presentation - Water

Seminar on Challenges in Procurement
and Contracting in Large Hydropower
Projects
The World Bank Group
Hydropower Community of
Practice (WBG Hydro CoP)
Washington DC
13th June 2012
1
Brief Company Overview
2
Impregilo corporate profile
● Listed on the Milan stock exchange
● Italy‟s Leading General Contractor
● Turn over US$ 2.7 billion/year, backlog US$ 32.5
billion (in share) as on December 31st 2011.
● More than 17,000 employees worldwide
● Over 100 years on the international construction
market
World-leading expertise on complex projects
Construction
● Over 30,000 km of roads and
56 km of bridges and viaducts
constructed to date.
 Longest bridge constructed to
date – second Bosphorus bridge,
1,087m main span.
● Expertise in construction in
technically challenging
environments.
 45
years
of
tunnelling
experience, with more than 100
projects completed in over 27
countries.
● Drilling and blasting and
mechanical boring capabilities.
World-leading expertise on complex projects
Construction
● High speed/capacity
specialist in railways.
● Over 5,700 km of line
tracks constructed to
date.
● Over 130 km of
subways line tracks
constructed.
● More than 185
metro stations.
● World leader in the
construction of dams
and hydro-electric
projects.
● 180 dams
constructed in more
than 80 countries.
● 200 hydro-electric
projects with 25,000
Mw of installed
capacity.
World-leading expertise on complex projects
Engineering & Plant Construction
Flue Gas Treatment
● In the world every
one of four electrical
power plants is
equipped with a flue
gas treatment plant
supplied by our
Group.
Waste treatment
● Waste incineration
and composting
plants.
Desalination
● Sea water
desalination plants.
World-leading expertise on complex projects
Concessions
● Supply of
water.
● Management
in the field of
medicals,
connected to
hospital
services.
● Over 2,000
km of roads
operated and
maintained.
● More than 192
MW of power
generation
capacity.
Impregilo Group: The result of M&As
Impresit-Girola-Lodigiani Impregilo S.p.A.
1959
LODIGIANI S.p.A.
IMPREGILO S.p.A.
1994
GIROLA S.p.A.
IMPRESIT S.p.A.
COGEFAR S.p.A.
ITALIMPIANTI S.p.A.
FISIA S.p.A.
Babcock Borsig AG
COGEFARIMPRESIT S.p.A.
1989
FISIA ITALIMPIANTI S.p.A.
1996
FISIA BABCOCK ENVIRONMENT GmbH
2002
1998
Impregilo Group in the World
Our current presence
A Global Group
Our operations in the last 15 years
Europe
Italy
Great Britain
Greece
Finland
Portugal
Romania
Russia
Spain
Switzerland
France
Germany
Iceland
Sweden
United Kingdom
Netherlands
Africa
Asia
Americas
Lesotho
Libya
Kenya
Malawi
Morocco
Mozambique
Nigeria
South Africa
Tanzania
Uganda
Zimbabwe
Algeria
Saudi Arabia
UAE
Qatar
China
Pakistan
India
Kazakhstan
Singapore
Thailand
Turkey
Kuwait
Argentina
Brazil
Chile
Colombia
Dominican Rep.
Ecuador
U.S.A.
Venezuela
Mexico
Peru
Uruguay
Republic of Panama
Design and Construction of the Third
Set of Locks, PANAMA Canal
● Contract period: 2009–2014
● The project provides for the
construction of a new system of
locks and is one of the world‟s
most important engineering works
actually under execution.
● The project envisages the
construction of two new series of
locks, one on the Atlantic the
other on the Pacific Ocean side,
to enable the Canal to handle
increased levels of commercial
traffic, therefore responding to the
increasing demands on the
maritime shipping market, where
builders are constructing larger
container ships with greater TEU
(Twenty-Foot Equivalent Unit)
capacity,
known
as
Post
Panamax vessels, than the Canal
is able to accommodate today.
● The works started in September
2009, involves more than 6,000
workers, and are expected to finish
by the end of 2014, the Centenary
year of the opening of the Panama
Canal.
