I N T E R N A T I O N A L

Water Power
& DAM CONSTRUCTION
WWW.WATERPOWERMAGAZINE.COM
JULY 2010

Pushing ahead
Progress reports on hydro tunnel projects

Tackling sediment at dams

Small hydro renaissance

Serving the hydro industry for over 60 years

 CONTENTS
I N T E R N A T I O N A L

Water Power & DAM CONSTRUCTION

WWW.WATERPOWERMAGAZINE.COM

REGULARS
Editor
Carrieann Stocks 4 WORLD NEWS 46 PROFESSIONAL DIRECTORY
Tel: +44 20 8269 7777 8 DIARY 48 WORLD MARKETPLACE
carrieannstocks@globaltrademedia.com

Contributing Editors
Patrick Reynolds FEATURES
Suzanne Pritchard
Editorial Assistants INSIGHT
Elaine Sneath, Tracey Honney 10 Constructive consultation COVER: Launching the invert
Advertising Sales Why is construction consulting needed in hydro projects? concrete work platform at Niagara
Scott Galvin power tunnel project in December
Tel: +44 20 8269 7820
scottgalvin@globaltrademedia.com
SMALL HYDRO 2008. For a detailed report on
progress at the project, see p20
12 Small hydro renaissance
Deo Dipchan
Private hydro developers share their experiences
Tel: +44 20 8269 7825
deodipchan@globaltrademedia.com 16 Bringing water power to the poor
Tim Price Micro hydro transforms lives in developing countries
16
Tel: +44 20 8269 7822 18 Energy recovery from public water systems
timprice@globaltrademedia.com
Making use of existing infrastructure
Classified Advertising
Diane Stanbury
Tel: +44 20 8269 7854
TUNNELLING
dianestanbury@globaltrademedia.com 20 Niagara progress
How is the Niagara power tunnel project progressing?
Senior Graphic Designer
Natalie Kyne 22 Glendoe bypass
Production Controller Details on the bypass to recover Glendoe’s headrace
Lyn Shaw 24 Meeting challenges in Ethiopia 22
Publishing Director Overcoming challenges at Beles II and Gilgel Gibe II
Jon Morton
Offices
27 Excavation challenges and solutions at Jinping I
United Kingdom: Global Trade Media,
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Details on obstacles encountered at the Chinese scheme
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JULY 2010 3
 WORLD NEWS
UK sees surge in hydro development
T
HE NUMBER OF LICENCES
issued for small hydro
power schemes by the UK’s
Environment Agency has increased
substantially in the last decade, the
government agency has announced,
with the number of new schemes
in the country expected to treble
by 2020.
At the Chartered Institution of Water
and Environmental Management
(CIWEM) National Hydropower con-
ference held yesterday, EA chairman
Lord Chris Smith said that 31 licenc-
es for hydro schemes were issued
last year, compared to only five
in 2000. This year the agency has
already granted licences for 31 new
schemes, with a further 166 applica-
tions under consideration.
Currently, there are approximately
400 hydro schemes in England and
Wales, and Lord Smith explained
Studies shortlist new dam sites in New Zealand
S
EVERAL SITES HAVE BEEN
identified as potential locations
for water storage dams on the
Ruataniwha Plains in New Zealand
following initial geological studies in
the region.
A report on the geological stud-
ies has assisted both Hawke’s Bay
Regional Council and the Ruataniwha
Water Storage Dam Leadership to
assess the viability of several sites.
During the prefeasibility process the
Regional Council started with an ini-
tial list of 30 potential sites. This was
then worked through and narrowed
down to 14 sites of which six were
considered most likely.
These original 14 shortlisted sites
have had on-ground, physical geologi-
cal/seismic assessments over the
last two months. Of these, five are
now considered unsuitable because
SN Power and IFC in Vietnam power agreement
N
ORWEGIAN RENEWABLE
energy firm SN Power and
the International Finance
Corporation (IFC) have entered into a
Joint Development Agreement (JDA)
that will see them develop sustaina-
ble hydro power projects in Vietnam.
This agreement will enable IFC,
acting through IFC InfraVentures, an
early stage project development fund,
and SN Power to develop an invest-
4 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
this number is expected to rise to
1200 by 2020.
In March this year, the EA released
the Hydropower Opportunities and
Environmental Sensitivities Map
which identified almost 26,000 new
locations where small scale hydro
power could be deployed in England
and Wales. Together, these sites
could generate enough electricity to
power up to around 850,000 homes
and produce 3% of the country’s
2020 renewable electricity needs. In
reality, however, only some of these
sites could be exploited due to envi-
ronmental sensitivities, as well as
practical constraints such as access
to the electricity network.
The new maps help to identify
areas where hydro power could make
a positive contribution to the local
environment, and sites where it is
less appropriate.
of ground condition risks. Some of the
remaining set of sites are looking very
positive but further assessment work
is still underway. Relevant landowners
in these areas are being contacted by
Hawke’s Bay Regional Council and
informed as sites are removed off
the list.
“This is a completely normal part of
the process to assess potential dam
sites. It’s a complex project and our
feasibility study as much about exclud-
ing sites that have risks as including
sites needing further investigation,”
said Bruce Corbett, Group Manager,
Water Initiatives for Hawke’s Bay
Regional Council.
The study report was presented to
the Ruataniwha Water Storage Dam
Leadership group chaired by Sam
Robinson earlier this month. The
group is working with Hawke’s Bay
ment strategy, policy, and guide-
lines to address Vietnam’s growing
demand for power. The partners will
acquire operating assets and invest in
greenfield projects to build up a port-
folio of renewable energy investments
in the country.
The project will be IFC’s first
investment in Vietnam through IFC
InfraVentures, and SN Power’s first
partnership in Vietnam.
The report found that a sensitively
designed hydropower scheme that
includes a fish pass could improve
the local environment as well as gen-
erate electricity in over 4000 sites.
These opportunities are particularly
concentrated on rivers such as the
Severn, Thames, Aire and Neath.
With the government soon to
offer subsidies of up to 20p for
every kilowatt hour of electricity pro-
duced, a medium-sized scheme that
typically generates enough electricity
for about 32 homes, could receive
around £25,000 a year. Average
set up costs range from £100,000
to £150,000. But, the Environment
Agency stressed, only schemes that
were well designed and had no nega-
tive impacts on the river wildlife or
the local environment would get the
go ahead.
“Some hydro power schemes have
Regional Council to step through the
feasibility work for the proposed water
storage dams.
The geological studies have shown
that there is ample dam site capacity
in the north of the Ruataniwha Plains
area but in the south there is less avail-
able storage capacity which reduces
options, particularly in Takapau.
The Council will focus further
assessments now on sites where
geological fatal flaws are not appar-
ent, and where sufficient and eco-
nomically achievable storage can go
ahead. Fortunately, there is very good
geological data available for the area
which identifies a lot of the numerous
fault lines and unsuitable soils.
Eight of the potential sites
now being studied can provide
90-110Mm3 compared to the maxi-
mum storage requirement of 90Mm3
“This IFC partnership will allows
us to find viable hydro power
projects and subsequently develop
and operate them in a sustainable
manner. SN Power has followed the
Vietnamese power market for several
years. We believe we can strengthen
Vietnam’s long-term renewable gen-
erating capacity through our power
market experience and technology
transfer,” said Erik Knive, Executive
the potential to deliver low carbon
electricity and improve the local
environment for wildlife, for exam-
ple by improving fish migration. But
there will inevitably be some sites
where the risk to the environment
outweighs the benefits of power gen-
eration,” said Tony Grayling, Head
of Climate Change and Sustainable
Development at the Environment
Agency. “With Government’s new
feed-in tariff for renewably generated
electricity, hydropower could become
an attractive income generator for
hydro power developers, if environ-
mental safeguards are met.
“The report recommends that
fish-friendly design needs to be
incorporated in all schemes, and
that grants for fish passes could
help to unlock the potential of
small scale hydro power in England
and Wales.”
to serve the entire area of 22,500
ha. Likely dam positions close to
those originally identified are also
being looked at.
The new and repositioned sites will
reduce pumping requirements as they
are more gravity fed. Two sites also
offer hydro power potential.
GNS seismic studies are currently
underway to confirm the geological
assessments. This will also provide
dam design parameters which will
influence construction costs and
therefore further decisions.
Parallel to this, the Regional
Council’s water project team will be
working with the Ruataniwha Water
Users Group, and will meet with cur-
rent irrigators and major dryland farm-
ers in the irrigation zones to gauge
and prioritise demand for stored
water.
Vice President SN Power Southeast
Asia.
SN Power and IFC have collabo-
rated previously on several of SN
Power’s global investments in wind
and hydro power plants in Chile,
India, and the Philippines. SN Power
uses IFC’s social and environmental
performance standards for conduct-
ing due diligence of acquisition and
greenfield power projects.

World Bank OK’s loans
to India, Pakistan
T
HE WORLD BANK HAS APPROVED
$350M to finance a Dam
Rehabilitation and Improvement
Project which aims to improve the
safety and sustainable performance
of over 220 selected dams in India,
and has also approved a credit worth
US$146M for the second phase of a
project to rehabilitate and modernize
the Jinnah Barrage in Pakistan, and to
improve irrigation and water manage-
ment in the country.
India is home to about 4700 com-
pleted large dams – almost half of
which are more than 25 years old
– with another 400 under construc-
tion. The total water storage capac-
ity of these existing dams is about
283Bm3. They have played a key
role in fostering rapid and sustained
agricultural and rural growth and
development – a key priority for the
Government of India since independ-
ence. Irrigated agriculture and hydro
power development have been major
pillars of the government’s strategy
to ensure food and energy security.
“Rainfall, which occurs mainly
in intense and unpredictable
downpours within short monsoon
seasons, is of high temporal and
spatial variability and does not
meet year-round irrigation and
other water demands. Considering
this, storage of water is essential
for India. However, many large
dams are in need of modern safety
measures and monitoring instru-
mentation,” said Joop Stoutjesdijk,
Lead Irrigation Engineer and Project
Team Leader. “The project will help
rehabilitate and modernize over
220 large dams in the states of
Kerala, Madhya Pradesh, Orissa,
and Tamil Nadu.”
In addition, the Project also aims
Nicaragua to boost hydro
N
ICARAGUA’S MINISTRY OF
Energy and Mines (MEM) has
confirmed that hydro gen-
eration activities in the country will
increase significantly within the next
four to five years with 18 hydroelectric
projects in the study phase and six
projects currently under construction.
Nicaragua has a hydroelectric
potential of 3280MW, of which only
98MW is currently being utilized. This
represents a huge potential for com-
panies interested in developing hydro-
electric projects in the country, in
WWW.WATERPOWERMAGAZINE.COM JULY 2010
to strengthen the institutional,
legal and technical framework for
dam safety assurance within the
Government of India and in the par-
ticipating states.
Meanwhile, the Punjab Barrages
Improvement Phase II Project aims to
strengthen and modernize Pakistan’s
Jinnah Barrage and affiliated works
to enable reliable and uninterrupted
supply of water for over 2.1 million
acres of farmland benefitting about
600,000 farm families for irrigation
and domestic water users; and to
build the capacity of Punjab Irrigation
and Power Department’s ( IPD) in
water resource management and irri-
gation system management.
“The development and manage-
ment of water resources of the Indus
Basin is a huge challenge, requiring
very high levels of administrative engi-
neering and scientific capability. While
there has been progress, the current
irrigation and drainage system suf-
fers from deteriorating infrastructure
and weak governance,” said Masood
Ahmad, World Bank Lead Water
Resources Specialist and Project
Team Leader. “To reduce volatility
to growth, Bank support will include
rehabilitation of barrages and con-
tinued capacity development at the
regional and federal level for manag-
ing water resources.”
The World Bank has a long his-
tory of partnership and collaboration
with Pakistan and has supported
more than 48 operations in irrigation,
drainage, water resources develop-
ment and the power sector. Jinnah
Barrage is one of the highest priority
barrages in the Indus System as it
provides a bridge over the Indus River
to link the roads between the Khyber
Pakhtoonkhwa and Punjab provinces.
addition to the opportunities in other
types of renewable energy sources,
said PRONicaragua, the Nicaraguan
Investment Promotion Agency.
The Tumarin project on the
Grande River in Matagalpa could be
one of the most important projects
in the last 50 years in Nicaragua,
according to representatives of the
National Assembly. It is estimated
to produce 250MW, one third of the
country’s current demand, and will
save up to US$100M in fuel imports
per year.
WORLD NEWS
From the Editor
Dear readers,
Big news from the US this month was that Senator Lisa
Murkowski, Representative of Alaska, introduced two
pieces of legislation aimed at increasing the produc-
tion of hydroelectricity in the country. The Hydropower
Improvement Act and the Hydropower Renewable Energy
Development Act have been developed to boost federal
support for hydropower projects.
In particular, the Hydropower Improvement Act, co-spon-
sored by Sen. Patty Murray, D-WA; Sen. Maria Cantwell,
D-WA; and Sen. Mike Crapo, R-Idaho, aims to increase the
capacity of the nation’s hydropower sources by up
to 75,000MW.
The legislation establishes a competitive grants program
and directs the Department of Energy to produce and
implement a plan for the research, development and dem-
onstration of increased hydropower capacity. The bill also
gives the Federal Energy Regulatory Commission (FERC)
authority to streamline the permitting and review process
for hydropower projects (a move I’m sure would be wel-
comed by the great majority of readers in the US), and calls
for studies on pumped-storage sites and the potential for
development at Bureau of Reclamation facilities.
The Hydropower Renewable Energy Development Act
classifies hydroelectric power generation as a “renewable”
resource for federal program purposes. This bill provides
parity treatment for hydro in the Production Tax Credit
(PTC) and expands the types of hydro that can qualify
for the PTC and Clean Renewable Energy Bonds
(CREBS) program.
When introducing the bills, Murkowski said she hoped
the Senate can finally recognize the important contribu-
tion hydropower, as a truly renewable resource, can
provide to the country’s clean energy goals . Hydropower
is the largest source of renewable electricity in the US,
providing 7% of the nation’s power. In Alaska, hydro sup-
plies 24% of the state’s electricity needs, and there are
more than 200 additional sites that look promising for
further hydropower development.
News of the bills was welcomed by the National
Hydropower Association, particularly the fact that the bill
includes provisions to help make existing hydro resources
more efficient, convert existing dams to energy-generating
resources, and support small conduit technologies, as well
as pumped-storage project development. “This approach
focuses on new technologies and new approaches, not
necessarily new dams,” said NHA Executive Director Linda
Church Ciocci, adding that the association stands ready
to work with Congress, the White House, and other stake-
holders to ensure that hydropower is supported in any
energy and/or climate bill that moves forward.
There is little doubt this is a great step forward for hydro
in the US, and is a great sign for the future. It would allow
the country to expand its exisiting developments and
ensure continued development of new technologies, as
well as offering extensive employment opportunities.
Best wishes
Carrieann Stocks,
Editor
5
 WORLD NEWS
In brief
MOZAMBIQUE IS TO
focus on developing its
immense hydro potential
before looking at other
energy sources, the coun-
try’s energy minister said
during a recent conference
in Basel, Switzerland.
According to reports from
Reuters Africa, Salvador
Namburete told the confer-
ence audience that the
country’s top priority in
terms of energy is to devel-
op some of its 12,000MW
hydro potential, later
focusing on natural gas,
wind and solar power.
Namburete was reported
as saying the country had
no immediate interest in
nuclear power.
CHINA SOUTHERN
Power Grid (CSPG) has
signed agreements with
the Laos government to
develop the Nam Tha 1
hydro power project and
build a national power grid
in the country, Dow Jones
Newswires has reported.
Signing took place dur-
ing a state visit to Laos by
Chinese Vice President Xi
Jinping earlier this month.
GLOBALDATA HAS
announced the release the
“Ukraine Small Hydro and
Mini Hydro Power Market
Analysis and Forecasts
to 2015” report which
analyses the growth and
evolution of Ukraine’s
small hydro power mar-
ket up to 2009 and gives
historical and forecast
statistics for the period
2001-2015. This research
also gives detailed analysis
of the market structures of
the technology and regula-
tory policies that govern it.
For further details, please
visit: www.globaldata.
com/reportstore
6 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
NYPA plans $460M upgrade for
part of Niagara power project
T
HE NEW YORK POWER AUTHORITY
(NYPA) is planning a major
overhaul of the Niagara Power
Project’s Lewiston Pump Generating
Plant (LPGP) to extend the life of the
hydroelectric project’s auxiliary facility
and enhance its performance.
The Power Authority Board of
Trustees approved a $460M Life
Extension and Modernization (LEM)
Program for the LPGP facility, which
operates during periods of peak
power demand in supplementing the
electricity output of the Robert Moses
Niagara Power Plant, the Niagara
Project’s main generating facility.
The trustees also authorized initial
capital expenditures of $131M for the
upgrade and the award of a 10-year
contract to Hitachi Power Systems
America, which was the lowest-cost
qualified bidder for replacing and mod-
ifying major components of LPGP’s
pump-turbine generators.
“The Niagara Power Project is a
tremendous asset to Western New
York in providing some of the lowest
cost electricity in the country, with
its power production supporting
tens of thousands of jobs on the
Niagara Frontier,” President and
Chief Executive Officer Richard M.
Kessel said, announcing the upgrade
project. “The Power Authority places
the highest priority on being a good
steward of this facility to ensure it
continues to bring the greatest value
to the region’s economy and the
state’s electric power system. The
Life Extension and Modernization
Program that we’re planning at the
Andritz resumes Ilisu supply contract
T
ECHNOLOGY GROUP ANDRITZ
says that it is to resume its con-
tract to supply equipment to the
Ilisu hydro power plant in Turkey after
improvements were made to aspects
of the project’s environmental and
social measures.
The supply contracts awarded to
Andritz as well as a number of other
European firms were suspended tem-
porarily in late 2008 after the export
credit agencies of Austria, Germany
and Switzerland said that specified
standards relating to the project’s
impact on the environment, cultural
heritage and resettlement had not
been fulfilled.
Andritz’s EUR340M contract
Lewiston Pump Generating-Plant is
in keeping with this imperative, which
also served as the basis for the
Power Authority’s completion only a
few years ago of a similar program at
the Niagara Project’s Robert Moses
Niagara Power Plant.”
In 2006, NYPA completed a $24M
maintenance program at LPGP in the
same year that it finished a $298M,
15-year program to upgrade the
Robert Moses Niagara Power Plant,
where the Power Authority replaced
turbines and retrofitted other compo-
nents of all 13 generating units. The
LEM at the pump generating plant will
be an undertaking of similar scope,
for overhaul of the plant’s 12 pump
turbine generator units, which date
back to 1961, when the Niagara
project was first placed into service.
The work will include replacing the
turbine runners, the rotating portion
of the equipment. The runners, which
typically weigh about 75 tons, trans-
fer energy from the water flow to the
generators.
The upgrade will begin in late 2012
under a schedule providing for the
overhaul of a turbine generator unit
every eight to nine months, with the
final unit completed in 2020. The
phase-in schedule provides for 11
of the 12 LPGP units to be available
for operation during the LEM so that
NYPA can meet its commitments to
its customers.
In addition to extending the life
of the pump generating plant, the
refurbishing will lead to greater effi-
ciencies, allowing the plant to gener-
includes the supply of engineering
services, six 200MW Francis tur-
bines, six generators and additional
equipment. The company is part of an
international construction consortium
led by Turkey’s Nurol Construction.
According to Andritz, its contract will
no longer be supported by the Austrian
export credit agency, Oesterreichische
Kontrollbank AG (OeKB).
In 2009, OeKB and two other
European banks withdrew their sup-
port for Ilisu after a deadline that
had been set for socio-economic and
cultural improvements to the project
was not met. The banks’ support
was designed to cover the European-
based suppliers for the project,
ate additional power with the same
amount of water.
LPGP is one of two major pumped
storage facilities in New York State -
the other being the Blenheim-Gilboa
Pumped Storage Power Project, anoth-
er NYPA facility. In May, the Authority
completed a four-year overhaul of that
facility, in the northern Catskills.
The selection of Hitachi Power
Systems America for replacing parts
of the pump-turbine generators and
associated equipment stemmed from
a Request for Proposals that NYPA
issued last December for the new
equipment and rehabilitation work. The
company, which was one of six bidders
submitting proposals in response
to the RFP, was awarded a $174M
contract for carrying out the overhaul
during the 2012 to 2020 time frame,
with the contract amount including
allowances for future inflation.
Hitachi was also the company that
upgraded and rehabilitated the pump-
turbine units at Blenheim-Gilboa.
Hitachi and other contractors are
expected to utilize local union trades
people, including machinists, electri-
cians, mechanics and welders, in sup-
port of the LPGP work, contributing to
economic development in the region.
The work will include the disassembly
and reassembly of equipment.
NYPA is also currently conducting a
LEM program at another hydroelectric
project, the St. Lawrence-Franklin D.
Roosevelt Power Project in Massena.
That initiative is more than three-
quarters complete and scheduled to
be finished by 2013.
including Andritz, Alstom, Ed. Zublin
AG, Colenco and Maggia.
Turkey, which sees the EUR1.2B
project as a key element of its social
and industrial development plans,
vowed to continue with Ilisu without
the banks’ support. According to a
statement from Andritz, the Turkish
government says that “it will abide
unchanged by the planned accompa-
nying measures relating to environ-
mental protection and to social and
cultural aspects”.
Ilisu is part of Turkey’s Southeastern
Anatolia Project, which aims to build
22 dams and 19 power plants on the
Tigris and Euphrates rivers and their
tributaries.
 DIARY
DIARY OF EVENTS
Let IWP&DC’s readers know about your forthcoming conferences and events.
For publication in a future issue, send your diary dates to: Carrieann Stocks, IWP&DC, Global Trade Media Ltd, Progressive House, 2 Maidstone Road,
Foots Cray, Sidcup, Kent, DA14 5HZ, UK. Alternatively, email: carrieannstocks@globaltrademedia.com, or fax:+44 208 269 7804
August
8-11 August
7th Brazilian Symposium on
Geotechnical and Geoenviron-
mental Mapping
Maringá, Brazil
CONTACT: Universidade Estadual
de Maringá, Brazil.
Tel: (0055) 44 3011
Fax: (0055) 44 3011- 4731
Email: 7sbcgg@gmail.com
www.7sbcgg.abge.com.br
16-20 August
Hydropower Africa
Johannesburg, South Africa
CONTACT: Spintelligent (Pty) Ltd,
PO Box 321, Steenberg 7947, South
Africa.
Tel: +27 21 700 3500.
Fax: +27 21 700 3501.
nicolaas.loretz@spintelligent.com
http://www.spintelligent-events.com/
hydropower2010/en/online-registra-
tion.php.
25-27 August
35th Conference on Our World in
Concrete and Structures
Singapore
CONTACT: Conference Secretariat,
CI-Premier Pte Ltd, 150 Orchard
Road, #07-14, Orchard Plaza,
Singapore 238841,
Tel: +65 6733 2922.
Email: cipremie@singnet.com.sg.
30 August - 3 September
ECEE 2010 (14th European
Conference on Earthquake
Engineering)
Ohrid, Macedonia
CONTACT: MAEE (Macedonian
Association of Earthquake
Engineering), 73 Salvador Aljende, PO
Box 101, 1000 Skopje, Macedonia.
Tel: +389 2 3 107 701.
www.14ecee.mk.
September
12-16 September
21st World Energy Congress
Quebec, Canada
CONTACT: Organsing Committee,
740 Notre-Dame Street West, 8th
8 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
Floor, Montréal, Québec, Canada
H3C 3X6.
Tel: + 1 (514) 397-1474.
www.wecmontreal2010.ca.
15-17 September
African Hydro Symposium
Arusha, Tanzania
CONTACT: African Hydro
Symposium, PO Box 32774, Lusaka
10101, Zambia.
Tel: 260 211 371 007.
Email: hbmmakungo@kgrtc.org.zm
www.africanhydrosymposium.org.
19-23 September
Dam Safety 2010
Seattle, WA, US
CONTACT: Association of State
Dam Safety Officials (ASDSO), 450
Old Vine Street, Lexington KY 40507,
US.
Tel: +1 859 257 5140.
Fax: +1 859 323 1958.
Email: info@damsafety.org.
www.damsafety.org.
22-23 September
8th ICOLD Euopean Club
Symposium: Dam Safety -
Sustainability in a Changing
Environment
Innsbruck, Austria
CONTACT: IECS2010 Organizing
Committee, Stremayrgasse 10/II,
A-8010 Graz, Austria.
Fax: +43 316 873 8357.
IECS2010@TUGraz.at.
www.iecs2010.tugraz.at.
27-29 September
Hydro 2010
Lisbon, Portugal
CONTACT: Hydropower & Dams,
Aqua~Media International Ltd, PO
Box 285, Wallington, Surrey
SM6 6AN, UK.
Tel: +44 (0)20 8773 7244.
edit@hydropower-dams.com.
www.hydropower-dams.com.
27 September - 2 October
Small Hydro Resources
Trondheim, Norway
CONTACT: International Centre for
Hydropower (ICH), Klaebuveien 153,
N-7465 Trondheim, Norway.
Tel: +47 73 59 0780.
Email: mail@ich.no.
www.ich.no.
28-30 September
2nd International Congress on Dam
Maintenance and Rehabilitation
Zaragoza, Spain
CONTACT: Daniel Ariza, TILESA
OPC, Londres, 17 - 28028 Madrid.
Tel: +34 91 361 2600
Fax: +34 91 355 9208
sepremzaragoza2010@tilesa.es
http://www.damrehabilitationcon-
gress2010.com
October
13-14 October
British Hydropower Association
Annual Conference 2010
Glasgow, UK
CONTACT: Ellan Long, British
Hydropower Association, Unit 6B
Manor Farm Business Centre, Gussage
St Michael, Dorset, BH21 5HT UK
Tel: + 44 (0)1258 840934.
Email: info@british-hydro.org.
www.british-hydro.org.
17-19 October
Power Generation & Water
Abu Dhabi, United Arab Emirates
CONTACT: IIR Middle East, Dubai,
United Arab Emirates.
www.powerandwaterme.com.
19-21 October
EFEF 2010 (European Future
Energy Forum)
London, UK
CONTACT: Turret Middle East,
ADNEC House, PO Box 94891, Abu
Dhabi, United Arab Emirates.
www.europeanfutureenergyforum.
com/home.
25-29 October
Risk Management in Hydropower
Development
Trondheim, Norway
CONTACT: International Centre
for Hydropower (ICH), Klaebuveien
153, N-7465 Trondheim, Norway.
Tel: +47 73 59 0780.
Email: mail@ich.no.
www.ich.no.
November
24-26 November
16th International Conference on
Hydropower Plants
Vienna, Austria
CONTACT: Dr. Eduard Doujak,
Institute for Waterpower and
Pumps, Karlsplatz 13/305, Vienna
Austria, A-1040
eduard.doujak@tuwien.ac.at.
www.viennahydro.com
26-28 November
Workshop on Optimization of
Construction Method for CFRDs
Yichang, China
CONTACT: HydrOu China.
Tel: +86717 672-1379
Email: mail.chenqian@gmail.com
http://www.hydrou.com/index.
php?option=com_content&task=vi
ew&id=166&Itemid=1
February 2011
15-17 February
6th International Conference on
Dam Engineering
Lisbon, Portugal
CONTACT: Eliane Portela, LNEC,
Concrete Dams Department, Av. Brasil
101, 1700-066, Lisbon, Portugal.
Tel: (351) 218443361.
Email: eliane@lnec.pt.
http://dam11.lnec.pt.
May/June 2011
29 May - 3 June
79th Annual Meeting of ICOLD
Lucerne, Switzerland
CONTACT: Swiss Committee on
Dams, c/o Stucky Consulting Engineers,
33 Rue du Lac, Case Postale, CH-1020
Renens, Switzerland
Email: swissdams@stucky.ch
http://www.swissdams.ch
14-17 June
IHA’s 2011 World Congress
Iguassu Falls, Brazil
CONTACT: International
Hydropower Association.
Tel: +44 20 8652 5290.
Email: congress@hydropower.org.
Website: www.hydropower.org.

