CIRCULATING W A T E R TUNNEL

UNDER LAKE O N T A R I O 3

By Edwin Radin 1 and N . S. Shashidhara 2

ABSTRACT: This paper describes the engineering and construction features of

the Circulating Water System (CWS) at the 643 MW Somerset Station located
on the south shore of Lake Ontario, approximately 45.06 km (28 miles) north-
east of Buffalo, New York. The paper discusses the aspects of the CWS that
are unique to Somerset Station (including fish deterrent/fish return system,
staged diffuser, intake velocity cap, etc.), and the provisions made in the de-
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sign to satisfy the stringent licensing requirements of regulatory agencies hav-

ing jurisdiction over the project such as the New York State Department of
Environmental Conservation and the U.S. Army Corps of Engineers. Finally,
the unconventional construction techniques which were used to enable the sys-
tem to be built within the framework of a tight construction schedule and en-
vironmental constraints are discussed.

DESCRIPTION OF SYSTEM

The N e w York State Electric a n d Gas Corporation's Somerset Station

was originally planned to be a n 850 M W Unit Station. In October of
1980, the unit w a s downsized to 643 MW a n d Ebasco Services Incor-
porated was retained as architect/engineer a n d construction manager.
Trial operation was scheduled for the fall of 1984. The Circulating Water
System (CWS) of the station w a s designed as a n open loop (i.e., once
through) system withdrawing water from a n d discharging to Lake O n -
tario (see Fig. 1).
The major components of the Circulating Water System include:

1. A n octagonally shaped precase concrete intake structure which is

16.46 m (54 ft) across flats and e m b e d d e d in the lake bottom about 9.14
m (30 ft) below mean lake level (see Figs. 2 a n d 3). The distance of this
structure from the shore line is about 752.86 m (2,470 ft). The intake
structure is provided with a velocity cap to change the flow pattern from
vertical to horizontal. The intake velocity is limited to 15.2 c m / s (0.5 fps)
at the face of the structure. This l o w approach velocity permits fish d e -
tection and avoidance thereby reducing the entrapment probability.
2. A n intake tunnel extending from the intake structure to the p u m p
house on shore (see Fig. 4). This intake tunnel located approximately
30.48 m (100 ft) below the lake normal water elevation r u n s approxi-
mately 835.15 m (2,740 ft) along the lake bottom almost perpendicular
to the shore line. The tunnel is concrete lined, 2.67 m (8 ft-9 in.) in di-
"Presented at the October 21-25, 1985 Seminar on Water Quality Issues at Fos-
sil Fuel Plants, ASCE Annual Convention and Exposition in Detroit, MI.
'Sr. Supervising Civ. Engr., Ebasco Services Inc., Two World Trade Center,
New York, NY 10048.
2
Prin. Engr.—Quality Assurance, Ebasco Services Inc., Two World Trade Cen-
ter, New York, NY 10048.
Note.—Discussion open until May 1, 1987. To extend the closing date one month,
a written request must be filed with the ASCE Manager of Tournals. The manu-
script for this paper was submitted for review and possible publication on March
18, 1986. This paper is part of the Journal of Energy Engineering, Vol. 112, No.
3, December, 1986. ©ASCE, ISSN 0733-9402/86/0003-0199/$01.00. Paper No. 21118.

199

J. Energy Eng. 1986.112:199-210.

 _ .208- — "
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1. LAKE BATHYMETRY INTERPOLATED

FROM C,W. RICE CO. DWG NO.
W,P,/N1,224,150,6 2I56-2A, DATED 5-22-74
E494.098.55 2. COORDINATES REFERENCED TO
NEW YORK STATE COORDINATE
C.W. PUMPHOUSE SYSTEM (WEST ZONE)
3. USGS 1929 DATUM
4. METRIC EQUIVALENTS ARE NOT
SCALE 1 " = 450' SHOWN FOR CLARITY

