--- title: "In situ control panel upgrades at hydro scheme" id: "5865" type: "post" slug: "in-situ-control-panel-upgrades-at-hydro-scheme" published_at: "2026-02-06T09:08:23+00:00" modified_at: "2026-02-06T09:11:13+00:00" url: "https://dulas.org.uk/in-situ-control-panel-upgrades-at-hydro-scheme/" markdown_url: "https://dulas.org.uk/in-situ-control-panel-upgrades-at-hydro-scheme.md" excerpt: "[fusion_builder_container type=\"flex\" hundred_percent=\"no\" hundred_percent_height=\"no\" min_height_medium=\"\" min_height_small=\"\" min_height=\"\" hundred_percent_height_scroll=\"no\" align_content=\"stretch\" flex_align_items=\"flex-start\" flex_justify_content=\"flex-start\" flex_wrap_medium=\"\" flex_wrap_small=\"\" flex_wrap=\"wrap\" flex_column_spacing=\"20px\" hundred_percent_height_center_content=\"yes\" equal_height_columns=\"no\" container_tag=\"div\" menu_anchor=\"\" hide_on_mobile=\"small-visibility,medium-visibility,large-visibility\" status=\"published\" publish_date=\"\" class=\"\" id=\"\" margin_top_medium=\"\" margin_bottom_medium=\"\" margin_top_small=\"\" margin_bottom_small=\"\" margin_top=\"\" margin_bottom=\"\" padding_top_medium=\"\" padding_right_medium=\"\" padding_bottom_medium=\"\" padding_left_medium=\"\" padding_top_small=\"\" padding_right_small=\"\" padding_bottom_small=\"\" padding_left_small=\"\" padding_top=\"\" padding_right=\"0px\"..." taxonomy_category: - "Hydro" --- # In situ control panel upgrades at hydro scheme #### Refurbishment and upgrade of control panels and associated equipment on four Biwater Francis turbines **Project overview** The client had been experiencing declining reliability of these schemes for some time. This was due to a number of factors including questionable original design choices, inadequate condition monitoring, minimal alarm reporting, and aging components. Dulas was initially requested to assist with the integration of new G59 relays under the Accelerated Loss of Mains Programme, however whilst undertaking this work it soon became apparent that there were many other issues with the control systems and that there was significant scope to improve the operation of the schemes. It was agreed that Dulas would design and install a comprehensive program of upgrades to improve availability and generation. The scope of these works included: - Design of new control strategy - Production of new electrical schematics - Installation of new instrumentation and equipment - Re-programming of PLC and HMI - Testing and re-commissioning - Working alongside the client’s own operational technology team to integrate the turbines into their organization-wide telemetry system **Background** Dulas has provided O&M services to the client for a number of years across a fleet of turbines totaling more than 16MW of installed capacity, and is increasingly requested to propose upgrades and improvements to these schemes **The challenge** The first step was to reverse engineer the existing systems as little documentation was available, and to assess which components could reasonably be re-used, and which were end-of life and would need replacement. Historically, the schemes were not capable of shutting down gracefully when non-critical alarms occurred, nor were they inherently fail-safe in the event of a failure of the normal control systems. It was the client’s wish that we should not replace the existing PLCs, so although the code was to be upgraded, this needed to work within the existing hardware. **Our solution** Building on Dulas’ extensive experience of hydro turbine controls design, a package of works was undertaken for each scheme which included: - Replacement of intermittent guide-vane position potentiometer with future-proof LVDT. - Addition of diverter valve to guide-vane hydraulics to ensure fail-safe shutdown capability. - Replacement of failure-prone and expensive proportional valve with SSR driven pulsed DCVs for guide-vane position control. - Replacement of synchroscope and synchronization routine improved with redundant safety interlocks. - Replacement of failing generator temperature transmitters with updated devices. - Upgrade of generator AVR for improved stability and power factor control. - Addition of real-time generator insulation resistance monitoring and enhanced protection. - Comprehensive upgrade of alarm handling and signaling to HMI and telemetry. **Impact** The Schemes’ turbines