Design and Construction of the Third
Set of Locks, PANAMA Canal
1. Deepening and widening of the
Atlantic entrance channel.
2. New approach channel for the
Atlantic Post-Panamax Locks.
3. Atlantic Post-Panamax Locks
with 3 water saving basins per
lock chamber.
4. Raise the maximum Gatun lake
operating water level.
5. Widening and deepening of the
navigational channel of the
Gatun lake and the Culebra Cut.
6. New approach channel for the
Pacific Post-Panamax Locks.
7. Pacific Post-Panamax Locks
with 3 water saving basins per
Lock chamber.
8. Deepening and widening of the
Pacific entrance channel.
Switzerland’s Alptransit route:
S. Gotthard Main Tunnel
● Contract period: 2001-2014
● 57 km long rail tunnel.
● Metamorphic rocks, mostly gneiss.
● Hard rock, gripper Herrenknecht
TBMs, diameter from 8.80m to 9.30m.
● Non-reinforced 30 cm concrete lining
includes both waterproofing and
insulting layers.
● In anticipation of high temperature (up to 45
degree) forecast during the excavation works
in many sections, an important cooling and
air conditioning device network had been
installed in order to maintain a temperature
of approximately 28 degree in working area.
Design and Construction of the
Messina Suspended Single Span
Bridge, Italy
Design and Construction of the
Messina Single Span Suspension
 Total Length of
Bridge, Italy
Suspended Deck: 3,666 m
 Length of Central Span:
3,300 m – Longest in the
World
Length of Each Side
Span: 183m
Height of Towers: 382 m
a.s.l
 6 Lanes for Road Traffic
 2 Service Vehicles Lanes
 2 Railway Tracks
 Total Quantity of Steel in
Strands: 166,750 tons
Hydroelectric Projects and Dams
16
Impregilo - World leader in Dams and
Hydro-Electric Projects
● More than 200 hydro-electric projects with dams of different
type (concrete, earth and rockfill, RCC) constructed in more
than 80 countries and over 85 powerhouses were constructed,
either open-air or underground.
● The overall installed power capacity of the Hydro-electrical
Power Plants constructed or to be completed exceed 25,000
MW.
Angostura Hydroelectric Power Plant,
Chile
 Contract Period: 2010 – 2013
Lot CHAN-CMC-21:
 Concrete faced earth fill dam
(high=25 m, crest length=1600m)
Lot CHAN-CMC-22:
 RCC main dam (high=63m; crest
length=153m) that includes a
spillway;
 Diversion Tunnel (long 290m,
internal dia. 14.4 m)
Lot CHAN-CMC-23
 Intake Works: concrete structure made of three parallel
and independent structures
 Underground Powerhouse with three units type “Francis”
with vertical axe. (total power installed 316 MW)
El Quimbo Hydroelectric Project,
Colombia
 Contract Period: 2010 – 2013
 Concrete faced rock
fill dam (high=150m;
crest length=635m)
 Auxiliary dam
(high=66m;crest
length=410m)
 Powerhouse has two
vertical axis “Francis”
turbines each of
200MW capacity.
Sogamoso Hydroelectric Project,
Contract 5/413 (Preliminary works) and
5/415 (Dam), Colombia
 Contract period: 2009 – 2013
 Excavation and lining of two
diversion tunnels (length=869
m and 829 m; diameter= 11 m);
excavation and lining main
access tunnel (length=340 m)
 Rockfill dam, with a concrete
“face slab”(high =190 m; crest
length= 300 m).
 Underground Powerhouse, with
three turbines type “Francis”
(total power installed 820MW).
