Dasu Hydropower Project

PAKISTAN WATER AND POWER DEVELOPMENT AUTHORITY
DASU HYDROPOWER PROJECT
FEASIBILITY REPORT
VOLUME 8
ELECTRICAL & MECHANICAL

FACILITIES
February 2009
National Engineering Services Pakistan(Pvt) Limited (NESPAK)

Associated Consulting Engineers-ACE (Pvt) Limited
Montgomery Watson Harza Energy & Infrastructure Inc. USA
Colenco Power Engineering Limited, Switzerland
In Association with:
Binnie & Partners (Overseas) Limited
Dasu Hydropower Project - Feasibility Report
Volume 8
ELECTRICAL & MECHANICAL FACILITIES

TABLE OF CONTENTS
1.
GENERAL
1-1
1.1
1.2
1.3
1.3.1
1.3.2
Introduction
Guide to the Reader
Unit Rating and Power Plant Configuration
General Considerations
Parameters
1-1
1-1
1-2
1-2
1-3
2.
POWERHOUSE MECHANICAL EQUIPMENT AND LAYOUT
2-1
2.1
Turbines
2-1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.1.7
2.1.8
2.1.9
2.1.10
2.1.11
2.1.12
General
Turbine Type
Rated Flow
Heads
Reference Standards
Principal Design Parameters
Turbine Rated Capacity
Synchronous and Runaway Speeds
Runner Design
Turbine Setting
Spiral Casing
Draft Tube Design
2-1
2-1
2-1
2-1
2-2
2-2
2-2
2-2
2-3
2-3
2-4
2-4
2.2
Powerhouse Layout
2-5
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
General
Layout of Units
Unloading / Erection Bays
Regulating Mechanism
Thrust Bearing Arrangement
2-5
2-5
2-5
2-6
2-6
2.3
Turbine Governors
2-6
2.3.1
2.3.2
General
Governor Equipment
2-6
2-7
2.4.
2.5
Turbine Inlet Valves

Cranes and Hoists
2-10
2-10
2.5.1
2.5.2
General
Design Criteria
2-10
2-11
2.6
Miscellaneous Mechanical Auxiliaries
2-11
2.6.1
General
2-11
Volume 8
2.6.2
2.6.3
2.6.4
2.6.5
2.6.6
2.6.7
2.6.8
2.6.9
2.6.10
Drainage and Dewatering Systems

Cooling Water Systems
Raw Water Supply System
Compressed Air Systems
Passengers and Goods Elevators
Oil Handling Facilities
Heating, Ventilating and Air-Conditioning Systems
Fire Protection Systems
Workshops
2-12
2-13
2-14
2-14
2-15
2-15
2-15
2-19
2-19
3.
GENERATORS AND EXCITATION SYSTEM
3-1
3.1
3.2
Design Considerations
Ratings
3-1
3-2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
Voltage.
Power Factor.
Short Circuit Ratio.
Synchronous and Runaway Speed.
Inertia.
3-3
3-3
3-3
3-4
3-4
3.3
3.4
3.5
Generator Connections and Neutral Earthlings

Excitation System
Auxiliary Switchgear
3-5
3-6
3-7
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8
3.5.9
3.5.10
3.5.11
Main Auxiliary Boards (11 kV)

Unit Auxiliary Supply Boards UASB (400 V).
Unit Auxiliary Boards UAB (400 V)
Common Services Boards CSB (400 V).
Essential Services Boards ESB (400 V)
Drainage & Dewatering Distribution Boards DWDB (400 V)
Substation Auxiliary Board SAB (400 V)
Lighting Distribution Board LDB (400 V)
Headworks Auxiliary Board HAB (11 kV)
Headworks Supply Board (0.4 kV)
Protection & Metering
3-8
3-8
3-8
3-9
3-9
3-9
3-9
3-9
3-10
3-10
3-10
3.6
Auxiliary Transformers
3-11
3.6.1
3.6.2
3.6.3
Main Auxiliary Transformers

Auxiliary Power Transformers
Rated Lighting Impulse Withstand Voltages
3-11
3-12
3-12
3.7
Miscellaneous Electrical Auxiliaries
3-13
3.7.1
3.7.2
3.7.3
3.7.4
3.7.5
General
Station Auxiliary Power Supply System
Standby Power Supply System
DC Supplies
Cables & Earthlings
3-13
3-13
3-17
3-18
3-19
ii
Volume 8
3.8
Control & Monitoring
3-20
3.8.1
3.8.2
3.8.3
3.8.4
3.8.5
3.8.6
General Control Philosophy

Generating Unit Control
Auxiliary Power
765 kV Substation
Control from NPCC (SCADA)
Gates
3-20
3-22
3-23
3-24
3-24
3-25
4.
POWER TRANSFORMERS AND EHV SUBSTATIONS
4-1
4.1
Power Transformers and Shunt Reactors
4-1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
General
Generator Transformers
Power Transformers for 765kV AIS Substations
765/3 kV Shunt Reactors for 765kV AIS Substations
Bushings
Spare Transformers/Shunt Reactors and Transfer Rail Tracks
Cooling Systems
Nitrogen Injection Explosion Prevention Fire Protection System
Oil Containment
4-1
4-1
4-2
4-3
4-4
4-4
4-5
4-5
4-5
4.2
EHV Substations
4-5
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
4.2.9
4.2.10
4.2.11
4.2.12
Transmission Voltage
Switching Scheme
Technology Options for the Substations at Dasu
Capacity of Substations at Dasu
Proposed solution
765kV Underground Substation
765kV Surface Substation (Transmission Substation)
Gas Insulated Bus (GIB) Risers
Extension of 765/500kV AIS Substation at Gujar Khan
New 765/220kV AIS Substation at Gatti
Design Parameters of GIS & AIS Substations
Key Diagrams
4-5
4-5
4-6
4-7
4-7
4-8
4-9
4-9
4-9
4-10
4-10
4-10
5.
Power Transmission System
5-1
5.1
5.2
General
Study Assumptions and Technical Criteria
5-1
5-1
5.2.1
5.2.2
Assumptions
Technical Criteria
5-1
5-1
5.3
5.4
5.5
5.6
Integrated Interconnection Studies by NTDC 2003-05

Basis for Updating WAPDA Studies
Feasibility Level Design Parameters
EHV Transmission Technology Options
5-2
5-3
5-3
5-4
iii
Volume 8
5.6.1
5.6.2
5.6.3
5.6.4
General
EHV Transmission Technologies.
Loadability Characteristics of EHV Transmission Lines
Number of Circuits.
5-4
5-4
5-6
5-8
5.7
Existing Generation System of WAPDA
5-9
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
Existing Transmission System of WAPDA

Load Forecast
Generation Expansion Plan of NTDC
Transmission Expansion Plan of NTDC
Transmission Line Route Corridors
Transmission Voltage Level
Interconnection Point and Intermediate Switching Station
Interconnection Alternatives
Study of the Alternatives
Conceptual Configuration of 765kV Substations
Line Parameters for 765 kV Transmission Lines
5-11
5-12
5-15
5-15
5-15
5-17
5-17
5-18
5-19
5-21
5-22
5.18.1
5.18.2
5.18.3
5.18.4
5.18.5
5.18.6
5.18.7
5.18.8
Conductors
Shield Wires Shield Wire / OPGW
Towers
Insulators
Hardware & Accessories
Dampers
Grounding
Tower Foundations
5-22
5-22
5-23
5-23
5-24
5-24
5-24
5-25
5.19
Cost Estimate of Transmission Alternatives
5-25
5.19.1 Quantities of Line Materials
5-25
5.20
5-26
Unit Cost for Line Materials
5.20.1 Towers
5.20.2 Conductor
5.20.3 Shield Wire
5.20.4 Shield Wire Fittings
5.20.5 OPGW
5.20.6 OPGW Fittings
5.20.7 Insulators
5.20.8 Conductor Accessories
5.20.9 Spacer Dampers
5.20.10Hardware
5.20.11Construction
5-27
5-27
5-27
5-27
5-27
5-28
5-28
5-28
5-28
5-28
5-28
5.21
5.22
5-29
5-29
Cost Comparison of Various Transmission Alternatives

Findings
iv
Volume 8
6.
HYDRAULIC STEEL STRUCTURES (GATE EQUIPMENT)
6-1
6.1
Spillway Gate Equipment
6-1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
Functional Requirements and General Arrangement

Radial Gates
Stoplogs
Lifting Beam
Gantry Crane
Main Parameters
6-1
6-2
6-3
6-4
6-4
6-4
6.2
Low Level Outlet Conduits Gate Equipment
6-5
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6

Regulating Gate (Submerged Radial Type)
Guard Gate (Bonneted Fixed Wheel Type)
Service Gates (Bonneted Fixed Wheel Type)
Overhead Travelling Cranes
Main Parameters
6-5
6-6
6-7
6-8
6-10
6-10
6.3
Power Intakes Equipment
6-11
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7
6.3.8

Guard Gates
Service Gates
Power Intake Shaft
Trashracks
Trashrack Cleaning Machine
Gantry Crane
Main Parameters
6-11
6-12
6-13
6-13
6-14
6-14
6-14
6-15
6.4
Draft Tube Gate Equipment
6-16
6.4.1
6.4.2
6.4.3
6.4.4

Draft Tube Gates
Overhead Traveling Crane
Main Parameters
6-16
6-16
6-17
6-17
6.5
Tailrace Tunnels Gate Equipment
6-18
6.5.1
6.5.2
6.5.3
6.5.4

Stoplogs
Cranes and Lifting Beams
Main Parameters
6-18
6-18
6-18
6-19
6.6
Diversion Tunnels Gate Equipment
6-19
6.6.1
6.6.2
6.6.3
6.6.4

Stoplogs
Lifting Beam
Main Parameters
6-19
6-19
6-20
6-20
Volume 8
7.
SCADA AND TELECOM SYSTEM
7-1
7.1
7.2
7.3
Functional Overview
Station Instrumentation and Control (I&C) System
Interface with Existing NTDC SCADA System
7-1
7-1
7-1
7.3.1
SCADA Facilities for Tele-Control by NPCC
7-2
7.4
Telecommunication System
7-3
7.4.1
7.4.2
7.4.3
7.4.4
Optical and Conventional Telecommunication Media

PAX/PABX Equipment
Teleprotection
Public Address System
7-4
7-4
7-4
7-5
7.5
7.6
7.7
Un-Interruptible Power Supplies (UPS)

Time Synchronization
Cost estimate
7-5
7-5
7-5
8.
COST ESTIMATES
8-1
8.1
8.2
8.3
Basis of Cost Estimate

Analysis of Adopted Unit Prices
Turbines, Auxiliary Equipment and Associated Mechanical Equipment
8-1
8-1
8-1
8.3.1
8.3.2
8.3.3
Turbines and Auxiliary Equipment

Powerhouse Mechanical Equipment
Estimated Cost
8-1
8-1
8-2
8.4
8.5
Generators, Exciters, Powerhouse Auxiliary and Electrical Equipment

Power Transmission Facilities
8-2
8-2
8.5.1
8.5.2
8.5.3
8.5.4
8.5.5
8.5.6
Substation - General
Dasu 765 KV Underground Substation (GIS)
Dasu 765 kV Surface Substation (AIS)
Gujar Khan 765/500 kV Surface Substation.(AIS)
Gatti 765 kV Surface Substation.(AIS)
Summary of Costs
8-2
8-3
8-3
8-3
8-4
8-4
8.6
8.7
8.8
Gates, Trashracks, Stop-logs and Handling Equipment

Control, Monitoring, SCADA and Telecom
Transmission Lines
8-4
8-4
8-4
8.8.1
8.8.2
8.8.3
8.8.4
8.8.5
8.8.6
8.8.7
8.8.8
General
Quantities of Line Materials
Towers
Conductors
Shield wire and Fittings
OPGW and Fittings
Insulators
8-4
8-5
8-5
8-6
8-6
8-6
8-7
8-7
vi
Volume 8
8.8.9
8.8.10
8.8.11
8.8.12
Conductor Accessories
Spacer Dampers
Hardware
Construction
8-7
8-7
8-7
8-7
8.9
Summary of Total Cost of Electrical and Mechanical Equipment Including

Transmission Lines
8-8
vii
1.
1.1
Volume 8
GENERAL
Introduction
This Volume of the Feasibility Report deals with the electrical and mechanical aspects of
the Project. The feasibility level design aspects of the project including plant size, power
plant equipment i.e. turbines, generators, gates equipments, transformers, cranes &
hoists, generator circuit breakers, EHV, MV and LV switchgear, 765 kV gas insulated
bus (GIB) from underground cavern to surface, power auxiliaries, batteries, control and
monitoring, SCADA and telecom system, have been developed and presented. The
layout of underground powerhouse facilities has been developed and equipment
arrangement including transformers and GIS galleries have been planned and laid out.
Keeping in view the existing and future expansion of generation and transmission
facilities, power transmission arrangements including transmission voltage, number of
lines, transmission line route, identification and evaluation of possible alternatives for
feasibility level design have been described.
Gate equipment along with associated mechanical facilities for the diversion tunnels,
spillway, low level outlets, power intakes, draft tubes, tailrace surge chamber, and
tailrace outlet gates have been developed and described in this Volume.
Cost estimates for electrical & mechanical equipment also form part of this Volume.
1.2
Guide to the Reader
The Electrical & Mechanical studies have been presented in this Volume of the
Feasibility Report in the succeeding sections as follows:
Section 1 provides introduction to the project and guide to the reader.
Section 2 outlines the design considerations and description of main parameters and
requirements for turbines and power plant auxiliary mechanical equipments and
description of cranes and hoists.
Section 3 covers generators, electrical auxiliaries. Interconnection of main electrical
equipment and auxiliaries, controls, protection and metering
Section 4 presents details about generator transformers, 765 kV substations, associated
switchgear and sketches of transmission substation at possible load centres i.e. Gujar
Khan, and Gatti.
Section 5 covers studies and design aspects for power transmission system. Technoeconomic comparison is also presented leading to recommendation of most suitable
transmission system for the project.
Section 6 presents types, sizes and design aspects of various gate equipments.
Drawings/sketches of the gates involved are also included.
Sections 7 deal with Control and Monitoring and SCADA and Telecom Systems.
Section 8 outlines cost estimates of mechanical and electrical equipment/facilities
including transmission system.
1-1
Volume 8
1.3
Unit Rating and Power Plant Configuration
1.3.1
General Considerations
As detailed in Volume 3 (Reservoir Simulation & Power Generation Studies) various

exercises were carried out to work out optimized capacity of Power plant. For the
selected option, with Dam at axis-5 and long tail race tunnel, installed capacity of 4320
MW was worked out.
The narrow width of the river associated with the steep valley slopes at the Dasu project
site were the main deriving forces and making a choice of the underground power
station against the surface option.
Studies were conducted to work out unit rating, dimensions of Electrical / Mechanical
equipment, Powerhouse and 765 kV Substations. It was kept in view that higher unit
rating and lesser number of units will result in capital cost saving. The influencing factors
in selecting the unit rating are feasibility of transportation on KKH, manufacturing
possibility, geotechnical considerations for cavern width of powerhouse, generator
transformer gallery and substation gallery. Implications of these influencing factors are
elaborated in the following paragraphs.
a.
Transportation on Karakorum Highway (KKH)
The portion of KKH between Thakot and the Project site, in its present state is critical
from the point of view of transportation. This portion comprises overhangs, narrow turns,
culverts and bridges.
To facilitate equipment and construction materials transportation for Diamer Basha Dam
Project, which is located 75 km upstream of Dasu, the Government has taken up an upgradation of the KKH up to Basha.
The Karakorum Highway (KKH) is being upgraded to a 2- lane paved width of 7.3m and
a minimum of 0.5 to 1.0m wide shoulder in hilly to mountainous terrain. Turning radii with
a minimum of 25m are being provided which long trailers transporting heavy equipment
can negotiate. To facilitate transportation of heavy equipment, large width lay bys at
regular intervals have also been considered for traffic management. The overhangs
causing vertical hindrance in the passing of heavy equipment have been duly considered
for improvement to provide the required clearance. A new bridge over river Indus is
under construction at Thakot crossing. Refurbishment of other bridges might be
necessary to cater for shipping weight of heavy equipment. Overall the, the upgraded
KKH will be capable of equipment transportation for Dasu equipment with the following
approximate dimensions.
Turbine Runner
Diameter (max)
Weight
6.3 meters
97 ton
9.5m x 8.0m x 8.0m

7.0m x 4.0m x 4.8m
230 ton
160 ton
Generator Transformer
Overall Dimensions (LxWxH)
Shipping Dimensions (LxWxH)
Overall Weight
Shipping Weight
1-2
b.
Volume 8
Manufacturing
Generators, power transformers and turbines for large machines of 500 MW and above
are being manufactured and already exist at many hydropower plants. The critical
component in this respect is the large sized inlet valve of diameter more than 6 meter.
Initially project layouts were developed with four headrace tunnels and each tunnel
bifurcating near to the power house to feed two generating units with inlet valve
arrangement. At that initial stage it was thought that provision of four headrace tunnels
with inlet valves might be a lesser cost option compared to the provision of eight
headrace tunnels. But when design parameters of these inlet valves worked out and
manufacturing possibilities of these inlet valves were explored, the response was not
encouraging.
Butter fly type of inlet valves would not be able to close under extreme conditions which
can arise at Dasu project. Spherical types of inlet valves are structurally capable of
operation, but these valves of approximately 6.5 m diameter have never been produced
before. Even, if any manufacturer expresses willingness over its manufacturing, the
weight of such inlet valve will be in the range of 400 450 tons and cost of one inlet
valve will be approximately 6,000,000 Euros and thus for the eight valves to be installed,
the total cost would be 48,000,000 Euros, which is very high for the said facility.
Moreover, these inlet valves can not be accommodated in power house cavern,
therefore a separate cavern will have to be excavated of cross section 11m 22 m (W x
H) and the length of this cavern will be almost equal to that of power house cavern,
requiring a separate crane and other auxiliary equipments for the handling of these inlet
valves plus an access tunnel. In view of these requirements, provision of eight headrace
tunnels, one for each turbine, being more economic option has been adopted, which
eliminates the need of the extraordinarily large-sized inlet valves.
c.
Geotechnical Considerations
The rock mass characteristics in the project area greatly influence the orientation and
width of the power station and the other caverns. At initial stage of the studies, the
powerhouse plans were developed with 30m width of the cavern. But from the
geotechnical studies of the project site, it was assessed that a cavern width of upto
about 26m would be a cost effective choice from consideration of the rock support
measures for the caverns.
Thus the cavern width of both powerhouse and transformer gallery have been restricted
to 26 meter by placing some of auxiliary equipment in between the generating units
and the underground Isolated Phase Busduct (IPB).
1.3.2
Parameters
To arrive at the optimum unit rating and parameters of the power plant detailed studies
for the various possible alternatives were carried out, which are included in Volume 3 of
the Feasibility Report. From these studies it was concluded that installation of generating
units of capacity 540 MW corresponding to 150 rpm synchronous speed would be the
optimum choice with an underground power station having cavern width of
approximately 26 meters. The project layout plan is shown in Figure 1.1 and the key
characteristics of the unit selected for Dasu Hydropower Project, are given below.
Installed capacity
No of Generating Units
Unit Rated Capacity
=
=
=
1-3
4320 MW
8
540 MW (Generator Output)
Volume 8

Plant Overall Efficiency
Transformer Capacity
Generation Voltage
Power Factor
Synchronous Speed
Powerhouse Cavern
Generator Transformers and
Substation Cavern
1-4
=
=
=
=
=
=
=
549 MW
91.64%(0.935(T)x0.985(G)x0.995(Tf)
570 MVA (3 x 190)
20 kV
0.95
150 rpm
340m 26m 68m (L x W x H)
=
=
340m 26m 45m (L x W x H)

765 kV (AC)
Dasu Hydropower Project Feasibility Report
2.
2.1
Turbines
2.1.1
General
Volume 8
POWERHOUSE MECHANICAL EQUIPMENT AND LAYOUT
For any hydro-electric power plant, efficient utilization of the available water is of vital
importance for optimum power generation. The type of turbine, its rating, the design
head and the rotational speed have to be selected after study of the available heads and
discharges at the selected site. For optimizing the unit size and rating, factors such as
transport limitations, energy benefits and equipment costs have been taken into account.
The following paragraphs deal with these and other related features of the turbine such
as its setting, the runner design, design criteria, the unit auxiliaries, etc.
2.1.2
Turbine Type
For the 135m to 196m range of operating net head at Dasu Hydropower Project, Francis
turbines are most suitable. The net heads and available flows result in a physically large
machine with a runner diameter in the range of 5.5 to 6.0m.
2.1.3
Rated Flow
Studies of power and energy production for each 10-day period for dry, wet and average
hydrological years have shown that the 2600 cumecs design flow will be optimum for
power generation through eight turbines, as described in Reservoir Simulation and
Power Generation studies contained in Volume 3 of this Feasibility Report. Rated flow for
each turbine will therefore be 325 cumecs.
2.1.4
Heads
Design of the turbines will correspond to upper reservoir water elevation and tail water
elevation for operation of eight units. Such chosen rated head has to determine the
position of turbine and optimum efficiency within whole range of turbine heads and
changing of loads. Rated head of turbine, as merits for turbine and generator rating is
chosen to make optimum rating of generator within the whole range of turbines
operations.
As can be seen from Figure 2.1, the reservoir remains at the maximum conservation
level of 950 meters for about 73 % of the time and at or above 925 meters about 95% of
the time. Normal tail water levels corresponding to flows through the power house only
are given below:
One unit operating
All eight (8) units operating
=
=
El. 749.2m
El. 755.4m
With reference to reservoir levels at EL 950m and EL 925m, the maximum and minimum
net heads, after accounting for water ways losses are as under:
Maximum net head (one unit operating) (950-749.2-5)
Minimum net head (eight units operating) (925-755.4-9.8)
Design rated head
((195.8-159.8) x 2/3 + 159.8)
=
=
=
195.8m
159.8m
183.8m
Corresponding to minimum reservoir level EL 900m, the minimum net head works out to
135m (900-755.4-9.8).
2-1
2.1.5
Volume 8
Reference Standards
For determining the preliminary dimensions and weights etc. of the turbine parts and
powerhouse dimensions, the following references are used:
i.
IEC 60199
ii.
Selection of Hydraulic Reaction Turbines (USBR Engineering Monograph No. 20)
iii.
Hydropower Engineering by C.C. Warnick.
iv.
Civil Engineering Guidelines for Planning and Designing Hydroelectric
Developments (ASCE / EPRI Guides)
v.
Water Hammer Analysis by John Parmakian
vi.
Applied Hydraulic Transient
2.1.6
Principal Design Parameters
The turbine runner size has been selected with due regard to its transportation on the
Karakorum Highway (KKH), and installation in the powerhouse cavern of 26m width.
Principal design parameters selected for the recommended turbine are given in Table
2.1. The selection was made through analysis of a number of turbine solutions obtained
from the reference standards.
The turbine parameters will be reviewed during the design stage on the basis of upto
date and more specific information obtained from the turbine manufacturers.
2.1.7
For determining the appropriate unit capacity, both technical and economic aspects have
been investigated. The factors which have been considered in the comparison comprise
equipment dimensions, transport limitations, power and energy benefits, manufacturing
experience, power system regulation, and cost estimates. These factors, especially the
transport limitations and the limited worldwide experience of the manufactures of larger
turbine runners, lead to the maximum runner diameter around 5.5m.
The reservoir simulation and power generation studied (Volume 3 of Feasibility Report)
indicated optimum capacity of 4320MW for the power plant. As a result, the unit rating for
8 units will be 540MW, and corresponding turbine output will be about 549MW.
Estimated turbine operation diagram is enclosed (Figure 2.2). Location of corresponding
heads, discharge and powers, within whole heads and discharges range of turbine(s)
can be recognized.
2.1.8
Synchronous and Runaway Speeds
The project will be able to supply a significant part of the demand on the WAPDA
network. Thus it must be dependable and trouble-free, and the turbines will be required
to have a long life. Therefore, special consideration has been given to the specific speed
of the turbines.
As a measure of the conservativeness of the turbine design and to compare it with
turbines at other projects, standard empirical formulae performance curves, the specific
speed for Dasu Turbine rated power and rated design head will be 164 (m kW units).
Synchronous speed =
Specific speed X (Design head) 1.25

----------------------------------------------- = 150 rpm
(Turbine power) 0.5
2-2
Volume 8
For this specific speed and maximum turbine output of 549MW the optimum rotating
speed is 150rpm.
For the design of the generators, it is necessary to determine the runaway speed of the
turbines; that is the speed the machine will reach if the generator is disconnected from
the system with the turbine operating at full gate opening and maximum head and the
governor failing to respond. The runaway speed is related to the turbine specific speed
and for Francis-type turbines is generally close to 200% of the synchronous speed.
Runaway speed at design head and full gate opening, based upon a study of existing
turbines, is given as 262 rpm
At maximum head, the runaway speed (nmax) will be 272 rpm.
2.1.9
Runner Design
The detailed design of the runner will be worked out by the turbine manufacturer to meet
the specifications and performance guarantees. However, it is necessary to establish, for
the station layout purposes, the leading dimensions of the turbine. The major turbine
dimensions are related to the runner discharge diameter, D3.
The prototype runner size is determined by the manufacturer in accordance with model
tests results and its design criteria. Turbines by different manufacturers vary slightly in
the runner discharge diameter for a given power and speed. The approximate discharge
diameter (D3) of the turbine is given in the range of 5.5m to 6.0m, according to different
empirical formulae and experience curves presented in various references. The selected
runner for Dasu Hydropower feasibility study is of discharge diameter 5.5m.
2.1.10 Turbine Setting
Turbine must be set at a level which avoids cavitation arising from insufficient
submergence.
The turbine setting is determined as follows from the referenced Standards.
Z
Hs
=
=
Hs + b + HL tw
(Hb HV) Hcr
Z
Hs
b
=
=
=
Hb
Hcr
=
=
=
=
=
Total draft head (m)

Static draft head (m)
Vertical distance from centerline of distributor to minimum runner
diameter
Barometric pressure of water at station site (m)
Maximum head at which turbine operates with full gate for
maximum generator output
Cavitation coefficient
Water vapour pressure (m)
Tail water tunnel loss (1.77m) (one unit operating)
Where:
Hv
HLtw
For the Dasu turbines, b will be 1.22m. (Hb-Hv) for the station at El. 740.5m is 9.23m of
water.
The cavitations coefficient , is normally quoted by the turbine manufacturer after
undertaking a series of cavitations model tests. However, for the specific speed of 164
2-3
Volume 8
mkW units, using USBR empirical formulae and curves the typical figure of = 0.1104
for operating conditions:
Hs
=
9.23 (0.1104 x 183.8)
=
-11.06m
Therefore,
z
=
-11.06 + 1.22 + 1.77= -8.07m
To allow for variations in the station barometric pressure, it is usual to set the machine
approximately 0.3m lower than the theoretical suction head, that is about 8.37m (say
-8.5m) below minimum tailwater level. For the minimum tailwater level of El. 749.20m at
Dasu with one unit operating, the distributor centerline has been set at El. 740.50m for
feasibility study.
2.1.11 Spiral Casing
Based upon a runner discharge diameter of 5.5m, the spiral casing inlet diameter will be
about 6.75m. The dimensions will be reviewed and designed in consultation with the
selected manufacturer during design stage. The spiral casing will be constructed of steel
plate formed in the manufacturers works and shipped in pieces for site assembly. The
spiral casing will be designed to withstand all internal hydraulic loads, including transient
pressure rises, without any assistance from the surrounding concrete.
The design of the spiral casing foundation block will be based upon embedment of the
spiral being undertaken whilst the spiral is full of water and pressurized to 50% of the
design hydraulic pressure.
2.1.12 Draft Tube Design
The trend in recent years to increase runner specific speeds results in greater energy
remaining in the water at the draft tube exit unless the draft tube is lengthened in
proportion. Without this modification, the value of the energy wasted at the draft tube
exits can exceed the savings in the equipment and powerhouse costs made possible by
high specific speeds.
The draft tube at the Dasu powerhouse will be designed to optimize the energy recovery
in the draft tube whilst maintaining unit stability.
In an underground hydroelectric power plant a greater height of draft tube does not result
in conceivable rise in cost that is why for Dasu the draft tube of greater depth has been
opted and measures are taken to limit the width so as to make it possible to leave the
pillars of rock between adjacent draft tubes. This is attained at the expense of the height
of the conical part and rather long diffuser. The elbow is made with a constant section
and it has the form of torus. Within the limits of the diffuser, its sections change from
round to oval with the same cone angle (with round dimension constant in plane). The
end of the draft tube has a rectangular section. This type of draft tube reduces the
excavation and filling works. The profile of the draft tube and the distance from runner
discharge to the lowest point of the elbow will be optimized so as to recover the
maximum runner discharge velocity head and thereby improve the turbine efficiency.
At Dasu the lowest point of the draft tubes will be about 23.5m below the distributor
centerline, the draft tubes enter the surge chamber 66.0m downstream of the unit
centerline.
2-4
2.2
Powerhouse Layout
2.2.1
General
Volume 8
The Dasu powerhouse would consist of two underground caverns: the main powerhouse
cavern and the generator transformer cavern. The transformer cavern is located about
25m downstream of powerhouse, but at higher elevation than the powerhouse and the
tailrace tunnels surge chamber. Access to powerhouse cavern is at elevation 758.00m
and to the transformer gallery at El. 831.00m. Access to both the caverns is from two
sides and is obtained from the main access tunnels. Salient feature of the powerhouse
layout are given below;
-
2.2.2
Two unloading / erection bays are proposed at El. 758m with the access tunnels
from the both sides of the powerhouse.
The center to center distance between two units has been kept as 32.0m. This
has been done considering the requirement for installation of generator
transformers in a gallery parallel to the longitudinal axis of the powerhouse but at
higher elevation.
The main mechanical - electrical equipment and respective auxiliaries have been
located on the turbine or generator floors on the space available between the two
units at El. 745.50m and 751.00m respectively, spiral casing access galleries and
in erection bay floors.
Layout of Units
The turbines for the project will operate at relatively high speed (150 rpm) and
consequently have smaller physical dimensions. They are well within the range of
existing units at other large installations and are well within the manufacturing capability
of all the major turbine manufacturers. The unit spacing and width of the power plant is
governed by the overall dimensions of the turbine spiral casing and generator. The width
of spiral casing associated with a runner discharge diameter of 5.5m requires a minimum
distance of 25.0m between the centerlines of units, taking into account the minimum
permissible thickness of concrete cover on either side of the unit block construction joint,
but due to unit transformers located in parallel gallery and requiring space of 32.0m for
transformers of each unit, the distance between the centerline of units will be 32.0m.
The proposed width of the machine hall is based on the size of generator housing and
the clearance required for handling the spiral inlet test head. The expected overall
diameter of the generator housing is of the order of 20m. Allowing about 5.0m clearance
at the centerline of the generator on the downstream of the generator housing for the
movement of personnel and light material plus downstream wall of 1 meter thickness,
and a clearance between the spiral inlet and the upstream wall for handling the test head
during the erection of the spiral casing, the overall width of the cavern hall will be 26.0m.
2.2.3
Unloading / Erection Bays
Two unloading / erection bays 84m long (40m + 44m) are planned at the access level
(El. 758.00m). A hatch 4m x 4m (to be reviewed at design stage) is proposed in each
unloading / erection bay floor to lower the equipment onto the lower floors at El.
751.50m, El. 745.00m, El. 738.0m and El. 733.0m.
The erection bays will allow simultaneous operation on large assemblies and subassemblies of electro-mechanical plant. For example, assembly of two rotors, and work
on one runner, one thrust bearing bracket and one turbine shaft can be handled in the
area at the same time.
2-5
Volume 8
Reference Figures
The location of powerhouse, water ways longitudinal and cross sections of
powerhouse transformer gallery / 765 kV GIS substation, and tailrace tunnel surge
chamber, location of mechanical and electrical equipment and facilities are shown in
figures listed below;
Fig. 2.1
Fig. 2.2
Fig. 2.3
Fig. 2.4
Fig. 2.5
Fig. 2.5
Fig. 2.7
Fig. 2.8
Fig. 2.9
Fig. 2.10
Fig. 2.11
Fig. 2.12
2.2.4
Comparison of reservoir level duration curves

Turbine Operation Diagram
L section of power arrangement.
Cross Section of Powerhouse, Substation and Tailrace Tunnel Surge
Chamber
Powerhouse Cross Section
Powerhouse Longitudinal Section
Powerhouse Plan at EL. 758.00 m
Powerhouse and Surge Chamber Plan at EL. 733.50 m
Regulating Mechanism
Two double-acting servomotors will be provided to operate the guide vane regulating
gear. The servomotors will be located in suitable recesses in the pit liner. The oil for
these servomotors will be supplied from the governor oil system.
2.2.5
Thrust Bearing Arrangement
With the distributor centerline set at El. 740.5m, sufficient height will be available to
adopt a thrust bearing supported by a spider resting on the concrete structure. This
provides plenty of working space in the turbine pit. This is in line with the designs
adopted at Mangla, Tarbela and Ghazi Barotha powerhouses. Therefore, an
arrangement of the thrust bearing supported by a spider set above the turbine pit has
been adopted for the Dasu units.
However, some manufacturers recommend that the thrust bearing is supported by a
conical structure fixed to the turbine top cover. This arrangement has two main
advantages: ease of access to the thrust bearing, and the transfer of the thrust back to
its point of origin, namely the turbine cover. At detailed design stage the technical
specifications should include this arrangement as an option for the manufacturer.
2.3
Turbine Governors
2.3.1
General
The governor system is the interface between the turbine, the operating staff and the
power system. The man-machine interface will usually be remote from the turbine in the
powerhouse control room, but facilities local to the unit will also be available for
commissioning and local control. The interface with the power system will comprise
connections to the generator which allow speed and power levels to be automatically
determined.
The governor will provide two types of control:
- Speed mode control (no-load operation, isolated operation), and
2-6
Volume 8
- Power mode control (network operation).

Power mode control will be specified to automatically revert to speed mode control if
system speed variations occur to enhance system stability. Power mode control without
overriding speed control can lead to system instability.
This concept corresponds to international practice regarding governor control for peak
load plants. It is recommended that forthcoming IEC publication Guide to Specification
of Hydro-turbine Control Systems should be specified for the governor performance, at
detailed design stage.
The governor parameters will be determined to control the stability of the turbine
generator. Careful selection of governor parameters will allow the unit to follow closely
the load demands of the system and prevent excessive speed and pressure rises during
load rejections.
The control system of the governor can be divided into electrical / electronic data, etc.,
whilst the latter provides the power to control the regulating gear of the turbine. During
recent years there have been significant developments with both the above sub-systems
and these changes will be taken into account in the governor design for this project. The
Digital Governor shall have the facility to separate adjustable / permanent speed droop,
proportional gain, integral and derivative time constants.
For each turbine governor, oil sump with oil pumps, control and distribution valves shall
be located between two units at turbine floor EL. 745.50m. Oil sumps shall have effective
volume of approximately 12 m3 and will be 2.5m wide x 3.5m long x 1.7m high. Besides
oil sump, two air oil pressure vessels shall be placed, each vessel with volume of 6 m3.
Governor control board shall be located on the same floor. Refer Figure 2.9.
2.3.2
Governor Equipment
2.3.2.1 Electronic Equipment

In recent years the advent of the microprocessor has changed the design of the
electronic governors from analogue to digital systems with much more effective manmachine interfaces. The electronic governor control provides functions such as turbine
start / stop, auto-frequency control and automatic load control, and provides interface
connections to a main control and instrumentation system. Its monitoring functions
include fault detection, alarm annunciation and unit shutdown. The governor also
provides facilities for manual control of the turbine.
The electronic equipment is extremely reliable and the digital technology allows
continuous self-checking of system operation. As the parameters for each turbine are
stored within computer programs, there is no need for printed circuit boards to be precalibrated. With a digital system all the data is stored either within memory circuits
(EPROMS) or is downloaded from a programming module or central computer. The
governor is normally designed to allow circuit modules to be replaced whilst the unit
remains connected to the grid. As the mean time between failures is usually a number of
years, a large stock of spares is not usually required.
2.3.2.2 Hydraulic Systems
The main development in hydraulic systems over recent years has been a steady
increase in the operating pressure of the governor hydraulic systems. This change has
been driven by two factors; cost and size. As the system pressure is increased the cost
of the hydraulic system decreases due to reduction in its size. With increasing system
pressure, the size of guide vane servo-motors, oil pumps, oil piping and tanks
decreases. The overall effect of an increase in system pressure is a reduction in the
turbine cost although there is some increase in the governor cost. For very large
2-7
Volume 8
turbines, the oil storage requirements at low system pressures are very large and this
has also encouraged the adoption of higher pressures.
One further advantage of reducing the size of the hydraulic system is that more of the
equipment can be assembled and tested within the manufacturers works. This means
that site work can be limited to simply connecting a skid-mounted package containing
low and high pressure tanks, oil pumps, control valves, etc., to the turbine servomotors.
The reduction of site work shortens the installation time and also increases the reliability
as there is less opportunity for contamination of the system.
It is recommended that a system pressure of 140 bars with air-over-oil accumulators
should be used for the turbine governor oil system.
2.3.2.3 Speed and Pressure Regulation
Due to short headrace tunnels, penstock and installed surge chambers on tailrace
tunnels have much better characteristics in respect of transient.
The preliminary investigation about speed and pressure regulation has been made
consisting of the following tasks:
-
Determination of the minimum required flywheel effect and temporary speed rise
Check of the pressure rise (water hammer) within the power conduit
Check of the pressure drop (water hammer) within the tailrace tunnel
2.3.2.4 Water Hammer within High Pressure Conduit

Water hammer is a pressure change in a close pipe caused by water deceleration or
acceleration for example due to opening / closing of the turbine wicket gate. The worst
case for water column deceleration within the power conduit is the emergency shut down
of the unit.
For the investigation of the worst case, a check according to the empirical formulae for
rigid water column theory by Parmakian, Ray S Quicks water hammer chart and Allievi
Chart for determining maximum pressure rise and also United States Bureau of
Reclamation (USBR) Table and empirical formulae for determining speed rise due to
load rejection has been applied. It shows the order of magnitude of the water hammer for
linear closing characteristic of the turbine guide vanes. The pressure rise and speed rise
due to an emergency shut-down of the units were calculated with 7 seconds servomotor
closing time. For closing time of 7 second, the pressure rise due to full-load rejection
from operation at the rated point p will be 27% and speed rise of 40% which are with in
permitted limits of pressure and speed rise. To minimize vibration, a speed rise not to
exceed 60 percent can be permitted in contrast to the 35 to 45 percent designed for
satisfactory regulation of independently operated units.
Wicket gate opening / closing time (using Gordons stability curve);
tw = 2.2sec. (Water starting time excluding that of draft tube)
tc = 7.0 sec. is effective wicket gate closing time .
tg = Wicket gate opening time
Using above parameters in Gordons stability curve for good regulation in isolated or
system operation, wicket gate opening time of 8.5 seconds is considered reasonable.
2-8
Volume 8
Water Hammer within Tailrace Tunnel

For Dasu, each turbine will have separate power conduit and tailrace tunnel upto the
surge chamber. Downstream of surge chamber two tailraces are combined to single tail
race tunnel up to river flow. Refer Figure 2.3 and 2.12.
The tailrace pressure drop downstream of the turbine has been determined which is
8.1m. The admissible setting of the turbine to prevent a water column separation during
a full-load rejection was determined as El. 740.5m which confirms the setting level as
shown in Figure 2.5.
Required Flywheel Effect
The flywheel effect has the stabilizing influence on the unit speed and speed change. If
isolated operation of the turbine generating unit would be required, the flywheel effect
has to be precisely calculated during detailed load and network studies. For Dasu,
isolated operation of the large units is not planned. Therefore, a simplified predetermination of the flywheel effect and the starting time of water column has been done
for speed sensitive governing of the generating unit and is given in Volume 6 Hydraulic
Design Studies.
In order to determine the minimum required flywheel effect, the starting time of the water
column tw has firstly to be calculated.
Considering the parameters of Dasu the value of tw is 9.1 seconds. In order to have a
normal speed sensitive governing of the generating unit, tw has to be in a certain
relationship to tm, the machine starting time for accelerating the rotating mass to the
rated speed.
i
ii
iii
t m > 2 tw
tm > 2(tw)2
tm > 3.0 tw
is reasonable for unit on an inter connected system.

can be expected to have good regulating property (USBR)
(Hydropower Engineering by Wornick).
The minimum tm from the turbine and generator available data is;
GD2 = 4WR2
WR2 Turbine = 1.796 x 103 ton m2
WR2 Generator = 19.465 x 103 ton m2
Total WR2 = 21.26 X 103 ton m2
tm
Where
GD2min =
P
n
GD 2 n 2
365000 P
85x103t-m2 (minimum
Turbine and generator)
= rated output in MW
= rated speed in rpm
available
combined
flywheel
effect
of
Dasu
Inserting the values of P and n and GD2 in above equation.

