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Blackberry Farm-CS240617
Operation and Maintenance Plan For Blackberry Farm Valley Storage Ponds City of Coppell Dallas County, Texas June 17, 2024 OEI Project No: 0347004 2340 E. Trinity Mills Rd, Ste. 220, Carrollton, TX 75006 Ph: 972-233-2288 | Fax: 972-233-2818 Celebrating over 35 Years! OBrienEng.com TBPE Firm No. F-3758 | TBAE Firm No. BR3993 SDVOSB | Texas HUB Firm | TxDOT SBE Firm 6/17/2024 Table of Contents I. Introduction ............................................................................................................................. 1 II. Background Data ..................................................................................................................... 1 III. Description of Appurtenances ................................................................................................. 1 IV. Operation and Records ............................................................................................................ 2 V. Inspections ............................................................................................................................... 4 VI. Maintenance and Repair ....................................................................................................... 12 VII. Recommended Maintenance and Inspection Schedule ........................................................ 13 VIII. References ............................................................................................................................. 14 IX. Telephone List ........................................................................................................................ 14 Tables Table 1 – North Pond Details Table 2 – South Pond Details Table 3 – Recommended Minimum Maintenance Schedule Table 4 – Telephone Contact List Appendices Appendix A – Exhibits Appendix B – TCEQ Inspection Form Appendix C – Sample Maintenance Log Form Appendix D – Flap Gate Specifications 1 I. INTRODUCTION Development of Blackberry Farm Subdivision involved the filling of portions of the floodplains of Elm Fork of the Trinity River and of Denton Creek. Mitigation of that fill, to satisfy the requirements of the City of Coppell and of the Corridor Development Certificate (CDC) included the construction of two ponds to prevent excessive loss of valley storage. Proper operation and maintenance procedures are vital for maintaining a safe and properly functioning pond and regular observations and inspections are a part of those procedures. This Operation and Maintenance (O&M) plan will provide guidelines for conducting routine inspections, monitoring, and maintenance for the pond areas. The O&M plan is prepared to fulfill requirements of the City of Coppell’s Stormwater Management Program (SWMP) and is for normal operations of the ponds. The homeowner’s association (HOA) for Blackberry Farm will be responsible for the maintenance and inspections of the Blackberry Farm ponds; as of June 2024, the HOA is managed by Holmes Builders. II. BACKGROUND DATA The two ponds are situated on a residential subdivision east of MacArthur Boulevard and north of Sandy Lake Road in Coppell, Texas. The ponds are located to the east of Denton Creek and to the west of the Elm Fork of the Trinity River. Both ponds were established by excavation; the north pond has a depth of 16 feet, while the south pond has a depth of 10 feet. The south pond is normally dry and has a flood storage capacity of 19 acre-feet. The north pond’s outlet is 4 feet above the bottom of the pond such that it has a 4-foot-deep normal pool holding 10 acre-feet. The flood storage capacity of the north pond – above the normal pool - is 30 acre-feet. Per Title 30 of the Texas Administrative Code §299.13, neither of the ponds would is classified as a dam. III. DESCRIPTION OF APPURTENANCES Each of the ponds is passively controlled by an 18” reinforced concrete pipe, fitted with a Waterman AF-41 flap gate positioned at the outlet face of the pipe. The flap gate is designed to prevent flow from Denton Creek from entering the ponds, while allowing water from the ponds to flow out into Denton Creek. Table 1 and Table 2 show details for each of the two ponds, while Exhibit 1 provides a location and vicinity map. The flap gate manufacturer provided specifications and an operation and maintenance manual which are both provided in Appendix D. 2 Table 1 North Pond Details Pond Name Blackberry Farm North Pond Location E. of MacArthur Blvd and N. of Sandy Lake Rd. Completion 2023 Normal Pool Storage 10 acre-feet Maximum Flood Storage Capacity 30 acre-feet Control Structure 18” RCP Pipe with Flap Gate on Outlet Pipe Inlet Elevation 434.50 feet Pipe Outlet Elevation 434.00 feet Table 2 South Pond Details Pond Name Blackberry Farm South Pond Location E. of MacArthur Blvd and N. of Sandy Lake Rd. Completion 2023 Normal Pool Storage 0 acre-feet Maximum Flood Storage Capacity 19 acre-feet Control Structure 18” RCP Pipe with Flap Gate on Outlet Pipe Inlet Elevation 433.90 feet Pipe Outlet Elevation 433.70 feet IV. OPERATION AND RECORDS The ponds, like creeks, rivers, floodplains, culverts, bridges, dams, and other hydraulic facilities are a part of the floodwater management system, which poses various dangers, including potential threat to life. The HOA should employ numerous courses of action to mitigate the 3 dangers, including, though not limited to: 1) prohibiting use of the ponds for anything other than flood control, 2) fencing the ponds to prohibit unauthorized access, while providing for emergency access, 3) placing signage warning of the potential for flooding, including flash flooding and/or prolonged inundation, and/or rapid draining, 4) educating residents and the public of the purpose, use, and dangers of the ponds, 5) monitoring the ponds and appurtenant facilities for unauthorized access, degradation, or changes, 6) annually (and after significant events) engaging third party expert services to review and evaluate facility conditions and make recommendations as may be appropriate, 7) maintain a log documenting observations, inspections, maintenance, and repairs, and 8) other measures, which may become necessary or advised in the future. The log should also include documentation of normal operation and optimal conditions as opposed to including only record of damage, degradation, maintenance, and repair; it should also include documentation of neglected inspections or inspection cycles. The ponds are designed to provide valley storage during significant flooding events along the Elm Fork and Denton Creek while preventing flow from small flooding events from Denton Creek from entering the ponds. The pond outlet structures are set at the required elevations to provide the necessary storage for the Trinity River Corridor Development Certificate (CDC) requirements. Any accumulation of sediment will negatively impact the effectiveness of the ponds and must be removed. Pond operation will also be compromised if the flap gates become obstructed from opening or fully closing; such obstruction must be removed immediately. Any damage that prevents intended flap gate operation must be repaired immediately. An inspection program should involve three types of inspections: (1) periodic technical inspections by specialists familiar with the design and construction of ponds; (2) periodic maintenance inspections assessing the operational condition of the ponds; and (3) incidental and periodic observations by residents and HOA personnel. The third type of inspection can be done by the HOA or any person familiar with the site and properly informed of potential areas of concern. All inspections should be thorough and properly documented to aid in repairing and maintaining the ponds. Organized and systematic documentation and the proper equipment are necessary 4 tools to perform a detailed analysis of the pond structure when evaluated over time or when reevaluated by an expert. Photographs and detailed written descriptions of the observed location, area dimensions, and details will also be useful when evaluating the ponds. A detailed inspection form from TCEQ that is used for reservoirs and dams is included in Appendix B. This form can be used to record observations on a regular basis. Inspection guidelines for recording observations, ensuring systematic coverage, and maintaining records can be found in TCEQ document titled “Guidelines for Operation and Maintenance of Dams, Chapter 5- Inspection Guidelines” 1. V. INSPECTIONS As noted previously, the ponds were established by excavation within the overbank areas of Denton Creek. The excavation left an earthen berm in place to function as a dam. As opposed to the normal function of a dam to contain water within