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    Tainter Gates O&M

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    chutton681
    This document discusses operation and maintenance considerations for Tainter gates, including issues with wire ropes, chains, trunnion lubrication, drainage, overtopping, and vibrations. It emphasizes the need for regular inspection, lubrication, exercising of equipment, and guidelines to address failures, corrosion, and structural integrity of these gates over time.

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    © All Rights Reserved
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    Tainter Gates O&M

    Uploaded by

    chutton681
    113 views49 pages
    This document discusses operation and maintenance considerations for Tainter gates, including issues with wire ropes, chains, trunnion lubrication, drainage, overtopping, and vibrations. It emphasizes the need for regular inspection, lubrication, exercising of equipment, and guidelines to address failures, corrosion, and structural integrity of these gates over time.

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    tainter gates operation maintenance

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    This document discusses operation and maintenance considerations for Tainter gates, including issues with wire ropes, chains, trunnion lubrication, drainage, overtopping, and vibrations. It emphasizes the need for regular inspection, lubrication, exercising of equipment, and guidelines to address failures, corrosion, and structural integrity of these gates over time.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    113 views49 pages

    Tainter Gates O&M

    Uploaded by

    chutton681
    This document discusses operation and maintenance considerations for Tainter gates, including issues with wire ropes, chains, trunnion lubrication, drainage, overtopping, and vibrations. It emphasizes the need for regular inspection, lubrication, exercising of equipment, and guidelines to address failures, corrosion, and structural integrity of these gates over time.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 49

    TAINTER GATE

    OPERATION
    AND
    MAINTENANCE
    by
    Dr. B.T.A. Sagar & C. Hutton

    USCOLD ANNUAL LECTURE


    JULY 11, 2000
    THE TAINTER GATE
    Developed by Jeremiah
    Burnham Tainter in 1886
    for Menomonie Dam on
    the Red Cedar River in
    Wisconsin

    Clever design that uses


    flowing water to open
    and close gate
    THE TAINTER GATE

    Designed to instantly
    release enough water
    from the mill pond to
    allow the ponderous
    "Red River strings" of
    lumber to float down to
    Dunnville and the larger
    Chippewa River
    THE TAINTER GATE
    (1886 - 1986)
    • 321 Tainter gates on upper Mississippi
    River Basin dams and locks from
    Minneapolis to St. Louis
    • 195 Tainter Gates in the Columbia River
    Basin on 26 dams, including Bonneville and
    Grand Coulee dams
    • 1,000’s more on other dams worldwide

    Ref: Where the Wild Rice Grows, Edited by Larry Lynch and John Russell
    Published by the Menomonie Sesquicentennial Committee
    FOLSOM FAILURE
    EMPHASIZED
    • Accounting for trunnion pin friction in
    gate design
    • Proper and frequent lubrication of the
    trunnion pins with dependable greases
    • Checking the structural integrity of
    existing gates with appropriate trunnion
    friction
    FOLSOM FAILURE
    EMPHASIZED
    • Strengthening the gates if they do not
    meet structural code requirements
    • Periodic detailed close-up climbing
    inspection of all gate components to
    check for corrosion and other deficiencies
    • Strengthening or replacement of corroded
    gate components including rivets or bolts
    OPERATION & MAINTENANCE
    CONSIDERATIONS
    • Wire Rope Failures
    • Wire Rope and Chain Maintenance
    • Trunnion Lubrication
    • Drainage of Gate Members
    • Overtopping Design
    OPERATION & MAINTENANCE
    CONSIDERATIONS

    • Painting / Lead Paint Removal


    • Standby Power
    • Gate Vibrations
    • Gate Jamming
    • Motor Stall Torque
    WIRE ROPE FAILURE
    ISSUES

    • Corrosion at water line


    • Corrosion at connections
    • Galvanic action due to zinc in wire
    rope sockets
    • Overstressing due to drum design
    WIRE ROPE FAILURE
    PROBLEMS
    Multilayer wire
    rope hoist drum

