PROPHO

Integrated Mini Hydropower Project - Sg Tuaran Afiepower Sdn Bhd

Salient Feature of the Project

Location Sg. Mulau I Sg. Mantaranau Sg. Mulau II

HydrologyCatchment Area Design discharge

140km2

6.25m3/s50 km2

3.45m3/s160 km2

6.25m3/s

River Intake Gravity Weir Gravity Weir Gravity Weir

Settling BasinReinforced Concrete basin

Reinforced Concrete basin

Reinforced Concrete basin

Low Pressure PipeSizeLength

2.0m diameter1700m

1.7m diameter2600m

2.0m diameter1500m

Surge TankSizeHeight

8m diameter10.5m

7m diameter10.0m

6m diameter8.0m

PenstockSizeLength

1.7m diameter500m

1.4m diameter600m

1.7m diameter300m

PowerhouseReinforced Conrete Frame

Reinforced Conrete Frame

Reinforced Conrete Frame

TailraceReinforced concrete canal

Reinforced concrete canal

Reinforced concrete canal

Turbine Type Francis Francis Francis

Generator Type Synchronous Synchronous Synchronous

Transmission Line 11kV to common 33kV system

11kV to common 33kV system

11kV to common 33kV system

Switching Station Reinforced Concrete Frame

Reinforced Concrete Frame

Reinforced Concrete Frame

Installed Power Energy Generation

5000kW30,500 MWh

2500kW14,200MWh

2000kW12,500MWh


EXECUTIVE SUMMARY

Afie Power Sdn Bhd (APSB) is proposing the development of an integrated

mini hydropower scheme at the Tuaran River basin in the district of

Tuaran, Sabah. This scheme would involved the setting up of three (3)

mini hydropower plants at the tributaries of the Tuaran River Basin with a

total installed capacity of 9.5 MW and an export capacity of 9.12 MW.

The development of this integrated mini hydropower scheme, on a build,

own and operate concept, will follow the guidelines outlined in the Small

Renewable Energy Program (SREP).

APSB, a joint venture company between a local Bumiputra

contractor, Afie Enterprise Sdn Bhd and H2RM Engineering Sdn Bhd,

the technical service provider, is confident for a smooth and fast

development of the Tuaran River basin mini hydropower plant as APSB

is backed by experienced and established parent companies.

APSB has, for the past one year, done a preliminary feasibility studies on

the proposed development through site visits, desk study and discussions

with SESB. A detail feasibility studies shall be carried out once APSB

obtained permission and support from the Ministry of Energy, Water and

Communication.


1.0 INTRODUCTION

APSB is a joint venture between Sabah contractor, Afie Enterprise Sdn

Bhd (Afie) and H2RM Engineering Sdn Bhd (H2RM), a company

rendering engineering and project management services in the

development of mini hydro power plants. APSB is formed upon the

discovery of the potential of Tuaran River Basin for the

development of a mini hydro power scheme which lies in the district

of Tuaran. The proposed power plants are located at Sg. Mulau and

Sg. Mantaranau. These rivers are major tributaries of Tuaran River.

The potential of Sg. Mulau and Sg. Mantaranau were discovered

during a river scouting exercise carried out by H2RM in identifying

viable site locations for the development of mini hydropower plants.

After a preliminary feasibility study was carried out by H2RM, it is

found that by combining Sg. Mulau and Sg. Mantaranau

development, it is possible to harness the mini hydropower

capacity leading to an installed capacity of 9.5MW and export

capacity of 9.12MW.

For the past one year, APSB has done a preliminary feasibility

studies on the potential and viability of Tuaran River basin for the

development of mini hydro power plants. APSB has visited the site in

the process of determining the location of the intake, pipeline route,

power house and the interconnection point. APSB has also studied

the topography of the site and a preliminary calculation of energy

was performed based on calculated assumptions of certain data.


APSB will conduct a detail and thorough study once the development

approval has been obtained from the Ministry of Energy, Water and

Communication.

APSB has also attended meetings and discussions with the District

Office of Tuaran and Economic Planning Unit of Sabah of which

clearance and support for the development was given on 4 th

December 2006 via a letter referenced PDTRN(S)400-9/2 Klt7/(93)

and 16 January 2008 via letter referenced UPEN 600-26/1/2 Vol.3/2

(attached).

