The Mount Coffee Hydropower Plant is located approximately 27 km northeast of Monrovia in Montserrado County, Liberia. It had been destroyed during the wars and is now to be rehabilitated, funded by the USA, Norway, Germany and Liberia.
The original four units are reha
bilitated using the same type of turbine–a Francis turbine. The modernized turbine units are reconnected to the grid with 22 megawatts each. In total these units will generate a higher output than the previous machines–the power output per turbine will be raised by about one third.
Other components of the rehabilitation include repair of the breached portion of the forebay dam, using laterite construction with an internal drain system); installation of a system of rock anchors to prohibit any additional movement; repair of generator floors and columns for support of the powerhouse crane and turbine/generator equipment during erection and future maintenance.
Overview
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Implementer |
LEC with Project Implementation Unit (PIU) coordinating implementation.
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Donors and budget |
The Government of Norway, European Investment Bank, and KfW (Germany) are each financing about 20% of the project, with the Millennium Challenge Corporation and Government of Liberia financing the remainder. In addition the Government of Norway committed to financing the operations of the Mt. Coffee Project Implementation Unit through December 31, 2017 |
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Start and end date |
2012 to 2018 |
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Aims/objectives |
• Repair of forebay dam, using laterite construction with an internal drain system • install a system of rock anchors in the block to prohibit any movement; • Repair of generator floors and columns for support of the powerhouse crane and turbine/generator equipment during erection and future maintenance.
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Geographic coverage |
Montserrado County |
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More information |
http://mtcoffeeliberia.com |
Technical details of original plant
The plant was a run-of-river scheme; a dam and a 10-bay spillway structure with radial gates were located in the original river channel. Inflows to the reservoir were diverted through a channel to the power house located at a bend in the river. This arrangement, combined with an excavated tailrace channel, allowed development of the maximum hydraulic head at the Mount Coffee site. The intake structure included provision for six units, although the powerhouse was only constructed for four units. Aside from partial excavation for the extension of the powerhouse substructure, none of the other civil works for units 5 and 6 was completed. The technical characteristics of the original four-unit hydropower plant were:
Gross Head 21.6 m
Unit Rated Flow 85 m3/s
Unit Rated Capacity Units 1 and 2 15 MW
Unit Rated Capacity Units 3 and 4 17 MW
Plant Rated Capacity 64 MW
Commissioning Year Units 1 and 2 1966
Commissioning Year Units 3 and 4 1973
The original four units were planned to be rehabilitated using the same type of turbine–a Francis turbine. The modernized turbine units will be reconnected to the grid with 22 megawatts each. In total these units will generate a much higher output than the previous machines–the power output per turbine will be raised by about one third.
During the period of civil unrest in Liberia, power generation at Mount Coffee had to be stopped and operation of the spillway gates was prevented by the hostilities. This resulted in surcharging of the reservoir until Forebay Dam No. 1 was breached in August 1990. Approximately 180 meters (m) of the 12.2 m high dam, which was founded on overburden, was eroded down to bedrock. With the shut-down of generation, the powerhouse was vandalized and virtually stripped of power and gate generation equipment as well as powerhouse cladding.
Ensuring standards and management of risks
Two Environmental and Social Impact Assessments (ESIAs) were prepared for the project including transmission lines resulting in permits from the Environmental Protection Agency (EPA).
An Environmental and Social Management Plan (ESMP) was prepared for both the Mt. Coffee plant and the transmission lines (the Bushrod-Mt. Coffee line, Paynesville-Mt. Coffee) and the reservoir area. A further addendum for the emergency spillway to be constructed on Buzzi Quarter Island downstream of the dam has been finalized in late 2016. To give space for the reservoir, the population of four villages was resettled into another village with better houses.
A Panel of Experts was set up to advise PIU and project funders. The Panel includes five independent experts of electromechanical engineering, hydrology, geology/geotechnical, dam design and safety, and environmental and social impact mitigation. The panel has conducted seven missions to Liberia.
The experts are tasked to ensure that
- the dam, spillway and associated hydropower generation components as designed and built, comply with international standards of excellence and safety for water resources infrastructure
- the project complies with local, regional, and international environmental and social guidelines.
