CALIFORNIA NATURAL RESOURCES AGENCY DEPARTMENT OF WATER RESOURCES DIVISION OF SAFETY OF DAMS INSPECTION OF DAM AND RESERVOIR IN CERTIFIED STATUS STATE OF CALIFORNIA Name of Dam New Exchequer Dam No. 58?2 County Mariposa Concrete Ogee Weir with Radial Gates and an Type of Dam Rock Type of Spillway Auxiliary Open Channel Broad?Crested Weir Water is 50.6 feet below spillway crest and 95.5 feet below dam crest. Water Elevation: 786.5-ft Weather Conditions Partly Cloudy Skies, Warm and Calm Contacts Made John Ellett and Peter Wade with the Merced Irrigation District Reason for Inspection Periodic Maintenance Inspection Important Observations, Recommendations or Actions Taken This dam and appurtenant structures are well maintained. Investigate the source of the leak in the ceiling ofthe upper gallery, and monitor the amount of water leaking and determine a course of action for repair. Patch the damaged area of exposed steel reinforcement of the right abutment?s gallery, located near the crest. Remove the sporadic woody vegetation that is starting to emerge along the toe of the Saddle Dike. Arrangements need to be made to cycle the low?level outlet during the next maintenance inspection. Due to the reservoir's historic low water levels, the District temporarily stored houseboats in the Auxiliary Spillway. The houseboats are scheduled for removal by the end of the summer. In the future, the District needs DSOD approval before any items are stored within the Auxiliary Spillway. The District is currently developing a work plan to have the upstream bulkhead gate brought back in operating condition. The Owner needs to submit the replacement proposal once it becomes available, and if we determine the work is essentially an in?kind replacement, it will be considered routine maintenance and we will not require an application. Although our approval was given in our letter dated February 24, 2014 to change the frequency of monument surveys to at least every three years, instrumentation reports covering other instrumentation needs to be submitted annually, and the current instrumentation report is overdue. Conclusions From the known information and visual inspection, the dam, reservoir, and the appurtenances arejudged safe for continued use. Observations and Comments Da_m Main Dam: The Main Dam is a large rockfill structure that is 492?feet high and 1,400-feet long with an upstream face that is lined with a series of (SO-feet wide by 50-feet in length reinforced concrete panels. New Exchequer Darn was constructed just of the original concrete arch? gravity darn between July 1964 and June 1966. The asphalt paved crest was level, uniform and the pavement was in good condition. Thembv?w 5i" Inspected by Bill Vogler . Photos taken? Yes No Date of Inspection 05/19-20/2016 1, U0 cc for Owner/Field Book/File Date of Report 06/20/2016 vaR 1261 (Rev. toros) Sheet 1 of 6 INSPECTIQN Or- DAM AND RESERVOIR IN STATUS Name of Dam New Exchequer Dam No. 58-2 . Date of Inspection 05/19?20/20?16 Observations and Comments Spillway DWR ?1261 (rev. 1 OIOQ) longstanding separation and offsets in the crest's upstream concrete parapet wall appeared unchanged as compared with previous inspection reports. The concrete panels that line the Upstream slope as viewed from the crest appeared satisfactorily aligned, having no sign of concerning movement or structural instability. The upstream steel expansion joint plates appeared adequately attached to the upstream concrete panels and in serviceable condition. The rock lined slope is steep and was viewed from the crest and toe. No concerning conditions were noted and the slope appeared in satisfactory condition having no sign of settlement, sloughing, or loss of grade. The groins were not walked due to safety concerns of the steep and uneven conditions, and no concerns with regard to erosion and abutment stability were noted as observed from the crest and toe. The powerhouse is located at the toe of the Main Dam, and no concerning conditions were noted throughout this area. Vegetation control was excellent throughout the Main Dam. Right Abutment Gallery: The right abutment gallery, near the entrance at the crest, has damage from rock fall which resulted in exposed steel reinforcement (Photo 1 and Photo 2). The areas having exposed steel reinforcement need to be repaired. inspected both the upper gallery and valve chamber. The concrete comprising the valve chamber and the upper gallery appeared in good to satisfactory condition. Approximately 8- feet past the left hand turn to access the lower valve chamber, a leak has developed in the ceiling of the upper gallery (Photo 3). The leak appears to be associated with an abandoned corroded pipe protruding from the ceiling. lVlr. Wade and Mr. Ellet agreed to investigate the source of the leak and determine a course of action of repair. it was also agreed to monitor the amount of water emanating from the ceiling. inspected the lower gallery all the way to the rectangular weir located in the original edit at the toe of the original dam. The lower gallery appeared in stable and satisfactory condition, particularly considering this portion of the darn was completed in 1926. Saddle Dike: I inspected the paved crest, upstream and groins, and the toe. The paved crest was uniform, level and in good condition. Both riprap lined slopes were uniform, stable, and in satisfactory condition. The groins and toe appeared normal and the abutments stable. No concerning rodent activity was observed and vegetation control was overall excellent. Sporadic woody vegetation was starting to emerge along the toe contact, to which Mr. Ellet agreed to have removed. The spillway consists of a gated section and an ungated auxiliary spillway section. The Main Spillway?s approach, control section, and exit were clear of concerning debris. performed a cursory inspection of the six radial gates that are 40?feet wide and 30?feet high and have a substantial reinforced concrete structure that supports the gates. I noted no distress or instability in the concrete comprising the invert, ogee weirs, retaining walls and the structures supporting the radial gate trunnions. The joints were well aligned in both the walls and invert. The concrete patching that was detached