Micro Hydro Station Upgrade & Automation

Excitation Control, Governor Conversion & Turbine Generators

MWRA Cosgrove Station After Upgrade
Sorensen Systems provided the governor and control systems for micro hydro station refurbishments.

When generating electricity from water ways, turbine generators are an important part of the conversion process. These turbines need regular maintenance. Sorensen Sytems is an expert at refurbishing and upgrading these components.

When the Massachusetts Water Resources Authority (MWRA) determined that turbine generators at Wachusett Reservoir needed upgrading and refurbishment, Sorensen Systems was awarded the contract for the project. The two vertically oriented, full Kaplan type 1,600 KW generators with six adjustable runner blades and two 2,240 HP turbines had been in operation since 1969. The upgrade was necessary to integrate the turbine operation with a newly configured water supply system.

The hydroelectric facility, locally referred to as the Cosgrove Intake, regulates the flow of water from the Wachusett Reservoir into the Cosgrove Aqueduct, which is an important transmission leg in the supply of water to the Boston Metropolitan area. There are two sections, the North and South intakes, and both intakes include a hydraulic turbine and two bypass lines. Each intake has three channels with traveling water screens. Each intake also has an upper intake sluice gate and lower intake sluice gate that allow operational flexibility to draw water from different levels of the reservoir.

Electrical control panels at the MWRA Cosgrove facility.
Sorensen developed electrical control panels for a micro hydro station upgrade project for the MWRA facility in Clinton, Massachusetts.

Hydro Station Automation

The engineers and technicians at Sorensen Systems provided design, manufacturing, installation supervision, commissioning, and training for the entire project, which included:

  • disassembly and refurbishment of the existing turbine generators
  • new static excitation systems
  • new turbine bearing cooling water systems
  • refurbished switchgear panels
  • new turbine control panels
  • new digital governor heads with the refurbished governor hydraulic pumping units
  • new station battery charging system