Transforming Hydropower with the Power of Digital Twins in Dam Operations
In an era where renewable energy sources are taking centre stage, hydropower remains a steadfast player. Yet, managing these complex systems has always been a challenge.
Today, thanks to innovative technologies like digital twins, dam operators can gain unprecedented control over their facilities, significantly boosting efficiency, lifespan, and resilience. This emerging digital revolution is paving the way for a future where hydropower can seamlessly integrate with solar, wind, and other green energy sources to power our sustainable future.
Understanding the Unique Nature of Hydropower Systems
Hydropower systems, while fundamentally similar in harnessing water flow to generate electricity, are as unique as fingerprints. Whether it’s their construction, age, or the various upgrades they’ve undergone over the decades, no two dams are exactly alike. As Nathan Fletcher, a senior hydropower engineer at the Pacific Northwest National Laboratory (PNNL), notes: “Hydropower facilities are like snowflakes; even individual turbines within a plant are unique due to their individualized construction and varying upgrades over the years.”
Operating and maintaining these systems is no small feat. The sheer number of components—some dating back several decades—means there’s always something that could go awry. Dam operators often face the daunting task of predicting failures before they disrupt operations. But, until now, this has largely been a reactive process.
Enter the world of digital twins—a game-changer for the industry. Developed by a collaborative team of experts, the Digital Twins for Hydropower Systems platform was launched in 2023 and has seen significant enhancements with its 2024 updates. This virtual solution allows dam operators to monitor, simulate, and optimise their machinery, reducing unexpected outages and extending the lifespan of aging infrastructure.
Customised Solutions for Tailored Maintenance
The brilliance of the digital twins platform lies in its adaptability. By creating a virtual model that mirrors the real-life conditions of a dam’s turbines, operators can foresee potential issues before they turn into costly problems. As Chitra Sivaraman, PNNL principal investigator, puts it: “Each dam requires a unique maintenance strategy to improve efficiency, and the new digital twins platform can provide those solutions. The platform is both extensible and scalable—capable of adapting to new facilities, data, and models.”
Using the dashboard, dam operators can upload historical data specific to their facility, enabling the platform to deliver insights tailored to their unique operational challenges. With this data-driven approach, the system can predict when maintenance is needed, reducing downtime and preventing expensive repairs.
Bridging the Knowledge Gap with Digital Twins
One of the most compelling benefits of digital twins is their ability to preserve institutional knowledge. Given that many of the nation’s dams are over 60 years old, much of the operational expertise is in danger of being lost as seasoned employees retire. Scott Warnick, PNNL’s technical lead on the digital twins project, highlights this issue: “The average age of the nation’s dams is around 60 years, meaning multiple generations of employees have worked on each turbine. And knowledge is inevitably lost as seasoned employees retire and new employees join the team.”
By using digital twins, dam operators can record, simulate, and document every change made over the years. This digital legacy ensures that future generations can access vital information, helping them make informed decisions without the steep learning curve.
Modernising Hydropower Operations
Digital twins not only help maintain existing equipment but also allow operators to simulate various scenarios, such as changes in water flow or demand spikes, without risking real assets. This functionality is a significant step forward in modernising hydropower management. According to Warnick: “The digital twins solution enables hydropower operators to simulate different scenarios, such as low water flow or varying water levels, and predict future performance or maintenance needs.”
The development team at Oak Ridge National Laboratory, led by Hong Wang, has been pivotal in refining the platform. By leveraging real-time data from the Alder Dam on the Nisqually River, they have fine-tuned the digital twin to mirror actual operations. The latest updates allow operators to adjust parameters like water flow rates and turbine speeds based on factors such as seasonal changes, weather patterns, and fluctuating energy demands. This ability to proactively tweak operations means fewer surprises and optimised energy production.
Enhancing Grid Resilience Through Integration
As the world races toward a greener energy future, hydropower’s role is becoming more dynamic. The updated digital twins model is specifically designed to help hydropower facilities seamlessly integrate with other renewable sources like solar and wind. As Sivaraman explains: “This platform is capable of extending the lifespan of the nation’s dams while at the same time integrating additional sources of renewable energy to the grid.”
In practical terms, this means that during periods when solar and wind power generation dips—like in the evenings or on calm, cloudy days—hydropower can pick up the slack. However, as Fletcher cautions: “too much use can age a dam’s components quicker. The key is generating enough energy when needed without overburdening the turbines themselves.”
By simulating power demand fluctuations, the digital twin helps operators make informed decisions on when to run turbines, thus balancing energy supply and extending equipment life.
Collaboration with Utility Partners
Collaboration with industry partners is essential to the continued success of the digital twins initiative. Tacoma Public Utilities (TPU) has been an early adopter, working closely with the team to refine the platform. Greg Kenyon, TPU’s automation engineering manager, praises the collaboration: “The PNNL and ORNL teams have the mathematical and practical skills needed to solve complex digital twin problems.”
Additionally, efforts are underway with Chelan County Public Utility to create a digital twin for the Rocky Reach Dam. By using historical data, this project aims to refine predictive maintenance capabilities, reduce operational risks, and optimise energy production—all at zero cost to the utility.
A Data-Driven Future for Hydropower
While the current focus is on turbine optimisation, the future holds even broader applications. According to Fletcher, the team is already exploring ways to incorporate features like monitoring biological build-up and improving environmental compliance. The ultimate goal? A data-driven, predictive maintenance system that eliminates unplanned outages, enhances efficiency, and maximises revenue.
Kenyon envisions a future where data analytics and predictive algorithms drive every aspect of hydropower asset management. “It’s one where there are no unplanned outages and lost revenue but rather outages determined by data-driven maintenance schedules and equipment replacements,” he said.
Embracing the Future of Hydropower
As the hydropower sector navigates the challenges of modernisation, digital twins offer a promising solution.
By digitising operations, preserving knowledge, and integrating with other renewable sources, this innovative technology ensures that hydropower remains a reliable and efficient contributor to the sustainable energy grid.
