CHAPTER 2 TAINTER GATES TABLE OF CONTENTS November 1950 Paragraph Page , 2-01 INTRODUCTION ______________ __ __ ______ __ __ ______ __ ____________________ _ 1 2-02 SCOPE _________________________________________________________ .- __ __ _____ 1 2-03 GENERAL FEATURES OF DESIGN______________________________________ 1 2-04 WORKING STRESSES_ ___________ ___ __ _ ___ _ _ __ __ __ _ _ __ __ _ _ _ __ _ __ __ __ _ ____ 2 2-05 DIMENSIONS_ _ ___ __________ __ ____ __ _ _ _ _ __ __ _ __ _ __ __ _ _ _ _ __ ___ _ __ __ _ __ ____ 2 2-06 TRUNNION AND SILL LOCATIONS_____________________________ _________ 3 2-07 WEIGHTS _______________ ~ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 3 2-08 DESIGN CONSIDERATIONS_______ __ __ _ ___ _ _ __ __ _ _ __ _____ _ __ _ _ __ _________ 4 2-09 SKIN PLATE ASSEMBDY _ _ ______________ __ _ _ __ __ ____ _____ _ ___ ___ __ _ _____ _ 4 2-10 HORIZONTAL GIRDERS__________ ____ ____ _ _ __ __ ____ _____ _ __ _ _ __ ______ __ _ 5 2-11 END FRAMES_ _ _ _ _ _____________ __ __ __ _ ___ __ __ __ ____ _____ _ __ ____ __ ____ __ _ 5 2-12 TRUNNION ASSEMBLY AND TIE_______________________________________ 5 2-13 ANCHORAGE GIRDERS ___________________________________ ~ _ ______ _ ______ 6 2-14 ANCHORAGES_ _ _ _____________ _____ _____ __ _ _ _ _____ _______ _ ____ _ ___ _ ______ 6 2-15 SPECIAL ANCHORAGES _________ ..... ___ __ _ _ _ _ __ __ __ __ __ __ _ _ ____ __ __ __ __ _ __ 7 2-16 SEALS _____________________________________ .. _ _ ___ __ _ _ __ _ _ __ ____ __ __ __ _____ 7 2-17 HEATERS_______________________ _ _ __ __ _ _ __ _ _ _ ___ ___ _ ______ _ _ __ __ _ _ ___ ___ _ 7 2-18 ERECTION _______________________ _ __ _ _ _ __ _ _ __ _ __ ___ _ __ _ ____ _ _ _ _ _ __ __ _ _ __ _ 8 2-19 HOIST-MECHANICAL_ __ _ _ __ ___ _ __ __ __ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ ___ _ __ ___ __ ___ 8 2-20 HOIST-ELECTRICAL EQUIPMENT______________________________ ________ 9 2-21 PAINTING_______________________________________________________________ 10 LIST OF ILLUSTRATIONS_ _ _ _ _ _ _ _ _ __ _ _ _ __ _ _ _ _ __ __ _ _ __ _ _ ____ _ _ __ _ ________ 11 921863 0 -51 1 2-01. INTRODUCTION PART CXXVII CREST AND HEAD GATES CHAPTER 2 TAINTER GATES November 1950 The tainter gate is considered the most economical, and usually the most suitable, type of gate for a controlled spillway because of its simplicity, light weight, and low hoist capacity requirements. The principal objectives of this chapter are to outline for the designer the procedure involved in developing a gate that will meet the requirements for dependable operation, minimum mainte- nance, and long life; to standardize on the use of materials and working stresses; and. to show typical details recommended. The material presented is based on studies and records of the Corps of Engineers as well as on information and advice furnished by gate manufacturers and erectors. 2-02. SCOPE The basic and alternate designs presented are intended for flood control spillways and should cover the more general applications for that purpose. For the design of special tainter gates such as the" submersible" and the" moment-resisting shell" types, reference is made to Part CXXVI-Navigation Lock and Dam Design. Certain other types of control gates, such as radial lock valves and sluice gates, may properly be called tainters but are not included in this chapter. 2-03. GENERAL FEATURES OF DESIGN A review of a large number of tainter gate installations reveals a striking diversity in the type of framing employed. Trusses, tied arches, and simple or continuous girders have been used, but the original cost and maintenance charges can be held to a minimum only by proper selection of type and sound design. It will be noted that emphasis is placed herein on simplicity of framing and the use of a minimum number of members of fairly heavy cross section. Uniform practice in this respect is desired as well as in the elimination of such basic errors in design as ignoring secondary stresses in the end frames or taking care of them by extravagant use of Existing gates of approximately the same size show weight variations of as much as 50 percent and framing peculiarities which have caused the unit bid price for fabrication and erection to vary even more. Excessive weight results in greater first cost for both gate and hoisting machinery. Complexity of framing and details results in higher unit first cost and in more difficult and costly maintenance. The principal elements of a tainter gate structure are the skinplate assembly, the members supporting the skinplate assembly, the end frames, the trunnions and the anchorages. Each element requires individual study. The skinplate assembly consists of the skinplate stiffened and supported by curved vertical beams. The members supporting the skinplateassembly are girders or trusses spanning the gate opening horizontally. The end frames carry the reactions from the horizontal supporting members to the trunnions and the trunnions transmit the reactions to the anchorages. Field splices in each element should be as few as possible, depending on shipping and erection clearances and capacity of handling equipment. 