tm = 9.7 sec
tm / tw = 1.066
Considering above i, ii and iii conditions and the available flywheel effect, the units to
2-9
Volume 8
have good regulating capacity tailrace surge chamber is required to assure acceptable
operating capability. However, the actual requirement of unit flywheel effect will be
determined by the turbine manufacturer and the generator will be designed accordingly
by the generators manufacturer.
2.4.
Turbine Inlet Valves
The valve is used to shut off water in case of turbine governor failure to close the wicket
gates, to relief pressure on the turbine wicket gates during shut down and to permit unwatering the turbines for maintenance.
Initially while planning the power generating system, consideration was given to four
headrace tunnels, each tunnel bifurcating near to the power house to feed two
generating units with inlet valve arrangement. But when design parameters of the inlet
valves were worked out and their manufacturing possibilities were enquired, the
response was not encouraging. Butter fly type of inlet valves would not be able to close
under extreme conditions, which can arise at Dasu project.
Spherical type of inlet valves are structurally capable of operation, but these valves of
6.75 m diameter have never been produced before, Even if any manufacturer expresses
willingness over its manufacturing, the weight of such an inlet valve will be in the range
of 400 450 t and cost of one inlet valve will be approximately 6000,000 Euros
(48,000,000 Euros for 8 inlet valves). These inlet valves can not be accommodated in
power house cavern, therefore a separate cavern will have to be excavated. The cavern
will have a cross section of 11m width 22m height and the length will be almost equal
to that of powerhouse cavern. In addition a separate crane and other auxiliary equipment
will also be required for handling of these inlet valves.
In summary, the non existence of manufacturing precedence, very heavy to transport
and handle if manufactured, extreme cost element, and need for excavation of separate
chamber makes the inlet valves non feasible for Dasu Hydro power project.
After elimination of inlet valves, a more feasible, direct and simpler option of providing
one headrace tunnel for each generating unit has been adopted. Considering above
facts, in hydraulic design of waterways the length of headrace tunnel and penstock has
been decreased to the possible extent and also a surge chamber on tailrace 66m
downstream of powerhouse centerline has been provided. This arrangement with short
headrace tunnel and surge chamber on tailrace tunnels provided not only peak load
operation of the plant but participation in secondary regulation of frequency in the
network as well as short headrace tunnel and penstock made possible to use power
intake gate installed in gate shaft of power tunnel as turbine shutoff valves. Refer Figure
2.3.
2.5
Cranes and Hoists
2.5.1
General
Cranes and hoists are the basic necessity of any power plant, not only during the
erection period but also during operational life of the plant. The cranes are extensively
used during plant erection period, and construction schedule largely depends upon the
availability of the cranes to various contractors involved in the Project. The number and
arrangement of the cranes play an important role in the planning and execution of a
power project in the optimum time. Keeping this in view, the powerhouse will be provided
with an arrangement of cranes that will cover all the needs both during Electrical /
Mechanical equipment erection period as well as during its operational life.
2-10
Volume 8
2.5.1.1 Powerhouse Cranes

Two bridge cranes (2X550t/50ton) will serve machine hall. Each main crane will have
single trolley with the main hook capacity of 550 metric tons and auxiliary hoist of 50
metric tons. Two vertical ladders for access to operators' cabins will be provided, one in
each erection bay. Recesses in the walls at the crane rail level will be arranged to
facilitate lubrication and replacement of the crane bridge wheels.
In the station workshop, which will be laid out with comprehensive facilities, a single 5
tons overhead electric traveling crane with pendent controls in the heavy and light
maintenance areas will be provided.
A variety of small capacity hoists and chain blocks running on universal beams operated
either manually or by electric motors, will be provided in areas remote from the station
cranes. The hoists will be used for handling smaller loads on various floors, such as
pumps, motors, cooling water filters, ventilation plants, air compressors, etc.
2.5.1.2 Transformer Gallery Cranes
Crane for Transformer Unloading Bay
One over head travelling bridge crane with main hoist capacity of 250 ton and an
auxiliary hoist of 25 ton will be installed in transformer unloading bay. The crane will
travel only in the transformer unloading bay (travel length 40m) see Fig 4.4. This crane
will be used for unloading of transformers and positioning of transformer on rails for
further shifting to their final location in the transformer gallery.
Crane for 765 kV Underground Substation
One traveling bridge crane of 5 ton capacity would be installed in the underground GIS
substation for errection and maintenance of equipment, unless larger capacity is required
by the GIS vendor.
2.5.2
Design Criteria
Selection of the cranes with respect to their types and capacities and classification of
service influences the design of all components of a crane. With these considerations
into account, the powerhouse cranes will be classified and designed according to
Federation European De La Manutention (FEM) and Crane Manufacturers Association of
America (CMAA) Standards for the class of service determined at the time of final
design.
The selection of correct speeds for the cranes is another important factor which
influences the initial and operating costs of the cranes. Hence, due consideration will be
exercised in selecting the crane speeds for hoisting, traveling and traversing facilities.
2.6
Miscellaneous Mechanical Auxiliaries
2.6.1
General
Powerhouse will be provided with all mechanical auxiliary systems required for reliable
and safe operation of a modern hydropower plant, comprising:
-
Turbine Dewatering and Filling System

Station Drainage System
2-11
Cooling Water System

Heating, Ventilating, and Air-conditioning (HVAC) System
Fire Protection System
Compressed Air System
Oil Handling and Purification System
Maintenance Workshops
2.6.2
Drainage and Dewatering Systems
Volume 8
Depending on the general layout, the station drainage system would be required to
handle waters from the powerhouse and from several other equipment and accesses
located below the maximum infrequent tail water level. These will include:
-
Cooling water of minor mechanical systems, such as: compressors, governing

systems and alike.
Water leaking to the turbine pit through the shaft seals and wicket gate stem
seals.
Water used for cleaning the floors of caverns and galleries.
Seepage of water to the caverns, galleries accesses and tunnels with the inflow
to fulfill geotechnical requirements to be established at the design stage.
Water from pressure relief perforations and systems to be established at the
design stage.
Any releases from the sprinklers of fire fighting water system.
Drainage and Dewatering Systems (pits & pumps) will be located below draft tube floor
(El.733.50m), beneath Erection Bay No. 1, and would consist of:
(i)
Drainage System of dewatering gallery, equipped with one open drainage pit
and two vertical pumps with submerged motors. Each pump with capacity of 25
l/s and for head of 25 m. The pit will be located close to the main dewatering pit,
but open at level of the dewatering gallery, so to collect leakage water in the
gallery. The pit shall be 2,5m x 2m in cross section and with bottom lower than
dewatering gallery. Water from this pit will be pumped to the main drainage pit.
(ii)
Main Drainage System of Power House, equipped with one open drainage pit
and four working and one stand by drainage pumps (vertical pumps with
submerged motors). Each pump with capacity of 100 l/s and for head of 60 m.
The pit will be located close to the main dewatering pit and connected with pipe
and non return valves to the dewatering pit. All the seepage and leakage water
from the plant will be collected in the main drainage pit by gravity flow and
channeled to the pit and then pumped to surge chamber. Cross section of the pit
shall be such as to accommodate the five pumps and pit accessories. For
automatically operation of the pumps, effective retention in the pit shall be a
minimum of 25m3.
Part of leakage water from the units (polluted by oil) and flowing water from
various power house floors shall be firstly led to the oil purification pit, equipped
with oil separator, and then after to the main drainage pit. Oil purification pit with
oil separator shall be located in front of the main drainage pit and on the same
draft tube elevation-floor. Drainage pit will be connected to the dewatering pit, by
means of pipe equipped with valve and non return flap, so that in emergencyflooding conditions dewatering pit and pumps can accomplish drainage. Non
return flap shall prevent water to flow from dewatering pit toward drainage pit.
2-12
(iii)
Volume 8
Dewatering System, equipped with closed dewatering pit and four working and
one stand by pumps (vertical pumps with submerged motors). Each pump with
capacity of 200 l/s and for head of 70m. Dewatering system is mainly intended
and designed for dewatering of downstream waterway structures (draft tube
tunnels, surge chamber and tailrace tunnels), as well as to assist in eventual
flood protection of the power house, by means of non return connection to the
main drainage pit. Dewatering pit will be located close to the main drainage pit,
deeper than bottom of draft tube and in cross section enough to accommodate
the pumps and pits accessories. Water to dewatering pit shall be directly brought
and controlled by pipes and valves connected to the draft tubes in the dewatering
gallery. As a closed type the pit will be water tight, equipped with water tight
manhole and with aeration pipe led over maximum water level in surge chamber.
The closed pit prevents eventual plant flooding in case of dewatering maloperation, while on another side it actively participate in eventual plant flooding
protection.
Water from dewatering pit will be pumped to the surge chamber, by pipe of 850
dia mm (laid beside one the of draft tube tunnels).
Capacity of one dewatering pump is such to pump out draft tube tunnel for 6-8
hours, while dewatering of one tailrace tunnel will take approximately four days,
with operation of all installed pumps.
Total protection capacity in eventual flooding of power house, including all
dewatering and drainage pumps, is 1700 l/s.
(iv)
Dewatering System of Head Race Tunnels and Penstock will be organized by

gravity, with pipe connected to the penstock on one side and directly discharged
to adjoining draft tube on another side, by means of 350 mm dia pipe and valve
located in a separate gallery beneath inlet of spiral casing.
2.6.3
Cooling Water Systems
Cooling water consumption is estimated as 600 l/s per unit, out of which 130 l/s belongs
to transformer. Each unit shall be equipped with its own cooling system with possibility
for interconnections between neighboring units, for eventual assistance. Cooling system
of each unit, as briefly explained here below, shall be built vertically around the unit, at
various elevations. Main cooling equipment, such as pumps, filters and coolers shall be
vertical type so that the floor area utilization is economized.
Water is taken from draft tube of each unit, by 700 mm dia pipe, and brought to units
cooling pumps located at the draft tube floor (El. 733.50m), in recess of spiral case
concrete support. Two working plus one stand-by pumps are foreseen for each unit,
each pump with capacity 300 l/s and for head of 25 m, equipped with necessary valves
on suction and discharging side. Pumps are vertical, and could be with or without volute
casing. Water will be pumped directly to the filters located above the pumps, at spiral
case floor (El.738.50m)
Two working plus one stand by automatic filters are located at spiral case floor
(El.738.50m), in recess of spiral case surrounding concrete, directly above the pumps.
Water from filters is further pumped vertically to turbine floor El.745.50m and from that
point distributed to the units consumers at various levels. At turbine floor level, branches
from cooling water are taken for fine filters (shaft sealing lubrication and compressors)
and for transformer cooling (booster pumps).
2-13
Volume 8
One working and one stand by booster pumps for transformer cooling are located at
turbine floor (El. 745.50m), each of capacity 130 l/s and for head of 90 m.
Main coolers of the unit (thrust bearing and generator) are located at turbine and
generator floors.
Cooling water is collected from all consumers and by return pipe 600 mm dia. discharged
back to the draft tube, downstream from intake pipe. Within the discharging pipe some
throttling (or break chamber) shall be installed so as to prevent vacuum development on
top of generator coolers.
The heated water from heat exchangers will be individually piped to discharge into a
common cooling water discharge header, which will be installed above the maximum tail
water level. Each discharge line will include a flow meter and a manually operated globe
valve to adjust the flow. The header will discharge by gravity into the tailrace.
2.6.4
Raw Water Supply System
Raw water supply systems in the plant shall comprise:

a)
Raw Water System. Water for various technical purpose in the plant, which shall
be supplied from one separate elevated tank in transformer hall. Raw water tank
will be fed directly from headrace penstock. Volume of the tank shall not be more
than 75 m3 and will be practically breaking and throttling chamber for high
pressure water from the penstock and as such the tank shall be permanently fed
in accordance with demands (floating valve installed on discharge to the tank).
Power house fire fighting system, transformer fire fighting system and branch for
potable water purification system shall be supplied from raw water tank.
b)
Potable Water System. Purification plant and reservoir of clear water, shall be
located in transformer hall, in line with fire fighting tank and raw water tank. Small
and compact purification plant will take water from raw water reservoir, purify and
discharge to clear water tank (volume of 50 m3), from which it will be distributed
further by gravity to power house.
2.6.5
Compressed Air Systems
Air Compressed Systems would be located at generator floor, beneath Erection Bay No.
1 at El 751m.
a)
High Pressure Compressed System will consist of one working and one stand by compressor, high pressure vessel and accessories. The system shall serve for
automatic refilling of air to the governors air-oil pressure vessels
(accumulators).The compressor will automatically feed pressure vessel and
maintain high pressure within. From the compressors pressure vessel governors
pressure vessels shall be refilled automatically and quickly. Rated pressure of the
compressor and its vessel shall be 200 bars. Capacity of the compressor will be
such to fill one governors pressure vessel in 12 hours. Volume of pressure
vessel shall be approximately 3 m3.
b)
Low Pressure Compressed System shall comprise one working and one stand by
compressors and will be equipped with two relatively big air storage pressure
vessels. The main purpose of this system is to provide pressurized air for plant
during regular operation and maintenance (pressurized air for various devices
2-14
Volume 8
and tools). Rated pressure of compressors and vessels shall be 15 bars. Two
pressure vessels will be installed, each of 5m3 capacity.
2.6.6
Two elevators, each with a capacity of 15 persons or 1200 kg load, are proposed for the
powerhouse.
Each elevator will be for passengers / small load, one located on the upstream side of
Erection Bay No. 2 operating from the erection bay floor down to draft tube gallery, and
the other located on the downstream side of Erection Bay No. 1.
2.6.7
Oil Handling Facilities
Oil Storage & Purification facilities shall be installed in a separately excavated chamber,
which will be located on downstream side of the main erection bay, on opposite side of
access road and out of power house profile. Oil storage facilities shall have steel tanks
for storage of one complete quantity of new oil for the unit at whole, and also for storage
of one complete quantity of polluted oil for the unit. Estimated complete quantity of new
oil for one unit is 40-50 m3. Mobile oil purifier and oil pumps shall be provided within
storage facilities so that with centralized piping system in storage and in powerhouse,
any manual or automatic manipulation with purified and polluted oil, as well as
purification, can be performed (within the chamber or at the unit spot and during the unit
operation). Space requirement of storage chamber, in respect of turbine(s) necessities is
6.5m width x 10m length x 6m height. Oil storage chamber will be closed with fire proof
gate.
The oil storage, handling and purification facilities for the generator transformers will be
located in the transformer gallery. The transformer insulating oil is purified and stored
before being transferred to the transformers. The system will be generally similar to that
provided for the turbine generator units but the purifier will be of a type suitable for
transformer oils. After the commissioning of all the generating units, the system will be
available for maintenance of the transformers.
2.6.8
Heating, Ventilating and Air-Conditioning Systems
2.6.8.1 Objective
HV AC system will be designed in view of the following objective:
(a)
To maintain indoor temperature at a pre-determined value by extracting heat from

indoor environment. The plant will have a capacity in terms of heat extraction rate
equal to maximum anticipated heat input to indoor environment from electricalmechanical equipment, lighting, people and conduction from fresh air.
(b)
To maintain indoor relative humidity at a pre-determined value for areas such as

control room, computer room, administration areas, electrical equipment rooms
etc. by condensation of moisture in air stream.
To provide clean air to conditioned space by filtration of re-circulated and outside
(fresh) air.
(c)
(d)
To pressurize the building upto 0.3 mbar to prevent infiltration of uncontrolled

outside air.
2-15
Volume 8
(e)
To provide winter heating in areas such as control room, administration areas,

computer room etc. by adding heat to indoor environment. Relative humidity will
simultaneously be controlled by adding moisture whenever required.
(f)
To recover equipment heat dissipation in winter and to use it for space heating
where possible.
2.6.8.2 Design Criteria

The proposed criteria for the purpose of designing HVAC system is as follows:
Outdoor Conditions
Summer:
Dry bulb temperature
Wet bulb temperature
Daily range
Winter:
Dry bulb temperature
39.6 0C
26.6 0C
15 0C
0.9 0C
Indoor Conditions
Summer:
Administration offices, computer
room, control room and relay room
Machine hall, galleries, electrical
equipment room
Winter:
Administration offices, computer
room, control room and relay room
All other areas
24 0C/50% rh
32 0C
22 0C
Uncontrolled
Ventilation Rates
Supply Air
Corresponds to load requirements

but not less than 2.5lit/sec per m2.
Outside Air (Fresh Air)
Corresponds to system requirements

but not less than
i. 7 lit/sec per person, or
ii. 1.27 lit/sec per m2 of floor area.
iii. 5%
of supply air, whichever

criterion results in more out side
air.
Exhaust Air
Wash Room
Battery Room
Turbine Pit
10 lit/sec m2 floor area

20 air charges per hour
15 air charges per hour
It is proposed to use filtered river water from station cooling water system of powerhouse
through water-to-water heat exchanges at 20C. Thus 20C cooling water with 5C
temperature difference through the cooling coil can provide cool air down to 25C only.
Air handling units (AHUs) have to cool air down to 13 - 24C range depending upon the
2-16
Volume 8
area served. Thus 20C cooling water alone cannot be used for cooling of air down to
these temperatures. It is therefore proposed to use cooling water at two temperature
levels as under:
a)
20 0C closed circuit cooling water

from second circuit of water-towater heat exchanger having
once-through river water in primary
Circuit.
For first stage cooling coils in all

AHUs, for cooling of air entering the
unit down to 25C for condensers of
refrigerating chillers.
b)
7 0C water chilled by refrigeration

cooling of air from 25 0C to 13 0C
For second stage cooling coils for
Winter Heating
Winter heating is normally not required as sufficient heat is generated by equipment. In
certain areas, however, such as administrative areas, control room and computer room
etc., duct mounted electric resistance heaters will be used for winter heating.
Standards
-
HV AC load will be determined as per ASHRAE Standard method (latest

revision).
Material specifications will conform to applicable ASTM Standards.
HV AC equipment will be specified to conform to ARI Standards for ratings,
ASHRAE Standards for filtration, ASME Standards for unfired pressure vessels,
ASTM Standards for materials, AMCA Standards for fans and louvers.
2.6.8.3 System Design and Plant Layout

HV AC Plant
HV AC plant will comprise of:
(a)
Three power driven, water-cooled, water chillers each of 50% required capacity.
Two operating, one standby, all connected to common supply and return pipe
headers.
(b)
Three chilled water pumps, end-suction, top discharge centrifugal with direct
coupled motors. Pumps will have mechanical seal. Two operating, one standby
all connected to common discharge and suction headers.
(c)
AHUs with fan section, coil section, filter section, mixing box section and plenum
section.
(d)
Interconnecting chilled water steel piping, fittings, valves and accessories

including closed expansion tank and air separator, will have high density glass
fibre insulation with vapour barrier and protective covering.
(e)
Galvanized steel sheet metal ductwork will have flexible glass fibre blanket
insulation with vapour barrier and protective covering. Three meter length of
ducts starting from air handling unit will have internal acoustic liner. Ducts will be
embedded in concrete where required.
2-17
Volume 8
(f)
Air diffusion devices will comprise of:
Ceiling supply and return diffusers, with opposed-blade dampers.

Side-wall supply and return registers, with double-deflection adjustable louvers
and opposed-blade dampers
Fixed-blade returns and transfer grilles.
Fixed-blade outside air inlet/exhaust air outlet louvers.
(g)
Exhaust fans will be centrifugal/propeller /tube axial type.
(h)
Resistance type electric heater will be installed in ductwork for winter heating.
(i)
Secondary cooling water for first stage cooling coils of air handling units and for
condensers of water-cooled chillers will be taken from station common auxiliary
cooling water system.
Coil section will have one stage and/or two stages; first stage using closed circuit cooling
water at 20C and second stage using closed circuit chilled water at 7C. Powerhouse
will be divided into five zones from air circulation point of view. Each zone will have its
own air handling units. Detail of zones is as under:
Zone Type No. 1
Areas at machine hall to transformer gallery
of each unit bay (The air handling units
delivering air at 25 0C to maintain room
temperature at 32 0C).
Zone Type No.2
Battery rooms and small workshops
(The air handling unit delivering air at 25 0C
to maintain room temperature at 32 0C).
Zone Type No. 3
Erection bay except Zone No. 2
(The air handling units delivering air at
25C to maintain room temperature at
32 0 C)
100% re-circulation with fresh air.
100% exhaust with fresh air.
Partially re-circulated air system.

Air down from outside will be
mixed with re-circulated room air,
cooled and then supplied to this
zone. Air from machine hall and
cable galleries will be exhausted
directly to atmosphere. Air from all
other areas of this zone will be
returned to air handling unit.
Zone Type No.4

Control room, computer room, relay room
And administration areas. (the air
handling units delivering air at 130 C to
maintain room temperature of 240 C).
Zone Type No.5
All areas of transformer gallery
(The air handling units delivering air at
25 0C to maintain room temperature of
32 0C)
2-18
Partially re-circulated fresh air

being added continuously.
Partially re-circulated; fresh air

being added continuously
2.6.9
Volume 8
Fire Protection Systems
All fire protection systems will comply with Pakistani National Standards and National
Fire Protection Association (NFPA) Standards.
The fire protection systems will be provided to extinguish fire of the following equipment
and areas:
-
Generators
Transformers
Oil storage rooms
Computer and control rooms
Remote computer control terminal units
Office and miscellaneous-spaces, electrical and control equipment galleries
Auxiliary powerhouse equipment and maintenance workshops
Diesel generator rooms located at head works.
Given its highly efficient fire extinguishing properties on electrical equipment and
inflammable liquids, carbon dioxide system complying with NFPA Standard "Carbon
Dioxide Extinguishing Systems" will be used for the generators and oil storage and
purification rooms. Carbon dioxide will be stored in suitable cylindrical containers of 45
kg capacity each, under a pressure of 52 bars. The required quantity of carbon dioxide
can be calculated considering the initial discharge of 1 kg of carbon dioxide per 0.75 m3
of generator compartment volume, plus an identical quantity for a retarded discharge and
a discharge of 1 kg/m3 of oil room volume. It is envisaged that there will be a total of nine
(9) banks of fire protection systems, eight for generating units and one bank as a spare
to cover the (n-1) contingency.
Each independent fire protection system will have adequate supply of CO2 bottles to run
both an initial discharge plus an extended discharge to the individual generator so as to
guarantee a CO2 concentration for at least 30 minutes.
Portable carbon dioxide fire extinguishers, complying with the requirements of NFPA
Standard No.10, will be provided in the powerhouse galleries, offices and miscellaneous
spaces, and in the emergency power diesel-generator rooms.
Transformer fire fighting water supply shall be branched off upstream of raw water tank
to terminate at the deluge values of transformer fire protection system. Reducing value
shall be provided to provide corresponding pressure on the nozzles. The design will
comply with the requirements of NFPA Standard No.15 "Standard for Water Spray Fixed
Systems for Fire Protection" and No.13 "Standard for Sprinkler Systems".
Clean Agent fire protection systems, complying with the requirements of NFPA
Standards No.12A and No.2001, will be provided for control rooms and computer rooms.
Sufficient quantity of clean agent will be stored under pressure in suitable cylindrical
containers.
Risk of carbon dioxide for personnel and necessary preventive measures shall be
investigated during the detailed design stage.
2.6.10 Workshops
Workshops will be provided at the powerhouse to allow maintenance of small to medium
sized mechanical plant, electrical and electronic equipment and instruments. Where
appropriate permanently installed lifting equipment will be provided to ease handling of
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Volume 8
heavier parts for repair or regular maintenance. A tentative list of the workshop
machinery is as under:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Gap bed heavy duty lathe

Gap bed medium duty lathe
High precision bench lathe
Shaping machine
Radial drilling machine
Drill stand
Pedestal grinder
Bench mounted grinder
Hydraulic press
Black smith forge
Machine hacksaw
Portable electric welding machine
Pipe bending machine
Anvil
2-20
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Sheet metal shear

Dry acetylene welding equipment
Quenching tank
Tool cabinets
Tool room racks
Lockers
Metal working benches
Electrical working benches
Hand tools
Air operated tools
Platform trucks
Wood saw machine
Volume 8
Table 2.1
PRINCIPAL DESIGN PARAMETERS
Parameter
Unit
Value
MW
No.
MW
4320
8
549
Type of Turbine
Maximum HWL
Minimum HWL
m
m
Vertical Shaft
Francis
950.0
900.0
Maximum TWL 8 units operation
755.4
Minimum TWL one unit operation
749.2
m
MW
183.8
549
m3/s
325
195.8
m
m
rpm
135
145.8
150
m-k W
164
rpm
m
272
5.50
-8.5
El.
740.50
Turbine
Total Installed Capacity (Generator output)
No. of Units
Capacity of each Unit Turbine
Rated Head
Maximum out put at Rated Head (assuring
Turbine 93.5% at rated head)
Discharge at Rated Head
Maximum Net Head Reservoir level at
El.950m
Reservoir level at El.900m
Minimum Net Head (8 unit operating)
Minimum Net Head (1 unit operating)
Synchronous Speed
Specific Speed
Runaway Speed at Max. Head
Runner Discharge Diameter
Turbine Setting with Reference to
minimum tail water level (one unit operating)
Level of spiral casing centerline
Direction of rotation (viewed from above)
Type of control
Governor
Governor type
Anticlockwise
Fully automatic with
distributed control system
and with facility of
manual control from unit
local control panel.
Digital electro-hydraulic with
P. I. D. control.
85 x 103 tm2
Generator and turbine inertia (GD2)

Permanent speed droop (bp)
Adjustable between 0 and

0.06
7s
8.5 s
Minimum servomotor closing time (tc)

Wicket gate opening time (tg)
Start up time of the unit (tm))
9.7 s
2-21
Volume 8
Figure: 2.1 Comparisons of Reservoir Level Duration Curves

955
950
945
RoR Operation
940
Reservoir Level (m)
935
Operation for
Maximum Firm Energy
930
925
Without considering the

reservoir lowering in July
for Sediment Flushing
920
915
910
905
2027
2057
2067 - Flushing at Basha, No Flushing at Dasu
2077 - Flushing at Basha and at Dasu
900
895
50%
55%
60%
65%
70%
75%
80%
Duration (%)
Figure: 2.2 Turbine Operation Diagram

Reference: Turbine Pro Software
2-22
85%
90%
95%
100%
3.
3.1
Volume 8
GENERATORS AND EXCITATION SYSTEM
Design Considerations
The generators will be three phase synchronous machines meeting the requirements of
the latest edition of IEC 60034 and will be designed taking into consideration the
operating experience gained at other similar units installed elsewhere. The design shall
be for 30 years minimum operating lifetime.
The stator insulation specifications are one of the important considerations in the
generator design. Worldwide, manufacturers of form-wound machines offer VacuumPressure Impregnated (VPI) insulation as an almost universal standard except for units
too large for available processing equipment. That trend has not been driven so much by
inherent superiority of one system over another as by economics. Resin-rich or "loaded
tape" insulation is still an option for the largest sizes. Both the technologies are being
used nowadays. For 20 kV Systems, resin rich insulation systems are not appropriate.
The stator insulation would be VPI. In either case, the coil insulation shall be applied
continuously throughout the coils with equal thickness to both the slot and end-turn
portions. Stator and rotor insulation will be rated for Class F although temperature rises
will be limited in operation to Class B values. The coils will be protected against surface
partial discharges (corona) outside the stator iron by a semi-conductive exterior layer
and an installation method to obtain maximum contact with the stator core slot. The
methods for corona suppression would be specified.
The generators shall be designed to withstand all fault situations which can be
experienced during operation without any displacement of its windings or mechanical
damage to any of its parts or to the generator foundations, such as short circuit between
two or three phases at its terminals, faulty synchronization, magnetic unbalance due to
pole winding failure and runaway conditions.
The generator shall be so designed that all repair works, maintenance and inspection of
the generator and turbine parts may be done with a minimum of disassembly work.
The stator frame will be split into sections for transport and reassembly at site. The stator
core will be stacked at site in the erection bay without joints, ensuring good mechanical
strength, low losses and circularity.
The bearing arrangement foreseen is the semi-umbrella type with a combined thrust and
lower guide bearing below the rotor and an upper guide bearing above the rotor. The
thrust bearing shall carry the total load of the generator rotor, generator and turbine shaft
and turbine runner, as well as the hydraulic thrust forces during operation, load rejection
and runaway conditions. The upper guide bearing is considered essential to ensure that
the rotor operates smoothly under all design conditions (short circuit, hydraulic
transients, etc.) and is properly supported to safely withstand the seismic forces during
the Maximum Credible Earthquake (MCE). Damage during MCE is permitted, but the
unit must safely shut down. The unit must also withstand the Operational Basis
Earthquake (OBE) with no damage, although the unit is allowed to trip. The thrust
bearing design will include an automatic high pressure oil injection system, which will
provide an oil film on thrust bearing pads in order to prevent damage to the bearing
during starting and stopping of unit.
A closed circuit air-cooling system with air/water heat exchangers will be specified. The
surface air/water heat exchangers arranged around the periphery of the stator frame
shall be mounted in a way that simplifies assembly, dismantling, maintenance and
repairs. Arrangement will be made that even with cooling coils equivalent to one
3-1
Volume 8
complete heat exchanger choked (capacity factor) or out of service the cooling system
will not be effected. It shall be possible to maintain the maximum continuous output
without the stator and rotor winding temperatures exceeding Class B permissible
temperature. The unit would never be run with one cooler fully disabled.
The generator housing will be an octagonal concrete structure. It will be sized to
accommodate the surface coolers, piping, main and neutral leads with sufficient space
for circulation of cooling air and for a walkway around the generator stator which should
be adequate for dismantling / installation of surface coolers and piping.
The generator will have a mechanical braking system.
An automatic carbon dioxide (CO) fire protection system is foreseen for each generating
unit.
An air gap and vibration monitoring system for each of the eight turbine generator units is
envisaged.
For partial discharge monitoring system capable of monitoring the stator insulation
system capacitive couplers from Iris Engineering or other alternative source, will be
installed on the circuit rings.
3.2
Ratings
The generator main parameters are shown in the Table 3.1 below for 540 MW Unit rating
considered in the study.
Table 3.1 Generator Preliminary Data
Unit Rating
Generator Main Parameters
540 MW
Rated Voltage [kV]
18 20 kV
Speed [RPM]
150
No. of pair of poles
20
Efficiency [%]
98.5
Power Factor
0.95
Short Circuit Ratio
1.07
Runaway Speed [RPM]
272
487
Line Charging Capacity [MVARs]
Rotor Dia [m]
10.27
Rotor Height [m]
3.59
Stator Outer Dia [m]
13.35
Rotor Weight [tons]
1000
Rotor Weight = [(rpm/400)-0.4]x[(MW/37.5)0.8] x K
For Dasu units K = 80.
GD2 [t-m2] Generator + Turbine
85000
2
2
WR [t-m ] Generator + Turbine
21260
Inertia Constant, H [kWs/kVA]
4.85
Mechanical Starting Time, Tm [s]
9.7
Stored Energy, E [MWs]
2757
Note: The generator parameters have been determined assuming a generator terminal voltage
of 20 kV. The actual voltage selection, and hence the final parameters, will be left to the bidders
of the generator equipment.
3-2
Volume 8
The data presented in Table 3.1 is preliminary and would need to be firmed up during
detailed design stage.
Synchronous condenser operation of the generators is not foreseen initially. However, it
may be prudent to prepare several of the units with minimum piping provisions for the
future eventuality of this requirement when more power stations are built on upper Indus
River and system voltage control may become an issue.
3.2.1
Voltage
The generator terminal voltage is selected taking into consideration the ratings of
commercially available connected equipment such as isolated phase bus and the
generator circuit breaker. There are only a few discrete choices of equipment that are
commercially available. The equipment ratings are governed by international standards.
The selection of rated generator voltage depends upon the benefits derived from overall
reduction in losses and the generator design has main effect in deciding the voltage.
Experience has shown that for the generator design of a particular MVA rating to be
economical, its terminal voltage shall be selected from the voltage ranges indicated in
Figure 3.1 for different generator ratings. Based on above considerations, a generator
rated voltage selectable within a range of 18 - 20 kV is suggested at this stage pending
further investigations at the design stage.
Figure 3.1 Optimum Range of Voltages for Different Generator Ratings
30
25
kV
20
15
10
5
0
100
200
300
400
500
600
700
MVA
3.2.2
Power Factor
It is highly desirable that the generator be designed for a power factor at which it will
operate in order to improve system stability. In view of the fact that the Dasu power plant
will be located remote relative to the load centres and will have long EHV transmission
lines with inherent capacitances, a power factor of 0.95 is proposed for the generator.
The choice of this power factor has to be authenticated by system stability studies to be
conducted at tender design stage.
3.2.3
Short Circuit Ratio (SCR)
The short circuit ratio is the ratio of generator field current that produces rated open
circuit voltage to the field current required to produce rated stator current when the
3-3
Volume 8
generator terminals are short-circuited. A higher value of short circuit ratio results in
improved inherent stability of the machine. At the tender design stage, a system stability
study is necessary to determine whether higher-than-normal short circuit ratio is
required. Increasing the short circuit ratio above normal increases the machine size, the
flywheel effect (WR2) and the machine costs, and decreases the efficiency and transient
reactance of the generator. Figure 3.2 shows the expected price additions to the
generator basic cost and reductions in efficiency when higher than normal short circuit
ratios are required. SCR is also a measure of machine robustness and overall, the
quantity of iron in the core. Manufacturers will want to provide SCR at values below one
(SCR 0.8 to 0.85) because the machine will cost less to produce. As the machine owner,
having the more robust machine serves in the favour of the Owner (SCR 1.0 to 1.1).
Only extreme conditions would dictate going outside of these values.
35
0.7
30
0.6
25
0.5
20
0.4
15
0.3
10
0.2
0.1
0
1
1.5
2.5
Reduction in Efficiency
Price Addition
(% of Basic Price)
Figure 3.2 Higher than Normal Short Circuit Ratios versus Cost / efficiency
Short Circuit Ratio

0.8 pf
0.9 pf
0.95 pf
1.0 pf
Reduct. In eff
A normal short circuit ratio of 1.07 corresponding to 0.95 power factor is being suggested
pending the outcome of the stability studies to be performed at design stage.
3.2.4
Synchronous and Runaway Speed
The synchronous speed of the generator will be 150 rpm as determined by turbine
hydraulic considerations and design net head. Runaway speed has been provisionally
estimated at 272 rpm and that will be authenticated at detail design stage.
3.2.5
Inertia
The natural inertia is estimated at 85000 tm2. Inertia Constant, H [kWs/kVA] = 4.85 has
been assumed based on typical hydro units of large size. Based on this, the Stored
Energy, E would be 2757 [MWs]. A detailed study including the effects of hydraulic
transients, response to load variations, fault conditions, sudden full load rejection and
system stability requirements will be undertaken during the detailed design stage. These
studies will form the basis for selecting the final value of inertia, inertia constant and
stored energy.
3-4
3.3
Volume 8
Generator Connections and Neutral Earthing
The generator will be connected to the generator step-up transformer by means of

isolated phase bus (IPB). The IPB will be fitted with branch connections to the unit
auxiliary transformer, excitation transformer, voltage transformers and surge arrestors. A
generator circuit breaker with isolating and ground switches will also be fitted in the IPB
connections.
The IPB will be adequately rated thermally and dynamically. Natural or forced air-cooling
can be employed, as may be required. The IPB will be evaluated on the conductor and
shield losses, efficiency of cooling, and effectiveness of reducing ingress of dust or
moisture, as well as the method of construction, jointing and maintenance facilities.
Natural air (self) cooled IPB up to 30 kA rating is available from various manufacturers
and has been successfully used.
The neutral ends of the generator windings will be star-connected and high-resistance
earthed via a single phase neutral grounding transformer loaded with a suitable resistor
to limit the stator earth fault current to about 10 A.
The Generator Circuit Breaker would be specified based on the requirements of IEEE
Std C37.013-1997 IEEE Standard for AC High-Voltage Generator Circuit Breakers rated
on a Symmetrical Current Basis.
Based on the selected unit size and generator terminal voltage, the estimated ratings of
the IPB and the generator circuit breakers are depicted in Table 3.2.
Table 3.2 Preliminary Ratings of IPB and Generator Circuit Breakers
Equipment description
Generator Circuit Breaker
Rated Maximum Voltage [kV]
Estimated Data
24
Full Wave Withstand Voltage, Crest [kV]
125
Rated Short time power freq. 1 minute withstand voltage [kV]

Rated Continuous Current @ 50 Hz [kA]
Short Circuit Current Rating, [kA]
Phase center to center distance for connection to IPB [mm]
Isolated Phase Busduct
Rated Voltage [kV]
Lightning Impulse Withstand Voltage [kV]
Rated Short time power freq. 1 minute withstand voltage [kV]
Rated Current @ 50 Hz [kA]
Short Circuit Current Rating, [kA]
Conductor Diameter [mm]
Enclosure Diameter [mm]
Minimum Clearances
Phase Center to Center [mm]
Phase Center to Side Wall [mm]
Phase Center to Bottom/ Ground [mm]
Phase Center to Top/ Roof [mm]
60
3-5
17
160
1200-2000
24
125
60
17
160
550
1270
1600
1200
900
1000
Volume 8
The ratings depicted in the table are preliminary and are required to be firmed up during
detailed design stage based on the generator and transformer ratings / parameters
finally selected. It is to be noted that a variety of generator circuit breakers and isolated
bus ducts with vide range of ratings for use with large generators are available from
various equipment manufacturers to absorb changes, if any, in the generator ratings in
the detailed design stage.
3.4
Excitation System
A Static Excitation System with a Digital Automatic Voltage Regulator is envisaged for
Dasu units being the state-of-art for generators. Excitation power shall be taken from the
generator itself, through a branch-off from the generator terminal bus bars and supplied
to the excitation rectifier via the excitation transformer.
The excitation transformer will be installed in a self-supported steel plate cubicle to
achieve personnel safety. The excitation transformer shall be AN cooled and of dry
insulated type using non-flammable Class B insulating material. Embedded temperature
detectors (Pt-100) for monitoring winding temperatures will be included. However, Single
phase excitation transformers can also be provided to maintain the iso-phase
construction used on the units.
The excitation rectifier envisaged will be of solid-state type with controlled silicon power
thyristor for both polarities. It will be capable of reversing its output voltage to obtain fast
response in case of load rejection and unit over speed. Each rectifier branch will consist
of at least two parallel thyristor, so that one thyristor can be removed during operation
(redundant bridges). The number of thyristor bridges supplied will be one complete
thyristor bridge more than the required number of bridges to achieve rated capability
(n+1), but not less than two complete bridges.
The rated continuous output of the excitation rectifier will correspond to not less than the
excitation power required for continuous operation of the generator at rated output and
power factor and 105% of rated voltage. The excitation system would require a dynamic
response range typically 150% to 200% of the continuous rating.
The excitation rectifier will preferably be of the self-ventilated type. If forced ventilation is
offered, redundancy of the cooling system must be provided to avoid shutdown of the
generator in the event of breakdown of the fan motors. Cooling fans must be self
powered from the excitation transformer so that loss of station service does not cause
excitation failures.
The thyristors will be protected against D.C short circuits with high-speed fuses. Blown
fuses will be detected and signalled.
Digital excitation is controlled in both automatic and manual modes by the same
computer control system. To avoid single contingency failures in the excitation system,
what is known as a redundant channel is to be provided. This includes a separate
processing unit, as well as redundant fibre optic thyristor firing outputs.
The excitation system will comprise one D.C field circuit breaker. The breaker will be
cubicle mounted. The circuit breaker shall be able to break the field current under the
most unfavourable fault conditions, i.e., short circuit of the generator from full load or loss
of synchronisation, without causing damage to the breaker or adjacent equipment. The
construction of the breaker shall be such as to allow easy inspection, maintenance and
testing
3-6
Volume 8
De-excitation during normal shutdown of the unit will be performed by opening of the
field circuit breaker. Simultaneously, the AVR shall trigger all thyristors simultaneously to
fully open state, thereby providing a "free-wheeling" circuit for the field current. This is the
one way to do this. Other technically equal methods will also be explored.
The field suppression system will consist of voltage-dependent resistors, dimensioned to
withstand the excessive field currents resulting from fault conditions. Tripping of the field
circuit breaker will instantaneously put the field suppression system into operation. Many
modern excitation system supplied today do not include a field breaker, only a
defibrillating circuit (crowbar circuit) to de-excite the main field. This option may be
studied at the detailed design stage.
An over voltage protection against induced over voltages in the field circuit will be
included.
The generator is envisaged to have a state-of-the-art static excitation system with a
digital Automatic Voltage Regulator (AVR). The AVR shall be equipped with fully
redundant controllers with automatic and manual channels with auto-followers to track
position of the digital controller that is in control to provide bump less, two-way transfers
between controllers and manual-auto control. Part of the redundancy scheme requires
redundant voltage transformers on the generator isolated phase bus duct.
Over- and under-excitation limiters will be included. The under-excitation limit shall
match the static and dynamic stability curves for the generator. Volts per Hertz limiter will
also be included.
The AVR will include adjustable voltage droop compensation for both reactive and active
load and frequency compensation adjustable in the range 0 - 5% of UN per Hz.
The AVR shall include software functions for a power system stabilizer (PSS) unit with
adjustable parameters. The supplier will be required to perform modelling and field
testing to correctly determine setting to cause the voltage regulator response to optimize
on frequency instead of voltage.
The excitation system shall have built-in protection and supervision equipment. All fault
signals shall be displayed on the AVR front panel.
The entire excitation system is foreseen to be totally self sufficient, in that it self excites
the generator, provides all of the required power supplies for cooling and thyristor
control, etc from the secondary of the excitation transformer. External power is supplied
in the form of dc control voltage, field flashing source, and power supply for cubicle
lighting and power sockets. The system is foreseen to have a touch screen operator
interface for local control. The equipment will provide input transducers for all generator
quantities and therefore will display all unit quantities in digital format. The digital AVR
will interface directly to the digital control system for the station. All power and control
circuits will use circuit breakers or mini-circuit breakers for protection and disconnection
means. Fuses will not be allowed.
3.5
Auxiliary Switchgear
The Unit and Station Auxiliary Supply System configuration showing auxiliary switchgear
is depicted in Figure 3.3.
3-7
3.5.1
Volume 8
Main Auxiliary Boards (11 kV)
Four (4) Main Auxiliary Boards (MAB-1 thru 4) connected to their respective Main
Auxiliary Transformers are provided. The transformers and the MABs will be directly
connected with the isolated phase bus of the relevant generating unit. MAB-1 & 2 will be
able to be interconnected to one another via bus coupler circuit breakers, although
during normal operation the two boards will operate independently with the bus coupler
in normally open (NO) position. The MAB 3 & 4 will have similar arrangement.
The Main Auxiliary Boards (MAB-1 & 4) feed the following switchboards in the station:
-
The unit auxiliary supply boards UASB-1 & 2;

