Cowlitz Falls Hydroelectric Project

The Continuing Saga of the Cowlitz Falls Sluice Gates

2003 Repairs By Steve Grega & Jim Byrd NW Hydro Conference June 9, 2005

Overview of Cowlitz Falls Project

Where is Cowlitz Falls Dam?

Chehalis

I-5 SR-12

Randle

Cowlitz Falls Dam

Cowlitz Falls Project History

Started Studies in 1977 License Application in April 1981 NEPA EIS April 1983 Licensed in June 1986 Permitting until 1991

Construction Started June 1991

Digging

Blasting

Construction Continued Through 1993

Equipment

Concrete

Commercial Operation June 1994

Dam

Cowlitz Falls Statistics

145 feet off of Bedrock 700 feet Long 2 Kaplan-Type Turbines 2 35MW Generators 265,000MWHr Annually

Dam Unique Features

Floating Debris Barrier (Queen Mary)

Powerhouse Spillway Overflow Design

Operation of Cowlitz Falls Project

Run of River Operation SCADA holds Lake at nearly Constant Level Up to Two Foot Daily Reservoir Variation If Flows are between 1000cfs and 1800cfs, Generate only Part of Day Inflow below 1000cfs and Riffe Lake below Elevation 750, Pass Inflow Drawdown if flows are great than 15,000 cfs in Randle. 10 to 20 dependant on Inflow

Staffing Operation
Staff of 7 Full-Time Employees Man the Plant 7 days / week, 365 days/ year 8 Hours / day On-Call 16 hours / day Manned Full Time when Conditions warrant

Flood Operations
December 1995 Flood 70.000 cfs

February 1996 Flood of Record 100,000 cfs

Flood Operations

Gates 2 & 3 Full Open

Gates 1 & 4 Full Open

The Sluice Gates

Two gated lowlevel outlet tunnels under Spillway #4 Tunnel is equipped with 12 wide by 16 high wheeled gates Third diversion tunnel blocked off

Purpose of Sluice Gates

Assist in passing silt in front of dam Assist in passing flows in access of turbine flow >10,500cfs Passing low flows during time inflows below turbine minimums Dewatering Reservoir below spillway ogee

Sluice Gate Design

Regulating Wheel Gate 74,000 pounds w/ballast Design Head 92 feet 12 Stainless steel wheels 19.7 diameter Hydraulic Raised, Gravity Closed 3.5 diameter rod @ 1000psi raises gate

Sluiceway Dewatering
Maintenance Bulkhead Gate Closes only under balanced head conditions Guides do not come to surface Requires divers and 50-ton crane to install and retrieve

Original Gate Design

Top & Bottom flanged wheels to restrain lateral movement

Top & Bottom spring rollers to restrain upstream movement

First Problems May 1994

Start-up testing of Sluice Gates Both Gates Noisy Both Gates jammed Would not move up or down Drained Reservoir Found gates off track

Modifications #1 Dec 1994

Experts Unsteady Pressures exist that cause gate to jump Add Heavier spring assemblies Add side rails & bumpers Modify top Lintel Chamber ceiling Repair Wheels, etc.
Some improvement but still loud banging

Modification #2 Aug 1996

Installed pressing system To hold gate downstream Control software modifications open gate to 112% to remove from waterway
Still too much gate movement

Modification #3 Nov 1997

Installed 4 zero-clearance side guide shoes Installed stainless steel side guide rails

Testing & Acceptance of the Gates

Full operation testing conducted in Mar 98 Gates smooth to 80% 90% to 112% rough operation 112% open and spillway gate 4 open 3, sounds reduced SG#4 to 10 open,sound reduced Manufacture & Engineer left us

Gate operation Problems 1999 2003

Apr 99 Notice a bottom Bumper was missing Sep 99 Inspection found 3 of the 4 bottom bumper gone Bolts failed in tension Lower section of side rail missing Reduced max opening to 63% or 10 Continued to Operate Gates Top Side Bumper

Failed Components
Box holding bumper pads

Bolts securing bottom bracket failed in tension

Feb 2003 Operational Failure

Plant manned during moderate flood heavy sediment load, drawn down reservoir 14 feet (elev. 848) Spilling from Spillways 1 & 4 SCADA system opened sluice gates 1 & 2 to 5

2003 Operation Failure Corrective Actions

Operator closed Spill Gate 4 followed by the closing of sluice gates Sluices closed to foot Re-opened spill gate 4 to pass flood Other attempts were made to close sluices Both gates stuck at 9 open
Stuck sluice gate from D/S side

Drain the Reservoir? Yep!

After analyzing situation balance closure with sluice bulkhead required Must obtain permits Clean out moorage site Move Debris Barrier Construct a 2nd bulkhead Drain Reservoir Install bulkhead gates

Drawn Down Reservoir

Silt?

Bulkhead Closure

After some coaxing bulkheads finally seated & stopped the flow

Removal of Sluice Gate #1

Difficult & expensive to find crane to handle load 1st remove hatch cover Remove cylinder & rod Remove top platform Remove top bumpers

Removal of Sluice Gate #1

Requires a 300-ton crane Experienced Ironworkers

Inspection & Findings

Wheel Friction, 6 of 12 wheels could not be turned by hand

in poor condition

IWheel thrust washers

Inspection
Wheel & Rails indicated scoring on surfaces (from wheels not turning)

spring rollers indicated heavy impact

ISide

Inspection

Indications of Lateral movement (rail scoring)

Concrete slot erosion

Conclusions
Gates Stuck do to increased wheel bushing friction Wheel Damage caused by large impact forces Bushing Damage caused by dirt and possible bushing material swelling no clearance Gravity closure safety margin too small Lower bumpers subject to high velocity flows & debris impact

Gate Repairs & Modifications

Replaced wheel bushings - Lubrite mang-brnz with G-10 lubricant Add seals to reduce contamination

thrust washers (Manganese-Bronze) IFace cut wheels

IReplaced

Gate Repairs & Modifications

Rebuilt side roller spring assemblies Combined lower roller spring & zeroclearance guides

Orkot Sliding Pad with Rubber Pad behind

Gate Repairs & Modifications

Repaired Guides and Concrete
Used Emaco S88, fiber-reinforced structural repair mortar

Gate Repairs & Modifications

Rebuilt hydraulic cylinder Rebuilt electronic position device (temposonic)

Gate Repairs & Modifications

Repaired pressing system roller rails Repaired Gate Seals

Final Check and Installation

Rehabilitation Complete

Where do we go from here?

Tested gates to 10 Evaluate adding additional ballast to gates Evaluated adding upper snubber system to reduce movement in full open position Extend gantry crane rail across bay 4

Cowlitz Falls Hydroelectric Project

Questions?