Your next era
of rack cleaning.
Build on recently renewed equipment. Automate routine cleaning, move debris farther, and preserve the gate-picking capability your site needs.
Less routine intervention.
More operational confidence.
Central Hudson has two Cross Machine nested tube rack cleaners. With Dashville’s boom recently rehabilitated and its gantry rubber hoses replaced, the next investment can focus on automation, farther debris placement and continued gate picking.
24/7/365
The requested operating objective
Beyond the rack
Move removed debris to a more useful receiving location
One accountable partner
Mechanical equipment, hydraulics, controls and field integration
Unattended operation is a design objective within agreed conditions. Scheduled maintenance and operator response to exceptions remain necessary.
Choose the platform
that earns its investment
| Decision factor | A / Targeted modernization | B / New articulating system |
|---|---|---|
| Best fit | Build on Dashville’s recently renewed boom and hoses | Farther debris placement is worth a new operating platform |
| Mechanical scope | Retain renewed assemblies; add specific mechanical and control upgrades | New articulated boom and site-specific support/travel package |
| Debris-handling reach | Existing envelope remains unless a separate handling solution is added | Design the reach and payload around the desired receiving point |
| Gate-picking requirement | Preserve and validate the existing method and interfaces | Retain a compatible lift arrangement or engineer a separate solution |
| Primary uncertainty | Retrofit interfaces and downstream material handling | Loaded reach, reactions, clearances and gate-picking integration |
Both paths target unattended routine cleaning with defined exceptions. A boom-only gantry conversion is an engineering alternate, not a priced drop-in replacement.
Recently renewed.
Ready for the next step.
Cross Machine confirms the boom was recently rehabilitated and all gantry rubber hoses replaced. Build on that work when defining the next investment.
Scope & site requirements
Credit the completed work
Retain the renewed boom and hoses where compatible. Target controls and specific mechanical refinements.
Gate picking is required
Survey the picking beam, receptacle, lifting interfaces and later site modifications. Preserve a viable method in either path.
Verify both machines
Confirm today’s debris route and required discharge reach. The second machine needs its own condition and interface assessment.
Basis: Cross Machine’s current condition update; Dashville picking-beam/receptacle photographs and hydraulic gate-lift-cylinder record. Archive photos do not certify current condition or lifting capacity.
Build on the work
already completed.
Dashville’s recent rehabilitation makes a controls-led modernization a credible path. Specify the remaining work against its current condition.
Scope & site requirements
Preserve the renewed asset
Verify the recent boom work and hose routing, then target remaining wear, interfaces and service-access needs.
More controllable motion
Evaluate proportional hydraulics, position feedback, operating limits and compatible retained components.
Resolve material handling
Automation alone does not extend reach. Assess a separate transfer arrangement if the current discharge point remains a constraint.
The revised Path A allowance credits the recent boom rehabilitation and gantry hose replacement. Any separate debris-transfer equipment and gate-picking modifications need defined scope and pricing.
Move debris farther.
Make removal more useful.
The driver is what happens after debris leaves the racks: reach a more useful receiving location and reduce secondary handling.
Scope & site requirements
Design backward from the destination
Measure the receiving point, discharge height, travel path and required loaded reach—not just maximum unloaded reach.
Carry and place the load
Match boom capacity, rake retention and clearances to representative wet debris along the full route.
Keep gate picking available
Check interference with existing lifting arrangements. Select a retained or separate engineered method before choosing the boom.
Proposed benefit, subject to measured geometry and load studies. No reach or lifting capacity is promised; an articulating cleaner is not automatically a gate hoist.
Olympus gives us
a documented foundation
The Olympus Dam operating manual describes an integrated mechanical, hydraulic and PLC-controlled system with automatic operation.
Scope & site requirements
Automatic initiation
Water-level differential, scheduled timer and remote start commands.
Position-aware motion
Three absolute encoders for swing, main boom and knuckle boom; station limit switches and motion interlocks.
Operator visibility
Manual and semi-automatic operation, HMI water-level and timer screens, alarms and encoder maintenance functions.
Source: Olympus O&M manual, pp. 6–10. This documents past functionality, not a measured 24/7 availability record or the final Central Hudson design.
Automate the whole
cleaning cycle
Proposed automatic cleaning sequence for either platform. Gate picking remains a separate, operator-controlled mode with agreed interlocks.
