Drowning Machines: Low Head Dam Hydraulics and Hazard Remediation Options Anita Rogacs, Cole Marr, Anizka Garcia Rose-Hulman Institute of Technology, Terre Haute, Indiana Introduction 1.1 Introduction A father and two sons set out for a day of excitement as they head off to Licking River, Kentucky. Chad, the youngest, has never been kayaking and this is his big chance to ‘learn the ropes’. With life jackets fastened, all three embark on their quest for fun as they start into the water. Slipping through the waves, there are bright smiles on their faces and excitement in their eyes, when the father, Larry Ratliff, catches sight of a menacing horizon up ahead. He recognizes the danger and looks for his sons. Chad is too far away to be warned and as his father watches in horror, his youngest son drops out of sight. In a panic Larry paddles over the low-head dam after his son, thinking that somehow he will save Chad. Larry is immediately pulled into the hydraulic as well. Both father and son struggle, but ultimately lose their battle. Both are pronounced dead at the scene. (“Kentucky”) Many more tragic stories just like the one related above happen every year, and have been occurring since the creation of low-head dams. A low head dam is a water control structure usually below 10 feet high, (Elverum, 2003) and has several uses. These uses include: ensuring a constant water supply in low flow conditions (White River, 2005), grade control, aesthetics, and protection for utility crossings. They also have recreational uses; they provide pools of water in the river for fishing and boating, and are jumps that canoeists and kayakers paddle over for a thrill. (Low Dams) Figure 1: Rafters at low-head dam ( Popular Mechanics) 1.2 History Powering mills was one of the main reasons for the development of the low-head dam. Water wheels were used to power mills in the 19th century, and these wheels required a constant supply of water. Low head dams fulfilled this need because they enable the storage of water for use in low flow conditions. (Colley) Figure 2: Mabry Mill, Virginia ( Davis, Allen) Figure 3: Reed Springs Mill, Missouri ( Davis, Allen) Low-head dams also came into use as early settlers became concerned with the storage of irrigation water. Originally local water supplies held enough water for their limited needs. Unfortunately, this dependence on natural water resources forced them to cope with the varying seasonal discharge. During the late 1880’s and early 1890’s a few dams were built, but they were “make-shift affairs,” in some cases beaver dams were upgraded. Orcharding accelerated technological growth due to the increased need for more elaborate irrigation works and an increased need for storage of water. In the early 1900’s dams of varying sizes and qualities were built, including earth dams. Earth dams were common because of the availability of construction materials, and their relatively low cost. (“Irrigation Technology”) 1.3 Types of Dams Dams consist of timber, rock, earth, masonry, concrete, or a combination of the afore mentioned materials. (dam, 2005) Four basic types of dams will now be considered. These are: 1) Concrete Gravity Dams, 2) Earth Dams, 3) Earth and Rock Fill Dams, and 4) Concrete Faced Rock Fill Dams. These structures can be as simple as a flat-topped weir or as complicated as a multiple arch dam. Concrete Gravity Dams rely on their own weight to withstand the applied forces. (Woodward, “Types” 2004) If the water flowing over the dam produces any cavitation or turbulence, it will slowly erode the structure, to reduce this effect, many of these dams are made in an Ogee style. ( Encyclopedia:Dam) Earth Dams are consist completely of homogenous, impermeable earth material. Earth and Rock Fill Dams have an impermeable earth or clay core, covered with a permeable rock fill outer layer. Concrete Faced Rock Fill dams mainly consist of permeable rock fill, which is then covered on the upstream face with an impermeable concrete slab. (Woodward, “Types” 2004) Figure 4: Concrete Gravity Dam (ASDSO) Figure 5: Ogee spillway Figure 6: Earth Dam Figure 7: Earth and Rock Fill Dam Figure 8: Concrete Faced Rock Fill Dam 1.4 Cost The cost of construction varies widely due to the many variables involved in an estimate. The type of dam influences the amount of manpower needed and the type of construction materials required. (“Concrete”) In the case of an Earth and Rock Fill Dam or a Concrete Faced Rock Fill Dam, many times the most economical way to obtain the large volume of rock needed is to use the rock that needs to be excavated during the building of the spillway. This may not be possible if the quality of the rock acquired from the spillway is not acceptable for construction. Another important variable to take into account is the distance that the construction materials must be hauled to get them to the work site. (Woodward, “Construction” 2004) Also, the river on site has to be redirected in