in a few locations was minor and does not warrant immediate attention. All six radial spillway gates were last fully cycled by the on October 14-15, 2015 with no reported problems. According to Mr. Ellett, the gates are cycled twice a year and three are operated with emergency back?up power and the other three are operated from the power grid. The most recent thorough inspection of the spillway gates was performed by Black Veatch Corporation in April Sheet of 6 INSPECTION OI- DAM AND RESERVOIR IN STATUS Name of Darn New Exchequer Dam No. 58-2 Date of Inspection 05/ 1 9-201201 6 Observations and Comments Outlet Seepage 2008 with no reported problems or concerning conditions. The spillway gallery was not inspected during this inspection, and was last inspected by DSOD during the September 24, 2013 inspection. The gallery was found to be in good condition, and the underdrains were open and clear (Note: Inspection of the access gallery requires a confined space entry permit and fall protection gear). The entrance to the auxiliary spillway was free of concerning debris, and the concrete sill remains in satisfactory condition. Due to success years of drought and the low reservoir water level, houseboats were stored within the control section of the auxiliary spillway. The Mr. Wade informed me that the reservoir?s water elevation forecast had a 10% chance of reaching El. 810, approximately (SO?feet below the auxiliary spillway?s crest elevation, and the houseboats were scheduled to be removed shortly. The temporary storage of the houseboats did not appear to be an immediate darn safety issue provided they will be removed before the end of summer. I informed Mr. Wade that in the future, the District needs DSOD approval before any items are stored within the auxiliary spillway. The low-level outlet consists of a hydraulically operated 14-foot by 23?foot bulkhead gate located in the intake structure that controls flow into a 113-foot long and 18?foot diameter tunnel that terminates into the dam?s gate chamber. Two 7?feet by 10.5-feet hydraulically operated slide gates located in the gate chamber controls flow into a pipeline that passes through the dam and into the powerhouse. Just upstream of the powerhouse, the pipeline bifurcates into a 13-feet diameter penstock that serves the turbine generator and a 9?feet diameter penstock that serves as a bypass. Bypass flows are controlled by a 108-inch Howell-Bunger valve and a 13?foot diameter butterfly valve is used as the turbine shutoff valve. The owner is required to cycle the two slide gates located in the gate chamber and the Howell-Bunger (HB) valve located in the powerhouse for dewatering requirements. None ofthe gates or the HB valve were operated during this inspection. The intake slide gates were last cycled during February 1?4, 2016, and the HB valve was last cycled September 24?25, 2015. DSOD last witnessed the cycling of the HB valve on November 14, 2013, and the slide gates on December 5, 2013. DSOD requires the cycling of the designated low?level outlet valves at least once a year, and in our presence every three years. Arrangements need to be made to cycle the upstream and outlet controls during the next DSOD maintenance inspection. Based on the DSOD files, there is no record ofthe upstream bulkhead gate being operated, and the hydraulic controls are not functional. The District is currently developing a work plan to have the upstream bulkhead gate brought back in operating condition. A dive inspection ofthe upstream bulkhead gate was performed in early 2016 to evaluate the condition of its mechanical and hydraulic components. According to Mr. Ellet, the hydraulic controls will most likely be abandoned and the bulkhead gate will be stored on shore and operated from a barge. The Owner needs to submit the replacement proposal once it becomes available, and if we determine the work is essentially an in?kind replacement, it will be considered routine maintenance and we will not require an application. No seepage or evidence of seepage was observed on the slopes, groins, and toe areas on both the Main and Saddle Dike. Leakage from the main dam passes through five ports in the concrete wall to the left of the DWR1261(rev.10f09) Sheet 3 of 6 INSPECTION OF DAM AND RESERVOIR IN STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 05/19-20/2016 Observations and Comments powerhouse. The level in the pool behind the wall is monitored by a transducer and a conversion table is used to determine the leakage in cfs. There is also a 12-inch rectangular weir located in the original adit at the toe of the original dam that monitors total flow from the galleries ofthe original dam. The original dam?s vertical/horizontal drains that flow into the left gallery gutter were flowing clear. A few ofthe drains were completely clogged with minerals build-up (appeared to be calcium carbonate), but adjacent drains appeared to compensate by releasing a little more water than the other drains. The clogged drains do not appear to be a dam safety issue since the old dam is independent of the new dam, and the measured seepage from these drains is not increasing and remains within historical norms. . The following measurements for seepage were taken during this inspection: Location Weir Reading (ft) Flow Original Dam 12?inch rectangular 0.11 53 Powerhouse Weir remote reading 13.96 5 Saddle Dike Saddle A (22.5-deg) dry dry Saddle Dike Saddle (22,5-deg) dry dry Saddle Dike Saddle (22.5?deg) dry dry Train Tunnel 45-degree V-notch 0.29 20 All seepage values appeared appropriate for the low reservoir water elevation and all flows were clear. The instrumentation at this dam consists of 40 monuments that measure the settlement and displacement on the upstream concrete panels, seven crest monuments, six seepage locations and joint gap measurements on the upstream concrete panels. The latest instrumentation report was submitted on April 17, 2015, and covered the period through December 2014. The report was reviewed in the May 18, 2015 inspection report and the available data indicated the dam is performing satisfactorily. Although the Division approved the District?s proposal to change the frequency of monument surveys to at least every three years in our letter dated February 24, 2014, instrumentation reports covering the other instrumentation needs to be submitted annually, and the current instrumentation report is overdue. The previously reviewed instrumentation data indicated that this dam is performing adequately. Therefore, the existing instrumentation and their monitoring frequency are judged sufficient at this time. own 1261 (rev. 10109) Sheet 4 of 6 INSPECTION OI- DAM AND RESERVOIR IN CERTII-IED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 05/ 9?20/.3. A..