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Home My WebLink AboutHydro Power 1996An ITT Industries company ITT Flygt Corporation September 30,1996 Mr.David Lockard State of Alaska,Dept.of Community &Regional Affairs 333 W.4th Ave.,Suite 220 Anchorage,AK 99501-2341 Dear David: I received your business card from Gunnar Hovstadius,and left a phone mail message for you.I did not want to delay your receiving the information Gunnar promised,so I send you this package and invite you to call me at your convenience if you have any questions or comments. With that said,I thank you for your interest in Flygt state of the art,submersible hydroturbines. Our turbines are a semi-Kaplan design,and they have been a part of the extensive Flygt submersible product line since the beginning of the 1980's.We have units installed worldwide, with more than 100 units operating in the U.S.alone. The units are designed for long life with extended maintenance periods.All units have heavy cast iron casings with aluminum bronze or stainless steel runners supported on 100,000 Hr.rated, sealed bearings (standard configuration).The gearbox is a planetary type and has an AGMA rating of "infinite".The generators are induction type,built by Flygt,selected to suit your specifications.All turbine combinations have been tested in model scale to assure that published performance levels will be met. Budgetary pricing ranges from $30K -$400K per unit,depending on configuration.Delivery ranges from 4-6 months.In addition to the submersible hydroturbine,a draft tube,turbine seat and automatic gate will be required.Flygt can either supply these components or provide the drawings to you for local fabrication.Budgetary pricing based on selected units and installation criteria will be provided for your review once information regarding site specifics (such as head,flow and physical limitations)have been supplied to us.Prices include Flygt's exclusive 5-Year Hydroturbine Warranty. It is our goal at ITT Flygt to supply you with the highest quality equipment and service in the industry,while minimizing installed cost per KW produced.It is this goal that will optimize the economics of your site,and keep it running efficiently year after year. I trust that you will find the enclosed material informative,and hope that ITT Flygt can be of assistance in the near future. Sincerely, Te im Torony, Project Manager Hydroturbines JT:tl Attachment Cc:S.Abelin G.Hovstadius FLYGTL/0930DL 35 Nutmeg Drive,P.O.Box 1004,Trumbull,CT 06611-0943 Telephone:(203)380-4700 Facsimile:(203)380-4705 FLYGT SUBMERSIBLE HYDROTURBINES witet REFERENCE INSTALLATIONS 5/396 1981 Barsbro Sweden 2 EL 7100 3.5 160 1983 Buer Norway 3 EL.7585 16 1350 1983 Glen Colusa USA 2 EL 7570 6.1 180 1983 Winnipesaukee USA 3 EL 7650 3.5 735 1983 Little River USA 1 EL 7555 7 45 1983 Little River USA 4 EL 7585 8.9 944 1983 Rocky Gorge USA 1 EL 7555 8.8 110 1983 Rocky Gorge USA 2 EL 7570 12.5 472 1983 Cocheco Falls USA 3 EL 7570 9.4 708 1983 Musser Dam USA 1 EL 7555 §.5 45 1983 South Bend USA 1 EL 7585 2.5 63 1983 Kingsbury Branch USA 2 EL 7555 8.2 220 1984 Mjorud Norway 3 EL 7570 6.1 420 1984 Stoval 1 USA 1 EL 7555 4 37 1984 Stoval 1 USA 1 EL 7570 4 60 1984 Jim Knight USA 1 EL 7555 6.7 110 1984 Jim Knight USA 2 EL 7570 6.7 440 1984 W.Dudley USA 1 EL 7600R 3.7 110 1984 Lockmere Dam USA 1 EL 7555 §.2 33 1984 Lockmere Dam USA 4 EL 7620 §.2 1200 1984 Milburmie USA 1 EL 7600R 4 110 1984 Milburnie USA 2 EL 7650R 4 530 1984 Maxwell USA 1 Et 7570 2.4 75 1984 Watson Dam USA 1 EL 7650 3.8 265 1984 Antwerp USA 1 EL 7620 4.1 210 1984 Antwerp USA 1 EL 7570 4.1 75 1985 lridea Austria 1 EL 7600R 3.5 90 1985 Haas Austria 1 EL 7585R 7 200 1985 Prinzersdorf/Stéber Austria 1 EL 7585R 3.3 90 1985 S:t Paul Canada 1 EL 7570 7.6 220 1985 S:t Paul Canada 1 EL 7600 76 300 1985 Penman Canada 2 EL 7600 7.9 600 1985 Rheidol Dam Great Britain 1 EL 7555 10.1 110 1985 SMI Jepan 1 EL 7555 12.8 85 1885 Jung Up S.Korea 4 EL 7585 15.3 2120 1985 Getasjokvam Sweden 1 EL 7570 3.6 60 1985 Strémsbergskvarn Sweden 1 Et 7570 7 140 Sida 1 FLYGT SUBMERSIBLE HYOROTURBINESEuirrqsREFERENCEINSTALLATIONS 5/3/96 Plant n Turbine eee Eee Head (myer.cee KwiunSagebrushUSA1EL75557.3 110 Sagebrush USA 2 Et 7570 7.3 220 Tallassee USA 1 EL 7570 6.7 115 South Sutter USA 1 EL 7570 4 7§ South Sutter USA 2 EL 7620 4 170 Pocono Lake USA 1 EL 7555 7.5 63 Pocono Lake USA 2 Et.7570 7.3 115 Mad River USA 2 EL 7570 11.6 236 Steven's Mill USA 1 EL 7620R 46 236 Avery Dam USA 1 EL 7650R 2.9 200 Carishatte 1 Germany 1 EL 7585R 4 126 Current River Canada 1 EL 7585 16.8 530 Colombieres France 1 EL 7650R 5.8 450 Colombieres France 1 EL 7620 5.8 250 Rane France 1 EL 7620 5 250 Ranc ©France 1 EL 7650 5 450 Ranc France 1 EL 7650R 5 450 Montebelluna italy 1 EL 7620R 3.9 170 Ziche Italy 1 EL 7620R 3.6 170BinottoItaly1EL7620R2.7 110PluviotecnicaItaly1EL7570460ManciniItaly1EL7650R§.1 450SaperItaly1EL758510.2 250CasarottoItaly1EL7650R5450GapestadNorway3EL758514.7 450 Park 2 S.Korea 5 EL 7585 20 530 Mooju .-S.Korea 4 EL 7620 10 §30 Gerona Spain 1 EL 7555 7 110HammarbyverkenSweden1EL7585R10.5 315 Tannery Island USA 3 EL 7650 46 375 Tannery Isaind USA 2 EL 7650R 46 375 Briggs Canal USA 1 EL 7620R 6.1 300WinooskiUSA1EL7555763WinooskiUSA1EL7620R8.4 530WinooskiUSA1EL7585R8.4 300PineValleyUSA1EL75556.1 75Bethel's Mill USA 1 EL 7555 §.2 55 Sida 2 FLYGT SUBMERSIBLE HYDROTURBINES REFERENCE INSTALLATIONS 5/36 n Turbin wiunit 1986 Jim Boyd USA 3 EL 7585 10.5 300 1986 Jim Boyd USA 1 EL 7685R 10.5 300 1986 Columbia USA 1 EL 7620R 49 265 1986 Columbia USA 1 Et 7620 4.9 265 1987 KWG/Deutenham Austria 1 EL 7570 46 85 1987 Berghofer Austria 1 EL 7600R 3.4 132 1987 Piuviotecnica 2 Italy 1 EL 7620R 3.2 170 1987 Brekke Norway 3 EL 7585 15.5 450 1987 Murgues Spain 1 EL 7585R 4.8 140 1987 Murgues Spain 1 EL 7585 4.8 140 1987 Lillpite Sweden 3 EL 7570 §.5 140 1987 Ashuelot Paper USA 1 EL 7650R 46 300 1987 Ashuelot Paper USA 2 EL 7650 46 300 1987 Potter Valley USA 1 EL 7600R 46 160 1987 Potter Valley USA 1 EL 7600 4.6 160 1987 Lower Robertson USA 1 EL 7650R 46 300 1987 Lower Robertson USA 2 EL 7650 46 300 1987 Ontelaunee USA 1 EL 7620R 10.8 §30 1987 Ontelaunee USA 1 EL 7555 6.1 56 1987 Ontelaunee USA 1 EL 7600R 10.2 375 1987 Forest Port USA 1 EL 7600R 10 375 1987 Newport USA 1 EL 7620 3.8 200 1987 Ogdensburgh USA 1 Et 7600 3 125 1987 Hollow Dam USA 2 EL 7650R 6.4 530 1987 Hoosik Falls USA 1 EL 7650R 6.1 530 1987 Hoosik Falls USA 1 EL 7600 6.1 300 1987 Schénach Germany 1 EL 7555 4.4 37 1987 Harzwasserwerke Germany 1 EL 7585R 7 160 1987 Carishatte 2 Germany 1 EL 7555 4 451987DettingenErmsGermany1EL75705.8 1001988Deis/KW Tambergau Austia 1 EL 7620R §2501988WijnegemStuiceBelgium1EL7620§2501888MontgaillardFrance1EL76009.6 4501988MontgaillardFrance1EL7600R9.6 4501988ManautoFrance1EL7585R6.6 1851988Pontefelcinoitaly1EL75855.5 1851988PontefelcinoItaly3EL76505.5 450 Sida 3 FLYGT SUBMERSIBLE HYDROTURBINESfiuijaREFERENCEINSTALLATIONS 5/3/96 2 urbine: 1988 Pontefelcino Italy 1 EL 7650R §.5 450 450 1988 Resita Roumania 1 EL 7555 8 §5 §5 1988 Posco S.Korea 1 EL 7570 16 236 236 1988 Salto Cervia Spain 1 EL 7555 9 110 110 1988 Bimbo Spain 1 EL 7555 3 30 30 1988 Vedevag Sweden 1 EL 7585 §.2 160 160 1988 Vedevag Sweden 1 EL 7650R §.2 450 450 1988 Edeforsen Sweden 2 EL 7650 §.18 450 900 1988 Greenwich,NY USA 1 Et 7650R 41 300 300 1988 Greenwich,NY USA 1 EL 7650 41 300 300 1988 Greenwich,NY USA 1 EL 7650R 39.4 300 300 1988 A.E.P./Twin Branch USA 4 EL 7650 6.1 600 2400 1988 ReichenbactFils Germany 1 EL 7600R 3.4 132 132 1989 KW -Madstein Austria 1 EL 7600R 6.9 250 250 1989 Ste.Catherine Canada 4 EL 7620 10.6 §30 2120 1989 Maple Hill Canada 3 Et.7650 3.4 245 735 1989 Neuville/Ain France 3 EL 7650 3,0-4,46 3758 1125 1989 Cardiccia/Corse France 1 EL 7555 11.6 85 85 1989 Cardiccia/Corse France 4 EL 7600 11.6 450 1800 1989 Cardiccia/Corse France 1 EL 7600R 11.6 450 450 1989 Pirapola Italy 2 EL 7620R 6,7-7,6 315 630 1989 Gazzi Italy 2 EL 7620R 8,8-9,3 450 $00 1989 Ecotecnica/Rovereto Italy 1 EL 7555 §.2 37 37 1989 SOTER/S.Salvatore Italy 1 EL 7620 7 450 4501989SOTERYS.Salvatore Italy 1 EL 7620R 7 450 450 1989 Niggeler &Kupfer Italy 1 EL 7650 6.4 450 450 1989 Badiolegui Spain 1 EL.7555 7.4 110 110 1989 Badiolegui Spain 1 EL 7570 7.5 200 2001989MenargensSpain1EL75555SS551989EronozoSpain1EL7600R62502501989HidodeCastelifullitSpain1Et755591101101989RabackenSweden1EL7600R9.7 450 4501989StrémsbroSweden1EL755510.8 85 651989KrokforsSweden2EL76205.8 450 9001989BissellPointUSA1EL76206,0-7,6 500 §001989Sdsetalsperre/Harzwasserwerke |Germany 1 EL 7050 5 22 221989LangeneierHammerGermany1EL75553.2 30 30 Sida 4 FLYGT SUBMERSIBLE HYDROTURBINESEiHWlpaREFERENCEINSTALLATIONS 5/3/06 PS Tc {Country:fn 4Tarbin : 1990 Chariton Canada 2 EL 7585 250 500 1990 EDF -Puyoo France 1 EL 7620 3.5 220 220 1990 Bortolussi Italy 1 EL 7600R 45 150 150 1990 Data Engineering Italy 1 EL 7870 6.1 100 100 1990 Frontino Italy 1 EL 7555 12 110 110 1990 Lerida Spain 1 EL 7555 7.8 110 110 1990 Central de Lizarkola Spain 1 EL 7555 17.5 110 110 1990 Central de Lizarkola Spain 1 EL 7570 17.5 250 250 1990 Central de Lizarkola Spain 1 EL 7585 17.5 450 450 1990 Urgell Spain 4 EL 7585R 300 1200 1990 Flemminge Sweden 3 EL 7620 4,85-5,85 315 9451990FlemmingeSweden1EL7620R315315 1990 Lower Saranac USA 1 EL 7585R 8.5 300 300 1990 Schopfheim Germany 1 EL 7570 4.45 100 1001990SchopfheimGermany1EL7585R4.45 160 1601990DortmundGermany1EL755555555 1990 Pforzheim/Eutingen Germany 1 EL 7620 4.15 220 220 1990 Pforzheim/Eutingen Germany 2 EL 7650R 4.15 400 8001990PodmelecYugoslavia1Et75858,3-12,0 425 425 1991 KW -Ausseerfand Austria 1 EL 7600R 6.8 250 250 1991 Plounice P3 Czechoslovakia 1 EL 7600R §,9-6,9 250 250 1991 NeumOhie Germany 1 EL.7570 60 60 1991 Trameacque Italy 1 EL 7650R 4 290 290 1991 Zatti Eredi Italy 1 EL 7555 9.5 110 110 1991 Chubu Electric Co Japan 1 EL 7585 355 355 1991 Central Suria Spain 1 EL 7570 6.3 140 140 1991 L-15 Piensos Tagsa Spain 1 EL 7575R 7.5 160 1601991CentralCasasSpain1EL7620R4.2 265 2651991CasetaSpain1EL7620R2652651991ForssaSweden1EL76504.6 375 3751991ForssaSweden1EL7650R463753751991BackeboSweden2EL7620R6,7-7,4 §20 10401991AEP/Twin Branch Ii USA 4 EL 7650 600 24001991Avery2-Lake Port USA 1 EL 7650 2.4 210 2101992KW-Ungarfeld Austria 2 EL 7585R 7.5 250 5001992KW-Wagner Austria 1 EL 7600R 5.6 200 2001992Ayerst/Lachute Canada 2 EL 7650 390 780 Sida 5 FLYGT SUBMERSIBLE HYDROTURBINESrierREFERENCEINSTALLATIONS 5/3/96 No.of: :untry "un Turbine:: 1992 Ayerst/Lachute Canada 1 EL 7650R 4,5-4,7 390 390 1992 Plounice P3 Czechoslovakia 1 EL 7600 §,9-6,9 250 250 1992 EDF Ste Marie France 1 EL 7650 4,3-5,5 365 365 1992 Wolkenstein Germany 1 EL 7555 §.55 55 55 1992 Wolkenstein Germany 1 EL 7620R 5.64 375 378 1992 River Tawe Great Britain 1 EL 7570 85 85 1992 Aberdulais Great Britain 1 EL 7585R 200 200 1992 Dam Rygene Norway 1 EL 7556 14.5 110 110 1992 Bukowka Poland 1 EL 7650 420 420 1992 Bukowka Poland 1 EL 7650R 3,6-4,8 420 420 1992 Central los Batanes Spain 2 EL 7556 9 110 220 1992 Untra/Storgysinge Sweden 2 EL 7650 Max 5,8 520 1040 1992 Eau Galle,WI USA 1 EL 7585R 8,2-9,4 345 345 1992 Fallon Hydro USA 1 EL.7650R 600 600 1992 Fallon Hydro USA 1 EL 7650R 300 300 1992 Fallon Hydro USA 2 EL 7650R 450 $00 1992 Enosburg USA 1 EL 7620R 6.1 375 375 1992 City of Auburn USA 1 EL 7650R 9.4 800 800 1993 KW Pols Austria 2 EL 7600R 6.1 230 4601993CooTroisPontsBelgium1EL7620R84204201993TGVSeraingBelgium1EL7650R7,2-8,3 290 2901993HiirikoskiFinland1EL7650R4,2-4,8 420 4201993PuuppulankoskiFinland1EL7570152752751993PuuppulankoskiFinland1EL7556151101101993CasamozzaFrance2EL76208.57 §20 10401993CasamozzaFrance1EL7620R7,77-8,57 520 §201993EDF/Castetarbe France 1 EL 7650 5 §20 §201993AugsburgGermany1EL7585R4.2 110 1101993BitburgGermany1EL7620R5,9-8,4 420 4201993Markisch-Buchhoiz Germany 1 EL 7585R 5 185 1851993Markisch-Buchhoiz Germany 1 EL 7556 5 55 551993NossenGermany1EL7620R31501501993CMValliTaroeCenoItaly1EL757014,0-16,5 230 2301993CMValliTaroeCenoItaly1EL755614,0-16,5 110 1101993L.C.A Rieti Italy 1 EL 7585 6.7 155 1551993ISAFitaly1EL76504.5 465 4651993KaimaiNewZealand1EL75859,3-10,8 350 350 Sida 6 $/3/96 FLYGT SUBMERSIBLE HYDROTURBINES REFERENCE INSTALLATIONS Sida 7 Pla 'un Turbl : 1993 Kliczkow Poland 1 EL 7650R 4,95-6,5 §20 §20 1993 Nysa Poland 1 EL 7650R 2,8-3,65 315 315 1993 Sromowce Poland 2 EL 7650R 3,4-10,2 §20 1040 1993 Sromowce Poland 2 EL 7650 3,4-10,2 520 1040 1993 Topola Poland 2 EL 7650R 3,0-8,9 520 1040 1993 Topola Poland 1 EL 7650 3,2-6,2 520 §20 1993 Mosvodocanal Russia 1 EL 7570 13,6-20,5 365 365 1993 Dong Jin S.Korea 4 EL 7585 21 §30 2120 1993 Central Tauste Spain 5 EL 7556 4.7 57 285 1993 Salt de Penelles Spain 1 EL 7585R 9 250 250 1993 Forsa nedre Sweden 2 EL 7650R 4.2 365 730 1993 Gammelby Sweden 2 EL 7650 6.1 §20 1040 1993 Gammelby Sweden 2 EL 7650R 6.1 520 1040 1993 Smedjebacken |Sweden 2 EL 7650R 4 420 840 1993 Smedjebacken |Sweden 1 EL 7650 4 420 420 1993 South Edwards USA 1 EL 7570 14,3-17,4 250 250 1993 Watertown,WI USA 1 EL 7650R 3,0-3,8 265 265 1994 KW Zobing Austria 1 EL 7650R 3.3 230 230 1994 Moulin de Ia ville France 1 EL 7585R §,0-5,35 165 185 1994 Schwarzenberg Germany 1 EL 7585R 4 100 100 1994 Kickenbacher Hammer Germany 1 EL 7556 2.6 22 22 1994 WK Hennersdorf Germany 1 EL 7585 3.1 75 75 1994 WK Hennersdorf Germany 1 EL 7620R 3.1 135 135 1994 Lew Augsburg Germany 1 EL 7570 3.83 63 63 1994 Ikervar Hungary 2 EL 7650R 7.5 520 1040 1994 tkervar Hungary 2 EL 7650 7.5 §20 1040 1994 Villetta Barrea Italy 1 EL 7600R 6 245 245 1994 Kliczkow II Poland 1 EL 7570 §,7-6,6 125 125 1994 Lundstré6mmen Sweden 1 EL 7650 3 245 245 1994 Lundstrommen Sweden 1 EL 7650R 3 245 245 1994 Lake Flower,NY USA 1 EL 7620R 8,0-12,0 200 200 1995 Pirttikoski Finland 1 EL 7650 2,5-4,12 260 260 1995 Pirttikoski Finland 1 EL 7650R 2,5-4,12 260 260 1995 Koskenpaa/Kalliokoski Finland 1 EL 7650R §,0-5,5 500 500 1995 Central Molino Olivares Spain 1 EL 7570 9.5 170 170 1995 Berrien Springs -AE.P.USA 6 EL 7650 8.2 700 42001995(del.-96){Berrien Springs -AE.P.USA 6 EL 7650 8.2 700 4200 FLYGT SUBMERSIBLE HYDROTURBINESfiHlrm_REFERENCE INSTALLATIONS 5/3/96 0.of Pajaras Lithuania 1 EL 7585 Central de Puerto Spain 1 EL 7620R La Forge France 1 EL 7600R Siemianéwka Poland 2 EL 7556 Central Molino Olivares Spain 1 EL 7570 IMWHA S.Korea 2 EL 7650 Lyna Poland 1 EL 7650 Opunake New Zealand 1 EL 7570 Lavancia France 2 EL 7650R Lavancia France 1 EL 7585R Salahmi Finland 2 EL.7585 Jylli Finland 1 EL 7620R Pajaras 2 Lithuania 1 EL 7585 Pajaras 2 Lithuania 1 EL 7570 Gorzugia Poland 2 EL 7650R Gorzugia Poland 2 EL 7650 Thirlmere Enland 1 Et 7585 ?Spain 1 EL 7570 La Orade Energl France 1 Et 7600 396 Sida 8 MINIMUM FLOW UNIT INSTALLATION AT THE SOUTH EDWARDS HYDRO PLANT Paul Bernhardt and David Bates' ABSTRACT Niagara Mohawk Power Corp.owns and operates the 3.3 MW South Edwards Hydro Plant in Northem New York.The FERC license for this plant requires a minimum flow release in the bypass region of the river.NMPC submitted a license amendment to the FERC to permit the addition of a minimum flow unit to take advantage of this flow.The amendment was accepted, permitting the installation of the 236 kw,60 cfs unit to proceed.The unit was installed and commissioned in 1994. CONCEPTUAL ENGINEERING The project was initially conceived in 1991 when the NMPC Power Delivery Dept.requested a budgetary proposal for a minimum flow unit from Flygt Turbines.The unit would take advantage of the 40 cfs flow that was continuously released through an existing 20"pipe tee off the 10'main pipeline. This 20"tee was installed in 1987 to comply with the new license issued in 1983. A feasibility study contract was issued with Kleinschmidt Associates in late 1991.The study would address the technical as well as economic feasibility of installing a Flygt submersible unit in the bypass reach of theOswegatchie River at South Edwards. Kleinschmidt focused on the flow specifications and station location for the new unit.It was determined that a unit operating at 40 cfs would not provide 1 Mechanical and Civil Engineers,Niagara Mohawk Power Corporation,300 Erie Boulevard W.,Hydro D-1,Syracuse,NY 13202 450 MINIMUM FLOW UNIT INSTALLATION 451 enough incremental generation to provide a positive B/C ratio;a minimum threshold of 60 cfs was established.This proved to be economically feasible, even counting the loss of 20 cfs to the existing units in the downstream powerhouse (higher head generation). Two station locations were studied for siting;one at the existing 20" bypass pipe,and the second approximately 80'downstream in a lower pool.It was determined that the lower pool location,yielding higher gross head,was the best site for the unit as shown in Figure 1.This would also permit maintaining the 20"bypass for minimum flow passage when the unit is out of service. The new unit would be installed inside a 4 foot diameter pipe that was tied into the 10 foot main pipeline.The 4'pipe would discharge through a draft tube directly into the riverbed.The unit's 480 volt power would be stepped up to match the plant substation's low side voltage of 2,400 volts. oo STA,1074¢NEw UNIT te!/-.a/ee 1B é ir '|ee- a ane WIRE ROPE 4° aa ay?+FACE wire «(2'ACCESS -_®CY Bes ME fone Re Te aed WALKWAY 'N NSTOCK ee bd stW/REUOV AGE \|-BUTTERFLY saree IY |La -- <Fy fsBEROtToapopteEERCCSTSS CPO ae res| Wf.nat :|rhe piss i 4 Bh --_1 |rq _---a _-r ;-_vai --t "a '' af Pee2..Oo ee -e e _.yr Me.oe we.oo p=if 22 EA NEO RS ARNE a]S \ -peasMSeSeldes ROCK OUTLINE - PLAN OF MINIMUM FLOW UNIT FIGURE1 LICENSE AMENDMENT PROCESS Preparation of a license amendment by NMPC began in 1992.FERC regulation 18 CFR 4.38 describes the addition ofa new generating unit as an amendment requiring full three stage consultation.This is a long and costly process that would have precluded the possibility of installing a minimum flow unit at South Edwards since its economics was marginal.Therefore,NMPC requested and was granted waiver of the first stage of consultation.The various associated agencies,including the New York State Department of Environmental 452 WATERPOWER °95 Conservation (NYSDEC)and the U.S.Fish and Wildlife Service (USFWS), would be given 60 days to review and comment on the proposed amendment. One of the major comments resulting from the review process involved the operation of the existing 20"bypass valve,which was to remain as an alternate means of passing flow if the new unit was ever shut down.NMPC had proposed leaving the valve manually operated and calling out a traveling operator to open the valve upon unit trip.This would mean that the minimum flow could be suspended for several hours until the traveler reached the site.The NYSDEC was opposed to this idea and felt that the valve opening should be automated.NMPC agreed to this change,even though it involved added cost. The application for license amendment,submitted in June of 1992,was approved and an order amending license was issued in March of 1993. N NGINE Preliminary engineering began in July of 1992 with the layout of the mechanical components.These included the turbine/generator,draft tube,4' penstock sections,4'elbow,butterfly valve,and expansion joint.A preliminary site survey was accomplished and the components where laid out to fit into the existing site configuration to determine final penstock lengths and elevations. In addition,a preliminary single line schematic was created to identify electric equipment requirements and protection schemes.The generator,a 480 volt induction machine,would be connected through a non-reversing contactor and a motor circuit protector to the 2,400 volt line using a grounded wye-delta pole-mounted transformer bank.No capacitor bank for power factor correction was planned.Relay protection would consist primarily ofa Beckwith multifunction relay,one of the first to be utilized in an NMPC hydro plant. The majority ofNMPC's hydro units are connected to an EMS (Energy Management System).The initial plan included connection ofthis unit to EMS. However,due to economic limitations,the unit was left off EMS.Generator output would be recorded via a watt transducer and a paperless chart recorder that could be downloaded to disk storage for reporting and archiving. P 1IT , On November 10,1993 Niagara Mohawk notified the United States Army Corp of Engineers of the project and filed application for a permit under Section 10 (River and Harbor Act of 1899)and Section 404 (Clean Water Act of 1977), prohibiting obstruction or alteration of U.S.navigable waters and discharge of dredged or fill material into U.S.waters,respectively. MINIMUM FLOW UNIT INSTALLATION 453 On March 18,1994,a permit was issued under the U.S.Army Corp.of Engineer's Nationwide General Permit Program,allowing Niagara Mohawk to install a cofferdam,dredge river bed material,and construct concrete foundation, draft tube,and penstock in the riverbed. Due to the preexistence of a 401 Water Quality Certificate issued November 17,1978 and supplemental permit modifications (May 18,1993), NMPC was only required to submit plans and specifications to the New York State Department of Environmental Conservation for review and comment. Special conditions of the permit required NMPC to maintain minimum flow in the bypass reach.NMPC proposed to pipe the minimum flow to a location immediately downstream of the construction area and explained that any habitat loss during the construction period would be offset by the net gain in habitat in the bypass resulting from an increase in the minimum flow from 40 cfs to 60 cfs upon completion ofthe project.Piping the minimum flow downstream of the work area eliminated the need for a cofferdam,thus significantly reducing project costs. In accordance with Section 12.11 of the FERC's Part 12 Regulations, ReportingModificationsoftheProjectWorks ,NMPC submitted for review and comment the proposed scope of work,plans,and specifications to the FERC, obtaining approval on July 25,1994. FINAL ENGINEERING Final engincering began after issuance of the license amendment by FERC in March of 1993.This task was split into three different but coordinated disciplines;mechanical,civil/structural,and electrical. MechanicalDesi A decision was made early in the project to have the detailed design of mechanical components completed by the awarded equipment supplier. Therefore,NMPC had only to specify the basic dimensions of components,design criteria,materials,and safety factors.The exception to this was design interface of the hydraulic actuator to the existing 20”bypass valve,which required design ofa mounting bracket,operating lever,and counterweight.These were designed by NMPC personnel. The design package produced included final procurement drawings and specifications for the turbine/generator,draft tube,penstock and supports,air and vacuum valve,access walkway,butterfly valve and actuator,expansion joint,and turbine control package.The specification was written as a"performance spec”; 1.e.,providing the required performance requirements without a large amount of 454 WATERPOWER °95 detailed criteria found in a typical utility specification to help hold costs down. The final design arrangement is as shown in Figure 2.This design package was then sent out for bids and Hydro Management Co.of Troy,NY was the awarded vendor. The unit was rated at 236 kw at 52'net head and 61 cfs,with output at 480 volts and speed of 725 rpm (direct connected).Delivery was specified for the summer of 1994. ee SHONN FOR CLARITYELB38FfEXIST.7-7 DAFRPPENWSTOCK EXPANSION JOINT BUTTERFLY VALVE48FRPTEE f RI wsacTyaTOR GIRDER --_&COUNTERWEIGHT W6sl,|N . =STRU /+.a" geof-op Si -_ee ae %|PIP: \sO :SUPPORTS.