TRUSTIFAI GmbH has completed the inspection of an artificial intelligence (AI) system developed by Global Hydro Energy GmbH for the real-time detection and quantification of sediment-related turbine wear in hydropower plants. The inspection was carried out in cooperation with TÜV AUSTRIA.
The AI system is based on Global Hydro’s SediSense digital solution and integrates AI-powered analytics within the company’s Hydrox platform. Information generated by the system can be visualised through HydroxConnect and used to support operational management.
According to the companies, the system uses structure-borne sound sensors mounted externally on the turbine casing together with machine learning methods to detect and assess wear directly at the plant. The resulting information is intended to support predictive maintenance and operational planning.
The companies said the technology has been developed in response to changing operating conditions for hydropower, including increased sediment loads associated with climate change, which can contribute to turbine wear, maintenance requirements and operational costs.
Global Hydro said the AI-based solution enables sediment loads to be detected directly at the turbine in real time, allowing operators to optimise operating strategies, plan maintenance work and extend the service life of plant components.
As part of the inspection, TRUSTIFAI assessed the AI system’s technical performance, scope definition, data quality, governance processes and planned measures for human oversight and risk minimisation.
The inspection also examined the system’s integration into operational processes. According to TRUSTIFAI, the system supports operators by providing recommendations rather than making autonomous control decisions. It also includes mechanisms to identify uncertain predictions and activate a fallback mode if input data is missing or faulty.
“The successful completion of this inspection demonstrates how trustworthy AI can be implemented in critical industrial applications. Innovative technologies are particularly effective when transparency, reliability, and technical robustness are considered from the outset,” said Andreas Gruber, Managing Director of TRUSTIFAI.
The project received support through the “aws AI Adoption: Green” funding programme, which is intended to accelerate the adoption of artificial intelligence for environmental applications.
Global Hydro said the solution contributes to the objectives of the European Green Deal by extending turbine service life, reducing maintenance costs and improving operational efficiency.
“With SediSense, we are bringing artificial intelligence directly into power plant operations. For the first time, operators receive reliable information about sediment-related wear in real time, enabling them to plan maintenance measures more effectively, increase plant availability, and sustainably extend the service life of their turbines. The successful TRUSTIFAI inspection confirms our commitment to developing innovative AI solutions that are not only high-performing but also transparent and trustworthy,” commented Thomas Stütz, Head of Digital Solutions at Global Hydro.
The companies said the project demonstrates collaboration between industry, research institutions and independent testing organisations in the implementation of AI systems for safety and economy-critical applications.
