A.02_CPFFCD19_PWS_Attachment_1.pdf

System Operations and Maintenance Manual

Portable Floating Fish Collector

June 2014

Fish Collection Facility –System O&M Manual Final

Table of Contents

1. Chapter 1: General Information ......................................................................................................... 1-1

1.1. Purpose and Scope ..................................................................................................................... 1-1

1.2. Parts of the Manual ................................................................................................................... 1-1

1.3. Project Description ..................................................................................................................... 1-1

2. Chapter 2: System Description........................................................................................................... 2-1

2.1. 3-D Image ................................................................................................................................... 2-1

2.2. Power Systems ........................................................................................................................... 2-1

2.2.1. Shore Power Supply ........................................................................................................... 2-1

2.2.2. PFFC Mounted Power Distribution Systems ...................................................................... 2-2

2.2.3. Motor Control Equipment .................................................................................................. 2-4

2.2.4. Lighting and Lighting Control ............................................................................................. 2-5

2.2.5. Miscellaneous Electrical Components ............................................................................... 2-6

2.3. Pump Control Panel, PCP ........................................................................................................... 2-7

2.3.1. System Hardware and Software ........................................................................................ 2-7

2.3.2. System Sensors .................................................................................................................. 2-8

2.3.3. Other Instrumentation and Sensors ................................................................................ 2-11

2.4. Floats ........................................................................................................................................ 2-11

2.4.1. Adjustable Ballast ............................................................................................................. 2-11

2.5. Mooring System ....................................................................................................................... 2-13

2.5.1. Anchors ............................................................................................................................ 2-14

2.5.2. Wire Rope ........................................................................................................................ 2-14

2.5.3. Fairleads ........................................................................................................................... 2-14

2.5.4. Tension Meters ................................................................................................................ 2-14

2.5.5. Winches ............................................................................................................................ 2-15

2.5.6. Controls ............................................................................................................................ 2-15

2.5.7. Hydraulic Power Unit ....................................................................................................... 2-15

2.6. Exclusion Screens (V-Screens) and Porosity Control ................................................................ 2-16

2.7. Water Control .......................................................................................................................... 2-18

2.7.1. Slide Gate ......................................................................................................................... 2-18

2.7.2. Constrictor Panels ............................................................................................................ 2-19

June 2014 Page i

2.8. Fish Capture/Transfer System .................................................................................................. 2-19

2.8.1. Crowder ............................................................................................................................ 2-19

2.8.2. Segregation Panel ............................................................................................................ 2-20

2.8.3. Grader (NOT INSTALLED) ................................................................................................. 2-20

2.8.4. Hopper ............................................................................................................................. 2-20

2.8.5. Hopper Crane ................................................................................................................... 2-21

2.9. Pumps ...................................................................................................................................... 2-22

2.9.1. Level Control Pump .......................................................................................................... 2-22

2.9.2. Attraction Flow Pumps ..................................................................................................... 2-22

2.9.3. Service Water Pump......................................................................................................... 2-23

2.9.4. Submarine Cable and Spooler .......................................................................................... 2-24

2.9.5. Manual Crane ................................................................................................................... 2-25

2.9.6. Support Facilities .............................................................................................................. 2-26

3. Chapter 3: Theory of Operation ......................................................................................................... 3-1

4. Chapter 4: Operations ........................................................................................................................ 4-1

4.1. System Operations ..................................................................................................................... 4-1

4.1.1. Facility Startup ................................................................................................................... 4-1

4.1.2. Normal Facility Operation .................................................................................................. 4-4

4.1.3. Normal Facility Shutdown ................................................................................................ 4-12

4.1.4. Emergency Operations ..................................................................................................... 4-13

4.2. Equipment Operations ............................................................................................................. 4-14

4.2.1. Electrical ........................................................................................................................... 4-14

4.2.2. Alarm Panel/PLC ............................................................................................................... 4-14

4.2.3. Mooring ............................................................................................................................ 4-16

4.2.4. Submarine Cable and Spooler .......................................................................................... 4-17

4.2.5. Exclusion Screens and Porosity Control ........................................................................... 4-17

4.2.6. Water Control Systems .................................................................................................... 4-17

4.2.7. Transfer Systems .............................................................................................................. 4-17

4.2.8. Pumps............................................................................................................................... 4-18

4.2.9. Manual Crane ................................................................................................................... 4-18

5. Chapter 5: Preventative Maintenance (TO BE ADDED BY USACE) ..................................................... 5-1

5.1. System Maintenance ................................................................................................................. 5-1

June 2014 Page ii

5.1.1. General Maintenance Policies ........................................................................................... 5-1

5.1.2. Contractor Supplied O&M Manual .................................................................................... 5-1

5.1.3. Routine Maintenance Policies............................................................................................ 5-1

5.1.4. Pre-startup Procedure (from USACE/Cherokee) ................................................................ 5-1

5.1.5. Basic Maintenance Procedures .......................................................................................... 5-1

5.2. General ....................................................................................................................................... 5-1

5.2.1. Lubrication, Including Spooler and Davits ......................................................................... 5-1

