JPRS ID: 9464 USSR REPORT ENERGY

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• Document Page Count: 95
• Document Creation Date: November 1, 2016
• Sequence Number: 45
• Content Type: REPORTS

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JPRS L/9464
31 December 1980
~ USSR Re ort
p
ENERGY
- (FOUO 27/80)
F~IS FOREIGN BROADCAST INFORMATION SERVICE -
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NOTE
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COPYRIGHT LAWS AND REGULATIONS GOVERNING OWNERSHIP OF
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JPRS L/9464
31 December 1980
USSR REPORT
~NERGY
(FOUO 27/80)
CONTENTS
ELECTRIC P(~1ER
~ Designing Ele ctrical Equipment fo r the Oil, Gas Industry
(ELEKTROOBORUDOVANIYE NEFTYANOY I GAZOVOY PROMYSHLENNOSTI.
UQiEBNIK DLYA VOZOV. IZD. 2-e, PERERAB. I DOP, 1980).......~.... 1
High-Speed Construction of the Kurpsayskaya C~S
(V. S. Shangin; ENERGETICHESKOYE STROITEL~STVO, Oct 8Q)......... 6
Efficient Lining Components on Boilers With Gas-Tight Shie lds ,
(Yu. S. Tsarikov; ENERGETICHESKOYE STR(JITEL'STVO, Oct 80)..~.... 16
New Grouping Solutions for the TPP-312A Boiler ,
(A. G. Isarev, A. G. Kravets; ENERGE~'iQiESKOYE STROITEL~STVO,
Oct 80) 32
Cutting Labor Costs in Overhead Electric-Power Transmission Line
Construction
(Yu. V. Bushuyev, et al. ; ENERGETIQiESKOYE STROITEL' STVO,
Oct 80) 42~: -
Research on Structural Components of an AES Reactor Section
(G. E. Shablinskiy, A. V. Gordeyev; ENERGETI(HESKOYE
STROITEL'STVO, Oct 80) 61 ~
Planning and Studying Underground Fuel-Delivery Tunnels
(V. I. Stepanov, et al.; ENERGEZ'l.Q~ESKOYE STRiOITEL'STVO,
Oct 80) 73
FUELS
Drilling Oil and Gas Wells
_ ` (BURENIYE NEFTYANYi~i I GAZOVYKFi SKVAZIiIN, 1980) . . . . . . . . 83
- a - [III - USSR - 37 FOU.O]
Cl1D i1CL'f~'T A T T!CL' !~M V
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Handbook on Drilling Muds
( SP RAVO Q~IN IK PO B UROVYM RAS TVO RAM, 19 79 ) . . . . . . . . . . . . . . . . . . . 86
Table of Content From ' TECTONICS OF SIBERTA'
(TEKTONIKA SIBIRI, 1980) . 90
. - b -
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ELECTRIC POWER
UDC(622.323+622.324):621.313(075)
DESIGNING ELECTRICAL EQUIPMENT FOR THE OIL, GAS IIvDUSTRY -
Moscow ELEKTROOBORUDOVANIYE NEFTYANOY I GAZOVOY PROMYSHLENNOSTI. UCHEBNIK DLYA
WZOV. IZD. 2-e, PERERAB. I DOP. (Electrical Equipment for the Oil and Gas
Industry. Textbook for VUZ. 2nd revised and expanded edition) in Russian 1980,
p 2, 475-478
[Annotation and table of contents from book by S.G. Blanter and I.I. Sud, Nedra,
478 pages]
[Excerpts] The book is a textbook for "Electrical Equipment" courses for students
of petroleum WZ and departments offering instruction in the fields of "Technology _
and Full Mechanization for Working Oil and Gas Deposits," "Drilling Oil and Gas
- We11s," "Design and Operation of Oil and Gas Pipelines, Gas Storage Tanks and -
Bu1k0i1 Plants," and "Construction of Oil and Gas Pipelines, Gas Storage Tanks
and Bulk Oil Plant~," as well as in the course "Compressor and Pump Installation
Drive" for the field of "Machinery and Equipment for the Oil and Gas Fields." ~
Its contents is in accordance with programs for these courses confixmed by the
USSR Ministry of Higher and Secondary Specialized Education.
The book may also be used as a guide by engineers and technical workers engaged in -
the design and operation of electrical equipment for the oil and gas industry.
In it power supply and electrical power equipment for drilling rigs, recovery and _
industrial oil preparatic+n facilities, oil field compressor and pumping stations,
mainline oil and gas pipelines and machinery for laying mainline pipelines are
_ examined. .Questions of electric lighting for oil and gas fields, operation of elec-
trical equipment, accident prevention and electric gower conservation are set forth.
In the present second edition of the book (the lst edition was in 1971), the mater- ,
- ial is updated in acr_ordance with new technica]. decisions for facil~ties and elec-
trical equipment and advanced engineering achievements which have appzared since
_ the publication of the first edition of the book.
27 tables, 200 illustrations, 17 titles in the bibliograpny.
REVIEWER. Department of General and Specialized Electrical Engineering, Groznyy
Petroleum Institute.
1
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CONTENTS
Introduction 3
Chapter 1. Sources of Electric Power and its Distribution at Enterprises ~
. of the Oil and Gas Industry ,5
1. Power Sources and Requirements for Power Supply Fa~ilities 5
2. Load on Electric Power Receivers, Load ~alculation 12
3. Sasic Types of Electric Network Circuits 1~i
4. Calculation of Wire Cross-sections for Electric LinPS .'.0
5. Basic Design Elements for Electric Lines 27
6~ Short Circuit Currents and ~heir Effect on the Equipment 33
Chapter 2. Electrical Equipment for Transformer Substations and Dis-
tribution Devices Rated at More Than 1000 V 46
7. Power Transformers and Their Selection 48 -
8. Switches for Voltages Above 1000 V 55
9. Circuit Breakers, Load Switches and Other Switching
Equipment for Voltages Above 1000 V 64
- 10. Actuators for Controlling Power Switches for Voltages Above
1000 V and Circuit Breakers ~ 74
11. Measuring Current and Voltage Transformers and Their Selection 79
12. Distributor Design Bus Conductors [Russian--Shinnyye konstruk-
tsii raspredelitel'nykh ustroystv tokoprovody] 88
13. Relay Prctection 9p
14. Automatic Line Reconnection and Automatic Conxiection of
Reserve Capacities 111
15. Designs for Distributor and Substation Components 115
Chapter 3. Electric Motors and Their Service Properties 122
16. General Informatian on Electric Drive 122 _
17. Mechanical Characteristics of Industrial Equipment
and Electric Motors 12g
18. Start-up and Regulation of Electric Motor Rotation Speed 146
19. Design Versions and Operating Properties of Electric
Motors 168
Chapter 4. Selection of Electric Motors 177
20. Ganeral Assumptions 177
21. Heating and Cooling of Electric Motors 179
22. Electric Motor Load Diagrams and Operating Conditions 183
23. Selection of Motor Duty Rating 185
- Chapter 5. Electric Motor ~ontrol Apparatus and Circuits 190
24. Control and Protection Equipment 190
25. Control System Classification and Means for Their
Responsibilities 208
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26. Typical Electric Motor Cantrol Assemblies and Circuits 210
Chapter 6. Explosion Res3stance of Electrical Equipment 219
27. Classification of Dangerously Explosive Mixtures and Places
in ~the Oil and Gas IndustrY 219
~ 28. Electrical Equipment With Explosion-proof Housing 222
29. Electrical Equipment With Improved Explosion Safetq 225
30. Electrical Equipment Exhausted at Gage Pressure
[Russian--produvayemoye pod izbytochnym d~vleniyem] 226
31. Oil-filled electri~al Equipment 229
32. Specially designed Spark-safe Electrical EQuipment With
Quartz Filling 231
~ 33. Features of Facilities for Electric Power Supply to Dan-
gerously Explosive Installations 232
Chapter 7. Electrical Equipment for Drilling Rigs ' 234
34. General Assumptions 234
-35. Electric Power Distribution on Drilling Rigs 23$
36. Electric Bit Drive 241
37. Automatic Bit Feed Ragulators 256
38. Electric Drive of Drilling Hoist 262
39. Electric Drive of Drilling Pumps 275
40. Diesel Electric Drive 2g4
41. rlectrical Equipment for Off-shore Drilling Rigs 288
42. Electric.al Equipment for Auxiliary Machinery 289
Chapter 8. Electrical Equipment for Oil Well Pumping Operations 293
43. Deep-well Pump Rod Installations 293
44. Efficiency and Power Factor of the Electric Motor for a
Pumping Unit 297
- 45. Determining the Power of Electric Motors for Pumping~ilnits 299
46. Electric Motors for Pumping Units ~ 302
47. Power Supply Circuits, Automatic Start-up of Pumping Unit
Electric Motors and Control Equipment 306
_ 48. Installations With Rodless Deep-well Pumps 311
49. Deep-well Electric Motors and Their Waterproofing 313
50. Devices and Power Supply Circuits for Installations With
PED Motors 319
51. Deep-~ell Electric Motor Control Stations 322
52. Selection of Electrical Equipment for a Rodless Pumping
Installation 32~
Chapter 9. Electrical Equipment for Oil Field Compressor and Pumping Stations
and for Oil Preparation Installations 330
~
53. Compressor Houses, Pump Houses and Installations for Com-
" plete Preparation of Oil in Oil and Gas Collection Systems 330
54. Electrical Equipment for Oil Field Compressor Installations 331
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SS. Automatic Start-up of 0~.1 Field Compressor Stat3on Motors 339
56. Electrical Equipment for Oil Field Pumping Stations, Re-
quirements for Electric Pump Drive 342
57. Electrical Equipment for Intra-field Oil Transfer ' 345
58. Electrical Equipment far Water Pumping Systems To
Maintain Formation Pressure � 349
59. Dehydration anii Desalinization of Oil Using an Electric
Field 353
60. Electric Dehydration and Desalinization Oil Field
Installations 35?
61. Eler_trical Installations for Heat Treatment of the
Critical Zone and Well Deparafinization ~h2
Chapter 10. Electric Lighting for Oil and Gas Fields 365
62. Electric Light Sources, Fixtures and Lamps 365
63. Systems and Types of Lighting 368
64. Methods for Rating Lighting Equipment 369
65. Lighting for Main Oil Field Ob~ects 373
Chapter 11. Electrical Equipment for Compressor and Pumping Stations of
Mainline Pipelines 376
66. General Charact~ristics of Mainline Gas Pipeline Com-
pressor Stations 376
67. Electric Drive for Centrifugal Force Pumps 379
68. Auxiliary Electrical Equipment for Compressor Stations 389
~ 69. Electric Power Supply for Compressor Stations With
Electric Drive for Centrifugal Force Pumps 391
70. Electric Power Supply for Compressor Stations With Gas
Turbine and Gas Engine C~mpressor Drive 399
71. General Characteristics of Ma.inline Pipeline (Oil Pipeline)
Pumping Stations 399 `
72. Electric Drive for Main and Priming [Russian--podpornyye~
P~PS 402
73. Auxiliary Electrical Equipment for Oil-transfer Pwnping
Stations 409
74. Electric Power Supply Installations for Oil-Transfer
Pumping Stations, Block Substations 410
75. Controlled Electric Drive of KS [compressor station] Cen-
trifugal Force Pumps and the Main Pumps of Transfer
. Pumping Stations 414
Chapter 12. Electrical Equipment of Machinery for Constructing Mainline
" Pipelines 419
76. General Assump;:ions 419
77. Electrical Equipment for Portable Electrical Power Plants 420
78. Start-up of an Asynchronous Squirrel-cage Motor From a
Synchronous Generator of Comparable Power 427
79. Electric Drive for Trenching Machinery 42g
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80. Electric Drive for Auxiliary Machinery 437
- 81. Electric Pipeline Welding Equipment 438
- Chapter 13. Power Rating and Conservation of Electricity 448
82. General Assumptions 448
83. Improving the Power Rating 452
- 84. Arrangement and Hook-up Diagrams for Compensating
Devices 455
85. Conservation of Electricity 458
Chapter 14. Electrical Equipment Operation and Accident Prevention When
_ Operating Eleci:rical Equipment 461
86. Basic Rules for the Operation and Safe Servicing of
Electrical Installations 461
87. Protective Grounding and Protective Disconnection 465
88. Rendering First Aid to Electric Shock Victims 472
~
Bibliof;raphy 474
COPY'RIGHT: Izdatel'stvo "Nedra", 1980
- 9194
CSO: 1822
5 ~
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ELECTRIC POWER
unc 6z6/6z7
HIGH-SPEID CONSTRUCTION OF THE KURPSAYS2C~YA~: GES
Moscow ENERGETICHESKOYE STROITEL'STVO in Russian No 10~ Oct 80 pp 2-8
~Article by Engineer V. S. Shangin: "High-Speed Construction of the Kurp- ~
sayskaya GES'J ~
The brief titae periods for the
~TextJ ~FROM TH~~ IDITORS .
erection of the Kurpsayskaya Hydroelectric Foxer Station ,
with its high concrete dam and excellent quality of con-
struction work have evoked ca;siderable interest. The set i
of articles published beloW illwninates the most important
construction~ organizational, and engineering solutions
which have been adopted in the process of designing and
building this station in the Naryn Cascade.*~ ~in italics1` ;
The Kurpsayskaya GES (Fig. 1)~ nox under construction in Kirghizia is the ~
= fourth hydroelectric power station on the Naryn River and the third (of
the proposed five) in the Lower I3axyn Cascade. i
The principa.l technical and economic indicators of this hydraulic develop- -
_ ment are cited below : ~ -
Rated capacity of the GES~ in MW (mega.Katts) 800
~
Number of units 4 !
!
Capacity of the reservoir~ in millions of cu. m 37o i
Including the following regulated amount 35
i
Design (~alculated) pressure head~ in meters 91�5 I
~
Design (calculated) discharge of the GES~ in cu. m per sec. 972 I
* This set of articles about experience gained in building the Kurpsay- ;
~ skaya GES utilizes photographs by Ye. Kuluzayev. ~
- ;
,
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;I
~
~ i
_
,
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Height of the dam, in meters 115
Total volume of concrete~ in millions of cu. m............ 1
Average annual production of electric poKer, in billions -
of kW-hrs. (kilowatt-hours) 2.63
Estimated construction cost, in millions of rubles 193
Including the folloWing for SMR (Construction
and Installation Work) 1$1
Production cost of electric power~ in kopecks per kW-hr. 0.13
Time required. for return of investment on this
hydraulic developa?ent Less than
one year
_ The introduction of the first two units of the Kurpsayskaya GFS are sche-
duled to take place in 1981~ and that of the remaining txo units--in 1982,
xhile the planned deadline for completing construction occurs in 1983�
The site of the Kurpsayskaya GES, situated at a distance of
4~0 Ian (loKer along the river's course) from the Toktogul'skaya GES~ is
_ typically mountainous. The width of the gorge cut by the water amounts
- to 40--50 meters~ rrhile at the point of the dam's crest it is approximately
360 meters. The average incline (declivity) of the riverbed is about 0.003.
Passing alongside of the gorge is the Frunze--Osh Highxay~ which falls with-
in the zone of reservoir flooding.
The re~ion where this hydraulic developnent is located, including the
reservoir, is characterized by heterogeneous~ extremely complex tectonic
structures and engineering-geological cond.itions. This explains the
presence of large discantinuous dislocations in the immed.iate vicinity
of the hydraulic development~ as well as a~egional thal~o-Fergana' -
depth fracture~ occurring at a distance of 60-65 Ian north of the hydra.ulic
development; this has undergone rejuvenation at all stages af tectogenesis,
including those of the present day. ~
The ba.sic structures of this hydraulic developnent are situa.ted in a single `
structural tectonic block; in accordance with the data of the Institute af
Earth Physics (IFZ) of the USSR Academy of Sciences, a maximum possible
earthquake intensity of nine points has been adopted into the design of
_ these structures.
The basic rocks are interstratified. sandstones and axgillites~ xhose layers
intersect the va.lley alm~st perpendiculaxly Kith respect to the upper head
at an angle of 50---6s�. The proportion of sandstones herein comprises
7~--75 Percent, while that of argillites amounts to 25--30 percent. With
7
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respect ta thickness~ the sandstones are subdivided into thin-layered (with
a stratwn thickness of less than 0.1 m), medium-layered (0.1--0.6 m) and -
~hick-layered (more than 0.6 m). The argillites have a thin-layered struc-
ture. ~uaternary deposits have an tnsignificant distribution here. Within
the riverbed the thickness of alluvial deposits does not exceed 1--2 m. The
following shift characteristics of the foundation rocks have been adopted
= in ths design: tgt~=~1.9 a~d S~.3 MFa (megapascals). ~
- The climate of the Naryn River Basin is continental. With an avsrage annua.l
air temperature of +13.8�C, the minimum observed in January is -30'C, and
a maximum in July of -N+4` C. Moreover ~ the inter period is characterized
by frequent strong Hinds~ the velocity of xhich rea.ches 35 meters per secon!i.
Frosts may be observed in October (-10�C) and April (-4�C). The av~rage
annual amount of precipitation comes to 378 mm. The fluctuation of water
levels in the river amounts to 12--16 m.
The Toktogul'skaya GES, xhich is located higher on the course of the river, ~
has completely regulated the flow of the Naryn River; in designing the
Kurpsayskaya GES this has allowed a substantial red.uction to be made in
the design construction discharge, and it has been a.dopted as equa.l to
1,100 cu. m per sec in ~966 ~t amounted to 2~ 880, and in 1969 it was
2~6Z1~0 cu. m per second). After the construction of the Toktogul'skaya GES
there was also a pxincipal cha,nge in the river's temperature cycle; practic -
ally no ice and slush phenomena are nox observed.
The basic structures of the Kurpsayskaya GES (Fig. 2) include the following: ~
- a concrete gravity dam, a GES building attached to the dam, an interior
water spillway in the body af the dam~ a surface water spillway, an ORU
(open distributive appara.tus) of 220 kV (kilovolts) and tine of 1!0 kV.
The concrete gravity dam has a triangular cross-section; the upper pressure-
head edge is vertical~ while the loker edge has a foundation of 0.7 for the
riverbed sections and 0.75--0.8 for the side sections. Within the dam a
sectional cut has been provided; herein the design of the intersectional
seam provides for the possibility of the joint operation of the sections
under loa.d. With its length along the crest of 364 m the dam is divided
intc 13 sections as follows: four riverbed sections with turbine water ~
conduits and nine bank sections. The width of the sections vaxies fmm ;
- 19.5 to 30 m. In the sections with a width of 30 m along the upper and
lower edges further joint incisions are made to a depth of 5 m. Within the
body of the dam provisions have been made to install a system of rooms~
stairwells, freight openings, as well as elevators~ service areas and so
forth (Fig. 3). ,
The construc~ion of the body of the dam has been planned with a zonal distri- ;
bution of concrete: the interior zone is made of non-frost-resistant M 150
concrete~ the exterior underwater zone--of M 250 concrete, and the exterior
surface zone--of M 300 concrete. Provisions have been made to carry out
anti-filtra.tion (well drainage) and reinforcement (cementa.tion) measures. ;
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- The dar~ includes a xater intake 43 meters high, situated in its four river-
bed ~ections; the loxer edges of these sections have turbine wate.r conduits
seven meters in diatneter~ r+hiah ~xtend beyond the ].imits of the dam's cross-
_ section.
