Reference_-_Bridge_Ops_Manual_2022_2f_3.pdf

Operation and Maintenance of Ohmsett Contract E17PC00014

Bridge Systems Operation Procedures

Prepared for:

Bureau of Safety and Environmental Enforcement (BSEE) Contracting Officer’s Representative (COR)

Frank Jurado BSEE Oil Spill Preparedness Division

45600 Woodland Road Sterling, VA 20166

Email: Frank.Jurado@bsee.gov Ph. 571-279-7896

Prepared by:

Applied Research Associates, Inc.

Operating Contractor

Ohmsett Facility Naval Weapons Station Earle (NWSE)

Waterfront Route 36 P.O. Box 150, Leonardo, NJ 07737

Date: September 30, 2022

Operation and Maintenance of Ohmsett Contract E17PC00014 i

TABLE OF CONTENTS

1. REQUIREMENT

2. APPROACH

3. BRIDGE SYSTEM CONFIGURATION AND ADJUSTMENT

4. SYSTEM OPERATION

4.1. SYSTEM CHECK

4.2. OPERATING THE MAIN BRIDGE

5. BRIDGE DRIVE MAINTENANCE

5.1. BRIDGE CONNECTIONS

5.2. BRIDGE DRIVE CABLES CARE

5.3. CABLE TENSION ADJUSTMENTS

5.4. CABLE TENSIONING PROCEDURE

5.5. CONVERSION OF BRIDGE DRIVE SYSTEM FROM MASTER ONLY TO DUAL DRIVE

5.6. CONVERSION OF P&H BRIDGE DRIVE SYSTEM FROM DUAL DRIVE TO MASTER ONLY

5.7. WINCH

5.8. DRIVE TRANSMISSION

5.9. P&H ELECTRO-TORQUE

5.10. FESTOON AND FAIRLEADS

6. ANCILLARY COMPONENTS

6.1. SLOWDOWN AND STOP LIMIT SWITCH CONTROL CIRCUIT

6.2. BRIDGE SPEED AND DISTANCE METERS

APPENDIX A. CHECKLIST: OHMSETT FACILITY BRIDGE OPERATION

TABLE OF FIGURES

Figure 1. Top View of Ohmsett Bridge Systems

Figure 2. Cable Clamp Used to Attach the Vacuum Bridge to the Main Tow Cable

Figure 3. Bridge Drive HMI Control Panel

Figure 4. Motor Enable/Disable Screen

1. REQUIREMENT

Contract E17PC00014, Task Order E17PD00117, Section 2.4.1.12.E Detailed Operations Manuals. These manuals detail required routine activities and are to be used as references by the Contractor in operating the systems described. These manuals also guide the routine operations and maintenance of the facility.

The Contractor shall update the manuals as needed when major changes occur.

2. APPROACH

This manual describes the bridge drive control system and the three Ohmsett bridges, their function, operational procedures, and routine maintenance. The bridges, which traverse the Ohmsett test basin, are each capable of traveling up and down the length of the basin via two parallel tracks installed along the top of each wall of the basin. The main bridge, which is the primary drive bridge, is cable-driven and can attain speeds up to 6.0 knots or 10.1 feet/second (f/s). The auxiliary bridge and vacuum bridge can also be attached to the drive cable. The bridges can be positioned at various distances relative to one another. This allows flexibility in the configuration of test equipment and instrumentation to meet the test requirements (Figure 1).

Figure 1. Top View of Ohmsett Bridge Systems

3. BRIDGE SYSTEM CONFIGURATION AND ADJUSTMENT

The diversity of testing available at Ohmsett is facilitated by the numerous positional configurations utilizing the main, auxiliary, and vacuum bridges. These bridges can be positioned at any distance parallel to each other. This will depend on the required operations scheduled during testing. One typical configuration would consist of the auxiliary and main bridge at approximately 250 feet (75 meters) apart.

