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Upgrading Dam Under Operation

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Upgrading Dam Under Operation Upgrading Dam under Operation YAMAUCHI Kazunori : Manager, Gate & Penstock Design Department, Steel Structure Engineering Division, IHI Infrastructure Systems Co., Ltd. FUKUSHIMA Noriaki : Manager, Gate & Penstock Design Department, Steel Structure Engineering Division, IHI Infrastructure Systems Co., Ltd. TAMURA Hiromichi : Manager, Gate & Penstock Design Department, Steel Structure Engineering Division, IHI Infrastructure Systems Co., Ltd. In recent infrastructure development, it is required to further utilize existing stocks, and many projects of the upgrading dam are implemented and planned in the water control and water utilization. IHI Infrastructure Systems Co., Ltd. has also participated in several upgrading dam projects and introduces previous experiences from the standpoint peculiar to upgrading dams in order to make reference to similar projects in the future. 1. Introduction of flood control and water utilization (power generation) in 1959. Japan is currently facing the need to make effective use of The riparian release conduit installed in this project was existing stocks while reducing total cost for infrastructure designed to eliminate cold water release and prevent the development, and endeavors to respond to this need is being prolongation of turbid water release, as well as to suppress made nationwide. From this perspective, it is thought that the eutrophication of reservoirs. efforts to utilize existing dams for a prolonged period of time This conduit is connected to selective water withdrawal in an effective and sustained manner are important for equipment that was separately installed (beyond the scope of addressing challenges in water control and utilization; and this project) on an intake conduit, enabling water to be various approaches, including flexible management, upgrading released at a rate of up to 10 m3/s at the lowest water level dam heights, and construction of tunnel spillways, are being after dam improvement. planned and implemented for many existing dams. Since the project was executed while the dam was in service, IHI Group has often contributed to the implementation of difficult work that involved underwater operations at a depth such approaches as it has expertise in the design, fabrication, of about 30 m was performed upstream in the lake created by and installation of steel structures, which is key to these the dam. approaches. The chamber, one of the unique aspects of this project, had IHI has long been making reports(1), (2) on renovations of two major roles: during the digging of the tunnel through existing facilities. Focusing on “upgrading existing dams,” which the intake conduit was installed, it served as a which has a broader scope than renovations of a single facility, temporary cofferdam① when the tunnel was cleared; and it this article describes technical measures for various subjects constituted part of the intake conduit channel through which in the execution of works on an in-service dam, in order for water was conducted from the selective water withdrawal② the measures to serve as a reference for entities participating equipment to the main control gate after the completion of in future projects. the selective water withdrawal equipment. 2. Kanogawa Dam Riparian Release Conduit Since the chamber was a complicated welded structure Installation Project subjected to a high water pressure and needed to be divided into six blocks due to transportation-related constraints, it Project title FY2012 – 2013 Kanogawa Dam Riparian was challenging to accomplish the on-site assembly of the Release Conduit Installation Project(3) chamber with high dimensional accuracy. In addition to Owner Shikoku Regional Development Bureau, ensuring high accuracy for the chamber itself, we had another Ministry of Land, Infrastructure, Transport challenge; we had to work underwater to achieve high and Tourism installation accuracy on site. Figure 1 shows the outline of Term of project From October 2012 to October 2014 the chamber and block arrangement for transportation. 2.1 The course of events during the redevelopment 2.2 Brief specifications of key facilities project and challenges in the execution of works The following are the brief specifications of each facility. The Kanogawa Dam is a multipurpose dam with an effective (1) Main control gate reservoir capacity of 29.80 million m3. It was constructed on Type Jet flow gate the Hijikawa River — in the area beyond Hijikawacho Effective diameter f 1.200 m Yamatosaka, Ozu City, Ehime Prefecture — for the purposes 24 Vol. 52 No. 2 2019 (a) External configuration of the chamber (b) Segmentation of the chamber into blocks CB-1 Intake conduit CB-2 CB-3R CB-3L Chamber main body CB-5 Support structure CB-4 (Note) CB-* : Block code Fig. 1 Outline of the chamber and block arrangement for transportation (a) Step 1 (b) Step 2 (2) Intake conduit Installation Structure Steel stiffener system reference line Bell-mouth tube diameter f 1.950 – 1.500 m Reference Intake conduit