CECW-EE

Engineer Manual1110-2-4205

Department of the ArmyU.S. Army Corps of Engineers

Washington, DC 20314-1000

EM 1110-2-4205

30 June 1995

Engineering and Design

HYDROELECTRIC POWER PLANTSMECHANICAL DESIGN

Distribution Restriction StatementApproved for public release; distribution is

unlimited.

DEPARTMENT OF THE ARMY EM 1110-2-4205U.S. Army Corps of Engineers

CECW-EE Washington, DC 20314-1000

ManualNo. 1110-2-4205 30 June 1995

Engineering and DesignHYDROELECTRIC POWER PLANTS

MECHANICAL DESIGN

1. Purpose. The purpose of this manual is to provide guidance and criteria pertinent to the designand selection of hydroelectric power plant mechanical equipment and systems.

2. Applicability. This manual is applicable to all HQUSACE elements, major subordinate commands,districts, laboratories, and separate field operating activities having responsibility for civil worksprojects.

3. General. This manual discusses many items related to the planning and design of powerhousemechanical equipment and systems. It is not intended as a comprehensive, step-by-step solution topowerhouse mechanical design, but as an experience-oriented guide and a basis for resolvingdifferences of opinion among competent engineers at all levels.

FOR THE COMMANDER:

Colonel, Corps of EngineersChief of Staff

This manual supersedes EM 1110-2-4205, dated 30 June 1980.

DEPARTMENT OF THE ARMY EM 1110-2-4205U.S. Army Corps of Engineers

CECW-EE Washington, DC 20314-1000

ManualNo. 1110-2-4205 30 June 1995

Engineering and DesignHYDROELECTRIC POWER PLANTS

MECHANICAL DESIGN

Table of Contents

Subject Paragraph Page Subject Paragraph Page

Chapter 1IntroductionPurpose . . . . . . . . . . . . . . . . . . . . . 1-1 1-1Applicability . . . . . . . . . . . . . . . . . . 1-2 1-1References . . . . . . . . . . . . . . . . . . . . 1-3 1-1Limitations . . . . . . . . . . . . . . . . . . . 1-4 1-1Contents . . . . . . . . . . . . . . . . . . . . . 1-5 1-1Design Procedures . . . . . . . . . . . . . . 1-6 1-1Other Design Information . . . . . . . . . 1-7 1-2Deviations . . . . . . . . . . . . . . . . . . . . 1-8 1-2General Design Practices. . . . . . . . . . 1-9 1-2Safety Provisions . . . . . . . . . . . . . . . 1-10 1-2

Chapter 2Turbines and Pump TurbinesGeneral . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1Francis-Type Turbines. . . . . . . . . . . . 2-2 2-1Francis-Type Pump Turbines. . . . . . . 2-3 2-3Kaplan-Type Turbines. . . . . . . . . . . . 2-4 2-4

Chapter 3Generators and Motor-GeneratorsGeneral . . . . . . . . . . . . . . . . . . . . . . 3-1 3-1Turbine Considerations . . . . . . . . . . . 3-2 3-1Handling Provisions . . . . . . . . . . . . . 3-3 3-1Service Systems. . . . . . . . . . . . . . . . 3-4 3-1

Chapter 4GovernorsGeneral . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1Considerations . . . . . . . . . . . . . . . . . 4-2 4-1

Chapter 5Penstock Shutoff Valves at thePowerhouseGeneral . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1

Valve Requirement . . . . . . . . . 5-2 5-1Valve Selection . . . . . . . . . . . 5-3 5-1

Chapter 6Cranes and HoistsGeneral . . . . . . . . . . . . . . . . . 6-1 6-1Cranes . . . . . . . . . . . . . . . . . . 6-2 6-1Crane Lifting Accessories . . . . 6-3 6-6Hoists . . . . . . . . . . . . . . . . . . 6-4 6-8

Chapter 7ElevatorsGeneral . . . . . . . . . . . . . . . . . 7-1 7-1Justification . . . . . . . . . . . . . . 7-2 7-1Location . . . . . . . . . . . . . . . . 7-3 7-1Size . . . . . . . . . . . . . . . . . . . 7-4 7-1Type . . . . . . . . . . . . . . . . . . . 7-5 7-2Speed . . . . . . . . . . . . . . . . . . 7-6 7-2Control . . . . . . . . . . . . . . . . . 7-7 7-2Design . . . . . . . . . . . . . . . . . . 7-8 7-2Procurement . . . . . . . . . . . . . . 7-9 7-2

Chapter 8Engine-Generator SetGeneral . . . . . . . . . . . . . . . . . 8-1 8-1Location . . . . . . . . . . . . . . . . 8-2 8-1Engine . . . . . . . . . . . . . . . . . . 8-3 8-1Exhaust Provisions . . . . . . . . . 8-4 8-1Cooling . . . . . . . . . . . . . . . . . 8-5 8-2Fuel System . . . . . . . . . . . . . . 8-6 8-2Installation . . . . . . . . . . . . . . . 8-7 8-2

Chapter 9Maintenance ShopGeneral . . . . . . . . . . . . . . . . . 9-1 9-1Shop Room . . . . . . . . . . . . . . 9-2 9-1

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Subject Paragraph Page Subject Paragraph Page

Equipment Selection . . . . . . . . . . . . . 9-3 9-1Shop Layout . . . . . . . . . . . . . . . . . . 9-4 9-2Drawing . . . . . . . . . . . . . . . . . . . . . 9-5 9-2

Chapter 10Water Supply SystemsGeneral . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1Generator and Turbine Cooling

Water System . . . . . . . . . . . . . . . . 10-2 10-1Transformer Cooling Water . . . . . . . . 10-3 10-2Fire Protection Water . . . . . . . . . . . . 10-4 10-3Potable Water System. . . . . . . . . . . . 10-5 10-3Raw Water System. . . . . . . . . . . . . . 10-6 10-5

Chapter 11Unwatering and Drainage SystemGeneral . . . . . . . . . . . . . . . . . . . . . . 11-1 11-1Unwatering System. . . . . . . . . . . . . . 11-2 11-1Drainage System. . . . . . . . . . . . . . . . 11-3 11-3Equalizing (Filling) . . . . . . . . . . . . . . 11-4 11-6Venting . . . . . . . . . . . . . . . . . . . . . . 11-5 11-7

Chapter 12Oil SystemsGeneral . . . . . . . . . . . . . . . . . . . . . . 12-1 12-1System Requirements. . . . . . . . . . . . 12-2 12-1Oil Storage Room. . . . . . . . . . . . . . . 12-3 12-1Oil Storage Tanks. . . . . . . . . . . . . . . 12-4 12-1Pumps . . . . . . . . . . . . . . . . . . . . . . . 12-5 12-2Oil Piping . . . . . . . . . . . . . . . . . . . . 12-6 12-2Oil Purifiers . . . . . . . . . . . . . . . . . . . 12-7 12-3Alternate Systems. . . . . . . . . . . . . . . 12-8 12-3

Chapter 13Compressed Air SystemsGeneral . . . . . . . . . . . . . . . . . . . . . . 13-1 13-1Service Air System . . . . . . . . . . . . . . 13-2 13-1Brake Air System . . . . . . . . . . . . . . . 13-3 13-3Governor Air System . . . . . . . . . . . . 13-4 13-3Draft Tube Water

Depression System. . . . . . . . . . . . . 13-5 13-4Miscellaneous Provisions. . . . . . . . . . 13-6 13-5

Chapter 14Plumbing SystemsGeneral . . . . . . . . . . . . . . . . . . . . . . 14-1 14-1Fixtures . . . . . . . . . . . . . . . . . . . . . . 14-2 14-1Water Supply . . . . . . . . . . . . . . . . . . 14-3 14-1Sanitary Piping . . . . . . . . . . . . . . . . . 14-4 14-1Sewage Treatment . . . . . . . . . . . . . . 14-5 14-1

Chapter 15Fire Protection SystemsGeneral . . . . . . . . . . . . . . . . .15-1 15-1Oil Storage and

Purification Rooms . . . . . . . . 15-2 15-1Paint and Flammable LiquidStorage Room . . . . . . . . . . . . 15-3 15-1

Generators . . . . . . . . . . . . . . .15-4 15-2Motors . . . . . . . . . . . . . . . . .15-5 15-2Transformers . . . . . . . . . . . . . 15-6 15-2Portable Fire Extinguishers . . . 15-7 15-3Detections . . . . . . . . . . . . . . .15-8 15-3Isolation and Smoke Control . . 15-9 15-3Fire Hose . . . . . . . . . . . . . . . .15-10 15-3

Chapter 16Piezometers, Flow Meters, andLevel GaugesGeneral . . . . . . . . . . . . . . . . .16-1 16-1Turbine Piezometers. . . . . . . . 16-2 16-1Miscellaneous Piezometers. . . . 16-3 16-2Water Level Gauges . . . . . . . . 16-4 16-2

Chapter 17PipingGeneral . . . . . . . . . . . . . . . . .17-1 17-1Design Considerations. . . . . . . 17-2 17-1

Chapter 18Heating, Ventilating, andAir Conditioning SystemGeneral . . . . . . . . . . . . . . . . .18-1 18-1Design Conditions . . . . . . . . . 18-2 18-1Design . . . . . . . . . . . . . . . . . .18-3 18-2Design Memorandum . . . . . . . 18-4 18-5

Chapter 19Corrosion Mitigation ConsiderationsGeneral . . . . . . . . . . . . . . . . .19-1 19-1Design Considerations. . . . . . . 19-2 19-1

Appendix AReferences

Appendix BReference Drawings and Data

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Chapter 1Introduction

1-1. Purpose

This manual provides information and criteria pertinent tothe design and selection of hydroelectric power plantmechanical equipment and systems for new and rehabilita-tion projects. It is applicable to all such work within theU.S. Army Corps of Engineers responsibility.

1-2. Applicability

This manual is applicable to all HQUSACE elements,major subordinate commands, districts, laboratories, andseparate field operating activities having responsibility forcivil works projects.

1-3. References

Required and related publications are listed inAppendix A.

1-4. Limitations

a. Information covered in other manuals.The selec-tion, procurement, and specification of certain majormechanical equipment are covered in other existing orpending engineer manual and guide specifications, includ-ing turbines, pump-turbines, governors, and mechanicalaspects of generators. Information contained herein perti-nent to such equipment is principally to aid in preparationof contract specifications based on the guide specification.

b. Detail design. This manual is not intended as acomprehensive, step-by-step solution to powerhousemechanical design nor as a substitute for sound engineer-ing resourcefulness and judgment. Used as a “guidepost,” not a “hitching post,” it provides experience-oriented guidance and a basis for resolving differences ofopinion among the competent engineers at all levels.

c. Material generally available. The manualstresses information that is of particular applicability topowerhouses. Other material useful in powerhousemechanical design which is readily available in standardpublications is not generally repeated or referenced herein.

1-5. Contents

This manual is divided into 18 chapters, each coveringone or more closely related items of powerhouse

mechanical equipment or system, a Chapter 19 on corro-sion mitigation, and two appendices. Equipment andsystems where the detail design responsibility is normallydelegated to the contractor, or where other engineeringmanuals are applicable, are covered with the emphasis onapplication, selection, and specification aspects. Equip-ment and systems where the detail design is normally aCorps of Engineers office function are covered in greaterdetail or referenced to applicable standard design codes orhandbooks. Appendix A lists references to other materialsuch as guide specifications, codes, industry standards,and other engineering manuals provided throughout thismanual as applicable. Appendix B contains specificationexcerpts, typical system schematics, and drawings ofequipment and details typical of powerhouses and otherinformation not readily available from commonly knownsources.

1-6. Design Procedures

a. Standard procedures.Department of the ArmyCivil Works Guide Specification CE-4000 provides thestandard procedure for development of a powerhousedesign. These procedures include a Preliminary DesignReport, Feature Design Memoranda, an Analysis ofDesign, Contract Drawings, Specifications, and Cost Esti-mates. CE-4000 prescribes the timing, preparation, andapproval procedure for this material and also referencesother applicable manuals and guides. While the formatand instructions of CE-4000 imply applicability only toArchitect-Engineer design contracts, the design proceduresnoted therein should be followed by all district or divisionoffices performing powerhouse mechanical design. Fund-ing problems, fluctuations in planned manpower, andconflicts in design scheduling will tend to alter the pre-scribed order of procedures. However, all stated require-ments should be met unless prior approval of an alternateprocedure is obtained from higher authority.

b. Additional procedures.

(1) Shop drawing review. The checking of contrac-tor shop drawings and other material for adequacy andcompliance with specification requirements is normallyassigned to the engineers who prepared the design.

(2) Operating instructions. The preparation of oper-ating instructions for each item of equipment and systemis normally a design office responsibility. This requiresthat all design considerations and assumptions be recordedand filed during the design development.

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1-7. Other Design Information

a. Sources. Information which may be helpful indesign is available from many sources other than pre-scribed Corps of Engineers material and standard hand-books. Design memorandums and drawings from otherprojects, manufacturers’ catalog information, sales engi-neers, project operation and maintenance reports, fieldinspectors, operation and maintenance personnel, and thepowerhouse electrical and structural design personnel areall valuable and readily available sources. Good com-munication with other Corps of Engineer District andDivision offices can often expedite information on a par-ticular problem.

b. Evaluation. Evaluation of available informationshould be approached with skepticism and judgment.Relying on previous satisfactory designs requires that thedesign conditions and requirements be carefully comparedfor applicability. The obtainment and evaluation of infor-mation from field sources is improved by the personalacquaintanceships and observations resulting from designengineer visits to under construction and operating plantsas well as supplier plants. Office policies should permitand encourage these visits.

1-8. Deviations

Considerable flexibility in design is available to thedesign engineer within the manual provisions. It is recog-nized that new applications and techniques may justifydeviations from the stated provisions. In such circum-stances, advance consultation with higher authority issuggested.

1-9. General Design Practices

a. Factors during fabrication.Design should reflectthe quality of materials, workmanship, and general qualitycontrol normally experienced. The engineer will not haveabsolute control over these factors during fabrication butcan often make practical design concessions which willmake the equipment or system less critical to deviationsfrom specified tolerances.

b. Design computations. Design computationsshould be consistent with available data and assumptions.Precise computations are seldom justified with incompletedata and rough assumptions.

c. Simple designs.Designs should be as simple aspracticable. Increased complexity for minor operationaladvantages is usually not warranted.

d. Backup requirements. Backup requirementsshould be evaluated both on the probability and effect ofmalfunction. Frequent, minor malfunctions can be expen-sive; a major-once-in-a-hundred year malfunction can becatastrophic.

e. Reducing personnel.The continuing emphasis onreducing operation and maintenance personnel should bereflected in designs requiring frequent operation andmaintenance.

f. Generous tolerances.Tolerances and fits shouldbe generous as practicable. Precision workmanship isexpensive and undependable to obtain.

g. Design computations. The design computationsshould include the sources of all existing designs fol-lowed, sources of data, a record of alternate designsinvestigated, actual design computations used, andplanned operating procedures. In providing design refer-ences, particularly where more than one reference islisted, a specific reference to the particular source isessential. A general listing of references potentially appli-cable to a system or item of equipment is of little valuefor review or record purposes. Providing specific refer-ences is essential in design memorandums as well asdesign computations in general.

h. Environmental quality. Incorporating environ-mental quality in project design is essential. Opportuni-ties for enhancement through design will be vigorouslysought. Specific ecological considerations in hydropowermechanical design include, but are not limited to, the useof environmentally safe lubricants, actions to preserve orenhance the survivability of fish (fish survival rate versusturbine efficiency), and actions to maintain or enhancewater quality (location of the water intakes).

i Infestations. In areas with potential for zebramussel contamination, many hydropower components,such as cooling systems, will be at risk of failure or dis-ruption due to zebra mussel infestations. Design consid-erations in preventing these infestations should beincluded. For control strategies, refer to Zebra MusselResearch Technical Note ZMR-3-05, compiled by ZebraMussel Research Program at Waterways ExperimentStation.

1-10. Safety Provisions

Certain safety provisions will be required by guide speci-fications, trade standards, codes, and other manuals refer-enced herein. In addition, the requirements of the

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Occupation Safety and Health Administration (generallyreferred to as OSHA Standards) are to be consideredminimum requirements in Corps of Engineers design (seeEM 385-1-1). Areas of particular concern, to mechanicaldesign, are noise levels, personnel access provisions,

working temperature conditions, air contamination, andload handling provisions. Modification and expansion ofOSHA Standards are on a continuing basis, requiringconformance with the latest published requirements.

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Chapter 2Turbines and Pump Turbines

2-1. General

Mechanical design responsibilities in connection withturbines and pump turbines include selection of type ofunit, power rating, operating characteristics and number ofunits, preparing contract specifications, checking contrac-tors drawings, and coordinating related powerhouse facili-ties including generator, governor, air, water, and oilsystems, handling provisions, and structural requirements.The guidance for turbine and pump-turbine selection isincluded in ETL 1110-2-317. Design of turbines is acontractor responsibility and is included under the supplycontract used for turbine procurement. Coverage in thischapter is generally limited to considerations in prepara-tion and completion of the project specifications. Tur-bines are a major and critical item in powerhouses andwarrant maximum effort to assure practical, well-coordi-nated specifications with reasonable assurance of respon-sive bidding. In addition to the guidance referencedabove, the specifications should reflect Corps experiencewith previous similar units and preliminary exchange ofinformation and proposals with potential suppliers.

2-2. Francis-Type Turbines

a. Scheduling. Drawing and data submittal times,commencement and completion of work, deliveryschedules, and installation work scheduling should becoordinated with general project scheduling and turbinemanufacturers. Suppliers of hydraulic turbines are lim-ited. Therefore, early contact with potential suppliers isadvisable to determine their capability for bidding to theproposed dates and to assure a competitive biddingresponse.

b. Stainless steel runners.Stainless steel runnersshould be specified where possible. In many cases, theymay be more economical than carbon steel runners withstainless steel overlay. However, where the benefits ofstainless steel are not necessary, a carbon steel runnermay be more feasible.

c. Runner overlay. The extent of chrome-nickeloverlay on the runner, required for cavitation protection,is usually indeterminate at bidding time, but an estimatedarea is required in the specification for bid evaluationpurposes. The estimate should be made on the basis ofprebid information obtained from suppliers and compari-sons with previous units. Extensive studies are not

warranted since required areas will be determined afterrunner design is complete and model tested, and paymentwill be adjusted accordingly. The final determination ofrequired area made by the contractor is usually acceptedsince it would be a factor in the cavitation guarantee.

d. Shaft diameter.The minimum shaft diameter fornew construction should be computed on the basis of38,000 kPa (5,500 psi) maximum shear stress and unitypower factor. On projects where the units are beinguprated the limit should be set at 41,000 kPa (6,000 psi).The maximum torsional stress should be calculated usingthe Mohr’s circle which combines the following stresses:stress due to the weight of all rotating parts carried by theshaft; stress created by the maximum steady-state operat-ing hydraulic thrust; and the stress produced by the maxi-mum torque the turbine would be allowed to produce,normally the maximum continuous duty rating (MCDR) ata power factor (PF) of 1.0.

e. Shaft length. The estimated elevation of the tur-bine shaft coupling should be set to realize a minimumrequired height of powerhouse walls, taking in to accountrequired handling clearances of the generator rotor andshaft and the turbine rotor and shaft.

f. Shaft inspection hole.The minimum diameter ofthe axial hole through the turbine shaft for inspectionpurposes is about 100 mm (4 in.). Holes which havediameters of 150-200 mm (6-8 in.) are normally specifiedon the larger shafts where the reduction in strength wouldbe insignificant. The larger holes expedite inspection andremove additional core material prone to shrinkagecavities.

g. Bearing oil heat exchanger.The pressure ratingfor the heat exchanger should be based on pump shutoffhead if a pumped supply is required and on maximumpool plus surges where a spiral case source is to be used.The hydrostatic test should be at 150 percent of ratedpressure. The maximum pressure differential across thecooler is usually specified at 68.9 kPa (10 psi) to assuresatisfactory cooling. The cooling water temperatureshould be the maximum of the source water. However,this will usually be somewhat indeterminate, and the tem-perature specified should include an appropriate contin-gency. The cooling water source should be the same asfor the generator air coolers, requiring coordination ofsupply heads and pressure drops. In powerhouses whereavailable gravity head would be adequate for turbinerequirements but marginal for the generator requirementsa pumped supply should be provided for both. For addi-tional comments on cooling water, refer to Chapter 10.

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h. Guide bearing oil pumps.Pressurized lubricationsystems are sometimes used for guide bearings, and theguide specification includes the pump requirements.However, self-lubricating bearings are practicable and arepreferred for reliability and to reduce the connected DCload. An oil sump drainage pump is required when it isnot practicable to drain the sump to the oil storage roomby gravity. Capacity should usually be based on drainingthe sump in 3-4 hr. The installed pump option is pre-ferred over a portable pump for convenience and savingsin operational manhours.

i. Stay ring.

(1) Internal pressure. The stay ring should bedesigned for an internal pressure based on maximum poolhead plus water hammer.

(2) Grout holes. Holes required for placing of groutunder the stay ring are normally 50 mm (2 in.) in diam-eter. A diameter of 20 mm (3/4 in.) is satisfactory forvent holes.

j. Spiral case and spiral case extension.The spec-ific requirement is dependent on the need for a fieldhydrostatic test, the need for a valve at the end of thepenstock, and the method of connecting spiral case exten-sion to the penstock or penstock valve.

(1) Hydrostatic test. Standard practice is to require afield hydrostatic test on all units requiring field welding.Elimination of field welding is practical only with verysmall cases permitting full shop assembly and shipping.The test should be specified at 150 percent of design headincluding water hammer. When a hydrostatic test is spec-ified, the alternative of magnetic particle inspection forcircumferential shop and field welded joints may be used.A field hydrostatic test will also require the alternative ofproviding a test pump and sealing off devices at the stayring opening and inlet end of the spiral case extension.Also, when a field hydrostatic test is performed, theembedment of the case is performed while pressurizedand the test pump is used to maintain design pressure inthe case. The relief valve specified should be capable ofbeing set at both the design pressure and test pressure.The pressure alarm should be actuated at a 68.9-kPa(10-psi) drop below design pressure. If circumstances aresuch that embedment with pressurized spiral case isimpracticable, a mastic blanket covering the spiral caseand extension is usually required to minimize the trans-mittal of operating head load to the concrete. An alterna-tive requiring an additional 76-mm (3-in.) length of spiral

case extension is necessary for cutting and finishing whenremoving a test head.

(2) Penstockk valve. Chapter 5 discusses factorsrelating to the requirements for penstock valves. Valvesmay be of either the butterfly or spherical type. The pen-stock extension-to-valve connection options are not influ-enced by the type of valve. Valves may be procuredunder the turbine contract or provided by a separate sup-ply contract. A separate schedule should be providedwhen the valves are included so that award can be madeby schedule or by a combination of schedules to eliminateundesirable effects on competitive bidding.

(3) Connection to spiral case extension. The choiceof a flexible sleeve-type coupling or a welded joint forconnecting the spiral case extension to the penstock valveor penstock depends primarily on structural consider-ations. These considerations involve the most practicablepoint at which to take the closed valve reaction and theprobability of differential settlement or other structuralfactors affecting alignment of the penstock and spiral caseextension.

(a) With penstock valve. Where a penstock valve isused, the reaction of the closed valve is generally takenby the penstock and a flexible coupling provided to con-nect the valve to the spiral case extension. This connec-tion requires a straight section of penstock extension withtolerances to meet the coupling requirements and longenough to permit assembly and disassembly. Guide spec-ification options are included for obtaining the straightsection. A welded connection for valve-to-spiral caseextension is satisfactory with closed valve reaction takenby the penstock and structural and foundation conditionsindicating no potential misalignment problems.

(b) Without penstock valve. A welded connectionshould generally be used unless structural and foundationconditions indicate a possibility of misalignment prob-lems. Where a flexible coupling is indicated, the straightpenstock section will be required as with the valve-typeinstallation.

(4) Service water. A service water connection onthe spiral case extension is primarily for generator aircoolers and generator and turbine bearing coolers. Unitgland water may also be from the service water connec-tion, and in some powerhouses raw water for other pow-erhouse requirements is obtained from this source. Theconnection size specified should be based on preliminaryestimates of cooling water requirements by potential

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generator and turbine bidders, requirements at existingprojects, crossover requirements, and the proposed power-house piping system. A connection is not required wherea tailwater pumped supply is justified. If piping andvalve location considerations warrant, the supply connec-tion may be specified on the spiral case rather than on thespiral case extension.

(5) Drain. The spiral case-extension drain should besized in accordance with the considerations noted inparagraph 11-2b(3).

k. Runner wearing rings.Wearing rings on the run-ner are not normally specified as operating experience hasindicated little or no requirement for replacement. Sta-tionary wearing rings above and below the runner shouldbe specified.

l. Facing plates and wicket gate seals.Facingplates above and below the wicket gates are not requiredwhen gate seals are provided. Gate seals are usuallyjustified. Rubber seals without facings are generally satis-factory to about 91 m (300 ft) of head. Bronze or stain-less facings should be required over 91 m (300 ft) ofhead.

m. Air depression connection.Where an air depres-sion system for depressing the draft water below therunner is planned, or is a future probability, a flangedconnection in the head cover should be provided. Consid-erations pertinent to sizing the connection are discussed inparagraph 13-5.

n. Wicket gate shear pin detection.A pneumaticsystem for detecting a broken shear pin is not normallyinstalled until operating experience indicates a need. Thetapped hole option should be included in the specificationas the cost is minimal.

o. Wicket gate servomotor pressure.Nominal sys-tem operating pressures (high end of operating range)range from 2,100-6,900 kPa (300-1,000 psi). Optimumpressure is dependent on a number of factors including:required pump displacement, pipe sizes, cost of hydrauliccomponents, pumping horsepower, tank sizes, blade andgate servomotor sizes and location (see paragraph 2-4a),and service experience. Evaluation should be on the basisof overall cost of the turbine and governor system. Theevaluation must be on the basis of advance informationobtained from potential turbine and governor supplierssince the turbine and governor are normally obtainedunder separate contracts. When the advance information

indicates the cost of alternate pressure systems to beapproximately the same, the lower pressure system shouldbe specified. System piping, fittings, and packing appro-priate for the operating pressure should be specified. Astandard pressure should be specified (refer to GuideSpecification CW-11290).

p. Gate locking device.A manual device is satisfac-tory for the open gate position. An automatic device forthe closed gate position should be provided for all units topermit automatic locking on unit shutdown.

q. Pit liner. The minimum elevation of top of pitliner should be specified to be approximately 0.6 m (2 ft)above the servomotor elevation. Minimum plate thicknessshould be 13 mm (1/2 in.) to permit tapped holes for themounting of piping and equipment. One personnelentrance to the turbine pit is sufficient unless safety regu-lations would require an additional access for emergencyescape.

r. Draft tube liner. The minimum draft tube linerthickness is usually specified at 16-19 mm (5/8-3/4 in.)depending on the draft tube size. The liner should extenddown to protect concrete from water velocities over 9 m/s(30 fps) and a minimum of 0.9 m (3 ft) below the maindoor.

s. Rotation. The direction of rotation of the turbinerunner may be specified as either clockwise or counter-clockwise as far as operating characteristics of the turbineand generator are concerned. However, direction of rota-tion affects powerhouse layout and handling facilities tosome extent and should be specified for optimum conven-ience and economy. Considerations in the determinationof the offset of the generators with respect to the centerline of a powerhouse bay are as follows: the direction ofrotation, the location of the assembly area, proposedbridge crane arrangement, and proximity of the closestend wall to the generator center line. Normally cranes aredesigned and specified to interpose no significant restric-tions on turbine design. In the case of an additional unitto be installed in an existing powerhouse, however, spaceand crane limitations should also be considered in specify-ing turbine rotation.

2-3. Francis-Type Pump Turbines

The considerations noted under paragraph 2-2 are gener-ally applicable in completing specifications for Francis-type pump turbines.

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2-4. Kaplan-Type Turbines

Items listed in paragraph 2-2 are generally applicable toKaplan units also. Additional considerations pertinent toKaplan units are as follows:

a. Blade servomotor location.A location requiringremoval and disassembly of the runner to effect repair orreplacement of the servomotor is not recommended. Thiswould normally rule out an upper hub location as anacceptable option. Location of the blade servomotor is afactor in selecting the governor operating pressure. Whenthe servomotor is located in the shaft, higher pressureswill permit a reasonable shaft and flange diameter at theservomotor. Locating the servomotor in the runner conebelow the blades is an acceptable alternative to the shaftlocation.

b. Head cover drain pumps.Reliability of the headcover drain pumps and power supply is of primary impor-tance to provide maximum safeguard against flooding ofthe turbine guide bearing and a prolonged unit shutdown.One AC and one DC pump will usually ensure the mostreliable installation. However, there is normally consider-able opposition to the additional load on the station batter-ies. The reliability of the AC supply depends on anumber of factors involving inhouse and outside sourcesand inhouse distribution. If a reliable backup electricalsource is not practicable to obtain, backup air operatedpumps or water jet educters may be justified. Themechanical design memorandum should include a discus-sion on the reliability of the power supply of the headcover drain pumps and backup provisions along with anevaluation of the seriousness of one or more units out ofservice for the necessary cleanup operation.

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Chapter 3Generators and Motor-Generators

3-1. General

Design of generators and motor-generators is specified asa contractor responsibility. Design requirements andspecifications are the responsibilities of electrical disci-pline within the Corps of Engineers (see EM 1110-2-3006for guidance). Guide Specification CW-16210 providesthe basis for preparation of contract specifications.Mechanical design includes the following responsibilities:coordination of turbine and generator mechanical charac-teristics; required generator handling facilities; and oil, air,carbon dioxide (CO2), and water service connections tothe generator. Design considerations for the generator asrelated to the turbines, cranes, and piping systems arecovered under the respective chapters of this manual.Discussion in this chapter pertains to mechanical consider-ations in completing generator guide specifications.

3-2. Turbine Considerations

Powerhouse scheduling normally requires contracting ofthe turbines prior to preparation of generator specifica-tions. This permits the required turbine data for the gen-erator specification to be obtained from the turbinespecification, the turbine bid data, and the turbine modeltest. Preadvertising correspondence with turbine andgenerator suppliers should provide verification that theturbine related stipulations in the generator specificationare practicable. The required flywheel effect of rotatinggenerator parts must be computed on the basis of allrelated factors. This includes turbine characteristics aswell as penstock, generator, governor, and power systemcharacteristics. Maximum speed rise and pressure riseupon loss of generator load are normally the criticalmechanical factors. Turbines and generators are specifiedto withstand stresses due to runaway speeds; however, thedamaging effects of vibrations are indeterminate andrequire conservative limits on speed rise. Maximumspeed rise should normally be limited to 40 percent abovesynchronous speed when the required WR2 can beobtained with a normal generator design. When the40 percent limitation would require a special generatorrotor rim design or separate flywheel, a greater allowablespeed rise may be warranted but should not exceed60 percent in any case. Maximum pressure rise at theturbine is usually limited to 30 percent above the maxi-mum static pressure.

3-3. Handling Provisions

The powerhouse crane is normally sized to handle thegenerator parts, and no size or weight restrictions shouldbe included in the generator specification. Certain power-houses may justify two (2) cranes coupled together forhandling the heavier parts. These should also be designedto meet the generator requirements. Exceptions to thispolicy may be required where a new unit is being pro-vided in an existing crane equipped powerhouse, or wherescheduling revisions require a crane to be under contractbefore a generator contract is awarded. In either case, theappropriate crane limitation should be included in thegenerator specification. Ratings for a crane procuredbefore generator data are available should be based onprebid exchange of information with generator suppliers.Crane design guidance is covered in Chapter 6 of thismanual. For existing powerhouses, a crane clearance dia-gram, powerhouse access limitations, and other applicablephysical limitations should be included in the generatorspecifications.

3-4. Service Systems

a. Oil. The powerhouse lube oil system supply andreturn lines which serve the generator bearing system arenormally terminated within the generator housing near thetop or bottom of the turbine pit. It is generally not practi-cable to determine exact locations at the preparation timeof generator specifications, so it is satisfactory to negoti-ate final connecting points for generator and powerhousepiping during shop drawing review. Filtering and purify-ing of lube oil at the unit is normally not required exceptat the initial filling. This should be accomplished withgovernment furnished filters and powerhouse portablepurifiers. Oil coolers with water coils are normally sup-plied from the same cooling water system as the air cool-ers and turbine bearing coolers. Paragraphs 2-2gand 10-2 provide guidance concerning maximum differen-tial pressure, design pressure, test pressure, cooling watertemperature, and cooling water supply.

b. Air. Compressed air for operation of the genera-tor brakes is supplied from the powerhouse brake airsystem as discussed in paragraph 13-3. Generator specifi-cations should normally include values of 689 kPa(100 psi) as the nominal system pressure and 517 kPa(75 psi) as minimum system pressure. Piping termina-tions are generally as noted above in paragraph 3-4a foroil piping.

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c. Carbon dioxide systems.The CO2 piping termi-nations are generally as noted above in paragraph 3-4a foroil piping. In powerhouses where the CO2 powerhouseheaders are routed above the generator floor elevation, itmay be preferable to route the connecting lines overheadto enter the generator housing near the top. Para-graph 15-4 provides guidance on generator CO2 systems.

d. Water. Powerhouse cooling water supply and dis-charge lines serving the generator air coolers and bearingoil coolers are normally terminated in the lower generatorhousing. Cooling water head and temperature consider-ations and test pressures should be as discussed in para-graph 2-2g for turbine bearing coolers. Related comments

on generator cooling water supplies are included underparagraph 10-2. Temperature modulation of the generatorcooling water should be provided for units where it isnecessary to modulate the cooling water flow to assure acooling water discharge temperature which meets power-house heating requirements. The generator specificationshould include a statement on the type of control that willbe provided in the powerhouse cooling water piping andthe modulated temperature. When modulation is proposedfor other reasons, a statement to this effect should also beincluded in the generator specification. In all cases wherethe cooling water flow is modulated, a low-flow bypassshould be provided around the modulating valve to allowminimum flow for startup.

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Chapter 4Governors

4-1. General

The design of governors for turbines and pump-turbines isspecified as a responsibility of the governor manufacturer.In general, the governor operating requirements and char-acteristics will be determined from the electrical, mechan-ical, and hydraulic characteristics of the generator,turbine, and penstock. Guide Specification CW-16252provides the basis for preparing specifications. EM 1110-2-3006 provides guidance for the electrical and electroniccontrols of the governor. Coverage in this chapterincludes considerations pertinent to selecting the guidespecifications mechanical options.

4-2. Considerations

a. System pressures.The nominal pressure of gov-ernor-servomotor systems is selected from a series ofstandard pressures ranging from 2,067-6,890 kPa (300-1,000 psi). Turbine requirements will usually indicate thedesirable nominal pressure (refer to paragraph 2-2o).Since turbine contracts are normally scheduled in advanceof governor contracts, the nominal pressure will havebeen determined before the governor specification is pre-pared. However, it is important to exchange informationwith potential governor suppliers during preparation of theturbine specification. The working pressure range shouldbe appropriate for the nominal system pressure as indi-cated in the guide specification. The differential pressureacross gate servomotor ports (and oil head ports of Kap-lan units) is assumed 80 percent of the minimum workingpressure range for figuring servomotor capacity. Thisassumed value allows for piping and valve losses andrequires that the governor and turbine contractors cooper-ate to limit the pressure drop in the system accordingly.System design pressure should be at the pressure tankvalve setting which is normally 110 percent of nominalsystem pressure.

b. Oil heaters. The minimum and maximum designambient temperatures should be the heating and ventilat-ing system design temperatures for the room with allow-ance for nonuniform temperature conditions in the room.The minimum ambient temperature stated may be of sig-nificance to the governor contractor in determining theneed for oil heaters if oil of higher viscosity than standardturbine oil will be used in the governor system. If oilheaters are used, care must be taken to ensure that the

surface temperature of the oil heater does not cause anychemical change of the oil, such as chemical breakdown.

c. Pressure tank.

(1) Location. The powerhouse equipment layoutshould provide the pressure tank location(s) with theshortest and most direct lines practicable from the tank tothe actuator and servomotors in order to minimize pres-sure losses.

(2) Tank design and pressure. The tank and safetyvalve shall be designed in accordance with the latestversion of the American Society of Mechanical Engineers(ASME) “Boiler and Pressure Vessel Code.” The tankdesign pressure should be a minimum of 115 percent ofthe maximum system operating pressure. This will allowfor variations in the pump stop switch and oil pump pres-sure relief valve and safety valve blowdown pressure. Apilot-operated ASME safety valve should be used whichhas a 98 percent cracking pressure and a 4 percent blow-down. The safety valve setting should never exceed thestamped tank pressure rating but should be equal to orless than the stamped tank pressure rating. An example isas follows:

Stamped Tank Pressure. . . . . . . . . . . . . . . 4,795 kPa(696 psi)

Stamped Safety Valve Setting. . . . . . . . . . 4,168 kPa(605 psi)

Safety Valve Cracking Pressure. . . . . . . . . 4,086 kPa(593 psi)

Safety Valve Blowdown Pressure. . . . . . . . 3,996 kPa(580 psi)

Oil Pump Pressure Relief Setting. . . . . . . . 3,962 kPa(575 psi)

Governor Oil Pump High-Pressure Stop Switch(Maximum system operating pressure) . . . 3,790 kPa

(550 psi)

(3) Tank test pressure. Shop test pressure should bein accordance with the ASME “Boiler and Pressure Ves-sel Code.” This is typically 150 percent of the stampedtank pressure.

(4) Tank height. A specification restriction on tankheight should be avoided unless required by powerhousestructural configuration.

(5) Tank oil level alarms. High and low oil levelalarms will normally be required to permit monitoring ofpressure tank and sump tank oil level in the control room.

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In addition, pressure tank high-level and sump tank low-level contacts are used for pump control to stop the pumpand lock it out in case of pump unloader valve failure.

d. Distributing valve adjustment. The requiredsetting for the wicket gate opening or closing rate isdependent on the design for maximum unit overspeed andthe water hammer design stresses in the penstock andturbine. The timing usually stated in the specifications isbetween 8 and 20 sec. For turbine blade adjustment, arapid response is not required and can impose undesirablestresses in the blade operating mechanism. Then thetiming usually stated in the specification is between 20and 60 sec.

e. Maximum runaway speed.The maximum run-away speed to be specified should be based on the turbinemodel test results.

f. Brake air valve. The air pressure for the brakeair valve should normally be specified at a nominal689 kPa (100 psi). If there is reason to expect the stationservice air will be controlled to a higher pressure, thepowerhouse construction contract should require a pres-sure-reducing valve in the brake system air supply. If theturbine runner is below minimum tailwater elevation, atimer to effect intermittent operation of the brake air valveis seldom justified as satisfactory operation is normallypossible by allowing the unit to decrease to 30 percentspeed with no brake application, then apply brakescontinuously.

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Chapter 5Penstock Shutoff Valves at thePowerhouse

5-1. General

Butterfly and spherical valves are typically used at Corpsof Engineers projects when shutoff capability is requiredat the powerhouse end of the penstock. Mechanicaldesign responsibilities for these valves include the deter-mination of need, selection of type and size, selection ofauxiliary equipment, coordination of location and spacerequirements, preparation of contract drawings and speci-fications, review of contractor submittals, and preparationof instruction manuals.

5-2. Valve Requirement

A shutoff valve may be required at the powerhouse end ofpenstocks for either turbine or pump-turbine units. Thepurpose of this valve is to provide emergency shutoff incase of flooding-type failure or loss of speed control,reduction of leakage through wicket gates, and for mainte-nance of the turbine. However, shutoff provisions areusually required at the intake of each penstock. As aresult, a shutoff valve at the unit may not be required.Several factors should be considered when deciding theneed for a shutoff valve at the unit. The factors includebut are not limited to the following:

a. Type of shutoff at the penstock intake.A quickclosing shutoff at the penstock intake, operable underemergency conditions, may be an alternative to a shutoffat the powerhouse. Where maintenance and emergencyshutdown can be satisfied with the intake shutoff, therequirement for powerhouse valves can seldom bejustified.

b. Length of penstock.A long section of penstockdownstream of the shutoff will increase the time requiredto shut the unit down during an emergency closure,increase the time required to unwater the unit, andincrease leakage losses. Maintenance and emergencyshutdown requirements will usually justify a powerhouseshutoff when the penstock is several hundred feet long.

c. Head. A shutoff valve near the unit will reducethe effective head on the unit, which in turn will reducethe leakage.

d. Multiple units per penstock. Operational andmaintenance flexibility will normally require a separateshutoff valve for each unit. Generally, maintenancerequirements alone will justify powerhouse shutoff valvesfor multiple unit penstocks.

e. Type of wicket gate seal.A tight seal reducesleakage losses. However, deterioration of the seal withtime should be considered when determining the effects ofleakage.

Evaluation of the factors should consider their effects onmaintenance, emergency operations, and costs. The fac-tors considered and basis of determination should beincluded in the mechanical design memorandum.

5-3. Valve Selection

Butterfly and spherical valves are generally available as acatalog item for heads up to 183 m (600 ft) and in sizesup to 2.4 m (8 ft). Valves for conditions exceeding theselimits are typically designed for the specific application.Factors to be considered include initial cost, maintenance,head loss through valve, and requirements for transitionsections.

a. Spherical valves.

(1) General. Spherical valves consist of a valvebody, valve rotor, bearings, and operator. In the openposition, the rotor has a full diameter water passage axi-ally aligned with the penstock. Head loss through thevalve in the full open position is approximately the sameas an equal length of penstock. When rotated 90 deg (theclosed position), the valve presents a solid surface, closingthe water passage. Movable seal rings permit tight shut-off. Wear of the sealing surfaces is minimized becausethe wear rings are not in contact with the mating surfacesuntil after valve rotation is complete. Fabrication andmachining costs are relatively high when compared withbutterfly valves.

(2) Detail requirements are as follows.

(a) Design conditions. Valves should be designedfor maximum penstock head including water hammer.Because of the significance of a water hammer, studiesshould be conducted and documented in the design pro-cess. Since the valve may be used to test the penstockand/or spiral case, and during spiral case grouting, thedesign should also be adequate for these heads as

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applicable. The installation may require the valve towithstand heads from either direction when closed. If thevalve is to be used for emergency closure, the operatorshould be capable of closing the valve in 2-5 min aspracticable for the size.

(b) Valve body. The valve body should be made inhalves of fabricated or cast steel, properly annealed, andadequately designed to resist the hydraulic forces actingdirectly on the body and those resulting from the thrustfor any position of the valve rotor. Integrally cast orforged (if fabricated) steel flanges, suitably machined,should be provided for bolting the body pieces togetherand circumferential flanges for bolting to the pipeextensions.

(c) Rotor. The valve rotor should be made in onepiece of annealed cast or fabricated steel and should ade-quately resist the bending and shearing load resultingfrom the hydraulic and operating forces.

(d) Seals. Retractable seal rings should be providedto permit separation of the sealing surfaces during rotationof the rotor. Sealing surfaces should be corrosion resis-tant and of different composition and hardness to mini-mize galling. One seal of 300 series stainless and one of400 series stainless will perform satisfactorily in mostwaters. However, the source water should be checked forunusual corrosiveness. Then the materials should bespecified accordingly. Both sealing surfaces should beremovable for replacement. The retractable seal ringshould normally be oil-hydraulically operated. Bothupstream and downstream seals may be justified to allowmore flexibility in scheduling of seal replacement.

(e) Trunnion bearings. Trunnion bearing with renew-able self-lubricating bronze sleeves and bronze thrustwashers should be provided. Bearing housings should beintegral to the body casting. A means of adjusting andcentering the rotor should be provided. Pressure relief forleakage water through the gland should be verified.

(f) Bypass. A bypass valve permitting equalizedpressure on both sides of the spherical valve before open-ing should be provided. The bypass is normally motoroperated for automatic control.

(g) Valve operator. A double-acting hydraulic cylin-der operator should be provided for opening and closingthe valve. The operator should be capable of closing thevalve at maximum pool head and maximum discharge.Opening capability should be at balanced head conditions.The operator should also be suitable for continuous

pressurization to hold the rotor in either the fully closedor open position. All valve and operator componentssubject to loading from operator action should bedesigned for the maximum hydraulic cylinder forces.

(h) Operator control. The type of control should beappropriate for normal unit operation and emergencyshutdown requirements. Pumps are normally on pressureswitch control and are protected with relief or unloadingvalves. Cylinder action is normally controlled withmotor-operated tight sealing four-way valves and pres-sure-compensated flow control valves set to obtain therequired opening and closing times. Spool-type controlvalves are not suitable for extended pressurizing periodsin one direction. Impurities tend to filter out in the spoolclearances causing sticking and failure to operate.Gauges, isolating valves, filters, alarms, control panels,and limit switches should be provided as applicable.

(i) Pipe extensions. Pipe extensions for connectingthe valve to the penstock and spiral case extension aregenerally procured with the valve. The extensions shouldbe designed on the same basis as the penstock. One endof each extension should be provided with a flange toconnect to the valve flange. The other end of each exten-sion should be prepared for a welded and or sleeve-typeconnection, as required. When required, the sleeve cou-plings are normally procured with the extensions.

(3) Safety provisions.

(a) A lockable, mechanical latch should be providedfor securing the valve in the closed position. The latchshould be capable of withstanding any opening forceobtainable from the hydraulic operator to protect workmenfrom accidental opening of the valve.

(b) A mechanical hydraulic hand pump and manu-ally operable control valves should be provided for man-ual operation of the valve in either direction.

(c) The valve operating cylinder should be cushionedto prevent damage due to the valve slamming in the eventoil pressure is lost.

(d) Additional flow control valves should be pro-vided in the hydraulic circuit at the cylinders. Thesevalves should limit the flow to 125 percent of normalclosure flow if line pressure is lost.

(e) Hydraulic pumping capacity should be providedwith two pumps in a lead-lag control arrangement, either

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of which is capable of performing a normal opening oremergency closing.

(f) Accumulators should be provided in the hydraulicsystem with capacity sufficient to fully close or open allspherical valves on the system with both pumps inopera-tive after the low system pressure alarm has beenactivated.

(g) All parts and components subject to loading fromoperation of the hydraulic operator should be designed formaximum stress of 75 percent of yield point with a maxi-mum attainable pressure in the cylinder. Maximumattainable pressure should be assumed as either pumpshutoff pressure or maximum setting of the relief valvesized for maximum pump delivery.

(h) Valve bodies and rotors should be hydrostaticallytested at 150 percent of design head in both directions andwith rotors open and closed.

(4) Design. Design of spherical valves and operatorsshould be specified as a contractor responsibility. How-ever, the valves are a critical item in obtaining and main-taining satisfactory unit operation. Therefore, thespecifications should require equipment of a designproven in service. Standard catalog equipment is pre-ferred when available. Where a size and head rating notpreviously in use is required, the specifications shouldrequire the bidder to have experience in designing andmanufacturing similar valves of the approximate size andhead rating.

b. Butterfly valves.

(1) General. Butterfly valves consist of a valve body,valve disc, bearings, and operator. Head loss through abutterfly valve is higher than for a spherical valve.Losses are higher for lenticular-type disks versus the opentruss-type disc. Head loss may justify an oversize valvewith suitable transition sections. Some leakage is charac-teristic of the metal-seated butterfly valves.

(2) Detail requirements.

(a) Design conditions (see paragraph 5-3a(2)(a)).

(b) Valve body. The valve body should be of eithercast or fabricated construction and include connectingflanges. Design and fabrication should be in accordancewith Section VIII of the ASME “Boiler and Pressure Ves-sel Code.”

(c) Disc. The valve disc should be of cast or fabri-cated construction and either lenticular or open trussdesign. Design stresses should not exceed 50 percent ofyield point or 25 percent of ultimate at design head. Fab-ricated designs should be stress relieved before machin-ing. Disc design should provide for wedge sealing actionwith the disc at less than 90 deg to valve axis, and thedisc should have positive overtravel limits. The limit maybe provided by mechanical stops or by bottoming of oper-ator piston.

