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Hydropower plants have been integral to our clean energy mix for more than a century. As utilities work to strengthen grid resilience, enhance flexibility, and meet long‑term clean energy targets, hydroelectric assets are being called on to do more than ever before. Yet many operators still rely on legacy equipment and aging control systems that can limit operational insight and make it difficult to maintain reliability fleet-wide. Against this backdrop, modernization has become essential.

One major U.S. energy provider faced this challenge with its more than 100 hydroelectric units, some built over 100 years ago. Past upgrades were done piecemeal, resulting in a fragmented system with limited automation and inconsistent data availability. The lack of standardization created operational inefficiencies, increased maintenance demands and reliability concerns. To prepare these units for another 80 years of service, the utility launched a comprehensive modernization program and partnered with Emerson to build a unified automation foundation across its entire hydroelectric fleet. To date, 13 generating units have been modernized, serving as a repeatable, scalable model for this comprehensive fleet modernization project.

The backbone of the automation solution is Emerson’s unified Ovation™ Automation Platform. By standardizing on a single control architecture, the utility can now operate its hydro plants with consistent logic, shared operator graphics, and a common approach to equipment tagging. This solution replaces the complexity of varied PLC systems and custom integrations with a cohesive platform designed specifically for critical infrastructure.

The Ovation platform now monitors and controls a wide range of functions across the fleet, including:

• Governor, lube oil, aeration, cooling water, and braking system control
• Balance of plant operations for service air/water, switchgear, sump, unwatering, lake level/pond, spillway gate, headgate and inlet valve systems
• Integration of excitation, electrical protection, energy management, weather station and enterprise data historian systems
• Interplant coordination of remote operations, river management and optimization

Consolidating these functions into one environment gives operators clearer visibility, faster troubleshooting capabilities and better decision-making based on real-time and historical data.

As one principal engineer on the project noted, “Ovation technology is an all‑encompassing solution—graphics, logic, alarms, historian—everything is built into one platform. We’re just beginning to unlock the opportunities within the Ovation Automation Platform.”

A key benefit of standardization is improved data quality and access. Consistent control logic and modern Emerson Rosemount instrumentation measuring level, pressure, flow, position, and temperature, equips the utility with a unified data structure across all sites. With this stronger data foundation in place, the utility can now access advanced capabilities that were previously out of reach, including:

• Centralized monitoring through a 24/7 Monitoring & Diagnostics Center
• Predictive maintenance using integrated vibration monitoring and machinery health tools
• Fleet‑wide trend analysis to inform long‑term planning
• Faster response to abnormal conditions, reducing downtime and maximizing water availability

Of course, as operational technology environments become more connected, a strong cybersecurity posture is essential. The modernization program also incorporates Emerson’s Department of Homeland Security certified cybersecurity suite, which streamlines antivirus management, patching, and compliance documentation across all hydroelectric sites. In addition, standardizing the control architecture simplifies cybersecurity management, reduces exposure, and ensures long‑term regulatory readiness.

One of the challenges of this project was updating nearly 30 different configurations of hydraulic power units (HPUs) that had been built to unique specifications over the years. This required an approach that balanced uniformity with site‑specific needs. Emerson’s engineering team adopted a configure‑to‑order strategy, establishing standardized component families—pumps, motors, valves, sumps, and accumulators—that can be adapted to each plant. Additional instrumentation now enables monitoring of wicket gate pressures, accumulator levels, sump conditions, and hydraulic performance. This approach puts the utility in a better position to maintain and troubleshoot equipment, regardless of site.

As the hydropower workforce evolves, operators increasingly need technology that simplifies training and improves mobility. A consistent automation environment—shared HMIs, reused logic libraries, and standardized engineering conventions—reduces onboarding time and helps teams move more fluidly between plants. Simulation tools built into the Ovation environment further enhance readiness by allowing operators to practice procedures and validate logic changes before implementation. This creates a stronger, more adaptable skills pipeline across the organization.

Complementing these workforce benefits, the modernization program also strengthens the fleet’s underlying automation infrastructure. Emerson’s solution addresses long‑term challenges such as component obsolescence, evolving regulatory requirements, and the need for greater operational flexibility. By unifying controls under the Ovation platform, the utility can layer in advanced analytics, simulation capabilities, and emerging technologies like AI‑driven optimization. This ensures the fleet’s automation system evolves with industry demands, enabling sustained performance and long‑term adaptability.

Hydropower’s role in a balanced clean energy future is only growing. Learn how you can eliminate the complexities of legacy hydropower systems with Emerson’s Ovation automation software. Our scalable platform unifies hydropower operations, enhancing reliability, improving visibility, and providing a foundation for data‑driven decision‑making.

Discover how Emerson’s Ovation Automation Platform can modernize your hydropower operations and support a more resilient, flexible clean energy future.

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