FIG. 1.—Intake and Discharge System Location Plan

ameter. Embedded in the concrete lining are two 0.25-m (10-in.) diam-
eter heated water lines, whose purpose is to minimize ice buildup, and
two 0.25-m (10-in.) diameter fish return lines.
3. A discharge tunnel 2.74 m (9 ft) in diameter, concrete lined and
extending from the seal weir along the lake bottom for a distance of
approximately 786.38 m (2,580 ft). The discharge tunnel is also located
approximately 30.48 m (100 ft) below the lake normal water elevation
(see Fig. 5). A 121.92-m (400-ft), nine-port staged diffuser is provided to
allow for better mixing and thermal dispersion.
4. An onshore circulating water pump house containing three vertical
wet pit pumps and service water and fire pumps. The traveling water
screens and the fish removal screens are also housed in this structure.
The channel approach velocity is approximately 0.61 m/s (2 fps).
5. A seal weir structure to prevent air from entering the conduit and
blowing back into the condenser. The siphonic action created by sealing
200

J. Energy Eng. 1986.112:199-210.

 S. 8'-9 4- I N T A K E PIPE
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NOTE:
METRIC EQUIVALENTS
ARE NOT SHOWN FOR
S C A L E ! " = 8'

FIG. 2.—Intake Structure—Plan

t INTAKE STRUCTURE

L— SOUND ROCK 1
C_8'-9"(S INTAKE PIPE NOTES:
TREMIECONCRETE
1. BAR RACKS & HEATED
WATER RISERS TO BAR
RACKS NOT SHOWN
FOR CLARITY
2. METRIC EQUIVALENTS
ARE NOTSHOWN FOR
CLARITY

FIG. 3.—Intake Structure—Cross-Sectional Elevation

201

J. Energy Eng. 1986.112:199-210.

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0 (500 FT) (1000 FT) (1500 FT) (2000 FT) (2500 FT)

DISTANCE FROM PUMPHOUSE, METERS (FT.)

FIG. 4.—Intake Tunnel Profile

0 125 M 250 M 375 M 500 M 625 M 750 M

0 (500 FT,) (10D0FT.) (1500 FT.) (2000 FT.) ' (2500 FT.)

DISTANCE FROM SEAL WEIR, METERS (FT)

FIG. 5.—Discharge Tunnel Profile

the intake conduit at the seal weir greatly reduces the total pumping
head. The elevation of the weir crest is established such that the dis-
charge water level is sufficiently high above lake level to provide the
gravity head needed to drive the discharge at the required velocity through
the diffuser.

INTAKE STRUCTURE DESIGN CONSIDERATIONS

For an offshore intake structure such as the one at the Somerset Site,
a velocity cap is the most effective fish deterrent. This velocity cap changes
the flow patterns from vertical to horizontal (see Fig. 6). Velocity caps
are effective because studies have shown that while fish do not react
well to vertical changes in flow direction, they have a marked ability to
detect and avoid horizontal changes (Shashidhara, et al. 1983). Plan and
cross-sectional views of the CWS intake structure are shown in Figs. 2
and 3, respectively.
The Somerset velocity cap has been designed to induce a horizontal
approach velocity of 15.2 cm/s (0.5 fps). This minimizes the possibility
of fish entrapment. The intake points were located at a level approxi-
202

J. Energy Eng. 1986.112:199-210.

 VERTICAL INFLOW
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VELOCITY DISTRIBUTION WITHOUT VELOCITY CAP

VELOCITY CAP

HORIZONTAL INFLOW

VELOCITY DISTRIBUTION WITH VELOCITY CAP

FIG. 6.—Operation of the Velocity Cap Intake

mately one-fourth of the vertical distance from the lake bottom to the
mean lake level. This had the advantage of being sufficiently high to
minimize the probability of drawing benthic (bottom oriented) species
into the system while it was low enough to preclude impact from winter
ice floes. The final configuration of the velocity cap was based on a com-
bination of experience and hydraulic model studies conducted on other
projects.
Flow conditions upstream of and within the intake pumphouse were
investigated using a 1:10.8 undistorted Froude-scale physical model
(Larsen & White 1980). Some of the initial designs tested showed that
they would have resulted in excessive flow separation and created areas
where fish could become entrapped. As a result, model studies were
conducted to locate and reduce such undesirable conditions as vortex
activity, swirl, dead areas and nonuniform velocity distribution patterns,
all of which can enhance the potential for fish entrapment. Concerns for
the survival of fish entering the intake governed the configuration of the
forebay upstream of the traveling screens. Using the results of the model
studies, the pumphouse configuration was optimized to reduce the po-