The common services boards CSB-1 & 2 ;
The essential services boards ESB-1 & 2;
The substation auxiliary board SAB;
The main lighting distribution boards LDB-1 & 2
The Main Auxiliary Boards (MAB-2 & 3) also feed all the above boards with the exception
of SAB and additionally feed head-works auxiliary board.
The main auxiliary boards are proposed to be located in the respective unit galleries.
3.5.2
Unit Auxiliary Supply Boards UASB (400 V)
There are two (2) unit auxiliary supply boards (UASB-1 & 2), each with two bus sections
interconnected via a bus tie circuit breaker. Each of the bus sections is supplied from the
respective Main Auxiliary Boards via related unit auxiliary transformers. Each bus section
of the unit auxiliary supply board is connected to unit auxiliary boards (UAB) of two units.
During normal operation, the bus tie circuit breaker remains open and closes
automatically when the incoming supply of any of the two bus sections fails.
The unit auxiliary supply boards will be located one each in the respective galleries of
Unit No. 3 and Unit No. 6 so as to minimize the cable lengths.
3.5.3
Unit Auxiliary Boards UAB (400 V)
There is a dedicated unit auxiliary board for each generating unit fed from the respective
unit auxiliary supply board (UASB) as described above.
The principal design of the UAB is a double-ended motor control centre (MCC) with
manually operated main and tie breakers. One bus is designated the essential bus which
carries the loads required to be able to start a generator (i.e. only one main governor oil
pump, the cooling water pump and thrust bearing oil injection pump etc.) and the balance
of the loads that are not essential for starting of a main unit are placed on the normal
bus. During emergency start conditions, a diesel generator is configured to supply only
the critical loads. All motor starters for the unit auxiliary equipment will be located in the
UAB rather than providing local starters. In this way, the control wiring is eliminated, the
motor starter control designs are common regardless of the starter size, the starting
equipment will be of the same manufacturer for the entire station minimizing spare parts
requirements, and the equipment will be contained in draw-out cubicles so they may be
removed for servicing. MCC wiring standards will be defined at the time of detailed
design. Motor controllers and feeders are all to be of the circuit breaker controlled type
rather than fuse type. Control circuit protection will be via miniature circuit breakers.
The unit auxiliary boards are proposed to be located in the respective unit galleries.
3-8
3.5.4
Volume 8
Common Services Boards CSB (400 V)
There are two common services boards (CSB-1 & 2). The CSBs are identical in
construction and features to the UASB and are similarly supplied from the Main Auxiliary
Boards. The CSBs provide power to major, non-unit electrical loads in the station
including those of drainage, dewatering and lighting systems, which are supplied through
their respective distribution boards. The majority of these loads appear in the
erection/service bay of the powerhouse. Like the UAB, the loads are divided into
essential and normal loads. The essential loads are ventilation, elevators and battery
chargers etc.
The common services boards are proposed to be located in the erection bay.
3.5.5
Essential Services Boards ESB (400 V)
There are two essential services boards (ESB -1 & 2). The ESBs are identical in
construction and features to the CSBs and are similarly supplied from the Main Auxiliary
Boards. The ESBs provide power to major unit and non-unit electrical loads in the station
including those of lighting systems, which in turn are supplied through their respective
distribution boards. The unit essential loads are the main governor oil pump, the cooling
water pump and thrust bearing oil injection pump whereas other common essential loads
include ventilation, elevators and battery chargers etc.
The essential services boards are proposed to be located at end of the powerhouse
opposite the erection bay.
3.5.6
Drainage and Dewatering Distribution Boards DRDB, DWDB (400 V)
The 400 Volt DRDB & DWDB are also identical in construction and features to the
UASBs. However, their service is limited to the drainage and dewatering pumps and
their controls. Independent feeders from the CSB 1 & 2 to each of the DRDB & DWDB
are provided. Dual, non-contact analogue sensors are foreseen for level sensing in each
sump. The actual levels upon which the control is to be accomplished can then be
accomplished within the digital controller. Additional remote input/output (I/O) signals are
required for sensing of drainage and dewatering valve positions. Status and operation
will be displayed graphically with digital information supplied on status (position of
valves, water levels, etc).
3.5.7
Substation Auxiliary Board SAB (400 V)
The 400 Volt SAB is similar in construction and features to the UASB. SAB provides the
required power to the GIS and the main power transformer auxiliaries. Principal loads
are stored energy mechanisms for circuit breakers, cooling pumps for the transformers
and electric heaters as may be required. GIS hall and transformer gallery normal lighting
loads will also be supplied from this board.
The substation auxiliary board SAB is proposed to be located in the GIS room.
3.5.8
Lighting Distribution Board LDB (400 V)
Two (2) 400 volt LDBs will be provided that are identical in construction and features to
the UASB. Each LDB is supplied from the CSB & ESB. Being an underground
powerhouse, lighting is a critical function. The emergency light system will be powered
from the station batteries, and has limited duration and limited light output. When the
time comes to restart the station and/or trouble shoot the problem, the first thing needed
3-9
Volume 8
is normal lighting. Being directly supplied from the essential and common buses of ESB
& CSB, this configuration minimizes the potential path interruptions and makes the
lighting easier to restore if lost. The diesel generators located at headworks back up
essential buses.
The main lighting distribution boards are proposed to be located adjacent to the common
services boards.
3.5.9
Headworks Auxiliary Board HAB (11 kV)
The 11 kV Headworks Auxiliary Board (HAB) is supplied from the Main Auxiliary Boards
2 & 3. The HAB has two 11 kV bus sections interconnected through a bus tie circuit
breaker. The two bus sections supply their dedicated 2000 KVA headworks auxiliary
transformers to feed the 400 V headworks supply switchgear. The bus tie remains open
during normal operating conditions and closes automatically if either one of the two
incomer circuit breaker trips due to fault conditions.
The headworks auxiliary board is proposed to be located in the local control building for
the gates.
The HAB is connected to two diesel generator sets of each about 2000 KVA, which start
automatically in case of loss of complete power supply. These diesel generator sets will
be located close to the local control room.
Each diesel generator shall be adequate capacity to:
-
be able to start auxiliaries for one unit start-up.

Operate the station drainage pumps
Operate the powerhouse HVAC system
Operate the access tunnel lighting system
Operate the powerhouse emergency lighting system
Operate one dewatering pump
To be able do this job, each diesel generator will be a large unit, estimated at around
2000 KVA. The actual size of these units will be selected during detailed design.
3.5.10 Headworks Supply Board (0.4 kV)

The 400 Volt board at the headworks supplies the spillway, the intake gates, lighting, for
any required outlet works, access tunnel lighting, and required external ventilation etc.
3.5.11 Protection and Metering

Protection and metering equipment is foreseen at three locations. The first group is with
each generating unit. The second group is with the underground GIS and the third group
is with the surface AIS substation. Protection relays are foreseen as numerical relays in
rack mounts that directly interface with the distributed control system (DCS) for indication
of both tripping and alarm signals. The primary outputs are wired to lockout relays in the
same switchboard for high speed direct tripping. All trip circuits are directly wired to the
device being tripped. Relay protection will be conservatively applied with appropriate
reserve protection. If possible, the reserve protection will be a second identical protective
device that is fed by separate instrument transformers. Metering devices will be included
as part of the distributed control system. High accuracy measurement circuits will
independently measure and record information for a particular energy measurement. The
same devices will be able to place the recorded information on the bus of the distributed
3-10
Volume 8
control system for access at any point on the distributed control system via the manmachine interface. VT secondary protection will be in the form of miniature circuit
breakers. Fuses are to be avoided to the extent possible.
3.6
Auxiliary Transformers
3.6.1
Main Auxiliary Transformers
As the generator circuit breaker scheme is being proposed for the Dasu Hydropower
Project, the need for Station Service Transformers connected to the 765 kV switchgear is
eliminated. Instead, Main Auxiliary Transformers stepping down the voltage from the
generator terminals to 11 kV level can be used to supply the unit and station auxiliary
loads. It is not necessary to install a Main Auxiliary Transformer for each unit. It is
considered economical to provide 20 kV/11 kV transformers on four of the eight units as
shown on Fig. 3.3. Each Main Auxiliary Transformer will be capable of supplying full unit
auxiliary loads of four units plus full load of Headworks Installations and 765kV
substation, and half of the station common and essential loads. Each Main Auxiliary
Board (MAB) is supplied from its dedicated Main Auxiliary Transformer and alternately
from its neighbouring Main Auxiliary Board. The load of each Main Auxiliary Transformer
is estimated at 8 MVA.
Manual taps covering the range of 5% in steps of 2.5% are proposed. An impedance
voltage of 8% is foreseen.
The primary windings of the Main Auxiliary Transformers will be connected to the
generator IPB and should therefore be of a construction which minimizes the possibility
of either phase-to-phase or earth faults. This could be achieved by fitting phase
segregation barrier plates. Proper isolation of bus enclosures can be provided and
barriers extended into the transformer enclosure to well below the phase connections.
Single phase transformers will fully satisfy the iso-phase construction requirement.
In accordance with normal industry practice and as a safeguard against fire hazards,
transformers filled with mineral oil will not be used inside buildings. Epoxy cast resin
insulated dry type transformers are, therefore, proposed.
Class H insulation material (operated at class F temperatures) shall be used with the
windings impregnated and cast under vacuum into moulds of glass fibre reinforced
epoxy resin. The windings shall not absorb any humidity. The insulation material shall be
nearly inflammable and self-extinguishing upon the removal of electrical fault energy.
The transformers shall be designed for natural air cooling and be housed in a steel sheet
or aluminium sheet enclosure of adequate mechanical strength.
The following additional accessories are envisaged for each transformer.
-
Three (3) resistance type temperature detectors (Pt 100) inserted in the LV
winding, for local temperature measuring.
Winding temperature monitoring device applying several sensors, with separate

contacts for warning and tripping.
3.6.2
Auxiliary Power Transformers
The following auxiliary power transformers of dry indoor type are envisaged for supplying
their respective auxiliary boards:
3-11
Volume 8
4 Nos 11 / 0.4 kV Unit Auxiliary Transformers, each supplying the unit auxiliary
loads of two (2) units during normal operation but sized to supply full unit auxiliary
loads of four (4) units. The size of each Unit Auxiliary Transformer has been
estimated as 2000 kVA.
4 Nos 11 / 0.4 kV Common Services Transformers, each supplying one fourth of

the total station common auxiliary loads of the complete power station during
normal operation but sized to supply half of the total common auxiliary loads of
the complete power station. The size of each Common Services Transformer has
been estimated as 2500 kVA.
4 Nos 11 / 0.4 kV Essential Service Transformers, each supplying one fourth of

the total station essential services loads of the complete power station but sized
to supply half of the total essential services loads of the complete power station.
The size of each Essential Service Transformer has been estimated as 2000
kVA.
2 Nos 11 / 0.4 kV Substation Auxiliary Transformers, each supplying half of the

total auxiliary loads of the 765 kV substation during normal operation but sized to
supply full auxiliary loads of the 765 kV substation. The size of each Substation
Auxiliary Transformer has been estimated as 1000 kVA.
2 Nos 11 / 0.4 kV Headworks Services Transformers, each supplying half of the

total auxiliary loads of the headworks installations during normal operation but
sized to supply full auxiliary loads of the headworks. The size of each Headworks
Services Transformer has been estimated as 2000 kVA.
The design and construction features of the auxiliary transformers will be similar to those
of Main Auxiliary Transformers except for primary winding connections, which will utilize
cable connections instead of Isolated Phase Bus connections envisaged for the Main
Auxiliary Transformers.
3.6.3
Rated Lightning Impulse Withstand Voltages
The proposed values of lightning impulse withstand voltages for transformer windings
that are in line with IEC Standards are as follows:
Voltage Rating
a.
b.
kV
20 kV Voltage Windings
Nominal voltage
Rated short-duration power frequency withstand voltage
Rated lightning impulse withstand voltage (peak)
20
50
125
11 kV Voltage Windings
Nominal voltage
Rated short-duration power frequency withstand voltage
Rated lightning impulse withstand voltage (peak)
11
28
75
Further studies during the detailed design stage should be undertaken to confirm the
above values. Surge arresters will also be considered on the terminals of all major
equipment (main transformers, aux transformers, generators).
3-12
Volume 8
3.7
Miscellaneous Electrical Auxiliaries
3.7.1
General
The power plant will be provided with the following electrical auxiliaries, which are
needed for the reliable operation of a modern station:
-
Unit and Station Auxiliary supply system;

Standby power supply system;
DC and uninterruptible power supplies; and
Cables and earthing
For dimensioning, design and layout of the various plant components and installations,
the following features and aspects have been considered:
-
Ratings to safely cope with normal and fault conditions, the prevailing site
conditions, avoiding any over-stressing of material and equipment.
Equipment to be of standard design, providing highest degree of safety, reliability,
availability, redundancy concepts and ease in operation.
Equipment arrangements to consider adequate space and access for transport,
installation, commissioning, operation and maintenance.
The layout, design and manufacturing of all electrical equipment shall comply with the
latest edition of the relevant IEC standards.
3.7.2
Station Auxiliary Power Supply System
The electrical main connections constitute the major part of the electrical equipment in a
hydropower plant having close relation with the power system, protective relaying and
the selection of electrical equipment. The main connections directly affect the operation,
maintenance and investment in the hydropower plant. Comprising of connections
between the generators, transformers, circuit breakers, CTs, PTs, transmission and
station auxiliary supply power distribution, the main electrical connections are
undoubtedly the key to the electrical design of the hydropower plant. The pre-requisites
for the selection of the main connections are the reliability of the power supply to the
consumer, simplicity in the design, operational flexibility, ease in maintenance and of
course low capital and operation costs.
The final electrical configuration is chosen based on the size of generating units keeping
in view the above mentioned selection requirements. There are several types of
electrical main connections available, each having advantages and disadvantages as
compared to each other in terms of reliability, simplicity, operational flexibility etc. While
some configurations offer maximum advantages, the same may not be economically
justifiable. These options must be explored at the feasibility study stage of a hydropower
scheme.
For the Dasu Hydropower Project, several electrical systems configurations were
explored based on schemes implemented in large hydropower plants. In particular, the
unit and station auxiliary supply system configurations of Ghazi Barotha Hydropower
Plant, Tarbela Hydropower Third Extension Project Units11-14, Neelum-Jhelum
Hydropower Project and Basha-Diamer Hydropower Project were studied. None of the
schemes were found to be directly applicable for Dasu Hydropower Projects owing to its
larger size units characterized by higher auxiliary loads. Consequently, a unique scheme
has been developed for Dasu Hydropower Project that satisfies the following reliability,
operational flexibility and design criteria:
3-13
Volume 8
The AC power supply system shall be designed to provide all electrical load
requirements for units and other station auxiliaries to operate under maximum
expected conditions.
Failure of one start-up source shall not prevent any unit from being started or
shutdown. The supply to running loads of all eight units shall be available when
these trip simultaneously.
Each Unit Auxiliary Transformer shall supply the auxiliary loads of two units,
however it shall be sized to supply the loads of four units.
Each 11 kV Main Board and 400 V Boards shall have redundant supply in feeds.
The largest motor shall be capable of being started without allowing the bus
voltage to drop below 90% of the bus rated voltage. The motors shall be
designed for starting at as low as 80% of their nameplate voltage ratings.
The MV switchgear shall be IEC 12 kV with 25 kA short circuit interrupting
capability for use on a 11kV nominal voltage system. It will be confirmed by short
circuit study at the detailed design stage before finalizing the specifications.
The LV switchgear shall IEC 400 V with 50 kA short circuit interrupting capability
for use on a 400V nominal voltage system, to be confirmed at the detailed design
stage.
The power plant auxiliary supply system shall be designed to provide satisfactory
performance during emergency conditions for power system (grid) voltage as low
as 90%.
The main features of the proposed unit and station auxiliary supply system configuration
are briefly described below:
The station auxiliary power supply system is based on the generator circuit breaker
concept wherein four (4) main auxiliary transformers are to be installed on the generator
output side after each generator circuit breaker on four (4) generating units.
The proposed scheme of the station auxiliary power supply system is shown in fig 3.3.
Four (4), 20 kV/11 kV Main Auxiliary Transformers of about 8 MVA rating each are
installed on units 1, 3, 6 & 8. These transformers feed the 11 kV Main Auxiliary Boards
(MAB 1, 2, 3 & 4).
The Main Auxiliary Boards (MAB 1 & 2) feed the respective auxiliary transformers of the
Unit Auxiliary Supply Board (UASB 1), the Common Services Board (CSB 1) and the
Essential Service Boards (ESB 1). MAB 1 & 2 additionally feed the Substation Auxiliary
Board (SAB) and the Headworks Auxiliary Board (HAB) respectively.
The Main Auxiliary Boards (MAB 3 & 4) feed the respective auxiliary transformers of the
Unit Auxiliary Supply Board (UASB 2), the Common Services Board (CSB 2), the
Essential Service Boards (ESB 2). MAB 2 & 3 additionally feed the Headworks Auxiliary
Board (HAB) and the Substation Auxiliary Board (SAB) respectively.
There are two (2) 400 V Unit Auxiliary Supply Boards (UASB 1 & 2) each of which serves
to supply unit auxiliary loads of Units 1, 2, 3 & 4 and Units 5, 6, 7 & 8 respectively. Each
of the Unit Auxiliary Supply Boards (UASB 1 & 2) is fed from the respective Main
Auxiliary Boards via two (2) 2000 kVA, 11 kV / 400 V auxiliary transformers. Each unit
auxiliary transformer has been sized such that it should cater for all the unit auxiliary
loads of four units connected to the respective Unit Auxiliary Supply Board in case the
second unit auxiliary transformer of the board fails.
There are two (2) 400 V Common Service Boards (CSB 1 & 2) each of which serves to
supply common auxiliary loads of the entire powerhouse. Each of the Common Service
Boards (CSB 1 & 2) is fed from the respective Main Auxiliary Boards via two (2) 2500
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Volume 8
kVA, 11 kV / 400 V auxiliary transformers. Each common auxiliary transformer has been
sized such that it should cater for all the common loads of the entire powerhouse
connected to the respective Common Service Board in case the second common
auxiliary transformer of the board fails.
There are two (2) 400 V Essential Service Boards (ESB 1 & 2) each of which serves to
supply essential auxiliary loads of the entire powerhouse. Each of the Essential Service
Boards (ESB 1 & 2) is fed from the respective Main Auxiliary Boards via two (2) 2000
kVA, 11 kV / 400 V auxiliary transformers. Each essential service auxiliary transformer
has been sized such that it should cater for all the essential loads of the entire
powerhouse connected to the respective Essential Service Board in case the second
essential auxiliary transformer of the board fails.
There is one (1) 400 V Substation Auxiliary Board (SAB) which serves to supply auxiliary
loads of the 765 kV Substation. The Substation Service Board (SAB) is fed from the
respective Main Auxiliary Boards via two (2) 1000 kVA, 11 kV / 400 V auxiliary
transformers. Each substation auxiliary transformer has been sized such that it should
cater for all the substation auxiliary loads connected to the Substation Auxiliary Board in
case the second substation auxiliary transformer of the board fails.
There is one (1) 11kV Headworks Auxiliary Board (HAB) which serves to supply auxiliary
loads of the Headworks installations. The Headworks Auxiliary Board (HAB) is fed from
the Main Auxiliary Boards (MAB 2 & 3) and supplies the 400 V Headworks Supply Board
(HSB) via two (2) 2000 kVA, 11 kV / 400 V auxiliary transformers. Each headworks
auxiliary transformer has been sized such that it should cater for all the headworks
auxiliary loads connected to the Headworks Supply Board in case the second auxiliary
transformer of the board fails. The HAB is also connected to 2 X 2000 kVA, 11 kV
emergency diesel generators that start upon total failure of 11 kV supply and feeds the
essential load of the headworks installations such as intake, spillway and for lighting and
powerhouse through MAB 2 & 3.
Each generating unit has one 400 V Unit Auxiliary Board (UAB). The Unit Auxiliary
Boards of Units 1 & 2 are fed from the left side bus sections of the Unit Auxiliary Supply
Board (UASB-1) and Essential Service Board (ESB-1). The Unit Auxiliary Boards of
Units 3 & 4 are fed from the right side bus sections of the Unit Auxiliary Supply Board
(UASB-1) and Essential Service Board (ESB-1). The Unit Auxiliary Boards of Units 5 & 6
and those of Units 7 & 8 are similarly fed from Unit Auxiliary Supply Board (UASB-2) and
Essential Service Board (ESB-2).
The above described configuration of the Unit and Station Auxiliary Supply System was
modelled utilizing ETAP Power Station Engineering Software Package and a short circuit
study was conducted to determine the three phase short circuit levels at various Plant
Buses. Simplified assumptions and estimated / typical data were used. The summary of
results is depicted in the table 3.3.
3-15
Table 3.3
S/No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Volume 8
Results of the Short Circuit Study
3 SC Current,
kA
Switchgear Bus
11 kV Main Auxiliary Board (MAB-1)
400 V Unit Auxiliary Board (UAB-1)
400 V Unit Auxiliary Supply Board (UASB-1)
400 V Unit Auxiliary Supply Board (UASB-2)
400 V Common Services Board (CSB-1)
400 V Common Services Board (CSB-2)
400 V Essential Services Board (ESB-1)
400 V Essential Services Board (ESB-2)
400 V Switchyard Auxiliary Board (SAB)
5.1 (10.2)
5.1 (10.2)
5.1 (10.2)
5.1 (10.2)
19.5 (20.8)
19.5 (20.8)
19.5 (20.8)
19.5 (20.8)
19.5 (20.8)
19.5 (20.8)
19.5 (20.8)
19.5 (20.8)
37.0 (42.6)
37.0 (42.6)
43.4 (46.4)
43.4 (46.4)
37.0 (42.6)
37.0 (42.6)
20.0 (21.5)
Note: Values in brackets indicate short circuit currents when bus ties between MAB-1 &
MAB-2 and MAB-3 & MAB-4 are closed.
The main design parameters of major equipment are shown in the following tables.
These parameters are preliminary and will be refined during the detail design
development stage.
Table 3.4 Main Design Parameters of 11 kV Switchgear
Parameter
MV SWG
Nominal System Voltage
Rated Voltage
Rated short time withstand current
Nominal current (bus bars)
Insulation medium
Frequency
Aux. and Control Voltage (DC)
Circuit Breakers
Type
Rated nominal current
3-16
Unit
Value
KV
KV
kA
A
Hz
V
11
12
25
1250
air
50
220
A
kA
Vacuum
1250, 630
25
Table 3.5
Volume 8
Main Design Parameters of LV Switchgear
Parameter
LV SWG
Nominal System Voltage
Rated Voltage
(max)
Nominal current (bus bars) max.
Insulation medium
Frequency
Aux. and Control Voltage (DC)
Unit
Value
V
V
400
1000
kA
A
50
4000
air
50
220
Hz
V
Table 3.6 Main Design Parameters of Main Auxiliary Transformers
Parameter
Rating
Rated Voltage Ratio
Vector group
Tap changer
Number of steps
Tap-changing-range in % of voltage
Voltage adjustment
Impedance voltage (UK)
Rated frequency
Type / Cooling
Unit
kVA
kV/kV
%
%
%
Hz
-
Value
8000
21/11
Dyn11
NLTC
5
2.5
5
8
50
Dry / AN
Table 3.7 Main Design Parameters of Auxiliary Transformers
Parameter
Rating
Rated Voltage Ratio
Vector group
Tap changer
Number of steps
Tap-changing-range in % of voltage
Voltage adjustment
Impedance voltage (UK)
Rated frequency
Type / Cooling
3.7.3
Unit
MVA
kV/kV
%
%
%
Hz
-
Value
1.0/2.0/2.5
11/0.4
Dyn11
NLTC
5
2.5
5
8
50
Dry / AN
Standby Power Supply System
The standby power supply system is the diesel generator systems already described
above. Diesel generators are installed at headworks / dam to ensure a reliable power
supply for units and the gates regardless of what may happen in the underground
powerhouse.
The scheme is designed for the headworks systems to have at least two levels of
contingency built in. Normal power is supplied at 11 kV from the powerhouse Main
Auxiliary Boards (MAB 2 & 3). The first contingency is when the supply from either of the
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two Main auxiliary Boards fails. In such a case, the headworks will be supplied from the
healthy Main Auxiliary Board. The second contingency is to start the local diesel
generators and supply the 11kV bus locally when the supply from both the Main Auxiliary
sources MAB-2 and MAB-3 fail.
The diesel generators located at the Headworks can be connected to supply any single
load throughout the complex for one generator. The loads must be selected so as not to
overload the generator. The generators need to be supplied with governors and voltage
regulators such that they are capable of paralleling and automatic synchronizing. The
units are for standby duty only, a day tank located in the engine frame can supply the
unit for up to 8 hours of operation, and may be sufficient for the entire operation.
Diesel generators with brushless excitation systems are foreseen.
The design parameters of emergency diesel generators are shown in the following table.
These parameters are preliminary and will be refined during the detail design
development stage.
Table 3.8 Main Design Parameters of Emergency Diesel Generators
Parameter
Rated Capacity at IEC Conditions
Generator rated voltage
Unit
kVA
Headworks
2000
kV
11
0.85
Rated power factor

Hz
Rated Frequency
3.7.4
50
DC Supplies
The DC system is foreseen as redundant 220 VDC batteries in the Powerhouse and
Headworks building. 220 VDC becomes the standard means of control throughout the
powerhouse. All important DC loads shall be provided with redundant DC sourcing in
uninterruptible method. This includes all protective relays, control systems for the units,
and the digital control system.
Each battery will have redundant battery chargers supplied from the Common Services
Boards (CSB 1 & 2) for the powerhouse and from the Headworks Service Board for the
Headworks installations. Each battery in turn will supply a DC circuit breaker panel board
of major feeders. Those feeders are sub-divided into further circuit breaker panel boards
as required to supply each actual load with a miniature circuit breaker.
Many important modern loads require AC rather than DC. This includes components of
the microprocessor based control systems (Distributed Control System (DCS) and
Programmable Logic Controllers (PLC) etc), but also things like fluorescent lights that
may be used for emergency lighting. Two uninterruptible power supply systems (UPS) of
230 VAC, single-phase are to be provided, each being supplied from the separate
Powerhouse 220 VDC Batteries/ Battery Chargers. The principal element of the UPS is
the inverter. The quantity of inverters needs to be the total number required in parallel to
achieve capacity plus one more for redundancy. In this way, a single inverter failure has
no impact on operation of the UPS. An important component of these systems is a static
switch. The static switch is used to select between a normal AC source and a UPS
source. Normally, the load is simply taken from the UPS. But the static switch allows the
system to be completely shut down without interrupting the circuits, although they would
then be supplied from normal supplies. Also, if a second inverter fails, or an overload
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occurs on the system, the static switch would switch back to the normal source, again,
without interruption to the loads. The static switch is capable of switching in less than 0.5
milliseconds. The inverter frequency is synchronized to the normal source so that
switching can occur instantly. One of these systems per powerhouse is required.
Alternatively, a number of small inverters can also be considered for the sake of
providing emergency lighting using low wattage mini-fluorescent AC lamps. This is very
important for an underground powerhouse. Nothing too fancy for lighting circuits except a
transfer switch. A separate 48 V battery system will be provided for the SCADA and
Telecom systems.
Table-3.9 Main Design Parameters of DC and UPS System
Parameter
DC SYSTEM
Nominal System Voltage (DC)
Rated Voltage (DC)
UPS SYSTEM
Nominal Input Voltage (DC)
Nominal output voltage (AC)
3.7.5
Unit
Value
V
V
220
220
V
V
220
230
Cables and Earthing
3.7.5.1 Cables
The following main types of cables are foreseen:
-
11 kV power cables;
230 V/400 V power cables;
multicore protection and control cables;
multicore communication cables;
co-axial high frequency cables;
fibre optic cables; and
Data highway cables (special cable).
It is proposed that all cables have copper conductors with the following types of
Insulation:
-
Cross-linked polyethylene (XLPE) for 11 kV;

XLPE for 230 V/400 V power cables;
Polyethylene (PE) or XLPE for multi core control cables; and
CPE (Chlorinated Polyethylene) for communication and co-axial high frequency
cables.
Wire sizing will follow IEC standard rules throughout. Raceway fill with cables will also
follow IEC rules. To the extent possible, cables will be routed using ladder type cable
trays.
Cables will be specified to meet IEC standards with the desired options from the
standards selected. In particular, conductors are to be copper, insulation is to be XLPE
whenever possible, medium voltage power cables are to be copper foil shielded and
terminated with proper stress relief devices, outer jackets are to be thermosetting type,
colour coding is to use actual insulation colour (not all black with number identification).
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Steel conduit or other armouring will be used on cables laid outside the powerhouse and
for cables close to the mechanical plants requiring higher mechanical strength.
Co-axial and other special cables will be in accordance with the particular requirements
of the media for which they are being used.
3.7.5.2 Earthing
The design of the earthing system will generally follow the main requirements outlined in
the IEEE publication No.80 Guide for Safety in Substation Grounding.
The main powerhouse earth will derive from connections to the turbine penstocks, spiral
casings and draft tube liners. A station earth ring will be routed around the station to
connect all the installed electrical equipment to earth buses and to bond principal pieces
of exposed steel to the earthing network. Earthing of doorframes, stair treads, and other
incidental equipment is not intended. A system of ground plates which can be connected
to by bolting will be specified for connection of principal components to the main grid
system.
At the time of detailed design, earthing system calculations should be performed to
determine minimum conductor size and the quantity and size of conductor and earth
rods to obtain the required station ground resistance (usually about 0.5 ohms). Step and
touch potential calculations should be carried out to ensure that all areas are safe from
electrical hazard.
3.8
Control and Monitoring
3.8.1
General Control Philosophy
The Dasu Hydropower Plant and related facilities including the head regulator and power
intake system will be controlled and monitored through a modern state-of-the art
Distributed Control System (DCS). The control philosophy is based on a structure with
the following hierarchical levels:
1.
2.
3.
4.
Supervisory Control Level

Central Control Level
Unit Control Level
Local Control Level
The supervisory control & monitoring level will be limited exclusively to the control of the
substation 765 kV circuit breakers and automatic load frequency control of generating
units; and for limited monitoring of the generating units and the 765 kV substation from
the National Power Control Centre (NPCC), Islamabad via SCADA.
The overall control and monitoring of the entire powerhouse will be carried out from a
central control room, which will constitute the second highest level in the control
hierarchy.
The next lower level of the hierarchy will be the unit control. This level will deal with the
control of individual units, which include the generating units, 765 kV substation,
electrical distribution, gates, and other auxiliary systems.
The bottom of the hierarchy will be the local control. This will comprise hardwired
instrumentation and control of the local control panel e.g. local panels of circuit breakers,
generators, gates etc.
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Monitoring at all levels will be done simultaneously.

The general control and monitoring philosophy is indicated on fig 3.4. The control system
proposed is a distributed control system (DCS), with fibre optic data highways between
the various controllers. The main man-machine interface point is the central control room
of the powerhouse where four (4) Operator Workstations will be located. Another manmachine interface point would be the gate control building where one (1) Operator
Workstation dedicated for the control and monitoring of the head regulator gates will be
located. Additionally, an engineering workstation will be located in the Programmers
room.
The DCS will monitor both analogue and digital instrumentation throughout the station to
provide the operators with the required information to safely and efficient operation of the
station. The primary means for interaction between the station operators and the DCS
shall be by means of Visual Display Unit (VDU) based operator workstations. The
operator workstations shall allow the operator to perform control actions, enter data or
request specific information or displays. The operator workstations shall also notify the
operator of abnormal conditions relating to the station processes or equipment. The
operator workstations shall also notify the operator of abnormal conditions within the
DCS.
Each operator workstation will be capable of controlling up to two VDUs from the same
trackball/mouse and keyboard.
All graphic displays associated with equipment, systems and processes controlled,
monitored and alarmed from the main control room will be available for display on any
VDU from any main control room work station on the operator control console. .
The DCS design will incorporate functional and component redundancy to ensure
maximum reliability during system operation. No single component failure in the DCS
will adversely affect the control, alarm and data acquisition functions of the system.
Critical trip functions, which are developed within a particular processor and used by
another processor, will be hard-wired between the processors in addition to the signal
being transmitted over the data highway.
All distributed processing units envisaged will have a redundant architecture. The
redundant distributed processing units will include redundant functional processors,
redundant memory and redundant communications equipment. One member of a
processor pair will be active and shall be functioning to fulfil the requirements of the
functional controller or processor. The other member of the processor pair will be
operating in a hot standby mode and will be continuously updated to be aware of the
actual status of the activities being conducted. If the operating processor suffers a
disability as determined by continuously running diagnostic routines, all the functions will
immediately be assumed and conducted by the hot standby member and the transfer
shall not result in any disturbance to the process. An alarm of the transfer will be
provided in the Central Control Room. Continuously running diagnostics and failure
alarming will be provided for the hot standby member also.
A redundant high-speed data highway system is envisaged for communication between
the hardware components of the Distributed Control System. The system will include
redundant communication processors, redundant communication transmitters and
receivers and redundant cables. A break in a cable at any point or a failure of
communication equipment or components shall not result in transmission failure, since
the second cable and the redundant communication equipment or components will
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provide full backup at all times. Any failure of the communication network will be
alarmed. The data highway will utilize fibre optic cables.
All DCS equipment power supplies will be redundant with automatic switchover for
uninterrupted operation in the event of power supply failure. An alarm will be actuated in
the event of any power supply failure.
The engineering workstation will be capable of interfacing directly to the redundant data
highways. So interfaced, the engineering workstation will be capable of entering, altering
and monitoring all DCS programs interfaced to the data highway.
In addition to
providing immediate and long-term storage of all programmed system software, the
engineering workstation will also be capable of providing hard copy documentation by
driving a text printer and VDU copier. All software and control processor programs shall
be loaded and saved on engineering workstation each time the programs are altered.
Any controller defined as an integral part of the DCS will be programmable from the DCS
engineering workstation.
The programming station will include provisions to ensure that unauthorized program
entry and alteration cannot occur.
The internal clocks of the DCS will be time synchronised with the GPS Clock.
3.8.2
Generating Unit Control
Each generating unit will be provided with a redundant processor unit (RPU) located at
the Unit Local Control Panel (ULCP). The RPU will contain all the start and stop logic
required for all modes of operation. The controller will also provide the required signals
or information to the governor and excitation controllers. The units will be capable of
operation from a ULCP near the unit in automatic or manual mode. The local control
system is foreseen with an operator interface consisting of a colour digital touch screen
only. The control of the intake gates of the units will be through the ULCP of the
respective units for which the RPU of the unit will be interfaced with the related control
system of the intake gate.
The RPU of each generating unit will be housed in the respective ULCP and will be
interfaced with the following equipment / systems for control of the unit through operator
workstations of the DCS:
Local Control Panel
-
Touch Screen Panel part of ULCP
Generator & Auxiliaries

-
Generator Terminal Box

Static Excitation System including AVR
Rotor Temperature Monitor
Air Gap and Vibration Monitor
High Pressure Pump
Turbine & Auxiliaries

-
Turbine Terminal Box

Digital Turbine Governor
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Intake Gate(s)
-
Local Control Panel
Automatic Synchroniser
-
Automatic Synchroniser Panel
Generator Circuit Breaker

-
Local Control Panel
Generator & Transformer Protection

-
Generator & Transformer Protection Relay Panel (s)
Unit Auxiliary Switchgear

-
Unit Auxiliary Board

Unit Auxiliary Supply Board (Connected to RPUs of Units 1 & 6 only)
Other Unit Related Auxiliaries

-
Other Systems & Auxiliaries not covered above.
3.8.3
Auxiliary Power
Two RPUs, each covering the following MV/ LV Switchgears are proposed to be
interfaced with DCS:
Redundant Processor Set # 1
-
11 kV Main Auxiliary Boards MAB 1 & 2

Common Services Board CSB 1
Essential Services Board ESB 1
Substation Auxiliary Board SAB 1
Redundant Processor Set # 2

