Project parameters
Following a comprehensive hydraulic assessment, Litostroj developed and delivered new Francis runners using advanced CFD and FEM analysis. The modernization eliminated vibration, cracking and unstable part-load operation, increased installed capacity from 6.5 MW to 8.4 MW, and has provided reliable, trouble-free operation since 2020.
Restoring confidence in a century-old hydropower plant
Located on the Menominee River in Michigan, USA, the Sturgeon Falls hydropower plant has been generating renewable electricity for more than a century. Despite previous upgrades, recurring operational issues had compromised the reliability of two historic Camelback Double Francis units. In 2018, the City of Norway selected Litostroj to deliver a comprehensive hydraulic redesign that would restore long-term performance and dependable operation.
Overcoming persistent hydraulic challenges
Earlier runner replacements had failed to deliver the expected results. Severe vibration, unstable part-load operation and structural cracking led to repeated maintenance interventions, with the latest runners reaching the end of their service life after only six years. The challenge was not simply to manufacture new runners, but to identify the root causes of these failures and develop a hydraulic solution capable of delivering reliable performance across the entire operating range.
Engineering a solution built to last
Litostroj carried out a comprehensive assessment of the turbines, combining site inspections, signature testing and hydraulic measurements with advanced CFD simulations and finite element analysis. Based on these findings, the engineering team developed completely new Francis runners optimized specifically for the plant's operating conditions.
Beyond the hydraulic redesign, Litostroj managed the complete modernization process—from manufacturing and installation to correcting embedded part misalignment and commissioning the upgraded units.
Conclusion
The modernization increased the plant's installed capacity from 6.5 MW to 8.4 MW, while eliminating vibration, cracking and unstable operation. Since commissioning in 2020, the upgraded units have operated smoothly and quietly, consistently meeting or exceeding all guaranteed performance targets. Regular inspections continue to confirm excellent mechanical condition, with no signs of cavitation or structural damage.