5.2.2. Electrical System Check and Testing .................................................................................. 5-1

5.2.3. Preventative Maintenance Management .......................................................................... 5-1

5.2.4. General ............................................................................................................................... 5-1

5.3. Equipment Inspection and Maintenance ................................................................................... 5-1

5.3.1. Power ................................................................................................................................. 5-2

5.3.2. Alarm Panel/PLC ................................................................................................................. 5-2

5.3.3. Float Platform .................................................................................................................... 5-2

5.3.4. Mooring .............................................................................................................................. 5-2

5.3.5. Submarine Cable and Spooler ............................................................................................ 5-2

5.3.6. Pumps................................................................................................................................. 5-2

5.3.7. Preventative Maintenance ................................................................................................. 5-2

5.3.8. Equipment and Structure Maintenance ............................................................................ 5-2

5.3.9. Screens ............................................................................................................................... 5-2

5.3.10. Transfer Systems ................................................................................................................ 5-3

5.3.11. Hopper ............................................................................................................................... 5-3

6. Chapter 6: Trouble Analysis ............................................................................................................... 6-1

6.1. Alarms and Alarm Response Procedures ................................................................................... 6-1

6.1.1. General ............................................................................................................................... 6-4

7. Chapter 7: Corrective Maintenance and Checkout Procedures ........................................................ 7-1

7.1. Commissioning Checklists (use post-commissioning checklists) ............................................... 7-1

7.1.1. Shore Power Engergization ................................................................................................ 7-1

7.1.2. Submarine Cable Spooler ................................................................................................... 7-4

7.1.3. PFFC Energization ............................................................................................................... 7-8

7.1.4. Branch Circuits ................................................................................................................. 7-12

7.1.5. PLC System ....................................................................................................................... 7-14

June 2014 Page iii

7.1.6. Mooring System ............................................................................................................... 7-17

7.1.7. Ballast System .................................................................................................................. 7-22

7.1.8. Pumps............................................................................................................................... 7-24

7.1.9. V Screens .......................................................................................................................... 7-29

7.1.10. Crowder-Hopper Area ...................................................................................................... 7-31

7.1.11. Hydraulics ......................................................................................................................... 7-36

8. List of Figures ..................................................................................................................................... 8-1

9. List of Tables ...................................................................................................................................... 9-1

10. Abbreviations and Acronyms ....................................................................................................... 10-1

11. Appendices ................................................................................................................................... 11-1

11.1. Appendix A - Master Equipment List ................................................................................... 11-1

11.2. Appendix B - As-Built Drawings ............................................................................................ 11-1

11.3. Appendix C - Contractor’s O&M Manuals ............................................................................ 11-1

June 2014 Page iv

1. Chapter 1: General Information

1.1. Purpose and Scope

USACE CENWP and the Willamette Project will be responsible for the operation and maintenance of the Portable Floating Fish Collector (PFFC). The PFFC is a unique, one of a kind facility developed for the purposes of furthering research on the behavior of downstream migrants in the reservoirs found behind the dams at Cougar, Detroit, and Lookout Point. The PFFC contains many different systems with interacting mechanical, electrical, and hydraulic components. In addition, the hydraulic performance must be carefully controlled so that the PFFC operation meets NOAA Fisheries criteria as closely as possible while creating conditions conducive to fish attraction. This System Operation and Maintenance Manual (SOMM) provides the necessary guidance in the general system operation and describes the specific operation and maintenance of each component in the system.

1.2. Parts of the Manual

There are seven chapters in this manual including:

1. General Information

2. System Description

3. Theory of Operation

4. Operations

5. Preventative Maintenance

6. Trouble Analysis

7. Corrective Maintenance and Checkout Procedures

Appendices include:

A. Master Equipment List B. As-Built Drawings C. Contractor’s O&M Manuals

1.3. Project Description

The PFFC represents a small-scale, portable floating fish collection device for use in collecting additional information on juvenile fish movement in Willamette Valley Project (WVP) reservoirs. Currently, there are two critical needs for which the USACE, Portland District expects to deploy the portable floating fish collector:

• As a cost-effective and economical means of safely obtaining juvenile fish (anadromous salmonids and potentially bull trout) in WVP reservoirs for use in research, monitoring, and evaluation efforts; and

• To gather information on the behavior and collection efficiency of both tagged and run of river fish near a small scale floating surface collector.

June 2014 Page 1-1

Primary species of concern are: Endangered Species Act (ESA)-listed Upper Willamette River (UWR) spring Chinook salmon (hatchery and natural origin), ESA-listed UWR winter steelhead. Other potential target species in the reservoir include bull trout and resident fish (including non-native and predator species).

The PFFC is primarily constructed of an assemblage of off-the-shelf equipment and components allowing for any failed components to be repaired by readily available spare parts.

The initial deployment will be at Cougar Reservoir. There will need to be additional mooring analyses, a determination of how to connect the PFFC to on-shore power and how to reestablish alarm and monitoring functions at any future deployment site. A photo of the PFFC deployed in front of the Cougar temperature control tower is provided below in Figure 1-1.

