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Fully rehabilitation: integration of a small hydro cascade into a water supply

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Article  in  International Journal on Hydropower and Dams · October 2016

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 Rehabilitation of the centenary Fully hydropower scheme:
a cascade of small plants integrated in a water supply system

Pedro Manso*
Laboratory of Hydraulic Constructions (LCH)
Ecole Polytechnique Fédérale de Lausanne (EPFL)
EPFL-ENAC-IIC-LCH
Station 18, CH-1015 Lausanne, Switzerland
*formerly at Stucky SA.

Jérôme Filliez
Stucky SA (Gruner company)
Rue du Lac 33
1020 Renens VD, Switzerland
jfilliez@stucky.ch

Bastien Mösching
SEIC-Teledis
Grand Rue 2
1904 Vernayaz, Switzerland
bastien.moesching@seic-teledis.ch

1. Introduction
The Fully hydropower scheme was commissioned in 1915 and hold until the 1930’s the record of the highest head
worlwide (approx. 1640 m). The scheme is situated in the Canton of Valais in Switzerland, between Martigny and
Sion, on the right bank of the Rhône River valley (Figure 1). Until 2005 the Forces Motrices de Fully (FDMF) were
own by Alpiq (formerly Energie Ouest Suisse - EOS), one of the largest energy utilities in Switzerland. A new
concession was awarded in 2005 until 2085, in which the local municipality took a 72% share of the company and
SEIC-Teledis holds the remainder share (since end of 2015).
The steel penstock has shown ageing signs over the years, both due to leakage induced by frozen trench soil in
altitude reaches and corrosion progress. In 2011 a thorough assessment of the buried penstock showed that residual
safety factors would reach values below the acceptable threshold of aptitude for service before the concession term
in 2085. The paper presents the main steps of the rehabilitation studies as well as an overview of the construction
challenges.
The retained rehabilitation concept consists of reducing the internal pressure on the penstock and on changing the
operational pattern of the power scheme (with reduction of the design discharge), whilst guaranteeing an equal
annual energy production and the future water supply of the Fully municipality. The original single-stage
hydropower plant with additional pumped inflows is converted into a cascade of three plants, coupled to the city’s
water supply system. The project’s feasibility relies on the cost side on a detailed assessment of the residual life of
existing structures, reuse of the penstock, construction of two new powerhouses and adaptation of a third one. On
the revenue side, it benefits from the existing feed-in-tariff incentive policy for renewable energies. The project
takes place at several different locations between 2100 and 500 m of altitude with the inherent difficulties of access
and seasonality. Works on site started in September 2015 and commissioning of the last unit is expected end 2016.

