Renovation & Modernisation

Hydro Rehabilitation and Modernisation

We help owners of ageing hydropower assets recover performance, improve reliability, and extend plant life through targeted renovation and modernisation programmes. Our services combine diagnostics, upgrade engineering, implementation support, and performance verification.

We transform ageing hydro assets into high-performance powerhouses — restoring efficiency, extending plant life, and delivering measurable returns.

Why R&M?

Your Plant Has More Life in It

Many small hydro plants experience efficiency loss over time due to wear, outdated components, and operating degradation. A well-planned rehabilitation programme can recover output, reduce maintenance exposure, and improve the long-term economics of the asset.

Engineers lifting a large turbine runner assembly using overhead crane
Turbine Runner Extraction & Replacement — Live R&M Operation
Transformation in Practice

Before & After — Turbine Overhaul

A visual testament to the precision of modern turbine modernisation — from worn, oxidised runners to freshly machined, high-efficiency assemblies.

Kaplan turbine runner — refurbished high-efficiency assembly
Kaplan Runner — Refurbished High-Efficiency Assembly. From Worn, Oxidised Components to Renewed Precision.
Historic early 20th century hydro powerhouse — turbine hall
Legacy Powerhouse — Early Turbine Hall & Control Equipment (c. 1920s). Plants Like This Are Our Speciality.
Turbine Expertise

Modernisation Across Major Turbine Types

Our teams have deep expertise in the renovation and modernisation of all major hydro turbine types, from high-head impulse runners to low-head reaction designs.

Comprehensive Scope

End-to-End Modernisation Services

Our modernisation approach covers mechanical, electrical, and digital systems within the powerhouse, enabling coordinated upgrades that support stronger long-term plant performance.

⚙️

Hydro Turbines

  • Runner refurbishment & replacement
  • Wicket gate & guide vane rehabilitation
  • Nozzle & needle upgrades
  • Main Inlet Valve (MIV) servicing
  • Cavitation repair & coatings

Hydro Generators

  • Stator & rotor rewinding
  • Insulation system upgrades
  • Bearing overhaul & replacement
  • Capacity uprating studies
  • Efficiency testing & optimisation
🖥️

Protection & Control

  • Digital protection relay panels
  • Plant automation & PLC upgrades
  • Switchgear modernisation
  • Battery & DC system upgrades
  • Grid code compliance
📡

SCADA & Governors

  • Modern digital governors
  • Real-time SCADA implementation
  • Remote operation capability
  • Data logging & analytics
  • Cyber-secure communication
🔌

Substation & Transmission

  • Transformer replacement & uprating
  • HV switchgear upgrades
  • Metering & protection systems
  • Substation civil works
  • Grid interconnection improvements
🏗️

Civil & Structural Works

  • Powerhouse structural repairs
  • Draft tube & spiral casing lining
  • Dewatering & intake upgrades
  • Dam safety works
  • Penstock inspection & lining
Our Methodology

A Structured Path to Recovered Performance

1

Assess & Diagnose

Detailed condition assessment, efficiency review, and root-cause analysis across plant systems.

2

Engineer & Design

Site-specific upgrade engineering, equipment specification, and techno-commercial reporting.

3

Execute & Integrate

Installation planning and execution support with attention to minimising generation loss during implementation.

4

Verify & Hand Over

Performance verification, compliance review, and operator support before handover.

Why Modernise Now

The Case for Rehabilitation is Compelling

20%

Output Recovery

Depending on asset condition and upgrade scope, modernisation can support recovery of lost output and improved hydraulic performance.

40%

Reduced Maintenance Exposure

Upgraded components can reduce breakdown frequency and lower annual maintenance expenditure.

+25yrs

Extended Plant Life

A well-structured rehabilitation programme can extend the useful operating life of a hydropower asset by many years.

<5yrs

Stronger Asset Economics

Improved generation and reduced operating cost can materially strengthen project payback and asset value over time.

Discuss Your Hydropower Asset

Contact our R&M specialists today for a complimentary assessment and to discuss how we can revitalise your hydro assets.

Get in Touch
Site Documentation

Renovation & Modernisation — In the Field

A photographic record of our R&M operations: from runner repairs and turbine installation to SCADA commissioning and trash-rack maintenance.

Runner repair — precision overhaul in progress
Runner repair — refurbished turbine runner assembly
Francis turbine installation — electromechanical works
SCADA commissioning — control system integration
Trash cleaning rake — intake maintenance operations
Pelton turbine nozzles — inspection and servicing
Kaplan low-head turbine — modernisation works
Small hydro low-head installation