Thus, in line with the launching of the Small Renewable Energy

Program by the Government of Malaysia, APSB is most happy to

support the program with a proposal for the development of an

integrated mini hydropower scheme at Tuaran River basin, in the

district of Tuaran, Sabah.


2.0 DEVELOPER BACKGROUND

APSB , a Bumiputra company, is 51% owned by Afie Enterprise Sdn

Bhd (Afie) and 49% owned by H2RM Engineering Sdn Bhd (H2RM).

Afie, incorporated in August 1998, is a 100% Bumiputra Kelas A PKK

contractor involves in civil and structural engineering works. With a paid

up capital of RM 800,00.00, Afie has been awarded contracts mainly

from Government sectors worth RM 140 million of which contracts

worth RM 94 million are ongoing. Among the on going contracts are the

Design, Build and Commissioning of Water Treatment Plant at

Sipitang, Sabah worth RM 56.8 million and the Design, Build and

Commissioning of Water Treatment Plant at Kudat, Sabah worth RM

30 million.

H2RM is an engineering company, specially formed for the purpose of

the joint venture for the development of the Tuaran River basin mini

hydropower scheme. H2RM is wholly owned by SSM Associates Sdn

Bhd (SSM), an engineering consulting company, providing engineering

and management services in civil, structural, mechanical and electrical

in buildings, roads and bridges, substations, sewerage and water

treatment, renewable energy projects such as are solar hybrid, wind

electrical power, mini hydropower, and electrical transmission facilities.

SSM started off as a partnership concern in 1991 and incorporated as

a private limited company in 1996. At present, SSM is the consultant to


three mini hydro power plants development of total 9 MW in Sabah,

2MW mini hydro power plant in Selangor and 2.8 MW mini hydro power

plant in Kelantan.

3.0 PROJECT LOCATION

The proposed site is located at 20 km south east of Tamparuli town.

Access to site is through an asphalt road from Tamparuli town to Kg.

Pukak and finally through a well maintained laterite roads.

The proposed project areas are located about upstream of the

confluence of Sg. Tuaran and Sg. Mulau. The project sites are all

located on Sg. Tuaran tributaries; Sg. Mulau and Sg. Mantaranau.

The total catchment area of these three rivers amounting to 230km2

afforded a very good potential for development of mini hydropower.

These sites are about 6km upstream of the above river confluence

and located where there are good water gradient along the river

alignments. Such features would lead relatively high water head and

economically viable mini hydropower schemes. The powerhouse

locations are situated reasonable close to each other which allow a

common 33kV distribution system. This system is then connected to

the nearby SESB distribution system.

The locations of the diversion weirs, pipelines and the proposed

power house areas are shown in the attached location map in

Appendix 1.


4.0 HYDROLOGICAL STUDIES

4.1 BASIN CHARACTERSTICS

The proposed project is located at three (3) major tributaries of

Tuaran River. The total catchment area of upstream of the

proposed intake site is 230 km2. All the catchment area of Tuaran

basin lies below 1000 m. The project site is located in the Western

Sabah Region at latitude N06°05’028”-05°56’528” and longitudes

E116°17’308”-116°23’372”. Whole catchment area lies in the Tuaran

District. The basin is leaf shape and shown in Figure 4.1

The upper drainage basin of Tuaran lies within the Crocker range.

The maximum altitude of the basin is 1000m amsl. The total length

of the Tuaran main stream up to the sea confluence is about 60 km

and its catchment area is about 546 km2.

The intake and powerhouse sites are in Sg. Mulau and Sg.

Mantaranau. They are located about 6km upstream of their

respective confluence with Tuaran River.

4.2 CLIMATE STUDY

The basin experiences warm and humid climatic condition throughout

the year. The yearly maximum temperature of the project sites are

about 35°C and the minimum temperature about between 20° C.


The relative humidity in percent is 90% and is quite consistent

throughout the year.

