Design Guidelines

For
Electrical Design of Hydroelectric Projects
The major electrical parts of a hydroelectric project
which will be applicable for water to wire design are
as followings:-
Note: - the followings specification will be applicable for the design of electrical
parts of a hydroelectric projects, switchyard, power substation and grid
connection arrangement.

Generator

The Generators shall be complete with accessories, fittings and instrumentation, controls, auxiliaries
such as excitation system, voltage regulating equipment, neutral grounding, generator terminal
equipment including CTs, PTs, surge protection equipment, lubricating system, oil, water and air
piping and cabling connected ready to operate with valves, fittings, instrumentation, controls and
safety devices, including sufficient mandatory spares for 5 (five) years trouble free operation of the
plant, special tools and testing devices.

The type and axis of turbine will be decided based on the design discharge (from hydrological data)
and the available net head.

The generator shall confirm to the following standards:-

IS 1271: 1985 Thermal evaluation and classification of electrical insulation

IS 1885: Part 35: 1993 Electrotechnical vocabulary: Part 35 Rotating machines

IS 4722: 1992 Rotating electrical machines

IS 7132 : 1973 Guide for testing synchronous machines

IS 7306 : 1974 Methods for determining synchronous machines quantities from tests

IS 12360 : 1988 Voltage bands for electrical installations including preferred voltages and
frequency

IS 12802: 1989 Temperature rise measurement of rotating electrical machines

IS 13364: Part 2: 1992 AC generators driven by reciprocating internal combustion engines: Part 2
Alternators rated above 20 kVA and up to 1250 kVA

Power transformers

This section covers the design, manufacture, assembly, shop test, supply, delivery, installation works
and field test of the power transformer complete with all accessories, fittings and auxiliary equipment
for efficient and trouble-free operation.

The power transformers shall conform to the latest edition of the appropriate IEC specifications and/or
other recognized international standards. In particular:

IEC 76 Power Transformer

IEC 137 Bushings for alternating voltages above 1 kV
 IEC 156 Method of determination of electric strength of insulating oils
IEC 296 Specification for unused mineral insulating oils for and switchgear
IEC 551 Measurement of transformer and reactor sound levels
IEC 616 Terminal and tapping markings for power transformer
IEC 722 Guide to lightning and switching impulse testing of power
IEC 733 Determination of water in insulating oils.
IEC 5493 Protective coating of iron and steel structures against corrosion

Distribution transformers

This section covers the design, manufacture, assembly, shop test, supply, delivery, installation works
and field test of the service transformers complete with all accessories, fittings and auxiliary
equipment for efficient and trouble-free operation.

The distribution transformers shall conform to the latest edition of the appropriate IEC specifications
and/or other recognized international standards. In particular:

IEC 76 Power transformers

IEC 137 Bushings for alternating voltages above 1 kV
IEC 156 Method of determination of electric strength of insulating oils
IEC 296 Specification for unused mineral insulating oils for transformers and
switchgear
IEC 551 Measurement of transformer and reactor sound levels
IEC 616 Terminal and tapping markings for power transformer
IEC 722 Guide to lightning and switching impulse testing of power transformers
IEC 733 Determination of water in insulating oils.
IEC 5493 Protective coating of iron and steel structures against corrosion.

Auxiliary equipments

This section covers the design ,manufacture, testing before shipment, transportation to site, erection
and commissioning and performance tests of the following:-

(a) Overhead traveling crane

(b) Diesel engine generating set
(c) Oil handling and purifying equipment
(d) Tools and meters
(e) Air handling and air conditioning equipment
(f) Fire fighting equipment

Outdoor Switchgear equipments

1.1 Outdoor circuit breakers

This section covers the design, manufacture, assembly, shop test, supply, delivery, installation works,
field test and commissioning of outdoor circuit breaker complete with all accessories for efficient
and trouble free operation as specified hereunder.
The equipment specified in this Section shall conform to the latest edition of the appropriate IEC
specifications and/or other recognized international standards. In particular:

