Stop Forced Trips Before They Start
Turbine control systems react in milliseconds to data that hasn't been verified. Expanso validates every signal at the source, so control decisions are based on what's actually happening at the unit.
No infrastructure replacement. No changes to control systems. Works alongside your SCADA and historian.
Small data errors escalate into turbine trips and mechanical damage
Duplicated sensor readings, timing drift across generating units, and incomplete data windows cause control systems to react to phantom conditions. The turbine trips, but the equipment was fine.
Control systems react in milliseconds to unverified data
A 2-second timing drift between a turbine vibration sensor and a gate position sensor can make the control system believe the turbine is operating outside safe parameters. The system trips the unit. Engineers spend hours tracing the cause back to a data artifact, not a mechanical fault.
Timing drift across generating units compounds into false conditions
When unit A's vibration data arrives 3 seconds before unit B's gate position data, the control system correlates mismatched readings. The resulting control action is based on a physical state that never existed.
Each false trip accelerates wear and costs generation revenue
A single unnecessary turbine trip costs hours of lost generation and adds mechanical stress that shortens component life. When trips happen weekly due to data artifacts, the cumulative cost is substantial.
Fault investigations stretch from hours to days
After a trip, engineers can't immediately tell whether the cause was mechanical, electrical, or a data artifact. They have to trace back through the historian, compare timestamps, and eliminate false readings one by one.
Signal integrity, enforced before it reaches control
Expanso validates every turbine sensor reading, gate position signal, and substation measurement at the source. Your control systems only receive data that passes validation.
What we validate
Cross-unit timing alignment - signals from all generating units synchronized
Duplicate suppression - retransmitted readings stripped before they reach control
Vibration and bearing data completeness - no gaps in safety-critical windows
Sensor drift detection - readings that diverge from calibration baselines are flagged
What your systems receive
Time-aligned data across all generating units and substations
Deduplicated streams that reflect actual equipment behavior
Complete data windows with no safety-critical gaps
Drift alerts that arrive before corrupted data reaches control logic
Large-Scale Deployment
14,847 distributed endpoints. 4.7 PB/month. Edge-first validation at scale.
A major U.S. deployment validated Expanso's approach across 14,847 endpoints. Processing moved to points of presence, raw data stayed local, and only metadata and flagged events flowed upstream.
Before: centralized ingestion at 4.7 PB/month
All telemetry sent upstream without validation. 7-day retention limit due to volume. Investigations took 3 days because teams couldn't trust the data they were looking at.
Deployment: validation pushed to the edge
Expanso deployed at points of presence across the distributed infrastructure. Raw data processed locally. Only metadata and flagged events sent upstream. Pilot completed in 8 weeks.
After: 47 GB metadata + 230 GB flagged clips upstream
99%+ reduction in centralized volume. Retention extended from 7 days to 5 years. Investigations dropped from 3 days to 4 hours. Full rollout in 5 months.
"Don't we already have SCADA for this?"
SCADA visualizes your process data. Historians store it. Control systems react to it. None of them verify that the signals arriving from turbines, gates, and substations are complete, time-aligned, and free of duplicates.
Expanso validates those signals at the source - before SCADA displays them, before historians store them, and before control systems act on them. Your existing stack stays exactly where it is. The difference is the signals feeding it are now trustworthy.
Built for hydropower operations
Covers turbines, gates, and substations across the plant
Vendor-agnostic across all OT/IT systems
Deploys plant by plant without disruption to operations
No changes to existing control infrastructure
Why teams deploy Expanso
Fewer false trips mean more stable turbine control
Lower mechanical stress from fewer unnecessary adjustments
Fault isolation in hours instead of days
Scales across multiple plants and dam systems
If the signal isn't stable, neither is the turbine
Lock in the signal. Operate with precision.