Final Report of Group 6 Sundarijal HPP

KATHMANDU UNIVERSITY SCHOOL OF ENGINEERING DEPARTMENT OF CIVIL AND GEOMATICS ENGINEERING

FINAL REPORT ON RUM OF SUNDARIJAL HYDOPOWER PLANT A fourth year mini project for the partial fulfillment of requirement requirement of Bachelor ’s Degree in Civil Engineering (CIEG 406)

PROJECT MEMBERS: GROUP: 6 Biplav Acharya (Roll No. 01) Ashish Dangal (Roll No. 12) Mingma Lama (Roll No. 31) Radheshyam Mandal (Roll No. 32) Rishab Nakarmi (Roll No. 33) Pratik Shahi (Roll No. 47) Sagun Shrestha (Roll No. 53)

SUBMITTED TO: DEPARTMENT OF CIVIL AND GEOMATICS ENGINEERING Prof. Dr. Ing. Ramesh Kumar Maskey Project In-charge

January 4, 2014

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ACKNOWLEDGEMENT We would like to thank Prof. Dr. Ramesh Kumar Maskey, for providing us an opportunity to work on this project and helping in various aspects during consultation. We would also like to thank the staffs of DOCGE and friends for their unending support and encouragement.















ABSTRACT Sundarijal Hydropowe Hydropowerr Plant, although being an old plant is generating 640kW, its installed capacity. The plant is already in the process of of RUM by NEA which is on on its way for increase in power power generation. The The RUM project carried out by us, a team of 7 students of Fourth Year Civil Engineering program has detected some components that have degraded and has given suitable design, drawings and suggestions. The hydropower plant is found to be optimistic in terms of further development and more hydropower generation.















Table of Contents ABSTRACT .............................................. ........................................................................ ............................................. ............................................. ..................................................... ........................................ ............. 3 ACRONYMS ............................................ ............................................................... ............................................. ..................................................... ..................................................... ....................................... ............. 7 1. INTRODUCTION........................................... ............................................................. ............................................. ..................................................... ..................................................... ............................... .... 8 2. PROJECT AREA............................................. ............................................................... ............................................ ..................................................... ..................................................... ............................... ..... 9 2.1 History........................................... ............................................................. ............................................. ..................................................... ..................................................... ....................................... ............ 9

2.2 Geography............................................. ............................................................... ............................................ ..................................................... ..................................................... ............................. ... 10 2.3 Climate ............................................. ............................................................... ............................................. ..................................................... ..................................................... .................................. ....... 10 3. THEORY .............................................. ........................................................................ ............................................. ............................................. ..................................................... ...................................... ........... 11 3.1 Rehabilitation........................................................... ...................................................................................... ..................................................... .................................................... ............................ .. 11 3.2 The Bathtub Curve ........................................................... ...................................................................................... ..................................................... .............................................. .................... 12 3.3 Levelling: ........................................... .............................................................. ............................................. .................................................... .................................................... ................................. ....... 12 3.4 Bowditch Rule:............................................................. ....................................................................................... .................................................... ................................................... .........................13 3.5 Penstocks: ............................................. ............................................................... ............................................ ..................................................... ..................................................... ............................. ... 14 3.6 Penstock Alignment ............................................. ........................................................................ ............................................. ............................................. ........................................ .............14 3.7 Gross Head (H) and Net Head (h): ............................................ ............................................................... ............................................. ............................................. ................... 15 3.8 Firm Powe r and Secondary Power: ............................................... ......................................................................... ............................................. .................................. ............... 15 3.9 Flow Duration Curve: ........................................................ ................................................................................... ..................................................... ............................................. ................... 15 3.10 Mass Flow Curve ...................................................... ................................................................................ .................................................... ............................................. ........................... ........ 16 3.11 Support Piers................................................. ............................................................................ ............................................. ............................................. ............................................. ..................16 3.12 Energy and Hydraulic Grade Lines: ......................... ................................................... ..................................................... ..................................................... ............................ 16 The Bernoulli Equation ........................................... .............................................................. ............................................. .................................................... ....................................... ............. 17 4. RATIONALE ............................................. ............................................................... ............................................. ..................................................... ..................................................... .................................. ....... 17 5. SCOPE OF THE PROJECT .................................................... .............................................................................. .................................................... ............................................. .......................... ....... 18 6. OBJECTIVES ............................................ ............................................................... ............................................. ..................................................... ..................................................... ................................. ....... 18 7. METHODOLOGY ............................................. ........................................................................ ............................................. ............................................. .................................................... .........................18 8. Field Measurement Of Head O f Sundarijal HPP ....................... ................................................. ..................................................... ......................................... .............. 19 8.1 Height Difference From Powerhouse To Dam S ite ........................................ ........................................................... ........................................... ........................ 19 8.2 Height Difference From Dam S ite To Powerhouse ........................................ ........................................................... ........................................... ........................ 22 ............................................................... ............................................. ............................................. ................... 25 8.3 Correction By Bowditch’s Method ............................................ 9. FIELD MEASUREMENT OF DISCHARGE.............................. DISCHARGE......................................................... ..................................................... ................................................... ......................... 30















