ASSOCIATED TECHNOLOGIES (PVT) LIMITED

FEASIBILITY STUDY REPORT

Executive
Summary
FEBRUARY 2014



545 MW KAIGAH
HYDROPOWER PROJECT

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Kaigah Hydropower Project Executive Summary

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Table of Contents

1. PROJECT HISTORY ................................................................................................... 4

2. PRESENT STUDY ....................................................................................................... 4
3. CONFIGURATION OF FEASIBILITY STUDY REPORT ............................................. 6
4. SALIENT FEATURES ................................................................................................. 6
5. PROJECT LOCATION ................................................................................................ 7
6. ACCESSIBILITY .......................................................................................................... 8
7. TOPOGRAPHIC AND HYDROGRAPHIC SURVEYS ................................................. 9
8. HYDROLOGY & SEDIMENTATION .......................................................................... 10
9. GEOLOGICAL AND GEOTECHNICAL STUDIES .................................................... 10
10. NEOTECTONICS AND SEISMIC HAZARD ANALYSIS ....................................... 12
11. PROJECT LAYOUT STUDIES .............................................................................. 12
11.1. Stream Flow Records ....................................................................................... 13
11.2. Hydraulic Scheme ............................................................................................. 13
11.3. Geological and Geotechnical Restrictions ..................................................... 14
12. CAPACITY OPTIMIZATION AND POWER POTENTIAL ...................................... 15
13. DESIGN OF PROJECT STRUCTURES ................................................................ 15
13.1. Diversion Tunnel ............................................................................................... 15
13.2. Pre-Cofferdam ................................................................................................... 16
13.3. Upstream Cofferdam ........................................................................................ 16
13.4. Downstream Cofferdam ................................................................................... 16
13.5. Dam .................................................................................................................... 16
13.6. Spillway .............................................................................................................. 17
13.7. Bottom Outlet .................................................................................................... 17
13.8. Intake Structure ................................................................................................. 18
13.9. Headrace Tunnel ............................................................................................... 19
13.10. Surge Tank ........................................................................................................ 20
13.11. Powerhouse, Cavern of Transformers and Appurtenant Works .................. 20
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13.12. Discharge Works ............................................................................................... 21

13.13. Thauti Nullah Derivation and Headrace .......................................................... 22
14. MECHANICAL EQUIPMENT ................................................................................. 22
15. ELECTRICAL EQUIPMENT STUDIES .................................................................. 24
16. POWER TRANSMISSION LINE STUDIES ............................................................ 24
17. TRANSPORTATION STUDY ................................................................................. 24
18. ENVIRONMENTAL STUDIES ................................................................................ 26
19. COST ESTIMATES & FINANCIAL ANALYSIS ..................................................... 26

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EXECUTIVE SUMMARY

Kaigah Hydropower Project has been proposed on the River Kandiah, a tributary of River
Indus upstream of proposed Dasu Hydropower Project. The Project area is spread from
upstream of Karrang village to a few kilometers downstream of Thuati Bridge in Kandiah Valley
with profile length of approximately 23 km. The site is accessible from Islamabad via
Mansehra-to Thakot and via Karakorum Highway to Dasu town at 340 km from Islamabad.
The Project site is about 55 Km from Dasu town.


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1. PROJECT HISTORY

With the financial assistance of Canadian International Development Agency (CIDA) to
Pakistan, identification of Hydropower Potential on Rivers Indus, J helum and Swat started
during 1980s, and Montreal Engineering Company Limited (MONENCO) was engaged to
undertake the preparation of an inventory of potential hydropower generation sites, alongwith
their ranking.
Later, during the eighties and nineties, identification and ranking studies for hydropower
schemes on the Rivers and tributaries of Azad J ammu and Kashmir (AJ K) and Khyber
Pakhtunkhwa (KPK) including Northern Areas of Pakistan were also carried out by WAPDA
and Pakhtunkhwa Hydel Development Organization (PHYDO) in collaboration with the
German Agency for Technical Co-Operation (GTZ). A number of sites for development of
small and medium size hydropower projects, including Kaigah Hydropower Project in the
Kohistan Valley, with power potential of 548 MW, were identified.
PPIB issued LOI to the sponsors in 2008. Associated Technologies (Pvt) Limited (ATL) is the
Main Sponsor and Consultants of Colombian origin M/s. Integral S.A. were taken on board to
carry out the Feasibility study and prepare a bankable Feasibility Study Report (FSR).
2. PRESENT STUDY

A number of site studies and analyses have been made for all Project components, including
the location of dam, spillway, diversion and power / headrace tunnels and the powerhouse.
Reservoir level is fixed at 1500 m.a.s.l taking into account the proposed upstream Karrang
Hydropower Project.
The Consultants studied four layout options with the project components on the right and left
bank side. Drill & Blast alongwith TBM underground construction methods were analysed.
Detailed studies have been carried out for alternative under consideration. As a result of these
studies left bank alternative has been selected for its technical and economic viability.
The left bank layout proposal has a headrace system composed of the main headrace tunnel,
pressure shaft and three penstock tunnels that will deliver the water to the three turbines of
the project. The headrace tunnel is of approximately 17 km of length with five horizontal curves
with the radius 3 times the diameter of tunnel and a constant slope of 1%. At the end of the
headrace the pressure shaft begins and connects with the powerhouse.
Drill and blast construction method is being considered for the excavation of headrace tunnel
and pressure shaft.
The underground powerhouse is located on Thauti Nullah right bank, followed by tailrace
tunnel of 3.3 km in length until it discharges in the Kandiah River.
The powerhouse is of cavern type where the turbine-generator sets for the three generator
units and the other auxiliary equipment are located. In a parallel cavern the power
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transformers and the corresponding auxiliary equipment are to be installed. The two caverns
are interconnected by an access gallery between the main floors, and by three bar output
galleries.
The scheme has the possibility to include two additional intakes at Thauti Nullah, with a total
additional discharge of 11 m
3
/s, which will increase the annual energy production, and have a
positive impact on the economic viability. At the chainage 13360 m, the Thauti Nullah
headrace tunnel will deliver the water from the Thauti Nullah river to the main headrace tunnel.

