R0002.pdf

PDF 8 MB Posted Apr 7, 2016

Attached to: Mud Mountain Dam 9-Foot Tunnel Rearmoring
Solicitation number: W912DW-16-R-0006
Issued by: Department of the Army Corps of Engineers Engineering District Seattle

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AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

W912DW-16-R-0006 Mud Mountain Dam 9-Foot Tunnel Rearmoring, Enumclaw , WA

(see continuation page)

1. CONTRACT ID CODE PAGE OF PAGES

1 2

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 07-Apr-2016

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X W912DW-16-R-0006

X 9B. DATED (SEE ITEM 11)

15-Mar-2016

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning 1 copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

07-Apr-2016

CODE

USA ENGINEER DISTRICT, SEATTLE

ATTN: CECT-NWS

4735 EAST MARGINAL WAY SOUTH, BLDG. 1202

SEATTLE WA 98134-2388

W912DW 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

W912DW-16-R-0006

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION 00 10 00 - SOLICITATION/CONTRACT FORM

The required response date/time has changed from 14-Apr-2016 02:00 PM to 21-Apr-2016 02:00 PM.

SECTION SF 30 - BLOCK 14 CONTINUATION PAGE

The following have been added by full text:

R0002

1. This amendment two (0002) provides the following for informational purposes:

a. Section 01 10 00 – APPENDICES

b. Section 01 33 39.00 27 – ADVANCED MODELING (BIM/CIM/GIS/CAD) REQUIREMENTS

2. The proposal submittal time and date is extended to April 21, 2016 at 2:00:00 p.m. LOCAL TIME.

3. The attached revised sections are to be replaced in their entirety. Specifications changes are generally identified, for convenience, either by strikeout for deletions, and double underlining of text for additions or a single dark line in the margin. All portions of the revised sections shall apply whether or not changes have been indicated.

4. NOTICE TO OFFERORS: Offerors must acknowledge receipt of this amendment by number and date on offer.

Encl:

01 10 00 Appendices (draft) 01 33 39.00 27 (draft)

(End of Summary of Changes)

MMD 9-Foot Tunnel Re-armoring 16011

W912DW-16-R-0006 Appendix A Page 1

APPENDIX A MMD 9-FT Tunnel Rearmoring Conceptual Drawings

W912DW-16-R-0006 Appendix A Page 2

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20' 40'0 S-001

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1" = 20'-0"

S-002

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N39, 22'14.7"E

P C

EL 887.78

E 1,726,797.852 N 53,722.147

EL 891.53

E 1,726,956.920 N 53,846.927

(CENTER OF MIXING CHAMBER)

E 1,726,970.853 N 53,863.549

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EXISTING EL 890.05

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N 53,806.003

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PARTIAL SITE PLAN

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28.5°

28°

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STRAIGHT SEGMENT OF TUNNEL 1318.82 ±

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20'-0"

3.0° 3.0°

3.0°

18.2°

3.2° ±

R 4

LENGTH (TYP)

STEEL BM

15' 30'0

S-004

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PARTIAL PLAN FOR STEEL BEAMS

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'-0

5.5° 5.5°

5.5°

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S-005

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PARTIAL PLAN FOR STEEL BEAMS

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TOP WEAR PLATE

PLATE JOINTW6 STEEL BEAM (TYP)

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(N) W6 STEEL BEAM

(E) TUNNEL FLOOR PLATE

S-007

A DETAIL

1 1/2" = 1'-0"

1' 2'0 6"

21"21"3"3"

EXISTING WALL

EXISTING WALL PL 1" THICK (TYP)

6" 6"

(TYP)

PER DETAIL 1/S-007

PLATE TO STEEL BEAM

HOLE WELD LOWER

(TYP)

12"

(TYP)

12"

PENE

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(TYP)

PER DETAIL 1/S-007

PLATE TO LOWER PLATE

HOLE WELD TOP WEAR

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3'-0"3'-0"3'-0"

1/8 "

1/8 " SOLID GROUT

HEADED STUDS

(E) 7/8" x 6"

(E) S8x18.4

ORIGINAL ASCE RAILS

(E) ST4x11.5

SPACING (TYP)

ANCHORS x 3' @ 2'-0"

(E) #8 DYWIDAG ROCK

S-007

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A TYPICAL CROSS SECTION

1" = 1'-0"

0 1' 2'6"

0 1" 2"1/2"

12" = 1'-0"-

(TYP)

1 1/2 "Ø HOLE

5/16

PENE

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PENE

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STEEL PL 1" THICK

PLATE CONNECTION DETAIL (TYPICAL)

TOP SURFACE

FINISHED FLUSH WITH PLATE

APPROVED EQUAL FILLER

BELZONA 1111 OR 1121 OR

DETAIL 1/S-007 (TYP)

TO W6 BEAMS PER

WELD LOWER PLATE

5/16 3 AT 12

TYP

DETAIL 1/S-007 (TYP)

TO LOWER PLATE PER

WELD TOP WEAR PLATE

LEGEND

(N) : NEW

(E) : EXISTING

1" THICK ASTM A36

(N) STEEL LOWER PLATE

(TYP)

1/8" JOINT GAP

PROVIDE 1/8" ±

AR500

1" THICK,

(REMOVABLE)

WEAR PLATE

(N) TOP

B SECTION

1" = 1'-0"

0 1' 2'6"

15'- 0"

HORIZONTAL

5 DEGREES ABOVE

3"Ø WEEP HOLE INCLINED

TUNNEL SIDEWALL

F L

O W

EXISTING ROCK

LOCATION

SEE PLANS FOR

BEAMS (4) REQUIRED

CL (N) W6x25 SPACER

(LOCATED HALF WAY BETWEEN EXISTING WALL JOINTS)

