DESIGN GUIDELINES FOR HEADWORKS OF HYDROPOWER PROJECTS

4. FINDINGS OF FIELD STUDY

4.1 GENERAL
In order to incorporate typical Nepali conditions in the guidelines, the Consultant studied
six operational and one under-construction run-of-river hydropower projects in Nepal to
comprehend their planning, design, construction, operation and maintenance. The
findings of the study are summarized in this chapter.

4.2 PROJECT DETAILS

General details of the studied projects are listed in Table 4-1. The data in the table
indicates that the study can be considered representative of run-of-river hydropower
development in Nepal in terms of age, scale, engineering and mode of development and
operation.

Table 4-1: General details of projects

S.N Project Type1 Capacity Year of Owne Engineer
. (MW) commissionin r
g
1. Kali PRoR 144 2002 NEA Morrison Knudsen
Gandaki “A” Inc., USA
HEP
2. Modi Khola SRoR 14.8 2000 NEA Saman Engg.,
HEP Republic of Korea
3. Marsyangdi PRoR 69 1989 NEA Lahmeyer Int.,
HEP Germany
4. Upper Bhote SRoR 36 2001 BKPC Harza Engg.
Koshi HEP Company, USA
5. Sun Koshi PRoR 10.05 1972 NEA People’s Republic
HEP of China
6. Andhi Khola SRoR 5.1 1991 BPC BPC Hydroconsult,
HEP Nepal
7. Middle PRoR 72 Under NEA Fichtner JV,
Marsyangdi construction Germany
1
PRoR – Pondage Run-of-River; SRoR – Simple Run-of-River.

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HEP

4.3 OBSERVATIONS AND FINDINGS

The study yielded valuable information on the components of the various headworks,
their functions and their principal planning and design parameters. It also provided
insight into the construction practices adopted for these headworks, major problems
encountered and their solutions. Useful knowledge on the problems faced in the
operation of the headworks components and their major maintenance requirements was
also obtained. These issues are discussed in the following sections.
4.3.1 Headworks Components
The basic components of the seven headworks were their diversion structure, intake and
desander. However, the configuration of these components was found to be unique for
each project. These configurations are summarized in Table 4-2. Details of these
configurations are presented at the end of this chapter.
Table 4-2: Principal features of headworks
S.N. Project Diversion structure Intake Desander
1. Kali Gandaki Concrete gravity Gated side intake Twin chamber
“A” HEP dam with gated with undersluice surface basin with
spillway intermittent
flushing
2. Modi Khola Ungated concrete Gated vertical Twin chamber
HEP gravity weir and gravity type intake surface basin, side
flushing sluices with gravel trap spillway,
intermittent
flushing
3. Marsyangdi Gated concrete Ungated intake sill Single chamber
HEP gravity weir with flushing sluice surface basin,
intermittent
flushing
4. Upper Bhote Concrete gravity Gated side intake Single chamber
Koshi HEP dam with gated surface basin, end
spillways and side spillways,
continuous flushing
5. Sun Koshi Concrete barrage Gated side intake Single chamber
HEP with gated with sand-trapping surface basin,
spillways and channel continuous flushing
sluiceways
6. Andhi Khola Ungated concrete Gated side intake Twin chamber
HEP gravity weir with with gravel trap surface basin with
undersluice and excluder serpentine system,
intermittent
flushing
7. Middle Combined gated Submerged tunnel Three desander
Marsyangdi concrete gravity intakes and intake caverns,
HEP dam and rockfill tunnel intermittent vertical
dam flushing system

From Table 4-2, it can be observed that the simple run-of-river plants, viz. Andhi Khola
and Modi Khola have ungated weirs to divert the river water towards their intakes. Gated