To firm up the location of the project components detailed surface and sub-surface geological
and geotechnical investigations have been carried out. More than 1100 m of drilling was done
along with test pits and geological mapping.
These investigations have shown a thick alluvial layer on the dam site, which played an
important role to decide the configuration of the dam as Asphalt Faced Rockfill Dam (AFRD).
Detailed neo-tectonic and seismic hazard and risks studies were also carried out, keeping in
view high seismic activity of the area.
The overall findings of the EIA studies show that the Kaigah Hydropower Project is
environmentally and socially viable subject to the development and implementation of a full
Environmental Management Plan brought out in the study.
Detailed construction schedule of Kaigah Hydropower Project has been estimated to be
completed during a period of 55 months.
The EPC cost estimate for Civil and E&M Works along with detailed BoQs is provided in
chapter for costs while the Non-EPC Costs are estimated based on best international practices
and in line with the costs finalized for all other similar projects in Pakistan. The Total Estimated
Project Cost is 1,564.761 million USD.
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Cash flows of Project are discounted at the cost of capital (6.79%) and the NPV of the Project
resulted into USD 464.07 million, which passes the NPV test for the acceptance of Project as
a profitable investment.
3. CONFIGURATION OF FEASIBILITY STUDY REPORT

The Feasibility Report has been prepared in fourteen (14) volumes, which are:
a) Volume 1 Main Report
b) Volume 2 Topographic Survey Study Report
c) Volume 3 Hydrology and Sedimentation Study Report
d) Volume 4 Geological and Geotechnical Study Report
e) Volume 5 Neo-tectonic and Seismic Hazard Analysis
f) Volume 6 Hydropower Planning Study Report
g) Volume 7 Dam & Generation Works Study Report
h) Volume 8 Mechanical Equipment & Hydraulic Steel Structures
i) Volume 9 Electrical Equipment Study Report
j) Volume 10 Transportation Study Report
k) Volume 11 Transmission Line Study Report
l) Volume 12 Environmental & Social Impacts Assessment Study Report
m) Volume 13 Cost Estimates & Financial Analysis
n) Volume 14 Project Drawings

4. SALIENT FEATURES

This report has been finalized with the salient features described as under.
Hydrology (Design flows)
Design discharge 125 m
3
/s
Mean Annual Flow 68.3 m
3
/s
Design flood (PMF) 2113 m
3
/s
Reservoir
Reservoir length 3500 m
Reservoir area 74300 m
2

Max. reservoir operating level 1500 m.a.s.l
Min. reservoir operating level 1480 m.a.s.l
Reservoir capacity at 1500 m.a.s.l 40.39 MCM
Reservoir capacity at 1480 m.a.s.l 19.65 MCM
Dam Structure
Dam height 100 m
Dam crest level 1510 m.a.s.l
Dam crest length 400 m
Spillways
No. of Bays 1
Number of gates Ungated
Discharge capacity 2150 m
3
/s
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Bottom Outlet
No. of bays 3
Guard gate type sliding gate
Guard gate size (WxH) 3.0 x 6.0 m
Gate type Radial gate
Gate size (WxH) 3.0 x 6.0 m
Discharge capacity 407.5 m
3
/s
Power Waterways
Power Intake
Type
Deep Frontal
dd ti

No. of gates 2
Gate size (WxH) 5.3 x 6.7 m
Deck elevation 1511.0 m.a.s.l
Intake sill level 1464.0 m.a.s.l
Headrace Tunnel
Diameter 7.7 m
Length 17058 m
Surge Shaft
Diameter 5.30 m
Height 38.67 m
Surge Tank
Diameter 10.5 m
Height 260 m
Power Generation
Gross head (HWL-Turbine centre line) 527.35 m
Max. Net head 523.9 m
Min. Net head 480.0 m
Plant Design discharge 125 m
3
/s
Installed plant capacity 545 MW
Plant Factor 44.24 %
Turbine Type Pelton vertical
No. of units 3
Turbine centerline level 972.65 m.a.s.l
Generator 3
Design Annual mean energy 2112 GWh
Power house type Cavern .
Size of powerhouse (LxWxH) 105.5x27.1x47.9 m.
Transmission line 500 KV
Tailrace Tunnel
Size of tunnel 8 m
Length of tailrace tunnel 3,383.4 m

Project Cost 1564.8 MUSD
Levelized Tariff 9.5 Cents/KWh

5. PROJECT LOCATION
The proposed Kaigah Hydropower Project is identified along Kandiah River with dam near
Karrang village and powerhouse site is on left bank of Kandiah River.
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Kandiah River has its confluence with the Indus River near Kandiah Bridge, about 20
kilometers upstream of Dasu town.
Table 5-1: Coordinates of Dam and Powerhouse Site
Site Latitude Longitude
Dam site 35-28-26.9 72-58-16.9
Powerhouse site 35-28-49 73-08-34

