Report of the visit of Shri Manoj Tripathi, Chief Engineer (HPM), CEA

to Tehri Pumped Storage Scheme (4x250 MW=1000 MW) in

Uttarakhand on 20th November, 2021 to review the physical progress
of works of the project

The Tehri Pumped Storage Scheme (TPSS) was visited on 20th November, 2021
to review the physical progress of various works of the project. Discussions were also
held with the Officers / Site Engineers and Contractors of TPSS on various aspects of
the on-going works, problem areas and measures taken/necessary to accelerate the
pace of works with the aim of timely commissioning of the units as per schedule. The
status of works, critical areas / activities and observations during the visit are as under:

1.0 Introduction:
The Tehri Complex (2400 MW) consisting of three component projects viz. Tehri
Dam Project Stage-I (4x250=1000MW), Tehri Dam Project Stage-II (4x250 = 1000 MW
pumped storage project) and Koteshwar Dam Project (4x100=400 MW), envisages
integrated development of the water resources of the Bhagirathi river in its lower
reaches before its confluence with the Alaknanda river.

The Tehri Project Stage-I multipurpose project involving construction of 260.5 m

high rockfill dam and an underground power house near dam site having 4 units of 250
MW each was commissioned in the year 2006 – 07. The Koteshwar Dam Project
(4x100 MW) involving construction of 97.5m high concrete gravity dam, is located 22km
downstream of Tehri Dam, was commissioned in the year 2011-12. At present
construction of Tehri Pumped storage scheme is under progress since July, 2011,
which envisages construction of an underground power house (adjacent to
underground power house of Tehri-I) and other related structures. Civil Works of Dam,
Intake, HRT and Transformer cavern were taken up along with Tehri St. I work and has
already been completed. The major civil works taken up in Tehri St.II (PSS) involve
Upstream Surge shafts (2 Nos.), Penstocks (4 nos.), Machine Hall, Downstream Surge
Shafts (2 Nos.) and Tail Race Tunnels (2 Nos.). The reservoir created by the Tehri Dam
St. I would function as the upstream reservoir and the Koteshwar Dam, will create a
balancing reservoir to regulate the releases from the Tehri reservoir and serve as the
downstream reservoir for Tehri PSS.

Tehri Pumped Storage Scheme (PSS) with an installed capacity of 4x250 MW

has been envisaged to generate 1000 MW of peaking power for enhancing system
reliability and also to provide balancing load to the grid during off peak hours.

The unique features of the project as observed during the visit are as under:

 Large variation (about 90m) between maximum and minimum head, under which
reversible units will operate.

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 Variable speed units to cater for the large variation of head for improving the cycle
efficiency and better power regulation capability.
 First Pumped storage scheme in the Northern Region/ Himalayas and the first
pumped storage scheme to be implemented by the Central Sector PSU’s.
 The overall cycle efficiency will be about 80.4 % considering conventional energy
generation and 74.1 % considering pure pump operation. Annual generation from
the project would be 1377 MU (1268 MU based on pumping + 109 MU Conventional
Energy Generation). The Energy requirement for pumping operation will be of the
order of 1712 MU during off peak hours.
 The Tehri PSS Power House cavern is one of the largest and widest underground
power house caverns [of dimensions 201 m (length) x 25.4m (max. width) x 57.3 m
(height)] in the Himalayan geology.

The general layout plan of the Tehri PSS project is placed at Annex-I & salient
features at Annex-II.

Techno-Economic Clearance:

The project was accorded Techno-Economic clearance (TEC) on

18.11.1988 for an estimated cost of Rs. 531.02 Crores (Oct., 1987 Price Level).
It was later on decided to initially implement Tehri Dam & HPP St. I (1000 MW)
along with essential works of Tehri PSS in view of the financial constraints.

Project Approval: -

Government of India approved the execution of Pumped Storage Plant

(4x250 MW) in July, 2006 at a cost of Rs. 1657.60 cr. including IDC of Rs. 81.64
cr. at Dec.’05 price level with debt equity ratio of 70:30. Due to specialized
nature of work, engagement of foreign consultant (M/s Coyne-Et- Bellier, France)
for preparation of tender documents, poor response of bidders, clarifications by
bidders and time extensions, litigation, and L-1 bid being more than the cost
estimates for the project the work could not be awarded till the year 2011 and
necessitated a revised approval.

