M. Barker, B. Vivian, J. Matthews and P. Oliver
This paper discusses reliability issues of the fourteen 3.85m high by 7.89m wide radial gates at Glenmaggie Dam in Victoria and the twin 3.6m high by 16.5m wide drum gates at Little Nerang Dam in Queensland. The Glenmaggie dam radial gates are manually controlled using electrically driven (mains and diesel generator power supply) hoist motors with a petrol driven hydraulic pack for use in the event of complete electrical power supply failure. A detailed fault tree analysis was developed for the spillway gate reliability of the Glenmaggie Dam gates as part of the risk assessment for the dam, which was being completed at the time of publishing the paper. Each of the identified components of the spillway gates, including human error in operation was used to evaluate the probability of failure of a single gate or multiple gates for inclusion in the event tree to estimate the risk and assist the evaluation of the requirement for remedial works. The Little Nerang drum gates are fully automatic hydraulically operated gates with independent operating mechanics and a common override system in the event of automatic system failure. Drum gates are uncommon on dams and the system operation is discussed together with an assessment of the reliability and measures taken for handling operating risks during floods for the dam, which has some stability concerns.
The paper highlights the fundamental importance of correct data selection and storage for the quality of Asset Management demanded for today’s water industry infrastructure.
In developing this theme, the concept of Risk driven maintenance is introduced to focus attention on those issues that not only the identify the appropriate data to be collected and stored, but also, by way of illustrated examples, the direct relevance and application of reliability engineering principles in Risk Analysis.
The author’s principle objective is to demonstrate that the historical data on reliability, condition and performance must be supported with detailed costing information if any worthwhile outcomes are to be forthcoming from analysis.
Churchman Brook Dam is a 26m high earthfill dam with a puddle clay core and impounds a reservoir of 2.2GL. Various remedial works have been undertaken since completion of construction in 1928. In September 2000, a sinkhole in the right abutment was observed during a routine dam inspection. Following this incident, detailed site investigations were carried out. These investigations revealed that there are soft zones and possibly voids formed in the upper part of the clay core.
A comprehensive dam safety study and a risk workshop undertaken in 2002/2003 showed the dam to be deficient in aspects associated with piping, spillway adequacy and outlet works condition. A rational geotechnical model was developed for the foundation utilising triaxial test data from 1980s and recent investigations. The existing spillway chute will be upgraded with a concrete liner attached to the existing chute incorporating no-fine concrete as a free-draining medium. This paper presents the various aspects of the remedial works currently being designed.
David Snape and Brian Simmons
Sydney Catchment Authority (SCA) has been progressively enhancing its asset management capability for dams and other headworks infrastructure since 1999. A key to the development of the integrated asset management system has been the application of asset condition assessment and Failure Modes, Effects and Criticality Analysis (FMECA) across the water supply mechanical and electrical assets. This has provided vital data necessary to:
Asset management features as a key result area within the SCA’s Corporate Business Plan. Integrated asset management is achieved by cascading corporate outcomes, strategies, objectives and responsibilities down through divisional and team work plans to individual staff members. This paper covers a range of issues that have a bearing on the day-to-day integrity of the infrastructure required to deliver bulk raw water to the SCA’s customers.
The management of maintenance at Warragamba Dam is used as an example to demonstrate the effectiveness and practicality of the application of the contemporary asset management system.
Bellfield dam is a 78,500 ML drought reserve storage for the Wimmera-Mallee Stock and Domestic System. The 800m long by 57m high zoned earth and rockfill dam is located on Fyans Creek upstream of the Grampians tourist town of Halls Gap in north western Victoria. The dam was built in the period 1963-67. Later in 2002-03 as part of a flood security upgrading (FSU) program, had its rock chute spillway deepened by 3.4m and its embankment crest raised by 1.9m to withstand a PMF.
To manage the FSU’s likely construction constraints and risks, Wimmera Mallee Water’s Headworks Group successfully undertook the upgrading by a mix of schedule of rates contracts and direct management.
This paper complements a companion paper by WMW’s design consultants, URS and describes why and how direct management was used, plus unconventional aspects of spillway deepening and the raising of a narrow dam crest with earthworks and a pre-cast parapet wall.
Hydro Tasmania has recently upgraded the control systems for the spillway gates of three of its dams, Clark Dam, Meadowbank Dam and Liapootah Dam. The upgrades followed internal reliability assessments that highlighted high reliance on operator attendance, single points of failure and operational difficulties on each of the three gate systems.
The three gates are of contrasting types. Clark Dam Spillway Gates are submerged orifice type radial gates, operated by wire rope hoists. Meadowbank Crest Gates are flap type gates, held by 10 hydraulic cylinders per gate, a design that has had a difficult operating history. Liapootah is a floating drum gate. The upgrades for each gate therefore required different solutions, albeit within a common basis of design framework. The solutions arrived at are innovative, and meet or exceed worlds best practice.
All three gates are now fully automatic, with PLC control. The use of PLC’s significantly enhances the reliability of the gates. Extensive use is also made of the PLC in monitoring key systems. For example, an impossibly rapid lake level rise detected by one transducer, but not its duplicate, will be alarmed but ignored to avoid unnecessary discharge. All systems incorporate appropriate redundancy. The PLC systems also provide some automatic functional testing functionality and enhance remote alarms and local fault finding.
Mechanical systems were modified to facilitate automation and increase reliability. Stand by power sources used include auto-start diesel genset, DC batteries and a micro hydro generator.
The design and implementation of each of the upgrades was carried out by the Electrical and Mechanical Group of Hydro Tasmania’s Consulting Division, in conjunction with Generation Division’s Project Management Group.