(N) 3"Ø WEEP HOLE AT 24'-0" OC, TYP (EACH SIDE)

OBSTRUCT WEEP HOLES

EACH SIDE OF TUNNEL (TYP). DO NOT

WALL SURFACE ABOVE STEEL WALL PLATE ON

APPROVED EQUAL) APPLIED TO EXISTING

INDICATED WITH BELZONA 1111 OR 1121 (OR

(N) CLEAN AND RESURFACE WALL AREAS AS

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S-008

T R

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GROUT SOLID

BOTTOM PLATE

(E) HORSESHOE TUNNEL

(N) W6 SPACERS

(N) 1" LOWER PLATE

ASTM A36

1" LOWER PLATE

GATE CHAMBER

9-FT TUNNEL

P T

S T

GROUT BARRIER

3/4" ASTM A36

HOLE WELD

ASTM A36

1" LOWER PLATE

GROUT SOLID

B SECTION

1/2" = 1'-0"

0 2' 4'1'

1' 2'0 6"S-004

A TRANSITION RAMP

1 1/2" = 1'-0"

(TYP)

TAPERED STEEL BEAM

TAPERED STEEL BEAMS

S-007

DETAIL 1 ON

(TYP) PER

HOLE WELD

U T

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GATE CHAMBER FLOOR STEEL PLATE (EXISTING)

NOTE:

ADDITIONAL TYPICAL INFORMATION

SEE DWGS S-006 AND S-007 FOR

(N) 1" TOP WEAR PLATE

AR500

TOP WEAR PLATE

1" REMOVABLE

1" THICK FLOOR PLATE

NEW AR500

3" = 1'-0"

6"0 3" 1'

AR500

1" TOP WEAR PLATE

(GRIND FLUSH)

FULL PENE

PL JOINT

FOR TUNNEL WIDTH

WELDS USE 9" WELD SPACING

FOR THIS FIRST ROW OF

12'-0" TRANSITION/RAMP

3"3" 8" 8" 8" 9" 9" 9" 3" 1'-6"3" 3"8"8"

AND GROUT UNDER

REMOVE EXIST FLOOR PL

NEW FLOOR PL

AR500 PLATE

1" THICK

AS REQUIRED

STEEL SHIM

DETAIL

HEADED STUD (TYP)

3" 9"8"8"8"8"

8" OC MAX (TYP)

AND SPACED @

DETAIL 1/S-007

HOLE WELD PER

LOWER PLATE

STUDS AT 15" EW

(E) 7/8"Ø x 6" HEADED

ASTM A514

EXISTING FLOOR PLATE

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IDENTIFICATION

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US Army Corps

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DESIGN FILE: L:\2015\100-SET-15-078 - MMD 9FT Tunnel\cadd\struct\Sheets\MMD9FT_S-009.dgn

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W912DW-16-R-0006 Appendix B Page 1

APPENDIX B Existing Reference and As-Built Drawings

The existing MMD 9-Foot Tunnel Reference Drawings are attached for reference.

The existing drawings and as-built drawings are for information only as some of the drawings have been superseded by the modification of the existing structures and the addition of new structures. The existing conditions, including dimensions, elevations, and details shall be field-verified by the D-B Contractor prior to the start of construction. The upper portion of the alignment for the 9-FT Tunnel was changed after the new intake tower was constructed. This should be noted when reviewing the existing drawings.

W912DW-16-R-0006 Appendix B Page 2

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G3ECDGK3

Polygon

INVERT AT START

W912DW-16-R-0006 Appendix C Page 1

APPENDIX C Technical Specifications List and Brief Descriptions

The following technical specifications are anticipated to be required for this Tunnel Rearmoring project.

The D-B Engineers shall start with the Unified Facilities Guide Specifications and shall modify them as required for the specific design and project requirements. A brief summary of what is required to be provided in each technical specification section for this project is also shown in this appendix.

W912DW-16-R-0006 Appendix C Page 2

W912DW-16-R-0006 Appendix C Page 1

Specification Draft Table of Contents

Division 03 – Concrete

03 31 01.00 10 – Cast-in-Place Structural Concrete for Civil Works

Division 05 – Metals

05 12 00 – Structural Steel

05 50 15 – Civil Works Fabrications

Others

Weep Hole Coring

Specification Descriptions

03 31 01.00 10 – Cast-in-Place Structural Concrete for Civil Works

This specification shall include the following information, but is not limited to the following:

All miscellaneous concrete in place shall be 7,000 psi minimum strength at 28 days. Concrete shall be tested in accordance with Section 5.6 of ACI 318.

All grout shall be non-shrink, 5,000 psi minimum strength at 28 days. Nonshrink grout must conform to ASTM C1107/C1107M, and be a commercial formulation suitable for the proposed application. Nonshrink grout must be a ready-mixed material requiring only the addition of water.

Water content must be the minimum to provide a flowable mixture and completely fill the space to be grouted without segregation, bleeding, or reduction of strength.

Belzona 1111 or 1121, an epoxy-based composite for metal repair, or equivalent, shall be used to fill and flush connection openings at the top wear plate and lower plate.

Grouting Plan Requirements: The D-B contractor shall provide a grouting plan for review demonstrating its capabilities of grouting the space between existing and new steel plates and performing the work.

The material shall be mixed in equipment of sufficient size and capacity to provide the amount of grout material for each stage in a single operation.

Gauges to monitor grout pressure shall be attached immediately adjacent to each injection port.