(d) Seals. Valve body and disc seals should be ofcorrosion resistant steel of different composition andhardness to minimize galling. Both seals should bereplaceable without dismantling the valve, and the bodyseal should be adjustable from outside the valve. Suit-ability of the seal composition to resist corrosion in thepenstock water should be verified by prior operatingexperience or chemical analysis. Seal design should notbe compromised to allow a manufacturer’s standarddesign.

(e) Valve shaft. The valve shaft for lenticular discsshould be one piece. Shafts for open truss-type discs maybe bolted on. Corrosion resistant sleeves should be pro-vided at the packing boxes if noncorrosion resistanceshafts are used.

(f) Bearings. Shaft bearings should be sleeve type,self-lubricated and should include adjustable thrust sur-faces for centering the disc.

(g) Bypass (see paragraph 5-3a(2)(f)).

(h) Valve operator (see paragraph 5-3a(2)(g)).

(i) Operator control (see paragraph 5-3a(2)(h)).

(j) Pipe extensions. Pipe extension provisions forbutterfly valves are generally as described in para-graph 5-3a(2)(i) for spherical valves. In some cases, itmay be hydraulically justified to design the downstreamextension as a transition section to minimize the effect ofthe velocity change at the valve. The downstream end ofthe transition section should be as required to permit thewelded or sleeve-type connection to the spiral caseextension.

(3) Safety provisions (see paragraph 5-3a(3)).

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(4) Design. The design of butterfly valves and opera-tors should be specified as a contractor responsibility.However, the valves are a critical item in obtaining andmaintaining satisfactory unit operation. Therefore, thespecifications should require equipment of a designproven in service. Standard catalog equipment is

preferred when available. Where a size and head ratingnot previously in use is required, the specifications shouldrequire the bidder to have experience in designing andmanufacturing similar valves of the approximate size andhead rating.

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Chapter 6Cranes and Hoists

6-1. General

a. General. Cranes and hoists are used in power-houses for operational functions and for maintenance andrepair. The general hoisting functions involved are simi-lar for most powerhouses, but loadings, frequency ofusage, powerhouse configuration, installed equipment,value of downtime, and availability of portable equipmentcan affect the optimum provisions for a particular project.Normally, initial planning should be on the basis of anexisting project with similar requirements, but carefulconsideration of the variables should precede final selec-tion of cranes and hoists.

b. Terminology. “Cranes” and “Hoists” are some-what interchangeable terminology since the actual liftingmechanism of a crane is commonly referred to as a hoist.For purposes of coverage in this chapter, “Hoists” will beconsidered as separate items of equipment that includeinstallations where the hoist machine is fixed and there isno controlled lateral movement of the hook(s) or liftingblock(s). Other applications are covered under “Cranes.”

c. Emergency closure.For safety reasons, two dif-ferent closure methods to shutoff the water supply to theturbine are required. One method is considered to be thewicket gates. The other method shall be a penstock shut-off valve (refer to Chapter 5), or an intake gate loweredby a hoist. Fixed hoists at each intake gate slot are usedto lower the intake gates in an emergency situation.Intake gantry cranes are not normally used to lower intakegates in an emergency because of the much slowerresponse time and potential crane-capacity problems.

6-2. Cranes

a. Types. Cranes for powerhouse requirementsinclude several types: bridge, gantry, monorail, jib,mobile, and floor cranes. Coverage in this chapter is asfollows:

(1) Powerhouse bridge crane. The principal overheadtraveling crane serving the turbines, generators, and auxil-iaries in typical indoor powerhouses.

(2) Powerhouse gantry. A gantry-type crane servingthe same functions as the powerhouse bridge crane foroutdoor powerhouses or in unusual cases involving aspecial structural design of indoor powerhouses.

(3) Intake gantry. A gantry-type crane servingintake gates, trashracks, bulkheads, fish screens, and mis-cellaneous items on the intake decks of powerhouses.

(4) Draft tube gantry. A gantry-type crane servingstop logs, bulkheads, and miscellaneous items on thetailrace deck of powerhouses.

(5) Mobile crane. A self-propelled, rubber-tiredcrane for general use, principally on intake or tailracedecks and miscellaneous nonpowerhouse project functions.

(6) Maintenance shop bridge crane. A maintenanceshop bridge crane, usually a trolley-mounted electric hoistsuspended from a single girder bridge, serving equipmentin the maintenance shop.

(7) Floor crane. A light, portable crane with wheelsfor mobility on powerhouse and maintenance shop floorareas, normally manually being propelled.

(8) Monorail crane. A trolley-mounted, motorizedor manual, hoist running on an I beam track for specialapplications.

(9) Jib crane. A wall or pillar-mounted, rotatingbracket with an electric or manual hoist for specializedlifts with limited horizontal movement requirements.

b. Preliminary considerations. For each power-house, the following preliminary considerations shouldprecede design and specification work on the individualcranes:

(1) Items handled. A preliminary listing of all majoritems to be handled by powerhouse cranes during con-struction, operation, maintenance, and repair should beprepared. The listing should include estimated weights,pickup and set down points, and the crane to be used.

(2) Area layouts. For each crane, layout drawingsshould be prepared showing points at which the cranemust pick up or set down material, including loading orunloading of trucks and railroad cars, intermediate ortransfer points, maintenance and repair areas, and equip-ment installation points. These layouts should includepoints for required lifts and points or areas at which cranelifts may be desirable but not required. Areas which maybe used as storage or warehouse areas should be indicatedalso. Lifting or handling of heavy items (e.g. a smalltransformer), which may require moving for which craneservice is not planned, should be indicated along with theproposed means of handling.

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(3) Coordination. The preparation of the listing ofitems to be handled and area layout drawings shouldinclude information exchanged with construction andoperation divisions as well as other engineering responsi-bilities. All reasonable adjustments in equipment locationto provide effective and economical crane service shouldbe negotiated also.

(4) Miscellaneous preliminary considerations. Corro-sion mitigation is discussed in paragraph 19-2.

c. Engineering and design.Most engineering anddetail design criteria for powerhouse cranes are covered inengineering manuals and guide specifications as refer-enced herein under the particular crane type. Final detaildesign and construction of cranes are responsibilities ofthe supplier as provided under the procurement contracts.The responsibility of the powerhouse design office is toobtain and coordinate all preliminary information noted inparagraph 6-2b; to determine requirements for each cranebased on the preliminary information; to prepare craneclearance drawings based on sufficient design studies; toassure a practical and economical crane; to prepare speci-fications; and to review shop drawings, design computa-tions, and operating instruction manuals. Documentationof assumptions and reasons for selecting particular liftingprocedures and equipment arrangements should be a partof the design records. The preliminary studies and coor-dination are important in obtaining the optimum crane forthe required service, and shortcuts should not be made.

d. Bidder qualifications. Bidder qualifications arenot normally an engineering responsibility, but in the caseof powerhouse cranes, it is particularly important for thepowerhouse mechanical designers to exert their influencein obtaining qualified contractors. Providing cranes readyfor service on schedule is very important to avoid impactto overall powerhouse construction schedules. Contractorsinexperienced in design and construction of cranes havecaused costly delays and impacts to other constructionwork. Many times a two-step bidding process is prudentin order to obtain a quality product on schedule.

e. Powerhouse bridge cranes.

(1) General. General criteria and design procedures,along with data on existing cranes, are available inEM 1110-2-4203. Detail design criteria for indoor bridgecranes are covered in Guide Specification CW-14330.For outdoor powerhouses, the powerhouse crane willnormally be a gantry type for which design criteria notedin Guide Specification CW-14340 should be used as indi-cated in paragraph 9 of EM 1110-2-4203. Coverage

herein is limited to additional general factors which enterinto crane requirements and crane selection. The discus-sion is applicable particularly to powerhouses with con-ventional vertical units; however, most factors noted arealso applicable to cranes servicing slant or bulb units.Some slant units may require two cranes, one upstreamand one downstream, because of horizontal distancebetween generator and turbine. Special intermediate liftand handling facilities are usually involved with eitherslant- or bulb-type units. These special facilities shouldbe determined and furnished by the generator and turbinecontractors subject to the normal design office shop-draw-ing reviews.

(2) Number of cranes. The choice of providing oneor two cranes is an important consideration in power-houses with several units or heavy capacity requirements.Factors entering into this determination are:

(a) Procurement cost. This cost considers one craneversus two.

(b) Powerhouse structural costs. A single crane mayincrease structural costs because of greater physical size,though generally only moderate additional cost isinvolved.

(c) Construction and erection advantages of two-crane availability. Two cranes will usually be more bene-ficial in long multiunit powerhouses and may havesignificant advantages where the construction schedulerequires continued erection work after several units are inoperation.

(d) Additional crane clearance. The necessity toprovide two-crane lifting beam configuration will increasethe roof height.

(e) Hook coverage limitations. Unusually largecapacity single cranes result in greater floor areas notaccessible to a lifting hook.

(f) Additional maintenance cost. Maintaining twocranes versus one does increase this cost.

(g) Value of unit downtime. Two cranes may expe-dite maintenance or repairs.

(h) Comment relative to two cranes for bulb or slantunits (see paragraph 6-2e(1)). Seldom will two cranes bejustified in powerhouses with less than five units. Forfive or more units, the design memoranda should include

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the considerations pertinent to the selection of one or twocranes.

(3) AC versus DC drive systems. Current technologyof AC variable frequency drives enables them to haveperformance similar to a DC drive, and the cost isapproximately the same. One advantage of the AC driveis reduced maintenance since induction motors do nothave brushes as DC motors do. The guide specificationslist several alternatives to be determined for each specificapplication.

(4) Crane capacity. EM 1110-2-4203 includes guid-ance for determining crane capacity. In applying thecriteria the engineer should be aware that numerous fac-tors beyond engineering control tend to disrupt orderlyscheduling, and it will frequently be necessary to preparecontract drawings and specifications for cranes beforeaccurate final loads are determined. It is also sometimesnecessary to firm up powerhouse structure design affectedby crane capacity and clearances prior to final confirma-tion of lifting loads. In such cases, capacity should bebased conservatively on estimated loads (to avoid laterincreases). Loadings due to planned or potential futureunits should also receive consideration in determiningcrane capacity and be included in the design computa-tions. It has been the Corps of Engineers practice tospecify crane ratings that allow up to 10 percent overloadfor infrequent special heavy lifts such as the generatorrotor when a preferred crane rating falls within this range.For cranes designed in accordance with Corps of Engi-neers guide specifications, this overload is well within theallowable stresses permitted by the Crane ManufacturersAssociation of America (CMAA) standards and is inaccordance with ANSI standards and OSHA’S interpreta-tion of their regulations.

(5) Appearance. Powerhouse bridge crane appearanceshould be consistent with the interior finish of the power-house. It is usually advisable to rely on the powerhousearchitect for determination of an acceptable appearance,but compromises are necessary where preferred appear-ance impairs maintenance, full utility, or safety.

(6) Access. In the early stages of powerhouse layout,convenient and safe access to bridge cranes should beconsidered. In larger powerhouses, the vertical distancefrom erection areas to the crane cab level may be 15 m(50 ft) or more. This makes it desirable to provide accessfrom a level served by an elevator when practicable.Access via convenient stairs is preferred when elevatorservice is impracticable, but the most common access,

particularly in the smaller powerhouses, is via ladders. Aladder located to permit direct access to the cab elevationis preferred. Via corbel, bridge, and ladder descent intocab is the least desirable means of access but is accept-able when required by powerhouse arrangement. Thecrane “parking” location should be reasonably close to theprincipal crane use area. Safety is the first considerationin crane access, and architectural emphasis should not beat the expense of either safety or convenience.

(7) Drawing. Typical powerhouse bridge craneclearance and coverage diagrams appear in Appendix B,Figure B-1.

f. Powerhouse gantry cranes.

(1) General. General considerations noted in para-graph 6-2e(1) are applicable. Powerhouse cranes of thegantry type are usually limited to outdoor powerhouses.In the case of an indoor powerhouse such as Libby Damin Montana with construction making it impractical tosupport bridge crane rails, a gantry or semigantry may berequired. There has been very limited application forsuch cranes in Corps of Engineers projects, but data onthe Libby crane are available from the HydroelectricDesign Center, North Pacific Division, Portland, Oregon,for reference purposes. The design generally should fol-low applicable criteria for outdoor powerhouse gantries.

(2) Number of cranes. More than one gantry cranewill seldom be justified since cost and bulkiness tend tooffset the advantages. Portable equipment can usually beutilized for major work at outdoor powerhouses furtherdiminishing the value of a second crane.

(3) DC versus AC drive systems. Current technol-ogy of AC variable-frequency drives enables them to haveperformance similar to a DC drive, and the cost is approx-imately the same. One advantage of the AC drive isreduced maintenance since induction motors do not havebrushes as DC motors do. The guide specifications listseveral alternatives to be determined for each specificapplication.

(4) Crane capacity. Comments in paragraph 6-2e(4)are applicable. In cases where additional hoists are pro-vided serving the functions of draft tube gantry cranes orintake gantry cranes, capacity of those hoists should be asdescribed in paragraphs 6-2h(5) and 6-2g(5).

(5) Appearance. Comments in paragraph 6-2e(5) areapplicable.

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g. Intake gantry cranes.

(1) General. The powerhouse intake gantry cranemay be utilized as a dual-purpose powerhouse intake-spillway crane but is more commonly restricted to power-house intake service. Intake deck-hoisting requirementsvary widely from project to project, and good judgment isrequired to select the optimum provisions for each crane.Present publications of crane design data on existingprojects do not include intake gantry cranes. However,data on existing cranes, to meet most new requirements,are available, and sources can be obtained on requestfrom the Office of Chief Engineers, Washington, DC.Coverage herein includes general factors pertinent to theselection and type of equipment. Detail design criteria areincluded in Guide Specification CW-14340.

(2) Intake gantry lifting functions.

(a) Intake gates and bulkheads. The heaviest liftsnormally involve handling of the intake gates and bulk-heads. Trolley-mounted hoists permit handling of thegates and bulkheads with the same hoist. Routine raisingand lowering, maintenance support, and transfer to storageslots or other repair locations are normal requirements. Insome instances, the crane is used during gate delivery anderection; however, construction scheduling usuallyrequires contractor cranes being available for gate erec-tion. Intake gantry cranes are not used to lower intakegates in an emergency because of the potential loadcapacity problems resulting from gate hydraulic downpullin addition to the slow response. The total time for acrane crew to come on site, pick up an intake gate, travelto the affected generating unit, lower the intake gate, andrepeat the sequence to install the other two intake gates ismuch too long to avoid major damage to the unit andprotect the integrity of the powerhouse. Even if theintake gantry crane was built with three hoists to carrythree intake gates to provide faster closure, the responsetime is still too long.

(b) Fish guidance equipment. Raising and loweringfish guidance equipment, such as submerged travelingscreens or submerged bar screens, and vertical barrierscreens, is a major task for intake gantry cranes at somepowerhouses. Additional provisions are needed to handlefish guidance equipment, such as tugger hoists, an auxil-iary hoist, faster main hoist speeds, and additional liftingdevices. Careful planning is needed to assure all neededprovisions are included in the crane design.

(c) Trashrack service. Raising and lowering of trash-rack sections and raking of trashracks are common intake

gantry crane functions where distances from gate andbulkhead slots to trashracks are moderate. For widerdecks, use of a standard commercially available rake andhoist unit or a separate trashraking crane is morepractical.

(d) Handling of individual gate hoists. Where indi-vidual gate hoists are provided, placement and removal isnormally an intake gantry crane function, and the clear-ances for hydraulic cylinders, load transfer supports, andprocedures for raising and lowering cylinders betweenvertical and horizontal positions require careful planning.

(e) Transformer handling. Where main power trans-formers located on intake decks are within the crane loadrating otherwise required, loading and unloading of thetransformers is a common crane function. Increasingcrane capacity, hook coverage, or number of hoists fortransformer handling alone is seldom justified as tempo-rary facilities are practical for the infrequent movements.

(f) Loading and unloading of rail cars and trucks.Intake decks are usually accessible to trucks and, in somecases, rail cars. Crane clearances and hook coverageshould provide convenient handling.

(g) Miscellaneous lifts. As applicable, miscellaneouslifts should also be considered in crane design. Lighterlifts may be made using mobile cranes, but availability,accurate control, and safety usually favor the use of anintake gantry crane.

(3) Number of cranes. More than one intake gantrycrane will seldom be justified.

(4) AC versus DC drive systems. Current technol-ogy of AC variable-frequency drives enables them to haveperformance similar to a DC drive, and the cost is approx-imately the same. One advantage of the AC drive isreduced maintenance since induction motors do not havebrushes as DC motors do. The guide specifications listseveral alternatives to be determined for each specificapplication.

(5) Crane capacity. Crane capacity should be deter-mined in accordance with Guide Specification CW-14340.

(6) Appearance. Intake gantry crane appearanceshould be consistent with the intake deck area of thepowerhouse. It is usually advisable to rely on the power-house architect for determination of an acceptable appear-ance, but compromises are necessary where preferredappearance impairs maintenance, full utility, or safety.

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(7) Dual-purpose cranes. Use of the intake gantry forboth intake deck and spillway deck functions should beconsidered where usage for routine operational purposes isnot required on either deck. Agreement should beobtained from the operations division involved on theacceptability of a dual-purpose crane.

h. Draft tube gantry crane.

(1) General. The principal function of a draft tubegantry crane is to handle the draft tube bulkheads. Alter-nate provisions are sometimes practical and should receiveconsideration. This includes using a monorail hoist wheredeck configuration and slot location are unsuitable for agantry or a mobile crane, or where there will be only oneto three units. Then the project will have a mobile craneavailable full time for other purposes. Commercial mono-rail hoists are generally restricted to about 4.5-tonne(5-ton) lifts. Mobile cranes are less desirable for operat-ing convenience and safety reasons, so procurement of amobile crane specifically for handling draft tube bulk-heads is not recommended. Detail design criteria for drafttube gantry cranes are included in Guide SpecificationCE-1603.

(2) Lifting functions.

(a) Draft tube bulkheads. This function will deter-mine the crane rating.

(b) Deck slot and hatch covers.

(c) Fish facility equipment. At projects where fishfacilities are incorporated in the draft tube structure, thedraft tube crane may be required to handle gates, bulk-heads, stop logs, machinery, weirs, diffusers, etc.

(3) Number of cranes. One draft tube gantry willprovide all required service.

(4) DC versus AC drives. Current technology of ACvariable-frequency drives enables them to have perfor-mance similar to a DC drive, and the cost is approxi-mately the same. One advantage of the AC drive isreduced maintenance since induction motors do not havebrushes as DC motors do. The guide specifications listseveral alternatives to be determined for each specificapplication.

(5) Crane capacity. Guide Specification CE-1603should determine this capacity.

(6) Appearance. Draft tube crane appearance shouldbe consistent with the tailrace area of the powerhouse. Itis usually advisable to rely on the powerhouse architectfor determination of an acceptable appearance, but com-promises are necessary where preferred appearanceimpairs maintenance, full utility, or safety.

(7) Trolley. For draft tube bulkhead service alone, afixed hoist in accordance with Guide SpecificationCE-1603 is adequate. If other service such as fish facilityhandling is required, a trolley-mounted hoist inaccordance with Guide Specification CW-14340 may bejustified.

i. Mobile cranes. Mobile cranes will seldom befurnished specifically for the powerhouse since they arenormally an item of general project equipment. They areusually specified to match an existing, commerciallyavailable item. The powerhouse design should considerwhich powerhouse lifts will be handled with a mobilecrane, the loads, and required hook travels and boomlengths. Special slings, lifting beams, and lifting eyes toachieve required safety factors usually have to be pro-vided for each type of lift.

j. Maintenance shop bridge crane.

(1) General. All required lifting and transportingoperations in the maintenance shop can be accomplishedwith an economical floor crane plus a minimum of tempo-rary rigging. The provision of the more costly bridgecrane requires considerable justification. Since a bridgecrane can expedite handling, the potential for a heavyvolume of essential work in the shop at one time wouldbe the principal justification. Project work external to thepowerhouse, as well as work from other projects, shouldbe considered. For powerhouse work alone, 10 or moremain units along with a fully equipped shop will usuallyjustify a bridge crane in the maintenance shop. Designcriteria for maintenance shop bridge cranes are availablein Guide Specification CW-14601.

(2) Crane characteristics. It is preferable that thecrane be kept as simple as practical, avoiding the moresophisticated control options and writing the specificationsaround generally available catalog equipment. Single-speed hoist control in the range of 0.06-0.09 m/s(12-18 fpm) is satisfactory. Powered trolley travel isavailable as a catalog item and is justified. Poweredbridge travel is also justified, particularly in the case of along narrow shop. Hoist and powered travel push-button

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controls should be located in a pendant-type box. Capac-ity should be 1.8-4.5-tonne (2-5-tons).

(3) Precautions.

(a) When a bridge crane appears justified, early plan-ning is required to assure a powerhouse structural layoutpermitting adequate shop ceiling and lighting clearancefor the bridge.

(b) Structural support for the crane rails is an earlyplanning consideration.

(c) Specifications should require a bridge and hoistcapable of withstanding pullout torque forces applied tothe hook.

k. Floor cranes. Maintenance shops not equippedwith a bridge crane should be provided with a portablefloor crane. This will include essentially all shops in1-4-unit plants and many shops in 5-10-unit plants. Thecrane should be a standard catalog item, preferablyhydraulically-operated, manually-powered, and equippedwith antifriction bearing wheels and casters. A1.8-2.7-tonne (2-3-ton) capacity should be specified.

l. Monorail cranes. The most common powerhouseapplication for monorail cranes is handling of draft tubebulkheads at small powerhouses where the slot location isclose to the downstream wall. Rated capacity and maxi-mum lifting stresses should meet Guide SpecificationCE-1603 requirements. Standard catalog units are pre-ferred, but proof-testing of the hoist and rail to pulloutshould be required. Other powerhouse handling applica-tions with lifting and travel requirements in restrictedareas may warrant monorail installations. Before a mono-rail decision is made, each requirement should be care-fully evaluated for practical alternate provisions, such asembedded lifting eyes and portable hoists or crane hookaccess hatches permitting lifts to be made with the bridgecrane or a deck gantry. Monorail hoists have had someapplication in maintenance shops but lack the versatilityof a bridge or floor crane. Design criteria for monorailcranes are available in Guide Specification CW-14340.

m. Jib cranes. Jib cranes have limited application inpowerhouses since most areas with adequate head room toaccommodate a jib can be serviced with the bridge craneor a deck gantry. They are most suited to hoisting appli-cations requiring limited horizontal movement, as on oroff a truck, or a limited transfer movement to or from alocation just beyond bridge or gantry crane hook cover-age, and locations where an embedded eye and portable

hoist are impractical. Mounting of a jib crane on a gantrycrane leg to handle hatch covers, gratings, or heavy main-tenance equipment is sometimes an advantage. A goodselection of standard catalog jib cranes is available. Man-ual winches or chain hoists are normally adequate for jibuse. Electric hoists are justified if they will be used fre-quently. The uncertainty of maximum loading with amanual hoist makes it important that jib structural mem-bers and anchor bolts be designed with high safety fac-tors. Design criteria for jib cranes are available in GuideSpecification CW-14340.

6-3.6-3. CraneCrane LiftingLifting AccessoriesAccessories

a. General. Crane lifts may require one or moreintermediate devices connecting the crane hooks or blocksto the load. Certain lifts require a device for supportingthe load in storage or intermediate positions. Thesedevices include lifting beams, adapters, spreader beams,support beams, and “dogs.” Standard rigging-type slingsshould normally be selected and procured by constructionor operations offices. Spreader beams, support beams,and “dogs” will usually be either bought with the crane orequipment. Powerhouse bridge-gantry equipment differsappreciably from intake gantry and draft tube crane equip-ment, and coverage herein is divided accordingly.

b. Powerhouse bridge-gantry lifting accessories.

(1) General. Lifts made by the powerhouse bridgeor gantry cranes are accessible for visual observation andalso to personnel for attachment and release. This permitsdesign based on known loads and manual means of con-nection and release.

(2) Lifting beams.

(a) General. Cranes with more than one main hookrequire lifting beams to connect the hooks to generatorrotor and turbine runner assemblies. A single beam isrequired with a single, two-hook crane and three beamswith two, two-hook cranes. The beams should provideconvenient manual connections of the load to the cranehooks, essentially moment free, vertical lifting forces onthe load, and stable operation under all loaded orunloaded conditions. These lifting beams are normallydesigned and furnished under the crane contract.

(b) Design. Data on existing beams are included inEM 1110-2-4203, and detail design requirements are inGuide Specification CW-14330. Cooperation between thecrane contractor and generator-turbine contractors toassure fit and utility of the lifting beams will be required

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under the supply contracts. However, it is a responsibilityof the contracting office to monitor the exchange of infor-mation for timing and accuracy. The design office isusually required to do preliminary design and beam layoutto assure a practical powerhouse structural layout andcrane clearance diagram.

(3) Adapters and attaching devices. Adapters forfitting the lifting beam to the generator rotor and turbinerunner assembly are made a responsibility of the genera-tor- turbine contractor under the supply contracts.

(4) Slings. Slings for major lifts of the powerhousebridge-gantry cranes are not required. Lifts requiringslings utilize standard rigging.

(5) Drawings. Figure B-1 illustrates conventionallifting beam configuration as part of a typical crane clear-ance diagram.

c. Intake gantry and draft tube gantry crane liftingaccessories.

(1) General. Intake gantry and draft tube gantrycranes are regularly used for handling gates, bulkheads,stoplogs, and fish guidance equipment below the watersurface where the point of attachment to the load is non-visible and nonaccessible to operating personnel.Obstructing debris or silt can hinder operations, and“cocking” or “binding” of the load or lifting beam in theslots can occur. Slings remaining attached to the sub-merged load or lifting beams with dependable remotecontrol of latching and unlatching are required. Most liftscan be made with either an attached sling or a liftingbeam, and the selection should be made only after carefulconsideration of the following factors:

(a) Dependability. In all cases, dependability favorsan attached sling since the potential for latching andunlatching problems, as well as the uncertainty of asecure latch having been effected, is eliminated.

(b) Sling size. Sling size may become large enoughto cause handling and storage problems.

(c) Hook travel limitation. Limited crane hook travelcombined with deep load settings may require severaldogging operations with slings and a consequent impracti-cal time requirement.

(d) Multiple unit loads. Where more than one gate,bulkhead, or stoplog section are required in a single slot,slings are usually impractical. Design of lifting

equipment for underwater loads should normally be basedon pullout or maximum controlled torque lifting forces.Exceptions should be clearly noted and justified in themechanical design memorandum. The expense and haz-ards of diver operations to remedy faulty operation plusmonetary loss from delay in returning generator units toservice warrant maximum design emphasis on reliability.

(2) Lifting beams.

(a) General. Lifting beams may be provided forintake gates and bulkheads, draft tube bulkheads, trash-racks, fish guidance equipment, and for miscellaneoussmall gates and bulkheads in water conduits, fish chan-nels, and sluices. Weight-operated latching mechanismswith manual tagline unlatching is preferred except wherephysical size of latches or pins make manual operationnonfeasible. Tagline operation should be assumed a one-man effort, and maximum required rope pull should notexceed 223 N (50 lbf). The design should have clear-ances and dimensions that provide source engagement ofalignment pins with sockets, hooks with latches, andlatching pins with sockets with all accumulated construc-tion and installation tolerances considered. Beam lengthto guide height proportions should minimize wedgingtendencies in guides, or end clearances should precludewedging. Weight of lifting beams is normally a minorfactor in total lifting loads; therefore heavy and ruggeddesigns are desirable to stand up under severe operatingconditions and to ensure positive lowering and latchingthrough debris. Multipurpose beams requiring a varietyof special adapters, special guide shoes, length or offsetadjustments, and interchange of hooks are not recom-mended. An assembly drawing for each beam should beincluded in the mechanical design memorandum showingslots, load pins, beam hooks, aligning pins when applica-ble, guide shoes or rollers, operating mechanism andcritical dimensions, tolerances, and clearances indicatingcorrect operation under all conditions. Figures B-2and B-3 include drawings of a typical intake gate-bulkhead lifting beam and a manual hook-release typelifting beam, respectively.

(b) Intake gate, bulkhead, and fish guidance equip-ment beams. A single lifting beam is normally providedfor intake bulkheads, gates, and fish guidance equipment.Early coordination of gate, bulkhead, fish guidance equip-ment, and slot design to assure a practical single liftingbeam without adapters is necessary. Procurement is usu-ally included in the intake gantry crane supply contract,and final design is made a contractor’s responsibility.Initial design criteria are included in Guide SpecificationCW-14340.

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(c) Miscellaneous beams. Basic structural andmechanical unit stresses should be in accordance with theapplicable requirements of Guide Specification CE-1603with normal loadings considered as lifting loads plusfriction and pullout loadings based on the applicable cranehoist. Pullout loadings for mobile cranes should be con-sidered as boomup tipping load. Hooks should bemechanically linked together to assure simultaneousmovements.

(3) Slings. Special purpose slings for intake gantryand draft tube gantry crane use should be made of corro-sion resistant rope and galvanized fittings. Ultimatestrength of sling assemblies should provide a safety factor(FS) as shown in Table 6-1 based on the maximum load.The slings should normally also have a FS of 2 based onthe hoist pullout torque, maximum controlled torque, orcrane-tipping load. Exceptions should be clearly notedand justified in the mechanical design memorandum. Alesser FS may be used provided that by detailed analysis,it can be shown that under imbalanced load conditions aFS of 5 is provided for the sling leg or lifting beam com-ponents having increased loads. Sling clevis pins andother pins requiring disassembly under normal use shouldhave ample clearance to minimize binding under averagefield-handling conditions. A 1.6-3.2-mm (1/16-1/8-in.)clearance is preferred for average field-handling con-venience. Design of intermediate links, storage links,support beams, and sling storage provisions should con-sider convenience and safe handling along with requiredstrength.

6-4.6-4. HoistsHoists

a. General. Fixed hoist applications in powerhousesinclude operation of intake gates requiring emergencyclosure capability, operation of gates and weirs requiringautomatic or remote control, and miscellaneous lifts non-accessible to a crane. Fixed hoists may be of several

types, the most common being hydraulic and drum-wirerope. Portable equipment is preferable to fixed hoistsfrom a maintenance standpoint and should be consideredfor all applications with infrequent, noncritical usage.

b. Intake gate hoists.

(1) General.

(a) Fixed gate hoists. These hoists are applicable forvertical lift, wheeled, or roller-mounted gates. The mainpurpose of fixed hoists is to provide emergency closure.The normal use of fixed hoists will be for maintenanceand repair operations. Potential conditions which couldrequire emergency closure include loss of wicket gatecontrol, head cover failure, an inadvertently opened orfailed access hatch, or precautionary closures duringabnormal operation. The frequency of such emergenciesis recognized as remote. However, the potential for majordamage does exist, and the emergency closure provisionsof fixed hoists are justified. The design should providemaximum dependability and rapid closure under remotecontrol plus backup manual closure under power failure.In addition, necessary provisions for normal gate opera-tions should be included. The type of hoist selected willdepend upon the size of gates involved and the configura-tion of the intake structure. The three types of fixedhoists generally considered are direct acting hydraulichoists, hoists consisting of hydraulic cylinders connectedby wire rope through deflector sheaves to the gates, anddrum-wire rope hoists.

(b) Performance criteria. Closure of all gates on asingle unit should be accomplished simultaneously andwithin 10 min from initiation of the closure sequence.The lowering speed of the gate at the point-of-contactwith the sill should not exceed 0.05 m/s (10 fpm). Gate-raising speeds are not critical. Depending on size, it is

Table 6-1Safety Factors

Application FS for Load Visually Observed FS for Load not Visually Observed

For permanent crane or hoist not involving slings 5 x ML* 5 x HC*

For permanent crane or hoist utilizing bridle slings 5 x ML 8 x HC

For permanent crane or hoist lifting beam (without slings) 5 x ML 5 x HC

For mobile crane use 5 x ML 8 x ML

* ML = Maximum load to be picked up; HC = Hoist capacity rated.

** FS to be increased in cases where a significant load imbalance between two or more slings is possible (based on the maximum possibleload imbalance which the hoist can exert on a sling or lifting beam member, such member shall have a FS of 5).

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usually satisfactory to take 10-20 min to open a gate.When the penstock or power tunnel is filled by crackingthe intake gate, it is essential to fill the tunnel slowly inorder to avoid sudden changes in pressure. This is doneby allowing the intake gate to creep to about 3 percentopen before opening at normal speed. Intakes utilizinggates with upstream seals and a limited area behind thegates have developed dangerous gate-catapulting forcesduring filling. Emergency closure should be possibleunder complete failure of the normal power supply.

(2) Hydraulic hoists.

(a) General. Hydraulic hoists normally consist of asingle acting cylinder, pumps, reservoir, controls, andpiping. The preferred arrangement is to place the cylinderabove the gate and support it in the slot. The rod is con-nected to the gate, and the gate and rod hang from thepiston. Adding or releasing oil from the cylinder controlsthe gate position. Two cylinders per gate are common forlarge gates. Where intake and deck elevations do notpermit hanging the gate below the cylinder, it may benecessary to recess the cylinders within the gate structure.All intake gate hoists in a powerhouse are normally con-nected to a common pump-piping system, and systempressure is maintained above the minimum pressurerequired to prevent gate drift. A typical hydraulic circuitand cylinder drawing are shown in Figures B-4 and B-5,respectively. Guide Specification CW-11290 providesguidance for hydraulic power systems for civil worksstructures. Complete drawings and specifications of exist-ing satisfactory designs can be obtained from the Hydro-electric Design Center (HDC), North Pacific Division,Portland, Oregon.

(b) Hoist capacity. Maximum hoist capacity will bedetermined by the load because of emergency shutdownof the unit, or opening the gate to equalize unit to poolhead.

• Hydraulic downpull load. The emergency shut-down load is composed mainly of gate dead-weight, hydraulic downpull load resulting fromhigh-velocity flow under the gate, head on thegate upper seal, and deadweight of the rod.Hydraulic downpull will vary greatly, dependingon configuration of the gate bottom, static head,and location of the skin plate and seals. In mostcases, the load caused by the hydraulic downpullwill be the major load that the hoist will see inemergency shutdown. Extreme care must betaken when determining these loads. Moreinformation on hydraulic downpull can beobtained from the HDC.

• Seal breakaway load. The equalizing load iscomposed mainly of gate deadweight, seal fric-tion, roller chain or wheel tractive load, and rodweight. Seal breakaway friction tends to beunpredictable as it depends on type of seal, sur-face condition, seal material, elapsed time withseal under head, and seal preload. However, itcan be of greater magnitude than the maximumdownpull forces. Maximum downpull load shouldnot occur simultaneously with seal breakawayload. Normal gate movements are made underbalanced head conditions and usually involveessentially only gate and rod buoyant weights,seal friction, and roller chain tractive load. Thedesign hoist capacity should be conservative,reflecting the indeterminate nature of major loads.Hoist loadings on a variety of existing gates,based on hydraulic system pressure gage readings,can be obtained from the HDC.

(c) System design operating pressure. A 20,670-kPa(3,000-psi) design system pressure is recommended.Hydraulic components for this pressure are very common.Required hoist capacity can usually be obtained withpractical cylinder sizes using 20,670-kPa (3,000-psi) pres-sure as well. Operating pressures for normal balancedhead gate movements or for holding gates in the openposition will usually be within 8,270-13,780-kPa(1,200-2,000 psi) when cylinders are designed for maxi-mum downpull and breakaway loads at 20,670-kPa(3,000-psi) operating pressure.

(d) Cylinder. Internal diameter and nominal externaldimensions of the cylinder should be determined by thedesign office, but final cylinder design should be made acontractor’s responsibility. The cylinder should be of onesection with heads bolted onto the cylinder flanges. Thereare different types of flanges that could be used andshould be open to the contractor.

(e) Rod. The outside finish of cylinder rods must beof corrosion resistant material. Base material should beof high strength to minimize rod displacement and, inmost cases, must have good welding and machining prop-erties. Specifications and contract drawings shouldinclude material options appropriate to the required rod,rod dimensions, coupling provisions, finishes, physicalproperties, and special fabrication and testing techniques.The following four satisfactory options for the base mate-rial are normally available:

• Chromemolybdenum steel rods with hard chrome-plated surface. This option provides an excellent

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rod at reasonable cost when rod dimensions arewithin capacity of commercial plating facilities.

• Chromemolybdenum steel rods with formed andwelded on monel cladding. Although satisfactoryservice is obtainable by this method, fabricationproblems are to be expected unless the fabricatoris experienced in such work. Specificationsshould emphasize to prospective bidders therequirement for fabrication experience.

• Solid, age-hardening, stainless rods. Rod mate-rials of this type offer good strength, weldability,and corrosion resistance. They are becomingincreasingly available and are an acceptable alter-nate when competitively priced.

• Ceramic-coated rods. These rods have asprayed-on ceramic coating that is very durableand impact and corrosion resistant. Care shouldbe taken to assure qualified fabricators apply thistype of coating.

(f) Latch. A manually engaged latch should be pro-vided to lock the piston and rod in the retracted positionfor raising the gate to the dogging position with the crane.The engagement is normally a threaded connection in thetop of the piston rod with the latch pin located in an oil-sealed hole in the cylinder head. The latch pin should beof corrosion resistant material. A removable T-wrenchshould be provided to permit convenient operation of thelatch pin.

(g) Pumps. Pumps are positive displacement pistonor vane type with standard catalog ratings to providerequired displacement and pressure. Delivery should besufficient to open a single gate in approximately 20 minor less. It is usually desirable to provide the required dis-placement with two identical pumps to provide backup inthe form of reduced speed raising in event of pump fail-ure. It is usually also desirable to provide makeup oil tomaintain pressurization of the system with a separatesmall displacement pump to avoid frequent starting orcontinuous unloading of one of the raising pumps. Deliv-ery should be 150-200 percent of anticipated leakage.The small displacement pump may have a higher pressurerating than the raising pumps to aid in breaking loose agate for equalizing. Pumps should be mounted to providea positive suction head and be equipped with auxiliariesrecommended by the manufacturer. Relief or unloadingvalves should be provided to limit maximum stress inhoist components to 75 percent of yield point. The

75 percent yield-point pressure should be the maximumrelieving pressure to which the valves can be adjusted.

(h) Valves.

• Lowering valves. Lowering valves should beessentially drop tight at gate support pressure,should operate within their catalog flow rating atrequired lowering flows, and should be suitablefor remote control of opening. Cylinder-operated,shear-seal type valves and pilot-operated checkvalves are two that are in satisfactory service.Solenoid valves in the pilot circuit are normallyused for remote control to open the valve. Valveclosing should be manual only to minimize possi-bility of accidental raising of a gate on anunwatered unit. Two valves in parallel should beprovided to allow emergency closure in event of asingle-valve malfunction. The lowering valvesshould be suitable for emergency manual oper-ation, or separate manual lowering valves shouldbe provided.

• Flow control valves. An adjustable pressure-com-pensated flow control valve should be provided inthe high-pressure line from each cylinder to regu-late gate lowering speed and to match loweringspeeds where more than one gate per unit isrequired.

• Manual valves. Manual valves should be of thequick-acting, low-operating force type suitable forpanel mounting. A valve should be provided inthe high-pressure line to each cylinder to permitindividual manual gate control and to isolate thecylinder from the hydraulic system.

(i) Pump controls.

• Pressurization-breakaway pump control. Thepressurization pump should be on automatic start-stop pressure control to maintain system pressureabove minimum no-drift pressure. A manualmomentary-contact override switch should beprovided at each panel to permit applying tempo-rary breakaway pressure. Pump relief-unloadingvalve settings should normally be about 5 percentabove normal maximum system operatingpressure.

• Raising pump controls. Raising pumps should beon manual start with adjustable time-switch

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shutdown. Remote start should be provided ateach unit hydraulic control panel.

(j) Control panels. Gate movement controls andvalves for one main unit should be mounted on one com-mon control panel at each unit, generally in a gallery nearthe gate slots. A steel panel designed for standard panel-mounted hydraulic valves is preferred. A similar panelshould be provided near the pumps for pump controls.

(k) Piping. High-pressure piping of Schedule 80seamless with socket welding fittings is satisfactory.Low-pressure piping is normally Schedule 40 with socketwelded fittings. Due to both internal and external corro-sion problems, the piping should be stainless steel such asAmerican Society of Testing and Materials (ASTM)A312, Grade TP304. If it is necessary to utilize two oilreservoirs on a single system, the equalizing headerbetween them should be substantially oversized to pre-clude overflow from unbalanced return flows. Low-pressure piping should be sized to provide a positive headthroughout the system unless there are minor, shortduration, negative pressures under emergency closureoperation.

(l) Reservoir. A reservoir sized to contain the dis-placement of all piston rods on the system plus the vol-ume of one cylinder, 15 percent reserve oil, and15 percent air volume should be provided. Reservoirsshould have an interior painted finish conforming to MIL-C-4556. Reservoirs should be located to assure a positivesystem head and should be heated as required to precludecondensation.

(m) Accumulators. Accumulator capacity on the sys-tem should be sufficient to ensure a pressurizing pumpcycling time of not less than 10 min.

(n) Support beam. The cylinder support beam ofstructural steel should be accurately fabricated, stressrelieved after welding, and machined on bearing surfacesto assure uniform bearing loading. Connection of thecylinder to the beam with separate nuts on extended cylin-der head bolts is recommended. The support beam shouldfit over locating dowels on the support pads and shouldbe bolted down to preclude movement if subjected toupward forces transmitted through the cylinder rod.

(o) Gate position indicator. When gate position indi-cators are not otherwise provided, they should normallybe included with the hydraulic hoist design. They areessential with hydraulic hoists to monitor gate positionand to obtain prompt indication of gate drift. Stainless

tapes connected to the gate tops with tension maintainedby counterweighing or spring take-up reels have givensatisfactory service.

(p) Design. Design of the hydraulic hoist system isusually a responsibility of the government. Service andsize requirements are usually not compatible with com-mercially available catalog equipment, and suppliers’ spe-cial designs are contractually difficult to control. Thedesign should be adaptable to a variety of pumps andcontrol valves, seals, piston rings, cylinder construction,etc., to avoid unnecessary bidding restrictions.

(3) Wire rope hoists.

(a) General. Wire rope hoists are applicable tointake configurations requiring gates with deep submer-gence or gates with shallow settings, either of which makehydraulic hoists undesirable. Unusually deep gatesrequire several rod extensions resulting in slow installa-tion and removal of cylinder-operated gates. Shallowgates may require portions of a hydraulic hoist to beabove deck level interfering with movement of vehiclesover the deck. Individual stationary hoists are usuallyprovided for operating each service gate. The gates arenormally held by the motor brake in the operating posi-tion just above the waterway, and control switches areprovided at the unit governor cabinets and in the controlroom to permit rapid closure in an emergency. Arrange-ment of the hoists varies greatly depending on the intakeconfiguration. Hoists may be located below or on theintake deck adjacent to or over the gate slots. Whenlocated on the deck over the gate slots, provisions shouldbe made for uncoupling the hoist blocks when the gatesare in the upper dogged position, and for removal of thehoists from over the gate slots to permit transfer of thegates to the gate repair pit by use of the intake gantrycrane.

(b) Description. Each hoist consists of a cable drumor drums and a system of sheaves and blocks which areelectric motor driven through an arrangement of shafts,speed reducers, and spur or hellical gears. The motor isusually 460-V, 3-phase, 60-cycle, squirrel-cage, inductiontype with suitable enclosure. Two speeds are sometimesprovided to permit lowering at approximately twice theraising rate. The hoist brake is of the shoe type, springset, DC magnet-operated type, with a watertight enclosureand a capacity of not less than 150 percent of the full-load torque of the motor. The wire rope is of stainlesssteel with an independent core. During normal operation,the lower block is immersed, with part of the associatedreeving immersed and part exposed. When the hoist is

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located on the intake deck over the slots, the hoistmachinery should be mounted on a platform of sufficientheight, so that the gate can be hoisted to a dogging posi-tion where it can be readily uncoupled at intake decklevel. With this arrangement, the hoist machinery frameand support columns form an integral structure designedto support the hoisting machinery and gate includingprovisions to permit its removal from over the gate slotby use of the intake gantry crane. Base plates with locat-ing pins should be provided in the intake deck structure topermit quick and accurate resetting of equipment.Machined bearing pads to support machinery components,necessary openings to provide clearance for ropes andmoving parts, and grating to permit inspection and main-tenance should be provided. A minimum area of opengrating should be provided for airflow when the supply isthrough the service gate slots in which the required areashould be based on a maximum air velocity of 45 m/s(150 fps). Sockets embedded in the intake deck concretepermit installation of safety handrailing around the gateslots when grating and/or hoists have been removed. Themotor controller for each hoist should be housed in awatertight control cabinet supported from the hoist frame.A traveling nut-type or intermittent geared type high-accuracy limit switch and a dial-type gate position indica-tor, as well as a slack cable limit switch, balancedpressure switch, and an extreme upper travel limit switch,are provided. Accuracy of limit switch trip and resetshould be considered when gate cracking or other similaraccurate positioning is needed, especially for gates withlong travel. Removable power and control plugs shouldbe furnished to permit disconnecting of all incoming leadsto the hoist prior to its removal.

(c) Design. Each gate hoist should be designed for arated capacity equal to the sum of the gate weight, rollerchain tractive load, seal friction, and maximum hydraulicvertical forces with normal stresses. Mechanical parts ofthe hoists should be designed for the rated capacity with aminimum FS of 5 based on the ultimate strength of eachcomponent. In addition, mechanical components shouldbe designed to withstand the forces produced by hoistmotor-stalled torque with resultant stresses not in excessof 75 percent of yield point of the materials involved.Reducers should be sized in accordance with AmericanGear Manufacturers Association (AGMA) Standard forClass I Service using conservative values for starting andrunning efficiencies. Wire rope hoists should be in accor-dance with the requirements of Section 5 of Guide Speci-fication CW-14340. Hoist capacity and speeds shouldfollow paragraphs 6-4b(1)(b) and 6-4b(2)(b). Wire ropeshould be of corrosion resistant material.

(d) Location. Wire rope hoists should be located onthe deck when practicable. Locations in recesses belowthe deck may be required where deck access would beimpaired by a deck location. Controls along with reliablegate position indicators should preferably be located in agallery close to deck elevation.

(e) Power failure operation. When it is necessary tomake provisions to lower the gates without power, brakerelease and means of speed control should be provided,such as a hydraulic pump driven by the hoist motor withan oil reservoir and flow control valve. If a hydraulicpump is used, a dual-purpose hydraulic pump-motorreplacing the electric hoist motor should be considered.

c. Miscellaneous wire rope hoists.

(1) General. Fixed wire rope hoists may be requiredfor lifting applications inaccessible to cranes or for controlgate operation where frequent adjustments or automaticcontrols are necessary. Portable commercial equipment ispreferred whenever practicable. Powerhouses with fishpassage facilities frequently require fixed hoists for weiradjustment and control gate operation. Fixed hoists mayoccasionally be justified for ice and trash sluice controlgates. Fish facility equipment criteria are normally sup-plied by fishery agencies; however, powerhouse designresponsibility includes safety, dependability, and satisfac-tory service life.

(2) Design. Wire rope hoists should comply withthe applicable requirements of Section 5 of Guide Specifi-cation CW-14340. Corrosion resistant wire rope shouldbe used for all applications where any part of the line willoperate submerged. Underwater bearings should be waterlubricated except where presence of abrasive silt requiressealing. The cost of miscellaneous wire rope hoists isoften moderate and may not appear to justify extensiveengineering. However, several factors can affect satisfac-tory operation, maintenance, and service life. The designprocedure should not shortcut the necessary investigationswhich include the following:

(a) Climatic conditions. These conditions includethe effects of icing, moisture, and heat.

(b) Water quality. The presence of abrasive silt orunusually corrosive materials in the water should beconsidered.

(c) Gate guide alignment, material, and clearances.These factors, while not primarily a mechanical design

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responsibility, can materially affect hoist operation, socoordination with the responsible design group is neces-sary. The possibility of gates temporarily “hanging-up” isoften overlooked.

(d) Water hydraulic conditions. The possibility ofunusual turbulence, surging, or wave action causing addedhoist loading, uplift, or vibration should be investigated.

