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Condition Assessment of Gates and Related Components Stuart Foltz Construction Engineering Research Laboratory

2. 2/25/2012. Briefing Topics. Condition index overviewTainter gate condition indexTrunion frictionOther gate indexesEmbankment dam condition indexCondition indexes and reliability. 3. 2/25/2012. Condition Indexes?. ProblemHQUSACE requires assistance in evaluation of maintenance and repair requirements and prioritiesInspection proceduresObjective evaluation of conditionDetermination of requirementsEstablishing M

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Condition Assessment of Gates and Related Components Stuart Foltz Construction Engineering Research Laboratory

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    1. 1 2/25/2012 Condition Assessment of Gates and Related Components Stuart Foltz Construction Engineering Research Laboratory

    2. 2 2/25/2012 Briefing Topics Condition index overview Tainter gate condition index Trunion friction Other gate indexes Embankment dam condition index Condition indexes and reliability

    3. 3 2/25/2012 Condition Indexes? Problem HQUSACE requires assistance in evaluation of maintenance and repair requirements and priorities Inspection procedures Objective evaluation of condition Determination of requirements Establishing M&R priorities Justifying resource allocation

    4. 4 2/25/2012 Brief History of CI's REMR: Operations Management program closed SEP98 Non-Deferrable Work Package Prioritization Aid gauge physical deterioration reduce subjectivity via data driven decisions articulate needs in consistent manner

    5. 5 2/25/2012

    6. 6 2/25/2012 What is a Condition Index? A calculation based on condition inspection data: A number between 0 and 100 (quantitative) repeatable measurements where possible guidance where subjectivity unavoidable Representative of a structure’s Condition Safety Ability to function (to varying extents) Based on expert rules

    7. 7 2/25/2012

    8. 8 2/25/2012 Expert Rules - What are they?

    13. 13 2/25/2012 CI Benefits Regimented, checklist style inspection "up close & personal" Closer Monitoring of Structures Set benchmarks for comparison Establish and track trends in condition Discover hidden problems Knowledge institution Assist in setting M&R priorities Document M&R needs Justification for expenditures And for “non-expenditures”

    14. 14 2/25/2012 Negative Feedback Already know condition Perceived as too costly for routine use Some systems still too subjective Could be simplified and get same info

    15. 15 2/25/2012 Level of Effort Tainter gate example: Trunion bushing wear and anchorage movement Is the most complex measurement

    16. 16 2/25/2012 Briefing Topics Condition index overview Tainter gate condition index Trunion friction Other gate indexes Embankment dam condition index Condition indexes and reliability

    17. 17 2/25/2012 Tainter Gate Condition Index

    18. 18 2/25/2012 Tainter Gate Condition Index

    19. 19 2/25/2012 Assembly Distresses for Tainter Gates Anchorage assembly deterioration 19.3% Trunnion assembly wear 16.4% Corrosion / erosion 13.2% Cracks 11.3% Vibration with flow 11.2% Noise, jump, and vibration 10.6% Misalignment 8.0% Cable / chain plate wear 5.8% Leaks 2.6% Dents 1.6%

    20. 20 2/25/2012 Gate CI Algorithm CIgate = S CIi • Wi

    21. 21 2/25/2012 Distress Weight Adjustment Factor

    22. 22 2/25/2012 Misalignment Distress Condition R ating Differential vertical movement of top of the gate when it is opened 2 feet. Rating is based on an exponential function comparing measured movement to a pre-determined unacceptable relative movement

    23. 23 2/25/2012 Misalignment Measurement

    24. 24 2/25/2012 Misalignment Measurement

    25. 25 2/25/2012 Trunnion Assembly Wear

    26. 26 2/25/2012 Trunnion Assembly Wear

    27. 27 2/25/2012 Tainter Gate Inspection

    28. 28 2/25/2012 Tainter Gate Inspection

    29. 29 2/25/2012 Tainter Gate Inspection

    30. 30 2/25/2012 Briefing Topics Condition index overview Tainter gate condition index Trunion friction Other gate indexes Embankment dam condition index Condition indexes and reliability

