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UNDERGROUND POWERHOUSES
1. Introduction
It is impossible, and was not intended for these guidelines, to cover civil engineering
design aspects of underground powerhouses in great detail. However, some usable infor-
mation dealing with the requirements for rock support provisions is presented because that
information is needed to assess project cost comparisons during conceptual studies.
For additional information, the reader is referred to the excellent publication, Water Power
Development, volume 2, by Professor Emil Mosonyi [I960]. It contains a wealth of infor-
mation on the design of underground powerhouses. Reference is also made to part C of the
Pumped Storage volume of these Guidelines for additional illustrations of underground
powerhouses.
The intent of these guidelines is also to close the more than 25-year gap since Professor
Mosonyi’s excellent illustrations on underground powerhouse concepts and sizes. New
information is especially needed in the area of the structural support for the excavated
faces of the caverns. Whereas the designs of three decades ago relied heavily on stiff con-
crete roof arches and linings for caverns that seldom exceeded 20 meters (65 ft) in width,
the present-day designs for much wider caverns resort to much lighter and more flexible
support systems. These are discussed herein.
2. General Location
Underground powerhouse types are illustrated in subsection B.l. A brief discussion of the
reasons for their selection on their application is given in subsection B.2. According to
UGPH location, the following classification has been established [Mosonyi, I960].
a. Upstream (Swedish Concept). — The UGPH is located near the reservoir and connected Upstream
upstream with a short pressure conduit to the intake (fig. l-99a). This arrangement is used location
in relatively flat-dipping valleys which would require relatively long underground pen-
stocks (expensive pressure conduits) if the head would be utilized with the units located
near the tailrace.
Unless the tailrace tunnel is in very poor rock, requiring substantial support and must be
concrete lined, the cost for the tailrace tunnels, as a general rule, is substantially less than
for die pressure conduits.
The access to the upstream UGPH is generally via an access tunnel from a topographically
suitable portal in the valley or via a shaft next to the powerhouse.
Intermediate b. Intermediate Location. — Sometimes the UGPH can be located at an intermediate point
location between the reservoir and the tailrace. An advantageously low topographic depression,
such as a valley, may offer economically short access to the powerhouse and provide for
suitable surge chamber location (fig. l-99b).
In this arrangement, a lengthy low pressure tunnel (with higher allowable velocities) may
be more economical than a free-flowing tailrace tunnel used for the upstream location.
With the downstream development, long low-pressure power tunnels conduct the water to
steeply dropping pressure shafts bifurcating into penstocks at the powerhouse level.
Sometimes it is economically preferable to locate the bifurcation (or trifurcation) at the
power tunnel level and provide two or three individual surface penstocks down to the pow-
erhouse. These may again bifurcate surface for powerhouses with several units.
For the downstream concept, the tailrace tunnel is very short as is the access tunnel unless
a convenient portal location near the powerhouse is not available.
The downstream UGPH locations allow the development of the maximum head available.
The length of the power tunnels can be several kilometers long. In fact, some European
designs have multi-reservoir and tunnel systems supplying a single plant.
All above discussions assume that the underground powerhouses are located in a rock for-
mation suitable for construction of an UGPH. Other aspects are discussed in subsections 5
and 6.
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c. Downstream Location
• Suitable foundation level for the underground substructure is at the selected location
and elevation of the UGPH and not under layers of alluvium in the river bed, or collu-
vium on the valley banks, as is frequently the case for the surface powerhouses.
Higher • Underground excavation costs are substantially higher than costs for open excavation
excavation (approximately 4 to 5 times higher) because of limited accessibility, controlled exca-
costs vation procedures to preserve the surrounding rock, ventilation requirements, and
delays caused by installation of provisions for rock support (where needed) and
instrumentation.
Rock support • The surrounding rock may need substantial provisions for support, such as:
° Rock bolts
° Multi-layer shotcrete with wire mesh
° Post-tensioned tendons
Instrumentation • Substantial instrumentation may be required to monitor rock deformations.
Less space • Because of excavation costs are at a premium, so is the cost for the space needed.
Therefore, there is a greater tendency to limit the space to a minimum resulting in a
smaller interior space than for surface powerhouses.
Consolidation • The surrounding rock may need to be consolidated and drained to control seepage
and drainage/ from groundwater, nearby reservoir, or tailwater.
Representative UGPH types are presented in subsection B.l.g. They basically fall into two
categories:
• Pit powerhouses
• Cavern powerhouses
Individual cylindrical pits, called shafts, are a subtype of pit type powerhouses and offer
structural advantages where deep submergence is required. For this reason they find appli-
cation mostly for pumped storage developments and are, therefore, treated in the pumped
storage volume of these design guides.
