the lock valves are worn out, now what?
TRANSCRIPT
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US Army Corps of Engineers BUILDING STRONG®
Repair and Replacement Guidance for Lock Culvert Valves or The Lock Valves are Worn Out, Now What? U.S. Army Corps of Engineers Navigation Structures Research Program U.S. Army Engineer Research & Development Center Coastal and Hydraulics Laboratory Navigation Branch Richard Stockstill
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Current Situation Design Life Many structures have reached or exceeded their design life. Valves are being repaired or replaced. Engineering Design Maintenance, rehab, or replacement of lock valves often requires
engineering design. EM 111-2-1610 “Hydraulic Design of Lock Culvert Valves” has not
been updated since 1975. O & M Experience Some replacement valves have not performed well
► Larger hoist loads – both downpull and uplift. ► Vibration issues.
Field measurements suggest that current design guidance under-predicts hoist loads.
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Webinar Outline References: Sources of Information Lock Filling & Emptying Systems Types of Lock Valves
► Vertical Lift ► Conventional Tainter ► Reverse Tainter
Hydraulics of Lock Valves ► Flow Conditions during Operation ► Cavitation Potential
Hoist Loads Repair & Replacement Project Examples
► Watts Bar Lock – Tennessee River ► Snell & Eisenhower Locks – St. Lawrence Seaway ► Bankhead Lock – Black Warrior River ► John Day Lock – Columbia River
Valve Stabilizers Summary
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USACE HQ Engineering Manuals
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Hydraulic Design
Planning
Mechanical & Electrical Design
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Corps’ Design Guidance
Hydraulic Design EM 1110-2-1604 “Hydraulic Design of Navigation Locks” EM 1110-2-1610 “Hydraulic Design of Lock Culvert Valves” Mechanical Design EM 1110-2-2610 “Engineering and Design – Lock and Dam Gate
Operating and Control System” General Discussion EM 1110-2-2602 “Planning and Design of Navigation Locks”
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Physical Model
Prototype Experience
Navigation Structures Research Program Publications
Computational Model
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Design Considerations
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Navigation Projects Visited or Tested Lock Project River/Waterway Chamber Size, Width
and Length, ft Culvert Width and Height at Valve, ft Valve Radius, ft Reverse Tainter
Valve Design Lift, ft
Eisenhower St. Lawrence Seaway 80 x 860 12 x 14 21.0 DSP 43
Snell St. Lawrence Seaway 80 x 860 12 x 14 21.0 3 DSP, 1 VF 49
Bankhead Black Warrior 110 x 600 14 x 14 20.0 VF 69
Holt Black Warrior 110 x 600 12.5 x 12.5 17.0 VF 64
Melton Hill Clinch 75 x 400 8 x 10 16.0 VF 54
Cheatham Cumberland 110 x 800 12.5 x 12.5 18.0 DSP 26
Barkley Cumberland 110 x 875 16 x 16 24.0 DSP 57
Fort Loudoun Tennessee 60 x 360 6 x 7 10.7 DSP 70
Watts Bar Tennessee 60 x 360 6 x 8 10.75 VF 70
Chickamauga Tennessee 60 x 360 8 x 8 10.58 VF 50
Wheeler Tennessee 110 x 600 12 x 14 20.5 DSP 48
Wilson Tennessee 110 x 600 15 x 15 22.0 DSP 94
Kentucky Tennessee 110 x 600 12 x 12 16.0 DSP 56
Demopolis Tombigbee 110 x 600 12.5 x 12.5 18.25 PDSP 40
Whitten Tennessee-Tombigbee 110 x 670 14 x 14 20.0 VF 84
Heflin Tennessee-Tombigbee 110 x 600 13.5 x 13.5 19.0 VF 36
Bonneville Columbia 86 x 675 12 x 14 19.5 VF 69.5
The Dalles Columbia 86 x 675 12 x 14 19.5 DSP 90
John Day Columbia 86 x 675 12 x 14 19.5 DSP 110
McNary Columbia 86 x 675 11 x 12 17.0 DSP 92
[1] Tool (1980) [2] Neilson (1975) [3] McGee (1989) [4] Waller (1997) [5] Neilson and Pickett (1986) [6] US Army Engineer Waterways Experiment Station (1960)
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Physical Model Studies
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Lock Project River/Waterway Model Scale
Prototype Culvert Width x
Height, ft
Model Culvert Width x
Height, ft
Reverse Tainter Valve
Design
Lift, ft
Snell St. Lawrence
Seaway 1:15 12 x 14 0.83 x 0.83 DSP & VF 49
Holt Black Warrior 1:15 12.5 x 12.5 0.83 x 0.83 VF & DSP 64
Watts Bar Tennessee 1:10 6 x 8 0.60 x 0.80 VF & DSP 60