- Photo 1. The red arrow points to the right abutment gallery?s damaged area with exposed steel reinforcement. Photo 2. A close?up view of the exposed reinforcement on the exterior of the right abutment gallery that requires patching. DWR 1261 (rev. 10I09) INSPECTION OF DAM AND RESERVOIR IN CERTII-IED STATUS Name of Darn New Exchequer Dam No. 58-2 Date of Inspection 05/ 1 9-20/201 6 ?'Photo 3. The red arrow points to the leak that has developed in the ceiling of the upper gallery. The yellow arrow points to an abandoned and corroded pipe. Photo 4. A View of the houseboats that are being stored within the auxiliary spillway. - Sheet 6 of DEPARTMENT OF WATER RESOURCES DIVISION OF SAFETY OF DAMS INSPECTION OF AND RESERVOIR IN CERTIFIED STATUS STATE OF CALIFORNIA JALIFORNIA NATURAL RESOURCES AGENCY a i Name of Dam New Exchequer Dam No. 58?2 County Mariposa . Concrete Ogee Weir with Radial Gates and an I Type ofDam Rock Type ofSpillway Auxiliary Open Channel Broad-Crested Weir Water is 2015 feet below spillway crest and 255.5 feet below dam crest. Water Elevation: 628.5-ft Weather Conditions Clear Skies, Mild and Calm Contacts Made Bill Cochran, Samantha Long, John Ellet, and John Wiersma with the Merced Irrigation District Reason for lnsoection Periodic Maintenance Inspection Important Observations, Recommendations or'Actions Taken I This dam and appurtenant structures are well maintained. Due to the drought, the reservoir water level is unprecedentedly low. In our letter dated May 18 1988, we requested the District to keep the water surface elevation of the water impounded between the original I Exchequer and New Exchequer dams to no higher than 20 feet above that of the reservoir. The District had adequately pumped out the water between the two dams. A construction project not requiring an application to improve the access and safety of the upper gallery and lower valve chamber has been adequately completed. As requested, an updated instrumentation report through 2014 has been submitted. The report was well organized and written. The District is currently evaluating the possibility to have the upstream bulkhead gate brought back into operating condition. Thefollowing maintenance items were performed as requested during the previous maintenance inspection: 1. 2. 3. The void in the crest was repaired as requested during the previous inspection. The bush growing on the Saddle Dike that is located at the crest?s shoulder, near the mid? section ofthe dam was removed as requested during the previous inspection. The leak in the 12?inch sharp?crested rectangular weir located within the gallery of the original dam was repaired as requested during the previous inspection. Conclusions From the known information and visual inspection, the dam, reservoir, and the appurtenances are judged safe for continued use. Observations and Comments Dam Main Dam: The Main Dam is a large rockfill structure that is 492-feet high and 1,400-feet long with an upstream face that is lined with a series of (SO-feet wide by 50?feet in length reinforced concrete panels. New Exchequer Dam was constructed on top ofthe original concrete arch?gravity darn between July 1964 and June 1968. Due to recent drought conditions, the original Exchequer Dam was visible. In a Division letter dated May 18 1988, we requested the District to keep the water surface elevation of the water impounded between the original Exchequer and New Exchequer dams to be no higher than 20 feet above that reservoir. According to Mr. Cochran, water was pumped out between the two dams to reduce the LYI - tutfxt GI Inspected by Vogler Photos taken? Yes N0 Date 05/18/2015, prfJ-?) cc for Owner/Field Book/File Date of Report 06/10/201 5?14" stint; owa12s1 (Rev. 10109) Sheet 01 INSPECTION DAM AND RESERVOIR lN CERT. El STATUS Name of Dam New Exchequer Dam No. 58?2 Date of Inspection 05/1 8/2015 Observations and Comments ?pillway DWR1261(rev.10t09) Sheet 2 of hydrostatic pressure on the original concrete arch, which complied with our 1988 request. The asphalt paved crest was level, uniform and the pavement was in overall excellent condition. The void below the small hole in the crest?s asphalt pavement located at the interface to the parapet wall near the right abutment was repaired, as requested during the previous inspection. The longstanding separation and offsets in the crests upstream concrete parapet wall showed no signs of recent movement and appeared unchanged as compared with previous inspection reports. Due to the recent drought and the extremely low reservoir water level, a large portion of the original clam was exposed and I was able to inspect theupstream concrete panels from the crest of the original dam and from the crest of the present dam (Photo 1). The panels appeared satisfactorily aligned with no sign of concerning movement or structural instability. The upstream steel expansion joint plates appeared adequately attached to the upstream concrete panels and in serviceable condition. The rock lined slope is steep and was viewed from the crest and toe. No concerning conditions were noted and the slope appeared in satisfactory condition with no sign of settlement, sloughing, or loss of grade. The groins were not walked due to safety concerns ofthe steep and uneven conditions, and no concerns with regard to erosion and abutment stability were noted as observed from the crest and toe area. The powerhouse is located at the toe of the dam, and no concerning conditions were noted throughout this area. Vegetation control was excellent throughout the Main Dam site. The capital improvement project in the upper portion of the gallery and the valve chamber located in the original dam to improve ventilation and safe access to the lower