There are certain arrangement and structural features that are different for pit and cavern
powerhouses; therefore, the two types are discussed separately in the following sections.
Pit
6. Pit Powerhouses powerhouses
a. General Discussion. — Pit powerhouses, as the name implies, are located in a pit exca-
vated from the surface. Usually, the roof is at ground surface or somewhat above it to:
• Simplify construction
• Obtain convenient access to the roof level which may be used as part of the
switchyard
• Ensure positive drainage runoff where climatic conditions would so dictate
The switchyard can be located on the roof which aspect represents an economic advantage
over layouts with switchyards separated from the powerhouse.
In some cases, it is advantageous to raise part of the structure above the ground level as
shown on figure 1-41.
Personnel The access for personnel and equipment generally is from the ground level similar to sur-
access face semi-outdoor type powerhouses. Indoor cranes are provided if roof hatches for equip-
ment access to individual units are not provided.
Indoor crane An indoor crane should be considered if the depth of the pit, as governed by the unit set-
ting, is of sufficient height. The structure can be raised above the ground level to gain the
height needed for an indoor crane if hatches for equipment access with an outdoor gantry
crane are undesirable. This may be the case when the switchyard, or a part of it, is located
on the roof.
Cut-and-cover Pit powerhouses are basically a cut-and-cover construction design. Part of the excavation is
construction performed from the surface. The lower part of the pit, however, will, most likely, be exca-
vated through a construction tunnel that would also serve for excavation of the connecting
water conduits. If the portal of the construction tunnel is set high enough above the tailwa-
ter, it can also be used as a surge/vent tunnel.
Costs The top part of the excavation and rockbolting may be comparable in cost with or slightly
more expensive than for a conventional surface powerhouse. The costs for excavation of
the lower part may approach those for pure underground excavation.
All concrete cost, however, may be comparable to that with surface powerhouses, or may
be even less, because all concrete is lowered into the pit.
The above discussions and the advantages and disadvantages presented in subsections H.2
and H.3, as applicable to pit powerhouses, may or may not govern decisions in favor of a
pit powerhouse. Appropriate economic studies should be performed to enable evaluation of
all alternatives considered.
There are relatively few pit powerhouses in existence. One reason may be that the rock
quality at the ground surface is not well suited for the excavation of the steep slopes
required.
Head ranges, b. Applicable Head Ranges, Location, Connection to Water Conduits. — Pit powerhouses
location can be provided for low, intermediate and high head installations, figures 1-40 and 1-41
show the former case, whereas figures l-39a and figure 1-107 may be representative of
designs for intermediate and high head.
Pit powerhouses are, by necessity, connected to underground power conduits — the pen-
stocks on the upstream side and the tailrace tunnels, with or without surge chambers, on the
downstream side.
The length of the tailrace tunnels can vary greatly depending at which point of the stream
the head is developed. Sudden drops or loops in the stream may offer the opportunity to
develop a higher head than would be possible immediately downstream of the dam (figs.
1-100 and 1-101).
WATERFALL
TAILRACE TUNNEL
CONSTRUCTION
ACCESS TUNNEL
TAILRACE TUNNEL
Construction To economically excavate the bottom of the pit, a construction access tunnel may be need-
access-surge ed. If such is provided, it can also serve as a downstream surge chamber if connected with
tunnel the tailrace tunnel. The portal of such a tunnel must be set above the maximum tailwater
level to maintain free release to the atmosphere.
Pit geometry c. Pit Geometry Considerations. — The foregoing discussions imply that pit powerhouses
would be feasible only where the geological conditions are such that they are suitable for
excavation of a steep-walled pit and underground conduits, i.e., reasonably competent rock
at or near the ground surface.
t UNITS
- P R E F E R R E D VERTICAL WALLS
MAXIMUM
PRE-SPLIT HEIGHT-
M I N I M U M OFFSET FOR AVERAGE SLOPE OF
SHALLOWER PRE-SPLIT LIFTS
N E X T DRILLING L I F T —
Pit powerhouses are economical if the in-place rock can be utilized to function as the exte-
rior walls of the powerhouse. The steeper the excavated face, the more economical the con-
struction will be. Rock formations with horizontal or nearly horizontal bedding planes and
vertical joint systems will allow excavations with vertical o r nearly vertical faces
(1OV;1H).
Pit wall For excavation purposes, the maximum presplit blast-hole depth is governed by the ability
excavation to control die alignment of the bottom of the hole, i.e., that does not wander too far from
other holes and thus reduce the presplit effects. See also figure 1-102. Consequently, the
maximum presplit height is limited to approximately 50 feet.
Flatter slopes will increase the width of the pit at the ground level with added cost for the
roof and its supports. For that reason, slopes flatter than 4V:1H should be avoided unless
the added space can be utilized.