EXECUTIVE MOVEMENTS
Here you will find details on some of the executive appointments made by companies within the hydro power and dams industry
over the past few months. To submit details of appointments for publication in a future issue of the magazine,
please send an email to the editor, Carrieann Stocks, at: carrieannstocks@globaltrademedia.com
New CEO for Hydro Tasmania
Hydro Tasmania has announced its
new CEO, Roy Adair took up the
position on 21 June 2010.
Hydro Tasmania Chairman
Dr David Crean said Adair has
extensive national and interna-
tional experience at the highest
level in the energy industry.
Adair was President and
CEO of Senoko Power Ltd,
Singapore’s largest integrat-
ed electricity generation and
retail supplier for six years to
November 2009. Previously he
was Chief Operating Officer for
Pacific Hydro, one of Australia’s
leading renewable energy busi-
nesses and a major player in
the development of the national
wind industry.
Dr Crean said Adair brought a
wealth of experience to the posi-
tion and was the best person
to lead Hydro Tasmania as it


sought to build on its position
as one of Australia’s leading inte-
grated energy businesses.
Adair’s previous roles
include:
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He is a graduate economist
and a qualified accountant and
is currently a Board member
of the Centre for Energy and
Greenhouse Technologies.
BC Hydro appoints president
and CEO
BC Hydro has appointed Dave
Cobb the new president and chief
executive officer of BC Hydro.
“Dave comes to BC Hydro with
a strong mix of business experience,
senior leadership skills, and man-
agement of major projects,” said
Dan Doyle, Chair of BC Hydro’s
Board of Directors. “His strategic
thinking and issues management
experience will be a great fit for BC
Hydro. I am confident that under
WWW.WATERPOWERMAGAZINE.COM JULY 2010
his leadership we will deliver the
many objectives outlined in the
recent Clean Energy Act.”
Cobb recently served as the
executive vice-president and deputy
CEO of the Vancouver Organizing
Committee for the 2010 Olympic
and Paralympic Winter Games
(VANOC), where he was respon-
sible for leading a broad portfolio,
including games operations, financ-
es, revenue planning, and commu-
nications. Prior to joining VANOC,
he spent 12 years with Orca Bay
Sports Entertainment (Vancouver
Canucks), including senior roles
as chief operating officer and chief
financial officer.
“This is a very exciting time in
BC Hydro’s history and the future
of our province and I look forward
to the challenges and opportunities
that lie ahead as we implement the
province’s ambitious new Clean
Energy Act,” said Cobb.
Mott MacDonald expert
appointed visiting
professor at the University
of Southampton, UK
growth strategy’ for Deritend,
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able energy director, Dr Simon
ported by this investment,” he said,
visiting professor at the University
our core markets, further develop
our product offering and ramp up
As part of his role, Dr Harrison will
lecture on electrical engineering at
the university as well as participate
on an industrial panel.
Dr Harrison, who is based at
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in Brighton, plays a key role leading
the consultancy’s renewable energy
business in the UK and internation-
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is playing key roles in major projects
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power scheme in Pakistan, off-
shore wind farms across Europe,
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one of the world’s most sustain-
able urban developments in Abu
Dhabi.
Dr Harrison has a long history
with the university, having studied
for both his BSc and PhD degrees,
he was also a full time member of
the academic staff for several years
at the University of Southampton’s
Electrical Engineering Department.
Commenting on his appointment,
Dr Harrison said, “The University
of Southampton is renowned for
both its research and teaching activ-
ity in electrical power engineering. It
is a great privilege to be part of such
an institution again and re-establish
my connections.”
Dr Harrison is chairman of
the Institution of Engineering and
Technology Energy Sector Panel and
a fellow of the Energy Institute.
Deritend appoints
non-executive chairman
Deritend Industries – a UK based
industrial maintenance, service and
repair group – has announced the
appointment of David Garman
as non-executive Chairman with
immediate effect.
The company, with headquar-
ters in Wolverhampton, operates
from a national branch network.
The appointment comes close on
the heels of a recent multi-million
pound investment in the company
and will support the ‘ambitious
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“With David on board and sup-
Reed held various leadership posi-
“we are looking to consolidate
the senior state executive for the
Indiana, Texas and Kentucky
our energy efficiency services for
customers across the spectrum of
British industry.
“David is a key figure in a range
of industry sectors, with a proven
track record of achieving rapid and
sustainable growth,” continued
Hale. “He will be a valuable asset to
the company, with the knowledge
and experience to help us imple-
ment this planned expansion.”
Garman’s experience includes
spending nine years as Chief
Executive of logistics group TDG,
which he held from 1999 until the
company’s takeover in 2008.
Prior to TDG, Garman spent 20
years at United Biscuits in a range of
management roles and was a direc-
tor and chief executive of Allied
Bakeries, a subsidiary of Associated
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include non-executive director of
Phoenix Group plc and non-execu-
APPOINTMENTS
tive director of Carillion plc, where
he is also senior independent director.
Garman is also an Associate of Duke
Corporate Education and a Business
Adviser for Enterprise Ireland.
Duke Energy names President
of Indiana operations
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W. Reed president of its Indiana
service region. Reed will be respon-
sible for the company’s Indiana
regulatory work, governmental
relations, and economic develop-
ment and community affairs.
He replaces Jim Stanley, who
is transitioning to senior vice
president of power delivery for the
company’s US operations. Reed is
currently commissioner of Indiana’s
Department of Transportation. He
will join Duke Energy on June 14.
Reed, of Cicero, has led the
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where he was responsible for
approximately 4,000 employees
and a $2 billion annual budget to
construct and maintain the state’s
road system. He reported to
and is a member of his cabinet.
Prior to his work with the state,
tions at GTE/Verizon. He was
operations. In that role, he had
overall responsibility for customer
service, delivery, construction,
maintenance, large and medium
customer account management,
budgets, and regulatory and legis-
lative relations.
Early in his career at GTE, he
was the first quality director for
the company’s largest subsidiary,
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Additionally, he directed annual
revenue and expense budgets
of more than $1B as budget
and finance director for GTE’s
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Reed has a broad base of util-
ity experience. He served as execu-
tive director of the Indiana Utility
Regulatory Commission from 2006-
2009, where he managed the com-
mission’s electricity, water, sewer,
natural gas, pipeline safety and con-
sumer utility industry divisions.
9
 INSIGHT
Constructive consultation
The current economic conditions and political environment have changed the way that
construction projects, such as hydropower, are approached, executed and managed.
Todd Vandenhaak gives an insight into why more construction consulting is now required
T
HE economic downturn has
changed the contract delivery
methods for many infrastructure
projects in Europe, the Middle East
and Africa (EMEA). An example of which is
a trend of fewer cost-reimbursable contracts
and more lump sum contracts. Additionally,
public private partnership delivery is being
implemented on many infrastructure projects,
and even recent hydropower projects have
seen governments tender for private con-
cessionaires to design, build, operate and
transfer these projects. As contract delivery
methods change, it transfers the risk alloca-
tion between the parties, which should be
considered in the risk assessment and affects
the structure of disputes.
Recent industry trends indicate that
construction disputes are on the rise.
Additionally, owners and contractors are
continuously trying new, alternative methods
of dispute resolution to minimise the time
and cost to settle their disputes.
In general, disputes are driven by change,
regardless of a project’s geographic location.
Additionally, changes in construction today
are still driven by the same common project
conditions that have driven changes in recent
decades, such as differing site conditions, errors
and omissions, owner-directed changes, etc.
What has changed as a result of the cur-
rent economic conditions and political envi-
ronment is the way projects are approached,
executed and managed. More focus and
exposure appears to be directed at the pre-
planning phases, which heightens the need
for a transparent risk management pro-
gramme. Owners are looking more aggres-
sively at ways to better manage costs, while
contractors are actively seeking options to
protect or improve tighter profit margins.
Hydropower projects
Marsh Construction Consulting profession-
als have been engaged in numerous hydro-
power projects in Europe and Asia. These
projects range from combined irrigation
and hydroelectric projects to hydropower
programmes of multiple power generation
stations. Additionally, our experience has
included consulting for both developers and
contractors, providing services throughout
the project life cycles. This has allowed a
balanced perspective in identifying con-
struction risks during development phases,
resolving disputes during negotiations, and in
some cases providing expert analysis and
10
testimony in International Chamber of
Commerce (ICC) arbitration.
As an indication of a representative
engagement, Marsh consultants were
retained on a hydropower plant that was a
joint implementation project between two
European countries within the framework
of the Kyoto Protocol. The project had
some unique aspects as it was designated as
a pilot project located in a mountain range
at a country border, and was to be part of
a string of power stations along the nearby
river. The above-ground storage power sta-
tion had an installed capacity of 80MW and
a standard production of 185GWh/yr, while
the reservoir had a volume of 111Mm3 and
was contained by a 125m high arch dam.
The conventionally driven intake water
tunnel partly cut across a geologically problem-
atic zone. While all projects contain their own
unique issues, the political profile and challeng-
ing site conditions added an element of risk for
which Marsh professionals were engaged to
analyse and identify areas of impact, delays,
and potential risk for the project.
The need for risk assessments for these
infrastructure projects varies significantly;
based on the types of projects and the capac-
ity in which these assessments are conducted.
For example, in one particular engagement,
Marsh Construction Consulting profession-
als led a risk assessment and contractor esti-
mate validation exercise of a multi-billion
US dollar landmark submersible flood gate
system in Italy. In this case, the need was for
a detailed quantitative risk assessment of the
cost to complete the ten-year programme.
From this assessment, we were able to pro-
vide a specific recommendation on the appro-
priate allocation of risk in the EPC contract
and determine the appropriate range of con-
tingency for the programme. Studies such as
this are often used as the basis to approve
funding for unique ‘one-of-a-kind’ projects.
Insurance claims
Specific industry expertise has proved valu-
able in assisting with insurance claims related
to hydro construction projects. For example,
to address a force majeure event (flood) on a
hydroelectric station in Asia, Marsh formulat-
ed a written acceleration plan for submission
to the insurers. This plan specifically outlined
the parameters and components of the mitiga-
tion and recovery of the time impact of the
force majeure event on project completion.
In order to adequately address these
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
specific needs of owners and contractors for
risk assessments and claims services, signifi-
cant expertise across multiple disciplines is
required. Additionally, to continue to add
value to hydropower and dam clients, it is
imperative that construction professionals
stay abreast of the dynamic environment in
which these projects develop. While this can
prove challenging, it’s also a very interesting
time for finding hydropower solutions, given
the current focus on renewable energy and
environmental concerns.
project controls
It has always been good practice to imple-
ment reliable project controls and project
governance methods for large, complex con-
struction projects. However, today’s dynam-
ic political and economic environment has
placed an increased emphasis on hydropower
projects in particular. When these factors are
combined with balancing the world’s grow-
ing energy needs with an intense focus on
renewable energy sources and environmen-
tal concerns, creative solutions are needed to
address these challenges.
One could say there’s less room for error in
this environment, or put another way, it will
be more costly to address changes or risks
that are not identified and mitigated early in
the project life cycle. Additionally, ensuring
that the best practice project controls and
governance procedures are in place for a par-
ticular project is not enough. It is becoming
more and more important to ensure proper
implementation of these controls at every
step throughout execution.
Most will agree the level of scrutiny in
which these projects are designed, built, and
operated has increased in the last decade. The
need for improvement goes beyond advanc-
ing the methods of execution with technol-
ogy improvements. It means understanding
how risks are transferred amongst the parties
throughout the project life cycle, as contract
delivery methods, funding mechanisms, and
stakeholder needs continue to evolve. It’s
not just the project success goals that have
changed in the last decade, but the ways in
which we achieve those goals and the tools we
have developed to ensure transparency and
control throughout the life cycle. IWP & DC
Todd Vandenhaak is Leader of the
Construction Consulting Practice for
EMEA at Marsh Risk Consulting.
Email: todd.vandenhaak@marsh.com
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www.poyry.com
 SMALL HYDRO