Walter Boulden Coosa 1:15 12 x 12 0.80 x 0.80 VF 130
Lock 19 Mississippi 1:12 14.5 x 14.5 1.21 x 1.21 HF 38
McNary Columbia 1:20 11 x 12 0.55 x 0.60 DSP 92
John Day Columbia 1:25 12 x 14 0.48 x 0.56 DSP 113
DSP = Double-Skin Plate VF = Vertical Frame HF = Horizontal Frame
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Lock Filling & Emptying Systems
Classification by Lift
Range of
Maximum Design
Lift
Project
Classification
% of CoE
Locks
Suitable Design Types
0 to 10 ft Very Low Lift 25 End F&E (primarily sector gate)
10 to 30 (or 40) Low Lift 60 Side-port system or Lateral w/ 1
Culvert
30 (or 40) to 100 High Lift 15 Longitudinal Manifold System
100 to ? (not yet
determined)
Very High
Lift 1
John Day is the exception w/ design
lift of 107 ft
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ELEVATION - LANDWARD CULVERT
PLAN
Landward Wall
Intermediate Wall
Filling Valves Emptying Valves
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Sidewall-port System
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Sidewall-port System
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Interlaced Lateral System
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Split Lateral System
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Single H System
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Single H System
Bottom Longitudinal Filling & Emptying System with Reverse Tainter Valves
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Double H System
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McAlpine
Marmet
In-chamber Longitudinal Culvert System (ILCS)
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In-chamber Longitudinal Culvert System (ILCS)
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3 Valve Configurations
FLOW
PLAN
ELEVATION
W
B
Vertical Lift Valve
Bulkhead Slot
Vertical-Lift Valve
L
R
B
C bb
c
hPiezometric Gradeline
HL
V
V2
Conventional Tainter Valve
Bb
R
h
C b
L
c
Piezometric Gradeline
HL
V
V2
Reverse Tainter Valve 19
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Vertical Lift Valves
FLOW
PLAN
ELEVATION
W
B
Vertical Lift Valve
Bulkhead Slot
Vertical-Lift Lock Culvert Valve
0.1
1
10
100
1000
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Area of Valve Opening/Area of Culvert
Valv
e Lo
ss C
oeffi
cien
t, K
v
Physical Model CW 803Dorena Prototype
Suggested Design CurveHDC Chart 320-1
Hoist Loads
Loss Coefficient
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Conventional Tainter Valve
Flow is Right to Left
Free Surface Flow Downstream of Valve
Flow Conditions During Valve
Opening
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Reverse Tainter Valve
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Bb
R
h
C b
L
c
Piezometric Gradeline
HL
V
V2
Hydraulics of Lock Culvert Valves
Reverse Tainter Valve Schematic
Important geometric features
• Valve opening (b/B)
• Valve radius
• Rib members
• Valve lip
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Flow Conditions at Valve During
Filling Operation
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Flow Patterns at Reverse Tainter Valves
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Hydraulic Coefficients Reverse Tainter Valves
Discharge Coefficient Contraction Coefficient
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Horizontal – Farrel and Ables (1968) found that first 2-4 ports can be located in valve’s low pressure zone Vertical – Cavitation Potential (Cavitation Index > 0.6)
• Either high enough to draw air or • Deep enough to ensure positive pressure
Valve Position
Cavitation Index
gV
PPP va
2
)(2−+
=σ
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cC b
Vb
B Rh
HGL
HV /2g2
EGL
LV
gV
PPP va
2
)(2−+
=σ
Cavitation Index
PRESSURES DOWNSTREAM OF VALVES
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PRESSURES DOWNSTREAM OF VALVES
Flow is controlled by the valves Typically, reverse tainter valves Low pressure zones are located in the area of contracted flow V = Q/A A ↓ at a contraction, so V ↑ and P ↓ Where P = pressure at the contraction
• Slower valve times result in longer periods of contracted flow • Inertial effects suggest that high-head locks should operate with fast valve openings, so that the concentrated flow period is small.