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Chapter 7Elevators

7-1. General

Principal considerations relative to powerhouse elevatorsinclude justification, location, size, type, and operatingcharacteristics. Design criteria are available in Corps ofEngineers Guide Specification CW-14210 and industrystandards ASME A17.1 and A17.2.

7-2. Justification

a. General. The justification for powerhouse eleva-tors rests on a number of interrelated factors, the combi-nation of which can indicate a clear requirement, norequirement, or be equivocal. Many existing powerhousesare satisfactory without elevators, and rather definite justi-fication should be apparent to warrant including one ormore in the powerhouse design.

b. Principal factors.

(1) Powerhouse location. Powerhouses forming aportion of the dam invariably have considerable foottraffic between the intake deck and powerhouse levels,and the vertical distances are considerable. Such power-house locations usually justify one or more elevators.

(2) Number of units. The number of main units isnot directly related to elevator requirements, but conven-tional-type powerhouses with six or more main units willhave maintenance schedules and repair requirementsrequiring considerable interlevel foot traffic and also besubject to heavy interlevel foot traffic during installation.Such traffic normally justifies one or more elevators.

(3) Number of operating levels. Three or less operat-ing levels with total vertical distance of 12 m (40 ft) orless will seldom justify an elevator. When the importanceof various operating levels is assessed, the type andamount of foot traffic should be considered. For example,a drainage gallery with seldom operated valves requiringlittle foot traffic and infrequent tool movements would notrequire elevator service. A maintenance shop and toolroom located above or below the erection and principalmaintenance level could require a great deal of up anddown movement of personnel, tools, and equipment andcould be a strong factor in justifying an elevator.

(4) Visitors. Where visitors are to be permitted andtheir entry to, or movements within, the powerhouse

involve more than a single level, access for the handi-capped may well override all other elevator justificationfactors and dictate an elevator.

(5) Portable equipment movement. Movement ofportable equipment such as an oil purifier or floor craneshould not normally be used as justification for an eleva-tor as it will usually be more economical to provide dupli-cate equipment. Where an elevator is otherwise justified,the movement of portable equipment should be consideredin sizing and locating the elevator. Design memorandashould include the factors considered in the decision foror against provision of an elevator.

7-3. Location

Elevator location should be considered early in the gen-eral powerhouse layout to provide the best access to thecontrol room, locker and rest rooms, maintenance shop,erection bay work level, and where applicable, externaldecks. A common location is in or near the upstreamwall of the main generator-turbine room in the erectionbay. Where a second elevator is justified in a longpowerhouse for operation and maintenance purposes, thesecond elevator is usually located to minimize as much aspracticable the distance from all points in the powerhouseto the closest elevator.

7-4. Size

a. Small powerhouse.For small powerhouses withservice requirements limited to operators and maintenancepersonnel, a 5,340-N (1,200-lbf) elevator approximately1.5 × 1.2 m (5 × 4 ft) is usually adequate. Should theelevator be justified on the basis of visitors, the size andcapacity should be increased as required to accommodatethe projected visitor traffic.

b. Large powerhouse. Large powerhouses (6 ormore main units) with service limited to operators andmaintenance personnel will usually be adequately servedwith a 11-kN (2,500-lbf) elevator approximately 2.1 ×1.5 m (7 × 5 ft). A powerhouse with a constructionschedule requiring joint use of the elevator by projectpersonnel and contractor personnel should be providedwith up to a 18-kN (4,000-lbf) elevator with proportion-ately larger dimensions. In the case of very large power-houses (12-20 units) with powerhouse elevator service tothe intake deck and extended joint construction-operationusage, it may be justified to provide two elevators in theerection bay area to reduce waiting time. Joint visitor-construction elevator service is usually impractical andshould not enter into elevator sizing.

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c. Standard size. In all cases the size selectedshould be a standard size and capacity from the elevatormanufacturers.

7-5. Type

Elevators should be basically the passenger type for con-ventional powerhouses. Freight or combination freight-passenger types may be required where powerhouse areasare planned for warehousing or when needed for themaintenance shop. Finish and appointments should beappropriate to the architecture of the levels served.

7-6. Speed

Operating speeds in the 0.5-0.8-m/s (100-150-fpm) rangeare adequate for elevators not carrying traffic to or froman intake deck level. Elevators serving the intake decklevel and with potential for heavy construction or visitortraffic may be up to 1.3 m/s (250 fpm).

7-7. Control

Selective-collective control is justified for most power-house elevators with visitor or extended construction

usage. Nonselective-collective automatic control is satis-factory for other installations. Alternate manual controlmay be justified where heavy visitor traffic is projected.Door opening should be automatic.

7-8. Design

Design of elevators and appurtenances should be a con-tractor responsibility and be in accordance with applicableprovisions of Guide Specification CW-14210 and codesreferenced therein. Powerhouse mechanical design sec-tions should perform required studies, coordinate architec-tural, structural, and electrical requirements, and preparecontract drawings and specifications in accordance withinstructions included with CW-14210.

7-9. Procurement

Procurement is normally under the powerhouse construc-tion contract.

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Chapter 8Engine-Generator Set

8-1. General

Engine-generator sets are provided as a source of emer-gency electric power when there is a loss of station ser-vice power. The requirements for an emergency enginegenerator is dependent on the reliability of station servicepower and usually is justified for plants without stationservice generators. The decision for or against providingan engine-generator set should be made during the pre-liminary design memorandum stage. The power require-ment is normally moderate, being confined to the requiredpower to return a main unit to service along with criticalcontrol and pumping requirements. The mechanicaldesign responsibility includes location; engine specifica-tions; and exhaust, cooling, and fuel and ventilation provi-sions. Further guidance is provided in Corps of EngineersGuide Specifications CE-16263 and 16264.

8-2. Location

a. General. To determine a suitable location for anengine-generator set, access, space for maintenance, noise,ventilation, exhaust piping, fuel piping, humidity, andtemperature are all factors that must be considered. Alocation within the powerhouse structure with dependable,controlled temperature conditions and moderate noiseisolation from the main working areas and other occupiedareas is preferred. An above tailwater gallery location isfrequently used.

b. Access. Personnel access should be reasonablyconvenient for routine inspections. Access for installationor replacement of the complete unit need not be conve-nient but should be practicable, and it should be verifiedthat future powerhouse construction or equipment installa-tion will not preclude replacement of the complete diesel-generator unit.

c. Maintenance. Space for normal in-place mainte-nance and overhaul should be provided.

d. Noise. Practically all unit operation will occurduring routine testing; therefore extensive sound isolationprovisions are unnecessary. A gallery location or otherlocation away from principal working areas will usuallybe satisfactory as far as noise problems are concerned.Vibration isolators for mounting of the engine-generatorset should be provided in the procurement contract.

e. Ventilation. A location where normal ventilationwith the engine nonoperational can be provided from thegeneral powerhouse system.

f. Exhaust piping. The location should permit ashort, direct routing of the exhaust pipe to an outdoortermination which will not exhaust directly on personnelnor near an intake vent.

g. Fuel piping. The engine-generator location rela-tive to the outside oil storage tank should permit practicalrouting of the oil supply piping of reasonable length andfree of unnecessary offsets and changes in slope. Thefuel transfer pump is normally located at the engine,limiting maximum allowable suction losses.

h. Humidity. The generally high-humidity character-istic of below tailwater galleries is undesirable for long-term maintenance. An above tailwater location ispreferred.

i. Temperature. A location free from subfreezingtemperatures is preferred for all installations but is essen-tial when heat exchangers utilizing river water for enginecooling are used.

8-3. Engine

a. General. The engine should be a diesel, a stan-dard product of the manufacturer, and should be a modelwhich has performed satisfactorily in an independentstationary power plant for a minimum of 8,000 hr in atwo-year period of base-load operation. Options shouldbe permitted in the type of engine and number ofcylinders.

b. Detail requirements. Typical detail specificationrequirements pertinent to the engine and auxiliaries pro-cured with the engine can be found in “Piping-Cleaning,and Flushing,” Appendix B-1, which is an excerpt froman existing diesel-generator procurement specification. Todetermine the requirements for a new installation, all ofthe provisions noted should be considered and modified asappropriate for the size of unit required, powerhouselocation, and cooling water conditions. Each requirementspecified should be consistent with equipment normallyavailable as standard or optional in the industry.

8-4. Exhaust Provisions

The muffler should be furnished with the diesel-generatorunit, and exhaust pipe size should be as recommended by

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the engine supplier. Black steel pipe is satisfactory. Thatportion of the exhaust pipe located within the powerhouseshould be insulated. The muffler is usually located out-doors, and protection provided as required for personnelsafety.

8-5. Cooling

Powerhouse locations usually provide reasonable access tocooling water from a piping system, pool, or tailwatermaking the heat exchanger the preferred option for enginecooling water heat rejection. An exhaust fan removing airheated by engine surfaces and generator-exciter unit maydischarge to either outdoors or main generator room,depending on the most practicable fan and ductinginstallation.

8-6. Fuel System

a. General. The engine-mounted portion of the fuelsystem, day tank, and transfer pump are specified andprovided with the engine-generator set. The storage tank,piping from storage tank to the transfer pump-day tankunit, piping from day tank to engine, and day tankinstallation details are normally mechanical designresponsibilities.

b. Storage tank. The storage tank is preferably acommercial steel aboveground tank coated externally andinternally with suitable epoxy paint for corrosion protec-tion. Capacity for approximately 24 hr of full-load diesel-generator operation is normally provided. Auxiliariesinclude a foot-valve, fuel level indicator with remoteindication transmitter, and magnesium anodes for externalcorrosion protection. Underground tanks should beavoided because of environmental concerns caused byleaking tanks.

c. Piping. Piping from the storage tank to the daytank and from the day tank to the engine should be hard

drawn copper tubing with solder joint fittings. If the lineis buried, it should be coated and the couplings insulatedat the tank connections (see paragraph 19-2). Size shouldlimit suction lift on transfer pumps to 4.6 m (15 ft). Nogalvanized pipe or fittings should be used in the fuelpiping system. The capacity of unenclosed day tanksshould not exceed a total of 2,498 L (660 gal) in accor-dance with National Fire Protection Association (NFPA)Standard 37 (see paragraph 6.3.2.3.1).

8-7. Installation

a. General. The installation of the engine-generatorset and all auxiliaries is normally accomplished under ageneral powerhouse construction or installation contract.Contract drawings and specifications should be coordi-nated with the installation recommendations of the engine-generator supplier.

b. Engine. The engine should be supplied on acommon base with the generator. Anchor bolts andvibration isolating pads should follow the supplier’srecommendation.

c. Fuel oil storage tank. This tank should beinstalled as close to the engine-generator set as possibleand at an elevation limiting maximum suction lift on thefuel oil transfer pump to 4.6 m (15 ft). If installed under-ground, the tank should be installed in sand bedding mate-rial and have a total containment system as required byEnvironmental Protection Agency (EPA).

d. Day tank. The fuel oil day tank should be locatednear the engine at an elevation with maximum tank oillevel 127 mm (5 in.) below the injector pump.

e. Piping-ventilation. Piping and ventilation installa-tion provisions should be generally in accordance withChapter 17 of this manual.

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Chapter 9Maintenance Shop

9-1. General

Maintenance shops are provided in powerhouses to facili-tate preventive maintenance and to provide moderaterepair capability. The intent is that each powerhouse havethe capability to take care of the average work promptlyand efficiently. Capability for all possible requiredrepairs is not intended even in the most well-equippedshop as factory replacements or contract work can bemore practical. Normally, the operations divisions willdetermine the requirements for hand tools and portableequipment, and procure all equipment. The maintenanceshop layout should provide adequate space and power forboth initial and future requirements of installed and porta-ble equipment. Most powerhouses will require anin-house shop. However, shops may be omitted where anadequately equipped project shop is to be provided out-side the powerhouse at a nearby location, or where asmall powerhouse is located close enough to an adjoiningproject with an adequate maintenance facility to permitpractical joint usage.

9-2. Shop Room

a. Location. A location close to the erection areaand on the same elevation is preferred. Convenient trans-fer of material, equipment, and parts from the powerhousebridge crane and trucks to the shop transporting facilityshould also be planned. The location should permit theshop to be enclosed and be provided with a large accessdoor permitting free movement of material and the trans-porting facility.

b. Area. Shop area should provide adequate spacefor the planned equipment with consideration for thefollowing: size and configuration of pieces to be workedon; space for dismantling and reassembly; and space forsafe, efficient movements of personnel. An area of about75-95 m2 (800-1,000 ft2) should be the minimum area fora reasonably equipped shop in a small plant. An area of150-170 m2 (1,600-1,800 ft2) may be justified for a largemultiunit plant or a central facility serving several smallprojects. An adjoining area for a lockable tool and stor-age room should be available and should be a minimumof 10 m2 (100 ft2).

9-3. Equipment Selection

a. Factors. Factors affecting the selection of equip-ment include the following:

(1) Size of plant (volume of work).

(2) Physical size of parts to be repaired.

(3) Location of plant (access to other government orcommercial facilities).

(4) Equipment cost (probable usage to justifyinvestment).

(5) Available shop space.

(6) Personnel planning (type of equipment to beconsistent with personnel skills).

b. Equipment guides.

(1) For small to medium powerhouses with well-equipped commercial or government shops available1-4-hr travel time away, the following equipment, or equi-valent, should be planned:

(a) 1.8-tonne (2-ton) floor crane.

(b) 300-amp welder.

(c) Welding hood and exhaust fan.

(d) 50-mm (2-in.) pipe threading machine (portable).

(e) 150- x 150-mm (6- x 6-in.) power hacksaw orbandsaw.

(f) 50-tonne (60-ton) press.

(g) 250-mm (10-in.) pedestal grinder.

(h) 380-mm (15-in.) floor-mounted drill press.

(i) 300-350-mm (12-14-in.) lathe.

(2) For large multiunit powerhouses, shops servingseveral projects, or for smaller powerhouses in remotelocations, the following equipment, or equivalent, shouldbe planned:

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(a) 1.8-tonne (2-ton) floor crane.

(b) 300-amp welder.

(c) Welding hood and exhaust fan.

(d) 50-mm (2-in.) pipe threading machine (portable).

(e) 150- x 150-mm (6- x 6-in.) power hacksaw orbandsaw.

(f) 50-tonne (60-ton) press.

(g) 300-mm (12-in.) pedestal grinder.

(h) 200-mm (8-in.) bench grinder.

(i) 1.0-m (3-ft) radial drill press.

(j) 300-mm (12-in.) bench-mounted drill press.

(k) 450-mm (18-in.) engine lathe.

(l) 250-mm (10-in.) bench lathe.

(m) 0.2- × 1.0-m (10- × 40-in.) milling machine.

A 2.5-tonne (3-ton) bridge crane can be justified forheavy work volume shops.

9-4. Shop Layout

Machines should be located to provide good access forplacing parts and materials in each machine. Repair-oriented shops normally require more free area aroundmachines than production shops where specific operationscan be scheduled. Space for two to four 1.0- x 3.0-m(3- x 10-ft) work benches will usually be required. Openfloor area for assembly, disassembly, and short-term stor-age of parts is desirable. The welding area, burning area,and grinders should be away from precision machinework and assembly areas. Power should be provided forall fixed machines to be installed and for portable tools atbenches and assembly areas.

9-5. Drawing

Figure B-6 is a layout of a shop typical of the typedescribed in paragraph 9-3b(1).

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Chapter 10Water Supply Systems

10-1. General

a. Water supply. The water supplies covered in thischapter provide water for the following requirements:

(1) Generator air coolers and bearing coolers.

(2) Turbine bearing coolers, wearing rings, andglands.

(3) Transformer cooling.

(4) Fire protection.

(5) Potable water (domestic water).

(6) Air conditioning systems.

(7) Pump bearing prelube.

(8) Compressors and aftercoolers.

(9) Deck washing.

The various requirements are divided into several power-house systems for convenience in coverage. However,powerhouse and project requirements, interconnection ofsystems, and suitable water sources vary from project toproject, and the designer will be required to apply theinformation noted to the best advantage for each particularpowerhouse. General piping requirements for all systemsare covered in Chapter 17, “Piping.”

b. Zebra mussel. It is expected that zebra mussels(Dreissena polymorpha) will eventually infest all majorfresh water bodies of the continental United States exceptthe southernmost portion of the Gulf Coast states.ETL 1110-2-333 provides monitoring guidance for deter-mination of presence/absence of zebra mussels and collec-tion of information for detailed studies of zebra musselpopulations. Technical Note ZMR-3-05 provides controlstrategies for zebra mussel infestations of various hydro-power plant components.

10-2. Generator and Turbine Cooling WaterSystem

a. General. The generator and turbine cooling watersystem provides cooling water for generator air coolers,generator and turbine bearing oil coolers, and when ofsuitable quality, the turbine glands and wearing rings.The overall system is a joint design effort involving thewater supply, discharge, and external equipment deter-mined by the powerhouse designers, as well as the unitrequirements and equipment determined by the generatorand turbine manufacturers. Close coordination betweenthe design responsibilities is required.

b. Water requirements.

(1) Cooling water. The water flow requirements aredetermined by the generator and turbine suppliers but aredependent in part on water supply temperatures furnishedby the powerhouse designers. The temperatures should beverified by all available sources and take into account theextremes in climate conditions for the site. Flow require-ments are usually large, in the 25-100-L/s (400-1,600-gpm) range for typical units, requiring major,dependable sources. Purity requirements are moderate,permitting nonpotable supplies with limited silt insuspension.

(2) Gland and wearing ring. Gland and wearing ringflow requirements must be obtained from the turbinesupplier. Turbine contracts require the supplier to furnishthese figures, and turbine guarantees are in part dependenton the stated flows being provided. Previous projectsshow little correlation between unit size and shaft size orspeed with required flows. However, they can total asignificant demand as stated requirements have been up to3 L/s (35 gpm) or more per unit. Rough figures shouldbe obtained in the preadvertising correspondence thattakes place with prospective turbine bidders, and finalwater supply design should be based on turbine contractfigures. Quality requirements are nominal requiring onlythe removal of abrasive material.

c. Sources.

(1) Spiral case. For units with heads up to about76 m (250 ft), the preferred source of cooling water is agravity supply from an inlet in the spiral case or spiral

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case extension. In multiunit plants, an inlet is providedfor each unit with a crossover header connecting all unitsto provide a backup water supply to any one unit. Cross-overs between pairs of units only are not regarded asadequate since there would be no emergency source froman unwatered unit. The spiral case source is usually satis-factory for unit bearing coolers, as well as the generatorair coolers, and can be adequate for gland and wearingring use with proper filtering and adequate head.

(2) Tailwater. For higher head projects, above 76 m(250 ft), the usual source of cooling water is a pumpedsupply from tailwater. This normally provides water ofessentially the same quality as the spiral case gravitysystem.

(3) Other sources. It is unlikely that other suitablesources will be available or required for cooling require-ments, but alternate sources should be considered forgland requirements. Silt or other abrasive material isusually present in varying degrees in reservoir water, atleast seasonally, and since abrasive material is injurious toglands, an alternate source or additional treatment is usu-ally required. The potable water system is normally thebest alternate if the supply is adequate or could be eco-nomically increased. This would usually be in the case ofa well supply requiring little chlorination. Where potablewater is used, cross connections from the cooling watersource, with backflow protection, should be provided foremergency use.

d. Head requirements. Normally the cooling watersupply should provide a minimum of 68.9-kPa (10-psi)differential across the connection to the individual coolerheaders. Available gravity head, cost of a pumped sup-ply, and cost of coolers all enter into an optimum coolerdifferential requirement and require early design consider-ation to assure a reasonable figure for the generator andturbine specification. Gland and wearing ring differentialhead requirements should be obtained from the turbinesupplier.

e. Treatment. Water for coolers, glands, and wear-ing rings will normally require only straining or filtration.This should be verified from operating experience atnearby existing plants on the same stream. Where exist-ing plants are remote or the project is on a previouslyundeveloped stream, a water analysis should be the basisof determining the likelihood of corrosion or scale depos-its and the need of additional treatment. Typical strainerrequirements for coolers permit 3-mm (1/8-in.) perfora-tions, but strainer specifications for existing projectsshould be obtained as a guide to complete design

requirements. Strainers should be the automatic typeunless the system provides other backup provisions forcontinuous water supply or the p.h. is small. Unnecessar-ily fine strainers requiring more frequent servicing shouldbe avoided. Filters are required for gland water unlessthe supply is the potable water system. The systemshould provide for continuous operation when an individ-ual filter requires cleaning.

f. Pumps. A pumped cooling water supply requiresa standby supply for a pump out of service. This can beprovided with two pumps per unit, each of which is capa-ble of supplying cooler requirements, or one pump perunit consisting of a common pump discharge header to allunits and one or more backup pumps. Other arrange-ments to provide backup pump capacity may also beacceptable. Pumps should be located such that floodedsuctions occur at minimum tailwater. Continuously risingpump performance curves are required, and the pumpshould not exceed 1,800 rpm.

g. Piping.

(1) Refer to Chapter 17 for general pipingconsiderations.

(2) Water takeoffs from the spiral case or the spiralcase extension should be within 30 deg of horizontalcenter line to minimize debris and air.

(3) A valve should be located as close to the casingas practicable for emergency shutoff.

(4) Balancing valves should be located in coolersupply lines.

(5) A removable 0.9-m (3-ft) section of straight pipeshould be provided in the generator bearing supply linefor temporary installation of a flow meter.

h. Drawings. Typical generator and turbine coolingwater systems are shown in Figure B-7.

10-3. Transformer Cooling Water

Most plants now utilize air-cooled transformers, so thereis very limited application of transformer cooling watersystems. The general principles noted in paragraph 10-2are applicable for transformer cooling water except wheretransformers are located on the intake deck of a dam-powerhouse structure. There the pumped supply wouldnormally be from pool water rather than tailwater. Waterpressure in heat exchangers should be less than the oil

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pressure to prevent water from entering the transformeroil under minor seepage conditions. Transformer coolingwater systems must be protected from freezing wherefreezing can occur.

10-4. Fire Protection Water

The requirement for fire protection water is normallylimited to deluge systems for main power transformers.Refer to Chapter 15, “Fire Protection Systems,” for dis-cussion of deluge systems. The deluge system water sup-ply will normally be from the pool and should be agravity supply if practicable. A booster pump should beprovided if required. A pumped tailwater source is anacceptable alternate. Two water intakes are requiredeither of which can supply the rated delivery of the pump.Consideration must be given to providing a source ofpower for pumping when the circuit breakers supplyingthe transformer are automatically tripped because of atransformer fault. The pump, piping, appurtenances, andinstallation should conform to the applicable provisions ofNFPA Standard 851.

10-5. Potable Water System

a. General. The primary demand on the potablewater system is drinking and sanitation water for thepowerhouse. In addition, the potable water system isoften used as the main source for gland and wearing ringwater and, in some projects, supplies other potable waterrequirements, external to the powerhouse.

b. Water requirements. The powerhouse drinkingand sanitation flow demand, including provision for visi-tors, should be determined in accordance withTM 5-810-5. This will normally be on a fixture unitbasis. However, in the case of large powerhouses, themain rest rooms near the service bay are usually adequatefor all personnel requirements, and additional facilities areprovided, remote from the service bay, for convenience.These require the piping design on a fixture unit basis, buta reduction in the fixture unit basis water demand, com-mensurate with the intended usage, can be justified.Gland and wearing ring flow requirements are as deter-mined under paragraph 10-2b(2). Principal qualityrequirements are safety in health considerations andacceptable taste qualities consistent with the area in whichthe project is located.

c. Sources.

(1) General. Sources for powerhouse requirementsinclude the following: pool water, tailwater, powerhouse

well, general project supply, existing construction supply,and local public supply. The order of preference dependson several variables, but it is generally preferable to sup-ply all project potable water requirements from one sys-tem whether it be a powerhouse or nonpowerhousesource. All sources should be considered, and a choicemade on the basis of reliability, purity, required treatment,and cost. For nonpowerhouse sources, the powerhousedesign responsibility is limited but includes mutualverification of demand, supply, reliability and cost, andprovisions for necessary standby sources.

(2) Wells. Good wells usually provide the bestsource of potable water from purity, treatment, and tem-perature considerations. The existence of good wells inthe vicinity along with favorable geological indicationswould suggest serious consideration of a well supply.The system No. 1 well and storage reservoir should beadequate for all initial and potential expansion demands,and there should be a backup well at least adequate forsystem operation under conservation operation. In theevaluation of a potential well supply, other considerationsshould include the following: water rights; probability ofincreased domestic, agricultural, or commercial demandfor underground water; and effects of pool raising andpool level variations. The power plant design analysisshould include a record of all factors considered in theselection of a well supply.

(3) Pool or tailwater supply. Reliability is the majoradvantage of either a pool or tailwater source. Quality isusually questionable, and treatment plants providing coag-ulation, chlorination, sedimentation, and filtration may berequired. It will usually be desirable to combine a poolor tailwater potable supply with other nonpotable, power-house raw water requirements as far as intakes, intakepiping, and strainers are concerned. Intakes from eitherpool or tailwater should not be located in penstocks, unitintakes, or draft tubes in such a way that system water isnot available 100 percent of the time.

(4) Construction source or public supply. An ade-quate existing construction source or public source isunlikely but should be investigated in view of the obviousadvantages, particularly of a substantial, state-regulatedsystem.

(5) General project supply. A general project supplymay be from one or more of the previous sources dis-cussed and may originate under powerhouse design ornonpowerhouse design. It will usually be the optimumarrangement for the project as a whole. If the design isnonpowerhouse, all powerhouse requirements should be

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determined, and adequacy of the supply verified by thepowerhouse design office.

(6) Factors. TM 8-813-1 provides a discussion offactors to consider in evaluating water supplies.

d. Pump versus gravity considerations (pool-tailwater source).

(1) High head projects. Projects with over 76-m(250-ft) head should be provided with a pumped potablewater supply with the pumps taking water from a tailraceintake. Pressure-reducing valves to utilize gravity headsfrom higher pools are not recommended unless tailwateris excessively contaminated or not always available.

(2) Low head projects. Project with under 76-m(250-ft) head may utilize gravity head to good advantage,providing pool fluctuations will not result in less than103-kPa (15-psi) pressure at the highest fixture served.Pressure-reducing valves with downstream relief valvescan be used to provide a reasonably constant pressure ifnecessary. Temporary failure of a pressure-reducing orrelief valve will not endanger fixtures or piping up to76 m (250 ft) of head.

e. Pump requirements (pool-tailwater source).Pumped potable water requirements should be providedby two pumps with either pump capable of pumping thetotal system peak demand. Pumps should normally beeither vertical or horizontal centrifugal with constantrising characteristic curves and should be located toensure a flooded suction under all operating conditions.Turbine-type pumps should also be considered for low-flow higher-head requirements. Controls should be con-ventional lead-lag for a hydropneumatic tank or gravitytank as applicable. Unless the potable water pumps arepumping from a strained raw water supply, duplex suctionstrainers are required.

f. Water treatment.A water quality analysis shouldbe obtained to determine the treatment required. In eventthat full treatment is not initially indicated, space, pipingsizes, and connections should be provided to expandtreatment facilities should subsequent changes in waterquality so require. Power plant uses do not require allwater qualities considered desirable for domestic use, sojudgment in applying treatment criteria is necessary.Potable water should meet the minimum requirements asspecified in ER 1130-2-407. For treatment plant design,refer to ASCE-AWA-CSSE published by American Water

Works Association (AWWA). Other references includeTM 5-813-3, applicable state plumbing codes, and EPArequirements.

g. Storage tank.

(1) Gravity tank. A gravity tank, or other gravitysources, with capacity and head to sustain the project fora week or more under conservation operation is the mostdesirable storage facility. When a suitable tank location isavailable, and particularly where there is a substantialnonpowerhouse project demand, design emphasis shouldgive first priority to a gravity system. The design respon-sibility for the storage facility will usually be nonpower-house for such systems. Refer to TM 5-813-4 for waterstorage considerations.

(2) Pressure tank. Where a gravity system is notfeasible, a hydropneumatic tank located in the powerhouseis normally provided for the powerhouse requirements.The tank should be sized so that in combination withhigh-average system demand and pump delivery, it willprovide a minimum 30-min chlorine contact period andallow approximately 10 min between pump starts. Tanksshould conform to Section VIII of the ASME “BoilerPressure and Vessel Code.” Tanks smaller than about1,676 mm (66 in.) in diameter should be galvanized insideand out depending on plant capabilities in the supply area.Larger tanks should be painted inside and out.

h. Hot water.

(1) Powerhouse fixture requirements. The type,number, and location of fixtures requiring hot potablewater are normally determined by architects. The pipingsystem designer should cooperate in the planning to effectthe most practical grouping of fixtures for efficiency ofhot water distribution.

(2) Demand. Demand should be computed on thebasis of Table B-2 and information noted in Appendix B,paragraph B-5, “Powerhouse Electric Water Heaters.”

(3) Heaters. Heaters should be the electric tank typeand should be selected in accordance with Appendix B,paragraph B-5. Where fixtures are isolated by more than18-24 m (60-80 ft) of piping, the provision of separateheaters may be more economical and should be investi-gated. Electrical load should be coordinated with theelectrical design.

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i. Piping. Refer to Chapter 17 for general pipingconsiderations. Disinfecting of potable water piping inaccordance with AWWA Standard C 601 should be pro-vided. Backflow preventers are required between thepotable water system and gland water piping also in anyother interconnection between potable water piping andpiping with the potential for containing nonpotable water.

j. Drawing. Figure B-8 presents a plan of a typicalpotable water system.

10-6. Raw Water System

a. General. The raw water system normally pro-vides water for the following requirements:

(1) Air compressors and aftercoolers.

(2) Air conditioning cooling water.

(3) Fire protection-deck washing.

(4) Pump prelube.

(5) Unwatering and drainage deep well.

In addition, certain projects may utilize water from theraw water system for gland water, transformer delugesystem, station transformer cooling water, and a sourcefor the potable water system.

b. Water requirements. Flow requirements for aircompressors, aftercoolers, and pump prelube should beobtained from equipment suppliers and verified againstexisting projects with similar equipment. Air conditioningflows will be as computed for the air conditioning system.Fire protection - deck washing hose valve requirementsshould be based on 3-L/s per 40-mm (50-gpm per 1.5-in.)hose and should assume three hoses operating at one time.Quality requirements for the raw water system are nomi-nal, requiring straining only unless water analysis indi-cates a need of treatment to limit scale formation incooling coils.

c. Sources.

(1) General. Raw water should normally be obtainedfrom the pool or tailwater. Other reliable sources areunlikely to be economically available; however, an exist-ing or planned adequate gravity project source wouldoffer some advantages and should be considered.

(2) Pool. For projects up to about 76-m (250-ft)head, a gravity pool supply is usually preferable.

(3) Tailwater. For projects over 76-m (250-ft) head,or where pool head fluctuates over a wide range, apumped tailwater supply will normally be utilized. Forhigh head projects in tidal locations with brackish tail-water, special materials and/or equipment will be required.

d. Head. Optimum head for raw water requirementscan vary considerably depending on the particularequipment selected and its location. System designshould consider the inherent flexibility in required differ-entials across coils and heat exchangers, as well as loca-tions, to effect the simplest and most dependable system.The provision of booster pumps or pressure-reducingrelief valve stations to provide different head in a portionof the system should be evaluated on the basis of require-ment rather than desirability. The fire protection-deckwashing hose cabinets are intended as backup fire-protection only, permitting reasonable fluctuations inavailable head.

e. Treatment. Strainer perforations of 3 mm(1/8 in.) will normally be adequate for all raw watersystem requirements (see paragraph 10-2e for furtherrecommendations).

f. Pumps. The pump principles noted in para-graph 10-2f are generally applicable. The system designshould provide standby pump capacity for all pumpedrequirements. For pumped tailwater systems, the rawwater system requirements can be included in the genera-tor cooling water pumps capacity and supplied throughthe crossover header, with booster pumps provided ifrequired.

g. Piping.

(1) Refer to Chapter 17 for general pipingconsiderations.

(2) The generator cooling water crossover headershould normally be the supply to the raw water system.

(3) Where the generator cooling water is a gravitysupply which is not always available, a standby raw watersupply intake and piping should be provided.

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(4) Piping for fire protection-deck washing hose cabi-nets subject to freezing should be provided with automaticdrainage.

(5) A 20-mm (3/4-in.) hose valve should be providedat each turbine head cover for cleanup.

(6) A 40-mm (1.5-in.) hose connection should beprovided near turbine access hatches to wash down theturbine.

h. Fire protection-deck washing hose cabinets.Thefire protection-deck washing provisions are intended basi-cally to meet the normal standards of a deck washingsystem and to further serve as a backup means of firecontrol. Powerhouses are considered to be low fire haz-ard structures with code fire protection provisions limitedto generators, oil storage and pump rooms, paint storagerooms, and in some cases, transformers. Protection for

these hazards are covered in Chapter 15, “Fire ProtectionSystems.” To provide backup protection, the fire protec-tion-deck washing system should include 40-mm (1.5-in.)hose connections, hose and reels, spaced throughout thepowerhouse and decks, to permit minimum hose nozzlecoverage of all occupied areas except drainage galleriesand locations where a stream could contact high-voltageelectrical equipment. Areas used for loading or unloadingfrom vehicles or railroad equipment, heavy maintenanceareas, potential storage areas, and where there is oil pip-ing should be accessible to simultaneous hose-nozzlecoverage from two directions. Where the fire protection-deck washing system is supplied by pumps, the pump andstandby pump should receive power from separatesources.

i. Drawings. Figure B-9 shows typical raw watersystems.

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Chapter 11Unwatering and Drainage System

11-1. General

The unwatering and drainage system provides the meansfor unwatering main unit turbines and their associatedwater passages for inspection and maintenance purposes,as well as the collection and disposal of all powerhouseleakage and wastewater other than sanitary. The provi-sions for equalizing (filling) are closely related tounwatering and are included in this chapter. The safetyof personnel and plant is of vital concern in this systemand should have continuing priority throughout the design.

11-2. Unwatering System

a. General. The principal volumes to be unwateredin all powerhouses are the spiral case and draft tube. Inaddition, there is usually a considerable volume down-stream of the headgates or the penstock valve. Someprojects include extensive fish passage facilities with largevolumes of water in pumps, channels, and conduits to beunwatered.

b. Detail requirements.

(1) Unwatering procedure. Normal procedure afterunit shutdown requires the following: closing of theheadgates or penstock valve; drainage of all unit waterabove tailwater to tailwater elevation through the wicketgates, and spiral case or spiral case extension drain; place-ment of draft tube bulkheads or stoplogs; and draining theremaining unit water to sump with the sump pumpsoperating.

(2) Unwatering time. Aside from safety, the requiredelapsed time for completing a unit unwatering is themajor factor in unwatering system design. Unit downtimewill usually be of a value justifying facilities to accom-plish unwatering in 4 hr or less. This can mean that in atypical plant all necessary valve, gate, and stoplog orbulkhead operations should be done in approximately 1 hrand draining of the pumping system in approximately3 hr. Such a schedule has been attainable and justifiableon existing projects.

(3) Spiral case drains. Spiral case drains should nor-mally be sized to preclude draining of the spiral casesfrom becoming a controlling factor in total unwateringtime. Oversizing to the point where misoperation couldresult in excessive unseating head and damage to draft

tube stoplogs or tailrace structure must be avoided, partic-ularly in plants where opening the drain valve is part ofthe equalizing procedure. It will usually be found thatwith properly sized drains the unseating force on the drafttube stoplogs will result in enough leakage to prevent adamaging pressure rise. The drains should normally beprovided with manually operated rising stem-gate valvesfor control. However, portable or fixed power operatorscan be justified on the larger sizes. Maximum flowvelocities will usually render butterfly valves unsuitable.The designer should be aware of the flooding hazardresulting from a failure in this line and provide a layoutwith conservatively rated components and in which align-ment and necessary flexibility can be reasonably attained.Typical sizes in existing plants are in the 100-200-mm(4-8-in.) range for small Francis unit plants and in the400-500-mm (16-20-in.) range for large Kaplan unitplants. Spiral case drains should discharge to the drafttube to preclude pool head on the unwatering sump. Aconnection for introducing station compressed air immedi-ately upstream from the control valve to dislodge packedsilt and debris is normally required.

(4) Draft tube drains.

(a) Draft tube drains should be sized with consider-ation for leakage from the following: intake gates, intakevalves, and structural relief drains; draft tube bulkheads orstoplogs; the required unwatering time; and the assuranceof seating the draft tube bulkhead or stoplogs. With aver-age design and workmanship on bulkheads, stoplogs, andguides, the 3-hr draining requirement usually will result ina large enough draft tube drain to seat the bulkhead orstoplogs. A short drain line discharging into a large con-duit and sump results in a high initial flow rate ideal forthe seating requirement. Where drains are manifoldeddirectly into the pump intakes, the individual draft tubedrains tend to be smaller, and the maximum capacity ofthe entire system should be evaluated for the possibility ofunseated leakage, plus other leakage, which equals orexceeds the drainage capacity.

(b) Valves for the draft tube drains are usually eithera submerged rising plug type (mud valve) or standardin-line rising stem-gate valves. The rising plug typeoffers a drain line installation not subject to pluggingfrom packed silt and no exposed components subject toflooding hazard failures. Its disadvantage is the headrequirements, for large units with deep submergence areusually not within standard valve ratings which result innonstandard equipment. Attempts to upgrade standardvalves usually causes problems in obtaining valves withadequate safety factors for all hydraulic forces and

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operator forces. Standard gate valves and operators areavailable as off-the-shelf items for installations in a drypit location accessible to the embedded drain line, but thepotential for line plugging between the draft tube andvalve is disadvantageous. Short lines with compressed airblowout connections will minimize unplugging problems.This type of valve installation is ordinarily restricted tosmaller plants without an unwatering header or tunnel.For the larger units with deep submergence, the preferredvalve is either a standard design gate valve suitable forsubmergence in a draft tube recess or special design plug-type valve with design for the required head completelydetailed in the contract drawings. Stainless steel water-type knife-edge gate valves suitable for submergedextended stem operation have been used at several recentprojects and are expected to give reliable service. Twovalves should be installed in draft tube locations to pro-vide unwatering capability with one valve inoperable, butrequired unwatering time should be on the assumptionthat both valves are operable. Powered operators, eitherportable or fixed, are usually justified for the larger instal-lations. Butterfly valves are generally unsuitable becauseof high velocities.

(c) Draft tube drains may be run individually to theunwatering sump in small plants but are usually dis-charged into a large pipe header or formed conduit lead-ing to the sump in large plants. The formed conduit hasdefinite advantages in large Kaplan unit plants as it canbe large enough for inspection and cleanout, can form aneffective addition to sump capacity, and is often moreeconomical than a pipe header.

(d) The flooding hazard precautions noted in 11-2b(3)are also applicable to draft tube drains.

(5) Unwatering sumps.

(a) Sump provisions in most projects require eitherjoint usage in both the unwatering and drainage systems,or separate sumps with the unwatering sump serving as abackup or overflow for the drainage sump. Size and con-figuration specifications require close coordination withthe planned pumping provisions and inflows to permitpractical pump cycles with adequate backup and effectivehigh-level warning provisions. Whenever space and rea-sonable cost permit, it is preferable to provide oversizedsumps to allow more flexibility to accommodate unex-pected leakage, additional or larger pumps, or revisedoperating procedures.

(b) Sumps should be designed for maximum tail-water head with assumed pump failure and be ventedabove maximum tailwater.

(c) Floors should be graded to a small sump within asump to permit use of a portable pump for maintenanceunwatering the main sump.

(d) With separate sumps, the drainage sump over-flow should be above the lag pump “on” elevation and beprovided with a check valve which has a pressure ratingbased on maximum tailwater.

(6) Unwatering pumps. The unwatering and drain-age pumping provisions require, along with the sumps,consideration of their individual and joint usage require-ments. Usually, more than one combination of pumpswill be practical for any application. However, the fol-lowing general principles should be observed:

(a) Sump configuration and automatic start-stop set-tings should allow a minimum of 3-min running time percycle for all pump selections.

(b) Pumps should be suitable for operation at zerostatic head.

(c) Pumps should have continuously raising perfor-mance curves.

(d) Pump motors and controls should be locatedabove average peak flow tailwater.

(e) Silent-type check valves should be used in pumpdischarge lines.

(f) Where space is available, the preferred provisionsshould include the following: separate unwatering anddrainage sumps, separate unwatering and drainage pump-ing provisions, and automatic overflow from the drainagesump to unwatering sump.

(g) With separate systems, unwatering pump capac-ity should permit unwatering in 3 hr or less of pumpingtime with total capacity divided in two pumps of the samecapacity. Either pump used alone should be capable ofaccomplishing an unwatering. Since unit unwatering willnot be scheduled under powerhouse design flood condi-tions, rated unwatering pump discharge should be for amaximum planned tailwater under which unwatering will

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occur. To provide backup for the drainage system, theunwatering pumps should have a reasonable capacity atpowerhouse design flood conditions.

(h) With separate systems, the drainage pump capac-ity should be divided between two pumps of the samecapacity. Each should be capable of pumping a minimumof 150 percent of maximum estimated station drainage atan average peak-flow tailwater and with combined capac-ity to handle estimated station drainage at powerhousedesign flood.

(i) With combined single-sump systems, the drainage-unwatering two-pump capacity should meet the statedminimum requirements for separate systems. The twopumps should pump from an in-sump manifold withvalved connections from unwatering lines and a valvedinlet from the sump. The manifold inlet valves should bemanual, and design should be based on station drainageaccumulating in the sump during an unwatering operation.A third manually controlled pump of the same capacityshould be installed as backup for the drainage function.Suction for the third pump should be directly out of thesump, not through the header.

(j) Pumps of the deep well water-lubricated type willusually be preferred. Water jet educators can seldom bejustified from an efficiency standpoint, and dry pit pumpinstallations are less desirable in safety and cost consider-ations. Submersible motor and pump combination unitsmounted on guide rails permitting the pump units to beraised or lowered by the powerhouse crane have beenused on several recent jobs. Provisions are included forautomatic connection to the pump discharge line. Thisdesign eliminates the long pump shafts and simplifiesmaintenance.

(k) Either pneumatic bubbler-type or float-type con-trols are satisfactory for pump control. A separate floattype of control should be provided for the drainage sump(or combined drainage-unwatering sump) for high-wateralarm. Automatic lead-lag with manual selection of thelead pump is preferred.

(l) Whenever practicable, minimum piping (particu-larly embedded), sump capacity, and pump arrangementbackup provisions should permit the addition of futurepumping capacity.

(7) Discharge piping. Unwatering system dischargelines normally terminate above the average peak-flowtailwater. Therefore, reliance is on the discharge checkvalves for prevention of backflow at high tailwaters and

permission of line and check valve maintenance at lowertailwaters. Individual pump discharges to the tailrace arepreferable, but a single discharge header for combinedunwatering-drainage pumps and a single header each forseparate unwatering and drainage systems will usually befound more practicable to use.

(8) System diagrams. Figure B-10 shows typicalunwatering-drainage systems.

c. Miscellaneous.

(1) Unwatering of nonpowerhouse facilities. It isacceptable to utilize the unwatering conduit, sump, andpumps for unwatering of fishway conduits, channels, andpumps as well as other facilities in or adjoining the pow-erhouse. However, frequency of use, length of lines, lineplugging, safety, required unwatering time, cost, andpossibility of conflicting unwatering schedules should becarefully evaluated. Portable equipment is frequently apreferable choice.

(2) Construction usage. Use of the unwatering facil-ities for construction requirements or for maintaining skel-eton (future) powerhouse bays in an unwatered conditionshould not be planned. Questionable condition of equip-ment and fouling of lines with construction debris aftersuch usage will be usually experienced.

11-3. Drainage System

a. General. The drainage system handles three gen-eral types of drainage as follows: rain and snow waterfrom roofs and decks, leakage through structural cracksand contraction joints, and wastewater from equipment.Discharge is to tailwater either by gravity or by pumpingfrom a drainage sump.

b. Roof and deck drainage. Roof and deck drainageshould normally be directly to tailwater by gravity. How-ever, where the powerhouse forms a portion of the damstructure, it may be feasible to drain the intake deck topool. A minimum of two roof drains per bay should beprovided to minimize flooding from plugging. Deckdrains should be located to eliminate standing water andshould consist of short vertical runs of piping whereverpracticable in freezing areas. Decks with open block-outtype of rail installations should be provided with block-out drains. Size of roof and deck drains should be basedon the greater of applicable code requirements or maxi-mum 1-hr rainfall figures for the area. Deluge systemflows should be added where applicable.

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c. Floor drainage.

(1) Drainage galleries. Drainage galleries and othergalleries with a wall in contact with water or a fill belowhigh tailwater should be provided with a drainage trench.The trench should be sized and graded for maximumestimated leakage based on existing similar powerhouses.Unless located in grouting galleries, trenches should notcross contraction joints without provision of water stops.Conduits connecting the trenches to the drainage sumpand the conduit entrances should be carefully designed topreclude overflow of the trench onto the gallery floor.Contraction joint drains should discharge visibly into thedrainage trench to permit monitoring of joint leakage. Afloat-operated alarm should be provided to indicate flood-ing of the lowest gallery.

(2) Oil storage and purifier rooms. Where oil storageor purifier rooms are provided with sprinkler systems,provide a chilling drain with a gravel pocket of sufficientcapacity to handle the sprinkling system flow. When aCO2 protected room is drained, the floor drain should beof nominal size and provided with a normally closedmanual valve. Oil storage or purifier room drains shouldnot drain directly to tailwater. They should first be routedto an oil separator facility.

(3) Battery room. Battery room floor and sink drainsshould be of acid resisting material, have a minimum2 percent slope, no pockets or traps, and should dischargedirectly to the sump or tailrace.

(4) Miscellaneous area floor drains. Miscellaneousarea floor drains should be provided in accordance withASME A 31.1 and the Unified Plumbing Code. All floorareas below average peak-flow tailwater, and all otherfloor areas subject to flushing, leakage from, or periodicdisassembly of water-filled equipment or piping should bedrained. Any drains that come from a source that can addoil to the water should not drain directly to tailwater butshould first be routed to an oil separator facility. Thefollowing areas are typical of most powerhouses, but therequired areas of each powerhouse should be determinedindividually:

(a) Turbine rooms.

(b) Galleries.

(c) Water treatment room.

(d) Pump rooms.

(e) Locker rooms.

(f) Toilet rooms.

(g) Machine shop.

(h) Heating and ventilating equipment room.

(i) Gate repair pits.

(j) Gate and bulkhead storage pits.

(k) Pipe trenches.

(l) Elevator pits.

(m) Rigging rooms.

(n) Valve pits.

(5) Location of floor drains. Locating floor drainsrequires close coordination with structural and architec-tural requirements, but the following general consider-ations should apply.

(a) All areas where leakage, rainwater, water fromdisassembly, flushing, etc., is normally expected shouldhave floors with continuous slope to the drain location.Examples of these areas are around pumps, strainers,janitor closets, outside decks, shower rooms, unloadingareas, and drainage galleries.

(b) In other areas with unfinished level floors, it isdesirable to locate drains in the center of a 910-1,220-mm(36-48-in.) depressed area to assist in directing water tothe drain.

(c) In finished areas (terrazzo, tile) where slope or adepressed area can not be obtained, the drain location andelevation should be determined by the architect.

d. Equipment wastewater drainage.

(1) Gravity wastewater. The following equipmentwastewater is normally drained to the sump through thedrainage system piping:

(a) Pump gland drainage.

(b) Strainer drains.

(c) Condensate.

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(d) Air compressor cooling water.

(e) Turbine head cover leakage.

(f) Heat exchanger.

(g) Turbine pit liner drainage.

Drainage should be collected and piped to the floordrains, sealed connections, or sight funnels. Open flowsrunning horizontally across floors or drain lines should beavoided. Francis-type turbines are normally drained bygravity, and drainage from propeller turbines is normallypumped out of the turbine pits with pumps furnished bythe turbine manufacturer. Capacity of gravity drain pipesmay be estimated from Appendix B, paragraph B-6,“Capacity of Cast Iron Drain Lines.”

(2) Pressure wastewater.