1 PART CXXVU, CHAPTER 2 November 1950 All shop fabrication should be by arc welding. Modern shop methods have reduced welded fabrication costs to a competitive level with costs of riveted work, and the saving in weight of material and surfaces to be maintained are of great advantage. Residual stresses can be reduced to a great extent by furnace stress relieving. Although steel trusses for the horizontal supporting members have been used in many installa- tions, there appears to be little reason for selection of this type of design. It is evident by reference to Table 1, paragraph 2-07, that gates with trussed horizontal members are considerably heavier than gates designed as recommended herein. Moreover, fabricators usually bid a higher unit price for truss work than for girders and, generally, a truss of any type requires more work in design, drafting, fabricating, erecting, inspecting, and maintenance. For small to medium size gates the .horizontal supporting members may be rolled sections but for the larger sizes it may be necessary to use welded built-up girders with deeper webs. . The structural parts of gates, anchorages, and hoists should be of structural carbon steel of welding quality conforming to Federal Specification QQ-S-74i, Type II, Grade A or, where justi- fied, of low alloy, high strength steel conforming to ASTM Designation A242. 2-04. WORKING STRESSES In general, working stresses should be in accordance with part CXXI, chapter 1, of this manual. The basic allowable stress in structural carbon steel is 18,000 p. s. i. When secondary stresses are included in the analysis, values 50 percent in excess of the basic stresses are permissible, provided the resulting section meets the requirement for primary stress. This overstress allowance does not apply to columns or struts with l/r greater than 60, or to beams with ~ ~ greater than 600. Unit bearing on concrete should normally not exceed 0.30 j ~ . In the case of an intermediate pier anchorage when one gate is fully loaded and the adjacent gate is unloaded, the maximum allowable bearing stress of the embedded girder on the concrete may be increased to 0.45 j ~ , pro- vided the normal allowable stress is not exceeded for symmetrical loading. No tension value should be ascribed to concrete. Unit bearing for bronze bushings in trunnions should not exceed 3,000 p. s. i. and should preferably be limited to 2,000 p. s. i. The entire projected area is used in computing bearing values. It should be noted that, although it would be unusual for one of a pair of adjacent gates to be fully loaded while the other is unloaded, the secondary stresses which may be induced in the anchorage members in an intermediate pier under this condition are so large that it is advisable to use the 18,000 p.s. i. base for primary stresses in order to minimize distortion and thereby reduce the secondary stresses. The end pier anchorages will, of course, be designed for the normal un- symmetrical loading at normal basic stresses for both steel and concrete. 2-05. DIMENSIONS The pier spacing and width of gate is limited by practical considerations such as maximum desirable lengths of monoliths, length of spillway bridge spans, drift hazards, and loads on trun- nions and anchorages. Ordinarily, the width of gate will be the width of monlith less the thick- ness of pier, since more than one contraction joint per gate opening is undesirable. . The depth of gate is usually determined chiefly by hydraulic requirements. Within limits it is desirable to use a deep rather than a wide gate to secure a given discharge, since a shorter and cheaper spillway results. On the other hand, it is desirable, hydraulically, to use gates as wide as practicable in order to minimize the obstruction to flow. For example, using 0.015H as the end con- traction coefficient and assuming (1) a 600-foot net spillway length (2) a surcharge of 30 feet on the crest and (3) piers 8 feet thick for gates 50 feet wide or under and piers 9 feet thick for gates greater than 50-foot wide, the over-all obstruction to flow is about 15 percent for 60-foot openings, 16 percent for 50-foot openings and 21 percent for 40-foot openings. However, the trunnion loads, which 2 PART CXXVII, CHAPTER 2 November 1950 2-08. DESIGN CONSIDERATIONS The tainter gate design discussed herein is illustrated on Plates Nos. 1 to 3, inclusive. Among the features are the inclined end frames (see paragraph 2-11) and the trunnion tie. A trunnion tie is desirable, structurally, because it relieves the piers of nearly all lateral loads from the gate but it is often impracticable because of possible interference with the nappe or with passage of debris. In that case, vertical thrust beams in the anchorage assemblies, as indicated on Plate No.5, may be used to transmit the lateral thrusts from the gate to the piers. The gate shown on Plate No.4 is not as economical as that shown on Plate No.3 and the end frames will be subject to considerable bending stress. However, its weight is not excessive and it may be desirable to select this type if a trunnion tie cannot be used and if the lateral thrusts on the piers would be too great with fully inclined end frames. In order to minimize percentage reduction in section by possible corrosion, all members carrying calculated stress should have a minimum thickness of % inch, except for webs of wide flange members used as bracing for which %s-inch thickness is permissible. 