2. Existing power scheme

The power scheme uses the natural inflows to two mountain lakes, located at high altitude above the town of Fully.
The upper lake is the largest and its storage capacity was increased by the construction of a 14 m high masonry dam
at the natural outlet (Figure 2a). The lower lake is Sorniot Lake, whose inflows have been so far pumped to the
upper lake (Figure 2b). The lower lake catchment accounts for one third to half of the total inflows to the system.
Figure 1. Location of the project in Switzerland (small map). Aerial view of the Rhône River bend at Martigny and detailed
location of the Fully and Sorniot lakes, of the Garettes platform and of the historical powerhouse (“La Belle Usine”) in Verdan.
The water is conveyed from the upper lake directly to the powerhouse located in the Rhône River plain,
approximately 1600 m below, in one single stage, via a steel penstock of 600/500 mm diameter. Pumping between
the two lakes is done using the same penstock. The steel penstock is 4673 m long, of which roughly 1 km divided in
three tunnels and the remainder length in buried trenches. The steel pipe thickness is 6 to 8 mm between the two
lakes, increases regularly to 20 mm from Sorniot to Garettes (at 1550 m asl) and is maximum 41 mm at the entry of
the powerhouse (Chenaud & Du Bois, 1922). The powerhouse (Figure 2c) was built to house 4 units, each a 2.2 MW
horizontal Francis group. The scheme was operated until January 2013 for peak power production, filling up the
main reservoir during snowmelt in spring time (and eventually using the excess water for production) and then
waiting until winter time to generate energy mainly at peak time. Keeping the reservoir full or close to full during
most of summer and autumn often led to spillage and dam overtopping. The average annual inflows to the system
are 3.6 hm3 with significant variation (approx. between 2.5 to 5.3 hm3 over the last 20 years), leading to an average
electricity production of 10 GWh/year. In 1961 a second entry to the intake tower was done underwater, which
increased the useful volume. The Fully dam reservoir could thus be managed at lower levels and spilling was
significantly reduced. In 1967 the four turbine units were replaced by a single 6 MW unit with a rated discharge of
480 l/s, placed at the basement of the powerhouse. A new 460 hp pump was installed at Sorniot. The net water
equivalent coefficient of the scheme is estimated at 3.4 kWh/m3.
Penstock failure due to landslide
In 2000 a major accident occurred between Sorniot and Garettes with rupture of the penstock. A major landslide
occurred immediately at the Sorniot tunnel outlet taking 900 m of DN600 penstock pipes with it. No casualties were
registered downstream and the scheme was out of service. Works were carried out from 2004 to 2006 to build a new
stretch of tunnel circumventing the landslide zone and new DN500 penstock pipes were installed. The power
scheme lost the production of 5 snowmelt seasons. During that period a watertight membrane was installed on the
upstream face of the dam and several hydro-mechanical elements were replaced at the intake and intermediate valve
chamber.
 a) b) c)
Figure 2 – a) Fully dam, upstream view, during snowmelt (dam crest level at El. 2135.71 m asl); b) Sorniot lake in summer
(natural outlet level at El. 1987.77 m asl). Existing pumping station seen from upstream (the penstock crosses the lake in a trench
before entering a tunnel); c) “La Belle Usine” powerhouse amid the Fully vineyards (existing turbine axis level at El. 496 m asl).

Assessment of penstock aptitude for service

After renewal of the concession and re-commissioning of the scheme, frequent repair of penstock leakage and
evidence of corrosion on the broken penstock pipes aroused renewed interest on the structural status of the penstock.
Doubts over the penstock’s aptitude for long-term service justified carrying out extensive measurements of penstock
thickness (over 250 point measurements) and assessment of its residual structural safety factor. Deduced corrosion
rates reached locally values as high as 25 and 34 m/year, which are higher than the general 20 m/year general
recommendation for each of the penstock faces by the Technical Standards for Gates and Penstocks (1991). Based
on a rate of 25 m/year and known material properties and operation loads a thorough structural assessment was
carried out for future time milestones. The results showed that an important reduction in structural safety factors
beyond acceptable threshold values and for several penstock reaches will be attained before the term of the present
concession in 2085.

3. Rehabilitation concept
Motivation for rehabilitation
Two main arguments pledged in favour of launching a major rehabilitation of the scheme:

 The need to guarantee penstock safety throughout the new concession term until 2085;
 The interest of the new reference shareholder, the Municipality, to use the mountain water resources to
satisfy the population’s needs all year round, as an alternative to pumping wells located in the Rhône River
valley, thus combining electricity production with water supply.
To satisfy the first objective several technical options were considered, from local replacement of old pipes by new
ones as per the needs, or tubing (placing new thinner pipe inside old one) or reduction of internal pressure by
creation of intermediate stages. Coping with the second objective revealed however that a major change in operation
practice is required since water supply is required all-year round.
Context incentives to small-hydro production
Following the accident at Fukushima nuclear plant in Japan in 2012 the Swiss Confederation established a new
strategy up to 2050 aiming, among other things, at reducing the dependency on nuclear energy and increasing the
share of electricity of renewable endogenous sources. The existing framework set by the Energy Directive (OEne)
since 1998 has been object of several updates, the applicable law for small hydro project entering in force in 2012
(updated in 2015). The existing framework allows hydropower owners and/or developers to apply for a fixed-
remuneration program, in which all energy produced is bought by the grid at a fixed rated during 25 years (reduced
to 15 years after 01.01.2014 in most cases with increased rates). The fixed rate is estimated via a procedure taking
into account the cost of the facilities (without the electromechanical equipment) and the electricity produced. It is
labelled “remuneration at cost price” similar to a feed-in tariff scheme. The program for grid connection of small
hydro plants is presented in the Appendix 1.1 of the revised OEne (2015). Of particular interest for FMDF is the fact
the use and upgrade of existing schemes is clearly seen as contributing positively to reaching the 2050 goals. Also,
the feed-in tariff may comprise a bonus for rehabilitation works carried out over the past 30 years (as function of
their residual value according a linear decay rate). This is an extra incentive for generalised good maintenance of
hydropower facilities in Switzerland and part of the penstock repair works carried out by the FMDF in 2004/06 were
eligible.
Connection with the water supply system
Water demand is fairly low throughout most of the year, in average 55 l/s (or approx. 4600 m3/day) reaching 150 l/s
during summertime due to irrigation. This scenario is more adapted to a progressive slow depletion of the main
reservoir after snowmelt and in autumn, in direct conflict with the previous operation pattern of FMDF which was
driven by seasonal water transfer and peak energy production in winter. By linking the SHP with the water supply
system the electricity production will be governed by the demand for water downstream instead of electricity prices;
the SHP will operate much more in summertime than before. Only during snowmelt can the FMDF operate free of
downstream constraints, when inflows largely exceed the water supply demand and during which the upper reservoir
is filled up in roughly 2 months. The operation of the SHP after the term of the fixed-tariff scheme will likely be
more variable, as function of a regular assessment of the comparative value of high-altitude water compared with
pumped groundwater at low-altitude and other mountain sources, considering the opportunity benefits from
electricity production and costs for pumping.
Alternatives for scheme rehabilitation
Renewing the penstock for identical head would correspond to a large investment, after 5 years of outage (2001-
2006). Therefore, the favoured rehabilitation strategy was to reuse the existing penstock by reducing its internal
pressure with the creation of two intermediate stages. The main questions were therefore where to place the new
stages, how many stages should be considered and what should be done to the pumping station at Sorniot. No
alternatives implying new long penstocks were considered. Two main groups of alternative layouts were
investigated, with and without pumping. “Without pumping” meant conveying the lower lake inflows down
independently (in time) from those from the upper reservoir, using the same penstock. Or, that an intermediate stage
would be created at Sorniot, reducing the internal pressure on the remainder penstock downstream by approx. 140
mWC (meter water column). In any case, “without pumping” meant that no possibility to store excess water during
flood events at Sorniot up at the dam would be kept. In this case, the maximum pressure acting at the lower reaches
of the penstock would still be of 1490 mWC. Therefore, in both groups of alternative layouts, intermediate stages at
either Garettes or Planuit were investigated, reducing the maximum internal pressure of additional 400 to 600 mWC
downstream. The identified alternatives were compared in terms of energy output, construction and equipment
supply cost and main economic indicators such as NPV and IRR.
Energy studies and selected rated discharges
The energy output and the rated discharge for each stage were defined using a simulation model of the complete
cascade. First the existing scheme and its operation pattern were reproduced. In the absence of direct measurements
of the inflows to the two lakes and of the used discharge, the model was built using as initial data the lake levels, the
generated energy at La Belle Usine and the consumed energy for pumping at Sorniot. Assumptions were made
regarding water extraction for other users. The outcome was an estimation of the spillage, per typical hydrological
years (dry, average and wet years). Second, the new cascade layouts were tested, one by one, considering the same
hydrological conditions. The rated discharge for each stage was investigated such as to guarantee the downstream
water demand and minimize spillage. The most important conclusions of this study were:

 For identical hydrological conditions, the new cascade produces identical electricity output (in average 10
GWh/year with total 3.3 MW of installed capacity) although with a different annual pattern;
 The rated discharge between the lower lake and the Rhône River plain is around 250 l/s, considerably lower
than the present rated discharge, reducing flow velocities, friction losses and transient pressures on the
penstock, as well as the cost of the groups and valves;
 The rated discharge between the two lakes can be lowered to 150 l/s using the Sorniot Lake as buffer;
 Spillage is significantly reduced;
 The annual water level variation range of the upper lake is of approx. 20 m, most of which within the
natural lake elevation range, thus using only the first 3-5 m of the 14-m high dam.
Selected layout alternative
The economic analysis led to the selection of a layout without pumping. In fact, instead of storing all water at the
dam for winter electricity generation, the inflows to the lower lake are directly used in a run-of-the-river pattern. The
selected layout comprises three stages (see Figure 3), the first being created in between the two lakes, with 138 m of
gross head. An intermediate stage is located at Garettes (El. 1552 m asl), which is the uppermost location one can
access by forest road and exactly the downstream end of the repaired penstock reach in 2005/06. The internal
pressure on the lower stage penstock, between Garettes and La Belle Usine (Verdan), is thus reduced of almost 600
m of head, being limited to 1054 m of downstream. The lower lake with a live storage of 30’000 m3 is used as
headpond for the two lower stages. At Garettes a 48 m3 forebay is used to make a transition between the second and
third stages. The final connection with the water supply system is done at the Verdan tailrace, where the
municipality will install between 2020 and 2025 a pumping station to their water filtration plant.