Electrical Accessories - Circuit Breakers for Over Current Protection for

IS 8828 : 1996
Household and Similar Installations
Dimensions for general purpose push-pull three-pole circuit breakers for
IS 8834 : 1978
aircraft
IS 9135 : 1979 Guide for testing of circuit breakers with respect to out-of-phase switching
Specification for Low-voltage Switchgear and Controlgear - Part 2 : Circuit
IS 13947 : Part 2 : 1993
Breakers
High Voltage Alternating Current Circuit Breakers - Guide for Short-circuit
IS 14658 : 1999 and Switching Test Procedures for Metal-enclosed and Dead Tank Circuit
Breakers
IEC 60056 High-voltage alternating switchgear
IEC 62271 High-voltage alternating switchgear and control gear
IEC 60376 Specification and acceptance of new sulphur hexafluoride
IEC 60529 Degree of protection provided by enclosures
Common specifications for high-voltage switchgear and controlgear
IEC 60694
standards

1.2 Disconnecting switches

This section covers the design, manufacture, assembly, shop test, supply, delivery, installation works,
field test and commissioning of outdoor type disconnecting switches complete with all accessories for
efficient and trouble-free operation.

The equipment specified in this Section shall conform to the latest edition of the appropriate IEC
specifications and/or other recognized international standards. In particular:

Specification for Alternating Current Disconnectors (Isolators) and Earthing

IS 9921 : Part 1 : 1981
Switches for Voltages Above 1 000 V - Part I : General and Definitions
Alternating current disconnectors (isolators) and earthing switches for
IS 9921 : Part 2 : 1982
voltages above 1000 V: Part 2 Rating
Specification for Alternating Current Disconnectors (Isolators) and Earthing
IS 9921 : Part III : 1982
Switches for Voltages Above 1000 V - Part III : Design and Construction
Specification for Alternating Current Disconnectors (isolators) and Earthing
IS 9921 : Part 4 : 1985
Switches for Voltages Above 1000 V - Part 4 : Type Tests and Routine Tests
Specification for Alternating Current Disconnectors (Isolators) and Earthing
IS 9921 : Part 5 : 1985 Switches for Voltages Above 1 000 v - Part 5 : Information to be Given with
Tenders, Enquiries and Orders
IS 14259 : 1995 Vibration and shock - Isolators - Procedures for specifying characteristics
IEC 60129 High-voltage alternating current disconnectors and earthing switches
IEC 60529 Degree of protection provided by enclosures

1.3 Miscellaneous materials for switchyard

This section covers the design, fabrication, properly packing for transportation, delivery, installation,
testing and putting into efficient and trouble-free operation of the bus materials, insulators and
miscellaneous items complete with all accessories.

Control switchboard

This section covers the design, manufacture, assembly, testing at manufacturer's works, supply and
delivery, installation, testing and commissioning of control switchboard and appurtenant equipment to
be supplied for control room and unit control board as necessary for successful control and operation of
generator, turbine, transformer, line feeder, telemetry and their protection.

The equipment provided shall be in agreement with the following specifications:

IEC 51 Indicating Instruments

IEC 73 Colour of push buttons
IEC 211 Maximum Demand Indicators, Class 1.0
IEC 217 Electronic Voltmeters
IEC 255 Electric Relays
IEC 297 Dimensions of Panels and Racks
IEC 359 Expression of the Functional Performance of IEC Electronic Measuring
equipment
IEC 447 Standard Directions of movement for actuators which control the operation of
electrical appartus
IEC 521 Class 0.5, 1 and 2 Alternating-current watt-hour meters
IEC 34 Recommendation for rotating electrical machines
IEC 56 HV AC circuit breakers
IEC 71 Insulation co-ordination
IEC 73 Colors of indicating lights, push buttons
IEC 76 Recommendations for power transformer
IEC 81 Tabular Fluorescent lamps for general nightly services
IEC 86 Primary batteries
IEC 99 Lightning arrestors
IEC 113 Diagrams, charts, tables
IEC 129 A.C. Isolators
IEC 137 AC Bushings above 1000 V
IEC 41 Tests on oil-filled and gas pressure cables and their accessories
IEC 144 Degree of protection of enclosure for L.V. switchgear
IEC 157 LV distribution switchgear
IEC 158 LV control gear
IEC 162 Lighting fittings for tabular fluorescent lamps
IEC 185 Current transformer
IEC 186 Voltage transformers
IEC 214 On-Load tap-changers
IEC 228 Conductors of insulated cables
IEC 269 LV fuses with high breaking capacity
IEC 337 Control switches
IEC 408 L.V. air break switches
IEC 547 Modular Plug-In Unit and Standard 19-Inch Mounting Unit Based on NIM
Standard
ISA PP18-1 Annunciator Sequences
ANSI C37.90 Relays and relay system associated with electric power appartus
ANSI C37.90.1 Guide for surge withstand capability (SWC) Tests
 ANSI C37.91 Guide for protective relay applications to power transformers
ANSI C37.93 Guide for Protective Relay Application of Audio Tones