The dam site identified near Karrang village is about 28 km in the Kandiah valley from the
confluence of Indus and Kandiah Rivers. It has a reservoir spread over 4 km in the
upstream valley. The dam axis is proposed downstream of confluence of Bangroan Khwar
on the right bank and of Dadli Khwar on the left bank where the Kandiah valley becomes
narrow and the valley slopes become steep and form the entrance of a ravine.
The River bed elevation at dam site has been observed as 1420 m a.s.l and reservoir
level is proposed as 1500 m.a.s.l. The headrace tunnel crosses the mountains on the left
River bank to the powerhouse cavern, which is situated on the left Kandiah bank near
Thauti village. Previously, the headrace tunnel was proposed on the right bank of Kandiah
River which followed a nearly straight line upto then proposed powerhouse location just
opposite to the village Kaigah, on the right bank of River Indus.
The powerhouse cavern was proposed at an elevation approximately 800 m a.s.l but to
cater for the proposed Dasu Hydropower Project, cavern had to be shifted ahead of the
maximum reservoir level of approximately 950 m.a.s.l.
6. ACCESSIBILITY
Dasu town is located about 340 kilometers from Islamabad. The main accessibility to
Dasu town from down country is through the Karakoram Highway. Dam site is accessible
from Dasu town by a jeepable road. Karrang village is located on Kandiah Kalam Road
about 30 kilometers from Kandiah Bridge and connected to the latter through a jeepable
road which has been badly damaged by flashy floods of 2010.
A jeepable road exists in Kandiah valley on its right bank between KKH upto a few
kilometers upstream of Karrang village. The scheme is recommended to be constructed
before upstream identified project Karrang is developed, therefore the improvement of
existing roads and construction of new access roads between KKH and Karrang are
necessary. The access road must be designed for heavy loads.
The construction of an Indus bridge is necessary to connect the next access road system
in Kandiah valley with the KKH on the left Indus bank. It is estimated that about 28 km
long length of the truckable roads is necessary to be upgraded, including some bridges
to make the various construction sites accessible.
Post flood 2010 conditions necessitate to rebuild the damaged portion of road within
Kandiah valley.
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Adit roads of good quality are of huge importance for the construction and maintenance
of the plant. Additionally the roads shall serve as an improvement in living standards of
the local people by providing them better accessibility, improved medical care and better
education facilities. The present condition of the few roads and the mule paths is poor.
The terrain is characterized by steep embankments in narrow valleys. The roads and mule
paths are subject to landslides, rockfall and avalanches. Therefore, a good quality of
design and construction of the roads is essential.
It has to be mentioned, that the design of the roads has been carried out to prevent
blockage of the road by rockfall, landslides or avalanches as far as possible considering
a justifiable expenditure, but it can not be excluded totally.
Therefore, it will be necessary to provide appropriate equipment (e.g. bulldozer) for
cleaning of the roads or perhaps to close the road for few days due to the danger of
avalanches. For the purpose of road maintenance, local people could be employed.
7. TOPOGRAPHIC AND HYDROGRAPHIC SURVEYS
The topographical survey and mapping comprised of the following elements:
Initial reconnaissance and collection of available data.
Establishment datum and detailed location of ground control points (GCP) for Kaigah
Hydropower Project.
Acquisition of SPOT-5 Digital Elevation Model (DEM) data for the whole project area
(30 m raster data).
Derivation of Digital Elevation Models for the reservoir area from SPOT-5 data and
GCPs.
Topographical mapping of the whole project area using DEM data.
Detailed topographical ground survey and cross sections in the areas of the main
structures of the project and the reservoir:
Dam site and reservoir area 1:1,000
Powerhouse site 1:1,000
Project Layout 1:5,000
The survey has been carried-out for four alternative project layouts, which have been
conceived and selected for field work. The survey locations have covered the weir,
reservoir, power intake, surge shaft, pressure shaft, powerhouse and tailrace areas.
Topographic survey work has been conducted for accessible areas and longitudinal profile
of potential stretch of the Kandiah River. The survey maps, profiles and cross sections of
the river are presented in Volume 2 (Topography and Surveying)
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8. HYDROLOGY & SEDIMENTATION

The hydrological studies have been carried out to establish the proposed project for an
optimal development of hydropower scheme on Kandiah River. The following main
aspects of hydrology and sedimentation were studied in the present work and have been
described in subsequent sections:
Climate
Estimation of flows
Estimation of Flood
Sedimentation
Moreover, a stage-discharge measuring gauging station has been installed on Kandiah
River near Thauti village which is in operation since April 2012.
Probable Maximum Flood (PMF) has been worked out as 2113.7 m
3
/s whereas estimated
sediment transport for Kandiah River catchment is 1.66 - 2.88 Mt/yr.

The floods at proposed dam and powerhouse sites are obtained by the regional flood
analysis are given in Table 8-2.
Table 8-2: Floods at Proposed Dam and Powerhouse Sites
Return Period
(years)
Flood (m
3
/sec)
Dam Site Powerhouse site
1800 (km
2
) 2374 (km
2
)
5 997.0 1173.9
10 1118.5 1309.6
100 1716.1 1970.9
1000 2170.2 2471.7
10,000 2667.3 3029.5

Dam Break Modelling has also been performed and is included in Volume 3 of the
Feasibility Study Report.
9. GEOLOGICAL AND GEOTECHNICAL STUDIES
Based on the geological mapping, drilling boreholes, seismic refraction survey and test
pits performed and the field observation undertaken in the dam area; it was detected
unconsolidated material including fans, terraces, talus and scree on slope faces. On other
hand, the depth of the alluvium deposit was found to be at less 100 m under the river bed
and the width varies between 150 m to about 350 m at the widest point according to the
geotechnical investigation performed in the dam zone; these factors are duly considered
in the Dam & appertenunt structures design.
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The geomechanics and geology characterization were conducted according to the results
of the field investigation and the laboratory test and constitute Volume-4 of the Feasibility
Study Report.
The field investigations have been carried out to explore its influence in the area of works.
Eleven boreholes were drill at the Dam site and three at the powerhouse.
Table 9-1: Boreholes at Dam and Powerhouse Site Area
Borehole
number
Depth (m) Location
1 90 Right abutment and spillway
2 100 River bed, right abutment
3 100 River bed, right abutment
4 90 Left abutment
5 50 Left abutment
6 30 Left abutment near SL-1
7 50 Left abutment near SL-5
8 30 Left abutment
9 30
River bed, right u/s of Dam axis near under
sluice-1
10 90 Right bank
11 50 Right bank near spillway-1
14 200 Surge Tank and power house
15 30 Intake 2
16 100 Low zone Thauti Nullah

The permeability of the rock was obtained from the Lugeon test performed in the drilled
boreholes. The results data was assuming to be a representative data for the rock mass
even if no representative data were obtained in other areas of the project.