Figure 1-1. PFFC Deployed at Cougar Reservoir

The Portable Floating Fish Collector includes the following major features:

a. Shore Power system including:

i. Connection to Station Power at the Intake Tower

ii. Panel boards in the Intake Tower

iii. Earth Leakage Ground Fault Detection System

iv. Electrical Power Shunt Trip

v. Submarine Cable routed from the Intake Tower to the PFFC

b. Submarine Cable Spooler

i. Spooler Control Panel

c. On Board Power including:

i. Lighting

ii. Pumps

iii. Spooler

iv. HPU

v. Electric Hopper Crane

June 2014 Page 1-2

vi. Convenience Outlets

vii. Emergency Power Inverter System

viii. Ground Fault Monitoring System

d. PLC System including:

i. Pump Control Panel, “PCP”

ii. Process Monitoring and Alarms

e. Mooring system including:

i. Hydraulic Power Unit

ii. Winches

iii. Fairleads

iv. Anchors

f. Pumps including:

i. Attraction Flow Pumps

ii. Level Control Pump

iii. Ballast Pumps

iv. Service Water Pump

g. Fish Exclusion Screens including:

i. Exclusion Screens

ii. Porosity Plates

h. Fish Capture/Transfer Systems including:

i. iPIT Tag Reader

ii. High Velocity Throat

iii. Grader

iv. Crowder

v. Segregation Panel

vi. Hopper

vii. Hopper Crane

i. Hydraulic Systems including:

i. Slide Gate

ii. Constrictor Plates

June 2014 Page 1-3

2. Chapter 2: System Description

2.1. 3-D Image

2.2. Power Systems

2.2.1. Shore Power Supply

Power to the PFFC originates from the Intake Tower Structure at the Cougar Dam Reservoir. The shore mounted main power panel for the PFFC is located at an elevation of 1690 feet in the Intake Tower. The main power panel is located adjacent to the existing Motor Control Center (MCC), “MCC-DQ1”. Power to this main panel originates from one of two transformers, tagged T-05 and T-06, located at the level below MCC-DQ1. Redundant transformer power supplies are provided allowing the USACE to preform maintenance on the transformers with only a short interruption of power to the PFFC. Both transformers are normally energized, and each transformer is rated 277/480 volt, 3 phase, 4-wire. There is one service entrance feeder from each transformer to the main power panel. Each feeder terminates on its own main circuit breaker. The two main breakers are mechanically interlocked, allowing only one of the two breakers to be energized at the same time. The main circuit breakers are 4-pole type, allowing each transformer, including the neutral conductor, to be completely isolated from one another.

Each main breaker is rated for a 350-amp trip. Each breaker is also equipped with an “Earth Leakage” ground fault detection module. The ground fault protection module in the main overcurrent device which provides power to the PFFC is installed to meet the requirements of the 2011 National Electric Code (NEC), NFPA 70, Article 553.4. Per the 2011 NEC, the main overcurrent protective device that feeds the floating structure shall have ground fault protection that does not exceed 100 mA. This ground fault protection requirement affects the design of the power distribution systems installed on the PFFC.

These features are discussed in further detail later in this manual.

The shore mounted main power panel includes two branch circuit breakers. One of the branch circuit breakers is used to supply power to a control power transformer. The other branch circuit breaker is a 400-amp trip, 3-pole breaker with shunt trip, and it feeds power to the PFFC. The control power transformer is used to shunt trip the 400-amp branch breaker feeding power to the PFFC. The shunt trip is activated by pressing the emergency “Kill Electrical Power” mushroom head push button on the PFFC.

When the emergency button is pressed, all power is disconnected at the main shore power panel. It is important to note that because of the potential safety hazard if this system is not functional, the 15-amp breaker feeding the shunt trip system should remain on (energized) at all times.

Electrical power for the PFFC is routed in metallic conduit from the shore mounted Main Power Panel, up through the Intake Tower to the roof, where it is connected to a “submarine cable”. The cable terminations are in the stainless steel enclosure on the roof of the Intake Structure. A photo of the submarine cable termination cabinet is shown below in Figure 2-1. The submarine cable is deployed over the edge of the Tower, down to the Cougar Reservoir, and out to the PFFC. A “J-tube” is mounted

June 2014 Page 2-1 near the bottom of the intake tower that is used to restrain the cable as it enters the water. The submarine cable is discussed in greater detail in Section 2.9.4.

Figure 2-1.Submarine Cable Termination Enclosure Mounted on Top of the Cougar Temperature Control Tower

2.2.2. PFFC Mounted Power Distribution Systems

Power from the shore is provided to the PFFC via a submarine cable. In order to allow the PFFC to move its location in the reservoir, as well as account for changing reservoir water levels, the submarine’s cable deployment length is controlled by a motorized cable spooler. The submarine cable consists of three #500 kcmil copper conductors for 480-volt power, a #1 AWG copper neutral conductor, a #1 AWG copper ground conductor, and 12#14 AWG within a shielded jacket used for discrete controls from the PFFC to shore. The cable assembly is encased in 0.021 inch thick neoprene inner jacket, wrapped with Aramid fiber braided strength members, and encased in an 0.20 inch thick outer jacketing.

