LADM NO. 1130-2-36 Fullerton Dam FCB O&M Manual 08-1970.pdf

L A D M NO. 1130-2- 26

OPERATION AND MAINTENANCE

MANUAL

FOR

FULLERTON DAM

SANTA ANA RIVER BASIN AND ORANGE COUNTY

EAST FULLERTON CREEK IMPROVEMENT

CALIFORNIA

DEPARTMENT OF THE ARMY LOS ANGELES DISTRICT

CORPS OF ENGINEERS

AUGUST 1970

LADM NO. 1130-2-26 Department of the Army, Los Angeles D i s t r i c t , Corps of Engineers Augus t 19 70

F O R E W O R D

1. This manual prescribes standard procedures f o r the operation and maintenance of the federally constructed Fullerton Dam and Flood-Control Reservoir, Orange County, California.

2. The Operations Branch of the Construction Division i s responsible f o r the preparation of t h i s manual and f o r keeping the manual up to date.

Suggestions f o r revisions should be forwarded through channels t o tha t branch.

3. A l l exhibi ts not attached to t h i s manual may be found i n the Operations Branch, Construction Division.

4. This manual rescinds LADM NO.

D i s t r i c t Engineer

TABLE OF CONTENTS

TITLE

PART I . GENERAL

Int roduct ion

1 . Authority 2 . Purpose 3 . P a r t s of manual 4 . Scope of manual

Pro jec t Description

5 . Authorization 6 . Pro jec t loca t ion 7 . Protect ion provided 8 . Pr inc ip le fea tu res 9 . Hydrographic i n s t a l l a t i o n s

10 . Communication f a c i l i t i e s .................................. 11 . Construction h i s t o r y

12 . Per t inen t data

PART I1 . OPERATION AND MAINTENANCE

General

2 . Reference drawings and manuals 3 . Functions of the Construction Division 4 . Functions of the Engineering Division 5 . Functions of the Real Es ta te Division

PAGE

............... . . . 6 Functions of the U S Geological Survey

......................... . 7 Functions of the Safety Office

. ............................. 8 Duties of the Dam Operator

Reservoir and Embankments

9 . Dam ....................................* . 10 Inspections and maintenance

11 . Flood-emergency inspection Outlet Structures

12 . Main features . 1 3 Approach and intake channel

14 . Intake tower 15 . The gate control house 16 . Gated out le t s 17 . Ungated ou t l e t 18 . Outlet conduit

...................... 19 . Outlet channel and s t i l l i n g basin

20 . Inspections and maintenance Spillway

21 . &in features ........................w.....o 22 . Inspections and maintenance

Service Gates and Hoists

23 . Description ............................. . 24 Inspection and maintenance

- - - - - - - .............................. 25 . Test operation of gates..

26; Five-Year inspection and maintenance

E l e c t r t c a l F a c i l i t i e s

27 . Power supply

28 . Standby generator

29 . Switchboard

Operation of e l e c t r i c a l f a c i l i t i e s

Inspection. maintenance. and tests

Five-Year inspect ion and maintenance

Communication Fac i l ik ies

Commercial telephone service

Radio f a c i l i t i e s

Hydrographic I n s t a l l a t i o n s

Hydrographic gages

Buildings and Appurtenances

Maintenance by Dam Opeator

Fire-Fighting Equipment. F i r e and Accident Prevention

Control house

Inspections. tests. and maintenance

Accident prevention

Foundation and Materials Instrumentation

Instrumentation a t Ful ler ton Dazn

Responsibil i ty f o r instrumentation measurements

EXHIBITS

NO. TITLE

Pro jec t Location

General Plan

1 Sheet

1 Sheet

Drawings, Half-size (Unattached) 1 Sheet

Reference Manufacturers Manuals 1 Sheet (Unattached)

Inspection Check L i s t 1 Sheet

Tes t Reports 1 Sheet

Gate Operation Gate Hoists

S t a r t i n g the UD 236 Diesel Standby U n i t

Operation of Switchboard

General Safety Requirements EM 385-1 (Unattached)

1 Sheet

4 Pages

2 Pages

1 Sheet

Foundation and Materials Instrumentation 1 Sheet

OPERATION AND MAINTENANCE MANUAL

FOR

FULLERTON DAM AND FLOOD CONTROL RESERVOIR

ORANGE COUNTY, CALIFORNIA

PART I - GENERAL

Introduction

1, Authority.-- This manual was prepared pursuant to ER 1130-2-304, dated 25 March 1966, which d i r e c t s the preparat ion and prescr ibes t h e coverage of operat ion and maintenance manuals f o r completed c i v i l works p ro jec t s operated by the Corps of Engineers.

2. Purpose.-- The purpose of t h i s manual is to provide guidance and ins t ruc t ions t o the Dam Operator and District operating personnel f o r proper operat ion and maintenance of Ful ler ton Dam. These ins t ruc t ions w i l l insure the continuous maintenance of s t r u c t u r e s and equipment and t h e i r operat ion i n such a manner and a t such times as w i l l obta in optimum b e n e f i t s .

3. Par t s of manual.-- This manual has been prepared i n two par t s :

(1) General descr ip t ion of the completed p ro jec t , and (2) Operation and Maintenance ins t ruc t ions , f o r the major and c r i t i c a l p ro jec t equipment and f a c i l i t i e s i n s t a l l e d a t Ful ler ton Dam.

4. Scope of manual.-- The scope of t h i s manual i s l imi ted t o e s s e n t i a l operat ion and maintenance ins t ruc t ions and describes the operat ing p a r t s , t h e i r purpose, and technique of operat ion i n s u f f i c i e n t d e t a i l t o insure proper operation.

P ro jec t Descript ion

5. Authorization.-- The Flood Control Act, approved 22 June 1936, a s amended by the Flood Control Act approved 28 June 1938, authorized a plan of improvement f o r flood control i n Orange County. Ful ler ton Dam

0 and Reservoir is a u n i t of t h i s authorized plan.

6. Pro jec t location.-- Ful ler ton Dam is a p a r t of the f lood con t ro l p ro jec t f o r Santa Ana River bas in i n Orange County, Cal i fornia . (See Exhibit A.) The dam s i te i s on East Ful ler ton Creek, approximately

1.6 miles nor th and 2.1 miles east of t h e City of Fullerton, j u s t above the mouth of a small canyon from which the stream emerges onto the coas ta l p la in .