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10. NEOTECTONICS AND SEISMIC HAZARD ANALYSIS

For the neotectonic studies of Kaigah Hydropower Project, a good basis is provided by the
Geological Map produced by Searle and Asif (1995) and Geological Map of the J ijal- Dasu
Region, Indus Kohistan, NW Pakistan produced by Gerold Zeilinger (2001) which indicate
the various lithological units and faults of the area identified on the basis of geological
mapping conducted along the Karakoram Highway (KKH) and up several tributary valleys,
further supported by satellite image interpretation.
Based on the desk study and field observations following conclusion are made;
Kandiah valley lies in the Khostan Isand Arc, which is sandwitched by the MKT (Mian
Karakorum Thrust) in the north and MMT (Main Mantle Thrust) in the south. The
geology is dominantly comprise Chilas Complex (CC) rocks with subordinate pendants
of Gilgit Complex meta-sedimentary rocks (Gm).
In the valley, terraces are present both in uniformly layered and disturbed forms, Since
the region is characterized by steep slopes where erosion is predominant over
deposition, interaction between faults and younger sedimentation is not likely to be
determined in this region.
Small scale faults and shearing besides the major lineaments have been observed in
rock units during field observation which appear to be the result of localized
adjustments to release the accumulated stress induced by the regional stress regime.
The overall study lead to suggest that the movement has occurred before the recent
period of deposition as no evidences have been observed to support the recent activity.
However, these findings are not intended to be considered as the guideline for the
design of structures due to the reason that both MKT and MMT are active faults
surrounding the project area.
Also, Seismic Risk Analysis is performed in Volume-5 of the Feasibility Study Report.
11. PROJECT LAYOUT STUDIES
Four different layout options have been considered for the Project. A detailed comparative
analysis is performed in the Volume-6 of the Feasibility Study Report. The results clearly
show the economic benefits of the alternative by the left bank over right bank layout. Gross
revenues of the project would increase about 23 MUSD / year, which are equivalent to
189 MUSD, considering a useful life of 50 years and a discount rate of 12%.
On the other hand, the incremental costs of project at left bank increases to 47 MUSD, if
we compare this value with the NPV of revenues, it is found that the latter are far superior,
so that the Benefit / Cost represents an attractive indicator and, therefore, recommends
the development of left bank scheme.
The study of alternate layouts for the scheme is based on the following assumptions.
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11.1. Stream Flow Records

A design discharge of 125.0 m
3
/s on site project was defined at the early stage for the
feasibility study, which is available for about 22.0% of the time (on year to year bases)
based on the Flow Duration Curve for Kandiah River.
In case, the construction of two intakes on Thauti Nullah are also considered. A design
discharge corresponding to the mean annual flow was assumed for the study (11.0 m
3
/s).
11.2. Hydraulic Scheme
The layouts being considered for the proposed project are both on the left bank and right
bank of river Kandiah. The design criteria being fixed for different components of the
project such as headrace tunnel, tailrace tunnel, pressure shaft, adits and powerhouse are
as following:
The dam and discharge site were fixed during office studies using all the investigation
data and reports and were confirmed during the site visit for any alternative scheme.
There is not other possible site to pleace the dam.
The gross head initially proposed has been taken as such for this study along with the
reservoir operating level, turbine centreline level and discharge level.
Based on the various field studies, the installed capacity of the plant and design
discharge have been fixed.
It is also considered that the headrace tunnel and pressure shaft will have a flow speed
of 3.00 m/s in the concrete lining and 5.00 m/s in the penstock tunnel for pressurized
operation conditions.
The headrace tunnel will fall under rock cover criteria, where the weight of the rock,
vertically above the tunnel will be at least equal to the static water head and horizontally
at least twice the head. This criterion will apply to the powerhouse location as well.
The penstock length will be defined by a gradient of 3 to 1.
The slopes considered in the design will be such that the headrace tunnel will have a
slope less than 3% over its length due the construction method using railroad. In the
other hand the adits can have 12% of maximum slope and they are excavated to allow
gravity drainage.
The tailrace tunnel is proposed to operate at free flow with a flow height equal to 70%
of cross section height with 1,0 m/s design velocity for a design discharge of 125 m
3
/s,
and has 0.2% constant slope.
For the location of adits portals the important criteria is to consider the geological maps
and to stay away from fan deposits and talus presented in some sections of the river
bank.
In left bank layout presented is important the headrace tunnel crosses perpendicularly
the Kandiah valley fault and shorten the effective tunnel distance affected by it.
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11.3. Geological and Geotechnical Restrictions

Along the Kandiah River valley one can see a narrow and deep canyon of steep slopes,
locally smoothed at the bottom by Quaternary accumulations such as alluvial fans, colluvial
and fluvioglacial deposits. The rock on the slopes is covered by a very thin layer of
granular soils mainly due to physical weathering and abundant deposits of talus type
produced by the constant falling of rock fragments. For more detailed geological
information see the Geology Report (Vol-4). Main rock is the gabbronorite of Chilas
complex, very hard but highly fractured at surface, which outcrops along about 70% of the
headrace tunnel. Also appearing in the middle of the tunnel, as an isolated lithological body
covering about 30% of the tunnel, are psammites and green schist from Gilgit Complex,
these are weaker than the gabbronorite. Most of the bottom and base of the canyon slopes
are covered by talus, fan, moraines and alluvial deposits. Its potential instability could
produce slides because of which its geological and geotechnical condition have been
evaluated in the study.