The gauge shall conform to an accuracy of no more than one-half percent error over the full range of the gauge. The range of the gauge shall not be more than 100 percent greater than the design grout pressure.

No grout holes, or vent holes, or sealing plugs shall be provided in the top wear plates. Grout holes and vent holes may be provided in the bulkheads/diaphragms and in the lower plates.

W912DW-16-R-0006 Appendix C Page 2

Grouting equipment shall be such that sudden surges in pressure at refusal do not occur.

All pipe shall conform to ASTM A53/A53M standard weight. The fittings shall be malleable iron Type I in accordance with ASME B16.3, ASME B16.5, and ASME B16.9, Class 150. Pipe shall be black steel of the diameter shown or as directed.

The D-B contractor shall submit a grouting plan that shall include but not limited to:

• The proposed grouting mix

• The proposed densities and viscosities

• Initial set time of the grout

• The proposed grouting method

• The maximum injection pressures

• The 24-hour and 28-day minimum compressive strength

• Proposed grout volumes

• Bulkhead/diaphragms designs

• Buoyant force calculations

• Flow Control

• Pressure gauge certification

• Vent location plans

05 12 00 – Structural Steel

This specification shall include the following information, but is not limited to the following:

All structural top wear plates shall be AR500 steel with a nominal Brinell Hardness of 500.

Structural and miscellaneous steel shapes shall conform to ASTM A572, GR. 50 ksi and supporting plates shall confirm to ASTM A36. The D-B Contractor shall provide grout and vent holes in plates. The D-B Contractor is not limited to welded connections and may develop connections not shown in the conceptual design provided they satisfy the design criteria and performance requirements. The welding of structural and miscellaneous steel shall conform to the 2010 edition of “Structural Welding Code – Steel” (AWS D1.1). High strength bolts shall conform to ASTM A325 Type 1, ASTM A490 Type 1 or 2.

The D-B Contractor shall be able to provide the necessary inspectors qualified as follows:

Certified Welding Inspectors (CWI) shall be qualified and certified in accordance with the provisions of AWS QC1. The laboratory and all personal performing nondestructive testing shall be qualified in accordance with ASNT CP-189. Only individuals qualified for NDT Level II or individuals qualified for Level I and working under the direct supervision of a Level II shall perform nondestructive testing. Level III NDT Inspectors shall possess a currently valid ASNT Level III certificate in each of the processes they are qualifying inspectors to. Copies of the certifications, including the Level III NDT Technician that certified the Level I and Level II Technicians shall be included in the submittals.

Prior to any welding, a CWI supplied by the D-B Contractor shall visually inspect the preparation of material for welding to assure compliance with the applicable AWS Code (D1.1 or D1.5) and approved WPS. The CWI shall also perform visual test (VT) inspection throughout the welding process to assure compliance with the applicable AWS Code (D1.1 or D1.5) and approved

W912DW-16-R-0006 Appendix C Page 3 welding procedure specification (WPS). All completed welds shall be cleaned free of oxide, flux, scale, or other foreign matter before inspection. All welds shall be visually inspected by a CWI to insure compliance with the requirements of the applicable AWS Welding Code.

Making, evaluating and reporting ultrasonic testing of welds shall conform to the requirements of AWS D1.1, Section 6, Part F or AWS D1.5 Subsection 12.16, as applicable. A record shall be made of each weld tested.

Making, evaluating and reporting radiographic testing of welds shall conform to the requirements of AWS D1.1, Section 6, Part E or AWS D1.5 Subsection 12.16, as applicable. Only film types designated as “fine grain” or “extra fine” shall be employed.

Magnetic particle inspection of welds shall conform to the applicable provisions of ASTM E 709 or AWS D1.5 Subsection 12.16, as applicable and in addition all magnetic particle inspections of welds shall be made using the Wet Contrasting Black on White Method.

Welds shall be unacceptable if shown to have defects prohibited by AWS D1.1, Section 6, Part C or AWS D1.5 Subsection 12.16, as applicable.

The D-B Contractor shall VT inspect all full penetration welds as indicated on the drawing.

Additionally, there will be twenty-five percent (25%) random testing of the remaining welds.

This testing shall be done by the ultrasonic testing (UT) and/or radiographic testing (RT) procedures described above. This additional twenty-five percent (25%) shall include a representative sample of welds from all welders. The random testing shall be spread throughout the project. A schedule for implementing the random testing shall be developed by the contractor and submitted for approval prior to fabrication. The RT will have to meet the acceptance criteria stated in AWS D1.1, Section 6.12.1. The UT will have to meet the acceptance criteria stated in AWS D1.1, Section 6.13.1.

The D-B Contractor shall VT inspect all fillet welds as indicated on the drawing. Additionally, there will be twenty-five percent (25%) random testing of the remaining welds. This testing shall be done by the magnetic particle testing procedures described above. This additional twenty-five percent (25%) shall include a representative sample of welds from all welders. The random testing shall be spread throughout the project. A schedule for implementing the random testing shall be developed by the contractor and submitted for approval prior to fabrication.

Defective weld metal shall be removed by air carbon-arc or oxygen gouging to sound metal. The surfaces shall be thoroughly cleaned before welding. The resulting cavities shall be rewelded in compliance with AWS D1.1, Subsection 5.26. When deemed necessary by the Contracting Officer, the D-B Contractor shall submit a welding repair plan for approval before repairs are made. Welds that have been repaired shall be retested by the same methods used in the original inspection. All costs of repairs and testing shall be borne by the D-B Contractor, except for repair of members cut to remove test coupons that were found to contain acceptable welds.