The open-type GES building with its single-series units is directly attached
to the dam in its riverbed section. The turb~ne equipment is being supplied
by the Turbine Plant PO (Producti~n Association) (from the city of Kharkov)~
and the genera.tors from the Sibelektrotyazhmash Plant (from the city of
Novosibirsk
The structures for absorbing construction outlays are traditional for an
analogous grouping of a hydraulic development under mountain conditions:
a by-pass tunnel, an upper cofferdam up to k0 m in height, and a lower
cofferdam approximately 18 m in height.
The deep interior water spillway~ consisting of a single-aperture rectangulax
, pipe with a cross-section of SX7 m and equipperl xith working segTnental
and repair flat gates, located in one of the ri~t-bank sections of the dam.
- I?uring the period of reserv~oir flooding it will be used to pass water through
into the tailrace. Within the GES building a spillxay is made in the fozm -
of an elbow, and beyond the station the elbox makes a transition to a ter-
minal section xith a lateral overflow .
In building the Kurpsayskaya GES a complex of progressive engineering tech-
nical and organizational economic solutions was adopted; thei~r realiza~iQr~
created the prerequisites for caxzying out under complex mountain conditions
this high-speed construction in order to put into operation hydraulic units _
_ with capacities of 200 MW (megawatts) tirithin a single five-year period
after the sta,rt of construction. Let's enumerate just the principal solu-
tions here.
1. The beginning of the basic operations on the Kurpsayskaya hydraulic
developnent was coordinated (albeit xith a certain delay) xith the final
phase of these operations at the Toktogu]'skaya GE5. Thus, they managed
to create favorable condi#,ions for the effective use in the construction of
the Kurpsayska.ya CES of the existing groups of highly skilled workers and -
ITR (engineering and technical personnel).
2. In order to erect the Kurpsayskaya GES, use has been made of the chief
productian bases (the concrete plant, the gravel-grading system, the
reinfbrced-concrete product construction yard~ the transfer center~ and so
forth) which were built in their time for the construction of the Toktogul'-
_ skaya GES.
By the time construction began on the Kurpsayskaya GES in 1976 the facilities -
of the production ba.se of Naryngidro~nerg~stroy had been mainly shifted
to tr+o areas ( to the city of Kara-kul' and the village of Shamaldy-Say) and
guaranteed the repair of the construction equipmrent and motor transport~
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the production of commercial concrete and a~gregates for it, structural
components made of precast reinforced concrete, ~the necessary ou+.put of -
xooden items etc. Moreover~ there existed a rrell-devel~ped transfer base
and Narehouse system of the UF'I'K (Production--Techno? egica]. Administrati.on
for Equipment Outfitting); all construction and installation organi- ~
� zati~ns also maintained their own systems. But directly in the region where
- the hydraulic develupment is being built there is os~s~ac~annot benseparated
enterprises which~ as regards their technical purpo
from the construction site (Fig. 4).
3. The presence in the city of Kaxa-Kul' of a well-laid-out residential se~-- -
tlement with a11 the necessaxy social and cultural facilities has made it
possible to co~npletely avoid residential and civil construction at the site
of the Kurpsayskaya CxES; it has adopted and carried out a scheme for sup-
plying the workers~ the ITR and the office em~,i.oyees at the construction
- site.
4. In developing structural components for the hydraulic development's prin- ,
cipal structures attempts have been made at insuring a high degree of teeh-
nology in their erection as well as a decrease in the labor consumption of
the operations. Furthern~ore, thanks to the close interrelatior.ship between ;
the builders and planners~ already during the construction process addition-
- al corrective measures Hfor thepmot rapidtpossibledstart- peofhthecfirst I
lumes of Hork ne.essary I
- few units. ;
In order to cur~cail the duration of the preparatory period, Naryngidrostroy~
together with the planners, carefully and thoroughly analyzed. the follo~ring
questions:
the possibilities of cur~tailing maximum amounts of work needed
to be carried out prior to the start of concrete laying in the principal
structures and the maximun? combination of separate types of operations dur-
ing this period;
determining ~he minimum necessary list of temporaxy buildings and structures
which had to be built at the construction site of the Kurpsayskaya GES (in-
cluding those prior to the beginning of concrete laying); ~
the acceptability of the existing plan solutions for the hydraulic develop-
ment's individual elements from the viewpoint of their fastest possible re-
alization, as well as the presence of the necessary material and technical
resources.
With this same goal in mind a number of effective measures have been imple-
mented on this construction project:
- the replacenient of the open se~nent of the F`runze--Osh road running along _
the lef~ bank above the hydraulic developaent by"a tiznnel made it possible
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to combine in time work on building the rcad and the dam;
the replacement of the right-barik trar.sport tunnel by an open section of.
the road solved the problem of allowing transit tz~nsport through~ and it -
insured the necessary rapid pace of excavating the foundation pit of the
principal structures;
- organizing the area of the pioneer period ir_ direct proximity to the place
where the main operations were being carried out permitted a considerable -
curtailment of the time periods required for putting into operation su~h ex- -
tremely importa.nt facilities as the compressor~ the xater-collecting basin,
~ dining-room etc., as well as ~to reduce expenditur$s for erecting communica-
tions a.nd insuring the necessary increase in the pace of operationsi
a change in the construction of the upper cofferdara insured the erection
of its principa.l part prior to sxitching over discharges into the tunnel
and the required allorrances during the groxing season~ and it also consi-
derably simplified the transport scheme at the loxar levels of the pit dur-
- ing the period xhen its excavation was being co~apleted and conerete-laying
operations were beginning;
a change in the scheme of the water supply of the construction sites made _
it possible to avoid building a complicated cluster of water-colleeting -
s~tructures, laying mairi water lines of as much as 10 km in length, includ-
ing one along the rocky cliff over which the above-mentioned Frunze-Osh
HighNay passes; -
a reduction of the design construction discharge from 1800 to 1100 cu. m
per sec.;
the complete avoidance of building housing facilities in the region of the .
Kurpsayskaya GES made it possible not to divert labor and material resour~
ces~ equipnent~ etc. from the main operations.
Directly on.the const~~sction site of the Kurpsayskaya hydraulic network
work began on putting up the section of 'che 110-kV (kilovolt) VL (overhead
line) xhich pa.sses through the gorge along the operational Frunze-Osh High-
rray and is situated above the future structures and construction sites. For
this purpose it was necessary to install 15 metal poles (supports) on the _
rocky "crests" of cliffs which xere accessible only to mountain-climbers=
_ materials and structural components from the assimilated levels were de-
livexed. to a height of as much as 300 m sometimes by hand~ sometimes by
utilizing helicopters. The total length of the raised section amounted to
approximately five ]Qn. At the same time a 110~6-kV substa.tion was built in
ord.er to insure electric-power operations and to solve the problem of high- -
Frequency communications betxeen the Kurpsayskaya GES site~ the city of
Kara-Kul' and the settlement of Shamaldy-Say.
From the very beginning of production operat~ons there arose ~he extremely
acute problem of insuring the reliability of th~ tra~nsport tyes with the
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left-bank site, necessary for transferring the
earth-mo~+~ing equipnient and working the soil under the hydraulic develop-
ment's principal structures, Before the completion of che pennanent bridge
across the Naryn River~ Hhich was put into operatiur, in 1980 anci became paxt
of tne section of the F~unze-Osh Highway taken out of the flood zone, use
was ma.de for these purposes of a temporary bridge~ erected by the bridge- -
builders of the USStt h;inistry of Transport Construction.
' In May 1977 the rock drillers of the Kirghiz 5pecial AdministraLion of the
Cidrospetsstroy AI1-Union Association completed work on the approach pas-
sage and began cutting through the construction tunnel. In accordance w~th '
- the plan, 'this tunnel ha.s a length of 634 m, designed to pa.ss through dis-
charges of as much as 1100 cu. m per sec., and it was supposed to }-~ave a
reinforced-concrete facing along its entire length. Ho?+ever, upon the ir;.-
~tiative of the builders~ the facing was revised and xas replaced along mc,st
= of the tunnel's length by a jacketing of sprayed concrete. This made it
possible to reduce the amount of concrete work by 8~000 cu. m~ outlays of
reinforc-r.~ent by 350 tons and forms by more than 7,000 sq. m. ,
But the main effect derived from introducing this progressive jacketing con-
sisted in curtailing the length of time required to erect the facility. ~
Thus, xork on building the tunnel was completed in one year, and on 10 May
197$ the riverbed of the Naryn River in the line oi direction of the Kurp-
sayskaya GES was shut off.
In accordance with irrigation requirements~ within 20 days after the shut-
off a discharge was needed. through the hydraulic development's line of di-
rection amounting to 8f50 cu. m per sec. For this purpose it was necessary ~
to erect an upper cofferdam more than 40 m high. In accordance with the
initial plan, the cofferdam (with a total fill of 220.000 cu. m) was sup-
pose~ to be made of rock-fill with a core of clay-loam. The material for ,
- erecting this cofferdam was supposed to be delivered from three independent
quarries at hauling distances of 10--50 km. To i.mplement this solution,
even in case of suspending the pit excavation (because of a transport shor-t-
age) would have required 3--4 months.
The workers' planning section of Gidroproyekt's SAO (Central Asizn Division)~ ;
upon a proposal by the construction division developed xithin a very brief
period of time a nex design for a cofferdam which could be built within the � '
required deadline at a considerable reduction in cost. Moreover, maximum
and successful use was made of local conditions: the cofferdam's line of
direction was arranged along the axis of the previously built, temporary i
bridge xith concrete abutments and joining Ka11s; the main part of the anti- ;
filtration facing took the forn~ of a concrete wall betxeen abutments on a ;
cleaned rock foundation; directly in the riverbed section provision was made ~
for a fill made with a natural gravel-sand mixture, to be injected subse- ~
quently Hith a clay-cement groutir,g solution. By the growing season of
19?9 the cofferdam being erected was built up further, and this insured the
- paysage of the required amounts from the reservoir of the Toktogul'skaya
GES. i
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Despite considera.ble pressure head~ the filtration discharge through the
upper cofferdam after the first stage of the ceiaentation curtain was com-
pleted did not exceed 100 l~s (liters per second).
At the sam e time that the tunnel was being built Kork was begun on excavat-
ing the foundation pit of the principal structures~ the site of the ORU
(open distributive appaxatus), and other facilities. The complex topogra-
phical conditions and the virtual impracticability of arra,ngin~ transport -
routes to a whole number of intennediate points brought about the need for
a differentiated approach to the solution of this problem. `
In the first place, as we have already noted~ there was a careful and tho-
rough analysis o~ the possibility of reducing the volume of work, especially
at the upper levels, which are difficult of access. The decision not to use
cable cranes enabled us to cut out the excavaticn of 3~0~000 cu. m of rocky
cliffs above the dam's foundation pit, the heighth of whose slopes reached
60 m~ and to reduce the total length of time taken by these operations by
at least six months. There was an extremely substantial reduction in the
amounts of rock excavation in the dam's foundation pit by means of reducing
the depth of the cut and removing only the eroded surface zones with cracks
which had filled in with suspended loamy material xhich did not lend itself
. to cementation. Moreover, the thickness of the layer being removed at times
did not exceed 3--5 m. Also reviewed and adopted xere a nwnber of other
proposals, likewise aimed at reducing the work volLmmes and curtailing the
construction time period.s. As a result, the total amount of earthmoving
and rock excavation work carried out xith regard to the principal structures
came to approximately 1.2 million cu. m, while the heighth of the founda-
- tion pit's slopes is about 130 m.
The earthmoving work xas carried out by EKG-4.6 excavators along with the
use of BelAZ-54~0 and KrAZ-256 dump trucks. The principal amount of these
operations was completed over a 1.5-year period ending in December 1978�
Among the schemes utilized for excavating the foundation pit, the following
deserve special menticn:
1. On the right bank between points 105.0 and 50.0 m it was practically im-
possible to complete the transport i~vels. In order to arrange the founda-
tion pit within these points~ it xas decided to carry out an excavation by
means of a single explosion, and for this purpose they provided a set-up at ~
the 76.0-m point of a contour tunnel with a cross-section of 6--8 sq. m and
a length of 80 m. Drillin~; out the massive rock was casried out from above
as well as from the tunnel itself. Special attention was paid here to
drilling holes for contour blasting, spaced at intervals of 0.8--1 m. Inas-
much as the slopes of the foundation pit amounted to 1: 1 on an average,
for the purpose of carrying out bulk loading after blasting at the lowest
possible points~ the two lower tiers of excavation between points 30.0--
50.0 m were removed first. This made it possible to utilize the two most
convenient lower transport levels for excavating earth after mass blasting.
The blasting of this ~ection of the foundation pit was completed within two
months after the Naryn River was cut off.
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2. On the left bank the dam's foundation pit was inaccessible to machines
at height of more than 100 m. The upper pa.rt of the founc~ation pit to a
heighth of about 40 m was excavated from modest-sized areas (created by the
small borehole method)~ using i~KR-tQ0 machines. Fracessing the blasted
earth was carried out by GMN-250 hydraulic monitors (excavators). In ac- -
cordance with a specially developed plan regas~ding the bulk load which was
being fonned from ti.~e blasted and excavated earth, two D-271 bulldozers and
an SBU-2N drilling rig were hoisted by traction to a height of 60 m. F~r-
ther excavation of the earth to existing transport levels was carried. out
with the aid of these machines and hydraulic monitors at a step height, of
= 2.5--3 m.
- 3. The excavation of the foundation pit's lower tier was completed with-
out maintaining a protective layer or the small borehole drilling of the
final 1.5--2 m, as provided for in the plan. ~uch a decision was preced.;d
by tests and full-scale research carried out directly in the foundation pit.
Under the specific conditions of building th~ Kurpsayskaya GES the possibi-
lity of avoiding the installation of a protective layer was guaranteed by ,
drilling the main boreholes ~.5 m higher than the plan outline~ by reduc-
ing the diameter of the boreholes~ and by increasing the density of bore- ~
holes to 2 x 2.5 m. In order to clean up the foundation after the excava-
tion of the earth~ bulldozers were used, equipped with special ripper-
blades~ as well as hydraulic monitors and mounted shafts.
- In December 1978 the earth and rock excavations in the dam foundation pit ~
- were completely finished; on 26 December the first cubic meter of concrete
was laid into its foundation.
The avaidance of building a complex for grading gravel and a concrete sys-
tem in the region of the Kurpsayskaya GES~ despite the considerable dis- '
tance needed to transport the conerete mix (40 Iau)~ insured.from the first ~
few months on that the concrete would be laid at a smooth rate and that it ~
would be of the required good quality. In 1979 so~2 25~~000 cu. m of con-
crete xas laid into the foundat~.on se~^tio~~ moreover, beginning in March,
the average monthly pa.ce amounted to 23.800 cu. m(with a low of 17,200 and
a high of 29~700 cu. m). Here again we should mention the high technology
in the design of this hydsaulic develognent's principal structure--~he da.m,
thanks to which as early as the first yeat of its construction the labor
productivity was greater tha.n during the years of mass concrete laying in
building the dam of the Toktogul'skaya GES. In separate months of 1979
output per man-day exceeded seven cu. m(these calculations made use of
' a method__ analogous to those employed in the construction of the Toktogul'
skaya and Chirkeyskaya GES's).
In accordance xith the start-up scheme~ by tre time the first unit is
started up the dam should be built up to a heighth of 75 m and 680,000 cu.
- m of concrete should be laid into the basic structures. As of 1 July 1980~
approximately 450~000 cu. m of this amount had been laid.
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f At the beginning of 1980 the work front was prepared for installing tha in-
' sertion parts of the turbine sta.tor and the spiral chamber of Unit No. 1; in ~
June the basic operations were completed on the deep interior spillxay, a.nd
work had begun on installing the columns and sub-crane beams of the power-
house (machine room).
In conclusion~ it should be mentioned that i:he experience we have gained in
_ building the KurpsayskayaGES has already convincingly demonstrated the genu-
ine possibility of putting high-capacii;y hydro units into operation within
the course of a single five-year period from ~he time operations 2re staxted.
The principal prerequisites for this are as follows: _
a sharp reduction in the length of time required for the preparatory period;
maximum utilization of the existing experience gained in erecting analogous
structures;
high technology of the structural components of the hydraulic development's
principal and auxiliary structures~ guaranteeing the required labor produc-
tivity and high-quality worlananship.
COPYRIGHT: Izdatel'stvo Energiya, "~ergeticheskoye stroitel'stvo", 1980
238~
CSO : 1822 -
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run vrrl~lew u~r. uivL~
. ELECTRIC POWER ~
unc 621.185�5
CFFICI~vT LINING COM?=0'vTENTS Or' BOILERS WITH GAS-TIGHT SHI~LAS
Moscow ENERGETICHESKOYE STROSTEL'STVO in Russian No 10, Oct 8Q pp 28-32
IArticle by Engineer ]u. S. Tsarikov: "Efficient Lining Components on Boil-
ers with Gas-Tight Shields'] -
~ jText,J The lining of boilers with gas-tight~ all-welded shields ma.de of
firu~ed tubes possesses essential advantages over the lining of boilers
with smooth-tube shields. In such boilers the lining fulfills the function
of inerely a thennal isolation of the radiating surfaces whose temperature
does not exceed 600�C. At the present time boilers of both the single-pass
- type as well as the drum-type boilers kith gas-tight shields are being turned
out by the Red Boilermaker Production Association (TKZ) (Taganrog Boi].er
Plant and the Barnaul Boiler P1ant (BKZ). The plant designs provide the
following for the lining components of these boilers: the base layer ,
uses insulation made of inlaid products--perlite, vulcanite~ and calcareous- _
siliceous panels (IKP) and sprayed rr~th asbestos-perlite and asbestos
compounds; for the coating layers plaster is used with fiberglass glued ~
on an epoxy base or thin-sheet steel. ,
The USSR Ministry of Power and Electrification has accumulated considerable
experience in manufacturing the above-mentioned linings at assembly areas
and at installation sites. In a n~unbQr of instances~ when there is a lack
of the materials provided for by the plan~ their quality is poor~ or there ;
is insufficient time for installati~n~ upon agreement with representatives I
of the electric poxer stat~ons and boiler plants, lining components kave ;
been m~,de which are not in the plan. At the present, therefore~ electric '
power stations now have about 12 types of linings in operation. ,
In connection with the above, the need has arisen to detezmine the quali-
tative and technical characteristics of these components, to compare them,
- and to develop the necessary recommendations on the basis of this. Thermal ~
tests of the linings are being systematically conducted by the quality-
control service of the special administrations of the Soyuzenergozashchit ~
VO (All-Union Association) and the Soyuztekhenergo PO (Froduction Associ- ;
ation) (in conjunction with representatives of the electric power sta,tions) i
;
~
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in accordance with the requireipents of the "Instructions on Testing Thermal
Insulation in Electric Power Stations." For this purpose use is made of
the ITP-6 thermal-flow measuring instruments of the Institute of Technical
Thermal Physics of the Ukrainian SSR Academy of Sciences. When necessary,
the measurements are double-checked by the flat t:~ermometers designed by _
the Teploproyekt V~JIPI (All-Union Scientific Research and Design Institute).
The temperature on the surface is measured by semi-conductor heat sensors
of tha TP-3 type and surface thezmocouples~ while the distribution of tem-
peratures throughout the thickness of the layer is determined with the aid
of chromel-cupriliferous and chromel-aluminiferous thermocouples. -
The methodology for processing the data received is based upon the indicator -
of the component's thernial conductivity at an average operating temperature.