a pond, an unusual feature of these dams is that they are relied upon to hold water from entering the ponds during lesser flood events; floodwater will enter the ponds by overflow from the adjacent Elm Fork Floodplain, during substantial flood events, and then drain through the 18 inch drain pipes and flap gates as the floodwater in Denton Creek recedes. Floodwaters in Denton Creek emanate from two primary sources: releases from Grapevine Dam, and releases from Lake Lewisville Dam. A secondary source would be due to a regional storm concentrating immediately downstream of both dams and upstream of Carrollton Dam. Depending on numerous factors, it is possible for flood levels to fluctuate substantially and rapidly. It is also possible for floodwater to remain high for long periods of time with no significant velocity and for significant velocities for sustained periods. It is also likely that these dams will be subjected to extended droughts. These situations result in the need for vigilant observation of dam and pond conditions and immediate action to remediate damage and degradation. Listed below are some of the most common problems faced by earthen embankments. These conditions should be watched for and dealt with immediately. Any repair of a pond should always be executed under the direction of a qualified engineer familiar with pond repair. Pond levels may have to be lowered to properly inspect cases where the structure damage occurred near or below the water surface. A detailed list of potential problems and repair options can be found in 5 TCEQ document titled “Guidelines for Operation and Maintenance of Reservoirs, Chapter 5- Inspection Guidelines”1. A. Sinkhole – The phenomenon known as piping can cause a sinkhole in or around the pond structure. Piping is the unwanted creation of a flow path through an embankment due to uncontrolled seepage, which removes soil particles allowing for increasing flow volumes, typically outside of the spillway. Cloudy water around the structure outlet is a warning sign of erosion. Left unchecked, piping can lead to pond failure. Conduct a thorough inspection of the ponds for additional sinkholes or seepage areas. Contact a qualified engineer to conduct an evaluation and provide recommendations for repair. B. Large Cracks – Foundation movement or soil settling from loss of stability can cause large cracks on the pond surface. Upon discovery of these signs, a registered engineer should be notified to assess the situation and extent of the damage. C. Slide, Slump, or Slip – Foundation movement or too steep of an embankment can cause areas of the pond to shift or slip, which often creates large voids on the pond structure. Inlet blockage and shifted material are indicators of a problem. Evaluate and monitor the extent of the slide or slip. A qualified engineer should be notified immediately to assess the problem and provide recommendations. D. Scarps, Benches, Oversteep Areas (Beaching) – “Beaching” can occur on unprotected upstream slopes due to wave action or settling. This happens when waves repeatedly strike the embankment and erode the fill material in turn displacing it further down the slope. If wave action is not combated, the possibility for cracking, sloughing, and seepage could increase. To prevent beaching several different methods can be utilized. These include riprap barriers, shallowing of the slope, and vegetative buffer strips. The appropriate method of repair should be utilized quickly to prevent further damage to the structure. 6 E. Slide or Slough – Sloughing is a situation in which a significant amount of soil slides down the embankment slope. Some indications of sloughing are arc-shaped cracks or scarps along the top of the slide as well as an obvious bulge running along the bottom. This condition is typically caused by poor compaction of the soil during construction, excessively steep embankment slope, sudden lowering of pond levels, undercutting of the embankment toe, and saturation of the embankment. Generally, sloughs are divided into two different groups: shallow and deep-seated. Shallow slides are limited to the moving of the top two to three feet of embankment and are usually not considered immediately threatening to the integrity of the pond. These often result from wave action, collapsed animal burrows, and saturated soil. On the other hand, deep-seated slides can be considered serious and are generally immediate threats to the safety of the ponds. These sloughs extend several feet into the embankment and can even extend below the foundation of the pond itself. Small slides can be repaired by removing the vegetation and any unsuitable fill from the area, compacting suitable fill, and adding topsoil to make the embankment uniform, and establishing a healthy grass cover. If a shallow or deep-seated slide is discovered, a qualified engineer should be retained to investigate the slide. Plans and specifications may need to be prepared for its repair depending on the findings of the investigation. F. Transverse Cracking – Structural instabilities and settling within the embankment can cause large cracks to form on the slope. These cracks allow water to seep through, which could further erode the embankment and could cause pond failure. Monitor and measure the extent of the crack. A qualified engineer can determine the cause of the cracking and provide a recommendation for repairing the damage. Excavation of the slope between the cracks and the addition of proper backfill material will help prevent seepage through the damaged area. Regular observations of the previously damaged will be necessary to help monitor future problems around the ponds. G. Cave-in or Collapse – Piping, unstable soils, animal burrows, and inadequate compaction could cause a cave-in or collapse of the slope. Inspect the pond for the cause of the 7 damage. If an animal burrow is the cause, take action to repair the damage and deter the animals from burrowing. A qualified engineer should inspect the pond for other structural instabilities caused by piping, improper compaction, or inadequate fill materials. H. Longitudinal Cracking – Shrinkage and drying out of the soil can cause cracks to form along the embankment. Water within the cracks can cause further erosion of the embankment or cause the fill material to slide, leading to pond failure. Under the supervision of a qualified engineer, compacted fill material can be added to the cracks to prevent further seepage and to maintain proper moisture of the embankment. I. Slump (localized condition) – Slump is the erosion of the embankment often near the base of the slope. It can cause further slope deterioration and settlement, leading to pond failure. Inspect and monitor the slump area, noting the dimensions and location. Contact a qualified engineer to conduct an evaluation and provide recommendations for repair. J. Degradation of Toe – Runoff running uncontrolled along the length of the toe can develop into rills and gullies. Ultimately this could lead to the undermining of the pond’s toe and possibly failure. Once apparent, these conditions should be repaired immediately. Minor rills and gullies can be repaired by filling them with compacted cohesive material. Topsoil should be a minimum of 4 inches deep. The area should then be seeded and mulched. Not only should the eroded areas be repaired, but also the cause of the erosion should be addressed to prevent a continued maintenance problem. K. Erosion and Wash Outs – These are dramatic and sudden erosion actions which are normally caused by rapid changes in both the elevation and velocity of water running over and down the pond embankment. If left unchecked a serious threat to the pond could be created very quickly. The suspect area should be excavated to soil of the correct density and then refilled with appropriate soil and compacted to the density called for while matching adjacent grading. Erosion protection, such as gabions, vegetation, or riprap, should be added to ensure future protection of the embankment. 