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HomeMy WebLinkAboutImages of the San Roque Dam Second Edition by Alfredo E. Belen, Jr 2003About the Author Alfredo Belen Jr.,or "JB”as he is better known,was Assistant Camp Manager in the Operators Village of the San Roque Dam Project.Prior to this assignment, he worked in the same capacity at the Mauban Coal- fired Plant in Quezon Province in Southern Luzon, Philippines. JB is now in partnership with Lothar Vogt in managing camps for power projects and has also set up a corporate publishing company. JB is an accountant by profession,having received his degree from the University of the Philippines in Quezon City,Philippines.He ended up in the food service industry after his initial stints working for a popular international fast food chain polished his planning and organizational skills in the service industry. Jojo Robles is a journalist who currently writes a four times weekly column for the Manila Standard,a daily newspaper in the Philippines.He has written for and edited various publications over the past 17 years. Marvin Quien worked as supervising graphic artist of apre-need company in Manila.He also do freelance design work for various companies like Panasonic,ABN- AMRO and Sunlife of Canada.He is currently in the US doing freelance design work. IMAGES of the SAN ROQUE DAM SECOND EDITION By ALFREDO E.BELEN,JR. Praise for 'Images' Images of the San Roque Dam by Alfredo E.Belen,Jr.is a wonderful photo chronology of WGI's San Roque Multipurpose Water Resource and Hydroelectric Project. The enclosed book provides the next best means for gaining an understanding of our project challenges and the outstanding results produced by the entire project team. Two WGI legacy companies,United Engineers International and Raytheon-Ebasco Overseas Ltd., entered into contracts with a subsidiary of Sithe Energy Inc.on March 6,1998,to provide the complete engineering,design,equipment procurement and installation,construction,start-up and commissioning on a lump-sum basis for the $1.2 billion San Roque Project. -STEPHEN G.HANKS President and Chief Executive Officer Washington Group International The shareholders,directors,officers and staff of San Roque Power Corporation greatly appreciate the initiative and hard work in conceiving and completing this marvelous book commemorating the design and construction of the San Roque Multipurpose Project. All associated with the SRMP now can use it to reminisce on their participation in this major undertaking and to share their experiences graphically with friends and family. -PATRICK J.McALLISTER President San Roque Power Corp. Mr.Alfredo "JB”Belen is to be congratulated for having the foresight,expending the extra effort and having the talent to produce a document,recording the endeavors of the many involved in building a great Project. -WILLIAM R.CATLIN Senior Vice President,WG! IMAGES |OF THE SAN ROQUE DAM IMAGES OF THE SAN ROQUE DAM ALFREDO E.BELEN,JR.ytnaRLSat Copyright 2003 ©Alfredo E.Belen,Jr. All rights reserved.No part of this publication may be reproduced,stored in a retrieval system or transmitted in any form or by any means,electronic,mechanical,photocopying,recording or otherwise without the prior written permission of the publishers and copyright holders. 'ISBN 971-92647-1.3 Da & ee Editor:Jojo Robles *Graphic Designer:Marvin Quien».ee covet photo and design:Stanley $.Ong'* Principal Photography:Bert Dimsom,FranzAlbert Dimson,Jun Belen,Stanley s.Ong,Larry Adair'Additional photography-Jerry Scott,David Rosenbaum,St ::SRPC Archives,WGI Archive:: ”7 a tents',Published and exclusively distributed by«Power Publishers”: This book is dedicated to the thousands of people who made the San Roque Project a reality. It is also dedicated to my family and friends who have made the publication ,of this book possible.seesngeoneggeeos|iiaihee haeoa Table of Contents :'Chapter I : GEOGRAPHY AND BACKGROUND 11 Chapter2 PROJECT OVERVIEW 24 Chapter 3 -..STARTING THE PROJECT 42 SF i:Chapter 4*””RESETTLEMENT ACTION PLAN 52 Chapter5 _ENGINEERING AND DESIGN 67 Chapter 6 THE MAIN DAM AND THE COFFERDAMS 95 Chapter 7 THE TUNNELS AND POWER WATERWAYS 110 Chapter 8 ; THE SPILLWAY 125 Chapter 9 PROCESS PLANT AND CONVEYORS 137 _,Chapter 10 THE POWERHOUSE AND THE 147 SWITCHYARD Chapter 11 PROJECT SUPPORT 165 Chapter 12 HEAVY EQUIPMENT 177 Chapter 13 THE RESERVOIR 195 Message from the WGI President To our clients around the world: Images of the San Roque Dam by Alfredo E.Belen,Jr.is a wonderful photo chronology of WGI's San Roque Multipurpose Water Resource and Hydroelectric Project.The magnitude of this project in the Philippines warrants a site visitto best appreciate it.The enclosed book provides the next best means for gaining an understanding of our project challenges and the outstanding results produced by the entire project team. Two WGI legacy companies,United Engineers International and Raytheon-Ebasco Overseas Ltd.,entered into contracts with a subsidiary of Sithe Energy Inc.on March 6,1998,to provide the complete engineering, design,equipment procurement and installation,construction,start-up and commissioning on a lump- sum basis for the $1.2 billion San Roque Project.A fast-track 58-month schedule was required,and it is my pleasure to report that this aggressive schedule is about to be achieved. We believe that the San Roque Project is the largest privately financed water resource project ever undertaken by a single EPC contractor.Consider some of its outstanding features: *Main earth and rockfill dam:Height:656 feet (World's 12th highest);volume of 52 million cubic yards Length at crest:Two-thirds of a mile Base width (upstream toe to downstream toe):One-half mile Four miles of tunnels:Two diversion tunnels:33 feet by 49 feet (horseshoe shape) Power tunnel:29 feet in diameter Low level outlet tunnel:18 feet in diameter Surge shatt:66 feet in diameter by 377 feet deep ¢Gated concrete spillway:328 feet wide by one quarter of a mile long,capable of passing 452,000 cubic feet of water per second Shaft-style semi-underground powerhouse with three units,each producing 115 MW WGI also developed the San Roque construction infrastructure,including a 22-MW temporary power plant and site transmission system,housing for supervisors and craft workers,a construction equipment maintenance facility,and site access roads.Imported to carry out the project was perhaps the largest fleet of new construction equipment ever assembled in the Philippines for a single project.Our team conducted intensive labor training programs,resulting in a world-class construction operation. We invite you to explore this fine testimonial to the WGI design engineers,purchasing specialists,quality assurance engineers,construction supervisors,craft labor,and the balance of the support team who worked together to bring the San Roque Multipurpose Project from an idea to reality. Regards, caePHENG.HANKS President and Chief Executive Officer Foreword The shareholders,directors,officers and staff of San Roque Power Corporation greatly appreciate the initiative and hard work in conceiving and completing this marvelous book commemorating the design and construction of the San Roque Multipurpose -x eee Project.All associated with the SRMP now can use it to reminisce on their participation in this major undertaking and to share their experiences graphically with friends and family. Thank you. Cg Pe While the commercial operations of the SRMP mark the beginning of 2003,initialaansoehe,oe studies of the Project date back as far as 1949.NPC studied the hydropower potential ._--ca of the Agno River in 1974,and included irrigation and other purposes at the request ofioceeos+NIA.This led to a preliminary recommendation in 1976 for the development of two2Shoae na.|Sites,the more promising of which was the downstream site at San Roque.NPC then porte MELE toy " .commissioned a detailed feasibility study and decided against developing the upstream Tn co site for social,cultural and environmental reasons.A detailed feasibility report was"completed in March 1979and updated in 1994.As built,SRMP remains remarkably :mo -'consistent with its recommendations,even after extensive additional data collection, model studies,and final design engineering. The perspectives of the SRMP are diverse.They span the Republic of the Philippines, which designated it a Flagship Project;the National Power Corporation;the affected local communities,including 2 provinces,3 municipalities and numerous barangays; the affected peoples,including 781 households who relocated;the EPC contractor - composed of subsidiaries of Washington Group International and such major equipment suppliers as Toshiba,Alstom,ABB,IHI,and VA Tech Voest MCE;the equity participants and shareholders of SRPC -Sithe,Marubeni and Kansai; ,and the project lenders,including the Japan Bank for International es :Cooperation and a group of Japanese commercial lenders.The.successful completion of this Project reflects the careful integration of these perspectives into a set of mutually compatible expectations. Again,thank you to Mr.Alfredo "JB”Belen for documenting in words and photos the challenge of building the SRMP PATRICK J.McALLISTERPresident&CEO Foreword The San Roque Multipurpose Project was built to produce electrical energy, provide year-round irrigation benefits,reduce flooding and enhance downstream water quality.The primary feature of the Project is a 200 meter high,1.2 kilometer long embankment dam on the Agno River spanning the . municipalities of San Manuel and San Nicolas,Pangasinan,nearly 200 km north of Metro Manila. San Roque Dam consists of 42 million cubic meters of embankment material,impounds 12.8 square kilometers of reservoir surface area providing water to a silo type powerhouse capable of producing 345 megawatts of electrical power.A major feature of the Project is the six gated Spillway designed to discharge the "probable maximum flood”of 12,800 cubic meters per second.The Spillway required excavating nearly 12 million cubic meters of earth and rock and placing 240,000 cubic meters of concrete.Construction of the Project required driving nearly 8,000 lineal meters of tunnels and concrete lining over 5,000 lineal meters. The Project was built by the most industrious of the Filipino people.During the peak construction period over 4,600 workers were employed performing every task the construction industry offers.During the performance of their tasks the workers developed a world-class safety culture. |was honored to be a part of the San Roque Project and very pleased to have been requested to write the foreword for a book dedicated to documenting the construction effort.|believe the book will be very informative to those seeking insight to the Project and will be cherished by those associated with it becoming a reality. Mr.Alfredo "JB”Belen is to be congratulated for having the foresight,expending the extra effort and having the talent to produce a document,recording the endeavors of the many involved in building a dy KA.WILLIAM R.CATLIN Senior Vice President great Project. Washington Group International 1 ARI aR TNOEAE TIEag LF :Yt ayen*iyi?ate Pe A2.ryeae=ist¥: Chanter1 Geography and Background The Agno River winds down the Cordillera mountain range. Project Location HE Project is located in Central Luzon, along the western toe of the Cordillera Central range where the Agno River cuts its valley,extends southwards and thereafter flows southwest into the Pangasinan plain.It is favorably located in relation to the irrigable lands,energy consumption centers and existing transmission lines,which are readily and easily accessible.The Site is located approximately 30 km and 38 km downstream of the Binga and Ambuklao hydro plants which also dam the Agno River. The Cordillera Central is geographically a young mountain range,whose erosion phenomena are still very pronounced and steep slopes and narrow gorges characterize its morphology.Erosion has considerably increased after a major earthquake in 1990. Recent deforestation and the geology of the river basin also hasten its erosion.The Pangasinan plain downstream of the Project is a wide,flat low land.These lands have been filled with sediment carried by the rivers and deposited in fans and bars.This sedimentation process tends to isolate low areas between relatively higher lands so that large portions of the Pangasinan plain suffer from inadequate drainage and flooding.This occurs particularly in the lower part of the Agno River plan. Rainfall over the projected catchment area is very intense,producing an average run-off in the San Roque section of about 84 cubic meters per second. 11 The areas surrounding the Site provide construction materials of various types which can be utilized for the dam.These materials can easily be transported to the Project Area. The rocks in the area are made of dioriteor metasediments with good to excellent mechanical characteristics. Geography The Agno river has drainage area of 5,646 sq.km.and with a total length of 221 kilometers,is the third largest river in Luzon next to the Pampanga and Cagayan rivers. Half of the drainage area,particularly the watershed in Benguet Province is mountainous having an average elevation of about 2,000 meters above sea level (masl}. The river originates in the Cordillera Mountains near the common boundaries of the provinces of Ifugao,Nueva Vizcaya and Benguet.Flowing north to south,it emerges from the Cordillera mountain range at the towns of San Manuel and San Nicolas, Pangasinan.It breaks up into several channels in the flat central plains of Luzon and meanders through major settlements in the provinces of Tarlac and Pangasinan before emptying into the Lingayen Gulf. The main tributary is Tarlac river (the drainage area is about 1,900 sq.km including Poponto Swamp),which joins the Agno river ° midstream from the left at Bayambang.The Tarlac river has its source on Mt.Pinatubo (elevation is 1,745 meters)located in the boundary of three provinces,namely Pampanga,Tarlac and Zambales. After passing through the mountainous area,the Agno River forms a vast alluvial fan and a delta,and then flows into Lingayen Gulf. This fan and delta is called the Pangasinan Plain,and has long been developed economically,together with the Pampanga Plain forming the Central Luzon granary. The Agno river has a course of more than 200 km,90 km of which runs in mountainous zones,forming deep canyons.The average slope of the riverbed is about 1/50 in canyons, and about 1/1,000 on the plain.Poponto Swamp is located in the vicinity of Bayambang where the Tarlac River joins the Agno River. The swamp has an area of about 25 sq.km and temporarily retains floodwater from the Tarlac river. Dagupan City and Sta.Barbara form the center of the Pangasinan Plain,which was formed as a result of floods from the Agno river.Changes in the river course as well as river improvement works led to the separation of the Agno river from the plain.The plain is at present protected from the flood by the dike systems along the right riverbank. . The Agno River has carved deep canyons in the mountainside. Starting the San Roque Project Sosy Bob Resch Perhaps one of the most demanding tasks in a project of a scope as the San Roque Dam is that of securing the project and laying the groundwork for the incoming construction team. To properly estimate the construction costs,the project deliverables have to evaluated, construction components estimated,and project risks analyzed and managed. The first of many challenges facing a design/build contractor is the need for a fast and effective mobilization of the engineering and construction teams following the receipt of a Notice-to-Proceed. The San Roque Multipurpose Project presented added challenges due in part to its fast track,58 month schedule,the magnitude of the work,and the remoteness of the site.It required an immediate initiation for all aspects of design, equipment tendering,and pre-construction activities,including site preparation.With construction activities scheduled to commence just two months later,there was_no time to waste. The responsibility for leading this effort was placed in the hands of Robert Resch,a 34 year 12 veteran with Washington Group International (WGI)and its legacy companies,who had managed many of the Company's large power and water resource projects in the United States and abroad.Bob is a licensed professional engineer with a bachelor's degree in Civil Engineering from the City College of New York and a master's degree in Industrial Engineering from New York University. In June 1997,Bob was assigned to the San Roque Project as Project Manager to assist the developer,Sithe Energies,Inc.in completing the prerequisite tasks and agreements necessary for initiating the Project.His task-was to finalize the Project definition,establish an execution plan, complete the cost estimates and critical path schedules and prepare a proposal for undertaking the work.A team of specialists, each renowned in their own field of expertise, was assembled to assist in the awesome task. The team included A.D.(Doc)Poteat (a long time M K executive and construction manager), Donn Routolo (50 years plus in planning major water resources projects and developer of the San Roque Execution Plan),Earl Woodward (tunnelling and shafts;also over 50 years of experience),Steve Summy and Steve Hankla (construction equipment selection),Charles (Chuck)Faris (also over 50 years experience in conveyors and processing plants),and Joe Ehasz e keBeisel dormant some of their equipment. (Company consulting civil engineer and expert in dam design). Following a period of negotiations,the contract was signed on March 6,1998 and the notice-to- proceed with the design and construction works was issued immediately thereafter. Raytheon Engineers and Constructors (RE&C),a company that eventually merged with Morrison Knudsen (M K)to form Washington Group, International,won the bid to design,supply,and construct the San Roque Project.With a lower bid and a shorter construction time frame,their bid fitted Sithe Energies'financial programs and timetables perfectly.According to Bob,"The shorter timeframe did involve some risk.The risk of significant rainfall and runoff during the wet seasons suggested a longer schedule.With an effective execution plan,constant coordination and new construction equipment,we were confident we could mitigate most scheduling problems” The locally quarried clay which forms the Dam's impervious core material was a major consideration.Initial site investigations concluded that the clay would need to be dried in order to achieve optimum moisture content for placing in the core.We believe the competition relied on natural drying by spreading large quantities of clay on the ground during the dry seasons.We Ulrich Cordon (back row,second from right)and the Engineering crew display ee CE ee et. planned on an accelerated drying process using a rotary kiln drier.Our approach would facilitate some progress on the Dam during the wet seasons,while it is likely the competition discounted a major portion of progress during each of the wet seasons',he adds. Aside from the weather and materials factor, there were a lot of other matters that had to be considered,like the remote location of the Project,the availability of qualified labor,and the fact that there were minimal utility services to facilitate initial site mobilization. In order to meet the Projects'time constraints and ensure early and continuous progress,Bob had to act quickly and make a number of mission-critical decisions.Strategic subcontracts for labor supply, road completion and site improvements had to be promptly awarded.Temporary offices were opened in Urdaneta and on the Project Site. Design and construction for o@n-site housing and _felated facilities were established formanagement,professional and craft labor.Water supply and waste treatment facilities were installed.Medical,food and recreation facilities had to be established.Literally a small city had to be built from ground up. Building a world-class Project also entailed mobilization at a scale rarely seen in the 13 Other Dams in the Area There are two existing dams on the Agno River upstream of San Roque,each of which serves hydropower stations:Ambuklao and Binga.The Ambuklao Project was completed in the mid-1950s.The Binga Project was completed in 1961. They both have embankment dams constructed of sand,gravel and clay,similar to the SRMP Their reservoir capacities are small relative to San Roque,and have been further reduced by accumulated silts and sediments,especially in the years following the major earthquake of July 1990 due to massive landslides along the river gorge. Neither dam was damaged by the earthquake (7.8 Richter scale),which propagated along a fault located about 33 kilometers east of the dams. Philippines.Orders were released for the entire fleet of new construction equipment.It was perhaps the largest project-related equipment purchase in the Philippines and was a welcome shot-in-the-arm for the Philippine economy. Temporary site electric power had to be provided which was eventually replaced by a full 22- megawatt construction power plant.A 500,000 gallon diesel fuel storage facility was erected. Even the main access road from San Manuel had to be repaired and paved to improve the movement of workers,equipment and materials. Compared to other infrastructure projects probably the most outstanding aspects of the San Roque Project are its magnitude and scope, the level of risk,and the total design/build obligation of the contractors.San Roque has been described as the world's largest privately financed infrastructure development,and certainly the largest undertaken by a contractor', Bob concludes. Getting a good start to any major construction project improve its chances for ultimate success. Management decisions have long-term implications that affect the conduct of the project for the succeeding years of construction.The strong foundation that Bob Resch and his team laid out for the San Roque Project is a major factor in its success. Site and Access The main access road from the town of San Manuel to the site includes a bridge crossing over the Agno River.Raytheon Ebasco Overseas Ltd.,the Projects primary contractor, have converted the access road into an all- weather road capable of handling all vehicles and loads required during both Project construction and operations.The access road and the bridge became the main access to the diversion area tunnel and the Powerhouse area. Choosing the Site The final selection of the San Roque Project site was the result of years of careful study and analysis of the water resources of Northern Luzon.The studies date as far back as 1949,when several agencies and organizations conducted water resource studies of the Agno River basin and the Pangasinan plain.In fact,no fewer than ten different dam sites and power/irrigation schemes were considered. In September 1974,the National Power Corporation (NPC)commissioned a study of the hydropower potential of the Lower Agno River.In December 1975,the National Irrigation Administration (NIA)requested that the scope of the study be expanded to include possible irrigation scenarios. A preliminary report was completed in July 1976.Two possible sites were short-listed for consideration.Sitio Tabu,Barangay Dalupirip, ltogon in the province of Benguet province was identified as a possible site.The other site was in Pangasinan,on the boundary of the municipalities of San Manuel and San Nicolas. Based on the 1976 preliminary report, NPC commissioned a detailed feasibility study in May 1977.The study was completed in March 1979.It showed the Pangasinan site as the better choice,as the Sitio Tabu site was deemed less feasible,for social,cultural and environmental reasons.NPC implemented these recommendations in 1981. NPC began operating a micro-seismic monitoring network for the San Roque Multipurpose Project (SRMP)in March 1982. The purpose of the network is to document the occurrences of earthquakes generated by the neighboring Philippine Fault System.This network has functioned continuously since then,gathering data for use in the design, construction and operation of the SRMP and for scientific purposes.The micro-seismic monitoring network is being expanded as part of the construction and implementation of the Project. Seasonal rains can cause floods in the cities Ae us Sr aan NSMea wonacralAueAySee!A easesHeavyrainscancausetheAgnoRivertorisetodangerousheights. NPC environmental firm in July 1983 to perform engaged an_independent an environmental impact assessment of the Project.The study was completed in May 1984 and was released in the form of an Environmental Impact Statement (EIS).The EIS described the Project,took into consideration physical,its biological,hydrological, chemical,ecological,socioeconomic, archeological and aesthetic impacts, considered alternatives (including not proceeding with the Project),and proposed measures designed to mitigate the Projects' effects. The Environmental Impact Statement (EIS) was submitted to the National Environment Protection Council for its consideration.An Environmental Compliance Certificate (ECC) was granted to NPC on November 26,1985. The ECC allowed NPC to construct and operate the SRMP. 15 ott : NPC initiated site development and preparation activities,which consisted mainly of the construction of an access bridge and roads.All work was suspended,however,due to delays in financing. 1993 saw the Philippines gripped by a power crisis of nationwide proportion.The economy was at a standstill and could not move forward due to the lack of power generation facilities.This caused renewed interest in the SRMP Previous studies of the Project were reviewed.A revised feasibility study was compiled in August 1994. 1997,the San Multipurpose Project was implemented under the Build-Operate-Transfer Law (Republic Act 1957).In October 1997,NPC executed an agreement with a consortium of three In May Roque international firms for the execution of the Project.These three firms are the shareholders of the San Roque Power Corporation (SRPC). ¥e,BlessFaeaev,'2. The river winds slowly through downstream flatlands. Making the San Roque Dam a Reality. me4 NY Glenn Gaydar * In the middle of 1996,the area of what was to be the site of the San Roque Dam was a mountain with sporadic foliage and undefined footpaths.A single wire cable strung across the expanse of the Agno River suspended a small one-man basket. "Passengers”boarded the basket and were shoved over the river's foaming waters unto the east bank cliff.Upon arriving on east side, it was a long hot climb to the area where the San Roque Dam now stands.A small group of people made its way across the river and to the site.Glenn Gaydar was a member of that small group that made the trip in 1996. Glenn made that trip representing Sithe Energies.They have come to study the feasibility of building the San Roque Dam. 'The National Power Corporation had started works on the project but abandoned it in the 1980's due to funding problems.Sithe Energies and its partners later formed the San Roque Power Corporation to make the San Roque Dam a reality.Sithe Energies is an international force in the energy market.It is 'a leader in independent power generation in North America and among the top five independent power producers in the world. Glenn has degrees in Mechanical and Civil Engineering.He also has 30 years of "experience in hydropower design, construction,operations &maintenance,and management.His experience in the industry enables him to source and assess market opportunities,secure project financing, manage environmental compliance and build plants that benefit the community. According to Glenn,"San Roque is a project the Philippines can be proud of as today,it represents the largest single infrastructure project attempted and completed in the Philippines.This fact should be of immense interest to future investors in the country”. On building the Dam,Glenn adds, "Certainly no project becomes successful without talented and dedicated people to pave the way.The San Roque Project has been gifted with top-notch experts on all 16 fefons= = :7.Ne =RAPbeerehh levels:from the EPC contractor and subcontractors,the variety of technical and social consultants,managers,advisors,and agency specialists.The dedication of the tradesmen and women who made up the backbone of the San Roque workforce provided a strong foundation to support this huge undertaking.The teamwork of all involved has resulted in a world-class project that all can take pride in.With such a good start,San Roque has all the potential for delivering all its expected benefits for flood control,irrigation and clean renewable power generation for the benefit of the Filipino people for many years to come.” In May 2002,Glenn walked the crest of the San Roque Dam after the last load of fill was placed.He looked back at remembered what it was like in 1996 when he first visited the area.He has seen the Project grow from a dream and becomea reality.He sees the potential for the San Roque Dam to be a positive force in the lives of thousands of people.So he savors that walk,knowing and appreciating all the blood,sweat and tears that went into the achievement. The San Roque Dam is the story that is written by thousands of people over a number of years.Glenn was there every step of the way.Glenn has helped make the San Roque Dam a reality. One of the first requirements placed on SRPC was the updating of the original EIS to incorporate a broad range of social, biological and technical studies that had been conducted since the ECC was issued, although the original EIS remained in full force and effect.NPC also prepared a Resettlement Action Plan that conforms to accepted international standards,in consultation with the communities and families affected by the Project.The Resettlement Action Plan also set forth NPC's social commitments in terms of compensation,resettlement and livelihood. In late 1994,NPC began intensive consultations with affected communities and families.These consultations culminated in a Host Agreement,signed by the stakeholders in 1996.Each of the government units'subsequently issued Community Memorandum of December local resolutions endorsing the SRMP.Such consultations continue to this day,but now regularly include SRPC,the Department of the Environment and Natural Resources (DENR) and the National Commission on Indigenous Peoples,and periodically,NIA and the Welfare & Development,Public Works and Highways, Departments of Social and Agriculture. The updated EIS,which incorporated the original ElS as a separate volume in its entirety, was submitted to the Environmental Management Bureau (EMB)of DENR in accordance with current Philippine laws,rules and regulations.EMB then convened an independent review committee of respected environmental and technical experts from academia,government and non- governmental organizations to review the EIS. On February 12,1998,the Secretary of DENR issued additional terms and conditions to the ECC upon the recommendation of the Review Committee and the EMB,thereby enabling project implementation to continue. One of these conditions mandated NPC and DENR to:prepare a comprehensive plan to manage the San Roque watershed-a designated critical watershed area that was a focus of the Review Committee.This enabled construction of the SRMP to start on March 6, 1998. Since then,three independent and world- renown environmental firms have been engaged by prospective and ultimate lenders to the SRMP to verify compliance with accepted international standards.The firms exhaustively reviewed the environmental impact studies and regulatory approvals.Two of them evaluated compliance prior to financial closing.The third was retained by the lenders to SRPC and to NPC to monitor social and natural environmental compliance during implementation,primarily via comprehensive semiannual fact finding missions.None of these reviews have disclosed any significant issues with respect to the project's impact on biodiversity or local communities. Floodwaters make the Agno River dangerous during the rainy months. The floods could submerge entire houses. Kansai Power and the San Roque Dam Project =e | Junya Yamamoto In the mid-90's,the Japanese government initiated discussions aimed at deregulating Japan's power industry.In response,private utility companies studied ways of diversifying their core businesses. Investments in overseas projects were considered as a viable option.Kansai Electric Power Co.,Inc (Kansai),one of Japan's largest power producers,was willing to give this option a try. Kansai invested in the San Roque Project and owns 7.5 percent interest in the San Roque Power Corporation.With more than 140 hydropower plants in operation and 50 years of experience in hydropower development and operations,Kansai was expected to contribute much to SRPC in terms of technical assistance.This assistance included the deployment of engineers to the San Roque Project. Junya Yamamoto was one of the engineers assigned to the Project by Kansai. Junya,a civil engineer by profession,joined the company in 1979 and has been engaged in hydropower development,design, construction,operation and maintenance work in various projects.He has worked in the design and construction of the 124MW Otozawa hydropower plant,the 2280MW Kaneihara pumped storage plant,the 23MW Minokawai hydropower plant and has been involved in the operations and maintenance of Kansai's other hydropower plants. "Instead of merely looking at the business aspects of the a project,Kansai went after projects where it could contribute its expertise to.Kansai's experience in hydropower development and operations as well as its technical and environmental aspects could help a lot in the Project's success.”,says Junya. "The San Roque Project is Kansai's first international investment.In fact,it was the first international IPP for all of Japan's utility companies.It served as a blueprint for the other power companies to follow”,Junya adds. Aside from Junya,Kansai has also sent over engineers like Yoshiro Yamabayashi, Tadahiko Seoka and Kimio Takahashi to the Project to lend their expertise and 18 experience.They worked hand-in-hand with the local engineers,assisted them and gave advice on the environmental and operational aspects of the Dam.Their advice on such matters as the sedimentation of the Dam, flood control measures and effective use of the Reservoir were very helpful to the Project. While this is Junya's first overseas assignment,he feels that he has also learned a lot from the experience."Every experience in the Philippines and in the international business world is new and exciting for me. The discussions I had with the staff of SRPC, WGI,UEI and the Philippine Government have taught me a lot.There are cultural differences in the way project requirements are fulfilled and in the approach required to resolve problems. The Filipino people are very supportive and very easy to work with.The engineers are very knowledgeable and are willing to learn about the latest technology and methodology.All in all,it has been a very memorable and impressive experience for me.",Junya concludes. Another view of the Agno River (above)highlights the Project Site.The river starts in the Cordillera mountains (below). A photo of the Watershed Area (above)shows sporadic tree cover.This is an overview of the project area in the early stages of construction works (below).The Agno River travels down the Cordillera mountain range (opposite). aye gba. reeTe SeatoeWg7%Ad tye Og ae ete SRPC rehabilitated the old NIA Weir to increase its efficiency. Aerial view shows the new San Nicolas Bridge (opposite). The same bridge (inset)was left unfinished when the Project started. 22 fe8fot eas whol"ck?<t as24 . 