4.3 HYDROLOGY STUDY

The reference metrological stations are the Tamu Darat and

Tuaran river stations, which provide both the rainfall and daily flow

records. From the available data, it is noticed that most of the

rainfall occurs over the basin during beginning and middle of the

year. The low rainfall usually occurs in March and August. The

flows in the rivers correspond concurrently to the rainfall data.

Flow duration curves each project intake sites are derived from the

above two stations. This is depicted in Table 4.1

Table 4.1: Flow Duration Curve Data – Integrated Tuaran River Scheme

PercentageExceedance

Sg Mulau Flow(m3/s)

Sg. Mataranau Flow(m3/s)

Sg. Mengkaladom Flow(m3/s)

0%5%10%15%20%25%30%35%40%45%50%55%60%65%70%75%

47.135.927.022.018.716.114.112.310.99.608.407.506.605.805.104.30

16.8012.809.607.906.705.805.004.403.903.403.002.702.302.101.801.50

13.5010.307.706.305.304.604.003.503.102.702.402.101.901.701.401.20


80%85%90%95%

100%

3.602.902.201.600.30

1.301.000.800.600.10

1.000.800.600.400.10


5.0 GEOLOGICAL STUDIES

Generally the project site is under laid by the Kulapis Formation. The

lithology of the site comprises of limestone, shale, siltstone and

sandstone.

The regional geology of the project area is given in the

fig.5.1.

The project area is covered with limestone, shale, and siltstone

and sandstone material. It is expected the geological conditions at site

would pose little problem for construction of the mini hydropower

project.

Figure 5.1 Figure 5.1 Geological condition at site

Kulapis Formation


6.0 MINI HYDRO POWER PLANT DESCRIPTION

Mini hydro is a form of renewable energy adopted by the

government as the fifth fuel resource. The fuel used in this system

is water, which is the main force to run the turbine consequently

generate electricity. This technology is proven on the reliability of

continuous supply of electricity.

Run-of- river concept will be employed in the proposed scheme.

It refers to the mode of operation in which the hydro plant uses

only the water that is available in the natural flow of the river.

Run-of-river implies that no water storage or flooding and that

power fluctuate with the stream flow. This concept requires low

diversion weir and the environment impact are less significant.

In adopting this concept, certain hydraulic features have to be

incorporated in the design and are described below:

6.1 DESCRIPTION OF PHYSICAL FACILITIES

6.1.1 CIVIL WORKS

6.1.1.1 Intake Structures

A water intake is a structure to divert water into a pipelines or

waterway. An intake must be able to divert the required


amount into the penstock without producing a negative

impact on the local environment and with minimum head loss.

Its design, based on geological, hydraulic, structural and

economic considerations requires special care to avoid

unnecessary maintenance and operational problems that

cannot be easily remedied and would have to be tolerated for

the life of the project.

The water intake will consist of concrete gravity structure with

an overflow spillway section with two gated undersluice.

Attached to the side, shall be the settling basin structure. The

basin will allow suspended sand particle to be settled and

flushed away. The basin is connected to the pipeline system.

The typical drawings of the intake system are attached in the

Appendix 1. The dimensions of intake structures for the three

project locations are summarized in Table 6.1.

Sg. Mulau ISg.

MantaranauSg. Mulau II

Intake type

Intake length

Intake height

Gravity

30m

4m

Gravity

25m

4m

Gravity

25m

4m

Table 6.2 Dimensions for the settling basins.

Sg. Mulau ISg.


Type

Basin length

Reinforced Concrete

Reinforced Concrete

Reinforced Concrete


Basin height30m

4m

25m

4m

25m

4m

6.1.1.2 Pipeline

Mild steel pipeline or open channel will be adopted to convey

water from the intake to the turbine in the power house. For steel

pipelines, it may be installed over or under the ground,

depending on factors such as the nature of the ground itself, the

penstock material, the ambient temperatures and the

environmental requirements. Thrust blocks will be constructed at

all vertical and horizontal bends. Pipes that are installed above

ground will be supported by reinforced concrete pipe supports.

It is expected that the pipeline system be divided into two main

portions; the low pressure pile and the penstock. These portions

are divided by the surge tank which is required to allow proper

operation of the turbine system. The penstock connects the

surge tank to the power house and is usually faced with high

water pressure and will require higher thickness. The

dimensions and details of the pipeline and surge tank are stated

in Table 6.3.

