HUB COAL POWER PROJECT

PRESENTED BY
Muhammad Sohaib Shahid

2013-EE-121

Anas Tariq

2013-EE-112

Muahmmad Muneeb

2013-EE-24

Department of Electrical Engineering

University of Engineering and Technology, Lahore

Hub Coal Power Project Site

The map shows the location of
the existing Hub oil-fired power
plant, in Hub tehsil, Lasbela
district, Balochistan province.
Hub, a Balochistans industrial
estate, is 56-kilometer from
Karachi Pakistans port city and
financial center.
The new coal-fired plant would
be built adjacent to this existing
oil-fired plant

Project Outset
A part of China Pakistan Economic Corridor
(CPEC), HUBCO is the only power project
under CPEC in Balochistan.
The project is being undertaken through a
joint venture between HUBCO and China
Power International Holding Limited (CPIH), a
wholly-owned core enterprise of State Power
Investment Corporation (SPIC), one of the five
State Power Corporations in China.
The construction consortium included:
Ansaldo ENERGIA of Italy, technical
coordinator and designer and supplier of the
turbine generators.
Design and supply of Boilers will be done by
Japan heavy industries Co Ltd.
SGE SNC France is given the civil contract of
the project.

Generation Capacity

Hub power plant, a coal-fired power

plant with a capacity of generating
1320 megawatts.
The power plant would have two units
of 660MW each.
The cost of the project is estimated at
$2.4 billion and it would be one of the
largest private-sector investments in
Pakistan.

ELECTRICAL SYSTEM
There are four generators which develop a power of 380 MVA each (power factor
0.85) and are of the windings direct cooling type. The stator winding is cooled by
the circulation of de-ionised water which passes through the hollow conductor
which forms part of the semi-coils. The rotor winding is cooled directly by hydrogen.
The generated power is dispatched to WAPDAs grid through two overhead 500 kV
lines through a half-breaker scheme, SF insulated substation. There are also two startup transformers. Station power supply and unit auxiliary power supply are provided
to minimize any effects of equipment failure or maintenance on continuity of
service.
The electrical auxiliary power system rests on three major sub-systems:
AC power system
DC power system
AC emergency power system
The station transformers performs the start-up and shut-down of the plant and
supplies the common services boards.
The emergency ac source is ensured by emergency diesel and 110V inverters,
supplying the loads necessary for the safe shut-down of the power plant.

Electricity Tariff

The reference levelised tariff awarded to

the project is8.117 Rs/kWh with the
project being foreign financed and using
imported coal.

SITE DETAILS

The Hub Power Plant consists of two

generating units with a coal-fired single reheat boiler and tandem compound, two
cylinder condensing steam turbines directly
coupled to a hydrogen cooled generator.
The design net available output will be
exported to WAPDAs national grid via the
power stations 500kv switchyard. Both the
plant configuration and the steam
conditions represent conventional design
based on proven technology

Coal Jetty

The coal-handling jetty will be

constructed as a whole by China
Harbor Engineering Co, a subsidiary of
China State Construction Engineering
Corp.
The jetty will serve the China-Pakistan
Hub 2x660MV coal-fired power plant
being built at Hub in Balochistan, and
perform as a transport center and
support facility for the power plant.

How Will the Coal be Transported

The construction of the jetty is

expected to be completed by
September 2018, with an uploading
requirement of 4.4 million tons of coal
being met annually.
Initially it will bring imported coal to
run the plants as well as set up a coal
jetty for handling supplies. Later, the
company will switch to Thar coal.

Why will Imported Coal be used ?

Although Pakistan has very large coal reserves but mostly it is of inferior quality.
Miners have to go 500 1000 feet deep, which ultimately increases cost of production.
The local coal mines are not mechanized and this results in high production cost
Coal is by no means a homogenous term; and in fact can be categorized or ranked
according to the degree to which the original plant material has been transformed into
carbon.
The ranking of coal therefore, from most to least carbon content are:
Anthracite
Bituminous Coal
Sub-Bituminous Coal
Lignite
Pakistans coal reserves are almost exclusively comprised of Lignite-known to be the
dirtiest of the fossil fuels.
(Contd)

The Calorific Values of the coal that will be imported along with weighted
average of the calorific values of local coal and imported coal are given as
following;

The low weighted average calorific values of local coal solidifies the point of
importing coal from countries having coal reserves with good calorific
values.

THERMODYNAMICS OF PLANT
The Plant design and engineering are based on proven technology. It
operates on the basis of a conventional steam cycle such that the steam
produced by the boilers drives the turbine generator sets to make
electricity.
The thermodynamic characteristics of the units are as follows:
Steam pressure and temperature: 170 bar, 540OC;
single re-heating up to 540OC;
condensate and feed-water pre-heating, up to 250OC;
turbine exhaust pressure: 0.087 bar (2.5 in Hg). This is somewhat higher
than is normal because of the high average temperature of
circulating water available at the plant site.
The plant, when operating at full load converts energy in the residual
fuel oil (RFO) at a thermal efficiency of approximately 38.9%.