7 +3 Chapter 2 v=TE ee Project Overview Project Description HE Project involves the construction of a 195 meter-high embankment dam along the Agno River.The dam will create a Reservoir with a capacity of 850 million cubic meters,which will inundate an area of approximately 12.8 square kilometers, extending into the municipality of ltogon, Benguet. San Roque Power Corporation (SRPC)is financing and constructing the SRMP under an agreement with the National Power Corporation (NPC)on a build-operate- transfer (BOT)basis.Ownership of the dam and spillway will transfer to NPC upon construction completion,as NPC is contributing funds for the non-power componenis.SRPC will own and operate the power generating facilities for 25 years,after which ownership will transfer to NPC. Beginning in early 2003,the SRMP will provide power,irrigation,flood control and enhanced water quality benefits to the surrounding region,which includes the Northwest Luzon Economic Growth Quadrangle. Power The SRMP has an installed rated capacity of 345 megawatts (MW).It operates primarily as a peaking plant during periods each day when the electrical output of base and intermediate load power plants cannot fulfill consumer demand. The plant can operate year around at its dependable capacity of 85 MW for a minimum of eight hours a day -even during periods of extreme drought.Whenever surplus water is available,the SRMP can either provide extra peaking capacity (beyond 85 MW)or generate off peak power,or a combination of the two. Based on the historic flow data for the Agno River,average annual energy generation capacity is approximately 1,000 gigawatt-hours (GWh).About 250 GWh is energy arising from the plant's dependable capacity of 85 MW,which is the basis for the 24 A similar view shows the Main Dam,Spillway and the river in August 2002. Delivering on a Commitment The San Roque Project is more than just a dam,a flood control facility,an irrigation project and a power generation facility.It is a commitment and an investment in the future of the Philippines.When the partners formed the San Roque Power The task is a very challenging one. There are so many facets to the Project that have to be addressed.Keeping the Project on track is one of them. According to Pat,"I am confident that we can meet the schedule.While there are still some critical Corporation,they made a commitment to improve the lives of the people,to provide a reliable and renewable source of power and to build a world-class project that the Filipino nation could be proud of. Patrick McAllister is tasked to deliver on that commitment.As President and Chief milestones that can influence the completion of the Project,we stand a good chance of completing it on time if we all work together. Keeping everything ontrackhasbeenarealchallenge.We have been successful because of the unselfish dedication of Executive Officer of San Roque Power Corporation,he is responsible for the overall operations of the corporation,from finance to construction management,from government and community relations to operations and maintenance.Pat joined Sithe China in 1999 serving as Vice President of Program Management in their Beijing Office.Previous to that,he was Vice President of Technical Operations for Coastal Power China.In the year 2000,Pat was seconded to San Roque Power Corporation. Pat McAllister the team that we have here at San Roque. Without them,the success that the project enjoys today would not be possible.” Aside from the construction works, there were other challenges."The most challenging aspect of the San Roque Project has been on the land,social and government aspects.The private sector proponent needed to exert a tremendous level of effort to implement the Project. The timely delivery of lands and the securing of government consents and permits were an enormous challenge. 25 capacity payments under the power purchase agreement.The balance is surplus power that reduces dependence on imported fuel oil and also lowers the variable operating expenses of other power plants. The economic analysis conducted by NPC and the National Economic Development Authority identified the additional power capacity and the peaking power capacity of the dam as its major technical benefit.Aside from those mentioned in the NPC analysis,SRMP offers other benefits.Most of these benefits are unique to large hydroelectric facilities. The private sector proponent and the government team worked closely together to prevent serious delays. Working as a team,we have been successful in accomplishing seemingly impossible tasks.As with any other hydroelectric project in the world today, certain NGOs have continued to challenge the Project but we have been steadfast in our commitment and found ways to overcome the challenges”,says Pat. Aside from the Dam's well-known benefits,there are many other benefits for the Filipino people."REOL has provided a world class level of training in construction and safety that has benefited thousands of workers employed in the construction of the project.These new skills will allow the workers to go anywhere in the world and earn enough money to provide them and their families with a decent standard of living.Additionally,with the support of the. government and SRPC,the livelihood projects for the project-affected families will give them an opportunity to establish a better quality of life.Through our donations of books,computers and school rooms,we hope to lay the foundation for a better way of life.”,Pat adds. The San Roque Power Corporationhasbecomeavitalpartofthelocalcommunity.Its entry into the communitycamewithapromisetomakeapositiveimpactinthelivesofthepeoplewhose lives it has touched.SRPC is determined to fulfill its commitments.And Pat McAllister and his team are in the forefront of that commitment. For example,the water turbines can be maintained in "spinning reserve”when not on line;that is,turning at 60 hertz under no load,able to deliver as much as 400 MW within seconds in the event of a regional power outage.This capability improves the overall quality of power needed by high technology industrial consumers. Even if completely shut down,the turbines can be restarted and energized in a matter of minutes,as no warm up cycle is required.In addition,the water turbine-generators have "black start”capability,which enables them to be the initial source of power following a blackout so that other plants can be restarted. They also can be used to stabilize system voltage and frequency,and as a source of reactive power. Irrigation The SRMP will provide year-round irrigation benefits for about 70,800 hectares (ha)of farmland downstream of the dam, including parts of Lower Pangasinan,Nueva Ecija and Tarlac,with a partially diversified crop during the dry season. Alternatively,the irrigation benefits can be extended to 87,000 hectares by means of a completely diversified crop during the dry season.These choices are the subject of further studies by the National Irrigation Administration (NIA)in consultation with local irrigators'associations. The irrigation component includes: A re-regulating pond that supplies water to the Agno River and the irrigation system during the 16-hour off-peak period when the power component may not operate; A siphon intake serving irrigated lands on the east bank in San Nicolas; Rehabilitating about 47,000 ha of existing irrigation and drainage system;and Developing a new irrigation and drainage system serving about 23,700 ha. NIA estimates that more than 53,000 farmers will benefit from the irrigation component. Flood Control The SRMP produces a marked attenuation (reduction)in the perennial flooding of the Agno River,which affects at least 16 Pangasinan and Tarlac towns.For tloods up to a 50-year event (that is,one so large as to recur only once in 50 years),peak outflows from the dam are at least one third {1/3)less than peak inflows to the reservoir. The reservoir does not contain floods,but rather attenuates them;that is,it reduces outtlows released downstream by storing a portion of the inflows received from upstream. In fact,the SRMP attenuates all floods up to the 200-year event -a flood so great as to recur only once every 200 years.The flood attenuation gradually reduces from about 1/ 3 for the 50-year flood to zero for the 200- year event. ;SRPC. This is a closer view of the NIA Weir rehabilitated by During typhoons,the reservoir level is allowed to rise above the normal maximum operating elevation of 280 meters above sea level (mas!)and may reach the maximum exceptional elevation of 290 masl.This is consistent with SRMP design criteria. During extreme events:namely,floods beyond the 200-year event,all inflows received from the upstream Cordillera watershed must be released downstream.In that scenario,flood conditions will be same as those prevailing had the SRMP not been constructed. °:re In other words,the spillway is operated Sewn Cee sols yt baer 2a Aud.SO that the peak outflow during a flood eventWesNSdoesnotexceedthepeakthatwouldhave occurred without the dam and the rate of rise of the water in the downstream channel does not exceed the natural rate without the dam. Water Quality The SRMP improves the quality of the water in the Lower Agno River by serving as a settling basin,trapping sediments transported by the runoff of typhoons or the tailings generated by unregulated small-scale mining activities.The volume of sediments primarily depends on the watershed management plans being implemented by the NPC and the Department of Environment and Natural Overall view of the Spillway,Main Dam and Switchyard shows progress of the Resources (DENR)in consultation with the work by January 2002.affected local government units. DENR also is developing a regulatory process suitable for the needs of small-scale miners and the environment,as thousands of families in the Agno River watershed depend on such mining for their livelihood. Nonetheless,the design of the SRMP assumes that sedimentation rates experienced over the past 50 years will continue.The SRMP reservoir has substantial "dead storage” capacity -representing the volume of water at its lower levels that is not available for power generation,irrigation or flood control. The dead accommodate the historic sedimentation reservoir's storage can rates,including the massive volumes released following the major July 1990 earthquake, for a period of some 90 years. Water Management As a multipurpose facility,the Project will manage and control stored water for use in power generation,flood control and irrigation of downstream farmlands.The Reservoir will be operated to store excess runoff flows during the flood season.This stored excess will later be released during periods of low flow. Another aerial view higlights the Process Plant. Providing Project Oversight The San Roque Dam is full of significance for all the parties involved in the Project.For the Philippines,it is a Flagship Project that symbolizes an investment in the future.The irrigation and flood control benefits of the Dam will change the way people will live in the downstream areas.It is expected to provide increased productivity and efficiency in the field of agriculture.The power produced by the Dam will provide stability to the regional power supply and reduce the demand for fossil fuels.For the San Roque Power Corporation and its investors,the Project represents a blueprint for future undertakings and a major investment in the future of the country. For the Washington Group,it is a major design/build effort on a scale that is rarely seen in the industry.The San Roque Project is recognized internationally as one of the largest design/build projects ever and showcases the tremendous capabilities of the Washington Group. Such significance magnitude.Working on every engineering position the company had to offer,Bill eventually took on management tasks that had him handling international operations in countries such as Egypt, required the appointment of one of Washington Group's senior personnel,Bill Catlin, to the Project as Executive Sponsor.Bill was part of the due diligence team for Morrison Knudsen that oversaw the purchase of RE&C's Construction Division that led to the formation of the Washington Group,International. Wo ¢js Oman,Turkey,Russia, Philippines,Singapore and Cuba. The San Roque Project presented it's own set of challenges.The nature of the contract required the US-based design team to coordinate closely with the field team in the Philippines.The distance factor and the time difference betweenBillstartedhiscareerinSati construction as a draftsman _Bill Catlin at Montana's Yellowtail Dam.Still a student at that time,the exposure fueled his ambition to obtain the knowledge and skills required to manage a project of that 28 the parties made communications critical. The tragedy of 9/11 that claimed the lives of WGI employees working in the World Trade Center also affected the Project's timetable.Furthermore, wheSoOFe "ieneSeertPOAYJeareSrPye:"igh+atthe. Photo shows the Conveyor line,as seen from the air. the change in ownership brought about by Morrison Knudsen's purchase of RE&C entailed a major adjustment in management style and philosophy. "Some of the difficulties encountered were related to time,personnel and business philosophy.I got involved midstream in the Project and this situation abbreviated the allowable time for me to become acquainted with the capabilities of the design and construction personnel.There were also differences between the philosophies of the former and the new owners of the company on the degree of involvement by the home office in Project Management,Project Controls and Scheduling.Another major challenge was that of implementing the necessary changes in accounting and cost reporting systems to conform to procedures used by Morrison Knudsen,a legacy company of Washington Group, International,”says Bill. "Probably the most sensitive challenge was not to cause disruptions or delays while initiating or implementing changes to an established group that had already developed their own project culture.”Bill concludes. Bill approached the challenges squarely. He sat down with his key personnel on the field,assessed the Project's needs, reassigned personnel to critical tasks and provided logistical support to critical Project areas.He used the resources of the Washington Group and applied them to the San Roque Project to accelerate its progress. He worked closely with the US offices to make sure that the San Roque Dam received continuous engineering and financial support for its needs. The San Roque Project is a legacy to the efforts and talents of thousands of people who worked hard to see it completed.Bill Catlin's perseverance and support helped make it a reality. 29 This type of Water Management will enable NPC to generate electricity,as well as provide irrigation and flood control benefits from the Agno River.It will also complement the generation output from the Binga and Ambuklao hydro plants upstream on the Upper Agno River.The 2 upstream hydropower facilities currently generate most of their output during the wet season and are near outage conditions during the driest months. In the event of heavy rains and floods that increase the water level in the Reservoir water level higher than the maximum Reservoir operating water level,the Power Plant may be instructed by NPC to generate power ona continuous basis in order to delay or avoid the need to discharge water through the spillway. Plant Design San Roque Power Corporation (SRPC)is responsible for the design and construction of the SRMP on a build-operate-transfer basis for NPC.SRPC engaged the services of Raytheon Engineers and Constructors (RE&C) and United Engineers,International (UEI)to design and construct the Project and to procure all equipment and materials,such as the water turbine-generator units,main transformers,spillway gates and other major equipment.In July 2000,RE&C and UE!were acquired by Morrison Knudsen Corporation,. a US engineering and construction giant.The union of these major engineering and construction companies produced Washington Group International,Inc.(WGI). In the Philippines,a RE&C subsidiary, Raytheon Ebasco Overseas Limited (REOL), serves as the lead contractor for the Project. In accordance with the Construction Contract and the Engineering and Procurement Contract,SRPC and REOL accepted the geotechnical risks associated with the construction of the project.NPC had conducted prior geotechnical studies on the /Project,and the results of these studies were f incorporated into the 1979 Feasibility Study / which was included as one of the bidding / documents for the Project./ SRPC's geotechnical consultant, Electowatt,has reviewed the data and core samples from the initial study and completed an independent geotechnical survey of the cee fe fo Project area,drilling bore holes in the dam,legs ie aspillway,power tunnel and powerhouse areas,' as well as conducting seismic refraction tests ae of :on over 50 survey lines.The geotechnical oo program also opened several inspection adits, and undertook an extensive material sampling program for clay core,embankment materials ve . and riprap.The samples collected were Nes - examined to verify the data which was detailed ii he |. : in the original Feasibility Study.SRPC and -oe ay,eT / REOL then reviewed the information collected '-* and were satisfied with the initial findings. Diversion Works an .N In order to start work in the main of fe 2 Tye a) construction area,a series of diversion nTipastructures had to be built.During the construction period,REOL and SRPC were responsible for accommodating all river flow ee y See .: Pa conditions up to the 100-year flood event. The diversion system was designed for a flood :&ok foe = with a minimum 30-year return period and ee ee ab tee./Yo.\both SRPC and REOL have determined the ae -see oo «i , size of the diversion tunnels to pass floods up ee eee fh ue Bs oe a to a 30-year flow.In order to control flows OT ee ae |ap aes greater than the 30-year event,the upstream eae) cofferdam was designed with an overflow At 'i. channel.The channel was constructed near /|: the right abutment of the cofferdam and 7)a ie {Ld directed water away from the construction fi 4 'area.Se:i } -a33a3ii,\i :oy% 3 laraiiwei2secapnieTransmission lines are installed to connect the San Roque Project to the San Manuel Substation (opposite).Workers (above)conduct excavation work at the River Embankment. The upstream cofferdam was 65 meters high.A portion of the upstream cofferdam wos ultimately incorporated into and form part of the main dam structure.During the construction period,river flow was directed by the upstream cofferdam into three 850 meter long Shotcrete lined diversion tunnels. The diverted water was released downstream of the dam construction area where it rejoins the river channel.The tunnels where sealed off after completion of dam construction. Another cofferdam was built downstream of the down construction area to prevent the flow of water backwards into the construction works,as some of the works had to carried out at a level below the river bed.The diversion works were completed and the river was diverted by July 1999. 31 Dam The dam was constructed to a height of about 195 meters above the existing river valley floor.It contains nearly 40 million cubic meters of fill material.At its crest of 295.0 meters above sea level (masl},the dam is 1,130 meters in length.The dam was built in 5 stages:Construction of Cofferdams and Water Diversion Structures;Excavation of Loose material Below the Dam;Foundation Treatment;Placement of the Clay Core and Embankment Materials;and Closing of the Water Diversion Structures to begin Reservoir filling. Mobilizing for the Project After the Washington Group has received the go-signal to commence with the construction works in the Project Site, it put into motion simultaneous activities in the offices of the Washington Group in the United States and in the due to a shut down would have enormous impact for all local employees related to the project as well as the company. Harold and his long-time associate, Joyce Materum,worked together to ensure that all the government Philippines.Initiating the preparations in the Philippines was industry- veteran Harold McQueen. Harold has been involved in other civil projects in the Philippines for another US-based civil engineering firm and was part of a team submitting a proposal for a Light Rail Project in Manila when the San Roque Project permits and licenses were secured for the Project. They worked with the various local and national government _officesconcernedwiththe Project and =spentconsiderabletimeand effort to make sure that the Project conformed to all applicable laws and statutes.Harold also set up and the Washington materialized.He was tasked to inspect the site and handle the numerous permits and licenses required for theProject.He was also asked to immediately set up the ground work necessary to mobilize for this major undertaking. The largest,most difficult and time- consuming challenge was obtaining the required licenses and permits from the government offices.Timing was of utmostimportancetotheprojectsbeginningandcompletiondatesthatanydelayswould cause a shut down.The lost time and costs This is how the Main Dam, Reservoir and Dave's Mountain looked in July 2002. Harold McQueen Groups'office in Makati to handle all of these tasks. In addition to the permits and licenses,over $170 million dollars worth of construction equipment had to be purchased,shipped,processed through Customs,off loaded and then trucked to the site.And it all had to be done on time as delays in the delivery of equipment could result in major cost overruns. The Makati office secured the services of a very reliable and dependable freight forwarding company.Together,they oversaw each shipment and processed the clearing of Customs and the delivery of the equipment to the site.They held weekly meetings to track the status of each ship, the contents,and expected arrival date to make sure all deliveries were on schedule. Harold also ensured that a licensed broker took care of the stand-by letters of credit that are required by Customs before shipment is released. The Makati Office also oversaw the arrival of expatriates and transported them Safely to and from the site.With each arrival on site,the office had to obtain all the necessary work visas,arrange for home andemergencyleaves,any _hospitalrequirements,and meets the everyday needs of the workers and their families at San Roque.All passports,work visas, Philippine licenses and permits also had to be up-to-date.The office also took care of compiling and submitting all income taxes that are due from employees.While such items may seem to be routine in nature, failure to comply with such regulatory requirements could result in unnecessary complications. "All in all it has been very challenging in a lot of areas.We have a team of very dedicated and professional employees.With their knowledge,understanding,and dedication,we have overcome the hurdles that we had to deal with everyday”,Harold concludes. The dam structure consists of an embankment with a massive central core serving as an impervious barrier.A mixture of residual clay and sandy gravel make up the material for the central core.The components of this material matrix were excavated from designated borrow areas located approximately 4 kilometers downstream of the dam structure.The materials were conditioned on Site prior to placement in the dam.The clay core foundation was carefully cleaned and treated with grout to prevent any leakage of water.A grout foundation controls seepage in the dam foundation.Combination drainage and grouting galleries were installed to collect and discharge any water seeping from the foundation area. Filters of fine and coarse sands were located on either side of the core.These layers protect the central core and serve as transition and drain zones between the core and the outer shell.The shell on the main sections of the dam were made of pit-run sand-gravel, including small boulders and random rocks which were sourced from excavations in the borrow areas.The outermost dam surfaces are protected from waves and erosion by layers of rock. Spillway The concrete spillway is situated on the right abutment,(looking downstream)of the dam.The spillway is designed for a flow of 12,800 cubic meters per second.This corresponds to the Probable Maximum Flood, an internationally accepted criterion for determining the size of spillway capacity required to handle the maximum possible flood given the watershed characteristics and given the climate of an area. The spillway protects the dam from overtopping whenever inflows to the reservoir cause the surface elevation to rise above 290 meters above sea level (mas!).The normal The switchyard connects the Powerhouse to the Transmission Lines.ieMsReree tte wicas in i sind reat” The Reservoir,Dave's Mountain and p this August 2002 photo. maximum operating reservoir surface elevation is 280 masl.During a typhoon,the reservoir is allowed to rise above the normal maximum operating elevation to the maximum surface elevation of mas!.This is consistent with the design criteria for the dam. Power Waterways The power waterways are composed of the following components:Intake Structure; Power Tunnel;Surge Tank;Penstock;Manifold and Tailrace Tunnels.SSKana NA pii422S)asEs Work on the Spillway (background) and the Switchyard (foreground)was nearing completion by June 2002. The Power Tunnel is a concrete lined tunnel with a length of 722 meters."Jumbos”, large tunneling machines were utilized for drilling the power tunnel.The Power Tunnel is 8.2 meters in diameter and was constructed through the lett abutment of the dam. The tunnel intake is 90 meters lower than the crest of the dam and is below the minimum normal water level required to operate the turbines.The intake structure contains trash racks that prevent large debris from entering the tunnel and damaging the turbines.190 meters from the intake,bulkhead gates are installed in a gate shaft.These gates can be lowered for normal inspections or in emergency situations to close off water flow into the tunnels. 34 Powerhouse and Switchyard At the end of the penstock,waterflow is directed into the Powerhouse for power generation. The Powerhouse has three vertical Francis hydraulic turbine units.Each turbine has a synchronous generator,and a net rated output of 115 megawatts (MW).Every unit is capable of operating independently of the other units. The main transformers are located at the access level on the downstream side of the Powerhouse.Gas-insulated switchgear located in the adjacent switchyard connects the facility to a 230 kilovolt (kV)double-circuit transmission line. Aerial view of the Spillway and Main Dam in July 2002 shows progress of work by that month.SRPC provides assistance to the livelihood projects of relocated residents (below).=rz>mrn;:wumz The year-round irrigation and flood control provided by the Project results in increased yields to downstream fields (above).Photo below shows the small streams from the Cordillera Mountains that feed the Agno River. a parent gtBateFOaeSAS ,+ee 36 The water discharged through the turbines will pass through steel-lined draft tubes and will flow back into the Agno River through the Tailrace Tunnels. Lower Level Outlet A low level outlet is also provided to remove sediment and debris from the intake area.It is also designed to discharge Reservoir water to a level below the power waterway inlet in order to allow for emergency upstream dam surface repair or maintenance.It also serves as a minimum flow outlet if the Powerhouse in unavailable to discharge water. The intake to the Low Level Outlet is located adjacent to the power waterway ,and is about 100 meters below the crest of the dam.The tunnel is 1.3 kilometers in length and is initially parallel to the power waterway. The tunnel then leads a straight path and its contents are discharged into the Agno River at a location approximately 500 meters downstream of the Powerhouse. This discharge feature is composed of an opening at the intake structure and a tunnel that passes through a gate chamber at the bottom of an open vertical shaft.The gate chamber is equipped with whee!l-mounted and hydraulically operated gates.Upstream slide gates were also installed for inspection and maintenance purposes. Transmission Lines The National Power Corporation (NPC) is responsible for constructing the 230 kilovolt (kV)double-circuit transmission line from the switchyard to the San Manuel substation approximately 9 kilometers away.The Power Purchase Agreement requires NPC to complete the transmission line no later than six months before the targeted Unit Completion Date for Unit One in order to allow the commencement of the testing process.REOL is then responsible for connecting the Power Station to NPC's transmission system. In orderto accommodate the addition of more than 2,000 megawatts (MW)of hydro and coal-fired power plants in Northern Luzon,NPC built a 500 kilovolt {kV)Extra High Voltage transmission backbone stretching from Labrador through the San Manuel and San Jose substations to the south.Completion of this backbone enables the power generated from San Roque and other power plants up north to be delivered to Metro Manila. (Overleaf)This dramatic aerial view of the Surge Shaft, Spillway and Main Dam was taken in July 2002. The Switchyard and the Tailrace Tunnels are clearly seen in this aerial view. Ky PRY fe oe :CH ddsades olde dssfesegSeigePhePATIYeANale ag 4 bsa&ee 7Pigeeee ee Fi ae ee Fs patnoes | pres ety osspeaoeiceaane wae SS are se President Gloria Arroyo inagurates the San Roque Multipurpose Project.Below,a scale model of the Project is shown to the President. eehecenethme-"CY iets cd fe ae ta "»2 Ewan ot ke a AF meOeoe ”ee madaeeee te a 40 hee woh, Another aerial view of the Spillway and the Main Dam Area (top)as it looked in June 1998.Above photo was taken in August 2002. 41 Chapter 3 tarting the Project Reviving a Stalled Project HE National Power Corporation (NPC}started work on the San Roque Project in the 1980's,after securing an Environmental Compliance Certificate (ECC)from the National Environment Protection Council in 1985.The ECC allowed NPC to construct and operate the SRMP NPC initiated site development and preparation activities,which consisted mainly of the construction of an access bridge and roads. All work was suspended,however,due to delays in financing. The power crisis of the early 90's prodded the government to review the Project for possible reactivation.Previous studies of the Project were reviewed and a revised feasibility study was compiled in August 1994.In 1996, the government solicited bidders for a build- operate-transfer (BOT)contract to develop power at San Roque for Luzon's electrical grid. Several potential developers considered the project too risky.Of six teams pre-qualitied to submit bids by the February 1997 deadline, four dropped out.One remaining developer team included New York City-based Sithe Energies Inc.,the largest independent power producer in the U.S.,along with Tokyo-based Marubeni Corp.,one of Japan's leading general trading companies and a 29%owner of Sithe.The other team included Italian-Thai Development Public Co.Ltd.,a major Asian contractor that also was set to build San Roque.The two teams merged and submitted the only bid.But Asia's 1997 financial panic forced lItalian-Thai off the team.Kansai Electric Power Co.Inc.,Japan's second- largest electric utility replaced Italian-Thai. Kansai Electric Power Co.Inc.,has a long history of hydro projects and was a perfect fit for the Project. 42 Another aerial view shows the Dam (top,opposite page),while photo below is of the upstream excavation in Dave's Mountain with the dam face in the foreground. The developers then solicited a \contractor,choosing Raytheon Engineers and Constructors,an affiliate of Boise-based Washington Group from among three bidders.Raytheon Engineers and Constructors was picked not only because of its price but also based on its promise to complete the project nearly nine months sooner than the two other bidders. The San Roque Power Corporation San Roque Power Corporation (SRPC),a special-purpose company incorporated in the Philippines in October 1997,is the owner of the San Roque Multipurpose Project (SRMP). SRPC was formed as a stock corporation in accordance with the Corporation Code of the Philippines and the Foreign Investments Act of 1991.Ownership of the dam and the spillway will transfer from SRPC to NPC upon construction completion.SRPC will own and operated the power generating facilities for 25 years,after which ownership will transfer to NPC. PER”SAR MEE EMRE ESLER RR STI ROOMS,ce RR ges.3 -_ae acs pe ae a Ay pe i 7 Ie ' aye . "F z "4 ishatteOEiZTSe4NOES":-, .'*y a oe caerAOTE7Wrkamaytteaseste7 ; " .sSdbay¢ep ie are ASL!ee wy |i bondLendl fey4.aie -git vr ,. fe ¢M ee "a "i <ayo!;SEM nab a eee es sett 8 DS egaeSayPRESEOEEaarp poe oR,Ee eee eee ee es j Me Wit 2 aie BR a bate TEI RE pte ea=a eraat aeOea,ae aewses aex7 ARRASSates2¢,FY3£4,Leg,t,ihYRArne''ontae':%ee'$aapa,2 i .a :as a ar SU oe ;Rina sTage%,wey 5 gen,Tes NaN neeie'ee)sh .:aT BS eee ata I tates eae .4 * ' cate Ag OT 2 age it os eee yee tapes am nid Th sod -5 SRPC will be responsible for all operations and maintenance activities for the San Roque Multipurpose Project upon completion,including the dam and the spillway.This responsibility will continue throughout the 25-year expiration period. The corporate shareholders of SRPC are Sithe Philippines Holdings,Inc.(Sithe), Marubeni Corporation (Marubeni)and KPIC Singapore Pte Ltd.(KPIC).Economic interests in SRPC are held 50.05 percent by Sithe Philippine Holdings,Inc.,42.45 percent by Marubeni and 7.50 percent by KPIC.Each of the shareholders has significant experience and expertise in the development or operation of power projects in Asia. Sithe Philippines Holdings,Inc. Sithe Philippines Holdings,Inc.is an indirect subsidiary of Sithe Energies,Inc., which is headquartered in Manhattan,New York.It is one of the largest private-sector power generation companies in the world, bars Lee BA having grown consistently since its formation in 1985 to develop,own and operate electric generating facilities throughout the world.It has been active in Asia for many years, including such countries as China,Thailand, South Korea,Indonesia and Pakistan. Sithe's experience as a power plant developer embraces all necessary steps to advance hydroelectric and thermal power projects from the pre-feasibility,permitting and financing stages through project implementation,including engineering design,construction,startup and plant operations. Marubeni Established in 1858,Marubeni is one of Japan's leading general trading companies. Its operations encompass international trading businesses throughout the world and extend from the development of natural resources to the retail marketing of finished products. **.e@ Local traditions called for ritual dances and animal sacrifice to be performed at the start of the project. =£ ao ¢Aeeh foapkepyspea, :ateeDe Bl poy yepeneteoy a"anerem oat oe edi 29. This is how the Main Dam and Powerhouse Area looked in April 1999. Recognizing the growth potential of the independent power market,Marubeni's Power Project Department has actively pursued power generation projects,both as developer and contractor,through its worldwide network. The Department is involved in a comprehensive range of electric power and related projects,including the construction ond rehabilitation of steam turbines, combined-cycle,geothermal and hydroelectric power plants,as well as all types of power transmission lines and substations. KPIC Singapore Pte Ltd. KPIC Singapore Pte Ltd.is an indirect, wholly owned subsidiary of The Kansai Electric Power Co.,Inc.("Kansai”).Founded in 1951, Kansai is the second largest electric power company in Japan.It possesses extensive experience in the power industry,particularly in the development of hydroelectric power, which accounts for 20 percent of its total installed capacity.In fiscal years 1999 and 45 2000,Kansai produced 16,177 and 13,880 million kWh of hydroelectric power, respectively. It is a vertically integrated power company to more than 20 million residents in the Kansai region,covering such major cities as Osaka, Kyoto,Kobe and Nara,and the industrial area along the coast of Osaka Bay.Electricity consumption in these areas totals about 17 percent of total national consumption.Kansai owns.power generation plants and transmission lines and distributes electricity. It owns and operates 145 hydropower,18 fossil fuel and 3 nuclear plants,with a total installed capacity of 37,456 MW. SRMP Cost and Funding The total cost of the SRMP is US$1.2 billion,including the cost of acquiring the Project site,resettling affected families and implementing social development programs. Eaasraaeiepineetmn anaes Ri:Ue=om A Sane uapre NeevagBal,Caan ae La EE a ESS The volume of materials to be excavated required the use of a lot of heavy equipment.The Project Area (below)is characterized by competent core rock. SRPC financed the power component of the Project with equity (25%)and nonrecourse debt (75%)totaling nearly US$600 million. NPC financed the non-power components (irrigation,flood control and water quality enhancement)with a sovereign loan totaling US$400 million.NPC,NIA,the Department of Energy and Natural Resources (DENR),and the Department of Public Works and Highways (DPWH)will share the repayment of the untied loan in accordance with an interagency memorandum of agreement. In addition,NPC funded land acquisition, resettlement,social development and project administration costs of about US$200 million out of operating expenses.The non-recourse team lenders to SRPC consist of the Japan Bank for International Cooperation (JBIC},the Bank of Tokyo-Mitsubishi,the Fuji Bank,the Sumitomo Trust and Banking Company,the Sakura Bank,the Sumitomo Bank and The Norinchukin Bank. JBIC is the sole lender participant in the united loan to NPC.The Fuji Bank serves as intercreditor agent.The Bank of Tokyo- Mitsubishi is agent for JBIC and technical agent for the independent consultants and advisors.Chase Manhattan serves as the onshore and offshore collateral agent for the parties. REOL and Washington get to work In 1998,United Engineers International Inc.and Raytheon Ebasco Overseas Ltd., subsidiaries of the former Raytheon Engineers &Constructors Inc.