{"id":11356,"date":"2019-07-11T12:48:11","date_gmt":"2019-07-11T17:48:11","guid":{"rendered":"https:\/\/blog.wika.com\/us\/\/?p=11356"},"modified":"2025-11-12T13:17:52","modified_gmt":"2025-11-12T18:17:52","slug":"monitor-and-maintain-a-hydroelectric-plant-for-optimum-efficiency","status":"publish","type":"post","link":"https:\/\/blog.wika.com\/us\/applications\/monitor-and-maintain-a-hydroelectric-plant-for-optimum-efficiency\/","title":{"rendered":"How to Monitor and Maintain a Hydroelectric Plant for Optimum Efficiency"},"content":{"rendered":"<p><strong>A hydroelectric power plant requires\u00a0constant\u00a0monitoring for it to operate safely and efficiently. Another essential is regular maintenance, which reduces unplanned downtime and lengthens a facility&#8217;s\u00a0lifespan. WIKA has a comprehensive portfolio of high-quality instruments for measuring and monitoring pressure, flow, force, temperature, and level.<\/strong><\/p>\n<p>A <a href=\"https:\/\/blog.wika.com\/us\/\/knowhow\/how-does-a-hydroelectric-plant-work-a-brief-history-and-basic-mechanics-of-hydropower\/\">hydropower plant<\/a> is built to last decades, yet harsh conditions and normal wear and tear do take a toll on its\u00a0various components:<\/p>\n<ul>\n<li>Turbines suffer abrasions from suspended solids.<\/li>\n<li><span style=\"font-size: 1rem\">Metals are more prone to corrosion in the watery environment.<\/span><\/li>\n<li><span style=\"font-size: 1rem\">High pressure, stress cycles, and water hammers often cause fatigue cracking.<\/span><\/li>\n<li><span style=\"font-size: 1rem\">Partial load operations generate pulsating flows, turbulence, and cavitation.<\/span><\/li>\n<li><span style=\"font-size: 1rem\">Unbalanced and misaligned shafts cause vibration and wear out bearings.<\/span><\/li>\n<li><span style=\"font-size: 1rem\">Overheating can lead to deformation, metallurgical failure, and fires.<\/span><\/li>\n<\/ul>\n<p>To keep the entire plant operating at peak efficiency and safety, engineers need to closely monitor and control a\u00a0variety of parameters at numerous points.<\/p>\n<h2>What to Measure, Where to Measure,\u00a0and What to Use for Measuring<\/h2>\n<p>In a process that relies so heavily on water, the two obvious considerations are <strong>water level<\/strong> and <strong>flow rate<\/strong>. However,\u00a0today\u2019s sophisticated hydroelectric plants also require regular monitoring of many other parameters, including\u00a0<strong>temperature<\/strong> and <strong>pressure<\/strong>. Conditions vary from one spot to another within the plant, and the type of gauge or\u00a0sensor needed depends on the particular point of measurement. In addition, instrumentation needs to be checked\u00a0and calibrated regularly to make sure they continue to work within acceptable limits.<\/p>\n<p>Here is a brief overview of what areas of a hydropower plant are measured, and the WIKA instruments that can be\u00a0used for such measurements:<\/p>\n\n      <div class=\"wp-caption alignright\" style=\"max-width:58px;\"><img decoding=\"async\" src=\"https:\/\/blog.wika.com\/us\/\/files\/2019\/07\/lf1_resized.png\" \/><p class=\"wp-caption-text\">LF-1<\/p><\/div>\n    \n<p><strong>1. Reservoir water level<\/strong> <span>\u2013 how much potential\u00a0<\/span>energy is available in the reservoir and the hydrostatic\u00a0pressure in the turbine.