Mangla Power Refurbishment

REFURBISHMENT & UP-GRADATION OF GENERATING UNITS 

Location: Mangla Dam / Power Station is located on River Jhelum at about 120 Km from Islamabad

Purpose: Mangla Dam is a multipurpose Project, primarily designed for Irrigation. The other by products are Power Generation, Fish Culture, Tourism and Navigation.

Construction: Mangla Power House was completed in four stages. The initial phase comprising of four units of 100 MW each was completed in 1967-69. The first extension of Unit No. 5&6 (2X100 MW) was completed in 1974 while second extension comprising Unit No 7&8 (2X100 MW) was completed in 1981. The project attained its maximum capacity of 1000 MW with the final extension of Unit No 9&10 (2X100 MW) in 1993-94.

Dam Raising: Mangla reservoir had initial gross capacity of 5.88 MAF, which reduced to 4.674 MAF (Year 2005) and was likely to reduce further with the passage of time due to sediment deposition. Keeping in view the capacity loss due to sedimentation and provision for raising in the original design and construction, Raising of Mangla Dam was started in 2004 and the Project was completed in 2009. The Dam height has been raised by 30 feet while maximum conservation level increased from 1202 feet to 1242 feet corresponding to additional water storage capacity of 2.88 MAF. There will be additional energy generation of 644 GWh due to availability of more water and rise in net head of machines.

Location:                    

 

Up-Gradation/ Refurbishment Scheme:         

There are four age groups of Mangla machines Units 1~4 (43 years), Units 5~6 (38 years), Units 7~8 (32 years) & Units 9~10 (18 years). The first 6 Units with age of 30~40 years have outlived their useful lives due to which more cost and time are required for maintenance of old equipment besides less operational reliability. Some of the important aspects are:

  • Efficiency of Turbines has reduced from their designed values.
  • The Hydraulic/Mechanical Equipment have become unreliable due to aging.
  • Generators winding of existing Units 1~4 & 7~8 is of Class-B insulation whereas the latest Class-F has higher tolerance of temperature.
  • Control & Protection Equipment of old units have become obsolete and their spare components are not available for being out of production.
  • Dam life has enhanced after completion of the Dam Raising Project but the old generating units will not have life compatibility with the Dam.

                                   

                                                                       

Submission of

Feasibility Study

Mangla Refurbishment Project JV (MRP JV) submitted Final Feasibility Report in December, 2011 and based on the results of extensive studies, recommended up-gradation from 1000 to 1310 MW at 0.8 Power Factor as it satisfies all the objectives of Scope of Work.
  • FIRR with / without CDM = 15.5/15.4%
  • EIRR with / without CDM = 17.5 /17.4%
 
  Project Financing

The Construction Cost under this option is estimated to be US$ 483 Million with the ten (10) years completion time. Implementation of Project is expected to commence in 2014.

   

US AID grant

(Project Implementation Letter signed on 06-03-2014)

USD 150 million (U 5-6 and Balance of Plant)
    Loan 1 (not yet identified) USD 102 million (U 1~4)
    Loan 2 (not yet identified) USD 111 milllion (U 7~10)
    Remaining WAPDA’s own resources
 

Progress          

Status

 

  1. PC-I has been approved by ECNEC on 31-12-2013 amounting to PKR 52,224 million.
  2. Invitation to Bid for Package I&VII (Unit 1~6) has been advertised in newspapers and on WAPDA & PPRA website. Bid opening date is 03-09-2015.
  3. Bids for Package II (Power House Cranes Refurbishment) were opened on 16.04.2015. Two (02) No. bidders submitted their bids which are under Evaluation.
  4. Bids for Package III (Main Power Transformers) were opened on 28.01.2015. Seven (07) No. bidders participated and Evaluation of their bids is under process by the Consultants.
  5. Proposal by M/s Hitachi Mitsubishi Hydro (OEM) for Package IV (Turbine Inlet Valves Refurbishment) is under Evaluation by the Consultants.