(RE&C),signed two contracts totaling $705 million to engineer, procure and construct the project.Now,those units hold the contracts as part of Washington Group International Inc.,the former Morrison Knudsen Corp.that acquired RE&C in July. pee : j es *y hip Lath Sieve Raytheon was provided initial funding for the project in March 1998.The San Roque Power Corporation released approximately US$100 million in project funding at that time, and Raytheon began work immediately.The Export Import Bank of Japan and a commercial syndicate led by the Bank of Tokyo-Mitsubishi,Ltd.,the Fuji Bank Ltd.,and the Sumitomo Bank Ltd.,provided additional funding in the amount of US$600 million Raytheon's experience'includes construction of the 350 foot high New Waddell Dam in Arizona and design of the Eastside interconnected dams ranging from a half mile Reservoir,including three to 2.2 miles,in California.The company has also designed or constructed more than 1,000 power plants,more than any other engineering and construction firm in the world.The company's experience includes generating units powered by virtually every source,including hydroelectric. In addition to the dam and power plant, the work will include several other related facilities.These include a concrete chute spillway that will enable excess water to pass the dam,diversion tunnels that will reroute the river around the dam site during the construction phase,a power tunnel/penstock that will serve as the conduit for routing water from the reservoir to the power plant,and an electrical substation through which electricity from the power plant will flow into the transmission system of the National Power Corporation,the Philippines stated-owned power company. 47 ou tkTEEReeahae. River excavation work proceeds in the upstream area of the Dam. (Overleaf)The excavation at the River Embankment is captured in this aerial photograph. Saatryeee INSoerew ences Sea Nie RF PONGatageaom aieStoie me:.teea bated: esea eaeS55 The acquisition of Raytheon Engineers and Constructors (RE&C)by Morrison Knudsen paved the way to the formation of the Washington Group,International,Inc.,an international organization with more than US$ 5 billion in annual revenues and one of the largest companies in the engineering and construction industries.This development provided Raytheon with additional resources in equipment and personnel that enabled it to comfortably meet the Project deadlines. Drilling was done in the Spillway area in July 1999 to reach a competent rock base. Leading the Construction Team The San Roque Ludlam sounded him Project is easily one of the largest construction projects in the world.With the Dam itself reaching 200 meters in height,800 meters at the base and over a kilometer in length,it can be seen as far as 40 kilometers away.At the peak of its construction,it employed more than 5,000 workers working in various trades and crafts. Managing a project of this size can be a daunting task.After WGI decided that a Project off for the San Roque Project.Knowing a good challenge when he sees one,Bill accepted the offer. With his considerable overseas experience and his hands-on management skills, Bill was a perfect choice. When Bill arrived on site,the Project's key areas where in various stages of completion.Some areas were progressing as per Manager was required full-time on site,finding the right person for the task was the next critical step.Roger Ludlam, President and CEO of Washington Group Infrastructure and Mining and Executive Vice President of WGI,tapped Bill Scott for the job. Bill Scott had previously worked with Roger Ludlam in SJ Groves Construction,and was uniquely suited for the job.Bill worked for SJ Groves for 23 years,starting off in surveying and ending up handling SJ Groves' overseas projects.By 1986,Bill was Vice- President for Green Construction and working on the Merrill Creek Dam as well as a mining project in Guyana.By 1999,Bill was in semi- retirement after having sold off his interests in the Guyana mining venture,when Roger Bill Scott schedule while some areas were running behind. Superintendents were trying their best to get their own areas done on time but there was a need to synchronize their efforts so that everyone was working from the same page. Bill reviewed the various aspects of the job,sat down with the Area Managers and worked with them to come up with a common schedule that everyone would adhere to.The "bible”,as the schedule was fondly called, specified concrete deadlines that have to be met in the various areas to bring the job into on-time completion.The development of the "bible”,as well as some other critical adjustments in the Project brought the construction works in a position to meet its 51 The core rock is marked for subsequent drilling and grouting (top left,opposite page,and left). guaranteed completion date of December 31, 2002. "It was important for everyone to believe that the Project would be completed on time. It was also important for everyone to work as part of the team and focus on the tasks at hand.As Project Manager,I had to look at the bigger picture and make decisions in terms of the whole Project.We had to concentrate on the critical areas,complete the tasks and move on to the next critical area.” "We took a couple of key steps that helped us meet our committed turnover dates.We increased the efficiency of our Conveyor System;deployed additional equipment; made organizational changes that gave emphasis to the work in the borrow areas; and worked on the basis of a unified schedule.We set our sights on a common goal and worked hard to attain it”,said Bill. "This is truly a world-class Project.And we have been fortunate to have a world-class crew working with us.Everyone,from the expatriates to the Filipino employees did a great job.There were so many challenges along the way that would have stymied others but our people were determined to get the job done on time.This is a Project we could all be proud of.It took the collective efforts of everyone on this Project to accomplish what we did.”Bill concludes. The San Roque Dam is a legacy for everyone who has been involved in the Project.It is also a legacy to Bill Scott's management and leadership. Chapter4 Resettlement Action Plan Site Acquisition NDER the terms of its agreement with SRPC, NPC is responsible for making the entire Site (including the Reservoir area)available to SRPC,and ensuring that SRPC has peaceful and exclusive possession of the Site at all times. NPC is responsible for all the costs related to Site acquisition,relocation of displaced residents and registration of titles.NPC is also responsible for obtaining and maintaining the required governmental permits and rights-to- use in respect of inalienable land.SRPC was also granted the right to use the Site at all times from the Preliminary Delivery Date / Confirmation Date to the end of the 25-year Cooperation Period.All real estate taxes and assessments,rates and other charges with respect to the Site,as well as the structures and improvements thereon are also the responsibility of NPC. NPC also made available to SRPC all land,easements,and rights-of-way required for sourcing aggregates,the deposit and disposal of borrow material,the temporary storage and deployment of construction materials and equipment,housing for construction personnel and other temporary facilities,and for other purposes in relation to the construction,repair and maintenance of the Multipurpose facility. The Resettlement Action Plan As defined in the PPA,all social acceptability issues arising from the implementation of the Project are the responsibility of NPC,including the development of a resettlement plan for all affected families.A resettlement plan was prepared in December 1995 and updated in May 1998 by the Social Engineering Department of NPC for the relocation of the families affected by the implementation of the Project.The plan was prepared in accordance with the existing Corporate Resettlement / Relocation Policies and Guidelines and as amended by NPC Board Resolution 95-199 on September 11,1995.The Resettlement Action Plan also set forth NPC's social commitments in terms of compensation, resettlement and livelihood. SRPC built an elementary school for the children in the San Nicolas Resettlement Area.(Opposite)A woman pans for gold along the Agno River. 3 28 yt ee TRA AEC Ia:'ity & oe Oe tree<6 ae Fr tae tea ae"%Sete 2 oem OS yiFREOKA,OE1amae'a at,-mete ga SayCisBe,ae pon *Z.ee fer mp aemetean wr 3 Lee?atic'ea 2 Nee Pe hee gg 5 a 3 'Le.gy he .;as fe ; ' *Weep as ,*>vor Re are:4 ;y "O ef « 0%*yanecesOL,:Lege et ae pi athy mE SL we rea Cee oe e Sey ven A aa NS ory223"a ae ane aa a waa .)MASS hg oR .ary wg ae ca "ro ere Ee 2oeswy-aren'en re so a ae?in ene *SN "24hd-eee <nett wre 7 'gers =fy :: Lai aT ersooNeteeteewaae olymoo. en ieweomaSoria s fs*;4 pena Ss Peo eeeachSad1,etn:SeAnMON?|eek GCN oe”MAR "2450b. a FORTTTthee sOEeen2aea'eS ee eh sh ceePihandhaadeelLSPReROY Carabaos still roam freely in the Process Plant area.Photo below shows thatched hut that some of the area's residents used to live in. who. eon; OO an Developing Social Acceptability One of the most sensitive issues facing the San Roque Multipurpose Project is developing social acceptability.Regardless of the fact that thousands of residents in the Pangasinan and Tarlac area will directly benefit from the Project,there are still quite a number of people and organizations that believe otherwise.And there are even more Admiral Marcelo brings a wealth of experience and insight to the task of information dissemination and education.A highly respected member of the local community,Admiral Marcelo's involvement in the Project gives it a local face as well as added credibility and acceptability. "Part of people who are not fully aware of the real and potential!benefits of the Project.The matter is of utmost importance as the social acceptability of the project determines how the Project is perceived by the Filipino nation and by the whole world. Furthermore,a high level of social acceptability ensures that the Project has the continuing support of the local community and by the society. Taking the lead role in this task is retired AFP Vice-Admiral Virgilio Marcelo.Currently a Vice-President and Director for Community and Government Programs for the San Roque Power Corporation,Admiral Marcelo is uniquely suited for this task.He was previously an Undersecretary for the Department of Environment and Natural Resources,a director for the National Power Corporation and just as importantly,a resident of the affected barangay of Narra in San Manuel.A product of the Philippine Military Academy, Class of 1961,with a string of military and civilian trainings and an MBA under his belt, This Resettlement Area in San Roque,San Manuel is where many of them live now. Admiral Virgilio my responsibility is to reach out and communicate to the local community.My office coordinates and assists affected families in filing their land claims with the National Power Corporation;organizes and supervises the implementation of livelihood programs;and facilitated the relocation of families displaced by the Project.We have also embarked on information dissemination programs to educate the local community of the benefits that the Project will bring to them and the region as well”says Virgilio. "Generally,the local community has accepted the Project as a part of their lives.In fact,the irrigation component of the Project will enhance the value of the farmlands in the area as farmers could diversify their crops or add an additional harvest to the current once or twice annually.The flood control portion of the Project will likewise protect the riverbank areas from inundation and make it safer for the families living there.However,there are some cause-oriented groups that fail to see the bigger picture and push for their own Marcelo agendas.While such opposition is a normal occurrence worldwide for projects of this scale,we have to work doubly harder to reach a wider audience”he adds. To address the livelihood needs of the relocated families,SRPC has provided families with livelihood assistance,arts and crafts training programs and given -employment priority.to qualified family members.Initial programs that have been introduced have encountered difficulties due to the lack of marketing and organizational skills of the participants.However,the Department of Social Welfare and Development,other government offices and SRPC have fine-tuned the programs to make it more responsive to the needs of the community. Under the supervision of Admiral Marcelo,SRPC has also been involved in other ways to help the local community. Books and other school facilities have been donated to nearby public elementary schools. SRPC has facilitated life-saving emergency responses to flash floods caused by heavy typhoons.Hand in hand with WGI,roads and bridges have been repaired at no cost to the local or national government. "SRPC is committed to the development of the community,the region and the country. We are all partners in progress.If we all work together,we can make the San Roque Project a model for a world class project in a world class community”he concludes.With Admiral Marcelo's charisma and the hard work of his team,it is no wonder that the host communities have come to embrace the Project. Both resident and non-resident owners, as well as tenants and tillers of lands within the SRMP boundaries compensated for the fair market value of their have been lands,crops,trees and for the full replacement cost of structures and improvements.All affected families received assistance in reestablishing sustainable livelihood so that they have the opportunity to generate income that is at least as good,or even better than the income they had prior to the Project. Approximately 5,000 hectares of land had to be acquired for project purposes; about 4,500 hectares in Pangasinan and about 500 in the Benguet area.It affected around 1,700 landowners and tenants.The Resettlement Action Plan provided for a number of positive actions that would address the concerns of all the landowners and tenants that have been displaced by the Project. In total,781 families had to be resettled. 487 families came from San Manuel,233 families from San Nicolas and 61 families from the Itogon,Benguet area.Two 56 A hog-raising facility in the Resettlement Area provides livelihood opportunities for relocated residents. resettlement areas have been developed by NPC in Pangasinan.The first one is in Sitio Camanggaan in San Roque,San Manuel and the second one is in Sitio Lagpan,Barangay San Felipe East,San Nicolas.Each relocatee in Pangasinan had the choice of self- relocation or relocating with NPC assistance to one of the resettlement villages.Both sites are of generally flat land.The 7.5 hectares at Sitio Camanggaan is some 200 meters from the provincial road ,and is rainfed agricultural land.The five hectares at Sitio Lagpan is located about 4 kilometers from the site and is accessible via barangay roads. The area is classified as pasture land/cogonal land. In June 1997,processing and payment of relocation compensation started in Pangasinan.More than P50 million pesos have been paid by May 2001.On the other hand,payment for lands,crops,plants and trees started in March 1998.By May 2001, more than P400 million has been paid to claimants in San Nicolas and San Manuel. Processing and payment of relocation compensation for the ltogon relocates was completed in August 1999,with more than P18 million paid out to qualified relocatees. Payment of crops,plants and trees on ancestral lands began in December 2000 and have reached P51 million by May 2001. In 1998,when the Land Acquisition process was getting bogged down by conflicting claims to various land titles,SRPC advanced about US$4 million to landowners. Going even further outside the original scope of its obligations,SRPC also took on some responsibilities for relocations,title searches, even teaching new skills such as quilt-making to uprooted residents. Livelihood Programmes The issue of sustainable livelihood for all project-affected families has received considerable attention from NPC and SRPC. Local residents use makeshift vehicles such as this for transportation. This includes the resettled families,as well as the non-resident landowners,tenants and tillers and seasonal resource users such as gold panners and fishermen.The NPC has funded numerous skills training and livelihood programmes even before the start of construction. The Office of the President of the Philippines has also responded to this need by forming a special inter-agency task force on resettlement and livelihood that is chaired by the Department of Social Welfare & Development.This task force has organized and mobilized the resources of other government agencies and programmes in support of the resettlement action plan developed by NPC.It has surveyed the minimum basic needs of the affected families, assisted them in identifying and establishing community organizations and leaders,and conducted training programmes for these leaders. }WSS Fears =aT PRS:i mua na"A WHOA gfeFEMA57]asMTHS ag:al >Ww SALA NAT,ime securing Land for the Project One of the most difficult tasks in getting the Project off the ground was ensuring that the location of the Project was available to SRPC the year 2000.Her primary task is to coordinate and monitor NPC's Land Acquisition Program and see to it that the needed and WGI for its use.This includes not only the land for the Dam,Spillway, Powerhouse and attendant structures but also the main excavation, borrow areas and the land that will be inundated once water is impounded in the Reservoir. Under the Memorandum of Agreement between SRPC and the National Power Corporation,NPC is responsible for making the entire Site (including the Reservoir area) available to SRPC,and ensuring that SRPC has peaceful and exclusive possession of the area at all times.In the case of private land, NPC would obtain a written and notarized permission to enter from the landowner,or a Writ of Possession from the court.In the case of public land,NPC must obtain a Special Land Use Permit to enable SRPC to utilize the property. There were a myriad of problems in the land acquisition process.Some landowners have developed emotional attachments to their land and would decline to sell their properties.Others have apprehensions due to the land acquisition payment problems experienced in the Binga and Ambuklao dams.Some properties were not properly documented and had multiple claimants.In the case of tenant farmers who do not hold title to the lands that they occupy,they could only claim for the improvements in the property and ask for financial assistance from SRPC.Furthermore,payment from the NPC took longer than expected.In fact,SRPC eventually had to advance payments to the landowners just to speed up the land acquisition process. Digna Ugalino is in the forefront of the land acquisition process for SRPC.She started off as Assistant to the Land Acquisition Coordinator in 1998 and assumed the position of Land Acquisition Coordinator in land is delivered in accordance with the agreed land delivery schedule.She also reviews and evaluates all requests for advance payments and sees to it that the payments are in accordance with the SRPC and NPC agreement. "I had to familiarize myself with myself to the local customs and property attachments of the people. The biggest problem was how to create credibility,to gain the trust of the land claimants and to make them feel confident that I was there to help them”says Digna. "Historically,there has been apprehension on the part of landowners as to the compensation of their properties.To be able to win their trust,there is a need for constant consultation with the affected land owners and tillers and inform them of the need to acquire their properties and educate them on the electrification and irrigation benefits that the Project brings”she adds. In order to get the people's trust and confidence,Digna worked hard to get close to them.She visited them at home,had meals with them,listed to their concerns and explained to them the payment and valuation process.Digna made herself accessible to all the land claimants.She would shuttle back and forth to the various affected communities and organize town hail meetings,and make sure that everyone was informed of developments on the Site. Digna's down-to-earth and people- oriented attitude has really paid off. Landowners,tenant-farmers and relocatees have come to trust and respect her.As she reaches out and explains the benefits that the Project will bring to the community and the region,the San Roque Dam continues to gain social acceptability.Digna's work with the affected communities helped SRPC develop a fruitful partnership with them. 58 A key element of the resettlement plan is the conducting of skills training programs and livelihood projects for participants from the atfected municipalities.Over P2 million was spent in 1996 and 1997 on various skills training programs including General Electricity,Basic Heavy Equipment Maintenance,General Automotive,General Welding,Building Construction,Basic Pipefitting and Sewing Machine Operations. These programs were attended by 201 participants from the affected municipalities. Of the P18.47 million allocated for livelihood projects such as cattle fattening,purchase of farm implements and tricycles,over P14.9 million has been spent as of April 30 1998. Tricycles and bicycles (above)are the main means of transporation in the area.Digna Ugalino inspects the Nursery that SRPC set up for SRPC's environmental activities (below right). The SRMP also provided employment opportunities for numerous skilled,semi- skilled and unskilled workers from the local community.At its peak,The SRMP employed over 5,000 people of which some 80 per cent are residents of affected local government units.About half of the families residing in the San Manuel resettlement community were able to get jobs in the Project.In addition, the SRMP provided training to employees that upgraded their skills.One of the most notable programs was that of training the ladies from the Resettlement Area to drive and operate heavy equipment on site. Another salient provision in the Resettlement Action Plan (RAP)is the implementation of Republic Act No.7638 (Department of Energy Act of 1992).The law provides direct benefits to the province,city, municipality,people affected and the region that hosts the energy resource or energy- generating facility. President Gloria Arroyo congratulates Pat McAllister during the SRMP Inauguration.The Program provides the amount of PO.025 per kilowatt-hour to be used for development/livelihood;PO.025 per kilowatt- hour for electrification and PO.025 for reforestation/environmental and health.It is estimated that the San Roque Project will generate around P2.3 million pesos annually to be utilized for livelihood projects.This benefit will apply to Benguet and Pangasinan and to all affected barangays and municipalities. The Fund is established as a trust in the name of the local government where livelihood funds are sourced.It is then extended to people's organizations or cooperatives in the form of a non-interest bearing loan.Repayment of the capital is made to the local government units (LGU)or NPC.A total of P16.4 million pesos has already been disbursed by NPC through the LGU to all the 28 accredited associations/ cooperatives in the affected communities. In addition,SRPC,NPC and the Special Committee on Resettlement and Livelihood (SCRL)are maintaining several start-up 60 ReLELeLTeSPEIPIOreelivelihood and community development projects in all the affected communities.For example,a quilt-making project is being implemented at the Camanggaan Resettlement Site and loom-weaving is being set up in Amoucao and Dalupirip,Itogon. As one of the conditions precedent to the PPA Effective Date,NPC provided SRPC with a certificate on January 27,1998 to the effect that the resettlement program it has implemented is in accordance with the requirements imposed by the EMB. Watershed Management Program The San Roque Watershed is part of the lower Agno Watershed Reservation set aside by Proclamation No.2320.Under the same proclamation,a total of 9,5550 hectares were declared as the immediate watershed of San Roque to be under the administration, jurisdiction,management,supervision and control of the Department of Energy through its implementing arm,the National Power Corporation (NPC). The watershed lies along the western toe of the Central Cordillera Mountain where the Agno River cuts its valley,and extends southwards where the river flows through a long narrow valley between the ranges of the Central Cordillera Mountain and emerges at Barangay San Roque at an elevation of about 92 meters. There deterioration of the vegetative cover of the has been a_progressive watershed in the downstream direction.A great portion of the watershed is open land covered primarily with grasses and shrubs. The Resettlement Action Plan (RAP)aims to use the local community to rehabilitate the San Roque Watershed and make it a renewable resource of livelihood for the people affected by the San Roque Project. Among the proposed rehabilitation components are the Family/Community Approach to Reforestation,Industrial Tree Plantation,Agroforestry and Tree Farms. The affected communities that are willing to participate would directly benefit from the project.They will be tapped and as partners in the rehabilitation and protection of the watershed. As envisioned,the Program will cover an initial area of 50 hectares.The Program will operationalize projects that are self- liquidating.NPC will provide technical assistance and funding support for project implementation until the participants realize revenues from their produce. This is a photo of the completed Main Dam,the Low Level Outlet and the Operator's Village in December 2002. ae SERA ay PGR Ree re67webecant omeosverses,fir : i " _iiiainedRRS estesLesteBre&Peersawa.*- ie] --ee e, Rr me teal Aside from reforestation,rehabilitation and protection programs,reservoir and aquatic resources management programs are also envisioned.The reservoir will sustain aquatic life and resources that are of economic importance.The reservoir will be seeded with species that are adaptable to the reservoir environment.Fish sanctuaries will be identified and protected.The fish population will be monitored for sustainable harvesting levels.Efforts will be exerted to ensure high quality of the water in the reservoir so that it will support an abundance of fish communities. Medical Missions,Infrastructure and Electrification Health programs including medical and dental missions were conducted for San Roque and Itogon residents.More than 1,000 residents were attended to for such ailments as colds,cough,respiratory tract infections and dental cavities. In compliance with the Memorandum of Agreement,infrastructure projects were also undertaken in the provinces and the various barangays.More than P86 million was allocated for this purpose.Various road improvements,rehabilitation and construction of barangay and municipal facilities, ..schoolrooms,and water supply systems in the host barangays and municipalities were undertaken under the Memorandum of Agreement. More than P23 million was allocated for rural electrification.More than P15 million was allocated for Pangasinan and over P8 million was allocated for the Benguet Province.Barangays San Roque,Narra,San Felipe West,San Felipe East,Dalupirip and ltogon were all beneficiaries of this program. Providing Site Security epsF The San Roque Project is spread over a very large area.The area of the Main Dam and the construction site itself stretches over the two municipalities of San Manuel and San Nicolas.At its peak,there were more than 5,000 people working on the Project 24 hours a day for over 4 years. There were millions of dollars of equipment devoted to the Project and there was the constant threat from communist rebels who operated around the Project areas. The Project also employed more than a hundred expatriate personnel, mostly Americans.They were housed in the Operators Village,an on-site housing facility that sought to provide them with amenities they would expect at home.In order to create a congenial work atmosphere,expatriate personnel were also allowed to bring over their families for the duration of their contracts and their children were provided online education at the Village School. Providing critical security for the Project is Ben Lichtenberg.An ex-US Marine and a security expert,Ben oversaw the security for the Projects' property and personnel.He coordinated with local and international security experts and 62 Ben Lichtenberg advised the Project management on appropriate security precautions and measures.He initiated and implemented security systems to protect corporate assets and Project personnel. Ben was uniquely suited to the task.Bens'wife,Rosie is from the Philippines and he has a deep understanding of local customs, traditions and psychology.He speaks the Filipino language and has a fair knowledge of the local dialect.His rapport with his personnel made it easier for him to enforce discipline and order among the ranks. In the aftermath of 9-11 tragedy that also resulted in the loss of life of Washington Group personnel in the United States,security became an even more important concern for US companies'overseas.By keeping himself updated on the latest threats and security situation affecting the Project,Ben was able to take a proactive stance and advise Project management on policies and procedures that secured the Projects' assets.The relatively trouble-free security record the Project has enjoyed over its'duration is in part due to the efforts of Ben and his security team. Public Information and Awareness Campaigns NPC and the San Roque Power Corporation have gone to great lengths to reach out and make the public aware to the San Roque Project and the benefits that it will bring to the community. The first public information campaign was staged in San Manuel on March 2,1995. The Municipal officials of San Manuel and San Nicolas,as well as the local barangay officials from the host barangays attended the affair.Favorable endorsements were received subsequent to that presentation. These public information campaigns were repeated in the other host municipalities Lady truck driver gets the keys to the CAT777-D assigned to her. and was well-attended by the local residents. NPC arranged for local officials to visit the resettlement sites for the nearby Sual Coal- tired Thermal Project so that they may see the living conditions in comparable projects. The first batch of 21 Skills Training Program participants started their training in Dasmarifas,Cavite in January of 1996. Other training programs were conducted immediately after the first program.A batch of 100 participants took part in a 45-day Skills Training Program in La Union in February 1996.Another batch of trainees were sent to the Cavite training center in the same month. S ae20-2021 By the first quarter of 1997,a number of cooperatives and have already started drawing from the livelihood fund for their projects.NPC even assisted in the conceptualization and formation of more cooperatives seeking to provide livelihood for their members.The Department of Social Welfare and Development even conducted basic Business Management training for new cooperatives. Public consultation and information campaigns continued over the years.Public acceptance surveys were also conducted to monitor the effectivity of the campaigns. Socioeconomic surveys were also conducted throughout this period to monitor the effects of the Project on the lives of the project- affected families. SRPC and WGI continually hosts site tours for students,government officials and local communities so that they may see the Project Site and appreciate its accomplishments. A maintenance worker services project equipment.Opposite page shows local employees at work at the switchyard. 64 ee ee ORSAY SRRiaotetpacca as TD abe ce RKaoe 99 f ate fernfOUd}}0 U8}Uy}zapoourbuypoUuryEF.herb sttr Cae eeral aedSSNOHUIDd FGUSAS OMT ¥SNRGLVAIq be wateseioveSewereaescoeGorewees?LL 'wun /ices 37,ws ees Bo co SS owe eae2 eetboosbuyper a 8 Rina Zz Laas WVIOVIG SOT VORLOTT LNW Id "ity"wasawOnE=)ee tee'TAN fain REE-W-Celed CROWN tee Gee Ge ae 7 qt [a --608 OO Me LEDd Chapter 5 Engineering and Design Getting Started Site Investigations The original feasibility study for the San Roque Project was prepared by Electroconsult and issued in 1979.In support of the study, a fairly extensive subsurface investigation was conducted,consisting of a total of 43 boreholes and 25 test pits.The program covered all major project features.In addition, 8 exploratory adits were excavated and the exposed geology mapped. While reasonable in scope,this early program was of limited usefulness.Twenty years had passed since the exploration work had been conducted,and much of the original data could not be located.It was therefore necessary to perform additional investigations to confirm the assumptions drawn from the general summaries stil!available from the initial investigations,and to increase the general knowledge of the site conditions. Prior to finalizing the design/build contract, SRPC arranged for an additional 12 borings and a seismic refraction investigation in the footprint of the dam.A second phase exploration was added at WGI's request to include another 10 borings and additional seismic refraction work plus a series of test pits in the proposed borrow areas.A third phase investigation was subsequently added consisting of 52 more borings,additional test pits and yet more seismic refraction studies. i.AFierePeerage.pap This is how the Dam Site looked like before construction work started on the Project. Based upon the results of these investigations, a number of changes to the conceptual design were implemented.The quantity of excavation under the dam shells was greatly increased so as to remove any material of questionable strength or that could be prone to liquefaction in an earthquake.The slopes of the excavations for the spillway and various tunnel portals were laid back,also for stability reasons.In addition,the location of the powerhouse was shifted about 200 m to avoid what appeared to be an old landslide. 