diameter f 1.500 m template Reducing tube diameter f 1.500 – 1.440 m Outlet tube diameter f 1.700 m Support (3) Guard gate structure template Type Plate structure steel roller gate Clear span 1.950 m - The reference template was - The support structure template was Effective height 1.950 m positioned in alignment with the positioned in alignment with the (4) Chamber reference line. reference template. Type Steel box girder structure (c) Step 3 (d) Step 4 — inside skin plate type — Inner space width 4.000 m Anchor bolt Inner space height 4.000 m Inner space depth 3.200 m 2.3 Key points for addressing challenges Support structure In order to ensure the dimensional accuracy of the chamber itself, it was important to avoid misalignment between blocks. - The support structure was - The anchor bolt was positioned in We therefore devoted much energy to ensuring accuracy; for positioned in alignment with alignment with the reference template. example, we first temporarily assembled all blocks and the reference template. performed positioning of the surfaces to be machined, and (e) Step 5 (f) Step 6 then disassembled the blocks and machined the joining surface of each block. Guide frame In addition, we took several steps to ensure underwater Anchor bolt fitting installation accuracy; for example, we used high-accuracy templates in the installation of the chamber, which had been Chamber preassembled to the guard gate guide frame. Thus, we were able to successfully ensure high installation accuracy within - The reference template was - The chamber was attached to the the limited time allowed for the execution of the work. removed. guide frame at the ground and was Figure 2 shows the installation procedure using the original then fixed to the support structure. steel templates. Fig. 2 Installation procedure using the original steel templates 3. Additional outlet facilities of the Tsuruda Dam middle of the Sendai River, is a multipurpose dam with an effective reservoir capacity of 77.50 million m3. It was 3.1 The course of events during the redevelopment constructed for the purposes of flood control and water project and challenges in the execution of works utilization (power generation) and was completed in 1966. The Tsuruda Dam (Kagoshima Prefecture), situated in the Figure 3 provides a panoramic view of the Tsuruda Dam. Vol. 52 No. 2 2019 25 3.2 Brief specifications of key facilities 3.2.1 Additional discharge pipes Project title Tsuruda Dam Additional Discharge Pipe Fabrication and Installation Project(4) Owner Kyushu Regional Development Bureau, Ministry of Land, Infrastructure, Transport and Tourism Term of project From October 2012 to March 2016 Table 1 lists the additional discharge pipe specifications. 3.2.2 Additional outlet gates Project title Tsuruda Dam Additional Outlet Gate Fabrication and Installation Project(4) Fig. 3 Panoramic view of Tsuruda Dam Owner Kyushu Regional Development Bureau, Ministry of Land, Infrastructure, Transport In July 2006, there was the great damage in watershed area and Tourism of the Tsuruda Dam by the catastrophic flood caused by the Term of project From February 2013 to March 2016 record torrential rains centered on the northern part of Regarding the additional outlet gates, Table 2 lists the main Kagoshima Prefecture, and the Tsuruda Dam Redevelopment control gate specifications and Table 3 lists the guard gate Project was planned. Specifically, it was planned to increase specifications. the maximum flood control capacity from 75.00 million m3 3.3 Key points for addressing challenges to 98.00 million m3 in order to reduce the damage caused by 3.3.1 Additional discharge pipes a flood. This plan included the installation of additional outlet In order to reduce operations performed concurrently with facilities, which involved the construction of five tunnels associated works, as well as operations in small spaces, we through the dam, and for this purpose, drilling was performed formulated a discharge pipe installation plan. First, with while the dam was in service. From this perspective, this consideration given to the constraints involved in the project was the largest in scale among the dam redevelopment transportation from the factory to the installation site, the projects in Japan. IHI Infrastructure Systems Co., Ltd. discharge pipes fabricated at the factory were delivered to the undertook part of this dam redevelopment project. installation site in the form of half segment pipes with a In this project, we faced several challenges. For example, it length of 3 m. Then, in the assembly yard provided outside was required to reduce the operations performed concurrently the dam, the half segment pipes were assembled into a with associated works performed in the bored tunnels for 6-meter-long pipe (cylindrical pipe). The longer pipes were installing discharge pipes, as well as to reduce the number of then transported to the installation site. Since the transportation operations that had to be performed in a tunnel in order to route included a section of a general road, the section was avoid having to work in such a small space.
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