Figure 3. Schematic representation of the project in its present (in blue) and future (in red) configurations.
New operational patterns and challenges
The new cascade operation mode is characterized by two distinct patterns. During snowmelt, most of the generation
is done using the direct inflows to the lower lake, storing all inflows to the upper lake. Only when inflows to the
lower lake recede will water from the upper lake be used as a complement. In this pattern, operation is governed by
the level of the lower lake, to reduce spillage as much as possible. The water used for power generation at Verdan in
excess of the municipality needs for water supply is released to the downstream river system. Outside snowmelt
period, electricity production will be done only when water is conveyed to the water supply system, as per the
demand diagram. Daily modulation (to adapt production to best remuneration hours) might be possible depending of
the downstream pumping and storage capacities of the municipality. The main reservoir will be progressively
depleted and little to no water will leave the system.
The above operation pattern corresponds to a new multi-purpose role of the scheme including the Fully dam, which
was formerly a pure hydropower scheme depending solely on hydrology, storage capacity and electricity market
prices. That will now be the case only during snowmelt, when the cascade is regulated based on the upstream water
levels. Throughout the remainder of the year the cascade is governed from downstream, as function of the water
level in the Verdan tailrace. The command-control system of the cascade must therefore guarantee the proper
functioning of the cascade in these two normal operation patterns, as well as for the abnormal operation scenarios.
Despite the small-hydro characteristics of the project, the complexity of the cascade present unusual challenges. The
design of the forebays as well as of the turbine regulators must guarantee proper reaction of the system, without
unacceptable spillage, transient pressure or air entrainment. The measuring devices must feed properly the SCADA
system with reliable, accurate and redundant data.

4. Rehabilitation project
Following the selection of the layout, a specific design adapted to each location was developed. Works are carried
out at 2100, 1990, 1550 and 500 m of altitude with different constraints regarding the physical environment, briefly
presented below. The selection of the hydro-and electro-mechanical equipment aimed at guaranteeing good enough
efficiency for a large range of discharges throughout the year, guarantee the continual supply of water to the
municipality (in case of turbine or transmission line failure and so on) and limit noise. However, some challenges
were rather unusual, as selecting Pelton turbines for over 1050 m of head, or pressure-release valves for 436 and
1054 m of head without having large reservoirs for residual energy dissipation. Since water treatment for the
different consumers supplied by the Municipality is done downstream of the hydro cascade and to reduce the needs
for treatment, all new powerhouse piping and fittings in contact with water are stainless steel, including the nozzles
and turbine runners. Turbine lubrication is biodegradable.
Further to the penstock and dam ageing issues, and to make matters worse, an accident with the operating group in
January 2013 lead to turbine outage. Failure of a few runner buckets lead to the collapse of the turbine cast iron
casing and major damage to the entire machine hall, fortunately without human injury. The FMDF then decided to
step up the pace of the rehabilitation project, discarding all options of repairing the damaged turbine as well as of
reusing the Belle Usine, which in recent years had become one important location for performing arts rehearsal and
public shows.
Sorniot SHP. The Sorniot powerhouse results from the conversion of the pumping station at El. 1990 (Figure 4) and
reuses the existing 10 kV aerial transmission line. The existing pump and ancillary devices are dismantled, as well
as the oil transformer and electrical cubicles. The existing 4-ton overhead crane is kept. A 3-jet 166 kW vertical
Pelton unit is installed at the old location of the pump. The connection with the upstream penstock includes a turbine
by-pass system equipped with a pressure reduction valve. At the basement of the powerhouse two basins are
available and communicate with the lake: one is used to collect the water passing through the turbine, another feeds
the intake for the second stage between Sorniot and Garettes. The intake for the next stage is equipped with a safety
valve closing by counterweight action upon overspeed detection. At the machine hall level a new partition is done to
house a new resin transformer and medium-voltage cells. The civil works (Figure 5) are being carried out by a team
composed of 2 multitasking workers and a foreman, resident on site four days per week.

