Document 85Qrw34BwoxNwzEw80j5jEzje

HISTORY PLAINTIFF'S EXHIBIT 32 General The sound economic growth of the company's service area based on expanding population, manufacturing, processing of natural resources, and other industrial activities, together with the long standing agriculture, livestock processing and commercial distribution aspects provide a broad base for con tinuing area development. Denver suburban area population ranked fourth in rate of growth among 56 metropolitan suburban areas in a U.S. census survey. An important factor of this growth in addition to new customers' attached, is the increased utilization of electrical service by present customers through additional application of electricity. In order to keep pace with these increasing demands for electrical service, additional generation was indicated for 196G, After careful analysis, it was decided to install 150,000 kil watts of capacity as the most economical size consistent with growth. This would increase the company's total generating capacity approximately 17 percent and put it over the one Tl) million kilowatt capacity mark. The company's growth rate, while continuing up, had slowed down to a lesser rate than in the previous decade. When it became apparent that the 44,000 kilowatts of capacity from the Cameo Steam Plant, a mine mouth plant on the Western Slope, would be available in i960, the future generating program was reviewed. After due deliberation by management in which rate of growth, generating capability, design engineering schedules versus increased costs due to material escalation and labor increases, it was decided to delay start of construction for nine months. This interrupted a continuing construction program in the Denver area that started In August of 194$. The location chosen was the existing plant known as the Cherokee Steam Electric Station, which carries out the naming of'plants after Indian Tribes, started in 194-3. It is located just north of the City and County of Denver limits in Adams County, Colorado, where the previous two units were in stalled in 1957 and 1959. The new unit will be known as No. 3 and all facilities necessary can be made by extending those existing except for a new chimney, ash settling pond and circu lating water cooling tower with its associated piping and intake. The general plant arrangement, showing locations of various structures and facilities, is shown elsewhere in this report on Drawing G-130496, "Plot Plan", which is a drawing originally made for Unit No. 1 and revised to include Units Nos. 2 and 3. The architectural features of the station building maintain the motif set up for Unit No. 1 and includes unlined corrugated asbestos siding on steel framing with the turbine and auxiliary bays enclosed and the outdoor type boiler. The frontispiece, a general aerial view, clearly shows the relative positions of all the structures. WAD00696 33 The site was originally acquired between 1953 arid 1955 and the Unit Ho, 1 construction was started in August, 1955 The main advantage of this site was that the Public Service Company of Colorado transmission departmentTs Arsenal Junction was located at the southeast intersection of North Washington Street and East 62nd Avenue, which is now the main entrance to the plant. The switchyard installed for Unit No. 1 transferred the junction^ switching facilities to its ring bus. A total of eight (3) transmission lines are now installed including one (l) added during Unit No. 3 construction. The site, specifically, is in the northeast quarter of Section 11, Township 3 South, Range 68 West, and contains 1 57. 7j2 acres. It is bounded (with exception to 3 tracts) by aasi oqth Avenue on the north, by North York Street ,on the east, by the Northwestern Terminal Railroad (Denver and Rio Grande Western Railway) on the south, and by North Franklin Street and its extension on the west. The exceptions to this closure are the C.V. Miller retention (5.5 acres) in the southeast corner, 3 adjacent residences (311.5? x 12.5) midway along 64th Avenue, and a residence truck farm strip (approximately 2.00 feet-wide) from 62nd to 64th Avenues along Franklin Street. The South Platte River, flowing north, parallels the site immediately east of North York Street. All clearing, grubbing and grading were per formed during Unit No. 1 construction and the plant and yard grade Elevation of 51295 was established at that time. The contract authorizing Ebasco Services Incorporated to act as agent for Public Service Company of Colorado to provide engineering, purchasing, factory inspections, expediting and construction services for this installation, was a supplementdated November 15, 1957, (accepted November 27, 1957) to an existing contract dated August 30, 1954, and accepted September 10, 1954 The Ebasco Engineering Order Numbers assigned to this project were No. 7988 for the generating plant and No. 7989 for the substation facilities. Engineering was started early in 1950 with composite study drawings of equipment location, main and reheat piping systems routings, general arrangements available for review and a preliminary project outline was released July 1, i 9 v 8 ,, Electrical engineers were In Denver July 15, 16 and 17 to discuss the electrical design and it was then decided that the generator would be a liquid cooled type. In August, civil and structural engineers were in Denver to review past design and discuss foundation revisions necessary to hold existing spacing for keeping plant and architectural continuity. In