Monitoring systems |


Digitally transforming hydropower condition monitoring


Mike Hastings and Jon Fox of B&K Vibro explain how hybrid condition monitoring solutions can play a role in optimisng limited resources as part of the digital transformation of the hydropower industry


ALTHOUGH MANY CLAIM THAT hydropower units are some of the most robust, reliable machines in the industry, which require little to no machine condition monitoring, current power generation requirements are in fact changing that perception. The automation and digital transformation that is taking place in the hydropower industry is also forcing energy companies to pay more attention to their asset healthcare, not only to the operation, maintenance and reliability of the units but also to the monitoring systems themselves that can support this healthcare.


Traditional vs. new hydropower


Below: Figure 1. Monitoring strategy of Unit 1 from a hydropower station in Brazil


methods Traditional hydropower methods feature overdesigned units, whereas newer methods feature value-engineered units that are streamlined to the application. The newer units are more cost-effective to manufacture, but often they can be less robust. Traditional methods feature continuous baseload operation, whereas newer methods are based on load following, peaking and pumped storage, often with many stops and starts. This, plus the effects of partial loading, risk over-stressing the machinery and wearing out components prematurely. Life extension and performance upgrade is available for some older units,


but the added performance raises the stress levels applied to those original components that have not been changed. Traditional maintenance strategies utilised fixed


time intervals and were well staffed and well equipped for maintenance and overhauls. This enabled the hydropower units to operate for many years without problems, and therefore condition monitoring requirements were minimal, if needed at all. With newer operation and maintenance strategies, fewer maintenance and diagnostic staff are utilised, even though there is less tolerance for downtime. This means there is more need for predictive maintenance, and condition monitoring is an important part of that. Finally, whereas traditional methods are typically


state-owned and not focused so much on profitability, newer methods are more geared to reducing life cycle costs and improving operation and maintenance practices. Consequently, this means newer hydropower methods are more open to implementing automation and digital transformation technologies.


Reliability and profitability in modern hydro units


One of the biggest differences from the past is that hydropower utilities now place a great deal of importance on reliability and profitability. They must economically fulfill consumer demand (peaking and variable load power), as well as minimse disruption and bolster profit for the utilities and stakeholders. Reliability centered maintenance; ISO 55000 must be in place. Today, there are more potential failure modes to


detect as greater stress is placed on the modern streamlined units and on those older units that have been upgraded. In addition to this, monitoring must be performed at different machine states to handle the variable generation loads now required. Moreover, more lead time is needed for fault detection and diagnosis. Because of all of this, condition monitoring systems must meet these requirements and comply with new data management needs thanks to industry- wide digital transformation.


Condition monitoring’s role in a plant’s


digital transformation Industry 4.0 and IoT are transforming the industrial landscape by driving the need for digital transformation, and the hydropower industry is no exception. These technologies offer unparalleled connectivity, data availability, and automation capabilities, leading to improved efficiency, productivity, and innovation.


28 | August 2025 | www.waterpowermagazine.com


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