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HMC's role as future leader in the manufacture of power plants.

The present crisis of Power in the country is quite serious and it is becoming more and more acute with the passage of time. Pakistan is fortunate that it has a large hydel energy potential which is estimated to be 30,000 MW. At present the installed capacity of hydel plants is only 3700 MW which is only 12 per cent of the available potential. Unlike fossil fuel, hydel source of energy does not deplete with time except if major ecological changes take place in the region. Therefore, for reducing dependence on oil it is of paramount importance that highest priority is accorded to early exploitation of hydel potential.

A major hydel project, however, takes about 5-10 years for its completion. As a short term measure, therefore, it would be advisable to concentrate on mini/small hydel power projects both in Northern Areas as well as suitable sites on rivers, canals and streams in Punjab and Sindh.

As is evident from the foregoing, the country needs to pay special attention to the Power Sector so as to meet the fast growing needs of energy. The allocation made to this sector during 6th & 7th Five Years Plans are the manifestation of our desire to solve this problem at the earliest. During 6th Plan the actual achievement was considerably below the target. In power generation, an addition of only 2018 MW was achieved against a target of 3795 MW (shortfall of 47%). During 7th Plan addition of 8396 MW was envisaged which could not be achieved. One of the reasons for shortfall is our heavy dependence on imported plant and machinery. If we want real break-through in Power Sector, we will have to produce our power generation equipment and machinery locally. HMC, a unit of State Engineering Corporation (SEC), has already made a modest start in this direction and is planning to expand this activity to achieve maximum self-reliance in this field, provided a national policy on lines similar to what has been done in India is developed and implemented.

HMC during 6th Plan, planned its entry into Energy Sector because of the priority given by the Government to this Sector and resultant business opportunities thus available. It invested about Rs. 20 million in additional plant and machinery for producing components of power boilers. HMC also entered into technical collaboration with a world renowned firm Deutsche Babcock (DBW) of West Germany engaged in the manufacture of power boilers. HMC secured orders for the equipments of power boilers of Bin Qasim Thermal Units 3 & 4. Its share in these units was about 16 per cent by value but it manufactured about 50 per cent equipment by weight.

HMC in collaboration with Marubeni Corporation of Japan successfully manufactured and delivered major portion of boiler for 210 MW KESC power plant at Bin Qasim Unit 5. The job was completed by HMC ahead of schedule.

It is commendable that HMC completed the jobs of Bin Qasim unit 3, 4 & 5 to the entire satisfaction of customer as well as its foreign partners. In addition to this, HMC also manufactured steel structure and some pressure parts for combined cycle power plant at Guddu in collaboration with CMI of Belgium. Till this time HMC's share in the manufacture of power plant equipment was not much and following the directive of the Prime Minister that emphasis should be put for achieving maximum level of indigenization in the Energy Sector, it became essential that HMC should augment its manufacturing capabilities viz-a-viz power plants. We, therefore, decided to install machines which will enable HMC to manufacture about 60 per cent of the total equipment of 300 MW thermal power plants including balance of plant area.

For this purpose HMC has embarked upon modernizing its manufacturing capabilities in phases in collaboration with Chinese and Western sources. In phase I & II, we have decided to install state-of-the-art machines for the manufacture of membrane walls, headers and coils of higher modules, pressure vessels and pressure piping for 210/300 MW thermal power plants. Orders for these machines have already been placed and are expected to be installed by 1st quarter of 1994.

In phase III, HMC-III will come up which will have special machines of much higher capacity to be used for the manufacture of steam drums, high pressure feed water heaters and condensers. HMC-III which is expected to come up by end of 1996 will have machines specially for the purpose of manufacturing power plants.

On the similar lines, HMC planned to start progressive manufacturing of small hydel turbines in its Works. It has all the necessary facilities to manufacture complete turbines. However, it will need technical assistance and addition of certain machines for manufacture of critical items such as runners and wicket gates.

