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1The Eco-efficient design of Small Hydropower Stations -A handbook of Life Cycle Design guidelines for Small Hydropower Stations

Eco-efficient design of Small Hydropower Stations -A handbook of Life Cycle Design guidelines for Small Hydropower Stations

Politecnico di Milano - School of DesignMaster of Science in PSSD -

Product Service System Designa.y. 2015-2016

Session 27 July 2016

student: Iulia Mălina Miu matr. 803539

Tutor: Dr. Carlo Arnaldo VezzoliCo-tutor: Dr. Carlo Proserpio

Dr. Emanuela Delfino


Life cycle design guideline handbook

ECO-EFFICIENT DESIGN OF


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Summary Introduction

1. SUSTAINABLE DEVELOPMENT AND LOW ENVIRONMENTAL IMPACT PRODUCTS DESIGN Sustainable development Life cycle assessment Design for life cycle environmental impact reduction (Life Cycle Design)

2. LIFE CYCLE ASSESSMENT OF SMALL HYDROPOWER STATION Data collection and quality The Life Cycle Model - The System boundaries Functional unit of Halmagel Small Hydropower Station

3. COMPONENTS LIFE CYCLE Equipment life cycle Pipeline life cycle Powerhouse life cycle Intake life cycle

4. LIFE CYCLE ASSESSMENT RESULTS5. LIFE CYCLE ASSESSMENT INTERPRETATION

6. STRATEGIC DESIGN PRIORITIES IDENTIFICATION 7. The priority calculation sheet - Total8. Small Hydropower Station Priorities9. Small Hydropower Station Component Priorities

A. MINIMIZE MATERIAL CONSUMPTION Equipment Pipeline Powerhouse Intake

TABLE OF CONTENTS


4448525558

6163

6568727579

8386889092

9496

100

103

B. PRODUCT LIFETIME OPTIMIZATION Equipment Pipeline Powerhouse Intake

C. MINIMIZE TOXICITY / HARMFULNESS REDUCTION Equipment

D. OPTIMIZING MATERIAL LIFESPAN Equipment Pipeline Powerhouse Intake

E. RENEWABLE AND BIO-COMPATIBLE RESOURCES Equipment Pipeline Powerhouse Intake

F. MINIMIZING ENERGY CONSUMPTION Equipment

G. DESIGN FOR DISASSEMBLY - ALL

CHECKLISTS


This handbook is the main results of the “Eco-efficient design of Small Hydropower Stations -A handbook of Life Cycle Design guidelines for Small Hydropower Stations” thesis performed by Iulia Malina Miu in Product Service System Design- Master Degree in Politecnico di Milano- 2016. The purpose is to provide the desi-gners with a contribution in products development/design, in order to face the transition towards sustainability. This assessment results in identifying areas of priority when designing future, eco-efficient Small Hydropower Stations.

The handbook firstly introduces the concepts of sustainable development, Life Cycle Assessment (LCA) and Life Cycle Design (LCD).This is followed by the main results of an LCA study made using SimaPro8 Software.The main indication that emerges, looking at the environmental impact of considered life cycle phases (material production, component manufacturing, use, maintenance, distribution and disposal) is that impact of the material production, and component manufacturing (material used).

Design decisions to integrate environmental requirements in product development process are grouped in the fol-lowing strategies. Then, for each one, a priority indicator, in relation with the other strategies, is defined with IPSA method (Identificazione Priorità Strategiche Progettuali / Strategic Design Priorities Identification, developed by DIS1), based on the potential environmental improvement.

Design for Disassembly is functional to Product and components lifetime extension and to Material lifetime exten-sion and therefore it doesn’t have any priority indicator.

The most important priority value is defined as 100; inferior values stand for relative minor priority.

1DIS - Design and System Innovation Sustainability - Politecnico di Milano

Summary


HIGH PRIORITY (100) – Material consumption reduction: design strategy that aims at the reduction of products environmental impact by reducing the material consumption of the whole product, the single component.

MEDIUM HIGH PRIORITY (71.4) – Product and components lifetime extension: design strategy that aims at the reduction of products environmental impact by extending the life span of the whole product, the single component.

MEDIUM LOW PRIORITY (19.51) – Material lifetime extension: design strategy that aims at the re-duction of products environmental impact by exploiting them in respect of landfill through recycle, energy recovery or composting.

LOW PRIORITY (exhaustibility DEGREE – 3.69%) – Bio-compatibility and conservation: design strategy that aims at the reduction of products environmental impact by using renewable and not exhausting resour-ces (material and energy), as well as bio-compatible in the disposal phase.

VERY LOW PRIORITY (0.27) – Energy consumption reduction in use: design strategy that aims at the reduction of products environmental impact by reducing energy consumption in use.

Each design strategy is accompanied by some graphs indicating further intervention priority (in terms of environmen-tal impact potential reduction).

For each strategy, a guidelines and checklists set for high eco-efficient SHPS design has been made.The methodology, that has been used, is based on Life Cycle Design (LCD), or eco-design criteria and on a method for guidelines product specification1 adopted by DIS-Politecnico di Milano.

1 Vezzoli C., Sciama D., Life cycle design: from general methods to product type speci-fic guidelines and checklists: a method adopted to develop a set of guidelines/checklist handbook for the eco-efficient design, Journal of Cleaner Production, USA, 2006


The design criteria and generation guidelines is meant to help designers introduce product environmental requi-rement as early as the development stages of a hydropower station project, in order to achieve energy and environ-mental eco-efficiency through assessments and environmental reduction guidelines.

This handbook is divided in three parts.

In the first one there is a short introduction about the concepts of:• Sustainable development• Life Cycle Assessment (LCA)• Life Cycle Design (LCD).

The second part shows the results of environmental impact assessment made using SimaPro8 Software based on a life cycle model data that is described in the same part.

The third part deals with the setting of low environmental impact design strategies and guidelines for the SHPS; for each strateg, a derived design priority indicator is put to define the potential environmental improvement in relation with the other strategies.The strategies are integrated with some graphs that show where it is more important to develop innovative solu-tions, in the design process, i.e. where the potential for environmental impact reduction is higher. In other terms it contains:• the environmental impacts of the elevator in its life cycle phases• the set of prioritized indicators for strategic environmental design• the general description of six environmental design strategies• the guidelines and checklists set for high eco-efficient elevators design• the checklist chart related to the guidelines setThis set has been developed with the help of DIS-Politecnico di Milano, through feedback requests and a final review (workshop).

Introduction


It was about twenty years ago that the concept of sustainable development was introduced by the document “Our Common Future” by the World Commission for Environment and Development. Then it has been used as background by the United Nations in Conference on Environment and Development held in Rio de Janeiro in 1992.

This expression refers to the systemic conditions for which, at a regional and global level, human activities would not exceed biosphere and geosphere resilience limits, beyond which irreversible decay phenomena take place, and, at the same time, they would not impoverish the natural capital that will be handed down to future generations, meant as the whole not renewable resources and the environment systemic skills of reproduce the renewable ones.

To the previous considerations an ethical one has to be added: the principle of equity according to which it’s stated that everyone, in the sustainability context, has the right to the same environmental space, that is to say the same availability of global natural resources.

1. SUSTAINABLE DEVELOPMENT AND LOW ENVIRONMENTAL IMPACT PRODUCTS DESIGN

SUSTAINABLE DEVELOPMENT

LIFE CYCLE ASSESSMENT

The most used and recognised method to measure how much an industrial product determines negative effects for the environment is the Life Cycle Assessment (LCA). The LCA, according to ISO 14040, is a technique to estimate environmental aspects and potential impacts during the whole life cycle of a product or service through:• inventory of significant inputs and outputs coming from product-system life cycle processes• assessment of potential impacts related with these inputs and outputs• interpretation of the results of the previous two steps and evaluation, in reference to the goals of the study.

The LCA, in other words, considers the environmental impacts, in the ecologic and human wealth field as in resour-ces depletion, in relation with the material, energy and emissions flows of different processes that characterize the product in its life cycle: pre-production (material production), production (component manufacturing), distribution (delivery, installation and packaging), use (maintenance and assembly), end of life treatment.

To define the processes that characterize the product in its life cycle, it’s assumed as a reference its function (fun-ctional unit), that is to say the service or result that it provides; the function of the SHPS is the quantity of renewable energy produced.


Moving from the Life Cycle Assessment of a product to its design, the references are criteria, methods and tools of Life Cycle Design (LCD). The fundamental criterion is that design has to consider all life cycle stages, that is to say having a systemic approach. LCD environmental scope is then to reduce material and energy inputs, as well as all emissions and wastes impact, both in quantity than in quality (considering also effects harmfulness), taking function or result provided by a specific product as a reference for the environmental improvement assessment.

The importance of a LCD approach is to find and conjugate environmental advantages with economic and compe-titive advantages (eco-efficiency). In fact, considering environmental requirements since the first phases of design is much more efficient than trying to recover the damage (end-of-pipe solutions).

A first fundamental step for an effective life cycle design is the LCA study of a specific product typology product; in fact this allows to identify phases and processes that have the biggest impact and then to effectively define design intervention priorities.

Design guidelines are also important LCD tools; the more these are defined specifically for product type and priority (environmental improvement potential), the more effective they are.This text shows the main design strategies and priorities related to the SHPS, a further work could lead to the definition of specific guidelines to integrate environmental requirements in the design of low environmental impact SHPS.

DESIGN FOR LIFE CYCLE ENVIRONMENTAL IMPACT REDUCTION (LIFE CYCLE DESIGN)


DATA COLLECTION AND QUALITY

The data was acquired from a public document called: “Explanatory report for acquiring the Environmental agree-ment license for Halmagel Hydro-energetic development in the county of Arad” (Botoc, Cret, Roman, & Floarea, 2012)1 found on the Environmental Ministry of Romania’s website. For the in depth calculation a detailed project was made using the above mentioned document and expertise litera-ture “Designing and Building Mini and Micro Hydropower Schemes, A Practical Guide” (Rodriguez & Sanchez, 2011)2.For the LCA the four components were analyzed independently in order to highlight the one with the highest envi-ronmental impact.

Exact data:Some of the data was exact, such as: the gross size of the powerhouse construction and the materials used, the pi-peline dimensions and the materials, the flow of the river and the flow required for power generation, the power of the equipment and the typology, additional power generation equipment and typology, illumination, safety, time required for each of the parts construction and also pictures were available.

Assumed data:For the rest of the project design, following the available data and literature, the sizes of the intake were inferred, and also different details about the powerhouse were assumed. Thus the decision to create a technical project was made, together with technical drawings. The materials calculations were made on the resulting volume and information about materials used and typologies were accrued from the practical guide2, some of the assumption are detailed in the inventory of each component.

1 Botoc, G., Cret, D., Roman, S., & Floarea, I. (2012). Memoriu de Prezentare in vederea obtinerii acordului de mediu Amenajare hidro-energetica Halmagel Judetul Arad. Cluj-Napoca.

2 Rodriguez, L., & San-chez, T. (2011). Designing and Building Mini and Mi-cro Hydropower Schemes A Practical Guide. Rugby: Practical Action Publishing.

2. LIFE CYCLE ASSESSMENT OF A SMALL HYDROPOWER STATION


THE LIFE CYCLE MODEL - THE SYSTEM BOUNDARIES

Pre-production:Following the volumetric design and the details found in the expertise literature (Rodriguez & Sanchez, 2011) about materials used in this kind of construction (weights, density etc.) a bill of quantities was made and the materials inventoried were added as pre-production in the life cycle phase of each of the components. Those are considerate raw and at plant.

Production:The materials processed were calculated considering the quantities resulted in the pre-production phases. For the construction on site, construction machinery’s fuel consumption was calculated on available data. The machinery used in this construction are assumed to be: one tractor, one dozer, one excavator, one pipe-layer, three trucks, and one mechanical pump).The average was calculated for each component of the station, taking into consideration that the overall con-struction time was 8 months, as said in the explanatory report. The construction started upstream with the intake – about 2 months, after the completion, the pipeline was started – about 6 months. After one month, the construction of the powerhouse started, so that the system can be finished at the same time – construction time 5 months. The results were added as production phases in the inventory of the life cycle of each component.

Distribution:Distribution was considerate for readymade materials traveling from a distance of 126 km, from the biggest city, Arad, with a 16 ton truck. For the machinery transportation to site was taken into account the use of one 32 ton truck, operating on the same distance.

Use:For the use phase of the life cycle inventory, the lighting system (3 safety lights 8W, 3 - 150W lights, 3 – 58W lights, 2 – 36W lights) and other automatization devices (one command panel – estimating 10Kwh and two motors of 4 kWh) and also the turbine power efficiency loss (10% of the overall power generated) were considerate as speci-fied in the explanatory report.


SMALL HYDROPOWER ENERGY SCHEME IN APUSENI MOUNTAINS REGION (ROMANIA), HĂLMĂGEL RIVER


THE FUNCTIONAL UNIT OF HĂLMĂGEL SMALL HYDROPOWER STATION

Disposal:The disposal was assumed on average, about 70% recycled and 30% landfilled. Detail information is found in the in depth description of each component.

The appointed software and LC model design was made using SimaPro. In order to highlight the component of the SHPS that has the biggest environmental impact, the model was split in four components: the Intake, the Rapid Pipe-line, the Powerhouse and the Equipment.

The assembly of this components contained the materials and processes for pre-production and production. In the life cycle, the assembly was added together with independently calculated quantity for transport. The equip-ment has an extra energy use and an additional life cycle – the mineral oil that was created as an individual assembly and added.

