FUNIL HYDROELECTRIC POWERPLANT

ON THE GRANDE RIVER

Author: Michael Sucharov (Based on reports and drawings furnished by SPEC).

Main Brazilian Dams III

FUNIL HYDROELECTRIC POWERPLANT

ON THE GRANDE RIVER
1. INTRODUCTION 3. Closure of diversion structure up to the start of
power generation (1st unit): 3 months.
The Hydroelectric Powerplant of Funil is a low head The first generating unit was put in commercial
run of river powerplant and has a final installed capacity operation in February 2006.
of 180 MW, is owned by the consortium Consórcio Optimization studies for the final design were carried
Brasileiro de Aimorés - CBA which belongs to the Vale out by the Construction Consortium and a complementary
do Rio Doce Company and CEMIG, the State of Minas program of site investigations were made to cover areas
Gerais Power Company. It is located on the Grande River where there was not enough geological information. This
upstream from Furnas dam and before São Miguel dam, led to some important modifications of the preliminary
in the municipalities of Perdões on the right bank and design, listed below:
Lavras on the left bank, in the state of Minas Gerais, 1. The concrete structures were relocated from the
Brazil. It is situated along the São Paulo - Belo Horizonte left bank to the right bank in a more compact layout,
highway (BR-381), 395 km and 221 km respectively from with the following advantages:
• It eliminated one of the critical paths of the construction
both state capitals.
The catchment area is 15,153 km2 and the mean annual of the spillway in the river bed. This reduced the schedule
flow 341 m3/s. The reservoir covers 34,71 km2 at the to 29 months for commercial operation of Unit 1, from
maximum normal water level of El. 808.0 and impounds the start of construction.
• A reduction in the number of five radial gates to four, due
268.93 x 106 m3 of water.
The following studies were carried out on the Grande to a more favorable flow in the spillway stilling basin and
river for hydroelectric development : discharge channel.
• Shorter lengths of penstocks with a smaller distance
• The first studies for the Hydroelectric Development of
the Grande river, in the area called Funil were carried out between the intake and powerhouse.
• Only one upstream gantry crane would be necessary
in 1955 by IECO - The International Engineering
Company. for maintenance of both the intake and spillway structures
• In the 60's, the first systematic studies were made for
as they would be adjacent.
• The first stage cofferdam was eliminated by the use of
the Hydroelectric Inventory of the Grande River basin,
and determined the partition of the falls along the river. the natural rock outcrop at El. 780.0 along the riverbank
These studies were made by a consortium of two with the new layout of the structures.
companies, Canambra and CEMIG. 2. The main dam was designed with three sections,
• Pre-feasibility engineering studies and site
one of earthfiil, another of rockfill and a third zoned, for
topographical, geological and geotechnical investigations the following reasons:
• To minimize the required excavations in the riverbed
in the hydroelectric area were carried out and forwarded
in 1971 to DNAEE, the federal agency responsible for and banks.
• To use most of the excavation materials in the main
hydroelectricity.
• The preliminary design was elaborated between 1990
dam.
and 1992. Further studies to consolidate the preliminary 3. The river diversion through a tunnel on the left bank
design were made in 1996 with an alternative layout that of the Grande River permitted the construction works of
would dam the river with a roller compacted concrete the main structures at the same time as the tunnel, and
dam (RCC) in the riverbed, and an incorporated spillway. a more flexible project schedule.
The power circuit that included an intake, penstocks and 4. As a result of the modifications, the dam axis of
powerhouse was located on the left bank; because of the concrete structures was moved slightly upstream to
the geology, a rockfill dam closing the right bank would improve the layout.
have had to be built.
To carry out the construction a consortium of 2. LAYOUT
companies was formed and named "Construction
Consortium for the Hydroelectric Powerplant of Funil". Funil's final design and construction can be
The companies were IMPSA, Servix/Mendes Junior, considered as composed of two parts (Figure 1):
SPEC, ORTENG, DELP and ULTRATEC. 1. A main earthfill dam that bridges the Grande river
Main construction phases and schedules were: valley, 50 m high and 420.0 m long at the crest; the right
1. Start of works up to river diversion: 5 months; end of the dam has a sharp right angle curve that abuts
2. River diversion to 1st phase closure: 22 months; against the intake.

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2. The concrete structures that include the spillway the powerhouse that houses three turbine/generator units.
and intake; the first has four gates and a 7.356 m3/s The intake adjoins the spillway at a 15° angle, and in
discharge capacity; the second is part of the hydraulic turn ends at the right rockfill dam.
power circuit, that includes, a short 50 m penstock and

Figure 1 - General Layout of Funil HPP

Photo 1 - View of Funil Dam from Downstream

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Main Brazilian Dams III

3. GEOLOGY AND GEOTECHNICS OF brown when originating from amphibolite and biotite
THE FOUNDATIONS gneiss, and red silty clay when originating from diabase.

