Pre-Shipment Inspection Report of Tungun-Thosne and Khani Hydropower Projects Lalitpur, Nepal

Transcription

1 Pre-Shipment Inspection Report of Tungun-Thosne and Khani Hydropower Projects Lalitpur, Nepal Submitted To : Dept of Electricity Development Nepal Electricity Authority Consortium of Banks Submitted by: Khani Khola Hydropower Co. Ltd 126 Milap Marg, Bishalnagar, Kathmandu, Nepal November 2014

2 Contents 1. Pre-shipment Inspection Schedule Pre-shipment inspection team Background Observation Findings Appendices Bill of quantities Inspection Notes Memorandum of Meeting held at China signed by all inspection team including two pages test report. Photos Tungun-Tosne and Khani SHPs, Lalitpur District Page 2

3 1. Pre-shipment Inspection Schedule Date: November 2014 Day 1 (12 th Nov): Reached Guanzhou, China at 05:00 hrs Flight from Guanzhou-Changsha departing at 08:40 hrs reaching Changsha at 10:00 hrs. Visited Control and Relay Protection Panel factory at Hunan Unisplendour M & C Co Ltd, 456 of Lasong Road, La Valley in Hitech Zone, Changsha, Hunan Visited Medium Voltage Switchgear factory at Hunan Unisplendour M & C Co Ltd, 456 of Lasong Road, La Valley in Hitech Zone, Changsha, Hunan Stayed at Changsha. Day 2 (13 th Nov): Departed Changsha at 08:30 hrs and travelled by road and reached Shayoyang, Hunan at 12:00 hrs. Tour of Hunan Allonward Hydro Generating Equipment Co., the manufacture of turbines and generators. Witnessed random electrical testing of one generator for Khani Project Verified the rating and diagram plate of transformers Conducted visual inspection of transformers and associated inbuilt protection. Stayed at Shayoyang, Hunan. Day 3 (14 th Nov): Reached Hunan Allonward Hydro Generating Equipment Co. at 09:00 hrs. Witnessed random electrical testing of one generator for Tungun Project Conducted visual inspection of Governor for Tungun Project Conducted visual inspection of Inlet valve for Tungun Project Conducted visual inspection of Crane for Tungun and Khani Project Participated in meeting with designer for final verification of equipment layout in powerhouse for both projects. Departed Shayoyang and travelled by road, reached Changsha at 16:30 hrs. Visited Hunan Allonward second factory at Changsha Stayed at Changsha, Hunan. Day 4 (15 th Nov): Departed Changsha at 08:20 hrs. and reached Tianjin at10:30hrs. Visited Tianjin Seri Factory Base, manufacturer of turbines and generators partnership of Hunan Allonward Hydro Generating Equipment Co. at 11:30hrs. Travelled to Beijing and stayed at Beijing. Tungun-Tosne and Khani SHPs, Lalitpur District Page 3

4 2. Pre-shipment inspection team The pre-shipment inspection team had following participation from multi-disciplinary field. Name Designation Company Representative Mr. Bijaya Man Sherchan Chairman, Board of Directors Khani Khola Hydropower Co Ltd.( KKHPCL) Mr. Binod Sherchan Director KKHPCL. Mr. Batu Lamichhane Director KKHPCL Mr. Ganesh Karki Alternate Director KKHPCL Mr. Prabal Adhikari Deputy Manager, Power Trade Nepal Electricity Department Authority Ms. Ranju Pandey Electrical Engineer, Power Trade Department Nepal Electricity Authority Shankar Prashad Dahal Representative of Bank Citizens Bank International Ltd Mr Suraj Dahal Representative of Bank Civil Bank Ltd Mr. Mani Raj Dahal Mr. Santosh Dhakal Chief Engineering Officer Clean Energy Consultants Electrical Engineer Clean Energy Consultants Consultant to KKHPCL Consultant to KKHPCL Mr. Jeetendra K. Gurung Resident Engineer KKHPCL Mr. Bharat Thapa Manager KKHPCL Mr. Pralad Adhikari Ass. Resident Engineer KKHPCL Tungun-Tosne and Khani SHPs, Lalitpur District Page 4