The Main Power Panel on the PFFC, Panel “FCQ4”, is a 277/480-volt, 3-phase, 4-wire panel with a 400-amp main circuit breaker. This panel provides power to the hydraulic pump unit, the two attraction pumps and the level control pump. A 15 kVA, dry type transformer is used to step down the voltage and provide power to 120/208 volt 3-phase, 4-wire panel, Panel “FCR1”. Panel “FCR1” powers the other electrical loads onboard the PFFC including lighting, receptacles, and the Davit crane. A 1.5 kW isolation transformer provides power to the PIT Tag system. The 480-volt panel and the 208-volt panel are mounted inside a stainless steel, 2-door enclosure to provide environmental protection for the equipment. The isolation transformer is also mounted inside the enclosure. The heat from the

June 2014 Page 2-2 transformer inside the enclosure helps to reduce condensation inside the enclosure, and helps keep the equipment dry.

As mentioned earlier, the National Electric Code requires a 100 mA ground fault protection system be installed on the main shore mounted power supply. This means ground fault leakage currents as low as

0.10 of an amp will cause the shore mounted main circuit breaker to trip and power will be lost to the PFFC. In an attempt to reduce nuisance tripping of the main breaker, and to help assist maintenance personnel in locating ground faults, a ground fault monitoring system is installed on the PFFC. See Figure 2-2. The system is specifically designed to provide advanced warning of developing ground faults and can be set as low as 10 mA response range. The unit monitors seven circuits on the PFFC; the main feeder to Power Panel “FCQ4”, the main feed to transformer “FT3”, the spooler, the hydraulic pump unit, each of the two attraction pumps, and the level control pump. Each of these circuits have a ground fault monitor connected back to the central control unit. The ground fault control unit includes a data logger with history memory, which includes date and time stamps. The ground fault unit is powered from the UPS in the main PFFC supervisory control and data acquisition system (SCADA), and reports all ground fault alarms to the onboard instrumentation and alarm system. The central ground fault monitoring control unit is mounted in a hinged-cover, weatherproof enclosure, located adjacent to the power panel enclosure.

Figure 2-2. Ground Fault Monitoring Panel

The PFFC is also equipped with an emergency power supply in case of loss of shore power. The emergency power supply consists of an outdoor rated uninterruptible emergency lighting inverter system. The unit is powered from panel “FCR1” and includes a rectifier; sealed back-up batteries, an inverter; and a circuit breaker panel board. The unit is self-testing with self diagnostic features, an automatic event and alarm log, and also includes an internal bypass switch. All of the lighting on the

June 2014 Page 2-3

PFFC, as well as the mooring system tension meters, is connected to the panel board in the emergency power supply enclosure. Upon loss of shore power, the system will provide a minimum of 90 minutes of power at the full rated load. Operating time could be much longer depending on the connected (operating) load.

There are two mushroom head emergency stop buttons mounted on the back rail of the PFFC. See Figure 2-3. One of the buttons is labeled “Kill Electrical Power”, and the other button is labeled “All Pumps Stop”. Pressing the “Kill Electrical Power” button will disconnect all electrical power to the PFFC at the shore. The operation of this button is discussed in more detail in Section 2.2.1. Operation of the “All Pumps Stop” emergency stop button will cause the two attraction pumps, AT1 and AT2, and the level control pump CP1 to immediately stop. An alarm will annunciated by the PFFC monitoring and control system. After operation of the “All Pumps Stop” push button, the pumps can be restarted by resetting the push button, and resetting the alarm on the monitoring and control system.

Figure 2-3. Emergency Stop Buttons

2.2.3. Motor Control Equipment

Motor loads on the PFFC include the two 40hp Attraction pumps, the 27hp Level Control Pump, the 40hp hydraulic pump unit, the fractional horsepower service water pump, and the 1.3hp Hopper crane.

The attraction pumps, level control pumps, and the hydraulic pumps are powered from the 480-volt panel, panel “FCQ4”. The smaller motor loads are connected to the 208-volt panel, panel “FCR1”. The Hopper crane and the service water pump are self-contained units, complete with the manufacturer’s standard controls. The hydraulic pump unit (HPU) is also a self-contained unit, which includes the motor starters and disconnect, as well as all the hydraulic system sensors and controls provided by the unit’s manufacturer. The HPU is discussed in greater detail in Section 2.5.7.

Attraction Pumps: Each of the two attraction pumps are controlled from a variable frequency drive (VFD). The VFD’s used for the PFFC are ultra-low harmonic type drives, mounted inside a stainless steel

June 2014 Page 2-4 weather proof housing. The housing includes cover mounted control operators, a run time meter, a disconnect switch, a condensate heater, and cabinet exhaust ventilation. The pumps include seal leak sensors and over temperature sensors that are monitored and alarmed by the central PFFC control and alarm system. Other motor parameters are monitored by the central control system including the pump speed and the actual motor power.