67 Ge:WaLENEpCawai My Initial San Roque Experience I arrived at San Roque in early Novem- ber,1997.My task was to verify the geologic conditions and report back to the design team.The geologic investigations were being performed by CDSI and directed by Francois Morel and Nene Florendo,but it was hard to find the drill rigs amidst the jungle. The last bridge span across the Agno was missing,the few buildings at the Operators Building were derelict,and the usual mode of transport to the dam site was by motorized raft from the barrio at the end of the road. On a typical day,we'd travel from Urdaneta to the river,take the boat up to the dam,check out the latest drilling results at the main camp there,then continue with the days program that might include hiking to a drilling site or to one of the re-opened adits originally excavated in 1980,checking faults mapped 20 years ago,and always looking for clues to the geologic condi- tions. Sarah Wilkinson-Kemp 68 As a geologist I was accustomed to cross country travel,but it was a new experience for me to go out with a local guide who cleared my path through the brush with his bolo knife (and carried my knapsack). One thing that always struck me was the Philippine hospitality.For example,it was a long hike up to the surge tank area, where the drillers had a small camp. A cup of Nescafe was always ready as we sat down and caught our breath.If it was lunch time,someone would be strumming a home-made guitar.One special treat was the day we were served python adobo-it tastes like chicken. Life was easier after construction started and there were roads and bridges, telephones and fax machines,and on- site housing and meal service.But the opportunity to be a part of the start-up was special.Not only did I see the ruggedness of the site before it was transformed by machinery,but I was able to meet and work with the local communities on a daily basis. When the EPC Contract was signed in March 1998,UEI quickly completed the assembling of its engineering,design and procurement team,and proceeded with early critical tasks. Concurrently,REOL construction forces started mobilizing the site. The first major item on the construction schedule was the excavation for Diversion Tunnel portals,and especially for Tunnel 3.Contract signing had originally been contemplated for January 1,1998,and the nine-week delay placed added pressure on the team to make up the lost time.Tunnel 3 was Critical since it had to be completed by the end of 1998,so that the River could be diverted around the Dam site during the dry season (low River flow),allowing work on the upstream cofferdam to proceed.Since there was no access to the portal location,the first order of business was to build some roads.With its own construction equipment coming from overseas,and months away from arriving at the site,REOL needed to improvise in order to maintain the required progress. For this REOL turned to Philippine contractor F F Cruz.As soon as REOL got the go-ahead from SRPC,the engineering team issued a subcontract package to F F Cruz for detailed design and construction of the access road to the diversion tunnels downstream portals. The scope also involved a ford to cross the river (since the bridge was not yet complete) and some preliminary excavation at the portals. Project engineers had to find their way through thick foliage. Offices and Subcontractors Given the magnitude of the design work that needed to be done to make the San Roque Project a reality,and the short time available,UE!mobilized a number of WGI's engineering offices and outside consulting firms.The headquarters for the work was in WGl's New York office,where the designs for the Diversion Tunnels,Powerhouse,Spillway, Power Tunnel and Low Level Outlet were done.The other major design center was WGl's office in Bellevue,WA,which handled the subsurface investigation work and the designs for the temporary conveyors,process- ing plant,Cofferdams,Main Dam and the Grouting Galleries. 69 In addition,Golder Associates handled the rock mechanics engineering from their Atlanta GA office,the layout and specifications for the Operater's Village were produced in WGl's Princeton NJ office,hydraulic model testing for the Spillway was done by at Northwest Hydraulics'laboratory in Vancouver,BC and Spillway aeration studies were done by Electrowatt Engineers in Switzerland.All these offices and firms were coordinated by the Project Engineering Manager to produce the final engineering packages,consisting of over 1,250 drawings and 200 specifications. The Team Mini-bios of key personnel It is extremely important for the ultimate success of a Design/Build Project to establish a sound technical baseline before the work begins.For this reason,WGI assigned Ed OjConnor as the Project Engineering Manager over nine months prior to the notice-to- proceed.Ed participated in the very first meeting with Sithe Energies,and continued his engineering leadership role through the completion of performance testing,and Project acceptance. A licensed professional engineer,he has a Bachelors Degree in Civil Engineering from Manhattan College and a Master of Science Degree from Polytechnic Institute of New York.Ed has over 29 years of experience in major water resource developments and power projects,and is a veteran of a several design-build hydroelectric project,including the 192 MW Sidney A Murray Jr Project in Louisiana and the 4O0MW Allegheny 8 and 9 Projects in Pennsylvania for Sithe Energies.Ed has also managed the work for reconstruction of over 20 dams in the Northeast U.S. The broad technical scope which defines the San Roque Project required that the work be divided between two experienced engineering leaders;one to head up the dam and its galleries,and the otherto lead the balance of work.Mike Pavone was selected to head up the engineering and design for the dam,and Leo Gertler was assigned to lead the work for all remaining areas including tunnels and shafts,powerhouse,and spillway,and including all associated equipment. Ed O'Connor Leo Gertler 70 Leo Gertler is a Senior Consulting Engineer with 50 years of experience in civil,hydraulic, and hydro-mechanical engineering and design for major water resource develop- ments and power projects.He is a licensed professional engineer with a bachelor degree in Civil Engineering and a Diploma in Civil Engineering/Hydraulic Structures from the Institute of Civil Engineering,Bucharest, Romania. Leo was the Engineering Manager on the Sidney A.Murray Jr.Hydraulic Project in Loui- siana,the Companyis first major design/build hydroelectric project.He also served as supervising engineer or project engineer on several other hydroelectric projects including Keban in Turkey and two U.S.projects; Ludington Pumped Storage and Davis Pumped Storage Projects. The San Roque Multipurpose Project is world class in several aspects.Perhaps its most prominent feature is the massive 40 million cubic meter,200 meter high (12 highest in the world),1,100 meter long earth and rockfill dam.The importance of the dam and its affect on the entire project required that it receive special attention. Mike Pavone was assigned this responsibility, serving as the Project Engineer for the dam. Mike,a licensed professional engineer with 30 years of experience in civil and geotechnical engineering,earned his Bachelor Degree in Civil Engineering from Manhattan Col- lege and a Master of Science Degree from Polytechnic Institute of New York.Mike has,and continues to be responsible for the engineering and design of major water resource dams in the U.S.and overseas, including Hakkari in Turkey,Souapiti in the Republic of Guinea in Africa,and South Fork of the American River in California Mike has routinely performed dam safety evaluations,dam stability analyses,flood evaluations,and seismic evaluations at over forty major dam projects in the Northwest US.Many of these projects required structural rehabilitation and/or completely new construc- tion. Mike Pavone The responsibility for leading the engineering and design for approximately 400,000 cubic meters of concrete required for the spillway, powerhouse,intake structures,tunnels and galleries,and miscellaneous structures,was placed in the hands of Shiam Goyal,a highly experienced veteran of over 45 years of major engineering assignments. A licensed professional engineer,Shiam graduated in Civil Engineering from one of the oldest and renowned engineering universities in India (The University of Roorkee, Roorkee),and later earned a Masters Degree in Hydraulics and Mechanics from the University of lowa.In addition to his work on large hydroelectric projects in India,Shiam has been associated with number of water resources projects,namely,Ludington and Davis Pump Storage Projects;S A Murray Jr., Hydroelectric Project,City of Vidalia;Lock and Dams 8 and 9 Hydroelectric Project;and several projects for the New York Department of Environmental Protection. 71 Shiam Goyal Rich Humphries Rich Humphries was born in Zimbabwe,went to university in Britain,and has worked in Africa,France,Canada and the USA.He is a Principal of Golder Associates,the rock engineering consultant to WGI for the San Roque Project.He has worked on the design and construction of water resources and hydroelectric projects in many parts of the world and has specialized in the rock engineering aspects of these projects - particularly the tunnels,rock slopes and dam foundations.Many of these projects have been large,complex,multipurpose projects but none have been as challenging, as satisfying,as large or as interesting as the San Roque Project. Sam Martinovich 72 For the San Roque project,the responsibility for the electrical system design was assigned to Sam Martinovich,a licensed professional engineer with over 30 years of experience in electric utility work,Sam,earned his Bachelor of Engineering Degree from Stevens Institute of Technology,He was previously the lead electri- cal engineer on Sithe Energy's Independence Project,a 1,000 MW combined cycle power station in Oswego,NY and the 350 MW coal-fired Ezhou power station,a boiler and controls island project in mainland China. "For the electrical team,the San Roque Project was much more than designing a power generating station,”remarked Sam."It was also an opportunity to be part of building an infrastructure and supporting the evolving needs of construction on a demanding schedule.Every challenge became an opportunity for creative solutions.The success of this monumental project is a testimony to that talent,skill and dedication,”he concludes. The Civil/Architectural Engineering and Design Team (below)is composed of (seated,left to right)Steve Totah,Bob Resch,Rita Meloy,Leo Gertler, Shiam Goyal;(standing,left to right)Eddie Wong,Dave Hunter,Rashil Levent,Katie llachinski,Hasmukh Patel,Nabha Bhasathiti and Bob Podolak The New York Project Controls Group (below)is composed of (seated)Angela Decresenzo,Bob Resch;(standing,left to right)Steve Kaufman,Jerry Zerboulis,Jorge Wong Jeannie Patti and Howie Hildebrand The Bellevue Civil,Geotechnical and Geology Team (above)is comprised of:(rear)Danh Nguyen,Bill Shafer,Dan Osmun,Santi Manalang,Bonnie Witek, Lois Loesch (front)Sarah Kemp,Mike Finn,Steve Benson,Rahim Nasserziayee,Charles Denque and Mike Pavone The Electrical,Mechanical and Instrumentation &Controls Group (above)is composed of (seated,left to right)Sam Martinovich,Magda Brown,Ed O'Connor and Peter Fiala; (standing,left to right)Peter Trombetta,Francisco Chen, Peter Passiglia,Bill Gesztes,Ruzena Danciger,Maureen DeCoursey,Rudy Baird,George Hauser and Hahn Kim The Bellevue Mechanical,Electrical and CAD Team (right)is = comprised of:(rear)Jim Stevenson,Nancy Bautista,Jennifer E coe BDeLong,Lois Diemert,Shyam Oberoi,(front)David Jahn,Jeff ae-Bast,-Paine,Tom Merritt and Kathy Kitterman S coef 73 The engineering of the Instrumentation and Controls for the San Roque Project was performed by a team of engineers and designers in WGl's New York office,under the leadership of Magda Brown. Magda received her Bachelor of Mechanical Engineering degree from Cooper Union Col- lege in New York,and has more than 30 years Instrumentation and Control experience on various power-generating projects,domestic as well as international.Some of her more recent assignments included the 1,000 MW independence co-generation project for Sithe Energies built in Oswego,New York and the two unit,350 MW each,Ehzou fossil fueled project built near Wuhan,China,for the Hubei Provincial Power Company. "|was assigned to the San Roque team soon after the contract was signed,and therefore | had the great privilege to work on this project from its preliminary design phase through its completion,”commented Magda.As lead engineer for the I&C team,in addition to working closely with the Client and the various system and equipment suppliers,Magda also interfaced with NPC to achieve the dispatch control objectives for this installation. Magda Brown Peter Fiala,the lead Mechanical Engineer,has over 30 years of experience in engineering and design of hydroelectric,fossil fueled, simple cycle,cogeneration,combined cycle and nuclear generating stations.He received his Master of Science degree in Mechanical Engineering from the Polytechnic Institute of New York.His experience includes complete thermal cycle design and balance-of-plant mechanical systems with a strong background in system calculations,heat balances,equip- ment sizing,and preparation of major plant equipment specifications.He has also acted as a lead mechanical engineer and project manager on several in-house projects. 74 me for & :€|wefaSewdad™e Peter Fiala Assisting Mike Pavone in the design of San Roque's dam were Keith Moen and Dan Osman.Keith,a civil/hydropower engineer with 15 years experience,has a master's degree in civil engineering from the University of Washington and a year of study at the Norwegian Institute of Technology.He has been involved with several international projects including geotechnical investigations for a project in Nepal,feasibility studies for a project in Namibia and site reconnaissance for a project in Guinea in west Africa.On the San Roque Project,he performed many activities associated with the damis foundation and underground galleries,and the specifica- tion and installation of the microseismic network.mmmTNEbKeith Moen Dan Osmun 75 Dan Osmun has 15 years of civil and geo- technical engineering experience special- izing in embankment dam design,analysis, inspection and construction.His experience includes dam safety inspections of existing concrete and earth dams,technical evaluation of proposed earth dams,exploration,analysis, design,and specification preparation aspects of dam design and rehabilitation.He has completed three significant multi-year rockfill dam design assignments since 1993.Mr. Osmun contributed to the design of five new dams involving a cumulative total of over 150 million cubic meters of earth and rockfill. Assignments on these dam design projects included both field work and office engineer- ing analysis to support the designs and the evaluation of associated soil and rock borrow areas. On San Roque,he was the lead engineer for embankment analyses,including seepage, stability and seismic deformation.He was responsible for documenting analyses in comprehensive reports as well as preparing design drawings and embankment specifica- tions.Responsibilities during construction involved coordination of design changes, evaluations of alternative borrow materials, and site visits to observe construction tech- niques and develop design modifications to facilitate construction.Mr.Osmun prepared and delivered presentations to the Project Consulting Panel. eee] The San Roque Consulting Panel Early in the discussions and formulation of the EPC contract between Washington Group International subsidiaries UEI and REOL,and Sithe,it was recognized that design and construction of the San Roque Multipurpose Project would require a high level of expertise and review commensurate with its "world-class”stature.Given that the San Roque embankment dam would be the twelfth highest such dam in the world, it was extremely important to develop an independent panel of experts to review the design and construction of the Project. The panel would have to be highly experi- enced in both design and construction of large dams and power projects,and be acceptable to all involved,including the Owner,the Owner's Engineer,the EPC Contractor and the lending agencies.The Panel that was selected consisted of three thirty to forty year veterans of design and construction of dams,hydraulic structures, and power facilities. The chairman is Mr.Alan O'Neill,an independent consultant and engineering geologist with over 40 years experience in geology,geotechnical,foundation engineering,and grouting on large dams and civil works. The second member is Mr.David Kleiner, a civil engineer and 40-year veteran with MWH Americas,the Owner's Engineer on the Project.Mr.Kleiner's experience and expertise is in geotechnical engineering, foundation treatment,materials for dam construction and extensive experience in dam design and hydraulic structures. The third member is Mr.Joseph Ehasz, a civil engineer and a 36-year veteran with Washington Group International, the EPC contractor of the Project.Mr. Ehaszis experience and expertise is in the geotechnical,foundation engineering, earthquake engineering and construction of dams and heavy civil structures. ee a iA ."UPPER TET GALLERY i Seer = The Consulting Panel met at the site on a regular basis (above). Their work included checking actual conditions in the field *(top right).. These three experts met 13 times at the Project site and reviewed everything with respect to design and construction,ranging from the original design criteria to the location of instruments to monitor the performance of the Project.They normally spent one week at the site every three or four months or as needed on special project milestones. The Panel functioned as both a panel of experts reviewing all major technical aspects of the design and construction as well as a disputes review board when technical issues reached an impasse during construction.Several field changes were necessary to adapt the design to the actual field conditions.These were formally presented to the Panel,discussed thor- oughly and panel recommendations were presented. The Panel operated independently and prepared a formal written report following each meeting.The reports were also presented orally to the Owner and all parties involved with the project;including engineering and the construction staff. Each report was thoroughly discussed sO everyone understood its content and significance.This process was very effective in maintaining efficient communications among all the parties as well as establishing a quality project on schedule. 76 The Challenges San Roque was not the first large hydroelectric *The site's highly variable geology project performed by WGI's engineers under *High seismicity (earthquake)criteria a design build contract.From previous *Wide seasonal variations in rainfall experience on large turnkey hydroelectric and river flow projects,the team was aware of the challenges *Survey problems (steep terrain,heavy it faced to successfully complete such a cover and conflicting data from project,given the high quality standard,tight successive surveys) schedule,substantial liquidated damages *Communication with the Site Personnel, for late completion,and penalties for non-with up to thirteen hours time dif- performance of guaranteed output.In addi-ference between the design offices tion,and as typical for EPC projects,the and the site schedule dictated that the detail design would *Long lead time for procurement of only be partially complete prior to the start special construction materials (not of construction.available locally)and equipment due to the minimum of six weeks Performing the engineering /design work for required for shipment the San Roque Project created a multitude of very challenging tasks,despite the teamis previous experience.The specific nature of this project required the design to address additional critical issues including: RSrnSe CR CSSa Floods like these made early work on the Project very challenging. The highly variable geology required extensive additional subsurface investigations to be performed concurrent with design,so that the location and configuration of all major project features be finalized.This resulted in a number of significant changes as the design progressed,thus: Three alternative locations of the pow- erhouse were evaluated before the final one was selected *The excavated slopes for the spillway and various tunnel portals were laid back considerably for stability reasons. *The quantity of excavation under the dam shells was greatly increased so as to remove any material of ques- tionable strength that could be prone to liquefaction in an earthquake. The wide seasonal variation in rainfall and river flow was a major factor in the design of The difference in river flows between the wet and dry season the river diversion schemes. can be as much as a factor of ten.The selected diversion scheme included three diversion tunnels:one smaller tunnel (6m wide,6m high)with enough capacity for the dry season flow,and two larger tunnels (10m wide,15m high}capable to pass the wet season diversion design flood.The small diversion tunnel was designed so that it could be completed in time for the second dry season allowing work to proceed on the cofferdam and on the main dam foundation. The seasonable variations also atfected the closure (plugging)sequence of the diversion tunnels as the dam and spillway were being completed.Only one of the large diversion tunnels was closed during the dry season, while the second large tunnel and the smaller one had to be left open during part of the wet season and their closure was done in the wet season so that the reservoir filling could be started permitting the commissioning of the units on schedule. The closure of the large tunnel during the wet season required a modification of the original design of the diversion tunnel intake, to accommodate the use of the spherical bulkhead from the hydrostatic test of the bifurcations for tunnel closure. Engineers had to account for rainfall variations in designing the Diversion Tunnels. Civil Engineering Interaction between oftices in NY,Bellevue,Golder The Civil engineering/design of the project was pertormed in the New York and Bellevue,WA offices of WGI and in the Atlanta office of subconsultant Golder Associates. The New York office handled the design engineering for all the project features except for the cofferdams,the main dam and the associated grouting galleries, which were designed by the Bel- levue office.Golder Associates addressed the rock mechanics engineering aspects of all project features. Although the work was done in different loca- tions,the interaction between the offices was coordinated through the use of computer file sharing,e-mail and the internet to eliminate the problems which not so many years ago could have come up. The design of the civil works presented a number of technical challenges.The first of those encountered was the effect the terrain at the site had on topographic surveys. The heavy tree cover made aerial surveys inaccurate,while the steep slopes in many areas made ground surveys practically impos- sible.As a result,in many places,the actual topography could not be well defined until eeoe.w Tunnel work entailed a lot of blasting by trained personnel. after the construction forces had established access and cleared the area.The engineering team had to proceed based on the best information available,and quickly update the design to suit the actual terrain as soon as an accurate survey was available without delaying the ongoing construction work. The design of the spillway presented a special challenge.While there are standards for laying out such structures,and the engineering team had a lot of experience with similar spillways,the final proof of such a hydraulic structure is by model testing.For San Roque, WGI worked with Northwest Hydraulic Consultants of Vancouver,British Columbia, ona 1:50 scale model of the spillway.The model filled a moderate size warehouse building,and tock one year to construct and test.The results of the model were used to finalize such details as the curve of the upstream training wall,the taper at the end of the gate piers and the angle of the flip bucket. 79 Work on the cofferdam had to be rushed in order to be ready for the heavy rains. Another challenge for the Civil Design team was the Powerhouse,constructed in a rock shaft 85 meter long,28.5 meters wide and 46 meters deep._in the early stages of the effort,it was determined that the originally planned location for the Powerhouse was unsuitable due to unstable ground.As a result,the structure was moved about 200 meters west to a better location.The design for the shaft excavation was based on an extensive subsurtace investigation,but still required modifications as the work proceeded and the actual underground conditions were revealed. The design of the various tunnel and shafts were also heavily dependent on the condition of the existing rock,and required modifica- tions as the work proceeded to account for actual conditions. The design feature that evolved the most over the life of the project was the diversion tunnel closure.Due to changes in the anticipated closure date and the wide variation in river flow between the wet and dry season,four very different designs were prepared.The final scheme involved placement of an 8.2m diameter semi-spherical steel head into an opening in a concrete structure,in an operation completed in a matter of hours during the early part of the wet season Joe Ehasz,member of the Board of Consul- 80 tants,commented on the evolutionary design process that ithe design-build process facilitated the early recognition of the actual field materials and foundation conditions, maintained the construction schedule and enabled the project design features to be enhanced throughout the construction of the project.The design of the spillway plunge pool,the powerhouse location and support systems,the power tunnel lining systems as well as the diversion closure were modified and adapted to the actual site conditions to effect a project on-time completion while maintaining sound engineering,safety and quality. Designing the Dam Embankment Design Improvements The original project design was completed in the late 1970s and early 1980s,and was state of the art for that time.WGI improved on this decades-old design by taking advantage of advancements in engineering and construc- tion technology and increased understanding of seismic design. The dam is a central core,zoned embankment with alluvial fill and rockfill shells.The original broadly graded transition zones on either side of the core were replaced with 4-m wide transition,filter and drain zones to comply with current filter criteria and reduce the | required quantity of processed materials. Other improvements to the design included modifying the upstream cofferdam section, making better use of excavated material that would otherwise have been wasted,and changing the dam's crest width. rea ae Heavy equipment are shown excavating materials from the alluvial borrow area. 81 The 1982 design envisioned using clay borrow material blended with gravel in a processing plant (to reduce compressibility) for the impervious core.The original clay borrow source would have required significant drying,particularly during the 6-month-long wet season. During Washington's initial design,the quality and engineering characteristics of the residual soil and weathered rock from the required abutment and the spillway excavations were unknown,and therefore,these materials were designated as spoil.However,using excavated residual soil proved such a success during construction of the upstream cofferdam that the designers considered use of this material in the main dam. Subsequent laboratory permeability,com- pressibility,and strength data confirmed the residual soil would make excellent core mate- rial without blending and drying.Specification requirements for this material permitted its use in the main dam up to about 80 percent of the height and would thus comprise approximately 80 percent of the damis core volume.This allowed placement of more than 4 million m?of excellent core material that would have otherwise been wasted.The use of these materials in the dam eliminated the environmental impacts associated with the original plan to obtain core material from pre-determined impervious soil borrow sites downstream of the dam. Foundation Design Improvements The depth of core foundation excavation was based on the assessment of rock quality. The base rock had to be suitable to allow grouting.Where geologic features such as joints,fissures,faults,shears,etc.were encountered,the features had to be tight and characterized by a general absence of erodible materials that may be washed out under pressure,an effect known as "piping.” The original design requirement for the shell foundation excavation consisted of clearing and minimal stripping of soil.This was revised to require the removal of any unsuit- able materials to a depth where the founda- tion materials have strength and elastic characteristics equal to or greater than the overlying shell zone materials and would not be prone to liquefaction during an earthquake. An extensive testing program was undertaken prior to construction using state-of-the art techniques to determine the extent and required depth of the materials which had to be removed.This included geophysical tests and large-scale field density and gradation tests.The geophysical tests consisted of seismic refraction lines,shear wave measure- ments,electrical imaging (resistivity),and spectral analysis of surface waves.The design depths were confirmed by additional testing during and atter excavation. The San Roque Project is located in a seismi- cally active region.Some of the significant active crustal faults on the island of Luzon are nearby,including the San Manuel fault (8 km to the southwest),the San Jose fault (10 km to the east)and the Digdig fault (26 km to the east). Studies conducted by NPC in the early. 1990's concluded that there were no active faults at the site,and that the maximum creditable earthquake (MCE)ground motion is dominated by a magnitude 7.2 event on the San Manuel fault.To account for this, the embankment was designed for a Peak Ground Acceleration (PGA)of 0.60g.4MRSTEMETALWRNoeerfieroy,Grouting works required attention to detail and extensive use of manpower and equipment.CUp Conveyors The San Roque Dam consists of 41 million cubic meters of earth and rock,all carefully placed in various zones in accordance with engineering specifications.The original construction execution plan relied heavily upon a sysiem of belt conveyors nearly 10 kilometers long to transport this material from downstream borrow areas to a processing (screening)plant,and from the processing plant to the left and right side of the Dam. The Dam material was excavated in the alluvial borrow areas of the downstream Agno River and hauled by 100 ton trucks to one of three loading stations and rock crushers along a Collector Line conveyor.That line stretched 3.5 kilometers,and had a capacity of 7,200 tons per hour,carrying the discharge from the loading stations to a Processing Plant.At the plant,the conveyed material was sorted and distributed to one of four piles,representing four of the major zones of the Dam.Material was also conveyed for additional screening to produce the required concrete aggregate. Conveyors were required to transport materials over long distances. From the Processing Plant,shell material was conveyed to the west side of the Dam on a 3-kilometer conveyor with a capacity of 6,000 tons per hour.The conveyor terminated at a 400-ton mobile hopper which was stationed on the Dam iill.The hopper was designed to load trucks with capacities of up to 150 tons.The trucks would pull within the framed structure and under its two discharge hop- pers,receive their allocations of material, and proceed to the location on the Dam designated to receive the material.As the Dam progressed,increasing in height,the hopper,which was self-propelled,was moved into new positions. Transition,filter,and drainage zones of the Dam were supplied from the Processing Plant to the east side of the Dam by means of a 2,500-ton per hour conveyor,terminating at a second 400-ton mobile hopper.From there the zoned material was transported by truck to its designated location on the Dam. The entire system was operated from a control tower centrally located in the Processing Plant.From there the material flow on each conveyor could be monitored and controlled through a computer system. Mechanical Engineering The mechanical auxiliary systems for supplies make-up water and main- the San Roque Project included:tains pressure in the Fire Protection System ¢Dewatering and Filling,which allows the *Lube Oil,which processes the dirty lube water passages and turbines to be oil from the turbine generator lube emptied of water for maintenance oil reservoirs and from the hydraulic and refilled for operation.pressure unit sumps *Cooling Water,which pumps water from *Drainage,which collects,treats and the turbine outlet and circulates it discharges water from leaks,seepage through the generator coolers to and spills. remove excess heat.It also provides *Potable Water,which provides treated seal water for the turbine generators drinking water for project staff's *Service Water,which provides water to use. Hose stations at various locations in Ventilation and Air Conditioning,which the Powerhouse and Service Water __provides fresh air and controlled temperatures Pump Intake Structure.In addition,it within the structures: Cooling water pumps are an intergral part of the Powerhouse design. 84 World Class Quality Management Managing the design,procurement,equip- ment testing and material inspection entailed the use of the most current industry techniques and philosophies for assuring the highest quality in material and fabrication.The project involved procure- ment of materials and manufactured product from the four corners of the globe. Design activities of major component suppliers had to be integrated into the overall plant system designs and the configuration of systems and components constantly monitored. To assure a consistent approach to the quality of the design efforts as they - evolved,through material selection, product development and production a uniform approach to quality was established through the application of the international standard commonly known as ISO-9001. This approach provided a baseline in which to monitor and assure the quality of the product whether it be a design element or piece of operating equipment,from the turbine generator sets to the electrical boxes,cable and fuses used through the station. Managing the overall development and implementation of the UEI/REOL Quality Assurance Program for the San Rogue Dam is Bill Stuckey.Despite his over 25 years of experience in developing and managing quality systems on large multi-participant projects,San Roque presented a unique set of challenges due to the remote project location,time differential and number of international suppliers utilized. Mr.Stuckey's prior quality management experience on numerous large multi- participant projects for the commercial power industry (nuclear and fossil),U.S. Department of Energy,as well as large infrastructure programs such as the Hudson Bergen Light Rail transportation systems in New Jersey,was invaluable in meeting schedule and quality performance objectives. Major equipment had to be subjected to a routine series of quality control checks. For major items constructed on site such as the penstocks quality checks points were established for the rolling and milling operations,fit up inside the tunnels through weld production on the seam and girth welds.Specialized techniques were utilized for the performance of nondestructive examinations in order to establish the acceptability of the work. Other major pieces of equipment were inspected during the course of fabrication or production with in shop testing and inspection witnessed by the client and or his representative.Quality Assurance Shop Inspection activities occurred in Manila,Japan,China,Europe (Italy,France, Belgium),the United States,and at other location where components deemed critical to the successful completion,start up and operation of the Dam,Power House and associated systems.Such inspections involved the resources of selected support organizations in order to obtain the benefit of skill inspection personnel with the benefit of operating in the host country (communication skills). Bill Stuckey managed the Quality Assurance Program for the Project. The Quality Assurance Engineering group assisted the site QC organization in the development of testing tools and tech- niques,and identification and interpreta- tion of QC standards.In addition each aspect of the Quality Program underwent a continuous evaluation for performance improvement through a series of system assessments and program audits occurring in the design office as well as at the construction site. The design and implementation of an effective Quality Assurance/Quality Control program played a vital key role in the successful completion of this World Class Project. 