{"id":9064,"date":"2025-07-28T14:56:30","date_gmt":"2025-07-28T12:56:30","guid":{"rendered":"https:\/\/blog.fichtner.de\/?p=9064"},"modified":"2025-07-29T12:19:13","modified_gmt":"2025-07-29T10:19:13","slug":"modernization-projects-at-mozambiques-largest-hydropower-plant","status":"publish","type":"post","link":"https:\/\/blog.fichtner.de\/en\/modernization-projects-at-mozambiques-largest-hydropower-plant\/","title":{"rendered":"Modernization Projects at Mozambique\u2019s Largest Hydropower Plant"},"content":{"rendered":"

Modernization Projects of Hidroel\u00e9ctrica de Cahora Bassa in Mozambique<\/p><\/h2><\/div>

Organizing Projects and Minimizing Downtime<\/p>\n<\/div>

The operator of the Cahora Bassa hydropower plant in Mozambique wants to tackle two major modernization projects: replacing the generators in the power plant and modernizing the Songo HVDC converter station, via which most of the generated electricity is exported to South Africa over a distance of 1,420 km. This will inevitably involve downtime for plant components, but this can be minimized by carrying out the two projects at the hydropower plant and the converter station in parallel, thus also minimizing economic losses. The interface management required to achieve this is being handled by Fichtner. Our team is also assisting with the tendering process for modernization of the Songo station and with selection and contracting of the HVDC supplier.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

\"Modernisierungsvorhaben<\/div><\/div><\/div><\/div>

Hydroelectric Power \u2013 An Important Source of Income for Mozambique<\/h3>\n

Since the late 1970s, a 165-meter-high dam has been impounding the Zambezi, Mozambique\u2019s largest river, in its lower reaches. The resulting reservoir, which is around 270 kilometers long, feeds the Cahora Bassa power plant, whose five generators together produce more than two gigawatts (GW) of electrical power. Most of the electricity is sold to South Africa. For the power plant operator Hidroel\u00e9ctrica de Cahora Bassa (HCB)<\/a>, which is majority-owned by the Republic of Mozambique, the export of electricity is an important source of income.<\/p>\n

To ensure minimal electrical losses along the 1,420-kilometer route to South Africa, the electricity is transported via a 533-kilovolt high-voltage direct current (HVDC) transmission system. Today, HVDC technology is widely used to transport large amounts of electricity over long distances, but it was still a rarely used technology back when the Cahora Bassa power plant was built. In fact, the connection between the Songo HVDC converter station in Mozambique and the Apollo HVDC converter station in South Africa was one of the first in the world to use thyristors \u2013 which are controllable power semiconductors, i.e. electrical valves \u2013 to convert alternating current into direct current.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

\"HG\u00dc-Konverterstation<\/span><\/div><\/div><\/div>

From the Songo station in Mozambique, most of the electricity generated at the Cahora Bassa hydropower plant flows through 1,420 kilometers of HVDC lines to the Apollo station in South Africa.<\/em><\/p>\n<\/div><\/div><\/div><\/div><\/div>

<\/div>

Many Important Installations in Need of Extensive Renovation<\/h3>\n

Five decades or so will take their toll, even on power plant equipment and power grids. The HVDC line was repaired after damage caused by the civil war, and modernization projects were carried out in Mozambique and South Africa that addressed its aging. Among other things, the oil-cooled thyristors at the Apollo station in South Africa were replaced with new, water-cooled thyristors just over 15 years ago.<\/p>\n

The first-generation thyristors are still in use in Songo. Due to their age, the risk of failure is high and replacement is urgently recommended, which also applies to the control system and parts of the DC and AC switchgear. In addition, the generators in the hydropower plant are now due for replacement. Both are projects that will lead to production restrictions or temporary shutdowns.<\/p>\n

Interface Management Keeps Export Losses to a Minimum<\/h3>\n

HCB\u2019s goal is to keep losses of electricity exports as low as possible. Therefore, the modernization works on the hydropower plant and those on the HVDC converter station should not be performed at different times. Instead, downtime during the modernization should be kept to a minimum, and works on the power plant and the Songo station should be carried out in parallel. In 2020, HCB awarded the contract for interface management to us.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

<\/div><\/div>

Interface Management:
\nAn Organizational Task for Engineers<\/p><\/h2><\/div>

The modernization projects at the Cahora Bassa hydropower plant and the Songo HVDC converter station demonstrate how important engineering expertise is in preventing unnecessary plant downtime. To keep losses in revenues to a minimum, it is essential to carefully plan the work steps and coordinate the parallel projects through interface management. Without knowledge of the plant technology and the necessary work steps as well as experience from other modernization projects, it is virtually impossible to manage HCB\u2019s renovation plans with minimal disruption to electricity exports.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