-
11 kV Main Auxiliary Boards MAB 3 & 4

Common Services Board CSB 2
Essential Services Board ESB 2
Substation Auxiliary Board SAB 2
The control of the MV (11 kV) switchgear (all circuit breakers) and LV (400 V) switchgear
(Incoming & bus coupler breakers only) will be carried out through DCS via operator
workstations in the central control room (CCR) or from local points at the switchboards.
However, the status of all circuit breakers of both MV and LV switchgears along with the
bus voltages will be displayed at the Operator workstations in the central control room.
One RPU will be dedicated to the two emergency diesel generators located at
headworks. Loss of station power would cause automatic starting of diesel generators
and reconfigure the switching to limit the loading on the diesel generators. Once a main
unit has been restarted, power can be fully established by the main unit, and the diesel
unit can be stopped. Then the power is reconfigured to normal. This configuration and
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reconfiguration can occur automatically or manually. Manual operation would be

supervised by the control system to prevent switching errors.
The diesel generators will be capable of being monitored, started, synchronised, loaded
and unloaded and shutdown from the operator workstations for periodic testing. The
synchronising facilities are also required for reconnection of a normal supply, following a
blackout, before shutting down the diesel generator.
3.8.4
765 kV Substation
One 765 kV GIS substation, in the underground substation cavern and one 765 kV AIS
surface substation are envisaged for the Dasu hydropower project. While the
underground substation will comprise circuit breaker bays for connection of the generator
step-up transformers of the eight generating units and for interconnection of the
underground and surface substations, the surface substation will cater for connection of
the outgoing 765 kV transmission lines. Both the substations are based on the breakerand-a-half scheme.
The protection and metering panels of each of the above substations would be installed
in a protection relays cum local control room adjacent to the respective GIS hall and AIS
room. These rooms will also house control panels for the circuit breakers, disconnect
switches and earthing switches operation.
One Remote Input / Output Unit (RIO) each, located in the respective protection relays
cum local control rooms of the respective 765 kV substations will be interfaced with the
control & protection relay panels and with the substation equipment as required to
enable control of the circuit breakers, disconnect switches and earthing switches and
monitoring of the substation equipment from the central control room. The RIOs will be
connected to the remaining DCS through data highway comprising of redundant fibre
optic cables.
3.8.5
Control from NPCC (SCADA)
It will be possible to control the 765 kV surface substation, and the generators from the
National Power Control Centre (NPCC), Islamabad. NPCC needs to be given direct
close-open control over each 765 kV circuit breakers. This provides control over the
transmission lines.
Load and frequency control and status signals will be exchanged via a SCADA-DCS
data link for each unit. The command signals to the unit shall be sourced from the DCS,
including SCADA signals, which will be automatically passed on to the units. It will be
possible to control each unit through Automatic Load Frequency Control (ALFC) mode.
All the interface equipment/devices necessary for operation under ALFC mode from
National Control Centre (NCC), Islamabad would be provided at Dasu powerhouse.
A gateway controller/inter-centre communication controller, especially tailored for data
interchange between the Distributed Control System (DCS) computers and the SCADA
master system installed at NPCC Islamabad, will be installed at the Dasu powerhouse
for monitoring and control of the station equipment under SCADA.
The amount and type of information (scope of signals) to be exchanged between the
main SCADA computers at NPCC and the DCS process computers will be controlled by
software blocking/authorization in the gateway controller and the DCS system; such that
in future if any additional information is required to be transmitted, it can be done with
minimum work.
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The design of the gateway controller will be based on redundant processors with
duplicated database and operating system. These processors will be configured in a
"hot-standby" mode with switchover from one processor to the other without any
interruption to the SCADA system. The gateway will interface with the DCS equipment
through the dual redundant Data Highway Network in the powerhouse as shown in the
DCS configuration drawing. The gateway controller will communicate with the main
SCADA equipment at the NPCC via the Front End computers utilizing duplicated data
channels on separate physical routes.
3.8.6
Gates
Six hydraulically operated crest type radial gates will be installed at spillway. The
hydraulic hoist will consist of two cylinders and a hydraulic power and control system.
The gates will be operable individually from their respective local control panels, and
individually, jointly or in batches from spillway gate control building and remotely from the
powerhouse central control room and shall open automatically when the reservoir level
exceeds the design level.
The control system, working on DC from storage batteries, will include gate operation
signals, alarms, solenoids, gate position indicators and interlocking devices. The control
system needs to include some form of downstream warning before initiating opening of a
gate. Depending on the simultaneous change of flow, the warning system may have to
extend downstream a considerable distance to be effective. Operation of the warning
system should be automatic, regardless of the point of control. The second part of the
system is the open and close sequence for the gates. The control must be capable of
local operation from the gate, including possible manual operation. It should be capable
of manual adjustment from the gate control building.
The spillway gates are foreseen as radial gates with hydraulic operators. It is normal that
this system of gates be controlled from either the gate control building or the powerhouse
central control room. It should be capable of automatic position adjustment to meet a
flow requirement based on head and number of gates open. It should be capable of
maintaining reservoir level at a constant level through controlled operation of gates by
the distributed control system (DCS). The control system operator can then select the
control method to be implemented, based on the prevailing conditions at the time. The
most likely operation required is to operate adequate numbers of gates and set the
opening so as not to exceed the maximum reservoir level. If the system were left in
automatic reservoir level control mode, operation of the gates would occur automatically
when high levels of the reservoir occur. The control program would require remote
reservoir level sensing to accurately determine rates of reservoir rise and fall. The
system is foreseen as one where a gate opening is given to the local control system, and
the local control system adjusts the gate to meet that requirement. The gate control
distributed control system can compute the required opening for each of the modes
described and then send the required gate opening value to the gates. Dead bands for
the set point and maximum number of operations per hour are needed to avoid
continuous oscillations in the positioning of the gates.
Seven low level outlet conduits of the size 5m wide X 7.2m high will be required for
sediment sluicing and emptying reservoir in an emergency. A hoist control module
consisting of hydraulic and electrical controls will be provided with each gate to control
the operation of hoist. A local control panel will be provided near each gate. One of the
primary uses of these gates is emergency lowering of the water in the reservoir. It may
also be desirable to use them to release water when the power generating units are
unable to be used for that function. As such, manual operation and positioning is
foreseen from local control panels, and from the gate control building. An automatic
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system is foreseen similar to that for the spillway gates where a required gate opening
value is given from control centre to the local gate controller that in turn automatically
adjusts the gate to meet that requirement. A downstream warning before initiating
opening of low level outlet gates will be interfaced with the spillway gate warning system.
One Redundant Processor Unit (RPU) will be dedicated for the control and monitoring of
the main spillways gates and, low level outlet conduits / gates. The local control panels
of each of these gates will be interfaced with this RPU. The RPU will be connected to the
DCS redundant data highway through which it will communicate with the operators
workstation located in the gate control building and with the operator workstations
located in the powerhouse central control room. This way all the gates will be able to be
monitored and controlled through the DCS.
Two gates will be installed in power intake shaft, one in front (downstream side) of intake
as a service gate and another behind it as a guard gate. The fixed wheel gates of
nominal size 6.0 m wide x 8.5 m high; will act as guard gates for protection of turbines
and penstocks. The service gates of nominal size equivalent to fixed wheel gate size will
be vertical lift type, designed for operation under balanced head conditions. The gates
will be capable of being operated from their respective local control panels installed
adjacent to the gates. The local control panels will be interfaced with the RPU of
generating units to enable control of the intake gates automatically through the DCS
logic and manually from the operator workstations in the central control room.
Control of gates (stop logs) at the tailrace tunnel surge chamber and outlet works
structures is strictly a manual affair. These gates are used only when it is necessary to
dewater an outlet tunnel. Hence no control system is required for these gates.
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4.
Volume 8
POWER TRANSFORMERS AND EHV SUBSTATIONS
4.1
Power Transformers and Shunt Reactors
4.1.1
General
Selection of power transformers has been made keeping in view the load requirements
and transportation constraints. For generator transformers at Dasu, single phase water
cooled units have been selected. Power transformers to be provided at Gujar Khan and
Gatti substations as well as the transformer to be installed at Dasu AIS substation for
meeting the power requirement of the local area at 132kV will be single phase units; air
cooled as per the general practice at NTDC 500kV substations.
Sizes of the shunt reactors to be provided at Dasu, Gujar Khan and Gatti will be in
proportion to the lengths of the 765kV lines on which these shunt reactors will be
installed. In the absence of pertinent studies, two shunt reactor banks, each bank
comprising three single phase units, have been assumed at both ends of long 765kV
transmission lines. Rating of single phase unit has been taken as 125MVAR, which is
purportedly the maximum rating practically envisaged by the manufacturers. ONAN (Oil
Natural Air Natural) cooled single phase shunt reactor units have been envisaged in
accordance with the general practice at 500kV substations in NTDC system.
Oil filled transformers and shunt reactors will be equipped with explosion prevention and
fire protection system.
4.1.2
Generator Transformers
For the proposed 540MW generators at 0.95 power factor, a step-up transformer of
570MVA will be required. Transportation limitations on KKH preclude the heavier design
of 3 phase units. As such three 190MVA single phase units have been proposed for
each bank associated with each generator. Based on the information obtained from one
of the transformer manufacturers, following dimensions and weights have been
estimated for single phase unit:
a) Rated power
190MVA
b) No. of phases
c) Voltage ratio
20kV/765/3kV
d) No. of windings
e) Transport dimensions (LxWxH)
7000mmx4000mmx4800mm
f)
9500mmx8000mmx8000 mm
Overall dimensions (LxWxH)
g) Transport weight
160,000kg
h) Overall weight
215,000kg
With the transport dimensions given above, it would be possible to transport the
transformers on the upgraded KKH. However, thorough review of the transportation
arrangement will be carried out during the detailed design stage before finalizing the
generator transformer design.
The insulation levels of the transformers as per IEC 60076-3 will be as hereunder:
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Volume 8
HV Winding
LV Winding
Nominal voltage, kV, rms
765
20
Highest voltage for equipment, kV, rms
800
24
--
50
Rated switching impulse withstand voltage, kV, peak
1550
--
Rated lightning impulse withstand voltage, kV, peak
2100
125
Rated short-duration induced or

Separate source AC withstand voltage, kV, rms
The transformer impedance will be selected at detailed design stage so as to provide

good regulation and to limit system short- circuit current that may flow through the power
transformers.
For the generator transformers, changing of the taps is not frequently required. Therefore
no-load tap changers are proposed with 2 taps above and 2 taps below the rated voltage
tap in steps of 2.5% covering a voltage range of 5%.
Since power plant is located deep underground, putting the generator transformers at the
surface will require very long, high current carrying and expensive isolated phase buses
to connect 20kV generators to the generator step-up transformers. Longer lengths and
large currents will also cause high losses in these buses. The generator step-up power
transformers are therefore recommended to be located underground in a cavern close to
the power plant to minimize the cost and power losses associated with long buses.
Oil-SF6 type bushings are recommended for high voltage side of the transformers to
eliminate electrical clearance problems and minimize space requirements. The low
voltage side of the transformers will be connected in delta using isolated phase buses to
make a delta-wye connection of the bank.
To minimize the size of the transformers, ODWF cooled transformers have been
proposed using oil/water heat exchangers. Firewalls have also been proposed between
single-phase transformers. The 8 metres transformer width provided by one of the
manufacturers marginally allows for 3 single-phase transformers bank to fit within a unit
bay length of 32 meters. Other manufacturers therefore should be contacted at the
tendering stage of the project for possible reduction in the width of the transformers for
convenient movement thereof during installation/replacement.
4.1.3
Power Transformers for 765kV AIS Substations
As part of the dispersal of power generated at Dasu and Basha, one (1) 1500MVA,
765/500kV auto-transformer bank comprising three (3) 765/3/500/3kV, 500MVA single
phase auto-transformers at Gujar Khan Substation and three (3) 1200MVA, 765/220kV
auto-transformer banks, each bank comprising 765/3/220/3 kV, 400MVA single phase
auto-transformers, at Gatti substation have been proposed.
To meet the local power requirement at Dasu, one 160MVA, 765/132kV transformer
bank has been proposed at Dasu 765kV AIS Substation.
Major parameters of the transformers are as follows:
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Volume 8
Gujar
Gatti
Dasu
Khan
AIS
Substation Substation Substation
(1)
Power ratings of the bank
(2)
No. of banks
(3)
No. of single phase units/bank
Three (3)
Three (3)
Three (3)
(4)
Power rating of single phase unit 500MVA
400MVA
53.3MVA
(5)
Rated voltage ratio
765/3/
765/3/
765/3/
525/3/kV
231/3/kV
132/3/kV
(Tertiary voltage ratings to be determined
at the detailed design stage)
(6)
Voltage tapping range as

percent of rated normal
voltage (by on-load
tap changer)
+ 10% in
steps of
1.25%
+ 10% in
steps of
1.25%
+10% in
steps of
0.77%
(7)
No. of steps
+8
+8
+ 13
(8)
Insulation levels:
1550
1300
1550
850
1550
-
2100
1550
2100
950
2100
650
i)
1500 MVA
1
1200 MVA
3
160 MVA
1
Rated switching impulse

withstand voltage phase
earth, kV, peak:
HV winding
LV winding
ii) Rated lightning impulse

withstand voltage phase
earth, kV, peak:
HV winding
LV winding
As per the existing practice in NTDC system for 500/220kV auto-transformers installed in
500kV substations, ONAN/ONAF1/ONAF2 type cooling system is proposed for the
power transformers to be installed under this project.
4.1.4
765//3kV Shunt Reactors for 765kV GIS/AIS Substations
To control over-voltages at the receiving ends of the 765kV transmission lines, shunt
reactors have been proposed at Dasu, Gujar Khan and Gatti 765kV substations.
Major parameters of the shunt reactors are as follows:
(1)
System nominal voltage, line to neutral, kV, rms.
765/3
(2)
Reactor rated voltage, phase to neutral, kV, rms.
800/3
4-3
Volume 8
(2a)
Continuous overvoltage rating, line to neutral, kV, rms.
880/3
(3)
Rated 2 second over voltage rating, line to neutral, % of

nominal rating, not less than.
173
(4)
Rated frequency, Hz.
50
(5)
Neutral rated voltage, kV, rms.
72.5
(6)
Method of system grounding.
Solid
(7)
Insulation levels:
(a) Rated lightning impulse withstand
voltage, kV, peak.
i)
(b)
Line End (Internal) of the winding.
2100
ii) Neutral End (Internal) of the winding.
325
Rated switching impulse withstand

Voltage, phase-earth, kV, peak.
i)
Line End (Internal) of winding.
1550
ii) Neutral End (Internal) of winding.
280
(8)
Cooling ONAN
(9)
Winding Connection
Y-Neutral
Exact MVAR ratings of shunt reactors will be finalized at the tendering stage of the
project after carrying out proper studies.
4.1.5
Bushings
For the generator transformers, oil to SF6 bushings are proposed so that transformers
could be directly connected to GIS through gas insulated buses (GIBs). More important
in this case is that no consideration is required for external electrical clearances from
765kV bushing. Oil to SF6 bushing also considerably reduces overall height of the
transformers as compared to oil to air bushings. Neutral bushing for HV winding however
will be exposed to air.
Oil to air bushings will be required for power transformers and shunt reactors at AIS
substations at Dasu, Gujar Khan and Gatti.
4.1.6
Spare Transformers/Shunt Reactors and Transfer Rail Tracks
Owing to unique ratings of the generator transformers not available at any other power
station and due to transportation difficulties, two (2) spare single phase generator
transformers have been proposed at Dasu to avoid extended outage due to failure of
units in service. The spare units will be placed in the transformer gallery adjacent to the
other generator transformers in the underground substation. Transfer rail tracks will be
provided to shift the transformers on wheels from one position to the other during initial
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Volume 8
installation or during change-over to a spare unit. After the transformer is at its

designated location, it will be secured into position against seismic forces. Pulling eyes
will be provided at strategic locations along the track system. The transfer rail track
system for transformer handling will be extended up to the main access portal for offloading from the trailer.
One spare unit (single phase) is also recommended at each 765kV substation (Dasu,
Gujjar Khan, Gatti) corresponding to each rating of the power transformers and shunt
reactors to be installed under this project. Transfer rail tracks shall also be provided at
the 765kV substations for moving the power transformers and/or shunt reactors on
wheels during installation and for replacement of defective unit.
4.1.7
Cooling Systems
As also indicated hereinabove, oil directed water forced (ODWF) cooling is

recommended for generator transformers for Dasu. The cooling system will be tapped
from the unit cooling water circuits. Water booster pumps will be required to supply water
to coolers whereas oil pumps for coolers will be an integral part of the generator
transformers.
ONAN/ONAF1/ONAF2 type cooling system will be provided for the power transformers
to be installed at Gujar Khan, Gatti and Dasu Surface AIS substations as per NTDCs
practice at its 500kV substations. Shunt reactors will be ONAN cooled.
4.1.8
Nitrogen Injection Explosion Prevention Fire Protection System
The 20/765kV generator transformers and 765/500kV, 765/220kV and 765/132kV power
transformers and 765//3kV shunt reactors will be equipped with Nitrogen Injection
Explosion Prevention and Fire Protection System.
4.1.9
Oil Containment
Provision shall be made in the foundations of transformers and shunt reactors by

constructing peripheral walls to contain oil of the transformers/shunt reactors in case of
leakage/damage therein. This oil would then be drained either to oil collecting pit of
appropriate size under gravity flow or pumped from the containment into tanker trucks.
4.2
EHV Substations
4.2.1
Outcome of the transmission alternatives studied by WAPDA is that 765kV AC would be

more suitable for the dispersal of power, expected to exceed 20,000MW, in the context
of ultimate development of the transmission network in corridor constrained area for
hydropower projects planned on upper Indus River. Diamer Basha Dam Project which is
now in implementation stage is already proceeding with 765kV voltage level for the
transmission of power from Basha to Gujar Khan through Dasu. Accordingly, 765kV
substations have been considered at Dasu Hydropower Plant for inter-connections
between the generator transformers and 765kV transmission network.
4.2.2
Switching Scheme
Compared with various other switching schemes (single bus single breaker, double bus
single breaker, main and transfer bus and ring bus) breaker and half arrangement
affords more flexibility in operation, high reliability, minimum interruption in case of
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Volume 8
breaker failure and uninterrupted operation of the connected feeders for bus bar faults.
Additional reliability of double bus double breaker scheme comes at considerably higher
cost. One and half breaker scheme is proposed for the high voltage substations at Dasu
and Gatti keeping in view NTDC/WAPDA satisfactory operating experience at its 500kV
and 220kV substations for which breaker and half scheme has been standardized.
Single-bus, single breaker scheme will be adopted for 132kV switchyard at Dasu AIS
Substation.
4.2.3
Technology Options for the Substations at Dasu
Two technology options can be considered for 765kV substations at Dasu. The
substations can comprise conventional air insulated switchgear (AIS) or it can be built
with gas insulated switchgear (GIS).
Different GIS manufacturers were contacted to get data/information on 765kV GIS.
Detailed information however has not been forthcoming. While 765kV GIS is reportedly
in operation in South Africa for quite some time, its design is no more valid because of
changes at the CIGRE committee to which all of the manufacturers are parties. However,
some other manufacturers have developed or are in advanced stages of development of
GIS of this voltage level, it appears that present demand for 765kV GIS substations
worldwide is not attractive for the manufacturers to bring it in commercial production.
Even the manufacturer of the GIS in South Africa reportedly has declined to provide
extension for the same reason. However, keeping in view the envisaged programs of
utilities in various countries including India, China, South Africa and Venezuela for bulk
power transfer over long distances, for which 765kV/800kV is also being considered, it is
expected that by the time Dasu hydropower project will enter the implementation stage, a
number of manufacturers would be active in the production of 765kV GIS.
A GIS based substation requires fraction of space needed for a similar capacity AIS
substation. For example, a 765kV one and half breaker GIS substation having capacity
to accommodate eight (8) generating units and eight (8) transmission lines would require
an area measuring 68m(W) x 200m(L) [13,600m2] compared with 500m(W) x 550m(L)
[275,000 m2] for an AIS substation. On the other hand, since cost of 765kV Surface GIS
Substation - Layout Plan (Fig: 4.8) is considerably higher than that of 765kV Surface AIS
Substation - Layout Plan (Fig: 4.7), unless the space constraints dictate otherwise,
substation based on AIS technology is preferred.
For the reasons described in the sub-section 4.2.5 hereinafter, it has been decided that
765kV substation at Dasu will be constructed in two parts; one underground and the
other at the surface.
Providing appropriate space underground for an AIS substation will be extremely difficult
from rock mechanics point of view and prohibitive cost-wise. Therefore, AIS was
adjudged as not viable for 765kV underground substation. It was thus considered
expedient that underground 765kV substation shall be based on GIS technology.
It has been determined that space can be made available at the proposed location of the
surface substation at Dasu. Accordingly, the surface substation can be based on AIS
technology. However, at the detailed design stage and to attract more manufacturers to
this project GIS station may also be considered for surface substation.
4-6
4.2.4
Volume 8
Capacity of Substations at Dasu
Besides eight (8) generator transformer feeders, substations at Dasu shall have the
capacity to accommodate the transmission lines needed to evacuate power from the
power plant as well as the lines that would inter-connect Dasu with other upstream and
downstream power plants on river Indus. Tender stage design details of Diamer Basha
Dam project (4500 MW) indicate (3) 765 kV Transmission Lines rom Basha to Gujar
Khan. For Power dispersal of dasu underground power ststion (4320 MW) various
alternatives have been studied and the following has been considered as technical
feasible and favourable alternative.
-
4.2.5
Dasu HPP will have two 765 kV substations Dasu underground powerhouse
GIS substation and Dasu surface AIS transmission substation.
Dasu underground GIS substation for connection of eight generator transformers
and three (3) 765 kV lines from underground to surface substation.
Dasu surface AIS substation:
All the three (3) 765 kV Basha Gujar khan lines to be made in and
out at Dasu.
Two (2) 765 kV lines from Dasu to Gujar khan for power dispersal of
Dasu.
Three (3) 765 kV circuits from underground substation.
One 160MVA, 765/132kV transformer along with one bay each of

765kV and 132kV voltage levels have also been considered for the
supply of power to the local area around Dasu.
Proposed Solution
Whether to locate the 765kV GIS substation at the surface or underground is governed
by the arrangement for connecting the substation to the generator transformers and the
transmission lines.
Since the power plant will be deep underground, it would not be feasible to place the
generator transformers at the surface due to the long lengths of the high current capacity
isolated phase buses (IPBs) that will be required to interconnect the generators with
these transformers at the envisaged nominal generation voltage of 20kV. On the other
hand such constraints are not foreseen with regard to the lengths of the EHV gas
insulated bus bars (GIBs) or gas insulated transmission lines (GILs). Therefore, the
generator transformers will have to be located as near to the generators as possible,
preferably within 100m, to minimize the lengths of the IPBs. This necessitates that the
generator transformers are installed underground. Being filled with large volume of oil,
the generator transformers shall be segregated from other parts of the power plant.
These transformers shall therefore be installed in a separate cavern measuring 340m x
26m.
Building a substation at the surface would require long lengths of GIBs/GILs from eight
(8) generator transformers. Locating it underground would entail long GIBs/GILs to
connect up to eight (8) transmission lines to the substation. Hence, with generator
transformers placed underground near to the generators, both the options vis--vis
locating the substation at the surface or underground can be considered at par with
regard to the requirement of the GIBs/GILs.
Shunt reactors would also be needed to control over-voltages especially on long 765kV
transmission lines. Five banks of shunt reactors, one bank on each Dasu-Gujar Khan
transmission line, comprising three single phase units may have to be installed (exact
requirement to be finalized from system studies). Accordingly, up to sixteen (16) shunt
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reactors including one spare unit along with their associated circuit breakers and
disconnectors would have to be catered for vis--vis space for installation thereof at the
Project Site. The shunt reactors would have to be installed in another cavern if these are
to be located underground. Since space of the order of 404m (L) x 70m (W) at the
surface would anyway be required to terminate the EHV transmission lines and its allied
terminal equipment, placing the shunt reactors at the surface adjacent to the lines
terminal equipment area would be relatively advantageous compared with construction
of another cavern and cost thereof involved for installation underground.
Keeping in view the foregoing, taking into account that cost of 765kV GIS is considerably
higher than the cost of the conventional AIS and considering that space can be made
available adjacent to the location where line terminal equipment and shunt reactors at
Dasu for 765kV transmission lines can be installed, it has been decided that:
-
A surface AIS substation will facilitate integration of Dasu Power Plant with
NTDC/WAPDA 765kV power transmission network.
Due to limitations on the lengths of the IPBs, an underground 765kV substation

will be constructed to provide interconnection between the generator transformers
and the surface substation.
4.2.6
765kV Underground Substation
General
The underground substation will include the generator step-up transformers for eight (8)
units and will be as close as practical to the powerhouse to minimize the losses
dissipated in the high current carrying IPBs. The gas insulated switchgear (GIS) and
generator transformers have therefore been proposed in a cavern with GIS installed on
the floor above the transformer gallery.
Gas Insulated Switchgear (GIS)
Various manufacturers were contacted to get information on 765kV GIS. However, only
two manufacturers supplied possible GIS configurations for the 765kV substations.
Based on the two configurations received and in view of the constraints of the cavern
width, a more compact arrangement of their equipment was developed.
Based on this arrangement, the dimensional requirement to accommodate GIS for eight
(8) generating units and three (3) GIB/GILs is 26m x 200m. However, length of GIS
gallery has been kept equal to the length of transformer gallery i.e. 340m. This will leave
space in the area for relay panels, interface cubicles, auxiliary power supplies cooling /
fire fighting systems, store, maintenance / staff rooms etc.
Inter-connections of GIS
Underground GIS will be connected to the HV side of the generator transformers with
GIBs while connections to surface AIS will be through combination of GIBs/GILs and
overhead transmission lines. Since the 765kV GIS/GIB/GIL might be commonly available
at a relatively lower price at the implementation stage of the project, possibility of
extending the GIBs/GILs right up to the surface AIS substation could also be explored at
that time.
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Control and Protection Equipment

While normal control of the underground substation will be executed from the power
plant control room, as back-up to the remote control and for use during testing &
maintenance local control panels will be provided adjacent to each GIS bay.
It is proposed that the protective devices associated with the gas insulated transmission
line protection, breaker failure protection, bus bar protection and back-up protection for
transformer feeders shall be installed in a room adjacent to the GIS gallery. This
arrangement will significantly reduce the cabling requirement compared with locating the
protection system far away from the GIS.
4.2.7
765kV Surface Substation (Transmission Substation)
General
The transmission substation will be located on the surface southeast of the power house
at a distance of around 3km.
Air Insulated Switchgear (AIS)
Space required for the 765kV surface AIS substation to cater for six (6) AIS bays in one
and a half breaker scheme including space for outdoor shunt reactors and terminal
equipment for eight (8) 765kV transmission lines as well as 765/132kV power
transformer and 132kV conventional air insulated substation is estimated as 523m x
404m.
Control, Protection, Metering and Monitoring Equipment
A Control House Building for the 765kV AIS surface substation has been proposed
adjacent to the 765kV switchyard to accommodate control, protection, metering &
monitoring systems and AC/DC auxiliary supplies equipment.
4.2.8
Gas Insulated Bus (GIB) Risers
A total of three (3) 765kV Gas Insulated Bus (GIB) risers are recommended between the
underground (powerhouse) and surface (transmission) substations to maintain the n-1
loss of line capability. These GIBs will be laid in two small excavated shafts to carry all
station power to the surface AIS substation.
4.2.9
Extension of 765/500 kV AIS Substation at Gujar Khan
In addition to three (3) 765kV circuits from Basha to Gujar Khan through Dasu, two (2)
additional 765kV circuits have been proposed from Dasu to Gujar Khan to disperse
power generated at Dasu. The 765kV switchyard to be constructed under Basha project
will therefore be extended to accommodate the above two (2) 765kV lines and two
765kV lines to Gatti. One (1) 765/500kV auto-transformer bank comprising three (3)
500MVA, 765/3/5003kV single phase auto-transformers and one (1) 500kV bay in one
& half breaker scheme will also be added under Dasu Hydropower Project. It has been
assumed that provision will be made in the Control Building to be constructed under
Basha project for the installation of control, protection, metering and monitoring
equipment to be provided under Dasu Project. It has further been assumed that AC/DC
auxiliary supply systems is provided under Basha project and the same will only be
extended to supply the loads of the equipment to be added under Dasu Hydropower
Project.
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4.2.10 New 765/220kV AIS Substation at Gatti

As part of the dispersal of power generated at Dasu, a new 765/220kV AIS substation
under one and a half breaker scheme has been proposed at Gatti. Two (2) 765kV
transmission lines from Gujar Khan will be terminated at this substation with a provision
for another 765kV line in future. Three (3) 765/220kV, 1200MVA auto-transformer banks,
each bank comprising three (3) 400MVA, 765/3/220/3kV single phase autotransformers, and two (2) 220kV bays in one & half breaker scheme have been proposed
to disperse power to local area at 220kV voltage level. Shunt reactor banks have also
been proposed for controlling the over-voltages on the 765kV transmission lines.
4.2.11 Design Parameters of GIS & AIS Substations
The GIS & AIS substations and equipment thereof will be designed in accordance with
the applicable international standards that would be prevalent at the time the project
enters the implementation phase. Main design parameters would be as hereunder:
Nominal voltage
Rated voltage
Rated continuous current
Rated short time current (1 sec)
Rated lightning impulse withstand
voltage
Rated switching impulse withstand
voltage
Rated short duration (1 min)
Power frequency withstand voltage
765kV
800kV
4000A
50kA,
500kV
550kV
3150A
40kA,
2100kV
1550kV 1050kV 650kV
1550kV
1175kV
680kV
220kV
245kV
3150A
63kA,
460kV
132kV
145 kV
2000A
40kA
The above insulation levels are applicable for altitude less than 1000m.
4.2.12 Key Diagrams
Following are the conceptual diagrams pertaining to the 765kV GIS and AIS substations:
FIG: 4.1
FIG: 4.2
FIG: 4.3
FIG: 4.4.
FIG: 4.5.
FIG: 4.6
FIG: 4.7
FIG: 4.8.
FIG: 4.9
FIG: 4.10
FIG: 4.11
FIG: 4.12
Dasu 765kV Underground GIS Substation-Single Line Diagram

Dasu 765kV Underground GIS Substation-Layout Plans
Dasu 765kV Underground GIS Substation-Transformer Gallery
Plan.
Dasu 765kV Underground GIS Substation-Longitudinal Section
B-B through Transformer Gallery
Dasu 765kV Underground GIS Substation-Transverse Section
C-C through GIS and Transformer Gallery
Dasu 765kV Surface AIS Substation-Single Line Diagram.
Dasu 765kV Surface AIS Substation-Layout Plan
Dasu 765kV Surface GIS Substation-Layout Plan
Gujar Khan 765/500kV AIS Substation-Single Line Diagram.
Gujar Khan 765/500kV AIS Substation-Layout Plan.
Gatti 765/220kV AIS Substation - Single Line Diagram.
Gatti 765/220kV AIS Substation - Layout Plan.
4-10
5.
5.1
Volume 8
POWER TRANSMISSION SYSTEM
General
The Monencos ranking study of hydropower projects on Indus river (1984) did not
include studies for dispersal of power from Dasu. However, in year 2003-2005 WAPDA
carried out extensive system studies to propose interconnection schemes for dispersal of
power from large sized hydropower projects on river Indus and its tributaries to the load
centres. These interconnection schemes were proposed in an integrated manner based
on updated Load forecast, and Generation Expansion Schedule given in the Vision 2025
Plan (October 2003).The study also analyzed the different voltage levels, types of
technology which are currently being used in the world for bulk power transfer over long
distances.
As part of the feasibility study of Dasu Hydropower project, the Consultants are required
to look into the transmission interconnection scheme for dispersal of power from Dasu,
and to propose different options based on present power system configuration, future
demand forecast, generation and transmission expansion plans. In pursuance of these
requirements, the study has been conducted to determine.
-
A suitable transmission voltage level

A suitable transmission line corridor
Required number of transmission circuits
Interconnection point (s) and intermediate switching/tapping stations
5.2
Study Assumptions and Technical Criteria
5.2.1
Assumptions
The system studies are based on the following assumptions:

-
5.2.2
Diamer Basha Dam project with 4,500 MW installed capacity and located on
Indus river 75 km upstream of the Dasu Hydropower project will be on line
DISCO Load Forecast (MW) - Normal (Base Year 2006-07)
Future Generation Plan updated up to 2029-30
500 & 220 kV NTDC transmission plan up to 2011-12 and its expected update up
to 2029-30
Technical Criteria
The technical criteria for selection of suitable interconnection option for a power plant is
the reliable operation of the transmission lines within prescribed technical limits as
mentioned below both under normal and single line out contingency condition.
The Voltage criterion for all buses of the system is that, under normal operating
conditions their voltages should remain at/within the limit of 5% of the nominal rated
value. However, in view of longitudinal system topology in Pakistan and with bulk
generation sources at extreme ends, the higher side voltage limit can be relaxed up to
+8% under normal operating conditions. Under n-1 emergency conditions, bus voltages
should remain at/within 10% of the nominal rated value as given in table 5.1 below.
5-1
Table 5.1
Volume 8
Voltage Level at n-1 Contingency
Nominal
Maximum (+10%)
Minimum (-10%)
765 kV
842 kV
689 kV
500 kV
550 kV
450 kV
220 kV
242 kV
198 kV
132 kV
145 kV
119 kV
The operation of surge arrestors at this voltage level will be checked during tendering
stage when load flow studies will be carried out and amended accordingly.
Under normal operating conditions, transformers should not be loaded beyond 100% of
their normal long-term ratings. However, under single component contingency, loading
may be relaxed up to 120% of the transformer nominal ratings.
Transmission line loadings should not exceed 85% of their normal ratings under steady
state operating (normal) conditions. Under outage/contingency conditions, the
transmission lines may be loaded up to their short term or emergency ratings which are
equal to their Surge Impedance Loading (SIL) or thermal ratings depending upon the line
length involved.
The reliability criteria adopted by WAPDA for its present 500 kV and 220 kV transmission
lines in the central and southern plains and desert areas is a normally cleared three
phase or single phase to ground fault. However, as the transmission line corridor
between Dasu Hydropower and Thakot is subject to landslides, tower failure criteria has
been adopted for the transmission lines connecting Dasu Hydropower and other
proposed hydroelectric plants in the upper reaches of the Indus River and its tributaries
to load centres, in line with WAPDA requirements.
For Bipole DC lines, the normal criteria (n-1) are the blockage of one pole. Although,
adopting tower failure as the reliability criteria for mountainous areas does not affect
contingency considerations for AC lines, it necessitates considering blockage of the
complete Bipole Line, which is effectively (n-2) in respect of HVDC.
5.3
Integrated Interconnection Studies by WAPDA
In year 2003-05 NTDC (WAPDA) carried out extensive system studies based on
Generation Expansion Schedule of Vision 2025 Plan its associated Transmission plan
and the updated Load forecast associated with the vision and proposed an
interconnection scheme for large hydropower projects along river Indus and its
tributaries.
The important conclusions of the studies relating to Dasu hydropower were:
-
765 kV HVAC is by far the most economical system for the hydropower stations
on Indus River and its tributaries
765 kV HVAC system is just an up gradation of the existing 500 kV system and it
is easy to interconnect it with the existing 500 kV and 220 kV networks at several
points. Moreover, NTDC has lot of experience of maintaining the 500 kV HVAC
5-2
Volume 8
system. 765 kV HVAC system is technically sound and economically attractive as

compared with 500 kV HVAC system as about 50% less number of transmission
lines are required in 765 kV system for the same amount of power transfer.
-
All proposed 765 kV lines are fully justified on the basis of maximum flows
encountered throughout the year and good receiving end voltage and reduced
losses. The system has been designed to provide transmission lines at 765 kV
voltage level to all parts of network so that the entire grid system is integrated at
765 kV, 500 kV and 220 kV levels.
The 500 kV HVDC system has its own advantages i.e. stability and point to point
transmission and is economically feasible for distances in excess of about 800
km and above, when the fixed cost of the terminal equipment has been
overcome, and the lower cost of DC towers begins to dominate. However, HVDC
system is extremely difficult to maintain and NTDC has no experience of its
operation and economically its viability is yet to be maintained. HVDC does not
readily reconfigure for addition of loads as is done with AC circuits.
Any change in load forecast and generation expansion plan i.e. generation capacity,
expected year of commissioning and/or order of generation induction in the system may
significantly affect the scope of work associated with the proposed interconnection
scheme of a power plant as mentioned in the report.
5.4
Basis for Updating WAPDA Studies
The major factors necessitating revision/updating of the transmission interconnection

studies of 2003-05 are as under.
The increase in rating of the Project is the most important factor as it is the governing
parameter for selection of voltage level, number of circuits and degree of compensation
required. WAPDA studies were carried out without optimising the generation of the
proposed hydro stations. The capacities of Diamer Basha, and Dasu for instance were
taken as 3660 MW and 2712 MW respectively, against the present optimized generation
of 4500 MW and 4320 MW for Diamer Basha and Dasu respectively.
There are substantial changes in the distribution of loads, future projections of peak
demand, generation and transmission expansion plans. The load forecast has multiplied
many folds with the improved economical conditions and higher GDP. The least cost
generation plan has also changed significantly with delayed financial closure of most of
the generation projects in the private sector and change in the expected date of
commissioning of all the expected generation, both in public and private sectors.
5.5
Feasibility Level Design Parameters
A review of available data indicates that the loading conditions and degree of
contamination along the line route corridor through Indus Valley are about the same as
have been considered for EHV transmission lines constructed north of Guddu except
that ice loading in addition to above, as per National Electric Safety Commission (NESC)
medium category, has been considered in the line reach from Dasu to Gujar-Khan.
Feasibility level design parameters have accordingly been established and cost
estimates prepared. The parameters considered for line materials and tower foundations
are discussed in sub section 5.18.
5-3
5.6
EHV Transmission Technology Options
5.6.1
General
Volume 8
This sub section presents an overview of the available EHV transmission technology
options for interconnection of Dasu Hydropower Plant with the interconnected NTDC grid
system. As a number of hydroelectric plants have been proposed in the upper reaches of
the Indus River and its tributaries (i.e. upstream of Tarbela Dam), the power dispersal
scheme for Dasu Hydropower has been conceived in such a way that it provides the
required flexibility for integration of the future hydroelectric plants in a technically feasible
and economically viable manner.
The transmission lines from Dasu Hydropower and other hydroelectric plants (on the
Indus River located upstream of Tarbela) to mid-country load centres have to pass
through tough mountainous terrain with route/corridor constraints. The requirements
such as proven technology, reliability, availability of equipment and spares, flexibility in
operation and maintenance, competitive prices, etc. combined with route/corridor
restrictions, further limit the interconnection options. Therefore, only those transmission
technologies are considered which are not only suitable for interconnection of Dasu
Hydropower but also provide flexibility for integration of the future hydroelectric plants
and are also promising for dispersal of a total of over 17,000 MW through a limited width
corridor.
A brief commentary on the commercially available EHV/UHV AC and DC transmission
technologies and load ability characteristics of overhead transmission lines is presented
hereunder along with a review of experience and capability of the local power sector
participants i.e. utility, consultants/design firms and contractors.
5.6.2
EHV Transmission Technologies
Power transfer capability of the transmission line depends on its voltage level, length,
type and degree of compensation and other system characteristics/ conditions.
A broad range of EHV/UHV AC and DC technologies are available to transmit large
blocks of power over long distances. The promising transmission technologies
considered are:
-
500 kV AC
765 kV AC
1000 kV AC and above
HVDC
500 kV Consideration:
The 500 kV HVAC is not considered appropriate for the dispersal of Dasu power
because of the following reasons:
The ratio of the effective voltage between 765 kV and 500 kV is about 1.52 times. Hence
adopting 500 kV voltage level would result in an increase of about 50% in the number of
circuits for the same power transfer capability. Therefore, the 500 kV voltage level is not
an appropriate voltage level for interconnection of the proposed cascade of hydroelectric
plants (in the upper reaches of Indus River) subjected to severe corridor constraints.
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Volume 8
The 765 kV appears to be the most appropriate voltage level for the dispersal of Dasu
Power, due to the following reasons:
-
It is the highest commercially available voltage level for transmission at present,

and as stated above it will reduce the number of transmission lines required for
the dispersal by about 50% when compared to 500 kV transmission lines.
Transmission systems with voltage levels of 735 kV and 765 kV have been used
in USA, Canada, Brazil, former USSR, Venezuela etc. for interconnection of
remote generation sources to distant load centres.
WAPDA studies of the system for vision 2025 projects (2003-05) have already
concluded that 765 kV is by far the most economical system for the dispersal of
large hydropower stations on the river Indus.
Diamer Basha project of 4500 MW has already selected 765 kV voltage level for
its dispersal. Interconnection within the Indus corridor will be easier with this
voltage level
Although Pakistans power sector has no experience of 765 kV transmission

voltage level, but with its rich expertise in operating 500 kV transmission system
for the last 30 years it will be a doable task for Pakistan to design, construct,
operate and maintain a 765 kV transmission system. International assistance
from experienced utilities/consultants can also be sought where necessary
The Ultra High Voltages (UHV) of 1000 kV and above is not considered appropriate for
Dasu dispersal for the following reasons:
-
Countries like former Soviet Republics, Japan, USA, Italy, China, Brazil and India
have been conducting research programs to develop the related technology.
However, very few lines at present are operating at 1000 kV and above. As per
available information, 1100/1200 kV transmission system is in commercial
operation in Kazakhistan and Russia and one line has been designed and
constructed for operation at 1000 kV in Japan. The Japanese 1000 kV line is still
operating at 500 kV and there is not much information available regarding the
operational experience, performance and reliability of Russian 1150 kV
transmission system. Similarly, no practical examples have been found in
technical literature for commercial transmission systems operating at 1500 kV,
though it is reported that the technology is available awaiting commercial
applications.
Based on the fact that the technology for UHV systems (1000 kV and above) is
not in commercial operation on a wide scale and it is not likely to gain acceptance
in Europe or North America due to environmental issues, it is inferred that such
systems will be expensive and difficult to design, construct and operate in
Pakistan. This is further supported by the fact that Pakistan depends on import of
equipment and spares even for 500 kV substations, though part of the
transmission line materials are produced locally. 1000 kV and above voltage
levels are therefore not considered as an option for interconnection of Dasu and
other hydroelectric plants.
5-5
Volume 8
HVDC Consideration:
The HVDC is not a very good option for the dispersal of Dasu power because of its
inflexibility to accommodate other stations in between the route, and its higher cost for
shorter lines. Its most likely application will be with Bunji or any other Hydropower Project
which is at the upper most location on the river Indus, where the distances begin to make
HVDC economical for the following reasons.
-
For very long distance/high capacity transmission, the HVDC alternative is being
widely used in USA, Canada, Brazil, China, Western Europe, former USSR, etc.
A number of DC transmission systems operating at 500 kV are under
commercial operation around the globe. A 600 kV, 6300 MW HVDC system
comprising of two bipolar circuits of 3150 MW capacity each (which as per
available information is regarded as the highest voltage - highest rating HVDC
system in operation throughout the world) is in operation since 1985 in Brazil
which connects the Itaipu Power plant to load centres some 800 km away.
-
The reliability of HVDC systems has improved whereas there is a decrease in

prices due to advances in high voltage-high power thyristor technology. Hence,
HVDC systems are used as an adjunct to conventional EHV AC systems for
interconnection of regional systems, asynchronous inter-ties, and transmission of
power from remote generating source to load centres, transmission of large
blocks of power over long distances, improving transient performance of power
systems, damping of power swings and inter-area oscillations, etc. However, high
terminal costs, especially under tower outage contingency criteria, are off-set by
reduction in line cost only beyond a certain distance involved. The study shows
that 500 kV HVDC will be appropriate for the last hydro station in the upstream
of Indus like Bunji. The distance from Dasu to the principal load is approximately
580 km
The loading for bi-pole DC Transmission line of 500 KV will be 2250 MW, but it
is expensive and suitable only for very long distances with point to point transfer
of power.
5.6.3
Loadability Characteristics of EHV Transmission Lines
The power transfer capability i.e. loadability of a transmission line depends on its voltage
level and length. The loadability of a line is generally expressed as a percentage of its
SIL permissible within the allowable thermal, voltage drop and stability limits. An
increase in power transfer through a transmission line results into increase in current
flow through the line, with the following undesirable effects:
-
Increase in heat production and rise in conductor temperature due to increase in

resistive losses (I2R loss)
Increase in sag and decrease in clearance to ground due to conductor expansion
at higher temperature
Increase in voltage drop along the line (Vdrop = I x Z)
Increase in transmission angle (i.e. angular displacement between two ends of
the line)
Each of the above effects imposes limitations on the maximum power transfer capability
of transmission lines. However, the governing limitation is different for different lines
depending on line length, type & degree of compensation, and system
characteristics/conditions. Based on the practical considerations and experience, St.
Clair developed transmission line power transfer capability curves covering voltage
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Volume 8
levels between 34.5 kV and 330 kV and line lengths up to about 650 km. These curves,
known as St. Clair Curves, have been regarded as a valuable tool for transmission
planning engineers for quickly estimating the maximum line loading limits. St. Clairs
work was later extended by Dunlop, Gutman and Marchenko by presenting analytical
basis for the St. Clair curves so as to be able to cover higher voltage levels up to 1500
kV and longer line lengths up to about 960 km. Fig. 5.1 shows the universal loadability
curve for overhead transmission lines applicable to all voltage levels. The curve shows
the limiting values of power that can be transmitted as a function of line length. The
universal loadability curve is based on the following assumptions:
-
The line is without shunt or series compensation;