Project Progress Timeline
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Time |
Activity |
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2008 |
In a feasibility study, Stanley Consultants identified major rehabilitation work, stating that most of the civil works, with rehabilitation, can be reused, the forebay dam breach was reparable. Reuse of the remaining structures was found to be much more cost effective than redevelopment of the site. |
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2012, February |
Engineering and preliminary site investigations required for preparation of tender documents for the Project were completed (partially revised in June 2012) with EU-Africa Infrastructure Trust Fund financing, implemented through the West African Power Pool (WAPP) Secretariat. |
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2012, May |
Project Implementation Unit at LEC started operations |
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2012, July |
Permit received for the Mt. Coffee transmission lines after an Environmental and Social Impact Assessment (ESIA) |
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2012, September |
Additional Environmental and Social Impact Assessment (ESIA) for the project was prepared and finalized |
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2012, December |
signing of a Financing Agreement between European Investment Bank (EIB) and the Government of Liberia. |
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2013, January |
the PIU completed pre-qualification of generating equipment suppliers |
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2013, May |
LEC signed a consulting contract with Norplan AS of Norway in joint venture with Fichtner GmbH of Germany, to serve as Owner’s Engineer |
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2013, June/July |
Government of Norway (GON) signed two Cooperation Agreements with the Government of Liberia committing grant financing to the Mt. Coffee Project Implementation Unit and the Hydropower Plant Rehabilitation Project, respectively. |
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2013, August |
The Environmental Protection Agency (EPA) permit was received for the project i(renewed in January 2016) |
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2013, September |
Grant agreement between KfW Development Bank (Government of Germany) and the Government of Liberia was signed, signalling full commitment of project funds. The Government of Liberia committed to financing a portion of the project. |
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2013, October |
The contract for generating equipment supply was signed by Voith Hydro GmbH & Co. KG, a German company, that had started with engineering of the turbines in August after signing an MOU. |
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2013, December |
LEC signed the advanced Enabling Works contract with Dawnus International Ltd. of the United Kingdom |
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2014, Jan- October |
Dawnus International Ltd did advanced Enabling Works. Construction began, included lifting of the gates |
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2014, June |
LEC signed a contract with Andritz Hydro GmbH of Austria to carry out the Rehabilitation, Design, Supply and lnstallation of Hydraulic Steelworks and Auxiliary Systems. An MOU signed on May 15 enabled Andritz to begin some of the early engineering works while contract negotiations were being finalized. |
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2014, September |
Ebola outbreak delays the project so that the goal of first power to Monrovia by December 15, 2015 cannot be achieved |
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2014, December |
LEC signed contract with National Contracting Co. Ltd. (NCC), a Saudi Arabian subsidiary company of the Rezayat Group, for supply and construction of the 66/132 kilovolt (kV) Substation at Mt. Coffee, and extension of the two existing substations in Paynesville and Bushrod to accommodate the power from Mt. Coffee. |
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2015, March |
Reservoir Resettlement Action Plans (RAP) were publicly disclosed |
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2015, April |
LEC signed a contract with a Liberia-based Joint Venture of Pan African Engineering Group, Sigma Group Inc., and Mamba Point Hotel for Contract 5, Camp Construction Works and Provision of Camp Services. PSM-JV’s scope of work includes preparing the site for the remobilization of project contractors starting in June 2015 and providing the necessary accommodation and working facilities and services for the rehabilitation works throughout the period of the project |
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2015, May |
LEC signed a contract with Eltel Networks of Sweden for the new construction of two double circuit 132kV transmission lines (24 km and 27 km) from Mt. Coffee to Monrovia (Bushrod and Paynesville substations, respectively), and dismantling of old existing towers and foundations. LEC signed a contract with Dawnus International Ltd for the Main Civil Works Contract 2A. This contract includes reconstruction and rehabilitation of the main dam, powerhouse, spillway, and intake; and other infrastructure and road works. With signing of this contract LEC completed the major construction procurement for the project |
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2015, August |
Resettlement Action Plans (RAP) for the Bushrod-Mt. Coffee line was completed |
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2016, January |
Resettlement Action Plans (RAP) for the Paynesville-Mt. Coffee line was completed |
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2016, July |
Construction and rehabilitation of the dam is completed |
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2016, August |
Hydro Operation International of Switzerland signed the Operation, Maintenance and Training (OMT) contract, for which tendering began in May 2014, was paused during the Ebola crisis, and resumed in June 2015. The HOI team mobilized to Monrovia in mid-September 2016. |
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2016, September |
Government of Norway signed a new bilateral agreement with the Government of Liberia related to the operational funding of the Project Implementation Unit (PIU) |
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2016, October |
Seven spillway gates were rehabilitated and strengthened |
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2016, December |
The first generating unit and associated equipment/systems, including the transmission line from Mt. Coffee to Bushrod, were commissioned. A Mount Coffee powered Christmas tree in Monrovia was switched on by the President of the Republic of Liberia, Ellen Johnson Sirleaf. |
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2017 |
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Project results and updates
Over the first two years of project implementation it became evident that the project budget was under-estimated, and cost increases also occurred due to the Ebola crisis and design optimization decisions agreed by the stakeholders. Additional financing was sought in 2015. As a result, the Millennium Challenge Compact was signed between the U.S. Government (through MCC) and the GOL on October 2, 2015, which includes grant funds for the Mt. Coffee Project as well as additional support for the environmental/social activities of LEC. Additional financing is also being provided by the original funders: a Supplemental Financing Agreement was signed between KfW and GOL on November 26, 2015, and an Addendum to the original Cooperation Agreement between the GON and GOL was signed on December 1, 2015. In order to ensure full availability of financing, the GOL also requested EIB to consider provision of additional loan funds.
Due to the one-year delay in the project caused by the Ebola crisis, and a need for additional financing due to currency devaluation, the Government of Norway signed a new bilateral agreement with the Government of Liberia related to the operational funding of the Project Implementation Unit (PIU) in September 2016.
2016
The project has completed
- Construction and rehabilitation of the dam
- Seven spillway gates were rehabilitated and strengthened by early October,
- the upstream cofferdams were removed, allowing for impoundment of the reservoir to 28.5 meters above sea level.
2017
As of the second quarter of calendar year 2017, the project
- has completed Phases 1 (Project Planning and Investigations) and Phase 2 (Detailed Design, Preparation of Tender Documents, Prequalification, Bidding, and Award of Contract),
- is in the advanced stages of Phase 3 (Construction, Commissioning and Taking Over), with most of the construction works wrapping up by July and full project completion to be achieved by end-December 2017.
Phase 4 (Defects Liability) Period begins at different stages for each contract and will stretch into 2019.
The official project website detailing the progress of the hydropower plant and more project pictures can be found at http://mtcoffeeliberia.com/.