05 50 15 – Civil Works Fabrications

This specification shall include the following information, but is not limited to the following:

Provide a detailed Work Plan for fabrication, including descriptions of shop facilities, equipment, number of personnel, and related information prior to the Pre-fabrication Conference, and procedures for safe conduct of the work, careful removal and disposition of materials, protection of property that is to remain undisturbed, and coordination with other work in progress.

W912DW-16-R-0006 Appendix C Page 4

Weep Hole Coring

Provide a detailed Work Plan for preparation and coring weep holes in the sidewalls of the 9-Foot Tunnel. The D-B Contractor shall use the coring section on the Conceptual Drawings to provide necessary details.

W912DW-16-R-0006 Appendix D Page 1

APPENDIX D Existing Steel Floor, November 2013, 9-FT Tunnel Steel Floor Thicknesses

W912DW-16-R-0006 Appendix D Page 2

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ATTACHMENT 2

November 2013 9’ Tunnel Steel Floor Thicknesses

9 ft Tunnel Steel Floor Readings

Seam Number

Station ‐

Measured from radial gate in feet

6" in from

Left Wall Center

6" in from

Right Wall Notes

0 20 0.335 0.603 0.846

0.5 30 0.326 0.673 0.839

1 42 0.260 0.670 0.860

2 52 0.239 0.621 0.845

3 62 Hole 0.621 0.800

4 72 Hole 0.660 0.800

5 82 Hole 0.642 0.820

6 91 0.143 0.657 0.828

7 101 Hole 0.682 0.845

8 111 0.141 0.724 0.822

9 121 Hole 0.816 0.843

10 131 Hole 0.699 0.836

11 141 Hole 0.776 0.868

12 151 Hole 0.651 0.857

13 161 Hole 0.767 0.880

14 170 Hole 0.768 0.910 0.657 0.689

15 180 Hole 0.780 0.878

16 190 Hole 0.772 0.900 0.719 0.835

17 200 Hole 0.739 0.884

18 210 Hole 0.751 0.907 0.707 0.823

19 220 Hole 0.796 0.905

20 230 Hole 0.800 0.903 0.675 0.796

21 240 Hole 0.720 0.899

22 250 Hole 0.758 0.911 0.668 0.774

23 260 Hole 0.714 0.928

24 270 Hole 0.744 0.911 0.603 0.769

25 280 Hole 0.724 0.898

26 290 Hole 0.704 0.885 0.638 0.769

27 300 Hole 0.720 0.889

28 310 Hole 0.641 0.862 0.540 0.769

29 320 Hole 0.627 0.878

30 330 0.115 0.642 0.855 0.546 0.702

31 340 0.212 0.630 0.859

32 350 Hole 0.655 0.848 0.529 0.781

33 360 0.206 0.767 0.855

34 370 0.158 0.612 0.860 0.534 0.748

35 380 0.395 0.657 0.872

36 390 0.204 0.611 0.842 0.545 0.751

W912DW-16-R-0006 Appendix D Page 3

- 25 -

37 400 0.347 0.633 0.847

38 410 0.334 0.623 0.850 0.524 0.753

39 420 0.397 0.618 0.846

40 430 0.407 0.517 0.863 0.429 0.743

41 440 0.500 0.521 0.857

42 450 0.570 0.520 0.831 0.423 0.708

43 460 0.620 0.505 0.841

44 470 0.625 0.448 0.828 0.459 0.729

45 480 0.626 0.615 0.844

46 490 0.685 0.539 0.815 0.394 0.491

47 500 0.663 0.375 0.835

48 510 0.684 0.488 0.831 0.334 0.581

49 520 0.715 0.490 0.812

50 531 0.712 0.382 0.803 0.400 0.691

51 541 0.724 0.437 0.822

52 551 0.728 0.451 0.818 0.393 0.641

53 561 0.756 0.466 0.867

54 571 0.775 0.390 0.821 0.410 0.612

55 581 0.757 0.365 0.832

56 591 0.738 0.224 0.804 0.376 0.640

57 601 0.781 0.423 0.836

58 611 0.698 0.298 0.821 0.370 0.519

59 621 0.777 0.422 0.848

60 631 0.737 0.377 0.831 0.400 0.602

61 641 0.758 0.215 0.831

62 651 0.772 0.284 0.811 0.378 0.543

63 661 0.784 0.355 0.795

64 671 0.745 0.291 0.794 0.387 0.478

65 681 0.764 0.344 0.817

66 691 0.795 0.293 0.838 0.402 0.550

67 701 0.779 0.348 0.835

68 711 0.757 0.211 0.816 0.373 0.501

69 721 0.779 0.222 0.807

70 731 0.777 0.125 0.804 0.468 0.480

71 741 0.776 0.236 0.796

72 751 0.797 0.116 0.822 0.375 0.484

73 761 0.805 0.328 0.832

74 771 0.797 0.242 0.848 0.430 0.467

75 781 0.823 0.387 0.837

76 791 0.803 0.211 0.790 0.457 0.404

77 801 0.868 0.283 0.783

78 811 0.745 0.387 0.810 0.378 0.440

79 821 0.820 0.449 0.845

80 832 0.796 0.296 0.800 0.482 0.483

81 842 0.780 0.258 0.819

W912DW-16-R-0006 Appendix D Page 4

- 26 -

82 852 0.801 0.233 0.777 0.411 0.480

83 861 0.799 0.269 0.803

84 871 0.786 0.209 0.802 0.457 0.473

85 881 0.803 0.318 0.777

86 891 0.799 0.219 0.785 0.587 0.451

87 902 0.864 0.191 0.785

88 912 0.802 0.177 0.782 0.568 0.339

89 922 0.782 0.260 0.803