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side undersluices are provided in these headworks to control the water level at the intake
and to flush out the bed load downstream to have unobstructed passage for the intake.
Gated concrete weirs are provided in the four pondage run-of-river projects (Kali
Gandaki “A”, Marsyangdi, Middle Marsyangdi and Sun Koshi HEPs). These weirs work
as spillways during the flood season, store water behind the structures for diurnal
pondage and divert water towards the intake structure.
Different types of desanding, with differing degrees of sophistication, are provided in the
projects. Both intermittent and continuous flushing arrangements are present.
4.3.2 Principal Design Parameters
For Nepali projects, the design flood, the level of seismic resistance and the desander
trapping efficiency are design parameters that primarily govern the hydraulic and
structural adequacy of headworks. These parameters for the seven projects are listed in
Table 4-3.
Table 4-3: Principal design parameters
S.N Project Diversion structure Desander
.
Design flood Seismic coeff. Trapping efficiency
1. Kali Gandaki “A” 1,000 year 0.3g 100% particles > 0.2 mm,
HEP 95% particles > 0.15 mm
2. Modi Khola HEP 100 year 0.1g 95% particles > 0.2 mm
3. Marsyangdi HEP 1,000 year Not known 100% particles> 0.125
mm, 80% particles > 0.05
mm
4. Upper Bhote 10,000 year 0.2g 99% particles > 0.5 mm,
Koshi HEP 95% particles > 0.3 mm
5. Sun Koshi HEP2 2,150 m3/s 8 grade 100% particles > 0.25 mm
6. Andhi Khola HEP 100 year - 100% particles > 0.3 mm
7. Middle 10,000 year 0.2g 95 % particles > 0.2 mm
Marsyangdi HEP

The design parameters show considerable variation and inconsistency. The design flood,
for example, varies from the 100 year flood to the 10,000 year flood. Although the
selection of flood is very site specific, the choice of very different floods for projects on
the same river and/or with similar consequences of failure is difficult to explain.
The seismic design coefficients also vary considerably. Except in the case of the Kali
Gandaki “A” HEP, the selection of the design seismic coefficients appears to have been
made without sufficient analyses. Considering the fact that Nepal lies in a seismically
active zone, the correctness and variation of the coefficients is a matter of concern.
The trapping efficiency specified for the desander depends primarily on the
characteristics of the sediments in the river. Nevertheless, the frequent wear and tear of
turbines clearly indicates at the insufficiency of these trapping efficiencies at most
projects.
4.3.3 Major Issues in Construction
The main issues related to headworks construction are river diversion during
construction, quality control, instrumentation and monitoring and environmental
2
Equivalent values in terms of return period and percentage of acceleration due to gravity (g) not available.

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monitoring and control. Of these, the first two issues seem to have been appropriately
taken care of in each project. However, the other two issues, namely instrumentation and
monitoring and environmental monitoring and control, have been introduced to different
extents in most of the recent projects.
4.3.4 Major Issues in Operation and Maintenance
The headworks of six projects studied by the Consultant have been in operation for
varying periods of time. During these periods, some of these headworks have followed
good practices aimed at ensuring proper functioning of the projects. However, these
practices are outweighed by the operational problems and structural damage faced by
these headworks.
The good practices followed at the headworks that were studied are listed in Table 4-4.
The major problems at these headworks are enumerated in Table 4-5.

Table 4-4: Good practices in headworks operation

Project Good practices
Kali Gandaki “A” HEP  Regular sediment sampling and testing
 Post-construction environmental auditing
Marsyangdi HEP  Regular hydrological and sediment data collection
 Regular instrumentation monitoring and reporting
 Regular monitoring of desander efficiency
Upper Bhote Koshi HEP  Regular instrumentation monitoring and reporting
 Regular hydrological and sediment data collection
 Post-construction environmental auditing

Table 4-5: Major problems in operation

Project Major issues
Kali Gandaki “A” HEP  Reservoir sedimentation occurring at rapid pace
 Frequent desander flushing during monsoon
 Reduction in power production during desander
flushing
 Irregular and inadequate instrumentation
monitoring
 Desander efficiency not monitored
 Spillway ogee surface regularly damaged (Photo
4-1)
Modi Khola HEP  Frequent desander flushing during monsoon
 Reduction in power production during desander
flushing
 Frequent choking of trash racks
 Desander efficiency not monitored
 Weir surface frequently damaged
 Sluice steel lining torn away and reinforcement
exposed (Photo 4-2)
 Significant movement of right bank wall
 Downstream apron and riprap eroded
 Fish ladder ineffective
Marsyangdi HEP  Rapid reservoir sedimentation, flushed twice
 Frequent desander flushing during monsoon

