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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Cellular cofferdams for hydropower use. Final report

This report presents the results of a comprehensive study on a proposal to use cellular cofferdams as basis for the design and construction of water retaining structures to sustainably and cost-effectively harness hydropower. Previously, cellular cofferdams have been widely used mainly as temporary water exclusion devices to permit dry construction of in-water structures such as dams, locks, bridge footings and piers, and hydroelectric power plants. Design and construction requirements for cellular cofferdams are less stringent than for hydropower dams. To make cellular cofferdams suitable for permanent hydropower use, different design concepts that utilize cellular cofferdams as the main or core element of the water-retaining dam structure are proposed. One key design concept is the so-called “dry construction technique” in which the granular fill in cofferdam cells and the downstream berm are permanently kept dry in contrast to the wet construction technique for temporary use of cellular cofferdams. The viability of the proposed permanent cellular cofferdam design concepts is demonstrated using well-established structural and geotechnical design procedures and computational modeling. The improved performance of the proposed design concepts, particularly in combination with the dry construction technique, show cellular cofferdams have the potential to be used as basis for the construction of permanent hydropower dam structures that are versatile, with less impact on the environment, and will cost less to build than conventional hydropower dams.

13 HYDRO ENERGY↗
DOE OSTI2022

Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains

Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.

13 HYDRO ENERGY↗
DOE OSTI2020

Feasibility of Using Additive Manufacturing to Produce Axial Flow Hydropower Turbine Housing, Runner, and Draft Tube

Oak Ridge National Laboratory (ORNL) worked with AMJET Turbine Systems, LLC (ATS), to demonstrate additive manufacturing of components for low head hydro turbine/generator applications. Several different types of additive manufacturing systems were used. Components were finished and assembled for testing in a turbine. However, one of the processes, Big Area Additive Manufacturing (BAAM),produced components that did not adequately perform due to persistent leaks that were caused by porosity in the parts produced. Therefore, the BAAM system was eliminated from contention. Vacuum infusion of rein into the parts eventually solved the porosity problem.Components were installed in anATS-8 turbine to be tested on the Keokuk Dam for operationally testing the unit.

13 HYDRO ENERGY↗
DOE OSTI2020

Harnessing the Hydroelectric Potential of Engineered Drops (Final Technical Report)

The potential for low-head hydropower in the engineered drops in both federal and private irrigation system is well known and significant. The environmental and socio/recreational impacts of harnessing this renewable energy resource in man-made conduits are much less, and often insignificant, compared with comparable hydro-electric potential in natural water features on rivers, lakes, and streams. Yet, few new plants have been commissioned in more than two decades. Over the same time period, low head hydro installations in Germany have more than doubled. The challenge is in finding economical ways to harness the hydro-electric potential in the engineered drops, and efficiently deliver the power to the grid. The objectives of Percheron Power, LLC's (Percheron Power) Project were to design, develop, permit, and operate an innovative low-head hydro-electric generation facility on an existing engineered drop of a large irrigation canal system. The hydro-electric generation facility was designed to employ a new type of turbine and technology, called an Archimedes Hydrodynamic Screw (AHS), to harness the existing potential of the engineered drop. The goal was to demonstrate the new lower cost AHS technology system to federal agencies, irrigation districts and other system owners and to support further development of new small hydropower projects at previously marginal low-head sites in the U.S. The objective of this funding opportunity of the Department of Energy Water Power Technologies Office was to reduce the Levelized Cost of Energy (LCOE) for small hydropower to less than ${$}$0.07/kWh (${$}$70/MWh) to be competitive with existing base-load power sources such as coal-powered power plants.

13 HYDRO ENERGY↗
DOE OSTI2020

Optimization of Archimedes Screw for Use in Hydroelectric Projects

In 2017, the Department of Energy’s (DOE) Water Power Technologies Office (WPTO) made federal funding available to several awardees to investigate and provide innovative technological solutions to reduce capital costs of installed hydroelectric facilities at non-powered dam’s (NPD’s) across the United States, while maintaining a high level of efficiency. Awardees were to develop specific technologies that showed promise of reducing installed capital cost (ICC) by at least 20% over a given baseline and maintain a water-to-wire efficiency of at least 80% at head levels of 50 feet or less and flows of 1000 cubic feet per second (cfs) or less. Canyon Hydro (Canyon) was selected as an awardee for this funding and worked to refine the implementation of the Archimedes screw turbine for use at these site conditions. Canyon and its project partners analyzed several dam inventory datasets to determine the most common head and flow range of current NPD’s in order to best select design conditions for a turbine that would perform successfully at common heads and flows. Computational Fluid Dynamic (CFD) analyses were conducted after site conditions had been selected to optimize the turbine geometry for efficiency. Through this effort we were able to estimate water-to-wire efficiency over a range of flows. Equipment design focused on concepts of modularity and pre-fabricated construction. These methodologies were used where possible to reduce costly on-site construction and shorten deployment timelines. Cost modeling was conducted with input from industry experts in general construction, pre-fabricated concrete construction, and composite fabrication. As a hydroelectric turbine manufacturer of 35 years, Canyon drew upon its own knowledge base in steel fabrication, water-to-wire component specification and ancillary systems to develop the remaining cost matrix for the project. As a result of these efforts, Canyon was able to present findings that indicated a modular Archimedes screw turbine system could be designed that reduced ICC by 23.9% and maintain a maximum water-to-wire efficiency of 82.3%, meeting the goals of the project.

