MANGLA REFURBISHMENT PROJECT – AN INTRODUCTION

Mangla Dam Project was commissioned in 1967 primarily to increase the amount of water that can be used for
irrigation from the natural flow of the river Jhelum, and secondly to generate electrical power from the water being
released for irrigation purposes. Flood control was an added benefit of the original construction. Mangla Dam is
3140m long and 147m high covers a surface area of 251 km 2 with gross storage capacity of 10.2 billion cu.m. of
water.

The Powerhouse was constructed in four stages over a period from 1962 until 1994, resulting in four different
designs by the different suppliers of the generating units. The powerhouse has ten units of 100 MW each for a
total nameplate capacity of 1,000 MW at rated head.

In recent years, WAPDA completed a dam raise that changed the maximum conversation level from EL. 1202 ft
to EL. 1242 ft. increasing the available static head on the turbine generators from approximately 360 feet to 400
feet.

While power delivery is an important function of the overall project, the water rights are owned by Pakistan
irrigation entities and WAPDA does not have the right to alter the 10-day average water release schedule. Rather,
its job is to maximize the benefit obtained from the releases of water from the reservoir, which is regulated by
another Pakistani governmental agency.

In 2011 and 2012, MWH (Montgomery Watson Harza, USA) conducted a feasibility study to identify
improvements required to continue the reliable, safe and sustainable use of the power generation facility for
another life cycle. A number of equipment refurbishment alternatives were investigated and evaluated, ranging
from a baseline of making the fewest improvements necessary, to an opportunity-based approach that
considered the added benefits of replacing/upgrading the equipment so as to optimize plant performance,
consistent with the intended future use of the plant and reservoir by WAPDA and other government authorities.
The Mangla Hydropower station is being refurbished to increase its power generation capacity (35%) from 1 GW
to 1.3 GW.

Because of the dam raised (increasing head), older units nearing the end of their design life, other equipment
(e.g., controls, protection, instrumentation, switchgear) becoming obsolete, newer, and more-efficient power-
generation technologies, and increased domestic power demand, improvements to the plant have become both
more necessary and feasible. WAPDA is currently in the process of identifying, prioritizing, and grouping these
improvements in to individual Bid Packages.

Mangla Project Type Hydropower Plant Refurbishment/Rehabilitation

Refurbishmen
Location River Jhelum, Azad Jammu & Kashmir (Pakistan) – 120 kms from Islamabad
t
Project Operator Water and Power Development Authority (WAPDA)
Refurbishment 2018
Started
Expected Completion 2027
Total No. of Units 10
Average Annual 5 billion units to 6.5 billion units
Electricity Generation
Capacity
Generating Units 1-4 (commissioned on 1967)
5-6 (commissioned on 1974)
7-8 (commissioned on 1981)
9-10 (commissioned on 1994)
Estimated Cost & 52.2 billion PKR = 423 million USD
Financing USAID (United States Agency for International Development) = 150 million USD
French Development Bank Agency (Francaise de development) = 95 million
USD
WAPDA = 178 million USD
Consultants MWH (Montgomery Watson Harza, USA) / Stantec
National Engineering Services Pakistan (Pvt.) Limited, Lahore (NESPAK)

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 Associated Consulting Engineers, Lahore (ACE)

MANGLA REFURBISHMENT PROJECT – PHASE - I

Package I + VII Contractor’s Name ALSTOM Hydro France, France

(Turbine-Generators for
Units 1-6) Date of Bid Submission September 12, 2015
Date of Letter of Award (LOA) August 16, 2016
Package I = 5-6 Units Date of Signing of Contract Agreement August 29, 2016
Package VII = 1-4 Units
Commencement Date October 03, 2016
***. Completion Date (Period) ***.
Unit 1+2 (1530 days) Contract Cost
December 11, 2020 Total: 10,810,713,407 (Eqv. PKR)
Turbine-Generators for Units 5-6 =
Unit 3+4 (1170 days) 4,781,392,035PKR
December 17, 2020 Turbine-Generators for Units 1-4 =
6,029,321,371PKR
Unit 5+6 (810 days) Exchange Rate
December 22, 2020 1USD=103,059PKR for Units 5-6
1EUR=115,172PKR for Units 1-4
1CNY=161,383PKR for Units 1-4
Performance Guarantee (10%) PKR:424,213,869; EUR:2,447,360
Standard Chartered Bank, Lahore USD:2,672,827; CNY:6,167,400
Date of Issue of Performance Guarantee August 19, 2016
Date of Expiry of Performance
May 30, 2024
Guarantee

 Design, supply, and installation of generating units 1 through 6 turbines, generators,

governors, excitation systems and other minor civil repairs.
 Installation of Units 1 through 4 (P-VII) will occur following completion of Units 5 and 6 (P-I)

