KCS served as the prime contractor for the comprehensive modernization of the downstream navigation lock gate hoist system at Lower Monumental and Ice Harbor lock and dam systems. A major focus was replacing the electrical and control systems used to operate the 1.5-million-pound gates, including new PLC and VFD equipment, sensing systems, encoders, and fiber-optic and Ethernet communications. Working with ETS Automation, KCS identified gaps in the original control designs early, coordinated necessary revisions with USACE, and prefabricated and tested equipment before the outage to reduce fieldwork and schedule impacts. The projects were completed under an aggressive navigation lock outage schedule and included significant mechanical and structural upgrades.
- Upgraded the lock stand control consoles, primary gate-position drum encoders, and installed backup SSI string encoders to improve gate-position monitoring and system reliability.
- Replaced the VFD and PLC control cabinets in all four gate towers, along with associated conduit and control and power-feed wiring.
- Installed new brake resistors, isolation transformers, and PLC I/O cabinets supporting upstream and downstream lock stands.
- Installed new water-level sensing systems at the forebay, lock chamber, and tailrace, as well as position encoders for two fill valves and two drain valves.
- Established new fiber-optic and Ethernet communication networks and completed the integration, testing, and commissioning of the upgraded control systems.
- Coordinated the electrical improvements with new VFD-driven motors, brakes, and gearboxes.
- Completed extensive structural repairs to each 18-ft diameter hoist drum to provide fully rehabilitated and dependable gate-hoist systems.