Level Control Pump: the level control pump is controlled from a VFD. The VFD and pump controls for the leveling pump are the same as the attraction pumps.

2.2.4. Lighting and Lighting Control

The PFFC is equipped with marker lights located on all four corners of the deck. The lights can be switched on or off from the circuit breakers located in the panel board, panel “FCA1”, within the emergency lighting inverter enclosure. See Figure 2-4. The marker lights will continue to operate with the loss of shore power.

Figure 2-4. Emergency Panel FCA1, Lighting Controls

Fluorescent lighting is provided under the canopy on the deck of the PFFC. The lights are enclosed and gasketed, suitable for wet locations, and include low temperature ballasts for cold weather operation.

The canopy lights are controlled from a weatherproof light switch, mounted on one of the canopy support columns. The canopy lights are connected to the emergency power supply (inverter) and will continue to operate with the loss of shore power.

In addition to the fluorescent lights under the canopy, there are two H.I.D. flood lights mounted on the roof of the canopy. These lights are intended to provide task lighting for the hopper and intake for nighttime operation. The flood lights are mounted using swivel connectors, allowing the fixtures to be aimed as needed. The hopper flood lighting is switched on or off from the circuit breakers, located in the panel board, within the emergency power supply (inverter) cabinet. The lights are H.I.D. type, meaning they will take a few minutes to come up to full brightness when switched on. The hopper lights use

June 2014 Page 2-5 metal halide lamps, which provide a white light with good color rendering properties. The hopper flood lighting will continue to operate with the loss of shore power.

The PFFC has a light pole mounted on all four corners of the deck. The poles are used to mount the marker lights described earlier, as well as flood lighting. Each pole has a yoke with two flood lights mounted on the yoke. Each flood light includes a fixture mounting knuckle that allows the fixture to be aimed as needed. Both flood lights could be aimed to provide deck lighting, or they could be used to illuminate the surrounding water. The pole mounted flood lights are individually switched on or off from the circuit breakers, located in the panel board, within the emergency power supply (inverter) cabinet.

The lights are H.I.D. type meaning they will take a few minutes to come up to full brightness when switched on. The flood lights use metal halide lamps, which provide a white light with good color rendering properties. The pole mounted flood lights will continue to operate with the loss of shore power.

2.2.5. Miscellaneous Electrical Components

Transient Voltage Surge Protection: Surge protective devices are mounted on the power input wiring to the three VFD’s controlling the attraction pumps and the level control pump.

Grounding: A three phase, four wire, power supply was selected for the PFFC for numerous reasons.

First, the neutral grounded conductor insures the maximum voltage to ground is 277-volts. Secondly, since the neutral conductor is grounded at the transformer, there may be a reduced ground impedance capable of producing sufficient currents to reliably trip the breakers should a fault occur. In addition to the equipment ground conductor and the neutral conductor in the submarine cable, the PFFC itself is extensively grounded. The neutral and ground for the 480-volt supply is bonded at each of the two intake tower mounted distribution transformers. All equipment ground busses and neutral bussing are separate, except at the step down transformer “FT3” used to provide 120/208 volts for lighting and other electrical loads. For this separately derived power, the neutral and ground are bonded at the transformer.

A Principal Main Ground Bus (PMGB) is located inside the stainless steel two door enclosure housing the power distribution circuit breaker panel boards. See Figure 2-5. All equipment grounds are bonded to the PMGB with 2-hole compression fittings for a good ground connection. Each of the Flexifloats modules include a visible equipment ground connection that can be disconnected, should the PFFC need to be disassembled for relocation.

June 2014 Page 2-6

Figure 2-5. Principal Main Ground Bus (PMGB) Located Inside Power Panel Enclosure

2.3. Pump Control Panel, PCP

2.3.1. System Hardware and Software

The PFFC includes a SCADA. The enclosure housing the main system components is referred to or tagged the Pump Control Panel (PCP). The primary purpose of the SCADA system is to provide a control platform for the attraction pumps and the level control pump. The SCADA also serves as a process alarm panel, capable of monitoring on-board process components and sensors, and annunciating abnormal operating conditions to personnel both on the boat and on shore.

The PCP is a floor standing stainless steel enclosure housing an industrial-rated, PLC. The PLC used for the SCADA system is the Allen Bradley ControlLogix PLC using the Allen Bradley 1756 ControlLogix-XT, Rockwell Software Studio 5000. The PFFC mounted SCADA system includes a PCP-mounted color touch screen computer that is used to interface the controls to the PLC. The touch screen is referred to as an HMI or human machine interface. There is a rotating beacon light mounted on the top of the cabinet and an alarm horn mounted on the face of the cabinet pointing toward the main deck of the PFFC. Most of the functions and control settings are accessed by the operator via the touch screen display but some of the control functions are hardwired to control operators mounted on the cabinet face. These control operators include two position selector switches to enable or disable the alarm horn and beacon, as well as an alarm acknowledge push button. A screen capture of the HMI interface is shown in Figure 2-6.

