Erection experiences, unusual problems, and their solutions encountered in the installation of majorheavy hydroelectric equipmentby Donald C Beckman

A THESIS Submitted to the Graduate Faculty in partial fulfillment of the requirements for theprofessional degree in Mechanical Engineering at Montana State CollegeMontana State University© Copyright by Donald C Beckman (1955)

Abstract:The installation of a third generating unit and all associated equipment in the Fort Peck Power Plant atFort Peck Dam, Fort Peck, Montana, presented a number of unusual erection problems and necessitatedimmediate and correct solutions to insure the proper installation of the heavy hydroelectric equipment,A satisfactory Construction Progress Schedule, taking into consideration all possible reasons for delay,had first to be prepared to insure that the work was completed in the allotted time. When the actualerection of the penstock was started, difficulties were encountered in obtaining "tight" rivets. It wasnecessary also to analyze the penstock stresses to determine the best joint for the closure section.

The placement of the immense 82 ton butterfly valve was accomplished after considerable planning.Turbine erection problems included the proper alignment of the curb ring, the speed ring and the shaft.

The assembly of the rotor laminations, the installation of the keys, the assembly of the thrust collarassembly on the drive shaft, and the assembly of the rotor on the thrust collar all present problems thathad to be satisfactorily solved during the process of the assembly and erection of the generator.

When the work was completed an overspeed and turbine efficiency test was performed. Thesatisfactory results obtained indicate that the erection problems encountered were solved satisfactorily. 

ERECTION EXPERIENCES, UNUSUAL PROBLEMS, AND TTTETR SOLUTIONS ENCOUNTERED IN TIE INSTALLATION OF MAJOR

HEAVY HYDROELECTRIC EQUIPMENT

%y

DONALD C . BECKMAN

A THESIS

Submitted to the Graduate Faculty-

in

p a r t i a l fu lf illm e n t o f the requirements

fo r the p ro fessional degree in

Mechanical Engineering

a t

Montana S ta te College

Approved*

i j - P r v L u i i J L i!'.Ti --j~— ‘"U'1 n ' Wrr1

Bozeman, Montana May, 1955

IAJBLS 07 c o m m

A b s t r a c t .................................. . . . . . . . . . 3

I a t r o f ln c t lo a ................................................................... 4

The F o rm a tio n o f A C o n s t r u c t io n P r o g r e i e S c h e d u l e . .................... 6

P e n a te o k B r e e t lo n P r o h le e s ............................................................................. 9

S r s c t l e a o f t h e 16- F o o t D ia m e te r B u t t e r f l y T a l r e .........................23

S r e e t l e a L a y o u t P r o h le a s ...................................... Sg

G e n e ra to r S r e e t l o a P r e h le a e ...................................................................................3g

T e s t in g o f The C e r o le te d Work, O v erep eed andS f f l e l e n e y T e s t s . . . . . ........................................... 4$

L i t e r a t u r e C i t e d an d C o n s u lte d .................................. ....

11 * r r ?

ABSTRACT

The in s ta l la t io n o f a th ird generating u n it and a l l associated equipment in the F o rt Peck Power P lan t a t F o rt Peck Dam, F o rt Peck, Montana, presented a number of unusual e rec tio n problems and necessitated immediate and c o rrec t so lu tions to insure the proper in s ta l la t io n o f the heavy hydroelectric equipment,

A sa tis fa c to ry C onstruction Progress Schedule, taking in to con­s id e ra tio n a l l possib le reasons fo r delay , had f i r s t to be prepared to insure th a t the work was completed in the a llo t te d tim e. When the ac tual e rec tio n of the penstock was s ta r te d , d i f f ic u l t ie s were encounter­ed in obtaining " tig h t" r iv e ts . I t was necessary also to analyse the penstocK s tre sse s to determine the b e s t jo in t fo r the closure sec tion .

The placement o f the immense 82 ton b u tte r f ly valve was accomplished a f te r considerable planning. Turbine e rec tio n problems included the proper alignment of the curb rin g , the speed ring arxi the sh a f t .

The assembly of the ro to r lam inations, the in s ta l la t io n of the keys, the assembly o f the th ru s t c o lla r assembly on the drive sh a f t, and the assembly o f the ro to r on the th ru s t c o lla r a l l p resen t problems th a t had to be s a t is fa c to r i ly solved during the process o f the assembly and erec­tio n of the generator.

When the work was completed an overspeed and tu rb ine e ffic iency t e s t was performed. The sa tis fa c to ry re s u lts obtained in d ica te th a t tho erec­tio n problems encountered were solved s a t is f a c to r i ly .

I r a o IXJCTIOB

The p ro b le m s p r e s e n t e d I n t h i s t r e a t i s e a r e uzm eual to th o s e w h ich

n o rm a l ly o c c u r I n t h e e r e c t i o n o f h e a v y h y d r o e l e c t r i c e q u ip m e n t, and th e y

a r e a l s o d i s t i n c t i v e b e c a u se t h e i r s o lu t i o n s w ere p r i m a r i l y d e p e n d e n t upon

th e s u c c e s s f u l a p p l i c a t i o n o f sound e n g in e e r in g know ledge an d p r a c t i c e s .

A l l o f th e p ro b le m s d i s c u s s e d i n t h i s t h e s i s a c t u a l l y o c c u r r e d d u r in g th e

i n s t a l l a t i o n o f a 5 0 ,0 0 0 h o rse p o w e r F r a n c i s ty p e t u r b i n e , a I 6 - f o o t d iam e­

t e r b u t t e r f l y v a lv e , a n d a 3 5 ,0 0 0 k i l o w a t t c a p a c i ty g e n e r a to r , w i th th e

a s s o c i a t e d e q u ip m e n t, i n th e F o r t P e c k Pow er P l a n t . The w r i t e r was i n t i m a t e ­

l y a s s o c i a t e d i n th e p ro b le m s an d t h e i r s o l u t i o n s .

The F o r t P e c k P ow er P l a n t i s l o c a t e d n e a r th e r i g h t a b u tm e n t o f th e F o r t

P eek Dam. T h is dam i s t h e l a r g e s t h y d r a u l i c e a r t h f i l l dam i n e x is t e n c e i n

t h e w o r ld to d a y , a n d may a lw a y s be s o , s in c e th e a d v e n t o f im proved h e a v y

d u ty e a r t h m oving eq u ip m e n t m akes h y d r a u l i c p la c e m e n t m ethods u n e c o n o m ic a l.

The F o r t P e d c Dam i s l o c a t e d a c r o s s t h e M is s o u r i B iv e r a t B lv e r M ile ISB g .J ,

w h ich i s 1 8 6 8 .7 m i le s above i t s p o i n t o f c o n f lu e n c e w i th t h e M is s i s s i p p i

B lv e r , a c c o r d in g to t h e 1941 a d j u s t e d r i v e r m ile a g e e s t a b l i s h e d by th e 0 . S.

C o a s t a n d C eoded lo S u rv e y . The r e s u l t a n t im poundm ent c r e a t e d by t h i s dam

h a s a s h o r e l in e o f a p p ro x im a te ly 1600 m i l e s , i s 189 m i le s lo n g , h a s a maximum

c a p a c i t y o f 1 9 ,4 1 2 ,0 0 0 a c r e - f e e t o f w a te r when f i l l e d to th e e l e v a t i o n o f

2250 mean s e a l e v e l , and d e v e lo p s a t o t a l h e a d f o r pow er g e n e r a t i o n o f 210

f e e t a t t h i s e l e v a t i o n . A s i s com m only know n, th e pow er d ev e lo p m en t o f t h i s

p r o j e c t was a c c o m p lis h e d w i th F e d e r a l f u n d s , a u th o r i z e d b y A c t o f C o n g ress

d a te d 18 May 1938 , w i th t h e C orps o f E n g in e e r# d e s ig n a te d a s th e c o n s t r u c t i n g

- 5 -

ag en c jr. W hile th e pow er d ev e lo p m en t o f t h i s p r o j e c t I e o f m a jo r Im p o r ta n c e ,

o t h e r m u l t ip l e p u r p o s e s o f t h i s p r o j e c t a r e c o n c e rn e d w ith f lo o d c o n t r o l ,

n a v ig a t io n , i r r i g a t i o n an d r e c r e a t i o n f e a t u r e s .

Tha w o r t o f i n s t a l l i n g th e h y d r o e l e c t r i c eq u ip m en t m en tio n e d above

b eg an i n Ju n e o f 1 9 5 0 , by m eans o f a c o n s t r u c t i o n c o n t r a c t i s s u e d by th e

D e p a rtm en t o f th e Army, Oozpe o f E n g in e e r s . The s u c c e s s f u l b id d e r to th e

c o n t r a c t was th e E . V. L ane Company, S a g in e e r s a n d C o n t r a c to r s , o f P a lo A l to ,

C a l i f o r n i a .

THE 3P05R&TI05 OF A OOHSTRUCTlON PBOflRESS SCHEDULE

S in c e th e te rm s o f th e c o n t r a c t r e q u i r e d a l l o f th e work to be com­

p l e t e d by 15 Decem ber 1 9 5 2 , and b e c a u se t h a t f i r m d a te h a d been e s t a b l i s h e d

w i th th e pow er m a rk e t in g a g e n cy a e th e d a te upon w hich th e p r o d u c t io n o f

p o w er from t h e n e w ly i n s t a l l e d u n i t w ould be a v a i l a b l e , i t was n e c e s s a r y

t h a t a c a r e f u l l y p r e p a r e d i n s t a l l a t i o n s c h e d u le be e s t a b l i s h e d . The p r e p -

r-r a t io n o f t h i s s c h e d u le , w h i le i n o u tw a rd a p p e a ra n c e s was s im p le , was f u l l

o f t ro u b le so m e p ro b le m s . U nex p ec ted work c o n d i t io n s an d e r e c t i o n d i f f i ­

c u l t i e s w ith r e s u l t a n t d e la y s r e q u i r e d c o n s id e r a t io n i n th e f o r m u la t io n o f

an a c c u r a te c o n s t r u c t i o n s c h e d u le . The p ro b le m was a p p ro a c h e d by c o n s id ­

e r i n g a l l o f th e s a l i e n t f e a t u r e s o f th e w ork , an d th o s e m e n tio n e d a b o v e ,

an d a l lo w in g f o r r e a s o n a b le c o n t in g e n c ie s , th e n p l o t t i n g th e o r d e r o f work

on a g ra p h . The g r e a t e s t d i f f i c u l t y e n c o u n te re d was th e b e w i ld e r in g num ber

o f n e b u lo u s v a r i a b l e s in t r o d u c e d when th e c o n s id e r a t io n s s t a t e d above w ere

t a b u l a t e d , an d th e e s t im a te d w o rk in g t im e s w ere com puted f o r e a ch ite m o f

th e c o n t r a c t . The se q u en c e o f th e work was p e rh a p s th e e a s i e s t d e te rm in a ­

t i o n to make in th e p r e p a r a t i o n o f th e s c h e d u le . The c o n s o l id a te d r e s u l t s

o f th e e s t i m a t e s a p p e a r a t P l a t e I , t i t l e d CONSTRUCTION PROGRESS CHART. The

e s t im a te d s c h e d u le d p r o g r e s s o f th e e n t i r e am ount o f th e work u n d e r th e

c o n t r a c t i s p l o t t e d o n th e c h a r t in a s o l i d h ea v y l i n e , en d th e a c t u a l p r o g ­

r e s s o f th e work i s p l o t t e d on th e c h a r t w i th a h e a v y b ro k e n l i n e . I t ca n

Se se e n from th e c h a r t t h a t th e c o n t r a c t was s u c c e s s f u l l y c o m p le te d w i th in

t h e s p e c i f i e d t im e . I t i e c o n s id e r e d t h a t t h i s s u c c e s s was due to a c a r e f u l ­

l y p r e p a r e d s c h e d u le , and th e d i l i g e n t e f f o r t s o f th e c o n t r a c t o r an d th e

CONSTRUCTION PROGRESS CHART! . .N H - T lC * - IW T 4 V L I W T h iiid O tW H A T W S UWT AW ) A A e u H T f e e e o n

PL

AT

E

I

e i to e r v le ia g eng ineer to a d h e re to th e s c h e d u le . I t may a l s o he s t a t e d

t h a t a m inIaum o f o v e r t im e was w orked on t h i s c o n t r a c t , r e s u l t i n g i n

s a v in g s to th e c o n t r a c t o r . I t i s b e l i e v e d t h a t a c h a r t o f t h i s n a tu r e

s h o u ld be p r e p a r e d f o r e v e ry c o n t r a c t .