valve chamber has been completed. The new spiral staircase installed in the dry well shaft now provides safe access from the upper gallery to the valve chamber. inspected both the valve chamber and lower gallery. The new spiral staircase appeared well attached to the dry well shaft, and although mineral deposits obscured the concrete lining the shaft, no distress or concerning conditions were observed. The valve vault is now well lit, well ventilated, and dry. The concrete comprising the valve vault and the newer gallery appeared in goOd condition. Although the original gallery had areas of minor surface spalling and most ofthe surfaces were covered with mineral deposits, the concrete appeared in overall satisfactory condition. i did not observe any concerning conditions throughout the valve chamber and in the new and old galleries. Saddle Dike: inspected the paved crest, upstream and groins, and the upstream and toe areas. The lower water conditions allowed inspection of the upstream toe. Both toe areas were normal and the abutments were stable. The paved crest was uniform, well aligned and in good condition. Both riprap lined slopes were uniform, stable, and in satisfactory condition. No concerning rodent activity was observed and vegetation control was overall excellent. The bush growing at the crests shoulder, near the mid-section of the dam, was removed as requested during the previous inspection. The spillway consists of a gated section and an ungated auxiliary spillway section. The approach, control section. and exit were clear for both spillway sections. The log boom was lying on the ground and intact and appeared in satisfactory condition. I performed a cursory inspection of the six radial gates that are 40~feet wide and 30~feet high and have a substantial reinforced concrete structure that supports the gates. inspected the concrete comprising the structure from DAM AND RESERVOIR IN CERT. ED STATUS Name of Dam New Exchequer Darn No. 58?2 Date of inspection 05/18/2015 Observations and Comments Outlet Seepage the upstream, the road, and locations. I noted no distress or instability in the concrete which included the invert, ogee weirs, retaining walls and the structures supporting the radial gate trunnions'. The joints were well aligned and I noted some of the concrete patching was detaching but this was minor and does not need immediate attention. The spillway gates were last cycled by theowner in October, 2014 with no reported problems. According to Mr. Ellett, the gates are cycled twice a year and three are operated with emergency back?up power and the other three are operated from the power grid. The most recent thorough inspection ofthe spillway gates was performed by Black Veatch Corporation in April 2008 with no reported problems. The spillway gallery was not inspected during this inspection, and was last inspected by DSOD during the September 24, 2013 inspection. The gallery was found to be in good condition, and the . underdrains were open and clear. Fall protection gear is required to access the gallery. The low?level outlet consists of a hydraulically operated 14?foot by 23?foot bulkhead gate located in the intake structure that controls flow into a 113-foot long and 18?foot diametertunnel that terminates into the dam?s gate chamber. Two 7?feet by 10.5?feet hydraulically operated slide gates located in the gate chamber controls flow into a pipeline that passes through the dam and into the powerhouse. Just upstream of the powerhouse, the pipeline bifurcates into a 13?feet diameter penstock that serves the turbine generator and a 9?feet diameter penstock that serves as a bypass. Bypass flows are controlled by a 108?inch Howell?Bunger valve and a 13-foot diameter butterfly valve is used as the turbine shutoff valve. The owner is required to cycle the two slide gates located in the gate chamber and. the Howell-Bunger (HB) valve located in the powerhouse for dewatering requirements. None of the gates or the HE valve were operated during this inspection. DSOD last witnessed the cycling of the HB valve on November 14, 2013, and the slide gates on December 5, 2013. DSOD requires the cycling ofthe designated low-level outlet valves at least once a year, and in our presence every three years. Based on the DSOD files, there is no record ofthe upstream bulkhead gate being operated. This gate has not been maintained and cycled regularly since it is prudent to have upstream control for the outlet tunnel. According to Mr. Cochran, the District is evaluating the possibility to have the gate brought back into operating condition. lVlr. Cochran informed me that he will keep the Division apprised ofthe evaluation and any plans to bring it back into operation. Due to successive low water years, the reservoir water elevation was extremely low during this inspection. No seepage or evidence of seepage was observed on the slopes, groins, and toe areas on both the Main and Saddle Dike. The seepage area of the Saddle Dike?s toe that was reported in the September 19, 2010 DSOD inspection report was dry, but this was expected since this seepage appears at higher reservoir water elevations. The District has constructed a weir in an attempt to quantify the seepage in this area. Leakage from the main dam passes through five ports in the concrete wall to the left of the powerhouse. The level in the pool behind the wall is monitored by a transducer and a conversion table is used to determine the leakage in cfs. There is also a 12?inch rectangular weir located in the original edit at the toe ofthe original dam that monitors total flow from the galleries of the original dam. The 12?inch sharp-crested rectangular weir located within the gallery of the original dam was repaired as requested during the previous inspection. Sheet 3 of 7 INSPECTION DAM AND RESERVCIR IN CERT. ED STATUS Name of Dam New Exchequer Dam No. 58?2 Date of Inspection 05/18/2015 Observations and Comments The following measurements fer seepage were taken during this inspection: Location Weir Reading (ft) Flow Original Dam 12-inch rectangular 0.03 7.5 Powerhouse Weir remote reading 0 0 Saddle Dike Saddle A (22.5?deg) dry dry Saddle Dike Saddle (22.5?deg) dry dry Saddle Dike Saddle (22.5?deg) dry dry Train Tunnel 45-degree