order to be able to build the dam. This cost depends on how large the river is and how accessible a place to redirect it is. If, for example, we looked at a 15 ft. wide by 5’ tall dam, with a road into the site, with no materials at the site (all material and equipment has to be brought in), and about 20 miles from the materials, the price for the dam construction might be around $50,000. If one was to try to use this same dam as a power source, the construction including a power house and all the extra equipment, could cost around $300,000-$500,000. Or, if one were to consider a bigger dam, one 200 ft. wide and 15 ft. high, also with access to a road, and material or equipment on site, and about 70 miles from the materials, the construction cost could amount to 1-2 million dollars. (Desrochers, 2005) 1.5 Safety Low-head dams are found throughout the United States and pose a considerable safety risk to the general public. The safety risk arises from the fact that the structures often look harmless or even inviting to the recreational water user. The danger of these overflow structures is that the downstream side of a low-head dam contains a submerged hydraulic jump or “hydraulic” as it is referred to in the boating community (Tschantz, 2003). The hydraulic jump creates a recirculating current which can trap water-goers in a seemingly endless cycle of being pulled under, struggling back to the surface, being pushed back toward the falling water, and once again being pushed under (Elverum & Smalley, 2003). These low-head dams put an unsuspecting public in danger time and time again. Figure 9: Roller Effect (Curry, Reed) The exact number of low-head dam structures throughout the United States is somewhat vague. Some states do keep track of these structures, but even in these cases the numbers can be inaccurate. Pennsylvania maintains a list of 280 low-head structures and Virginia estimates between 50 and 100 in their state (Tschantz, 2003). Some confusion also arises from the fact that there are no universal definitions or dimensions available to define a “low-head” dam. According to Leutheusser and Birk (1991), in order to “drownproof” one of these structures the weir height would have to be increased to approximately seven times the original height. The fact that there have been no easy or inexpensive retrofits developed for these structures means that year after year low-head dams are claiming lives throughout the world. While Larry Ratliff, mentioned previously, recognized the danger of low-head dams and would not have willingly gone over the structure if not for his son, this is exactly what many people do. Many times canoeists and kayakers along with other pleasure-seeking riders, willingly ride over these dams. A typical example of this is an event in Minnesota described by Elverum and Smalley (2003) in a brochure for the Minnesota Department of Natural Resources titled “The Drowning Machine.” In July 1979, a 25-year-old man on an air mattress went over the Berning’s Mill Dam, apparently on a dare. He was caught in the recirculating current and began a cycle of being pulled down and trapped against the dam. Two canoes attempted to help, both of which were pulled into and trapped in the recirculating current of the dam. A state trooper and several bystanders attempted a rescue, but were unsuccessful. In the end three people died in an event that is all too typical at low-head dams. The structure appeared harmless in the beginning, as most do, and in the end kept its reputation as one of the most dangerous aspects of our nation’s waterways. 1.6 History of the Charles Mill Dam The Charles Mill is located in Marion Indiana, in Grant County, and was originally built in 1855 by John and Jacob Secrist. At this time the mill was called Marion Mills, and was operated by James Charles, who came from England to work for Secrist. The building, one of the oldest in Grant County, is still in use after more than a century. In its earlier days farmers drove their grain to the mill and waited in long lines for their turn to unload their corn, wheat, or feed for weighing and grading. It was a grist mill, powered by the dam built at its side. The dam was also built by Secrist, and this dam powered the machinery in the mill until about 1940 when electricity was substituted. (Simons, 1976) The dam on the site today is called the Old Mill Dam and was built in 1936 by the Work Projects Administration (US Government) as a recreation area. After a time the ownership of Charles Mill Dam, like countless others, was lost in paperwork. As Owners die and leave no one in charge of the dams, these structures fall into disrepair and become the property of the state. The Charles Mill Dam is currently the property of the city of Marion and is still in use as a recreational site, and the mill itself has shops and apartments within. (“Low Hazard,” 2002) Unfortunately, this historic landmark has tragedies in its past. For example, on June 15, 2003, Neil W. Cornell (45 yrs. Old) died after diving into the Mississinewa River at the Charles Mill Dam to save his twin 11 year old sons who became trapped in the reverse roller at the base of the dam. The sons were rescued, unfortunately the father could not be saved.