8 L. Erosion and Drainage Rills – If the embankment is in good condition any water that runs off the embankment will be spread out in a thin layer which is known as “sheet flow.” Likewise, when the sod is in poor upkeep, flow can begin to concentrate at one or more locations causing gullies and rills along the structure. Prompt repair of these conditions is required to prevent the loss of material and to assist in the ease of maintaining the ponds. Minor rills and gullies can be repaired by filling them with compacted cohesive material. Topsoil should be a minimum of 4 inches deep. The area should then be seeded and mulched. Not only should the eroded areas be repaired, but also the cause of the erosion should be addressed to prevent a continued maintenance problem. M. Loss of Shallow Rooting Plants – Bare spots along the embankment promote the creation of rills and gullies. This ultimately leads to the erosion of existing materials and potential reduced stability of the pond itself. Bare spots should be seeded, mulched, and watered in a manner that promotes growth but is not excessive. Consult the seed provider to determine correct watering intervals. N. Trees, Obscuring Brush – The extensive root system of these types of vegetation can provide seepage paths for water (piping) and therefore should not be allowed to grow on earth spillways. Large trees that could possibly be blown over can leave large holes in embankment and lead to erosion or slope failure. Brush typically provides a favorable habitat for burrowing animals and may slow the growth of desired ground vegetation. Tree and brush growth near concrete structures can eventually cause damage to the concrete and should be removed as soon as possible. Prior to removal of the tree of interest, the pond should be lowered below the effective root zone in intervals of no more than 6 inches per day. Upon cutting and removing the tree, the stump, and all associated roots larger than 1 inch should be grubbed out of the embankment and the resulting hole filled with a well-compacted suitable soil. This newly placed soil should then be graded to adjacent conditions and covered with the appropriate grasses. Mowing the embankment regularly should prevent the growth of trees and brush. The owner should not mow after a rain event to prevent marring the existing embankment grade. 9 O. Rodent Activity – Burrowing animals pose a particular problem to the structural integrity of earth embankments. A few of the more common problem causing mammals are the beaver, groundhog, nutria, and muskrat. Due to the burrowing nature of these animals, passageways for the conveyance of water through the embankment can be created which may lead ultimately to the breaching of the structure. The pond operator should be aware of the existence of these problems. The most common symptom of animal presence is fresh dirt located at burrow entrances, freshly peeled sticks that appear white underwater, and newly placed mud, usually on the spillway or other flow paths. Upon discovery of these signs, action should be taken to alleviate the problem and repair the damage. For more area specific solutions to animal problems the Texas Wildlife Services should be contacted. Muskrat control barriers to prevent burrowing offer the most practical protection to earthen structures. A properly constructed riprap and filter layer will discourage burrowing. Heavy wire fencing laid flat against the slope and extending above and below the water line can also be effective. Eliminating or reducing aquatic vegetation along the shoreline will discourage muskrat habitation. Where muskrats have inhabited the area, trapping is usually the most practical method of removing them from a pond. Beavers will try to plug spillways with their cuttings. Routinely removing the cuttings is one way to alleviate the problem. Any trapping should be done under the advisement of a trained trapper, such as available from the Texas Wildlife Services. The recommended method of backfilling a burrow in an embankment is mud-packing. This is a simple repair, which involves filling the animal burrow with specified soil. All entrances should be plugged with well-compacted earth and vegetation re-established. Dens should be eliminated without delay because damage from just one hole can lead to failure of the ponds. P. Livestock – Livestock should not be allowed to graze on an embankment surface. When soil is wet, livestock can damage vegetation and disrupt the uniformity of the surface. Moreover, livestock tend to walk in established paths and thus can promote severe erosion. Such paths should be regraded and seeded, and the livestock permanently fenced out of the area. 10 Q. Fire Ants – Fire ants have become one of the most serious pests in Texas. Fire ants require water to survive and have been found on dams throughout much of the eastern two thirds of Texas. These ants can create problems in the pond itself and with any of its electrical components. In some habitats, fire ants can move as much or more soil as earthworms, thereby reducing soil compaction. Nest galleries can penetrate in a V-shaped pattern below the nest, penetrating as much as four feet deep in the soil. These galleries can create pathways for surface water to penetrate the pond embankment, possibly resulting in internal erosion and collapse of the surface. The ants could also create pathways for water from the pond to flow through the embankment when the water surface level is high. Fire ants left undisturbed can build mounds that become very large (10–12" in diameter) and tall (12–14 inches high). These can create problems for mowing. However, frequent mowing can induce the colonies to migrate to neighboring, undisturbed areas. Fire ants often infest electrical equipment and utility housings, in which whole colonies will move at certain times of the year. Worker ants will import soil for nesting. This material can cause corrosion and interfere with maintenance operations. Ants chew on insulation and can cause short circuits or interfere with switching mechanisms, resulting in electrical components for operating gates and valves not working properly when needed. Ants nesting in these units are highly defensive of their colony and can be a medical threat to maintenance personnel. Worker ants, which have an affinity for oscillating magnetic fields, can cause a particular problem when they enter switching mechanisms of electrical equipment. Once ants in a switching mechanism bridge the gap across an open switch, they are electrocuted. The shocked ants release communication chemicals or other signals that attract more worker ants. The result is that switching units can become tightly packed with the bodies of dead worker ants, causing a failure of the mechanism. 11 There are many options for managing fire ants. Use only pesticides labeled as suitable for the location you want to treat. Make every effort to avoid contaminating water with pesticides. For information on managing fire ants, contact: Texas Imported Fire Ant Applied Research and Education 412 Minnie Belle Heep Center Attn: Bart Drees Texas A&M University College Station, Texas 77843-2475 979/845-7026 http://fireants.tamu.edu R. Cracking Concrete structures – Concrete is well suited for use in pond construction but, due to the possibility of poor workmanship, construction procedures, or materials, problems may arise at a future time that will require repair. Neglecting to perform periodic maintenance and repairs to concrete structures as they occur could result in failure of the structure from either a structural or hydraulic standpoint. Before attempting any repair work, the governing factors of the deterioration of the structure must be determined to choose the best repair option. The opinion of a qualified engineer familiar with pond structures should be sought to devise a repair plan. S. Pipe Spillway and Flap Gate - As with concrete spillways, pipe spillways that become plugged with debris or trash reduce spillway capacity. As a result, the potential for overtopping is greatly increased, particularly if there is only one outlet. Additionally, the pond is designed to provide flood storage in higher-intensity storms and if the pond is unable to drain from a previous storm in a timely manner, the function of the pond becomes compromised. The pipe shall be cleaned regularly, especially after heavy storms, to prevent debris and trash from building up and to keep the pond functioning as designed. 12 Flap gates are designed to allow flow out of a pond while preventing flow from entering it from the downstream side. If the flap gate is unable to close and seal tight around the outlet pipe, flow will be able to enter the pond, limiting the storage potential during higher intensity storm events. It is recommended that the flap gate is cleared of debris regularly to ensure that it is properly closed. Additionally, the flap gate should be cycled regularly to ensure proper function and reduce likelihood of sticking. Inspection of flap gates and verification of proper function should follow manufacturer’s recommended maintenance schedules. VI. MAINTENANCE AND REPAIR TCEQ lists three key maintenance classifications to adequately maintain the pond structure: immediate maintenance, required maintenance, and continuing maintenance. See Appendix B for a maintenance log form. a) Immediate maintenance items include: i. presence of seepage caused by piping or material settlement, ii. excessive seepage or abnormal flows emanating from the pond structure. b) Required maintenance items include: i. removal of overgrown, brushes and trees, ii. filling of rodent burrows, iii. flap gate cleaning and lubrication (as appropriate). c) Continuing maintenance items that should be performed on a regular basis include: i. mowing, ii. reseeding any barren embankment areas, iii. removing debris and excessive sediment buildup, iv. cycling of the gate valve, v. observing, and documenting areas of seepage. d) A detailed discussion of maintenance problems and procedures can be found in TCEQ document titled “Guidelines for Operation and Maintenance of Reservoirs, Chapter 7- Maintenance Guidelines” 1. 