(a) Wastewater from generator air coolers and bearingcoolers are normally piped directly to the tailrace. Somepowerhouses also require pressure drains for transformercooling water and air conditioning cooling water.

(b) The point of discharge for pressure drains requirescareful consideration as several factors are involved.These include the following:

• Tailwater fluctuations.

• Available head (where the source is pool water).

• Pumping costs.

• Pressure conditions in coils and other equipment.

• Icing conditions.

• Requirement for flap valves or other protectiveshutoff valves.

• Line and valve maintenance.

• Esthetics (visibility of discharge).

• Fish passage channels.

An optimum discharge location would be above maximumtailwater for safety reasons. Where this is not practicable,a location above normal operating tailwater and the provi-sion of a readily accessible shutoff valve at the pointwhere the line becomes exposed in the powerhouse are

preferred. A vented loop to prevent backflow from tail-water is satisfactory, but space requirements and the addi-tional piping can make this provision impractical.

(c) Pressure discharge lines should be designed formaximum obtainable pressure conditions, and if an isolat-ing valve is used, the effect of an inadvertent closureshould be considered. Flap valves located below mini-mum tailwater are unsatisfactory because of inaccessibilityfor inspection and maintenance.

e. Drainage piping.

(1) General. Refer to Chapter 17 for general pipingconsiderations.

(2) Embedded detail requirements.

(a) Embedding piping should be cast iron soil pipe.

(b) Horizontal turns should be long sweep.

(c) Vertical turns may be quarter bend.

(d) Minimum line size is 76 mm (3 in.).

(e) Slope in horizontal lines is preferably 2 percentand a minimum of 1 percent.

(f) Routing should be generally parallel with build-ing lines to minimize interference with reinforcing steeland other embedded material.

(g) Lines crossing contraction joints requireprovision for flexibility. See detail in Appendix B,paragraph B-6.

(h) Lines more than one-third the thickness of wallor slab should not be embedded.

(3) Backflow valves. Drains in lower powerhouseareas may be fitted with backflow valves to minimizeflooding under adverse conditions. However, suchdevices are not considered as positive protection againstbackflow in system design.

f. Drainage sump. The provisions noted in para-graph 11-2b(5) are applicable to drainage sumps. Thedrainage sump or joint unwatering-drainage sump shouldbe located low enough to provide gravity flow from alldrained areas under all dry powerhouse design tailwaterconditions and up to the float-operated alarm, sump waterelevation. Deviations from this requirement can occur in

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the case of certain low-drainage galleries deemed noncriti-cal for short-term drainage interruptions. However, suchapplications should be discussed with review officesbefore proceeding with design.

g. Drainage pumps.Drainage pumps, whether sepa-rate or as combined drainage-unwatering pumps, shouldmeet the provisions of paragraph 11-2b(6).

h. Drainage pump discharge. Refer to para-graph 11-2b(7) and Chapter 17 for pump dischargerequirements.

i. Drainage sump overflow. The drainage sumpshould be provided with an overflow to the unwateringsump where separate drainage and unwatering sumps areprovided. The overflow should be located slightly abovethe high water-level alarm elevation and should be pro-vided with a flap valve to prevent flow from the unwater-ing sump to the drainage sump. The flap valve should bereasonably accessible for maintenance. It should be sizedto bypass the drainage sump inflow capacity or unwater-ing pumps combined capacity to permit maximum utilityin the event of an accident or flooding in the powerhouse.

j. Safety pool. Some projects with separate sumpsprovide for a “safety pool” of water in the draft tubewhen work is being done on the turbine runners. This isusually accomplished by allowing the unwatering sumpwater level to rise and overflow into the drainage sumpthrough a valved opening. Thus, a valved openingbetween sumps is required. Drainage pump capacity hasto handle the increased flows from all leakage into theunwatering sump.

k. Estimating drainage leakage. Leakage throughcontraction joints and cracks in floors and walls is usuallythe major uncertainty in estimating total drainage facilityrequirements. Where the powerhouse is a structure sepa-rate from the dam, 0.2 L/s per meter (1 gpm per foot) ofpowerhouse length is sometimes used. This tends toincrease appreciably when the powerhouse is integral withthe dam. Drainage to the powerhouse from a separateintake structure frequently is routed to the powerhousedrainage sump, and this is subject to the same uncertaintyas the powerhouse leakage itself. The most reliable esti-mate is one based on an existing powerhouse of compara-ble size, configuration, and head conditions. Informationon existing designs and operational experience is readilyobtainable from district offices and through reviewoffices.

l. External drainage. For some projects, it is expe-dient to route some of the drainage from the dam or otherproject facilities to the powerhouse drainage system.Such drainage should be limited to minor flows totallingnot more than 10 percent of the estimated powerhousedrainage since any significant addition to potentialflooding of the powerhouse should be avoided. Estimateddrainage from such sources are subject to many variables,and it is a responsibility of the powerhouse designer toverify the estimates.

m. Transformer vault drains. Drains from areas inwhich oil-filled transformers are located should be dis-charged to draft tube gate slots when the water above thedraft tube exit is confined to a holding pond, or to a simi-lar method of storing spilled oil for later pumpout anddisposal.

11-4. Equalizing (Filling)

a. General. A number of methods have beenemployed for equalizing at existing projects, but twopreferred methods are described. Other methods involv-ing equalizing headers or crossover connections are satis-factory in operation but introduce additional piping andvalves along with increased flooding hazards in event offailure.

b. Low head projects. Low head projects up toabout 38m (125 ft) usually have one or more intake gatesand a set of draft tube bulkheads or stoplogs. Equalizingon these projects can be accomplished by opening thespiral case drain, cracking the intake gates, and filling thedraft tube to tailwater then lowering the gates. Afterremoving the bulkheads or stoplogs and closing the spiralcase drain, the intake gates are again cracked open, andthe spiral case and intake allowed to fill and equalized topool head. The entire operation takes place with thewicket gates closed. No additional piping or valves areprovided.

c. High head projects. Higher head projects pro-vided with a penstock valve have a bypass valve for equa-lizing pressure across the penstock valve. Equalizing onthese projects can be accomplished by filling to tailwaterthrough valves provided in the draft tube bulkhead orstoplogs, removal of the bulkhead or stoplogs and filling,and equalizing the spiral case through the penstock valvebypass. The entire operation takes place with the wicketgates and spiral case drain closed. Additional equipmentinvolved consists of one or more tag-line operated valves

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in a draft tube stop log or bulkhead. The tag-line oper-ated valves should be a balanced type of valve to permitconvenient tag-line operation in both directions and shouldbe located near the top of the bulkhead or stoplog. Valvesizes should be consistent with the unwatering time notedin paragraph 11-2b(2). When upstream intake gate sealsare used, cracking the gates to fill the penstocks should beavoided because of the possibility of gate catapultingduring filling. For more information, see the April 1977WES publication TRH-77-8. This publication can bepurchased from the National Technical Information Center(NTIS), 5285 Port Royal Road, Springfield, Virginia22161 as report AD A043 876. Costs of hard copies ormicrofiche copies of such reports are available from theNTIS on request.

11-5. Venting

When a penstock valve is utilized, the spiral case requiresan air and vacuum relief valve to permit filling and unwa-tering. This valve and line should be sized to prevent lessthan one-half atmospheric pressure developing in thespiral case and should open to release air under poolpressure. The takeoff should be from the top of the cas-ing or spiral case extension, and the vent line should beprovided with a cutoff valve located as close to point oftakeoff as practicable. Termination should be in ascreened opening, above maximum tailwater, and clear ofpersonnel areas.

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Chapter 12Oil Systems

12-1. General

Installed systems for two types of oil, governor-lubrica-tion oil (governor-lube) and insulating oil, are required inmost powerhouses. The systems are based on the use ofa common oil for unit lubrication and governor-systemsand for transformers and circuit breakers. Should there beuncertainty regarding the common use of these oils, pre-design discussion with review offices is recommended.Other powerhouse oils which may be necessary are han-dled in portable containers and are not covered in thischapter. The storage, pumping, purification, and pipingfacilities for governor-lube oil and insulating oil are simi-lar, but the design must be based on maintaining completeseparation of the two oils through the use of separatefacilities due to the special purification requirements ofinsulating oil. Separation is not necessary in disposal.Design emphasis should provide maximum protectionagainst misrouting and mixing of oils and fire hazardsresulting from spillage (see paragraph 15-2). Separatepiping systems should be provided insofar as possible forinsulating oil for the transformers and circuit breakers tominimize the chance of mixing these oils. Additionalguidance can be found in Guide Specifications CW-15487for turbine lubricating oil and CW-16321 for electricalinsulating mineral oil.

12-2. System Requirements

a. Governor-lube oil. The following operations arenormal system requirements:

(1) Filling dirty oil storage tank from tank car ortruck.

(2) Moving oil from clean oil storage tank by eitherthe purifier or transfer pump to the generator-turbine unit.

(3) Draining or returning overflow oil from the gener-ator-turbine unit to the dirty oil storage tank.

(4) Moving oil from either storage tank to a tank caror truck for disposal.

(5) Flushing of any supply line to generator-turbineunits.

(6) Recirculating oil in any equipment on generator-turbine unit through purifier and back to equipment.

(7) Recirculating oil from any storage tank throughpurifier and back to tank.

b. Transil oil. The system requirements for insulat-ing oil are essentially as for governor-lube oil in 12-2awith each operation relative to transformers or circuitbreakers instead of generator-turbine units.

12-3. Oil Storage Room

The oil storage room should be located at a low elevationin the powerhouse. A depressed area in concrete shouldbe provided below all openings in the room of sufficientvolume to contain all oil stored in the room. Space forpurification equipment in the same room is desirable tosimplify CO2 fire protection. The room should be in massconcrete but, in any case, should be of fire resistant con-struction and have automatic closing fire doors. The floorshould slope to a sump to collect small oil spills for re-moval. A valved, inverted outflow line should drainwater from the bottom of the sump. A personnel emer-gency escape door or hatch should be provided in a desir-able location away from the main door. If separate oilstorage and purification rooms are provided, the roomrequirements are similar.

12-4. Oil Storage Tanks

a. Capacity. Clean and dirty insulating oil tanksshould each hold a minimum of 110 percent of the oilrequired to fill the largest transformer on the system.Clean and dirty governor-lube oil tanks should each holda minimum of 110 percent of the oil required to fill thegovernor system and all the bearings of the largestgenerator-turbine unit.

b. Design. Storage tank design should conform tothe applicable requirements of American Petroleum Insti-tute (API) Standard 650, Underwriters Laboratories (UL)Standard 142, or ASME “Boiler and Pressure VesselCode” (design pressures 15 psi and over). Minimum wallthickness should be 6.4 mm (1/4 in.). To determine thetype and configuration of tanks, the following factorsshould not be overlooked:

(1) Shipping limitations.

(2) Shipping costs.

(3) Space and scheduling for field erection.

(4) Testing of field-erected tanks.

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(5) Limitations on oil room configuration.

Tanks should be provided with direct reading liquid-levelgauges and the interior finish should be an epoxy-basedpaint system.

12-5. Pumps

a. General. Oil system pumps should be the posi-tive displacement type and should be provided with safetyrelief valves and high temperature shutdown. Suction liftshould not exceed 4.5 m (15 ft), and pump speed shouldbe limited to 1,200 rpm. Control should be manual, buttimer switches should be used to prevent continuous pumpoperation beyond the normal time required for each oiltransfer. Pump capacity may be provided in single orduplex units, but if single, a standby pump for convenientexchange should be available.

b. Dirty oil pumps.

(1) Waste oil. A pump should be provided to pumpwaste oil to a deck waste valve. Capacity should permitemptying the largest tank in approximately 8 hr or less.The pump should have a hose valve suction connectionfor the hose connecting to the insulating oil tank,governor-lube oil tank, or floor sump. A suction linefilter is required to protect the pump from foreignmaterial. Manual-timer switches should be located in theoil room and at the deck valve.

(2) Nongravity return oil. Projects where it is notfeasible to return oil from generator-turbine bearings andgovernor to the dirty oil tank by gravity should be pro-vided with pumps for this service. The location will usu-ally be in the turbine pit at each unit.

c. Clean oil pumps.

(1) Governor-lube oil. A governor-lube oil pumpsized to fill the bearings and governor of the largest unitin approximately 8 hr or less should be installed in the oilstorage room. An adjustable back pressure valve and thesafety relief valve should bypass excess oil back to theclean governor-lube oil tank. The safety relief valveshould be set to maximum system operating pressure, andthe adjustable back pressure valve to pump rating but nothigher than 95 percent of the safety relief valve setting.Manual-timer switches should be located in the oil roomand at each unit.

(2) Insulating oil. The insulating oil pump shouldhave approximately 105-110 percent of the capacity of the

purifier to be used at the transformers. Back pressure andrelief valve provisions should be as noted in 12-5c(1).Manual-timer switches should be located in the oil roomand at each deck valve.

12-6. Oil Piping

a. General. Refer to Chapter 17 for general pipingconsiderations. Figures B-11 and B-12 show typical oilsystems. Appendix B specification, “Powerhouse Piping,”provides flow losses for oil in tubing (see paragraph B-3).

b. Special provisions.

(1) Supply piping should be sized to deliver fullpump flow to the most remote outlet without exceedingallowable tubing pressure.

(2) Return piping should be sized to drain the mostremote transformer or generator-turbine-governor within8 hr.

(3) Return lines should be routed to avoid air traps.Loops discharging to the bottom of tanks should bevented to the top of the tank.

(4) Flushing connections are required between endsof each supply line and return line. Connection shouldinclude a check valve.

(5) Normal overflows and leakage should generallydrain by gravity to the dirty oil tank. Where this is notpossible, an automatic float-operated pump and sumpshould be provided.

(6) The piping layout should provide for pipe drain-age back to the tank wherever practicable.

(7) Pressure gauges with isolating cocks should beprovided on the suction and discharge of each pump.

(8) Sampling cocks should be provided at bottom oftanks and at one-fourth points up to the top.

(9) Fixed piping connections are used for generatorand turbine bearing sumps and governor tanks.

(10) Hose valves and hoses are used for connectionsto transformers and circuit breakers.

(11) The piping material schedule, Figure B-13, pro-vides for type K hard drawn copper tubing for oil systempiping. Soft solder connections are normally satisfactory.

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(12) Overflow drains to the dirty oil tank should beinstalled without valves.

(13) Purifier hose connections should be provided inthe oil storage room, transformer locations, and atgenerator-turbine units.

12-7. Oil Purifiers

a. General. Each powerhouse should be providedwith a governor-lube oil purifier and with, or have con-venient access to, an insulating oil purifier. Portablepurifiers are preferred. Overall purifier dimensions,access doors and ramps, and elevator sizes must be coor-dinated in the early powerhouse planning to permit puri-fier access to the oil storage room, transformer locations,and purifier connections at generator-turbine units. Foradditional guidance, refer to ETL 1110-8-12.

b. Governor-lube oil purifier. The governor-lube oilpurifier should be either a centrifuge or coalescent type.A low-vacuum purifier may be added to remove excesswater and dissolved gases. The purifier should be capableof processing oil with up to 1 percent water and 0.5 per-cent solids by volume to no more than 0.25 percent water

and 0.02 percent solids and remaining solids not exceed-ing 40 microns in size. The separated water should notcontain more than 0.5 percent oil by volume. Purificationshould be attained in one pass. The purifier rating shouldnormally provide for purification of the dirty oil tankcapacity within 8 hr. However, in the case of very largetank requirements, reasonable access for the portable puri-fier may limit its size and justify longer periods. Purifierunits should include required pumps, oil heaters, controls,and wheeler carriage.

c. Insulating oil purifier. The insulating oil purifiermust be designed so that the processed oil meets thetransformer oil purity requirements. This normally con-sists of a filtration system and a high-vacuum purifier.

12-8. Alternate Systems

For small powerhouses with reasonable availability ofinsulating oil supply via tank truck to source, it can bepracticable to omit the installed insulating oil storagefacilities and service the transformers directly from thetruck via the purifier.

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Chapter 13Compressed Air Systems

13-1. General

Compressed air systems are required in powerhouses foroperation and to facilitate maintenance and repair (seeTM 5-810-4). Service air, brake air, and governor aircomprise the three systems needed in all powerhouses.Some powerhouses will require a draft tube water depres-sion system in addition. Reliability, flexibility, and safetyare prime design considerations.

13-2. Service Air System

a. General. The service air system is a nominal700-kPa (100-psi) system providing air for maintenanceand repair, control air, hydropneumatic tank air, chargingair for the brake air system, and in some cases, air for icecontrol bubblers.

b. Service air requirement.

(1) Routine maintenance. Supply 25-40 L/s(50-80 cfm) for wrenches, grinders, hammers, winches,drills, vibrators, cleaning, unplugging intakes and lines,etc.

(2) Major maintenance and repair. Supply 140-190 L/s (300-400 cfm) for sandblasting, painting, clean-ing, etc. Normally this capacity should be provided withportable equipment. For projects too remote from a gov-ernment or commercial source of temporary portableequipment, installed capacity should be provided.

(3) Ice control bubblers. Supply 1-2-L/s per 3-m(2-4-cfm per 10-ft) width of trashrack with bubblers oper-ating on intakes for up to four units simultaneously.

(4) Operational requirements. Supply 7-12 L/s(15-25 cfm) with individual assumptions as follows:

(a) Brake system charging air1-2 L/s (2-4 cfm) per unit

(b) Hydropneumatic tank3-5 L/s (5-10 cfm) per unit

(c) Control bubbler1-3 L/s (2-5 cfm) per unit

(d) Leakage1-3 L/s (3-5 cfm) per unit

(5) Total service air.

(a) Computed basis. The total service air require-ment may be computed on the basis of the previouslymentioned (1) to (4) individual allowances. The figuresnoted are representative estimates from several existingprojects and should be modified as appropriate for theparticular project with due regard for planned operationand maintenance, equipment sizes, number of units,service factors, and information from existing similarprojects.

(b) Standard provision basis. It will be found thatthe computed basis will usually require several arbitraryassumptions and service factors to arrive at a total serviceair requirement. In lieu of the computed basis, the fol-lowing standard provisions may be used as the basis oftotal air requirement:

• 1-2 unit plants 40 L/s ( 75 cfm)

• 3-4 unit plants 50 L/s (100 cfm)

• Over 4 unit plants 60 L/s (125 cfm)

In addition, provide 175 L/s (375 cfm) for major mainte-nance and repair. If this will be supplied with portableequipment, add computed ice control bubbler requirementto the above standard provisions. If the 175 L/s(375 cfm) is to be installed, assume that ice control andmajor maintenance will be nonsimultaneous requirements,and the 175 L/s (375 cfm) will cover the ice control bub-bler requirements.

(6) Service air pressure. A nominal 700-kPa(100-psi) pressure with system variations from 580-760 kPa (85-110 psi) is satisfactory.

c. Compressors.Compressors should be heavy duty,water cooled, flood lubricated, and cooled rotary screwtype rated for continuous duty. Normally, aside frommajor maintenance, service air should be supplied by twoidentical compressors each of which is capable of supply-ing approximately 75 percent of the requirement. Whereice control bubbler demand exceeds 12 L/s (25 cfm) andthere is no installed major maintenance compressor, it willusually be preferable to supply the bubbler demand froma separate compressor. Installed major maintenance and

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repair capacity should be provided with a singlecompressor.

d. Receivers. Each air receiver should conform todesign, construction, and testing requirements of theASME, “Boiler and Pressure Vessel Code.” Receivercapacity should provide a minimum 5 min-running timewith no air being used from the system for the largestconnected compressor on automatic start-stop control.One or more receivers may be used for the system. How-ever, galvanized receivers are preferred, and sizes shouldbe checked against galvanizing plant capabilities.

e. Controls. The two service air compressors shouldeach be provided with selective manual or automaticcontrol. They should have pressure switch lead-lag con-trol automatic selection and conventional load-unloadoperation for manual selection. A major maintenancecompressor or a separate ice control bubbler compressorshould be on manual control with conventional load-unload provisions. Cooling water should be controlled toflow only when the compressor motor is energized.Automatic shutdown should be provided for low oil pres-sure, low oil level, and high-discharge air temperature.

f. System details.

(1) Control air. Control air is provided for bubbler-type controls and gauges. The flow is minor but is acontinuous system load. A 700-kPa (100-psi) air supplyis satisfactory, but instruments and gauges operate atlower pressures, and reducing valves are normallyincluded with the control equipment. Pneumatic air con-ditioning control and operators are sometimes suppliedfrom the service air systems. However, package air sup-ply units supplied with the air conditioning equipment arepreferred to avoid possible contamination problems.

(2) Hydropneumatic tank. Refer to Chapter 10 forhydropneumatic tank requirements.

(3) Ice control bubblers.

(a) General. An ice control bubbler system will ordi-narily be supplied from the power plant at projects wherethe powerhouse structure forms a portion of the dam andincludes the intake provisions. A bubbler system is usu-ally provided where severe freezing conditions over anextended period of time could result in heavy ice accumu-lation at the reservoir surface and cause damage to thetrashracks. Where freezing weather is probable, but bub-bler installation is to be postponed until icing conditionsare determined, minimum required embedded piping

should be installed. The principle on which the bubblersystem operates is the raising of warmer subsurface waterto prevent surface freezing. Nozzles will operateeffectively with a minimum submergence of 3.0 m (10 ft)and are effective to a submergence of 7.6 m (25 ft), per-mitting a single-level installation of nozzles to functionsatisfactorily over a 4.6-m (15-ft) range of reservoir waterlevel. Each nozzle will provide an approximate 3.6-m-(12-ft-) diam ice-free area above the nozzle.

(b) Design. Nozzle orifice should be 6 mm (1/8 in.)in diameter and 10 mm (3/8 in.) in length. Nozzlesshould discharge down. The maximum distance betweennozzles should be 3 m (10 ft). Nozzles should be locatedclose to trashrack bars and clear of trashraking equipment.A control valve at each takeoff from the service airheader is required to match the differential across theorifice as closely as practicable to that required for thesubmergence. Excessive differential can result in nozzlefreezing from air expansion.

(c) Piping. The bubblers for each main unit shouldbe on a separate branch from the service air header withan isolating valve, throttle valve, pressure gauge, andvacuum release for automatic draining of air lines tonozzles. Piping should be pitched to assure drainagethrough nozzles when bubblers are off and there is a dropin pool level. Embedded piping should be plugged priorto pouring to prevent the entry of foreign material.

(4) Intake and line clearing. Water intakes, suctionlines, and drains subject to plugging with debris or siltshould be provided with service air connections (blow-outs) to assist in unplugging. A manual valve should belocated near the blowout connection.

(5) Hose connections. Hose connections should beprovided throughout the plant in galleries, on decks, in thegenerator-turbine room, in turbine pits, in generator hous-ings, and in the maintenance shop. Generally, it shouldbe possible to reach any area where maintenance air maybe required without exceeding 30 m (100 ft) of hose. Inthe maintenance shop, hose connections should be locatedat each bench and machine tool. A hose connectionshould be provided at each governor tank for prechargingthe tank to service air pressure.

(6) Brake air. The brake air system is one or moreseparate storage and distribution systems supplied fromthe service air system and is covered under para-graph 13-3. Piped connections to the brake air systemsshould be made from the service air headers.

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(7) Portable compressor connections. For power-houses where the major maintenance and repair air is tobe supplied with portable compressors, deck hoseconnections should be provided at intervals along thedecks connecting to the main headers. The location ofconnections should permit convenient compressor locationand reasonably short runs to the location of expectedmajor maintenance or repairs. Headers should be sizedaccordingly.

g. Drawing and material schedule. Figure B-14shows a typical compressed air system, and B-13 presentsa material schedule.

13-3. Brake Air System

a. General. The brake air system comprises one ormore semi-independent storage and distribution installa-tions for providing a reliable supply of air to actuate thegenerator braking systems. Air is supplied from the ser-vice air system, stored in receivers, and distributedthrough the governor actuator cabinets to the generatorbrake systems.

b. Air requirement. Air is required in the system tostop all generator-turbine units simultaneously withoutadding air to the system and without reducing systempressure below 520 kPa (75 psi). Each unit may beassumed to require 42.5 L at 520 kPa (1.5 ft3 at 75 psi).When this figure is being verified from generator manu-facturers’ data, the storage capacity computations shouldconsider the number of brake applications per stop, themaximum brake cylinder displacement with worn linings,and the volume of all piping downstream from the controlvalve.

c. Piping-receivers. Each subsystem includes areceiver, piping from the service air system to thereceiver, piping from the receiver to the governor cabi-nets, and piping from each governor cabinet to the respec-tive generator brake system. Normally, a separatesubsystem will be provided for each pair of generatorunits. In the case of plants planned for an ultimate oddnumber of units though, one of the subsystems may serveone to three units. Each receiver should be sized to sup-ply air for the units connected thereto and should bedesigned, manufactured, and tested in accordance with theASME “Boiler and Pressure Vessel Code.” Each receivershould be supplied with air from the service air systemthrough an isolating valve, strainer, dryer, and check valveto make the subsystem unaffected by a temporary loss ofpressure in the service air system. A bleed-off valveshould be provided between the isolating valve and the

check valve to permit convenient testing of check valvetightness. A pressure reducing valve preceded by astrainer should be provided at the discharge from eachreceiver to limit brake air pressure to 700 kPa (100 psi).Piping should be in accordance with the piping schedule,Figure B-13.

d. Control. Control for application of the brakes isnormally included in the governor cabinets and providedby the governor supplier.

e. Drawing. Figure B-14 shows a typical brake airsystem in a powerhouse.

13-4. Governor Air System

a. General. The governor air system provides theair cushion in the governor pressure tanks. When thegovernor system is to be placed in operation, the pressuretank is filled approximately one-fourth full with oil, andthe tank is then pressurized to governor-operating pressurefrom the governor air system. Corrections to maintain theproper oil-air ratio are required at intervals during plantoperation. The governor pressure tank size and operatingpressure will be determined by the turbine servomotorvolume. Pressures for various sizes of units currentlyvary 2,100-6,900 kPa (300-1,000 psi). Guide Specifica-tion CW-16252 provides additional guidance for tank andpump capacities.

b. Air requirements.

(1) Quantity. Compressor delivery should be suffi-cient to effect a complete pressurization of a governortank with the proper oil level in 4-6 hr. The pressuriza-tion time should include prepressurizing to service airsystem pressure by hose connection where such procedureis warranted.

(2) System pressure. The operating pressure shouldbe approximately 10 percent above the rated governorsystem pressure.

c. Compressor. The total air-delivery requirementshould be provided by two identical compressors, eachrated at not less than 50 percent of the requirement.Compressors should be heavy duty, reciprocating, wateror air cooled, and rated for continuous duty. “Packageunits” are preferred. Each package should include com-pressor, motor, base, aftercooler, controls, and otheraccessories recommended by equipment manufacturers toprovide a complete air-system supply except for the airreceiver.

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d. Receiver. Since manual-start, automatic-unload-ing control is used for governor air compressors, receivercapacity is required only to assure reasonable controlaction. A receiver capacity which will provide 3-5 min-compressor running time to raise receiver pressure fromatmospheric to system pressure will normally be suitable.Receivers should be galvanized and conform to design,construction, and testing requirements of the ASME,“Boiler and Pressure Vessel Code.”

e. Controls. Each compressor should be providedwith manual start-stop and automatic load-unload control.

f. Drawing and material schedule. Figure B-14shows typical piping in the air compressor system.Material should be in accordance with Figure B-13.

13-5. Draft Tube Water Depression System

a. General. A draft tube water depression system isrequired in plants with submerged turbine or pump-turbinerunners where planned operations include the operation ofone or more main units for synchronous condenser opera-tion, motor starting for pumping, or spinning reserve.The system function is to displace and maintain draft tubewater to a level below the turbine runner permitting therunner to turn in air. Normally, the system should beindependent of other powerhouse air provisions, althoughsome plants have been designed with connections to per-mit using the draft tube air depression system to supplystation air. System components, particularly receivers andpiping, will generally be of large physical size, and pre-liminary design should take place concurrent with firstpowerhouse layouts to assure space for a practical systemarrangement. Refer to NFPA “Hydraulic Turbine WaterDepression Systems for Synchronous Condenser Opera-tion” by J. R. Taylor and ASME Paper No. 66-WA/FE-9for discussion on these systems.

b. Air requirement. The system should supply suffi-cient air to displace the draft tube water clear of the tur-bine runner in approximately 10 sec, and down to 1.0 m(3 ft) below the bottom of the runner in approximately60 sec plus additional volume to cover air losses duringinitial depression. Loss of volume during initial depres-sion should be calculated at 10 percent of the requiredwater displacement air volume with an assumed adiabaticexpansion of the air in the receivers. Deviation from trueadiabatic in the receivers during a 10 sec-depression isminor, and the additional air resulting therefrom should beneglected in the computations. Air must also be availableafter initial depression to maintain the water level approx-imately 1.0 m (3 ft) below the runner. A close estimate

of this air requirement is difficult since it is primarilydependent on leakage of air through the shaft gland andwater leakage through the wicket gates. For designpurposes, it can be assumed that gland leakage will becontrolled to a minor flow and that required makeup airdue to wicket gate water leakage will approximate 3 L/sper meter (2 cfm per foot) of unit diameter at the wicketgates. Unit operating head, type of unit, workmanship,and wear can all influence the leakage figure, and thedesign should include minimum provisions for doublingthis assumption if required. The air requirement for ini-tial depression must be available in receivers because ofthe high, brief flow requirement. Capacity for depressingmore than one unit at a time or in rapid succession willseldom be justified except for motor starting for pumping.Additional capacity should be provided when supportedby a favorable benefit to cost ratio. Air requirement formaintaining depression must be based on the plannedmaximum number of units requiring depression within aspecified period of time.

c. System pressure.The minimum system operatingpressure during initial depression should be approximately100 kPa (15 psi) higher than the pressure required todepress the draft tube water 1.0 m (3 ft) below the runner.Maximum system pressure depends on required displace-ment volume and receiver capacity, but a nominal700-kPa (100-psi) system will usually provide a practica-ble compressor-receiver-operational pressure. For largeKaplan units with deep submergence, an economic studyshould be made to determine possible economies fromhigher system storage pressure. Included should be costsof compressors, power and receivers, receiver configura-tion and location, and piping costs.

d. Compressors. Compressors should be heavy duty,water cooled, reciprocating, or flood-lubricated and cooledrotary screw type rated for continuous duty. The initialdepression air and maintaining air usually are supplied bythe same compressors. The required capacity should bebased on raising receiver pressure from minimum to max-imum operating pressure while supplying makeup air tomaintain depressed units. To provide a minimum ofstandby with a compressor out of service, the requiredcapacity should normally be provided in two identicalcompressors, each rated at 50-60 percent of the totalrequired capacity. For a project requiring several largeunits on motoring operation at one time, the design stud-ies should include providing the maintaining air with oneor more low-pressure compressors.

e. Receivers. Receiver capacity should be providedin one or more receivers conforming to design,

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construction, and testing requirements of the ASME,“Boiler and Pressure Vessel Code.” Configuration andindividual volumes will often be determined by spaceavailable. Consequently, early preliminary planning isnecessary to secure a desirable receiver location in thepowerhouse. Outdoor locations may be required in thecase of large units. Receivers should normally be sizedfor the full initial depression requirement. Additionalcapacity should be provided when needed. Due to costand space problems, an air storage facility other thanASME code tanks may sometimes appear desirable. Insuch a case, advance discussions with review offices isrecommended.

f. Control. Compressor start-stop control, automaticshutdown control, and cooling water control should be asdescribed in paragraph 13-2e for the service aircompressors.

g. System details.

(1) Piping. Depression system air piping will tend tobe appreciably larger than conventional air lines. Besidesthe additional air storage provided, successful air depres-sion depends on the rapid injection of air under the headcover. Coordination is necessary to assure adequatespace, especially in the congested areas around the tur-bines. A material schedule and a typical draft tube watersystem are included in Figures B-13 and B-15,respectively.

(2) Valves. Control valves for initial depression andfor maintaining depression should be quick acting withremote control. An air cylinder-operated, rubber-seated,butterfly valve will usually be satisfactory for control ofthe initial depression. Remote electrical control shouldactuate a four-way solenoid valve in the air cylinder-oper-ating air line. For maintaining depression, air flow willbe small enough to permit use of a solenoid valve in asmall line bypassing the butterfly valve.

13-6. Miscellaneous Provisions

a. Compressor room. The compressor room shouldbe located in a noncritical noise area on a solid founda-tion free from vibration. The room requires adequateventilation for temperature control and compressor intake.

b. Compressor discharge lines. Compressor dis-charge lines to aftercoolers and receivers should not besmaller than compressor outlet and should generally notinclude shutoff valves.

c. Ample space. Compressors, intercoolers, after-coolers, and receivers should be located with ample spacefor disassembly, maintenance, and safety of operatingpersonnel.

d. Piping. Piping generally should be sized to holdpressure loss from compressor to point-of-use to10 percent.

e. Loop headers. Loop headers offer pressure lossand reliability advantages and should be utilized, particu-larly in multiunit powerhouses with headers required inupstream and downstream galleries.

f. Automatic traps. Automatic traps should be pro-vided at moisture separators, on receivers, and at lowpoints in piping.

g. Compressor, intercooler, and aftercooler waterdischarge. Compressor, intercooler, and aftercooler waterdischarge should be through sight funnels.

h. Headers. Headers should be sized adequately forplanned plant expansion.

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Chapter 14Plumbing Systems

14-1. General

Powerhouse plumbing systems include the followingfixtures: water supply piping from in-house treatmentplant, storage tank or main at building line, hot watersupply, fixture drains and vents, in-house sewage treat-ment facility, and effluent and sludge pumps. The basiccode for design is the National Association of Plumbing-Heating-Cooling Contractors (NAPHCC) 1265, “NationalStandard Plumbing Code.” Refer to TM 5-810-5 which isintended basically for military construction but containsdesign data that can be useful in powerhouse design.Also, Guide Specification CE-15400 is basically intendedfor military construction but is a useful reference forpowerhouse specifications. Its value as a powerhouseguide specification is limited because of the large quantityof nonapplicable material.

14-2. Fixtures

Fixtures of the system that may be included are listed inTable 14-1. Location, selection, and quantities of fixturesare normally architectural determinations. The mechani-cal design engineer should be involved in early coordina-tion to assure practical pipe routings and space, facilitiesconsistent with proposed water supplies and sewage treat-ment, and optimum groupings of fixtures. Tank-typewater closets in lieu of flush valves are acceptable insmall plants with minimum rest room requirements.

14-3. Water Supply

a. Cold. Cold water from the potable water system(see paragraph 10-5) is provided to all fixtures.

b. Hot. Hot water should be provided to all fixtureslisted in paragraph 14-2 except water closets, urinals,drinking fountains, and deluge shower-eyewash. Seeparagraph 10-5h(3) for water heater provisions.

c. Piping. Hot and cold water mains, branches, andrisers should normally be sized for 2.4-3.7-m/s (8-12-fps)velocity on flows obtained from fixture-unit flow demandcurves in ASME A 31.1. Where flow is continuous incopper lines, the velocity should not exceed 2.1 m/s(7 fps). Continuous temperatures in the range of 60-77oC(140-170oF) for both copper and galvanized steel shouldbe avoided. Individual fixture supply pipes should be

15 mm (1/2 in.) except for 25-mm (1 in.) supplies toflush valve fixtures and deluge shower-eyewash. Shutoffvalves should be provided in supply lines to groups offixtures to facilitate maintenance. Refer to Figure B-8 fortypical potable water and sanitary system, Figure B-13 formaterial schedule, and Chapters 17 and 19.

14-4. Sanitary Piping

a. Drains. Drains from sinks, water closets, standardshowers, and lavatories should be routed to the septic tankor other treatment facility. Drains from battery room sinkand deluge shower-eyewash are normally routed to thestation drainage system. Water coolers may be drainedeither through sanitary drains or drainage system piping.Sizing should be on fixture unit basis in accordance withASME A 31.1. Minimum slope on drains 80 mm (3 in.)and smaller is 2 percent. Minimum slope on larger drainsis 1 percent with 2 percent preferred. Minimum size ofany drain line subject to flow of raw sewage from a watercloset is 80 mm (3 in.). (See Figures B-8 and B-13.)

b. Vents. Vents should be provided as required byASME A 31.1. Termination of vent stacks will normallybe above roofs. However, other code termination loca-tions may be acceptable subject to architectural approval.Minimum slopes noted in paragraph 14-4a are also appli-cable to vents.

14-5. Sewage Treatment

a. General. Sewage treatment should generally becombined into one facility for the entire project. Thefacility will frequently be located away from the power-house and coordination will be required. The powerhousedesign will usually be limited to collecting and possiblypumping of the raw sewage. When a powerhouse loca-tion is most practical, the treatment plant will be includedin the powerhouse design. The Corps of Engineers policyis to comply with federal and state sewage treatmentrequirements. The requirements vary considerably fromproject to project, in part due to site differences, but to agreater extent from revisions in the federal and state regu-lations. The design office should obtain the earliest possi-ble approval for proposed facilities at each project topermit an orderly development of piping, pump, and treat-ment design.

b. Septic tanks.

(1) General. Septic tanks are the preferred treatmentfacility from design, cost, operation, and maintenance

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Table 14-1Powerhouse Plumbing Fixtures

Size and Type of Power Plant

2 Unit 6 UnitManned Manned 14 UnitNo visitor Visitor Manned

2 Unit Facilities Facilities VisitorUnmanned Moderate Moderate Facilities

Fixture No Visitors Visitor Load Visitor Load Heavy

Water Closet 1** 2 9 11Lavatory 1 2 5 11Urinal 1 1 6 8Service Sink 1 1 3 2Drinking Fountain 1 2Water Cooler 2 3 7Fountain Wash 1 1Eyewash * 1 1 1 1Safety Shower * 1 1 1 1Kitchen Sink 1 1 1Battery Room Sink 1 1 1 1Shower 1 1 2First Aid Sink 1 1 1

* Fountain eyewash and safety shower are currently required at all powerhouses with a battery room.

**Figures indicate fixtures installed at four types of existing plants but are for reference only. For new plants, figures should be modified asrequired to suit personnel and visitor requirements, available water supplies, waste disposal, and other project facilities.

standpoints and should be provided whenever an approvedleaching field location is reasonably available. Septictank effluent discharge directly to tailwater is notpermitted.

(2) Location. A septic tank may be located either inthe powerhouse or away from the powerhouse. In-housetanks are normally located in mass concrete at a low ele-vation providing gravity drainage from all fixtures. Thelocation should permit access to the tank through man-holes and adjoining space for installation and servicing ofeffluent pumps, sludge pumps, and chlorinatingequipment.

(3) Design. Septic tank design and chlorinationequipment should conform to state code requirements forthe state in which the leaching field will be located.Mechanical design responsibility will include coordinationof piping, pump, chlorination, and valve locations with asuitable tank location.

c. Other treatment facilities. Facilities other thanseptic tanks will normally be a civil engineering responsi-bility and will involve one of several types of secondaryon tertiary treatment processes. Mechanical design

responsibility will include piping, valves, pumps, ejectors,chlorination, and coordination.

d. Nongravity sewage. Where it is impractical tomove raw sewage from the powerhouse collection point tothe treatment facility by gravity flow, a duplex pneumaticsewage ejector or duplex nonclog centrifugal pumps capa-ble of passing a 51-mm (2-in.) sphere should be provided.Duplex nonclog pump installations require the following:all sewage to be screened before entering the sump pump,the screen to be self-cleaning with each pump operation,pumps to be of the wet pit type, automatic interchange ofthe operating and off pumps on every start, and eachpump capable of handling rated system inflow. Theserequisites can be accomplished by connecting the inflowline from the powerhouse sanitary system into the pumpdischarge lines with commercially available equipmentand collecting the solids on the discharge line screen ofthe off pump while the liquids are backed through the offpump to the sump. The subsequent pump operation willclear the screen. Valving, screens, and interconnectionsshould follow manufacturers’ recommendations. Thesmallest capacity pneumatic sewage ejectors and nonclogpumps tend to be higher than the required capacity formost powerhouses, and the specifications should permit

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the contractor the option of supplying either ejectors ornonclog pumps.

e. Sludge and effluent provisions.

(1) General. Effluent will be pumped via fixed pip-ing to leaching fields or, in the case of approved second-ary or tertiary treatment plants, may be pumped or dis-charged by gravity to tailwater through an underwaterdischarge. Sludge will normally be pumped via fixedpiping to a deck hose valve accessible to trucks. Mini-mum line size should be 80 mm (3 in.).

(2) Pumps. Sludge and effluent pumps should havenot less than a 40-mm (1.5-in.) inlet and outlet and shouldpass a 25.4-mm (1-in.) sphere. Where both effluent andsludge pumps are required for the same treatment plant orseptic tank, it is preferable to provide identical pumps toallow each pump to serve as backup for the other.

Backup operation is temporary only and should be pro-vided for by hose and hose valves, tied to the suction anddischarge piping of each pump rather than fixed piping.Alternate backup provision is a spare pump and pipingconnections suitable for rapid exchange of pumps. Con-trol of effluent pump should be automatic and providedby either float or bubbler control. Control of sludgepumps should be manual and should include an adjustabletimer switch to limit pump operation to the normal sludgepumping time requirement.

(3) Line losses. Pumping head computations forsludge pumps should reflect the higher line losses due toentrained solids. Computing overall losses on basis ofwater and using a multiplying factor of 2.5-3 will besatisfactory for most powerhouse applications. If veloci-ties exceeding 1.5 m/s (5 fps) are encountered, the factormay be reduced to 1.5.

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Chapter 15Fire Protection Systems

15-1. General

Powerhouses are generally low fire hazard structures withspecial installed fire protection usually limited to thefollowing four specific hazards: oil storage and purifica-tion rooms, a paint and flammable storage room, mainpower generators, and transformers. The principal fireprotection for all other areas and hazards is portable extin-guishers and fire hoses. Manned fire hoses are not gener-ally relied on as a first line fire protection because of thepotential damage to equipment inherent in powerhousesexcept as noted in paragraph 15-10. The deck washingsystems provided in all powerhouses offer limited fireprotection in most areas (see paragraph 10-6h for furtherdiscussion of backup provisions). NFPA Standard 851and ETL 1110-2-311 provide guidance for fire, protectionfor hydroelectric generating plants, and hydroelectricpower plants, respectively. Fire protection systems usingHalons are prohibited.

15-2. Oil Storage and Purification Rooms

a. General. Oil storage rooms contain large quanti-ties of transformer oil and lubricating oil with the poten-tial for fire. Because of the seriousness of such a fire, anautomatic carbon dioxide (CO2) extinguishing system isprovided to limit damage within the rooms and to limitthe spread of smoke and noxious fumes through the pow-erhouse. Normal practice is for the design office to per-form preliminary design to determine the approximatenumber and location of CO2 bottles and nozzles, locationof controls and piping, and to prepare design memorandaand contract specifications. Final system-design responsi-bility is normally assigned to the contractor. Safety ofpersonnel should have continuing design priority since thedischarge of CO2 can impair visibility, will result in lossof consciousness from oxygen shortage in total floodingspaces, and may impair breathing in low-elevation areasexposed to drifting gas. Planned use of the room shouldnot include storage of volatile, low flash-point materialssusceptible to explosion. Miscellaneous combustiblematerials, especially paper products, should not be storedin the oil storage room.

b. Room construction.Oil storage and purificationfacilities are preferred to be in a common space but maybe in separate rooms when required for structural reasons.Rooms should be in mass concrete, but in all cases shouldbe of 2-hr minimum fire-resistant construction with

automatic fire doors or dampers at all openings. Whereseparate rooms are used, independent CO2 systems areusually provided. However, a combined system may beprovided where room locations and relative volumeswould result in a lesser cost and there is no connectingdoor between the rooms.

c. System design.

(1) General design considerations are as follows:

(a) The system should be a total flooding type withminimum design concentration of 34 percent and withoutextended discharge.

(b) The amount of CO2 discharged from the nozzlethat is effective in extinguishing a fire varies from70-75 percent of the total quantity of CO2 contained inthe cylinder. Therefore, for design purposes, it is neces-sary to increase the nominal cylinder capacity by 40 per-cent (see NFPA Standard 12).

(c) A CO2 release should be actuated by a roomthermostat, manual operation of a switch outside the roomat the exit, and manual operation of a cylinder release.

(d) A 20-sec delay should occur between actuationand release of CO2 from cylinders with a continuousalarm sounding in the room.

(e) A CO2 release should stop oil pumps and fansand close fire doors and dampers.

(f) Piping should be sized to preclude freezing oflines.

(g) Refer to Figure B-16 for a typical CO2 fire pro-tection system.

(2) Detail system design and materials should com-ply with applicable provisions of NFPA Standard 12 andCorps of Engineers Guide Specification CW-15360.

15-3. Paint and Flammable Liquid Storage Room

a. General. Projects lacking outside facilities for thestorage of paint, lacquers, thinners, cleaners, and othervolatile, low flash-point material should be provided witha room in the powerhouse for such storage. Operatingexperience at some projects indicates a tendency to utilizethe oil storage rooms for storage of hazardous materialsbecause of a lack of adequate space in the paint and flam-mable liquid storage room. Therefore, space in the paint

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and flammable liquid room should be generous, on theorder of 9.3-11.2 m2 (100-120 ft2) of floor area.

b. Room and system design. The provisions of para-graph 15-2a, b, and c apply generally except for refer-ences to oil and tanks. Refer to Figure B-16 for a typicalCO2 fire protection system.

15-4. Generators

a. General. Generators with closed air-circulationsystems should be provided with automatic CO2 extin-guishing systems. Up to four generators may be on onesystem, with CO2 cylinder storage based on discharge in asingle unit. Design responsibilities and safety concernsnoted in paragraph 15-2 are applicable. Piping withingenerator housings is normally provided by the generatorcontractor.

b. System design.

(1) General design considerations are as follows:

(a) The contractor shall coordinate his design with thegenerator contractor to assure that a CO2 concentration of30 percent will be maintained within the generator hous-ing for a minimum period of 20 min without the use of anextended discharge. See NFPA Standard 12 and GuideSpecification CW-15360.

(b) CO2 release should be actuated by the following:

• Generator differential auxiliary relay.

• Thermoswitches in the hot air ducts of each aircooler.

• Manual operation at the cylinders.

• Remote manual electrical control.

(c) Refer to Figure B-16 for a typical CO2 fire pro-tection system.

(2) Detail system design and material should complywith applicable provisions of NFPA Standard 12 andGuide Specification CW-15360.

15-5. Motors

Larger motors with a closed air-circulation system areoccasionally used in powerhouses. CO2 fire protectionshould be provided similar to that indicated for generators.

15-6. Transformers

a. General. Fire protection at a transformer is pro-vided to limit damage to other nearby transformers, equip-ment, and structure. It is assumed that a transformer firewill result in loss of the transformer. Deluge systems areprovided for outdoor oil-filled transformers and CO2 sys-tems for indoor oil-filled transformers.

b. Outdoor transformers.

(1) General. Main power transformers are com-monly located outdoors, on intake or tailrace decks, in theswitchyard, or on an area adjoining the powerhouseupstream wall. They are sometimes individually semi-isolated by walls on three sides. The frequency of trans-former fires is extremely low, but the large quantities ofoil involved and absence of other effective fire controlmeasures normally justify installation of a deluge systemwhere there is a hazard to structures.

(2) System design.

(a) The system should be a dry pipe, deluge type.Deluge valves should be actuated automatically by athermostat, manually by a switch in a break-glass stationlocated in a safe location near the transformer, or manu-ally at the valve. Where exposed transformers (withoutisolating walls) are located closer together than the greaterof 2-1/2 times transformer height or 9 m (30 ft), the sys-tem should be designed for spraying the adjoining trans-formers simultaneously with the transformer initiatingdeluge.

(b) System detail design should be in accordancewith NFPA Standards 851 and 15.

(c) The deluge system water supply is discussed inparagraph 10-4.

(3) Figure B-17 presents a typical transformer delugesystem.

c. Indoor transformers. Oil-filled indoor transform-ers should be protected in accordance with NFPA 70 “TheNational Electric Code.”

d. Outdoor oil-insulated. Oil-insulated power trans-formers located outdoors should be provided with chillingsumps which consist of a catchment basin under the trans-former filled with coarse crushed stone of sufficientcapacity to avoid spreading an oil fire in case of a tankrupture.

