WWW.WATERPOWERMAGAZINE.COM JULY 2010 43
COMMENT
Analyzing the data, the author found that there is a factor of about 2.5
between a ‘documented’ as compared with a ‘non-documented’ design
and managed project, as shown in Figure 1. There are two distinct lines
on the gure. The lower line (B) represents the man-hours for a ‘non-
documented’ design, and the upper line (A) represents a documented
design. Both lines can be expressed by the following equation
Man-hours = k (MW/h
0.3
)
0.54
(1)
Where: h = rated net turbine head in meters; MW = installed capacity
in megawatts; k = a factor with a value = 8,300 for a non-documented
design, and = 21,000 for a documented design.
In other words, a documented project requires over 2.5 times the
effort expended on a non-documented project. This is very important,
and a factor which must be taken into account by any owner contem-
plating awarding a contract for engineering services.
There are some projects on the chart which do not t the data.
These can be explained by:
r 2 – Snare Falls. The dam site on this project was changed at the last
minute, when the owner decided that the project capacity should
be increased by about 50%. This was accomplished by moving the
dam site downstream to the next set of rapids, after all contracts
had been issued for tender. This required a complete re-design of
the project layout.
r 4 – Rattling Brook. This project proceeded with only a pre-fea-
sibility study, requiring extensive additional studies on dam and
spillway locations.
r 10 – Dadin Kowa. This project was terminated when the client ran
out of money, and still requires completion of the powerhouse and
installation of spillway gates.
r 13 – Cat Arm. During the design engineering work, the owner
decided to add about six utility engineers to the consultant’s electri-
cal design team to learn how to design the automatic controls, with
the intent to retrot the design onto older powerplants. Also, there
were signicant changes to the project concept when detailed design
work commenced, which included use of a U-shaped weir spillway
instead of a gated spillway, impulse units instead of Francis units,
and elimination of the surge tank.
r 7 – Bighorn. This project was undertaken after a change in the man-
agement at the utility. The new management required all contracts
to be tendered instead of being negotiated, adding substantially to
the weight of both the technical and contractual conditions in speci-
cations, and requiring more formal documentation of the work.
It is remarkable how consistent the data appears to be. All of
the projects were undertaken by Monenco, with the exception
of Wreck Cove, engineered by SNC, with Monenco acting as the
owner’s consultant, and LG3, engineered by SNC in association
with Cartier Engineering, a subsidiary of Monenco. Also, two
of the projects, at Maskeliya Oya and Bayano, were designed
from project ofces in Colombo and Panama, staffed with a few
Canadian engineers, with all the other engineers and draftsmen
being provided by the utility client.
The chart is based on data from projects undertaken before the intro-
duction of computerized drafting, (CAD) which one would expect to
reduce drafting time. The author has tried to determine whether CAD
has had a signicant effect on man-hours, to no avail, since consult-
ants are naturally reluctant to divulge such data. However, the author
is of the opinion that CAD and other similar programs have instead
increased drafting time, since now it is very easy to produce more draw-
ings, and to produce three-dimensional images of powerplant interiors
and even individual concrete pours, both of the latter requiring signi-
cant additional input data. The added engineering simplies construc-
tion work, but increases engineering man-hours.
Also, the work was undertaken before personal computers became
available. Again, one would expect that computers would reduce
the engineering effort. However, based on observing the extent and
detail of recent specications for large developments, the author is
of the opinion that computers have indeed facilitated, but have also
increased engineering man-hours.
HYDRO SPECIFICATIONS FOR DOCUMENTED AND
NON-DOCUMENTED PROJECTS
This raises the issue of the effort required to produce specications and
contract documents. A perfect illustration of the difference is shown in
Figure 2, where the large 3-ring binder contains the technical specica-
tions only for the civil works on a medium-sized documented 200MW
hydro project, and the small document on the left contains the civil
specications, the geological report, contractual conditions and the
environmental guidelines for the civil works contract at a small low-
head non-documented 600kW hydro development. The right-hand
document was produced by a large consultant in Vancouver, and the
other document by a small consultant in Halifax.
The author is of the opinion that it is very difcult for a large hydro
consultant to produce a short specication. Large consultants have
the ability to retain specialists in many disciplines, and consequently
have few ‘generalists’ able to work on a variety of structures and
equipment. For example, the mechanical department in a large con-
sultant’s ofce could have an engineer specializing in powerhouse
cranes, another in gantry and gate hoists, another in powerhouse
pumps, compressors and piping, and another in turbines. All would
be required to contribute towards an equipment specication, and
the result would be a document requiring considerable co-ordination
between the specialists. On the other hand, a small consultant would
have perhaps only one mechanical engineer, and this person would
be required to produce the specications for all the mechanical equip-
ment. The resulting document would be more concise than that pro-
duced by the large consultant.
DOCUMENTED PROJECT DESIGN AND MANAGEMENT
To illustrate the difference in project management between a docu-
mented and non-documented work, the data for the large document-
ed Jebba hydro project is presented. Jebba is located on the Niger
River in Nigeria, and includes a large shiplock. It was commissioned
in 1984. It has an installed capacity of 560MW at 27.6m head from
6 vertical axis Kaplan turbines. The completed project can be clearly
viewed on Google Earth at 9-08-20N, 4-47-27E.
Major project quantities at Jebba included:
r Earth excavation: 1,230,000m
3
.
r Rock excavation: 3,270,000m
3
.
r Earth ll: 2,120,000m
3
.
r Rock ll and rip-rap: 2,930,000m
3
.
r Spillway, lock, weir concrete: 241,000m
3
.
r Powerhouse concrete: 245,000m
3
.
Total cost of the project was over $1B in 1980 US$. Time
spent on engineering and project management was 386,000
1,000.000
100,000
10,000
Manhours
110100 1,000
MW/h 0.3
>
Non-documented projects
Documented projects
2
4
10
7
13
A
B
Figure 1: Design engineering man-hours