Champions Automate Navigational Lock Controls for Numerous U.S. Waterways

For over 20 years, Champion personnel have been involved in the United States Army Corps of Engineers (USACE) navigational waterways controls. Champion successfully designed and implemented entire control strategy upgrades at 10 USACE locks. These locks are located in regions throughout the country including the Atchafalaya River (Old River Lock and Berwick Lock), the Mississippi River (Port Allen Lock, Harvey Lock, Algiers Lock, and Inner Harbor Navigational Canal Lock), the Chicago River (Chicago Harbor Lock), and various intercoastal waterways (Calcasieu Lock, Bayou Sorrel Lock, and Bayou Boeuf Lock).

USACE Motivations to Upgrade
Though project locations ranged across the country, similar motives pushed the USACE to seek lock controls automation upgrades. Aging equipment at the sites combined with a need to retrieve more operational and diagnostic information from the locks fueled the Corps’ desire to upgrade the systems. The locks also needed up-to-date documentation for the systems including accurate sets of design drawings. Consistency across the lock control systems (in design and method of operation) and safety (addition of interlocks to protect personnel and equipment) also proved to be motivators for these large project undertakings.

Lock Automation Upgrades Overview
Champion completed each project as a full, turn-key installation—Champion, with installation assistance from its electrical subcontractors, accomplished each aspect of the projects including drawings, electrical and automation work, fiber installation, and startup and commissioning. At each site, the automation upgrade consisted of a control system retrofit. Each lock control system has a primary PLC system and a backup system. The backup systems are hardwired at all lock locations excluding Inner Harbor Navigational Canal Lock which has a redundant control system. Champion also provided the following as part of the upgrades:

• Motor Control Center (MCC) modernizations
• Power distribution
• Analog and digital camera systems
• Water level monitoring and recording
• Control room renovations

The Champion team also supplied startup and commissioning support for each lock control system. This effort involved countless hours spent onsite supervising subcontractors, testing the system, and training operators. Each startup consisted of a hot cutover that had little or no impact on lock operation. No PLC cutover activities had more than a four hour impact on operations.

Innovative Technology
Champion used Allen-Bradley ControlLogix PLCs and 1756 I/O to control lock gates and valves. HMI PCs provided for the upgrades equipped with FactoryTalk FTE software give operators the ability to control the gates and valves via the PLC system. A fiber optic ring network independent of any existing network media ties together the PLC I/O racks and HMI stations at each site. The fiber optic ring network provides a level of redundancy for enhanced control system reliability. At several of the locks, Champion also installed and programmed large marquee signs to provide information to the public using the waterways.

For two of the USACE locks (Berwick and Calcasieu Lock), Champion implemented a radio control system to provide remote control of the gates.

Champion created and assembled a custom quadrature encoder using two photo-eyes and a laser jetted optical target to provide information that was previously unavailable to lock operators. The encoder provides position feedback such as percent open and percent close for the gates and direction of travel while being able to handle severe misalignment.

Measurement technology implemented at the locks consisted of the following instrumentation:

• Limit, proximity, and photo switches
• Weather stations (to measure rain, snow, wind speed/direction, humidity, and temperature)
• Laser transmitters (to provide water level/gate position)
• Ultrasonic transmitters (to provide water level)
• Radar transmitters (to provide water level)

Success of the Projects
Champion and only one other company were selected as qualified to bid on several of the lock automation upgrades under a $10 million dollar Multiple Award Task Order Contracting (MATOC) agreement. Under the contract, Champion won each competitive bid.

For each project, Champion’s team focused on not only meeting project specifications but also particular lockmaster wants and requirements. Lockmasters sought up-to-date, detailed drawings, user-friendly systems, and even special features such as remote control. By delivering on these requests, Champion ensured overall control system satisfaction and seamless adoption of the new technology by lock personnel. Champion also worked around mechanical construction schedules for the projects to preserve as much waterway uptime as possible.

Success achieved during the lock automation upgrades can be fully attributed to the organization and hard work of the Champion project teams. Efficient project management, attention to detail, and the teams’ technical expertise allowed each project to be completed in a timely, professional manner and to exceed USACE expectations.

This is a basic red beans and rice recipe that gets its rich, meaty flavor from smoked ham hocks and pickled pork.

Don’t forget the hot sauce.

“Monday wouldn’t be Monday in Louisiana without red beans and rice. Legend has it that since Monday was traditionally wash day, an all-day affair before electric washers and dryers, a pot of red beans spent the morning simmering on the back of the stove. If there was a ham bone left over from Sunday’s dinner, it was thrown into the pot of beans. When the laundry was done, so were the beans. Red beans ladled over fresh steamed rice with a pile of French bread for sopping up every last drop.”

Recipe Courtesy of Emeril Lagasse

8-10 servings | Prep Time: 30 minutes | Total Time: 3 hours

INGREDIENTS:

• 2 tablespoons vegetable oil
• 2 cups chopped onions
• 1/2 cup chopped celery
• 1/2 cup chopped bell peppers
• Salt and cayenne, to taste
• 4 bay leaves
• 4 sprigs fresh thyme
• 1 pound dried red beans, rinsed and sorted over, soaked and drained
• 1 pound smoked ham hocks
• 1 pound sausage (Andouille or Tasso), cut into bite-sized pieces
• 1/2 pound boiled pickled pork meat – Optional *(See note)
• 3 tablespoons chopped garlic
• 10 cups chicken stock, or water
• 4 cups cooked white rice
• 1/4 cup chopped green onions

PREPARATION:

1. Place the beans in a large bowl or pot and cover with water by 2 inches. Let soak for 8 hours or overnight. Drain and set aside.
2. In a large pot, heat the bacon grease over medium-high heat. Add the sausage and cook, stirring, for 1 minute. Add the onions, celery and bell peppers to the grease in the pot. Season with the salt, pepper, and cayenne, and cook, stirring, until the vegetables are soft, about 4 minutes. Add the bay leaves, parsley, thyme, ham hocks or pork meat, and cook, stirring, to brown the pork and ham hocks, about 6 minutes. Add the garlic and cook for 1 minute. Add the beans and stock or water, stir well, and bring to a boil. Reduce the heat to medium-low and simmer, uncovered, stirring occasionally, until the beans are tender and starting to thicken, about 2 hours. (Should the beans become too thick and dry, add more water, about 1/4 cup at a time.)
3. Remove from the heat and with the back of a heavy spoon, mash about 1/4 of the beans against the side of the pot. Continue to cook until the beans are tender and creamy, 15 to 20 minutes. Remove from the heat and remove the bay leaves.
4. Serve over rice and garnish with green onions.

TIPS & NOTES:

1. *Pickled pork meat needs to be blanched for 5 minutes in boiling water and then drained before using.