Siblings Celeste and William Fay have a long history and unique
perspective in the small hydro industry. Here they share their
experiences and explain how the endless quest for renewable
energy is prompting a renaissance for small hydro in the US

Prospecting potential micro-hydro sites in New Hampshire,

Site pictured is a 100 hp turbine directly connected to an air compressor

Small hydro renaissance

A
SIMPLIFIED history of hydropower in the New England
area begins hundreds of years ago as small mill owners
harnessed the energy available in falling water and convert-
ed it to usable mechanical power. Later, this energy was
converted to electricity and by 1940 approximately 40% of the US’
electrical demand was met through hydroelectric generation. With
the increased use of inexpensive fossil fuels, the majority of these
smaller hydropower facilities were eventually left to ruin. Today in
a seemingly endless quest for renewable energy, we have returned to
our roots and the hydropower boom has once again begun.
There are many challenges associated with small hydropower devel-
opment. For those involved in the industry it will be no surprise to see
regulation discussed first. However, there are other important challeng-
es such as acquiring the initial capital investment, overcoming market
instabilities, and for now let’s say finding some ‘Yankee Ingenuity’.
R EGULATIONS
With few exceptions, new hydropower is heavily regulated under
the Federal Energy Regulatory Commission (FERC). The process of
obtaining permission to construct, maintain and operate a hydroelec-
tric plant through the means of a licence or exemption document is
typically a lengthy and expensive process. Pursuant to 18 CFR 4.38
and 5.1 (d), and 16.8, an applicant seeking an exemption or licence
must consult with relevant federal, state, and interstate resource agen-
cies, Indian tribes, and non-governmental agencies.
Comments and suggestions by these stakeholders can be in refer-
ence to fish and wildlife mitigations but also extend to historic con-
cerns, recreational issues, and the aesthetic impact of the project on
the surrounding area. Furthermore, there are provisions that licences
for hydroelectric projects must include conditions to protect, mitigate
damages to, and enhance fish and wildlife resources.
Specific project conditions required for a hydro plant are deter-
mined through a stakeholder consultation process, which typically
includes a series of costly studies. The results may not only indicate
measures to reduce impacts during construction but also permanent
operations measures that may reduce the overall annual energy gen-
eration of the project.
In general the small hydropower community in New England is
a tight group of hard working folks who are environmentally con-
scious. They support fair-minded measures which assist them in con-
structing and operating their sites in a manner that is environmentally

12 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION


friendly. The heart of the issue is very simple. Why does a proposed
50kW hydroelectric project at an existing dam site, with minimal
additional environmental consequences, go through the same lengthy
and expensive process as a new 5MW site? Why isn’t there a stream-
lined process for non controversial projects or low impact projects?
To be fair, FERC itself held a workshop in December 2009 on
small non federal HEPs where these same questions were asked. The
cumulative results were summarised in a FERC press release from
April 2010 which stated that the commission is working to ease the
regulatory burden of small hydro regulations through developing new
online resources, creating simplified licence/exemption application
templates and improving coordination with resource agencies.
F INANCE ISSUES
Acquiring the initial capital investment and overcoming market
instabilities to be able to develop small hydropower are intertwined
issues. Sometimes it is possible to obtain a fixed power sales con-
tract. However, more likely than not, the energy generated is sold to
a larger electric company based upon ISO New England open market
rates. In other words, the value of the energy is based upon supply
and demand, which is subject to wild fluctuation and can be difficult
to predict.
French River Land Co (FRLC) in Ware, Massachusetts owns
the Tannery Pond HEP that sells energy to National Grid for open
market rates. FRLC receives a spreadsheet on a monthly basis that
details, on an hourly basis, the amount of energy generated and the
corresponding rate. It is not unusual to see the value of energy reach
a high of US$300/MWh but a low of US$0MWh. As an example, for
the ISO New England central/western Massachusetts zonal area, the
average value of energy for this year to date (June 2010) is around
US$48/MWh. However, having a potential value of US$0/MWh does
not typically make a financial institution feel comfortable lending a
developer the funding required to get the project off the ground.
Renewable energy certificates (RECs) have assisted in this area.
Typically, a fixed value contract for the RECs is signed for a year or
more. However the average value in the New England area is only
around US$20-30/MWh for financing purposes.
Y ANKEE INGENUITY
Now we come to the Yankee Ingenuity. Large hydropower produc-
ers have the luxury of additional monetary resources, which means
that there is more room for outsourcing of engineering and construc-
tion services. The small hydro producer must be more careful in this
respect, be able to evaluate available resources and make them work
to their advantage. If we look at sites that are making an average
annual energy generation between 100MWh/yr and 2000MWh/yr
RIght: Will moving the Tannery Pond turbine; Below: 18 Inch Rodney Hunt Type
60 being rehabilitated for the Tannery Pond HEP Grant; Below right: Celeste rigging
a 640kW generator into a rehabilitated HEP
WWW.WATERPOWERMAGAZINE.COM JULY 2010
SMALL HYDRO
and assume an average energy value of US$50/MWh with an addi-
tional US$30/MWh in RECs, the average annual value of the site’s
energy is approximately US$16,000 and US$160,000.
Some costs such as environmental studies, engineering, and con-
struction materials are more or less fixed; therefore, others must be
minimised to the extent possible for a small project to be financially
viable. Depending on how one looks at it, the opportunity or chal-
lenge here is in planning and designing a site to use existing structures
and equipment.
In New England, a new dam is very difficult to construct and really
is not a necessary requirement. With tools such as Google Earth and
GIS data, the ability to find existing, unused dams has been greatly
enhanced. Many old mill sites still have extensive civil works such as
penstocks, powerhouses or tailrace structures. Of course, it is rare
to find these structures in a state such that they do not require some
rehabilitation. Yet often, a simple economic analysis will show that
using these structures will drastically increase the economic viability
of small hydro.
Additionally, many hydroelectric facilities today are generating
using equipment that is almost 100 years old and with a surprisingly
high efficiency. Whether it is the equipment found on-site or procured
from somewhere else, used equipment is not something that the small
hydro developer should overlook even if it requires rehabilitation. A
small hydro site does not necessarily require all the bells and whistles
and will likely not be economically successful if anything other than
the bare minimum is installed.
For example, a colleague of ours uses a simple mechanism consist-
ing of a rope, pulley, telephone repeater, and weighted paint bucket as
a regulating mechanism for the governor on his turbine and it works
great. This approach is not for everyone but if the average annual
generation of a site is below a certain threshold, this kind of plan of
attack is critical to success. It should be noted that the primary goals
of some developers is not to generate an income stream. Companies
may be looking to meet green goals or to preserve their long-term
sustainability by offsetting their electrical demand with renewable
energy. These folks will still find benefit in using Yankee Ingenuity
but it may not be quite as critical.
13
 SMALL HYDRO

Technical data on the FRLC projects

Tannery Pond Ashland
Dam type Gravity Dam Gravity Dam
Dam material Laid fieldstones Concrete capped granite
blocks
Dam length 125ft 80ft
Dam height 6ft 12ft
Spillway type Overflow weir w/ Overflow weir w/
flashboards flashboards
View of Ashland hydroelectric project
Year constructed 1913 1925
Impoundment surface 8 acres 12 acres turbine that had poor design characteristics. The turbine could not
area operate efficiently and was removed.
River Millers Squam In 2009, FRLC obtained a US$461,000 grant through the
Massachusetts Technology Collaborative to install two remanufactured
Drainage area 49 square miles 67 square miles
Francis turbine-generating sets and computer controls in the Tannery
Average flow 92 cfs 88 cfs Pond plant. This work will be completed by the end of 2010.
Average annual 4 cfs 15cfs Around the same time, we removed a Leroy-Somners, Hydrolec,
minimum flow semi-kaplan turbine from a mill in New Hampshire. The turbine, hel-
Bypass reach length 760 ft 320 ft ical gearbox, and generator are located within an oil-pressurised bulb,
in a flanged pipe section, mounted on a penstock. The unit was thor-
Minimum bypass flow 21 cfs 32 cfs
oughly dilapidated and required a full rehabilitation. Unfortunately,
Installed capacity 189kW 84kW parts and mechanical specifications for the unit were not available.
Turbine type Unit 1 – 38” Rodney Hunt Unit 1 – 36” Leroy It took almost a year of part-time work to rebuild the unit with new
Type 80, Unit 2 – 48” Somners Semi-Kaplan roller bearings, gears, and various other parts. The rehabilitation was
Leroy Somners Semi- completed in 2005 and the site successfully produced electricity.
Kaplan
Generator type Unit 1 – 1800 rpm Unit 1 – 1800 rpm
induction generator, Unit induction generator
S EARCHING FOR SMALL HYDRO
2 – 900rpm induction During the same period we were looking for other small hydroelec-
generator tric projects. Our limited financial resources restricted us. However,
Hydraulic capacity 230 cfs 79 cfs we located a potential project on the Squam river in Ashland, New
Hampshire, which we were able to purchase through the graces of
Average annual 510,000kWh/yr 420,000kWh/yr
generation
owner financing in 2005. The Ashland hydroelectric project is an
84kW FERC licensed project constructed in 1984. The station had
Regulatory status FERC exemption from FERC exemption from originally been under a generous power sales contract from the
licensing licensing
1980s that set the value of energy at about US$20/MWh; but this
had expired previous to our purchase.
R EPOWERING SITES We were fortunate though to negotiate a power and sales con-
tract with the Ashland Light Department, which included provisions
This is the business model that we have built as a result of our limited for the department to conduct limited operations. The station has a
economic resources and our abundance of hydropower knowledge. Leroy Somners, Hydrolec tube turbine, rated at 84kW on 5.5m of net
We became involved in hydropower at a young age because we grew head. The unit had been struck by lightning, disassembled, and left in
up in and around hydroelectric power plants. When we were chil- a field for almost five years.
dren, our father would bring us to various HEPs and we would do Our 18-month part-time rehabilitation of the turbine included the
small tasks to assist with both engineering and hands-on site reha- replacement of just about every mechanical and electrical component
bilitation tasks. As we gained more of a grasp on exactly what it was in the unit. A fair amount of guesswork was involved since no parts,
that we were doing, we gained more interest and enthusiasm for the plans, or specifications were available from the original equipment
hydroelectric field. manufacturer. But with the use of our father’s machine shop, we were
Towards the end of our high school careers, our father and his able to repair the unit and it began generation in November of 2007.
partner had acquired larger power plants in the 1200kW to 4000kW
range. The Tannery Pond hydropower station in Winchendon,
Massachusetts was originally licensed for 189kW and it was quickly E NJOYING THE CHALLENGE
becoming obsolete in comparison to a 4000kW project. We wanted As our skills and knowledge expanded, our involvement in the
to become more involved in hydropower and eventually took over engineering portion of hydroelectric power plants also expanded.
French River Land Company and the Tannery Pond HEP. The We both enjoy the challenge and joy of sharing our hydroelec-
Tannery Pond facility had not produced electricity prior to us taking tric knowledge with others by finding economical solutions for
over the project. The station posed many challenges but we perse- the development of small hydropower throughout New England.
vered and were able to repower the site. There is once again a small hydro renaissance occurring not only
When we took over the Tannery Pond project, the station had a in New England but also throughout the county and it is an excit-
FERC exception, an interconnection, two non-operational turbine- ing time to be involved in the industry. IWP & DC
generating units and all the necessary civil works such as the dam,
intake, trash racks, and powerhouse. The first unit was a Rodney
Hunt 96cm diameter runner, type 80 Francis turbine, coupled Celeste N. Fay, GZA Geo-Environmental, Email:
through a 200hp Paramax 90 degree gearbox, to a 150hp-1800rpm cfay0570@yahoo.com and William D. B. Fay, French
induction generator, which had the potential to produce 80kW on the River Land Company. Email: wfay@frenchriverland.com
3.4m of available head. The second unit was originally a homemade www.frenchriverland.com
14 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
WKV_86x134_E_4c_RZ 07.07.2010 12:37 Uhr Seite 1

Turbine & Alter nator Manufacture

  
 
 





 
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Governors Tel. + 49 7685 9106 - 0
Switchboards Fax: + 49 7685 9106 - 10
gugler 31/3/09 14:10 Page 1 www.wkv-ag.com 



 










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 SMALL HYDRO
Bringing water power to the poor
Development charity Practical Action believes that the right idea, no matter how small,
can change lives. Here Teodoro Sanchez shows how micro hydro schemes are helping to
transform lives around the world
Civil engineering for a micro hydro system in Bocatoma, Peru
F
OR many families around the world, access to modern
energy is a pipedream. People are forced to cook on open
fires that fill their homes with toxic smoke and as the light
fades each evening so too does the possibility of adults
working into the evening, children studying, and families cooking
safely in well-lit, clean homes.
This lack of access to energy traps people in a constant cycle of
poverty that they unable to break free from.
Over 1.6B people – almost one third of the world’s population – have
no electricity. In Africa four out of five families live without electricity,
according to international development charity, Practical Action.
C HANGING LIVES
Practical Action believes that the right idea, however small, can change
lives. The charity works with some of the world’s poorest women,
men and children helping to alleviate poverty in the developing world
through the innovative use of technology and facilitating access to
energy for poor communities through a variety of means, enabling
them to lift themselves out of poverty and change their lives.
The charity was founded in 1966 by radical economist E.F.
Schumacher who strongly believed in using small scale, low cost
and appropriate ideas to change people’s lives and that ethos still
rings true today. Specifically, Practical Action is working to imple-
ment small scale renewable energy schemes in rural communities
that aren’t linked to the national grid. It is enabling them to be
involved in the construction and management of renewable projects
16
and provide a sustainable source of energy for the first time that will
safeguard future generations.
M ICRO HYDRO SYSTEMS
Practical Action has developed small scale micro hydro schemes with
communities in Peru, Nepal, Sri Lanka, Kenya and Zimbabwe as
well as in Nicaragua, Guatemala, El Salvador, Bolivia, Mozambique
and Malawi as part of the charity’s extension work from its country
offices. These systems, which are designed to operate for a minimum
of 25 years, are usually run-of-river systems.
A system with a capacity of 6kW is big enough to drive a mill and
provide electrical lighting for up to 20 families.
As well as driving a generator to provide electricity, micro hydro is
also used in these areas to supply power to remote villages via recharge-
able batteries that can be used for lighting and to play small radios and
power TV sets. Lighting is one of the basic needs of poor people and
they can have much better and safer lighting at a lower cost through the
use of this technology by replacing candles and kerosene lamps.
Practical Action is different to other development charities in that it
uses a participatory approach in all of the work that it carries out in
the communities. Engineers from the charity will enter a community,
assess its needs and resources and also determine the most appropriate
technology for the particular conditions. When micro hydro is decided
upon as the best option, decisions will be made following calculations
to determine the most appropriate materials to use and how much the
scheme is going to cost based on the number of families it needs to
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

serve, the potential growth of the community and their possible eco-
nomic development. It’s also necessary to assess the capacity of the
country as to whether national industry can produce equipment and
components that will fit the needs of the project or is already produc-
ing them. If it is the case that presently there is not such a capacity,
Practical Action provides technology and technical assistance to enable
local manufacturers to produce the equipment required.
Once a technology is decided upon and manufactured, the tech-
nology is implemented and then the training begins. Members of
the local community will be selected in a participatory manner and
trained to manage the operation and maintenance of a micro hydro
system and the community must decide how they will pay for its
upkeep – repairs, replacement components etc. A tariff scheme will be
devised by the community with Practical Action’s help, ensuring that
the scheme will be sustainable and last for many years to come.
C ASE S TUDIES
Chipendeke, Zimbabwe
One such project has recently been implemented in Chipendeke,
Zimbabwe, situated along the Wengezi river. This micro hydro scheme
provides 25kW of electrical power which serves almost 130 families.
This quantity of energy provides enough electricity for domestic needs
such as lighting, as well as providing power to a health centre, school
and numerous small businesses being run by community members.
The cost of this scheme ran to Euros 87,000 (US$108,000) and
85% of the cost was part funded by the EU. The other 15% was
funded by the community contributing with labour and local materi-
als. With the initial investment taken care of, the community is only
left responsible for paying for management and maintenance of the
system which consists of a small payment each month.
Chorro Blanco, Peru
Chorro Blanco is an isolated community in the Cajamarca region
of the Peruvian highlands. The cost of rural electrification through
the national grid would probably have meant that Chorro Blanco
remained without modern energy for many generations. The supply
of micro hydropower provided electricity for 60 rural families and 90
families from neighbouring villages for the first time in their lives. The
scheme provided electricity for domestic and public lighting, small
businesses and battery charging.
The scheme comprises the intake weir, conveyance ditch, settling
basin and forebay tank, penstock and anchors, powerhouse and dis-
charge channel. The local community is also making a sizeable con-
tribution to the manpower requirements of the project, transporting
materials to the site and assisting with labour.
This scheme generates 20kW of electrical power; it uses a locally made
Pelton turbine, a penstock made of PVC and an electronic load control-
Children use electric light provided by the micro hydro system to study after dark
WWW.WATERPOWERMAGAZINE.COM JULY 2010
SMALL HYDRO
ler. The electricity is transported from the powerhouse to the village using
1.6km mid-tension lines and set-up and step-down transformers.
C HALLENGES
Working with poor communities, and sourcing materials, within a
developing country presents a number of social and cultural obstacles
to Practical Action staff when implementing micro hydro schemes.
The poverty of the families involved leads to issues with funding par-
ticularly when there is no outside investment from local governments
or bodies, and many families can struggle with budgeting for mainte-
nance payments for their systems.
In rural communities that use energy sources such as kerosene or
biomass for their needs, fuel is typically purchased in small quanti-
ties. Families have never needed to budget and commit to a regular
monthly payment which can be a difficult concept to adapt to but is
essential to ensure the sustainability of the schemes. To resolve this,
extensive training is undertaken within the communities to explain
the costs and implications of sustaining a micro hydro system.
T HE FUTURE
Practical Action works continually with staff based in its country offices
identifying opportunities and communities that can benefit from small
scale renewable energy schemes. The charity works to engage with local
governments and decision makers to source funding and continue its
work. Practical Action adopts a ‘bottom-up’ approach where local gov-
ernments are encouraged to learn from the technologies implemented,
adopt them and replicate them across the country once they can see the
difference they are making to people’s lives.
G ET INVOLVED
Practical Action is currently campaigning for ‘energy for all’ by 2030.
Modern energy transforms lives; improves health and education and
lifts people out of poverty. The charity will be developing a group of
energy ambassadors towards the end of the year, to find out more
email campaigns@practicalaction.org.uk . IWP & DC
Teodoro Sanchez is an Energy Technology and Policy
Adviser at Practical Action.
Email: Teodoro.sanchez@practicalaction.org.uk.
For more information about Practical Action’s work in
renewable energy around the world please visit
www.practicalaction.org.uk.
A woman sits by the forebay tank for a new micro-hydro system, Peru
17
 SMALL HYDRO

Energy recovery from

public water systems
Public water systems are often an ideal application for small hydro systems. The existing
water supply provides a finished intake and penstock, and in many cases a pressure
reducing valve can be bypassed with a hydro turbine that generates a positive return on
investment for the community. Michael Maloney reports.