- 9 -

p m s t o c k k b e c tio h pb o h leh s

The n e x t p ro b le m w hich was o f m a jo r lo n o r ta a c e o c c u r r e d d u r in g th e

e r e c t i o n o f th e p e n s to c k , w h ich In t h i s c a s e a p p e a r s a s i te m num bered 9

on t h e C o n s t r u c t io n P r o g r e s s S c h e d u le . The work ite m d e s ig n a te d a s

• P e n s to c k en d R is e r* In v o lv e d th e i n s t a l l a t i o n o f a p p ro x im a te ly 7 9 0 ,0 0 0

p o u n d s o f shop f a b r i c a t e d s t e e l p l a t e . The p e n s to c k c o n s i s t e d o f 7 /g

in c h t h i c k c a rb o n s t e e l p l a t e s r o l l e d so a s to f o r * a 14 f o o t d ia m e te r

t u b e . T h ese p l a t e s w ere jo in e d by a s in g l e r i v e t e d b u t t j o i n t w hich

fo rm ed th e c i r c u m f e r e n t i a l j o i n t s . E ach row o f th e I in c h d ia m e te r b u t to n

h e a d r i v e t s fo rm in g t h i s c i r c u m f e r e n t i a l j o i n t was sp a c e d 2 - 5 /8 in c h e s

a p a r t an d p i t c h e d 3 ~ 3 A in c h e s . T h e se h o t d r iv e n r i v e t s w ere i n s t a l l e d

In l - l / l 6 in c h d ia m e te r ream ed h o le s in th e s in g l e 5/8 in c h t h i c k ex­

t e r i o r b u t t s t r a p a n d th e 7/8 in c h t h i c k p e n s to c k p l a t e . The l o n g i t u d i ­

n a l j o i n t s i n th e p l a t e s w ere made up o f d o u b le r i v e t e d b u t t j o i n t s

e m p lo y in g I in c h d ia m e te r r i v e t s d r iv e n i n l - l / l 6 in c h d ia m e te r ream ed

h o l e s p i t c h e d > 3 / 4 in c h e s in th e l l / l 6 in c h t h i c k i n t e r i o r s p l i c e p l a t e ,

th e 7/8 in c h t h i c k p e n s to c k p l a t e , and th e 5/8 in c h t h i c k e x t e r i o r s p l i c e

p l a t e . The i n t e r i o r s p l i c e p l a t e was f a b r i c a t e d l a r g e enough to accom­

m odate an e x t r a row o f I in c h d ia m e te r r i v e t s p i t c h e d 9 in c h e s . L ig h t

c a u lk w e ld s w ere u t i l i z e d i n m aking th e j o i n t s w a t e r t i g h t w here th e lo n ­

g i t u d i n a l p l a t e s m et th e c i r c u m f e r e n t i a l j o i n t s .

The r i s e r g r o t# c o n s i s t e d o f a " te c * t h a t was r i v e t e d to th e p e n s to c k ,

a n d a 11 f o o t d ia m e te r tu b e w hich c o n n e c te d th e t e e to th e 50 f o o t d ia m e te r

s u rg e ta n k . The t e e was f a b r i c a t e d from w elded and r o l l e d s t e e l p l a t e , th e

-1 0 -

c o m l e t e d a s se m b ly o f w hich w eighed a p D r o x la a te ly S5 t o n s . T h is t e e

w as fo rm ed on th e o r d e r o f s s a d d le , h s v in g an o u t l e t a t th e to p o f

th e t e e * l c h was c o n n e c te d by r i v e t s to th e 11 f o o t d ia m e te r s t e e l p l a t e

tu b e c o n n e c t in g th e p e n s to c k to t h e s u rg e ta n k bo w le . The p l a t e s and

j o i n t s c o n n e c t in g th e r i s e r s e c t i o n s t o g e t h e r w ere o f th e s-m e tyr>e a s

th o s e In th e p e n s to c k , t ' l t h l n th e 11 f o o t d ia m e te r o p e n in g w hich fo rm ed

th e to p o f th e t e e o r r i s e r , was a w e lded s t e e l g r Idw ork d e s ig n e d to a c t

a s a n o r i f i c e and i n some p a r t r e s t r i c t t h e s u rg e s o f w a te r t h a t w ould

r e s u l t w henever th e t u r b i n e w ic k e t g a t e s w ere c lo s e d r a p i d l y . T h is s t e e l

g r id w o i t c o n s i s t e d o f a w eldm ent o f h - l / 2 In c h t h i c k p l a t e s . The g r id w o rk

was w e lded to th e body o f th e t e e by f u l l s t r e n g th w e ld s . The body o f th e

t e e was o f 2 - 3 /4 In c h t h i c k r o l l e d s t e e l p l a t e , an d was p ro v id e d w i th f u l l

l e n g t h m ach ined h e a r i n g s u r f a c e s f o r s t e e l co lum ns d e s ig n e d to s u p p o r t th e

e n t i r e w e ig h t o f t h e r i s e r , t e e , a n d th e p o r t i o n o f th e p e n s to c k lo a d

fchioh was a p p l i c a b l e . P l a t e I I l a a p h o to g ra p h o f t h i s m a ss iv e member,

and shows a to p v iew o f th e t e e a s i t was b e in g moved in to p o s i t i o n . The

r i s e r was a p p ro x im a te ly two w eeks l a t e In d e l i v e r y to th e p r o j e c t due to

th e f a c t t h a t d i f f i c u l t y was e x p e r ie n c e d l a f a b r i c a t i n g th e h ea v y member.

T h e re was b u t one s t e e l f a b r i c a t o r in th e w e s t c o a s t a r e a who h a d r o l l s

s u f f i c i e n t l y l a r g e enough to r o l l th e h e a v y 2 - 3 /4 In c h t h i c k s t e e l p l a t e

bo d y , n e c e s s i t a t i n g s h ip p in g th e t e e to th e f a b r i c a t o r and r e t u r n i n g I t

when d o n e . The e x tr e m e ly h e a v y w e ld s employed. In j o i n i n g th e 4-1/ 2 in c h

g r id w o rk c a u se d d i s t o r t i o n an d in d u c e d i n t e r n a l s t r e s s e s o f g r e a t

-1 1 -

PLATE I I - 25 TON TEE

m a g n itu d e s . T h ie c o n d i t io n r e q u i r e d a s p e c i a l h a c k e te p p in g w e ld in g

p r o c e d u r e 1 to he f o l lo w e d i n w e ld in g , an d f i n a l s t r e s s r e l i e v i n g o f t h e

e n t i r e w eldm ent in an a n n e a l in g f u r n a c e .

Ifoon p e r f o r m in g th e w ork o f r i v e t i n g th e p la te w o rk an d a sse m b le d

s t r u c t u r e s t o g e t h e r many lo o s e r i v e t s w ere fo u n d d u r in g th e f i r s t r i v e t i n g

o p e r a t i o n s . The r i v e t s w ere t e s t e d f o r l o o s e n e s s i n th e f o l lo w in g m anner:

a . F i r s t a l i g h t hammer blow was s t r u c k th e s id e o f th e c o o le d

b u t to n h e a d o f th e r i v e t to be t e s t e d .

b . n e x t , a l /2 in c h d ia m e te r s t e e l b a l l was h e ld a g a i n s t th e p l a t e

a n d th e b u t to n h e a d o f th e c o ld r i v e t , and a h e a v y hammer blow s t r u c k th e

r i v e t h e a d from th e s id e o p p o s i te th e s t e e l b a l l an d o p p o s i t e th e d i r e c t i o n

p r e v i o u s ly s t r u c k .

I f t h e r e l a s l i g h t lo o s e n e s s in th e r i v e t , th e s t e e l b a l l w i l l n o t

re s p o n d t o t h e hammer b low ; c o n v e r s e ly , i f th e r i v e t i s t i ^ x t , th e s t e e l

b a l l w i l l reb o u n d from th e r i v e t and th e p l a t e . F ig u re I i s a s k e tc h o f

t h e a p p l i c a t i o n o f t h i s t e s t i n g m ethod .

I t was fo u n d t h a t t h e r e w ere many l o o s e r i v e t s when t h i s t e s t m ethod

w as a p p l i e d , and i t becam e n e c e s s a r y to d e te rm in e th e t r o u b l e b e fo re p ro ­

c e e d in g .

The r i v e t s i n i t i a l l y w ere b e in g h e a te d to th e p r o p e r d r iv i n g tem p ers ,

a t u r e b y m eans o f a g a s f i r e d f u r n a c e . Tfoon a n a l y s i s , i t w as d is c o v e r e d

I . The L in c o ln E l e c t r i c Company, 1950 N in th " U t i o n , PROCEDURE HuV 300K OF ABC WSLDING, DESlOS ASD PBACTICl, P . 306, The L in c o ln E l e c t r i c Comoany, C le v e la n d I , O h io .

- 1 3 -

Stee l ballbrazed on 1 / 8 rod —-------

Hammer b low

Hot driven rivet

Penstoc k pl ate Spl ice plate

Not drawn to scale

RITST TESTING METHOD

4 FI GURE I

- I i t -

t h a t th e s u lp h u r and o t h e r i m p u r i t i e s I n th e g a s w ere c a u s in g a g l a s s

to f o i e on th e s u r f a c e o f t h e h e a te d r i v e t , an d when d r iv e n , th e g la z e

c ru m b led i n to a h a r d h u t p o ro u s ty p e s c a l e . W hile th e r i v e t was c o o l in g ,

t h i s s c a le a llo w e d th e c o n t r a c t i o n o f th e r i v e t to he ta k e n up i n c ru s h ­

in g th e s c a l e , when f i n a l l y th e r i v e t was c o ld , i t was l o o s e , an d th e

p l a t e s th ro u g h w h ich i t h a d b een d r iv e n w ere n o t g r ip p e d . The e l i m i n a t i o n

o f t h e g se f i r e d r i v e t h e a t e r was th e o b v io u s s o lu t i o n to t h i s t ro u b le so m e

p ro b le m . When th e r i v e t s w ere h e a te d w ith a coke f i r e d o v e n , th e d i f f i ­

c u l t y was e n t i r e l y e l i m i n a te d , v e r i f y i n g t h a t th e a n a l y s i s o f th e t r o u b l e

was c o r r e c t .

D u rin g th e p r o c e s s o f I n s t a l l i n g th e p e n s to c k and r i s e r , th e q u e s t io n

a r o s e a s t o w h ich o f t h e many- c i r c u m f e r e n t i a l j o i n t s s h o u ld be s e l e c t e d

f o r th e c lo s u r e s e c t i o n . As shown i n F ig u r e 2 , th e p e n s to c k an d r i s e r

b o th w ere r e s t r a i n e d a t e a c h en d . I t w as i n i t i a l l y c o n s id e r e d t h a t a

l a r g e te m p e ra tu re d i f f e r e n t i a l o c c u r r in g a f t e r th e work o f i n s t a l l i n g th e

p e n s to c k and r i s e r w as c o m p le te , w ould p r o b a b ly h av e u n d e s i r a b le e f f e c t s

on th e c o m p le te d a s se m b ly .

S in c e th e r e w ere no e x p a n s io n j o i n t s i n e i t h e r th e p e n s to c k o r r i s e r

a s se m b ly t o p r o v id e f o r e x p a n s io n o r c o n t r a c t i o n , i t was n e c e s s a r y to

a n a ly s e th e c o n d i t io n s t h a t w ould a f f e c t th e f i n a l c lo s u r e . The p l a n s

and s p e c i f i c a t i o n s w ere n o t c o m p le te i n t h i s r e s p e c t , t h e r e f o r e th e

a n a l y s i s o f w here to make th e c lo s u r e j o i n t s , and u n d e r w hat c o n d i t io n s ,

was one o f t h e d e c i s i o n s t h a t h a d to b e made i n th e f i e l d d u r in g c o n s tr u c ­

t i o n . The c a l c u l a t i o n o f th e s t r e s s e s due to t h e te m p e ra tu re v a r i a t i o n s

ia the penstock, and r ise r aeetloas were simple applications o f engi­

neering practice and led to the determination o f the closure section ,

and the conditions under which I t was deemed safe to make the closure.

-1 5 -

t h e a n a l y s i s a p p e a r h e lo w I

G e n e ra l D e s ig n D a ta

n o rm al w a te r te m p e ra tu re r a n g e ................................ U5 to 55 d e g re e s 7 .

A m hient te m p e ra tu re r a n g e . . . ..................................... 40 to 85 d e g re e s I .

D e s ig n maximum h e a d e x e r t e d on p e n s to c k . ............................ 210 f e e t .

Maximum r e c o rd e d s u rg e p r e s s u r e ................................................... 115 p g i .

C o e f f i c ie n t o f e x p a n s io n . ............... ................................... ................ OOOOO671

Maxlsram a l lo w a b le w o rk in g s t r e s s i n t e n s i o n , c o m p re ss io n and

te n d in g .................................................................... .................. 1 5 ,0 0 0 p e l .

Maximum a l lo w a b le w o rk in g s t r e s s i n s h e a r in g .......... 1 2 ,0 0 0 p e l .

Maximum a l lo w a b le w o rk in g s t r e s s i n b e a r in g ............. 2 0 ,0 0 0 p e l .

B a s ic O a le u la t lo n s

A re a o f p e n s to c k s e c t i o n ........................................................ .. ( lU ) 2( .7 8 5 )

w h ich e q u a ls 154 S quare f e e t .

W eight o f w a te r p e r f o o t o f p e n s to c k ................................ (6 2 .4 )(l5 4 )

w hich e q u a ls 9,610 p o u n d s .

