Attachment 1 - Operations and Maintenance Manual.pdf

Operations and

Maintenance

Manual

Segmental Bulkhead Closure

System

Broken Bow and Hugo Lake Dams

Document prepared for

United States Army Corps of

Engineers – Tulsa District

Document prepared by

February 2019

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Notice to Users of this Manual

Regulations specify that this Operations and Maintenance Manual be used in loose-leaf form, and only those sections, or parts thereof, requiring changes will be revised and printed. Therefore, this copy should be preserved in good condition so that inserts can be made to keep the manual current.

Table of Contents

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Table of Contents

Page

Part I – General

1. Introduction

A. Purpose and Scope

B. Authorization and Location

C. Safety

D. References

2. Description of Closure System and Pertinent Project

Components

A. Bulkhead Assembly

B. Mechanical Utility Skid

C. Ancillary Equipment

D. Storage Facility

E. Launch and Retrieval Sites

3. Mechanical Utility Skid

A. General

B. Mechanical Skid Description

C. Process and Instrumentation Diagram

D. Valve Sequencer Charts

Part II – Operation

4. Handling and Transport

A. Bulkhead Segment Handling

B. Transport

5. Launch Site Construction (Broken Bow Lake)

A. Deployment and Retrieval Reservoir Data

B. Crane Pad Construction

C. Crane Requirements

D. Pre-lift Test

6. Bulkhead Deployment

A. Required Operation Guide for Specific Bulkhead Assembly

B. Deployment Instructions

7. Bulkhead Assembly (In Reservoir)

8. Bulkhead Operations (In Reservoir)

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A. WARNING

B. Instructions for Rotating the Bulkhead to the Vertical

Position

C. Instructions for Seating the Bulkhead on Sill

D. Instructions for Un-Seating the Bulkhead from Sill

E. Instructions for Moving the Bulkhead from Gate Bay to

Gate Bay (vertical position)

F. Instructions for Rotating the Bulkhead to the Horizontal

Position

9. Mechanical Utility Skid Operations

A. Energizing the Mechanical Utility Skid:

B. Skid Operation

10. Bulkhead Disassembly

11. Bulkhead Retrieval, Transport, and Storage

A. Retrieval and Transport

B. Storage

12. Launch Site Restoration (Broken Bow Lake)

Part III – Inspection and Maintenance

13. Segmental Bulkhead

A. General

B. Inspection

C. Maintenance

14. Mechanical Utility Skid

A. Maintenance

15. Storage Facility Equipment

A. Storage Shelter

B. Bulkhead Support Pedestals

C. Storage Shelter Equipment

D. Storage Facility Access Drive

16. Ancillary Items

A. Inspection

B. Maintenance

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Appendices

A Broken Bow Launch Site Location

B Temporary Crane Pad Construction Plans

C Segment Combination & Range of Operation Chart

D Estimated Required Personnel

E Operation Guides for Bulkhead Assemblies:

E1 – Assembly ABE

E2 – Assembly ACE

E3 – Assembly ABFG

E4 – Assembly ABEG

E5 – Assembly ACEF

E6 – Assembly ABCDE

E7 – Assembly ABCEG

E8 – Assembly ABCDEF

E9 – Assembly ABCDFG

E10 – Assembly ABCDEFG

F Mechanical Utility Skid Valve Position Chart

G Mechanical P&ID Sketches

H Mechanical Utility Skid Flow Sketches

I Upstream Girder Bolt Installation Information

J Manufacturer O&M Information

J1 – Load Turning Device

J2 – Mechanical Utility Skid

J3 – Metal Storage Shelter

J4 – Hoist

List of Contributors

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List of Contributors

The following individuals contributed to the development of this document:

Jeff Anderson, P.E. – Engineer of Record, Mead & Hunt

Bill Black, P.E. – Structural Engineer, Mead & Hunt

Samantha Gulick – Administration, Mead & Hunt

Warren Hayden, P.E. – Quality Assurance, Mead & Hunt

Charlene Jones – CAD Technician, Mead & Hunt

Miroslav Kurka, P.E., PMP – Project Manager, Mead & Hunt

Craig Pomeroy, P.E. – Naval Architect, Hockema Whalen Myers Associates

Frank Ransley, P.E. – Mechanical Engineer, GFR Machine Concepts

Gary Ruchti, P.E. – Structural Engineer, Mead & Hunt

Dan Story – CAD Technician, Mead & Hunt

Karen Wiemeri, P.E. – Civil Engineer, Mead & Hunt

Part I – General

Section 1

Introduction

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1. Introduction

A. Purpose and Scope

1) This manual has been prepared to serve as a guide for the operation and maintenance of the segmental bulkhead system to be used at both Broken Bow and Hugo Lakes. Operation and maintenance instructions for storage, handling, transport, launch site construction, bulkhead deployment /retrieval, and operation are presented. This manual has been written for project personnel who will be responsible for operation and maintenance of the segmental bulkhead system.

2) The intent of the operating instructions is to provide information needed for safe, orderly, and efficient operation of the bulkhead system when used to block water from flowing through the tainter gate bays while the tainter gates or civil structures are being serviced or inspected.

Guidance with respect to inspection and maintenance is provided to promote long-term equipment utilization and limit the potential for breakdowns.

B. Authorization and Location

1) The authorization for this project was provided by the Tulsa District, U.S. Army Corps of Engineers

(SWT) for replacement of the bulkheads at Broken Bow and Hugo Lakes. The project was funded and constructed under this authorization by the Tulsa District, U.S. Army Corps of Engineers.