V-notch 0.06 0.5 All seepage values appeared appropriate for the reservoir water elevation and all flows were clear. The instrumentation at this dam consists of 40 monuments that measure the settlement and displacement on the upstream concrete panels, seven crest monuments, six seepage locations and joint gap measurements on the upstream concrete panels. The latest instrumentation report was submitted on April 17, 2015, and covered the period through December 2014. The District's proposal to change the frequency of monument surveys to at least every three years was approved in our letter dated February 24, 2014. More frequent surveys will be required if there is an increase in movement rends, or a change in seepage conditions. in addition, a survey must be completed immediately after a ?felt? earthquake at the dam. Suwe Crest Settlement: There are seven monuments that are located along the crest of the Main Dam. The base survey was established in 1967 and the maximum settlement of 3.165?ft has occurred at Monument No. 5, which is located near the maximum section of the dam. The largest incremental change in settlement between the 2013 and 2014 survey was 0.022-ft which also occurred at Monument No. 5. The long-term and short?term survey data displayed consistent behavior for a rock filled dam, and no concerning or abnormal conditions were noted from the data. Upstream Concrete Panels: The concrete panels that cover the upstream slope of the Main Dam is divided into fourteen rows, and there are 40 survey monuments installed on seven horizontal lines. Settlement and horizontal displacement is measured for each line since the dam was completed in 1966. The largest settlement and horizontal displacement since 1966 was measured at 5.325-ft and 2.031-ft respectively, and occurred at Monument is located near the maximum section of the dam and approximately mid?point between the crest and upstream toe. Incremental movements between the 2013 and 2014 have been minimal; most are on the order of 0.02?ft Monuments along Lines A, FE, and H-l continue to display normal and expected behavior for both settlement and displacement. Sheet 4 of 7 INSPECTION DAM AND RESERVOIR IN CERT .ED STATUS Name of Dam New EXChequer Darn No. 58?2 Date of Inspection 05/18/2015 Observations and Comments Seepage Main Dam: The seepage from the Main Dam is monitored by a rectangular weir installed in the lowest of five square ports through the concrete retaining wall located on the left side ofthe powerhouse tailrace. The weir has a water level transducer that is read and recorded daily, and is reported in cubic feet per second (cfs). Data for the rectangular weir is available since 1991, and the seepage closely follows the reservoir level and typically drops to zero when the reservoir?s water level drops below El. 717. Since 1991, maximum seepage spikes of 10?cfs were common, and the seepage during 2014 was zero because of the low reservoir water levels. Original Exchequer Darn Gallery Weir: The District installed a 12?inch rectangular weir in the gallery of the old dam in 2009 to measure seepage through the old dam and abandoned access tunnel. A data logger was installed and began recording seepage on July 1, 2011. The seepage closely responds to the reservoir water level. The maximum seepage of 138 was recorded on July 1, 2011, and a minimum seepage of 4 was recorded during 2014. During this inspection, we measured 7.5 gpm, and this descrepency may be attributable to the repair of the leak in the weir. Saddle Dike: Due to the lower reservoir water elevation during 2014, Weirs A and were dry, which is expected since seepage typically occurs when the reservoir water level is above El. 820. Tunnel Weir #2 is located approximately 300-ft of the Saddle Dike, and collects seepage from the dike that discharges into the concrete plug of the old Yosemite Railroad tunnel. During 2014, seepage from the tunnel weir ranged between 0.2 to 1.5 gpm. This seepage is within historical norms for the low reservoir elevation during 2014. The reviewed instrumentation data indicated that this dam is performing adequately. Therefore, the existing instrumentation and their monitoring frequency arejudged sufficient at this time. Sheet 13 of 7 INSPECTION DAM AND RESERVOIR IN ED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 05/ 8/2015 . - 1. Photo 2. A View of the concrete panels covering the upstream slope of the dam. DWR1261 (rev.10i09) Sheet 6 of INSPECTION (L DAM AND RESERVOIR IN STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 05/ 1 8/2015 Photo 3. A view of four radial gate bays located at the Saddle Dike. Photo 4. A view of the air vents to the upstream slide gates located in the valve vault. The vault was well-lit, well-ventilated, and safely accessed as a result of the recently completed renovation project. DWR 1261 (rev. 10109) Sheet of 7 CALIFORNIA NATURAL RESOURCES AGENCY: DEPARTMENT OF WATER RESOURCES DIVISION OF SAFETY OF DAMS INSPECTION OF DAM AND RESERVOIR IN CERTIFIED STATUS 1 STATE OF CALIFORNIA 'l 11/ 11 - . I Name of Dam New Exchequer Dam No. 58-2 County Mariposa Type of Dam Earth/Rock Type of Spillway Unlined Open Channel Water is 129 feet DEIOW spillway crest and 174 feet below dam crest. Water Elevation: 708 ft Weather Conditions Clear Skies and Cool Contacts Made John Eliett, Trelawney Gaus, and Steve Sandlin with the Merced Irrigation District Reason for Inspection Periodic Maintenance Inspection Important Observations, Recommendations or Actions Taken The two 7?feet by 10.5-feet hydraulically operated slide gates located in the gate chamber were fully cycled during this inspection. The operation went smoothly and no problems were encountered. Conclusions From the known information and visual inspection, the dam, reservoir, and the appurtenances arejudged safe for continued use. Observations and Comments Outlet This inspection was scheduled to operate the two 7?feet by 10.5?feet hydraulically operated slide gates located in the gate chamber during a scheduled shutdown at the powerhouse. The low?level outlet consists of a hydraulically operated 14?foot by 23-foot bulkhead gate located in the intake structure that controls flow into a tlS?foot long and 18-foot diameter tunnel that terminates into