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 Power outage during desander flushing

 Erosion of concrete ogee surface
 Steel lining in sluice worn away and concrete
eroded
Upper Bhote Koshi HEP  Frequent desander flushing during monsoon
 Desander efficiency not monitored
 Frequent damage to spillway ogee surface and
stilling basin, with exposure of reinforcement
Sun Koshi HEP  Frequent obstruction of guide vanes of flushing
channel
 Frequent desander flushing during monsoon
 No instrumentation and monitoring
 Desander efficiency not monitored
 Sluice bays steel lining washed away and concrete
eroded
 Damage to gates and trash racks by boulders and
debris (Photo 4-3)
Andhi Khola HEP  Very frequent desander flushing during monsoon
 Operation of serpentine system difficult in
monsoon, requiring manual cleaning
 Reduction in power production during desander
flushing
 No instrumentation and monitoring
 Desander efficiency not monitored

Photo 4-1: Repaired ogee surface of diversion dam spillway at Kali Gandaki “A” HEP

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Photo 4-2: Missing steel lining (left) and exposed reinforcement (right) in flushing sluice at
Modi Khola HEP

Photo 4-3: Damage to trash rack from logs at intake of Sun Koshi HEP

4.4 CONCLUSIONS OF THE STUDY

The study of the hydropower projects clearly identified several important issues related
to the planning, design, construction, operation and maintenance that, in the context of
Nepal, need to be considered seriously. These issues are discussed below.
4.4.1 Design Parameters
The procedures for selection of design parameters, such as design floods and seismicity,
for the headworks should be well founded. Appropriate methods for selection of the

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design parameters should be defined in the proposed guidelines to ensure consistency in

approach, adequate safety and economy.
4.4.2 Desanding and Flushing
Despite adoption of different design parameters and techniques, desanding of river water
due to inefficient sediment settling remains a major problem in all projects. An equally
serious problem is the flushing of the settled silt from the desander.
Inadequate desanding has resulted in frequent damage to turbine runners at all projects.
Inefficient flushing mechanisms of the desanders have given rise to the need for frequent
flushing. In most cases, flushing is associated with reduction in power generation. At
present, such outages are inconsequential due to the surplus power available from other
plants during the rainy season; however, they may assume serious proportions in the
future.
In view of the present situation, methods for improving the sediment settling efficiency
of desanders need to be introduced in the proposed guidelines. Efficient flushing
mechanisms that do not require power outages also need to be addressed.
4.4.3 Structural Damage by Sediment-laden Water
Irrespective of their size, Nepali rivers carry large amounts of bed load and suspended
load. The sediments frequently damage the gate sills, spillway ogee surface, glacis and
downstream aprons of diversion structures. Greater damage is witnessed at the
undersluice gate sills, ogee surface and downstream part of energy dissipaters than at
higher levels of the spillways. In some projects, even mild steel plate armoring of the
undersluice surface has been worn out or torn away by the sediment-laden rivers.
This problem is typical to all the projects studied by the Consultant, and the project
owners are spending huge sums on the repair of the damages thus caused. As such,
appropriate methods need to be investigated and incorporated in the guidelines to address
this problem.
4.4.4 Instrumentation and Monitoring
Several of the projects do not have any instrumentation in the headworks. A few of those
that have a comprehensive instrumentation scheme in place do not monitor the
instruments due to lack of trained manpower or malfunctioning of equipment. Regular
and systematic monitoring of instruments, along with recording and interpretation of the
data, is only being performed at Marsyangdi HEP.
The importance of instrumentation and monitoring for the safety of headworks structures
cannot be overemphasized. The insight it can provide into the behaviour of the structures
can be useful for developing specific design procedures suitable for Nepali conditions.
As such, provisions for implementing suitable instrumentation in the projects,
monitoring them and recording and interpreting the data need to be included in the
guidelines.
4.4.5 Data Collection and Documentation
Apart from the Marsyangdi HEP, none of the operational hydropower projects covered in
the study maintains a methodical record of hydrological and sedimentological data. Such
data can be of immense use for analyzing the performance of the concerned headworks
and in its operation. They can also prove valuable input for the design of future projects
in Nepal. As such, mandatory provisions should be made in the guidelines for collection
of hydrological and sedimentological data at the headworks and submission of these
records to DoED.