W eight o f p e n s to c k p l a t e p e r l i n e a l f o o t o f p e n s to c k n o t in ­

c lu d in g b t t t t s t r a p e and s p l i c e p l a t e s ............... ( 1 4 f t . ) ( 3 . l 4 )

( 3 5 .7 l b s . p e r s q u a re f o o t ) e q u a ls 1,570 p o u n d s .

I . A m erican I n s t i t u t e o f S t e e l C o n s t r u c t io n , 1941 ST13L GONSTRUCTIOI, P . 338 , A m erican I n s t i t u t e o f S t e e l C o n s t r u c t io n , Hew Y ork , H. I .

-I*.

#&*le O alculatloni(Oont1A)

A ron o f r i s e r s e c t i o n ...................... ................ (1 1 f t . d t a a . ) 8( .7 B 5 )

e q u a ls 95 s q u a re f e e t .

W eigh t o f w a te r p e r f o o t e f r i s e r ....................................... ( l l ) ( 62. h )

e q u a ls 686 p o u n d s .

W eigh t e f r i s e r p l a t e p e r l i n e a l f o o t o f r i s e r , n o t in c lu d in g

t a t t s t r a p s a n d s p l i c e p l a t e s .............................. (11 f t . ) ( 3. l 4 )

( 35.7 I t s . p e r s q u a re f o o t ) e q u a ls 1*233 p o u n d s .

A s s u a ia g t h a t th e w o r s t p o s s i b l e c o n d i t io n w ould p r e v a i l , th e s t r e s s -

e s i n t e n s io n r e s u l t a n t fro m th e c o n t r a c t i o n o f t h e p e n s to c k a n d r i s e r

a r e c a l c u l a t e d f o r t h e c o n d i t io n o c c u r r in g when th e a s su m p tio n I e

t h a t t h e c lo s u r e s e c t i o n w ould he made when th e a m b ie n t te m p e ra tu re wae

85 d e g re e s P a r e n h e i t a n d th e p e n s to c k wae d e w a te re d , fo l lo w e d by f i l l i n g

t h e p e n s to c k an d r i s e r w i th U5 d e g re e P a r e n h e i t w a te r u n d e r th e f u l l

d e s ig n h e a d e f 210 f e e t an d a s u rg e o f 115 p s i o c c u r r e d . She I n c r e a s e

i n u n i t t e n s i o n s ! s t r e s s f o r th e abo v e d e s c r ib e d c o n d i t io n fo llo w s*

^ te n s io n * c^ i t e lo n g a t io n * M odulus o f E l a s t i c i t y . I n t h i s e a s e ,

t h e u n i t e lo n g a t io n i s 0 . OOOOO67 in c h e s p e r In c h m u l t i p l i e d b y UO d e g re e s

P . an d e q u a ls 0 .0 0 0 2 6 8 in c h p e r in c h . The M odulus o f e l a s t i c i t y f o r th e

S t e e l p l a t e I e 2 9 ,0 0 0 ,0 0 0 ^ . T h e r e f o r e i t f o l lo w # t h a t th e u n i t t e n s lo n -

a l s t r e s s d e v e lo p e d i n th e p l a t e s a s a r e s u l t e f th e te m p e ra tu re change

w ou ld b e 7,772 p o u n d s p e r s q u a re i n c h , l a b o th t h e r i s e r a n d p e n s to c k

TI A m erican I n s t i t u t e o f S t e e l C o n s t r u c t io n , 1941 , S T m (X)NSTHaCTIOH,P . 3 3 7 . A m erican I n s t i t u t e e f S t e e l C o n s t r u c t io n , le w T o rk 1 I . f .

17-

p la tee .

In addition to the etreeese developed due to the temperature

d iffe r e n t ia l , the longitud inal s tress in the p la te s from the hydro­

s ta t ic pressure was e&leul&ted, using the basic relationsh ip . S tress =

P/h , and appear* below;

S1 r 5,520 p e l.

In addition to the induced temperature s tr e sse s , and those devel­

oped by tbs hydrostatic pressure from the maximum recorded surge pres­

sure o f 119 p e l, the approximate s tr e s se s due to the uniform loading

between penstock supports was calcu lated. I f the penstock were analysed

throughout I te length , a# shown in Figure Z o f th is th e s is , the dia­

grammatical leading e f the penstock, using beam analogy would appear

as shown in Figurs 3* the complete an alysis e f a member o f th is type

was considered d i f f ic u l t due to the in a b ility te solve fo r a l l the re­

a c tio n s , a condition created by the unknown e ffe c t o f the induced tem­

perature s tr e sse s ca the r ise r group which was connected to the penstock,

to f a c i l i t a t e the a n a ly sis , the s tress in the penstock due to the water

leading was calcu lated for the longest restrained span, om itting one

intermediate column support which gave calculated value# higher than

the actual streee , but fo r th is purpose was considered as an added sa fety

fa c to r . The an a lysis e f the penstock section using the above considera­

tio n i s shown in Figure 4 .

The maximum moment equals wl8/lZ fo r th is condition, where w i s the

%

—1.8—

Surge tank

Riser

Concrete imbedment for scroll case

Concrete wallButterf Iy valve x

Scrol I k case x r /ex ten-

/ sionCol lar

J e eFlow

!5 8 8

S uppert pad

Supportcolumn

ELEVATION OF PENSTOCK - RISER LAYOUT

No s c a l e

FIGURE 2

% .,<'

T e n s i o n in r i se r

' - r

S K E T C H OF P E N S T O C K - R I S ER L A Y O U T

FIGURE 3

- 2 0 -

I nterme d iote support OmittedxTee and riser group

SHEAR DIAGRAM

MOMENT DIAG RAM Maximum moment = w I 2

FIGURE

u n i t lo a d In p o u n d s p e r l i n e a l f o o t , an d I I e th e d i s t a n c e be tw een

s w ro o r te i n in c h e s , w h ich i n t h i s c a s e 1» c a l c u l a t e d a s f o l lo w s :

M * 6 6 ,7 0 0 ,0 0 0 I h s . i n .

The moment o f i n e r t i a s h o u t th e c e n t r a l a x i s o f th e p e n s to c k i s

fo u n d from th e r e l a t i o n s h i p I 0 • 0 .0 4 9 0 8 7 Cdl t - d ^ ) I , and i s com puted

b e lo w :

The u n i t s t r e s s i n b e n d in g ca n th e n be d e te rm in e d from th e r e l a t l o n -

th e d i s t a n c e i n In c h e s fro m th e c e n t e r o f t h e s e c t i o n to th e e x trem e o u t e r

f i b e r , and I i s th e moment o f i n e r t i a a b o u t th e c e n t r a l a x i s o f th e member.

By a d d in g th e in d u c e d te m p e ra tu re s t r e s s e s , th e h yd ro s t a t i c s t r e s s e s

a n d th e b e n d in g s t r e s s e s , a maximum u n i t s t r e s s o f 1 7 ,6 9 2 i s o b ta in e d .

T h is v a lu e I s s l i g h t l y i n e x c e s s o f t h e maximum a l lo w a b le w o rk in g s t r e s s

f o r t e n s i o n , and I t w as t h e r e f o r e c o n s id e r e d n e c e s s a r y to re d u c e th e

s t r e s s e s c r e a te d b y th e te m p e ra tu re d i f f e r e n t i a l a s much a s p o s s ib l e when

th e f i n a l c lo s u r e s e c t i o n w as mads i n b o th th e p e n s to c k an d r i s e r . The

work w as s c h e d u le d i n th e w i n t e r , a n d th e c o n t r a c t o r w as i n s t r u c t e d t h a t

t h e maximum te m p e ra tu re t h a t th e c o n n e c t io n c o u ld be made was 70 d e g re e s

F a r e n h e l t , a l th o u g h i n a c t u a l i t y th e a c t u a l te m p e ra tu re o f th e s t e e l was

I 6 s 0.049087 J 69. 25)4 - ( 16S ) 4 J

I 0 • 1 ,6 5 8 ,0 0 0 I n 4

s h ip S 3 % IjfLJB , w here M i s th e b e n d in g mement i n pound in c h e s , c i s

- 2 2 -

th e tarn a* t h r t o f t h e w a te r tA en th e c lo s u r e was m ade. The a n a ly s i s

I n d ic a te d t h a t an y s e c t i o n o f th e r i s e r w ould be s a t i s f a c t o r y f o r a

c lo s u r e s e c t i o n , an d th e j o i n t n e a r e s t th e s u rg e ta n k w as s e l e c t e d m e re ly

b e c a u s e o f I t s c o n v e n ie n c e . The a n a l y s i s I n d ic a te d t h a t th e b e s t j o i n t

f o r th e c lo s u r e s e c t i o n o f th e p e n s to c k w ould be a j o i n t n e a r e s t one o f

th e f i x e d e u o p o r te , a n d I n t h i s c a s e th e j o i n t n e a r e s t th e b u t t e r f l y

v a lv e was s e l e c t e d b e c a u s e o f i t s a c e e s e a b i l i t y . S in c e t h e n o n s to c k

and r i s e r w ere d e s ig n e d w ith e q u iv a l e n t u n i t s t r e s s e s in b e n d in g , com pres­

s io n , b e a r in g and s h e a r , c o n s i s t e n t w i th t h e a l lo w a b le s t r e s s e s s t a t e d

p r e v i o u s ly , i t i s n o t c o n s id e r e d n e c e s s a r y to p r e s e n t them i n t h i s p a p e r ,

a s i t i s f e l t t h a t to do so w ould be u n n e c e s s a r i ly r e p e t i t i o u s .

A f t e r th e c lo s u r e s e c t i o n s w ere made an d th e n o n s to c k and r i s e r

w a te re d u p , i t was fo u n d t h a t o n ly a few r i v e t s r e q u i r e d t o o l c a u lk in g

t o make them w a te r t i g h t , w h ich i n d i c a t e d t h a t th e c lo s u r e h a d been made

u n d e r c o n d i t io n s w h ich h a d n o t o v e r ly s t r e s s e d th e j o i n t s , o r t h e r e w ould

h a v e b een many r i v e t s t h a t w ould h av e le a k e d due to t h e i r b e in g d i s t u r b e d .

The i e p r o n e r c lo s u r e p ro c e d u re o r s e l e c t i o n o f c lo s u r e te m p e ra tu re s c o u ld

h av e r e s u l t e d i n c o n s id e r a b le d e la y and l o s s o f t im e i n r e p a i r i n g l e a k s

an d r e p l a c i n g r i v e t s .

MlOfICW OF IM 16-jfiBGf DIAKm a

BUTTEEFLY YALTS

Aa in te r sBtiag problem occurred when the preparations were being

made fo r the erection o f the huge 16-foot diameter b u tterfly valve. The

d isc portion o f th is valve was made o f east s e a l- s te e l , while the trun­

nions consisted o f 2b Indt diameter so lid machined sh a fts pressed Into

the oast body, the aggregate e f which weighed 82 tons. The valve body

was fabricated o f 2 - l /b Inch th ick re lie d s te e l p la te s , reinforced with

heavy welded gusset p la te s , and was ca refu lly machined on the Inside sur­

face to close to lerancee. She valve body was fabricated In two section s,

one o f whiA formed the tep h a lf o f the va lve, and provided a support

platform fa r the bearing housing and operating mechanism. The lower

o f the valve body provided a support for the bottom bearing housing and

supports fo r the assembled valve.