( Ross, 2005) 1.7 Project Description The Indiana Department of Natural Resources (IDNR) Engineering and Dam Safety Group and the IDNR Division of Law Enforcement appointed our research group to conduct an intensive investigation on low head dam hydraulics and affordable hazard remediation alternatives. Since the hazards of low head dams have been recognized, over the last few decades, various attempts have been made to eliminate the dangerous hydraulics at these structures. However, some proving to be more effective than others. Due to IDNR’s wide range of needs, testing will be performed on two characteristic lowhead dams, one will be a model of the Charles Mill Dam. The goal in modeling these dams is to arrive at a suitable remediation alternative for the majority of low-head dams in the state by designing a retrofit that reduces the dangerous hydraulics or by improving an already existing design. The current options may serve as a useful starting point for improved hazard remediation options. Along with the reduction of dangerous hydraulic features, we are also concerned with the environmental impact and implementation cost of any remediation option which may be available. Despite the fact that our retrofit design will be applicable to similar low-head dams, only those that have the same design as the models tested can be expected to follow the experimental results. The standards for classification of low-head dams, fatality statistics, final retrofit solution, and guidelines for implementation will be provided to IDNR in the final report. CHAPTER 2 Literature Review 2.1 Introduction In the last two decades attention has been drawn to the dangers that exist at low-head dams throughout the country. The dangers include being pushed toward the dam face and pulled under, being caught in the recirrculating current at the base of the dam, and decreased buoyancy due to increased aeration from the recirriculating current. State governments have published several brochures and papers warning recreational users of these dangers. Newspaper articles show up all too often detailing the tragic drownings that take place at low-head dams every summer; yet, to date little has been done to rectify the problem. Some states, such as Minnesota, have started documenting low-head dam accidents. During the 29-year period ending in 2002, The Boat and Water Safety Section of the Minnesota Department of Natural Resources reported 53 deaths and 50 injuries at low-head dams throughout the state (Tschantz 2003). While this is an alarming figure, many states do not keep such specific statistics, so the aggregate effect of these dangerous hydraulic structures can not be adequately quantified. However, it is clear that safety concerns at low-head dams must be addressed. Research into the components of the hydraulic characteristics found at low-head dam structures has taken place as far back as about a half century ago. Early investigations on the subject were chiefly concerned with the characterization of the submerged hydraulic jump which forms at most of these low-head dam sites. The initial investigations on this subject do not seem to acknowledge the life-threatening nature of these structures. They simply try to characterize the phenomena occurring in these locations. This section describes the previous research on hydraulic jumps and the recirrculating currents produced at low-head dams. Previous research and the pertinent equations needed to understand and control these hydraulic characteristics will be presented. In addition proposed retrofits or alteration plans to eliminate the dangers will be discussed. 2.2 Hydraulic Jump Hydraulic jumps occur most commonly in man-made channels as a way to dissipate energy, often gained as water flows down an overflow structure. A hydraulic jump occurs when flow changes from a supercritical level at the base of the dam to a subcritical level after the hydraulic jump. According to Hwang and Houghtalen (1996), critical flow is the flow at which a flow rate, Q, can be passed with minimum energy. This occurs at the critical depth. Therefore, it follows that if the water level in the structure drops, the velocity must increase in order to convey the same flow. This situation is called supercritical flow. When the water depth is greater than the critical depth the flow is called subcritical, which results in a lower velocity necessary to handle the same Q. The flow regime can be characterized by a comparison of the unit inertial reaction to the unit gravitational force or Froude number, F, (Forester & Skrinde 1949). It is defined by Hwang and Houghtalen (1996) as follows: F Where: In which: Where: V gD (1) V = velocity