trunion gate resistance analysis - … 3 motivation for work •folsum tainter gate failure •ferc...
TRANSCRIPT
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TRUNION GATE RESISTANCE ANALYSIS
Applied on Diablo Dam, Diablo WA
Robert Gordon| May 7, 2015
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DIABLO DAM GENERAL INFO
• Built: 1927-1929
• Concrete Arch Dam With Gravity Abutments
o389 feet high
o1180 feet at crest
o19 Tainter Radial Gate 20’-6” wide, 18’ to max. Lake
oGates 1-3 Automated in ~1980
oGates 4-19 Operated by Portable Hoist
oNormal Usage Sequence is 2, 3, Teens
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MOTIVATION FOR WORK
• Folsum Tainter Gate Failure
• FERC Part 12 Inspection Item
oModel and Determine Maximum Acceptable
Friction
oFriction Test Gates and Determine Current
Condition
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PRELIMINARY TESTING
• Contracted Consultant For:
oFEA Model of Gate
oDetermine Method to Test
oTest and Determine Friction Factor on a Portion of
the Gates
• SCL Assisted with Initial Testing
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METHOD OF TEST TO DETERMINE TRUNNION
FRICTION
• Cantilevered Beam (73” long) Temporarily
Mounted at Each Trunnion
• Digital Dial Indicator Mounted at The End Beam
• Serial Connection Between Indicator and PC
• Data Collected Using PC Running LabVIEW
• Collect Continuous Data at 10 Hz
• Raise Gate 1 Foot and 2 Foot
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FRICTION TEST RESULTS
• Gate 2 Friction
o0.9 Right
o0.6 Left
•Maximum
Acceptable
Friction Factor
0.3: this is
about
0.56mm*2
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ACCESS TO LOCATION
• Constructed Work
Platform
• Install Gate Restraint
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REMOVAL OF TRUNNION BUSHING CARRIER
• Remove Lead Paint on Trunnion
• Remove 18 1” Rivets Per Side
• Remove Bushing Carrier
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TRUNNION PINS
• Trunnion Surface Corroded ~0.025” deep
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•Machined With Climax PL2000 Portable Lathe
oRemoved ~0.050” off Diameter
oPolished to ~10 Ra
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IMPROVEMENTS TO BUSHING
•Original Bushing had 1 Port with “X” Grove
~+/- 30 Degree of Coverage
•New Bushing (Improve Grease Distribution)
oOuter Circumferential Groove
o4 ports OD to ID
o4 Distribution Bars
o2 Circumferential Grease Dams
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BUSHING CARRIER WORK
• Bore Was Damaged From Bushing Movement
•Medium Porosity Casting
• Counter Bore Bolt Holes
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REASSEMBLY OF TRUNNION
• Bolted Both Sides Together
oSocket Head Cap Screws
oNordlock Lock Washers
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FINAL TESTING
• Dry Gate Opening Test With Beam/Indicator
• Conduct Full Gate Opening
•Wet Gate Opening Test With Beam/Indicator
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TRANSDUCER, LOCATIONS, AND FIXTURES
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SIMPLIFIED LABVIEW DAQ CODE
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ACCESS TO INSTRUMENTED LOCATION
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PRE RING TEST
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WET GATE FRICTION TESTING DATA
• Repaired Trunnion Friction ~0.07
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ALTERNATIVE METHODS TO MEASURE FRICTION
•Mount Strain Gages on Involved Elements
• Strain Gage on Transferable Beam
• Laser/Camera/Burn Paper
• Encoders on Gate Hub
• Load Cells on Hoist Cable/Actuator
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KEY FEATURES IN TESTING SYSTEM
•Need Real-time Indications During Testing
•Method to Archive Test Data
• High Resolution
• Rigid Test Fixtures/High Natural Frequencies
•Weatherproof & Robust
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FUTURE WORK
• Refurbish of All 19 Gates To Greaseless Design
oReduced Future Labor Costs From Greasing
oBronze Bushing Cost ~= to Greaseless Bushing Cost
oLess Environmental Waste
o Instigation Cost Same
o Improved Worker Safety
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NEW GREASELESS BUSHING/TRUNNION DESIGN
• Turn Existing Trunnion to Round and Smooth
• Thermally Shrink Fit Stainless Steel Sleeve to
Trunnion Shaft
• Bore Out Cast Bushing Carrier for New Greaseless
Bushing
• Add Two Energized O-ring Seals on
Trunnion/Bushing Ends
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