85 Temporary Power and Fuel One of the first tasks facing Mechanical and Electrical Engineering was the design of a Construction Powerhouse.This facility was to be built during the early stages of construction to provide electrical power for the conveyor system,processing plant and the Operator's Village.Power needs had to be developed at the same time major loads such as the conveyors were still being designed.Changes in load had to be considered to account for growth and repositioning the conveyors as the dam increased in elevation.The size, number and speed of engine-generator also had to be optimized based upon anticipated operation and maintenance cycles and fuel economy considerations. Ultimately,a system of 13 identical Caterpillar diesel generators with parallel load sharing capability was chosen.A central PLC provided engine-generator control and load manage- ment.A separate PC-based data acquisition system was provided to monitor system performance,alarms and historical trends. A number of technical challenges had to be resolved prior to the commissioning of these 13 units with a total capacity of 22MW,which is enough to power a small city.Among these were the strict noise standards,which needed to be met so as not to disturb nearby residences.In addition,a large diesel fuel storage depot would be needed to ensure a constant flow of fuel. To satisfy the noise requirements,several studies were undertaken to minimize noise levels.The major evaluations included reorientation of the diesel generator noise mufflers and inclusion of wall mounted acoustical louvers in lieu of gooseneck ducts. All of these studies were accompanied by supplementary noise analyses. Temporary power was supplied from a 22MW generator building. In addition to the diesel oil requirements for the gensets,the same diesel oil was to be used by the construction equipment. Proposed fuel specifications from prospective bidders for the long-term fuel depot all deviated from the required fuel properties established for the end users.To resolve the incompatibility additional fuel analyses and testing were required.Issues relative to fuel oil lubricity,gums,distillation,and test methodology,were only a few of the open issues that had to be addressed before the final selection of a fuel supplier could be made. The Project's reliance on a continuous supply of diesel fuel exposed it to the risk of typhoon- caused interruptions.To mitigate this risk, a 500,000-gallon fuel storage depot was erected.The capacity was based upon the anticipated maximum daily fuel consumption, and an assumed two-week delay in fuel deliveries due to washed out roads and bridges following a major typhoon. 86 Once the design of the Construction Power- house was finalized an evaluation of fuel oil capacity requirements for the duration of construction had to be optimized.Atter selec- tion of the fuel oil supplier final configuration of the long-term depot was formalized.Issues relative to the routing of fuel supply piping from the storage tanks to the Construction Powerhouse,tank capacities,type of the unloading and forwarding pumps were all investigated before finalizing the system configuration, In spite of these technical challenges,the design of the Construction Powerhouse and Fuel Depot was completed in time to start the conveyor system operation and to meet the increasing power requirements for the project construction. Electrical Engineering San Roque presented many unique chal- lenges in designing the temporary and permanent electric power systems.The project encompassed an area over 31 square kilometers (12 square miles)and required power extending to many outreaches of that area.In the early phases of the project,WGI was faced with powering a conveying system which required over 16 MW of temporary power that had to be distributed over 10.6 kilometers (6.6 miles),much of it mountainous and forested terrain.The Operator's Village, which was under construction,required reliable power for the central construction administration facilities as well as for the housing being established for much of the Project's workforce.Additional power was needed for the various workshops, warehouses,and vehicle maintenance and repair facilities.A large processing plant area also needed power for segregating the various soils and aggregates into specified zones used in the dam construction and a concrete batch plant for producing the concrete necessary for the powerhouse, spillway,tunnels and shafts,and ancillary structures. With inadequate utility service power avail- able,the need for a central construction powerhouse with up to 22 MW of generating capacity soon became very apparent.A plant wide transmission system was also needed to distribute the power throughout the site.-It was desirable to have as much of the system as possible remain in place after construction to serve the permanent plant facilities.Design and construction of the evalving temporary power systems also had to proceed in parallel with that for the hydroelectric station and its 230 kV switchyard. This is a view of some switchyard elements. Together,a team of engineers from WGIl''s New York and Bellevue offices put the total project power needs and designs in place. "We had a knowledgeable and dedicated staff on the east and west coast that worked as a team towards a common goal,”commented Sam Martinovich,WGl's lead Electrical Engineer."The Electric Power Systems division in Princeton provided support for the site power transmission systems,the Infrastructure Electrical group in Bellevue designed the conveyor substations and controls and the engineers and designers in New York were busy with designs for the hydro-powerhouse, 230 kV switchyard and temporary power- house.There were many unknowns in the early phase of the project,but the engineers 87 and designers would always rise to the challenge,”says Sam. "The construction forces were moving at an extremely fast pace,often changing the landscape overnight.The electrical crews would want to get their equipment in the ground and out of the way as soon as possible.The site construction superintendents were very helpful in providing day-to-day progress reports,which allowed us to better focus home office resources in support of construction.The field electrical engineering group did a great job of interfacing with the various local subcontractors and became an important part of my design team,”he adds. oe eens tstoitleggy! , An array of panel boards,conduits and trays lines the Powerhouse. Sam remembers that critical power was needed long before the conveyors were constructed.The very first phase of the project,which started in March of 1998, required drilling and blasting three diversion tunnels over 860 meters long through the mountainside.The smaller tunnel,which measured 6 meters high by 6 meters wide, and two larger tunnels each 15 meters high by 10 meters wide had to be completed prior to the rainy season of 1999 to protect the upstream cotferdam. Thousands of meters of cables,hangers, connectors and lighting systems together with portable generators,transformers and distribution panels for circuit and personnel protection were required to get the operation underway.All of this material would be temporary,and much of it had to survive extremely harsh conditions within the tunnels. Materials and procurement quantities had to take this into consideration and needed to be coordinated with the tunnel drilling schedules to optimize material utilization during each stage. Temporary 4 kV transmission lines had to be designed as the conveyors and processing plant systems evolved.The design had to take into account the future permanent 13.8 kV site power distribution system and allow the 4 kV system to be upgraded and remain in place wherever possible.A network of underground electrical ductbanks was also required throughout the processing plant area to power the conveyors,loading stations, crushers and concrete production plants that were being added. 88 Virtually everything would be powered from the 22 MW temporary construction powerhouse which was also being designed and constructed by WGI.Reliability of that powerhouse was paramount to the success of the project and it performed admirably, operating around the clock for almost 3 years until the 230 kV switchyard was commissioned. Once the switchyard was completed and connected to the power utilityis transmission lines,it served as the central point for all site power distribution. Instrumentation and Controls The Instrumentation and Control scope of work on a hydroelectric project of this magnitude is relatively small in dollars and cents but has an immeasurable value in the In the end, this installation has to produce the required overall success of the project. power output and has to have the ability to be operated remotely and automatically.It is the plant control system that provides the necessary interlocks to achieve these requirements.The Instrumentation and Control aspect of the San Roque Project had many challenges.One of these challenges was to provide a istate of the art?control system taking into consideration the fast changing technology in the controls arena while working within the EPC Design/Build Contract.Working closely with the Client this challenge was more than realized. Trinitron One of the most difficult aspects of specifying and procuring the control system for this installation was to ensure that we did not have an obsolete system before we even powered-up the plant.The project was on the drawing boards for a long time before it became a reality,and the control system requirements went through a radical change between the original Electromechanical Works dated 1980 and 1982 and the final Contract dated 1998.The final Contract incorporated very specific Instrumentation and Control requirements. Per the Contract,a completely automated installation was to be provided utilizing Allen Bradley manufactured programmable control equipment.The Contract also specified the "type”and "model number”of the equipment to be used for this purpose.However,since the computer world is changing at a very rapid pace,the equipment specified in the Contract was obsolete even before the design work started.Together with the Client,WGI was able to update the control specifications and provide a "state-of-the-art”Allen Bradley control system for the San Roque installation. WGI contracted Phoenix Power Control,Inc. as the control system integrator to supply the hardware and software for this installation. The objective to provide a state-of-the-art control system with easy to operate Man Machine Interface graphic displays for operator interface was successfully achieved. It also includes provision for automated operation and remote access,as required by the Contract.The successful control system design is the result of hard work and dedica- tion by a team of engineers and programmers from WGI and its subcontractors. DO NOT INSERT ANY BIKETTE/¢p USED FORACQUIRINGANYDATAFROMTHEINTERNETIN.-_INTERNET Oy Beg MOAI LT2TGATEepestoonTana)awGarczrostion[sat]mwGASEFPOSIIKME-ear]- 'PLANT LOAD SCHEDULER.|Te oe Ty OcroaewTATWITEREF CERT METCerntnamraneAMRavecFRATSegntin1012FELDDosae, The MMI providesa "state-of-the-art”system for monitoring and controlling the Project. 89 Keeping Things Straight San Roque Multipurpose Project Project Controls The Project Controls group has been a key contributor to the success of the project and since project inception has been involved in the development and implementation of all of the cost and scheduling systems that were used to monitor and track this 58-month design-build project. Some of the major tasks carried out by project controls were:project execution plan,work breakdown structure,integrated project master schedule,detail account budgeting,cost reporting,commitment tracking,milestone payment schedule,cancellation liability schedule,change control,earned value analysis,unit cost analysis,unit rate analysis, schedule trend analysis,risk analysis,cash flow forecast,invoicing. One of the challenges of an international project is the collection and coordination of information and data from different project locations and time zones.Engineering,design and procurement and overall coordination was carried out of New York,dam and conveyor design was carried out of Bellevue, Washington and construction was carried out in San Roque,Philippines.With project controls personnel in all three project loca- contract/vendor procurement packaging,_tions,we can definitely say that project conirols progress monitoring and reporting,cost and -_-was on the job 24 hours a day. Vdaae eeeRiedyeiegrnn°Ge¢eepoteeeeyeegnl”es'acael8Mekiaanepe4'iCgeopaageruponnrunimsnyennIRetTom Baskett,Jim Alexander and the Control Room personnel give it a thumbs-up. This is a view inside the completed Powerhouse area (opposite page). 91 The Spillway Model Study UEI contracted with Northwest Hydraulic Consultants (North Vancouver,British Columbia)for a hydraulic model study of the proposed spillway design.A large vacant building was rented for the construction of the 1/50 scale model,which was approximately 50 meters long,15 meters wide and 4.3 meters high. The model was constructed and tests were carried out throughout the year 1999. The goals were to refine the design of the spillway approach channel,gate structure, chute,and flip bucket,and to evaluate the erosion of the plunge pool downstream. e The Approach Channel The approach channel must deliver flow to the spillway with smooth streamlines to avoid vortices that would decrease its capacity.The model showed the need to provide graceful elliptical guide wall,seen modeled in Photo 5 and as-constructed in Photo 6.Several different versions were constructed in the model to determine the shortest vortex-free length. A large building was required for the Spillway Model Study. e The Chute The spillway chute should pass up to 12,800 cubic meters per second without excessive waves or other irregularities of flow which could overtop the side walls or cause excessive wear of the concrete. During the course of the model tests, the downstream ends of the piers were tapered (see Photo 7)to eliminate irooster tailsi up to 8 meters high which formed downstream of the piers in the early tests. A steeper angle for the flip bucket was modeled,but the original 15-degree angle was found to work best.The angle of the aerator steps was reduced for smoother flow,and an inward curve was added to the sides of the flip bucket to deflect the jet away from the edges of the plunge pool. ¢The Plunge Pool Plunge pool erosion has been the subject of limited study,and there are no established methods of scaling rock properties for a model.However,since the size of the pool which will be formed by the plunging water is most dependent on the resistance of the rock to erosion,several different mixes of gravel,coarse sand and cement were used to form a channel that would erode in a manner similar to the existing rock. This is a closer view of the Spillway model. This enabled the engineers to determine an expected shape of the plunge pool and the pattern of downstream deposition of the eroded rock.The model also showed that sloping the initial channel slightly downward from the sides to the center would help confine the erosion more toward the center. This is an overview of the Spillway model.This photo shows the graceful guide wall required for the Spillway. The actual application of the design is shown here. 92 e Downstream Deposition The river channel was included in the model from the plunge pool to a point well past the powerhouse.Of primary concern was whether the rock eroded from the plunge pool could be deposited in or near the power plant tailrace,interfering with generation.The model showed that even up to the Probable Maximum Flood (PMF), the deposition tended to occur toward the center of the channel and the tailrace remained clear.The mode!was also used to determine the size of riprap needed along the left bank to withstand the PMF. Dave Hunter,a 27-year professional engineer with bachelor and master of science degrees from the University of Rhode Island,was assigned to the San Roque Project,responsible for the hydraulic analysis of the Low Level Outlet,Power Tunnel,Diversion Tunnels,and River Train- ing Works.He specializes in hydrology and hydraulics,with extensive experience in watershed modeling,channel and hydraulic structure design studies,scour and sedimentation analysis,and ocean engineering. ."Vo MS EONS, Dave Hunter supervises work on the Spillway model. TS7netaaebeTe The Spillway model required attention to detail. This model helped determine the final shape of the Spillway piers. In the early stages of the design,Dave made four trips to Vancouver to participate in the Spillway Model Study .As the construction of the Diversion Tunnels progressed and their design was revised due to field conditions,Dave performed a series of flood routing studies to make sure their capacity remained adequate. He performed similar studies to evaluate alternative sequences for closing of the diversion tunnels to start filling the reservoir. These studies made sure that the diversion capacity remained adequate until the dam and spillway were ready to handle possible floods. 93 are&sWegaaRAigdlataiek2a aig fyeeegniad, Chanter 6 The Main Dam and the Cofferdams NGINEERS from Raytheon Engineers and Constructors (RE&C)and United Engineers International {UEl)got to work in 1998 to update the 20-year-old design for the San Roque Dam.The original designs coming from the National Power Corporation (NPC)had to be reviewed and modified to take advantage of the latest materials and technology available,to save time and money and to improve the dam's ability to withstand earthquakes. The structure is a central-core,zoned- embankment dam with alluvial fill and rock- fill shells,along with 4-meter wide transition, filter,and drain zones.Design improvements to the project included moditying the upstream cofferdam section,making use of excavated material that would otherwise have been spoilt,and changing the dam's crest width. The filter,transition,and drain zones of the dam system were also modified to comply with current filter criteria and reduce the required Explosives are prepared for blasting tasks,opposite page.Photo below shows Core Foundation in March 2000. Grouting works are also shown going on. quantity of processed materials.Engineers also conducted liquefaction studies on site, and based on the results,set the minimum initial shell foundation excavation depth at 2 meters for the majority of the site and at as much as 6 meters in certain areas. The dam structure consists of an embankment with a massive central core serving as an impervious barrier.A mixture of residual clay and sandy gravel make up the material for the central core.The components of this material matrix were excavated from designated borrow areas located approximately 4 kilometers downstream of the dam structure.The design of the dam's core called adherence to stringent compaction and permeability standards.In some instances,the materials had to be conditioned on Site prior to placement in the dam.Conditioning may involve drying out the wet clay during the rainy season or watering it during the dry season. aay!¥,soa *onad {Aas ayees4iesCpTpesastFPoaePMR osa Gre i, The Core Trench (above)had to be grouted thoroughly.The rainy season creates unique problems in the Core Trench (below). ee:Oe:Set96 The rock foundation that supports the core has been treated with grout to prevent any seepage of water from occurring.Special grouting tunnels are constructed below the dam to monitor any water seepage from the foundation area.This enables engineers to identify and locate areas where additional grouting may be required.A grout foundation controls seepage in the dam foundation. Combination drainage and grouting galleries were installed to collect and discharge any water seeping from the foundation area Filters of fine and coarse sands were located on either side of the core.These layers protect the central core and serve as transition and drain zones between the core and the outer shell.The shell on the main sections of the dam were made of pit-run sand-gravel, including small boulders and random rocks which were sourced from excavations in the borrow areas.The outermost dam surfaces are protected from waves and erosion by layers of rock. Work Stages The dam was constructed to a height of about 195 meters above the existing river valley floor.It contains nearly 40 million cubic meters of fill material.At its crest of 295.0 meters above sea level (masl},the dam is 1,130 meters in length.The dam was built in 5 stages:Construction of Cofferdams and Water Diversion Structures;Excavation of Loose material Below the Dam;Foundation Treatment;Placement of the Clay Core and Embankment Materials;and Closing of the Water Diversion Structures to begin Reservoir filling.oiSeismic sensors on the Main Dam monitor earth movements. 97 Construction of the Cofferdams In order to start work in the main construction area,a series of diversion structures had to be built.During the construction period,REOL and SRPC were responsible for accommodating all river flow conditions up to the 100-year flood event. The diversion system was designed for a flood with a minimum 30-year return period and both SRPC and REOL have determined the size of the diversion tunnels to pass floods up to a 30-year flow.In order to control flows greater than the 30-year event,the upstream cofferdam was designed with an overflow channel.The channel was constructed near the right abutment of the cofferdam and directed water away from the construction area. The upstream cofferdam was 65 meters high,approximately 10 meters wide at its crest and almost 400 meters in total length.A portion of the upstream cofferdam was ultimately incorporated into and form part of the main dam structure.During the construction period,river flow was directed by the upstream cofferdam:into three 850- -meter long Shotcrete-lined diversion tunnels. The diverted water was released downstream of the dam construction area where it rejoins the Agno River channel.These tunnels where sealed off after completion of dam construction. Construction of the upper cofferdam began in July 1998 under the direction of Thurlo Hooper,a seasoned veteran of various dam projects in the United States,and one of the Projects'original crew members.Thurlo and his crew faced a myriad of problems such as the lack of existing roadwork to the site, delays in the arrival of heavy equipment on order and inclement weather. High Quality Control Standards Building the San Roque Dam entailed the use of a massive amount of labor and materials.The dam in itself required twenty-nine million cubic meters (29,000,000 cu.m.)of earth,while the major structures required 583,400 cubic meters of structural concrete.The earthen dam was constructed using materials sourced on site and transported to the dam through a 10-kilometer long conveyor system,perhaps the largest belt system ever used in the construction of adam. The embankment materials on both the upstream and the downstream side c the dam consist of a wide variety of graded soils to optimize the use of locally available materials.The composition of the core materials had to be carefully chosen to minimize the potential for liquefaction during moderate seismic activities.It was therefore very critical to make certain that the materials and processes used were up to international standards. The Quality Control (QC)Department played a key role in ensuring the Project's compliance with the specifiec design requirements.With a work fore that reached a peak of 106 employees,the QC Department had personnel deployed in all areas in ie 0 Ae s various disciplines.The Department ap was organized to handle civil,Asghar Zaidi electrical,mechanical and instrumentation activities.There was staff assigned to test all types of materials,from aggregates,cement,soil and concrete samples.Two well-equipped on-site laboratories were established to furnish to provide testing services in a timely manner.They provided round-the- clock testing services often seven days a week,in all days of the year. Managing the QC Department is Asghar Zaidi.With a Master's degree in Geology,a Master's degree in Civil Engineering and 35 years of experience on civil and environmental projects,Asghar brings considerable knowledge and experience into the Project.Asghar has worked for the Deep Tunnel Project in Chicago,The Mangla Dam Project in Pakistan,Locks &Dam No.26 in Missouri, the Merril Creek Dam in Phillsburg,New Jersey and the Sewage Tunnel Project in Staten Island,New York,to name a few.In addition,he has performed quality- related functions on nuclear power plants and light railroad projects prior to his assignment to the San Roque Project. "Design-build projects are always very challenging.We have to keep up with the frequent design modifications coming from the Project's design offices in New York.After receiving authorization from the New York office,we also had to communicate the change to the personnel on the ground here”says Asghar. "A lot of work also had to be subcontracted to local and foreign subcontractors with diverse backgrounds and specialties.The QC Department had to make sure that their work was up to the specified design requirements.We also had to provide oversight on quality issues and communicate expectations with them and that was quite a challenge,too”. "In the Main Dam,the grouting activities were very critical items.Major grouting operations were designed to provide a seepage cut-off and stabilize the shear zones.Grouting along the dam axis,spillway crest,galleries,adits,tunnels and shafts was one of the major activities supervised by the QC staff for an extended period”adds Asghar. The QC Department played a key role in the successful completion of the San Roque Dam.It's stamp of approval guarantees that the work met strict design specifications.Asghar and his team helped make the San Roque Dam truly a world-class project. 98 eo arte:atmieinnatdES Roo.e "e a .aLwh"anne ata fetnbineing AMIS . .t cane nny ating minal Ba aT The constant rain can make work in the Dam area dangerous. Another cofferdam built downstream of the construction area to was prevent the flow of water backwards into the construction works,as some of the works had to carried out at a level below the river bed. The downstream cofferdam was 16 meters in height,approximately 12 meters at its crest and 24 meters at its base and was around 100 meters long.The diversion works were completed and the river was diverted by July 1999. Excavation of Loose Material Below the Dam Even before any work could be done in the Dam's foundation area,excavation of all the loose material below the Dam was necessary.The objective of this excavation is to prepare a clean surtace that will provide optimum contact with the final dam material. 99 0 eT ER Excavations in the bedrock were extended to reach firm,fresh rock.The excavated materials were sorted by size and set aside for future use in the cofferdams and in the Main Dam. In general,all material under the base on a dam that could cause excessive settlement and leakage should be removed. In the case of the San Roque Dam,a lot "dental work”had to be performed.This meant the removal of material to considerable depths to reach acceptable bedrock. The foundation and the abutment areas were stripped and scaled prior to foundation treatment.Using an assorted of excavators, backhoes,pay loaders and other heavy machinery,the teams worked around the clock and excavated tons of materials for over:a year. The Right Abutment as it appears in an October 2000 photograph. In 1999,Jack Owens,was brought in as Site Manager and he took the lead role in the Excavation and Dam Embankment works in the San Roque Project.He was ably assisted by Joe Blades,Gregg Casten and Joey Ventura.Working 24 hours a day throughout a period of more than 2 years and using a wide assortment of trucks,haulers,excavators, the Excavation Team removed more than 2.5 million cubic meters of material from the cofferdam area,6.5 million cubic meters of material from the Main Dam,and more than 4 million cubic meters of material from the River Training Area. Foundation Treatment After the removal of all the loose material below the dam,foundation works could be started.The foundation works included the preparation of the bedrock,slash grouting,consolidation grouting and a grouting curtain.Grout is a liquid,either a uniform chemical substance or an aqueous suspension of solids that is injected into rocks 100 through specially drilled boreholes to improve bulk physical properties on to eliminate the seepage of groundwater. The bedrock is the portion of the rock base that will come in contact with the Dam. The goal of consolidation grouting is to improve the strength and bearing capacity of the bedrock and to prevent seepage that may damage the Dams'foundation.This is specially needed,as the rock base will be taking a considerable load. Grouting curtains are also a part of the dams'foundation.The grout curtain extended as deep as 80 meters below the surface and was designed to limit any leakage from the reservoir.Installing the grouting curtain entailed drilling by specialized equipment and pumping enormous quantities of grout into the drilled holes.Grouting galleries were also installed at the bottom of the dam to monitor seepage and take remedial action,if required. The Clay Core and Embankment Materials Among the most important variables of earth fill embankments are the placement of the core, affecting construction distribution of soils and other materials, method of placement,water content,and compaction. At its full height of 195 meters,the clay core of the San Roque Dam measures nearly 30 meters wide at the base and 12 meters wide at the top.Designed for impermeability with 4.4 million cubic meters of earth,at nearly 11%of the entire dam,the core is a very important feature of the dam.If it fails,water will seep through it and may damage the whole dam structure. This is how the Downstream Face of the Main Dam looked in January 2002. < La NEO ee © The core material had to be placed in horizontal layers and compacted to a specified ratio and thickness.The soil had to be homogeneous and free from lenses, pockets,organic material,or other imperfections.The materials'moisture content was also tested as it affected the materials compaction capabilities.The material for the Core and the Core Base were sourced from the nearby Clay Borrow Areas and the abutment excavations. Alluvial gravel of various sizes was used for the Transition,Filter and Drain Zones.They were used in specific portions of the dam and were subject to moisture tests to meet design standards.10-ton vibrating rollers were used to compact these materials. A photo of the Upstream Cofferdam taken in January 2000 (above)shows foundation at the bottom.A view of the Upstream Cofferdam in February 2000 shows the cofferdam almost completed (opposite page). World Class Dam Expertise In planning the San Roque Project, SRPC committed itself to build a dam that would live up to the highest international standards. Under tough physical conditions,he organized and supervised the additional geotechnical investigations.The work was to be done in three The National Power Corporation (NPC)had earlier commissioned an Italian company to prepare the feasibility study for the Project. NPC initiated construction based on that study but had to stop in 1983 due to funding problems.In 1997,to update the initial study,Sithe ( phases,and comprised of 70 drill holes and a seismic refraction survey at the dam site and surrounding areas.He prepared a testingprogramandevaluated all the geotechnical results arising from the tests.Those tests gave updated information that was used for design and construction purposes,- Energies,Inc.NY,one of the new Project proponents,contracted the services of Electrowatt Engineering Ltd.Electrowatt is a highly diversified engineering company based in Zurich, Switzerland with international expertise in the energy industry. Dr.Francois Morel was the Senior Engineering Geologist that Electrowatt Engineering sent to update the study. Dr.Francois Morel and formed part of the revised feasibility study. Before his participation in the San Roque Dam, Francois has been involved in more than 10 other dams.With a degree in Geology and a Doctorate in Science from the University of Lausanne,Dr.Morel is an international expert in the field of grouting and geology and is considered as one of the best in the field.He has worked in 102 dams in Senegal,Iraq,Togo,Turkey, Iran,Mongolia,Laos,India,and Syria. His expertise proved invaluable to the San Roque Multipurpose Project. "There is nothing really technically unique about the design of the San Roque Dam.The spillway and the main dam have very solid rock foundations and should present no future problems. Geologically speaking,dams have been built in even tougher locations and conditions”,says Dr.Morel."The San Roque Dam has been designed to withstand earthquakes with a magnitude of 7.8 in the Richter scale.The San Manuel Fault is approximately 8 kilometers away and should the Dam should withstand a strong earthquake along the San Manuel Fault”,he adds. In 1997,Francois Morel came to the Philippines for a short-term scientific study.Because of his knowledge and expertise,he was offered the position of Lead Grouting Engineer/Lead Geologist by REOL/WGI to stay and help build the dam.Francois Morel's involvement helped make the San Roque Dam truly a world-class project. Larger sized alluvial gravel was used for Clear Shell,Random Shell,Random Rocktill and Select Rockfill zones.The materia!for the Rockfill zones came from the excavations in the Core Trench,the Abutments,the Spillway and the slopes below the Lower Level Outlet and the Power Tunnel.Riprap coming from the approach channel was also used in the appropriate areas. By any standard,it was a monumental task. The Cofferdams alone used up more than 2 million cubic meters of material.The Zone 1A and Zone 1B Material for the Dam's Core and Core Base were sourced from the Clay Borrow Areas and the Abutment Excavations. More than 4.5 million cubic meters of material was used for this purpose. The Transition Zone,Filter Zone and the Drain Zone used Zone 2,3 and 4 materials that came from alluvial gravel.More than 1.9 million cubic meters of this material was placed on the Main Dam. Zone 5,6,7A,7B and 8 materials corresponding to Clean Shell,Random Shell, Random Rockfill,Select Rockfill and Riprap came from alluvial gravel and the various excavation areas.Almost 32.5 million cubic meters of these materials were used. All in all,more than 39 million cubic meters of material was used for the Main Dam and 103 more than 2.2 million cubic meters for the Cofferdams. The Grouting Galleries Grouting galleries were designed to extend the grouting treatment of the dam foundation to a total vertical depth of 80 meters from the surface.All access adits and grouting galleries also serve as inspection galleries during and after the impounding to monitor seepage quantities.They also house the dam instrumentation consisting of upstream and downstream sets of piezometers.Should the seepage exceed the contracts'specifications,additional remedial grouting may be performed from these galleries. The galleries consist of a lower gallery under the river bed and of two upper galleries excavated at higher elevations into the left and right abutments.Each grouting gallery has an access adit with portals located near the downstream of the dam. The upper grouting gallery is approximately 330 meters long.On the other hand,the lower grouting gallery is approximately 600 meters in length including the drainage collection gallery.Both the galleries are 3.5 meters wide and 4.5 meters high. This series of photographs (left to right,from above)shows the Left Abutment in June 1998,July 1999, December 1999,July 2000,December 2000 and April 2001. ,Mirietrmenc...;1 S25 Bow unieatROE cogatei 1 ke oni Sey ee 104 con iusee 105 Work on the Core Trench (above)required the use of a variety of heavy equipment.Various wheel loaders and haulers were required in the excavation process (below). rela af f,. éo4 4 sarod Caded cfatatbetar Dine ska] ben aF 106 ipment were needed for tunnel works.lized equlaSpec 107 d InspectioninganGrout talledins underneath the Main Dam to Galleries were Groutingmonitorseepage(left). work can be physically challenging (below) nnaey Suse igiBoe Set iret ee . re easiS 081 US Ambassador Francis Ricciardone (center)is briefed on the Project by Washington personnel. 