Sg. Mulau ISg.


Low Pressure Pipe

2.0m diameter1700m length



Surge Tank8m diameter

7m diameter10.0m height

6m diameter8.0m height


10.5m height

Penstock1.7m diameter

500m1.4m diameter

600m1.7m diameter

300m

Typical drawings of pipe and its ancillaries are attached in

Appendix 2.

6.1.1.3 Power house

The power house protects the electromechanical equipment

from incremental weather effects. The number, type and power of

the generators, their configuration, the scheme head of the site

controls the shape and size of the building. The building is usually

reinforced concrete frame with metal cladding for wall and roof. It

is divided into the turbine hall, control and switchgear room. Utility

room and toilet are also provided for storage and amenity

purposes. The outdoor transformers are installed on concrete

plinth, close to the switchgear room. Table 6.4 illustrates the

general dimension of the power house.

Table 6.4 General dimension of the power house.

Sg. Mulau ISg.


Power House Type

Reinforced concrete frame



Dimensions 30m x 15m 25m x 13m 25m x 13m


The general layout of the power house is attached in the Appendix

3.

6.1.1.4 Tailrace

Water in the pipeline, passes through the turbine in the power

house, returns to the river through a tailrace. Since the water

have high exit velocities, the tailrace shall be designed to

ensure that the powerhouse would not be undermined. The

design shall also ensure that, during relatively high flows or

flooding condition, the water in the tailrace does not rise so high

that it interferes with the turbine operation. The tailrace is usually

constructed of reinforced concrete canal with stop logs to control

the water level. This is imperative to ensure proper functioning of

the Francis water turbines.

6.1.2 ELECTROMECHANICAL EQUIPMENT AND AUXILIARIES

6.1.2.1 Turbine equipment

The purpose of the turbine is to transform the water potential

energy to mechanical rotational energy i.e. the water pressure

and velocity of the water react with the runner of turbine to

produce torque on the shaft. The type, geometry and dimensions

of the turbine will be fundamentally conditioned by the following

criteria:

a. Water Head


b. Design Flow

c. Rotational speed

d. Cavitations problems

Based on the data available and site conditions, the most appropriate

turbines would be of Francis type. This turbine type has been

employed successfully throughout the world for both large and small

hydro installation with moderately high water head. For ease in

maintenance and operation, it is envisaged that 2 turbines system be

adopted for each project location. Table 6.5 depicts the turbine

configuration based on optimizing of the derived hydrology data and

flow rates.

Table 6.5 Configuration of turbines

Sg. Mulau ISg.


Turbine Type Francis Francis Francis

No. and Rating

2 x 2500kW 2 x 1000kW 2 x 1250kW

Design FlowGross Head

6.25m3/s91m

3.45m3/s91m

2.55m3/s91m

6.1.2.2 Generators equipment

The proposed scheme will be installed with synchronous

generators which transform the mechanical energy into electrical


energy. The generator shall be horizontal shaft type, each

complete with exciter, AVR, and the necessary auxiliary

equipment. Each of these generators would be coupled directly to

their associated turbines. The power would be generated at a

rated voltage of 3.3kV, rated frequency 50Hz and a rated power

factor 0.85. Each generator in the powerhouse shall be connected

to a 3.3kV group bus. The power outputs from all the three project

locations 3.3kV group buses are stepped up to 11kV by means of

three-phase 3.3/11 kV transformers and shall be fed into the

transmission system at 11kV through a single circuit overhead line

to a common 11/33kV substation near Kg. Pukak. Table 6.6

illustrates depicts the turbine configuration based on optimizing of the

derived hydrology data and flow rates.

Table 6.6 Generator details

Sg. Mulau ISg.


Generator Type

Francis Francis Francis

No. and Rating

2 x 3000kVA 2 x 2500kVA 2 x 2600kVA

Power factor 0.85 0.85 0.85

The two generators at each powerhouse will be synchronized at

the 3.3kV generation busbar. Three core type CT shall be

connected in the stator for protection purpose. Insulation materials

shall be of class F. 11kV indoor single bus configuration shall be


adopted. SF6 circuit breakers are provided, on the transformer

secondary and line side. The transformer will be located at the

outdoor area. The surge arrestors are provided on the line side to

protect against over-voltages caused by lightning and switching

surges.