September, 1958, an engineering study was made for water requirements and wnen It was determined that an additional deep well was required, It was drilled before Unit No. 2 construction was completed as an emergency source for plant operation. Mr. G Chao, project engineer, visited Denver In October, 1958, bo discuss and finalize the mechanical design. The heating, ventilating and air con ditioning design was finalized duriiig various visits to Denver by C J Danowits, in conjunction with his consulting duties for the new Public Service Company-of Colorado office building in Denver. WAD00697 34 Construction started June 13, 1961, with excavation by bulldozer in the station building and boiler areas preparing for drilling of caissons. Ground breaking ceremonies took place June 20, I960, with Public Service Company of Colorado officers, directors and management, the Governor of the State of Colorado, representatives of the local press, members of the financial and. banking associations and Ebasco Services Incorporated field construction personnel in attendance. Trial operation was scheduled for April, 1962, and 'was realized April 26, 1962. However, the project was considered ahead of schedule and an anticipated late March, 1961, date was shelved when a directive from Public Service Company of Colorado engineering department dated December 6, 1961, added gas as a main fuel. Four (4) burners were to be revised to include gas burning immediately and provisions were made for the remaining twelve (12) at a future date. The additional engineering, pur chasing and delivery of equipment and piping, plus the changes to the already installed control equipment and piping which had to be revised for the fuel safety interlock controls kept the project from an ahead-of schedule start up. The construction work was practically complete by the end of June, 1962, with only painting, road paving and final clean up to be done. Road paving, except for the final seal coat and chips, painting and removing temporary construction buildings were completed by August 24, 1962, in time for an open house on August 27, 196, The construction office was closed approximately December 1, 1962. Construction Plant and Facilities The temporary construction buildings for this project were originally arranged with the temporary field office and 'ware house outside the construction area of the proposed six units. Most of the existing barracks type buildings used as employee change houses, shops and storage buildings remained in the original Unit No. 1 location which was outside of the construction area for three units. All buildings utilized for the Unit No. 2 construction were clear of Unit No. 3 construction except two, No. B-17 and B-34, which were relocated to clear the transformer yard extension and the circulating water cooling tower areas, respectively. The layout and identification of these buildings are shown on field drawing SK-7966-F25 entitled "Construction PlantT', and shown elsewhere in this report. The construction office is the same building purchased in 1946, with an additional twelve (12) foot bay added when moved to Cherokee in 1955, with a brick vault built on the north end. One warehouse was originally pur chased for the Arapahoe Unit No. 1 project in 1946 and the other was purchased new for Cherokee Unit No. 2 construction in 1957. No new buildings were required by our forces for Unit No. 3 con struction facilities. WAD00698 35 The two farm buildings existing on the site were again utilized as storage and field engineer buildings and other tem porary buildings were erected and dismantled by the following sub-contractors while they were located on the job: Babcock and Y/ilcox Co. s boiler erection; Slattery and Co., plumbing; Rust Engineering Co., chimney construction; Marley Co., cooling tower erection; Insulation Services Inc., piping and equipment insulation; Jamar-Olmen, boiler sheet metal lagging; and the toiler insulator, Insulation Specialties Co. provided a mobile trailer for use as a temporary office. The existing Hiller's deep well was used for the con struction potable water supply. Field office sanitary facilities were also those remaining from the Hiller property containing cesspool and leaching field. The sanitary toilet facilities for workmen installed for Unit ho. 2, north of cooling tower No. 1 were left in place for Unit No. 3 construction. The permanent railroad spur for the transformer yard was extended for Unit No. 3 and was utilised for material un loading. The temporary spur from the 'warehouse track to the boiler was relocated by the boiler erector, Babcock and Uilcox Co., and was used by them for moving the steam drum and pressure parts into position. Permanent tracks 1, 2 and 3 were utilized for storing boiler parts and the boiler contractor provided a locomotive crane for unloading, storing and reloading material aril switching cars into the construction area. One owned rail road flatcar was available and three others -were obtained from the railroad company by the boiler erector on a long-term rental. The access road and gate from East 62nd Avenue at Franklin Street were utilized for construction access and the future 230 kv switchyard area at the north end of the existing switchyard was enlarged and graveled for use as the construction emplo y e e ' s park!ng lot. Construction power was obtained from five (5) trans former power banks existing from the Unit No. 1 and No. 2 con struction programs. The scarce was a cubicle in the 4160 volt switchgear furnished with