SPIC Brasil and GE Vernova complete third unit upgrade at São Simão hydroelectric plant ahead of regulatory deadline

SPIC Brasil and GE Vernova announced on September 14 the completion of Generating Unit 3’s modernization at the São Simão Hydroelectric Plant — the third of six units fully renovated at the 1,710 MW facility straddling the border of Goiás and Minas Gerais. The plant supplies power to roughly 6 million Brazilian homes.

Three down. Three to go.

Third unit modernized in 10.3 months, below the 12-month regulatory cap

Finishing ahead of a regulatory deadline is one thing. Doing it faster than both previous attempts at the same plant is something else entirely.

GE Vernova leads a consortium that also includes Powerchina, covering hydromechanical systems, SDSC, and electrical and mechanical balance-of-plant (BOP) systems.

UG3’s modernization wrapped up in 10.3 months — shorter than the time recorded for the first two units and comfortably under the 12-month ceiling set by Brazil’s National System Operator (ONS) and the National Electric Energy Agency (Aneel). That combination of regulatory compliance and internal improvement suggests the project team has genuinely hit its stride. The next shutdown is already being planned for UG1, which becomes the fourth unit to enter the modernization cycle. Each completed unit adds to an operational baseline that the remaining three will need to match or beat.

Engineering complexity and logistical scale drove the project timeline

Getting to the actual modernization work wasn’t straightforward. Before any upgrades could begin, existing equipment had to be dismantled — a phase that took roughly three months on its own.

The physical scale was considerable. Teams moved components weighing up to 452 U.S. tons, including a railcar gate standing 39.4 feet high. Coordinating lifts of that magnitude inside an operating hydroelectric facility demands precise sequencing, and there’s little room for error when the margins are that tight.

GE Vernova leads a consortium that also includes Powerchina, covering hydromechanical systems, SDSC, and electrical and mechanical balance-of-plant (BOP) systems. GE Vernova holds responsibility for all engineering, integration, installation, and commissioning work — spanning turbines, generators, and auxiliary equipment across the plant’s main systems.

Lessons from earlier units shortened downtime and improved coordination

One of the clearest takeaways from UG3’s completion is that experience compounds. Lessons from the first two unit modernizations were applied directly to tighten processes and cut overall downtime on the third.

There’s also a structural advantage at play. The São Simão modernization program runs in parallel with a separate expansion project — the future UG7 — and the two efforts share resources and processes despite having distinct teams. SPIC Brasil CEO Adriana Waltrick pointed to that cross-project dynamic as a genuine performance driver. “Even with distinct teams dedicated to each project, we operate with similar processes, share resources, and maintain a high level of collaboration to help ensure the excellence and safety of both projects,” she said.

GE Vernova Hydro CEO Cláudio Trejger framed the result in broader industry terms. Completing the work “well below the average industry timeframe,” he said, reinforces the technical capacity of the joint team and demonstrates that refurbishing existing plants is “one of the smartest and most competitive ways” to support national energy security and update electricity infrastructure.

$220 million program targets full digital control and 30 more years of operation by 2029

UG3 is one piece of a much larger commitment. The full modernization program carries a total investment exceeding $220 million spread across ten years, structured around seven major work packages.

Those packages range from transformer replacement and overhead crane refurbishment to a complete overhaul of the plant’s control architecture — moving from a fully analog system to 100% digital controls. That last transition represents a meaningful shift in how the facility monitors and manages its own operations, not just an equipment swap. The move to digital control also positions the plant to integrate more readily with Brazil’s evolving grid management requirements.

All six generating units are expected to complete modernization by 2029. Once finished, the plant is projected to operate with superior reliability for the next 30 years, continuing to power roughly 6 million Brazilian homes while contributing to the country’s long-term energy security.

SPIC Brasil and GE Vernova completed the modernization of Generating Unit 3 at São Simão in 10.3 months — faster than the two preceding units and under the 12-month ONS/Aneel regulatory limit. Three of six total units are now renovated, with UG1 next in line. The consortium led by GE Vernova, which includes Powerchina, manages a scope covering hydromechanical, electrical, mechanical, and digital control systems. The broader program involves an investment exceeding $220 million, targets full completion by 2029, and aims to extend the plant’s operational life by 30 years through seven structured work packages — including a full transition from analog to digital control systems.

Kelly Lippke

Kelly is an experienced writer with 15 years of experience exploring the big stories that shape our world, from tech breakthroughs and space exploration to climate, energy, and the fascinating quirks of science. She has a talent for turning complex ideas into sharp, memorable insights that stay with readers long after they’ve finished reading.