01 / Request
Differential level or a scheduled cycle requests cleaning.
02 / Verify
Confirm cleaning mode, attachment, machine position, protected area and debris destination are ready.
03 / Clean
Follow the approved motion path while monitoring position and hydraulic response.
04 / Discharge
Follow the verified loaded-reach path and place debris at the agreed receiving point.
05 / Confirm
Record cycle outcome, recheck the intake condition and repeat within approved limits.
06 / Park or alert
Return to a known state. Escalate exceptions with clear instructions for the operator.
Gate-picking mode must inhibit automatic cleaning. Return to cleaning requires validated attachment, position and area checks. Full bins or blocked discharge paths also inhibit cycles.
The right feedback
for dependable automation
Know where the machine is
Position feedback for critical axes, travel references, endpoint checks and feedback plausibility.
Know how the system is behaving
Hydraulic pressure, oil level and temperature, motor health, water levels and cycle-completion monitoring.
Control access and exceptions
Risk-assessed guarding, emergency stops, mode/attachment checks, fault latching and authorized recovery.
Keep operations informed
Local PLC/HMI, alarm priorities, event logs and integration with Central Hudson's SCADA standards.
Proposed features. Final sensor count, safety architecture, controls platform and communications are selected during engineering. Remote access requires Central Hudson approval.
Plan the abnormal conditions
| Condition | Proposed response |
|---|---|
| Overload or stalled movement | Stop or hold in a verified safe state; allow only validated, bounded recovery attempts. |
| Position or level-sensor disagreement | Inhibit affected automatic movement and issue a diagnostic alarm. |
| Ice, unusual debris or out-of-envelope load | Suspend automatic operation and request an operator assessment. |
| Bin full or discharge path unavailable | Inhibit the cycle and notify operations before moving more debris. |
| Loss of power or communications | Apply the defined local fallback and restart permissives; avoid uncontrolled restart. |
| Protected area entered or emergency stop | Execute the engineered safety response; require authorized reset and revalidation. |
Responses are design proposals to validate. Mechanical load holding and the safe state must be resolved for each failure mode.
Define success
before equipment is ordered
Cleaning & debris placement
Demonstrate rack coverage, the agreed receiving point, loaded reach, retention and secondary-handling effort.
Gate picking & fault response
Validate the selected lifting method, interfaces, limits and mode separation; test jams, invalid feedback and power loss.
Sustained operation
Agree a witnessed trial duration, representative debris/water conditions, allowable interventions and seasonal follow-up.
Maintainable ownership
Deliver manuals, drawings, program backups, spares, training and a maintenance schedule.
Availability and intervention targets are to be agreed with Central Hudson. A short site trial alone cannot establish year-round performance.
A clear investment
for each path
Base-scope planning ranges per machine, September 2026 USD. Path A credits Dashville’s recent work. Required gate-picking changes remain unpriced; not a quotation.
| Budget component | A / Modernize | B / Articulating |
|---|---|---|
| Scope + equipment, supply only | $246.5–$448k | $612.5–$947.5k |
| Freight, install & commissioning | $45–$80k | $75–$125k |
| Installed base-scope total / machine | $291.5–$528k | $687.5–$1,072.5k |
| Second machine / program total | Survey & quote | Survey & quote |
Reference: $500k–$650k supply only for one new traditional cleaner with less automation. Totals exclude gate-picking modifications and new debris-transfer equipment. Quote each machine after survey.
Keep the capital
comparison consistent
Included in the model
Assessment, defined mechanical/automation scope, shop tests, freight/rigging, installation and commissioning. Path A credits Dashville’s recent renewal.
Required scope still to price
Gate-picking modifications or a separate lift system; any new debris-transfer equipment. Assess first, then add priced scope to the selected path.
Excluded from these totals
Tax, financing, generation losses, major civil/foundation work, site-wide rail/power upgrades and a new conveyor/bin system.
Two-machine program
Budget each unit against its actual condition and interfaces. Dashville’s recent work is not assumed to apply to the second machine.
Ranges cover the modeled scope and are not price ceilings. Both options must deliver a viable gate-picking method in the final project scope.
Assess both.
Prove the first. Then repeat.