The main bridge is fixed to the cable drive system; therefore, is considered a reference point. The auxiliary and vacuum bridges are fastened to the cable drive system by compression-type clamps. Obtaining the desired distance between main and auxiliary or vacuum bridges can be accomplished by manually guiding the bridges to the required distance from the main bridge. A second method is to operate the main bridge, and position it to the desired distance from the auxiliary or vacuum bridges. Once the bridges are approximately positioned, an accurate measurement must be taken between the established data on each bridge. The bridge distance will be measured using a single continuous tape. The resulting measurement error should not exceed 1/16-inch. When tightening the compression clamps of the auxiliary and vacuum bridges, alternate from bolt to bolt across the cable, gradually increasing torque until sufficiently tight. (The recommended dry torque for 3/4-inch SAE Grade 3 bolts is approximately 230 foot-pounds). A photo of one of these clamps is shown in Figure 2.

Figure 2. Cable Clamp Used to Attach the Vacuum Bridge to the Main Tow Cable

4. SYSTEM OPERATION

4.1. SYSTEM CHECK

Before operating the bridge system, it is necessary to perform a visual check of the mechanical system.

This is accomplished as follows.

Ensure the system power is “ON” in all the drive cabinets on the first floor of Building R-26.

• Confirm that there are no fault signals on the DC drives (total of four).

• Proceed along the west side of the tank and verify the cable tray and rail are clear and properly aligned. Ensure there are no loose bolts or extraneous objects, the cable is not frayed, and there is no damage to the turnbuckles or clevises connecting the cable to the main bridge. If either the auxiliary bridge or the vacuum bridge is in use, check the cable compression clamps for tightness.

If either the auxiliary bridge or the vacuum bridge is not in use, be sure the compression clamps are free of the cable.

• Inspect the bridge wheels. Ensure the four emergency-stop safety plugs, located at each turnbuckle connection of main bridge, are engaged.

• Check the fairleads at the south end of the test basin for damage, loose components, or obstructions.

• Return to the tower (Building R-26) along the east side of the tank, checking the condition of the cables, clamps, safety plugs, and turnbuckles. Check the Human-Machine Interface (HMI) inside the bridge house for fault codes.

• Proceed to the festoon system located under the east deck alongside the tank, and inspect for obstructions. Check the condition of the trolleys and cables, as well as safety switches.

4.2. OPERATING THE MAIN BRIDGE

The main bridge/cable system is operated from the third floor of the control tower (Building R-26) or from the main bridge house. Before the bridge system can be activated, the operator must ensure the decks are clear and verify two-way communication with the technician or test engineer on the main bridge. The main bridge technician or test engineer should also ensure the decks are clear and an announcement should be made on the public address system.

To start the bridge, proceed as follows:

• At the beginning of the test, verify that the joystick is in the NEUTRAL position.

NOTE: For the next step, refer to Figure 3. Turn the power key to the ON position and then activate the RUN button on the Touch Screen. Control power should now be on.

• Set the desired speed using the up/down buttons on the HMI touch screen, then move the joystick on the lower center of the panel slowly upward to move the bridge south, and slowly downward to move the bridge north.

Figure 3. Bridge Drive HMI Control Panel

To stop the bridge, proceed as follows.

• Slowly return the joystick to the neutral position. Stopping in this way will cause the bridge to coast to a stop at a software-defined rate.

• Once the bridge has completely stopped, push the red emergency stop (E-stop) button. This will deactivate the control power and warning lights.

Emergency Stop

• In the event the bridge system must be stopped in an emergency (e.g., equipment failure or fouling, or personnel endangerment), the person closest to the situation should use the red E-stop buttons located (1) on the third floor control panel, (2) on the first floor south electrical panel, (3) inside the main bridge house on the drive console, or (4) outside the main bridge house on the east and west sides.

5. BRIDGE DRIVE MAINTENANCE

The bridge drive consists of turnbuckles, cables, cable drums, drive gearboxes, DC electric motors, AC to DC rectifiers, and an operator's control station. Each of these components requires periodic preventive maintenance.

5.1. BRIDGE CONNECTIONS

Safety plugs, which form a continuous electrical circuit in the drive control, are attached with a steel lanyard to the bridge tow cable connection points on the main bridge. Each of the four-tow cable connection points have a receptacle where safety plugs are inserted during normal operation. If, for some reason, a cable were to part from the bridge, the lanyard would pull the plug, shutting down the drive system. Maintenance on the safety plugs is minimal. A lanyard should be replaced if it shows deterioration.