90 932 0.766 0.173 0.790 0.483 0.452

91 942 0.803 0.382 0.802

92 952 0.807 Hole 0.796 0.549 0.549

93 962 0.822 0.315 0.805

94 972 0.822 0.123 0.793 0.577 0.500

95 982 0.815 0.275 0.787

96 992 0.770 0.200 0.807 0.511 0.542

97 1002 0.797 0.266 0.802

98 1012 0.740 0.213 0.787 0.488 0.460

99 1022 0.795 0.270 0.788

100 1032 0.795 0.201 0.797 0.478 0.531

101 1043 0.792 0.289 0.794

102 1053 0.805 0.163 0.846 0.503 0.386

103 1063 0.777 0.286 0.785

104 1073 0.782 Hole 0.764 0.485 0.513

105 1083 0.819 0.324 0.798

106 1093 0.824 0.128 0.773 0.305 0.424

107 1103 0.816 0.337 0.814

108 1113 0.800 Hole 0.809 0.453 0.453

109 1123 0.826 0.298 0.795

110 1133 0.800 0.134 0.805 0.377 0.561

111 1143 0.784 0.314 0.822

112 1153 0.819 Hole 0.802 0.460 0.413

113 1163 0.793 0.755 0.785

114 1173 0.792 0.136 0.822 0.518 0.415

115 1183 0.788 0.318 0.786

116 1193 0.803 Hole 0.773 0.590 0.457

117 1203 0.806 0.315 0.809

118 1213 0.795 0.177 0.802 0.512 0.444

119 1223 0.795 0.204 0.807

120 1233 0.813 0.190 0.783 0.564 0.470

121 1243 0.827 0.343 0.812

122 1253 0.803 0.151 0.806 0.485 0.502

123 1263 0.806 0.283 0.795

124 1273 0.828 0.277 0.837 0.541 0.599

W912DW-16-R-0006 Appendix D Page 5

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125 1283 0.793 0.340 0.713

126 1293 0.805 0.115 0.833 0.513 0.417

127 1303 0.805 0.364 0.818

128 1313 0.821 0.251 0.837 0.601 0.504

129 1323 0.809 0.352 0.831

130 1333 0.852 0.118 0.824 0.472 0.444

131 1344 0.814 0.383 0.820

132 1354 0.842 0.255 0.831 0.496 0.537

133 1364 0.836 0.334 0.823

134 1374 0.847 0.202 0.882 0.498 0.458

135 1384 0.849 0.350 0.823

136 1394 0.840 0.278 0.838 0.588 0.602

137 1404 0.846 0.400 0.816

138 1414 0.842 0.224 0.840 0.605 0.455

139 1424 0.843 0.363 0.819

140 1434 0.825 Hole 0.817 0.576 0.458

141 1444 0.848 0.366 0.806

142 1454 0.861 Hole 0.831 Truck Truck

143 1463 0.818 Hole 0.842

144 1474 0.827 Hole 0.851 0.492 0.550

145 1484 0.822 0.432 0.844

146 1493 0.833 Hole 0.840

147 1500 0.888 0.344 0.827

148 1507 0.848 0.099 0.822

149 1515 0.827 0.268 0.847

150 1522 0.828 Hole 0.827

151 1529 0.877 0.400 0.797

152 1536 0.893 0.371 0.623

153 1543 0.868 0.666 0.565

154 1550 0.875 0.551 0.200

155 1557 0.901 0.741 0.258

156 1565 0.888 0.765 Hole

157 1572 0.900 0.780 Hole

158 1579 0.885 0.796 Hole

159 1586 Equipment 0.833 Hole

160 1593 0.960 0.824 Hole

161 1599 0.906 0.959 0.871

162 1607 0.899 Readings on Test Panels Below

163 1613 0.900 Readings on Test Panels Below

164 1619 0.900 Readings on Test Panels Below

165 1625 0.907 Readings on Test Panels Below

166 1631 0.899 Readings on Test Panels Below

167 1637 0.890 Readings on Test Panels Below

168 1643 0.890 Readings on Test Panels Below

169 1649 0.882 Readings on Test Panels Below

170 1655 0.874 Readings on Test Panels Below

171 1662 0.846 Readings on Test Panels BDownstream End of Tunnel

172 1670 0.889

W912DW-16-R-0006 Appendix D Page 6

W912DW-16-R-0006 Appendix E Page 1

APPENDIX E USACE MEMO on Hydraulic Conditions in MMD 9-FT Tunnel (7 July 2015)

W912DW-16-R-0006 Appendix E Page 2

CENWS-EN-HH-HE 7 July 2015

FROM: Chief, Hydraulic Engineering Section (Katz)

SUBJECT: Hydraulic Conditions in MMD 9-foot tunnel – (Excerpted from MFR AUG 2015)

Purposes.

This memorandum is intended as supplemental information for the RFP, and has the following purposes.

1. Describe the range of tunnel hydraulic conditions that can occur in the tunnel as currently configured.

2. Describe the range of hydraulic conditions that may occur when the tunnel is modified by the addition of a new tunnel liner.

References.

EM-1110-2-1601 - Hydraulic Design of Flood Control Channels

EM 1110-2-1602 – Hydraulic Design of Reservoir Outlet Works

HEC-RAS - Hydrologic Engineering Center River Analysis Software

Design Assumptions

Horizontal extent of replacement liner.

1. The nine-foot tunnel hydraulic conditions described in this memorandum were analyzed assuming that a steel liner will be installed through the horseshoe tunnel and to the downstream end of the discharge conduit.

