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16 installation of a new turbine for unit 5 that December. Hydro Plant Superintendent Harrison said the redevelopment effort is the biggest in 55 years for the 108-year-old dam. e unit 1 turbine was replaced in 2012 and unit 4 in 2013 but the other four turbines and 26 spillway gates will be replaced by 2026, along with new electrical components throughout the facility. Current carbon steel turbines are being upgraded with stainless steel models built in Slovenia by Litostroj Power. Every dam is unique, which requires turbines being built exclusively to varying dimensions. Harrison said it is generally a two- year process involving a year of research, design and engineering and another year to manufacture a turbine. e new turbines have one less blade than the carbon steel units, and are angled differently for better efficiency. e new turbines will be shipped across the Atlantic Ocean and go through the Port of Mobile to reach Lay Dam. A highlight of the current upgrades is a new generator step-up (GSU) transformer, which Harrison said is "the critical link between the power station and transmission lines." In January, contractors were paving the way to move the 15-foot- wide, 15-foot-tall GSU inside Lay once it is completed and shipped. "It takes well over a year to get a GSU made," said Harrison, who joined Alabama Power in 2006 and has been at Lay since July 2015. "You just can't get one of these off a shelf somewhere." SCS Construction Discipline Leads Brent Collins and Mark Mote are assisting Lay Dam's current employees on the GSU installation. KBH ompson is handling the major work, as Harrison anticipates the Atlanta company having about 50 employees on site by April and at least 100 workers by midsummer. "Right now, they have 10 electrical specialists working 10 hours a day just getting things ready, on top of our staff running cable trays and performing other electrical work that can be done beforehand with everything still operating," Harrison said. Later this year, all six Lay Dam generating units will be shut down to install the new GSU and replace breakers throughout the plant. Recently, an outside alternate feed power line was added for emergencies. It will provide power inside the plant for lighting, elevators, welding, computers and other bare bones needs until Turbines are replaced about every 50 years, take a year to construct. Each Lay Dam turbine is 86 inches tall, 175 inches wide, weighs 56,406 pounds and can produce 30 megawatts of power. Each Lay Dam turbine is 86 inches tall, 175 inches wide, weighs 56,406 pounds and can produce 30 megawatts of power. PHOTO BY MEG MCKINNEY PHOTO BY PHIL FREE