Civil Works Guidelines for

MICRO-HYDROPOWER IN NEPAL

Contents
Foreword ................................................................................................................................................................................................................................ iii
Preface ............................................................................................................................................................................................... v
Acknowledgements ............................................................................................................................................................................. vii
Contents .............................................................................................................................................................................................. ix
1 INTRODUCTION ........................................................................................................................................................................... 1
1.1 Hydropower and micro-hydropower ................................................................................................................................. 1
1.2 Aspects of civil engineering works .................................................................................................................................... 1
1.3 Components of micro-hydro schemes ............................................................................................................................... 2
1.4 The power equation .......................................................................................................................................................... 3
2. SITE SELECTION AND PLANNING ........................................................................................................................................... 5
2.1 Overview .......................................................................................................................................................................... 5
2.2 Principles of site investigation ........................................................................................................................................... 6
2.3 Selection of alternative layouts ........................................................................................................................................... 6
2.3.1 An overview of the site ............................................................................................................................................ 6
2.3.2 Location of components ......................................................................................................................................... 6
2.4 Geotechnical considerations ............................................................................................................................................ 8
2.4.1 Geology ................................................................................................................................................................... 8
2.4.2 Major weakness zones ............................................................................................................................................. 8
2.4.3 Slope stability ........................................................................................................................................................ 8
2.4.4 Soil and rock types ......................................................................................................................................................................................... 10
2.5 Hydrology and water availability .......................................................................................................................................................................... 10
2.5.1 Prediction methodologies ............................................................................................................................................................................. 10
2.5.2 Procedure to establish the design flow...................................................................................................................... 11
2.5.3 Seepage............................................................................................................................................................................................................... 12
2.6 Other considerations .................................................................................................................................................................................................. 12
2.6.1 Flood risk ........................................................................................................................................................................................................... 12
2.6.2 Cross drainage .................................................................................................................................................................................................. 13
2.6.3 Water rights....................................................................................................................................................................................................... 13
2.6.4 Land ownership and land use ................................................................................................................................................................. 13
2.6.5 High altitude sites .................................................................................................................................................................................... 13
2.7 Planning ................................................................................................................................................................................................................. 13
2.8 Checklist for site selection .................................................................................................................................................................................. 15
3 DIVERSION WORKS ..................................................................................................................................................................... 17
3.1 Overview .......................................................................................................................................................................................................... 17
3.2 General principles for selecting intake location....................................................................................................................................... 17
3.3 Intake location in relation to river characteristics .................................................................................................................................. 18
3.3.1 Characteristics of Himalayan rivers ................................................................................................................................................ 18
3.3.2 Example intakes....................................................................................................................................................... 20
3.4 Intake types....................................................................................................................................................................... 21
3.4.1 Description ........................................................................................................................................................................................................ 21
3.4.2 Selection criteria ............................................................................................................................................................................................ 21

3.5 Side intake ................................................................................................................................................................................................................................................................. 22