203

J. Energy Eng. 1986.112:199-210.

 9'-0" I.D. x 3/4" THK. WALL
EMBEDDED STEEL PIPE
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FIG. 7.—Circulating Water Intake House Substructure

tential for fish entrapment. This approach maximized the fish survival
potential while ensuring adequate plant flow. Final design of the cir-
culating water intake house substructure is shown in Fig. 7.
Modifications to the standard traveling water screen design were em-
ployed as part of the fish removal and return system. These modifica-
tions consisted of (1) Providing a fish bucket or tray fitted to the bottom
of each screen basket; and (2) providing a trough and low pressure water
spray system running along the downstream side of the screen.
The fish trough carries the fish to a collection pool which is the origin
of the fish return system discharging to the lake. The pool helps to min-
imize shock or disorientation of the fish. This pool can also act, by means
of a hinged gate, as a fish sampling basin; a separate chamber is pro-
vided in which nets can be lifted for fish sampling. The pool also pro-
204

J. Energy Eng. 1986.112:199-210.

 vides a mechanism for the addition of makeup water to maintain the
necessary static head for gravity flow of the fish back to the lake. The
makeup flows carry the fish to the return pipe where the fish are re-
turned to the lake.
The pipe, joints and bends in the fish return system are made of smooth
reinforced thermosetting resin to prevent fish abrasion. The pipe is de-
signed with long radius bends to minimize flow separation, backflow,
eddies and other undesirable characteristics. The discharge point of the
fish return pipe was selected to be at an adequate distance from the
intake and discharge structures, to be in open water below the potential
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depth of ice cover or ice floes and also to bd within the isothermal range
from which the fish were removed.

DISCHARGE STRUCTURE DESIGN CONSIDERATIONS

The Somerset plant, like other thermal plants, rejects unusable heat.
This is the heat in the steam cycle that is not usable for generating power.
Regulatory agencies require that the discharge structure be designed to
minimize the environmental impact resulting from thermal discharges
and stipulate specific numerical limits on the amount of heat, flow and
temperature that could be discharged into Lake Ontario. Regulations also
specify the limits for surface temperatures and aerial extent of surface
isotherms resulting from such discharges. To comply with regulatory
requirements, all parameters that have an impact on water quality (such
as plant flow, temperature rise, and actual lake hydrographic data) were
considered in the design of discharge structure. The final design was
achieved by balancing the environmental impacts of various design

VERTICAL VELOCITY AND

TEMPERATURE PROFILE
AMBIENT CURRENT

VERTICAL SECTION ALONG PLUME CENTERLINE

r-io"o
NOZZLE
, E E L 227.00'
' ' (MAX)
TEMPERATURE PROFILE

DIFFUSER PLUME SCHEMATICS

\ 36" ^ PIPE

DIFFUSER PORT (TYP)

[—MAX. PORT £. EL. 227.0
#7
AD#I (P#2 (P*3 IF4*4 j? #5 / p #6 (p
C"8 if" 9
^ — ^ - | -**- =s^_j_ - * n |
mmwt&b \n,n ''*/z3**'* J ^tSSSW*' M

FIG. 8.—Staged Diffuser and Plume Schematization

205

J. Energy Eng. 1986.112:199-210.

 schemes against the associated cost of construction and operation of each
design; in other words, a cost-benefit study led to the final design and
construction of the discharge structure. Adverse environmental impact
on Lake Ontario was minimized by (1) Optimizing the amount of cooling I
water flow required and plant temperature rise; (2) using the state-of- i
the-art design of the staged multiport diffuser for efficient dispersion
and mixing of plant effluents; and (3) using unique construction meth- I
ods. Schematics of the diffuser plume and details of the staged diffuser
are presented in Fig. 8.
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DISCHARGE STRUCTURE DETAILS

