Case Study
Sunrise Dam Power Generation Control System Upgrade
ACE supported EDL with the Sunrise Dam Expansion 8 project, integrating new generation and switchgear into the operating power station supplying Sunrise Dam Gold Mine.
Expanding generation while keeping the mine supplied
The expansion added a 4.5 MW gas-fuelled generator and an 11 kV feeder switchroom with a 21-tier switchboard. The control upgrade needed to accommodate the new equipment within the existing load-sharing, load-following and load-shedding arrangements.
With the power station operating around the clock and limited shutdown windows, ACE surveyed the existing plant, developed cutover procedures and coordinated staged installation and commissioning with the project and operations teams.
Control, SCADA and communications integration
- Control cubicle design, schematics, cable schedules and network drawings.
- Schneider PLC and CitectSCADA programming for the new generator and switchboard.
- Updates to generator load sharing, load following and load shedding.
- Protection relay interfaces using IEC 61850 and Modbus, with parallel redundant network paths and GPS time synchronisation.
- Interfaces to governor controls, battery chargers, drives, instrumentation and fire systems.
Managing brownfield and supply-chain constraints
Incomplete existing documentation, equipment shortages and contractor availability complicated delivery during the COVID-19 period. ACE combined site investigations, alternative equipment selection and flexible engineering support to accommodate the changing installation schedule.
Commissioning and handover
The new switchboard, protection relays and generator were integrated into the existing station. ACE implemented the parallel redundant protection communications network, upgraded the load-sharing arrangement and supported testing, commissioning, as-built documentation and operator training.
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