HMC entered into technical collaboration agreement with Sulzer Escher Wyss (SEW) of Switzerland, a name established in the field of hydel turbines. HMC with the association of (SEW) has so far completed schemes as listed at Annexure-I for the Northern Areas Public Works Department (NAWPD) during the period 1985-86. In these projects HMC share was limited to about 15 per cent.

HMC secured another contract from WAPDA for the supply of 4 x 1 MW Hydel Plant being set up at Gilgit for a total price of Rs. 32.5 million. These are Pelton type turbines and the local scope of manufacturing includes, penstock, sliding gates, base frames, turbines, misc. structural parts, overhead travelling crane, transformers and HT & LT panels. The share of local supply was 65 per cent. The project has been successfully commissioned.

HMC recently succeeded in securing contract for the supply of plant and machinery for 31 Nos. hydel projects located at various sites in Northern Areas. Detail list enclosed at Annexure-II. The total value of the contract is about Rs. 270 million. In this deal M/s. Bi-Water Hydro Power, UK, are the associated partners, who have assured complete technology transfer to HMC in this field. Deletion programme in this contract is given at Annexure-II.

The deletion programme given at Annexure-III reveals that on completion of this contract HMC will be able to design and manufacture complete turbines at its Works.

As already mentioned, Pakistan has large hydel resources for power generation. The first phase of two giant projects namely Mangla and Tarbela have been completed and their expansion is in progress. It is expected that soon, decision will be taken on the fate of Kalabagh and Bhasha Dams. In view of the large potential which needs to be harnessed in the near future, HMC is planning to expand its production facilities to undertake manufacturing of components for large hydel turbines and generators. However, other allied hydraulic items such as trash racks, gates, stop logs etc. are already being manufactured at HMC with the existing facilities.
List of Turbo Generating Sets supplied by HMC

Name of Scheme Type of Head Discharge Output Customer
 Turbine (M) MB/sec (KVA)

Khyber Hydel Francis 114 0.453 500 NA-PWD
Manthoka " 90 0.283 250 "
Chilas " 146 0.408 500 "
Garbochong " 90 0.283 250 "
Shakargarh " 46 0.283 250 "
Kargah Ph-IV Pelton 213 0.52 1250 Wapda
Hydel Projects Under Execution

 Output Type of Head Discharge
SITE (KVA) Turbine (M) M3/Sec

Juglote 2x625 Francis 76 0.91
Misgar 1x23 " 44 0.5
Phandar 2x625 " 50 1.39
Nagar 2x625 " 61 0.96
Khyber 1x500 " 113 0.431
Ishkoman 1x625 " 91 0.61
Singal 1x300 " 79 0.33
Thack (Chilas) 3x625 " 145 0.44
Gudai 2x400 " 91 0.42
Haroho 1x500 " 54 1.112
Turmic 2x500 " 148 0.64
Pion 2x625 " 136 0.43
Shirting 2x600 " 82 1.167
Shigar 2x500 " 115 0.444
Gole 1x500 " 131 0.372
Balagond 3x500 " 57 0.834
Kachlira 3x1250 " 126 0.903

ANNEX-III Deletion Programme

1st Phase: (8 Turbines) - Inlet Pipes & Draft tubes (12 Months) - Base frames etc. (4% by value)

2nd Phase: (7 Turbines) - Inlet Pipes & Draft Tubes (18-24 Months) - Base frames etc.
 - Inlet valves with Exp. joints.
 - Assy. of Turbines supplied in CKD condition.
 (10-14% by value)

3rd Phase: (11 Turbines) - Inlet Pipes and Draft Tubes (24-30 Months) - Base frames etc.
 - Inlet Valves with exp. joints
 - Complete Turbines less runner (65% by value)

4th Phase:
(5 Turbines) - Complete Turbines with all related items as
(36 Months) mentioned above (100% of value)
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Title Annotation:Special Section: Power Generation; Heavy Mechanical Complex
Author:Khan, Ashfaq Ahmad
Publication:Economic Review
Date:Jun 1, 1993
Previous Article:KESC will meet fully the power demand in Karachi.
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