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Hydro Turbine Control Retrofit for Faster Response at Kremasta Hydroelectric Power Station

Client

Hydroelectric Power Plant Operator, Greece (confidential)

Location

Kremasta Hydroelectric Power Station, Greece

Industry

Power Generation

Asset Type

Hydroelectric Power Station, 4 x 110 MW Francis-Type Hydro Turbines

Solution Category

Electronic Governing, Speed Sensing & Positioning Systems, Brownfield Retrofit, Unit Control & Protection Systems, HMI Systems, Hydro Turbine Control Systems

Hydro Turbine Control Retrofit for Faster Response at Kremasta Hydroelectric Power Station

Control and protection upgrade of four 110 MW Francis-type hydro turbines at a major 440 MW hydropower Hydroelectric Power Station in Greece.

The project addressed the limitations of ageing turbine control systems, where the existing hydro-mechanical controls required increasing maintenance and limited the stability, response speed and precision of turbine operation.

As the particular plant plays an important role in Greece’s daily power production program, the retrofit had to be highly reliable, fast to implement and executed with minimal disruption to plant availability.

MAS delivered an electronic turbine control retrofit based on the Woodward ATLAS turbine control platform, engineered to operate alongside the existing hydro-mechanical control system, which was retained as a backup.

The project covered design, installation and commissioning, with each turbine upgraded within a tightly controlled downtime window.

Key Outcomes

  • Improved turbine stability, control accuracy and operational response
  • Achieved 0–100% load response in less than 20 seconds
  • Completed the full upgrade campaign in 4 weeks
  • Limited downtime to a maximum of one week per turbine
  • Maintained plant operation during the upgrade using the remaining available turbines
  • Increased operational safety and reduced maintenance requirements

Technical Capabilities Demonstrated

This project highlights MAS’ capability to deliver hydro turbine control upgrades for critical power generation assets, where plant availability, fast response and operational safety are essential.

MAS engineered an electronic hydro turbine control system based on the Woodward ATLAS turbine control platform, integrating unit control and protection systems, electronic governing, redundant speed sensing, blade feedback, high-accuracy positioning systems and local HMI systems with remote indications to the control room.

The project also demonstrates MAS’ expertise in combining new digital control technologies with existing hydro-mechanical control systems, allowing the legacy system to remain available as a cold backup solution.

The scope included design, installation and commissioning, with execution carefully planned around limited turbine downtime and continued plant operation.

Hydro Turbine Control Retrofit for Faster Response at Kremasta Hydroelectric Power Station

Hydro Turbine Control Retrofit for Faster Response at Kremasta Hydroelectric Power Station Download the Full Case Study for deeper technical details, system architecture and project outcomes