T
APPING into the wasted energy of public water systems
doesn’t typically generate large amounts of power: a few
hundred kilowatts at best. On the other hand, the exist-
ing infrastructure already provides almost everything
needed for a hydro system except the turbine/generator set. Public
utilities routinely bleed off excess pressure that could be put to
work simply by opening a coupling and bolting in a turbine. Even
though power output may be nominal, this low cost solution can
quickly pay for itself.
Unlike most hydro systems, however, energy recovery systems are
often subject to unusual constraints. For example, community water
usage directly affects flow, which can vary dramatically over the course
of a day. In addition, it is often necessary to maintain water pressure
at the turbine output to ensure adequate pressure for the community.
These factors can complicate the selection of turbine equipment.
It is also important to remember system priorities. The highest pri-
ority is uninterrupted water supply to the community, with power
generation coming in a distant second. These priorities can collide at
times. For example, if an electrical problem abruptly trips the genera-
tor offline, water must continue to flow to the community even though
the turbine/generator may be suddenly freewheeling under no load. A 35kW Pelton-type SOAR GPRV installed for the County of Hawaii
Beyond technical issues, regulatory hurdles can significantly Department of Water Supply
delay an energy recovery project, if not kill it entirely. Conventional
wisdom would suggest approval would come quickly, since the entire In contrast, reactive turbine types such as Francis and Kaplan oper-
system is usually a simple revision of plumbing. But these low impact ate well in a pressurized environment, since they are never exposed
projects are subject to the same regulatory processes as larger scale to the atmosphere. As long as there is a pressure difference between
hydro systems, in the US requiring FERC permitting and – surpris- turbine input and output, reactive designs can produce power.
ingly – the need to deal with environmental opposition. Unfortunately, they are less forgiving of wide swings in flow. Below
SOAR Technologies specialises in solving these types of problems 50% of design flow, efficiency drops dramatically.
for communities. The company provides specialised turbine systems, Then there is the issue of priority. By definition, community demand
as well as assistance with feasibility assessment, technical design, and determines flow rate; the power generation system cannot alter flow
the long journey toward regulatory approval. Over the past few years, in any way. Water must continue to flow unimpeded even when the
SOAR has installed energy recovery systems in Hawaii, Vermont, generator is suddenly thrown offline. Impulse turbines have the advan-
Oregon, and other locations across the US. tage here; a deflector shield simply directs the stream of water away
from the runner without affecting flow. Reactive turbines are more of
a challenge since the flow of water always wants to spin the runner. In
T ECHNICAL CHALLENGES addition, the resistance of the runner itself has an effect on flow.
Two major issues are commonplace with water supply systems: varia- All of the energy recovery systems installed by SOAR are designed
ble flow and pressurised distribution to the community. These factors to run in parallel with the existing water system. This allows the tur-
create a challenging dilemma for hydro systems designers, especially bine/generator to be taken offline for maintenance without impacting
when encountered on the same project. the community water supply. Most systems use hydraulic actuators,
Variable flow, for example, would suggest the use of impulse tur- allowing switchover to be manual or automatic.
bines such as Pelton or turgo. With a broad efficiency curve, impulse
turbines can often deliver good performance down to 10% of design
flow. But a pressurised output complicates matters. Impulse turbines, D EVELOPING THE GPRV
by definition, run in open air and typically employ a tailrace that is In 2004, SOAR participated in a research project to develop a gen-
not easily pressurised. erating pressure reducing valve (GPRV). SOAR worked with the

18 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

 SMALL HYDRO

A line drawing of a Pelton-type GRPV. The SOAR Pelton-type GPRV pressuris-

es a sealed runner chamber with compressed air to maintain water pressure Air in
at the outlet Water in

California Energy Commission and San Diego State University to

develop a simple method for replacing existing PRVs with small
hydro systems. Over the course of several months a number of work-
ing test models were constructed to produce a preliminary design for
a pressurised impulse turbine system. SOAR later patented this design Deflector
for commercial production.
The original GPRV was essentially a Pelton turbine enclosed in a
sealed housing to maintain positive pressure at the tailrace. As with Adjustable
needle valve
all Pelton designs, the turbine runs in air, but the air is compressed
within a sealed chamber. SOAR teamed with Canyon Hydro to man-
ufacture this new design, and installed the first GPRV unit in a water
system on the island of Hawaii.
This early version of the GPRV employed a vertical (horizontal
shaft) Pelton runner, coupled with a standard air compressor to
pressurise the system. The expected power output was achieved but
there were significant issues with air entrainment. Air in the water is
not harmful; in fact, it tends to improve the water treatment process Pressurized
downstream. But since air must be compressed to run the system, chamber
and compressors require energy, any air loss down the pipeline is
essentially a loss of efficiency. With the vertical runner design, the Water
compressor was running almost constantly to replenish lost air.
To better manage air entrainment, SOAR engineers ran extensive
computational fluid dynamics simulations, resulting in development
of a new design that uses a horizontally-oriented (vertical shaft)
Pelton runner for significantly improved operation. Using a horizon-
tal runner, the water tends to spin its way out of the turbine, helping Water out
to separate the air before the water exits down the pipeline.
SOAR has also developed reactive versions of the GPRV using
Francis and reverse-pump designs. These fully immersed turbines
simplify pressurised operation but are constrained to a much nar- Whenever public water and public power come together, approvals
rower operating range for changes in flow. In addition, special provi- from both FERC and the local power company are required. Currently
sions are necessary to accommodate continuous flow even when the the lead time for gaining FERC approval of conduit projects is about
turbine trips offline. six months, and the FERC application itself usually takes at least
Flow through a Francis turbine changes drastically when generator two months to prepare. Before submitting the application, multiple
load is removed. A reactive turbine in an over-speed condition tends agencies, environmental groups, tribal leaders and other stakeholders
to choke flow, an unacceptable scenario in a water supply system. To must reach agreement.
alleviate this problem, SOAR developed a multi-stage Francis design Unfortunately, the cost to obtain regulatory approval sometimes
to maintain nearly constant flow in any situation. makes it impossible to justify an otherwise viable project. But good
The SOAR Francis GPRV uses a modified impeller design and uses news may be forthcoming. FERC has indicated that it will streamline
two to five Francis runners in series. Head pressure determines the and simplify applications for energy recovery projects.
number of runners in the system. Because space is often at a pre- Most of the inquiries SOAR receives originate from local water
mium in existing water systems, runners are oriented vertically to save system operators. These are the hands-on water experts who know
room. Unlike conventional Francis turbines, the water inlet and outlet their systems and can identify opportunities for energy recovery. Even
are aligned to facilitate easy installation into an existing pipeline. so, nearly every project requires buy-in at the executive level, and the
cost must always be justified. A good part of SOAR’s effort goes into
pulling many disparate groups together to ensure project success.
D ETERMINING PROJECT FEASIBILITY
The growing global focus on green energy and sustainability has
sparked a sharp spike in interest for energy recovery systems. Water L OOKING AHEAD
supply systems are the most common application; however, there is Worldwide interest in energy recovery appears to be growing, and
also potential for wastewater system applications. SOAR anticipates more projects will emerge as word spreads between
Wastewater systems are generally more difficult to cost justify. They water districts. Green energy, despite the economic slowdown, still
tend to be low head, high flow environments, which require physi- promises strong growth – especially on the heels of the disaster in
cally larger turbine systems to handle the additional flow. Because the Gulf of Mexico. As technologies such as the GPRV continue to
physical size bears a direct relationship to turbine cost, SOAR has yet improve, and assuming the regulatory process is further streamlined,
to evaluate a wastewater application that forecasts a positive return future energy recovery projects should be easier to justify and faster to
on investment. implement. IWP & DC
When invited to assess the feasibility of a potential project, SOAR
focuses on four key parameters: head, flow, flow duration (variabil-
ity), and regulatory process. Most of our systems have been installed Michael Maloney is president of SOAR Technologies,
for use with a net metering plan, where generator output offsets some a hydropower design and project consulting firm
of the power normally purchased to run the plant. In effect, net meter- based in Washington State, US.
ing pays the power producer retail rates for electricity, substantially Email: mmaloney@soartechinc.com.
accelerating system payback. www.soartechinc.com
Unfortunately, regulatory requirements are often a major obstacle.

WWW.WATERPOWERMAGAZINE.COM JULY 2010 19

 TUNNELLING
Niagara progress
Progress is pushing ahead on OPG’s
Niagara power tunnel after earlier geological
difficulties. By Patrick Reynolds
B
Y last moth more than two-thirds of the Niagara power
tunnel had been excavated by design-build contractor
Strabag for Ontario Power Generation (OPG) using a hard
rock TBM, which is driving along a realigned route fol-
lowing earlier geological difficulties. All activities had resumed by
June following a stop for maintenance and to launch the concret-
ing work for the permanent arch lining over the tunnel invert.
The 14.4m diameter main beam TBM, manufactured by Robbins, had
bored more than 7km of its 10.2 km long power tunnel route by early
this month, says OPG’s project director, Rick Everdell. In its first quarter
results, to 31 March, the utility reported that the TBM had advanced
almost 6.5km – progress of 2.7km over the previous 12 months.
With the alignment having been raised by 45m, the TBM is out
of the Queenston shale that had proven troublesome earlier in the
project and the machine is mostly now meeting whirpool sandstone
with tunnelling conditions further improving. “We are happy with
the current rock conditions and ground support system, as we haven’t
been short of challenges in the past,” said Strabag’s project manager,
Ernst Gschnitzer.
Niagara Tunnel Project will be the third headrace below Niagara Falls
and will help make use of the presently untapped allocation in Canada’s
share of the water under the 1950 Treaty with the US. The 12.8m i.d.
tunnel will convey a further 500m3/secs of water to the Sir Adam Back
complex and add an extra 1.6TWh/year of electricity generation.
The TBM – ‘Big Becky’ – is the largest hard rock machine manu-
factured and was also the first that Robbins assembled at a project
site using its Onsite First Time Assembly (OFTA) system. The shield
was launched in September 2006 to drive from the outlet and passed
though 10 layers of near horizontal strata, comprising limestone,
dolomite, sandstone and then reaching shale.
Originally, the Niagara Tunnel project was to have been completed
by last month. However, extensive difficulties with overbreak in the
Queenston shale led to delays and safety concerns. OPG has noted
that crown overbreak in the shale was up to 4m in depth into the
20
The Robbins Main Beam was the
first ever TBM initially assem-
bled at the jobsite using OFTA
rock and averaged about 1.5m. Significant modifications were needed
behind the cutterhead to the initial support area for the excavated
rock and worker safety.
The revised ground support system comprised spiles, rock bolts,
mesh, steel straps and shotcrete. The grouted spiles are 9m long to
help contain overbreak, and the rockbolts are 4m long, but in leaving
the Queenston shale the need for the spiles lessened.
Last year the contract between OPG and Strabag was renegotiated
and the tunnel realigned. The revised schedule is for the contract to
be completed by the end of 2013 and the budget has been increased
by about 60% to approximately Can$1.6B (US$1.5B).
Also last year, in the third quarter, a further rock fall happened but
it was far back along the tunnel, more than 3km behind the TBM,
in a stretch of tunnel that had previously suffered from problems of
crown overbreak. No injuries were caused by the incident.
Work to re-complete the circular profile of the tunnel has now
advanced to approximately 1.8km, notes Everdell. By the end of Q1,
reported OPG, the arch lining had advanced 1km and by early May
the activity had progresses a further 300m. Everdell adds that now
there is almost no overbreak in the TBM drive with the crown in
Grimsby sandstone about 7km along the route.
The secondary, final, lining for the tunnel will be formed of 600mm
thick continuously-poured concrete on a waterproof membrane.
Behind the TBM, almost 5km of the permanent lining for the invert
had been completed by May, and the activity has resumed following
the maintenance and outage activities. In its Q1 results, OPG said just
over 4.5km of permanent invert had been placed by 31 March.
Concreting works, to place the upper two-thirds ‘arch’ of the per-
manent lining over the invert began in late May, as planned, says
Everdell, and the activity is making progress.
OPG said the current progress should have the project completed
by the revised deadline and budget, possibly at less cost. The rene-
gotiated contract has incentives on delivery against the revised target
schedule and cost. IWP & DC
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

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 TUNNELLING
E
XCAVATION for the bypass tunnel at the top end of
Glendoe headrace is underway to overcome a rockfall
discovered almost a year ago, barely eight months after
the 100MW hydro project began operations. UK contrac-
tor BAM Nuttall has been brought in to the project to excavate a
short access adit and the water diversion tunnel.
The owner, Scottish and Southern Energy (SSE), said that a 900m
long bypass tunnel is being bored by drill and blast but the scale of
the recovery work for the project is unlikely to see the plant supplied
and generating again before the middle of 2011 – almost two years
after the problem was discovered.
In its 2009-10 Annual Report, issued in late May, SSE said that
BAM Nuttall had been retained to drive the two tunnels and that
work was already underway. However, no specific details have been
given about the local geology, tunnel build or cause of the rockfall.
Above, top left: Inside the Glendoe tunnel works during main construction.
Now, a bypass tunnel is being excavated by drill and blast after a rockfall near
the top of the headrace following completion of the project; Above, right: TBM
before launch to drive most of Glendoe headrace; Above: View of the dam
22
Glendoe bypass
A bypass tunnel is to recover
Glendoe’s headrace following a
rockfall, writes Patrick Reynolds
The Glendoe scheme near Fort Augustus, Scotland, has approxi-
mately 16km of tunnel network, including the 6.2km long headrace.
It was constructed under a design and build contract by the Hochtief
Glendoe JV, led by Hochtief and including Poyry as the designer. The
contract was awarded in late 2005. The client’s adviser is Jacobs.
Geology along the alignment of the headrace comprises quartz
mica schist and quartzite with some minor faults. Most of the head-
race was excavated using a 5.03m diameter open gripper TBM and
some drill and blast, while the rest of the network was bored by
drill and blast.
Depending on local ground conditions, four classes of support were
available for the headrace ranging from minimum of rock bolts plus
mesh and shotcrete, if needed, up to using all of those plus a steel set
full ring. The UCS of the rock at the top end was 30MPa-130MPa.
The successful tunnelling works were completed in early 2008.
When reporting the plant had to be shut down, SSE noted that no
equipment had been damaged in the underground powerhouse as a
consequence of the rockfall at the top of the headrace, which is fed by
a reservoir. The plant has a single, six-jet vertical Pelton turbine and
operates under a gross head of 608m with a flow of 18.62m3/sec.
Investigations in August 2009 revealed the rockfall to be ‘very
substantial’, said SSE. Then, it was anticipating that the plant might
remain shutdown until well into 2010 at the earliest. But by then end
of 2009 it had become clear the scale of repairs would have the plant
out of action until well into 2011. The recovery options all required
significant programmes of work.
In a presentation to the British Tunnelling Society (BTS) during
the construction phase, SSE noted that for risk management at
Glendoe it had a degree of geotechnical risk on the project, three
geologists on site, and the contractor’s tender was based on a ref-
erence ground classification system. It worked alongside the JV
contractor, which produced its own design and was responsible
for the tunnelling. IWP & DC
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
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 TUNNELLING
Beles II – The TBM completing
the headrace drive in Nov 2009
Meeting challenges in Ethiopia
The Beles II and Gilgel Gibe II projects have brought varied tunnelling challenges that were
successfully overcome by TBM manufacturer and subcontractor Seli. By Patrick Reynolds
I
N the last few years, four TBMs supplied by Italian manufac-
turer and tunnelling subcontractor Seli were used to traverse
varied, and often complex, geology in Ethiopia to construct tun-
nels for two major hydro power schemes – Beles Multipurpose
(‘Beles II’) and Gilgel Gibe II. The projects called for a range of equip-
ment, including one of the most advanced shields being used for weak
ground, as anticipated at Beles II, but it was at Gilgel Gibe II that
the most difficult challenges were faced when a double shield TBM
unexpectedly encountered an extremely difficult fault zone.
Seli has worked on a number of hydro projects among the many
sectors it has served over its 60 years of operations, which it celebrates
this year. In Ethiopia, as often elsewhere, it was able to draw upon its
experience as a tunnel subcontractor as well as innovative equipment
provider to have its crews and engineers plan ahead and address the
challenges to be faced, such as the known weak stretch of ground at
Beles II, but also work to cope with and overcome unexpected dif-
ficulties when met, such as on Gilgel Gibe II.
The developer on each project is the Ethiopian Electric Power Corp
(EEPCo), the main contractor was Salini Costruttori and the tunnel-
ling subcontractor – and equipment supplier – was Seli.
B ELES II
Located in Amhara region in north west Ethiopia, the Beles II scheme
takes water from Lake Tana along a 12km long headrace tunnel to
an underground powerhouse of 460MW (4 x 115MW, Francis units)
installed capacity. The plant discharges to a 7.2km long tailrace
which conveys the flow to the river Jehana, a tributary of the Beles.
The underground works on the project also include a 270m long
penstock shaft and a 90m high surge shaft.
24
Beles II - Headrace
Seli selected a dual mode TBM to operate either as a double shield
universal (DSU) or an earth pressure balance (EPB) machine to deal
with the varied geology along the alignment of the headrace. The
majority of the drive – approximately 10km – was in basalt up to
UCS 350MPa with some local faults, but the 8.1m diameter TBM
also had to bore through more than 1.8km of loose soils, described
as lake deposits.
The cutterhead was equipped with 52 x 17” backloading and
recessed discs for the hard rock drive, and switchover to EPB exca-
vation mode took a few weeks to perform on the machine, one of
Seli’s most advanced. The TBM, equipped to deal with squeezing
ground and to undertake face treatment, cost about 15% more than
a standard DSU TBM.
The tunnel is lined with 7.2m i.d concrete rings, each 1.5m long,
formed of 300mm thick segmental concrete segments (6+key).
The TBM was launched in late 2006 and made reasonable progress,
having bored about two-thirds of the tunnel after two years. Before
then, and just after the midway point in the basalt drive, there was
a large, blocky face collapse and recovery work called for polymer
resins from Innotek to fill the void and consolidate the rock mass,
restoring the ground for the drive to continue.
By early 2009 the TBM had switched excavation mode and was
driving through the lake deposits on the final stretch of its journey.
Boring through the lake deposits, the EPB-DSU holed through in
November last year.
Beles II - Tailrace
Geology along the tailrace was reasonably good basalt with some
stretches of agglomerates and tuffites, and overburden was up to
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

