New York Power Authority Selects Sensatek for Groundbreaking Hydroelectric Monitoring Pilot with EPRI

Niagara Falls, NY – In a major leap toward enhancing hydroelectric plant efficiency and reliability, the New York Power Authority (NYPA) has partnered with Sensatek and the Electric Power Research Institute (EPRI) to pilot ViDeoMAgic, an innovative video-based condition monitoring technology. The pilot project, conducted at NYPA’s Niagara Falls hydroelectric facility, aims to transform how turbine components, particularly wicket gates, are monitored and maintained.

This initiative is part of NYPA’s ongoing efforts to embrace cutting-edge solutions that enhance operational flexibility while supporting the increasing integration of renewable energy into the grid.

The Challenge: Increasing Demands on Hydroelectric Systems

The rise of renewable energy sources, such as solar and wind—which have grown by 18% since 2019—has created new demands for grid stability. Hydroelectric plants like those at Niagara Falls are crucial in balancing the grid but must now operate with greater flexibility. This increased cycling places additional stress on critical turbine components, such as wicket gates, leading to higher maintenance costs and a greater risk of unplanned outages.

Traditional monitoring solutions for wicket gates are often limited, providing little early warning of issues like shear pin failures or irregular gate movements. Expanding monitoring capabilities across individual gates would be prohibitively expensive and impractical for large-scale operations.

The Solution: ViDeoMAgic Technology

ViDeoMAgic, developed by Sensatek, offers a revolutionary approach to condition monitoring. The technology uses a NIST-calibrated video camera to perform non-contact, high-resolution vibration analysis, transforming each pixel in the video into a virtual vibration sensor. This enables precise monitoring of multiple turbine gates simultaneously, without the need for individual sensors or invasive installations.

The system captures critical operational data such as shaft runout, gate passing frequency, and other machine signatures, delivering valuable insights into turbine performance.

Pilot Results at Niagara Falls

During the pilot project at NYPA’s Niagara Falls facility, ViDeoMAgic demonstrated its ability to provide actionable insights into the condition of wicket gates and associated components. Key results included:

• Comprehensive Multi-Gate Monitoring: A single camera monitored the vibration and performance of all turbine gates simultaneously.
• Non-Intrusive Deployment: The system was rapidly installed with minimal disruption to plant operations.
• Enhanced Predictive Maintenance: ViDeoMAgic identified early signs of anomalous gate behavior, enabling prioritized maintenance and reducing the risk of unplanned downtime.
• Cost-Effective Expansion: The technology offered a scalable alternative to traditional sensor-based systems, reducing monitoring costs while improving coverage and accuracy.

A Game-Changer for Predictive Maintenance

EPRI and NYPA engineers noted the potential of ViDeoMAgic to significantly improve predictive maintenance programs. By trending vibration data over time, the system allows operators to detect issues early and schedule repairs before failures occur. This proactive approach supports NYPA’s mission of maintaining high levels of reliability and efficiency in its operations.

“ViDeoMAgic has proven to be an invaluable tool in enhancing our ability to monitor critical turbine components,” said a representative from NYPA. “Its non-contact design and rapid deployment make it ideal for real-world operations, and the insights it provides are instrumental in keeping our turbines running efficiently.”

Looking Ahead

With the successful completion of the Niagara Falls pilot, NYPA is exploring broader deployment of ViDeoMAgic across its hydroelectric facilities. Sensatek and EPRI plan to continue refining the technology to address additional use cases, such as shaft dynamics and broader structural health monitoring applications.

This collaboration represents a significant step forward in leveraging innovative technologies to address the challenges of modern hydroelectric power generation. As renewables continue to grow, solutions like ViDeoMAgic will play a critical role in ensuring the stability and reliability of the energy grid.