9.1 Determination of Cross Section .................................................. ............................................................................. ..................................................... ................................... ......... 30 9.2 Determination of Velocity.................. Velocity ............................................. ............................................. ............................................. ..................................................... ............................... ..... 32 9.3 Discharge ............................................. ....................................................................... ............................................. .............................................. ..................................................... ............................. ... 32 9.4 Measurement of discharge from canal ...................... ................................................ .................................................... ............................................. ........................... ........ 32 9.5 Flow Duration Curve ............................................................. ...................................................................................... .................................................... ........................................... ................ 33 9.5.1 MIP Method........................................................... ..................................................................................... .................................................... .................................................. ........................33 9.5.2 Flow Duration Curve .......................................................... .................................................................................... ..................................................... ...................................... ........... 34 9.6 Total Discharge ............................................ ............................................................... ............................................. ..................................................... ................................................ ..................... 35 10. FINDING HYDROPOWER POTENTIAL USING OBTAINED FIELD INFORMATION........................................... ............................................. .. 36 10.1 Design of penstock for that hydropower potential ................................................... .............................................................................. ............................. .. 36 10.2 Penstock Alignment........................................................... ...................................................................................... ..................................................... .......................................... ................37 10.3 Calculation of major and minor losses ..................... ............................................... ..................................................... .............................................. .......................... ....... 38 10.3.1 Calculation of friction factor ................................................... ............................................................................. ............................................ ............................... ............. 38 10.3.1 Calculation of head loss ........................................................ .................................................................................. .................................................... ................................. ....... 39 10.4 Remarks ............................................. ........................................................................ ............................................. ............................................. .................................................... .........................39 11 CALCULATION OF FIRM POWER AND SECONDARY POWER ........................................................... .......................................................................... ............... 40 12. CALCULATION OF FLOW MASS CURVE ...................................................... ................................................................................. ................................................... ........................42 13 .DESIGN OF SUPPORT PIER ............................................ ............................................................... ............................................. .................................................... ................................... ......... 43 13.1 Design ............................................ ............................................................... ............................................. ..................................................... ..................................................... ................................. ....... 43 13.2 Stability Analysis ............................................. ............................................................... ............................................. ..................................................... ........................................... .................47 13.3 Cost Estimation ........................................... .............................................................. ............................................. ..................................................... ............................................... ....................48 14. INSPECTION WORKS....................................... WORKS......................................................... ............................................. ..................................................... .................................................. ........................49 15. PUBLIC CONSULTATION ............................................ ............................................................... ............................................. ..................................................... ....................................... ............50 16. PROJECT SCHEDULE ............................................. ....................................................................... ............................................. .............................................. ............................................ .................51 17. OUTCOMES ........................................... .............................................................. ............................................. .................................................... .................................................... ................................. ....... 52 18. LIMITATIONS OF THE PROJECT ............................................................. ....................................................................................... .................................................... .............................. .... 52 19. CONCLUSION AND RECOMMENDATIONS............................................. ....................................................................... ............................................. .............................. ........... 52 20. REFERENCES ............................................. ....................................................................... ............................................. .............................................. ..................................................... ............................. ... 53 PICTORIAL HIGHLIGHTS........................................... .............................................................. ............................................. ..................................................... ............................................... .................... 54