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Cavitation Index Design Criteria
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Cavitation
Repairing cavitation damage on Bankhead Lock valve skin plate
Cavitation damage on downstream face of skin plate at Bankhead Lock valve
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Typical Reverse Tainter Valve Installation
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Top Seal
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Operations & Maintenance Experience Chickamauga, Watts Bar, and Fort Loudon Locks: replaced valves – new
valve has large uplift forces and cannot be closed under flow = safety issue during emergencies
John Day and the Dalles Locks: valves – cracks in wrapper plate have been repaired numerous times – rigid framed design considered for replacement.
Holt Lock: valve - maintenance problems since the lock opened - personnel describe the culvert valves as not being stiff enough. Holt Lock valve is the Corps’ recommended design (Davis 1989) -
Existing hydraulic design guidance does not reflect actual operational experiences and needs.
Bankhead Lock: operations personnel have commented that the Bankhead Lock valves perform well - valve design is much heavier than the Holt valve.
The reason for performance differences in the Bankhead and Holt valves is unknown. Perhaps because Bankhead valve is larger and heavier than the Holt.
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Recommended Design – Vertically Framed Holt Lock Model Study, Murphy and Ables (1965)
Davis (1989) recommends Holt Lock design for all
new construction
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Operations: Holt & Bankhead Locks Operations Personnel: - Poor Performance at Holt - Good Performance at Bankhead
Holt Lock 12.5’ x 12.5’ Culvert Bankhead Lock
14’ x 14’ Culvert
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Typical Hoist Loads: Reverse Tainter Valve
Horizontally Framed • Large Downpull • Large Vibration
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Field Modifications
Chickamauga Lock Modified Valve
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Kentucky Lock New Valve Snell Lock New Valve
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Original and Replacement Valves
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Watts Bar Lock Tennessee River
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Watts Bar Lock Valve 1:10-scale Physical Model
Vertical Frame
Double-skin Plate
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Watts Bar Lock Replacement Valve – Modifications
With Plate
Top Seal Plate
Plate Removed
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Comparison of Hydraulic Loads
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
0 1 2 3 4 5 6 7 8 9
Valve Opening, ft
Hyd
raul
ic L
oad,
kip
s
690 690 w/TP
CWSEL
With Top Seal Plate
No Top Seal Plate
Downpull
Uplift
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Snell & Eisenhower Locks St. Lawrence Seaway
Valve replacement often requires engineering design: - Double skin plated valve replaced with vertically framed design. - New valves are requiring more power to operate.