3.1. Foundation rock Saprolite

The foundation geology of the dam is made up of a These soils originate from the foundation rock mass
variety or rocks originating from the metamorphism of and occur in both banks. On the right bank this seam is
amphibolites, gabbro and granulites and are denominated up to 45 m thick while of the left bank it reached only
here as gneisses. Subsurface investigations carried out 10 m.
in the riverbed and banks, showed that below the alluvium The main origin of soils in the site area are from
layer there was a seam of medium to very decomposed gneisses and to a lesser degree from diabase and meta-
rock, highly fractured, with a permeability in the range of diabase rocks.
10-3 to 10-4 cm/s. The average thickness of this layer Soil particle size when originating from decomposed
was about 7.0 m and below it the quality of the rock gneiss was basically of silt and sand, with little clay and
mass improved and became adequate for the foundation, variable colors, mainly with tones of grey, white and yellow
being competent and occasionally fractured with a low indicating the rock origin.
permeability of about 10-6 cm/s, which for practical At the base of the saprolite soils, near the
purposes was considered impervious. decomposed rock surfaces, particle size was coarse
In the riverbed a 1 m horizon of extremely (medium to large) frequently mixed with fragments of
decomposed rock made up of bands of feldspar and decomposed rock. The average permeability of the soil
quartz, was found below another 5 m layer of sound or was 1 x 10-4 cm/s in the right bank and 4 x 10-4 cm/s in
lightly decomposed rock. the left bank. In general the soil resistance of saprolite
On the left bank of the river near the main dam crest by SPT tests indicated strengths above 10 blow counts
and the diversion tunnel, sound and lightly decomposed and sometimes reaching over 30 counts.
rock (D1/D2) was only to be found below a seam of 8 m
decomposed rock (D3/D4) which in some places was 3.3. Top soils (talus, colluvium and alluvium)
15 m thick. These soils were found on the banks of the Grande
On the right bank of the river, where the concrete river and in the riverbed at the dam site.
structures are located, medium to very decomposed rock
was found in a much thicker seam than that on the left Colluvium
bank, and reached 22 m along the crest axis, 12 m at This type of soil occurs on the surface of the original
the spillway and about 15 m in the area of the intake and landscape on both river banks, with a thickness between
powerhouse. Sound rock was found at lower elevations 2 and 3 m, but could be more than 4 m on the lower part
in places where gneiss and diabase were in contact and of the right bank. It is made up of sandy clay below the
also in some locations where gneiss with bands of quartz silty fraction, porous with a red brown colour. At the base
and feldspar predominate, and which was also found in of the left bank and below the colluvium soil there was a
the riverbed area. rock block strata up to 1.5 m thick and block size in the
At the end of the dam on the right bank, where the range of tens of cm. In some locations on the right bank
right rockfill dam is located, the decomposed rock seam the colluvium is overlayed with diabase.
had a permeability of 7 x 10-5 cm/s, while in sound rock The resistance of this soil is in general equivalent to
it was less pervious: 3 x 10-5 cm/s. less than 10 blow counts by the STP tests, and reached
In the area of the intake, powerhouse and the overflow more where there were fragments of rock or blocks. The
crest of the spillway, the average permeability of the rock permeability was between 10-3 a 10-4 cm/s.
mass was 3 x 10-5 cm/s, practically the same as in the
main dam foundation. Talus deposits
The strata of sound rock in the riverbed and in both These deposits were found at the base of the left
banks were found to be occasionally fractured and the bank with a height of less than 1 m. They were made up
amount of fractures diminished with depth. Highly of rock fragments and blocks.
fractured sections were not a common feature that could
be found in the sound bedrock. Alluvium
In the area of the main earthfill dam, alluvium was
3.2. Residual soils and saprolite distributed along the Grande river bed and the terrasses
Residual soils on the banks of the river. The depth of these deposits
These soils occur in the right bank between colluvium varied between 6.0 and 12.5 m. On the upstream and
and saprolite, and vary up to 3 m thick with the thicker downstream side of the dam where the cofferdams are
strata found higher up the river bank. The soils are located, the alluvium was 6.0 m deep; in the cutoff area
composed of silty clay sand, micaceous, and yellow of the riverbed it was 9.5 m; and in the central part of the
dam it was 12 m.