An overall disposal scenario was created assuming common materials are recycled and average recycling percentages.

The calculation was made comparative and on singular components.

Functional unit is: the availability of the 3.2 MWpower Small Hydropower station to produce (renewable) electricity for 70 years of operative lifetime. The energy produced per year = 1253 MWh, about 87.71 GWh/70years.

The construction site is located at and at 8 km from Halmagel village and 126 km from Arad the region’s residence city.

The specifications:• APeltonturbinewithaninstalledpowerof3,2mWinthepowerhouse• Anannualproductionof:1253mWh/year• Anintakesituatedat602,50maltitudewithamediumflowofQm=0,351m3/s• AØ600mmdiameterglassfiberreinforcedplasticpipewithalengthof1870meters• Apowerhousewithanaverageof70m2locatedat514,60maltitude.


3. Component Life cycle



Equipment

TurbineGeneratorEnergy TransformerMedium Tension CellEnergy Cables

Small

HydropowerEnergy

SchemePowerhouse

Pre-production

Production

Distribution

Use

Disposal

Intake

Rapid pipeline

Materials: - Copper - raw

- Chromium Steel - raw

16 ton truck 50 kilometers (average weight 18.5 ton - 86.7/life cycle 70 years)

Equipment loss: - 9648.1 Mgwh/70 years

Lights and other device - 268.8 Mgwh/70 years

Assumed Recycling: 80%Assumed Landfil: 20%

Manufacure and Assembly: - Average metal works (all)

- Wire drawing (energy

tramsformer and cables)

EQUIPMENT LIFE CYCLE


- Wire drawing (energy Equipment

Lenght: 1870 metersDiameter: Ø 600 milimetersDiference of hight:

h=88,8 metersSmall Hydropower

Energy Scheme

Powerhouse

Pre-production

Production

Distribution

Use

Disposal

Intake

Rapid pipeline

Materials: - Fiber Glass Reinforced Plastic

16 ton truck 50 kilometers (average weight 85.65 ton - 171.3 ton/life cycle 70 years)

No consumption


Manufacure and Assembly: - Extrusion plastic pipesConstruction on site: Disel fuel consumtion/average working time for variouse construction machinery (1

tractor, 1 excavator, 1 pipelayer, 2 truck /6 months)

PIPELINE LIFE CYCLE


Equipment

Machine room:H=6,3m L=9m W=7,65m

Canal connecting river bedH=1,5 L= 5m W=2,8 m

Small Hydropower

Energy

SchemePowerhouse

Pre-production

Production

Distribution

Use

Disposal

Intake

Rapid pipeline

Materials: - Concrete, Reinforcing Steel, Chromium Steel, Glass, Miscellaneous (Windows, Doors)

16 ton truck 50 kilometers (average weight 665.7 ton - 671.37 ton/life cycle 70 years)

No consumption


Manufacure and Assembly: - Concrete mixing, Metal WorksConstruction on site: Disel fuel consumtion/average working time for variouse construction machinery (1 tractor, 1 excavator, 1 dozer, 1 mechanical pump, 2 truck /900 hours)

POWERHOUSE LIFE CYCLE


Equipment

Tyrolian Intake, walls, headrace chanel, silt basin,

forbey tank:Hight= 2,5 meters

Lenght=11meters

Width= 5,5 meters

Small Hydropower

Energy

SchemePowerhouse

Pre-production

Production

Distribution

Use

Disposal

Intake

Rapid pipeline Materials: - Concrete (sand, garvel, cement, water)

Reinforcing SteelChromium Steel

16 ton truck 50 kilometers (average weight 531.1 ton - 533 ton/life cycle 70 years)

No consumption


Manufacure and Assembly: - Concrete mixing, Metal WorksConstruction on site: Disel fuel consumtion/average working time for variouse construction machinery (1 tractor, 1 excavator, 1 dozer, 1 mechanical pump 2 truck /360 hours)

INTAKE LIFE CYCLE


SMALL HYDROPOWER SCHEME - TOTAL LC phase SMALL HYDROPOWER SCHEME - COMPONENT

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Preproduction +Production

Distribution

Disposal

LIFE CYCLE PHASE UNIT POINTS1760,4

35

ReCiPe Endpoint Use 129,2

26,46

4. LIFE CYCLE ASSESSMENT RESULTS

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

ReCi

Pe E

ndpo

int %

Rapid pipeline IntakePowerhouseEquipment

100%

83.2%

36.5%

26%

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Rapid Pipeline

Equipment

Intake

Powerhouse

COMPONENT UNIT POINTS706

588

258

184

100%

7.33%1.5%1.98%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

ReCi

Pe E

ndpo

int %


Distribution DisposalUse


SMALL HYDROPOWER SCHEME - COMPONENTS

14.7

Concrete

33.3 33.8 4.9

Plaster mixing

8.8

Windows

0.58

Glass

3.4

Doors

85.1

0 pt

25 pt

50 pt

75 pt

100 pt

125 pt

150 pt

175 pt

200 pt

225 pt

250 pt

275 pt

300 pt

325 pt

350 pt

375 pt

400 pt

425 pt

450 pt

475 pt

500 pt

525 pt

550 pt

ReCi

Pe E

ndpo

int P

t

Pipeline

Extrusion,Plastic Pipes

49.8

reinforced plastic

553

124.7

Diesel burnt

construction

Intake

40.4 25.37.2 4.8 16.7

66.3

12

93.7

221

77.3

Steel low alloyed

Reinforcing steel

44.1

Powerhouse


Just by looking at the overall result the component with the highest impact is the Rapid pipeline as expected. His is because it has a high amount of plastic and fiber glass witch are by no means easily regenerative materials. Further-more, a lot of energy goes into manufacturing plastic as a raw material as opposed to wood or sand or gravel which only need minimum processing, and the same goes for fiber glass. On top of this we need to take into consideration the process of manufacturing pipes which requires large machinery and huge amounts of energy. Even though the weight cannot be compared to those of the constructed components like the powerhouse or the intake, the pipeline is volumetrically big, spreading on almost two kilometers. Another factor that rises the environmental impact is the fact that fiber glass reinforced with unsaturated polyester resin is a composite material, making it hard to separate in order to recycle and the fiber glass slows down the eventual combustion processes aimed at recovering the ener-gy content within plastic. It also has the longest construction on site time – 6 months and it involves large machinery.

The second most impacting component is the Equipment. This is due to the fact that it is composed mainly of metal which is an expensive material that goes through a lot of processing before it can be considerate raw, and this processing requires high amount of energy. Not to be overlooked is the fact that this processing can be highly polluting and has harmful impacts on human health. When looking at its weight, the Equipment is the lightest of all components but has ranked second in terms of environmental impact. It has no fuel consumption during installation as is the case with other components.

The Powerhouse and the Intake are the constructed immobile parts of the system, the main material inventoried is the concrete with all its components. The Powerhouse has a greater impact value mainly because of its size com-pared to that of the Intake and also because more materials go into the construction. However those rank last also because of their long lifespan, which is 70 years. It is half of that of the Equipment and 20 year longer than the Rapid Pipeline. The intake has the shortest construction time – 2 months; the Powerhouse’s construction lasted 5 months.

5. LIFE CYCLE ASSESSMENT INTERPRETATION


Strategic Design Priorities Identification



The priority calculation sheet - Total

5. STRATEGIC DESIGN PRIORITIES IDENTIFICATION

The results of LCA have been elaborated through the IPSA (Strategic Design Priorities Identification) method, obtai-ning a priority list in relation to the seven most important LCD strategies

The priorities for the strategies of environmental impact reduction are a set of formulas that use the results from a Life Cycle Assessment Software, in this case SimaPro, also named Eco-indicator points. Upon those formula coeffi-cients need to be applied according to different reasoning. For each strategy there is one formula. An exception to this are the Renewable and Bio-Compatible Resources and the Design for Disassembly, because the latter does not have an appointed priority. As for Renewable and Bio-Compatible Resources the sum of Eco-indicator points gives the priority rank, without a formula.


HOW IS IS CALCULATED?

General criteria: 1. how much can I gain in terms of environmental impact reduction if I design a product pursuing to the fullest a strategy of Life Cycle Design?

2. The LCD strategy pursued to the fullest that have bigger potential of environmental reduction impact will be pro-portionally prioritized in comparison to the others

Reducing consumption and selecting low-impact resources are objectives for all life cycles stages.Optimizing product lifespan determines an overall reduction in the environmental impact during stages of pre-pro-duction, production, distribution and disposal by means of the reduction of product flow necessary to satisfy parti-cular needs.

Extension of material lifespan is an objective for the stages of pre-production (less raw material consumption) and disposal.

Facilitating disassembly is needed for optimizing product lifespan and extending material’s lifespan.


The design guidelines for integrating environmental requirements in the development phase of the examined product are grouped into the folowing strategies:

Minimising Material Consumption (100% high priority)Optimisation of Product Lifetime (56% medium priority)Optimisation of Materials Lifespan (25.7% medium - low priority)Minimising Toxicity (15% low priority)Renewable and Bio-Comaptible Resources (3.36% low priority)Minimising Energy Consumption (0.12% very low priority)

IPSA

%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Minimising

Material

Consumption

Renewable and

Bio-Comaptible

Resources

Optimisation of

Product Lifespan

100%

56%

3.36%

Optimisation of Materials

Lifespan

25.7%

Minimising Energy Consumption

Minimising

Toxicity

15%

0.12%

6. SMALL HYDROPOWER STATION PRIORITIES


Minimising Material Consumption (100% high priority, 66.75%, 55.39%, 39.54% medium priority)Optimisation of Product Lifetime (71.4%, 66.75% high, 4.82%, 3.52% low)Minimising Toxicity (39.43%, 0% medium)Optimisation of Materials Lifespan (14.3%, 18%, 22.17% 12.71% medium)Renewable and Bio-Comaptible Resources (0.19%, 0.2%, .36%, 3.96% low)Minimising Energy Consumption (0.31%, 0% low)

7. SMALL HYDROPOWER STATION - COMPONENT PRIORITIES

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

66.75% 66.75%

55.39%

39.54%

71.4%

3.52%4.82%

0.31% 0% 0% 0%

100%

IPSA

%

Minimising Material Consumption

14.3%12.71%

18%

22.17%

0.19%3.96%0.2%

4.36%

Optimisation of MaterialsLifespan

Renewable andBio-Compatible

Resources

39.43%

0% 0% 0%

Minimising toxicity Minimising Energy Consumption

Optimisation of Product Lifespan

Equipment Intake Pipeline Powerhouse


Strategic Design PrioritiesA. MINIMIZE MATERIAL CONSUMPTION



The IPSA Calculation Sheet

The coefficients used to calculate this priority vary from one component to the other, that is why, even though the glass-fiber reinforce plastic (the materials of the pipeline) has a greater environmental impact the reduction coeffi-cient cannot be so big (0,5 would mean reducing the materials to half) that is why a coefficient of 0,3 was used. And as a result the reduction of the materials of the pipeline has a lower priority than that of the Equipment. In the case of the Equipment the Intake and the Powerhouse there is more flexibility so an uncertainty coefficient was used 0,7.ttThe results are also unexpected if we look at the quantities in kilograms. The Equipment has the smallest amount 6,4 ton the Pipeline 8,6 ton second, Intake 53,3 ton third and Powerhouse 67.1 ton last.

A. MINIMISE MATERIAL CONSUMPTION


Material consumption reduction, or minimization, describes a design approach that aims to decrease the use of materials in the life cycle phases.

Reducing resources denotes a design aimed at reducing the usage of materials for the entire product life cycle. Using less materials diminishes the environmental impact of a product due to minimizing the resources being extracted, but also due to the reduction or diminishing of the fabrication processes and the produced waste. Apart from their environmental costs products obviously also have economical costs. Less materials means savings in both contexts.


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

66.75%

55.39%

33.54%

100%

IPSA

%

Minimising Material

Consumption

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Rapid Pipeline

Equipment

Intake

Powerhouse

COMPONENT UNIT POINTS325,521

217,302

180,32

128,716

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Rapid Pipeline

Equipment

Intake

Powerhouse

COMPONENT UNIT POINTS

217,302

IPSAIPSAIPSAIPSA


EQUIPMENT

Pre-Production+Production UNIT POINTS

ReCiPe Endpoint

Steel low alloyed 77.3

ReCiPe Endpoint

Copper 223

ReCiPe Endpoint

Wire Drawing Copper 12

ReCiPe Endpoint

Metal Work (average) 93.7

34.66%

Steel low alloyed

0 pt

50 pt

100 pt

150 pt

200 pt

250 pt

300 pt

350 pt

400 pt

450 pt

409 pt

26.85 pt29.18 pt

128 pt

ReCi

Pe E

ndpo

int

Pt

Pre-production+Production



Design indications are grouped as:MINIMIZE MATERIAL CONTENT OF PRODUCTMINIMIZE OR AVOID PACKAGINGCHOOSE THE MOST EFFICIENT SYSTEM TO REDUCE THE MATERIAL CONSUMPTION IN USE

MINIMIZE MATERIAL CONTENT OF PRODUCT

• Dematerialisetheproductorsomeofitscomponents• Digitalisetheproductorsomeofitscomponents• Miniaturise• Avoidover-sizeddimensions• Reducethickness• Applyribbedtothestructuretoincreasestructuralstiffness.• Avoidextracomponentswithlittlefunctionality

MINIMISE SCRAPS AND DISCARDS:

• Selectprocessesthatreducescrapsanddiscardedmaterialsduringproduction• Useefficientmoldsforsteelparts• Engagesimulationsystemstooptimizetransformationprocesses.

