BergerWorld: 2nd Quarter 2007

For more than half a century, Klohn Crippen Berger Ltd. (KCBL) has worked on some of the world's most challenging power programs, offering engineering and environmental services to clients around the globe. KCBL's renowned reputation as an innovative leader in the energy field has created many opportunities to assist in the development of some of the world's largest power schemes.

The Snoqualmie Falls Project is located on the picturesque Snoqualmie River in Washington State. The hydropower facility consists of two powerhouses (plants one and two) with a combined capacity of over 44 megawatts and a diversion dam. Plant one is a five-unit powerhouse originally constructed in 1898 as the first underground powerhouse in North America. Plant two is a two-unit powerhouse originally constructed in 1910 and expanded in 1956. KCBL was retained by PSE to redevelop and rehabilitate the aging facilities. The Team's tasks included a condition assessment; preliminary and detailed designs; and tender documents for the rehabilitation of plants one and two. Because the falls are an attractive tourist site and the project is located in a particularly sensitive

ecosystem adjacent to the Snoqualmie Tribe lands, KCBL will develop methods to minimize adverse environmental impacts and preserve the aesthetic aspect of the site.

The Louis Berger Group assisted KCBL on the assignment by providing detailed economic assessments of the Snoqualmie Falls Project to support the issuance of the new FERC license. The analysis included a cost-benefit assessment of both the existing project and the proposed redevelopment. Berger also completed a review of the license articles related to the construction of the redevelopment and provided PSE with a management tool to implement the conditions specified in the articles. Construction will commence in 2011.

The Nam Theun 2 Hydroelectric Project (NT2) is the most important project in a long-term collaborative effort between the people of Laos and neighboring Thailand. The $1.5 billion project will develop up to 3,000 megawatts of hydropower in Laos for the export to Thailand. KCBL has been involved with NT2 since the mid-1990s, first evaluating the project and then recommending and designing a roller compacted concrete (RCC) dam and integral spillway.

More recently, KCBL was retained by the joint venture partnership of Nishimatsu Construction Company Ltd. and Italian-Thai Development Public Company Ltd. to design the two main civil works packages for the hydro facilities, CW1 and CW2. CW1 includes the RCC Nakai Dam structure and integral reinforced concrete spillway; the diversion tunnel; upstream and downstream RCC cofferdams; ten saddle dams; site access; and the headrace channel. The CW1 package earthworks are extensive, comprising over 4.2 million m? excavation for the headrace channel and over half a million m? earth embankment design associated with the reservoir saddle dams.

CW2 includes the intake structure and gates; headrace tunnel; surge shaft; pressure and penstock tunnels; units manifold; main powerhouse and adjoining pelton units powerhouse; tailrace and associated powerhouse area buildings; and other civil structures. A number of the CW2 underground works are large in scale and complex in design, including the pressure shaft and pressure and penstock tunnel sections of the conveyance system, where the normal pressure head is over 350 meters (not including transients). The steel-lined portions of the project require massive steel cans of considerable thickness, while the steel manifold is a double bifurcation structure with critical support and pressure design requirements. The main bifurcation, designed for 500 meters of pressure head, will have the greatest pressure-diameter combination of any such structure in the world. The project is expected to be in service by 2009.

KCBL's capabilities in the hydroelectric field have long been recognized by BC Hydro, for whom KCBL has provided a variety of services, including seismic upgrades of existing plants, single device isolation certifications and redevelopments of existing hydroelectric generating stations. BC Hydro's electrical generation system comprises 29 integrated hydroelectric generating stations with a total installed capacity of 10,800 megawatts, providing 50,000 gigawatt hours of energy annually. Eighty percent of the installed generating capacity comes from hydro facilities. To maintain the reliability of the generating fleet, add new capacity to meet increasing load growth and ensure the continued safe operation of its facilities, BC Hydro is planning an ambitious expansion program. The program is being implemented at a cost of $500 million per year for the next five to seven years and will continue at $300 million annually following the initial period.

KCBL is assisting BC Hydro to implement the plan and is currently providing preliminary designs for the proposed 900-megawatt Site C hydro facilities on the Peace River near Fort St. John, British Columbia. If constructed, the project would serve 500,000 households. KCBL is also providing designs and construction supervision for the redevelopment of the 105-megawatt Ruskin Powerhouse and Dam in Vancouver. KCBL recently completed designs and construction supervision for the 250-megawatt unit four expansion at the Seven Mile Dam on the Pend d'Oreille River in southern British Columbia.