of flow [m/s] D = hydraulic depth [m] g = gravitational acceleration [m/s2] D = A/T (2) A = cross-sectional area of flow T = top width of channel When a rectangular channel is used for the idealization of the phenomenon, as is common, hydraulic depth, D, is equal to d, the depth of flow in the section. By definition when F=1 the flow is critical, when F>1 supercritical flow has developed, and when F<1 the flow is subcritical. The water levels before and after the hydraulic jump, or, the change from supercritical to subcritical flow, is defined by the Belanger equation (Foster and Skrinde 1949; Leutheusser and Birk 1991; and Leutheusser and Fan 2001) : d2 1 2 1 8F1 1 d1 2 Where: (3) d1,d 2 = pair of sequent depths F1 = Froude number at supercritical depth The Belanger equation applies only to rectangular channels, but provides the only method for analysis of the jump phenomenon. Velocity of the flow rate per unit width, q, is determined by: V Where: q d (4) V = velocity of flow [m/s] q = flow rate per unit width [m2/s] d = depth of flow The flow rate per unit width of overflow, q, can be determined using the head on the overflow (Leutheusser and Birk 1991; and Leutheusser and Fan 2001 : q Where: In which: 3 2 Cw 2 g H 2 3 (5) Cw = Rehbock weir discharge coefficient H = head on weir [m] g = gravitational acceleration [m/s2] C w .611 .075 H P (6) H = head on weir [m] P = height of weir [m] According to Foster and Skrinde (1949) and Leutheusser and Birk (1991) a hydraulic jump will form when the downstream depth, d2, satisfies equation 3. From equation 3 it can be seen that there is an ideal manner for the jump to form. In reality these conditions do not occur readily in the field. 2.3 Submerged Hydraulic Jump While it is know how to produce an optimal hydraulic jump, the ideal situation does not usually occur at low-head dams. The phenomenon which takes place at these structures is referred to as a submerged hydraulic jump. When the tail water, dt, rises to become higher than the ideal condition would require in eq.3 the jump becomes submerged. A submerged hydraulic jump sweeps back on itself and creates a vortex (Leutheusser & Fan, 2001). “Vortex” is one term of many used to describe the phenomenon. Other terms for what occurs at a submerged hydraulic jump include “hydraulic”, ‘recirrculating current”, and “roller” which will be used throughout this paper. According to Leutheusser and Fan (2001) this roller swirls on a horizontal axis parallel to the dam creating a strong upstream surface velocity, pushing whatever it comes in contact with back into the dam. Rajaratnam (1965) and Leutheusser and Fan (2001) have described the behavior in terms of submergence of the jump using the following relationship: S Where: dt d 2 d2 dt = local tailwater depth d2 = second in pair of sequent depths [m] (7) The optimal jump occurs when S = 0, the jump is swept downstream if S < 0, and the dangerous submerged jump happens when S > 0 (Leutheusser & Fan 2001). This relation illustrates the fact that the submerged jump occurs if the tailwater depth downstream of an overflow structure exceeds the subcritical depth of the hydraulic jump (Leutheusser & Fan 2001). In review, the diagram below shows some of the possible situations at a weir, or dam. Situation A would be an example of an optimum jump. Situation B is where the hydraulic jump is submerged, and the reverse roller is produced. Case C is when the roller disappears and the flow is purely directed downstream. Early modeling of the horizontal surface velocity of the upstream directed wave was performed by Leutheusser and Birk (1991). With their initial investigation they developed an estimate of the surface velocity. In accordance with predicted results the velocity directed upstream decreased as the tailwater increased (Leutheusser and Birk 1991). Generally, the velocity at low-head dams is calculated to be near this maximum swimming velocity. It is also important to remember that a 2 m/s swimming velocity is only achievable by Olympic class athletes and would probably not be possible over the extended period of time necessary to escape the recirculating current. In 2001 Leutheusser and Fan developed a more comprehensive method to predict the free surface velocity: Vs 16Edm d1 V1 S 1 1 8F12 1 F12 Where: 1 3 (8) Vs = free surface velocity [m/s] V1 = average velocity of supercritical jump inflow [m/s] Edm = change in energy defined in Leutheusser & Fan 2001 d1 = first in pair of sequent depths = Experimental constant found in Table 1 of Leutheusser & Fan 2001 S = submergence as defined in equation 5 F1 = Froude number at supercritical depth The change in energy, Edm , is calculated using the equation: E dm Where: d1 4 2 2 2 S 1 1 8 F1 1 F1 1 C L (9) 2 2 2 2 S 1 1 8 F 1 1 CL = empirical loss coefficient CL is defined as: In which: CL E p q 2 d12 2 g (10) E p P H d1 q 2 d12 2 g (11) The experimentation of Leutheusser and Fan supports their statement that the free surface velocity, Vs in equation 8, is about one-third the unsubmerged jump supercritical inflow velocity V1 (2001). Using general hydraulic methods as well as the relationships determined by previous research it should be possible to quantify the dangerous hydraulic features occurring at low-head dam structures. 