Gilgel Gibe II – Breakthrough celebration
at the headrace tunnel in mid-2009
120m in areas, and 250m-370m elsewhere. About 17 major discon-
tinuities, mostly vertical and obtuse to the alignment, were expected
and would present locally poorer ground conditions.
Seli used an 8.07m diameter double shield TBM for the tailrace
drive, which was bored from the outlet end of the tunnel towards the
powerhouse. Like the headrace tunnel TBM, the tailrace machine’s
cutterhead was equipped with 52 x 17” backloading and recessed
discs. The cutterhead drive had a maximum torque of 5,250kNm,
and the maximum design advance rate was 6m/h.
To test the ground ahead of the TBM, the machine is also fitted for
probe drilling and 18 holes through which to extend the drills.
The tunnel lining for the tailrace was the same as for the head-
race tunnel, and the annular gap filled with 8mm-12mm peagravel
and grout.
The TBM was launched in mid-2007 and completed its drive just
less than a year later, in May 2008, and had advanced at an average
of approximately 20m/day, achieving a best day of 36m (24 rings)
and best week of 189m (126 rings).
Tunnelling operations on the tailrace were performed in 3 x 8hr
shifts, 7 days per week with scheduled daily maintenance in the morn-
ings, service extensions and probe drilling when required. In total, the
efficient tunnelling system had 51.9% of the time in excavation and
23.4% in maintenance. Where there was time lost a prime reason was
the blocking effect of the pea gravel from the quarry-derived, angular
aggregate because no local fluvial sources of gravel were available.
With the headrace drive by far the more difficult compared to the
tailrace on Beles II, the Seli tunnellers found the unexpectedly greater
technical challenge came on Gilgel Gibe II, underway at the same time.
G ILGEL G IBE II
Gilgel Gibe II is a 428MW (4 x 107MW, Pelton units) scheme. The
headrace tunnel is smaller diameter but, at 26km, is far longer than
that of Beles II. Geology anticipated along the alignment included five
main rocks – tertiary volcanics, rhyolite, trachyte, basalt and some
dykes. As hard basalt was anticipated for the bores, the TBMs select-
ed for the headrace drives were two 6.98m diameter DSUs that would
bore from either end of the tunnel, on Inlet and Outlet drives.
The tunnel lining is 1.6m long concrete rings of 6.8m outside diameter
and formed of four hexagonal, 250mm thick honeycomb segments.
In the end, the TBMs encountered 24 geological difficulties, or clas-
WWW.WATERPOWERMAGAZINE.COM JULY 2010
TUNNELLING
sified, ‘events’, of varying scale and nature on the headrace excava-
tions – 15 in the Inlet drive and nine in the Outlet drive. By far the
most difficult to overcome was Event 19, on the Inlet drive.
Gilgel Gibe II – Inlet Drive
The drives started well and advanced 10m-20m per day despite
the almost continuous presence of weaker rock and ravelling faces.
Probes were drilled up to 50m ahead of the TBMs, From early on,
though, it was the Inlet drive that was being more hampered by geo-
logical problems – more than three times as many events to deal with
even before Event 19 struck.
Chemical grouting was employed for local face stabilisation
and some bypass digs were required to handle the early events.
Overcutting helped to counter squeezing ground. The geological
events caused hold-ups ranging from a few days to about a month.
But when Event 19 occurred, in October 2006, about 14 months and
just over 4km into the Inlet drive, it was to take more than 20 times
as long to resolve.
The TBM had already stopped when the problem emerged that
would be classified as Event 19. There was a sudden extrusion and
collapse of the face against the TBM, the progressive creep of the rock
mass and crushing force against the shield bent and broke parts of the
TBM, pushing it back more than 600mm and displaced it laterally
by more than 400mm. Probing ahead, with some difficulty, hot and
high pressure mud was found – 40 degrees Centrigrade and up to 35
bar- 40 bar pressure.
Efforts were made first to open a small tunnel over the TBM to
start to release the shield but high rock pressures prevented success.
Next, a Back Chamber was to be opened up fully around the TBM
and also an exploratory adit was excavated to the left from which
boreholes would be drilled to probe the weak rock mass nearer the
fault. However, the mud broke into the adit and overtopped bulk-
head to reach and partly bury the TBM in the main tunnel. Two
further surges of mud soon followed, and measurements showed they
caused rapid reduction in acting pressure.
The tunnellers proceeded by opening up an adit to the right from
which exploratory galleries were formed and much longer boreholes
drilled to reach into and beyond the fault. A programme of drainage
helped to lower the pressure in the rock mass around the TBM head
and the partly constructed Back Chamber around the shield. The adit
was then turned towards the front of the TBM to create space for the
insitu recovery and repair work but could not continue due to loads
and deformation rising, as a consequence, in the Back Chamber.
Eventually, without further excavation and the Back Chamber
completed, the TBM could be fully accessed and was dismantled by
early 2008. Removed to the surface, it was refurbished, rebuilt and
re-assembled, and the cutterhead diameter was increased, to 7.07m,
to help the TBM reduce the squeezing effects from rock mass with
plastic behaviour. The shield was assembled again underground in a
new chamber, located about 400m back from the site of Event 19.
The intervening distance had been backfilled with concrete.
The TBM was relaunched in August 2008 on a bypass route
around the fault, through which resin injection was used to help con-
solidate the clayey basalt and to limit squeezing. Beyond the fault the
TBM rejoined the headrace alignment.
The time and difficulty in overcoming the problem of Event 19
meant that the Outlet drive did much more of the overall excava-
tion than originally planned, and the Inlet drive would only bore the
same distance again beyond the fault zone. The TBMs completed the
headrace excavation in the middle of last year.
With the four TBM bores finished on Beles II and Gilgel Gibe II, and
the machines long gone, there is one remaining challenge at the latter
project. Some months after the operations began at the hydro scheme a
blockage was found in a short section of the headrace, on what was the
Outlet drive. The investigations have revealed the cause to be a rock-
fall at a zone of undetected, weak ground above and well behind the
tunnel lining. It is believed the weak rock mass, comprising some loose
large blocks in weak soil, was agitated by hydraulic pressure variations
induced by the active headrace. Recovery work is well underway and
the repairs to the tunnel should be completed soon. IWP & DC
25
22nd - 23rd September 2010 Innsbruck, Austria

DAM SAFETY
Sustainability in a Changing Environment
'XULQJ WKH ODVW GHFDGHV VLJQL¿FDQW FKDQJHV LQ
personnel resources for design, construction, and
operation of dams occurred in many European
countries, leading to a decrease of skilled practiti-
oners. In contrast to that, the construction of new
dams undergoes a renaissance now, due to the de-
mands of sustainable water and energy management,
whereas the existing dams require increasing efforts
for their maintenance and upgrading in order to sustain
adequate safety and operability.
Therefore, strategic resource management beco-
mes more and more important for the dam industry.
http://www.IECS2010.TUGraz.at
TOPICS
‡ Sustainability of Know How
‡ Public Awareness of Dams and Dam Safety
‡ Maintenance and Rehabilitation
‡ Regulations and Guidelines
‡ Small Dams
‡ Surveillance Practice
PROGRAMM
21st September 2010
Day 1

One main aspect thereby is the transfer of valuable Technical Excursion: Finstertal, Zillergruendl
Evening: Meeting European Working Groups
experience and knowledge from senior practitio-
ners to their successors – an issue crucial for all 22nd September 2010
Day 2

parties involved: dam owners, designers, and contrac-

SYMPOSIUM

Sypmposium
tors, as well as authorities. Accordingly, sustainable Evening Event
management of knowledge transfer between the ge- 23rd September 2010
Day 3

nerations and between science and “day-to-day-busi- Symposium

ness” will be one main scope of the symposium. Evening: Meeting European Club Board

24th September 2010

Day 4

Organized by Technical Excursion: Finstertal, Zillergruendl

ATCOLD
 TUNNELLING

Excavation challenges and

solutions at Jinping I
Shiyong Wu, Ziping Huang and Ge Wang present details on the engineering challenges
and solutions developed during excavation of the underground powerhouse complex at
Jinping I hydropower project in China

T
HE Jinping I hydro power project is located in Sichuan Above, left – Figure 1:
Province in the Southwest of China, about 150km upstream Layout of the power-
of the Jinping II hydropower scheme (Wu and Huang, house and a horizontal
2008). A 305m high arch dam – the highest of its type in geological profile at
the world – has been developed as part of the project, with a total res- EL.1665;
ervoir storage of 7.765Bm3 at a normal water level, and an adjustable Right – Figure 2: 3D
storage of 4.91Bm3. The project construction began in November illustration of the
2005, with the first generator planned to commence in 2013 and the underground power-
whole project construction to be completed in 2015. house complex;
The power plant is designed to have a total installed capacity of Right, top – Figure
3600MW with a large underground powerhouse complex, consist- 3: Topography above
ing of headrace tunnels, a machine hall, bussbar tunnels, a trans- the powerhouse area,
former chamber, two tailrace surge chambers and tailrace tunnels. photo by Ziping Huang;
The layout of the powerhouse complex is shown in Figure 1, with Right, bottom – Figure
horizontal cover 110~300m and 180~350m vertical overburden. 4: Three dominate
The underground powerhouse caverns are set in massive marble with faults intersecting the
faults and Lamprophyre veins crossing the caverns. The in-situ stress powerhouse
in the powerhouse region is high.
The powerhouse caverns include the machine hall (276.99m
× 28.9m × 68.8m; length × width × height) with roof elevation at
1675.10m, the transformer chamber (197.10m × 19.3m × 32.7m)
wall to wall distance of 45m downstream from the machine hall
with roof elevation at 1679.20m, and surge chamber 1# (height of of 45.0°~55.0° and 45.0°~60.0° to fault f13 and f14, respectively,
80.5m, diameter of 41m and 38m upper and lower chamber, respec- and a small angle to NWW oriented joint set. The layout of the pow-
tively), surge chamber 2# (height of 80.5m, diameter of 37m and 35m erhouse complex is designed to be favorable to the stability of the
upper and lower chamber, respectively). The center to center distance surrounding rock masses. However, during the excavation, severe
between the two surge chambers is about 95.1m. A 3D illustration of engineering problems were encountered such as cracks in shotcrete
the caverns is shown in Figure 2. at downstream springlines both in the machine hall and the trans-
The machine hall and the transformer chamber longitudinal axes former chamber. Large deformation in the rock masses in the vicinity
are parallel and oriented N65°W, with angles within 6.0°~ 36.5°, of the faults and overstress of support elements were monitored. As
average of 16.3°, to the direction of the major principal stress, angle a result, the excavation had to be paused in order to add additional

WWW.WATERPOWERMAGAZINE.COM JULY 2010 27

 TUNNELLING
Figure 5 (a) Layer VI in the machine hall, St0+103,
fault f14 wide around 0.8~3.5m, affected zone
of 20m wide in the hanging wall of the fault; (b)
Lamprophyre veins in the northern end wall of
the machine hall
rock support to enhance the stability of the
rock masses.
D ESIGN OF THE UNDERGROUND
POWERHOUSE
Engineering geology
Yalong River flows towards N25 ºE at the
dam site where the V shape deep valley is
straight and narrow and the mountain is over
1000m high above the river. The base rock
outcrops are shown in Figure 3. The rock
formation in the powerhouse area is affected
by tectonic movement with development of faults, shear zones and
joint sets. The powerhouse complex is located in marble of Triassic,
with thin layers of greenschist. Lamprophyre veins invaded
stretching straight over 1000m, with a width of about 2~3m, up to
7m, oriented N60~80°E/SE 
70~80°, developing small faults in
the vicinity of the veins. The body of veins is crushed with poten-
tial instability problems. The bedding of the rock formation in the
powerhouse is oriented N50~60°E/NW 
30~40° dipping towards
the valley. The faults f13, f14 and f18 are NE oriented, as shown in
Figures 1 and 4 and are significant to the stability of the rock masses.
Fault f14 intersects the machine hall and the transformer chamber
having a broken rock zone of 0.2~3m wide and an affected zone of
3~5m in each side of the fault. Locally the affected zone is about 20m
wide, such as on the downstream wall of the machine hall at EL.1640
St. 0+103, where the rock masses are strongly weathered, as shown
in Figure 5.
The major portion of rock masses in the powerhouse is classified
as III in Chinese rock mass classification system with saturated uniax-
ial compressive strength of 60~75MPa, deformation modulus of
6~15GPa. Fault zone and affected zone, lamprophyre zone, intensive
joint zone are classified as IV-V with saturated uniaxial compressive
strength of 25~45MPa, deformation modulus of 0.4~3GPa. After
excavation of Layer VI of the machine hall and the bussbar tunnels
was completed, it was noted that the quality of revealed rock masses
is in line with what assumed during the investigation. The in-situ
stress is high in the area of the powerhouse. The major principal
in-situ stress T1 is in a range between 20~30 MPa with a maximum
of 35.7MPa, oriented N30~50°W/20~35°. Some borehole core discs
are shown in Figure 6 taken during investigation. Other high stress
induced rock phenomena include slabbing in the adit, buckling, etc.
The measured rock strength to in-situ stress ratio is about 1.5~4.
After excavation, large deformations of rock masses were record-
ed and rupturing of rock masses, buckling of shotcrete, and large
increase of load or stress in rockbolts and prestressed cable anchors
took place.
S TABILITY ANALYSIS OF POWERHOUSE CAVERNS
AND ROCK SUPPORT DESIGN
Principle of rock support for the powerhouse caverns
The major engineering geological challenges are the presence of three
faults intersecting the underground powerhouse caverns and the fact
that the rock mass strength is not very high. The following princi-
ples of rock support of the powerhouse caverns are thus considered
and implemented: Make use of rock masses to support themselves by
applying flexible rock support approach, use systematic rock support
with local enhanced support; implement dynamic support approach
to adjust the rock support by systematic analysis combining excava-
tion revealed rock conditions and the monitoring data with numerical
back analysis of the rock deformation.
28
Stability analysis of the rock mass in the powerhouse
The layout of the underground powerhouse caverns was designed to
be favourable to the stability of the surrounding rock masses. One
joint set, set No. 4 oriented N60~70°W/NE(SW) 
80~90°, is nearly
parallel to the walls of the machine hall and the transformer chamber
and thus not favorable to the stability of the walls. The rock masses
are generally stable with potential local instability. At locations with
faults and the affected zones, the lamprophyre veins and intensive
fractured zones the strength of the rock masses are low under the
condition of high in-situ stress, and there is potential local instability
of the rock masses featured by large deformations or rock failures.
Rock support design and the actual rock support
The systematic rock support includes shotcrete, pattern rockbolts,
and prestressed cable anchors. Additional rockbolts or cable anchors
with smaller spacing and longer bolts, steel ribs, weak rock replace-
ment with concrete and consolidation grouting were also applied to
enhance the local stability, as shown in Figure 18.
In the machine hall roof, rock support includes a pattern rockbolts
of 32, L=7.0m, prestressed rockbolts of 32, L=9.0m, prestressed
to 120kN, spacing 1.2m ×1.4m, wire mesh ( 8@20×20cm) shot-
crete C30 and C25 20cm thick. For fault f14, above the springline
at EL.1665.5m, longer rockbolts of L=9m, prestressed rockbolt of
L=12m, spacing at 1.2×1.3m, and shotcrete steel rib were applied.
The rib is 0.5m wide and spacing 1.2m~1.4m, containing two layers
shotcrete C30 with each layer 20cm thick. Each shotcrete rib layer
has main reinforcement rebar of 3 36@20cm, and distribution rebar
22@30cm.
E NGINEERING CHALLENGES AND SOLUTIONS
Excavation progress
The machine hall is divided into 11 vertical layers for excavation.
Excavation of an adit in the roof began in May 2005. In July 2009,
excavation and rock support above Layer VI at EL1640m was com-
pleted. Excavation and rock support of the transformer chamber
commenced in May 2007 and was completed in November 2009.
In July 2009, excavation of the two surge chambers reached Layer
II at EL.1668m. Excavation and rock support of six bussbar tun-
nels between the machine hall and the transformer chamber have
been finished.
Local instability of rock masses during excavation
During excavation, rupturing (Figure 7), buckling, slabbing, slip-
ping or shear along joints (Figure 8) in rock masses took place.
Monitoring data indicated large displacements in extensometers
and that stress or load exceeded the designed limit in some rock-
bolts and prestressed cable anchors. At several locations cracks
occurred in the shotcrete, steel ribs were bent by large deformation
of the surrounding rock masses in the roof of the machine hall, as
shown in Figure 9~10.
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

