Project Name: Curtis Station Units 4 & 5 Rehabilitation

Summary: Replacement of two horizontal turbines with new vertical units

Client: Curtis Palmer Hydroelectric Company

Project Location: Corinth, NY

Project Size: 2.4 MW (Units 4&5)

Services Provided:
• Layout and Structural Design
• Construction Opinions of Cost
• Contractor Bidding Assistance
• Construction Assistance

Project Timeframe: 2012 - Present

Relationship with Client: Since 1984

Client Needs:
Curtis Palmer Hydroelectric Company (CPHC) required design services and generation of a cost opinion for structural modifications to their Curtis Powerhouse. The modifications were necessary to facilitate the replacement of the existing Units 4 & 5 horizontal turbines with new vertical Canadian Hydro Component (CHC) Kaplan units and future maintenance access to those units.

Kleinschmidt Solution:
Kleinschmidt assisted CPHC with a conceptual level study to determine the modifications necessary and a construction opinion of cost to install new CHC units in the existing location of Units 4 & 5 horizontal turbines. Based on Kleinschmidt’s conceptual design, CPHC contracted with the CHC to provide new turbines and reconfigure the existing generators to replace the existing Units 4 & 5. The concept proposed by CHC was a vertical double regulated axial flow Kaplan turbine with the generator located within the existing headworks area. Kleinschmidt prepared a final design which incorporated removal of the existing horizontal turbine components and the placement of new structural concrete to support the new vertical turbines. The final design also defined the modified water passage and the required modifications of the structure for access for the installation of the turbine components and future maintenance of the equipment. For the new vertical units, the turbine pit floor was lowered by over 8 feet resulting in a significant increase in the unsupported height of the existing unreinforced concrete wall. A finite element analysis was performed to determine anticipated stresses in the wall and the required wall reinforcement was designed to ensure adequacy of the structure under the new conditions.

Client Benefits:
Due to the limited construction access to the site and the work area, the sequencing and constructability of the project was a significant consideration during the design process. Kleinschmidt worked with the selected contractor to provide the most cost effective and efficient design for the project and minimized the duration of turbine outages.