Package II Contractor’s Name Zirva – ISIK – Petrocon (ZIP) JV

(Powerhouse crane Date of Bid Submission April 16, 2015
refurbishment and
upgrade) Date of Letter of Award (LOA) August 21, 2015
Date of Signing of Contract Agreement November 10, 2015
Commencement Date
Completion Date (Period)
Contract Cost 348,486,355 PKR
Exchange Rate 101.8 PKR per USD
Performance Guarantee (10%) 202,096 USD
United Bank Limited, Islamabad
Date of Issue of Performance Guarantee September 22, 2015 / December 29, 2017
Date of Expiry of Performance December 11, 2019
Guarantee
 Powerhouse crane refurbishment and upgrade.
Package III-a Contractor’s Name CHINT Electric Co., Ltd. China
(Design and supply of
Date of Bid Submission January 28, 2015
Four 220 KV generator
setup (GSU) Date of Letter of Award (LOA) December 29, 2015
transformers (for Units Date of Signing of Contract Agreement March 11, 2016
3,4,5 and 6)
Commencement Date
Completion Date (Period)
Contract Cost 5,239,807 USD
Exchange Rate
Performance Guarantee (10%) 261,990.35 USD
Askari Bank Limited, Lahore
Date of Issue of Performance Guarantee
Date of Expiry of Performance March 13, 2023
Guarantee

 Providing all instructions, procedures, and method statements needed by Employer to off-load,
store, handle, erect, commission and test the transformers; and
 Providing on-Site Contractor’s representative during erection, commissioning, and testing of
the transformers, if so requested by the Employer after award of the Contract. This is not
currently part of the Package-III-a Contract.

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Package IV-a Contractor’s Name Kokusai Commerce Co., (KC)
(Turbine Inlet Valves for
Date of Bid Submission December 16, 2014
Units 1-6)
Date of Letter of Award (LOA) August 21, 2015
Date of Signing of Contract Agreement
Commencement Date April 13, 2016
Completion Date (Period)
Contract Cost 686,624,116 JPY
Exchange Rate for FCC
Performance Guarantee (10%) 17,578,692 JPY
United Bank Limited, Lahore
Date of Issue of Performance Guarantee January 31, 2019
Date of Expiry of Performance Guarantee April 31, 2020

 Design and supply of components for refurbishment of turbine inlet valves for generating Units
1 through 6