It characterizes not only the material and the manufacturing quality of
the lining, but it also takes into consideration to a certain degree the
influence on it of thertnal-conductive metallic and other inclusions. The
reliability of this indicator of thermal conductivity is guaranteed by the
large number of test measurements carried out. These tests have enabled
us to make a comparison between the design values of the thermal conductivity
of the lining components aiid the measurements obtained in the process. At
the present time~ in calculating the thickness of a lining we proceed.from
the reference values for the theimal conductivity of the materials which
are included in its design. The thickness of a lining layer which is
manifested as the fiesult of calculation is being increased somexhat, and
it is being accepted (in the case of all kinds of materials) as equal to 160 -
and 210 mm for the TKZ and BKZ boilers respectively. In connection with `
the absence in the literature of the design values for thermal conductivity
of combined. components (those made of various materials and products),.an
_ attempt has been made to determine them on the basis of data obtained. as
the re:sult of tests; for this purpose the data were grouped by types of ~
_ materials and~methods of carrying out the operations.
Examined below are the most efficient lining components.
Sprayed lining ( insulation ).~in boldfaceJ Spraying asbestos and asbestos-
perlite masses is a reliable method for obtaining seamless lining components.
In recent years such components have been widely adopted on BKZ and TKZ
boi lers. The spra~ring is carried out on mounted equipment (BKZ) and pa.rtial-
ly at assembly areas (TKZ). As the spraying material use is made of Grades-
II I~ V, and VI asbestos, uffed-up perlite, vulcanite, and other binders--
ac rylic resin (Plexiglass~~ an aluminum chromophosphate solution, and
c ement. Spraying a lining, in accordance with the requirements of the .
instruction now in effect Ilr~ must be carried out using Grade-III asbestos.
How ever, this instruction I'if contains a stipulation concerning the possi-
bil ity (as an exception) of utilizing a mixtixre consisting of ~ Gra,de-III
asbestos and ,50~ Grade-V asbestos. In practice~ because of a shortage of
Gra.de-III asbestos, this ratio has recently been altered in favor of increa-
sing the proportion of Grade-V asbestos~ and even Grade-VI asbestos is being
used~
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Everyxhere attempts are being ma.de with regard to the possibility of using
non-asbestos compoLUids. At the Kuybyshevskaya 2'ETs (Heat and Electric Po-
wer Station) and the VAZ (Volga Automotive Plant) TETs the lining and the
insulation of the corners of the furnace (fire box), the drums~ and the gas-
conduit ducts have been made as ?n experiment with a compou.-~d based on gra-
nules of mineral wool with an additive of Grade-V asbestos and a binder of
acrylic resin. At LnP Maryyskaya GRES (State Re ianal Electric Power Sta-
tion) the spraying of a lining of a cold hopper ~funnel) of one of the boi-
lers has been done using I1:I (calcareous-siliceous) granul~s. Widesprea.d �
use is now being made of ready-made dried asbestos-perlite mixes produced
by the Dmitruvskiy Thermal Insulation Froducts Plant and consisting of -
Gracie-V (or VI) asbestos and puffed-up perlite in a ra,tio. of 2: 1.
Test data on sprayeci linings are cited in Table 1.
The material is usually sprayed on cold heating surfaces, though in some ca-
ses it has been done on heated ones (Minskaya TETs-4). There is some expe-
rience in spraying at belox-f.reezing temperatures; nephelinic antipyrine~
which is recommended by the technical specifications as a coagulant of acry-
lic resin when spraying on a cold surface, is not always used. Furthermore,
the lack of ready-made mixes with antipyrine and the existing technology of ~
spraying do not permit us to make a confident judgement about the effect of
nephelinic antipyrine on the quality of a finished component. There is an
opinionthat in the spraying process a considerable portion of the dust-type I_
coa~ulant is blown away by the air stream. This opinion needs to be checked
out. In processing the test results run on existing operational boilers,
indicators of component thermal conductivity have been obtained which differ
substantially from the design indicators adopted in accordance with data in
instructions and literature from the sources--- the Zi0 [possibly the Podol'sk
Machinery Plant imeni Ordzhonikidze], the TsETI [Central Electrical and Heat
Engineering Institute for Structural Components imeni Kucherenko]: for a
lining made of Grade III asbestos 0.071 + 0.00013~P and made of Grade
V asbestos 0.125 + 0.00008~~ p,
- -
The discre cy between the actual and the design values of thermal conduc-
tivity j~an be demonstrated by making a calculation of the thickness of
the lining layer of a BKZ 420-14~0 boiler, proceeding from a normative levsl
- of heat losses of 349 Watts per sq. m and a lining surface temperature of
~ 55'C and a shield surface temperature of 345�C. The design value of the
lining component's thezmal conductivity, i. e., of a component made of
Grades-III and V asbestos~ under these conditions is equal to 0.097 and 0.
141 Watts~(m . K) respectively. The thicknesses of the lining layer axe
as follows:
SIII = O.o97 (3~5-55)/3~9 = 8o mm;
d~i = o. lu 1( 3~+5 -55 )/349 = 1 i4 mm .
It is obvious ~hat with such a thickness of the lining components it is im- ~
possible to insure a normative level of heat losses and temperature.
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Table 1 (Continued)
Thermal Conductivity of Component, Length of Time
in Watts~(m � K) in Operation,
in hours
Design Test Measurement .
0.09? o,liz
0.097 0. i66 $986 �
1000
0.097 o,i6 92~
0.142 1~~
0.~63 5252
I o.i67 -
o.~i41 0.2 ` ~975 :
o. iwi o.23 ~ z9628 ~
o.i41 o.zi3
o, i41 0. i87 1 I 1800
~ 0.287 ~ I 6562
~
' ~ 0.184- I I 20,000
Testifying to this is the operating experience of the BKZ 420-14~0 NGN No.
5 boiler of the Bobruyskaya TETs-2, which had a lining thickness of 1~1-0 mm.
After its start-up the need arose to spray on an additional la~er of insu-
lation with a thickness of 20-30 mm. ~
It should be noted tha'~ the indicators of the insulation being sprayed, in
particular density and thermal conductivity~ depend, to a great extent, on
a number of objective factors such as the type of installation and the de-
~ree of asbestos swelling furnished by it~ the air pressure and outflow ve-
locity of the air mixture~ the amount and density of the binder, the dis-
tance of the nozzle from the surface being sprayed (it should amount to be-
- tween 400 and 700 mm). The operator's experience is also quite important.
The ratio between the density of the layer and the velocity of the air mix-
ture's outflow as well as its saturation has been confi~ed. by the results
of an experiment which was conducted at the Dzhatnbulskaya GRES. The scheme ,
of the unit for spraying insulation (Fig. 1) included a cyclone centrifuge ~
(separator; (Fig. 2;~ which permitted the excess dust-removed air to be dis-
charged through a pistol-type ~,tomizer. T~e density of the test samples was
lowered, according to the data of the construction laboratory of the Dzham-
bulskaya GRES Special Administra.tion by an average of 20 kg per cu. m. The '
� use of such a meth~d of spra.ying with a discharge of excess air also per-
mitted dustiness to be averted..
20
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5 6 7
8
~j - -
3 ~
17l ~
Z~ ' 10 9 -
i
1
Figure 1. Schematic of Test Installation
for Spraying Insulation
Key: ~
1~ Ejection machine 9. Material hose for enriched '
2. Air collector for air mixture
~ � feeding air 10. Cyclone centrifuge
3. Receiving bunker (hopper) (separator) -
4. Air hose I Air mixture feeding -
5. Compressor receiver II Discharge of atomized
6. Tank for binding mortar
7. Hose for feeding mortar air mixture
to pistol-type atomizer III Discharge of excess air
- 8. Pistol-type atomizer ,
In view of the shortage of Grade-III asbestos~ a study was made of the pos-
sibility of using Grade-V asbestos for spraying insulation. Grade-V asbes-
tos has shorter fibers than Grade-III asbestos. In spra.ying, therefore, it
requires an.increased discharge of binder and creates a denser mass of fi-
bers, possessing less elasticity. As a result of such a subjective factor
as the operator's attempt to red.uae dustiness in the work zone~ there is an
excess moisture in the mixture. In the case where acrylic resin is used as
the binder the excess moisture in the mixture does not cause any signifi-
cant reduction in the lining's thernnal conductivity. When the lining layer
is heated up~ the moisture contained within the acrylic resin evaporates,
and the material becomes porous. Design calculation and experience have de-
monstrated the possibility of using Grade-V asbestos for spraying xith a
layer thickness of 210--220 mm. This thickness is sufficient to insure a
noimative level of heat losses and temperature at the insulation surface
(See Table 1).
~ 21
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~ , ~
r
~
: ~ ,
. ~
Y
. 1
i
F
I
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f I
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~ Figure 2. Cyclone Centrifuge (Sepaxator)
Key:
1. Housin~ (Casingj 5. 3upporting structure
2. Nozzle (Outlet) for dis- 6. Nozzle for discharging
charging excess air enriched air mixture
3. Discharge regulator
4. No2zle for feeding ai~
mixture ~ -
Linings made of panel-fozmed products. ~in boldfaceJ The traditional ;
block-inlaid material for BKZ boilers consists of vulcanite panels(plates). i
Recently calcareous-siliceous panels (IlCP) have been used for lining BKZ ~
boilers installed at electric power stations in the European pa.rt of the
USSR and TKZ boilers installed at TES's in other regions. According to the
plant designs~ the following thicknesses have been provided for the linings
made of IKP: in the TKZ boilers 160 mm (105+5+50~ where 105 and 50 axe the ~
thicknesses of the IKP, ar~d 5 is the thickness of the mastic layer)~ in the ~
BKZ boilers 210 mm (105 x 2). Despite the lack of.IKP with a thickness of ;
j0 mm in production~ corrective adjustments in the Korking drawings of the
TKZ's have not been made up to now~ and this has led to various difficul- ,
ties. In installing these panels, it is necessary to replace the existing i
- ones with materials having equal values. For example, at the TGMP-204 boil- ~
ers No. 5~ 6, and 7 of the Zaporozhskaya GRES it was agreed upon with the
manufacturing plant to replace IICP panels ,50 mm thick with perlite ones.
i
22 ~
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FOR OFFICIAL US~ ONLY '
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_
FOR OFFICIAL USE ONLY
Other TES's have selected materials xith suitable thicknesses. For lin-
- ing these same types of boilers at the Ugle~arskaya GRES as a first l.ayer
they used perlite and perlite-phosphogel ~ panels whose thickness has
- not always corresponded to the needs. Hence~ the layer thickness of such
_ a lining amounted to 160--195 mm. At the TGME-206 No. 1 boiler of the Pe-
- chorskaya GRES, for the same reason and because of a lack of suitable pro- _
ducts~ perlit,e-phosphogel panels 90 mm thick had to be cut in such a way -
that their thickness amounted to 50 mm. and this lec~ to considerable waste.
- The results of tests run on lining components made of panel-type products
are cited in Table 2.
It is obvious from Table 2 that the linings of the TGMP-204 boilers at the _
Uglegorskaya GRES have the highest indicators. This may be explained by the
fortuitous selection of materials for the component (the first~ "hot" layer
was ma.de of products with a lower. lineax shrinkage coefficient than that
possessed by IK P--perlite and perlite-phosphogel panels~ which guaranteed _
less openings of the seams ,(joints,r, and the second layer xas made of IKP),
, as well as by exceptionally care�ul execution of work in the assembly area.
- The TKZ boiler laboratory followed up on the lining of this'same No. 5 boi-
ler at the Zaporozhskaya GRES. In the report on the tests it was noted that
in certain spots the temperature of the facing sheets reached 71� C. Unsa-
~ tisfactory work on the lining component of this boiler is the explanation
for the shrinkages in the IKP layer, xhich reached 2 percent (according to
the engineering snecifications) or 20 mm per meter. When the covering la-
yer was removed, gaps (breaks) were revealed between the panels (of as much
as 15--20 mm). Inasmuch as the first layer was made of sovelite ~?,J panels,
their increased Y~ennetj.c qual3ty (6 times gredter than perlite panels and
12 times greater than IKF panels) caused a high temperature to occur in tl~ie
zone where the I~CP had been installed. and, con~equently, an increased shrin-
kage in the latter.
Laboratory tests run by Sibtekhenergo have established that IKP shrinkage
- amounts to 1.47--4.2 percent at a temperature of 600� C. Also included.
among the shortcomings of IKI are t,heir hi~h hygroscopicity and density
- under moist conditians. In the design calculations of the installed loads
the density of the products is usually taken as equal to 225 kg (kilograms)
per cu. m(in accordance with the engineering specifications). However, at
times pressed IlCP axe delivered to the installation areas with a density of
- 35o ax?d 450 kg per cu. m~ inasmuch as the hygroscopicity of the calcareous-
siliceous products is very high, their moisture upon delivery according to
the engineering specifications may comprise 70 percent~ and the actual den-
sity of the IKP may exceed the design calculated amount by a factor of 4~
or 5. At the CheY:oksarskaya TETs-2, when the lining IKP of the boiler _
unit~were being hoisted up~ they fell, since this unit's lining components
had been kept in the construction yard for three months without being co-
- vered up. Tests which were conducted on samples of the lining panels in
connsetion with this accident shoxed that their density amounted to 39b--
672 kg per cu. m, and their xater absorption, when immersed in water for
~3
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24
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Table 2 (Continued)
Thexmal Conductivity of Comporient, Length of Time
in Watts~ (m . K) in Operation,
in hours
Design Test tf easurement
~ 0.091 0.395 59~217 -
- 0.091 0.486 12,7c~,
o.o9i o,226 zo~i3o
0.09 0.368
0.094 o.i86 ~ 600 ~
0.098 o.zo7
0.12 0.160
0.12 0.184- 25,079 =
0.112 8,814
0.114~
_ o.i74
o.i23
- ~ o.16i
~ 0.085 ~ 150 -
30 minutes reached as high as 144 percent. For the exact same reason at the -
Heftinskaya GRES the shield unit of a P-S7 boiler~ lined with panels from
TsKBenergo (Central Power Design Bureau), and fell, while it was being -
hoisted up.
Combination-type linings made of block-inJ.aid products, Il{P, and
sprayed materials (Table 3).~in boldface,~ In order to reduce the influence -
~ of IKP's shrinkage phenomena and lack of compaction between panels to the
level of heat losses, a combination-type of lining has been utilized in a
number of boilers upon agreement with the plants concerned. On the BGZ 420-
140 NGFI Nos. 1 and 2 boilers of the Kaunasskaya and Minskaya TETs's, in ac-
cordance with the plan~ the first layer has been applied consisting of IICP
_ with a thickness of 105 mm, and the second layer--consisting of an asbes-
tos-sprayed layer of material 100 mm thick. A lining of analogous compo- _
nents has been used on these same types of boilers at the Petrozavodskaya
TETs~ except that instea.d of IlCP~ wlcanite panels were utilized in the
first layer. Thennal testing confinned the high efficiency of the compo-
nent which had been selected.
25
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26
FOR OFFICIAL USE ONLY
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Table 3 (Continued)
Thexmal Conductivity of Component~ Length of Time
(Test Measurement}, in Operation,
in Watts~ (m . K) in hours
o.zio 6,960
0.174 1,440
o.i46
0.152
0.14 z,o56 -
0.~62 5,838
0.112 12~OOQ
o,i57 z~o56
o.os~ 150
o.o7a 150
0.096 200
~
0.057 16~390
0.0675 i~oo0
0.073 3,000
Linings made of mineral-WOOl mats and sprayed materials. ~n boldface7
At the Ufimskaya TETs-5 a boiler lining was made of a layer of mineral-wool
' sewn mats with a thickness of 70 mm within a lining made of steel mesh~
installed at a distance of 100--300 mm from each other~ and a layer of
sprayed asbestos material l00 mm thick~ Which also filled in the spaces
between the mats. This component worked reliably for more than two years.
Thezmal tests which were run by the Soyuzenergozashchita VO (Al1-Union
A~sociation) and the Soyuztekhenergo PO (Production Association) at
various times and after the boiler had been operatiag for various numbers
of hours~ confirmed the high operational indicators of such a lining. _
Analogous components were placed on the boiler of the Petrozavodska.ya TETs.
Linings made of block-inlaid products and minera.l-wool mats. Cin boldface,J
In order to verify the possibilities for eliminating wet processes on the
TGP~E-206 No. 1 boiler of the Pechorskaya GRES lining components of two types
were installed, retaining the planned layer thickness as follows: nne of
the IKP and the mineral=wool.mats were given layer thicknesses of 105 and
80 mm respectivelyi the other was made of a la;;er of mineral-wool mats, IKP~
and a second layer of mats (the thickness of the mat layers was 40 mm each,
a1d that of the IKP xas 105mm). Observations on the data derived from these
27 ~
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components allow us to make preliminary conclusions about their rather high
efficiency and reliability. The TGME-464 boiler of the Mazheykyayskaya TETs
was given a lining witr. a thickness of 160 mm on all the shield heating sur-
faces, made of IKF (hot layer) and mineral-xool sewn mats~ In carrying out
the second type of boiler lining at the Pechorskaya GRES and the rIazheykyay-
skaya TETs a levelling mastic layer xas not applied between the tubes.
Also checked, out was the possibility of lining boilers with gas-tight shields
made of mineral-wool products~ which would allow us to obta.in seamless indust-
rial components and ensure their reliable u~e over the course of a prolonged.
period of time. With this goal in mind, the No. 3 boiler of the Minskaya
TETs was furnished with a lining component on one section of the shield~ ma.ae
of mineral-wool mats. Tests xhich were run on this section demonstrated ,,..~t
at a layer thickness of 200 mm the density of the heat flow amounted to ''r5
Watts per sq. m, while the tetnperature of the lining surface was 42'C; the ;
thermal conductivity of the lining xas 0.099 Watts/ (m�K�)~ A followup study
was also made on the condition of a similar �lining in the Finnish soda-rege-
neratin~ boiler with a steam productivity of 90 tons perhour (P=3.9 MFa~mega-
pascals~) at~the TETs of the Svetogorskiy TsBK, which went into operation
in 19?6 and which by the time of the tests had been operating for 16,390 hours.
The lining components of this boiler are made of a carpet-like matting of
"rock Frool" (basalt diabase), threaded on pin-hooks 6 mm in diameter. With
a thickness of 200 mm this lining had a thermal conductivity of 0.057 Watts
~(m�K), the density of the heat flow amounted to 60 Watts~m2~ and the tean-
perature of the lining surface xas 3b�C. ~
Recently, increasingly wider acceptance has been gained by 13ning components
made of high-temperature fibrous materials--basalt fiber and kaolin wool.
VNIPI (All-Union Scientific Research and Design Institute) Teploproyekt~ on
- the basis of results of researching the properties of various fibrous mate-
_ ria1s~41~ ~~ca~nmended for use in ine d~signs of t:~exmal ins4laiion the
following optimum densities: mineral-wool 150--16Q kg per cu. m, wool mad.e
of super-thin fiberglass 90, wool made of ba,salt super-thin fiber (BSTV)100~
and highly aluminous wool 200 kg per cu. m.
In order to make an experimental industrial verification of the possibility
of ut~lizing basalt super-thin fiber and kaolin wool in lining components,
the TGMF-204 Nos. 6 and 7 boilers of the Uglegorskaya GRES were furnished
with test sections of a lining made of rolled VGR-130 kaolin xool and BSTV
of varying density. Tests which xere conducted for 3,500 hours after these
sections were installed and subsequent observations of them over the course
of 6~000 hours demonstrated the high reliability and economical nature of
these lining components (Table 4). Moreover, it was established that the
best indicators were achieved by utilizing BSTV with a density of 90--97
kg per cu. m. At the present time the TGM-1202 boiler of the Kostromskaya
GRES has been furnished with lining components made of a layer of ba.salt
fiber with a thickness of 160 mm, as provided for in the plan for IKP.
28
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For the purpose of economizing~ the coefficient of installation compaction
of plant-manufactured mats made of BSTV h~s been accepted as equal to 3�5.
and this insures their density at 81 kg~m , Ar 13 kg per sq. m of surface.