Original Valve
New Valve
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Snell Lock Valve 1:15-Scale Physical Model
Dry Bed View Looking Downstream
Dry Bed View Looking Upstream
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Close-up Views of Valve
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Snell Lock Valve 1:15-Scale Physical Model
Trunnion Load Arm
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Physical Model – Instrumentation
Load Arm in Trunnion
Load Cell in Hoist Rod
Pressure Cell
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Double-Skin Valve
Half-section View of Double-skin Plate Valve, the Hidden Lines
Show the Internal Framing Members
Double-skin-plate Reverse Tainter Valve
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Vertical Frame Valve
Vertical-frame Reverse Tainter Valve
Half-section View of the Vertical-frame Valve
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Vertical Frame Valve – Computational Flow Model
CAD Model
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Surface Mesh
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Double-Skin & Vertical Frame Valves
Flow Passages Must Be Open
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Snell Lock Valve – Hoist Loads
Hoist loads for vertical-frame and double-skin-plate valves
Hydraulic loads for vertical-frame and double-skin-plate valves
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Close-up Views Of Valve
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Snell Lock Physical Model Data 1:15-scale model used to determine:
► Hoist loads: load cell in valve stem
► Anchorage forces: load cells in trunnion
► Head losses: pressure cell and piezometers
► Velocity distribution: PIV
0 1 2 3 4
Valve Opening, ft
Hor
izon
tal F
orce
on
Eac
h Tr
unni
on, k
ips
Note: All data obtained with energy elevationupstream from culvert valve at approximately82 ft above the culvert floor.
5 6 7 8 9 10 11 12 13 14 150
10
20
30
40
50
60
70
80
90
100
Val
ve O
pene
d Fu
ll
Type 5 Valve
Maximum
Minimum
Average
0 1 2 3 4
Valve Opening, ft
Ver
tical
For
ce o
n E
ach
Trun
nion
, kip
s
Note: All data obtained with energy elevationupstream from culvert valve at approximately82 ft above the culvert floor.
5 6 7 8 9 10 11 12 13 14 150
5
10
15
20
25
Val
ve O
pene
d Fu
ll
Type 5 Valve
Maximum
MinimumAverage
30
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150
5
10
15
20
25
30
35
40
45
50
55
60
Valve Opening, ft
Tota
l Hoi
st L
oad,
kip
s
Val
ve O
pene
d Fu
ll
Average
Dry Valve
Maximum
Minimum
Note: All data obtained with energy elevation upstream from culvert valve at approximately 82 ft above the culvert floor.
Type 5 Valve
PIV Image
Trunnion Load Cell
Trunnion Loads
Hoist Loads
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Bankhead Lock Valve Extraction – CAD Model
Center of Gravity 52
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The Dalles & John Day Locks
The Dalles NAVLOCK TV#1 Built 1954
John Day NAVLOCK TV#3 Built 1960
John Day NAVLOCK TV#2
The same valve design is used for Lower Monumental, Ice Harbor, Little Goose, and Lower Granite Locks.
Thanks to Tom North, NWP
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Cracking in Trunnion Plate & Spreader Pipe Welds
Cracking in Lifting Eye Welds
Cracking in Lower Trunnion Arm Welds
Cracks in Plug Welds
John Day Lock – Problems
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John Day Lock – Computational Flow Model
CAD Model
Surface Mesh
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John Day Lock Valve – Computational Flow Model
CAD Model
Flow Model Results
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BUILDING STRONG®
John Day Lock – Velocities and Flow Patterns
Flow is Directed Upward Against the Skin Plate
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BUILDING STRONG®
John Day Lock Valve Computational Flow Model Results
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BUILDING STRONG®
John Day Lock Valve Computational Flow Model
Pressure Distribution
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CFD Results Coupled with FEA Model
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John Day Lock Valve – Fabrication
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Installation & Inspection
John Day Lock Valve – Replacement
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Valve Stabilization – Dampers
Mounted on Valve Well Wall
Chickamauga Lock,
Tennessee River
Mounted on Valve Arm
Snell Lock,
St. Lawrence Seaway
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BUILDING STRONG®
Valve Stabilization – Dampers
Chickamauga Lock,
Tennessee River
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Summary
Reverse tainter valves are used almost exclusively in lock culverts
Valve Position Horizontal: manifold is not very sensitive to location Vertical: High enough to draw air or deep enough to
avoid cavitation (s > 0.6) Many projects are rehabilitating or replacing lock valves Vertical frame tainter valve is the recommended design Rib geometry is important regarding uplift loads Design guidance is being updated – EM 1110-2-1610
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QUESTIONS?
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