\u00a0WIKA manufactures a complete line of\u00a0<a href=\"https:\/\/blog.wika.com\/us\/\/products\/level-products\/submersible-pressure-sensor-level-measurement\/\">submersible pressure transmitters<\/a> for\u00a0level measurement in rivers, lakes, and\u00a0other bodies of water. <strong><a href=\"https:\/\/www.wika.com\/en-us\/lf_1.WIKA\" rel=\"external\" target=\"_blank\">LF-1<\/a><\/strong>, for example,\u00a0is designed to withstand harsh operating\u00a0conditions. Its extremely robust case is\u00a0hermetically sealed and fully welded. The\u00a0options of lightning protection, Hastelloy<span><sup>\u00ae<\/sup>\u00a0<\/span>construction, and FEP cables make it even\u00a0more robust. For highly accurate readings,\u00a0Model LF-1 can be integrated with\u00a0temperature measurement to compensate\u00a0for temperature fluctuations.<\/p>\n\n      <div class=\"wp-caption alignleft\" style=\"max-width:77px;\"><img decoding=\"async\" src=\"https:\/\/blog.wika.com\/us\/\/files\/2019\/07\/s-20_resized.png\" \/><p class=\"wp-caption-text\">S-20<\/p><\/div>\n    \n<p><strong>2. Flow and pressure at the penstock<\/strong> <span>\u2013 to\u00a0<\/span>determine how much water will hit the turbines and at\u00a0what rate.\u00a0<a href=\"https:\/\/www.wika.com\/en-us\/s_20.WIKA\" rel=\"external\" target=\"_blank\"><strong>S-20 \u00a0<\/strong><\/a>is a top-of-the-line, precision-engineered\u00a0pressure transmitter. It\u00a0features a piezoelectric sensor and\u00a0thin-film technology and is highly\u00a0resistant to pressure spikes and\u00a0vibration. The S-20 has an all-welded\u00a0stainless steel measuring\u00a0cell inside a compact stainless steel\u00a0case for added hardiness. A variety\u00a0of available electrical and process\u00a0connections meet the requirements of\u00a0almost any application.<\/p>\n<p><strong>3. Differential pressure in the filtering system<\/strong> \u2013 to evaluate how\u00a0clean or clogged the filter is.\u00a0<a href=\"https:\/\/www.tecsis.us\/pressure-transducers\/differential-pressure-transducers\/configurable-differential-pressure.html\" rel=\"external\" target=\"_blank\"><strong>SP007 <\/strong><\/a>is a completely customer-configurable pressure transducer.\u00a0It has a standard accuracy of 0.25% and an optional high accuracy\u00a0of\u00a00.1%. Model SP007 can accurately measure the difference in\u00a0pressure between the two sides of the filter, which gives\u00a0<span style=\"font-size: 1rem\">a good\u00a0indication of the cleanness of the filter. Users have a choice of 6\u00a0pressure ports, 5 electrical connections, and a voltage or current\u00a0output to match the needs of their applications.<\/span><\/p>\n\n      <div class=\"wp-caption alignright\" style=\"max-width:108px;\"><img decoding=\"async\" src=\"https:\/\/blog.wika.com\/us\/\/files\/2019\/07\/23x.54.png\" \/><p class=\"wp-caption-text\">23X.54 with InSight glow-in-the-dark dial<\/p><\/div>\n    \n<p><strong>4. Pressure at the turbine <\/strong>\u2013 to indicate whether the turbine is full\u00a0or empty, and if it is ready to start or needs to be shut down.\u00a0The <a href=\"https:\/\/www.wika.com\/en-us\/232_54_233_54.WIKA\" rel=\"external\" target=\"_blank\"><strong>23X.54 <\/strong><\/a>is a stainless steel industrial <a href=\"https:\/\/www.wika.com\/en-us\/lp_bourdon_tube_pressure_gauge.WIKA\" rel=\"external\" target=\"_blank\">Bourdon tube pressure\u00a0gauge<\/a> with bayonet bezel ring. It has been specifically designed\u00a0to work extremely well in applications subjected to high dynamic\u00a0pulsations and vibration. Model 23X.54 can measure pressures\u00a0up to 15,000 psi. It can be outfitted with WIKA\u2019s <a href=\"https:\/\/blog.wika.com\/us\/\/applications\/improving-industrial-gauges-readability\/\">InSight glow-in-the-dark and reflective dials<\/a> for better readability in poor light and\u00a0visibility conditions.