2.4 Alternatives/Solutions Increased Spillway Elevation According to Leutheusser and Birk (1991) many overflow structures are constructed too low to produce a hydraulic jump that effectively dissipates the increased kinetic energy of the flow. Although the operational requirements of the low-head dams were satisfied, Leutheusser and Birk claimed that engineers failed to notice that the low overflow structures did not allow the flow to go through the optimal, free hydraulic jump. The faulty hydraulic condition, therefore, posed great danger. The suggested method for eliminating the dangerous rollers, produced at the base of low-overflow structures, was to simply elevate the height of the dam. It was theorized that by using the combination of tailwater depth and the rate of flow at the downstream end of the roller, it would be possible to determine the required height of the overflow structure that would produce the optimal hydraulic jump. However, Leutheusser and Birk , realized that the required height in many cases would be so great that this design option would be impractical (1991). Baffled Chutes Leutheusser and Birk (1991) suggested an alternative retrofit to eliminate the “hydraulic” of overflow structures completely, see Figure 1. It was thought that “baffled chute spillways” would provide “continuous energy dissipation by cascade action” (Leutheusser & Birk 1991). Hotchkiss and Comstock (1992) later experimented with baffled chutes and found the claim flawed. Baffled chutes dissipated energy by creating a turbulence that presented a new safety hazard for boaters navigating through the baffles. Physical models of the baffled chutes showed that scale model boats were often trapped in the baffled chutes. Furthermore, the collected floating and suspended debris may result in the overtopping of the basin and damage to the baffle blocks. This occurrence would require regular cleaning of the blocks. Figure 1. Baffled Chute Basin. (Dam Safety 1999) Labyrinth Weir Hauser et. al. (1991) proposed an alternative design, called a labyrinth weir (Figure 2), for low-head hydropower dams. The new structure increases minimum flow between generating periods. Hauser et. al. claim rollers are created when the discharge per unit width is high. By enlarging the crest length the labyrinth weir has a lower discharge per unit width reducing the chance of roller formation. Disadvantages of the design include the difficulty of increasing the crest length and the non-navigable nature of the labyrinth. Such disadvantages have precluded the Labyrinth Weir from becoming a viable solution. Figure 2. Labyrinth Weir. (Physical Hydraulic 2005) Stepped Spillways Stepped spillways are also used as energy dissipaters for low overflow structures (Figure 3). The flow over the steps can be defined as either nappe flow or skimming flow. In nappe flow, as water hits each step, it dissipates energy by either breaking up the water flow in air or mixing the flow on each step. This process may or may not form partial hydraulic jump on the step (Rajaratnam 1990). In the skimming flow, the flow from each step travels as a consistent stream, “skimming” over each step creating recirculating rollers. The momentum transfer to these rollers enhances the energy dissipation over the structure. Christodoulou (1992) conducted experiments to validate Rajaratnam’s estimates on the energy loss over stepped spillways. It was found that the amount of energy lost is mainly governed by the ratio of the critical depth of the water flow passing over the spillway to the step height (dc/h), and the number of steps N. Furthermore, greater number of steps and decreasing values of dc/h result in increased energy dissipation over the spillway. With further experimentation Chamani and Rajaratnam (1994) were able to present a method to estimate the energy loss within the nappe region flow and find a relationship for the variation of energy loss at each step. To retrofit a low head dam, Freeman and Garcia (1996) constructed a four- and a six-step spillway. The conclusion reached was that even though the six-step spillway performed better, the fourstep arrangement is more cost effective and a more feasible solution. Figure 3. Four-step spillway. (Freeman 1996) Rock Arch Dam Conversion Rock arch rapids are a new retrofit for low-head dams that is currently being investigated by Dr. Luther Aadland, who is currently taking data at multiple locations where the design has been implemented. The retrofit design uses three different sized field stones, which are placed as seen in Figure 4. The downstream end of the rock arch rapids curves and then becomes flat as it