1 Statement of Work.pdf

Project: Hume Lake SCADA Installation

STATEMENT OF WORK

SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM

A. BACKGROUND

Hume Lake dam is the first multi-arch reinforced concrete dam constructed in the world. It impounds about 130 acre-feet of water. It is a high hazard dam. It is currently operated manually which requires the operator to drive over an hour to accomplish. The intent is to allow operation and monitoring from remote locations over a secure connection.

B. LOCATION

Hume Lake Dam is located in the Kings Canyon watershed. The locations of key elements of this contract are:

1) Generator building: 36.794284, -118.902530

2) Valves/outlet works: 36.794194, -118.901296

3) Reservoir monitoring system: On the generator building

C. DESCRIPTION AND TASKS OVERVIEW

The dam outlet works is currently operated manually via controls housed in a generator building approximately 350 feet away through wiring contained in a conduit. The conduit runs from the valves on the outlet works on the downstream side of Bay 6 through the dam, along the upstream dam toe into the generator building. A pressure transducer is positioned in the reservoir to monitor pool levels via a satellite terminal. The generator building is accessible by road. The outlet works is accessible by foot on a trail along the downstream dam toe.

The work entails the design and installation of a Supervisory Control and Data Acquisition (SCADA) system to allow the control and adjustment of the outlet valves from remote locations using a secure connection. Site drawings have been included which detail the general location, configuration, and composition of the current monitoring and control system.

The work also includes a speaker warning system and an optional camera that will be used to monitor valve operation.

The Contractor will retain the current manual controls for contingency use and add the ability to operate both valves remotely over a secure connection in manual and automatic control modes. The remote-control configurations that will be developed include:

1) Manual remote control to set the ball valve (used for throttling) to a specific percent open, and open or close the knifegate (isolation) valve.

2) Automatic remote control to set a reservoir pool elevation, plus a maximum or minus a minimum tolerance, to be maintained automatically. The maximum and minimum tolerances need to be adjustable for different times of the year.

SCADA REQUIREMENTS

SCADA system functionality will include:

1) Automatic Control When selected, automatic control will adjust flow through the existing 36-inch diameter throttling ball valve to maintain a set reservoir elevation based on measurements from the installed pressure transducer. The rate of change in transducer measurements will determine the degree the throttling valve will be opened. The following is the initial control algorithm which can be adjusted, During reservoir rise –

a. If the rate of increase is 1 foot per day or more when the reservoir elevation exceeds the target elevation plus the maximum tolerance the valve will be open 80% until the target elevation is re- established.

b. If the rate of increase is ½ foot per day to 1 foot per day when the reservoir elevation exceeds the target elevation plus the maximum tolerance the valve will be open 60% until the target

c. If the rate of increase is 1/3 to ½ foot per day when the reservoir elevation exceeds the target elevation plus the maximum tolerance the valve will be open 40% until the target elevation is re-established.

d. If the rate of increase is 1/4 to 1/3 foot per day when the reservoir elevation exceeds the target elevation plus the maximum tolerance the valve will be open 20% until the target

e. If rate of increase is 0 to 1/4 foot per day when the reservoir elevation exceeds the target elevation plus the maximum tolerance the valve will open 10 % until the target elevation is re-established.

f. The percent open will adjust to match the rate of change ranges indicated in (a) through (e) above. In otherwords, if the valve is open to 10% and the rate of change in the reservoir elevation increases to 2 feet per day the valves will open to 80% of maximum.

g. The rate of opening may not exceed 5% at any given time. Open the ball valve at 5% increments, with 15-minute intervals between openings (i.e. 5/10/15% etc.).

h. Install a waterproof speaker at the outlet works that can withstand the elements to warn downstream users that flows will increase and to leave the area downstream of the dam. Set warning at 5 minutes and 1 minute prior to opening of the valve, as well as at the time the valve is opened. The audio warning system must have a sound level at least 15 dB above the average ambient sound level measured when the ball valve is 50% open.

Control on the isolation gate valve upstream of the throttling valve (ball valve) will open the isolation valve prior to opening the throttling valve and close the isolation valve after the throttling valve is completely closed. The isolation valve shall be completely open any time the throttling valve is open. Ensure that the Forest Service can override the sequencing in the event either valve becomes inoperable.

During reservoir fall – If, for whatever reason, the reservoir falls below the target elevation minus the minimum tolerance (that is adjustable depending on time of year) below the target elevation, the valves will close.