M ONITORING DATA AND ANALYSIS
Monitoring design and results
Monitoring of rock masses deformation and rock supports stress is
to ensure the safety of the construction and the operation, to provide
effective tools to optimize the excavation and rock support design and
excavation process. At nine cross sections intersecting the machine
hall, the transformer chamber and the surge chambers, and the three
faults, f13, f14, f18, extensometers rockbolt dynamometers and pre-
stressed cable anchor dynamometers were installed (Figure 11).
Up to 4 May 2009, the number of measurement points with displace-
ment less than 10mm is about 57.6% of the total points, the number
of points with displacement between 10~50mm is about 31.9%, while
the number of points with displacement greater than 50mm is about
10.5%. In about 72.8% of the total deformation measurement points
the displacement is less than 30mm. The maximum roof vault settlement
is recorded about 2.2mm, and the maximum displacement in the down-
stream side rib of the roof 7.2mm. At St.0+031, St.0+126 and St.0+196,
at EL.1659 and EL.1651, upstream side wall of the machine hall there
are four points with displacement larger than 20mm. At St. 0+126, in
the vicinity of fault f14 a displacement of 41.6mm was measured. In the
downstream wall of the machine hall, there are 15 points with displace-
ment larger than 20mm. There are seven points in the machine hall with
displacement at rock surface larger than 50mm, with a maximum of
96.8mm. Among five points near the downstream springline there are
two points in the vicinity of faults f14 and f18, three points related to
joints of fissures, the deformation developed within 0~9m deep (Figures
12 and 14). Another two points with displacement more than 50mm
are at EL1650 and EL.1659, between Unit 3#~4#, in the downstream
wall where the rock is integrated, the large deformation develops up to
12m deep in the rock mass. This is probably caused by high in-situ stress
(Figures 13 and 15). Normally the deformation takes place within the
first 5m in the rock masses.
In the transformer chamber the number of measurement points
with displacement in three categories of less than 10mm, between
10~50mm and larger than 50mm at rock surface is about 33%, 48%
and 19% of the total measurement points, respectively. The number
of points with displacement less than 30mm is about 70% of the total
measurement points. The chamber roof settlement is less than 5mm.
Most measurement points in the upstream wall show displacement
less than 12mm, large displacements up to 55.7mm were monitored
between Unit 4#~6# at EL.1668. In the downstream wall at the same
elevation, Unit 2#, 5# and 6#, displacement between 28.5~57.5mm
with a maximum value of 132.7mm at Unit 5# were monitored.
There are two and three points with displacement larger than 50mm
at rock surface in the upstream and downstream walls, respectively.
WWW.WATERPOWERMAGAZINE.COM JULY 2010
TUNNELLING
In the upstream wall, the two points were located in integrated rock
masses, large deformation develops down to 12m in the rock (Fig 16).
After excavation of Layer II in surge chambers 1# and 2# (EL.1688
to EL.1668), the doom settlement is about 0.1mm and 4.7mm,
respectively. The maximum wall displacement in surge chambers 1#
and 2# is about 11.5mm and 47.9mm both in the upstream wall at
EL.1668, respectively, where the fault f18 and lamprophyre veins
intersect the chambers.
Among 88 rockbolt dynamometers in the machine hall, with stress-
es in ranges less than 100MPa, 100MPa~200MPa, 200MPa~300MPa
and larger than 300MPa, the corresponding percentage of measure-
ment points to the total points are 54.5%, 19.3%, 8% and 18.2%,
respectively. There are six rockbolt dynamometers in the roof rib
and springlines of the machine hall, and 10 in the walls exceeding the
measurement limit (300MPa). The measurement points are within
2~6m deep in the rock.
There are 18 rockbolt dynamometers in the transformer cham-
ber, with stresses in ranges less than 100MPa, 100MPa~200MPa,
200MPa~300MPa and larger than 300MPa, the corresponding per-
centage of measurement points to the total points are 50%, 22.2%,
16.7% and 11.1%, respectively. The measurement points are within
2~4m deep in the rock.
In the surge chambers there are 18 rockbolt dynamometers,
with stresses in ranges less than 100MPa, 100MPa~200MPa,
200MPa~300MPa and larger than 300MPa, the corresponding per-
centage of points to the total measurement points are 44.4%, 16.7%,
22.2% and 16.7%, respectively.
There are 32 prestressed cable anchor dynamometers in the
machine hall, among which about 76% dynamometers the measured
load exceeding the locked value, 38.6% of the dynamometers exceed-
ing the designed capacity, with a maximum exceeding load at St.
0+42.7, EL.1662.5, downstream wall. Of the 24 cable dynamometers
in the transformer chamber, about 75% measured load exceeding
the locked value, and 33% of the dynamometers exceed the designed
capacity, at EL1664.5 (3) and EL.1661 (5) both in upstream and
downstream walls of the transformer chamber. From the load devel-
opment curve it is noted that the load tends to stable (Figure 17).
A NALYSISON THE LARGE DEFORMATION OF ROCK
MASSES AND OVERSTRESS IN BOLTS AND CABLES
The large deformation of the surrounding rock masses in the caverns
may be related to the engineering geological conditions and the exca-
vation and rock support performance. The saturated uniaxial com-
pressive strength of intact marble is not high while the in-situ stress is
significant. The ratio of strength to stress is between
2~3.8, even as low as 1.7 locally. According to a
Chinese Standard, in-situ stress in the powerhouse
region belongs to high and extreme high locally.
Observations made on the behavior of the rock
masses during the excavation are in line with the
descriptions of the rock under the same geological
conditions in the Standard, including rock ruptur-
ing, slabbing and fracturing. Therefore, large defor-
mation in integrated rock masses may be expected.
In the vicinity of the faults f13, f14 and f18 in
the machine hall and the transformer chamber, the
quality of rock masses in the fault and the affected
zones is poor. Even though there is no large rock
block identified from combination of faults and
joints and fissures. Geological investigations indi-
cated that some combination of joint sets might be
Far left: Figure 6 Borehole core discs from the left bank
indicating high in-situ stress;
Left, bottom: Figure 7 (a) Rupturing of rock in the down-
stream side rib of the machine hall at St.0+150
Left, top: Figure 8 Sliping along a joint indicated by shear
movement of the blasting borehole on the upstream wall of
the machine hall at St. 0+150m and EL1654–1650
29
 TUNNELLING
unfavorable to the stability of high walls. Thus the geological struc-
tures may also lead to large deformation of the surrounding rock
masses.
The monitoring data shows that after excavation large deformation
of rock masses develops relative shallow where the geological struc-
tures presented while large deformation develops deeper in integrated
rock masses with higher in-situ stress.
Obviously the large deformation in rock masses caused the over-
stress in bolts and prestressed cable anchors. It may be necessary to
analyze a proper support pressure that allows certain deformation
of the rock masses while the stress or load built up in the bolts and
prestressed cable anchors is limited to a certain extent.
M EASURES TO CONTROL THE LARGE
DEFORMATION OF THE ROCK MASSES
Rock support measures are requested to limit the shallow deforma-
tion in the rock masses by reinforcing the loosened rock masses and
thus prevent it developing further inside the rock, creating a rein-
forced deformable rock ring to support rock inside and thus ensure
the overall stability of the surrounding rock masses.
To control the large deformation in the vicinity of faults in the roof
where large displacements were monitored, rock support measures
include systematic rockbolts, shotcrete, double layers rebar reinforced
shotcrete rib, systematic prestressed cable anchors, and fault anchors.
Figure 11 shows the concrete beam and prestressed cable anchors in
the downstream side, at springline and upper wall of the machine
hall. The monitoring data indicates that the displacements of the rock
and stress of the rockbolts and cable dynamometers tend to be stable
after the installation of the extra rock support.
At locations with large deformation in the walls of both the
machine hall and the transformer chamber, the loosened rock
blocks were removed and heavy rock support was applied such as
steel fibre shotcrete, random rockbolts, prestressed rockbolts, pre-
stressed cable anchors. At some locations when the displacement
did not converge prestressed, so many cable anchors were installed
that there was no room to install any more, see Figure 18. Finally,
the rock masses are stable.
30
D ISCUSSION
After excavation of Layer IV in the machine hall, due to large defor-
mations, the excavation of the machine hall had been paused for
about half a year in order to apply extra rock supports. An option
to avoid large deformation of walls could be that the high wall was
designed as an arch shape rather than a straight line. There might be
less deformation due to smaller loosened zone in the shallow region
and thus probably such heavy rock support might be not requested.
Much smaller displacements in the roofs of the caverns provide some
evidence on the design alternatives of the wall. Numerical modelling
could have been applied to simulate this option. Economical evalua-
tion should be carried out to compare the options on cost and exca-
vation progress. For the long term stability of the surrounding rock
masses the arch shape walls may be favorable.
Delay of the rock support after excavation may have partly contrib-
uted the large deformation. After blasting, if the rock support was not
installed in time, the joint may open and blasting induced fissures may
further develop and cause larger loosening zone. This is against the prin-
ciple of NATM to make use of the reinforced rock ring to support the
surrounding rock masses themselves. And thus large deformation took
place, with high stress built up in rockbolts and cable anchors.
With regard to rock bolting, under the conditions of low strength
stress ratio large deformation of the rock masses may be expected,
end anchored rockbolt combining grouting should have been consid-
ered, such as CT-bolt widely used in Norway, where full grouting of
the bolt is applied later. The cable anchors were probably prestressed
too much to stand for further support pressure due to further defor-
mation development. Therefore so many prestressed cable anchors
were overstressed beyond the designed capacity. The support was
probably too stiff to accommodate future displacement of the rock
masses. Numerical modeling and analytic study may be useful to
study a proper prestress load level and timing of installation of the
cable anchors combining a study on an acceptable and reasonable
displacement magnitude of the rock masses in caverns.
C ONCLUSIONS
The geological challenges of the Jinping I hydro power project under-
ground powerhouse are the presence of faults and lamprophyre veins
intersecting the caverns, high in-situ stress in the region, integrated
marble and thus low strength to stress ratio. During excavation large
deformations of the rock masses occurred, high stresses built up in
some rockbolts and prestressed cable anchors in the machine hall
and the transformer chamber. The monitoring data shows that large
deformation of rock masses develops relative shallow where the geo-
logical structures presented while it develops deeper in integrated rock
masses where the high in-situ stress plays important role.
The stability of the caverns was under concern and the excava-
tion was paused for months in order to apply extra rock supports to
enhance the reinforcement of the roof and the walls of the caverns.
The additional rock supports were heavy and effective. At present the
monitoring data indicate that the displacement in rock masses and
stresses in rock supports are stable. Observations also confirm that
the surrounding rock masses are stable overall.
The additional rock supports were costly and impacted the con-
struction progress considerably. What we could learn from the
excavation and the design may be meaningful. Given that a large
deformation of the surrounding rock masses is expected, a design of
arch shape walls rather than straight high walls may lead to smaller
displacement of the walls and reduced amount of rock support, even
though the excavation work may increase. Prestress level and timing
of installation of the cable anchors could have been optimized in
order to save cost and to increase the reliability of the rock support
elements, and secure the long-term safety of the support and stabil-
ity of the powerhouse caverns during operation. Rock support of
end anchored rockbolts and shotcrete installed in time is critically
Left top and bottom: Figure 9 (a) Spalling of shotcrete at St. 0+170 down-
stream rib of the machine hall roof; (b) Spalling of shotcrete in detail;
Left, small image: Figure 10 Bending of the reinforced shotcrete rib in the roof
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
 TUNNELLING

important in forming a reinforced rock ring to ensure the rock

masses support themselves, and thus prevent loosen zones For further information, please contact the authors via email:
deteriorating further into rock masses. IWP & DC Ziping.Huang@norconsult.com

References
Wu, S. and Huang, Z. 2008. Tunnel vision at Jinping. International Water Power &
Dam Construction. September 2008. Pp17-18.

CHIDI 05.2009, Stability analysis and rock support review report on the surrounding
rock masses of Jinping I hydropower project underground powerhouse caverns.

CHIDI 09.2003 Feasibility study of Jinping I hydropower project.

Above: Figure 18 – Enhanced rock support in the downstream side roof,

springline and upper wall of the machine hall, photo by Ziping Huang

Left: Figure 11 – Layout of the monitoring cross sections, 1-1~9-9 in the powerhouse
complex, with the location of faults; Above: Figure 12 – Displacement distribution in
extensometers at Cross Section 4-4, in the machine hall and the transformer chamber;
Below: Figure 13 – Displacement distribution in extensometers at horizontal profile at
EL.1666, in the machine hall, transformer chamber and surge chambers; Left, below:
Figure 14 – Displacement curve with M6ZCF-Z3 at St.0+95.10 downstream wall of the
machine hall, in the vicinity of fault f14; Bottom, left: Figure 15 – Displacement curve
with M4ZCF3-5 at St.0+79.20 downstream wall of the machine hall at EL.1650, inte-
grated rock mass; Bottom, middle: Figure 16 – Displacement curve with M4PS2-8 at
St.0+126.8 downstream wall of the transformer chamber at EL.1668, integrated rock
mass in the vicinity of fault f18; Bottom, right: Figure 17 – Load vs. time of a cable
dynamometer at EL1661, downstream wall of the transformer chamber

WWW.WATERPOWERMAGAZINE.COM JULY 2010 31

 NEW TECHNOLOGY
IWP&DC looks at
Atlas Copco’s latest
developments in
generation technology
The generation game
N
EW from Atlas Copco is the QAS 500 generating set which
offers dual frequency operation rated at 500kVA at 50Hz
(571kVA at 60Hz). It also has noise reduction and envi-
ronmental protection features for continuous on-site power
in industrial, public utilities and construction applications.
The QAS range, comprising a wide variety of models rated between
14–571kVA has been designed for fast, easy and safe transportation
and on-site handling on virtually any unprepared surface.
Housed in a noise attenuated enclosure made from zinc plated steel
and painted with powder coating paint, the QAS 500 meets a sound
power level (LWA) of 99 dB(A) at 50Hz; making it suitable for appli-
cations in noise sensitive areas. The enclosure also provides optimum
resistance against corrosion ensuring that it remains in good condi-
tion and retains an improved resale value, says the company.
An integrated lifting structure on the enclosure has been designed
to contribute to the total sturdiness of the set to ensure safe and effi-
cient handling. It is positioned in the centre point of gravity for cor-
rect balancing and is dimensioned to support at least four times the
maximum weight without breaking.
The integration of forklift slots also saves time and facilitates
safe and efficient handling and transportation. Well placed fixation
points ensure safe transportation around the construction site, while
integrated bumpers protect the enclosure against mechanical impact
during transportation and handling.
The frame is also a 110% containment base for all the necessary
liquids such as oil, coolant and fuel.
E ASE OF MAINTENANCE
Large access doors allow easy access to all service points and the gen-
erator components; developed to make any preventative maintenance
and repairs faster and easier.
External drain points are positioned to allow easy and efficient
draining of oil, coolant and fuel with minimised risk of environmental
spillage. Special drain points are also fitted to allow the fuel tank to
be cleaned and water removed from the base frame; once again with
minimal environmental impact.
A 905 litre standard fuel tank, positioned in the centre of the base
frame ensures continuous operation at full load for a complete shift.
The new QAS 500 features a dedicated compartment for the electrical
cubicle making it safe to access even when ‘running.’ Isolating the electri-
cal components from the engine compartment provides reduced vibration
and temperature impact on the more sensitive electrical components.
An industrial type B-curve, four-pole main circuit breaker safeguards
the alternator against external short circuits by an instantaneous trip
three to five times the nominal current. All main circuit breakers fitted
in the QAS range are Omnipolar – an essential feature for compatibility
with the different configurations of customers’ applications.
F AIL SAFE PROTECTION
Critical engine parameters such as oil temperature, oil pressure and
coolant temperature are monitored by means of a failsafe system.
32
Should a sensor or transducer fail, the system automatically shuts
down to avoid any damage to the engine.
A dual stage fuel filter with integrated water separator and a heavy
duty dual stage air filtration system ensure longer service intervals
and increased engine life and up-time. An extra safety cartridge filter
element allows air filter replacement during operation.
Generator control, protection and monitoring are provided with a
local or remote start digital control module (Qc1002). Fitted as stand-
ard, the system is ideal for all automatic controlled applications. All
Qc controllers are equipped with external communication protocols
prepared to support the Cosmos option for satellite monitoring.
The Qc4002 controller is available as an option for multi start
paralleling operations. As a standard, this controller is equipped with
PMS (Power Management system), that enables the user to save fuel
and to extend the life time of the engine.
F ULFILLING DEMANDS
To fulfil the demand in the market for 800kVA, Atlas Copco has
upgraded its QAC 750 to the QAC 800.
The new QAC 800 delivers 800kVA of prime power at 50Hz to
meet increasing demands from generator users in the market. The QAC
series generators are built to withstand the most extreme temperatures,
and are designed to work in all weather conditions. A built-in engine
coolant heater ensures quick and easy start-up in cold conditions, while
a variable speed electric cooling fan allows continuous operation in
higher temperature environments, as in desert environments.
Designed with safety in mind, all QAC series generators have a
four-pole main motorised circuit breaker, providing overload and
short circuit protection, an emergency stop, automatic engine alarms
and shut-downs.
The double skinned and removable fuel tank with leakage sensors
and spillage free frame construction prevents accidental engine fluids
or fuel spills, eliminating the risk of any ground pollution.
Easily handled by crane, lift or truck, the robust 20ft CSC ISO con-
tainer enclosure has lockable wide opening doors so that all compo-
nents are always within reach, ensuring that maintenance and service
is both easy and stress free, says the company.
The innovative dual compartment design – with the engine/alterna-
tor compartment separated from the cooler compartment – ensures
maximum efficiency while operating in the most extreme conditions.
With the separated power cubicle, opposite to the control cubicle, a
safer operation is achieved.
The state-of-the-art Atlas Copco Qc 4002 control panel includes
features such as an LCD screen with numerous read-outs, warn-
ings and shutdowns – all displayed in various local languages.
Applications from ‘Island operation’ and ‘Automatic Mains Failure’
to the most complicated paralleling operations such as ‘Load shar-
ing,’ and ‘Base load’ operations, are done with this single, high-tech
generator controller.
This multi-purpose control system makes the QAC series genera-
tor an easy-to-operate machine, offering a single solution to varying
applications, says the company. IWP & DC
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
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 GENERATORS
Generating interest in EMMA
Restored controls at a micro hydro site in Andover
T
HE energy and micro-generator manager (EMMA) is a
device that is installed alongside a micro-generator for
hydro, PV or wind. It monitors in real-time what your
micro-generator is producing and what energy you are
using in small commercial buildings or households. If it detects
there is surplus electricity available it then diverts this to an immer-
sion heater for the production of hot water or similar resistive load
device. This energy can then be stored and used when required.
The EMMA is beneficial as between 45%, and in some cases 80%,
of what you generate is exported to the grid because of the miss-
match between the electricity generation and the demand profiles.
EMMA matches these two curves. Up to 40% of household energy
requirements are for hot water and so the excess electricity is usually
put to good use satisfying this requirement. Over 60 devices have
been installed across Ireland and the UK.
T HE YOUNG EMMA
EMMA was developed over two and a half years ago in Ireland where
there was no export tariff for any electricity put into the grid from a
micro-generator. Prior to development we had searched worldwide to
try and find a similar technology, but as none was found we decided
to develop it ourselves.
The unique technical feature of the EMMA is that it seamlessly
ramps the electricity up and down to the immersion heater (or similar
resistive load device) using patented control technology. This may
seem a simple solution but it has taken many thousands of hours
of development time. In some countries the technology is financially
very attractive. For example, in the UK you only get 3 pence per kWh
exported and so it makes sense to use the electricity in the house
34
Richard Linger from CoolPower Products in
Ireland introduces IWP&DC to EMMA: an
energy and micro generator manager which
is being used to optimise the performance of
a 90-year-old water turbine in the UK
Drive mechanism at the Andover hydro site
rather than re-import it later. You receive the feed-in tariff based on
what you generate, not what you export. This is not impacted by
installing EMMA.
There are a variety of uses for EMMA, which include:
r


In any country where the export tariff for electricity is low or zero.
r

Any house/small commercial/school with more than 1kW micro-
generator with immersion/ hot water tank.
r

Install with micro hydro, PV or micro wind.
r

Where client wants a micro-generator and a thermal solar system.
Put EMMA instead of thermal solar at 30% of the costs.
r

Where hot water is produced from electricity/gas/oil central heating
and uses a hot water cylinder.
r

Up to 30kW (larger units are bespoke).
r

Grid connected - three phase or single phase.
The main benefits of using EMMA technology are that you can sig-
nificantly increase the rate of return on investment in your micro-
generator; help stabilise the distribution network; and further reduce
reliance on fossil fuels.
Figure 1 shows actual data from a site where an EMMA is installed.
There is a significant miss-match between the demand and generator
output profiles. This is typical of most sites where we have installed
EMMA and have been able to monitor this data.
Figure 2 shows the same site with the EMMA switched on. Here
the profiles are matched perfectly within the operating constraints
of the generator. There are some times where the overall demand is
higher than the output from the generator. In this case the EMMA
ramps the immersion to zero and some electricity will be imported
to the household.
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
 GENERATORS

8000 4000
7000 Demand 3500 Output
6000 Output 3000 Demand
5000 2500
4000 2000
3000 1500
2000 1000
1000 500
0 0

17:45:00
0

19:00:00
0

20:15:00
0

21:30:00
0

22:45:00
0

00:00:00
0

01:15:00
0

02:30:00
0

03:45:00
0

05:00:00
0

06:15:00
0

07:30:00
0

08:45:00
0

10:05:00
0
19:00:00

01:05:00

07:10:00

13:15:00

19:20:00

01:25:00

07:30:00

13:35:00

19:40:00

01:45:00

07:50:00

13:55:00

20:00:00

02:05:00

08:10:00

Effectively the energy produced from the micro-generator is priori- Top left: Figure 1 – Site where an EMMA is installed; Top right: Figure 2 – the
tised. First use is always allocated to the household. Secondly to the same site with EMMA switched on; Left: EMMA in stainless steel housing;
hot water production, if required, and thirdly to export to the grid. Right: Mill race and sluice gate at a micro hydro site in Andover, Hampshire, UK
This ensures the most effective payback for the user.
The EMMA can be used with other technologies and has been
connected to storage heaters and electric underfloor heating systems. The EMMA GVS monitors the network voltage and the export
It comes in a standard range of sizes from 4kW single phase up to capacity. It can react by limiting export levels when the voltage is
30kW three-phase phase systems. We can do larger devices but these higher than a specified point or simply limit the export capacity. The
would be bespoke designs. benefits are that you do not have to pay for a costly network upgrade
and can install a larger micro-generator to match your requirements.
You also get all the benefits of the EMMA in terms of usage of energy
M ICRO HYDRO INSTALLATION on-site, and reduced imports/costs.
We recently installed an EMMA with a 3.7kW micro-hydro genera- The EMMA GVS can also be used where you have a high concen-
tor in Andover, Hampshire, UK. This project has been a great success. tration of micro-generators in an area. Here the benefits are a stable
The client restored a 90-year-old turbine which had remained idle for network and optimised use of the electricity being generated. There
many years. On this site the client installed two heat storage systems, are projects underway in the US trying to determine a solution for this
one for his domestic hot water and the second for the central heating. type of problem. EMMA GVS offers a solution.
When there is excess electricity available it is put into the domestic The future offers exciting opportunities for EMMA technology. For
hot water cylinder first, when this is full it then starts to heat the cen- example, we are scoping an opportunity to pilot the use of EMMA
tral heating cylinder. The EMMA paid for itself in a matter of months in demand side management/smart grids. As you are able to control
as the client was no longer using his large oil-fired boiler to heat his devices in response to signals sent to the EMMA, or in response to
domestic hot water. voltage peaks or troughs, it can therefore be used to reduce the cost of
We are planning to install EMMA in a number of other micro- electricity supply or stabilise grid networks. IWP & DC
hydro projects in the UK over the next 12 months. Most of these are
in remote areas where the EMMA can help further displace fossil
fuels and increase the rate of return on the micro hydro investment. Richard Linger, Director Coolpower Products Ltd,
A recent development of the product is the grid voltage stabilisation 89 Booterstown Ave, Blackrock, Co. Dublin. Ireland
version (GVS) which we are trialling with UK network operators. The Email: Richardlinger@coolpower.ie
EMMA GVS allows you to connect larger micro-generators to the www.Coolpowerproducts.com
grid in areas where the network operator is imposing limits.

