CHAPTER VII.

Design-POWER WATERWAYS
54. LOCATING PENSTOCKS. (a) General.-Eight In addition to the above criteria, there were limits
15-foot-diametersteel penstocks for delivering water to to the permissible spacing of the contraction joints in
the turbines in the powerplant are embedded in the the dam. To preclude difficulties in cooling of the
dam (figs. 129 and 130). The centerline of each blocks and grouting of the contraction joints, the
penstock intake is at elevation 3470 which is about 45 minimum and maximum block widths, measured along
feet above estimated silt elevation after 150 years of the axis of the dam, were 40 and 70 feet, respectively.
reservoir operation. The minimum water surface for The layout criteria were satisfied by selecting a system
power operation i s elevation 3490. A 13.96- by of blocks using maximum and minimum permissible
22.45-foot fixed-wheel hydraulically operated closure widths, bending two of the penstocks inside the
gate which can operate under unbalanced head was powerplant structure, and anchoring horizontal bends
provided at the upstream face of the dam for each to the mass concrete in the dam where the bends were
penstock. An unlined transiton section from near the downstream face of the dam.
rectangular to round was provided at the entrances of
the penstocks for a smooth increase in flow velocity 55. STRUCTURAL DESIGN. (a) General.-The
and to reduce the width required for each closure gate design was based on concrete having a compressive
(fig. 131). A reinforced concrete trashrack structure strength of 3,000 pounds per square inch at 28 days
(fig. 132), with structural steel trashracks, protects the for structural concrete and 2,500 pounds per square
entrances. Guides and seats for stoplogs were installed inch at 28 days for mass concrete. The allowable
upstream from the closure gate to provide a means for working stresses are shown on figure 71 except that the
inspecting the gate frames and guides if required. allowable stress in the reinforcement around the pipe
Special joints to take movement in three directions in the dam was increased to 25,000 pounds per square
were designed for the penstocks, where they leave the inch.
dam, to provide for movements of the dam under
variable load. These joints were set in special vaults at ( b ) Trashrack Structures.-The concrete
the toe of the dam (fig. 133). The penstocks are trashrack structures were designed for a differential
supported between the dam and the powerplant on waterload of 20 feet, temperature effects, and dead
reinforced concrete piers which, in turn, are carried to load. The gate guide supports were designed for
bedrock (figs. 134 and 135). The backfill in the area unwatering the gate guide area with normal water
between the dam and powerplant was placed above the surface.
top of the penstocks, and a drainage system was
provided as shown on figure 83. ( c ) Gate Hoist Structure.-The gate hoist
structure was designed for the following conditions:
(b) Layout.-The layout of the penstocks in the
dam was dependent upon the following criteria: (1) A 25' F. temperature change.

(1) The penstocks had to be radial at the (2) A 20-foot differential waterhead around
upstream face of the dam, and so located that the structure and 5' F. temperature change.
trashrack structures did not cross contraction joints.
(3) Stoplogs in place-water on sides-thrust
( 2 ) The minimum distance from the from stoplog seats.
centerlines of the penstocks to the radial
contraction joints in the dam had to be at least one (4) A pullout hoist load of 668,000 pounds
and one-half pipe diameters. which included the force to overcome any jamming
of gate during lifting operation.
(3) There were to be no bends in the
penstocks between the dam and the powerplant. The gate hoist structure has a removable cover
(see fig. 136). For details of the gate hoist structure see
(4) The minimum permissible bend radius figure 137.
was to be four pipe diameters.
(dl Gate Hoist and Stem Storage Platform. -The
(5) The spacing of the generators in the gate hoist and stem storage structure is shown on figure
powerplant was to be 65 feet on centers. 138. It was designed to store the gate hoist and the
DESIGN
POWER WATERWAYS
 -
POWER WATERWAYS
DESIGN
POWER WATERWAYS
DESIGN
POWER WATERWAYS
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DESIGN
Figure 138.-Penstocks gate hoist and stem storage platform, and gate erector platform-Plans and sections.
 DESIGN