5 3. Background Khani Khola Hydropower P. Ltd. (KKHPCL) is implementing the Tungun-Thosne and Khani Small Hydropower projects of installed capacities of 4.36 and 2.0 MW respectively in Khani basin located in the frontier of Bhattedanda, Ikudol and Sankhu VDCs of Lalitpur District. Khani Project is being developed as cascade scheme in the downstream of Tungun-Thosne Project. The projects were initially developed by Pashupati Energy Development Co. P Ltd (PEDC). The Connection Agreement for the projects were signed with the arrangement whereby the power generated from the projects would be evacuated to a 33 kv substation to be constructed by NEA in Malta. The Connection Agreement between PEDC and NEA wee signed on 23 March The PPA s for the two projects were subsequently signed between PEDC and NEA on 14 February The Generation licenses or the two projects were acquired from Dept of Electricity Development on 14 February For implementation of the projects PEDC adopted measures whereby a SPV called Khani Khola Hydropower Development Co P Ltd was instituted with 51% shareholding by PEDC and the remaining equity being provided by two institutional and four individual promoters. The company was subsequently converted into a public limited company Khani Khola Hydropower Co Ltd (KKHPCL).The PPAs were transferred to the ownership of KKHPCL on 2070/3/12 (26 June 2013). The generation licenses were transferred to the ownership of KKHPCL on 2069/12/15 (28 March 2013). KKHPL invited bids for design, manufacture, supply, installation and successful commissioning of Eletro-mechanical equipment for both projects as well as successfully connecting at NEA s under construction 33 kv substation at Malta VDC. The bids were received from different vendors. The lowest and technically responsive bid received from Hunan Allonward Hydro-Equipment Co. Ltd (HAHCL) was evaluated suitable for the supply of Electro-mechanical equipment for both projects. The Contract between KKHPCL and HAHCE was signed on 3 January HAHCE offered turnkey services for the design, manufacture, delivery, erection and commissioning of the plants on a turnkey basis with free maintenance services for 5 years and free spare part supply for 2 years. Electro-mechanical equipment required for hydropower projects compromises of different components which are not manufactured by a single manufacturer. The components confirming with the technical requirement of purchaser specification are purchased from different manufacturers/suppliers and supplied through one manufacturer/supplier. Tungun-Tosne and Khani SHPs, Lalitpur District Page 5

6 As a part of the conditions of the Contract, the pre-shipment inspection of major goods was pre-requisite, to be conducted at the manufacturer premises. In addition as part of the quality control, the offered equipment has to be routine tested to conform to national and international standards. The routine test which either can be witnessed by the purchaser representative and test results to be submitted as part of the shipping document. 4. Observation The several components were part of the Contract. It was agreed by KKHPCL and HAHECL to conduct pre-shipment inspection of three factories which manufactured major components and were turbines, generators and control systems. On Day 1, the inspection team visited Hunan Unisplendour M & C Co Ltd which manufactured protection and control systems for both projects. The protection and control system is the heart of hydropower equipment that controls, operates, senses the abnormalities and isolates the system for smooth execution of the equipment within the set parameters. Fig 1: Testing of Panel Board with testing facilities and Injection Kit The control and protection panels as per the bill of quantities (Appendix 1) were manufactured, routine tested and ready for dispatch. The inspection team did the visual inspection of the panels and verified the routine test results. The offered control and protection systems were conforming to the Connection Agreement, single line diagram as well as to the specification as part of the Contract. The functionality test was Tungun-Tosne and Khani SHPs, Lalitpur District Page 6

7 witnessed by the inspection team and results conformed to the agreed single line diagrams. The SCADA systems for both projects and its operation remotely from the computer was verified and found satisfactory. To confirm with the emerging technology, it was discussed whether it was appropriate to include the data acquisition of both projects remotely through KKHPCL, Kathmandu Office using the mobile technology. Fig 2. Checking of Scada system and its parameters The proposal was unanimously accepted by the inspection team and was requested with HAHECL. HAHECL agreed to include in the supply free of cost for both projects. Few other minor corrections for improvements were noted and discussed with the manufacturer and the summary is tabulated in inspection notes in Appendix 2. The inspection note was also distributed to the HAHECL representative Mr. Chen Guoming who was with the inspection team throughout the inspection duration. During the later part of the Day 1, the team was taken to the switchgear factory at, Changsha. The offered switchgear was routine tested ready for dispatch. The switchgear were verified visually and found confirming with the specification. KKHPCL specification for Tungun-Thosne Project had requirement to use 6.3kV disconnecting switch after the 6.3kV busbar before the step up transformer. Instead of disconnecting switch the HAHECL proposed to use vacuum circuit breaker (VCB), for better reliability and performance, without any additional cost to KKHPCL. The proposal was accepted by the Tungun-Tosne and Khani SHPs, Lalitpur District Page 7

8 inspection team. Higher current rating VCB was part of the switchgear and was acceptable. The few changes were noted which is in inspection notes in Appendix 2. Fig 3. Inspection Visit to MV panels ready for dispatch Day 2 started with the factory tour of Hunan Allonward Hydro-Generating Equipment at Shayoyang. Hunan Allonward has a long history of manufacturing turbines and generators. It had supplied turbines and generators in more than 12 hydropower projects in Nepal which are operating smoothly. Generators and turbines for both projects were manufactured, routine tested and ready for dispatch except packaging. The turbine runner chemical composition test results were verified and conformed to the specification as part of the Contract. The generators routine test at factory as per the relevant standard was completed as part of the quality check. The test results for five generators were provided to the inspection team. The results were verified and found satisfactory. The inspection team requested random electrical test to be conducted for one generator from each project. One generator for Khani Project was randomly selected and setup in test bench. The adequate capacity three phase motor was used to drive the shaft of the generator. The no-load and short circuit tests were performed and relevant parameters were measured Tungun-Tosne and Khani SHPs, Lalitpur District Page 8

