Peter Sutherland Sr. Generating Station
Ontario Power Generation and Coral Rapids Power Corporation (a company wholly owned by Taykwa Tagamou Nation) are equity partners in the Peter Sutherland Sr. Generating Station. Named after a respected community elder, the 28 MW hydroelectric power station is remotely located at the confluence of the Abitibi River and New Post Creek within the Taykwa Tagamou Nation traditional territory of northeastern Ontario. A portion of the flows from New Post Creek have been harnessed to provide clean, renewable hydroelectric energy.
KGS Group worked closely with Ontario Power Generation and Coral Rapids Power through the conceptual and preliminary design stages, ultimately acting as the owner’s representative through the design-build construction phase that was performed by Kiewit and Aecon. KGS Group staff were onsite throughout construction assisting and collaborating with the owners and contractor team.
Construction was completed safely, on budget, and ahead of schedule. The project is not only an investment into Ontario’s clean energy future; it is a symbol of reconciliation and the culmination of a strong partnership between Taykwa Tagamou Nation and Ontario Power Generation that will benefit the community for generations.
Project Highlights
- Powerhouse construction with two horizontal‑axis Francis turbines with a total plant capacity 28 MW
- Gated intake structure and approach channel with controlled conveyance from New Post Creek
- 4 m diameter steel penstock 250 m long
- 520 m long embankment dam with a cement-bentonite core
- Two-bay gated spillway
Mayo B Hydro Enhancement Project
KGS Group was retained by the Yukon Energy Corporation to review feasible hydro projects in the territory, which culminated in the selection of the Mayo B project. To develop the $120 million Mayo B, KGS entered into an early contractor involvement alliance partnership, sharing the financial risks and project rewards. This partnership was the first of its kind in the Canadian hydroelectric industry.
We conducted a feasibility study as well as completed the preliminary and final design of a new powerhouse downstream of the existing Mayo hydroelectric development. Reusing the already in-place dam and intake structure, the work also included connecting and conveying water to the new powerhouse through a new 3.8 km tunnel and penstock system.
Overcoming challenging conditions to make way for the new tunnel and “tie it” into 60-year old infrastructure, we used careful mapping and characterization. This helped support concurrent tunnel design and excavation, and slope stabilization. Precision LiDAR 3-D survey techniques and modelling were also integral to the work.
Within a remote, sub-arctic climate, KGS was also responsible for on-site construction management including all contract administration and quality assurance for the civil, mechanical and electrical works, as well as the supply and installation of the turbines and generator equipment.
As a result, total hydro power generation capacity went from 5.4 MW to 12 MW, increasing Yukon’s renewable and sustainable electricity generation capability. The on-budget, on-schedule project also displaces diesel generation, offsetting up to $10 million in annual fuel costs and eliminating approximately 25,000 tonnes of greenhouse gas emissions per year.
Project Highlights
- A new downstream powerhouse and 3.8 km tunnel and penstock system
- Integrated new infrastructure with the existing 60-year-old dam and intake infrastructure
- Generation capacity increased from 5.4 MW to 12 MW
- Up to $10 million/year fuel cost offset
- 25,000 tonnes of CO₂ avoided per year
- $120M project completed on time and on schedule
Lafleche Dam Low Level Outlet Conduit Remediation
The Lafleche Dam in southwestern Saskatchewan was originally constructed in 1958. The dam’s reservoir (Thomson Lake) is used for municipal water supply, irrigation and recreation. The dam offers flood protection, and its low level outlet conduit is needed for reservoir management and riparian flow passage.
In 2018, an inspection of the conduit revealed severe deterioration of the pipe which presented a significant dam safety risk due to internal erosion. KGS Group developed a solution using an array of innovative conduit replacement and rehabilitation methods, including trenchless technologies such as slip-lining and Cured in Place Pipe (CIPP) replacement. The work required excavations and other construction activities at the toe of the in-service dam which necessitated a comprehensive dam safety surveillance program. KGS implemented a state-of-the-art instrumentation plan with telemetry to monitor the performance of the dam during critical high risk construction stages.
The project was completed on schedule and within budget just before winter onset, under a relatively short construction season. The low level outlet was returned to full service in September 2022 following final commissioning of the new slide gate equipped with a cathodic protection system.
Project Highlights
- Inspection and assessment, detailed design, construction supervision, dam safety surveillance and real‑time instrumentation with telemetry
- Renewal of low‑level outlet conduit at an in‑service dam and work at the dam toe through a short construction season
- Trenchless methods (slip‑lining, Cured‑in‑Place Pipe), new slide gate, cathodic protection system and state‑of‑the‑art monitoring through critical stages
El Dorado Forebay Dam- FERC Dam Safety Project
The El Dorado Forebay Dam and Reservoir acts as storage for domestic and irrigation water supply, and for hydroelectric power generation. The dam itself had been performing reliably since its construction in 1923. However, it no longer met current dam safety standards and had lost nearly one third of its original volume capacity. It was determined that the site needed to undergo design and construction improvements.