hoist stems when a penstock fixed-wheel gate is being (9) Supports.-The supports shown on figures
serviced. The structure was designed to support i t s own 129, 130, 133, 134, dnd 135 consist of the following
weight as well as the dead load weights of the gate component parts:
hoist and stems.
(1) Vaults (two upstream supports) or
(e) Gate Erection Platform. -The gate erection bearing walls
platform is also shown on figure 138. It was designed
for the erection and servicing of the penstock (2) H-column
fixed-wheel gates and the river outlet bulkhead gate.
The river outlet bulkhead gate will be stored on the (3) Footing
platform.
The vaults were designed for the following loads:
( f ) Penstock Concrete Reinforcement.-The
reinforcement requirements for the penstocks were (1) Dead load of structure
broken into three sections, as follows:
(2) Backfill to elevation 3157
(1) The approximately 21-foot-long upstream
transition which has no steel liner. (3) Temperature effects

(2) The circular section with steel liner (4) Earthquake effects
extending from the downstream end of the
transition to a point approximately 30 feet
(5) Penstock reactions
upstream from the downstream face of the dam.
The bearing walls on the supports without vaults
(3) The circular section with steel liner from
were designed for the following loads:
a point 30 feet upstream from the downstream face
to the downstream face of the dam.
Temperature effects
Since the transition section has no steel liner,
Earthquake effects
cracks could open into adjacent galleries and openings
which could result in excessive leakage. In order to
control cracking, the transition section was reinforced Penstock reactions
for tensile forces caused by dam stresses, internal
bursting pressures, and temperature effects. The overall dimensions of the H-columns were
determined in part by the vaults or supporting walls
The circular section with steel liner, except the above. The length to depth ratio was kept within the
approximately 30-foot-long downstream section, has short column range. The individual legs of the
enough mass concrete cover that tension cracks cannot H-column were given a small length-to-depth ratio to
propagate to the surface of the dam. There is no prevent buckling.
leakage problem since the penstock has a steel liner.
Therefore this section of the penstock was reinforced The H-column and i t s members individually were
only for tensile forces caused by dam stresses and designed for the following loads:
temperature effects.
(1) Dead weight from above
The downstream approximately 30-foot section
presents no leakage problem since it has a steel liner; (2) Penstock reactions
however, tension cracks could open to the downstream
face of the dam in the area. In order to control (3) Earthquake effects
cracking this section was reinforced for tensile forces
due t o dam stresses, temperature effects, and internal The footings were stepped with the top part
bursting pressure, including waterhammer effects. In having the same exterior dimensions as the H-column
addition, anchorage reinforcement was provided for and the bottom part widened in both directions to
the unbalanced forces in the horizontal bends in this increase stability and reduce foundation stresses.
area.
POWER WATERWAYS