-\|°si]"f f-SUPPORT CABLE IN af 2 =os on é¢ \,'4 ¢OIA PIPE\kt a \' te -EXISTING REINFORCED =-->S|CONC.BE AM/WALKWAY \,EL 793.4AT-4 =S||=[7 OVE RSION WALL 646 PRESSURE -TREATEQ -*---E4]--HP x42 (TYP) TiMMBERS (TYP)\an =A...=\Ey Et 783.4 rimn RE INF "7 EL 7834 "CONCRETE -- ,ORAFT TUBE FOUNDATION ELEVATION OF MINIMUM FLOW UNIT CRO6S-8ECTION FIGURE 2_THRU_UNIT _ne Civil/Structural Design The civil/structural design was a joint effort between NMPC engineering and Hydro Management Co.'s consulting engineer.HMC's engineer was responsible for providing the design of the 4 ft.diameter penstock and appurtenances,penstock supports,and walkway platforms,the loadings at all anchors and foundations,and a transient analysis of the new 4'diameter penstock. MINIMUM FLOW UNIT INSTALLATION 455 NMPC engineering was responsible for checking HMC's design calculations and performing design calculations for the pipeline support and draft tube foundations,the diversion wall,the air bubbler system ,and the tailrace. Additionally,NMPC analyzed the affected existing structures to ensure their structural integrity was maintained. Penstock restraints were required to resist various loading conditions including dead loads,operating water pressures,snow,wind,and seismic loads. The vertical support columns supporting all vertical loads were designed rigidly to resist horizontal wind and seismic forces.The horizontal steel support was designed as a tension member to resist hydraulic thrust on the penstock elbow (or valve when closed)as well as a column for wind and seismic forces parallel to the support's axis.Both the horizontal and vertical steel support reactions were transferred to a reinforced concrete foundation anchored to bedrock to resist overtuming.Rather than the expense of a rigid horizontal support to resist lateral wind and seismic forces on the vertical riser,wire rope was selected to transfer the loads to rock/concrete foundations with the use of adhesive anchors. The various loading combinations on the penstock required that the horizontal section be analyzed for biaxial bending and the vertical riser pipe be analyzed as a beam-column. Beetle Engineering Associates were contracted to design,fabricate and deliver a 48"fiberglass pipe tee with adjustable slide bearing support.The pipe tee was specified to connect the new 4'pipe to the existing 10'pipe and would project 7'-6"from the centerline of the 10'pipeline.The slide bearing support in conjunction with the 4'expansion joint allowed the 10'pipeline to translate longitudinally. With the expansion joint positioned immediately following the fiberglass tee,the thrust occurring on the valve (when closed)or the penstock elbow (valve open)is isolated from the |0'pipeline.This arrangement results in an unbalanced distribution of hydraulic pressure on the walls of the 10"pipeline transferring undesirable horizontal reaction forces to the 120"ring girder supports.The solution was to transfer the unbalanced force from the two ring girder supports to the rock face adjacent to the pipeline using steel wide flange struts.(See Figures 1 &2.) An air bubbler system was designed by NMPC engineering to prevent freezing in the draft tube and lower section ofthe vertical riser,where the turbine/generator is located,should the minimum flow unit trip during winter months. 456 WATERPOWER °'95 A reinforced concrete foundation was designed to encapsulate the draft tube foundation and support vertical loads from the penstock riser,turbine,and hydraulic thrust.A cantilevered reinforced concrete diversion wall was incorporated into the draft tube foundation to protect the lower section of the riser and the turbine/generator from damage caused by debris and ice. The tailrace was designed to achieve the optimum tailwater elevation with minimal rock excavation utilizing geometric limitations recommended by Flygt. Electrical Desi The goal of the electrical design for this project was to safely control and protect the generator as simply as possible.Two outdoor cabinets were specified for this project.One contained power components and cabling while the second contained the control components and wiring.The cabinets were to be mounted on a concrete pad located on a rock ledge overlooking the unit. Three pole-mounted 100 kVa transformers step up the induction generator's output to the station's 2,400 volt bus.The bank was connected grounded wye-delta.Three disconnect fuses protect the bank's high side. The generator leads run to a power cabinet that includes a 400A motor circuit protector (MCP),a size 6 full voltage non-reversing contactor,current and potential instrument transformers,a 15-kVa station service transformer,and a station service distribution panel. A control cabinet is located next to the power cabinet.This cabinet encloses a Beckwith M0420 multifunction relay,a GE general purpose 12HFA relay used for lock out,Flygt's turbine generator monitor (Contro!and Status Unit or CAS)with tripping capabilities,a GE Fanuc programmable logic controller (PLC)with control software designed by Lee Mechanical,and a paperless recorder to record generator output. The PLC provides all the main control functions for the unit and butterfly valves,while the CAS provides status and outputs for any sensing devices (stator and bearing temperature RTD's,etc.).All of the automatic controls existent in the PLC can be duplicated manually at the cabinet. The lockout scheme trips both the contactor and the motor circuit protector whenevera relay or controller initiates a trip or drops out the lockout relay's coil. A manual push button operation is required to reset the scheme and re-start the unit. MINIMUM FLOW UNIT INSTALLATION 457 INSTALLATION CONTRACT Competitive bids for the installation of the minimum flow unit and appurtenances were received on July 15,1994.With the two lowest bids significantly higher than the NMPC estimate and resulting in a near critical benefit/cost ratio,the project was in jeopardy. NMPC provided the two lowest bidders with an excellent value engineering opportunity by holding brainstorming sessions to find a way to reduce the costs of the project.The alternatives generated were evaluated,criticized,and reduced to those providing the greatest potential for cost savings.The two major alternatives proposed were (1)to design and construct a timber diversion wall supported by embedded steel HP shapes in lieu of the reinforced concrete cantilever wall and (2)meet minimum flow requirements during construction by designing a piping system originating from a manhole in the 10'pipeline anchor block already located downstream of the work area rather than piping from the existing minimum flow pipe or siphoning from the reservoir,both of which originate upstream of the work area.Upon evaluation of the revised bids, Tuscarora Construction Co.,Inc.was awarded the installation contract. Construction began August 1,1994. With the proposed unit location in a gorge downstream from the dam, access to the work area was one of the more difficult and costly aspects of the job. Tuscarora used a 75 ton crane positioned near the edge of the rock cliff to transport materials and equipment. Rock excavation began for the draft tube foundation and tailrace on August 9,1994,Blasting was not permitted by NMPC.Pneumatic demolition equipment,a track backhoe placed in the riverbed,and skip buckets facilitated excavation and removal.Boulders were split into manageable sizes and hamessed or pinned for removal.A total of 450 CY of both loose rock and bedrock were excavated and placed at a disposal site adjacent to the crane.Many of the larger boulders were left in place or repositioned to act as rip rap around the draft tube foundation. Once excavation was complete,a concrete leveling pad was constructed. The draft tube was then lowered into position,anchored,and encapsulated in reinforced concrete,along with the steel timber wall supports.At the same time, the reinforced concrete foundation for the horizontal and vertical pipe restraints was constructed.With the riser base plate already shop fabricated to the riser,the riser was positioned on the foundation and connected to the draft tube with a full penetration weld.The temporary minimum flow piping was removed and the tailrace rewatered.The remaining components and their supports,including the penstock elbow,horizontal penstock,butterfly valve and actuator,expansion joint, 458 WATERPOWER '95 and walkway platform were then erected,leaving the installation ofthe fiberglass tee and slide bearing support for last. The 10°pipeline was dewatered to allow for the installation of Beetle's fiberglass tee connection between the 10'pipeline and 4'penstock.A Beetle representative was on site to provide instructional supervision to the contractor during the fiberglass overlay connection.Also,while the 10'pipeline was dewatered,the contractor was able to rotate the existing 20"valve 180 degrees and mount the new valve actuator. Tuscarora completed the contract work and demobilized on October 11, 1994. ELECTRICAL INTERCONNECTION AND WIRING All of the electrical interconnection work for this project was completed by Niagara Mohawk Power Delivery and Electric Customer Service personnel based in Potsdam,NY.This work began the end of September 1994 and was completed early in November.The concrete pad for the outdoor cabinets was placed in a location that would permit the placement ofa mobile crane for future maintenance work on the unit.Galvanized steel conduit was utilized for all cable runs with the exception of a cable tray on the access walkway to the unit. The cables to the pole-mounted step-up transformers were run through a buried conduit.This also improved mobile crane access to the site. COMMISSIONING Startup and commissioning ofthe unit began November 1,1994.The unit was inspected by Flygt personnel and a system electrical check was accomplished by NMPC and Lee Mechanical personnel.Part of this check was a phase rotation test to determine if the unit was properly connected to the grid.This was accomplished by pulling the unit out of the vertical penstock and "bumping"the unit with a momentary contactor closure to see if it rotated in the right direction. Several problems surfaced during startup ofthe unit.The most significant was a problem with the AC-operated non-reversing contactor.Initially,the contactor would not stay closed when attempts were made to start the unit.After much head scratching it was detected that the control voltage,fed off the main generator bus througha station service transformer,was dipping quite low (82 volts)when the contactor was expected to close.This was due to drop in the generator buss voltage resulting from high starting currents at pre-synchronous speed.The voltage drop prevented a good contactor closure resulting in contact chatter and the eventual opening ofthe contactor.Initial thoughts were that the MINIMUM FLOW UNIT INSTALLATION 459 contactor was underrated but this was ruled out once the low control voltage condition was discovered.The control voltage was switched over to another station service transformer which provides power to the headgates and the problem was eliminated since the voltage was up near the 115 volts required.A magnetic trip coi!was also added to the motor circuit protector for backup tripping capability. A second problem encountered was that the 20"bypass valve,normally closed,would drift open over time.This was diagnosed as improper pressure settings on the hydraulic actuator. Another problem surfaced when the unit tripped on water leak indication in the cable junction box on the unit itself.The unit had to be pulled out of the penstock to repair a loose grommet on one of the power cables. Fortunately,the problems were resolved and the unit starts and operates without any significant vibration. An acceptance test of the unit was performed by Flygt and witnessed by NMPC.Power was measured via a portable power analyzer while flow was measured by a permanent two-path ultrasonic flowmeter.Headwater elevation was measured bya level sensing transducer;inlet pressure to the turbine by a pressure transducer;and tailwater elevation by a calibrated staff gauge.Four test points,at different net heads and therefore flows,were established by changing the position of the butterfly valve.The test showed that the unit's performance exceeds the manufacturer's guarantee. CONCLUSIONS Minimum flow releases are requirements of nearly all new license applications.It is ideal to capture this flow and generate with it if possible.The application of the minimum flow unit at South Edwards was successful in that (1) adequate head and flow was available;(2)rigid cost controls were maintained to meet the extremely tight budget and economic criteria;and (3)vigilant control of vendors was maintained in regards to quality and schedule.These governing principles will be required for any future minimum flow units at Niagara Mohawk as well as other utilitics and owners. ACKNOWLEDGEMENTS This project would not have succeeded without the hard work and long hours put in by NMPC's Power Delivery and Meter and Test crews. Technical Information Berrien Springs Hydro Redevelopment General Information Location:Near Benton Harbor,Michigan, on the St.Joseph River Plant Capacity:7.2 MW Maximum Flow:4,200 cfs Anticipated Annual Output:39,200 MWh Redevelopment Team Owner:Indiana Michigan Power Company Project Manager:American Electric Power Service Corporation Turbine-Generators:ITT Flygt Corporation Controls:ABB Phoenix Controls Civil-Mechanical Construction:Meg-A- Lift Electrical Construction:M.J.Electric Inc. Trash Rakes:Cross Machine Inc. Equipment Turbines (12 units) Fixed propeller 4-blade 270 rpm complete penstock dewatering,the units promise to reduce maintenance costs for Berrien Springs.They can be hoisted out of their cylinders for mechanical and electrical maintenance.Because the tur- bine and generator form a unit,no com- plicated shaft alignment is necessary. Electrical improvements at the Ber- rien Springs redevelopment included installation of new controls,switch- gear,protective relays,cables,a larger remote temininal unit,and improved plant lighting. The 2.3 kV switchgear dating back to 1920 is being replaced with 4.16 kV medium-voltage motor controllers to pro- vide the switching and protection for the new generators.The existing 2.3-kV transformers are being replaced with equipment rated for 4.16 kV.The four in- dividual generator step-up (GSU)trans- formers for the old synchronous genera- tors have been removed and replaced with one GSU (4.16/34.5 kV,7.5/9.3 MvVa)for the entire generating bus. The old generator control panels are being replaced by a new system that will control the 12 new induction generators, the three dam tainter gates,and other plant systems.This system will consist of a line of panels that include protec- tive relays,control switches,three com- puter terminals,a programmable logic controller (PLC),and associated devices for unit and plant control.The system 4 HYDRO REVIEW/APRIL 1996 350 cfs discharge Generators (12 units) 1,210 rpm 4.16 kV 3 phases 60 Hz 600 kw 6-pole induction Construction Dams (2) 1 earth embankment 1 concrete gravity 6 tainter gates (3 remote-controlled) Penstocks 2 penstocks adjoining the powerhouse 4 bays per penstock Transmission 4.16/34.5 kV,7.5/9.3 MVa transformer Connects to Indiana Michigan Power Company transmission system also will consist of two cabinets that contain the remote devices for unit instrumentation,one for each penstock. The heart of the control system is a Turbine Installation Made Easy American Electric Power Corporation selected submersible hydroturbine generators for rede- velopment of the 7.2-MW Berrien Springs hy- dro plant in Michigan.Assembly and instatla- tion takes only a few minutes.Here,the assembly crew is connecting the shaft to the generator,which is suspended from a hoist. After connection,the generator is mated with the turbine,which is in the background. GE Fanuc Series 90-70 PLC provided by ABB Phoenix Controls.This micro- processor-based system continuously optimizes operations of the plant by automatically starting and stopping gen- erating units and/or operating the tainter gates to maintain the operator-pre- scribed headwater level setpoint. The control system also includes a supervisory control and data acquisition (SCADA)feature that provides for local and remote operation employing man- machine graphical software.A series of screens have been custom designed to separate the information into logical groups.Scrolling through the screens,an operator can monitor plant status,ac- knowledge alarms,initiate reporting functions,and perform control functions. The SCADA system includes the ability to access the same screens remotely,per- mitting operators to contact the plant con- trol system from their offices or homes for information or control. The new automated plant control sys- tem,along with the new turbine-genera- tor units and the associated hydraulic gate system,and the upgrade of the switchgear,will result in marked improvements in water management, generation,and plant data acquisitions. Hitting the Target with Technology The Berrien Springs redevelopment is being undertaken in two phases.Phase I, which involves the removal of two origi- nal units from the east penstock,instal- lation of six new units,and the electrical upgrade,was completed in December 1995.Phase II,which includes removal of the other two original units and installation of the final six new units, began in the spring of 1996 and is to conclude in the third quarter of the year. Technological pioneering has been a tradition for AEP.By rehabilitating the Berrien Springs hydro facility with modern electrical and mechanical com- ponents,the company has ensured for itself and its customers a low-cost,envi- ronmentally acceptable energy source that will provide long-term reliability and reduce maintenance cost.