Investigation Report for Hale HPP

Investigation Report

For

Rehabilitation of Hale Hydropower Station

September 9, 2022

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 Investigation Report for Hale HPP

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 Investigation Report for Hale HPP

目录
1 Road.................................................................................................................................4
2 Storage Weir dam...........................................................................................................5
3 Intake...............................................................................................................................8
3.1 Intake gates..................................................................................................................8
3.2 Trash rack and Trash Rack Cleaning Machine........................................................9
3.3 Sluice gate and Maintenance gate............................................................................10
3.4 Headrace tunnel.........................................................................................................11
4 Spillway.........................................................................................................................12
4.1 Spillway Radial Gate...................................................................................................12
5 Substation......................................................................................................................16
6 Gantry building.............................................................................................................23
7 Power house...................................................................................................................26
7.1 1# Unit........................................................................................................................26
7.1.1 Governor................................................................................................................26
7.1.2 Draft tube and spiral case.....................................................................................28

1 Tail water, stay ring, penstock, cone and elbow..............................................................28

1.1 Tail water.................................................................................................................28
1.2 Spiral case and stay ring..........................................................................................28
1.3 Penstock...................................................................................................................29
1.4 Elbow tube...............................................................................................................29
7.1.3 Main shaft..............................................................................................................37
7.1.4 Spherical valve of Unit No.1..................................................................................37
7.1.5 Sandblasting and anti-corrosion for the unit.......................................................39
7.1.6 Generator...............................................................................................................39
7.1.6.1 Stator......................................................................................................................39
7.1.6.2 Excitation system...................................................................................................40
7.1.6.3 Bearing and lower bracket....................................................................................41
7.1.7 Technical water supply..........................................................................................41
7.1.8 EM equipment in PH.............................................................................................42
7.1.9 Draft tube gate.........................................................................................................43

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 Investigation Report for Hale HPP

7.2 Unit No.2....................................................................................................................43

7.2.1 Governor................................................................................................................44
7.2.2 Spherical Valve of Unit No.2.................................................................................45
7.3 Bridge Crane in the Power House............................................................................46
7.4 Ventilation System.....................................................................................................47
7.5 Cable Shaft.................................................................................................................48

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 Investigation Report for Hale HPP

1 Road
Hale Hydropower Station is located on National Road A14, 270 kilometers away from Dar es
Salaam port in Tanzania and 70 kilometers away from Tanga port. The goods can be transported
by road from Dar es Salaam to the Hale project site, or by barge to Tanga port, and then
transported by land to the Hale power station project site.

There is asphalt road from A14 national road to Hale substation and the powerhouse, the road
surface is in good condition.

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 Investigation Report for Hale HPP

From A14 national road to intake area (left and right banks), dam of the reservoir are all dirt roads,
however, there is no problem for transportation when the weather is fine.
2 Storage Weir dam
Storage weir dam is located 4.1km upstream of the intake. Extension sections of the dam on both
banks are masonry berms of 3 meters wide, and cranes cannot pass.
Two radial gates and one flap gate were damaged seriously and need to be removed.

Traffic bridge Right bank with width of 80cm

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 Investigation Report for Hale HPP

Hoist machinery seriously corroded

The gate was washed away 200 meters downstream of the dam

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The bracket is hang on the hinge support

Flap gate in the middle position

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3 Intake
3.1 Intake gates
On September 2, the Employer dewatered intake through the sluice gate, and cleaned the
sedimentation area in front of the intake. There is water leakage at the right bottom side of intake
gate. Due to the leakage is small, the concrete of the intake gate shall be in good condition, only
the seal shall be replaced.

Intake

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Leakage of Intake gate (In July)

Leakage of intake gate (In Sep 2)

3.2 Trash rack and Trash Rack Cleaning Machine
The two trash racks at the intake were severely corroded, and shall be replaced after dewatering of
the intake.

Trash Rack at the Intake

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Trash Cleaning Machine

3.3 Sluice gate and Maintenance gate
The sluice gate could work properly, necessary anti-corrosion method shall be performed on the
mechanical parts. Control equipment shall be replaced.
The intake equipment shall be rehabilitated during dry season next year, coffer dam is necessary
for the work.

