Hardy Station Unit #3 Rehab

Project Name: Hardy Station Unit 3 Rehabilitation

Summary: Upgrades improve capacity, address agency concerns

Client: Consumers Energy Company

Project Location: Big Prairie Township, MI

Project Size: 10.485 MW

Services Provided:
•  Hydropower Facility and Equipment
    Condition Assessment
•  Hydro Feasibility & Planning
•  Specifications development / Bid
    Preparation and Evaluation
•  Hydro Turbine Generator Inspection,
    Performance Testing, and Installation
    Problem Solving
•  Water Quality Assessment
•  FERC Amendment Assistance
•  Agency Consultation
•  Stakeholder Facilitation

Project Timeframe:
2006 - 2010

Relationship with Client: Since 1994

Client Needs:
Consumers Energy Company’s (Consumers Energy) Hardy Hydroelectric station had three 1931 vintage turbines which had operated reliably, yet efficiency decreases and agency concerns over tailrace Dissolved Oxygen (DO) levels resulted in Consumers Energy's interest in potential station upgrades.
Kleinschmidt Solution:
Consumers Energy began the planning process by working with Kleinschmidt on a comprehensive upgrade evaluation of the turbines and controls that considered turbine condition, controls, electrical protection, station operation, water management, and project environmental/licensing issues and concerns. Based upon the study, Kleinschmidt assisted Consumers Energy with upgrades including: preparing the runner replacement procurement specifications and bidding documents and later evaluating the bids for Unit #3, incorporating turbine venting into the new runner solicitation to address the station’s DO issue, inspecting and evaluating the disassembled components of Unit #3 to determine the appropriate extent of component rehabilitation, performing periodic inspections at the turbine vendors shop to review the new and refurbished components at critical milestones, obtaining necessary permits, monitoring water quality, and consulting with resource agencies concerning DO issues.
Client Benefits:
Kleinschmidt’s comprehensive services provided project efficiencies allowing Consumers Energy to access equipment condition assessment, feasibility, planning engineering design, procurement, ecological, FERC Licensing, and permitting expertise through one vendor. Our ability to perform site inspections at the turbine vendor’s shop helped to confirm conformance to the technical requirements and also expedite delivery. Consumers Energy realized revenue gains and regulatory compliance as the new runner’s maximum capacity increased from 10,114kW to 10,485kW and has provided significantly higher DO levels sufficient to address agency concerns.