2) Manual Remote Control In manual remote mode the operator will be able to control the position of the throttling valve following the control algorithm already in place. In manual mode the throttling valve will be operated on the valve operating curve with set points at 5% intervals of calculated max Q (estimated from the reservoir level as indicated on the pressure transducer installed in the reservoir), with the ability to manual override to fully open if needed in an emergency. At a minimum, the new remote system will display the pressure transducer elevation along with the dam crest elevation and rate of reservoir rise. Ensure that when in manual mode, all automated systems are overridden including thresholds and tolerances established for automated operations.

3) Solar Power System

Design of a battery bank and solar array to power the SCADA system, pressure transducer monitoring system (AMCI panel), and the generator battery for up to three days without sunshine.

The solar system will be mounted on the roof of the generator building and designed for year round operation. If the solar array does not provide enough power to operate the SCADA controls, pressure transducer, and generator battery the control system will automatically turn on the generator and recharge the batteries for the control system and generator. The solar array will be positioned/constructed to optimize power generation during all seasons.

4) General requirements and information for both automatic and manual remote control

Notifications will be transmitted if a fault condition is detected to government emails and phones in the system. A field allowing input of at least 5 emails and 5 phone numbers (smart phones) shall be included. Notification could occur through existing asset tracking service or directly to government PCs and phones.

Alarms will be enabled when the reservoir elevation is out of the specified range.

Remote operation can be disabled at the generator building with a manual (analog) switch.

The ability to control the system remotely will be disabled if a system check finds any error which could include but are not limited to,

a. Pressure transducer voltage out of range,

b. Generator indicators not within range or the generator is not starting

c. Valve position indicators are not in the proper range at the start or during operation

d. Weak signals that prevent reliable operation by remove controls.

An error message will be sent indicating that an error exists (naming the error) and that only local control is available.

Current controls put the knife gate valve into two positions - open or closed. Controls ensure the knife valve is never closed unless the ball valve is in the closed position.

The ball and knife gate valves are operated sequentially currently. SCADA control will duplicate current operation to ensure the knife gate valve is fully open when the ball valve is open any percentage and fully closed when the ball valve is closed; however, the SCADA system will allow direct control of each valve.

The system will provide the ability to remote start the generator that provides power to the valves.

The system will integrate the existing pressure transducer and AMCI control panel into the SCADA system to remotely monitor and control reservoir levels. The pressure transducer data shall be utilized to control flow through the control valves. The AMCI pressure transducer control panel shall be relocated from the pole outside the generator building to inside mounted on the wall adjacent to the valve control panel. The small solar panel and satellite link with the AMCI control panel will not be used.

The satellite link may use Hughes Net service compatible equipment, Starlink, or other suitable and available service as approved by the CO. The Government will need to verify that they are able to subscribe to the preferred service provider prior to its approval for use. Equipment and initial installation to provide an operational system is included in the work. The cost of monthly subscription service is not included in the scope of this solicitation.

Additional wiring was pulled that is intended for a possible micro-hydro unit sometime in the future. Excess wiring was pulled that may be used for SCADA.

The valves are subject to extreme variations in temperature and exposed to ice, wind, and water.

Design of control equipment located around the valves needs to account for anticipated climatic conditions.

The dam periodically overtops. The cascading water may interfere with wireless communications to the valves. As indicated additional wiring has been installed that the Contractor can utilize in their design.

The SCADA system control equipment may be housed in the generator room which is sheltered from wind, snow, and rain. The generator room is subjected to freezing temperatures.

The valve actuators currently do not have position indicator circuits installed. The SCADA system needs to include installation of position indicator circuits in the ball valve actuator, and the knifegate actuator verifying fully open or fully closed.

The existing generator is a Kohler 14 kw propane fueled generator model # 14RESA. The existing generator building is a wood framed 12’ x 16’ building with a standing seam metal roof.

Load parameters on the motor used to open and close the existing ball valve are:

220 volt, 3 phase power to the existing ball valve on the dam.

Nominal load is 10.4 amps. Amps locked rotor: 72 amps.

Horse power = 3.4.

OPTIONAL VIDEO CAMERA

Installation of a video camera on the trail bridge downstream of the valves to visually monitor valve operation and dam conditions. The video camera should communicate using a wireless link (such as 900 MHz) between the trail bridge mounting location and the generator building (approximately 430’ distance). The camera does not need to be streamed but could be a sequence of still images. Still images should be available in real time-on-demand for manual operations.

D. CONTACTS

The Contractor will obtain authorization to contact once contract is awarded.

Existing controls designer – McJunkin Redman, Valve & Engineering Center, Bakersfield, California Lake level monitoring system – designed and monitored by AMCI wireless, Denver, Colorado.

