REHABILITATION UP-GRADATION & MODERNIZATION
OF WARSAK HYDROELECTRIC POWER STATION
Location River Kabul at about 30 Km in North West of Peshawar.
Purpose The Project was completed under Colombo Plan in two phases, financed by Canadian Govt. The 1st phase consisted of construction of Dam, Irrigation tunnels and installation of four power generating units, each of 40 MW capacity with 132KV transmission system and completed in 1960. Two additional generating units each of 41.48 MW Capacity were added in 1980-81 in the 2nd phase thus raising the total installed capacity to 242.96 MW (say 243 MW). 
Rehabilitation (Phase-I) 

 

 In the late Eighties, the Power generating capability of Warsak Power Station reduced to 150 MW due to the following two major problems.
  • Structural deformation of the Powerhouse.
  • Rapid erosion in the hydraulic equipment due to quantity and abrasive nature of the silt carried on the Kabul River.

In order to resolve of the above problems, the Governments of Pakistan and Canada planned a Rehabilitation Project to meet with the following objectives.

  • To restore full generating capacity of Warsak Power Station.
  • To prolong useful life of the Project by another 30 to 40 years by rectifying various problems of civil structures and electrical & mechanical equipment.
Project Features
 Approved PC-I Cost
Actual Cost Incurred
Commencement Date
Completion Date
Works Complted
Rs. 1325 Million (1992)
Rs. 1000 Million incl C$ 27.0 Million
31-12-1996
30-04-2006
 
Replacement/repair of Turbine components, intake gate repair, Draft tube repair, Rehabilitation of butterfly valves, Generator mechanical works, new trash racks & TRCM, Embedding of sill plates in concrete of spillway gates, Repair of Crane-rail, Filling of roof cracks in power house roof, Floor anchoring and Generator floor cutting etc. 
Rehabilitation/
Up-gradation scheme (Phase-II)		 The works carried out under Rehabilitation Project (Phase-I) were envisages about 20 years ago. Since then many more problems have cropped up due to further aging of Electro-mechanical equipment and old civil works. Wapda has planned to carryout second phase of Rehabilitation with the objective to ensure  that the six (6) generating units of Warsak Power Station, having spent life of 50 years (Units 1~4) and 30 years (Units 5~6) are made capable to operate efficiently & reliably at the total installed capacity of 243 MW for another 40~50. Following reasons have particularly necessitated taking up the proposed Project.
Feasibility Study As a first step it is intended to hire the services of Consultants for carrying out a Feasibility Study and preparation of Detail Design & Tender Documents and PC-I for Rehabilitation, Up-gradation and Modernization of Warsak. The basic objective is to determine the most viable options, technical as well as economical keeping in view of the aging effects of Electrical & Mechanical Equipment and Civil Structures and then prepare Detail Design & Tender documents and PC-I for implementation of the Project. 
Scope of Studies
  • Determination of viable solutions and the required works to raise the rated capacity of Units 1~4 from 40 MVA (Unity Power Factor) to 47 MVA (0.85 Power Factor) and also to ensure smooth and reliable operation of Units 5&6 at the rated output of 40 MW without any constraint, thus to achieve operation of Warsak Hydroelectric Power Station at 243 MW (against the existing 213 MW) meaning a capacity gain of 30 MW.
  • Study of the erosion of Turbine   runners due to sever effects of silt particles and suggest protective measures. 
  • Study for Rehabilitation, up-gradation and Modernization of the old equipment like Cooling Water System, Excitation System, Mechanical Governors, Protection and Instrumentation, control System, 400 V Station Service System, Trash Racks Cleaning Machine, Spillway Gates, Operating mechanism and to propose installation of the latest state of art Equipment.
  • Cost Estimation, Economical, Financial, Sensitivity Analysis etc of the recommended Solution(s) and preparation of Time schedule of the project.
  • Determine causes of defects in Civil Structures of Warsak and preparation of Tender Documents for implementation of the required remedial works.
  • Review of previous Sedimentation Management Studies of Warsak Dam and carry out further studies for suggesting the most viable and cost effective solution preparation of PC-I for complete Rehabilitation Works (Phase-II).
Expected Benefits The benefits will be worked out in the Feasibility Study, however according to the preliminary estimation following benefits are envisaged.
  • Capacity increase from 213 MW to 243 MW.
  • Annual energy increase of about 150 GWh.
Status

The process of hiring of Consultants was started in October 2009. After completion of all codal formalities, Consultancy Agreement between WAPDA and M/S RSWI (Canada)-DCE (Pakistan) JV was signed on September 13, 2011. The said Agreement became effective Dec. 12, 2011. The first site visit of Warsak Hydroelectric Power Station by the Consultants for Detailed Condition Assessment of E&M Equipment and Civil Works has been completed (from Dec. 17 tp Dec. 22, 2011). The preparation of Feasibility Study is in Progress. A second site visit of Warsak by the Consultant is expected in Feb, 2012.
Completion Time 12 Months from the date of effectiveness of the Agreement.
Estimated Cost & Schedule Accurate Cost/Schedule will be determined by the Consultants in Feasibility study by Sep, 2012 depending on the most viable option. Tentative cost of the Project including. Consultancy for Construction Supervision is US$ 305 Million Implementation of Project is expected to start and 2014 and completed.
  Updated as on 31-03-2012