the Unit No. 2 project. The powerbank No. 1 adjacent to the 4160 volt switchgear feeds through existing or new spare ducts in the permanent duct banks to supply load centers in the station building area. The trans former bank locations and various routings of temporary power are shown on field drawing SK-7906-F3O, which is included in the drawing section of this report. No new telephone facilities were required except an underground line from the manhole east of the timekeeper's shack to the boiler contractor's office and the piping erection con tractor's temporary quarters. Heat for the field office building and warehouse office was by electric heaters and the remainder of the temporary con struction buildings were heated by saturated steam radiators, supplied by the plants (Unit No. 2) auxiliary steam system. WAD00699 Compressed air for construction purposes at 100 psi was supplied in several different ways. During the early stages of construction and for work in outlying areas, either of the two portable diesel engine driven, AC-1 (365 cfm) or AC-2 (500 cfm), compressors were used. During the peak of boiler erection, two electric-driven compressors were employed. One was owned by Babcock and Wilcox Co. and our AC-4 (445 cfm) which we skid mounted with a receiver. They were located in a sheet metal enclosed shack at the southeast corner of the boiler and after Babcock and Wilcox completed their work, only the AC-4 was used in the final stages of construction. A four (4) inch rubber covered heavy duty hose served as a riser up the boiler to the header stations at various levels. Gasoline and diesel oil were purchased from Standard Oil Company and they were dispensed from underground tanks by means of electric motor driven pumps all furnished by them and installed for Unit No. 1. Oxygen and aceytlene were supplied as required in standard size containers with a three to four day supply main tained in stock at the warehouse. Due to a questionable demurrage agreement with the original supplier, a new order was placed with Acetylene Service Incorporated approximately 1/3 through the job. Babcock and Wilcox Company, during boiler erection, used a propane-oxygen arrangement with bottles and regulators located on the grade level at the north side of the boiler with rubbercovered hoses running up the structure with header outlets lo cated at several elevations. The B. F. Shaw Company used individual oxygen and acetylene bottles and the same supplier, Ac'etylene Service Incorporated, supplied all three contractors on the job. Construction progress photographs were taken from three main locations: One on top of a 50 foot pole, 125 feet north of boiler column nJa-14Tt; another on the top of the slope adjacent to the switchyard; the other from the top of the service water cooling tower. The pole was equipped with a ladder, plat form and pully for use by the photographer. Major construction equipment was owned and transferred from the previous projects. It consisted chiefly of: One, 50 ton Northwest Crawler Crane with 130' boom and 20' jib One, 45 ton Northwest Crawler Crane with 130' boom and 20T jib One, 1 cuyd Marion Crawler Crane with 90' boom and 10* jib One D-G Caterpillar Tractor with bulldozer One D-6 Caterpillar Traxcavator with front loader One 40 foot flatcar Minor equipment included: 4 air compressors, 6 pumps, 5 air hoists, 1 concrete mixer, 1 mortar mixer, 1 brick saw, 1 stress relieving machine, 25 welding machines, concrete vibrators, miscellaneous minor equipment and small tools. Other equipment from previous projects was available but was not utilized for Unit No. 3 construction. A minim-urn amount of equipment was WAD00700 Wm 37 purchased for Unit No. 3 construction and consist-I of two mechanical earth tampers,'a magnetic electric drill, and automatic torque control impact wrench the main items purchased. The vehicles used on this project were new as noted, or owned and transferred from previous construction and consisted of: One, Ford 4 door Sedan, I960 (new) - #l6l One, Ford Station Wagon, I960, 6 cylinder, (new) - #160 One, 2 ton, GMC Flatbed Truck - #136 Two, 5 cuyd, GMC Dump Trucks - #146 and #150 One, International Truck, hydraiift and winch - #154 One, Mack Truck, A-frame and winch - #152 One, 2-1/2 ton International Truck, A-frame and winch - #155 One, 1-1/2 ton, Mack Truck, Flatbed, 1961 (new) - #162 One, 2 ton Mack Tractor and lowboy Trailer, - #136 & TTl One, 2-1/2 ton Hyster Truck, fork lift - #15$ On occasion, owned equipment was rented to subcontractors or performed work for them under "Work Order." The schedule of rental rates is shown elsewhere in the report as "Owned Equipment Rental Rates Per Hour." There is also a chart, "Equipment Operating Record," which shows a theoretical profit or loss on operating versus job cost, based on a rate per hour schedule which is lower than rental rates of local equipment agencies. The major subcontractors supplied their own equipment for use on the job and these are as follows: Babcock & Wilcox, $0 ton Manitowoc Crane, 25 ton Locomotive Crane, 30 welding machines, 3 air hoists, special electric driven hoist for drum erection; B. F. Shaw Company, 12- welding machines, 1 stress relieving machine, 3 air hoists; Schriber Decorating Company, all small tools, scaffold and 3 spray pots; W. H. Nichols Company, 3/4 ton rail Motocrane, vibrators and tampers; Winslow Construction Company, 3 DW21 tractors and scrapers, 2 bulldozers and motor operated grader; Rust Engineering Company, electric driven hoistand