13 HYDRO ENERGY↗
DOE OSTI2022

Restoration Hydro: A Watershed Approach to Standard Modular New Hydropower

The objectives of FOA DE- FOA-0001836- “Standard Modular Hydropower” included designing a standardized, modular, and environmentally compatible hydropower schematic for implementation in greenfield sites that generate up to 10 MW of capacity. Utilizing funds competitively awarded under DOE’s Water Power Technologies Office, the Natel Energy team developed a concept for modular new stream reach (NSR) hydropower that incorporates multi species upstream and downstream fish passage, improved river channel connectivity, and recreational modules. The in-stream design of the collective modules minimized site specific design and maximized the opportunities for modularity. Financial data was also presented using actual costs from regional suppliers, with figures provided in 2022 dollars. While the project team did not address potential permitting process improvements, the site selection criteria did consider established barriers to hydropower development such as tribal and preserved lands, interconnection proximity, and endangered species to exclude or deprioritize. The project’s design schematic met the objectives of the FOA, and presented a unique solution that targets alluvial pockets as natural features for sustainable development. Natel’s concept also incorporated the company's fish-safe Restoration Hydro Turbine for safe downstream passage, while featuring a rock arch that integrates fish passage, water, recreation, and grade control modules (including sediment). Alignment with the Department of Energy Office of Energy Efficiency and Renewable Energy (EERE) “Innovative Design Concepts for Standard Modular Hydropower and Pumped-Storage Hydropower” Program: According to the Hydropower Vision (DOE, 2016), approximately 16 GW of hydropower growth is possible with the development of technology solutions that balance efficiency, economics, and environmental sustainability. The desired outcome of the SMH program is transformational innovation specifically in the site identification, conceptual, and detailed design phases of technology development lifecycles (DOE, 2018). In developing the SMH design schematic, the team aimed to address the opportunities outlined in the Vision through an inverted design philosophy; rather than singularly prioritizing efficiency and power production, the team focused on integrating hydropower with restoration of degraded streams to optimal ecosystem function and provision of exceptional recreation value as design criteria. To achieve this, Restoration Hydro incorporates the principles of nature-based engineering (WWAP, 2018) and biomimicry (Biomimicry NL.) to strategically deploy complementary combinations of permanent, semi-permanent, and ephemeral low-head structures - such as natural and engineered log jams - that harness geomorphological and hydrological processes at the landscape-scale. Primary applications of Restoration Hydro include: 1) restoration of degraded watersheds’ natural ecological function and enhancement of hydrological connectivity; and 2) creation of associated co-benefits to hydro production, including increased groundwater recharge, improved sediment transport and management, improved water security and water quality. Restoration Hydro projects build upon proven watershed restoration engineering techniques by integrating hydropower turbines into low-head structures using innovative and evolving civil works concepts that facilitate fish and sediment passage, and in some cases create additional revenue-generating recreational opportunities. Powering low-head structures creates a directly monetizable layer of economic value in the form of flexible, reliable, renewable energy on top of the already high-value water, environmental and recreational benefits of watershed and river restoration. The approach aims to create a virtuous, self-reinforcing cycle whereby Restoration Hydro projects support the scaling of ecosystem restoration activities, creating a water-energy-carbon multiplier effect that, through the principles of adaptive change management: 1) improves the resilience of landscapes and downstream population centers for changing hydrological cycles; 2) creates a reliable energy resource that facilitates the integration of intermittent renewable power sources into grids; and 3) supports climate change mitigation through grid decarbonization and enhanced ecosystem carbon capture and retention.