7. Protec t ion provided.-- The p ro jec t was designed t o provide protec t ion from floods f o r the City of Ful ler ton and t h e adjacent highly developed coas ta l p l a i n area by reducing the f lood flows i n East Ful ler ton Creek before they reach damaging s tages . The p ro jec t design f lood under the u l t imate plan has a peak inflow of 4,600 cubic f e e t per second. Reservoir capacity is 706 ac re f e e t a t the spil lway crest.

8. Pr inc ip le features.-- The p r inc ip le s t r u c t u r e s a r e an e a r t h f i l l dam, an approach channel, an in take with t r a sh racks, two 3-by 5-foot gated o u t l e t s , one 3-by 2-foot ungated o u t l e t , t r a n s i t i o n ducts joining the flows from the gated and t h e ungated o u t l e t s and d i rec t ing them i n t o a s i n g l e 4-by 6-foot conduit extending through the dam, a s t i l l i n g bas in ending 200 f e e t below t h e conduit p o r t a l , and an excavated trapezoidal channel, extending from the s t i l l i n g bas in t o the e x i s t i n g n a t u r a l channel of East Ful ler ton Creek. The ogee spillway is designed t o discharge 5,650 cubic f e e t pe r second with 5.6 f e e t of freeboard.

The concrete-lined spillway channel continues f o r a dis tance of 304 f e e t , and terminates with an energy-dissipating s t r u c t u r e consis t ing of a drop and a bucket. (See Exhibit B.)

9. Hydrographic ins ta l la t ions . - - Hydrographic i n s t a l l a t i o n s include a reservoir water-surface s t age recorder; two gate opening recorders;

a remote control outflow gaging s t a t i o n ; a standard glass-tube r a i n gage; automatic recording r a i n gage, s t a f f gages, ga te ind ica to r s , and sedimentation monuments.

10. Communication f a c i l i t i e s . - - Communication f a c i l i t i e s include a radio t ransmit t ing and receiviGg s t a t i o n and telephone a t the control house.

11. Construction history.-- Construction w a s accomplished under two d i f f e r e n t contrac ts , copies of which a r e on f i l e i n the Office of the District Engineer, Los Angeles D i s t r i c t , Corps of Engineers. Per t inent d a t a on the 2 major contrac ts a r e a s follows:

a. Dam and spillway .-- Contractor: Chas. U. Heuser Contract No, : W-509-ENG-1042 Work s t a r t e d : 24 May 19 40 Work completed: 8 May 1941 Accepted by the U, S. : 17 May 1941

. b . Service gates Fabrication...

Contractor: F . R . Galbreath Contract No . . W-509-ENG1053 Work s ta r ted : 3 June 1940 Work completed: 30 November 19 40 Accepted by the U . S . : 17 February 1941

12 . Pert inent data.--

Drainage area. .......................... s q . m i ..

Reservoir:

Capacity a t spillway c r e s t ........... ac-ft..

Capacity a t max . water surface ....... ac-ft. .

Dam:

Type Top elevation ........................... f t . . ..... .. Crest length ....................... ft .................. Height above streanibed f t . .

Outlet s t ruc tures :

. ............................. Gates number - s i z e ............................ f t . . ..................... Ungated o u t l e t ' number -size .............................bt.. ............... Conduit - number and s i z e f t . .

-length ......................... f t . . ..................... Gate s i l l elevation ft,.

Spillway:

......................... Crest elevation f t . . .. ............................ Crest length f t Maximum water surface e levat ion ......... f t . .

Discharge a t M . W . S ................. c.f.s..

ear thf ill

3x5

3x2 one- 4x6 328.5

PART I1 - OPERATION AND MAINTENANCE

General

1. Information.-- Specia l terms used i n t h i s m a n d l are:

a . "Flood Season" r e f e r s t o the period from 15 October t o 15 Apri l when most pas t f loods have occurred.

b. "Emergency Flood Conditions" r e f e r s t o periods during which the reservoir water surf ace rises above the c r e s t of the spillway a t e levat ion

290.0. A l l e levat ions r e f e r t o mean s e a l e v e l datum.

2. Reference drawings and manuals.-- Drawing f i l e numbers i n t h i s manual r e f e r s t o "as-constructed" drawings; ha l f -s ize reductions a r e included a s Exhibit C and are separa te ly bound. - Drawings, manuals, and ins t ruc t ions f o r manufacturers' equipment a re l i s t e d i n Exhibit D and a r e on f i l e i n the D i s t r i c t Office, Maintenance Yard, and a t the projec t .

3. Functions of the Construction Division.-- Operation and maintenance and a l l inspections a r e under the supervision of the Construction Division, which assigns t h i s r e spons ib i l i ty t o the Operations Branch. The general du t i e s include the following:

a . The Operations Branch s h a l l t r a i n key personnel i n order t h a t regular inspection, operation, and maintenance work w i l l b e performed e f f i c i e n t l y and t o insure t h a t unexpected problems r e l a t e d t o f lood con t ro l may be handled i n an expeditious and order ly manner. The men s h a l l become fami l i a r with the provisions of t h i s manual, the supplements A, B, and C of LAD OM 500-1-1, and the "as-constructed" drawings.

b. The Operations Branch s h a l l r epor t v io la t ions of outgrant terms t o Real Es ta te Division f o r o f f i c i a l ac t ion when they cannot be handled in£ ormally .

c. The Operations Branch prepares and executes a l l f lood f igh t ing plans and through the Regulation and Meteorology Section d i r e c t s the Dam Operator o r h i s a l t e r n a t e i n the operat ion of the gates. It s h a l l keep records of r ese rvo i r s t ages , inflow t o - t h e reservoir , re leases through the o u t l e t s t ruc tu res , and spillway flow.

d. The Regulation and Meteorology Section, Operations Branch is responsible f o r the inspection, servic ing, and maintenance of a l l hydrographic i n s t a l l a t i o n s and radio i n s t a l l a t i o n s . (Their rou t ine inspections a r e made by the Dam Operator.)

e. Per iodic inspect ions s h a l l b e made by t h e Engineering Evaluation and Inspection Section, Operations Branch, i n order t o determine mainten-ance measures necessary t o insure s e r v i c e a b i l i t y of the works i n time of flood. Such inspect ions s h a l l be made immediately following each major highwater period, a t i n t e r v a l s no t t o exceed s i x months, and a t such other times as may be necessary. Immediate s t eps s h a l l be taken t o cor rec t dangerous conditions d isc losed by such inspections, and regu la r maintenance r e p a i r measures s h a l l b e accomplished during the appropriate season as scheduled by the Chief, Operations Branch, A l l r e p a i r s s h a l l be made i n accordance with standard engineering p rac t i ce t o l i n e , grade, and q u a l i t y and i n accordance with re levant d e t a i l s shown on "as-constructed" drawings, Exhibit C.

f . The Engineer Evaluation and Inspection Section, Operations Branch, reviews plans and furnishes comments to Real Esta te Division on requests from publ ic o r p r i v a t e i n t e r e s t s f o r c o l l a t e r a l use of land and water areas and performs inspections during construction t o assure compliance with approved plans.

g. The Maintenance Section, Operations Branch, s h a l l e s t a b l i s h a f i l e of a l l r epor t s and records concerning the maintenance and operat ion of the p ro jec t work.