The cooling water discharge system was designed to return the heated [
water to the lake via a tunnel connected to the 121.92-m (400-ft) staged \
diffuser. An onshore shaft was drilled and blasted to accommodate the
discharge piping. The discharge pipe was tunneled into rock below the
lake bed to a point approximately 670.56 m (2,200 ft) offshore. The dis-
charge tunnel has an inside diameter (ID) of 2.74 m (9 ft) and runs at
an angle of 0.52 rad (30°) from the intake tunnel (see Fig. 1). i
The final 121.92 m (400 ft) of the rock tunnel connects to nine indi-
vidual 0.91-m (3-ft) ID shafts which extend vertically from the tunnel to
the lake bottom forming the multiport staged diffuser, each discharging
through 0.57-m (l-ft-10.5-in.) ID nozzles. The discharge tunnel has pro-
gressively smaller inside diameters in the area of the diffuser shafts, al-
though the outside diameter remained the same. The 121.92-m (400-ft)
long diffuser tunnel consisted of three sections. The inshore one-third t
section has an inside diameter of 2.74 m (9 ft). The middle one-third has j
an inside diameter of 2.29 m (7 ft-6 in.), and the offshore one-third has
an inside diameter of 1.83 m (6 ft).
The nine 0.57-m (l-ft-10.5-in.) ID nozzles were spaced on 15.3 m (50
ft) centers (see Fig. 8). Ports alternate at an angle of 0.44 rad (25°) from
the manifold centerline. These discharge ports produced a mixing ve-
locity of approximately 5.18 m/s (17 fps) under normal operating con- i
ditions. The diffuser ports were located such that the maximum eleva-
tion of any discharge port centerline will be at an elevation of 69.19 m
(227 ft) (MSL), and the minimum elevation of any port will be 1.52 m i
(5 ft) above lake bottom. A minimum navigational clearance of 4.57 m ;
(15 ft) was provided.

EFFECTS OF PLANT DISCHARGES ON WATER QUALITY

AND DEMONSTRATION OF REGULATORY COMPLIANCE >

Thermal plume data was used to compute the dilution of plant ther-
mal and chemical effluents and to demonstrate compliance of plant dis-
charges with the water quality criteria. Thermal effects were computed
using plant operating data, diffuser details (number of ports, velocity,
etc.), and actual lake hydrographic data (lake temperature, currents, and
bathymetry). Details of the environmental impact studies were submit-
ted as licensing documents to the State of New York, and the U.S. Army
Corps of Engineers. Thermal effects were computed in the (1) Initial mix- '
ing zone; (2) near field; (3) transient far field; and (4) large scale far field
206

J. Energy Eng. 1986.112:199-210.

 regions. The State of New York discharge permit places specific require-
ments on effluents from the Somerset Station. The results of our study
showed that discharges from the Somerset Station will be in compliance
during operation. For instance, specific requirements for minimum jet
discharge velocity and the mixing zone (i.e., aerial extent of the 1.7° C
or 3° F isotherm of temperature rise) were 4.57 m/s (15 fps) and 7.28
hectares (18 acres), respectively, and the predicted diffuser performance
resulted in a velocity of 5.18 m/s (17 fps) and a mixing zone of only 5.26
hectares (13 acres).
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SELECTION OF CONSTRUCTION METHOD

When Ebasco became the architect/engineer on the project, construc-

tion had not yet commenced on the Circulating Water System. However,
the intake and discharge lines had already been designed as a piping
system extending out into Lake Ontario for approximately 0.8 km (0.5
mile). The construction procedure which was visualized for embedment
of these piping systems into the lake bottom was a conventional "cut
and cover" technique.
However, the Ebasco Construction Manager, acting in concert with
home office engineering, decided that a considerable amount of lake work
could not be performed during the winter season, which lasted from
November through March because of adverse lake conditions, cold
weather, and ice accumulations. Furthermore, the permit for this work
which was issued by the U.S. Army Corps of Engineers did not allow
blasting in the lake "in waters having a depth of 10 ft or less from June
15th through August 15th." The reason for this was to minimize un-
desirable effects on aquatic biota. This left an effective construction sea-
son of two 2-1/2 month periods, or only five months per year. In ad-
dition, it was anticipated that a certain portion of the allowable 5 months
would be lost due to "blow days," i.e., those days when conditions on
Lake Ontario would be too rough to allow construction.
As a result of this shortened work season, Ebasco was faced with a
very tight, delay-sensitive construction schedule (see Fig. 9). The sched-
ule called for the work to be completed during the 1983 construction
season. Any slippage would have forced the work to be delayed until
the following spring when conditions on Lake Ontario would once more
become favorable. This would have jeopardized the overall completion
date of the station for which trial operation had been set for August
1984.
An alternative construction approach of tunneling under the lake bed
out of the influence of weather was therefore adopted. Studies had re-
vealed that the tunneling scheme was economically feasible when com-
pared with the cut and cover method. A study of the geological char-
acteristics of the rock through which the tunnels were to be drilled was
made. This rock is the Queenston formation which consists of a uniform
sequence of red to dark red fine to very fine grained siltstone and sand-
stone. The rock is medium soft and is easily broken along the bedding
planes. The borings taken in the area revealed that the rock quality des-
ignation was generally in the range of 45-100%. Studies were made of
the unconfined compression strengths of the rock and these studies in-

