To research the issues and challenges in construction of hydro tunnel in extreme geological condition in India an attempt has been made to discuss various geotechnical problems encountered during tunnelling in Vishnugad-Pipalkoti HE Project (444MW) which is under construction on Alaknanda River in Distt Chamoli, in the state of Uttarakhand. This Project will generate 444 MW Power by installing four turbines of 111 MW each. The central feature of this project is its 13.5Km long head –race-tunnel with an 8.8m finished diameter. Out of its 13.5 km length,12.3km is to be bored by using a 9.86-meter-diameter double-shield TBM and the remaining 1.2km to be bored with the help of DBM. The present study is 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 report also covers the design and analysis of a large-scale adit that was dug in incredibly bad rock conditions, as well as the creative approaches used to build it. © 2023, Central Board of Irrigation and Power. All rights reserved.