Sustainable operation of turbines and generators in hydropower plants

3 ways how KROHNE can support your hydropower projects ​

Hydropower utilises the kinetic energy of flowing water to generate electricity. By building dams and reservoirs, water is stored and released in a controlled manner to drive turbines that generate electrical energy. This method is one of the world's most reliable and cost-effective renewable energy sources.  Hydropower plants also offer flexibility in energy production as they can be quickly ramped up or down to respond to fluctuations in electricity demand. This capability further contributes to cost efficiency as energy production can be precisely matched to demand.

The efficient and safe utilisation of hydropower requires precise and reliable measurement technology. This technology is crucial for monitoring the plant, optimising energy production and ensuring the structural integrity of dams and turbines.

Challenges

Due to the complexity and variability of their operating conditions, hydropower plants place special demands on measurement technology. Accurate monitoring of water levels in reservoirs and downstream areas is crucial for the safety and optimisation of energy production. Predicting water levels and flow behavior requires robust systems capable of withstanding environmental factors such as turbulence, sediment buildup, and pressure fluctuations.

Run-of-river plants, which operate without significant energy storage, rely on precise measurements to manage large water volumes and low differential pressures. Pumped-storage plants face additional demands, including managing significant elevation changes of up to 400 meters and ensuring seamless operation during energy storage and release cycles.

Key challenges include monitoring differential pressures in penstocks and turbines, detecting leaks in high-pressure pipelines, and ensuring accurate flow measurements under varying conditions. The harsh environmental conditions, including rapid flow changes, variable water properties and mechanical stress on equipment, demand measurement solutions with long-term stability and reliability. These challenges emphasise the need for advanced and adaptable technologies to ensure the safe and efficient operation of hydropower plants.

How can KROHNE provide support?

Penstock Leak detection system

The safety of dams is a critical aspect of hydropower utilisation. This monitoring is crucial to prevent disasters such as pipe ruptures, which not only cause high costs but can also endanger human lives. The sophisticated KROHNE Penstock Leak detection system (PLDS) is based on several different field proven leak detection models. It produces zero false alarms and triggers emergency shutdown in case of pipe rupture or any turbine over-speeding, plus has also a low-level leak detection capability. It can be used on the data from existing flowmeters and takes into consideration the characteristics of the different flowmeters installed.

Flow meter for all pipe sizes

The robust and reliable OPTIFLUX electromagnetic flowmeters are the best choice for measuring technical water for the supply of the bearings and for cooling purposes. Its enhanced diagnostic capabilities maintain a reliable measurement over decades of operation. KROHNE OPTISONIC ultrasonic inline flowmeters are all factory calibrated and cover pipe diameters of up to 3,000 mm. For even larger pipes, clamp-on versions are also available, which can be installed directly on site on existing pipework. Thanks to this flexibility and high measuring accuracy, the OPTISONIC devices are ideal for use in demanding conditions such as high flow velocities and turbulent flow conditions.

Forecast of the upper and lower reaches of the watercourse

Level measurement and the precise forecasting of the upstream and downstream water body is essential for a safe and efficient operation of the power plant. Installed at multiple points on the upstream and downstream water body the contactless OPTIWAVE FMCW radar level transmitter accurately and reliably measures water level.

Contribution to Sustainability

  • Resource efficiency: Precise monitoring optimises water use, reducing waste and enhancing sustainability.

  • Environmental protection: Early detection of issues minimises leaks and protects surrounding ecosystems.

  • Habitat preservation : Controlled water levels protect downstream ecosystems, promoting biodiversity

Further Benefits

  • High plant availability: Reliable instrumentation with enhanced integrated diagnostic capabilities maintains a high plant availability with a reduced need for maintenance. 

  • Improved use of resources : Efficient flow and level monitoring minimises unnecessary water diversion, conserving vital water resources.

Contribution to Sustainability

Hydropower, as a renewable energy source, plays a crucial role in sustainable energy generation, but it faces operational challenges that must be carefully managed to ensure minimal environmental impact. High flow velocities, changing water volumes and fluctuating levels can lead to inconsistent readings and increase risks to the infrastructure. Additionally, temperature and pressure fluctuations can affect turbine efficiency and durability, while sediment buildup and remote locations complicate maintenance. Reliable monitoring and regular upkeep are essential to maintain safe, stable and sustainable hydropower operations.

KROHNE supports the sustainable use of hydropower with advanced, environmentally-conscious monitoring solutions. The KROHNE Penstock Leak Detection System (PLDS) enhances dam safety by detecting leaks without false alarms, allowing for prompt shutdowns to prevent potential environmental damage. KROHNE OPTISONIC ultrasonic flowmeters deliver highly accurate measurements, reducing the need for invasive maintenance and extending equipment lifespan, while the OPTIWAVE FMCW radar level transmitter enables precise, contactless water level monitoring, helping to optimise water resource management. Together, these solutions promote operational efficiency, environmental safety, and long-term sustainability in hydropower plants.

Related Products, Services & Solutions

Ultrasonic flowmeter for liquid process applications

  • Accurate 3-path meter: large dynamic range, maintenance-free, no pressure loss
  • Cryogenic (-200°C/-328°F) and HT (+250°C/+482°F) versions; viscosities up to over 1000 cSt
  • Flange: DN25…3000 / 1…120", max. PN200 / ASME Cl 1500; also weld-ends
  • 3 x 4…20 mA, HART®, Modbus, FF, Profibus-PA/DP

Ultrasonic clamp-on flowmeter for temporary flow measurement of liquids

  • Portable, battery-powered meter used to collect additional flow data or for cost-effective on-site verification of inline flowmeters
  • For pipes DN15…4000 / ½…160"; up to +120°C / +248°F
  • Portable signal converter with integrated data logger
  • Commissioning, monitoring and data analysis via a mobile smart device using the OPTISONIC 6300 P mobile app (for Android or iOS) in combination with a USB cable or wireless Bluetooth connection®

Radar level transmitter for basic applications with liquid chemicals and open channel flow

  • Cost-effective non-contact level measurement in IBCs, chemical tanks (up to 5 bar / 72.5 psi), (waste)water applications with high accuracy requirements
  • Compact and robust 80 GHz radar with flush-mounted PVDF Lens antenna, waterproof (IP68); for use as level and flow transmitter
  • Measuring range: 0…15 m / 49.2 ft
  • 2-wire 4…20 mA HART®7; user-friendly commissioning via Bluetooth® using the OPTICHECK Level Mobile app

Radar level transmitter for liquids in standard process applications

  • Continuous, non-contact level measurement in closed tanks or in the open air
  • 24 GHz radar, Horn or Drop antennas
  • Measuring range: 0…100 m / 328 ft
  • -50…+130°C / -58…+266°F; -1…16 barg / -14.5…232 psig
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