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 MANGLA REFURBISHMENT PROJECT – PHASE - II
Package III-b
(Two 132 KV GSU Transformers
for Units 1 & 2)
Package V
(Balance of Plant Mechanical
Works)
***.
- Delivery of materials for
pressurized water system for
Unit 5+6 (180 days)
June 10, 2020
- Completion of drainage and
dewatering system (1095 days)
December 12, 2022
- Completion of new elevator
(1095 days)
December 12, 2022
- Completion of Tunnel 3 intake
gate and seal work (1095 days)
December 12, 2022
- Completion of intake gate
refurbishments work for each
tunnel – except Tunnel 3
T1 = October 31, 2021
T2 = October 31, 2020
T3 = December 12, 2022
T4 = December 12, 2023
T5 = December 12, 2024
Contractor’s Name Boading Tianwei Boabian Electric Co.,
China
Date of Bid Submission June 20, 2019
Date of Letter of Award (LOA) March 03, 2021
Date of Signing of Contract Agreement July 19, 2021
Commencement Date
Completion Date (Period)
Contract Cost 2,711,600 USD
Exchange Rate for FCC
Performance Guarantee (10%)
Date of Issue of Performance Guarantee
Date of Expiry of Performance Guarantee
 Design and supply of Two 132 KV GSU transformers for Units 1 and 2
Contractor’s Name Zhejiang Orient Engineering Co. Limited,
Hangzhou, China
Date of Bid Submission October 19, 2017
Date of Letter of Award (LOA) March 21, 2019
Date of Signing of Contract Agreement June 19, 2019
Commencement Date December 13, 2019
Completion Date (Period) ***.
Contract Cost Total: 3,031,015,173 (Eqv. PKR)
a. 18,423,116USD (FCC)
(1,934,427,180 – Eqv. PKR)
b. 1,096,587,993PKR (LCC)
Exchange Rate for FCC 1USD=105.00PKR
Performance Guarantee (10%) Pak Rupees Equivalent to
Bank Alfalah Limited, Karachi USD 1,824,311.60 Plus
PKR 109,658,799.30
Date of Issue of Performance Guarantee April 17, 2019
Date of Expiry of Performance Guarantee June 24, 2025
 Refurbishment/replacement of pressurized water systems for all generating units
(pumps, piping, valves, strainers, etc.);
 Refurbishment/replacement of the drainage and dewatering systems (pumps, piping,
controls etc.);
 Refurbishment/replacement of air compressor systems (equipment, piping, outlet
stations);
 Replacement of the control block elevator;
 Refurbishment/replacement of HVAC equipment of powerhouse;
 Refurbishment of power intake trash racks;
 Refurbishment of the power intake gates and the draft tube gates including furnishing
and installing new rubber seals;
 Supply and replacement of lubricating oil for TIVs;
 Inspection based tunnel repairs and other miscellaneous concrete work;
 Tunnel digital surveys
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Package VI + VIII
(Balance of Plant Electrical
Works & Control Systems)
Package IX
(Switchyard)
Contractor’s Name Sinohydro Corporation Ltd, China
Date of Bid Submission October 05, 2017
Date of Letter of Award (LOA) December 01, 2018
Date of Signing of Contract Agreement January 08, 2019
Commencement Date July 01, 2019
i.e., delivery at site of manufactured
section 9.1-1.05 for Unit 5-6
Completion Date (Period) (200 days)
Contract Cost 3,818,086,574 USD
23,798,931 (FCC)
1,308,489,300 (LCC)
Exchange Rate for FCC 105.45 PKR/USD
Performance Guarantee (10%) USD 2,379,893.10
Bank Alfalah Limited, Lahore PKR 130,848,930
Date of Issue of Performance Guarantee December 27, 2018
Date of Expiry of Performance Guarantee December 03, 2025
Subpackage VI-a:
 Three generator circuit breakers (GCB) for Units 3, 5 and 6;
 Four configurations of Isolated Phase Bus (IPB) to suit the design condition of the
units as follows: Units 1, 2 4 & 6 – new IPB complete, structures, auxiliary equipment
on units with no GCB; Units 3 & 5 – new IPB complete, structures, auxiliary equipment
on Units with GCB; Units 7 & 8 – no IPB supply, no changes to existing equipment;
and Units 9 & 10 – new outdoor IPB only, connect to existing IPB at indoor interface,
outdoor structures, auxiliary equipment on unit with GCB;
 Station service branch, including CLiP current limiter, 13.2 KV circuit breaker, and 3.8
MVA oil-filled outdoor transformer.
Subpackage VI-b:
 Installation of Employer-furnished main power (GSU) transformers for Units 1 through
6 and 9 through 10 and station transformer procured under Packages III-a, III-b and
III-c. Refurbishment of existing main power transformers for Units 7 and 8.
 Demolish old, and furnish and install new station service system.
Subpackage VIII:
 Design and supply of the Turbine-Generator Protection and Control System (PCS) for
the Project, including all software, data bases, screens, interfaces, and hardware
necessary for the protection and control and monitoring of the entire power plant and
facilities from any of the Human Machine Interfaces (HMI), complete with all
appurtenances and spare parts.
Contractor’s Name China CMAC Engineering Co., Limited,
China
Date of Bid Submission September 12, 2017
Date of Letter of Award (LOA) June 13, 2018
Date of Signing of Contract Agreement September 17, 2018
Commencement Date
Completion Date (Period)
Contract Cost Total: 1,683,865,473 (Eqv. PKR)
a. 7,310,438.25USD (FCC)
(771,251,238 – Eqv. PKR)
b. 912,614,237PKR (LCC)
Exchange Rate for FCC 1USD=105.50PKR
Performance Guarantee (10%) Pak Rupees Equivalent to
Askari Bank Limited, Lahore USD 1,824,311.60 Plus
PKR 109,658,799.30
Date of Issue of Performance Guarantee July 12, 2018
Date of Expiry of Performance Guarantee December 20, 2022
 Sub-station automation system and powerhouse control system interface;
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  Main switchyard CT and VT replacements and upgrades;

 Earth mat revisions;

 New switchyard protection equipment;

 New switchyard control building and switchyard subsystems

MANGLA REFURBISHMENT PROJECT – PHASE – III

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Package III-c Contractor’s Name
(Two 220 KV GSU
Date of Bid Submission
Transformers)
Date of Letter of Award (LOA)
Date of Signing of Contract Agreement
Commencement Date
Completion Date (Period)
Contract Cost

Exchange Rate for FCC

Performance Guarantee (10%)
Date of Issue of Performance Guarantee
Date of Expiry of Performance Guarantee

 Design and supply of Two 220 KV GSU transformers for Units 9 and 10

Package X Contractor’s Name

(Generating Units 7and 8)
Date of Bid Submission
Date of Letter of Award (LOA)
Date of Signing of Contract Agreement
Commencement Date
Completion Date (Period)
Contract Cost

Exchange Rate for FCC

Performance Guarantee (10%)
Date of Issue of Performance Guarantee
Date of Expiry of Performance Guarantee

 Design, supply and installation of generating Units 7 and 8 turbines, generators,

governors, and excitation systems.

Package XI Contractor’s Name GE Hydro, France

(Generating Units 9 and 10)
Date of Bid Submission February 03, 2022/ August 01, 2022
Date of Letter of Award (LOA) November 15, 2022
Date of Signing of Contract Agreement January 10, 2023
Commencement Date February 02, 2023
Completion Date (Period)
Contract Cost 11,922,908,293 PKR

Exchange Rate for FCC

Performance Guarantee (10%)
Date of Issue of Performance Guarantee
Date of Expiry of Performance Guarantee

 Design, supply and installation of generating Units 9 and 10 turbines, generators,

governors, and excitation systems.

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