Figure 11-1: Kandiah River Valley in the Dam Site

At the axis of the proposed dam there is rock of good quality at both abutments, with a
possible talus-colluvial deposit in the spillway zone. On the bottom, there is a wide
alluvium bed, probably of more than 50 m depth. Its characteristics are duly explored to
define the dam type.
In terms of geology and geotechnics there are no restrictions that do not allow the
construction of any of the project alternatives; however, the investigations and their results
have been employed to a logically correct conclusion.
The rock mass classification, in order to estimate the tunnel support, is based on GSI
parameter, which defines five rock types from R1 for the best to R5 for the poorest quality.
Table 11- based on Geology Report which gives rock type along with the percentage as
shown below;

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Table 11-1: Type of Zones Expected in Tunnels

Rock Type Percentage in the excavation
R1 47%
R2 14%
R3 4%
R4 31%
R5 4%

According to GSI classification, the tunnel is divided in different homogenous zones.
12. CAPACITY OPTIMIZATION AND POWER POTENTIAL
Based on the selected project layout (left bank) and the prefixed dam height, study was
carried out to find the optimal installed capacity.
Design discharge of 125 m
3
/s has been selected after deliberations. The Project is
designed for the power potential of 545 MW which yields 2112 GWh of annul energy. The
details are incorporated in Volume-6 of Feasibility Study Report.
13. DESIGN OF PROJECT STRUCTURES
The main features of the Project are summarized below and are discussed in Volume-7 of
the Feasibility Study Report:
Dam: will be an asphalt faced rock fill dam across the Kandiah River, 100 m height
and will develop a superficial reservoir area of approximately 1.500.000 m
2
.
Diversion tunnel: is located in the right bank of the river, 730 m length, is developed
in a D-section and is complemented by a pre-cofferdam, an upstream cofferdam and
a downstream cofferdam.
Spillway: has been designed to evacuate the probable maximum flood (PMF), is in
the left bank of the river and is set by three channel sections.
Bottom outlet: its purpose is to keep a useful volume of the reservoir of 20 million of
cubic meters, evacuating the sediments that can be deposit on it; is a structure
under the spillway structure which is a tunnel that will have a horseshoe section and
440 m length.
13.1. Diversion Tunnel
The diversion tunnel is located on the right bank of the River Kandiah, has a length of
730.00 m and has basically an intake structure where the closure gates are located, an
outlet structure, and a concrete plug for the final closure.
During the design flood of 879.20 m
3
/s, corresponding to 50 years return period the
maximum flow velocity in the tunnel will be of 15.70 m/s and the reservoir level will be of
1453.00 m.a.s.l. Based on that, the level of the upstream cofferdam has been set at
elevation 1455.00 m.a.s.l with a free board of 2.00 m.
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13.2. Pre-Cofferdam
The pre-cofferdam is formed of a rock-fill structure with upstream slopes of 2H:1V and
downstream slopes of 1.5H: 1.0V to retain the design flood of 407.50 m
3
/s (2.33 years
return period). The pre-cofferdam will have a crest elevation of 1445.00 m.a.s.l and 210
m width approximately without free board.
13.3. Upstream Cofferdam
It will be a rock-fill structure with upstream slopes of 1.8H: 1.0V and downstream slopes
of 1.5H: 1.0V to retain the design flood of 879.20 m
3
/s (50 years return period). The
upstream cofferdam will have a crest elevation of 1455.00 m.a.s.l, 220 m width
approximately and 2.00 m free board.
13.4. Downstream Cofferdam
It is a rock-fill structure with upstream slopes of 1.5H: 1.0V and downstream slopes of
1.5H: 1.0V to prevent the evacuated backwater flows by diversion tunnel interference with
the construction of the dam. The downstream cofferdam will have a crest elevation of
1425.00 m.a.s.l, 265.00 m width approximately and 2.00 m free board.
13.5. Dam
Two dam sites were considered. The dam location was defined by taking into account
several reasons, most of them regarding to geological and geotechnical aspects such as:
downstream of the dam area a narrower valley zone was detected; however, according to
the. The comparison shows that the geological conditions for dam axis -02 is poor on the
right abutment (heterogeneous properties of the deposit material (scree/talus material))
and flushing outlets with spillways has to be placed on the left bank. The right bank has to
be rock fill. Dam axis 01 provide additional 70 m gross head or 13% more power and
energy as compared with alternative dam axis. Considering these factors, dam axis -01
has been found techincally feasible and economically attractive.
The selection of the dam height of Kaigah project has two main constrains that practically
set it, without possibility to perform an optimization study.
The maximum high of the dam is given by the Tailrace Water Level (TWL) of 458 MW
Karrang HPP at level 1510 masl, according with GTZ report On the other hand the
minimum level of the crown of the dam is given by the necessary dead volume of the
reservoir to ensure its life without sediment flushing. According with calculations, the
useful capacity of the reservoir will be affected by the sediments, so a higher dam is
desirable but this is not possible for the reason given before. Finally, the height of the dam
is set as the maximum possible with out affect the tailrace level of Karrange project.
Given the particular characteristics of the project, this report discusses the possible dam
types considering: Earth-core rockfill dam (ECRD); Concrete face rockfill dam (CFRD) and
Asphalt face rockfill dam (AFRD), based on the compatibility deformational behavior of the
foundation and the availability of materials in the area. Others types of dams (Concrete
dams) were dismissed due to the depth required for the dam foundation (see Volume 7):
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In this study, the alternative of asphalt face rockfill dam has been selected; nevertheless,
given the similar conditions, the recommendations of this particular AFRD dam selection
is applicable to asphalt core rockfill dam as well.
The height of the dam is 90 m (100 m from foundations); the inclinations of the slopes are
1:1.5 for upstream and downstream is 1:1.65.
The face thickness of asphalt is 40 cm with two sealing layers and an internal drainage
filter.
The plinth of concrete reinforcement will be embedded in rock in the slopes and the alluvial
bed will consist of three slabs 2 meters articulated between slabs, called floating plinth for
not being in contact with the rock mass.
The foundation is considered a highly permeable medium, so it is considered necessary
to build a wall to ensure the tightness of the dam wall. The wall will have a length of 100
meters by 1 meter thick. With the length will reduce the hydraulic gradient approximately
67% under ideal sealing.
13.6. Spillway
The spillway has been designed to evacuate the probable maximum flood (PMF) of the
Project, which correspond to the maximum entrance flow to the reservoir of 2113.70 m
3
/s.
The ogee geometry was defined by the outlet flow (2113.70 m
3
/s) according to the US
Bureau of Reclamation criteria.
The spillway will be set by three channel parts with the next geometrical characteristics:
the first section will be a rectangular horizontal adduction channel, with variable section in
its width, which is expected to be found in rock; the second section will be 22.50 m constant
width and approximately 200 m length where are going to be slopes changes that will help
to develop velocities that wont represent a risk for the concrete durability. That section of
the channel will have a ogee, two piles, a slab and two lateral walls along the channel, and
a ski jump that will allow the water to advance in to the energy dissipator well; and the third
section correspond to the energy dissipator well where the water that is spilled will return
to the natural riverbed of the Kandiah River.
The stilling basin was designed to prevent the scour that will generate the impact of the
spillway water, considering different magnitude of floods that is expect to occur in the
structure. Stilling basin will be at 1395 m.a.s.l and will be set in vertical slopes, banks 10
m height and berms 3 m width between the 1395 and 1435 m.a.s.l.
13.7. Bottom Outlet
The bottom outlet structure consists of a horseshoe tunnel located on the left bank of the
Kandiah River; the invert of the tunnel at the entrance is placed at elevation of 1435.00
m.a.s.l and the invert of the outlet at 1415.00 m.a.s.l of the stilling basin that will be shared
with the spillway discharge. The major purpose of the structure is the evacuation of
sediments to keep a useful volume of the reservoir of 20 million of cubic meters.
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The length of the structure will be approximately 440 m and will have a constant slope of
4.60%. Its horseshoe section is a semicircular vault with a diameter of 13.00 m and 6.50
m in gables length, except in the section that corresponds to the sluice chamber in which
a larger space is available for the handling of three radial gates and their respective
auxiliary sliding gates.
The bottom outlet dimensions were defined to evacuate, by open flow, a flood of 407.50
m
3
/s, which corresponds to a 2.33 years return period. When the reservoir is at maximum
operation level and the three gates are totally opened, this structure will be able to
evacuate a flood of about 1150 m
3
/s.
13.8. Intake Structure
The following table summarizes the main features of the intake structure:
Table 13-1: Intake Structure Features
Hydraulic capacity - Design flow: 125.00 m
3
/s
Reservoir levels and crown dam
level
- Minimum operating level: 1480.00 m.a.s.l.
- Maximum operating level: 1500.00 m.a.s.l.
- Maximum water level in 100 years of return period:
1501.30 m.a.s.l.
- Maximum water in 1000 years of return period:
1501.50 m.a.s.l.
- Maximum probable water level: 1508.00 m.a.s.l.
- Crown dam level: 1510.00 m.a.s.l.
General layout
- Intake structure located on the left abutment of the
reservoir, near the dam and immediately upstream
of the bottom outlet.
- Deep Frontal adduction, consisting on a reduction
rectangular section. It is equipped with a trash rack,
a trash cleaning equipment and two gates as it is
detailed below.
- Vertical tower divided into three pits: a) auxiliary
gate b) service gate: c) aeration pit.
- Lower floor of the intake: 1464.00 m.a.s.l.
- Operation floor: 1511.00 m.a.s.l.
- Maintenance floor 1502.00 m.a.s.l.
- Floor Foundation of the Structure and approaching
channel: 1460.00 m.a.s.l.
- Total height of the structure: 51.00 m
- Height of the bridge crane: 10.00 m
Intake submergence
- Measured between the minimum reservoir
elevation and level of the top intake gate: 9.30 m
Trash rack
Inclination
- 80 respect to horizontal axis
Trash rack type
- Fixed rack divided into six modules, each one with
net area of 23.65 m
2
, 4.30 m wide and of 5.50 m
high
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- Minimum size retained by the rack: 40 mm,

