1. One Corps Serving the Armed Forces and the Nation Navigation Lock and Dam Inspection and Emergency Repairs Workshop 18 - 20 April 2006 Mel Price – Auxiliary Lock Downstream Miter Gate Repair

2. One Corps Serving the Armed Forces and the Nation Mel Price Locks and Dam Project Location

3. One Corps Serving the Armed Forces and the Nation Mel Price Locks and Dam

4. One Corps Serving the Armed Forces and the Nation Mel Price Accident 3 October 2004 What Happened? Why Did It Happen?

5. One Corps Serving the Armed Forces and the Nation Mel Price Accident What Happened?

6. One Corps Serving the Armed Forces and the Nation Miter Gate Functioning Normally

7. One Corps Serving the Armed Forces and the Nation Gate Leafs Forced Downstream From Normal Mitered Position Gates Of Normal Position

8. One Corps Serving the Armed Forces and the Nation Gate Leafs Forced Downstream From Normal Mitered Position

9. One Corps Serving the Armed Forces and the Nation Mel Price Accident Damage Summary

10. One Corps Serving the Armed Forces and the Nation Damage to Gate Anchorages

11. One Corps Serving the Armed Forces and the Nation Damage to Gate Anchorages

12. One Corps Serving the Armed Forces and the Nation Damage to Gate Anchorages

13. One Corps Serving the Armed Forces and the Nation Failed Operating Struts

14. One Corps Serving the Armed Forces and the Nation Diagonal Failure

15. One Corps Serving the Armed Forces and the Nation Damage to Miter End of Leafs

16. One Corps Serving the Armed Forces and the Nation Pintle Socket Sheared Off

17. One Corps Serving the Armed Forces and the Nation Bent & Cracked Pintle Socket

18. One Corps Serving the Armed Forces and the Nation Pintle Ball Retainer Sheared Off

19. One Corps Serving the Armed Forces and the Nation Bottom Seal Damaged

20. One Corps Serving the Armed Forces and the Nation Mel Price Accident Why Did It Happen?

21. One Corps Serving the Armed Forces and the Nation Gate Operating Arm Failure Tube

22. One Corps Serving the Armed Forces and the Nation Operating Arm Failure Tube Failure Bolts

23. One Corps Serving the Armed Forces and the Nation Failure Tube Failure Bolt Fractured Strut

24. One Corps Serving the Armed Forces and the Nation Normal Miter Block Position

25. One Corps Serving the Armed Forces and the Nation Central Control House Local Control House Gate Control Stations

26. One Corps Serving the Armed Forces and the Nation Magnetic Proximity Switch on Gate

27. One Corps Serving the Armed Forces and the Nation Switches on Machinery Rack

28. One Corps Serving the Armed Forces and the Nation Modification of PLC Logic

29. One Corps Serving the Armed Forces and the Nation Miter Gate Sill

30. One Corps Serving the Armed Forces and the Nation Miter Gate Sill Gate Stop Bottom Seal Miter End Of Leaf Top of Sill

31. One Corps Serving the Armed Forces and the Nation Investigation Report Findings Increased hydraulic system relief pressures and fracture of the strut failure tube failure bolts. Leaves not mitered. PLC programming incorrectly indicated that the downstream gate was mitered (closed). No operator verification of miter or intervention. Filling of lock chamber with the downstream gate leaves not in miter. Appreciable unbalanced head on the unmitered downstream gate leaves Catastrophic failure – miter gate leaves move past miter

32. One Corps Serving the Armed Forces and the Nation Actions Taken By MVS Based on Report Recommendations 1.Standard Operator Procedures and Training 2.Programming Ladder Logic Control 3.Additional Miter Gate Switch 4.Policy on Changes and Inter-Office Coordination 5.Relief Valve Gages and Mechanical Linkages

33. One Corps Serving the Armed Forces and the Nation Helper Boat – Main Lock

34. One Corps Serving the Armed Forces and the Nation Inspection – Main Lock

35. One Corps Serving the Armed Forces and the Nation All-Discipline Team

36. One Corps Serving the Armed Forces and the Nation Concentrate On Critical Activities

37. One Corps Serving the Armed Forces and the Nation Variety of Contract Instruments Best Value AE IDIQ MIPR Purchase Order Lump Sum Contract Credit Card

38. One Corps Serving the Armed Forces and the Nation Gate Repairs

39. One Corps Serving the Armed Forces and the Nation Gate Repairs Pulling Gate

40. One Corps Serving the Armed Forces and the Nation Position of Leafs After Accident

41. One Corps Serving the Armed Forces and the Nation Cutting Gate Anchors

42. One Corps Serving the Armed Forces and the Nation Removing Illinois Leaf Rock Island District Crane “Hercules”

43. One Corps Serving the Armed Forces and the Nation Placing Illinois Leaf on Spare Gate Barge

44. One Corps Serving the Armed Forces and the Nation Guy Cables Installed

45. One Corps Serving the Armed Forces and the Nation Guy Cables Installed

46. One Corps Serving the Armed Forces and the Nation Both Leafs Secured on Spare Gate Barge

47. One Corps Serving the Armed Forces and the Nation Damage Inspection

48. One Corps Serving the Armed Forces and the Nation Surveying Damaged Gate

49. One Corps Serving the Armed Forces and the Nation Survey Results – Illinois Leaf 2’ 1’ 1.5’ 0.5’ 2.21’ max deflection