For this purpose, mats were laid down in a layer 560 mm high and then com-
pacted from above by a metallic frame to a thickness of 160 mm. At the
_ planned heighth the frame is affixed by a wire "moustache~" welded to the
_ pins. The possibil~ty of making a lining out of VGR-13U kaolin xool for the
TGME No. 1 boiler of the Khax'kovskaya TETs-5 xas at,~*reed upon with the TKZ~ -
but because of organizational reasons it replaced the planned lining made of
IKP only on the bottom shields and the lower shield of the transfer gas con-
duit. Rolls r~ade of kaolin xool were also placed on the pins and tightez:ed
~ by the frame. Thereby a compaction coefficient of 1.5 xas insured, and
this all~~~ed a layer compaction of 210 kg~m3 to be achieved.
However, ta.king into consideration the high cost of basalt and kaolin fiLer,
we should probably use combination-type components with the second layer
ma.d.e of cheap mineral-xool groducts.
Conclusions _
1. For lirting the gas-tight shields of boilers being produc;ed by the TKZ
and the BKZ, a layer thickness of a lining made of block-inlaid form of
thern?a1 insulation products (except for those made of sovelite) equal to
160 mm is sufficient to guarantee a normative level of heat losses.
The principal factor detern?ining the level of heat losses under stable,
equal conditions is the henaetic quality of the lining layers.
2. A combination-type lining made of block-inlaid products, mineral-wool
mats~ and sprayed materials in various combinations successfully combines `
the stable thenno-physical properties of rigid-form products with the pro-
perties of mineral-xool items and a sprayed layer. This makes it possible
to forni a seamless, elastic component.
The efficiency of using this type of compon~nt on BKZ boilers can be in-
creased if the BKZ~ like the TKZ, peYmits lining operations to be carried
out in assembly (prefabrication) areas. '
3. The thenno-physical properties ~f sprayed insulation made of Grade-V -
asbestos fully meet the requirements for heat insulation raaterials for the
high-temperature surfaces of electric-power engineering equipment.
4. Linings made of fibrous materials (mineral-wool, basalt~ kaolin, and
others) are the most effective of all those being made at the present time.
The use of ba.salt and kaolin fibers for linings permits us to reduce the
thickness of the lining components, the outlay of materials, and the weight
of a boiler unit.
30
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BIBLIOGRAPHY
1. "Vremennaya instruktsiya po vypolneniyu elementov obmurovochnykh kon-
struktsiy parageneratorav napyleniyem" jProvisional Instructions on
Making Elements of Zining Components for Steam Generators by means of
Sprayir?~~ Moscow ~ Infornlenergo ~ 1975 ~ 3~?~ pa8es.
2. "Vypolneniye obmurovochnykh konstruktsiy parovykh kotlov metodom napy-
_ leniya" aking Lining Components for Steam Boilers by the Spraying
Methoc~ ~Shkola peredovogo opyta. Tezisy dokladov, Baku~ 1975~~ Moscow~
Informenergo ~ 1975 ~ 95 P~es,
3. Kozlov, Yu. V.; O1'shanskaya; Voronkov, S. T.; Vlasov~ G. B. "Testing
Rapid-Hardening Sprayed Insulation with a Gas-Tight Exterior Coating"
in Series III --"Teploizolayatsionnyye i izolyatsionnyye raboty" IHeat
Insulation and Insulation OperationsJ~ 1976~ Issue 6(114)~ pp 5-8 -
(TsBNTI Minmonta.zhspetstroya SS~R).
4. Semenov, S. I.;Semenov~ V. A.; and Taxkhov, A. A. "Issledowaniye teplo- ~
provodnosti materialov pri polozhitel'nykh tempera.turakh" ~Reseaxch on
Thermal Conductivity of Materials at Temperatures above Freezingf in
"Sb. trudov VNIFI Teploproyekt. Konstruktsii i stroitel'stvo spetsial'-
_ nykh sooruzheniy" ~Collected Works of VNIPI Teploproyekt. Components and
Construction of Special Structures~ Issue 47, 1978~ PP 112-124~.
COPYRIGHT: Izdatel'stvo Energiya, "Energeticheskoye stroitel'stvo", 1980
. 238~
CSO: 1822 ~
31 ~
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ELECTRIC POWER
Ui7C 621.181.002.72 _
NEW GROUPII3G 50LUTIOt1S FOR THE TPF-312A BOILER
Moscow ENERGETICHESKOYE STROITEL'STVO in Russian No 10~ Oct 8~ pp 33-37
~Article by ~ngineer A. G. Isarev and Candidate of Technical 5ciences A. G.
Kravets: "New Grouping Solutions for the TPP-312A Boiler'J I
~Text,J At the Zuyevskaya GRES-2~ which is under construction in the Donbass I
according to a plan of the Khar'kov Division of Teploelektroproyekt~ provi-
sions have been made to insta.ll eight power units having a capa.city of 300 ~
MW (megawatts) each with TPP-312A boilers produced by the Krasnyy kotel'
shchik ~Red Boilermaker) PO (Production Assaciation~. These boilers have
been designed to operate on GSSh coal dust; their steam capacity (boiler
rating) is 1,000 tons per hour each.
Such boilers were also installed at the La.dyzhinskaya~ Zaporozhskaya~ and '
Uglegorskaya GRES's. Their auxiliary equigment is the same, but their
grouping solutions vary slightly. This is connected with the fact that the _
boiler groupings at the Zaporozhskaya and Uglegorskaya GRES's were optimized
on the basis of an analysis of the plan solutions for the main power unit of .
the Ladyzhinska}a.GRES and a study of the experience gained in constructing it,
Froposals for optimizing the boiler groupings were implemented to the maxi-
mum degree on the first stage of the Zaporozhska.ya GRES; this pernmitted us
- to curtail metal outlays for manufacturing dust-gas-air conduits (flues) and
= their supporting structures, to simplify the scheme of dust-gas-air conduits
and~ at the same time~ to increase their reli.ability~ to introduce a highly
efficient mechanization scheme, and, thanks to this, to reduce installation
time periods and labor outlays.
The experience gained in building and operating the TtiP-312A boilers at the !
Zaporozhskaya GRES confirmed the advanta~es of the improved grouping~ and the ;
latter was utilized by the general planner and the plant manufacturer for the
boilers of the Zuyevskaya GRES-2 with minor changes. Thus, because of the ;
soil characteristics at the GRES site, the general planner a.dopted a base- ~
ment-less grouping for the equipnent of the pow erhouse (machine room}~ and '
this led to a raising of the operational grade level of the turbine unit (to
12.6 m, instead of the 9.6 m used. at the other three electric power stations
mentioned above). In order to create a common operational level, as well as i
32 ~
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_ I-
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to eliminate the differences between the levels of the condensation floor
of the powerhouse and the ash floor of the boiler section. the boilers were
installed on reinforced-concrete subcolumns at a height of 3 meters. The
profile of the site also caused a difference of 1.2 m betxeen the grade
levels of the boiler ash floor and the open area of the regenerative air
heaters (RVP) and the electrostatic precipitators.
These changes in the boiler grouping Were reflected only in the vertical
dimensions of the individual circuits of the dust-gas-air conduitsi but the
arrangement of the auxiliary equipment and the layout of the dust-gas-air
- conduits at the Zuyevskaya and Zaporozhskaya GRES's are the same.
The boiler sec tion of the main building of the Zuyevskaya GRES-2 has floor-
plan dimensions of 45yC48 m~ and its height to the loKer girder zone amounts
to 61.07 m.
Hot air is fed to the burners (the front and back Kalls of the furnace have
four burners each) through a double tier of air conduits~ txo of Which are
situated beloK the operational grade level~ while the other two are located
above it. Also extended under this level are the primary air conduits~ gas -
conduits for admixing inert gasses to the dust system and a suction circuit -
from the slag shafts. The smoke suction tubes for recir~ulating the sanoke
gasses of the GD-20-500U are located along both sides of the convection shaft~ -
- while the TsN-15 cyclones (separators) are placed behind it at the 35.0-m
grade level.
The RVP-98 regenerative air heaters xere installed on reinforced-concrete
footings (the upper footing grade level is 13.75 ~)r the VDN-32B draft fans
were installed perpendiculax to the~+all on the G row of the main building,
and the CO-110 heating elements Kere placed under the RVP.
The hot air conduits from the RVP are introduced. into the boiler section at
gra.de levels 8.6; 22.1 (air conduits for the secondary air) and 8.0 m(for
the primary air); a baffle was placed between the RVP. The gas conduits
from the bunkers of the convective shaft ( i n the forn? of two inclined boxes )
upon coming out of the boiler unit are joined at first in order to insure
the intermixing of gasses, and. then they axe branched into the air heaters.
In the area where the RVP are located the gas-air conduits are fastened to
metallic structural components.
in ortler to repair the RVP, the draft fans ~ and the gas-air conduits, a
semi-gantry crane has been provided, which travels along tra.cks extended
on the columns of the main building and the supporting structural elements
of the RVP.
The grouping solutions for the TPP-312A boilers of the Zuyevskaya GRES-2~ as
- developed by the Khaxkov Division of the Teploelektmproyekt Institute and the
Red Boilernaker PO (Fig. 1), were thoroughly analyzed by the Kharkov Branch
of the Energomontazhproyekt Institute prior to executing the workin~ drawings
33
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35 960
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FOR OFFICIAL USE ONLY
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Figure 1. Initial Boiler Grouping
Key:
1. TPP-312A boiler 5. ~ Flue-gas pump for recirculating
2. Cyclone (sepa.rator) a.sh- smoke gases
collector of recirculating 6. Electrical engineering
smoke-gas c ircui.t heating element
3. Regenerative air heater 7. VDN-32B draft fan _
4. Coa1-pulverizing mi13
of the dust-gas-air conduits. As a result of this analysis a.dditional possi-
bilities w ere sought to perfect boiler grouping~ insuring a reductibn of
capita.l and labor expenditures in building a GRES~ improving the conditions
of boiler operations, increasing their installation technology and ease of
_ repairs~ as well as reducing the expenditure of electric power for the
- station's own requirements. Technical solutions for optimizing boiler group-
ings were worked out by a group of specialists at the Khaxkov Branch of ~
the Energomantazhproyekt Institute and the Zuyevskaya GRES-2. After review
by the Donba.ssenergo PEO (Planning and Economic Section), Soyuztekhenergo P0, ~
- the Red Boilermaker P0~ Glavteploenergomontazh. the Teploelektroproyekt In-
stitute, the Glavenergoremont TsKB (Gentral Design Bureau)~ and the Soyuz-
energozashchita VO (All-Union Association), they were approved by the USSR
Ministry of Poxer and Electrification. Based on these solutions, the Khaxkov
Branch of Energcmontazhproyekt, in con junction rrith the Red Boilermaker P0,
developed a new boiler grouping (Fig. 2) and adjusted the engineering speci-
fications for the auxiliary equipnent, while the Kharkov Division of the
Teploelektroproyekt Institute introduced the necessary changes in the plan
for the GRES. _
One of the unsatisfactory, solutions in the initial grouping was the placement
of the electrical engineering heating elements directly under the RVP
nozzles~ which did not allow mechanized equipment to be u.sed in repairing
and replacing the heating elements and shut-off valves~ which were located
in the flow zone of aggressive washing waters.
In the new grouping these heating elements have been brou~ht out from under
the RVP footings and placed to the side of the boiler section~ which elimin-
ates the possibility of the washing Waters falling on the heating units and
the shut-off valves. Thanks to the placement of the heating elements in the
operating zone of the semi-gantry crane, installation and repair work has
been simplified, and supplementary hoisting apparatus is not required. The
baffle betw een the groups of heating elements insures the possibility that
both air heaters may operate when one of the fans is shut, off. The draft
fans are installed not parallel to the axis of the boiler~ as they were in
the initial grouping, but at an angle to itj this is caused by the structure
and tr.e reciprocal placement of the boiler footings, the RVP,and fans, as
well as by the need to insure an even supply of air and an increase in the
relative length of the defuser behind the fan for lowering the circuit's
resistance. Also reduced is the aerodynaraic resistance of the cold-air
- 35
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36
FOR OFFICIAL USE ONLY
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l7 -
Figure 2. New Boiler Grouping
~ (with positions the sam e as in Figure 1) ,
suction section of the air conduit by m eans of i.nstalling a pocket ahamber
in the boiler unit and eliminating two bends in the section of the air con-
duit before it reaches the fan.
Removing the heating units from under the air heaters pexmitted a reduction -
in the height of the PVP footings by 5.8 m and, bFlcause of this~ a reduction
~ of the outlays required to build them. It also allowed us to substantially
improve the gas-air-conduit circuits outside of the boiler section and to
simplify the design of the supporting structural components. The gas-con-
duit loop passes irom the bunkers from the boiler's convective shaft to the
- RV'F in the common chamber (box) on a horizontal plane~ and it branches out
only alongside of the entrance nozzles of the F~VP. In comparison w ith the
initial grouping, this salution has the following advantages: a better in- -
termixing of the gases in the common cr~amber is assured; design of the gas-
conduit supporting structural components is simplified; there is an improve-
ment in the aonditions for installation and repairs; there is a possibility
for lowering the height of the semi-gantry crane for servicing the RVP and '
the draft fans; there is also an impravement in the external appeaxance of _
the electric power station's main building.
_ In the new grouping the cross-section of the gas conduit is reduced~ and
this decreases the expenditure of inetal and thennal insulation materials.
It also assures the gas velocities necessary to avoid falling ash when the _
boiler is operating under low operating loads. Moreover~ the circui-~'s
aerodynamic resistance is not increased. .
" The hot-air conduits from both RVP ara joined (as a result of which there
is no further need to install a baffle between the RVP) and are led into
the boiler unit in the fonn of a common inclined chamber (Fig. 3). This
chamber is divided by internal partitions into eight channels in ~~.cordance
with the dust-gas-air conduit scheme.
i
0
_ ' J ~ ' ~ f �
0
o ~ -
2 ' ~ f 2
d~ J200 ~ J200 Bo0
8000
Figure 3. Commor~ Hot-Air Chamber _
37
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~
Keys
1. Channel of secondary air to the burners (with Venturi tubes) ~
2. Channel of primary air to the dust system (with Venturi tubes) ,
_ 3. Channel for recirculating hot air into the suction shaft and '
admixtures into compacting the smoke-gas recirculation circuit
In the area of the boiler the air conduits are at first f'pd to the burners
along the axis of ttie power unit in two branches (each of x~ich is divided
by internal partitions into four channels with a cross-section of 1.4~X.1.6 m
with Venturi tubes), and then, after the air has been fed back to the rear ,
~ burners ~--b3r .two _chaabers Hith dividing partitions to the front burners. '
Under the boiler air conduits are placed in a horizontal plane; they axc
suspended from the metal structural componen~;s of the convective shaft
framE and the furnace door, and they do not interfere with the ha~Ylage of
the slag-shaft transporters~ nor with access to the hatches for removing
slag from the tap holes. Air is fed to all the burners from below, and ~
for this reason the chamber's four burners~ which were previously aimed
upwards~ have been turned asound. j
~
The use of a single-eared circuit of chambers for feeding hot air to the
burners, along with reducing the expenditure of inetal and thermal insu-
lation materials, insures a reduction of the circuit's aerodynamic resist-
ance, improvement in the conditions of carrying out repair operations '
thanks to a freeing up of the zones around the boiler, a reduction of heat
releases above the operating level, and a simplification of the supporting '
structural components. The positioning of the shut-off and regulating -
valves on the same level as the burners allows their servicing to be faci- ~
litated. The length of the primary air conduits has also.�been reduced,
and their.configuration has been improved.
In addition to improving the gas-air conduit circuit~ the new grouping pro-
- vides for a reduction in the number and type size of their valves alongside
the RVP. Only valves with a cross-section of 2.8X4 m are used in the feed '
and exhaust gas-air conduits. I
i-
The boiler's dust systern was not subjected to any substantial changes. In ~
optimizing the grouping a provision was made only to increase the cross-~ ;
section of the air conduit feeding hot air to the mill fan and laying ~
through a new loop of dust conduits to the rear burners. The first of ~
these changes (it was introduced at the request of the Donbassenergo PEO ;
~Planning and Economic Section~, based on experience in operating boilers
at the Uglegorskaya GRES) was brought about by the fact that because of
the air conduit's insufficient cross-section, a portion of the air nece-
ssary for transporting the dust when the mill was not in operation had to ,
- be forced through it, and this increases the danger of igniting the dust ;
in the drum and excludes the possibility of carrying out repa,ir opez~a.tions.
38
FOR OFFICIAL USE ONLY ~
i
i
~
,
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Changing the air-conduit circuit feading hoi: air to tha burners allowed
us to position the dust conduits near the main back burners and the jet
burners ranged directly along the side walls of the furnace. In compari-
son with the initial grouping, this solution has the following advantagess
the length of the dust conduits is reduced (by 13--15 m)~ and~ inasmuch as -
- this section determines the fan pressure necessaxy to transport the dust,
there is a reduction in the expenditure of electric power for the station's
own needs;
repair operations are simplified both for the dust conduits and for the
boiler unit as a whole;
there is a decrease in the outlay of inetal for manufacturing the dust con-
duits and their supporting structural components. ~
The smoke-gas recirculation loop has undergone substantial changes. The new
air-conduit circuit for hot air has allowed the shifting of the cyclones
down below and a considerable lessening of the recirculation loop's aerody-
namic resistance thanks to a reduct3on in the number of bends and in the
extent of the gas conduits. The sorting of the gases is accomplished di-
rectly from the bunkers (previously they had been sorted from the gas con-
duit outside of the boiler unit), which~ in addition to improving the re-
circulation loop's aerodynamics~ also guarantees that the boiler unit's
xall guard structures will have a simplified design. However, in connection
with the fact that the general planner in the adjusted working drawings has
not fully realized the advantages of the new grouping, the cyclones have
been installed not at the servic~ grade level~ but at a~oint 6 m higher.
- ~esides the basic dust-gas-air conduits listed above, auxiliary loops have
also been improved.
The basic data testifying t~ the advantages of the new boiler grouping of
the Zuyevskaya GR~S-2, as compared to the initial grouping, axe cited in
the table shown below.
_ r.quipanent Weight~ Aerodynamic Reduction
in tons Resistance of Design
of Loop, in MPa Drive Capa-
- city, in kW
~ir conduits 305i228 0.0038/0.0036 71
Gas conduits from the boiler 262~218 0.0018~0.0017 32
to the electrostatic precipi- .
tators
Recircu~ating smoke-gas � 104~78 0.0035~0.0029 112
conduits
Iiu~t conduits to burners 115/90 0.0038~0.0029 105
Exhaust loop from the tap holes 14~8
rletal structures in the RV P 215/133
area
- 39
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Table (Continued)
Totals . . , 101j/75S ~
Npte: The numexatar shows the indicators of the initial grouping,
_ while the d~-:ominator shows the indicators of the new groupin~. ;
According to the data of ,organizations which have conducted thermal-ansta.l-
lation and thern?al-insulation operations during the construction of these '
same kinds of electric-power units at the Uglegorskaya and Zaporozhskaya
G:~ES's and who will carry them out at the Zuyevskaya GRES-2, the reductior
in the work volumes and the increase in the grouping's techr.ology will al-~
low them to lower labor outlays for the installation o~ each boiler by a..- '
most 2,500 man-days, to curtail the installation time periods and raise
the safety level of operations.