4. Functions of the Engineering Division.--

a. Conducts o r p a r t i c i p a t e s i n pe r iod ica l condition surveys of the p ro jec t with representa t ives from Construction Division, South P a c i f i c Division, and Office of t h e Chief of Engineers. These surveys serve a two-fold purpose: (1) a sce r ta in t h e condition of the various p a r t s of the p ro jec t ; and (2) see t h a t a l l r epa i r s and improvements have been c a r r i e d out t h a t were previously recommended.

b. Performs engineering review of plans of proposed development on p ro jec t land o r water areas , as requested by the Construction Division.

c. Furnishes engineering comments on request of publ ic o r p r iva te i n t e r e s t s f o r c o l l a t e r a l use of land and water areas as requested by Construction Division.

d. Reports t o Construction Division a l l t respass o r v i o l a t i o n of outgrants discovered by Engineering Division personnel.

5. Functions of the Real Estate Division.--a . Processes a l l permits, l i censes , easements, o r l eases through appropriate channels and administers completed i n s truanents .

b. Insures compliance through per iodic inspections and acts upon a l l v io la t ions of outgrants .

c. Furnishes t h e Construction Division copies of a l l permits, l icenses , easements, o r leases.

6. Functions of the U. S. Geological Survey,-- By agreement with the Corps of Engineers, the U. S, Geological Survey (USGS) services the outflow gaging s t a t i o n below Ful ler ton Dam and makes discharge measure-ments. Outflow records are published i n t h e i r "Water Supply Papers.''

7. Functions of the Safety Office.-- A l l functions involving s a f e t y a r e under the supervision of the Chief, Safety Office. The Safety Off i c e s h a l l perf o m per iodic inspections t o insure compliance with appropriate sa fe ty codes and standards of a l l a c t i v i t i e s i n t h e p ro jec t area.

8. Duties of the Dam Operator.-- The D a m Operator o r h i s a l t e r n a t e is required t o perform the following dut ies :

a . B e present a t the dam when r a i n f a l l o r runoff occurs.

b. See t h a t a l l equipment a t the p ro jec t , including recording and ind ica t ing gages, ga te mechanism, power u n i t s , radio, e t c , , is i n operat ing condition.

c. Operate the gates i n accordance with ins t ruc t ions from the Operations Branch, Construction Division.

d. Follow the f ixed gate operat ion schedule posted i n the con t ro l house i n the absence of communications with the Operations Branch, Construction Division, o r i n the absence of a representa t ive from t h a t group.

e , Service a l l gages and recorders, wind the clocks, i n s t a l l new records, paper, e t c .

f . Guard the p r o j e c t agains t vandalism, sabotage, and f i r e s .

g. Guard aga ins t unsafe conditions i n the projec t area.

h. Report on t respass ing and encroachment on rights-of-way.

i. Maintain records, including water surface e levat ions , outflow gage heights , p r e c i p i t a t i o n amounts, ga te openings, and logs a l l radio and telephone c a l l s on prescribed forms.

j, Keep premises and equipment clean and i n good repa i r ; pa in t ing w i l l be performed by t h e Dam Operator when necessary. On l a r g e r jobs requir ing sandblast ing and painting, the maintenance crew w i l l a s s i s t .

k. Per iodic inspections of s t r u c t u r e s , eqdpment, and the p ro jec t a rea s h a l l be made by t h e Dam Operator o r h i s a l t e r n a t e t o determine maintenance measures t h a t a r e required. These inspections during the non-flood seasons s h a l l b e made a t i n t e r v a l s of no t more than 90 days; during the f lood seasons a t i n t e r v a l s of not more than 30 days;

a l s o immediately following each flood. More frequent inspections s h a l l be made i f required, f o r the s a f e t y and e f f i c i e n t maintenance of some fea tu res of the p ro jec t . During each inspection, items re-qu i r ing maintenance s h a l l be checked and described on the inspect ion check l i s t included a s Exhibit E. Af ter each inspection, one inspect ion check list s h a l l b e promptly submitted t o Chief, Engineering Evaluation and Inspection Section, Operations Branch. Maintenance s h a l l b e performed by t h e Dam Operator, i f f e a s i b l e . Note: I f maintenance requires add i t iona l labor o r equipment, the Dam Operator s h a l l no t i fy the Chief, Maintenance Section, of the recommended maintenance measures required. Normal maintenance a h a l l b e made without delay.

1. The Dam Operator o r h i s a l t e r n a t e s h a l l test operate t h e se rv ice gates and e l e c t r i c a l f a c i l i t i e s i n the control house every 30 days and the standby power u n i t every 15 days. Test operat ion repor t s (Exhibit F) s h a l l be completed i n t r i p l i c a t e , a f t e r each test.

One copy s h a l l b e promptly submitted t o the Chief, Maintenance Section, one copy t o the Chief, Engineering Evaluation and Inspection Section, and one copy kept on f i l e i n the con t ro l house of the dam.

Reservoir and Embankments

9. Dam.-- Ful ler ton Dam is a compacted earthblll s t ruc tu re . It i s approximately 575 f e e t long, 15 f e e t wide a t the c r e s t , and 46 f e e t high with c r e s t e levat ion a t 307 f e e t . The upstream face a s w e l l as t h e downstream face has a s lope of 1 on 4 t o e levat ion 285 and 1 on 3 from elevat ion 285 t o the c r e s t . The upstream s lope is paved with a 2-foot b lanket of graded r ip rap placed on a 12-inch gravel blanket and the downstream s lope i s covered with a 12" gravel blanket. A rock dra in , c u t i n the o r i g i n a l ground under the dam, is p a r a l l e l t o and 68 f e e t downstream from t h e a x i s of the dam and is connected t o the o u t l e t channel by a 36-inch concrete pipe. (See drawings 431111 and 431112 of Exhibit C.)