2-09. SKINPLATE ASSEMBLY Because of the constant span under varying loading on the skinplate, it is usually economical to use two or more sizes of plate with %-inch minimum at the top and increasing with the depth by Xs-inch increments as necessary. For very shallow gates, however, the entire skinplate may be of one thickness. A thickness greater than % inch will rarely be required for any gate. Reservoir operation will usually permit maintenance painting of the upstream side of the gates during periods of pool drawdown. If the minimum pool will always or nearly always be above the spillway crest, the computed thickness of skinplate should be increased by Xs inch to allow for abrasion and corrosion. The skinplate should be protected from contact with the hoist chains by narrow wearing plates of carbon steel welded in place. The skinplate should be designed as a continuous member spanning horizontally across the vertical supporting members. Attempts to treat the plate as a two-way member by using hori- zontal intercostals will involve the designer in a very complex problem. The curvature of the plate in one direction and its indeterminate action due to the wide difference in stiffness of the panel supporting members make an accurate analysis extremely difficult, if not impossible. Refer- ence is made to Timoshenko's "Theory of Plates and Shells", pages 219 and 228, wherein the au- thor states that two-way design is not applicable to cylindrical plates. Paragraph 43, of the same reference, contains a discussion of the difficulties in analyzing flat plates on panel supports of different rigidities. Reference is also made to a discussion by 1. K. Silverman of Schorer's Paper No. 1938 in Volume 62 of the Transactions ASCE (1936). The discussion points out that large stresses may be caused in horizontal skinplate supporting members, especially the bottom mem- ber, by the arch thrusts of the loaded curved plate. The magnitude of these thrusts is difficult to determine. In further discouragement of the two-way treatment, fabricators have estimated the cost per pound of a skinplate assembly with vertical beams and horizontal intercostals at about 10 percent higher than one with vertical beams only. The skinplate supporting members should be vertical curved beams without horizontal inter- costals because of the greater likelihood of debris clinging to horizontal members and causing cor- rosion for reasons cited above. The beams will usually be standard rolled sections but may be built up of plates, if necessary, or formed by splitting standard or wide flange beams. Tee sections with the stems welded to the skinplate are preferred to H or I sections in order to avoid the corrosion which is likely to occur under a contacting flange welded at both edges. Angles, split channels or flanged bent plates may also be used. The skinplate assembly should be made up in shop fabricated sections consisting of a width of skinplate welded to the curved supporting beams. The sections should be as wide as shipping 4 PART CXXVII, CHAPTER 2 November 1950 increase directly with the width and as the square of the depth, may become excessive for the larger gates. A tainter gate of moderate size, say 40' x 28' *, will have a reaction of about 500 kips at each trunnion,and an 8-foot pier will be adequate. When the gate size is increased to 50' x 37' or 64' x 30', the trunnion reaction is about doubled, and the anchorage and pier design problems become more difficult. As the depth is increased, the turning radius, which is usually about equal to the depth, must also be increased. This may require wider piers for proper location of the trunnion girder . . 2-06. TRUNNION AND SILL LOCATIONS The trunnion should be located above the water surface of the maximum flood nappe to avoid contact with floating ice and debris. It will usually be advantageous to place the center line of the trunnion at about the depth of the gate above the sill in order to transmit the maximum reaction approximately horizontally to the trunnion girder. The sill should be located so that a vertical plane tangent to the skinplate arc will intersect the spillway at or downstream from the crest. This requirement alone will usually place the sill about two feet downstream from the crest. Operating clearances from the bridge and the location of the hoist will usually require the sill to be placed still further downstream but the distance from the center line of crest to the sill should be as small as possible in order to economize on depth of gate and size of pier. r07. WEIGHTS Weights of typical tainter gates of structural carbon steel are shown in Table 1. Data for gates Nos. 1,2, and 3 are taken from designs by the Oorps of Engineers as recommended herein. Data for gates Nos. 4, 5, and 6 are from truss type designs by others. All weights are for the movable gate structure only. Gate No. TABLE NO. 1 TAINTER GATE WEIGHTS Nominal dimensions (feet) L __ _ _ _ _ _ __ _ _ _ ___ __ _ _ _ 64 X 30 _______ ::' __ ___________ _ 2___ _ _ _ _ _ _ __ _ _ __ _ _ _ _ _ _ _ 50 X 37 ______ ::. ___ ___________ _ 3__ _ _ _ _ _ __ __ __ __ _ _ __ _ _ _ 40 X 28 _______ _: ___________ _ 4__ _ __ _ _ _ _ _ _ __ __ _ _ _ _ _ _ _ 40 x 32 ______ j?,- _.? __ J_.:'-,: ___________ _ 5 ________ ________ ----- 40 X 25 _______ __ ___________ _ 6 ______________________ 32 x 23.5 _______ __ c __ ____________ _ Area (square feet) 1,920 1,850 1,120 1,280 1,000 750 Total weight (pounds) 146,000 136,000 73, 500 129, 100 90,000 61, 000 Weight per square foot (pounds) 76 74 66 101 90 82 Gates Nos. 4,5, and 6 are included to show the heavier weights per square foot of typical truss