THE CONDENSER AND FEEDWATER SYSTEM

The condenser into which the steam from the LP turbine is discharged is a closed
vessel fitted with tubes through which sea water is circulated by the main
circulating pumps. The outside of the cold tubes condenses the steam from the
turbine back into feed water.
The condenser is a single-pass surface type, with divided water-boxes to facilitate
inspection and maintenance. The pressure in the condenser is 0.084 bar when the
circulating water enters at a temperature of 33C.
The condensate and feed heating system includes seven heating stages; the
heating medium is based on the steam extracted from the turbine.
Four surface-type LP heaters are provided for heating the condensate. These
receive steam extracted from the LP section of the turbine. A direct-contact
heater is provided to deaerate the feedwater and to be used as suction-tank for
the feedwater pumps; this heater receives steam from the turbine IP section
exhaust.
The boiler feed pump sets are provided to supply about half of the feedwater
needed by the boiler at full load and each pump set has a constant speed
motor and booster pump, a hyraulic speed changer with step-up gear and a
variable speed high pressure main feed pump.
Two surface type HP heaters are provided for the heating of the feedwater. HP1
receives steam extracted from the IP section of the turbine whereas HP2 gets
steam from the cold reheat line.

COOLING WATER
The cooling water used in the condensers and for the auxiliary plant is
drawn from the Arabian Sea through submerged concrete inlet channel
about 300m long
The sea water flows from the circulating water intake through screens to
remove debris and is pumped by the main sea water circulating pumps
through the intake piping and valves to the condensers.
The water is discharged through further piping and valves into a culvert
and seal pit before flowing into the Hub River estuary through a 1,000m
discharge canal.
The remainder of the auxiliary plant and systems are cooled by a closed
circuit water system, using demineralised water.

THE CONTROL SYSTEM

A microprocessor control system (DCS) is used to control and monitor the performance
throughout the plant.
A Bailey INFI90 DCS supports a de-centralized hierarchical structure which allows for
maximum mobility and flexibility to different plant locations. Thus control functions and data
processing can be undertaken at the detailed plant area while at the same time retaining
the ability to operate all control functions from the center. It is sufficiently flexible to serve a
wide range of requirements at loop and component level without any changes to
hardware.
The DCS includes:
The process control unit
The data communication system
The operator interface
A dedicated engineering workstation (EWS) provides for fast off-line development of
control strategies.
The automation system design operates on a principle of high availability level.
The DCS which is in place ensures a safe, reliable, available, economical and simple
operation of the boiler turbine generator units, together with their associated auxiliary
plants.

AUXILIARY PLANTS
In addition to the main electricity production and fuel storage facilities, the
plant has auxiliary plant or sub-plant facilities which include:
A desalination plant to convert sea water into feed, demineralised and
potable water
Water and waste water treatment plant
RFO and lubricating oil processing plant
Safety equipment
A fire fighting system
Hydrogen gas generation facilities
An auxiliary boiler house

CONNECTION TO THE WAPDA GRID

Each generator is connected by a 21.5

kV/500 kV step-up transformer to a gas
insulated switchgear outdoor substation
which in turn is connected to two
overhead export lines designed by
WAPDA and constructed by Saudi Cable
of Saudi Arabia. Two station transformers
supplied from the 500 kV substation
provide power for start up of the Plant
and for common services

REFERENCE TARIFF FOR 660 MW IMPORTED COAL ON FOREIGN FINANCING

NEPRA has determined and approved the

provided upfront tariff for China
Power Hub Generation Company (Pvt) Limited
at Hub Baluchistan and
adjustments/indexations for imported coal
power generation for delivery of electricity to
the power purchaser.

Environmental Concerns
According to the financial statement, the
Balochistan Environmental Protection Agency
has granted CPHGC a no-objection certificate
for initiating work on the hub power plant and
construction work at the site has been started
a long ago.
Earlier, HUBCO conducted an environmental
and social impact assessment study, with the
assistance of renowned consultants Hagler
Bailey and submitted a report to the
environmental protection agency.
This was followed by a public hearing as well.
The remarks of the report were quite
satisfactory concerning the plant.

SOCIO-ECONOMIC BENEFITS
The project shall be instrumental in socioeconomic uplift of the remote area of Hub
The project construction will provide
employment opportunities through induction of
skilled, semi-skilled and unskilled workforce for
the project besides adding a significant amount
of power output to the national grid.
Hub coal power project will not only bring
prosperity to the country but will also accelerate
the pace of development in Balochistan by
generating employment opportunities for the
local population

SUMMARY OF PROJECT COST

The following subject to adjustments at the

time of COD.
The minimum reference net LHV thermal
efficiency of 39% has been established for
calculating reference fuel cost component.
project cost for 660MW has been assumed in
the upfront coal tariff which will be
Plant Size Fixed O&M
Variable O&M
660 MW Rs.0.287/kW/h Rs.0.114/kWh

 The financial closing of the plant is expected

by August 2016, with the project likely to come
online in 2020 at the latest, with an early target
set for 2018. Once completed, it would be
one of the biggest private-sector investments
in the country.
According to reports, the plant is expected to
utilize at least thirty percent local
subcontractors and suppliers a mandate set
up by the Pakistan Engineering Council which
issues constructors and operators licenses for
such projects.
So in the long term, the project can also help
the Pakistani government gradually adjust the
nations energy and electricity structure,
optimize the investment environment and
facilitate infrastructure construction, which will
contribute to the public good,