Measuring the performance of hydraulic machines

Accurate performance measurement not only validates contractual guarantees for new equipment but also helps optimize the operation of existing installations and monitor efficiency trends—particularly in response to erosion. By using state-of-the-art measuring equipment and innovative solutions such as VertHEX (Visualize Efficiency in Real Time), HYDRO Exploitation SA helps to maximize energy production and ensure optimal asset management for its customers.

Methodology

1. Problem definition and consulting

The problem is characterized by collaboration with plant operators to determine the most suitable measurement method. Additional services may include assessing head losses in galleries and pipelines, calibrating flowmeters, optimizing injector switching thresholds for Pelton turbines, or identifying optimal coupling for variable-speed machines.

2. Characterization of physical phenomena

Various methods—such as Gibson, index, or thermodynamic—are applied using equipment compliant with IEC 60041 standards, suitable for all types of facilities. Tests are scheduled to minimize equipment downtime.

3. Data Analysis and recommendations

Data is analyzed during and after the measurement process to ensure reliable results. Targeted recommendations are then provided to optimize production and extend machine lifespan.

4. Continuous monitoring with VertHEX

As a complement or alternative to conventional measurement campaigns, the VertHEX system enables real-time monitoring of efficiency and flow rate over extended periods. Based on a simplified version of the thermodynamic method (IEC 60041), VertHEX delivers highly accurate performance and flow data without requiring water extraction—significantly reducing or eliminating downtime. This system enables continuous detection of sediment erosion or other anomalies affecting unit performance, supporting predictive maintenance and optimized operation of turbines and pumps.

Specific skills

HYDRO Exploitation specialists offer:

• Expertise in various performance measurement methods
• Deployment and integration of real-time monitoring solutions (VertHEX)
• Use of high-precision equipment compliant with IEC 60041
• Extensive experience from numerous campaigns across all types of hydraulic installations

Client benefits

The owner of the hydroelectric facility benefits from:

• Validation of contractual guarantees through precise performance verification of new or refurbished equipment
• Continuous performance monitoring via real-time systems (VertHEX), enabling early detection of efficiency losses and proactive maintenance planning
• Optimized production through identification of improvement opportunities
• A comprehensive service delivered by experienced specialists who are among the few experts in Switzerland in this field