DOE OSTI2013
The Boulder Canyon Hydroelectric Project (BCH) was purchased by the City of Boulder, CO (the city) in 2001. Project facilities were originally constructed in 1910 and upgraded in the 1930s and 1940s. By 2009, the two 10 MW turbine/generators had reached or were nearing the end of their useful lives. One generator had grounded out and was beyond repair, reducing plant capacity to 10 MW. The remaining 10 MW unit was expected to fail at any time. When the BCH power plant was originally constructed, a sizeable water supply was available for the sole purpose of hydroelectric power generation. Between 1950 and 2001, that water supply had gradually been converted to municipal water supply by the city. By 2001, the water available for hydroelectric power generation at BCH could not support even one 10 MW unit. Boulder lacked the financial resources to modernize the facilities, and Boulder anticipated that when the single, operational historical unit failed, the project would cease operation. In 2009, the City of Boulder applied for and received a U.S. Department of Energy (DOE) grant for $1.18 million toward a total estimated project cost of $5.155 million to modernize BCH. The federal funding allowed Boulder to move forward with plant modifications that would ensure BCH would continue operation. Federal funding was made available through the American Recovery and Reinvestment Act (ARRA) of 2009. Boulder determined that a single 5 MW turbine/generator would be the most appropriate capacity, given the reduced water supply to the plant. Average annual BCH generation with the old 10 MW unit had been about 8,500 MW-hr, whereas annual generation with a new, efficient turbine could average 11,000 to 12,000 MW-hr. The incremental change in annual generation represents a 30% increase in generation over pre-project conditions. The old turbine/generator was a single nozzle Pelton turbine with a 5-to-1 flow turndown and a maximum turbine/generator efficiency of 82%. The new unit is a double nozzle Pelton turbine with a 10-to-1 flow turndown and a maximum turbine/generator efficiency of 88%. This alone represents a 6% increase in overall efficiency. The old turbine operated at low efficiencies due to age and non-optimal sizing of the turbine for the water flow available to the unit. It was shut down whenever water flow dropped to less than 4-5 cfs, and at that flow, efficiency was 55 to 60%. The new turbine will operate in the range of 70 to 88% efficiency through a large portion of the existing flow range and would only have to be shut down at flow rates less than 3.7 cfs. Efficiency is expected to increase by 15-30%, depending on flow. In addition to the installation of new equipment, other goals for the project included: Increasing safety at Boulder Canyon Hydro Increasing protection of the Boulder Creek environment Modernizing and integrating control equipment into Boulder's municipal water supply system, and Preserving significant historical engineering information prior to power plant modernization. From January 1, 2010 through December 31, 2012, combined consultant and contractor personnel hours paid for by both the city and the federal government have totaled approximately 40,000. This equates roughly to seven people working full time on the project from January 2010 through December 2012. This project also involved considerable material expense (steel pipe, a variety of valves, electrical equipment, and the various components of the turbine and generator), which were not accounted for in terms of hours spent on the project. However, the material expense related to this project did help to create or preserve manufacturing/industrial jobs throughout the United States. As required by ARRA, the various components of the hydroelectric project were manufactured or substantially transformed in the U.S. BCH is eligible for nomination to the National Register of Historic Places due in part to its unique engineering features and innovative construction techniques. Special efforts were directed toward documenting the (largely original) interior of the plant and installing new equipment without modifying the power plant exterior in order to preserve the historical significance of the facility. In addition, a significant portion of the historical equipment within the power plant was preserved in place. The modernization project began with DOE grant award on January 1, 2010, and the project was completed on December 31, 2012. In addition to city engineering and hydroelectric staff, major project participants included AECOM (design/engineering) Canyon Industries (turbine/generator manufacture), Gracon Corporation (general construction contractor), Exponential Engineering Company (electrical engineering) and URS Corporation (historical documentation), as well as numerous other subcontractors and consultants.