should be a minimum of 50 mm outside the perimeter of the spall. For a single spall,
the repair area should have a minimum width of 100mm in any direction. If a number of spalls are
closely located to each other, these spalls should be included in a single area marked for repair.

Cut shall be made along the marked boundary, normal-to-the surface. It should be made with power
driven chisel or chisel and impact hammers. Minimum depth of cut shall be 10 mm. Diamond cutter
shall not be used to avoid cutting the reinforcing steel due to inadequate concrete cover.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

Chipping to remove all the unsound and weak concrete material shall be done carefully from the
damaged portions of structural members by adopting mechanical or manual means up to the required
depth to produce sound concrete surface to a near uniform depth for the repair area. Chipping shall be
done using chiselling hand tools or pneumatic hammers depending on the thickness of cut.

Inspection and soundness testing, after concrete removal & cleaning, for weaknesses and delamination
of exposed surfaces shall be visually carried out. If required, additional removal will be done.

Cleaning of debris and dust shall be carried out from within the chiselled/ chipped area.

1.3 Removing concrete all around embedded rusted reinforcement


(Optional)
This procedure is to be adopted, if reinforcement gets exposed during surface preparation

A full-depth chiselling and removal of concrete all round reinforcement shall be carried out, if the
concrete in contact and in immediate vicinity of the reinforcement is carbonated.

The concrete around reinforcement shall be removed so as to have a near uniform air gap of about 5
mm plus the nominal size of coarse aggregate to be used in repair concrete/mortar. However, the air
gap shall not be less than 15 mm in any case.

Cleaning of debris and dust shall be carried out from within the chiselled /chipped area.

1.4 Removing and cleaning reinforcement of rust from its surface to give it a
shining bright metal (Optional)
This procedure is to be adopted, if reinforcement gets exposed during surface preparation

Remove the rust manually from all round the surface along the length of reinforcement, using hand
tools like chisels, hammers, wire brushes, abrading cloth/paper, etc. This shall be continued manually
along the length of the rusted reinforcement till such time that the steel surface is cleared of all rust that
could be removed manually.

Remove the rust by sand blasting and/or using tested chemicals in case results of manual rust removal
are unsatisfactory.

By sand blasting:

Coarse sand shall be sprayed under pressure over the exposed reinforcement so as to cause an intense
abrading of the reinforcement surface and removal of rust from its entire surface to achieve shining
bright metal.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

Using chemicals:

Chemical rust remover shall be brush applied over the reinforcement surface thoroughly all around the
circumference and along the full length of rusted reinforcement. After 24 hours of its application, the
surface shall be cleaned with wire brush and all loose particles removed. It shall be washed with water
thoroughly and allowed to dry.

2 SEALING THE CRACKS IN EXISTING CONCRETE


2.1 Sealing the cracked or honeycombed concrete with injection grouting
(Optional)
This procedure is to be adopted, if the concrete is weak or has cracks / honeycombing. Epoxy mortar
like Fosroc Nitomortar S (or equivalent) shall be sealed in the cracks and grouting shall be done with
Fosroc Conbextra EP 10 / EPLV (or equivalent) while doing epoxy grouting.

Identify the Cracks and mark the area for injection grouting.

Drill holes at least 25 mm diameter and 40mm deep along crack lines at spacing of 300 mm or thickness
of the structural member, whichever is less. In honey combed area holes shall be @ 9 nos per sqm.

Remove coarse debris and dust in opened up cracks and drilled holes by blowing oil free compressed air,
if available with air compressor, otherwise with hand operated blow out pump. Concrete surfaces
required to be grouted shall be free from all loose and unsound materials by means of mechanical
abrasion using stiff wire brushes, after removing all loose areas with chisel and hammer. Area shall be
made free from any deleterious materials, such as oil dust dirt etc. by means of oil free jet of
compressed air.

Insert 12mm dia specified injection nipples in holes drilled along crack lines and fix them by sealing only
its sides with epoxy or polymer modified mortar.