Figure 4. Sorniot pumping station in 2011 (photo by Figure 5. Sorniot powerhouse (June 2016) after dismantling of
Thierry Jacob). the former pump and transformer.

Garettes SHP. The powerhouse is located on a narrow platform at El. 1550 (Figure 6) at the location of the lower
station of the original cableway for construction and access to Sorniot, no longer in operation. The mountain road
ends at this location. The powerhouse is located approximately 40 m eastwards from the penstock in order to move
away from the avalanche risk zone and come closer to the existing 16kV aerial transmission line. However it is
located in a zone of various geological risks, which justified carrying out detailed rock fall trajectory studies. A
dynamic protection barrier is built on the mountain side of the powerhouse. The location is also a protection zone for
groundwater recharge, which obliged reducing excavation depth and developing a specific concept for foundation
drainage preventing groundwater contamination. Garettes powerhouse is entirely new and will house a 2-jet 900 kW
vertical Pelton group, a turbine by-pass system equipped with a pressure reduction device, a 48 m3 water reservoir,
the transformer room, electrical cubicles and the intake for the lower (third) stage. The powerhouse is linked to the
existing DN500/600 penstock via new DN300 extensions in cast iron. The powerhouse’s footprint was sized mainly
according to the group’s main dimensions. The reservoir’s height was imposed by the water volume required to
guarantee a proper hydraulic regulation between the 2nd and 3rd stages of the cascade and intake submergence,
whereas the machine hall height was mainly conditioned by the height of the generator and of the transformer.
Equipment manoeuvring on site is done using a mobile crane and equipment access during erection and/or
maintenance is done by means of one removable hatch cover on the top slab. Manholes and grating plates provide
access to the reservoir and valve cubicles. An overflow weir followed by a 110 m long conduit release spillage water
directly on a neighbouring torrent.

Figure 6. Garettes powerhouse, left) before (2013), right) in July 2016.

Verdan SHP. The Verdan powerhouse is located immediately upstream from the Belle Usine. Two alternative
equipment solutions were tendered, one considering one single unit and a by-pass equipped with an energy
dissipation device (to guarantee downstream water supply in case of unit breakdown or repair), another considering
two units. In cost terms both solutions came out quite close, but the solution with one single unit was finally retained
for two reasons: 1) it allowed deferring the investment on the pressure reduction device (likely a monovar valve
type) for a future occasion when the water supply utility would be sufficiently motivated to pay for it, thus making
this solution cheaper; then 2) it allowed having a higher unit installed capacity for grid regulation services (which
may be useful after the feed-in-tariff term); and finally 3) it reduced the number of parts (and increased their sizes,
less clockwork).

Figure 7. Verdan powerhouse: view from East showing the Figure 8. Verdan powerhouse: South - East corner during
new powerhouse (right) and the Belle Usine (left). Source: works (July 2016).
Bureau Nunatak.

The retained architectural concept creates an explicit contrast between the ancient and new powerhouse buildings
(Figure 7). The powerhouse comprises a machine hall level, a 167 m3 water reservoir below and under the same
 footprint, and an appended underground pumping station diverting water to the Municipality water supply system
(Figures 11 and 12). The group transformer is placed on the roadside next and partly above the penstock anchor
block. The equipment is manoeuvred during erection and maintenance with the help of a mobile crane and
equipment access to the powerhouse is done by means of a removable hatch cover on the top slab.

5. Conclusions and Outlook

The project was awarded a 20-year feed-in-tariff contract in 2015 and is currently under construction. Major civil
works at all three sites have been completed, secondary works are being carried out in parallel with equipment
assembly on site. The first unit will be installed at Garettes in October 2016. The total project cost is about
8 million CHF. The business model of the new scheme is based on a lower installed capacity (3.2 MW instead of
6 MW) same energy output (approx. 10 GWh/year) remunerated during the first 20 years through a feed-in-tariff
scheme at rates between 0.13 and 0.18 CHF/kWh, which accounted for the residual value of former repair works
carried out in 2006. Some specific features of the project are paid by the water supply services. Commissioning of
the last unit at Verdan SHP is scheduled for December 2016.