MINIMISE OR AVOID PACKAGING:

• Avoidpackaging• Applymaterialsonlywhereabsolutelynecessary• Designthepackagetobepart(ortobecomeapart)oftheproduct

MIMIMIZE MATERIAL CONSUMPTION - EQUIPMENTDESIGN GUIDELINES


ENGAGE MORE CONSUMPTION-EFFICIENT SYSTEMS:

• Designformoreefficientconsumptionofoperationalmaterials• Consideroptimizingtheshapeofthecoolingcoilsinstallation• Choosingatypeofoilwithhigherlifespanforthecoolingcoilsinstallation• Designformoreefficientsupplyofrawmaterials• Designformoreefficientuseofmaintenancematerials• Designforcascadingrecyclingsystems• Reusemineraloilaspaintforprotectingwoodsurfacesfromexteriordegradation.• Facilitatethepersonmanagingmaintenancetoreducematerialsconsumption

ENGAGE SYSTEMS OF FLEXIBLE MATERIALS CONSUMPTION:

For the oil from the cooling coils installations of the electromechanical equipment• Engagedigitalsupportsystemswithdynamicconfiguration• Engagearemotesystemforadjustingtheoilconsumption• Designareservetankinadditiontothecoolinginstallation,thatrefillsthelostoil• Designdynamicmaterialsconsumptionfordifferentoperationalstages• Engagesensorstoadjustmaterialsconsumptionaccordingtodifferentiatedoperationalstages• Useanadjustingsystemtooptimizetheuseofoilduringperiodsofhighenergygeneration• Reduceresourceconsumptionintheproduct’sdefaultstate

MINIMISE MATERIALS CONSUMPTION DURING THE PRODUCT DEVELOPMENT PHASE:

• Minimisetheconsumptionofstationerygoodsandtheirpackages• Engagedigitaltoolsindesigning,modellingandprototypecreation• Engagedigitaltoolsfordocumentation,communicationandpresentation


PIPELINE

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

ReCi

Pe E

ndpo

int %

Pipeline

Disel burnt(construction on site)


9.01%

100%

21.70%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%100%

0%0%0.32%

ReCi

Pe E

ndpo

int %


Distribution DisposalU se


MIMIMIZE MATERIAL CONSUMPTION - PIPELINEDESIGN GUIDELINES


MINIMIZE MATERIAL CONTENT OF PRODUCT• Dematerialise the product or some of its components• Applyribbedtothestructuretoincreasestructuralstiffness.• Applyribbedtothestructuretoincreasestructuralstiffnessforthepipeline

MINIMISE SCRAPS AND DISCARDS:• Selectprocessesthatreducescrapsanddiscardedmaterialsduringproduction• Useefficientmoldsforplasticparts• Engagesimulationsystemstooptimizetransformationprocesses


• Designformoreefficientconsumptionofoperationalmaterials• Designformoreefficientsupplyofrawmaterials• Designforcascadingrecyclingsystems




POWERHOUSE

0%

10%

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30%

40%

50%

60%

70%

80%

90%

100%Re

CiPe

End

poin

t %

Concrete

Powerhouse

Chromiumsteel

Reinforcing steel

51.8%

39.1%39.7%

5.8%

17.6%

10.5%4% 0.68%

100%

Plaster mixingMetal workDiesel burnt(construction

on site)

Door sGlassWindows

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%100%

0%2.58%9.9%

ReCi

Pe E

ndpo

int %

ReCiPe Endpoint %

ReCiPe Endpoint %

ReCiPe Endpoint %

ReCiPe Endpoint %ReCiPe Endpoint %

Chromium Steel

Reinforcing Steel

Doors

Glass

Metal Work (average)

PRE-PRODUCTION+PRODUCTION UNIT POINTS

ReCiPe Endpoint %Concrete 33.3

44.1

33.8

ReCiPe Endpoint %Plaster Mixing 4.94

15

ReCiPe Endpoint %Diesel burt (construction on site) 85.1

ReCiPe Endpoint %Windows frames 8.82

3.38

0.58



MINIMISE MATERIAL CONTENT:• Dematerialisetheproductorsomeofitscomponents• IfthesiteallowsitbuildthePowerhousepartiallyburiedundergroundorconstructedclose to a stone wall, in order to minimize the amount of material used• Useonsitegroundtoprovidesoundproofingbypartiallycoveringthehouse• Usearemotecontrolsystemforthestationinordertoavoidtheneedofaseparatecontrolroom. If possible design all the component in one room. • Avoidover-sizeddimensions• Startthedesignofthemachineroomfromthesizeoftheturbinethatisgoingtobeusedfor the specific flow.• Researchuptodatestandardsforstructuraldesigndimensions.• Researchfornewandmoreperformingmaterialsavailabletoreducetheoverallamountof materials.• Useappropriatesoftwaretounderstand,testandmakesimulationsfornewresistance specifications and materials.• Reducethickness–ofwallsofconstruction

Powerhouse – not on site• Useperformantreadymadepartswithrequiredconfigurationfortheconcretecomponents to reduce thickness of the walls of the construction• Useadiverserangeofconcretesfordifferentpartsoftheconstructione.g.thepartsindirect

MIMIMIZE MATERIAL CONSUMPTION - POWERHOUSEDESIGN GUIDELINES


contact to the water can be denser and more resistant to freezing and the ones buried can be less.• Considerchangingthesteelrebarwithalightermoreefficientreinforcementlike:usingfiber glass, carbon fiber, reinforced polymer or bronze-aluminum

Powerhouse – on site• Changingthequalityoftheconcretebyaddingmorecementwillreducetheneedofthicker walls.• Applyribbedtothestructuretoincreasestructuralstiffness.• Applyribbedtothestructuretoincreasestructuralstiffnessforthewallsofthepowerhouse


• Selectprocessesthatreducescrapsanddiscardedmaterialsduringproduction• Useefficientmoldsforreadymadeconcreteproductstoreducethescrapsanddiscarded materials during the production• Engagesimulationsystemstooptimizetransformationprocesses.• Vibrationpumpscanbeusedonsitetooptimizethedensityofconcrete.

ENGAGE MORE CONSUMPTION-EFFICIENT SYSTEMS:• Design for more efficient consumption of operiational materials• Designformoreefficientsupplyofrawmaterials• Use/acquirethenecessaryaggregatesforconcreteonsiteorcloserfromtheconstructionsite• Designformoreefficientuseofmaintenancematerials• Designsystemsforconsumptionofpassivematerials• Designforcascadingrecyclingsystems




0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%Re

CiPe

End

poin

t %

Concrete

Intake

Chromiumsteel

Reinforcing steel

60.3%

39.25%

23.58%

5.88%10.45%

100%

Plaster mixingMetal workDiesel burnt(construction

on site)

PRE-PRODUCTION+PRODUCTION UNIT POINTS

ReCiPe Endpoint

Concrete 26.51

ReCiPe Endpoint

Reinforcing Steel 40.4

ReCiPe Endpoint

Chromium Steel 15.8

ReCiPe Endpoint

Plaster Mixing 3.94

ReCiPe Endpoint

Metal Work (average) 7

ReCiPe Endpoint

Diesel burt (construction on site) 67

INTAKE

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%100%

0%2.91%11.30%

ReCi

Pe E

ndpo

int %


DistributionDisposal Use


MINIMISE MATERIAL CONTENT:

• Dematerialisetheproductorsomeofitscomponents• Avoidover-sizeddimensions• Researchuptodatestandardsforstructuraldesigndimensions.• Researchfornewandmoreperformingmaterialsavailabletoreducetheoverallamount of materials.• Useappropriatesoftwaretounderstand,testandmakesimulationsfornewresistancespecificationsandmaterials.• Reducethickness–ofwallsofconstruction

Intake – not on site• Useperformantreadymadepartswithrequiredconfigurationfortheconcretecomponentstoreducethick-ness of the walls of the construction• Useadiverserangeofconcretesfordifferentpartsoftheconstructione.g.thepartsin direct contact to the water can be denser and more resistant to freezing and the ones buried can be less.• Considerchangingthesteelrebarwithalightermoreefficientreinforcementlike:usingfiberglass,carbonfiber, reinforced polymer or bronze-aluminum

Intake – on site• Changingthequalityoftheconcretebyaddingmorecementwillreducetheneedof thicker walls.• Applyribbedtothestructuretoincreasestructuralstiffness.• Applyribbedtothestructuretoincreasestructuralstiffnessforthewallsofthepowerhouse, of the intake exterior basin and of the pipeline

MIMIMIZE MATERIAL CONSUMPTION - INTAKEDESIGN GUIDELINES


• Avoidextracomponentswithlittlefunctionality


• Selectprocessesthatreducescrapsanddiscardedmaterialsduringproduction• Useefficientmoldsforreadymadeconcreteproductstoreducethescraps and discarded materials during the production• Engagesimulationsystemstooptimizetransformationprocesses.• Vibrationpumpscanbeusedonsitetooptimizethedensityofconcrete.


• Designformoreefficientconsumptionofoperationalmaterials• Designformoreefficientsupplyofrawmaterials• Use/acquirethenecessaryaggregatesforconcreteonsiteorcloserfromtheconstructionsite• DesignformoreefficientuseofmaintenancematerialsSilt basin (intake)• Chooselonglastingtools(shovel,broomsorother)formaintenancematerials.• Designsystemsforconsumptionofpassivematerials• Designasystemthatusesthewateroftherainortherivertocleantheexteriorsurfaces.• Designsidegatesatthebottomofthesiltbasinthatallowswaterfromtherivertocleanthe silt from the basin• Designforcascadingrecyclingsystems• Facilitatethepersonmanagingmaintenancetoreducematerialsconsumption

ENGAGE SYSTEMS OF FLEXIBLE MATERIALS CONSUMPTION:

• Engagedigitalsupportsystemswithdynamicconfiguration• Designdynamicmaterialsconsumptionfordifferentoperationalstages• Engagesensorstoadjustmaterialsconsumptionaccordingtodifferentiatedoperationalstages• Reduceresourceconsumptionintheproduct’sdefaultstate


Strategic Design PrioritiesB. PRODUCT LIFESPAN OPTIMIZATION




B. PRODUCT LIFETIME OPTIMISATION

ENVIRONMENTAL STRATEGIC DESIGN PRIORITIES

Optimizing the lifespan of a products is to design for the extending of the product and its components lifespan and for intensifying product (and its components) use. A product with longer lifespan than another with the same functiona-lity, generally determines smaller environmental impact. A product with accelerated wear will not only generate unti-mely waste, but will also determine further impact due to the need of replacing it. Production and distribution of a new product to replace its function involves the consumption of new resources and the further generation of emissions.


This was calculated for those parts of the components of the station, which have an inferior life than that of the station (70 years). As follows: for Equipment: all the parts; for the pipeline: all the parts; for the Powerhouse: doors, windows, fencing system, lighting conductor; for the Intake: the grills and the sluice gates. All of this were calculated as replaced only once. So the coefficient used was 0,5 (double existing the lifespan- 35 years increase) for parts that were assumed on average with a lifespan of 35 years (powerhouse, intake, equipment) and 0.3 (25 years increase) for the pipeline that has a lifespan of 50 years.

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Rapid Pipeline

Equipment

Intake

Powerhouse


217,302

15,716

11,482

66.75%

71%

3.52%4.82%

Optimisation of

Product Lifespan


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

IPSA

%

IPSAIPSAIPSAIPSA


Total EcoIndicator points (35 years) of curent design - compared to 70 years lifetime extension


0 pt

25 pt

50 pt

75 pt

100 pt

125 pt

150 pt

175 pt

200 pt

225 pt

250 pt

ReCi

Pe E

ndpo

int P

t

77.3 pt

221 pt

Steel lowalloyed

Equipment

Copper

The components that have a lifespan inferior to the lifespan of the whole Small Hydropower energy scheme, that in the pre-production, production, distribution and disposal have the highest environmental impact are:

Macro component Equipment (Turbine, Generator, Medium Tension Cells, Transformers) - material: Copper

Macro component Equipment (Turbine, Generator, Medium Tension Cells, Transformers) - material: Steel low alloyed

EQUIPMENT


PRODUCT LIFETIME OPTIMISATION - EQUIPMENTDESIGN GUIDELINESDESIGN APPROPRIATE LIFESPAN:

• Designcomponentswithco-extensivelifespan• Makeapartbypartlifespanassessmentofallofthecomponentstounderstandifthereare parts that need works of maintenance or reparations and not total replacement. • Designlifespanofreplaceablecomponentsaccordingtoscheduledduration• Designaccordingto70yearsmultiples• Selectdurablematerialsaccordingtotheproductperformanceandlifespan.