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15-7. Portable Fire Extinguishers

Portable CO2 handheld extinguishers are the first line fireprotection for powerhouse hazards other than those specif-ically covered and should be provided in locations inaccordance with NFPA Standard 10.

15-8. Detections

a. Thermal detectors. Thermal detectors are bestsuited for locations within equipment such as generatorsor near flammable fluids.

b. Ionization detectors.Ionization detectors are bestsuited for gases given off by overheating, such as electri-cal cables or a smoldering fire. Location near arc-produc-ing equipment should be avoided. They are not suited foractivating CO2 systems.

c. Photoelectric detectors. Photoelectric detectorsare best suited for the particles given off by an open fireas caused by a short circuit in electrical cables. Their usein staggered locations with ionization detectors along acable tray installation would provide earliest detection.They are not suited for activating CO2 systems.

d. Location. Detectors should be located at or nearthe probable fire source such as near cable trays or in thepath of heating and ventilating air movement. In areaswhere combustible materials are not normally present,such as lower inspection galleries, no coverage may beappropriate.

e. Reliable detection.The earliest “reliable” detec-tion is required. The detector type or types, location, andadjustment should be carefully considered. The detectorsensitivity adjustment should be adjusted to eliminate allfalse alarms. A fire detector system should be providedin the cable gallery and spreading rooms of allpowerhouses.

f. Alarm system.The power plant annunciation and,if applicable, the remote alarm system should be used tomonitor the fire detection alarms. An alarm systemshould be provided for each area. Properly applied, thesesystems will provide more reliable and useful alarm datathan the alarm monitor specified in the fire codes.

15-9. Isolation and Smoke Control

Smoke and fire isolation is probably the most importantfire control item. Smoke inhalation is one of the majorcauses for loss of life. The toxic fumes from a minor fire

could require total evacuation of the powerhouse. Manyof the existing heating, ventilating, and air conditioningsystems contribute to spreading the smoke as they encom-pass the entire powerhouse or have a vertical zone com-posed of several floors. The fire area should be isolatedby shutting down the ventilating system or exhausting theair to the outside where feasible to prevent the spread ofsmoke and to provide visibility for fire fighting reentry tothe area. In most cases, the available oxygen is sufficientto support combustion, and little can be gained by notexhausting the smoke. Smoke and fire isolation should beprovided in areas where isolation can provide a real bene-fit. The requirements for fire stops should be consideredon a case-by-case basis. Where cable trays pass througha floor or wall which could be considered a fire wall, orwhere cables leave a tray and enter a switchgear orswitchboard through a slot, a fire-stop should be consid-ered. A 12.7-mm (1/2-in.) asbestos-free fireproof insu-lation fireboard can provide the basic seal with the voidsbeing closed by packing with a high-temperature ceramicfiber. Single conduit or single cables which penetrate afire wall can be sealed with a special fitting. Thick sealsshould be avoided as they could contribute to an exces-sive cable insulation operating temperature. For fire-stopping, refer to TM 5-812-2. A HVAC system usingoutside makeup air solely dedicated for the control roomshould be provided to maintain isolation and smoke con-trol. The HVAC system should be capable of pressuriz-ing the control room with outside air during a fire alarmto prevent smoke infiltration. Stairways in manned pow-erhouses that are used for emergency access and egressshould be pressurized with outside air in accordance withASHRAE recommendations.

15-10. Fire Hose

Certain conductor insulation or cable jackets have beenassociated with fires that resisted extinguishing with con-ventional fire control methods. These fires are easilyextinguished using water. Water should be considered asa safe and effective electrical fire-fighting method. NFPAStandard 803 lists the required consideration for use ofwater on energized electrical equipment. The safeapproach distance to live electrical apparatus with hand-held fire hoses connected to the power plant raw-watersystem has been established by tests. The following dis-cussion is based on using water at 689 kPa (100 psi),water resistance of 1,524 ohm cm (600 ohm in.), and acurrent of 3 mA or less in the fire hose stream. The safeapproach distance varies with the water resistance, pres-sure, and type of water stream (i.e., solid stream or spraystream). The solid stream water pattern and conductivityis maintained for a greater distance as the size of the solid

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stream nozzle and the water pressure is increased. Solidstream nozzles less than 32 mm (1.25 in.) in size can beused on live low-voltage (less than 600 V) circuits at alldistances greater than 1.5 m (5 ft). Table 15-1 should beused to establish the safe approach distance to electricalequipment. Floor drains, trenches, or curbs should be

provided to remove or contain the water and preventdamage to other equipment and areas. Powerhousedesigns should provide fire hoses with spray nozzles in allcable galleries and spreading rooms. The use of fixedmounted spray nozzles should be avoided.

Table 15-1Safe Distance

Kilovolts Safe Distance

Line to Line Line to GroundSolid Stream

(m) (ft)Spray Stream

(m) (ft)

4.16 2.4 4.6 15 1.3 4

8.32 4.8 6.1 20 1.3 4

13.80 8.0 6.1 20 1.3 4

44.00 25.4 9.2 30 1.9 6

115.00 66.4 9.2 30 2.5 8

230.00 130.0 9.2 30 4.3 14

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Chapter 16Piezometers, Flow Meters, and LevelGauges

16-1. General

Piezometers, flow meters, and water level gauges are uti-lized in a variety of powerhouse applications to determineflows, water levels, and differential heads. The readingsobtained are necessary in the evaluation of turbine perfor-mance, operational monitoring, trashrack clogging, fishfacility conditions, and for control purposes. All piezom-eter taps, installed piping, and floatwells are a mechanicaldesign responsibility. However, control designers andstructural designers are usually involved with the designprocess.

16-2. Turbine Piezometers

a. General. Turbine piezometer taps are providedfor Pressure-time and Winter-Kennedy tests and to operateflow meters. Applicable embedded provisions are consid-ered justified on all units.

b. Pressure-time provisions.

(1) Applicability. Piezometer taps and embedded pip-ing should be provided for all turbines where the penstockis of sufficient length to meet the minimum requirements.(The majority of Kaplan units do not have suitable intakesfor Gibson tests.)

(2) Location of taps. The test section should belocated in conduit meeting the following conditions:

(a) Length should be a minimum of 9 m (30 ft).

(b) Length should be greater than two times thediameter.

(c) Length times mean velocity should be less than200.

(d) Diameter should be uniform.

(e) Bends in the test section should be avoided.

Four taps are provided at each end of the test section.Final location of the test section and taps should be deter-mined by the organization which will make the officialGibson tests.

(3) Tap design. Figure B-18 shows details of therecommended Gibson test piezometer tap.

(4) Piping. An individual line should be run fromeach tap to a convenient access location in the power-house and terminated with a globe valve. All lines shouldterminate at the same location to permit manifolding.Depending on powerhouse configuration and access, themanifolding location may also be the location for connect-ing the test equipment. Where this is not convenient, twolines should be run from the manifolding location to thetest equipment hookups. Piping will normally be 20-mm(3/4-in.) hard-drawn copper tubing. However, pipingmust be checked for suitability at maximum conduit headincluding water hammer. Each line should slope continu-ously toward the manifolding connections at not less than2 percent to minimize air pockets and permit purging.Piping adjacent to taps on embedded conduit and spiralcase should be arranged and wrapped as shown in Fig-ure B-18 to prevent high stresses from developing follow-ing release of conduit pressure after embedment. Alsorefer to Figure B-18 for typical piezometer piping installa-tion. Consideration should be given to providing bleedvalves at high points in the piping system.

(5) Coordination. Coordination of tap and pipinginstallation may be required where tap locations are in aportion of the conduit that is not part of powerhousedesign.

c. Winter-Kennedy.

(1) Applicability. Piezometer taps and embeddedpiping for Winter-Kennedy tests should be provided on allKaplan and Francis units.

(2) Location of taps. Taps are located on a radialplane near the middle of the first quadrant of the spiralcase. One tap is located on the outside wall at the spiralcase horizontal center line while one to three taps arelocated on the inside wall above the stay ring. One outerand one inner tap is required for the tests. However, twoadditional inner taps are normally provided to aid inachieving the appropriate pressure differential. In steelspiral cases, the taps are normally installed by the turbinecontractor. In concrete semispiral cases, the taps are fur-nished and installed under the construction contract.

(3) Tap design. Tap design should be as shown inFigure B-18.

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(4) Piping. Piping provisions noted in para-graph 16-2b(4) are applicable except that wrapping ofpiping is not required with concrete spiral cases. Linesshould terminate at location selected for connection of testequipment. See Figure B-18 for typical installation.

d. Net head piezometers.

(1) Applicability. Piezometers upstream of the spiralcase are required on all units for use in conjunction withtailwater sensors to determine net head on the unit. Tail-water sensors are covered in paragraph 16-3b.

(2) Location of taps.

(a) Francis units. For Francis units, taps are locatedby the turbine contractor in the spiral case entrance orspiral case extension. Four or more taps are provided inthe conduit wall, equally spaced on a plane normal to theflow. Detail of the location and number of taps is deter-mined by the turbine manufacturer.

(b) Kaplan units. For Kaplan units, two taps arelocated opposite each other in the sidewalls of the turbineintake, about half way between the floor and roof and1.5-3 m (5-10 ft) upstream of the upstream intersection ofthe cone with the intake floor and roof.

(3) Piping. Piping should be as noted in para-graph 16-2c(4) for Winter-Kennedy taps.

e. Flow meters using Winter-Kennedy taps.Flowmeters are used in most powerhouses for measuring andrecording turbine discharge. When an in-plant centralprocessor is available, either unit output and net head oroutput from a differential pressure transducer can be usedto calculate flow. Differential pressure can be obtainedfrom the Winter-Kennedy taps for input to the flow meteror central processor.

f. Ultrasonic flow meters. Recent advances havemade ultrasonic flow meters a realistic means of measur-ing flow in Francis and Kaplan units. ASME PTC 18should be used as a guide for selection and installation ofultrasonic flow meters in Francis units. Manufacturerrecommendations should be considered for Kaplan units.

16-3. Miscellaneous Piezometers

a. Trashracks.

(1) General. Where the powerhouse forms a portionof the dam, minimum provisions for monitoring or alarm

of high differential heads across the intake trashracksshould be considered. Trashrack design may not be basedon full clogging of the racks with attendant differentialheads so abnormal trash accumulations could cause rackfailure. Loss of efficiency due to partial clogging mayalso be significant. The requirement for a separate trash-rack monitoring system is a joint electrical-structural-mechanical determination.

(2) Minimum provision. When the decision hasbeen made to provide an independent trashrack monitor-ing system, minimum provisions should include a piezom-eter tap upstream of the racks to sense pool level, a tapdownstream of each trashrack, and embedded piping fromthe taps to a gallery location convenient for connecting todifferential pressure switches or manometers. The pooltap should be located in a pier nose, and the tap down-stream of the rack should be in a pier wall between therack and intake gates. Pool tap elevation should be belowminimum operating pool, and downstream tap elevationshould be at an elevation to record maximum allowabledifferential across the racks. The control system may besuch that the pool level indication could come from thepool level floatwell. When this is practicable, the trash-rack upstream pool tap will not be required.

(3) Tap design. Tap design should be as shown inFigure B-18 for concrete installation. If the completesystem will not be installed for an indefinite period, aclosure plate or plug should remain in place to protect theorifice and embedded piping from silting up. Plate orplug design should permit convenient removal by airpressure or divers.

(4) Piping. Piping should be 20-mm (3/4-in.) hard-drawn copper tubing and should slope continuouslytoward the gallery connection valve at not less than2 percent.

b. Pool and tailwater sensors.Where suitable loca-tions for float-type water level gauges are not practicable,bubbler-type pressure sensors have some application.However, with the bubbler-type control, it is difficult toobtain the required dampening without a well, and reli-ability is not as good as with the float type. Bubbler linesshould be sloped as indicated for other piezometer linesand should be provided with a source of clean dry air.

16-4. Water Level Gauges

a. General. This paragraph covers water levelgauges of the float type only. Water level gauges basedon pressure sensing are covered in preceding paragraphs

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of this chapter. Gauges of the staff type for visual read-ing of water levels should be installed in both tailwaterand poolwater locations but are normally designed andprovided under miscellaneous structural provisions. Floatgauges with the floats confined in wells are the preferredtype for remote water level indication and control pur-poses. The required sensitivity (dampening) is readilyattainable, and good reliability has been experienced atexisting projects.

b. Gauge locations. Gauges are required for tail-water levels and pool levels at all projects and for moni-toring and control of fish facility water levels at certainprojects. In some cases, more than one gauge may berequired to provided accurate measurement. The generallocation of the gauge will usually be determined by thecontrol function, pool or tailwater hydraulics, or structuralconsiderations. Detail of the location should permit ashort straight sensing line, provide safe physical access totop of well, and avoid a sensing line terminating in aneddy where trash concentration and silt deposits are likely.Normally a well location on a pier center line with thesensing line orifice at the outer pier face will be optimumfor tailwater and pool gauging. Where the pool gaugewill be located in a nonpowerhouse location, coordinationof the design with others may be necessary. The top ofthe tailwater floatwell should be above maximumtailwater.

c. Floatwell design.

(1) Size. The minimum size of a floatwell will usu-ally be determined by the required floatwell to orificedampening ratio and minimum orifice size to minimizeclogging. A 1,000:1 area ratio and 16-mm (5/8-in.) ori-fice diameter are considered appropriate for most applica-tions. This results in a well of approximately 510-mm(20-in.) inner diameter. The adequacy of the well diame-ter and length should be verified for the float and counter-weight of the intended control.

(2) Material. Floatwell material should be steel pipeand couplings with neoprene gaskets. The sensing linematerial should be 50-mm (2-in.) Schedule 40 brass pipe.

(3) Installation. Drawings should stress the require-ment that the floatwell be smooth and plumb for its entirelength. A drain for the instrument blockout at the top ofthe well should be provided.

(4) Freezing. Where freezing of a floatwell is antic-ipated, 0.6-0.9 m (2-3 ft) of oil in the top of the floatwellis usually the best solution. An alternative is to provideelectric heaters.

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Chapter 17Piping

17-1. General

The provisions of this chapter are applicable to all equip-ment and systems covered in this manual, wherever pip-ing is required.

17-2. Design Considerations

The design considerations noted in the following para-graphs are those more frequently encountered in thedesign of powerhouse systems but are not intended as acomplete listing. Other factors pertinent to the cost, life,and utility of piping in each particular powerhouse shouldalso receive proper consideration in the design and designanalysis. Caution and judgment are essential in applyingfactors and criteria available to ensure a satisfactory andeconomical design. The extent and degree of precision indesign analysis should be consistent with the assumptionsand other information available. For example, quantitiesor flow rates are often necessarily based on rather roughassumptions, and where this is true, a brief and approxi-mate analysis with conservative pipe sizing should be therule. Complex and extensive systems with well-verifiedassumptions warrant more detailed and exact analysis tomatch pipe sizes as near as possible to requirements.

a. Pipe sizing. The following factors should be con-sidered in determining suitable pipe sizes. Most of theseare interactive in their effect on pipe size, and care inselecting the critical factor is essential.

(1) Velocity. Velocity in itself will occasionallybecome a limiting factor in piping design, but this isusually only when erosion or cavitation would causepremature failure, noise could be a problem, or, in thecase of pipe used to transport fish or other materials,velocities are determined by other than piping consider-ations. Even when these limiting factors appear to apply,full consideration should be given to whether the limitingvelocity is normal, infrequent, or temporary. An infre-quent or temporary eroding velocity may well be justifiedin the interest of overall economy. For waterlines, veloci-ties in the range of 2.4-3.7 m/s (8-12 fps) are usuallyconsidered reasonable, but there is often good justificationfor higher or lower velocities. Copper waterline velocitiesshould not exceed 2.1 m/s (7 fps) continuously.

(2) Pressure loss. Pressure loss is often a limitingfactor on pipe sizing when a fixed gravity head is

available or where the pipe is a minor part of a pumpedsystem with the pump head determined by other majorrequirements.

(3) Pumping cost. Pumping cost can be a significantfactor in sizing pipe and requires careful analysis forextensive systems with high use factors, both in regard toenergy cost and connected electrical load.

(4) Corrosion allowance. Allowance for restrictionand increased pressure loss due to corrosion or mineraldeposits is necessary, depending largely on pipe materialand water chemistry. For steel pipe under average waterconditions, a reduction in cross-sectional area of 15 per-cent is a suitable corrosion allowance. Average pressureloss computations should be based on moderately cor-roded pipe.

(5) Code requirements. Minimum pipe sizes speci-fied by NAPHCC 1265, “National Standard PlumbingCode” or applicable state code should be complied with.

(6) Previous projects. Previous installations of simi-lar systems can be a valuable guide in selecting pipesizes, particularly when complete design analysis alongwith good service records are available.

(7) Other factors.

(a) Equipment connection sizes. These sizes aregenerally significant only for short runs of connectingpiping.

(b) Mechanical strength. When the pipe is small,consider where shock conditions could disturb pipe align-ment. It can be more satisfactory to use a larger size pipethan to provide the additional supports for a very smallpipe.

(c) Temperature. The use of copper and galvanizedsteel for hot water in the 60-77oC (140-170oF) range on acontinuous basis should be avoided.

(8) Precautions.

(a) Equipment demand forecasts. Where sizing isbased on advance equipment demand estimates, the analy-sis should so note, and office procedures should providefor rechecking analysis against contract figures.

(b) Coordination. Much of the information on whichpipe sizing is based comes from equipment supplier repre-sentatives, other engineering disciplines, and operation

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sources. Many costly design changes, change orders, andpoor operating conditions have resulted from thisexchange of information. It is the design engineersresponsibility to ask the right questions, make sure thelistener understands the purpose of the question, andverify, reverify, and coordinate answers from all availablesources.

(c) Plant expansion. Allowance in pipe sizing forpossible plant expansion is often warranted, particularly inembedded piping.

(d) Corrosion. See Chapter 19 for additional consid-erations on corrosion control.

b. Materials. A material schedule with recom-mended materials for all standard powerhouse applicationsis included in Figure B-13. Except as noted in the pipingschedule, whenever possible nonmetallic pipe should beused when buried outside of the powerhouse.

(1) Applying material schedule. To apply the mater-ial schedule, pipe wall thickness, fitting ratings, and valveratings should be verified for each application. Particularattention is due unusual pressure or shock possibilitieswhich could occur from misoperation, high pool or tail-waters, or equipment changes. The existence of unusualcorrosive characteristics of the fluid being handled shouldbe investigated, and material adjustments justifiedaccordingly.

(2) Deviations. In evaluating a proposed deviationthe following factors should be considered:

(a) Procurement cost.

(b) Installation cost.

(c) Life.

(d) Normal availability.

(e) Replacement cost.

(f) Maintenance.

(g) Appearance.

(h) Reliability.

Design memoranda should include justification for devia-tions, and advance consultation with review offices iswarranted, particularly in the case of new products.

(3) New products, testing, or experience record.Lack of a comprehensive experience record could justify alimited trial in a noncritical application if significantimprovements are otherwise indicated.

c. Routing.

(1) Embedded versus exposed. Embedded pipinghas several inherent problems and should be avoidedwhenever practicable (see Figure B-19). Some problemswith embedded piping are as follows: proper placementduring construction is difficult to enforce; damage fromaggregate may go undetected; filling with concrete occa-sionally occurs; it is difficult to obtain the necessary flex-ibility in crossing contraction joints; and corrosion,particularly near the point of emergence from concrete, isimpossible to completely monitor or control. For thesereasons, exposed piping is generally preferred. Usuallydrainage and vent lines are not practicable to run exposed.

(2) Routing considerations. The bulk of exposedpiping is generally placed in galleries, vertical pipechases, and covered pipe trenches. Obtaining adequatespace in these areas is often difficult and requires earlyplanning to avoid later compromises in good operationand maintenance. As soon as Preliminary Design Reporthas been approved, preliminary layouts showing tentativeequipment locations and preferred routing of all intercon-necting piping should be developed as a basis for request-ing the necessary structural and architectural provisions.The most effective approach to this layout is to refer todrawings of other recent, similar powerhouses and whenpossible obtain comments from operating and maintenancepersonnel on the pipe locations in these powerhouses.Design offices without file copies of recent powerhousesshould obtain drawings from other offices and consultwith experienced piping layout personnel in other offices.The following factors enter in to optimum routing andshould receive continued consideration during the designprocess:

(a) Dismantling and assembly.

(b) Valve maintenance and replacement.

(c) Supports.

(d) Draining.

(e) Provisions of sleeves and blockouts throughconcrete walls, floors, and columns.

(f) Length of lines.

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(g) Insulation.

(h) Expansion.

(i) Sound.

(j) Line failure.

(k) Corrosion.

(l) Leakage.

(m) Condensation.

(n) Appearance.

(o) Coordination with electrical and structuralrequirements.

Blockouts are usually preferred over sleeves since theypermit more flexibility in modifying the piping arrange-ment during design and construction and expediteinstallation.

d. Supports and anchors.

(1) General. Supports and anchors may be separateunits or may be combined in single units. Loadings arenormally quite readily determined, and commercial unitswith established load ratings should be used for mostapplications.

(2) Design practice.

(a) In horizontal lines, normally locate anchorsapproximately midway between expansion joints or loops.In longitudinal galleries, this usually results in anchorslocated near the center of each bay and expansion jointsor loops at the building contraction joints. However, it isoften expedient and satisfactory to provide the requiredexpansion joints or loops at other locations more conve-nient for assembly and disassembly.

(b) In vertical lines, locate anchors at upper endswhen practical to minimize the required number ofguides.

(c) A guide spool should be located close to and oneach side of expansion joints and loops.

(d) Multiple-type supports should provide space forservicing individual lines.

(3) Precautions.

(a) Where several pipes are to be mounted on oneseries of supports, spacing and load ratings should be asdetermined for the critical line.

(b) Supports at branches should be considered forrequired expansion in both lines.

(c) Friction in sleeve-type expansion joints should beconsidered in anchor design.

(d) Consider all possibilities for longitudinal forcesbecause of valve operation at changes in direction, includ-ing safety and relief valves.

(e) Include both pipe movement and structural dis-placement as contraction joints.

(f) All guide-type supports should provide freelongitudinal movement of lines. On the U-bolt type, twonuts, one on each face of the supporting member toensure a proper clearance, are required.

(g) Lock washers or double nuts should be used onall supports to avoid loosening from normal powerhousevibration.

(h) Anchor design should provide for forces imposedduring testing and any unusual temperature conditionsduring construction.

(i) Supports for copper lines should be copperplated, or the dissimilar metals isolated by a nonconduct-ing medium such as electrical insulating tape.

e. Pipe joints.

(1) General. The preferred types of joints for eachpiping system are listed in the “pipe” column of the pip-ing material schedule, Figure B-13.

(2) Location. Most joint locations will be deter-mined by available pipe lengths, the requirements forfittings, valves and connected equipment, fabricationprocess, and installation requirements. In addition, thefollowing should be provided:

(a) Union or flanged joints in all steel lines shouldbe downstream from valves.

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(b) Exposed sleeve-type joints are adjacent to thepoint at which embedded piping is continued withexposed piping.

(c) Sleeve-type joints should generally be providedwhere piping connects with pumps or other equipment,unless the piping involved is small and obviously flexibleenough to eliminate concern for vibration effects andstrain due to misalignment. Vibration and strain effectsshould be considered both on piping and the connectionequipment.

(d) Two sleeve-type couplings should be providedwhere embedded piping passes through valve pits (one oneach additional line that may enter the valve pit).

(e) Sleeve, U-Bends, or bellows-type flexible jointsshould be provided in exposed piping at, or near, contrac-tion joints.

(f) Insulating (dielectric) connections should be pro-vided between lines involving dissimilar metals andbetween ferrous pipe lines exposed in the powerhousewhich continues buried in soil outside. Fittings should belocated immediately inside of the powerhouse wall, andprecautions should be taken to assure that the pipes areisolated from the copper ground mat.

(3) Expansion joints.

(a) Flexible element. A number of flexible element-type joints are available as catalog items. These jointshave the capability for good service under severe condi-tions within their capabilities. Their principal advantagesover sleeve-type couplings are freedom from leakage aslong as they remain intact, lesser frictional forces, and theability to accept greater misalignment, except torsional.Their disadvantages are the necessity for immediatereplacement in case of failure and a lack of a recognizedspecification standard. Where predictably ideal designconditions can be obtained and maintained, their use canbe justified.

(b) Sleeve-type joints. Sleeve-type joints are wellsuited for expansion and contraction, as well as torsionaldisplacement, but are not suitable for radial misalignmentand will accommodate angular misalignment to only avery limited degree before axial displacement forcesbecome unpredictable. All sizes are commercially avail-able and should be applied in accordance with their limi-tations. Two joints in close proximity on the same linecan be used to provide for some radial displacement.

(c) U-Bends. U-Bends are an excellent type of jointfor all movements in piping and are trouble free whenproperly designed and installed. Space considerations areoften a problem in powerhouse application of U-Bends,and their cost is usually higher than other types of flexiblejoints. Their use has generally been confined to long,high-pressure, hydraulic oil headers in galleries. Com-mercially available U-Bends are available and should bespecified in accordance with their catalog ratings.

f. Valving.

(1) General. Valves regularly used in powerhousepiping include gate, globe, plug, ball, butterfly, check,pressure reducing, and relief valves. Valves should beprovided as required for control (open-closed-modulating);isolating; bypassing; prevention of backflow; protectionagainst overpressure; and in many cases, where not anactual requirement, for convenience of operation andmaintenance. They should be located, whenever practica-ble, for convenient access. If convenient access is notpracticable, they should generally be provided with remotecontrol unless their only use would be a very infrequentnoncritical maintenance operation. For maintenance pur-poses, design consideration should be given to minimizingthe number of types of valves in a particular powerhouse.Backseating valves or other types permitting repackingunder pressure should generally be provided.

(2) Valve selection.

(a) Gate valves. Rising stem, single-wedge gatevalves fulfill the bulk of the requirements for nonmodula-ting control valves. Nonrising stem gate valves withindicators can be used in special applications where spacedoes not permit a rising stem. However, the operatingdisadvantage of having the screw threads in the contentsof the pipe should be considered.

(b) Globe valves (including angle valves). For mod-ulating requirements and some critical drop-tight shutoffrequirements, globe valves should normally be used.

(c) Plug valves. Plug valves may be used for appli-cations where operation would be infrequent, a relativelyfixed modulation is required, or in some cases, wherequick operation is a requirement. They have the disad-vantages of a tendency to get frozen in a particular set-ting, developing small seepage leaks, and requiringlubrication in some applications, so careful considerationis necessary as to the actual overall benefits of their use.

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(d) Ball valves. Full-ported, nonmetallic, seated ballvalves are becoming increasingly available at competitiveprices and offer tight shutoff, quick operation, and rela-tively easy maintenance. Their use can be justified formany applications and locations, especially in smallersizes, 80 mm (3 in.) and less.

(e) Butterfly valves. Butterfly valves of the rubber-seated type offer significant cost advantages for somelow-pressure larger size applications. In some cases, theirrelatively low operating forces permit elimination of pow-ered operators. Butterfly valves may be used to modulateflow under certain circumstances but only through discopening angles of 45 to 90 deg. Their relatively inexpen-sive production plant requirements have made them apopular production item with many manufacturers oflimited experience. Particular care in obtaining a reputa-ble product in accordance with the material schedule isnecessary.

(f) Check valves. Conventional ball check, lift check,and swing check valves are all used regularly in power-house piping. Applications involving frequent flow rever-sals should generally be of the nonslam type. Someapplications requiring low-pressure loss and minimumshock can justify selection of one of several patented“silent” check valves.

(g) Pressure-reducing and relief valves. When pres-sure-reducing valves are required to maintain a lowerpressure system supplied by a higher pressure source, thelower pressure side should be further protected by one ormore relief valves. A slightly undersized relief valve ispreferable to an oversized valve to minimize erosion dueto near shutoff operation. A manual bypass around thepressure-reducing valve is permissible; however, the max-imum flow capacity of the bypass should be less than therelief capacity of the low-pressure system. A pressuregauge should be provided on the low-pressure system.The designer should be aware that pressure-reducingvalves, as well as relief valves, are subject to wear andmalfunctions, and great care is essential in their applica-tion, particularly in systems with maximum to zero flowrequirements. Where the pressure differential is sufficientto jeopardize plant operation or safety, a positive stand-pipe overflow relief system or an alternate low-pressuresource would be preferable.

g. Miscellaneous.

(1) Cleaning. In Appendix B specification, “Piping-Cleaning and Flushing,” the cleaning and flushing proce-dure of piping is covered (see paragraph B-2). Similar

provisions should be included in all powerhouse contractspecifications. The piping designer should be aware ofthe cleaning provisions and layout of the piping, particu-larly the embedded portion, to permit the best accesspossible. Wherever practicable, provide straight runs with-out bends or offsets between access points.

(2) Testing. As a general rule, all pressure pipingshould be tested to 1.5 times the maximum working pres-sure (embedded piping prior to embedment) with a mini-mum of 689 kPa (100 psi). Drainage waste and ventpiping should be tested to a minimum 3-m (10-ft) head.The designer should consider the testing during designand include any required special provisions to protectspecialized components of systems against the test pres-sure. Code test provisions are included in NAPHCC 1265and ASME A 31.1. A typical test paragraph, “PressureTests,” is included in Appendix B specification, “Power-house Piping,” (see paragraph B-3).

(3) Insulation. Insulation should be provided to pre-vent condensation on water and drain pipe passing overelectrical equipment or over suspended ceilings and onexposed interior roof drains. The requirement for insula-tion on water or drain piping to prevent freezing shouldalso be investigated. Wherever practicable, freeze protec-tion should be accomplished by protected routing of thelines or by planned draining of the lines in cold weather.Where this is not practicable, insulation (plus heating ifnecessary) should be provided. To evaluate the need forheating, all potential extended time no-flow conditionsshould be considered. Figure B-20 (sheets 1-6) shows atypical pipe insulation specification provision. Also referto Guide Specification CE-15250.

(4) Painting. Painting of piping is covered inEM 1110-2-3400 and Guide Specification CW-09940.However, the cost of painting and maintenance is affectedby pipe material routing and mounting and should beconsidered during design. Nonferrous piping is normallyleft unpainted. The cost of painting and maintenanceshould also be considered in the selection of galvanized orblack piping since painting of galvanized piping in non-painted areas is normally not required. In areas wherecondensation is likely to be continuous on cold waterlines, galvanized piping and supports may need to besupplemented with coatings or pipe insulation.

(5) Identification. A pipe and valve identificationsystem is required for each project. Specification provi-sions for a typical powerhouse are included in Appen-dix B, paragraph B-4, “Piping System Identification.”

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(6) Hydraulic piping. Piping for high-pressurehydraulic-operating systems is a specialty-type piping andis covered separately along with the hydraulic equipmentas a complete system.

h. Design analysis. A design analysis should beprepared for each piping system. Included should be

criteria, system assumptions, flow requirements, velocities,heads, losses, pipe sizing and materials, pump require-ments, routing considerations, expansion and contractionof piping and structure, expansion joint requirements,support and anchor loadings and selections, and otherfactors considered during system design.

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Chapter 18Heating, Ventilating, and Air ConditioningSystem

18-1. General

Powerhouse heating, ventilating, and air conditioning arerequired to maintain temperature and air quality condi-tions suitable for operating equipment, plant personnel,and visitors. Maintaining required conditions for operat-ing equipment is essential under all weather conditions atthe site. Personnel and visitor design conditions are alsoimportant, but temporary deviations under weatherextremes can be tolerated and should be reflected in thedesign. Energy conservation is a prime consideration.Figures B-21 and B-22 present typical heating, cooling,and ventilation systems. Drawings and specifications on avariety of systems in existing plants are available throughinquiry to review offices. Adaptations of existing designsto new plants should consider the increased emphasis onenergy conservation. The use of Class I ozone depletingchemicals (ODC) including all chlorofluorocarbon com-pounds (CFC), Halons, and their mixtures are prohibited.

18-2. Design Conditions

a. General. Assumed design conditions, both out-side and inside the powerhouse, have major effects onsystem adequacy, construction costs, and operating costssince they influence the type of equipment provided.Sufficient engineering time for research and coordinationof available data is essential to a practical design.

b. External conditions.

(1) Weather.

(a) Data sources. Sources of weather data include thefollowing: American Society of Heating, Refrigeration,and Air Conditioning Engineers (ASHRAE) “Handbook-Fundamentals,” TM 5-785, U.S. National Weather Ser-vice, power plants in the area, and miscellaneous privateand public records. The ASHRAE Handbook is a reliablesource for the locations listed therein, but power plantlocations will frequently be some distance away from alisted location, and design conditions can be appreciablydifferent in 50 miles (80.6 km) or less. In such cases, thedesigner should research other available data for applica-bility and authenticity. When other reliable data areunavailable, the interpolation procedure outlined in theASHRAE Handbook should be used.

(b) Data required. Weather data and designconditions as listed in the ASHRAE Handbook are pre-ferred and should be included in the mechanical designmemorandum. Duration of hot and cold extreme tempera-tures is not usually included but is valuable when avail-able to permit the design to reflect the “flywheel” effectof the normal massive construction of powerhouses.Outdoor design temperatures for comfort heating andcomfort cooling should be based upon the 97.5 and the2.5 percent dry bulb and corresponding mean coincidentwet bulb temperatures, respectively. Outdoor designtemperature for heating to prevent freezing conditionsshould be based upon the 99 percent dry bulbtemperature.

(c) Evaluation. Data other than ASHRAE should beevaluated on the basis of location of readings, periods ofrecord, probable dependability, and cross-checking toarrive at appropriate outside design conditions. The datashould be combined and presented as nearly as practicablein the form noted in ASHRAE. Mechanical design mem-oranda should include the evaluation factors along withbasic data and the assumed design conditions.

(2) Water temperatures. Streamflow temperatureswill usually be available from the general design memo-randum or other previous memoranda. Groundwater useis seldom economical for heating and cooling purposes,but temperature conditions are usually available throughthe U.S. Geological Survey offices. Probable pool watertemperatures should be available in the EnvironmentalImpact Statement, General Design Memorandum, or gen-erator cooling water studies. Summer and winter watertemperatures should be included in the design conditionsdata along with the data source.

(3) Ground and rock temperatures. General infor-mation on ground and rock temperatures is available inthe ASHRAE Handbook. Because of the limited effecton system design, extensive research is usually not war-ranted. The design memorandum should include theground and rock design temperature and the source orbasis of assumption.

c. Indoor conditions.

(1) General. Indoor design conditions are on thefollowing bases: project personnel requirements, takinginto account the type of activity, visitor requirements, andequipment requirements. Personnel and visitor require-ments are somewhat flexible allowing deviations duringextreme outside conditions. Equipment maximum and

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minimum conditions are more critical as deviations couldaffect plant capability or subject equipment to damage.

(2) Temperature-humidity. Indoor design temperaturewill vary with many factors, such as occupancy of thepowerhouse, type of equipment, and sponsor/ownerrequirements. The control room office and visitor type ofrooms should be heated and cooled to 20oC (68oF) and24oC (75oF), respectively. Rooms with equipment whichis sensitive to freezing conditions should be heated to aminimum of 4.5oC (40oF). Maximum humidity condi-tions should generally be limited to 50 percent in theoffice, control room, and visitor area. Minimum humiditycontrol will seldom be justified.

(3) Ventilation. Ventilation rates should be in accor-dance with ASHRAE 62. Equipment/gallery rooms,battery rooms, and turbine pits generally should haveminimum air exchange rates of 1, 2, and 4 air change perhour, respectively.

18-3. Design

a. General. The system design should be based oncriteria, factors, and details recommended or indicated inthe ASHRAE Handbook except as modified herein. Thedesign should be conservative while providing acceptableoperation with normal decreases in operating efficiencyand average maintenance. Unnecessary complications toachieve ideal conditions under all operating extremesshould be avoided. Heat gains from lights and equipmentshould be included in both heating and cooling loadrequirements with due reward for both initial and long-range plant operations.

b. Insulation. Powerhouse insulation is not normallya direct mechanical design responsibility. However,because of its influence on the required heating and cool-ing provisions and energy requirements, the mechanicaldesigners should be involved in the initial powerhouseplanning affecting insulation provisions. The most practi-cal applications for insulated construction are usually thepowerhouse walls above the bridge crane rails and roof.The “U” factors in the 0.05-0.09 range are practical forthese surfaces. The use of windows should be minimized,and double-pane windows used where justified.

c. Heating.

(1) General. With the required emphasis on energyconservation, studies on the heat source and type of con-version equipment merit major design attention. Severaloptions are open in most cases, and the factors pertinent

to the selection should be included in the design studiesand the design memorandum. System layout, equipment,and details in accordance with ASHRAE Handbook andreflecting previous powerhouse experience are normallysatisfactory.

(2) Heat sources.

(a) Generator cooling water. The waste heat avail-able in generator cooling water should be the primesource in all powerhouses where planned unit operationprovides a reliable supply, or where practical modifica-tions in unit scheduling could assure a reliable supply.Any plant with three or more units on baseload operationshould have the capability for a continuous supply. Plantswith planned intermittent or basic peaking operations mayalso provide a practical source if agreement on the neces-sary modifications in unit scheduling can be obtained.One or two unit plants located in areas subject toextended periods of subfreezing temperatures should notbe dependent on generator cooling water as the basic heatsource because of the limited backup capability. Pre-ferred source water temperature in the 16o-24oC(60o-75oF) range can be obtained with reasonable modula-tion; however, the generator specifications should includea stipulation to this effect.

(b) Solar heat. Solar heat should be investigated forthe powerhouse and visitor facilities. Solar heating stud-ies should be based on the Department of Defense (DOD)criteria which are current at the time the powerhouse isbeing designed.

(c) Outside air. Outside air, using air-to-air or air-to-water heat pumps, has limited potential as the basicheat source because of reduced efficiency during sub-freezing conditions. A study may be warranted for plantswithout a dependable water heat source, located in moder-ate climates.

(d) Pool water. Pool water may be a practical heatsource where winter water temperatures above 7oC (45oF)can be assured. Caution in accepting pool water tempera-ture estimates near 7oC (45oF) is advisable as the marginfor safe operation is limited, and there are many variablesaffecting pool water temperatures. The existence of asimilar project nearby on the same stream could provide areliable indication of expected pool water temperatures.

(e) Miscellaneous water sources. Groundwater fromwells or foundation relief flows can provide water ofdesirable temperature, but assurance of continued supply

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is questionable and these sources are not normallyrecommended.

(f) Electricity. Electricity utilized in resistance heat-ing is an available and reliable source at most powerplants. In many plants, it may be the most economical.Its disadvantage is the relatively low efficiency in theoverall energy supply. Its use in resistance heating as thebasic heat source should be limited to plants which meetthe following scenarios:

• Where a reliable more efficient heat source is notavailable.

• Where total annual costs of an alternate moreefficient source would exceed the cost of resis-tance heating by more than 25 percent.

• Where the total yearly heating energy demand isunder 100,000 kW hours per year. Electricalenergy used in resisting heating may be employedas required for auxiliary heat in occupied areasand temporary heat for maintenance and repairpurposes.

(g) Oil-gas. These sources may be practical in someareas. The use of oil or gas is preferred over electricalresistance heating where a reliable source is available.

(3) Conversion equipment. Equipment to be consid-ered for heating is water-to-air coil-type heat exchangers,heat pumps, and resistance heating coils. Heat pumpcapacity should be sized, or backup resistance heatingprovided, to assure capacity for maintaining above freez-ing temperatures within the powerhouse under minimumoutdoor temperature with one compressor inoperable.

(4) Source water piping. Source water taps andheaders should assure required water to the coils or heatpumps at all times. Generator cooling water should besupplied through a header connecting to a minimum ofthree units but may be justified to all units depending onplant size, proposed plant operation, and weather condi-tions. Pool water should not be subject to interruptionfrom main unit shutdown involving placement of stoplogsor closure of gates. Strainers in the source water supplyshould be duplex, with strainer perforations as large aspracticable and consistent with heat exchangerrequirements.

(5) Heat distribution. The bulk of the powerhouseheat requirements will be distributed through the ventila-tion system with water-to-air coils. Resistance elements

located in air-handling units or ducts should not be usedunless resistant heat is the only practical method ofheating the powerhouse. Heat distribution requirementsmay determine air quantities in the ventilation system.

d. Cooling.

(1) General. Cooling should be provided to meet thedesign conditions noted in paragraph 18-2. Whereverpracticable, cooling should be provided by circulation ofoutside air through the ventilation system or by circulationof pool or tailwater through water-to-air coil-type heatexchangers in the ventilation system depending on whichmethod is most economical. Where suitable outside air orwater temperatures are not obtainable, cooling may beprovided with chilled water coils in the ventilation systemor package-type air conditioning units.

(2) Cooling load.

(a) Outdoor. Outdoor design temperatures should bebased on ASHRAE summer design conditions as noted inparagraph 18-2. Allowance for sun exposure is particu-larly important for exposed gallery structures containingpower cables or busses and heat sensitive equipment.

(b) Indoor. Indoor heat gains are essentially electri-cal and should be based on equipment manufacturers’ dataor connected load with conservative efficiencies. It isessential that adequacy of the cooling provisions not be alimiting factor in equipment or electrical conductor opera-tion. It is also important that heat gain estimates for criti-cal areas such as galleries with concentrations of electricalload be verified. Design memoranda should recognizesuch areas, show source or basis of heat gain estimates,and include appropriate factors for contingencies. Inplants provided with indoor emergency diesel generatorssets, the heat gains therefrom may be of significance andshould not be overlooked.

(3) System and equipment.

(a) General. The bulk of the cooling requirementswill normally be provided through the ventilation systemeither with outside air or water-to-air coils located in theair handling units or ducts. Auxiliary or isolated zonecooling using package-type air handling units or package-type air conditioners may sometimes be most practical.Cooling requirements will frequently determine maximumventilation rates.

(b) Heat pumps. The joint use of heat pumps forheating and cooling requirements is the preferred method

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of heating and cooling if direct cooling from outside airor water is not practical.

(c) Compressors. Where cooling by mechanicalrefrigeration is justified, the compressor capacity shouldbe provided with two or more compressors rated to pro-vide approximately two thirds of system requirementswith any one compressor out of service.

(d) Humidity control. Dehumidification will normallybe accomplished, as required, in the system cooling coils.This may be a factor in determining required coolingwater temperature.

(e) Direct expansion coils. Direct expansion coils inthe main air system should be avoided. Chilled watercoils are preferred. Direct expansion coils may be usedwhere self-contained package-type air conditioners arejustified.

(f) Precooling coils. A combination of precoolingcoils using pool or tailwater and chilled water coils maybe used to conserve energy where economically justified.

(g) Package-type air conditioners. Simplification ofthe main powerhouse system and overall increased flexi-bility may frequently favor the use of package-type airconditioners with coil, blower, and filter for areasrequiring special temperature control. This should beconsidered in the early design stage to assure space forappropriate locations. Required ventilation and exhaustair and chilled or heated water are normally providedfrom the central system when package-type air condition-ers are used. Locations should provide for convenientaccess for servicing. Completely self-contained units withdirect expansion coils, electric heaters, fans, and filtersmay occasionally be justified for small areas remote fromthe central system.

e. Air filters.

(1) General. Filters should be provided in all ventila-tion systems to reduce powerhouse cleaning and mainte-nance costs, aid in maintaining coil efficiencies, andimprove air quality for personnel.

(2) Type. Several types of filters are satisfactory,including the following: electronic precipitator in combi-nation with automatic roll type, throw away type, replace-able dry media type, traveling screen oil bath type, andautomatic replacing roll type. Electronic precipitators arethe most efficient in removing both coarse and fineforeign material from the air but will range up to double

in annual costs over the other types. The other typeshave similar performance characteristics but differ inmaintenance requirements. Normally, the choice of filtershould be from the nonelectronic type with the selectionmade on the basis of lowest annual cost. Electronic typesmay sometimes be justified on the basis of unusuallyclean air requirements for certain equipment or to obtainbetter air quality for personnel in areas subject to unusu-ally severe pollen conditions.

(3) Location. Filters are normally installed in airhandling units, ahead of the coils, and in a position tofilter both recirculating and outside air.

f. Ventilation.

(1) General. Ventilation is required as a minimumto assure reasonable air quality conditions throughout thepowerhouse. Recirculation normally provides the princi-pal ventilation air with the balance provided from outsideair. The minimum outside air is based on the systemrequirements for rooms requiring outside exhaust, fordirect use of compressors and gas or diesel engines, plusan allowance to assure a positive pressure within thepowerhouse. Actual ventilation system air-handling capa-bility will usually be determined by heating or coolingrequirements. Provisions for heating, cooling, filtering,and humidity control are included in the system asrequired.

(2) Equipment. The principal supply and recirculat-ing fans are normally installed in or adjoining air handlingunits containing heating and cooling coils and filters.Auxiliary heating or cooling coils, booster fans, andexhaust fans are located as required in the overall system.Automatic dampers are normally provided in generatorroom roof-exhaust ventilators to control the powerhousepositive pressure to approximately 2.54 mm (0.1 in.) ofwater.

(3) Miscellaneous considerations.

(a) Paint spray areas. Repair rooms or repair pitswith paint spray equipment should be provided with sup-plemental ventilation for use during painting operations.The total ventilation provided should be at least 60changes per hour. In addition, the installation shouldconform to the applicable provisions of NFPA 33 and 91.

(b) Emergency generator rooms. Rooms with gaso-line or diesel engine-driven emergency generator setsshould be provided with ventilation to remove heat givenoff by the generator, exciter, engine surfaces, exhaust

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piping, and heat exchanger, as well as with ventilation forengine combustion. Ventilation should be provided asstated in paragraph 18-2c(3) when the generator is not inuse.

(c) Control room ceiling. Space above the controlroom ceiling should be provided with sufficient ventila-tion to remove the heat given off by the high-intensitycontrol room lighting. Outlets and inlets should bearranged to provide uniform cooling and to avoid hotspots.

(d) Exhaust provisions. Toilet rooms, a battery room,oil storage rooms, paint storage rooms, control rooms,rooms with mechanical refrigeration, and similar spacesshould be provided with exhaust to the outside during allseasons. Air from other spaces is usually recirculatedwhen ventilation with outside air is not necessary forcooling. Automatic dampers and variable speed fans aregenerally used where two or more rates of ventilation arerequired. Provisions are sometimes made to discontinueor reduce the exhaust from public toilets and similarspaces during periods of peak heating loads in order toreduce the amount of makeup air required during the peakperiods.

(e) Ducts. Ducts are usually constructed of galva-nized sheet iron with suitable stiffeners. Vertical buildingchases and galleries are often used as ducts where eco-nomical. Galleries or corridors are often practicable forlarge volume air movements but should not be used wherenormal traffic in and out is heavy and door opening orclosing would materially effect the operation of the venti-lating system. Unbalanced pressure effect on door opera-tion should also be considered, particularly where visitorsmay have access. Galleries with concentrations of heat-generating equipment may require metal ducts to permitconcentrated delivery of cooling air or pickup of exhaustair. Use of louvered doors and corridors as a substitutefor a return duct on an air conditioning system is unsatis-factory. Insulation for ducts should be provided whererequired to avoid condensation or where justified to

conserve energy. All insulation should be of a fire resis-tant type.

g. Controls.

(1) General. Controls should be of the automatictype wherever feasible to minimize required manualadjustment and to discourage random “personal prefer-ence”-type adjustments. In summer-winter air condition-ing systems, however, the master changeover shouldgenerally be manual to avoid unnecessary heating-coolingcycling during mild weather.

(2) Design. The general control system for eachpowerhouse should be developed along with the overallsystem layout to assure a well-coordinated design.Emphasis should be on minimizing energy usage andobtaining good average conditions in the powerhouse withminimum complexity and maximum dependability. Inmost powerhouse areas there is considerable latitude inacceptable conditions, which should be reflected in thecontrol method as well as the system layout. In the inter-est of energy conservation, control requiring simultaneouscooling and heating should be avoided. Final controlsystem design should be a contractor responsibility.Specifications should permit the contractor’s choice ofpneumatic, electrical, or electronic control or a suitablecombination.

