Kafue Gorge hydroelectric plant and 330 kV high-voltage distribution

Power technology

Location:	Zambia, South Africa
Systems/technology:	ABB Master Piece
Client:	Zesco, Zambia, through Comelex and ABB High Voltage
Implementation:	2004 - 2006

Project description:

The power plant switch gears and high-voltage systems in Kafue Gorge are the largest energy provision systems in central Africa. The Kafue Gorge hydroelectric plant and the 330 kV high-voltage distribution system began operations in the early seventies, making them over 30 years old.

On the high voltage side, in the early nineties, a power grid system was added, and in the mid-nineties, a new high-voltage control system; at the beginning of the millennium, a new high-voltage protection system was commissioned. No renovations had been made to the primary systems since the plant was built. On the power plant side, a new power plant controls system was also commissioned in the mid-nineties. No renovations had been made to the generator switch, the power plant switching system, the power transformers, or the generator protection system since the plant was commissioned.

The operating company, ZESCO, Zambia, had decided on a general overhaul of the high-voltage primary system and the power plant switching system, as part of the general overhaul of the power plant turbines. Some of the individual system components were also to be completely renovated, and some only modified. With the help of our consultant, SwedPower, ZESCO generated the concept for converting the plants, and contracted with a consortium for its implementation via an international request for proposals.

INP Switzerland took on the project planning of the open-air switchyard, and part of the power plant switch gears, as a sub-contractor of a consortium partner (ABB). The project planning job included all associated planning and renovation phases, as well as site and installation management, startup of the primary side components of the high-voltage equipment.

In the course of project implementation, INP Switzerland took on the role of an external consultant, and pointed out to the operating company, ZESCO, and to the customer consultant SwedPower, weak points in the project planning and execution of the secondary side system components, as well as problems with interfaces. INP Switzerland then generated a new concept for all of the secondary side systems, taking into consideration which sub-systems could be re-used, and which required replacement.

INP services

• Consulting
• Development of the lubrication scheme
• Planning and detailed project planning of the renovation of the 330 kV switchyard
• Project planning and calculation of construction work, especially foundations
• Mechanical project planning and calculation of steel columns, insulators, etc.
• Generation of purchasing and material BOMs
• Generation of a list of actions, with work instructions, for the overhaul of the components that were reused
• Development of schedules
• Generation of documentation
• Development of a block diagram for the secondary side 
• Description of a lockout system covering the power plant and high-voltage systems
• Description of the secondary side systems and auxiliary plants
• Description of interfaces with: power grid system, high-voltage protection, high-voltage controls systems, transformer protection, generator protection, power plant controls systems, lockout system, and auxiliary plants
• Description of an operating and display concept for the entire system

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