10. Inspections and maintenance.-- The Dam Operator o r h i s a l t e r n a t e s h a l l perform per iodic inspections and maintenance and s h a l l complete inspect ion check l i s t as shown i n Exhibit E. Maintenance work is described i n d e t a i l i n the following paragraphs:

a . Embankments .-- Maintenance methods f o r r epa i r o r reconstruct-ion of the embankments s h a l l depend upon the ex ten t of the damaged sect ion. I f the embankment damage is small, sand and gravel o r o ther coarse granular material may be placed i n 6-inch l ayers t o r e s t o r e the embankments. I f the damage is la rge , the f i l l s h a l l b e made i n the same manner as the o r i g i n a l construction. Homogeneo# material from borrow p i t s approved f o r the p ro jec t s h a l l b e placed i n uniform hor izon ta l l aye rs no t more than 6-inches i n depth and compacted t o a densi ty equal to the o r i g i n a l embankment sec t ion , b . Concrete and r ip rap , -- Damaged concrete o r r iprap s t r u c t u r e s s h a l l be repaired promptly. Broken concrete surfaces and exposed reinforcement steel s h a l l b e thoroughly cleaned by chipping o r sandblast ing and s h a l l b e b u i l t up t o the o r i g i n a l dimensions;

pneumatically placed portland-cement mortar is s a t i s f a c t o r y f o r t h i s work. Small cracks i n the concrete may be f i l l e d with asphal t .

Any ind ica t ion of set t lement, u p l i f t o r f a i l u r e of concrete s t r u c t u r e s s h a l l be reported t o the Chief, Operations Branch.

c, Access roads and berms.- Access roads and embankment toe berms s h a l l b e adequately maintained f o r vehicular t r a v e l so t h a t ordinary maintenance of t h e p ro jec t and flood-fighting operat ions w i l l be f a c i l i t a t e d . The c r e s t s with the roadway on the dam s h a l l be w e l l crowned and maintained t o d ra in readi ly .

d. Fences.-- Maintenance of the rights-of-way and s a f e t y guard fences s h a l l include keeping (1) l i n e posts firmly set and gates hung i n good alinement; (2) barbed w i r e t i g h t and broken s t rands repaired; (3) corner pos ts , ga te pos ts , and braces firmly set; (4) posts , braces, and gates t h a t require pa in t properly brush painted;

and (5) chains and locks at tached t o a l l gates.

e. Vegetation.-- Weeds and brush on the embankments s h a l l b e mowed i n May and August, and more o f t en i f they i n t e r f e r e with proper inspect ion of the embankments and adjacent areas f o r se t t lement , seepage, and burrowing animals. After removal, weeds and brush s h a l l b e sa fe ly burned i n accordance with the regulat ions of the l o c a l f i r e department.

f . Burrowing animals.-- Burrowing animals i n o r near the dam s h a l l be exterminated. Their runways and dens s h a l l b e opened up and thoroughly compacted a t the same t i m e they a r e backf i l led .

Trapping and poisoning may be used f o r the extermination of burrowing animals. Information about o ther methods of animal extermination may be obtained from the county a g r i c u l t u r a l agent.

g. Hazardous &structions.-- Reservation area used by authorized personnel s h a l l b e kept f r e e from obstructions t h a t may cause in jury o r impede inspection, maintenance, o r flood-fighting operations. Materials and aux i l l a ry construction equipment s h a l l b e s to red i n such a way t h a t they a r e not hazardous t o personnel o r capable of f l o a t i n g i n t o t h e gate s t ruc tu re .

a . During f lood periods, the embankments s h a l l be pa t ro l l ed continuously t o l o c a t e poss ib le sand b o i l s o r unusual wetness of the downstream s lope and t o take appropriate cor rec t ive measures f o r t h e following conditions:

(1) Indicat ions of s l i d e s o r sloughs developing.

(2) Wave wash o r scouring ac t ion.

(3) Other conditions which might endanger the s t ruc tu re .

(4) Inadequate l abor and mater ia ls t o meet a l l contingencies.

Immediate s t e p s s h a l l be taken t o con t ro l any condition which endangers the embankments and t o r e p a i r the damaged sect ion.

b . The p ro jec t works s h a l l b e continuou@y pa t ro l l ed during periods of f lood flow during which the water s t age i n the rese rvo i r reaches o r exceeds e leva t ion 275. A s t o r e of suppl ies and equipment ava i l ab le f o r emergency flood-fighting operations and emergency re-p a i r s s h a l l be maintained. I n t h i s connection, a copy of the l a t e s t revised "Natural Disaster A c i t i v i t i e s , OM 500-1-1" s h a l l be consulted f o r suggested methods of combating f lood conditions. Operating personnel assigned t o the p ro jec t s h a l l a t once dispatch a message t o the Chief, Regulation and Meteorology Section whenever t h e water surface reaches the f lood s t age indicated above, and a l s o keep him advised a t frequent i n t e r v a l s of p ro jec t conditions u n t i l the re-s e r v o i r s t age recedes t o e levat ion 275.

Out le t S t ructures

12. Main features.-- The o u t l e t s t r u c t u r e s cons i s t of an unlined approach channel, a rock-faced in take channel, a reinforced concrete in take , a ga te tower, a control house with se rv ice bridge, a concrete conduit through the dam, a reinforced concrete s t i l l i n g basin, and an e x i t channel.

13. Approach and in take channel.-- The approach and in take channel i s t rapezoidal i n sec t ion with a bottom width of 20 f e e t and s i d e slopes 1 on 2. The approach channel i s 815 f e e t i n length and unlined. The in take channel is paved with a 12-inch l a y e r of grouted rock on a 6-inch gravel blanket f o r a length of 52 f e e t . The in take s l ab of reinforced concrete extends from s t a t i o n 8+67.04 t o the t r a sh racks. Inver t e l eva t ion is 261. (See drawings 431/5 and 431/20 of Exhibit C.)