The maximum voltage drop along the line is 5%;
The minimum allowable steady state stability margin is 30% i.e. the load angle is
44;
The power system at both ends of the line is a well developed system i.e. the
system strength corresponds to 50 kA fault duty.
As identified in Fig. 5.1, the universal loadability curve is divided into three regions with
distinct characteristics as follows:
a)
The 1st region applies to transmission lines of 80 km length and shorter. The
loadability for a transmission line of 80 km is 3.0 times its SIL and increases
exponentially for lines of length shorter than 80 km. Hence, for short lines up to
80 km, the governing loading limit is the ground clearance and thermal rating.
b)
The 2nd region applies to transmission lines in the range of 80 km to 320 km and
the governing criteria for this region are the permissible voltage drop. The
loadability in this region decreases from 2.7 to 1.3 times SIL corresponding to
lengths of 80 km to 320 km.
c)
The 3rd region is applicable to long transmission lines with lengths in the range of
320 km to 960 km. The loading limit for a long transmission line of about
450 km is equal to its SIL rating. The loadability reduces gradually with increase
in length and loading limit for a 960 km long line is around 0.63 times SIL. This
region is governed by stability considerations under both small signal (steady
state) and transient conditions.
The universal loadability curve, as discussed above, provides a simple analytical tool for
estimating power transfer capabilities of transmission lines. It is useful for developing
conceptual guides to line loadability and preliminary planning of transmission systems.
However, it must be used with great caution as the loadability characteristics of EHV
transmission lines are quite complex and greatly influenced by the presence and
parameters of generators, shunt reactors, shunt capacitors, series capacitors, series var
compensator, control devices, etc. Hence, large complex systems must be analysed
thoroughly with the help of detailed system studies for assessment of their performance
and power transfer limits.
The power dispersal scheme for Dasu hydropower plant and other hydropower plants
and their interconnection with WAPDA grid system would be very complex. In addition, a
broad range of voltage/power control and reactive power compensation devices may
have to be applied, in view of the very narrow transmission corridor available. The
optimisation of the interconnection scheme, power/voltage control devices, power
transfer capability enhancement measures, etc. would therefore require detailed
simulations of the WAPDAs interconnected grid system with the help of sophisticated
computer tools, like Power System Simulation for Engineers (PSS/E).
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Volume 8
The following table presents the Surge Impedance Loading (SIL) and approximate
transfer capability of a 600-700 km long transmission line with intermediate tapping
station(s) for 500 kV and above voltage levels. These values are based on universal
loadability curve, transfer capability of transmission lines reported in technical literature
and inference to reported results based on detailed system studies carried out for a
number of projects in the past.
However in case of Dasu dispersal the length of Dasu - Gujar khan (intermediate station)
is 345 km, and Gujar Khan Gatti is 230 km.
Table 5.2 Surge Impedance loading & Transfer Capability of Transmission Line *
Voltage Level
(kV)
500
Surge Impedance
Loading (SIL)
MW per Circuit
Series
Capacitors
Compensation
0%
30-50%
50-70%
0%
30-50%
50-70%
1000
1000
1000
765
2200
2200
2200
1100
5000
1500
10000
With 600-700 km lines with intermediate tapping station
Approx. Transfer
Capability
MW per Circuit
700-800
1000-1200
1500
1600-1700
2500-2700
3300
Practical examples have been reported in literature where transfer capability in the range
of 2 to 2.5 times SIL rating have been achieved through a combination of high degree of
series capacitor compensation and application of Static Var Systems and stability
enhancement measures. However, considering the total size of the WAPDA system in
respect of generation and load and the anticipated consequences caused by outage of a
transmission line transferring a power of 2 to 2.5 times its SIL is not advisable. A
maximum transfer limit of about 1.5 times the SIL rating under normal operating
conditions, with suitable series compensation, is considered appropriate for development
of alternatives for interconnection of Dasu Hydropower Plant.
5.6.4
Number of Circuits
Number of circuits for a power transmission link is determined by the power carrying
capacity of a particular voltage level over the required distance. Power transfer capability
is influenced by voltage level, distance, current carrying capability of conductors,
environmental conditions and power system behaviour under normal as well as
contingency conditions. This requires a thorough and detailed computerised study on the
updated system model for the year when the power station is expected to be available
for commercial operation. However for preliminary selection of number of circuits
required, general information on loadability characteristics of power lines reported in
literature and based on experience is used.
The Surge Impedance Loading (SIL) of a 500 kV transmission line is 1000 MW. For the
required distance of around 600 km with two intermediate stations, a 500 kV line is
expected to carry power of the order of 1500 MW with around 50% series compensation.
The transfer capability MW/circuit for 500 kV single circuit without series capacitors
compensation is about 800 MW, but it can be increased to 1000 1200 MW with series
compensation in the range of 30 50%. Series compensation of 50% and above is not
recommended for Pakistan Integrated net work on 500 kV.
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Volume 8
Similarly, the SIL rating of a 765 kV line is around 2200 MW. For a distance of around
600 km with one intermediate station at about 350 km from the source end, the
loadability is expected in the range of 2500-2700 MW with series compensation of 30%
to 50%. The transfer capability MW/circuit for 765 kV single circuits without series
capacitors compensation is 1700 MW, but it can be increased to 2500 - 2700 MW with
series capacitor compensation of 30 50%. However for Pakistan integrated electrical
network series compensation of 40% and above is not recommended on 765 kV
network.
Therefore, in order to transfer 4320 MW, the required number of circuits for 500 kV and
765 kV while satisfying the single line contingency criteria are as follows:
Transmission Option
Minimum Circuits Required
500 kV with series compensation

765 kV without series compensation
765 kV with series compensation
5.7
4
3
2
Existing Generation System of WAPDA
WAPDA is responsible for supplying electricity to the whole of the country except
metropolis Karachi and parts of district Thatta and Lasbela, which are fed by KESC.
WAPDA owns approximately 95% of the total grid system in the country. The major
planning parameters such as existing and committed generation and transmission
systems, demand forecast, future expansion plans and planning criteria form the basis
for the present studies. Most of this information has been provided by Planning (Power)
Department of NTDC.
The power generation system of WAPDA comprises a mix of hydro and thermal power
plants. The major hydropower stations (Tarbela, Ghazi Barotha, Mangla and Warsak,)
with the exception of Chashma, are located in the northern region of the country. To
date, all the hydro power stations in the country except Jagran, are owned, operated and
maintained by WAPDA. Jagran Hydropower Station is located in the State of Azad
Jammu and Kashmir (AJK) near Muzaffarabad and is owned and operated by AJK
Hydroelectric Board (HEB).
The major thermal power stations feeding WAPDA system are located in the southern
(Guddu and Jamshoro) and central parts (Muzaffargarh, Multan and Faisalabad) of the
country. A nuclear power plant of 325 MW installed capacity also supplies power to
WAPDA system. The nuclear power plant is located at Chashma and is owned and
operated by Pakistan Atomic Energy Commission (PAEC). In addition to public sector
projects, a number of thermal IPPs, installed by private sector on BOO/BOOT basis
supports WAPDA system in meeting power and energy demand. As per Electricity
Marketing Data (Power System Statistics) 32nd issue of Jan 2008 the installed Generation
Capacity in MW of WAPDA is given in Table 5.3.
Table 5.3
Generation Type
Hydro
Thermal (Pvt.)
Thermal (Pub.)
Nuclear
Total
Installed Generation Capacity of WAPDA as in June 2007

Capacity (MW)
6,474
5,893
4,834
325
17,526
Percentage (%)
36.9
33.6
27.6
1.9
100
5-9
Winter Capability/Derated
1,902
5,278
3,933
300
11,413
Volume 8
Total hydro capacity is 6474 MW (capability in winter 1902 MW), Thermal private 5893
MW (derated 5278 MW), Thermal public 4834 MW (derated 3933 MW), and Nuclear 325
MW (derated 300 MW). Tables 5.4 to 5.6 given at the end of this section show the
installed capacity and generating capability of hydel, thermal and IPPs including nuclear
power plants installed in WAPDA system.
The total installed Capacity (MW) in Pakistan including KESC, and the percentage of
Thermal, Hydro, IPPs and nuclear generation has been tabulated in Table 5.7.
Table 5.7
Pakistan Installed Generation Capacity (MW)
Generation Type
Capacity (MW)
Percentage (%)
Hydel
6,474
Thermal
6,590
IPPs
6,155
Nuclear
462
Ref. WAPDA Statistic book 32nd issue
32.9%
33.5%
31.3%
2.3%
The installed capacity of hydroelectric plants stands at 6474 MW which is around 32.9%
of the total capacity installed in Pakistan. However, this capacity cannot be maintained
throughout the year because of low inflows during certain periods of the year, lower
heads available at reservoirs due to depletion in the winter and early summer seasons
and reservoir operation based on priority to irrigation requirements. The output
constraints are more severe on two big hydroelectric power stations i.e. Tarbela and
Mangla, which are the main sources of hydroelectric power. The situation becomes
critical in December and January when severe restrictions on water releases from the
dams reduce the power output to very low levels. Table 5.8 given below shows the
month wise maximum generating capability of existing hydroelectric plants (up to May
2008).
Table 5.8 Month wise Maximum Capability of Existing Hydroelectric Plants (2007-08)
Tarbela
Ghazi
Brotha
Mangla
Warsak
Chashma
Jagran
Small
Hydel
Total
July
3680
1450
1150
207
176
30
58
6751
August
3702
1450
1150
207
184
30
59
6782
September
3702
1450
1150
207
181
30
42
6762
October
3442
1450
1150
207
184
30
45
6508
November
2957
1450
1089
140
160
30
42
5868
December
2530
1450
808
135
135
30
36
5124
January
1068
1100
609
173
128
30
31
3139
February
1771
1350
694
173
115
30
36
4169
March
1675
1450
576
207
107
30
53
4098
April
1466
1450
732
207
138
30
58
4081
May
2024
1450
880
207
161
30
58
4810
June
3123
1450
1090
208
168
30
78
6147
Month
The variation in the WAPDA hydro system alone for the year 2007-08 has been in the
range of 6782 MW in the month of August, 2007 to 3139 MW in the month of January,
2008.
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Volume 8
A critical review of the monthly variations in the generating capability of hydel stations
shows that during high flow months i.e. July to October the hydroelectric plants are
contributing maximum whereas in the critical month of January, the output of
hydroelectric plants falls below 40% of their rated capacity. During months of March and
April the hydel output is around 50% of their rated capacity.
The effective generating capability (derated capability) of thermal plants also falls short
of the installed capacity due to ageing, temperature derating, annual maintenance and
overhaul, and other unscheduled outages. During winter, shortage of gas supply for
power generation also affects the output in thermal power plants.
5.8
Existing Transmission System of WAPDA
WAPDAs interconnected EHV grid system extends from Peshawar/Tarbela in the north
to Jamshoro/Hub in the south on the Arabian coast. The transmission system operates
at 500 kV, 220 kV and 132 kV voltage levels. A sub-transmission system operating at 66
kV and 33 kV voltage levels feeds areas with relatively lower load demand. Fig. 5.2
shows the existing 500 and 220 kV grid map of Pakistan.
The 500 kV transmission network serves as the backbone system connecting the major
load centres to generating sources and transferring bulk power over long distances. The
500 kV network is supported by a parallel 220 kV network. Most of the power stations
are connected at 500 kV and/or 220 kV voltage level except those located close to the
load centres or having relatively small output rating. The 132 kV and 66 kV networks are
used to transfer power to grids supplying load directly through 132/11 kV and 66/11 kV
transformers.
WAPDA system is interconnected with KESC system on 220 kV at two points i.e. by a
double circuit from Jamshoro to KDA-33 and IN & OUT of 220 kV Baldia KDA 33 circuit
through the 500/220 kV NTDC grid station at Karachi. Similarly on 132 kV side also they
are connected at two points by 132 kV single circuit transmission lines. The WAPDA and
KESC systems are operated almost independently by the respective utilities. However,
power exchanges take place as per requirement and availability of surplus power. The
two systems also support each other during emergencies.
The northern part of the country along Indus River is thinly populated and there exist only
a few large cities and towns (Gilgit, Skardu, Chilas, Dasu, Thakot etc.). The EHV system
(i.e. 500 kV & 220 kV network) along Indus River extends only up to Tarbela. The
northern areas are generally isolated from the national grid system and are mostly unelectrified. Part of the area is supplied electricity by isolated power networks fed by local
generation comprising of small hydroelectric and diesel power plants. From the
aforementioned statement, it is clear that the national grid system does not exist along
the Indus river upstream Tarbela and the EHV network has to be extended to connect
the proposed Basha, Dasu and other future Hydropower Stations in northern area.
The year wise increase in Transmission Lines by voltage and circuit for the total WAPDA
system is given in Table 5.9 on next page.
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Volume 8
Table 5.9 Year wise increase in Transmission Lines by Voltage & Circuit
Year ending
30th June
500 kV
S/C
D/C
S/C
220 kV
D/C
S/C
D/C
Total Ckt. Length

(A+2*B)
1980
330
272
915
602
915
2432
1981
209
209
209
1982
310
315
315
1983
78
78
156
1984
438
438
438
1985
80
80
160
1986
321
10
331
331
1987
105
105
210
1988
99
99
198
1989
1990
318
41
318
41
400
1991
312
101
312
101
514
1992
13
13
26
1993
30
30
60
147
442
147
736
172
692
172
1036
287
587
287
1161
180
181
180
541
1994
1995
1996
692
587
1997
181
1998
279
279
563
1999
19
19
38
2000
15
60
15
60
135
23
23
46
81
81
139
143
139
421
2001
2002
2003
5.9
442
Total
0
0
81
2004
143
2005
801
185
801
185
1171
2006
100
100
100
2007
259
524
-100
783
-100
583
4743
1612
2853
6355
2853
12061
Load Forecast
The load forecasting is the basis of additions of generation and transmission lines in any
grid system. The peak load met during 2006-07 has been in the range of 16,000 MW,
and all along these years the country has been passing through different stages of
development. Further more lot of hydro developments along upper Indus are yet to be
carried out, indigenous coal resources are to be harnessed for power generation and
import of power from neighbouring countries are options which may also be considered.
This undoubtedly will involve huge expenditures which will necessitate least cost options
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Volume 8
to be adopted, after assessing of future loads and developing of a long range power plan
to meet demand targets.
The load forecasting is the fundamental element of power system Planning. It basically
requires prediction of the future levels of power demand to serve as the basis for supply
and demand side planning. Load forecasts are prepared for different time frames and
different level of growth like Low, Normal and High demand scenarios.
The electricity demand depends on many diverse parameters, like the growth of
economic parameters in domestic, commercial, agricultural and industrial sectors. The
supply-side potential has to be assessed and developed to correspond to the demand
side requirements, and side by side the interconnecting system of transmission lines has
to be developed to transmit the generated power to load centres.
A Revised National Power Plan was prepared in the office of the General Manager
Planning (Power) under the supervision of Advisor to Power planning in 2008; its final
report has been issued in May 2008. It includes detailed Load Forecast for the period
from 2006-07 to 2029-30 of PEPCO, KESC, Self Generation and Country generation for
normal growth. The year wise Sale, Generation and Peak for all the four groups along
with five yearly growth and the average growth rate for the period 2006-07 to 2029-30 is
given in Tables 5.10 at the end of this section (Reference: Annexure1 of the report).
The report has not gone into details of distribution companys individual loads. However
in the Interim National Power Plan Pakistan of October 2007, DISCOs Load Forecast
in MW under normal growth with the base year 2006-07 was developed. The WAPDA
demand without export to KESC for the year 1920-21 and 1921-22 was 48,691 MW and
52,707 MW respectively as per this report. These figures correspond with the figures of
Load Forecast in Revised National Power Plan of 48,185 MW and 52,077 MW for the
year 2021-22 and 2022-23 respectively. Thus the demand is expected to be in the range
of 48,000 MW and 52,000 MW in the year 2021- 22 and 2022-23 respectively, when
Dasu is expected to start its commercial operation. The DISCOs - wise demand, total
diversified demand of all DISCOs, Transformer & Transmission (T&T) losses on 500
and 220 kV along with auxiliary consumption and total WAPDA demand without export
to KES for the year 2020-21 to 2022-23 (3 years) under normal growth have been
tabulated in the Table 5.11 on the next page.
A critical review of the load forecast shows that demand of Lahore Electric Supply
Company (LESCO) and Faisalabad Electric Supply Company (FESCO) will be the
highest in the year 202021 when Dasu is expected to be commissioned. Their expected
Peak demand in the year 2020-21 will be 10,645 MW and 7,664 MW respectively. This is
closely followed by Islamabad Electric Supply Company (IESCO) with 6,713 MW and
Multan Electric Power Company (MEPCO) with 5,965 MW. Gujranwala Electric Power
Company (GEPCO) though very compact and with least area of jurisdiction is not far
behind with 4,255 MW.
The peak as per revised NPP is 44,557 MW in the year 2020-21, 48,185 MW in the year
2021-22 and 52,077 MW in the year 2022-23. As the commissioning date of Dasu is still
uncertain we may assume the demand of DISCOs for any year between FY 2020 to
2023, as given above.
5-13
Table 5.11
Volume 8
DISCOs Demand for the years 2020-21 to 2022-23 (Normal case)
Name
LESCO
GEPCO
FESCO
IESCO
MEPCO
Peshawar Electric Supply Company
(PESCO)
Hyderabad Electric Supply Company
(HESCO)
Quetta Electric Supply Company
(QESCO)
Tribal Electric Supply Company
(TESCO)
DISCOs Demand (undiversified)
2020-21
10,645
4,255
7,664
6,713
5,965
Year
2021-22
11,511
4,601
8,287
7,259
6,450
2022-23
12,453
4,978
8,966
7,854
6,979
4,130
4,466
4,832
4,711
5,094
5.511
2,926
3.164
3.423
2,509
2,713
2,936
47,010
50,833
54,995
DISCOs Demand (Diversified)

Transformer and transmission (T&T)
Losses
(500 & 220 kV)
% T & T Losses (500 & 220 kV)
45,770
49,491
53,544
1,899
4
2,108
4
2,281
4
NTDC Demand
47,669
51,600
55,825
Auxiliary Consumption
% Auxiliary Consumption
WAPDA Demand w/o Export to KESC
1,023
2.1
48,691
1,107
2.1
52,707
1,197
2.1
57,023
The monthly factors to yearly peak demand for the last six year 2001-02 to
2006-07 and their average have been tabulated and adopted for the studies and are
shown in Table 5.12 given below.
Table 5.12 Monthly Factors to Yearly Peak Demand (2001-02 to 2006-07)
Year
Period
Jul
9968
10242
200304
10502
Aug
10109
10400
10905
2001-02
2002-03
Sep
9894
9756
Oct
9146
9300
Nov
8396
8704
Dec
8445
8662
Jan
8743
8839
Feb
8545
8642
Mar
8689
8818
Apr
9201
9575
May
9911
10128
Jun*
10099
10484
* Computed Peak of the Year
Factor
2004-05
2005-06
2006-07
11542
12283
13628
0.946
11491
12381
13318
0.952
10771
11571
12865
13371
0.947
9631
10602
11752
12982
0.880
8942
9642
10206
11293
0.794
8997
9972
10723
11103
0.804
9494
9999
10668
11603
0.824
9266
10005
10569
10970
0.805
10102
10086
10596
11741
0.833
10356
10955
11758
13163
0.902
10980
11230
12841
13940
0.958
11078
12035
13212
15138
1.000
Computed Demand without Export to KESC
5-14
Volume 8
In a financial year, June is the month of maximum demand with a monthly peak to
annual peak ratio of 1.0 per unit May is the month of 2nd highest demand with a ratio of
0.958 per unit followed by months of August, September and July with monthly peak to
annual peak ratios of 0.952, 0.947 and 0.946 per unit respectively.
5.10
Generation Expansion Plan of NTDC
In view of high rise in fuel prices and load forecast of 2007 prepared by Planning Power
of NTDC a revision of NPP (National Power Plan) was carried out the covering period
from 2009-10 to 2029-30 by running of WASP. The report has been issued in May 2008.
Sequence of generation addition in the base case indicates the options available for
different group of generating sets like Coal, Low Sulphur Furnace Oil (LSFO), combined
cycle on gas, Combustion cycle on gas, nuclear and Hydroelectric Projects. The details
are given in Table 5.13 at the end of this section (Reference: Annexure- 2 of rev. NPP
report).
As the base case has included Kalabagh, other scenario for sequence of additional
generation was developed with out Kalabagh Table 5.14 (Reference: Annexure 2A of
revised NPP Report). The revised NPP Report has discussed many other scenarios like
with reduced availability of gas (Annex: 2B), with 50% increase in Coal price case
(Annex: 2C), with 11% reduction in load due to DSM case (Annex: 2D), and finally Base
case without Committed Projects (Annex: 2E). However only the base case with and
without Kalabagh has been considered in the report. At this point of time Basha (4500
MW) is expected to be followed by Dasu (4320 MW) instead of Bunji. The total capability
will thus be 8820 MW instead of 10900 MW as envisaged in the report.
5.11
Transmission Expansion Plan of NTDC
The Least Cost Transmission plan has to be developed as a part of the Revised NPP by
NTDC. However during interim phase i.e. 2008-12, the philosophy of adding generating
plants will be in line with PPIB mandate which is in total disregard to NPP 1994
guidelines. The transmission addition case will be taken independently and through
review of the situation so as to avoid major deviations from 1994 power plan.
The Transmission Expansion Plans for the 500 kV and 220 kV systems up to the year
2011-12 is given in Table 5.15 and 5.16 respectively at the end of this section. The plan
provides interconnections of most of the hydel plants inducted in the WAPDA system
prior to Dasu Hydropower.
The new transmission plan based on the forecast as per May 2008 is under preparation
in the planning power department of NTDC.
5.12
Transmission Line Route Corridors
Injection of power generated at Dasu Hydropower to the National grid requires

construction of extra high voltage transmission lines for which possibility of feasible line
route corridor has to be explored in detail. The construction cost in this area is expected
to be very high with respect to line construction cost in plain areas.
However with three 765 kV BashaGujar Khan-Lahore transmission lines under
construction by the time Dasu is in the design stage it will comparatively be an easier
task. At that point of time it is expected that 765 kV transmission lines for the dispersal of
Dasu will be running in the proximity of 765 kV transmission lines for Basha dispersal as
far as practically possible, because there is no other line corridor available. The selection
and arrangement of transmission lines within the Indus corridor will have to be a
5-15
Volume 8
coordinated effort between projects so as not to preclude future projects from being able
to come into existence. The corridor and tower type selections will have to be controlled
at the WAPDA level to ensure that early projects do not use the entire corridor for their
own use only. The transmission line corridor between Dasu and Thakot is subject to
landslides as such WAPDA has adopted tower failure criteria for transmission lines
connecting Dasu and other proposed hydroelectric plants in the upper reaches of the
river Indus and its tributaries to load centres. This criterion has restricted the
development of 765 kV double circuit towers. However it may be mentioned that the 765
kV double circuit towers would greatly reduce the total width of transmission corridor
required for the dispersal of the same amount of power, and these double circuit towers
are already in use in South Korea, but presently their cost is two to three times of two
single 765 kV circuits.
The perspective line route corridors are required to be explored for laying Extra High
Voltage (EHV) transmission lines for interconnection of Dasu HPP with National Grid
System at major load centre(s). For dispersal of 4320 MW of power generated from
Dasu Hydropower Plant, two 765 kV transmission lines have been planned for
interconnection with the National Grid at Gujar Khan in northern part of Punjab and Gatti
in Central Punjab. Dasu HPP will be built on upper Indus River, and is located 245 km
upstream of Tarbela and about 72 km downstream of the planned Diamer Basha Dam.
Due to route corridor constraints and continuous mountainous range along the river
Indus & KKH, there are no alternate route options from Dasu to Thahkot except to route
the transmission lines mostly along the Indus river and KKH up to Thakot, about 80 Km
downstream of Dasu. The transmission line route will traverse through Oghi, cross
Mansehra, and then lead to Gujar Khan and Gatti. The route along the river Indus up to
Thahkot is composed of high mountains with altitude ranging from 1200 m to 1900 m
with deep, steep gorges.
The routes were marked on 1:50,000 (SOP) sheets which have been divided into two
sections. One section is along the Indus valley through Dasu to Thakot, then from OghiMansehra-Islamabad and up to the collector station Gujar Khan which is about 330 km.
The other section is from Gujar Khan to Gatti Substation which is about 230 km from
Gujar Khan. The tentative routes of transmission lines have been marked on the
geographical map of the area as from Dasu HPP shown in Figure 5.3. Total line length
comes out to be about 560 km. For development of feasibility level design parameters
and cost estimation of transmission lines, the route has been broken down into different
sections with respect to the terrain/area conditions, as shown below with approximate
lengths:
Dasu Thakot
Thakot-Mansehra
Mansehra-Gujar Khan
Gujar Khan Gatti
80 km
65 km
185 km
230 km
Consultants conducted a reconnaissance site visit of the proposed routes to identify the
problems of areas along the routes marked. Available data on geography and climatic
conditions along the route corridors was studied to check the suitability of the route
corridors. Discussions were also held with the locals of the area to gather first hand
information about the prevailing conditions.
It has been observed that almost the entire route up to Mansehra has difficult terrain and
will have to be approached from KKH. Local tracks/Katcha roads are sporadic and
insufficient therefore connecting approaches from KKH would be required. At some
places the existing tracks/Katcha roads require widening for the transportation of
5-16
Volume 8
construction machinery and line materials. Steep gorges around Dasu and Pattan have
been observed. Careful design consideration such as providing of longer spans and
heavy angle towers will cover the expected problems. The types of rock observed along
the line route corridor are mainly Norite, Diorite, Gabbro, and Granite, foliated granite,
foraminate and schist, all of which are suitable for tower foundation on hill slopes.
Controlled blasting will be required both for making approaches and tower foundations. It
has been observed from the available meteorological data that although the areas along
the KKH/Indus river are subjected to snowfall, the snow is not expected to be heavy.
Similarly strong winds and high intensity rains also do not appear to be prevalent. From
Mansehra to Gujar Khan the line route traverses the hills of Oghi, Abbotabad, Margala
(Islamabad), which are light snow bound areas and are filled with lacustrine clay, gravel
or boulders.
From Gujar Khan to Gatti the proposed transmission line route traverses the Potohar
Plateau and the salt range. The plateau consists of open, undulating country, mainly
sandstone covered by varying thickness of loamy deposits. The line traverse two major
water courses i.e. the Jhelum River and the Chenab River. The terrain between the salt
range and the Gatti terminal station is flat and consists of stream bed and meander bed
deposits, some marshy zones, irrigated, agricultural lands, terrace and flood plain
deposits.
The assessment of transmission line routes and estimation of distances between
different sections is for the purpose of feasibility study. Before or during the design stage,
detailed survey will be carried out to provide routes alignment, plan and profile drawings
and spotting of towers. Actual information about distances between different line
sections, type and number of towers and other material will then be available to prepare
engineering estimate along with the design and tender documents. At this point of time ,
though double circuit towers are not being used commonly but the limitation of the Indus
valley transmission corridor especially down stream of Dasu may restrict the dispersal on
single 765 kV towers.
5.13
Transmission Voltage Level
A voltage level of 765 kV is considered to be appropriate at this point time as Power from
Diamer Basha will also be dispersed at the same voltage level.
Feasibility level design parameters have been established and accordingly cost
estimates have been be prepared. The parameters for line materials and tower
foundations have been finalized after discussion with the relevant specialists. The
estimated cost of Dasu transmission arrangements will provide a source of cross
comparison with the cost of Basha transmission arrangements on per kilometre basis for
transmission lines and per bay cost for the Switch yard.
5.14
Interconnection Point and Intermediate Switching Station
WAPDA system comprises eight (8) major load centres namely Peshawar, Rawalpindi,
Gujranwala, Lahore, Faisalabad, Multan, Hyderabad and Quetta. Presently, major hydel
plants of Tarbela (3478 MW) and Warsak (240 MW) are situated close to Peshawar load
centre. Mangla (1000 MW) is feeding into Rawalpindi, Gujranwala and Lahore load
centres. Another low head hydel station Chashma (184 MW) and a nuclear power plant
of 325 MW installed rating are feeding into Faisalabad load centre. The Lahore and
Faisalabad load centres have some local thermal generation which is only a small part
compared to anticipated loads. Multan area has major thermal generation in the central
part of the country including Muzaffargarh, Kot Addu, Multan NGPS, and a number of
thermal IPPs which are feeding into Lahore, Faisalabad and Gujranwala areas. Similarly
5-17
Volume 8
Guddu, Liberty, Jamshoro and Hub power plants are situated in the Hyderabad load
centre. The only generation close to major load area of Quetta is a 140 MW Combined
Cycle plant. Another power plant in the private sector is located within the Balochistan
province (Uch 586 MW) but is far away from the major load centers. The least cost
generation expansion plan of WAPDA envisages a large number of hydel plants in
northern areas and AJK which will satisfy the demand of Peshawar and Rawalpindi load
centres.
The biggest load centre Lahore will be receiving power directly from Basha through
newly constructed 765 kV Lahore substation. Technical feasibility of another 765 kV
substation at Gujranwala being in the vicinity (60 Km) of Lahore and strongly connected
with Lahore through 500 and 220 kV circuits is not justified, especially when thermal
generation of 450 MW each from Nandipur and Chichoki-Mulian thermal power stations
on 132 kV will be available in the GEPCO to ensure proper voltage in the 132 kV
network
A critical review of the existing system configuration and expansion plans shows that
Gatti (Faisalabad) is the preferred choice for feeding the power from Dasu. The ultimate
choice for feeding the power of Dasu is therefore Faisalabad (Gatti). With the
transmission arrangement of Basha already finalized as far as the voltage level, number
of circuits and interconnecting station is concerned; the transmission of Dasu power to
Gatti will also be through Gujar Khan which will be the intermediate switching station.
5.15
Interconnection Alternatives
Dasu power project requires a dispersal of 4,320 MW. Three alternatives have been
considered for this dispersal. The first alternate was proposed by NEAC during the
feasibility study of Diamer Basha Dam project with Dasu capacity of 2,710 MW in August
2004. However with optimised capability of 4320 MW at this point of time this scheme is
no longer relevant.
The other two new alternatives with three options each have been considered adding
one element at a time to the initial proposal of NEAC, so as to the reach most
appropriate option for the dispersal of 4320 MW from Dasu. These alternatives have
been devised with optimised Dasu capacity of 4320 MW, and after study of the following.
-
The demand projection for each DISCO up to the year 2030, their diversified
demand and total WAPDA demand without export to KESC.
The present generation in Pakistan and the Revised NPP of May 2008 of
WAPDA (NTDC) up to the year 2030, especially with 4500 MW generation of
Basha on bar, before commissioning of Dasu.
Present National Transmission and Dispatch Company (NTDC) 500/220 kV
transmission network and its expected updates up to the year 2011-12.
The alternatives have been planned keeping in view the normal transfer capability of
1,700 MW for 765 kV single circuit line. The two 765 kV single circuits exclusively
recommended for Dasu, along with the In & Out arrangement for all the three 765 kV
single circuits from Basha to Gujar Khan at Dasu will reinforce the dispersal scheme for
both Basha and Dasu.
The five circuits from Dasu to Gujar Khan will be dispersing 8,820 MW (4,500+4,320), in
total. Each 765 kV single circuit will carry a load of 1,764 MW under normal operating
conditions which is the normal operating capability of 765 kV single circuit without any
series compensation.
5-18
Volume 8
The addition of series compensation has been recommended only for n-1 contingency
and that also up to 30% only. The flow with single n-1 contingency, on each circuit will be
about 2205 MW which is within the Surge Impedance Loading (SIL) of 765 kV single
circuits. This has been done with the view that above 30% series compensation should
not be considered without proper and detailed study of the system behaviour during the
tendering stage.
The detail of above mentioned three alternatives are as under:Alternative 1 Same as proposed in Basha studies except with increased Dasu Output
(Figure 5.4)
Single 765 kV Dasu Gujar Khan Gatti circuit
All the three 765 KV Basha Gujar Khan Lahore circuits made In & Out at
Dasu.
Additional 765/500 kV 11500MVA Power Transformer at Gujar Khan
765 kV Gatti grid station with provision of 765/220 kV, 3x1200 MVA power
transformers.
Alternative 2A Same as Alternative 1, except addition of one more 765 kV circuit from
Dasu to Gujar khan to cover the n-1 contingency at Dasu. (Figure 5.5)
Alternative 2B Same as Alternative 2A except that double Dasu- Gujar Khan circuit is
extended up to Gatti to cover n-I contingency at Gujar Khan. (Figure 5.5)
Alternative 2C Same as Alternative 2B, except adding one more 765 kV circuit from
Lahore to Gatti, for strengthening the system. (Figure 5.5)
Alternative 3A Same as Alternative 2A, except that Gatti (FESCO Load Centre) is
replaced by Gujranwala (GEPCO Load Centre) to cater for its demand. (Figure 5.6)
Alternative 3B Same as Alternative 3A, except that one more 765 kV circuit is added
from Gujar Khan to Gujranwala to cover n-1 contingency at Gujar Khan. (Figure 5.6)
Alternative 3C Same as Alternative 3B, except that in addition two 765 kV circuits from
Gujar Khan to Lahore are made In and Out at Gujranwala to further strength the system.
(Figure 5.6)
5.16
Study of the Alternatives
Alternative 1
One 765 kV circuit with optimised capability of 4320 MW of Dasu can not cater for the
load even under normal operating condition. The normal permissible flow on 765 kV line
is 1700 MW. With all the three Basha-Gujar Khan-Lahore circuits being in and out at
Dasu the total generation that has to be dispersed from Dasu will be 8,820 MW (4,500
from Basha + 4,320 from Dasu), while total number of 765 kV circuits in Dasu-Gujar
khan section will be four (three coming from Basha, and one newly constructed circuit for
Dasu dispersal). These four 765 kV circuits from Dasu to Gujar Khan will carry 2205 MW
each under normal system condition, while with n-1 contingency the flow will be about
2940 MW. Similarly in the section between Gujar Khan-Gatti the normal flow will be
8820-1425 (Load of 2*1500 MVA Power Transformer with 0.95 Load Factor and sharing
50% load each). The normal flow will be 1849 MW, while in n-1 contingency the flow will
be 2466 MW. This arrangement thus can not be considered as technically feasible with
the present capability of 4320 MW.
5-19
Volume 8
Alternative 2A
The configuration will be same as in Alternative 1. However one additional 765 kV circuit
is proposed from Dasu to Gujar Khan to cater for the increased output from Dasu. The
normal flow with five 765 kV circuits in this section will be 1,764 MW. During single
contingency of n-1 criteria the flow will be of the order of 2,205 MW and will require about
30% series compensation to cover the contingency criteria between Dasu and Gujar
Khan.
This alternative however does not cater for the Gujar khan Gatti section as on this
section the normal flow will be 1,849 MW, and during single contingency of n-1 it will be
2,466 MW.
Alternative 2B
The configuration will be same as in Alternative 2A. However one additional 765 kV
circuit is proposed from Gujar khan to Gatti to cater for the increased output from Dasu.
The normal flow with an added 765 kV circuit between Gujar Khan and Gatti will be
1,479 MW. During single contingency of n-1 criteria the flow will be 1849 MW, and will
require about 20% series compensation.
This configuration is not only technically feasible but is also the least cost alternative,
and is recommended as the best choice for dispersal of 4320 MW of Dasu (Figure 5.5),
to Gatti Load Centre.
Alternative 2C
The configuration will be same as in Alternative 2B. However one 765 kV circuit is
proposed from Lahore to Gatti to further strengthen the system. The normal flow with this
arrangement will be same as in Alternative 2B, for both normal and n-1 contingency. This
case has not been studied further due to the extra cost of 765 kV single circuits from
Lahore to Gatti.
Alternative 3A
The configuration will be same as in Alternative 2A, except Gatti is replaced by
Gujranwala as the end point. The flows on the circuits between Gujar khan - Dasu will be
the same i.e. 1764 MW during normal flow and 2205 MW during n-1 contingency. The
series compensation of about 30% will be required.
However this configuration does not cover the contingency of n-1 between Gujar KhanGujranwala sections. The normal flow will be 1849 MW while during n-1 contingency it
will be 2465 MW thus this alternative is technically not feasible.
Alternative 3B
Same as Alternative 3A except that with one more 765 kV circuit from Gujar Khan to
Gujranwala the normal flow in this section will be 1479 MW and with n-1 contingency it
will be 1849 MW that can be covered by addition of appropriate series compensation.
This alternative is also technically feasible and economical. However as stated in section
5.14, the thermal generation of 450 MW each at Nandipur & Chichoki Malian is already
under execution and will be sufficient to cater for the load of Gujranwala load centre.
Alternative 3C
5-20
Volume 8
Same as Alternative 3B, with addition of two of the three circuits from Basha to Gujar
Khan to Lahore made in and out at Gujranwala the system will be further strengthened.
The normal and n-1 contingency flow will be same as in Alternative 2A, but will be result
in a more stable system. This is a better alternative than 3A, but the high cost may not
justify its selection.
Conclusion
Alternative 2B (Figure 5.5) for dispersal of Dasu 4320 MW is recommended. A total of six
220 kV lines will be needed to disperse power from 3 X 1200 MVA power transformers at
Gatti.
However the cost of 220 kV lines and the required 220 kV bays have not been included
in the project cost.
5.17
Conceptual Configuration of 765 kV Substations
(i)
Dasu
The space constraint due to the limitation of cavern dimension for the underground
power station has restricted the choice to GIS substation which is much smaller in
dimension compared with conventional substation. Further more the non availability of
space at surface for a substation near the power station has resulted in two substations.
One under ground (on top of the generator transformer cavern) and the other surface
substation about two kilometre away from the power station and with space available for
in and out of all the three 765 kV Basha-Gujar khan circuits. Provision will also be made
for three 765 kV circuits emerging from underground substation, the surface station will
include two additional 765 kV circuits to Gujar Khan and one 160 MVA 765/132 kV
transformer for local supplies. (Fig 5.7)
(ii)
Gujar Khan
It has been assumed that 765 kV Gujar Khan Substation will be operational with all the
three 765 kV Basha - Lahore circuits being in and out at Gujar Khan and one 1500 MVA
765/500 kV power transformer fully integrated with the 500 kV system in the area. Dasu
scope will add two more 765 kV circuits coming from Dasu and then going to Gatti, along
with an additional 1500 MVA 765/500 kV power transformer to supplement the 500 kV
net work in the area and sharing MVARS with generating units of Mangla and Tarbela
hydroelectric power, especially during winter month of restricted water out flows.
(iii)
Gatti
Gatti will be a new 765 kV substation with provision of two 765 kV circuits from Gujar
Khan. It will also have three step down power transformers of 1200 MVA 765/220 kV
each to be fully integrated with the 220 kV net work in the area by NTDC.
5.18
Line Parameters for 765 kV Transmission Lines
The parameters considered for line materials and tower foundations for different
alternatives are described below for comparison purpose
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Volume 8
5.18.1 Conductors
Conductor sizes are usually not a direct function of the thermal rating of the line.
Environmental factors such as maximum electric fields, television interference (TVI),
radio interference (RI), corona loss and audible noise are also taken into account to
determine the conductor size and the number of conductors in a bundle. All these
criteria/parameters are site specific, and have to be evaluated at project design stage.
Based on loading conditions, temperature variation and power flow requirements,
following conductor in-quad bundle configurations have been referred for evacuation of
power from Dasu to the interconnection point.
-
ACSR Nuthatch, Dipper and Lapwing for 765 kV single circuit
ACSR type conductors have primarily been selected because of their higher mechanical
strength, due to steel core, in view of the rugged terrain, which will require long spans.
Size of the conductor has been based on the power flow and corona requirement and
quad bundle configuration has been considered to ensure fulfilment of corona and
surface gradient requirements. All the three conductors proposed for power transmission
on 765 kV voltage level are capable of transferring required power using 765 kV voltage
level of transmission. However, cost of 765 kV transmission line with Dipper Conductor is
low as compared to line cost using other conductors (even by considering PR & Corona
losses). Consequently, Dipper conductor has been proposed for power transmission on
765 kV voltage level.
The essential parameters of the conductor proposed are given in Table 5.17 below.
Table 5.17 Parameters of the Proposed Conductor
Conductors Code
Conductor Dia (mm)
Cross Section (mm)
Stranding (Al/Steel)
Unit weight (kg/km)
UTS (kg)
DC resistance at 20C (/km)
Current Rating (A) at 0.6 m/sec wind velocity,
40C ambient and 65C Conductor temperature
ACSR Dipper
35.16
732.26
45/7
2275
16400
0.0419184
800
All other site specific criteria and environmental factors will be evaluated at project
design stages.
5.18.2 Shield Wires Shield Wire/OPGW
Two shield wires per tower have been proposed, to ensure adequate lightening
protection, out of which one shall be Optical Fibre Ground Wire (OPGW) to provide
communication link between terminal stations coupled with lightening protection. The
parameters of the shield wire and OPGW are the same as are being used in WAPDA
network based on the prevalent isokeraunic level information and the communication
requirements. However, the parameters would be reviewed at the Project design stage
based on actual isokeraunic level obtained from meteorological department for the
relevant area and the actual communication requirements of the Client. Parameters of
the proposed shield wire & OPGW are as given in Table 5.18 below.
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Volume 8
Table 5.18 Parameters of Shield Wire & OPGW

