Vishnugad-Pipalkoti HE Project(444MW) is under construction on Ala-knanda River in Distt Chamoli, in the state of Uttarakhand. This Project will generate 444 MW Power by installing four turbines of 111MW each. The central feature of this project is its 13.5Km long headrace tunnel with an 8.8 m finished diameter. Out of its 13.5 km length,12.3 km is to be bored by using a double-shield TBM of 9.86 m diameter and the remaining 1.2 km to be bored with the help of DBM. The present authors want to highlight the issues and challenges faced during transportation and installation of the TBM and the universal geological surprises faced by the working team after starting the boring and the remedial measures adopted, therefore. The paper also discusses the analysis and design of the large-sized adit bored in the extremely poor rock conditions and the innovative measures undertaken for its construction. © 2023 The Author(s).