type gates as compared with gates Nos. 1, 2, and 3. However, gates of welded or riveted girder design with weights per square foot almost equal to those shown for the truss type have been built. Although the data for gates Nos. 1,2, and 3 show a reduction in unit weight with reduction in gate area, there is little saving in weight per square foot for gates smaller than gate No.3. The weights of end frames, trunnions, seals,etc. do not decrease in proportion to the gate area, and the requirement for %-inch minimum material further limits weight savings. *Where gate size is shown in this manner the width is given firsti e. g. a 50"x 37' gate is 50' wide and 37' deep. 3 .'" PART CXXVII. CHAPTER 2 November 1950 clearances will permit, usually about 12' 6". Edges should be stiffened and prepared in the shop for field splices running the full depth of the gate, as shown on Plate No.3. Holes for bolting the splices during field welding are provided in each edge stiffening plate and in the matching vertical beam of the adjacent section. 2-10. HORIZONTAL GIRDERS Ordinarily, two horizontal girders should be used for gate depths up to about 28 feet, and three for depths from 28 to 37 feet. For deeper gates four or even more may be required. A design using a minimum number of girders will simplify fabrication and erection and facilitate maintenance. Girders may be either rolled sections or weldments made up of plates. The skinplate assembly sections may be attached to the upstream flanges of the girders in the field by riveting, bolting or welding at each vertical beam. If the connections are welded, holes for fitting up bolts must be provided. The girders should be spaced so that bending moments in the vertical beams at the girders are about equal. This spacing will result in a heavier load on the lower girder of a two-girder gate but, for a three-girder gate, the loads on the two lower girders will usually be so nearly equal that the same section can be used for each. Diagonal bracing across the downstream flanges of the girders is commonly used on tainter gates and is designed for stresses occurring when the gate is supported at one end. The arm of the resisting couple is assumed equal to the height of the gate. Unit stresses should not exceed the elastic limit of the material. Such bracing is of doubtful use in a gate of this type since the plane of the bracing will be very close to the stiff skinplate assembly and normally will probably serve only to reduce dead load bending stresses in the flanges of the girders at the panel points. Vertical struts may be used as an alternate to the diagonal bracing,as shown on Plate No.3. Weep holes properly located for drainage should always be provided in the girder webs. 2-11. END FRAMES Maximum economy in the horizontal girders will be obtained by inclining the end frames to intersect the center line of girders at a point about one-fifth of the width of the gate from each end (Plate No.3). The maximum moment in the center span will then be very nearly equal to the end cantilever moments, and bending in the end frames, which would tend to bind the trunnion bearing, will be minimized. The side thrust component of the gate reaction introduced by inclining the end frames may be resisted by a trunnion tie (paragraph 2-12) or by designing the anchorage to trans- mit the thrust to the pier (Plate No.5). The slightly inclined end frame design (Plate No.4) is suitable for moderate-size gates where a tie is undesirable and where large side thrusts cannot be transferred to the piers. 2-12. TRUNNION ASSEMBLY AND TIE The trunnion assembly consists of a cast steel trunnion to which the main end frame members are attached; a cast steel shoe rigidly attached to the anchorage girder; and a forged steel trunnion pin, which transfers the gate reaction from the trunnion to the shoe. Both castings should be annealed. The trunnion should be provided with a bushing of bronze conforming to Fed. Spec. QQ-B-691b, Oomposition 8. The trunnion shoe is bolted to the trunnion girder after final adjust- ment by horizontal and vertical jack screws. Keys welded to the girder provide for lateral forces on the shoe and a poured zinc filler assures uniform contact between the shoe and the girder. The trunnion tie is usually a steel pipe with end flanges bolted to the trunnion castings. If a tie is used, the design of the trunnion assembly must take into account the lateral forces caused by temperature variations in the tie. Olearance for the maximum sidewise movement of each trunnion should be provided in the trunnion shoe to limit the thrust to the frictional resistance of PART cxxvn, CHAPTER 2 November 1950 the trunnion pin in the bearing. Clearance from the tie to the nappe should be at least equal to that provided for the bottom of the gate structure in the raised position. 