3.5.1 Description ............................................................................................................................................................................................................................................... 22
3.5.2 Trashracks for side intakes ......................................................................................................................................................................................................... 22
3.5.3 Orifice design ......................................................................................................................................................................................................................................... 23
3.6 Diversion weirs ...................................................................................................................................................................................................................................................... 25
3.6.1 General ...................................................................................................................................................................................................................................................... 25
3.6.2 Temporary weirs................................................................................................................................................................................................................................... 25
3.6.3 Gabion weir ............................................................................................................................................................................................................................................. 26
3.6.4 Permanent weir ................................................................................................................................................................................................................................... 29
3.6.5 Head over weir ........................................................................................................................................................................................................................................................ 31
3.7 Bottom intakes ............................................................................................................................................................................................................................................................................ 31
3.7.1 Description ............................................................................................................................................................................................................................................................................... 31
3.7.2 Trash racks for bottom intake.................................................................................................................................................................................................... 32
3.7.3 Design of bottom intake ................................................................................................................................................................................................................ 32
3.8 River training works .....................................................................................................................................................................................................................................................35
3.9 Checklist for diversion works ................................................................................................................................................................................ 35
4. HEADRACE ........................................................................................................................................................................................................................ 37
4.1 Overview .................................................................................................................................................................................................................................................................... 37
4.2 Canal types ................................................................................................................................................................................................................................................................ 37
4.2.1 Earth canals.............................................................................................................................................................................................................................................. 37
4.2.2 Stone masonry in mud mortar canals ................................................................................................................................................................................... 37
4.2.3 Stone masonry in cement mortar canals ............................................................................................................................................................................. 38
4.2.4 Concrete canals .............................................................................................................................................................................................................................................38
4.2.5 Other types of canal .......................................................................................................................................................................................................................... 38
4.3 Canal design ........................................................................................................................................................................................................................................................................44
4.3.1 Design criteria ...................................................................................................................................................................................................................................... 44
4.3.2 Manning's equation.................................................................................................................................................................................. 44
4.3.3 Sediment deposition in canals ..........................................................................................................................................................................................................45
4.3.4 Design procedure ..................................................................................................................................................................................... 47
4.4 Spillways ..................................................................................................................................................................................................................................................................... 50
4.4.1 Location of spillways ........................................................................................................................................................................................................................ 50
4.4.2 Spillway design ....................................................................................................................................................................................................................................... 50
4.5 Crossings................................................................................................................................................................................................................................................................................53
4.6 Headrace pipe ....................................................................................................................................................................................................................................................... 54
4.6.1 General ...................................................................................................................................................................................................................................................... 54
4.6.2 Design criteria ...................................................................................................................................................................................................................................... 54
4.6.3 Design procedure ................................................................................................................................................................................................................................ 59
4.7 Construction of canals ..................................................................................................................................................................................................................................... 65
4.7.1 Description ............................................................................................................................................................................................................................................... 65
4.7.2 Setting out ............................................................................................................................................................................................................................................... 65
4.7.3 Bench cut ................................................................................................................................................................................................................................................... 65
4.7.4 Canal excavation ................................................................................................................................................................................................................................ 66
4.7.5 Canal lining ............................................................................................................................................................................................................................................ 66
4.8 Checklist for headrace works ....................................................................................................................................................................... 67
5. GRAVEL TRAP, SETTLING BASIN AND FOREBAY ................................................................................................................................ 69
5.1 Overview ......................................................................................................................................................................................................... 69
5.1.1 The sediment problem ..................................................................................................................................................................................................................... 69
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5.1.2 Function of the structures ............................................................................................................................................................... 69

5.1.3 Location of the structures ...................................................................................................................................... 69
5.2 Gravel trap ...................................................................................................................................................................... 70
5.3 Settling basin .................................................................................................................................................................... 71
5.3.1 Design criteria ..................................................................................................................................................... 71
5.3.2 The ideal settling basin .......................................................................................................................................... 71
5.3.3 Fall velocity of sediment (particle size) ............................................................................................................... 72
5.3.4 Settling design ....................................................................................................................................................... 73
5.3.5 Storage design ....................................................................................................................................................... 73
5.3.6 Components of a settling basin.............................................................................................................................. 73
5.3.7 Flushing arrangements .......................................................................................................................................... 75
5.3.8 Other considerations ............................................................................................................................................ 77
5.4 Forebay ............................................................................................................................................................................ 82
5.4.1 General ................................................................................................................................................................ 82
5.4.2 Pipe level ............................................................................................................................................................. 82
5.4.3 Design of a forebay .............................................................................................................................................. 82
5.4.4 Forebay'size........................................................................................................................................................... 82
5.4.5 Trashrack............................................................................................................................................................... 82
5.4.6 Spillway ............................................................................................................................................................... 84
5.4.7 Gate and vent......................................................................................................................................................... 84
5.5 Construction of water retaining structures ....................................................................................................................... 86
5.6 Checklist for gravel trap, settling basin and forebay work ............................................................................................... 86
6. PENSTOCKS ................................................................................................................................................................................ 87
6.1 Overview ........................................................................................................................................................................ 87
6.2 Selection of the penstock alignment ................................................................................................................................. 87
6.2.1 Site work ............................................................................................................................................................... 87
6.2.2 Profile of the selected alignment ........................................................................................................................... 89
6.3 Pipe materials ................................................................................................................................................................. 90
6.4 Pipe diameter ................................................................................................................................................................... 91
6.5 Surge calculation .............................................................................................................................................................. 93
6.5.1 General ................................................................................................................................................................ 93
6.5.2 Pelton turbine ........................................................................................................................................................ 93
6.5.3 Crossflow turbine .................................................................................................................................................. 94
6.5.4 Quick method for small schemes with crossflow turbines ................................................................................... 95
6.6 Pipe wall thickness ........................................................................................................................................................... 95
6.6.1 Positive internal pressure....................................................................................................................................... 95
6.6.2 Negative internal pressure ..................................................................................................................................... 96
6.7 Pipe jointing .................................................................................................................................................................................................. 102
6.7.1 General ......................................................................................................................................................................................... 102
6.7.2 Site welding ..................................................................................................................................................................................... 102
6.7.3 Flange connection ...................................................................................................................................................................... 102
6.7.4 HDPE and PVC pipes ................................................................................................................................................................. 103
6.8 Pipe lengths ............................................................................................................................................................................................... 103
6.9 Exposed versus buried penstock ...................................................................................................................................................... 104
6.10 Expansion joints ................................................................................................................................................................................... 105
6.11 Painting ............................................................................................................................................................................................. 107
6.12 Installation ............................................................................................................................................................................................... 108
6-13 Maintenance .......................................................................................................................................................................................... 109

6-14 Checklist for penstock work ........................................................................................................................................................................... 109

7.

ANCHOR BLOCKS AND SUPPORT PIERS .................................................................................................................................................................................................... 111

7.1 Overview ........................................................................................................................................................................................................................................................................................ 111
7.2 Anchor blocks ..............................................................................................................................................................................................................................................................................
7.2.1 General ...........................................................................................................................................................................................................................................................................
7.2.2 Location of anchor blocks ...........................................................................................................................................................................................................................
7.2.3 Construction of anchor blocks ...................................................................................................................................................................................................................
7.3 Support piers ......................................................................................................................................................................................................................................................................

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111
111
111
113

7.3.1 General ................................................................................................................................................................................................................................................................. 113

7.3.2 Location of support piers ..................................................................................................................................................................................................................... 113
7.3.3 Construction of support piers ..................................................................................................................................................................................................................... 115
7.4 Design of anchor blocks and support piers ........................................................................................................................................................................................... 116
7.4.1 General ................................................................................................................................................................................................................................................................. 116
7.4.2 Description of forces ............................................................................................................................................................................................................................... 119
7.4.3 Design procedure ........................................................................................................................................................................................................................................... 120
7.4.4 Sizing of anchor blocks for small schemes............................................................................................................................................................................... 126
7.4.5 Sizing of support piers for small schemes........................................................................................................................................................................................ 127
7.5 Checklist for anchor block and support pier works ................................................................................................................................................................................. 127
8. POWERHOUSE AND TAILRACE ........................................................................................................................................................................................................................................... 129
8.1 Overview ........................................................................................................................................................................................................................................................................................... 129
8.2 Location of powerhouse..................................................................................................................................................................................................................................................... 130
8.3 Design of powerhouse ......................................................................................................................................................................................................................................................... 130
8.3.1 General .............................................................................................................................................................................................................................................................................. 130
8.3.2 Size of the powerhouse ...................................................................................................................................................................................................................................... 130
8.3.3 Powerhouse wall and other details .......................................................................................................................................................................................................................... 131
8.4 Design of machine foundation .................................................................................................................................................................................................................................. 132
8.5 Tailrace ............................................................................................................................................................................................................................................................................................. 136
8.5.1 General ........................................................................................................................................................................................................................................................................... 136
8.5.2 Design of the tailrace channel ..................................................................................................................................................................................................................... 136
8.5.3 Design of tailrace pipe ........................................................................................................................................................................................................................................ 136
8.6 Checklist for powerhouse and tailrace ................................................................................................................................................................................................................ 137
9. SLOPE STABILISATION .................................................................................................................................................................................................................................................................... 139
9.1 Overview ........................................................................................................................................................................................................................................................................................... 139
9.2 Implications of natural geological processes ................................................................................................................................................................................................... 139
9.3 Bio-engineering works .......................................................................................................................................................................................................................................................... 140
9.4 Retaining structures ................................................................................................................................................................................... 140
9.5 Terracing and dry stone wall ................................................................................................................................................................................................................................................................. 141
9.6 Check dams and gully control ....................................................................................................................................................................................................................................... 143
9.7 Maintenance ................................................................................................................................................................................................................................................................................. 144
10

INNOVATIONS .............................................................................................................................................................................................................................................................................. 145

10.1 General ......................................................................................................................................................................................................................................................................................................... 145
10.2 Coanda intake ........................................................................................................................................................................................................................................................................................ 145
10.3 De-beader for HDPE pipes ...................................................................................................................................................................................................................................... 146
10.4 Bursting disc ......................................................................................................................................................................................................................................................................................... 147
10.5 Flexible steel support pier for Jharkot micro-hydro .................................................................................................................................................................................. 148
10.6 PVC Pipes..151
10.7 Anchor block design. 151