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Hydroelectric power plant automation and modernisation

Your trusted adviser for hydro plant modernisation

Bring new life to ageing hydropower plants with Eaton's hydro electrical engineering services team. Highly skilled in hydro automation projects, excitation systems, and protection and control system replacements and upgrades, our engineers guide every step of the process, from inception to completion. Eaton makes it easy for you to update, revitalise, modernise and maintain your hydroelectric assets to achieve reliable, efficient operation.

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The time for hydro revitalisation is now

Nearly three-quarters of US hydroelectric facilities currently rely on outdated infrastructure, with many operating mismatched and obsolete hardware and controls. With Eaton as your trusted adviser, you get access to a single source of highly customised turnkey services and solutions to modernise your hydro plant. From developing the vision to seamlessly navigating the process, we meet all project objectives while staying within your budget.

Nearly 70% of North American hydropower facilities are more than 40 years old.

- International Energy Agency

Get a free hydroelectric facility site assessment

Discover how modernising your facility will make it more reliable, better able to meet regulatory standards and capable of adapting to new challenges. 

Request your free site assessment now.

Village of Potsdam; a hydro modernisation story

Discover how we helped the Village of Potsdam modernise their hydroelectric plant beyond their expectations.

The expertise to take your hydro project from start to finish

The success of your hydro plant modernisation depends on ensuring that a multitude of objectives come together seamlessly. With Eaton, you gain a provider with a proven track record who can oversee the complete scope of work required, engineer and deploy the optimal solutions to meet your goals, and ensure minimal disruption to your operations. Take a look at our full range of modernisation offerings for hydroelectric plant.

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Before and after photos from an electrical room upgrade

Missed our Hydro Modernisation webinar series?

Visit our on-demand education library to access the series' recorded webinars. Topics include: Hydro upgrade strategies, switchgear modernisation, excitation upgrades, Eaton arc-quenching switchgear and system protection.

Say goodbye to modernisation complications

Considering the expense and coordination inherent in hydropower dam upgrade projects, it makes sense to rely on a dedicated, experienced engineering and project management team to oversee the process. With Eaton, you can avoid missed deadlines, going over budget and the risk of extending past planned time frames. Find out more about Eaton's turnkey hydro modernisation process. Our capabilities include:

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  • Determining the project scope
  • Engineering the modernisation design
  • Specifying and deploying equipment
  • Ensuring all regulatory requirements
  • Completing power system and safety studies
  • Automating functions
  • Delivering ongoing field service and maintenance
  • Recommending and implementing optimised solutions

We make hydro plant modernisation easy

When upgrading your hydro plant, you need a provider with broad capabilities, a proven track record and the expertise to not only oversee the process but also resolve any unforeseen hurdles along the way.

Eaton’s hydro services team streamlines and simplifies your modernisation process through:
  • Switchgear modernisation that increases reliability and safety and extends equipment lifespan at a fraction of the cost of replacement
  • Circuit breaker repair to safely and cost-effectively modernise equipment through conversions, retrofits, retrofills and other options
  • Grounding solutions that increase production, ROI and asset life
  • Excitation upgrades to ensure selection of the best solution and optimise system performance
  • Field service teams that provide ongoing support for plant systems and reduce downtime
  • Arc flash safety solutions and system studies that enable you to identify and achieve safety goals
  • Digitalisation and system monitoring with industry-leading engineering, application and technology expertise 

Bring new life to ageing facilities

With decades of experience in the modernisation and retrofit of ageing hydroelectric facilities, Eaton offers the complete, highly customised turnkey services needed to effectively upgrade your site. Find out more about how we can help define and implement the solutions that will enable you to control, monitor and manage your plant well into the future. 

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Turn your vision into reality

Regardless of your modernisation goals, it is essential to gain a thorough understanding of your system before embarking on any changes. Eaton offers a complete range of power system studies to help you plan, manage and modernise your grid – ensuring the optimal and safest design. Performed by experienced engineers, our studies can evaluate performance, make recommendations for improvements and provide assurance that you are meeting the latest industry standards and requirements.

