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Modernization is essential for many U.S. hydropower plants to maintain clean energy output – especially as demand for electricity increases alongside the electrification of buildings and transportation. At the same time, experienced professionals are retiring, so automating and upgrading equipment is essential for a new generation of professionals less familiar with the particulars of operating vintage equipment.
For many hydropower plants in operation beyond 45 years, upgrades and updates enable improved performance and flexibility. (Source: IEA) In the U.S. alone, hydroelectric plants have operated, on average, for 64 years. This means there are powerful opportunities to increase output by 5 to 10% and improve plant flexibility, which is critical for electricity systems amid the energy transition that are increasingly incorporating distributed energy resources such as wind and solar PV.
In any aging hydroelectric plant, major electromechanical equipment will likely need to be replaced. There are also opportunities to enhance personnel safety and digitalize operations by applying modern innovations in control systems, cybersecurity, plant and fleet modernization methods, outage management, condition monitoring equipment and more.
For example, an aging hydroelectric facility operated by the Village of Potsdam in New York experienced reoccurring failures. The fix required comprehensive rehabilitation, as earlier reconditioning and repair attempts could not prevent recurring failures of two 500-kVA units.
Where do you start modernization projects?
With more than 50 years of experience modernizing hydroelectric facilities, we deliver proven, dependable power system products in a comprehensive and cost-effective solution.
Here are four hard-earned lessons:
- Clearly define goals and objectives. Both new and existing system components in a generation facility need to be evaluated to ensure overall system requirements are met.
- Consider every possible factor. Regulatory, compliance, safety, reliability, capacity, cost, operational constraints must inform project parameters.
- Maintain flexibility and creativity. As you get into a project, there could be additional opportunities that improve plant reliability and increase output.
- Thoroughly document changes and performance. This helps ensure that future operation requirements are met and that new plant operators have the information they need.
The major system components to consider as you define modernization project goals include switchgear and associated breakers, protection systems, control systems and plant auxiliary systems. Many of these systems include mechanical and hydraulic systems that require controls.
Case in point: modernizing the hydroelectric plant in Potsdam, New York
The project at the Village of Potsdam hydroelectric facility centered around refurbishing turbine generators, upgrading gear boxes, unit rehabilitation, and control system replacement. We at Eaton also provided turnkey engineering support and a comprehensive integration approach.
For the Potsdam project, our services encompassed power system evaluation; rehabilitation (including design) of all systems and subsystems; project construction management and oversight; start up, testing and commissioning; and assurance of integration.
During the modernization process, new opportunities to improve the facility’s reliability were uncovered, which had not initially been identified during the project specification. Our flexible and creative approach enabled incorporation of the additional improvements.
Today, the Village of Potsdam can operate confidently and efficiently in varying conditions. When potential problems arise, the system provides alarms and enables easy troubleshooting. The project not only improved the reliability and functionality of hydro generation, but also helped the municipality improve efficiency and sustainability by offsetting electrical usage.
Hydro modernization has a big payoff
Hydroelectric power is a significant resource that’s essential amid the energy transition to balance the intermittent, unpredictable nature of other renewable energy and provide reliable and predictable power.
As a country, our collective demand for power continues to increase. Workforce retirements mean experienced professionals familiar with the operation of vintage equipment will be increasingly hard to find. So plant modernization projects must reduce maintenance and improve performance.
It is vital to strategically approach any plant upgrade and automation project to extend the serviceable life of equipment while improving efficiency, reliability and safety. At Eaton, our deep understanding of hydro systems, experience with major projects, and dedicated team combine to deliver a comprehensive, flexible, and creative approach that makes a big impact – for the Village of Potsdam and beyond.
Learn more about the Village of Potsdam project.
