The project involved the design, supply, construction, installation, testing and commissioning of substations with additional miscellaneous works under Nepal Electricity Authority's Hetauda Bharatpur Bardaghat 220 kV Transmission Line Project. The works covered the construction and completion of 132 kV New Hetauda Substation, completion of 132/11 kV New Bharatpur Substation, expansion of the existing Hetauda Substation and remaining works associated with Bardaghat Substation.

The scope combined new equipment, completion of previously initiated works and integration with existing substation infrastructure. It included 132 kV switchgear systems, circuit breakers, disconnecting switches, instrument transformers, lightning arresters, control and relay panels, Substation Automation System, RTU and communication systems, XLPE power cables, battery systems, grounding, structural works and civil infrastructure. The project also required integration of substation data with the SIEMENS Spectrum Power 7 system at the Load Dispatch Center.

MSI executed the project within a multi site and multi system environment where electrical, civil, communication, automation and protection works had to be coordinated with both existing and newly installed infrastructure. The revised completion date was 30 September 2025, and Nepal Electricity Authority issued the completion documentation confirming completion of the identified facilities, subject to completion of outstanding items listed by the Employer.

Objectives

The project was designed to achieve the following goals:

To complete and expand the identified substations under the Hetauda Bharatpur Bardaghat 220 kV Transmission Line Project
To install and integrate high voltage switchgear, protection, control and communication systems required for substation operation
To complete electrical and civil works across Old Hetauda, New Hetauda, New Bharatpur and associated Bardaghat works
To integrate RTU, communication and substation data with the NEA Load Dispatch Center
To carry out testing and commissioning of the completed substation systems in accordance with the project requirements

Key Deliverables

The following systems, instruments, and tools were supplied, installed, and commissioned as part of the project:

High Voltage Switchgear and Protection Systems

145 kV SF6 circuit breakers, 145 kV disconnecting switches and associated 132 kV switchyard equipment
145 kV current transformers and capacitor voltage transformers for measurement and protection functions
120 kV and 60 kV lightning arresters with associated discharge counters and accessories
132 kV transmission line control and relay panels, busbar protection and transformer differential protection systems
Supporting protection relays, interlocking arrangements and associated switchgear components

Substation Automation and Communication

Augmentation and integration of existing 132 kV control and relay panels with the Substation Automation System
RTU systems for data transmission, remote operation and integration with existing communication infrastructure
Optical Line Terminal Equipment, multiplexers and teleprotection signalling equipment
Telephone and communication systems required for coordination between substations and the Load Dispatch Center
Integration of substation data with SIEMENS Spectrum Power 7 at the Load Dispatch Center

Power, Control and Auxiliary Systems

132 kV and 66 kV XLPE power cables with termination and interconnection arrangements
600 V power, lighting and control cables for electrical and communication works
110 V and 48 V VRLA battery systems with battery chargers and associated DC distribution equipment
Earthing, grounding and lightning shield systems for switchyard and substation equipment
Switchyard lighting, air conditioning and fire protection systems for supporting substation facilities

Civil and Structural Works

132 kV take off gantry, internal gantry structures, earth masts and equipment supporting structures
Foundations for switchgear equipment, cable head supports, towers and associated steel structures
Cable trenches, switchyard drainage, site grading, crushed rock surfacing and RCC road works
Dismantling and erection of 66 kV tower structures with associated cable interconnection works
Fencing, site development and supporting civil works required for completion of the substation facilities

Challenges

The project involved several technical, execution, and coordination challenges associated with implementing a substation augmentation through an integrated project scope:

Coordinating completion and expansion works across multiple substations with different levels of existing construction and equipment readiness
Integrating new electrical, protection, automation and communication systems with equipment and panels already available at site
Managing compatibility between existing RTU, communication and control infrastructure and newly installed systems
Executing civil, structural and electrical activities in the correct sequence to support equipment installation, cabling, testing and commissioning
Managing modifications to existing drawings, wiring, cable schedules and site arrangements where required to match actual field conditions

Solution

MSI adopted a structured execution and coordination approach to address the technical and implementation requirements of the project:

Reviewed existing site conditions and coordinated design and drawing modifications where necessary for actual implementation
Integrated new switchgear, protection, control and communication systems with existing substation equipment and infrastructure
Coordinated RTU, optical communication and automation interfaces to support data exchange with the Load Dispatch Center
Sequenced civil, structural, electrical and cabling activities to support systematic installation and commissioning across the substations
Carried out cleaning, rewiring, adaptation, installation, testing and commissioning of existing and new systems where included within the defined scope

Impact

The New Khimti Substation Augmentation project supports the implementation of planned power infrastructure works for Nepal Electricity Authority through an integrated approach to design, plant supply, construction/installation, testing, and commissioning.

Supported completion and expansion of 132 kV substation infrastructure across the identified project locations
Established integrated protection, control, automation and communication functions for coordinated substation operation
Improved connectivity between field level substation systems and the NEA Load Dispatch Center through RTU and communication integration
Strengthened electrical and civil infrastructure through new switchgear, cabling, grounding, structural and auxiliary systems
Achieved the revised completion milestone of 30 September 2025 for the identified facilities, with NEA issuing the completion documentation and identifying the remaining outstanding items for completion

Conclusion

The Hetauda Bharatpur Bardaghat substation project involved the design, supply, construction, installation, testing and commissioning of a broad range of electrical, automation, communication, structural and civil systems. The assignment combined completion of existing works with new installations and system integration across multiple substations within Nepal Electricity Authority's transmission infrastructure.

MSI's role required coordinated execution across engineering, equipment supply, civil works, high voltage installation, protection, automation, communication and commissioning activities. The project demonstrates MSI's capability to manage technically interconnected substation works where existing and new infrastructure must be integrated within a structured power transmission environment.