The contract plans and sp ec ifica tio n s provided that the lower h a lf o f

the valve body was to be Imbedded la concrete A i A formed a foundation

pad. A l i f t i n g p in was provided In the c e l l in g e f the b u tterfly valve

corridor w hlA was Intended fo r use In l i f t i n g the heavy parts Into p o s i­

t io n , but upon carefu l a n a ly sis . I t was discovered that the l i f t i n g p in

and toe supporting structure was e f In su ffic ien t strength to support the

leed e e f h o istin g the valve d isc and trunnion Into p o sitio n , toe problem

was further complicated by the restr ic ted space fo r maneuvering toe valve

and i t # p arts. I t was in i t i a l l y planned to use the generator bay crane to

h o is t the valve p a rts , move them from the erection bay f lo o r , and lower

->21’—

th e n i n to th e p e n s to c k a r e a . T hese p a r t e th e n h ad to be moved down th e

p e n s to c k c o r r i d o r , and f i n a l l y h o i s t e d i n to p o s i t i o n i n to th e b u t t e r f l y

v a lv e c o r r i d o r . I t wae q u e s t io n e d w h e th e r th e s l o t in th e f l o o r s e p a r a t ­

in g th e p e n s to c k a r e a from th e b u t t e r f l y v a lv e c o r r i d o r was l a r g e enough

to accom m odate th e d i s c and t r u n n io n , and w h e th e r t h e r e was room i n th e

a r e a s m e n tio n e d f o r th e r e q u i r e d m a n e u v e rin g . The f i n a l d e te r m in a t io n

was made b y c o n s t r u c t i n g a p a p e r s c a l e m odel o f th e v a lv e p a r t s and ma­

n e u v e r in g them on t h e c r o s s s e c t i o n a l d ra w in g o f th e a r e a s a f f e c t e d , from

w h ich th e b e s t m ethod o f a s se m b ly was d e r iv e d . The h o i s t i n g o f th e v a lv e

p a r t s i n t o p o s i t i o n i n to t h e b u t t e r f l y v a lv e c o r r i d o r was th e b o t t l e n e c k

t o t h e p ro b le m . Q ie c o n t r a c t o r p ro p o se d to u s e th e l i f t i n g lu g m en tio n ed

ab o v e to h o i s t th e o p e r a t i n g m echanism an d th e to p h a l f o f t h e v a lv e

body in to p o s i t i o n , them u t i l i z e th e top h a l f o f t h e v a lv e body I t s e l f

f o r th e a n c h o r and s u p p o r t f o r h o i s t i n g th e d i s c an d t r u n n io n in to p o s i ­

t i o n . T h is m ethod w as r e j e c t e d b e c a u se th e v a lv e m a n u fa c tu re r s t a t e d

t h a t t h e v a lv e body w ould be p e rm a n e n tly d e fo rm ed , an d th e g u a ra n te e d

le a k a e e minimum c o u ld n o t be m et. A f t e r s e v e r a l o t h e r m ethods o f h o i s t ­

i n g th e v a lv e i n to p o s i t i o n w ere c o n s id e r e d , one m ethod becam e o b v io u s

a s t h e b e s t s o lu t i o n to t h e p ro b le m . The to p h a l f o f th e v a lv e and th e

o p e r a t i n g m echanism w ere h o i s t e d i n t o p o s i t i o n u s in g th e l i f t i n g lu g ,

a s th e y e a c h w eighed l e s s th a n 30 t o n s , a n d h o i s t e d s in g l y w ould n o t

o v e r lo a d th e l i f t i n g p i n . Then s t e e l beam s w ere u s e d to b r id g e th e open­

in g i n th e f l o o r , an d th e to p h a l f o f t h e v a lv e body was s u p o o r te d by th e

beam s. I n s id e th e v a lv e body a te m p o ra ry "A" fram e was b u i l t , w h ich was

supported the s te e l beams. J i n a l J y , a jacking bar was b u ilt , and

hydraulic jacks were used to l i f t the d isc and trunnion into p o sitio n .

The remainder of the valve was assembled without further d if f ic u lty ,

and vhen the sea ls were f in a l ly adjusted and tested , tho to ta l leakage

was le s s than 8 ga llon s per minute, the guaranteed leakage, th is in ­

dicated that the valve body was not deformed or abused in the d if f ic u lt

assembly. P la te I I I Ie a photograph o f the valve w h ile being assembled

and P la te IT i s a photograph showing the Jacking arrangement.

PLATE I I I - PA R TIA L ASSEMBLY OF VALVE

- 2 7 -

p l a t e IV - JACK ING ARRANGEMENT

#

xaEGTio* uiyoui paosots

° n a p ro b le m # ca-usin^ ttie m oat c o n c e rn d u r in g th e ! n a t a l —

l a t l o n o f t h i s g e n e r a t i n g u n i t was th e m a t t e r o f l a y o u t an d a c c u r a te

c o n t r o l o f e l e v a t i o n s , and a l ig n m e n ts . The c o n t r a c t p l a n s w ere c o m p le te

i n t h e e s ta b l i s h m e n t o f e l e v a t i o n s , d im e n s io n s and a l ig n m e n ts , b u t to

t r a n s f e r e n d c o n t r o l th e s e p o i n t s In th e f i e l d was a m a t te r o f c o n s ta n t

c o n c e rn . I t may l e n d e m p h a s is to th e p o i n t somewhat i f we c o n s id e r th e

m a t t e r o f th e e l e v a t i o n o f th e c u rb r i n g , vfclch fo rm s th e f o u n d a t io n

upon w hich th e t u r b i n e i s u l t i m a t e l y e r e c t e d . S in ce an e r r o r o f l / 6 4

in c h i s a b o u t a l l t h a t th e t o l e r a n c e in l e n g t h o f th e s h a f t c o u p lin g

th e tu rb in e to th e g e n e r a to r w i l l p e r m i t , th e e l e v a t i o n o f a l l th e com­

p o s i t e p a r t s o f th e t u r b i n e m ust be c a r e f u l l y c o n t r o l l e d . To a c c o m p lish

t h i s , c o n t r o l p o i n t s w ere c a r e f u l l y e s t a b l i s h e d in c o n v e n ie n t l o c a t io n s

th ro u g h o u t th e w ork a r e a , b o th f o r c r i t i c a l e l e v a t i o n s and f o r a l ig n m e n t .

T h ese c o n t r o l p o i n t s w ere l a i d i n w i th th e t r a n s i t and l e v e l , b u t even

by c a r e f u l c lo s i n g an d c h e c k in g o f a l l c e n t e r l i n e s an d e l e v a t i o n s , i t

becam e n e c e s s a ry to d e s ig n in s t r u m e n ts m ore a c c u r a te th a n th e s e to accum

r a t e I y e s t a b l i s h a l ig n m e n ts and e l e v a t i o n s . The c u rb r i n g was th e f i r s t

p o r t i o n o f th e t u r b i n e t h a t c a u se d t h i s c o n c e rn . The r i n g was s e t to

e l e v a t i o n by m eans o f a dumpy l e v e l and c h e ck ed f o r l e v e l w i th a m achin­

i s t s l e v e l p la c e d on th e m ach ined to p s u r f a c e o f th e c u rb r i n g . To o u r

a s to n is h m e n t , n e i t h e r a g re e d w ith t h e o t h e r l e v e l , f o r when th e c u rb r i n g

was l e v e l e d w i th th e e n g i n e e r 's l e v e l , th e m a c h i n i s t 's l e v e l w ould n o t

c o n f irm th e r i n g a s b e in g l e v e l . T h e r e f o r e i t was c o n s id e r e d t h a t th e

e n g in e e r* g l e v e l wf « c a u e in g th e ice ,<3c u ra c y ^ue t s th e i n a b i l i t y o f

t h e r e n d e r to r e a d th e ro d c l o s e l y enough . A " m ic ro m e te r rod* v i t h

a l i g h t t a r g e t w e th e n c o n s t r u c te d , and th e l e v e l w as e q u ip p e d w ith

a s h o r t r e a d in g e y e p ie c e . The r e s u l t a n t work w ith t h i s equ ip m en t gave

b e t t e r a c c u ra c y th a n t h a t i n d i c a t e d by a m a c h i n i s t 's l e v e l . R e fe r to

P l a t e num bered V w hich i s a p h o to g ra p h o f th e " m ic ro m e te r r o d " . I t i s

c o n s id e r e d t h a t w i th o u t t h e u se o f t h i s s p e c i a l l y d e s ig n e d t o o l t h a t

th e su b se q u e n t e r e c t i o n o f th e t u r b i n e w ould n o t h av e been a c c u r a te .

T h is f a c t i s b o rn e o u t b y th e f a c t t h a t th e Ho. I u n i t in t h i s pow er

p l a n t , w hich i s s i m i l a r t o t h e Ho. 3 u n i t d i s c u s s e d h e r e i n , h a s a lw a y s

b e e n s l i g h t l y o u t o f p lum b , en d c o n s e q u e n t ly th e t h r u s t en d g u id e b e a r- ,

in g In u n i t No. I c o n s t a n t ly r e q u i r e s r e a d ju s tm e n t b e c a u se th e u n i t i s

l e a n i n g i n to one s id e o f th e b e a r in g s . No such d i f f i c u l t i e s h av e been

e x p e r ie n c e d i n th e Ho. 3 u n i t , and a r e n o t e x p e c te d . I t I s c o n s id e re d

t h a t th e above d e s c r ib e d m ethod o f l e v e l i n g r e p r e s e n t s one s o lu t i o n to

m a jo r l e v e l i n g p ro b le m s i n th e i n s t a l l a t i o n o f h e a v y h y d r o e l e c t r i c

e q u ip m e n t.

C oup led w ith th e l e v e l i n g p ro b lem o f th e c u rb r i n g m en tio n e d in th e

p r o c e e d in g p a r a g r a p h , th e a lig n m e n t o f th e speed r i n g becam e somewhat

c r i t i c a l when i t w as d is c o v e r e d t h a t a f t e r th e s c r o l l c a s e h a d been

r i v e t e d t o t h e sp e e d r i n g , an d a l th o u g h c a r e f u l p r e c a u t i o n s and c o n c re te

p la c e m e n t p r o c e d u r e s w ere f o l lo w e d , th e sp eed r i n g was fo u n d to be o u t

o f ro u n d a p p ro x im a te ly 0.050 o f an in c h on th e I n n e r b o r e . I t was fo u n d

t h a t t h e h e a v y c a u lk w e ld s made i n j o i n i n g th e r i v e t e d s c r o l l c a s e p l a t e s

-31*'

to th e sp eed r i n g c e u se d t h l e o u t o f round c o n d i t io n , h u t th e p ro b lem

wne th n t ' I t h th e sp e e d r i n g o u t o f ro u n d , th e to p and b o tto m p l a t e s

w ould no l o n g e r f i t p r o p e r l y and a lig n m e n t o f th e t u r b in e w ic k e t g a te

Kteme end g a te s w ould be m ost d i f f i c u l t . By r e f e r e n c e to th e t r u e

c e n t e r l i n e e s t a b l i s h e d by th e c o n t r o l p o i n t th e am ount o f o u t - o f - r o u n d

was d e te rm in e d , en d th e " egged* p o r t i o n was th e n t r u e d up by g r in d in g

by h a n d ; a very t im e consum ing , c o s t l y , en d p a in s t a k in g Jo b . I t h a s

s in c e been c o n c lu d e d t h a t a more a c c u r a te an d e x p e d i t io u s m ethod Ig to

e r e c t a g r in d in g arm by s e t t i n g up a s p id e r In th e t r u e c e n t e r l i n e o f

th e u n i t , th e n s e t t i n g th e g r in d e r on a m ach in ed aim from t h i s c e n te r

and g r in d o r m ach ine o u t a new t r u e r a d i u s f o r th e to p an d b o tto m p l a t e s

c o n s i s t e n t w i th th e a l lo w a b le t o l e r a n c e s . I t h a s b een d e te rm in e d im­

p r a c t i c a l to a t te m p t t o p r e v e n t th e m is a lig n m e n t o r " e & lng* due to v e ld -

In g b e c a u se th e c a u lk w e ld s e r e n e c e s s a r y to p r e v e n t le a k a g e p a s t th e

s c r o l l c a se p l a t e s . I n any c a s e , i t i s n e c e s s a r y to c a r e f u l l y e s t a b l i s h

a t r u e c e n t e r l i n e o f u n i t r e f e r e n c e p o i n t s i n a s u i t a b l e l o c a t i o n in

o r d e r t h a t i t may be u s e d th ro u g h o u t th e e n t i r e e r e c t i o n o f th e u n i t , and

i t I e a ls o c o n c lu d e d t h a t th e l a t t e r m ethod o f t r u i n g up th e m achined

b o re s o f th e sp eed r i n g w i l l r e s u l t i n a b e t t e r end m ore a c c u r a te m ethod

o f m a in ta in in g th e I n s t a l l a t i o n o f t h e u n i t on a t r u e c e n t e r l i n e .

Aloag with the a llgaaeat o f the turbine d istrib u tor or * speed ring*

on a true cen terlin e was the problem o f a lign in g the turbine shaft with

the turbine guide bearing and a t the same time se ttin g up the generator

guide bearing alignment, and the thrust bearing adjustment. Thl# turbine-

generator un it has three major bearings, two o f which arc guide bearings

and one o f which Ic a thrust bearing. The generator guide bearing con­

s is t* o f a ser ie s o f adjustable shoes, babbitt lin ed and adjustable by

means o f rad ial jack-screws set Into the bearing housing. This bearing

maintains v e r tic a l shaft alignment.

®he generator thrust bearing accepts the en tire v e r tic a l loading o f

the weight o f the rotor, shaft, turbine runner, and the hydraulic down-

thrust. Zn th is ease the to ta l combined weight o f these p arts i s 130,000

pounds or 65 tone. The hydraulic downthruet a t f u l l load i s 2*7,000

pounds, fhe bearing supporting th is v e r t ic a l leading Is o f the Kingsbury

typo, having adjustable thrust shoes, fh e problem i s to adjust each o f

the thrust shoes in the Kingsbury thrust bearing, and each o f the guide

sheet In the generator guide bearing while maintaining the true alignment

with the here o f the turbine guide bearing, the la t t e r o f which I s not

adjustable, while simultaneously maintaining the correct e levation at the

l ip o f the runner. Mention Is made e f the la t te r consideration because

a d ifference o f l /S Inch In elevation o f the turbine runner with relation

to the gate ring threat w ill resu lt In major cav itation d i f f ic u lt ie s and

g rea tly reduce the unit* ■ e ffic ie n c y , fhe problem e f alignment o f these

three bearings, and e lev a tiea a l control was approached in the follow ing

a a a n e r t F i r s t th e K ln g sh u ry t h r u s t sh o e s w ere b ro u g h t to h e a r on th e

t h r u s t c o l l a r a f t e r th e s h a f t h a d toeon ro o m ily c e n te r e d . u t i l i s i n g

th e " s lu g g e d a re * m eth o d , t h e ja c k sc re w s w ere g r a d u a l ly t i g h t e n e d u n t i l

t h e s h a f t w i th th e t u r b i n e r u n n e r a t t a c h e d w as r a i s e d b y th e K in g sb u ry

t h r u s t sh o e s u n t i l t h e ru n n e r w as w i th in 1 /6 4 in c h o f th e d e s i r e d a l e v a -

t i o n . By t h i s t im e th e t h r e a d s on th e ja e k e c re w s h a d “worn in * s u f ­

f i c i e n t l y to p e rm i t e a a d ju s tm e n t t o be m a in ta in e d . The s h a f t was th e n

c e n te r e d up I n t h e b o re e f t h e t u r b i n e b e a r in g h o u s in g a n d th e g e n e r a to r

g u id e b e a r in g t h r u s t sh o e s w ere t i g h t e n e d up s n u g ly . T h is o p e r a t io n

p e r m i t t e d t h e s h a f t a eaem b ly t e f r e e l y sw ing l i k e a g i g a n t i c p lum b bob .