The Skins Lake Spillway was developed in 1953 as part of the 900-megawatt Kemano Hydroelectric Project in British Columbia. Other than discharges through the Kemano Powerplant, Skins Lake Spillway is the only flow release facility on the 125-mile Nechako Reservoir. Comprised of a two-gate structure, central pier, side walls and base slab, the spillway was constructed on a local bedrock exposure with earthfill saddle dams erected on each side of the structure. A "starter channel" was dozed to the downstream and the gates were opened to permit releases to develop the discharge channel to Skins Lake. In the years since its development, the Skins Lake Spillway has encountered a number of problems. A natural plunge pool developed and flows were deflected laterally by a resistant bedrock ridge at the end of the plunge pool, causing erosion near the toes of the saddle dams. Continuous releases through the spillway to accommodate the spawning season of the lake's fish population further increased the erosion rate near the saddle dams. To prevent additional erosion, particularly during large flood events that could threaten the integrity of the saddle dam and the overall spillway facilities, Alcan Smelters and Chemicals Ltd., who own and operate the spillway, commissioned KCBL to undertake the Skins Lake Spillway Rehabilitation Project.

KCBL's tasks entailed supervising hydraulic model tests; developing preliminary and detailed designs for the spillway facilities; preparing contract documents; and supervising the construction. The project included excavating a stilling basin and adding 100-meter-long training dykes on each side of the basin and channel to safely discharge flows well beyond the toes of the dams. Approximately 9,000 m? of RCC was used to fill the naturally developed plunge pool up to the level of the stilling basin and beneath the structural concrete chute. The project also involved excavating a discharge channel through the bedrock ridge and extending the spillway walls. Two diversion pipelines, 1.5 meters in diameter with a total capacity of 30 m?/s and a design head of 16.5 meters, were constructed to maintain the release of water flow for the local fish populations.

Brilliant Expansion Power Corporation (BEPC) has initiated the $207 million, 120-megawatt Brilliant Dam Expansion Project on the Kootenay River near Castlegar, British Columbia. KCBL was commissioned by BEPC to review final designs; prepare contract documents and technical specifications; and monitor construction and off-site manufacturing. The Team will also oversee the design-build contracts, which entail all civil, mechanical and electrical works, including connection to a nearby 230-kilovolt switchyard. The expansion of the Brilliant Dam will include a 150-meter-long power tunnel that will convey flow around the existing dam to a new single-unit powerhouse. The construction of a tunnel rather than an open channel minimizes adverse environmental disturbances and reduces the volume of excavated rock. Tailrace improvements will also be provided, including widening and deepening a short portion of the river channel to lower the water level by one meter, yielding a gross head of 32 meters.

The existing Waneta hydroelectric facility is located on the Pend d'Oreille River in southeastern British Columbia, approximately half a kilometer upstream from the Canada-United States border. The facility includes a 350-megawatt, four-unit surface powerhouse. The Waneta reservoir has limited storage and is operated in a run-of-river mode, while the hydraulic capacity of its turbines is substantially less than those of the nearby Seven Mile and Boundary Projects. To upgrade the capabilities at the existing facility, KCBL was retained by the Columbia Basin Trust (CBT) and the Columbia Power Corporation (CPC) to review development options and prepare conceptual designs for the $440 million Waneta Expansion Project. The 435-megawatt expansion will include a new facility on the right bank of the Pend d'Oreille River that makes use of the head at the existing Waneta Dam with a separate powerhouse 250 meters downstream from the existing dam and powerhouse.

In phase one, KCBL prepared a Project Definition Report, which included a detailed compilation of all technical, engineering, hydraulic modeling and environmental data required for the expansion; descriptions and analysis of the existing facilities; existing and proposed reservoir operations; proposed operational changes to upstream projects; design, construction and operation criteria and concerns; evaluation of alternatives; energy estimates; transmission requirements; possible environmental impacts during construction and operation; potential mitigation measures; overview of environmental and project licensing requirements; and supporting documentation for the Environmental Assessment Certificate. KCBL also prepared the Project Approval Certificate Application and participated in consultation meetings with public and private stakeholders and concerned local officials.

In phase two, KCBL will assist CBT/CPC with the implementation of the design-build process, including the selection of the design-build team and the finalization of the contract. KCBL will also be responsible for reviewing the proposed final design and administering the contract from commencement until commercial operation in 2011.

