Project Brief

Malakand-III Hydropower Project was identified after the construction of Auxiliary Tunnel under Swabi SCARP on the Upper Swat Canal System. The Upper Swat Canal System was completed in 1918. It emanates from the Swat River at Amandara Head Works and irrigates 121,400 hectares of land.

Due to increase in irrigation water demand the Amandara Head Works was upgraded under the Swabi SCARP and another auxiliary tunnel, parallel to the existing Benton tunnel was constructed to carry the increased design discharge of 51 Cumecs. In order to avail this additional discharge for hydropower, before it is fed into Machai branch, the Malakand-III Hydropower Project having a capacity of 81 MW was conceived. This project was proposed to be operated in conjunction with the two existing power stations of Jabban and Dargai keeping in view the variation in water availability in Swat River.

It is important to add that subsequent to the feasibility of Malakand-III, it was identified that 25,000 acres of land can be irrigated under the project, in addition to hydel benefits. Therefore, from the outlet of sediment excluder of Malakand-III HPC “Baizai Scheme” was constructed and which irrigates about 25,000 acres of land.

Malakand-III Hydropower Project was completed in 2008 and interconnected with National Grid through 132 kV Dargai Grid Station. The power generated is being sold to NTDC under a Power Purchase Agreement (PPA) with NTDC for 25 years. The rate for sale of power to NTDC has been determined by NEPRA. The Project had achieved its Commercial Operation Date (COD) on November 1, 2008.

Overall, the Malakand-III Hydropower Project stands as an important source of renewable energy, contributing to the power supply of the region while also facilitating irrigation for thousands of acres of land. It exemplifies the successful utilization of water resources for both electricity generation and agricultural development, making it a crucial infrastructure project for the region's socio-economic growth. Till date the power plant has generated over 40 billion revenues to the government exchequer.

Salient Features

Capacity	81 MW
Design Discharge	51 m3/s
Net Head	181 m
Length of Power Tunnel	3.3 km
Annual Energy	549 GWh
Project Cost	Rs. 5750 Million
COD	1st November 2008
Tariff
Levelized (1-25 Years)	4.0294 Rs/kWh

                                                               

Innovation & Achievements

Innovation Steps (Indigenous Major Overhauling)

For the first time, the major overhauling of unit # 3 was carried out without foreign technical assistance. Expertise from the local market were engaged through O&M Contractor and successfully completed the major overhaul. This innovative step improve the turbine efficiency of the hydropower plant by up to 15%. As a part of the efficiency improvement efforts, stability in machine operation was achieved. This is crucial for smooth and reliable power generation without unexpected shutdowns or disruptions.

Challenges Faced During Year (2022-23)

Due to heavy rain and flooding in upper swat canal during the month of August 2022 arrival of heavy trashes, sand/ silt in forebay and sediment, resulting in choking of trash racks and cooling water systems. Due to influx of heavy sand the underwater parts of turbines such as head cover, wicket gates, bottom ring, and runner are eroded by abrasive sand particles. This led to multiple plant shutdowns during the peak season and a substantial loss of turbine efficiency. The unit operated at partial load due to unstable bearing temperatures and heavy vibrations in the unit.

Achievements

1.   The initiatives for turbine efficiency improvement and stability in machine operation resulted in an improvement in the plant availability factor. This indicates that the hydropower plant was operational and available to generate electricity more consistently. The implementation of innovative steps, particularly the improvement in turbine efficiency, led to an increase in the annual energy generation of the hydropower unit. As a result, it can be expected that more electricity will be generated in the next financial year (Financial Year 2023-24).

           The major overhauling of unit # 3 was completed in a short period of 50 days. After successful completion of the major overhauling, Unit #3 was synchronized with the National Grid and operated at its maximum load of 27.10 MW. This achievement highlighted the restored capacity of the unit to generate electricity at its full capacity.

2.        The successful completion of the Demonstrated Complex Energy Test (DCET) conducted from June 08 to June 09, 2023 witnessed by CPPAG test witnessing Team. The test demonstrated that the hydropower complex can generate energy equivalent to 81.480 MW.

Overall, the innovative steps and achievements at the Malakand-III Hydropower Complex signify the commitment to improve plant efficiency, optimize operations, and to achieve the generation capacity.