LIST OF FIGURES Figure 1 Location of Sundarijal in Nepal ......................... ................................................... ..................................................... ..................................................... ................................. ....... 9 Figure 2 View of Bagmati from Sundarijal Source: Wikipedia.org ........................................... .............................................................. ........................... ........ 10 Figure 3 The figure illustrates how energy production is lost over time . The Upgrade vs Life extension .......... 11 Figure 4 Bathtub Curve ........................................................... ..................................................................................... .................................................... .................................................. ........................ 12 Figure 5 Differential Levelling ................................................... ............................................................................. ..................................................... ............................................. ..................... ... 13 Figure 6 Cross Section A-A of river............................... river.......................................................... ..................................................... ..................................................... .................................. ....... 30 Figure 7 Cross Section B-B of River .......................................... ............................................................. ............................................. .................................................... .............................. .... 31 Figure 8 Flow Duration Curve ......................................................... .................................................................................... ..................................................... ......................................... ............... 34 Figure 9 Penstock Alignment .......................................................... ..................................................................................... ..................................................... ......................................... ............... 37 Figure 10 Moody Diagram ............................................. ........................................................................ ............................................. ............................................. ........................................ ............. 38 Figure 11 Flow Mass Curve ......................... ................................................... .................................................... .................................................... ............................................. .......................... ....... 42 Figure 12 Cross S ection of Penstock .................................................. ............................................................................ ............................................ ....................................... ..................... 44 Figure 13 Support pier e levation with saddle and penstock ........................................................... .............................................................................. ................... 45 Figure 14 Cross section of penstock resting on support pier .......................................................... ............................................................................. ................... 46

















ACRONYMS ASME – American American Society of Mechanical Engineers BM – Bench Bench Mark HPP – Hydropower Hydropower Power Plant JNN – Journal Journal of Nanoscience and Nanotechnology MIP – Medium Medium Irrigation Project RUM – Rehabilitation Rehabilitation Upgradation and Modernization Modernization USBR – The The United States Bureau of Reclamation (USBR) VDC – Village Village Development Committee

















1. INTRODUCTION Sundarijal HPP is the second oldest hydropower established in Nepal which lies in Sundarijal VDC named after Hindu goddess ‘Sundarimai’. The VDC touches Nuwakot and Sindhupalchowk district and is located in Shivapuri National Park at the north of Kathmandu Valley. It is 15 km northeast from the centre of Kathmandu. The climate is of Temperate type. During summer, the temperature is 25.5 ˚ C in average and

temperature drops down to 0 ˚ C during winter. Tamangs, Chheteris and Brahmins are the major ethnic group of this region. The major religion here is Buddhism.

With installed capacity of 640 kW and annual design generation of 4.77 GWh was commissioned in 1934 AD in a grant from British government.The powerhouse powerhouse lies near Sundarijal Buspark. Initially, there were three units of turbines; one of 600kW and two of 320kW. Due to mechanical failure, the larger one was shut down. The salient features of Sundarijal HPP is listed below:

Type Location Installed capacity Annual average energy Maximum net head Penstock Turbine Number and Type Type Rated output Rated Speed Generator Rated output Rated voltage Rated frequency Power factor Power transformer Transmission line

Run of River Sundarijal, Kathmandu 640 kW 4.77 GWh 750 ft. (228.6m) 1700 m long, 0.61 m dia.

2, Horizontal Pelton 485 kW 900 rpm 377 kVA 3.3 kV 50 Hz 0.85 3.3/11 kVA, 2 Nos. 11 kV

Table 1: SAILENT FEATURES OF SUNDARIJAL HYDROPOWER STATION

















2. PROJECT AREA

Figure 1 Location of Sundarijal in Nepal

Country: Nepal Zone Bagmati Zone District: Kathmandu District Area Total: 5.18 km2 (2.00 sq mi) Population (2001) Total: 2,586 Density: 500/km2 (1,300/sq mi) Time zone: Nepal Time (UTC+5:45) (UTC+5:45) Postal code: 44603 Area code(s): 01 Sundarijal is a village development committee in Kathmandu District in the Bagmati Zone of central Nepal.

2.1 History The VDC was named after the Hindu goddess, Sundarimai. A temple is dedicated to the deity in

















2.2 Geography Sundarijal is located 15 kilometres (9 mi) northeast of Nepal's capital, Kathmandu. It is west of Gagalphedi, east of Nayapati and Baluwa, and north of Aalapot. The VDC touches Nuwakot and Sindhulpalchok Districts to the north. Sundarijal covers an area of 5.18 square kilometres (2 sq mi). The Bagmati River flows through the VDC, where it is joined b y the Shyalmati and Nagmati Rivers. Largely hilly in its terrain with few flat areas, the VDC is covered by forests. Shivapuri National Park covers large amounts of the Sundarijal.

Figure 2 View of Bagmati from Sundarijal Source: Wikipedia.org

2.3 Climate

The climate of Sundarijal is temperate. The average for the summer is 25.5˚C while that for the winter is 0˚C.

















