BESTPRACTICESANDBENCHMARK

IN
HYDROPOWERGENERATION

http://www.cea.nic.in/best_practices_hydro.html

INTRODUCTION

result of enormous intellectual effort by various power sector

utilities, the document on the Best Practices and Bench Marks in
hydro power generation is so far the most outstanding and valuable
document of its kind in this field. This chapter enlists the names of
individuals and organizations, who have made tremendous
contribution to this gigantic task.

1.

With a view to bring out a detailed document on the best practices and bench
marking covering various aspects of hydro power generation, the Central
Electricity Authority (CEA) constituted a committee under the Chairmanship
of Member (Hydro).

2.

The composition of the committee at the time of inception is given below:

i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)

3.

Member (Hydro), CEA

Representative of NHPC
Representative of KPCL
Representative of MSEB
Representative of HPSEB
Chief Engineer (HMD), CEA
Chief Engineer (HP&I), CEA
Chief Engineer (HAD), CEA
Chief Engineer (HE&RM), CEA
Chief Engineer (HE&TD), CEA

Chairman
Member
Member
Member
Member
Member
Member
Member
Member
Member-Secretary

The broad frame work of the document envisaged is as under:

i)
Design and Engineering philosophy Best Practices & Bench
Marking
ii)

Bench Marking of Generation Technologies

1

4.

5.

iii)

Project Construction & Monitoring and Bench Marks of Project

Completion.

iv)

Investigation of Hydro Projects Best Practices & Bench Marking

v)

Appraisal of Hydro Projects Best Practices & Bench Marking

vi)

Renovation & Modernisation of Hydro Projects Best Practices &

Bench Marking

First meeting of the committee was held on 4th Oct. 2002 in the office of Sh.
B.K. Aggarwal, Member (Hydro), CEA at New Delhi wherein it was decided
to co-opt members from Central Water Commission, Irrigation Department,
Govt. of Maharashtra & Andhra Pradesh Generation Power Corporation Ltd.
also. The frame work of the document was also discussed in detail and it
was decided that a chapter on Best Practices in Operation & Maintenance
of Hydro Power Stations shall also be included. Views / suggestions /
supplementary information was desired from all the members of the
committee on the following chapters prepared by HE&TD / HE&RM Divisions
of CEA:(a)

Best Practices in Design & Engineering of Hydro Power Stations.

(b)

R&M and Uprating of Hydro Power Stations.

(c)

Monitoring of R&M Schemes.

After co-opting the members from various state entities, the composition of
the committee became as under:i)
ii)
iii)
iv)
v)

Member (Hydro), CEA

Sh. R.S. Chadha, Chief Engineer (HE&TD)
& (HE&RM),CEA
Sh. V.K. Kanjlia, Executive Director
(O&M & Comml), NHPC
Sh. P. Vishwapala Gowd, Chief Engineer
(Elect. Designs), KPCL
Sh. Vatsal Chopra, Chief Engineer (Designs),
HPSEB
2

Chairman
Member-Secretary
Member
Member
Member

vi)

Sh. A.S. Gupta, Chief Engineer(Generation),

HPSEB
vii) Sh. S. M. Phadke, Chief Engineer (Hydro),
MSEB
viii) Sh. S.N. Huddar, Chief Engineer(WR) & Joint
Secretary, GOMID
ix) Sh. P.K. Gokhale, Chief Engineer(Elect),
GOMID
x)
Sh. G. Adiseshu, Supdt. Engineer
(Hydel Designs), APGENCO
xi) Sh. A.K. Bajaj, Chief Engineer
(Dams Safety Orgn), CWC
xii) Sh. S.M. Dhiman, Chief Engineer (HP&I),
CEA
xiii) Sh. Ashok Kumar, Chief Engineer (HMD),
CEA
xiv) Sh. M. Subramaniam, Chief Engineer (HAD),
CEA

Member
Member
Member(Co-opted)
Member(Co-opted)
Member (Co-opted)
Member(Co-opted)
Member
Member
Member

6.

Second meeting of the Committee was held on 24th Oct, 2002 in CEA, New
Delhi wherein inputs received from NHPC, MSEB & KPCL were circulated
to all members of the committee for observations / views. Draft document
prepared on the basis of the material received from the members was
discussed in the third meeting of the committee held on 17th March, 2003 in
the office of Sh. V. S. Verma, Member (Hydro) CEA,

7.

Based on the material / comments received so far from various members of

the committee, the document has been prepared which consists of following
topics:i)
ii)
iii)

Best Practices on Survey & Investigation of Hydro Electric Projects

Best Practices in Planning & Appraisal of Hydro Electric Projects
Best Practices in Planning, Designs & Construction of Civil woks of
Hydro Power Projects

iv)

Design & Engineering Philosophy for Electro- Mechanical Works of

Hydro Power Projects Best Practices & Bench Marking
v)
Best Practices in Construction Monitoring of Hydro Electric Projects
vi) Best Practices in Operation & Maintenance of Hydro Power Stations
vii) R&M and Uprating of Hydro Power Stations
viii) Monitoring of R&M Schemes.
8.

The book was released by the erstwhile Honble Minister of Power in March
2004 and circulated to all Government power departments, Electricity Boards,
generation utilities & other organizations dealing with hydro power sector in
the country. The book has been widely received and suggestions for
modifications & enlargement of the scope were received from many quarters.
Sh. G. K. Pharlia, Member (Hydro), CEA also held a meeting with the
Committee members on 5th May, 2004 and suggested to bring out the latest
edition incorporating all the suggestions. Accordingly, an updated version
of the publication having revisions in the following chapters has been brought
out.
-

9.

Best Practices on Survey & Investigation of Hydro Electric Projects.

Best Practices in Planning & Appraisal of Hydro Electric Project.
Best Practices in Planning, Designs & Construction of Civil Works of
Hydro Power Projects
Design & Engineering Philosophy for Electro-Mechanical Works of
Hydro Power Projects - Best Practices & Bench Marking
Best Practices in Operation & Maintenance of Hydro Power Stations.

It is hoped that the latest edition of the book will provide valuable guidance
to all persons working in various power utilities /organizations dealing with
hydro power sector in the country. Comments / suggestions to further improve
the book are welcome.

CHAPTER - 1

BEST PRACTICES ON SURVEY AND INVESTIGATIONS

OF HYDRO ELECTRIC PROJECTS

Survey and Investigation of the proposed hydro power project site

is the preliminary requirement that needs to be met by using state-ofthe-art scientific tools and techniques. The following chapter outlines
all the various necessary steps needed for this essential exercise.

1.1

INTRODUCTION

1.1.1

Detailed Project Reports (DPRs) of hydro power projects prepared by

all concerned utilities are submitted to CEA for techno-economic approval.
These are also examined by the Central Water Commission (CWC) for
hydrology design, safety and cost estimates of civil structure aspects.

510 MW Teesta Stage-V Project (Sikkim)-Tail Race Tunnel Under Construction.

5

1.1.2

Besides, these DPRs need to get clearance from the Central Soil and
Material Research Station (CSMRS) from construction material aspects
and the Geological Survey of India (GSI) from geological aspects.

1.1.3

Presently, the Survey and Investigation (S&I) and preparation of detailed

project report of hydro projects are required to be carried out by various
utilities as per Guidelines for preparation of Detailed Project Reports
( DPRs) of irrigation and multipurpose projects issued in 1980 by Ministry
of Irrigation (now Ministry of Water Resources). These guidelines updated
all earlier versions including some specific ones published by Indian
Standard Institute (now BIS) on guidelines for preparation of River Valley
Projects and guidelines for presentation of project reports etc. In view of
the various changes that had taken place in the project formulation,
funding and execution of the projects during the intervening period, a
working group was constituted by Ministry of Water Resources in May
1999 to review and update the guidelines. The guidelines were reviewed,
updated and finalised in April 2000. The updated version is presently
under print.

1.1.4

With the recent technological advance, the practice of investigations has

undergone redical changes. Detailed explorations may sometimes
reveal adverse geological features which in turn may either lead to drastic
changes in the design or even render a particular structure un-feasible.
An ideal approach in phasing out the total gamut of survey and
investigation of hydropower projects constitute a four stage programme
viz. (i) Pre-feasibility State, (ii) Feasibility Stage, (iii) Detailed Investigation
(DPR) Stage and (iv) Construction Stage. These stages are described
in detailed manner in para 1.3.

1.2

VARIOUS ACTIVITIES OF SURVEY & INVESTIGATION (S&I)

1.2.1

The following activities are carried out for the various alternatives
considered to justify the final choice of the location of different components
of the project :a)
b)

River surveys
Reservoir surveys
6

c)
d)
e)
f)
g)

Head works surveys (dams, barrage, weir, etc)

Plant sites and colonies
Canal, branch canals, and water conductor system
Major canal structures
Power house, switch yard, surge shaft, tail race tunnel(s), adits,
penstocks etc.
i) Surveys for command area including Ground Confirmation Survey
j)
Soil surveys
k) Soil conservation
l)
Construction material surveys.
m) Any other i.e. Archeological, Right of way, communication etc.
1.2.2

The different activities of survey and investigations which are carried out
before preparing a Detailed Project Report are given in Sub-para 1.2.2.1
to 1.2.2.4.

1.2.2.1 Topographical Survey:

The Survey of India (SOI) has published topographical maps covering
the whole country in 1:2,50,000 and 1:50,000 scale. Besides SOI has
also published topographical maps of many parts of the country
in1:25,000 scale and they are already on the job of producing maps in
1:25,000 scale for the whole country. However, in addition, the following
maps are also required for the job.
i)

Dam Site: Dam site area covering upto 500m upstream and 500 m
downstream of the dam axis (can also be finalized based on the
other important features like height of dam, location of diversion
portals, coffer dam and also the work area required on both the u/s
and d/s of the dam etc.) extending upto an elevation of top of dam +
1/4 of dam height depending upon the geological requirement and
slope stability vis-a-vis abutment stripping. The contour interval
should be 1m to 5m depending on the topographical characteristics
of the valley. The dam site survey should also include the area
required for diversion arrangement, intake structure, and other
appurtenant structures. The scale of the maps may vary from1:500
to 1:2000 depending upon the size of the area.
7

Tilaiya Dam-Damodar Valley Corporation.

ii)

Reservoir Area Survey: This survey should cover elevation upto

5m + MWL; the contour interval is influenced by slope characteristics.
The scales normally chosen are given as follows:
Water spread upto 2 square km - 1:2000
Water spread upto 10 square km - 1:5000
Water spread more than 10 square km - 1:10,000

iii)

Survey for Power Channel: The width of the area considered for
contoured map/survey is 150m on either side of the center line of
the channel. The scale of the map should be 1:2000 to 1:5000.

iv) Survey for tunnel: The project area maps are used for initial
geological mapping and fixing of alignment of tunels, adits etc. in
consideration with the required rock cover. Later for detailed studies
and layout finalization 100 m to 400 m wide strip along the tunnel
alignment in a scale of 1:2000 to 1:5000 is considered. The
8

methodology to be adopted is given as under :

-

Survey for Adit portals may be carried out in a scale of 1:200 in 50

M width on either side of Adit alignment.

Physical Survey over the tunnel alignment by walking may be carried

out to see the topography.

Adit junctions with main tunnel may be located as far as feasible

kept at 900

Adit portal may be located in areas where sufficient space is

available for provision of infrastructure facilities for the works.

v)

Other Surveys: Generally for power house, switch yard,

construction lay down area, quarries, surge shaft area, generally
topographical maps on a scale of 1:1000 to 1:2000 are considered
adequate depending upon the size of area.

vi) Project area map: The scale for the topographical map of the project
area is decided based upon the spread of the project area. If the
project area is spread upto 5 km, a scale of 1:5000 is adequate.
For project spread upto 10 km, normally a scale of 1:10,000 is
considered and for bigger area, a scale of 1:15,000 is adequate.
1.2.2.2 Engineering geological, geophysical, Seismological and
Construction material survey
(i)

General
These investigations are now considered as a fundamental
requirement of planning & design of large civil engineering structures
pertaining to hydroelectric Projects. All dam sites, power house
locations, tunnel alignments, major bridges etc. need to be thoroughly
explored before arriving at their techno-economic feasibility.
Subsurface exploration, comprising particularly of diamond core
drilling and exploratory drifts are the main stay of geological
investigations.
9

Geological investigations of hydroelectric projects are of paramount

importance in understanding the geological set up of varied terrains
and their geo-dynamic development. The purpose of most
engineering geological work is to ensure that a proposed structure
is built at the lowest cost consistent with currently accepted safety
standards. The need base of survey and investigation module for
hydroelectric projects constitutes delineation of lithology, stratigraphy
and geological structure of the area, geo-mechanical properties of
the ground and identification of extraordinary phenomenon, if any.
The extent of survey and investigation depends on the Stage of
investigation, a common approach being preliminary and
reconnaissance investigation in the initial phase while detailing and
accuracy can be improved subsequent phase/stage of investigation.
The BOQ is evolved on the basis of geological data/details and
reasonably accurate cost estimate is accordingly framed.
ii)

Engineering Geological Survey

a)

Surface investigations
After ascertaining the regional geology of the area the site specific
geological mapping is taken up by intensive surface traverses of
the project area and also with the aid of aerial photographs & satellite
imagery, for coverage of inaccessible area comprehensively.
Observations and measurements of the items such as nomenclature
and classification of rock, stratigraphy and geological structure,
properties of the ground are recorded and the data that is necessary
for knowledge of the general geological condition is gathered.

b)

Sub surface investigations

The direct tools include exploratory pits, trenches, drill holes, drifts,
which provide a detailed information of the ground under survey.
Test pits and trenches are best suited for shallow exploration on
moderately steep slopes. Rotary drilling is the most extensive and
common technique employed for detailed exploration to know the
10

condition of soil and rock. Water tightness of the bed rock is

determined by conducting water pressure tests. These tests are
normally carried out at proposed dam sites, powerhouse, other
caverns and reservoir locations etc. Drifts are generally made to
explore dam abutments, adit / tunnel alignments.
(iii) Geotechnical Survey
Estimation of Rock classes is done by Geomechanical classification
for tunnels/ underground works and slope stability measures to
evolve type & quantity of support system.
(iv) Geophysical Survey
Geophysical methods are employed as an aid to geological
investigations for assessment of in-situ conditions and engineering
properties of the rockmass mainly by using seismic and electrical
methods. These methods provide subsurface information which
include depth of overburden, depth and quality of rockmass, major
faults, folds, dykes and water saturation conditions. Besides,
resistivity measurements are also utilised for determination of the
true resistivity values for the use of earthmat design of switchyard
and power house areas. Vibration monitoring studies are conducted
for controlled blast design and for safe excavation of major structures.
Slope stability design and analysis is carried out by utilizing the
inputs from inclinometer studies.
State-of-the-art computer aided seismic tomography is utilized for
scanning the rockmass conditions in the dam foundation and
powerhouse areas. Resistivity imaging techniques are also
employed for scanning the rockmass in terms of resistivity values.
Some of the widely used methods in hydroelectric project
investigation are as under :
a)
b)

Seismic refraction / reflection method

Seismic tomography involving P-wave and S-wave
measurements.
11

c)
d)
e)
f)
(v)

Resistivity imaging and resistivity sounding.

Micro Earthquake (MEQ) studies.
Vibration monitoring studies.
Inclinometer studies.

Seismological Survey
Details of seismological events are collected from IMD, New Delhi
and site specific design earthquake parameters are evaluated either
by the institutes such as IIT, Roorkee or CWPRS, Pune, for working
out the site specific design earthquake parameters. These
parameters are further put up to National Committee on Seismic
Design Parameter for final approval before adopting the same in
detailed design of the project. Micro Earthquake studies are also
conducted for the assessment of seismicity of the area and
demarcation of the active faults in and around the project area,
depending upon the sensitivity & magnitude of the project.