The footings were designed for the following pressures so that, in general, an 8-inch slab would be
loads: stable. Near the left training wall, studies indicated that
saturation of the fill and bedrock behind the wall
(1) Dead loads. caused higher uplift adjacent to the wall and the slab
thickness was increased t o 12 inches. At the weir, the
(2) Penstock reactions. slab was made 12 inches thick to provide additional
stability for the weir.
(3) Fill material (partly saturated).
During the April through July runoff period in
(4) Earthquake effects. 1965, discharges up to 50,000 cubic feet per second
were released in order to obtain a rated head at Lake
A minimum o f 1 percent of vertical Mead and maintain Lake Powell at about elevation
reinforcement was placed in the H-columns. 3490. The discharge was obtained by using
combinations of the discharges from the turbines, the
56. TAILRACE TRAINING WALLS. Tailrace diversion tunnel outlets, and the river outlets. The river
training walls are provided on each side of the tailrace outlets were used to their design capacity when the
downstream of the powerplant. On the left side of the tunnel outlets were closed.
upstream 75 feet of the wall is a gravity section and the
rest of the wall is cantilevered off the mass concrete During the night of April 20, 1965, the slab was
under the river outlets and hollow-jet valves. It is undermined and portions of it sank from sight. At the
shown on figure 114. I t also serves as a retaining wall time of the failure the reservoir water surface was at
to retain the fill for the powerplant parking area. The about elevation 3490, four of the eight units in the
right training wall is of the line-drilled type and was powerplant were operating, the diversion tunnel outlets
doweled to the rock, figure 139. and outlet No. 1 were closed, outlet No. 2 was 25
percent open, outlets No. 3 and 4 were 90 percent
The left training wall was designed for the following open, and the tailwater was 4 to 6 feet lower than had
loads: been predicted and used in the model studies.
Operating the river outlets at reservoir water surface
(1) Parking area fill material (saturated). elevation 3490, instead of at normal water surface
elevation 3700 as used in the model, caused the jets t o
(2) 100-ton trailer unit including impact from impinge closer to the weir.
bumping curb.
Observation of flows in the tailrace area, after the
(3) Earthquake effect. failure, showed a reversal of flow due to a large eddy
extending to the location of the weir. This reverse flow
57. TAILRACE SLAB. To insure a minimum had an unexpected velocity estimated to be 15 feet per
tailwater for the turbines, a tailrace slab (fig. 140) was second. The operation of the outlets at the lower head,
constructed between the tailrace walls. This slab sloped operation of only four powerplant units instead of
up o n a 6 to 1 slope from the draft tubes to form a eight, and the lower tailwater all intensified the eddy
weir at elevation 3132, 180 feet downstream of the action over that predicted from the model. The scour
powerplant. From the weir the slab sloped down until from this reverse flow, caused by the large eddy,
it was approximately 20 feet below riverbed. It was undermined the toe of the slab and rapidly removed
originally planned that the tailrace channel and weir large amounts of fine bedding material, causing
would be constructed of riprap, but lack of suitable collapse of the slab. The extensive use of the river
rock within economical haul distance dictated the outlets at near full capacity with the reservoir at about
change t o a reinforced concrete slab. The riprap weir elevation 3490 and with only four of the powerplant
was tested in a hydraulic model.' units operating had not been anticipated and had not
been checked in the model.
The maximum drawdown rate of the tailwater over
the weir was established at 10 feet in 10 minutes. To date (June 1969) the floor slab has not been
Studies showed that porous concrete drains at 10-foot repaired or replaced, as observation has indicated no
centers each way provided adequate relief from uplift further significant erosion in the tailrace floor.

'"Hydraulic Model Studies of the Spillways and Outlet Works-Glen Canyon Dam-Colorado River Storage
Project, Arizona," Hydraulic Laboratory Report No. Hyd-469, Bureau of Reclamation, February 18, 1964
(unpublished).
DESIGN
 !
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PLAN-SLAB
SHOWIN5 fEIMORCEVEHT AND S W I H S FOR WEEPHOLES

SECTION H-H
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Figure 140.-Concrete slab for tailrace area-Plans, sections, and reinforcement.