Description
Code
Shield Wire
EHS Gal. Steel
Dia (mm)
Cross Section (mm)
Unit Weight (kg/km)
UTS (kg)
No. of Optic fibers
9.15
51.08
406
6985
-
OPGW
50/30-18S
(with stainless tube)
12
88
460
7000
16
5.18.3 Towers
Self-supporting type lattice steel galvanized structures have been proposed to support
bundle conductors suspended in V-string configuration of insulators on suspension
towers and connected in horizontal string configuration of insulators with tension towers
(dead-end towers/structures). Based on wind velocity of 160 km/hour, ice thickness of
6.25 mm of ice zone sections, wind pressure on towers and conductors and
subsequently transverse wind loadings on towers (to calculate estimated towers
weights) have been calculated according to ASCE manual No. 74 (latest edition). All
loading conditions required for design of different types of towers for the selected
Alternative will be calculated at detail design stage.
Typical outline drawings of towers for 765 kV single circuits are shown in Figures 5.8 and
5.9. The outline of these towers have been established, keeping in view the electrical
clearances from conductor to tower and conductor to ground as per NESC code for the
relevant altitude through which the lines would traverse. Typical values of these
clearances are also shown on the outline drawings of the towers referred above which
compare favourable with the data available for lines of similar voltage level in different
parts of the world.
To establish these clearances in view of safety & health effects and other environmental
impacts within ROW corridor, a detailed study will be conducted during/before detail
design stage.
5.18.4 Insulators
Number and type of insulators for 765 kV A.C. transmission line has been proposed
considering Equivalent Salt Deposit Density (ESDD) level of 0.15 mg/cm, relevant
voltage level, altitude, loading conditions, conductors tension, safety factor, behaviour of
A.C. discharge and A.C. withstand voltage. Typical A.C fog type insulator is shown in
Figure 5.10.
Withstand voltage of an insulator is proportional to contamination degree. The
relationship of A.C. line is given below:
A.C. withstand (ESDD) 1/5
Typical characteristics and number of insulators, for the transmission line opted for
study, are as given in Tables 5.19 and 5.20 below.
Table 5.19 Typical Characteristics of AC Fog Type Insulator
Description
Disc
Diameter
(mm)
5-23
Unit
Spacing
(mm)
Creepage
Distance
(mm)
Unit
Weight
(kg)
300 kN
210 kN
160 kN
80 kN
400
320
320
254
Volume 8
195
170
170
146
740
590
570
434
20.5
12
11
7
Table 5.20 Numbers of Insulators Proposed for Dipper Conductor

with Respect to the Zones
Description
Tension Insulators 210 kN
Ice Zone
44
No Ice Zone
34
Suspension Insulators 300kN
35
27
Jumper Insulators 160 kN
48
36
Detail contamination/insulation study is however required to be conducted at detailed

design stage.
Ceramic type insulators have been proposed for their proven reliability in extreme
environment conditions over other types of insulators.
5.18.5 Hardware & Accessories
Maximum conductor tension, working loads, conductor bundle configuration, safety
factor and corona level have been considered while proposing, strength and general
shape of hardware & accessories. Typical hardware details are shown in Figures 5.11
and 5.12. Based on the pollution level in the corridor area, galvanized steel hardware
has been considered feasible. The assembly design will be finalized at detailed design
stage.
5.18.6 Dampers
For the purpose of feasibility level study, the dampers have been proposed considering
conductor diameter and conductor bundle configuration. Quad bundle spacer dampers
for holding sub-conductor spacing of 457 mm and suppress Aeolian Vibration such that
dynamic strain caused by vibration in vertical direction should not exceed 200 microstrain at suspension point.
5.18.7 Grounding
Since the major transmission line corridor has traversed through dry and rocky soil
conditions, a particular care is required for ensuring requisite earth resistance. For
towers, in reasonable soil condition, it is expected that the footing resistance will be 10
ohms or less.
However, for purpose of feasibility, radial grounding, producing a number of parallel
paths, has been considered as most feasible. This will be further refined after carrying
out soil resistivity survey along the line route(s).
5.18.8 Tower Foundations

Keeping in view rocky soil conditions of the transmission line corridor, it is envisaged that
rock anchor/under cut types of foundations would be required to be installed in long
stretches of the corridor. Normal spread footing foundations would also be installed in
5-24
Volume 8
many stretches. Typical drawings for spread footing, rock anchor and under cut
foundations are shown in Figures 5.13. Pending decision of the requirement of
foundation type(s) until sub-soil investigations are conducted at detail design stage,
spread-footing foundations have been considered as a basis of cost estimates for the
feasibility study.
For the feasibility level design of the spread footing foundations for different types of
towers, moments, vertical weights & base width of relevant full height towers, and
consequently foundation working loads are calculated. Taking into account the
foundation working loads, size(s) of foundation(s)/volume of reinforced concrete and stub
sizes for different types of towers have been worked out. Foundation loads and volume
of reinforced concrete foundation for different types of towers are shown in Table 5.21
below.
Table 5.21 Approximate Foundation Loads/Concrete Volume in Foundations for
Different Types of Towers
Description
Tower Type
765 kV Single Circuit

Dipper
Uplift/Leg
Suspension
48
Working Load (Ton)

Compression/Leg
Working Load (Ton)
Concrete Volume in Foundation
(cu. m)
Angle
Suspension
Angle
Suspension
Angle
167
60
185
32
136
5.19
Cost Estimates of Transmission Alternatives
Cost of any transmission line depends basically on quantity of line materials, unit cost of
the line materials and cost of construction. Other factors considered in working out these
cost estimates are inland transportation, incidental charges (which include charges for
letter of credit, insurance, landing, clearing etc,), engineering & administration and some
factor for contingencies. Custom duties and sales tax have not been considered while
preparing the cost estimates. The cost estimates of the transmission lines for the
proposed alternatives have been worked out by using the quantities and unit rates
worked out as described in the following sub sections. The cost estimates are shown in
Table 5.22.
5.19.1 Quantities of Line Materials
Quantities of conductor & shield wire/OPGW for any transmission line configuration are
dependent upon the line length, whereas quantities of tower steel, insulators and
hardware etc. are dependent upon the span distribution i.e. number of structures.
From review of parameters of the existing lines, it was concluded that average span for
the transmission line alternatives under consideration should be 365 m. This gives 2.74
numbers of towers per kilometre. For the purpose of cost estimates, ratio of suspension
to dead-end/angle towers for different line sections has been taken as given below:
Table 5.23
Sr. No.
1
2
Ratio of Suspension to Angle Tower for Each Line Section
Name of Line Section

Dasu-Thakot
Thakot-Mansehra
Ratio of Suspension to Angle Towers

20:80
40:60
5-25

3
4
Mansehra-Gujar Khan
Gujar KhanGatti
Volume 8
60:40
80:20
This distribution accounts for the expected higher number of angle towers which are
anticipated in the mountainous region. Angle towers will also include vertical angle
capability that is often required in mountainous regions where towers are continuously in
an uplift condition.
The weights of suspension and dead-end/angle towers were calculated by using Ryles
Empirical formula taking into consideration transverse wind loads, conductor tension,
required ground clearances and sag values for ruling span length of 365 m. The weights
of the towers so calculated for the proposed Alternatives are shown in Table 5.24 below:
Table 5.24 Approximate Average Tower Weights Configuration (B+0+6)
Condition
Without ice
With 6.25 mm ice
Voltage Level
Conductor Type
Conductor Temperature
Suspension Tower
Tension Tower at 60 Angle
(kg)
(kg)
13,800
30,500
17,200
32,000
765 kV Single Circuit
Dipper
65 C
Quantity of conductor was based on actual line length, times number of phases and subconductors, including 2% allowance for sag, jumper/wastages etc. EHS galvanized
shield wire and OPGW are also based on the actual length including 2% allowance for
sag and jointing/jumpers.
Quantity of the insulators per assembly is based on the insulation level required for the
area and transmission voltage. Consequently, total numbers of different types of required
insulators are calculated considering number of different types of assemblies as per type
of structures required. Subsequently, quantities of other line materials were calculated
taking into account the required number of structures/spans and configuration of each
line.
5.20
Unit costs for transmission line materials have mainly been calculated by applying an
escalation factor of 3.0% per annum to the latest available unit rates from the
executed/under execution contracts of Dadu-Khuzdar Transmission System Project
and Transmission Arrangements for Power Dispersal of Ghazi Barotha Hydro Power
Project keeping in view the rise in steel price in international market and wherever rates
if not available from contracts of aforesaid project then the rates from Transmission
Extension and Reinforcement Project were considered. Escalation factor has been
calculated based on the month & year of execution of the particular contract.
For conductor, the price was obtained from London Metal Exchange (LME) and for
galvanized steel wire from Contract 2017-3 (Item-2) for supply of Shield wire for In & Out
arrangement of Tarbela Gatti 500 kV circuits 1&2 at Barotha. Rate of galvanized steel
wire was escalated according to the steel prices in international market, since it covers
additional cost for galvanizing and manufacturing. Cost per km of proposed conductors
were calculated by multiplying the quantity of aluminium and steel respectively in per km
and thereafter adding per km manufacturing cost & profit.
5-26
Volume 8
For hardware, dampers and accessories etc. requirement for higher strength material as
compared to those already procured has been considered and consequently unit cost
has been increased by 10% of the escalated cost obtained from the executed/under
execution contracts.
5.20.1 Towers
Data from Contract No. 2878 Dadu-Khuzdar Transmission System Project (turnkey
based) was used for obtaining unit rate of the galvanized steel towers. The unit rate
given in Contract No. 2878 is for 220 kV towers and escalated @ 15% to account for the
recent rise in the price of steel in March 2008 and ratio of high strength steel in proposed
towers. Twenty percent of this rate was considered as local manufacturing cost.
Consequently unit cost of steel tower in foreign and local currency was worked out. The
unit rate so calculated was multiplied with the relevant towers weights calculated by
Ryles Formula, number of structures estimated per km and estimated percentage of
relevant type of tower in respective sections to obtain the budgetary cost estimates of
different types of towers.
5.20.2 Conductor
Unit rate of aluminium was taken from LME as on April 2008 and that of steel from
Contract 2017-3 (Item-2) for supply of shield wire for In & Out arrangement of TarbelaGatti; 500 kV circuits 1&2 at Barotha, signed between NTDC (WAPDA) and M/s.
Newage Cables in April 1999 and escalated keeping in view the steel price in
international market. The same were multiplied with standard weights/km (including 2%
for sag & wastage) of aluminium & steel respectively of the conductor. This gives 80% of
the conductor cost, since as estimated, 80% of total cost is that of material & 20% is that
of manufacturing including shipment & profit. Subsequently, manufacturing cost @ 20%
of total cost was added to get per km cost of proposed conductor.
5.20.3 Shield Wire
Unit rate was obtained from above referred Contract 2017-3 and the same was
escalated according to the steel price in international market. Two percent is added for
sag & wastage.
5.20.4 Shield Wire Fittings
Quantity required per km for shield wire fittings is calculated. Subsequently per km rate
of shield wire fittings is calculated by multiplying these quantities with the unit rates of the
relevant fittings in Contract 1150-22, (Item-3) for supply of Hardware for Third JamshoroGuddu 500 kV transmission line, signed between NTDC (WAPDA) and M/s. Sicamex
France in May 1996. The rate so calculated is escalated @ 3.0% per annum.
5.20.5 OPGW
Per km rate of OPGW was obtained from Dadu-Khuzdar Transmission System Project in
October 2007. The rate so calculated is escalated @ 3.0% per annum. Two percent is
added for sag and wastage.
5.20.6 OPGW Fittings
Quantity required per kilometre for OPGW fittings has been worked out. Per km cost of
these fittings are calculated by multiplying these quantities with unit rates of relevant
fittings obtained from above referred Contract.
5-27
Volume 8
5.20.7 Insulators
The data and budgetary cost provided by one of the reputed manufacturer for Basha
Diamer Dam Project is used to estimate the cost of insulators to be used for 765 kV
voltage levels keeping in view the strength & type of suspension & tension insulators and
number of each type of insulators per string, after applying the escalation factor.
5.20.8 Conductor Accessories
Quantity required per km for conductor accessories are worked out. Subsequently, per
km rate of conductor accessories are calculated from the unit rates of these accessories
given in Contract No. 2017-3 (Item-3) for Supply of Accessories for In & Out
Arrangement of Tarbela-Gatti 500 kV circuits 1&2 at Barotha, signed between NTDC
(WAPDA) and M/s. Sicamex France in May 1999. The rates of accessories for
conductor were enhanced by 10% to cater enhanced strength because the proposed
conductor Dipper has more strength and weight than the Drake for which the cost was
available. The rates thus obtained have been escalated @ 3% per annum to get the per
kilometre rate of conductor accessories as on January 2008 price level.
Quantity required per km for spacer dampers are calculated. Subsequently, per km rate
of dampers is worked out from the unit rates of these dampers given in Contract No.
1150-24 (Package-2) for Supply of Dampers for Conductor and Shield wire for Third
Jamshoro-Guddu 500 kV Transmission Line signed between NTDC (WAPDA) and M/s.
Dulmison Thailand in September 1995. The rate of dampers for conductor was
enhanced by 10% to cater required enhanced strength because the proposed conductor
Dipper has more strength and weight than the Drake for which the cost was available.
The rates thus obtained are escalated @ 3% per annum to obtain rate of dampers per
km as of January 2008 price level.
5.20.10 Hardware
Quantity required per km for hardware is calculated. Also, per km rate of hardware is
calculated from the unit rates of the hardware given in above referred Contract No. 115022 (Item-3). The rates of hardware for conductor are enhanced by 10% to cater
enhanced strength because the proposed conductor Dipper has more strength and
weight than the Drake for which the cost was available. The rates thus obtained are
escalated @ 3% per annum to obtain rate of dampers per kilometre as of January 2008
price level.
5.20.11 Construction
Due to variation in terrain area independent unit rates for different items of Transmission
Line Construction were developed for the four Sections i.e. Dasu-Thakot Section,
Thakot-Mansehra Section, Mansehra-Gujar Khan Section and Gujar Khan-Gatti Section
based on recent 500 kV Contracts for Rewat-Gakhar-Lahore Line and 220 kV contracts
for mountainous areas. The same were multiplied with the quantities of relevant items
thus calculated to obtain cost of construction material and per km cost of each Section
and consequently cost of the entire line being studied.
5-28
5.21
Volume 8
Cost Comparison of Various Transmission Alternatives
For the purpose of comparison, the cost of each alternative has been worked out on the
basis of quantities and unit rates. In preparing these estimates, factors such as
mountainous terrain, specialized construction methods and construction of
R.O.W/approach roads, transport of line materials and construction equipment to remote
mountainous locations, have also been accounted for where considered necessary. The
cost comparison is shown in Table 5.25 below:
Table 5.25 Cost Comparison of Various Transmission Alternatives
Cost Estimate of 765 kV Single Circuit T/L in US$/km.
(figures in thousand)
Sr. No
1
2
3
4
Description
From Dasu to Thakot

From Thakot to
Manshera
From Manshera to Gujar
Khan
From Gujar Khan to Gatti
From Lahore to Gatti
Distance
(km)
2A
2B
2C
Single
Cct.
Two S/C
Two
S/C
Two S/C
Three
S/C.
80
51,600
103,200
103,200
103,200
154,800
65
32,175
64,350
64,350
64,350
96,525
185
69,375
138,750
138,750
138,750
208,125
230
78,200
78,200
156,400
156,400
234,600
560
231,350
384,500
462,700
462,700
694,050
95
78,200
78,200
772,250
5.22
Findings
A study of the alternatives discussed in detail under various sections above indicate that
at this point of time with the latest load forecast of DISCOS up to 2030, the sequence of
generation as per revised National power Plan also up to 2030, and after Daimer Basha
4500 MW end dispersal at Lahore the natural dispersal of Dasu 4320 MW will be Gatti
(Load centre of FESCO), by the year 2021 to 2023. The Alternative 2B for the dispersal
of Dasu 4320 MW is recommended.
5-29
Volume 8
SECTION NO. 6
HYDRAULIC STEEL STRUCTURES
GATE EQUIPMENT
TABLE OF CONTENTS
Sr. No
Description
Page No.
6.
HYDRAULIC STEEL STRUCTURES (GATE EQUIPMENT)
6-1
6.1
SPILLWAY GATE EQUIPMENT
6-1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6-1
6-2
6-4
6-4
6-5
6-5
6.1
LOW LEVEL OUTLET CONDUITS GATE EQUIPMENT

6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.3

6-6
6-10
Main Parameters
POWER INTAKES EQUIPMENT

6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7
6.3.8
6.4

Radial Gates
Stoplogs
Lifting Beam
Gantry Crane
Main Parameters
6.4.2
6.4.3
6.4.4
6-7
6-8
6-12
6-12
6-13

6-13
Guard Gates
Service Gates
Power Intake Shaft
Trashracks
Gantry Crane
Main Parameters
DRAFT TUBE GATE EQUIPMENT

6.4.1
6-6
6-14
6-15
6-16
6-16
6-16
6-17
6-17
6-18

6-18
Draft Tube Gates
Overhead Travelling Crane
Main Parameters
6-i
6-19
6-19
6-19
6.5
6.6
Volume 8
TAILRACE TUNNELS GATE EQUIPMENT
6-20
6.5.1
6-20
6.5.2
6.5.3
6.5.4
6-21
6-21
6-21

Stoplogs
Main Parameters
DIVERSION TUNNELS GATE EQUIPMENT

6.6.1
6.6.2
6.6.3
6.6.4

6-22
Stoplogs
Lifting Beam
Main Parameters
6-ii
6-22
6-22
6-23
6-23
6.
Volume 8

GATE EQUIPMENT
6.1
6.1.1
Gate equipment for spillway will primarily comprise crest type radial gates, hydraulic
hoists, stoplogs, lifting beam, gantry crane, embedded metal parts and appurtenances.
Slots for the stoplogs will be provided upstream of the gates. A gantry crane and lifting
beam will be provided to handle the stoplog sections.
The general arrangement of the gate equipment and main elevations are shown in
Fig.6.1, 6.2 and 6.3.
The gate equipment will be designed to meet following functional requirements:i.
The gates and the hoists will be operable at full reservoir level as well as under
dry condition.
ii.
The gates will be capable of regulating the discharge from 7% of gate opening to
full opening.
iii.
The gates and their hoisting system will be capable of withstanding the Maximum
Credible Earthquake specified for the Project.
iv.
The gates will be operable locally from the spillway control room and remotely
from the powerhouse control room and will open automatically when the reservoir
level exceeds the design level
v.
The gates hoisting control system will be capable of lifting all gates,
simultaneously.
vi.
The gates will be designed to close under gravity
vii.
Emergency diesel power supply will be provided to operate the gates in the event
of failure of normal power supply to the gates.
viii.
Stoplogs will be provided for dewatering the bays and inspection of gates and
their embedded parts.
ix.
The stoplogs will be designed to operate under balanced head condition.
x.
Gantry crane is supposed to manipulate stoplog sections and for the

maintenance of radial gates.
Six hydraulically operated crest type radial gates will be installed at spillway. The
operating system will consist of two hydraulic cylinders and a hydraulic power and
control unit. The gates will be designed to regulate the spillway releases. Full capacity of
one spillway bay is approx. 4773 cumecs, in total 28638 cumecs.A wave deflector will be
provided, which will be bolted to any gate undergoing maintenance to prevent water
waves slopping-over the gate. The wave deflector will be designed for a 1.0 m high wave
impacting at 5 m/s speed.
Each radial gate clear opening will be 16.5 m wide and 20.0 m high. The top of gate will
6-1
Volume 8
be 0.5 m above normal reservoir level of 950.0 m to prevent waves topping over the
gate. The radius of skin plate will be 23.00 m.
One set of stoplogs of nominal size16.5 m wide x 22.0 m high, having ten sections, will
be provided for installing upstream side to close any bay for repair and maintenance of
the radial gate. The stoplogs sections will be individually lifted by the lifting beam hooked
on gantry crane. The second section of the stoplogs from bottom will be equipped with a
150 mm diameter filling valve actuated by lifting beam by pushing down the stems
installed in stoplogs sections.
Main features of the gate equipment are described below:
6.1.2
Radial Gates
Each radial gate will consist of three components: skinplate assembly, two arm
assemblies and two trunnion assemblies.
Skinplate Assembly
The skinplate assembly will be of welded structural steel construction with the skinplate
reinforced on downstream side by horizontal beams. The horizontal beams will be
supported by vertical and horizontal girders, which in turn will be supported by arm
assemblies. The skinplate assembly will be divided into sections suitable for
transportation and handling in the field. These sections will be field assembled by bolting
and seal welding.
Guide Rollers and Guide Shoes
Guide rollers will be installed on each side of the skinplate assembly which will restrict
the lateral movement of the gate. These guide rollers will bear against the sidewall
sealing surfaces. At fully opened position atleast two guide rollers will remain in contact
with side seal bearing plates.
Seals and Sealing Surfaces
The sealing system for radial gates will consist of L type rubber side seals with
fluorocarbon cladding and wedge type bottom rubber seals.
The side and bottom sealing surfaces will be flush with the waterways. The side sealing
surfaces will be of corrosion resisting steel plates embedded in the concrete walls and
will extend from sill to the top of the pier. The bottom seal seating surface will be
corrosion resisting steel plate attached to the sill beam.
Arm Assembly
Two arm assemblies will be provided for each radial gate. Each arm assembly will
consist of two box section compression members. The arm assemblies will be arranged
for field bolting to the vertical girders and trunnion flanges.
Trunnion Assemblies
Each of the two trunnion assemblies will consist of a trunnion hub with self-lubricating
bushing, a trunnion yoke and a trunnion pin. The trunnion hub will be of forged or cast
steel. The yoke will be of welded steel construction. The trunnion pin will be either of
stainless steel or forged steel with stainless steel rim. Jack screws will be provided to
6-2
Volume 8
permit horizontal and vertical movement of the yoke before final fixing.
Hoists and Controls
Each radial gate will be fitted with two single acting hydraulic hoist cylinders. The hoist
cylinders will be mounted on the deck along sidewalls on either side of the waterway and
will be designed to have enough lifting force to lift the gate under any foreseeable
operating condition. Hydraulic oil for cylinders will be supplied by motor driven oil pump.
Two oil pumps one active and other standby per gate will be provided for the sake of
reliability. Each oil pump will be capable to supply oil at the required pressure and rate to
lift the gate at the maximum lifting speed selected for the gate. Lowering of the gate will
be accomplished by gravity. The lifting and lowering speeds of the gates will be 0.3 m
and 1.0 m per minute respectively. In addition to electric motor driven pumps one hand
operated oil pump will be installed as well.
Selector switch will be provided for three operating modes: (a) continuous, (b) stepped
and (c) preset opening. The stepped mode will be arranged to raise or lower the gate in
steps of about 1000 mm. The controls will be arranged to provide manual gate operation
at all reservoir levels. When reservoir water level rises to a designed height above El.
950, an automatic emergency level controller will automatically raise all the gates.
Each gate will have individual oil hydraulic and control system housed in a gate control
module near the gate. The oil hydraulic system will consist of oil pumps, oil reservoir and
valves. The control system, working on DC from storage batteries, will include gate
operation signals, alarms, solenoids, gate position indicators and interlocking devices.
The gates will be operable individually, jointly or in batches from the spillway control
room and from power house control room. For operation during repair and maintenance,
local control panels will be installed on all the gates. An interlocking system will be
provided to limit the differential openings between adjacent gates within a maximum
preset range.
Embedded Parts
Each crest type radial gate will be provided with one set of embedded parts which
includes one sill beam, two side seal and track plates, embedded dogging device and
erection studs. The erection studs will be welded to the welding pads embedded in first
stage concrete. The side seal and track plates will be curved to an arc concentric with
the trunnion axis and will extend from sill beam to the top of the piers. The side seal and
track plates and exposed top plate of the sill beam will be of corrosion resisting
steel.Trunnion assemblies will be attached to the trunnion support girders through bolts
which will be grouted after tensioning. The space between the trunnion yoke and its
support girder will be filled with epoxy grout.
6.1.3
Stoplogs
The stoplog sections will be of welded steel construction with downstream skinplate
reinforced by vertical and horizontal girders. The stoplogs will have downstream wedge
type bottom rubber seals and J type side rubber seals. Guide shoes will be provided at
the top and bottom of each side of the stoplog sections to engage the guides embedded
in the concrete. For alignment of stoplog sections, guide pins will be installed on top of
lower sections and guide sleeves in the bottom of upper sections. The stoplogs will be
designed to be handled by a lifting beam and gantry crane. A 150 mm dia. Filling valve
operated by lifting beam, will be provided in the second section of the stoplogs from the
bottom to achieve the balanced head condition for raising the stoplogs.
6-3
Volume 8
Embedded Parts
Each set of embedded parts for stoplogs will consist of two side seal bearing plates and
guide plates and one sill beam. The side seal bearing plates and guide plates and
exposed top plate of sill beam will be of corrosion resisting steel. The seal bearing and
guide plates will form a continuous slot lining from the sill beam to the top of the
waterway. The embedded parts will be installed in the blockouts and adjusted by means
of the erection studs welded to the welding pads embedded in the first stage concrete.
Storage
The stoplog sections will be stored on either side of the spillway.
foundations will be made to store each section independently.
6.1.4
Proper concrete
Lifting Beam
The lifting beam will be of welded steel construction equipped with two semi-automatic
engaging and disengaging hooks. The hooks will be mounted on corrosion resisting steel
pins and self-lubricating bushes. The beam shall be led within guides of stoplogs, and for
this purpose equipped with two pairs of side wheels with self lubricating bearings.
6.1.5
Gantry Crane
One gantry crane of 40 tons capacity will be provided at the spillway to handle stoplogs
in normal operation and for radial gates maintenance. The crane will be an electrically
operated outdoor type, with an operators cabin located on the upstream side and raised
above the deck for good visibility of all crane operations. The gantry crane will operate
on rails extending over the full length of the spillway deck.
6.1.6
Main Parameters
The main parameters of spillway gate equipment are given hereunder:

Radial Gate
Type of gate
No. of gates
Width of gate opening
Height of gate opening
Full reservoir level (FRL)
Elevation of radial gate sill
Radius from trunnion centre to inside face of skinplate
Elevation of trunnion centre
Elevation of top of gate in closed position
No. of arm assemblies per gate
Type of construction
Embedded parts
Radial, Crest
6
16.5 m
20.0 m
950.0 m
929.5 m
23.0 m
937.75 m
950.5 m
2
Welded
6 sets
Gate Hoist
Type of hoist
No. of hoist cylinders per gate
Rate of gate opening
Rate of gate closing
Hydraulic
2
0.3 m per minute
1.0 m per minute
6-4
Volume 8
Stoplogs
Type of stoplogs
Width of stoplog opening
Height of stoplogs
Elevation of sill of stoplogs
Elevation of top of stoplogs in closed position
No. of sets of stoplogs
Sections per set
Embedded parts
Vertical-lift
16.5 m
22.0 m
929.0
951.0 m
1 set
10
6 sets
Wave Deflector
No. of wave deflectors
Type of wave deflector
Width of wave deflector
Height of wave deflector
Elevation of top of wave defector when installed
1
Removable
16.5 m
1m
951.5 m
Welded
Lifting Beam
No. of lifting beams
1
Welded
Gantry Crane
Capacity of gantry crane
Span
Runway length
40 ton
10.5 m
160 m
6.2
Low Level Outlet Conduits Gate Equipment
6.2.1
Seven low level outlet conduits of size 5 m wide x 7.2 m high each, will be required for
sediment sluicing and emptying reservoir in an emergency. Normal range of operation of
low level outlets is from El. 810 m to El. 950 m and maximum capacity of each outlet is
1573 cumecs at water EL. 950m.
The gate equipment at each conduit will consist of one bonneted gate at inlet structure
and one bonneted gate along with one submerged radial gate at outlet structure.
The submerged radial gate at outlet will act as regulating gate. The downstream
bonneted gate will act as guard gate where as upstream bonneted gate will be used as
service gate for maintenance of tunnel steel liner and guard gate. Both the bonneted
gates will be fixed wheel type. In normal operation the guard gate will work under
balance head condition, but will be capable of closing under unbalance head condition if
regulating gate starts malfunctioning. The service gate will always work under balance
head condition. The balance head in both the gates will be obtained through by-pass
filling valves.
The nominal size of radial gate will be 5.0 m wide x 7.0 m high and that of bonneted
gates will be 5.0 m wide x 7.2 m high.
6-5
Volume 8
The general arrangement of low level outlet conduits gate equipment is shown in Fig.
6.4.
6.2.2
The radial gate will be submerged type consisting of skinplate assembly, arm assembly,
trunnion assembly and hoisting system.
Skinplate Assembly
The skinplate assembly will be of welded construction with the skinplate claded on
external side by stainless steel layer and reinforced by horizontal beams on internal side.
The horizontal beams will be supported by vertical and horizontal main girders, which in
turn will be supported by arm assemblies. The skinplate assembly may be divided into
sections suitable for transportation and handling in the field. These sections will be field
assembled by bolting and seal welding. External side (stainless steel layer) will be fined
machined to accept tight contact with stable rubber sealing on upper lintel beam.
Seals and Sealing Surfaces
The radial gates will be fitted with inflatable J-type double stem rubber side and top
seals, with fluorocarbon cladding. Bottom rubber seal will be wedge type. In addition to
the top seal on the gate one stable inflatable seal will be installed at upper lintel beam.
All seal bearing surfaces will be from stainless steel, fine machined.
Arm Assembly
Two arm assemblies will be provided for each radial gate. Each arm assembly will
consist of two strong box type compression members so as to decrease counter
movement of sealings). The arm assemblies will be arranged for field bolting to the
vertical girders and turnnion flanges.
Trunnion Assemblies
Each trunnion assembly will consist of trunnion hub with semi spherical bearing, a
trunnion yoke and a trunnion pin. The bushing will be self-lubricating. The trunnion pin
will be either of stainless steel or forged steel with stainless steel rim.
The turnnion assemblies will be supported by horizontal concrete beam.
Hoists and Controls
Each radial gate will be provided with two single acting hydraulic hoist cylinders. The
hoist cylinders will be mounted on the hoist supports at the top and will be designed to
have enough lifting force to lift the gate under any foreseeable operating condition.
Hydraulic oil for raising the gate will be provided by motor driven oil pumps. Two oil
pumps per gate will be provided for the sake of reliability. Each oil pump will be rated to
supply oil at the required pressure and rate to lift the gate at the maximum lifting speed
selected for the gate. Normal lowering of the gate will be accomplished by gravity. Lifting
and lowering speeds of the gate will be 0.3 m and 1.0 m per minute respectively.
Each gate will have individual oil hydraulic and control system housed in a gate control
module near the gate. The oil hydraulic system will consist of oil pumps, oil reservoir,
valves etc. The control system, working on DC from storage batteries, will include gate
operation signals, alarms, solenoids, gate position indicators.
6-6
Volume 8
Embedded Parts
Each regulating gate will be provided with one set of embedded parts which includes one
sill beam, two side deal and track plates, one lintel beam, embedded dogging device and
erection studs. The erection studs will be welded to welding pads embedded in first
stage concrete. The side deal and track plates, top sealing plates and exposed top
sealing plates of sill beams will be of corrosion resisting steel.
6.2.3
Guard gate is located just upstream of regulating gate and it is bonneted fixed wheel
type, consisted of gate leaf, gate frame, conduit lining, bonnet, bonnet cover, hydraulic
hoist controls and accessories. Guard gate has to provide emergency closing of water
conduit, if the regulating gate fails, under any flow conditions and supposed to operate
under head range of 140 m WC. Guard gate has clear opening of 5 m wide x 7.2 m
high.
Gate Leaf
The gate leaf will be constructed of structural steel skinplate reinforced by welding
horizontal and vertical members to resist the hydraulic load.
The guard gate will be provided with downstream skinplate and downstream rubber
sealing. Wheels will be with corrosion resistant steel rims mounted. Wheels will be
installed on self lubricating semi spherical bearings. The guard gate will be lifted under
balance head condition, created by means of by-pass valves, but will be capable of self
closing in emergency if regulating gate fails to close. Self lowering will be provided by
gravity and action of hydrodynamic force on top of the gate (downpull).
Embedded Gate Frame
The embedded frame for the gate will be of welded steel construction. The frames will be
fitted with stainless steel guides and seal bearing plates. The gate frame will be provided
with flanges on upstream and downstream ends and also at the top with bolt holes to
match the corresponding bolt holes of the upstream and downstream conduit linings and
the bonnet at the top respectively.
Conduit Steel Liner Sections
The conduit steel liner sections will be of welded steel construction with ribs placed on
the outer surface. These ribs serve to stiffen the lining against the stresses caused by
water pressure from inside the upstream conduit when the gate is closed and to sustain
external pressure of grouting. A straight section of conduit steel liner will be provided
immediately upstream of the gate leaf. The upstream straight section which belongs to
the gate, will have a minimum length of one gate width. The steel conduit linings will be
placed along with the gate frame and the bonnet before concreting of conduit is done.
Downstream portion of steel liner will extend up to regulating gate and further to the end
of the outlet cross section. Upstream and downstream steel liner portions will be so
hydraulically shaped to minimum hydraulic losses and cavitations effects in the gate
slots.
Bonnet
The bonnet will be of welded steel construction fitted with stainless steel guide bars. Just
6-7
Volume 8
like conduit lining, the bonnet will also be provided with horizontal ribs at outer surface to
take care of the stresses. The bonnet will have flanges at the top and bottom with holes
for bolts to match the corresponding holes in bonnet cover at top and gate frame at the
bottom.
Bonnet Cover
The bonnet cover will be of welded steel construction with stiffeners at outer surface. It
will be a rectangular cover with a circular top on which the hoist hydraulic cylinder will be
installed. Rubber gasket will be installed between the flanges of bonnet and bonnet
cover to prevent water leakage. The bonnet cover will be designed for the water
pressure underneath and the forces of cylinder at the top. The bonnet will be equipped
with aeration valve and by-pass valve.
Hoist and Controls
Hydraulic hoist will be installed to operate the gate. Single acting hoist cylinder will be
used for the guard gate.
Lifting of guard gate will be under balanced head condition created by means of by-pass
valves after the penstock is filled. Self lowering of the gate under emergency conditions
will be attained by providing the skinplate & sealing on downstream side and controlled
by throttling on servomotor oil discharge. Hydraulic fluid for raising the gate will be
supplied by motor driven oil pumps. Two oil pumps one active and other standby will be
provided for each gate for the sake of reliability. The hydraulic system will consist of oil
pumps, one hand operated oil pump, reservoirs, valves and etc. The hoists will be
designed to raise and lower the gates at a rate of 0.3 m per minute and 1.0 m per minute
respectively.
A hoist control module consisting of hydraulic and electrical controls will be provided with
the gate to control the operation of hoist. A local control panel will be provided near the
gate. The selector switch will provide two operating modes normal and maintenance.
During gate maintenance the selector switch will be placed in maintenance mode.
6.2.4
Service gate is located at intake of low level conduit and it is bonneted fixed wheel type
consisting of gate leaf, flap, gate frame, conduit lining, bonnet, bonnet cover, hydraulic
hoist, controls and accessories. Service gate will be used for inspection and
maintenance of downstream tunnel lining and guard & regulating gate. The gate is
supposed to operate under no flow conditions, under head range of 140 m. The gate
has clear opening of 5 m wide x 7.2 m high.
Gate Leaf
The gate leaf will be constructed of structural steel plate reinforced by welding horizontal
and vertical members to resist the hydraulic load.
The service gate will be provided with upstream skinplate and upstream rubber sealing.
Wheels will be with corrosion resistant steel rims. Wheels will be installed on self
lubricating semi spherical bearings. The service gate will exclusively work under balance
head conditions.
6-8
Volume 8
Flap
A flap will be installed below the main gate leaf in the bonnet of service gate. The flap
will be position used for maintenance of service gate by isolating it from permanent
upstream water in the reservoir. The flap will also work under balance head condition.
The flap will be opera table hydraulically. Casing of the flap will be part of bonnet.
Embedded Gate Frame
The embedded frame for the gate will be of welded steel construction. The frames will be
fitted with stainless steel guides and seal bearing plates. The gate frames will be
provided with flanges on upstream and downstream ends and also at the top with bolt
holes to match the corresponding bolt holes of the upstream and downstream conduit
linings and the bonnet at the top respectively.
Conduit Steel Liner Sections
The steel conduit liner sections which belong to the service gate will be of welded steel
construction with ribs placed on the outer surface. These ribs serve to stiffen the lining
against the inside stresses caused by water pressure in the upstream conduit when the
gate is closed and also to sustain external pressure of grouting. The upstream straight
section which belongs to the gate, will have a minimum length of one gate width and will
be made from stainless steel, while downstream section which also belongs to the gate
will have minimum length of two gate widths and will be made from ordinary carbon
steel.
The steel conduit linings will be placed first along with the gate frame and the bonnet
before concreting of bell mouth and conduit is done.
Cross sections of upstream and downstream steel liners portions will be so hydraulically
shaped to minimum hydraulic losses and cavitation effects in the gate slots.
Bonnet
The bonnet will be of welded steel construction fitted with stainless steel guide bars. Just
like conduit lining, the bonnet will also be provided with horizontal ribs at outer surface to
take care of the stresses. The bonnet will have flanges at the top and bottom with holes
for bolts to match the corresponding holes in bonnet cover at top and gate frame at the
bottom. In the gate bonnet, the provision will be made for installation of the flap casing.
Bonnet Cover
The bonnet cover will be of welded steel construction with stiffeners at outer surface. It
will be a rectangular cover with a circular top on which the hoist hydraulic cylinder will be
installed. Rubber gasket will be installed between the flanges of bonnet and bonnet
cover to prevent water leakage. The bonnet cover will be designed for the water
pressure underneath and the forces of cylinder at the top. The bonnet will be equipped
with aeration valve and by-pass valve.
Hoist and Controls
Hydraulic hoist will be installed to operate the gate. The hydraulic cylinder for service
gate will be single acting.
Lifting and lowering of the service gate will be under balance head condition after
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Volume 8
downstream penstock is filled through by-pass filling valve. Hydraulic fluid for the hoist to
raise the gate will be supplied by motor driven oil pumps. Two oil pumps one active and
other standby will be provided for each gate for the sake of reliability. The hydraulic
system will consist of electrically operated oil pumps, one hand operated oil pump,
reservoir and valves. The hoists will be designed to raise and lower the gate at a rate of
0.3 m per minute and 1.0 m per minute respectively.
the gate to control the operation of hoist. A local control panel will be provided near the
gate. The selector switch will provide two operating modes normal and maintenance.
During gate maintenance, the selector switch will be placed in maintenance mode.
Operation of the flap installed on the service gate will be manual.
Accessories:
-
The service gate will be equipped with aeration valve behind the bonnet on
downstream side to serve during filling and emptying of the tunnel.
High water pressure installation will be provided for washing out sediments from
the slots.
6.2.4
The electrically operated overhead travelling cranes will be provided, one for regulating
and guard gates in outlet structure and other for service gate gallery to handle the gate
equipment during installation and later on for maintenance purposes. The cranes will
operate on rails in the gate galleries spanning all the gates. Both the cranes will have
capacity of 100 ton each.
6.2.6
Main Parameters
Main parameters of low level outlet gate equipment are given hereunder:
Regulating Gates
Gate
Type
No. of gates
Maximum reservoir level
Elevation of radial gate sill
Elevation of trunnion centre line
Radius from trunnion centre to inside face of skinplate
No. of arms per gate
Embedded parts
Gate Hoist
Type of hoist
6-10
Submerged radial
7 sets
5.0 m
7.0 m
950 m
810 m
818.70
10.0 m
4
Welded
7 sets
Hydraulic
0.3 m per minute
1.0 m per minute
2
Volume 8
Bonneted Gates
Description
Type of gate
No of gates
Elevation of gate sill
Full reservoir level
Gate Hoist
Type of hoist
Hoist cylinder stroke
Type of cranes
No of cranes
Main hoist capacity
Auxiliary hoist capacity
Span
Length of runway
Lift
6.3
Guard Gates
Vertical lift fixed wheel
bonneted
7 sets
5.0 m
7.2 m
810 m
950 m
Welded
Service Gates
bonneted
7 sets
5.0 m
7.2 m
810 m
950 m
Welded
Hydraulic
0.30 m per min.
1.0 m per min.
1
7.2 m
Hydraulic
0.30 m per min.
1.0 m per min.
1
7.2 m
Electrically Operated
1
100 ton
25 ton
17 m
165 m
25 m
Electrically operated
1
100 ton
25 ton
5.5 m
165 m
24 m
Power Intake Gate Equipment
Power intake consists of power intake itself equipped with trashracks and cleaning
machine, and power intake shaft equipped with service and guard gates. Discharge
through one intake tunnel is 325 cumecs and through all eight tunnels is 2600 cumecs.
6.3.2
The equipment at power intake will be designed to meet the following functional
requirements:
i.
Two gates will be installed in power intake shaft, one in front (downstream side)
as a service gate and another behind (upstream side) as a guard gate.
ii.
The guard gates will be capable to close under full flow in the tunnels in an
emergency, if the penstocks fail or turbines overspeed.
iii.
The guard gates will be designed to self lower under gravity and hydrodynamic
forces (downpull).
iv.
The guard gates hoisting system will be operable from local control panels as well
as from power intake control room.
v.
The service gates will be provided for inspection and maintenance of guard gates
and tunnels.
vi.
The service gates will be designed to operate under balanced head condition (no
flow conditions).
6-11
vii.
Volume 8
Trashracks will be installed at power intake structure to prevent entry of large size
trash into the tunnels and clogg the turbines.
A gantry crane operating on a runway spanning the entire structure will be provided for
maintenance of the guard gates and handling of the service gates.
One hydraulically operated guard gate is installed in each shaft and two sets of service
gates are envisaged for all the eight shafts.
The guard gates of clear opening 6.0 m wide x 8.5 m high, will be used for emergency
protection of turbines and penstocks (and will over take the role of turbine shut-off valve).
The service gates of clear opening equivalent to that of guard gates will be vertical lift
type, designed for operation under balanced head condition.
Trashrack on each power intake will consist of three vertical sections divided by vertical
concrete piers, and each section will comprise of three panels divided by horizontal
concrete beams. Clear opening of trashrack is 26 m wide x 20 m height. Trashrack is
inclined at 50% with horizontal. A trashrack cleaning machine will operate on the deck of
intake structure and will clean the trashracks of all the eight intakes.
The general arrangement of the power intake gate equipment is shown in Fig. 6.5.
6.3.2
Guard Gates
The guard gate will be of welded steel construction with downstream skinplate reinforced
by horizontal and vertical members/girders. The skinplate assembly will be divided into
two sections for ease of transportation and handling at the site. These sections will be
field assembled by bolting and seal welding.
The gate will be provided with downstream J-type double stem side and top rubber seals
with fluoro carbon cladding. A flat bar type rubber seal will be mounted at the bottom of
the skinplate on downstream side. Wheels will be with corrosion resisting steel rim
mounted. Wheels will rotate on stainless steel spherical bearings (or self lubricated
bearings).
Hoists and Controls
Hydraulic hoists will be installed for the operation of guard gates. Each gate hoist will
include one hydraulic cylinder, hoist support, piping, gate position indicator, and
appurtenances.
The hoist cylinder will be mounted on the deck and will be designed to have enough
lifting capacity to lift the gate and operating rods under any foreseeable operating
condition. Normal lifting of the gate will be under balanced head condition after the
penstock is filled through by-pass filling valves dia 350 mm. Hydraulic fluid for raising the
gate will be supplied by motor driven oil pumps. Two oil pumps one active and other
standby will be provided for the sake of reliability. The hydraulic system will supply oil to
all the cylinders and will consist of oil pumps, reservoir, valves etc. The hoist will be
designed to raise and lower the gate at a rate of 0.3 m per minute and 1.0 m per minute
respectively. Emergency lowering of the gate at 3 m per minute will be accomplished by
gravity and hydrodynamic force (downpull) with oil below the hoist piston exhausting
under controlled flow rate to the oil reservoir.
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Volume 8
each gate to control the operation of the hoist. A local control panel will be provided near
each gate and a common remote control panel for all the guard gates will be installed in
the control room at intake. The remote control panel will include one selector switch for
each gate. The selector switch will provide two operating modes: normal and
maintenance. The selector switch will be locked in normal mode under which mode the
gate in full open position will be interlocked with the turbine governing system. Local or
manual operation of the gate will not be possible under this mode. During gate
maintenance, the selector switch will be placed in maintenance mode, which will permit
manual operation of the gate from the local control panel.
Provision will also be made for emergency closure of the guard gate from the
powerhouse central control room for the protection of turbine against sustained over
speed if the governor malfunctions.
Embedded Parts
Embedded parts for the guard gate will include anchorages for hoist cylinder, side and
top seal bearing plates and guide bars, rails and sill beams. The side and top sealing
surfaces will consist of corrosion resisting steel plates embedded in concrete. The
bottom sealing surface will also be corrosion resisting steel plate attached to a structural
steel sill beam embedded in the concrete floor. The embedded parts will be installed in
blockouts and adjusted by means of erection studs attached to the welding pads
embedded in first stage concrete.
Aeration pipe of 2 m diameter will be installed behind (downstream side) the guard gate
to provide aeration of tunnel in normal and emergency operation of the guard gate.
6.3.3
Service Gates
Two sets of service gates will be provided for all eight intake shafts. Guides, sealing
frames and other embedded parts will be installed upstream of each guard gate for
closure of the intake by a service gate. The service gate will be of welded steel
construction having J-type double stem side and top rubber seals and flat bar type
bottom rubber seal installed on upstream side. The gate will have upstream skinplate
and sealing and will be lowered or raised under balanced head condition with the help of
gantry crane. Stainless steel rim mounted wheels will be installed on either side of each
gate, A 300 mm dia. Penstock-filling valve will be provided in the service gate for
achieving the balanced head condition.
Embedded Parts
Embedded parts for service gate will consist of two side seal bearing and guide plates,
top seal bearing plates and sill beams. Side and top seal bearing plates and guides and
exposed top plate of sill beam will be of corrosion resisting steel. The embedded parts
will be installed in the blockouts and adjusted by means of erection studs attached to
welding pads embedded in the first stage concrete.
6.3.4
Power Intake Shaft
Each power intake shaft in which the gates are installed is of 8 m diameter and is
provided with service chamber in the upper part, steps and ladders through the shaft and
an aeration pipe of dia 2000 mm on downstream side. Erection chamber will be
equipped with accessories and storage for dismantled stems and intended for reparation
and maintenance of the gates.
6-13
6.3.6
Volume 8
Trashracks
Trashrack on each power intake covers clear opening of 26 m wide x 20 m high.

