NIPSCO Oakdale Dam floodgates and stoplogs replacement project
The Client
Northern Indiana Public Service Company (NIPSCO) is the largest natural gas distribution company and the second-largest electric distribution company in Indiana, with more than 1.2 million customers statewide. As part of its commitment to producing clean and renewable energy, NIPSCO owns and operates two hydroelectric plants in northern Indiana, the Norway Hydro Plant — which Superior rehabilitated in 2021 — and the Oakdale Hydro Plant. Both facilities use floodgates to regulate water levels along the Tippecanoe River and maintain the proper flow of water through power turbines needed to produce energy.
NIPSCO sought Superior for its expertise in managing water and wastewater facilities upgrades and providing unique solutions to the environmental challenges these projects present. The complex systems used in megastructure rehabilitations and expansions require a depth of expertise and knowledge of state-of-the-art technology to ensure the work is completed safely and efficiently.
Project Fast Facts
Client: Northern Indiana Public Service Company (NIPSCO)
Location: Monticello, Indiana
Work Performed: Removed and replaced concrete to facilitate the installation of embedded parts for new floodgates and stoplogs; built and installed a cofferdam system, demolished the existing superstructure in two phases, employed a crane on a mobile marine barge, and hired professional divers for underwater repairs
Project Schedule: Twelve months
Completion Date: March 2023
The Work
The Superior team partnered with engineering firm Enspect, Inc., Chicago Underwater, Inc., and Hard Rock Concrete Cutters to address the environmental challenges of safely replacing the Oakdale Hydro Plant floodgates and stoplogs. On average, the plant can discharge 4,010 cubic feet of water per second. That tremendous water flow can be incredibly dangerous to crews working to demolish the existing superstructure and install the new equipment.
The design-build process allowed Superior’s project management team to develop new solutions and recommendations for the construction sequencing and implementation. Enspect, Inc. designed a cofferdam system, which the Superior team built and installed, creating a wall that allowed construction crews to work safely at 30 feet below the level of Lake Freeman.
Another innovative solution: Superior dismantled the existing superstructure and installed its replacement using a crane fixed to a mobile marine barge. Employing this highly technical method improved the quality of the work and enhanced safety. Superior also contracted professional divers with Chicago Underwater, Inc. to complete underwater repairs and install the cofferdam system and other components that cannot be installed dry.
The scope of work included installing the following owner-furnished equipment: two vertical lift wheel gates (30’ W x 22.3’ H) and embedded parts; one set of stoplogs (3 pieces) (30’ W x 28.8’ H) and two sets of embedded parts with one lifting beam and storage device; two sets of flood gate motorized actuator hoists with screw-type bevel gear drives; and one 20-ton monorail stoplog hoist.
The Result
Due to the potential dangers of working near an operating dam, and the infrastructure’s value to the community, this project required considerable coordination and attention to detail. If the floodgates and stoplogs fail, the runoff could threaten thousands of acres of valuable farmlands throughout central Indiana and, more importantly, cause loss of life and property.
Rehabilitating the dam was an enormous responsibility, but by employing forward-thinking construction methods, Superior extended the life of NIPSCO’s Oakdale Hydro Plant and secured a valuable piece of infrastructure for the Monticello community.
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