2. It was assumed that the present tunnel floor slope would be maintained, from its entrance to the mixing chamber, downstream through the rectangular tunnel, and the radial gate chamber. A 12-ft transition from the existing floor to the new floor is assumed in the transition to the horseshoe tunnel. The slope of the proposed floor in the horseshoe tunnel is the same as its existing floor.

Vertical position of replacement liner.

1. This analysis assumes that the replacement floor panels will be installed eight (8) inches above the existing liner. This allows abandoning in place the current damaged steel liner and building a new steel plate armored floor above the original damaged floor.

2. Hydraulic analysis found that any floor raise of eight inches or less will provide a tunnel discharge at the current pool limit (elevation 930 feet) that is sufficiently close to its current discharge to avoid a significant change in Water Management reservoir regulation. The reduction in discharge at the pool limit (930 feet elevation) due to the new liner is estimated at 360 cfs.

3. The current design requires a floor raise of 8 inches for structural reasons. While this is acceptable hydraulically, any further design change that moves the new liner

W912DW-16-R-0006 Appendix E Page 3 closer to the existing liner profile is likely to improve future hydraulic conditions and reduce the risk of occurrence of a new, undesirable hydraulic condition (e.g., hydraulic jump or slug flow).

Monitoring and Post-Construction Modification

1. It is assumed that the tunnel hydraulic conditions will be closely monitored and the tunnel floor inspected regularly after installation of the new tunnel liner.

2. Operations. If the restriction caused by the new liner results in conditions described above (e.g., slug flow observed at the tunnel exit), it is recommended that operational adjustments be considered. Modified operations, if needed, could include reducing the normal gate setting to about 75% or less, and allowing the reservoir pool to rise, to approximately the 940-foot to 950 foot elevation range.

3. Maintenance. Worn areas will be replaced before holes develop in the protective steel floor. Since the tunnel liner was already damaged before the pool elevation was restricted, the effectiveness of the new liner in minimizing damage is not absolutely clear at this time. Damages may continue to occur in areas where it has been previously observed, or in other areas due to changed hydraulic conditions.

a. To provide additional protection, and a maintainable surface, the entire horseshoe tunnel will be lined with a two-layer floor; the lower layer a permanent 1-inch thick steel; the top layer will be composed of 1-inch thick steel plates securely connected to the lower layer (2-inch total thickness of steel).

b. The top plates plates will be about 8 feet by 3 feet in size, and are designed to be replaced as needed by project personnel. The connection between the two layers of plates will be filled and smoothed to minimize asperities/roughness

c. If feasible, this system will be tested in advance of the full tunnel relining project.

Outflow discharge probability of occurrence1

The probability of occurrence of outflow discharges described in this MFR can be estimated from the percent of time an equivalent inflow discharge is equaled or exceeded, by assuming that Mud Mountain Dam is simply passing inflows.

Low Flow (1,000 cfs): exceeded 60% of the time Intermediate Flow (2,000 cfs): exceeded 20% of the time.

Pool Limit (present) (2,400cfs): exceeded 13% of the time.

For reference, the MMD median inflow/outflow is 1,170 cfs.

Hydraulic Conditions.

1 Source: Senior Water Manager Ken Brettmann - statistics on mean daily MMD inflows (a good representation of outflow statistics assuming an operation of passing inflows).

W912DW-16-R-0006 Appendix E Page 4

Methods

1. Discharge Rating Curves. Discharge rating curves for present and proposed conditions were prepared using methods described in EM-2-1110-1602, Appendix D, Computation of Discharge Rating Curves for Outlet Works.

2. Water Surface Profiles. Water surface profiles were computed by one-dimensional hydraulic modeling using Corps of Engineers HEC-RAS software.

Model files are available for review.

3. Calibration. Discharge Rating Curves and Water Surface Profiles closely match (Figure A-3; Table 1).

4. Super elevation at channel bends was calculated using the approach in EM 1110-2-1601, Section 2-5, Flow in Curved Channels.

5. If conditions other than those described in this MFR are needed for design purposes, (e.g., if the final design liner is placed at a different elevation), changes can be calculated relatively quickly with the HEC-RAS model and spreadsheet described above.

Results

1. Hydraulic Roughness.

a. Discharge rating curves and HEC-RAS model simulations were performed with low and high roughness. The Darcy Weisbach f was varied from 0.009 to 0.014, and the Mannings n from 0.010 to 0.012. At this time, the lower roughness values best match the USGS gage data. However, data includes only one point above elevation 910; we will investigate opportunities to add more data points in this range.

b. The proposed new liner decreases discharge by about 350 cfs when comparing the same roughness assumption with fully open gate at the pool limit. The range of roughness assumptions makes approximately the same difference (350 cfs) when comparing the current and proposed floors at the pool limit and fully open gate (Figures A-4 to A-7).

c. Tunnel hydraulics is sensitive to hydraulic roughness when open channel flow occurs and when full flow occurs. For a given discharge, pool elevation increases with increasing roughness (Figure A-10).