5.2. BRIDGE DRIVE CABLES CARE

The bridge drive cables require periodic lubrication with cable grease. This should be performed twice each year at the change of seasons to lubricate with the different greases required for warm and cold weather.

5.3. CABLE TENSION ADJUSTMENTS

Twice a year, or in preparation for special tests, the cables must be tensioned. Normal use of the cable system may cause stretch, and thermal excursions will cause significant linear expansions/contractions. A qualified technician with thorough understanding of the designer/manufactures' manuals is required to supervise the cable adjustment. The large mass of each component infers the use of adequate materials-handling equipment in a safe manner. Personnel in other areas around the Ohmsett test tank should be notified and protected before starting the adjustment procedures. A qualified bridge operator is required in the bridge house.

5.4. CABLE TENSIONING PROCEDURE

The following cable-load parameters have been employed and provide satisfactory bridge drive cable system performance.

• Make two reference marks on the east and west decks: one at the north end of the tank at 100 feet from the end and one at the south end of the tank 200 feet from the end.

• Start by adjusting cables approximately equal by observing any slack in the cable system both at the bridge and at the winches.

• Next, move the bridges to the south limit and then to the north limit. Repeat this procedure and return to the north end to take a measurement from the reference points on the east and west sides. This measurement should be equal; if not, adjust the cables as necessary and repeat the above procedure.

• When the measurements coincide, again visually check the cable sag at the bridge and the winches; if satisfactory, the bridge is ready for use.

5.5. CONVERSION OF BRIDGE DRIVE SYSTEM FROM MASTER ONLY TO DUAL DRIVE

This procedure is to be done by qualified personnel only. The bridge speed and load requirements of certain tests may require the use of both drive motors. This is accomplished by changing the configuration of the parameters in the software on the tower HMI.

• Press the Maintenance button on the home screen and Access the Motors screen by pressing the Motors button on the Maintenance screen. Choose which motor to run as Master and press the Master button; it will turn green. Also, confirm the other motor is enabled and is labeled Slave; if not, press Enable. Note: Either motor can be assigned to be the Master motor at any time.

• Return to the Main Screen by pressing the House logo button at the bottom right of any screen.

Figure 4. Motor Enable/Disable Screen

5.6. CONVERSION OF P&H BRIDGE DRIVE SYSTEM FROM DUAL DRIVE TO MASTER ONLY

This procedure is to be done by qualified personnel only.

To run on one motor only:

• Enable the desired motor and Disable the other motor.

• The Enable button will turn red; the software will automatically read the encoder on the current

Master motor for speed feedback.

• It is possible to run on one motor only, since a central shaft always turns both drums at the same speed and interconnects the two winch drives; this avoids the bridges becoming skewed by being pulled from one side only.

5.7. WINCH

The winch should be lubricated according to Table 1.

Table 1. Winch Lubrication

Index Item Type Frequency Recommended 1 Drum Bearings (2) Pressure

60 Days Marine GR

2 Cross Shaft Bearings (6) Grease Grease 3 Gear case Drain/Fill

90 Days

SAE 40

4 Reducer Drain/Fill Oil 5 Electric Motor

See Manufacturer's Manual 6 Brake

5.8. DRIVE TRANSMISSION

The Appleton winch drive transmission should be checked monthly for lubricant level. Consult the Appleton manual for other details.

5.9. P&H ELECTRO-TORQUE

The Siemens drives are solid state and should only require annual cleaning of the drive cabinets, cabinet filter cleaning and tightening, and checking the electrical connections. For details, consult the Siemens maintenance manual.

5.10. FESTOON AND FAIRLEADS

Annual maintenance for the festoon is limited to cleaning and inspection. The drive cable fairleads require visual inspection and lubrication. Grease is added to bearings through standard grease fittings. There are four locations on the test basin that have fairleads: two at the north east and west corners and two at the southeast and west corners. The festoon, suspended below the east deck, has 44 carriages with sealed bearing rollers.