13 HYDRO ENERGY↗
DOE OSTI2022

1.1.1.401 - Groundbreaking Hydro and I AM Hydro Prizes

The Hydropower Geotechnical Foundations Prize ("Groundbreaking Hydro Prize") offered a total of $300,000 in cash prizes to elicit and advance innovative concepts for low-head (up to 30 ft of hydraulic head) hydropower geotechnical foundation technologies. The Innovations in Advanced Manufacturing for Hydro (I AM Hydro) prize sought to identify new ideas with the potential to have a disruptive impact in the hydropower industry and offered up to $250,000 in cash prizes.

HYDRO ENERGY↗
DOE OSTI2023

Advanced Compact Generation Module with Fish Safe Runner Technology

Hydropower is an important contributor of stable, load-leveling renewable energy to our national grid. Increasingly, the development of new hydropower facilities or the retrofit of existing ones hinges not only on minimizing costs but also environmental impact. In this report, the analysis and testing of a modular and scalable low-head hydropower generation design using Natel Energy’s Restoration Hydro Turbine is described. This design leverages many established industry approaches for compactness and efficiency while simultaneously allowing for safe downstream fish passage through the turbines themselves. This unique approach reduces overall hydropower facility costs and enables a simpler inclusive method of project design and operation. To assess this design, mechanical and fluid computational analyses were used to study and optimize key parameters. Passage tests of important migratory species (salmonids, American eel) were conducted through representative turbines. The unique propeller geometry of the fish-safe Restoration Hydro Turbine was subjected to detailed design and testing using advanced manufacturing composite techniques. Comprehensive module cost models were developed and assessed alongside hydraulic efficiency. The results of this project show promising and economical applications for downstream passage offish through Restoration Hydro Turbine modules.

13 HYDRO ENERGY↗
DOE OSTI2022

Environmental design of low-head run-of-river hydropower in the United States: A review of facility design models

We state that the goal of run-of-river hydropower is to produce cost-competitive renewable electricity with minimal disruption of the natural riverine ecosystem. Modeling and feasibility analysis of alternative design options are crucial for developing new run-of-river hydropower projects. Our review shows that existing run-of-river hydropower design models focus on maximizing economic potential at high-head diversion schemes with limited consideration of environmental outcomes. Since nearly three-quarters of new hydropower potential in the United States is found at low-head sites and environmental performance standards are imperative to project success, new models are needed to address the multi-dimensional design challenges at these sites. To aid in formulating holistic models, we synthesize the performance objectives and design variables related to early-stage run-of-river facility design. The objectives span six potential impact areas, including hydrologic alteration, sediment continuity, water quality, aquatic species passage, social, and economic. Based on these reviews, we identify three key areas to enhance the capabilities of run-of-river hydropower design models. These are 1) expanded model formulations, 2) assessment of barrier effects, and 3) explicit environmental objectives. The resulting modeling improvements would accelerate the identification of run-of-river hydropower designs that minimize environmental impacts, promote economic competitiveness, and incorporate the value of non-power benefits.

13 HYDRO ENERGY↗
DOE OSTI2021

Bulb-style Kaplan Turbine - Run-of-the-river (ror) Hydro Governor And Turbine Model

This software package includes hydro governor and turbine models developed in Simulink (Mathworks Inc.) and RSCAD (RTDS Technologies) for low-head bulb-style Kaplan turbine hydropower plants. The model developed in Simulink has been designed and tuned to match the governor-turbine response for a real-world hydropower unit owned by Idaho Falls Power (IFP). The Simulink and RSCAD models enable real-time testing in a hardware-in-the-loop (HIL) implementation using OPAL-RT and RTDS digital real-time simulators, respectively. An automatic initialization for dynamic simulation has also been integrated to each model in both Simulink and RSCAD. The RSCAD initialization involves a novel python-based interfacing for automatic modification of the initial conditions in the model. The parameters of these models can be tuned to match other hydropower plants in this class.

Alam, SMShafiul↗
DOE OSTI2021

Heat Based Power Augmentation for Modular Pumped Hydro Storage in Smart Buildings Operation

