At Knight Const. & Supply, Inc. (KCS), we understand some facilities cannot afford unexpected downtime. Our mission-critical construction and maintenance services support essential power generation, industrial, and infrastructure systems where reliability, safety, and precise execution are critical to continued operations. With extensive experience working in complex operating facilities, KCS provides the skilled personnel and field expertise required to safely execute challenging projects under demanding conditions and schedules.
Our experience includes work on critical electrical and control systems such as ISO phase bus and high-voltage switchyard systems, as well as major outage work involving navigation lock systems. KCS teams are experienced in coordinating work within tightly controlled outage windows, working around existing equipment and operations, and completing complex installations, upgrades, and repairs while minimizing impacts to facility operations.
From planned maintenance and system upgrades to outage support and emergency repairs, KCS provides a dependable partner for mission-critical infrastructure. Our self-performing capabilities, experienced craftspeople, equipment resources, and in-house fabrication capabilities allow us to efficiently support projects from preparation and fabrication through field installation and completion. Every project is approached with a focus on safety, quality, coordination, and schedule reliability.
KCS brings decades of heavy industrial and hydroelectric construction experience to projects where performance matters. Whether supporting power generation, industrial operations, navigation infrastructure, or other critical systems, our team is prepared to deliver reliable solutions in environments where downtime is not an option.
McNary Isophase Bus and High-Voltage Switchyard Improvement
KCS provides construction, modernization, and design-build services for mission-critical hydroelectric facilities which support America’s bulk power system and overall grid reliability. Our teams understand the operational sensitivity of working in active power-generation environments, where planning, safety, quality control, and outage coordination are essential to keeping critical energy infrastructure performing reliably.
- The isophase bus were modernized at McNary Dam.
- High-voltage tubular bus and rooftop disconnect switch inspection, maintenance, and replacement were performed at McNary Dam.
- Design, fabrication, installation, and commissioning of 5000A breaker disconnects were provided for all 14 main power generation units.
- Generator-unit intake gate improvements, rehabilitation, and replacement were completed, including hydraulic cylinder, control, and hydraulic system upgrades.
- Outage-based installation work was coordinated to minimize generator downtime and support Bonneville Power Administration and U.S. Army Corps of Engineers operational requirements.
- Critical equipment acceptance, commissioning coordination, and deficiency-free closeout were supported for completed outage scopes.
Lower Monumental and Ice Harbor
KCS served as the prime contractor for the comprehensive modernization of the downstream navigation lock gate hoist system at Lower Monumental and Ice Harbor lock and dam systems. A major focus was replacing the electrical and control systems used to operate the 1.5-million-pound gates, including new PLC and VFD equipment, sensing systems, encoders, and fiber-optic and Ethernet communications. Working with ETS Automation, KCS identified gaps in the original control designs early, coordinated necessary revisions with USACE, and prefabricated and tested equipment before the outage to reduce fieldwork and schedule impacts. The projects were completed under an aggressive navigation lock outage schedule and included significant mechanical and structural upgrades.
- Upgraded the lock stand control consoles, primary gate-position drum encoders, and installed backup SSI string encoders to improve gate-position monitoring and system reliability.
- Replaced the VFD and PLC control cabinets in all four gate towers, along with associated conduit and control and power-feed wiring.
- Installed new brake resistors, isolation transformers, and PLC I/O cabinets supporting upstream and downstream lock stands.
- Installed new water-level sensing systems at the forebay, lock chamber, and tailrace, as well as position encoders for two fill valves and two drain valves.
- Established new fiber-optic and Ethernet communication networks and completed the integration, testing, and commissioning of the upgraded control systems.
- Coordinated the electrical improvements with new VFD-driven motors, brakes, and gearboxes.
- Completed extensive structural repairs to each 18-ft diameter hoist drum to provide fully rehabilitated and dependable gate-hoist systems.