13 VII. RECOMMENDED MAINTENANCE AND INSPECTION SCHEDULE Regularly scheduled monitoring, inspection, and maintenance of a pond is critical for functionality and safety. Below in Table 2 is a summary of recommended maintenance and inspection intervals. In the occurrence of extreme or critical events, additional inspections should be completed. The pond should be monitored during such events and inspected immediately following significant rainfall, high winds, floods, spillway releases, earthquakes, or other events resulting in near peak pool elevations. Inspection by a qualified engineer should be performed to evaluate the impact of critical events on the ponds. Table 3. Recommended Inspection and Maintenance Schedule Activity Minimum Recommended Frequency Inspection: Routine Visual Monthly Inspection: Visual Inspection of entire pond Annually Inspection: Critical Event During or immediately following the event Maintenance: Vegetation (Mowing) Monthly (during active growth) Maintenance: Flap Gate Cycling 30-day frequency per manufacturer’s recommendation Maintenance: Vegetation (clearing of shrubs) Every 6 months General Cleaning and Inspection: Flap gates Monthly Maintenance: All other maintenance as discovered during inspections Immediately following discovery 14 VIII. REFERENCES State Manuals 1. Texas Commission on Environmental Quality, 2009, “Guidelines for Operation and Maintenance of Dams, Chapter 5- Inspection Guidelines, Chapter 6 – Instrumentation and Monitoring Guidelines, Chapter 7 – Maintenance Guidelines.” Texas Online: 2. Texas Commission on Environmental Quality (TCEQ). <tceq.state.tx.us> IX. TELEPHONE LIST Refer to Table 4 for a current listing of important telephone numbers for those responsible for maintaining the ponds. Phone numbers can change periodically so this list shall be verified annually and updated periodically with any changes to the information provided. Table 4. Telephone Contact List Updated / Confirmed Correct as of Date: June 14, 2024 Name Title Telephone Number Terry Holmes President, Holmes Builders 469-446-1165 Jon Dostert Operations, Holmes Builders 817-504-7416 Appendix A Exhibits Maxar, Microsoft © OpenStreetMap (and) contributors, CC-BY-SA OEI JOB #: 0347004 EXHIBIT THE HOLMES BUILDERS DALLAS COUNTY, TX Date: 5/29/2024 2340 E. Trinity Mills Rd. Ste 220, Carrollton, Texas, 75006 p: 972.233.2288 f: 972.233.2818 www.OBrienEng.com Texas Registered Engineering Firm F-3758 PROJECT SITE 0 200 400 Feet ±NOTES: VICINITY MAP NO SCALE N Document Path: P:\0347004 - Blackberry Farms\GIS\Blackberry Farms\Blackberry Farms.aprxNorth Pond Embankment North Pond Outlet South Pond Embankment South Pond Outlet VICINITY MAP Legend Pond Outlet Pond Embankment Appendix B TCEQ Inspection Form Inventory No: Start Time: End Time: Weather: _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ Texas Commission on Environmental Quality Dam Inspection Form Dam Name:__________________________________________________________ ________________________ Name of Inspector/s: _______________________________________________________________________________________ Name of Contact/s: ________________________________________________________________________________________ Date of Inspection: _________ ________ _________ ___________________________________ Crest level (at center) above water: _____________________________________________________________________________ Service spillway level ❑ Above or ❑ Below water: _____________________________________________________________ Emergency spillway level above water: __________________________________________________________________________ Ground Moisture Condition: ❑ Dry ❑ Damp ❑ Wet ❑ Snow ____ ❑ Other: __________________________________ Crest of Embankment General Condition: ❑ Good ❑ Fair ❑ Poor Width: ______________________________________ Problems Noted: ❑ None ❑ Rutting ❑ Erosion ❑ Poor Drainage Height: ______________________________________ ❑Trees ❑ Depressions ❑ Bulges ❑ Livestock Damage ❑ Cracks Length: _____________________________________ ❑Misalignment of Crest ❑ Misalignment of Utility Poles ❑ Misalignment of Fences or Rails ❑ Sinkhole ❑ Burrows ❑Breached ❑ Other: ___________________________________________________________________________________ Comments: _______________________________________________________________________________________________ Upstream Embankment General Condition: ❑ Good ❑ Fair ❑ Poor Slope: ___________________________________ Problems Noted: ❑ None ❑ Rip-Rap ❑ Erosion ❑ Too Steep ❑ Burrows ❑ Trees ❑ Cattails ❑ Depressions ❑Bulges ❑ Livestock Damage ❑ Slides ❑ Concrete Decay ❑ Cracks ❑ Sinkhole ❑ Benching ❑Misalignment of Rip-rap ❑ Open Joints in Concrete Comments: _______________________________________________________________________________________________ Downstream Embankment General Condition: ❑ Good ❑ Fair ❑ Poor Slope: ________________________________ Problems Noted: ❑ None ❑ Sloughing ❑ Erosion ❑ Too Steep ❑ Burrows ❑ Trees ❑ Cattails ❑ Depressions ❑Bulges ❑ Livestock Damage ❑ Slides ❑ Concrete Decay ❑ Cracks ❑ Sinkhole ❑ Other:_______________________ Comments: _______________________________________________________________________________________________ Seepage on Downstream Slope Amount: ❑ Major ❑ Moderate ❑ Minor ❑ None Found Problems Noted: ❑ None ❑ Saturation Starts at ___________________ % up Embankment ❑ Presence of Sediment in Flow ❑Cattails at Toe of Dam ❑ Surface Water at Toe of Dam ❑ Seepage Associated with Sloughing ❑ Continuous Flow ❑Sporadic Flow Comments: _______________________________________________________________________________________________ TCEQ-20361 (2/07) 1 __________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ Downstream Hazard Conditions ❑ Narrow Canyon ❑ Wide Canyon ❑ Lightly Sloping Prairie ❑ Pastureland ❑Large Trees and Forest ❑ Brushy and Scrubby Forest ❑ No Homes ❑ Lightly Populated ❑ Moderately Populated ❑Densely Populated ❑ Industrial ❑ Businesses Estimated number of homes: ______________________ Comments: ________________________________________________________________________________________________ Service Inlet Structure General Condition: ❑ Good ❑ Fair ❑ Poor Problems Noted: ❑ None ❑ Blockage ❑ Not Located ❑ Steel Corrosion ❑ Concrete Spalling ❑ Concrete Cracking ❑Reinforcement Corrosion ❑ Missing Parts ❑ Timber Decay ❑ Leakage Below Water Level ❑ Inoperable Valve ❑Other:_________________________________________________________________________________________________ Comments: _______________________________________________________________________________________________ Service Outlet Structure General Condition: ❑ Good ❑ Fair ❑ Poor Problems Noted: ❑ None ❑ Blockage ❑ Not Located ❑ Corrosion of Conduit ❑ Presence of Sediment in Flow ❑Inaccessible ❑ Concrete Cracking ❑ Concrete Spalling ❑ Reinforcement Corrosion ❑ Misalignment of Walls/Slabs ❑Open Joints Comments: _______________________________________________________________________________________________ Service Spillway Condition: ❑ Good ❑ Fair ❑ Poor Depth: ____________________ Width: _____________________ Problems Noted: ❑ None ❑ Blockage ❑ Not Located ❑ Trees ❑ Burrows ❑ Back-Cutting Erosion ❑ Inaccessible ❑Livestock Damage ❑ Concrete Cracking ❑ Concrete Spalling ❑ Reinforcement Corrosion ❑ Damaged Water-stops ❑Open Joints ❑ Sinkholes ❑ Holes in Spillway Chute ❑ Seepage ❑ Misalignment of Walls/Slabs ❑ Damaged Gates ❑Nonfunctional Gates ❑ Lubrication of Gates ❑ Testing of Gates Comments: _______________________________________________________________________________________________ Emergency Spillway Condition: ❑ Good ❑ Fair ❑ Poor Depth: __________________ Width: __________________ Problems Noted: ❑ None ❑ Blockage ❑ Not Located ❑ Trees ❑ Burrows ❑ Back-Cutting Erosion ❑ Inaccessible ❑Livestock Damage ❑ Concrete Cracking ❑ Concrete Spalling ❑ Reinforcement Corrosion ❑ Damaged Water-stops ❑Open Joints ❑ Sinkholes ❑ Holes in Spillway Chute ❑ Seepage ❑ Misalignment of Walls/Slabs ❑ Damaged Gates ❑Nonfunctional Gates ❑ Lubrication of Gates ❑ Testing of Gates Comments: _______________________________________________________________________________________________ Other Items ❑ Major road along crest of dam ❑ Private road or driveway along crest of dam ❑Vehicle bridge along crest of dam ❑ Culverts built into crest of dam ❑Pipeline immediately downstream from dam -Type of pipeline: ____________________________________________________ ❑Water supply line in crest of dam ❑ Other: __________________________________________________________________ Comments: _______________________________________________________________________________________________ TCEQ-20361 (2/07) 2 Topics of Training: _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ _________________________________________________________________________________________________________ __________________________________________________________________________________________________________ _________________________________________________________________________________________________________ __________________________________________________________________________________________________________ _________________________________________________________________________________________________________ __________________________________________________________________________________________________________ Repair Items Ranked by Priority Item 1: __________________________________________________________________________________________________ Item 2: __________________________________________________________________________________________________ Item 3: __________________________________________________________________________________________________ Item 4: __________________________________________________________________________________________________ Security Issues ❑ Vehicle Accessible ❑ Vehicle Gates ❑ Vehicle Fences and Railing ❑ Pedestrian Accessible ❑Pedestrian Gates and Fences ❑ Obscured from Surveillance ❑ Locks ❑ Breaches in Fence ❑ Evidence of Parties ❑Graffti ❑ Security System Comments: _______________________________________________________________________________________________ Operational Procedures ❑ SOP Available Location Kept: ____________________________________________________ ❑Logbook Location of Logbook: ________________________________________________________ ❑Major Events Noted ❑ Staff Training ______________________________________________________ ❑Manual Gate Operations ❑ Powered Gate Operations ❑ Automated Gate Operations Comments: _______________________________________________________________________________________________ Communications ❑ Directory Available ❑ 24-Hour Coverage ❑ Telephone Available at Dam ❑Cell Phone Coverage—Provider: ____________________________________________________ Comments: _______________________________________________________________________________________________ Emergency Action Plan ❑ Available ❑ Filed with TCEQ ❑ Change in Downstream Hazard Frequency of Update: _____________________________ Date of Last Revision: ______________________________ Date of Last Exercise: _____________________________ Comments: _______________________________________________________________________________________________ Instrumentation ❑ Present ❑ Adequately Maintained ❑ Inadequately Maintained ❑ Operational ❑ Data Collected ❑Data Analyzed ❑ Adequately Protected Comments: _______________________________________________________________________________________________ Early Warning System ❑ Present ❑ Adequately Maintained ❑ Inadequately Maintained ❑ Operational Frequency of Maintenance: _____________________________________ Date of Last Exercise: ______________________________ Comments: _______________________________________________________________________________________________ TCEQ-20361 (2/07) 3 Date of Last Exercise: _________________________________________________________________________________________________________ __________________________________________________________________________________________________________ _________________________________________________________________________________________________________ __________________________________________________________________________________________________________ Reservoir Drawdown Capability Method of Drawdown: _____________________________________________________ Maximum Drawdown: _______________________ c.f.s. Frequency of Testing: ________________________________________ Comments: _______________________________________________________________________________________________ Backup Power ❑ Present ❑ Adequately Maintained ❑ Inadequately Maintained ❑ Operational Frequency of Maintenance: _____________________________________ ______________________________ Comments: _______________________________________________________________________________________________ TCEQ-20361 (2/07) 4 Appendix C Maintenance Log Form Maintenance Log Blackberry Farm Ponds Coppell, Dallas County, Texas Date: _____________________________________________ Completed by: ______________________________________ Location Maintenance Activity Start Date Completion Date Additional Action Needed (Specify) Embankments Outlet Pipes Flap Gates Other (Specify): Inspection Date: ____________________________________ Inspected by: ______________________________________ Inspector Signature: _________________________________ Appendix D Flap Gate Specifications OPERATION AND MAINTENANCE MANUAL Equipment: Medium and Heavy Duty Drainage Flap Gates FOR: MANUFACTURED BY: MPI Plant & Industrial 25500 ROAD 204 EXETER, CA 93221 PHONE: (559) 562-4000 SERVICE: ARRANGED THROUGH THE FACTORY PHONE: (559) 562-4000 CONTACT: Matt Allen Field Service Technician REV:5/10/24 OPERATION AND MAINTENANCE MANUAL TABLE OF CONTENTS INTRODUCTION Pages 1-3 FOREWORD RECEIVING HANDLING AND STORAGE INSTALLATION Pages 4-15 PROCEDURE FOR INSTALLING FLATBACK OR FLANGEBACK FLAP GATE INITIAL OPERATION ADJUSTING HINGE ARMS FIELD PAINTING TROUBLE SHOOTING GUIDE FOR FLAP GATES MAINTENANCE Pages 16-20 EQUIPMENT MAINTENANCE SUMMARY SPECIAL TOOLS SPARE PARTS LIMITED WARRANTY EMERGENCY AND SAFETY INSTRUCTION Bookmarked & Hyperlinks on pg# Pages 15 INTRODUCTION PAGE 1 WATERMAN VALVE FOREWORD he purpose of this manual is to provide information to the engineers, contractors, plant operators and associated personnel involved with the installation, operation and maintenance of equipment supplied by WATERMAN VALVE for this project. Although every care is taken in our factory to ensure top quality equipment, we cannot be responsible for damage caused by negligence after shipping. Therefore, described herein are WATERMAN VALVE recommended methods of handling, storage, installation, adjustment, and initial operation for standard situations to be used in conjunction with the approved installation drawings provided by WATERMAN VALVE. If proper care and accuracy are exercised in the field when installing our gates, they will operate as designed at maximum efficiency. T 2 WATERMAN VALVE RECEIVING HECK COUNT all parts when you receive shipment. All individually shipped parts or assemblages are listed on the packing list(s). Should a shortage exist, notify WATERMAN VALVE immediately. We cannot be responsible for any shortages reported more than 30 days after receipt of shipment. Special care should be taken in accounting for and safely storing all bolts, nuts, and small items, which are often misplaced at jobsites. Unless your contract with WATERMAN VALVE states otherwise, all equipment is shipped F.O.B. factory. If any equipment has been damaged in transit, the purchaser will be responsible for filing claim with the transportation company. For assistance in filing any claim and/or replacing equipment, please contact WATERMAN VALVE directly. C 3 A WATERMAN VALVE HANDLING AND STORAGE ll WATERMAN VALVE gates and appurtenances are precision machinery and should be handled accordingly. While all parts are of rugged design, it is still possible to warp machined surfaces, stems, etc., through improper storage and handling. To avoid all problems of this nature we recommend the following: 1.Lift gates through stem hole in top of lift nut box on cover only when shipping stops are in place, taking particular care of wedges and seats. 2.Support full length of stems at all times, being sure not to damage threads. 3.Store equipment on an even, clean, dry surface to prevent distortion. 4.Cover all equipment to protect machined surfaces. 5.DO NOT stack equipment without protection and proper spacers. 6.Handle lifts as you would any precision machinery. 