18-4. Design Memorandum

The design memorandum should include the backgroundinformation essential to selection of design conditions.The choice of methods of heating and cooling should bediscussed and justified. Special conditions that warrantdeparture from the usual design criteria should beexplained. Heat gains and losses should be tabulated byroom or space and summarized by system. A flow dia-gram for each system should be furnished. Separate con-trol diagrams for heating and cooling seasons aredesirable on the air conditioning systems.

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Chapter 19Corrosion Mitigation Considerations

19-1. General

a. The intent of this chapter is to supplement spe-cific recommendations on corrosion control made in thepreceding chapters.

b. Corrosion is a problem because of the ease withwhich it takes place on low-cost construction metals. Therequirements for corrosion are the presence of a conduct-ing fluid on a metal (or metals in intimate contact) and aflow of DC current. The presence of corrosion stimula-tors, such as oxygen or chlorides, contribute to a morerapid attack.

19-2. Design Considerations

a. General. To control corrosion, it is necessary toeliminate one or more of the above-mentioned require-ments for corrosion. The following considerations sug-gest ways to exclude the conducting fluids from metals,suppress or halt the flow of DC current, and control cor-rosion stimulators.

b. Goal = least cost programmed life.As prices oflabor and materials change and information on the perfor-mance of materials becomes available, past practiceshould be reviewed to determine if the goal is beingachieved. For example, bare steel with an appropriatecorrosion allowance may provide programmed life atlower cost than a coated structure.

c. Environment. It is sometimes useful to considerthe possibility of altering the environment in which theequipment will be placed. The cost of protecting equip-ment from its environment can be changed significantly.For example, consider whether the equipment can beplaced indoors rather than outdoors. Once the environ-ment is set, proceed to select appropriate materials towithstand the environment or means of excluding fluidsfrom a metallic structure, such as coatings.

d. Design geometry.Outdoor equipment in particu-lar should avoid designs which allow water to be trappedor include sharp edges, crevices, numerous bolts, etc.,which make coating application difficult. Similarly,places inside the powerhouse may require extra attentionsuch as in water and sewage treatment rooms.

e. Material selection. In general, the Corps of Engi-neers engineering manuals and guide specifications pro-vide conservative advice. The environment for somepower plants (weather, water quality, etc.) may be moresevere or less severe to such a degree that deviation fromestablished guides may be warranted and should be docu-mented in design memoranda. Also, the consequences ofplacing dissimilar metals in contact where moisture can bepresent should be evaluated. An alternative may be theuse of nonmetallic materials.

f. Protecting metals. Methods of protection forvarious environments are indicated below. Actual choicesshould consider the aggressiveness of the environment(e.g., water analysis, soil resistivity).

(1) Immersed. This method includes structuresimmersed in water and the interior of water piping sys-tems. The choices include corrosion resistant metals,metallic and nonmetallic coatings, dielectric isolatorsbetween dissimilar metals, and cathodic protection.Closed systems may also employ chemical treatment.

(2) Underground/embedded. The choices for under-ground are the same as for immersed described previ-ously. Embedded structural metals normally do notrequire protection, except for aluminum or at the point ofemergence from concrete.

(3) Atmospheric. The choice is usually madebetween corrosion-resistant metals and alloys or the use ofcoatings to protect ferrous materials in exterior exposures.Similar choices are used for interior exposures, dehumidi-fication, and insulation.

g. Galvanic couples. Where galvanic coupling ofdissimilar metals is expected to cause corrosion problems,the choices for prevention include dielectric isolation,coating of both metals, or cathodic protection. Uninten-tional galvanic couples such as ferrous underground orimmersed piping, which is metallically connected to thecopper station ground mat or coated steel piping adjacentto stainless steel tracks in an intake gate slot, will alsocreate problems. In these latter cases, the relative area ofnoble metal is high due to the coating on the steel, andpitting can be rapid.

h. Future maintenance.Give consideration to howcorrosion damage may be further retarded by renewingcoatings, anodes, components, etc.

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i. Safety and critical items. Items which involvelife safety and require regular inspection (e.g., pressurevessels, hoist cables, etc.) should be planned to make suchinspections or tests easily accessible for accomplishment.

j. Miscellaneous factors.Other factors which affectcorrosion and require consideration in design are tempera-ture, velocity, chemical concentration, contamination, andabsence of film-forming properties in some waters.

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Appendix AReferences

A-1. Required Publications

TM 5-785Engineering Weather Data

TM 5-810-4Mechanical Design; Compressed Air

TM 5-810-5Plumbing

TM 5-812-2Firestopping

TM 5-813-1Water Supply Sources and General Considerations

TM 5-813-3Water Supply; Water Treatment

TM 5-813-4Water Supply; Water Storage

ER 1130-2-407Operating and Testing Potable Water Systems in Com-pliance with the “Safe Drinking Water Act”

EM 385-1-1Safety and Health Requirements

EM 1110-2-3006Hydroelectric Power Plants Electrical Design

EM 1110-2-3400Painting: New Construction and Maintenance

EM 1110-2-4203Design Data for Powerhouse Cranes

ETL 1110-2-311Fire Protection-Hydroelectric Power Plants

ETL 1110-2-317Selecting Reaction-Type Hydraulic Turbines and PumpTurbines and Hydroelectric Generators and Generator-Motors

ETL 1110-2-333Sampling Methods for Zebra Mussels

ETL 1110-8-12 (FR)Testing and Purification of Lubricating Oil forHydroelectric Power Plants

CE-1603Draft Tube Gantry Cranes

CE-4000Lump Sum Contract for Engineering Services for Designof Hydroelectric Power Plant

CE-15250Thermal Insulation for Mechanical Systems

CE-15400Plumbing, General Purposes

CE-16263Diesel-Generator Set Stationary 100-2500 kW, withAuxiliaries

CE-16264Diesel-Generator Set Stationary 10-99 kW, withAuxiliaries

CW-09940Painting; Hydraulic Structures

CW-11290Hydraulic Power Systems

CW-14210Elevators, Electric AC and/or DC

CW-14330Indoor Traveling Cranes (AC/DC)

CW-14340Dam Gantry Cranes

CW-14601Cranes, Bridge and Gantry, Top-Running, 30-Ton Maxi-mum Capacity

CW-15360Carbon Dioxide Fire Extinguishing Equipment

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CW-15487Turbine Lubricating Oil

CW-16210Hydraulic Turbine-Driven Alternating Current Generators

CW-16321Electrical Insulating Mineral Oil

CW-16252Governors for Hydraulic Turbines and Pumping Turbines

A-2. Related Publications

Federal and Military Specifications

SS-C-160Cement, Insulation, Thermal

L-P-535Plastic Sheet (sheeting), Plastic Strip, Vinyl ChloridePolymer and Vinyl Chloride Vinyl Acetate Copolymer,Rigid

VV-F-800Fuel Oil, Diesel

W-B-133ABattery, Storage (Lead-acid Industrial for Cycle Service)

W-H-171Hangers and Supports, Pipe

MIL-C-20079Cloth, Glass, Tape, Textile, Glass, and Thread Glass

MIL-C-4556Coating for Steel Fuel Tanks

American Petroleum Institute (API)American Petroleum Institute (API). API-650 - 1993,Welded Steel Tanks for Oil Storage

American Society of Heating, Refrigeration, and AirConditioning Engineers (ASHRAE)American Society of Heating, Refrigeration, and AirConditioning Engineers (ASHRAE). ASHRAE - 1993,Handbook-Fundamentals

American Society of Heating, Refrigeration, and AirConditioning Engineers (ASHRAE)American Society of Heating, Refrigeration, and AirConditioning Engineers (ASHRAE). ASHRAE 62 - 1989,Ventilation for Acceptable Indoor Air Quality

American Society of Mechanical Engineers (ASME)American Society of Mechanical Engineers (ASME).ASME A 17.1 - 1993, Safety Code for Elevators andEscalators

American Society of Mechanical Engineers (ASME)American Society of Mechanical Engineers (ASME).ASME A 17.2 - 1988, Inspector’s Manual for Elevatorsand Escalators

American Society of Mechanical Engineers (ASME)American Society of Mechanical Engineers (ASME).ASME A 31.1 - 1992, Power Piping Code

American Society of Mechanical Engineers (ASME)American Society of Mechanical Engineers (ASME).ASME PTC 18 - 1992, Hydraulic Turbines (PerformanceTest Codes)

American Society of Mechanical Engineers (ASME)American Society of Mechanical Engineers (ASME).ASME Paper 66-WA/FE-9, Analysis and Solutions of aDraft Tube Water Depression Problem

American Society of Mechanical Engineers (ASME)American Society of Mechanical Engineers (ASME).ASME 1992, Boiler and Pressure Vessel Code

American Society for Testing and Materials (ASTM)American Society for Testing and Materials (ASTM).ASTM A 312 - 1993, Seamless and Welded AusteniticStainless Steel Pipe

American Water Works Association (AWWA)American Water Works Association (AWWA).AWWA C 601 - 1992, Disinfecting Water Mains

American Water Works Association (AWWA)American Water Works Association (AWWA).AWWA Paper ASCE-CSSE, Water Treatment PlantDesign

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EM 1110-2-420530 Jun 95

National Association of Plumbing-Heating-CoolingContractors (NAPHCC)National Association of Plumbing-Heating-CoolingContractors (NAPHCC). NAPHCC 1265 - 1993, NationalStandard Plumbing Code

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA). NFPA 10 -1990, Portable Fire Extinguishers

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA). NFPA 12 -1993, Carbon Dioxide Extinguishing Systems

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA). NFPA 15 -1990, Water Spray Fixed Systems for Fire Protection

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA). NFPA 33 -1989, Spray Application Using Flammable CombustibleMaterials

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA). NFPA 37 -1994, Stationary Combustion Engines and Gas Turbines

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA). NFPA 70 -1993, National Electric Code

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA). NFPA 91 -1992, Installation of Exhaust Systems for Air Conveyingof Materials

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA).NFPA 803 -1993, Fire Protection for Light Water NuclearPower Plants

National Fire Protection Association (NFPA)National Fire Protection Association (NFPA).NFPA 851 - 1992, Fire Protection for HydroelectricGenerating Plants

Taylor, J. R.Taylor, J. R. Hydraulic Turbine Water DepressionSystems for Synchronous Condenser Operation

Underwriters Laboratories (UL)Underwriters Laboratories (UL). UL 142 - 1993, SafetySteel Aboveground Tanks for Flammable and Combusti-ble Liquids

U.S. Army Engineer Waterways Experiment Station(WES)U.S. Army Engineer Waterways Experiment Station(WES). WES Technical Report H-78-8 - 1977, Power-house Intake Gate Catapult Study, Big Bend Dam, SouthDakota, and Stockton, Harry S. Truman and ClarenceCannon Dams

U.S. Army Engineer Waterways Experiment Station(WES)U.S. Army Engineer Waterways Experiment Station(WES). WES ZMR-3-05 - 1992, Zebra Mussel ResearchTechnical Notes, Control Strategies, Components ofHydropower Projects Sensitive to Zebra MusselInfestations

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Appendix BReference Drawings and Data

B-1. General

System drawings (Figures B-1 through B-22) and specifi-cation excerpts presented next in paragraphs B-2, B-3, andB-4 are essentially systems and equipment used in variousexisting powerhouses, but both have been modified incertain respects to make them more generally applicable.However, their use for new powerhouse design will sel-dom be practical due to the differing requirements charac-teristic of each new project. They are included toacquaint the designer with satisfactory designs typical ofone or two sizes and types of powerhouse. Certain linesizes and elevations have been retained on the drawingsas an aid in visualizing the particular system layout butshould be regarded as relative only. Where a figureincludes two, three, or more separate drawings, apprecia-ble differences in powerhouse requirements and systemprovisions will be noted. These figures and specificationsare referenced in the manual write-ups and as otherwiseneeded during design.

B-2. Piping-Cleaning and Flushing

a. General. Prior to installation, piping, fittings, andvalves shall be cleaned as required to remove all foreignmatter. During installation, openings in the piping shallbe covered to prevent entry of foreign material. Concrete,curing water, or construction debris shall not be washedinto drains. Piping shall be kept clean, and the contractorshall demonstrate that the pipes and drains are unob-structed when so directed by the Contracting Officer.Any stoppage or other damage to materials, equipment, orparts of the building due to the contractor’s failure toproperly clean the piping systems shall be repaired by thecontractor without cost to the government. The contractorshall provide all materials and equipment required toclean and flush the piping systems including temporarypiping, solvent, and circulating pump except as otherwisenoted. After installation and prior to connection to equip-ment, each system shall be thoroughly flushed until clean.Unless otherwise noted, the flushing and cleaning fluidshall be the same as medium specified for the pressuretest. Temporary cross connections shall be installedbetween supply and return lines at each branch extremity,and each branch shall be cleaned and flushed in a separateoperation. The supply and return lines in the oil roomshall be isolated from the tanks and pumps until testingand flushing operations have been completed. Oil usedfor flushing shall not be drained to the dirty oil tank but

shall be collected for disposal by the contractor. All suchoil shall be drained from the low points in the lines.

b. Cleaning oil system.Special care shall be takento ensure that materials used in the oil system are cleanand that shavings, solder, or other foreign materials do notenter the system. The contractor shall obtain approvalfor his cleaning and flushing procedures by the Contract-ing Officer prior to starting cleaning operations. Anorganic solvent which will remove the flux residue andalso will be soluble in the subsequent hot oil flush shallbe passed through the piping until the flux residue isremoved. Prior to this solvent cleaning operation, thecontractor shall demonstrate by the use of test sections ofsoldered copper tubing and fittings that the solvent clean-ing operation will effectively clean out the flux residueleft in the soldering process. Lines shall be drained ofsolvent and shall be blown out prior to being pressuretested.

c. Flushing oil system. After the piping has beensolvent cleaned and pressure tested, but before the oillines are connected to the generators, turbines, governorequipment, and oil storage tanks and pumps, oil shall becirculated through the supply and return lines at a mini-mum velocity of 4.6 m/s (15 f/s) for 8 hr or until they areclean. An 80- by 80-mesh screen or comparable filtershall be installed at the end of the return oil line. Cleanwarmed oil shall be circulated through all circuits of thepiping until the screen remains clean. The oil temperatureshall be between 60-66°C (140-150°F). The oil used forthe pressure testing shall be used for flushing. The oilshall be recirculated so that the quantity required will notbe excessive. The contractor may use the oil purifier toheat the oil. The purifiers and government-furnished oilswill be made available to the contractor at the locationsneeded. Oil circulating pumps used in conjunction withthe oil purifier shall be matched to the volume flow rateof the purifier and shall be equipped with a bypass. Adetailed drawing of the proposed circulating pumps-oilpurifier joint operation shall be submitted for approval. Ifan extension power cord for the oil purifier is needed, itshall be provided by the contractor. The purifier shall becleaned and serviced after use.

B-3. Powerhouse Piping

a. Pressure tests.

(1) General. The contractor shall furnish all equip-ment and materials required to make complete tests,except as otherwise specified. The tests shall be madewith blank flanges or with suitable caps on ends of the

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pipe sections to be tested. The pipings tests shall be con-ducted before the equipment has been connected to thepiping. All sections of the piping specified herein shallbe tested by the contractor and approved by the Contract-ing Officer before acceptance. Any defects or leaks dis-closed by tests shall be satisfactorily repaired and retestedby the contractor at no additional cost to the Government.The contractor shall notify the Contracting Officer insufficient time before starting any test to permit a repre-sentative of the Contracting Officer to witness the test.Each welded joint shall be hammered while under testpressure. All piping shall be tested at the pressure shownin Table B-1 for a length of time sufficient in the opinionof the Contracting Officer to determine tightness but in nocase less than one hour except as noted. Air lines testedwith water shall be thoroughly dried after testing andbefore connecting to equipment.

(2) Test pressure and mediums. The test pressuresand mediums are shown in Table B-1 for the followingcategories of piping:

b. Carbon dioxide piping.The carbon dioxide pip-ing, including that portion in the generator housing, shallbe pressure tested as follows. All piping including theflexible tubing shall be subjected to a gas pressure test of6,894 kPa (1,000 psi). Only nontoxic and nonflammablegases shall be used to test. The gas pressure shall not fallbelow 6,205 kPa (900 psi) at the end of a test period of5 min. All personnel shall be removed to positions ofsafety while the systems are under test pressures, with thepressure gauge used for testing being the only pressurizedcomponent directly exposed to personnel. Examinationsfor leaks shall be conducted only after the maximum pres-sure test pressures have been reduced below 2,068 kPa

Table B-1Test Pressures and Mediums

Test Pressure TestkPag (psig) Medium

Unwatering and Filling Piping 689 (100) Water

Service Air Piping 1,724 (250) Water

Governor and Lubricating OilPiping (distribution) 1,551 (225) Lubricating Oil

at 100oF

Generator Cooling Water Piping 689 (100) Water

Piezometer Piping 1,034 (150) Water

Low Pressure and Brake Air Piping 1,379 (200) Air

Governor Air Piping 1 1/2 times WaterMax. GovernorOperatingPressure

Potable and Raw Water Piping 1,034 (150) Water

Gland Water Piping 1,034 (150) Water

Carbon Dioxide Piping See above (para B-3b)

Roof Drainage Piping 1.5 m (5 ft) WaterHead at RoofSurface

Drain, Waste, and Vent Piping 3.0 m (10 ft) WaterHead at FloorSurface

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(300 psi). Before making the specified pressure test, thecontractor shall submit for approval a description of themethod to be followed and the type of gas to be used toproduce the required pressure for the leakage test.

B-4. Piping System Identification

a. General. All exposed piping and valves includingthose furnished by the government and by the contractoras specified in other sections shall be identified as hereinspecified. Identification includes the following:

(1) Piping system designations and flow directionarrows on the piping.

(2) Gauge nameplates.

(3) Painting valve control handles to indicated normalvalve position.

b. Piping system designation.Pipes and tubing hav-ing an outside diameter including pipe covering of 20 mm(3/4 in.) or larger shall be identified, and the direction offlow indicated on the piping by means of colored prefab-ricated labels on pressure sensitive self-adhesive clothtapes. The labels shall have black lettering and flowarrows on a yellow background. The labels shall adheretightly and neatly on the pipe. Any labels that do notadhere completely shall be removed and reapplied. Letterand arrow size shall comply with the schedule below:

Outside Diameter of Pipe Minimum Size Minimum Lengthor Covering of Letter of Arrow Markermm (in.) mm (in.) mm (in.)

20-32 (0.75-1.25) 13 (0.5) 102 (4)

38-51 (1.5-2.0) 19 (0.75) 102 (4)

64-152 (2.5-6.0) 32 (1.25) 178 (7)

203-254 (8.0-10.0) 64 (2.5) 178 (7)

Over 254 (10.0) 89 (3.5) 178 (7)

Piping and tubing less than 20-mm (3/4-in.) outside-diam-eter shall be identified with engraved laminated sheetplastic or anodized aluminum flow arrows and nameplateswith standard Gothic lettering not less than 6 mm (1/4 in.)in height similar to the nameplates used on control cen-ters. Nameplates shall be firmly attached to the piping.The markings shall be applied after cleaning, painting,and insulation of the piping is completed. Identificationand direction of flow arrows shall be provided on eachside of walls, partitions, floors, or similar barrier whichinterferes with tracing a line, at all valve locations andnear branch lines. Wherever two or more pipes run

parallel, the designations shall be applied in the samerelative location so as to be in either vertical or horizontallinearity, whichever the case may be. The markings shallbe located so as to be readily conspicuous at all timesfrom any reasonable point of vantage but in no case atintervals greater than 14 m (45 ft).

c. Pipe marking schedule. The following markerlegends are typical:

RAW WATER-DECK WASHING

RAW WATER-GEN COOLING

RAW WATER-THRUST BEARING

RAW WATER-TURBINE BEARING

RAW WATER-GEN GUIDE BEARING

RAW WATER-TURBINE PKG GLND

RAW WATER-AIR COMPR

CO2

CO2-GEN NO. 1

AIR 2590 KPA (375 PSI) GOV

AIR 830 KPA (120 PSI)

AIR 690 KPA (100 PSI) GEN BRAKES

ROOF DRAIN

SPIRAL CASE DRAIN

SPIRAL CASE FILL

TURBINE PIT LINER DRAIN

TURBINE VACUUM BREAKER VENT

LUBE OIL-DRAIN

LUBE OIL-SUPPLY

LUBE OIL-RETURN

LUBE OIL-BYPASS

LUBE OIL-THRUST BEARING

B-3

EM 1110-2-420530 Jun 95

LUBE OIL-TURBINE BEARING

LUBE OIL-GEN GUIDE BRG

LUBE OIL-GEN JACK SUPPLY

LUBE OIL-GEN JACK RETURN

GOV OIL

GOV OIL-RETURN

GOV OIL-SUMP UNIT NO. 1

GOV OIL-SERVO OPEN

GOV OIL-SERVO CLOSE

GOV OIL-TURB BLADES RAISE

GOV OIL-TURB BLADES LOWER

d. Valve tagging. The contractor shall provideapproved identifying tags complete with engraved plastic,aluminum, or brass plates with attaching chain for valvesin the powerhouse. The government will prepare andfurnish to the contractor a list showing the required num-bers, letters, and descriptive information to be used foreach valve and will mark the piping diagrams indicatingtheir location. The list and marked diagrams will be fur-nished to the contractor not later than six months prior tothe scheduled completion of all work under this contract.The valve list will include all operating and isolatingvalves installed under this contract and those which arefurnished with the government-and contractor-furnishedequipment but will exclude check valves, relief valves,gauge cocks, receiver drain valves, valves mounted oncontrol panels, and air and water service connectionvalves. For estimating purposes, the following may beconsidered a typical example of the valve designations:

1 - CW - 1, #1 Generator thrust bearing cooling watersupply.

Valve tags shall be securely fastened to handwheel-operated valves with approved brass-jointed ball chainapproximately 200 mm (8 in.) long, size No. 6, 8 or 10.The chain shall be passed through grommets in the enve-lope, around the valve stem, and the ends shall be joinedtogether with a reusable coupling. In cases where thevalve handwheel is below the valve, the chain shall bepassed through the handwheel rather than around the

stem. On other than handwheel-operated valves the tagsshall be attached by securing the brass ball chain aroundthe valve body with a figure-8 wrap or around a suitablepart of the valve.

e. Painting valve handwheels.Valve handwheels oroperating levers shall be painted in accordance with thefollowing listed colors to indicate the normal position ofthe valve:

Normal Operating Color of HandwheelPosition of Valve of Operating Lever

Closed Red

Open Green

Either Open or Closedor Throttling Yellow

B-5. Powerhouse Electric Water Heaters

The method of water heater selection is as follows:

a. Obtaining volume flow rate sum.From Table B-2below obtain the sum of the volume flow rate served bythe heater.

Table B-2Hot Water Demand

DemandFixture L/s (gph)

Fountain, Wash 1.4m (54 in.) 0.105 (100)Lavatory 0.008 (8)Shower 0.105 (100)Sink, Battery Room 0.021 (20)Sink, First Aid 0.008 (8)Sink, Kitchen 0.010 (10)Sink, Service 0.021 (20)Conversion Factor:

Storage 0.30Recovery Rate 0.20

b. Obtaining tank size. Multiply this sum by thestorage factor to obtain tank size.

c. Standardized heating elements. Since recoveryrate is unlikely to be a factor in powerhouses wheredemand briefly occurs at lunch time and at end-of-shift,heating elements should be standardized as indicatedbelow.

B-4

EM 1110-2-420530 Jun 95

d. Check recovery rate. In the case of public lava-tories where visitor use may be heavy at times, the recov-ery rate should be checked. Multiply the sum of thevolume flow rate (step 1) by the recovery rate demandfactor. If this valve exceeds the capacity of standardheaters, then select other heaters or call for simultaneousoperation of standard dual elements. The heating capabil-ity of standard heaters for a 38°C (100°F) rise are:

2,500-W element - 0.6 L/s (10.2 gpm)4,500-W element - 1.2 L/s (18.4 gpm)

B-6. Capacity of Cast Iron Drain Lines (Water)

The following data are provided to estimate the capacityof gravity drain pipes:

Pipe InnerDiameter

Slope 1% Slope 2%

Velocity Flow Velocity Flow

mm (in.) m/s (fps) L/s (gpm) m/s (fps) L/s (gpm)

102 (4) 0.6 (1.8) 4.5 (72) 0.8 (2.6) 6 (100)

152 (6) 0.8 (2.5) 14.2 (225) 1.1 (3.6) 20 (315)

203 (8) 1.0 (3.2) 31.5 (500) 1.4 (4.5) 45 (710)

254 (10) 1.2 (3.9) 60.9 (965) 1.7 (5.4) 83 (1310)

305 (12) 1.3 (4.4) 97.2 (1540) 1.9 (6.2) 138 (2190)

381 (15) 1.6 (5.2) 181.7 (2880) 2.3 (7.4) 255 (4050)

457 (18) 1.8 (6.0) 299.7 (4750) 2.6 (8.4) 416 (6600)

533 (21) 2.0 (6.7) 454.2 (7200) 2.9 (9.4) 637 (10100)

610 (24) 2.3 (7.4) 662.4(10500) 3.2(10.4) 927 (14700)

686 (27) 2.5 (8.1) 908.5(14400) 3.4(11.1) 1274 (20200)

762 (30) 2.7 (8.7) 1205.0(19100) 3.7(12.2) 1697 (26900)

914 (36) 3.0 (9.8) 1955.8(31000) 4.2(13.9) 2776 (44000)

Assumed Conditions:

1. Water level a top of pipe at inlet.2. Free discharge at outlet.3. Cast iron pipe--coated--good to fair condition. (Also, visitor load applies to concrete or vitrified clay pipe in average condition.)

B-5

D

c

B

A

CORPS OF ENGINEERS VALUE ENGINEERING

c. RAl.

23 010 C.C. RAl.S

U/S P.H. WALL

2 820 IIAX.

n 735 MAX. OVERALL

SEE

t TROLL

RAl.

DETAIL "B"

TOP OF GEN. SHAFT EL. 28 960 EST.

EL. 19 510 lo!IN. RAISED POSITIO<!:NL--f=-.;r

El. 18 590 EL. 17 675 MAX. LOWERED POSITION

fLOW

4

LFT CENTE TYP

ELF ·CLOSING GATE TYPICAL AT N..L ACCESS OPENINGS ON CRANE N4D TROLLEYS

PLAN

PEND .ANT CONTROL (CONTROLS DIS TROLLEY)

GENERATOR FLO

SCALE' NONE

EL. 8 535

.. POWERHOUSE ELEVATION

100 MIN. CLEMNICE BETWEE TROLLEY N'lO HANDRAl. WITH

~:- COioiPRESSED'---i-'i 1--

LIGHTS UNDER ACCESS COVERS JN LOWER WALKWAY TYP.

200

1 370 MAX. TYP WITH TROLLEY BUMPERS AGAINST STOPS .AND UNCOMPRESSEO

f 500 MIN.

FOR ACCESS

BRIDGE TRUCK

1675

c. L POWER COLLECTOR

CORBEL

WILL INCREASE YOUR PROFITS

100 MIN. Ct..EioR.ANCE WITH 9UioiPER JN COMPRESSED POSinON AS SHOWN----...

t GIRDER TYP.

DIS P.H. WALL

EL. 29 415 CRANE BUioiPERS Wl.L BE WOUNTEO ON GOVT. FURNISI 'ED EWBEOOEO

CRANE OLITLJNE

4

-

. ..

;~E:L1~2~/~e~m~--+~~~-r-11-----Ll EL. 28 194 NOWINAL 40

DIA. H.ANDRAl.

~~ :~o~· 27?....:.~4-....:..J.-.1=6--~::::::lb=C:::;Ll WN..KWAY EL. 27 20

1070

TYP. BUMPER & WALKWAY DETAIL CORBEL L EL. 27 200

'100 TYP. EDGE 0 LOWER WALKWAY TO CORBEL

ACCESS LADDER FROM LOWER WALKWAY TO OPERATORS CAB

--

~GIRDER

NO SCALE

END VIEW NO SCALE

ACCESS TO LOWER WALKWAY FROM CORBEL, TYPICAL 4 PLACES

ACCESS LADDER FROM LOWER WALKWAY TO UPPER WALKWAY, TYPICAL

DIS HOIST CONTROL TRN4SF"£R SWITCH

EMERGENCY STOP

DIS TROLL£Y CONTROL

0/S MAIN • AUXILIIoRY HOIST CONTROL

fOOT OPERATED GONG

~~~J::=~~~~~~~B~~P~D~OOR

ELECTRICAL PANEL

DETAIL "A" CAB

NO SCALE

2

U/S MAIN • AUXILIARY HOIST CONTROL

BRIDGE TRAVEl CONTROL

U/S HOIST CONTROL TRANSFER SWITCH

PENDANT TRANSF"l:R SWITCH

4

.d 4

4 .. .d

.....

•

.....

4

t RAl.

U. S.ARMY

100 STL. TUBING W/10 GA. SHT • CONDUCTOR GUARO

'-= CLEMANCE BETWEEN COLL£CTOR loiOUNTING SURF ACE ON CRANE AND fACE OR CORBEL

DETAIL "B" UPSTREAM CORBEL

NO SCALE

CRANE RATED CN>ACITY

MAIN HOIST RATED CN>ACITY HOISTJNG SPEED HOOK TRAVEL

UPPER UWIT - I[ PIN LOWER LlloiiT - j! PJN

AUXILIARY HOIST RATED CAPACITY HOISTJNG SPEED HOOK TRAVEL

UPPER LIWIT - I[ PJN LOWER liMIT - !; PIN

TROLLEY TRAVEL SPEED

BRIDGE TRAVEL SPEED SP.AN

NOTES:

4 003KN

2 002KN 19.1-21.6mm/. 32 3ID WIN. EL. 27 430 MIN. EL.- 4878

267KN 140 TO 160mm/• 36 730 MIN EL. 27 890 loi1N. El.- 8840

11125 180 TO 230mm/a

270 680 460 TO 5!10mm/a 23 0'10

1. PROVISIONS SHOWN ARE TYPICAL fOR AN 8-UNIT PL.ANT. INITIAL INSTALLATION OF 4-UNITS AND FUTURE INSTALLATION OF 4-UNITS.

2. SEE COVERAGE OIAGRAiol PN:iE. A-19.1.

ALL DIMENSIONS ARE MILLIMETERS UNLESS OTHERWISE

HYDROELECTRIC DESIGN CENTER NORTH PACIFIC OIV •• PORTLAND. OR

IN NOTED

D

c

B

~~~~~~~~---,----------------------------------------~A

SUBWITTEO:

Figure B-1 . Bridge crane clearance and coverage (continued)

Gl£NN R. MELOY, P. E.

D

c

-

B

A

CORPS OF ENGINEERS

5 4-5 TYP.

23 010 rM

c. c. RAILS

11125 TROLLEY

4

VALUE ENGINEERING WILL INCREASE YOUR PROFITS U. S.ARMY

D

fl.. OW

t

267KN AUX. HOIST COVEIUIGE

HATCH~. EACH~

c

ERECTION BAY GENERATOR BAY SERVICE BAY

----~--------------------------------------------------------------------270 ~ B~DGE TRAVEL.------------------------------------------------------------------------------------~

POWERHOUSE DOOR

CRANE COVERAGE DIAGRAM SCALE• NONE

UICROSTATION VER 4.0

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER

B

NORTH PA.clFIC OIV., PORTLAND, OR loc~.~~o~.----,---------------------~------------~1>.

Figure 8-1. (Concluded)

SUBIMTTEO•

GI.Dii R. MELOY, P. E.

CORPS OF ENGINEERS I VALUE ENGINEERING WILL INCREASE YOUR PROFITS l

D

c

--+

B

A

~-------------------------------------------3454-----------------------------------------------------i

~-----------------------------------1676 ------------------------~

·r~""' 371 ""lr------------------------------1 f-+-

FLOW

-

- ] ,l_ --------------- 8H-- --- --- --d-

- -_j

PARTIAL PLAN VIEW

u

BL._

t LIFTING SECTION A-A BEAM

SCALE• NONE -FLow--

+ f-1-

I I I

I /~ I

I I

I I

I I

W-

VIEW B-8 SCALE' NONE

4 I 3

~

- -14 9

18 ..........

J 17

lJ

111 / ~

t

-

_..,......:tl JJ. JJ

i'---" ~

,____

-

STOP FOR COUNTERWEIGHT

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

~

~ ~

---------~ ~

77r.rn

SECTION C-C SCALE' NONE

2 I

U. S. ARMY

PARTS LIST ITEM QTY. DESCRIPTION NO.

1 1 BEN.I

2 2 LATCH PIN

3 2 LATCH LOCK

4 2 MALE CLEVIS ~---+----~------------------------------------~ D

5 2 JN.l NUT, 3/4 16-UNF-28, <MATERIAL ---)

15 2 JN.l NUT, 1- 12-I.JNF-2B, (MATERIAL ---)

7 2 LATCH LOCK CLEVIS

II 2 LATCH LOCK CLEVIS PIN

II 12 RETAINNG RING, THRUARC •4100-75-H OR EQUAL

10 1 LATCH ARM

11 1 BELL CRANK ~---+----~------------------------------------~---

12 1 LATCH ARM

13 1 KEEPER

14 2 LATCH ARM CLEVIS PIN

15 2 CLEVIS PIN

115 2 BELL CRANK BUSHING

17 1 BEll CRANK SHAFT

111 1 BELL CRANK SPACER

Ill 1 BELL CRANK SPACER

20 2 HEX. HO. CN> SCREW, 10-16 UNC-2A X 2S,CMAT'l,---l

WITH lOCKWASHER

NOTES: 1. LIFTING BEN.l SHOWN IS USED WITH INTAKE GANTRY CRN£

TO LIFT INTAKE GATES AND BULICHE.<DS.

2. LIFTING BEN.l DRAWINGS SHOULD CONSIST OF" AN ASSEiollll Y DWG., F"RNolE DETAIL DWG. AND PARTS DET All DWG.

3. MATERIAL IS SHOWN ON DETAIL OR PARTS LIST.

4. LINE BORING TO BE DONE AFl'F.R FABRICATION OF FRI\IoiE WELDMEMT.

5. THE LATCH MECHANISM CONSISTS or A COUNTERWEIGHT, A BELLCRANK. LATCH AR!ijS, lATCH PINS, AND LATCH LOCKS. THE LATCH LOCKS CAN LOCI< THE loiECHANIS!ij IN EITHER THE LATCHED OR UNLATCHED POSITION. BOTH GATE liFTING EARS loiUST BE PROPERLY ENGAGED IN THE LIFTING BEAM TO RELEASE BOTH LOCKS BEFORE THE iijECHANISiol CAN BE t.IOVED. WHEN BOTH LOCKS ARE RELEASED, THE LATCH MECHANJS!ij CAN BE ENGAGED BY iijQTION Of THE COUNTERWEIGHT, OR DISENGAGED BY THE LATCH MECHANISM.

6. THE LATCH RELEASE MECHANISM CONSISTS or A DUAL-TORQUE (OR TWO SINGLE-TORQUE) TORQUE MOTORCSI CONNECTED TO A SMALL HOIST DRUM WITH C,IBLE TO OPERATE THE LATCH MECHANISM BY RAISING THE COUNTERWEIGHT. WHEN POWER IS OFf. A SPRING-SET, MAGNET RELEASED BRAKE PREVENTS DRUM ROTATION. WHEN POWER IS ON, THE BRAKE IS RELEASED AND THE TORQUE MOTOR IS ENERGIZED AT lOW TORQUE TO KEEP THE HOIST C,IBLE TAUGHT DURING BOTH RAISING AND LOWERING Of THE LIFTING BEN.l. TO UNLATCH, DR TO HOLD THE MECHAN!Siij UNLATCHED. THE TOROUE lijQTOR IS SWITCHED TO HIGH TORQUE WHICH LIFTS THE COUNTERWEICHT AND RETRACTS THE LATCH. THE LIFTING BEAM MAY BE MOVED EITHER UP OR DOWN WITH THE TOR QUE iijOTOR!Sl AT EITHER HIGH OR LOW SETTING. WHEN THE TORQUE MOTOR IS SWITCHED FROil HIGH TO LOW TORQUE, COUNTERWEIGHT lOWERS AND THE LATCH ENGAGES •

HYDROELECTRIC DESIGN CENTER NORTH PACIFIC DIV., PORTLAND, OR

B

--

·~Wt.~~oft.,-----,--------------------------------------~ A

Figure B-2. Intake gate and bulkhead lifting beam

GLENN R. MELOY, P. E.

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I 1 U.S. ARMY

PARTS LIST ITEM QTY. DESCRIPTION NO.

1 12 ROLLER

2 24 SLEEVE BEARING

3 24 PI..AIN WASHER, 211 D x .311 00 x 4.8 O•IATL--1

4 • SPN:ER, 2~ STO. PPE x '18.8 LONG

D D 5 12 KEEPER

• 24 HVY LOCK WASHER, 10. CIIAT'l --1

7 24 C» SCR£W, 10 - 11 UNC-2A x 20, INAT'l ---l

II 4 ROLLER SHAFT

1- • • ROLLER SHAFT

I

51120 OUT TO OUT ROLLLRS ll!EFl T I 10 • SPICER, 2~ STO PPE " l5.1LOHG

2810 IREF.l 11 • SPN:ER, 2~ STtl PPE X 511.4 LONG -

I . -

12 1 TWO L£G 8RDI..E SUiG - WICICWIRE ICF • ll ASSEJ.I9L Y "A" WITH STYLE TOS

I I LEGS, 2440 LONG x 25 VERY IMPROVED PLOW STEEL WITH IWRC WR ROPE OR EQU..._ c 4 I I~~ I I I I I

13 2 HOOK u--. ~I 14 2 HOOK SHAFT

L _j I l5 4 HOOK BUSHNG

A A ,. 1 BELL CRNiK SHAFT

c PARTIAL PLAN VIEW 17 8 RETM'l~NG RING TRUARC -5100·75-H OR EQ. c

SCALE: NONE 1 2 3 4 I! 111 2 LATCH ARM

,. 3 KEEPER

f ( ~'\ 20 1 ROPE POLYPROPYLENE 1S DIA x 23000

~ ./ 1111. -R-24849A

fl\ 21 1 BEJN

'-..1/

~ r 22 1 BELL CRANK • COUNTERWEIGHT - 23 2 LATCH ARM ClEVIS PIN 1-24 2 BELL CRANK BUSHING

1491 IREFI {1.AUJ.l.n.T 12

1575 (REf)

1~~1CE TO EYE OF

25 2 ClEVlS I'W _,7 BEt

21 II CAP SCREW, 10 X 2S,IIoiAT'l---l COUNTERWEIGHT

~ Win! LOCKWASHER G..._V.

~ B r--~ ~ I"J:'-,. /T lg NV \.l

#~ ..# ~ .I __--J' \

NOTES:

"" I 1. LFTNl BEAiol IS TYPIC..._ FOR I.FTNl TJW;H RJICKS.

B B

~ 1"'1-:::.. \ l!lU<HEAOS, GATES ANO STOPLOGS. WEIGHT OPERATED

\ rJ_ I' ' LATCHING ANO liANUAL RELEASE CRANK LEVER HANOLE WEIGHT PROVDES TORQl£ FOR LATCHING. TAG LWE

...........

~ ~ ~ ~

PROVDES IIEANS FOR IHJ.TCHNG.

'"I~x·.o~ 2. ''SKIN PLATE" DESIGNATION REFERS TO BUU<l£Ail SKIN

f---- PLATE FOR PROPER ORIENTATION OF BEAiol.

~----~- 3. UFTING BEAiol DRAWINGS SHALL CONSIST OF AN ASSEioiBI. Y DWG, BEAiol DET M. DWG, AND PARTS DET Ill. DWG.

4. loiATERIJIL IS SHOWN ON DETAIL OR PNITS UST.

END VIEW 5. UNE BORINC TO BE DONE AFTER FABRICATION OF FRJNE

v~ WELDMENT.

~E•NONE 1524

111 ALL DIMENSIONS ARE IN - 2618 c... MILLIMETERS UNLESS NOTED -

II ~~ OTHERWISE ELEVATION SECTION A-A J Ol ~ sc~•NONE

-SECTION B-B -SC..._E•NONE - -- ..... - -HYDROELECTRIC DESIGN CENTER

NORTH PACIFlC OIV., PORTLAND, DR A A ...,..,_.,.

'""'- Figure 8-3. Lifting beam ~

.....,._.,. manual hook release type

SUBWITTED< 8CAl..Z: Aa SHO- ~~-GLENN R. IEl.OY. P. E. --

4 I 3 t 2 I 1

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I , U.S. ARMY

OIL STORACE T IH< LP HEADER -t8:]-' IIANUAL. SHUT-Of"F VALVE - NORioiALL Y OPEN

LP ' t~ 181- IIANUAL. SHUT-Of"F VALVE -NORMALLY CLOSED

r-0-J >0 LP EXPN>ISION JOHT

~....--- ( ).?481 S1 ff' EXPNISION JOINT 1!5

~z t~ i LINES TlflU HEADWALL

t - FLL OR

"-TO ORMI

&:1 ~ \LP lODER 0 0

NTN<E OECIC .__

&:1 NOTES:

~¥ ~ J~ 1. SYSTEM SHOWN IS TYPICAL OF A 15-IHT KN'I..AN PUHT

I l ' I WITH 3-GATES PER !.HT,::I UNTS t4 Nn.-1.. t4STIU.ATION AND 3 FUTURE !.HTS.

IL ~

~ij_ ~ ~_j ~ ~ij_

~_j ~ ""-""

~ ~_j ~ 2. GATES ARE NORNAL1. Y SUPPORTED N OPEN POSITION BY 01.

~LP N CYLINDER WITH SYSTEiol PRESSURE IUiiNT At4ED ABOVE WNioiUU NO-DRFT PRESSURE BY PRESSURIZJ,IC UNT.

3. 2 LOWERING VALVES CONNECTED N PMALLEL LOWER ALL

LP ~ 3 GATES Willi AUTOMATIC BACK UP FOR NOIPERATIVE VALVE. VALVES SHOWN ARE 4-WAY VALVES CONNECTED AS 2-WAY

ELEC. FOR HIGHER FLOW CN'.ABI.ITY. -- PIMP PF" WTR. TO FUTURE L.NT e It~ t~ E' It~ 4. loiNAJAL RAISING VALVE IS NORNAL1. Y OPEN EllJT IS CLOSIED PRECEDING NORWAL. GATE CLOSURES IH:) FOLLOWING EloiERGENCY CLOSURES. LP

~~ --c8}-0ff' ~ I~ 5. FOR CYl.NOER DETM. SEE PAGE A-23. .., J ~) I \D I I

~ .J 1 """" I ......,. J

"' 15. GRAPHC SYWEIOLS ~ CONFORiol TO NISISTADN!OS.

""'"""' \ ~ I I \ "--"' GALLERY

/;----- ---UM_OADING VALVE

\_..,HEADER

POW!ER UN~ \L~. "'-CONTROL PANEL

ALL DIMENSIONS ARE IN '--.--v-!TYPICAL I MILLIMETERS UNLESS NOTED

c CHECK VALVE OTHERWISE c BAY 3 BAY 2 BAY 1

_..............RELIEI' VALVE SYSTEM DIAGRAM t ~ ~DRAIN OR [PRESSURE COI.IPENSATED FLOW CONTROL VALVE ITYPl PURIFIER

rSOLENOI) OPERATED PLOT VALVE !TYPl

'-- DRAIN LtiE \ JPLOT OPERATED 2-WAY LOWERING VALVE ITYPI SEE NOTE 3 rCONTROL PANEl.

~~ - 110 LP, HEADER

'

\ I I I - t~ - ---+

\ I I t i+-LP LP

~ I fLP ~II I ~I I ..,..,.. t (S} ..,...,., "-"' ~ "'-""

POWER UNIT DIAGRAM ......,. .., I Ill ~ ~ I~ ~11 ~ - .., ~

ff' ......,.

I ~

i~~ ~ ~

6~ ~ "-""

?~ B ~

1 LP ,'i ~ _j IJ. .ll L

HF T T IT t t T T T t .., - II It ....

B

II ff' - B

.... 1 1 FLT

--c8}-0LP 11 1 = t'---U«AGE =I .tl• IP LP _Ij ~ LP~

'-"'=' I T 1

ELEC. I , .., ~ LP PUMP PF" WTR. 32 If> HEADER

' I -- L • . O:J • . . . . . . .. . . . . . . . · .. . . : . . . . . . . . . . . . . . .. . . . \ -. .

~ ... ~~

~ - - ~

t~ - ...,...,.. ~~

""-"" ~ ........ I -CHECK VALVE

L,.~ ....... ~ -

[)\ [)\ A - -- .... - -

--B VALVE SEE NOTE 4 HYDROELECTRIC DESIGN CENTER

1

NORTH PACIFIC OIV •• PORTI..AND. OR

3 2

A A PRESSURE SWITCH ~

OfUWNo Figure 8-4. Intake gate hoist CH£CI<EZ>O

GATE CONTROL DIAGRAM PR£J> ....... hydraulic system

tp t SCA..£S M ..,_. 1#11£ BASED ON M ..,. SIZE

PRESSURIZING UNIT DIAGRAM ORIQirUIL. na Dlt'JIIII: I!UtY HN1E IEDI JI£DUCfD.. SUBNITTED< ~..W..OWM I...,... NO. ~ ICM....E rt U.C CRAPtiC SCIU: INL

IIICROSTATION VER 4.0 Gl..EH'I R. IIEl.OY, P. E. --

4 I 3 i 2 I ,

D

c

a

A

SECTION A-A SCAlE' 1'!~

lB120 CPISTON LATCH ENGH>Eil WITH PISTON!

11010 I SPACES e 1II3S

CYLINDER 8c SUPPORT BEAM ASSEMBLY SCALE• 1•20

921 TYP

PARTIAL SECTION SCALE• 1•10

VIEW A-A SCAI..E'Ni

f'OR ASSEIABl Y DETAL SEE SECTION A-A

MICROST ATION VER 4.0

NOTES: 1. CYLINOER SHOWN IS TYPICAL f'OR A 11-lNT KN'l.AN PLANT

WITH 3-20" X 50" INTAKE GATES PER lNT. NOt.IINAI.. SYSTEM. HYDRAIA.IC PftESSURE-2000 P.SJ. MAX. PRESSURE-3000 P.S.l.

2. CYLt«lER ROO COUPLED TO INTAKE GATE STUB ROO WITH SPECIAL COUPI..JNG NUT.

3. CYLINOER PISTON LATCH IS OPERATED WITH EXTENOEO T·WRENCH ANO IS USED TO SECl.RE GATE IN OPEN POSITION. f'OR MAINTENJiNCE ANO FOR RAISING GATE - CYLINOER ASSOIBI.. Y WITH INTAKE GANTRY CRANE.

4.1U.TERIAL IS SHOWN ON DETM. OR PARTS LJST. 5. SEE HYDRAlA.IC SYSTEW DIAGRAW PAGE A-22.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

Figure 8-5. Intake gate hoist --~==! cylinder assembly

D

-

c

B

-

A

CORPS OF ENGINEERS

4

~ 4

4

.d

~

4

4

4

4

4

11

4

.d

4

A

~

4

r+-4

~

.d

4

.d

TOOL ROOM

• SMALL PAATS

STORN:l£

X V "II

HOOD/ 1200 X 2 400 WELDING T ASI.E

.300-PORTABLE

WELDER

I

4

VALUE ENGINEERING

1 200 • 2 400 WORKBENCH ,.,, 7 ~-~~ ..... /

\

1 800 • 900 WORK BENCH WITH TOOL GRINOER

~PEDESTAL l__j ~'~

356 LA

MAINTENANCE 8c ELECTRICAL SHOP

I '-=~ I

4 4 4 4

r I

PLAN

WILL INCREASE YOUR PROFITS

... v

"-T--

4r-------------~d--~

4

~ ~

L_

41

4

4 A

-;;,

/I

I I I ,,

- ~

~

2

l

! FLOW

~ ~ ~~ ~ 0 0 0 ~ ~~ ~ ~Y:

I. .1. ERECTION

BAY CDIERATOR

BAYS

KEY PLAN

! ~ POWERHOUSE BRDGE CRN£ ~ N.JX HOOK COVERAGE

NOTES: 1. MRANGEioiENT SHOWN IS TYPICAL Of' A IHNT

PlANT LOCATED ABOUT 2 HOURS TRAVEL T1UE fROU COMMERK:AL l.t~ SHOP F ACI.ITES.