109 Chanter] 'The Tune! Racing Against Time ROM the time that the Notice to Proceed was received on March 6, 1998,the works on the tunnels and the power waterways have been a critical factor in the on-time completion of the San Roque Dam.With a guaranteed turnover date of December 31,2002,the progress of the tunnel works would directly affect other areas of the Project.For example,work on the Dam's foundation depended on the Diversion Tunnels being able to accommodate the water diverted by the Upstream Cofferdam. Likewise,the start of the penstock and related powerhouse works were related to the progress of the power tunnels. The nature of tunneling works did not help at all.Tunnel works is an exact science and there is little margin for error for inexperienced personnel.Working in a confined space with heavy equipment,explosives and less-than- perfect lighting makes tunnel work inherently more dangerous that work done above the ground. 110 This is another aerial view of the Power Tunnel Inlet and Diversion Tunnels in July 2002. The rainy seasons experienced in the area also affected the work schedule.The diversion tunnels had to be completed before the rainy season of 1999.Failure to do so may cost the Project to lose the cofferdam.The rainy season also brought in flood silt that had to be removed so that tunneling could continue. Initially,Woodward Construction,a US- based company with a legacy in the field, was called in to evaluate tunnel construction. Working with them were experts from Golder and Associates,an engineering design firm based in Georgia,USA.Kevin Miller,Don Todd,Mark Funkhouser and Kenny Mcleod led the multinational team of tunneling veterans in racing to complete the tunnel works on time. The tunnel team was up to the task. Working round-the-clock and using the best equipment available in the market,the tunneling teams were able to complete Diversion Tunnel number 3 around March 1999.All the diversion tunnels were completed and the Agno River was diverted by July 24,1999.Along the way,they managed to achieve a world-class safety record that enabled them to win an award from the International Society of Mine Safety Professionals. This is a photo of the drop shaft from the tunnels underneath. Power Waterways The power waterway comprises the following main components:Intake Structure, Power Tunnel,Surge Tank,Penstock,Manifold and Tailrace Tunnels. The water is conveyed from the Reservoir to the Powerhouse via a concrete intake structure,a Power Tunnel through the left abutment of the Dam,a Penstock and Manifold.This tunnel measures 8.5 meters in diameter and is 722 meters long. The Tunnel Intake is situated 20 meters below the minimum normal water elevation of 225 meters above sea level to assure the submergence required to operate the water turbines.This intake structure is fitted with trash racks to prevent large pieces of debris from entering the tunnel and damaging the turbines. 111 The Power Tunnel is 1.3 kilometers long and has a diameter of 8.5 meters.It is a low- pressure sub-horizontal tunnel with a Gate Shaft approximately 80 meters high and 12 meters in diameter,about 190 meters downstream from the intake.Bulkhead gates are installed in this gate shaft.These gates can be lowered to close off the flow of water into the power tunnel for routine inspections or for emergency purposes. A Surge Shaft is located 530 m downstream of the Gate Shaft.It consists of a 100-meter high vertical shaft and prevents the over-pressuring of the power tunnel during rapid opening or closing of the turbine wicket gates,as well as enhancing the stability of the power generated. A Drop Shaft with a vertical length of 55 meters separates the Low Pressure Tunnel from the High Pressure Tunnel.Water coming from the Low Pressure Tunnel drops through this shaft and gathers speed and pressure. The downstream end of the power tunnel after the Drop Shaft is lined with a steel penstock extending about 500 meters in length.The penstock is 8.2 meters in diameter and serves to further increase the water pressure.The penstock terminates into a manifold that trifurcates the water flow into three smaller penstocks leading to the hydraulic turbines,each of which has a shutoff valve installed to isolate the turbine from the reservoir. Allin all,the Power Tunnel alone used up more than 49,000 cubic meters of concrete lining and 4,470 tons of steel lining.The Low S51See2weetaaiefleeoSem2a Level Outlet and the Tailrace structures used up 14,000 and 5,700 cubic meters of concrete lining respectively. Diversion Tunnels During the construction period,WGI was responsible for accommodating all river flow conditions up to the 100-year flood event. The diversion system was therefore designed for a flood with a minimum 30-year return period and this was calculated to be around 5,600 cubic meters per second, Three diversion tunnels were constructed to divert the Agno River.Diversion Tunnel number 1 was both 16 meters in height and 10.4 meters in width.It was 860 meters long and was located between Diversion Tunnels 2 and 3. Diversion Tunnel number 2 was also 16 meters high and 10.4 meters wide.It was around 902 meters long.It was on the left of number 1 facingDiversionTunnel downstream. On the other had,Diversion Tunnel number 3 stood 6 meters high by 6 meters wide.It had a length of around 820 meters. 112 Lasers (opposite and below)are used as guides for tunnel civil works. All of the three diversion tunnels were lined with fiber-reinforced Shotcrete.Swellex- brand rockbolts were used to support sections of the tunnels as they were being constructed. These hydraulically expanded bolts gave immediate rock support and a full-column bond. All the diversion tunnels were eventually plugged with concrete 30 meters in length during the reservoir filling process.This ensures that no water will pass through the diversion tunnels after it has been plugged. Low Level Outlet A low level outlet is provided to remove sediment and debris from the intake area, and also to discharge Reservoir water to a level below the power waterway inlet to allow emergency upstream dam surface repair or maintenance.It also allows the release of flows to the Agno River channel in the event the power tunnel is being dewateredor if flows cannot be released via the powerhouse. The intake to the lower level outlet is located adjacent to the power waterway about 100 meters below the crest of the dam.The tunnel is approximately 1.3 kilometers long, has an internal diameter of 6 meters,and is initially parallel to the power waterway.The tunnel then leads a straight path and its contents are discharged into the Agno River approximately 500 meters downstream of the powerhouse. The discharge feature comprises an opening at the intake structure and a tunnel - that passes through a gate chamber at the bottom of an open vertical shaft 95 meters high.The gate chamber is equipped with wheel mounted and hydraulically operated gates.Upstream slide gates were also World-class Tunnel Experts The tunnel work for the San Roque Dam represents one of the most impressive phases of the Project.More than 8.5 kilometers of tunnels had to be built under a very tight schedule.Tunnel work is a very demanding task.Tunnel crews had to drill and blast their way through solid rock.The. resulting loose material and muck would have to be cleared out to give way to more drilling and blasting.A lot of the work had to be in confined spaces,under unnatural lighting levels and in wet and humid conditions.It was backbreaking work and it required a crew of world-class tunnel experts to pull it off. Leading the Tunnel team was a seasoned tunnel veteran,Kevin Miller.Kevin had just come off the East Side Reservoir Project when his expertise was called on to do the San Roque Project.Kevin has been working on tunnels for decades,with stints in the Metros in Washington,DC;with the Super Collider Project in Dallas,Texas and the Calaveras Dam in California to name a few. Together with other seasoned experts like Dick Coppage,Don Todd and Mark Funkhouser of Golder Associates,they started working on the tunnels in 1998.They also hired local miners from Baguio and Itogon to help them complete the job.These local miners were 2"and 3 generation miners who already have extensive work experience in tunneling.- It was a very challenging task.A lot of other phases of the Project were dependent on their progress and they had to accomplish much in a limited time frame.In the early stages of the Project,proper mining equipment was not readily available.The rainy season brought in exceptionally heavy rainfall that hampered access to the work area. Compounding the problems was the fact that tunnel work is physically demanding and inherently dangerous.The confined workspace and the reduced airflow could prove to be a lethal combination.Fires, cave-ins,industrial accidents are real dangers that have to be faced constantly. Kevin and his team were up to the task.The completed the diversion tunnels in record time and allowed work on the cofferdams to commence.They then moved on to making the Power Tunnels and the Low Level Outlets.To top it all,they completed their work with an exceptional safety record that earned recognition from the International Society of Mine Safety Professionals.Their record of more than 7.6 million hours without a lost time accident in 2001 is a remarkable feat,even based on international standards. "We have taken a proactive approach to - Kevin Miller Safety in the Tunnels.We were the first team on the job to use a full-time safety crew.Wespentalotoftimetrainingourcrewonsafe work practices and we constantly monitored their activities to make sure that they practiced what they were taught.We set out and made our people appreciate the value of safe work practices instead of penalizing them for infractions.Our efforts paid off as the workers eventually recognized the need for safety awareness and accident prevention”, says Kevin. "The personnel we had were very professional and carried a lot of experience with them.Some of them even have overseas tunnel experience.They knew what the job entailed and were capable of performing the task.Because of their hard work and dedication,we were able to complete the tunnels on time and enable others to carry on with their assignments.We have completed world-class tunnels that live up to the highest quality control standards in the industry and with an impeccable safety record.We are all proud to be part of the San Roque Project”,Kevin concludes. Loose material is taken out of the shaft in this file photo (opposite). Above photo shows the Power Tunnel Surge Shaft from the bottom with the Tunnel Needle Beam in the background. constructed for inspection and maintenance purposes. Tunneling Procedures The tunneling started with the proper surveying of the tunnel locations.Survey crews used an assortment of tools and equipment to ensure that the proper elevations and bearings were followed.The corresponding rock surfaces were marked and tunnel openings were outlined on the outlying face. Pilot holes were drilled on the rock face and prepared for blasting.Explosives were then set on the holes and set off.For the tunnels,some explosives were set off in sequence to maximize their effect and result in a wider opening. 115 Mucking out operations were then pertormed using Atlas Copco Wagner ST- 7.5Z units.These machines loaded the mine trucks that hauled the debris out of the tunnels for dumping unto the trucks outside the tunnel portals.Working on two shifts round the clock, Kevin Miller and his crew would advance an average of seven meters a day for every face that they worked on.At times,they would be working simultaneously on six different rock faces.Doing so accelerated their progress and made up for previously lost time. After drilling,blasting and mucking out, the exposed rock is then sprayed with an initial 50 to 75 millimeter thick layer of fibre- reinforced concrete in preparation for rock reinforcement bolts.Some of the bolts were 4 meters long and were strategically placed in the roof and walls of the headings before a second spraying of Shotcrete achieved a (Clockwise from top left)This series of photographs shows the progress of work in the Diversion tunnels and the power intake tunnels from May 1999 to August 2002.482tyaras,aPEULSLraeet 4 peti a dea deedXdsatinBee td wut o™ Bes ' fa - Z 2dIIITeuSRI*"4Progressive work on the Power Tunnel Intake structures is shown from May 1999 (top left)to February 2002 (bottom,right).Wiseese.pel dene wDrane ats "i 118 * vt ee”| . =.Szaaees!poatemmalitare(aNtd £'Fe olieesioeifs!a {eowens Ay Ms= - | = ti x 3 Tm a] a mt : SS 4 Ss ee : os mek F xe Ze : : 2 SSS SSeee ee RSS Sates Zee SSS SSS SSS 2S225S: SSS 4 rer =a SS es SSS SSS SSS 4 Saws SaaaossSeer aes Se =F SasSSSSSSSS SSeS SSE Fats =- S375 SSSESSsSSS SSS SSE Bags | =====S = = Ss Se forts Sos Sees SSSSSSs ESSE SSE Sa came F==sees SeasSSeae==SSS SSS SS SE Zee SS Se ee SS SSS ESS SEES SS Ee = SSSSSS SS SS SSS SSS ES SSS SET ty SSS SSS SSS ESSE Sa-s SSS SS SS td Ss SS SSSSSSSS SSS SESS SSS SSSSE SSS SSS SSS SSESSSSESs ESESS SSS SS: eee = ESS SSS SSSSSS SSS SS SS a! 119 geen,¥,INaw The rock surface is marked in preparation for pilot «drilling of the tunnel opening. Workers install the formwork required for the diversion tunnels.More formwork is done at another diversion tunnel. oFeste;MPa7aBEAfo.&BRAISCABieSxl2-BISaral[wre+ca=¥arereatefone¥XN,ieShotcrete is applied to the outlying rock surface to smoothen the surface area. the tunnels. These are the completed Diversion Tunnels by June 2000.AOS2YEWagso A hydraulic press bends the steel plates into the proper form. VA Tech personnel assemble the penstocks in an Workers inspect the welded sections of the power tunnel. on-site assembly yard. Various sections of the steel liners are welded into place. 122 Ege il|Se ca a al The penstock is formed into various sections.tunnels. The steel plates form an integral part of the bifurcations. AY eseaaarepos italanaos fy. 4 'a eo AAS can ?aR ctf A dramatic aerial view of the Spillway in operation in August 2003 (opposite). The Spillway Spillway Rationale and Description PILLWAYS are structures on or at the side of a dam that contains and guides the flow of excess water supplied to a reservoir.For the San Roque Dam,the normal maximum operating reservoir surface elevation is 280 meters above sea level (masl).During typhoons,the reservoir is allowed to rise above the normal maximum operating elevation to the maximum exceptional surface elevation of 290 meters above sea level (masl),which is consistent with design criteria for the dam. During normal spillway operations,the water level in the reservoir is monitored by the National Power Corporation.Studies conducted by the National Power Corporation,the San Roque Power Corporation,PAGASA and the National Water Resource Board has resulted in a Spillway Operators Roll Curve to guide in the operations of the Spillway.NPC also employs a Flood Forecasting and Warning System for 125 Dam Operations that provides guidelines for water releases through the Spillway.Based on their forecasts and the needs of the downstream areas,water may be released through the Spillway. The overflow of an embankment dam outside of a spillway can have disastrous consequences so that safety usually requires that the spillway be capable of containing at least a hundred-year flood.The San Roque Dam Spillway is designed for a flow of 12,800 cubic meters per second.This value corresponds to the Probable Maximum Flood, an internationally accepted criterion for sizing spillway capacity,given the watershed characteristics and its rainfall parameters.No flood approaching the Probable Maximum Flood estimate for the San Roque Dam has ever occurred in the recorded history of the area.By comparison,the magnitudes of 100- year and 200-year floods are 5,600 and 6,200 cubic meters per second,respectively. weftHoyeA*. "i aAt we: mand =reg heaodSTS A:= The concrete spillway is situated on the right abutment (looking downstream)of the Dam.The spillway is fitted with six gates that can be opened individually or collectively.The Spillway is 100 meters wide and about 525 meters long,with a drop of 170 meters. Construction of the spillway required deep excavation to reach competent rock required for a solid foundation.In fact,more than 11 million cubic meters of materials was excavated from the Spillway area.Much of the material excavated during the spillway construction was used as construction material for the Dam. Spillway Chutes The spillway chutes are the means by which water is transferred over the crest of the spillway to the riverbed below the dam. Their function is to channel the water through a predetermined path and thus prevent damage to the valley walls and the Main Dam that could occur if the discharged water is uncontrolled. The spillway of the San Roque Dam is concrete-lined and is separated by two longitudinal walls into three sections.Each section has 2 chutes.The width of the chutes were determined by the length and arrangement of the spillway crest,the total energy in the water and the economical relation between the width and the height of the sidewalls of the chute.The height of the chute wall is also important because the water could erode the side slopes of the nearby valley wall. The Spillway Training Wall (top)is ready for concrete works by April 2001.Concrete Mixers (middle) line up for the concreting of the Spillway Training Wall in July 2001.Bottom photo shows progess on the Spillway Training Wall by September 2001. Each of the spillways'3 bays is over 30 meters wide and extends from the top of the spillway to just above the flip bucket.The abutment walls of the spillway are 8 meters high and protect the Spillway from the bare walls on either of its side.The two partition walls that separate the Spillway into 3 sections are also 8 meters high.There are also 6 sets of aeration galleries over the length of the spillway that serve to dissipate the force of the water rushing down the spillway by providing for an airflow to break the water surface. The spillway design also includes a flip bucket at the bottom of the chute.The purpose of the flip bucket is to throw the water well clear of the structure to induce disintegration in the air.Without it,the toe would absorb the full force of the water and would quicklybeLATSTRoeSate The base of the flip bucket had to be reinforced.erode The flip bucket extends over the full width of the spillway and is characterized by the 70-foot drop.Water flowing down the spillway at a high speed is literally thrown up in the air and flipped by the upward curvature at the end of the spillway.The water then drops down unto the toe of the spillway with considerably less force.The spillway's toe is reinforced by concrete slabs 10 meters thick to preclude erosion by the force of the water. The flip bucket is characterized by a 70-foot drop that dissipates the force of the water falling down the Spillway chutes. POR Ry Fy.a poapreeEeeWasPn ise: Materials Used The Spillway of the San Roque Dam is truly a massive structure.The volume of concrete used for Spillway construction alone exceeded 200,000 cubic meters.This is equivalent to more than 5.5 million bags of cement. The materials used for the Spillway had to meet very high standards of quality control. The Project required high quality,low-alkali, sulfate resistant Portland cement with moderate heat of hydration.Type II Sulfate- Resistant Portland cement was specified as this type of cement generates less heat and does so more slowly than Type |cement.It causes minimal rise in temperature of the concrete mix,which is important for the Projects' concrete structures. Eventually,WGI sourced its cement requirements from Union Cement Corporation.Samples of the cement being supplied by Union Cement were tested weekly by an independent laboratory and by the WGl's own Quality Control Laboratory to monitor continued compliance to standards. The Spillway Ogee Area looked like this in May 2002. Radial Gates and Stop Logs The design specifications for the Project called for a gated Spillway.The design called for radial gates for each of the 6 spillway chutes.Each gate stood 19 meters high and 15 meters wide.The leats for the Radial Gate weighs 14 tons per piece. The Radial Gates face outward into the water in the reservoir and is subject to tremendous water pressure.The water pressure applied against the curved gate leaf is transmitted through the support arms into the pivot points that are embedded in the concrete wall.Since the gate leaf is curved, the water also applies pressure upward, thereby lowering the lifting force required. Each gate is fitted with rubber seals,retained by steel bars,along the side and bottom edges of the gate face.The seals are designed to bear on the walls and bottom of the structure to insure a watertight fit when the gate is closed. _Seaside2aatf5a7Ieeeyea?The gates consist of a curved skin plate reinforced with structural members,and radial arms transmitting the water pressure to two trunnion bearings.The radial gates rotate about a horizontal axis,which passes through the centers of trunnion bearings and coincides with the axis of curvature of the skin plate. With this arrangement,the line of action of the water pressure passes through the center of the trunnion bearings and no unbalanced movements are created. The Radial Arms are hydraulically operated.Each radial arm is more than 16 meters long and weighs over 6 tons. The design specifications also called for 6 stop logs.Stop Logs are flat,box-like structures made of steel that are used to shut off water flow in a dam upstream from the radial gates,enabling repair and maintenance works.The Stop Logs for the San Roque Dam Spillway would allow for repair and maintenance works to be performed on the Radial Gates even when the water level in the reservoir area reached the level of the Radial Gates. Each Stop Log is 3.6 meters high and 15 meters wide.Every unit weighs about 32 tons and is moved to the its required location by a gantry crane kept in place on top of the spillway structure for this purpose. Sequence of Works Work on the spillway started in the first quarter of 1999 with the excavation works on the right abutment of the Dam.Loose materials were excavated and set aside for possible future use.The Spillway had to be set ona solid rock foundation and excavation works continued until such competent rock was reached.Drilling and blasting operations were also required to trim rock that did not meet the right slope and contour. As the excavation works progressed,the rock face on both sides of the Spillway was exposed and was treated to prevent future erosion that may damage the Spillway.This was accomplished with the use of rockbolts and Shotcrete. 129 Ana.Hebiii So This photograph is an overview of the Spillway and the flip bucket in March 2002. ReSetseatssoee,* eek Aye ry, OSsRu4 < 2: We in'wa y) a Cree ess Sete se9,ere rsmercate' Fi aleeSane Jsitet sasiraied ' Kefe)os aeae neeaceeiaks SaSE REARS,ci Feis va zh ces PRSSs aS ead "fe aes $e.otRaposSie ey WEnee{ eeaRevietod "al PAL? Yevette Opie' A ood *By, rsaS Sor S asre tick SeFIPSBe [ook 130 Felt0iecarsDIEgrt"4wahWise?osgOy Aetee +. e, falsete Building the Spillway The concrete spillway is one of the most visible structures of the San Roque Dam.With a width of 100 meters,more than a kilometer in length and a drop of 170 meters,it is a massive structure that could be seen from as far as 6 kilometers away.The excavation process started in late 1999 and continued until mid-2002 as deep excavation was required to reach competent rock required for a solid foundation.The concrete placement alone took a period of almost 2 years as more than 530,000 metric tons were required in its construction.That quantity is the equivalent of almost 5 million bags of cement. For the task of managing the Spillway works,WGI called on a seasoned veteran, Duffy Walker.Duffy had worked in the 10,000 megawatt Guri Dam,Venezuela's largest dam and the world's second largest in terms of installed capacity;in the 2,900 megawatt Macagua Dam in Venezuela;in the Upper Stillwater Dam in California;and the Winfield Lock and Dam in West Virginia,among others.His primary task was to ensure that the Spillway and Miscellaneous Structures were completed on time and up to the client's stringent specifications. Duffy Walker had a hardworking team of superintendents to back him up.His team consisted of experts from different countries. Bill Dunn,a Scot;Wolfgang Pichler,an Austrian;Alex Tamowicz, an Australian;Paul schedule the task as the weather was unpredictable and could change on you quickly.In order to meet our high standards,there Learmonth,an Englishman; Leonilo Fernandez,a Filipino and Americans like Page Ward,Doug Warmoth and Rick Huston made an interesting mix.Working 2 shifts,24 hours a day,7 days a week,Duffy Walker, his superintendents and a complement of around 800 Filipino personnel finished the spillway in record time to meet the Project's schedule. "The San Roque Spillway wasn't a particularly tough spillway to work on.The 27%slope was a little tricky but manageable.Sometimes,just getting the equipment into the right position for pouring cement could be very difficult.The equipment we had was not exactly what we had hoped to use but we were able to modify it and make it work”says Duffy."Pouring cement during the rainy season did pose some problems.At times,it was difficult to Duffy Walker 131 were instances when we had to scrap the pour due to heavy rains and start all over again when the weather improves”. "We had a schedule to keep and we had to meet high quality contro! standards and that made the job challenging.The whole team had to up to the task.All in all though, Filipinos are very good workers.They had good basic knowledge of the job and are easy to manage. All that they needed was good leadership” adds Duffy Walker. Duffy Walker and his team contributed a lot to the successful completion of the San Roque Dam.The spillway that they have built is a monument to their efforts that will continue to be seen by generations to come. Different types of works were ongoing at different parts of the Spillway at the same time. Concrete pouring and curing would simultaneously be happening in the Ogee, the Concrete Piers and the Training Walls while excavation would be going on in another section. On the spillway chutes,work was being done in sections.Each section would have a foundation plan showing the exact elevations and bearings required.Pouring the concrete foundation was an arduous task.Crane rail supports had to be provided for cranes working ona slope,rebars had to be installed, formworks and water stops had to be in place even before the cement could be poured.After concrete placement,the concrete had to be cured and the forms had to be stripped.This work had to be done section be section from the top of the spillway until the flip bucket was reached. Frank Crouch led the pioneering crew on the Spillway in 1999.Frank and his crew worked very hard to put the Spillway construction in the right footing.In mid-2001, WGI sent over Dutty Walker,a veteran of a number of dam projects in South America and the United States to manage the Spillway construction area.Duffy Walker led a team of over 800 personnel in completing a major part of the Spillway works.He assigned his key Superintendents,Page Ward,Alex Tamowicz and Doug Warmoth to oversee different areas of the Spillway and bring that section of the Project up to speed. The final sections of the spillway's chutes including the flip bucket were finally completed in July 2002.The installation and dry-testing of all the Radial Gates were completed by its manufacturer,ABB Alstom by May 2002.The Stop Logs were installed and tested shortly thereatter. A Test of Character The San Roque Project is more than just a big construction project.It is the product of the combined efforts of all the workers who pooled their energies to 'achieve a common goal.It works and gave timely advice on engineering matters.This accelerated the work as we were able to concentrate on the actual job supervison”,says Nilo. "At one point in is an achievement not only for the expatriate personnel but also for the thousands of Filipinos who have contributed to its success. Everyone who has been involved in the Project has a story to tell,and none more than the Filipino superintendents who interfaced with the expatriate managers and the local personnel.| time,we were 3 months behind schedule. Everyone,from Management to the laborers,pitched in to help us make up the slack. Management provided additional equipment and manpower and gave all- out support for our efforts. The Spillway personnel worked 24 hours a day, every day of the week for Leonilo Fernandez,Nilo Fernandez Spillway Superintendent is one such fellow.Standing less than 5 feet tall,Nilo is not such an imposing physical presence.In fact,it is Nilo's ready smile that is bound to catch your attention.Yet at one point in time,Nilo had more than 500 workers under his supervision in the Spillway.It was a challenging task that Nilo handled with flying colors. As local superintendent,Nilo first worked -for Frank Crouch and later on for Duffy Walker and Page Ward.His main activities were building and designing formworks for use in the Spillway.The work also entailed planning for concrete pours up to three weeks in advance,conducting daily safety meetings and lining up the workers'activities for the day.Nilo had been working for an outside contractor on erosion control in 1999 when he caught Management's eye and was eventually absorbed into the Company's fold. "In the beginning,it was really a struggle for me.When I came in,we were just starting to organize and hire qualified personnel so we had to do a lot of the work ourselves. However,with the assistance of the Engineering Department,everything gradually fell into place.They helped us in the planning and set-up of the formworks,provided us with detailed plans of excavation and construction Left photo shows a downstream view from the cement being poured for the Spillway Piers. 133 a number of months so that we could make up for backlog.Our efforts paid off and we were able to place our final pour in the Spillway by August 2002,which was the original scheduled completion date.”Nilo adds. "Being a superintendent in charge of hundreds of workers is a very challenging role.Training,educating and teaching people is not that easy.I have to be consistent and firm with my decisions as our role in the Project is a very critical one.There were times whenI felt like giving up and quitting my job because of the tremendous pressures involved.I was fortunate to have very supportive colleagues who encouraged me and gave me the strength to carry on.I hung tough and completed the job.This Project has helped me become a stronger leader.I now have the confidence to take on other challenges because I know I have the talent and strength to do so.”Nilo concludes. The San Roque Project is a success because thousands of people worked towards a single objective.It was a test of character that brought out the best in people. Nilo Fernandez's experience in the San Roque Project made him a better supervisor. 'Nilo and the Spillway team helped make the San Roque Project 'and success. Spillway chute.Inset shows gatoaSeenoe) 134 Beharthygatlht Ilway at work2.”)xe]i) - 2Qa.oOESo°ON oSo "3s eaa éifi? aw eee 135 orfeFigiedhea Chanter 9 Overview URING the planning stage of the San Roque Dam,the problem of how to haul millions of cubic meters of materials from the designated haul roads to the embankment areas was given considerable thought.With an annual rainfall of nearly 80 inches annually,hauling the material over haul roads using trucks and regular transport equipment was neither practical nor cost-effective. The practical solution was a system of conveyors from the excavation and borrow areas to a processing and sorting plant and onwards to the final embankment site. Washington Group installed one of the largest conveyor systems ever built for this type of project.The system,which is 10.6 kilometers long and cost $40-million more than doubled the earthmoving production at the site. The conveyors main collector line carries up to 7,200 tons per hour,and terminates at a processing and screening plant.The plant produces all of the main dams filter material, 80 percent of the shell material and all the projects concrete aggregate.Two conveyors, each four kilometers in length,deliver material from the processing and screening plant to the dam. anne SUEDE Extending from the borrow pits to a screening-and-sorting facility,the conveyor's main collector is fed by four intermediary loading stations with crushers.From the screening facility,two conveyors lead to either side of the dam. The Conveyor System was designed specifically for the San Roque Dam.The ditferent components that were used in the system were ordered separately and assembled into a working system on-site by WGI personnel.This resulted in significant cost savings for the Project and demonstrated Washington Group's expertise in heavy civil projects. BF Steel,a Philippine company specializing in steel structural works, fabricated the Loading Stations and the WGIl's specifications.The jaw crushers installed in Conveyor Lines to design the loading stations came from Cedarapids, USA.Alignment-free drives used in the Conveyor system was supplied by Falk and the Conveyor belts were standard sized belts supplied by BF Goodrich. The Conveyor was instrumental in transporting tons of material to the Main Dam. 137 Loading Stations and the Conveyors The process starts at the Loading Stations, huge steel structures where haul truck dump their loads for crushing and transport to the Process Plant.There were four Loading Stations located downstream of the Main Dam.They were centrally located near the river excavation areas to decrease the travel time required for the haul trucks that needed to dump their loads. Loading Stations |to 3 all had crushers with an average capacity of 465 tons per hour and 2 feeders at each station with a capacity of 1,800 tons per hour.Loading Station 4 had a crusher with a capacity of 600 tons per hour. The outputs of the Loading Stations were dropped into a 60-inch conveyor belt with a capacity of 3,450 tons per hour.This conveyor belt brought the material to the Process Plant. The materials were segregated mechanically at the Process Plant,stockpiled by type and material size and sent on demand to the Embankment Areas through the East Conveyor Line and the West Conveyor Line. The East Conveyor Line had a 48-inch wide belt and was capable of transporting 2,400 tons of material per hour.On the other hand, the West Conveyor Line had a 72-inch-wide belt and was capable of transporting 6,000 tons of material per hour. The East and West Conveyor Lines ended up on both ends of the Main Dam,where 400-ton hoppers accepted the material and loaded them unto waiting haul trucks.This process generated enormous savings of fuel and haulage costs and greatly reduced transport time,thereby ensuring that the Main Dam Embankment was completed on schedule. The Johnson Ross Batch Plant (above)supplied the cement needs of the Project.