 DESIGN

58. PENSTOCK STEEL DESIGN. (a) Descrip- accommodate the displacement of the dam amounting
tion.-Eight penstocks are provided to conduct water to 2-114 inches downstream and 2-114 inches vertically
from the reservoir through the dam and to the eight downward a t centerline elevation of the
turbines in the powerplant. The penstock alinements 14-foot-diameter pipes. Sleeve-type coupled field joints
and profiles are shown in figures 122, 141, and 142. downstream from the expansion joints were also
Fabrication was performed by a separate contract designed to allow small angular displacements in the
under invitation No. DS-5052. alinements of the penstocks. The 14-foot-diameter
penstock sections in earthfill were designed against
The penstocks begin as 15-foot-inside-diameter flotation on the assumption of nonfluid fill material
pipes at the downstream ends of formed concrete weighing not less than 40 pounds per cubic foot in
rectangular-to-circular transitions in the upstream face water, or 102.4 pounds per cubic foot in air.
of the dam at centerline elevation 3470.0. Extending
downward toward the dam toe, they taper through
Penstock sections, including expansion joints and
reducing bends to an inside diameter of 14 feet, then
stiffener rings, were fabricated of steel plates
level off at centerline elevation 3140.0 and emerge
conforming to ASTM Designation A 201, grade 6 .
from the dam. Passing through fill for an average 150
Middle rings and follower rings of sleeve-type couplings
feet, they then enter the powerplant. Sleeve-type
were fabricated of steels conforming to ASTM
coupled makeup sections 10 feet long connect to the
Designations A 212, grade B, and A 7, respectively.
turbine spiral cases. Makeup sections are designed and
supported so that they may be disconnected and
displaced laterally to permit access to penstocks for All permanent joints were welded. All girth and
major inside inspection and maintenance. Penstocks in longitudinal welds in penstock shells, expansion joint
fill are sleeve-type coupled 50-foot sections, excepting inner and outer sleeves, and sleeve-type coupling
those sections nearest the dam which are coupled with middle rings were fully radiographed in accordance
special double-end expansion joints. Penstocks in fill with Section VIII of the ASME Boiler and Pressure
are supported by concrete piers which extend to Vessel Code. Code basic design working unit stresses
bedrock. The average length of each penstock i s about for ASTM A 201 and A 212 steels used were 15,000
610 feet. Minimum and maximum penstock plate and 17,500 pounds per square inch, respectively. Joint
thicknesses are 718 inch and 1-13/16 inches, efficiency was 95 percent for both steels. All field
respectively. erection sections, including expansion joints and
sleeve-type couplings were furnace stress relieved in
A 24-inch outside-diameter penstock filling accordance with the afore-mentionedcode.
header pipe extends across and above the penstocks
near t h e i r upstream ends. Individual 20-inch Completed sections of penstocks, including
outside-diameter valved riser pipes connect each expansion joints and sleeve-type couplings were
penstock to the header. hydrostatically tested a t pressures computed from the
formula:
(b) Design.-The penstocks were designed for a
maximum total head of 695 feet including water
hammer, measured at the centerlines of the generating
units. The maximum designed static head i s 560 feet at
where:
this point. Water hammer was calculated for the most
severe combination of reservoir water surface elevation
P = test pressure in pounds per square
with normal discharge and a turbine wicket gate
inch,
closure time of 5 seconds from full open position.
T = minimum thickness in inches, of
Each turbine discharge is 3,580 cubic feet per
plate course in section tested, and
second at 450-foot rated head. The corresponding
average velocities in each penstock are 20.26 and 23.26
D = inside diameter of pipe in inches.
feet per second for the 15- and 14-foot-diameter
portions, respectively.
A 24-inch-outside-diametermanhole is located in
the first bend of each penstock. The formed inlet
The special double-end expansion joints
mentioned above in subsection (a) were designed to
-
-
POWER WATERWAYS
DESIGN
POWER WATERWAYS

transitions may be reached by temporary ladders to provide a bulkhead for inspection and maintenance
brought inside the penstocks through the manholes and of the fixed-wheel gates and appurtenances. One set of
laid on inverts. A 20-inch-inside-diameter manhole is stoplogs, sufficient for one unit, is provided for the
installed in each penstock immediately upstream from penstock intakes.
the first expansion joint.
The following log sections were furnished for
Two piezometer orifice stations 50 feet apart are stacking in accordance with drawing No. 557-D-2080*:
9 lower log sections, approximately 24.5 feet wide by
located on each penstock in its level portion near the
4.80 feet high, weighing 24,700 pounds each; 7
powerplant. Individual 314-inch pipes lead from each
intermediate log sections, approximately 24.5 feet
piezometer connection into the powerplant.
wide by 5.30 feet high, weighing 25,100 pounds each;
and 7 top log sections, approximately 24.5 feet wide
(c) Installation and Coating.-Penstock sections by 6.79 feet high, weighing 27,200 pounds each. A
were installed under the prime contract, excepting lifting frame was also furnished for grappling purposes.
makeup sections, which were installed under the All material was furnished under invitation No.
completion contract, specifications No. DC-5750. DS-5354.