B la l i n d i c a t o r s w ere th e n f a s t e n e d to th e t u r b i n e g u id e b e a r in g h o u s in g

an d th e p r o c e s s o f b r in g i n g th e r u n n e r up to e l e v a t i o n w h ile e a u a l l s i n g

th e p r e s s u r e on e a c h o f th e t h r u s t sh o e s w as b eg u n . Te v e ry a c c u r a t e l y

c e n t e r th e s h a f t i n t o t h e b o re o f th e t u r b i n e g u id e b e a r in g , to a c c u r a t e l y

d e te rm in e th e s t r a i g h t n e s s o f t h e A a f t a n d to m a in ta in p lum b In th e s h a f t

a t a l l t im e s a s p e c i a l t o o l 1 w as c o n s t r u c te d an d u s e d . B e f e r to P l a t e T I

A l d a i s a v lsw o f t h i s t o o l . S e x t .0 0 8 d ia m e te r p ia n o w ire was su sp en d ed

fro m th e g e n e r a to r b e a r in g h o u s in g from a d j u s t a b l e p o i n t s e q u i d i s t a n t

fro m t h e c e n t e r o f th e g e n e r a to r g u id e b e a r in g . T h ese f o u r w ir e s suspend ­

e d a s d e s c r ib e d a b o v e w ere w e ig h te d w i th PO p o u n d s o f l e a d , and th e s e

w e ig h ts w ere im m ersed In l ig h t w e ig h t l u b r i c a t i n g o i l to dampen a n y sw ing

I . T h is t o o l w as u s e d i n t h e f o l lo w in g m anner* H e a d se t l e a d s w erea t t a c h e d to th e t a p e a s A ow n on th e p h o to g ra p h . The v e e b lo c k was p la c e d a g a i n s t th e s h a f t , a n d th e m ic ro m e te r a d ju s t e d u n t i l i t con­t a c t e d th e w i r e . Upon c o n ta c t a “ c l i c k * was a u d ib le I n th e h e a d s e t .

-3 3 -

PLA TB V I - SPEC IA L A L IG N IN G TOOL

-3 4 -

e a u e e d Iqr T l I) r a t i o n , th ro u g h o u t th e p r o c e s s o f b r in g in g th e s h a f t I n t e

l i n e , t h e s e v i r e s w ere u s e d to ch eek th e p lum b o f th e s h a f t , a n d th e

c e n t e r i n g . P r i o r to th e f i n a l s e t t i n g o f a l l b e a r in g s , th e s h a f t was

c h e e k e d f o r e tm lg & tn e e s by r o t a t i n g I t b y q u a r t e r t u r n s a n d c h e c k in g

t h e " ru n o u t* a t s e v e r a l p l a c e s a lo n g th e w i r e . I t was fo u n d t h a t th e

b e l t s a t th e c o u p l in g h a d n e t b een t i g h t e n e d u n i fo r m ly , an d t h a t th e r e

w as c o n s id e r a b le m is a lig n m e n t o f t h e s h a f t . By s lu g g in g up th e n u t s w i th

a s lu g g in g w rench made f o r t h a t p u r p o s e , t h e c o u p l in g b o l t s w ere t i g h t e n e d

u n i fo r m ly u n t i l th e s h a f t r a n t r u e . I t w as d is c o v e r e d t h a t th e s p e c i a l

t o o l u s e d f o r t h i s p u rp o s e w as a e e u r a te to 0.00025 o f a n In c h , f i n a l l y ,

th e t h r u s t sh o e s o n t h e K in g sb u ry b e a r in g w ere s lu g g e d up u n t i l a r e a d ­

in g e f 0 .0 1 0 ln d b w as r e c o r d e d o n t h e d i a l I n d i c a t o r r ig g e d up i n th e

h e r e e f t h e t u r b i n e b e a r in g h o u s in g o p p o s i t e t h e p o s i t i o n o f th e t h r u s t

s h o e . Then th e o p p o s i t e t h r u s t shoe was s lu g g e d up u n t i l i t s c o rre s p o n d ­

in g d i a l I n d i c a t o r r e a d s e r e a g a in , and t h i s p r o c e s s was r e p e a te d a ro u n d

th e e n t i r e c i r c l e e f t h r u s t g h e e s . When th e p r o p e r e l e v a t i o n f o r th e

r u n n e r h a d b e e n a c h ie v e d , t h e t h r u s t sh o e s w ere a l l e q u a l l y le a d e d by

t h i s m eth o d , an d th e s h a f t r e s t e d I n th e t r u e c e n te r o f t h e n o n a d ju e ta b le

t u r b i n e b e a r in g a n d w as p e r f e c t l y p lu m b . The c a l c u l a t e d c le a r a n c e f o r

th e g e n e r a to r r a d i a l g u id e b e a r in g sh o e s was 0 .0 1 8 I n c h , w h ich was ob ­

t a i n e d by b a c k in g o f f th e r e t a i n i n g sc re w s u n ifo rm ly by c a l c u l a t i n g th e

p i t c h o f t h r e a d i n t h e Ja c k s e re w s an d t u r n i n g th e sc re w s t h e c a l c u l a t e d

am ount to g iv e 0 .0 1 8 in c h c le a r a n c e . When th e u n i t was p l a c e d in to

o p e r a t i o n , th e ru n o u t e f t h e s h a f t w as m e a su re d Iqr m eans o f a d i a l

-3 5 -

In d lC H to r p la c e d a t th e t u r b i n e g u id e b e a r in g h o u s in g a n d a t th e g e n e r -

r a t e r g u id e h e a r in g b r id g e . H te maximum ru n o u t m easu red w i th th e i n ­

d i c a t o r w&e l e s s th a n 0. 000$ I n c h , w h ich I e e x c e p t io n a l ly good f o r t h i s

e l s e s h a f t . The t o t a l b e a r in g c le a r a n c e s a t th e t u r b i n e g u id e b e a r in g

w ere s e t up a s s ix to e ig h t th o u s a n d th s o f a n In c h . H te te m p e ra tu re In ­

d i c a t o r f o r t h i s b e a r i n g i n d i c a t e d I t w as p r o p e r l y a l i g n e d , s in c e th e

te m p e ra tu re s w ere w i t h in t h e r e q u i r e d l i m i t s . The t o t a l o f two th o u ­

sa n d th s o f a n ia e h I s a l lo w e d f o r t h e c le a r a n c e n e c e s s a r y f o r th e lu b ­

r i c a t i n g o i l .

H ie t r u e t e s t o f w h e th e r t h e g e n e r a to r b e a r in g t h r u s t sh o e s w ere

p e r f e c t l y lo a d e d w as th e te m p e ra tu re r e c o r d e d b y th e r e c o r d in g c o l i e

p l a c e d in e a c h o f th e s h o e s . A f t e r th e u n i t w as p l a c e d I n to o p e r a t io n ,

e a c h o f th e te m p e r a tu r e s o f th e sh o e s w ere r e c o r d e d a# e q u a l , I n d i c a t i n g

e q u a l lo a d in g . I t w ould h a v e b e e n v e r y c o s t l y to s to p th e u n i t an d r e ­

a d j u s t th e b e a r in g s by th e " o u t and t r y * m ethod em ployed b y some e r e c t o r s ,

a n d In t h i s e a s e may h a v e d e la y e d th e p la c e m e n t e f t h e u n i t i n t o s e r v i c e .

A l a r g e u n i t r e c e n t l y I n s t a l l e d a t th e H ungry H orae P r o j e c t s u s ta in e d

h e a r i n g f a i l u r e due t o im p ro p e r a d ju s tm e n t e f th e t h r u s t b e a r in g , and i t

l e c o n s id e r e d t h a t th e f a i l u r e may h a v e b e e n d u e , l a f a c t , m ust h av e b een

due t o th e one segm ent o f th e t h r o a t b e a r in g b e in g r e q u i r e d to s u s ta i n

th e e n t i r e l o a d . W hile t h i s m ethod o f A a f t a lig n m e n t a n d b e a r in g lo a d ­

in g w as n o t in I t s e n t i r e t y d e v e lo p e d a t t h i s p r o j e c t , e s s e n t i a l l y A e

m a jo r p r i n c i p l e s a n d p r o c e d u r e s w e re , t o g e t h e r w i th A e s p e c i a l t o o l s ,

w h ich i t I s b e l i e v e d , a s s i s t e d g r e a t l y i n t h e a c c u r a te a l ig n m e n t e f t h e

-3 6 -

37-

b e s tr ln e e t o th e f i r s t a t t e m p t . T h is m ethod o f a lig n m e n t was em ployed

I n r e a l i g n i n g th e e x i s t i n g s i m i l a r u n i t a t th e F o r t P e c k P ow er P l a n t ,

and was fo u n d t® c o r r e c t m ost o f t h e t r o u b l e s e x p e r ie n c e d w i th t h i s

u n i t p r e v i o u s ly , ev en th o n g * th e s h a f t c o u ld n o t be p la s h e d t o I t s

e n t i r e t y . Sue to l i m i t a t i o n * l a th e a d ju s tm e n t s . T h e r e f o r e I t i s c o n -

e lu d e d t h a t t h i s m eth o d o f b e a r in g a lig n m e n t 1» d e v e lo p e d a s one o f th e

b e s t m ethod* e f e s t a b l i s h i n g t r u e b e a r in g l o a d in g a n d a l ig n m e n ts f o r

h y d ro u n i t * o f t h i s ty p e .

-3 8 -

SffiOffiAlOB BBSCTKS PROBLEMS

B a r ia c th e p r o c e s s o f t h e a s se m b ly an d e r e c t i o n o f t h e 3 5 ,0 0 0 H f

g e n e r a to r , s e v e r a l p ro b le m s d e v e lo p e d , e n d i n o r d e r o f t h e i r o c c u r r e n c e

th e y w ere a s f o l lo w e l

a . A ssem b ly o f th e r o t o r l a m in a t io n s .

b . I n s t a l l a t i o n o f th e k e y s b in d in g th e r o t o r s p id e r t o th e

l a m in a t io n s , a n d th e k e y s b in d in g th e f i e l d p o l e s to th e

l a m in a t io n s .

c . A ssem bly o f th e t h r u s t c o l l a r a s se m b ly on th e d r iv e s h a f t .

d . A ssem bly o f t h e r o t o r on t h e t h r u s t c o l l a r an d th e i n s t a l ­

l a t i o n o f t h e k e y s t h a t b in d t h e s h a f t to t h e c o l l a r .

The d i f f i c u l t i e s w i l l b e d i s c u s s e d i n o r d e r o f t h e i r o c c u r r e n c e .

The f i r s t i n d i c a t i o n o f t r o u b l e i n th e a s se m b ly o f th e r o t o r -

! n a t i o n s w as e x p e r ie n c e d when a n a t te m p t w as made to i n s t a l l t h e lo n g

s l e n d e r I in c h d ia m e te r b e l t s th ro u g h th e s le e v e d h o l e s i n th e i

t i o a e w h ich h a d b e e n s ta c k e d o n th e r o t o r s p id e r r im . I t w as d is c o v e r e d

t h a t t h e r e warn a m ark ed d i f f e r e n c e i n th e t o t a l t h ic k n e s s o f th e r o t o r

I a a l n a t i o n o no th e r o t o r was s ta c k e d . A t f i r s t , i t was c o n s id e r e d t h a t

t h i s c o n d i t io n w as due to i r r e g u l a r i t i e s i n t h e s p a c e s b e tw een th e lam­

i n a t i o n s a n d th e i n s e r t i o n o f t h e b in d in g b e l t s w as th o u g h t to be th e

m oans w hereby th e l a m in a t io n s w ould bo co m p ressed to fo rm a u n ifo rm ho­

m ogenous m a ss , b u t i t w as fo u n d t h a t t h i s w as n o t th e e a s e . I n th e f i r s t

p l a c e , th e b o l t s w e re , a c c o r d in g t o th e m a n u f a c tu r e r 's recom m endation , to

b e t i g h t e n e d to a u n ifo rm t e n s i l e s t r e s s n e t g r e a t e r th a n t h e n o rm al

a l lo v a 'b le w o rk in g s t r e n g t h o f th e m a t e r i a l , w hich i n t h i s c a s e was «114

s t e e l , w i th an a l lo w a b le s t r e s s o f 2 0 ,0 0 0 p s i . A f t e r c a l c u l a t i n g th e

e a o n n t o f e lo n g a t io n n e c e s s a r y t o p ro d u c e t h i s s t r e s s , a g a g e was made

w h ic h m ea su red th e e lo n g a t io n a c c u r a t e l y . The n u t# w ere th e n t ig h t e n e d

down on th e b e l t s u n t i l t h e p re d e te r m in e d e lo n g a t io n was m ea su red w i th

t h e g a g e . I t w as fo u n d t h a t a f t e r t h e s e b e l t s t h a t w ere su p p o sed to

b in d th e r o t o r l a m in a t io n # t o g e t h e r w ere t i g h t e n e d , t h e r e s t i l l rem a in ed

c o n s id e r a b le d i f f e r e n c e i n th e th ic k n e s s o f th e s ta c k e d r o t o r l a m in a t io n s .