(Below)The Conveyor transports materials to the 400-ton hopper, which loads them into Haul Trucks. :Mawitineeaes'Sa "SY xTayeA3 ,Te esweethNabani”2 Se so lroning out the Kinks Getting the Conveyor system to work as it was designed to took longer than expected. Early in the project,it was decided that the different components of the conveyor system would be specified and purchased separately. Such a move would result in cost savings but would necessitate on-site adjustments by highly experienced personnel to make the system work. During the actual operations of the conveyor system,a number of unique situations came up that needed extra attention.First of all,the conveyor belts kept ripping at transfer stations where sharp-edged rocks must fall nearly 3 meters from one conveyor onto another.In other instances, sharp metal objects were inadvertently picked up during the excavation process and caused damage to conveyor belts,too. Bill Groth The San Roque Project stands out in the engineering and construction industry as one of the largest EPC (engineer,procure and construct) contracts ever.While there may be larger dams and projects,contracts are usually awarded for certain portions or phases of a project and rarely to one single contractor.Thus,the San Roque Project awarded to WGI-affiliate Raytheon is a very unique contract.An office in New York handled the major procurement tasks while local procurement and Contracts Administration functions were carried out through offices on-site.The design phase was done in offices in Bellevue and New York while an on-site engineering team was tasked to implement the designs. Bill Groth is the WGI's Senior Resident Engineer for the San Roque Project.A product of Gonzaga University in Spokane,Washington,Bill visited the San Roque site in December 1998 and came back in February 1999 to work on a full-time basis.A seasoned veteran of other hydroelectric projects,Bill had just come from the Eastside Reservoir Project to the Philippines to take on the challenge of the San Roque Dam. There was a lot of work to be done. Bill and Bob Vine set up and organized the Engineering Department to be responsive to the Projects needs.The on-site Engineering Team had to 139 On-site Engineering Supervision implement the designs coming from the US offices;record on-site data for transmittal to the US;provide construction support in the form of quality control tests,surveys, topographic information and formwork design as well as coordinate design changes and critical construction information.The 12-hour difference between the Philippine and US time zones complicated communications even further.The fact that the US offices worked 5 days in a week as against the 6 working days set for the Philippine office also entailed work adjustments. According to Bill,"This Project was unique in so many ways.Normally,you would have a couple of contractors on a Project of this size,with each contractor working at a particular portion of the Project.In this case, there is only one primary contractor responsible for getting all the work done.There was just a lot of work going on simultaneously in different areas.The Main Dam,the Spillway,the Tunnels were all critical areas that required our simultaneous attention and coordinated action.We had to keep up with ail the construction activities on-site and we really had to be on top of the action every working day.” "What strikes me the most in this Project is the collection of talented people that I have been able to work with.The people we have in here are dedicated,hard-working and dependable.They can work with little supervision and I can count on them to get the job done.There is so much going on all the time and it is impossible to be in all places at one time but I was confident that my people will be able to get it done properly.It would have been impossible to do this job on time if it were not for them.Iam proud of them and they can take pride in having done a world-class job”,Bill concludes. WGI brought in Dave Atteberry and Jack Chiu in 2000 to iron out the kinks and streamline the Conveyor system.They worked on fine-tuning the conveyor control systems, installed magnets in strategic locations,and made key adjustments that increased the systems efficiency and reliability.They went over the conveyor lines meter by meter and made sure that the system worked as designed. The Process Plant The Process Plant was the center of the Conveyor Systems'operations.It received the materials from the different Loading Stations, segregated the materials according to size and type,stockpiled the materials and sent the required materials up to the Main Dam Embankment as required.All of the Dam's filter material and concrete aggregates,as well as 80%of the shell material passed through the Process Plant. The Process Plant was strategically located at a flat area near the Loading Stations.The East and West Conveyor lines converged at the Process Plant and transport material uphill over a distance of about 4 kilometers on each line. 140 Quality Control personnel (above) monitor and check every cement batch.Aggregates (opposite)are segregated into various sizes at the Process Plant. A World Class Safety Record Historically,construction work in dams has been a dangerous task.Giant dams of the past have seen injuries and fatalities in various aspects of the job, Safety Performance of any Project”from the International Society of Mine Safety Professionals.The award was for achieving over Seven Million specially due to the work that had to be done in the confined spaces of tunnels, the time limitations involved in pouring concrete and the sheer volume of earth and material that have to be moved from one point to another. Under the direction of Bill Scott,Project Manager and Marty O'dell,Project Safety Manager,and with the (7,000,000)Labor Hours Without a Lost Time Injury. The Project has recognized and rewarded personnel for achieving significant Project Safety milestones.The most important Safety Milestone achieved by the Project was reaching over Seventeen Million (17,000,000)Labor Hours assistance of the Safety Team,and all craft workers and their Superintendents, the San Roque Project has again qualified for the Washington Group's President's Award for Safety Excellence.As of July 2002,the San Roque Dam has won over seven such President's Awards for Outstanding Safety Performances in the years 2000 and 2001. This prestigious award is awarded by the Washington Group for exemplary safety records and represent the highest honor of its kind in the Company. In addition,the Project has received two awards for 1999 and 2000 for the "Best Marty O'dell with only two lost-time injuries. These records are even more remarkable considering that it was achieved on a project that included thousands of workers and supervisors with different backgrounds in safety practices and philosophies,coming from diverse cultural backgrounds and speaking different languages and dialects. Marty O'dell,Project Safety Manager,is tasked to implement and enforce the Company's Safety Policies,as well as to ensure compliance with a host of guidelines from the Philippine Department of Labor and Employment (DOLE)and Federal OSHA regulations.A seasoned veteran of other dam projects,Marty O'dell was the Safety Manager for the Morrison Knudsen Corporation for the West Dam of the Metropolitan Water Company in California prior to his assignment to this Project. According to Marty,"Developing a Safety Culture is a major challenge.It is important to make line management responsible and accountable for Safety”.Under Marty's supervision,the Project embarked on an aggressive cross-cultural safety program, which has produced outstanding results. Safety Officers conducted a series of training programs,like Confined Space Safety Training and Heavy Equipment Drivers Training,to help develop a Safety Culture on the job site.Marty also trained his Safety Officers to act an perform as professionals to earn the respect of Line Management,and to make the right calls and disallow unsafe work practices. The Presidents'Award for Safety Excellence are a testimony to the safety culture that Marty,the Safety Team and the Project personnel have developed on this Project. The material arriving at the Process Plant would be automatically sorted out by size using a rock screens.Zone 2,3 and 4 materials would be segregated into 3 different piles near each other,ready for dispatch on short notice.Because of the specific moisture requirements,Zone |material had to be kept separately.A storage area was designed and constructed for the purpose of drying out the clay during the rainy seasons.Separate piles for aggregate materials were located at an area near the Batch Plant. Operations in the Process Plant were monitored through a control tower overlooking the material stockpiles.Trained personnel monitored the screening and piling process and responded to requests for materials from the personnel working in the Main Dam. The Loading Stations (below)are massive structures that handle tons of materials daily.The Johnson Ross Batch Plant (right)amply provided the cement needs of the Project.Eee,Ltseusracta2pre _ : Ve fa bE ee a nS,"aU Tra ela ERs* +:Fsatt See ane The Loading Stations (above)employ a series of belts and mechanical controls to send the material to the Process Plant.Huge chains (right) serve as a screen for oversized material in the Loading Station. (Previous overleaf)Photo gives a close view of the Loading Station.Inset shows Cement Mixers lining up at the Batch Plant while Maintenance work continues overhead. _eeeeeie2.eeae ext - .ay et 32 on eeLomtFeeegME5ee+.«ies . ome ntme t WPtraealahatetbatSc,PAMeinMMeala ahdMeeae:8):ns arsqosWikiaeteig, This is how the West Conveyor Line appeared when it was being laid.spinachanThe Conveyor Line transports materials to the Main Dam Embankment. A Hopper in the East Line Conveyor brings materials to another set of belts.vey)seueaeaSw Gauges and meters have to be constantly 'monitored by trainedpersonnel. Chapter 10 The Powerhouse ama the Switchyard Powerhouse and Switchyard ATER enters the system from the Reservoir through the Power Tunnel Intake,a massive concrete structure fitted with steel Trash Racks to prevent the entry of debris that may damage the power generation equipment.The water then passes through the Lower Pressure Power Tunnel until it reaches the Drop Shaft. speed due to the drop and enters the steel- {t then gathers lined Power Tunnel into the Penstock.The Penstock directs the waters into three separate flows through the use of bifurcations.The bifurcations lead to the chambers where the turbines are located. The powerhouse has three vertical Francis hydraulic turbine units supplied by Toshiba. Each turbine has a synchronous generator, and has a net rated output of 115 megawatts (MW).Each unit is capable of independent operation.The main transformers are located at the access level on the downstream side of the powerhouse.Gas-insulated switchgear located in the adjacent switchyard connects the facility to a 230-kilovolt (kV)double circuit transmission line.The Switchyard,consisting of large breakers and towers,is used as the distribution center where electrical power is sent from the plant to the San Manuel Substation through the transmission lines. Toshiba,one of the world's largest manufacturers of turbines and generators supplied the power generating units for the San Roque Project.Included were 3 units of hydraulic turbines,3 units of hydro-generators 147 with excitation system,3 units of isolated phase bus duct and middle-voltage switchgear,3 units of step-up transformers and 1 start-up transformer,as well as the Control System for these hydropower generation units. The water used for generating electricity is from the turbines into tailrace tunnels that flow back into the Agno River. Transmission Lines NPC is responsible for constructing the 230 kV double-circuit transmission lines from the switchyard to the San Manuel substation approximately 9 kilometers away.NPC is required to complete the transmission line no later than 6 months priorto the targeted Unit Completion Date for Unit One in order to facilitate the commencement of the testing process. It is the responsibility of the Washington Group to connect the San Roque Power Station to NPC's transmission system. To accommodate the addition of more than 2,000 megawatts of hydro and coal- fired power plants in Northern Luzon,NPC is building a 500 kV Extra High Voltage transmission backbone stretching from Labrador,Pangasinan through the San Manuel and San Jose substations to the south. This 500 kV transmission backbone will serve to deliver power generated from San Roque, as well as from other power plants in the north, to Metro Manila. The scheduled completion date for the San Roque Multipurpose Project is 31 December 2002,with commercial operation commencing in 2003.Impounding in the Reservoir started in August 2002. Turbine-Generator Unit Toshiba,one of the world's largest manufactures of power generation equipment,supplied the turbines and generators used in the San Roque Project. Toshiba has been involved in the construction of numerous power stations all over the world and therefore has a rich experience in delivering hydro turbines of small,medium and big sizes.Their major target products are Francis and Kaplan turbines of any possible sizes and other types especially for hydro power stations. The Water Turbine used for the San Roque Project is a vertical shaft,Francis type turbine. Each of the turbines for the San Roque Project weighs more that 20 tons and has a rated capacity of 137 megawatts (MW)-225 revolutions per minute (rpm). The Generator units are vertical,semi- umbrella type,150 MVA (megavolt-ampere) generators.It uses air as its cooling medium and the cooling air is driven by the fan action of the rotor.Due to its well-balanced rotor, the upper guide bearing is self-cooled.The general stators weigh 155 tons and the general rotors weigh 267 tons. Even if completely shut down,the turbines can be restarted and energized in a matter of minutes,as no warm up cycle is required.In addition,the water turbine-generators have "black start”capability,which enables them to be the initial source of power following a blackout so that other plants can be restarted. They also can be used to stabilize system voltage and frequency,and as a source of reactive power. Starting Up the Power One of the most critical tasks in the San Roque Project is making sure everything functions as it was designed to work. Considerable time and effort is devoted to make sure that all the works are up to specifications and meet the Projects'needs. The process of ensuring that the San Roque Multipurpose Project is properly handed over to the owners and operators of the project is a precise and very demanding task.The power plant's operating and maintenance personnel must be trained;Project Turnover Documentation must be acquired,reviewed, approved and transmitted to SRPC;and all the completed works must be properly commissioned.For the San Roque Project, these responsibilities are in the purview of the Start-up Manager's duties and responsibilities. 148 WGI called on industry-veteran Scott Kos for the job.With over 31 years of experience in power generation,Scott is a valuable asse to the San Roque Project.His experience includes startup and commissioning of coal- fired,oil-fired,gas-fired and hydropower plants.The power projects he has worked on range from 60-megawaitt plants to 2600- megawatt plants.He was the Startup and Training Coordinator for the 1200MW Combined Cycle Ilijan Project in the Philippines.He also performed Startup work for the AES Warrior Run Project in Maryland, for the Spartan Steel Project in Michigan,and the Lal Pir Power Project in Pakistan,among others.In addition,he has several years of experience in the training of power plant operations and maintenance personnel such as the Maraven IPP Project in Venezuela. The very nature of design-build projects means that Scott and his team has to continually be able to cope with the engineering changes emanating from the Engineering Team in New York.At times,they The Powerhouse Box uses huge cranes. have been called to implement changes in a system just as they have finished training on the previous revision."The way we overcame this issue was with a diligent,efficient staff, who followed up on these issues as soon as they arose.If it weren't for the experience of the people that we have working for us,we would have a much harder task.In addition, we had difficulty acquiring parts for systems because the equipment has been purchased from different parts of the world.We stayed up late and came to work early just so we could communicate with the vendors and discuss our needs and schedule requirements.It called for dedicated people and a lot of extra time to coordinate/resolve these issues”says Scott. According to Scott,"Communications is one unique challenge in this Project.It is a full time job to stay in touch with all the various disciplines like engineering,civil,electro/ mechanical,as well my own start-up personnel.Everyone needs to stay in step in order to accomplish a given task on time. There are always multiple activities going on that need continual attention and clear communications.” "It is very rewarding for me to see my staff succeed in Project completion requirements. Every day,the startup and commissioning staff encounter various challenges and opportunities.And every day,they come back and meet these challenges and opportunities and persevere with complete confidence. They are the reason for this Project coming to completion.I am personally very proud of each and every one of the people that came forward to meet the challenges and opportunities with a positive attitude and a desire to succeed”he concludes. 149 Governors and Excitation Equipment The hydraulic turbine governor is the equipment used for controlling the guide vanes.It detects turbine speed and regulates the guide vane opening in order to keep the turbine stable and regulate its output. Accordingly,the controllability of the power station and the quality of an electric power depends on the performance of the governor. In order to expect high reliability,high system function and easy maintenance,static excitation equipment are adopted to most of hydro generators.Synchronous generators like the one supplied for the San Roque Project require such an excitation system.Toshiba manufactured and supplied the excitation equipment for use in the San Roque Project. There are also 3 sets of Isolated Phase Bus ducts (IPB).The IPBs feed the transformer with the power coming from the generators. There are also 3 sets of 166 MVA Main Transformers and one set of 5.5 MVA Auxiliary Transformers.The 16 MVA Transformers have a rated capacity of 13.8kV/230kV and are oil-immersed,forced-air-cooled transformers. They weigh 132 tons each and have an oil volume of 34,000 liters.The auxiliary transformer,on the other hand,weighs 46 tons and has an oil volume of 19,600 liters. Supervisory and Control Equipment Recent advances in technology have resulted in the development of digital equipment based on microprocessors and made them economically feasible for applications in the field of hydropower generation.For the San Roque Project, Toshiba supplied the state-of-the-art PC architect control system.The optical fiber link connects the Control Room to the Intake Gate and the Spillway Gate Control Room. Breakers dwarf the workmen assigned to install them. nol Yr oCay)eea The supervisory and control equipment is installed in the Control Room of the{omcy Powerhouse.The Control Room also provides overall monitoring of the operations of the hydroelectric power station.Aside from theannnentetl central controls,there are local automatic fsFI S¥controls that provide automatic sequence and 7Amonitoring of each generating unit and auxiliary equipment on an individual level.WA¢eueeneedeanhteyHow Power is Generatedyp The water in the Reservoir is considered aaanesaacnneVUVEreserarstored energy.When the gates are open,the water flowing through the power tunnel becomes kinetic energy because it is in motion.The amount of electricity that is generated is determined by several factors. Two of those factors are the volume of water flow and the amount of hydraulic head.The head refers to the distance between the water surface and the turbines.As the head and flow increase,so does the electricity generated.The head is usually dependent upon the amount of water in the Resérvoir. The water falling through the Drop Shaft gathers momentum and energy.It then reaches the steel-lined power tunnel where the decreased diameter of the tunnel and the penstocks concentrate water into a smaller area with higher pressure.This leads to the Spiral Casing of the Water Turbine.The force of this water pushes against the turbine's blades and causes the turbine to spin.The spinning turbine converts the kinetic energy of the water into mechanical energy.The most common type of turbine for hydropower plants is the Francis Turbine,which looks like a big disc with curved blades.This is the type of turbine used for the San Roque Project. Fated)Ty en am cat pen The Governor System controls the volume of water let into the Water Turbine to maintain a constant rotating speed of 225 revolutions per minute,which is equivalent to 50 hertz (Hz).The generator is connected to the turbine by a shaft so that when the turbine spins it also turns a part of the generator called the excitor.The Excitor sends an electrical current to the rotor.The Rotor is a series of large electromagnets that spins inside a tightly- wound coil of copper wire,called the stator. The large electromagnets (rotors)rotate past the copper coils (stators),producing alternating current (AC)by moving electrons. This converts the mechanical energy from the turbine into electric energy. The Generator produces electric power at a voltage of 13.8 kilovolts (Kv).This electric power is fed to the Transformer through the Isolated Phase Bus Ducts.The transformers convert the voltage from 13.8 Kv to 23 Kv. The higher voltage current is then sent to the Switchyard. The Switchyard uses large transformers to convert the generator's voltage (which is at the thousands of volts level}up to extremely high voltages for long-distance transmission on the transmission grid.The Switchyard also has "buses”that can split the distribution power off into multiple directions.It also has circuit breakers and switches that can be used to disconnect from the transmission grid as required. The used water is carried through pipelines,called tailraces,and re-enters the river downstream.Since the water is only used to produce electricity,the quality of the water discharged through the Tailrace Tunnels is the same as what is was when it entered the Power Tunnel. The Switchyard Elements,Circuit Breakers and Transformers are seen in various stages of installation. be NTS DN:<a SNeae amy assyPEA f a o>"7,aaSGralaawaaaali Acrane is set against the background of the Switchyard. 153 Building the Powerhouse The powerhouse box was cut to a depth of 77 meters by blasting and excavating.Rod extensometers from Slope Indicators,USA were used to monitor movements of the rock wall during the excavating process.The rod extensometers detected only acceptable movement during the excavation works and provided assurance that the walls were stable. This allowed the excavation to proceed more rapidly,since no additional rock anchors were required, Powerhouse excavation started in the year 2000 under the direction of Greg Casten. More than 2 million cubic meters of material was excavated from the Powerhouse area.The material excavated was used in the Dam Embankment.All the excavation works were completed by October 2000. The Powerhouse structure is 6 levels deep below the ground level and used up more than 35,000 cubic meters of concrete.Exact concrete forms were required for areas around the Turbines and the Generators,as well as in the Tailrace Tunnels. The turbines and the generators were delivered in March 2001.Prior to its delivery, work on the Draft Tubes had started on December 2000.Installation and assembly of the units were done on site,as a lot of structural works had to be performed in synchronicity with the equipment themselves. Electrical and mechanical controls were required throughout the Powerhouse and the installation works are scheduled for completion by September 2002. The Mechanical Completion and Functional Tests are being performed on various areas and equipment as they become available and the Commissioning and Reliability Tests should be finished in time for the guaranteed Delivery Date of December 31,2002. Work proceeds on the Powerhouse Shaft in July 1999. Two views of Powerhouse works progress:(from right) in November 2000 and February 2001. 154 feRexe6Photo shows in May 2000. Ww ss me the Povwerhouse Shaft 155 f i Se eet uw Heavy equipment work on the Powerhouse Shaft in July 2000. Se,PTET etaanazee MostPM6cage (Opposite,from far left)The Powerhouse works proceeded rapidly in September 2001 to November 2001.An aerial view shows both the Powerhouse and Switchyard in July 2002 (below). |ralMoe*eo Expertise in Hydropower Projects The San Roque Project is expected to provide the benefits of power,irrigation,flood control and improved water quality to the residents of Northern Luzon plants for 22 years.His experience covers all facets of hydropower plants;from planning, design,construction,installation,operations and maintenance.He has for generations to come. The San Roque Power Corporation is determined to operate the project as a world-class facility and deliver on its commitments. To this end,SRPC has strived to entail the services of the best people in the industry.From the main EPC contractor to the various project consultants to the powerhouse operators,SRPC has given premium to proven performance and experience. The Operations and Maintenance Team of SRPC Is a perfect example of this policy. Headed by Bill Connell,the team boasts of a highly qualified team of hydropower industry professionals.Each of the team members was chosen for his knowledge,experience and ability to work as a member of the team. As head of the Operations and Maintenance Team,Bill Connell has a major role to play in the operations of the San Roque Project.Aside from operating the facility for the next 25 years,he Is also responsible for the training of the Powerhouse operators on the varlous operating systems of the facility.He also has to monitor and oversee the Start-up and Commissioning phases of the Powerhouse.In addition,he has to make sure that the facility meets the design specifications and requirements set for the job. Bill brings Impressive credentials to the Project.He has been involved In hydropower Bil Connell worked on hydropower projects in North America, South America and Asia. Prior to the San Roque Project,he was working on a hydropower project in Nepal. "There are a number of challenges ahead of us.The testing and commissioning process is a major activity that needs attention to detail and a thorough understanding of the facility's operating systems.The training of the Operations and Maintenance team is another crucial activity.Our Plant Operators have to be fully trained in all aspects of powerhouse and spillway operations In order to assure trouble-free plant operations”says Bill, "It Is our responsibility to operate the facility within the budgets set forth by the company.We also have to comply with the various regulatory,environmental,legal and safety requirements applicable to us.There are a lot of expectations from this Project and It ls our duty to meet those expectations”Bill concludes. The San Roque Power Corporation Is committed to build and operate a world-class facility.Bill Connell has accepted the challenge of leading the Operations and Management Team in achieving the corporate commitment.With his expertise and the help of his experienced crew,Bill is confident of living up to the challenge. 158 a nee boa,Yh "PANN i.nis \eas eo oe 4 BORE Teck SON ch aNauladPadWORNwin'A a oe oe ERE Cs 'ee oe RAR wen 'Fae WEA NI AVN,ANE Above photo shows an overview of the Spillway and the Switchyard.Building the Switchyard sometimes involves working at great heights (right). é =A TaeSaal= (This page,top to bottom)The Turbine Frame is shown in various stages of assembly in July 2001. (This page,top to bottom)ABB Alstom personnel installing the circuit breakers,IPB's and Transformers in the Switchyard. STUNT SINwer ge ¥ automcAUSION yam:AUTION CAUTEC 1 2<e Y Caterina (This page,top and middle)The Runner and the Shaft are made ready for installation.Bottom photo shows the Toshiba Runner as it leaves the production line.iaealinersee2waved Bo ERNE A wins'.mre Wil.oe ye eh EE OY ]id \a iy is a8 'a3Be:ve abla A}u ;Toye cau Pe:;WAa 162 (This page,top to bottom)The Upper Bracket is set into place.Toshiba personnel work on the Rotor and the Stator.Workmen are shown inside the Stator Coil Assembly. ST TT EION GFITS 163 es".Installing the Trash Racks-_--required the coordinationof aoonumberofworkteams.#+:..©02?» se Chapter 11 Local personnel provided on-site maintenance to all the Project equipment. Project Support HE San Roque Project is more than just an engineering accomplishment.It is the combined efforts of thousands of people working towards a common goal.The Project had to be ably backed by teams providing critical support in many different areas.Their involvement helped keep the Project on track and on schedule. Equipment Maintenance By the middle of the year 2000,the San Roque Project had more than $100 million worth of equipment on site.Crews were working round the clock in various locations of the Project.There were more than 1,000 different pieces of equipment being used, from water pumps and generators,to trucks and bulldozers.With a fast-track schedule that had to be kept,equipment availability was a major concern. To meet the demands of the Project,an equipment maintenance yard was constructed in the area.The Maintenance Yard was designed to conduct planned maintenance and provide repair services to the Project's equipment.More than 100 maintenance personnel provided services 24 hours a day, 7 days a week,all the days of the year. Adjacent to the yard,a 500,000-gallon diesel fuel storage facility was constructed to meet the fuel needs of the hundreds of vehicles and equipment deployed in the Project. In addition,there were more than a dozen Mechanics'Trucks,Lube Trucks and Fuel Trucks that provided services to the equipment in the field.Maintenance crew could conduct on-site repairs and get the equipment back into operation within a small period of time. There were welders performing patchwork on damaged bulldozers and excavators, mechanics performing emergency repairs and tire trucks providing on-the-spot tire tune-ups. There were also Satety Inspection Teams going around the site to monitor equipment and conduct necessary tests on them. 165 Aerial view (above)shows the Operators Village which houses the managerial staff of WGI and SRPC.Teaching Aides (below)provide personalized supervision to the School's students.aengamenrteeeDon Johnson came to the San Roque Project in 1998 and set up the Equipment Maintenance Department.He started off with a handful of mechanics that he trained to meet the demands of the Project.As the workload increased,more personnel were required to handle the job.The equipment maintenance staff reached more than 150 people at its peck.They achieved high levels of equipment availability that resulted in increased productivity from the operators in the field. Camp Services The Projects'remote site created transport problems for it's personnel.The nearest city center is almost an hour's drive away and housing the supervisory and management personnel off-site would mean valuable time lost to shuttling back and forth to the Project Site. The practical solution was to provide housing facilities for key personne!on-site. The Operators Village was created for this purpose.Resembling a small city,the Village has more than a hundred rooms to accommodate the expatriate personnel of Washington Group.Aside from the dining facilities,the Village had its own commissary, cable TV system,recreation facilities,a full- service laundry and even a school. Built on top of a hill in the edge of San Roque,the Operators Village had to be built from scratch.A full 22-megawatt power plant provided power to the Village and the company's offices.Water from the Agno River had to be pumped into a reservoir and processed through a Reverse Osmosis system to provide potable water for the residents. Sewer systems and a Sewage Treatment Plant had to be provided to handle the waste material generated in the Village. Calling the shots in the Operators Village is Lothar Vogt.Lothar and his crew of over 100 personnel catered to the needs of the Village residents and other company personnel.On a daily basis,almost a thousand meals had to be prepared,around 350 kilos of laundry had to be processed, and about 20,000 gallons of water had to be filtered to meet the needs of the personnel using the Operators Village. Administrative Support At its peak,the San Roque Dam had more than 5,000 personnel working on the Project. The fixed assets on site easily amounted to hundreds of millions of dollars.It represented i :;we cae | 'NO STANDBY:|SUSE SIT GOWN a major investment on the part of Washington Group.Keeping the Project organized and in control proved to be a major administrative task. Mike Gavin came in 1998 to manage the Administrative Group for Washington Group International.It's scope eventually included the Procurements and Contracts Department;the Central Warehouse;the Personnel Department;Camp Management and the Site School;the Security Department as well as the Accounting Department. The Procurement and Contracts Department managed and processed all the various procurement tasks for WGI.They also managed the various subcontracts that were required for the Project.John Hogarth started off the Procurement section in 1998 with a small team of buyers who are familiar with the Philippine market.As the Project picked up,more personnel were hired.Jay Fisher came in 2000 as the workload from contracts administration got heavier and more hands were needed.At its peak,this Department had more than 20 staff under its wing. The Project is ably supported by qualified engineers (top to bottom,this page). Critical Administrative support It is June 1998.The San Roque Project is mobilizing at a frantic pace.Expatriate superintendents have to be brought in from the United States.Work visas,travel arrangements and employment contracts have to be worked out.On site,there are a number of important permits and licenses that have to be secured to enable the work to move on.There are critical equipment requiring Import Licenses and Tax Declarations before they can be released from the ports.Local contractors have to be screened and Management,Personnel,and the operation of the Operators'Village. "There's a whole lot of work involved in getting that guy out there working on the job,and we have to make sure they get all the support they need”, says Mike,"It may not be as physically challenging as working out there in the field but nevertheless,it is a big challenge.” 'This Project has a guaranteed completion date. Everything revolves around making that deadline.In order topre-qualified to perform key Mike GavinservicesfortheCompany. In addition,the Management Information System has to be set up to be able to report critical financial information to the US offices of Raytheon Engineers and Contractors.A hundred things are happening all at the same time. Fast forward to June 2002.Some phases of the work have started to wind down.The Project is entering the demobilization phase. Arrangements have to be made for the repatriation of US-based personnel.A lot of loose ends have to be tied up.More than 1,500 pieces of vehicles and equipment need to be disposed off.All financial records have to be updated in preparation for closure. Hundreds of loose ends have to be tied up before the Project's completion. In the eye of the storm sits the Project Business Manager,Mike Gavin.A veteran of RE&C's projects in Saudi Arabia,China and the Dominican Republic,Mike has to wear quite a few hats and juggle the various responsibilities under him.Aside from the Accounting Department,he manages Payroll, Security,Equipment Accounting, .Warehousing,Procurement and Supply Chain accomplish that objective, all the field-operating units must get the support they need to get their jobs done.There should be no disruptions that will preclude the work for getting done on time.We have worked through difficult times.We have gone through things like an ownership change,changes in the financial reporting systems,the tragedy of 9/11,labor interruptions and even natural calamities.We still got the job done on time” adds Mike. "This Project would not have been possible without the superb group of people that we have.The Filipinos on this Project were highly qualified and really made it easier to get things done.They delivered results and really made things happen.While there may have been cultural differences that required adjustments in our management style,it was also a learning experience for us.”Mike concludes. Mike Gavin and the Administrative Group played a major role in the success of the San Roque Project.Their efforts made it easier for everyone else do their part of the job.Mike and his team helped make this a world-class project. 4 i The Commissary (above)serves t Village.The Laundry Section (belc Machines to handle the Operator: -=sexeealSardlkOdaMoees| ds of the residents of the Operators' »s three heavy-duty Maxiwash Laundry :volume of washing. 