(vi) Rock & Soil Mechanic Testing and Construction Material Survey
a)

Laboratory Testing
It is conducted to evaluate the engineering properties. Some of the
laboratory tests are

b)

Determination of deformability of rock materials in uniaxial

compression
Triaxial compression tests
Determination of tensile strength
Determination of Direct Shear Strength
Rheologic properties of rocks

Field Testing
These include the following

Rock stress determination using flat jack, over coring and hydro
fracturing
12

Determination of modulus of deformation by Goodman Jack test

and cyclic plate load test

Laboratory and field tests for following materials are carried out

Soils for impervious, semipervious and previous zones of earth dams

Sand
Rock and aggregate
Bricks and tiles
Pozzolana
Steel
Cement and lime stone

Preference should be given to identify quarry sites in area of

submergence (reservoir) keeping in view the environmental aspects and
other related complexity of forest clearance / land acquisition, etc.
1.2.2.3 Hydrological & Meteorological Survey
These surveys are carried out to establish

Rainfall
Gauge
Discharge
Sediments
Water quality
Evaporation
Availability of water for the benefits envisaged
Design flood for various structures

1.2.2.4 Environment and Forest surveys

These surveys / studies are carried out on the following aspects

Environmental survey
Forest area involved
Likely displaced persons
13

1.3

Environment impact assessment

Environment management plan

STAGE OF PROJECT INVESTIGATION

The different stages of project for which investigations are carried out
are :

1.3.1

Pre-Feasibility Stage
Feasibility Stage
Detailed Investigation (DPR) Stage
Construction Stage

Pre-Feasibility Stage
It is more of a desk study with limited field checks. Based on the 1 :50000
or 1 :25000 scale Survey of India toposheets, possible hydroelectric sites
are marked. These sites are examined by preliminary field traverses
wherein topography, broad geological aspects in terms of locating the
project components are looked into.
If required, broad assessment of the terrain at the likely site is also carried
out by geophysical survey to understand the sub surface condition of
the rocks.

1.3.2

Feasibility Stage
After selecting the site during Pre-feasibility stage, intensive field
traverses are under taken. Detailed survey like contour plans and sections
in 1: 1 000 to 1 :5000 scale are prepared for various important structures
such as dam, tunnels, powerhouse, etc. One or two alternate axis are
probed by detailed geophysical survey and a few drill holes to ascertain
depth and quality of bed rock besides carrying out broad geological
mapping & collection of regional geological information. The hydrometeorological data collection is also started during this stage. Based
on this data, lay-out of the project is prepared and its techno-economic
viability is established.

14

1.3.3

Detailed Investigation (DPR) Stage

Detailed geological mapping is undertaken during this stage. For dam,
ancillary structures & power house it is recommended to use 1 :1000
scale with 2.5m contour interval for geotechnical assessment. For
reservoir area, construction material sites, access roads the mapping is
carried out on 1 :5,000 to 1: 15,000 with 5m to 10m contour interval.
Depending upon the requirements, a suitable scale is adopted within
the above range, considering the size of the study area & availability of
topographic plans. Geological mapping of areas of special importance
in the reservoir is recommended by using 1 :5,000 to 1 :2000 scales with
2.5m contour interval. Sufficient geological data is collected to decide
on the remedial measures for reservoir rim treatment and to comment on
water tightness & mineral submergence. All the selected Borrow Areas
& Quarry Sites are mapped on 1 :2000 and 1 :5000 scales with 2.5m
and 5m contour interval respectively.
Exploratory drilling for a dam is carried out by drilling few holes on either
abutment and in the river. The holes are generally aligned along the axis
or in a grid pattern depending upon the expected geological features,
ascertained during geological mapping covering the base upto
downstream toe of the dam. The depth of the holes depends on the
geological set up and type and height of dam, but generally the holes
are drilled into fresh and sound rock to the extent of 10 to 25 meters.
During exploratory drilling maximum core recovery is attempted and
presence of weak and weathered seams, faults, shear zones, is
deciphered.
Both the abutments are probed further by two or three level exploration
drifts with cross cuts. The number and length vary depending upon the
size of the dam. Nowadays, the dam base is scanned by seismic
tomography depending upon the site conditions/requirements. All other
tests like grouting, shear tests are also carried out. Insitu test for
ascertaining bearing capacity of the foundation may be required. In some
cases SPT tests may also be necessary depending on geological
conditions.
15

At least one drill hole shall be placed specifically for energy dissipation
arrangement immediately after the spillway. A provision of at least three
drill holes is generally kept separately for spillway in case it is a side
channel spillway, away from the main body of the dam. The location of
coffer dam in the river bed portions especially for the upstream one is
required to be probed by a drillhole to understand nature of overburden
material and bedrock depth. Similarly, for diversion tunnel also, a
provision of minimum three drill holes is kept with one each at the inlet &
outlet portals and the third one suitably placed on the tunnel alignment,
depending on the geological set-up and topographic considerations.
Exploratory drilling for water conductor tunnels (HRT/TRT) is carried out
to establish rock cover available above the proposed crown level of the
tunnel especially in low cover zones such as in the beds of stream and
to know the substrata along the proposed alignment of the tunnel. Drill
holes are proposed at the intake and portal sites at outlet and along
proposed alignment of the tunnel. These holes are drilled to the proposed
invert level of the tunnel. It would be desirable to probe the expected
tunneling media to the extent possible. But, in view of the high rock cover
above the tunnel alignment, normally drilling of holes down to tunnel
grade is a difficult task. Hence, majority of the tunnel forecast is based
on detailed geological map & projections. However, certain major weak
zones such as faults or thrusts etc should be probed by advance core
drilling during the tunneling activity to identify the exact condition and to
minimize geological uncertainties.
Tunnel Portals are mapped using 1: 500 scale with 2m contour interval
instead of 1: 1 000. For Adits / Access Roads, Borrow Areas / Quarry
Sites all construction as well as access adits are mapped on 1 :2000
scale with 4m contour interval. Vulnerable areas on access roads are
also mapped on the above scale. As such, all geological maps are
updated in this stage. If there have been certain changes in the layout,
additional areas are covered.
For powerhouses, sub-surface exploration is carried out by holes drilled
at least 5m below the proposed level in order to assess the nature of the
16

rock for the foundation of the power house if rock cover is less. Similarly,
drill holes for ascertaining the geology of surge shaft and pressure shaft
etc. are also carried out.
Permeability tests should be conducted in all the drill holes selective
pits & trenches. Geological logging of Drill Holes, Drifts, Trenches & Pits
is carried out using 1:100 scale.
Groutability tests to assess the grout intake and reduction in permeability
values are generally done in this stage of investigation.
Generally the rock mechanic or soil tests are carried out in the DPR
stage for detailed design. Moreover, some of the detailed & expensive
tests like mortar bar test for construction material survey and insitu rock
stress measurements for design input are done at this stage.
The seismotectonic studies are pursued in detailed manner during this
stage for getting site specific earthquake parameters.

Salal Power Station, 345 MW (J&K) Dam

17

1.3.4

Construction Stage
Large scale foundation grade mapping for dam, progressive 3D
geological logging of ongoing tunnels, probe holes on the tunnel face
etc are carried out during this stage. Foundation grade geotechnical
mapping of earth & rockfill dam is done on 1 :500 scale and 3-D
geological logging of diversion tunnel is carried out on 1: 100 scale. For
Concrete Dam, Power House Excavation, Tunnel Excavations,
foundation grade geotechnical mapping and geological logging is done
on 1 :100 scale.
In case of underground works especially for tunnels, major identified
grey ares are probed by advance drilling or drifting to minimize geological
uncertainities.

1.4

OPTIMISATION OF METHODS FOR SURVEY AND INVESTIGATION

OF HYDROPOWER PROJECTS
An ideal method in optimising the investigation for hydropower projects
emerge after due consideration of its ability to solve technological
complexity of the area within the stipulated cost, time effectiveness,
approachability and reliability of the practice. Some of the important
practices are highlighted below.

1.4.1

Wider induction of remote sensing data in geological

reconnaissance
Aerial photographs and satellite imagery are used for rapid interpretation
of geomorphology, lithology, structure and preparation of land use
thematic maps which are widely used in environmental impact
assessment of the project.

1.4.2

Utilization of advance tools of positioning and analysis

particularly in hostile terrain
Geographical Information System (GIS) is used for mapping and
analyzing things that exist and events that happen on earth. GIS
technology integrates common database operations and statistical
18

analysis. The process of making maps by GIS is much more flexible than
traditional manual or automated cartography approaches. Existing maps
are digitized and computer compatible information are translated into
GIS.
Remote sensing using sensors such as cameras carried on aeroplanes,
GPS receivers, or other devices collect data in the form of images and
provide specialized capabilities for manipulating, analyzing, and
visualizing these images.

19

CHAPTER - 2
BEST PRACTICES IN PLANNING & APPRAISAL OF
HYDRO ELECTRIC PROJECTS

Planning

and appraisal of hydro electric projects is a highly

specialised task that requires detailed analysis of various integrated
operational studies, power potential studies, storage hydro schemes,
determination of installed capacity and preparation of detail project
reports (DPRs).Once this work is done, DPRs need to be submitted
for scrutiny and clearance from various relevant bodies including the

Central Electricity Authority (CEA).

A.

PLANNING OF HE PROJECTS

2.1

INTRODUCTION
A hydro electric plant harnesses power from water flowing under pressure
through the prime mover known as water turbine. A Hydro Electric Project
may be conceived exclusively for power generation or power may be
one of the benefits along with flood control, irrigation etc. when it is termed
as Multipurpose Project.
The planning is very important component for the optimum development
of a hydro electric project in a river basin. A river valley can offer many
sites potentially attractive to the planners of hydro electric development.
Investigations at these sites can help eliminate certain number of them
and the optimum dimensions of dam, reservoir and powerhouse can be
worked out that could give the most economical scheme. Process of
selecting the best option depends upon the judgement and experience
of decision makers.
Hydro Electric Project forms an integral part of overall development of
water resources of the river basin. The hydro schemes also form part of
20

the complex integrated power generation system with diverse power

generation resources. In the planning of hydro development and deciding
on installed capacity etc, these two inter-connections viz. with the water
resources developments of the river basin and with the power system
are to be kept in view.
In the overall basin context, the impact of operation of upstream projects,
constraints imposed by the downstream projects, irrigation diversions
downstream, flood moderation etc. are to be considered. Further, with
progressive development of consumptive water use and new water
resources based development projects in the river basin, water
availability would undergo considerable changes over the life of the plant.
These are some of the important aspects which have to be considered
while planning hydro electric/multipurpose projects.
2.2

TYPES OF H. E. SCHEMES :
There are many types of hydro electric schemes. Based on the functions,
these may be classified as under :-

2.2.1

Run-of-River Schemes
Run-of-River schemes are the schemes either having pondage sufficient

Barrage of Uri Hydro Power Station - 480 MW (J&K)

21

to meet diurnal variation of power demand or no upstream pondage (i.e.

all the incoming water is fed into the turbine at the same time).
2.2.2

Storage Schemes
These are the schemes having large storage capacity reservoir to store
excess water in monsoon months and to generate power in non-monsoon
months .

2.2.3

Pumped Storage Schemes

These are the schemes having two reservoirs, upper & lower. Water flows
from upper reservoir to lower for generation during peak hours and vice
versa for pumping back water during off-peak hours.

2.2.4

Canal Power House Schemes

These are the schemes utilising irrigation canal flows for power
generation.

2.3

ESSENTIAL COMPONENTS OF HYDRO ELECTRIC SCHEMES

2.3.1

Storage Reservoir
It is an essential component of storage based hydro electric schemes.
Water available from the catchment area is stored in reservoir during
monsoon period so that it can be utilised to run the turbines for generating
electric power according to the requirements during lean flow period.

2.3.2

Dam
Dams are the civil structures built across the rivers for intercepting storage
of water and also to create head. These are also an important feature of
storage based hydroelectric schemes. Run of River scheme normally
have Weirs for diversion of river water.

2.3.3

Water conductor system

It is the system through which water is carried from the dam to power
house. It may consist of tunnels, canals, forebays, pressure shafts/
22

penstocks, surge tank and inlet valves etc.

2.3.4

Power House
Power House is a building housing the turbines, generator, control and
protection equipments etc. including auxiliaries for operating the
machines.

2.3.5

Tail race
Tail race carries the water discharged from the turbines to a suitable
point where it can be safely disposed off into the river in case of a
conventional hydro schemes. In case of a pumped storage schemes, it
carries water to tail pool or lower reservoir to be pumped back into the
upper reservoir.

2.3.6

Switchyard
Power generated by the generating units is pooled in the switchyard and
transmitted to load points. As far as possible, the switchyard is located
near to the Power House.

2.4

STEPS INVOLVED IN THE PLANNING OF A HYDRO-ELECTRIC

PROJECT
i)
ii)
iii)

Site Identification
Survey & Investigation
Project Planning and Project Optimisation Studies for determination
of optimum Project Parameters
iv) Assessment of power & energy benefits
v) Economic Evaluation
vi) Preparation of Detailed Project Report
2.5

SELECTION OF 90 PER CENT DEPENDABLE YEAR

Planning of HE Project is carried out based on 90 per cent dependability
criteria. For determination of 90% dependable year, the total energy
generation in all the years for which hydrological data is available (say
23

N year) is arranged in descending order and the (N+1) x 0.9 th year would
represent the 90 per cent dependable year. The 90 per cent dependable
year is thus, termed as the year in which the annual generation has the
probability of being equal to or exceed 90 per cent of the time on annual
basis during the expected period of operation of the scheme.
For example, if inflow data is available for a period of 20 years (N=20),
then,
90% Dependable year = ( 20+1)*0.9= 18.9 = 19th yr
2.6

POWER POTENTIAL STUIDES

Power Potential studies are carried out for assessment of available Power
Potential of a river/basin based on a set of inflows and available head
conditions under various operating policies. These studies play an
important role in the optimisation and design of new hydro facilities. They
are used for examination of various configurations and their integration
into existing networks. The studies are carried out for optimization of
project parameters and for evaluation of Energy and Power benefits.

2.6.1

ROR Schemes without Pondage

In case of ROR schemes without pondage, the flow data is arranged
hydrological year wise i.e. June to May etc. and Unrestricted Energy
Benefits are worked out for all the years. Based on the above, 90%
dependable year is selected. To determine the optimum installed capacity,
a number of alternatives of installed capacities are considered and
energy generation during the 90% dependable year is computed for each
of the alternative installed capacity scenario based on average 10-daily
inflows. Installed capacity is selected after carrying out Incremental
Analysis for the most attractive alternative. The unit size is selected by
considering pattern of generation in various periods, transportation
constraints, if any, and system considerations etc.