Interior surfaces of penstocks were coated with The stoplogs are installed in vertical guides on the
face of the dam and in the trashrack structures. The
coal-tar primer and coal-tar enamel. Exterior surfaces
stoplogs are placed in the guides in one stack. Effective
in backfill, except the sleeve-type couplings, were
sealing is obtained by means of music-note-typerubber
coated with coal-tar primer, coal-tar enamel, seals bolted to the log sections.
bonded-asbestos felt, and kraft paper wrap. Exterior
surfaces of sleeve-type couplings in backfill were The stoplogs were designed for a maximum head of
coated with coal-tar primer and coal-tar enamel, and 250 feet at safe stress.
surrounded by sand shields. The penstock exterior
embedded surfaces were not coated. Exterior surfaces 61. 165-TON GANTRY CRANE. (a) Descrip-
of penstocks, makeup pieces, and sleeve-type couplings tion.-A 165-ton gantry crane (fig. 274) is installed on
exposed to view in the powerplant were coated with rails on top of the dam for the installation and
maintenance of penstock gates and hoists and river
phenolic-resin aluminum paint.
outlet gates and stop logs. The crane was manufactured
under invitation No. DS-5521 and is an outdoor,
59. PENSTOCK TRASHRACKS. A total of 280 cab-operated, electric gantry crane with a trolley
trashracks are provided for the penstock trashrack supporting a 165-ton main hoist and a 25-ton auxiliary
structures to protect the turbines from oversize trash. hoist.
The 280 trashrack sections, approximately 9.33 feet
wide by 12.5 feet high, as shown on figure 143 were The main hoist i s reeved 6 parts double with
furnished under invitation No. DS-5512. 1-112-inch-diameter, 6 by 37, improved plow steel,
fiber-core wire rope. The block has a lifting eye in lieu
The trashracks are installed in vertical slots in the of a hook. The hoist has a lift of 53 feet, is powered by
penstock trashrack structures. The racks consist of 2- a 40-horsepower, 1,200-r.p.m., direct-current motor,
by 518-inch trash bars supported by 9- by 1-inch and operates at incremental speeds up to 3.7 feet per
horizontal load carrying plates which transmit the load minute hoisting and 4.3 feet per minute lowering with
to the side members. The 4-318-inch clear opening a 165-ton load.
between the trash bars conforms with the
recommendations of the turbine manufacturer. The The auxiliary hoist is reeved 2 parts double with
estimated weight of the 280 trashracks is 980,000 1-inch-diameter, 6 by 37, improved plow steel,
pounds. fiber-core wire rope. The block has a sister-type hook
bored for a horizontal lifting pin. The hoist has a lift of
The trashracks were designed for a differential head 380 feet, is powered by a 40-horsepower, 1,200-r.p.m.,
of 20 feet a t a stress of 33,000 pounds per square inch. direct-current motor and operates at incremental
speeds up to 24 feet per minute hoisting and 28 feet
60. PENSTOCK STOPLOGS. Twenty-three per minute lowering with a 25-ton load.
stoplog sections were required for the penstock intakes

