The CCS Hydropower Station headrace tunnel in Ecuador was constructed by a large diameter double-shields tunnel-boring machine(TBM)with an excavation diameter 9. 11 m. The cutterhead was blocked due to the collapse of the surrounding rock in a fault fracture zone when it reached K16+127. 0 m. Based on the results of geophysical prospecting by seismic method along with borehole core analysis, the width of the fault fracture zone and its influencing zone was determined to be about 70 m. The main composition of the surrounding rock was graded as class Ⅳ and class Ⅴ locally, indicating a very poor stability. The upper part of the segment 16. 26 m behind the cutterhead was removed to excavate flank tunnels along the two sides of the main tunnel wall. When the flank tunnels reached the cutterhead, the pilot tunnel was enlarged along the headrace tunnel axis as far as it passed through the fault fracture zone. The advanced anchor bolts and consolidation grouting were used for advanced support before the pilot tunnel excavation. Steel arch, system anchor bolts, hanging net and shotcrete were used for system support after the pilot tunnel excavation. With these support methods, top arch collapse of the pilot tunnel could be prevented during TBM tunneling. When TBM tunneling in fracture zones, the consolidation grouting to the surrounding rock ahead of the tunnel face should be performed at every tunnel cycle to prevent rock collapse. With the employment of above technologies, the TBM was back in normal operation and it successfully passed through the fault fracture zone.