corresponding to the spacing between bars,
defined by the type of Pelton turbine.
Gross design speed
- Maximum gross speed: 0.88 m/s
Net speed without obstruction rack
- Net speed water between bars with the plant at full
capacity: 1.25 m/s
Net speed with 25% obstructed rack
- Net speed water between bars with the plant at full
capacity: 1.70 m/s
- The retained waste by the trash rack will be
removed through a trash cleaning equipment.
Auxiliary and main gates
Features
- Vertical gates.
- Threshold elevation: 1464.00 m.a.s.l.
- Elevation lintel: 1470.70 m.a.s.l.
Dimensions
- Width: 5.30 m
- Height: 6.70 m
- Width / Height: 0.79
- Speed: 3.52 m/s
- Pressure: H=36.00 m
Close type
- Main gate: it closes against flow; It works with
hydraulic hoist.
- Auxiliary gate: it closes with balanced pressures;
operated by the bridge crane.
Crane
- Operative Distance: 8.40 m
- Capacity: 40.00 ton

13.9. Headrace Tunnel
The headrace system of the Kaigah Hydropower Project is composed of the main
headrace tunnel, pressure shaft and three penstock tunnels that will deliver the water to
the three turbines of the project.
The headrace tunnel begins from the intake structure near the Karrang village and ends
at 17 km downstream of the dam site with the connection with the pressure shaft; three
adit tunnels are proposed to construction and equipment access to the tunnel during the
construction stage and future inspection. The adit tunnel 1 and adit tunnel 2 are located at
5.1 km and 10.5 km respectively and will allow the access in the intermediate part of the
tunnel; and the adit tunnel 3 located at 17.02 km will allow the access to the connection
of the headrace and the pressure shaft. At the chainage 13360 m the Thauti Nullah
headrace tunnel will deliver the water from the Thauti Nullah to the main headrace tunnel.
In addition the pressure system will be protected by a surge system composed by an
elevator shaft of 1.5 m radius of 67 m length and surge tank of 6 m radius of 265 m length.
This system will control the hydraulic oscillation protecting the system against water
hammer.
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The pressure shaft begins at chainage 17.06 km. This branch is inclined and divided in the
last part into three horizontal independent penstock tunnels that will deliver the water to
the three turbines located in the powerhouse.
The characteristic and assumed criterion are described in the following part and detailed
in the drawings (see Volume 14).
13.10. Surge Tank
The surge system is located immediately upstream at the beginning of pressure shaft. Its
geometry is on a vertical axis and consists of an elevator shaft followed by an restricted
orifice and an surge tank which goes out to a yard at elevation 1600 m.a.s.l., and an
exterior protection structure of 4.00 m high.
The surge tank has concrete lining with circular cross section with diameter and heights
as follows:
Elevator shaft: D=5.30 m; and H=38.67 m, between elevations 1299.48 m.a.s.l. and
1338.15 m.a.s.l.
Restricted orifice: D=3.00 m at elevation 1340.00 m.a.s.l.
Surge tank: D=10.50 m; and H=260.00 m, between elevations 1340.00 m.a.s.l. and
1600.00 m.a.s.l.
Exterior protection structure: D=10.50 m; and H=4.00 m on a yard.
The surge tank has the following levels:
Static level: 1500.00 m.a.s.l.
Normal operation level: 1476.00 m.a.s.l.
Maximum oscillation level: 1580.00 m.a.s.l.
Minimum oscillation level: 1361.00 m.a.s.l.

