Sanjen (Upper) Hydroelectric Project - 14.

8 MW
Procedure for Installation of Intake Trash Rack

Document No: SAU TR 01-01

Contents

1. Purpose ..................................................................................................................................................1
2. Scope ......................................................................................................................................................1
3. Quality ....................................................................................................................................................1
4. Site storage & Local Transportation ......................................................................................................1
5. Order of Installation Work .....................................................................................................................1
5.1 Firs Stage Embedded Parts ............................................................................................................1
5.2 Second Stage Embedded Parts ......................................................................................................2
5.3 Trash Rack Panel ............................................................................................................................2
6. Material ..................................................................................................................................................2
7. Checking Works......................................................................................................................................3
8. Correction Works ...................................................................................................................................3
9. Touch up Painting ..................................................................................................................................3
10. Handover to Employer ...........................................................................................................................3

Submitted By: Nepal Hydro & Electric Limited

 Sanjen (Upper) Hydroelectric Project - 14.8 MW
Procedure for Installation of Intake Trash Rack

Document No: SAU TR 01-01

1. Purpose
The purpose of Trash Rack is to restrict the entrance of material of considerable dimensions
present in water through headrace tunnel and penstock which could cause damage to generating
machines and equipments of hydropower plant. The Trashracks are comprised of arrays of
vertical bars that are generally held together by horizontal beams. Trashracks, particularly when
not cleaned, produce unwanted energy-losses that directly reduce energy production.

2. Scope
The scope covers the installation of two (2) set of fixed trash rack in the Tunnel Inlet portal. The
installation work includes storage & transport to the site, erection, bolting, welding and painting
where required of supporting beam and trash rack panels.
3. Quality
The quality will be controlled and carried out as per the Quality Plan (QP) Procedure made for the
entire process of erection. The Quality Supervisor will lead the quality related matters and
provide feedbacks (if any) timely to the technical team.

4. Site storage & Local Transportation

a. At first, the Trash Rack parts will be transported from Butwal workshop to site on trucks
and will be temporary stored in the allotted storage yard of Lot 4 Contractor.
b. For transport of Trash Rack parts from temporary storage yards to Tunnel Inlet Portal,
truck will be used.
c. For loading and unloading purpose at storage yard and tunnel Inlet Portal, 16 ton capacity
mobile crane will be used.
5. Order of Installation Work
The procedure for the installation of Trash Rack is as listed down below. During the installation,
the first stage embedded parts/pads are the first to be installed followed by second stage
embedded parts, intermediate horizontal support beams and Trash Rack Panels.

5.1 Firs Stage Embedded Parts

a. The installation of first stage embedded pads will be done in stages as per the civil works
proceeds.
b. The first-stage embedded pads are set-in with the rebar works as per approved drawings
so that the flat face of embedded pad comes at the finished level of concrete.
c. The first stage embedded parts will be fixed properly by welding with sufficient numbers
of rebars so that civil work shall not affect the alignment.
d. As the embedded pads get installed, the concreting also goes on proceeding till the final
height of the Trash Rack is reached.

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Submitted By: Nepal Hydro & Electric Limited
 Sanjen (Upper) Hydroelectric Project - 14.8 MW
Procedure for Installation of Intake Trash Rack

Document No: SAU TR 01-01

5.2 Second Stage Embedded Parts

a. Immediately after the front gets cleared i.e. no obstructions on the way for installing
second stage embedded parts, we would install top and bottom sill beams on blockouts
in accordance with the final approved drawing by welding studs-bolts on first stage
embedded pads.
b. The elevations will be perfectly checked with the Total Station (Survey Equipment) and
leveling done rightly. It will be adjusted with the nuts on stud-bolts up and down. If
required, other anchors are also placed for proper fixing of the sill beams.
c. Then before providing the front to civil for concreting, we would check, along with the
Consultant, the dimensions as per the drawing with certain allowable tolerances and
provide it for the second stage concreting inside it.
d. After concreting, removal/cutting of all the projected re-bars will have to be done from
the area of all side.

5.3 Trash Rack Panel

Fixing of Trash Rack Panel will be done by bolting with the embedded guides (at bottom & top) in
accordance with the final approved drawings. This is the most time taking job of installation of
such parts. Following procedure will be followed during installation work.

a. The Trash Rack Panel will be installed one by one from bottom to top in accordance to the
final approved drawings. All the bars will be 10 mm thick except at the skip grab roller
track which will be of thickness 20 mm. The positioning, alignments of these bars (20mm
thickness) will be checked with great care since the TRCM skip grab rolls on these bars.
b. Firstly, the rack panel will be lifted in balance position with help of crane (or chain block),
then it will be lowered and landed in embedded guides in position as per drawing.
c. During landing rack panel, we will ensure the clamp plates of rack screen perfectly fits in
the stud bolts welded on embedded guides.
d. After landing, the trash rack panel will be fixed and tighten by nuts of stud bolts.
e. If clamp plate does not perfectly fits in the stud bolts welded on embedded guides, then
rectification will be done in stud bolt or clamp plate as per requirement.
f. In same manner, other trash rack panel will be fixed and tighten on embedded guides.

6. Material
The complete Trash Rack materials will be delivered at site. Upon receipt of the material, it will
be checked for the correctness in material and its completeness at site. If any discrepancies are
found, it will be notified immediately to the concerned persons for necessary action.

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Submitted By: Nepal Hydro & Electric Limited
 Sanjen (Upper) Hydroelectric Project - 14.8 MW
Procedure for Installation of Intake Trash Rack

Document No: SAU TR 01-01

7. Checking Works
As is also mentioned in the installation procedures, that there would be checking mechanisms at
various times of work, since various parts assembled together, working in harmony between each
other.
Checking of the following items will be done:
i. Elevations & leveling
ii. NDT of site welding
iii. Bolt tightness, accuracy works, cleaning works, etc.

8. Correction Works
During the time of checking and testing works, there may be many corrections which will be
rectified immediately after the testing works are completed. The correction works will be cross-
checked by the Consultant, as and if required.

9. Touch up Painting
a. The surfaces at welded areas of studs connected with the sill beam and top beam will be
made smooth with the help of grinder followed by a coat of primer and epoxy.
b. Final touch up painting work will be carried out as per the procedure specified in quality
plan.

10. Handover to Employer

After confirmation of entire works from Engineer, whole of the works of Trash Racks will be
handed over to the Employer as Completion of Erection of that component.

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Submitted By: Nepal Hydro & Electric Limited