the dam?s gate chamber. Two 7-feet by 10.5-feet hydraulically operated slide gates located in the gate chamber controls flow into a pipeline that passes through the dam and into the powerhouse. Just upstream of the powerhouse, the pipeline bifurcates into a 13-feet diameter penstock that serves the turbine generator and a Q?teet diameter penstock that serves as a bypass. Bypass flows are controlled by a 108? inch Howell-Bunger valve and a 13?foot diameter butterfly valve is used as the turbine shutoff valve. The owner is required to cycle the two slide gates located in the gate chamber and the Howell Bunger valve located in the powerhouse for dewatering requirements. Only the two slide gates were fully cycled during this inspection. Both gates were initially open 100% and both gates were fully closed and then opened. The closing of each gate took approximately 25 minutes. iVlr. Eliett operated the gates from the control room located at the crest ofthe dam and I observed the operation within the gate chamber. was able to observe the progress of each valve operation by observing the vertical position indicator that is coupled to the non?rising stem ofthe valve. The operation went smoothly and no problems were encountered. Construction crews were completing the construction of the new spiral staircase that was being installed in the dry well shaft that provides access from the upper gallery to the valve chamber. Entry into the valve chamber is a permitted confined space entry and the District completed a confined space entry permit. An attendant was stationed at the entrance in which we had direct communication during the entire Operation. Each entrant entering the chamber had an air monitor. Based on the DSOD files, there is no record ofthe upstream bulkhead gate being operated. It is not clear from our files why this gate has not been maintained and cycled regularly since Inspected by Bill Vogler I/Vl?jt Photos taken? Yes NO Date 12/5/2013 cc for Owner/Field Book/File Date of Report 12/13/2013 \wa'?g Shem 0f INSPECTION A: DAM AND RESERVOIR IN CER x'lED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 12/5/2013 Observations and Comments it is prudent to have upstream control for the outlet tunnel. The District is currently evaluating the possibility to have the gate brought back into operating condition. Photo 1. The controls to the slide gates are operated at the crest. The red arrow points to the control section for the bulkhead slide gate Photo 2. A View ofthe top of the right slide gate. DWR1261(rev.10f09) Sheet 2 of 3 INSPECTION JF DAM AND RESERVOIR IN CER STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 12/5/2013 Photo 3. A View close?up View of the right slide gate?s position indicator nearing the closed position limit switch. ?1 Photo 4. Due to the low water elevation of the reservoir, the top of the original dam could be seen from the crest. Sheet 3 of STATE OF CALIFORNIA - I CALIFORNIA NATURAL RESOURCES AGENCY I I . I DEPARTMENT OF WATER RESOURCES I i I . I I DIVISION OF SAFETY OF DAMS INSPECTION OF DAM AND RESERVOIR IN CERTIFIED STATUS Name of Dam New Exchequer Dam No. 58-2 County Mariposa Type of Dam Type of Spillway Gated Open Channel Water is his feet below spillway crest and Na feet below dam crest. Weather Conditions Windy and Gold, 45 degrees F. Contacts Made Bill Cochran and John Ellett with MID. Reason for Inspection Outlet Inspection. Important Observations. Recommendations or Actions Taken The Howe l~Bunger fixed cone valve was fully cycled during the inspection. The upstream twin slide gates which are normally left Open for generation were fully closed on this date to facilitate the cycling of the Howell- Bunger valve. An investigation should be conducted to assess the Operability Of the upstream bulkhead gate, which has not been cycled since the construction of the new dam in 1966. Conclusions From the known information and visual inspection, the dam, reservoir, and all appurtenances are judged safe for continued use. Observations and Comments Outlet The low level outlet is an 18?foot diameter tunnel equipped with a hydraulically Operated 14-foot by 23?foot bulkhead gate at the upstream intake, and terminating at the gate Chamber inside the dam, where twin hydraulically operated 7?foot by 10.5-foot slide gates control flow to the penstock. Just upstream of the powerhouse, the penstock bifurcates into a 13?foot diameter turbine penstock and a 9-foot diameter bypass equipped with a IDS-inch Howell?Bunger valve. Upon arrival, I found that the upstream twin slide gates had already been fully Closed, and the penstock had been drained in preparation for the cycling of the Howell? Bunger valve. I observed as the 108?inch Howell?Bunger valve cycled full open, and then Closed again without any problems. The valve remains in good condition with only minor damage to the fins and the interior edge of the steel cone. Because of other work taking place in the penstock, we were unable tO reopen the twin slide gates in the gate chamber on this date. Based on a thorough examination of DSOD's files, there is no record of the Upstream bulkhead gate having been operated since the construction of the new dam in 1966. NO one with MID was able to recall the gate having been operated, or could say with any certainty whether it remains in operable condition. DSOD held a phone conference with MID afterthe inspection, and suggested that an investigation be conducted to assess the operability Of the bulkhead gate. AGK tut-1? IZI 17?