| Messrs.Steinmetz and Puckett may be contacted at American Electric Power Service Corporation,|Riverside Plaza, Columbus,OH 43215.Mr.Steinmetz's telephone number is (614)223-2956; Mr.Puckett's is (614)223-2105.Mr. Torony may be contacted at ITT Flygt Corporation,35 Nutmeg Drive,Trum- bull,CT 06611;(203)380-4856.NK Reprinted from HYDRO- REVIEW The Magazine oftheNorthAmericanHydroelectric Industry Volume 15,Number 2,April 1996 ©Copyright HCI Publications,1996 e 410 Archibald Street,Kansas City,MO 64111 e 816-931-1311 i, Small Hydro Re-Energizing an Aged Hydro Plant When the 7.2-MW Berrien Springs hydro project began to experience failures after 90 years of heavy use,the project owners needed a cost-effective approach to restoring the plant's capability.Their redevelopment plan blends new technology and design innovations to give the facility a productive new life. By William G.Steinmetz,Brian R.Puckett,and James Torony hen one unit failed and three others became unreliable, managers of the Berrien Springs Hydroelectric Plant in south- western Michigan were certain that a major refurbishment was in order.What wasn't clear was how the renovation would occur.The 7.2-MW facility was important to Indiana Michigan Power Company's system,but the value of a major refurbishment investment would have to be measured against a broader standard.Could the redevelopment be accomplished within the constraints of overall power industry economics? The answer is yes.With state-of-the- art equipment and some innovative engineering,the owners and operators of the Berrien Springs hydro plant are redeveloping the facility.The first half of the redevelopment scheme was com- pleted in late 1995,and the second phase is to be done by the end of 1996. The new plant includes 12 turbine-gen- erators and the latest in remote operat- ing technology.The owners expect the new Berrien Springs facility to operate Bill Steinmetz is senior engineer in the Civil Engineering Division of American Electric Power Corporation (AEP).He was project engineer for the Berrien Springs redevelopment.Brian Puckett, P-E.,senior engineer in the Electrical &Controls Engineering Division of AEP,coordinated the electrical aspects of the redevelopment.Jim Torony is project manager,hydroturbines,at ITT Flygt Corporation.He performed the turbine-generator installation engi- neering and project management for the manufacturing. 2 HYDRO REVIEW /APRIL 1996 'sa fa Keeteweoeusae The 7.2-MW Berrien Springs hydro plant near Benton Harbor,Michigan,originally had fourhorizontalspoke-type generators installed in the early 1900s.This photograph shows one ofthegenerators.As part of a refurbishment begun in 1995,project manager American ElectricPowerCorporation(AEP)is replacing the original equipment with 12 submersible induction generators with rated capacity of 600 kW. more efficiently and more productively for decades to come. The Ravages of Time Berrien Springs hydro was constructed on the St.Joseph River near Benton Harbor,Michigan,in 1908 by Berrien Springs Power &Electric.The plant originally had three 1.8-MW units.A fourth unit was added in 1918 for a total nameplate rating of 7.2 MW.Today,the plant is owned by Indiana Michigan Power Company (I&M)and operated as _arun-of-river hydro,providing baseload energy to I&M_'s customers.The plantbecameapartoftheAmericanElectric Power system in 1922. The original generators were horizon- tal spoke-type.The turbines were Fran- cis camel-back units with four turbines connected to a common shaft.Two tur- bines from adjacent units discharged into a common draft tube.The four units had a long and productive run,but by the 1980s they were experiencing seri- ous operating and maintenance trouble. The Unit 2 generator experienced bear- ing failures,stator failure,and rheostat failure in the early 1990s.In 1993,the generator failed,and the unit was retired in place.A shaft on Unit |broke,and one camel-back section had to be sealed and removed from service in 1987,cur- tailing output by 25 percent.The casing on the Unit 3 turbine cracked in 1990, causing misalignment.All the units exhibited significant shaft runout due to excessive wear at the bearing journals. Unit 4 also experienced turbine and gen- erator problems that led to a 25 percent reduction in output.The original lignum vitae turbine bearings were severely worn on all units,making adjustment minimal.Efficiency losses resulting from aged equipment had reduced the overall plant rating to 56 percent. Plant controls also were outdated and did not meet current needs.Control failures resulted in lost efficiency and lost generation from downtime for repairs.Operation and maintenance cost increased 370 percent between 1974 and 1992.Additional losses in efficiency and availability were expected in the near future.Essentially, the existing plant equipment had reached the end of its serviceable life. In 1993,AEP engineers conducted a comprehensive study of rehabilitation and redevelopment options for the Berrien Spring facility.The evaluation resulted in four primary alternatives: -Rehabilitating the existing units, including generator rewinds,repair or replacement of turbine components,and repair of existing controls; -Replacing all electrical controls and substituting submersible turbines-gener- ators for the original equipment; -Replacing the existing turbines and generators with modern materials and hydraulic design in a horizontal arrange- ment similar to the original units;or -Installing new wet-pit Francis units. Of the four alternatives considered, replacement with submersible turbine- generators appeared to be the most cost- effective option,providing efficient uti- lization of the river and optimum generation.This alternative also would provide the best return on investment with the lowest redevelopment cost. Using Equipment That Works The submersible hydroturbine generators selected for the redevelopment were the same as previously installed at I&M's 4.8-MW Twin Branch Hydroelectric Plant in Mishawaka,Indiana.Manufac- tured by ITT Flygt Corporation,each unit is a semi-Kaplan turbine with a man- ually adjustable,four-bladed aluminum- bronze runner set at an optimized pitch to extract the maximum amount of power from the water.The turbine is close-cou- pled to a planetary speed increaser that drives a six-pole induction generator rated at 600 kW and 4.16 kV. The turbine-generator can be lowered through the open top of a vertical cylin- der and onto the turbine seat,where a special gusset system seats the unit with- out bolts.Unit installation or removal can be accomplished in minutes. Essentially,the unit is held in place by its own weight with a large O-ring in the turbine bottom to provide sealing. Flow to each unit is turned on or off by a cylinder gate.Flow baffles behind each unit are used to minimize velocity distribution deviations caused by the tandem installation.The baffle design was optimized using a model scale test at the Royal Institute of Technology in Stockholm,Sweden. Each turbine-generator unit is deliv- ered after site preparation is completed, lowered into its respective cylinder, plugged in,tested,and put on line.As a result,the unit cost does not accrue until the end of the project,yet revenues start immediately after unit installation. Blending Concept,Innovation Conceptual engineering originally called for replacing the four existing Francis machines at Berrien Springs with 11 Flygt Model EL7650 turbine-generators rated at 650 kW each.The units were to use steel elbow draft-tube liners.These liners would be designed to provide maximum energy recovery and would fit inside the larger existing concrete draft tubes.However,these draft-tube liners and related underwater work that would have been required proved to be prohibi- tively expensive. An alternative solution that would eliminate the draft-tube liners and most of the underwater work was developed. Only a short-turning steel elbow,which would fit inside the existing concrete draft tube,was to be used.A constant area concrete section would be cast in place downstream of the elbow to develop velocity profile after the turn. Radiused edges ease the transition into the existing draft-tube liner.This tech- nique allows the same elbow configura- tion to be used on both upstream and downstream units,and permits dewater- ing of the penstock exit section without the use of a cofferdam. The alternative design resulted in some hydraulic efficiency loss from the reduced recovery of the short-turn elbow section.To compensate,engi- neers added a 12th turbine-generator to the design.The penstock configuration was changed to place six turbine-gener- ators in three of the four bays in each penstock.The fourth bay of each pen- stock will have a cap placed on each draft tube opening for future develop- ment possibilities.The generators are rated at 600 kW each. Analysis suggested the re-engineered concept would restore the plant's name- plate capacity while increasing annual generation by 50 percent.The cost of the additional unit is more than offset by eliminating the draft-tube liners and reducing construction expense,thereby reducing the redevelopment budget by $1 million.By eliminating the need for As seen in this photograph,the St.Joseph River downstream from the 7.2-MW Berrien Springs hydro plant is a popular recreational location.Officials of the project manager,American Elec- tric Power Corporation,believe a major rehabilitation project being concluded at the project will improve water management at the site,benefiting recreationalists. HYDRO REVIEW/APRIL 1996 3 ITT FLYGT CORPORATION 35 Nutmeg Drive P.O.Box 100-4 Trumbull,CT 06611-0943 Tel:(203)380-4856 Fax:(203)380-4705 FLYGT Jim Torony Systems |Applications Engineer &Project Manager ft 60 30 k ,"i : iia oft *By . 7 -.at %NS est ee at a ge Ee Se ett the Bae agian are Bael 20 ONG 'aa of i oats esr nh is i Pere :. .prere wad 1 4 LE BM ENS eos cremate 3a St aE Bee GiyReton gyi ete oe 4 OD rk ts . :--_._$,, -... ty -T juaes P al 10 y :i we& 4 fy peces, T T T T f t a 20 2000 cfs Qa m 20 XN XNwbSAONTEON"GyNNNoeCy10 = N V)fry SCe)ae ee as Sie )iw )NxSiAa)Gi ab (a5wooN/KX /| T YAR XI/3 oN NA AN2.5 40 kW 100 kW 200 kW 2 1 T T T > v t Lu ls Tot T 0.5 1 2 5 10 ITT Flygt Corporation Regional Offices | A SUBSIDIARY OF ITT tOt envio o South San Francisco,CA 94080 ro eg Ove 35 Nutmeg Drive,P.O.Box 1060,Trumbull,CT 06611 Trumbull,CT 06611 Tel.203/380-4870 Telephone 203 380-4700 N27 W23291 Roundy Drive,Pewaukee,WI 53072Telefax203380-4705 Tel.414/544-1922 90 Horizon Drive,Suwanee,GA 30174 Tel.404/932-4320 2400 Tarpley Road,Carrollton,TX 75006 Tel.214/418-2400 ITT Flygt Canada 300 Labrosse Avenue,Point Claire Quebec H9R 4V5 892490 Tel.1 514/695-0100 Hydro02.01.Am2M.07.93TrosaTryckeriAB OPOWER IS AN INVESTMENTforthefuturewithacleanenvironment Water is a wonderful source of energy - it 's clean and renewable. In small-scale hydropower, water is used for only a few seconds while flowing through the hydropower station.Energy is released from the water before resuming its natural flow.This process is a nonpolluting source of power. and a better world. The energy is distributed from the hydro station as electricity,a clean, instantaneous source of power. Every kWh produced by small scale hydro replaces an equal amount of energy fromanon-renewable,polluting source. WHY SUBMERSIBLES? ITT Flygt is the originator and world's largest producer of submersible machines having over 40 years of experience with the submersible concept. Flygt hydroturbine generators utilize standard production components that are readily available.The turbine and generator are integrated into a single unit ready to be lowered into a seat .There is no alignment required when installing the turbine. Draft tubes,seats,turbine tubes,gates and elbows are manufactured as prefabricated steel units.Construction is uncomplicated and fast.Old structures can often be adapted using minor alterations. In an ITT Flygt hydroturbine generator all components are designed to operate as an integrated unit with short production and delivery times.Spare parts are quickly obtainable.The units are designed for easy maintenance. Due to the advantages inherent in this concept,design and construction times are minimized leading to lower costs and profitable utilization of small scale hydro stations. TOTAL ECONOMY cfs -Finally the most important factor is total economy.Neither the machinery itself nor the DAILY AVERAGE FLOW ra Turbine o+-+-t+-$-_++++++f 10 20 30 40 50 60 70 80 90 100 Time %of year CLOSE CONTACT WITH THE CUSTOMER ITT Flygt is a large reliable company with world-wide distribution and service.ITT Flygt does not forget you after delivery.We advise before and after you build your power station,provide installation,start up and service contracts, and help you plan your profitable small-scale hydro. THE SUBMERSIBLE CONCEPT IS COST-VAN construction should be evaluated seprately.It is the total project that counts. The advantage with the submersible concept is the symbiosis between the integrated machinery and the construction together with optimized energy production, short delivery and building time,simple automatic controls, easy service and high reliability. The flexibility of multi-unit station design allows each unit to run at peak efficiency and the flow duration curve to be optimally utilized. The key factor is energy production compared to cost.We have the knowledge and experience of calculating the energy production from the flow duration curve and will support you with optimized layouts and cost alternatives. EFFICIENT AND MINIMIZES THE IMPACT CA KS ON THE ENVIRONMENT -. SUBMERSIBLE HYDRO PAYs!!! SUPPORT AND DOCUMENTATION G20 gs ITT Flygt has developed and tested a large number of standardized station designs for penstocks,dams,flumes, canals and industrial outlets. The most common types are presented in the conceptual layout section in this brochure.Many other configurations have also been built.These basic designs can easily be adapted to individual conditions. In our publications you will find the general data and guidelines about our products and station designs.The basic information is presented in the E-section of our Global catalog.Our extensive documentation covers reference lists,installation examples,case stories from all over the world and other important functions such as care &maintenance manuals and spare parts lists. For your specific project,we will support you with equipment selection,engineering data,hydraulic layout and perfor- mance information required to optimize your hydropower station.We work with you in sharing our extensive experi- ence in economical system design whether it is utilizing ex- isting structures or designing new simple lowcoststructures. HYDRO FOR THE FUTURE ITT Flygt is continually looking toward the future with new products,improvements and applications.Comprehensive R&D efforts are ongoing in the area of flumes,siphons and draft tubes,silent stations,integrated outlets etc. THE SUBMERSIBLE CONCEPT FLUME AND CYLINDER GATE The flume is narrow in order to optimize the flow of water into the turbine.In the basic flume concept a cylinder gate is placed over the hydroturbine generator.The cylinder gate is balanced and closes automatically by gravity,it prevents vortexing and allows low flume water depths.A rubber seal at the lower end of the cylinder closes tightly against the inlet bellmouth.Of course sluice gates can also be used. COOLING While running,the generator is cooled by water flowing around it. THE SEAT The hydroturbine generator rests on and is sealed off against a bottom seat.It is held in place by its own weight and the water pressure while running. DRAFT TUBES Prefabricated elbow or straight conical draft tubes recover dynamic energy downstream of INSTALLATION AND SERVICE The hydroturbine generator is not bolted into the structure. It is simply lowered down to a bottom seat for installation and it can be easily hoisted for inspection and service.The cylinder gate can also provide access for inspection. THE UNIT The submersible hydroturbine genera- tor,an integrated turbine,generator and gearbox if required. (-> ALSO IN PIPES AND SIPHONS The same basic principles are used for higher heads. Here the hydroturbine gene- rator is lowered through a service cover on the inlet elbow down to a seat at the bottom of a vertical tube. In covered flumes and siphons access is also provided through service covers. Ne 7 the runner.They are matched with the turbines to give maxi- mum recovery. FROM FEASIBILITY STUDY...AROUND THE WORLD f in PR Fy ete hg INE MANUFACTURING :The Flygt hydroturbine Wen,oageneratorsareproducedWily=z eae in ITT Flygt's modern manufacturing facilities while work at the site is progressing. on RE Be Eh,<a FMson ae ae COVERED FLUME:TANDEM FLUME: DELIVERY Buk6 | |_ukowka,Poland 1992 Fleminge,Sweden 1990Duringthetechnicalandeconomicalfeasibilitystudy,ITT The units are delivered and installed E7650 +E7650R H=14-15ft Q=125-750 cis P=748kW 3x ree tyson H=16-19ft Q=65-850 cfs P=1.4 MWFlygtwillsupporttheprojectbyproposingstationdesigns,when construction is complete. --":;no equipment selection,and performing energy studies. CONSTRUCTION Excavation and construction is The prefabridated components are installed atthe site ,ready started while steel draft tubes,to be cast in place.The ITT Flygt hydroturbine generators seats,turbine tubes and gates are simultaneously manufactured.' are manufactured. 0 1 2 3 y, ,eel alsin 08 se la UNDERWATER CHAMBER:CHAMBER SIPHON: Reichenbach,Germany 1988 Neuville-sur-Ain,France1989STUDYANDPROJECTSIMULTANEOUSconetmemonmanractuneE7600RH=11 ft Q=35-125 cfs P=90kW 3 x E7650 H=10-15 ft Q=345-1025 cfs P=850kW SUBMERSIBLE HYDROPOWER aaeteve SOA bs .;:'al PENSTOCK: Glen Colusa,USA 1983 2 x E7570 H=20 ft Q=60-120 cfs P=160kW \. hoe Nd] tae INTAKE SIPHON: St.Catherine,Canada 1989 4x E7620 H=24-35 ft Q=270-950 cfs P=2 MW ,Ragasieie a\,_Tia,”eos7con CONTROL AND SWITCHGEAR Arriving as prefabricated units,control and switchgear are installed. INSTALLATION The turbines are lowered onto their seats and electrically nected. ...[OQ ENERGY PRODUCTION COMPLETION The power station is ready to start and operate 6-9 months after construction begins due to the concurrent site construction and equipment manufacturing.This results in lower installed dollar per kw and early revenue generation. Hundreds of ITT Flygt Hydropower stations have now been built. All over the world in old structures and newloca- tions the hydroturbine generators serve plants atdams and weirs,lakes and rivers.They operate either with storage or in run-of-the-riversystems. They run in sluices,irri- gation canals,release flow outlets,waste water discharges and they are used as energy recovery units in industrial cooling water systems. i MONTHS ee es 5 6 7 9BIFURCATIONS:\Park 2,South Korea 1986 5xE7585 H=65 ft Q=100-500 cfs P=2,5 MW |er |-_oD ikYanmoaranmnabeTANDEM FLUMES 10-30 ft (310M)HEADS The ITT Flygt series of hydroturbine generators consists of 6 turbine sizes. Each turbine is adapted to specific design conditions by the use of different guide vane angles,number of runner blades,runner blade angles and speeds. The many combinations make it possible to select units that provide the most efficient utilization of theavailable energy. The total efficiency of a hydroturbine generator is the product of the individual efficiencies of the generator, gearbox and turbine,including the draft tube. Extensive model testing has been completed in our hydraulic lab,enabling ITT Flygt to accurately determine performance. Since ITT Flygt supplies the entire generating package,the performance curves provi- ded to the customer show the actual electrical output. If space is limited,two turbine generators can be placed in tandem in the same flume.With cylinder gates they can be operated independently.Compact multi- flume concept.a OPEN OR COVERED FLUME WITH © CYLINDERGATE 10-30 ft (3-10 M) HEADS : (ALSO IN FLOOD-PROOF VERSION) The most compact,simple and efficient flume concept.A cylindergate is placed over or around the hydroturbine gener- ator. The flume can be covered,and with a ventilated cylindergate cover,it can be flooded after shut down. OLE SUBMERGED UNDERWATER CHAMBER 10-25 ft (3-8 M)HEADS AND LARGE FLOW Covered flume,placed below the crest of a dam,bypassing release "and flood water. Removable or inflatable flashboards over the station serve to adjust the crest level. x s : CHAMBER SIPHON 10-25 ft (3-8 M)HEADS AND LARGE FLOW To reduce the depth of excavation the flume can raise to a concrete siphon chamber. Simple operation is provided with("4 vacuum pump and vacuumbreakervalve. HEADS Horizontal or inclined penstock,with butterfly valve and elbow with servicecover.. The turbine generator is lowered in a vertical pipe section. trate,©oS Sie oN BeneINTAKESIPHON10-65 ft (3-20 M) HEADS Inclined penstock,connected to a *siphon at the intake or integrated with+the service cover elbow. B HEADS .; One single penstock,connected to a dam or a tunnel,can feed a number of hydroturbine generators,individually controlled with butterfly valves. FLUME 10-30 ft (3-10 M)HEADS The hydroturbine generator is installed in an open flume with sluice gate.Multi-unit stations use parallel fiumes. Seat OS Na a ne 2 ene EE waa Bear INCLINED PIPE 10-65 ft (3-20 M) HEADS : When connected to penstocks or to release water outlets placed at low levels,the direct drive units can be placed in an inclined pipe section controlled with a butterfly vaive,intake gate or siphon.' a iEy SATU"Stee eS SRSESe wal=eSS CONTROL CENTER -THE BRAIN OF THE HYDROPOWER STATION A small hydropower station has to operate unattended in order to be profitable.The ITT Flygt control center achieves this by automatically starting, regulating and stopping the turbines.mananemicaoerarerarseresGecenaeeeaere44aosveeet.