KGS Group’s work involved a comprehensive background review of key dam safety documents, along with evaluations of design, construction and analyses of record. This included preparing potential incident reports, performing failure mode analyses, conducting inspections and meeting with federal commission officials to address comments.
Our recommended improvements resulted in improved availability and reliability of water supply from Forebay, a safer dam that meets all modern safety standards, grading, paving and accessibility improvements to the Forebay day use area and realignment and improvement to the walking trail along the north side of Forebay Reservoir.
Project Highlights
- Conducted a comprehensive background review of key dam safety documents, along with evaluations of design, construction and analyses of record
- Prepared potential incident reports, performing failure mode analyses, conducted inspections and meeting with federal commission officials to address comments
Caribou Falls Block Dam 2 Reconstruction
Block Dam 2 is one of four embankment dams that contain the Caribou Falls Generating Station reservoir in northwestern Ontario. After 60 years of operation, the dam sustained unexpected slope movements. With KGS Group retained to carryout detailed design and construction supervision, Ontario Power Generation awarded the construction contract to Peter Kiewit Sons Ltd. Together, OPG, KGS and Kiewit reconstructed the dam through most of 2019 and finalized the work in late 2020.
The team applied advanced investigation and laboratory testing techniques, innovative materials, sound engineering judgement and progressive construction methodologies to design and build a new zoned rockfill dam with a cement-bentonite wall (CB wall) core. The design integrated constructability, risk mitigation and schedule saving strategies at the planning level.
Despite unforeseen challenges, all parties persevered using a “One Team” approach. As a result, the project was successfully completed, restoring the dam to modern standards and the station’s generating capacity while preserving the natural surroundings in this wild and beautiful project setting.
Project Highlights
- Detailed design, materials and lab testing, constructability planning, risk management assessments and construction supervision
- Full reconstruction of a 60-year-old structure
- New rockfill dam with cement‑bentonite cutoff wall core
- Progressive construction methodologies and schedule‑saving strategies embedded at planning
- Restored generating capacity and dam service, compliance with modern standards and improved stability and performance
Water Security Agency Owner’s Engineer
KGS Group served as owner’s engineer to help the Water Security Agency (WSA) reduce their project backlog and bring consistency to their capital delivery services. Acting as project managers, our team scoped, managed and executed over 20 project procurements on behalf of the WSA.
Our project managers also assisted the WSA with oversight of their larger portfolio of owner’s engineer projects. Our role covered portfolio oversight, procurement leadership and risk and schedule control across multiple projects.
At the start of the contract, KGS mostly worked on process definition, engineering standards development and project engineering. In the later years, KGS was able to progress the work through engineering to construction. Because of this, the WSA spent its full capital allocation, with KGS-managed projects accounting for the majority of the spend, with this trend continuing to this day.
The KGS team accelerated project delivery and budget utilization while establishing a repeatable framework for future projects, enabling continued success for WSA.
Project Highlights
- Managed and executed over 20 project procurements
- Managed over 45 engineering, long‑lead procurement and construction contracts
- $53 million in capital construction delivered (November 2020 – March 2024)
- Helped create a framework enabling consistent, sustainable asset maintenance
- Clearer engagement model for ACEC‑SK members
Calabogie Generating Station Redevelopment
KGS Group served as owner’s engineer to redevelop Calabogie Generating Station, extending its life and increasing its output to 11 MW. We guided the project through feasibility, design and execution phases. The project included constructing a new powerhouse, expanding intake and tailrace channels, rebuilding the forebay dam and adding a new substation and fish habitat compensation features.
In 2006, KGS Group completed a feasibility study to explore options for the site’s refurbishment and redevelopment and was consequently awarded the role of owner’s engineer in 2017. We presented the client with a list of new turbine vendors, developed user requirements and preliminary specifications, supported environmental assessments and assisted with stakeholder consultations, including engagement with Indigenous groups.
Our team then assisted in procuring the contractor for the project who completed the final optimization, design and construction. Key design refinements included a more compact powerhouse, a redesigned forebay dam and a reworked intake channel supported by hydraulic modelling and a physical model. The project also included measures to make the site ready for eel passage and to facilitate future downstream passage.
KGS Group provided oversight, in collaboration with the resident engineer, throughout the project including full-time inspection services, ensuring quality and regulatory compliance, while mitigating risks and following safety standards. We helped complete commissioning and turnover of the project providing consistency and project knowledge from feasibility design to close out.
Project Highlights
- New powerhouse with expanded intake and tailrace channels and a rebuilt forebay dam
- New substation with fish habitat compensation features and a site ready for eel passage and future downstream passage
- Environmental assessments and stakeholder consultations
- Supported contractor procurement, optimized hydraulic and physical modelling
- 3D digital design for multi‑discipline coordination and field execution
- 11 MW output, extended asset life, improved reliability and operability
Lake Manitoba and Lake St. Martin Outlet Channels
Following severe flooding events in 2011 and 2014, the Province of Manitoba retained KGS Group for the design of the Lake Manitoba and Lake St. Martin Outlet Channels Project. The outlet channels will serve as new, permanent flood control infrastructure for both lakes.