207

J. Energy Eng. 1986.112:199-210.

 1981 1982 1983
J F M A M J J A S O N D J | F | M | A | M [ J | J|A|S|O|NJD J|F|M|A|M| J | J | A ] S | O | N | D
INTAKE, DISCHARGE TUNNELS

EXCAVATE COMMON ACCESS

SHAFT
TUNNELLING

BORE DISCHARGE TUNNEL

_____
BORE INTAKE TUNNEL
—• ___
LINE DISCHARGE TUNNEL
• _ _._.
LINE INTAKE TUNNEL

OFFSHORE STRUCTURES

DIFFUSER SHAFTS
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FISH-RETURN SHAFT —
MARINE

INTAKE SHAFT -_-."

INTAKE STRUCTURE

PREFAB
— ——
SET
——
ONSHORE PIPING — —__-,^
FLOOD SYSTEM __._?.-

—••« ACTUAL ™ ~ PLANNED ——CRITICAL

FIG. 9.—Construction Schedule for Intake and Discharge Systems, Tunneling and
Marine Work

dicated that tunneling could be accomplished using a Tunnel Boring Ma-

chine and it was estimated that tunneling could progress at the rate of
15.24 m (50 ft) per shift (Schlumpf & Campbell 1984).
The environmental impacts of tunneling versus "cut and cover" were
also reviewed. The permit for a "cut and cover" scheme had already
been issued at the time of the downsizing; however, work could not
have proceeded until the following construction season (Spring 1981).
Licensing efforts for the tunneling scheme emphasized (1) The smaller
portion of the lake bed that would be disturbed; and (2) the overall re-
duction in excavated quantities with accurately bored tunnel versus the
"cut and cover" scheme (drilling and blasting) and accompanying over-
break.

TUNNEL BORING MACHINE AND TUNNELING SCHEME

The tunneling logic was based on excavation in rock using a Tunnel

Boring Machine (TBM), or "mole." Initially, a 7.62-m (25-ft) diameter
onshore vertical shaft was excavated using conventional drill and blast
methods. This shaft is common to both the intake and discharge lines,
and was sized to provide adequate construction access for muck removal
and TBM mobilization.
Technical evaluation of the tunneling scheme centered on the hy-
draulic sizing and geological conditions of the rock at the tunneling el-
evations. The finished inside tunnel diameters were designed as 2.67 m
(8 ft-9 in.) for the intake line, and 2.74 m (9 ft) for the discharge line. A
minimum 0.3-m (1-ft) thick, cast-in-place unreinforced concrete liner was
installed to prevent erosion of the tunnel rock surfaces (see Fig. 10).
208

J. Energy Eng. 1986.112:199-210.

 2-10" I.D. FISH
RETURN LINES \ 9 ' 0 I.D.
2-10" I.D. Vjg DISCHARGE PIPE

RETURN LINES Wt£# \

§m& L— 2 6 ' * SHAFT
8'-9 I.D.
INTAKE PIPE CONC. FILL
ROCK SHAFT PLAN
1 ' = 20'
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2-10" I.D.
FISH RETURN LINES
(EMBEDDED)
(INTAKE ONLY)
2-10" I.D. HEATED
WATERLINESTO
BAR RACKS
(INTAKE ONLY)

CONCRETE LINING

ROCK TUNNEL SECTION

1"=4'
METRIC EQUIVALENTS
ARE NOT SHOWN FOR
CLARITY

FIG. 10.—Intake and Discharge Tunnel Details

To produce approximately equal discharges from each of the nine ports

of the diffuser, the discharge tunnel cross section was designed to have
progressively smaller inside diameters in the area of the diffuser shafts.
The overall drilled diameter of the tunnel was kept the same and the
concrete lining was thickened to accommodate the smaller diameters.
This allowed the same TBM cutter head to be used for the entire tunnel
length.