*HYDROPOWER CONTROL AND SWITCHGEAR Flygt has developed specific control centers and switch- gears to operate small hydro power plants equipped with submersible hydroturbine generators. The control provides logic for starting and stopping sequences.It also provides equipment protection by monitoring fault alarms from built-in sensors. The control centers are based on programmable logical control (PLC)units.The headwater level is maintained by varying the number of turbines in use or by adjusting the runner blade angle. A switchgear,integrated with the control,can be provided to meet local utility requirements. GENERATOR A high efficiency induction generator specifically designed for submersible applications.Class F insulated stator windings rated at 155°C (310°F).Shrink-fitted stators provide for maximum heat transfer. GENERATOR BEARINGS Robust,low maintenance design,with roller and ball bearings,lubricated with a high quality grease. SHAFTS Short overhang increases the bearing and seal life,and results in low vibration levels and silent operation.The runner shaft is completely isolated from the water. SHAFT SEALING JUNCTION BOX Cables enter the junction box through a patented double sealing gland combined with a strain relief function.The junction box is hermetically sealed from the generator. GUIDE VANES In order to provide optimal performance overa wide range,four different fixed guide vane angles are available. WEAR RING The system for sealing the shaft consists of two mechanical!tungsten carbide face seals mounted in tandem.An oil chamber in between, containing a special environmentally-safe oil, lubricates and cools the seal faces.It also provides security against water penetration. PLANETARY GEARBOX Turbines that require a speed increaser are equipped with a heavy duty planetary gearbox,- designed for long life and high |\ efficiency.The gearbox is i lubricated and cooled with gear oil.It has a pressurized system for lubrication, filtration and cooling.The gears are designed for infinite life according to American Gear Manufacturers'Associ- ation (AGMA)standards,and all roller bearings have design lives well in excess of 100,000 hrs. An easily replaceable wear ring in alumi- num bronze or stainless steel will main- tain high efficiency. RUNNER Runners are available with either four or five blades.The runner blades are avail- able in aluminum bronze or stainless steel and the blade angles can be set manually in increments of 1°. The four largest hydroturbines (E7585 to E7650)are also available with auto- matically adjustable runners (semi- Kaplan turbines)for run-of-the-river conditions. THE POWERFUL SUBME FAULT PROTECTION LyThejunctionboxisprotectedbyafloat' switch sensor. Each winding is protected by a thermal switch or RTD sensor. A generator leakage detector is located well below the windings. The lower generator bearing is protected by an RTD sensor. Each unit can also be equipped with the following internal sensors: Upper bearing temperature sensor (RTD),gearbox oil flow sensor and oil temperature sensor. MATERIAL AND COATING All major cast parts,except the runner and wear ring,are made of high quality cast iron.Parts in contact with water are coated with a two component high solids RSIBLES ,& ml : Zoteeiliee imei imme E 7556 E 7570 E 7585 E 7600 E 7620 E 7650 THE HYDROTURBINE GENERATOR FAMILY The integrated units range from 30 kW to 850 kW in 60 Hz and can handle flows up to 425 cfs. +xze¢-PROFITABLE HYDRO '.VITH SUBMERSIBLE TECHNOLOGY A siphon installation vacuum operatedfor low heads 8-16 ft (2,5to5 my). An open flume instal- lation with sluice gate fora head range of16-33ft (5 to 10 m). An open flume installation withelbowdrafttubeforaheadrangeof10-20 ft (3 to 6 m).This ts the most typical installation with sub- mersible hydvoturbine generators. A cylinder gate,which is raised and lowered hydraulically,regulates the flow to each hydroturbine generator. REED Tye pee peg Py prey ssaceLS a2 A penstock installa-| tion with butterfly valve is suitable for heads greater than 20 ft (6m). The submersible hydroturbine generator is a highly competitive alternative for use in construction of new and in rehabilitation of old small hydropower plants.In many cases it is vital for achieving profitability in such projects.Quick delivery and simple installation make the machine a cost- effective option. These are some of the factors that instantly have established Flygt's submersible hydroturbine generators on the market for small hydropower plants.In the past seven years,approximately 250 hydroturbine generators with a combined capacity of over 70 MW have been installed in North America,Europe and Asia. The submersible hydroturbine generator inte- grates an axial flow turbine,a planetary gearbox and an induction generator in one sealed package to be installed submerged in the waterway. The modular design enables manufacturing of a wide range of sizes within the power range from 30 to 700 kW. Oe ITT Fluid ome Yt OCEAN WAVES AS AN ALTERNATIVE ENERGY SOURCE SPRINGTIME FOR MINI POWER PLANTS YI)1 De _THE RUNNER aae,asPptzyteeaeaeaeoeee:aa4zReSoetM'sagtmyatae3-IainedbaOPNyO?oef:rae;oonal2.Se5of.aa=eiyteksaan'bs¢anesomeee;4Atie:coneaa:aSaneacopey:oepees.im:aeeS..oheg.*.iyeesotea7.oy'4shaay \\\y' _[|FROMTHE FLYGTGROUP ===1991 Aes 7 '< Fs é bbeaeel ques CONTENTS:= 2 Runners for the Future. 3 Flygt in the World Market Place. 4 Springtime for Mini power plants. 8 The Submersible Hydroturbine Generator -Revolutionizing Hydro Power. 11 Small Hydropower Plant in the Center of Town. 12 More Reliable through Model Testing. 16 Profitable Power from the Old Mill Stream. 18 Ocean Waves as an Alternative Energy Source. 21 Flygt's Small Hydro Solution for an Italian Beauty Spot. 22 New Profitability in Old Power Plants 24 Generate Your Own Power the Energy Solution of a Medium-sized,Italian Firm. 26 A "Fish Lift” for Hydro Plants. RUNNERS FOR THE FUTURE Impeller The Runner ©1991 A news magazine about ITT Flygt,its products and services and their applications around the world. PUBLISHER: Bjorn von Euler Communications Manager, ITT Flygt AB Epiror AND PRODUCTION: Margareta Rindforth Tel:(46)8/627 67 06 AuTHors: Bo Forsberg Steve Minett Appress: Market Communication, ITT Flygt AB Box 1309 ©$-171 25 Solna Sweden ConTRIBUTORS: Bert Lundmark, Bo Stjernstrém, Géran Bruske, Zbigniew Czarnota Grapuic DEsIGN: Swerre Nygren PRINTED BY: Trosa Tryckeri AB,Trosa 1991 ISSN 0345-5181 ©ITT FLYGT AB RUNNER 10.01.Eng.2.5M.04.91 This special hydro issue of the news magazine Impeller, The Runner,contains a selection of articles about submersible small hydro. decade ago,Flygt launched a new approach to small hydro, the Submersible Hydroturbine Generator,ready to fit into a pre fabricated seat. For over a hundred years,the machinery had been bolted into the structure.Now the one-piece machinery,produced in series,could easily be lifted in and out throught a vertical column.Looking upon flumes with new eyes,ITT Flygt's engineers turned the column into a balanced self-closing gate.Simple basic station designs ranging from penstocks and open flumes_to siphons were developed. During this period 250 submers- ible units have been installed in nearly 150 stations with outputs ranging from 50 to 2500 kW.Based on 40 years of experience with sub- mersible equipment,they are now running in Scandinavia,Europe, North America and Asia. Renewable,non-polluting energy is our future.There are thousands of disused and worn out small hydro sites waiting to be refurbished and to spin again.The submersible machinery is designed to fit right in,with a minimum of construction work. ITT Flygt have been fore-runners in small hydro,and we still are. Completely submerged power sta- tions with release and flood flow going over the stations are just one of the latest concepts incorporating the powerful submersibles.F Bo Stjernstrom Market Area Manager HyprO TURBINE GENERATORS ce teTTSeono **+ [oe a a ee eeryeidd Sania dR 4,4OoWEEImpeller -The Runner +1991 number of laws to help protect the State's environment and strengthen its fish,game and conservation laws.One such law required that all ponding dams,hydroelectric dams and ob- structed river outfalls be provided with means to allow fish to swim upstream and spawn. The law did not specify what method was to be used.This was left up to the individual companies and entrepren- eurs that held title to the water body, provided that the method chosen fulfill the requirements of the new law. "Fish ladder”problems Conventionally,the most common method to provide for the upstream trek of spawning fish is the fish ladder. There are,however,two drawbacks to the use of a fish ladder;first,it's veryexpensivetoconstruct,and it must be remembered that many small hydro- electric generation sites are owned by entrepreneurs or small investors with little capital.Secondly,the fish ladder allows a large and constant spillage. This means that a considerable volume of water bypasses the hydroturbine, with a consequently loss of potential energy. Mixer current One of Flygt's hydro turbine customers in Maine came up with a better idea: Why not simply collect the fish in a bas- ket,lift them out and put them back in 26 |the river upstream of the hydro facility. fish into the basket.A fish attraction system was designed utilizing Flygt's PP-4000 mixers.When energized,the mixers create a current that attracts the spawning fish.They swim towards the current and can,therefore,be caught in large,metal baskets attached to a winch. The pictures are from the Ellsworth plant of the Bangor Hydro Company, Maine,where such a system is in op- eration.A PP-4501 is located on the left side of the hydroturbine tailwater and dam spillway.The trough,where the basket is housed,has an integral plexiglass viewing port,enabling the fish to be seen as they enter the current trough and lift basket.The basket has a one-way gate to prevent the captive fish from escaping. Increased salmon population There are now four hydro sites operat- ing this system.Two to three times a day a State of Maine Fish and Game Warden visits each site to officially count,measure and actually sort the fish species.The officials keep a log on the number of salmon that they "lift” up to a point above the dam.They are also able to keep out any undesirable species of fish during the sorting pro- cess.The Fish and Game Commission of the State of Maine is extremely happy with the first year's results:Pro- jections show that the salmon popula- tion will increase significantly thanks to the use of the mixerelevator system. c me| I:1987,the State of Maine enacteda The problem then was how to get the | .This is a view of the dam spillwater. The PP-4501 current generator is mounted on the left -center of the picture. .The concrete wall on the left is the actual fish attraction trough.The steel column/beam structure at the left is the "elevator”. .The 20 Hp PP-4501 is being lowered into position. .The PP-4501 is in position ready for operation. .This is a view of the current being generated to attract the spawning fish. .This is a look down the fish trough towards the "elevator”. .Raising of the elevator basket. .A bucketful of spawning Atlantic Salmon to be counted,sized and set free upstream of the hydro site. Impeller -The Runner +1991 «Cont'd from p 11 "Small hydropower plant...” also contains four Flygt propeller pumps,capacity 700 l/s at 10 metres, each of which feeds its own heat pump with effluent. The heat pumps recover the thermal energy from the water and transfer it to the district heating network in Stock- holm.The cooled effluent is then dis- charged into the sea. Before this happens,though,the water is deprived of another portion of its energy content.The vertical drop from the heat pumps to the surface of the sea is about 10 metres.Here, Stockholm Energi has installed a small! hydropower plant in the form of a Flygt hydroturbine generator that produces 315 kW for delivery to the power grid. The hydroturbine generator is of the semi-Kaplan type with fixed guide vanes and variable-pitch runner blades and is intended for completely sub- merged installation. Installation is carried out simply by lowering the hydroturbine generator into a steel pipe,which in this case is about 10 metres long and ends in a straight diffuser.There was little need for blasting or other civil engineering measures.In addition to a low con- struction cost,this method of installa- tion also results in a low sound level during operation. A small hydropower plant usually has a large pond or reservoir that evens out the flow variations in the water supply.In Hammarby,the flow is de- pendent on how many pumps are in operation,and the volume of the pond is small -its free water surface area is only 35 m?.Nevertheless,the hydro- turbine generator operates smoothly thanks to its variable-pitch runner blades,which are controlled by means of a quick and precise automatic hydro plant monitoring and control centre. One of the client's requirements was to make it possible to perform service and maintenance on the hydroturbine generator without interrupting the operation of the heat pump station. This requirement is met thanks to the simple installation method -closing a cylinder gate and hoisting the machine is the only work required.By the end of 1988,the hydroturbine generator in Hammarby had logged more than 10,000 hours of trouble-free running time.0 MODERNIZATION OF RURAL,SWEDISH HYDRO-PLANT "Bffattenfall”,the Swedish State Power Board,is renovating one of its older,small hydro-power stations. Krokfors,which is situated 20 km north of Bengtsfors in western Sweden, was built in 1908,originally to power grind stones.In the 1920's it was con- verted to a power station,with a head of 6 m and a flow through of 6 m?/s. This will now be increased to 15 m?/s. -WORLD MARKETP:J The Board has bought two Flygt EL 7620 submersible hydroturbine gener- ators to effect the upgrading of the sta- tion.The existing power house will be demolished and the new turbines will be housed in existing structures.This work is being carried out by the major Swedish contractor,Skanska. The Krokfors station is located in an area of great natural beauty,close to the Krokfors lock on the Dalsland Canal.The district supports consider- able tourism and all kinds of outdoor leisure activities.Great care has been taken,therefore,to minimize environ- mental disturbance,for example, noise from the station will be min- imal.0 South Korea: IRRIGATION CANAL PROVIDES ELECTRICITY Fo Flygt 7585 turbine-generatorsconstitutetheheartofthenewJung Up power station near the city of the same name in the Republic of Korea. The turbines were installed in Septem- ber 1986 and will produce up to 465 kW each. The Jung Up station was built by a private person with state support.The electricity is sold to the national power utility Kepco. The station is situated next toa 1.5 km long irrigation canal that is fed by a large reservoir.The head from the canal to the turbines is about 15 m.The water in the canal is regulated from the reservoir and supplies a constant flow to the turbines ten months a year,when the turbines are able to produce maximum output. Besides the turbines,Flygt also de- livered a prefabricated building with all control equipment and a switchgear for the Jung Up station.0 HYDRO-POWER FOR TEXTILE PLANT he Swiss textile manufacturer, Niggeler &Kupfer,has bought three hydroturbine generators from Flygt Italy.They will provide power for one of the company's plants in northern Italy.There is already a synchronous hydroturbine generator at the plant. When the Flygt units arrive this will be removed and renovated,during a two year period.Over these two years the Flygt hydroturbine generators will all run continuously,i.e.24 hours a day, seven days a week.At this rate of op- eration they will generate 10 million kWh per year.All three units are EL 7650 models,each with a generating capacity of up to 450 kW.O Impeller -The Runner +1991 ver since the Middle Ages,water has been the foundation of our steadily rising material prosperity. Flowing water in creeks,streams and rivers has driven waterwheels,which have been the prime movers of flour mills,saw mills,trip hammers and paper mills.The water decided where people would live and work.Water pro- vided the essential power source and so determined the location of factories and communities. Aside from the fact that water- wheels were replaced by more efficient water turbines,nothing essentially new happened until the invention of the electric motor and the generator.Then it suddenly became possible to trans- port energy over long distances.In- dustries did not necessarily have to be located at the site of the water power. The power plants grew larger and larger during the 20th century.The electrical energy from the hydropower plants was supplemented by energy from coal,oil and nuclear power plants. Energy from these larger sources was cheap.Much cheaper than from the mini power plants that had replaced the waterwheels and the turbines.One by one,the mini power plants were closed down.Most were forgotten and only arouse in interest of industrial roman- tics and local historians. So why are the mini power plants now experiencing a rebirth -a spring- time?Well,it all started back in 1973. That was when energy -at least the energy we get from oil -suddenly started to cost much more money, whereas it had formerly been,if not free,at least very cheap.Then came the public's awakening interest in eco- logy,environment and pollution.The interest in mini power plants has really taken off over the past few years,due to policy changes in anumber of countries in the pricing of electrical energy from small power plants,together with the development of small-scale power- producing units that make it possible to produce energy in mini power plants at competitive prices. No environmental nuisances The electrical energy from hydropower plants is in itself an attractive form of energy.It comes from a renewable energy source that does not cause any pollution or environmental nuisances. The mini power plants in particular have very little ecological impact. What was lacking was mini power plants that could produce energy at a low cost.This is where Flygt entered the picture and contributed towards the new springtime which mini power plants are now experiencing. Flygt's interest in mini power plants was quite natural.The difference between a turbine and a pump is not very great;the pump can serve as a tur- bine when run in reverse,and Flygt knows pumps.Pumps,moreover,that are integrated with motors -which can also function as generators! Special turbine-generator The goal of the development work started by Flygt's engineers was to de- sign a turbine-generator specially suited for mini power plants.What has been done before had largely been to reduce larger power plants in size.This simple approach had preserved com- plex and expensive designs.Designs which did not give the largest possible amount of energy at the smallest pos- sible cost.This,however,was the goal established by Flygt for its work. Flygt started working in earnest with mini power plants around 1977. Several years earlier,the company had developed a type of propeller pump, primarily for pumping large quantities of water at power plants,for example on the Rhone River in southeast France. SPRINGTIME FOR |POWER PLANTS Impeller +The Runner +1991 ae:ee Ihe ey rae Y The textile manufacture builted up in 1889 by Giovanni Festi and Cesa- re Rasini near the river Serio for using the hydraulic energy. A The restoration of the Pirapola power station was facilitated by the use of Flygt submersible turbines. A A simple installation reduced design and construction times and provided economic advantages.BersieeL\_{).Flygt turbines installed in the old Gazzi plant inside the Nuova Festi e Rasini factory. A Power production at the Gazzi and Pirapol hydropower plants has become profitable again with Flygt submersible turbines. Flygt turbine installed in its housing A and ready to produce all energy required by the factory. Impeller +The Runner -1991 taly is particularly blessed with potential for small hydro facilities. The country has an abundance of small,energetic watercourses and in the early 1900's thousands of these were being exploited for hydro-power. Most of these small plants sub- sequently fell into disuse.Many of their desolate,old buildings can still be seen. Small hydro revival In recent times,though,the combina- tion of uncertainties over the cost of energy and concerns about the en- vironment have lead many Italian firms to take a new look at their "obsolete” small hydro facilities.Flygt has proved itself to be a useful partner in many such reconsiderations:It can provide advice as to the technical and economic feasibility of such projects.And,where this analysis produces positive results, Flygt can provide the equipment to carry the project through.It can simply supply a submersible hydroturbine generator or it can provide a complete, "turn-key”solution. Flygt's hydroturbine generators are particularly suitable for reviving small hydro facilities:Firstly,because they can operate optimally at low or very low heads (2.5 to 20 m)and with relatively high flows (0.7 to 12 m*/sec).And, secondly,because Flygt's small hydro systems can be set up using the exist- ing buildings and structures of the old hydro plant,thus enabling major savings in civil engineering costs. Thirdly,the standardized nature of Flygt's turbine generators also minim- izes costs,whilst additionally supply- ing a guarantee of reliability -dozens of units of the same model have already been proven in practice at other sites around the world.