} Inspected by A. C. Roundtree Photos taken? Yes No Date of Inspection 11/14/2013 We? I oo for Owner/Book Date of Report 12/17/2013 Sheet 01? INSPECTIOK JF DAM AND RESERVOIR lN CER - .FIED STATUS Name ofDam New Exchequer Dam No. 58?2 Date of Inspection 1 1/14/2013 7- I 1. Howell-Bunger valve full closed. ., I II ?Iii/1mm - ?mun, mumn Howell-Bunger valve full open. Sheet 2 of INSPECTIOIK. JF DAM AND RESERVOIR IN CER. .FIED STATUS Name ofDam New Exchequer Dam No. 58?2 Date of Inspection 11/14/2013 DWR 1261 (rev. 10mg) Sheet 3 of STATE OF CALIFORNIA I I I CALIFORNIA NATURAL RESOURCES AGENCY I I I I '1 DEPARTMENT OF WATER RESOURCES DIVISION OF SAFETY OF DAMS INSPECTION OF DAM AND RESERVOIR IN CERTIFIED STATUS Name Of Dam New Exchequer Dam No. 58?2 County Mariposa Concrete Ogee Weir with Radial Gates and an Type of Dam Rock Type of Spillway Auxiliary Open Channel Broad?Crested Weir Water is 18.07 feet below spillway crest and 153.07 feet below dam crest. Water Elevation: 718.93 ft Weather Conditions Clear Skies, Mild and Calm Contacts Made John Ellett, Hicham Eltal, and Marco Bell with the Merced Irrigation District Reason for Inspection Periodic Maintenance Inspection Important Observations, Recommendations or Actions Taken 0 The instrumentation submittals need to be annually submitted and are overdue. . A construction project not requiring an application to improve the access and safety ofthe upper gallery and lower valvechamber was ongoing during this inspection. I requested the owner to complete the following work: 1. Investigate the extent of the void located at the crest and parapet wall interface near the right abutment and perform the necessary repairs. 2. Remove the bush growing on the Saddle Dike that is located at the crests shoulder, near the mid?section of the dam. 3. Repair the leak in the 12?inch sharp-crested rectangular weir located within the gallery of the original dam. 4. Evaluate the possibility to have the upstream bulkhead gate brought back into operating condition, Conclusions From the known information and visual inspection, the darn, reservoir, and the appurtenances are judged safe for continued use. Observations and Comments 2% Main Dam: The Main Dam is a large rockfill structure that is 492?feet high and 1,400?feet long with an upstream face that is lined with a series of BO-feet wide by 50-feet in length reinforced concrete panels. New Exchequer Dam was constructed on top of the original concrete arch-gravity dam between July 1964 and June 1966. The asphalt paved crest was level, uniform and the pavement was in overall excellent condition. A small hole In the crests asphalt pavement located at the interface to the parapet wall near the right abutment was observed and a void could be seen. It was difficult to assess the extent ofthe void and I requested the District to investigate the extent of the void and perform the necessary repairs, to which Mr. Ellett agreed. The longstanding separation and offsets in the crests upstream concrete parapet wall showed no signs of recent movement and appeared unchanged as compared with previous inspection reports (Photo 1 and Photo 2). The visible portion of the concrete lined upstream face was inspected from the crest and the panels appeared satisfactorily aligned with no sign of concerning movement or structural instability. The upstream steel expansion joint plates appeared adequately attached to the upstream concrete panels and in serviceable condition. The rock lined slope is steep and was viewed from the crest and toe. No concerning conditions were noted and the slope appeared Inspected by Bill Vogler wq-?LN Photos taken? Yes No Date 9/24/2013 sb? cc for Owner/Field Book/File Date of Report 10/23/2013 MW DWR1261 (Rev. 10/09) Sheet of 5 INSPECTIOL JF DAM AND RESERVOIR IN CERIIFIED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 9/24/2013 Observations and Comments Spillway satisfactory condition with no sign of settlement, sloughing, or loss ofgrade. The groins were not walked due to safety concerns of the steep and uneven conditions and no concerns with regard to erosion and abutment stability were noted as observed from the crest and toe area. The powerhouse structure is located concerning conditions were noted throughout this area. Vegetation control was excellent throughout the Main Dam site. A capital improvement project was underway in the upper portion of the gallery and the valve chamber located in the original dam to improve ventilation and safe access to the lower valve chamber. Workers were completing the new spiral staircase that was being installed in the dry well shaft that provides access from the upper gallery to the valve chamber. Metal steps, ventilation, lighting, handrails, and a spiral staircase were some of the major items that were being installed. No application was required since the project did not modify or impact the operation of the dam. The ongoing work appeared adequate and of good quality. The upper portion of the gallery is located in the new portion of the dam and the lower portion of the gallery is located in the original dam. descended into both the valve chamber and lower gallery. The new spiral staircase that had just been installed appeared well attached to the dry well shaft, and although mineral deposits obscured the concrete lining the shaft, no distress or concerning conditions were observed. The concrete comprising the valve vault also appeared in good condition. The condition of the concrete comprising the newer gallery was good and satisfactory in the original gallery with no sign of instability or distress. In the original gallery, there were areas of minor surface spelling and most of the surfaces were covered with mineral deposits. Saddle Dike: inspected the paved crest, upstream and groins, and the upstream and toe areas. The lower water conditions allowed inspection of the upstream toe. Both toe areas were normal and the abutments were stable. The paved crest was uniform, well aligned and in good condition. Both riprap lined slopes were uniform, stable, and in satisfactory condition. No concerning rodent activity was observed and vegetation control was overall excellent. I requested the removal of the bush growing at the crests shoulder, near the mid?section ofthe dam, to which Mr. Ellet agreed. The spillway consists ofa gated section and an ungated auxiliary spillway section. The approach, control section, and exit were clear for both spillway sections. The log boom was lying on the ground and intact and appeared in satisfactory condition. The gated section consists of six radial gates, 40-feet wide and 30?feet high and a substantial reinforced concrete structure that I supports the gates. inspected the concrete comprising the structure from the upstream and locations. I noted no distress or instability in the concrete which included the invert, ogee weirs, retaining walls and the structures supporting the radial gate trunnions. Thejoints were well aligned and I noted some of the concrete