3. THEORY 3.1 Rehabilitation Hydroelectric station rehabilitation covers a broad set of activities, including repairing/replacing repairing/replacing components, upgrading generating capability and availability, realigning services to meet market opportunities and new market requirements and modifying the management of water resources to enhance ecosystems. In the current study, rehabilitation is focused on the major electrical electrical and mechanical equipment associated with power generation, namely namely the turbine and generator. Other components would be included in most rehabilitation rehabilitation projects and would would contribute to the overall cost cost but major civil civil works changes (with the possible exception of draft tube modifications) are excluded. Rehabilitation can start with the replacement of equipment on a “like for

like” basis where there is minimum effort to enhance the overall output of the station. The primary objective of this is to provide

“life extension” to the existing facilities and restore their initial performances. performances. In contrast it can often be j ustified to include

an “upgrade” of the equipment (efficiency, output) which yields greater output but at increased costs which is justified by the additional revenue over over service life of the Figure 3 The figure illustrates how energy production is lost over time. The Upgrade vs Life extension equipment. This study examines examines both of these investment scenarios. Non-structural optimization, such as improved operation rules based on improved hydrology, timing of releases in cascades etc has not been considered. Project Expansion

Hydroelectric generating generating stations have been known to have service lives of up to 100 years and in some instances even longer. Where the service life is long then it is quite likely that the station may not be developed to its economic potential based on today’s energy and capacity values and equipment cost and performance. performance. In such instances instances an increase increase in station capacity capacity (Project Expansion) Expansion) by installing installing



















3.2 The Bathtub Curve

Figure 4 Bathtub Curve

The bathtub curve is widely used in reliability engineering. It describes a particular form of the hazard function which comprises three parts. The first part is a decreasing failure rate, known as early failures. The second part is a constant failure rate, known as random failures. The third part is an increasing failure rate,



















Differential Leveling

Differential leveling (also called direct leveling) is generally used in determining elevations elevations of points to establish a chain or network of BMs for future use. It requires a series of instrument setups along the survey route; and for setup, a horizontal line of sight is established, using a sensitive level.

Figure 5 Differential Levelling

Some terminology used in Levelling: Set: The location of the level. (where it is set-up) Bench Mark (BM): A permanent point of known elevation. Temporary Bench Mark (TBM): A point of known elevation. Turning Point (TP): An intervening point between BMs or TBMs upon which a backsight and a foresight are taken. Backsight (BS): A rod reading taken by "looking back" at a point of known elevation such as a BM or TP.



















3.5 Penstocks: A penstock is a pipe that conveys the flow from the forebay or surge tank to the turbine. Penstocks are designed to carry water to the turbines with the least possible loss of head consistent with the overall economy of the project. These are pressurized water conduits which convey water to the turbines from free surfaces. Design of penstock pipe: Using USBR formula, Veco=0.125√2gH D=√(4Q/πv) Sarkaria Formula, D = 0.62 P 0.35 H0.65 From JNN Guideline, D=(5.2Q3/H)1/7 For thickness of penstock pipe: Pressure inside Penstock (p) = ρg (H+H0) = kg/cm2 Where, H = static head ; H0= dynamic head = v 2/2g t= pD/2σaη + ε As per ASME code: t= pR/(σaη-0.6 p) + 0.15 tmin= D/ 288 t = (D+200)/400



















3.7 Gross Head (H) and Net Head (h): The gross head is the difference between the water level in the headrace and the water level in the tailrace. For storage plant, gross head (H) is the difference in water level in the reservoir and the water level in the tailrace. For run-of river plant, it is a difference in water level in the point of diversion of water and water level at the point where the water is returned back to river. Net head is the head available available for the turbine. turbine. It is equal equal to the difference difference of total head at at the point of entry and at the point of exit of the turbine. This includes the respective pressure and velocity pressure and velocity head at both places. For impulse turbine, Net head, h=H-Z-hf ; where, hf is headloss

3.8 Firm Power and Secondary Power: The power, which is insured to a consumer at any time of the day, is known as firm power. Firm power is completely dependable and available 100% of time. Such power corresponds to minimum stream flow. Such power can e increased by the use of pondage so that greater minimum flow is available for 100% of time. The secondary power is the amount of power, which is excess of the firm power. It is also called surplus or non-firm power. The plant can deliver the secondary power only for a part of a year. It is comparatively comparatively less valuable and useful in an interconnected system of power plants.



