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Table 4-6: Salient features of Kali Gandaki “A” headworks

Catchment area 7,618 km2
Average annual 288 m3/s
inflow
Minimum inflow 40 m3/s
Annual sediment 37.4 million tons
load
Reservoir levels Operating maximum: El. 524 m
Operating minimum: El. 518 m
Reservoir volume 7,700,000 m3 at El. 524 m
Pondage volume 3,100,000 m3
Diversion dam  Concrete gravity dam, 99.263 m long and 43 m high
 31.763 m long, concrete monolith non-overflow section
 67.5 m long spillway section with three hydraulically operated
radial gates and upstream and downstream stop logs
 Roller bucket energy dissipaters with riprap protection
 Upstream and downstream bridge decks with gantry cranes
Forebay  Concrete guide walls and concrete ogee weir with training wall
 Forebay monolith with forebay bottom outlet channel
 Fish conveyance facility consisting of hopper, vertical drop shaft
and fishway with outlet
Intake  Side intakes with six radial gates, trash racks and stop logs
 Eight steel-lined sediment undersluices with trash racks, stop logs
and slide gates
 Undersluice tube
Desander  Twin chamber surface desander
 Intermittent flushing through 12 steel-lined sediment sluices with
radial gates
 Collector channel with slide gates

Table 4-7: Salient features of Modi Khola headworks

Catchment area 510 km2
Average annual 45.3 m3/s
inflow
Minimum inflow 8.8 m3/s
Normal water level El. 936.30 m
Diversion weir  5.5 m high, 33 m long concrete gravity structure with uncontrolled
overflow, crest at El. 936.3 m
 Two 3 m wide flushing sluices with 3 m wide, 3.8 m high gates
 Fish ladder on left bank
Intake  20.5 m wide, 8.7 m high vertical gravity type
 One roller gate, 4.80 m wide and 3.25 m high
 Four sets steel trash racks
Box culvert  250 m long conduit between intake and desanding basin
 Two 2.25 m wide, 3.2 high chambers
 20.8 m long, 1 m high flushing gallery with gate
Desander  Two bay Dufour II type, with 100 m long, 10 m wide and 6.5 m
high basins

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 34 m wide, 1 m high side spillway

 Intermittent flushing through flushing pipes and gates

Table 4-8: Salient features of Marsyangdi HEP headworks

Catchment area 3,850 km2
Average annual 210 m3/s
inflow
Minimum inflow 33 m3/s
Annual sediment 31.9 million tons
load
Reservoir levels Operating maximum: El. 337.5 m
Operating minimum: El. 333.0 m
Diversion weir  102 m long concrete gravity weir
 Five spillway bays with hydraulically operated radial gates
 Stilling basin with downstream riprap protection
 Upstream bridge deck with gantry crane
Embankment  400 m long rock fill embankment with central clay core
Intake  Intake sill at El. 331 m
 Gated sediment sluice
 Intake canal to pass water to settling basin
Settling basin  Single chamber surface desander
 Intermittent flushing through gated flushing structure
Compensating pond  120 m long pond passing water to power intake

Table 4-9: Salient features of Upper Bhote Koshi HEP headworks

Catchment area 2,132 km2
Average annual 66.4 m3/s
inflow
Minimum inflow 10.5 m3/s
Annual sediment 10.7 x 106 m3
load
Head pond levels Normal operating level: El. 1434 m
Design flood level: El. 1435 m
Diversion dam  Concrete gravity structure, 87 m long and 22 m high
 66 m long concrete gravity dam
 Two 8 m long spillway bays with hydraulic radial gates and stop
logs
 16.5 m long stilling basin
 Upstream and downstream aprons and downstream riprap
protection
 Upstream bridge decks over spillway bays
Intake  Two intake gates for desanding basin, one for bypass conduit
 Trash racks and stop logs for each gate
 Mechanized trash rack cleaner
Desanding basin  Single chamber surface basin
 Continuous flushing through three transverse flushing channels and
sluice gates