<\/p>\n\n      <div class=\"wp-caption alignleft\" style=\"max-width:126px;\"><img decoding=\"async\" src=\"https:\/\/blog.wika.com\/us\/\/files\/2019\/07\/tr10.png\" \/><p class=\"wp-caption-text\">TR10-3<\/p><\/div>\n    \n<p><strong>5. Oil and metal temperatures of the bearings in\u00a0turbines, generators, and other systems<\/strong> \u2013 to identify the\u00a0hot spots and overheating that can lead to increased wear\u00a0and tear.\u00a0The <strong><a href=\"https:\/\/www.wika.com\/en-us\/tr10_0.WIKA\" rel=\"external\" target=\"_blank\">TR10 <\/a><\/strong>and <a href=\"https:\/\/www.wika.com\/en-us\/tr40.WIKA\" rel=\"external\" target=\"_blank\"><strong>TR40 <\/strong><\/a>resistance thermometers are ideal\u00a0for measuring temperature in bearings and bushings, oil\u00a0and water tanks, air tanks, and heat exchangers.<\/p>\n<p>The TR10\u00a0series of RTD sensors can be mounted into a thermowell,\u00a0or directly into the process with a spring-loaded\u00a0compression fitting for easy installation and replacement.\u00a0TR10 RTDs can come with a transmitter to convert the\u00a0resistance signal into an analog or a digital output, which\u00a0can be easily customized to a variety of conditions. The\u00a0TR40 series of cable resistant thermometers is designed\u00a0for high performance in a wide range of temperatures:\u00a0from \u2212320\u00b0F to +1,112\u00b0F (\u2212196\u00b0C to +600\u00b0C). Choose\u00a0from a tubular or sheathed\u00a0design, and from 2-, 3-,\u00a0or 4-wire configuration. A\u00a0variety of cable materials \u2013\u00a0PVC, silicone, PTFE, glass\u00a0fiber \u2013 ensure that the TR40\u00a0meets the requirements of\u00a0most applications. Both the\u00a0TR10 and the TR40 series\u00a0are available in explosion-protected\u00a0versions.<\/p>\n<p>The <strong><a href=\"https:\/\/www.wika.com\/en-us\/tr58.WIKA\" rel=\"external\" target=\"_blank\">TR58 <\/a><\/strong>bearing RTD\u00a0sensor is small, compact, and\u00a0has been designed for areas\u00a0where space is an issue. It\u00a0uses thin-film technology\u00a0and responds extremely fast.\u00a0With no moving parts, it is\u00a0vibration resistant and perfect\u00a0for measuring temperature in\u00a0thrust bearing plates, shafts,\u00a0and motor windings. The\u00a0TR58 can be spring loaded\u00a0into the bearings\u2019 housing or\u00a0held in position with a high-temperature epoxy resin.<\/p>\n<p><strong>6. Flow, temperature, and pressure of fluids in the\u00a0cooling systems<\/strong><\/p>\n\n      <div class=\"wp-caption alignright\" style=\"max-width:116px;\"><img decoding=\"async\" src=\"https:\/\/blog.wika.com\/us\/\/files\/2019\/07\/psd_30_2_resized.png\" \/><p class=\"wp-caption-text\">PSD-4<\/p><\/div>\n    \n<p><strong>7. Lubricant level and pressure of hydraulic systems\u00a0and turbines<\/strong> \u2013\u00a0WIKA\u2019s electronic pressure switch <a href=\"https:\/\/www.wika.com\/en-us\/psd_4.WIKA\" rel=\"external\" target=\"_blank\"><strong>PSD-4<\/strong><\/a>, the updated\u00a0version of the award-winning PSD-30, is the component of\u00a0choice for measuring pressure in bearings and bushings,\u00a0oil and oil pump control circuits, air tanks, and suction\u00a0pipes. It is recognized for its robustness, user-friendly\u00a0construction, and exceptional functionality. A large display\u00a0and simple navigation menu make setup fast and intuitive.