2.6.2

ROR Schemes with Pondage

In case of ROR schemes with pondage, same procedure as explained
24

for ROR schemes (without pondage) is adopted except that in case of

selection of installed capacity, load factor is also considered and studies
for cost of alternative Thermal/ Gas and Hydro sometimes carried out in
order to work out optimum installed capacity. Hourly operation of the
pondage is carried out to work out pondage requirements for peaking.
The unit size is selected by considering, transportation constraints, if
any, and system considerations etc.
2.6.3

Storage Hydro Schemes (Simulation)

The storage provided at a site can be either for annual operation which
means that every year it would be drawn down to its minimum drawdown level or it may be carried over with a view to carry over waters from
good hydrological year to the lean flow year that may follow. The purpose
of providing storage is to achieve, wherever economically feasible, higher
utilization of the inflows approaching very close to the long term average
inflows.
The 90% dependable output in case of carried over storages should be
higher than the output which would have been possible on the basis of
utilization of inflow available on annual basis.
Minimum draw down level (MDDL) of the reservoir is selected from
consideration of estimation of siltation in the reservoir during the life of
the project, optimization of power benefits and safe limit of operating
heads of turbines taking into consideration site specific constraints, if
any.
Full reservoir level (FRL) for the scheme is determined considering
geological and other constraints in raising the dam height and also
considering various other related aspects of submergence and
rehabilitation etc. For selection of FRL, tailrace level of upstream
developments whether existing or planned, if any, is also taken into
consideration.
For selection of optimum FRL, Reservoir simulation studies are carried
out for entire hydrological data for alternative FRL & MDDL scenarios, to
25

work out firm power and 90% dependable energy generation benefits
corresponding to each of these scenario. The variation in the efficiency
of generating unit at heads lower and higher than rated head and
variations in tailrace level is also considered in computing energy
benefits, if available.
For selection of optimum FRL, the benefits (B) and the cost (C) for each
alternative are computed and Incremental Cost and Benefit Studies are
carried out to select optimum FRL from the consideration of maximization
of benefits.
2.6.4

Data Requirements
For carrying out Power Potential Studies, the requisite data is entered
into the Simulation model under the following categories.
a)

Configuration
Prior to carrying out simulations, the physical characteristics of the
development, its hydraulic links and down stream points of
discharges are to be defined.

b)

Hydrological Data
Hydrological Data consists of sequences of uncontrolled natural
inflows into the reservoirs.

c)

Evaporation Data
The month wise evaporation rate in the reservoir (in mm) is required
for simulation.

d)

Physical Characteristics
The physical dimensions of the reservoir constitutes the basis for
the determination of head on the Power Plant. Storage availability
has a direct impact on the possible degree of regularization. Area
capacity curve, minimum and maximum operating levels for reservoir
i.e. Full Reservoir Level (FRL) and Minimum Draw Down Level
(MDDL) are required for simulation.
Similarly for power house, the tailrace rating curve, turbine and
26

alternator efficiency and head losses in water conductor system are

taken into account for calculation of power production.
e)

2.7

Operating Objectives and Limits

The objective of the simulation may be the maximisation of firm power,
maximisation of average energy production or limitation of the
number of energy failures. Similarly the operating limits may also
be fixed on the minimum or maximum values of discharges through
power house to cater to downstream irrigation requirements etc, if
any.

DETERMINATION OF INSTALLED CAPACITY

For selection of installed capacity, benefits from the project with different
possible installed capacities are evaluated. Optimum installed capacity
is selected after carrying out Incremental analysis for the most attractive
alternative and also considering the system load factor (LF). In addition,
cost of generation from alternate sources such as coal based thermal,
gas turbines, combined cycle gas turbines (CCGT) and hydro are worked
out. The least cost of energy from among these options is adopted for
evaluating the benefits of the installation. Benefits of the seasonal energy
(total annual energy firm annual energy), which can be absorbed in
the system, are evaluated with the average incremental cost of fuel
consumed in the alternative plant for generating the same energy.

2.8

UNIT SIZE
The units size is determined depending upon the transportation
constraints, flexibility of operation and system considerations and
geological constraints like permissible cavern size in case of
underground power houses.

2.9

PUMPED STORAGE SCHEMES

A pumped storage scheme utilises the surplus energy available from
base load stations (thermal & nuclear plants) during off-peak hours for
pumping the water from a lower reservoir to the upper reservoir and the
27

same is released during peak hours for generation by running the units
in generating mode. The capacity of upper/lower reservoirs, availability
of surplus off-peak energy, intended operating pattern of the pumped
storage scheme determines its installed capacity. The procedure for
optimization of the installed capacity and deciding the number of units is
same as applied for run-of-river schemes/ storage based schemes.
B.

APPRAISAL OF HYDROELECTRIC PROJECTS

2.10

Preparation of Detailed Project Report

2.10.1 Hydro electric projects are capital intensive involving high technology
and relatively long gestation period. Due to their complex nature, a large
amount of preparatory work is done by the project proponents before
detailed project report (DPR) is submitted to CEA for clearance.
Preparatory work covers detailed field investigations, planning,
assessment of benefits, design & engineering studies, detailed cost
estimates based on analysis, cost of inputs & equipment, identification
and tie up of inputs, project need, justification, economic and environment
studies, safety aspects etc.
2.10.2 The DPRs of Hydro Electric Projects are prepared as per the guidelines
issued by Government of India, Ministry of Irrigation (now MOWR) in
1980 and Guidelines for formulation of Project Reports for Power
Projects issued by CEA in October, 2002. The summary of guidelines
for formulation of power projects is given at Annex-I. Broad aspects to
be considered and covered in DPR include investigations, data collection
& analysis, selection of scheme of development, assessment of benefits,
project need & justification, design & engineering, environment & safety
aspects, tie-up of inputs, analysis of costs, cost estimates and financial
analysis etc.
2.10.3 Information on environmental aspects of the project are included in DPRs
as per the relevant performae/ guidelines of MOEF. As regards the forest
clearance, while the basic data (on the forest area) are included in the
report, action is taken separately to process the clearance through the
State Forest Department under Forest (Conservation) Act, 1980. The
28

best practice in the preparation of DPRs of Hydro Projects is to follow

the guidelines issued by MOWR/ CEA/ MOEF.
2.11

Submission of Scheme for Concurrence under Section 8 of

Electricity Act, 2003

2.11.1 Section 8 of Electricity Act, 2003 provides that any generating company
intending to set up a hydro generating station shall prepare and submit
to Authority for its concurrence a scheme estimated to involve a capital
expenditure exceeding such sum as may be fixed by Central Government
from time to time by notification.
2.11.2 At present the Central Government have fixed the following cost limits
for submission of DPRs for hydroelectric projects for concurrence of the
Authority:
i)

In relation to a scheme selected through

competitive bidding

Rs 1000 Crores

ii)

In relation to a scheme for which tariff is fixed

by CERC/ SERC

Rs 2500 Crores

iii) In relation to a scheme of company not owned by Rs 20000 Crores

Central/ State Government for supply of power
to more than one state and approved in
accordance with a scheme proposed by a
committee or body authorized by Central
Government
iv) In relation to all other schemes

Rs 250 Crores

All schemes utilizing water of inter-State rivers irrespective of capital

cost shall be submitted to the Authority for its concurrence.
2.11.3 For private sector Hydro Electric Projects, the clearance from the SEB/
State Government would be required in the area of water availability,
Rehabilitation & Resettlement (R&R) of displaced persons, land
availability and environment & forest clearance. The Report duly
accepted by SEB/State Government is to be submitted to CEA.
29

2.11.4 Section 10 (3) (a) of Electricity Act, 2003 provides that Every Generating
Company shall submit technical details regarding the generating station
to the Appropriate Commission and the Authority.
2.12

Appraisal of Schemes
In order to cut short the time in CEA clearance the revised procedure for
examination of project reports & its time frame for Hydro Projects have
been finalised and procedure have been made interactive. CEA has drawn
up a time bound procedure for processing of DPR so as to complete the
examination of DPR in a period of 3 months or less as per the time
schedules. This will be possible only when the project report is complete
with all the details and all the requisite clearances are available at the
time of submission/ registration of DPR in CEA. The project developers
are required to strictly adhere to the time schedules for furnishing
clarifications and attending to Standing Projects Appraisal Committee
and TEC meetings in CEA.
Appraisal of Schemes shall be in following parts i)

Three stage clearance for Central Sector Hydro Electric Schemes.

Cost estimates for Stage I activities

Feasibility Report (FR) for assessing commercial viability

Cost estimates for Stage II activities

ii)

Appraisal of Hydroelectric Schemes for concurrence (Detailed

Project Report)

2.12.1 Three Stage Clearance for Central Sector Hydro Electric Schemes
Three-stage development procedure for Central Sector Hydro Electric
Schemes shall be as follows:
(a) Cost Estimates for Stage-I Activities

The generating company shall prepare and submit cost estimates

of Stage-I activities of the project included in National Electricity
30

Plan for vetting by the Authority.

The report shall contain the justification for taking up the proposed
scheme for survey & investigation.

The activities to be carried out during Stage-I are:

Data collection/preparation of application for site clearance by

MOEF.

Establishment of gauge and discharge sites and meteorological

observatories. Hydrological measurements and meteorological
observations continue till construction of the project.

Obtaining of site clearance from MOEF

Essential geological exploration for establishing type of dam

and its foundation and other civil structures

Topographic survey of the project area and detailed survey for

the purpose of preliminary layouts of dam, water conductor
system, power house etc.

Essential temporary infrastructure/access required for carrying

out the above works

Commencement of Environmental Impact Assessment Studies

(EIA) and Environmental Management Plan (EMP) studies.

Formulation of feasibility report for assessment of commercial

viability of the project.

Preparation of estimates for Stage-II activities and their

submission to the Authority (CEA).

The activities under Stage-I shall be completed within one year from
the date of sanction.

(b) Commercial Viability on Feasibility Report

The generating company shall prepare a Feasibility Report (FR)

31

and submit for accord of the commercial viability by the Authority

(CEA).

The FR should establish whether the scheme is conceptually sound

and feasible.

The report shall also specify downstream benefits, if any. The report
shall contain the chapters on Introduction, Salient features, Scheme
Cost, Hydrology, Power Optimization Studies, Geology and
Construction Material, Design of Civil Engineering structures, Hydro
Mechanical Equipment, Power Plant- Electrical and Mechanical
Equipment, Environmental aspects, Infrastructure facilities,
Construction Methodology, Equipment Planning and Construction
Schedule, Economic Evaluation.

The report shall also contain the Vicinity Map, Scheme Layout plan,
Geological Plan of Scheme, Index Plan of Borrow Area, Diversion
Structure Plan, Diversion Structure - Longitudinal Section, Water
Conductor system - Longitudinal Section, Power House General
Arrangement & Cross Section, Construction Schedule.

The schemes which have been found to be commercially viable and

have obtained site clearance from MOEF would be considered for stageII development.
(c) Cost Estimates for Stage-II Activities

The generating company shall prepare and submit cost estimates

of Stage-II activities for vetting by the Authority (CEA). The activities
under Stage-II are:

Essential survey and investigation works comprising of the following:

o

Detailed topographical survey of reservoir area and project area.

Procurement of satellite imageries including aerial maps

wherever required

32

Geo-physical surveys comprising seismic and resistivity tests

etc.

Hydro-meteorological observations

Collection of silt data and its analysis

Geological exploration comprising surface mapping, drilling,

drifting and their logging etc.

Construction material survey, both quantitative and qualitative

Preparation of Detailed Project Report (DPR)

Submission of DPR to the Authority (CEA) and obtaining its TechnoEconomic Clearance.

Submission of Environmental Impact Assessment (CEA) and

Environmental Management Plan (EMP) to MOEF and obtaining
environment and forest clearances of the project.

Temporary/permanent buildings (residential and non-residential)

Roads and permanent bridges as may be required for approaching

work sites and transportation of heavy equipment.

Acquisition of land required for the execution of the project. Initiating

the process of acquisition of land for the reservoir submergence
area.

Arrangement of construction power.

Preparation of tender specifications and bid documents.

Submission of PIB Memo/CCEA Note

Stage-II activities shall normally be completed in 1 years from the
date of sanction.

2.12.2 Appraisal of Detailed Project Report

Techno- economic examination of project reports of hydro electric/
multipurpose project is an interactive and complex process and involves
33

Baspa HEP - A view of the Machine Hall in Distt. Kinnaur (H.P.)

various disciplines like hydrology, civil design, electrical & mechanical
design, geology etc. DPRs are examined in specialized formations in
CEA and CWC with a view to finalize the features of the project based
on the optimal plan development of water resources and also considering
techno-economic feasibility and requirements of system. All the multipurpose project proposals with power component are first appraised by
CWC, then by Advisory Committee in Irrigation, Flood Control and Multipurpose Projects of Ministry of Water Resources. After clearance of the
Advisory Committee, CEA examines and clears the power component
of the scheme.
Appraisal Procedure
CEA acts as single agency as far as clearance of techno-economic
aspects of the projects is concerned. CEA coordinates the examination
of DPRs with CWC and GSI on aspects pertaining to water availability,
design and cost estimates of civil engineering works, inter-state/ international aspects and geological aspects.
34

2.12.2.1 Appraisal of DPR by CWC

Demarcation of responsibilities in Govt. of India
As per the demarcation of responsibilities in Govt. of India, the
following are some of the aspects related to hydro projects assigned to
MOWR:

Hydrology of the project

Hydraulic Structures for hydropower
Water Management
Flood Control
Dam Safety
Regulation and development of inter-state rivers and river basins
Water laws legislation
International water laws
The matter regarding rivers common to India and neighboring
countries: Joint River Commission for Bangladesh and India, Indus
Water Treaty, Indus Commission
The above aspects are being looked into by CWC and wherever
necessary in consultation with MOWR. It is therefore necessary to
have approval of CWC/ MOWR for these issues i.e. hydrology of
the project, clearance from inter-state/international angles, hydraulic
structures and dam safety aspects etc.

Aspects Appraised by CWC

i)

Hydrology: CWC appraises the hydrological inputs and carry out

hydrological studies as they play a vital role in the planning of
hydroelectric projects and the design of various hydraulic structures.
An over estimate of water availability may lead to larger investment
and project may become costlier resulting in a higher installation.
On the other hand, a lower estimate of water availability may result
in a wastage of some hydro potential and non- utilization of selected
site optimally. Hydrological studies include assessment of quantities
of available water at the project site and time variation, estimation
35

of design flood, silt studies for estimation of life of the project etc.
ii)

Construction Machinery: CWC carries out detailed planning and

appraisal of the construction machinery and construction
methodology, number of equipment required, use rate of equipment,
unit rates of work etc in order to have a realistic estimates of the cost
of the project and the time required for construction.

iii)

Foundation Engineering, Dam Safety and Civil Design Aspects:

CWC have specialized formations to examine foundation
engineering aspects and civil design aspects of civil structures
including dam safety aspects for various structures related with
hydroelectric schemes.

iv) Inter-State/ International Aspects: CWC also examines interState/ inter-national aspects related with a hydroelectric project in
consultation with Ministry of Water Resources, if considered
necessary and provides necessary suggestions to CEA.
v)

Cost Estimates of Civil Works: Before cost estimates of civil works

are cleared by CWC, the project is evaluated from the angle of
various aspects like hydrology, civil design, dams design, gates
design, dam safety, foundation engineering, power plant
engineering, barrage & canal design, construction machinery
aspects etc. by CWC. It is essential because the cost depends upon
all the above mentioned clearances. A change in these may affect
the cost of aspect.
Once all the aspects are finalized, the cost estimates included in
DPR are verified. To verify the estimated cost of civil works, hourly
use rates of equipment and analysis of rate of main works like
excavation, concreting, RCC works, stripping, filling, grouting etc.
are determined for each activity. Based on the construction designs
finalized, the quantities of the items required are worked out. Based
on these, the estimated cost of civil works proposed in DPR is
reviewed/ finalized.

36

2.12.2.2 Aspects Appraised by CEA

i)

Legal Aspects: CEA examines and ensures whether the project

authorities have complied with all the legal provisions as stipulated
in Electricity Act, 2003.

ii)

Justification of the Project: CEA carry out studies and forecasts

the Power Supply Position with and without the proposed project
and examines the need/ justification of the project from system
demand point of view. Necessary inputs/ information regarding future
system demand in both peak demand and energy requirement for
these studies are provided by Electric Power Survey Report
published by CEA.

iii)

Hydro Power Planning Aspects: CEA examines the general layout

of the hydro scheme as proposed by the project authorities and
suggest modification, if any. CEA also examines the power potential
studies carried out by the project authorities for all the years for which
hydrological data is available, proposed installed capacity & unit
size etc. CEA also examines the basin development and how the
project proposal fits into it.

iv) Designs Aspects of E & M Works: CEA examines design aspects

pertaining to various electrical/ mechanical equipment of the power
house and switchyard i.e. turbine or pump/turbine (for Pump Storage
Schemes), generator or motor/generator (for Pump Storage
Schemes), main step-up transformer with cooling water
arrangement, switch-yard equipment (conventional or gas insulated
switch gear), control and protection equipment, electrical and
mechanical equipment for auxiliaries and power house and
switchyard layouts, single line relaying and metering scheme and
aspects relating to transportation etc as mentioned in the DPR.
v)

Cost of Elecro- Mechanical Works: For E & M Works, estimated

cost is verified by CEA based on cost data of similar equipment
available in CEA.