6.1.2.3 Control and Protection

The powerhouse will normally be attended. Full automatic control

of units will also be possible. Both manual and automatic control

will be provided.

The protection panels will accommodate the turbine-generator, the

main transformer, transmission line and auxiliary transformer

protection relays.

Turbine shall be provided for various protection schemes.

Different protection schemes will be adopted for generation

protection such as; differential protection, field loss protection,

reverse power protection, over-voltage and over-current protection

and ground-over protection.

6.1.2.4 Interconnection Facilities

The interconnection facilities would consist of the common

11/33kV substation facility and the outgoing 33kV transmission

line. The substation shall be located near Kg. Pukak. It shall be a

reinforced concrete frame structure with switchgear and control


rooms to accommodate the associated equipment.

The incoming 11kV line from the three project sites shall be

connected to 11kV group busbar. These are then stepped up to

33kV by means of one three-phase 11/33kV transformer and shall

be fed at 33kV through a single circuit overhead transmission line

to the existing SESB Tambalugu, Tuaran substation. A new 33kV

bay comprising all necessary equipment shall have to be procured

and installed to allow the interconnection.

6.1.2.5 Interconnection Facilities

Apart from the above, auxiliary equipment are needed to ensure

proper and smooth running of the hydropower facilities. The

required equipment can be summarized as follows;

• Water shut off valve(s) for the turbine.

• Bypass gates and controls.

• Hydraulic control system for the turbine and valve

• Electrical protection and control system

• Electrical switchgears

• Auxiliary Transformers

• Telecommunication system

• DC battery systems

• Powerhouse crane

• Utility interconnection or transmission and distribution

system.

A single line diagram illustrating the all above installation is


attached in the Appendix 4.

7.0 ENVIRONMENTAL IMPACT ASSESSMENT (EIA)

The environmental impact arising from the development of mini

hydro scheme to this area is very minimal. The concept to be

adopted in the development of the mini hydro at this area is of a

run-off-river concept, which means that there is no submergence

of either flora or fauna.

As for the construction activities, the impact is minimal to the

surrounding as the activities of construction is similar to that of a

general civil engineering construction works.

8.0 PROJECT COST AND FINANCING

Until a detail feasibility study is carried out, it is estimated that the

total development cost shall be in the region of RM 96.9 million.

APSB will be responsible wholly in financing the development

costs.


9.0 SELLING PRICE

APSB is proposing a selling price of 19.5 sen for the whole license

period of 21 years, on a willing seller willing buyer and take and pay

basis.

10.0 PROJECT VIABILITY

At a proposed selling price of 19.5 sen for a licensed period of 21

years, the project is found to be economically viable with a project

Internal Rate of Return of 10.2%, which is slightly higher than

APSB’s cost of capital.

The Tuaran Integrated River Basin mini hydro power plants, with an

installed capacity of 9.5 MW and generating capacity of 9.12 MW, is

expected to be developed within 24 months at an estimated cost of

RM 96.9 million, including Interest During Construction.


11.0 CONCLUSION

The proposed development of Tuaran Integrated River Basin mini

hydro power plants is in line with the Government of Malaysia Fifth

Fuel Policy and the Small Renewable Energy Program in promoting

renewable energy as the fifth source of energy generation mix in

Malaysia.

APSB, backed by Afie Eterprise Sdn Bhd, a local Sabah company

with 9 years construction experience and H2RM Engineering Sdn

Bhd, a wholly owned subsidiary of SSM Associated Sdn Bhd, an

engineering consultant company with 16 years experience in project

management and consultancy, is confident to develop the proposed

project successfully as APSB has the technical and financial support

from its parent companies.

Hence, APSB is very hopeful that Ministry of Energy, Water and

Communication approve our proposal to develop the Tuaran


Integrated River Basin mini hydro power plants in supporting the

Government strategy to intensify the development of Renewable

Energy as the fifthr fuel resource.

PROPHO

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