\u00a0Large ergonomic keys allow for easy adjustments. The\u00a0PSD-4 is easy to mount in almost any configuration.<\/p>\n<p><strong>8. Temperature near the endcaps of the stator winding\u00a0and at the transformer nucleus in the generator \u2013<\/strong>\u00a0to avoid\u00a0hot spots, overheating, and fires.<\/p>\n<p><strong>9. Air pressure at the generators\u2019 ventilation circuits<\/strong> \u2013 to\u00a0ensure proper cooling.\u00a0Hydropower plants routinely choose WIKA\u2019s differential\u00a0pressure switch <span>A2G-40 <\/span>to monitor flow in air filters, fans,\u00a0cold air circuits, and ventilation ducts. The compact switch\u00a0is very easy to assemble and install. The robust <a href=\"https:\/\/www.wika.com\/en-us\/a2g_40.WIKA\" rel=\"external\" target=\"_blank\"><strong>A2G-40<\/strong><\/a>\u00a0can operate at ambient temperatures between \u221240\u00b0F and\u00a0+185\u00b0F (\u221240\u00b0C to +85\u00b0C), and medium temperatures\u00a0between \u221220\u00b0F and +160\u00b0F (\u221229\u00b0C to +75\u00b0C).<\/p>\n\n      <div class=\"wp-caption alignright\" style=\"max-width:173px;\"><img decoding=\"async\" src=\"https:\/\/blog.wika.com\/us\/\/files\/2019\/07\/ti.30_resized.png\" \/><p class=\"wp-caption-text\">TI.30<\/p><\/div>\n    \n<p><strong>10. Temperature at the bus bars and thyristor bridges in\u00a0the high voltage area<\/strong> \u2013 to prevent fires.\u00a0<a href=\"https:\/\/www.wika.com\/en-us\/dial_thermometers.WIKA\" rel=\"external\" target=\"_blank\"><strong>TI.30 <\/strong><\/a>is a completely stainless steel bimetal thermometer\u00a0specifically designed for temperature measurements in\u00a0harsh and aggressive environments. Liquid dampening\u00a0makes it perfectly suitable for high vibration applications.\u00a0It has an accuracy of 1.0% FS and can measure\u00a0temperatures from -100\u00b0F to (-73\u00b0C) to + 1000\u00b0F (+538\u00b0C).\u00a0<\/p>\n<p>In addition, WIKA offers a wide range of valves, valve manifolds, and monoflanges for shut-off, venting, and\u00a0compensating functions. These accessories separate instrumentation from the process and allow problem-free\u00a0recalibration and replacement of the instrument. A variety of sizes, brackets for wall and pipe mounting,\u00a0and connection types \u2013 including NPT and G (metric) connections \u2013 make installation easy. WIKA also\u00a0manufactures siphons, snubbers, overpressure protectors,\u00a0and a complete line of diaphragm seals to further\u00a0protect the integrity of the instrument and of the process.<\/p>\n<h2>WIKA Instruments in Hydropower Plants<\/h2>\n<p>WIKA is known throughout the hydropower world for high-quality instruments when\u00a0measuring temperature, pressure, level, flow, and force. Here are some of the projects\u00a0where WIKA products have been utilized:<\/p>\n<h3>China<\/h3>\n<p>WIKA has manufactured pressure, temperature, and level instrumentation for more than\u00a020 hydropower plants in China. This includes 2,200 units for the <strong>Three Gorges Dam\u00a0station<\/strong>, the largest hydroelectric plant in the world (22.5 GW capacity), and 1,130 units for\u00a0the <strong>Xiluodo station<\/strong>, the third largest (13.86 GW capacity) in the world.<\/p>\n<h3>Brazil<\/h3>\n<p>WIKA\u2019s measuring instruments are found in the <strong>Jirau and Santo Antonio hydroelectric\u00a0plants<\/strong> on the Madeira River in Brazil\u2019s Porto Velho area. Our experts worked hand in hand\u00a0with the contractors of these two large hydroelectric plants (3,750 MW and 3,150 MW,\u00a0respectively) to design and manufacture the components that best fit their requirements.