Energy Box Canyon Turbine Upgrades

Project Highlights

• Fully refurbished two hydroelectric turbine units, including stators, rotor spiders, turbine hubs, and runner blades.
• MacKay Sposito provided dedicated on-site construction management to coordinate global supply logistics and schedule-critical tasks.
• The team facilitated complex coordination between international suppliers and remote contractors while ensuring clear communication and budget control.

Project Description

At Box Canyon Dam in Pend Oreille County, Washington, MacKay Sposito played a pivotal role in the $80 million turbine and generator upgrade project for Pend Oreille PUD. Stepping in mid-way through Unit #2 and managing the complete rebuild of Unit #1, MacKay Sposito provided a hands-on construction manager to oversee day-to-day operations and ensure success in a highly complex and logistically challenging environment.

The scope included replacing major generator components such as rotor spiders, stators (joined from two halves), exciter systems, governor systems, and rotor poles. On the turbine side, transitioning from five-blade to four-blade runners improved fish passage and generation efficiency. These upgrades required extensive global coordination, with components sourced from Slovenia, Austria, Korea, and Canada, and on-site crews managed from North Carolina. MacKay Sposito’s strength in coordination, schedule tracking, and communication was vital in mitigating risks posed by long-lead items and protecting the owner’s budget and timeline.