(Over 200 of Flygt's submersible hydroturbine generators have been installed at plants in N. America,Europe and Asia.) Textile plant An excellent example of this revital- ization of small hydro plants in Italy is the case of a 100-year-old textile plant, situated on the banks of the Serio river, not far from the town of Bergamo in north eastern Italy.The plant was 4 |founded by some of the most success- RENN GENERATE YOU A ENE 1G ite ies,aoe:ams "REAP pron ge aR ig eer ee -THE ENERGY SOLUTION OF A MEDIUM-SIZED,ITALIAN FIRM ful Italian financiers of the period. Prominent among these were,Gio- vanni Festi and Cesare Rasini,hence the name of the company;"Festi e Rasini”.The factory was located in a village called "Villa d'Ogna”and was situated close to a waterfall,which had been used as a source of mechanical energy since the Seventh Century.By 1908 the company was using this water course to operate two hydro plants, known as "Pirapola”and "Gazzi”.To- gether they generated about 400 kW. This was a huge amount for the time. After the nationalization of electri- city generation by the Italian govern- ment,many of Italy's small hydro plants were shut.This happened to one of the textile factory's two plants.The other plant continued to produce power but its equipment was,in any case, obsolete by this time.In the late 1980's,though,following discussions with Flygt,it was decided to revitalize them and,in 1988,four submersible hydroturbine generators were in- stalled:The Pirapola plant,which has a head of 6.7 m,was equipped with two EL 7620R units,which have a power rating of 304 kW each,anda maximum flow rate of 5.5 m/sec per unit.Two units of the same model were installed in the Gazzi plant,though these have a slightly higher head,8.8 m,and a higher power rating;400 kW. 50%of energy needs The two plants now supply 80 million kWh per year to the Villa d'Ogna fac- tory,which is more than half of its total annual energy requirement.The fac- tory employs about 150 people and its annual sales average ITL 20 billion (USD 15 million).It thus nicely illus- trates the sort of contribution that modern,small hydro solutions can pro- vide for the energy problems of a medium-sized firm,and -as an added bonus -the system inflicts minimal damage on the environment.0 Impeller +The Runner +1991 wainenngYied=.cSPIIVIIDweileadpecaeanearvsiesaewiidei.f'These pumps were submersible, with motor and pump integrated in one unit.They were lowered into vertical shafts,sealed under their own weights against the bottom and were able to start working immediately.They could then be lifted up when they required routine inspection and service. All of these features would also be advantageous in a hydropower plant. The use of a vertical flow shaft elimi- nates the need for complicated engi- neering structures for the flow of wa- ter.It is often possible to use parts of existing shafts.It is also often possible to use prefabricated steel or concrete elements,which considerably reduce construction costs,especially as the work requires no particular skills and can be done by local labour. The power station structures with waterways on the one hand and the turbine-generators on the other hand are two separate units.They can there- fore be built separately -and simul- taneously -which greatly shortens the construction period. The turbine-generators do not have to be delivered until they are ready tobeputintouse,which further reduces total costs for the power plant.> Impeller -The Runner - Contd from page 5 Turbine and generator in one means that no complicated installation and alignment work is required,which is otherwise often necessary,noris a spe- cial generator house necessary.These are factors that further reduce costs. The fact that the turbine-generator package is submersible also greatly re- duces the sound level,which is a con- siderable advantage! Special casing and vanes Flygt's engineers never doubted that the system with submersible turbine- generators would work.Flygt is a pion- eer in the manufacture of submersible pumps,having produced one million units during a 40 year period! The only question was whether the existing pumps could be run in reverse as they were -in other words, whether they could be used as turbine- generators without any modifications -or whether they would have to be re- built. Owing to the economics of scale and the other advantages of mass-produc- tion in long series,costs and delivery times could be further reduced if it were possible to make use of already existing pump designs. Mathematical calculations and test runs showed that the pumps operated in reverse as turbine-generators gave a good,but not quite satisfactory energy yield. Additional calculations and test runs showed that the yield could be con- siderably improved if the pump casing and pump vanes were replaced with a special turbine casing and special tur- bine vanes.This could be done at rela- tively low costs and without sacrificing the advantages of serial production. And thus it was!Soon,Flygt was able to present a range of six turbine- generators with capacities from 20 to 500 kW.These turbine-generators could,moreover,be combined with each other to produce stations with a capacity of up to 2,000 kW.The tur- bines have an efficiency of over 90%, incidentally,which puts them in the highest international class.aa:2=oonVora.=asAs=44Three Flygt EL 7650 turbine-generators were installed during 1983 in Winni- pesaukee,New Hamp- shire,USA. Thanks to the fact that the design of the sta- tion can be simplified, it is possible to use prefabricated concrete units or steel pipe. Impeller -The Runner -1991 os since March 1987,the old plant is once again generating electricity thanks to Joaquim Ramirez de Cartagena and a turbine-generator from Flygt. The submersible turbine-generator has replaced one of the two traditional turbines in the old power plant.The other turbine was reconditioned and put back into operation in 1986. The new turbine-generator pro- duces 75-80 kW of power.It was sold and installed by Flygt's representative in Spain,Técnicas de Filtraci6n y Bom- beo,S.A. The project was implemented in cooperation with the Institute of Technology in Gerona.Financing was facilitated by favourable government loans.The plant is now also being used by the Institute of Technology for re- search purposes. The old power plant at Murgues i Ventas de Yanci in Navarre has been restored to operation in a similar man- ner.It stood abandoned and dilapid- ated for 25 years.The roof had dis- appeared and the canal silted up.Fol- lowing renovation that commenced at the beginning of 1987,the station now produces 195 kW with the aid of two submersible Flygt turbine-generators. Service in an hour In comparison with older technology, the turbine-generator is very simple to install and maintain. In the old power plants,the turbine was installed in the water while the generator was housed in a special structure above the water or on the shore.This technology required ex- tensive building works and a complex turbine to generator power transmis- sion train employing combinations of belts,shafts and gears. Once the station had been built,it required expensive maintenance. When repairs were necessary,it had to be shut down for days at a time so that the different components could be re- moved.This outage meant a loss of in- come. Flygt's submersible turbine-gener- ator can be installed in existing stations with a minimum of civil engineering. Service or inspection can be done in an hour.The machine is simply hoisted out of the water with a crane and doesn't even need to be disconnected from the controls.The outage time is negligible. These initial installations in Navarre are based on a Spanish study which estimates that there are around 1,000 large or small mini power plants in Catalonia and the northern Basque provinces (including Navarre)alone that are potentially profitable to rehab- ilitate using the new technology. Even though the harnessable en- ergy varies widely from place to place, it is relatively easy to find a turbine- generatoor of the right size.At pres- ent,Flygt has six different turbines that can be combined with a large num- ber of asynchronous generators.When you also consider the variations made possible by the use of different types of propellers and other components,you get no fewer than 5,000 different com- binations,which should cover most needs.0 Impeller -The Runner »1991 The power plant at Arenys d'Empordas is one again producing electricity - with the aid of a Flygt turbine- generator. ini power plants in various forms were common in the early days of the industrial revolution.Thousands of mills and smail-scale electric power plants were built in Spain in the early part of the century to harness the energy of small watercourses. Larger power stations were eventu- ally built on the large watercourses. Employing large-scale technology, they generated inexpensive electricity that could be distributed over long distances to large and small towns.The mini power plants eventually became uneconomical.The plants remained as monuments to a bygone era when clean but inefficient and unprofitable techno- logy was acceptable.Interest in small-scale technology was reawakened by the energy crisis of the early 70s.Not only did oil rise sharply in price -all energy became more expensive.The energy content of small watercourses therefore became a subject of renewed interest. In order for the limited quantities of energy in small watercourses to be i an :yt|a eee os ai os .|i Hii i t Hl tti 1t t 4 t The official reopening of Arenys d'Empordas,in which the Institute of Technology in Gerona is a part-owner. Two disused mini power plants were reopened in Spain in 1987.The plants had been given new life and new profit- ability with Flygt hydro turbine-generators.The sub- mersible turbine-generator, with its low installation and maintenance costs,offers an increasingly popular means to revitalize small-scale hydro- power plants. harnessed profitably,installation costs must be minimized.A great deal is therefore gained if it is possible to reuse old,disued mill ponds.The question is:How can old,existing power-generating structures be re- vitalized with new power technology? KY NEW PROFITABILITY IN OLD POWER PLANTS At right:The canal downstream of Murgues is cleaned after 25 years of neglect.Now Murgues generates 195 kW. The turbine-generator The solution is Flygt's submersible tur- bine-generator.It is available in dif- ferent sizes from 50 to 700 kW and can be used with available heads of 3-20 metres and capacities up to 10 m?/s per unit.The turbine has a very high ef- ficiency,up to about 90 per cent. This high efficiency and the possibil- ity of simple installation in old,aban- doned mini power plants have created a new potential for profitable energy pro- duction on a small scale at many sites all over the world. In the small town of Arenys d'Em- porda on the lower reaches of the Fluvia river in northeastern Spain,an old power plant was recently recom- missioned thanks to this new techno- logy. The original power plant at Arenys d'Emporda was built in the wake of industrialization in 1921.In 1976,after 55 years,the power plant seemed to have reached the end of its useful life - and indeed had,for the time being.But Impeller -The Runner -1991 670,000 kWh are pro- duced every year by the two EL 7570 turbine generators in Glen Colusa,California. Troublesome and costly alignment procedures are eliminated,since the turbines are de- livered as integral units. A flour mill was converted The first turbine-generators were in- stalled at Barsbro in southern Sweden. An old,disused electrical power sta- tion,originally a flour mill,was con- verted there into a modern mini power- plant in the space of nine weeks.This short rebuilding period was made pos- sible by,among other things,the use of standardized,prefabricated concrete units for the water flow. Then it was America's turn. An abandoned flour mill was given new life as a mini power plant in Little River, North Carolina,in the foothills of the Appalachians.The old inlet channel was cleaned up and two concrete boxes were added to the old mill pond.Four submersible turbines now produce 235 kW each. A new mini power plant was built to exploit the power in the water that fell from the Tehema-Colusa Canal down into the Glen Colusa Canal in the irriga- tion system in California's Central Val- ley east of San Francisco.Two sub- mersible turbines,each 85 kW,now produce approximately 670,000 kWh per year,which is equivalent to around 1,100 barrels of oil. More than 20 plants Experience from these two installa- tions was so good that new projects were quickly planned all over the United States.Only one year later,six more mini power plants with 13 Flygt turbine-generators had already been built.A total of some 20 or so mini power plants equipped with Flygt tur- bine-generators were expected to be in operation before the end of 1984.0 Impeller -The Runner -1991 E80 ae tasSoSames2 THE SUBMERSIBLE HYDROTURBINE GENERATOR -REVOLUTIONIZING HYDRO POWER "inihydro”and minicomputers have one thing in common - they are not just scaled-down versions of their bigger predecessors:Both re- quired original ideas and innovative de- signs.Both were promoted by new companies exclusively specializing in these respective "mini”technologies and in both cases established manufac- turers had to follow their lead in order not to lose out on the growing market they created.The main trends which have emerged in the technologies de- signed for the small-scale hydro market have been standardization of equipment,"package”solutions and the minimizing of civil engineering work. Submersible hydroturbine generators The submersible hydroturbine genera- tor is one of the most interesting inno- vations on this small-scale hydro mar- ket.These are particularly suitable for low head developments where the size of the turbine is large in relation to the size of the generator.Because they integrated turbine and generator in a single unit and because they are sub- mersible,the entire generating unit can be directly installed in the water- way.This eliminates the need for mechanical power transmission and, consequently,a conventional power house is not required:Local labour and simple construction equipment can be used to erect a power station.More- over,submersible hydroturbine gen- erator installations can be easily adapted to specific site conditions and offer advantages from both the en- vironmental and the aesthetic points of view.Submersible hydroturbine gen- erators are manufactured in six basic sizes with runner diameters from 550 mm to 1500 mm (22-59 inches).They are designed for heads ranging from 2.5 to 20 m (8-70 ft),and a flow ratefrom0.5 to 12 cu.m/s (20-420 cts). Generating capacities range from 50- 700 kW. Installation principles The optimal mode of installation for a submersible hydroturbine generator is inside a vertical tube with a bottom flange.This flange serves as a turbine seat and connects to a draft tube.The weight of the hydroturbine generator is sufficient to keep it in place without ad- ditional fastening,which is a great ad- vantage from the installation and ser- vice point of view.This installation principle is equally suitable for both hydraulic systems,open channels and closed conduits.The turbine tube can be joined with a penstock,or installed in an open flume or a closed chamber. Basic installation layouts To exploit the unique qualities of the submersible hydroturbine generators to the maximum,Flygt has developed three basic station designs.These are designed for the most common condi- tions within the head range from 2.5 to 20 m (8-66 ft).Despite their simple geometries these station designs pro- vide ideal flow conditions for the tur- bine,giving a high total water-to-wire efficiency.Crucial parts of these de- signs,such as the flume configuration, the intake submergence and the siphon geometry,were studied in hydraulic models.These tests allowed us to opti- mize the station design from the con- structional point of view,while,at the same time,maintaining efficient hy- draulic operation,free from problems related to vortices,cavitation,insta- bilities and vibrations.The basic in- stallation layouts are as follows; Impeller -The Runner -1991 ver since the oil price crises of the 1970's there's been a demand for alternative energy sources.Prominent among these is,of course hydro-power and,given the altered cost compari- sons,attention has now also been given to smaller water courses.Pre- viously these may not even have been FLYGT'S SMALL HYDRO SOLUTION FOR AN ITALIAN BEAUTY SPOT considered,especially where there was low head and variable flows.It was just assumed that they could not be ex- ploited for power generation purposes at an economically justifiable cost.The energy crises changed this however and now technologies for small hydro- power stations have been evolved. Oe Flygt in the forefront Foremost among these are Flygt's sub- mersible hydroturbine generators. They are available in six different sizes, with a capacity range from 30 to 450 kW.The designs are suitable for heads ranging from 2.5 to 20 mand flow rates of between 0.7 to 11 m?