'h~e should also anticipate a substantial reduction in labor outlays and in
the time periods needed to carry out repa.ir work with regard to both the ~
dust-gas-air conduits and the boiler unit as a whole, improvement in ac-
cess to the places where the operations are carried out, and a, reduction
in the clogging of the boiler section and the RVP zone with dust-gas-air .
conduits.
Optimiza-tion of the boiler grouping will allow us to improve the conditions
- of its use. Thanks to the change in the dust-gas-air conduit circuit and
the dimensions of the safety-enclosure surfaces~ heat releases will be re-
duced in the boiler section, especially at the operational level~ and wori~-
ing conditions for the operating personnel will be improved. I~r~hermore,
as a result of the reduction of the insulated surfaces of the boiler's dust- ;
gas-air conduits the amount of thezmal insulation operations will be cur-
tailed by 410 cu. m. For each operating power unit the yearly savings in
electric power for the station's own needs will comprise about two m3.llion
k'~!-hrs.
It should be noted that in developin~ the new grouping for the boilers of ;
the Zuyevskaya GR~.~-2 it was impossible to fully utilize all the possibili- ~
ties for its optimization~ inasmuch as the general planner had already com- ~
pleted the basic araount of the plan documents~ and the individua.l structu- ,
ral components were still in the manufacturing stage. However~ even under
these conditions successful technical solutions were found which conditioned
the efficiency of introducir.g the new boiler grouping.
~ Tmproving the grouping of the TPP-312A boiler once again confirms the fea-
sibility and efficiency of the joint work of the planning, operational, and
specialized organizations, along with the plants manufacturing the equip-
ment~ taking part in the planning and the building of an electric power ~
station. Sucn a method of operation ought to become mandatory at the pre-
sent time~ rrhen questions of red.ucin~ the time periods required for con-
struction, insuring savings in capital and labor expenditures, deficit .
40
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~
~ '
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materials~ and electric power, as well as improving the conditions of uti-
lizing electrical engineering facilities~ are particularly urgent.
COPYRIGHT: Izdatel'stvo Energiya~ "EY~ergeticheskoye stroitel'stvo"~ 1980 =
2384
CSO: 1822
' 41
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ELE;CTRIC POWER
uDC 62i.315.i7:621.315.i.oo~.z
- CUTTIiJG L?~OR COSTS IN OVERHEr1D ELECTRIC-POWER T:~Ai1SMISSION LINE CONSTRUCTION
t9oscow i;;VERG~TICHESKOYE STROITEL'STVO in Russi:n No 10, Oct 80 pp 41-48
~~Article by En~ineers Yu. V. Bushuyev~ V. A. Druzhkov, G. N. Elenbogen:
"~everal Ways to ~ut Labor r~xpenditures in Constructing Overhead 1150-kV
Electric-FoH~er Transmission Lines'J
~Text~ The need to transmit the laxge capacities of the Ekibastuz and
Kansk-Achinsk energy complexes and the Surgutskaya GRES to the country's
industrial regions has required the creation of electric-pawer transmission
lines with new voltage classes~ i.n particulax~ 1150-kV overhead lines.
During the lith Five-Year-Plan the volume oP construction and installation
operations in building the 1150-kV overhead lines should comprise 15~,
earthmoving operations 10~~ installation of precast reinforced concrete
15~~ steel structural components 20~, conductors (wires) and cables 20;6
of the yearly amounts of the respective types of operations in building
35-kv overhead lines and higher.
In order to carry out this program within the established time periods, an
approach is necessary which is new in principle~. based on a progressive
organization of production, rationalization of planning and technical solu-
tions, as well as a widespread use of the achievements of Soviet and
foreign science and technology. Such a complex problem must be solved by
the jaint efforts of organizations and enterprises taking part in building
the 1150-kV overhead lines. Nioreover, it is necessary to insure coordination
and the centralized administration of the entire complex of operations with
regard to creating such unique facilities of Soviet electric-power ~ngineer-
ing.
In connection with this. the Orgenergostroy Institute has developed a com-
prehensive technological targetted program entitled "Organizing the Con-
struction of 1150-kV Electric-Power Tran;~aission Lines," in the implementa-
tion of which the following a.re taking parts the Kuybyshev (the leading
develope-r)~ Leningrad and Novosibirsk branches of the institute,
Glavvostokelektroset'stroy, enterprises of Glavenergostroymekhanizatsiya,
42
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The ~oyuzelektroset'izolyatsiya VPO (All-Union Production Association), the
Energostroytrud Center, the VNIIPANKh GA [expansion unknown], the SibNIIE (Si-
berian Scientific Research Institute for Electrical Engineering) and others.
Positive expPrience has also been accumulated in cooperation with the general
planner of the first 1150-kV electric-power transmission lines--the Long- .
Distance Transmission Division of the Energoset'proyekt Institute. In parti-
- cular~ taking into consideration the technical schemes which have been worked
out for the footings and poles, a check-up has been carried out on the latter -
for the additional stresses which arise during the insta,llation af poles,
conductor and cable; an engineering plan has been workFd out for the Eki-
bastuz--kokcheta.v 1150-kV electric~Wer transmission line and others.
- ~lnalysis of the technology of the plan solutions. ~in boldfaceJ The prin-
cipal difference between the projected structural components for the first
1150-kV overhead lines and the analogous structural components of 500-kV
and 750-kV overhead lines is the considerable increase in weight and size.
As footings for the poles of the 1150-kV averhead lines the following pre-
cast reinforced-concrete elements have been proposed: sub-footings and a.nchor
slabs~ analogous to the mass-produced, standardized structural components
of overhead-line footings. However, the dimensions xhich have been adopted
for the sub-footings have led to a situation xb~ereby the amount of earth
_ handled by the excavators has sharply increased. Thus, the volume of ttaP
pit under the footing of an anchor-corner hole in certain soil categories
amounts to 7000 cu. m. The weight of individual footing elements exceeds
the hoisting capacity of the cra.nes now existing in the electric-network
organizations.
The anchor-corner poles of the 1150-kV overhead lines axe analogous to the
_ triple-support free-standing poles of the 500-kV and 750-kV overhead lines.
However~ increasing the base of the pole supports, paxticularly in con~unc-
tion with block-supports 5 and 7 meters in height, has complicated their
assembly. There has been a considerable increase in the volumes of opera-
tions with regard to.~ssembling pole units at heights of more than 10 m.
Intezm ediate poles of 1150-kV overhead lines on braces resting on a single
point. Cin boldfaceJ Trro types of such poles have been developed,s POT
(Triangular Intermediate Pole) and POG (Horizontal Intern?ediate Pole)(Fig. 1), _
which differ in the arrangement of the condu~tors (for the POT--triangular~
and for the POG--horizontal).
Increasing the sizes and weight of the intern?ediate poles, taking into con-
sideration their geometrical shape~ has brought about a raising in the center
of gravity to a height of as much as 31 m(Table 1). -
The designs of all the 1150-kV overhead-line poles are of the bolt type, made
of low-alloy steel and St3-type steel~ zinc-plated. ~
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Comparative indicators for the 11,50-kV overhead-line poles and analogous
structural elements of the 500-kV and ?50-kY overhead lines are cited in
Table 2.
? r.
~
\ i ~ ~ .
~ ~ ~
- ' ' ~ , - ~ � ~-t, _;1~
~ 1. . t
1:__ _ .
- -
i / ` r , .
~ \\\1 ~ Z
' _ ~ ' _ j~ -'t-_~I
a 6~
Figure 1. Intennediate 1150-kV Overhead-Line Poles
(a) POT type (b) POG type
Table 1
I)imensions of Pole (Fig. 1), Weight of Position of
Type of in mm Pole, in t Center of
Gravity H, m
pole h 11 ~ hl 12 13
PUT-- ~?~0~000 20,200 13~000 12~250 21~000 18.3 30.8
_ PoT i-i 40,000 20,20o i3,ooo i2~z5o 27,200 11.9 31
roT-i5 40,000 24,200 6,000 17,500 19,500 19.9 3o.z
Foc-2o 37,000 23,000 6~000 17~500 17~,50o i7.8 28.1
~oc 1150
-1 40~000 24,200 6,000 17,50~ 19,500 21.2 30.8
Table 2
Voltage, Type of Pole Weight of No. of Bolts Estimated ~
;
in kV Pole, in t per pole labor con-
sumption per
installed Irni ~
of line, in ~ '
500 F~-1 6.6 1480 100
u2+5 z1.4 3070 -
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Table x (Continued) -
~
750 Nabla 12 2100 140
us75o-1+5 4z.i ~loo _
i15o Poc-15 19.9 3zoo
- ui~5o+5 51 4900 260
The design of the Ekibastuz--Kokchetav phase of the 1150-kV overhea.d line
has been accepted as a bundle of eight AS (Automatic Synchronization) 330~
43 conductors; two AS 70~72 conductors each are used as lightning-protective
cables. Thus, each pole has 28 conductors and cables suspended from it.
The tension strands axe quadruple-circuit~ supporting--single-circuit and
V-shaped--from PS-300 and FS-400 insulators. The length of an intezmediate-
pole strand is 11 m.
With the existing technology for building 35--750-kV overhead lines~ 48.5
percent of all types of operations IlJ axe carried out manually~ while 51.5
percent are accomplished by mechanical means. With regaxd to each type of
operation~ the proportion of outlays ~or manual labor is characterized by
the following indicators: assembly of steel poles 73.1 percent~ installation
of conductors and cables 67.3 percent~ construction of footings under steel
poles 42.1 percent~ and setting up steel poles 24.3 percent. Herein only
at the tKO most labor-consuming types of operations (the assetnbly of steel
poles and the installation of conductors and cables) does the amount of ma-
nual operations comprise 60 percent of the total outlays of manual labor.
Analysis of the design solutions adopted at the present time for 1150-kV
overhead lines, taking the traditional technology into consideration~ indi- _
cates that the level of manual labor in building these electric-power tra.ns-
mission lines will be higher than the indicators cited for the 35--750-kV
overhead lines by an average of 15 percent. The distribution of labor out-
lays bv types of operations for 500-, 750- and 1150-kV overhead lines are
cited ~n Table 3(actual labor outlays are given for the 500- and ?50-kV
- overhead lines~ while estimated labor outlays are given for the 1150-kV
overhead lines). -
In comparison with the 500-kV overhead lines, the estimated labor outlays
per km of the 1150-kV overhead lines show an increase in earthmoving opera-
tions by a factor of 1.6; installing footings--1.6, assembling poles--2.6;
setting up poles--1.9; installing conductors and cables--2.8; loa,ding and
unloading and other operations--1.8. Total labor outlays show an increase
by a factor of 2.2.
The solution to the problem of reducing labor outlays, and particulaxly
those of manual labor, in building 1150-kV overhead lines lies in ratio-
nalizing traditional technology as well as in working out designs which are
new in principle~ along Nith mechanized means and technical processes. -
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Table 3
Jistribution of Labor Outlays by ~rpes of Operations~
in ~
o age o~arthinoving nstalling ssembl- Setting nstalling Loading,
U.H. Line~ Footir?~s ing Poles Up Pole onductors Unloading,
in kV d Cables etc.
50o ii.8 7.6 23.6 12.2 21.1 z3.7
75Q 8.8 6 3o.i so.8 z1.8 2z.5
li5o 8.5 5�5 32 I 10.2 25.5 18�3 -
Based on the results of an analysis of the projected structural componer.~~s
of the 1150-kV overhea.d lines, as w ell as of the construction technology
now existing in the electric network a~ong with the status of the means
of inechanization and transportation, the Orgenergostroy Institute has out-
lined the following basic principles for planning the organization of con- ~
struction production:
increasing the technology of the structural components;
building facilities by means of technical flow lines, based on the spe iali-
zation of the production units of trusts (sections, mechanized columns~~ for
the basic types of construction and installation operations; ~
comprehensive mechanization of operations, based on the use of efficient
means of inechanization and transpor-tation;
transferring labor-consuming processes and those which depend on weather and
climatic conditions to stationary~ highly mechanized axeas~ assembly and pre-
paratory sections;
mastering technological processes which are new in principle.
Organization of construction. ~in boldfaceJ Building 1150-kV .overhead : ;
lines is characterized by the followin traits: considerable volumes of
operations~ great length of the lines ~routes), a minimum amount of type ,
~ sizes of the structural components to be used, and a litnited number of
plant-suppliers. These characteristics predetennine the necessity and fea-
sibility of organizing construction by the flow (assembly-line) method.
In the authors' opinion~ in working out an organizational structure for
- assembly-line-type construction~ it is necessa_7y to guarantee a functional
division of the production units. Mor.eover~ top priority must be given to
solving the problem of filling out complete production-technology sets for -
the canstruction of 1150-kV overhea.d lines. With this goal in mind~ the _
construction and installation trust must include the crea.tion of an Adminis-
tration for Equipment Outfitting (UPTK), which
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wi~l insure that oxrlers are received on time to obtain the material and
technical resources for technically complete sets; the organization of a
base warehouse system; the preliminary preparation of structural compo-
nents (enlarged assembly of steel intexmediate pole aections~ making stays~
braces, and rigging~ enlarged asaembly of insulator atrands, ~Artin~ ~~pa
w1t~h ~~~~n~1~~~at~)E'~ aral lit;r~t,~liri~4prcitecLlve ~~t~lee~ carrying out the cutting -
of U-shaped bolts, waterproofing footings); as well as conducting loading
and unloading and transport operations.
The efficiency of assembly-line-type construction is detennined by the le-
vel of technical specialization~ consolidation and functional duration of
the assembly lines. Three variants are possible in organizing asse~nbly
lines (flow lines): I--specialized brigades (xithin a construction super-
visor's section); II--specialized sections (within a mechanized column);
III--specialized mechanized columns (within a construction-and-installation
trust). A comparison of these variarits shows that the efficiency of as-
sembly lines increases as they become consolidated. Thus~ the reduction in
the nwnber o� workers when utilizing variant III amounts to 7 percent in
compaxison with vaxiant II and 11 percent in compa,rison with variant I.
The Institute has xorked out a structural scheme for organizing assembly-
line construction of 1150-kV overhead lines for a construction-and-insta,l-
_ lation trust with an annual volume of SMR (construction and ins~tallation
operations) of about 40 million rubles (Fig. 2).
CmpoumeneMO- '
raoHma~cNe~u
mpecm ,
~z) C3 ~hl � b3 ~7~
npaBneNU,e neTKOl10MHQ SKO/10NNa 1 n~ZKOJfOHHQ /10 Mea�ononHano esKOnoNNa.
OMl1/I[K/77Q~ !70 170l~20/l70B1L~ IIO LnC!!IL' Q60!lidM HIfJlE- MOHlf7QJIL(J n0 MOHl172JIf(~
L(LLIL 4 lrleAbNb/M �i16H6IM 17P060dOB tt 1
_ paNCno mn pa6amar~ a6omant 8ozo �~cKna onop mpoco8
~ U! ; ~ (11) -
ba aoBeie
~K~ ~ ae, o tl Y o o ~ o~'~;,~ , -
E,�o,o Eoy Eo~a'o
tlay d~E d~4 E
yv~ -~cK c M i, ~ Y aE ~ ~
Konniermsuuu
3 (I~F)
Ro: _rnei yQ~mon nazpy-
3ovHO-pa3tpy3o4-
y~Py~,, ,~mrno- Me~z u mp�HC-
~~nu :6cpKU opmNa~s a6om
cnaa
Figure 2. Structural Scheme for Organizing Assembly-L1ne Construction
of 1150-kV Overhea.d Lines
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Key: ; -
1. Construction-and-instal- 8. Base warehouses
a lation trust 9. Section for
_ 2. Administration for f ill- shifting base
ing out sets and trans- 10. Section for prepasing ;
portation route (righ~-of-way) !
3. Mechanized caliunn for pre- 11. Section for reconstruction
paxatory operations and rearrangement �
riechanized colimin for spe- 12. Section for filling out sets
cial operations 13. Construction aseas for
5. i~iechanized column for consolidated assembly of
zero-cycle operations poles
6. riechanized column for 14. Section for loading and _
installing poles unloa~.in,g and transport
7. Mechanized column for operations
installing conductors
and cables '
Introduction of the scheme presented here will a11ow the following: to
free up the basic production units from carrying out auxiliary, transpor- i
tation, and other subordinate operations;
to carry out consolida.ted assembly of p~les, waterproofing of footings, con-
solidated assembly of insulator strands~ cutting U-shaped and anchor bolts,
repairing structural components, etc. not on the route but under the sta-
tionary conditions of a specialized construction yard, section~ or area;
insuring centralized repair and technical servicing of the machinery; to
- put an efficient dispatching communications system into good order; to
- guarantee an increase in labor productivity and rapid rates of construc- '
tion; to raise the coefficient of utilizing machinery and to insure the
comprehensive mechanization of the principa.l types of construction and
installation operations.
Cyclograms have been worked out for the construction of 1150-kV ovez~head !
lines~ as well as traffic schedules for the specialized. mechanized columns i
within the construction-and-installation tr~~.st (Fig. 3).
In working out the cyclogram~ the following factors were taken into consi-
deration: the opti~num composition of the brigades, selected on the basi.s I_
of the technical schemes of operations; the monthly output of the brigades~ ,
determined on the basis of the physical labor productivity with regard to
tlle individual types of operations; the number of brigades insuring an even ~
~ and precise rhythm of assembly-lirie construction; technical placements by
types of operations; distribution of capital investments by years, proceed-
ing from the conditions of the maximum (even} load of the specialized me-
chanized colwnns for the construction period. ;
Cyclograms and schedules have been made for an amount of operations in ;
building 1150-kV overhead lines for a length of ,500 Ian. Noreover, the i
~
48 , _
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500 , , , ~ ~ -
~
KN ~ ~ ~ I ~ ~ (
~
_ ~ ~
~ ~ , ~ ' ' _"r'~' '
iI I~ ~ ~ ~ ; ~ ;
I ~ ~
I
~ ~
3 75 ~ ~ -
i ~ � . -
~ ~~T (
~ . . . '
~ ~ - - - ~
250 r, ~ ~ i I I
~
; ~ ' ' ~ ~ ~ --~---T.. ~ I
~ ~ ~ ~ ~
- ; . ~ ~ : - - ~
>ZS i i~--~~ ~ ; +(1~ MoHma.~c npo0odo u mpoca(2dp~czade~now?veq
~
~ I ~ ~ ~~C6vpKa u~ ycmayoBKa'onop(i6pazada~no~2ve~j
~ ~f � PaGomsr~y ne8 z~ uxnc. ~ 1
'~~,i't'~ i j I ~~Q~__s~IL2� bI~OZ~A~ I
lTodz mo8 me~anbie a.6 ,nb~ ~
ven
II ~III ZY 1 II Ill 1P I II KBapmaa II I17 � IY I II III 8 I II x zopa
1980 1981 1982 2oa� 19~80 i 1981 TMQKC ` ~9BZ
1040 ~ ~tP
~ Tc.n tcB~
_ CpedNee Kon-Bo pa6ovrc,z 93oven_ 67Z ~ Tcr
704 - -
36B ..x;~~ 3,~6 .
