KHANI KHOLA-1 HYDROPOWER PROJECT

Monthly Progress Report

GREENLIFE HYDROPOWER LIMITED Kamalpokhari, Kathmandu

Phone: 977-1-4411373 Fax: 977-1-4411373

KHANI KHOLA-1 HYDROPOWER PROJECT

Dolakha, Nepal

MONTHLY PROGRESS REPORT September - 2021

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TABLE OF CONTENTS

1.0 Civil Works

1.1 Head Works 3

1.1.1 Intake 3

1.1.2 Feeder Pipe 4

1.1.3 Underground Feeder Tunnel 5

1.1.4 Desander and Flushing 5

1.1.5 Head Pond 7

1.1.6 Headrace Tunnel 7

1.2 Surface Penstock 8

1.3 Power House 9

1.4 Switchyard 10

2.0 Electro Mechanical Works 11

3.0 Hydro Mechanical Works 14

3.1 Head Works 14

3.2 Headrace Tunnel 14

3.3 Surface and Underground Penstock 15

4.0 Transmission Line 17

5.0 Project Schedule 18

6.0 Observation and Conclusion 19

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1.0 CIVIL WORKS

1.1 HEADWORKS

1.1.1 INTAKE

WEIR: 100% completed

INTAKE: 100% completed

UNDERSLUICE: 100% completed

GRAVEL TRAP: 100% completed

Figure 2: Headworks (Intake side view)

Figure 2: Headworks (Intake top view)

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1.1.2 FEEDER PIPE

The feeder pipe connecting the bell mouth intake and feeder tunnel has already been 100% completed

with all the anchor block and pier block supports.

Figure 3: Feeder pipe (towards feeder tunnel)

Figure 4: Feeder Pipe (from intake)

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1.1.3 UNDERGROUND FEEDER TUNNEL

Excavation is 100% complete. PCC and soling at the invert is going on and will be completed within

the month of Asoj.

Figure 3: Feeder Tunnel inlet

1.1.4 DESANDER AND FLUSHING

70% of the work is completed. Desander section is divided into 3 sections

Bay 1 (D1) Excavation, Stone masonry work and concreting work of basin is completed. Inlet gate sections are

raised up to the sill beam level. Concreting work is going on at outlet gate and will be ready within

Asoj for the hydro-mechanical team for erection of gate frames.

Figure 4: Desander(concreting works at the inlet gate)

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Bay 2 (D2)

Excavation is 100% complete. Concreting work on hopper is completed. The concreting work of final

6m portion of the desander is completed upto 1.5m and further concreting works will be completed till

the month of Asoj.

FLUSHING GATE

The flushing gate base slab has been concreted leaving the groove for the gates and further HM installation for

gate frames.

Figure 5: D2 (Concterte works upto 1.5m)

Figure 5: D2 (Concterte works upto 1.5m)

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1.1.5 HEADPOND (HP)

Excavation is 100% complete. This section can only be initiated once D2 concreting is complete.

Concreting can only be initiated after erection of HM gates and flushing pipes. The expected time for

completion of the headpond is 30 days (Magh 30, 2078).

FLUSHING TUNNEL

The excavation has been completed. The finishing touch is left, which can only be completed after we

install the flushing pipe.

1.1.6 HEADRACE TUNNEL

The excavation is completed 100%. Pipe laying work from adit to downstream is going on.Grouting and

invert cleaning work is going on. We are expecting it to be completed within the month of Kartik.

Erection of tunnel steel lining is ongoing.

The details are as below:

Total length of lining = 1223m

Lengh finished upto date = 991m

Lengh remaining upto date = 232 (delayed due to 5 ton ropeway breakdown).

Figure 6: Headpond

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1.2 SURFACE PENSTOCK

AB1, AB2, AB17, AB18 are remaining. The drilling of holes for anchorage for anchor block no. 18 is

finished. The reinforcement work is completed. The section of AB-17 and Ab-18 has mass concreting so

construction material plays a critical role. We have already managed sand and aggregate for this section.

They will be available at site within a month. Once materials are available, it will be completed in a

month (expected date Kartik 30,2078).

Figure 7: AB 17 Ongoing Works

Figure 8: AB 17 Ongoing Works

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1.3 POWERHOUSE

Column and beams has been erected. Roof has been

completed. The foundation for the electromechanical

equipments has been concreted.

The cable trench leading towards the switchyard has

been excavated and concreting will be soon

completed.

The reinforcement works for water pump and other

water outlet components’ foundation are going on.

The second stage concreting at turbine and generator

is 70% completed.

The concreting turbine and generator foundation will

take 15 days to complete and will be concluded in the

3rd

week of Asoj.

The drilling of the bifurcation has been completed.

Concreting in branched penstock near the

powerhouse is yet to be done and will completed with

in Asoj.