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The alluvium layer on the right bank terrace was 8 m out along the right slope between the spillway and the
thick and on the left bank it was only 2 m and the coarse main dam and included various soils and rocks, such as
particles varied according to the following locations: colluvium, residual soil/saprolite, decomposed rock
• In the riverbed there could be found mainly clean medium (D3/D4) and sound to decomposed rock (D1/D2).
sand, lightly micaceous, with 1.0 m of pebbles and rock Excavations were up to 35 m deep and blasting
blocks at the base of the layer. heights in decomposed rock were around 20 m deep.
• In the riverbank terraces, alluvium was made up basically In the intake and powerhouse area there were some
of fine silty sand, light grey in colour and mixed with weak areas where the decomposed rock excavations
colluvium soil. and extreme fracturing had to be treated with gunite and
• In the left bank downstream from the diversion tunnel anchored wiremesh.
portal there was a layer of rock blocks of sizes varying The deepest excavations were in the powerhouse area
between centimeters and meters in a 25 by 40 m area. down to El. 747 and in sound rock they reached 33 m
The resistance of the soil, based on SPT tests, was deep along the axis of the units. The excavations of the
low along the river terraces and high in the riverbed. On right and left wall were done in 10 m vertical cuts with
the right terrace the tests required 1 to 2 blow counts 0.5 berms and where required, surface reinforcement was
down to 6.0 m deep. In the riverbed in general the tests with 6 cm thick gunite with fibers, anchored in a 2 x 2 m
required over 15 blow counts, with exception of the net with 1" rebars 2.5 m deep.
investigation SM-22 bore hole in the downstream cutoff In some places where the foundation rock surface of
trench where SPT tests required less than one blow these structures was very fractured or decomposed, the
count, with a high permeability between 10 -2 and weak area was removed and filled with dental concrete
10-4 cm/s. or grout and consolidation grouting was carried out.

3.4. Foundations of the Structures Spillway and Stilling Basin

Main Earthfill Dam and Right Rockfill Dam The specifications of the spillway and stilling basin
On the right bank there is a layer of residual/saprolite structures required that the foundations be of a good
soil in the area of the right rockfill dam that reached geomechanical quality. The spillway foundations were of
40 m. A layer of colluvium 1 to 3 m thick covers the sound gneiss lightly decomposed (D1/D2) light to medium
residual soil. Between the altered soil horizon and sound fractured (F2). The gneiss foliation was 43° in relation to
bedrock there is a 20 m layer of decomposed rock the spillway axis and dips between 60° and the sub-
(D3/D4). Part of the altered soil was removed to build the vertical in the downstream direction. Apart from the
earth and rockfill dams. The saprolite seam of silty sand foliation there are two fracture systems that intercept
had a resistance by the SPT tests requiring more than the dam axis, the first is 30° and dips sub-vertically
10 blow counts, and reaching more than 40 counts in downstream while the other is 55° and dips between
some tests with a permeability of 10-4 to 10-6 cm/s. The 10° and 45° downstream.
decomposed layer below the altered soil had a The spillway excavations revealed bands of
permeability of 6 x 10-5 cm/s. amphibolite-biotite rocks and diabase rocks with
On the left bank where the main earthfill dam is located downstream sub-vertical dips.
there is a layer of 4 to 5 m of saprolite and overlaying it For the right wall the excavations were the deepest in
there is a layer of 1 to 2.5 m of blocks of rock and colluvia. the following materials: colluvium, residual soil/saprolite,
The earth dam was founded on the altered soil layer. decomposed rock (D3/D4) and sound to lightly
Some permeability tests in decomposed rock showed decomposed rock (D1/D2).
results that were quite high, between 10-3 and 10-4 cm/s, In the stilling basin after the removal of the altered
requiring a grout curtain. soil, excavations were carried out in decomposed rock
Between the alluvium and the foundation rock in the (D3) and sound to decomposed rock (D1/D2), with
riverbed and the bank terraces there is a 5 to 12 m layer 45° slopes 10 m high. Weak slope areas were treated
of decomposed and very fractured rock (F4/F5). with standard steel mats or fiber, gunite and rebar
In this stretch the dam was based on the alluvium. anchors.
About 70 m upstream from the dam a cutoff trench At the bottom of the end upward slope of the stilling
was built intercepting the 9.5 m thick layer of alluvium, basin there was an area with decomposed rock at
and reaches down to the decomposed rock surface below; El. 760 that was treated with dental concrete, as well as
a grout curtain was carried out along the cutoff to reduce some other areas. Dikes of diabase with a big
subsurface flow. downstream dip (70° to 80°) and decomposed near the
The dam slope design considered a 0.04 g seismic contact with the gneiss matrix didn't affect the excavated
acceleration. slopes because of the slant relative to the side walls of
the stilling basin.
Hydraulic Generation Circuit The excavation of the soils above the maximum
Excavations for the intake - powerhouse were carried normal tailwater elevation - El. 785 were 35 m high with

