Small Hydro – classroom presentations

Presentations are:

Development of a New Turbine for Small Hydro High Head Applications, presented by Boualem Hadjerioua, Mesa Associates, Inc.

Evolution of New Small Hydro Design – Lessons Learned, presented by David Brown Kinloch, Appalachian Hydro Associates, Inc.

Unique Licensing Strategies for Small Hydro, presented by Emily Waters, SWCA Environmental Consultants

Details about each presentation and the speakers are below:

Development of a New Turbine for Small Hydro High Head Applications
Presented by Boualem Hadjerioua, Mesa Associates, Inc.

Mesa Associates, Inc. recently completed the design and modeling effort for a newer NuSTREEM high head dual regulated Kaplan hydro turbine that will operate with heads of up to 110 feet. The efforts focused on modifying the existing Mesa NuSTREEM low head turbine design for its adaptability to higher head conditions. The runner blades were redesigned, and the turbine case and other components were reconfigured for use in higher head applications. The design team determined the size of the turbine, identified critical components, and developed a 3D CAD model including wicket and runner geometries.

Computational Fluid Dynamics (CFD) was used to assess the hydraulic characteristics and provide predicted power and efficiency over a range of operating conditions, along with maps of velocity and pressure. Using the CFD solution, Finite Element (FE) analysis was performed to assess the mechanical and structural design of the turbine and its components, in particular the evaluation of stresses, fatigue life, and vibration potential.

Engineered 3D CAD designs, details and assembly drawings, and bill of materials for the high head turbine have been created. Mesa is working with various machine shops, fabricators, and component suppliers to insure a successful design for final production.

The controller software and design schematic for the NuTECH Controller are currently being configured.

An application has been filed with the U.S. Patent Office for this high head turbine design by Mesa Associates, Inc.

The current Mesa NuSTREEM turbine is US made and is capable of operating with heads up to 40 feet, which will produce up to 250 kW. With the higher head design the power output could potentially be doubled within approximately the same footprint. This high head design will allow Mesa to pursue a much broader range of application opportunities in the United States and abroad.

Evolution of New Small Hydro Design – Lessons Learned
Presented by David Brown Kinloch, Appalachian Hydro Associates, Inc.

After the success in restoring an abandoned 2 MW hydro plant at Lock 7 on the Kentucky River, the partners in Appalachian Hydro Associates decided to develop new hydro plants upstream at abandoned lock and dams along the river. To achieve this, we partnered with Kleinschmidt Associates to design and construct these small hydro plants. This collaboration leveraged our local knowledge of the Kentucky River's unique challenges, such as extreme floods, and Kleinschmidt’s extensive experience with numerous other hydro sites.

Focusing on Lock 12 first, the new design began similar to the restored plant at Lock 7, where the powerhouse is elevated to avoid large floods. One key constraint was that the new design had to fit within the existing abandoned lock chamber, eliminating the need for an expensive cofferdam. The original design resulting from this collaboration was rather conventional, with turbines below the head pond level and air-cooled generators above the floodwaters. However, this design would be challenging and expensive to build due to the significant height of the powerhouse, which exceeded 100 feet from base to roof.

This prompted numerous collaborative brainstorming sessions. The innovative solution was to use submersible turbine-generators, which were just reaching the market, including the reintroduced Flygt units and the new Voith StreamDiver. A design incorporating the Flygt submersibles was developed and constructed at Lock 12, coming online in 2021.

The Lock 12 project provided valuable lessons, prompting the collaborative team of Appalachian Hydro and Kleinschmidt to seek an improved design. After considering and refining numerous innovative ideas, the collaborative design team settled on “Concept 15.” This design features six horizontally mounted Voith StreamDivers, with an underwater horizontal trashrack, and a rubber dam at the downstream end of the powerhouse that can be lowered to flush debris. The result is a nearly maintenance-free small hydro plant. This final design is currently under construction at Lock 14 on the Kentucky River and will be operational in 2025. Appalachian Hydro plans to implement the “Concept 15” design at four additional new hydro plants on the Kentucky River, which are now in the development pipeline, including Lock 11 which is planned to begin construction in 2025.

Unique Licensing Strategies for Small Hydro
Presented by Emily Waters, SWCA Environmental Consultants

Many of the small hydro sessions I have attended either at previous Clean Currents conferences, NWHA, or in committee meetings have focused mostly on operations, dam safety, and maintenance and very little on the regulatory environment for these facilities. While many small hydropower facilities are already exempt from licensing requirements under the Federal Power Act, many smaller facilities which were licensed in the last 30-40 years are approaching relicensing deadlines and, given that conduit and small hydropower exemption regulations were added to the FPA in the last 15-20 years, we are finding that owners of small hydro facilities have more options to consider when approaching relicensing, including converting an existing license to an exemption or pursuing a license surrender, amendment, or other combination (surrender and amendment, amendment and relicense, etc.).

The goal of the presentation would be to highlight the uniqueness of small hydropower – both from a technical and a regulatory perspective. The configuration, resource issues, and economics of each facility vary, and therefore, owners and operators of small hydro are in a position to pursue unique and exciting regulatory strategies.

We would provide a high-level overview of what is required under each option (exemption, surrender, relicensing) so that attendees understand pre- and post-filing obligations. Additionally, we would provide 2-3 case studies of various small hydro regulatory strategies.

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