Figure 9: Power House

Figure 10: EM items inside powerhouse

Figure 11: Turbine Bifurcation and branch pipe

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1.4 SWITCHYARD

The Previous location where the works for the switchyard has been badly destroyed by the flood of

Hanabu Khola (Asar 9, 2078). So, that location is discarded and new safe location is selected.

The engineering design of the retaining wall & foundation for the electrical equipment’s erection is

completed. These works will be completed within 2 months and further works of erection will be

completed in the next month. So, the expected time for the completion of switchyard is Manshir 30,

2078 barring all required items purchased on time.

The materials and equipment near the switchyard area has totally been either destroyed or swept away

by the flood. Engineer from the Insurance Company has already visited the affected area on 24th

of

Bhadra and we are in the process of claiming the insurance.

Figure 12: Discarded Switchyard Location

Figure 13: New Safe Switchyard Location

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2.0 ELECTRO-MECHANICAL WORKS

The overall progress of the Electro-mechanical works is shown in the table below:

S.

No Description / Items Qty.

Erection

Progress / Status Remarks

1 Repair & Maintenance of EOT Crane, 45/10 Ton,

10.5m Span 1 Set. Completed

2 Erection of Lighting System at Power House 1 Set. Completed

3 Turbine Housing (Seat) Assembly, Unit # 1 1 Set Completed

4 Turbine Housing (Seat) Assembly, Unit # 2 1 Set Completed

5 Turbine Runner, 1,650mm PCD, Unit # 1 1 Set Completed

6 Turbine Runner, 1,650mm PCD, Unit # 2 1 Set 90 % Completed

7 Turbine Nozzle Assembly, Unit # 1 1 Set Completed

8 Turbine Nozzle Assembly, Unit # 2 1 Set Completed

9 Turbine Servo Motor Assembly, Unit # 1 1 Set Completed

10 Turbine Servo Motor Assembly, Unit # 2 1 Set Completed

11 Turbine Water Deflector Assembly, Unit # 1 1 Set Completed

12 Turbine Water Deflector Assembly, Unit # 2 1 Set Completed

13 Turbine Bifurcation (600mm to 450mm I.D.), Unit # 1

1 Set Completed

14 Turbine Bifurcation (600mm to 450mm I.D.), Unit # 2

1 Set Completed

15 Turbine Branch Pipe (450mm I.D.) , Unit # 1 1 Set Completed

16 Turbine Branch Pipe (450mm I.D.) , Unit # 2 1 Set Completed

17 Water Pipe Line from MIV to Turbine Nozzle Unit # 1

1 Set Completed

18 Water Pipe Line from MIV to Turbine Nozzle Unit # 2

1 Set Completed

19 Generator Foundation Base Frame Unit # 1 1 Set Completed

20 Generator Foundation Base Frame Unit # 2 1 Set Completed

21 Generator Stator, Unit # 1 1 Set Completed

22 Generator Stator, Unit # 2 1 Set 80 % Completed

23 Generator Rotor, Unit # 1 1 Set Completed

24 Generator Rotor, Unit # 2 1 Set 80 % Completed

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25 Main Inlet Valve (MIV), 600mm I.D., Unit # 1 1 Set Completed

26 Main Inlet Valve (MIV), 600mm I.D., Unit # 2 1 Set Completed

27 Transformer Body, 132 kV/11kV, 18 MVA, Unit # 1 1 Set 90 % Completed

28 Transformer Body, 132 kV/11kV, 18 MVA, Unit # 2 1 Set 90 % Completed

29 Generator 400mm Pedestal Radial Bearing, Unit # 1 1 Set Completed

30 Generator 400mm Pedestal Radial Bearing, Unit # 2 1 Set 75% Completed

31 Generator 600mm Pedestal Radial Bearing, Unit # 1 1 Set Completed

32 Generator 600mm Pedestal Radial Bearing, Unit # 2 1 Set 75% Completed

33 Erection of Base Steel Channel at Control Room for

Control Panel 1 Set Completed

34 High frequency power switch supply panel 2 Set 75% Completed

35 High frequency charge panel 1 Set 75% Completed

36 High frequency meter 1 Set 75% Completed

37 Earthing panel 2 Set 75% Completed

38 Incoming cabinet 1 Set 75% Completed

39 Feeder cabinet 6 Set 75% Completed

40 Incoming cabinet 1 Set 75% Completed

41 Withdrawable metalclad AC switchgear 10 Set 75% Completed

42 Excitator panel 1 Set 75% Completed

43 1 # Unit LCU panel 1 Set 75% Completed

44 2 # Unit LCU panel 1 Set 75% Completed

45 Station transformer protection, measuring and control panel

1 Set 75% Completed

46 110 KV Line protection panel 1 Set 75% Completed

47 Public LCU panel 1 Set 75% Completed

48 Synchronizing panel 1 Set 75% Completed

49 Measurement panel 1 Set 75% Completed

50 Net panel 1 Set 75% Completed

51 110 KV line light equation protection panel 1 Set 75% Completed

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52 1 # Unit generator protection panel 1 Set 75% Completed

53 2 # Unit generator protection panel 1 Set 75% Completed

54 Central control station 1 Set 75% Completed

55 Power Cable & Control Cable Bridge (Ladder) 1 LS 60% Completed

Table 1: Overall Erection Progress of KK1HPP Electro-Mechanical Items.