/sec.By utiliz- :ing standardized parts,bulk manufac- _,turing and standard civil structures -4 they can achieve remarkable cost sav- -!ings.For example,design costs are re- -duced,delivery times are shortened ;and parts are more easily available.But perhaps even more important than all this is the reliability of the hydrotur- bine generator,which being part of a standard product,has already been thoroughly proven at over a 100 loca- tions around the world.In addition to all this,submersible hydroturbine gen- erators are light-weight,and conse- quently easy to handle,and silent in operation. Saving the environment The significance of all these advan- tages was not lost on Pietro Petesse, Consultant Engineer to the Pontefelci- no hydropower station,on the Tevere River,a few kilometers from Perugia, in Italy.He opted for the Flygt solution for all the reasons given above but also because of the submersible hydrotur- bine generator's low-visibility and positive environmental character- istics.These were particularly import- ant here as this plant is located in a very picturesque,natural setting,which is an important local resource for recrea- tion and leisure activities. Flexible operation There was already a hydro-power sta- tion at this site with a weir and canal. The canal has been enlarged and shortened and now provides a flow of 42.5 m°/sec.The maximum head is 5.4 m.To optimize power generation, given the hydraulic parameters and the large variation in flow rate,five of Flygt's submersible hydroturbine gen- erators were installed.Four are EL 7650 units with a capacity of 450 kW (one with automatic variable pitch blades).The fifth unit (an EL 7585)has a capacity of 185 kW.This configura- tion,providing 1985 kW of installed power,enables a viable level of flow ex- ploitation even if one of the hydrotur- bine generators is idle.Annual energy output from the plant is estimated at 8.5 G Wh.Part of this will be delivered to the Italian national network,Enel. The remaining power generated will be utilized by a local tannery,Valle Esina. In addition to the five submersible hydroturbine generators,Flygt alsosuppliedalltheelectro-mechanical equipment for the plant,including two step-up transformers,LV switchgear, small hydro power plant control center, plus lighting system and wiring.O Impeller +The Runner -1991 ron a -rao Yo oa Lees co ts ith? thinner cable to carry the energy ashore. The fibre rope comes out of the piston through a wear protection mouth. capil TP RR Pa Kim Nielsen with the first scale model of a converted Flygt 4350 mixer. EES A submersible transformer allows a Underneath the float is a trumpet mouth guiding the 25 m long parafil (synthetic fibre)rope,which is at- tached to the piston.The whole float section weighs 20 tons.When the base was in place,divers then assisted in connecting the float to the piston.The vertical concrete tube for the cylinder is lined with steel and this has been coated with epoxy.Seawater provides lubrication for the piston.There are also rubber bumpers at the top and bot- tom of the cylinder to dampen the pis- ton's action in high,short waves. Second unit half price A great deal was learnt about how to construct the unit during the produc- tion of the first one.Bent Serensen, Danish Wave Power's site foreman, pointed out,for example,that a lot of the reinforcement bars and other strengthening features turned out to be not really necessary.These can be re- duced by about half on the second unit. Consequently the second unit will be cheaper and easier to build:The price should drop from around DKK5 million to DKK 4 million per unit.In addition the 3 km long power cable that has al- ready been laid from the shore to the first unit has enough capacity to carry the power generated by the second unit.The cable comes ashore about 1 km north of Hanstholm harbour and from this point the power is transmit- ted to the Danish national electric power system. Why Hanstholm? Hanstholm had several advantages for the purposes of this project:Ithas deep water close to the coast.There are very few breakwaters in the area,to reduce wave sizes;due west of the harbour there is nothing but open sea for three hundred miles.The prevailing winds are from the west and northwest.As a consequence of all this it has the big- gest,average coastal waves in Den- mark.In addition,a lot is now known about the pattern of waves around Hanstholm:In 1978 a "wave rider” buoy was placed outside the harbour. This contains electronic instruments which register wave heights and fre- quencies. This data was gathered originally for navigation purposes.(It's wave height that determines when a ship can enter the harbour.)But,of course,it was an enormous advantage for the wave power project to be able to use it.The data shows that average wave heights at Hanstholm vary between 1 and 1.5 meters throughout the year.During storms ten-metre waves are quite com- mon and waves of up to 12 m have been recorded on several occasions. Hanstholm's average wave heights provide good operating conditions for the wave power units and they have been designed to withstand the excep- tional storm waves.The first unit has its own "wave rider”buoy to provide precise data on the wave patterns it is operating in. Navigational safety Measures have been taken to ensure navigational safety in relation to the wave power units.Four buoys are posi- tioned around the unit.These markers conform to international regulations governing safety at sea and thus should be easily interpreted by all marine traf- fic.Chr.J.Christiansen,the harbour captain at Hanstholm,stated:"The presence of the wave power units creates no problem at all for us.They are marked very well and present no more of a hazard than,say,a North Sea oil rig.” Breeding grounds &storm protection The navigational safety aspects are im- portant because if the Hanstholm test proves successful then the density of the units in coastal waters may become quite high.In the future it may be a question of hundreds of wave power units concentrated in one area.These concentrations,however,might also have positive advantages:they could provide suitable breeding grounds for fish and,on the leeward side,they would create calm,sheltered waters for vessels during storms. 10-30 %of Denmark's power B.Hojlund Rasmussen,of Consulting Engineers and Planner A/S (one of the consortium of companies that form Danish Wave Power),estimates that 3,000 to 4,000 of the Nielsen-type wave power units could generate be- tween 10 and 30%of Denmark's electri- city requirements.The other compan- ies that make up Danish Wave Power are the Danish construction company Hojgaard &Schultz,NKT (Nordisk Kabel og Traad)and Flygt Denmark.O Impeller -The Runner +1991 Per he Y 7555 7570 7585 Penstock A penstock installation is suitable for heads greater than 6 m (20 ft).It con- sists of a horizontal or inclined pen- stock,a Y-junction,a vertical turbine tube and a draft tube.The flow can be controlled by a valve installed at the lower end of the penstock or by a sluice gate at the intake.There are four varia- tions of the penstock installation:The draft tube can be either straight or el- bowed and can be combined with either a narrow or wide turbine tube,depend- ing on the flow rate.The elbow-type draft tube is best where a low runner setting is required.Otherwise a straight draft tube is preferable be- cause of its lower cost. Open flume An open flume installation with a straight draft tube is most suitable for a head range of 5 to 10 m,(16-33 ft). The main elements are a short flume,a turbine tube and a straight draft tube. The flow is controlled by a sluice gate. The optimum width of the flume is twice the nominal turbine tube diam- eter.The positioning of the turbine tube near the back wall of the flume,to- gether with the corner fillets,prevent formation of vortices at the turbine in- take and allow a uniform distribution of flow.For a still lower head,from 3 to 6 m,(10-20 ft),an open flume with a conventional elbow draft tube,and the same flume geometry as described above,is optimal.Here the flow is con- trolled by a cylinder gate.The cylinder gate is simply a piece of pipe with a rub- ber seal around its lower circumfer- ence.Since the hydrostatic pressure on the cylinder is balanced,the gate can be moved up and down with very little friction.It can also be closed by its own weight which is an important safety feature.A cylinder gate or a sluice gate are alternative options in all types of open flumes. A compact siphon power station: Siphon For a very low head,2.5-5 m,(8-16 ft),with a relatively large flow,5-10 m?*/s,(175-350 cfs),a siphon installa- tion is most suitable.Such a configura- tion,where the turbine chamber op- erates as a siphon,can be incorporated into a dam or an overflow weir.The main advantage of this siphon form is that the excavation depth for the foun- dation of the station is reduced as com- pared with open flume installations.In addition,this configuration does not require a gate.The flow is initiated by a vacuum system,which evacuates air from the chamber and it can,therefore, be stopped by admitting air.This sys- tem,with few moving parts,is ad- vantageous in cold climates because it minimizes problems associated with freezing. -eng nat Tass LR AIP 2 AROS16iAgem,BOR Neuville-sur-Ain,France -3 units EL 7650/375 kW. The siphon design has been exten- sively tested in a hydraulic model.This revealed that its simple geometry com- bines optimally with an excellent hy- draulic function:The flow distribution at the turbine inlet is uniform and prim- ing of the siphon is greatly assisted by the turbulent mixing of air with water in the initial stage.Another type of siphon configuration,which is suitable for higher heads,is a penstock siphon. This can be mounted over the top of an existing dam without interfering with its structural function or safety.A pen- stock siphon,in addition,can use the minimum,environmental discharge from a reservoir which is normally wasted in spillage. Design concept. Impeller +The Runner +1991 An underwater power station: Reichenbach,West Germany -1 unit EL 7600R/132 kW. eee Floodproof and underwater stations A unique application for submersible hydroturbine generators is floodproof, or even underwater,power stations: An open flume and a siphon configura-tion can be made floodproof by locating the control equipment beyond the reach of floodwater by means of ex- tended cables and hydraulic lines.Not only does a flood not damage the sta- tion but,where there is sufficient head of water,the station can even continue to operate while under water. The first floodproof station with submersible hydroturbine generators was built in the upper reaches of the Loire river,France.A precondition for its construction was that it should not interfere with the flood flow of the val- Design concept. ley,allowing passage of debris and flood waves up to 6 m (20 ft),above the dam crest.An open flume type installa- tion with three units and cylinder gates was selected.The flumes were covered with concrete decks and the gates were furnished with covers to protect the equipment from debris,which is usu- ally heavy at this site.The control equipment was installed safely on the second floor of an old building on the river bank. The first completely submerged power station was constructed in West Germany.The power station which is of the closed flume type with the upper deck below the surface of the water has been incorporated into an overflow weir.The flow through the station can be shut-off with a telescopic cylinder gate.The power and control cables from the station extend up to the top of the high river bank.In normal condi- tions,the station is 0.1m (0.3 ft)below water level;the minimum flow of 0.6 m?/s (21 cfs),is constantly discharged over the weir to create picturesque rapids.The only part of the station pro- truding above the water surface is a pair of walls,0.5 m (1.5 ft)high.These enable the installation of stoplogs and provide access to the machine.During the flood season,approximately one month per year,there is no access to the machine but the station can still operate if the head is sufficient. Wastewater as a hydro resource One of minihydro's great advantages over traditional hydropower techno- logy is that it can utilize a wider variety of energy sources.For example,many sewage treatment plants have a signifi- cant head drop at the outlet,which,of course,provides a potentially recover- able source of energy.Treated waste- water can be used there to drive tur- bines.Submersible hydroturbine gen- erators are excellent for this applica- tion,firstly,because they are easy to install in an existing sewage plant,and second (and more importantly)be- cause they enable the entire generating unit to be removed for servicing pur- poses and reinstalled without service personnel being required to enter the turbine chamber.This first power plant of this type,with a capacity of 30 kW, was built in Italy.Another one,with a capacity of 600 kW,is under construc- tion in the U.S.A. Another unusual energy source is being utilized in a,so far,unique sys- tem in Stockholm:A submersible hy- droturbine generator has been in- stalled in a heat-pump plant,which supplies a large part of Stockholm's central heating system.The heat Impeller -The Runner +1991 bed.Construction of the apparatus was carried out at Hanstholm harbour, where Danish Wave Power has a small facility employing ten men.The concrete base was cast on the slip-way, in a small boat yard,and rolled down rails into the water -in the same man- ner as a boat is launched.Ninety cubic meters of concrete were used in its construction and it weighs 200 tons. The base There's a rectangular chamber inside the circular structure.The inlet from the cylinder containing the piston is in the middle of this chamber.The sub- mersible hydroturbine generator (a Flygt EL 7555,rated at 45 kW)is mounted in a seat on the roof of the chamber,on one side of the cylinder and on the other side is a vent,for the discharge of the water expelled by the piston's down-stroke.(The descend- ing piston also,of course,pushes water out but if this flow of water were also used for generating purposes it would create too much resistance and reduce the performance of the wave power converter.)On either side of the central chamber are ballast chambers. These were left empty at launching, which enabled the base (which has a diameter of 9 m)to float:It has a weight of only 90 tons in the water. Three kilometres out Once afloat the base was attached to a specially adapted barge:Two large steel girders were attached to the deck of the barge and protruded out several meters over its stern.Four steel cables \/Hydroturbine Piston ,generator" x Valve Ne Base beSead¥\ Soy When a wave lifts the float,the piston water is sucked through the turbine and power is generated. Between waves,the piston returns to the bottom position pushing out water through a flap valve. Flygt EL 7555 hydroturbine generator in Top left:The 6-metre-wide float. es "sadnOEptSipupaeor .front of the 200 ton concrete base. were run,through pulleys,along these girders and attached to eyes cast into the top of the concrete base.The barge then towed the base out to its pre- established position,3 km due north of Hanstholm harbour.Before lowering the base,divers,equipped with high- pressure water hoses,were sent down to clear sand and other loose material from the site.The seabed here consists of fairly flat limestone.The base was then lowered to the seabed,30 m be- low sea-level.This was achieved through a combination of pouring sand into the ballast chambers,while simul- taneously paying out the steel cable from a hydraulic winch.Approximately 200 tons of sand was required for this purpose,thus giving the base a final, seabed weight of about 400 tons. The float The float section consists of a steel cyl- inder 6 m in diameter and 1.5 m high. This is filled with polyurethane foam, held in place by a 8 cm "plug”of fibre reinforced concrete top and bottom. Impeller -The Runner -1991 OCEAN WAVES-AS AN ALTERNATIVE ENERGY SOURCE he basic concept is to use a float to transmit the wave energy:The float is attached by a synthetic fibre rope to a piston.The piston moves up and down in a vertical cylinder,firmly fixed in a concrete base on the sea bed. As the piston is pulled up by the crest of a wave it sucks water through a sub- mersible hydroturbine generator.As the water is sucked in it turns the tur- bine and the generator. Prototype The basic idea and design for the wave power converter came from a Danish civil engineer,Kim Nielsen.He first built a 1 kW,scale model wave power unit as part of a project at the Technical mm University of Denmark.The turbine A field test is taking place off the Danish coast to try and generate electricity from the energy of waves.If successful, this could open up a whole new energy option -a clean, renewable source of energy with minimal environmental disruption. generator in this model was a re- designed Flygt mixer (a 4350 unit). The model was first tested in a wave channel and then field tested in "The Sound”(the straights between the dfDanish and Swedish coasts,immedi- ately east of Copenhagen).The current field test in Denmark is on a much bigger scale.Its's being undertaken by a joint venture called Danish Wave Power aps (Ltd)and the site they have selected is the fishing town of Hanstholm on the West coast of Jut- land.Two units are planned,both of which will have a capacity of 45 kW. The first was taken out to sea in Sep- tember this year and work on the second is scheduled to begin in the Spring next year. Impeller's editor visited Hanstholm in late August and was able to see the completed first unit just before it was taken out for positioning on the sea- Impeller -The Runner -1991 pumps recover heat from treated wastewater which is pumped to the station and then discharged to the sea -creating a head of 10 m (33 ft).A single hydroturbine generator of 315 kW capacity installed there.This now supplies about 60 %of the energy used for lifting wastewater within the sta- tion. Rehabilitation of old stations With the advent of submersible mini- hydro technology,the rehabilitation of older hydro-power stations has also become simpler and cheaper:Old Francis turbines installed in open flumes can,in particular,be very simply replaced by submersible hydro- turbine generators.After removing the old turbine a turbine tube is put in its place,usually with a draft tube adapter.Then renovation of the flume and the gate is all that's necessary before a hydroturbine generator can be installed.The old power house becomes redundant.A partial rehabil- itation of multiple turbine power sta- tions can be done in a similar way.In these cases a cylinder gate must also be installed in order to allow independent operation of the submersible unit in a flume shared by two or more turbines. Some thirty old stations have now been refurbished in this way in both Europe and North America. Further innovation One hundred and twentythree stations employing submersible hydroturbine generators have been built to date in North America,Europe and Asia,wit- hin the last six years -48 of them in the USA and Canada alone.Clearly, submersible mini-hydro has an enormous versatility of application, only a small part of which has been described here.In addition,it can compete successfully against vertical propeller and Kaplan turbines,hori- zontal or inclined tubular turbines,low head Francis turbines and cross-flow turbines.Given this,and the ingenuity and entreprenuerial spirit of small hydro developers,further innovative and unconventional applications for this new technology will doubtless soon be emerging.O LL am | fsSMALLHYDROPOWERPLANT IN THE CENTRE OF TOWN Stockholm Energi Produktion AB,the Stockholm power utility company, installed a hydroturbine generator in the effluent discharge pipe from its large pump plant in Hammarby,in the centre of the Swedish capital. mall hydropower plants are usually found in small water courses in the countryside,but now Flygt has in- stalled a hydroturbine generator in the Hammarby Plant in the centre of Stock- holm. At the end of 1986,the municipal power utility,Stockholm Energi Pro- duktion AB,commissioned Sweden's largest heat pump plant ever,the Hammarby Plant.Here,four heat pumps produce a total of 110 MW of thermal energy,which is fed into the district heating network in the south- ern part of Stockholm.An expansion to 175 MW is planned. What makes the Hammarby Plant unique is not only its size,but also its source of thermal energy,which con- sists of treated,warm effluent from the sewage treatment plant in Henriksdal 2.5 km away.The water flows to Hammarby in a rock tunnel with a cross-section of 7 m?and a maximum capacity of 5 m?