June 2014 Page 2-7

Figure 2-6. Screen Capture of Main HMI Display

The enclosure is a NEMA 4X rated cabinet, complete with a condensate heater to reduce moisture build up inside the enclosure and a closed loop type air conditioning system designed to keep the electronics inside the cabinet from over heating. The cabinet also houses a UPS system to maintain power to the PLC and HMI touch screen at all times. The SCADA system is equipped with redundant power supplies with built-in monitoring that will signal an alarm if one should fail.

2.3.2. System Sensors

The SCADA system PLC is connected to various sensors on the PFFC to monitor system parameters and pump performance. These sensors or control devices include both discrete and analog devices.

Examples of discrete sensors on the PFFC include limit switches on the spooler that close when the submarine cable is completely spooled out. Analog devices include continuous level and pressure transducers used to monitor water levels in the hopper or discharge pressure on the level control pump.

Water Level Sensors: There are six analog type level sensors mounted on the PFFC. The sensors are used to monitor the water levels in the hopper and shroud, relative to the lake level, as measured from the deck of the boat. These level transducers are cord–mounted, pressure transducers that are suspended from the deck of the PFFC in stilling wells, accessible under the deck grating. The sensors are mounted opposite one another on the port and starboard side of the PFFFC. There are a pair of sensors (port and starboard) used to monitor the level of the hopper, a pair of sensors for the shroud level, and a pair of sensors for the lake level. The PLC continuously monitors these levels for the pump controls, June 2014 Page 2-8 but will also compare the reading on opposite sensors to check for proper sensor reading, or to alarm unusual boat positions.

Pressure Transducer : A pressure transducer is mounted to the discharge of the level control pump. The pressure signal from this sensor is used in the flow rate algorithm used to monitor pump performance and estimate water flow rates generated by the level control pump.

A complete listing of all connected sensors and control inputs and outputs are listed below:

Table 2-1. SCADA I/O

DESCRIPTION FUNCTION TYPE QTY ALARM

Hopper Level Pressure Transducer Port Sump Water Level AI 1

Low Level Pump Cut Off Alarm

Hopper Level Pressure Transducer

Starboard Sump Water Level AI 1 Differential Level Alarm Shroud Water Level Pressure Transducer, Port Shroud Water Level AI 1

High Level, Low Level, Differential Alarm

Shroud Water Level Pressure

Trans., Starboard Shroud Water Level AI 1

Lake Level Pressure Transducer, Port Lake Water Level AI 1 High Level, Low level, Lake Level Pressure Transducer, Starboard Lake Water Level AI 1

CP1, Discharge Pressure Pump Discharge Pressure AI 1

Attraction Pump 1, AT1 Pump Not In Auto DI 1 Pump Not In Auto

Attraction Pump 1, AT1 Pump Run DI 1

Attraction Pump 1, AT1 VFD Fault DI 1 VFD Fault

Attraction Pump 1, AT1 Pump Over Temperature DI 1 Pump Over Temperature

Attraction Pump 1, AT1 Seal Leak Warning DI 1 Seal Leak Warning

Attraction Pump 1, AT1 Run DO 1 Pump Run

Attraction Pump 1, AT1 Pump Alarm DO 1 Pump Alarm

Attraction Pump 1, AT1 Speed Reference AO 1

Attraction Pump 1, AT1 Speed AI 1

Attraction Pump 2, AT2 Pump Not In Auto DI 1 Pump Not In Auto

Attraction Pump 2, AT2 Pump Run DI 1

Attraction Pump 2, AT2 VFD Fault DI 1 VFD Fault

Attraction Pump 2, AT2 Pump Over Temperature DI 1 Pump Over Temperature

Attraction Pump 2, AT2 Seal Leak Warning DI 1 Seal Leak Warning

Attraction Pump 2, AT2 Run DO 1 Pump Run

June 2014 Page 2-9

DESCRIPTION FUNCTION TYPE QTY ALARM

Attraction Pump 2, AT2 Pump Alarm DO 1 Pump Alarm

Attraction Pump 2, AT2 Speed Reference AO 1

Attraction Pump 2, AT2 Speed AI 1

Level Control Pump 1, CP1 Pump Not In Auto DI 1 Pump Not In Auto

Level Control Pump 1, CP1 Pump Run DI 1

Level Control Pump 1, CP1 VFD Fault DI 1 VFD Fault

Level Control Pump 1, CP1 Pump Over Temperature DI 1 Pump Over Temperature

Level Control Pump 1, CP1 Seal Leak Warning DI 1 Seal Leak Warning

Level Control Pump 1, CP1 Run DO 1 Pump Run

Level Control Pump 1, CP1 Pump Alarm DO 1 Pump Alarm

Level Control Pump 1, CP1 Speed Reference AO 1

Level Control Pump 1, CP1 Speed AI 1

Ground Fault Monitor Ground Fault Monitor DI 1 Ground Fault Alarm

Spooler Travel Minimum Capacity, limit switch Spooler Alarm DI 1 Spooler Travel Alarm 1 Spooler Travel Maximum Capacity, limit switch Spooler Alarm DI 1 Spooler Travel Alarm 2 Spooler Control Panel General Alarm Spooler Alarm DI 1 Spooler Alarm

