Schneider Electric was commissioned to upgrade aging protection systems at two pump-generator power stations for Eraring Energy. This involved replacing outdated electromechanical relays with numerical relays and integrating them with the existing systems. The upgrades required overcoming challenges like interfacing new and old equipment and addressing operational mode differences. Through their expertise and custom engineering, Schneider Electric was able to successfully complete the upgrades while ensuring safety and communication with stakeholders.

1. Make the most of your energySM
Upgrade provides power supplier with superior
safety and communication devices
The Challenge
At the time, two pump-generator units were installed at the Bendeela and
Kangaroo Valley Power Stations. More than 30 years later, they needed to
upgrade the aging equipment.
In May 2008, Schneider Electric (formerly AREVA T&D Australian
Automation) received a request from Eraring Energy to provide panel
sections for the protection systems at both power stations. The project
required approval and coordinated effort from a number of stakeholders,
including: Eraring Energy (the customer); Aurecon (the consultant); AEMO
(grid regulators); Transgrid (the transmission utility); plus all subcontractors
and suppliers.
Site installation and pre-commissioning were completed over a period
of four weeks for each unit. Eraring Energy provided assistance onsite,
while Schneider Electric and their subcontractors completed the bulk
of the work.
Delivering a Complex System
Using local expertise, Schneider Electric assessed each site and proposed
to Eraring Energy a comprehensive solution – to replace their out-dated
equipment, with state-of-the-art numerical terminals.
Integrating new technology with the existing system was no easy task.
It required extensive design, engineering, system study and settings
report, plus technical assistance for approvals from the System Operator.
Schneider Electric’s solution included the provision of new protection
systems for generators, transformers and the transmission line, along
with replacement of cable communication carrier systems for turbine
inlet pipeline guard gate trips. This was carried out using DIP5000 (a
comprehensive, digital tele-protection system) and communication of
the relays on DNP3 to the SCADA system. In addition, Schneider Electric
was commissioned to install fault/disturbance recorders and a global
positioning satellite (GPS) system.
Unique Design and Engineering
Despite an innovative design, the upgrade required a solution that could
accommodate the challenges imposed by a 30-year-old system – namely
retrofitting the existing protection panels and creating an interface between
the old and the new systems. The units can run in both “generator” and
“pump” modes, and one of the main challenges arose while implementing
the negative-phase sequence protection on the generator, under these
modes. In “pump” mode, the Intelligent Electronic Device (IED) would
sense an unbalanced current in the system as in “Phase A” and
“Phase B” were reversed. In order to resolve the issue, the scheme had to
be designed so that the logics (programmed in the IEDs) could suitably
handle both modes of operation. Schneider Electric’s local expertise
and “creative engineering” were the keys to finding a solution for these
technical challenges.
Infrastructure Eraring Energy, Shoalhaven District, New South Wales
LOCATION
• Shoalhaven District, New South Wales.
OBJECTIVE
To provide Eraring Energy with superior safety
and communications devices.
How THIS WAS ACHIEVED
• replacement of generator and transformer
protection systems
• integration with existing systems
• operator and technician training
PrOjECT AT A GLANCE
• Protection panels including Schneider Electric
MiCOM & GE SR range of relays
• SCADA communication
• Site refurbishment
• 3rd party coordination and approval
In 1977, the Electricity Commission of NSW commissioned their 16kV, two-stage,
pumped storage hydroelectric scheme in the Shoalhaven district.

2. ©2012SchneiderElectric.AllRightsReserved.
Building the Protection Panels
There are two pump-generator units at each
of the locations. At Kangaroo Valley, both units
consist of a 16kV 93MVA synchronous motor-
generator. At Bendeela, the units consist of a
16kV 51.1MVA synchronous motor-generator.
The existing protection systems were primarily
made up from discrete electromechanical relays.
They were used as part of a retrofit, using an old
two-carrier communication system for the line
protection between the Bendeela and Kangaroo
Valley Power Stations. The electromechanical
relays were also integrated with the new
equipment. A new communication carrier system
was used to provide redundant tele-protection
for guard gate tripping, in the event of any fault
in the pipeline.
A total of eight panel sections have been
installed by Schneider Electric at the Bendeela
Power Station:
• 2 x unit protection A panel sections
• 2 x unit protection B panel sections
• 1 x transformer and line protection A panel
section
• 1 x transformer and line protection B panel
section and
• 2 x station transformer panel sections.
A total of 11 panel sections were installed
by Schneider Electric at the Kangaroo Valley
Power Station:
• 2 x unit protection A panel sections
• 2 x unit protection B panel sections
• 2 x transformer A panel sections
• 2 x transformer B panel sections
• 2 x station transformer panel sections and
• 1 x standby generator panel section.
‘Schneider Electric’s local expertise and
“creative engineering” were the keys to finding
a solution for these technical challenges.’
Most of the protection equipment used, was Schneider Electric MiCOM
and GE Relays. The panel sections comprise:
• unit protection A panel section – (MiCOM P343, MiCOM P122)
• unit protection B panel section – (GE G60, MiCOM P122)
• transformer and line protection A panel section – (MiCOM P633,
MiCOM P543)
• transformer and line protection B panel section – (GE T60, GE L90)
• station transformer panel section – (MiCOM P141, MiCOM P122)
• standby generator panel section – (MiCOM P122)
The panel sections were successfully built and tested at Schneider
Electric’s testing facility. Eraring Energy also received extensive training
support for Operators and Technicians.
Communication Was the Key
The new protection equipment installed by Schneider Electric was
connected to the existing SCADA system. This setup enabled the customer
to access data communications in real time so relay settings, fault records
and event records could be accessed on demand. This was done through
the serial COM port of EKI-1522, on the second rear communication port
of the IEDs.
DIP5000 teleprotection units replaced the old analogue cable carrier
system that was used for the tripping of the guard gate system. The
DIP5000 was designed to transfer protection commands coming from
protective relays, to the remote location via either fibre optic cables (digital
mode) or pilot cables (analogue mode). Using the latest digital signalling
processing technology and advanced coding algorithms, the DIP5000
offers the highest level of security and speed of transfer for this
protection system.
Completing the Work
Protection upgrades to the Bendeela and Kangaroo Valley Power
Stations were, for the most part, completed in July 2009 and December
2011 respectively. The protection systems remain fully operational and
Schneider Electric is in the completion stage for any outstanding items, as
per the contract.
The Site-Specific Safety and Environment Plan was also prepared to
account for the activities that took place at the Kangaroo Valley and
Bendeela Power Stations. According to this plan, all work carried out by
Schneider Electric (and its subcontractors) was completed safely and with
no lost time due to workplace incidents.
Infrastructure Eraring Energy, Shoalhaven District, New South Wales
Schneider Electric (Australia) Pty Ltd 78 Waterloo Road, Macquarie Park, NSW 2113 Australia. Tel: 1300 369 233 Fax: 1300 369 288 www.schneider-electric.com.au
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