approaches the dam crest. The slope of the rapid is approximately 5%, which allows fish to swim upstream. The slope of the weirs varies to match the grade. “Weirs are integrated into the bank and gaps between the large boulders near the bank are filled with smaller stones to reduce leakage and create pools” (Aadland 2005). The rock arch dam conversion utilizes varying sized stones. The different sizes are necessary since each serves a specific purpose. Boulders function as strengthening elements that add stability to the flow and direct the rapids towards the mid-channel, therefore, reducing the flow velocity and stress on the river banks. The size of the field stones or boulders range between three and six feet in diameter. They are set one foot above the grade and are spaced according to the slope for a maximum of one foot head loss per weir (Aadland 2005). “Cobble” is used for filling voids near the crest. The size of these smaller field stones change from one foot to three feet depending on the shear stress exerted on the rocks due to the varying flow rates. The size of a cobble can be between one and six inches in diameter. Aadland claims that the retrofit completely eliminates the “hydraulic” and provides a pathway for migrating fish. The primary concern with the design is the mobile nature of stones, which has led to questions regarding the permanence of the structure. 30o ANGLE OF WIER TO BANK FLOW 5% slope or lower SLOPE D A M C R E S T Figure 4. Rock Arch Dam Conversion (Aadland 2005). CHAPTER 3 Project Approach 3.1 General expectations To carry out our project successfully, we first conducted an intensive literature search on low head dam structures, hazards and fatality statistics. After obtaining the necessary background information, two characteristic low head dams were be chosen for experimentation. The phenomenon was tested by numerical modeling using Flow3D (Flow Science Inc.), a fluids modeling software that utilizes finite element analysis. Both quantitative and qualitative testing was conducted on the velocities and flow direction of the recirculating and eddy currents using different flow rates. A physical model was then built to verify the accuracy of the numerical model. Furthermore, successful simulation of a retrofit that results in a significant reduction of the dangerous hydraulics was tested on the physical models as well. For the physical modeling the characteristics of both the recirculating and eddy currents were observed. Using objects of varying size and material we will also assess the reaction of a human body that comes in contact with the recirculating current. The data from the analytical and physical models will be compared, and if they do not agree we will revise the computer model to be in line with the physical model. The agreeing models will be re-tested and the final data compiled. 3.2 Experimental Procedure Two types of Dams were tested in the laboratory, an ogee style dam, and a straight dam. To see the dimensions and composition details of these models see Appendix # . Figure 14: Straight Dam Figure 15: Ogee Dam Three different flow rates were used on each dam, one of high, one of low, and one of medium intensity. The tailwater depth was controlled by using a flat panel which was slid up and down to trap water, or let more pass underneath. Figure 16: Tailwater Depth Control Weir In order to determine the reach of the roller created, styrofoam was placed in the water to see which direction it drifted. The height where the current changed from a reverse current to a forward flowing current was estimated using an air pump connected through a tube to a fine pointed syringe. The small bubbles created were used to determine the direction of the flow deeper in the water. In order to accurately determine the flow rate, the water pump was calibrated. A series of tests were done and yielded a chart which could be used to identify the calibration factor needed for each flow rate. (See Appendix# ) 3.3 Numerical Modeling Notation: The following are used in the paper: g = acceleration due to gravity F = Froude number F1 = Froude number at jump inflow d1= supercritical depth d2 = subcritical depth dc = critical depth N = number of steps h = step height H = head on weir Cw = weir coefficient q = flow rate per unit width S = submergence dt = local tailwater depth of channel Vs = surface velocity Edm = change in energy defined in Leutheusser & Fan 2001 = Experimental constant found in Table 1 of Leutheusser & Fan 2001 References Aadland, Luther “Rock Arch Dam Conversion Design” Email to Anita Rogacs. June 9, 2005. Chamani, M.R., and N. Rajaratnam. “Jet Flow on Stepped Spillways.” Journal of Hydraulic Engineering. ASCE. Vol. 120, No. 2. (1994): pp 245-259. Christodoulou, G. C.. “Energy Dissapation on Stepped Spillways.” Journal of Hydraulic Engineering. ASCE. Vol. 119, No. 5. (1993): pp 644-650. Forester, J.W., and Raymond A. 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