37

vi) Evacuation of Power: CEA examines the adequacy of power

evacuation system proposed by the project authorities to evacuate
the power generated by the project and suggests necessary
modifications.
vii) Construction Programme: CEA examines activity-wise, item-wise
and year-wise targets/ schedule of construction for each of the major
components of the project, which are based on detailed Bar/PERT
Chart. The completion cost of the scheme is worked out based on
detailed construction Programme.
viii) Financial and Commercial Aspects: Financial and commercial
aspects of a hydro electric projects are examined by CEA which
includes examination of financial package, calculation of interest
during construction based on different financial packages, year-wise
tariff calculation for the entire life of the project, levellised tariff
calculation etc.
2.12.2.3

Appraisal of DPR by GSI

The geological aspects are appraised by Geological Survey of India

2.12.2.4

Clearance from MOEF

Development of hydroelectric projects have also adverse impacts on
the surrounding environment. Hydroelectric projects may involve
submergence causing environmental & ecological aspects,
rehabilitation & resettlement and forestland. This necessitates scrutiny
and clearance from Ministry of Environment & Forest. In case the
projects involves diversion of forestland, clearance is also required
from forest angle from MOEF under Forest Conservation Act, 1980.

2.12.2.5

Clearance from Defence

If a hydroelectric project involves defence aspects, then the clearance
from Ministry of Defence is also required from Defence angle. The
request is made to Ministry of Power to take up the case with Ministry
of Defence.

38

2.12.2.6

Techno Economic Clearance of CEA

After CEA is satisfied about the technical and economic viability of the
project and if necessary inputs/ clearances for the scheme are tied up,
it accords TEC to the proposal as proposed or subject to some
conditions as an interim step prior to its concurrence. The intimation
regarding according of TEC for hydroelectric projects are given to the
Project Authorities, Ministry of Power, Planning Commission and other
Government Departments for further action to obtain investment
sanction/ approval.

2.12.2.7

Techno Economic Concurrence of CEA

After all the specified statutory sanctions and clearance from various
Government Departments/Organizations have been obtained, CEAs
concurrence is conveyed as per Section 8 (2) of Electricity Act, 2003.

2.12.2.8 Final Financial Package

CEA also examines the final financial package submitted by the project
authorities and accord its approval.
2.12.2.9 Issues Related With Techno-Economic Appraisal of Hydro
Schemes
i) Often it is found that the DPR submitted by the Project Authorities
lack details required for proper examination and finalization of the
project features. Some DPRs lack proper surveys and investigations
studies, hydrological data/ studies, design details, proper power
potential studies, proper evaluation of quantities of civil works,
detailed cost estimates etc.
ii) During the course of examination when deficiencies involving data/
investigation etc. are found, back references are made to the project
authorities for obtaining complete information and it normally takes
some time for them to attend to such observations. In case the DPRs
of hydroelectric projects are prepared as per the guidelines of CWC
and various quarries/ clarifications raised by CEA/ CWC/ GSI are
39

replied promptly by the Project Authorities, a scheme could be

accorded TEC by CEA within a short period after the receipt of DPR.
2.13

Concurrence to Revised Cost Estimates

In every case where the project cost over-run is 20% and is
accompanied by time over-run of over 10% or such other time and
cost over-run norms as may be deemed appropriate by the Authority,
the revised cost estimates shall be prepared by the generating
company and submitted to the Authority for approval including cost
estimates for civil works and Electrical & Mechanical works.
For the works, which have already been completed and for the
material already received, actual cost incurred shall be incorporated
in the RCE.
For the balance of material and works, the cost should be on the
basis of orders placed. In case orders for certain materials have not
been placed, the prevalent market rate should be adopted.
The establishment charges in case of RCE should be on the basis
of actual expenditure and quantities up to the time of preparation of
RCE and for the balance period on the basis of projections. The
establishment charges in RCEs should not be based on the
percentage of the revised cost of the works.
The increase in the estimated cost over the sanctioned estimates
should be computed under the following heads. Detailed reasons
for such increases should also be given:
o

Cost increase due to exchange rate variation (if applicable)

Cost increase due to escalation of prices or material,

equipment and labour

Cost increase due to inadequate provisions/new items

Cost increase due to change in quantities/scope/design

parameters; and
40

Cost increase due to other reasons (to be specified)

In case the time gap between the techno-economic approval of the

scheme by CEA and actual start of work on the project is three years
or more, the scheme with the Revised Cost Estimates should be
submitted to CEA for fresh techno-economic approval before starting
the works.
Where expenditure much in excess of the approved cost of a project
has been incurred without getting the approval of the Revised Cost
Estimates, the Head of the Department/Project would have to satisfy
himself about the reasonableness of the same, as CEA would not
be able to examine such fait accompli Revised Cost Estimates.
Generating Company shall include Financial package in the RCE
Generating Company shall include tariff calculations first year tariff
and levellised tariff in the RCE.
RCE shall conform to the checklist prescribed by the Authority.
2.14

Concurrence to Final Completion Cost

As per the Tariff Notification of Govt. of India dated 30th March, 1992
(as amended from time to time), the actual capital expenditure
incurred on completion of the project shall be the criterion for fixation
of tariff. Where the actual expenditure exceeds the approved project
cost, the excess expenditure over & above that approved by the
Authority shall be deemed to be the actual capital expenditure for
the purpose of determining the tariff, provided that such excess
expenditure is not attributable to the generating company or supplier
of contractors.
The notification also provides that where a power purchase
agreement entered between the generating company and the Board
prescribed a ceiling on capital expenditure, capital expenditure shall
not exceed such ceiling. In case of multi unit projects, the percentage
of capital cost is specified in the techno-economic clearance, which
41

is considered for fixation of tariff after commercial operation date

(COD) of the progressive units. In case of delay in commissioning
of second or subsequent unit from the schedule dates, the project
cost for the period of delay shall be retrospectively approved for the
tariff purpose in the ratio of proportionate allocation of units.
In order to meet the above obligations, the following conditions are
stipulated in the Office Memorandums conveying TEC to the
generating projects:
o

The completion cost of the scheme shall be submitted to the

Authority duly recommended by competent Government for
approval as soon as possible after the commercial operation
date (COD) of the plant but not later than three months from the
COD of the plant.

Completion cost of the scheme shall not exceed the TEC

approved cost except on account of variation in foreign exchange.
Change in rates of statutory taxes and duties and changes in
Indian Law resulting in change in cost.

The generating company shall prepare Final Completion Cost of

Hydroelectric Scheme including cost estimates for civil works and
Electrical & Mechanical works as per Guidelines for Submission of
Completed Cost for Hydroelectric Schemes published by Central
Electricity Authority.
The increase in completed cost on account of the delay in following
shall not be taken into account:
o
o
o

2.15

Acquisition of land
Finalization of Power Purchase Agreement
Financial Closure

Modalities of Simplified Transfer of Techno Economic Clearance

CEA has evolved Modalities of Simplified Transfer of Techno
Economic Clearance of Hydroelectric Schemes already cleared by
42

CEA in the name of other Agency. These modalities are below:

2.15.1

For Schemes without any change in Scheme Features and Cost

Estimates
i) In case the new agency furnishes a certificate to the effect that there
is no change in the cost estimates and in the project features as
was approved by the Authority originally, the TEC will be transferred
to it by the Authority on receipt of the following:
a)
b)
c)
d)
e)

A request by the new agency for transfer of TEC.

Approval of the Competent Government(s) for transfer of
the scheme to the new agency.
Approval of the Competent Government(s) in favour of the
new agency.
Implementation Agreement between the new agency and
the Competent Government(s).
Compliance of Electricity Act, 2003.

ii) The above transfer of TEC shall be subject to furnishing the following
by the new agency within ONE YEAR of the transfer of TEC.
a)
b)
c)
2.15.2

Clearance of CWC from Inter-State/Country aspects.

Consent of beneficiaries to purchase power from the project.
Valid Environment and Forest clearance in the name of the
new agency.

Schemes Envisaging Changes in Scheme Features and/or Cost

Estimates
i) In case the new agency envisages changes in the scheme cost
estimates and/or changes in the scheme parameters of the project
with respect to the Techno-Economic Clearance already accorded
by the Authority, the transfer of TEC in the name of new agency
shall be effected, on submission of the documents mentioned at 1(i)
(a) to (e). Such transfer shall be valid for a period of TWO YEARS,
within which, the new agency shall furnish the following in respect
43

of the revised scheme, for consideration of fresh Techno-Economic

Clearance, by the Authority:
a)

b)
c)
d)
e)

Cost estimates, updated hydrology, optimization studies,

technical parameters, etc. with supporting details and
justification.
Compliance of Electricity Act, 2003.
Clearance of CWC from Inter-State/Country aspects.
Consent of beneficiaries to purchase power from the project.
Valid Environment and Forest clearance in the name of the
new agency.

2.15.3.

Authority shall have the right to revoke the transfer of TEC, if any of the
conditions stipulated in para 1 & 2 above are not fulfilled.

2.16

Estimation of Realistic Cost

While estimating the cost of civil and electro-mechanical works, the
generating company shall take into account the following for arriving
at the realistic cost of the scheme:
The layout of the dam, water conductor system and powerhouse
should be optimum.
New technology in designs of various structures and construction
of various components of the projects shall be adopted.
Adequate techno- economic analysis shall be carried out for adopting
turnkey based contract or with many packages.
Adequate designs shall be carried out for realistic estimation of
quantities of civil works.
The rating of Electro-mechanical equipment shall be optimum.

44

Annexure-I
SUMMARY OF GUIDELINES FOR FORMULATION OF PROJECT
REPORTS OF HYDRO ELECTRIC POWER PROJECTS
1.

INTRODUCTION
Hydro Power Schemes are broadly classified as run-of-river schemes
and storage schemes. The Detailed Project Report (DPR) for these
works should be formulated by the State Electricity Boards (SEBs),
Public Sector Undertakings, Private Sector/ Joint Sector Utilities/
Companies who intend taking up the projects for implementation and
forward to CEA for techno-economic concurrence. DPR for
hydroelectric schemes would be submitted to CEA, while DPRs for
multi-purpose project would be submitted to Central Water Commission.
Submission of the Schemes shall be as follows (i) Three stage
clearance for Central Sector Hydro Electric Schemes (Cost estimates
for Stage I activities, Feasibility Report (FR) for assessing commercial
viability, Cost estimates for Stage II activities) (ii) Appraisal of
Hydroelectric Schemes for concurrence (Detailed Project Report).

2.

POWER POTENTIAL STUDIES

In order to optimize installed capacity, Power Potential Studies should
be carried out based on the 90% dependable flows, considering
number of alternatives of installed capacities. The total energy
generation during the 90% dependable year is computed for each of
the alternatives of installed capacity. The benefits of the project with
different installed capacities should be evaluated to determine the
optimum installed capacity. For this purpose, the costs of generation
from alternative sources such as coal based thermal, gas turbines and
combined cycle gas turbine are worked out. The least cost of energy
from among the three options (Thermal, GT and CCGT) is adopted for
evaluating the benefits of installation considering the corresponding
load factors of operation.

3.

ALTERNATIVE & STATE OF PREPAREDNESS

In the DPR, various alternatives studied and justification for the finally
45

accepted proposal should be clearly brought out. The state of

preparedness and infra-structural back up should be spelt out. It is
advised that the promoters/ developers of power projects familiarize
themselves with updated relevant documents and prepare DPR as per
latest practice.
4.

FINANCIAL LIMITS
Government of India has fixed Rs 1000 crores in relation to hydroelectric
generating stations prepared by a Generating company selected
through a process of competitive bidding by competent Government or
Governments, Rs 2500 crores for generating stations where tariff for
sale of electricity is determined by CERC/ SERC, Rs 20,000 crores for
a generating company not owned by Government for supply to more
than one state and approved in accordance with a scheme proposed
by a committee authorized by Central Government and Rs. 250 crores
for other hydro-electric schemes, as sum of capital expenditure
exceeding which the scheme shall be submitted to Central Electricity
Authority for its concurrence. However, all hydroelectric schemes
utilizing waters of inter-state rivers shall be submitted to CEA for its
concurrence.

5.

THREE STAGE DEVELOPMENT FOR CENTRAL SECTOR

PROJECTS
Three-stage development procedure for Central Sector Hydro Electric
Schemes shall be as follows:
(a) Cost Estimates for Stage-I Activities
The generating company shall prepare and submit cost
estimates of Stage-I activities of the projects included in National
Electricity Plan for vetting by the Authority (CEA).
The report shall contain the justification for taking up of the
proposed scheme for survey & investigation.
The activities under Stage-I shall be completed within one year
from the date of sanction.

46

(b) Commercial Viability on Feasibility Report

The generating company shall prepare a Feasibility Report (FR)
and submit for according the commercial viability by the Authority
(CEA).
The FR should establish whether the scheme is conceptually
sound and feasible.
(c) Cost Estimates for Stage-II Activities
The generating company shall prepare and submit cost
estimates of Stage-II activities for vetting by the Authority.
Stage-II activities shall normally be completed in 1 years from
the date of sanction
6.

SUBMISSION OF SCHEME FOR CONCURRENCE UNDER

SECTION 8 OF ELECTRICITY ACT 2003
The Developer / State Governments after completing essential site
survey and investigation will prepare Detailed Project Report (DPR)
of Hydroelectric Project in accordance with the Guidelines lines for
preparation of Detailed Project Report of Irrigation & Multipurpose
Projects published by erstwhile Ministry of Irrigation (Now MOWR)/
Central Water Commission (revised from time to time). Cost estimates
of civil works in DPR shall be as per Guide lines for preparation of
Estimates for River Valley Projects (latest edition) published by Central
Water Commission. The Electrical & Mechanical cost estimates shall
be prepared as per CEA formats. Developer/State Government after
obtaining the required clearances shall submit to the Central Electricity
Authority the complete DPR for obtaining Techno Economic Clearance.
To ensure speedy processing, CEA on its part has prescribed the
following procedure/ sequence of activities and timeframe for
processing:

47

Sl. Activity
No.
1.

Time
(Days)

Registration, first stage checking of legal and other major

inputs/ clearances as per check list.

2.

Distribution of DPR

3.

Second stage checking of the completeness of DPR

4.

Detailed Examination of DPR in various specialized

formations of CEA/CWC/GSI (as applicable) and issue of
comments

21

5.

Furnishing of clarifications by Utilities

6.

Pre-SPAC discussions/Site visit

10

7.

Notice period for SPAC Meeting

8.

SPAC meeting and issue of Minutes

9.

Furnishing of clarifications by Utilities

10. Examination of Clarification and Notice period for TEC

Meeting

11. TEC Meeting/ resolving of issues raised in the meeting

and Finalization/ Issue of Minutes

10

12. Issue of TEC letter

Total

90

In order to facilitate quick examination and processing of the Detailed

Project Report (DPR) for Techno-economic clearance of CEA, formats
and procedure have been devised and included in the Guidelines. Two
check lists have also been included to be filled in and submitted along
with DPR. To facilitate simultaneous examination of the DPR in different
formations, sixteen copies are required to be submitted. The DPR
should conform to the stipulations made in the Check List-A and Check
List-B. The complete details of the check list are given in the document
Guidelines for formulation of Project Reports for Power Projects issued
by CEA in October, 2002.
The DPR (complete document) may also be submitted on Compact Disk
(CD) for facilitating quick examination/ checking. The power potential
calculations etc may be submitted in Microsoft office (Excel) format.
48

The Check List-A is for checking of legal and other major clearances
at the time of receipt/registration of DPR. If the requirements as per
Check List-A are not met, the proposal would not be accepted for
processing in CEA. If the requirements as per Check List-A are met,
the proposal would be examined for meeting the requirement as per
Check List-B. The Check List-B is for checking of the completeness of
the DPR. If the requirements as per Check List-B are not there, the
proposal would be returned.
If the proposal is found to be meeting the requirements as per Check
List-A and Check List-B, it would be further processed and clarifications/
additional information, if necessary, may be sought. If the clarifications/
additional information needed by CEA are not received within the time
stipulated by CEA, the proposal will be deemed as returned.
For such proposals deemed as returned, project authorities would be
required to submit the proposals afresh and the case would be
processed afresh.
7.