'Not included.
DESIGN
POWER WATERWAYS

The trolley is driven by a 15-horsepower, operator's cab, in the control room, and on the trolley
1,200-r.p.m., alternating-current motor at 4.8 feet per access walkway. One 100-watt lamp is installed in the
minute in either direction, through a rack and pinion operator's cab and one in the control room, each with
drive. The gantry is driven by four 5-horsepower, conveniently located wall switches. Two 100-watt
1,I 50-r.p.m., alternating-current motors at incremental lamps are located on the trolley access walkway. One
speeds up to 48 feet per minute in either direction. 750-watt narrow-beam floodlight is mounted under the
trolley access walkway. Two 500-watt medium-beam
A single motor-generator set installed in the floodlights are mounted on the upstream side of the
control enclosure supplies direct-current power for crane and two 500-watt wide-beam floodlights are
both hoist motors, the hoist motor controls being mounted to illuminate the roadway under the crane.
electrically interlocked so that only one hoist may be There is a 240-volt, 3-kilowatt heater installed in the
energized a t a given time. Full magnetic controllers for operator's cab.
each motion of the crane are located in the operator's
cab. Five-point-speed control is provided for each Spring bumpers are mounted on the gantry legs
direction of the main hoist, auxiliary hoist, and gantry a t one end of the crane only. Double-acting spring
drive, and single-speedcontrol for the trolley drive. bumpers are provided on the trolley. Ladders and
walkways provide access to the trolley, control room,
Each hoist motor is equipped with two and operator's cab.
alternating-current magnetic brakes, one on each side
of the motor, which are released when the hoist motor (b) Design.-The crane was designed according
circuit is energized. Each of these brakes is capable of to the Navy Department's standard of design for
overcoming the full-load torque of the motor with structural steel using a base stress of 16,000 pounds per
which it operates. The trolley drive is equipped with a square inch. Computations of stress took into account
similar brake which i s capable of overcoming at least wind loads, all dead and live loads, and loads due to
three-fourths of the full-load torque of the drive acceleration and deceleration. Allowable stresses due to
motor. combinations of these stresses were increased according
to the Navy standard noted. A factor of safety of not
Each of the gantry drive motors is equipped with less than five, based on the ultimate strength of the
a hydraulic brake, all of which are actuated by a single material and rated capacity of the crane, was used in
foot pedal located in the operator's cab. Each brake is the design of all mechanical parts.
capable of overcoming the full-load torque of the
motor with which it is associated, simultaneously with 62. 13.96- BY 22.45-FOOT FIXED-WHEEL
the other gantry drive brakes, with no more than 50 GATES FOR PENSTOCK INTAKES. (a) DescrIp-
pounds of operating force on the foot pedal. Each tion.-Eight fixed-wheel gates are provided in the
brake is equipped with an automatic, spring-applied, penstock intakes for emergency closure of the
parking feature. penstocks in case of damage to the penstocks or the
powerplant equipment, and also to permit unwatering
Block-actuated limit switches on each hoist limit of the penstocks for inspection and maintenance.
the upward travel of the hook. A two-contact-geared Normally, the gates will close only after flow through
limit switch on the auxiliary hoist limits the lower the penstocks has been stopped by closing the wicket
travel of the hook and lights a red light in the gates. However, in an emergency the gate may be
operator's cab. Each contact is individually adjustable closed with water at full reservoir head flowing through
within the last 30 feet of travel. the penstock. The gates were manufactured by Voest
Co. of LinzIDonau, Austria, under invitation No.
A limit switch on the main power cable reel, DS-5577. The frames were manufactured by Rockwell
adjustable within the last 10 feet of cable, stops the Engineering Co. of Blue Island, Ill., under invitation
gantry before the cable is unwound lighting a green No. DS-5469. The general arrangement and some
indicating light in the operator's cab and setting the details of the 13.96- by 22.48-foot fixed-wheel gate
parking brake. A momentary contact pushbutton installation are shown on figure 144.
station, located near the gantry travel master switch,
permits the operator to move the gantry back into the Each gate is made in four units, fabricated from
limit switch zone. welded shapes and plate connected by rivets and rib
bolts. Six wheels on each side of the gates carry the
The crane i s equipped with a 120-volt permanent waterload to the tracks embedded in the downstream
lighting system. Service outlets are located in the side of the gate slots. Rubber seals are mounted like a
DESIGN
POWER WATERWAYS

picture frame on the downstream skinplate and bear

against metal seats which surround the penstock
intakes. Rollers a t the sides of the gate provide lateral
guidance for the gate and bear on embedded guides in
the gate slot. A single hoist connection, located on the
center of gravity, is provided. The gate travel is 26 feet
5 inches. The estimated weight of each gate is 231,000
pounds and of each frame is 70,000 pounds.

(h) Dean.-Each gate was designed for a static

head of 270 feet. The hoist connection a t the gate was
designed for the maximum hoist capacity,

Bending stresses in the horizontal and vertical

beams were limited to T5.W pounds per square inch
tension and 14,000 pounds per square inch
compression with the web shear limited to 9,500
pounds per square inch. Equivalent stress in the
skinplate due to beam bending and skinplate bending
was limited to 20,000 pounds per square inch. A
portion of the skinplate was considered to be an
integral part of the downstream beam flanges. The
skinplate was also assumed to act as a haunched
continuous beam with the 5upports on the centerline
of the webs,

