Rehabilitation – Poster Presentations
CLEAN CURRENTS 2026
Time: 11:15 AM - 12:15 PM
Day: 9/24/2026
Room Number: CC Central: Learning Center (Thursday Posters)
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Details about each presentation and the speakers are below:
In this session:
Improving Hydropower Technologies through Advanced Manufacturing and Materials Research
The Complexities of Retrofitting Hydromechanical Equipment at Existing Hydropower Facilities: Tesla Turbine Inlet Valve Replacement Project
Improving Hydropower Technologies through Advanced Manufacturing and Materials Research
Presented by Scott DeNeale, Oak Ridge National Laboratory
Manufacturing and materials science innovations have enabled wide-reaching advancements across many industries. At the forefront of such research and development (R&D), the U.S. Department of Energy's Manufacturing Demonstration Facility (MDF) provides a unique structure for collaborating with industry, academia, and government to forge stronger supply chains and rapidly distribute knowledge and technologies.
The MDF, managed by Oak Ridge National Laboratory (ORNL), is supporting the hydropower industry through innovative projects of varying sizes. During this poster presentation, we will highlight progress on the Rapid RUNNERS project (headlined during a 2024 Clean Currents POWERHOUSE session) in which ORNL is teaming up to additively manufacture metal Francis turbine runners, culminating in a 4.3-meter diameter unit near the end of the 3-year project. We also anticipate showcasing a scaled-down version of a printed blade at the conference. In addition, we will provide updates on the Water Power Technical Collaboration Program that offers additional opportunities for the hydropower industry to collaborate on advanced manufacturing and materials science R&D.
The Complexities of Retrofitting Hydromechanical Equipment at Existing Hydropower Facilities: Tesla Turbine Inlet Valve Replacement Project
Presented by Jin Kang, Stantec (formerly of AECOM)
Retrofitting hydromechanical equipment at existing hydropower facilities presents a unique set of technical and logistical challenges. The Tesla Spherical Valve Replacement Project serves as a representative case study. The Tesla Hydroelectric Facility (FERC P-9195) is a 763-psi, 25-MW hydropower facility that provides approximately 70% of the raw water supply for the City of Colorado Springs, Colorado.
The project involved replacing an existing spherical valve with a new ADAMS 36-inch ASME Class 400 spherical valve assembly, a new hydraulic power unit (HPU), and a new local PLC control cabinet integrated into the existing facility's Balance of Plant (BOP) PLC and Turbine Overspeed Protection System. The work was completed within tight spatial constraints and a limited outage window (less than five weeks) to ensure timely return to service for municipal water delivery.
This presentation highlights key lessons learned to help practitioners anticipate challenges and reduce risks on future hydropower retrofit projects.
This session takes place in the Learning Center, which is sponsored by:
