Julius Nyerere Hydropower Station ― the Republic of Tanzania

ELSEWEDY ELECTRIC PSP, a subsidiary of ELSEWEDY ELECTRIC, in a joint venture with the Arab Contractors of Egypt is currently building the Julius Nyerere Hydroelectric Dam. The project is located across the Rufiji River in Selous Game Reserve at Morogoro area, South West of Dar es Salaam where this national project will provide clean electricity to more than 60 million Tanzanians through 9 huge turbines, each with a capacity of 235 megawatts, and a total of 2,115 megawatts.

The construction of the project includes building the main dam, with a total length of 1025m at crest level and 131m in height with a capacity to impound approximately 34 billion m3 of water. The plant will be the largest in Tanzania, with average annual electricity production of about 6,307 GWh.

The generated power is transferred by 400kv transmission lines to a substation where the generated power will be merged with the public power grid. In addition to these, the project includes the construction of four saddle dams for reservoir impounding. It will feature a main spillway located in the center of the main dam, an emergency spillway, and a 660m long diversion tunnel. In addition to the construction of three water transfer tunnels, it will include a permanent concrete bridge and two temporary bridges on the Rufiji River. 

For such a mega project, 3D software becomes crucial since it reduces rework and collisions on-site, and allows the 6000 workers and engineers to work in harmony. The coordination with Trimble's Tekla Structures is very efficient since the software can easily be exported to many extensions. Additionally, many extensions can be imported into Tekla, making modeling and coordination much easier.

“Tekla software's ability to process large and complex models, as well as finding any interferences in the model, helped ELSEWEDY ELECTRIC PSP avoid any errors or defects before construction began. Additionally, materials were saved as a result of increased accuracy.”  Ibrahim Amin, Engineering Director. Elsewedy PSP.

The erection drawings from steel suppliers are much more convenient to review, especially for lattice structures, where the erection drawings cannot show all the information and it is difficult to track thousands of members by tables manually, causing delays in delivery in addition to lack of communication. In Tekla, once the members are selected, the data is immediately displayed, including sections, material grades, bolts, etc.

Effective Estimation & Design

All types of transmission towers and substations gantries can be modeled easily with Tekla Structures, from foundation planning to tower layout and details. With higher levels of collaboration and automation, we optimized production and reduced fabrication and erection errors, and achieved the following:

• 3D models that are accurate as they were built.
• Easily integrated into analysis and design processes.
• Design and detailing are more efficient.
• Machine-to-machine integration.
• Integrated installation schedule.
• Accurate estimation and design.

An as-built 3D prototype expedites estimation and design processes. It allows you to produce more accurate bids. Using Tekla's tower templates and components can dramatically reduce the time and effort you spend on manual work and avoid human error

Efficiencies that benefit the entire tower project.

Tekla software has helped produce an accurate 3D model of the tower's foundations, body, cage, cross arms, and peak. In addition to ladders, platforms, and body extensions, as well as quantity estimations, drawings, and project scheduling.

The 3D model serves as a go-to resource. While the model interfaces with MIS systems and CNC machines, the software integrates with the leading tower analysis solutions and follows industry standards

Smooth project management.

As everyone has access to reliable project information throughout the entire project lifecycle, engineers, detailers, project managers, and others can view or control the model simultaneously.

During the modeling process, conflict is already apparent centralized model data allows collaborative and integrated project management and delivery. It is possible to assure quality control for each item, including assembly drawings and lists of materials that can be accessed easily and are always up-to-date, smooth change management and revision control minimize costly mistakes.

In the case of simple structures that are subjected to many changes, it is best to extract design drawings from Tekla. That way, once you update the model, the drawings are automatically updated accurately.

Tekla Structures excelled at this task by providing a constructible 3D model, error-free information, and reliable modeling for steel structures, Data sharing and communication, Visualization, Clash detection, Building data, Waste and rework, Design tools and integration, These features were integrated into a seamless workflow process throughout the entire design and construction process.

About the company

ELSEWEDY Electric PSP is the EPC turnkey arm of ELSEWEDY ELECTRIC Group. It is a leading Engineering, Procurement, and Construction Contractor in the region with extensive experience in power generation, transmission, water and wastewater, and infrastructure projects. It was established in 2003 to serve the power and energy sectors in a diversified manner.

The company provides a portfolio of services that include conceptual design, supply, construction, as well as installation and maintenance services, nationally and internationally. The company has successfully completed several projects in a diverse range of sectors, such as:

• Beni Suef 4800 MW COMBINED CYCLE POWER PLANT.
• Diwaneya 400 kV GIS Substation.
• Al Layyah Combined-Cycle Power Plant, Sharjah, UAE.
• H-Station at Al Aweer, Dubai, UAE.

Project Objectives:
Generating electricity with a capacity of 2115MW to meet the needs of Tanzania. Control the water flow during a period of flooding and provide the necessary amount of water.

Main items:
Total excavation is about 4 million m3
Total aggregate backfilling is about 7.5 million m3
Total volume of concrete is about 2.6 million m3
Total weight of reinforced steel is about 64000 ton.