Hydroelectric power plant automation and modernization

Modernizing an aging hydroelectric facility

The Village of Potsdam operates two hydroelectric dams located on the Raquette River. Originally constructed in the early 1900s, however, over the years the units experienced a decrease in reliability and routinely failed. Read how The Village of Potsdam modernized their facility with Eaton resulting in the long-term, reliable solution that more than met their initial needs.

Summary

Challenge

An aging hydroelectric facility required an integrated approach to modernize a pair of turbine generators and upgrade its overall infrastructure to achieve efficient, reliable operation.

Solution

Turnkey project development and implementation including generator, turbine and gear box upgrades.

Results

The turnkey hydroelectric modernization project facilitated the complete rehabilitation of the plant’s turbine generators, along with upgrading the facility’s electrical and control systems — resulting in the long-term, reliable solution desired.

Challenge: aging hydroelectrical facility needing turnkey modernization

Among the most significant issues that the Village of Potsdam faced in upgrading the aging hydroelectric station was addressing the facility’s two gear boxes. While most plants feature a direct drive setup in which the turbine is directly coupled to the generator, the Village of Potsdam’s East Dam had paired a slow-speed turbine with a high-speed generator, which necessitated the addition of a speed-increasing gear box. In addition, the plant’s control system had become obsolete and was contributing to operating inefficiencies. Additionally, only minimal OEM documentation existed for the plant’s systems, which would make it challenging for the company who was awarded the project.

Eaton bid a turnkey project with an approach that would improve reliability, decrease plant outages and downtime, and address other system enhancements needed within the hydroelectric facility.

We went in with key partners to provide specific scope items that are not in our traditional hydro wheelhouse

Kevin Quirion, the lead engineer for Eaton’s generator protection and control group

trusted-advisor-people-sunrise-GettyImages-1166661514-500x500.jpg

Eaton’s turnkey solutions team takes the worry and hassle out of large-scale electrical system projects. By working with a single point of contact from conception through commissioning, you gain a safer, more reliable and cost-efficient electrical turnkey project. Our engineer/procure/construct (EPC) engineers are experts in upgrades and designs for grid modernization, hydroelectric plant systems and controls, and more.

Solution: Eaton's turnkey services with a flexible plan and additional enhancements

The core of the project centered around refurbishing the pair of turbine generators and upgrading the gear boxes. Eaton conducted a unit rehabilitation and control system replacement, which included fully automating and protecting both units, as well as the station and adjacent distribution equipment.

We also completed a power systems evaluation and rehabilitation, which included replacing one panel board and the entire low-voltage generator switchgear, This reconfiguration better utilized the electrical infrastructure and helped make the plant more reliable.

Kevin Quirion, the lead engineer for Eaton’s generator protection and control group

Results: Eaton’s turnkey project provided The Village of Potsdam…

Safety, reliability and uptime with proven components to provide the facility with a long lasting, exceptionally reliable and cost-effective solution
A highly flexible and adaptable comprehensive approach incorporating work beyond the traditional scope of expertise, exceeding their needs
A complete, turnkey solution enabling The Village of Potsdam to gain quality power while improving the reliability and functionality of hydro generation

Want to read more on this story?

Download the full story

Watch the transformation video

Watch video now

Eaton is an intelligent power management company dedicated to improving the quality of life and protecting the environment for people everywhere. We are guided by our commitment to do business right, to operate sustainably and to help our customers manage power ─ today and well into the future. By capitalizing on the global growth trends of electrification and digitalization, we’re accelerating the planet’s transition to renewable energy and helping to solve the world’s most urgent power management challenges.