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slopes 1V:1,3H and 1V:1H, with 3 m berms in every layers. The top layers of colluvium had average thickness
10 m heights. Protection of these slopes was with planted of 2.0 m in area 1 and 2.9 m in area 2. In previous studies
grass and sometimes with gunite where grass could not it was classified as fine sand and secondarily as medium
take hold. to coarse sand with fractions of silt and clay, of medium
Excavations in saprolite between El. 785 and the to high plasticity, and considered as MH material by the
decomposed rock in an area subject to tailwater Unified Soil Classification System (USCS).
fluctuations has slopes of 1V:1.3H with berms of 5 m The underlying horizon is a residual soil with average
every 10 m of height and protected with transition and thicknesses of 7.5 m in area 1 and 6.2 in area 2. It was
rockfill. In the intake channel the area of the slopes mainly fine silty clay sand of medium plasticity, and
subject to the reservoir fluctuations were also protected. also classified as MH soils by the USCS.
In the same way as in the stilling basin, the slopes in The estimated volume of these soils was:
decomposed rock (D3) of the spillway were less inclined 1. Borrow Area 1
(1V:1H) and were treated in weak areas with the standard • Colluvium 247,600 m³
gunite, steel wiremesh or fiber and anchored to the rock • Residual Soil 784,300 m³
foundation. 2. Borrow Area 2
In sound rock excavations reached 17 m high with • Colluvium 459,600 m³
vertical cuts and 0.5 m berms, and the deeper cuts were • Residual Soil 549,100 m³
made in the stilling basin area.
The tailrace channel is in decomposed rock (D3) and 4.2. Coarse Grained Soils
at the end in saprolite. Where there was soil or very The prospection of sand and gravel deposits was
decomposed rock the channel was over excavated carried out in the river bed downstream from the dam
between 1 and 2 m below the bottom at El. 765 and filled axis. The depth of the deposits varied, reaching 12 m
in with rockfill for protection. deep as was the case of the one along the dam axis.
The deposits were mainly of medium sand and
4. CONSTRUCTION MATERIALS secondarily of coarse sand and gravel that were tested
in the laboratory. The estimated volume of the deposits
4.1. Soils was 400,000 m³
Based on studies before the preliminary design that
indicated two potential areas for materials for the dam 4.3. Rock Materials
construction and denominated borrow areas 1 and 2, a Bedrock materials were used as coarse aggregate
program for investigations was elaborated to sample soils for concrete, rockfill for the dam and transitions and drains
for laboratory tests. Both borrow areas were located on and were obtained from the excavations for the foundation
the right bank of the Grande river at a distance of about of the structures, the diversion tunnel and channels. Two
1100 m from the dam axis. types of rock were found: sound rock and decomposed
The borrow areas had the same geological to medium decomposed rock, and were used in the dam,
characteristics differing only by the thickness of the cofferdams and various fills.

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5. DESCRIPTION OF THE MAIN being carried out. The compacted earthfill was raised up
STRUCTURES to the level of the cofferdam crests and the whole structure
was overlayed with a blanket of rockfill for protection. In
5.1. River Diversion and Tunnel the flood season the high river flows were discharged
The construction of the civil works was done in two through the diversion tunnel and overflowed the main dam.
stages. In the first the Grande river was kept in its natural During the dry season of 2002 the protection blanket
riverbed while the diversion tunnel was being excavated of rockfill was removed to complete the construction of
in the left bank and the concrete structures on the right the main earth dam, with the river flowing again only
bank. In the second stage with the upstream and through the tunnel. The design flow for this stage was
downstream cofferdams damming the river bed, the river 1,094 m3/s
was diverted through the tunnel.
The diversion tunnel structure was divided in the 5.2. Main Dam
approach channel, the control structure, the tunnel and The construction of the main dam was planned to
the outlet channel. The approach channel was 164.0 m use the maximum amount of material from the
long, 20.0 wide and narrowing at the end to 14.6 m, excavations of the concrete structures and the diversion
excavations were in soil and rock. The control structure tunnel. Because of the geological-geotechnical conditions
at the upstream portal has two openings for the closure of the foundation, the dam was divided in three typical
gates 5.0 x 11.6 m. The actual tunnel is 211.0 m long sections:one is rockfill with an impervious core, the
with a bottom rectangular cross section 11.6 m wide and second a mixed section of earth and rockfill and the third
semi-circular at the top. The outlet channel is 142.5 m a homogeneous earthfill. The crest of the main dam is at
long and 13.0 to 20.0 m wide from the tunnel to the end El. 811.3.
of the outlet. The diversion tunnel excavations were done The first section on the right bank, adjoining the intake,
in sound and lightly decomposed gneiss. with a length of 25.0 m, is rockfill with an earth core and
The upstream cofferdam was built by dumping rockfill transitions; the upstream and downstream slopes are
across the river flow at about 1 m above the water level. the same: 1V:1.3H; this section of the dam had its
After dumping transition material and sealing, the foundation on decomposed rock.
cofferdam was raised with compacted soil up to The second section toward the riverbed, about 80 m
El. 776.20, which is the diversion elevation for a recurrence in length, has a mixed section with rockfill on the
river flow of 20 years for the dry period of the year. To downstream slope with an inclination of 1V:1.8H and an
prevent a backflow of water through the tunnel from the earth slope on the upstream side, sand drains and
downstream channel outlet, a downstream cofferdam was transitions (Figure 2). This section was founded on
built similar to the upstream one with a crest at El. 773.00. decomposed rock and residual soil. Where the foundation
The cofferdams were built with material from the was on residual soil a cut-off trench 8.0 m wide was
excavations for the foundations of the structures. excavated into the decomposed rock below.
The following diversion scheme with the overtopping The third section is about 270 m long, from the riverbed
of the partially constructed main dam was tested in the to the left bank, and has a typical homogeneous earth
hydraulic models and used for the river diversion: section, founded on an alluvium layer in the riverbed and
gneissic saprolite on the left bank. The upstream slope
First Stage Diversion is 1V:2.1H and the downstream is 1V:1.9H from the crest
The first stage river diversion of the Grande river was down to El. 785.0. From there on and until the
made with the use of two natural septa that were left on incorporated cofferdam crest 12.0 m below, at El. 773.0
the left bank to protect the excavations of the diversion the slope is 1V: 2.0H. In the riverbed a cut-off trench
tunnel and the tunnel's intake and discharge channels. 25.0 m wide had to be excavated through the 9.0 m
The leftover septa heights were derived from the rating alluvium layer and the slopes of the trench were 1V:2H
curves made by CEMIG, based on two river water level in decomposed rock. The dam section has an internal
gauges installed nearby. vertical sand drain with a horizontal base.
The maximum diversion design flow of 2,442 m3/s led For slope protection on the upstream side of the whole
to water levels of El. 778.4 and El. 777.3 at the upstream main earth dam, where the reservoir water level varies, a
and downstream septa, and determined that both should protection layer of graded sound rockfill was placed. On
be left 1.0 m above these elevations: El. 779.4 and 778.3. the downstream side protection of the slope from rain
was made with rockfill and transitions.
Second Stage Diversion
In the dry season of 2001, the second stage diversion 5.3. Intake
started after May, with the river flowing only through the The intake is located between the dividing wall and
tunnel. In the meantime the foundation treatment of the the main earthfill dam. It is a concrete gravity structure
riverbed section and cutoff of the main earth dam were 44.7 m long and 34.0 m high, divided in three blocks.
The upstream side has a 1V:0.1H slope and each block

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Figure 2 - Main Dam - Composite Section

On the left upstream side of the intake is the "L"

shaped concrete left guide wall that evens the flow in the
approach channel and abuts the main earthfill dam. The
concrete abutment wall continues on the downstream
side to sustain the earth dam's horizontal load.
There are removable trashracks on the upstream side
with two sections for each intake and are removed for
maintenance with the auxiliary hook of the crest gantry
crane.
Figure 3 shows a cross section of the intake.

Photo 2 - View of Funil Dam from Left Bank

has a sluiceway connected to a penstock that leads to a

powerhouse turbine-generator unit. In each sluiceway
there is an emergency wheeled gate 5.8 x 7.0 m
hydraulically operated. At 2.75 m upstream from the
wheeled gate there is a second slot for stoplogs that will
be used for maintenance of the emergency gates. The
sluiceway flares hydro-dynamically from the gate width
of 5.8 m to an upstream width of 11.4 m which is divided
by a trashrack supporting beam 2.3 x 0.8 m, and has
curved flow surfaces. The intake upstream sill is at
El. 784 and the upper-sill is 14.52 higher at El. 798.52.
At the downstream side of the intake there is a
transition from the 5.8 x 7.0 m center sluiceway section
to a circular 7.0 m diameter concrete section in a 30o
elbow connecting to the penstock.
There is a 3.0 x 2.5 m grout curtain and drainage
gallery, similar to the spillway, on the upstream side at
El. 779.0, 2 m above the foundation, that runs along the
length of the structure with an access through the dividing
wall.
There are two 7,0 x 3,6 m rooms at El. 806.70, that
house the hydraulic equipment for the intake emergency
gate operations, with access by a steel ladder fixed to
the downstream side of the structures. Figure 3 - Intake - Cross Section

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5.4. Penstocks 19.83/19.52/20.52 m long; the 18.50 m long erection -

There are three 7.0 m diameter steel penstocks, one service bay block and the 15.75 m unloading area block.
for each unit that connects the intake to the powerhouse; Figure 5 shows a cross section of the powerhouse.
both ends are horizontal and the difference in height The layout assumed a maximum normal upstream
between them is 26.5 m with the centerline elevations water level and a minimum normal downstream water
at El. 788.5 and the distributors at El 762.0. The lengths level to assure a minimum positive head on the turbines
of the penstocks are about 47 m, with small differences for cavitation free operation, and as a result the center-
because of the layout. In plan view the distance between line of the distributor was fixed at El. 762. Each unit draft
each penstock at the intake is 14.90 m, and increases tube outlet was divided in two 6.56 m wide discharge
to 19.52 at the powerhouse, and as a result the side passages by a 2.5 m pier, with slots for stoplog closure,
units' penstocks 1 and 3 are at opposite angles of about for maintenance, operated by the draft tube gantry crane
16º in relation to the straight center one of unit 2. rated at 157 kN and with the runway on the downstream
The geometry of the 7.0 m diameter penstocks, from draft tube deck at El. 786.
the intake to the powerhouse is roughly: 1) 30º elbow in The unit and service transformers are located on the
concrete, that is part of the intake; 2) a 30º elbow in upstream transformer deck at El. 786, which is the same
steel with a 17.285 m radius; 3) followed by a short as the draft tube deck and the discharge platform.
10.5 m straight section; 4) and last, another elbow, 60º The electric gallery is at El. 779.3, the mechanical
in steel with a 17.38 m radius. At both ends the penstocks gallery at El. 774, the piping gallery at El. 767.7 and the
are anchored to concrete blocks. Figure 4 shows a profile penstock gallery at El. 757.7; the erection bay is at
of the penstocks. El. 774 and the equipment discharge platform at El. 786
The penstocks are all encased in an octogonal 8.6 m at the entrance to the powerhouse on the left side.
wide concrete structure on the upper side and rectangular The station drainage sump and the unit dewatering
on the bottom. Considering that the intakes are also light sump are located at the end of the powerhouse on the
structures like the spillway, the concrete enclosures right side and the pump room for both systems is at
around the penstocks with 60% of the width of the intake El. 766.73. The bottom of the sumps are at El.746.23
blocks, become structural additions to the stability of and El. 741.73.
the Intakes. The powerhouse has one overhead travelling crane
The penstocks have pipe connections, just before the for the erection and maintenance of the turbine - generator
scroll cases, to feed the raw water systems for general units and appurtenances, with rails at El. 797 and travels
use and generator cooling. These pipes are also used all the way from the equipment discharge platform to the
for dewatering the penstocks for turbine maintenance. pump sumps at the end of the generator hall. The crane
is rated at 900 kN on the main hook and 250 kN on the
5.5. Powerhouse auxiliary hook.
The powerhouse is an indoor type with an overall length The draft tube discharges into the Grande riverbed
of 92.37 m and divided into five major structural concrete channel that was excavated in soil and rock and is
blocks that house the three turbine - generator unit blocks: 315 m in length and 59 m wide.

Figure 4 - Intake/Powerhouse - Generation Circuit

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Figure 5 - Powerhouse - Cross Section

The 138 KV substation occupies an area 90 x 65 m equipment room at El. 806, with access by an outside
and is located on the right riverbank at steel stairs on the downstream face of the wall.
El. 790 downstream from the dam axis
5.7. Spillway and Stilling Basin
5.6. Dividing Wall The spillway is a gated surface type, with a capacity
Adjoining the intake and the spillway is the angled to discharge the design flood of 7,356 m³/s. The structure
dividing wall, a concrete gravity structure that has a is 64.6 m long with four 12.5 m bays and dividing piers
tapered 15º plan configuration and connects both 3.0 m thick and based on a sound rock foundation. There
structures. To smooth out the flow to both structures, are five concrete blocks for the four gates divided in two
the upstream taper ends in a circular nose with a radius 9.05 m side ones for ½ gates and three central 15.5 m
of 7.94 m. ones for 2 x ½ gates each. The radial gates are 12.5 m
The wall is 26 m high, about 17.5 m in the flow wide and 15.0 m high and hydraulically operated. Figures
direction, and variable thickness. There is a shaft at the 6 and 7 show the plan and profile of the spillway.
crest for access to both drainage galleries by a vertical The structure is light with the ogee 8.5 m above the
ladder, and at the downstream level at El. 787.0, two base of the foundation rock. The refinement of the
meters above the rock foundation. The wall is not exactly structure resulted in a 7 m long extended downstream
a symmetrical structure because on the left side of the foot, 2.0 m thick that bears a large part of the load on the
spillway, the 2.8 m side wall is embedded in a recess of toe at El. 780.0 where the piers also end. The horizontal
the dividing wall. There is a 4 x 4 m shaft on the wall's foundation rock surface of the main base of the structure
left side as a fish passage from upstream to downstream; is at El. 785.0 and 2.0 m above the 25.0 m wide excavated
the reservoir water is fed into the shaft through a 1.2 m rock trap adjoining the spillway. The approach channel
steel pipe; there is also a 7.0 x 5.5 x 3.5 m high electrical is 5.0 m above at El. 788.

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Figure 6 - Spillway - Plan

Figure 7 - Spillway - Profile

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Main Brazilian Dams III

The ogee has a Creager profile with the sill at reduce these instabilities a guide wall with a crest at
El. 793.5. The crest is 5,5 m above the approach channel El. 811.0 was included in the design.
and discharges into a stilling basin that is 83.4 m long
from the spillway toe to the basin end and 59.0 m wide.
After the end of the spillway, the rock excavation surface
is overlayed with a concrete slab 0.5 m thick, that
increases to 1.0 m by the time it reaches the channel
bottom at El. 758.0, and maintains this thickness until
the basin end. The slabs are all anchored to the rock
foundation. The basin has an upward slope at the basin
end 12.12 m in length and 7.0 m in height (1V:1.73H)
and the lip is at El. 765.0.
The spillway crest is at El. 811.0 where there is a
roadway to cross the river and the runway rails of the
gantry crane. There is only one gantry crane for the
spillway and intake and it travels all along the concrete
crest structures up to the right gravity wall where the
stoplogs of both structures are stored. The crane has a Photo 3 - View of the Spillway and Powerhouse
capacity of 200 kN on the main hook and 45 kN on the
auxiliary monorail winch. 5.8. Right Rockfill Dam
The reservoir load of the radial gates on the vertical Closing the dam on the right side by the spillway is
spillway piers are absorbed by the concrete post- the small right rockfill dam that abuts against the concrete
tensioned trunnion beams that are also post tensioned gravity dam that extends on the right side of the spillway.
and anchored into the upstream side of the piers. The It is made of rockfill and has an earth compacted core.
cables were laid in a horizontal direction and the upstream
side has a tensioning chamber 3.0 m long at El. 797.5, 6. CONSTRUCTION SEQUENCE
the same elevation of the trunnion beams.
There are four 2,40 x 5,50 x 3,50 m rooms, one for The basis for determining the construction sequence
each gate, on the crest of each pier, that houses the considered the following important aspects:
hydraulic equipment to operate the gates. • Compliance with the project schedule and all
The drainage gallery is at El. 787.0, and 2.0 m above construction phases.
the foundation, runs along the length of the structure with • Coordination of excavations with the production of rock
an access through the dividing wall. The gallery has a aggregate and earthfill for dam construction, to minimize
3.0 x 2.5 m section and the grout curtain was drilled on transport distances.
the upstream side and vertical drains on the downstream • Concrete construction schedules not to interfere with
side. To certify that the uplift would be always low, there the electro-mechanical work and cause erection and
is a top/bottom circular/rectangular 0.8 m drain parallel installation delays.
to the gallery and 8.5 downstream on the horizontal rock • Control of production volumes to reduce peaks and
surface, and another drain along the toe, 5.0 below. There optimize the use of manpower and equipment.
are two drains under slope of the concrete basin surface,
3.0 and 11.0 m below the spillway toe with 2% slopes First Phase: The Grande River Flowing in the
from the center to the basin side walls, to prevent uplift. Riverbed
The approach channel was excavated in soil and The following activities were carried out:
rock at El. 788.0. The channel width diminishes from • Stakeout of the jobsite.
70 m to 40 m. Along the right spillway side wall which • Construction of the campsite and lodgings.
contains the first gate trunnion beam, the upstream part • Construction of access roads.
is designed with a curve to direct the approach flow and • Excavation of the diversion tunnel approach and
has an "L" section to withstand the right rockfill dam discharge channels, except the rock septa for cofferdams.
lateral loads. Adjoining the spillway and the right side • Tunnel excavation.
wall is the concrete gravity dam that joins the concrete • Excavation of the main structures on the right bank,
structures to the right rockfill dam. This concrete structure except the rock septum at El. 780 along the riverbed
is 22.0 m long at the base and 20.0 at the crest, 10.0 m that was used as a cofferdam.
wide and contains the stoplog storage shaft, • Start of concrete works, except the spillway.
7.5 x 14.0 m x 10.5 m deep.
Results from the hydraulic model tests showed that Second Phase: Diversion Through the Tunnel
instabilities were noticed on the right side of the approach • Removal of the septa located at the channel ends.
channel that reached up to gate 4 of the spillway. To • Construction of the cofferdams: upstream (El. 776.2)

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and downstream (El. 773.0). Tailwater

• Dewatering of the cofferdam area. Maximum flood level 787.40 m
• Excavation of the cutoff trench at the base of the main Normal level (3 Units) 771.52 m
dam. Minimum level (1 Unit) 769,03 m
• Grouting of the bottom of the cutoff trench.
• Compacting of earthfill in the trench. River Diversion
• End of construction of the concrete intake tunnel portal. Type Tunnel
• Start of construction of the structures: erection bay and Length of Tunnel 211.0 m
equipment discharge platform, powerhouse units 1 and Section: half circular/rectangular Ø 10.6 m
2 blocks, intake units 1 and 3, right side guide wall, stilling
basin walls and slabs, left side guide wall and the gravity Diversion Flows
wall. Flow Recurrence:
• Start of the substation construction and second stage 25 years: All 1st Phase 2,442 x m3/s
concrete of powerhouse units 1 and 2. 20 years: Dry Period 2nd Phase 1,094 x m3/s
• Start of spillway concrete placement. 50 years: All 3rd Phase 2,791 x m3/s
• Construction of the earth dam on the right bank.
Tunnel Closure Gates
Third Phase: Diversion Through the Tunnel and Quantity 2 gates
Riverbed Width 5.0 m
• Partial opening of the upstream and downstream Height 11.6 m
cofferdams, which were submerged and the floods
passing through both the diversion tunnel and the riverbed. Power Generation
• Continuation of concrete placement in the structures: Installed Capacity 180 MW
erection bay, first stage concrete of powerhouse unit 1, Firm Output 99.77 MWh/h
intake units 1 and 3, right side guide wall, stilling basin
walls and slabs, left side guide wall and concrete gravity Guaranteed Output (95%)
dam. Peak Load 180 MW
• Continuation of construction of the substation and Off Peak Load 29 MW
second stage concrete of powerhouse units 1 and 2. Annual Output 874,000 MW/h
• Continuation of concrete placement on the spillway. Peak Load 139,000 MW/h
Off Peak Load 735,000 MW/h
Fourth Phase: Only Tunnel Diversion
• First stage cofferdams recovery. Main Dam
• Main dam foundation surface cleaning and treatment. Type Earth-Rockfill
• Construction of the main dam riverbed section and Length 420.0 m
left bank section. Height 50 m
• End of right rockfill dam construction. Crest Elevation 811.3 m
• End of construction of all concrete structures and Width of crest 8.0 m
substation.
• Sealing of the diversion tunnel with a concrete plug. Spillway
• Reservoir filling. Length 64.6 m
• End of architectural finishing and landscaping around Spillway crest El. 811.0
the powerplant. Overflow ogee sill El. 793.5
Gate type and operation Radial - Hydraulic
7. TECHNICAL DATA Size and number of gates 12.5 x15.45 m-4 units
Design flood (10,000 years) 7,356 m3/s
Reservoir Gantry crane capacity 200 kN/45 kN
Area at El. 810.70 38.32 km2 Spillway Stoplogs 6 sections/slot
Area at El. 808.00 34.71 km2 Size/number 12.5 x 2.4 m / 6 units
Total storage at El. 808.0 268.93 x 106 m3
Total storage at El. 807.0 241.30 x 106 m3 Intake
Active storage 25.84 x 106 m3 Type of structure Gravity
Maximum flood level elevation 810.7 m Length 44.7 m
Maximum normal level elevation 808.0 m Number of blocks 3
Minimum normal level elevation 807.0 m Intake crest El. 811.0

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Intake Emergency Gates Generator

Gate type and operation Wheel - Servo Type Vertical axis
Number: 1 per Intake block 1x3=3 Rated capacity 63.2 MVA
Size: width x height 5.8 x 7.16 m Voltage 10.0 kV
Gantry crane (serves Spillway as well) - Frequency 60 Hz
Intake Stoplogs 3 sections/slot Transmission Line Connection Works
Size/number 5.8 x 3.0 m / 3 units 1. Powerplant - Substation Interconnection
3 x 138 kW Transmission Lines - 1 Double and 1 Single
Penstocks Circuit: CAA aluminium cables - 400 m distance between
Number of penstocks 3 structures
Length 48 2. Substation Interconnection to CEMIG's Distribution
Diameter 7.0 m System
Sectioning of the Campo Belo - Lavras Transmission Line
Powerhouse near the FUNIL Powerplant
Type Indoor Construction of 2 double circuits, 138 kV Transmission
Length 85.0 m Lines - 2000 m distance
One - Overhead crane 900/250 kN Construction of 1 single circuit, 138 kW Transmission
Draft Tube Stoplogs 2 sections/slot Line - 19,000 m distance
Size/number Transmission Cables: CAA 170.5 mm² - LINNET
2 sluiceways x 2 sections 6.56 x 4.55m: 4 units Lightening Arrestor Cables: 5/16" HS - Galvanized Steel
Draft tube gantry crane 160 kN
Project Developers
Turbine Owners CVRD Companhia Vale do Rio Doce, Cemig
Type Kaplan Engineer SPEC
Rated capacity 61.5 MW Contractor Consórcio Construtor Funil (IMPSA,
Centerline of distributor El. 763.0 Servix/Mendes Júnior, Spec, Orteng, Delp e ULTRATEC)
Rated Flow 191 m3/s
Rated Head 35.3 m
Maximum Head 39.0 m
Minimum Head 32.5 m
Design Head 35.5 m
Operating speed 150.0 rpm

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