Completed under tight schedule restrictions, the conceptual design work involved:
- Remote field investigations
- Extensive review and analysis of the various channel configurations
- Preparation of concept designs, cost estimates and constructability reviews
- Identification, assessment and screening of potential environmental and socio-economic impacts
The diverse range of design components and unique site conditions resulted in a challenging engineering undertaking that was successfully managed by the multidisciplinary team of experienced engineers, GIS technicians and support staff assembled by KGS Group.
KGS Group subsequently completed the preliminary, final design and tender preparation for the outlet channel from Lake St. Martin to Lake Winnipeg. The project includes roughly 23 km of channel excavation, multiple drop structures, and construction of a water control structure near the channel inlet complete with gates, hoists, bridge deck and ancillary buildings. The total estimated budget for this portion of the project is over $300 million. The construction phase of the project is pending regulatory approval.
Once constructed, the outlet channels are projected to maintain both lakes below flood stage over 99 per cent of the time. They will provide the ability to better regulate the lakes and reduce the impact of future floods, benefiting residents and businesses in the area.
Project Highlights
- Design for 23 km of channel excavation with defined sections and earthworks quantities
- Design of multiple drop structures sized for hydraulic control and energy dissipation
- Water control structure near the channel inlet for operational regulation
Pointe du Bois Spillway Replacement
The Pointe du Bois Generating Station is the oldest operating hydroelectric plant in Manitoba. Despite extensive upgrades and ongoing maintenance over the years, the original spillway required replacement. The Pointe du Bois Spillway Replacement project included the design and construction of a new remotely operated 7-bay spillway and a new 1km long zoned earthfill dam, complete with an ancillary support building for electrical switch gear and control systems, a backup diesel generator, and other related infrastructure.
As the prime consultant, KGS Group worked collaboratively with Manitoba Hydro as the designer in an early contractor involvement project delivery process. KGS also provided full-time technical support and quality assurance assistance through construction, commissioning and close-out activities.
The final design was carried out entirely within a 3D digital environment, and was paramount for the successful execution of all stages of the project. This innovative approach gave the team the ability to visualize the end product at the design stage and enabled harmonious advancement of the project across multiple disciplines.
The several hundred-million-dollar project was successfully completed without any interruptions to the ongoing operation of the plant, while protecting and preserving established lake sturgeon habitat and restoring the natural landscape in this environmentally sensitive provincial park setting.
Project Highlights
- New remotely operated seven bay spillway, support building and backup diesel generator
- New 1km long zoned earthfill embankment dam
- 3D digital design environment
- The several hundred‑million‑dollar capital program was completed without operational interruptions
- Enhanced safety and control, extended asset life and a more reliable discharge capacity
- Lake sturgeon habitat protected and the landscape in the provincial park was restored
Boundary Dam Spillway Upgrade
Boundary Dam Reservoir serves as a source of cooling water for the Boundary Dam Power Station, SaskPower’s largest generating station. KGS Group was retained to perform a dam safety assessment of the Boundary Dam structures.
The dam safety review identified a number of concerns, the most critical of which were insufficient spillway capacity and deficiencies with the condition of the existing spillway. Our team was then retained to design spillway upgrades to extend the life of the 50+ year old structure and to double the discharge capacity of the spillway. We performed preliminary and final design for complete replacement of the spillway chute and basin, while maintaining the reservoir at full supply level. The work also included the installation of over 400, +30-metre-long anchors.
The team overcame complex foundation issues with bentonite seams, coal layers and high groundwater. Another critical site challenge was to design and complete each year’s construction such that the spillway could potentially pass spring flood flows. Despite many challenges, the project was completed on schedule and near budget.
Project Highlights
- Dam safety assessment, spillway upgrade design, construction support
- Complete replacement of spillway chute and basin while maintaining full supply level
- Discharge capacity doubled to improve flood performance and safety
- Installation of 400+ anchors, each over 30 metres in length
- Foundation treatment addressing bentonite seams, coal layers and high groundwater
Brandon Third Street Dam Replacement
For more than 70 years, the Third Street Dam on the Assiniboine River supported the City of Brandon’s drinking water supply and provided social, environmental and commercial benefits. When the dam was irreparably damaged, KGS Group moved quickly to design temporary emergency measures that limited further habitat impacts and preserved Brandon’s water supply.
We then developed a functional, cost-effective, permanent solution that also removes a 70-year-old barrier to fish passage. The new overflow rockfill weir, with a low flow rock ramp fishway, preserves Brandon’s water supply, restores fish passage, adds spawning habitat, and improves the safety and aesthetics of the river adjacent to Dinsdale Park.
Working with the City of Brandon and regulators, the team demonstrated how preserving vital infrastructure can go hand‑in‑hand with prioritizing and enhancing the environment.
Project Highlights
- Designed and implemented temporary emergency measures to stabilize the river and maintain municipal water supply during dam failure
- Constructed an overflow rockfill weir to replace the damaged dam and secure long‑term water levels for intake reliability
- Constructed a low‑flow rock ramp fishway to restore year‑round fish passage and remove a 70‑year barrier
- Integrated spawning habitat through rock ramp geometry and material gradation, enhancing local fisheries