E. DELIVERABLES

It is the responsibility of the Contractor to verify all information contained in this contract. The Contractor shall develop a cost estimate for the indicated bid items to accomplish the required work.

This Contract may be exercised in its entirety or partially by bid item depending on budgetary constraints. The Contractor will make every effort to simplify operation and maintenance of the system. Proposed simplifications to these requirements to enable that objective are encouraged. The Contractor will take into account year round climatic conditions at the site. Work includes all transportation, installation, or placement costs. Anything not listed will be considered incidental and shall be included in the cost of the listed items.

Pay Item 1 – Site visit, and coordination.

The Contractor will conduct any testing that might be required during the site visit to ensure integration of the SCADA system with existing controls. The Contractor will coordinate with existing vendors who designed and service the current controls and monitoring systems to integrate the new SCADA system.

Pay Item 2 – Furnish and Install SCADA

a) The Contractor will develop preliminary designs and cost for the following option:

i) Automatic and manual remote control

b) Furnish and install remote control of outlet works; solar array, battery bank, control panel, and accessories at generator building and outlet works as required. Size solar array and battery bank to power monitoring system only (not valve actuator). Combine all solar power demands into a single solar array and eliminate the very small panels that currently support the AMCI control panel and the generator’s standby monitoring panel. Utilize existing wiring between the outlet works and generator building if needed. Coordinate with current vendors and controls designers to integrate the system.

The proposed SCADA system will be accessible over government computers and smart phones. It must provide off-site visibility of lake level using the existing transducer and valve status (open or closed for knifegate valve, percent open or closed for ball valve), and control of valve settings from off-site over a secure connection. On-site controls (at the generator building and at the valves) must still function. A manual analog switch on the control panel will enable/disable remote control capabilities.

The SCADA system should provide the functionality indicated in Section C. Installation of an audio warning system (Speaker) with a sound level at least 15 dB above the average ambient sound level measured when the ball valve is 50% open is incidental to this pay item.

Technical Proposal: Provide product cut sheets for primary components of proposed system. Specify solar panel model, size, quantity, output capacity, and mounting system. Specify battery type, model, capacity, quantity. Describe satellite communication system including equipment, operational frequency, and proposed service provider. Describe how the proposed SCADA system will work including display of data both onsite and offsite, how the existing systems on site (actuators and valve controls, pressure transducer system) will be modified, and how the SCADA system will incorporate the existing systems and components. Describe what software the SCADA system will use and how it ensures security from cyber attacks. Describe what software the SCADA system will use, and whether it is web-based or on site PC based. Specify camera model and capabilities. Describe wireless communication system between video camera at trail bridge and generator building including equipment and operational frequency. Explain how the system will provide reliable communication with the generator building through all of the vegetation on site.

Optional Pay Item 3 - Furnish and Install a video camera at trail bridge with solar panel, battery, and wireless controls/data transfer for video camera.

Camera image resolution should be 2048 x 1536 minimum with day and night capability; capture 1 frame per minute minimum; and stream data continuously or on demand. The solicitation does not describe installation requirements. If a separate enclosure is required for batteries and hardware it should be installed at the end of the bridge (west abutment) in a secure weather tight container that is accessible from the ground for ease of installation and maintenance; see photos at end of document.

The video camera, solar panels, and wireless transmitter should be installed along the bottom of the upstream side of the 140’ long trail bridge as required to function properly. The camera mounting location is 20’-30’ above the ground. If required, any conduit will run along the inside of the upstream bridge truss back to any separate enclosure. The camera must have a clear view of the downstream face of the dam and outlet valves. Solar panels must have clear exposure to sunlight.

Wireless transmitter must have reliable communication with the generator building. The distance from the camera location to the generator building is approximately 430 feet. The area between the two locations is heavily forested with pine trees and undergrowth so there is not a clear line of sight.

Equipment should blend in with existing features as much as possible.

The camera requirements may be adjusted if satisfactory alternatives are identified.

Technical Proposal: Provide product cut sheets for primary components of proposed system. Specify camera model and capabilities. Specify solar panel model, size, quantity, output capacity, and mounting system.

Specify battery type, model, capacity, quantity. Describe wireless communication system to generator building including equipment and operational frequency. Explain how the system will provide reliable communication with the generator building through all of the vegetation on site. The camera system should be designed to operate for up to five (5) days on battery power, and then go into standby mode until enough power to operate is available.

F. PAYMENT

The items will be paid at the contract price per unit of measurement for the pay items listed in the bid schedule. Payment will be full compensation for the work prescribed in this Section.

Items not listed will be considered incidental and shall be included in the cost of the listed items.