4 PROCEDURE FOR INSTALLING A FLATBACK GATE ON A CONCRETE HEADWALL AUTOMATIC DRAINAGE GATE INSTALLATION INSTRUCTIONS FOREWORD The purpose of this manual is to provide the contractor with pertinent information for the proper installation of our automatic drainage gate. Although every care is taken in our factory to insure top quality equipment, we cannot be responsible for damage caused after shipping. Therefore, described herein are Waterman's recommended methods of installation, handling, storage, and adjustment for standard situations, to be used in conjunction with the approved installation drawings provided by Water Industries, Inc. If proper care and accuracy are exercised in the field when installing our gates, they will operate as designed at maximum efficiency. RECEIVING, HANDLING AND STORAGE Check count on all parts upon receipt of a shipment, noting any shortages immediately. We cannot be responsible for shortages reported after any lengthy delay. Special care should be taken in accounting for and safely storing all bolts, nuts and small items which are often misplaced at jobsite. Waterman double counts these parts to assure accuracy. All Waterman gates and appurtenances are precision machined and should be handled accordingly. While all parts are of a rugged design, it is nevertheless possible to warp machined surfaces through improper storage and handling. To avoid all problems of this nature we recommend the following: 1. Support gate carefully at all times when moving, taking particular care of seat faces. 2. Store equipment on an even, clean, dry surface to prevent distortion. 3. Cover all equipment when in storage to protect machined surfaces. 4. DO NOT stack equipment. (1) Frame (2) Cover (3) Pivot Lug (4) Hinge Link (5) Hinge Stud (6) Hinge Nut (7) 7) nge Pin (8) Hinge Bushing (9) Washer (10) Spring Pin (11) Set Screw (12) Jam Nut Figure 33 1. Secure all anchor bolts in proper position in the forms, checking carefully to see that size, projection, perpendicular and horizontal alignments conform to requirements shown on our installation drawing. Extreme care must be exercised in this initial procedure in that bolts which are improperly set will cause gate warpage and therefore excess leakage between the seating surfaces. DO NOT FORCE GATE ONTO MISALIGNED BOLTS. 2. Each bolt has been provided with two nuts to facilitate proper mounting of the gate. In setting the forms, sufficient grout space must be lift for adjustment of the back nut as shown in Figure 34. 3. After concrete has been poured and the forms have been stripped, place one nut on each anchor bolt then slip gate into place over anchors. (Again we must reiterate, DO NOT FORCE GATE ONTO MISALIGNED BOLTS, See Figure 34.) Place the second nut on each bolt and bring both front and back nuts into finger-tight contact with gate frame, aligning it as necessary. Make sure gate seats and joints are clean. At this point, check for excess clearance between seating surfaces with .004" feeler gauge. In the event INSTALLATION INSTRUCTIONS FOR AUTOMATIC DRAINAGE GATES 5 that the gate is not seating properly, check to see if gate has been warped during installation. If so, adjust nuts on anchor bolts to bring frame into flatness. 4. After gate is found to be seating properly, carefully drypack or grout between frame and headwall using a non-shrink material. Check for voids after it has set and fill as necessary. 5. Lightly tighten all nuts on anchor bolts uniformly, taking care not to warp gate to conform to uneven surface. 6. Adjust pivot lugs (if applicable). See section on gate sensitivity. 7. Lubricate bushings when fittings are provided. Gate is now ready for operation. Figure 34 PROCEDURE FOR INSTALLING A FLATBACK GATE ON A WALL THIMBLE OR PIPE FLANGE 1. Place the thimble in correct position in the forms and secure in place. The top is marked on the flange face and should be aligned with a plumb. If a standard 25# or 125# flange mount has been specified, studs should be screwed into two top holes (on each side of center-line). Place carpenter's level on these two studs and rotate thimble until tops of studs are level. Thimble should be flush or projecting slightly from the headwall face. 2. Use timbers or other bracing on the inside of the opening to support the thimble and prevent warpage during the pour. This is especially important on large thimbles or when the concrete will be especially high. 3. Plug the tapped holes in the thimble with the studs provided or other removable plugs that will prevent concrete from entering the tapped holes. 4. Pour concrete, using care not to tilt or move thimble from its original position in the forms. 5. Let concrete set, then remove forms and bracing. Thoroughly clean the front machined face of the thimble and place cleaned studs into tapped holes provided. Figure 35 6. Clean the back of the gate frame thoroughly. Apply a thin coat of mastic (such as butyl rubber compound or black asphaltic compound) on the front face of the thimble. 7. Mount the completely assembles gate on the thimble. Place nuts on studs and tighten uniformly until a metal to metal contact is made, removing excess mastic. Make sure gate seats and operating joints are clean. 8. Check clearance between seating surfaces with .004" feeler gauge. One cause of improper seating is warpage of gate frame due to mounting on a thimble which has been warped during the pouring of the concrete. If steps one through five are strictly adhered to this will be avoided and the mounting of the gate will be a simple procedure. 9. Adjust pivot lugs (if applicable). See section on gate sensitivity. 10. Lubricate bushings when fittings are provided. Gate is now ready for operation. PROCEDURE FOR INSTALLING A SPIGOTBACK GATE ON CORRUGATED PIPE 1. Place spigotback gate over pipe end. 2. Drill pipe through holes provided in spigot (13/32" or 7/16" drill bit). 3. Secure gate to pipe with galvanized steel or brass rivets or bolts. DO NOT FORCE THE BOLTS OR RIVETS. 4. Apply a sealant (hot tar or other mastic) to the joint between gate and pipe, inside and out. 5. Brace inside of pipe. DEFLECTION OR DISTORTION OF THE ATTACHED PIPE SECTION MAY CAUSE WARPAGE OF GATE SEAT AND LEAKAGE. This is particularly true of larger gates. 6. Place coupled gate and pipe in form of ditch and backfill or pour as required, making sure that gate frame is vertical and that links are equidistant from vertical centerline of opening. Gate seats are angled 2¹⁄₂º to 5º from the vertical plane to prevent gate from 6 hanging open should the installation be slightly off vertical or due to subsequent settling of pipe. 7. Remove bracing and clean gate seats and operating joints. Check to see that seats make proper contact around full periphery of gate. (Use .004" feeler gauge.) 8. On those gates with adjustable hinge brackets make adjustments until desired sensitivity is attained. (See section on gate sensitivity.) 9. Lubricate bushings when fittings are provided. Gate is now ready for operation. "sb" Spigotback for annular or spiral corrugated pipe. Figure 36 The light gauge galvanized taper setting collar is used as a "form" for placing grout and as a means of locating a gate in the end of concrete pipe. 1. Place gate on pipe or opening inserting the taper collar until a snug fit is obtained or gate is stopped by the structure or pipe. 2. Align gate in a vertical and horizontal plane and place rich grout around gate, making a heavy band sealing and attaching the cast iron frame ring to the pipe. Grout is normally lapped over the frame flange and smoothed in place with laying mitts or gloves. NOTE: If desired, anchor bolts or reinforcing rod can be attached in the anchor bolt holes and placed in the grout band for added strength. 3. After band has dried, check for cracks and repair as needed. Open gate and pack grout in void between collar and pipe. 4. Check gate for grout on seats or in slide grooves and clean as required. With galvanized steel taper setting collar for concrete pipe, or headwalls (F-10C) Figure 37 ATTACHING GATE TO CONCRETE PIPE WITH TAPER SETTING COLLAR 7 PROCEDURE FOR CONTROLLING SENSITIVITY OF ADJUSTABLE DRAINAGE GATES (Models F-20, F-25, F-40 and F-55 only) The sensitivity of a drainage gate is determined by the location of the upper pivot in relation to the flap pivots. The gate is most sensitive when the pivots are adjusted forward to a point where further forward movement would cause the gate to open. As the pivot lugs are moved toward the frame the sensitivity decreases. Procedure for adjustment is as follows: 1. To increase sensitivity, loosen front nuts on lugs and move them out to desired position. 2. Move back nuts forcing pivot lug out against front nuts. Both lugs should be parallel after adjustment. 3. Loosen lock nuts on hinge set screws. 