Issue #1. Chirkeysk H.E.P.S.
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The perfect location for a game-designer is usually an engineering marvel which took lots of work to make
The Sulak river begins after the confluence of the Avarskoe Koysu river and the Andiyskoe Koysu river, which are begin in Caucasus mountain and flows into the Kaspiyskoe sea. The length of the river is 160 km, the square of watershed is 13400 km2, the grade is 331m, and average annual run-off is 5.58 km3.
Project of the unique dam and HEPS on Sulak was made by the famous Leningrad institute - NII "Lenhydroproject". HEPS construction started in 1963, ended in 1978.
It was the first such project in the USSR, and it remains the highest
arch dam in Russia.
The Chirkeysk dam is 232,5 meter high and 338 m long, 6 to 30m thick. The Chirkeysk HEPS is a 1 Gigawatt HEPS and the 15th most powerful HEPS in Russia. It makes 2,47 terawatt-hours yearly.
Works amount:
The excavation of rock soil 2143 ths. m3
The embankment of soil 410 ths. m3
Rockfills, drains, filters 133 ths. m3
Concrete and reinforced concrete 1491 ths. m3
Metal construction and mechanisms 9,8 ths. T
Estimated construction cost in the prices of 1969 year - 207,4 million. rub
A. Construction of hydrotechnical buildings - 260,89 million. rub
The cost of storage - 10.9 million. rub
Constructive-wiring works - 215,87 million. rub
B. Cultural and house building - 18,7 million. rub
Capital investments in energy - 283 million. rub
Unit capital investments per 1 calculated kWt - 180 rub
per 1 kWt-hr - 7,3 kop
Schemes:
[
(1) - more stats and schemes at Lenhydroproject]
Construction and trivia:
During the work on such a narrow and deep ravine (width at bottom 15m, at top 350m) for the first time in the Soviet Union the technology of "straight-surface fracture" was used for forming the bank cliffs. The quality of this fracturing done by HydroSpetsStroi on this construction site is referred to as exemplary even until today.
CAPTION: Construction of Chirkeysk HEPS was started like this... 1965. (Work on the foundation pit)
A smaller construction waterway tonnel was first made (seen up on the scheme):
Then, on 29 October 1967 a directed blast in mere seconds displaced 130,000 cubic meters of stone into the Sulak riverbed, forcing the river to flow into the construction tonnel. The blast was 37 tons TNT, with three slow-down stages with an 25m/s interval.
CAPTIONS: Sulak closed with direct blast. Foundation pit works at riverbanks.
On 28th February, 1970 the first concrete is laid in the dam foundation. During the construction of the deep cement hold in the foundation of the arch dam, on 14th May, 1970, the dam was in the epicentre of a Magnitude 9 earthquake in Dagestan. It did not suffer, but the left bank cliffs which should have been holding the arch dam became unstable. It was thus strenthened with concrete and very strong steel anchors. To do this, on 6 various levels three shafts were run, housing each 32 anchors, each under a 50-ton stress, in total the anchors numbering around 300. Their condition is controlled by engineers until this day. There are a total of 34 small anchor shafts, 40 to 98 meters deep.
CAPTION: Concrete strengthening of the unstable cliff massive.
During the creation of the deep concrete block in the base of the dam, for the first time in Soviet HEPS construction a fully-automated system of cementing control was used. The peak of cementing fell on 1972-1975, when during a single month up to 4,5 thousand metres of cracks were cemented.
The construction was done very fast, with concrete filled in by special cable cranes, then straightened by vibro-machines. The unique cable crane system - three cable cranes with a lift mass of 25 tons and a 205-meter rise, with cables as long as 500 meters thrown across the cliffs from one bank to the other, moving 8 cubic meter concrete-filled buckets. To mechanize the works, a tractor chassis vibromachine, a self-propelled cleaner machine to take off the concrete layering on everything around and a excavator-chassis manipulator to move the encasement. All this mechanization allowed to achieve a tempo of up to 12 m^3 of concrete per one man-workday. This method of concrete-laying was dubbed "chirkeysk laying" and marked by high awards in the USSR.
Finally the dam body was filled with 1,275 million m^3 of concrete, and the total amount of concrete laid is around 1,5 million m^3. That is equivalent to a concrete cube with a 110 m side.
CAPTIONS: Concrete is being delivered by cable-cranes and vibrated by machinery. Montage of waterways.
The waterways are huge metallic tubes 5 meters wide and 170 meters long. To strengthen and protect them from outside damage, they were encased into 1,5m thick concrete.
(courtesy: www.audi80.ru)
And so in 1974 the dam body was finished and it was launched in a festive opening ceremony, when in December it gave the first electricity. The date of launch was planned much earlier than the dam reservoir would get filled, and so around half the dam height, an auxillary entrance was made into the first waterway, which put water to the turbine. Later it was removed.
CAPTIONS: The dam is ready. The first hydrounit - ready! Launch!
From 1974 to 1976, all four hydrounits (waterway+turbine) were launched. Due to the narrow ravine, the hydroturbines were placed in chess order, which was also a unique solution for the time. Each turbine is 250 MWt.
CAPTIONS: Hydrounit stator shaft. The hydrounit rotor is delivered. Everyone is ready for the hydroplant launch...
In the HEPS, looking at wires and the dam (courtesy: www.audi80.ru)
A spare rotor - size demonstration (courtesy: www.audi80.ru)
The construction waterway tonnel was cut off, and thus the Chirkeysk reservoir began to fill up. During the fill up, the village Chirkey - the dam's namesake - was sunk. The villagers were moved to New Chirkey (Noviy Chirkey) on the riverbank. For the sinking of their village, they received new housing for free and huge compensations - even until now they legally used free electricity.
CAPTION: Chirkey village (sunk)
To drain excess water in the reservoir, a huge new drain tonnel was built, 10 meters wide and 700 meters long. Around 2400m3 of water can pass through it with a speed of 50 m/s.
CAPTIONS: Construction of the water drain tonnel /coating done now/. Waterways are finished.
The HEPS is almost finished. 01.06.1978, by A. Zybin.
There's also a 800m long automobile tonnel through the right bank cliffs to get to the powerplant. Over the dam on a mountain 500 meters higher, stays the city of Dubki (lit.
Oaks). It is the city of hydroplant workers and builders, most of them still live and work there. It used to be a small town:
CAPTION: The town of the hydro-builders - DUBKI
A huge reservoir panorama from DUBKI
The explosive, drilling and cementing works done by HydroSpetsStroi have been marked by many
VDNKH (All-Soviet Economy Exposition) awards. The collective of engineers and builders of the Chirkeysk HEPS for the following feats - strengthening an unstable cliff massive, arranging electric transmission from a narrow ravine's bottom, constructing the water drain end which allows to throw water off-bank, the waterways for turbines and the "chirkeysk concrete laying" method - were awarded the
Premium of the Council of Ministers of the USSR.
On 9th of February, 1981 the hydrosystem was accepted into industrial exploitation.
15.08.1981, Somov Yuri.
SOURCE MATERIAL:
1. DAG SPETSHYDROSTROI webpage on Chirkeysk HEPS
2. ChirkeyskGESStrois (main construction company) webpage on Chirkeysk HEPS
3. LenHydroProject page on Chirkeysk HEPS
4. RIAN Image Library, "Chirkeysk HEPS"
5. A Chirkeysk HEPS visitor Alenok, who also borrowed most of the photos of construction from a private builder's album
6. Chirkeysk HEPS visitors from Audi80.ru website
7. OAO CDU-ES SOUTH page on the Chirkeysk HEPS