Seal the crack or the honey combed surface between the nipples by means of epoxy mortar after
applying epoxy primer or polymer modified mortar. The epoxy mortar shall be air cured for 24 hours,
whereas the polymer-modified mortar shall be moist cured for 1-3 days and allowed to gain strength
before actual grouting commences.

Epoxy component shall be mixed in a clean container free from harmful residue or foreign particles.
Epoxy component shall be thoroughly blended in a mechanical mixer to a uniform and homogeneous
mixture. Small batches (up to 1 liter) however may be allowed for manual mixing using spatulas,
pallattes, knives, etc.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

Inject the grout into the cracks by means of suitable gun or pump at a pressure of 1- 2 kg./cm2 for epoxy
grout and 4-7 kg./cm2 for cementitious grout.

In case of vertical cracks injection shall be started at the lowest nipple and continued until the injected
grout begins to flow out at the next higher nipple. Whereas in other cases of horizontal locations, the
injection shall be started from one nipple and continued until the injected grout begins to flow out at
the other nipple.

The first nipple shall then be closed off and injection continued at the second until the grout flows out at
the third. The process shall be repeated until the whole of the crack has been sealed. As soon as the
system is cured, the nipples shall be cut.

In case of Honeycombed Area, each grout hole shall be grouted individually. Grouting pressures to be
used in the work will vary with the conditions encountered and different areas and the pressure used
shall be between 1 to 4 kg/cm2.

3 APPLYING BONDING COAT TO EXPOSED REINFORCEMENT &


EXISTING CONCRETE

3.1 Apply Passivating & bonding coat over the cleaned reinforcement
(Optional)
This procedure is to be adopted, if the reinforcement has to be exposed while doing surface
preparation. An anti-corrosive epoxy zinc primer Fosroc Nitozinc primer or equivalent shall be applied
to protect the rods from further corrosion.

Components of the passivating/ bond coat mix shall be weigh batched and mixed in specified
proportions as per manufacturers instructions in a clear container free from harmful residue or foreign
particles. The components shall be thoroughly blended with a mechanical mixer to a uniform and
homogeneous mixture. Small batches (upto 1 litre) may however be allowed by manual mixing using
spatulas, palette, knives etc.

It shall be applied to reinforcement surfaces by stiff nylon bristle brush. The coating material shall be
worked well all round the periphery and along its exposed length using a stiff brush ensuring that no
pinholes are remaining. The second coat, if required, the same shall be applied as per manufacturers
recommendation after the first coat is touch dry.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

3.2 Apply bond coat on the cleaned concrete substrate


Saturate the surface with water but shall be free of excess surface water, debris and dust, where
cementitious bond coat is to be applied. Otherwise, surface to remain dry and clean of debris and dust.

Components of the bonding coat mix shall be weigh batched and mixed in specified proportions as per
manufacturers instructions in a clear container free from harmful residue or foreign particles. The
components shall be thoroughly blended with a mechanical mixer to a uniform and homogeneous
mixture. Small batches (upto 1 litre) may however be allowed by manual mixing using spatulas, palette,
knives etc.

The specified adhesive shall be applied to concrete surface at atmospheric temperatures below 40oC for
epoxy adhesive and below 30oC for polymer modified cement adhesive. Bonding coat shall be applied by
spray equipment or stiff nylon bristle. The bonding material shall be worked well into the surface of the
parent body ensuring that no pinholes are visible.

4 FIXING ANCHOR FASTENERS


After 7 days when the concrete gets hardened, embedded parts shall be fixed using the chemically
bonded anchor fasteners as shown in drawing and as per manufacturers instructions.