RELIABILITY DESIGN:

• Reduceoverallnumberofcomponents• Simplifyproducts• Eliminateweakliaisons

FACILITATE UPGRADING AND ADAPTABILITY:

• Enableandfacilitatesoftwareupgrading• Designthesoftwareforoilconsumptioninstallationsinordertobeupgradableforuse of new, more efficient or more ecofriendly oils consumption• Enableandfacilitatehardwareupgradingformoreefficientturbines.• Designmodularanddynamicallyconfiguredproductstofacilitatetheiradaptability for changing environments.• Designonsiteupgradeableandadaptableproducts• Consideranapproachinwhichseveralsmallerturbinesarelinked,sothattheenergygeneration can continue also with low water flows• Designcomplementarytoolsanddocumentationforproductupgradingandadaptation


FACILITATE MAINTENANCE:

In the case of the SHPS we are talking of two kinds of maintenance:The cleaning processes that ensures the proper functioning of the system.The power generation machinery maintenance. In this case it is usually performed by technicians due to high safety risks.• Simplifyaccessanddisassemblytocomponentstobemaintained• Simplifyaccesstothesiltbasinformanuallycleaning.• Avoidnarrowslitsandholestofacilitateaccessforcleaning• Equiptheproductwitheasilyusabletoolsformaintenance• Equipproductswithdiagnosticand/orauto-diagnosticsystemsformaintainablecomponents• Aremotesystemcheckingthewell-functioningofthesystemandthesafetyparameters of the turbine.• Anadvancedremotesystemofsurveillanceandadjustmentsforthecoolingcoilsoil consumption and quality. • Placeadiagnosticsystemonthenozzlespreventdamageduetohighwaterpressure or high speed• nozzleshavetobedesignedorchosentobeperformantbecausetheyaresubjecttohigh pressure and friction. • Sensorsarealsoneededforthepipes,theinletsandjetsornozzlescomposedinthewatersupply inside the Powerhouse • Designproductsforeasyon-sitemaintenance• Integrityinspectionofthecoolingcoilscanbetestedonsitebytheconductivityorhelium gas methods. • Designcomplementarymaintenancetoolsanddocumentation• Designproductsthatneedlessmaintenance

FACILITATE REPAIRS:

• Arrangeandfacilitatedisassemblyandre-attachmentofeasilydamageablecomponents• Chooseordesignaturbinewithreplaceableanddetachablebuckets


• Replaceablebucketsfortheturbineneedtobeavailableonsiteforrepairs.• Designcomponentsaccordingtostandardstofacilitatesubstitutionofdamagedparts• Equipproductswithautomaticdamagediagnosticssystem• Damagediagnosticsystemcanbeplacedonnozzles,onpipesunderhighpressureand on bearings or their proximity.• Designproductsforfacilitatedonsiterepair• Designcomplementaryrepairtools,materialsanddocumentation

FACILITATE RE-USE:

• Increasetheresistanceofeasilydamagedandexpendablecomponents• Arrangeandfacilitateaccessandremovalofretrievablecomponents• Designmodularandreplaceablecomponents• Designcomponentsaccordingtostandardstofacilitatereplacement• Designre-usableauxiliaryparts• Facilitatecleaningthefiltersofoilthatareinplace• Designorchoosefiltersmadeofadurablematerial

FACILITATE RE-MANUFACTURE:

The industrial equipment that have long lifespans (turbine 35 years) are more suitable for remanufacturing. A design aimed at easy removal and replacement has to be considered.• Designandfacilitateremovalandsubstitutionofeasilyexpendablecomponents• Designstructuralpartsthatcanbeeasilyseparatedfromexternal/visibleones• Provideeasieraccesstocomponentstobere-manufactured• Calculateaccuratetoleranceparametersforeasilyexpendableconnectionslikethenozzles.• Designforexcessiveuseofmaterialsinplacesmoresubjecttodeterioration• Designforexcessiveuseofmaterialforeasilydeterioratingsurfaces• Designasmallerbearingboxaroundtheplaceofthebearings,independentfromthebody of the casing, so overall replacement of the casing will not be necessary


DESIGN APPROPRIATE LIFESPAN:

• Designcomponentswithco-extensivelifespan• Extendthelifespanofthepipelinefrom50to70yearsbyinstallingadiagnosticsystem that points damaged or vulnerable parts

PIPELINE

Fiber Glass Reinforced Plastic

0 pt

5 pt

10 pt

15 pt

20 pt

25 pt

30 pt

35 pt

40 pt

45 pt

50 pt

55 pt

Pipeline

553

The components that have a lifespan inferior to the lifespan of the whole Small Hydropower energy scheme, that inthe pre-production, production, distribution and disposal have the highest environmental impact are:Macro component: Pipeline - material: Fiber Glass Reinforced Plastic


• Designlifespanofreplaceablecomponentsaccordingtoscheduledduration• Selectdurablematerialsaccordingtotheproductperformanceandlifespan.Forthepipeline lifespan from 50 years to 70 years.

RELIABILITY DESIGN:



• Designmodularanddynamicallyconfiguredproductstofacilitatetheiradaptability for changing environments.• Designonsiteupgradeableandadaptableproducts• Designcomplementarytoolsanddocumentationforproductupgradingandadaptation


• Simplifyaccessanddisassemblytocomponentstobemaintained• Avoidnarrowslitsandholestofacilitateaccessforcleaning• Equiptheproductwitheasilyusabletoolsformaintenance• Equipproductswithdiagnosticand/orauto-diagnosticsystemsformaintainablecomponents• Sensorsforpressure,temperatureandeventualdepositscanbeplacedinsidethepipelineto signal if there are any hydraulic leaks that can create slits and cracks during freezing seasons.• Sensorsarealsoneededforthepipes,theinletsandjetsornozzlescomposedinthewatersupply inside the Powerhouse • Designproductsforeasyon-sitemaintenance

PRODUCT LIFETIME OPTIMISATION - PIPELINEDESIGN GUIDELINES


• Designcomplementarymaintenancetoolsanddocumentation• Designproductsthatneedlessmaintenance

FACILITATE REPAIRS:

• Arrangeandfacilitatedisassemblyandre-attachmentofeasilydamageablecomponents• Designcomponentsaccordingtostandardstofacilitatesubstitutionofdamagedparts• Equipproductswithautomaticdamagediagnosticssystem• Damagediagnosticsystemcanbeplacedonnozzles,onpipesunderhighpressureand on bearings or their proximity.• Designproductsforfacilitatedonsiterepair• Makelocalexcavationstofixthecracksofthepipeline,usingthediagnosticsystem• Abandagesystemcanbeused,oracollarlikemodulecanbefixedinplaceofthedamaged one after cutting the cracked part.• Designcomplementaryrepairtools,materialsanddocumentation

FACILITATE RE-USE:

• Increasetheresistanceofeasilydamagedandexpendablecomponents• Thewoodformworkscanbereplacedwithreadymademetalorplasticones.• Arrangeandfacilitateaccessandremovalofretrievablecomponents• Designmodularandreplaceablecomponents• Designcomponentsaccordingtostandardstofacilitatereplacement• Designre-usableauxiliaryparts


• Designandfacilitateremovalandsubstitutionofeasilyexpendablecomponents• Provideeasieraccesstocomponentstobere-manufactured• CalculateaccuratetoleranceparametersforeasilyexpendableconnectionsforthePipeline,inlets, jets or nozzles.• Designforexcessiveuseofmaterialsinplacesmoresubjecttodeterioration• Designforexcessiveuseofmaterialforeasilydeterioratingsurfaces



Macro component: Miscelaneous: Chromium SteelMacro component: Window framesMacro component: Doors

POWERHOUSE

0 pt

5 pt

10 pt

15 pt

20 pt

ReCi

Pe E

ndpo

int P

t

Powerhouse

16.9 pt

4.41 pt 1.64 pt0.58 pt



• Designcomponentswithco-extensivelifespan• Designlifespanofreplaceablecomponentsaccordingtoscheduledduration• Designaccordingto70yearsmultiples• Selectdurablematerialsaccordingtotheproductperformanceandlifespan

RELIABILITY DESIGN:



• Designmodularanddynamicallyconfiguredproductstofacilitatetheiradaptability for changing environments.• Designmultifunctionalanddynamicallyconfiguredproductstofacilitatetheiradaptability for changing cultural and physical individual backgrounds• Designonsiteupgradeableandadaptableproducts• Designcomplementarytoolsanddocumentationforproductupgradingandadaptation


• Simplifyaccessanddisassemblytocomponentstobemaintained• Avoidnarrowslitsandholestofacilitateaccessforcleaning• Equiptheproductwitheasilyusabletoolsformaintenance• Equipproductswithdiagnosticand/orauto-diagnosticsystemsformaintainablecomponents

PRODUCT LIFETIME OPTIMISATION - POWERHOUSEDESIGN GUIDELINES


• Designproductsforeasyon-sitemaintenance• Designcomplementarymaintenancetoolsanddocumentation• Designproductsthatneedlessmaintenance

FACILITATE REPAIRS:

• Arrangeandfacilitatedisassemblyandre-attachmentofeasilydamageablecomponents• Designcomponentsaccordingtostandardstofacilitatesubstitutionofdamagedparts• Designproductsforfacilitatedonsiterepair• Designcomplementaryrepairtools,materialsanddocumentation

FACILITATE RE-USE:

• Increasetheresistanceofeasilydamagedandexpendablecomponents• Avoiddamagingtheformworksusedforconcrete,inordertofacilitatetheirreuse. The wood formworks can be replaced with readymade metal or plastic ones.• Arrangeandfacilitateaccessandremovalofretrievablecomponents• Designmodularandreplaceablecomponents• Usemodularreadymadeconcretepartsfortheconstructionofwalls,topsorlidsorother simple components.• Designcomponentsaccordingtostandardstofacilitatereplacement• Designre-usableauxiliaryparts


• Designandfacilitateremovalandsubstitutionofeasilyexpendablecomponents• Designstructuralpartsthatcanbeeasilyseparatedfromexternal/visibleones• Provideeasieraccesstocomponentstobere-manufactured• Calculateaccuratetoleranceparametersforeasilyexpendableconnections• Designforexcessiveuseofmaterialsinplacesmoresubjecttodeterioration• Designforexcessiveuseofmaterialforeasilydeterioratingsurfaces



Macro component: Sluice Gates and Grills - material: Steel Low-alloyed

INTAKE

0 pt

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15 pt

ReCi

Pe E

ndpo

int

Pt

It k

Steel low-alloyed

12 pt



• Designcomponentswithco-extensivelifespan• Designlifespanofreplaceablecomponentsaccordingtoscheduledduration• Designaccordingto70yearsmultiples• Selectdurablematerialsaccordingtotheproductperformanceandlifespan

RELIABILITY DESIGN:



• Simplifyaccessanddisassemblytocomponentstobemaintained• Simplifyaccesstothesiltbasinformanuallycleaning• Designabiggerlid,madeofalightermaterialtoallowapersonenteringandmorelight.• Avoidnarrowslitsandholestofacilitateaccessforcleaning-allofthecomponentsof the Intake• Equiptheproductwitheasilyusabletoolsformaintenance• Equipproductswithdiagnosticand/orauto-diagnosticsystemsformaintainablecomponents• Implementsensorsshowingifmaintenanceisneeded• Triggerautomaticcleaningsystemsforthesiltbasin• Triggerautomaticsystemsforopeningthesluicegatesincaseofoverfloodingorobstruction.• Designproductsforeasyon-sitemaintenance

PRODUCT LIFETIME OPTIMIZATION - INTAKEDESIGN GUIDELINES


• Designcomplementarymaintenancetoolsanddocumentation• Designproductsthatneedlessmaintenance

FACILITATE REPAIRS:

• Arrangeandfacilitatedisassemblyandre-attachmentofeasilydamageablecomponents• Designcomponentsaccordingtostandardstofacilitatesubstitutionofdamagedparts• Equipproductswithautomaticdamagediagnosticssystem• Designproductsforfacilitatedonsiterepair• Designcomplementaryrepairtools,materialsanddocumentation

FACILITATE RE-USE:

• Increasetheresistanceofeasilydamagedandexpendablecomponents• Avoiddamagingtheformworksusedforconcrete,inordertofacilitatetheirreuse. The wood formworks can be replaced with readymade metal or plastic ones.• Arrangeandfacilitateaccessandremovalofretrievablecomponents• Designmodularandreplaceablecomponents• Usemodularreadymadeconcretepartsfortheconstructionofwalls,topsorlidsorother simple components.• Designcomponentsaccordingtostandardstofacilitatereplacement• Designre-usableauxiliaryparts• Facilitatecleaningthefiltersofoilthatareinplace• Designorchoosefiltersmadeofadurablematerial


• Designandfacilitateremovalandsubstitutionofeasilyexpendablecomponents• Provideeasieraccesstocomponentstobere-manufactured• Calculateaccuratetoleranceparametersforeasilyexpendableconnections• Designforexcessiveuseofmaterialsinplacesmoresubjecttodeterioration• Designforexcessiveuseofmaterialforeasilydeterioratingsurfaces


Strategic Design PrioritiesC. MINIMISE TOXICITY




C. MINIMISE TOXICITY


Design to favor the use of resources (materials) that relative to the entire life cycle minimize dangerous emissions and all the processes that characterize it. However it must be remembered that toxic or harmful emissions occur during any stage of the products life cycle and might be caused by certain additives to the material rather than the material itself (therefore they are substituted or avoided).

In this section, the mineral oil was considered in the priorities calculation as a harmful material used in the cooling coils and the electric transformer part of the Equipment component. High values are going to be generated, one ton per year. The material was inventoried in SimaPro with all its life cycle phases, including also different transportation for maintenance because it needs changing every year.


