High Falls No.1 is Vale’s oldest generating station in Sudbury, Ontario, originally built in the early 20th century.

The major existing electrical equipment was well past the anticipated life expectancy. The goal of this project was to extend operating life by 30 years.

BESTECH completed the multidisciplinary detailed engineering required to bring the project to its issued construction phase. The upgrade brought the generation station up to the latest standards of safety, efficiency, and best practices to eliminate concerns about the service life limit, maintenance cost, reliability, performance, and environmental hazards.

The scope of work included the following:

  • Electrical, civil, and structural design for the 69kV substation, generator building, 5kV switchgear line-ups, and associated infrastructure.
  • Protection and control schemes for the new substation
  • Grounding grid study
  • Lightning protection study
  • Replacement of protection and control for the generators, excitation systems and AC/ DC distribution.
  • Short circuit, coordination, and arc flash studies
  • Constructability review
  • Process hazard review
  • Demolition and removal package for existing infrastructure
  • SCADA and RTU
  • Construction and commissioning support