Sluice gate
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Inlet of sluice gate

3.4 Headrace tunnel

Inside of the headrace tunnel(a)

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Inside of the head race tunnel (b)

Stone inside the headrace tunnel

4 Spillway
4.1 Spillway Radial Gate
Many cracks are found on the spillway pier.
There are two spillway gates of different sizes, one larger and one smaller. When the larger gate is
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closed, left side of the gate leaks seriously. According to the previous investigation, it was found
that the turbulent vortex at the bottom of the large gate is serious, which means the bottom sill of
the gate may be damaged. In addition, there are 3 holes in the upper part of the gate , which need
to be repaired.
There is also leakage at the small radial gate, and the seal needs to be replaced.
The wire rope of the hoist used to lift the radial gate was severely corroded and needs to be
replaced with a new wire rope. The radial gate is eccentric, which requires two cranes working
together to dismantle. Due to the space is limited, it is recommended to carry the repairing, anti-
corrosion work at site.
The internal structure of the radial gate operating mechanism is complete, and individual parts are
rusted. Necessary cleaning, anti-corrosion work shall be performed on all mechanical part, seals
and electric parts shall be replaced.
All the lighting street lamps were damaged, and the blocking nets and handrails were partially
damaged.
Rehabilitation of the radial gates is planned to be carried out in the dry season next year. At the
meeting, the Employer pointed out that there is no problem with the sealing and water stop using
needle stop logs. However, the number of needle stop logs is currently insufficient, and more
needle stop logs need to be supplied. It is recommended to adopt the owner's proposal, use the
maintenance needle stop logs for repairment of the radial gates. According to on-site observation,
the exit of the radial gate is relatively low. In order to prevent the backflow of the downstream
water, it is also necessary to build a small cofferdam on the downstream side when maintenance of
the radial gates.

remove sediment and silt at the intake

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Cracks on the concrete

Radial spillway gate

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Holes observed on the large radial gate

Hoist housing

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Needle stop logs

5 Substation
Almost all the 132 kV substation equipment needs to be replaced, except a few parts which can be
repaired or reused, such as the metal structure and foundation of 132 kV equipment, line traps, one
circuit breaker (requires overhaul) and T5 transformer, etc.
The original control and protection system and 33kV switchgear need to be completely removed
and replaced, and a new 33kV indoor switching station and control building will be built.
33/11kV Transformer T5 and local power supply bay 11kV circuit breaker does not need to be
replaced, but the foundations need to be rebuilt according to the new arrangement.
Routine for 33kV cable/overhead line and 400V cable/overhead line is not clear right now, need
further investigation.
According to the Employer's requirements, during the rehabilitation of the 132kV substation, it is
necessary to ensure the power supply in Tanga city, and by – pass connection is required.

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Control room at the old control building

132kV incoming line from Chalinze

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132kV outgoing line to Tanga, Pangani, Kiyungi

132kV busbar

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Layout of the project

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Substation panorama (shooting point - surge shaft)

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Photos of the original substation area (shooting point - surge shaft)

New 33kV indoor switchgear area

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Scrapyard for old equipment

Original control building

6 Gantry building

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The steel structure part of the bridge crane needs cleaning and anti-corrosion treatment, and the
rest electrical parts needs to be replaced, such as power boxes, lighting, DC, ventilation systems,
etc.
The bridge and trolley can move properly, but break of the driver for bridge can’t work.
The main hook can’t work properly, and the whole trolley may need to be replaced, including the
wire rope and electric parts.
Power supply for driver of the bridge is recommended to be replaced with new one.
Because the space between the top of the trolley and the roof is limited, when installing the trolley,
the roof of the building shall be removed, and a mobile crane will be used to lift the trolley to the
main bridge girder.