EQUIPMENT


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

IPSA

%

39.43%

0% 0% 0%

Minimising toxicity

0 pt

10 pt

20 pt

30 pt

40 pt

50 pt

60 pt

70 pt

80 pt

90 pt

100 pt

14.64 pt

0 pt

18.06 pt

Mineral oil - Equipment

104 pt


DistributionD isposal Use


Many of the materials commonly used for construction are or contain toxic compounds. However those were not included in the priorities for environmental strategy (IPSA) calculations of minimizing toxicity that is why this strategy ranked in the third place. However the following guidelines include minimization of toxicity also of other materials, together with the mineral oil. SELECT NON-TOXIC AND HARMLESS MATERIALS:

• Avoidtoxicorharmfulmaterialsforproductcomponents• Minimisethehazardoftoxicandharmfulmaterials

The mineral oil • Measurementsforsafetransportneedtobetakentopreventspilling,absorbingmaterials should be available on site for cleaning. • Avoidmaterialsthatemittoxicorharmfulsubstancesduringpre-production(cement,steel)• Avoidadditivesthatemittoxicorharmfulsubstances• Avoidtechnologiesthatprocesstoxicandharmfulmaterials(concreteandsteelmanufacturing)• Avoidtoxicorharmfulsurfacetreatments• Designproductsthatdonotconsumetoxicandharmfulmaterials• Avoidmaterialsthatemittoxicorharmfulsubstancesduringusage• Avoidmaterialsthatemittoxicorharmfulsubstancesduringdisposal

SELECT NON TOXIC AND HARMLESS ENERGY RESOURCES:

• Selectenergyresourcesthatreducedangerousemissionsduringpre-productionandproduction• Selectenergyresourcesthatreducedangerousemissionsduringdistribution• Selectenergyresourcesthatreducedangerousemissionsduringusage• Selectenergyresourcesthatreducedangerousresiduesandtoxicandharmfulwaste

MINIMIZE TOXICITY - EQUIPMENTDESIGN GUIDELINES


Strategic Design PrioritiesD. OPTIMIZING MATERIAL LIFESPAN




D. OPTIMIZING MATERIAL LIFESPAN


A design of adding environmental value to materials (within a product) to avoid premature disposal, by reproces-sing them to obtain new prime secondary materials (by recycling or composting) or burning them to recuperate their energetic content.

There is a double advantage in the process: a) The environmental impact and the cost of disposal of the materials are avoided. b) The production and acquisition costs connected with buying virgin materials are avoided. Naturally the


processes of composting, recycling and burning also have their own environmental and economic costs. In conserva-tory terms we can adopt a series of measures in relation with all the phases of the process of recycling to minimize such costs: collection and transportation; identification and separation; disassembly and/or fragmentation; cleaning and/or washing; pre-production of prime secondary materials.

Generally the following principle is followed: the material should be recycled as much as possible before it loses its material properties, then, at that point, the object should be incinerated to recuperate its energy content.

In the SimaPro software an average of most commonly recycled was made because recycling data was not available to this detail. The landfill percentages are as follows: Equipment (iron, steel, copper) 20%, Pipeline (glass-fiber rein-forced with polyester resin) 20%, Powerhouse (concrete, reinforcing steel, steel) 57%, Intake (concrete, reinforcing steel, steel) 40%. However this percentage can vary in reality.

Because it has the highest amount of landfill and of material in general the Powerhouse has the biggest priority among the four, followed by the Pipeline the Equipment and the Intake. Again because of the high values of the eco-indicator points, the Pipeline and the Equipment over rank the Intake at the priority even though the Intake has more materials overall.

20%

12.71%18%

22.17%

Optimisation of MaterialsLifespan


0%

10%

20%

30%

IPSA

% ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Rapid Pipeline

Equipment

Intake

Powerhouse


58,72

72,17

41,38

IPSAIPSAIPSAIPSA


Distribution

0.28% 0.28%Disposal

1.01%

Use

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

ReCi

Pe E

ndpo

int %


P

PP

14.8%

59.5 %

20 %

Potential Impact Avoided

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Preproduction (14.8%)

Production

Preproduction + Production

Distribution

Use (lights)

LIFE CYCLE PHASE - no oil UNIT POINTSReCiPe Endpoint Preproduction (59.4%) 243.2

60.8

105

409

1.181.15

ReCiPe Endpoint

Disposal 4.15

EQUIPMENT


ADOPT THE CASCADE APPROACH:

• Arrangeandfacilitaterecyclingofmaterialsincomponentswithloweraestheticalrequirements

SELECT MATERIALS WITH MOST EFFICIENT RECYCLING TECHNOLOGIES:

• Selectmaterialsthateasilyrecoverafterrecyclingtheoriginalperformancecharacteristics• Avoidcompositematerialsor,whennecessary,chooseeasilyrecyclableones• Engagegeometricalsolutionslikeribbingtoincreasepolymerstiffnessinsteadof reinforcing fibers• Preferthermoplasticpolymerstothermosetting• Preferheat-proofthermoplasticpolymerstofireproofadditives• Designconsideringthesecondaryuseofthematerialsoncerecycled

FACILITATE END-OF-LIFE COLLECTION AND TRANSPORTATION:

• Designincompliancewithproductretrievalsystem• Minimiseoverallweight• Minimiseclutteringandimprovestackabilityofdiscardedproducts• Designforthecompressibilityofdiscardedproducts• Providethebeneficiarywithinformationaboutthedisposingmodalitiesoftheproductor its parts

MATERIAL IDENTIFICATION:

• Codifydifferentmaterialstofacilitatetheiridentification• Provideadditionalinformationaboutthematerial’sage,numberoftimesrecycledinthepast and additives used

EXTENDING THE LIFESPAN OF MATERIALS - EQUIPMENTDESIGN GUIDELINES


• Indicatetheexistenceoftoxicorharmfulmaterials.Likeisthecaseofthemineraloil.• Usestandardizedmaterialsidentificationsystems• Arrangecodificationsineasilyvisibleplaces• Avoidcodifyingaftercomponentproductionstages

MINIMISE THE NUMBER OF DIFFERENT INCOMPATIBLE MATERIALS:

• Integratefunctionstoreducetheoverallnumberofmaterialsandcomponents• Adoptastrategy,inwhichcomponentswiththesamematerialaregroupedtogetherandaresplit from other materials, in order to reduce the overall number of parts and the duration of disassembly. • Useonlyonematerial,butprocessedinsandwichstructures• Usecompatiblematerials(thatcouldberecycledtogether)withintheproductorsub-assembly• Forjoiningusethesameorcompatiblematerialsasincomponents(tobejoined)

FACILITATE CLEANING:

• Avoidunnecessarycoatingprocedures• Avoidirremovablecoatingmaterials• If possible instead of painting the metal pieces against corrosion use oxidation-resisting steel, or electrical

corrosion techniques• Facilitateremovalofcoatingmaterials• Usecoatingproceduresthatcomplywithcoatedmaterials• Avoidadhesivesorchooseonesthatcomplywithmaterialstoberecycled• Preferthedyeingofinternalpolymers,ratherthansurfacepainting• Avoidusingadditionalmaterialsformarkingorcodification• Markandcodifymaterialsduringmolding• Codifypolymersusinglasers

FACILITATE COMBUSTION:

• Avoidmaterialsthatemitdangeroussubstancesduringincineration


• Forthemetalpartsuseoxidationresistingalloysinsteadofcoating.Zincortinemanates emissions during recycling processing that are barely filterable.• Avoidadditivesthatemitdangeroussubstancesduringincineration• Facilitatetheseparationofmaterialsthatwouldcompromisetheefficiencyofcombustion (with low energy value). Like the metals.


PIPELINE

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint



Production


DistributionUse

LIFE CYCLE PHASE UNIT POINTS110.6

442.4

169

7222.34

0ReCiPe EndpointDisposal 0

0.32%0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0% 0%

ReCi

Pe E

ndpo

int %



P

PP15.32%

61.27%

23.11%




• Selectmaterialsthateasilyrecoverafterrecyclingtheoriginalperformancecharacteristics• Avoidcompositematerialsor,whennecessary,chooseeasilyrecyclableones• Avoidusingglass-fiberreinforcedpolymersandreinforcedconcrete• Engagegeometricalsolutionslikeribbingtoincreasepolymerstiffnessinsteadof reinforcing fibers• Usepolymerpipelinewithexteriorribbingtoincreasethestiffness.• Preferthermoplasticpolymerstothermosetting• Preferheat-proofthermoplasticpolymerstofireproofadditives• Designconsideringthesecondaryuseofthematerialsoncerecycled


• Designincompliancewithproductretrievalsystem• Minimiseoverallweight• Minimiseclutteringandimprovestackabilityofdiscardedproducts• Designforthecompressibilityofdiscardedproducts• Providethebeneficiarywithinformationaboutthedisposingmodalitiesoftheproductor its parts


• Codifydifferentmaterialstofacilitatetheiridentification• Provideadditionalinformationaboutthematerial’sage,numberoftimesrecycledinthepast and additives used• Indicatetheexistenceoftoxicorharmfulmaterials.Likeisthecaseofthemineraloil.• Usestandardizedmaterialsidentificationsystems

EXTENDING THE LIFESPAN OF MATERIALS - PIPELINEDESIGN GUIDELINES


• Arrangecodificationsineasilyvisibleplaces• Avoidcodifyingaftercomponentproductionstages


• Integratefunctionstoreducetheoverallnumberofmaterialsandcomponents• Adoptastrategy,inwhichcomponentswiththesamematerialaregroupedtogetherandaresplit from other materials, in order to reduce the overall number of parts and the duration of disassembly. • Useonlyonematerial,butprocessedinsandwichstructures• Usecompatiblematerials(thatcouldberecycledtogether)withintheproductorsub-assembly• Forjoiningusethesameorcompatiblematerialsasincomponents(tobejoined)


• Avoidunnecessarycoatingprocedures• Avoidadhesivesorchooseonesthatcomplywithmaterialstoberecycled• Theplasticpipeshouldbechosenordesignedtobecouplingoneinsidetheother.• Preferthedyeingofinternalpolymers,ratherthansurfacepainting• Avoidusingadditionalmaterialsformarkingorcodification• Markandcodifymaterialsduringmolding• Codifypolymersusinglasers


• Selecthighenergymaterialsforproductsthataregoingtobeincinerated• Avoidmaterialsthatemitdangeroussubstancesduringincineration• Avoidadditivesthatemitdangeroussubstancesduringincineration• Facilitatetheseparationofmaterialsthatwouldcompromisetheefficiencyofcombustion (with low energy value). For the glass fiber inside the pipeline.


POWERHOUSE

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0%9.91% 2.58%

ReCi

Pe E

ndpo

int %



P

PP

30.86%

23.28 %

45.85 %


ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint



Production


DistributionUse


53.32

105

2295.90

ReCiPe EndpointDisposal 22.7





• Selectmaterialsthateasilyrecoverafterrecyclingtheoriginalperformancecharacteristics• Avoidcompositematerialsor,whennecessary,chooseeasilyrecyclableones• Avoidusingreinforcedconcrete• Preferthermoplasticpolymerstothermosetting• Preferheat-proofthermoplasticpolymerstofireproofadditives• Designconsideringthesecondaryuseofthematerialsoncerecycled


• Designincompliancewithproductretrievalsystem• Minimiseoverallweight• Replace steel rebar with other reinforcing non rusting materials like: Fiber glass, Carbon fiber,

reinforced polymer, and bronze-aluminum bars.• Minimiseclutteringandimprovestackabilityofdiscardedproducts• Designforthecompressibilityofdiscardedproducts• Providethebeneficiarywithinformationaboutthedisposingmodalitiesoftheproductor its parts


• Codifydifferentmaterialstofacilitatetheiridentification• Provideadditionalinformationaboutthematerial’sage,numberoftimesrecycledinthepast

EXTENDING THE LIFESPAN OF MATERIALS - POWERHOUSEDESIGN GUIDELINES


and additives used• Indicatetheexistenceoftoxicorharmfulmaterials.Likeisthecaseofthemineraloil.• Usestandardizedmaterialsidentificationsystems• Arrangecodificationsineasilyvisibleplaces• Avoidcodifyingaftercomponentproductionstages


• Integratefunctionstoreducetheoverallnumberofmaterialsandcomponents• Useonlyonematerial,butprocessedinsandwichstructures• Usecompatiblematerials(thatcouldberecycledtogether)withintheproductorsub-assembly• Forjoiningusethesameorcompatiblematerialsasincomponents(tobejoined)



corrosion techniques• Facilitateremovalofcoatingmaterials• Usecoatingproceduresthatcomplywithcoatedmaterials• Avoidadhesivesorchooseonesthatcomplywithmaterialstoberecycled• Preferthedyeingofinternalpolymers,ratherthansurfacepainting• Avoidusingadditionalmaterialsformarkingorcodification• Markandcodifymaterialsduringmolding• Codifypolymersusinglasers



• Selecthighenergymaterialsforproductsthataregoingtobeincinerated• Avoidmaterialsthatemitdangeroussubstancesduringincineration• Forthemetalpartsuseoxidationresistingalloysinsteadofcoating.Zincortinemanates emissions during recycling processing that are barely filterable.• Avoidadditivesthatemitdangeroussubstancesduringincineration• Facilitatetheseparationofmaterialsthatwouldcompromisetheefficiencyofcombustion (with low energy value). Like concrete and ceramic materials that oppose incineration. • Torecyclethereinforcingsteelfromtheconcrete,agoodcleaningwillincreasetheefficiency during processing and re-use.