In the U.S., building sector is responsible for around 40% of total energy consumption and contributes about 40% of carbon emissions since 2012. Within the past several years, various optimization models and control strategies have been studied to improve buildings energy efficiency and reduce operational expenses under the constraints of satisfying occupants’ comfort requirements. However, the majority of these studies consider building electricity demand and thermal load being satisfied by unidirectional electricity flow from the power grid or on-site renewable energy generation to electrical and thermal home appliances. Opportunities for leveraging low grade heat for electricity have largely been overlooked due to impracticality at small scale. In 2016, a modular pumped hydro storage technology was invented in Oak Ridge National Laboratory, named Ground Level Integrated Diverse Energy Storage (GLIDES). In GLIDES, employing high efficiency hydraulic machinery instead of gas compressor/turbine, liquid is pumped to compress gas inside high-pressure vessel creating head on ground-level. This unique design eliminates the geographical limitation associated with existing state of the art energy storage technologies. It is easy to be scaled for building level, community level and grid level applications. Using this novel hydro-pneumatic storage technology, opportunities for leveraging low-grade heat in building can be economical. In this research, the potential of utilizing low-grade thermal energy to augment electricity generation of GLIDES is investigated. Since GLIDES relies on gas expansion in the discharge process and the gas temperature drops during this non-isothermal process, available thermal energy, e.g. from thermal storage, Combined Cooling, Heat and Power system (CCHP), can be utilized by GLIDES to counter the cooling effect of the expansion process and elevate the gas temperature and pressure and boost the roundtrip efficiency. Several groups of comparison experiments have been conducted and the experimental results show that a maximum 12.9% cost saving could be achieved with unlimited heat source for GLIDES, and a moderate 3.8% cost improvement can be expected when operated coordinately with CCHP and thermal energy storage in a smart building.

Chen, Yang↗
DOE OSTI2022

Coupled Heat Power Operation of Smart Buildings via Modular Pumped Hydro Storage

In the United States, building sector is responsible for around 40% of total energy consumption and contributes about 40% of carbon emissions since 2012. Within the past several years, various optimization models and control strategies have been studied to improve buildings’ energy efficiency and reduce operational expenses under the constraints of satisfying occupants’ comfort requirements. However, the majority of these studies consider building electricity demand and thermal load being satisfied by unidirectional electricity flow from the power grid or on-site renewable energy generation to electrical and thermal home appliances. Opportunities for leveraging low-grade heat for electricity have largely been overlooked due to impracticality at small scale. In 2016, a modular pumped hydro storage technology was invented in Oak Ridge National Laboratory, named Ground Level Integrated Diverse Energy Storage (GLIDES). In GLIDES, employing high-efficiency hydraulic machinery instead of gas compressor/turbine, liquid is pumped to compress gas inside high-pressure vessel creating head on ground level. This unique design eliminates the geographical limitation associated with the existing state-of-the-art energy storage technologies. It is easy to be scaled for building level, community level, and grid level applications. By using this novel hydro-pneumatic storage technology, opportunities for leveraging low-grade heat in building can be economical. In this research, the potential of utilizing low-grade thermal energy to augment electricity generation of GLIDES is investigated. Since GLIDES relies on gas expansion in the discharge process and the gas temperature drops during this non-isothermal process, available thermal energy, e.g., from thermal storage, combined cooling, heat and power system (CCHP), can be utilized by GLIDES to counter the cooling effect of the expansion process and elevate the gas temperature and pressure and boost the roundtrip efficiency. Here, several groups of comparison experiments have been conducted, and the experimental results show that a maximum 12.9% cost saving could be achieved with unlimited heat source for GLIDES, and a moderate 3.8% cost improvement can be expected when operated coordinately with CCHP and thermal energy storage in a smart building.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower

ORNL worked with Cadens, LLC to explore the use of additive manufacturing (AM) for the production of low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials, and operates a micro-hydro lab to test AM components in controlled environments. Until now Cadens’ tests have been limited in size to components that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end use parts of a hydropower system using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. The components have been in use for more than three years without a 3D printed component failing.

13 HYDRO ENERGY↗
DOE OSTI2020

Utility of Big Area Additive Manufacturing for Part Production for Low-Head Hydropower (CRADA NFE-18-07280 Final Report)

ORNL worked with Cadens, LLC, to explore the use of additive manufacturing (AM) to produce low-cost parts for low-head hydropower systems. Cadens develops design optimization software that leverages the flexible, low-cost, high-strength benefits of AM and composite materials. Cadens also operates a micro-hydro lab to test AM components in controlled environments. Until now, Cadens’ tests have been limited to components of a size that they can cost-effectively manufacture using local commercial systems. This project provided an opportunity for Cadens to scale up their modular AM hydropower parts using the capabilities of Big Area Additive Manufacturing (BAAM). This project was a success and resulted in the design and fabrication of several end-use parts of a hydropower system, using a Big Area Additive Manufacturing (BAAM) system. The fabricated parts include a draft tube, thimble, runner housing mold, PVC end fitting and two PVC pipe supports. In addition, a runner system was fabricated using fused deposition modeling on a 3D Platform Workbench 400 Series System.

