Experimental Development and Field Validation of an Advanced Penstock Repair Process for Extending Service Life in a Hydropower Plant

The rehabilitation of critical water-conveyance infrastructure plays a fundamental role in the water–energy nexus and constitutes a key strategy for extending the operational lifetime of hydropower facilities. These interventions are aligned to the United Nations’ 2030 Agenda, which declare that ensuring access to affordable, reliable, sustainable, and modern energy systems is essential for long-term energy security. This paper presents a field-validated, non-thermal repair methodology developed for the Chivor II hydropower penstock, a critical water conduction tunnel used for energy production in Colombia, that has been affected by a circumferential fatigue crack. Due to the geometric confinement of the penstock within the rock mass, conventional thermal or stress-relief treatments were unfeasible. Therefore, the proposed methodology uses controlled material removal with a welding sequence designed to release stored elastic energy and induce compressive stresses through the Poisson effect. Its main contribution is demonstrated through pilot-scale validation and full-scale implementation under real operating conditions, achieving 50% reduction in tensile stresses and left 99% of the examined surface under compression, which represents effective residual-stress stabilization, structural recovery, and hydraulic reliability. The methodology ensures reliable water conveyance for hydropower generation and can be applied to other pressurized conduits and pipelines where accessibility and heat treatment are constrained, strengthening SDGs 7 and 9 on clean energy, water sustainability, and resilient infrastructure.