Trahrack is consisted of three vertical sections divided by vertical concrete piers, each
section covers clear opening of 7 m wide x 20 m high. One section consists of three
dismantleable panels supported on horizontal concrete beams. Each panel has
dimension 7 m wide x 6.67 m high. Panels consist of vertical flat bars with cross section
25 mm x 250 mm and with 180 mm clear spacing between the bars which protects
turbine from clogging. Trashrack will be designed for 6 m wide differential pressure. At
each 1750 mm length, the trashrack bars will be laterally supported against the
vibrations. Trashracks will be completely dismantleable and bolted connections will be
with stainless steel bolts and carbon steel nuts. Trashrack bars will be hot dipped zinc
galvanised and then painted with epoxy paint as abrasive protection against cleaning
teeth of rake of trashrack cleaning machine. Trahsracks will be equipped with differential
pressure gauge for detection of trashrack clogging. Approaching water velocity to
trashrack will be 0.63 m/sec.
Embedded Parts
Embedded parts for trashracks will consist of steel frame embedded in concrete. The
frame will be installed in blockout and adjusted by means of erection studs attached to
the welding pads embedded in the first stage concrete.
6.3.6
Trashrack cleaning machine will be installed on power intake deck and will cover all
intakes for cleaning operations. Trashrack cleaning machine will consist of welded steel
construction carriage, cabin, rake and trash container. The machine will operate
automatically and manually. Automatic operation will be carried on through automatic
timer and on signal from pressure detectors installed on trashracks. Manual control will
be directly from cabin. Information about automatic operation on trashrack will be
transferred to the powerhouse control room. Width of rake will be 3500 mm and teeth
will be made from plastic and will be removable. Trash container of volume 8 cu.m will
be of standard type and will be suspended on the carriage, so that trash will be collected
during automatic operation of cleaning machine. When trash container is full, it will be
taken out for disposal and empty one will be suspended on the carriage.
6.3.7
Gantry Crane
One gantry crane of 150 tons capacity will be provided at the power intake. The crane
will be an electrically operated outdoor type, with an operators cab located on the
upstream side and raised above the deck for ensuring good visibility of all crane
operations. The gantry crane will operate on rails extending over the full length of the
intake deck. The crane will be required to handle the service gates and for reparation
and maintenance activities within the intake shafts.
6.3.8
Main Parameters
The main parameters of power intake gate equipment are given hereunder:
6-14
Volume 8
Guard Gate
Type of gate
No. of gates (one set per tunnel)
Elevation of gate sill
Full reservoir level
Embedded parts

8 sets
6.00 m
8.50 m
875 m
950 m
Welded
8 sets
Gate Hoist
Type of hoist
Normal rate of gate opening
Normal rate of gate closing
Emergency rate of gate closing
Hoist cylinder stroke
Hydraulic
0.3 m per minute
1.0 m per minute
3.0 m per minute
1
8.50 m
Service Gates
Type
Sill elevation
No. of sets of service gates
No. of sets of operating rods
Handling
No. of embedded parts
Vertical-lift fixed wheel

875 m
6.00 m
8.50 m
2
2
By gantry crane
8 sets
Trashracks
Type
Plane dismantleable,
consisted of sections and
panels
875 m
3
7.0 wide x 20 m high
24 sets
180 mm
0.63 m/s
Sill elevation
No. of sections per tunnel
Nominal size per section of trashracks
Embedded parts
Clear space between bars
Approaching water velocity
Width of rake
Rake ascending speed
Rake lowering speed
Cleaning machine travel speed
Travelling rails span
Rail length between stoppers
3.50 m
15 m/min (max.) stepless
30 m / min (max.) stepless
10 m / min (max.) stepless
3.3 m
225 m
6-15
Volume 8
Gantry Crane
Type
outdoor
1
150 t
25 t
225 m
24 m
9.50 m
No. of gantry cranes

Main hoist capacity
Auxiliary hoist capacity
Length of runway
Lift
Span
6.4
6.4.1
For installation, maintenance, inspection and repair of turbines, it is necessary to

dewater the turbines and their related waterways. Draft tube gates are required to act as
bulkheads for preventing entry of surge chamber water into the waterways when the
turbines and their waterways are emptied for maintenance and inspection. Draft tube
gates will work under balanced head conditions.
The draft tube gates will be vertical lift bulkhead type designed for operation under
balanced head conditions created through filling valves installed on the gates.
Two sets of draft tube gates will be provided to close two draft tubes. One set will consist
of five sections.
Draft tube gate equipment will consist of bulkhead gates, lifting beam and overhead
travelling crane. The draft tube gates will be installed at the end of draft tubes discharges
of the powerhouse in the surge chamber.
The draft tube discharge tunnel of each turbine will have opening size 8.15 m wide x
12.5 m high at the location of the draft tube gates in the surge chamber.
Each of these openings will be closed by one set of draft tube gates.
The general arrangement of the draft tube gate equipment is shown in Fig. 6.4.
6.4.2
Draft Tube Gates
Gate Leaf
The draft tube gates will have upstream side seals and downstream bottom sealing.
Skinplate will be on downstream side. This concept of sealing and skinplate position is
to prevent any uplift effect during surge tunk operation. Each section will be of welded
steel construction. The top section will have wedge type bottom seal and caisson type
side and top seals with fluorocarbon cladding while the lower sections will have sealing
plate at the top on which the upper section will be seated to seal the water passage.
Guide shoes will be provided at the top and bottom of each side of the gate sections to
engage the guides embedded in the concrete. For alignment of draft tube gate sections,
guide pins will be installed on the top of lower sections and guide sleeves in the bottom
of upper sections. Lifting pins will be provided to handle the gate sections by a lifting
beam. Filling valve dia 300 mm will be installed on the second section of the draft tube
gates from bottom. The filling valve will be operated by lifting beam.
6-16
Volume 8
Embedded Parts
A set of embedded parts will consist of a sill beam, a lintel beam, two side seal bearing
plates, two guide rails for installation of draft tube gates along with two guide rails and
bottom supports for storage of draft tube gate sections. Welding pads will be embedded
in first stage concrete to facilitate the alignment of the parts embedded in the second
stage concrete. The sill and lintel beams will provide sealing surfaces for bottom and top
sections of the gates respectively. All sealing surfaces will be of corrosion resisting steel.
6.4.3
One electrically operated 30 ton capacity overhead travelling crane will be provided for
handling the draft tube gates and inlet stoplogs of tailrace tunnels with the help of lifting
beams. The lifting beams will operate in the slots and guide rails provided for the draft
tube gates and inlet stoplogs for tailrace tunnels. The crane will operate over the rails
spanning all the draft tubes of the powerhouse.
6.4.4
Main Parameters
The main parameters of draft tube gate equipment are given hereunder:
Draft Tube Gates
Type
No. of gates
No. of sections per set
Deck elevation
Sill elevation
Maximum surge level
Gate handling
Vertical-lift bulkhead
2 sets
8.15 m
12.5 m
5
781.5 m
725 m
780 m
By lifting beam and overhead
travelling crane
8 sets
Embedded parts
Type
No. of cranes
Main hoist capacity
Aux. hoist capacity
Length of runway
Lift
Span
1
30 t
7.5 t
258 m
62 m
20 m
Lifting Beam
1
Welded
6-17
6.5
Tailrace Tunnels Gate Equipment
6.5.1
Volume 8
Four tailrace tunnels each 10 m wide and 12.50 m high D-shaped will be required at
downstream of the surge chamber. One tailrace tunnel will handle discharge from two
units. The inlet of each tailrace tunnel will have opening of size 10 m wide x 12.5 m high
each. The outlet of each tailrace tunnel will be divided into two openings of size 5 m wide
x 12.5 m high each. Both openings will be closed with stoplogs. Stoplogs at inlet will be
handled by lifting beam and overhead travelling crane in the surge chamber while the
stoplogs at outlet will be installed with the help of lifting beam and mobile crane.
The stoplogs for tailrace tunnels will be vertical lift type designed for operation under
balanced head condition.
Three sets of stoplogs (one for inlet and two for outlet) will be provided to close one
tailrace tunnel. One set of stoplogs at inlet will be divided into 6 sections while one set of
stoplogs at outlet will comprise of 5 sections to facilitate handling. For complete emptying
surge chamber 8 sets of stoplogs will be required to close outlet of all tailrace tunnel.
Powerhouse will be closed by closing power intake gates.
The general arrangement of gate equipment of tailrace tunnels is shown in Fig. 6.6 and
6.7.
6.5.2
Stoplogs
Leaf Assembly
The stoplogs will be of welded steel construction. The stoplogs at inlet will have
downstream skinplate and downstream seals where as the stoplogs at outlet will have
upstream skinplate and upstream seals to stop water entry from upstream and
downstream sides respectively. The stoplogs sections at inlet will have double stem Jtype rubber seals while stoplogs at outlet will have J-type single stem side rubber seals.
All stoplogs will have wedge type bottom rubber seals. The top sections of inlet stoplogs
will have double stem J-type single stem rubber top seals where as the top sections of
outlet stoplogs will be equipped with J-type rubber top seals. Guide shoes will also be
provided on either side of each section to facilitate lowering of stoplogs. For alignment of
stoplog sections, guide pins will be installed on top of lower sections and guide sleeves
in the bottom of upper sections. Second sections from bottom of inlet & outlet stoplogs
sets will be equipped with 350 mm dia. filling valves which will be operated with lifting
beams through stem rods.
Embedded Parts
A set of embedded parts will consist of a sill beam, a lintel beam, two side seal bearing
plates and two guide rails for installation of stoplogs. Three sets of embedded parts (one
for inlet and two for outlet) will be required for each tailrace tunnel. Welding pads will be
embedded in first stage concrete to facilitate the alignment of parts to be embedded in
second stage concrete. The sill and lintel beams will provide sealing surfaces for bottom
and top seals of the stoplogs. All sealing surfaces will be of corrosion resisting steel
plates.
6.5.3
The stoplogs sections at inlet will be handled by overhead traveling crane and lifting
6-18
Volume 8
beam where as the stoplog sections at outlet will be handled with the help of 100 ton
mobile crane and lifting beam. The lifting beams will be of welded steel construction
equipped with two semi-automatic engaging and disengaging hooks. The lifting beams
will operate in the slots and guide rails provided for stoplogs. The overhead traveling
crane used to handle draft tubes gates will also handle the tailrace inlet stoplogs in the
surge chamber.
6.5.4
Main Parameters
The main parameters of tailrace tunnels gate equipment are given hereunder:
Stoplogs
Description
Inlet
Outlet
Type
Opening size( w x h )
Vertical lift
10 m x 12.5 m

Elevation of top of stoplogs in closed
position
725 m
737.9
Vertical lift
5 m x 12.5 m
(2 Nos)
744 m
756.9
Max. surge level in surge chamber

Downstream water level at outlet
structure
780 m
755 m
No. of stoplogs sets required

Sections per set
Embedded parts
1
6
4 sets
8
5
8 sets
1
Welded
1
Welded
Lifting Beams
6.6
Diversion Tunnels Gate Equipment
6.6.1
Two (2) diversion tunnels have been proposed to divert the river flows during
construction phase. The inlet of each diversion tunnel is divided into two openings of 6.0
m wide x 20.0 m high each. Four sets of stoplogs will be required for plugging the inlets
of these tunnels. Each set will have ten sections. The stoplogs sections will be handled
with the help of mobile crane and lifting beam.
The general arrangement of gate equipment for diversion tunnels is shown in Figure 6.8.
6.6.2
Stoplogs
The stoplogs at inlet will be of welded steel construction having downstream skinplates
and seals. All the stoplog sections will have downstream skinplates and J-type rubber
side seals and wedge type rubber bottom seals. The top sections will be equipped with
downstream rubber top seals of same type as side seals. Guide shoes will also be
provided on either side of each section for ease of installation.
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Embedded Parts
Four sets of embedded parts will be required at inlet of the diversion tunnels for installing
stoplogs. A set of embedded parts will consist of a sill beam, a lintel beam, two side seal
bearing plates and two guide rails. Welding pads will be embedded in first stage concrete
to facilitate the alignment of parts to be embedded in second stage concrete. The sill and
lintel beams will provide sealing surfaces for bottom and top seals of the stoplogs. All
sealing surfaces will be of corrosion resisting steel plates.
6.6.3
Lifting Beam
The lifting beam will be of welded steel construction equipment with two semi-automatic
engaging and disengaging hooks. The hooks will be mounted on corrosion resisting steel
pins and self lubricating bushes.
6.6.4
Main Parameters
Main features of diversion tunnels gate equipment are given hereunder:

Stoplogs
Type
Opening size
Max. water level till the tunnel inlet is
plugged
Elevation of top of stoplogs in closed
position
No. of sets
Sections per set
Embedded parts
Vertical lift
6.0 m wide x 20.0 m high
768 m
850 m
788.4 m
4
10
4 sets
Lifting Beam
1
Welded
6-20
7.
7.1
Volume 8
Functional Overview
The SCADA and Telecommunication system shall comprise three sub-systems:

-
An In-plant Instrumentation and Control system allowing monitoring and control of

the Dasu power plant (referred hereafter as the station) including generators, all
auxiliaries, the associated switchgear, and 765 kV switchyard.
An interface to the existing NTDC SCADA system at the National Power Control
Center (NPCC) Islamabad enabling system dispatchers partial control of the
Dasu Power Plant from Islamabad.
A Telecommunication system for the distribution of voice and data within the
Dasu Power Plant and for exchange of voice and data with NPCC Islamabad.
7.2
Station Instrumentation and Control (I&C) System
An in-plant I&C system shall be deployed for the monitoring and control of the power
house and auxiliary systems, including:
-
Control of generators including output power and ALFC.
The monitoring of rotor vibration and air gap for generators.
The monitoring and limited control of spillway gates, power intakes flows and
water levels, and their auxiliaries.
The operation of 765 kV Circuit Breakers (in association with NPCC).
The plant instrumentation and control functions can be performed by either a hierarchical
SCADA or a distributed control system (DCS). In view of the modularity and superior
fault tolerance capabilities of the DCS the latter is proposed for the in-plant or station I&C
system. This DCS shall comprise smart transducers and instruments installed across the
plant. The controllers, transducers and associated field devices shall communicate over
a plant wide LAN. Internet Protocol (IP) and other open standard protocols shall be
deployed with built in diagnostics to monitor device health and predict problems thereby
avoiding downtime. Field transducers shall communicative with the controllers over
industry standard protocols. The station operational staff shall be provided with a
Human machine interface (HMI) set up in the station control room for control and routine
operation of the power plant.
7.3
Interface with Existing NTDC SCADA System
Selective key parameters of the Dasu power complex shall be remotely monitored by
NPCC and key functions will be remotely controlled from the National Power Control
Centre (NPCC), Islamabad in line with NTDCs standard operational practices. The
generation of power and 765kV transmission system at Dasu will be managed by NPCC
and the DCS in control room of Powerhouse will be responsible for station control and
instrumentation requirements.
NPCC will be responsible for the overall generation and transmission management
associated with the Project, while the station DCS will be responsible for the overall
station control and instrumentation requirements as well as interfacing with NPCC
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through appropriate hardware.

All the important plant parameters like active and reactive power of generators, and
transmission lines, station frequency, busbar voltage, reactors disconnect switches and
faults alarms will be monitored remotely.
The plant DCS shall monitor and display position of circuit breakers, isolators, all
local/remote switches for generators and circuit breakers and indication of Automatic
Load Frequency Control (ALFC) etc.
7.3.1
SCADA Facilities for Tele-Control by NPCC.
To enable NPCC to control selective key parameters of the Dasu power plant, the
following two alternative methods have been considered:
7.3.1.1 Alternative 1
This alternative is an extension of the existing hierarchical SCADA system based on
front end computers deployed at NPCC Islamabad. It deploys conventional Remote
Terminal Units (RTUs) serving the NPCC SCADA System and is independent of the
station DCS at Dasu.
The SCADA requirements will be handled by two separate RTUs, one for monitoring and
control of the Powerhouse and one for monitoring and control of 765 kV GIS.
Inter RTU communication shall be provided, if required. The RTU in the powerhouse will
be configured in the most effective manner, for example:
-
as a separate RTU, or
as a distributed input/output module from the GIS RTU, or
as a slave unit scanned by the GIS RTU.
The RTU equipment will be capable to cater for future requirements of Powerhouse and
switchyard augmentation.
The details of Tele-information plan is given in Table 7.1
For the measurements of MW, MVAr, kV and frequency etc., separate transducers will
be provided in the SCADA Interface.
Advantages
Since the RTUs would be obtaining their own information from the field mounted sensors
and transducers a breakdown in the station DCS would not hamper the flow of
information from the field.
7.3.1.2 Alternative 2
This alternative comprises hardware establishing an inter-computer data communication
link bridging the station DCS with front end computers hosting the NPCC SCADA
applications. A redundant gateway controller/inter-center communication controller, for
data inter-change between the station DCS and the SCADA master system at NPCC
Islamabad will be installed in the station control room for monitoring and control of the
station equipment under SCADA. Dual processors configured as online and hot standby
with duplicated database and operating system will be employed in the gateway
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controller. The gateway will interface with DCS equipment through dual redundant
communications infrastructure. Gateway or Inter-center communication controller
fulfilling all aspects of the communications between NPCC and Dasu Control Room.
In this alternative no information shall be collected afresh by NPCC rather a subset of
information already collected by the station DCS for station control shall be passed on
through the Communications Gateway to NPCC. This would save duplication of
transducers for data collection, thereby precluding additional interfacing. For reliability,
both path and media redundancy shall be deployed for data communication between the
station DCS and NPCC utilizing PLC, optical fiber or alternate telecommunication
means.
The amount and type of information exchanged between the station DCS and NPCC
shall be a software configurable parameter of the gateway controller. The authorization
of 765 kV circuit breakers control will be from the NPCC and the station DCS will only
monitor the status of circuit breakers. However, this authorization can be set to local
control during emergencies or maintenance. The authorization of each 765 kV circuit
breaker control will be set individually from the DCS operator console. The selectable
authorization levels shall be SCADA, DCS, or local. Similarly, the assignment of ALFC
authorization of each generator will also be done from DCS.
Local/Remote Switches
Three position (i.e. SCADA/DCS/Local) switches will be provided in the local control
panels of 765 kV switchgear equipment and the generator/governor local control panels
(LCP) for the 20 kV circuit breakers and generating units respectively.
SCADA Control Philosophy
Normally the operation of 765 kV circuit breakers will be from NPCC and the switchyard
DCS will only be monitoring their status. However, during emergencies or maintenance,
the control authorization of circuit breakers will be set on local control (either station DCS
or local control panel). The authorization of each 765 kV circuit breaker control shall be
set from the individual three position local/remote switch (SCADA/DCS/Local).
The assignment of each generator set point control or ALFC authorization to
SCADA/DCS/Local will also be done from the respective generator local/remote switch.
ALFC control from NPCC will be either in the form of a set point value or
increase/decrease command to the units governor. Operation of the plant local/remote
switches will be authorized from NPCC.
RTU communication with NPCC Front End Computers will be through duplicated data
channels along the PLC/fiber optic links.
7.4
Telecommunication System
Dual play data transmission media for transmission of speech, facsimile, data (including
energy metering) shall be set up between NPCC and Dasu Powerhouse. Teleprotection
channels, provision of telecom equipment for power interface with existing NTDC
operational telephone network for operational traffic between Dasu and NPCC/existing
stations, along with the facilities to meet the administrative traffic for the Power Complex
and Colony shall also be set up as part of the Telecommunication system.
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7.4.1
Volume 8
Optical and Conventional Telecommunication Media
Speech, data and teleprotection channels shall be carried over fiber optic cables and
augmented by conventional PLC links on the 765 kV overhead power transmission line.
The communication of speech and data from Powerhouse to nearest major NTDC
telecom node i.e. the Diamer Basha Hydro Power Project (DBHPP) will be via
OPGW/PLC. From here onward transmission to NPCC shall be over a combination of
optical fiber and wireless (microwave) media. Since the NTDC telecom network is
constantly undergoing augmentation by the addition of new and enhancement of
telecommunication infrastructure working out details of signal transmission south of
DBHPP is premature at this point in time and shall be done at the time of the detailed
design keeping in view the exact availability of exiting media and infrastructure at that
point in time.
For optical fiber link, OPGW on 765 kV transmission line will be employed. New Optical
fiber terminal equipment based on SDH SSTM-1 technology will be provided. The optical
fiber terminal equipment will be modular in structure. The OPGW/terminal equipment will
be designed to provide high performance/availability in service.
7.4.2
PAX/PABX Equipment
Administrative speech and data traffic will primarily be routed via public switched
telephone network connected with different locations of the Power Complex via Private
Automatic Branch Exchange (PABX). Independent PABXs will be provided for the
powerhouse and residential colony. The PABXs will be interconnected with each other.
The powerhouse PABX will be provided with local area network (LAN) for administrative
and maintenance traffic.
The PABX will be equipped with latest features available in modern telephony. It will be
modular in structure to allow future expansions. Due to the remote location of the
Project, the channels from the public network will be interfaced with the nearest suitable
point of presence (POP) of the public switched telephone network.
For operational speech and data traffic, Private Automatic Exchange (PAX) for
interconnection with WAPDA network will be utilized. The PAX will be capable of fully
integrating with the existing network comprising DCX-5, DCX-600, ECS-F/FX and AKNR
exchanges. The PAX to be installed at Powerhouse will be based on standard 4-digit
numbering scheme with features for priority intrusion and forced release available to the
NPCC operators and important subscribers over the network. Remote subscribers of the
PAX system will be provided at important locations i.e. CCR, spillway and senior officials.
The routing plan for the PAX system will incorporate a main route, with the minimum
number of intermediate nodes and at least one alternative route. Dual data channels
along separate routes from all sites shall preferably be employed along with duplicated
speech channels between the main sites.
7.4.3
Teleprotection
For 765kV transmission lines emanating from the Powerhouse, duplicated teleprotection
channels will be provided for high speed direct tripping (for breaker failure and reactor
protection) and permissive tripping (for distance protection) of lines along with blocking of
tripping. In order to achieve maximum security and redundancy, the direct tripping
signaling will utilize different equipment to that used for permissive/blocking schemes.
The teleprotection signals will not interfere with the speech signals. The equipment for
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teleprotection will have the flexibility for transmission over any communication medium
i.e. PLC or OPGW.
7.4.4
Public Address System
For announcement and instructions to the staff in the Powerhouse area, a Public
Address system shall be provided which consist of a central power amplifying unit/ and a
number of microphones and loudspeakers.
Control consoles with microphones will be provided in the CCR and in each local control
area. The complete system will be modular in structure. The system will be capable of
selecting a single loudspeaker or a group of speakers.
7.5
Un-Interruptible Power Supplies (UPS)
A 48 V DC UPS system will be provided for SCADA & telecom equipment to remain
functional and operative at all times. The UPS will supply the loads for PLC, Fiber Optic
Terminal, RTU, Teleprotection, PABX, PAX and public address equipment. The UPS
system will be fully redundant and will comprise duplicated battery chargers, battery
banks and DC distributed boards to supply the loads.
7.6
Time Synchronization
For tagging of events satellite based Global Positioning System (GPS) with accurate
time synchronization, will be utilized with time receivers at Powerhouse and NPCC.
These receivers will communicate with Powerhouse and NPCC master clock system.
7.7
Cost estimate
The estimated cost for SCADA system is US$ 5.02 million. Details are given in section -8
of this Volume.
7-5
8.
8.1
Volume 8
COST ESTIMATES
Basis of Cost Estimate
Price estimates used for E&M equipment including transmission lines and substations
come from a variety of sources. Pricing from contract agreements for relevant WAPDA
projects in Pakistan and budgetary quotations from suppliers, as requested by the
Consultants, including their in-house data and experience make up the basis for the
estimates as detailed below. Selection of a specific source to utilize in the cost estimates
is based on the relative value of the equipment and its importance in the overall pricing
scheme. The sources of unit prices include the following.
-
Budgetary price quotations for proposed equipment from world wide suppliers
including M/s Hyundai, M/s VA TECH (2008)
In-house price information;
Tarbela Units 11-14 Project E&M equipment prices (1987-90)
Ghazi Barotha Project E&M equipment prices (1998-99)
500 kV Tarbela-Gatti in & out arrangement at Barotha (Contract No 2017-3)
Dadu-Khuzdar Transmission system contract.
Contract prices -Gakkhar 500 KV Substation Contract no: 2017-21 (2005)
Contract prices - Neelum Jehlum Project E&M equipment (2007-08)
8.2
Analysis of Adopted Unit Prices
Where price quotations could not be obtained from suppliers, the prices have been
adopted from existing Contract Agreements of WAPDA projects. These prices have been
adjusted first according to the relative capacities or the equipment, and then further
refined according to escalation over the time period. The limitation of this estimating
method is that there is no consideration for changes in technology.
Price quotes from suppliers must be considered carefully, as these often represent only
ex-factory pricing rather than delivered and installed. Delivery includes a wide variety of
expenses that must be included as burdens to the quoted pricing. Those various
expenses include marine and overland transport costs, insurance for transport, customs
duties and associated overhead costs, expenses to client for quality assurance of the
product before leaving the factory, and engineering review costs for submittals. Hence
multipliers are used to adjust ex-factory and FOB pricing to be representative of actual
final cost estimates.
8.3
Turbines, Auxiliary Equipment and Associated Mechanical Equipment
8.3.1
Turbines and Auxiliary Equipment
The cost estimate for the turbines and auxiliary equipment includes the cost of turbines,
governing systems, spiral case, draft tubes and other auxiliaries and is based on GhaziBarotha project contracts, current market and the experience of the Consultants of
similar units. The calculated prices have been checked with the prices of hydro projects
in Pakistan on prorate basis.
8.3.2
Powerhouse Mechanical Equipment
Powerhouse Mechanical Equipment is mainly comprised of Overhead Main Cranes,

Service Cranes, Dewatering Pump System, Station Drainage System, Cooling Water
System, HVAC System, Fire Protection System, Oil Storage and Handling System,
Emergency Wicket Gate Closure system and Elevators. Prices for these systems have
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Volume 8
been worked out on the basis of adaptation of prices from previous contracts.
8.3.3
Estimated Cost
The estimated cost including FOB price, transportation, erection, testing &
commissioning expenses for turbines, auxiliary equipments and associated mechanical
equipments comes to US$ 338 Million as given in Table 8.2.
8.4
Generators, Exciters, Powerhouse Auxiliary and Electrical Equipment
Cost estimate for generator, exciters, Powerhouse auxiliary and electrical

equipment(generator circuit breaker, isolated-phase bus, gas insulated bus, all as
described under paragraph Interconnection Equipment and other smaller equipment
such as 400 volt switchboards, 11 kV switchboards, auxiliary transformers, diesel
generators, wire and cable, erection, testing, and commissioning etc.) has been adopted
from similar pieces of equipment from previous contracts of Ghazi-Barotha and Neelum
Jhelum projects by adding appropriate escalation rates.
Interconnection equipment includes the 20 kV isolated-phase bus (IPB) between
generators and transformers and bus taps to various equipment, the 20 kV generator
circuit breakers, surge arresters and instrument transformers. The cost of these items is
based on Neelum Jehlum project contract prices on prorate basis by adding annual
escalation at 3.5%.
The cost of these electrical works of powerhouse comes to US$ 552 Million as given in
Table 8.3.
8.5
Power Transmission Facilities
8.5.1
Substation - General
Dasu power house is an underground installation. High voltage equipment for the Project
has been optimized at 765 kV. Owing to geological conditions the maximum cavern
width has been kept as 26 meters and this width of power house cavern cannot
accommodate generator transformers. Further three (3) 765kV circuits of Basha- Gujar
Khan Transmission lines are to made in and out at Dasu 765 kV substation to reduce the
overall transmission costs. On account of space constraints, only possible way to fit
substation equipment into the project site is using gas insulated substation (GIS)
equipment. To minimize system losses and the quantity of long high voltage isolated
phase buses (IPBs), the generator transformers and powerhouse 765 kV Gas insulated
Substation (GIS) are located underground and are close coupled. Interconnection
between underground equipment and risers to the surface are planned using Gas
Insulated Bus (GIB) and Gas Insulated Lines (GIL) respectively. Dasu Underground
Substation will be connected to Dasu surface substation through three (3) 765 KV
circuits, where in and out arrangement of three (3) Basha- Gujar Khan Circuits will also
be made. The Dasu power dispersal scheme will have following four (4) substations:
1)
2)
3)
4)
Dasu 765 kV underground substation (GIS)

Dasu 765 kV surface substation (AIS)
Gujar Khan 765/500 kV surface substation (AIS)
Gatti 765/220 kV surface substation (AIS)
Pricing details of the four Substations are given below.
8-2
8.5.2
Volume 8
Dasu 765 KV Underground Substation (GIS)
For generator transformers, there are several different comparisons that can be used to
cross check price estimates. Budgetary price for 3x190 MVA transformer banks at 765
kV was received at US $ 10.615 million from Hyundai in 2008. Tarbela units 11-14
utilized Generator Transformer of 480 MVA (3x160 MVA) at 500 kV, contracted in 1987
for US$ 2.615 million. Escalating the price at 3.5% per annum makes it US$ 5.4 million in
2008. Multiplying by MVA capacity ratio (3*190/3*160) and voltage ratio (765/500) the
cost works out to US$ 9.79 million.
Budgetary prices for 3x160 MVA transformer banks at 500 kV received in November
2002, which was US$ 3.9 million. Escalating at 3.5% per annum and multiply by capacity
and voltage ratios, the cost works out to US$ 9.1 million.
In October 2003, prices were received from ABB for 450 MVA banks using 765 kV in the
amount of Euros 1.7 million per single phase unit or Euros 5.1 million for the bank.
Escalating at 3.5% per annum and multiplying by capacity and voltage ratios, the price
works out to Euros 7.69 million (~US$ 11.92 million based on exchange rates Euro=
1.55 US$).
Owing to high escalation particularly in steel, copper, oils and difficulties that are
expected to be encountered with inland transportation of transformers and possible
requirement for additional field assembly and testing, this price has been taken as US$
10.615 million according to the budgetary price of M/s Hyundai.
The cost estimate for generator transformers, gas insulated switchgear(GIS) bays and
gas insulated buses(GIBs) is based on budgetary price of M/s Hyundai, while cost of 765
KV circuit breakers, general equipment, protection systems etc is based on contract
prices of 500 kV Gakkhar substation adjusted for escalation and equipment rating.
The cost for Dasu underground 765 kV Substation inclusive of generator transformers
has been estimated to US$ 378 million as in Table 8.4.1.
Cost of civil works is included but the cost of land is not included in this estimate. The
cost of land is included in Volume 11 of the feasibility report.
8.5.3
Dasu 765 kV Surface Substation (AIS)
Dasu surface substation is proposed for (1) making in-out arrangement of three 765 KV
BashaGujar Khan circuits (2) inter connection of Dasu underground and surface
substations through three 765 KV circuits (3) Two 765 kV circuits for interconnection
between Dasu & Gujar Khan (4) plus one bay for 765/132 kV transformer for supply of
electricity to local areas.
The cost of shunt reactor equipments is based on budgetary prices received from M/S
Hyundai & M/S VA Tech , while prices for the remaining equipments of this surface
substation are based on contract prices of 500 kV Gakkhar Substation.
The estimated cost for this surface substation works including civil works and cost of
land comes to US$ 175 million as shown in Table 8.4.2.
8.5.4
Gujar Khan 765/500 kV Surface Substation.(AIS)
This Substation will be an extension to the 765 kV Substation presumed to exist for
power dispersal of Basha power plant. The extension will accommodate two 765 kV
Dasu-Gujar Khan lines, two 765 kV Gujar Khan-Gatti lines and one 1500 MVA 765/500
8-3
Volume 8
kV transformer.
The cost of transformers and shunt reactors is based on budgetary prices of M/s VA
Tech. This cost was compared with the adjusted price level of 2008 from the previous
contracts. The cost for the remaining equipment is based on adjusted contract price of
500 kV Gakkar Substation. The estimated cost of this Substation, including civil works
and cost of land, amounts to US$ 111 Million as shown in Table 8.4.3.
8.5.5
Gatti 765 kV Surface Substation (AIS)
This Substation is proposed for interconnection between Gujar Khan and Gatti through
two 765 kV transmission lines, installation of three 765/220 kV, 1200 (3 x 400) MVA
transformers and interconnection at 220 kV with the existing 220 kV Gatti Substation.
The cost for transformers and shunt reactors is based on budgetary prices of M/S VA
Tech, while rates for the remaining equipment have been derived from the contract of
500/220 kV Gakkhar Substation.
The estimated cost of this Substation including cost of civil works and land amounts to
US$ 153 Million as shown in table 8.4.4
8.5.6
Summary of Costs
The summary of estimated cost of all the four aforementioned 765 kV Substations is
shown in Table 8.4 and the total cost works out to US$ 817 Million
8.6
Gates, Trashracks, Stop-logs and Handling Equipment
Gates, trashracks and stop-logs are priced essentially by the ton of equipment supplied.
The tonnage of equipment varies with the head conditions and operating requirements.
The estimate has been prepared by working out the weights based on feasibility level
design and applying present rates of different materials by selecting similar type of
projects and averaging pricing, scaling the pricing relative to the actual equipment size,
then projecting the costs with appropriate escalation rates to the 2008 level. The cost
estimate for gate equipment comes to about US$ 130 million (Table 8.6). This is the
installed cost including transportation, insurance and erection.
8.7
Control, Monitoring, SCADA and Telecom
The cost of control, monitoring, SCADA and telecom equipment has been estimated on
the basis of previous Contracts (Ghazi Barotha Project) and current prices for supply,
installation, testing and commissioning. The price change trend in the international
market shows that there is an increase in the price of computer software involved, which
is off-set by a similar decrease in the price of hardware. Therefore, price escalation has
not been considered. The cost of control, monitoring, SCADA and telecom equipment for
all the four substations estimated on the above basis comes out as US$ 5.02 million as
given in Table 8.7.
8.8
Transmission Lines
8.8.1
General
Basis of cost estimate for transmission lines has already been given under sub-section
5.20, and is reproduced below.
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Volume 8
Cost of any transmission line depends basically on quantity of line materials, unit cost of
the line materials and cost of construction. Other factors considered in working out these
cost estimates are inland transportation, incidental charges (which include charges for
letter of credit, insurance, landing, clearing etc,), engineering & administration and some
factor for contingencies. Custom duties & sales tax have not been considered while
preparing the cost estimates. The cost estimates of the proposed transmission line has
been worked out by using the quantities and unit rates worked out as described in the
following sub sections. The cost estimate of 765kV transmission lines amounts to US$
520 millions, shown in Table 8.5.
8.8.2
Quantities of Line Materials
Quantities of conductor & shield wire/OPGW for any transmission line configuration are
dependent upon the line length, whereas quantities of tower steel, insulators and
hardware etc. are dependent upon the span distribution i.e. number of structures.
From review of parameters of the existing lines, it was concluded that average span for
the transmission line under consideration should be 365 m. This gives 2.74 numbers of
towers per kilometre. For the purpose of cost estimates, ratio of suspension to deadend/angle towers, for different line sections have been taken as follows:
Ratio of suspension to Angle
Towers
Name of Line Section