13 HYDRO ENERGY↗
DOE OSTI2020

Hydropower Geotechnical Foundations: Current Practice and Innovation Opportunities for Low-Head Applications

Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to challenges frequently encountered with traditional approaches. With this understanding, it is critically important to understand and document the current state of practice for hydropower geotechnical foundations, identify key challenges, and define opportunities for innovative solutions. To this end, this report documents the current state of practice across the three main phases of geotechnical foundation development: (1) geotechnical site assessment, (2) design, and (3) construction for hydropower systems. It also describes the major challenges with conventional approaches and identifies opportunities for innovation to reduce hydropower foundations costs, timelines, and risks. Key takeaways from this report include the following: Approximately 80% of available low-head sites are expected to have foundations on soil beds rather than rock beds, suggesting that rockfill and earthfill dams may be the most cost-effective conventional dam type for new projects.; Geotechnical and geologic investigation activities are time-consuming and expensive but are essential to define the parameters and criteria needed for foundation design.; Certain riverbed soil and bedrock types present significant technical challenges or require expensive foundation construction, which can prove financially prohibitive for low-head project development.; Modular hydropower design and prefabricated modular foundations represent a promising but unproven paradigm for new hydropower development. Design and construction approaches using optimized and highly repeatable, reliable components would benefit project cost, time, and risk but require additional research and development.; Temporary construction features for foundations, including cofferdams, water diversion, and water control systems, can prove costly and have inherent construction risk.; For economically viable development, hydropower geotechnical foundations should be limited to 4 to 15% of the project’s total initial capital costs. Many proposed projects have experienced cost overruns attributable to foundation difficulties or surprises during construction. These overruns may have been due to inadequate investigations, lack of adequate engineering effort to tailor the structures to site geology and topography, and/or contractual terms, among other considerations.; Challenges for hydropower foundations and opportunities for innovative technology solutions are identified in the following areas (consistent with the three main phases of foundation development): Geotechnical site assessment, Foundation design and materials, Construction methods and technology. Ultimately, this report aims to provide information about geotechnical foundations for low-head hydropower and to motivate transformative technologies to support hydropower growth.

13 HYDRO ENERGY↗
DOE OSTI2022

Needs and Opportunities for Testing of Hydropower Technology Innovations

Despite hydropower’s status as a well-established technology, changes in the global energy sector have prompted a variety of necessary hydropower technological innovations. Examples include efficient lowhead turbines, more flexible and dispatchable hydropower and pumped storage systems to complement variable and intermittent renewable resources, and technologies providing higher environmental performance. However, while innovative technologies are currently being proposed to meet these development challenges, small hydropower facility owners do not have sufficient risk-bearing capacity to adopt new, unvalidated technologies. This discourages manufacturers from bringing nascent technologies to market and stalls the technological growth of the sector. To reduce the risks associated with new technologies and promote further innovation, systemic (and sometimes unconventional) validation activities and new testing capabilities for hydropower are highly desired. These testing capabilities must demonstrate the safety, environmental acceptability, reliability, and performance of innovative technologies to quantify their value compared with existing technologies. Establishing these capabilities through dedicated testing facilities will be key to promoting hydropower growth in the United States. Following direction from the House Energy and Water Development Committee, the US Department of Energy’s Water Power Technologies Office (WPTO) has been tasked with understanding the state of hydropower testing in the United States. This scoping report discusses the needs and opportunities of hydropower testing in the United States, with a specific focus on small hydropower. Future developments will likely mostly target low-head sites with less than 30 ft (9.1 m) from new stream-reach developments, non-powered dam retrofits, and rehabilitation/upgrade of existing plants.

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DOE OSTI2022

The waterSHED Model: User Guide

The ideal design and operation of small hydropower plants is a complex optimization problem with economic, social, and environmental objectives. The waterSHED (Water Allocation Tool Enabling Rapid Small Hydropower Environmental Design) model is a user-friendly tool that allows hydropower stakeholders to model the trade-offs among these objectives using the Standard Modular Hydropower (SMH) framework. The SMH framework employs modular technologies that can be represented as blackbox objects and combined within a river to create a hydropower facility. For a given site, the waterSHED model aims to determine which modules should be placed in a facility and how those modules should be operated. This user guide describes how to use the graphical user interface and related functionalities. This document also summarizes the background research and mathematical formulations that are explained indepth in the accompanying doctoral dissertation. This model is an early step toward a new hydropower design process that employs standardization and modularity to reduce costs, development timelines, and challenges regarding social and environmental mitigation measures for low-head, small hydropower development. The waterSHED model is a Python application that will require the ability to download a GitHub repository, import the necessary packages, and run a set of Python script files using an integrated development environment. The script produces a graphical user interface to coordinate inputs, simulate operation, and visualize results, so no coding experience is needed once the script is running. Additionally, the waterSHED Workbook is a Microsoft Excel file that works with the Python script to facilitate data entry

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