2-13. ANCHORAGE GIRDERS Many existing gates transmit the end frame reactions to forged trunnion pins which extend through the downstream ends of the anchorage members, thus serving "also as anchorage girders. In the intermediate anchorages, one pin serves adjacent gates. Since a solid cylindrical section is very inefficient in bending, the cost of such a design is considerably more than that of the box girder with trunnion shoes and pins described herein. At one such installation the trunnion pins are 26 inches in diameter, 17-feet long, and weighed nearly 16 tons each before machining. In addition to the inefficient use of material, a further objection is the lack of provision for inde- pendent adjustment of the trunnion pins. The box-type anchorage girder should preferably be entirely outside of the concrete pier. If embedment is unavoidable the girder should be covered with at least W' of cork mastic to permit free deformation of the member under load. Concealment should not be a factor since the box design presents a good appearance. Besides shear and bending stresses, the girder will be subjected to torsion which will be greatest when the gate is partly raised and the pool is at maximum level. Strain gage tests, made by the Corps of Engineers on an a.ctual anchorage, show that torsional stresses will not be excessive. A comprehensive discussion of torsion in structural members is given in Paper No. 1941 by Lyse and Johnston in Volume 62 of the Transactions ASeE (1936). 2-14. ANCHORAGES The anchorage shown on Plate No.5, consisting of two standard rolled beams or built-up sections welded to the anchorage girder and to the embedded girder, should be adequate for most gates. The tie beams should be placed so that at least 8 inches 'of concrete will cover the steel nearest the face of the piers. The embedded girder should be designed to transmit the entire load from the tie beams to the pier in bearing. To permit free deformation of the tie beams and prevent tension in the pier concrete, the beams should be mechanically isolated from the concrete for their full length by a coating of at least W' of cork mastic. A loaded end anchorage, or an intermediate anchorage with one gate loaded and the adjacent gate raised, will be subjected to severe racking on the frame formed by the anchorage girder and tie beams. In addition to the large direct tension stress in the tie nearest the loaded gate, there will be both primary and secondary bending stresses in the frame. Since the frame is restrained against sidesway, the primary bending stress will be negligible. In order to minimize the secondary bending stress, the tie beams should have a stiffness value as low as practicable in the plane of the frame .. For this reason an I beam, or built-up member with narrow flanges, will be more suitable than a wide flange beam. The length of tie beams should be limited to approximately two-thirds of the radius of the gate. The anchorage shown has short vertical embedded beams at the inner edges of the tie beams, with brackets in cont.act with the top and bottom flanges of the tie beams. The purpose of these vertical beams iato transmit to the pier the side thrust from the inclined end frames and the vertical components (upward or downward) of the trunnion reactions. Bronze plates permit free longi- tudinal movement of the tie beams. If a trunnion tie is provided on the gate, there will be little side thrust except that due to temperature changes or to tendency of the anchorage frame to side- sway under unsymmetrical loading, but the vertical beam will still be required for vertical loads and to act as erection supports for the anchorage. Plate No.6 shows a suggested arrangement for the end pier anchorages. 6 2-15. SPECIAL ANCHORAGES PART CXXVII, CHAPTER 2 ,- November 1950 When trunnion loads are heavy and the piers must be light, it may be necessary to use an anchorage which will transmit the load to the concrete below the pier rather than to the pier itself. In this case (see Plate No.7), the anchor ties should be inclined at an angle with the horizontal large enough to place the embedded girder well below the bottom of the pier, and columns should be provided under the anchorage girder to take the vertical component of the trunnion loads. Cork-tar mastic should be used to isolate the anchorage members from the concrete except at the embedded girder and the column footings. This type of anchorage will be heavier than that shown on Plate No.5; but the reduction in pier reinforcing ~ t e e l will partly compensate for the extra weight of structural steel. 2-16. SEALS Side seals should be of natural rubber with physical characteristics as listed in Civil Works Engineer Bulletin No. 49-18. The seal section should be one which can be made by most manu- facturers from their existing molds. The section shown on Plate No.3 will meet this requirement. The method of attaching the seal to the gate should permit field adjustment for slight initial pressure against t h ~ side seal rubbing plates. The side seal rubbing plates should be of corrosion-resisting clad steel to insure a permanently smooth surface. Adjustable anchors in blockouts in the piers permit accurate alinement of the plates after the piers are completed. . The type of bottom seal will depend upon the particular project requirements. If the bottom of the flood-ctmtrol pool is below the spillway crest, and a small amount of leakage under a closed gate is of little importance, the contact between the finished bottom edge of the skinplate and a corrosion-resisting surface on the sill will be adequate. If storage of water for conservation, navi- gation or power is involved, and the top of the operating pool is above the crest, a tighter bottom seal may be required. In this case, the sill may consist of a channel into which hot lead is poured. When cool, the surface of the lead is dressed to serve as the contact with the bottom edge of the skinplate. The seal arrangements described