Instrument transformers

This section covers the design, manufacture, assembly, shop test, supply, delivery, installation works,
field test and commissioning of outdoor and indoor instrument transformers as specified hereunder.

The equipment specified in this Section shall conform to the latest edition of the appropriate IEC
specifications and/or other recognized international standards. In particular:

IEC 60044 Voltage transformers

IEC 60044 Instrument transformers
IEC 60529 Degree of protection provided by enclosures

The current transformers shall confirm to the following standards:-

IS 2705 : Part 1 : 1992 Current transformers: Part 1 General requirements

IS 2705 : Part 2 : 1992 Current transformers: Part 2 Measuring current transformers
IS 2705 : Part 3 : 1992 Current transformers: Part 3 Protective current transformers
Current transformers: Part 4 Protective current transformers for special
IS 2705 : Part 4 : 1992
purpose applications
IS 4201 : 1983 Application Guide for Current Transformer
IS 6949 : 1973 Summation current transformers

The potential transformers shall confirm to the following standards:-

IS 3156 : Part 1 : 1992 Voltage transformers: Part 1 General requirements

IS 3156 : Part 2 : 1992 Voltage transformers: Part 2 Measuring voltage transformers
IS 3156 : Part 3 : 1992 Voltage transformers: Part 3 Protective voltage transformers
IS 3156 : Part 4 : 1992 Voltage transformers: Part 4 Capacitor voltage transformers
IS 4146 : 1983 Application guide for voltage transformers
IS 5547 : 1983 Application guide for capacitor voltage transformers
IS 7700 : 1975 Quadrature phase-shifting voltage transformers
Code of practice for installation & maintenance of outdoor PLC equipment:
IS 9859 : Part 3 : 1983
Part 3 Coupling capacitors/capacitor voltage transformers

Indoor switchgear equipments

This section covers the design, manufacture, assembly, factory test, supply, delivery field test and
installation of metal clad, indoor switchgear, complete in all respects with all equipment fittings and
accessories for efficient and trouble-free operation.

One (1) lot of metal clad, cubical type indoor switchgears consisting of the following circuits:
 - Generator circuit breaker cubicle
- Busbar disconnecting switches cubicle
- Station service transformer circuit cubicle
- Transformer circuit.
- Three phase surge absorber
- Three phase excitation transformer cubicle
- Three phase potential transformer cubicle for bus bar

Low voltage distribution panel

This section cover the design, manufacture, assembly, testing at manufacturer's works, supply and
delivery, properly packed of low voltage distribution boards.

The equipment covered by this section shall, be designed, constructed and tested in accordance with
the applicable section of the latest relevant IEC Specification. The equipment conforming to any
other national standard which ensures equivalent quality is acceptable.

The following distribution boards shall be furnished:-

a) AC main distribution panels for Power House
b) AC sub-distribution panels at Diesel Generator Room
c) AC sub-distribution board for Power House Illumination etc.
d) DC sub-distribution board for powerhouse emergency lighting.
e) DC distribution boards (24 V, 48 V, 110 V, 220 V etc).
h) AC and DC distribution panels for operation of different equipment of transmission line

Cables
This section covers the design, manufacture, factory test, supply, delivery, installation, field-testing and
commissioning of all Power, Control, Instrumentation and Communication cables required for the
project.