Rio Caroni Hydroelectric Project, Venezuela
Contract 1.1.104.003.05: Tocoma Dam
 Contract period: 2007-2013
 61 m high main concrete gravity dam,
housing a 2.160 MW capacity
powerhouse (concrete volume=1.3
million m³)
 41 m high concrete faced
rock fill dam on the left side
(crest length = 3,800 m,
embankment volume = 3.5
million m³, face concrete
volume = 26,000 m³)
 50 m high earth/rock fill
dam on the right side (crest
length = 1,900 m,
embankment volume = 2.5
million m³)
 Concrete made spillway
equipped with n° 10 radial
gates (L=176 m, W=75 m,
H=61 m)
Karahnjukar Hydroelectric Project,
Iceland - Contract Kar 11: Halslon Dam
 Contract period: 2003-2008
 198m high concrete faced rock
fill dam – CFRD (crest length =
730m, total embankment volume
= 8.7 million m³)
 400mm to 600 mm thick concrete
face (total volume = 42,800 m³)
 D/S cofferdam in RCC - Rolled
Compacted Concrete (total
volume = 26,400 m³)
 The biggest dam ever
constructed in Iceland and one of
the biggest of its type in the
world
 Very tough and challenging
working conditions
Ghazi-Barotha Hydropower Project,
Pakistan - Contract C-01 and C-02
 Contract period: 1995-2003
 An earth fill barrage with a designed discharge capacity of 18,700 m³/s,
on the Indus river (embankment volume = 9 million m³)
 A 52-km long trapezoidal reinforced concrete-lined power channel
(excavation volume = 76 million m³, concrete lining volume=800,000 m³)
 20 open-flume standard bays, each 18.3 m wide and 8.3 m high, with
radial gates
 8 under sluice orifices, each 18.3 m wide and 3.5 m high, with radial
gates
Xialoangdi Multipurpose Dam Project, P.R.C.
Contract XLD-IC-1: Main Dam
 Contract period: 1994-2000
 154 m high zoned earth and
rock fill dam (crest length =
1,667 m, excavation volume = 9
million m³, embankment volume
= 50.6 million m³, 7.8 million m³
of clay core)
 Embankment composed of 17
zones of fill material, each
having specific characteristics
 Extensive consolidation and
waterproofing works
Ertan Hydroelectric Project, P.R.C.
Contract No. ET/IC1: Arch Dam Works
 Contract period: 1991-1999
 Total installed capacity of 3,300
MW
 The concrete parabolic double
curvature arch dam has a
maximum height of 245m, a crest
length of 775m and a volume of
4,192,357m³ of concrete
 The plunge pool, which is located
downstream of the arch dam, is
approx. 300m long and 110 m
wide
 Downstream structure a 32m high
concrete weir was constructed
Yacyreta Hydroelectric Project
Argentina/Paraguay
 Contract period: 1983 – 1998
 Earthfill and concrete gravity dam
42 m high; dam reservoir with
surface area of 1,600 Km² and 21
billion cum. in volume.
 Oper-air powerhouse with 20
Kaplan turbines (total installed
capacity of 3200 MW).
 Two spillways (16 +18 radial gates;
total discharge capacity 95,000
m³/s), including stilling basins.
 Inlet
and
outlet
channels
(9,163,000 m³ of excavation works
and 856,000 m³ concrete).
 Navigation Lock: concrete structure
is long 270 m and 27 m wide.
Yacyreta Hydroelectric Project
Argentina/Paraguay
Tarbela Hydroelectric Project, Pakistan
 Contract period: 1968 - 1977
 148 m high earth and rock fill dam
(crest
length=2,740
m,
total
embankment volume=121,000,000 m³.
 Open-air powerhouse with four
turbine-generator sets (700 MW total
installed capacity)
 Two spillways: 7 + 8 radial gates
(total discharge capacity of 42,200
m³/s).
Tarbela Hydroelectric Project, Pakistan
Kariba Hydroelectric Project,
Zimbabwe/Zambia
 Contract period: 1956 – 1960
 Double-curvature concrete arch dam
(high 128 m; crest length=620 m; total
embankment volume=975,000 m³)
 Underground powerhouse with six
turbine-alternator units (600 MW total
power generating capacity).
 450,000 m³ of excavations; 110,000 m³
of concrete
Kariba Hydroelectric Project,
Zimbabwe/Zambia
Lessons learnt from Contracts and
Procurement on Hydropower
Projects
Brief History:
• Key Role of the World Bank in the
Development of Major Hydropower
Projects.
• The WB Procurement Rules and
Procedures were the Guidelines for
most of the projects financed by others.