    Problem: round
    wire rope causes
    high stresses and
    accelerated wear
    WIRE ROPE FAILURE
    ISSUES
    Corroded wire
    rope connection

    Problem: stainless
    steel leaf with
    carbon steel
    bracket
    WIRE ROPE FAILURE
    SOLUTIONS

    • Replacement with stainless steel


    • Replacement of wire rope every 5 years
    • Research to understand galvanic
    corrosion between stainless steel and
    zinc
    WIRE ROPE DESIGN
    SOLUTIONS
    • Wire rope should be 6 × 37, preformed,
    lang lay, independent wire rope core,
    18-8 chrome-nickel corrosion-resisting
    steel
    • For multilayer hoist drum-winding, use
    6 × 30 Type G, lang lay, independent
    wire rope core, flattened strand wire
    rope
    WIRE ROPE DESIGN
    REFERENCE

    U.S. Army Corps of Engineers


    Engineering Manual EM 1110-2-2703
    30 June 1994
    Engineering and Design
    LOCK GATES AND OPERATING
    EQUIPMENT
    WIRE ROPE AND CHAIN
    MAINTENANCE
    ISSUES
    • Binding due to corrosion
    • Part of chain or wire rope submerged
    – Difficult to lubricate
    – Difficult to inspect
    • Lubrication frequency
    • Lubricant environmental issues
    WIRE ROPE AND CHAIN
    MAINTENANCE
    Tension
    linkage chain
    (roller chain)
    with pins,
    rollers and
    sidebars
    WIRE ROPE AND CHAIN
    MAINTENANCE
    Divers required
    to lubricate
    submerged
    chain
    WIRE ROPE AND CHAIN
    MAINTENANCE

    Broken guard
    due to
    binding of
    chain
    WIRE ROPE AND CHAIN
    MAINTENANCE
    Damaged
    hoist frame
    due to
    operator error
    and lack of
    limit switch &
    torque limiter
    WIRE ROPE AND CHAIN
    MAINTENANCE
    Link type
    lifting chain
    and hoist
    drum
    WIRE ROPE AND CHAIN
    MAINTENANCE
    SOLUTIONS
    • Stainless steel pins with self
    lubricating bushings
    • Hoist modification for wire rope
    • Regular periodic operation
    • Bulkhead or stoplogs for access
    • Environmentally acceptable lubricants
    TRUNNION LUBRICATION
    AND FRICTION
    ISSUES
    • Access
    • Frozen grease ports
    • Frozen pins
    • Frequency of lubrication
    • Type of lubricant
    TRUNNION LUBRICATION

    Difficult access
    TRUNNION LUBRICATION

    Frozen pins
    TRUNNION LUBRICATION

    Remote lubrication lines


    TRUNNION LUBRICATION
    AND FRICTION
    SOLUTIONS

    • Provide access
    • Remote / automatic lubrication
    • Lubricate before and while operating
    • Use bulkhead to avoid wasting water
    TRUNNION LUBRICATION
    AND FRICTION
    REFERENCE

    U.S. Army Corps of Engineers


    Engineering Manual EM 1110-2-1424
    28 February 1999
    Engineering and Design
    LUBRICANTS AND HYDRAULIC FLUIDS
    DRAINAGE OF GATE
    MEMBERS
    ISSUES
    • Often overlooked in design
    • Holes too small
    • Inadequate removal of debris
    • Premature coating deterioration
    • Shortened life span of gate
    DRAINAGE OF GATE
    MEMBERS
    Girder and
    arm
    corrosion
    due to poor
    maintenance
    and clogged
    drain holes
    DRAINAGE OF GATE
    MEMBERS
    SOLUTIONS

    • Add drain holes where needed


    • Enlarge drain holes
    • Minimum size 1”x2” oblong or 2”dia
    • Clean gate at least annually to
    remove debris
    OVERTOPPING DESIGN
    ISSUES
    • Inadequate spillway capacity
    • Increased runoff in watershed
    • Loss of reservoir storage capacity
    • Human error or slow response
    • Loss of emergency power supply
    • Mechanical or electrical failure
    OVERTOPPING DESIGN
    REALITY

    ARE WE WILLING TO TAKE THE RISK?