Figure 13: EM Control Panel inside of Power House at Control room

Figure 13: EM Control Panel inside of Power House at Control room

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3.0 HYDRO-MECHANICAL INSTALLATION

3.1 Headworks

The gate frames for Under sluice, Bell mouth intake and both the Desander inlet has been installed.

Connecting pipe installation has been completed.

3.2 Headrace Tunnel

HRT pipe has been divided into 2 sections:

1. 0m to 950m chainage (Section A)

Channel placing from 0m to 950 has been installed.

Figure 14: under sluice gate frame erection

Figure 16: Pipe being hauled into HRT Figure 15: Channel laying inside HRT

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2. 950m to 1200m chainage (Section B)

Channel from 950m to 1200m has been transported inside the tunnel. Pipe laying work from

chainage 950m to 500m has been completed.

We feel this HRT pipe section will be completed within 2 months barring unforeseen issues

cropping up.

3.3 SURFACE AND UNDERGROUND PENSTOCK

A) AB1 TO AB2‘s design has been completed. The location of Ab1 has been spotted on site.

AB3 to AB16 has been completed.

Figure 17: Pipe Being hauled into HRT Figure 18: Preparing to haul pipe into HRT

Figure 19: Penstock AB2 to AB16

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B) AB17 to AB18 (VERTICAL SHAFT SECTION)

This section is the most critical part of our project. Due to small shaft diameter, we had to come up with

a new methodology to erect the pipe. We designed a lifting arrangement especially for this project. This

methodology and technique has never been attempted anywhere (as per our knowledge) in the world.

Our earlier attempt was not a success and this greatly hampered the timeline of our project. After

rehashing and correcting the design of the lifting mechanism, we have been successful in lifting the

pipes. Currently, out of 278 m, we have successfully completed 278m (100%). Drilling of anchor holes

for anchor block no. 18 has been completed and reinforcement laying work is on going.

Figure 17: Dewatering for AB 18 foundation

C) AB18 to PH

The majority of the pipes, bend and bifurcation

has been completed in this section. The remaining

section will be completed once we finish the

vertical pipe section. The backfill concreting in

the vertical shaft is remained.

Figure 18: Lifting of vertical pipe

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4.0 TRANSMISSION LINE

Till now 25 of the total 56 towers are already erected. The foundation of the 44 towers has been

completed and others are on-going. Two special towers has been designed and procured as per the site

need.

Items such as ACSR conductor, Hardware fitting, Gantry for switchyard and Singati Substation, special

towers & optical arrangement at powerhouse and Singati Substation are required in the site for the

further work progress which will be ordered immediately.

At the current pace, the remaining foundation on-going with be completed till Asoj, 2078. Once

foundation is completed, Remaining works will be completed within two & half months barring all

items mentioned above are purchased on time.

Figure 21: Transmission Tower

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5.0 PROJECT SCHEDULE

The project schedule for the remaining works is as follows:

Works Asoj Kartik Manshir Poush Magh

Civil Works

Hydro Mechanical works

Electro Mechanical works

Switchyard

Transmission line

Testing & Comissioning

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6.0 OBSERVATIONS AND CONCLUSION

The major section of this project has been progressing at a desired rate except for the HRT pipe pulling

which is affected by the flood on the Power House area in Asar 9, 2078 as we are unable to operate 5

ton ropeway.

The major works of headworks, desander, HRT pipe, vertical pipe and major anchor blocks has been

completed by falgun. The final finishing works is still in progress. We feel confident that we can

complete this project shortly besides Transmission Line and EM works. The completion of Transmission

Line depends on the availability of the required materials, equipment & Indian skilled manpower.

With the reference to work completed in the site till august, 2021 we found 90% of Civil works has been

completed and the remaining will be completed till Kartik, 2078. Also, 50% & 95% of Electro

Mechanical and Hydro Mechanical works respectively has already been completed and we are planning

to complete the remaining works till Poush, 2078. Further 50% of the transmission line has also been

completed and the remaining works will be completed till Poush, 2078.

Thus, if everything goes in our favor and if we achieve our targeted works as planned we could be able

to produce around 13.33 MW (one third of our Plant capacity i.e. wet power) from Magh, 2078. After

that we will be going ahead for additional 15 MW power by diverting water from Hanabu khola and

Napke khola which are itself the tributaries of Khani khola.