CONTENTS OF DPR
Detailed Project Report for hydro electric schemes submitted in the
CEA for techno-economic clearance should cover the following
information:

Detailed Salient features of the project

Description of the project proposals

Cost Estimate for the proposals, Interest during construction & Tariff,
etc.

Phasing of Expenditure, Mode of Funding and Sensitivity Analysis.

Environment & Forest clearance aspect

Drawings and PERT Chart

The brief description of the requirements to be mentioned in the DPRs

for each of the above aspects is given in following sub paras :
49

7.1

SALIENT FEATURES
Detailed salient features of the project i.e. Location, Hydrology and
climate, Dam, Reservoir, Spillway, Submergence, Diversion/Head
Race Tunnel, Sediment chamber, Surge shaft, Penstock, Power house,
Tailrace, Switchyard, Power benefits etc. should be mentioned.

7.2

DESCRIPTION OF PROJECT PROPOSAL

Full description of the HE Project viz. Type, Location, Background
history, infrastructure Need & Justification of the Scheme from power
supply demand consideration, Population effected by the project,
submergence, Inter-state/ International aspects etc. should be given.
Full details of river Basin development, Chapters on Geology, Survey
& Investigation, infrastructure works Hydrology, Dam/ Reservoir, Power
Potential studies, Project optimization studies, Civil structures, Design
of Electrical & Mechanical Equipment, Transmission lines &
Telecommunication system, Construction programme, Construction
equipment & Plant Planning, Construction Materials, Manpower
Planning, Chapter on Economic & Financial studies, Calculations for
tariff, Financial packages, Chapter on Environment & Forest aspects,
R&R aspects, Calculations for quantities of civil woks, Design
calculation for Dam, Civil structure etc. should also be submitted.
Preparedness of the project authorities for implementation of the project
should be brought out. The DPR should indicate whether necessary
studies and investigation have been completed. Alternatives
considered and justification for the finally accepted proposal & whether
it is least cost option, should be clearly brought out.

7.3

COST ESTIMATES, INTEREST DURING CONSTRUCTION AND

TARIFF
The cost estimate for Civil, E&M works along with General Abstract of
cost should be prepared on the basis of Guidelines for Preparation of
Project Estimates for River Valley Projects March 1997 issued by
50

Central Water Commission. The details of cost of generation/sale rate,

tariff, depreciation etc. should be as per various GOI Notifications &
Guidelines and incorporated in the project report. The cost estimates
of Electrical & Mechanical equipment shall be prepared as per CEA
formats.
The cost estimates should be prepared on the basis of prevailing prices
of various materials and equipment/budgetary offers at the time of
preparation of the estimates. The price level reference currencies
alongwith their exchange rates and their reference period,
contingencies adopted for working out cost estimates should also be
furnished in the project report. The foreign exchange requirement and
details of important equipment may be separately indicated in the
prescribed formats of CEA.
The cost estimates should also include Interest During Construction
(IDC) and detailed calculations thereof should be furnished in the
project report, clearly indicating the extent of equity and debt.
Completed cost (for private generating companies), Present Day Cost
(both for SEBs and for Generating Companies in Public Sector) may
be incorporated as per various prescribed formats in the report. Chapter
on Economic & Financial studies, Calculations for tariff & Financial
packages should also be included.
7.4

PHASING OF EXPENDITURE, MODE OF FUNDING & SENSITIVITY

ANALYSIS
Year-wise and work-wise requirements of funds for execution of the
project may be worked out and indicated in the Report. Details as to
how the cost of the project would be financed should be clearly
indicated.
Although the Project Report is prepared on the basis of realistic
assumptions/ estimates, there is every possibility that these
assumptions may undergo change. It may therefore, be necessary to
carry out sensitivity analysis to indicate the projects financial viability of
the project when there are changes in the estimates of any parameters
51

such as Capital Costs, Foreign Exchange Component, Operating Cost,

etc. The extent of changes could be based on past experience.
7.5

ENVIRONMENT AND FOREST CLEARANCE ASPECT

All hydro- electric projects, with investment of Rs 50 crores or more,
require the clearance of the Ministry of Environment and Forest from
the environmental angle. A notification issued by MOE&F, on 27.1.94
has made environment clearance statutory for river valley, hydro electric
and major irrigation projects and their combination including flood
control projects. In April, 1997, MOEF had made public hearing as
statutory for all departmental projects including hydro-electric projects.
In case the construction of hydro projects involves diversion of forest
land for non-forest use, its clearance is required from MOE&F in terms
of Forest (Conservation) Act, 1980 (reported under revision).

View of Balimela P.H. Orissa (6 x 60 MW)

52

7.6

DRAWINGS & PERT CHART

All drawings including Location Map, Index Map, Hydrological Map,
Contour Plans, various drawings of dam/civil structure, Layouts of the
power house, head works, water conductor system, transmission lines,
Single Line Diagram for Relaying & Metering for the power house
should be furnished. Single line diagram of the layout of the substation and a PERT Chart for the project execution activities may also
be furnished.
CHECK LIST-A FIRST STAGE CHECK LIST FOR HYDRO
ELECTRIC PROJECTS
a) Registration of the Company as per the Company Act and
authorization of the State Government/Central Government as the
case may be in accordance with Electricity Act, 2003.
b) Compliance of Electricity Act, 2003, with reference to the
Publication of the scheme in State Gazette and newspaper.
c)

Land & water availability certificate from State Government.

d) Clearance from Ministry of Environment and Forest, Govt. of India.

e) Justification of the Scheme from power supply demand
consideration
f)

Completed cost , Present Day Cost (for SEBs) and both for
Generating Companies in Public Sector as per CEA formats.

g) Financial & Commercial aspects as per CEA format.

h) Defence clearance if applicable.
i)

Salient features as per CEA format

j)

Cost estimates as per CEA format.

Legal Aspects (As applicable)

Compliance as per Electricity Act, 2003

Power Purchase Agreement (PPA)
53

Tariff Notification
Equity Participation
Change of name of implementing agency
General / Specific conditions

CHECK LIST-B SECOND STAGE CHECK LIST FOR HYDRO

ELECTRIC PROJECTS
A

Hydro Electric Schemes Description

a)

General Data of Project (Location, State, District etc.)

b)

Registration of the Company as per the Company Act and

authorization of the State Government/Central Government as the
case may be in accordance with Electricity Act, 2003.

c)

Compliance of Electricity Act, 2003, with reference to the

Publication of the scheme in State Gazette and newspaper.

d)

Land & water availability certificate from State Government.

e)

Clearance from Ministry of Environment and Forest, Govt. of India.

f)

Justification of the Scheme from power supply demand

consideration

g)

Completed cost, Present Day Cost (for SEBs) and both for
Generating Companies in Public Sector as per CEA formats.

h)

Financial & Commercial aspects as per CEA format.

i)

Rehabilitation and resettlement plan from State Revenue

Department.

j)

Defence clearance if applicable.

k)

Electricity Act, 2003 (for private sector projects).

l)

Competent Governments recommendation of DPR and cost (in

case of private generating companies).

m) Detailed information regarding the following aspects of concerned

H.E. Project must be incorporated in the Detailed Project Report/
Feasibility Report:
i)

Planning
54

ii)

Inter-state/ International aspects

iii)

Surveys (Topographical, construction material etc.)

iv)

Investigations (Geological, Seismic, Foundation, Hydrological

and Meteorological etc.)

v)

Hydrology

vi)

Land acquisition and resettlement of oustees

vii) Design & model studies carried out

viii) Flood control & Drainage
ix)

Power planning & related proposals regarding transmission

system, energy charges etc.

x)

Construction programme and man power & plant planning.

xi)

Foreign exchange & financial resources

xii) Estimates
xiii) B.C. Ratio & Revenue.
xiv) Ecological aspects & Soil Conservation (if needed).
B

Details of financial package

a) Financial package should be in CEA prescribed Performa
1001-1004 filled up as under
1001

Financial package Summary.

1002

Financial Package Abstract.

-

1002

Financial Package Abstract.

-

1003

Broad details of hard cost, interest during construction

and financing charges.

Financial structure i.e. Amount of foreign/domestic

debt and equity (foreign/ domestic/ promoters/ other
partners), exchange rates etc.

Financial Package Details.

55

1004

Details of each debt package (amount, source,

interest rate, repayment period, moratorium period,
financing charges etc.)

Phasing of expenditure & drawl of fund statement.

b)

Commitment letters from foreign/ domestic lenders along with their

terms and conditions.

c)

Equity partner agreement

d)

Package wise Interest during Construction (in respective currency)

along with detailed calculations.

e)

Package wise Financing Charges (in respective currency)

including guarantee fee and commitment charges along with
calculations.

f)

In case of projects of SEBs / Central Sector the calculations of IDC

and financing charges are required both at current and completed
costs.

Break up of Cost Estimates

Break up of Cost Estimates of Electrical & Mechanical and Civil works
of Hydro Electric Project as per CEA format / CWC Guidelines.

15.

CONCURRENCE TO REVISED COST ESTIMATES

In every case where the project cost over-run is 20% and is
accompanied by time over-run of over 10% or such other time and cost
over-run norms as may be deemed appropriate by the Authority, the
revised cost estimates shall be prepared by the generating company
and submitted to the Authority for approval including cost estimates for
civil works and Electrical & Mechanical works.

The increase in the estimated cost over the sanctioned estimates

should be computed under the following heads. Detailed reasons

56

for such increases should be also be given:

16

Cost increase due to exchange rate variation (if applicable)

Cost increase due to escalation of prices or material, equipment

and labour

Cost increase due to inadequate provisions/new items

Cost increase due to change in quantities/scope/design

parameters; and

Cost increase due to other reasons (to be specified)

In case the time gap between the techno-economic approval of

the scheme by CEA and actual start of work on the project is three
years or more, the scheme with the Revised Cost Estimates should
be submitted to CEA for fresh techno-economic approval before
starting the works.

CONCURRENCE TO FINAL COMPLETION COST

As per the Tariff Notification of Govt. of India dated 30th March, 1992
(as amended from time to time), the actual capital expenditure
incurred on completion of the project shall be the criterion for fixation
of tariff. Where the actual expenditure exceeds the approved project
cost, the excess as approved by the Authority shall be deemed to
be the actual capital expenditure for the purpose of determining
the tariff. Provided that such excess expenditure is not attributable
to the generating company or supplier of contractors.

The notification also provides that where a power purchase

agreement entered between the generating company and the
Board prescribed a ceiling on capital expenditure, capital
expenditure shall not exceed such ceiling. In case of multi unit
projects, the percentage of capital cost is specified in the technoeconomic clearance, which is considered for fixation of tariff after
commercial operation date (COD) of the progressive units. In case
57

of delay in commissioning of second or subsequent unit from the

schedule dates, the project cost for the period of delay shall be
retrospectively approved for the tariff purpose in the ratio of
proportionate allocation of units.

17

In order to meet the above obligations, the following conditions

are stipulated in the Office Memorandums conveying TEC to the
generating projects:
o

The completion cost of the scheme shall be submitted to the

Authority duly recommended by competent Government for
approval as soon as possible after the commercial operation
date (COD) of the plant but not later than three months from the
COD of the plant.

Completion cost of the scheme shall not exceed the TEC

approved cost except on account of variation in foreign
exchange. Change in rates of statutory taxes and duties and
changes in Indian Law resulting in change in cost.

MODALITIES OF SIMPLIFIED TRANSFER OF TECHNO

ECONOMIC CLEARANCE
CEA has evolved Modalities of Simplified Transfer of Techno
Economic Clearance of Hydroelectric Schemes already cleared by CEA
in the name of other Agency.

58

CHAPTER - 5
BEST PRACTICES IN CONSTRUCTION MONITORING OF
HYDRO ELECTRIC PROJECTS

Eternal vigilance is the price of liberty- these

words of wisdom are

nowhere more relevant than in the case of hydro power projects and
their construction monitoring. Constant construction monitoring
ensures freedom from trouble and assurance of quality and maximum
output. Monitoring involves setting up of objectives, assessment of
critical items, planning and organisation, personnel management,
contract management and adoption of an appropriate mechanism for
reducing time and cost over-runs.

5.1

MONITORING SYSTEM FOR HYDRO- ELECTRIC PROJECTS

Monitoring is a general term implying continuous tracking of progress in
comparison to a predetermined plan, i. e. the schedule, and to avoid and
remedy any straying from the schedule. Monitoring is essential for all
kinds of projects or jobs where a certain task is to be completed within
given time and/or cost by proceeding on a determined path. In a
hydroelectric project, it is all the more important as the delay can cost
heavily. Whenever a hydel project is visualized for execution, the most
important aspect to be taken care is the time (duration) required for its
completion. The viability of the scheme depends largely on the execution
period since the cost and benefits vary considerably with period of
completion and even good projects can be rendered unprofitable due to
large time overruns and cost overruns.
Since big projects involve huge investments and massive engineering
activities, stakes are large and it is essential that the progress of various
activities be kept under a constant vigil at various levels in order to check
any avoidable straying from the schedule of construction. At the time of
198

approval of a project for execution, the target of completion, cost of each

activity and the overall completion date of the project are fixed. The
monitoring of a project comprises:
a.
b.
c.
d.

Defining and setting targets

Reporting achievements against the targets.
Deviations from the targets and reasons thereof.
Corrective action to undo and to contain the damage and avoid
further delay.
e. Rigorous follow-up for enforcement of the decisions of the
management for augmenting the progress, directly as well as
indirectly.
The overall plan of project works and completion of all activities up to
commissioning are spelt out in a project schedule. The overall aim of
whole monitoring process is to adhere to this schedule and commission
the project by the scheduled commissioning date. It is essential therefore
that various components of the project are completed as per their
respective schedules.
5.2

Objectives of Monitoring:
The following are the main objectives of monitoring mechanism:

5.2.1

Completion Period:
This covers determination of period of construction project as a whole
and firm up the completion dates of each of the project components. The
determination of completion period depends on the following factors :i) Location of the project.
ii) Number of major components.
iii) The most critical item of each of the components.

5.2.1.1 Location of the Project

To assess the working months available.
Proximity to important rail line & roads.
Communication facilities.
199

5.2.1.2 Number of major components

Determine the actual number of major components as independent
packages.
Time factor with matching financial back for these major components.
5.2.1.3 Critical items
The various critical items in each of the components of the project.
All other items of respective components to match the critical path as
parallel activities to match the completion of critical items.
5.2.2

Implementation Plan: Implementation plan with organizational and

financial implications. This is practiced with,
i) Network Technique planning with detailed realistic programme.
ii) Need based planning.
iii) Term work planning and responsibilities.

5.2.2.1 Network Planning: This include development of Network; tabulation of

objectives and requirements and Realistic & Accurate Estimation.
-

Detailed programming of various important items of all components.

Determining the critical path (main item) for all components.
Develop network of various activities culminating them with the critical
item.
Develop master network with all components indicating the main
critical activity of each of these components.