Acknowledgments
The authors acknowledge all previous team members from Stucky and the Forces Motrices de Fully (FMdF) for their positive
contributions to the rehabilitation project since the first studies in 2011, as well as all the project stakeholders including
geologists, architects, environment impact engineers, local organizations, surveyors, contractors and suppliers. The FMdF are
also acknowledged for their consent to publish.

References
1. Chenaud H., Du Bois, L. (1922-1923). Usine hydro-électrique de Fully (Valais, Suisse): la plus haute chute du monde
(1650 mètres), Bulletin technique de la Suisse Romande, No. 21 (pp. 241-248), No. 22 (pp. 253-256), No. 23 (pp. 265-271),
No. 24 (pp. 279-284), No. 26 (pp. 301-304); No. 27 (pp. 2-7), No. 28 (pp. 14-18), No. 29 (pp. 30-35). ETH-Bibliotek
(http://retro.seals.ch) http://dx.doi.org/10.5169/seals-37426 [online access 15.08.2016].
2. Stucky (2013). Projet d’adduction en eau et de mini-centrales hydroéléctriques à Fully, Final Design, 92 pp.
3. Hydraulic Gate and Penstock Association (1991). Technical standards for gates and penstocks, Japan, 375 pp.
4. Swiss Federal Office for Energy (2015). Directive on electricity remuneration at cost price. Art. 7a LEne. Petites centrales
hydrauliques (appendice 1.1 OEne). Versio n 1.8 du 1er avril 2015. in: Département fédéral de l'environnement - DETEC,
(Eds.). http://www.bfe.admin.ch/themen/00612/02073/index.html?dossier_id=02168&lang=fr (online access 26.11.2015).

The Authors
Dr Pedro MANSO graduated in civil engineering at the Lisbon University (IST/UL) in 1998 and has since been working in the
Water and Energy sectors, in particular in hydraulic works, dam engineering and water economics. He started his career at DHV
Portugal in the water & environment department in 1998. In 2001 he joined the Laboratory of Hydraulic Constructions (LCH) at
the Ecole Polytechnique Fédérale de Lausanne (EPFL) where he conducted several engineering and research projects until 2006.
He obtained a PhD on the field of rock scour downstream of dam spillways in 2006. In 2003 he received the ICOLD honor
certificate for the Next Generation and in 2006 he was granted the ASCE J. C. Stevens Award. From 2006 to 2014 he worked in
Stucky Ltd in Lausanne as project engineer & manager for greenfield hydro projects and rehabilitation and upgrading of existing
hydropower schemes and dams in Europe, Africa and Asia. In 2010-2012 he served as Stucky’s branch Director in Portugal. He
is currently senior associate of the Swiss Competence Center for Energy Research (SCCER), where he leads research projects in
hydropower together with the electricity utilities and public authorities, pertaining to the 2050 energy transition strategy. He was
project manager of the Fully rehabilitation project for two years from 2012 to 2014, during the feasibility, environmental impact
assessment, licensing and (partly) tendering phases.

Jerome FILLIEZ is a civil engineer with over 10 years of experience in the hydropower field. He graduated from the Ecole
Polytechnique Fédérale de Lausanne (EPFL) in 2006. He joined Stucky Ltd in 2006. He has worked on various hydropower
projects in Switzerland, such as the rehabilitation of the Cleuson-Dixence, the extension of Lavey power plant (Lavey + project)
and the construction of the new Muttsee dam included in the Linth-Limmer 1000 MW pumped-storage scheme presently being
commissioned. Since August 2015, he is the project manager for the realization of the Fully rehabilitation project.

Bastien MÖSCHING is an electrical engineer graduated from the Ecole Polytechnique Fédérale de Lausanne (EPFL). He
carried out his master thesis on the rehabilitation of the Vouvry hydropower plant (approx. 900 m of head), in particular the
analysis of the coupled hydraulic and electric transients. He joined SEIC-Télédis Group in 2015 as project manager for new
renewables energies. His main tasks concern the development of PV and mini-hydropower plants. Following the entrance in 2016
of SEIC-Télédis in the shareholding structure of the Forces Motrices de Fully (FMdF), he is the Client representative for the
project.

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