Gantry building （front）

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Gantry building (back)

Bridge crane in the gantry building

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Trolley conductor
7 Power house
7.1 1# Unit
The 1# unit has been out of operation for many years. The Collector ring, Generator room,
Turbine room, Governor, spherical valve, arrangement at generator and turbine floor.
Water Wheel Chamber: The water guide bearing has been disassembled, and the water guide shoe
has been removed. Connecting parts and screw nuts are seriously corroded, which increases the
difficulty for dismantling of the unit. 1 # Technical water supply system has been discontinued and
its filter element has been removed.
Spherical valve: The spherical valve has been closed for many years, and no water leakage has
been found. The flange surface connecting the upstream short pipe and the valve expansion joint is
seriously corroded and needs to be repaired and painted; the bolts need to be replaced.
Stator pit: The technical water supply pipe has been removed, and some of the pipes are placed on
the ground of the stator pit. The stator air cooler has been removed.
Spiral case, Stay ring, and elbow tube: It is not possible to go inside the spiral cose and elbow tube
due to the water inside. Further investigation and measurement need to be performed during
implementation.
7.1.1 Governor
The space for installation of governor is narrow (size : 3000*1600mm ). The design shall consider
the existing space and foundation. New pre-embedded part may be necessary for the governor, and
second-stage concreting work will be required.

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1# governor (side view)

1 号机调速器前视图片
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1# governor (front view)

1# unit servomotor
7.1.2 Draft tube and spiral case
1 Tail water, stay ring, penstock, cone and elbow
1.1 Tail water
Due to the deep accumulation of water at the gate of the tailrace, it was impossible to go inside the
tailrace tunnel and draft tube for investigation. There is still some water flowing out of the tailrace
water tunnel even the intake gates were closed, therefor, it is necessary to build a cofferdam at the
intake during rehabilitation of the powerhouse. Moreover, small cofferdam at the tailrace tunnel
may be necessary to prevent the water for downstream going inside the powerhouse when heavy
rain comes.
1.2 Spiral case and stay ring
Inside of the spiral case and stay ring of unit No.1 has not been investigated, further investigation
in the future will be performed.
Spiral case of unit No.2 : the spiral case has 20 sections from the extension section (spherical
valve flange connection) to the spiral case end section. The water inside the spiral case was
drained through drainage valve on the spiral case and technical water supply pipe on the spherical
valve. Due to the continuous water flow form the surge shaft, there was accumulated water in the
spiral case of 400mm deep, and the accumulated sediment in the spiral case is about 150mm deep.
The inside surface of the spiral case is corroded seriously, repairment and anti-corrosion works
need to be carried on it.
The surface of the stay ring and fixed guid vane is corroded, and the paint needs to be removed
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and anti-corrosion works is required; most of the fixed guide vanes need repairment at the head
area. Stay ring and the base ring was not inspected, and they will be carefully checked after
dismantling.
1.3 Penstock
The inner surface of the penstock is seriously corroded, and the thickness of the penstock plate
will becomes thinner after rehabilitation. There is continuous water flow from the headrace tunnel,
the water is from the leakage of the intake gate and seepage water in the earth. It is necessary to
further evaluate the impact of the seepage on work inside the penstock for rust removal,
sandblasting and painting. There is a lot of sediment at the bottom of the penstock, the bottom is
seriously worn and corroded, and the amount of grinding and repair work is very heavy.
1.4 Elbow tube
The cone tube is inspected through the manhole, due to the elbow tube is full of water, the elbow
tube couldn’t be fully inspected, the first section of elbow tube was observed through the cone
tube manhole. The paint on outer of the cone tube of the 2# unit has fallen off, and the screw is
rusted, so it is necessary to replace the bolts and paint. Material of the cone tube is stainless steel,
and the condition of cone tube is good. It is recommended not to replace the cone tube. In order to
reduce cavitation at the lower end of the cone pipe, it is advised to install the air supply tube at the
bottom of cone tube.

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Gate of tailrace channel

Outlet of the tailrace tunnel

Corrosion on the surface of spiral case

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Corrosion on the surface of spiral case

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Stay ring and guide vane

Stay ring and guide vane

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Penstock, spherical valve and spiral case of Unit No.2

Bifurcation pipe to Unit No.1

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Penstock upstream of spherical valve of Unit No.1

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Water flow and sediment inside the penstock

Corrosion on the surface of penstock

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Corrosion on the surface of penstock

Cone tube and first section of elbow tube (unit No.2)

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Air filling pipes at the bottom of cone tube

Cone tube of Unit No.1

To remove and replace the damaged part of the draft tube and spiral case, it is necessary to cut off
the steel plate at site and remove the concrete before installing new draft tube and spiral case. To

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ensure the welding quality, double-sided welding is required, and the depth of the concrete
removed must exceed 500mm to facilitate welding works, and a manhole must be left in the end
so that people can come out from the space between the spiral case and concrete.
7.1.3 Main shaft

Main shaft
7.1.4 Spherical valve of Unit No.1

The spherical valve has been out of operation for many years, and no leakage was found. Flange
surface between upstream pipe and the expansion joint of the spherical valve is seriously corroded
and needs to be repaired and painted. All the screw rods are seriously corroded and can not be
dismantled. The flange shall be cut and replaced by a new one.