Revised Cost Estimate:-

CCEA has approved Revised Cost Estimate (RCE) of the Project

amounting to Rs 2978.86 Cr including IDC of Rs. 405.04 Cr. at Apr-10 PL in
Nov’11 with scheduled completion of the Project by Feb, 2016. Further, approval
of RCE-II of Rs. 4825.60 crores at Feb,,2019 PL has been accorded on
31.07.2021 with completion by June’22.

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2.0 Award of Major Works:

Major works of the project are being executed through a single EPC
contract. Agreement for EPC/Turnkey execution of the Project was signed with
the consortium of M/s Alstom Hydro, France and M/s Hindustan Construction
Company on 23rd June, 2011. The grand total equivalent contract value in INR is
1843.49 Crores. Work on the project has commenced w.e.f. 27th July, 2011 with
stipulated time for Completion as 54 months.

3.0 Project Status:

A. Works already executed before award of EPC contract:

Essential works of Tehri PSP already completed along with the execution of
Tehri Stage-I & before award of EPC contract are as follows:

 Two Headrace Tunnels for PSP

 Intakes for Headrace Tunnels of PSP
 Transformer Hall constructed under Tehri Stage-I has been planned to
accommodate Generator Transformers for the PSP also.
 Main Cable Gallery
 Interface Facility (Civil works)
 The protection wall in front of TRT outlet up to level of El. 622.0 M.
 Excavation of various Adits leading to Machine Hall, Down Stream Surge Shaft
and link shafts to isolate approach of Tehri HPP from PSP works.

B. Civil Works:
The status of the civil works is as under:
 Upstream Reservoir: The Tehri Dam/ Reservoir (live storage of 2615
MCM), which was commissioned in the year 2006-07, will act as the
Upper Dam/ Reservoir.
 Upstream Intake: Already constructed along with Tehri –I work.
 Head Race Tunnels (2nos.- HRT-3: 8.5 m dia, 932 m long & HRT-4:
8.5 m dia and 1060 m long): Already constructed along with Tehri –I
work.
 Construction of Approach Adits & Drainage Galleries: 14 Access
Adits to different structures (total 2146 RM) have been completed. Major
portion of Drainage Galleries of different structures (total 1670 RM) have
been completed.
 Upstream Surge Shafts (3 & 4): Excavation of Pilot shafts in Upstream
Surge Shaft (4 &3) (total length 280RM) has been completed using raise
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 climber. Three Grouting cum Drainage Galleries around Upper Chambers
of U/s Surge Shaft-3 &4, (Total length 327 RM) have been completed.
The widening of surge shafts is in progress and 25 m/ 21 m balance (out
of 140m) is to be completed for SS-3/4 respectively.
 Butterfly Valve Chamber (BVC): Completed.
 Penstock Assembly Chamber (PAC): Completed.
 Penstocks: Excavation of all four Upper and Lower Horizontal Penstocks
has been completed. Excavation of all four Pilot shafts of Vertical
penstock (135 m each) has been completed. The widening of the vertical
penstocks is in progress.
 Machine Hall: Machine Hall excavation completed and concreting is in
progress in the unit area.

 Downstream Surge Shafts (3 & 4): Excavation completed.

 Tail Race Tunnels (TRT-3 & TRT-4): TRT-3 (1151 RM): Heading
excavation is 113 m balance and 893 m overt lining balance. TRT-4
(1255RM): Excavation in Heading: 170 RM balance and lining 795 m
balance.
 Downstream Reservior: The Koteshwar reservoir (live storage 47 MCM),
which was commissioned in the year 2011-12, will act as the downstream
reservoir.

C. Electro-Mechanical Works:

The EOT cranes have been made operational in the service bay. 60T EOT crane made
operational in all the four units. Presently erection works is in progress in all the units.

D. Hydro-Mechanical Works:

Design and drawing of HM equipment are in progress. Fabrication of Penstock

steel liner has been completed.