S in c e t h e la m in a t io n * w ere o f c a r e f u l l y s tam p ed s t r e t c h e r l e v e l e d m ild

s t e e l , a n d a f t e r c a r e f u l m easu rem en ts h a d b e e n made w ith a m ic ro m e te r ,

i t a p p e a re d a s i f a l l l a m ia a t lo n s w ere one s a d th e sam e, no r e a s o n c o u ld

r e a d i l y be e s t a b l i s h e d f o r t h e d i f f e r e n c e i n t h e t h ic k n e s s o f th e com­

p l e t e l y s ta c k e d r o t o r . P l a t e V II i s a p h o to g ra p h o f th e p a r t i a l l y s ta c k e d

r o t o r . She a s se m b ly o f th e g e n e r a to r w as s te p p e d u n t i l a r e a s o n f o r t h i s

v a r i a b l e t h ic k n e s s c o u ld be fo u n d , b e c a u s e i t w as known t h a t to e g r o a t a

d i f f e r e n c e i n r o t o r r im t h ic k n e s s w ou ld a f f e c t th e b a la n c e o f th e m ac h in e .

As m e n tio n e d b e f o r e , t h e l a m in a t io n s w ere ch e ck e d a n d r e c h e ck e d f o r a n y

s i g n i f i c a n t d im e n s io n a l d i f f e r e n c e s w i th o u t a n y s a t i s f a c t o r y r e s u l t s .

Vhe l a m in a t io n s w ere f l a t s tam ped s h e e t s t e e l 0 .0 7 8 in c h ( l h g a g e ) t h i c k ,

a p p ro x im a te ly 18 in c h e s w ide a n d 5 f e e t lo n g m easu red o n a n a r e e f ap­

p r o x im a te ly 22 f e e t r a d i u s . Vhe t o t a l l a m in a t io n s a s s ta c k e d on th e

r o t o r s p id e r w eighed 8 8 ,4 2 5 p o u n d s . The s o l u t i o n to o u r p ro b le m became

re m a rk a b ly s im p le when I n d e s p e r a t i o n , we com pared th e w e ig h ts ©f v a r io u s

l a m in a t io n s . I t w as fo u n d t h a t a l th o u g h th e d im e n s io n o f t h e la m in a t io n #

-3 9 -

- 4 0 -

i

v e r e q u i t e s i m i l a r , t h e i r w e l ^ i t e w ere v a r i a b l e , a s m odi a s 8 o u n c e s .

The l a m in a t io n s w ere th e n s o r t e d I n to s e v e r a l p i l e s , u s in g 2 ounce i n ­

c re m e n ts a s th e m eans o f s o r t i n g . T h ese r e s o r t e d l a m in a t io n s w ere th e n

r e s t a c k e d on t h e r o t o r s o l d e r , t a k i n g c e r e t o s t a c k a row o f l a m in a t io n s

o f th e same w e ig h t u n t i l a l l h ad k een s ta c k e d . I t was fo u n d t h a t th e

l a m in a t io n s s ta c k e d by u n ifo rm w i g h t s e l e c t Ion gave a v e r y u n ifo rm r o t o r

t h i c k n e s s , a n d t o o , when th e b in d in g h o l t s w ere t i g h t e n e d down, a l l h o l t s

a c c e p te d a u n ifo rm e lo n g a t io n b y th e gage w i th o u t d i f f i c u l t y . P r o o f t h a t

t h e r o t o r w as p r o p e r l y s ta c k e d an d b a la n c e d becam e e v id e n t d u r in g th e

o v e rs p e e d t e s t . The v i b r a t i o n s m easu red d u r in g th e o v e rs p e e d t e s t s w ere

o f l e s s th a n n o rm a l m a g n itu d e . I t c a n b e p o i n t e d o u t t h a t w h i le some

e r e c t i o n p ro b le m s a r e s im p le I n s o l u t i o n , a n Im p ro p e r s o l u t i o n can hav e

l a s t i n g e f f e c t s , s in c e I n t h e a s se m b ly o f p r e v io u s u n i t s o f t h i s k in d ,

no c o n c e rn w as g iv e n to w a rd u n ifo rm l a m in a t io n * s ta c k in g * a n d a # a r e ­

s u l t , t h e s e g e n e r a to r s w ere o u t o f b a la n c e . Humber 2 u n i t a t t h i s p r o ­

j e c t w as I n su ch a s t a t e o f u n b a la n c e when i t was t e s t e d t h a t i t c o u ld

n o t b e ru n w i th o u t e x c e s s iv e v i b r a t i o n s . The b a la n c in g o f t h e r o t o r was

a c c o m p lis h e d by a p p ly in g san d b ag s to th e r o t o r r im and t r y i n g v a r io u s

w i g h t s I n v a r io u s l o c a t i o n s u n t i l a c o n d i t io n w as o b ta in e d w here th e

v i b r a t i o n s o c c u r r in g d u r in g r a t e d sp e ed a n d o v e rs p e e d w ere re d u c e d to s

s a f e l e v e l . T h is b a la n c in g p r o c e s s r e q u i r e d two w eek s, an d s in c e no l o s s

o f t im e u s e i n c u r r e d f o r b a la n c in g th e num ber t h r e e u n i t . I t a p p e a r# a s

I f t h e t h r e e d a y s t im e l o s t w h i le t h e l a m in a t io n s w ere s o r t e d a n d r e s ta c k e d

was w l l o c c u p ie d . The m a n u f a c tu r e r h a s a d o p te d th e p r o c e d u re o f w e ig h in g

-%2-

an d s o r t i n g th e l a m in a t io n s a s th e y a r e f a b r i c a t e d , an d s k ip p in g them

In m arked o r a t e s a s a r e s u l t o f t h i s a z p s r l e n n e .

The n e x t p ro b le m o f im p o r ta n c e e x p e r ie n c e d I n t h e e r e c t i o n o f th e

g e n e r a to r w e th e I n s t a l l a t i o n o f th e k e y s t h a t b in d o r lo c k th e r o t o r

r im la m in a t io n s t o t h e s p id e r . A c c o rd in g to th e p ro c e d u re e s t a b l i s h e d

b y th e m a n u f a c tu r e r , th e r o t o r p o le w in d in g s , e a c h w e l d i n g a b o u t 1,350

p cun d a , w ere I n s t a l l e d i n t h e d o v e t a i l s l o t s i n t h e r o t o r l a m in a t io n s ,

an d a l l e l e c t r i c a l c o n n e c t io n s made up t o c o n n e c t t h e f i e l d p o l e s In

s e r i e s . Two h e a v y e l e c t r i c w e ld e rs w ere th e n c o n n e c te d I n to t h e w ind­

in g s a n d a f u l l o u tp u t o f 800 am peres was p a s s e d th ro u g h th e w in d in g s

f o r a p e r i o d o f a b o u t Hg h o u r s , o r u n t i l t h e r o t o r w in d in g # a n d la m in a ­

t i o n s w ere up to th e te m p e ra tu re o f IS 5 d e g re e s F a r e n h e i t . A c c o rd in g to

t h e m a n u fa c tu re r* s c a l c u l a t i o n s , t h e te m p e ra tu re o f 125 d e g re e s F a r e n h s l t

w ou ld c a u se t h e r o t o r l a m in a t io n s to expand e n d p e r m i t t h e o v e r s i z e k e y s

t o b e d r iv e n I n to t h e m ach in ed s l o t s on th e s p id e r and th e stam ped s l o t s

i n th e l a m in a t io n s . I t w as soon fo u n d t h a t t h i s w as n o t th e e s .se , a s

t h e la m in a te d r o t o r r im d id n o t expend a c c o r d in g t o th e la w s f o r a s o l i d

m em ber, and th e a c t u a l e x p a n s io n was fo u n d t o b e much l e s s th a n t h a t

o r i g i n a l l y c a l c u l a t e d . T h e r e f o r e , some m eans h a d to b e fo u n d w hereby

t h e s p id e r c o u ld b e sh ru n k enough t o p e r m i t t h e k e y s to b e d r iv e n in to

t h e i r s l o t s . "D ry Ic e * o r c a rb o n d io x id e I n s o l i d fo rm was a p r a c t i c a b l e

m eans to a c c o m p lis h t h i s , a n d ?,HOO p o u n d s o f I t w ere p r o c u r e d an d p a c k e d

on th e s p id e r a rm s . The k e y s th e m s e lv e s w ere p a c k e d i n t h i s m a t e r i a l an d

f i n a l l y , whan th e r o t o r r im was a s warm a s i t c o u ld s a f e l y b e made by

p a s e i a * th e w e ld in g c u r r e n t th ro u g h th e f i e l d p e l# w in d in g # a n d th e

k e y # an d r o t o r s p i d e r w ere n s c o ld a s t h e s o l i d c a rb o n d io x id e p a c k ed

a ro u n d them w ould c o o l th e n , th e a t te m p t w as made to d r iv e th e k e y s . A

h e a v y Jackham m er w as u s e d , an d w ould s in k t h e k e y s f u l l l e n g t h e a s i l y .

I t w as d is c o v e r e d when t h e t e m p e r a tu r e s w ere a l lo w e d to e q u a l i s e t h a t th e

k e y s w ere f i r m l y s e iz e d .

I n p r e v io u s m a c h in es o f t h i s ty p e , an d i n p a r t i c u l a r t h e u n i t e a t

t h i s pow er p l a n t , d i f f i c u l t y h a s b e e n e x p e r ie n c e d I n th e p a s t o f s e c u r ­

in g th e p r o p e r f i t o f t h e k e y s t h a t a r e I n s e r t e d i n th e d o v e t a i l s l o t s

t h a t h o ld th e f i e l d p o l e s In p l a c e . U su a l p r a c t i c e I a t o f i l e th e k e y

u n t i l i t c a n be d r iv e n i n t o p l a c e , an d i t I e ho p ed t h a t th e v i b r a t i o n

a n d te m p e ra tu re c h a n g e s w i l l n e t lo o e e n i t . I t was c o n s id e r e d t h a t th e

s u c c e s s f u l m ethod e x p e r ie n c e d i n th e i n s t a l l a t i o n o f t h e k e y s u s e d to

b in d th e r o t o r l a m in a t io n s t o t h e s p id e r c o u ld b e a d a p te d to t h i s a s se m b ly .

A c c o rd in g ly , th e k e y s w ere sh ru n k b y p a c k in g them i n " d r y i c e " and th e

s p a c e i n t h e d o v e t a i l s l o t was made a # l a r g e a e p o s s i b l e by a l l s w in g th e

f i e l d p o l e s t o c o o l to t h e a m b ie n t. I h e k e y s , o v e r s i z e b y 0 .0 1 0 In ch

w ere d r iv e n e a s i l y a n d te m p e r a tu r e s a l lo w e d to e q u a l i z e , f h e k e y s w ere

e f f e c t i v e l y s e iz e d i n t h e i r s l o t s , a n d no lo o s e n in g o f t h e f i e l d p o l e s

h a s b een e x p e r ie n c e d to d a t e .

D u rin g th e a s se m b ly o f th e t h r u s t c o l l a r on th e s h a f t , a s l i g h t

v a r i a t i o n o f t h i s m ethod warn u s e d . I h e t h r u s t c o l l a r h a s a n i n s i d e b o re

o f 30.900 in c h e s w i th t o l e r a n c e s o f p l u s n o th in g and m inus .0 0 1 in c h ,

an d h a s n t o t a l l e n g t h o f f i t t e d s u r f a c e o f 18 in c h e s a t t h e s e d im e n s io n s .