2) Broken Bow Dam is located on the Mountain Fork River, a tributary of the Little River, at river mile

20.3, approximately 9 miles north-northeast of Broken Bow in McCurtain County, Oklahoma.

Hugo Dam is located on the Kiamichi River at river mile 17.6, about 7 miles east of Hugo in

Choctaw County, Oklahoma, and 30 miles north of Paris, Texas.

C. Safety

This manual is provided to supplement health and safety requirements provided by the United States

Occupational Safety and Health Administration (OSHA) and the U.S. Army Corps of Engineers Safety and Health Requirements Manual (EM 385-1-1). It is not the intent of this manual to replace or supersede compliance with OSHA or EM 385-1-1 requirements.

D. References

Related documents referenced in this manual are provided as follows:

Title Date Purpose

Construction Design Drawings Nov-18 Design and Operation Information

OSHA Current Edition Occupational Safety

EM 385-1-1 Current Edition Safety and Health Requirements

EM 1110-2-6054 Current Edition Inspection Methods for HSS

ER 1110-2-8157 Current Edition Responsibility for HSS

Section 2

Description of Closure System and Pertinent Project Components

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2. Description of Closure System and Pertinent Project Components

A. Bulkhead Assembly

The bulkhead assembly is comprised of individual bulkhead segments that, when joined, constitute a bulkhead floating in a horizontal orientation that can be ballasted to rotate to a vertical orientation for placement at the upstream end of a spillway bay. Different combinations of the individual segments can be assembled to produce bulkheads of various heights for use at both Hugo and Broken Bow Lakes.

B. Mechanical Utility Skid

The mechanical utility skid is designed to pump ballast water to and from floodable chambers in the bulkhead segments during deployment of the bulkhead assembly. The skid is connected to the bulkhead assembly by a series of 100-foot-long rubber hoses that are used for filling, pumping out, and venting the ballast chambers.

C. Ancillary Equipment

Ancillary equipment required for operation of the bulkhead assembly is stored in containers and must be moved from the Broken Bow storage facility to the crane pad launch site. Required ancillary equipment for operation includes hoses, lines, anchors, marine fenders, tensioning connectors, refill valve operating stem components, access ladder and platform railing components, staff gauges, upstream girder flange bolts, ballast bags, tethering lines, and other miscellaneous components.

D. Storage Facility

The storage facility, located east of the Broken Bow Powerhouse, consists of a metal storage shelter used to store the bulkhead segments and two dry storage containers used to store the mechanical utility skid and ancillary equipment.

1) Metal Storage Shelter – The metal storage shelter is oriented so the Ford Louisville 9000 haul truck and an Eager-Beaver 50-ton capacity low-bed trailer can enter and exit the building without having to back up. The bulkhead segments are supported on two concrete pedestals spaced 30 feet apart, with timber blocking between the segments and the top of the concrete pedestal. The segments are stored at a slight angle lengthwise to improve drainage of water remaining in the segments after use. The storage building is equipped with a bridge crane with two 15-ton hoists fixed to the bottom flange of the bridge beam. The bridge crane is able to traverse the length of the building. The storage building is also equipped with two load-turning devices that are suspended from the hoists.

These devices are used in tandem to rotate the bulkhead segments about their long axis. A SWT-owned generator is used to power the storage shelter, which will connect to a 600-volt, 200 amp rated fused disconnect at the northeast corner of the storage shelter.

2) Dry Storage Containers – The 20-foot-long and 40-foot-long dry shipping containers have been located to allow the mechanical utility skid and ancillary equipment storage containers to be moved with a forklift truck. The equipment and skid housing the manifolds, pumps, and valves are

Section 2

Description of Closure System and Pertinent Project Components

X:\3167300\180503.01\TECH\Reports\DRAFT\O&M Manual\O&M Manual Draft.docx 3 stored in the 20-foot-long container, while the hoses and ancillary equipment are stored in the 40-foot-long container. Both containers are located next to the metal storage shelter.

E. Launch and Retrieval Sites

1) Broken Bow Lake – Bulkhead launch and retrieval operations for Broken Bow Lake will be conducted at the Deer Drive boat ramp located in the Hochatown State Park, as shown in

Appendix A. A temporary crane pad will be constructed of rock fill adjacent to the boat ramp to provide a level surface for the crane to receive delivery of the bulkhead segments on the low-bed trailer. The crane pad may be removed once the bulkhead segments have been removed from the water or left in place for future deployment.

2) Hugo Lake – Bulkhead launch and retrieval operations for Hugo Lake Dam were not determined at the time this manual was developed.

Section 3

Mechanical Utility Skid

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3. Mechanical Utility Skid

A. General

The mechanical utility skid is designed to pump ballast water to and from chambers in the bulkhead segments during deployment of the segmental bulkhead system. The mechanical utility skid is connected to the segmental bulkhead by 100-foot-long hoses which allow filling and venting of the segment ballast chambers. Refer to Process and Instrumentation Diagrams (P&ID) which illustrate hose connections for specific bulkhead configurations, and mechanical utility skid hose connection charts provided in the operational instructions for each specific bulkhead configuration.