Broadly, following steps are involved in fixing of anchor fasteners:

Drill with hammer drill a hole into base material to the size and embedment depth as
shown in drawing.
Standing water in the bore hole must be removed before cleaning. Starting from the
bottom or back of the bore hole, blow the hole clean with compressed air or a hand
pump. The hand pump can be used for anchor sizes up to bore hole diameter 20 mm. For
bore holes larger than 20 mm or deeper 240 mm, compressed air must be used.
Attach the brush to a drilling machine or a battery screwdriver. Brush the hole with an
appropriate sized wire brush. Finally blow the hole clean again with compressed air or a
hand pump.
After cleaning, the bore hole has to be protected against re-contamination in an
appropriate way, until dispensing the mortar in the bore hole. If necessary, the cleaning
repeated has to be directly before dispensing the mortar.
Prior to inserting the anchor rod into the filled bore hole, the position of the embedment
depth shall be marked on anchor rods.
Starting from the bottom or back of the cleaned anchor hole, fill the hole up to
approximately two-thirds with adhesive. Slowly withdraw the static mixing nozzle as the
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

hole fills to avoid creating air pockets. For embedment larger than 190 mm an extension
nozzle shall be used.
Push the threaded rod into the anchor hole while turning slightly to ensure positive
distribution of the adhesive until the embedment depth is reached. The anchor should be
free of dirt, grease, oil or other foreign material.
Be sure that the anchor is fully seated at the bottom of the hole and that excess mortar is
visible at the top of the hole. If these requirement are not maintained, the application has
to be renewed. For overhead application the anchor rod should be fixed.
Allow the adhesive to cure to the specified time prior to applying any load or torque. Do
not move or load the anchor until it is fully cured.
After full curing, the add-on part can be installed with the max. torque as per
manufacturers instructions by using a calibrated torque wrench.

5 SHUTTERING & PLACING DRAFT TUBE IN POSITION


Draft tube with anchorages as shown in drg and as approved by manufacturer shall be placed in
position. Shuttering for laying the reinforcement and concrete as shown in drawing shall be provided.
Ensure that shuttering is water tight.

Water / air pipes required to be embedded in concrete as per the vendor drawing shall be provided.

6 CONCRETING AND CURING


Fosroc Renderoc RG or equivalent shall be used for micro-concreting. Compressive strength of concrete
shall not be less than 40 N/sqmm after 7 days.

Prepare self compacting, free flowing micro-concrete as per manufacturers instructions simultaneously
along with above so as to have a uniform consistency and texture in a mechanical concrete mixer by
adding a specified proportion of water in the pre weighed dry mix of pre-batched, prepackaged, single
component micro concrete.

Pour the fresh micro-concrete in the shuttering mould and over the surface prepared to receive it, while
the bond coat is still tacky.

For thickness more than 100 mm, addition of pre-calculated aggregates shall be done as per
manufactures instructions.

Grouting pockets shall be kept in concrete as per the vendor drawing.


PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

Keep the exposed surfaces continuously damp after its final setting (i.e. after a maximum of 8 hours of
concreting) by ponding with a sheet of water or by covering with a layer of sacks, canvass, hessian or
similar water absorbent materials constantly kept wet by water sprinkling for at least 7 days.

7 SHELF LIFE OF CHEMICALS


Products like Nitozinc Primer, Lokfix, Cebex 100, Renderoc RG etc. carries shelf life of 6 months only and
hence procurement of the products shall be planned accordingly.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 4: ESSENTIAL PARAMETERS


FOR REPAIR MATERIAL
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

ESSENTIAL PARAMETERS FOR REPAIR MATERIALS


Besides being of compatible properties, repair materials for cement concrete/mortar shall also be
easy to apply and require no attention after the repair has been applied. The essential parameters
for deciding upon a repair material for concrete are:

Low shrinkage properties


Requisite setting/hardening properties
Workability
Good bond strength with existing sub-strate
Compatible coefficient of thermal expansion
Compatible mechanical properties and strength to that of the sub-strate
Should allow relative movement, if expected, particularly in case of sealing of cracks or dealing
with expansion joints.
Minimal or no curing requirement
Alkaline character
Low air and water permeability
Aesthetics to match with surroundings
Cost
Durable, non-degradable or non-biodegradable due to various forms of energy, life, UV rays,
heat etc
Non-hazardous/non-polluting

1. Low Shrinkage
It is well known that the cementitious repair materials shrink with passage of time. Most of the
shrinkage generally takes place in the initial period from the time of casting to 21 days. Therefore,
cementitious repair material in its original form, if used for repair to concrete/ mortar, is likely to get
either delaminated due to de-bonding or develop shrinkage cracks on its surface due to shrinkage
strains and stresses. Shrinkage cracks so developed in the repair patch would allow the easy access
of atmospheric air and water, which could be harmful for concrete and reinforcement.