2. Present Configuration

a. Low flow; low roughness. When the tunnel is operating at relatively low flow

(e.g., 1000 cfs; pool elevation about 902; Figure A-4) with the radial gate fully open, it is a fully open channel from the entrance in the mixing chamber to the tunnel exit at the tailrace. At this discharge, the pool in the mixing chamber is approximately at the top of the bell-mouth tunnel entrance, the water depth at the tunnel entrance is about 7.3 feet, and near the tunnel exit, the water depth is approximately 3.5 feet. Water velocity varies from about 15 feet per second at the tunnel entrance (critical depth) to about 32 feet per second at the downstream end (normal depth) (Figure A-8; Table 2). The super elevated water surface at the upstream bend will be approximately 0.3 feet

W912DW-16-R-0006 Appendix E Page 5 above the centerline depth at the outside of the bend, and about 0.3 feet below the average depth at the inside of the bend (calculated from guidance in EM 1110-2-1601, Hydraulic Design of Flood Control Channels, Section 2-5, assuming the bend radius of 500 feet, average depth of 4.9 feet, and the average velocity about 22 feet per second). At the bend near the tunnel exit, the super elevated water surface will be approximately 0.8 feet above the centerline depth at the outside of the bend, and about 0.8 feet below the centerline depth at the inside of the bend (assuming bend radius is 350 feet, the centerline depth is 3.5 feet, and the average velocity is about 32 feet per second).

b. Intermediate flow (Figure A-8 and Table 2). When the tunnel radial gate is 100% open, the upper limit of open channel flow probably occurs when the upstream pool elevation is near 915 feet, and discharge is about 2000 cfs (Figure A-8; low roughness). This discharge is exceeded about 20-percent of the time. This scenario produces slightly pressurized flow and water depths in the range of 9 feet at the tunnel entrance, and open channel flow with a water depth of 6.5 feet near the tunnel exit, with corresponding velocities of 25 fps to 36 fps.

i) When much of the tunnel, especially at the upstream end, operates at close to full flow depth, the effectiveness of the air intake may be reduced, and slug flow can occur. Such conditions have been observed at the outlet of the tunnel, including a cycling between full flow and open channel flow at the tunnel exit portal. No distinct negative consequences have been observed, such as noise, vibration, or widely fluctuating discharge2.

We will look for opportunities to make further observations over the next season.

ii) Super elevation in the tunnel would be the same or less than in the low-flow condition, because the free water surface is narrower in cross-section, and the water velocity is only slightly higher; it is difficult to predict because the tunnel is nearly full, and normal methods do not apply. At both tunnel bends, the tunnel could be pressurized due to cross-waves.

c. Pool Limit (Figure A-8 and Table 2). Currently, the 9-foot tunnel is left open until the water level in the mixing chamber at the upstream end of the tunnel is predicted to rise above 930 foot elevation. This occurs about 13% of the time. At the pool limit, assuming the radial gate is 100% open and closure operations have not begun, the tunnel probably is flowing full, and is slightly pressurized in most of its length. Air bubbles and larger air pockets may move downstream as the tunnel may be in a transition phase from partly full to pressurized discharge. Since the tunnel is pressurized, there is no free water surface, and no super elevation occurs.

d. Very High Pool (Figure A-9 and Table 3). The nine-foot tunnel is not currently used when the pool is above 930 elevation. If the tunnel was opened in the

2 Personal conversation between Dan Katz and Doug Knapp, NWP, June, 2015

W912DW-16-R-0006 Appendix E Page 6 most extreme possible event, the upstream pool would be 1220 feet in elevation, the tunnel would be fully pressurized, the estimated hydraulic and energy grade lines would be as shown in Figure A-9, and associated depths and velocities at corresponding points in the tunnel would be as listed in Table 3.

2. Modified Configuration.

a. General.

1. It is assumed the new liner will be 8 inches above the existing liner.

Detailed differences between the existing and 8-inch raised floors can be found in Appendix figures and tables.

2. The area reduction resulting from the proposed new tunnel liner produces a reduction in tunnel capacity of up to 350 cfs for pool elevations below the 930-foot limit (Figures A-4 to A-7).

3. Although the 9-foot tunnel will have less capacity than the current tunnel, and a pool elevation of up to 950 might be required to match the discharge of the current tunnel at the 930 pool, it is unlikely to be operated up to the 950 pool elevation. This is because the 23 foot tunnel is available for use at pool elevations above 930.

b. Low flow. When the tunnel is operating at low flow (e.g., 1000 cfs) with the radial gate fully open, its hydraulic conditions are nearly the same as the tunnel in its current configuration; it is a fully open channel from the entrance in the mixing chamber to the tunnel exit at the tailrace. The estimated velocities, depths, and super elevation are as given above, in Results – Present Configuration - Low Flow.

c. Intermediate flow When the tunnel radial gate is fully open, the upper limit of fully open channel flow probably occurs when the upstream pool elevation is about 910, and discharge is about 1650 cfs (Figure A-10). Above that elevation, the tunnel begins to transition to fully pressurized flow. Thus, for a discharge of 2,000 cfs, the tunnel probably flows full, as shown in Figure A-8 and Table 2. While current operational rules require the tunnel gate to be operated either fully open or fully closed, in the future it may need to be operated less than fully open to avoid slug flow and to assure proper airflow with the new liner. Such a change would require coordination with stakeholders / agencies.

d. Pool Limit. Unless operational changes are needed as described immediately above, the 9-foot tunnel will be left open as it is currently - until the water level in the mixing chamber at the upstream end of the tunnel is predicted to rise above 930 foot elevation. At this limit, assuming the radial gate is 100% open and closure operations have not begun, the tunnel will flow full, and will be pressurized. As with current operations, air bubbles and larger air pockets may move downstream as the tunnel is in a transition phase from partly full to pressurized discharge. Since the tunnel is pressurized, there is no free water surface (Figure A-6), and no super elevation occurs.

e. Very High Pool. The nine-foot tunnel is not to be used when the pool is above 930 elevation. However, if the tunnel was opened in the most extreme

W912DW-16-R-0006 Appendix E Page 7 possible event, the upstream pool would be 1220 feet in elevation, the tunnel would be fully pressurized. The estimated hydraulic and energy grade lines would be no higher than as shown in Figure A-10, and associated depths and velocities at corresponding points in the tunnel would be no greater than as listed in Appendix Table, “Mud Mountain Tunnel – RAS Model Results for High Water Conditions.”