13.11. Powerhouse, Cavern of Transformers and Appurtenant Works
The powerhouse consists of a cavern where the turbine-generator set for the three units
and the other auxiliary equipment are located. In a parallel cavern the power transformers
and the corresponding auxiliary equipment are localized. The two caverns are
interconnected by an access gallery between the main floors, and by three bar output
galleries.
The access to the powerhouse is through a two-way vehicular tunnel that starts from a
yard. The tunnel reaches the right sidewall of the cavern, directly to the assembly room.
A lower auxiliary tunnel, leading down to the floor of the excavation of the powerhouse
cavern at the right sidewall, is connected to the access tunnel of the power house. In
addition, an extension of this auxiliary tunnel is linked to the outflow tunnel. This auxiliary
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tunnel is employed as permanent access to the turbine area and as an emergency exit
way from the powerhouse cavern during the operation stage.
The left sidewall of each of the two caverns is joined to a tunnel that starts at each cavern
vault. Those two tunnels are connected to an upper auxiliary tunnel that emerges to an
independent plaza. Initially during construction, this tunnel is used for the construction of
the vaults of the caves, and finally during operation it will used as an out way for the power
cables to a porch which is located in that plaza, where the transmission line is started. Also
goes through this tunnel, hanging on the vault, the fume pipe.
All previous tunnels are used as part of the ventilation system of the powerhouse and, of
course, as escape ways from the caverns.
The location of the caverns for the powerhouse and the transformers has been selected
on the left bank of the River Kandiah considering the topographical, geological and
geotechnical characteristics of the rock mass, which is formed by diorite. In addition the
following requirements were taken into account:
The layout of the final section of the conduction tunnel and the pressure well
The layout of the access tunnel to the powerhouse and the output tunnel for the power
cables
The location of the equilibrium chimney and the connection to the derivation of Thauti
Nullah
The layout of the outflow tunnel.
13.12. Discharge Works
Discharge works consists of three branches which receive the released flows by the
turbines; and the tailrace tunnel, the structure and outlet channel which return the flows by
the plant to the Kandiah River.
The collector is made up of three branches, each for every turbine which converge to a
collinear branch with the tailrace tunnel. The branches are parallel mutually and
perpendicular to the powerhouse axis, and they cross under transformers cavern. The
collector has concrete lining. Each branch will have guides to allow installing a gate and
being operated from the transformer cavern floor. The collector will only have a gate in
case of being necessary.
The alignment of tailrace is almost parallel and close to Kandiah River, to be of a shorter
length and with a proper vertical coverage. At the end of tailrace tunnel, in a short length,
the tunnel alignment turns to right to find the Kandiah River.
Structure and outlet channel have been defined with conventional characteristics. The
outlet structure considers a cut and cover tunnel at the end of tailrace tunnel. It is possible
through guides to install in case of being necessary, stop-logs which offer protection
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against river levels to allow tunnel inspection; allowing to locate on the top of a mobile
crane to install the stop logs. The outlet channel will be in the form of expansion with angles
12 ; the section will be excavated in rock with trapezoidal pattern, and treatment with
shotcrete and (tentatively) with concrete floor slab.
13.13. Thauti Nullah Derivation and Headrace
The diversion works of the scheme will be two Tyrolean weirs (one by each stream), each
one with a screen bar, a collector channel, a well to deposit gravels, a conduction channel,
a lateral excess weir, a desander with three cells, a control thin wall weir and a stilling well.
The Tyrolean weirs will work as spillway during the floods and at the same time will work
as an intake using the screen bar that will be along the weir and over it. Under this screen
bar there will be a channel to conduct the water to the headrace channel, at the beginning,
it will have a tank where the gravels are going to be deposited. Downstream of the tank,
on the left lateral wall of the channel the lateral excess weir will be located. Downstream
of the lateral excess weir, there will be a trifurcation in the channel that would allow to
conduct the water to each one of the desander's cells where the particles in suspension
will be settled. At the end of the desander's cells, there will be a thin wall weir that will
work like an hydraulic control and will allow to cross the water into a stilling well, which is
connected to a Morning Glory structure.
The Thauti Nullah headrace system will consist of a tank and morning glory-spillway, intake
structure, a pressure shaft and headrace tunnel.
14. MECHANICAL EQUIPMENT
Following characteristics of Pelton turbine units have been worked out in Volume-8 of the
Feasibility Study Report
Symbol Feature Units Value
Maximum normal Operating Level m.a.s.l 1500
Minimal Operating Level m.a.s.l 1480
Turbine Runner center line m.a.s.l 971.1
H
b
Normal Operating Gross Head m 528.9
Conduction losses m 28.8
Total Flow m
3
/s 125
Number of units Number 3
H
n
Net design head m 500
Hn
max

Maximum net head (one unit operating at
100%)
m 525.25
Qd Turbine rated flow m
3
/s 41.7
i Number of jets Number 6
N
sj
Specific velocity for jet calculated m.kW 18.9
Et Turbine efficiency % 91.0%
Pd Designed power kW 185,829
max Maximum Power (one unit operating) kW 195.174
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Symbol Feature Units Value