KCBL was commissioned by the Ashlu Hydro Project Limited Partnership, comprised of the Ledcor Group of Companies and Innergex Power Income Fund, to develop the $110 million run-of-river Ashlu Creek Hydroelectric Project in Squamish, British Columbia. Run-of-river projects require little water storage to generate electricity and emit virtually no greenhouse gas emissions, while the energy produced comes from the naturally flowing mountain waters. The 49-megawatt project will generate sufficient electricity to power 23,000 homes per year. KCBL's assignment included energy estimates as well as preliminary and final designs. Based on the energy estimates, the Team selected the appropriate turbine unit. The designs included the intake structure, rock-fill weir, gated bypass spillway, penstock and powerhouse. The powerhouse incorporates three horizontal Francis units and a large bypass valve arrangement capable of handling the full plant flow for extended periods. The extensive bypass requirements were dictated by the recreational and environmental constraints, which require long river ramping times. The powerhouse design also included a control/switch room, an emergency diesel generator, a powerhouse crane, stoplogs, fire systems, and drainage and dewatering systems. The transmission line and switchyard were constructed early to allow the tunnel boring machine to be powered from the grid, saving considerable cost in diesel fuel. The project is currently under construction and is expected to enter operation in 2009.

Twin Gorges Generating Station was constructed on the Taltson River in 1965 to provide power to a lead and zinc ore mine in Pine Point, Northwest Territories. After the mine closed in 1986, Twin Gorges remained decommissioned for 20 years. The Northwest Territories Power Corporation (NTPC) is considering supplying power to the newly opened Snap Lake Diamond Mine from existing or new power facilities at or near the original Twin Gorges Generating Station.

KCBL was commissioned by NTPC to prepare a feasibility study for the Twin Gorges Expansion Project. The KCBL team initially assessed the feasibility of constructing a new facility at the outlet of Nonacho Lake using the forebay at the existing Twin Gorges plant, as well as upgrading the Twin Gorges plant by replacing its Ossberger units with more efficient equipment and upgrading the existing turbine, generator and associated gear. The study determined that the Taltson Basin was capable of supporting additional capacity at Twin Gorges. NTPC then retained KCBL to prepare designs and cost estimates for the expansion of Twin Gorges and the development of new control facilities at the outlet of Nonacho Lake.

KCBL's design includes a 1,250-meter-long rock-cut power canal with an invert width of 10 meters; twin power intakes; two 223-meter-long penstocks, 4.3 meters in diameter; a powerhouse consisting of two 300-rpm vertical-shaft, Kaplan-type turbine-generator units; a 340-meter-long rock-cut tailrace channel; a 40-megavolt-ampere switchyard; and a 161-kilovolt transmission line. The new control facilities at Nonacho Lake will include a reinforced concrete and rock-fill gravity structure containing four 2.4 m2 sluices equipped with trash racks, stoplogs and electrically powered regulating gates. Power for the control structure will be provided by an integral load-controlled 35-kilowatt micro-hydro station with diesel backup. The facility will be remotely controlled from the Twin Gorges station using a PLC unit equipped with a communication module linked via satellite with the NTPC's SCADA system. Benefiting from the Twin Gorges power, Snap Lake Diamond Mine is expected to be in service by late 2007.

KCBL was retained by Tercon Industrial Ltd. to review the generation-potential estimates and to prepare preliminary and final designs for the Zeballos Lake Hydro Project. Located on the west coast of Vancouver Island, Canada, Zeballos Lake was formed more than 300 years ago by a rock fall that blocked the Maraude Creek Valley. Because seepage occurs from under and through the makeshift rock fall dam, as does occasional overtopping, KCBL experts reviewed the geotechnical conditions at the lake outlet and developed a methodology for sealing the landslide debris to provide a proper watertight barrier. The Team also designed a weir connected to the barrier to control flow from Zeballos Lake. The completed $30 million Zeballos Lake Hydro Project will comprise a single-power intake; a 900-meter-long power tunnel with a "hot tap" into the lake bottom; a 550-meter-long, low-pressure penstock; a 35-meter-high surge tank; and a 1,100-meter-long, high-pressure penstock. The main powerhouse, with two Francis units, will use the 245-meter head between Zeballos Lake and the lower reach of the Maraude Creek. A 500-meter-long fish penstock and a fish powerhouse with a single Francis unit will be constructed to return water to the Maraude Creek, below the rock fall, for riparian flows. The total capacity of the site is 22 megawatts, and the development will provide 99 gigawatt hours of energy annually.

KCBL was retained by Irrigation Canal Power Co-operative Ltd. to design the Irrican Hydro Project, a 7-megawatt run-of-canal hydropower plant located on the St. Mary's Irrigation System, an extensive irrigation development that serves 500,000 acres of irrigated agriculture, in southern Alberta, Canada. The project concept was to use the head across three canal energy dissipation drop structures to construct a hydropower plant that develops a total head of 15 meters. The services included concept through final design engineering, preparation of procurement and contract documents and construction monitoring. The design services included power and energy studies; structural, hydraulic and geotechnical design; and technical analysis and selection studies for the turbine-generator package, including unit sizing and optimization. KCBL designed an economic, functional powerhouse and intake to suit the selected equipment. The powerhouse included an overhead crane, a service bay and a central control room for operating the Irrican Project and the owner's other plants.

Developing Alberta's Oilsands

Oilsands are deposits of bitumen, a heavy, black viscous oil that must be heated or diluted with lighter hydrocarbons to produce gasoline and diesel fuels. Large portions of bitumen were deposited in Alberta, Canada, over 110 million years ago when the region was covered by a shallow tropical sea. Second only to the Saudi Arabia reserves, Alberta's oilsands deposits are considered the nation's greatest energy treasure, and could potentially satisfy the world's demand for petroleum over the next century. In recent years, government and industry have worked together to find innovative ways to extract and process the oilsands, resulting in the current production of more than one million barrels per day (bpd). After 40 years and over $30 billion of investment, the Alberta oilsands industry expects to produce two million bpd by 2010. By 2030, investments in excess of $100 billion and the daily production of more than five million barrels are anticipated.

KCBL provides services to all of the operating oilsands surface mines in Alberta, including Mildred Lake Mine, operated by Syncrude Canada; Suncor Energy's Steepbank and Millennium Mines; and Muskeg River Mine, operated by Albian Sands Energy. KCBL is also working on a number of new oilsands mines in Alberta's Fort McMurray region.

The oilsands mine operations require the management of tailings and water at an unprecedented scale. Oilsands leases are located in underdeveloped wilderness areas, creating significant challenges for orderly development and adequate environmental mitigation; entire watersheds may need to be mined right up to buffer limits along creeks, rivers and lakes that are to be protected and maintained; and tailings facilities may need to be situated directly over regional groundwater aquifers that must remain intact and be maintained as sources for water.

KCBL was recently retained by Suncor Energy, Inc. to design and provide environmental management services for the South Tailings Pond, a 12-square-mile facility 10 miles north of Fort McMurray. The Team was able to address unique project challenges, including the location of the tailings pond on a buried sand channel and significant pond seepage, by providing an innovative tailings pond design that ensures dyke stability, sound environmental management and efficient mine operations. The South Tailings Pond includes a seepage management system that uses site geology and existing mine infrastructure to contain tailings seepage within the site. The system design includes an interception well-field, engineered seepage blankets, pump stations, pressure relief wells and cut-off walls to capture and contain the tailings water within a closed system. The captured water is returned to the extraction plants at the mine to reduce withdrawal from the Athabasca River. When three miles of McLean Creek had to be rerouted around the South Tailings Pond, KCBL developed a sustainable, permanent wetland and inundation floodplain with compensatory stream habitat. KCBL is also assisting with a number of research initiatives associated with the South Tailings Pond to develop improved reclamation techniques.

Additionally, KCBL conducted dam breach, inundation and emergency planning studies at tailings facilities on the Suncor lease, including the South Tailings Pond, analyzing multiple piping and overtopping failure mechanisms and scenarios, such as the domino failure of adjacent ponds. Breach flows were routed in a hydraulic model through the Suncor site and into the Athabasca River. Similar dam breach, inundation and emergency planning studies have been completed for Syncrude's Mildred Lake Mine and Albian Sands' Muskeg River Mine.

KCBL has also assisted Suncor to address a number of critical drainage issues in the main upgrading plant area, including the provision of piped drainage systems to decant fire-fighting water from the North and South Tank Farms; increasing secondary containment capacity; upgrading surface water drainage systems to prevent inflow of surface and drain runoff accumulations; and replacing damaged tank dewatering industrial drains.

KCBL is currently providing design, construction and operations support for both external and in-pit tailings dams at the Muskeg River Mine. Shell Canada Energy, majority owner of Albian Sands, recently retained KCBL to provide mine waste, tailings planning and environmental engineering services for the modernization and expansion of the mine. The planned expansion will add 450,000 barrels of oil per day to Shell's oilsands collection. The Team will assist in the planning and detailed design stages of the project, with the production of oil from the expanded facilities expected in July 2009.