Specializing in automation and
control of hydroelectric power generation plants & associated
Automation of 7 vertical Seagull turbines
Bishop Falls Hydro -
Casco Systems LLC offers a wealth of experience automating hydroelectric
stations and related projects such as fish ladders, elevators, and rubber
dams. A sample of typical projects is noted below.
Newport Hydro Automation (2005)
Developed PLC program and
HMI system for three unit hydroelectric station. This system provided
automatic generator start and stop capabilities, alarm monitoring and
annunciation, data logging and trending, and various control modes including
load level control, pond level control, and gate position control.
System also provided remote control of head gate and minimum flow gate via a
fiber optic Ethernet LAN. In addition the control system provides dial
in capabilities for remote monitoring of station condition by plant personnel.
Old Falls / New Dam Pond Level Control System (2005)
Provide PLC based water level control
system for one and two generator hydroelectric stations.
Lamoille River Control System (2005)
HMI / SCADA system to provide supervisory
control of four hydroelectric plants utilizing open architecture TCP/IP WAN
and CIMPLICITY HMI software.
Clark Falls, Milton, & Peterson Hydro Station Automation (2005)
Replace ACS RTU's with S90-30 PLC SCADA
system solution. Expand system to provide load, pond, and gate position
control, auto start / stop, and alarm annunciation. Interface with
Rubber Dam control system to coordinate water level control using dam, boards,
generators, and minimum flow gate.
Weldon Hydro Station Automation (2005)
program to retrieve data from 14 GE Multlin 489, 745, & 750 relays, 4
Cutler-Hammer Exciter Control Units, and 4 Nexus 1250 Power Meters. This
program retrieved all metering data necessary for display on the Station SCADA
Gardiner Hydro Station
Completed automation upgrade of a semi-Kaplan generator and related auxiliary
equipment. Project included removing an existing GE Fanuc Series 6 PLC
and OIT system. These were replaced with a VersaMax PLC and CIMPLICITY
HMI SCADA program. System is capable of automatic start and stop, pond
level control, and remote lockout reset to allow roving personnel complete
flexibility in operating the plant. SCADA access was provided using a
dedicated Web Server, allowing remote workers to connect to the site using
only a Java enabled web browser.
Currently working on
automation and semi-automation control system upgrades at different low-head
hydro plants in Maine, Vermont, and New Hampshire.
Commissioning Support (2002)
commissioning of a new automation system and hydraulic actuator controlling
two 2-MW generators.
Automation / HMI System Programming (2002)
Programmed a GE Fanuc
90-30 PLC and CIMPLICITY HMI operator interface system to control two 3-MW
generators and related equipment.
Project included interfacing to existing Woodward mechanical governors and
existing SCADA system. System
allowed fully unattended operation, remote control, and automatic water level
Governor / Automation Programming (2002-03)
Programmed eight AB
SLC 500s & PanelView 550s to control seven hydro-electric governors and
related equipment. System
automated all turbine/generator control and alarms functions, governor speed
and load regulation, auto
start/stopped units, interfaced with existing SCADA RTU, and communicated with
a high-level water level control system via an Ethernet Network.
Project included coordination of seven PLCs (one per unit) and a
shared automatic synchronizing system.
challenge on this project was the remote location and schedule for project
commissioning. This plant is located on the Exploits River in Bishop's
Falls, Newfoundland. Due to scheduling restrictions commissioning and
installation was performed during the winter of 2002-2003 under extreme
weather conditions. Commissioning of the control and hydraulic systems
as well as electrical control installation was supported by Casco Systems end
to end, culminating in the commissioning of six new American Hydro Seagull
horizontal 3MW turbine/generator units and the reconditioning of a seventh
existing unit. When completed the plant was able to be run remotely from
the clients SCADA control center, providing a reliable, cost-effective power
Program Conversion (2002)
logic program originally written for a Series One PLC to a new VersaMax PLC
platform. Project involved
determining how the original program worked and creating a new program with
matching functionality for water level control.
Electronic Actuator Control (2002)
programmed a GE Fanuc 90-30 & Maple Systems OIT based electronic actuator
control. The new system provided
off-line speed regulation and online gate position control of a hydroelectric
turbine. System was designed to
replace an existing digital governor with a simple to configure, reliable
Hydro Station Fish
commissioned GE Fanuc 90-30 PLC logic and Wonderware InTouch SCADA/HMI system
to automate a fish elevator and associated water control system.
This fully automated system controlled large 2 and 3 modulating
valves to provide attraction water through a fish passageway at specific flow
rates and velocities. As fish are
attracted by this water flow, they are automatically captured and then lifted
over the dam, allowing upstream passage for Atlantic Salmon and other species.
Involvement included all aspects of PLC and HMI system including motion
control, operator interface, safety, and process control.
Diesel Generator Unit
Control System (2001)
Modified an existing
Allen Bradley SLC 500 program and RS View HMI system to add control and
operator interface functions for a diesel generator.
Head Hydroelectric Station Automation
Programmed GE Fanuc
PLC based automated control systems for manual and automatic control of
multiple small hydroelectric stations.
Also implemented operator interface system for alarm annunciation and