Some consideration may be given for deeper setting with resulting higher turbine speeds
and smaller physical size of machines, as mentioned in section H.2. The pit excavation,
however, will become deeper and construction costs, unlike for the caverns, will go up
because there will be more underground excavation than open excavation.
e. Unit Bay Sizing. — The procedures established for monolith sizing of surface type pow- Unit bay
erhouses in section D apply also for pit type powerhouses. However, the draft tube widths sizing
should be kept as narrow as possible to gain maximum possible thickness for the rock pil-
lars separating the individual draft tube tunnels which connect to the tailrace tunnel. These
rock pillars, after excavation of the draft tube tunnels, will be the highest stressed features Narrow
of the underground excavation because the general rule for clear spacings between tunnels draft tubes
(e.g., 2 diameters) cannot be applied to draft tubes for economic reasons; thicker pillars
would result in wider unit bays and a longer powerhouse pit.
Depending on the number of openings (draft tubes), the stress concentration in the pillars
between the draft tube tunnels can vary between 3 to 5 times the stress from the rock load
above [Coates, 1970].
It is recommended that intermediate draft tube piers for pit powerhouses (and also for cav- Avoid
erns) be avoided, if at all possible, to obtain the narrowest draft tubes. The turbine specifi- intermediate
cations should establish the maximum draft tube width desired. D.T. piers
Because stability of the powerhouse structure is not a problem for underground powerhous-
es because there are no exterior loads causing overturning effects, the substructure founda-
tion, i.e„ the pit bottom should be made only as wide as needed for the functional arrange-
ment of the unit bay.
Providing service bays along the generating bay (machine hall) is reasonably feasible from
an economical point of view. The added cost is for the additional excavation resulting from
the wider pit. This extra expense is compensated to some extent by the fact that the exterior
walls will be somewhat less expensive than for surface powerhouses because the excavated
pit faces form the walls. The cost for any support provisions for the excavated rock faces,
including any instrumentation should be included in any cost comparisons.
In sizing of the unit bay width (normal to the flow direction) there is no need for the provi-
sion of shear walls discussed in subsection D.3.a. The reason for this are:
• Pit powerhouses are constructed in rock and practically no lateral forces act on the
structure; consequently, there are no problems with load distribution along the sub-
structure foundation,
• There are no high, massive superstructure walls whose weight and possible construc- No need for
tion loads must be distributed before the substructure concrete, with unit embedment, shear walls
is completed.
The omission of shear walls, where that is possible, result in narrower unit bays and shorter
powerhouses.
Substructure f. Substructure Outline. — There are basically two different approaches for shaping the
outline foundation excavation of the substructure:
1. Uniform profile throughout the length of the powerhouse for all units, i.e„ no pits for
draft tubes
2. Minimum excavation around draft tubes and spiral cases
-
Each of these approaches has advantages and disadvantages, which are discussed below.
Uniform (1) Uniform Profile Excavation. — The uniform profile excavation (fig. 1-102) approach
profile results in lower unit price of rock excavated because the profile to be excavated represents
excavation the simplest outline requiring no “sculpturing" of the rock around the draft tubes and spiral
cases. On the other hand, the volume excavated will be substantially greater than for mini-
mum excavation of approach 2. Moreover, the excess excavation must be replaced by
expensive concrete whose cost will offset the gains of lower unit price for the simpler
excavation.
The uniform profile excavation may indicate construction scheduling advantages if excava-
tion alone is considered. This is offset somewhat because of increased work volume for
concrete placement.
Minimum (2) Minimum Excavation. — Just as for surface powerhouses, some designers prefer the
excavation approach of minimum excavation around the draft tubes and spiral cases (fig. 1-103).
advantages
Based on what is discussed for approach (1) above, approach (2) offers only the following
advantages:
EXCAVATION OUTLINE
Another advantage of approach (2) is that all rock left in place serves as lateral support for
the pit walls. This is especially desirable if the pit walls are high and the stratigraphy of the
surrounding rock is such that it could lead to stability problems. In this connection, it
should be noted that for most rock formations the near-ground surface rock (which is the
case for pit powerhouses) is more fractured and jointed than that at greater depths.
The advantages indicated for approach (1) would appear to represent obvious disadvan-
tages for approach (2).
(3) Recommendations. — Each approach, (1) or (2), should be considered on its own mer-
its, depending on the size and the number of units. It would appear that for one- or two-unit
powerhouses the extra work involved with the complicated excavation outline of approach
(2) will not be too excessive when compared with approach (1). For several units, however,
case 1 approach may reduce the excavation time considerably and thus allow earlier start
of unit installation.
In general, the simpler the design approach is, the simpler also the construction is.