N Calculated Rotational Speed min
-1
253.7
N' Selected Synchronous Speed min
-1
230.77
N
sj'
Single J et Specific speed m.kW 17.2
J et Maximum Head Velocity m/s 98.9
n
f
Runway Speed min
-1
415
Eg Generator Efficiency % 98.3%
Generator Power Factor 0.85
PG Generator Capacity MVA 202.93
Generator Adjusted Capacity KVA 215,000
Etr Transformer Efficiency % 99.50%
C.I. Installed Capacity kW 545,170

Capacity to Bridge, Gordon's criteria kN 3560
Capacity to Bridge, recommended kN 3900
SIZING BY SIERVO Y LUGARESI
Wheel Dimensions
Ku Runner Peripheral Velocity Coefficient 0.48
D2 Wheel Pitch Diameter m 3.9
Dj J et diameter, Dj<0,27m m 0.306
D2/Dj Relationship of diameters 12.8
D2/B Relationship Dpitch/B 3.8
D3 Wheel Outer Diameter m 4.95
H1, B Bucket Width m 1.03
H2 Bucket Length m 0.96
Casing Dimensions
L Pelton turbine casing length m 11.2
G
Distance between the runner centerline and
top of the casing
m 2.1
F
Height between the runner centerline and
the floor channel
m 9.0
W
Height between the wheel centerline and
water level
m 4.0
H Channel height m 6,4
F-H
Height between the wheel centerline and the
metal pit
m 2.7
I Discharge channel width m 5.4

Spiral Case Size
v Water velocity at the spiral case inlet m/s 8.83
A Inlet diameter m 2.45
B Distance axis unit to exterior outside input m 8.34
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Symbol Feature Units Value

C Distance axis unit to the entry opposite side m 8.0
D Distance groups axis to spiral end side m 7.6
E Distance groups axis to downstream side m 8.25

15. ELECTRICAL EQUIPMENT STUDIES

During the alternatives evaluation studies, the sizing and budget of the electrical
equipment for the proposed alternatives has been carried out
As a result of the optimization studies, the alternative with three generating units driven by
Pelton turbines, arranged vertically in an underground powerhouse has been selected.
Each generator will be connected through the corresponding circuit breaker to a single-
phase transformer bank, to raise the voltage to 500 kV. From the terminals of the
transformers, it will be run out, through a tunnel, three three-phase circuits on high voltage
insulated cables, to a square on the surface, where it will be installed to a 500 kV
substation receiving the three generator circuits and the lines for interconnection to the
national grid.
Details can be found in Volume-9 of the Feasibility Study Report.
16. POWER TRANSMISSION LINE STUDIES
Volume-11 of the Feasibility Study Report proposes a transmission system for dispersal
of power generated at Kaigah powerhouse to load centres of Mardan and Peshawar.
The Route of the proposed corridor of Option-I for 500KV transmission line from
Basha-1 to Kaigah has been described below:
It is proposed that a 500 KV transmission line emanating from Basha-1 be connected
to Kaigah via In-Out Basha-1 to Mardan S/C at Kaigah.
Kaigah-Mardan New 500 kV D/C (operated as an interim arrangement until the
commissioning of 2nd stage of Basha).
Since there are steep V-shape Mountains on both sides of River, availability and
access to the corridor 50m wide will have to be confirmed before finally designing the
transmission line. It is anticipated that land uses will remain relatively unchanged during
the next few decades. Increase in growth is expected but overall rural character of the
project/corridor area should remain un-changed.
17. TRANSPORTATION STUDY
545 MW Kaigah Hydropower Project is proposed in a difficult terrain in terms of
accessibility and transportation.
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Existing road network does not have capability of improvement or up-gradation and almost
the whole length of approximately 25 km is to be attended within Kandiah valley.
The existing bridge at Kandiah-Indus confluence is the sole connection of the valley with
KKH which will be submerged in the reservoir of proposed Dasu Hydropower Project.
The bridge over River Indus at Shatial will not be affected by the reservoir level of proposed
Dasu Hydropower Project but it is not a feasible option due to its distance of about 35 km
from the existing Kandiah Bridge.
Construction of a new bridge at the same location i.e. confluence of Kandiah River and
Indus River is also not recommended because at the safer elevation, the span of bridge
exceeds 450 meters which is not a feasible option for the required purpose.

The Consultants of proposed Dasu Hydropower Project have proposed the construction
of bridge near Seo village to provide access to the inhabitants of Kandiah valley to KKH.
The Consultants of Dasu Hydropower Project have proposed a road along the right bank
of River Indus which will enter the Kandiah valley upto the proposed Dasu reservoir.
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It is recommended that sharing of proposals and plans with the Owner Agency of Dasu
Hydropower Project be made at an earliest. In order to develop a mutually beneficial and
integrated approach towards the development of access to Kandiah valley from KKH and
road infrastructure within the Kandiah valley as described in Volume-10 in detail.
18. ENVIRONMENTAL STUDIES
Environmental & Social Impact Analysis has been performed and presented in Volume-12
of the Feasibility Study Report. It concludes :
The study of the environmental and social setting of the Kaigah Hydropower Project,
and the implications of the proposed interventions, i.e. construction of a dam,
excavation of tunnels, creation of the reservoir, and construction of underground
powerhouse and so on, do not indicate any significant negative impact of such nature
or magnitude that would suggest the project is environmentally unfriendly.
The study has identified some potential impacts, which are not of serious nature and
can be ameliorated or mitigated within normally acceptable levels through practicable
control and management measures.


The overall findings of the EIA studies show that the Kaigah Hydropower Project is
environmentally and socially viable subject to the development and implementation of
a full Environmental Management Plan.
19. COST ESTIMATES & FINANCIAL ANALYSIS
A detailed Cost Estimate of the Project alongwith Financial and Economical Analysis have
been developed which yields total Project cost as1564.8 Million USD. Whereas, feasibility
level tarrif is calculated as 9.5 cents per KWh.
Cash flows of Project are discounted at the cost of capital (6.79%) and the NPV of the
Project resulted into USD 464.07 million, which passes the NPV test for the acceptance of
Project as a profitable investment.
Details are presented in Volume-13 of the Feasibility Study Report.