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Engineering

Supporting all aspects of hydropower from conception to production.

Engineering

Engineering Services

Hydro Tech delivers engineering solutions for hydroelectric assets throughout North America. Combining decades of field experience with advanced analytical tools, our engineers provide practical solutions for equipment rehabilitation, modernization, performance improvements, and failure investigations.

Our expertise includes turbine and generator engineering, bearing design, finite element analysis, reverse engineering, precision metrology, 3D laser scanning, and custom equipment design. Whether supporting a planned capital project or addressing an urgent operational issue, Hydro Tech helps clients improve reliability, extend asset life, and maximize equipment performance.

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Engineering Services
Hydro Industry-Specific Expertise
Consulting

Consulting Services

Hydro Tech engineers act as a trusted extension of your team across the project lifecycle — from condition assessment and planning through procurement, execution and handover.

Owner Support & Project Management

Owner’s-engineer support and full project management for overhauls, retrofits and capital projects — covering scope, schedule, budget and contractor coordination.

Inspection, Diagnostics & Failure Analysis

Mechanical testing and inspections to verify condition, targeted diagnostics on running equipment, and root-cause investigation of in-service failures.

Performance Testing & Condition Assessment

Acceptance and performance testing to validate units, plus independent condition assessments of unit health and recommended scope.

Specifications & Written Procedures

Technical specifications and tender documents, on-site contract monitoring, and written procedures so maintenance and inspection work stays repeatable.

From Concept to Drawing Set

Design Services

Mechanical design backed by hands-on hydro experience — we design what we build.

01

Mechanical Designs

Original mechanical design of components and systems for hydro generators, turbines and powerhouse equipment.

02

Design Studies & Reviews

Feasibility studies, options analysis and independent design reviews of new builds and proposed modifications.

03

Engineering for Retrofits

Reverse engineering of legacy components to produce drawings and specifications for accurate replacements and upgrades.

Custom Engineering

Specialized Designs

One-off engineered solutions for station-specific problems — each design is tailored to the constraints of an existing facility, not pulled from a catalogue.

Thrust Bearing Oil Lift

Hydrostatic oil-lift systems for thrust bearings, reducing start-up wear on heavily-loaded vertical units.

Generator Brake Systems

Custom-engineered generator brake assemblies to safely stop and hold rotating machinery during outages.

Portable Transformer Fall Arrest

Portable fall-arrest systems for safe access to transformer maintenance, designed for site reuse.

Generator Oil Effluent System

Engineered effluent containment for generator oil systems, protecting the environment and meeting compliance requirements.

Featured Projects

Recent Engineering Work

A look at recent engineering programs supporting major hydro generating stations across North America.

RH Saunders Generating Station — Units 1–16 Overhauls

Client: OPG Location: Cornwall, Ontario Timeline: September 2022 – Ongoing (16-unit multi-year program)

Services Provided

  • Mechanical and electrical engineering support
  • Planning and design
  • Procurement and fabrication support
  • Demolition and removal
  • Equipment installation and commissioning
  • Project management and reporting
  • Quality management and documentation
  • Construction and field execution support

Project Overview

Hydro Tech is supporting Ontario Power Generation on a multi-phase overhaul program for Units 1–16 at RH Saunders Generating Station.

The project involves providing engineering, technical oversight, and execution support across all phases of the overhaul, including planning, design coordination, procurement, installation, and commissioning activities.

Working within OPG’s standards and project framework, Hydro Tech plays a key role in ensuring the successful delivery of this large-scale rehabilitation program, supporting long-term performance and reliability of the generating units.

Croton Generating Station Units 1 & 2 Onsite Machining and Alignment

Client: Consumers Energy Location: Michigan, USA Timeline: Completed June 2023

Services Provided

  • Onsite machining and line boring
  • Shaft alignment support
  • Turbine guide bearing preparation
  • Field machining and technical services

Project Overview

Hydro Tech completed onsite machining and alignment work for Units 1 and 2 at Croton Generating Station as part of a broader overhaul and equipment upgrade program.

The scope included precision machining of turbine guide bearing surfaces and line boring of shaft coupling components to restore alignment between turbine and generator systems.

Working within a constrained field environment, Hydro Tech executed the work with specialized onsite machining techniques to ensure accuracy, proper fit, and reliable unit performance.