14. In take tower.-- The in take tower i s a reinforced concrete s t r u c t u r e with a t o t a l he ight of 60.9 f e e t . An 18-inch f l o a t recorder w e l l is provided f o r a water l e v e l recorder i n the control house, and a 30-inch OD pipe connects t h i s f l o a t w e l l with the outdoor w e l l a t approach channel s t a t i o n 8+17. The outdoor we l l i s connected t o the rese rvo i r by three 3-inch pipes at e levat ions 262.00, 264.00, and

266.00. I f necessary, the gates may be removed through a hatch i n the control room f l o o r by a chain h o i s t hung from a U-bolt i n the control room ce i l ing . (See drawings 431121 through 431126, of Exhibit C .)

15. The gate con t ro l house.-- This i s a reinforced concrete s t r u c t u r e , 16 by 19 f e e t ins ide and 1 3 f e e t high. Access from t h e main dam roadway t o the control house i s provided by a s t e e l g i rde r bridge (design loading is H-20) approximately 60 f e e t long, 10 f e e t across the deck, and with s t e e l p ipe s i d e r a i l i n g s , (See drawings 431121, 431122, and 431124, of Exhibit C.)

16. Gated o u t l e t s .-- There a r e two 3-by 5-foot gates i n the base of the gate tower a t i n v e r t e levat ion 261, separated by 8 f e e t of concrete. The discharges from the gate openings merge and a t s t a t i o n 9+21.5 e n t e r a s i n g l e 4-by 6-foot conctete conduit which extends through the dam embankment and en te r s the s t i l l i n g bas in a t s t a t i o n 12+50. The metal s l i d e gates a r e operated by motor-driven screw-stem h o i s t s located i n the con t ro l house. An 8-inch a i r vent pipe is provided f o r each of the two gates. (See drawings 431122, 431/23, and 431127, of Exhibit C.)

17. Ungated outlet.-- A 3-by 2-foot ungated by-pass with entrance c r e s t a t e levat ion 275 is provided t o prevent permanent s torage above that: elevation. A t r a n s i t i o n s e c t i o n with l e v e l i n v e r t a t e levat ion 261 extends about 26 f e e t downstream and merges the flows from t h e gated and ungated openings and d i r e c t s them i n t o the o u t l e t conduit.

With t h e pool a t spillway c r e s t l eve l , e l eva t ion 290, the capacity of t h e ungated by-pass under t h i s condit ion of head is 200 cubic f e e t per second. (See drawing 431122, of Exhibit C.)

18. Out le t conduit.-- A s i n g l e concrete conduit sec t ion connects with the gate chamber and continues through the dam. This conduit is 328.5 f e e t long with a s lope of 0.00189. It consis ts of 17 sec t ions .

The ins ide dimensions a re 4 f e e t i n width and 6 f e e t i n height with a waste water p ipe l ine recess below, approximately 2 feet deep by 2 f e e t wide. (See drawings 431127 t o 431129, of Exhibit C.)

19. Out le t channel and s t i l l i n g basin,-- The o u t l e t conduit discharges i n t o a concrete o u t l e t channel about 167 f e e t long, 4 to 11 f e e t wide, and with w a l l s varying i n height from 9 t o 17 f e e t . It s lopes from e leva t ion 260.4, i n v e r t of conduit a t exit, t o e levat ion 243 a t the i n v e r t of the s t i l l i n g basin. A drainage system f o r r e l i e f of hydros ta t i c pressures behind the wal ls has been provided. The drainage system consis ts of weepholes, 4-inches i n diameter, spaced at 10 f e e t on centers through the wal ls t o discharge the water co l l ec ted i n g rave l - f i l l ed trenches 2 f e e t deep by 1-foot 6-inches wide. The s t i l l i n g bas in continues about 33 f e e t , r i s i n g t o a l i p e levat ion of

248.1 f e e t . A 242-foot long trapezoidal sec t ion , with 8-foot bottom width and s i d e slopes 1 on 2, provides an e x i t channel f o r the s t i l l i n g basin. This channel and the above 33-foot sec t ion of s t i l l i n g bas in are l ined with grouted rock. The grouted rock paving i s 12-inches th ick on a 6-inch gravel backing f o r the s i d e slopes and is 18-inches th ick f o r the i n v e r t s , except a t the upstream and downstream ends where the channel l i n i n g is thickened by trenches f i l l e d with derr ick stone. A chain l i n k s t e e l fence s t rung on steel posts and topped with barbed w i r e serves as a s a f e t y guard f o r the channel and s t i l l i n g basin. (See drawings 431130 and 431131, of Exhibit C.)

20. Inspections and maintenance.--a . Adequate measures s h a l l be taken by the Dam Operator t o insure t h a t i n l e t and o u t l e t channels a r e kept open and t h a t t rash , d r i f t o r debr is i s not allowed to accumulate near i n l e t o r o u t l e t s t ruc tu res .

The o u t l e t conduit s h a l l be inspected annually during the period of low water , and set t lement o r o ther conditions a f fec t ing functioning of the s t r u c t u r e s h a l l be noted. Per iodic inspections s h a l l be made (See P a r t 11, paragraph 8) to b e c e r t a i n tha t :

(1) Pipes, gates, operat ing mechanisms, r iprap, and a l l channel and other s t r u c t u r e wal ls a r e i n good condition.

(2) I n l e t and o u t l e t channels a r e open.

(3) Approach and o u t l e t channels a r e s u f f i c i e n t l y c l e a r of obs t ruct ions and debr is t o permit proper functioning of the p ro jec t works.

(4) Care is being exercised t o prevent the accumulation of t rash near the s t r u c t u r e s .

(5) Erosion i s not occurring adjacent to the s t r u c t u r e s which might endanger t h e i r water t ightness or s t a b i l i t y ,

(6) Safety guard fences a r e i n good condition. Immediate s t eps w i l l be taken t o r e p a i r damage, replace missing o r broken p a r t s , o r remedy adverse conditions disclosed by such inspections.

b. A t each pe r iod ic inspect ion the following items, i f applicable, s h a l l be p a r t i c u l a r l y noted:

(1) Damage o r set t lement of concrete pipe o r conduit.

(2) Condition of gate l ea f guides, stems, and h o i s t s .

(3) Condition of e l e c t r i c a l f a c i l i t i e s .

(4) Condition of se rv ice bridge t o control house.

(5) Condition of control tower.

(6) Condition of control house.

(7) Condition of embankment adjacent t o o u t l e t s t r u c t u r e s .

(8) Condition of r ip rap o r s tone blankets adjacent t o o u t l e t s t r u c t u r e s .