32
Lessons learnt from Contracts and
Procurement on Hydropower
Projects
The Main Points Which in Our Opinion
Need to Be Considered:
• Eligibility of Bidders
• Prequalification Principles and
Standards
• Lowest Price vs. Best Value For Money
• Integrity in Public Procurement
33
Lessons learnt from Contracts and
Procurement on Hydropower
Projects
• Choice of the Advisors / Consultants
• Choice of Forms of Contract (FIDIC,
NEC 3 …)
• National Procurement Systems
• Follow Up of the Projects (WB Panel of
Experts …)
• Dispute Resolution (DRB, DAB,
Adjudicator …)
34
Lessons learnt from Contracts and
Procurement on Hydropower
Projects
„‟The current policies and procedures
remain appropriate for large-scale
investments in infrastructure but they
seem less well tuned for the variety of
applications and development
challenges faced today‟‟
In my opinion we need to look into the
policies and procedures for large
hydropower projects too.
35
Kárahnjúkar Hydroelectric
Project Iceland
Challenges …. On the
Field
36
•Main Kárahnjúkar Project Characteristics
•Catchment area
1800km2
•Mean Flow
103m3/s
•Design discharge
144m3/s
•Hálslón reservoir storage
2100hm3
•Kárahnjúkar dam CFRD
198m

8.9 million m3
•HRT 40km 3 TBM and D&B
dia 7,2m - 7,6m
•Jökulsa diversion Tunnel
13,3km dia 6m
•Surge tunnel
1.7km, dia 5m
•Pressure shafts 2x dia 3.4m vert. H=418m
•Powerhouse rated head 524m, underground 6
francis Units 6x115MW= 690MW - 4450GWh/year
•Reyðarfjörður Aluminium Plant ALCOA
322,000t/year
•This is the 4th tallest Dam of this kind in the world
Main Characteristics
37
WEATHER
Snow / Wind Storms Speeds up - to 48 m/s
Heavy Snow Falls during Winter
Temperature Falls to - 25 Co
Very Poor Visibility During Winter
Unexpected weather through-out the year
Only 2 months without Snow
Difficult & Dangerous Working & Living
Conditions
38
Low Temperatures, Wind and Drifting
Snow Make Outside Work Hard
39
Main Camp & Facilities
40
Workshops & Warehouse
41
Concreting was done under cover – not a
problem, if properly planned
42
Jökuldalur Canyon: Plants & Conveyors
43
Kárahnjúkar dam – Canyon
Contract signed in March 2003
Start of Dam Excavation, on Right and Left
Bank, in April 2003
44
Dam Fill
Processing
Plant
Conveyor
Distribution
Rock Ladder
45
Typical work day at Kárahnjúkar
46
47
Face Slab Construction: Concrete by Slip-form
Face Slab FS28 Concreting – 20 December 2005
48
Face Slab Construction
49
Plinth Construction: Winterization
Rockfall
protection
Erect
protective
shelter
Winterizing
50
Plinth Construction: Placing Steel under Shed
RB Plinth – 29 November 2005
51
Spillway Construction – Winter Protection
Measures
Spillway – 01 October 2005
52
Spillway drainage below bottom slab– 26 October 2005
53
Spillway side canal- bottom slab reinforcement
November 2005
54
Spillway Construction: Concreting in Winter
Spillway Concreting – November
2005
55
Not Only Weather but also …. Water
56
Excessive Water Inflow at the Front
57
Partial filling of Headrace Tunnel and Pressure Shaft
Ufsarlón reservoir
Hálslón reservoir
625 m a.s.l.
670 m a.s.l.
625 m a.s.l.
m a.s.l.
600
Surge tunnel
550 m a.s.l.
13 km
530 m a.s.l.
Jökulsá tunnel
Adit 1
500
485 m a.s.l.
Adit 3
Adit 2
430 m a.s.l.
400
600 m
pressure
shaft
300
200
100
36 m a.s.l.
Simplified Sketch Waterways
0
-5
0
5
10
15
20
25
26,5 m a.s.l.
4 m a.s.l.
30
35
40
45 km
The 42 nationalities employed on site
59
THANK YOU
60