Dasu-Thakot
20:80
Thakot-Mansehra
40:60
Mansehra-Gujar Khan
60:40
Gujar Khan-Gatti
80:20
This distribution accounts for the expected higher number of angle towers, which are
anticipated in the mountainous region.
The weights of suspension, dead-end and angle towers were calculated by using Ryle
Empirical formula taking into consideration transverse wind loads, conductor tension,
required ground clearances and sag values for ruling span length of
365 m. The estimated weight of the towers so calculated for the proposed transmission
line is given in table 5-24.
Quantity of conductor was based on actual line length, times number of phases and subconductors, including 2% allowance for sag and jumper/wastage etc. EHS galvanized
shield wire and OPGW are also based on the actual length including 2% allowance for
sag & jointing/jumpers.
Quantity of the insulators per assembly is based on the insulation level required for the
area and transmission voltage. Consequently total number of different types of
insulators required is calculated considering number of different types of assemblies
required as per type of structures required. Subsequently, quantities of other line
materials were calculated taking into account the required number of structures/spans
and configuration of each line.
8.8.3 Unit Cost for Line Materials
Unit rates for transmission line materials have mainly been calculated by applying an
escalation factor of 3.0% per annum to the latest available unit rates from the
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executed/under execution contracts of Dadu-Khuzdar Transmission System Project

and Transmission Arrangements for Power Dispersal of Ghazi Barotha Hydro Power
Project keeping in view the rise in steel price in international market and wherever rates
if not available from contracts of aforesaid project then the rates from Transmission
Extension and Reinforcement Project were considered. Escalation factor has been
calculated based on the month and year of execution of the particular contract.
For conductor, the price was obtained from London Metal Exchange (LME) and for
galvanized steel wire from Contract 2017-3 (Item-2) for supply of Shield wire for In & Out
arrangement of Tarbela Gatti 500 kV circuits 1 and 2 at Barotha. Rate of galvanized
steel wire was escalated according to the steel prices in international market, since it
covers additional cost for galvanizing and manufacturing. Cost per km of proposed
conductors were calculated by multiplying the quantity of aluminium and steel
respectively in per km and thereafter adding per km manufacturing cost and profit.
For hardware, dampers and accessories etc. requirement for higher strength material as
compared to those already procured has been considered and consequently unit cost
has been increased by 10% of the escalated cost obtained from the executed/under
execution contracts.
8.8.4
Towers
Data from Contract No. 2878 Dadu-Khuzdar Transmission System Project (turnkey
based) was used for obtaining unit rate of the galvanized steel towers. The unit rate
given in Contract No. 2878 is for 220 kV towers and escalated at 15% to account for the
recent rise in the price of steel in March 2008 and ratio of high strength steel in proposed
towers. Twenty percent of this rate was considered as local manufacturing cost.
Consequently unit cost of steel tower in foreign and local currency was worked out. The
unit rate so calculated was multiplied with the relevant towers weights calculated by
Ryles Formula, number of structures estimated per km and estimated percentage of
relevant type of tower in respective sections to obtain the budgetary cost estimates of
different types of towers.
8.8.5
Conductors
Unit rate of aluminium was taken from London Metal Exchange (LME) as on April 2008
and that of steel from Contract 2017-3 (Item-2) for supply of shield wire for In & Out
arrangement of Tarbela-Gatti; 500 kV circuits 1 and 2 at Barotha, signed between NTDC
(WAPDA) and M/s. Newage Cables in April 1999 and escalated keeping in view the steel
price in international market. The same were multiplied with standard weights/km
(including 2% for sag and wastage) of aluminium and steel respectively of the conductor.
This gives 80% of the conductor cost, since as estimated, 80% of total cost is that of
material and 20% is that of manufacturing including shipment and profit. Subsequently,
manufacturing cost at 20% of total cost was added to get per km cost of proposed
conductor.
8.8.6
Shield wire and Fittings
Unit rate was obtained from above referred Contract 2017-3 and the same was
escalated according to the steel price in international market. Two percent is added for
sag and wastage.
Per km rate of shield wire fittings is calculated by multiplying the required quantities with
the unit rates of the relevant fittings in Contract 1150-22, (Item-3) for supply of Hardware
for Third Jamshoro - Guddu 500 kV transmission line, signed between NTDC (WAPDA)
8-6
Volume 8
and M/s. Sicamex France in May 1996. The rate so calculated is escalated at 3.0% per
annum.
8.8.7 OPGW and Fittings
OPGW per kilometre rate was obtained from Dadu - Khuzdar Transmission System
Project in October 2007. The rate is escalated at 3.0% per annum. Two percent is added
for sag and wastage.
Per km cost of the OPGW fittings is calculated by multiplying the required quantities with
unit rates of relevant fittings obtained from above referred Contract.
8.8.8
Insulators
The data and budgetary cost provided by one of the reputed manufacturer for Diamer
Basha Dam Project is used to estimate the cost of insulators to be used for 765 kV
voltage levels keeping in view the strength and type of suspension and tension insulators
and number of each type of insulator per string, after applying the escalation factor.
8.8.9
Conductor Accessories
Per km rate of conductor accessories are calculated from the unit rates of these
accessories given in Contract No. 2017-3 (Item-3) for Supply of Accessories for In & Out
Arrangement of Tarbela-Gatti 500 kV circuits 1&2 at Barotha, signed between NTDC
(WAPDA) and M/s. Sicamex France in May 1999. The rates of accessories for conductor
were enhanced by 10% to cater enhanced strength because the proposed conductor
The rates thus obtained have been escalated at 3% per annum to get the per kilometre
rate of conductor accessories.
Per km rate of dampers is worked out from the unit rates of these dampers given in
Contract No. 1150-24 (Package-2) for Supply of Dampers for Conductor and Shieldwire
for Third Jamshoro-Guddu 500 kV Transmission Line signed between NTDC (WAPDA)
and M/s. Dulmison Thailand in September 1995. The rate of dampers for conductor was
enhanced by 10% to cater required enhanced strength because the proposed conductor
The rates thus obtained are escalated at 3% per annum to obtain rate of dampers.
8.8.11 Hardware
Per km rate of hardware is calculated from the unit rates of the hardware given in above
referred Contract No. 1150-22 (Item-3). The rates of hardware for conductor are
enhanced by 10% to cater enhanced strength because the proposed conductor Dipper
has more strength and weight than the Drake for which the cost was available. The
rates thus obtained are escalated at 3% per annum to obtain rate of dampers per
kilometre.
8.8.12 Construction
Due to variation in terrain, separate unit rates for different items of Transmission Line
Construction were developed for the four Sections i.e. Dasu-Thakot Section, ThakotMansehra Section, Mansehra-Gujar Khan Section and Gujar Khan-Gatti Section based
on recent 500 kV Contracts for Rewat-Gakhar-Lahore Line and 220 kV contracts for
8-7
Volume 8
mountainous areas. The same were multiplied with the quantities of relevant items thus
calculated to obtain cost of construction material and per km cost of each section and
consequently cost of the entire line.
8.9
Cost of Electrical and Mechanical Equipment and Transmission Lines
The summary of total cost based on the above prices and quantities indicated on the
plans for all Electrical and Mechanical items are shown in Table 8.1. The Estimated Total
cost of Electrical & Mechanical facilities works out to US$ 2360 millions.
It is to be noted that:
-
Cost of civil works and land of Power House is not included in the cost estimates,
which is included in Volume 10 of feasibility report.
Cost of land of underground substation is included in Volume 11 of feasibility
report.
Cost of civil works and land of surface Substation of Dasu, Gujar Khan and Gatti
is included in this cost estimates.
8-8
TABLE 8.1
BASE COST ESTIMATE OF ELECTRICAL / MECHANICAL EQUIPMENT AND AUXILIARIES FOR POWER
GENERATION AND 765 kV POWER TRANSMISSION FACILITIES.
Item No.
A.
Amount.
M US$
Description.
POWER HOUSE MECHANICAL EQUIPMENT.

Turbines, Governors Auxiliary Equipment. Powerhouse Misc. Mechanical
Equipment incl. Cranes & Hoists. Cooling Water system, Compressed Air system, HVAC,
Oil Handling system etc.
(Detail in Table 8.2)
TOTAL (A).
B.
TOTAL (B).
C-1
C-2
C-3
C-4
C-5
C-6
377.708
377.708
1396.050205
TRANSMISSION LINES.
113.52
70.785
152.62
172.04
10.64
Dasu to Thakot.
Thakot to Mansehra.
Mansehra to Gujar Khan.
Gujar Khan to Gatti.
Cost of 15kM Interconnection.
TOTAL(E).
F.
129.411205
DASU SUBSTATIONS.
TOTAL (D).
TOTAL (A to D).
E-1
E-2
E-3
E-4
E-5
551.363
36.3351
4.39735
4.09355
26.98705
40.7216
5.1119
117.64655
11.764655
Power Intake Gate Equipment.

Draft Tube Gate Equipment.
Tailrace Tunnels Gate Equipment.
Spillway Gate Equipment.
Low Level Outlets Conduits Gate Eqpt.
Diversion & Low Level Tunnels Gate Equipment.
Total
Contingencies at 10%
Dasu Underground incl. Generator Transformers. (GIS)

(Detail in Table 8.4.1)
E.
551.363
GATE EQUIPMENT.
TOTAL .
D.
337.568
POWER HOUSE ELECTRICAL EQUIPMENT.

Generators (540 MW), Exciters, Generator Circuit Breakers & Auxiliary Equipment.
Auxiliary Transformers, Spares. Powerhouse Misc. Electrical Equipment incl. MV & LV
Switchgear, Lighting system, Grounding, Control & Monitoring
C.
337.568
519.605
OTHER SUBSTATIONS.
F-1
F-2
F-3
Dasu Surface. (AIS)

Gujar Khan 765 / 500 kV Substation. (AIS)
Gatti 765 / 220 kV Substation. (AIS)
(Detail in Table 8.4.2, 8.4.3, 8.4.4)
G.
SCADA SYSTEMS.
174.928
111.1
152.624
TOTAL(F).
SCADA system at Dasu 765/500 kV Substation, PLC Communication system

765 kV Substation for Gujar Khan & Gatti / Gujranwala.Optical Fibre system at Dasu,
Basha and Gatti / Gujar Khan Substation.
TOTAL(G).
TOTAL TRANSMISSION FACILITIES (E+F+G).
GRAND TOTAL E&M COST (A to G).
438.652
5.014
5.014
963.271
2359.321205
Sheet 2 of 2
Table 8.2
Sheet 2 of 2

Cost Estimate of Turbines, Auxiliary Equipment and Powerhouse Mechanical Equipment
Unit
Quantity
Unit Price
US$
Francis Turbines (549 MW)
No.
26,598,000
212,784
42,557
170,227
V. Corak
2305
Governors with Auxiliary Equipment
No.
2,083,781
16,670
3,334
13,336
V. Corak
2310
Transportation, Erection, Commissioning etc
L.S.
37,200,000
37,200
7,440
29,760
V. Corak
266,654
53,331
213,323
26,665
5,333
21,332
Section Total
293,319
58,664
234,655
Total for Turbines & Mech Equipment
337,568
67,511
270,057
Code
Description
2500
Turbines & Auxiliary Equipment
2305
Sub-total
Other Items
Notes:
10%
1. Price level June 2008.

2. For E&M Equipment Actual Market Rates have been used.
Total Amount
Local
Foreign
(US$ x 1,000) (US$ x 1,000) (US$ x 1,000)
Remarks
Sheet 1 of 4
Table 8.3
DASU HYDROELECTRIC PROJECT
COST ESTIMATE
ELECTRICAL WORKS
Unit
Qty
Unit Price
(Eq US $.)
Total Price
(Eq US $.)
1.1.1 Generator Unit
No
25,653,572
205,228,576
1.1.2 Generator Accessories
No
11,926,143
95,409,146
1.1.3 Generator Circuit Breaker
No
1,464,466
11,715,731
1.1.4 Generator Earthing Switch
No
162,724
1,301,792
1.1.5 Generator C.T (Two Sets)
No
209,286
1,674,284
1.1.6 Generator V.T (Two Sets)
No
63,188
505,504
1.1.7 Surge Arrestor
No
28,499
227,992
1.3.1 Main Transformer, 20/765kV

OFWF ( 24 Single Phase, 2 Spare)
No
27
Included in
765kV
underground
S/s.
1.3.2 8000kVA Main Auxiliary Transformer, 20/11 kV.
No
628,835
2,515,339
1.3.3 2500kVA Auxiliary Transformer
No
173,049
692,196
1.3.4 2000kVA Auxiliary Transformers
No
10
151,017
1,510,174
1.3.5 1000kVA Auxiliary Transformers
No
98,991
197,983
1.3.6 Main Auxiliary Board (MAB),11kV
No
166,859
667,436
1.3.7 Headworks Auxiliary Board (HAB), 11kV
No
233,639
233,639
1.3.8 Unit Auxiliary Board (UAB), 0.4kV
No
57,560
460,480
1.3.9 Unit Auxiliary Supply Board (UASB), 0.4kV
No
177,976
355,953
1.3.10 Common Services Board (CSB), 0.4kV
No
183,087
366,174
1.3.11 Essential Services Board (ESB), 0.4kV
No
213,572
427,143
1.3.12 Substation Auxiliary Board (SAB), 0.4kV
No
73,211
73,211
Item
No.
1
1.1
1.3
Description
MAIN PLANT:
Hydro Generating Unit:
Electrical Equipment:
Sheet 2 of 4

COST ESTIMATE
ELECTRICAL WORKS
Unit
Qty
Unit Price
(Eq US $.)
Total Price
(Eq US $.)
1.3.13 Headworks Supply Board (HSB), 0.4kV
No
138,206
138,206
1.3.14 Isolated Phase Busducts (IPB)
Lot
1.4.1 1000AH, 220VDC Batteries.
No
181,195
362,390
1.4.2 150A, 220VDC Battery Chargers
No
59,598
238,391
1.4.3 DC Distribution Panel, Generating Unit.
No
17,270
138,162
1.4.4 DC Distribution Panel, Auxiliary System..
No
11,538
23,077
1.4.5 UPS
No
60,217
120,434
1.4.6 UPS Distribution Board.
No
11,885
23,770
1.5.1 250AH, 220VDC Batteries.
No
63,584
127,168
1.5.2 40A, 220VDC Battery Chargers
No
25,825
103,300
1.5.3 DC Distribution Panel.
No
7,923
7,923
1.5.4 UPS
No
30,108
60,217
1.5.5 UPS Distribution Board.
No
11,984
11,984
1.6.1 Generator Protection.
No
307,794
2,462,352
1.6.2 Main Transformer Protection.
No
287,713
2,301,708
1.7.1 Emergency Diesel Generator, 2 X 2000 KVA,

11 kV, 50Hz
No
871,757
1,743,514
1.7.2 Diesel Oil Tanks
No
30,351
60,702
1.7.3 Control & Protection For Diesel Generating Sets
No
278,057
556,114
Item
No.
1.4
1.5
1.6
1.7
Description
23,953,315
DC System for Power House:
DC System for Intake:
Protection:
Auxiliary Equipment:
Sheet 3 of 4

COST ESTIMATE
ELECTRICAL WORKS
Unit
Qty
Unit Price
(Eq US $.)
Total Price
(Eq US $.)
1.8.1 Generating Units(RPU#1 to RPU#8)
No
334,213
2,673,705
1.8.2 MV/LV Switchgear (RPU#9 and RPU#10).
No
266,302
527,491
1.8.3 765kV Substation (RPU#11)
No
225,714
225,714
1.8.4 Remote I/O's for 765kV Substation.
No
16,738
33,476
1.8.5 Interface Equipment to NPCC
No
50,214
50,214
1.8.6 System Software
Lot
334,560
334,560
1.8.7 Optical Fibre Cables.
Lot
219,970
219,970
1.8.8 GPS Clock System
No
83,689
83,689
1.8.9 Alarm System for Power House
Lot
33,476
33,476
1.8.10 Operator Workstation (Including 1xEWS).
No
39,696
198,478
1.8.11 Text Printer
No
6,041
6,041
1.8.12 VDU Copier (Including one for EWS).
No
6,041
12,083
1.8.13 Alarm Printer + Utility Printer + Log Printer.
No
1 each
1.8.14 Printer Desk.
No
11,687
23,374
1.9.1 2xDG's + MV/LV Switchgear (RPU#12).
No
395,619
395,619
1.9.2 Headworks (RPU#13)
No
176,293
176,293
1.9.3 Alarm System for Intake.
Lot
33,476
33,476
1.9.4 Operator Workstation
No
39,616
39,616
1.9.5 Text Printer and Alarm Printer.
No 1 each
1.9.6 Colour Plotter.
No
26,741
26,741
1.9.7 Printer Desk.
No
11,786
11,786
Item
No.
1.8
1.9
Description
Control System for Power House:
18,025
Control System for Intake:
12,083
Sheet 4 of 4

COST ESTIMATE
ELECTRICAL WORKS
Item
No.
Unit Price
(Eq US $.)
Total Price
(Eq US $.)
Unit
Qty
1.10. Lighting Facility / Small Services
Lot
4,561,818
1.11
Earthing Facility
Lot
819,265
1.12
Fire Alarm System
Lot
2,484,141
1.13
Cables (MV, LV & Control Cables).
Lot
27,057,328
1.14
Spare Parts & Tools
Lot
16,609,185
1.15
Errection & Testing Equipment
Lot
5,035,791
1.16
1.17
Description
Total FOB price for Electrical Equipment in

power house.
417,698,913
Other / Non specified items @ 10%
41,769,891
Total for Electrical Equipment in power house.
459,468,804
Errection, Insurance, Shipping & Local

Transportation etc @ 20% of total Eqpt +
Other items cost.
91,893,761
GRAND TOTAL.
551,362,565
Table 8.5
DASU HYDRO POWER PROJECT
COST ESTIMATES OF 765kV SINGLE CIRCUIT TRANSMISSION LINES
Line Length
Material Cost
(CIF)
Construction
Cost
Cost
Total Section Cost

of One Circuit
Approx. (km)
US$/km
US$/km
US$/km
US$/km
(1)
(2)
(3)
(4) = (2) + (3)
(5) = (1) x (4)
Dasu-Thakot
80
460,000
185,000
645,000
51,600,000
Thakot-Manshera
65
405,000
90,000
495,000
32,175,000
Manshera-Gujarkhan
185
315,000
60,000
375,000
69,375,000
Gujarkhan-Gatti
230
270,000
70,000
340,000
78,200,000
Item
No.
A
B
C
D
Section
Total Cost of one 765 kV circuit from Dasu to Gatti via Gujar Khan in US$
231,350,000
Total Cost of two 765 kV circuit from Dasu to Gatti via Gujar Khan in US$
462,700,000
Cost of 15 kM 765 kV Line for interconnection of Dasu surface Substation with Basha
Lines (3x2kM). And Dasu underground Substation (3x3kM). = 15 x 645000
GRAND TOTAL (F + G).
Other / Non specified items @ 10%
Total Cost of Transmission Lines. (H + I).
9,675,000
472,375,000
47,237,500
519,612,500
Note:
1. Additional 765 kV Lines - 15 kM.
- Basha 765 kV Lines in & out arrangement (3 x 2kM = 6kM)
- Dasu U/G and surface Substations interconnection through 765 kV Lines
(3 x 3kM = 9kM)
TOTAL (6 + 9) = 15kM
2.
Estimated 10% of cost has been added for Non specified items inclusive of incidental, transportation,
engineering & administration cost.
Cost of Land underneath the Lines & Towers is not included in

the above cost estimate.
Sheet 1 of 2
Table 8.6
DASU HYDROPOWER PROEJCT
GATE EQUIPMENT
COST ESTIMATE
The cost estimate is based on international market rates.
Sr.No
1.0
1.1
Description
1.2
1.3
1.4
1.5
1.6
2.0
Total:
Low Level Outlets Conduits Gate Equipment
2.2
2.3
2.4
2.5
Set
Set
Set
No
No
No
6
1
6
1
1
1
2.338
1.253
0.113
0.017
0.054
1.381
14.028
1.253
0.678
0.017
0.054
1.381
17.411
Regulating gates complete with hydraulic hoists,

controls and embedded parts
Guard gates complete with hydraulic hoists,
Overhead travelling crane for regulating and guard
gates
Service gates complete with hydraulic hoists,
Overhead travelling crane for service gates
Set
1.195
8.365
Set
1.118
7.826
No
0.879
0.879
Set
No
7
1
1.259
0.389
8.813
0.389
Total:
26.272
3.0
Power Intake Gate Equipment
3.1
4.0
Guard gates complete with hoists, controls and

embedded parts
Set
Service gates
Set
Embedded parts for service gates
Set
Trashracks with embedded parts
Section
Gantry crane
No
Trashracks cleaning machine
No
Total:
4.1
4.2
4.3
4.4
Draft tube gates

Embedded parts for draft tube gates
Lifting Beam
Overhead travelling crane
3.2
3.3
3.4
3.5
3.6
Amount
M. Euro
Qty
For design, manufacture, transportation, erection,

testing and commissioning of following gate
equipment.
Radial gates complete with hydraulic hoists,
Stoplogs
Embedded parts for stop logs
Lifting beam
Wave deflector
Gantry Crane
2.1
Unit Price
M. Euro
Unit
Set
Set
No
No
Total:
8
2
8
24
1
1
1.374
0.759
0.246
0.292
1.381
0.575
10.992
1.518
1.968
7.008
1.381
0.575
23.442
2
8
1
1
0.524
0.168
0.008
0.437
1.048
1.344
0.008
0.437
2.837
Sheet 1 of 2
Sr.No
Description
Unit Price
M. Euro
Amount
M. Euro
Unit
Qty
Set
Set
No
Set
Set
No
1
4
1
8
8
1
0.686
0.221
0.010
0.100
0.032
0.005
0.686
0.884
0.010
0.800
0.256
0.005
2.641
Set
Set
No
4
4
1
0.621
0.202
0.006
Total:
2.484
0.808
0.006
3.298
Total:
75.901
Grand Total:
GRAND TOTAL equivalent to Million US$.
7.590
83.491
129.411205
5.0
Tialrace Tunnels Gate Equipment
5.1
5.2
5.3
5.4
5.5
5.6
Inlet Stoplogs
Embedded parts for inlet stoplogs
Lifting beam for inlet stoplogs
Outlet Stoplogs
Embedded parts for outlet stoplogs
Lifting beam for outlet stoplogs
Total:
6.0
Diverstion Tunnels Gate Equipment
6.1
6.2
6.3
Inlet stopogs
Embedded parts for stoplogs
Lifting beam
Unforseen items / contingency 10%
Note:
- US$ = 1.55 x Euro.
Sheet 1 of 7
TABLE 8.7
765 kV SURFACE GIS-DASU-GUJAR KHAN-GATTI
DASU 765 / 132 kV GIS.
UNIT RATE.
ITEM
NO.
E
E.1
TOTAL.
FOREIGN CURRENCY (EURO).

DESCRIPTION.
UNIT. QTY.
FOB
PRICE.
MARINE
FREIGHT.
MARINE
INSUR.
CIF
KARACHI ERECTION INLAND
.
FREIGHT.
OR POET
QASIM
LOCAL CURRENCY (PKR).

INDIGENOUS GOODS.
CIF
EXSTORAGE
FACTORY
YARD AT
PRICE.
SITE
ERECTION
.
FOREIGN
LOCAL
CURRENCY CURRENCY
(EURO).
(PKR).
TELECOMMUNICATION SYSTEM:
PLC Communication System for Dasu s/s 765 kV System:
E.1.1 PLC Coupling Equipment:

E.1.1.1 Line Trap, 765 kV, 1.0 mH (min. inductance), 400
ohms, with pedestal insulators, HV connectors and
steel support structures, complete as specified.
Each
16
39,589
1,348
366
41,302
10,090
127,342
19,541
660,832
2,511,568
E.1.1.2 Line matching unit for phase- phase coupling

complete with coupling filters, hybrid transformer
protection circuits and all materials needed for a
complete installation (set comprises 2 units).
Set
6,992
606
165
7,763
2,363
5,735
10,685
62,104
150,264
3.40
0.20
0.10
3.70
8.00
0.00
8.00
75.00
7,400
182,000
29,178
1,413
156
30,747
10,769
25,912
21,370
245,976
464,408
E.1.1.3 Carrier frequency cable.
Meter 2,000
E.1.2 PLC Indoor Equipment:
E.1.2.1 PLC SSB Set, min. 80 watts, with swing rack type
cabinet, channel equipment, compandors and all other
material required for a complete installation.
Each
E.1.2.2 Protection signaling equipment
Each
Lot
11,194
340
83
11,617
751
6,345
7,847
11,617
14,943
Each
39,589
1,348
366
41,302
10,090
127,342
19,541
330,416
1,255,784
E.1.3 All other ancillary equipment such as cables, connectors,

jumpers, harnesses, mounting frames, fuses, relays,
nuts & bolts etc. for a complete and functional system.
E.2
Included in item E.1.2.3
PLC Communication System for Gujar Khan s/s 765 kV System:

Sheet 2 of 7
TABLE 8.7
UNIT RATE.
TOTAL.
ITEM
NO.
DESCRIPTION.

UNIT. QTY.
Set
Meter 2,000
CIF
.
FREIGHT.
OR POET
QASIM

INDIGENOUS GOODS.
CIF
EXSTORAGE
FACTORY
YARD AT
PRICE.
SITE
FOREIGN
LOCAL
CURRENCY CURRENCY
(EURO).
(PKR).
FOB
PRICE.
MARINE
FREIGHT.
MARINE
INSUR.
6,992
606
165
7,763
2,363
5,735
10,685
31,052
75,132
3.40
0.20
0.10
3.70
8.00
0.00
8.00
75.00
7,400
182,000
29,178
1,413
156
30,747
10,769
25,912
21,370
122,988
232,204
ERECTION
.

Each
Each
Lot
11,194
340
83
11,617
751
6,345
7,847
11,617
14,943

Each
39,589
1,348
366
41,302
10,090
127,342
19,541
165,208
627,892

Set
6,992
606
165
7,763
2,363
5,735
10,685
15,526
37,566
3.40
0.20
0.10
3.70
8.00
0.00
8.00
75.00
7,400
182,000

E.3
PLC Communication System for Gatti/ Gujranwala s/s 765 kV System:

Meter 2,000
Sheet 3 of 7
TABLE 8.7
UNIT RATE.
TOTAL.
ITEM
NO.
DESCRIPTION.
UNIT. QTY.
CIF
.
FREIGHT.
OR POET
QASIM

INDIGENOUS GOODS.
CIF
EXSTORAGE
FACTORY
YARD AT
PRICE.
SITE
FOREIGN
LOCAL
CURRENCY CURRENCY
(EURO).
(PKR).
FOB
PRICE.
MARINE
FREIGHT.
MARINE
INSUR.
29,178
1,413
156
30,747
10,769
25,912
21,370
61,494
116,102
83
11,617
751
6,345
7,847
11,617
14,943
ERECTION
.
Each
Each
Lot
E.4.1 Installation/commissioning of STM-1 Optical terminal

and multiplex equipment complete fiber optic links on
Dasu from Basha
Set
473,231
1,419,693
E.4.2 Installation/commissioning of digital teleprotection

equipment complete for transmission of three commands
over the fibre optic links on Dasu from Basha
Set
467,468
1,402,404
Each
25,378
37,188
116,220
236,616
709,847
30,470
42,210
175,395

E.4
11,194
340
Optical Fiber System at Dasu s/s substation,

Basha and Gatti/ Gaujar Khan substation:
E.4.3 Digital teleprotection equipment complete for transmission

of three commands over the fibre optic links on Dasu for Basha
E4.4
Augmentation in Optical terminal and multiplexer equipment complete fiber

Optic links at Basha substation
11,524
688
184
12,396
6,595
6,767
Set
E.4.4 Extension of approach optical fiber cables from

temporary housing to control building at Dasu s/s in
PVC cable conducts and termination on optical terminating
and patching panels redeployed from temperary housing at
Dasu s/s.
Lot

Dasu from Gujar Khan
Set
473,231
946,462

over the fibre optic links on Dasu from Gujar Khan
Set
467,468
934,936
8,166
248
28
8,442
1,670
2,939
Sheet 4 of 7
TABLE 8.7
UNIT RATE.
ITEM
NO.
TOTAL.

DESCRIPTION.

of three commands over the fibre optic links on Dasu for Gujar Khan
UNIT. QTY.
Each

Gaujar Khan from Dasu
Set

over the fibre optic links on Dasu from Basha
FOB
PRICE.
MARINE
FREIGHT.
MARINE
INSUR.
11,524
688
184
CIF
.
FREIGHT.
OR POET
QASIM
77,480
473,231
946,462
Set
467,468
934,936
Each
25,378
24,792
77,480

Gaujar Khan from Gatti/ Gujranwala
Set
473,231
946,462

over the fibre optic links on Gaujar Khan from Gatti/ Gujranwala
Set
467,468
934,936
Each
25,378
24,792
77,480

of three commands over the fibre optic links on Gaujar Khan from Gatti/ Gujranwala
E4.4

Optic links at Gaujar Khan substation
11,524
688
688
184
184
12,396
12,396
6,595
6,595
6,767
FOREIGN
LOCAL
CURRENCY CURRENCY
(EURO).
(PKR).
24,792
11,524
6,595
ERECTION
.
25,378

of three commands over the fibre optic links on Dasu for Basha
12,396

INDIGENOUS GOODS.
CIF
EXSTORAGE
FACTORY
YARD AT
PRICE.
SITE
6,767
6,767
Set
236,616
709,847

Gatti/ Gujranwala from Gaujar Khan
Set
473,231
946,462

over the fibre optic links on Gatti/ Gujranwala from Gaujar Khan
Set
467,468
934,936
Each
25,378
24,792
77,480
Set
236,616
709,847

of three commands over the fibre optic links on Gatti/ Gujranwala from Gaujar Khan
E4.4

Optic links at Gatti/ Gujranwala substation
11,524
688
184
12,396
6,595
6,767
Sheet 5 of 7
TABLE 8.7
UNIT RATE.
TOTAL.
ITEM
NO.
DESCRIPTION.
E.5.9 All other ancillary equipment and services needed

for fully functional optical fiber links.
UNIT. QTY.
FOB
PRICE.
MARINE
FREIGHT.
MARINE
INSUR.
CIF
.
FREIGHT.
OR POET
QASIM

INDIGENOUS GOODS.
CIF
EXSTORAGE
FACTORY
YARD AT
PRICE.
SITE
ERECTION
.
FOREIGN
LOCAL
CURRENCY CURRENCY
(EURO).
(PKR).
Lot
11,194
404
46
11,644
751
6,344
7,847
11,644
14,942
Lot
109,280
4,569
1,220
115,069
32,975
86,318
177,395
115,069
296,688
E.6.2.1 Desk mounted.
Each
15
138
148
92
83
359
2,220
8,010
E.6.2.2 Wall mounted.
Each
138
148
92
83
359
740
2,670
Each
844
28
881
92
484
609
1,762
2,370
E.6.4 Main distribution frame (1200 pair) with quick-connect

modules and protection equipment for external circuits
complete with self-standing cabinet and tools.
Lot
7,707
1,982
514
10,203
24,877
37,399
25,378
10,203
87,654
E.6.5 Hardware/Software augmentations in existing PAXs at

peripheral substations.
Lot
21,847
661
174
22,682
10,685
12,355
76,885
22,682
99,925
E.6.6 Public address/paging system complete as specified.
Lot
171,783
5,129
1,367
178,279
31,555
96,920
40,571
178,279
169,046
551
147
19,049
2,337
10,518
29,218
57,147
126,219
E.6
Operational Telephone (PAX) System at Dasu s/s substation:
E.6.1 Private automatic exchange with swing rack cabinet

and all equipment required for a complete installation
equipped with:
- 48 analogue trunks/48 analogue subscribers
- 4x2 Mb/s digital trunks/4 digital subscribers
E.6.2 Normal telephone sets.
E.6.3 Executive telephone sets
E.7
Data Communication System:
E7.1
Data modems:
- At Dasu 765 kV Substaion
- At NPCC Islamabad
E.7.1 Hardware augmentation (including interface equipment

at intermediate stations) for establishment of complete
end-to-end data links.
E.7.2 48V DC System at Dasu 765 kV Substation:
Each
Each
Lot
Included in section F
Included in section F
18,351
Sheet 6 of 7
TABLE 8.7
UNIT RATE.
TOTAL.
ITEM
NO.
DESCRIPTION.
UNIT. QTY.
FOB
PRICE.
MARINE
FREIGHT.
MARINE
INSUR.
1,367
138
E.7.2.1 Lead acid Plante battery, 2x540 AH, complete with

mounting racks, intercell connectors etc; required for
a complete installation.
Each
45,786
E.7.2.2 Automatic static battery charger, 100A continuous

rating in 1+1 configuration.
Each
Included in item E.10.1
E.7.2.3 DC distribution board with 20 circuit breakers, rated

10 A, 15 A or 20 A as appropriate two DC buses,
battery voltmeters, isolating switches, DC contactors
etc. required for a complete installation.
Each
Lot
not applicable
Lot
20,920
E.7.2.4 Any other item required for a complete installation.

(Bidder to provide details in the Bid)
E.7.3 Augmentation in 48V DC power supplies at existing 765 kVBasha, Gujar Khan and
Gatti/ Gujranwala Substations (Bidder
to provide detaile in the Bid).
633
64
CIF
.
FREIGHT.
OR POET
QASIM
47,291
21,617

INDIGENOUS GOODS.
CIF
EXSTORAGE
FACTORY
YARD AT
PRICE.
SITE
ERECTION
.
14,025
11,771
1,236
94,582
54,064
156,108
157,360
25,378
338,846
10,685
11,771
162,285
64,851
554,223
2,490,392
20,895,170
TOTAL OF ITEMS E1 TO E12:

F
F.1
FOREIGN
LOCAL
CURRENCY CURRENCY
(EURO).
(PKR).
SCADA SYSTEM:
SCADA System at Dasu 765/500 kV (Dasu s/s):
F.1.1 Remote terminal unit complete with input/

output cards, processor, memory etc. complete
with swing rack cabinet, cables and accessories.
Each
192,409
3,019
807
196,235
107,188
87,988
196,235
195,176
F.1.2 SCADA interface cabinet(s) with wiring and

interface circuitry with swing rack cabinet and
all material required for a complete installation.
Each
219,110
3,817
1,018
223,945
122,298
80,558
223,945
202,856
F.1.3.1 Active power transducers
Each
Included in item F.1.2
F.1.3.2 Reactive power transducers
Each
F.1.3.3 Voltage transducers
Each
F.1.3.4 Coupling relays for status indications
Each
F.1.3 Transducers and Relays:
Sheet 7 of 7
TABLE 8.7
UNIT RATE.
ITEM
NO.
DESCRIPTION.
UNIT. QTY.
FOB
PRICE.
MARINE
FREIGHT.
MARINE
INSUR.
CIF
.
FREIGHT.
OR POET
QASIM
TOTAL.
INDIGENOUS GOODS.
CIF
EXSTORAGE
FACTORY
YARD AT
PRICE.
SITE
ERECTION
.
FOREIGN
LOCAL
CURRENCY CURRENCY
(EURO).
(PKR).
Each
Each
Lot
F.2.1 Hardware/software modification at NPCC to include new

Dasu substation.
Lot
106,986
3,202
853
111,041
111,041
F.2.2 Augmentation of mimic board and associated equipment

including engraving of tiles and provision of fully functional
LEDs to actively display new Dasu. 765 kV
substation.
Lot
21,654
651
174
22,479
22,479
553,700
398,032
TOTAL OF ITEMS (E + F).
3,044,092
21,293,202
TOTAL OF ITEMS (E + F) equivalent to US$.
4,718,343
304,189
F.1.3.5 Coupling Relays for Control Orders of CBs

F.1.4 Time synchronization equipment
F.1.5 All cabling and wiring for connection with the process
and any other equipment required for fully functional system
F.2
SCADA System at NPCC Islamabad:
Note: * = Bidder to state quantity in bid.

TOTAL OF ITEMS F1 TO F2:
GRAND TOTAL equivalent to US$

GRAND TOTAL equivalent to Million US$.
Note:
US$ = 70 PAK RS.
US$ = 1.55 x Euro.
5,022,531
5

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PAKISTAN WATER AND POWER DEVELOPMENT AUTHORITY

DASU HYDROPOWER PROJECT

ELECTRICAL & MECHANICAL

National Engineering Services Pakistan(Pvt) Limited (NESPAK)

Binnie & Partners (Overseas) Limited

Dasu Hydropower Project - Feasibility Report

ELECTRICAL & MECHANICAL FACILITIES

POWERHOUSE MECHANICAL EQUIPMENT AND LAYOUT

Turbine Inlet Valves

Miscellaneous Mechanical Auxiliaries

Dasu Hydropower Project - Feasibility Report

Drainage and Dewatering Systems

GENERATORS AND EXCITATION SYSTEM

Generator Connections and Neutral Earthlings

Main Auxiliary Boards (11 kV)

Main Auxiliary Transformers

Miscellaneous Electrical Auxiliaries

Dasu Hydropower Project - Feasibility Report

Control & Monitoring

General Control Philosophy

POWER TRANSFORMERS AND EHV SUBSTATIONS

Power Transformers and Shunt Reactors

Power Transmission System

Integrated Interconnection Studies by NTDC 2003-05

Dasu Hydropower Project - Feasibility Report

Existing Generation System of WAPDA

Existing Transmission System of WAPDA

Cost Estimate of Transmission Alternatives

5.19.1 Quantities of Line Materials

Unit Cost for Line Materials

Cost Comparison of Various Transmission Alternatives

Dasu Hydropower Project - Feasibility Report

HYDRAULIC STEEL STRUCTURES (GATE EQUIPMENT)

Spillway Gate Equipment

Functional Requirements and General Arrangement

Low Level Outlet Conduits Gate Equipment

Functional Requirements and General Arrangement

Power Intakes Equipment

Functional Requirements and General Arrangement

Draft Tube Gate Equipment

Functional Requirements and General Arrangement

Tailrace Tunnels Gate Equipment

Functional Requirements and General Arrangement

Diversion Tunnels Gate Equipment

Functional Requirements and General Arrangement

Dasu Hydropower Project - Feasibility Report

SCADA AND TELECOM SYSTEM

SCADA Facilities for Tele-Control by NPCC

Optical and Conventional Telecommunication Media

Un-Interruptible Power Supplies (UPS)

Basis of Cost Estimate

Turbines and Auxiliary Equipment

Generators, Exciters, Powerhouse Auxiliary and Electrical Equipment

Gates, Trashracks, Stop-logs and Handling Equipment

Dasu Hydropower Project - Feasibility Report

Summary of Total Cost of Electrical and Mechanical Equipment Including

Dasu Hydropower Project - Feasibility Report

Guide to the Reader

Dasu Hydropower Project - Feasibility Report

Unit Rating and Power Plant Configuration

As detailed in Volume 3 (Reservoir Simulation & Power Generation Studies) various

Transportation on Karakorum Highway (KKH)

9.5m x 8.0m x 8.0m

Dasu Hydropower Project - Feasibility Report