The following cables shall be furnished in accordance with specification:

a) 132 kV power cable

b) 12 kV power cable
c) 7.2 kV power cable
d) 600 volt power cable
e) Control and instrumentation cable
d) Communication cable

Lightning arrestors

This section covers the design, manufacture, factory test, delivery, installation, field test and
commissioning of lightning arresters, complete with all accessories.

The equipment specified in this Section shall conform to the latest edition of the appropriate IEC
specifications and/or other recognized international standards. In particular:

IEC 60099-4 Metal-oxide Surge arrester without gap for a.c. system
 IEC 60099-5 Surge arrester - Selection and application recommendations
IEC 60529 Degree of protection provided by enclosures

Battery and battery chargers

This section covers design, manufacture, assembly factory test, supply, delivery, installation works field
test and commissioning of a stationary battery or batteries each complete with battery charger,
distribution board and control gear. The batteries to be provided for generating equipment’s operation,
control, and protection,132kV switching equipments system and transmission line equipment operation
and shall have sufficient capacity for the scope of works.

Batteries and battery chargers shall be furnished in following manner:

- Battery and battery charger for protection, control, emergency lighting, etc (for 110V
DC, 220 V DC)
- Battery and battery charger for 24V DC for Programmable Logic Controller (PLC)
- Battery and battery charger for 48V DC for communication, with positive pole
permanently earthed

Grounding system

This section covers the design, supply, delivery, installation and testing of the complete grounding
system of power house and outdoor switchyard area.

The complete station grounding work shall be in accordance with the recommendation in the "Guide for
Safety in Substation Grounding" IEEE No.80.

Civil and structural works

This section covers the general requirements for exploration, design, manufacture, factory test, supply,
construction and field testing of civil and structural works for the outdoor switchyard / substation
construction for power plant.

All equipment, materials, fabrication and tests under these Specifications shall conform to the latest
applicable standards:-

ACI American Concrete Institute

AISC American Institute of Steel Construction
ANSI American National Standard Institute
ASCE American Society of Civil Engineers
ASTM American Society for Testing Materials
AWS American Welding Society
JIS Japanese Industrial Standards
DIN Deutsches Institute für Normung

Illumination system
This section covers the scope and general description of the illumination design and installation which
will be incorporated in the powerhouse construction works.

The lighting level of the following shall be maintained as per the requirements:-
a. Powerhouse M/C floor
b. Control Room
c. Equipment Rooms
d. Outdoor Switchyard
e. General/Roads/ Headworks area
f. Access tunnel/Cable gallery

SCADA and Communication system

This section covers the design, manufacture, assembly, shop test, supply, delivery, installation, field
testing and commissioning of SCADA and communication system (Fiber Optic systems) complete with
all accessories for efficient and trouble-free operation.

The following equipments shall be furnished:-

a) Outline of the existing SCADA system
b) Responsibility and scope for compatible interfacing
c) Optical line termination equipment (OLTE)
d) Multiplexer (MUX)
e) Communication channel for relaying
f) Telephone system
g) Remote terminal unit (RTU)
h) Wiring
i) Spare parts and test equipment

Detail design of transmission line:-

1. Design Guideline:-
During the construction of the transmission line, the design requirements as stipulated in the
Electricity Regulation 2050 (1993) shall be strictly followed especially relating to ground clearance,
right of way, line span, protection, change over switch, earthing and insulation, quality of equipment.

The following sub-sections should be included:

1.1 Transmission line

Based on the line length and the range of line angles, the towers will be either tension type or the
suspension type.
Refer to Classification of Transmission tower based on line span and angle.