2. MAINTENANCE SHOP IS LOCATED ON MAIN ERECTION ELEVATION. RELATIVE PUNT LOCATION IS INDICATED IN KEY PUN. POWERHOUSE BRDGE CRANE PASSES ABOVE SHOP CEiliNG PROVDING AI.JXI..INn' HOOK COVERAGE TO SHOP DOOR.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

U.S. ARMY

1r-

SKELETON BAYS

-

D

1-

c

I+-

B

-

HYDROELECTRIC DESICH CENTER NORTH PACifiC OIV., PORTIJHD, OR

~~==~==~~--~------------------------------~A

l

Figure 8-6. Maintenance shop arrangement

Cl..n.l R. IIELOY, P. E.

D

c

--+

B

A

CORPS OF ENGINEERS VALUE ENGINEERING WILL INCREASE YOUR PROFITS

250

115

32

300

50

300

.----------- AIR COOLER VENT HEADER

,------- GENERATOR AIR COOLER

25 25

300

20

IN CASE

AIR BLOWOUT

TYPICAL MAIN UNIT SHOWING GENERATOR GUIDE AND THRUST BEARING COOLING WATER

NOTE 8

EL 10 1170 =NORMAL

- WAX. T.W.

EL. 2 591 -=- MIN. T.W.

250

300

TO DRAFT TUBE EL. -16 450

300

STRAINER STRAINER FLUSH TO DRAFT TUBE

300

TYPICAL MAIN UNIT SHOWING TURBINE GLAND TURBINE BEARING COOLING WATER

2

300

300

AND

MICROSTATION VER 4.0

U.S. ARMY

SYMBOLS 1><1 GATE VALVE

I><J GlOBE VALVE

N CHECK VALVE

~ ANGLE V AI.. VE

~ BUTTERFLY V AI.. VE

,......,.._ BALL VALVE W/ UNIVERSAL ~~'"r-~-AI_R_HO_S_E_C_~_E_C_T~_N ______ ~D

MOTORIZED BALL VALVE

VENTURI TUBE

PULP STOCK VALVE

ORIFICE FLANGE

FLOW METER

COOLING COL

REDUCER

• SELF -CLEANING STRAINER

DfS) DIFFERENTIAL PRESSURE SWITCH

~ PRESUURE CAGE

E§i3 INTAKE GRATING

3-WAY. 2-PORT,IKl' PLUG VALVE

SLEEVE TYPE COUPLING

CENTRlfl.JGAL PUll!'

THERWOWETER WELL

HOSE ADAPTER W/ Clf' • CH.-.N

NOTES: 1. SYSTEM SHOWN IS TYPICAL OF AN 8·UNIT Klf'LAN PLANT WlTH

GRAVITY SUPPLY fROM SPIRAL CASE TO GENERATOR f>HJ TURBINE COOLERS.

2. RAW WATER HEADER SUPPLIES COOLING WATER FOR HEAT AND VENT, RAW WATER SYSTEMS AND STANDBY WATER TO UNIT WHEN STAINER OR INT AKf' IS OUT OF SERVICE.

3. PROVlOE A WARM WATER HEADER CONNECTING TO AT LEAST 3 UNITS WITH t.IODULATED AIR COOLER FLOWS WHEN HEAT f>HJ VENT SYSTEM REQUIRES A WARM WATER SOURCE.

4. UNSHADED VALVES • NORIAALL Y OPEN, SHADED VALVES NORMALLY CLOSED.

5. FOR RAW WATER SYSTEM SEE PAGE A-3

II. FOR COOLING WATER SYSTEW IN SMALL HIGH HEAD PLANT SEE PAGE A-2

7. POTABLE WATER SYSTEM HAS CURRENT FULL RELIABlUTY FOR GLAND WATER

II. HIGH POINT OF' VENTED l)jSCHARGE LOOP SHOULD BE ABOVE NORMAL MAX.TAILWATER AND ABOVE l)jSCHARGE RING HEADER.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER

B

NORTH PACIFIC OIV .• PORTLAND, OR ~~~~~~~~--.--------------------~ A

SUBNITTED•

Figure 8-7. Main unit cooling water system (Continued)

GlDii R. loiE!.OY. P. E.

CORPS OF

D

~ "" .... g u

"' 011:

-~ Jh

-

c

t

B

A

ENGINEERS 4 I

n I GEN UPPER GUIO£

AND THRUST BRG.

~ I

tf -- -t- "" "' g UNIT 2 "il !i

.l~

.f--sJ GENERATOR LOWER r

GUIDE BEARING

s-~

I

s-

s-

.L x

VALUE ENGINEERING

- i:L i ~

15 8 u

15 ~

c___-{i~

WILL INCREASE YOUR PROFITS

n I GEN UPPER GUIDE I

N4D TfflUST BRG.

I

UNIT 1

r ¢ --

t

-~-~~~~--------------;------------L---4--~~

' ~g --

12S

' r---

....... I GENERATOR LOWER I GUDlE BEARING

so

32

-I ... A I ,.....,.

125

•

I

EL. 478 755 OlSCHAAGE TO TALWATER

__ IIAX. TALWATER -= EL.I7 500

25 --r-~----------------;---------------------------~~~----------~T~~~NE~~~~SUF'~~~y~~~~~~~--r-~--r--t-----------------r------~--~~------~-----------3-2 ______________ ~~ ~~~~R~~~~

(,. J TURBINE BEARING r -)

Yj GLAND I I RUNNER )

l..._,'-------J

200

TAIL WATER INTAKE

t El. 4119 540

125

' UNIT 2 COOLING

125

125 TO HI.V WATER

SYSTEW

TO RAW

WATER BOOSTER

SEE NOTE 3

TO POTABLE WATER

SYSTEW

TO RAW WATER SYSTEW SEE NOTE J

I

so

125

127 ~ 12 STN>IDBY UNIT 1 UMT COOLING COOLING

125 125

125 125

SEE rNOTE 5

200

~r· 200

RAW

I

WATER PUMP ROOM EL. 469540

t

.4e,E NOTE

I RUNNER )

~......_____,

200

WlGROSTATION VER 4.0

i 2 I

1 u.s. ARMY

SYMBOLS C><J GATE VALVE

t:<l GLOBE V .AL VE

N CHECK V .AL VE. SWING

~ CHECK V .AL VE, LIFT

cfl:J BUTTERH Y VALVE

[';ala 111U. V.II.VE WI HOSE ADN'n:R WI CJf' - Ql.flj

• SINGLE BASKET STR,t,INER

t SIGHT FL.NNEL

[>+- WATER INTAKE, GRATED

0 CENTRlFUG.AL PUMP

ill ORIFICE FLANGE

IEH FLOW IIETER

a SLEEVE TYPE COUPLING

&l ANGLE VALVE

NOTES: I. SYSTEI.I SHOWN lS TY~ OF A 2-UNIT IFRANClSl PLANT

WITH PUioiPEO SUPPLY FROM TAL WATER PROVIDING .ALL PLANT WATER REQUIREI.IENTS.

2. FOR F'OT.ABLE WATER SYSTEII SEE PAGE A-5.

3. FOR RAW WATER SYSTEM SEE PAGE A-4.

4. FOR COOLING WATER SYSTEM IN LARGE LOW HEAD PLANT SEE PAGE A-1.

S. !-EAT • VE!o!T SYSTEW IN THIS PLANT UTILIZES RAW WATER FOR COOLING COILS.

II. UNSHADEO V.ALVES-NORio!ALL Y OPEN, SHADED VALVES -NORI.IALL Y CLOSED.

7. TEES FOR INTALLATION OF FUT~ FILTER IF REQUIRED.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER

D

:-

c

1+--

B

-

NORTH PACIFIC DfV .• PORTLAND. OR ~~~snQC..,~~---,--------------------~--------------~A

Figure 8-7. (Concluded)

SUBio!ITIEO:

~ R. WELOY. P. E.

CORPS OF ENGINEERS

D

p 40L­

-I~ 1 eo --+-,-----;

c

B

A

'

KITCHEN SINK

15 15

I~ BATTERY ROOM SINK

32

TO TURBIN GLAND WATER SUPPLY SEE NOTE 4

80

25

40

SAFETY SHOWER

I VALUE ENGINEERING WILL INCREASE YOUR PROFITS VENT ./1 EL. 4111490 ..../ 1.__ __ 1o_o __ --.-~

I

80

r eo

I 65 VENT~

85

50 100

WATER CLOSET WATER CLOSET

80 !MOP DID['J a:e- 32 Lr~ 32 ~ VVENT 80

eo WASTE LINE~

80

80 100

80 ( )

J

100

EL.481 280~ DISCHMGE SUMP W F AIR TIGHT COVI::R

v _:_VERT EL. 4eo 590

LTO SEWAGE DISPOSAL SYSTEM

.--­'------'

~ """ ~ EL.472 470

.---. ~

U. S.ARMY

SYMBOLS

1><1 GATE VALVE

[::<} GLOBE VALVE

N CHECK VALVE, SWING

~ CHECK VALVE:, LIFT

l><}o GATE VALVE WI HOSE CO!H:CTlON

Y SlCHT FLNNa r-~=-r-------------------~0 ~ SOLENIOO CONTROLLED VALVE:

~ THERMOSTATIC CONTROLLED VALVE:

[I THERMOI.IETER

@-- CLEANOUT

A SHOWER HE..O

0- PRESSURE GAGE

~ PRESSURE RELIEf" VALVE 1-

!:J PRESSURE • TEMP. RELIEF VALVE:

~ PRESSURE SAFETY VALVE

BP~ BACK PRESSURE VALVE

~ SPRING LOADED VALVE, FOOT CONTROLED

~ BUTTERFLY VALVE

WATER HEATER

0v-HIGH LEVEL ALARM

I:8Ee] BACK FLOW PREVENTER

25 151 LITERS

HOT WATER

ELEC. WATER COOLER

.----

~POTABLE WATER

50

.. .....

~ !.-..__EL.41!1 51!4

l

SHOWER

... ...

I

SANITARY SYSTEM

URINAL

20 WATER

»~~~~ LAVATORY

MOP

5? lT I I

I 25 25

20 I 15 I 15 I

40

TO PRESSURE SWITCH

r ~J,FRDM SERVICE AIR SYSTEM

SET a 760 KPA)J ~7 ... ""' ' '->-

DETENTION TANK I .._... ~ rv-"l:::~ ..... 80

~ M 50 15

!"-.-SEWAGE LIFT STATION

-

80

........ = .... ~ .......... \......_/........ '

PUI.IPS

v-...; =V V>o..__, I

,........ '

~ PRESSURE REDUCING VALVE W/ STRAINER C

(]j-o PLUG VALVE, 3-WAY 3-PORT, HOSE CONN.

rP TEMPERATURE RELIEF VALVE

~ ELECTRIC WATER COOLER

~ PRESSURE SWITCH

-@- SIGHT CLASS

o:u;:) LIQUIO LEVEL CONTROL

....2-. Y·TYPE STRAINER

-6- COCK, WRENCH·HE..O, 2-WAY

NOTES: I. SYSTEMS SHOWN ME TYPICAL OF A SMALL PLANT USING

TAILWATER AS A SOURCE FOR POTABLE WATER AND DISCHAAGING UNTREATED POWERHOUSE SEWAGE TO A PROJECT TREATioiENT PLANT.

2. Tf!lS SYSTEM SUPPLIES POT ABLE WATER TO OTHER PROJECT FACILITIES.

3. WATER COOLERS AND BATERY ROOM FIXTURES DRAIN TO TAILWATER OR DRAINAGE SYSTEW.

4. FOR GLAND WATER SYSTEM SEE PAGE A-1 AND A-2.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

B

-

1136 LITERS

L L c

'----

~2911 LITERS

80

100

{

SOLUTIONtCROCK WATER t.IETER

~ ,7 @o~----C::.~-+--:=>----\(~ HYPOCHLORINATUIJ /. ~

DRAIN_/ [:::...., ~

PRESSURE Fll TER -

HYDROELECTRIC DESIGN CENTER NORTH PAClFlC DIY., PORTLAND, OR

~~~s~~~~~-~------------~------~--------------~ A

32 .. ~

100 HYDROPHEUMATIC TANK~ POTABLE WATER

y TO SERVICE BUILDING AND RECEATIONAL FACILITIES SEE NOTE 4

SYSTEM

80

MUL TIPORT VALVE

Fll TER BACKWASH • RINSE TO TAILWATER

MICROST ATION VER 4.0

2 l

, ... __ Figure B-8. Potable water and sanitary systems

GL£HN R. MELOY, P. E.

CORPS OF ENGINEERS

D

c

-+ ~~CTION

B

40

65

1:40 T-'ILWATER OECKWASH

ERECTION BAY BAYS 1,3,5,7

DECK EL 27 430 • • 4 a

'-P' ' ~ 40 OR-'IN

--o

----.+..-------1----iiOE;=CK El. 1& 7&0 . . .

- 15J DRAIN

40 TYP.

~EL.1J 110

~EL.II530

--i><l----c EL. 1 525

...

1----"• 'y· ,___ so

f---STRAINER FLUSH LINE

50

~TRANSFORio£R SPRAY HE.tiOER \ IN El. 1 525 GAILLERY

I

40

VALUE ENGINEERING

40 TM.WATER r: DECKWASH HOSE CABINET -'Ill BAYS EXCEPT S.B. . . . ·.

'-f/ f '---- 15 DRAIN

20 TURBINE PIT TYPIC-'ll

25

-----r I AFTERCOOLER I

'

20

I 20

T

WILL INCREASE YOUR PROFITS I

25 20

t-- 20 20

AFTERCOOLER I I AFTERCOOLER I AFTERCOOLER J ,-1

0 ~ ~~ L..L-------1

~ ~l....L.--.::..:;__20 ---l 15 2D

SERVICE AIR COMPRESSORS

2D

TO UNWATERING PUioiPS PRE -LUBE

' EL. 1 !12!1 G-'ILLEIIY POTABLE GLAND WATER HE.tiOER SEE NOTE 4

fi5 '

TM.RACE OECKWASH HE.tiDER El.152!1 G-'ILLERY

(SERVICE BAY!

TO DRAINAGE PUioiPS PRE -LUBE

40 TYPIC-'ll

E~ 40

E~ SERVICE

T

40 BAY

c--t><l- 50 EL.1 525 ~

7 .1:1.

... ...

... ...

as

50 ~L------J~----------------------~~~~---L-~--------------~E~L~.-~10~3~6~0~----------L_-------~~-------------------------------------J~ 4D

A

,-I

I I I I I I I I

BAY 5

- -r---

..........

~E~NOT£ ~

DRAIN

--

DRAIN

LOCATED BETWEEN INT .tiKE GATE N<0 BULKHEAD SLOT

2.50

-I

I I \720

~OWOOJT I

EL. 6 1DO

~

20 I I I I I I FLUSH TO

TAIL WATER ______________ _j

I

)

i 2

40

GATE REP .aiR PIT

MICROST ATION VER 4.0

I

20

U.S. ARMY

SYMBOLS l><l GATE V-'ILVE

[:::<] GLOBE V .all VE

-f!> 3-WAY 3-PDRT PLUG V-'ILVE

~ BUTTERF1. Y V .all VE

[;x:x:Jc B.llL VALVE WI l.NVERSIL ~ HOSE CON\ECTlON

_®. MOTOR OPERATED B.tlll V-'ILVE r-~~~t---------------------------10

l)i<j SOLENIOD CONTROLLED V .all VE

---J>i<jl THERI.KJSTAT CONTROLLED V .all VE

-0- PLUG V-'ILVE J-WAY 2-PDRT 18D"

N CHECK V-'ILVE

>- INTN<E

• SELF-CLEANING STRAINER

,......C... Y-TYPE STRAINER -

r-r.-+----------------------~ ® AIR COMPRESSOR

~ BACK PRESSURE VAILVE

t SIGHT F1HIEl

--- FLEXBLE CONNECTOR

--o HOSE .tiDN>TER W/ C-'IP • ~

r-~-r-------------~c '[_ THERUOioiETER WELL

~ INTAKE GRATING

~ PULP STOCK V-'ILVE

• SINGLE BASKET STRAINER

~ ELECTRIC THERMOSTAT

~ ROTOR V-'ILVE 3-WAY 2 PORT 90"

~ OlFfERENTI.tll PRESSURE SWITCH

NOTES: 1. SYSTEiol SHOWN IS TYPIC-'ll Of N< 8-UNIT KAPLAN PLANT WITH

INTAKE STRUCTURE AND GATES PMT Of THE POWERHOUSE.

2. FOR RAW WATER HE.tiDER SEE PAGE A-1

3. .all TERNATE INTAKE FOR OECK WASH .tiNa TRANSFORtoiER SPRAY PUMPS WOULD BE RAW WATER HE.tiDER.

4. POTABLE WATER IS SUPPLED FROM LARGE GRAVITY TANK. <NON-POWERHOUSE)

5. DECK WASH HOSES PROVIDE BACK-UP FIRE PROTECTION. TRANSFORIAER SPRAY PUMP PROVIDES BACK-UP FOR OECK WASH PUMP.

6. UNSHADEO V-'ILVES - NORW-'ILLY OPEN, SHADED VALVES NORWALL Y CLOSED.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC OES1GN CENTER

-

B

-

NORTH PACiF1C OIV., PORTLAND, OR l~wso.~~~~--r---------------------1 A

SUENTTED:

Figure 8-9. Raw water system (Continued)

GLENj R. MELOY, P. E.

CORPS OF ENGINEERS

20 I I I - I

D

-~'!' I <7

;.. _/

I ~7 ' ~ I. I

J~ '7 ~

I

j

~ '--

~ I

15 ~7 &5 ' NR

COot ED

J-.,-'1_ ~ n UNWATERING • DR,tjNAGE

PUt.IP PRE -LUll£ c

GOVERNOR AIR

a

A

VALUE ENGINEERING WILL INCREASE YOUR PROFITS

40

I

\ DECK BASE CABINET

~- ~ ..... "" ~ ""1~

50 1~ 15 40

CLOSES WHE~~ PUt.IPS OPERATES ~

..... 15

TO DRAIN

DECKWASH PUMP SEE NOTE J

50

I 40

I ' ~ -

I I. 25 7 ;..

I ~~ <$) ·d w ~7 '

~ I 2~ ~ '

I '7 ~

L.._

•}

t' SEWAGE PUI.IP '15

ij] !

AIREA

..r:.

b @) WATER COOLED

SERVICE AIR

20

50 -~2~ ........ r

TURBlNE FLOOR

~7 ·~20

20 TURBINE PIT

UNIT 2

-

50

..(f) IJ~ECKWASH PUt.IP I~ ~EENOTEJ

.L....__ FROM GENERATOR COOLING WATER SUCTION HEI\DER SEE NOTE 2

i

WATER TF!EI\TMENT ROOt.l

20 n-~

'7 1.~20

20

TURBINE PIT

UNIT 1

--COOLING WATER LOW PRESSURE ANNUNCIATION SET AT 70 KPA

I ~I \0_ 'f 40

r--

20

I

~ ....... ........

__r.,..-t

40

""

50

40

2

I

l I

I

I ~~ I

I 15

.I 40

jtl ........ * ...r'--l g @) WATER COOLED

t.IICROST 1\TION VER 4.0

I

, U.S. ARMY

SYMBOLS

[><] GATE VALVE

N CHECK VALVE, SWING

tYi CHECK VALVE, LIFT

[;o:}c !l.ti..J. V,t;.VE W/ t.NVERS,t;. ~ HOSE CONNECTION

ill THERI.IOt.IETER

~ SOLENIOD CONTROLLED VALVE

-W- THERI.IOSTATIC CONTRotLED VALVE

~ Y-TYPE STRAINER

l<P TEt.IPERATURE RELIEF VALVE

I~ BACK PRESSURE VALVE

'L THERI.IOt.IETER WELL

[X] GLOBE VALVE

Q OPEN HUB

g MOISTURE SEPARATOR

~ CONDENSATE TRAP

o=::lJ AFTER COOLER

® NR COWPRESSOR

-- NR LINE

lj FLOOR DRAIN 'II/FUNNEL

&--<=' ANGLE VALVE 'Ill HOSE CONNECTION

NOTES: 1. SYSTEM SHOWN IS TYPICAL OF A 2-UNIT PLANT

2. fOR GENERI\TOR COGLING WATER SYSTEM SEE PAGE A-2

J. DECKWASH PUMPS PROVIDE HIGHER PRESSURE fOR DECK WASHING AND BACK-UP FIRE PROTECTION, 1KJ SERVE AS BACK-UP FOR RAW WI\TER LOW PRESSURE REQUIREMENTS.

4. UNSHI\DED VALVES -NORMALLY OPEN, SHAIOED VALVES NORI.IALL Y CLOSED.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

-

HYDROELECTRIC DESIGN CENTER

D

1-

c

B

-

NORTH PACIFIC DIV., PORTLAND, OR l~~~~~~~--.--------------------t A

Figure 8-9. (Concluded}

GLENN Fl. t.IELOY, P. E.

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I 1 U.S. ARMY c.o. r SLOPE TO CENTER _ EL. 492 405 SYMBOLS

-vSCUPPER -c.o~ ~ POWERHOUSE ROOF ~ fLOOR DRAIN - • ROOF DRAIN _j f f--J _j - GUTTER DRAIN

~ fLOOR DRAIN WITH FUNNEL

ROOf DRAINS GUTTER ' • 5PRIIi.. CASE HOUSING llRAII

EL 486 460 [><J GATE VALVE 0 c ~ -FLOW FLOW ~ CHECK VALVE LFT

0 E.L. 485545 ~ BUTTERFLY VALVE

...---- DOWNSTRENol 80 UPS TREMl

UPSTREAM -----. ..---DOWNSTRENol UPSTREAM -----. [:o:] DRAIN !TYPl - BALL VALVE ---UPSTRENol 80 DOWNSTRENol :.--so VENT DOWNSTRENol --............. I><}:J GATE VALVE W/ HOSE CONNECTION

GUTTER 1HO

/ TRANSFORWER CELL

ROOW DIUIN ITYPI---. / T~ DECK DRAIN -i\ BACKWATER VALVE

UPSTREN.I~AGE HEADER \ TO TAILRACE-

ri UNLOADING AREA y SIGHT fli'INEl.. • TAILRACE DECK

- ~~~ - eA eA 8 - i?J - EL. 481585 0 VERITCAL BALL VALVE -

~TRANSfORWER OIL r::.::::::~ SCUPPER

300 HOLDING BASIN r----.-100 DISCHARGE TO TAILWATER 9 ~ ~ ~

SEALED DRAIN CONNECTION

~ ~ VENTLATING AIR

INTAKE SHAFT ~ y GUTTER OUTLET

• GENERATOR AIR COOLER_/ RESTROOW AREA Q OPEN HUB ,..,-- HOLDING BASIN

I ~ RELEASE VALVE [] ELECTRIC WATER COOLER 80

li ii 8 eA al ~1 40 ,.-- CONTROL VALVE fOR RATE OF

RELEASE TO OIL TRAP EL. 477 774 IS.:] BATTERY ROOW SINK

~ GENERATOR! HOUSING I I l I l c tj c ~v - PUt.~!'

(vn n ' "l ,,.. ~~~ i!ll y ~/

EL 477 620 _($) PRESSURE GAGE

EL.472 5110 ~ ,...,_....---;'50 TURBINE w 0 BACKFLOW .?t l:l. ~ - '"""' "-""" 1 - VACUUM BREI«ER SAFETY PRE VENTER MOTORIZED PLUG VALVE

~~ 80 ./

AIR HANDLER ~~·~ "-~~~'M -1 STANDBY DISCHARGE TO

~HE MAX TAILWATER - DIRECTION fLOW

TURBINE DRAINAGE T~:ATER ]_ 6A

8

OR EYEWASH

OR:OISC7.

EL 475 ODO

~BLOWOUT fL;7 PUMP;-y

ri 8 ~ rsy -(- FL TER BACKWASH c.o. CLEN«JUT

~ a ~ f 8 ii n ii o ell a ~~~ ~~ a an e!tnn a EL. 474 270

v ' / v~ I I II I I I I I '-c.o. ~~OI.t---" I I I I - 100

I OOiol_/ 14--

IIECH. EOUIP. I I NOTES: 1

~ VoRAIN h

BATTERY ROOW WATER TREATMENT ROOM

_..... SPIRAL CASE EXTENSION 1. SYSTEM SHOWN lS TYPICAL OF A 2-UNIT !fRANCIS PLANT>

c()~ ~lNG HEAD COVER WITH TRANSFORIIER OIL HOLDING BASIN. OIL TRN' UNWA

DRAIN CONNECTION~ fACIUTY AND COMBINED UNWATERING-ORNNAGE SUt.IP. PUioiPS

E~ 80 TO TAILWATER EL. 475 490 EL 470 915 2. OIL IS PUMPED fROM OIL TRAP WITH PORT ABLE PUIIP. c:--- / I I ' so ---' 1'--,-/ ..-.- I I 3. SUMP DIUIN SUCTION LINE NORMALLY CLOSED CURING

A t~ l:. A'- EL. 470 1111 UNWATERING.

TO OIL TRAI" ~~

BLOCKOUTS~ I= OIL TRN' OUTLETS TO

4. UNSHADED VALVES-NORMALLY OPEN, SHADED VALVES-

¢ EL 470 3S5

~~ q 1 .... 1~ ~ ~ TAILWATER

NORMALLY CLOSED. IIC 100 BLOWOUT B

{EL470 ~ ~ f-EL 489 0117 5. FOR L1NW ATERING SYSTEII IN TYPIC..._ B UNIT KN'LAN B PLANT SEE PAGE A-10.

ll. 'L ':£, ~ tl"'

100 ~~_j pgb <} lD !8 EL 46S 173

" v u___ ALL DIMENSIONS ARE IN

INLET TO MILLIMETERS UNLESS NOTED OIL TRAP- so- 1 ~SE:ED ~ -l\

OTHERWISE TCH

DRAFT TUBE - UNIT NO. 2 DRAFT TUBE • L ~IT 0.1

- / ~"~ "~'" '""'"-' -..,........,.-c- PUWP VALVE !ELECTRO-HYDRAULIC-

v COLUIINS EL 454 820 SYSTEM-OPERATED!

'tlf" Yc:!l'

_.,/

I~ 125 PENSTOfK BRANCH SPIRAL C EXTENSION

125

L f- SUCTION 20 20 ( !./ ............ ) MANIFOLD - ~ - -lL.. lA

12s~ET-' UNWATERING ~~ ,.:, /.,., HYDROELECTRIC DESIGN CENTER

DRAINAGE-.............. .......... ~---~---)-- BYPASS LINE NORTH PACIFIC DIV., PORTLAND, OR

A ra· I FOR EQUALIZING OCS~D• A

OOUWN• Figure B-1 0. Unwatering -CHECKD>o

VIEW A-A OREPAA£Do drainage system (Continued}

TYPICAL BOTH PENSTOCKS

UNWATERING AND DRAINAGE SUBII!TIED• SCAL..& Aa SHOWN I SHErr ""'·

NO SCALE GLENN R. '-ELOY, P. E. --4 I 3 i 2 I ,

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I , U.S. ARMY

~· UPSTREAU 111111 100 •• OOWNSTRENd. 100 _A UPSTREAU --~ 0 . • ~fR~~ • .0. POWERHOUSE ROOF SYMBOLS

EL :59 014 ! 100 1125 I L 0 AAEA OR FLOOR DRAIN I

VISITOR - CUTTER OR CURB ORIIIN

.~~.~ ~ .Ill .111.111 .11..11. ~ _.. "~"'- .Ill .111.111.111 .11..111.11. .II. • EL 34 520 ....__._, 1-' L ?io' ~ 1--' .... ~

.... ~ L.l1IO..... _j ROOF DRAIN

!10 D... 0 0 0 0 0 0 0 0 0 0 CONSTRUCTION JOINT ORAAI ~ ~ Lhl ~!{SrfiE~ o 100

<S> UPSTr 100 OOWNSTREAU DRIP TRENCH DRAAI

TYj;. II TYP. OF L,.,_ UPSTREAM 0 "D. INTAKE DECK y 0 EL 27 430

Dl50 l sol::IOL

100~ _y Y YlooJ RAIL DRNN 0

80 --- t.._TO INTAKE GATE SLOT TO ICE . t 125 i SUB FLOOR DRNN TO POOl

TO INTAKE TRASH SLUICE '0

EL 25 :5bo GATE SLO

EL 25 3arf"" EL 25 :50C FLOOR CRAIN 'WIFUNNEL ~0. (?<.0.

c.o~>- .~ - - 100 £ ,..c.o. SERVICE GALLERY 0 SPIRAL CASE DRAIN

EL 21950 __j SLUICE G ... TE ~ L_ _j [Q]

~~,.-~ OPERATING STEM FISHWAY DIFFUSION CH...UBER DRAIN

RAIN [I] .16 .. 17 100 80 Sut.IP VENT roc.o. FISHWAY SUPPlY CONOU!T DRAIN

50 ",.,. ... ~7 , ........ ~ 80 vc.o. !XI VENT UPSTR£AU /c.o. vc.o. vc.o. GLOBE VALVE

- TYP. OF 6 t><J GATE VALVE -OOWNSTR TYP. a;;~ 80 1!0

~ GAL ~.R0~CK BALL V/>LV[ 'W/ UNIVERSAL

EL 11! 785 0 0 0 0 0 TAIL RACE DECK J-{::<1 JIIR HOSE CONNECTION

I 1:550 ~ ;~8- ~~ DRN'T L f.-J ! L ~YE WASH~lK L

~~ 80 -x lK N

080 UBE B.H. TO ICE I.

CHECK V/>LVE -----c-sLgz__ rr' BD 150 SUMP VENT y B"TTERY ROOM

EL 15 545 350 100 0 0 0 0 0 TRASH SLUICE ~

~D.r f--J L

~0 0

BUTTERFLY V/>LVE 450

~62.0x 2{ 450 ..,.

WATER LEVEL ~ c*J OIL-WATER SEP~TOR

r-"1 r-"1 ......... KNIFE EDGE GATE VALVE

LOWER BEN!ING BR...CKET L5 ~

BAY 16 200

JOO .... XL DRAIN 3 PLIICES -. '-4SC

~

450

p~ C..\ 1- FLAP VALVE y '-TO 250

TNLRIICE \0 TNLRIICE/ EL 12800~ La TNLRIICE~ ~ 100

~~~~~~ - ~ c----~ f--- ~

~ FLOAT Cf£CK VALVE

c ~9 <~ ~~

A TURS.-GEN.

A c 450 FLOOR, ELECT. VALVE STAND

100 HATCH EQUIP. GALLERY lo .,eo 100~ 050 !I o100 r-, o~N 0 0 80 oc -, /-, J'---'\. ;- '\.ooooo oBS VISITOR GALLERY ---<:}-

EL 8 5.35 AIR OPERATED FlOOR STANO

1-J ~ 1SC ~/ I' D.. I !~ ~ 1-J 5~100 r ~ I I I I I I I NORM/>Liol~~ t 100 / TAIL WATER SIGHT FUNNEL

125 .~ ·~ ,,5 150 80 y /1) ~t 300>- JDO 0 0 STOR,t,GE ROOMS INLET

_j - TRENCH ,_.J ~.c TUR. VIC. BR. >- COMPRESSOR ROIDM 80 MECHANIC"'L - DISCHAAOE

HEAlD COVER PUMPS Qyy EQUIPMENT

80 1) B'"' G~ERY yc.o. CLEAN OUT J EL 1525

"'~~'- J·~ 1-rtrl80 50 I .J'-.- TRENCH I I h-rrl llrrmbnJI I L I I I r ~ L IICROSS CAL 0Y

VENT

--- RING DRAIN 4 BD -100 PLACES 50 OIL R007 6 FLOOR <TYP.l SEALED HATCH

PIT LINER DR~ c.o. s 0 s es oC.O. o 80 0 L_j t L.J t l Ll':, '" 1J 1:'8:1 SLUICE GATE

100

N'TERCOOLER DRAIN 100 150 f'EL15 545 " ~~~

a:r:::O= DEEP WELL PUMP MOTOR B"Y 5 ONLY "----

!FROM C.B. JIIR

~-~' "''~'~ 150 :----1-

.., 100 100 i i ~ DEEP WELL PUMP • C"51NG COioiPRESSORSl -==

150 BAY 14 .J!lC 1---

) ;><FISH S. r-0 CONDUIT VENT SUioiP UPSTREAU ? CHILLING SUloiP

BAY 11. S DRAIN,t,GE I. GROUTING E- PIPE C~ (FISHS. G~LERY

CONDUT DRAIN> ~ B

~A*- *20

THREE·WAY VALVE B DRAIN...CE .. zoJ-tx]-- ~ ~

20[)--, / eoo lnF ? GROUTING

l$1 I .... ~· .., SCUPPER DRAIN GALLERY

~ L'" EL -10 OliO

LE REPAIR PIT

EL VAAIES ~, ~7 ,l J. i.;> v~ I DRAINS NOTES:

" ..... UNW ... TERING SUMP OVERFLOW DRAFT TUBE 1. SYSTEloiS SHOWN AAE TYPICAL OF AN DRAFT TUBE .......... fOR CONTROL OF SAFETY POOlL I

~ loiANOOOR DRAIN ...CCESS G/>LLERY 8-UNIT <KAPLAN TYPEl POWERHOUSE

0 WITH SERVICE BAY ""'D ERECTION BAY EL -"11 21!0 \J.J h-ni

(NOT SHOWN! "T OPPOSITE ENOS. fiSH I 50 ,., COLLECTION SYSTEM. OIL -WATER

SEPERATOR AND ICE· TRASH SLUICE-WAY. TRENCH 100 2.fOR UNW ... TERING-DRNN...c£ SYSTEM IN

100 500 TYPICAL 2 UNIT FRANCIS PLANT - ALL DIMENSIONS ARE IN SEE PAGE A-11. -

MILLIMETERS UNLESS NOTED :5.UNSHAIDEO VALVES-NORM/>LLY OPEN.

c SHACED V/>LVES NORMALLY CLOSED.

ORHNAGE TUNNEL EL.-15 240 OTHERWISE

-5CO FROM ,_/ EL "16 460 (2) 500 OR,I,/NAGE SUMP OVERFLOW ERECTION BAY -

u u -

300 250 '\ -- """' - -DRAFT TUBE HYDROELECTRIC DESIGN CENTER

I ,..,'--\_ r~ NORTH PACIFIC OlV .• PORTLAND. OR

A OE5fONEO• A

"""-450 450

CHI!:CI'(CO• Figure B-10. (Concluded) I DRAINACE SUI.IP PFti:.P~D•

$ ~ ~ EL.-23 165

UNWATERING TUNNEL EL.-25 :500 ...... -----U~WATERING SUMP EL.-28 345

S1.16MITIED' SC.otoi...X A8 ....OWN jBH<ET ..... MAIN UNIT BAY SERVICE BAY GLENN R. MELOY. P. E. --

4 3 i 2 l ,

D

c

B

A

CORPS OF ENGINEERS I

s

AIR • OtL

80

VALUE ENGINEERING

80

GOVERNOR PRESSURE TANK

GOV. CAB.

WILL INCREASE YOUR PROFITS

TO TURBINE BLADE SERVO MOTOR

~ /THRUST BEARING

/ ""'\

.---------'-lr____, I ~ HIGH PRESSURE LUBE OtL

rlf------!:><l--1~::::-::;:;;~:_------,t// _,.-UPPER GUIDE BEMING

~ I J>< I I ~ y /BEMING OVERFLOW ,-------' r----~v L>< .I ~t

,., r~~ · 1 ~~~, r 1 4oo-~~3--.-D<r--L---~~~~~~~-;>~~~~---65-----~---I--1--------~-~~~--r==============;--f---i------r--r------t------~---l

~ l8o ,~ _.LJ...LL

r

-~BR~~EAIR~~~~r= ~~~~~~c~~~~ 55 "'-- JACK LEAK LINE

115 SUPPLY --

I

MATCH A -s=u=PP=L=Y=HE=AD=ER:__ ___ L _____ so _________ ~==~lr:; - { ""¢" ~ sQENT • DRAIN '----'---'-1 ~ ..- I / ~ - i"{EE NOTE 2 L :y

I ~ LOWER GUIDE BEARING ;-----50

-R_E_TUR_N_-____ r.u._TCH __ ~..., ~~ ~

NEW 01..

U. S. ARMY

SYMBOLS GLOBE Vf>I..VE

GATE Vf>I..VE

NEEDLE Vf>I..VE

BALL VALVE

CHECK Vf>I..VE

~---o~~~H~O~S=E~AD~AP~T=E~R---------~0 &- ANGLE Vf>I..VE

PRESSURE GAGE

FILTER

-©- CYLUNDER ISIGHTl GLASS

o-- 0 HOSE W/ FEMALE SWLVEL

0 OL LEVEL N>ICATOR

~ SAFTY VALVE 1-~A-+~~~------~

L.J LOW LEVEL ALARM

ELECTRIC THERMOSTAT

ANGLE RELIEF Vf>I..VE

AIR • VACUUM fLOAT VALVE

BACKPRESSURE V/'LVE

LIQUID LEVEL GAGE

c u CONT.liNER

3-WAY, 2·PORT PLUG VALVE 1755 SERVICE BAY/, ~WASTE OIL

EL.15 765 t ~

-- UNION

t PUMP PRIMER

I I > I ~ -?t-2~ TURBINE SHAFT

l / OtL DRlP CATCHERS

JACKING HOSES~ N~OT-E 2 1-W ANDPUIIP

~ GATE SERVO IIOTORS 1--

1 } . .. >-- - -:c- I ::;:;::~ '~"" •~

MATCH A--

WATCH 8 ---

50

80

115

NEW • DIRTY 01..

2365!1 LITERS

40

40

BO

n AILRACE DECKl FIXED DISPLACEMENT PUMP

r 50

3-WAY VALVE

BO

Q FIXED DISPLACEMENT PUMP

~~-,--+-W-IF_L_O_A_T_V_I'L_VE _________ ~I+-

~ ~-.. r PF 1----------....J ~

1 LITER/S RETURN PUMP

PUMP SUCTION RESERVOIR W/ FLOAT SWITCHES r- -t- NOTES:

TO OtL -WATEr/

15 l><l-

SAIIPLING COCKS

40

CLEAN OIL

23656 LITERS

80

40

TYPICAL UNIT

------------------------.--------1--1------

50

L 1---....l_.J

80

GOV .• LUBE CLEAN Oil

PUMP 1.26 LIS

40 65

40

PF

65

SEPARATOR

40

'., I (} • A_ ~~>~..coL cooN.-NEC-TIO-NS _•o -------,

~~ L CENTRIFUGE TYPE l/ ~-----l--f-~~::1-c.--- _..-o.{X} g~v~~~~RI. LUBRICATING

~~

v v " 4

"

~~~<r~&---------l------------~-~~=-s_s __ ~ OIL PURIFICATION ROOI.I SERVICE BAY EL. - 915

65 65 ...