Daniel M. Katz Chief, Hydraulic Engineering Section

Seattle District

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APPENDIX

Figures

A-1

A-2

A-3. Roughness calibration of HEC-RAS model with Discharge Rating Curve

A-4. Discharge Rating Curve of Current Nine-Foot (R3) Tunnel at Mud Mountain Dam.

A-5. Discharge Rating Curve – Current Nine-Foot (R3) Tunnel at Mud Mountain Dam with High Friction Factor.

A-6. Discharge Rating Curve – Proposed Nine-Foot (R3) Tunnel at Mud Mountain Dam with Low Friction Factor.

A-7. Discharge Rating Curve – Proposed Nine-Foot (R3) Tunnel at Mud Mountain Dam with High Friction Factor.

A-8. Water surfaces and hydraulic grade lines for normal pool elevation (low friction factor).

A-9. High Pool Hydraulic Grade Lines (low friction factor).

A-10. Comparison of High and Low Mannings n.

Tables

1. Data displayed in Figure A-3 (roughness calibration).

2. HEC-RAS output for Figure 8 (Water surfaces and grade lines for normal pool elevation and low n).

3. HEC-RAS output for Figure 9 (Water surfaces and grade lines for high pool elevation and low n).

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Figure A-3. Demonstration of close calibration of HEC-RAS model with Discharge Rating Curve (both with Manning n = 0.01 or equivalent Darcy-Weisbach f). x-axis: pool elevation (feet); y-axis: discharge, cfs).

Table 1. Data displayed in Figure A-3.

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Figure A-4. Discharge Rating Curve – Current Nine-Foot (R3) Tunnel at Mud Mountain Dam with Low Friction Factor (Darcy Weisbach f = 0.009). Physically possible operations are on and left of: “inlet” curve between elevation 892 and 905; “100% gate” between elevation 905 and 915; and “100 pipe” above elevation 915. Transition from open channel to pressure flow: rough operation may occur with gate openings 80% to 100% above approximately pool elevation 905. Points in red are associated with the downstream USGS gage used for curve calibration; “14% mix cham” and “50% mix cham “ show, respectively, show USGS measured data points with gate 14% and 50% open, respectively.

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Figure A-5. Discharge Rating Curve – Current Nine-Foot (R3) Tunnel at Mud Mountain Dam with High Friction Factor (Darcy Weisbach f = 0.014). Physically possible operations are on and left of: “inlet” curve between elevation 892 and 905; “100% gate” between elevation 905 and 915; and “100 pipe” above elevation 915. Transition from open channel to pressure flow: rough operation may occur with gate openings 80% to 100% above approximately pool elevation 905. Points in red are associated with the downstream USGS gage used for curve calibration; “14% mix cham” and “50% mix cham “ show, respectively, show USGS measured data points with gate 14% and 50% open, respectively.

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Figure A-6. Discharge Rating Curve – Proposed Nine-Foot (R3) Tunnel at Mud Mountain Dam with Low Friction Factor (Darcy Weisbach f = 0.009). Physically possible operations are on and left of: “inlet” curve between elevation 892 and 905; “100% gate” between elevation 905 and 915; and “100 pipe” above elevation 915. Transition from open channel to pressure flow: rough operation may occur with gate openings 80% to 100% above approximately pool elevation 905. Points in red are associated with the downstream USGS gage used for curve calibration; “14% mix cham” and “50% mix cham “ show, respectively, show USGS measured data points with gate 14% and 50% open, respectively.

W912DW-16-R-0006 Appendix E Page 13

Figure A-7. Discharge Rating Curve – Proposed Nine-Foot (R3) Tunnel at Mud Mountain Dam with High Friction Factor (Darcy Weisbach f = 0.014). Physically possible operations are on and left of: “inlet” curve between elevation 892 and 905; “100% gate” between elevation 905 and 915; and “100 pipe” above elevation 915. Transition from open channel to pressure flow: rough operation may occur with gate openings 80% to 100% above approximately pool elevation 905. Points in red are associated with the downstream USGS gage used for curve calibration; “14% mix cham” and “50% mix cham “ show, respectively, show USGS measured data points with gate 14% and 50% open, respectively.

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Figure A-8. Water surfaces and hydraulic grade lines for normal pool elevation. Comparison of discharges from 1000 cfs to 2400 cfs for the existing and proposed tunnel configuration with low roughness (n = 0.01). Note: Pool elevation in mixing chamber best represented by elevation at about station 1760 (Limit of gray shading). Elevations shown beyond gray shading near station 1800 are not realistic and can be ignored.

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Table 2. HEC-RAS output for Figure 8 (Water surfaces and grade lines for normal pool elevation and low n).

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Table 2 Continued.

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Table 2 Continued.

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Figure A-9. High Pool Hydraulic Grade Lines. Comparison of Discharges from 4000 cfs to 4750 cfs for the existing and proposed tunnel configuration with low roughness (n = 0.01). Note: Pool elevation in mixing chamber best represented by elevation at about station 1762 (near limit of gray shading). Elevations shown at and beyond limit of gray shading (station 1800) are not realistic and can be ignored.

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Table 3. HEC-RAS output for Figure 9 (Water surfaces and grade lines for high pool elevation and low n).

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Table 3 Continued.

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Table 3 Continued.

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Figure A-10. High and Low Mannings n. Comparison showing the effect of low and high Mannings n Roughness Coefficient (n = 0.01; n = 0.012) at two different flow rates: 1650 cfs and 2400 cfs for the existing condition. Notes: 1) Pool elevation in mixing chamber best represented by elevation at station 1762.

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