2009 ICOLD Edition

URR 1 DAm - COLOmBIA

An environmentally friendly solution with Fusegates to boost the hydropower generation

As the public and political concerns are getting louder for any development lacking sustainable and environment friendly solutions, the construction of new dams faces an increasing number of difficulties. Any alternative that has little environmental impact, and that does not generate social and political opposition, presents much greater value in the present context.
Increasing the storage capacity of existing dams without raising the maximum water level, when technically feasible, constitutes an attractive solution as it minimizes the environmental impacts. A good example of this solution is the alternative developed by Urr Esp SA in Colombia with use of the Fusegate system. Urr 1 is an 360mW hydropower scheme located in Cordoba, Colombia, owned and operated by Urr Esp SA. It includes a 73m high rockfill embankment impounding 1 740 hm3 of water and a 182m long spillway spanned by a bridge over its entire length with piers at every 14 m. After an evaluation of a number of options for increasing storage capacity and flood mitigation, Urr Esp SA has awarded in November 2008 a contract to Hydroplus to design, manufacture and install a spillway control system consisting of Fusegates and flap gates to allow for raising the normal reservoir elevation by 2 m with very limited environmental impacts. The additional 150 hm3 in reservoir storage capacity and the raise in water head above the turbines will increase the hydropower generation by 3 to 5 %, translating to an amortization of the costs in only 3.5 years.

Urr 1 dam spillway overspilling

What is a Fusegate?
A Fusegate is typically composed of a water-retaining structure and a water inlet well which daylights in a chamber located beneath the unit. Fusegates can be built using either steel or concrete, depending on project requirements and economical considerations. The system comprises independent and free-standing units installed side by side on top of a free overflow spillway sill. At the Urr 1 Dam, 22 steel Fusegates, measuring 2 m high by 7 m wide, are installed on the existing spillway.
Steel Fusegate being installed on Upper Layang dam, malaysia.

The triggering process

The major innovation associated with the system is the Fusegate operation process: during rare occurring large floods that might threaten the dam, the Fusegates overturn one by one like fuses in an electrical circuit, thus allowing the water to be discharged through the spillway. When the reservoir level reaches a specific, predetermined elevation, water will start flowing into the inlet well and then filling the base chamber. Uplift pressure will rapidly increase, causing the Fusegates to pivot on the toe abutments and rotate downstream. Each Fusegate overturns in a series, depending on the magnitude of the flood. As more of the Fusegates overturn, more water is discharged over the spillway. In the case of Urr 1 Dam, the normal water level in the reservoir is maintained at or below the crest of the Fusegates. The first Fusegate has been designed to overturn for floods corresponding to a 100 year event.

How do es it operate?
The majority of the dams are equipped with a spillway designed to discharge floods and thus prevent the generation of excess pressure from being exerted on the dam. Usually, the spillway forms an intentional breach built into the dam embankment. Fusegates fit onto the spillway sill and operate much like a labyrinth weir. When the water is below their crest, the Fusegates work as a watertight barrier. In case of small to moderate floods, water spills over the Fusegates crest.
Light overspilling above the Fusegates crest at mcClure dam, New mexico, USA.

Fusegate in winter at Khorobrovskaya, Russia.

Actual Fusegate tipping at Saint Herbot dam, France.

Fusegates, a reliable alternative

The Fusegate system can significantly increase the safety level of dams. This is achieved by lowering the existing spillway sill, and recovering the storage capacity by installing Fusegates on top of the new spillway platform. The Fusegate system can also increase the storage capacity of the reservoir by up to 30 %, by raising the normal pool elevation. Fusegates operate completely independently no need for human supervision, electrical power or systems control. Fusegates are designed to protect, at all times and under all conditions, the dam as well as people and property located downstream. Fusegates also provide a level of reliability and operational accuracy that is superior to that of traditional non-mechanical systems, such as fuseplugs. Rigorous studies, using scale models and full-scale prototypes, have been conducted on the stability of Fusegates and on conditions that can have an impact on overturning, such as earthquakes, impacts from heavy objects, ice pressure, lack of maintenance, vandalism, sabotage, degradation of joint seals, and the obstruction of drain holes and inlet wells. These studies have demonstrated the exceptional reliability of Fusegates, a key benefit in an area where system failures can have catastrophic consequences.

URR 1 DAm - COLOmBIA

The versatility of the Fusegate system

The project requirements at Urr 1 Dam are met with the installation of 22 Fusegates accommodated on 11 of the 13 bays of the spillway, and with flap gates on the remaining 2 bays after they have been lowered by 3.5m. Each flap gate is 5.5 m high and 12 m wide. Among the attractive features of the project is the fact that the Fusegates have been designed with a unique labyrinth shaped overspilling crest maximizing the hydraulic efficiency. In addition, the Fusegates at Urr 1 dam are installed directly on top of the existing ogee crest with the use of lateral flanges that can be adapted to the geometry of the spillway.

Spillway before (1) and after (2) modification.

The environment
Raising a hydropower dam is by nature an environmentally friendly solution. It actually allows for additional power generation offering real and measurable emission reductions. Should an approved baseline and monitoring methodology be validated, such a project would definitely qualify as a CDM project. Nevertheless,theproject implementation was subject to the prior approval by the Colombian Authorities through a comprehensive environmental impact study. A methodology was developed to identify all the environmental and social impacts and to evaluate their consequences. It was concluded that the reservoir raising has not only negligible impacts on the area surrounding the reservoir, but will also flood attenuation. Hydroplus implemented an environmental management system in compliance with its ISO 14001 program as required for every project. It includes efforts to minimize environmental impacts and to efficiently manage energy and water utilization.

Hydroplus Proud Participant

Hydroplus is thrilled to participate to the 23rd ICOLD Congress. We will answer question 90, Upgrading of existing dams. The presentation will take place on Wednesday afternoon, May 27. Hope to see you there!

5 cours Ferdinand-de-Lesseps 92851 Rueil-malmaison Cedex Tel.: +33 1 47 16 44 34 Fax: +33 1 47 16 42 12 contact@hydroplus.com Aerial view of Urr 1 dam.

Hydroplus