INTAKE

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0%11.3%

2.91%

ReCi

Pe E

ndpo

int %



P

PP17.4%

11.6%

71%


ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint



Production


DistributionUse


49.6278.3

1614.68

0ReCiPe Endpoint

Disposal 18.2





• Selectmaterialsthateasilyrecoverafterrecyclingtheoriginalperformancecharacteristics• Avoidcompositematerialsor,whennecessary,chooseeasilyrecyclableones• Avoidusingreinforcedconcrete• Designconsideringthesecondaryuseofthematerialsoncerecycled


• Designincompliancewithproductretrievalsystem• Minimiseoverallweight• Replace steel rebar with other reinforcing non rusting materials like: Fiber glass, Carbon fiber,

reinforced polymer, and bronze-aluminum bars.• Minimiseclutteringandimprovestackabilityofdiscardedproducts• Designforthecompressibilityofdiscardedproducts• Providethebeneficiarywithinformationaboutthedisposingmodalitiesoftheproductor its parts

EXTENDING THE LIFESPAN OF MATERIALS - INTAKEDESIGN GUIDELINES



• Codifydifferentmaterialstofacilitatetheiridentification• Provideadditionalinformationaboutthematerial’sage,numberoftimesrecycledinthepast and additives used• Indicatetheexistenceoftoxicorharmfulmaterials.• Usestandardizedmaterialsidentificationsystems• Arrangecodificationsineasilyvisibleplaces• Avoidcodifyingaftercomponentproductionstages


• Integratefunctionstoreducetheoverallnumberofmaterialsandcomponents• Useonlyonematerial,butprocessedinsandwichstructures• Usecompatiblematerials(thatcouldberecycledtogether)withintheproductorsub-assembly• Forjoiningusethesameorcompatiblematerialsasincomponents(tobejoined)



corrosion techniques• Facilitateremovalofcoatingmaterials• Usecoatingproceduresthatcomplywithcoatedmaterials• Avoidadhesivesorchooseonesthatcomplywithmaterialstoberecycled• Avoidusingadditionalmaterialsformarkingorcodification• Markandcodifymaterialsduringmolding



• Selecthighenergymaterialsforproductsthataregoingtobeincinerated• Avoidmaterialsthatemitdangeroussubstancesduringincineration• Forthemetalpartsuseoxidationresistingalloysinsteadofcoating.Zincortinemanates emissions during recycling processing that are barely filterable.• Avoidadditivesthatemitdangeroussubstancesduringincineration• Facilitatetheseparationofmaterialsthatwouldcompromisetheefficiencyofcombustion (with low energy value). Like concrete and ceramic materials that oppose incineration. • Torecyclethereinforcingsteelfromtheconcrete,agoodcleaningwillincreasetheefficiency during processing and re-use.


Strategic Design PrioritiesE. RENEWABLE AND BIO-COMPATIBLE RESOURCES




E. RENEWABLE AND BIO-COMPATIBLE RESOURCES



Design with the aim to save resources for future generations, preferring renewable resources, or at least non-exhau-stible ones. It refers both to selection of renewable and bio-compatible materials and energy resources.

Many of the inventoried materials if not all, are not renewable, moreover some of them like copper are in short sup-plies. The same can be said about the pre-production of cement and steel that require huge amount of energy, which is usually generated in the traditional way using fossil fuel. A high impact is also brought by the use of carburant in large machinery during construction on site.

Apart from this appreciations the results tend to be characterized by the overall weight of the materials used during construction which consequently are bigger in the case of the Powerhouse (67.1 ton) and Intake (53,3 ton) compared to those of the Equipment (6,4 ton) and Pipeline (8,6 ton).

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

ReCiPe Endpoint

Rapid Pipeline

Equipment

Intake

Powerhouse


0,67

14,2

12,9

IPSAIPSAIPSAIPSA

0.19% 3.96%0.2%

4.36%

Renewable and Bio-CompatibleResources


0%

10%

20%

IPSA

%


0 pt

25 pt

50 pt

75 pt

100 pt

125 pt

150 pt

175 pt

200 pt

225 pt

ReCi

Pe E

ndpo

intP

t

77.3 pt

12 pt

221 pt

93.7 pt

Steel lowalloyed

EQUIPMENT


SELECT RENEWABLE AND BIO-COMPATIBLE MATERIALS:

• Avoidexhaustivematerials• Replacecopperusedinthecoolingcoilswithamixtureofstainlesssteelandotheralloyscanbecombined to substitute partially or entirely the copper. • Useresidualmaterialsofproductionprocesses• Useretrievedcomponentsfromdisposedproducts• Userecycledmaterials,aloneorcombinedwithprimarymaterials

SELECT RENEWABLE AND BIO-COMPATIBLE ENERGY RESOURCES:

• Userenewableenergyresources• Engagethecascadeapproach• Selectenergyresourceswithhighsecond-orderefficiency

EXTENDING THE LIFESPAN OF MATERIALS - EQUIPMENTDESIGN GUIDELINES


PIPELINE

0 pt

25 pt

50 pt

75 pt

100 pt

125 pt

150 pt

175 pt

200 pt

225 pt

250 pt

275 pt

300 pt

325 pt

350 pt

375 pt

400 pt

425 pt

450 pt

475 pt

500 pt

525 pt

550 pt

ReCi

Pe E

ndpo

int

Pt


49.8 pt

reinforced

plastic

553 pt

124.7 pt

Diesel

burntconstruction

0 pt

100 pt

200 pt

300 pt

400 pt

500 pt

600 pt

700 pt

800 pt722 pt

2.35 pt0 pt0 pt

ReCi

Pe E

ndpo

int

Pt


Transport Disposal Use



• Avoidexhaustivematerials.• Useresidualmaterialsofproductionprocesses• Useretrievedcomponentsfromdisposedproducts• Userecycledmaterials,aloneorcombinedwithprimarymaterials


• Userenewableenergyresources• Biofuelcanreplacetheclassicfuelfortheconstructionmachinery(constructionphase)• Engagethecascadeapproach• Selectenergyresourceswithhighsecond-orderefficiency

EXTENDING THE LIFESPAN OF MATERIALS - PIPELINEDESIGN GUIDELINES


0 pt

25 pt

50 pt

75 pt

100 pt

125 pt

150 pt

175 pt

200 pt

225 pt229 pt

5.9 pt22.7 pt

0 pt

ReCi

Pe E

ndpo

int Pt


TransportDisposal Use

0 pt

25 pt

50 pt

75 pt

100 pt

ReCi

Pe E

ndpo

int

Pt

Concrete

Powerhouse

Chromiumsteel

Reinforcing steel

44.1 pt 33.3 pt33.8 pt

4.94 pt14.7 pt

8.82 pt 3.4 pt 0.58 pt

85.1 pt

Plaster mixing

Metal work

Diesel burnt

construction Doors GlassWindows

POWERHOUSE



• Userenewablematerials• Researchsubstitutesforcement,like“green”cement• Designlatticebeamsmadeofwoodinsteadofmetalforcellingsupportandroofwindows.• Ecofriendlymaterialsofconstructionsuchaswood,clayorecobrickscombinedwithastrongstructuralde sign, can substitute the concrete used for the powerhouse construction• Avoidexhaustivematerials• Useresidualmaterialsofproductionprocesses• Selectcementsuppliersthatuseresidualmaterialsforprocessing.Selectedwasteandby-productswith recoverable calorific value can be used as fuels, replacing a portion of conventional fossil fuels, like coal, if they meet strict specifications.• Squarehaystacksandclaycanprovideaverygoodsoundandtemperatureinsulationandcanalsobeused to construct walls.• Useretrievedcomponentsfromdisposedproducts• Choosecementcontainingflyashfromcoalthermicenergygenerationprocesses.Becauseflyashaddition allows a lower concrete water content, early strength can also be maintained. • Userecycledmaterials,aloneorcombinedwithprimarymaterials• Selectcementsuppliersthatusewasteandby-productsincementgeneration.(calcium,silica,alumina,and iron can be used as raw materials in the cement kiln, replacing raw materials such as clay, shale, and limestone.• Usebio-degradablematerials• Researchandusetraditionalbuildingmaterialsthatarebio-degradable.


• Userenewableenergyresources• Biofuelcanreplacetheclassicfuelfortheconstructionmachinery• Engagethecascadeapproach• Selectenergyresourceswithhighsecond-orderefficiency

EXTENDING THE LIFESPAN OF MATERIALS - POWERHOUSEDESIGN GUIDELINES


INTAKE

0 pt

25 pt

50 pt

75 pt

100 pt

ReCi

Pe E

ndpo

int

Pt

Intake

Reinforcing steel

40.4 pt

Concrete

25.3 pt7.2 pt

Metal

work

4.8 pt

Plaster mixing

Chromiumsteel

16.7 pt

66.3 pt

Diesel

burntconstruction

0 pt

20 pt

40 pt

60 pt

80 pt

100 pt

120 pt

140 pt

160 pt

180 pt

161 pt

4.68 pt18.2 pt 0 pt

ReCi

Pe E

ndpo

intP

t


TransportDisposal Use



• Userenewablematerials• Researchsubstitutesforcement,like“green”cement• Avoidexhaustivematerials• Useresidualmaterialsofproductionprocesses• Selectcementsuppliersthatuseresidualmaterialsforprocessing.Selectedwasteandby-productswith recoverable calorific value can be used as fuels, replacing a portion of conventional fossil fuels, like coal, if they meet strict specifications.• Useretrievedcomponentsfromdisposedproducts• Choosecementcontainingflyashfromcoalthermicenergygenerationprocesses.Becauseflyashaddition allows a lower concrete water content, early strength can also be maintained. • Userecycledmaterials,aloneorcombinedwithprimarymaterials• Selectcementsuppliersthatusewasteandby-productsincementgeneration.(calcium,silica,alumina,and iron can be used as raw materials in the cement kiln, replacing raw materials such as clay, shale, and limestone.• Usebio-degradablematerials


• Userenewableenergyresources• Biofuelcanreplacetheclassicfuelfortheconstructionmachinery(constructionphase)• Engagethecascadeapproach• Selectenergyresourceswithhighsecond-orderefficiency

EXTENDING THE LIFESPAN OF MATERIALS - INTAKEDESIGN GUIDELINES


Strategic Design PrioritiesF. MINIMIZE ENERGY CONSUMPTION




F. MINIMIZIE ENERGY CONSUMPTION


For this calculation the eco-indicator points of the energy used during the lifetime of the station were used and not the turbine loss that adds up to 10% of the total energy crea-ted, this is essentially the energy used in order to generate energy. Instead the lighting system and other automatization devices were taken into account. With a total of 1.035 eco-in-dicator points, minimizing energy is in last place for priority of environmental impact reduction. This value was considered under Equipment in the overall result for each component.

0.31% 0% 0% 0%


Equipment

0%

10%

20%

IPSA

%


0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%100%

2.61%

ReCi

Pe E

ndpo

int %

Electricity generation Equipment

Loss

Lights+ Other Equipment

ReCiPe Endpoint ReCiPe Endpoint

Power Generation Equipment Loss

Lights + Other Equipment


1.15

EQUIPMENT


The energy that the SHPS uses for electricity generation is considered under turbine loss, however the Pelton tur-bine has a high efficiency rate around 90% at optimal flow. In the calculation of the functional unit, which is the total amount of energy generated by the station in 70 years (its lifespan), an efficiency of 90% was used, so basically excluding the turbine loss. The size of the turbine and the number of buckets is customized according to the available flow and drop specifi-cation for the proper functioning of the station. Maximizing this parameters, if the site allows it, will result in lower environmental impact because the same station generates more energy. So this should always be the first consi-deration in projecting a small power station. However the aim is to generate guidelines to reduce the overall environmental impact resulted from SHPS for this amount of energy produced. Hence to produce the same energy with a lower environmental impact.As such, in the minimizing the energy consumption priority, only the adjacent energy used was considered: the in-terior and exterior lights, the control equipment and outside engines (of the two sluice gates).

However the next guidelines will refer to the all life cycle system of this station.

MINIMISE ENERGY CONSUMPTION DURING PRE-PRODUCTION AND PRODUCTION:

In the Pre-production and production we understand all the exploitation and processing that the raw materials un-dergo before becoming suitable for construction and the construction and assembly manufacturing phases. In this inventory a particular emphasis was put on the construction on site duration, because detailed data was available.