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See turnkey management in action

Eaton engineers have the expertise to take your hydroelectric modernisation project from conception to completion, resulting in a safer, more reliable and cost-efficient power system. From a single point of accountability to a reduced risk of delays, we can transform your hydroelectric systems to serve you today and well into the future. See the difference in these actual customer installations.

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Achieve uptime, all the time

Even the most reliable hydropower plant will occasionally experience a planned or unplanned outage. From equipment failure to environmental compliance projects to routine maintenance and system upgrades, Eaton helps facilities keep their electrical distribution and control systems safe when the power is out.

Eaton’s engineering services team

Eaton’s engineering services team is dedicated to understanding your business so we can optimise your power system for safety, reliability and efficiency. As one of the largest and most experienced teams in the industry, we offer a comprehensive portfolio of services and solutions tailored to every stage of a power system’s life cycle. Eaton strives to create a zero-incident culture through the implementation of our safety policy, including division safety managers and layered risk assessments. Our team has experience with electrical power distribution equipment from all leading manufacturers and is on standby, ready to support you 24/7, wherever and whenever you need us.

Design engineering solutions for hydroelectric power generating plants:

  • All projects are highly customised to meet  specific customer needs, enabling optimisation of hydro-operational strategies 
  • Turnkey project management, along with life extension programmes and automation solutions, improves efficiency, reliability and safety of hydroelectric power plants while reducing costs
  • Eaton’s consulting and engineering services include studies and tests to diagnose problems and identify improvements, such as arc flash studies for NFPA 70e CSA-Z462 compliance
  • All project documentation is completed to meet customer standards and specific requirements
  • Eaton’s expert engineers take your project from conception through to completion, with a single point of accountability
Specifications
As ageing hydroelectric plants across North America reach the end of their life cycle, the Eaton Electrical Services & Systems team provides a one-stop shop to upgrade equipment, coupled with customised, turnkey project management. With a complete range of solutions to extend equipment life, reduce costs and enhance reliability, Eaton breathes new life into ageing facilities. The following testimonials provide a brief snapshot of services that have been undertaken by Eaton.

Helping a utility to become NERC compliant

Challenge: The NERC Standards continue to evolve, with additional standards being introduced that may require compliance within a short period of time. This ever-changing regulatory world can be complex for utilities and may not allow sufficient time to understand the standard requirements or ensure proper data collection to support the new compliance needs.

Solution: Eaton engineers began each site evaluation with an assessment of the previous site PRC study reports, the existing power system equipment documentation and the protective relay setting information. Eaton evaluated the available data and confirmed assumptions for unknown data as per standard requirements; then completed all necessary calculations and system modelling to ensure compliance, as per the stated standard, and provided reports.

Result: In addition to the completion of NERC compliance reports, Eaton helped the utility to develop an understanding and knowledge of the new industry standard. This knowledge sharing supported the customer in developing a plan to ensure ongoing data collection for the compliance process. 

Eaton brings outdated hydroelectric facility back to life

Problem: Electrical gear was obsolete and in poor condition at a hydroelectric plant supporting eight turbine generators. The facility, which had been out of operation for 14 years, required a complete equipment upgrade.

Solution: Eaton Electrical Services & Systems facilitated the entire design-build project, upgrading and rehabilitating the electrical distribution system with an extensive range of equipment that included relay protection, substations, arc-resistant switchgear, new cabling and bus work, and more. In addition, the Eaton team completed testing and commissioning of all systems, including arc flash analysis, as well as providing drawing package and manuals, and delivering operator and maintenance training.

Result: After 14 years of non-operation, the generation facility is up and running once again, thanks to an extensive equipment upgrade and turnkey project management, all provided by Eaton.

Automation and protection system upgrades

Problem: An obsolete control system was creating operational challenges for a hydro facility that consisted of two 9,500 kVA turbine generators operating at 4.16 kV, and multiple remotely controlled gate houses. 

Solution: Eaton’s turnkey contract included designing, supplying and installing the upgraded protection and control system. The solution featured a new PLC control system with HMI and remote monitoring; generator, transformer and station service protection; governor and excitation upgrades, and more.

Result: The solution enhanced the utility’s ability to remotely monitor the condition and status of the generating facility, resulting in faster response to plant issues and significantly reduced start-up and shut-down times.

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