Real-Time Sedimentation and Operational Technology Integration to Enhance Hydropower Operational Reliability: Case Study of the Chivor Hydropower Plant in Colombia

This study addresses the critical challenge of sediment-driven degradation in aging hydropower infrastructure by implementing a novel Digital Operational Technology modernization framework at the AES Chivor Hydropower Plant in Colombia. While conventional sediment monitoring relies on sporadic manual campaigns, this research introduces a continuous, real-time sensing architecture that integrates hybrid acoustic–optical sensors, covering a range of 10 to 6000 mg/L, directly into the plant’s SCADA (Supervisory Control and Data Acquisition) system. The novelty of this approach lies in the seamless coupling of high-frequency physical data (15 min sampling) with an Operational Decision Support Module, enabling adaptive turbine management. Statistical validation against laboratory gravimetric standards yielded a robust correlation of 0.93, confirming the system’s precision in quantifying suspended sediment concentrations. By identifying critical fine particle fractions in real time, the proposed model enables a precision-based maintenance strategy that significantly reduces unscheduled production downtime and mitigates accelerated wear in Pelton turbines. These findings provide a scalable benchmark for extending the operational life of large-scale hydropower facilities facing advanced sedimentation risks through digital transformation.