B. Mechanical Skid Description

1) Components and Functions

The mechanical utility skid components are mounted on a base frame designed to be placed on a barge or work boat during deployment of the bulkhead system. The mechanical utility skid contains a self-priming water pump, air compressor, fill and pump-out manifold, and vent and pressurized air manifold with pressure controls. Pressurized air is required for assisting the water pump in lifting water out of the segment chambers when the bulkhead assembly is in vertical orientation and the elevation between the segment(s) and utility skid exceeds the lift capability of the pump. Pressurized air is also used for blowing the ballast water out of the segments in the event of inadvertent sinking of the bulkhead assembly. Engineering should be consulted in the event of a sinking prior to making recovery efforts. The entire piping system of the skid is provided with manual hand operated valves. The pump and compressor are both engine driven.

There are no electrical components or controls on the skid outside of the engine ignition systems.

2) Hose Connections

The bulkhead segments contain ballast chambers which must be filled and emptied during operation of the system. Segment A contains three (3) floodable chambers, and Segments B, C, D, E, F, and G each contain one (1) floodable chamber. Each floodable chamber has two (2) hose connections. The water fill and pump-out connection is 1-1/2 inch, and the vent hose connection is 2-inch. The hose connections on the utility skid are made with cam and groove quick disconnect couplings with the skid containing the male connector and the hose containing the female connector. Hose connections on the bulkhead segments are made with lug unions.

Hose connections on the bulkhead assembly that are not used for rotation of the assembly must be capped prior to rolling the bulkhead to a vertical orientation. There is also a quick disconnect air fitting on VA-9 for inflating the buoyancy bag.

Additional hose connections on the utility skid include a 2-inch hose connection for return to reservoir flow, a 2-inch hose connection for pressure relief on the pump discharge, and a 3-inch connection for the pump suction hose. The 2-inch return to reservoir hoses are approximately 4 feet long, and the pump suction hose is approximately 10 feet long. These hoses should be tethered to the edge of the barge or work boat to prevent whipping of the free end of the hoses during operation.

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3) Valves

The utility skid contains valves for routing the flow of water and pressurized air to and from the hoses attached to the bulkhead chambers, as well as the buoyancy bag and ballast bag.

Positioning of the valves for various operations are listed in valve sequencer charts in this operations manual and shown graphically in the P&IDs and flow diagrams based on the P&IDs, as shown in Appendices G and H, respectively.

a) Pump and Compressor Valves

Valves V1-V3, and V-5 are located on the piping connected directly to the water pump.

Valve V1 is located on the pump suction and is a 2-way valve. Valve V2 is a 3-way valve located on the pump discharge that provides flow routing to the ‘fill and pump-out manifold’, or bypass line from the pump discharge back to the reservoir. Valve V3 is a 2-way valve on the shunt line running from the ‘fill and pump-out manifold’ to the pump suction. Valve V-5 is located on the bypass line and is used to provide back pressure to the pump during pump priming and provides throttling capability during pump-out when the pumping rate may exceed the rate water can flow to the suction point through the segment internal stiffeners. These valves allow the pump piping to be configured in three ways:

1) To prime the pump with discharge flow back to the reservoir

2) To pump water out of the reservoir and into the segment chambers via the ‘fill and pump-out manifold.’

3) To pump water out of the bulkhead chambers via the ‘fill and pump-out manifold’ and return to the reservoir.

Valve V4 is located on the compressor discharge piping and controls the flow of pressurized air from the compressor to the ‘vent and pressurized air manifold’. A pressure regulator valve is provided between the compressor outlet and V4. The pressure in the

‘vent and pressurized air manifold’ should be set according to the figures provided in the valve sequencer chart. A pressure relief valve is also provided on the manifold to prevent over-pressurizing the bulkhead chambers during pump-out in the event the pressure reducing valve setting is incorrect or the pressure reducing valve malfunctions.

b) Fill and Pump-out Manifold Valves

The utility skid ‘fill and pump-out manifold’ contains nine (9) 2-way valves. The valves are labeled VF1-VF9. Each valve is located on the branch leg of a tee in the manifold main line, and the valve outlets are piped to the end of the skid. The end of the pipes from the valves are provided with a cam and groove connector to mate with the fill and pump-out hoses.

c) Vent and Pressurized Air Manifold Valves

The utility skid ‘vent and pressurized air manifold’ contains ten (10) valves labeled VA1-

VA10. Valves VA1-VA8 as shown on the assembly drawings are 3-way T port valves and are piped to the end of the utility skid where they are provided with cam and groove connectors for the vent hoses. The valves are configured so that in one position the vent hose is open to atmosphere. In the other position, the hose is piped to pressurized air in

X:\3167300\180503.01\TECH\Reports\DRAFT\O&M Manual\O&M Manual Draft.docx 6 the manifold. VA9 is a 2-way valve with the outlet piped to the end of the skid with a quick disconnect fitting for attachment of the air hose for the buoyancy bag. VA10 is located on a tee connection off the VA9 discharge side and is open to atmosphere on one end.

When VA9 is open and VA10 is closed, pressurized air flows to the buoyancy bag. When

VA9 is closed and VA10 is open, air flows out from the buoyancy bag.

d) Pressure Gauges

Pressure gauges are provided on the ‘vent and pressurized air manifold’, and on the ‘fill and pump-out manifold’ to allow operators to determine pressures of the air and water delivered to the segment chambers.

e) Pressure Regulators

Pressure reducing valve PR-1 is in place to reduce the pressure of the air from the compressor to a level that will not damage the bulkhead segments. Pressure relief valve

PRV1 is provided to prevent over-pressuring if PR-1 is set incorrectly or malfunctions.

Pressure relief valve PRV2 is in place to prevent over pressuring the pump in the event the skid valves are set incorrectly and there is no flow path for water discharged from the pump.