    31. 31 2/25/2012 Trunnion Friction Attributed with causing failures Not considered or under-weighted in many designs Significantly impacted by maintenance and operational policies Not considered in Tainter Gate CI

    32. 32 2/25/2012 Friction Measurement Strain gages Load cell Motor load Laser sighting Cantilever

    33. 33 2/25/2012

    34. 34 2/25/2012

    35. 35 2/25/2012

    36. 36 2/25/2012

    37. 37 2/25/2012

    38. 38 2/25/2012

    39. 39 2/25/2012

    40. 40 2/25/2012 Analysis Calculations Determination of strain Determination of hinge friction Generic quantification Repeatable Simple Universally applicable and consistent

    41. 41 2/25/2012 Briefing Topics Condition index overview Tainter gate condition index Trunion friction Other gate indexes Embankment dam condition index Condition indexes and reliability

    42. 42 2/25/2012 Operating Equipment Condition Index Mechanical and hydraulic components related to moving lock or dam gates.

    43. 43 2/25/2012 Operating Equipment Assemblies Exposed Gear Enclosed Gear Gear Rack Strut Arm Rocker Arm Cable Chain Hydraulic Cylinder Coupling

    44. 44 2/25/2012 Exposed Gears

    45. 45 2/25/2012 Assembly Distresses for Exposed Gears Noise, jump, and vibration 27.5% Anchorage movement/deterioration 26.8% Bearing/bushing wear 12.3% Roller supports wear/damage* 7.0% Cracks critical Tooth wear 2.6% Reduced tooth contact 9.0% Damaged teeth 14.8%

    46. 46 2/25/2012 Distress Weight Adjustment Factor

    47. 47 2/25/2012 Tooth Wear Measurement

    48. 48 2/25/2012 Roller Gate

    49. 49 2/25/2012 Roller Gate

    50. 50 2/25/2012 Tainter Valve

    51. 51 2/25/2012 Briefing Topics Condition index overview Tainter gate condition index Trunion friction Other gate indexes Embankment dam condition index Condition indexes and reliability

    52. 52 2/25/2012 Embankment Dam Condition Index Extended the CI concept beyond a standardized and quantified inspection procedure Created a framework for evaluating and quantifying existing inspection and engineering information Limited ability to consider consequences

    53. 53 2/25/2012 Focus The intent of this condition index process is to focus attention on the most important components in the worst condition.

    54. 54 2/25/2012 Matrix Methods Hudson’s interaction matrix Stanford cross impact method Analytical hierarchy Value engineering Expert elicitation

    55. 55 2/25/2012 Flow Charts Failure Prevention Failure Detection

    56. 56 2/25/2012 Benefits Evaluate importance of existing deficiencies Assist repair prioritization and justification Tool for communication with management Training tool Long-term condition tracking

    57. 57 2/25/2012 Briefing Topics Condition index overview Tainter gate condition index Trunion friction Other gate indexes Embankment dam condition index Condition indexes and reliability

    58. 58 2/25/2012 Some Reliability Analysis Basics Statistically based estimates of failure probability Limited performance data Age, cycle, or generic modeling of performance over time Analytical or subjective estimates of performance Limited or no consideration of inspection information Need quantified data

    59. 59 2/25/2012 Condition Indexes and Reliability Parameter in a detailed reliability analysis (Tainter Gate CI) Screening tool for prioritization of more detailed reliability and risk analysis (Tainter Gate or Embankment Dam CI model) Primary component in simplified risk analysis (Embankment CI model)

    60. 60 2/25/2012 CI/Reliability Obstacles No data to tie CIs to failure probability CIs don’t directly correlate to specific failure modes. Relation between various failure modes and CIs is variable

    61. 61 2/25/2012 Software and Reports http://owww.cecer.army.mil/fl/remr/remr.html

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