_ 2~8 ' ,
� 11 IZf IY 1 11 Ill !Y I II KBapman, ~
19B0 '98l ~ 19BZ Zod
Figure 3. Cyclogram of the Construction (a) and Traffic
Schedule of Specialized Mechanized Columns (b) ~
and T~Ianpower (c ) Used on 1150-kV Overhead Lines
Key:
1. Installation of conductor and cables (2 brigades of 42 men each)
2. Assemb~.y and set-up of poles (2 brigades of 42 men each)
3. Zero-cycle operations (2 brigades of 20 men each) -
li. Preparatory operations (52 men)
5. Average nwnber of workers (950 men)
_ _ _ _ _ _ Preparatory operations; _ _ . _ Zero-cycle operations _
Assembly and set-up of Installation of conductors -
poles; a.nd cables;
t Time for developin~ specialized
p assembly lines; ~~Time for curtailing specialized
assembly lines;
f Time of maximum operational 1
~stress; T~~y Time of praducing finished work
_ f~~~ Length of time required for construction ~
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capital investments are distributed in the follorring manner: during the
first year of canstruction, 11.4 million rubles; during the second year,
31.9 million rubles, and for the third yeax (first tr;o quarters), 12.7
million rubles. The length encompassed by an overnead section with the
volume of work appropriate for the year's program of a specialized me- '
chanized column is accepted as equal to 125 km. ~
Calculations have shoNn that in using specialized mechar.ized columns to
build overhead lines productivity in the individual types of operai:ions
increases by 16--20 percent. Aioreover, the neczssary reduction is ,
achieved in t5e number of workers as well as the number of machines
(Table 4).
Table 4
Indicator Traditional Organi- Assembly-Line Savings
zational Structure Method of Opera-
tional Organi-
zation '
i
Labor outlays~ in ~
thou, man-days 663.7 557�9 105�8 -
~ivera.ge number of
workers 1171 954 z21 ~
iYumber of constr.zctio
machines 24~4 211 33
Yroposals for raising the technical level of structural components and for
improving the technology of 1150-kV overhead-line construction. `in bold-
face,J The use of technical structural components which meet the require-
ments of the optimal processes for their manufacture~ transportation
schemes and installation methods comprises one of the ways to reduce labor
outlays. As was noted., the utilization of the accepted components for the ;
1150-kV overhead lines does not solve the problem of reducing labor outlays,
and especially those of manual labor. It should also be noted that these
structural components do not satisfy ~:he requirements for saving outlays on
building materials nor for those on transportation expend'.tures. The de-
ficiencies noted pertain primaxily to precast reinforced concre~te footings.
In the authors' opinion, subsequent plans for the footings of 1150-kV over- ,
he~.d-line poles to be installed in rocky soils should make use of the spe-
cial embedments in the form a cluster of thin cement anchor-piles which
have been developed by the Energoset'proyekt Institute. Such footings can _
be made by a mechanical method, utilizing mortar-mixing units with forced
feeding of the mortar(grouLing~ into the holes. When an overhead line pas-
ses over relatively ~:eak and uater-saturated soils~ we should examine the
possibility of installing footings made of reinforced-concrete piles.
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In soils with improved mechanical chaxacteristics it is feasible to install
V-shaped footings. The use of V-shaped footings and mechanical methods of
operation ia installing them allows us to avoid excavating the soil and
compacting the backfill on individual sections of the overhead line.
In building 1150-kV overhead lines there are also prospects for utilizing
scre~r-oile footings, paxticularly in xater-saturated soils. Experience in
utilizing screw-piles rrith reinforced-concrete shafts on the individual -
F,icket-points of the ?50-kV Konakovskaya Gc'~,'S--Moscow overhead 1 ine has '
shown that their construction requires 80ib less reinforced concrete and
- 4
~ less steel than in building precast reinforced-concrete sub-f~oti.ngs,
Herein the labor outlays are reduced by 75f~ while the cost of o perations
is reduced by 40y~. t~~oreover, the utilization of these footings allows
us to practically avoid earthmoving operations, as well as operations with
regard to installing pole groundings ~2f . In order to introduce screw
piles on a widespread basis~ it is necessary to develop a special vehicle
for sinking thern (ba,sed on a self-powered machine). Such a vehicle must
have a high roadability~ a rather low propor~tionate load on the soil (the
presently existing machines~ based on the KrAz-type trailer-truck, do not _
meet the above-mentioned requirements~, and at the same time sufficient
speed to avoid the necessity of using trailers to haul it.
abandoning the embedded precast reinforced-concrete footings, which have
been accepted for all soil conditions~ and the adoption of a differentiated
approach to using new structural components will make it possible~ in com- -
bination with a mechanized technology~ to reduce total labor outlays on
a zero cycle by an average of 25--3a`I�
~
' Technical practice has shown that in creating new structura~ c omponents
- for the 1150-kV overhead line ~ it is necessary to take the following con-
ditions into consideration: the technical and economic basis of the struc - _
tural components for which ne~r mechanized means need to be developed;
the possibility for a consolidated assembly of bolt-type structural com-
ponents of poles at construction yards or ~,lants;
the maximum and comprenensive utilization of helicopter equipm ent~ primasily
where the route passes through difficult conditions (high mountains or
swamps;;
the use of new and progressive materials~ designs and complexes;
the use in the structural components of technical assemblies (permanent
hinge joints ~ ri ging-reinforcement assemblies, suspension lines for lami- -
nated units~ etc~.
- Carrying out the conditions enumerated above is only possit,le with joini -
opera.tions by the planners and engineers, and this should be begun in the
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early stages of planning a 1150-kV overhead line (for example, .~c the sta.ge
of technical and economi.c groundwork).
It should be particularly emphaslzed that such a jni.nt operation must cer- _
tainly be carried out For planning overhead lines whose routes pass through _
difficult conditions. ~
I~iechanization of operations.~in boldface1 The Orgenergostroy Institute is
devoting particular attent:Lon to the problems of rai~ing ~he level of inecha-
nization of construction and installation operations on 1150-kV overhead
lines. The motor pool and supply of machinery now existing in electric-
net4rork organizations does riot guarantee an increase in tYae efficiency of
carrying out operations to install planned struct~.iral ec~^ponents whose wei,ni
and dimensi.ons are cons~derable. Thus, in order to install footings, we
must use K-162 and MKP-25 cranes instead of t!z` most widespread. TIC-53 an,. _
T-7S cranes. The ta.sk of setting up intermediate poles cannot be efficient-
- ly solved without utilizing special cranes Hith a lax~e hoisting capacity.
Up-to-date methods of installing conductors also require renavation of the
machinery products list. 'This will allow us to introduce the following
more progressive methods: laminating conductors under tension and a conti-
nuous technical cable, stringing conductors and lightning-protective cables '
rrithout letting them sag to the ground~ combining conductors by using break
energy, etc.
The transportation of' siructural components is a complex task. It should ~
be no ~ed. that a specialization of transport means is necessary for hauling
reinforE:ed-conerete sub-footings~ consolidated sections of intermediate _
steel poles and drums with conductor and cable. Hauling the remaining
items (reinForced-concrete flat structural elements~ metal in cases~ strands
~ of insulators~ and circuit azmatures) is furnished by the existing trans-
port means listed in the electric-network trusts (panel trucks with high _
- roadability~ log~in~ trucks and other trucks used in building 500--750-kV _
overhead. lines). The ~olutions adopted by the institute with regard. to _
mechanizing operations for the construction of 1150-kV overhead lines pro-
vide both for the hidespread utilization of vehicles and machines in regular
production Uy Soviet industry and which are being used in other ministries
and departments, and the creation of new special means of inechanization i
and transportation (for example~ the KVL-iZA installation crane with a
hoisting capacity of 12 t, the TKB-3 crane for assembling bolt-type poles,
a set of vehicles for erecting conductors under tension, etc).
The use of these recommended means of inechanization instead of the tracii-
tional ones, in conjunction with improved techr.~ques in conducting opera-
tions~ will allow us to reduce the total labor outlays in building 1150-kV ;
- overhead lines by 30;0.
Assembly of poles. ~in boldfaceJ In the assembly of steel bolt-type inter-
mediate poles on braces (stays)~ supplizd to the route in individual
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ti: .
elements, the principal thrust in reducing labor outlays and the level of
manual labor is the widespread utilization of inechanized construction yards
along the route for preparatory consolidation of the pole sections. ,
The Kuybyshev branch of the institute has developed a standard mecha.nized
construction yard for the consolidated assembly of bolt-type steel~pole
sections~ using electro-telphers with a hoisting capacity of one ton (Fig. 4)
o~ gantry cranes with a hoisting capacity of five tons.
A distinguishing chaxacteristic of this construction yard with an electro-
telpher is the possibility of increasing its productivity~ since it is
. composed of single-type technical sections.
When climatic conditions are unfavorable on an overhead-line route, such a
construction yard can be enclosed, utilizing steel or reinforced-concrete
sections of buildings which can be rapidly erected. In its enclosed. vasiant
this construction yard comprises a two-span building made of folding-type, ~
sections created by the Energotekhprom enterprise.
The introduction of such an enclosed standar3 construction yard for the _
preparatory assembly of poles will allow us to make more rational use of
hoisting apparatus~ as k�ell as to brin the organization of work si-tes as
close as possible to plant conditions ~to red.uce th~ influence of weather
conditions~ to irnprove li~hting~ tool storage~ an~ to utilize additional
means of inechanization, as well as to organize work tw< ~r three shifts).
;
The prepaxatory consolidation of sections at the constructi~n yaxd and ~
completing the pole assembly at the stake-point, as compaared to assembling
the poles from the individual e~ements at the stake-point~ allor+s us to
guarantee a growth of labor productivity in the assembly process by 30~. -
In overhead-line construction as a whole~ taking into consideration the
other types of operations, labor productivity increases by 10go while the
level of manual labor is reduced fmm 73~b to
~ more significant reduction in labor out]~.ys and the level of manual labor
may be attained by organizing the plant manufacture of intermediate steel
poles on braces and supplying them in sections. Caxrying out such a measure
will also allow us to find an easier solution to the problem o~' the overall
supply of st?~uctural components to the route and~ furthermore, to cut down
' on the metal losses in building 1150-kV overhead lines.
Thexe are several progressive variants of plant manufacture and supply of
steel intexmediate poles: welded large sections; large sections~ assembled
at the plant from welded or bolted flat sections; and flat sections (welded -
or bolted.).
~'~s the results of studies have shown l3J~ the consolidated assembly of poles
on the overhead-line route, made of large sections manufactured at the plant,
in comF,axison with the preparatory consolidation of sections at mechanized
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- i_ ' _
~ - ~
i
2 y
3 , ~
_ _ ,
- . 1 / j
. - ,
, ,
- ~
;
,
~
, -
y ~ _ ~ - ~
' r~.~ ,
. ~
./5
~'igure 4. Construction Yard for Consolidated ~ssembly of
Poles for 1150-kV Overhead Lines '
,
Key:
1. Telpher with a hoisting 4. Tilter
~ capacity of one ton 5. Rack (stand) i
2. Conductor (jig) ~
- 3. Roller conveyor (table) ;
~
construction yards and final assembly on the route, allows labor producti- ~
vity to be increased in th:: process of trole assembly by 270 percent, and
with regard to overhead lines as a whole (ta.king other types of operations !
into considerationj by at least 23 percent. j
i
A less efficient measure is to organize the manufacture of the individua,l ~
flat sections (bolted or welded) at the plants. In this case~ according
to a preliminary estimate~ labor productivity for overhead lines as a '
whole increases by 15 percent.
- ~
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The results of computing the savings in labor out].ays per Ifln of 500--1150-
kV overhead line under normal construction conditions~ when the assembly
of inteYmediate pole sections with the braces occurs at a constructian yard
and when they are manufactured at a plant~ are cited in Table 5. 'rfhen the
overhead line passes through a forested or swampy locale~ the savings in ~
- labor outlays increase to 10 percent and 1~ percent respectively.
Table 5
~stimated Savings in Labor Outlays per Ian of Overhead
Line ~ in Man-Days
Voltage of Using i~;echanized M~,nnufactured at a Plant
Overhea.d Line~ Construction Yard Laxge Sectians Flat Sections
in kV for Assembling
Sections from In-
dividual ~lements
5co 20 60 30
_ 750 30 85 4~
li5o 5o i2o 60
Depending on the conditions through which the overhead-line route passes,
the assembly of the anchor-corners of free-standing poles is caxried. out
in accordance ~rith one of three technical schemes.
In mountainous and srrampy regions the pole base stands. support props and
supplementary stands are assembled at a consolidated-assembly site (first
scheme). Herein the stand sections the geometrical dimensions of whose
bases are greater than their height ase mounted in a vertical position from
the standard kork areas. In order to strengthen the zones of the intezme- _
diate sections and the support props in the vertical position, standard
stamped conductors (jigs) are employed. The area is serviced by TK-53 and
T-75 cranes~ a lever-~ype derrick~ a compressor with a set of pneumatic nut
drills, and a mobile light tower. I~;I-6 or MI-lOK helicopters may be uti-
lized to deliver the pole sections to the picket-sta.kes and to install them.
Under plain-type conditions~ where cranes may be used having greater ho'st-
ing capacity (!~F-25~ ~-z55 ~d MKT-6-4~j~ poles are mounted by the method
of augm enting the consolidated sections (second scheme).
The technology of carrying out operations in accordance with the third ~
- scheme is traditional. In this case the pole stands are assembled entirely
on the ground and axe lifted into a vertical position by means of a hinge-
joint rrith the aid of an installation boom or crane with traction from a
tractor or a truck.
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~etting up poles. ~in boldiace~ In examining a number of sche~nes for set-
ting up intern?ediate poles, including those previously utilized by the elec-
tric-r.ettirork trusts for the 750-kV Konakovskaya GRFS--Leningrad Overhead
T.ine and the development of ne~~ scnemes using a falling installation boom~
tho c~nclucion w~:, clrZrtr~ th~t 1;r,d schontes to lift poles by the ~lew].ng me-
thod is not ratior~l for the ~'OG and FOT type poles~ even if certain im-
provements ~ ere to be :nade in them. Utilization of these schemes does not
allow a reduction in the labor outlays, and especially not in the outlays
- of manual labor, since it requires a considera.ble amount of supplementary
operations to be carried out. F~zrthennore. in this case the process of
controlling the pole liftin~ becomes moxe complicated~ and hence its reli-
ability is decreased.
In order to set up intermediate poles of 11~O~kV overhead lines~ it is .aa-
_ sible to utilize the method of lifting the poles "in suspension" tirith the
aid of t~~o trailer-tyge hoists havin~ a hoisting capacity of 12 tons each
and a hoisting height of 32 meters, being developed by the Kuybyshev branch
of the institute. Such hoists may also be used to set up anchor-corner and
free-standing intennediate poles in conjunction with tractor traction.
The Orgenergostroy Institute has also proposed a scheme for hoisting inter-
mediate poles of 1150-kV overhead lines, using two pneumatic-tired cranes
~�rith load-hoisting capacities ~f 40 tons each. and now in serial production
by Soviet industry (Fig. 5).
3
2~ 3
/
- Z , ,
�o ~
0 0
~ - H
- I ~
-1 1 1 1
,
' 1600D 16000 1BOG~ 7B000
a~ 6~
iigure 5. Scheme for Hoisting Intezmediate Poles of 1150-kV Overnead Lines
~T Type (a;~ and DCi Type (b} with the Aid of Zlao ineumatic-
Tireci Cranes with Hoisting Capacities of 4G~ Tons Each
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,
Key :
1. Pneumatic-tired crane= 2. Inatallation crosspiecei
3. Position of center of gravity
Installation of conductors. ~in boldface1 In building 1150-kY overhead
lines the labor outlays for installing 24 conductors~ using the tradition-
al technology~ are estimated to comprise 25.5 percent of the total labor
outlays. Noreover~ in compa,rison with 500-kV overhead lines~ the labor out-
, lays for carrying out this type of operation increases by a factor of 2.8.
Therefore, the Orgenergostroy Institute has developed new technical solu-
tions for installing conduc~tors.
In order to suspend tne conductors, it is proposed to use installation
double-roll units ~ fastened on terniinal boats ~?J. The clamp assembly
which has been developed allows the unit to be easily mounted and dis-
mounted. The advantage of the method under examination is the possibility
of carrying out at the same time as the suspension the lamination of the
conductors within the terminal clamps of the supporting strand. Moreover~
in this case~ in order to restring the conductors, they do not have to be
lowered to the ground. With the introduction of such a method of insta,lla-
tion labor outlays are reduced by 15 percent.
In order to combine conductors, the Kuybyshev branch of the institute~ in
conjunction with the SibNIIE~ has proposed the use of break (explosion)
energy . At the present t~ae positive experience has been gained in
using this method for the simultaneous combination of eight conductors.
Combining conductors by the use of the break-energy method~ in comparison
with the pressizig method allows a considerable reduction in labor outlays
and an increase in labor productivity ~+J.
The Kuybyshev branch has also proposed a method of laminating conductors
with the aid of a continuous technical cable. It insures the simultaneous
- lamination of two-phase conductors~ which is paxticulasly efficient for in-
stallation under difficult~ complex conditions of a route's passage and in
transient situation4.
. The method of installing conductors with a preliminary marking (measuring)
off has good future prospects. In order to introduce this method it is ne- `
cessary to create a number of special attachments and instruments.
In installing conductors by the proposed raethod the following technical
operations are carried out: measuring out conductors in accordance with
tables of installation lengths included in the overhead-line plan; measure-
ments of the actual distances in the spans; office processing of the mea-
surements with adjustments made.in the planned installation lengths of the
conductors in the spans; lamination~ combination~ and reinforcement of the
conductors in the supporting terniinal-clamps of the strands or attachment
to the tension strands, setting up distance tie beam s and hoisting them
onto the poles.
57
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- 58.
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In comparison with the traditional methods, the pr~posed technology al-
lows us to eliminate such operations as suspending the conductors in la- -
minated apparatus~ sighting and restringing conductors with lowering to
~ the ground~ as a result of khich lab~r outlays and manual-labor outlays
are reduced by more than 50 percent, while there is also a considerable '
increa~e in ogerational safety.
It should be noted that the introduction of the latter method will facili-
tate the solution of the problem of installing conductors not only on the -
_ 1150-kV overhead linesbut also on 500-kV, 750-kV, and 1500-kV overhead
lines.
Utilization of helicopters. /in boldface/ The Orgenergostroy Tnstitute
has carried out preliminary work on the technology of building 1150-kV
overhead lines with the aid of h~licopters. Results of cooperation with
the VNIIPANKh GA [expansion unknownJ have already made it possible to put
into operational plans the conduct of transport and a complex of instal-
lation operations with the aid of helicopters.
- . . _ . - - -
An analysis of ~ndicators of the estimated reduction of labor outlays for
the basic types of operation~ involved in building the 1150-kV overhead
lines~ to be carried out using the new technical and design solutions
which have been developed and proposed for introduction~ as compared Frith
the indicators achieved by using the traditional technology and designs,
are cited in Table 6. .
4s the results of calculations have show*;~ the introduction of the design
- and technical solutions proposed by the Orgenergostroy Institu�e will per-
~ mit us to cut doc�~n labor outlays in building 1150-kV overhead lines by an
average of 25 percent.
However, it should be emphasized once more that in order to successfully
implement what has been outlined here,it is necessary that all operations
connected �ith the creation of electric transmissions with the new voltage
` ~lasses be carried out in accordance with a unified and comprehensive tax-
= geted program, where the central place must be assigned to the problems of
developing new designs and technology. I~oreover, the joint development of
the designs and technology for building very high volta,ge transmission
lines must be~in with the initial stages of plannin~ these lines. And~ of
course~ pasticular attention must be paid to the development and serial
production of special means of inechanization~ organization of asssmbly-
line type of construction an~~ precise specialization according to kinds of
oTerations b~ the subdivisions engaged in building electric-network
facilities.
BIBLIOGRAPHY
1. Zil'berman~ I., "On the Problem of Reducing rtanual Labor in Build-
ing ~.lectric-i~o:�rer Transmission Lines~" EivERGETICHESKOYE STROITEL'STVQ,
i~o 9, 1~79, Pp 36-37. ~
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~
~ �S , i-
2. Vishnyakov, V. Tv.; rrenk, V. A.; and Elenbo~en, G. N., troitel stvo ~
linii elektroperedachi 750 kV Konakovskaya GRES" ~Building the 750-kV
Konakovskaya G~S ~lectric-Power Transmissic~n LineJ, bloscow~ Energiya,
1969 ~ 8B pages.