<\/div>

Establishing the Conditions for Project Launch<\/h3>\n

The goal of completing the extensive works within the same timeframe appeared to be in jeopardy in early 2024, however, as no contract had yet been signed for the replacement of the oil-cooled thyristors with new, water-cooled ones. HCB therefore contracted us to assist with the award of the contract for modernizing the Songo HVDC converter station. Our experts reviewed the available documents, made adjustments where necessary, and assisted with contract negotiations between HCB and the potential plant manufacturer. The contract is to be concluded as soon as possible, by summer 2025 at the latest. This will allow for the planning and final coordination of the modernization at Songo station and the generator replacement at the hydropower plant to go ahead soon.<\/p>\n

As is customary in the industry, the fact that Fichtner is playing a key role in the contract award and negotiation phase means we will not be involved in supervising the subsequent execution of the Songo retrofit project. Our team is therefore currently assisting HCB in its search for a suitable owner\u2019s engineer.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

<\/div><\/div>

Familiarity with the Energy Landscape in Mozambique<\/h2><\/div>

For Fichtner, the assignments described in this article are not its first in Mozambique. Our experts in energy generation and electrical grids have already been able to actively participate in various projects and get to know the country\u2019s energy industry:<\/p>\n<\/div>

1997 \u2013 2000<\/p>\n<\/div><\/div><\/div>

More than 25 years ago, Fichtner developed a master plan on the energy supply to southern Mozambique for the national electricity provider Electricidade de Mo\u00e7ambique (EDM) and handled all planning, tender support, and construction supervision for a new 110 kV transmission line with substations.<\/p>\n<\/div><\/div><\/div><\/div>

2008 \u2013 2023<\/p>\n<\/div><\/div><\/div>

During renovation of the Chicamba and Mavuzi hydropower plants, Fichtner assisted EDM from the outset by providing tender support and subsequently performed the owner\u2019s engineering and warranty tracking. In addition, we provided technical support and supervision for emergency repairs at the Mavuzi I hydropower plant, which were required following a cyclone in March 2019.<\/p>\n<\/div><\/div><\/div><\/div>

2016 \u2013 2019<\/p>\n<\/div><\/div><\/div>

As part of a power transmission project between Mozambique and Malawi, Fichtner performed the feasibility study and basic design for a 400 kV transmission line with related switchgear and also prepared the tender documents.<\/p>\n<\/div><\/div><\/div><\/div>

since 2020<\/p>\n<\/div><\/div><\/div>

Hidroel\u00e9ctrica de Cahora Bassa (HCB) has contracted Fichtner to provide interface management in the modernization projects for the Cahora Bassa power plant and the Songo HVDC converter station (see article).<\/p>\n<\/div><\/div><\/div><\/div>

2021 \u2013 2024<\/p>\n<\/div><\/div><\/div>

Fichtner conducted a study for the electricity provider EDM to assess grid capacity with regard to fluctuating renewable energies.<\/p>\n<\/div><\/div><\/div><\/div>

2022 \u2013 2025<\/p>\n<\/div><\/div><\/div>

Fichtner is supporting EDM in projects to expand power plant and power transmission capacity. The focus is on identifying and eliminating project obstacles in order to speed up the projects.<\/p>\n<\/div><\/div><\/div><\/div>

since 2023<\/p>\n<\/div><\/div><\/div>

As owner\u2019s engineer for EDM, Fichtner is supervising the retrofitting of two approximately 600 km-long 220 kV power lines with optical ground wires (OPGW) as part of their telecommunications network.<\/p>\n<\/div><\/div><\/div><\/div>

2024 \u2013 2025<\/p>\n<\/div><\/div><\/div>

The Fichtner team is supporting HCB in modernizing the Songo HVDC converter station by providing contract award services and helping to find an owner\u2019s engineer to supervise the works (see article).<\/p>\n<\/div><\/div><\/div><\/div><\/div><\/div><\/div><\/div>

<\/div>

June 2025<\/em><\/p>\n<\/div><\/div><\/div><\/div><\/div>

\"Fichtner<\/span><\/div>
<\/div><\/div><\/div>

Uwe Armonies<\/h3><\/div>

Senior Project Manager in the Power Transmission & Distribution Department<\/p>\n<\/div><\/div><\/div>

\"Fichtner<\/span><\/div>
<\/div><\/div><\/div>

Dewald Viljoen<\/h3><\/div>

Director Business Development Africa<\/p>\n<\/div><\/div><\/div><\/div><\/div><\/p>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":8,"featured_media":8882,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[18,79,24],"tags":[130,129],"class_list":["post-9064","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-energy","category-projects-en","category-renewable-energy-and-environment","tag-hydropower","tag-power-supply"],"yoast_head":"\nModernization Projects at Mozambique\u2019s Largest Hydropower Plant - Fichtner Connected<\/title>\n<meta name=\"description\" content=\"Fichtner is responsible for interface coordination for two major modernization projects at the Cahora Bassa hydroelectric power plant in Mozambique.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/blog.fichtner.de\/en\/modernization-projects-at-mozambiques-largest-hydropower-plant\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Modernization Projects at Mozambique\u2019s Largest Hydropower Plant - 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