Grand Egyptian Museum – OC/BESIX JV

JIJI AND MULEMBWE

HYDROPOWER PROJECT 1
Project Overview
Production and Distribution of Water and Electricity Ministry of Energy in
Client :
Burundi
Client’s Consultant: AECOM
Contractor : Fully Integrated JOINT VENTURE “ CMC - OC”

EPC Contract (Design, Procurement, Construction, and Commissioning of

Contract Type:
2 Hydroelectric Power Plant) ( Civil Re-measurable - E&M Lumpsum )

17 October 2018
Contract Signature Date:

For JIJI (3X 11.239) 33.717 MW = 51.285 MW

Output Capacity:
For Mulembwe (3X5.856) 17.568 MW

Contractual Guaranteed
output Required 49.5 MW

Engineering Consultant: Aurecon south Africa

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Design stage

JIJI Project Mulembwe Project

 Completion of JIJI Plant: 35

Months

 Completion of MULEMBWE
Plant: 42 Months
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Design stage

Required reports
 Environmental impact study report
 Survey report (it was conducted with Ladder Survey )
Which is required for all hydraulic calculation and storage capacity and
head losses for HWL and LWL
 flood hydrology report
Which is required for all hydraulic calculation and storage capacity and
head losses for HWL and LWL
 Sedimentation report
 Seismic Report
 Geotechnical and geophysics study
which is required to determine the type of dams and rock bed level
All Tests for Undistributed samples are mandatories and soil infiltration
(seepage) for jet grouting, curtain grout and consolidation grout if
required

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Design stage

• Location of Piezometers to be determined at the beginning of

construction as it is required for monitoring water level during
construction , test and commissioning as well
• Type of Dam has been selected based on the storage volume and height
and based on our case we applied massive concrete dams
• Based on all the above and type of dam selection, we had started the
design of diversion works
1- JIJI project :- we applied a concrete channel and temporary
earth work cofferdam and provided earthwork drawings for
excavation process

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Design stage

2- Mulembwe :- we applied part of desilting tank for water

diversion due the topographic condition

 We modified type of spillway with applying the piano key in order to

reduce its width in order to decrease cutting and soil stability works

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Design stage

 Descender or Desalting tanks

It’s water structure and the main issue for the design and construction the
inlet part with has to be designed with zero settlement and we eliminate
the jet grout with another technical proposal to support the intake direct
on the rock bed

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Design stage

 Tunnel &portal (exist and inlet) excavation work :-

The following options were considered:
Gravity/reinforced earth retaining wall
Pipe-jacking & TBM machine
Soil nailing with shotcrete
Fore-poling
Horizontal jet grouting
Vertical jet grouting
Anchored secant / contiguous pile wall
• Based on the topographic survey, soil report and site condition we moved
with soil nailing with shotcrete and using manual excavation and
Sinohydro Company as a subcontractor was selected

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Design stage

 Penstock
we recommended to go with steel pipe above ground with concrete pads
instead of Buried pipes for some commercial reasons as well slope of
penstock was a very steep and excavation for buried pipes will be difficult
and costly as well.
Transient calculation to check the pressure
along the waterway to be above
the ambient pressure for an opening
time of 25 s if only one unit is loaded
at a time!

• We eliminated surge tank after proof that the given pressure and speed
rise will not affect the penstock pipe, reflector and inlet valve.

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Design stage

 Powerhouse
the hec-Ras calculation are required to make sure the required net
pressure is complied with the required

Andritz supplier has been selected to supply all powerhouse equipment and
turbines. we applied horizontal turbine with 3 jet to guarantee the output
power

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Concrete quantities
Concrete quantities is about 110,000 m3
Concrete work for JIJI Dams only is about 27,500 m3 according to the below table
which excluded the quantities for ( tunnel work and concrete pads & anchor block
for penstock & powerhouse building & tailrace)channel