Light On Alarm Light Indicator DO 1

Sounder On Alarm Horn DO 1

Alarm Acknowledge Pushbutton DI 1 Alarm Acknowledge

Power Supply Fail Equipment Alarm DI 1 PCP Power Supply Fail

UPS- Control Panel Line Fail DI 1 Line Fail Alarm

UPS- Control Panel Battery Low DI 1 Battery Low Alarm

UPS- Control Panel Alarm DI 1 UPS Alarm

UPS- Control Panel On Bypass DI 1 UPS on Bypass

Hydraulic Pump Unit Winch Alarm HPU Alarm

Alarm 1 – Shore SCADA Tie Submarine Cable DO 1 *User chosen alarm

Alarm 2 – Shore SCADA Tie Submarine Cable DO 1 *User chosen alarm

Emergency Trip Shore Power Em Stop DI 1 Emergency Stop Alarm

June 2014 Page 2-10

PLC Input / Output Type:

• DI – Discrete Input

• DO – Discrete Output

• AI – Analog Input

• AO – Analog Output

2.3.3. Other Instrumentation and Sensors

2.4. Floats

2.4.1. Adjustable Ballast

The adjustable ballast system consists of two ballast pump assemblies and two ballast tanks, which are port and starboard in the aft Flexifloat of the PFFC. The ballast pump assemblies are made up of a 45 gpm automatic sump pump, 25 feet of suction hose, a-20 foot long rope tied to the pump handle, and a 20-foot long cord. The adjustable ballast pump assemblies are used to move water in and out of the tanks in order to level the PFFC in both static and varying operating conditions. The pumps are placed by hand as needed to add or remove water to/from the ballast tanks. Pumps are equipped with a low-water cutoff. The pump assemblies are stored on the aft float of the PFFC.

Figure 2-7. Ballast Pump Assembly (Typical of 2)

June 2014 Page 2-11

Figure 2-8. Ballast Tank Starboard Hatch Cover and Pump Dewatering Tank

Figure 2-9. Ballast Pump in Tank

June 2014 Page 2-12

Figure 2-10. Port Ballast Tank Access and Cover

2.5. Mooring System

The mooring system restrains the PFFC from to moving too far due to internal (e.g., attraction flow pumps) or external (e.g., wind, waves, current, etc.) loads. The allowed excursion is considered the PFFC’s watch circle, which can be controlled by the tension in the mooring system. The mooring system is comprised of several components: anchors, cables, fairleads, tension meters, winches, controls, and a hydraulic power unit. Other than the anchors, all of the mooring system components have been supplied by Appleton Marine, Inc. Figure 2-11 shows one of the four mooring control stations.

Figure 2-11. Mooring System Control Center

June 2014 Page 2-13

2.5.1. Anchors

There are two types of anchors: concrete and rock anchors. The concrete anchors are constructed of reinforced concrete and made up of two types of parts. The first part is the “anchor,” which consists of a square flat with a cylindrical column in the middle; there are three of these deployed and one in storage.

The other part is the “doughnut,” which is a square with a cylindrical hole in the center; two of these are stacked on one of the “anchors” and the other two “anchors” have none. The rock anchor consists of four rock bolts and a chain bridle.

2.5.2. Wire Rope

Each of the anchors has 820 feet of wire rope. The wire rope is 0.5 inch in diameter, rotation resistant, compact 35, grade 2160, right lay, galvanized, and is manufactured by Alps. The nominal breaking strength is 36,400 lb. The wire rope is lubricated with Dynagard Blue for preservation; this is safe and should not harm fish. The wire rope is connected to the bridle or anchor mooring pad eye on the base with a shackle.

2.5.3. Fairleads

The wire rope is fed through a deck-mounted, double sheave balanced fairlead on to the PFFC. The swivel head fairleads use a sheave to allow the wire rope to change direction with minimal friction.

There are two sheaves on each fairlead, allowing for both a downward or upward pull. The fairlead is a Smith Berger Marine Model MD-2610-001; the sheaves are designed for a 0.5 inch wire rope and have 10 inch diameters.

Figure 2-12. Aft Starboard Winch, Cable, and Fairlead (typical of 4)

2.5.4. Tension Meters

Each anchor line is fitted with a Winch CPM 100 cable pull monitor to measure the tension in the wire ropes. These monitors are designed for up to 25,000 lb of pull with an adjustable alarm which can actuate a dump valve to release the brake on the winches.

June 2014 Page 2-14

2.5.5. Winches

There are four Pull Master H25 winches in the system. Two are counterclockwise rotation and the other two are clockwise rotation. Each winch is fitted with a high torque hydraulic motor with a displacement of 211 cubic centimeters, and has a maximum pull capacity of 16,000 lb and a maximum hoist rate of 44 feet–per-minute. Each winch drum is 10 inches in diameter, 11 inches wide, and has a 24 inch diameter flange. In the event of over tensioning of the anchor wire rope, an emergency brake release can be actuated to relieve the tension in the line.