patching was detaching but this was minor and does not need immediate attention. The spillway gates were last cycled by the owner on August 27, 2013 with no reported problems. According to Mr. Ellett, the gates are cycled twice a year and three are operated with emergency back-up power and the other three are operated from the power grid. The most recent thorough inspection of the spillway gates was performed by Black Veatch Corporation in April 2008 with no reported problems. The spillway gallery was inspected and the concrete comprising this section of the spillway was in Sheet 2 of 8 INSPECTICL JF DAM AND RESERVOIR IN CER I IFIED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 9/24/2013 Observations and Comments Seepage owe 1261 (rev. 10mg) Sheet satisfactory condition with no sign of instability or distress. The underdrains were open and clear i and several pipes had standing water, but there was no flow in the drainage troughs. Fall protection gear is required to access the gallery and was able to use the District's equipment. The low?level outlet consists of a hydraulically operated 14-foot by 23?foot bulkhead gate located in the intake structure that controls flow into a 113?foot long and 18-foot diameter tunnel that terminates into the dam's gate chamber. Two 7?feet by 10.5-feet hydraulically operated slide gates located in the gate chamber controls flow into a pipeline that passes through the dam and into the powerhouse. Just upstream of the powerhouse, the pipeline bifurcates into a 13??feet diameter penstock that serves the turbine generator and a 9?feet diameter penstock that serves as a bypass. Bypass flows are controlled by a 108?inch Howell-Bunger valve and a 13-foot diameter butterfly valve is used as the turbine shutoff valve. The owner is required to cycle the two slide gates located in the gate chamber and the Howell Bunger valve located in the powerhouse for dewatering requirements. All three valves were cycled during the December 17, 2012 DSOD inspection. The penstock was last inspected on February 4, 2009 and no concerning issues was reported. The next scheduled powerhouse shutdown is in November 2013 and DSOD will witness the cycling of the outlet valves and inspect the penstocks. Based on the DSOD files, there is no record of the upstream bulkhead gate being operated. It is not clear from our files why this gate has not been maintained and cycled regularly since it is prudent to have upstream control for the outlet tunnel. I requested the District evaluate the possibility to have the gate brought back into operating condition. Due to successive low water years, the reservoir water elevation was well below normal during this inspection. No seepage or evidence of seepage was observed on the slopes, groins, and toe areas on both the Main and Saddle Dike. The seepage area of the Saddle Dike?s toe that was reported in the September 19, 2010 DSOD inspection report was dry, but this was expected since this seepage appears at higher reservoir water elevations. The District has constructed a weir in an attempt to quantify the seepage in this area. Mr. Eltal and I inspected and discussed this area in detail and it will be monitored closely for any adverse changes in seepage. Leakage from the main dam passes through five ports in the concrete wall to the left of the powerhouse. The level in the pool behind the wall is monitored by a transducer and a conversion table is used to determine the leakage in cfs. There is also a 12-inch rectangular weir located in the original edit at the toe of the original dam that monitors total flow from the galleries of the original dam. 3 of 8 INSPECTIOK .JF DAM AND RESERVOIR IN CER I IFIED STATUS Name ofDam New Exchequer Dam No. 58-2 Date of Inspection 9/24/2013 Observations and Comments The following measurements for seepage were taken during this inspection: Location Weir Reading (ft) Flow Original Darn 12-inch rectangular 006* 21 Powerhouse Weir remote reading 5.0 5.0 Saddle Dike Saddle A (22.5ndeg) dry dry Saddle Dike Saddle (22.5?deg) dry dry Saddle Dike Saddle (22.5-deg) dry dry Train Tunnel 45?degree V?notch 0.09 3 All seepage values appeared appropriate for the reservoir water elevation and all flows were clear. *The 12?inch sharp?crested rectangular weir located within the gallery of the original dam was leaking water on its right side (Photo 8) and needs to be repaired. The instrumentation at this dam consists of 40 monuments that measure the settlement and displacement on the upstream concrete panels, seven crest monuments, six seepage locations and joint gap measurements on the upstream concrete panels. The latest instrumentation submittal was dated June 2011 and covered the period through December 2011. This report was previously reviewed in the February 23, 2012 DSOD inspection report and no unusual trends or conditions were noted. The instrumentation submittals need to be annually submitted and are overdue. The previously reviewed instrumentation data indicated that this dam is performing adequately. Therefore, the existing instrumentation and their monitoring frequency are judged sufficient at this time. DWR1261(rev.10109) Sheet 4 of 8 JF DAM AND RESERVOIR IN CERTIFIED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 9/24/2013 ?ap 1' 2? new? Photo 1. A View of the crest and a partial View of the upstream face as seen from the right abutment. Photo 2. A close up View of the offset' In the parapet wall located on the crest near the right abutment. Sheet 5 of INSPECTIO. JF DAM AND RESERVOIR IN CERTIFIED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 9/24/2013 Photo 3. A void under the crest's pavement near the left abutment was observed that needs to be investigated and repaired. serviceable condition. Sheet 6 of 8 INSPECTIOIL JF DAM AND RESERVOIR IN CERTIFIED STATUS Name of Dam New Exchequer Dam No. 58-2 Date of Inspection 9/24/2013 Photo 5. A View looking down into the upper gallery showing the newly constructed stairs, ventilation, and lighting that was being installed during this inspection. this . .. Photo 6. A View looking up in the dry well shaft of the newly installed spiral staircase that provides safe access to the lower valve chamber. 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