-4 3 -

S la e e b o th m a t e r i a l s a r e s i m i l a r m e ta l , and a r e h ig h c a rb o n s t e e l

f o r g i n g s , t h e n o rm a l p r o c e d u r e f o r f o r c i n g th e t h r u s t c o l l a r o n to th e

s h a f t b y m eans e f h e a v y Ja ck e o re w s w as c o n s id e r e d I n e f f i c i e n t an d in ­

v o lv e d some r i s k , s in c e i f t h e r e w as a s l i g h t ro u g h n e ss a n e i t h e r f i t ­

t e d s u r f a c e . I t m ig h t c a u se g a l l i n g , and th e c e l l a r m l# » t becom e s e i s e d

e r s tu c k , t h e c o l l a r waa h e a te d to a m o d e ra te ly h ig h te m p e ra tu re o f lUO

d e g re e s f a r e n h e l t a s c a l c u l a t e d to g iv e p l e n t y o f c l e a r n e e . and a l u b r t -

e a n t c a l l e d eM o ly k o te w w h ich c o n s i s t e d e f a n molybdenum s u lp h id e compound

was em ployed a t th e f i t t e d s u r f a c e s . The c o l l a r s l i p p e d on I n a m a t te r

o f m in u te s , s a v in g much tim e a n d e l i m i n a t i n g th e r i s k o f g a l l i n g m en tio n e d

a b o v e . I f th e c o l l a r e v e r h a s to b e rem oved , i t I s b e l i e v e d t h a t th e

l u b r i c a n t w i l l a s s i s t th e h y d r a u l i c J a c k s t o rem ove I t .

Xhs n e x t d i f f i c u l t y e n c o u n te re d o c c u r r e d when th e a s se m b le d r o t o r

w as lo w e re d an d a s se m b le d on th e t h r u s t c o l l a r s h a f t a s se m b ly . Xhe r o t o r

w as I n te n d e d to b e s e c u re d to th e t h r u s t c o l l a r s h a f t a s se m b ly b y m eans

o f t h r e e k e y s two I n c h e s s q u a re , a n d 36 I n c h e s lo n g a n d c u t on a d ia g o n a l .

The s l o t s o r k e y s e a t s In t h e t h r u s t c o l l a r d id n o t m atch th o s e i n th e

s p i d e r h u b , a l th o u g h th e y w ere o u t 120 d e g re e s a p a r t . I t w as o u t o f th e

q u e s t io n t o r e c u t t h e s e a t s , so th e o b v io u s s o lu t i o n w as t o a l t e r th e k e y s .

C a r e f u l m easu rem en t# w ere ta k e n w i th a f e e l e r g ag e an d th e k e y s w ere c u t

t o f i t th e o f f s e t I n t h e s e a t s . T h is s o l u t i o n sav ed many d a y s t im e , made

a s a t i s f a c t o r i l y t i g h t f i t , an d t h e r e 1« no d a n g e r o f t h e k e y s lo o s e n in g

i n t h e s l o t s .

TSSTIHS 0 7 THE COMPIEfXD

MOM, OYSHaPKSD ASS SFyiCIEHCT SBSfH

S h*r« w ere two p r i n e l p l e t e s t a w h ich th e w r i t e r wee a s s o c i a t e d

w i th t h a t w ere c o n d u c te d a t t h e c o m p le tio n o f t h e work o f I n s t a l l i n g

th e u n i t m e n tio n e d i n t h i s p a p e r . One t e s t was th e e v e r s p e e d t e s t ,

a n d th e o t h e r was t h e p e r fo rm a n c e , e r t u r b i n e e f f i c i e n c y t e s t .

t h e e v e r s p e e d t e s t c o n s i s t e d o f a l lo w in g th e u n i t to o p e r a t e a t

runaw ay sp e e d w i th t h e g a t e s b lo c k e d open f o r e minimum p e r i o d e f f i v e

n l n e t e e . The p ro c e d u r e f o l lo w e d I n p e r f o r m in g th e e v e r s p e e d t e s t , In

g e n e r a l , w as a s fo llo w s *

▲ s e n s i t i v e ta c h o m e te r was c a l i b r a t e d to a g re e w ith th e known sp e ed

e f t h e m ach ine when o p e r a t i n g a t sy n c h ro n o u s sp e e d , no l o a d c o n d i t io n s ,

w h loh i s 1 2 8 .6 r p a f o r t h i s m ac h in e . The ta c h o m e te r u s e d was a c t u a l l y

a n e l e c t r i c v o l tm e te r c o n n e c te d i n t o t h e g o v e rn o r e l e c t r i c ta c h o m e te r

m a g tc te c i r c u i t . The ta c h o m e te r a # c a l i b r a t e d from th e known sp e ed an d

th e c h a r a c t e r ! e t I e c u rv e e f t h e ta c h o m e te r m ag n e to , t h e c o n n e c t io n o f a

s u i t a b l y a s c u r a t e ta c h o m e te r to t h e t u r b i n e - g e n e r a to i- u n i t was one e f t h e

d i f f i c u l t i e s e f t h e t e s t . T h e re w as no p r a c t i c a l way o f c o n n e c t in g a

ta c h o m e te r by m e c h a n ic a l m eans t o t h e t u r b i n e s h a f t , a s t r o b e scope c o u ld

h a v e b e e n u s e d w ith v e r y a c c u r a te r e s u l t s , b u t one was n o t e a s i l y o b t a i n ,

a b l e , t h e r e f o r e t h e m ethod d e s c r ib e d ab o v e o f u t i l i s i n g t h e m agneto o i r -

C t t i t a s t h e m ee t p r a c t i c a l , an d was em ployed .

A f t e r t h e ta c h o m e te r w as c a l i b r a t e d an d a d j u s t e d , th e g o v e rn o r c o n -

u n i t w as th e n b lo c k e d , t h e m ach ine d is c o n n e c te d fro m t h e b u s .

a n d th e f i e l d c u r r e n t c o n t r o l b ro u g h t to s e r e f i e l d . She m anual g a te

c o n t r o l w e th e n a c t u a t e d and th e t u r b i n e w ic k e t g a t e s o p en ed to 100

p e r c e n t , o r th e maximum o p e n in g , a n d h e ld t h e r e f o r f i v e m in u te s a f t e r

th e u n i t r e a c h e d I t e maximum sp e ed o f 225 r p a w hich w e 175 p e r c e n t o f

th e r a t e d sp e e d . D u r in g t h i s t im e , th e a c t i o n o f th e g o v e rn o r o v e rs p e e d

t r i p was o b s e rv e d t o d e te rm in e t h a t i t f u n c t io n e d to t r i p a t IJO p e r c e n t

o f th e r a t e d s p e e d . A t t h e c o n c lu s io n o f th e t e s t th e t r i p w e ch eck ed

t o d e te rm in e t h a t I t r e s e t a t 105 p e r c e n t o f th e r a t e d «peed . The g r o s s

o p e r a t i n g h e a d on t h e u n i t a t th e tim e o f t h e t e s t was 1 * 5 .9 f e e t . Ac­

c o rd in g to M arks* H andbook*, a n d th e p r a c t i c e s o f h y d r a u l i c t u r b i n e

a f a c t u r e r s , t h e o b s e rv e d o v e rs p e e d w as w i t h in t h e a c c e p ta b le ra n g e f o r

t h i s ty p e o f F r a n c i s t u r b i n e . S in c e th e o v e rs p e e d i s r e l a t e d to th e

s p e c i f i c sp e e d o f t h e t u r b i n e , t h e s p e c i f i c sp e ed f o r t h i s u n i t a t d e s ig n

c o n d i t io n s i s c a l c u l a t e d a s f o l lo w s I

The g e n e r a l fo rm u la f o r s p e c i f i c sp e e d i s n* = m ( P ) 1 ^ / E w here

a s i » t h e s p e c i f i c sp e e d , n i s th e r p a o f th e u n i t , P I s th e r a t e d h o r s e ­

p o w er o f th e u n i t* an d H i s th e n e t e f f e c t i v e h e a d l a f e e t . P o r th e u n i t

c o n s id e r e d h e r e i n , th e r p a o f th e u n i t a t sy n c h ro n o u s sp e ed i s 1 2 8 .6 , th e

r a t e d h o rse p o w e r o f th e u n i t I s 50. 000, e n d th e n e t e f f e c t i v e d e s ig n h e a d

i s IJO f e e t . A p p ly in g t h i s d a ta to th e f o rm u la , n B = —'- - "-̂ ^ -"- ^ o r U7 .

A s w as s t a t e d e a r l i e r I n t h i s p a p e r , t h e c h a r a c t e r i s t i c s o f th e

I . L io n e l S . M ark s, 1 $ 5 1 , F i f t h S d l t i o n , MBCBMlKtiL M a i iB JBtt S HAhHBOOK,P . 1 2 9 2 , M cG raw -H ill Soolc Company, I n e . , le w f o r k , B . Y.

m ach ine r e g a r d in g b a la n c e an d s t a b i l i t y w ere o b s e rv e d d u r in g t h i s t e s t ,

and i t was n o te d t h a t th e m ach ine r a n e x c e p t io n a l ly sm ooth d u r in g th e

o v e rs p e e d c o n d i t io n , an d was q u i t e s t a b l e , a e no "bumps* o r o t h e r h e a v y

v i b r a t i o n s w ere o b s e rv e d .

I t w e c o n c lu d e d a e a r e s u l t o f th e c v e r s p e e d t e s t t h a t th e

t e r i s t i e s o f t h e m ach ine w ere w i t h in s p e c i f i c a t i o n r e q u i r e m e n ts , and i n ­

s o f a r a e t h a t p a r t i c u l a r p h a s e o f t h e t e s t i n g was c o n c e rn e d , th e In e

v a c a c c e p ta b le u n d e r t h e te rm s o f th e c o n t r a c t .

She t u r b i n e e f f i c i e n c y t e s t m e p e rfo rm e d c h i e f l y f o r t h e p u rp o se

o f v e r i f y i n g th e c o n t r a c to r * e g u a ra n te e d e f f i c i e n c y f o r t h e t u r b i n e i n

l i e u o f p e r fo rm in g a n o f f i c i a l a c c e p ta n c e t e s t , a n d to v e r i f y th e e f f i ­

c ie n c y c u rv e p l o t t e d a e a r e s u l t o f t h e m odel t e s t f o r t h e s u b je c t t u r ­

b i n e . A c tu a l ly , a n a c c e p ta n c e t e s t c o u ld n o t be c o n d u c te d i n a c c o rd a n c e

w i th t i ie A . a .H . l . P ow er V e s t C odes, b e c a u s e t h e a c c u r a te m easu rem en t o f

t h e q u a n t i t y o f w a te r p a s s i n g th e t u r b i n e g a te # by an y o f t h e a c c e p te d

m e th o d s w ould b e d i f f i c u l t a n d e x p e n s iv e i n t h i s p l a n t , a e t h e m ala p e n -

s t e e k s u p p ly in g w a te r to th e t h r e e u n i t e I e a p p ro x im a te ly 5200 f e e t i n

l e n g t h a n d I e n o t a e c e e e a b le a t th e i n t a k e , o r may in te r m e d ia t e p o i n t ,

u n t i l I t t e r m in a te s i n a t r i f u r c a t i n g J o i n t , from w hich t h r e e s e p a r a te

p e n s to c k s o r i g i n a t e a n d c o n n e c t t h e i n d iv i d u a l t u r b i n e s to th e m ain

p e n s to c k . As s t a t e d p r e v i o u s l y , t h e s e i n d i v i d u a l p e n s to c k s c o n n e c t by

m eans o f a r i s e r i n t o t h r e e s e p a r a te s u rg e t a n k s , a n d th e s u rg e

a r e i n t u r n in te r c o n n e c te d b y p a i r s o f 5 f o o t d ia m e te r i n te r c o n n e c t in g

tu b e s l o c a t e d a t two l e v e l s . I n a d d i t i o n , th e m ain p e n s to c k i s e q u ip p e d

-Us-

w ltb a s e rg e te a k l o c a t e d n e a r th e in ta k e s t r u c t u r e . B etw een th e In ­

ta k e s t r u c t u r e w h ich d r , -Jfte w a te r fro m th e r e s e r v o i r , an d t h e t u r b i n e

w ic k e t g a t e s , a r e l o c a t e d a p a i r o f em ergency t r a c t o r ty p e v e r t i c a l l i f t

g a t e s , a t r a n s i t i o n s e c t i o n , a s u rg e ta n k o r s h a f t , a t r i f u r c a t i n g h e a d -

b lo c k , a r i s e r c o n n e c t io n to a n o th e r s u rg e ta n k w hich s e r v e s a n I n d lv i d a -

a l u n i t , an d a b u t t e r f l y v a lv e w ith s u i t a b l e t r a n s i t i o n s e c t i o n s , e l l e f

w h ich a r e c o n n e c te d by p e n s to c k s a n d fo rm th e w a te r c a r r y in g sy s te m . T hus

I t c a n be n o te d t h a t w a te r m easu rem en t* e f one in d iv i d u a l t u r b i n e c o n n e c t­

e d I n to t h i s sy stem w ould be d i f f i c u l t . C oup led w ith th e s e d i f f i c u l t i e s ,

was th e p ro b lem t h a t l e a d c o n d i t io n s and pow er com m itm ents w ere such t h a t

t h e o p e r a t in g c o n d i t io n s s p e c i f i e d In t h e A .S .H . l . Pow er T e s t C odel e o u ld

n o t be m a in ta in e d w i th in th e p r e s c r i b e d l i m i t s . T h e r e f o r e , i t was n e c e s -

s a r y t h a t an a d a p ta t i o n o f t h e In d ex T e s t i n g M ethod? be u s e d In t e s t i n g

t h e e f f i c i e n c y o f t h e u n i t .