6. ANCILLARY COMPONENTS

6.1. SLOWDOWN AND STOP LIMIT SWITCH CONTROL CIRCUIT

As the circuit is energized from the HMI, two safety circuits are energized. One loop is on the main bridge and controlled by the HMI on the bridge. The other loop originates at the drive cabinets and travels around the basin and back. These circuits are safety switches, in series, that are normally closed to maintain contact (continuous) loops. If all safety switches in these loops are closed, the PLCs will accept the RUN command, giving control power and enabling the bridges for use. If any of these safety switches are opened for any reason, then the loop is “broken,” and the PLC will not allow a RUN condition. The HMI display will indicate which one of the safety switches is open and will not allow the bridge to move until this condition is corrected.

6.2. BRIDGE SPEED AND DISTANCE METERS

Two rotary encoders, one on each motor, measure the main bridge speed and position. In Master-Slave configuration, the master encoder sets the speed of the Master motor and sets the Slave as a current follower. If either motor is disabled, the other motor’s encoder becomes the speed reference and the disabled motor encoder is disabled. The speed and position of the bridges are displayed on the main screen of the HMI.

APPENDIX A. CHECKLIST: OHMSETT FACILITY BRIDGE OPERATION

Inspector _____________________________________

Date _________________________________________

1. Check drives and HMIs for power and any fault indications.

2. Move to wire-rope drive mechanism on pad outside control tower and:

____ 2.1 Check that DC cooling motors are running (two each).

____ 2.2 Check that wire rope and drive drums are clear (two sets).

____ 2.3 Check that fence gates are locked (three each).

____ 2.4 Check that no one is inside the fence area.

3. Begin an inspection of the cable system that includes:

____ 3.1 Check that west fairlead rollers are clear.

____ 3.2 Check that east fairlead rollers are clear.

____ 3.3 Check that east wire rope tray is clear.

____ 3.4 Check east tray and rail for misalignment, loose bolts, obstructions, and damage.

____ 3.5 Check east wire rope for fraying.

____ 3.6 Check bolts on east auxiliary bridge clamps for tightness.

____ 3.6 Check east wire rope clevises and turnbuckles for tightness and damage.

____ 3.7 Check wave generator indicators for any abnormalities.

____ 3.8 Check pulleys, wire rope, and tray, inside and outside wave generator house.

____ 3.9 Check west tray and rail for misalignment, loose bolts, obstructions, and damage.

____ 3.10 Check west wire ropes for fraying.

____ 3.11 Check bolts on west auxiliary bridge clamp for tightness.

____ 3.12 Check bolts on vacuum bridge clamps for tightness, if necessary.

____ 3.13 Check bolts on main bridge clamps for tightness, if necessary.

____ 3.14 Check the west wire rope clevises and turnbuckles.

4. Festoon

____ 4.1 Check festoon system for obstructions and good working order.

____ 4.2 Check the return device trolleys and wire rope for good condition.

5. Inspect Main Bridge.

____ 5.1 Inspect wheels.

____ 5.2 Inspect cable safety pull switches.

____ 5.3 Check for skimming boom in full-up position on the main and auxiliary bridges, and that the safety circuit is engaged.

6. General Observations

____ 6.1 Decks are clear

____ 6.2 Nothing is extending more than 30 inches above railing

____ 6.3 Do not move the bridge without two-way communication between the test engineer (or a qualified technician) stationed on the bridge, and the bridge operator.

____ 6.4 Check speed control setting on the HMI (set to desired run speed).

____ 6.5 Press “Run” button (button should turn green).

____ 6.6 Check all systems’ safety status on the HMI screen.

____ 6.7 Wait for “Start” signal.

____ 6.8 At start signal, move joystick slowly from center position to limits of travel (either forward or reverse).

____ 6.9 If desired, the speed of the run can be adjusted up or down during the run by using the up/down buttons while the bridges are moving.

____ 6.10 At stop signal, slowly return joystick to center position.

____ 6.11 After bridge has come to a full stop, push emergency stop to shut down control power between runs.

Appendix A. CHECKLIST: OHMSETT FACILITY BRIDGE OPERATION