Tabulation of objectives and requirements

- The various requirements and inputs to be tabulated and enlisted
with probable date of requirement.
- The important objectives and targets termed as mile stones to be
enlisted with dates for achievement indicating incentives and
penalties.
- The dates of requirement and dates of targets to match the component
network and the master network.
200

 Realistic and Accurate Estimates

- Updated geology
- Firmed up design requirement and drawings in the chronological
order as per the plan.
- Accurate estimates of quantities.
Any deviation of any of the above factors will upset the smooth passage
of networks.
5.2.2.2 Need based planning: The need based requirement towards planning
are :i) Equipment planning
ii) Material planning
iii) Planning and evaluation of working cycle.
Equipment Planning: Determination of plant and equipment
requirement which will depend on :
- Topography of the area.
- Accessibility to various spots of working area.
- Speed of construction to be based on available time factor.
- Construction specifications of the components.
- Economy of construction.
- After determining the plant and equipments further planning for
optimum utilization of the plant and equipment.
- A shift pattern is devised to work at all available time for continuous
working system and optimum utilization of men and machinery.
Material Planning: Material inputs naturally available and those to
be supplied.
- Requirement of all types of materials to be enlisted.
- Daily, monthly and yearly requirements be determined and productive
and procurement planned accordingly.
- For natural materials like sand and aggregates, difficulties envisaged
and phased planning of extraction.
- For procured materials, competitive market rates to be assessed
before determining method of procurement.
201

 Planning and evaluation of working cycle: Evaluation of the

working cycle time for the main critical item.
-

Evaluation of the working cycle time for all other activities considered
as parallel activities.

The cycle time for men and machinery to be properly evaluated taking
into consideration Job & Management Factors.

Job & Management Factors: Availability of time and space depends

on several factors inherent in the job resulting from management
limitations. These are job and management factors.
Job factors pertains to the physical condition of the job apart from the
type of material to be handled. These factors are broadly classified as:

Site topography, magnitude of work, availability of working space.

Climate conditions and the climate of the area.
Geology of the area to determine the methodology of execution.
Accessibility to and within the site.
Specification of the work including sequence of construction and
testing procedures.
Management factors pertain to stability of organizational set up and
efficiency of operations of workmen and staff.
Selection of equipment.

Operational personnel Skilled and supervising honesty, diligence,

aptitude and skill. Incentive plans and inputs by HRD sector.
Finalizing plant layout, supervisions of works, maintenance of
equipments, works and communications.
5.2.2.3 Team work planning & Responsibilities: Determination of plant and
equipment requirement depends on personnel familiar with functional
areas such as Combined analytical intuitive approach/ Total
involvement of project team in planning stage itself. In a nut shell, it is a
total team work with commitment and responsibilities and understanding
specially at the supervision level that yields the desired planned results.
202

5.3

Computerization:
The various practices enlisted above can be computerized to yield better
practices.
i)

A computer solution for preparing and achieving the various

objectives can be developed.

ii) The daily, weekly and monthly reports are computed and analyzed
for lacunae and better results both at field level and Corporate offices.
5.4

Monitoring Mechanism:
The best practice at field at the end of the day is assessing the work
done during the last 24 hours, with various constraints and determining
the work for the next 24 hours envisaging constraints and thus providing
for optimum utilization of all men and machinery available.
Classify the project under one of the Job factors and one of the
Management factors. This would yield a single value of Job &
Management factor, which is used to compute the expected progress.
To keep a proper track of the progress, schedules are prepared for the
complete project (Level-I schedule which is the Master Control Network)
as well as for their individual components of works (Level-II schedules).
Further detailing of activities is done if required which gives a Level-III
schedule, generally in form of bar charts. The Level-I network therefore
enables one to gauge the overall position of works vis--vis the plans, at
any point of time.

5.5

The Schedules:
The Project Management consists of four major parts- Planning,
Organization, Execution and Control. Monitoring system carries out the
control part, i.e. controlling the activities of project so that they proceed
according to the plan and accomplish the required target in time.
Monitoring basically involves acting on feedback to avert any hindrance
203

affecting or likely to affect the activities. The yardstick for how the activities
should proceed is the schedule, while the feedback is the progress report,
i.e. the targeted and actual achievements up to any point of time. In other
words, it is a comparison of what significant milestone has been actually
achieved at a given point of time and when it was due. The primary tools
of monitoring are therefore, the schedules and the milestones derived
from it.
Hydroelectric projects, or for that matter any big project has large number
of interlinked activities, some of which are more important than the rest.
It is therefore, necessary to have a plan that gives a birds eye view of
how the whole project work will proceed and which activities are more
important than others, requiring special attention. Such a schedule is
termed Master Control Network or Level-I schedule, which is basically
a schedule based on Critical Path Method (CPM), and shows only the
major activities with their interdependence, start/end dates, allowable
delays (floats) and criticalities. The critical path in a schedule is the longest
chain of successive related activities without any float i.e. allowable delay
and therefore decides the total completion period of the project. Obviously,
there has to be at least one such path but there may be more than one
also. Critical path, by definition, has no float and therefore any delay in
critical activities results in the delay in completion of the project as a
whole. The activities lying on the critical path therefore have to be paid
special attention. Level-II schedule is more detailed, component-wise,
while Level-III is of still lower level, generally in form of bar chart and
indicates quantitative monthly or weekly targets. Level-I, II and III
schedules essentially have to be in conformity.
The Project work is required to proceed as per these schedules and
feedback on the progress given from site to the monitoring office is
compared with these schedules to gauge the deviations and pace of
progress.
The Master Control Network (Level-I Schedule) also shows the desired
completion dates of some important activities. A list of such milestones
is prepared and actual achievement compared with it. For monitoring at
204

highest level, say ministers level, even Level-I schedule is a bit too
detailed and cumbersome. In this situation, milestones i.e. completion
of an important activity, like excavation or concreting of tunnel, dam etc.,
is the best tool. A list of important milestones is derived from the Level-I
schedule. Achievement of each milestone by its due date simply means
that the work is progressing as planned. This saves the high level
management from trivialities. The Ministry of Programme Implementation
& Statistics monitors all major projects in the country, hydroelectric
projects included, through list of milestones.
5.5.1

Preparation of Schedules: Schedules can be prepared either upwards

or down wards. In upward scheduling first level-III schedule for each
work is worked out, then Level-II as aggregate of LevelIII schedules,
and finally Level-I or Master Control Network is prepared by aggregating
Level-II schedules. In preparing schedule downwards, first an empirical
Level-I schedule is prepared taking into account the constraints in the
project, like time, climate & weather etc. Level-II and Level-III schedules
downwards are then prepared which are in conformity with Level-I. Finally,
all the three schedules are refined later on according to the actual
conditions.
In hydroelectric projects, normally downwards scheduling has to be done
since without an idea of approximate time required for a project, contract
process cannot proceed at all. This overall period and an imperial
schedule are worked out at Detailed Project Report (DPR) stage after
investigations. After final approval of the project, actual working schedules
are prepared incorporating the required changes. These schedules and
the milestones derived from them are used for monitoring the project.

5.6

Contract Management:
Since most of the works are done through large contracts, the
management of contracts is very vital for the progress. After award the
contracts are operated by the site officials. Major components of the
project involve large civil and electrical works and supplies and have to
be executed in parts and mostly through contracts. Works are broken
down into various contract packages according to the quantum of work,
205

type, location etc. These contract packages are awarded to suitable

contractors selected through open tendering, and also from contractor
prequalified and short-listed.
The contractor is supposed to execute the awarded work as per the
specifications and schedule given to him. The schedules provided to all
contract agencies are in conformity with the overall schedule of the project
viz. the level-I schedule. Slippage of even one package from its
programme may lead to disturbance in other works and delay in
commissioning of the project, besides other legal problems that follow
the delays. Due care is therefore taken to keep the pace of work as per
the plan. Whenever there is any apprehension of delay or problem in
execution of work, necessary assistance is provided to the project.
5.7

Financial Control:
Adequate financial control is exercised on the project works at the
appropriate levels by suitable financing and accounting system. Normally
Finance & Accounts (F&A) Wing exercises the financial control, i.e. the
arrangement and control of funds in accordance with the approved cost
estimate of the project. The project furnishes in advance the detailed
budget proposals for each approaching year, which is approved and
accordingly the funds are provided to the projects through monthly bank
withdrawal limits at the local bank at site. In case the expenditure
overshoots the prescribed limits, the cost has to be revised and necessary
approval for the Revised Cost Estimate (RCE) is sought from the
Government.
The project is required to be completed within the approved cost that
was envisaged at the detailed estimate stage of the project. During the
execution stage, attempts are made to maintain the expenditure incurred
on each work within the provision kept for that work. All financial controls
are enforced both at the project level and at the Corporate Office level to
ensure this vital aspect by constant monitoring. However, sometimes due
to unforeseen or unavoidable reasons, the cost overshoots the prescribed
limit inspite of best efforts to contain it. In such circumstances the estimate
has to be revised and a fresh approval needs to be obtained by following
206

due procedures for the same which includes severe scrutiny by the Govt.
at various levels.
5.8

Monitoring mechanism adopted for reducing time and cost overruns:

Steps are required to be taken with a purpose of making Project
Management more effective in completing the projects as per the schedule
and eliminating or at least minimizing the time and cost over run. Towards
this end, following measures can also be taken:
i)

More aggressive and pro-active project monitoring at all levels; top

priority being accorded to issues effecting the progress and stringent
accountability at all levels.
ii) Advanced Project Management Software like Primavera/MS Project.
iii) Interaction with staff as well as contractors increased through Project
Review Meetings and other meetings for the purpose; claim and
dispute settlements being done at top priority.
iv) Improved communication.
v) Inventory Management to be computerized through special software,
in order to check blockade of money in non-productive inventory.
vi) Fund flow to Projects improved: no work suffering because of paucity
of fund.
vii) Improved construction methodology and equipment being deployed
at the sites. A team of geologists is stationed at every project to take
care of the geological problems to minimize the time over-run and
cost over-run.
5.9

Hydro Projects classification and commonly used equipment during

their construction:
Hydro power projects can also be classified broadly into three categories
from their operation point of view:
i)

Run-of-river project: As the name implies, the project is planned as

run of the river. Water is diverted from the river, routed through the
project & finally left back to the river at a lower level downstream. It
207

takes advantage of the drop in elevation that occurs over a distance

in the river and doesnt involve water storage. Conceptually very
simple, but it has one big problem, i.e., power generation fluctuates
with the river flow and the firm power is considerably low, as it
depends on the minimum mean discharge. Canal power projects
are also run-of-river projects.
ii) Storage Project: Storage projects provides storage or pondage, and
thereby, evens out stream flow fluctuations and enhances the water
head. Thus, it increases firm power & total power generation by
regulating the flow. However, providing storage is complicated &
costly as it involves construction of dam.
iii) Pump - Storage Project: Pump - Storage projects store the surplus
energy in the power grid system during the off-peak hours and utilize
the same energy during the peak hours. These involve reversible
turbines, which can generate power from water of upper reservoir
during peak hours & pump back water from lower reservoir to the
upper reservoir during off-peak hours. These are advantageous in
power grid systems of mix type, which have thermal & nuclear power
houses in addition to hydro power projects.
Selection of a particular type of Hydro power projects depends primarily
on techno-economic considerations, which varies from case to case
basis. This can be done only by undertaking a detailed study. The major
common components of a Hydro Project and the equipment normally
used in Hydro Stations component wise is as under:
-

The Main Dam/ Barrage

The Water conductor system (Head race Tunnel)
Surge Shaft/ Pressure Shaft
The Power House

a) Dam/Barrage: Location on rivers, where rock is available at larger

depth, Cut off Wall Trenching equipment is being used. River bed
excavation by Cut off Wall trenching equipment is very much
economical in comparison to conventional methods of deep river
208

bed excavation since it avoids re-handling of huge quantity of

materials and dewatering etc.
For excavation of Dam/ Barrage, Excavators of capacity between 0.9
Cum and 3.0 Cum may be used. The Transportation of muck carried out
with conventional Rear Dumper/Tipper result in higher down time and
retarded progress rate. The multi-axle Dumper with multi-drive system
may prove better to enhance the progress rate. Now a days improved
version of Dumpers are fitted with electronic engine monitoring system
which constantly monitor vital functions. The system also meters fuel
rate, engine torque and power levels to match job and equipment
requirements for optimum efficiency. All time better grip & traction is
available with least downtime. It has also been observed that
conventional Batching & Mixing Plant of indigenous makes pose
problems due to frequent break downs. These could be replaced with
improved version, computerized batching and mixing plants with
hydraulic drive motors, which control the batching & mixing operations
with greater accuracy.
b) The Water conductor system (Head Race Tunnel): Depending
upon geological predictions and length of the tunnel, use of drill
jumbos & other conventional equipment may be replaced with Tunnel
Boring Machine (TBM). Now improved design TBM are available in
market, which can tackle any unforeseen condition of geology with
probe drilling, roof shielding & other concurrent activities (shot-creting,
rib erection, rock bolting, fore-poling, grouting, erection of pre-cast
segments etc.) along with boring of tunnel. With the help of Probe
drilling, rock strata/geology could be investigated in advance so that
further advancement of TBM could be decided. Loose strata could
be tackled with fore-poling equipment which would ensure stability
in rock strata and smooth operation of TBM.
Excavation with Hydraulic Excavator or Front End Loader can be
considered to be replaced with Side Dump Loaders, which ensure
minimum mucking time. Transportation of muck could be carried out with
Low Profile articulated Dumper which can move in both directions with
209

low cycle time in comparison with conventional rear dumpers, which

require additional niches for turning.
For small tunnels, conventional excavation equipment could be replaced
with tunneling excavator-loaders, continuous muckers & rail bound shuttle
trains for quick removal of muck. In case of shear zones coming across
the tunnel alignment, we may tackle loose fall of collapsing rock with the
help of fore poling equipment. Holes are drilled in different directions
with this equipment. After inserting perforated tubes, grouting is carried
out with the help of jet grouting equipment at a pressure of 100 to 150
Kg/sq. Cms. By doing so, a consolidated solid mass is build up and then
tunneling is done through this media. This operation needs minimum
time as compared to any other conventional methods.
For continuous concreting hydraulic collapsible telescopic shutter/
gantries are available which would definitely reduce the time required
for concreting. Transit Mixer could be replaced with Agitator Mixers having
better efficiency wherever compatible with work requirement. For
ventilation, conventional steel duct system could be replaced by light
weight flexible duct or semi-rigid duct with twin blower at a particular
distance or jet fans.
c) Surge Shaft/Pressure Shaft: Raise borers are available now a days
with improved guidance system to maintain the accuracy and location
of shaft as desired. Inclined shaft also could be constructed with blind
hole boring version of raise boring machines with an angle of 45 to
90 degrees from the horizontal axis of shaft.
d) Power House: The three categories of Power House are:
Surface Power House: All components of the hydro power projects are
on the natural / excavated ground surface. This has the advantages of
determinate design & ease in construction. However, this has the
disadvantage of limitation of head available as per the topography.
Underground Power House: All major components of the hydro power
projects are underground in tunnels & caverns. In favorable geological
210

settings, this is very advantageous as it overcomes the limitation of head

available as per the topography and provide compact & economical
layout. However, this has the disadvantages of geological uncertainties
resulting into indeterminate design & construction problems leading to
time & cost over runs.
Semi-underground Power House: Some components of the hydro
power projects are underground, while others are on surface. Sometimes
the advantages of both surface & underground power houses are clubbed
together in a semi-underground power house, provided topography &
geology so permits.
In underground Power House generally excavation of top dome and
access tunnel are carried out with Hydraulic Excavator, Tunneling
Excavator & Rear Dumpers. By deployment of Side Dump Loaders &
L.P articulated Dumpers, excavation of access tunnel & dome could be
expedited.
In conventional method, the excavation of Power House cavern is carried
out with power winches & buckets. This could be replaced by drilling
nos. of drop shafts with raise borer & enlarging thereafter. One shaft (pilot
hole + reaming) requires around 15 days for a normal height powerhouse.
As such four to five shafts could be completed in 2-3 months. Further
benching down and pushing the muck through drop shaft to Adit down
below for mucking, could complete the total excavation in next six months.
Rock columns may be considered for providing the EOT crane beam in
underground power house as conventional methodology involving taking
the columns up from power house bottom to bottom of crane been takes
time and delays construction and erection activities.