·~""'.>'-~ OIL SUCTION SERVICE BAY

SUCTION HOSE

SUMP SUCTION r ~

~~~ :':: ~-r._,r~l---------------4

_44 __ __.,./

OL STORACE ROOII EL. -1 830

" .... 4

I i 2 I

1. SYSTEM SHO- IS TYPICAIL OiF AN 8-UNIT !KAPLAN) PLANT WITH SEPARATE OIL STORAGE AND PURIFIER ROOIIS, OtL DELIVERY BY TANK TRUCK AND A POWERHOUSE OIL-WATER SEPARATOR FACILITY FOR SPilLAGE.

2. WASTE OtL PUIIP HANDLES GOVERNOR-LUBE OtL i>J'jQ TRANSFORt.tERFOiL.

3. USE GRAVITY RETURN FROII UNIT TO STORAGE ROOII WHEN TURBINE CONFIGURATION PERMITS.

4. UNSHADED VALVES - NORNf>I..LY OPEN. SHADED Vf>I..VES NORMALLY CLOSED.

5. FOR TRANSFORMED~ Oil SYSTEM SEE PACE A-7.

ALL DIMENSIONS ARE MILLIMETERS UNLESS OTHERWISE

HYDROELECTRIC DESIGN CENTER

IN NOTED

-

B

--

NORTH PACIFIC DIV., PORTLAND. OR ~~~s~~rn~.---~.---------------~------~----------------1 A

Figure B-11. Governor -lubricating oil system

GLENN ~- llflOY, P. E . . ...,

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I , U.S. ARMY

A AA AA A SYMBOLS

!><] GATE VALVE

---{] HOSE ,&<;N>TE'i W/ CN' • CH.AJN

\'~"~"'" --

PURIFIER WASTE OIL 61 ANGLE VALVE SERVIC€ BAY

~~ i 1~ NEW OIL • FLOOR DR.AJN

M ... N UNIT I.!AIN UNIT 85 J TR.-NSFORI.([R TRANSFORMER NIGU RflH Vft. VE

~ ~ BACK PRESSURE V J>L VE D D 65 65

(~ .~~65 (~ 40 0 f)() ) 1o <:: PRESSURE GAGE

i.~ 115 40 0 f)() )

Q ~~ ELECTRIC THERMOSTAT I ..... .;:::: -o 65

40 I. ......... c; 65 40 1.~ I BAY !I TAILRACE DEO< EL 18 7115 BAY 2

......... 50 u u I D= LIQUID LEVEL GAGE

~ I~ 7 VENT

I - 40 1 l tx:J GLOBE VALVE

I J TO OIL WATER~ --1- 50 - 50 SEPARATOR N CHECK VALVE

- 40 I 40 -®= FIXED DISPLACEMENT PUI.!P -

I l,l;®t FIXED DISPLACEMENT PUI.IP 50 WITH rLOAT CONTROL

I t Put.IP PRIMER

40 ~ 3-WAY VALVE

! 1 f NOTES: 1 SYSTEI,j SHOWN IS TYPICAL OF AN !!-UNIT ICN>LANI

PLANT WITH SEPARATE OIL STORAGE AND PURIFIER c ROOMS, 011. DELIVERY BY TANK TRUCK AND A c

POWERHOUSE OIL-WATER SEPAIRATOR FACILITY FOR SPILLAGE.

2 WASTE OIL PUt.IP HANDLES GOVERNOR-LUBE OIL AND

rl!!.-TRANSFORI.([R OIL

rss J. UNSHADED VALVES-NORM.lLLY OPEN, SHADED VALVES-.1~ NORioiALL Y CLOSED. - 4. GOVERNOR LUBE OIL SYSTEM LOCATED ON PAGE A-8.

'1~ 50

ALL DIMENSIONS ARE IN .--- 40 50 MILLIMETERS UNLESS NOTED --+ 65 [J., 40

OTHERWISE If-65 ~ ·~

l l ~

~ ~ .........

65

rHOSE ALL -~-"'

CONNECTIONS 40

t.~ 1,. ........ ~ --v

~ , ""' CENTRIFUGE TYPE

TR.ANSFORMER TR.ANSFORt.IER ~ ,-., "A TRANSFORr.£R OIL

OIL STORAGE OIL STORAGE -1><1- ......... ......... ......... ,..., , ............ PURIFIER

~ TANK •2 TANK •1 ......... ........ .... ........... B B 23656 LITERS 7 23656 LITERS

' []::

c. ID=

l

~ f_ I u u I EL-915

- - - . I . . . . . . ~ g-~-,~~· L OIL PURIFICAT!ON ROOM l OIL PUioiP

F 1.119 L/S 1!0 SERVICE BAY

WASTE OIL

* 65

POSITIVE -DISPLACEWENT PUt.IP

- 1.28 LIS ......... -..... .... T

25 :::: <: T 7 ~'7 ,. ......... 65

"'>-.........

* 7

* '7 [~SUCTION HOSE •>-

65

·~ 55 65 j. -I

I I .--- ,.__,.., L ~ ~

80 ......... ..........

I OIL STORAGE ROOM FLOOR EL -1 1!30 j. - .... - -WASTE TRANSFORMER

~· HYDROELECTRIC DESIGN CENTER OIL SUCTION

I NORTH PACIFIC DIY., PORTLAND, OR

A . DI!!:59NI!!:OO

A

t 80 l----- FOOT VALVE

\_DR.AJN

"""WN' Figure 8-12. Transformer oil / ~--:;-

CH£eo<a>•

l---- SCREEN PftEP'~· system / ~-SERVICE BAY

L OIL ROOM DRAINAGE SUWP

SUBiiiTTEO' SCAi..E: AS SHQWM 1-·-GIDII R. WELOY, P. E. --

4 I .3 i 2 I ,

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I , u. s. ARMY

PIPING MATERIAL SCHEDULE UAX.

GROl.f' SYSTEW PRESS PIPE FITTINGS VAIL VES SEE NOTES 15 1o 17 NOTES: KPA

A GENERATOR COOLING OOl 865 LESS TH-'N 80, SEN.ILESS COPPER TUBING TYPE K .E:ili Il:lttt iHl' LESS TH-'N 80• !.80....»>D LAAGER IN STEEL LINES• 1. 8115 KPA CAST IRON FLANGES WITH RAISED FACE SERVICE RAW WATER SOLDER JOINT. ASTt.l B88M FOR COPPER TUB~G. WROUGHT COPPER, SOLDER JOINT .ANSI BRONZE. SOLDER JOINT IN COPPER Ul£5, TfflL'DED IN BRASS. GATF VA! lffS IRON·BDDY, OSlo'!', FL-'NGED, USS SP-70 FLANGES OR WAFER TYPE VALVES SHOULD BE AVOIOED. SPIRAL CASE DRAIN STD. B-16.22 OR CAST BRASS SOLDER·.JO>NT .tNSI STD.

2. PVC PIPE l5 -'NO LARGER ONLY IS COVERED UNDER SPIRAL. CASE FILL 80 ~ LAAGER• SEH.I.£55 BLJO( STEEL, ASTII A53. B-16."18 GATE. GLOBE, -'NCLE. AND CHECK. t.ISS SP·BO. DRAFT TUBE DRAIN

CS 207, St.IAILLER SIZES SHOULD BE WJ.NUF ACTURERS ST JoNDARO.

i.MIA TIRI>IC ~ [)R.IjNNl£ PUIIP SCHEDULE OR THICKNESS, SEE NOTE 7 .:6IER tfQSE lliBf~S= BAILL VAILVES• WSS SP-72 3. GROI..P A COPPER ELBOWS -'NO AILL GROUP E ELBOWS SHOULD BE DISCHAIRGE SIZES THRU 250 SCH. 40 ASWE B1.20.7 GLOBE AND ANGLE VN VfS, RON BODY BRONZE t.IDUNTED, OSI<Y LONG RADIUS OR LONG SWEEP.

D TURBINE GLN>IOS SIZES 300 -'NO LARGER 10 THICK WAILL. WITH RENEWAIBLE DISC -'NO SEAT RING, 865 KPA STEAt.f WATER SPRAY FRE PROTECTIOti RATING. loeSS SP-85. 4. USE GAIL V -'NIZED STEEL PIPE BETWEEN COt.IPRESSOR AN10 AFTERCOOLER D

CUPSTREN.I OF DELUGE VALVD ISAt.IE AS GROUP Cl fOR 65 AND LESS LOW PRESSURE AIR. TURBINE "R SUPPLY 80 ~D Lt!B~tB:! BUTTERFLY VAILVES• SEE NOTE 1 • 20. WSS SP-117.

BUTT WELDING, STEEL, BLACK. ANSI STD. B-1&·11 THCKNESS 5. WELDED GAIL V N>IIZEO PIPE SHOULD NORt.IAILL Y BE GAIL V ANIZEO SAt.IE AS PIPE. SEE NOTE 12 LifT CHECK• NON-SLAt.! TYPE, CAST IRON BODY, FL.tNGEO AIFTER F AIBRICA TION.

FOR 8115 KPA SERVICE, FACED -'NO DRILLED IN ACCORD-'NCE II. FULL PORT BALL VAIL VES ARE NORMAILL Y AV M.AIBLE THROUGH ~ 1040 KPA FORGED STEEl., WELDING, WITH ASA REQUIREIIIENTS. STAINLESS STEEL TRIM WITH

FV.T f,ICED WI"£N .-o.JN:ENT TO CAST fiON v.-...VES STAINLESS STEEL HELICAL. SPRING. DISC SHAILL BE SIZE 50 WHEN REQUIRED. N>IIO FITTINGS. SEE NOTE 10. USS SP-44 GUIDED WlTH TWO-POINT BEARING, ALL WEARING

7. PARTS SHAILL BE REPLACAIBLE. Et.I!EODED LINES OPEN TO T.M_WATER OR FOREBAY WITHOUT

CAST IRQN• EXTERNAL. PROVISIONS FOR READY SHUT ·Off SHOULD BE EXTRA FLANGED ASTM A121l BAl,L VALVES' !.ISS SP-72 FLANGED, fULL BORE. HEAVY STEEL (UP TO 15 WAILU FROt.l THE fiRST VALVE

TO A POINT BACK IN THE CONCRETE N>PROX. 1525. OTHER Et.I'!EODED LINES SHOULD MEET THE SAt.IE REQUIREMENTS FROM THE FIRST EXPOSED JOINT BACK INTO THE CONCRETE AT LEAST

- B POTAIBLE WATER 1!65 LESS TH-'N 80• SAt.IE AS GROUP A SAt.IE AS GROUP A EXCEPT BO AND LAIRCER PIPE IS SAt.IE AS GROUP A 1 X 25

-GAIL V ANI ZED. SEE NOTE 5 8. ONCE THROUGH AIR CONDITIONING WATER SHOULD BE GROUP A.

80 ~ V\RI:ER• GALV. STEEL, WEL!lED JOINT ASTt.l A-53 TYPE E SCH. 40 SEE NOTE 5 9. FOR COPPER OIL LINES ADO SEPARATE GROUP WITH REQUIRED

JOINTS WHEN TEMPERATURE OR PRESSURE EXCEED SOFT SOLDER

~ JOINT RATING. :z: c WATER SPRAY F"RE PROTECTION 1040 GAIL\IANIZED STEEL ASTW A·5J TYPE E LESS THo'l/! II~• SAt.IE AS GROUP A w !OOIINSTREAII Of !lfl.I..C£ VA!. VEl SCH. 40 GALVANIZED MAILLEAIBLE-IRON, THREADED, .ANSI B18.J AND ID. FOR CROUP A PIPING 80 ANIO LAAGER USE SLIP-ON WELDING > 0

LESS THAN 80 THRE...OED WSS SP-83, B111.Jil FLA>;GES OR PIPE N>IIO WELDING NECK FLANGES OR FITTINGS.

~ 80 JoND LARGER WELDED, SEE NOTE S 11. USE DIELECTRIC FITTINGS BETWEEN FERROUS PIPE OR EQUIPMENT 80 AND LARGER•

"' SAt.IE AS GROUP A EXCEPT GAIL V N>IIZEO, SEE NOTE 5 ANIO COPPER AIR -'NO WATER LINES. z ~ 12. IF SPEOFIEO WAILL THICKNESS IS UNAVAILAIBLE USE THE NEXT 0

D ,tjR CDN01110NNG CRCUJ.TINC 125 STEEL ASTU A-5J TYPE E LESS TH-'N 85• HEAVIER AVAA.AIBLE. <80 AND LARGER BUT WELD flTTINGSl

"' SAt.IE AS CROUP A

w WATER SEE NOTE !! LESS THN>I 65 GAL V. THREADED SA.IlE AS GROUP C, LESS THAN 80. 1J. IN DRAIN LINES USE COMBINATION "Y" AND 118 BENDS WHEREVER c ~ &5 JoND LARGER, BLACK, WELDED. POSSIBLE fOR BRMICHES FROt.l HOR1ZONT AIL RUNS. c 31: &5 AND LARGER•

SAt.IE AS GROUP A. 80 AND LAIRGER 14. HOSE THREADS SHOULD HAVE MANUFACTURERS TAG SHOWING THREAD SPECIFlCATION.

E BUILDING AND ROOF DRAINS EXPOSED• EXPOS EO• NONE 15. V...._VE NolO FITTING SHOULD NORMAILLY BE SAt.IE AS LINE SIZE.

SANITARY DRAINS SEAt.ILESS STEEL. ASTU ASJ SCREWED CAST IRON DRAINAGE, GAIL V N>IIZED ASTt.l A888 16. REFER TO NFPA FOR REQUIREWENTS OF C02 AND VENTS PIPE AND FITTINGS. WATER DISCHARGES ~URIEO NolO EIOBEDDEO• Et.IBEDDED. !UJLESS CAST IRON, CISPI30t BURIED -'ND EMBEDDED• 17. USE RISING STEU VAIL VES UNLESS OTHERWISE INDlCA TED WITH

SAt.IE AS PIPE PACKING -'NO SEAT MATERIALS SUTAIBLE FOR SERVICE. SEE NOTES 3 NolO 13

18. PIEZOWETER TUBING Et.IBEDDED IOORE THAN 150 WAY BE TYPE I(

F TURBINE V .tCUJt.; BREAKER AND 8L,tCK STEEL, WELDED JOM, ASTII I>:.J S THICK WALL. SAt.IE AS CROUP A. 80 ANIO LAIRCER. NONE ANNEAILED WITH BENT TURNS. SUMP VENTS SEE NOTE 7

19. PIPING LOCATION TERloii!NOLOGY --l> BURIED• IN SOIL '+-

G BATTERY ROOM DRAINS ~PVC U.S. DEPT. Of" COMI.lERCE STD. CS 207, SN>IE AS TYPE ANIO 1.1-'NUF ACTURER AS PIPE NONE EUBEODED• IN CONCRETE SCH. 8D OR I>CIO·RESISTNG "DURRON" OR "CORROSRON" EXPOSED' ACCESSIBLE OR EQUAL..

20. BUTTERFLY VAILVES SHOULD CONFORM TO THE AIPPLICAIBLE EMBEDDED' "DURIRON" OR "CORROSIRON" OR EQAIJL. REOUIREWENTS OF SECTIONS 5 THRU \4 Of AWWA STANIOARO

C504 UOOIFIED AS AIPPROPR!ATE FOR THE PARTICULAIR H PRESSURE SEWACE 700 EXPOSED• ~ GATE• IRON-BODY, OSioY, fLANGED. t.ISS SP 70-90 BAILL VAILVES• t.ISS SP-72 AIPPLICATION. SEATS SHOULD NORt.IAILL Y BE BURA-N OR EQUAL..

BLACK STEEL, WELDED JOINT, SCH. 80, ASTM A·5J. SAt.IE AS GROUP A BE LOCATED IN THE VAIL VE BODY, -'NO FIELD REPLACEAIBLE.

SWI'jG Ct£CJ(• IRON-BODY BRASS IICIONTED Wml RD£W~E BODY BUR lED OR EJOBEDDEO• II"'BIEtl ~11 EMfll:~Qf:l:!• SEAT RISG. 865 KPA STEAt.f RAnNG. MSS SP 71-90

DUCTILE IRON, ASTM A377. AWWA C110/A21.10 NolO C111/A21.1\

I PIEZOIOETER 865 SAt.IE AS GROUP A. LESS THAN 80 SEE NOTE 18 SAt.IE AS GROUP A. LESS THAN 80. N>IGL£ VAlVE' USS SP·BD, BRONZE, THREADED.

B I( GOV£R ... ER lo U.S OIL. CIRCUIT 1c•o S£MOL ESS COPPER Ti.JBNG TYPE K, ASTt.l B!IB. SN>IE AS GROUP A. LESS THAN 1!0. B BREAKER NjQ 1RANSFOI!IAER OiL SEE NOTE Q ALL DIMENSIONS ARE IN TR-'NSFORIOER OIL OIL HOSE THRE...OS• ASUE 31.20.7, SEE NOTE \4 GLOBE ANGLE »>J SWING CHECK• 1155 SP-80.

MILLIMETERS UNLESS NOTED =' TRA'<SFFR SYSTEMS. 0

OTHERWISE

"' SERVICE AIR 865 SI>ME AS GROUP B. SEE NOTE ~ SI>ME AS GROUP B. SN.IE AS GROUP A BRAKE ,t;R LNVERSAL HOSE COUPLNG' BRONZE, NfP(Al TJ.20.14 ORAIFT TUBE DEPRESSION AIR BUBBLER AIR LINES

0 CO\IERNER AIR ~~~0 GAL.VN>IiZED STEEL. THREADED. ASTt.f A-106 SCH. 80 LESS THAN 65' GALVANIZED lo!ALLE.>BLE -IRON, THREADED GLOBE VALVE' BRONZE, 6900 KPA 1.155 SP-80 CHECK VALVE' BRONZE, SWNG 6900 KPA W.O.G.

- ~ NITROGEN 4\40 KPA W.O.G. MIN. USS SP-80

65 .tND LARGER' FORGED STEEL 1.3800 I<PA W.O.G. -"' ~

p C02. SEE NOTE 16

R GOVER ... ER .o;R 7590 STAINLESS TYPE 304 OR 316 SCH. 40. STAINLESS TYPE 304 OR 316 13800 KPA SOCKET WELD STNt>I..ESS BALL VALVE, SOCKET WELD, REif>IFORCEO TEFLON SEAT USS SP-110-92 - -- -s HYPOCHLORITE SOLUTION PVC. US DEPT. OF CO!ot£RCE STD. CS 207, SCH. !J(} (NOTE 2l SAt.IE RATING -'NO MANUFACTURER AS PIPE. PVC

,__ .. " - -HYDROELECTRIC DESIGN CENTER

NORTH PAClFIC DIV., PORTLAND, OR A

~SIO-"«"D• A y FLOATWELLS EXPOSED• ~ SAlol£ AS CROUP B. NONE

<J SI>ME AS GROUP B """-Ill EMBEDDED' Figure 8-13. Piping material "' EMBEDDEO: S.AME AS PIPE ,...,CKE.,_ ~ CEIIENT WITH NEOPRENE GASKETS, ASTII C428 schedule PftEPN<EO•

z SLEEVES STEEL, BL.ACI<, ASTW A- 53 SCH. 4D

SUBIIITIEP. SCAt....!: A8 ...aWN IIIHIO<T ...... CL~ R. UELOY, P. E. _,.,

4 l :5 i 2 I 1

D

c

8

A

CORPS OF ENGINEERS I VALUE ENGINEERING WILL INCREASE YOUR PROFITS l U.S. ARMY

SYMBOLS GLOBE VALVE

~ l ~~ ::::~ I L_------~~>~~~~-----~--~

/

TRASHRIICK LOADINGS mENS~

0R 25 INT~E.--PECI< BAYS l,J,5 1o 7

~ I 50 " DOWN~REN.I s-+-------~-----------4'-~--.---..J_-------=-=.-----"'--""--""-'f--l:XJ-t----.-----c-::::.:::::o--------,--------l I 1----- ~~~~TI~~ ~~ILE~~~RESSED

DOWNSTREN.I __...{ 25 ~PA GALICE 25 ~~:>0 ~ l><l GATE VAI.VE

1''

15

t--2-0---c-c:::::::!:t'·r-L~ EL 16 765

1-------I:::~:::;~·~~'EL 13 105

1-------{X-::!H,:~:EL 8 535

Ao ..,.. ..... ..,..

~,

ERECTION BAY

15

POOL LEVEL SENSOR

25 TNLRIICE DECK ~

EL 1s 765 ~-~o:;.....,o:::...,r-------1

EL 15 105 ~r. _....

MAINTEN.oNCE SHOP

...

I ..........

l

15

HELB53S I.;> C!LLERY

20

20

UPSTRE~,~ o-J ~ ~ e31-103 KPA G~ I!£ ~ !BAY 4 ONLYJ _ ,l..,__~ •

--e: -"~ v "0

l 25 25 25

TO GOV. CABINET tTYP.l

25 ~ ... ...,"""\ -4-0 UPPER TURBINE' ';;~RE

25 .... .A

LOWER TURBINE -a~y

~0 TO TURBI~~ ~ AIR VALVE..-~ -

----..__:___.~u

l l \ L BUBBLlR SYSTEM <TYP.l

JACKING

20

BLOWDOWN TO D~TY

~~+u: U~UBE ~\A K

0-1110 KPA GA.

o-1110 _j ACTUATOR I KPA GA. ~ I CABlNET

1---c-: ..... 31'.-C:: TURBINE I ~ w ~~ SET AT 60 KPA GA. ~ F"LOOR 25~1----...; ~

TO ADJACENT ill-ltr"/ 15 I~ r;:9_.,' F 20 ~~E SEE NOTE 2 I \_ ~ RECEIVER

1---{>::~JCELECT. EQUIP. C!L. 25 ""\;"' SET AT '------() "(~}---'

<_} CREASE~ 760 KPA GA. ,... _.,

15

50

EL 16 765 :::J{>:::J-

7 ~

Hxlc 25 r-c-:x:

r-c-:x: Hxlc -{XJC

25 -{XJC

20 -r:-::J£;

GATE REPAIR PI~ 20 HOSE CONNECTIONS

EL 2 745-;:;: ~ 0·10 350 KPA GA.

.. ..,.

15

32

~OS

so]',.,...,

15 ---+---+1---------=.J --+---' ~ J]

EL l.J, 525 I ~ 'i::: EL 1 525 CALLERY '

~~~R~~B~~~~ UNITS &~MP g SO 1

2

: ._.

FUTURE AIR SUPPLY 20 'i l >.

SEE NOTE 5 •

T

CXJ-AIR I DRYER

20

c

25 DRI>lN

50

~HioV ROOM ~EL8 535

50

s

TO DISTRIBUTOR RING.y 1 PER UNIT l -"

25t8AY 1l r¥ GOVERNOR AIR SERVICE AIR - EL 1 525

EL ·915 ::J{>::J-C'\ 20

r~----T7-15--il!" _}- -lXJ --+-----.

1

-c-:r-.. ~-_..., ~::JL ~ PURIFIER ROOt.l

L-{XJC OIL ROOt.l

~ ~ ; ; ~ ~ ; ; 20

i'(> ;;>

15

EL -10 365 DRAFT TUBE CALLERY 32

DRAINAGE AND UNWATERINC PUMPS BUBBLER SYSTEM

EL 1 525

MAIN UNIT BAY SERVICE BAY

SCALES AS 9-tOMf ARE ~ 011 N4 ,.,.. SI2E ORIGINAL. THIS DRAWING WA'f 1-\A.V'[ SfTN R£0UC£0. DETERWN£ sc;.tU BY U51NC: ~ SCA...£ BAR.

MICROSTATION VER 4.0

I 2 1

N SWING CHECK VAI.VE

BALL VALVE

SAFETY VALVE

• 6 - NEEDLE V !L VE ~~~~----------------~0 ~ PRESSURE REDUCING VALVE

PIRESSURE CAGE

AIR F"ILTER

AIR COMPRESSOR

BUBBLER NOZZLE

~ AIR CIRCUIT BREAKER

..----f1 AFTERCOOLER I. MOISTURE 1

_

~ SEPARATOR ,-~-m=-~~TH~E~R~M~O~ME=T~E-R------------------~

ELECTRIC THERMOSTAT

FLOW DIRECTION

AIR RECEIVER

INVERTED BUCKET TRAP

(c) CYLINDER !SIGHT! CLASS

SIGHT CLASS W/SHUT-OFF V.

E- PIPIE CAP

t OPEN HUB

UNION - FLEXIBLE CONNECTOR

BUBBLER CONTROL

Y- TYPE STRAINER

UNIVERSAl. AIR HOSE CONN.

HOSE ADN'TER

NOTES: 1. SYSTE .. S SHOWN ARE TYPICAL OF .oN 8 UNIT POWERHOUSE

WITH KAPLAN UNITS. INTAKE GATES AND TRASH RACKS. GATE REPAIR PIT !<NO WITH SPILLWAY AIR CAPIICITY AVAILABLE FOR ICE BUBBLERS !<NO MAJOR lolloiNTENANCL

2. ONE BRAKE AIR SYSTEM FOR EliCH PAIR OF" UNITS. 3. SERVICE AIR·NOMINAL SOO KPA GOVERNOR AIR-NOMINAL

6900 PSI 4. UNSHADEO VAI.V£5-NORMALLY OPEN, SHADED VALVES­

NORMALLY CLOSED. 5. I.IINIMUI.I PROVISIONS FOR F"UTURE AIR SUPPLY TO

DISTRIBUTOR RING IS NECESSARY FOR ALL UNITS.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

c

8

HYDROELECTRIC DESIGN CENTER NORTH PIICIFIC DfV., PORTLAND, OR

~~~~~~~.----.--------------------------------------, A

Figure B-14. system

GlENN R. MEl..OY, P. E.

Compressed air

IIOHUT ...,_

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I 1 u. S. ARMY

SYMBOLS RAW WATER HEADE t--...,.. -0- SERVICE AIR

----- INDUSTRIAL WATER

• ---- PIPING FURNISHED BY GOV.

~ GLOBE VALVE FAAT. OPEN

[><J CATE VALVE

17 I

~ E!UTTERFL Y VALVE D ~~ [I]~

-........ D

~ H J SOLENOID V AI.. VE .... .._.

~-'-...._' AFTERCOOLER • IIOIST~~E SEPAAATi \ ~ 150 !:*] SAFETY V AI.. VE

! ......... - I h DEPRESSION AIR HEADER I I [l]r$, J1150 LITERS u ~110 ~ 50 150 BALL VALVE CYL. OPERATED

l ·~ H J .......... RECEIVER ~ .~

.,..

~ 7' - I~ 2-WAY ~-PORT SOLENOID VALVE v ~ - ""1:9 ..... I

I TO UNIT 1

.... ..., .... _.. .......... I ~ ~ FLOAT SWITCH ........ """" f '

? D FLOW SWITCH -! TO tMT 2

- """ ---<>-<>{!}-liD

~ -<><>{!) THERIIOST AT 1-~

LID /rsJ ~7 ~ ... ~ f--- 0 CONDENSATE TRAP

~ ' ......._ ~ !

,"': .......

C~PRESS~~ '~ THERIIOST AT CONTROLLED

::::::{1 CYLINDER OPERATOR COli PRESSOR ......... '""

TO DRAIN TO DRAIN TO DRAIN ......... )V

........

c ·~ I

c

PENSTOCK GALLERY TO DRAIN

----... 1+-NOTES:

/ FROII GENERATOR COOLING WATER SUPPLY 1. SYSTEM SHOWN IS TYPICAL OF A SIX UNIT FRMICIS PLMIT ,......., WITH 2-SO loiW UNITS MID ~-220 looiW UNITS WITH AILl

~ UPPER • LOWER W!EAAING UNITS EQUIPPED FOR DRAFT TUBE WATER DEPRESSION. ~EPRESSION AIR HEADER A - ~----~ 2. INITIAL CONSTRUCTION PROVIDES 2-DO IIW MID 1-220 IIW. BAY .3 ON!. Y SEE NOTE 2 RING COOLING WATER !50

17 7 DEPRESSION -'Ill HEADER TO BE EXTENDED FOR FINAL 3 UNITS. ' - ......... ......... ~ J. UNSHADEO VALVES-NORMALLY OPEN, SHADED VALVES-NORI.tALLY

-....___ DEPRESSION AIR - .... "-t t.;> '~ CLOSED.

)-o - 0 0 01 SERVICE

ALL DIMENSIONS ARE IN

l 0

B

! ,r SERVICE AIR

MILLIMETERS UNLESS NOTED B

'1 L:>

~ OTHERWISE

-0 0 .... c;>-....,

~ 'A ;( If 0

~ v \ I '\. ~~ 0

~~ _r-,,-t )J~ DRAFT TUBE --.,.$., liNN

if! _v....., [ y y ~ ~ <;>-_.,

\ ....2::r

.... <;>-.. I 'f -AUXILIAAY-:;-'

......... '- A

~~ & ~~ I l ~ .... - -

PENSTOCK DRAFT TUBE HYDROELECTRIC DESIGN CENTER GALLERY ALA.<.:.::. GAllERY .......... .... .... ... " I NORTH PACIFIC DIY., PORTLMID, OR

A A / " OCS~D•

TUBING WEARING RING CODLING WATER I. WICKET .,..,.._

Figure B-15. Draft tube water TO DRAINAGE GATE SEAL LEAKAGE DRAIN CHEO<Z:D•

TUNNEL depression system PR£PM£D•

~

UNIT 3 TYPICAL FOR ALL UNITS SCIII..ES A5 SHOW M£ 8ASED ON 114 ''f""' SIZE

ORIGitUL.. ntiS DflA't9tO WAY HAVE; liED R£DUCED. SUBIIITTED• SCAI...L" NJ llt'IOWN 111H£CT NO. ~ !JC:.iU B"t ~ CRN'MC 9Ctt.£ .......

IIICROSTATION VER 4.0 c:t.Ofi R. loEl.DY. P. E. --4 I ;3 t 2 I 1

D

c

--+

a

A

CORPS OF ENGINEERS

OIL PURifiER ROOM EL.- 915

OIL STORAGE AND PURIFIER ROOMS

SYSTEM N0.3

CROSSOVER HEIIDER TO SYSTEW NO. 2

UNIT J

UNIT 4 UNIT 2

,__------ SYSTEM NO. 1 ONLY

ROUTING VALVE RACK

VALUE ENGINEERING

OIL STORAGE ROOM EL.- 1 830

ROUTING VALVE RACK

GENERATOR CO 2 SYSTEM NO. 1 CSYSTEI.I NO. 2 SIWILARl

WILL INCREASE YOUR PROFITS

ERECTION BAY

KEY PLAN

C02 SYSTEM LOCATIONS

GENERATOR HOUSING

RING HEIIDER

GENERATOR AIR COOLING

2

u.s. ARMY

SYMBOLS ru-- PRESSURE 5'111~ CH

(i)-o- THERWOST AT ELECTRIC

~ C~ DISC.ARGE NOZZLE

-1SJ fiRE DOOR TRlP

~ AIR SUPPLY O.WPER TRIP

------., AIR EXHUAS T DAMPER TRIP

~ ROUTING VAL \IE WITH LOCI(INC DEVICE

n- HEIIDER SAfETY RELEASE DEVICE

cp COz PRESSURE BLEEDER

{><:}- GATE VALVE

r=:::::J fiRE DOOR

-P DISCHAAGE INDICATOR

PIPE CN>

COWBUST/ON PRODUCTS DECTECTOR

BALL CHECK VALVE

BREAK GLASS STATION

NOTES: 1. SYSTEiol SHOWN IS TYPICAL OF ~ 8 -UNIT PLANT WITH

PROJECT FACILITY FOR STORAGE OF PAINT AND FLAMNABLE LIQUIDS OUTSIDE POWERHOUSE

2. COioi~USTION PRODUCTS DETECTORS CONNECTED 10 ANNUNCIATION SYSTEM ONLY

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER NORTH PACIFIC DIV., PORTLAND, OR

D

c

B

~~~,~~~~----~--------------------------------------~ A

Figure 8-16. Carbon dioxide """"'~===~ fire protection system

(Sheet 1 of 3)

SUBiiiTTED•

GlDfoj R. t.IELOY, P. E.

D

c

B

A

CORPS OF ENGINEERS I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I

• _NOTE 1, PLATE 2 ......-ANN. _....-SEE DETAIL "A" _,.-ANN. _....-SEE DETAIL "A" ......-ANN. _....-SEE DETAIL "A"

--oiPS-18 l• •- / "'"PS 1A f.. PS-28 l• •- rk :I~PS 2A .&- PS-J8,J• • -~ ~ ikJ~PS-3A /' • • I ro---~ 1 . L-11, .~~ p ... ,-;---~ I - N p • • ,-;---~ - ~ I') ~ ~ ) ".

1 TRIPsJ I : ... . r TRIPsJ I X ... . rl TRIPsJ 1 x ........ . ~ 1

I ~--~ I ~- _~_ J ~ ~ g ~t~ ~--~ I b:__ J ~-~ g ~ ~ ~--~ I ~- J ~ ~ ( g ~ ~-~ ~~ l I sc I ,- - r- -I ~ .. ~ (G •• I sc I If- - r- -· -, ~ .. ~ (G • ,. I sc I r r- - ~ I ~ ,. . ~ (G •• I I ~

1 2~_ ;o~~ •00

I 1 2~ 10~~ •1

!Xl I 1 2]_;cp ©~~~ IXl 1 G·· 1 •• I NOTE 2, , ... /--''---- I I NOTE 2, ,•~r--- I NOTE 2, ,•p-'~----rJ I 21 I PLATE 2---1-- • • PLATE 2---1-- • ,. L I PLATE 2---1-- • • "" n.

I j_ RV-1 -+- - _I j_ RV-2 ~~- - . j_ RV-3 t- - .I CR-2

1 ----<) I :__ ----<) I :_ :-----0 I ~ :__

I I

..l.. I o--------_.J ..l.. l o---------'

QCR-1 ---o o-~.-----------------------------------~._ ____________________________________ ._ ______________________________________ ~ GENERATOR 1 GENERATOR 2 GENERATOR 3

GENERATOR PROTECTION CONTROL SYSTEM CTYPICAU

• ~NOTE 1, PLATE}- ANN. _,...- ANN.

;:tB } ~- ./ _ ,..--PS 4A .......-:,SEE DETAIL "A" PS-SB 1,. •""'- / ,..--PS-5A ./':.SEE DETAIL "A"

f±--~~~ ~~-J~ ~(/' oc( • • tt>t1u~l mp 1 .• • r±--~· II ~-l-"1 f/' oc( • • ~-~1u~I m "" I I T I IT I ...,. "' z a ...,. I - T I IT- I 'f r U) Cl It) "' L: ___ !__j L'.__ _ _.l 0f- ~ - 1-- 01- L: ___ !__j L'.___ _J 0f- ~ t-- 0f-l I ~- L.j 1 1 !-- 1 I I ~' 1 l '? I I- 1 I I I -- ...:;..,----, ~~ I g: g: I 1 .-- -:;~~I~ g: I

1 v;1c 1 I 76,1 I I 2p_IO~~<f'• m- .... I 1 2 IQ~~(~ ffi. ~· ~ .. 1

/ANN. / _ ,..--PS-6A .......-:,SEE DETAIL "A"

... T [L__J-l /' T ~1~1 I !i~~-.l. i f oc( • .. I- u (D ••

I - I 'f'_f Vl Cl <0 '-i..I.__ _.l ~f- ~ ~ !- v,+

I o~11'f' 1 t- 11 b '-1crcr I

I -r-~-, ~ , ........ I V?cJI

1

••• I I G G ~-,@ 1 ( .. ·: ! t _It G G I ( • .. : i Qr_ !r ~~-Q~ I I NOTE 2,1 ....)- - - - I 6 '51 ~-.. I NOTE 2,1 lJ- --__J c I It) ~... I

PLATE i-- ~-ti .a: ...rt- I PLATE i ..- }i111 It) t- -; 1 I .... c~: 2 1 2~ .... C)>: 2 1

I 2 ~~~~~I ~fl"''. ~-I I I

INOTE 2, I ~ - - - I 4.1 <0 ~-.I PLATE y ~ ·~9 o! ~·

;t ALARM T cr I ;t ALARM~ T cr I 1 ----<)r- <RESET IF REQ'Df..l I ----<)r- <RESET IF REQ 1Di-../ , I 3 ~· 3 ~· I CR8 I - £NOTE 3, PL~E 2 CR- A I

-1 ~ :!o!o!o!ol ~ --<) OIL STORAGE ROOM L'- - - - - -

;t ALARM o;: ~~ I cr r- <RESET IF REQ'D)J

~ FLAMMABLE STORAGE ROOM

OIL PURIFICATION ROOM

ROOM PROTECTION CONTROL SYSTEM <TYPICAU

CAL TERNATE 1)

a

b~-1 DETAIL "A"

TH 4

TH •" G

MICROSTATION VER 4.0

I T 2 I

U.S. ARMY

SYMBOLS CR CYLINDER RELEASE

PS PRESSURE SWITCH

TH THERMOSTAT

TS CIRCUIT CONTINUITY TEST SWITCH ~----+---------------------------~0

TDC

ANN

5C

181PS

®

© ...

MS

RV

TR

URX

TIME DELAY CLOSE

ANNUCIATOR CONTACT

COMPLETE SHUTDOWN RELAY

TIMING RELAY RESET-TEST SWITCH

CONTACT

BLOCKING DIODE

PRESSURE SWITCH

DISCHARGE NOZZLE

ALARM BELL

RED INDICATING LIGHT

GREEN INDICATING LIGHT

INDICATES SEVERAL CONTACTS IN PARALLEL

MANUAL SWITCH IN EMERGENCY BREAK GLASS STATION

ROUTING VALVE RELEASE

TIMING RELAY

UNIT RUN AUXILIARY RELAY

1-

c

:-~----+---------------------------~

87GX

D 0

UNDER VOLTAGE RELAY GENERATOR DIFFERENTIAL AUXILIARY RELAY LOCATED IN C02 CONTROL CABINET

SHUNT TRIP

2 POLE CIRCUIT BREAKER

ROUTING VALVE <AUTOMATIC OPENING)

~ CHECK VALVE

iJ- PRESSURE OPERATED RFl EASE (TRIP)

B

L LEVER OPERATED ~-Mf~~-P~L~U~G~V~AL~V;E~---------------4-

HYDROELECTRIC DESIGN CENTER NORTH PACIFIC OIV., PORTLAND, OR

-

~~~·~=m~~--.---------------------------~A

hii:.i'ii"i::~·::=. ==l Figure B-16. (Sheet 2 of 3)

SUBioiiTTEDt

GlEHi R. IEl.O'I', P. E.

D

c

B

A

CORPS OF ENGINEERS

NOTE

4

OIL PURIFICATION ROOM CONTROLS SIMILAR TO OIL STORAGE ROOM

VALUE ENGINEERING

FLAMMABLE STORAGE ROOM CONTROLS

<SEE NOT:.7 PS:4B

0T ,___L__-o I~

I I I I I I I I I I

OIL STORAGE ROOM

ROOM PROTECTION CONTROL SYSTEM <TYPICAL> (AlTERNATE 2>

I I I I I I 1

c----.

WILL INCREASE YOUR PROFITS

GEN. NOZZLE~

PRESSURE 1 SWITCHES IN t>

C02 HEADER

PS-1A

PS-18

RV-1

GEN. GEN. y y C>

C02 BANK

GENERATOR PROTECTION SYSTEM

OIL PURIFICATION ROOM

FLAMMABLE STORAGE ROOM

OIL STORAGE ROOM

OIL PURIFICATION FLAMMABLE ROOM STORAGE ROOM

PRESS.-OPERATED RELEASE, VENT SUPPLY

PRESS. OPERATED RELEASE, VENT EXHAUST

PRESS. OPERATED DOOR RELEASE CNO. AS REQ'Dl ------tiJ--1

RV-4

C02 BANK

ROOM PROTECTION SYSTEMS-TYPICAL (AlTERNATE 1l

C02 PIPING SCHEMATICS

PS-4A PS-48

SEE NOTE 4

PS-5A PS-58

CR-6A.~ C02 BANK

2

U. S.ARMY

TYPICAL TEST SWITCH (SPRING RETURN TO NORMAL)

CONTACT NORMAL TEST 1 X 2 X 3 X 4 X

NOTES:

1. LOCATED ON MAIN D-C SWITCHBOARD

2. EMERGENCY BREAK-GLASS STATIONS LOCATED ON UNIT ACTUATOR OR GENERATOR HOUSING FOR GENERATORS, AND OUTSIDE DOORS TO OIL STORAGE, PURIFICATION AND FLAMMABLE STORAGE ROOMS.

3. SHUNT TRIPS FOR OIL PURIFIER, GENERATOR, LUBE OIL AND INSULATING OIL PUMP BREAKERS.

4. FLAMMABLE STORAGE ROOM CONTROLS SIMILAR TO OIL STORAGE AND OIL PURIFICATION ROOMS, EXCEPT PRESSURE OPERATED SWITCH NOT REQUIRED FOR SHUNT TRIPS.

HYDROELECTRIC DESIGN CENTER NORTH PACIFIC OIV .• PORTL~D. OR

D

c

B

~~ru----.----------------------------~A

~==~--l Figure 8-16. (Sheet 3 of 3)

GLENN R. loiELOY, P. E • ..,..,.,...,... __

CORPS OF ENGINEERS VALUE ENGINEERING

D

c

150 150

a t f

0

150

A

+

WILL INCREASE YOUR PROFITS

TRANSFORMER DECK EL. 306 325

DELUGE HEADER

PENSTOCK GALLERY EL.291390 & 292 150

PUt.jp SUPPLY HEADER

200

250

150

2

150

t

D

250

150

t

FIRE PUMP !TYP.l 60 L/S

PUMP SUPPI.. Y HE.<OERS

U. S.ARMY

SYMBOLS -- SPRAY NOZZLE

-t><l- GATE VALVE

~ DELUCE VALVE

~ CHECK VALVE

~ BU"ITERFLY VALVE

-e- SINGLE STRAINER

-EJ PUMP

Y-TYPE STRAINER

NOTES: 1. SYSTEM SHOWN IS TYPICAL OF A IHJNIT PLANT WITH

TRANSFORMERS LOCATED ON OUTSIDE DECK. INITIAL INSTALLATION OF 8 TRANSfORMERS IS SHOWN WITH HEADER TO BE EXTENDED LATER FOR 4 .OODITJONAL TRAHSFORioiERS.

2. SINGLE AND 2 PUMP ARRN<GEioiENT SHOWN WAS QUE SPliCE CONSIOERI\TIONS IN CALLERY. ALL 3 PUt.jpS START ACTUATION OF ANY DELUCE VALVE.

l. PUioiPING CAPACITY BASED ON SPRI\YING ANY J .OOJOININC TRANSfORMERS SIMUL T N<EOUSL Y.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER

D

c

a

NORTH PI\CIFIC DIY., PORTLN<D, OR l~w-.Q«~gft..-----.--------------~------~--------------~ A

(~&~iftiT#l-~W1:1~5GENERATOR)

Figure B-17. Transformer deluge system

SUBMmED<

GtDI¥ R. WELDY, P. E.

D

c

B

A

CORPS OF ENGINEERS

<1

<1

A

<1

11580

<1

VALUE ENGINEERING

<1

<1

<1

<1

15 850

<1

<1

PLAN EL. 195070

WILL INCREASE YOUR PROFITS

...

'

ADN>TDR - COPPER SOLDER TO 20 NPT

10 OIA

~ GRIND PLUG NolO WELD fLUSH WITH SURFACE

DETAIL "A"

EL. 195070 FINISHED Fl.ODR

,5:/f\.. 150 A 150 l. 150 A 150 A 150

f-- r+- r+ - f+_ ~ -rt

v 2 <1A

V_ r

20 TYP

SECTION B-B

SECTION A-A

2

L

DRlLL AND UP 20 NPT

FACE OF PLATE TO BE FLUSH NCRETE SURF ACE WITH CO

DETAIL "B" v-20 TYP

U..184 920

U. S. ARMY

D

c

10

v .. ,.. /

r PIPE TRENCH

<I

Ll

NOTES: 1. PIEZOI.IETER PROVISIONS SHOWN AAE TYPICAL OF

THOSE IN A LAAGE K.tPLAN UNIT POWERHOUSE WITH CONCRETE SPIRAL CASES.

2. LINES SLOPE UP FROM T ,tp 1 PER 50 M!Nllo!UI.I.

J. UNES SHOULD BE PLUGGED AND IDENTitlED AS TO SOURCE BEFORE EMBEDI.IENT.

4. FOR PIEZOMETER PROVISIONS IN fRANCIS UNITS SEE PACE A·1J.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER

B

NORTH PACIFIC DIV .• PORTLAND. OR ~~~~---.---------------------------------------1 A

SUBMIT TEO:

Figure 8-18. Turbine peizometer provisions (Continued}

GLENN R. t.El.OY. P. E.

D

c

B

A

CORPS OF ENGINEERS

. .

q

SECTION D-D

4. ..

UNIT 2

~ EL

4 VALUE ENGINEERING WILL INCREASE YOUR PROFITS

00

UNIT 1

PLAN-ELEV. 1556

UNIT 1 ONLY A ~ '/ ~ ANGLE VAL \IE

~-4 R-3 R-2 R-1 C-1 C-~ =£ v 20 NPT .. A-A-A-A-A-·~· ~Y {EL. 474445

1120 150 150 150 150 150 150 120

r A

• 474115 e-e-e-A-.!.

-® SECTION E-E

J, __ J, ~EL. 473810

EL. 474675 CONNEC:nON OF TUBING FROW GIBSON T N>S ON WAIN PENSTOCK UPSTREN.I FROW BIFURCATION

CONNECTED DURING TESTING BY MANIFOLDS AND TUBING

DRILL FOR 0.005-0.010 CLEARANCE WITH PLUG

CUT ANO GRIND flUSH WITH PLATE AFTER FIELD PRESSURE TEST

BREAK CORNER AFTER GRINDING

10 DIA.

1830 1830 r,, C 3 ~ EL. 474 175l

C 2 {: EL. 4741755

4

. .

UNIT 1 ONLY

EL. 473355

SECTION C-C

7 5 3

__[50 .. l

~1 J ~ 230 230

. ...

230

2 4 6 8 A .

:f ~ 230 230 2.30 230 ~

20 GLOBE, NPT TYPICAL

SECTION 8-B

PIEZOMETER PLUG

BRASS !20 <;CH 40

20 COPPER TUBING

SEE NOTE 4

DETAIL "C" PIEZOMETER NIPPLE

2

. .

SECTION F-F

NOTES:

. 4

..

..

. . ..

1. PIEZOWE TER PROVISIONS SHOWN ARE TYPICAL Of A 2-UNIT FRANCIS PLANT WITH SINGLE PENSTOCK AND BIFURCATION CONNECTIONS TO THE TWO STEEL SPIRAL CASE EXTENSIONS.

2. ALL LINES SHOWN ARE 20 TYPE K COPPER TUBING.

3. SLOPE ALL LINES 1 PER 50 lotiNIWUN.

• SEE SET AIL "C" TYPICAL

4. ON ALL CONNECTIONS TO SPIRAL CASE AND SPIRAL CASE EXTENSION WRN> fiRST 230 OF TUBING ANO FITTINGS WITH 1" THICKNESS OF BURLAP TIE PLASTIC fiLiot OVER 8URLAP FOR WATER PROOFING.

5. PLUG LINES AND TAG AS TO SOURCE BEFORE EMBEDMENT.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER

U. S. ARMY

D

c

B

NORTH PACIFIC DIV., POIHLANO, OR ·~~~~noD•~---,--------------~------~--------------~ A

Figure B-18. (Concluded)

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Gl.E)fll R. MELOY, P. E.

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CORPS OF ENGINEERS

C.!. SOL PPE

CJ.SOL PPE

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FLOW

Ll A FIRST POUR

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VALUE ENGINEERING WILL INCREASE YOUR PROFITS

600 !WHERE STRUCTURE PERMITS)

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N 0 T E: WRAP P1PE Willi APPROX. 2~ THCK LAYER OF 1-WR FE!. T BURLN', STYRAFOAM OR FBER GLASS N>IO ENCLOSE WITH SHEET WETAL PPE.

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600 C\I'HERE STRUCTURE PERIIITSl

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DETAILS OF EMBEDDED DRAINS CROSSING CONTRACTION JOINTS

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NOTE: METHOO OF PASSING EloiBEDOED SOL P1PE THROUCH CONTRACTION JOINT WHEN CONCRETE AT DOWNSTREAM END OF PPE l.l£ IS PLACED BEFORE THAT AT THE UPSTREAM END.

ALL DIMENSIONS ARE IN MILLIMETERS UNLESS NOTED OTHERWISE

NOTE: METHOO OF PASSING EMIIEDOED SOLPPE THROUGH CONTRACTION JOINT WHEN CONCRETE AT UPSTRE..w END OF PPE l.l£ IS PLACED BEfORE THAT AT THE DOWNSTREAM END.

U.S. ARMY

HYDROELECTRIC OESICN CENTER

D

c

B

NORTH PACIF'IC DIV., PORTLAND, OR ~~~a«~~~---.----------------------------------~ A

IIICROSTAno.ll VER 4.0

SU!UTTED<

Figure 8-19. Embedded drains crossing contraction joints

GI..ENN R.loELOY, P. E.

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2.!5 3 4 ~ 6 7 B Q JC0 t.~ ::! L,~ 3 4 5 6 7 8 9 \000 1.!5 2 2.!5 3 4 7 B Q

LOSS'-FT. OF OIL PER 100 FT. OF TUBING

\0000 1.!5

by NPD, 2 2.!5 3 4

Corps of Engineers, 7 8 " 1

U.S.A.

D

c

B

A

CORPS OF ENGINEERS

D-1

1392 ---

1279 WIN. • 3284 MAX.

OUTSIDE AIR INTAKE

0 - 2010 WAX. RECIRCU..ATEO ---------

0-2

me n n -~ u u

EH-2 WC-2

I

ol-6711

VALUE ENGINEERING WILL INCREASE YOUR PROFITS

2359

354 IMN.

2.359 WAX.

• I CELINC VENTS -,--, I 472 --f-. I --

GENERATOR ROOW 1

.-- ---472

_j

472 --85 -=o -+------__J

r- 472

SPIRAL CASE CALLERY

1811

~ Ef-1 9------'7._,3~6 __ :1----------l------G----SF--2----SF-·-1---f----~-5~----- }~1;::8..:.11 __ /..J/---'f0--1-1---• OIL ROOW ~~-.L-~

~---------~

I 212 r-

1085

AH-2 101!5

PENSTOCK VALVE

- - - - - -- - - - - - - - - - - - - l ~-

I _____ _ 1180

DRAfT TUBE

GALLERY

f I I 95

I 95

MECHANICAL EQUIPMENT

1811 -f--., TO UC-1 I

95

ELECTRIC • TOOL

I 1---- I -

I

,-- ------------------ ---------------I

I I

47

I SEWAGE E..ECT!ON

I

~ 217

BATTERY

I I

1 283

WATER TREATMENT

-

217 j 283 -

I I I l

-t--

1

t I I I I

1- 1-I 1811 MAKE UP VF-1

-------1

I I I I I I I I I I

I

I 2534

I

L 2723 - -r-

AH-1

151

-EH-18

-2723

2-4-07 ~·-----~--+-~----~--

'----­

EH-1C

.----+ ... 24

165

lUNCH 151 151

-f- - -- - -- - -f-c-

CONTROL 2383

--f-

165 --------- -,-TOILETS • LOCKER

'---

EH-1A

24

JANITOR 24

-f-- - -- - -- - -

• 24

TOILET ATTIC

151

lUNCH

ATTIC

--- - -i

11!9

' I I I I

-- J

453

' I ---<]

283

' I -fJ

Ef-2

Ef-3

I U.S. ARMY

SYMBOLS FLOW DIRECTION

SUPPLY AIR

EXHUAST AIR

RECIRCLLATED AIR

~~~=IF~D~_F_RE~---'D~~~--------~ D

Sf"o SUPPLY F~

EXHUAST fNl

vFO H000 W/VENTLESS f~

AH AIR H~JNG UNIT

EH ELECTRIC HEATER

we WATER COOLING COILING

21!3 283

Sf"-4 SF-3

TURBINE PIT TURBINE PIT

i 283 283

UNIT NO.2 UNIT NO.1

NOTES: 1. SYSTEII SHOWN IS TYPICAL OF A 2-UNIT POWERHOUSE IN

IIlLO CLIMATE WITH POOL-TAILWATER AVAILABLE AT 7-C

FOR SUMMER COOLING ~D WINTER HEATING REQUIREMENTS

SUPPLIED WITH ELECTRICAL RESISTANCE HEATING.

2. IIAINTEN~CE SHOP IS OUTSIDE POWERHOUSE.

3. GENERATOR CEILING VENT DAI.IP£RS ARE SET TO WjNTAIN A

POSITIVE PRESSURE IN POWERHOUSE.

4. FOR CONTROL DIAGRAM SEE PAGE A-17.

ALL FLOWS ARE IN LITERS PER SECOND UNLESS NOTED OTHERWISE

HYDROELECTRIC DESIGN CENTER

c

B

-

-

NORTH PACifiC OIV •• PORTLAND, OR l~~~~n-0,~---r-----------~------~-----------~ A

SIJillotiTIED:

Figure B-21. Ventilation system

seAL..~!: M SHOWN IIIHEET NO.

MICROS! AT ION VER 4.0 ~ R.NELOY.P.E.

I 2 r

CORPS OF ENGINEERS 4 I VALUE ENGINEERING WILL INCREASE YOUR PROFITS I , u.s. ARMY

SYMBOLS

T-J CJ SUPPLY FAN

we WATER COIL

FS EH ELECTRIC HEATER I ~

DEH-~ WATER PUWP

~ SCR CONTROLLER LUNCH ROOM

~ D DIFFERENTIAL PRESSURE REGULATOR D

(i) TliERIIOSTAT

! rs FLOW SN'ETY SWITCH

r ~ I. (o) DAMPER ' OPERATOR

CONTROL

y·~· l

j- RECIRCULATED ..).® ROOiil

~ AIR l.tiXlNG OIWIPER/W OPERATOR

~ t.IODULATING 3-WAY VALVE T-4 ~

~ I r---

t -{lr- BIILANCING V IlL VE

-IS

,_ INSIDE

MAKE UP OS OUT SlOE

- ...:! ~

MECH. EQUIP. ROOM

YEH-1A

...... '":;~ N.C. NORMALLY CLOSED c BASIC FUNCTION AH-1 TOILET AND N.O. NORioiALL Y OPENED

LOCKER DRAIN TO 1. COOLING CAN BE INITIATED AND ~ MANUIIL Olot.IPER TAIL WATER CONTROLLED BY WARMEST OF THE

I THREE AREAS. 2. AREAS REQUIRING HEAT WILL

FS REHEAT THEIR SUPPLY AIR

-T-5

AS NEEDED. c c

'(

I h

AIR HANDLING UNIT AH-1 COOLING WATER SUPPLY

BASIC FUNCTION AH-2 ---9 1. CONTROL TEMPERATURE IN

,_ ROOF VENTS GENERATOR ROOiol'

~· f· ~-· f· A. BY VARYING t.IIXING DAIIPERS. 8. ELECTRIC RISIST ANCE HEAT. C. WATER COOLING COIL.

2. MAINTAIN A MINIMUM OF 1279 LITERS/SEC. OUTSIDE AIR !NT AKE •

.3. WAIT NN POSITIVE PRESSURE INSIDE POWERHOUSE.

NOTES: 1. CONTROL OtAGRN.!S SHOWN /4R£ THE POWERHOUSE

B SYSTEM SHOWN ON PAGE A-16. B -~~ 2. AIR HANDLING UNIT JIH-2 HEATERS OR COOLING WATER PUMPS DO NOT OPERATE UNTIL WODULATING

DPR-1 DAWPERS REACH LIMIT OF THEIR CONTROL CAPABILITY.

[ f!i:. -

I 0-1 N.C. -

~ i-

POWERHOUSE ---OUTSIDE AIR

1 1 f-----.-INTAKE

,.-----< -r'Fs I

SCR t 0-2 N.O. D

- ..:.r ~ - """' -- -SCR-1 ,..., '-2~ v GENERATOR ROOM SUB·IIASTER THERioiOST AT HYDROELECTRIC DESIGN CENTER c RETURN AIR

NORTH PACIFIC DIV., PORTLAND, OR T A T-2

I OCSQftoED• A

DRAIN TO TAIL WATER Df'tAWI'IIt

Figure 8-22. Heating-cooling-IN GENERATOR ROOII-..... r o<Ee><a)o

P'ltEPAA£0. ventilation system control lr"\.

WASTER THERIIOST AJ COOLING Vt.OiTER SUPPLY fROU TAILWATER

CENTRAL AIR HANDLING UNIT AH-2 SUBIIITTE~ SCAI...Z M SHOWN I SI-1U:T NO..

Gl.£N<I R. MELOY, P. E. ~~

_ .... 4 I 3 i 2 I 1