above are shown on Plate No.3. Rubber bottom seals have been used on tainter gates but will not usually be required. If used, care should be taken to provide protection from damage by debris passing under the gate. 2-17. HEATERS Heating devices for the side sealing surfaces should be provided for gates which must be operated in subfreezing weather. In areas subject to long periods of extreme cold it may be neces- sary to heat the bottom seal or to heat the entire face of the gate, but the extent to which heating should be provided depends upon the exposure conditions. While the main purpose of heaters is to free the gate for operation, they will also help to reduce hoist loads and to prevent thrust from the ice sheet in the reservoir. Electric heaters are preferable where side seals only are to be heated. Where both the bottom and side seals are to be heated, a design which circulates a suitable anti- freeze solution through pipes embedded in the concrete should also be considered. In the latter case, immersion type electric heating units should be used to heat the solution which is then forced through the embedded pipes by circulating pumps. The heating and circulating equipment can be located on the pier along with the hoisting equipment. Since a design employing electric heaters will have more frequent application, it is discussed below in detail. A side seal heating device of the electrical type consists of a heater unit in a recess behind the side seal rubbing plate. The recess should be insulated to direct the flow of heat toward the seal and should be watertight .. A suitable side seal heater design is shown on Plate No.8. The material in the space between the two channels should be granular vermiculite which provides good insulating properties and which can be easily poured into the space. '; PART CXXVII, CHAPTER 2 November 1950 The construction of the bottom seal heater of the electric type will be similar to that of the side seal heater, except that the access recess, for the insertion of the heater units and housing of the junction box for making the external electrical connections, would be at the center of the seal. The length of the access recess, in this case, should be held to a minimum. One junction box should be used for making the electrical connections to both heater elements. The bottom seal may also be effectively heated by means of a well-insulated heater element attached near the bottom edge of the skinplate on the downstream side. To heat the face of the gate, the heater units should be attached directly to the downstream side of the skinplate and covered with heavy transite or other effective insulating material. Power supply conductors should be attached to the gate near the trunnion and carried along the end frame to the heaters. The heater units should be of the tubular type, consisting of a helically formed coil of chrome- nickel resistance wire surrounded by a refractory insulating material (magnesium oxide) and encased in a seamless tube of corrosion-resisting, non-oxidizing metal. Each end of the heater unit should be provided with a terminal to which is connected a length of solid single-conductor, lead sheathed cable which is wiped to the tubing of the terminal to make a watertight connection. The cable terminates in a watertight junction box in which the connection to the power supply feeder is made. The heater unit is quite flexible and can be readily bent to fit the contour of the recess. The side seal heater installation detail on Plate No.8 shows the tubular type heater unit. Specifications for these units are available in the Office, Chief of Engineers. Reference is made to part CXXXII of the Manual, Chapter 2-Electrical Systems, for further data on design of electrical de-icing devices. 2-18. ERECTION Each gate should be completely erected in the shop to check accuracy of fabrication and to facilitate field erection. Holes for field connections should be reamed with the parts assembled and shipping pieces should be match-marked. In the field, the gate should be completely erected and alined before final connection of the trunnion shoes to the anchorage girders. The jackscrews and holding bolts in the trunnion shoe connection should then be tightened to hold the gate in alinement and the gate should be raised and lowered as a check. Molten zinc should then be poured between the base of the trunnion shoe and the face of the anchorage girder. It is advisable to require the fabricator to furnish an engineer to supervise erection. 2-19. HOIST-MECHANICAL The size of the gate, the type of reservoir to be controlled, the operating criteria of the reservoir, the type of service bridge, and the space available should be considered in determining the location and arrangement of the hoist. A general arrangement is shown on Plate No.9, and typical designs are shown on Plates Nos. 10, 11, and 12. Recent bidding has indicated that hoists similar to those shown on Plates Nos. 10 and 11, incorporating helical or herringbone type speed reducers, are less expensive than those using worm gear reducers as illustrated on Plate No. 12. The maximum load on the hoist usually occurs at. the beginning of the hoisting cycle but it may occur at other points in the cycle, depending on the gate radius and the relative positions of the gate and the hoist. The total load at the sprockets is the sum of the following loads: (1) Dead