/s. After arriving in Hammarby,the wa- ter is pumped up to a reservoir by three submersible Flygt waste water pumpswithacapacityof9601/s through a ver-tical shaft of 17 metres.The reservoir Cont.page 3 Schematic of the Hammarby plant.The Flygt submersible hydroturbine generator re- covers approximately 60 %of the energy used for lifting the effluent. HAMMARBY HEAT PUMP SICKLA PLANT VILLAGE Pumps StormwaterfromsouthernsuburbsHENRIKSDALS SEWAGE TREAT- MENT PLANT SEA Screen station VavAImpeller +The Runner +1991 MUKE KELIEBLE THR Pumps and turbines perform most efficiently and most economically if the flow of water to the machine is uniform.The best method of ensuring that such ideal condi- tions will exist is to carry out a model test prior to construc- tion of the station. Rae the best pump or turbine may not work satisfactorily in a badly designed sump.Sediment and air-en- training surface eddies or bottom eddies/vortices can cause clogging, vibration,loss of performance or other operational problems. In addition to excessive noise,this can lead to reduced efficiency and ser- vice of the machine.Poor inflow condi- tions cause vibration,which can dam- age bearings or impeller blades,and air entrainment,which can generate sud- den stresses in the machine.Both re- duce machine life. Flygt has been aware of these prob- lems and has studied them for a long time.The recommendations given by Flygt for standard installations of centrifugal and propeller pumps are based on practical experience and through model tests. Fast planning In some cases,the model tests have been verified by full-scale tests.The standard recommendations enable salesmen,customers and consultants to plan pumping stations quickly and easily. If the intake channel and pump sump in a project deviate from the documented standard cases or if the conditions require solutions where the flow pattern in the station cannot be predicted,it is wise to perform/under- take model tests. Cont'd page 14) When the intake head is very low,the intake to a turbine-generator can be designed as a siphon.The optimum flow conditions must then be created in the inlet to ensure trouble-free operation of the machine. The easiest way to do this is to carry out a model test,such as the one shown here at the Royal Insti- tute of Technology in Stockholm on a 1:10 scale model of a turbine-generator with a siphon inlet.The flow conditions are visualized by using a dye in the water. Impeller -The Runner +1991 he ated SchS.a oA tenet teat ete5 "é has SR A :yh tt ae ve oeale BiareneeetaESangsttury.Hundreds of small and very small stations have been shut down in recent years because it has not been econom- ical to renovate or replace the turbines. With the Flygt turbine-generator,it is now possible to give many small-scale power plants new life with good profit- ability for the owner. Flygt's three deliveries in Austria at the end of 1985 and the beginning of 1986 are typical examples: Project Haas In Bad Aussee,125 km southeast of Salzburg,Hugo Haas had long been the owner of a small sawmill on a stream called Grundlseer Traun.Next to the sawmill was a pond and a dilapidated water wheel that was no longer used. (seaSotaps sted PLANESPEODUKEober!oe eh,* Mr.Haas,who is technically in- clined,was fascinated by the design concept of Flygt's turbine-generator. Together with a consultant,he made a careful study of its technology,costs and profitability and decided on a 200 kW machine.It was installed in a 6 m deep shaft of concrete pipe about 200 m from the pond.A newly-laid line of concrete pipe with a diameter of 1.60 m conducts the water to the turbine.The maximum discharge is 3.5 m/s,at a head of 7 m. The station was taken into service in December 1985.It produces 190 kW efficiently at maximum flow and Mr. Haas,who has now turned over the sawmill to his son,sells the electricity to the local electrical utility. Project Stéber Stober Mithle is the name of a flour mill located on the Pielach River where it passes Loosdorf,70 km west of Vi- enna.The mill pond contains an old turbine,which was removed from ser- vice 15 years ago. The miller,Alfred Stéber,calcu- lated,with the aid of his electrician, that a turbine-generator could produce electricity at the mill profitably again. He therefore ordered a 90 kW turbine- generator,which was put on stream in January 1986. The turbine was installed in a simple shaft of cast-in-situ concrete,to which the water from the pond is fed through an existing,partially rebuilt canal.The draft tube consists ofa steel pipe cast in concrete. After these small investments,the machine now produces 55-60 kW, which is delivered to the local grid.The harnessed head is 3.3 m,the maximum discharge 2.5 m?/s. Project Iridea Indea GmbH is a fish farming station situated in Ferlach,15 km from Klag- enfurt in southern Austria.The firm saw the possibility of utilizing the run- off water from the fish farm tanks for small-scale power production and contacted several possible suppliers in the matter.Together with a consult- ant,Flygt developed a proposal with its turbine-generator that was accepted by Iridea,in part because of the un- complicated installation. The tanks are located in a parallelcanalalongatributaryoftheDrau River.From the tanks,the runoff water is led through a covered canal out into the tributary.A headrace was built in the canal consisting of a 13 m long steel pipe with a diameter of 1.50 m which discharges into a 2.40 m deep steel shaft embedded in concrete.A 90 kW turbine-generator was installed here. An additional 20 m of steel pipe was connected as a draft tube from the generator.The head is 3.5 m and the maximum discharge is 3.45 m3/s.0 Impeller +The Runner -1991 With a submersible turbine- generator,it is easy to create new,profitable electricity pro- duction in an abandoned mill pond or in a worn-out mini power plant that is too costly to renovate with conventional technology.Here are three examples from Austria. or more than a thousand years, water power has been the source of energy for flour mills,forges and saw-mills in Austria,and water power in the form of hydroelectric power is still the most important source of energy in this central European country,whose people said no to nuclear power in a national referendum in 1980. It was therefore natural for Flygt to start its continental introduction of the turbine-generator concept in Austria, which took place in 1983.Only 18 months later,an order had been re- ceived for two units,and another tur- bine-generator was ordered a couple of months later.Any hydroelectric pro- ducts that succeed on this knowledge- able and demanding market with its long-standing traditions should have a good chance of succeeding in sur- rounding European countries with hydropower resources as well. Austria has plenty of hydropower - it accounts for two thirds of the coun- try's energy production.The other third comes from thermal power,a sector that stagnated with the onset of the oil crisis in 1973 and is now shrink- ing.Fossil fuels are too expensive,and the increasingly environmentally- minded Austrians also dislike the sulphur emissions from thermal power plants,since they cause acid rain. Small is beautiful Still only about half of the exploitable hydropower resources in the country have been harnessed,and the em- phasis is now shifting increasingly fromlargeplantstosmallandmedium-sized ones.In addition,interest in renovat- ing worn-out or disused mini power plants has increased.Since the adop- arta ="is algssichanth tna ty oh Stéber Miihle (large picture replaced an old turbine with a Flygt submersible turbine-generator,which now produces 55-60 kW to the local grid. tion of a new energy policy in 1979,the federal government is encouraging both renovation and new construction of mini stations through tax breaks and interest subsidies. Flygt's turbine-generator,which is available in six basic sizes from 50 to 700 kW,is ideally suited for installation at old mill ponds or in worn-out mini power plants with low heads.The tur- bine-generator,which works com- pletely immersed in water,requires no special building.It merely has to be lowered into a steel pipe or a simple concrete shaft,where it can start con- verting water power to electrical ener- gy from the first day. Moreover,the machine can operate unmanned.It works fully automati- cally,monitored and controlled by a microcomputer in a control cubicle on land.Regulation of the turbine blades can also be done fully automatically with the aid of electronics. Thanks to low installation and oper- ating costs,the cost per kilowatt-hour of electricity produced by Flygt's tur- bine-generators in Austria is only half of the cost of a kilowatt-hour produced in a conventional plant of comparable size.To this must be added the special environmental advantages of the tur- bine-generator:Little or no noise and the possibility of a completely or al- most completely invisible installation. Most of Austria's small-scale hydro- power production capacity was in- stalled in the beginning of the 20th cen- Impeller -The Runner -1991 eosSe ; is PROFITABLE POWER FROM Toe-__QUGH MODEL TESTING canserae:Overy,oncreeelegeeoeennestenere:FeImpeller -The Runner -1991 See ee eos The model test shown here of a PL 7060 undertaken at the University of Nottingham clearly reveals a powerful floor vortex and a smaller wall vortex at pump inlet.These vor- tices,caused by poor pump inlet conditions, can be eliminated in a number of ways includ- ing changing the pump/wall clearance,in- stalling flow stabilizing baffle plates,or by modifying the sump inlet design.Testing con- tinues with various modifications until all problems are eliminated. ¢In the Docklands of London,Flygt is building the world's largest pumping station with sub- mersible pumps.It is a circular pumping sta- tion for storm water,equipped with 18 sub- mersible pumps.The station's capacity is 8 m?/s,A model of the station on a scale of 1:10 was tested thoroughly at Hydraulic Models Ltd. of Leeds,England.This testing included sedi- ment tests to reveal any stagnant areas in the sump where sludge deposits could accumulate. Sedimentation was modelled in the test by using coloured plastic spheres of varying den- sity.The different phases of the test were documented on still photographs and video film. >Vattenfall (the Swedish State Power Board)has a large sophisticated laboratory in Alv- karleby where model tests of Swedish hydro- power projects have been carried out since long.The construction of a coolant canal at a thermal power plant in Lagos,Nigeria needed a model test (see Impeller 23).Flygt delivered 36 large low-lift pumps with propeller dia- meters of 1,000 mm for installation in the canal.The pumps were positioned horizontally at the canal inlet to deliver 60 m'of sea water per second through the canal simultaneously raising the water level 0.42 m.The complex inflow conditions in the sump with so many closely packed pumps were studied thoroughlyinAlvkarlebyusingamodelonascaleof1:4.6 (picture).The result of these tests indicated the need for minor modifications to ensure optimum performances. 4 A wide range of problems are often en- countered with the intake channel hydraulics of older stations.When such stations are to be upgraded with new machines,it is recom- mended that model tests are performed to avoid unstable operation.This picture shows a model test on a scale of 1:10 in Flygt's de- velopment laboratory in Solna.The test was undertaken to improve the design of the inlet canal to a submersible turbine.The uneven shape of the canal caused flow disturbances that were eliminated by installing three steel baffles.The test,which took about three weeks including construction of the test rig,deter- mined the exact design and location of the baffles. Impeller -The Runner +1991 This is also true where pumping sta- tions are to be extended or upgraded or where solutions are sought for unsatis- factory performance in existing sta- tions.Flygt Systems Engineering has wide experience of such tests in its own laboratories and,through joint studies with institutions such as the University of Nottingham,Hydraulic Models Ltd.in Leeds,England,Vattenfall's Alvkar- leby Laboratories and the Royal Insti- tute of Technology in Stockholm. Reliable results These model tests have given Flygt a solid knowledge base for sizing and de- signing of pump stations.Even in ap- parently hopeless cases,it is possible after model tests to arrive at solutions that are both economically and tech- nically viable. Pumps and turbines perform most efficiently if the inflow of water is even and steady,without air entrainment or eddies.This is why model tests are al- most always prescribed nowadays in the planning stage of large stations. The model test is an inexpensive form of insurance against mistakes,expen- sive alterations,operational problems or,in the worst cases,total failure.0 Impeller +The Runner -1991 my3ts 4 wom!ae Bt aie 6.Engineering section meetings for Mike Bahleda's hydro section often involve planning turbine-replacement details.Reporting on the Twin Branch project to Group Manager Howard Humphrey and Dept Head Bruce Bennett are (seated left to right)Maria Karas, engineer;Frank Simms,senior engineer;Bennett;(standing left to right)Humphrey,Scott Merchel,mechanical engineer;Rob Dool,engineer;Bahleda aren't just for power generation."They're multiple-use projects.They provide flood control,water supply,irrigation,fisheries, and recreational benefits.”These aspects of a project are just as important as the gener- ation because they affect the public interest that must be accounted for in future reli- censing efforts. At Twin Branch,AEPSC is proposing toerectfishingfacilities-including a pier,fish-cleaning station,information bulletin board,telephones,restrooms,and park- ing-on the southern shoreline. Improvements to the existing canoe portage area are also proposed,says Heyd- lauff,as is an urban wildlife habitat with trees,shrubs,and wildflowers.Land has already been provided by IMP for the Twin Branch fish hatchery,just upstream of the plant.= -Elizabeth A.Bretz,Generation Editor POWER GENERATION System-wide hydro assessment triggers upgrades merican Electric Power Co's (AEP)comprehensive evalua-tion of the 17 hydroelectric facilities within its systembeganwithassessmentsoftheirpotentialforincreasingoutput,improving efficiency,and conducting more cost-effectivemaintenance.These initial assessments formed the groundwork fortheutility's current hydro-plant upgrade program. AEP's 842 MW of hydro resources break down geographically into two groups: those in the Virginias,and those on the St. Joseph River (Fig 1,table).Each group experiences different operating characteris- tics and maintenance requirements.Facili- ties in the Virginias are operated by Appalachian Power Co-a subsidiary that always has maintained tight control of hydro-plant operations, The St.Joseph plants,by contrast,ran with much less control and oversight,says Bruce Bennett,assistant vice president for civil engineering at AEP Service Corp (AEPSC)."And our evaluation of all the hydro sites told us we needed to standard- ize our approach to operations and mainte- nance at all of the hydro facilities.It also told us we needed to realize the full poten- tial of the St.Joseph plants,”explains Ben- nett. Prior to 1985,AEP did not have a for- mal procedure for identifying the specific requirements of its hydroelectric facilities. According to Bennett,"Before [1985],we just operated the plants.One of the first things we did to change things was to establish accountability for all hydro oper- ations by creating a single AEP hydroelectric plants Plant capacity,River Units MW Appalachian Power Co Smith Mountain Roanoke 5 547 Leesville Roanoke 2 40 Claytor New 4 90 Buck New 3 9 Byllesby New 4 22 Niagara Roanoke 2 2 Reusens James 5 13 Kanawha Valley Power Co London New 3 15 Marmet Kanawha 3 15 Winfield Kanawha 3 19 Ohio Power Co ' Racine Ohio 2 48 Indiana Michigan Power Co Berrien Springs St.Joseph 4 7 Buchanan St.Joseph 10 4 Elkhart St.Joseph 3 3 Twin Branch St.Joseph 8 5 Michigan Power Co Constantine St.Joseph 4 1 Mottville St.Joseph 4 2 Reprinted from March 1992 issue of ELECTRICAL WORLD.Copyright 1992,McGraw-Hill,Inc.All rights reserved. hydroelectric engineering sec- tion within civil engineering. The second thing was to estab-Service lish an operations and mainte- date nance function within Indiana Michigan Power Co (IMP),an 1965 AEP subsidiary,to manage our 1964 hydro resources along the St. 1939 Joseph River.This provided a 1912 consistent level of attention for 1912 all system hydro facilities.” 1954 "Our five-year planning pro- 1903 cess,established in 1986,identi- fied the operating and mainte- 1935 nance needs of the plants on a 1935 capital-dollars basis.We cata- 1938 loged the major improvements and upgrades necessary for the 1980 plants to conform to license requirements and maximize out- 1908 put,”Bennett continues.Note 1919 that AEP is one of several utili- 1913 ties embarking on major reha- 1904 bilitation projects.Others include Niagara Mohawk Power 1921 Co (see box),the Tennessee 1923 Valley Authority,and Bon- neville Power Administration. Mich Constantine TwinBuchananBranch .Ohio Ind Reusens "if Lf ©Hydro By Pumped storage 1.AEP's hydroelectric plants produce 842 MW for the system grid from sites along the St.Joseph River in Indiana and Michigan and along several rivers in the Vir- ginias and Ohio "Keep in mind that the 17 sites range in age from 11 to 90 years.And 15 of them were built before 1930,”adds Mike Bahle- da,manager of hydroelectric engineering. "Although we can't build more rivers,we are studying plans to develop our existing sites to maximize generation,to make bet- ter use of the available river flow.This includes Berrien Springs and Elkhart on the St.Joseph and Reusens on the James River.We may seem more focused on the St.Joseph plants,but this is a system-wide program-what we are doing at our other hydro plants in Ohio,Virginia,and West Virginia is equally significant,”Bahleda stresses. "Those plants built since the early 1930s have maintainable equipment that is funda- mentally sound.But the technology jumps since then,particularly in the area of con- trols,have been tremendous,”Bahleda says."For example,at Twin Branch sta- 83 tion,the gates are adjusted manually according to anticipated river flow.That means we can't take advantage of river flows in a timely fashion.Also,the genera- tors at Twin Branch use wood bearings. Spare parts simply aren't available,”he continues. "That's why one of our first tasks was to survey the equipment and identify upgrades where the equipment had out- lived its useful life,”says Bennett."And since we couldn't perform all of the upgrades simultaneously,we designed pre- ventive maintenance programs for the plants.They need to last until we're able to perform the upgrades.After all,”says Ben- nett,"one of our overriding goals is to maximize cost-effective hydroelectric gen- eration,and the three keys to reliable gen- eration are efficiency,availability,and maintainability.Certainly wood bearings aren't practical from an efficiency or main- tenance stance,”nor do they reflect the current state-of-the-art in hydropower tech- nology.” Upgrade controls first The first goal in the 1986 five-year hydro plan was complete electrical upgrades- including controls.Subsequent plans have scheduled these upgrades for the plants involved.The plants on the St.Joseph, while not under remote operation,are not run on-site either.A roving team of opera- tions and maintenance personnel visits each of the St.Joseph plants according to a pre-set schedule and manually adjusts gates and performs routine maintenance. "That means when it rains and we need to process water we can't necessarily take full advantage of the available flow,”states Bennett,"And water lost is opportunity lost.”The controls upgrades allow remote sensing of river levels and real-time adjust- ment of the gates from the central dispatch office in Mishawaka,Ind.The new pc- based controls allow dispatch to maximize river use,says Bahleda. "What has [the controls upgrade]really done for us?”asks Bennett."In 1985, hydro generation was in a slump at about 75,000 MWh/yr and going down.Since this program of upgrades,we've seen sig- nificant improvement.In 1990,it was 126,000 MWh;in 1991,108,000-and that was a drought year,”he asserts proudly. "Last year,all the equipment,except one plant down for maintenance,was available to run.We made the most of our opportuni- ties that way,”says Bennett. Twin Branch received new control sys- tems in February as part of its refurbish- ment