Therefore, approach 1 with a uniform excavation profile would appear to be the preferred
one, even though the resulting excess excavation must be replaced by rather expensive
excess concrete volume.
g. Superstructure Arrangement
(1) General. — The superstructure arrangement for pit powerhouses is basically the same Superstructure
as for the surface powerhouses presented in section 5. The only exception for pit power- arrangement
houses is that the exterior walls are formed by the excavated pit faces.
ROOF
ROCK ANCHORS
ROCK BOLTS
SUBSTRUCTURE
Geotechnical Figure 1-104 indicates the principal elements that must be considered in the geotechnical
provisions design of the excavated pit walls which form a part of the superstructure. Although each
case should be considered depending on the surrounding rock conditions, the following
minimum requirements are offered for consideration:
• Rock bolts. Provide in rock formations whose joint and bedding plane systems indi-
cate the need for reinforcement of the pit walls to make them self-supporting.
• Post-tensioned #8 rock bolts, 20 feet deep, and 10 to 15 feet on centers each way may
be more than adequate for many cases encountered. The bolts should be fully encap-
sulated to protect them against corrosion. See also the discussion under rock support
for cavern powerhouses.
* Shotcrete. Provide only if excavated rock surface may disintegrate because it is frac-
tured or when exposed to air. A thickness of 3 inches with light wire mesh will suffice
for most cases. Shallow (2-ft-deep) weep holes should be provided through the
shotcrete to prevent external pressure buildup. See also the section on cavern power-
houses for additional discussion on shotcrete provisions.
(a) Concrete walls (rock lining). — If greater watertightness or more substantial support Rock lining
for the excavated pit rock face is required, the rock may be lined with cast-in-place con-
crete which is anchored to the rock for composite action (fig. 1-105).
POSSIBLE
GROUNDWATER
ROCK BOLTS/ PRESSURE DIAGRAM
CAVITY WALL
ANCHORS- .
GUTTER
Figures l-105a and l-105b illustrate possible concepts for lining of excavated rock faces
with concrete for watertightness and structural stability. The walls should be reinforced for
crack-control (approximately 0.5% of cross-sectional area) and anchored to rock such that
the anchors provided can resist the full groundwater pressures acting against the walls.
The rock anchor (which serves also as rock bolt) depth shall be such that sufficient sub- Rock anchors
merged rock weight is engaged to make the system stable as indicated on figure 1-106.
Figure 1-1 05a illustrates a very workable concept with cavity walls. Possible leakage is Cavity walls
not exposed to the interior of the powerhouse. The interior face of the brick, concrete block
or precast concrete panel cavity wall will always be dry and can be painted i f desired.
ROCK
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Downstream (b) Downstream walls exposed to tailwater. — The exterior face of the downstream walls
walls may be exposed against tailwater as indicated on figure 1-107.
The wall is intended to span between the concrete piers (draft tube gate piers) which are
tied into nock as described under item (a) above. The surge tunnel is an extension of the tail
tunnel and daylights at ground surface. Initially, it served as construction access tunnel (fig.
1-101).
Roofs (3) Roofs — The roofs of the pit powerhouses can be of the same design types as described
under subsection F.6 for surface poweihouses. With the roof basically at ground level, it is
very convenient to utilize i t for accommodation of switchyards. The close proximity of the
switchyard to the plant is an advantage of the pit power poweihouses that should not be
overlooked during conceptual studies. In the design shown on figure 1-40, the roof con-
sists of a concrete arch that is covered by fill. On figure 1-108, providing the pit power-
house results in substantial shortening of the water conduits. These would be longer if a
surface powerhouse at the river bank had been used instead.
Erection bay h. Pit Powerhouse Erection Bay. — The powerhouse pit extends sufficiently to provide
space for unloading and erection of the equipment The space requirements are the same as
for surface powerhouses. For equipment access, the most convenient arrangement appears
to be an access at the roof level as for semi-indoor type powerhouses.
# Units
£ Aun'iliary Unit
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distributor E/. 3&. 00
83.00
Wa
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Min. lower pool level
raw
Figure 1-108. — Viiyui, Viiyui River, U.S.S.R. [Gluskin and Demidov, 1970].
MAIN CRANE
ERECTION UNLOADING
BAY BAY
Unloading bay The area under the equipment unloading crane can be designated as the unloading bay.
This space can also be used as a temporary erection space when no equipment is unloaded.
The equipment access can also be attempted via an access tunnel from the ground surface.
In that case, provisions should be made to keep out surface runoff and to have the portal set
above maximum tailwater.
A cavern is a fully enclosed rock chamber. The surrounding rode is utilized as a structural
shell to enclose the interior of the cavern. Rock reinforcement of varying amounts, depend-
ing on the quality and the physical and elastic properties of the rock, is needed to utilize the
surrounding rock effectively.