1.2 Spans
The Design Span or Normal/Nominal Ruling Span of the line should not exceed 330m for the
transmission line.
- Wind Span
- Weight Span

1.3 Electrical clearance

- Right of way
- Ground clearance
- Power line crossing
- Angle of shielding
- Loading conditions

1.4 Design of towers

- Design criteria
- Design temperatures
- Conductor configuration

1.5 Materials
1.5.1 Tower steel sections
IS Steel Sections of tested quality of conformity with IS: 2062 (Designated Y.S. 250 MPa) or /
and IS: 8500 grade 490 (Designated Yield Strength 350 MPa) are to be used in towers,
extensions, stub and stub setting templates.
1.5.2 Fasteners: Bolts, Nuts and Washers
- All hexagonal bolts and nuts shall conform to IS-12427.
- All bolts and nuts shall be galvanised as per IS: 1367 (Part-13) / IS: 2629.
- Nuts for hexagonal bolts should be double chamfered as per the requirement of IS: 1363
Part-III.
- The bolt positions in assembled towers shall be as per IS: 5613 (Part-II / Section 2) -1976.

1.6 Tower accessories

1.6.1 Steps bolts & ladder
Each tower shall be provided with step bolts conforming to IS: 10238.
1.6.2 Insulator string attachments
1.6.3 Earth wire clamp attachments
- Suspension clamps
- Tension clamps
1.6.4 Anti climbing device
- The barbed wire shall conform to IS-278 (size designation A1).
- The barbed wires shall be given chromating dip as per procedure laid down in IS:1340.
- The letters, figures and the conventional skull and bones of danger plates shall conform to IS-
2551
1.6.5 Tower fabrication
- Details of fabrication shall conform to IS: 802 (Part-II) or the relevant international
standards.

1.7 Drilling and punching

Before any cutting work is started, all steel sections shall be carefully straightened and trued by
pressure and not by hammering.

1.8 Erection mark

Each individual member shall have erection mark conforming to the component number given to it
in the fabrication drawings.

1.9 Galvanising
1.9.1 Fabricated tower parts & stubs
- The tower parts, stubs and pack washers shall be hot dip galvanized.
- The galvanization shall be done as per requirements of IS 4759 after all fabrication work is
completed.
- The contractor shall also take guidelines from the recommended practices for hot dip
galvanizing laid down in IS 2629 while deciding and implementing galvanizing procedure.
1.9.2 Fasteners
- For fasteners, the galvanizing shall conform to IS-1367(Part-13).
- Spring washers shall be electro galvanized as per Grade-IV of IS-1573.
1.9.3 Earthing
Pipe type earthing and counter poise type earthing wherein required shall be done in
accordance with the latest additions and revisions of:
- IS: 3043 Code of practice for Earthing.
- IS: 5613 Code of practice for Design, Installation and maintenance (Part-II/Section-2) of
overhead power lines.

2. Insulators
Insulator shall be of suspension or tension type. They shall be of best quality electrical porcelain,
vitrified with leadless glaze. Tension or Suspension Insulators shall comply with IEC 120, and the
internal height of the socket shall also comply with the requirements of IEC 372-1 (1977).

3. Conductors
It shall confirm to IEC 209, Aluminum Conductor Steel Reinforced (ACSR) or other equivalent
National or International standards.
3.1 Basic requirements
The maximum working tension of the conductor shall not exceed 40% of the ultimate breaking
strength under the severest condition.
3.2 Stringing line conductors
Phase color identification bindings of PVC sleeve shall be provided at every terminating point.
These shall be visible from ground level.
- Conductor joints
- Binding wire and line taps
- Jointing of conductors

5. Miscellaneous
5.1 Earthwork
Earthwork shall include only tower foundations and other safety regulation as per the national
(NEA) and international standards.
5.2 Tower Foundations
Sufficient tower foundation shall be provided depending upon the tower type and load.
5.3 Excavation in hard rock
All excavated hard rock shall be removed from site and under no circumstances it shall be used for
back filling. Poles on the rock will be installed using cement and concrete to give full strength.
5.4 Clearance
All bushes, including small trees and undergrowth shall be cut down to a height not exceeding 20
cm for a distance of 9 m on each side (from the center line of the Tower) of the route of an overhead
line.
5.5 Lightning protection
The transmission line shall be protected against lightning.

