IDI Hydropower Company Ltd.

( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes

In this infrastructure territory, all projects and its nature are different and we have an
unending flexibility for this entire project which pulls out our greatest effort on jobbing
methodology, however, the general methodology are as follows;

Planning Shop Drawings Material Preparation

Fabrication works at workshop

Test after Febrication - Cutting and Drilling Material Test before
works -Machining works Fabrication works
-Assembling works

Surface Treatment and Final check at workshop Transportation

Painting works

Final inspection, Testing Installation

Project Handover
and Commissioning

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 IDI Hydropower Company Ltd.( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes

1. Planning:
This is the initial step for handling project. This operation includes Site survey,
Reviewing of Designs and its analysis, Preparation of workshop drawing, engagement and
planning of manpower management, preparation of workshop and site working schedule and
instructions for all workers who are involved in the project.

2. Shop Drawings:

CAD Drawings

After receiving approved drawing and designs, we will draft shop drawing for easy and
accurate fabrication and installation process. The shop drawing is subjected to show the detail of
steel elements, joints, Welded joints, specific placement of nut blot connections, etc., where it
provides us low time consuming on construction. The final design and development of shop
drawing would carry out according to relevant codes and standards of Indian Standard and will
be submitted to the consultant for approval.

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 IDI Hydropower Company Ltd.( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes

3. Material Preparation:

We have 3000 Sq M of the raw material storage area. Therefore there is no

harassment to store and dump the raw materials and finished product for the project.
Some of items which may specially use for the project will send for procurement. After
receiving such raw material quantities from engineering department to Procurement
department, they took immediate action to fulfill the emptiness.

4. Material Test before Fabrication works:

Tensile Testing process of Material Result after test

at IOE, Pulchowk, lalitpur

As the client provide us their material composition certificate we will make a

cross check by testing its tensile strength at Test house of IOE pulchowk or as per
technical instruction mentioned in the bid document. The test certificate also will be
provided to the client.

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 IDI Hydropower Company Ltd.( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes

5. Fabrication works at workshop:

5.1 Cutting and Rolling

Hydraulic Shearing Machine Plasma Cutting Hydraulic four shaft Rolling Gantry Crane with Rolling
Machine Machine

For nonnegotiable project schedule, we are using fast cutting and Rolling
equipment and Machinery. As instructed design and drawings we work with Plasma
Cutter, Hydraulic Sharing Machine for cutting proposes. These are our hi-tech equipment
for best cutting edge which boosts 10 times faster than normal gas cutting. These are rare
technology in Nepali market. For Rolling, we are equipped with numeric controlled
Hydraulic four shaft roller machine which have pre bending system. All these machinery
provides our best in Time, Quality and competitive Price.

5.2 Machining works

Lath Machine Shaper Machine Milling Machine Completed Parts

For Gate’s Mechanical parts (ie. for roller and bronze machining), after cutting
process the work pieces would ready for machining work where cylindrical work would
carry out on Lath machine, surfacing work would carry out on Shaper machine and
cubical work would carry out in Milling machine.

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 IDI Hydropower Company Ltd.( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes
5.3 Assembling works

Arc Welding Assembled Product

After completing machined parts, it would assemble as per approved drawing

and specification .In the most common welding process of welding on steel, there are still
uses of electrical transformed heavy weight welding machine. In this fast changing
technology field, we only use Electronic portable MMA welding machine for ARC
welding with auto darkening welding helmets which insure quality, time and welder’s
health. The process will carry out with E7018 Electrode, certified 3G & 6G welders
according to relevant codes and standards of Indian Standard.

6. Test after Fabrication works:

DPT Welding Test MPI Welding Test Ultrasonic Test

Once all products fabricated well, we will test a welding joints, bolt joints. In
general NDT test includes DPT, MPI and Ultrasonic tests on welded joints are in our
practice.

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 IDI Hydropower Company Ltd.( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes

7 Surface treatment and Painting works

Cup wire Brush Sand Blasts Painting

We have a various kind of solution to remove rust. After all completed tests of fabricated
product we send the product to painting yard where, we generally use, Sand paper, Cup wire
brush, Flap wheels, Sand blast, Galvanization, GPRC Primer etc for surface treatment. For
painting we use red-oxide primer and paint, Automotive primer and paints, Epoxy primer and
paint, powder coating etc.

8 Final Check at workshop

Our QC engineer, technician, will check all small particles, corners, Dimensions, to insure
the quality, quantities etc., as per specification and drawing of the product, at workshop and send
it for transportation at site.

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 IDI Hydropower Company Ltd.( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes

9 Transportation:

Product loading at workshop Product transportation at site Product arrangement in site at require alignment

After completing all works at the workshop, including marking of all product and its
embedded parts with packing, it is time to transport the product to site.Loading will carry out by
electric hoist at the workshop and unloading at site will carry out by Crain and self made tripod
at required yard and alignment.

10. Installation:

Prepared Civil Foundation for saddle plate pipe placement at Site Installation

During civil foundation works, erection process starts with Saddle plate casting. After
transporting fabricated pipes near alignment, we will use winch machine and chain pulley blocks
to shift and lift the pipes in accurate level and alignment of casted saddle plate. We will carry out
this process with welding Bolting and painting. Using Hoist, Scaffolding, Tripod lifting tower,
Rope Winching machine, and other necessary equipment with sufficient manpower we, would
smoothly carry out the process in a triggered time frame.

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 IDI Hydropower Company Ltd.( 975 KW)
Methodology
For Headrace Pipes and Penstock Pipes

11. Final Inspection, Testing and commissioning:

In this last phase of the work, our QC engineer, and technician, will check all small
particles, corners, Levels, to insure the quality. Finally, Pipes are tested as water filling tests.
After completing all these testing process we will hand over the complete work to Project
Manager in behalf of Client. Headrace pipe water filling test,

12. Other

In this period of the project we also very awaken for the health and safety practice,
Insurance of all workers and project related activities, communication and co-ordination between
clients co-working partners and community, labor laws, site security, Waste management at site
etc.

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