2.5.6. Controls

Figure 2-13. HPU Control Panel

2.5.6.1. Control Stations

There are four custom designed control stations, which allow the operator to control and monitor the associated winches. Each control station consists of: a 3-position, joystick control valve; a manual, push button brake release; three pressure gauges to monitor the winch functions; the tension meter display for realtime wire rope tensions; and a selector switch to toggle the automatic brake release.

2.5.6.2. Human Machine Interface Screen

There is a screen on the HMI on the PFFC to allow the users to adjust the brake release time period of actuation. Additionally, the HMI will allow the user to adjust the low and high accumulator pressure set points.

2.5.7. Hydraulic Power Unit

The HPU consists of: a hydraulic pump, fluid reservoir, oil cooler, tank heater, accumulator, return filter, and distribution manifold. The purpose of the HPU is to supply fluid power to operate the winches. The

June 2014 Page 2-15 accumulator maintains a storage of hydraulic pressure to ensure the automatic brake release can be actuated in the case of an emergency. The hydraulic fluid is a fish-friendly biodegradable oil; however, precautions should be taken to ensure that oil never enters the reservoir. A photo of the HPU and containment is shown below in Figure 2-14.

Figure 2-14. HPU and Oil Containment

2.6. Exclusion Screens (V-Screens) and Porosity Control

The intent of the screens and porosity control system is to guide fish safely downstream through the fish collection module to the collector throat in a manner that reduces potential impingement, striking, and injury while gradually proportioning off the bulk of the attraction flow. Screens allow water to leave the fish collection module, bypass the fish collection system, and flow to the attraction pumps without allowing fish to exit through the bottom or sides. The exclusion screens are located in the forward section of the PFFC and are shown below in Figure 2-15. The porosity control system is used to balance the amount of flow that passes through each screen bay so that approach velocities are uniform throughout the fish collection module. Porosity can be adjusted to accommodate a wide variety of flow objectives and operating set points targeted within the fish collection module.

June 2014 Page 2-16

Figure 2-15. Exclusion Screens as Viewed from the Bow of the PFFC

The screening system includes 32 stainless steel wedge-wire screen panels possessing 1.75 mm wide slotted openings. Each slot is oriented perpendicular to flow: vertical panels have vertical slotted openings while the floor panels have slotted openings which are oriented side to side. Each screen panel is static and does not need removal or adjustment unless maintenance or repair activities are required.

The porosity control system includes thirty-two adjustable porosity assemblies: one for each screen panel. Each porosity assembly includes a fixed porosity plate and a moveable porosity plate. An operating rod and nut is attached to each moveable porosity plate. Each fixed and moveable porosity plate is composed of a perforated stainless steel plate. Perforations are configured in a pattern of 1-inch wide by 2-inch tall rectangular openings. When the openings are in-line with one another, they are considered to be “open,” (higher porosity). When the openings of the fixed panel are occluded by the blank areas of the moveable panel, they are considered to be “closed,” (lower/no porosity).

The wedge wire screen and porosity panels were custom fabricated by Hendrick Screen Company. Refer to the approved shop drawings for fabricated dimensions and details of each panel.

June 2014 Page 2-17

2.7. Water Control

2.7.1. Slide Gate

A slide gate is located in the upstream end of the collector throat and is used to control the presence of flow from the collector inlet into the collector throat. The intent of the slide gate is to stop water from flowing down the collector throat and to isolate the fish collection module from additional inflow during fish collection, maintenance, or repair activities. Opening the slide gate will allow water to flow again down the collector throat and into the fish collection module. Although capable, the slide gate is not intended to throttle flow entering the collector throat during fish collection operations.

The slide gate is composed of a fabricated aluminum assembly composed of a frame, slide panel, bulkhead, threaded rod, yolk, and operating nut. A handwheel is placed over the operating nut to operate the slide gate manually by hand. The handwheel is rotated to raise and lower the slide panel.

Figure 2-16. Fabricated Aluminum Slide Gate with Handwheel Operator Looking Upstream

June 2014 Page 2-18

2.7.2. Constrictor Panels

The constrictor panels are located within the collector throat: midway in-between the slide gate and the fish collection system. One panel is located on each side of the throat wall and the panels are to be used as a flow throttling mechanism. Panels can be placed in various positions to constrict flow within the collector throat. As flow is constricted, velocities upstream of the constrictor panels decrease, flow depths increase, and the point at which flow passes through critical depth moves further upstream.

Constrictor panels can be moved inward in small increments to achieve the desired flow rate, depth, and velocity regime through the collector throat. Each constrictor panel is intended to swing uniformly inward by no more than 6 inches to create a minimum 1-foot wide slot in the collector throat. A photo of the constrictor panels looking towards the stern is provided below in Figure 2-17.

Figure 2-17. Constrictor Panels with Stern to the right (down the throat)

The constrictor panels are composed of fabricated steel panels with hinges along the upstream vertical edge. Each constrictor panel possesses an operator handle that is mounted vertically to the downstream vertical edge.