Case Study

LHDA Hydropower Station — ABB 800xA Modernisation

AVR Replacement · Unit Controller Migration · HMI & Network Upgrade · Power Metering

Client Lesotho Highlands Development Authority (LHDA)
Location Lesotho
My Role Hardware engineering, cabinet builds, metering, HMI graphics, network hardware & commissioning

Overview

This project migrated an operational hydropower station from Advant Master to ABB 800xA. Scope: AVR replacement, unit controller migration (AC800M + S800 I/O), HMI redesign, redundant networking, server cubicle hardware builds, and power meter integration.

Technical highlights

  • Digital AVR excitation integrated into 800xA with field tests
  • Unit logic migration to AC800M with S800 I/O distributed marshalling
  • HMI graphics rebuilt to 800xA standards
  • Redundant network rings and server cubicle hardware builds
  • Power meter configuration (CT/PT scaling, Modbus mapping, PQ checks)

My Scope (detailed)

Hardware & Cabinets

I engineered new cabinet layouts, power distribution, earthing, terminal marshalling and produced all hardware drawings, cable schedules and loop diagrams. I planned the cutover to minimise plant downtime.

Server & Network Cubicles (hardware)

Physical build: rack mounting servers/switches, UPS and patching; structured cabling and grounding. Ensured mechanical & electrical compliance for SCADA/historian hardware.

Power Metering

Configured meters for CT/PT ratios, register mapping and integration into 800xA. Verified power quality, energy metering and synchronisation parameters — a revenue & safety-critical deliverable.

HMI Graphics

Built operator-focused 800xA graphics for AVR, unit control, alarms and diagnostics. Ensured efficient tag binding and consistent navigation for operator workflows.

Network Architecture

Defined redundant hardware topology, fiber/failover routing, VLAN segmentation and validated deterministic communications for controllers, HMIs, meters and relays.

Commissioning

Led hardware commissioning: power-up checks, loop tests, I/O validation and troubleshooting to achieve reliable plant operation during SAT with minimal punch-list items.

Challenges & Solutions

Mapping legacy Advant Master signals into S800 I/O required careful terminal numbering, signal type conversions and loop-by-loop verification. Implemented temporary bridging and phased cutover to avoid extended outages.
Performed CT/PT ratio checks, clamp tests, register mapping validation and cross-checks with portable meter readings to ensure billing-grade accuracy.
Reworked internal layouts, used compact marshalling and improved cable routes to fit new hardware while preserving reach to field terminations.

Outcome

The modernised ABB 800xA platform provided improved diagnostics, enhanced operator ergonomics, reliable network redundancy and accurate power metering. The hardware-first approach reduced field rework and improved maintainability for LHDA.

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