Toledo Bend Project - STI

Section 9
Spillway Gates

SECTION 9
SPILLWAY GATES

9.1

MATERIAL PROPERTIES

9.1.1 Type of Spillway Gates

a.

There are 11 tainter gates at the spillway, each 40 feet wide. The top
of the gates is at Elevation 173.00, which is 28 feet above the crest of
the weir. Conservation pool is at 172.0 ft MSL in the reservoir.
Releases are instigated when the reservoir level reaches 172.5 ft MSL.

b.

Two gate designs were originally considered by Forrest & Cotton in

1962, designated Design A and Design B. These are shown on
Figure 9.1-1. Design A was selected for construction.

9.1.2 Component Materials

a.

Material properties consist of the following:

Vertical ribs
Skin plates
Girders
Struts

ASTM A441 Steel

ASTM A441 Steel
ASTM A36 Steel
ASTM A36 Steel

b.

Location and sizes of the above components are shown under the
relevant isometric view on Figure 9.1-1

c.

Trunnion Material Properties.

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Trunnion Hub
Bushing
Trunnion Pin
Bearing Ring
Thrust Ring
Trunnion Yoke
Pin Cover Plate
Box Girder

Forged Steel Class C

Bronze Alloy ASTM B22 Alloy E
Forged Steel A237, Class B
Bronze Alloy ASTM B22 Alloy E
Zinc ASTM B69, Type III
Steel ASTM A36
Steel ASTM A36
Steel ASTM A36

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d.

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Section 9
Spillway Gates

Friction Properties. The friction properties of the trunnion are not

indicated in the available documents prepared by Forrest & Cotton.
However, Brown & Root contacted the Lubrite Company by phone in
1998, and were told that the trunnions are permanently lubricated and
the coefficient of friction could be in the range of 0.07 to 0.15.

Page 9-2

Figure 9.1-01
TAINTER GATES
DESIGN ANALYSES

Toledo Bend Project - STI

9.2

Section 9
Spillway Gates

SUMMARY OF STRESS ANALYSIS COMPUTATIONS

9.2.1 Stress Analysis

The stress analysis conducted by Forrest & Cotton in 1962 is summarized on
Figure 9.2-1 which includes eight design load cases on the gates. Critical
stresses and bending moments for the vertical ribs are shown on Figure
9.2-2. Further details of the calculations are not available.
9.2.2 Effect of Trunnion Friction on Struts.
In order to assess the effect of trunnion friction on the stresses within the
struts, a STAAD III space frame analysis was performed by Brown & Root in
1998. Conservative assumptions were used for the coefficient of friction
(0.15). The result of this analysis showed that the middle struts were
marginally overstressed at 1.1%, which was judged to be within acceptable
limits.

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Figure 9.2-01
TAINTER GATES
LOAD AND REACTIONS
Sheet 1 of 2

Source: Design Memorandum No. 2

Forrest and Cotton, 1962

Figure 9.2-02
TAINTER GATES LOAD
AND SHEER REACTIONS
Sheet 2 of 2

Source: Design Memorandum No. 2

Forrest and Cotton, 1962

figure 9.2-03
TAINTER GATES - SHEAR
MOMENTS AND STRESSES
Sheet 1 of 2

Figure 9.2-04
TAINTER GATES
SHEAR MOMENTS AND STRESSES
Sheet 2 of 2

Toledo Bend Project - STI

9.3

Section 9
Spillway Gates

TRUNNION LUBRICATION PROCEDURE AND SCHEDULE

The trunnion bushing is a Lubrite self-lubricating bushing. According to the
manufacturer, the bronze bushing is impregnated with graphite and will never
need lubricating. The trunnion anchor covers are welded closed. To date, an
inspection of the trunnion anchor rods has never been conducted.

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9.4

Section 9
Spillway Gates

SUMMARY OF GATE HOIST MOTOR LOAD TESTS

To date, no gate hoist motor test data has been collected or recorded on a
regular basis. The gates are tested at least annually, raised up to one foot
each and then lowered. During the 1998 FERC Part 12D Safety Inspection
Report, the motors were found to be drawing more amperage than their rating
recommended. Investigations regarding the high amperage draw on the
spillway lifting machinery motors should continue and remedial action taken if
appropriate. In 2004, this was investigated by Etheredge Electric from
Shreveport, Louisiana and a report with recommendations is pending. Their
initial investigation, according to Mike Rankin at TBPJO, state that it appears
the initial high amperage readings were a result of reading both the motor and
brake amperage together. Isolated readings of the motor amperage draw
need to be collected to determine if there is a real problem. The independent
consultant has not seen an official report, or made independent readings to
evaluate these statements. The PFMA Report, of 2005, recommends an
extra back-up motor be available on-site for emergency replacement if
needed. This was also recommended at the discovery of the motor
overloading.