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 Side and end spillways

Bypass conduit  Bypass canal and tunnel with separate intake

Table 4-10: Salient features of Sun Koshi HEP headworks

Catchment area 2,340 km2
Average annual 88 m3/s
inflow
Minimum inflow 13.4 m3/s
Annual sediment 6.72 million tons
load
Water levels  Normal water level: El. 808.4 m
 Flood water level: El. 811.3 m
Diversion barrage  70.55 m long concrete barrage
 Four gated overflow spillways and two gated scouring sluices
 Stilling basin with downstream cut-off wall, with steel lining in
sluicing portion
 Steel-lined flushing channel with sand guiding sills
 Six radial gates and maintenance gates
 Two operating decks and a vehicular bridge
Intake  Canal intake with four openings
 Slide gates and trash racks in each opening
Intake canal  Open canal between intake and desanding basin
 Lateral sand trapping channel discharging in sand sluicing gallery
Bypass canal  Open canal between intake and end of desander
Desanding basin  Single chamber surface desander
 Flow straightening walls in divergent section
 Continuous flushing through sand-trapping channels and sand
flushing galleries

Table 4-11: Salient features of Andhi Khola HEP headworks

Catchment area 444 km2
Average annual 29 m3/s
inflow
Minimum inflow 2.7 m3/s
Water levels Maximum: El. 636 m
Normal: El. 630 m
Diversion weir  65 m long, 6 m high concrete gravity weir
 60 m long ungated spillway with flip bucket and plunge pool
 2 m wide undersluice

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Intake  Side intake with two gates

 2.5 m wide, 2 m high radial gates, trash racks and stop logs
 Gravel trap and flushing system
Intake canal  10 m long enclosed, rectangular concrete canal
 35.8 m long open, stone masonry canal
Desilting basin  Twin chamber surface desander
 Intermittent gravity flushing with serpent sediment sluicing system

Table 4-12: Salient features of Middle Marsyangdi HEP headworks

Catchment area 2,729 km2
Average annual 99.5 m3/s
inflow
Reservoir levels Operating maximum: El. 626.0 m
Operating minimum: El. 621.0 m
Pondage volume 1,650,000 m3
Diversion dam  Combined concrete gravity dam and rockfill dam
 55 m long, 56 m high concrete gravity dam with three gated
spillways, crest at El. 629 m
 40 m long rockfill dam with impervious core, crest at El. 630 m
 Upstream and downstream bridge decks with gantry cranes
Intake structures  35 m long intake structure with three submerged tunnel intakes
having ogee overflow weirs, stop logs and trash racks
 70-75 m long, 4 m wide “D” tunnels connecting intake structure
with desander caverns, with roller gates at entrance
Desander  Three underground desander caverns, each 130 m long, 15 m wide
and 25-27 m high
 Two desander basins per cavern, each 100.75 m long, 7.5 m wide
and 25.1 m high
 Intermittent flushing using BIERI system
 30 m long, 15 m wide and 21 m high gate chamber structure with
outlet bulkheads to convey water to headrace tunnel
 119 m long flushing tunnel for discharging sediments into river

Table 4-13: Salient features of Sun Koshi HEP headworks

Catchment area 2,340 km2
Average annual 88 m3/s
inflow
Minimum inflow 13.4 m3/s
Annual sediment 6.72 million tons

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load
Water levels  Normal water level: El. 808.4 m
 Flood water level: El. 811.3 m
Diversion barrage  70.55 m long concrete barrage
 Four gated overflow spillways and two gated scouring sluices
 Stilling basin with downstream cut-off wall, with steel lining in
sluicing portion
 Steel-lined flushing channel with sand guiding sills
 Six radial gates and maintenance gates
 Two operating decks and a vehicular bridge
Intake  Canal intake with four openings
 Slide gates and trash racks in each opening
Intake canal  Open canal between intake and desanding basin
 Lateral sand trapping channel discharging in sand sluicing gallery
Bypass canal  Open canal between intake and end of desander
Desanding basin  Single chamber surface desander
 Flow straightening walls in divergent section
 Continuous flushing through sand-trapping channels and sand
flushing galleries

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