4.0 Issues:
At present differential cost is being paid to contractor for procurement of aggregate from
open market in the absence of Asena Quarry. Process for approval of Extension of
lease deed for quarrying from Asena quarry is under progress.

5.0 Financial Progress:

Expenditure incurred on Tehri PSP Project till Nov-21 is INR 4315.82 Cr. This includes
IDC & FC of INR 1001.44Cr.

6.0 Observations/ Suggestions during the visit-

 The excavation activities are now tapering off and the balance excavation activities
at upstream surge shafts, penstocks, TRT, etc. are expected to be completed by
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 the end of the financial year i.e March,22. The concreting activities/concreting
quantity is now picking up and expected to reach peak/maximum during the year
2022-23. Hence, THDC may accordingly plan for the batching plant, cement,
reinforcement steel and aggregate requirement that may cater to the peak
concreting requirements.
 To expedite the works and commission the project as per present schedule i.e by
June,23, very close monitoring is required, wherein, the cycle time of excavation of
surge shaft/ pressure shaft, surge shaft lining/concreting, pressure shaft lining, TRT
lining, etc. needs to be monitored and improvements in terms of man/ machine/
equipment needs to be augmented in activities wherever feasible and desirable.
THDC may also appoint “Independent Engineer” with the consent of the contractor
for dispute avoidance and close monitoring of critical activities. The IE may also
suggest extra requirements for man/material/ equipment, if needed, in a particular
activity.
 The 4 units of the Power House are fed by two independent water conductor
system (one system catering water to 2 units) consisting of 2 HRT, 2 u/s surge
shaft, 2 butterfly valves, 2 pressure shafts (bifurcating into 4 unit penstocks before
Power House). Since 2 units are planned/ scheduled to be commissioned during
the year 2022-23 and 2 units during 2023-24, hence the civil works related to the
water conductor system catering to two units planned for 2022-23 may be
expedited so that the civil works related to these units gets completed as per
schedule.
 The project is the first project which was undertaken by THDC on EPC/ Turnkey
basis, where the risk of the ground conditions lies with the contractor. The lessons
learnt in execution of this EPC contract may be utilized in framing contract
conditions and choosing type of contracting for new projects being executed by
THDC.
 THDC may try to finalize the plan to optimize the operation of the power station in
terms of no of cycles / period of operation keeping in view the pondage and peak
requirements, so that maximum benefits can be reaped from this Power Station.
 The Tehri PSP has advanced technical features, variable speed machines and first
PSP of THDC (and also first PSP of any CPSU), so THDC may also plan to train
people on simulator (or other means) for operation of the pumped storage units.
 THDC is advised to adhere to all the conditions of the TEC accorded by CEA and
also applicable safety, construction and other regulations being notified by CEA
from time to time. Further, change in salient features of the project, if any, may be
intimated to CEA , and got approved by CEA before implementation of the same.

7.0 Commissioning of the units-

As per the EPC contract, the project was programmed to be commissioned in the year
2015-2016 (Feb-16). However, due to various reasons, like poor geological strata,
stoppage of works at Asena Quarry, stoppage of works at muck dumping site, delay in
finalization of design & drawings, cash flow issues etc. the progress of works has been
hampered and the project is now scheduled to be commissioned by June-23.

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The two units of Tehri PSP are planned to be commissioned during 2022-23 with the
first unit planned to be commissioned by Dec,22. The other 2 units are planned to be
commissioned by June, 23. Considering the present status of works, it is expected that
one unit can be commissioned during the year 2022-23 i.e by March,23 with concerted
efforts and rest 3 units likely to be commissioned during 2023-24. THDC may go for
micro-planning along with corrective actions in case of deviation in order to complete
balance works on time. The cycle time of excavation and other works needs to be
closely monitored and optimized. With the commissioning of the Tehri PSP, the
Northern Grid will get its first pump storage plant.

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 Site Photographs

GIS HALL- COMMON FOR TEHRI-I AND TEHRI-II

TRT OUTLET
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UNIT NO 4-ARRANGEMENT FOR STAY RING

UNIT NO. 3-SPIRAL CASING COMPLETED

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SERVICE BAY-POWER HOUSE

UPSTREAM SURGE SHAFT-3

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