METHOD OF CONSTRUCTION

The construction methodology was developed together with the de-

sign of the tunneling scheme. Of primary importance was the organi-
zation of an overall schedule for construction activities that ensured ad-
equate slack both for total effort and for isolated marine tasks in relation
to usable marine construction seasons (see Fig. 9).
Initial construction efforts concentrated on long-lead-time item pro-
curement, excavation of the onshore common access shaft, and drilling
of the diffuser shafts in the lake bed. Conventional drilling and blasting
was used for rock removal from the onshore common-access shaft. The
9.14 m (30 ft) of overburden was excavated within steel lagging to pro-
vide a neat 7.62-m (25-ft) diameter shaft all the way up to grade, for
convenient location of the muck-removal crane, air-handling equipment,
etc. close to the shaft.
209

J. Energy Eng. 1986.112:199-210.

 Tunneling began in the winter of 1981. Since all operations except muck
disposal were performed u n d e r g r o u n d , essentially n o time was lost be-
cause of poor weather conditions. Even the shortened daylight h o u r s of
winter h a d no effect on tunneling, enabling a two-shifts-per-day sched- I
ule. I
The main intake shaft was drilled in the summer of 1982. A rotary- 1
core barrel drill driven from a jack-up barge was used to down-bore to I
the tunnel elevation. After setting a n d grouting the prefabricated fiber- /
glass intake shaft liner, the lake bed was prepared for setting of the j
intake structure.
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The lake bottom overburden was removed and tremie concrete p o d s

were placed. The intake structure h a d already been precast into four I
base sections a n d two roof sections (see Fig. 2). The base sections, each
weighing over 100,000 kg, were set from a barge onto the p o d s . After \
underwater alignment and connection of the sections, the roof panels
were installed a n d the entire base w a s set in tremie concrete. From first
to last, the operation was done "in the w e t , " with a m i n i m u m a m o u n t
of dewatering effort.
While the intake tunnel boring was nearing completion, the concrete \
liner was being placed for the discharge tunnel. Prior to liner placement 1
the comparatively small a m o u n t of water that h a d seeped into the tunnel \
was p u m p e d out. Liner placement for the intake tunnel followed during (
the winter of 1982-1983.
By the spring of 1983, all marine and tunneling work h a d been com-
pleted, only one month later than planned and almost four months ahead
of critical-path late-completion dates. Onshore work was completed dur- !
ing the summer and the system flooded in September, 1983. Because of j
these innovative techniques, trial operation was completed ahead of '
schedule during the summer of 1984. I

CONCLUSION t

Considerable ingenuity in engineering, design and construction is re-

quired w h e n a Circulating Water System is to be built u n d e r the lake
bed. The conceptual designs for the intake (velocity cap) a n d discharge .,
structure (staged diffuser) were finalized using the results of mathe-
matical models and tested using scale models. The intake and discharge \
tunnels were constructed using innovative techniques enabling the en- '
tire Circulating Water System to be built within the framework of a tight
construction schedule. In addition, the Circulating Water System was
built to comply with various regulatory requirements.
S
APPENDIX.—REFERENCES
Larsen, J. and White, D. K. (1980). "Hydraulic investigation of flow conditions '
in an intake house. Somerset unit number 1." Alden Research Laboratory, Hol-
den, Mass.
Schlumpf, W. R., and Campbell, R. A. (1984). "Mole meets scheduling needs
for underwater tunnelling in rock," 1984 Generation Planbook, McGraw Hill Book
Co. Inc., New York, N.Y.
Shashidhara, N. S., Schlumpf, W. R., and Tuttle, L. R. (1983). "Engineering de- '
sign of a fish deterrence and fish return system for a once-through steam elec-
tric station," Proc, 20th Congress of the International Association for Hy-
draulic Research, Moscow, USSR.

210

J. Energy Eng. 1986.112:199-210.