    IT HAS HAPPENED AT SEVERAL DAMS


    OVERTOPPING DESIGN
    SOLUTION
    • Ogee crest on top of gate
    • Side shields to protect gate arms
    • Redundant emergency power supply
    • Redundant control systems
    • Increased spillway design capacity
    • Provides skimming capability
    OVERTOPPING DESIGN

    Ogee Lip
    OVERTOPPING DESIGN

    Tainter Gates with ogee lip and side


    shields designed for overtopping
    PAINTING / LEAD PAINT
    REMOVAL
    ISSUES
    • Resources Conservation and
    Recovery ACT (RCRA)
    • Occupational Safety and Health
    Administration (OSHA)
    PAINTING / LEAD PAINT
    REMOVAL
    SOLUTIONS
    • Field & laboratory tests to detect
    existence and content of lead paint
    • Paint over existing coating (adhesion
    tests)
    • Remove lead paint and apply new
    coating
    PAINTING / LEAD PAINT
    REMOVAL
    COATINGS
    • Alkyd enamel and aluminum
    • Vinyl
    • Coal tar epoxy
    • Epoxy polyamide coating
    • Thermal coating (metalizing with zinc)
    PAINTING
    REFERENCE

    U.S. Army Corps of Engineers


    Engineering Manual EM 1110-2-3400
    30 April 1995
    Engineering and Design
    PAINTING: NEW CONSTRUCTION AND
    MAINTENANCE
    METALIZING
    REFERENCE

    U.S. Army Corps of Engineers


    Engineering Manual EM 1110-2-3401
    Engineering and Design
    THERMAL SPRAYING: NEW
    CONSTRUCTION AND MAINTENANCE
    29 January 1999
    METALIZING
    REFERENCE

    International Metalizing Corporation

    www.intmetl.com
    STANDBY POWER
    ISSUES

    • Lack of maintenance
    • Lack of periodic exercising
    • Untrained personnel
    STANDBY POWER
    SOLUTIONS
    • Regular periodic maintenance
    • Periodic exercising under load
    • Portable engine generator and
    operator
    • Backup emergency power supply
    GATE VIBRATIONS
    ISSUES

    • Improper gate bottom geometry and


    bottom seal configuration
    • Use of J-seal on bottom of gate
    • Impingement of gate members
    GATE VIBRATIONS
    SOLUTIONS

    • Prevention of jet impingement on


    gate members at the bottom during
    underflow
    • Provision of a thin rectangular seal
    at the bottom of the gate
    GATE JAMMING
    ISSUES
    • Bulging of concrete due to
    aggregate-silica-reaction
    • Trash or debris between gate and
    pier
    • Uneven chain or rope pull
    • Infrequent lubrication and seizing of
    guide rollers
    GATE JAMMING

    Tainter gate side


    shoe with rollers
    that can sieze and
    cause gate
    jamming
    GATE JAMMING
    SOLUTIONS
    • Trimming of pier concrete or gate
    skinplate
    • Frequent checks and annual
    inspections to ensure even rope pull
    • Turnbuckles to adjust rope pull
    • Guide rollers with stainless steel
    pins and self lubricating bushings
    SUMMARY
    • Research needed for:
    – environmentally acceptable lubricants
    – compatibility and corrosion of metals
    – training of operators
    – compatible wire rope and drum designs
    – guidelines for structural evaluation and
    trunnion friction
    – guidelines for proper operation and
    maintenance of tainter gates and hoists

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