During the iAMP-Hydro project, different measures will be taken to prepare two hydropower plants (HPP) for the digitalisation needs of the future. The two plants are Asomata HPP (operated by PPC, the Greek National Energy Company) and Makrochori HPP (operated by PPC Renewables, a 100% subsidiary company of the PPC Group).
At Asomata and at Makrochori the following aspects are worked on in the project to reach the iAMP-Hydro objectives:
We present the performed work until October 2025 very brief below. For further questions, please get in contact with Ingo Ball, WIP Renewable Energies (ingo.ball@wip-munich.de).
Makrochori SHPP is located in the Regional Unit of Imathia. The plant is a run-off river SHPP and it has no dam, reservoir, etc. The hydropower plant has an annual production of 30 GWh.
The water use is very diversified, with the main uses being: industrial water use, irrigation and drinking water supply. The plant is composed of 3 x 3.6 MW Kaplan turbines (10.8 MW) with a total nominal flow of 75 m3/s, and a nominal head of 15 m, at a nominal speed of 250 rpm.
For the hydrodynamic exploitation of Aliakmonas river, PPC has (sometimes) long ago constructed the following HPPs (upstream to downstream):
• Ilarion 153 MW (2014)
• Polyfyto 375 MW (1976)
• Sfikia 315 MW (1985)
• Asomata 108 MW (1985)
• Agia Varvara (2008)
The runoff/outflow of Asomata HPP feeds the downstream dam of Agia Varvara (useful volume ~3.5x106 m3), which serves as daily regulating dam and forebay reservoir for the main irrigation canal A0.
The A0 canal was constructed in 1959 with a flow capacity of ~78 m3/s, irrigating vast areas of Imathia and Pella Prefectures (≈ 90k hectares) and supplying water for the city of Thessaloniki (≈ 1M people).
Makrochori HPP seen from downstream (Source PPC R)
To enhance predictive maintenance and improve turbine reliability, condition monitoring systems have been deployed at the Asomata (Francis turbine) and Makrochori (Kaplan turbine) hydropower sites in Greece. The following works were done at Makrochori:
Sensors and Data Acquisition
• Sensor configurations were tailored to each site, optimising availability, quantity, and layout.
• Accelerometers and acoustic emission sensors are the primary instruments.
• Pressure sensors were included where suitable, based on existing site infrastructure.
• Installations include signal conditioning units, preamplifiers, and DAQs to ensure reliable, high-quality data capture, with analogue signals routed to control room systems for real-time monitoring and analysis.
Installed sensors for condition monitoring at Makrochori HPP (Source: TCD)
The sensor installation and analysis work
• Serves as a validation blueprint for future hydropower sites.
• Demonstrates successful implementation of the sensor planning framework.
• Ongoing data collection will support validation of numerical, CFD, and machine learning models developed from lab-scale studies.
The Asomata and Makrochori pilot sites have undergone detailed CFD analysis to simulate and predict failure mechanisms such as:
• Pressure pulsations
• Vibration
• Temperature fluctuations
• Cavitation and wear effects
A new Inverse Design with advanced optimisation method was used to overcome the lack of detailed turbine geometry data in ageing facilities — enabling accurate, validated CFD models despite limited documentation.
CFD Models for Makrochori after Reverse Engineering (Source: TCD)
These models provide essential input for the project’s predictive maintenance framework, contributing to improved reliability and performance across hydropower operations in Greece.
The same environmental probe as used in Asomata is operational at Makrochori intake and outlet. In addition, the environmental monitoring system measures oxygen levels in the runoff water from Makrochori.
Episodes with gas undersaturation at Makrochori outlet (green line) which is not present at Makrochori intake (blue line). Water level (yellow line, right axis) indicates hydropeaking events (Source: NORCE)
Preliminary results show comparable max TDG (Total Dissolved Gas) levels (~108 %) at outlet and intake, but undersaturated water at outlet (~ 80 %) compared to intake in times with low water level. Water levels are also fluctuating between 8 – 16 dm within 20 minutes several times per day, indicating signs of hydropeaking.
Weather-related datasets have been prepared for all iAMP-Hydro demonstration sites. For Makrochori, which is located at an irrigation channel coming from Aliakmonas river, this makes the flow prediction a veritable challenge.
View upstream at Makrochori HPP – dry weather (Source PPCR)
The operation of Makrochori HPP depends on the need of water for irrigation. The same time series analysis tools using MATLAB as for Asomata, were applied for one day ahead prediction for inflows, with very good results.
The iAMP-Hydro Platform brings together the data from the project’s results R1–R4, enabling the extraction of knowledge, under a common cloud-based platform that supports smarter, more connected hydropower operations and decision-making.
The platform supports multiple data collection modalities enabling the ingestion of information from diverse sources (sensors, monitoring systems, operational records, etc.). Once collected, data can be explored, analysed, retrieved and shared with trusted parties, through state-of-the-art tools designed to help hydropower stakeholders to extract real value from their assets.
Through its data analytics, the platform enables HPP operators to transform complex datasets into actionable insights that can improve HPPs operational and environmental performance, and enable them to make informed and evidence-based decisions. A dedicated marketplace enables secure and transparent sharing of data and derived insights. Powered by a blockchain-based framework, it guarantees data integrity, trust, full traceability of the exchange process; fostering trusted and reliable collaboration.
By combining strong data governance and data management mechanisms, advanced analytics, secure data exchanges and semantic interoperability, the iAMP-Hydro Platform establishes a strong foundation for more efficient, trusted and sustainable hydropower operations management.
The iAMP-Hydro Project invites interested stakeholders to learn and discuss the project results in the Community of Practice of the iAMP-Hydro project. We share there our latest results, and you can also watch the Co-Development Workshops which were organised before. There is, of course, no charge for registration as we are eager to discuss the future of digitalisation in hydropower together with you.
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