4. Adjust set screws in or out until seating surfaces are aligned. NOTE: To decrease sensitivity, reverse the procedure described above. (1) Frame (Flat or Spigotback) (2) Hinge Pins (3) Adjustable Hinge Bracket (Pivot Lug) (4) Studs and Stud Nuts (5) Cover Flap (6) Link (7) Washer (8) Retaining Spring Pin (9) Bushing (10) Set Screw DRAINAGE GATES (NONADJUSTABLE) MODEL F-10, FC-10, PF-25, AF-41 AND F-50 INSTALLATION: Thimbleorpipeflange. 1. Install studs in flange. 2. Apply mastic or rubber gasket. 3. Mount gate. 4. Install nuts on studs and tighten. FLATBACK (OR FLANGEBACK) Anchor Bolts 1. Anchor bolts should project from the wall a sufficient amount to allow for a one inch grout pad between the gate frame and the wall. Figure 39 8 WATERMAN VALVE PROCEDURE FOR INSTALLING A FLATBACK OR FLANGEBACK ON A CONCRETE HEADWALL 1. Secure all anchor bolts in proper position in the forms, checking carefully to see that size, projection, perpendicular, and horizontal alignment conform to requirements shown on our installation drawings. EXTREME CARE MUST be exercised in this initial procedure. Improperly set bolts will cause gate warpage, and therefore, excess leakage between the seating surfaces. DO NOT FORCE GATE ONTO MISALIGNED BOLTS. 2. Each bolt has been provided with two nuts and two washers to facilitate proper mounting of the gate. Sufficient grout space must be left for adjustment of the back nut as shown in Figure 1. NOTE: In this case, the projection specified on our installation drawings normally includes the proper amount of the grout space required. 3. After concrete has been poured and the forms have been stripped, place one nut and washer on each anchor bolt and run down against headwall. DO NOT DISASSEMBLE GATE FOR INSTALLATION. Place the completely assembled gate into position, carefully guiding it onto the anchor bolts. Again, DO NOT FORCE GATE ONTO MISALIGNED BOLTS. Place the second nut and washer on each bolt and bring both front and back nuts into finger tight contact with the gate surfaces. Check clearance between seat faces, (from back of gate if possible) with .004” feeler gauge. If gate is seating properly, the gauge will not be admitted at any point. In the event that the gate is not seating properly, check to see if the gate has been warped during installation. If so, adjust nuts on anchor bolts to bring frame flat. 4. After gate is found to be seating properly, carefully dry pack or grout in the gate between frame and headwall using a non-shrink material. Check for voids after this has set and fill in as necessary. 5. Tighten all nuts on anchor bolts uniformly, taking care not to warp gates to conform to uneven surfaces. Gate is now ready for initial operation. NOTE: In those locations where flangeback gates are used on headwalls without sufficient side or bottom clearance for nut adjustments, anchor bolts are brought through the gate frame to the front face. Special anchors and frame drilling must be provided. 9 2. Thread one nut on each anchor. 3. Mount gate on the anchors. 4. Thread another nut on each anchor. 5. Use the double-nut system to bring gate into plumb and level. Avoid warping the frame. 6. Complete the installation by packing a non-shrink grout between the frame and the wall. SPIGOTBACK GATES Bolt gate to pipe using predrilled holes in spigot as a guide. Bolted connections usually require a sealant between pipe and gate to make a watertight connection. Adjustment These gates are factory adjusted and require no field adjustment. Service A regular lubrication schedule is not necessary. These gate usually require no maintenance. 10 d n : FABRICATED FLAP GATE INSTALLATION (FLATBACK or FLANGEBACK) Finally, it is time to install your Waterman Standard Flatback Flap gate. There are several optional designs, but all gates that are designed to be mounted on a wall ar e similar. Your gate should be handled as one piece. Do not take your gate apart unless necessary. Pick Points During Installation: Fabricated Flap Gates shall be picked at anchor bolt holes near the cross rail for support or by using a sling as shown (Figure 1) close to the top of the gate. Referen c the red dots in Figure 2. Downward Opening Slide Gates shall be picked using the stem connection holes on the slide. Figure 1 1. INSTALLATION OF FLAP GATE GATE MOUNTING PROCEDURES: 1. Your gate shipped as a complete assembly banded together, forming a compact factory-aligned unit. Do not disassemble your gates. 2. Clearly mark both Horizontal and Vertical centerlines of your wall opening (Figure 3). Locating and installing all anchor bolts can be found in previous section 2.1 (Embedded Items). 3. After all anchors have setup, double-check all O.C. measurements, ensuring gate is vertical and plumb. Remember the gate frame should in no way obstruct the flow through the opening. 4. Place backing nuts (Figure 4) onto each anchor bolt and check for plumb and verticle alignment . 5. Slip your gate firmly against each backing nut and tighten retaining washer and nut. 6. Check clearance between seal and slide following installation with a .002” feeler gauge (see arrow in Figure 4). Gauge shoul not pass through at any point around seal perimeter with gate i a fully closed position. (Please see red marked locations in Figure 2 for seal perimeter.) After grout has cured, thoroughly clean gate and neoprene seals. Using extra care around the seals and smooth face of slide. Backing nut Figure 4 Figure 3 Figure 2 7 11 WATERMAN VALVE, LLC INITIAL OPERATION OF GATES 1. After gate, stem guides, stem, lifting mechanism, and other necessary appurtenances have been installed, check the following prior to operation: a. Check all assembly and mounting hardware for proper tightnes b. Remove any shipping stops on gates. c. Check gate guide grooves, seats and wedges for any foreign matter and clean as necessary. 2. Clean all dirt, paint, concrete splatter, or other foreign material from seating surfaces, wedges, flushbottom seal, etc. 12 WATERMAN VALVE, LLC INITIAL OPERATION OF GATES - (CONTINUED) 5. Grease all seating and wedging surfaces with water-resistant grease as noted below: a. For machined iron or bronze seating or wedging surfaces, grease with Intertol Grease Coating, as manufactured by Koppers, Inc., or equal.1 b. Grease stainless steel seats and wedging surfaces with Never-Seez, manufactured by Never- Seez Corporation or equal.1 For best results, mix Never-Seez with an equal portion of ten-weight oil. c. Seating surfaces of aluminum or fiberglass slide gates, including gates with UHMW polyethylene bearing strips, require no lubrication. 6. Close gate completely and check for proper closure. a. On all cast iron sliding gates (also applicable to flap gates and shear gates) check seat clearance with .004” feeler gauge. Best results can be obtained by checking seat faces from backside of gate when installation permits. Adjust any wedges as necessary per applicable wedge adjustment procedures following, until .004” feeler gauge cannot be inserted between seats. b. On fabricated slide gates, check to see that slide fits flat against seating surface. Check to be sure frame is not warped. CAUTION: Be extremely careful when closing gate so as not to apply excessive compressive force on stem. The stem under a compressive load is the weakest link in the system and can buckle (bow) if excessive force is applied to operator. Limit nuts should be in place if applicable. 7. Set any limit nuts or position indicators as required per applicable instructions. 8. Cycle gates with operators to ensure proper installation, alignment, and operation. 1 See lubrication chart (page 6.10) for equivalent lubricants. NOTE: Some installations may require food grade lubricants due to environmental conditions. If so, use Huskey “Husk-It” Lube-O-Seal or equivalent. WATERMAN VALVE PROCEDURE FOR ADJUSTING FLAP GATE HINGE ARM - (F-25/55 OR F-20/40) he hinge ann position is factory set and should not need adjustment. However, if it is deemed necessary to improve seating or opening characteristics, the following procedure should be used. 1.After installation, frame seat should be checked for flatness to frame was not warped during installation. Frame seats are machined to a flatness of .002" TIR. 2.Close cover and check seats with .004" feeler gauge. 3. Only upper hinge arm pivot can be adjusted and only in one direction. The hinge block is located on two (2) studs by nuts on either side of block. 4.Loosen two (2) nuts on side of hinge block in direction you wish to move block. Alternately turn nuts on opposite side of block to jack block into new position. Tighten bolts originally loosened. 5.Repeat above procedure as necessary until desired seating or ease of opening is reached. 13 T wATERMAN VAL VE, LLC FIELD PAINTING he following procedures should be followed for field painting equipment supplied with primer only or for recoating installed equipment for continued maintenance and protection. 