C. Process and Instrumentation Diagram

Process and instrumentation diagrams are provided in Appendix G for each configuration of the bulkhead assembly showing the hose connections between the mechanical utility skid and the bulkhead segment chambers.

D. Valve Sequencer Charts

Valve sequencer charts are provided in this operations manual for each specific bulkhead configuration.

The sequencer charts show valve positions for each type of operation such as prime, fill or pump-out.

Part II – Operation

Section 4

Handling and Transport

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4. Handling and Transport

A. Bulkhead Segment Handling

When not in use, the bulkhead segments are housed in the storage shelter at the Broken Bow powerhouse yard. The following steps shall be taken while moving each segment from storage to the low-bed trailer for transport:

1) Inspect all internal chambers and remove any tools or excess water that may be present.

2) Inspect all gaskets to ensure that they are in good condition and seated properly.

3) Ensure that all hatch doors are closed, that all nuts and washers are installed, and that all nuts are tightened to a snug tight condition as provided in Appendix I.

4) Ensure that all threaded caps at drains, draft leveling ports, and viewing ports are securely tightened using provided operating wrench.

5) Install belts for load-turning device and lift segment vertically in accordance with load-turning device manufacturer’s recommended operating procedures until it is clear of any neighboring segments. Operating procedures for the load turning device are provided in Appendix J1.

6) Following load-turning device manufacturer’s recommended operating procedures, rotate segment

90 degrees about its longitudinal axis until the upstream vertical girders are facing upward.

7) Move segment using bridge crane until it is positioned over the low-bed trailer.

8) Install blocking and lower segment onto low-bed trailer using 15-ton hoists.

9) Remove load-turning device belts and move lifting equipment clear of truck.

10) Secure bulkhead segment to low-bed trailer and install any safety signage and/or flagging as required by law. The segment is now ready for transport.

B. Transport

1) Equipment – The bulkhead segments are designed to be transported between the storage facility and the launch locations utilizing available SWT personnel and equipment. SWT Fleet Equipment available for use includes the following:

a) Link-Belt 8675 truck crane

b) Ford Louisville 9000 haul truck

c) Eager-Beaver 50-ton capacity low-bed trailer

Section 4

Handling and Transport

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To prevent potential damage to the external segment bracing, only one segment shall be transported at a time. Once at the launch site, the low-bed trailer will be parked adjacent to the crane for rigging, lifting, and placement of the segment into the reservoir.

2) Transport Routes:

a) Broken Bow Lake – The recommended route from the storage facility to the Deer Drive

Boat Ramp requires traveling along State HWY 259A, which is considered a restricted use route. As a result, it will be necessary to obtain an Oklahoma Department of Public

Safety (DPS) single trip permit from the Size and Weight Permit Division prior to transporting the bulkhead segments.

b) Hugo Lake – The recommended route from the storage facility to the Hugo Lake launch site was not determined at the time this manual was developed.

Section 5

Launch Site Construction (Broken Bow Lake)

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5. Launch Site Construction (Broken Bow Lake)

The Deer Drive Boat Ramp, located in Hochatown State Park, will be used for launch and recovery of the bulkhead segments at Broken Bow Lake. This will require constructing a temporary crane pad adjacent to the existing boat ramp with rock fill and riprap to create a stable and level surface for the SWT crane and low-bed trailer.

Note – Coordination and approval from the Hochatown State Park will be necessary prior to starting construction of the crane pad. The public boat ramp is regularly and heavily used during summer months.

Coordination with the State of Oklahoma Department of Tourism and Recreation will be needed to provide a safe and accessible boat ramp and parking area. Construction of the temporary crane pad shall not infringe upon use of the boat ramp, which will remain open at all times.

A. Deployment and Retrieval Reservoir Data

Bulkhead deployment and retrieval at the Deer Drive Boat Ramp shall be limited to the following reservoir ranges and conditions:

1) Deployment and Retrieval Reservoir Range:

Minimum pool Elevation 594.76

Maximum pool Elevation 601.00

Elevations provided based on NGS NAVD 88 vertical datum.

2) Bulkhead Draft Depth – 4 feet minimum

B. Crane Pad Construction

1) Plans for construction of the temporary crane pad at the Deer Drive Boat Ramp are provided in

Appendix B. The plans provided in Appendix B are for the minimum and maximum elevations for bulkhead deployment/retrieval reservoir. Actual conditions may vary depending on the reservoir level at the time of bulkhead deployment or retrieval. Interpolation between the minimum and maximum pool elevation scenarios provided may be necessary to accommodate for actual conditions in the field.

2) Prior to crane pad construction, it is recommended that a site survey be completed to establish the existing topography and contour of the work area. In addition, the condition of the boat ramp should be assessed, and any defects documented before construction of the temporary crane pad begins.

C. Crane Requirements

The Link-Belt 8675 (75 US ton) Telescopic Boom Truck Crane will include the following:

1) Outriggers fully extended with crane pads placed beneath each outrigger pad

2) Maximum 30-foot radius

3) 60-foot boom radius

4) Counterweight options 10,800lb, 14,400lb, or 18,400lb

Section 5

Launch Site Construction (Broken Bow Lake)

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D. Pre-lift Test

Following construction of the crane pad, and prior to lifting the bulkhead segments, the competence of the crane pad shall be tested and observed. The crane should be rotated through 360 degrees a minimum of three (3) times while equipped with its full counterweight and boom configuration to verify foundation adequacy and to evaluate the magnitude of outrigger settlement on the prepared crane pad. Differential settlements observed during rotation shall not exceed the manufacturer’s crane capacity chart limits. If settlements exceed the maximum limits, foundation support conditions and/or the crane pad stiffness shall be improved to ensure safe and adequate operating conditions.