It is, therefore, essential that the low shrinkage property of repair material shall be looked for while
selecting a material for concrete repair. Cementitious materials need additional non- shrink
compounds so as to be effective in achieving the desired property. Therefore, the formulation of the
patch mortar incorporates, in the cement matrix, several special chemicals to mitigate the
shrinkage. Using low cement content and low water cement ratio will also reduce the drying
shrinkage.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

2. Requisite setting/hardening Properties


It is desirable that the repaired structure shall be put to use at the earliest possible to reduce the
down time of plant, machinery, building or road. It is, therefore, essential that repaired patch shall
harden in the minimum possible time. However, in exceptional cases, it could also be essential to
have the slow setting property as a desirable property for repair material. Such situation could be
where more working time is required to work on repair materials or the repair process is intricate
that more working time is required.

3. Workability
The repair material is to be applied by the field workers and hence its acceptability by them is very
important. The property desired by the field workers is good workability. Hence optimum
workability is to be achieved without sacrificing the other desirable properties by use of suitabile
additives/admixtures.

4. Bond with the Substrate


The bond strength of repair patch with the substrate is essential to have a successful repair system.
If it is felt that the bond strength of the repair material with the base material is inadequate or less
than the strength of the base material, then some other suitable means could be explored to
improve bond strength between repair material and substrate. These could be use of:

Adhesive,
Surface interlocking system, and/or
Mechanical bonding

A variety of adhesives, in the range of epoxies, polymer modified cement slurries including
unmodified polymer applications are available. The selection depends upon available open

time for bonding etc, which are being specified for different applications. Surface interlocking
system and methods of mechanical bonding are, however, detailed out in the subsequent chapter
on Repair Methods.

5. Compatible Coefficient of thermal Expansion:


The difference in volume change because of temperature variation can cause failure either at the
bond line or within the section of lower strength material. Therefore, in the areas exposed to
temperature variations, the patches of repair should have same coefficient of thermal expansion to
ensure that no undue stresses are transferred to bonding interface or the substrate. Due to similar
coefficient of thermal expansion, cementitious materials are preferred over epoxy materials.
Coefficients of thermal expansion of commonly used construction/repair materials are given in
Table 5.1.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

No. Material Co-efficient of thermal


expansion in C
1. Stone
Igneous rocks 8 to 10
Lime stone 2.4 to 9
Marbles 1.4 to 11
Sand & sand stone 7 to 16
Slates 6 to 10
2. Metals
Aluminium 25
Bronze 17.6
Copper 17.3
Lead 29
Steel and iron 11 to 13
3. Brick and brick work 5 to 7
4. Cement mortar and concrete 10 to 14
5. General Purpose non-shrink concentitious micro- 10 to 12
concrete (Renderoc RG)
6. Polymers modified mortar/concrete 10-12
7. Epoxy mortar/Concrete 20-25

6. Compatible Mechanical Properties & Strength


The hardened material shall have compatible mechanical properties or rather slightly better
strength than that of base material. This property is desirable to ensure uniform flow of stresses and
strains in loaded structures. It is well known that the elastic modulus of two concretes would be
different for different crushing strength so if repair concrete is having strength much different than
the base, it could lead to non-uniform flow of stresses and may result in an early failure of the repair
patch. For example, if M-20 grade of concrete has been used in originalconstruction, the grade of
the repair material shall neither be less than M-20 nor higher than M-25.

7. Relative movement, if expected


Particularly in case of sealing of such cracks where movement is expected or at expansion joints, the
repair material selected shall be resilient and elastic to be able to absorb the anticipated relative
movements of the structure without any signs of distress or crack.

8. Minimal or no curing Requirement


It is desirable that the repair material shall not have any curing requirement after the repair has
been applied or even if it is required, it should be minimal to ensure that the repair patch hardens
and attains the desired strength without much post-repair-care. Only epoxies dont need any curing.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

Other material applications need nominal to moderate curing, which need to be specified. Such
materials have several other merits, which are to be kept in view, while making a selection. Curing
compound can be applied over cementitious materials used for repairs but after examining its
compatibility.