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9.5

Section 9
Spillway Gates

SPILLWAY GATE DETAILED INSPECTION REPORTS

NOTE: The following paragraphs contain extracts from prior inspection
reports pertaining to tainter gates Photographs referenced in that text are not
included in this report.

9.5.1 June 1974 FERC Part 12D Inspection Report

4-05. It was noted that some leakage was occurring at all the tainter gates in
the spillway (photograph 3) with the greatest amount flowing from gates 2, 4, 5
and 7. The leakage in every case was found at the bottom seal near the corner of
the gate and was not considered to be excessive or serious.
9.5.2 September 1979 FERC Part 12D Inspection Report
3-06. It was noted that portions of the spillway gate hoist equipment required
painting and lubrication. It is proposed to establish a program for servicing and
maintaining this equipment on a periodic basis.
3-07. A study is planned to determine the feasibility of double circuiting the
spillway gate hoists.

9.5.3 June 1985 FERC Part 12D Inspection Report

2.7

Spillway Gates & Machinery

The spillway gates were inspected for corrosion, and evidence of maintenance
and leaks around the seals on the sides and bottom of gates. The stoplogs were
inspected for corrosion, evidence of stress, damage, or any unusual condition.
The lifting machinery was inspected for evidence of maintenance, corrosion, and
general condition. The spillway gates, stoplogs, and lifting machinery appear to
be in good condition with no evidence of problems. The leakage from the
spillway gates is minimal. The gates, stoplogs, and machinery have been painted
in the recent past, as evidenced by photographs #32, #33, #34, and #35.

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Section 9
Spillway Gates

9.5.4 August 1988 FERC Part 12D Inspection Report

2.7

Spillway Gates & Machinery

The spillway gates were inspected for corrosion, and evidence of maintenance and
leaks around the seals on the sides and bottom of gates. The stoplogs were
inspected for corrosion, evidence of stress, damage, or any unusual condition. The
lifting machinery was inspected for evidence of maintenance, corrosion, and
general condition. The spillway gates, stoplogs, and lifting machinery appear to
be in good condition but there is evidence of corrosion beginning to appear as seen
in photograph #57, #58 and #61. This is an unexpected happening because it is
understood that the gates and machinery were painted in 1984. There has been a
definite deterioration since the 1985 inspection.
One spillway gate was exercised during the inspection. The discharge is shown in
photograph #59. The leakage from the spillway gates is minimal.
6.2.5 Spillway Gates - Corrosion is evident at certain limited areas of the gates
and lifting machinery. The gates were painted in the not to distant past. Touchup
painting of areas evidencing corrosion could be touchup painted to delay the
date when full painting will be repaired. No completion date is assigned to this
recommended action. Delay will result in more touchup work being required.

9.5.5 September 1993 FERC Part 12D Inspection Report

6. Spillway Gates and Machinery

At the time of the inspection the spillway gates and machinery were being painted.
In the painting operation, every gate is raised to the maximum open position to
facilitate surface preparation and painting.
The spillway gates were inspected for corrosion and evidence of maintenance and
leaks around the seals on the sides and bottom of gates. The stop logs were
inspected for corrosion, evidence of stress, damage, or any unusual condition. The
lifting machinery was inspected for evidence of maintenance, corrosion, and
general condition. Photographs #72 through #80 show the gates and equipment.
One spillway gate was exercised during the inspection and the machinery found to
be performing properly. Standby power located in the right abutment transition
section is automatically started weekly and shows to be in good operating
condition.

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Section 9
Spillway Gates

C. Maintenance of Spillway
The gated concrete spillway has eleven steel taintor gates with each gate having an
individual electric motor to hoist it. The hoisting equipment, consisting of the
electric motor, gear reduces and drum, is located above the gates well above
expected PMF water levels. The gates and lifting equipment are now being
painted. During the painting process all the gates are being exercised with each
gate lifted to the maximum up position by the hoisting equipment. Both the gates
and hoisting equipment are maintained by cleaning, painting, lubricating and
exercising on an as needed or periodic basis.
E. Adequacy of Operation of Spillway Gates and Standby Power
A trained, experienced and diligent staff with an appreciation and understanding of
the spillway gate opening consequences is in charge of operating the spillway
gates. During flood release, the staff has available an abundant amount of
information and refined judgement for opening and closing the spillway gates.
The Owners actions in past major flood releases demonstrate their capability in
operating the spillway gates in the prescribed manner. The standby diesel power
generator is adequate for emergency use.