WWW.WATERPOWERMAGAZINE.COM JULY 2010 35

 MODELLING
View west towards Goring and Streatley Weir
Assessing flood risks for Goring
and Streatley hydro
James Heptonstall from Peter Brett Associates provides an insight into the methodology
used for flood risk modelling on the River Thames in the UK
I
N March 2009 Dave Holt, hydro project leader of the Goring
& Streatley Sustainability Group (GSSG) wrote the article
‘Power to the people’ for IWP&DC. This gave readers an
insight into the innovative hydro scheme that is planned for
the River Thames at Goring and Streatley in the UK.
The scheme comprises of three Archimedes screws driven by the
head difference of the Goring weir complex resulting in an estimat-
ed 246KW peak output. This renewable energy will be sold to the
National Grid to generate an income that will fund other local sus-
tainable projects in the area.
Since March 2009 Dave Holt and the GSSG have progressed with
the project and commissioned Peter Brett Associates (PBA) to assess
the flood risk associated with the scheme. Flood risk is an inherent
issue with such an installation and needs to be evaluated and miti-
gated against accordingly. The evaluation of the flood risk therefore
lends itself to a comparative exercise comparing the current or base
line flood risk against the flood risk with the proposed design in place.
36
This is best evaluated by quantifying flood levels for both scenarios
with a solution showing no difference between the two.
Through close liaison with the Environment Agency, PBA agreed a
methodology to assess the scheme using the powerful tool of hydrau-
lic river modelling.
G ORING AND S TREATLEY WEIR
Historically, water levels within the non-tidal section of the River
Thames have been heavily modified and managed through the con-
struction of weirs and locks for navigation and for powering numer-
ous mills for industry.
These weir complexes are still used today for managing water levels
for navigation and also for managing the flood risk to the towns and
villages that have expanded into the Thames floodplain.
Typically a weir complex consists of fixed crest weirs with addi-
tional sluice or radial gates to manage water levels during times of
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

high or low flows.
The Goring and Streatley weir complex consists of two separate
areas divided by Withy Eyot. On the western (Streatley) side, the weir
complex incorporates a mill channel, two gated weirs, a Paddle and
Rymer weir, and a series of overflow weirs. On the eastern (Goring)
side, the weir complex consists of three gated weirs, a series of over-
flow weirs, a lock island, a lock and a mill channel.
The proposed hydro power scheme is to be situated on the 16m
long overflow weir adjacent to the lock keeper’s house on the Goring
side of the Thames. The screws would effectively obstruct 13m of
weir from the Goring and Streatley weir complex.
F LOOD RISK ASSESSMENT
English government Planning Policy Statement 25 (PPS25) requires
that new development does not create an increase in flood risk to
third parties.
The complexity of the Goring and Streatley weir complex and
flood hydraulics of the Thames along this reach required a hydraulic
modelling approach to satisfy the requirements of PPS25.
The Environment Agency, as regulators, worked closely with the
GSSG to produce a modelling specification that utilised their existing
strategic flood risk mapping ISIS (1 Dimensional) hydraulic model.
Using this model, PBA were commissioned by the GSSG to first
provide a review of the existing hydrology and hydraulics of this
‘baseline’ model to assess the suitability of the model for assessing
flood risk at Goring.
Secondly PBA were requested to produce a design model that
included the three Archimedes screws, associated housing and con-
trol building. Each model would be run for three increasingly greater
magnitude flood events (1:5 year (222m3/sec), 1:20 year (284m3/sec)
and 1:100 year (355m3/sec). The predicted increase in flows over the
lifetime of the development from climate change was also accounted
for by increasing the 1:100 year flow by 20%.
A comparative exercise would be then carried out to assess how the
hydro power scheme impacted on flows across the weir system and
how this might impact on flood risk to third parties.
S TAGE 1: MODEL REVIEW
The Environment Agency Strategic ISIS hydraulic model covers the
area between Sandford on Thames, 32km upstream of Goring, and
Whitchurch on Thames, 8km downstream of Goring.
The model represents the channel and floodplain using either
extended cross-sections or via a quasi two-dimensional approach
using lateral spills into reservoir units that represents large flood stor-
age areas within the Thames floodplain.
The strategic nature of the model meant that in rural areas,
WWW.WATERPOWERMAGAZINE.COM JULY 2010
MODELLING
Schematic of an Archimedes screws (Ritz-Atro)
where the channel and floodplain are uniform, model detail was
low with cross-sections spaced anywhere up to 700m apart.
However around the weir complexes such as at Goring and
Streatley, the model schematisation was found to be detailed and
provided a good representation of the weir hydraulics and there-
fore was suitable for the flood study.
The hydrology for the model was originally based on the
Dunsmore technique that estimates design flows from a flow-catch-
ment area relationship that can be derived from the long gauging
records on the Thames. The method was originally derived in 1991.
For this project PBA reviewed the results from the method using
the additional 17 years of extra flow gaugings made available by
the Environment Agency, which had been recorded on the Thames
gauge network since the method was derived. The method was
found to still provide a reliable estimate of design flows and so the
hydrology was left unchanged.
S TAGE 2: HYDRO POWER MODELLING
The main components of the scheme include three, 3.6m diameter
Archimedes screw turbines, a control building and an additional
gated weir for mitigation.
The control building is to be designed to flood with any sensitive
plant set above the 1:100 year flood level including an allowance
for climate change and freeboard. The building itself will be small
enough not to impact on flood flows.
The three turbines are expected to occupy a 13m section of the
16m wide fixed crest weir adjacent to the lock house. The additional
gated weir is then proposed to occupy the remaining 3m of the fixed
crest weir.
A conservative assumption was made that the three turbines
would create a complete blockage over 13m of the existing fixed
crest weir. This section of the weir was therefore removed from
the model.
Initial analysis of the model showed that the turbines had greatest
impact at low return period flood events, redistributing flow across
the other structures. The results also showed that the weir rapidly
became drowned out with increasing flows, caused by backing up
from a downstream railway embankment and bridge. As the weir
became drowned out, the impact from the turbines reduced to dis-
placing less than 4% of the total flow in the river, causing no change
in flood level.
Due to the sensitivity of some property in Goring and Streatley
to relatively frequent flood events, it was important that mitigation
was provided at the low return period events (1:5yr to 1:20yr design
events) to ensure no increase in flood risk to these receptors.
A gated weir was therefore proposed and modelled with a lower
fixed crest than the existing weir. This effectively allowed an increase
in flow across the structure at the lower return period flood events,
fully mitigating for the hydropower scheme.
S TAGE 3: APPROVAL
A flood risk assessment has been written based on the modelling
results and submitted to the Environment Agency, alongside the
hydraulic model for approval. The project has been run in close liai-
son between the Environment Agency, GSSG and PBA which has
thus far proved effective in moving the project forward in a consistent
direction. It is expected that this will continue with planning permis-
sion being sought later this year. IWP & DC
James Heptonstall, Assistant Hydrologist, Peter Brett
Associates, Caverhsham Bridge House, Waterman Place,
reading, Berkshire RG1 8DN, UK.
Email: jheptonstall@peterbrett.com
www.peterbrett.com
37
 SEDIMENTATION
Tackling a
growing problem
Worldwide experts will convene in South Africa in September 2010. At the top of their
agenda is the growing problem of river sedimentation. Professor Gerrit Basson explains
why tackling this issue is of great importance to the dams industry
L
ARGE dams have been constructed worldwide at a rate of
1.2 dams/day since 1930, based on the dams registered on
the ICOLD World Register of Dams. Many of these struc-
tures will continue to fill up with sediment as they age.
High rates of sedimentation in many reservoirs and better care of
long term sustainability have emphasised the importance of reser-
voir sedimentation. The main problems which can be encountered
include: loss of storage; damages to turbines and loss of hydropower
production; and downstream impacts.
The total world reservoirs storage is about 7000km3 (6100km3
based on the ICOLD Register of Dams, but if smaller <15m dams
are included, 7000km3 could be the current total storage). About
3000km3 of this is dead storage for hydropower. Of 4000km3 of live
storage, most of this is devoted to hydropower and about 1000km3
to irrigation dams, potable or industrial water storage; part of which
is in multipurpose dams.
The annual sediment load of the world’s rivers together is estimated
to be between 24-30B tons for a water inflow of 40,000km3, ie an
average sediment content of 0.6-0.75T/1000m3 of water but it varies
38
enormously according to the river and to the discharge. All rivers
are not dammed and all sediments are not trapped in reservoirs: the
accumulated sediment storage in world reservoirs has been evaluated
as 1400Mm3 for 30 to 40-year-old dams on average, ie in the range
of 40Bm3 per year, ie 0.6 % of the total storage per year.
The historical growth in storage capacity up to 2010 based on
the ICOLD World Register on Dams, and historical and predicted
reservoir sedimentation is shown in Figure 1.
Most sedimentation is at hydropower dams, partly in dead stor-
age but the loss of power supply is however not proportional to
the loss of live storage. The annual loss of power supply appears
in the range of 0.5% of a total investment of about US$1000B
for live storage, ie US$5B per year. As hydropower reservoirs silt
up however, they have to be replaced by new dams eventually at
a cost of the total storage capacity (dead and live) and at a total
investment of US$1700B, the annual cost of replacement is 0.6%
x 1700 = US$10B/year.
The annual loss of storage of irrigation reservoirs, possibly 7Bm3,
impacts directly on the irrigation capacity; for an investment of
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
 SEDIMENTATION

7000000 South America

North America
6000000

Gross storage capacity (million m3)

Middle East
Europe
5000000
Central America
Australasia
4000000
Asia
3000000 Africa

2000000

1000000

0
1940 1950 1960 1970 1980 1990 2000 2010
Time (years)

4500000

4000000 South America loss

North America loss
Sediment volume (million m3)

3500000
Middle East loss
3000000 Europe loss
2500000 Central America loss
Australasia loss
2000000
Asia loss
1500000 Africa loss

1000000

500000

0
1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050
Time (years)

Opposite page: Sedimentation at a dam in Algeria

Left: Abstraction works to limit sediment in the Berg River
Above: Figure 1a: Historical growth in global storage capacity; Figure 1b:
Historical growth in global reservoir sedimentation (Basson, 2010)

P OTENTIAL IMPACTS OF STORAGE CAPACITY

US$0.2-0.5/m3 for reservoirs in excess of 10Mm3, or up to US$1/
m3 for dams smaller than 50000m3 (often found in the Indian sub
continent and in Africa), with say a global investment cost of US$0.5/
m3 the annual loss may be in the range of US$3.5B. There is also the
cost of downstream damages and, for possibly 5 or 10% of hydro-
power plants, losses of power supply and cost of maintenance for
turbine wear.
The total yearly loss linked with sedimentation problems is thus
about US$15B (excluding downstream impacts) and with downstream
impacts considered the annual cost is about US$17B. This should how-
ever be compared with the annual overall costs and benefits of dams:
r Some US$40B of investments and US$17B for operation, main-
tenance and upgrading (0.7% x US$2400B; rate usually 0.3 to
0.7%), ie a total cost in the range of US$57B.
r Some US$125B of electric power supply (2500 TWH x US$0.05)
and other benefits (especially food by irrigation for over 500 mil-
lion people).
The total yearly impact of siltation of US$17B should thus be com-
pared with the overall yearly costs (US$57B) and overall yearly benefits
(US$175-225B) of world dams. The annual cost of reservoir sedimen-
tation (in terms of replacement cost) is about 30% of the overall costs
which is not insignificant. However, much less than 30% is currently
spent on sedimentation mitigation measures and the problems are
therefore postponed to future generations in many countries.
Based on the ICOLD World Register on Dams, hydropower dams
make up 81.5% of the world’s total current storage capacity. In
2006, 35% of the total storage capacity for hydropower had been
filled with sediment. By 2050 this predicted proportion of current
total capacity that would be filled with sediment has risen to 70%.
For dams for any other purpose (non-hydro), in 2006, 33% of the
available capacity was filled with sediment, rising to a predicted value
of 62% by 2050.
It is expected that non-hydro dams will be severely impacted on
when they reach a 70% sedimentation level. At this sedimentation
level there will be about a 40-50% water yield reduction, and there
could be problems at the intakes. Based on the global data this will
occur by the year 2065, and will occur per region as indicated in the
table (p40).
Hydropower dams can generally be filled with sediment to a higher
level than non-hydropower dams, as it is mainly necessary to main-
tain the head for the power generation, and a storage capacity suf-
ficient to meet all expected demands for power. It is expected that
hydropower dams will be severely impacted when they reach a level
of sedimentation of 80%. Based on the global data this will occur by
the year 2070, and per region as indicated in the table.
Countries that are anticipated to have critical sedimentation volumes
by year 2050 are: Afghanistan, Albania, Algeria, Bolivia, Botswana,
China, Columbia, Ecuador, France, Fiji, Iran, Iraq, Jamaica, Kenya,
Libya, Malaysia, F.Y.R.O. Macedonia, Morocco, Mexico, Namibia,

WWW.WATERPOWERMAGAZINE.COM JULY 2010 39

 SEDIMENTATION

6000000

Growth hydro
5000000 Loss hydro
Growth other

Storage capacity (mcm)

4000000 Loss other

3000000

2000000

1000000

Above: Testing of environmental flood releases at Berg River Dam
Right: Figure 2 – Global comparison of growth of dams by purpose
New Zealand, Oman, Pakistan, Puerto Rico, Saudi Arabia, Singapore,
Sri Lanka, Sudan, Tanzania, Tunisia and Uzbekistan.
S YMPOSIUM ON SEDIMENTATION
In order to help countries tackle the problems associated with sedi-
mentation, the 11th International Symposium on River Sedimentation
(ISRS) will be held in South Africa from 6-9 September 2010. The
ISRS is held to bring together scientists and engineers working in
the fields of river, lake and reservoir sedimentation, and covers theo-
retical and practical aspects related to sediment transport processes,
including environmental aspects. The impacts of hydraulic structures
on fluvial morphology as well as measures to limit the impacts for
sustainable development of water resources are also key elements.
Other noteworthy areas include a focus on catchment soil erosion
programmes, sediment monitoring techniques, reservoir flushing
and other techniques to limit sedimentation, environmental aspects
including water reserve determination for river ecology.
Keynote presentation topics include:
r Mega deltas and the climate change challenges by Dr Kim Wium
Olesen, Head of Water Resources Department, DHI.
r Sediment Data Collection in Rivers, Reservoirs and Lakes by Prof.
Dr. Manfred Spreafico, University of Berne, Switzerland.
r Erosion and Sedimentation Research Emphasis in the USA by Dr.
Matt Römkens, United States Department of Agriculture (USDA)
Agricultural Research Service (ARS).
r An introduction to latest developments in soil erosion and sedi-
ment transport modelling by Dr. Weiming Wu, National Center
for Computational Hydroscience and Engineering (NCCHE), The
University of Mississippi, USA.
0
1900 1920 1940 1960 1980 2000 2020 2040
Year
Symposium
The 11th International Symposium on River Sedimentation (SRS) is
organised by the University of Stellenbosch, near Cape Town. The ISRS
is held every three years with the World Association on Sedimentation
and Erosion Research (WASER) as the main sponsor. Others include: the
International Research and Training Centre on Erosion and Sedimentation
(IRTCES), UNESCO, ICOLD and the South African Water Research
Commission (WRC).
The main theme is sedimentation and the sustainable use of river systems.
Papers were also invited under the following themes:
r Reservoir/lake sedimentation modelling and management.
r
Sediment data collection in rivers, reservoirs and lakes.
r
Dam break analysis and sediment transport.
r
Reservoir sedimentation and management, such as flushing or dredging.
r
Sustainable tailings dams.
r
Unlined dam spillway scour.
r

Hydraulics and environmental aspects of river sediment transport
processes (fundamental and modelling).
r

Fluvial morphological and environmental impacts of hydraulic structures on
the downstream river and possible mitigation measures.
r

Impacts of river sedimentation on hydraulic structures (diversion,
abstraction works, bridges, etc.).
r

Sediment yield, soil erosion determination, modelling and management.
r

Climate change impacts on sediment yields, river and estuary morphology
More than 250 delegates are expected to attend the symposium in
September. Note that the deadline for registration is 31 July 2010. Full
details can be found at: www.civeng.sun.ac.za/isrs
r New challenges in sedimentation and erosion research by Professor
Zhao-Yin Wang, Tsinghua University, China.

The four-day symposium also includes a technical visit to the recently

Year that current storage will completed Berg River dam, the first in South Africa where environ-
reach critical sedimentation mental floods are released for ecology, in addition to erosion protec-
levels tion works at Cape Town. IWP & DC
Region Hydropower dams: Non-hydropower dams:
Date 80% filled with Date 70% filled with
sediment sediment Professor Gerrit Basson, Director of the Institute for
Africa 2100 2090
Water and Environmental Engineering; Department
of Civil Engineering; University of Stellenbosch, South
Asia 2035 2025
Africa. He is Chairman of the ICOLD Sedimentation
Australasia 2070 2080 Committee (2004 to 2010). He can be contacted directly
Central America 2060 2040 about the conference at grbasson@sun.ac.za
Europe and Russia 2080 2060
Middle East 2060 2030 References
North America 2060 2070 Basson (2010). ICOLD Bulletin: Sedimentation and Sustainable use of
South America 2080 2060 reservoirs and river systems. ICOLD Sedimentation Committee. Editor.

