Hydropower generators have long played a crucial role as a reliable and renewable source of electricity. However, hydro-operators typically limit flexible operation of a hydropower plant to limit operating in specific restricted operation zones, also referred to as ‘rough zones.’ Operating in ‘rough zones’ leads to hydropower unit vibration and wear and tear, causing hydropower operators limit operation in these zones, thereby restricting the flexibility hydropower plants can offer the power system. In this paper, we present novel innovative methodology that can increase operational flexibility of existing hydropower fleet throughout the world using a.) non-intrusive feedback monitoring, and b.) battery-hydro hybridization.

Firstly, this paper introduces the concept of Internet of Things (IoT) based non-intrusive monitoring and discusses its use in identifying ‘rough zones’ characterized by high vibrations. Secondly, leveraging the ‘rough zones’ information from non-intrusive monitoring, an optimal control strategy for a battery-hydro hybrid plant is designed to enable flexible operation in regions typically restricted for hydropower units. The results show the non-intrusive monitoring-based hydro-hybridization strategy not only helps hydropower units avoid operation in ‘rough zones’ but also improves overall plant flexibility and reduces the wear and tear.

The results from the studies conducted on an operational hydropower unit clearly demonstrate that the utilization of non-intrusive monitoring data within hydro-hybridization frameworks enables these plants to confidently operate in regions of their operational envelope that were traditionally considered off-limits due to concerns over mechanical stress and runner fatigue. By leveraging real-time feedback from cost-effective sensors and integrating this information with advanced control strategies, the proposed methodology provides a transformative enhancement in both the flexibility and efficiency of existing hydropower systems. This integration allows for dynamic adjustment of plant operations, ensuring optimal performance while simultaneously preserving asset health. The capability to identify and safely navigate previously “rough zones” not only reduces the risk of equipment damage but also expands the available dispatchable range, contributing to improved reliability and responsiveness of the system. Such improvements are particularly valuable in power networks with increasing penetration of intermittent renewable resources, where the need for adaptable, resilient generation assets is more pronounced. The hybridization of hydropower units with battery energy storage, guided by intelligent, non-intrusive monitoring and feedback control, supports more stable grid operations, facilitates load balancing, and enables rapid response to shifting demand profiles. Overall, the approach outlined in the study marks a significant advancement in hydroelectric asset management, making it possible to achieve greater operational efficiency and system reliability without the drawbacks of traditional, intrusive monitoring techniques. As renewable integration continues to grow, the adoption of these innovative methodologies will play a vital role in supporting the sustainable evolution of modern energy systems.

ACKNOWLEDGMENT - The authors would like to thank FirstLight Energy for providing access to their hydropower facility for the purpose of the data collection and for their valuable technical support throughout the project.

Acknowledgment and Legal Disclaimer (Abridged) included. The Recipient is required to include the following acknowledgement in publications arising out of, or relating to, work performed under this Award, whether copyrighted or not - ACKNOWLEDGMENT: This material is based upon work supported by the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy (EERE) under the Water Power Technologies Office (WPTO) Award Number DE-EE0010187. (ABRIDGED) LEGAL DISCLAIMER: The views expressed herein do not necessarily represent the views of the U.S. Department of Energy or the United States Government.