weight of the gate. (2) Side seal friction (0.5 of the effective force on the seal). (3) Dead weight of lifting chains. (4) Trunnion friction (0.2 of the pressure on the trunnions). PART CXXVII, CHAPTER 2 November 1950 (5) Formations of ice or silt deposits on the gate, where applicable. Where the antic- ipated amounts of such deposits or formations would produce a load less than 10 . percent of the load due to the dead weight, they may be neglected, since the overload capacity of the hoist can be depended upon to cover small infrequent loads of this nature. The design capacity should be based on the maximum load at normal speed. Loads on the component parts should include the above loads and the applicable friction losses in the reducers, bearings, gear trains, and chain. A hoisting speed of about 1 foot per minute has been found satisfactory for most installations. However, the hoist speed should be varied so that the horse- power requirement will approximately match a standard motor rating. Component parts of the hoist are designed for a factor of safety of 5 based on normal loading and, in addition, each part is designed for a unit stress not in excess of 75 percent of the yield point of the material under loads resulting from the maximum torque of the motor selected. Both normal loads and loads resulting from the maximum torque of the motors should be considered as equally divided between the two drives of a hoist. Shock, impact, and wear factors are considered negligible and may be disregarded. Hoist chains having a pitch of 12 inches in conjunction with seven-tooth sprockets usually provide the most economical over-all hoist design. Single width chains are less expensive to manufacture than double or triple width chains and should be used wherever the hoist loading will permit. The reduction ratio selected for the speed reducer, connected to the motor, should be such as to permit the use of the smallest commercial size motor-operated brake which has a torque rating of 160 foot-pounds, for a one-hour intermittent duty and a torque rating of 125 foot-pounds for continuous duty. Where double reduction worm gear units are used for the main reduction, ratios offering the best efficiency should be selected since the self-locking feature of units with small helix angles and low efficiencies serve no useful purpose on these hoists. Ratings of the reducers are based on the rated horsepower of the motor or on full load torque, depending on the type of reducer and the operating speed, reduced by suitable allowances for friction losses. 2-20. HOIST-ELECTRICAL EQUIPMENT The electrical equipment required for the operation of a tainter gate consists of the hoisting motor, electrically operated brake and controls. The type of equipment required by Guide Speci- fication CE-1907, Electrical Equipment for Gate Hoists, is best suited for this application, par- ticularly from the standpoints of operating characteristics, resistance to corrosion, and deterioration from exposure to damp environment and safety. In general, squirrel cage induction motors of the high-torque, high-slip type, with a frame of splashproof construction, are used. However, there may be applications, such as in dry and dusty locations, where the use of a totally enclosed type of motor, having the same above-described electrical characteristics, should be considered. If a totally enclosed motor is used, small weep holes must be provided in the lowest point of the motor frame to permit draining of condensation from the inside of the motor. Motors with continuous ratings are used in order to obtain the lowest over-all cost for the electrical system. The brake is of the shoe type, spring-set with motor operated release, arranged for floor mount- ing and provided with a watertight and dusttight enclosing case. The brake specified in the above cited Guide Specification is of corrosion-resistant construction, using nonferrous parts for bearings, pins, etc. The torque rating of the brake should be a value corresponding to 150 percent of full load motor torque, when referred to the shaft on which the brake wheel is mounted. The brake is set in the factory for the torque required and means should be provided to prevent increasing the torque in the field. 9: PART CliXVil. CHAPTER 2 November 1950 The control equipment consists of the controller, limit switch and master control station. The scheme of control shown and described on Plate No. 13 should be used for all crest gate instal- . lations using individual hoists. The controller is of the combination air-circuit-breaker disconnect and reversing magnetic contactor type, with thermal over-load protection, all enclosed in water- tight and dusttight enclosing case (NEMA Type IV). Two disconnects are required to allow con- nections to be made to either of the two dam power feeders. A main line contactor is provided to give additional reliability and safety. It will be noted that the overtravel contacts of the limit switch are connected in the circuit of the main line coritactor. The limit switch is of the heavy duty type and of precision construction in order to insure reliable operation of the control system In order to insure that the construction of the case will be sufficiently tight to keep the interior dry and clean at all times, the specifications require that all limit switches be subjected to the Navy watertight test, which requires submergence. 