3. Elenbogen~ G. N.~ "On Increasing the Efficiency of Building Very High '
Voltage Overhead Lines~" ENLRGETICHEShOYE STROITEL'5TV0~ 1977~ No 2,
~ pp 11--16.
4. Bolotov~ S. et al.~ "Schematic and Technology of Combining Overhead.- ;
Line Conductors by the Break I~~ethod," EA~ERGE'I'ICHESKOYL STROITEL'STV~,
_ Pto~~F, 19~~ ~ PP 21-23� ~
;
. COPYRIGHT: Izdatel'stvo ~ergiya, "Energeticheskoye stroitel'stvo", 19`.J ~
I
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CSO: 18?2 '
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~LECTRIC ;�O~IER
vnc 621.3ii.26:6zi.o39.001.57
S~RCH ON ~TRUCTUFWZ, COr1PONEi~TS CF A;~i A~S ~ACTOR S~CTION
yioscow ENEt~Gi'TIC}iESKOYE STROITGL' 5TV0 in Russian No 10 ~ Oct 80 '
Pp 53-57
~Article by CandidatE of Technical Sciences G. E. Shablinskiy and
e^.ngineer A. V. Gordeyev: "Dynamic Studies of Structural Components
of an Ai,S Reactor Section'1
~TextJ The structural components of an~S (nuclear power station,) con- -
stitute complex spatial structures which are affected by various types of
. static and dynamic loads, conditioned by the operation of turbine units,
_ gas blofrers, pumps,.etc. Another urgent problem is the dynamic interaction
betrreen the heat caxrier and the heat-protection element, the facin and
the individual structural assemblies of the reactor housing (casing~.
~ A substantial influence on the reinforced-conerete housing of a nueleax re-
actor is exerted by tne dynamic loads khich come into being during the pro-
cess of its preliminary pressurization (tensioning). These loads may de-
termine the preliminary tensioning of cable strength and, as a result, the
- metal consur,iption and economy of the design. _
~ necessay condition for evaluating the safety of an AES is also the protec-
tion a~ainst random (accidental) dynamic load.s, for example, those arising
as a resul~ of a crash by an airplane or ~ther objects.
The development of theoretical and experimental methods for researching the -
dynamic groblems which must be solved in planning an AES is a necessary con-
dition for successfully carrying out the tasks set by the Party in the field
of nuclear pokrer engineering.
Over the course of a number of years work has been done at the NISI (N:oscow
~tructural =~ngineering Institute imeni V. V. Kuybyshev~ on developing ex-
perinental and theoretical methods for researching the pressurized (stressed)
state of an tiLS's structural components ~i~ 2J. The fragment method of cal-
culation is utilized in the theoretical studies. in the equations of the
static and ~eometrical conjugation of the individual fraginents the influence
of local effects is taken into consideration. The design schematic must
- correctly reflect the operation of the actual structural component and its
- behavior characteristics under the assigned laads.
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~
In order to select the design schematics correctly~ to verify the results ~
obtained by using them, and, in a number of instances~ to make an experi-
mental study of the structural component uhose theoretical designs are
linked with great 4~fficulties~ experimental research is necessary.
In the process of developing research methods for studying the pressurized ,
state of ArS structural components, the authors have crea,ted new equipment
which pernmits an increase in the precision of the studies being carried out. '
Lxamined beloti~ are the results of model dynamic tests run oz~ ~^5 structural ,
comgonents, the characteristics of the experimental methodology and of thA
equipment which was developed.
As is known, at model structure scales of 1: 50--1 : 200 the operational- _
frequency range of a vibration stand (platfoiza) necessary to simulate the
spectrum of seismic vibrations must consist oi approximately 40--500 hertz
(cycles per second). The existing electrodynamic-type vibrators meet this
requirement. However~ in dynamic studies the model being tested must be ;
subjected to the effect of vibrations within assigned amplitudes, frequen-
- cies~ and directions. Because of the rise of resonance vibrations within
the ordinary support systems of vibration stands, it is particularly diffi-
cult to fulfill this condition. In order to create a vibration-stand sup-
port which ~rould gua.rantee the required direction of vibrations with the
least possible losses for friction and an elastic resistance with the mini-
mum (no more than 10--12 percent) of lateral shifting, the authors conducted
special studies and groposed the design of a hydrostatic support for the
vibration stand.
The principal difference between the indicated structural component (Fig.
l~a` and the knorrn ones is the presence of a scheme for automatically sta-
bilizing the platfozm along the coordinate axes. The adopted schematic
allows us to execute independent, assigned shifts (displacements) of the
platfozm alon~ each of its axes under minimum resistance rrith the aid of
a system of hydrodynamic suspension~ which comprises an operating chamber ~
1, an inlet valve or jet (nozzle) 3~ and an outlet valve or aperture 4 be- ;
t~~een the support and the platfoxm 2.
The liquid enterine into the operating charlber through the jet and flowing
ou~t through the aperture is under a set pressure P~ which depends on the
size of the aperture (the laxgerthe aperture~ the less is the pressure and
vice versaj. altering the model in the direction of opening the aperture "
rrider leads to a decrease in its width and an increa:,e in pressure. r~ sta- -
bilizing influence is exerted on the system by the throughput section of
the jet being greater and the hidth of the aperture iv' being wider. The pre- '
surre being transmitted to the model by the liquid which is in the operating ;
chamber is equalized by the external pressure of the air F as a result of a ~
vacuum being created under the model in a special chamber. The combination
of pressures F and I' prevents the emergence of conditions which would cause .
;
62 ~
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a change in the dimensions of the aperture, and this causes a stabiliza-
tion of the platfonn's vibrations. Change the section D of the jet allows
us to create forced vibrations of the model in the direction of the aper-
ture in accordance r:ith the booster scheme.
3uch a desi~-n for a hydrostatic support is also used to create vertical vi- -
brations. This is achieved by setting up controllable jets, which regulate
_ the pressure in the cha~ber and, therefore~ the aperture opening N as well.
r ig. I,b shoias the schesnatic of a three-component vibration stand. The ver-
tically oc~urring vibrations of the vibraticn-table-plate 2 axe created by
changing the pressure in chambers 1 with the aid of a controllable jet 3,
the size of whose opening is changed by a needle gate ~valve) 4~ connected
with a small-capacity electrodynamic vibrator 5. In this schematic the in-
ertia-less force F is created with the aid of a vacuwn chamber located be-
t~reen the vibration table and the base of the stand. The vibration table's
horizontal vibrations are provided by an electrodynamic-type heavy-duty vi-
- brator; instead of this, however~ use may be made of analogous supports to
those described~ with controllable jets turned to a 90� angle. The schema-
tic of the vibration stand presented in Fig. l~b allows us~ thanks to the
independence of the pressure controls in each chamber~ to obtain torsional
(relative to the vertical axis; vibrations of the vibration table simulta-
neously with horizontal and vertical vibrations.
ihe laboratory of the resistance of materials department of the r;ISI imeni
V. V. Kuybyshev has made a vibration stand with hydrostatic supports in ac- -
cordance with the working principle described above. This vibration stand
has three pressure chambers~ situated around the periphery~ and one vacuum
chamber in the center of the vibration table. The vibration table consists
of a circular steel plate 600 mm in diameter and 12 mm thick. The pressure
and vacuum chambers are fastened onto a steel disc which is mounted on six.,
steel~ T-section supports, embedded in a massive~ reinforced-concrete base.
The hei ht af the supports guaxantees the possibility of leading pipelines
(tubing~ to the pressure chambers from the oil pump and to the exhaust cham-
ber (vacuum space) f=rom the vacuum pump. The oil which flows out throt.~h
the circular apertures of the pressure cha?r:ber when the stand is in opera- ~
tion at first flows into the oil collector~ and then through a hose into
the oil pump's tank. The vibrations of the vibration table are created by
the V^~5-200 vibrator by means of a special linking clutch.
1'he vibration-stand tests indicated a good stabilization of vibrations with-
in the ire~uency ranoe of 10--400 hertz. Ancillary (lateral, vertical~ vi-
brations in this range (in amplitude1 did not exceed 10 percentof the ba.sic -
horizontal variations. :1t a frequency of approximately 400 hertz resonance
vibrations arose ir. the steel vibration-table-plate, caused ~y the first
current of its flexural (bending) vibrations. It is obvious that, in case
of necessity, this upper limit could be raised substantially further by
increasing the plate's rigidity by means of installing rigid fins (edges).
63
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~
~
- r ~ ;
~ !
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- ~ N ~ i ~
~ _ 4 S ' -
~ , ~ f' ` , I -
. ~ .~;li / : i ~ i
. y ' � _ t~a ;
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Q~ A' 6owyy~Macocy Y~10 ~71fA0 O/!J NGCOCO 6J ~
^igure 1. achematics of a Hydrostatic Support (a) and a
Three-Component Vibration Stand (b)
Its is a well-known fact that the si.milarity theory of solid defonnable bor
dies is ba.sed on the equality of the respective natural-sized and model de-
f~n,lations (~N =~M In order to fulfill this condition in carrying out
studies on the eartt~quake-resistance of structures with small-scale models,
using iow-capacity, high-frequency v'b~ation stands~ the models should be i
ma.c~ie of special materials with a lowered modulus of elasticity (EN : E M= -
- 10 ; 500 ) and an increased average density ('YM : YH,;,1=3 In a number of
instances, particularly when the basic purpose of the research is to study ~
a structure's dynarcic characteristics, the following ma.y be used as model -
materials: acrylic resin (plexiglass), epoxy resin~ and gypsum (plaster of
Parisl. In those cases whera ue need. to study the seismic stress and the i
behavior of a structural component ?t a limiting point~ model materials are
used ~r,zich are more complex in their composition~ including lead dust, shot~
rubber dust and ground limestone j1J. ,
~ vibration stand ~:ith the design described above was used to conduct tests
on a model of the reactor section of an AES building with a VV~;R (water-
moderated water-cooled reactor)-1000 in a scale of 1: 200, made of acrylic
resin (EM = 5200 T~;Pa,yM = 1.2 g per sq. m), as well as a model of the base
(footing) of a K-220-4~--TVV-220-2 turbine unit~ made of gypsum (~M = 2850 '
P;Pa~'YM = 0.86 g per cu. cm}.
The design of the reactor section of the Ar^~S building (Fig. 2a) comprises a
three-di.mensional structure, including a protective shell (shield), a vault
roof~ and the following components situated within it: the reactor shaft, ~
footings, and a system of auxiliary structures (walls, columns, and roofs), -
placed on the base foundation around the shell and around the reactor shaft ;
within it.
- The foundation of tne turbine unit (Fig. 2,b) represents the structural de-
sign of a three-dimensional frame system. ;
In the tests k~hich ~~ere conducted on the design of the reactor section of I
an ~ES building the frequencies and forms of its own vibrations were ~
64 ~
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55.00 ~ �
~ + J3. 70 .
- - - - - -
. 45000
~7.00
~ ~ 2
� ~ 'J DO
� -6_0
U DO ~
~,;.f 00 ~~C~ C~~~
~ -9.40 ~C'~~
~-13.0 /
! . ~ , ~
� a ~ - s - - e- -a j
I ~ ~
o a ~ t i- -0 + ~ e � ~
r a a 4 e ~ ~
~ .
e e e . a '
~ e a e- ~ o~_
0
~ ~ ~ O . a. N i
I~ ~
_ ~ _ -m l $ D- ~
".-o -e- � p I
- -i - .e--f e -e ~
-a s a- o- -+i -a 4 0 0
i ~
- e a o e-r~ Q_ 8~ a e- ~
' i
_ ~
72000 ~ ~ ~
-
Figure 2, a~esign of F?eactor 3ection of an AES Building
with Schematic of Aieasureanent i'oints
65 -
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N b '
01~ O i yt ~
~ ~
1 ~
~
` ~ ol
h;
. `I - - � ---I" ~ i
` +-1-- {�~~L ~ ~
~ OSl Z~- OSl Ol OOl o' I~
T_.
0
~n o ~
^ i h ~ � � ;
r~ u ~I ~ ~ ~ -
~I i,; i ro ~r i
~ ~ ~ ~ _ ~ ,
~ ~ ~ ~ ri ~ ~ ~ e o ~ ;
- ~ -L----' ~l._h _ bj
~X e ~ / ~ o aI
L~ , I~ . ~
~ ~ o,~, y
e~~ ~ ~ I h r ~i ~ ~ I . I -
` " i ~ ~ o '
~ ~
, _
~ o e
r- ~ ~
i~ ~ ~ ~ - - ~
i i , -
~ ~ ~ .
_ _ ~ - i~ ~ I o ~ � '
~ o
~ ~ T~ 'i~ a,~ .
Hr - .
.
e i , -
~ L ~ ~ 'e
ti ~ ~ ~ N � o ~
e ' ~ `O I ~ ti �o
~ L J . I ~v ~
~o ~ I I
~ O
O Oi O
~ I ~ ~ O. ~ ~ ~
oi l~ i O N~ y' ~ e ~ ~
~ ~ ~ o
e ~ ~ I
I
q o ~ i
�o OO N
~ ~
Figure 2~ b Design of a~Zrbine-Unit Foundati~n ~ase within
the Reactor Section of an AES Building
66
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deterrainsd~ as well as the amplitude-frequency characteristics (AChKhj of
its individual points. Inasmuch as the structure under study is a complex
three-dimensional structural component~ consisting of inter-related plates
(partitions and roofs; and stands (columns), its A~hKh has a multiplicity
of resonance peaks~ caused by these elements' becoming resonant in turn.
In the tests AChI~h of the structure ~:ere studied ranging from 0.4 to 13 hz.
(hertzj (here and further on all data are cited as converted to natural-
size structuresj, i~hich is completely sufficient for evaluating its reaction
_ to seismic influences. l,ost characteristic are the AChKh (Fig. 3, a) de-
terminin~ the vibrations of the top of the footing section (at the zero mark
~grade level,J)and the top of the protective shell (shield) (at the ,55.0-m
mar'cj in relation to the footing sole (bottom). The first two resonance "
peaks correspond to the cantilever vibrations of the entire structure as a
- unified ~rhole. The ba.sis of this cantilever design consists of the protec-
tive shell (the highest a.nd relatively least rigid element) on an elastic
foundation (the footing section) with the a.djacent rigidities and masses
(the ancillary structures, reactor~ and steam generators). The first reso-
nance peak (f, = 1.9 hz.~ corresponds to the first cantilever form of vi- -
brations~ and the following one = 3.5 hz.~--to the second one (Fig.
it should be noted that if the first tone of the vibrations are characterized
primarily by shift defoYmations of the entire structure as a whole (the -
graph of the distribution of accelerations along the high points is almost
a straight line)~ the second tone is characterized by fiexural-shift defor-
mations with a relatively bending at the place of a substantial change in
the structure's rigidity along its height (see the graph for = 3.5 hz'.~
Fi~;. 1~;. 'rr~us, the footing section in this case moves practically like a
_ rigid body. Then there is a Y~eak defox~nation in the lower third of the
shell (frorr the zero marx to the 17.0-m mark;, the rigidity of which has
been increased by means of installing internal partitions (baffles). But
_ the greatest defonnations arise in the middle third of the protective shell
(bet~~reen the 17.0-m and 33.8-m mark~--its most flexible paxt~ since above
~ it the rigidity is again increased by means of widenin~ the structural com- _
- ponent for the installation of the sub-crane beam and the juncture of the
vertical cylinder with the vaulted roof. -
The amplitude-frequency characteristics of 3 and 4(see Fig. 3~ b}, which
are situated almost on one mark (grade levelj, reflect the nature of the vi-
l~rations of the auxiliary structures and the reactor shaft. In the section
of the resonance curve with a frequency of 0.4--5.7 hz. the vibrations of
these points are practically the satne. At frequencies of more than 6 hz.
the structural components of the reactor shaft vi3~rate, so to speak~ inde-
pendently. I~ioreover~ the resonance curve of the shaft passes considerably
below the resonance curve of the auxiliary structures. The rigidity of the
reactor shaft, with its reinforcing paxtitions carrying out the function
of rigid fins is higher thaii that of the auxiliaxy structures. The shaft's
_ own vibration frec;uencies axe higher than 13 hz.~ whereas in the auxiliary
structures the first resonance peak arises at the frequency of 8 hz.~ and
the next three high resonance peaks in succession are 12~ 13.5, and 14.5
- 67
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rucc Ur'P'1(:tAL US~: UNLY
. - . ~ , ----T- I `y
, . . - I--- '~~--xr-~ e
I
' ~ i
~
- - - y.
r
'�x. ~
~ A~ ,
f ~
I__-_._.~ I ~�IY O
i w
i I i ~ i 1~
i ,
, ~ ~ ~ X ~
! ~ , .
i ~ i I
~ i i cp
~ I
~ ' ~
~ ~ I
~ N
~ ' I t i ~ ` ~
4
I j C W N
i o p ~ q
- ~ ~ ~ ~ ~o ~ N C ( v. ~ ' O
~o a N
i
~ : ~ 7 { ax. o
, ~ ~ , ~ ~~a o
, ~ Ie ~e ~ ~
i ~ ~ ~
, e
~ . ~
~ x ar. E
i
~
~ , x~ y ~ - ~
~ Q~.~. r ~ ~
_ ~ ~ ~ ~ d
~ ~ ~ ~ b w
, 4~ ~ I ~ - L r. ~
~ , b ~ d ~
~ N i ~ i h , I I_~ o0
F
~ ~ ~ ~ ~ - ~ ~
~ I ~ hl
I ~ ~ ~ ~ , �Qa~ ~ ;
.
, ~ I I , ~ N ~ ~ N ~
~ T
~ ' ~ x ~ '
~ ~o h a N . Cj ^ O oo co y,.. N O
i~i~;ure 3. ;lmplitude-rrequency Characteristics of Various
coints in the ~eactor Section (a, b) and the i
. ^ooting (Ease; of the Turbine Unit (c} ;
I
~ ~
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Key to r^igure 3:
1. Top of footing section 5~ 6. Lateral vibrations
2. Top of protective shell 7. Longitudinal vibrations
3. Reactor shaft at the level of the
4. f~uxiliary structures upper frame's axis
(17.0-m maxk;
ss J.~ ts ~ e ~a ro/{
J,1 J.l 1,7 f,!
JAf .
J,7 1,J .~9 '.7
n
r,Q q~ t
~
~ .~s a,Q
_ ~
~ > > >
Figure Graphs of Velocity Distribution along the
~tructure's Height (Its ~xis)
hz. The high levei of :1ChKh at frequencies above 10 hz. is caused by the
general resonance ba.ckground~ arising from the vibrations simultaneously
_ from several elemenis of the structure~ with a predominance of vibrations
from any one of them.