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Oil pressure supply unit

Spherical valve

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7.1.5 Sandblasting and anti-corrosion for the unit

The spiral case and cone tube are seriously corroded, and there is big quantity of work for
removing rust and painting. Since it is underground powerhouse, there shall be too much dust in
the power house.. It is recommended to use a polishing machine and steel wire ball to remove rust
before painting.

7.1.6 Generator
7.1.6.1 Stator

Due to the redesign of the stator foundation, its original foundation may be removed, and new
second-stage concrete required.

Generator nameplate

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Stator pit
7.1.6.2 Excitation system

New excitation system equipment will be supplied, including excitation transformer and
excitation cubicles, and more space will be required to place this equipment. It is recommended to
excavate more space for the control cabinet and excitation system at the entrance of the escape
tunnel.

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Outgoing line for generator

7.1.6.3 Bearing and lower bracket

Existing lower bracket has three support, but the new design has four support for the lower
bracket, the foundation of the lower bracket shall be removed and re-concreted.

Support of lower bracket

7.1.7 Technical water supply

The technical water supply shall be removed and replaced by new one, except for some pipes

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and embedded parts.

Pipes for technical water supply system

7.1.8 EM equipment in PH

The space for EM equipment in the power house is limited, and the environment is not
suitable for electrical equipment. In order to accommodate the electrical cubicle and batteries, it is
recommended to excavate two more rooms at the entrance of the escape tunnel.

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Gallery on the generator floor

Gallery on the turbine floor

7.1.9 Draft tube gate

Draft tube gate

7.2 Unit No.2

Unit No.2 is running at the capacity of 0.4MW, where its designed capacity is 1.05MW. After

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stopping the unit, the unit is till rotating, which means there is much leakage inside the spherical
valve when it is closed.

Spherical valve: Serious water spray was observed at the position of the servomotor. Screw bolts
and flange surface are seriously corroded.

Spiral case, stay ring, elbow tube: the spiral case and draft tube was not inspected due to water
inside, further investigation and evaluation is required in the future.
7.2.1 Governor

The same as Unit No.1, space for installation of governor is narrow (size : 3000*1600mm ).
Design shall take account ofexisting space and foundation. New pre-embedded part may be
necessary for the governor, and second-stage concreting work will be required.

Governor of Unit No.2

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Water wheel Room of Unit No.2

7.2.2 Spherical Valve of Unit No.2

There is water spraying at the valve servDuring operation, water is sprayed at the position of the
ball valve journal relay. After the unit stops, the unit rotates slowly, indicating that the ball valve
has serious water leakage. The flange surface connecting the upstream short pipe and the
expansion joint of the ball valve is seriously corroded and needs to be repaired and painted; all the
screw rods are corroded seriously and cannot be removed.

Spherical Valve for Unit No.2

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7.3 Bridge Crane in the Power House

The bridge crane in the workshop has a main hook and an auxiliary hook, lifting capacity of the
main hook is 40T, and lifting capacity of the auxiliary hook is 5T. The bridge and trolley could
work properly, only some problem on the braking system of bridge.

One supporting beam at the erection bay for bridge rail is seriously rusted and need to remove the
rust and painting.

It is recommended to cancel the bridge crane control room and use wireless control method.

40T/5T bridge Crane in the Powerhouse

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Bridge Crane in the Powerhouse

Bridge Crane in the Powerhouse

7.4 Ventilation System

The old ventilation system needs to be removed.

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Ventilation duct at Generator Corridor

Ventilation Duct at the Erection Bay

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Ventilation Duct in the Cable Shaft

7.5 Cable Shaft

Entry Hole of the Shaft

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Elevator in the Shaft（OTIS，Capacity of 4 persons）

The capacity of the elevator is too small, new arrangement of the shaft shall be taken in to
account.

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Shaft from the underground powerhouse

Entrance of the elevator and cable shaft (In powerhouse)

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