1. Before any sandblasting or painting, all seating and wedging surfaces should be properly protected by masking. Wedges should not be removed from gate. 2. The gate should not be disassembled unless absolutely necessary. The slide (disc) can be removed from the guides by removing shipping stops. 3. All machined surfaces not primed on gates and appurtenances (i.e. stem guide bushing, lift input shafts, gate flanges, etc.) should be properly protected by covering or masking. 4. Prepare all prime painted or previously painted surfaces in accordance with coating manufacturer's specification, prior to painting. 5. After painting, remove all masking and thoroughly clean all seating and wedging surfaces. Replace slides in gates if they have been removed. If gates are not installed, replace shipping stops. 6. Coat all machined sliding surfaces with grease of a type allowed by local or project specifications to be environmentally safe. 14 T TROUBLE SHOOTING 15 FLAP VALVE TROUBLE SHOOTING GUIDE he installation of slide gates requires a great deal of care to prevent damage to the gates and distortion of the frame. Slide gates are an economical choice for open channel flow applications where tight sealing is not necessary, and some leakage is to be expected. However, the following trouble-shooting tips may help to reduce the leakage and improve the performance of the gate. SYMPTOM: CAUSE: REMEDY: Concrete or debris wedged between cover and frame. Remove foreign material. SYMPTOM: CAUSE: REMEDY: Generally occurs on gates distorted by bolting to uneven concrete walls without the use of grout. Loosen anchor bolt nuts, shim gate to true plane, and fill in void between guide and wall with grout. T WATERMAN VALVE MAINTENANCE OF FLAP GATES ther than periodic cleaning as required to maintain smooth operation or painting to maintain appearance, no maintenance is required on the following listed equipment: FLAP GATES NOTE: Gates may require occasional cycling to alleviate sticking. Cycling at minimum 30 day intervals is recommended. Gate requires no maintenance other than listed previously. However, some pivot pin bushings in hinge arms have lubrication fittings. The bushings should be lubricated at least two (2) times a year with a good, non-water soluble grease, such as Mobilux 2EP or equal. O WATERMAN VALVE, LLC SPECIAL TOOLS he installation and adjustments of Waterman gates and equipment requires no special tools and can be accomplished using a minimum of the following standard tools: 10” or 12” Crescent Wrench (2 required) .004” Feeler Gauge While these are the minimum tools required, installation time can be greatly decreased with such standard tools as socket wrenches and box wrenches. T WATERMAN VALVE, LLC SPARE PARTS & PARTS REPLACEMENT ll products supplied by WATERMAN VALVE, LLC are designed to last indefinitely if properly maintained and operated, therefore, no spare parts are recommended. Should it become necessary to replace a part, refer to the enclosed installation or detail drawings for the appropriate parts number or size. Replacements may be ordered direct from the factory or through your local representative. Always be prepared to give the Waterman Job number and installation drawing number (see Field Service, Pg. 8.0). If certain spare parts were required by project specifications, they will be listed on sheet 7.0.1, under Spare Parts Addendum. Replacement parts for “vender supplied” products, i.e. motorized operators, hydraulic cylinders, etc. should be ordered as recommended in separate manufacturers O & M data located elsewhere in this manual. A EMERGENCY OPERATING INSTRUCTIONS 1.Manual gate operators have no emergency procedure. 2.Electric motor operators may be operated manually in the occurrence of an electrical failure by moving the handwheel clutch lever arm in the direction indicated on the operator housing. Rotating the handwheel will move the gate open or closed. The handwheel clutch will automatically disengage when unit is operated electrically. SAFETY INSTRUCTIONS 1.Sluice and Slide Gates a.DO NOT apply water pressure above the gate capacity listed on the engineering drawings. b.Keep hands, clothing, tools, etc. Away from moving gate. c.Do not work or loiter beneath an open gate leaf without providing stop blocks and removing electrical power from electrical operated gates. 2.Electric Motor Operators a.See operator instruction manual for manufacturer safety instructions. b. Operator electrical cabinet contains HIGH VOLTAGE. Do not attempt adjustment or repair unless qualified. Disconnect power before opening. 3.Flap Gates a.DO NOT apply water pressure above the gate capacity listed on the engineering drawings. b.Keep hands, clothing, tools, etc. away from moving gate. 4.Telescoping Valves a.Keep hands, clothing, tools, etc. away from moving valve. LIMITED WARRANTY: McWane Plant & Industrial, LLC, (“Seller”) warrants that goods manufactured by Seller (“Goods”) will be of the kind described in Seller’s quote and free from defects in material and workmanship under conditions of normal use for a period of twelve (12) months following delivery. Seller reserves the right to make any modifications required by production conditions to information set forth in Seller’s catalogues and advertising literature. Seller will not be liable or responsible for (A) any defects attributed to normal wear and tear, erosion or corrosion, improper storage, use or maintenance or use of Goods with incompatible products, or (B) defects in any part of Goods manufactured by others. If (B) above is applicable, Seller will, as an accommodation to Buyer, assign to Buyer any warranties given to it by any such other manufacturers; provided, however, that the foregoing will not extend Seller’s warranty to any accessory products unless Seller specifically agrees in writing. All warranties are void if Goods are modified or used in conjunction with products or accessories not manufactured or approved by Seller or which are incompatible with Goods. This warranty does not cover failure of any part manufactured by others, failure of any part from external forces, including but not limited to corrosive soils, earthquake, installation, vandalism, vehicular or other impact, application of excessive torque to the operating mechanism, frost heave or other force majeure. Any claim by Buyer with reference to Goods for any cause will be deemed waived by Buyer unless submitted to Seller in writing within ten (10) calendar days from the date Buyer discovered, or should have discovered, any claimed breach. Buyer will give Seller an opportunity to investigate. If Buyer gives prompt notice to Seller of any defect and an opportunity to inspect the alleged defect as provided above, Seller will, in its sole discretion, either: (i) repair the defective or nonconforming Goods; (ii) replace nonconforming Goods, or part thereof, which are sent to Seller by Buyer within sixty (60) calendar days after receipt of the Goods at Buyer’s plant or storage facilities; or (iii) if Seller is unable or chooses not to repair or replace, return the purchase price paid and cancel any obligation to pay unpaid portions of the purchase price of nonconforming Goods. In no event will any obligation to pay or refund exceed the purchase price paid. Repair and/or replacement as provided above will be shipped EXW (Ex-Works) Seller’s facility (Incoterms® 2020) unless otherwise agreed in writing by Seller. Buyer will prepay all transportation charges for return of all or part of Goods to Seller, unless otherwise agreed in writing by Seller. Seller will not be responsible for any labor, removal or installation charges that may result from repair and/or replacement of any Goods. Buyer’s exclusive remedy and Seller’s sole liability for any loss, damage, injury or expense of any kind arising from manufacture, delivery, sale, installation, use or shipment of Goods will be, at Seller’s option, the remedies described above, whether based on contract, warranty, tort or any other basis of recovery. THE WARRANTIES IN THIS PARAGRAPH ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED BY LAW OR STATUTE OR ARISING FROM TRADE USAGE OR COURSE OF DEALING. THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. If a warranted Good is believed to be defective, notify your MPI Sales Office and provide the date purchased and a copy of invoice or shipping documents. DO NOT attempt repairs or returns without authorization from MPI. Unauthorized repairs may void the warranty, and costs for unauthorized repairs performed or replacement parts purchased within the warranty period will not be reimbursed. A return authorization number must be obtained from MPI prior to returning any Goods. Warranty Owner: Warranty Effective/End Date: MPI Representative: