Jackson Mills
Hydroelectric Upgrade Project
CONFORMED PROPOSAL
Turbine / Generator Equipment
City of Nashua, New Hampshire
Essex Power Services Inc.
Mavel Project No. 0-29029.Rev.3
14 January 2020
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
www.mavel.com
Table of Contents
Jackson Mills Hydroelectric Upgrade Project
Technical and Cost Proposal
SECTION 1: Executive Summary
SECTION 2: Vendor Proposal Information
SECTION 3: Vendor Qualifications
SECTION 4: Technical Information (Rev.1)
SECTION 5. Commercial Terms
SECTION 6: Appendices
Appendix A: Turbine Installation Drawings
Appendix B: Performance and Energy Production Information
Appendix C: Standard Kaplan Turbine Technical Specification
Appendix D: Generator Information
Appendix D.1: Generator Drawings
Appendix E5: Electrical Balance of Plant Specifications — Eaton Corporation
Appendix £.1: | Eaton Corporation Brochure and References
Appendix F: Production and Delivery Schedule
Appendix G: Project Team and Resumes of Project Staff — Not Used
Appendix H: ISO Certificates — Not Used
Appendix |: Mavel References — Not Used
Appendix J: Mavel Brochure — Not Used
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
SECTION 1
Executive Summary
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
SECTION 1
EXECUTIVE SUMMARY
Owner
City of Nashua, New Hampshire
Operator
Essex Power Services, Inc.
Essex Hydro, LLC
55 Union Street, 4™ Floor
Boston, MA 02108
Representatives
H. L. Turner Group, Inc.
John R. Lavigne, Jr.
JLavigne@hiturner.com
603/228-1122, ext. 149
1.1 Proposal Request
The City of Nashua, New Hampshire (“Owner”) is interested in replacing the turbine-generator-control system (“TGC”)
at its Jackson Mills Hydroelectric Project (“Jackson Mills HPP” or the “Project”)). Essex Power Services, Inc. (“EPSI”), as
operator of the project, has invited Mavel Americas, Inc. (“Mavel”) to submit a preliminary technical and cost proposal
(“Proposal”) for a TGC replacement. The Jackson Mills HPP, originally commissioned in 1984, is located at the Jackson
Falls Dam on the Nashua River.
The Project involves the removal of the existing 1000 kW single-regulated turbine and generator set and replacement
with a new double-regulated turbine and generator package. The upgrade Project will also include replacement of the
electrical balance of plant equipment. The design parameters for the site are operating head of 21 ft. and flow rate of
800 cfs.
The Technical Specification Package and Request for Preliminary Vendor Equipment Proposals (“Proposal Request”),
prepared by the H.L. Turner Group Inc. (“Engineer”) indicates an interest in a TGC arrangement with a similar inclined
turbine within the existing powerhouse. Alternative arrangements will be considered provided that impacts to the
existing structure and fish passage facility are minimized.
The plant is currently limited to 1000 kW output due to net metering rules. The Owner and EPSI are interested in
additional capacity with this upgrade even though the new unit may have to operate in a restricted mode until rule
changes are implemented.
Exterior view of the Jackson Mill Hydro Station
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
F j ~
WWwWw.mMmavel.com
1.2 Revised Site Parameters
Mavel provided a proposal in March 2019 for installation of a Kaplan bulb turbine type Mavel KA1800K4 connected
to a synchronous generator via an angle-drive gearbox. At the original design head of 21 feet and rated unit discharge
of 800 cfs, the turbine would have an installed power of 1,226 kW measured at the turbine shaft. The generator
power would be 1165.2 kW based on gearbox and generator efficiencies.
A conference call was held on June 5, 2019 to review the March proposal. The Owner commented that the proposed
design was the most effective in minimizing changes to the existing structure. Concern was expressed for the amount
of possible excavation into the structure foundation and requested a review to determine if the unit centerline and
lower gallery floor could be raised to reduce risk. Revised design parameters for the site were provided for the
review. The revised parameters are an operating head of 19.9 ft. and flow rate of 750 cfs.
Mavel committed to review the arrangement and provide a revised proposal, which follows here.
13 Mavel Equipment Recommendation
Mavel affirms the original recommendation to replace the existing equipment at the Jackson Mills HPP with a Kaplan
bulb turbine type MAVEL KA1800K4. The turbine will have a runner diameter of 1800 mm, four runner blades and a
steel scroll case. The turbine will be connected to a synchronous generator via an angle-drive gearbox. The turbine
speed will be 240 rpm and the generator speed will be 720 rpm. At the design head of 19.9 feet and rated unit discharge
of 750 cfs, the turbine will have an installed power of 1,127 kW measured at the turbine shaft. The generator power
will be 1059 kW based on gearbox and generator efficiencies.
The estimated annual energy production for the operation of Jackson Mills HPP at full capacity based on the site
hydrology would be 4,161,354 kWh.
Cross Section of a Mavel Kaplan Bulb Turbine with Gearbox
The MAVEL KA1800K4 double regulated Kaplan bulb turbine was selected for the TGC replacement at Jackson Mills
HPP in order to maximize the potential of the site while minimizing changes to the existing civil structure.
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
www.mavel.com
Advantages of this solution are:
1. Power Potential. The TGC arrangement will meet the 1,000 kW maximum requirement but has the
potential for increased output if permits are in place. This would be readily accomplished via control
modifications.
Civil Modifications. The TGC arrangement, as proposed, will require minimal civil modifications. The bulb
turbine unit is an easy, compact solution that will fit within the existing structure. The intake is designed
to provide a smooth transition into the turbine. The draft tube will require change in order to assure
performance of the unit and provide a straight flow path.
|
Fish Passage. The MAVEL KA1800K4 turbine with four blades and operating at 240 rpm speed will
minimize the potential for impact on fish passage through the turbine. There will be no impact to the
upstream fish passage facility.
|
More information on Mavel’s Kaplan Bulb turbines are provided in Section 6: Appendix C Standard Kaplan Turbine
Technical Specifications.
Mavel will purchase all materials and major subcomponents from either American or European sub-suppliers.
The synchronous generator will be provided by Czech producer GAEM. The completed Bid Forms and Section 6:
Appendix D provide additional technical information on the generator and general information about GAEM.
The Electrical Balance of Plant (“EBOP”) sub-supplier is Eaton Corporation with base in Lewiston, ME. Eaton will design
and deliver the EBOP equipment per the RFP scope and requirements. Startup and commissioning services can be
provided at such time.
1.3 Commercial Terms
Not Used
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
1.4 Mavel Company Summary
Mavel is a leader in the supply of hydroelectric turbines and related equipment for projects utilizing turbines with
power of up to 30 MW. The Czech-American owned and managed company has installed or signed orders for about
500 Kaplan, Francis, Pelton and micro turbines over the past 25+ years at more than 325 sites in 43 countries. Mavel
has ISO 9001:2015, ISO 14001:2015, ISO 3834-2:2005 and OHSAS 18001:2007 certifications and designs and
manufactures the full turbine scope at its Czech Republic manufacturing facilities. Copies of the ISO certifications are
provided in Appendix H.
Mavel’s Headquarters outside of Prague, CZ
History. In 1990, Mavel was founded as the 176th company under the country’s new Commercial Code by a group of
hydroelectric power specialists and professors. From a small hydro-engineering firm in Prague, Mavel now has over
15,000 square meters (150,000 square feet) of facilities which house over 40 production machines, including a 5-axis
milling machine installed in 2010 and a 6-axis machining center installed in 2013. The top management team is the
same and has worked together for approximately 25 years.
Numbers. Mavel employs approximately 200 persons (including 60 engineers) and ships between 20 and 40 turbines
annually to sites around the world. Conservatively run, Mavel has virtually no long-term debt, a bonding facility with
for projects in North America and no history of penalties or liquidated damages related to late delivery or performance
guarantees.
Turbines and Kaplan Expertise. Mavel has over 100 proprietary turbine designs for Kaplan, Francis, Pelton and micro
turbines with power per unit ranging from 30 kW to 30 MW. The majority of turbines Mavel has installed since founding
have been Kaplan. This experience has provided Mavel the ability to develop designs for various low head site
conditions addressing their specific challenges. The company’s R&D department engages in the active development of
new turbine designs and equipment alternatives to best meet the requirements of its diverse customers.
North America. In 2005, Mavel established an office presence in Boston, MA. Today, sales, project management,
purchasing, field service and other activities for the Americas as well as global marketing are managed through the
company’s 100% owned subsidiary Mavel Americas, Inc. To date, Mavel has signed contracts for almost 60 turbines in
the Americas for a wide variety of customers from utilities to independent owner/operators.
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
15 Mavel Turbine Range
Mavel has over 100 proprietary turbine design configurations for Kaplan, Francis, Pelton and micro turbines ranging in
size from 30 kW to 30+ MW. This allows Mavel to provide customers with the best turbine option for both low head
and high head installations. Mavel’s turbines are suitable for projects with heads ranging from 5 feet to 3300 feet and
flow ranges per turbine from 4 cubic feet per second (cfs) to 7060 cfs.
Pelton Runner Francis Runner Kaplan Runner
1.6 Mavel’s Kaplan Turbines
The Kaplan turbine was invented in the Czech Republic in 1912 by Viktor Kaplan. Over the past 100 years, the design
has improved significantly and a number of Kaplan turbine variations have evolved. Mavel’s Kaplan turbines include
the “S”, Bulb, PIT, and “2” models with either vertical or horizontal configurations.
Mavel‘s Kaplan range generally targets sites between 100 kW and 20 MW and turbines are available with runner
diameters from 550 mm to 5500 mm, utilize three to six runner blades and can be single or double regulated.
The majority of the turbines MAVEL has installed since founding has been Kaplan. Mavel has signed contracts for the
supply of over 300 Kaplan turbines worldwide, including in Canada and the USA. In North America, Mavel has installed
or signed contracts for 36 Kaplan turbines.
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
121 Mount Vernon St., Boston, MA 02108, USA
Phone: +1617 242 2204 Fax: +1617 242 2205
SECTION 2
Vendor Proposal Information
Project No. 0-29029.Rev.3 www.mavel.com Jackson Mills Upgrade
1.
General Terms and Conditions
DEFINITIONS Unless otherwise required by the context, "Professional Engineer’, and its
successors, transferees and assignees (together “Professional Engineer’) includes any of
the Professional Engineer's consultants, sub consultants, contractors, and subcontractors
PROFESSIONAL ENGINEER STATUS The parties agree that Professional Engineer shall have
the status of and shall perform all work under this contract as a Professional Engineer,
maintaining control over all its consultants, sub consultants, contractors, or subcontractors.
The only contractual relationship created by this contract is between the City of Nashua
and Professional Engineer, and nothing in this contract shall create any contractual
relationship between the City of Nashua and Professional Engineer's consultants, sub
consultants, contractors, or subcontractors. The parties also agree that Professional
Engineer is not a City of Nashua employee and that there shall be no:
(1) Withholding of income taxes by the City of Nashua:
(2) Industrial insurance coverage provided by the City of Nashua;
(3) Participation in group insurance plans which may be available to employees
of the City of Nashua;
(4) Participation or contributions by either the Professional Engineer or the City
of Nashua to the public employee’s retirement system;
(5) Accumulation of vacation leave or sick leave provided by the City of
Nashua;
(6) Unemployment compensation coverage provided by the City of Nashua.
STANDARD OF CARE Professional Engineer shall be responsible for the professional
quality, technical accuracy, timely completion, and coordination of all work performed
under this contract. Professional Engineer warrants that all work shall be performed with
the degree of professional skill, care, diligence, and sound practices and judgment that are
normally exercised by recognized professional firms with respect to services of a similar
nature. It shall be the duty of Professional Engineer to assure at its own expense that all
work is technically sound and in conformance with all applicable federal, state, and local
laws, statutes, regulations, ordinances, orders, or other requirements. In addition to all
other rights which the City of Nashua may have, Professional Engineer shall, at its own
expense and without additional compensation, re-perform work to correct or revise any
deficiencies, omissions, or errors in the work or the product of the work or which result
from Professional Engineer's failure to perform in accordance with this standard of care.
Any approval by the City of Nashua of any products or services furnished or used by
Professional Engineer shall not in any way relieve Professional Engineer of the
responsibility for professional and technical accuracy and adequacy of its work. City of
Nashua review, approval, or acceptance of, or payment for any of Professional Engineer's
work under this contract shall not operate as a waiver of any of the City of Nashua's rights
or causes of action under this contract, and Professional Engineer shall be and remain liable
in accordance with the terms of the contract and applicable law.
Professional Engineer shall furnish competent and skilled personnel to perform the work
under this contract. The City of Nashua reserves the right to approve key personnel
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