9 and noted which is included in Appendix 3 as part of the Memorandum Of Meeting signed by inspection team with copy delivered to HAHECL representative. Fig 4: Testing of Generator by rotating with induction motor from drive side In the short circuit condition the generator was operated approximately 5% above the name plate rating to confirm the over load condition as well as 10% above the voltage rating in no-load condition. The drive side and non-drive side bearing absolute temperatures were constantly monitored and highest recorded was 35 0 C which is well within 85 0 C limit. The ambient temperature in the factory was approximately 15 0 C. No abnormal vibrations were noted hence tested generator was found satisfactory. The offered transformers by HAHECL were manufactured by Hunan Changde Guoli Transformer which is approximately four hours drive from Hunan Allonward. The transformers were already delivered to Hunan Allonward Generating factory. The transformers rating and diagram plate and specification was inspected and found conforming to the specification and single line diagrams as part of the Contract. The transformers were visually inspected together with inbuilt associated protection such as Buchholz relay, pressure relief device and winding temperature indicator and found conforming. The routine test results conducted at transformer manufacturing plant before dispatch were verified and found satisfactory. Transformers general arrangement layout including the foundation plan was requested with Hunan Allonward and agreed to supply as soon as possible. Based on the transformer general arrangement layout, the civil foundation including the reinforcement details need to be worked out at site. Tungun-Tosne and Khani SHPs, Lalitpur District Page 9

10 Fig 5: Transformers Ready for Dispatch Day 3 started with electrical testing of one of the generator for Tungun-Thosne Project. The generator was set up in the test bench and performed no-load and short circuit test. In the short circuit condition the generator was operated approximately 5% above the name plate rating to confirm the over load condition as well as 10% above the voltage rating in no-load condition. The drive side and non-drive side bearing absolute temperatures were constantly monitored and highest recorded was 38 0 C which is well within 85 0 C limit. The ambient temperature in the factory was approximately 12 0 C. No abnormal vibrations were noted hence tested generator was found satisfactory. Governors and inlet valves for Tungun-Thosne arrived from the relevant manufacturer whilst inspection team was in Hunan Allonward factory which provide an opportunity for visual inspection. The overhead electrical crane and its beams were also visually inspected. Tungun-Tosne and Khani SHPs, Lalitpur District Page 10

11 Fig 6: Inspecting Governors for the control of the turbine Later in the afternoon the meeting was held between Hunan Allonward designer and inspection team. The clarifications were sought on the submitted civil drawings for powerhouse on first and second stage concrete and also on the layout of panels and switchgear. It was noted that 33kV vacuum circuit breakers (VCB) for Tungun and Khani Powerhouse Switchyard have bushing current transformers within VCB panels hence separate foundations and steel gantries for 33kV current transformers are not required. Similarly, 33kV lightning arresters (LA) towards step up transformers can be installed on transformer above the radiators near the 33kV bushings of transformers hence separate foundations and steel gantries for 33kV LAs are not required. Few other minor changes were noted and compiled in inspection note in Appendix 2. While returning back from Shayoyang to Changsha, the opportunity to visit Hunan Allonward second manufacturing base at Changsha was available. The second manufacturing base looks much bigger in area and more modernised with cleaner working environment. This plant also manufacturers turbines and generators. Tungun-Tosne and Khani SHPs, Lalitpur District Page 11

12 Fig 7: Inspection of Tianjin Factory Base Day 4 started with two hours flight from Changsha to Tianjin. An opportunity was provided to visit Tianjin Seri Manufacturing base at Tianjin which HAHECL has recently been involved as a major stakeholder. This plant located in Tianjin City which is the one the largest industrial city in China. The manufacturing plant looks much bigger in size with modernised manufacturing set up. The quality control and the working condition looks much better as compared to other Hunan Allonward manufacturing base. 5. Findings The electro-mechanical components of hydropower project consist of several equipment manufactured by various manufactures at different locations. The supplier will outsource the required equipment from different vendors to comply with the project specification and requirements. The inspection and witnessing of test before shipment of every item will be time consuming and cost burden to the purchaser. The few major components such turbines, generators, transformers, control and protection should be visually inspected and if time permits witness the routine test before the shipment. Tungun-Tosne and Khani SHPs, Lalitpur District Page 12

13 Fig 8: Witnessing the online testing of generator It was discussed to include all the Operation and Maintenance manuals of all equipment including working drawings in soft copies as well as in hard copies. Manuals and label on the panels to be strictly adhered in English language. It was requested with HAHECL to offer the list of minimum required spare parts if found missing in the signed Contract including the unit prices and validity. KKHPCL inspection team observed that visually inspected items as detailed above were generally in satisfactory condition and conforming to the specification as part of the Contract, hence recommend for process for shipment without any delay. 6. Appendices Bill of quantities (signed by both parties) Inspection Notes (prepared by Manisir and issued to Mr. Chen) Memorandum Of Meeting held at China signed by all inspection team including two pages test report. Photos Tungun-Tosne and Khani SHPs, Lalitpur District Page 13

14 Appendices Tungun-Tosne and Khani SHPs, Lalitpur District Page 14