Sequence work around Central Hudson's outage constraints and the serviceability of each machine.
01 / Assess & define
Survey both units, recent work, debris destination and gate-picking arrangements. Define operating boundaries.
02 / Select & quote
Confirm loaded reach, lifting duty and reuse. Price all required interfaces before comparing final options.
03 / Engineer & build
Approve the control narrative, gate-picking method, mode interlocks and acceptance plan before fabrication.
04 / Factory acceptance
Witness normal sequences and simulated fault cases before the first machine ships.
05 / Site acceptance
Commission in supervised service, validate site conditions and authorize unattended operation in stages.
06 / Second machine
Apply accepted lessons to the second unit. Confirm spares, training and ongoing service requirements.
Dates follow supplier lead-time confirmation and outage planning. Continuity of cleaning during an outage requires a site-specific plan.
Measure value in the
work your team gets back
Operator & handling time
Measure attendance, interventions and the labor/equipment needed to move debris after rack removal.
Cleaning effectiveness
Track differential head and successful cleaning cycles under comparable water and debris conditions.
Maintenance effort
Track leaks, wear, unplanned repairs, downtime and spare-parts consumption.
Material-handling result
Compare receiving-point reach, rehandling moves, debris containment and continued gate access.
No staffing reduction, energy gain, payback period or uptime improvement is assumed. Establish the baseline with Central Hudson operations.
Equipment knowledge.
Project delivery.
We can evaluate the modernization path and the replacement path with the same understanding of how the machine must work at the intake.
Scope & site requirements
Your equipment history
Existing Cross Machine cleaners, recent Dashville boom rehabilitation and gantry hose replacement.
Relevant automation experience
Olympus combines articulated mechanics, hydraulics, position feedback and automatic cycle initiation.
Execution across disciplines
Mechanical design, fabrication, hydraulic and electrical integration, shop testing, installation and commissioning.
Capabilities also reflected in Cross Machine's approved website project and service material.
Let's define the right
upgrade for Central Hudson
Begin with a joint assessment and a budget-to-quote package for both machines.
Bring the operating history
Recurring faults, cleaning workload, ice/debris conditions and the desired unattended service window.
Confirm the interfaces
Desired debris destination, gate loads and picking interfaces, rails/foundations, SCADA and outage windows.
Leave with a decision
A recommended path for each machine, clear inclusions and exclusions, and an updated commercial proposal.
Sean Patry · President, Cross Machine Inc.
patrys@crossmachine.com · 603-752-6111 · Berlin, New Hampshire
Equipment scope & pricing
Per machine, USD. Path A uses Dashville’s recently rehabilitated condition. Both paths exclude unpriced gate-picking changes and new debris-transfer equipment. The second machine and total program require their own scope and quote.
A / Targeted modernization + automation$291.5–$528k base scope
| Scope | Range | Basis / assumptions |
|---|---|---|
| Condition assessment & mechanical design | $22.4–$39.2k | Site assessment, reuse decisions and mechanical interfaces, including review of gate picking. New or modified gate-lifting equipment remains unpriced. |
| Targeted boom checks & mechanical refinements | $11.2–$22.4k | Targeted checks and refinements to the recently rehabilitated boom. Retains compatible renewed components; no repeat full boom overhaul or blanket gantry hose replacement. |
| Travel, structure & drive repairs | $22.4–$50.4k | Localized travel, structure and drive work as required by the final modernization scope. Major rail and foundation replacement excluded. |
| Hydraulic motion-control upgrades | $39.2–$72.8k | Power-unit adaptation, motion-control valves, manifolds, filtration and integration. Retain compatible serviceable equipment and recently replaced gantry hoses. |
| Automation hardware & panel integration | $56–$95.2k | Controls, I/O, HMI, sensors, enclosures, networking and integrated panel work. Platform and safety architecture selected during engineering. |
| Controls software & verification | $78.4–$140k | Cleaning sequence, interlocks, fault handling, HMI/SCADA interfaces, simulation and verification. Field commissioning is separate. |
| Final shop acceptance, documentation & spares | $16.9–$28k | Integrated shop acceptance, documentation, initial spares and preparation for field delivery. |