9.5.6 October 1998 FERC Part 12D Inspection Report

6.

Spillway Gates and Machinery

The condition of the spillway gates and machinery is shown in photographs #65
through #73.
The spillway gates were inspected for corrosion, evidence of maintenance and
leaks around the seals on the sides and bottom of the gates. The lifting machinery
was inspected for evidence of maintenance and corrosion, and to assess general
condition. Photographs #72 and #73 show the gate lifting equipment.
The gates show corrosion stains with a particularly bad example in photograph #68.
The gates were painted in 1993 and cathodic protection was added in 1994. The
actual corrosion should be minimized by the cathodic protection. Future corrosion
will verify the effectiveness of the cathodic protection. Photograph #70 shows
corrosion in the top gate arm near the trunnion. This corrosion is caused by
standing water in the arm. A drain hole was undoubtedly supplied in the web of
the beam but the hole has probably become plugged and now should be cleared.
The Authority should continually check all gates and unplug holes to prevent this
condition, as shown in photograph #70.

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6.

Section 9
Spillway Gates

Spillway Gates and Machinery [Continued]

One spillway gate was exercised during the inspection and the machinery was
found to be performing properly.
One matter of concern is that the gate motors are drawing more amps and are
requiring more power to raise than should be needed. Investigations as to the
cause are being made and possible corrective actions are being taken including
lubrication of moving parts, adjusting the brakes and the use other meters to check
the amps. Results of these measures will indicate if the problem persists. If so the
Authority should take actions deemed necessary to correct the matter.
Standby power located in the right abutment transition section is automatically
started weekly and appears to be in good operating condition.

9.5.7 December 2004 FERC Part 12D Inspection Report

h. Spillway Gates and Machinery
1) The condition of the spillway gates and machinery is shown in
photographs S-130 through S-157.
2) The spillway gates were inspected for corrosion, evidence of needed
maintenance, and leaks around the seals on the sides and bottom of the
gates. The lifting machinery was inspected for evidence of needed
maintenance and corrosion, and to assess general condition. Photographs S130, S-132, and S-134 show the gate lifting equipment.
3) The gates show corrosion stains with a particularly bad example in
photograph S-135. The gates were painted in 1993 and cathodic protection
was added in 1994. The cathodic protection seems to have stabilized the
corrosion occurring on the upstream side of the gates. However, when the
anodes were welded to the gates, the paint buckled on the downstream side
which has since corroded at those locations. These spots have been touch
up painted. Photograph S-147 shows corrosion in the top gate arm near the
trunnion. This corrosion is caused by standing water in the arm. A drain hole
was undoubtedly supplied in the web of the beam but the hole has probably
become plugged and now should be cleared. It is recommended that all
gates be checked regularly and that any plugged drain holes be cleared to
prevent corrosion. During the 2004 inspection some minor amount of debris
and water were standing in the web of the beams which make up the gate
arms and gate stiffeners. This should continue to be watched and corrected
as needed.
4) Gate No. 1 was exercised during the inspection and the machinery was
found to be performing properly. Photograph S-136 shows one of the lifting
arms during operation.
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Section 9
Spillway Gates

h. Spillway Gates and Machinery (continued)

5) Gate No. 5 had a rolled J-bulb seal. Replacement at the first opportunity
is recommended because the seal will continue to deteriorate and leak. Gate
No. 4 has water jetting out of the ogee. The trunnion cover plate was
inspected at Buttress No. 11 and found to be welded closed all around.
6) One matter of concern is that gate motors are drawing more amps and are
requiring more power than should be needed. Investigations as to the cause
are being made and possible corrective actions are being taken including
lubrication of moving parts, adjusting the brakes and the use other meters to
check the amps. See Section 5.2 for further details. Results of these
measures will indicate if the problem persists. If so, the recommendation is
for the TBPJO to take actions deemed necessary to correct the condition.
7) A generator for standby power is located in the right abutment transition
section and is automatically started weekly. The system appears to be in
good operating condition.

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