\u00a0For these plants, WIKA developed special parts and supplied more than 4,600 units,\u00a0including:<\/p>\n<ul>\n<li>717 PSD-30 electronic pressure switches for measuring oil pressure at the oil\u00a0<span style=\"font-size: 1rem\">and oil pump controlling circuit, oil pressure in the bushings, and pressure at the\u00a0<\/span><span style=\"font-size: 1rem\">suction pump.<\/span><\/li>\n<li><span style=\"font-size: 1rem\">464 A2G-40 differential pressure switches for monitoring air pressure in the\u00a0<\/span><span style=\"font-size: 1rem\">generator\u2019s ventilation circuit.<\/span><\/li>\n<li><span style=\"font-size: 1rem\">56 <\/span><a href=\"https:\/\/en.wika.com\/landingpage_cella_en_co.WIKA\" rel=\"external\" target=\"_blank\"><span style=\"font-size: 1rem\">Cella <\/span><\/a><span style=\"font-size: 1rem\">pressure switches<\/span><\/li>\n<li><span style=\"font-size: 1rem\">756 pressure gauges<\/span><\/li>\n<li><span style=\"font-size: 1rem\">2,096 TR10\/TR40 temperature sensors for monitoring the temperature of air, heat\u00a0<\/span><span style=\"font-size: 1rem\">exchange, and oil in bushings and oil tanks.<\/span><\/li>\n<li><span style=\"font-size: 1rem\">180 TR70 temperature switches<\/span><\/li>\n<li><span style=\"font-size: 1rem\">112 <\/span><span style=\"font-size: 1rem\">Cella <\/span><span style=\"font-size: 1rem\">temperature switches<\/span><\/li>\n<li><span style=\"font-size: 1rem\">212 temperature gauges<\/span><\/li>\n<li><span style=\"font-size: 1rem\">28 level gauges<\/span><\/li>\n<\/ul>\n<p>Contact our power generation specialists for more information on WIKA&#8217;s one-stop-shop solutions for power plants.<\/p>\n<div style=\"width: 100%;float: left\"><a class=\"button white\" style=\"float: right\" href=\"https:\/\/www.wika.com\/en-us\/contact.WIKA\" rel=\"external\" target=\"_blank\"><span>Contact Us<\/span><\/a><\/div>\n<p>&nbsp;<\/p>\n<p><i>Don\u2019t miss the final article in this 3-part series: The Importance of Calibration and Force Measurement in Hydropower Plants.<\/i><\/p>\n","protected":false},"excerpt":{"rendered":"<p>A hydroelectric power plant requires\u00a0constant\u00a0monitoring for it to operate safely and efficiently. Another essential is regular maintenance, which reduces unplanned downtime and lengthens a facility&#8217;s\u00a0lifespan. WIKA has a comprehensive portfolio of high-quality instruments for measuring and monitoring pressure, flow, force, temperature, and level. A hydropower plant is built to last decades, yet harsh conditions and [&hellip;]<\/p>\n","protected":false},"author":188,"featured_media":11384,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[232],"tags":[809,985,799,819,687,437,987],"class_list":["post-11356","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-applications","tag-flow-measurement","tag-hydropower","tag-level-monitoring","tag-power-generation","tag-pressure-measurement","tag-temperature-measurement","tag-thermowell"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.2 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>How to Monitor and Maintain a Hydroelectric Plant for Optimum Efficiency<\/title>\n<meta name=\"description\" content=\"A hydroelectric power plant requires constant monitoring and regular maintenance for safety, 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