Rehabilitation – Poster Presentations
CLEAN CURRENTS 2026
Time: 11:15 AM - 12:15 PM
Day: 9/24/2026
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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 (Oak Ridge National Laboratory)
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 (AECOM)
Presented by Jin Kang, AECOM Technical Services, Inc.
Retrofitting hydromechanical equipment at existing hydropower facilities presents a unique set of technical and logistical challenges. The Tesla Turbine Inlet Valve (TIV) Replacement Project serves as a representative case study. The Tesla Hydroelectric Facility is a 763-psi, 25-MW hydropower facility that provides approximately 70% of the raw water supply for the City of Colorado Springs, CO.
The project involved replacing an existing turbine inlet valve with a new ADAMS 36-inch ASME Class 400 spherical valve, a new hydraulic power unit (HPU), and a new local PLC integrated into the facility's existing 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:
Conduct comprehensive record reviews supported by detailed field verification. Incomplete, outdated, or missing records, common in older facilities, can significantly affect design accuracy. Even new facilities with extensive documentation may contain inconsistencies. Validating all information in the field is essential.
Consolidate major equipment procurement whenever feasible. Bundling interconnected components into a single scope of supply reduces coordination risk, minimizes interface issues with existing infrastructure, and improves schedule reliability.
Engage the contractor early in design and procurement. Early involvement helps identify constructability constraints, accelerates procurement of long-lead items, and reduces uncertainty during installation.
Maintain strong collaboration among the valve manufacturer, contractor, and client. Clear and consistent communication is especially critical on sites with tight dimensional or operational constraints.
Account for moveable seal ring closure time separately from spherical valve closure time in transient analyses. Treating these closure speeds independently is essential for accurate modeling and safe system operation.
Ensure all welding submittals are fully approved before fabrication. Proceeding without complete approvals can lead to rework, schedule delays, and fabrication risk.
Anticipate welding-induced distortion when designing valve platforms. Significant warping can occur on structures with extensive welds. Plan for machining after welding to achieve flatness and design tolerances.
Prevent shortcuts during tight outage windows through proactive planning. Engage the contractor early to explore simplified design approaches, confirm sequencing of critical construction activities, and align expectations to meet contract requirements without compromising quality or safety.
