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team of 15 engineers developing methods for data collection and analysis to improve efficiency across Vattenfall’s power generation operations. “AI is helping us streamline operations and will play a key role in the green transition,” he says. AI is applied in multiple hydropower contexts. At the Goldisthal plant in Germany, drone imagery is analysed to detect cracking in the dam structure. At the Juktan plant, drones have mapped the entire facility, including underground tunnels, producing a 3D digital model to support refurbishment planning. Environmental monitoring is another focus. In Sweden,


AI systems at the Stornorrfors hydropower station detect fish numbers and assess their health. Algorithms can identify fungal infections, estimate length and weight, and monitor food availability. Similar projects track wildlife around wind farms in Scotland and Sweden. Predictive maintenance is also advancing with AI. Algorithms now forecast component failure to reduce unplanned downtime. In heat operations, AI models slag formation in incinerators, and at nuclear plants, it helps optimise fuel rod placement by predicting bending under operational conditions. Robotics are moving beyond data analysis. At Forsmark, Spot is equipped with cameras, sensors, and a grapple to carry out inspections and operations, even in radioactive areas. Tests have shown the robot can navigate the plant and perform assigned tasks safely. In the near future, humanoid robots could work in existing infrastructure without modifications, taking on hazardous or high-risk operations. The development of virtual training environments has accelerated robotic learning. Robots can repeatedly simulate tasks such as climbing stairs or operating equipment until they master them, reducing the need for human supervision during initial testing. According to Wästlund, robots and AI will become


routine in plant operations within the next decade, supporting both fieldwork and office tasks. By applying these technologies, hydropower and other energy sectors can improve efficiency, reduce risks to personnel, and support the transition to renewable energy.


Specialised robots in China China Yangtze Power (CYPC), a listed subsidiary


of China Three Gorges Corporation (CTG), has recently put three specialised robots into operation at hydropower stations, each designed for specific inspection and maintenance tasks. The first, an underwater inspection and maintenance


robot called Underwater Dragon, consists of a host unit with multiple add-on devices. It can operate in reservoirs, tailwater areas, flow channels, and culverts, reaching depths of up to 300m – five times deeper than human divers under the same conditions. The robot is equipped for underwater photography, scanning, salvage, measurement, cleaning, and cutting. By performing diving operations autonomously, it reduces safety risks and improves maintenance efficiency. The second robot, designed for concrete flow-path inspection and nicknamed Gecko, weighs 18.4kg and adheres to concrete surfaces. It can automatically detect and avoid obstacles, walk along the surface, and be remotely controlled for manual inspections. Gecko can locate defects, measure their size and depth, and perform detailed surface analysis. This is the first robot of its type used in concrete flow-path inspection in China and represents a significant advance in hydropower maintenance technology. The third robot, called Spiderman, is intended for inspection and maintenance of large steel pressure pipes, with diameters up to 12.4m. Equipped with HD cameras and dot-matrix laser scanners, it crawls along the domes of multi-story-high pressure steel pipes, creating 3D models of the inspection area. Spiderman can automatically detect flaws, measure their dimensions, and perform repairs including grinding, welding, and painting. The system includes a body structure, control system, ground-base station, and visual inspection system. These three robots extend operational capabilities


across hydropower plants, enabling safer, more efficient inspections and maintenance in areas that are difficult or hazardous for humans.


Left: CYPC has put specialised robots into operation at hydropower plants in China


www.waterpowermagazine.com | October 2025 | 33


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