50. One Corps Serving the Armed Forces and the Nation What Do We Do Now?

51. One Corps Serving the Armed Forces and the Nation Panel of Experts Retired construction and operations personnel from USACE (Similar Failure At Bankhead) Steel structures engineering experts from various universities Heat straightening expert Structural engineers from other USACE offices St. Louis District structural engineers, lock operations personnel and Rivers Project Office personnel

52. One Corps Serving the Armed Forces and the Nation Conclusions From Panel of Experts Gate could be repaired Repair would be quicker than replacement Heat straightening could be used Leafs should be layed down for repairs

53. One Corps Serving the Armed Forces and the Nation Gate Repairs Laying Leafs Down

54. One Corps Serving the Armed Forces and the Nation Original Lifting Beam For Vertical Lifting Only

55. One Corps Serving the Armed Forces and the Nation Redesigned Lifting Beam

56. One Corps Serving the Armed Forces and the Nation Lifting Beam In “Green Monster” Test Rack

57. One Corps Serving the Armed Forces and the Nation Installing Lifting Beam

58. One Corps Serving the Armed Forces and the Nation Turning Feet for Gate Laydown

59. One Corps Serving the Armed Forces and the Nation Removing Guy Cables

60. One Corps Serving the Armed Forces and the Nation Shreve Moving Leaf For Lay Down “Louisville” District Crane “Shreve”

61. One Corps Serving the Armed Forces and the Nation Aligning Turning Feet on Support Stands Turning foot Support Stand

62. One Corps Serving the Armed Forces and the Nation In Position for Laydown Crane Barge Sewell Winch Used to Initiate Rotation

63. One Corps Serving the Armed Forces and the Nation Rotation on Turning Feet

64. One Corps Serving the Armed Forces and the Nation Shreve Setting Leaf Horizontal

65. One Corps Serving the Armed Forces and the Nation Gate on Support Stands

66. One Corps Serving the Armed Forces and the Nation Gate Leafs in Horizontal Position

67. One Corps Serving the Armed Forces and the Nation Leaf Supported In Deflected Position Approx. 18”

68. One Corps Serving the Armed Forces and the Nation Enclosure on Delong Barge at Service Base

69. One Corps Serving the Armed Forces and the Nation Gate Repairs Heat Straightening

70. One Corps Serving the Armed Forces and the Nation Heat Straightening Crew

71. One Corps Serving the Armed Forces and the Nation Heat Straightening Vee Heats

72. One Corps Serving the Armed Forces and the Nation Spot Heats

73. One Corps Serving the Armed Forces and the Nation Heat Straightening Diagonals

74. One Corps Serving the Armed Forces and the Nation Diaphragms Before Heat Straightening

75. One Corps Serving the Armed Forces and the Nation Diaphragm After Heat Straightening

76. One Corps Serving the Armed Forces and the Nation Support Condition For Checking Straightness Single Support On Top Girder Two Support Columns On Bottom Girder

77. One Corps Serving the Armed Forces and the Nation Gate Repairs Structural Repairs

78. One Corps Serving the Armed Forces and the Nation Revised Strut Arms and New Pintle Sockets No Failure Bolts

79. One Corps Serving the Armed Forces and the Nation Machining Strut Arm at Service Base

80. One Corps Serving the Armed Forces and the Nation Fabrication Work at Service Base

81. One Corps Serving the Armed Forces and the Nation Welding Strut Arm at Service Base

82. One Corps Serving the Armed Forces and the Nation Modified Bottom End of Diagonal

83. One Corps Serving the Armed Forces and the Nation Modified Bottom Diagonal Gussets

84. One Corps Serving the Armed Forces and the Nation Modified Bottom End of Diagonal

85. One Corps Serving the Armed Forces and the Nation Castings Supplied By Rock Island Arsenal Anchor Bars And Gudgeon Barrels Pintle Sockets

86. One Corps Serving the Armed Forces and the Nation Gate Stops on Miter Gate Sill

87. One Corps Serving the Armed Forces and the Nation Lifting Repaired Leafs Vertical

88. One Corps Serving the Armed Forces and the Nation Installing Lifting Device

89. One Corps Serving the Armed Forces and the Nation Shreve Lifting Leaf Vertical

90. One Corps Serving the Armed Forces and the Nation Shreve Lifting Leaf Vertical

91. One Corps Serving the Armed Forces and the Nation Placing Leaf In Toaster

92. One Corps Serving the Armed Forces and the Nation Leafs In Toaster for Transport to Lock

93. One Corps Serving the Armed Forces and the Nation Reinstalling Gate

94. One Corps Serving the Armed Forces and the Nation Repaired Illinois Leaf in Place

95. One Corps Serving the Armed Forces and the Nation Welding & Boring Gudgeon Pin Plates

96. One Corps Serving the Armed Forces and the Nation Welding & Boring Gudgeon Pin Plates

97. One Corps Serving the Armed Forces and the Nation Installing Missouri Leaf

98. One Corps Serving the Armed Forces and the Nation Repaired Gate Leafs in Place

99. One Corps Serving the Armed Forces and the Nation Repaired Gate Leafs in Place Plumb Miter Blocks

100. One Corps Serving the Armed Forces and the Nation July 2005 - Auxiliary Lock Back In Service

101. One Corps Serving the Armed Forces and the Nation Thank You !!!