Section 6

Bulkhead Deployment

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6. Bulkhead Deployment

A. Required Operation Guide for Specific Bulkhead Assembly

Operation Guides for each specific bulkhead assembly are provided in Appendix E. WARNING – Wind and wave conditions should be considered throughout the deployment, assembly, and operation process. Work should be suspended if weather conditions do not allow safe operation.

B. Deployment Instructions

1) Determine the number and type of segments required as shown in the configuration chart based on the reservoir elevation. A chart of bulkhead assemblies for each project and their respective range of operation is provided in Appendix C.

2) Determine the required components for the specific bulkhead configuration to be assembled. A complete list of required components for each specific bulkhead configuration is provided in

Appendix E. Ancillary components, such as hoses, lines, anchors, marine fenders, tensioner bolts, refill valve operator stem components, access ladder and platform railing components, staff gauges, and flange bolts are provided in containers and must be moved from their storage location to the launch site for assembly. The mechanical utility skid will also need to be moved from the storage location to the launch site for placement on a barge or work boat. Note

– depending on the work being performed, a pump may be required to remove accumulated leakage water from the work area.

3) Determine the required personnel for bulkhead deployment. A list of estimated personnel required for bulkhead deployment is provided in Appendix D. Construct temporary crane pad at launch site as discussed in Section 5.

4) Set up and test stability of SWT-owned crane at the launch site in accordance with Sections 5.C and 5.D.

5) Transport Segment A and required components from the Broken Bow powerhouse storage shelter to the launch site as discussed in Section 4.

6) Launch work boats.

7) Place the mechanical utility skid and hose reels on barge or boat and move near the assembly location.

8) Attach rigging to crane hook and the four lifting eyes of Segment A.

Illustration showing Step 8

Section 6

Bulkhead Deployment

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9) Verify that all hatch doors, draft leveling ports, viewing ports, and drains are securely fastened as discussed in Section 4.

10) Lift Segment A off the trailer and place in the reservoir ensuring that at least four feet of draft is provided. Once Segment A has been successfully placed in the reservoir, return to storage shelter to load and transport the next segment in the bulkhead assembly to launch site.

11) Maneuver Segment A to the assembly location with two work boats, one on each end of segment.

12) Anchor Segment A at assembly location, with at least one anchor on each end of segment.

13) Disconnect rigging from Segment A and attach it to the four lifting eyes on the next segment in the assembly.

14) Lift the second segment off the trailer and place into the reservoir.

15) Using the work boats, maneuver the second segment into position near Segment A, and parallel to the first segment. Proceed with bulkhead assembly in accordance with instructions provided in Section 7.

16) Repeat steps 8-11 and 13-15 until all segments needed for bulkhead assembly have been transported to launch site and placed in the water. No more than two components (the partial bulkhead assembly and the next segment in the assembly) should be in the reservoir at the same time.

Illustration showing Step 12

Illustration showing Step 15

Section 7

Bulkhead Assembly (in Reservoir)

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7. Bulkhead Assembly (In Reservoir)

Instructions for assembly of the segmental bulkhead in the reservoir are provided below. These instructions assume that the mechanical utility skid, Segment A, and the next segment in the bulkhead assembly are already in the reservoir. Graphical representations of the assembly process shown below.

1) Move boat or barge-mounted mechanical utility skid near bulkhead assembly.

2) Install hoses for filling/pump-out and venting of second segment.

3) Energize the mechanical utility skid and prime the pump.

4) Set mechanical utility skid valves for draft leveling fill operation (valve sequence chart is provided in Appendix F).

5) Fill leveling chamber as required to achieve equal draft between segments (approximate anticipated fill depths are provided in Operation Guides in Appendix E). Depth of water ballast pumped into each segment shall be monitored and recorded via the draft leveling ports provided for each segment’s center chamber, as this information will be required for safe disassembly of the bulkhead later (see Section 10). Screw-on caps shall be removed with provided wrench. Once draft leveling is complete and depth of ballast water has been recorded, ensure that gasket is in place and replace and re-tighten draft leveling port cap using provided wrench.

6) Place marine fenders for Segment A on the side adjacent to the second segment.

7) Utilize lines and cleats to pull the second segment against the fenders.

8) Utilize lines and cleats to move segments parallel to each other until pins and sockets line up.

9) Remove fenders and utilize lines to bring the segments together, simultaneously pulling the pins into the sockets.

10) Place tension connectors into brackets.

11) Tighten tension connectors until gap between segments is substantially gone. Adjust tensions connector alignment as required. Tension connectors will remain installed until disassembly of bulkhead.

Illustration showing Steps 7 & 8

Section 7

Bulkhead Assembly (in Reservoir)

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12) Utilize drift pins to achieve final alignment of bolt holes at upstream vertical girder connection plates.

13) Install bolts, washers, and nuts at all upstream vertical girder connection plates and ensure all nuts are snug-tightened. Upstream girder bolt installation information is provided in Appendix I.

14) Install hoses for filling/pump-out and venting of third segment.

15) Repeat steps 3-14 above for subsequent segments as required to complete bulkhead assembly.

16) When assembly of all segments is complete, note water level in leveling chambers and record level and save for the disassembly process.

17) Configure mechanical utility skid for pump-out operation and pump-out leveling chambers at all segments except Segment A.

18) Cap all draft leveling ports and chamber connections that will not have hoses during the roll and placement operations.

19) Install re-fill valve stem and handle.

20) Install staff gauges.

21) Install both access ladders.

22) Install the buoyancy bag and ballast bag.

23) Make final hose hook-ups and bundle hoses in provided brackets with the hose bundle leading off the side of the bulkhead assembly near the anticipated waterline in the vertical orientation.

24) Make final hose hook-ups and bundle hoses in hose straps. Attach hose straps to tethering points with the hose bundle leading off the side of the bulkhead assembly near the anticipated waterline in the vertical orientation.

Illustration showing Steps 10 &11

Illustration showing Steps13 and 19

Illustration showing Step14

Illustration showing Step 21

Section 8

Bulkhead Operations (in reservoir)

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8. Bulkhead Operations (In Reservoir)

A. WARNING

This section provides detailed step by step general assembly instructions that should be followed for all bulkhead configurations. Operation Guides specific to each bulkhead assembly should also be followed.

These guides are provided in Appendix E. Failure to follow the instructions for each specific assembly may result in danger to personnel and/or inadvertent sinking of the bulkhead. As directed by SWT, the bulkhead segments have NOT been designed for hydrostatic pressures associated with sunken conditions and significant structural damage to the bulkhead may result under these conditions. In the event the bulkhead is inadvertently sunk, a qualified engineer should be retained to develop a recovery plan. The Design Engineer (Mead & Hunt, Inc.) should also be consulted in developing the recovery plan.

All spillway gates shall be closed during bulkhead deployment, rotation, seating, unseating and movement from gate bay to gate bay. Once the bulkhead has been seated and dewatered, only the 3rd gate and beyond will be allowed open. The two adjacent gates on either side of the bulkhead shall remain closed at all times. Note while the bulkhead has been seated and dewatered, the work boat or barge with the utility skid should be disconnected and removed from the bulkhead vicinity, if high flows through the gates that are opened (i.e. 3rd gate and beyond) are anticipated.

B. Instructions for Rotating the Bulkhead to the Vertical Position

1) Ensure all spillway gates are closed and maneuver bulkhead and mechanical utility skid no closer than 50 feet from upstream face of spillway with Segment A facing upstream.

2) Move boat or barge-mounted mechanical utility skid to one side of the bulkhead assembly as far away as hose bundle will allow, and anchor. Note that the hose bundle will have slight negative buoyancy and will tend to pull the mechanical utility skid toward the floating bulkhead assembly.

Use hose floats as needed to prevent hoses from sinking.

3) Energize the mechanical utility skid and prime the pump.

4) Set mechanical utility skid valves for fill operation (see Appendix E for valve position chart in

Operation Guide for specific configuration).

5) Partially fill end chambers of Segment A. The end chambers should be filled to the level specified in the Operation Guide.

6) Once the end chambers have been filled to the appropriate level, start filling the center chamber of Segment A. The bottom of Segment A will start to submerge as the bulkhead slowly begins to rotate. As draft increases at the bottom of Segment A and the exposed edge gets closer and closer to the waterline, the rate of bulkhead rotation will increase at an accelerated rate. At the

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7) After roll concludes, continue to fill until desired freeboard is achieved. For taller bulkhead assemblies, it will be necessary to add ballast water to the center chamber of the second and/or third segments from the bottom to achieve desired freeboard.

8) Adjust water levels in the end chambers of Segment A to achieve consistent freeboard along the length of the bulkhead.

C. Instructions for Seating the Bulkhead on Sill

1) Verify that the submerged portions of the piers, pedestals, and sill upstream of the gate bay to be dewatered are free of debris and damage. Failure to do so may result in damage to the bulkhead seals and/or excessive leakage due to a poor seal along the perimeter of the bulkhead.

2) Verify that fill /pump-out hoses and vent hoses are restrained by the hose guide bracket on the correct side of the bulkhead. When it is placed in a bay adjacent to an abutment wall, the hose bundle should exit the bulkhead face on the side opposite of the abutment wall.

3) Adjust bulkhead draft for minimum clearance of pedestals using the following steps:

• Note freeboard on the bulkhead staff gauges.

• Calculate bulkhead draft by subtracting freeboard from bulkhead assembly height.

• Calculate the elevation of the bottom edge of the bulkhead assembly by subtracting bulkhead draft from the reservoir elevation.

• For the bottom edge of the bulkhead to safely clear the pedestals during placement against the piers, the calculated bottom edge elevation of the bulkhead must be greater than:

Hugo Lake

Broken Bow Lake

Sill El. (ft) 374.00 585.21

Clearance (ft) 0.25 0.25

Bottom El. (ft) 374.25 585.46

4) Verify the assembly is floating in a level orientation and is not pitched toward or away from the piers. If leveling is required, ballast in Segment A chambers 1 and 3 may be adjusted to level the bulkhead assembly. Pitch may be adjusted utilizing the buoyancy bag and ballast bag. Pitch toward the piers must be eliminated so that the bottom of the bulkhead assembly contacts the piers when it is moved into position. Minor pitch away from the piers is acceptable since the work boats will provide enough force to eliminate minor pitch once the bottom of the bulkhead is in contact with the piers.

5) Maneuver the vertical bulkhead assembly toward the gate piers using two work boats. The seals should be facing the spillway.

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6) The bulkhead segments have two sets of vertical seals and crowned stop bars to accommodate use of the bulkhead system at Broken Bow (48-foot center-to-center span between piers) and

Hugo (50-foot center-to-center span between piers).

Adjust the location of the assembly left or right until the outer stop bar on one end of the bulkhead assembly is in line with the center of the pier nose. At Broken Bow, the inboard stop bar will line up with the center of the other pier nose on the opposite side of the bulkhead assembly. The bulkhead will extend past the center of the pier by 2.5 feet. This is normal. At Hugo, the outer stop bars will line up with the center of the pier noses. Push the bulkhead against the piers using the work boats, taking care to keep the stop bars centered on the pier noses. Failure to do so may result in damage to the side seals.

7) Verify that the bulkhead is oriented vertically against the pier noses. Adjust vertical orientation if necessary with buoyancy and/or ballast bags attached to bulkhead assembly.

8) Add ballast water to appropriate bulkhead chambers

(from lowest to highest) as indicated in Operation

Guides (Appendix E) until bulkhead contacts pedestal seats.

9) Use upstream ladders to install access platform railings on both sides of the bulkhead. While on top of the bulkhead, verify that the refill valve(s) is /are fully closed.

10) Maintain force pushing bulkhead assembly against the piers and dewater the gate bay at a rate of not more than one foot of water surface reduction per minute.

11) Once the bulkhead is in place and the gate bay is dewatered, the work boats used for pushing and maneuvering the bulkhead in place may be removed.

12) De-energize the mechanical utility skid.

13) Perform maintenance as required.

D. Instructions for Un-Seating the Bulkhead from Sill

1) Check Operation Guides (Appendix E) to verify reservoir is within operable range for the bulkhead assembly.

Illustration showing Step 9

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2) Before refilling the gate bay, check all non-filled chambers for evidence of leakage infiltration using viewing ports on downstream face of bulkhead. Pump-out or drain as required. Failure to do so may result in instability of the bulkhead during refloating and/or movement to an adjacent gate bay.

3) Refill gate bay by closing tainter gate and opening the refill valve(s). Both refill valves may be used to expedite this process in assemblies that include Segments B and C. Note, a handle extension or breaker bar may be required to open the refill valves.

4) Close refill valve(s).

5) Attach liner from each end of bulkhead to work boats.

6) Energize the mechanical utility skid and prime the pump.

7) Set mechanical utility skid valves for pump-out operation.

8) Commence pump-out, starting with highest previously-filled chamber in the assembly and progressing downward until the bulkhead assembly re-floats.

9) Bulkhead may remain in vertical orientation for transport to a different gate bay.

E. Instructions for Moving the Bulkhead from Gate Bay to Gate Bay (vertical position)

If it is desired to move the bulkhead from one gate bay to another, the assembly may be towed in the vertical orientation using two work boats. The procedure for un-seating the bulkhead assembly from the sill (Section 7.D.) needs to be completed prior to moving the bulkhead from gate by to gate bay. This procedure assumes the bulkhead assembly and mechanical utility skid will be moved separately by disconnecting the hoses from the bulkhead assembly. However, the bulkhead assembly and mechanical utility skid may be move together without disconnecting the hoses from the bulkhead assembly.

1) Attach lines from the mechanical utility skid to the work boat.

2) Disconnect and plug the hoses from the bulkhead assembly and tether the hose bundle the bulkhead assembly before moving.

3) Tow the mechanical utility skid a safe distance away from the bulkhead assembly and weigh anchor.

4) Tow the bulkhead assembly a safe distance up stream away from the gate piers.

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5) Tow the bulkhead assembly laterally to the next location of use.

6) Check the bulkhead assembly draft before attempting to install in the new location.

7) Install the bulkhead at the new location following steps in Section 7.C, Instructions for Seating the

Bulkhead on Sill.

NOTE: The filling/pump-out and vent hoses will remain attached to the bulkhead assembly during towing and the boat or barge-mounted mechanical utility skid will be moved alongside of the bulkhead. One work boat should be sufficient to provide the towing force. The second work boat should be positioned behind the trailing edge of the bulkhead and mechanical utility skid to apply reverse force to slow and stop the bulkhead and mechanical utility skid as necessary. WARNING – Exercise caution when starting and stopping movement of the bulkhead assembly. Due to the weight of the structure, this may take conservable time and effort.

F. Instructions for Rotating the Bulkhead to the Horizontal Position

1) Remove the top section of the valve stem operator and railing.

2) Utilize work boats to tow the bulkhead no less than 50 feet upstream of the piers to safely rotate the bulkhead into the horizontal position.

3) Utilize the buoyancy bag and ballast bag to obtain roll in correct direction. To accomplish this, the buoyancy bag should be attached on the upstream side of the bulkhead and the ballast bag should be attached on the downstream side of the bulkhead.

4) Add air to the buoyancy bag and water to the ballast bag to create initial lean of the assembly in the proper direction for return to horizontal. The upstream vertical girders should be on the side that will be facing up and the seals should be on the side that will be facing down.

5) Pump-out segment chambers sequentially from top to bottom until assembly returns to horizontal orientation.

6) Deflate pump-out and remove buoyancy and ballast bags.

Section 9

Mechanical Utility Skid Operations

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9. Mechanical Utility Skid Operations

A. Energizing the Mechanical Utility Skid:

1) Pump Priming

Set valves V-1, V-2, and V-3 per the valve sequencer chart for pump priming and follow specific directions in the factory supplied pump manual included in this operation manual.

2) Compressor Operation

Close valve V-4. Follow specific directions in the factory supplied compressor manual included in this operation manual when starting the compressor.