The g e n e r a l p r o c e d u r e o f c o n d u c tin g t h e t e s t was a s s t a t e d below ;

& B a s ic A s s u a p t i o n . In o r d e r to o b t a i n th e n e c e s s a r y t u r b in e

w a te r d le c h a rg e q u a n t i t i e s . I t w as assum ed t h a t t h e c a l i b r a t i o n o f th e

V ln tezw K enaedy m anom eter t a p e In th e s c r o l l c a s e o f T u rb in e Vo. 3 was

t h e same a s t h a t f a r th o s e I n th e s c r o l l c a s e o f T u rb in e Vo. I s in c e * 2

I .

M e c h a n ic a l E n g in e e r s , 29 V e s t 3 9 th S t r e e t , Hew Y ork , 5 . I .

2 . 6 . H. T o ad en , J u l y 19 5 1 , IHBBK TBSTIHG OH HTI)HA.ULIC TtBBIHBS, PayerHo. 5 0 -4 -5 2 , The A m erican S e c le ty o f M e d h an ie a l H n g ln e e re , 29 V e s t 3 9 th S t r e e t , Hew Y ork , H. T .

"both t u r b i n e s hav e I d e n t i c a l s c r o l l c a s e s w i th th e V in te r -K e a n e d y ta p e

l o c a t e d a t th e same p o i n t s , fro m p r e v io u s w a te r f lo w m easu rem en ts f o r

t h e c a l i b r a t i o n o f t h e W ln te r-K en n ed y t a p e i n th e s c r o l l c a s e o f Q h it

Ho. I , o p e r a t i n g s i n g l y , th e f o l lo w in g c a l i b r a t i o n was o b ta in e d :

QF 1043d1 / 2 , w here q e q u a ls t u r b i n e d is c h a r g e i n c u b ic f e e t p e r

s e c o n d , and d e q u a ls t h e m anom eter d e f l e c t i o n I n In c h e s o f m e rc u ry ,

when c o n n e c te d b e tw een th e h i g h - p r e s s u r e an d i n n e r - Io w -p re s su re

K ln te r -K e n n e d y t a p s I n t h e t u r b i n e s c r o l l e a s e .

4 . M easurem ent# t ^ a t u r o f W ate r. H ead in g s w ere ta k e n d u r in g

e a c h t e s t on t h e m e rc u ry m anom eters c o n n e c te d t o th e W lnter-K em nedy ta p e

i n t h e t u r b i n e s c r o l l e a s e , fro m w h ich t h e q u a n t i t y o f w a te r f lo w in g

th ro u g h th e t u r b i n e u n d e r t e s t was com puted fro m th e r e l a t i o n s h i p a b o v e .

c - M easurem ent o f Hew er O u tp u t. The g e n e r a to r o u tp u t was m easu r­

e d b y th e tw o -e le m e n t , t h r e e - p h a s e , w a t t - h o u r m e te r I n e a c h g e n e r a to r

c i r c u i t . An i n t e g r a l num ber o f r e v o l u t io n s o f th e w a t t - h o u r m e te r d i s c

w ere tim e d w i th a s to p w a tc h c a d th e g e n e r a to r o u tp u t com puted from t h e

d i s c c o n s ta n t an d c u r r e n t road p o t e n t i a l t r a n s f o r m e r r a t i o s . As a ch eck

on th e s e v a lu e s th e o u tp u t o f th e g e n e r a to r warn a l e e m ea su red by means

o f t h r e e c a l i b r a t e d i n d i c a t i n g w a t tm e te r s . The l e a d c u r r e n t s an d f i e l d

c u r r e n t f e r th e g e n e r a to r w ere a l e e m easu red i n o r d e r t h a t t h e g e n e r a to r

l e s s e e c o u ld b e m ore a c c u r a t e l y com puted .

&. M easurem ent o f l e a d . % e p r e s s u r e b e a d a t th e I n ta k e o f e a ch

t u r b i n e s c r o l l c a s e w as m ea su red by m eans o f B onrdon g a g e s l o c a t e d i n th e

t u r b i n e p i t s a t e l e v a t i o n 2052.0 an d e o n n e e te d to p ie z o m e te r t a p e l o c a t e d

-50-Su»* a p e t r e a e fro m e a c h t a r t In e I n ta k e . G a l i t r a t i o n c o r r e c t i o n , f o r

th e e # g a g e s w ere o b t a in e d t j r c l o s i n g th e w ic k e t g a t e s on a l l u n i t e and

c h e c k in g th e gage r e a d in g s a g a in s t th e s u rg e ta n k and r e s e r v o i r w a te r

e l e v a t i o n s . The t a i l r a c e w a te r e l e v a t i o n s f o r e a c h t e s t w ere ta k e n from

th e t a i l r a e e w a te r l e v e l r e c o r d e r i n th e c o n t r o l room, ( h i # r e c o r d e r

i n d i c a t e s t h e w a te r l e v e l I n a s t i l l i n g w e l l w h ich I e c o n n e c te d to th e

t a i l r a e e a t a p o i n t a d ja c e n t to th e d r a f t tu b e d i s c h a r g e o f T u rb in e S b .

I .

• • C o m p u ta tio n o f Pow er O u tp n t . The pow er o u tp u t w as com puted

from t h e r e l a t i o n s h i p :

— • * * * W = 5 8 % % : S B L w r

The g e n e r a to r m a n u f a c tu r e r 1 • g u a ra n te e d e f f i c i e n c i e s w ere u s e d i n com­

p u t i n g th e t u r b i n e o u tp u t f o r a l l t e s t s , s in c e th e r e s u l t s o f th e gen­

e r a t o r e f f i c i e n c y t e s t s w ere n o t a v a i l a b l e when th e s e t e s t s w ere m ade.

f C o m p u ta tio n o f T u rb in e S e t B ead , from th e c o r r e c t e d p r e s s u r e

h e a d a t th e e n t r a n c e t o t h e t u r b i n e s c r o l l c a s e a # m easu red b y th e

Sourdom gag e i n t h e t u r b i n e p i t a n d fro m th e e l e v a t i o n o f th e t a i l r a e e

w a te r l e v e l , t h e n e t h e a d on th e t u r b i n e was com puted u s in g t h e r e l a ­

t i o n s h i p h s 2 0 5 2 .0 ^ hp V Tz /2 g - ( t a i l r a e e w a te r e l e v a t i o n V T § /2 g ) ,

w here*

h e q u a ls n e t h e a d on t u r b i n e I n f e e t o f w a te r .

hP e q u a ls c o r r e c t e d p r e s s u r e h e a d I n f e e t o f w a te r m easu red

by th e t u r b i n e p i t gage a t e l e v a t i o n 2052. 0 .

T e q u a ls p e n s to c k v e l o c i t y o f t h e l o c a t i o n o f t h e t u r b i n e

IntalM piezometer taps and Is equivalent to q/ a where A

equals the croee-eeotioaal ere# o f the penstock; a t the

piezometer tape and i s l 60 square f e e t .

▼r equals the residual ta ilra c e v e lo c ity a t the section where

the ta llr a e e w t e r e levation was measured, (fhe value o f Ty

used was computed from the to ta l p lea t lead , assuming uniform

flew in the ta llra e e as a whole, using approximate turbine

and generator e f f ic ie n c ie s , by the equation Ty *

* -Q ggBU tatlon o f T u rb in e E f f i c i e n c y . The tu r b i n e e f f i c i e n c y w as

com puted from t h e e q u & tio a l

T u rb in e S f f l o l e n e y » 550 F 6 / Q eh, w here F e i s t h e t u r b i n e o u t ­

p u t i n E . F . , Q l a t h e q u a n t i t y o f w a te r u s e d by th e t u r b i n e

i n c a b le f e e t p e r se c o n d , w 1# th e w e ig h t o f w a te r p e r c u b ic

f o o t a n d i s 62. 57, and h i s t h e e f f e c t i v e n e t h e a d I n f e e t .

The t u r b i n e d i s c h a r g e an d o u tp u t h o rse p o w e r f o r e a c h t e s t

w ere r e d u c e d Se s c o n s ta n t e f f e c t i v e h e a d o f IJO f e e t by th e

assum ed r e l a t i o n s h i p s ^ 70 = p J 0 j l / 2 ^ P 170 = F e

T h eee r e l a t i o n s h i p s a r e n o t s t r i c t l y t r u e u n l e s s t h e sp eed o f

t h e u n i t e i s a d ju s t e d d u r in g t h e t e s t to e q u a l r a t e d sp e ed t im e s

x 8 . 85 . T h ie w as a v e ry m in e r c o r r e c t i o n

a a th e maximum v a lu e s w ere a b o u t O .J f e e t . )

w h ic h was I m p r a c t i c a l , s in c e t h e u n i t w as i n pow er

p r o d u c t io n and o p e r a t i n g a t sy n c h ro n o u s sp e e d .

-52*

O w v a lu e s o f % y o an d »170 w ere p l o t t e d s e p a r a t e l y a n d sm ooth

c u rv e s draw n r e p r e s e n t i n g th e mean o f th e o b s e r v a t io n s . Fromi . I ' 'I : U ’ ■ ' -

t h e s e two c u rv e s th e e f f i c i e n c y o f t h e u n i t was p l o t t e d end

com pared w ith th e m odel c u rv e e s t a b l i s h e d by th e m a n u fa c tu re r* •

m odel t e s t e f th e u n i t . B e f e r to P l a t e J i l l f o r th e r e s u l t a n t

c u rv e . I t w as fo u n d th e y com pared f a v o r a b ly , an d I t w as th e r e ­

f o r e c o n c lu d e d t h a t fo rm a l a c c e p ta n c e t e s t e f o r t h e u n i t w ould

b e u n n e c e s s a ry when th e e x p e n se o f c o n d u c tin g t h e t e e t e v e r s u s

t h e v a lu e o f t h e I n fo r m a t io n r e c e iv e d was com pared .

I n summary, I t c a n b e s t a t e d t h a t w h i le th e p ro b le m s , an d t h e i r s o lu ­

t i o n s d i s c u s s e d h e r e i n p e r t a i n to a p a r t i c u l a r u n i t i n a p a r t i c u l a r h y d ro ­

e l e c t r i c p l e a t and w ere p e c u l i a r o n ly to t h i s p l a n t , t h e p r i n c i p l e s an d

m ethods u s e d to s o lv e t h e s e d i f f i c u l t i e s ca n be a p p l i e d to s i m i l a r I n ­

s t a l l a t i o n s o f h e a v y h y d r o e l e c t r i c e q u ip m en t a n d a r e t h e r e f o r e b e l i e v e d

t o b e s u i t a b l e e x p e r ie n c e s to o f f e r to t h e f i e l d e f M e c h a n ic a l E n g in e e r in g .

-53

PLA TE V I I I - E FFIC IE N C Y CUHVE OF TURBINE

T-f I 'I■ • I •

I 111.

1 7 O f t . n e t h e a d e f f i c i e nc y c u r v e c o m p u t e d from Model t e s t s .

E f f i c i e n c y a t r a t e d n e t h e a d o f 17 O f t . f r o m f i e l d t e s t s .

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o t e s t p o i n t s

t u r b i n e o u t p u t HORSEPOWER

OOOi 401.000 I soiooo 6 0 ,0 0 0 i

LmRATOHB ClTSD ASD COHSOIjTBD

-$ k -

A a e r lc a a X a c t l t u t e o f S t e e l O o n e t r u s t lo a , I 9U1 , STEEL (XfflSTHJCTIOHtP P . 3 3 7 -3 3 8 . A a e r lc a a I a s t l t u t e o f S t e e l C o n e tra o - t l o n , Hew T e rk t H. T.

H a rk e t L io n e l S . , 1 9 5 1 , F i f t h B A lt lo a t MBCEAHICAl SSC IE -B * S HAHEBOOKfP . 1 2 9 2 , H c O ru v -H lll Book O oapaayt I n c . , Hew Torfct H. T .

The A m erlcaa S o c ie ty o f M e o h a a le a l B n g la e e r e t J u a e t 1938, A. S .H .E .POWHE TEST 001® TOH HTilEAULlC PXXMS MOTSESt The A m erican S o c ie ty o f M e c h a a le a l E n g in e e r# * 29 V e s t 3 9 th S t r e e t , Hew T o rk t X. T .

The L la e o la l l e c t r l c Company, 1950 H la th E d i t i o n , PROCBBOHK EAEDBOOK OTABC WELDIHO, ISSlfflX ASD PRACTICE, P . 306, The L ln e o la E l e e t r l e Company, C le w e laa d I , O h le .

T e a d e a t S . E . , J U ly 1 9 5 1 , MTOBt TBSTIHO OT ETDEAULIC TUHBIHBSt P a p e rHo. RO-A-52, IBie A m e r i c a S o c ie ty o f K e c h a n lc a l E n g in e e r s , 29 W est 3 9 th S t r e e t , Hew T o rk 1 I . f .

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