(9) Condition of approach and egress channels.

(10) Condition of s a f e t y fence.

(11) I f the inspect ion shows t h a t the control gates have been jammed by debr is o r o ther obstructions, they s h a l l be thoroughly cleaned s o t h a t they operate f ree ly t o a f u l l closure.

c. Damaged concrete o r r iprap s t r u c t u r e s s h a l l be repai red promptly. Broken concrete surfaces and exposed reinforcement steel s h a l l be thoroughly cleaned by chipping o r sandblast ing and s h a l l b e b u i l t up t o the o r i g i n a l dimensions; pneumatically-placed port land cement mortar is s a t i s f a c t o r y f o r t h i s work. Small cracks i n the concrete may be f i l l e d with asphal t . Any indicat ion of set t lement, u p l i f t , o r f a i l u r e of concrete s t r u c t u r e s s h a l l b e reported t o the Chief, Operations Branch, f o r analys is and f o r recommendation on remedial ac t ion.

Spillway

21. Main features.-- The spillway is detached from the embankment, and i s located through t h e h i l l s forming the e a s t abutment, nor theas t of t h e dam. It includes an approach channel, a control sec t ion, and an e x i t channel. (See drawings, 431115, of Exhibit C.) The t rapezoidal approach channel is approximately 300 f e e t long, i n v e r t e levat ion is 282, and s i d e slopes a r e 1 on 2. A t the upstream end of the spillway channel is a gravi ty ogee 8 f e e t high and 40 f e e t long with c r e s t e levat ion 290 f e e t . A twenty-foot steel shee t p i l i n g cutoff is provided under the ogee t o reduce seepage under the s t ruc tu re . The reinforced concre.te spillway channel i s of rec tangular cross sec t ion, 40 f e e t wide and 12 f e e t high. The i n v e r t s l a b of the channel is provided with t i l e and gravel drains. The channel terminates i n a f l i p bucket which is designed t o re turn the flow t o streambed e levat ion with a minimum of scour. Lip e levat ion i s 270. A cut-off w a l l of steel shee t p i l i n g 25 f e e t long i s provided across the end of the bucket. The exit channel i s approximately 250 f e e t long and 40 f e e t wide with s i d e slopes of 1 on 2. Derrick s tone is placed on i n v e r t and s i d e s lopes at the termination of the concrete channel, extending downstream 20 f e e t from the bucket. A sa fe ty fence is provided along t h e spillway channel wal ls . The fence consis ts of 3 f e e t of chain l i n k fencing s t rung on 1-518-inch OD s t e e l tubing grouted i n t o formed holes on 10-foot centers . The chain l i n k fencing i s topped with two s t rands of barbed w i r e . The Associated Road required a bridge across the spil lway channel. It is a c l e a r span s t r u c t u r e with a 42-foot span and a 20-foot roadway and i s designed f o r an H-20 loading. The bridge abutments a r e an i n t e g r a l p a r t of the channel walls . (See drawings 431115 t o 431119, of Exhibit C.)

22. Inspections and maintenance.--a . Adequate measures s h a l l b e taken by the Dam Operator t o insure t h a t i n l e t and o u t l e t channels a r e kept open, and tha t d r i f t o r debr is is not allowed t o accumulate upstream o r downstream from the ogee.

The spillway s h a l l be inspected annually during the low water season, and se t t lement o r o ther condit ions a f f e c t i n g functioning of the s t r u c t u r e s h a l l b e noted. Per iodic inspections (See P a r t 11, para-graph 8) s h a l l be made t o b e c e r t a i n tha t :

(1) A l l channel wa l l s a r e i n good condition.

(2) I n l e t and o u t l e t channels a r e open, and a r e s u f f i c i e n t l y c l e a r of obs t ruct ions and debr is t o permit proper functioning of the spillway.

(3) Erosion i s not occurring adjacent t o the s t r u c t u r e which might endanger i t s water t ightness o r s t a b i l i t y .

(4) Safety guard fences a r e i n good condition. Immediate s t eps w i l l be taken t o r e p a i r damage, replace missing o r broken p a r t s , o r remedy adverse conditions d isc losed by such inspections.

Service Gates and Hoists

a. I n the in take tower a r e two gates , 3 f e e t wide and 5 f e e t high. Inver t of f l o o r is a t e levat ion 261.0. Each gate is operated independently by a screw s t e m h o i s t mounted d i r e c t l y over i t on the f l o o r of the control house a t e levat ion 307.25. The design head, measured from the water su r face a t m a x i m u m spillway f lood t o center-l i n e of the gate l ea f is 34.5 f e e t . (See drawings 431151 t o 431161, of Exhibit C.)

b . Assembly .-- The assembly consis ts of the gate l e a f , the upstream and downstream gate frames, ga te frame extension, gate s t e m , s t e m . guides, air vent , and h o i s t floo; s tand. (See drawing 431151, of Exhibit C.)

c. Gates and gate seals.-- The gate l e a f s are constructed of c a s t i r o n and a r e c a s t i n one piece. The bottom s e a l is made by contact of the l ea f and a babbi t ted s i l l i n the gate frame. The gate l ea f weighs approximately 1,300 pounds, and i s connected t o the h o i s t by a copper n ickel a l loy s t e m 3.5 inches i n diameter, Stem guides a r e provided, mounted on 8-foot 7-inch centers .

d. Gate h o i s t s .-- Each gate is provided with a screw stem h o i s t manufactured by the King Manufacturing Company of Los Angeles. These h o i s t s a re located i n the control house a t e levat ion 307.25. The small ga te a rea and the low head of only 34.5 f e e t on gate centers , r e s u l t s i n a very moderate gate s t e m p u l l , permit t ing the use of a h o i s t of small s i z e , l i g h t i n weight, and occupying a minimum of f l o o r space. Motor controls a r e located on each h o i s t . Each h o i s t motor l i f t s and lowers a gate through a t r a i n of spur and worm gears a t an approximate speed of 1-foot per minute. Each gate i s provided with a mechanical pos i t ion ind ica to r mounted on the h o i s t and v i s i b l e from the motor control . L i m i t switches s top each gate l e a f a t i t s upper and lower l i m i t of t r ave l . Each h o i s t is provided with a wheel f o r hand operat ion, i n the event of f a i l u r e of both outside and standby power. The bearings and gears i n each h o i s t a r e greased through a standard grease-gun system with "Alemite" f i t t i n g s . The worm-gear assemblies a r e lubr ica ted by sight-feed o i l caps, which a r e turned on only during the operat ion of each h o i s t . (See drawing 431161, of Exhibit C.)

