Project Overview

Fail-Safe Electric provided comprehensive PLC control system design, fabrication, and programming services for the modernization of the Small Lock at the Hiram M. Chittenden Locks, commonly known as the Ballard Locks. This historic navigation facility, originally constructed in 1917, connects Puget Sound to Lake Washington and Lake Union, serving as a critical link in the Pacific Northwest maritime transportation network. The facility processes nearly 50,000 vessel passages annually and welcomes over two million visitors each year.

The modernization project replaced century-old electromechanical gate and valve operating machinery with a new hydraulic actuation system controlled by a modern PLC-based SCADA architecture. FSE's scope encompassed the complete electrical control infrastructure required to safely and reliably operate the Small Lock's miter gates and cylindrical filling/emptying valves.

Technical Scope

Main Control Panel (Operating House 4): Custom stainless steel enclosure housing an Allen Bradley CompactLogix 5380 PLC system with fiber optic Ethernet switching, 240V/120V control transformer, 24VDC power supply with UPS battery backup, environmental controls including internal heaters with thermostats, and panel lighting with door switches.

Operator Consoles (3): Three custom stainless steel operator consoles for the Lock Tower, Upstream Control Station, and Downstream Control Station. Each console features Allen Bradley 21.5-inch diagonal touchscreen HMI displays, push-to-test LED indicator lights, pushbuttons, emergency stop controls, and joystick controls for precise gate and valve operation. The Lock Tower console includes a remote I/O station for distributed control architecture.

Hydraulic Actuator Control Panels: Variable frequency drives for 30HP motors with line and load reactors, ventilated and heated enclosures, manual controls with status indication, and integration points for the hydraulic cylinder position feedback systems.

Fiber Optic Control Panel: SC Duplex fiber optic infrastructure connecting the distributed control system components across the lock facility.

Instrumentation: LED laser level transmitters for water level monitoring and magnetic proximity switches for position feedback on gates and valves.

Compliance & Standards

All control panels were designed and fabricated in FSE's UL 508A listed panel shop to meet USACE specifications. The project required compliance with NIST 800-171 cybersecurity requirements, USACE Inland Marine Transportation System (IMTS) Interlock Standard for navigation lock safety interlocks, IEC 61131-3 PLC programming standards, and NEC/NFPA 70 electrical installation requirements. Programming deliverables included comprehensive HMI/SCADA development with operator-configurable speed profiles, automatic calibration routines, and complete alarm management systems.

Project Significance

This project demonstrates FSE's capability to deliver complex control system solutions for federal navigation infrastructure operating under rigorous USACE specifications. The work required close coordination with hydraulic system suppliers, cybersecurity compliance documentation, and integration with existing large lock systems to ensure operational continuity. The project reinforces FSE's established track record with USACE, complementing prior work on the McNary Dam modernization and Lake Washington Ship Canal emergency closure projects.