6. Specific Protection Requirements

In general, the major protection schemes to be employed for transmission lines are as follows:
i) Main protection shall be with differential relays, employing current
comparison through Pulse Code Modulation (PCM) technique, which shall include:
- transfer trip facility for each independent pole through fiber optic link
- reclose facility with auto synchrocheck relay

ii) Back-up protection shall be with directional IDMT overcurrent / earthfault

(OC/EF) relays; and shall have additional definite time non-directional OC/EF feature. Such
directional OC/EF relays shall not be operated in case of potential loss. And, loss of potential
shall be lead to the alarm annunciator.

iii) Distance protection

In addition, 132 kV transmission lines will be guarded via distance protection relays with cross-
polarised elements and with under impedance as starting criteria.

For the design of the technical parameters (electrical) of the transmission line, please refer:
1. Power System Analysis and Design, B.R. Gupta, S. CHAND
2. Electrical Power Systems, 4th Revised Edition, ASHFAQ HUSAIN
3. Principles of POWER SYSTEM, V.K. MEHTA, ROHIT MEHTA

A tentative guideline for the Power Evacuation Study

of a hydropower project

Applicable for:-
1. Pre-feasibility study
2. Feasibility study
For the power evacuation study of a hydropower project, the following sections should be included:

1. Overview of the power scenario of Nepal

- An overview of the contemporary power scenario of Nepal
- The existing supply and demand situation, energy deficit in the country and the recent
developments regarding hydropower plants in general.
- Brief description of Integrated Nepal Power System (INPS)
- Analysis of present energy deficit and tentative energy deficit of that year when the
proposed hydropower is going to be commissioned.
- Recent hydropower developments (connected to INPS) in the country.

2. Existing electrical infrastructure in the project vicinity

3. Power evacuation possibilities
- Identify different feasible options for evacuating the generated power of proposed
project
- As per the clause 5.4.3.5 of NEA grid code, the prospective users seeking connection
to the grid may have the following options to secure connections;
a. Looping connection from the grid transmission lines; and
b. Connection from the grid substation

4. Load flow study

- Carry out load flow study to identify the impact of inclusion of the proposed
hydropower project to the INPS
- The study is envisioned to forecast the possible scenario of the system in the year of
its commissioning (with/without that HEP project)
- Load for the year of its commissioning year can be deduced using projections made
by Water and Energy Commission Secretariat (WECS), Ministry of Commerce and
Industries, and Federation of Nepalese Chamber of Commerce and Industries
(FNCCI).
- Off peak loads can be taken as 60% of peak load.
- The planned and probable transmission line reinforcement/modification (to its
commissioning year) will be considered as per the NEA transmission system
planning.
- Potential power plants (based on NEA and those with PPA) expected to be completed
by that year will be included as well.

Required Software for load flow analysis:-

1. Mat lab
2. NetBas
3. Etap

References:-
Feasibility study report of Bhimkhola HEP and Madi HEP, Pre-feasibility study of Balephi HEP,
Review report of Nyadi HPP (Available in BPC Hydroconsult library)

Rural electrification study, survey and design

The methodology of the study includes:

a. Consultation with the key stakeholders through community meetings.
b. Primary data collection of the number of households in each ward.
c. Primary data collection of the existing & potential enterprises of each ward.
d. Collection of information on the existing physical infrastructure such as roads, source line (11 kV
line), transformer, schools, health post through local leaders and visits to these locations.
e. Preparation of rough sketch of the line route indicating pole location, households, and name of
the place (tole) through field survey.

While designing distribution system, the design considerations should be made on the followings:-
a. High tension line
i. Voltage regulation
ii. Loss at the maximum load
b. Low tension line
i. Considered years
ii. Per Household load
iii. Annual Load growth
iv. Unity Power factor for residential Load
v. Coincidence factor for all types of load
vi. Potential Industrial Load with power factor
vii. Minimum voltage at the far end

c. Distribution transformer
i. Time span
ii. Annual growth rate
iii. Per Household load
iv. Power factor for domestic and potential industrial loads

d. Poles
e. Conductors
f. Hardware

Reference:-
Rural Electrification Survey, Study Report, Himal Power Limited, Bijaya Niwas, Jhamsikhel (BPC
Hydro consult work as a consultant for this study)