211

CHAPTER - 6
BEST PRACTICES IN OPERATION & MAINTENANCE OF
HYDRO POWER STATIONS

Operation and Maintenance of hydro power stations must aim at

reducing failure rate by ensuring smooth operational levels of the

power utility. This can be done by adopting timely preventive
maintenance schedule regarding all vital areas of the power project.
Engineers are well-advised here to follow the well-known dictum:
Prevention is better than cure.

6.1

Best Practices in Operation & Maintenance of Hydro Power stations shall

be such that by following such procedures, the downtime of individual
generating Unit & Plant should be minimum. The operational reliability
of the generating units of the hydro power stations shall be such that
whenever the grid demands, it should be available for generation. Some
of the aspects, which can be taken into consideration, in Operation &
Maintenance of Hydro Power Stations, are given as under :
i)

Each failure/tripping occurrence must be questioned with basic

minimum three questions a) Why this occurred? b) How this
occurred? And c) What is to be done to avoid its reoccurrence?
This will definitely reduce failure rate to the greater extent.

ii) Since It is important to adopt timely preventive Maintenance

Schedules covering all vital areas and plants, the detailed Daily,
Weekly, Monthly, Quarterly, Annually and Capital Maintenance
Sheets should be maintained properly.
iii) During replacement of any part or equipment after its full utilisation
or breakdown, it should be ensured that the replaced part or
equipment should be of improved version & of latest technology
having longer durability to meet all desired requirements so as to
212

increase plant efficiency and reliability.

iv) Operating conditions should continuously be monitored and recorded.
Records are very important to diagnose the causes of fault / failure/
replacement & to determine residual life. Early action can be taken
before any type of failure.
v) Eventhough Original Equipment Manufacturers recommend max./
min. permissible parameters for their equipment, the records/
experience/past history play important role to set limiting values of
parameters of these equipment, as characteristics of identical
equipment vary from unit to unit and required to monitor its set values.
vi) On the basis of past history/records & recommendations of OEMs
maintenance schedules can be framed. Breakdowns/forced outages
can be minimized by proper follow-up of the maintenance schedules
based on recommendations of OEMs.etc. Life of the equipment thus
can be enhanced.
vii) Starting/stopping of the units shall be planned to be minimum to
increase the life.
viii) Procurement of the equipment spares should be planned as per the
rate of the consumption, based on minimum requirement to optimise
the inventory.
ix) Optimum utilisation of the men & material to be planned.
x) It would be beneficial to arrange training to O&M staff to refresh their
knowledge and to give advanced technical information to improve
work quality & quantity.
xi) Interaction amongst working staff at various power stations in the
country needs to be organised to improve performance of plant and
equipment in totality so as to implement good Operation &
Maintenance Practices.
xii) Provision of On Line Condition Monitoring System on genenrator,
213

turbine and main transformers could be considered for installation

on all existing power stations.
xiii) Afforestation in catchment area
Catchment Area Treatment studies for the Stations in operation could be
got carried out and as per recommendations of the studies, the Power
Station should carry out afforestation work in the catchment area. This
would help in reduction of silt content in the inflow water.
6.2

MAINTENANCE PRACTICE
Some of the practices to be adopted at hydro power stations for
maintenance of certain main plant are broadly given below.

6.2.1

Water Intake, Water Conduit System and Associated Equipment

Water storage (Reservoir) & water conductor system comprising of intake,
head race tunnel, surge shaft, emergency valves & pressure shafts,
penstock, main inlet valves are very vital organ of a hydro power plant.
.Due to negative and positive water hammer during sudden changes in
water flow, it is essential to attend to these plant & equipment very
carefully. It is very important to regularly test operation of conduit isolation
system/equipment i.e. intake gates, butterfly valves, excess flow device,
surge equipment etc.
Periodic physical inspection of water conductor system from inside as
well as outside to know its condition, silt deposition, rusting/erosion of
conduit system is very much essential to find out various changes due to
aging factor, stresses developed due to water hammer etc.. The records
of such physical inspection should be maintained by noting all the details
i.e. normal as well as abnormal. These records can be compared with
the installation data. Any abnormality is to be further investigated by
carrying out hydraulic testing, measurement of thickness by Ultrasonic
testing & tests for measuring and computing stresses at strategic locations
such as intake point, bends, besides observing sudden changes in
elevations & sizes of pressure shafts, penstock etc. Leakages, if any,
should be scrupulously noted and records maintained. It should be
214

ensured whether inside / outside (wherever possible) painting is carried

out to protect the conduit system. The valve seals, if deteriorated should
be replaced by using new seals with latest materials for enhancing the
life of this equipment. Purification and frequent testing of hydraulic system
oil should be carried out as per recommendations of the manufacturers.
For oil purification on-line electrostatic liquid cleaners may give best
results. Some of the additional points as mentioned below also need to
be considered:

6.2.2

Cavitation & erosion at top portion due to rushing of air during fill up.
The inspection schedule for the durability of anticorrosive paints used.
Replacement schedule for various vulnerable parts such as bends,
open conduits etc.
Due to humidity open conduit deteriorates from outside. As such
inspection & cleaning to be carried out from time to time at regular
intervals.
Anticorrosive-painting schedules followed.
Timely Operation & Maintenance of the cranes & hoists.
Healthiness of control & protection for isolating gates/valves & for
cranes/hoists.
Maintenance of trash-rack/intake gate filter.
Maintenance of communication systems, availability of power supply,
equipment for emergency operations, approach roads etc.

Turbine & its Auxiliaries

Regular inspection of runners of turbines should be carried out and record
to that effect should be invariably maintained. Many a times it is not
possible for Francis Turbine being always immersed in water and needs
isolation on either side. For this it is done as recommended by
manufacturer without any compromise. Due to cavitation there may be
huge damages to turbine wheel causing adverse effect on performance
and consequently efficiency. Sometimes, it would be necessary to
undertake in-situ repairs of turbine buckets to recoupe/fillup erosions/
white pitting by using various cold compounds viz. Belzona compound,
Loctite, SS Metalset, Throtex compound etc. This may give satisfactory
215

New Turbine Runner of Unit No. 3 of Burla Power House of Hirakud Power
System being replaced for RIM & U Works.
results. Low heat input welding can also be tried at some of the locations
to some extent.
An effective system for monitoring of silt content (quantity and size in
PPM) may be installed & commissioned by each power station and silt
content may be monitored continuously on the basis of which action to
mitigate the damaging effect to under water parts may be initiated
reducing the down time of units / station.
Best efficiency microprocessor based digital PID speed governors
provide fast response. Periodical maintenance of speed governors
alongwith all associated mechanical, electrical, electronics component
should be carried out. The control circuit should be neatly dressed with
identification marks. The electronic components and cards should be
carefully maintained at appropriate temperature level to achieve desired
performance. Periodical calibration and testing of transducers, meters
216

etc. needs to be done. Desired purity level of hydraulic oil is to be

maintained to give trouble free operations. History of each important part
should be maintained. Following maintenance works also need to be
taken up:
Turbine

Periodic NDT viz. Ultrasonic, etc.

Polishing of the various under water parts of the turbines once in a
year to minimize the white pitting.
Inspection & testing of the runners from experts to decide residual
life so as to initiate action for procurement of runners for replacement.
Inspection of labyrinth seals in case of reaction turbines.
Painting of runner housing with anticorrosive I tar based paints.
Applying anti-erosion coating to the runner.
Checking of brake jet operation in power stations having Pelton
turbines once in three months.

Governor

6.2.3

Purification of hydraulic oils by centrifugal as well as electrostatic

liquid cleaner.
Periodic maintenance of the servo valves and motors after carrying
out inspection of the pistons & housings of the servo valves and
motors for their worn-out parts. Replacement of the leaking seals.
Survey of the component failure & procurement of the same and
maintain minimum inventory.

Generator & its Auxiliaries

Stator & rotor winding, bearings & excitation system are the main parts
of a generator. As regards stator and rotor windings, regular recording of
IR Values of these winding should be maintained at regular intervals.
Tan Delta and DLA tests of stator winding indicates the status I condition
of stator winding insulation. Likewise impedance test (voltage drop test
across each pole) indicates condition of the rotor winding. Proper cooling
system is to be maintained to limit rise in stator winding temperatures
and consequently increase the life of stator winding. Inspection of the
217

Machine Hall of Bhabba Power House 3x40 MW

stator winding is also required to be carried out to verify its firmness in
stator core slots and healthiness of overhang portion with firm end winding
caps & end spacers, slot wedges checked for healthiness. Windings are
revarnished to enhance their life. Looseness of stator core or inter
lamination, core insulation are direct factors affecting winding heating
due to eddy current loss. Thus recommended maintenance as per
schedule should be carried out its records maintained and corrective
actions be taken if necessary.
Another precision and very critical components of generator are its guide
and thrust bearings. The thrust bearing is main bearing holding complete
thrust of rotating mass of turbine and generator unit. The generator and
turbine guide bearings act as guides for controlling the vibrations of the
unit . If T -G shaft alignment with accurate shaft level is achieved then the
pad clearances are adjusted precisely and the rotating machine will
operate smoothly without rise in bearing temperature and increase life
218

of bearings. Following works also need to be taken up:

6.2.4

Periodic checking of the foundations, tightening the bolts. Filling the

foundations with epoxy.
Checking the vibrations periodically & history of the recorded
readings gives guidelines for realignment, looseness if any,
unbalanced electrical components, increase in bearing gaps,
coupling misalignment, uneven stator -rotor air gap etc.

Periodic cleaning or replacement of the generator air coolers and

bearing oil coolers to improve performance of the generator.

Primary and secondary testing of the protection system for its

healthiness and correct operation.

Inspection of the CTs, PTs and bus bars for over heating, temperature
rise etc.

Inspection of circuits for protection & control circuits & mock trials of
the fire fighting system alongwith evacuation system. Checking weight
loss of the CO2 cylinders and replenish as per recommendations of
OEM.

Transformer & Switchyard

Continuous monitoring of oil & winding temperature.

Periodic oil filtration.
Oil testing for various tests and Dissolved Gas Analysis.
Tandelta & insulation resistance etc. as per schedule.
Cleaning and replacement of oil cooler
Testing protection system for healthiness.
Mock trials of Checking, maintenance and inspection for Fire fighting
system, CO2 & mulsifire.
Tests for operation time of the breaker.
Operation & testing of isolator opening & closing.
Checking of control circuit & healthiness of operating system of the
breaker.
219

6.2.5

Emergency D. G. Set

6.2.6

Periodic cleaning of transformer bushings & insulator strings.

Switchyard are to be kept neat & tidy. Minimum area surrounding the
yard to be free from growth of scrubs and bushes to avoid any bush
fire damaging the equipment.

Regular maintenance of the emergency set. Checking control &

protection system.
Running of DG set at regular intervals.

Other P. H. Equipment

Periodic maintenance of unit auxiliary, station auxiliary & station

service transformer.
Checking healthiness of station batteries & battery chargers. The
two charges should be rotated once in a week.
Regular inspection of cable ducts to ensure proper ventilation / heat
dissipation.
Checking the healthiness of pressure relief valve, if provided.

220

CHAPTER - 6
BEST PRACTICES IN OPERATION & MAINTENANCE OF
HYDRO POWER STATIONS

Operation and Maintenance of hydro power stations must aim at

reducing failure rate by ensuring smooth operational levels of the

power utility. This can be done by adopting timely preventive
maintenance schedule regarding all vital areas of the power project.
Engineers are well-advised here to follow the well-known dictum:
Prevention is better than cure.

6.1

Best Practices in Operation & Maintenance of Hydro Power stations shall

be such that by following such procedures, the downtime of individual
generating Unit & Plant should be minimum. The operational reliability
of the generating units of the hydro power stations shall be such that
whenever the grid demands, it should be available for generation. Some
of the aspects, which can be taken into consideration, in Operation &
Maintenance of Hydro Power Stations, are given as under :
i)

Each failure/tripping occurrence must be questioned with basic

minimum three questions a) Why this occurred? b) How this
occurred? And c) What is to be done to avoid its reoccurrence?
This will definitely reduce failure rate to the greater extent.

ii) Since It is important to adopt timely preventive Maintenance

Schedules covering all vital areas and plants, the detailed Daily,
Weekly, Monthly, Quarterly, Annually and Capital Maintenance
Sheets should be maintained properly.
iii) During replacement of any part or equipment after its full utilisation
or breakdown, it should be ensured that the replaced part or
equipment should be of improved version & of latest technology
having longer durability to meet all desired requirements so as to
212

increase plant efficiency and reliability.

iv) Operating conditions should continuously be monitored and recorded.
Records are very important to diagnose the causes of fault / failure/
replacement & to determine residual life. Early action can be taken
before any type of failure.
v) Eventhough Original Equipment Manufacturers recommend max./
min. permissible parameters for their equipment, the records/
experience/past history play important role to set limiting values of
parameters of these equipment, as characteristics of identical
equipment vary from unit to unit and required to monitor its set values.
vi) On the basis of past history/records & recommendations of OEMs
maintenance schedules can be framed. Breakdowns/forced outages
can be minimized by proper follow-up of the maintenance schedules
based on recommendations of OEMs.etc. Life of the equipment thus
can be enhanced.
vii) Starting/stopping of the units shall be planned to be minimum to
increase the life.
viii) Procurement of the equipment spares should be planned as per the
rate of the consumption, based on minimum requirement to optimise
the inventory.
ix) Optimum utilisation of the men & material to be planned.
x) It would be beneficial to arrange training to O&M staff to refresh their
knowledge and to give advanced technical information to improve
work quality & quantity.
xi) Interaction amongst working staff at various power stations in the
country needs to be organised to improve performance of plant and
equipment in totality so as to implement good Operation &
Maintenance Practices.
xii) Provision of On Line Condition Monitoring System on genenrator,
213

turbine and main transformers could be considered for installation

on all existing power stations.
xiii) Afforestation in catchment area
Catchment Area Treatment studies for the Stations in operation could be
got carried out and as per recommendations of the studies, the Power
Station should carry out afforestation work in the catchment area. This
would help in reduction of silt content in the inflow water.
6.2

MAINTENANCE PRACTICE
Some of the practices to be adopted at hydro power stations for
maintenance of certain main plant are broadly given below.

6.2.1

Water Intake, Water Conduit System and Associated Equipment

Water storage (Reservoir) & water conductor system comprising of intake,
head race tunnel, surge shaft, emergency valves & pressure shafts,
penstock, main inlet valves are very vital organ of a hydro power plant.
.Due to negative and positive water hammer during sudden changes in
water flow, it is essential to attend to these plant & equipment very
carefully. It is very important to regularly test operation of conduit isolation
system/equipment i.e. intake gates, butterfly valves, excess flow device,
surge equipment etc.
Periodic physical inspection of water conductor system from inside as
well as outside to know its condition, silt deposition, rusting/erosion of
conduit system is very much essential to find out various changes due to
aging factor, stresses developed due to water hammer etc.. The records
of such physical inspection should be maintained by noting all the details
i.e. normal as well as abnormal. These records can be compared with
the installation data. Any abnormality is to be further investigated by
carrying out hydraulic testing, measurement of thickness by Ultrasonic
testing & tests for measuring and computing stresses at strategic locations
such as intake point, bends, besides observing sudden changes in
elevations & sizes of pressure shafts, penstock etc. Leakages, if any,
should be scrupulously noted and records maintained. It should be
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ensured whether inside / outside (wherever possible) painting is carried

out to protect the conduit system. The valve seals, if deteriorated should
be replaced by using new seals with latest materials for enhancing the
life of this equipment. Purification and frequent testing of hydraulic system
oil should be carried out as per recommendations of the manufacturers.
For oil purification on-line electrostatic liquid cleaners may give best
results. Some of the additional points as mentioned below also need to
be considered:

6.2.2

Cavitation & erosion at top portion due to rushing of air during fill up.
The inspection schedule for the durability of anticorrosive paints used.
Replacement schedule for various vulnerable parts such as bends,
open conduits etc.
Due to humidity open conduit deteriorates from outside. As such
inspection & cleaning to be carried out from time to time at regular
intervals.
Anticorrosive-painting schedules followed.
Timely Operation & Maintenance of the cranes & hoists.
Healthiness of control & protection for isolating gates/valves & for
cranes/hoists.
Maintenance of trash-rack/intake gate filter.
Maintenance of communication systems, availability of power supply,
equipment for emergency operations, approach roads etc.