3.10 Mass Flow Curve The flow mass curve is a plot of the cumulative discharge volume against time plotted in chronological order. The ordinate of the mass curve, V at any time t is thus

∫0  

V=

Where t0 is the time at the beginning of the curve and Q is the discharge rate. The slope of the mass curve at any point represents

=Q=rate of flow at that instant. 

3.11 Support Piers Support piers are required along the straight sections of exposed penstock between anchor blocks. The maximum spacing of support piers to avoid overstressing the pipe is generally 5m. Thin-wall plain pipe can buckle buckle at the support support piers with relatively relatively short spans. In In this case the permissile permissile span can be increased by welding a wear plate to the pipe at each support. This may be economical for pipes larger than 300 mm diameter. Corners of wear plates should e cut with a radius, to avoid stress concentrations. Note that a wear wear plates is also also required where where the pipe leaves leaves an anchor lock, if the span span to the first support pier exceeds that allowed for plain pipe. It is usually not economical to increase the pipe wall thickness in order to increase the s upport pier spacing, but this should be considered where the cost of support piers is significant. A 1400 bearing area from the centre of the penstock diameter should be provided to support the penstock





















The Bernoulli Equation For steady, inviscid, incompressible flow the total energy remains constant along a stream line as expressed through the Bernoulli Equation: p + 1/2 v2 + h = constant along a streamline where: p = static pressure pressure (relative to to the moving fluid) fluid) ρ = density ϒ= specific weight v = flow velocity g = acceleration of gravity





















5. SCOPE OF THE PROJECT The scope of this project is to study Sundarijal HPP under the constraints of hydrology, engineering survey and civil engineering under hydropower engineering. However, the study of catchment area and

the its basin isn’t studied. Similarly, the study of rocks, mines, minerals and other geological aspects are out of the scope.

6. OBJECTIVES 1. To study the hydropower hydropower systems of Sundarijal HPP





















8. Field Measurement of Head of Sundarijal HPP 8.1 HEIGHT DIFFERENCE FROM POWERHOUSE TO DAM SITE WL-M SN

FS

BS T 1

1.155

2 3

M

B

T

RISE M

FALL

B

RL

HD

0.885 CD

999.015

1.105

1.055

1.165

0.94

0.715

2.29

2.19

2.09

0

1.435

1.395

1.355

1.895

1.675

1.455

0

1000.000

30

30

1.085

998.915

89

119

0.735

998.180

31

150





















36

3.145

3.075

3.005

0.2

0.145

0.09

3.53

0

1089.610

26

731

37

1.955

1.855

1.755

0.265

0.205

0.145

2.87

0

1092.480

28

759

38

2.84

2.8

2.76

0.44

0.4

0.36

1.455

0

1093.935

15

774

39

2.95

2.92

2.89

0.325

0.29

0.255

2.51

0

1096.445

10

784

40

2.92

2.89

2.86

0.365

0.345

0.325

2.575

0

1099.020

12

796

41

2.97

2.94

2.91

0.23

0.2

0.17

2.69

0

1101.710

12

808

42

3.185

3.15

3.115

0.1

0.07

0.04

2.87

0

1104.580

13

821

43

3.665

3.615

3.565

0.17

0.14

0.11

3.01

0

1107.590

15

836

44

2.54

2.49

2.44

0.06

0.035

0.01

3.58

0

1111.170

20

856

45

3.42

3.37

3.32

0.46

0.41

0.36

2.08

0

1113.250

14

870





















77

3.57

3.54

3.51

0.255

0.235

0.215

3.405

0

1216.380

20

1302.5

78

0.31

0.24

0.17

0.53

0.46

0.39

3.08

0

1219.460

47

1349.5

79

1.525

1.405

1.285

2.165

2

1.835

0

1.76

1217.700

45

1394.5

80

2.995

2.93

2.865

0.3

0.195

0.09

1.21

0

1218.910

34

1428.5

81

3.04

2.93

2.82

0.68

0.575

0.47

2.355

0

1221.265

28

1456.5

82

3.655

3.62

3.585

0.215

0.185

0.155

2.745

0

1224.010

12

1468.5

83

3.625

3.585

3.545

0.15

0.125

0.1

3.495

0

1227.505

24

1492.5

84

2

1.865

1.73

1.165

1.085

1.005

2.5

0

1230.005

45

1537.5

85

2.82

2.685

2.55

0.39

0.3

0.21

1.565

0

1231.570

53

1590.5

86

0.495

0.435

0.375

0.97

0.84

0.71

1.845

0

1233.415

29

1619.5























































































































































































































































































































































































































































































































Final Report of Group 6 Sundarijal HPP

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