total 3.5MW of installed capacity. Therefore, when running, they produce a large amount of renewable energy, offsetting carbon and contributing a sizable revenue stream for the client as well as helping to meet the net zero targets of the organisation. By [Annika Faircloth](https://dulas.org.uk/author/dulasannika/) Published On: February 6, 2026 Share: [https://www.facebook.com/sharer.php?u=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F&t=Share%3A](https://www.facebook.com/sharer.php?u=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F&t=Share%3A) [https://x.com/intent/post?text=Share%3A&url=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F](https://x.com/intent/post?text=Share%3A&url=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F) [https://www.linkedin.com/shareArticle?mini=true&url=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F&title=Share%3A&summary=Refurbishment%20and%20upgrade%20of%20control%20panels%20and%20associated%20equipment%20on%20four%20Biwater%20Francis%20turbines%20%0D%0A%0D%0AProject%20overview%20%0D%0A%0D%0AThe%20client%20had%20been%20experiencing%20declining%20reliability%20of%20these%20schemes%20for%20some%20time.%20This%20was%20due%20to%20a%20number%20of%20factors%20including%20questionable%20original%20design%20choices%2C%20inadequate%20condition%20monitoring%2C%20minimal%20alarm%20reporting%2C%20and%20aging%20components.%20Dulas%20was%20initially%20requested](https://www.linkedin.com/shareArticle?mini=true&url=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F&title=Share%3A&summary=Refurbishment%20and%20upgrade%20of%20control%20panels%20and%20associated%20equipment%20on%20four%20Biwater%20Francis%20turbines%20%0D%0A%0D%0AProject%20overview%20%0D%0A%0D%0AThe%20client%20had%20been%20experiencing%20declining%20reliability%20of%20these%20schemes%20for%20some%20time.%20This%20was%20due%20to%20a%20number%20of%20factors%20including%20questionable%20original%20design%20choices%2C%20inadequate%20condition%20monitoring%2C%20minimal%20alarm%20reporting%2C%20and%20aging%20components.%20Dulas%20was%20initially%20requested) [https://api.whatsapp.com/send?text=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F](https://api.whatsapp.com/send?text=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F) [mailto:?subject=Share%3A&body=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F](mailto:?subject=Share%3A&body=https%3A%2F%2Fdulas.org.uk%2Fin-situ-control-panel-upgrades-at-hydro-scheme%2F) Strata Florida water treatment works hydroelectric scheme Strata Florida water treatment works hydroelectric scheme [Read more](https://dulas.org.uk/strata-florida-water-treatment-works-hydroelectric-scheme/) Gafr Hydro, Nant Peris Gafr Hydro, Nant Peris [Read more](https://dulas.org.uk/gafr-hydro-nant-peris/) An 800kW run-of-river hydro scheme near Loch Lomond An 800kW run-of-river hydro scheme near Loch Lomond [Read more](https://dulas.org.uk/an-800kw-run-of-river-hydro-scheme-near-loch-lomond/) Coanda screens in the Himalayas Coanda screens in the Himalayas [Read more](https://dulas.org.uk/coanda-screens-in-the-himalayas/) Fit for the future: Dulas upgrade Dŵr Cymru Welsh Water’s Elan Valley scheme Fit for the future: Dulas upgrade Dŵr Cymru Welsh Water’s Elan Valley scheme [Read more](https://dulas.org.uk/elan-valley-upgrade/) Increasing output through optimisation at the Llyn Brianne hydroelectric plant Increasing output through optimisation at the Llyn Brianne hydroelectric plant [Read more](https://dulas.org.uk/increasing-output-through-optimisation-at-the-llyn-brianne-hydroelectric-plant/) Inverhaggernie intake refurbishment Inverhaggernie intake refurbishment [Read more](https://dulas.org.uk/inverhaggernie-intake-refurbishment/) Glenmore Control Panel Refurbishment Glenmore Control Panel Refurbishment [Read more](https://dulas.org.uk/glenmore-control-panel-refurbishment/) Atholl Estates Run of River Hydro Scheme Atholl Estates Run of River Hydro Scheme [Read more](https://dulas.org.uk/atholl-estates-run-of-river-hydro-scheme/) Balnacarn Hydro Scheme Balnacarn Hydro Scheme [Read more](https://dulas.org.uk/balnacarn-hydro-scheme/) Iwrch Hydro Scheme Refurbishment Iwrch Hydro Scheme Refurbishment [Read more](https://dulas.org.uk/iwrch-hydro-scheme-refurbishment/) Upper Bryn Cowlyd 200kW new build Upper Bryn Cowlyd 200kW new build [Read more](https://dulas.org.uk/upper-bryn-cowlyd-200kw-new-build/)