40 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION


All systems go for Sedi-filter
A new dewatering system offers the dams
and hydropower industry a solution to
sedimentation problems
A
N environmentally-friendly dewatering system is being
launched after a successful pilot project which helped to
keep Britain’s canal network open to traffic. The Sedi-
filter system has been created as a complete solution to
dewatering engineering projects. Designed by environmental waste
management firm Aardvark EM, the system is manufactured by
DRM Industrial Fabrics, which specialises in performance filtra-
tion through design. Its creators believe the system will be of great
benefit to dam and hydropower plant operations involved in silt
extraction projects and the creation, stabilisation and restoration
of watercourses.
Sedi-filters have been designed to dewater large volumes of water-
based slurries generated from maintenance operations on lakes and
waterways and from industrial processes. They can also be used to
create artificial weirs, berms and reefs in watercourses, and for ero-
sion control in the marine environment.
Mark Clayton, managing director of Aardvark, has been heavily
involved in the development of Sedi-filter. “Sedi-filter is of great help
in terms of extracting silt as well as playing a key role in stabilising
watercourses by using filled dewatering bags in the water to help sta-
bilise banks,” he says. “There is really no limit when it comes to the
depth of water Sedi-filter can work in. We are looking at a project in
the Thames Estuary, near Canary Wharf, where they would operate
at a depth of 8m with no problems.”
Sedi-filters have already provided Midlands-based Blue Boar
Contracts – which has a national contract with British Waterways to
dredge canals to a navigable depth – with an environmentally-friendly
solution to the problem of containing and dewatering sediment in
confined areas and holding and treating contaminated sediment.
In a pilot project, the company used Sedi-filter’s bespoke dewater-
ing bags to contain and dewater sediment taken from a 3km stretch
of the Birmingham and Worcester Canal in the heart of Birmingham
city. After successful results during the three-month pilot project, the
company is now using Sedi-filter’s dewatering system to deal with
most of its contaminated sediment.
The dewatering system has a strong environmental benefit and can
be effective in a wide variety of dewatering and engineering applica-
tions, says the developers. The main gain is the removal of water from
WWW.WATERPOWERMAGAZINE.COM JULY 2010
SEDIMENTATION
sediment, transforming it into a drier state, which helps handling and
enables the sediment to be disposed of to landfill or used elsewhere.
Blue Boar director Simon Potter is impressed with the way the system
has helped his company’s work: “The use of the Sedi-filter system
means that we don’t have to add anything to the contaminated sedi-
ment to treat it before it is disposed of. That means we don’t have to
have a special licence to deal with the waste and we are not increasing
the weight of the sludge. We can dry it out using the Sedi-filter system,
so it can be accepted to landfill and, because the water is extracted,
we are actually reducing the amount we are taking away. This means
lower transport costs and less weight at the landfill weighbridge.”
D EWATERING SOLUTION
Sedi-filter dewatering systems have been created to tackle the environ-
mental problems associated with excavating and storing wet slurry,
sludges and sediments. Made from high-quality geotextiles, Sedi-filter
is designed to effectively capture solid materials without the use of
excessive or specialist machinery. It removes excess water from wet
wastes, such as sludges, dredged silts and washwaters, through a pas-
sive filtration process. Solids are held within the tube, as the water
passes through the fabric and flows back to its original source, sur-
rounding ground or another collection point. The result is a signifi-
cant reduction in the volume of solid waste that has to be handled
and dealt with – as up to 90% of the water is removed.
If the solid waste is contaminated, like the canal sediment, then the
wet material can be placed in the Sedi-filter and the water extracted. The
Sedi-filter can be used to contain contaminated sediment whilst treat-
ment is applied, as dewatering itself does not decontaminate sediment.
The bag is made of a close weave textile, which aids the dewater-
ing process. The filters are engineered to withstand pressure at the
base, which allows for stacking. They can be made to almost any size
depending on application. The standard size is 7m wide x 33m long
– with a volume of approximately 250m3.
Filling is via pumping, the dorsal openings at the top centre of the
bag combine an entry port and sleeve, this allows a pipe to be inserted
and clamped inside the sleeve. Filling is controlled through a mani-
fold/valve system, each tube is filled and allowed to dewater. Once
dewatered, the Sedi-filter is filled again and the process is repeated,
until the dewatered sediment volume is approximately 80%.
A wide variety of treatments can be applied to the slurry during and
after pumping. Air lines can be run through and clamped in place and
microbes added, as well as mixing and agitation. IWP & DC
www.sedi-filter.co.uk
41
 COMMENT

Hydro project engineering costs

One of the first questions owners ask is ‘what will be the cost of engineering services’.
This paper discusses the effect of documented/non-documented designs on project
engineering costs, based on detailed man-hour data obtained from 17 hydro projects
ranging in size from the 6.4MW Maggoty development in Jamaica, to the 2304MW
La Grande 3 development in Quebec. By J L Gordon, P.Eng

O
VER the past 58 years, the author has been fortunate general contractor on a design-build project, or that required for a
to work on both large and small hydro developments, small hydro development of less than about 50MW capacity.
and managed to keep detailed statistics on project engi- From 1952 until 1990, the author worked for Montreal
neering services. The author found that there was a Engineering (Monenco), a consultant who provided design, construc-
vast difference in the project documentation required by a private tion and operating services to many associated hydro utilities. These
utility, as compared with that demanded by a public utility. Also, utilities did not require any detailed project documentation; hence the
there was a significant difference in how the design and construc- author was able to accumulate data for non-documented engineer-
tion work was undertaken for small as compared with large hydro ing services, where most of the contracts for construction, turbine
developments. After many years, a distinct pattern in man-hours and generator were negotiated with reliable known contractors and
was discerned, as will be discussed in this paper. manufacturers. Bids for other equipment were solicited from, at most,
three manufacturers. Specifications were concise. For example, all the
technical specifications for civil works and mechanical equipment at
P ROJECT ENGINEERING MAN - HOURS the 356MW Brazeau project were contained in a 2.5cm three-ring
After completion of a feasibility report, one of the first questions asked binder. About 1960, Monenco began providing services to ‘outside
by the hydro project owner; is how much will the detailed engineering clients’ who required more formalized engineering with full documen-
work cost? This is very difficult for the consultant to estimate with any tation of the work, and required all contracts to be open for bidding
degree of accuracy. It was found to depend on several factors: by pre-qualified contractors. As a result, specifications became more
detailed and contractual conditions more complex. This provided an
r How much documentation will be required by the owner? opportunity to obtain data on documented designs. The results are
r How will equipment bids be analyzed and what justification will be shown in Table 1, where the data was accumulated over 32 years
required on contractor selection? between 1954 and 1986 for 8 non-documented projects and for nine
r How will orders for the equipment be placed? documented projects.
r Will the owner question all invoices for the engineering services?
Project man-hour statistics
The answers to these questions will directly affect the man-hours
Project Head Capacity MW/h0.3 Man-hours
required to undertake the design and project management, resulting (m) (MW)
in two types of engineering services offered to owners – (1) a docu-
mented design service, and (2) a non-documented design service. Non-documented projects
A documented design would entail the production of: 1. Maggoty (Jamaica) 88 6.1 1.6 10,850
2. Snare Falls (Canada) 19 6.7 2.8 28,900
r A ‘Design Criteria report’: A document showing the criteria to be
3. Umtru (India) 58 11.7 3.5 16,300
used in design of each structure, forwarded to the client for perusal
by the client’s Review Board, prior to starting detailed designs. 4. Rattling Brook (Canada) 94 12.5 3.2 20,220
r A ‘Design Transmittal’: A document showing how each structure was 5. Taltson (Canada) 30 18.3 6.6 22,176
designed, for permanent retention in the client’s project files, to be 6. Bearspaw (Canada) 15 15.2 6.7 17,460
used whenever there are repairs or modifications to the structure.
r A ‘Contract Award document’: A report on how the contractor was 7. Bighorn (Canada) 75 110 30.1 86,400
selected, to include all specifications and correspondence with the 8. Brazeau plant (Canada) 118 336 91.2 97,410
selected contractor prior to award. Brazeau pump (Canada) 7.6 20
r A ‘Project Completion Report’: This document would include
copies (on CD) of all project drawings and photographs, and copies Documented projects
of all progress reports issued during construction.
9. Charlot River (Canada) 29 11 4.0 45,100
r A ‘Project Operating Manual’.
10. Dadin Kowa (Nigeria) 28 34 12.5 66,000
Such detailed engineering services would normally be required for 11. Maskekeya Oya (Sri Lanka) 578 100 14.8 97,674
all major hydro developments, by large utilities and for international 12. Andekaleka (Madagascar) 214 112 22.4 135,000
bank-financed projects.
13. Cat Arm (Canada) 381 136 22.9 167,00
A non-documented design is one where a client or contractor is
willing to entrust the engineering services to a consultant, without 14. Wreck Cove (Canada) 350 200 34.5 131,200
requiring any documentation on the design or construction, and 15. Bayano (Panama) 50 300 92.8 261,000
the only documentation provided would be: a copy of all project 16. Jebba (Nigeria) 28 560 206.1 352,00
drawings; and an operating manual. This standard of work would
be equivalent to the design work undertaken by a consultant for the 17. La Grande (Canada) 79 2304 621.1 630,000

42 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION


1,000.000
Non-documented projects
Documented projects
A The chart is based on data from projects undertaken before the intro-
13
Manhours
100,000
7 ants are naturally reluctant to divulge such data. However, the author
10
2
B
4
10,000
1 10 100 1,000
MW/h 0.3
>
Figure 1: Design engineering man-hours
Analyzing the data, the author found that there is a factor of about 2.5
between a ‘documented’ as compared with a ‘non-documented’ design
and managed project, as shown in Figure 1. There are two distinct lines
on the figure. The lower line (B) represents the man-hours for a ‘non-
documented’ design, and the upper line (A) represents a documented
design. Both lines can be expressed by the following equation
Man-hours = k (MW/h0.3)0.54 (1)
Where: h = rated net turbine head in meters; MW = installed capacity
in megawatts; k = a factor with a value = 8,300 for a non-documented
design, and = 21,000 for a documented design.
In other words, a documented project requires over 2.5 times the
effort expended on a non-documented project. This is very important,
and a factor which must be taken into account by any owner contem-
plating awarding a contract for engineering services.
There are some projects on the chart which do not fit the data.
These can be explained by:
r 2 – Snare Falls. The dam site on this project was changed at the last
minute, when the owner decided that the project capacity should
be increased by about 50%. This was accomplished by moving the
dam site downstream to the next set of rapids, after all contracts
had been issued for tender. This required a complete re-design of
the project layout.
r 4 – Rattling Brook. This project proceeded with only a pre-fea-
sibility study, requiring extensive additional studies on dam and
spillway locations.
r 10 – Dadin Kowa. This project was terminated when the client ran
out of money, and still requires completion of the powerhouse and
installation of spillway gates.
r 13 – Cat Arm. During the design engineering work, the owner
decided to add about six utility engineers to the consultant’s electri-
cal design team to learn how to design the automatic controls, with
the intent to retrofit the design onto older powerplants. Also, there
were significant changes to the project concept when detailed design
work commenced, which included use of a U-shaped weir spillway
instead of a gated spillway, impulse units instead of Francis units,
and elimination of the surge tank.
r 7 – Bighorn. This project was undertaken after a change in the man-
agement at the utility. The new management required all contracts
to be tendered instead of being negotiated, adding substantially to
the weight of both the technical and contractual conditions in speci-
fications, and requiring more formal documentation of the work.
It is remarkable how consistent the data appears to be. All of
the projects were undertaken by Monenco, with the exception
of Wreck Cove, engineered by SNC, with Monenco acting as the
owner’s consultant, and LG3, engineered by SNC in association
with Cartier Engineering, a subsidiary of Monenco. Also, two
of the projects, at Maskeliya Oya and Bayano, were designed
WWW.WATERPOWERMAGAZINE.COM JULY 2010
COMMENT
from project offices in Colombo and Panama, staffed with a few
Canadian engineers, with all the other engineers and draftsmen
being provided by the utility client.
duction of computerized drafting, (CAD) which one would expect to
reduce drafting time. The author has tried to determine whether CAD
has had a significant effect on man-hours, to no avail, since consult-
is of the opinion that CAD and other similar programs have instead
increased drafting time, since now it is very easy to produce more draw-
ings, and to produce three-dimensional images of powerplant interiors
and even individual concrete pours, both of the latter requiring signifi-
cant additional input data. The added engineering simplifies construc-
tion work, but increases engineering man-hours.
Also, the work was undertaken before personal computers became
available. Again, one would expect that computers would reduce
the engineering effort. However, based on observing the extent and
detail of recent specifications for large developments, the author is
of the opinion that computers have indeed facilitated, but have also
increased engineering man-hours.
H YDRO SPECIFICATIONS FOR DOCUMENTED AND
NON - DOCUMENTED PROJECTS
This raises the issue of the effort required to produce specifications and
contract documents. A perfect illustration of the difference is shown in
Figure 2, where the large 3-ring binder contains the technical specifica-
tions only for the civil works on a medium-sized documented 200MW
hydro project, and the small document on the left contains the civil
specifications, the geological report, contractual conditions and the
environmental guidelines for the civil works contract at a small low-
head non-documented 600kW hydro development. The right-hand
document was produced by a large consultant in Vancouver, and the
other document by a small consultant in Halifax.
The author is of the opinion that it is very difficult for a large hydro
consultant to produce a short specification. Large consultants have
the ability to retain specialists in many disciplines, and consequently
have few ‘generalists’ able to work on a variety of structures and
equipment. For example, the mechanical department in a large con-
sultant’s office could have an engineer specializing in powerhouse
cranes, another in gantry and gate hoists, another in powerhouse
pumps, compressors and piping, and another in turbines. All would
be required to contribute towards an equipment specification, and
the result would be a document requiring considerable co-ordination
between the specialists. On the other hand, a small consultant would
have perhaps only one mechanical engineer, and this person would
be required to produce the specifications for all the mechanical equip-
ment. The resulting document would be more concise than that pro-
duced by the large consultant.
D OCUMENTED PROJECT DESIGN AND MANAGEMENT
To illustrate the difference in project management between a docu-
mented and non-documented work, the data for the large document-
ed Jebba hydro project is presented. Jebba is located on the Niger
River in Nigeria, and includes a large shiplock. It was commissioned
in 1984. It has an installed capacity of 560MW at 27.6m head from
6 vertical axis Kaplan turbines. The completed project can be clearly
viewed on Google Earth at 9-08-20N, 4-47-27E.
Major project quantities at Jebba included:
r Earth excavation: 1,230,000m3.
r Rock excavation: 3,270,000m3.
r Earth fill: 2,120,000m3.
r Rock fill and rip-rap: 2,930,000m3.
r Spillway, lock, weir concrete: 241,000m3.
r Powerhouse concrete: 245,000m3.
Total cost of the project was over $1B in 1980 US$. Time
spent on engineering and project management was 386,000
43
 COMMENT
man-hours, of which 27% (104,000mh) was on project
management and construction supervision. The project was fully
documented, which required the production of both “design
criteria” documents and “design transmittal reports” for each of the
nine major structures. Based on detailed statistics maintained through-
out project execution, the project management group supervised the
production and distribution of:
r 23 contract documents, with a total of 2478 pages of technical
specifications, plus contractual conditions.
r 364 tender drawings.
r 1406 construction drawings.
r 7335 manufacturer’s drawings received for review by the design
engineers.
r 131 construction reports, with a total of 12,569 pages.
The production of drawings had to be kept ahead of the contractors’
requirements, and peaked at 512 approved for construction draw-
ings issued in the month of February 1980. Of course, it was not
possible to engineer such a large number of drawings in one month;
they were produced over the previous year when design staff peaked
at 72 individuals. The general civil work contract was signed at the
end of January 1978, and in March seven copies of 198 drawings
were packed in a large box and sent by air freight to the contrac-
tors head office, knowing that it was essential to keep ahead of the
contractors requirements for detailed construction drawings.
Cost control was maintained by an accounting team at site, and
was complicated by having to use four currencies – US dollars, Italian
Lira, Japanese Yen and German Marks. During construction, it was
difficult to determine the current total cost due to the constant change
in the relative value of the currencies. The project was completed
in 1984, after six years of construction. Management staff averaged
nine persons over this period, and peaked at 13.
NON-DOCUMENTED PROJECT DESIGN AND MANAGEMENT
A non-documented design will not require such a large project man-
agement team as at Jebba. Another factor to be taken into account
is the recent use of water-to-wire equipment contracts, wherein the
contractor undertakes a major proportion of the powerhouse elec-
trical and mechanical design work. This means that the consultant
can often dispense with the services of electrical and mechanical
engineers, further reducing the cost of project execution. Another
Small – large hydro specifications compared
44
factor is the introduction of high speed internet services over the last
decade. This has allowed many engineers and technicians to work
from home, working within informal groups to provide design serv-
ices for small hydro projects. There are several such groups, where a
hydrologist, civil engineer, geotechnical engineer and a CAD drafts-
man produce all drawings, and all working from home.
An early demonstration of this concept was provided at Ragged
Chute, where the addition of a small 6.3MW, 13m head development
at an existing dam in Canada was undertaken in 1992. The work was
supervised by the owner (a retired contractor) from a rented nearby
cottage, a civil engineer and draftsman with no hydro experience
were engaged to undertake powerhouse and intake design, another
to design the penstock, a senior hydro consultant provided advice,
and costs were audited by a hydro engineer appointed by the bank
providing the financing. A geotechnical engineer was engaged to pro-
vide advice on slope stability during excavation work. Ragged Chute
is located at 47-16-35N, 79-40-19W, and is clearly visible on Google
Earth. Total staff involved were; three engineers (owner + civil +
draftsman) for about 18 months, plus another four engineers very
much part-time. There was a water-to-wire contract for the equip-
ment, and a general contractor undertook the construction and also
designed the plant plumbing, heating, lighting and ventilation sys-
tems. There was no documentation other than an operating manual
provided by the water-to-wire contractor, and a set of drawings.
C ONCLUSIONS
The first decision facing a hydro owner is how much documentation
of the project execution work will be necessary? For large projects,
documentation is required. There is a grey zone between about
25MW and 100MW where documentation is optional. However, for
small hydro work, of less than about 50MW, documentation should
be kept to a bare minimum.
Recently, the author has seen specifications issued by hydro utilities
for engineering services. They include extensive requirements for very
detailed project documentation, even for small hydro projects, and
the author is of the opinion that such specifications have been issued
without understanding the effect on engineering costs. It is hoped that
this paper will help to clarify such issues. IWP & DC
Jim Gordon is an independent hydropower consultant,
and can be reached at – jim-gordon@sympatico.ca
JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION
 RECRUITMENT
SMEC:Layout 1 21/7/10 15:07 Page 1

INTERNATIONAL EMPLOYMENT
OPPORTUNITIES

Hydro SE is engaged in the construction and implementation

of Hydro Electric Power Plants in the Balkans and
eastern Europe.

We are seeking a top level engineer to be part of a leading

SMEC International (Pty) Ltd (www.smec.com) is
a leading engineering consulting firm with over 4000
employees providing multidisciplinary engineering
services including in Dams, Hydropower, and Power
engineering. SMEC has an established network of
34 major offices throughout Australia, Africa, Asia,
The Middle East and the Pacific.
SMEC is currently expanding its Nairobi (Kenya)
Office which supports SMEC’s Dam, Hydropower
and Power projects throughout Africa. SMEC is
currently filling the following positions in its Africa
team and to become instrumental in decision making process,
managing sub-contractors and handling all critical aspects of
project implementation.
The prospect candidate must have:
1 MSC in Hydro Engineering.
2 10 years or more of experience in construction
of hydro power plants.
3 Experience in managing multiple and complex projects.
4 Excellent commercial understanding.
5 Willingness for substantial traveling.
6 Fluent English spoken and written is a must.
Additional languages - advantage.
The position holder will be required to relocate to Zagreb.
Excellent compensation package for the right candidate.

Division: Please send your CV and references in English to:

Hydroengineer1@gmail.com
8 /-(#!1
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Diane Stanbury:
For more information about positions, please visit
SMEC’s website. Tel: +44 (0)20 8269 7854

SMEC offers excellent employment conditions. or

Professionals with at least ten years of relevant email:

#5.#/'#,!#
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#5.#/'#,!#
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2 &/, dianestanbury@globaltrademedia.com
Africa are invited to send their detailed curriculum
vitae and a cover letter to proc.ken@smec.com or
submit their application via the “Career” section of our
website www.smec.com prior to 21 August 2010.

SMEC also accepts CVs of other experienced

engineers interested in working in Africa.

WWW.WATERPOWERMAGAZINE.COM JULY 2010 45

recruit.indd 1 23/7/10 12:11:41
CLASSIFIED PROFESSIONAL DIRECTORY

Over 40 years experience in Dams.

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46 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

 PROFESSIONAL DIRECTORY
Successful projects in
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Water Power & DAM CONSTRUCTION
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tel: +44 (0)20 8269 7854
or email:
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Copy deadline for August 2010 issue
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WWW.WATERPOWERMAGAZINE.COM JULY 2010
CLASSIFIED
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Final & Detail Design,
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E-Mail info@stellba-hydro.ch E-Mail info@stellba.de
www.yolsu.com.tr info@yolsu.com.tr
www.waterpowermagazine.com
The classified section in Water Power & Dam
Construction is a well established and popular
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digital circulation of 16,000. Commonly known
as where “the buyer meets the seller”.
Industry Showcases
The industry showcase section is made up
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47
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48 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

 WORLD MARKETPLACE

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WWW.WATERPOWERMAGAZINE.COM JULY 2010 49

 WORLD MARKETPLACE
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50 JULY 2010 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

 WORLD MARKETPLACE

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WWW.WATERPOWERMAGAZINE.COM JULY 2010 51

Compact Hydro
More than a small solution
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