program.Buchanan,Constantine,and Claytor are the next plants scheduled for controls upgrades.New systems are already in place at the Winfield,Marmet, and London plants on the Kanawha River, and at Mottville on the St.Joseph. "The new control systems will allow better use of the river's power without 84 increasing the impact of the plant on the river.At Mottville alone,we expect to see a 15 to 20%increase in annual genera- tion,”asserts Bahleda.Part of the reason for Mottville's improvement is that station output can be continuously adjusted in accordance with water flow via the new controls. Equipment refurbishment The latest project in the hydro-plant upgrade program is a turbine replacement at Twin Branch."It's a complete redevel- opment,”notes Tim Banta,manager of hydro generation for IMP,which operates Twin Branch."In essence,we are stripping out all of the old equipment and replacing it with new machinery.” The plant's Francis turbines and associ- ated generators,installed in 1904,are being replaced with smaller,more econom- ical,and more efficient machines (Fig 2). According to Bahleda,"When check-out is finished on the new units,Twin Branch will be capable of producing 57%more electricity.” Twin Branch consists of six open-flume bays each containing a camel-back Francis turbine coupled to a 1.2-MW generator. The turbines in Bays 1 and 6 have already been replaced with four new turbine/generators,each producing 600 kW.The remaining bays will receive one new unit each. The new hydraulic turbine/ generators,manufactured by Flygt Corp,Norwalk,Conn, operate completely submerged and do not require above- ground structures (Fig 3).The blades Generator of the new turbines have an optimized pitch to extract the maximum amount of power from the water.Blade size,shape,and configuration all are designed for maximum effi- ciency. Special mountingsystemspreclude Planetarytheneedtoboltthegearbox units in place.The units are installed in the flume space of the replaced tur- bine.This approach allows the draft tube,tur- bine inlet bell,and seat to be inserted as a single component from the top of the flume,through the existing flume floor opening,once the old turbine is Adjustable- runner blades 4]axial-flow guide/supports and baffle plates to the existing steel structure. Installation procedures for the new units are greatly simplified by this.Basically,the procedure (Fig 4)is to hoist the 10-ton tur- bine/generator by overhead crane (now motorized),maneuver it into position above the cylinder gate,lower it into posi- tion,and make the two-cable connection to the system (Fig 5).Gussets automatically guide the unit into position.Sealing is accomplished by the weight of the unit once it engages its seat. While this is the first US installation of the 600-kW submerged units,AEP is con- fident about their reliability because of the success of the first four units operating at Twin Branch since their 1990 installation. According to Bennett,"The vertical units we installed previously are exceeding even our most aggressive estimates of their per- formance.At Twin Branch,we expect pro- duction to jump by as much as 10,000 MWh annually with the new units.” In addition,maintenance has been dra- matically simplified with the increased access to the new units."Now we just lift it out with the overhead crane and perform the work.There's no need to shut an intake,pump out the water,and go down to the turbine,”says Banta. Three other AEP plants,Berrien Springs,Elkhart,and Reusens,have generating equipment reaching the end of its useful life.Berrien Z Springs and Elkhart are of the same design asCtypealTwinBranch-withwoodbearingsand brittle,cast-iron components which can no longer be maintained cost-effectively.The vertical-shaft units at Reusens are of an outmod- ed,inefficient design and the tur- bine runners are beyond repair. Plans for these plants are taking shape now. Other completed exchanger equipment projects include refurbishing all of the pre-1930s turbines.Installing spillway gates at Buchanan that yield more generation by better controlling water levels and mechanizing trash rakes at Berrien Springs have already improved unit efficiency and helped to control labor costs. "Our Kanawha Valley plants are alsoturbine removed.Only receiving new trash minor welding is 2,Submersible hydraulic turbine incor-rakes,ones similar torequiredtotietheporatesgeneratorinsingleunitforinstalla-those at Berriencylindergatetion,maintenance ease Springs.We are also investigating ways to use the latest turbine technology to improve generating capacity at Smith Mountain,AEP's only pumped- storage hydro facility,”asserts Bahleda. Buchanan's new crest gate provides additional hydraulic head and better pond control.The improvement in controlling pond level resulted in a 40%increase in annual generation for 1990 at the plant. Berrien Springs began the redevelop- ment process in 1991.Upgrade programs for this facility have taken scheduling con- cerns and system needs into account. Preliminary work investigated new tur- bine/generators and their impact on water usage.Similar redevelopment efforts for Reusens and Elkhart begin in 1992 and 1993,respectively.Development and revamp efforts will be timed to coincide with the license renewal process. Don't forget safety issues "After controls and equipment issues, the next most capital-intensive item in [AEP's]five-year plan relates to safety and stability upgrades,”Bennett notes."Regu- lations have changed since the plants were built,and criteria for evaluating safety con- ditions have also changed.Structural upgrades are a big dollar consumer within the context of the overall program.” In some cases,stability upgrades and structural changes are warranted in order to meet the new standards.Such is the case with the dams at Buck and Byllesby,built in the 1920s.The Elkhart,Buchanan,and Claytor plants require structural upgrades. Even Smith Mountain,AEP's only pumped-storage plant,is undergoing anal- ysis to determine what if any changes are warranted for safety reasons. Some changes are small,as are the safe- ty risks they correct.For example,when run-of-river plants operating as peakers discharge,a small wave may emerge.By the time it reaches downstream fishing areas it may be no more than a ripple in the water."But in order to alleviate concerns by fishermen,we installed safety sirens to warn them.We try to eliminate the safety concerns and reduce risk,no matter how small it is,and still generate low-cost hydropower,”asserts Bennett. "We're proud of our record,”Bennett declares."Last year our Virginia hydro plants received a regional safety award rec- ognizing efforts to promote public 4 water safety,and our Indiana and |Michigan facilities are being con- sidered for a similar award for Manager Howard Humphrey and,in turn, to Bennett (Fig 6). On an operational level,two managers, one from IMP for the northern plants,and one from Appalachian Power for the other 11 facilities oversee daily operation and maintenance duties for the plants.'"Devel- oping the five-year plan takes a coordinat- ed effort between the managers and myself,”Bahleda remarks."We have to balance their local needs with overall sys- tem planning.” On a weekly basis,that coordina- tion requires frequent phone calls.uzip "We try to integrate tasks and priori-a Cylinder gate<- turbine/generator|Ss SubmersibleWAOldturbine4| tize them for day-to-day operations and longer runs,”says Bahleda."We also meet formally at least twice a year to review the five-year plan.We check to see how we're progressing,and what needs have changed,and make the necessary revisions and updates.That way we're not caught unprepared when we write the next five-year plan,”he attests."After all,” comments Bennett,"our financial resources are not unlimited.Cir-=a cumstances change,too.Five-year Seat 3.New turbine/generator units at Twin Branch offer greater efficiency from the same river flow.Units install in flume space of old turbines their public-safety efforts in 1991.”When all is said and done,says Bennett,"It takes safety,good resource management,and efficient,economical electricity production for a balanced program.You can't do it with two out of three,it takes them all to be successful.” Emphasize communications,too Performing the engineering responsibilities for the hydro section,overseeing budgets, and other administrative tasks falls to Bahleda and his staff who report to Group 4.Installation procedure (left)for new tur- bine units is simplified by the lack of above ground structures.Bulk of procedure is low- ering unit into place 5.Connecting unit to grid involves straightforward two-cable connection plans have to work in real time,not a planning vacuum.” "One of the biggest advantages to this type of forecast planning, however,is that everyone knows upfront how much work,time,and money are involved.It doesn't come as a shock to [corporate budgeters]that the hydro section needs so-many million to engineer and design a dam upgrade in 1994 and x-amount for this 1992 equipment replacement project,”according to Ben- nett."Everyone can review the plan in advance and understand the work we see as necessary,why we think it is necessary, and how much money it will require,”he continues. "Once a year,”says Bahleda,"there is a meeting of all the hydroelectric person- nel-operations,maintenance,engineers, and management.We get together for sev- eral reasons.First,people share problems, maintenance tricks,things they've learned throughout the year. "While they may have talked about an idea or two by phone,there's nothing like sitting down with someone and discussing his experience with a piece of equipment, or a special tool,or a piece of software. Secondly,”he continues,"it gives people a chance to hear about where the money goes.If you realize that another plant got project funding and you did not,hearing funding recipients talk about what was done,why,and the benefits of the work, may help more people see the big picture, give them patience to wait until it's their turn.” Remember the public interest According to Dale Heydlauff,vice presi- dent for environmental affairs at AEPSC, the hydro facilities in the AEP system 85 COONODOARWN|EXISTING HYDRO PROJECTS Project Name Akutan Ouzinkie Larsen Bay Pelican King Cove Tazimina Existing AP&T Hydro Chester Lake Humpback Creek Silvis Lake Crystal Lake Annex Creek Purple Lake Goat Lake Ketchikan Falls Craig/Klawock Salmon Creek Beaver Falls Blue Lake Gold Creek Solomon Gulch Cooper Lake Green Lake Terror Lake Tyee Lake Swan Lake Eklutna Snettisham Bradley Lake Location Akutan Ouzinkie Larsen Bay Pelican King Cove Viamna Skagway Metiakatla Cordova Ketchikan Petersburg Juneau Metlakatla Skagway Ketchikan Black Bear Lake Juneau Ketchikan Sitka Juneau Valdez Cooper Landing Sitka Kodiak Wrangell/Petersb Ketchikan Palmer Juneau Homer Post-it?Fax Note -Installed Capacity (kW) Less than 100 135 475 700 800 825 975 1,000 1,250 2,100 2,200 3,200 3,900 4,000 4,200 4,500 5,000 5,400 6,000 7,300 12,000 17,200 18,500 20,000 20,000 22,500 30,000 78,210 90,000 7671 [Pa 1)ALL _|pobes> re Mick GoodynenCo./Dept.Co. Phone # From Pxurd L oe les Phone #6 T-4 Sy) Fax #FD 5SS-20979 Fax # ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annuai Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: northeast of Ketchikan If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: 6/7/95 Bradley Lake Across Kachemak Bay from Homer,AK 90 369,000 369,000 0 State of Alaska,Alaska Energy Authority (AIDEA) Mr.Stan Sieczkowski (907)561-8050 State of Alaska,Alaska Energy Authority (AIDEA) 480 West Tudor Road Anchorage,AK 99503-6690 None Solomon Gulch Valdez,AK 12 52,600 52,600 0 State of Alaska,Alaska Energy Authority (AIDEA) Mr.Stan Sieczkowski (907)561-8050 State of Alaska,Alaska Energy Authority (AIDEA) 480 West Tudor Road Anchorage,AK 99503-6690 None Swan Lake Southeast AK,central portion of Revillagigedo Island,22 air miles 22.5 82,000 82,000 ° 0 State of Alaska,Alaska Energy Authority (AIDEA) Mr.Stan Sieczkowski (907)561-8050 State of Alaska,Alaska Energy Authority (AIDEA) 480 West Tudor Road Anchorage,AK 99503-6690 None Page 1 of 8 ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWVH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH#): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: 6/7/95 Terror Lake Approximately 25 miles southwest of Kodiak 20 125,000 110,000 0 State of Alaska,Alaska Energy Authority (AIDEA) Mr.Stan Sieczkowski (907)561-8050 State of Alaska,Alaska Energy Authority (AIDEA) 480 West Tudor Road Anchorage,AK 99503-6690 This project is estimated to be fully utilized in the next five years. Tyee Lake Approximately 40 miles southeast of Wrangell 20 (capable of 30 with addition of third 10 MW unit) 135,000 40,000 95,000 State of Alaska,Alaska Energy Authority (AIDEA) Mr.Stan Sieczkowski (907)561-8050 State of Alaska,Alaska Energy Authority (AIDEA) 480 West Tudor Road Anchorage,AK 99503-6690 Intertie proposed:Swan Lake -Tyee Lake 'Annex Creek Juneau 3.2 24,000 (1989 estimated value) 24,000 (1989 estimated value) 0 Alaska Electric Light and Power Mr.James Webb,General Manager (907)586-2222 Alaska Electric Light and Power 612 W.Willoughby Avenue Juneau,AK 99801-1798 Page 2 of 8 ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWAH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH#): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH):Energy considered surplus/available: Project Owner: Contact: Phone: Address: 6/7/95 None Salmon Creek Juneau Upper 2.8;Lower 5:upper and lower cannot operate at the same time 25,700 (1989 estimated value) 25,700 (1989 estimated value) 0 Alaska Electric Light and Power Mr.James Webb,General Manager (907)586-2222 Alaska Electric Light and Power 612 W.Willoughby Avenue Juneau,AK 99801-1798 None Gold Creek Juneau 7.3 (zero firm capacity/run of river) 6,800 (1989 estimated value) 6,800 (1989 estimated value) 0 Alaska Electric Light and Power Mr.James Webb,General Manager (907)586-2222 Alaska Electric Light and Power612W.Willoughby Avenue Juneau,AK 99801-1798 None Snettisham Juneau 78.21 325,000 245,000 80,000 U.S.Government;Alaska Power Administration Mr.Mike Deihl,Administrator (907)586-7405 U.S.Government;Alaska Power Administration Page 3 of 8 ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) Known future plans or commitments: future. Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MW/H): Energy considered surpius/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: if not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWR): Energy considered surplus/available: Project Owner: Contact: 6/7/95 2770 Sherwood Lane,Suite 2B Juneau,AK 99801 As of February 1995,ali excess energy from Snettisham is allocated to the AJ mine per a contract between AEL&P and AJ mine.This contract can be reopened on set dates in the Eklutna Palmer 30 164,000 164,000 0 U.S.Government,Alaska Power Administration Mr.Mike Deihl,Administrator (907)586-7405 U.S.Government,Alaska Power Administration 2770 Sherwood Lane,Suite 2B Juneau,AK 99801 None Goat Lake Skagway Construction could begin in 1997. 4.0 20,000 Alaska Power &Telephone Mr.Alan See,Operations Manager (800)982-0136 Alaska Power &Telephone P.O.Box 222 Port Townsend,WA 98368 1 megawatt of excess capacity is considered available. Cooper Lake Shores of Kenai Lake near Cooper Landing 17.2 41,000 41,000 0 Chugach Electric Association Mr.Gene Bjornstad,General Manager Page 4 of 8 ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/avaitable: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: 6/7/95 (907)563-7494 Chugach Electric Association P.O.Box 196300 Anchorage,AK 99519-6300 None Humpback Creek Cordova 1.25 3,500 3,500 0 Cordova Electric Cooperative Mr.James Roberts,General Manager (907)424-555 Cordova Electric Cooperative P.O.Box 20 Cordova,AK 99574 None Ketchikan Ketchikan 42 See Silvis Lake See Silvis Lake 0 Ketchikan Public Utilities Mr.Thomas Stevenson,Utilities Manager (907)225-1000 Ketchikan Public Utilities 2930 Tongass Avenue Ketchikan,AK 99901 None Beaver Falls Ketchikan 5.4 See Silvis Lake See Silvis Lake 0 Page 5 of 8 ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) Project Owner: Contact: Phone: Address: Known future pians or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MW4H): Energy considered surpius/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): value). Current Production (MWh): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: \f not existing year expected on line: Size of Project (MW): Annual Energy Potential, 6/7/95 Ketchikan Public Utilities Mr.Thomas Stevenson,Utilities Manager (907)225-1000 Ketchikan Public Utilities 2930 Tongass Avenue Ketchikan,AK 99901 None Silvis Lake Ketchikan 2.1 Total for all three KPU hydro projects 62,700 Total for all three KPU hydro projects 62,700 0 Ketchikan Public Utilities Mr.Thomas Stevenson,Utilities Manager (907)225-1000 Ketchikan Public Utilities 2930 Tongass Avenue Ketchikan,AK 99901 None Purple Lake Metlakatla 3.9 Total for both Purple Lake and Chester Lake 22,150 (1986 estimated Total for both Purple Lake and Chester Lake 16,000 Unknown Metiakatla Power &Light General Manager (907)886-4451 Metlakatla Power &Light P.O.Box 359 Metlakatla,AK 99926 None Chester Lake Metlakatla 1.0 Page 6 of 8 ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWh): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Name of Project: Location: If not existing year expected on line: Size of Project (MW): Annual Energy Potential, in an average water year (MWH): Current Production (MWH): Energy considered surplus/available: Project Owner: Contact: Phone: Address: Known future plans or commitments: Nameof Project: Location: if not existing year expected on line: 6/7/95 See Purple Lake See Purple Lake 0 Metlakatla Power &Light General Manager (907)886-4451 Metlakatla Power &Light P.O.Box 359 Metlakatla,AK 99926 None Crystal Lake Petersburg 2.2 10,000 10,000 0 Petersburg Municipal Light &Power Mr.Dennis Lewis (907)772-4203 Petersburg Municipal Light &Power P.O.Box 329 Petersburg,AK 99833 None Blue Lake Sitka 6.0 See Green Lake See Green Lake See Green Lake City of Sitka "Mr.Steven Svec,Electrical Superintendent (907)747-6633 City of Sitka 304 Lake Street,Room 104 Sitka,AK 99835 See Green Lake Green Lake Sitka Page 7 of 8 ALASKA'S HYDROELECTRIC PROJECTS (1 MW OR GREATER) Size of Project (MW):18.5 Annual Energy Potential, in an average water year (MWH):116,000 then 136,000 in 1997 due to Blue Lake rewind Current Production (MWR): 90,000 Energy considered surplus/available:26,000 then 46,000 in 1997 Note:Water availability varies throughout the year thus varying capacity available Project Owner:City of Sitka Contact:Mr.Steven Svec,Electrical Superintendent Phone:(907)747-6633 Address:City of Sitka 304 Lake Street,Room 104 Sitka,AK 99835 Known future plans or commitments: 6/7/95 Page 8 of 8 -a a rs -_-:--.7 DEPARTMENT OF COMMUNITY AND REGIONAL AFFAIRS DIVISION OF ENERGY TONY KNOWLES,GOVERNOR 333 WEST FOURTH AVE.,SUITE 220 ANCHORAGE,ALASKA 99501-2341 PHONE:(907)269-4500 DIRECTOR'S FAX:(907)269-4645 ENGINEERING FAX:(907)269-4685 November 18,1998 Mr.E.W.Wester City Manager City of Chuathbaluk P.O.Box CHU Chuathbaluk,Alaska 99557 Subject:Request for Funding Dear Mr.Wester: |received your letter of November 6,1998,requesting technical assistance and funding for a proposed hydro project in the Chuathbaluk area.We encourage the development and use of renewable resources as a basis of energy generation. Presently,the Division has no funds available for the development of hydro projects.However, we can provide technical assistance by helping the community look for alternative ways to obtain funding and by providing them with information about developing hydro projects. As funding becomes available for such projects,Chuathbaluk's request will be given consideration.Some background assessment and feasibility work will have to be completed first to ensure the success of such a development in this area.The FY98 CDBG grant program is one such funding source now available for this type of work.Its deadline is December 11, 1998. |look forward to working with the City of Chauthbaluk in this endeavor.My staff will keep you informed on any new developments as they relate to funding,or related hydro projects. Chauthbaluk is also encouraged to continue to look for alternative funding sources for this project. If |can be of any further assistance,please contact my office. Sincerely, Perey Fiigby Director cc:David Lockard,Division of EnergyEricMarchegiani,Division of Energy