The stresses in the tracks and wheels were

investigated by a method of calculating stresses due to
the pressure of one elastic solid on another. The
bushings in the wheels have self-lubricating inserts and Figure 145.-Downstream elevation of .shop assembly of 13.96-
by 22.45-fool fixed-wheel penstock gate. P557-D-46362NA.
may be greased when assembled. Friction forces of the
loaded wheels, busings, seals, etc., were investigated to
be certain that the gate would have sufficient weight to Some installation and assembly details are shown
close without the aid of an externally applied force. on figure 146. The hydraulic hoists are installed on the
Bearing pressure on the projected area of the bushing slope of the intake structure (0.170:1)at the upstream
was limited to 4,000 pounds per square inch. face of the dam and are supported by steel beams a t
elevation 371 3.00. Each hoist is connected to the gate
Figure 145 shows the downstream face of the by a series of intermediate stems with an assembled
gate as fabricated in the manufacturer's shop. length of 172 feet 9-3/4 inches. Each hoist piston has
both packing and piston rings, is 30 inches in diameter,
63. HOISTS AND CONTROLS FOR THE 13.96- and has a stroke of 26 feet 5 inches. An individual
BY 22.45-FOOT FIXED-WHEEL control cabinet is located adjacent to each hoist in the
GATES. (a) Description.-A, hydraulic hoist and control house, and contains all the hydraulic and
control are provided to operate each of the eight electrical equipment for operating the hoist, and a gate
13.96- by 22.45-foot fixed-wheel gates. Normally, a position indicator.
hoist will be required to close the gate under balanced
pressure t o unwater the penstock for maintenance The estimated weight of the eight complete
purposes, but may be required to close the gate under hoists is 800,000 pounds and of the eight complete
flow conditions in an emergency. Eight hydraulic control systems is 42,000 pounds. Figures 147 and 148
hoists were furnished by the Pacific Coast Engineering show the shop assembly of the hoist and stems.
Co., Alameda, Calif ., under invitation No. DS-5601.
The controls were manufactured by Auto-Control (b) Design.-The hoists were designed to open
Laboratories, Inc,, Los Angetes, Calif., under invitation and close the gates normally with the water pressure
NO. <Dl90,638-A. balanced on both sides of the gates; t o open any one of
POWER WATERWAYS

Figure 147.4ntermediate stems and coupling hooks for the 13.96- by 22.45foot fixed-wheel gate. P5S7-0-37604.

the gates 14 inches for conduit filling with maximum designed to lower the gates, without operating the
unbalanced pressures on the gate; and in an emergency, pumps, by bypassing oil from the underside of the
to close the gates with full flow to the turbines under a piston directly to the top of the cylinder. The design
maximum head of 255 feet. The cylindw size for the time selected for opening the gates balanced was about
hoists was determined by the sum of the weights of the 20 minutes, and for closing unbalanced less than 2
gate and stems, plus maximum downpull, minus minutes, based on normal oif temperatures. The closing
friction of the coupling hooks sliding on the concrete time will increase slightly as the oi! temperature drops,
guide surface, and minus one-half the gate wheel and and decrease slightly when the gate is subjected to
seal friction. This load would produce a cylinder downpull forces during emergency closure. A hanger
pressure of approximately 1,200 pounds per square stud is provided in the upper cylinder head of each
inch during emergency closure; however, normal hoist to engage the piston stem and support the weight
balanced operations or conduit filling will require a of the stems and gate in the open position during gate
maximum cylinder pressure of less than 600 pounds installation or removal. During normal operation a he
per square inch. The hoists and sterns were designed for hanger stud will not be engaged, as the piston was
a relief valve setting of 1,000 pounds per square inch, designed to support the gate and stems on oil confined
using normal factors of safety. The pressure switch under the piston.
setting of 750 pounds per square inch provides a
minimum lifting force at the hoists of 437,000 pounds Two constantdelivery pumps, having a combined
which exceeds the 392,000-pound force required to delivery of 49 gallons per minute at a pressure of 1,000
open the gate for conduit filling. The hoists were pounds per square inch and a pump speed of 1,800
 DESIGN

Figure 1#.-Hydraulic hoist and intermediate stems for the 13.96- by 22.6foot f ixed-wheel gate. P557-D-37603.