B. Skid Operation

1) Chamber filling

a) Anchor the work boat or barge containing the utility skid near the floating bulkhead segment(s).

b) Attach the pump suction hose, return to reservoir hose, and pressure relief hose to the appropriate connection points on the utility skid.

c) Tether the hoses to the barge or work boat so that hose whipping does not occur.

d) Attach fill and vent hoses to segment chambers and appropriate connection points on the utility skid.

e) Set valve V-1 open, valve V-2 set in ‘bypass’ position (return to reservoir), valve V-3 closed, and valve V-5 partially opened.

f) Set all VF valves to ‘closed’ position.

g) Set all VA valves to ‘vent’ position.

h) Energize and prime the pump.

i) Once the pump is primed, valves V-1, V-2, V-3, and V-5 must remain set for priming until a VF valve is opened to provide a flow path to the chamber to be filled, and the corresponding VA valve is confirmed to be in the ‘vent’ position.

j) Verify vent valve is set to ‘vent’ position for the chamber to be filled.

k) Set VF valve to ‘open’ position for the chamber to be filled.

l) Change valve V-2 to ‘fill’ position.

m) Monitor level in the chamber that is filling.

n) When chamber is filled as required, return valve V-2 to ‘bypass’ position.

o) Change the chamber VF valve to ‘closed’ position.

p) Chamber VA valve remains in ‘vent’ position.

q) Repeat procedure for other chambers to be filled.

2) Chamber pump-out

a) Set valve V-1 to ‘open’, valve V-2 set in ‘bypass’ position (return to reservoir), valve V-3 to ‘closed’, and valve V-5 open.

b) Energize and prime the pump.

c) Energize the compressor.

Section 9

Mechanical Utility Skid Operations

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d) Set VF valve of the chamber to be pumped out in ‘fill’ position.

e) Set VA valve of the chamber to be pumped out in ‘vent’ position.

f) Change valve V-3 to ‘open’.

g) Change valve V-1 to ‘closed’.

h) Pump-out as required.

i) Near the end of pump-out for Segments A, B, C, D, E, the pumping rate may exceed the ability of water to flow through the segment internal stiffening plates. Utilize valve V-5 to throttle flow and slow the pumping rate if required.

j) If lift exceeds 20 feet, transition the VA valve of the chamber to ‘pressure’. This will assist the pump in lifting the water out of the chamber.

k) When pump-out is complete, return the VA valve to ‘vent’ position (if required).

l) Change valve V-1 to ‘open’ position.

m) Change valve V-3 to ‘closed’ position.

n) Change the VF valve to ‘closed’ position.

o) Note when chamber pump-out nears completion, the pump may lose prime as air enters the fill /pump-out hose, and the pump may have to be re-primed prior to subsequent fill or pump-out of other chambers.

Section 10

Bulkhead Disassembly

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10. Bulkhead Disassembly

1) After the bulkhead is in the horizontal position and ready for disassembly, pump all ballast water out of the Segment A chambers.

2) Fill leveling chambers in Segments B through G to same level as required for assembly (see Step

5 in Section 8). Fill levels shall be verified using draft leveling ports on upstream face of bulkhead

(facing up when bulkhead is in horizontal orientation). Failure to properly ballast segments may result in injury during removal of upstream vertical girder connection bolts.

3) Remove the access ladders and the remaining portions of the valve stem(s).

4) Remove nuts, washers, and bolts at upstream vertical girder connections between Segment A and next segment in bulkhead assembly. WARNING – If segments were not properly draft-leveled during Steps 1 and 2, one segment may shift abruptly relative to another while bolts are being removed.

5) Remove tension connectors between Segment A next segment in bulkhead assembly.

6) Pull disconnected Segment A away from the bulkhead assembly utilizing lines and work boats.

7) Repeat steps 4 through 6 to disassemble the remaining segments in the bulkhead assembly.

8) Remove hoses and coil hoses on hose reels.

9) Place vertical girder connection hardware and other loose parts in the storage containers.

Section 11

Bulkhead Retrieval, Transport, and Storage

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11. Bulkhead Retrieval, Transport, and Storage

A. Retrieval and Transport

1) Maneuver the segment to the assembly location with two work boats, one on each end of segment.

2) Assess the competency and elevation of the crane pad.

3) Set up SWT-owned crane at the launch site as described in Section 5.C.

4) Perform the crane pre-lift test instructions outlined in Section 5.D.

5) Attach rigging to the four lifting lugs of the segment to be removed from the reservoir.

6) Lift the segment from the reservoir and place on the low-bed trailer.

7) Remove plugs to drain residual water from bulkhead segment chambers.

8) Transport each segment and ancillary components to the Broken Bow storage shelter east of the powerhouse using the SWT-owned haul truck and low-bed trailer.

9) To prevent potential damage to the external bracing, we recommend that only one segment be transported at a time.

10) Lift utility skid from work boat or barge.

11) Drain utility skid and transport to storage area.

B. Storage

1) Park the low-bed trailer with bulkhead segment beneath the bridge crane beam.

2) Position the timber bearing blocks on the concrete support pedestal prior to lifting the bulkhead from the low-bed trailer.

3) Install belts for load-turning device and lift segment vertically in accordance with load-turning device manufacturer’s recommended operating procedures until it is clear of low-bed trailer.

4) Following load-turning device manufacturer’s recommended operating procedures, rotate segment 90 degrees about its longitudinal axis until the upstream vertical girders are perpendicular to the ground.