9. Alkalinity
In case of RCC, it is important to maintain the alkalinity of concrete around reinforcement with its
pH above 11.5 from corrosion protection point of view. In this context, it is necessary for the repair
material to have chemical characteristics such that it does not adversely affect the alkalinity of the
base concrete at a later date. The chemical characteristics of the repair material and its after effect
on the pH of RCC shall be examined beforehand. In addition, the pH of reinforcement protection
applications, bonding coats and that of the repair material must also be similarly alkaline. This would
ensure inbuilt compatibility.

10. Low air & water permeability


Permeable material allows easy permeation of environmental chemicals including carbon dioxide,
water, oxygen, industrial gases/vapours etc. It is essential that repair materials should have a very
low air/water permeability to provide protection to the reinforced concrete against ingress of
harmful environmental chemicals.

11. Aesthetics
It is desirable that colour and texture of the repair material should match with the structure and give
aesthetically pleasant appearance. If need be, this could be achieved through appropriate finishes.

12. Cost
Economics is important while considering various options for repair materials but cheaper repair
material should not be selected at the cost of performance characteristics.

13. Durability & Bio non-degradability:


The repair material selected should be durable under its exposure conditions during the service life
against chemical attack, resistant to any form of energy like ultra violet rays, infra red rays, heat etc
and should be bio non-degradable.

14. Non-Hazardous / Non Polluting :


The repair materials should not be hazardous to field workers. However adequate Safety measures
are required to be taken for repair Materials, which are hazardous to workers involved with their
application, etc. These should also be environment friendly.
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 5: DRAWINGS
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

LIST OF DRAWINGS

S. No. TITLE DRAWING No.


1 FIXING DETAILS OF TURBINE FOR UNIT NO. 3 STRUCTURAL AHA-JV/GSK/TURUT3/01
DETAILS
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 6: LITERATURE
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 7: LOAD CALCULATIONS AND


DESIGN LOADS
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

1. DESIGN LOADS

Following calculations have been provided by the vendor for vertical and tangential load on each base
plate

Foundation load during normal operation:


Weights ( upper bracket + lower bracket + cover + stator + rotor + brushless exciter + frame support
+ fire extinguish pipeline + lower & upper baffle plate + turbine thrust + turbine shaft +
runner )

= 37000+28000+8000

=73000kg=716.13KN 716kN

Vertical down-load for each foundation bolt

Vertical down load of each foundation bolt R3 = Turbine weight born by the foundation equally spaced
to 12pcs foundation bolt = embedded assembly + foundation assembly + distributor assembly + TGB
assembly + middle guide bearing assembly + others =4347.3+7317.6+12418+451+2774+215=27522.9Kg

DESIGN AS PER THE GIVEN LOADS

For the purpose of design the given loads have been taken to cause shear at the interface between the
old and new concrete.

Total Shear = 275 x 12 = 3300 KN

Factored Shear = 1.4 x 3300 = 4620 KN


PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

Recommended loads as per HILTI

Use 25 dia anchor re-bars

Required No of anchor re-bars = 4620 / 64.3 = 71.8, say 72 Nos.

Provide 25 dia, 36 Nos. chemically bonded anchor re-bars at top and bottom each

Also provide 16 mm dia circumferential bars as shown in drawing


PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CHAPTER 8: CONCLUSION
PDM & METHOD STATEMENT
AIPL-HUNAN ALLONWARD JV 3 x 1.62 MW GERESHK HPP
FOR FIXING TURBINE FOR UNIT 3

CONCLUSION

This PDM & Method Statement document has been compiled based on the Contract document,
ICB No. ICB-DABS/Gereshk HPP 012/2010, Tender drawings, data collected during Condition
Survey, etc. We have suggested methodology for fixing of hydro-generator in an existing
opening as per the Condition Survey collected data and visuals, above referred documents &
drawings.

Approval for use of specific chemicals to be used for each stage of work shall be done at
execution stage.