revolutions per minute were selected for each cabinet of the cylinder. A restoring cycle was incorporated in
to open the gate within the predetermined design time. the controls to maintain the gate automatically within
Two 15-horsepower motors, using 440-volt, 3-phase, close limits of the open position. A penstock pressure
60-cycle current were required to drive the pumps. The switch was included to prevent opening the gate until
two independent pump units were used to provide the penstock is full and the pressures on either side of
protection against failure of a single pump unit. A the gate are essentially balanced. Gate position
110-volt transformer was used to provide power for indication was provided in the cabinet using a vertical
most of the control circuits and the cabinet heater; scale with a pointer driven by a stainless steel cable
however, the control was designed to use a separate connected to the piston stem.
source of direct-current power from the powerplant to
operate the emergency close circuit and the The control was designed for normal gate
solenoid-operated, four-way valve which directs the operation by pushbutton from the control cabinet and
flow of oil to open, close, or stop the gate. for emergency gate closure by selector switch or
automatic protective devices from the powerplant. The
The control was designed for gravity closure of emergency close circuit was designed to override all
the gate with the closing speed controlled by a throttle opposing signals initiated from the control cabinet,
valve in the bypass piping from the bottom to the top

214
POWER WATERWAYS
 DESIGN

The 214-gallon oil tank was selected to provide 64. TURBINE DRAFT TUBE BULKHEAD
storage and expansion capacity for the hydraulic oil GATES. (a) Description,-Twenty-four bulkhead
used in the system. The control design was based on a are provided to seal the turbine draft tubes from the
nominal temperature of 35' F. and the use of a tailwater in the event that it is necessary to unwater
lightweight hydraulic oil with a viscosity of 153 the turbine units for inspection and maintenance of
Saybolt seconds universal at 100' F. and a viscosity either equipment or structure. The 24 bulkhead gates
index of 97. and related equipment (fig. 149) were furnished under
invitation No. DS-5341.
The design stresses used were as follows:
A gate having nominal dimensions of 12.42 feet
(1) Tension.-The allowable design stresses in wide by 15.95 feet high is available for each of the
tension for the following materials were based on draft tube openings. The gates and lifting frame
the yield point or the ultimate strength of the operate in steel guides embedded vertically in the
material. The smaller of the tabulated values was concrete structure. The gates are raised and lowered by
used in each instance. means of a 10-ton gantry crane. An automatically
engaging lifting frame is used for raising and lowering
the gates.

The gates are normally stored in the upper

Material portion of the gate slots. The gates are supported by
latches so located that the lifting lug on the gate is just
below the deck slot covers and is therefore easily
Steel Rolled or accessible from the deck. The latches consist of hinged
forged bars which will automatically engage the gate guide
Bolt Rolled or lugs during the raising cycle, and may be laid back out
steel forged of the path of the gate guide lugs to allow the gate to
Cast Castings lower.
steel
Brass or Rolled or Inasmuch as the gates must be raised and lowered
bronze only under balanced head conditions, a filling valve is
incorporated in the gate lifting stem of each gate for
(2) Compression.-The allowable design stress the purpose of creating the balanced head prior to
in compression used for the materials listed above raising the gates. In the event that high-pressure
were the same as for tension. penstock water is unintentionally admitted to the
turbine and draft tube while the gates are in place, a
(3) Shear.-The allowable design stresses in gate will blow off of i t s seat, shearing the bolts which
shear were not more than 0.6 of the allowable fasten the lower guide lugs to each side of the gate. The
design stresses in tension. top guide lugs are rigidly fixed to the gate, enabling the
gate to swing out in the event that the lower guide lugs
(4) Structural steel.-The allowable design shear. The estimated weight of the 24 gates is 396,000
stresses for structural steel in tension or pounds.
compression were not more than 20,000 pounds per
square inch. In general, structural steel stresses were (b) Design.-Maximum stresses are calculated on
based on the American Institute of Steel the basis of a dry draft tube and maximum tailwater
Construction "Specification for the Design, surface, the maximum head being 78 feet. Under these
Fabrication and Erection of Structural Steel for conditions the combined stresses of the faceplate and
Buildings," 1961. beams are permitted to reach 24,000 pounds per
square inch. Other stresses conform to the American
(5) Hoist cylinders. -The allowable design Institute of Steel Construction.
stresses for the hoist cylinders were based on the
recommendations of the ASME Boiler and Pressure
Vessel Code-Unfired Pressure Vessels-Section VIII,
1962.