Hub Power Station

The Hub Power Plant consists of four generating

units each rated at 323 MW gross output, with an
oil-fired single re-heat boiler and tandem
compound, two cylinder condensing steam
turbines directly coupled to a hydrogen cooled
generator. The design net available output is
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

The Hub Power plant is one of the most efficient oil

fired thermal plant and can provide 10+% of
countrys electricity demand. The plant is operated
in such a way that it is available at a short notice
during high demand period and can switch to
flexible operations during low demand periods.

The Hub Power Station site has an ongoing

proactive approach to safety management.
Stations commitment to safety procedures has
already earned it with Royal Society for Prevention
of Accidents (RoSPA) Gold Awards consecutively
for the last many years.

Technical Details

The Plant

The Construction Contract was signed with a

construction consortium in July 1991, to provide
 engineering, procurement, construction and
commissioning for a 1292 MW power plant on a
lump-sum, turnkey basis. The construction
consortium included:

Mitsui and Co. of Japan, consortium and

commercial leader;
Ansaldo ENERGIA of Italy, technical coordinator
and designer and supplier of the turbine
generators;
Ishikawajima-Harima Heavy Industries Co. Ltd of
Japan, designer and supplier of the boilers,
Campenon Bernard SGE SNC of France, the civil
contractor.

The Plant consists of four generating units which

are each rated at 323 MW with an oil-fired single
re-heat boiler and tandem compound, two cylinder
condensing steam turbines directly connected to a
hydrogen cooled generator. The net available
output power of 1200 MW is exported to the Water
and Power Development Authority (WAPDA) grid by
means of the stations 5OOkV switchyard. Fuel is
received by pipeline from Pakistan State Oil (PSO).
Load tanker unloading facilities are also available.

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 feedwater 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%.

Activities on the site began with soil investigations

in January 1993; two months later, work on site for
temporary structures could begin and within eight
months, work had started on the permanent
structures. The first energisation of the GIS
substation and start-up transformer took place in
February 1996; the first unit was first operated at
full load in June 1996.

The entire plant was fully commissioned on March

31, 1997.

The Condenser and Feed 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 to a siltation setting basin and than
through an open inlet canal some 650m long to the
circulating water pump house. 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.
 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

deionised 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 despatched to WAPDAs

grid through two overhead 500 kV lines through a
half-breaker scheme, SF insulated substation.
There are also two start-up transformers. Station
power supply and unit auxiliary power supply are
 provided to minimise 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.

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 decentralised
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 centre. 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

Arrangements for Despatch

Connections to the WAPDA Grid

Each generator is connected by a 21.5 kV/500 kV

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

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