• Selectmaterialswithlowenergyintensity• Researchreplacementforcementandsteelpartsthatcanbeconstructedusinglessenergyintensivematerials.• Selectprocessingtechnologieswiththelowestenergyconsumptionpossible• Engageefficientmachinery• Choosesuppliersforreadymadeconcretecomponentsthatareusingnewandefficientmanufacturing technologies

MINIMIZE ENERGY CONSUMPTION - EQUIPMENTDESIGN GUIDELINES


• Neworwell-maintainedmachineryshouldbeusedtoreduceasmuchaspossiblethefuelemissionsinthe environment, during construction on site. • Engagepumpandmotorspeedregulatorswithdynamicconfiguration• Equipthemachinerywithintelligentpower-offutilities• Optimisetheoveralldimensionsoftheengines• Facilitateenginemaintenance• Defineaccuratelythetoleranceparameters• Optimisetransportationsystemsandscaledowntheweightanddimensionsofalltransportablematerials and semi-products• Engageefficientgeneralheating,illuminationandventilationinbuildings

MINIMISE ENERGY CONSUMPTION DURING TRANSPORTATION AND STORAGE:

• Equipproductswithonsiteassembly• Scaledownthepackagingweight• Decentraliseactivitiestoreducetransportationvolumes• Selectlocalmaterialandenergysources

SELECT SYSTEMS WITH ENERGY-EFFICIENT OPERATION STAGE:

• Designforenergy-efficientoperationalstages• Afinetuningandaproficientdesignoftheturbine’snozzlescan,togetherwithaproficientmonitoring system, decrease the power lost during generation providing more efficiency. • Designforenergy-efficientmaintenance• Designsystemsforconsumptionofpassiveenergysources• Designthepartiallyundergroundpowerhousewithroofwindowsstructurethatcansubstitutethesidewindows.• Engagehighlyefficientenergyconversionsystems• Chooseefficientlamptypeaccordingtothespecificneed.• Design/engagehighlyefficientengines/generators• Design/engagehighlyefficientpowertransmission• Usehighlycaulkedmaterialsandtechnicalcomponents


• Designforlocalizedenergysupply• Measurethevicinitytovillagesorsmallmanufacturingworkshops,whichwouldrequireenergy,before choosing the station’s location• Scaledowntheweightoftransportablegoods• Designenergy-savingsystems

ENGAGE DYNAMIC CONSUMPTION OF ENERGY:

• Engagedigitaldynamicsupportsystems• Designdynamicenergyconsumptionsystemsfordifferentiatedoperationalstages• Engagesensorstoadjustconsumptionduringdifferentiatedoperationalstages• Usesensorofpresenceorlightintensitythatcansaveenergyduringthechangingseasons.• Equipmachinerywithintelligentpower-offutilitiesforsafety• Programproduct’sdefaultstateatminimalenergyconsumption

MINIMISE ENERGY CONSUMPTION DURING PRODUCT DEVELOPMENT:

• Engageefficientworkplaceheating,illuminationandventilation• Engagedigitaltoolsforcommunicatingwithremoteworkingsites


REDUCE AND FACILITATE OPERATIONS OF DISASSEMBLY AND SEPARATION:OVERALL ARCHITECTURE:

• Prioritizethedisassemblyoftoxicanddangerouscomponentsormaterials.Startwiththeturbineandthe electromechanical equipment, electric transformer, engine, sensors of the turbine, sluices gates, silt basin, the pipeline and then the concrete• Prioritizethedisassemblyofcomponentsormaterialswithhighereconomicvalue.Startwiththeturbineand the electromechanical equipment, electric transformer, engine, sensors of the turbine, sluices gates, silt basin, the pipeline and then the concrete• Prioritizethedisassemblyofmoreeasilydamageablecomponents• Engagemodularstructures• Ifreadymadeconcretepartsareinplace,designthosetobeeasilyassembled/disassembledand provide an assembly scheme to be put on site.• Dividetheproductintoeasilyseparableandmanipulablesub-assemblies• Thecasingoftheturbineshouldbeseparatefromthewheelwithbuckets.• Minimiseoveralldimensionsoftheproduct• Minimisehierarchicallydependentconnectionsbetweencomponents• Provideanopositeschemeofdisassembly.• Minimisedifferentdirectionsinthedisassemblyrouteofcomponentsandmaterials• Chooseareadymadeconcreateproviderthathasadisassemblyroute.• Choosedisassemblyprocessorsthatcanprocesselectriccomponentsandmetalpieces.• Increasethelinearityofthedisassemblyroute• Engageasandwichsystemofdisassemblywithcentraljoiningelements.• Theturbine,andthepowerhousebuildingshouldbeeasilydisassembledwithacrane.

G. DESIGN FOR DISASSEMBLY - ALLDESIGN GUIDELINES


SHAPE OF COMPONENTS AND PARTS:

• Avoiddifficult-to-handlecomponents• Avoidasymmetricalcomponents,unlessrequired• Designleaningsurfacesandgrabbingfeaturesincompliancewithstandards• Forthereadymadecomponents:tobedesignedwithanchoringfeaturesthatareeasilyattachabletothe crane cables• Arrangeleaningsurfacesaroundtheproduct’scenterofgravity• Designforeasycenteringonthecomponentbase

SHAPE AND ACCESSIBILITY OF JOINTS:

• Avoidjoiningsystemsthatrequiresimultaneousinterventionsforopening• Minimisetheoverallnumberoffasteners• Minimisetheoverallnumberofdifferentfastenertypes(thatdemanddifferenttools)• Achievablebymodularreadymadecomponentsfortheconcreteparts.• Avoiddifficult-to-handlefasteners• Designaccessibleandrecognizableentrancesfordismantling• Amarkingarrowsystemshouldbeused.• Designaccessibleandcontrollabledismantlingpoints

ENGAGE REVERSIBLE JOINING SYSTEMS

• Employtwo-waysnap-fitfortheelectricalcomponents.• Employjointsthatareopenedwithcommontools• Employjointsthatareopenedwithspecialtools,whenopeningcouldbedangerous• Designjointsmadeofmaterialsthatbecomereversibleonlyindeterminedconditions?• Usescrewswithhexagonalheads• Preferremovablenutsandclipstoself-tappingscrews• Usescrewsmadeofmaterialscompatiblewithjointcomponents,toavoidtheirseparationbeforerecycling


ENGAGE EASILY COLLAPSIBLE PERMANENT JOINING SYSTEMS:

• Avoidrivetsonincompatiblematerials• Avoidadditionalmaterialswhilewelding• Usesuccessivecouplingforplasticpipes.• Avoidgluingwithadhesives

CO-DESIGN SPECIAL TECHNOLOGIES AND FEATURES FOR CRUSHING SEPARATION:

• Co-designcuttingorbreakingpathswithappropriateseparationtechnologiesforincompatiblematerials separation• Employjoiningelementsthatallowtheirchemicalorphysicaldestruction• Makethebreakingpointseasilyaccessibleandrecognizable• Providetheproductswithinformationforthebeneficiaryaboutthecharacteristicsofcrushingseparation

Use materials that are easily separable after being crushed.Use additional parts that are easily separable after crushing of materials.


Checklist



CHECKLIST

Minimize Materials Consumption

Intake YES PARTLY NO NOT APPLICABLE

Did you dematerialise the product or some of its components?

Did you research and use up to date standards for structural design dimensions?

Did you research for new and more performing materials available to reduce the overall amount of materials?

Did you use appropriate software to understand, test and make simulations for new resistance specifications and materials?

Did you reduce thickness of the walls of construction?

Did you use performant ready made parts with required configuration for the con-crete components to reduce thickness of the walls of the construction?

Did you use a wider range of concretes for the intake (the parts in direct contact to the water can be denser and more resistant to freezing and the ones buried can be less)?

Did you change the steel rebar with a lighter more efficient reinforcement like: using fiber glass, carbon fiber, reinforced polymer or bronze-aluminum?

Did you change the quality of the concrete by adding more cement in order to redu-ce the need of thicker walls?

Did you apply ribbed to the structure to increase structural stiffness of the intake walls?


YES PARTLY NO NOT APPLICABLE

Did you select processes that reduce scraps and discarded materials during pro-duction ?

Did you use efficient molds for readymade concrete products to reduce the scraps and discarded materials during the production?

Did you engaged simulation systems to optimize transformation processes?

Did you use vibration pumps can be used on site to optimize the density of concrete?

Did you redesign for more efficient supply of raw materials?

Did you use/acquire the necessary aggregates for concrete on site or closer from the construction site?

Did you design for more efficient use of maintenance materials ?

Did you choose long lasting tools (shovel, brooms or other) for maintenance mate-rials, for the silt basin?

Did you design a system that uses the water of the rain or the river to clean the exte-rior surfaces?

Did you design systems for consumption of passive materials?

Did you design side gates at the bottom of the silt basin that allows water from the river to clean the silt from the basin?



Did you design for cascading recycling systems?

Did you facilitate the person managing maintenance to reduce materials consump-tion ?

Did you minimise the consumption of stationery goods and their packages?

Did you engage digital tools in designing, modelling and prototype creation?

Did you engage digital tools for documentation, communication and presentation?

NR. OF ASWERS

PERCENTAGE (nr. aplicable checklists/ nr. answers x 100)



Pipeline YES PARTLY NO NOT APPLICABLE

Did you avoid over-sized dimensions ?



Did you apply ribbed to the structure to increase structural stiffness of the pipeline walls?

Did you select processes that reduce scraps and discarded materials during production ?

Did you use efficient molds for readymade plastic products to reduce the scraps and discarded materials during the production?






NR. OF ASWERS





Powerhouse YES PARTLY NO NOT APPLICABLE


Did you use on site ground to provide soundproofing by partially covering the house?

Did you digitalise the product or some of its components ?


Did you start the design of the machine room from the size of the turbine that is going to be used for the specific flow.?

Did you avoid over-sized dimensions ?


Did you use a remote control system for the station in order to avoid the need of a separate control room. Did you design all the component in one room?

Did you build the Powerhouse partially buried underground or constructed close to a stone wall ?





Did you use efficient molds for readymade concrete products to reduce the scraps and discarded materials during the production?


Did you use vibration pumps can be used on site to optimize the density of concrete?


Did you use a wider range of concretes (the parts in direct contact to the water can be denser and more resistant to freezing and the ones buried can be less)?

Did you change the steel rebar with a lighter more efficient reinforcement like: using fiber glass, carbon fiber, reinforced polymer or bronze-aluminum?

Did you change the quality of the concrete by adding more cement in order to redu-ce the need of thicker walls?



Did you use performant ready made parts with required configuration for the con-crete components to reduce thickness of the walls of the construction?








Did you design a system that uses the water of the rain or the river to clean the exte-rior surfaces?

Did you design systems for consumption of passive materials?

Did you choose long lasting tools (shovel, brooms or other) for maintenance mate-rials, for the silt basin?

Did you use/acquire the necessary aggregates for concrete on site or closer from the construction site?


NR. OF ASWERS




Electromechanic Equipment YES PARTLY NO NOT APPLICABLE





Did you reduce thickness of the walls of parts?



Did you use efficient molds for readymade parts to reduce the scraps and discarded materials during the production?

Did you design for more efficient consumption of operational materials ?

Did you consider optimizing the shape of the cooling installation ?




Did you use a type of oil with higher lifespan ?





Did you engage digital support systems with dynamic configuration ?

Did you engage a remote system for adjusting the oil consumption ?

Did you design a reserve tank in addition to the cooling installation, that refills the lost oil ?

Did you engage sensors to adjust materials consumption according to differentiated operational stages?

Did you use an adjusting system to optimize the use of oil during periods of high energy generation?






NR. OF ASWERS



Optimization of Product Lifetime


Did you design components with co-extensive lifespan?

Did you eliminate weak liaisons?

Did you simplify access and disassembly to components to be maintained (silt basin)?

Did you equip the product with easily usable tools for maintenance?

Did you avoid narrow slits and holes to facilitate access for cleaning - all of the com-ponents of the Intake ?

Did you design a bigger lid, made of a lighter material to allow a person entering and more light ?


Did you simplify access to the silt basin for manually cleaning?

Did you select durable materials according to the product performance and lifespan ?

Did you equip products with diagnostic and/or auto-diagnostic systems for maintai-nable components?

Intake



Did you arrange and facilitate disassembly and re-attachment of easily damageable components?

Did you equip products with automatic damage diagnostics system ?

Did you design products for facilitated onsite repair?

Did you design complementary repair tools, materials and documentation?

Did you increase the resistance of easily damaged and expendable components?

Did you avoid damaging the formworks used for concrete, in order to facilitate their reuse. Or did you replaced the wood formworks with readymade metal or plastic ones?

Did you design products for easy on-site maintenance?

Did you design complementary maintenance tools and documentation?

Did you design products that need less maintenance?

Did you implement sensors showing if the silt basin needs maintenance ?

Did you trigger automatic cleaning systems for the silt basin?

Did you trigger automatic systems for opening the sluice gates in case of over floo-ding or obstruction?



Did you design for excessive use of material for easily deteriorating surfaces ?

Did you design components according to standards to facilitate replacement?

Did you design re-usable auxiliary parts?

Did you design and facilitate removal and substitution of easily expendable compo-nents like the filtering nets?

Did you arrange and facilitate access and removal of retrievable components ?

Did you design modular and replaceable components?

Did you use modular readymade concrete parts for the construction of walls, tops or lids or other simple components.?

NR. OF ASWERS







Did you simplify access and disassembly to components to be maintained ?




Did you extend the lifespan of the pipeline from 50 to 70 years by installing a diagno-stic system that points damaged or vulnerable parts ?


Did you install sensors for pressure, temperature and eventual deposits can be pla-ced inside the pipeline to signal if there are any hydraulic leaks that can create slits and cracks during freezing seasons?

Pipeline



Did you equip products with automatic damage diagnostics system ?


Did you make local excavations to fix the cracks of the pipeline, using the diagnostic system?Did you use a bandage system, or a collar like module can be fixed in place of the damaged one after cutting the cracked part?




Did you design components according to standards to facilitate replacement?


Did you design and facilitate removal and substitution of easily expendable compo-nents like the filtering nets?





Did you provide easier access to components to be re-manufactured ?

NR. OF ASWERS







Did you simplify access and disassembly to components to be maintained ?

Did you avoid narrow slits and holes to facilitate access for cleaning ?




Did you reduce overall number of components ?

Did you simplify products ?

Did you dsign lifespan of replaceable components according to scheduled duration?

Powerhouse


Did you design components according to standards to facilitate substitution of dama-ged parts?




Did you arrange and facilitate disassembly and re-attachment of easily damageable components?


Did you use modular readymade concrete parts for the construction of walls, tops or lids or other simple components.t?


Did you avoid damaging the formworks used for concrete, in order to facilitate their reuse. The wood formworks can be replaced with readymade metal or plastic ones ?

Did you increase the resistance of easily damaged and expendable components ?





