‘AI, IoT and Digital Twin are Revolutionising Dam, Power Stations Operations at NHPC’: Dr. Prashant Atrey, Executive Director (IT&C), NHPC Ltd

NHPC Limited is rapidly transforming its operations by leveraging cutting-edge technologies to drive efficiency, safety and sustainability in the hydropower sector. Dr. Prashant Atrey, Executive Director (IT&C), NHPC Limited, in an exclusive conversation with Bhaswati Guha Majumder, Senior Correspondent at APAC Media, shares how the organisation is integrating Artificial Intelligence, IoT, Digital Twin and advanced cybersecurity measures to modernise dam safety systems, optimise power station performance and contribute meaningfully to India’s Digital India and net-zero goals.

NHPC, as a major hydropower PSU, is increasingly adopting digital technologies. Can you share how emerging technologies like AI, IoT or digital twins are being leveraged in dam and power station operations

NHPC Limited is a Navratna Public Sector Undertaking of the Government of India. NHPC Limited is engaged in the construction and operation of renewable energy projects, viz., hydro, solar and wind power projects

NHPC is progressively integrating emerging digital technologies such as Artificial Intelligence (AI), Internet of Things (IoT), and Digital Twin into its operations. These technologies are revolutionising the way dams and power stations are monitored, maintained and optimised.

• Predictive Maintenance at Power Stations: Subsequent to the deployment of RTM tools for Generating Plant and equipment at Power Stations, the vital parameters like vibration, temperature and lubrication, etc., are being closely monitored through sensors and are being linked to various unplanned machine maintenance. Over a period of time, AI/ML algorithms will be used to arrive at predictive maintenance schedules. This will help in minimising unplanned outages and increasing machine availability.
• EWS/Water Inflow Forecasting at Dam / Barrage sites: Automatic Water Level Recorders (AWLRS) installed at Gauge & Discharge sites upstream of Dam/Barrages calculate the water flow and then with the help of AI tools, flood reaching at Dam / Barrage sites is being forecasted. Any sudden increase in flood is forecasted with sufficient lead time to save manpower/resources at vital locations.
• Digital Twin and Metaverse: This concept is being planned for Power stations so as to train Power plant engineers in Power house operations and deal with worst-case scenarios in case of a crisis.

• Dam Safety Management: A wide range of sensors (IoT devices) are installed across various components of a Power plant, like the Dam/Barrage, Power house cavern, Tunnels to monitor seepage, inclination, movement, earthquake, etc. It is being planned to deploy AI tools to integrate their inputs, analyse them to forecast any future probable event, so as to take remedial measures.

What are some key cybersecurity measures NHPC has implemented to secure its critical infrastructure and operational technology systems?

NHPC has a dedicated Information Security Group and a Cyber Security Operation Centre (CSOC). Information Security Group has trained cybersecurity professionals at NHPC Corporate office and cybersecurity nodal officers at each of the power stations, projects and regional offices. NHPC has focused on increasing security posture in the organisation through educating all stakeholders at NHPC power plants/locations about cyber safe behaviour. All guidelines being issued by various regulatory agencies are being complied.

NHPC has also been designated as CERT-Hydro for overseeing cybersecurity compliance at 35 nos. hydro utilities of the country and CISO-NHPC is responsible for providing guidance and monitoring cybersecurity compliance.

With the government’s push towards Digital India, how is NHPC contributing to this vision internally and externally?

1. Digitisation of Operations

Almost all business operations in NHPC are digitised and efforts are being made to improve them, viz.

• ERP Implementation: NHPC has had ERP since 2007 and is now switching over to SaaS based SAP ERP to bring value addition to various business operations.
• e-Office System: Implementation of the e-Office system since 2019 has reduced dependency on physical files and enabled faster, transparent decision-making.
• e-IoMs: NHPC, for the last many years, has deployed an electronic mode of inter-office communication.
• Document Management Systems (DMS): Digitally storing, accessing and tracking project-related documents has improved efficiency and compliance.

1. Cybersecurity & IT Infrastructure

• NHPC maintains a robust cyber-safe LAN / WAN in alignment with government guidelines.
• It has upgraded its data centres, secured networks to safeguard internal systems, essential for any digitally enabled organisation.

• Regular training programs are conducted for employees to enhance digital skills and encourage the adoption of digital tools and platforms.

1. Online Services and Public Interfaces

• Digital Payments: NHPC facilitates digital payments for vendors and contractors, aligning with the government’s push for cashless transactions.
• E-procurement & E-tendering: Full implementation of e-procurement ensures transparency, efficiency and wider vendor participation.
• RTI and Grievance Portals: Citizens can file grievances or RTI requests online, improving governance and transparency.

Data plays a crucial role in asset management and predictive maintenance. How is NHPC utilising big data analytics to improve efficiency and reduce downtime?

All generating plant equipment like turbines, generators, transformers and various civil structures continuously collect sensitive data in real-time mode about vibration, temperature, pressure, stress, inclination, seepage, water level, etc. This enormous amount of data is being processed, analysed using AI / ML for root‑cause diagnosis, predictive maintenance, supply‑chain optimisation, flood forecasting, etc., to improve efficiency and reduce downtime.

From a PSU perspective, what are some of the digital transformation challenges you face in terms of legacy systems, workforce reskilling, or procurement processes?

The challenges we have faced and are still facing are similar to other PSUs as well, but the stage may vary. So following are the major ones that all PSUs face:

1. LegacySystems:

• Obsolete Infrastructure: Many PSUs still rely on decades-old systems that are difficult to integrate with modern technologies like cloud, AI, or data analytics.
• Vendor Lock-In: Long-term contracts with legacy vendors often prevent the adoption of newer, more agile solutions.
• Security & Compliance Risks: Upgrading legacy systems can introduce vulnerabilities and require careful handling of sensitive citizen or organisational data.
• Data Silos: Information is often scattered across different systems and departments, making unified data access and analytics difficult.

2. Workforce Reskilling

• Skill Gaps: A large portion of the PSU workforce may lack training in emerging technologies such as cloud computing, cybersecurity, AI/ML, or agile methodologies.
• Resistance to Change: Employees may be reluctant to adopt new tools and processes due to a lack of digital awareness or fear of redundancy.
• Training Programs: Reskilling initiatives are often underfunded or poorly aligned with actual technological upgrades being implemented.
• Leadership Buy-In: Without top-down advocacy for digital upskilling, training efforts often lose momentum.

3. Procurement Processes

• Rigid Rules & Procedures: Traditional procurement frameworks in PSUs are slow and often not suited for rapidly evolving tech needs.
• Lack of Flexibility: Tenders often demand the lowest-cost bids, which can compromise quality and innovation.
• Slow Decision-Making: Multiple layers of approvals delay project initiation and technology adoption.
• Vendor Qualification Barriers: Startups and SMEs with innovative digital solutions may be disqualified due to stringent eligibility criteria.

Looking ahead, what are NHPC’s priorities in terms of IT modernisation and green technology integration to align with sustainability and net-zero goals?

NHPC’s priorities are clearly shifting toward becoming a digitally enabled, multi-renewable clean energy player. The fusion of IT modernisation with green technology not only boosts efficiency but also solidifies its commitment to net-zero emissions and sustainable development. The company’s future roadmap likely includes greater investments in AI, automation and hybrid renewable energy systems.

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