The graphs of the distribution of vibratioti velocities along the height of
the structure for several resonance peaks are represented in Fig. 4. The
first tti�ro ~;ra~hs have already been characterized above. The graphs con-
structed for 8 anc f= 10 hz. correspond to the third form of flexu-
ral vibrations (t~:o units in height). They diffex only in the nature of
the distribution of velocities by height. Thus, the maximum velocities ap- _
pear at the 17.0-m nark. The results of studying the structure's vibration
_ have sno�n that the maximum accelerations at this mark are linked jrith the
coincidence between the inherent flexural frequencies of the shell and the
inherent frequencies of the auxiliaxy structures. Tloreover, in the auxi-
liary structures they are determined by the presence of the roof. In the
floor plan each such roof consists of a square slab measuring 72x 72 m ~rith
a large opening in the center (47.5 m in diameter), reinforced by columns
on the floor~ ir:st.alled at intervals of 6 m~ and by walls (shells) around
the edges. ~:urinti the vibrations of such a plate (slab) in its flat plane
the columns r~ay the role of hinge-joint:fastenings (their rigidity in a
horizontal direction is insignificant)~ while the side walls play the role
69
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of ri~id fir.s. As a result of the general resonar~ce of the roof slabs of
the auxiliary structures and the shell, the structure as a ti�:hole is affected
by thP vibration of the complex~ three-dimensional form.
In order to evaluate the earthquake-resistance of the turbine-unit footing~
to detezmine its c'~rnamic characteristics (frequencies and forms of its in- _
herent vibrations) and the nature of the distribution of the accelerated ve- ~
locities betweeil the individual points~ depending on the frequency of the ;
forced vibrations~ aur research included an extremely detailed study of
the footing's vibration in the section of the spectrum (range) khich is cha.- -
racteristic of seismic activities. The equipm~cC installed in the upper fram~~
of the footing simulated the special loads placed on the model in accordance
r,ith the mass of the individual units. Herein the sizes of the loads wert. ,
selected so as to insure a position of the ec~aipment's centers of gravi..y
~hich tirould be similar to those in nature.
~11 tes~s on the footing Frere conducted for dynamic effects directed along
(longitudinal; and across (lateral) the turbine unit's axis.*
l~,ost dangerous for the operation of the turbine unit are the footing's la- 1
teral vibrations~ ~ince they may lead to a destruction of the coaxiality -
of the machine's individua.l parts (rig. 3, c). As may be seen from the ACh
Kh graph presented here~ the determining influence on the fozmation of seis-
mic loads iaill be had by the first tko tones of the inherent vibrations -
= 1.1 and ~x = 2.$ hz.;; rnoreover~ the second tone provides the most dynamic
coefficients (up to a= 10). In the re~aining section of the aChKh (to the ~
right of 4 hz.~ the dynamic coefficients ase basically less than the
unit and do not exceed a= 2 for the individual points. '
':he nature of the distribution of accelerations (in the forn? of dynamic co-
efficients) alon~ the axis of the footing's upper frame for the first two
resonance frequencies and for 12.7 hz. indicates (N'ig. 5) that the non- ;
syir.netricality of the footing design itself (in a lateral direction~ and the ;
placement on it of a mass of equipment along the longitudinal axis causes ~
- the appearanc;e of torsional vibrations.
The first t~~o graphs reflect the nature of the torsional vibrations in the ~
upper frame relative to certain centers of ~ravity located on the longitu-
dinal axis. For the first form of vibrations (~F, = 1.1 hz.) this center of ~
torsion is situated to the left, while the maximum amplitudes take place to
the ri~ht in the section with greater masses (turbines and condensors).
The second fom, of vibrations = 2.3 hz.).characterizes the maximum amp-
litudes of the section :~ith less masses (see rig. 5}, r;rereas the center of
torsion has shifted to i;he right. Obviously this testifies to the subse-
- quent entry into resonance of individual parts of the structural component: ~
at first~ the sections iaith lateral frames bearing the turbines (more fle-
xible), and then the sections with lateral frames bearing the generator and ~
~ In the lateral direction measurements ~rere conducted at 7 points of the !
upper frame along the axes of the lateral frames; in the longitudinal--also
at the upper-frame level along the footing's axis and the axes of the longi-
tudinal fra.~nes. `
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1~~ , ~ ~
~
,r
'~l, Z ' ?
4
-
, -
, , I
3, 6~
~~.0 ~s B,s ;s
fZ = 1,Blu
' SS
~ '
i
~ 1~ 0
- y----L-- - - - ' _
I i
!J = J7, 7!u ~~Z (
f, f
9, 4 0, 6 O,J 7, D
r-
S � f 1
- ~
Fi~ure 5. Graphs of Lateral Vibrations of a Footing's
Upper I~`rame
awci.liary equipment (more rigid).
The third graph (Fig. 5) for 12.7 hz. characterizes the distribution
of accelerations for one of the highest #~];ezural foxms of t~ie ixherent ~
vibrations of the footing's upper frame.
Thus, as follorrs from the graghs (Fig. 3~ c and 4)~ the greatest values ~
of the dynamic coefficients correspond to the second tone of the vibrations
( f = 2~8 hz. N.oreover~ if tire consider that the maximum accelerations
~~rithin seismic vibrations are characteristic of the frequency range 3--5 hz,
_ then the second tone of the vibrations will obviously be the deterntining
factor in forming the seismic loads on th~ footing in a lateral direction.
- Study of the footing's vibrations in a longitudinal direction has shown
that in this case the footing component behaves as a single-mass elastic
system; the frequency of its inherent vibrations amounts to 1.4 hz.
(Fig. 3, c). Thus~ it may be assumed that the dynamic rigidity of the
footing in both longitudinal and lateral directions is approxinately the
s~ne. rurthermore, as a result of the slower damping of the longitudinal
vibrations~ there occurs an increase by approximately 20`;o in the dynamic
coefficient ~as compared to the maximum for lateral vibrati.ons).
Conclusions
1. Study of the vibrations of the reactor section of an A~S building have
shown that the two lowest tones of the inherent vibrations = 1.9~ ~=�3�~
hz.) are detezmined by the flexural-shift defozmations of the entire
71
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structure as a unifieci ~rhole. .1t frec,uencies of more than 6 hz. the dynamic
operation of the structure will be determined by the inherent vibrations
- of tkle elements comprising it (shells, roof slabs, Nall:~). Herein the forms
of vibrations of the entire structure have a compler.~ three-dimensional
- nature.
2. The design of the turbine-unit foating studied here is s.~ ficiently
flexible (with a vibration period of T~,i 1 c~~ possessi.n~ approximately
the same dynamic rigidity in its longitudinal and lateral directions. The
dynamic operation of the Fcoting in its lateral direction is conditioned
by the torsional vibrations of the upper frame; herein the determining r,~le
_ in the forn~ation of the seismic load tiiill be played by the second tone of
the vibrations ( ~2 = 2 .8 hz . ; o( = 10 ) .
BIBLIO(,RAF}iY _
1. i~iedovikov, I.; Shablinskiy~ G. and Gordeyev, A. V., "Research
on the Dynamic Characteristics of Structural Components of an t1E5,"
EI~~:?GETICH~SI~OY"r~ ST~OITr~L'STVO, ;~io 9, 1975~ PP 36-39� ,
2. t~iedovikov~ A. I. et al. "The rragment Method of Calculating (Design-
ing)Thin-41a11~1 Fressure Vessels," ~NERG~TICHF;SKOY~, STROITEL'STVO,
tdo 2, 1979, PP 33-3s~ -
i
COPYR.iGHT: Izdatel'stvo ~nergiya~ "Energeticheskoye stroitel'stvo", 1980
z3~4 _
v5~: 1U22
" i
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ELECTRIC =C,�1~~R
~
u~; 621.311.z2:6zi.~67.662.63/67
PL.1iv.'~I.~G :~I~~ ~TliDY~,JG LivJ~RGftOUND FU~L-DELNE~Y TUNIr~~,LS
t~ioscow r;ivL?CUTICHi,'~KGY~ ~TROIT'r;L';;TVO in Russian Vo 10, Oct 80 pp 57-60 r
~.~rticle by ~andidate of Technical 3ciences V. I. Stepanov and Lngineer
V. G. tiovikov and 'J. T~. Favlov: "Planning Underground ~el-~elivery Tun-
nels and Studying Their Cperation'~
_ jText,~ The Ural Division of the VGPI (All-Union State Planning Institute)
TeploeleIctroproyekt (Ura1TEP) has developed fuel-delivery~ arch-type tres-
tles (scaffold bridges)~ made of structural s~eel with mineral-wool heat
insulation. The de~ign of these trestles contain practically no protrud-
ing ele,-nents on which dust may be deposite~ and~this significa.ntly im- '
proves the conditions for utilizing them. ,~t the same time underground
fuel-delivery tunnels~ whose operating conditions axe considerably worse i
than those in above-ground galleries (in connection with the :iiffi~ulty of
arranging transfers by conveyors and the presence of props (posts) within
the central pa.ssagej~ are being made, as before~ of VKT 3�5-3 rectangulax
elements. The constructional deficiencies of such tunnels~ it ~
~
should be noted~ alsc include a large amount of work on integrating the
hinge-type joints, the monolithic sections~ and placing concrete in the ~
floors, difficulties in manufacturing structural components at plants, as ~
well as the complexity of making the transition junction from the rectan- I
gular~ underground structural components to the arch-type, above-ground I
ones. i
i
I
TaI:ing this into consideration~ in planning the fuel-delivery structures
for the Reftinskaya~ Troitskaya and other GRES's, the liralT~P specialists
developed and introduced a design for precast, arch-type, undarground tun-
nels~ made of reinforced concrete. The arch-type tunnel (Fig. 1) consists
of a support slab and tNo semi-vaults~ connec~ed in a"keystone," as well
as a hinge-joint with the support slab. Lengthwise the elemPnts are con-
nected ~rith the aid of'welding the embedded parts. 41ith regard to its in-
terior outline the tunnel consists of a vault with a radius of 4100 mm. In
choosing the sections of its elements and the type of reinforcement, con-
sideration was given to the possibility of using them for the building of '
- the rotary gravity dwnps irith disk-toothed crushers at the grade level ~
where the underground tunnel comes out--13.8 m. ,
73 i
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_
~ Op
, V,G , e y\
\
y ~
" , " b. .
? ~ .9900 ; ~ ~
; ~ - - - .
6 ?=6 q_A
--1 FN i ol
I i~ ~ -
~-~'I i s ~l r~O o-~ 1 m ~ d+
~n, b . ' �
6 y ; to' ~ ~ i
~
s
'f'-::sa
I+ I tJ ~ZF ~/ll B=
B~ �o ' i
i ~ ~ - ~ i
; r ( �
- ' 1'n_~`~=�Q:s~~
.':n "
_ . .
B - f.9~0 0 ~
r- r ~ :
, -
. _ 9900 --~o
~ ~ - ~ e
Figure 1. Ciross-Section and Reinforcement Schematics of Structural
Cor~ponents of Underground~ Fuel-Delivery Tunnels ,
- In order to deter~ine the strength characteristics of the vault structure~ I
a test model was made and tests were run on it. In contrast to the plan .
- solution for the vault, the test model had a width of 1000 mm (instead of ;
19�0 mm) and an outline in the form of a broken circle, consisting of
12 stralght-line sections (instead of a circulax form~. ;
In order to concrete the semi-vaults~ metallic and wooden forms were made
with removabie sides. The semi-vaults werz concreted, and the fom~s were ;
set aside. ~Y~e reinforcement and the concreting of the supp~rt slab z�~ere
carried out in the operational pos~,tior.. '
The test model was assembled in the following manneri first~ the support ;
- slab was placed on a sand base, a special appaxatus was installed on it
in order to support the semi-vault in the plan position~ and then the
74
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semi-vaults were erected~ their position was adjusted and checked~ and the
joints in the "keystone" and "heels" were integrated. The data on the com-
pression strength of the concrete in these elements of the vault, as well ~
as the integrated concrete are cited in Table 1.
Table 1
Element T~Poraxy Resistance Actual Modulus of Elas-
~ to Compression, in NPa, ticity of Concrete~ in r1Pa
Semi-vault I ~ 23~500 -
Semi-vault II 56.8 19,8~
Key joint 43 23.800 =
- Support slab ~5�3 30~100
Notes: 1. Flan concrete maxk M400
2. Concrete mix (composition) (outlay per cu. m): M~bO~cement--
56o x~, granite crushed stone~ ranging in size (coaxseness~)
up to 44 mm--1250 kg~ granite sand--340 kg.
The test model of the vault was tested with three combinations of stress
- (loads); moreover, in all cases the distributed load was replaced by a con-
centrated one. The first combination of loads included within itself loads
from the soil, ground water and rolling stock (Fig. 2). In the second
P
P, .
1
P~ PZ~' ~PZ ~Pt Pi 1 ~ .
~ PZ Pz ~
P~ ~ P2 6 ~ B PZ ~ p~
P~ s ~ PJ ~
p~ f M N P _
~
- 3 17
� ~o
1 N. 13 +
N
.
N 74
- N
f550
Q)
p~ r~ PJ r~ PJ p' P~ p'
I ~ ~
S00 ~ bl00 1d00 UJ00 I?100 1300 l300 JDO S00
~
100 � 700
9900----------?j 61
c~igurs 2. Schematics of Loading in Testing Vault (a)
and Support Slab (b~
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combination the vault rras loaded only with vertical elements from the
first loading~ hhile in the third loading a one-sided loading of the
vault Was conducted with a vertical load (Table 2). The vertical load P
on the vault was created with the aid of 16 DG -50 pushing hydraulic jacks,
while the hori2ontal load utilized three DG3-63 pulling hydraulic jacks.
Defozmations and shif~5 of the vault during the test process were measured
by indicators (1 � 101 mm; and by deflectometers (1 ~ 10"~ ~ 1� 10~~' mm),
i�~hile stresses in its operational reinforcement were measured "by resistance
strain ga.ges (tensometersl.
Table 2
~om ina ion
_ Load Designation I II III
(Stress;
i
Vertical P~ 300/360 300/360 150/180
326/390 32~/390
~ P 2500/3000 2500/300 600/720 '
Horizontal N 236~280
~ N 1410~1680 ~
r~ote : The ni:merator gives the nonnative load ( in kH while the
denominator gives the design (estimated) load.
L'uring the first loadin~ of the vault the test load was gradually brought
up to the nozmative value. Herein vertical shifts in the keystone joint
comprised 3.79 and horizontal shifts 0.22 mm. The maximum stress in
the operational reinforcement rras equal to 78 P~iPa. Under normative load
the vault held out for 17 hours; in this case the increase in deformations ~
in not a single one of the vault's cross-sections exceeded 0.3 mm, i. e.~ ;
the structure operated in an elastic stage. The vault's remaining defo~na-
tions after unloading did not exceed 10 percent of the full deformations -
- under normative loadin~.
The results of repeated loa.d.ing of the vault up to the normative load rrere
practically indistinguishable from the results of the first loading.
- In the desi~n (estimated) loading the vertical shifts in the keystone joint
amounted to ~.74, while the horizontal shifts amounted to 1.7 mm. The
stress ( tension ) in the yau].t'.s operational reinforcement reached 100 I~1Pa.
The first cracks in the vault in the zone where the maximum moment was act-
ing under the conditions of ~ P= 4130 kH, ~I~ = 1320 kH.
76 -
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Fig. 3, a depicts a graph of the dependency of the vault's vertical shifts
in the keystone joint on the load (in compaxison with the design curves
for two-hinged and hin~eless vaults). It may be seen from the graph that
the curve. of the vault shifts~ constructed in accordance with the test
data~ practically coincide with the curve constructed in accordance with
the design data, obtained for a hingeless vault. Tt;is is probably
explained by the fact that under the given combination of loads the junc-
tion connecting the vault rrith the support slab operates rigidly.
In testing the vault the test load brou~ht to ~ y= 4820 kH, ~ Pd = 2720 kH,
exceeded the design load by a factor of 1.61. At this stage signs of the
vault's destruction were not revealed. In analyzing the dependence of
the vertical shifts on the loari (Fig. 3, a)~ exceeding the design load, we
observe the maintenance of the proportions between tYae shifts and the loads~
i.e.~ even beyond the limits of the design load the structure operates in
an elastic wanner. The maximum stresses in the reinforcement under con-
trolled-destruction loading did not exceed 150 MPa. After unloading the
_ residual deformations were insignificant, and this confirms the conclusion
regarding the elastic operation of the vault even under controlled-destruct-
ion loa.ding.
In tests made using the second combination without adding horizontal loads
the loading of the vault was also conducted in stages. Under a load of
~ ~ P= 2000 kH in the zone of the keystone joint cracks began to appear,
and under $ P= 2500 kH the xidth of their opening reached 0.4 mm.
I'ig. 3, b presents graphs of the changes in vertical shifts in the keystone
joint depending on the vertical load obtained by the test method and deter-
mined by the design for hingeless and two-hinged vaults. From a compa.xison
of the design of the test data it may be seen that under this loading
the. vault operates as a two-hinged unit.
Thus, depending on the type of loading the assembly which joins the vault
with the lower slab may operate both as a rigid and as a hinged joint. So,
~hhen the vault is loa.c~ed only by a vertica~ load (~'?P = 3000 kH) the shifts
- in the keystone joint amount to 18.7 mm~ while the tension stresses in the
operational reinforcement reach 222 i~1Pa, whereas when the vault is loaded
with loa.ds corresponding to operational ones P= 3000 kH~ ~ N= 1680 kH)~
these same indicators do not exceed 4.7 mm and 100 P~Pa respectively.
linder a vertical load of E P= 3900 ~cH rre observed the appeaxance of new
cracks and the iaidening of existing ones, as well as an inerease in ;~Iie..
deformations and s~tifts. Ho~rever, we did not note any clear signs of the
vault's destruction...
The last load.in~ o~ the vault was carried out in order to detern?ine the
moment and character of destruction under a one-sided loading (the third
combination;. The loading was caxried out in stages, and at a load of
P= 1200 kH, which exceeded the design load by a factor of 1.66,
?7
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A. nH p , , i~A ~ r r , .
e N ~ l~: ~ .
4000 - - 4000 �
900 ~ 2 ~ . 2 i ~
_ J000 �~30D0 - + �
f, ~ ' i
~
600 2DU0 Z000 ' ~ �
J00 lD00 ` f000 ' .1 - . ~
I, / I ~ i
_ 0 0,2 0,4 0,6 cn 0 ; T cn '
a! 01
Figure 3. Vertical Shifts in the Keystone Jo~nt when the
Vault is Loaded rrith the First (a) and Second
(ti) Combination of Loads
Key:
1. Test curves (loading--unloading---loading)
2.. 3 Design curves for hingeless and two-hinged. I
vau~ts respectively t
~
destruction of the vault occurred along an inclined section at a distance -
_ of approximately 1~3 of the semi-vault from the keystone joint (Fig. 4, a).
The support slab S�raS tested in an inverted ~osition (with the bottom. up) ~
for a combination of loads creating a maximum span moment. A load in the
fonn of concentrated forces rras created with the aid of DG-50 pushing hy-
draulic jacks.
_ Under a load co~prising 57 percent of the nonnative load crac3cs were re- ;
vealed in the central part of the span with a~�idth of as much as 0.1 mm.
Under the nozmative load r= 936 kH) the flexure of the slab in the mid-
dle af the span amounted to 24.6 mm~ the maximum stress in ths longitudinal '
reinforcement did not exceed 190 I~iPa, and the widtn of the crack opening ;
at~ained 0.3 r,un. Under the normative load the slab held up for 16 hours;
in this case, the increase in flexure amounted to 0.73 mm; the residual de- ;
- fonnations of the slab after unloading did not exceed 5 percent of the full
defarmations. The results of repeated load.ing of the slab to the normative
load i�iere practically no different from the results of the first loading.
At a load of ~ P= 1290 kH (a design load of ~ F= 1120 kH) there appeaxed
in the support zone of the slab an oblique crack with an opening width of
0.2 mm, Frhile at a load exceeding the design loa.d by a factor vf 1.49 de-
struction of this zone occurred along an oblique section (Fig. w, b).
Since the slab's support zone was destroyed under leading which was less
- thari the con~olled-destruction loading~ it was decided to conduct a test
78
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