Modernizing old hydroelectric power plants is a strategic way to improve the performance, reliability, and environmental friendliness of most hydroelectric power plants built in the 20th century. Modern technologies and the expertise of European companies, particularly Austrian equipment manufacturers, allow old plants to not just survive until major repairs are due, but to become truly new and efficient.
Stages and tasks of modernization
- Replacing turbines, generators and transformers with new, more efficient units (often using Austrian, German and Swiss technology) increases power with the same water consumption and improves efficiency by 5–20%.
- Control system reconstruction—the implementation of digital controllers and automated SCADA systems—allows for remote and predictive control of all units, online monitoring of operations, and proactive prevention of accidents.
- Replacing switchgear and electrical equipment not only ensures better compatibility with modern power grids, but also simplifies maintenance and reduces the risk of accidents and downtime.
- Environmental improvements include installing fish protection devices, optimizing discharges, reducing noise, and improving environmental safety.
Benefits for the energy sector
- Increased capacity - examples of modernized hydroelectric power plants show an increase in installed capacity by 20-30% and additional production of tens of millions of kilowatt-hours due to new working parts (blades, shafts, nozzles).
- Reduced maintenance costs– new equipment operates more reliably and efficiently, while protection and automation systems and digital technologies minimize emergency situations and downtime.
- Service life extension—a proper modernization can give the station another 30–50 years of effective operation without the need for a new dam or associated infrastructure.
The experience of Austria and Europe
Austrian suppliers (Gugler, Andritz, and others) are leaders in the reconstruction equipment segment: their turbines and generators demonstrate stable operation for more than 40–50 years with minimal degradation, which is confirmed by contracts for the modernization of hydroelectric power plants in the CIS, Europe, and Asia.
Conclusion: Modernization is not just a replacement of outdated hardware, but a path to the integration of global technologies, sustainable growth in capacity and savings - and it is no coincidence that the most long-term and cost-effective projects are implemented using European equipment.
- The stages of a comprehensive modernization of an old hydroelectric power plant include a technical survey, reconstruction design, replacement of turbines and generators, updating of electrical switchgear and relay protection systems, installation of automation and digital control systems (SCADA), adjustment and adaptation of infrastructure, and environmental improvements (fish protection, discharge monitoring).
- The key advantages of the new hydroelectric units are a 10–30% increase in installed capacity, a 5–15% increase in efficiency, a reduction in operating losses, increased generation stability in variable modes, and reduced maintenance costs (the service life of the new units is 30–50 years versus 15–20 years for the old ones).
- The hydroelectric power plant's environmental performance is improving due to the introduction of fish protection screens, reduced turbulence and noise pollution, more precise automatic discharge control, and minimized accidents. New turbines and automation allow for more efficient operation and a more environmentally friendly environment.
- Efficiency comparison: modernizing an old hydroelectric power plant is typically 1.5–2 times cheaper and faster than building a new small plant, especially if the dam and main structures are in good condition. Additional advantages include minimal approvals, maintaining the water balance, and a rapid return on investment.
- Operational risks are radically reduced—regular leaks, cavitation, vibration, electrical machine and generator failures, and the risk of unplanned breakdowns are eliminated, while the chance of unscheduled shutdowns is reduced through predictive diagnostics and digital equipment monitoring.
For the engineer: modernization is a way to increase capacity, reduce risks, and transition to a “smart” station without the need for large-scale construction.