24 . Inspection and maintenance.-- The Dam Operator o r h i s a l t e r n a t e s h a l l perform per iodic inspections and maintenance and s h a l l complete inspect ion check l i s t s as described i n P a r t 11, paragraph 8 of t h i s manual. Maintenance work per ta in ing t o se rv ice gates and h o i s t s is described i n the following paragraphs.

a . General.-- The gate and h o i s t assemblies s h a l l be maintained i n the b e s t poss ib le operat ing condition. Repairs, which s h a l l be made by e l e c t r i c i a n s and mechanics from the M s t r i c t Base Yard, s h a l l conform to standard requirements f o r the type of work involved. Loose, damaged, unserviceable, o r missing p a r t s s h a l l be promptly tightened, repai red , o r replaced.

b. Gates.-- Gates must come t o a t r u e and water t ight c losure agains t the bottom s e a l s . Gate-seal surfaces s h a l l be kept c lean and f r e e from mud and sand, and the bottom sea l ing surface s h a l l be kept f r e e of rocks o r o ther obstructions. To minimize the adhesion of abrasive dust and sand, the gate s e a l s , the gate frame s e a l s , and gate guides s h a l l never be lubr ica ted . Also, the gate stems and gate s t e m guides s h a l l b e kept clean and completely f r e e of lubr icant . The gate stems a r e monel metal and a r e not a f fec ted by water. The function of the s t e m guides i s t o prevent each s t e m from buckling i n case a gate leaf s e a t s on a log o r rock. To operate gates s e e Exhibit G.

c. Hoists and motors .-- The h o i s t s s h a l l operate smoothly and without abnormal noise o r v ibra t ion. Gates s h a l l s top a t the upper limits of t r a v e l and s h a l l c lose t i g h t l y without shock. A t l e a s t twice each year ball-bearing grease s h a l l be applied t o the bearings and gears of each h o i s t and the threads of each h o i s t s t e m .

The sight-feed o i l caps on the worm-gear assemblies s h a l l be r e f i l l e d with S. A. E. 20 motor o i l before they become empty. The h o i s t motors s h a l l b e lubr ica ted and maintained by qua l i f i ed e l e c t r i c i a n s from the Base Yard.

d. Painting.-- Exposed metal surfaces s h a l l be painted o f ten enough t o prevent r u s t and t o maintain a c lean presentable appearance.

Surfaces s h a l l be thoroughly cleaned before paint ing; o i l and grease s h a l l be removed with s u i t a b l e solvents and clean cotton rags; and r u s t spots and loose pa in t , with s t i f f w i r e brushes. Pa in t s h a l l be applied i n a workmanlike manner and i n accordance with the applicable paragraphs of the o r i g i n a l construction and supply speci f ica t ions .

Gates, ga te frames, ga te s t e m guides, t r a s h racks, and o the r metal surfaces exposed t o water s h a l l be painted with one coat of red lead and one coat of aluminum paint . The h o i s t f l o o r stands s h a l l be painted with a base coat of pure red lead o r machinery f i l l e r followed by a matching shade of pearl-gray machinery enamel.

25. Test operat ion of gates.-- The Dam Operator o r h i s a l t e r n a t e s h a l l test operate the two se rv ice gates on o r near the f i r s t day of every month and s h a l l complete and transmit test-operation repor ts as described i n t h i s manual. (See P a r t 11, paragraph 8.) Each month one gate s h a l l b e operated by standby power and the o ther gate s h a l l b e operated by Edison Company power. The source of power used t o operate each gate s h a l l be a l t e rna ted from month t o month. (See Exhibits G, H, and I which i l l u s t r a t e s operat ion of the gate h o i s t s , the standby generator engine, and the switchboard, respectively.)

26. Five-Year inspect ion and maintenance.-- Five-year inspection and maintenance t o be done by mechanics from the Maintenance Section on gate h o i s t gear reducers:

a . Remove inspect ion p l a t e and d ra in plug.

b. Flush out gear case and inspect gears and bearings.

c. Add f resh o i l (SAE 50 Mineral Type, AGMA #5 turbine o i l ) .

E l e c t r i c a l F a c i l i t i e s

27. Power supply.-- E l e c t r i c a l energy i s supplied to the p ro jec t by the Southern Cal i fornia Edison Company. A 2,100-foot extension of an Edison 3-phase 11,5QO-volt l i n e runs north to the se rv ice transformer rack located j u s t w e s t of the turnaround a t the west end of the dam c r e s t , about 300 f e e t southwest of the control house. From t h i s point , 3-phase power and single-phase l i g h t i n g a t 460 v o l t s i s ca r r i ed underground t o a manhole on the c r e s t of the dam a t the south end of the service bridge. The two services , consis t ing of a 3-conductor and a 2-conductor No. 8 lead cable a r e ca r r i ed t o the manhole i n separa te runs of r i g i d steel conduit i n the same t rench.& From t h i s manhole, the two services a r e ca r r i ed i n t o the control house i n r i g i d steel conduit ca r r i ed beneath the se rv ice bridge. Nominal l i n e voltage of 440 is stepped down t o 110-220 v o l t s , 3-wire, f o r l i g h t i n g by a 7-112 KVA air-cooled single-phase transformer mounted above the switchboard on the w e s t w a l l of the control house. Hoist motors a r e 3-phase, 440 v o l t s , 60 cycles. Control f o r a l l power and l i g h t i n g c i r c u i t s is centra l ized a t one switchboard. (See drawings 431/39 t o 431142, of Exhibit C.)

28. Standby generator.-- The standby power u n i t consis ts of an al ternating-current generator, driven by a d i e s e l engine. The generator suppl ies e l e c t r i c a l energy f o r power and l i g h t s whenever power company se rv ice f a i l s . A 6-cylinder In te rna t iona l Diesel Engine, Model UD 236, dr ives a Palmer a l t e r n a t o r r a ted a t 30 KW,2400 RPM, 60 cycles a t 480 v o l t s . The standby power u n i t takes ca re of the connected load. A 280 gallon tank, under the service bridge near the control house i s f i l l e d and measured through e i t h e r of two 9-inch hatch-covered handholes i n the bridge f loor . The tank i s vented i n t o the open a i r under the bridge. An American Bosch EPS-B-30 Hydrotor is used to s t a r t the d i e s e l engine. (See Exhibit I f o r s t a r t i n g standby power u n i t .)