Structure Concrete
Volume (m³)
1 Left Bank Tongue Wall 3 718
The ACI code for massive concrete has
2 Left Bank Training Wall (downstream of 537 been respected with reducing heat of
tongue wall)
hydration, construction sequence and
3 Piano Key Spillway (crest) 175
4 Spillway apron 683
curing to avoid early age cracks due to
5 Spillway Bridge (incl. pier) 192
differential temperature between the
6 Bottom outlet structure (incl. its apron) 2 998 core and surface
7 Desander Inlet 1 627
8 Desander Transition 1 922
9 Desander Main 8 786
10 Roadway (deck) 431
Total Structural Concrete 21 069

11 Mass Concrete Dam 4 541

12 Mass Concrete (under bottom outlet) 1 948
Total Mass Concrete 6 489

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Site Mobilization
 Tower cranes has been studied to match with the construction progress and site
facilities and sequence of work. Therefore, we reduce the required tower cranes
with Appling tower crane undercarriage at each dame in order to cover the
whole area of descender tank and dam which reduce the cost of shipping and
timing as well

 Site camp and offices

 Quarry and batch plant and trial test

specially for massive concrete

 Laydown area for all excavation

 Prepare test for excavated soil to be used for backfilling

 Formwork study and construction sequence …..etc

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 Schedule Critical Path

The total length of tunnel work in JIJI is about 1100 m and it is the critical path
where its total duration is about 24 months + 8 months for engineering + 3
months commissioning
 Monitoring equipment
- Seismic recorders
- Flowmeters
- Piezometers
- Inclinometers
- settlement beacons
- -water levels
 Commissioning
- Factor test has requested a prototype, but the prototype test has been
eliminated after convincing the client that with the selection of supplier and
using three nozzle instead of two
- All other tests ( water leakage, seepage, hydrotests and net pressure
,..etc.) will be performed according to the contractual specification

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 Commissioning
- Fire detection system and fire fighting;
1- service water system
2- refrigeration systems
3- lighting, telecommunication, air conditioning etc.
4- Functional verification of measuring instruments and the water intake
structure actuators and driving head (valves, cofferdams etc.);
5- Functional verification of measuring instruments, the control system
(internal services, ancillary services and general services) and electrical
and mechanical protection of plant systems;
6- Functional testing, blank, the inlet valves of turbines, injectors, baffles
turbines, time adjustment maneuver;
7- Inspection of the penstock in accordance with the technical specifications;
8- Commissioning of power transformers, in collaboration with supplier
market "building computer";
9- Commissioning of balance of plant, testing and system controls 6.6 kV;
10- Getting the service line 6.6 kV to head the works, and auxiliary of these
works.

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 Commissioning
17.2.2 Routine tests in water
After the successful completion of the preliminary inspections and tests,
and subject to approval by the Client of the results of these preliminary
tests and trials, the manufacturer will conduct impoundment of the
penstock and the listed tests and checks below will be performed on each
group in the presence of the Client or its project Director.
During the tests, critical parameters such as water level, pressure in front
of the driving speed in the driving voltage and frequency, rotational speed,
pressure in the oil hydraulic circuits, temperatures etc. will be measured
simultaneously by a digital measuring system for rapid sampling and high
accuracy, independent of the control system. These parameters will be
attached to test protocols as curves and data tables.
1- rotation test (run out) of the turbine together - generator, checking the
alignment routine checks;
2- Rotated at nominal speed, speed stabilization;
3- Running at nominal speed, excited, with the generator short-circuit and
unladen, voltage regulation controls and electrical protection;

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  Commissioning
4- Control of start and stop sequences of groups operating in different
modes and at different locations and control modes;
5- Synchronization to the national grid;
6- charging plugs, shedding trial and quick stop at 25%, 50%, 75% and
1000/0 of the load
7- Trial Unit full power and temperature stabilization (72 hours minimum)
8- operating tests in isolated network at low load, controls the speed
controller.

Finally, The results of these trials will mainly assess the following:
• Unit power turbines, speed control performance, maximum transient overspeed, etc .

• Warm-Ups alternator in the bearings of the alternator, voltage regulating performance.

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End of Slides

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