Kleinschmidt worked closely with ECRE as we coordinated the civil/structural design to incorporate Mavel’s water-to-wire equipment package, and Eaton Electric’s design, supply, and installation of the high voltage and balance of plant electrical and water-to-wire controls package to develop a conceptual layout for the new powerhouse for Unit #3. Access during construction, long-term operation, eliminating/reducing rock removal to reduce project costs were primary considerations. We considered the orientation of the tailrace for constructability, long-term operation, tailrace turbulence/headloss, and impacts to the berm protecting the upstream high-hazard earthen dam. Mid-project, ECRE and the New York Department of Environmental Conservation (NYDEC) noted language within the FERC license that requires the minimum flow to be provided at all times. Kleinschmidt’s proposed solution was for a minimum flow siphon system capable of delivering a minimum of 60-cfs when the Unit #2 penstock was dewatered. The siphon system is a 28-inch interior diameter HDPE pipe that allows ECRE to throttle the outlet manually. Kleinschmidt’s final design included drawings and specifications with sufficient detail for a qualified contractor to bid, procure materials, and construct the project. We assisted ECRE throughout construction by reviewing submittals, answering RFIs, and providing office assistance to answer miscellaneous questions from the field. We also performed periodic visits to the project site to observe construction activities.

Kleinschmidt coordinated closely with Mavel and Eaton Electric to assist ECRE in expediting the project schedule and coordinated the design elements from all three into a single design package for the Contractor. Kleinschmidt helped ECRE achieve economic incentives by providing an Independent Engineer’s (IE) report certifying that the project was commercially operational by December 31, 2019, to support ECRE’s NYSERDA application. This schedule was met even with the addition of the siphon system to the overall design and construction schedule.