29. Switchboard.-- A switchboard i n t h e control house controls power and l i g h t i n g c i r c u i t s . Separate a i r c i r c u i t breakers control incoming power and l i g h t services from both the power company and standby generator. Transfer switches permit s e l e c t i o n of e i t h e r source of energy f o r both power and l i g h t s .

30. Operation of e l e c t r i c a l f a c i l i t i e s . - - Operation of the e l e c t r i c a l f a c i l i t i e s is described i n d e t a i l i n the following paragraphs. A l l - -references t o exh ib i t s r e f e r t o Exhibits H and I. The i o c i t i o n on the switchboard of the instrument and c i r c u i t breakers a r e shown on Exhibit J.

a. Transferr ing p lan t to standby service.-- I n t r ans fe r r ing the p l a n t t o generator se rv ice from Edison Company se rv ice , use ins t ruc t ions shown on Exhibit J. Check voltmeter on generator s i d e t o make c e r t a i n t h a t generator i s up to f u l l voltage. --.

b. Transferr ing p l a n t t o Edison Company service.-- To t r a n s f e r t o Edison se rv ice , use ins t ruc t ions shown on Exhibit I.

c. Shutt ing down p l a n t during emergencies.-- I n shu t t ing down p l a n t during emergencies, use ins t ruc t ions shown on Exhibit I.

CAUTION: Never use t r a n s f e r switches to open c i r c u i t under load.

3@. Inspection, maintenance, and tests.-- The purpose of,maintenance work is t o insure continuous s a t i s f a c t o r y operation of equipment. It is, therefore, important i n such work t h a t ill poss ible causes of t rouble be found and corrected. P a r t i c u l a r a t t e n t i o n should be paid t o minor weaknesses which may lead t o fu tu re trouble. A t i n t e r v a l s of not t o exceed 30 days, a l l movable equipment s h a l l be inspected to make c e r t a i n t h a t i t i s properly lubr ica ted and ready f o r i n s t a n t use. An adequate supply of lubr ican t s f o r a l l moving machinery, f u e l f o r power equipment, and f l a s h l i g h t s f o r emergency l i g h t i n g s h a l l be kept on hand a t a l l t i m e s . Telephone service s h a l l be continuously maintained. A l l equipment, including switch-gear and transformers, s h a l l be tr ial-operated every 30 days; and the standby un i t , every 15 days. Megger tests of a l l insu la t ion s h a l l be made whenever wiring has been subjected to undue dampness. Only s k i l l e d e l e c t r i c i a n s and mechanics from the Base Yard s h a l l be employed on t e s t s - a n d repai rs . Any equipment removed from the control house f o r r epaf r o r replacement s h a l l be returned o r replaced as soon a s p rac t i cab le and s h a l l b e tr ial-operated a f t e r r e i n s t a l l a t i o n .

Test-operation repor ts and inspect ion check l i s t s s h a l l be completed and submitted a s described i n P a r t 11, paragraph 8. Inspection, maintenance, and t e s t s a r e described i n the following paragraphs:

a. Control house.-- The con t ro l house s h a l l be clean and orderly and i n a s t a t e of good r e p a i r a t a l l t i m e s , both ins ide and outs ide .

A l l plumbing connections s h a l l be t i g h t and f r e e from leaks. Metal p a r t s and the f loors s h a l l be per iodical ly painted. Care s h a l l be taken t h a t a l l l i g h t bulbs a r e operable. Windows, louvers, and doors s h a l l be i n condition t o exclude dust and the elements, and s h a l l be closed and locked a t a l l times when the bui ld ing is unoccupied.

The f lood l igh t s s h a l l be covered with detachable metal p l a t e s t o p ro tec t them from vandalism.

b. Power supply.-- Although a standby u n i t is provided, re-l i a n c e f o r power t o operate the e l e c t r i c a l f a c i l i t i e s a t the p ro jec t is primari ly placed on the Southern Cal i fornia Edison Company. Any conditions noted i n the inspections t h a t may a f f e c t i n any way the r e l i a b i l i t y of the p ro jec t power supply s h a l l be brought t o the a t t e n t i o n of t h a t company's l o c a l representat ive. The Chief, Maint-enance Section, s h a l l a l s o be no t i f i ed . No maintenance is required f o r power supply a s t h i s i s the respons ib i l i ty of the Southern Cal i fornia Edison Company.

c. Standby power unit .-- The standby power u n i t s h a l l be test-operated on o r near t h e 1st and 16th days of every month, Test-operation repor ts s h a l l be completed and submitted as described i n P a r t 11, paragraph 8. .

d. Switchboard.-- The switchboard and appurtenances s h a l l be kept clean and f r e e from dust by blowing with compressed air. Doors of a l l cabinets s h a l l b e kept closed t o exclude dust . Switches s h a l l be kept e l e c t r i c a l l y and mechanically operable, and a l l e l e c t r i c a l c i r c u i t s s h a l l b e maintained f r e e from shor t s and grounds and i n an operable condition a t a l l times. A l l necessary maintenance work and replacements s h a l l b e done only by s k i l l e d e l e c t r i c i a n s and mechanics, with p a r t s equal i n qua l i ty t o those o r i g i n a l l y i n s t a l l e d .

e. Outside lighting.-- A t t he t i m e of each regular inspection, a l l outside l i g h t i n g c i r c u i t s s h a l l be tr ial-operated t o make c e r t a i n t h a t a l l e l ec t r i ca l -wi r ing and lamps are i n operable condition. Any trouble with these c i r c u i t s s h a l l b e remedied a t once.

32. Five-Year inspection and maintenance.-- Five-year inspection and maintenance t o be done by mechanics from the Maintenance Section on standby generator:

a . Remove o i l pan and inspect bearings.

b. Clean o i l pump s t r a i n e r .

c. Remove sludge from o i l pan.

d. Add f resh o i l t o crankcase.

e. Clean f u e l tank.

f. Comply with manufacturers pe r t inen t maintenance ins t ruc t ions before replacing o i l pan. NOTE: A repor t s h a l l be submitted 15 days a f t e r the inspection and maintenance is accomplished t o the Engineering Evaluation and Inspection Section from the Maintenance Section.

Comm…