| Freight, installation & site commissioning | $45–$80k | Freight, planned crane/rigging, installation, site acceptance and operator training. Assumes accessible site and a planned outage. |
| Installed base-scope total | $291.5–$528k | Before unpriced gate-picking changes, debris-transfer equipment, other excluded items and taxes. |
B / New articulating system$687.5–$1,072.5k base scope
| Scope | Range | Basis / assumptions |
|---|---|---|
| Site survey, structural review & mechanical design | $44.5–$72.5k | Site survey, loaded-reach study, reactions, clearances and interface design. Gate-picking method assessed; its hardware changes remain unpriced. |
| Articulating boom, slew & pedestal package | $245–$334.4k | Custom boom, cylinders, pivots, slew and pedestal. Current supplier quotation required; no gate-hoisting capacity is assumed. |
| Base, trolley & support steel | $50.1–$89.2k | Site-specific base, trolley and support structure. Olympus provides a scale reference, not a Central Hudson takeoff. |
| Rake head & debris-retention assembly | $27.8–$50.2k | Rake, combs, retention/gripper and associated interfaces. Final debris and rack geometry set the design. |
| Hydraulic power, valves & hose package | $44.5–$72.5k | Electric hydraulic supply, valves, hoses, filtration and integration. Final hydraulic duty remains to be selected. |
| Automation hardware & panel integration | $61.2–$100.3k | Controls, I/O, HMI, axis feedback, safety devices and panel integration. Final controls platform subject to Central Hudson requirements. |
| Controls software & verification | $89.1–$150.5k | Coordinated articulated motion, limits, clearance logic, fault handling, HMI/SCADA interfaces and verification. |
| Final assembly, shop acceptance, documents & spares | $50.3–$77.9k | Final assembly, integrated shop acceptance, documentation and initial spares. Supports the complete equipment delivery. |
| Freight, installation & site commissioning | $75–$125k | Freight, planned crane/rigging, installation, site acceptance and training. Assumes accessible site and a planned outage. |
| Installed base-scope total | $687.5–$1,072.5k | Before unpriced gate-picking changes, debris-transfer equipment, other excluded items and taxes. |
Supplier pricing referencesSix component checks
| Component | Listed price | Application to this estimate |
|---|---|---|
| Parker PAVC65-family piston pump | $7,317–$8,145 each | Related family configurations; exact duty, rotation and control differ. Hydraulic component benchmark only. |
| 25 hp IronHorse motor | $2,368 each | MTCP2-025-3BD18, published catalog reference; reconfirm by quote. Motor only, not a complete power unit. |
| 10-inch operator touchscreen | $785 each | C-more CM5-T10W. Functional price comparator; Central Hudson's approved controls platform may cost more. |
| Radar water-level sensor | $1,180 each | VEGAPULS C 21 listing. Two sensors suggest $2,360 before mounts, wiring and integration; sensing design remains open. |
| 3/4-inch hydraulic hose | $5.91/ft | R2S-12: 50 ft = $295.50. Bulk single-line hose only; not an interchangeable twin-line reel-hose selection. |
| A36 plate, 1 × 48 × 48 inches | $1,495.30 per plate | Retail reference, approximately $2.29/lb using nominal steel density. Bulk sizes, grade, cutting and freight change purchase cost. |
Source records & estimate limitationsWhat still needs to be verified
Supplied project evidence
Cross Machine’s recent-work and operating-needs updates; Dashville picking-beam/receptacle photos and hydraulic gate-lift record; historical overhaul scope. Olympus O&M pp. 6–12 and mechanical, hydraulic, electrical and steel lists.
Current cost reference
Cross Machine supplied the $500k–$650k new traditional-machine supply benchmark. Selected public supplier listings provide component checks; all labor rates, labor hours beyond historical scope, custom packages and site allowances are estimating assumptions.
Revisions and applicability
Early Olympus documents show 75 hp and different pump/travel arrangements. The later manual records a 25 hp-class system. The estimate does not add both designs together or assume Olympus dimensions apply to Central Hudson.
Items to firm up
Loaded reach to the receiving point, wet-debris payload, gate weight/lifting duty and interfaces, boom quotation, current condition, control/safety design and unpriced gate/debris-handling work.
Proposed operational-technology integration: local machine control, segmented communications and authorized remote access, subject to Central Hudson standards. Reference: NIST SP 800-82 Rev. 3. No compliance certification is claimed.