Supporting the digitalisation of existing hydropower plants using computational fluid dynamics modelling

Computational Fluid Dynamics (CFD) is a vital technology in the digital transformation of hydropower systems, using it to perform sophisticated simulations with a view to improving design, efficiency, and sustainability. Although CFD is useful in optimising turbine design, predicting cavitation, evaluating flow-induced vibrations and handling sediment transport, its application to legacy hydropower plants is not without some challenges. These challenges are examined in this paper through the development and application of an Inverse Design Method and Advanced Optimisation Techniques. It is shown that these techniques can facilitate the development of CFD models without the need to shut down live plants or even have access to the components. An accurate digital model of an aged hydropower infrastructure for a 54 MW power plant in Greece was created by using operational performance data to generate target hydraulic profiles and then using simulation to refine potential design geometries. Furthermore, this paper shows how the inverse design method and digital twin integration can support the digital transition in the hydropower sector through real-time data applications, predictive maintenance, and adaptive operational strategies to improve performance, safety, and ecological compatibility. This study supports the inverse design method as a revolutionary way of digitalising legacy hydropower systems, and the advancement of CFD-driven digitalisation to improve the effectiveness and sustainability of hydropower operations.