169 The Central Warehouse was housed in a fabricated steel structure adjacent to the Maintenance Yard.Jim Ryan operated the facility.Jim and his staff received and distributed millions of dollars of tools,supplies and other sundry items to the various operating Departments.Aside from the Central Warehouse,there were a number of other remote warehouses on the site that stored various stock items and disbursed them to the requisitioning units. The Site School was opened in the year 2000 and offered free grade school education to children of the Operators Village residents.The school teacher,Guy Stieglitz was asked to come in the same year.He set up the initial facilities and moved the students to the new school building after it was built. The school offered online education from the Calvert School System and the progress of each student was monitored and augmented by the Guy and his staff. Personnel Administration was another critical function of the Administrative Group. More than 4,000 personnel were subcontracted from a labor subcontractor, Asia Konstruct.They constituted the bulk of laborers,equipment operators and construction personnel on site.The rest of the key personnel were hired directly by Washington Group.Gene Arrington managed the department in the early years of the Project.Josh Gerard arrived in the year 2000 and assumed the role of Human Resources Manager atter Gene's departure. On-site security has always been a major concern of the Project.The enormous coverage area,the thousands of people moving in and out of the site daily,the presence of a sizable expatriate population and the millions of dollars of fixed assets used in the premises,created a need for a reasonably large Security Team.Ben Lichtenberg was tasked to manage this team. The combination of a strong security force and good community relations resulted in a relatively peaceful work environment that helped the Project achieve on-time completion. Mike Gavin and the Administration Group meet regularly.(Opposite)The teacher,Guy Steiglitz,with his students. Completing the Administrative Support Group were Ruth Abad-Ricarte,REOL's Chief Accountant and David Dodd,WGIl's Equipment Accounting Manager.Ruth and Dave's teams worked to ensure the correctness,accuracy and conformity of the financial records to corporate and government standards.This was an equally critical task as it ensured that there was no disruption in the flow of materials and labor to complete the Project. :<:AE ae et Peete Cal Be eae Fo ER a RR ag a Ee an awhile TRG RSE Sade oe cei we ae ER SCE 170 Par Far are et = F ae,=WESTOP HC HAT"ane SOE PreeebitiesSeeman RSS Running a small City When the Washington Group first arrived on the site of the San Roque Multipurpose Project in 1998,there was lot of work to be done before construction could really get underway.The nearest city center was around 40 kilometers away and without on-site the isolated site,a swimming pool,tennis and basketball courts,a mini-gym,a mini-bar and a small golf course were also built. The area also needed power,potable water,food preparation areas and water treatment facilities.So,a small diesel generator accommodations,a lot of valuable time and money would be spent just transporting personnel to and from the Project.It was more practical to build a small "city”to accommodate management personnel. The Operators Village, as the management- housing facilities is called, includes a full-service building with a 22- megawatt capacity,a water purification system to filter and treat river water,anda sewage-treatment plant for the residents of the Operators Village,was built.A full Cafeteria was also constructed to provide meals for the Village residents. To run the Operators Village,the Washington dining area for the staff,an employee mess hall, laundry facilities,a commissary,full-time housing for around 150 residents,a small school for grade-schoo! children of expatriate personnel and a Guest House for site visitors.For off-duty activities at Lothar Vog Group called on Lothar Vogt.Having managed similar camps in Indonesia, Papua New Guinea,Malaysia and the Philippines,Lothar is uniquely suited for the job."Our goal is to provide a worry-free living environment that would enable to personnel to concentrate on their jobs.We take care of all the residents'basic necessities,from their meals,to cleaning their rooms,and taking care of their laundry as well”says Lothar."It can be quiet a challenge to find all the things that you need.Some items that are basic necessities back in the United States are | considered luxuries in here.”he adds. Hiring and training people also proved to be a challenge.There were limited positions available and too many applicants who did not have the right experience for the job."We were able to provide valuable skills training to members of the local community.The training and experience that they have gained from working in the Cafeteria and the Housekeeping Section are skills that they can bring with them to other jobs in the hospitality and food service industry”,according to Lothar. The Operators Village provided critical support services to the personnel working on the San Roque Project.Lothar and his crew helped make the employees more productive and boosted their morale. sempreofReeRRRmnepENOFOUNheRAIeeeeeeeageBill Scott and Jack Owens (above)preside over the daily Management meetings.Scott (below)is always on hand to discuss the Project with the Area Managers and the Board of Consultants.(Opposite)The Cafeteria provides for the needs of the Operators Village Personnel. a SeteceOSes_Fite er i = oy ei Ue Lnitsla'3 dtc Oeons, ae ie A '20 2019 oe Pe cme rnetirinen7aaeMULT IPUnse ne p.1 LASTLOADONDAMMAY25,2002 Field maintenance crews (opposite) provide critical support to heavy equipment.The Board of Consultants (above)visits the Project on a regular basis to monitor progress and resolve technical issues.The Swimming Pool is constructed (right). +Dopereperinaemarsoioe*ae - ",a a :.rr esMiibet0at(ener oar re on .ae oa at canefmtaatelyBeyinetpatieseoesRie", :os wi San ME ET Rn aeoner satel oH cana at Mu, Chapter 12 Heavy Equipment project with the scope and magnitudeAoftheSanRoqueDamrequirestheuseofworld-class equipment that could get the job done.At one point in time, the Project kept a $4-million parts inventory, including 3,000 tires,for $100 million worth of equipment.There were eight 150-ton bottom dumps,twenty-nine 100-ton rear dumps,forty 40-ton articulated rear dumps, 25 crawler dozers,15 crawler excavators,1] smooth-drum vibratory compactors,three tamping-foot compactors and more than 150 pick-up trucks.Aside from these equipment, there were a variety of cranes,drillers and specialized mining equipment that were deployed in the Project. The variety of works that had to be performed and the terrain where they were deployed in necessitated the use of specialized equipment from the most famous names in the market.Caterpillar tractors, Volvo dumpsters,Tamrock drillers,Atlas Copco mining equipment,Manitowoc cranes and Hitachi excavators all had a role to play in the Project. Track-Type Tractors The Project hosted a wide range of track- type tractors such as the Caterpillar DSM to the Caterpillar DIOR.The medium size dozers were used in finishing,grading and spreading of various types of materials.The larger dozers starting from D8R to D10R were used primarily in the excavation and in the rock quarry.They are the workhorses in the Borrow pit area,in Dave's mountain rock quarry,and in River Training excavation. Motor Graders Caterpillar 16H models were the primary road maintenance machines.They are also complemented by smaller models such as the 12H and 140H models.The 16H having has a 16-foot blade that is best suited to the wide haul roads where the 100-ton CAT 777Ds are running day and night.The Caterpillar Motor Graders provide a smooth riding surface for the big trucks so they can cycle fast and haul more materials.Well- maintained haul roads provide for better fuel economy,lesser shock loads on the truck frames and suspension and results in lower maintenance cost. Soil Compactors There were two types of soil compactors utilized in the Project.They are the Sheepfoot soil compactors and the vibratory soil compactors.The 825G models of Sheepfoot compactors were primarily used in compacting clay and clayish material and provided a kneading effect on the compacted material.The CS583C and the CS583D are high-speed compacting machines providing 60,000 Ibs of centrifugal force,more than enough to get the designed compacted density.They provide the best match in providing compaction requirements for dam construction. Jerry Scott and his crew assemble the first Caterpillar 777D unit for the Project and promptly load the vehicle. 177 Wheel Loaders The project also utilized a wide range of wheel loaders that came in different sizes, starting from Caterpillar IT28G,950F 966F, 980G,988F to the CAT 992G models.The smaller models were seen in the processing area doing a variety of tasks such as miscellaneous loading,carrying and truck loading.Others are used in loading the CAT D400E articulated trucks. The CAT 992G which is the biggest model used in the Project is equipped with a 11.5 cubic meter bucket that matched with the CAT 777D Off-Highway trucks.The 992Gs are utilized in the excavation and rock quarry applications.They were the primary loading equipment in the borrow pit area,in the Dave's mountain,and in the River Training area. In addition to the Caterpillar wheel loaders,there were also a number of Volvo L120C Loaders that were used in conjunction with the Volvo A35 and A40 haulers. an,'. i aN3 eS Workers (opposite)build the Equipment Maintenance Yard and the Warehouse structure.(Below)Grouting is done at the Dam's core. Waa tae:NPM Poa agenaUnin He nme Seanveee,ry eed S Caterpillar 777D 100-ton Truck The CAT 777Ds are the main hauling units utilized in the Project.They carry all types of materials for dam embankment.These trucks are equipped with 7-speed electronically controlled automatic transmission that has a speed-sensing device that automatically shifts transmission between the 1%gear and the gear selected by the operator.They are also equipped with Truck Payload Management System (TPMS)which has an on-board microprocessor to determine payload weight,cycle segment times,delay times,actual clock time and date of each cycle.Its electronically controlled engine results in better fuel efficiency and lesser emissions.lt complies with US Environmental Protection Agency (EPA)and California Air Regulatory Board (CARB)standards on emissions. The Project engineers have determined that the optimum hauling load is 100 tons per load and have chosen the Caterpillar 777D as the Project's truck of choice.With a 100-ton capacity,the 777D is the perfect fit for the quantity of materials that had to be transported.With gross power at 1,000 horsepower,a height of 16 feet and a wheelbase of 15 feet,the 777D is visually and technologically impressive machine that was well suited for the Project. Caterpillar 776D with 150-ton Mega Trailer These 150-ton Mega Trailers utilize the tractor of the 777D and therefore have the same 1000 gross horsepower available to pull its 150-ton trailer.As such,they were an imposing sight that immediately conveyed the enormity of the task assigned to them. The CAT 776Ds are designed to work in flat and slight grades.These machines are very instrumental in hauling processed materials from the 400-ton hopper bin up to the Main Dam.They would be positioned under the 400-ton hopper and be loaded with materials that were transported on the conveyors.This resulted in faster loading,dumping and turn- around times.They were also used in borrow pit and river training. Curly Escudero (opposite)inspects the equipment before they are dispatched. The Manitowoc Crane (below)is readied for its tasks. tata be"eS aeeaps 181 Caterpillar D400E Series II Articulated Truck The Project also had 23 units of D4Q0Es complimenting the fleet of 29 units of the 777D trucks.The CAT D4Q0Es operate in extreme applications -hauling different types of materials in varying road conditions and extreme grades.These trucks have 6-wheel drive capability and have wider tires suited to the terrain.They can maneuver in tight roads, climb steep slopes and run on wet and muddy roads,too.These trucks are also equipped with Caterpillars'electronically equipped engines and transmissions which made them easy for the operators to handle. Backhoe Loaders These very versatile machines were seen in the site equipped with a loader in front and a backhoe in the rear.They performed different tasks and acted as support machines in the Loading Stations.They dug ditches and trenches,laid pipes,and carried dirt from one area to another.Various models such as the Caterpillar 416B,426C and 436C were used in the Project. Mining Trucks The Project also hosted a large fleet of specialized mining equipment.Atlas Copco Wagner Inc.supplied what was probably the largest single fleet of their mining equipment in the Philippines to the San Roque Project. Every one of their underground rock excavation and transport solutions 'is engineered to maximize productivity and decrease operating costs to achieve the lowest cost per ton. The Project used the ST7.5Z,the ST 3.5Z and the ST-2D models.The Atlas Copco Wagner ST-3.5 Scooptram has been sold to mines and contractors all over the world since its introduction back in 1976.The ST-3.5 has the reputation as being one of the best and most reliable muckers ever introduced to the mining industry.The ST-2D is one of Wagner's more popular models.It has a bucket payload capacity of 3.6 tons and a maximum volume of approximately 2 cubic meters.Together, these specialized mining trucks proved their worth with a high level of equipment availability and their capacity to handle the demands of the job. Wagner's MT-436B Underground Hauler was also used extensively in the tunneling phase of the Project.These four-wheel drive, articulated underground trucks are used in applications with restricted heights.Measuring slightly over 3.3 meters long and 2.68 meters in height to top of operator canopy,the MT- 436B can dump its full payload in 14 seconds. The operator is side-seated for best bi- directional operation and visibility.These helped outstanding progress in the time frame given haulers the miners achieve to them. Surtace Drillers The surface excavation process is formed by a series of consecutive sub-processes including drilling,blasting,loading, secondary breaking,hauling,crushing and stockpiling.The San Roque Project used the Tamrock Ranger 600 Rock Drills,the Tamrock Maximatic 315-120 and the Tamrock H105D Mono.In addition,a number of Ingersoll- Rand ECM350 Track Drills and DM45E Drillcrawlers were also used. The surface rock excavation process is typically applied in rock quarrying for aggregates or for raw material in the field of civil engineering such as dam and road construction.The Tamrock and Ingersoll-Rand surtace drilling units are all fully hydraulic, independent units fitted with hydraulic top hammer rock drill and on-board flushing air compressor.The units used in the San Roque Project were fitted with cabin and mechanized drill rod cassettes ensuring operator comfort and high utilization rate.The units allowed for hole aligning,hole dip direction,hole length and hole bottom level settings for ease of use. The variety of surtace drilling units was used extensively in the tunnel areas as well as in the excavation areas.They also played a major part in the drilling and blasting works that had to be performed in major areas of the Dam. Cedarapids Jaw Crushers The Cedarapids Jaw Crushers are one of the less visible but very important pieces of heavy equipment used in the San Roque Project. They were installed in the Loading Stations and were used to break down the excavated aggregates to the desired size for use in the Main Dam embankment and in other work areas.Cedarapid Jaw Crushers set the industry standard for heavy-duty construction and low cost-per-ton crushing.Their highly versatile jaw crushers offer reliable operation and adaptability for all types of feed materials. One Caterpillar 777D can haul 100 tons of material with every load. (Inset)Curly Escudero readies his crew and equipment. 182 20-2018. ete:PCSiisee Csege ctseete«areata'atta! Among the salient features of the jaw crushers used in the Project are its submerged heavy- duty base frame,the self-aligning roller bearings,its large diameter,drop-forged chrome-nickel pitman shaft and large flywheels that ensure that inertia is maintained to crush even the hardest materials.The units deployed in the Project were used for various types of materials such as hard rock,sand and gravel.They proved to be very reliable and uniquely suited for the job. Cranes Work at the San Roque Project required the movement of heavy pieces of equipment and materials.Turbines and generators had to be lowered into the Powerhouse area, Radial gates had to be set in place in the Spillway and Trash racks had to be lifted into position in the Power Tunnel intake.In addition,heavy equipment such as graders, concrete mixers and generators sometimes had to be deployed in areas where transport over the regular road network was not possible. The Project hosted quite an assortment of cranes to fit a variety of loads.Grove cranes of 15-ton to 60-ton capacities were supplemented with Tadano 35-ton,50-ton and 60-ton capacity cranes for use in the excavation,process and spillway areas. For major lifting tasks,the Kobelco 100- ton crane was used in tandem with the Manitowoc 150-ton and 230-ton cranes.The Manitowoc cranes were used for setting the Trash Racks and the various Power Tunnel gates in place.The Manitowoc cranes were used in setting the Diversion Tunnel Plugs. CAT trucks are assembled. Jeff Dawson supervises workmen using Volvos to perform hauling tasks. es: A Hitachi EX1800 loads a Caterpillar 777D. 185 In addition,there are a number of gantry cranes and bridge cranes in the Powerhouse and in the Spillway area that serve as support equipment for maintenance and servicing tasks that may be required in the future. Excavators The huge volume of material that were to be excavated in the Embankment and the River Training areas required the use of excavators with huge capacities.However,the size of the excavators had to match the match the capacity of the haulers to be used.Using the wrong size of excavators would result in less than optimal loads that could result in damage due to overloading and dropped loads. In the San Roque Project,Volvo EC240LC and EC120LC excavators were used along with an assortment of Hitachi excavators.The Volvo EC240LC's had buckets that could accommodate almost a ton of material per load.Using the units in tandem with the Volvo A35 35-ton and A40 40-ton haulers resulted in a smooth and trouble-free workflow. The Hitachi excavators were called on to perform heavier excavating tasks.There were 3 Hitachi EX1800-3 units deployed in the Project,the only such fleet deployed in the Philippines.With an individual bucket capacity of 10.5 cubic meters,these units could move a lot of materials in a short period of time.These huge units were supplemented by a number of EX800H-5's and EX300-3's. The huge capacities of these excavators resulted in faster loading times and consequently,in better cycle times. Concreting Equipment The huge amount of concrete utilized for the San Roque Project required the use of a variety of specialized heavy equipment. Johnson-Ross supplied the concrete batching plant that was set up to meet the needs of the Project.There was an ice plant adjacent to the batch plant that manufactured ice for the batch plants'needs. A fleet of around 30 assorted Hyundai, Volvo,Kenworth and Maxon Transit Mixers provided critical support for transporting and preparing cement mixes for use in various areas of the Project. At the Spillway,a pair of 52-meter long Schwing pump trucks,a Putzmeister concrete pump and assorted concrete finishing equipment were used to ensure that the concrete was properly set in place. The Spillway also used Gomaco concreting equipment extensively.They were used for the concreting operations on the Spillways and flip buckets.In fact,a training platform was set up in the site to train workers on the use of these concreting equipment. For grouting tasks,a wide assortment of grout plants,mixer plants,grout pumps and holding tanks were used.Likewise,the Shotcrete used for the embankment and tunnel areas required the use of specialized Shotcrete pumps and tanks.All these specialized equipment ensured that the grouting process met the Project's high quality control standards., pi7o;pe aet Gg 4ENDOcalSRE Excavation Work (above)proceeds at the Spillway Area.(Below)Heavy Equipment are prepared for deployment at the Spillway Area.The 400-ton Hopper stands at the ready nearby. Providing Critical Equipment Support _+»The San Roque Project is certainly ranksasoneofthebiggestdeploymentsofheavy equipment that the Philippines has ever seen. At its peak,there were more than $100 million invested in heavy equipment and another $4 enormous fleet of vehicles,all aspects of heavy equipment use were studied and streamlined.Everything from tire usage,fuel consumption,loading factors,preventive maintenance to replacements of spark million in spare parts.With 2:4 plugs and brakes had to such an enormous outlay in "<4 be studied and addressed equipment,it was =as each of these factors imperative to keep them in "24 could affect the efficiency a high level of availability.Q of the equipment and itsThisenormous4]availability. responsibility fell on the ad Don also shoulders of Don Johnson.|had a lot of help from his A big man with a :-experiencedpronouncedSouthern drawl,Don was one of the eet= superintendents.George Stoll,Oscar Moberg,Lee pioneers of the Project.He 7 Babbitt and Atoy Andres joined up in 1998 and L--organized and ran the immediately got to work evaluating the Projects' enormous needs.Don had worked on four (4)other dams before and is an expert on the maintenance and repair of specialized mining and earth-moving equipment. Providing maintenance services to the fleet in the rural town of San Manuel was not an easy task.Spare parts for the specialized equipment were not that easy to come by. Some parts were available from Manila through the equipment's distributors but were considerably more expensive than in the United States.Other parts were not even available and had to be brought in by courier at an expense and sometimes,even with a costly delay.Experienced service technicians were also hard to find.Mechanics from Manila would find the salary rates offered to be unattractive considering the relocation expenses they would incur and the short time frame of the Project. Don Johnson worked with industry- veterans Charlie Sanders and Joe Martin on forecasting parts needs for up to a year in advance.Doing so resulted in lower parts costs and lower freight charges for the Project's needs.Strategic service contracts were entered into with choice equipment distributors to ensure quality servicing of specialized equipment.With such an Don Johnson Equipment Maintenance Yard and had it operating 24 hours a day,7 days a week,every day of the year for over 4 years. Long-time Caterpillar veteran Jerry Scott was likewise tapped in 2001 to lend his expertise in Caterpillar equipment.Together,they trained the Maintenance personnel,organized field maintenance teams,run fuel and lube trucks and worked hard to keep the equipment in working condition.Their hard work paid off,as overall equipment availability for the Project was kept around 90%at all times. According to Don,"The hardest part of the job was training the mechanics and service personnel.Some of our personnel are farmers whose only exposure to machines are motorcycles and small engines.We were fortunate to have such skilled and dedicated people like Oscar,George,Lee,Jerry and Atoy who spent a lot of time and effort with the personnel to teach them and train them to work on the equipment. We did our best to maintain a high degree of equipment availability.Our people knew their roles and responsibilities and worked with a lot of dedication.They could look back at this Project with a whole Jot of pride and say that they delivered results.This is a world-class project and our people did a world-class job”. pas fi =ps te i,ie8 187 A Euclid Water Truck (left)sprays water to supress dust.(Below) The Tamrock Ranger 600 Rock Driller at work. 5 Be ET.remit.te eat I SNetekeSSasftateasPhy.TENE The excavator's bucket can accomodate a lot of materials. (Below)Volvo excavators prepare the Diversion Tunnel area. 7 errs Wiesner cee eis ..Ag ve ane : A Schwing Concrete pump is used in the Switchyard area. Gomaco equipment were used in the application of concrete in the Spillway. PateSOA eens aspy,REAIN iti] we at atVyEMANEeaeath7 Concrete is poured in the Spillway chute as a host of heavy equipment works downstream. Cranes were used extensively in the Spillway area. -The Caterpillar 776 gets loaded with material for the Dam Embankment. A Grove Crane is shown at work in the Power Tunnel Intake area. The Hitachi 1800,the Caterpillar 777D and the Caterpillar 776 make a formidable combination for excavation activities. *ek:og * Mtn A Kone Gantry Crane (above)is permanently stationed in the Powerhouse.(Below)River Training works required a wide variety of heavy equipment. NReeunend ' Wen teks xa'SOSA AD : .mS ie Newer a msde wy %eee ty Begs.6 yaoaaTes.% a ".Sterne Rakie SinkSuneesMgataSEeeetcheeSataSaESaeiabiaBSRial These are some of the heavy equipment used in the Spillway excavation area. ivf asOe-Ue)ge rapsiiwasffpeaeai ee at eae2ifpeateae nNaetA? .ssoeS728oetiSstales The water level rises (above)in the Reservoir.(Opposite page)This aerial view of the Main Dam,the Reservoir and the downstream Agno River was taken in August 2002. Chapter 13 The Reservoir The Reservoir HE Reservoir is the area upstream of the San Roque Dam that impounds and stores the water for energy generation, irrigation and flood control.The upper Agno River feeds the Reservoir of the San Roque Dam.The drainage basin or watershed upstream of the San Roque reservoir measures 1,250 square kilometers.The surface area at its maximum normal water level is 12.5 square kilometers.It yields an average water flow at the dam of 83.6 cubic meters per second. The total storage volume of the reservoir is nearly 1 billion cubic meters.At its normal maximum surface elevation of 280 meters above sea level,the Reservoir has a maximum active storage capacity of 530 million cubic 195 meters for power generation,irrigation and flood control.The area between 280 meters and 290 meters above sea level is the active storage area for flood control purposes.The volume of water that could be stored in that area is about 140 million cubic meters.The area below the level of the power tunnel is called the dead storage volume,as it represents the level of water below which energy could not be generated.This area totals 320 million cubic meters. Filling Up the Reservoir The act of filling up the Reservoir is a signiticant Project Milestone.It represents the culmination of years of construction work and millions of man-hours of dedicated work. However,the process of impounding requires a number of important steps. Prior to impounding,the Diversion Tunnels have to be made ready for closure.A bulkhead had to be installed in Diversion Tunnel number 2,wheel gates have to be lowered in Diversion Tunnel number 3 and the slide gates on Diversion Tunnel number 1 have to be opened to allow the minimum flow of irrigation water. The Power Tunnel Intake and the Low Level Outlet Intake have to be functional.The Trash Racks have to be checked.Equipment and personnel must be available to keep the Trash Racks clear of construction debris.The Power Tunnel,the Surge Shaft and Tanks,the Drop Shaft and the Penstocks must be ready as well. At the Spillway,the approach channel,the structure and the exit channels must be complete.The Radial Gates and the Stop Logs must be fully functional.The Spillway chutes must be ready to handle any release of water. Likewise,SRPC and NPC have to ensure that all the upstream areas that will be inundated by the impounding process and clear of inhabitants.Failure to do'so could result in loss of life and property. It is only after SRPC and WGI engineers have verified that all the requirements and safety measures required for impounding have been met will instructions be given to close the Diversion Tunnels and start impounding of the water in the Reservoir. Filling up the Reservoir can take anywhere from 19 to 62 days depending on the weather and the release of water from the Binga Dam. Under normal inflows,the water in the Reservoir is expected to rise from 10 cm to 25 centimeters per hour.However,this may increase to around |meter or more per hour during or following a typhoon.On a dry year the water is expected to reach an elevation of 225 meters above sea level in 62 days. During an average year,it is expected to reach the same elevation in 32 days and on a wet year,the level could be reached in around 19 days from the time of tunnel closure. An aerial photo (above)shows the Spillway,Main Dam and the Reservoir in August 2002.Opposite page reveals another view of the Reservoir and Dave's Mountain. Monitoring Dam Performance During the process of reservoir filling,the performance of the Dam will be monitored visually and through a variety of dam instrumentation.There are a variety of instruments on the surface and within the structure and foundation of the Dam to record such parameters as pore pressure,settlement, deformation,seepage quantity and seepage turbidity.Other atmospheric and weather conditions such as instruments record temperature,precipitation and barometric pressure. Scientific monitoring of the Dam's performance entails the use of a number of sophisticated instruments.Piezometers are used to monitor pore-water pressures,uplift pressures and to determine free water surfaces within the embankment.The Project uses 4 197 different types of piezometers located in strategic areas in the foundation,in downstream drill holes in the galleries and adits,and in various locations in the Main Dam. Settlement cells are used to monitor internal settlement in the Dam.A total of 14 settlement cells are installed in the downstream half of the Dam.Their locations were surveyed and located during instrument installation and future surveys will measure their movements. Movement Survey Monuments are steel rods embedded into a concrete base and attached to a fixed structure.Like the settlement cells,their locations have been previously surveyed and will be continually measured. Flow Measurement Stations are located in the galleries and adits.They monitor seepage quantities under and through the Dam.These stations are aligned in series to isolate the amount of seepage in a section of the gallery.The data from the Flow Measurement Stations will indicate to engineers the areas of excessive seepage that may necessitate the need for remedial works in specific areas. Rainfall gauges are required to measure the amount of rainfall over the Dam area. 198 The Reservoir (above)starts to fill up.Note the Diversion tunnels,which are almost covered up.The Power Tunnel Intake is seen above.(Opposite page)Another aerial view shows a portion of the Reservoir. Barometers will be used to measure atmospheric pressure that may affect the readings from the piezometers. A joint WGI and SRPC team will read, monitor and evaluate the instrumentation data during the reservoir filling process.Data will then be evaluated on-site and the findings relayed to engineers for their appropriate action. tyeetegghKOE aySos sabe a ease Ne ras oan Oenoneyisp.fear er MEE Bas oF Le no ee Ste ae ao ":rr]ytfw.etl :'ng 7:,:2 °foufeteoeNreinaeeyNeeBalaaesit aie atl Es tlt mas "Another aerial view shows ThgasMainDam,Spillwayand the.Reservo re a in August 200 Maintenance personnel continually inspect the Reservoir and keep it clean of debris. This is a view from the top of the Spillway looking down on the chute (opposite). 203 Bill Scott,Joe Blades,Jeff Dawson and the Excavation Crew pose with the last load of the Dam in June 2002. 204 INDEX Abad-Ricarte,Ruth,170 Fisher,Jay,167 ABB Alstom,132 Flip bucket,127 Allan Bradley Control Systems,89 Fuji Bank,46 Ambuklao Dam,13 Funkhauser,Mark,87 Arrington,Gene,170 Galleries,33,69,75,197 Atlas Copco,115,177,182 Gavin,Mike,168,170 Atteberry,Dave,140 Gaydar,Glenn,16 Bank of Tokyo-Mitsubishi,Ltd,46 Gerard,Josh,170 Barangay San Felipe East,56,62 Gertler,Leo;70,73 Barangay San Felipe West,62 Golder and Associates,69,79,111 Barangay San Roque,19,55,56,60,62,147,166 Gomaco,186 Bayambang,12 Governor System,152 BF Goodrich,137 Goyal,Shiam,71,73 BF Steel,137 Groth,Bill,139 Binga Dam,13 Grouting,33,97,100,103,186 Blades,Joe,100 Grove,184 Brown,Magda,73,74 Hitachi,177,185 Build-Operate-Transfer Law,15 Hogarth,John,167 Casten,Gregg,100 Hooper,Thurio,98 Caterpillar,178,179,180,181 Humphries,Rich,72,73 Catlin,Bill,9,28 Hyundai,186 Cedarapids,137,182 .Ingersoll-Rand,182 Chiu,Jack,140 °Isolated Phase Bus,147,150 Cofferdam,24,31,67,69,70,71 Italian-Thai Development Public Co.Ltd,42 Connell,Bill,158 Itogon,14,24,56,57,60,62 Crouch,Frank,132 Japan Bank for International Cooperation,46 Dalupirip,14,60,62 Johnson,Don,187 DENR,27 Johnson-Ross,186 Diversion Tunnels,98,112,113,114 Kansai Electric Power Co,18,42,45 Dodd,David,170 Kenworth,186 DPWH,46 Kleiner,Dave,76 Drop Shaft,147,151,196 Kos,Scott,148 DSWD,57 Lichtenberg,Ben,62,170 Ehasz,Joseph,76,80 Loading Stations,32,137,138,181,183 Electroconsult,67 Low Level Outlet,37,113,114,183 Electowatt Econo,67 Manifold,33,111 Environmental Compliance Certificate,15,17 Manitowoc,177,184 Environmental Impact Statement,15,17 Marcelo,Virgilio,55 Environmental Management Bureau,17 Martinovich,Sam,72,73,87 Excitor,152 Marubeni,42,44,45 Export Import Bank of Japan,47 Maxon,186 Extensometers,153 McAllister,Patrick,25 Falk,137 McLeod,Ken,111 ;Fernandez,Leonilo,133 Memorandum of Agreement,17,46 FF Cruz,69 Miller,Kevin,114 Fiala,Peter,73,74 Moen,Keith,73,75 205 Morel,Francois,68,102 Morrison Knudsen Corporation,46,49 Municipality of San Manuel,11,14,55,56,62,63 Municipality of San Nicolas,11,14,26,56,63,62 NCIP,17 NEDA,25 NEPC,15,42 NIA,14,17,26,46 Norinchukin Bank,46 Northwest Hydraulic Consultants,69,79,92 NPC,14,15,17,24,25,27,30,37,42,43,46,52, 56,57,58,60,61,63 O'Connor,Ed,70,73 Odell,Marty,141 O'neil,Al,76 Osmun,Dan,73,75 Owens,Jack,100 Pavone,Mike,71,73 Penstock,33,34,47,110,111,112,147,151,196 Phoenix Power Control Inc.,89 Piezometers,75,197,198 Poponto Swamp,11,12 Power Tunnel,30,33,34,49,75,110,111,112,114, 147,151,152,182,184,195,197 Powerhouse,14,30,34,37,58,80,110,111,113, 147,151,153,158,180 Probable Maximum Flood,33,125 Process Plant,138,140,142 Putzmeister,186 R.A.1957,15 Radial Arms,129 Radial Gates,128,129,132,184,196 Raytheon Constructors and Engineers,29,43,46,50, 67,168 Raytheon Ebasco Overseas,Ltd.,12,14,29,46 Resch,Robert,12 Reservoir,52,58,62,69,72,112,113,114,115,125, 128,129,139,147,148,151,171,195,196,197, 198 Resettlement Action Plan,17,52,56,59,61,62 Ryan,Jim,169 Sakura Bank,46 San Manuel Substation,37,147 San Roque Consulting Panel,76 San Roque Power Corporation,15,16,18,24,25,28, 29,43,47,55,60,63,125,158 San Roque Watershed,60 Schwing,186 Scott,Bill,51 Sheepfoot,177 Sithe Energies,Inc,12,16,25,42,44,74 Sitio Camanggaan,56 Sitio Lagpat,56 Sitio Tabu,14 Skills Training Program,58,63,171 Slope Indicators,153 Spillway,24,27,30,33,43,47,70,74,75,125, 126,127,128,129,131,132,133,134,184, 186,196 Stieglitz,Guy,169 Stop Logs,128,129,196 Stuckey,Bill,85 Sual Power Plant,63 Sumitomo Bank,46,47 Surge Shaft,112,196 Swellex,113 Switchyard,34,37,147,152 Tadano,184 Tailrace Tunnels,33,37,111,112,147,152,153 Tamowicz,Alex,132 Tamrock,177,182 Todd,Donald,111,114 Toshiba,147,148,150 Transformers,29,34,147,150,152 Turbines,26,34,37,111,147,148,150,151,153, 184 Ugalino,Digna,58 Union Cement Corporation,128 United Engineers,International,29,95,97 Ventura,Joey,72 Vertical Francis Turbines,34,147 Vogt,Lothar,171 Volvo,177,178,185,186 Walker,Duffy,131,132 Ward,Page,131,132 Warmouth,Doug,131,132 Washington Group International,12,28,30,43, 46,50,69,81,114,137,141,147,166,167, 168,169,170,171 Wilkinson-Kemp,Sarah,68,73 Woodward Construction,111 Yamamoto,Junya,18 Zaidi,Asghar,98 Bee eeeee eee eee CUT HERE swe ORDER FORM IMAGES OF THE SAN ROQUE DAM NAME: ADDRESS: E-MAIL ADDRESS: CONTACT PHONE NO.: ORDER: QUANTITY REQUIRED UNIT PRICE SHIPPING TOTAL PRICE $80.00 $20.00 PAYMENT BY: CASH CHECK PLEASE MAKE PAYMENTS TO:ALFREDO BELEN OR ALFREDO BELEN RAYTHEON EBASCO OVERSEAS LIMITED BLDG.3005 UNIT 152 SAN ROQUE MULTIPURPOSE PROJECT 4440 NW 73rd AVE. SAN ROQUE,SAN MANUEL MIAMI FL 33166 PANGASINAN 2438 USA PHILIPPINES FOR INQUIRIES,VISIT THE BOOK'S WEBSITE AT:http://www.sanroquebook.com OR CONTACT THE AUTHOR AT:junbelen@mozcom.com OR sanroquebook@yahoo.com