2-21. PAINTING The painting should conform with requirements contained in Guide Specification for Oivil Works Oonstruction, OE-1409, "Painting." On flood control and multiple purpose dams where only the upstream surface of the skinplate of the gate is subject to submergence, the downstream surfaces may be treated as ferrous surfaces subject to atmospheric exposure only, with the surface preparation and first coat applied in the shop. The entire upstream surface of the skinplate. will usually be blast cleaned in the field and protected with one of the recommended submerged exposure systems. Finish painting of the electrical equipment should be in accordance with the standard practice or recommendation of the manufacturer, as prescribed in Guide Specification OE-1907. 10 LIST OF ILLUSTRATIONS Plate No. Subject 1 Load Diagrams 2 Typical Design Data 3 Typical Design 4 Alternate Design 5 Typical Anchorage, Intermediate Pier 6 Typical Anchorage, End Pier 7 Special Anchorage 8 Side Seal Heater Detail PART CXXVII, CHAPTER 2 November 1950 9 General Arrangement of Operating Machinery 10 Operating Machinery-Design "A" 11 Operating Machinery-Design "B" 12 Operating Machinery-Design "C" 13 Electrical Control System and Equipment Details U, S. GOVERNMENT PRINTING OFFICE: 1911 For sale by the Superiutendent of Documents, U. S. Government Printing Office Washington 25, D. O. Price 45 cents 11 DEPARTMENT OF ARMY Vertical 921863 51 back cover) top center bottom IN DESIGN. FOR CORROSION SHOULD BE (EXCEPT AS NOTED IN PAR.2-09 VERT. HORIZ. VERT. HORIZ. I' LENGTH OF GATE I' SPAC.ING OF BEAMS SCALES OF FEET D SCALES -rot Gote 01 C\JI LBS.)( lOS FEET CORPS OF ENGINEERS about t of gate FEET ENGINEERING MANUAL PARTCXXVII, CHAPTER 2 TYPICAL DESIGN DATA DEPARTMENT OF THE ARMY CORPS OF ENGINEERS ABOUT OF GATE A 921863 0 - 51 (Inside back cover) FIELD WELD SEE PLATE 8 FOR WITH HEATER GROOVES IN BRONZE BUSHIIIIG UNLESS NOTED. MANUAL PARr GXXVII, OHAPTER 2 TYPICAL DEPARTMENT OF CORPS OF ENGINEERS FIELD ABOUT CHANNEL ALL CONNECTIONS WELDED UNLESS NOTED NOT E: DESIIGN F!ECOMMEIIlDED ENGINEERING PART GXXVII,GHAPTER 2 ALTERNATE DESIGN NONE OFFICE, CHIEF OF ENGINEERS WASHINGTON,D,C. 921863 0 51 (Inside back cover) No. DEPARTMENT OF THE ARMY fACE , q = = = = = === p , q -----. ----.. ----. ---- -----. --' -1'-- ____ ----.. ------- ____ . ---- -. - ___ . _---'c.......:.. q. SLOT DOWNSTREAM FLANGE OF CROSS GIRDER FOR TIE BEAM FLANGES TIE BEAM- ROLLED OR BUILT -UP SE eTION ONLY 921863 0 - 51 (Inside back No.5 , p v fACE P L A ----.. APPR. CONSTR. Note "A" MASTIC APPLIED WHEREVER REQUIRED TO PROVIDE FREE LONGITUDINAL MOVE- MENT OF TIE OUTLINE Of PIER x o !II FACE OF PIER SLOT UPSTREAM FLANGE OF GIRDER FOR TIE BEAM FLANGES APPR. CONSTR. JOINT CORPS OF ENGINEERS HOLE) SYMMETRICAL t OF PIER ENGINEERING MANUAL PART CXXVII,CHAPTER 2 NOTE: ---- IF THE PIERS WILL REQUiRE EXCESSIVE REINFORCING TO WITHSTAND LATERAL THRUSTS FROM THE TRUNN- IONS,GATES WITH TRUNNION TIES OR WITH END FRAMES LESS STEEPLY INCLINED SHOULD BE USED. SCALE: NONE WASHINGTON,D.C. R TYPICAL ANCHORAGE INTERMEDIATE PIER OFFICE. CHIEF OF ENGINEERS OF THE ARMY l I' )" CONTINUOUS COLUMN FOR ERECTION <'. .1> ." TIE-BEAM, ROLLED OR SEE B-B DEPARTMENT OF THE ARMY a:: w tl. TAINTER 921863 0 - 51 (Inside back. cover) No. .. . \' ". 9 . ." APPROXIMATE CORPS OF ENGINEERS l j PIN :;::"" Note"A"-Plate No.5 I fw '// //# ,I OF SUGGESTED FOR LARGE TAINTER WITH LATERAL THRUST TAKEN BY TRUNNION TiE ACROSS GATE. ENGINEERING MANUAL PART CXXVII, CHAPTER 2 R G SPECIAL CHIEF OF ENGINEERS WORKS Corr05iof1-resi!Jtlng clod plot!}. Cleoronce for seo/ 2" 1: l seolplote E- clod plote 20'J{, sing/II 921863 0 ~ (Inside back cover) No.8 CORPS ENGINEERS GATE SEAL HEATER WIRING DIAGRAM GATE SEAL HEATER INSTALLATION DETAILS E-E GATE SEAL HEATER ELEMENT otherwise shown ond 511011 be tested with sholl be tested before ""t., "hm,np/ ENGINEERING MANUAL PART CXX VII TAINTER SIDE SEAL HEATER DETAIL ELECTRICAL a STRUCTURAL PLAN UNDER ROADWAY 921863 back CORPS OF ENGINEERS ENGINEERING MANUAL PART CXXVII CHAPTER 2 GENERAL ARRANGEMENT OF OPERATING MACHINERY induction type, with BRAKE - Shoe type, wiih mo1or operated release, and ",atertigl1!and du.f-fight constructiOil. C<lpccity of holsl- 160,000 pounds OF ENGINEERING MANUAL PART CXXVII CHAPTER 2 NGTON D.C. CIVIL ENGINEERING DIVISION FILE NO. EM 127- 2 - 10 Walkway to next pIer. Pier ECHANICAL SPEED REDUCER- Single reduction, worm gear type. SPEED REDUCER- Herringbone ,triple reduction DE EL FLEXIBLE COUPLlNG- locking hold in engaged or COUPLI NG- Ri g id flange ty pe. FLEXIBLE COUPLING-Single engagement,flooting shaft type. GATE POSITION INDICATOR COUNTER- Non reset,Veeder-Root or equal STATION - Push button dust-tight ",,,,,,t,,,,,,,ti(ln DISCONNECTING PLUG- CORPS OF Chain guard CURRENT p 8 Capacity of hOist-IOO,OOO pounds ENGINEERING MANUAL PART CXXVII, CHAPTER 2 SCALE: WASHINGTON D.C. R G OPERATING MACHINERY DESIGN B CIVIL WORKS ENGINEERING DIVISION FILE NO. EM 127-2 SEPTEMBER 1950 PLATE NO. II THE ARMY (Inside cover) ARRANGEMENT ELEMENTS T ronsformer PCL Power conloclor, /ower PlJsh button normally open PCM Power contactor, main and receptacle Thermal ollerload relay Blow -aut coil ACB Air CirclJif CORPS OF ENGINEERS DETAIL-A DETAIL- B
Microstructure and Cavitation Erosion Behavior of WC-Co-Cr Coating On 1Cr18Ni9Ti Stainless Steel by HVOF Thermal Spraying 2012 International Journal of Refractory Metals