Did you design and facilitate removal and substitution of easily expendable compo-nents ?

Did you provide easier access to components to be re-manufactured ?

Did you calculate accurate tolerance parameters for easily expendable connections ?

Did you design for excessive use of materials in places more subject to deterioration ?

Did you use a bandage system, or a collar like module can be fixed in place of the damaged one after cutting the cracked part?

Did you design for excessive use of material for easily deteriorating surfaces?

Did you design structural parts that can be easily separated from external/visible ones?

NR. OF ASWERS






Did you design components with co-extensive lifespan? Did you make a part by part lifespan assessment of all of the components to under-stand if there are parts that need works of maintenance or reparations and not total replacement?


Did you enable and facilitate software upgrading?

Did you design the software for oil consumption installations in order to be upgra-dable for use of new, more efficient or more ecofriendly oils consumption?


Did you reduce overall number of components ?

Did you simplify products ?

Did you design lifespan of replaceable components according to scheduled duration?

Did you design according to 70 years multiples ?

Electromechanic Equipment



Did you design complementary tools and documentation for product upgrading and adaptation ?

Did you design onsite upgradeable and adaptable products ?

Did you simplify access and disassembly to components to be maintained?


Did you avoid narrow slits and holes to facilitate access for cleaning ?

Did you create a remote system checking the well-functioning of the system and the safety parameters of the turbine?


Did you use an advanced remote system of surveillance and adjustments for the coo-ling coils oil consumption and quality?

Did you consider an approach in which several smaller turbines are linked, so that the energy generation can continue also with low water flows ?

Did you design modular and dynamically configured products to facilitate their adapta-bility for changing environments. ?

Did you enable and facilitate hardware upgrading ?


Did you perform integrity inspection of the cooling coils can be tested on site by the conductivity or helium gas methods?



Did you design nozzles to be performant as they are subject to high pressure and friction ?



Did you design components according to standards to facilitate substitution of dama-ged parts?


Did you choose or design a turbine with replaceable and detachable buckets ?

Did you arrange and facilitate disassembly and re-attachment of easily damageable

Did you make available replaceable buckets for the turbine on site for repairs?

Did you place a diagnostic system on the nozzles prevent damage due to high water pressure or high speed?



Did you increase the resistance of easily damaged and expendable components?

Did you arrange and facilitate access and removal of retrievable components?

Did you assign damage diagnostic system can be placed on nozzles, on pipes under high pressure and on bearings or their proximity ?



Did you design or choose filters made of a durable material?

Did you design re-usable auxiliary parts ?

Did you design components according to standards to facilitate replacement ?

Did you design modular and replaceable components ?

Did you facilitate cleaning the filters of oil that are in place?

Did you equip products with automatic damage diagnostics system?


Did you calculate accurate tolerance parameters for easily expendable connections for the Pipeline, inlets, jets or nozzles?

Did you design for excessive use of materials in places more subject to deterioration?

Did you design for excessive use of material for easily deteriorating surfaces?

Did you design structural parts that can be easily separated from external/visible ones ?

Did you provide easier access to components to be re-manufactured?


Did you design a smaller bearing box around the place of the bearings, independent from the body of the casing, so overall replacement of the casing will not be necessary ?

Did you design and facilitate removal and substitution of easily expendable compo-nents?

NR. OF ASWERS



Minimising Toxic Emissions


Did you minimise the hazard of toxic and harmful materials?

Did you avoid materials that emit toxic or harmful substances during pre-production (cement, steel) ?

Did you avoid technologies that process toxic and harmful materials (concrete and steel manufacturing)?

Did you avoid materials that emit toxic or harmful substances during disposal?

Did you avoid materials that emit toxic or harmful substances during usage?

Did you design products that do not consume toxic and harmful materials?


Did you avoid toxic or harmful surface treatments?

Did you take measurements for safe transport need to be taken to prevent spilling, absorbing materials should be available on site for cleaning

NR. OF ASWERS


Intake












NR. OF ASWERS


Pipeline













NR. OF ASWERS


Powerhouse














NR. OF ASWERS




Optimization of Material Lifetime


Did you select materials that easily recover after recycling the original performance characteristics?

Did you avoid composite materials or, when necessary, choose easily recyclable ones

Did you design considering the secondary use of the materials once recycled?

Did you design in compliance with product retrieval system?

Did you minimise overall weight?

Did you use polymer pipeline with exterior ribbing to increase the stiffness ?

Did you choose thermoplastic polymers to thermosetting ?

Did you choose heat-proof thermoplastic polymers to fireproof additives ?

Did you avoid using glass-fiber reinforced polymers or reinforced concrete?

Did you engage geometrical solutions like ribbing to increase polymer stiffness instead of reinforcing fibers ?

Intake


Did you provide the beneficiary with information about the disposing modalities of the product or its parts?

Did you codify different materials to facilitate their identification?

Did you provide additional information about the material’s age, number of times recycled in the past and additives used?

Did you minimise cluttering and improve stackability of discarded products ?

Did you design for the compressibility of discarded products?


Did you integrate functions to reduce the overall number of materials and components?

Did you arrange codifications in easily visible places ?

Did you use standardized materials identification systems ?

Did you indicate the existence of toxic or harmful materials. Like is the case of the mineral oil ?

Did you avoid codifying after component production stages?

Did you replace steel rebar with other reinforcing non rusting materials like: Fiber glass, Carbon fiber, reinforced polymer or bronze-aluminum bars?


Did you use the same or compatible materials as in components (to be joined)?

Did you avoid unnecessary coating procedures?

Did you avoid irremovable coating materials?

Did you use only one material, but processed in sandwich structures ?

Did you use compatible materials (that could be recycled together) within the pro-duct or sub-assembly?


Did you chosen or designed the plastic pipe module to be coupling one inside the other?

Did you use coating procedures that comply with coated materials ?

Did you facilitate removal of coating materials ?

Did you, instead of painting the metal pieces against corrosion use oxidation-resi-sting steel, or electrical corrosion techniques ?

Did you avoid adhesives or choose ones that comply with materials to be recycled?

Did you adopt a strategy, in which components with the same material are grouped together and are split from other materials, in order to reduce the overall number of parts and the duration of disassemblys?


Did you codify polymers using lasers?

Did you select high energy materials for products that are going to be incinerated?

Did you avoid materials that emit dangerous substances during incineration?

Did you avoid using additional materials for marking or codification?

Did you mark and codify materials during molding?


Did you facilitate the separation of materials that would compromise the efficiency of combustion (with low energy value). For the glass fiber inside the pipeline. Glass, metals, concrete and ceramic materials that oppose incineration. ?

Did you avoid additives that emit dangerous substances during incineration?

Did you use oxidation resisting alloys instead of coating for the metal parts ?

Did you use a good cleaning in order to increase the efficiency during processing and re-use, for the recycled reinforcing steel?

Did you prefer the dyeing of internal polymers, rather than surface painting parts and the duration of disassemblys?

NR. OF ASWERS















Pipeline













NR. OF ASWERS















Powerhouse













NR. OF ASWERS




Did you se renewable materials?

Did you research substitutes for cement, like “green” cement?

Did you select cement suppliers that use residual materials for processing?

Did you use square haystacks and clay to provide a better sound and temperature insulation or did you used those to construct walls?

Did you use retrieved components from disposed products?

Did you avoid exhaustive materials ?

Did you replace copper used in the cooling coils with a mixture of stainless steel and other alloys?

Did you use residual materials of production processes ?

Did you design lattice beams made of wood instead of metal for celling support and roof windows?Did you use eco friendly materials of construction such as wood, clay or eco bricks combined with a strong structural design, in order to substitute the concrete used for the powerhouse construction ?

Renewable and Bio-compatible Resourcese

Intake


Did you use bio-degradable materials?

Did you research and use traditional building materials that are bio-degradable?

Did you use renewable energy resources?

Did you use recycled materials, alone or combined with primary materials ?

Did you select cement suppliers that use waste and by-products in cement generation?


Did you select energy resources with high second-order efficiency ?

Did you engage the cascade approach ?

Did you use biofuel as replacement for classic fuel for the construction machinery ?

Did you choose cement containing fly ash from coal thermic energy generation processes?













Pipeline













Powerhouse




Did you select materials with low energy intensity?

Did you select processing technologies with the lowest energy consumption possible?

Did you engage efficient machinery?

Did you equip the machinery with intelligent power-off utilities?

Did you engage pump and motor speed regulators with dynamic configuration?

Did you use new or well-maintained machinery to reduce as much as possible the fuel emissions in the environment, during construction on site?

Did you optimise the overall dimensions of the engines?

Did you choose suppliers for readymade concrete components that are using new and efficient manufacturing technologies?

Did you research replacement for cement and steel parts that can be constructed using less energy intensive materialsDid you research and used up to date standards for structural design dimensions?

Did you facilitate engine maintenance?

Intake



Did you define accurately the tolerance parameters?

Did you engage efficient general heating, illumination and ventilation in buildings?

Did you equip products with onsite assembly?

Did you design for energy-efficient operational stages?

Did you select local material and energy sources?

Did you decentralise activities to reduce transportation volumes?

Did you use a fine tuning and a proficient design of the turbine’s nozzles and profi-cient monitoring system in order to decrease the power lost during generation?

Did you scale down the product weight?

Did you optimise transportation systems and scale down the weight and dimensions of all transportable materials and semi-products?

Did you design for energy-efficient maintenance?



Did you design systems for consumption of passive energy sources?

Did you engage highly efficient energy conversion systems?

Did you choose efficient lamp type according to the specific need?

Did you design for localized energy supply?

Did you use highly caulked materials and technical components?

Did you design/engage highly efficient power transmission?


Did you design/engage highly efficient engines/generators?

Did you design the partially underground powerhouse with roof windows structure that can substitute the side windows?

Did you measure the vicinity to villages or small manufacturing workshops, which would require energy, before choosing the station’s location?

Did you scale down the weight of transportable goods?



Did you design energy-saving systems?

Did you design dynamic energy consumption systems for differentiated operational stages?

Did you engage sensors to adjust consumption during differentiated operational stages?

Did you engage efficient workplace heating, illumination and ventilation?

Did you program product’s default state at minimal energy consumption?

Did you equip machinery with intelligent power-off utilities for safety?

Did you engage digital tools for communicating with remote working sites?

Did you use sensor of presence or light intensity that can save energy during the changing seasons?

Did you engage digital dynamic support systems?

NR. OF ASWERS















Pipeline












NR. OF ASWERS















Powerhouse












NR. OF ASWERS



Design for Disassembly


Did you prioritize the disassembly of toxic and dangerous components or materials?

Did you prioritize the disassembly of components or materials with higher economic value?

Did you prioritize the disassembly of more easily damageable components?

Did you separate the casing of the turbine from the wheel with buckets?

Did you divide the product into easily separable and manipulable sub-assemblies?

If readymade concrete parts are in place, did you design those to be easily assem-bled/ disassembled and provide an assembly scheme to be put on site?

Did you minimise overall dimensions of the product?

Did you engage modular structures?

Did you start with the turbine and the electromechanical equipment, electric transformer, engine, sensors of the turbine, sluices gates, silt basin, the pipeline and then the concrete?

Did you minimise hierarchically dependent connections between components?

Intake



Did you easily disassemble the turbine and the powerhouse building with a crane?

Did you avoid difficult-to-handle components?

Did you avoid asymmetrical components, unless required?

Did you design leaning surfaces and grabbing features in compliance with standards?

Did you design anchoring features that are easily attachable to the crane cables for the readymade components?

Did you arrange leaning surfaces around the product’s center of gravity?

Did you choose disassembly processors that can process electric components and metal pieces?

Did you increase the linearity of the disassembly route?

Did you engage a sandwich system of disassembly with central joining elements?

Did you provide an opposite scheme of disassembly?

Did you minimise different directions in the disassembly route of components and materials?

Did you choose a readymade concreate provider that has a disassembly route?



Did you use a marking arrow system?

Did you employ joints that are opened with common tools?

Did you design joints made of materials that become reversible only in determined conditions ?

Did you minimise the overall number of different fastener types by using readymade components for the concrete parts?

Did you avoid difficult-to-handle fasteners?

Did you design accessible and controllable dismantling points?

Did you design accessible and recognizable entrances for dismantling?

Did you employ two-way snap-fit for the electrical components?

Did you employ joints that are opened with special tools, when opening could be dangerous?

Did you design for easy centering on the component base?

Did you avoid joining systems that require simultaneous interventions for opening?

Did you minimise the overall number of fasteners?



Did you use screws with hexagonal heads?

Did you avoid rivets on incompatible materials?

Did you avoid additional materials while welding?

Did you use successive coupling for plastic pipes?

Did you avoid gluing with adhesives?

Did you use screws made of materials compatible with joint components, to avoid their separation before recycling?

Did you prefer removable nuts and clips to self-tapping screws?

Did you co-design cutting or breaking paths with appropriate separation technolo-gies for incompatible materials separation?

Did you employ joining elements that allow their chemical or physical destruction?

Did you make the breaking points easily accessible and recognizable?

Did you provide the products with information for the beneficiary about the cha-racteristics of crushing separation?



Did you use materials that are easily separable after being crushed?

Did you use additional parts that are easily separable after crushing of materials?

NR. OF ASWERS















Pipeline





NR. OF ASWERS















Powerhouse





NR. OF ASWERS



All the renderings and the graphs in the list are personally designed and realized by the author.

https://creativecommons.org/licenses/by/4.0/

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