Figure 209. --Operational tests for 150-ton crane. Total weight of This proved to be a very good electrode on the ASTM A 285, grade C steel. Preheating was only required at the beginning of each weld and thereafter the heat of welding was sufficient. All welds were X-rayed. This work was done as a subcontract by Protex Portable X-rays, Lakewood, Colo. All welding operators were qualified in accordance with ASME Boiler and Pressure Vessel Code, Section IX, for all position welding. (1) Penstock conduits. --A problem arose in alinement of some of the curved sections in the lower bends of penstocks 1 and 2, requiring rotation of the sections beyond the positions indicated by the matchmarks, and subsequent trimming of the ends of the sections to permit proper fit. As the problem was more pronounced for penstock 1, which had the greater horizontal bend, this was concluded to be caused by a fabrication error which did not incorporate the slight horizontal bends in the penstock sections. No similar problem occurred in penstock 3 which had no horizontal bend (see fig. 210). Work was started on the penstocks on March 22, 1961, and joint 7 between sections P2-3 and P2-2 was completed on November 2, 1961. Between these dates, seven sections were completed on penstocks 1 and 3 and eight sections on penstock 2. Penstock work was resumed with the placing of the last section of penstock 2 on April 19, 1962. Installation and embedment of the penstocks was completed on July 6, 1962, with the exception of penstock vents which were completed on October 27, 1962. A final check for interior surface defects of the river outlets was made in June and a final check of the penstocks was made in July 1962. The rising of the reservoir and the delays in penstock gate installation made it necessary to install bumped heads at the downstream end of each penstock. Gunther and Shirley Co., and E. V. Lane Corp., furnished, installed, and removed the bumped heads under order for changes No. 1 to specifications No. DC-5700. - (2) River outlet conduits. -The first sections of the river outlet conduits to be installed were sections R01-4 and R02-4 in block 10 of the dam (fig. 211). The section of R01-4 lined up satisfactorily, but R02-4 could not be turned to place the upper end on line and station without throwing the flanged section considerably out of line. Subsequent investigation revealed the same situation that had existed with the penstocks-the horizontal bends had not been incorporated in the pipe sections: Some sections were corrected by rotating the section and trimming the ends as described above for the penstocks. However, the supplier then made a complete check of all sections and corrected most of the fabrication errors before the sections were installed. If the section was too short, enough was cut off the section to add at least a 12-inch piece so the girth welds would not be too close together. Before installing the bellmouths a careful check was made of the flanges on section 1. It was found that each flange was about 2 inches too far downstream and was also out of plane. A tapered shim was machined and installed between the bellmouth and upstream flange in each river outlet to place the bellmouth at the proper station and plane. The contractor furnished the tapered shims. The first sections of river outlets were installed April 15, 1961; and on September 7, 1961, the bellmouths were attached to the flange on the upper ends of section 1. Although all sections were not embedded, the river outlet conduits were all installed in 1961. 222. River Outlet Gate Frames and Anchorage. (a) General. The river outlet bulkhead gate frames were furnished by Monarch Forge and Machine Works of Portland, Oreg., under invitation No. DS-5386. Installation of gate frames and anchorage was done by Arch Dam Constructors under specifications No. DC-5045, item 143. A spot check of the frames and guides was made shortly after they were received in May 1962, with no deficiencies being noted. (b) Installation. --Seal seats and guides were rough installed on the anchor bolts June 11, 1962. Installation was not begun until a wooden bulkhead and wire netting could be installed above the work area to reduce the hazard caused by carpenter crews working above on trashrack concrete forming. Alinement was obtained by measuring to piano wires supported by templates located by Government surveyors. Installation and alinement was completed to elevation 5840 on September 20, 1962. Embedment was completed to elevation 5835 on October 25, 1962. After embedment final alinement readings were always taken to ensure that no movement had occurred. The outlet bulkhead gate was temporarily installed in both frames on November 13, 1962, to check seating before the seal seats were inundated. Some bushing was required to obtain the correct concrete clearances. Work was resumed on April 24, 1963, and progressed rapidly. The last guide sections were installed on May 6 and final alinement was completed on June 21, 1963. 