Turbine & its Auxiliaries

Regular inspection of runners of turbines should be carried out and record
to that effect should be invariably maintained. Many a times it is not
possible for Francis Turbine being always immersed in water and needs
isolation on either side. For this it is done as recommended by
manufacturer without any compromise. Due to cavitation there may be
huge damages to turbine wheel causing adverse effect on performance
and consequently efficiency. Sometimes, it would be necessary to
undertake in-situ repairs of turbine buckets to recoupe/fillup erosions/
white pitting by using various cold compounds viz. Belzona compound,
Loctite, SS Metalset, Throtex compound etc. This may give satisfactory
215

New Turbine Runner of Unit No. 3 of Burla Power House of Hirakud Power
System being replaced for RIM & U Works.
results. Low heat input welding can also be tried at some of the locations
to some extent.
An effective system for monitoring of silt content (quantity and size in
PPM) may be installed & commissioned by each power station and silt
content may be monitored continuously on the basis of which action to
mitigate the damaging effect to under water parts may be initiated
reducing the down time of units / station.
Best efficiency microprocessor based digital PID speed governors
provide fast response. Periodical maintenance of speed governors
alongwith all associated mechanical, electrical, electronics component
should be carried out. The control circuit should be neatly dressed with
identification marks. The electronic components and cards should be
carefully maintained at appropriate temperature level to achieve desired
performance. Periodical calibration and testing of transducers, meters
216

etc. needs to be done. Desired purity level of hydraulic oil is to be

maintained to give trouble free operations. History of each important part
should be maintained. Following maintenance works also need to be
taken up:
Turbine

Periodic NDT viz. Ultrasonic, etc.

Polishing of the various under water parts of the turbines once in a
year to minimize the white pitting.
Inspection & testing of the runners from experts to decide residual
life so as to initiate action for procurement of runners for replacement.
Inspection of labyrinth seals in case of reaction turbines.
Painting of runner housing with anticorrosive I tar based paints.
Applying anti-erosion coating to the runner.
Checking of brake jet operation in power stations having Pelton
turbines once in three months.

Governor

6.2.3

Purification of hydraulic oils by centrifugal as well as electrostatic

liquid cleaner.
Periodic maintenance of the servo valves and motors after carrying
out inspection of the pistons & housings of the servo valves and
motors for their worn-out parts. Replacement of the leaking seals.
Survey of the component failure & procurement of the same and
maintain minimum inventory.

Generator & its Auxiliaries

Stator & rotor winding, bearings & excitation system are the main parts
of a generator. As regards stator and rotor windings, regular recording of
IR Values of these winding should be maintained at regular intervals.
Tan Delta and DLA tests of stator winding indicates the status I condition
of stator winding insulation. Likewise impedance test (voltage drop test
across each pole) indicates condition of the rotor winding. Proper cooling
system is to be maintained to limit rise in stator winding temperatures
and consequently increase the life of stator winding. Inspection of the
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Machine Hall of Bhabba Power House 3x40 MW

stator winding is also required to be carried out to verify its firmness in
stator core slots and healthiness of overhang portion with firm end winding
caps & end spacers, slot wedges checked for healthiness. Windings are
revarnished to enhance their life. Looseness of stator core or inter
lamination, core insulation are direct factors affecting winding heating
due to eddy current loss. Thus recommended maintenance as per
schedule should be carried out its records maintained and corrective
actions be taken if necessary.
Another precision and very critical components of generator are its guide
and thrust bearings. The thrust bearing is main bearing holding complete
thrust of rotating mass of turbine and generator unit. The generator and
turbine guide bearings act as guides for controlling the vibrations of the
unit . If T -G shaft alignment with accurate shaft level is achieved then the
pad clearances are adjusted precisely and the rotating machine will
operate smoothly without rise in bearing temperature and increase life
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of bearings. Following works also need to be taken up:

6.2.4

Periodic checking of the foundations, tightening the bolts. Filling the

foundations with epoxy.
Checking the vibrations periodically & history of the recorded
readings gives guidelines for realignment, looseness if any,
unbalanced electrical components, increase in bearing gaps,
coupling misalignment, uneven stator -rotor air gap etc.

Periodic cleaning or replacement of the generator air coolers and

bearing oil coolers to improve performance of the generator.

Primary and secondary testing of the protection system for its

healthiness and correct operation.

Inspection of the CTs, PTs and bus bars for over heating, temperature
rise etc.

Inspection of circuits for protection & control circuits & mock trials of
the fire fighting system alongwith evacuation system. Checking weight
loss of the CO2 cylinders and replenish as per recommendations of
OEM.

Transformer & Switchyard

Continuous monitoring of oil & winding temperature.

Periodic oil filtration.
Oil testing for various tests and Dissolved Gas Analysis.
Tandelta & insulation resistance etc. as per schedule.
Cleaning and replacement of oil cooler
Testing protection system for healthiness.
Mock trials of Checking, maintenance and inspection for Fire fighting
system, CO2 & mulsifire.
Tests for operation time of the breaker.
Operation & testing of isolator opening & closing.
Checking of control circuit & healthiness of operating system of the
breaker.
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6.2.5

Emergency D. G. Set

6.2.6

Periodic cleaning of transformer bushings & insulator strings.

Switchyard are to be kept neat & tidy. Minimum area surrounding the
yard to be free from growth of scrubs and bushes to avoid any bush
fire damaging the equipment.

Regular maintenance of the emergency set. Checking control &

protection system.
Running of DG set at regular intervals.

Other P. H. Equipment

Periodic maintenance of unit auxiliary, station auxiliary & station

service transformer.
Checking healthiness of station batteries & battery chargers. The
two charges should be rotated once in a week.
Regular inspection of cable ducts to ensure proper ventilation / heat
dissipation.
Checking the healthiness of pressure relief valve, if provided.

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CHAPTER - 7
RENOVATION AND MODERNISATION AND UPRATING OF
HYDRO POWER STATIONS

Renovation and modernisation (R&M) of

hydro power plants is a

cost effective way of dealing with the problem of low production levels.
It is comparatively easier than constructing new projects and can
yield results in about three to four years. The following chapter
provides tips on selecting various R&M activities along with residual
life assessment studies.

7.1

7.2

Renovation & Modernisation (R&M) of old plants is considered to

be the best option to bridge the wide gap between demand and
supply of power as R&M programmes are cost effective having much
lower gestation period compared to setting up of new plants.

Renovation, modernization and uprating of hydro generating units

(RM&U) which have outlived their normative operating life and the
relatively new machines with generic problems are recognized to
yield considerable additional benefits of energy at minimum cost.
RM&U programmes can be expected to yield benefits in about 3 to 4
years as against installation period for new hydro generating capacity
of 6 to 7 years.

RM&U programmes may be taken up timely to prevent deterioration

in operation of generating units which may lead to their premature
retiring. By undertaking timely RM&U & Life extension programme,
the generating plant can be made to operate for another extended
period of 20 to 25 years with improved reliability and availability.

NEED FOR RENOVATION, MODERNISATION & UPRATING OF

HYDRO POWER PLANTS
-

The normative operative life of hydro electric power plant is 30 to 35

221

years after which it normally requires Life extension through

renovation.

7.3

By undertaking activities involving replacement of worn out or

damaged components the availability of the generating unit and to
some extent its life would be increased but no improvement in output
or efficiency can be expected.

The output and efficiency of generating units can be increased by

replacing old or damaged components by redesigned components
using State of the art materials. Especially in old equipment a
significant increase in output and/or efficiency can be achieved by
the use of new materials and advanced engineering methods. In
addition, the overall life expectancy of the equipment will also be
increased.

By undertaking uprating programmes it is possible to uprate the

generating capacity of existing units by 10 to 30% based on the water
availability, operating margin and technological upgradation. This
programme may be involving rewinding of stator from Class B to
Class F, restoring stator core, improving air gap, replacing turbine
runner with advanced blade profile and material while carrying out
uprating of the plant, modernization by replacing conventional
excitation system with static excitation system, replacing conventional
governing system with micro processor based electro hydraulic
governing system, retrofitting existing control and protection system
to modern state of the art system etc. may also be undertaken for
improvement of reliability in operation of the plant. However, uprating
of generating capacity may be taken up after detailed investigations
and studies.

APPROACH FOR SELECTING R&M ACTIVITIES

The performance of the generating units should be the guiding factor in
selection of R&M activities rather than the period of their operation.
The following aspects/requirements to be kept in view whole selecting
R&M activities:222

7.4

Activities covering main equipment i.e. turbine, generator and C&I

equipment and other plant equipment essential for efficient and
sustained performance of the units as well as station be identified.
Activities which have direct impact on improvement of generation,
efficiency, machine availability etc. be assigned higher priority.
Activities which yield uprating benefits because of rewinding with
Class F insulation, runner with improved profile be given priority.
For silt prone hydro power stations, R&D activities on advanced
techniques like plasma coating on under water parts of turbine, and
development of new materials may be given priority. Adoption of
closed circuit cooling system, Cu-Ni tubes for coolers etc. may also
be considered.
Activities which include state of the art equipment such as electronic
governors, static excitation system, micro processor based controlled
high speed static relays, on line monitoring devices and silt content
in water.
Activities like argumentation of water conductor system which may
increase the discharge/head & hence the peaking capacity &
additional generation of the generation station.

RESIDUAL LIFE ASSESSMENT (RLA) STUDIES

RLA studies may be carried out so that a realistic picture is available in
regard to the residual life/condition of the entire power station
equipments, systems and sub systems.
Whole power project is divided into 4 categories for the purpose of RLA
studies. These are as under:Category I

: Hydro turbines, generators, valves, governors, excitation

system equipments and station auxiliaries.

Category II : Main power transformers and switchyard equipments

Category III :Hydro mechanical equipments like gates, trash rack, stop
logs and gate operating mechanisms
Category IV: Civil engineering elements/components namely dams,
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intake, water conductor system, power house building,

foundations etc.
i) Besides non-destructive/destructive tests and interpretation of test
results, the following should also constitute the RLA study programme:7.5

Visual examination
On line diagnostics
Review of operational history
Review of plant documents
Discussions with plant authorities and O&M staff on the health of the
equipments
Identification of critical components

STRATEGY OF RM&U & LE PROGRAMME

The strategy of RM&U & LE programme is to determine the optimum
RM&U & Life extension works, so as to achieve restoration/enhancement
of the plants average performance, reliability, availability, safety of
operation, Life extension for another 20-25 years and updation/
upgradation of equipment/system and to determine the potential for
uprating the capacity of the units/plant as a whole.

7.6

METHODOLOGY FOR IMPLEMENTATION

-

Scope of R&M works and life extension programme in respect of

generating units having completed more than 30 years of service life
should be firmed up based on RLA studies. Uprating, if feasible
shall also be taken up along with life extension programme.
RLA studies should be got conducted through competent vendors
and the Detailed Project Report for the scheme be prepared based
on the findings of RLA studies.
Job of RLA studies and execution of R&M works should be tendered
out separately with the later being based on the findings of the first
one.
Prior to undertaking uprating works, it is necessary to go for uprating
studies. Uprating studies should be got conducted through reputed
agencies like CWPRS, CPRI, BHEL, etc.
224

R&M works as firmed up in the detailed project report should

preferably be tendered out on turn-key basis to the reputed
manufacturers/vendors.
A high level task force be constituted by the utility for implementation
of R&M schemes as per time bound programme.
Completion of activities as well as performance of the equipment
after R&M should be guaranteed through stringent penalty clauses.
Addition/deletion of R&M activities from those incorporated in the
DPR should not be permitted. Allocation of funds should be activity
based and implementation of the scheme should be monitored
activity-wise.

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CHAPTER - 8
MONITORING OF R&M SCHEMES

Procedural delays in finalising the implementation of Renovation

and Modernisation schemes has proved to be a major cause for time
and cost over-runs. Experts have often voiced the need to create a
Task Force, a separate high powered committee, in each board
invested with full decision making powers, is the only viable solution
to this persistent problem.
8.1

INTRODUCTION :

8.1.1

It is experienced from the implementation of R&M schemes that a lot of

time is taken by some of the boards in taking decisions in finalization of
orders. This is due to procedural delays and long channels of decision
making etc. As such, there is a need to set up a separate high powered
committee, in each board with full powers to take decision in all matters
relating to implementation of R&M schemes.

8.1.2

The committee may be headed by a senior level officers of the rank of

Member (Technical) and comprise of head of power stations, Senior
Finance Officer of the Board.

8.1.3

This committee may have the financial powers to place orders and take
all policy decisions. This will cut short the delays in taking decisions
and thereby help in reducing time and cost over runs. The committee
shall also periodically review the progress of R&M works for timely
completion.

8.2

R&M UNITS AT POWER STATIONS/HEADQUARTERS

The officers and staff at power stations normally remain busy in their
day-to-day O&M works and are not able to pay much attention to the
R&M works. As a result, the R&M programme gets delayed. Therefore,
226

there is a need to set up separate dedicated R&M unit at each power

station and at the Headquarters to deal exclusively the R&M schemes.
8.3

PROCUREMENT OF SPARES
Due to fast changing technologies especially in the field of electronics/
control & Instrumentation, the system gets obsolete frequently. As a result
the power stations have to go for replacement of the system resulting in
extra financial burden. To overcome the problem, power stations should
procure sufficient initial spares. Also it may be clearly mentioned in the
contract that in the event of manufactures going out of production of certain
items, shall inform the users well in advance so that sufficient spares
could be procured by them and they should also submit details of
drawings for its manufacture.

8.4

TURNKEY ORDERS
Wherever possible orders on turnkey basis may be placed so as to have
single point responsibility on the bidder.

8.5

PRIORITISATION OF R&M WORKS

The R&M works should be categorized on the basis of priorities and
work relating to safety, availability and environment needs to be taken
up as a first priority.

8.6

CENTRALISED ACTION FOR SIMILAR R&M WORKS AT DIFFERENT

POWER STATIONS
In case a similar R&M activity is implemented at more than one power
station of the same board centralised action for procurement may be
taken to reduce time and cost overruns as well as to avail concessional
price for bulk order.

8.7

PROPER PLANNING OF R&M WORKS

Unit-wise approach for carrying out R&M works should be followed rather
than carrying out R&M works in piecemeal or activity-wise.
227

As far as possible, the overhauls of the units should be planned in such

a way that maximum number of R&M works could be executed during
overhauls so as to avoid separate shutdown for carrying out R&M works.
Proper planning of resource (men, material & money) should be made to
match with the planned shutdown of unit for R&M.

228

CONCLUSION
The book has been prepared to provide guidelines to the Planners,
Consultants, Power Utilities & other organizations in the country who are
associated in one or more aspects of Survey & investigation, Planning,
Designs, Construction, Operation & Maintenance, Renovation,
Modernisation and Uprating and Monitoring for projects under
construction and under operation. International practices, Indian
Practices and Expected Benchmarking for various parameters of Hydro
Power Generation have also been included in the document. It is hoped
that the guidelines / suggestions contained in the report will help in
improving overall performance, achieve higher level of equipment
availability, help in improving the morale & dedication of the staff of all
such Indian organizations serving in the field of hydro generation in the
country.
The material given in the document has been contributed by the
members of the Committee & suggestions for improvement received from
various officials of the organizations in the hydro power generation &
reflect the practices followed by their respective organizations.
Since it is an attempt to compile & disseminate such information to
all users in the country, contents of the document, suggestions about
the best practices and bench marking in various areas of hydro
power generation by the various utilities to enrich the document
are earnestly sought. Interaction with the Chairman & MemberSecretary of the Committee and feedback regarding the contents
would be also welcome.

229