223. River Outlet Bulkhead Gate. (a) General. --The 7.75- by 7.75-foot bulkhead gate was furnished by The Delaney Co. of Houston, Tex., under invitation No. DS-5587. Critical dimensions of the gate were checked shortly after it was received at the project. It was found that the gate was warped about one-eighth inch across the plane of the brass seal seats. The brass seal seating surface was remachined by a machine shop in Salt Lake City and the cost was backcharged to the supplier. (b) Installation. --Installation of the gate, including the rubber seal, was performed by Arch Dam Constructors under item 146 of specifications No. DC-5045. Before installing the gate in each opening, a wooden template was built by the contractor and attached to the bottom of the gate. When the gate was lowered into position, this template which extended approximately 2 feet below the gate could be used to determine if debris had accumulated on the trashrack cantilever base up to the inlet of the outlet pipes. The gate in outlet No. 1 had to be lowered several times before seating, but the gate in outlet No. 2 seated during the first attempt. It was believed the amount of debris indicated in outlet No. 1 would not be detrimental. The gate leakage in both outlets was negligible. The cost of extra work and material for the wooden template was paid under a purchase order. The river outlet bulkhead gate lifting frame was furnished by Charles C. Steward Machine Co., of Birmingham, Ala., under invitation No. (D)90, 059-B. General.--Penstock 224. Penstock Fixed-Wheel Gate Frames and Anchorage. (a) gate seal frames, side guides and track assemblies were received on the project in June 1962. They were furnished by Rockwell Engineering Co. of Blue Island, Ill., under invitation No. DS-5501. Arch Dam Constructors did the installation work under specifications No. DC-5045. (b) Installation. -- Frame anchorage was embedded as the trashrack structure mass concrete progressed. On June 19, 1962, a check by Bureau personnel was started on the metalwork to be installed at the penstock openings. Each seal seat frame and lower track assembly was made up and leveled for a check on squareness, makeup, and critical measurements of each unit. The minor deficiencies noted were as follows: (1) Some dowel holes did not match up. (2) Gaps and offsets existed at some of the seal seat joints. (3) Some of the rubber seal under the stainless steel seal seats was out of the grooves and damaged. (4) Boltholes for the track rail clips were not tapped deep enough. Corrective work was completed by an ironworker crew of two men on August 9, 1962, and costs for the extra work were backcharged to the supplier. Prior to metalwork installation, blockouts were cleaned up and anchor bolt threads were chased. On August 22, 1962, the first frames and lower track assemblies were installed in block 14 at the penstock opening. Bureau survey crews established elevations for the centerline of the lower horizontal seal seat on each intake. These crews also located all the alinement templates for metalwork control as the installation progressed. Final template check on the lower two sets in block 14 was made October 3, 1962, when wires were crossed over the opening from template to template to assure that they were in one plane. Alinement of the metalwork started in block 14 on October 5, 1962, but the work was halted because of winter weather. In January 1963 the three penstock trashracks were winterized with polyethylene panels, and butane space heaters were installed for heating. Alinement work began again in block 14 on January 23, 1963. Fixed-wheel gate side guides were alined with the lower track assembly. Some transverse warpage was noted across the face of the lower half of the side guides, so they were set so that the minimum tolerance in the overall width across the opening was kept. After alinement, the metalwork was embedded and then a final alinement check was made to ensure that movement had not occurred during concrete placement. On two different occasions it was necessary to chip out sections of embedded rail and realine them. The first misalinement occurred because the control wire had been accidentally moved out of position by formwork. It was necessary for the contractor to chip and realine 15 feet of rail at this time. The second corrective work was required because of a surveying error in setting one of the templates. It was necessary to chip 25 feet of rail out at this time. This latter work was paid for under order for changes No. 15. As the frame rails were completed and embedded, a template built to the outside tolerance of the gates was lowered down each opening to check alinement and concrete clearances. Work on the penstock gate guides was completed in September 1963. 225. Penstock Fixed-Wheel Gates. (a) General.--Johnson Machine Works, Inc., of Chariton, Iowa, furnished the fixed-wheel gates under invitation No. DS-5508. Each of |