derrick for chimney erection; Meredith Drilling Company, 50 foot kelly bar earth auger (2); Esco Paving Company, 25 ton Ga'lion pneumatic roller, Barber Greene asphalt paving machine, tracks and Galion road patrol. On occasion, several pieces of equipment were rented for short term use on the site. These pieces of equipment were mainly a 1 cubic yard Bucyrus Erie backhoe used for station building shale excavation, a l/4 cubic yard tractor mounted backhoe for trench excavation, 2 electric driven conveyors for ash hopper excavation and a 1/2 cubic yard Unit truck mounted backhoe for storm sewer excavation. Other minor tools and equipment were rented as required for special uses and in one instance, a special type of concrete form tie (Gates) and clamp was rented for cooling tower basin construction. At termination of this construction project, all owned equipment had to be disposed of due to a Public Service Company of Colorado change in policy in which major construction would be WAD00701 33 performed by separate contractors. The various divisions of the company had first choice on all major and minor equipment, and small tools. The balance was then turned over to the salvage department for final disposal. Safety Program The safety program was essentially identical with those of the preceeding projects in which we recognize the in herent hazards of building construction. Accident prevention is largely a matter of human relations and, to be effective, the responsibility for education, vigilance and cooperation is the duty of management from top supervision thru sub-foreman. A 20 minute weekly safety meeting was convened each Thursday afternoon, attended by most of the Ebasco and sub contractor superintendents, supervisors and foreman. Each month a different chairman was appointed from among those who attended regularly. It was the intention that the supervisors and foremen took the highlights and job conditions discussed, and passed them on to his men. Each person attending was given an opportunity to bring up any unsafe practice noted, and then one person was designated by the chairman to see that the con dition was corrected. A weekly report of the safety meeting was made up and posted in each craft changeroom. One of the safety meeting highlights was a movie presented by PSCC demonstrating mouth to mouth resusitation. At the end of the meeting, a wallet size recap of the movie substance was given to each person for ready reference. A first aid man was on' the site at all times with basic first aid material for accidents. Stretchers, blankets, splints, etc., were kept at several accessable places on the job site. Employees having accidents requiring medical attention were taken to a clinic a few miles away by the project car. Emergency cases were sent to the nearest hospital in Denver by ambulance. Ebasco New York Safety Department furnished the job with safety posters at regular intervals and these were posted in conspicuous places throughout the job site. Travelers Insurance Company was retained by Ebasco Services to handle all injury and compensation cases for the projects. As Ebascofs agent in dealings with the Industrial Commission of Colorado, it presented all reports, argued all cases, and made all payments as directed by the Commission, in accordance with Colorado law. All lost time or compensable accidents were reported to Travelers on their Form Nos. 40 and 20. Travelers representatives made several unannounced visits to the job site and made recommendations for improvements.* based upon their visual inspections. 5* This project received two (2) awards of Certificate of Achievement in Accident Prevention for the years I960 - 1961 and 1961 - 1962. The latter year we won the Gold Plaque denoting WAD00702 39 our record as the best of all Ebasco Services Incorporated projects. Reproductions of the Certificates and the Lost Time Accident Trend Report presenting the statistics with charts on which these awards were made are included elsewhere in this report. Labor Policy Labor procurement policies used on this unit were essentially the same as those used on previous projects since 194-8, wherein Ebasco Services Incorporated was the general con-? tractor acting as agent for Public Service Company of Colorado. The following crafts were hired directly and paid weekly on the Ebasco field office construction payroll. Bricklayers Boilermakers Carpenters Concrete Finishers Ironworkers Laborers Millwrights Operating Engineers Pipefitters Reinforcing Rodmen Truck Drivers The construction crafts were paid the wages established in the Denver area. Discharge slips could be issued either by the supervisor or by the general foreman, after consulation with the general construction supervisor. Crafts employed by the sub-contractors are included in the following: Asbestos Workers Boilermakers Electricians Glazers Ironworkers Millwrights Operating Engineers Painters Pipefitters Plasterers Plumbers Roofers Sheetmetal Workers Tile Setters There was a duplication of crafts employed by Ebasco and the sub-contractors because it was elected to sub-contract the erection of the boiler and its supporting structural steel and to install with our own forces all piping two inches and under in diameter including all instrument piping. Also the condenser, primary air duct, and the breeching were installed with our own boilermakers. A schedule of wage rates showing the rates in effect for all crafts at the beginning of the job, with all subsequent increases until completion, is shown elsewhere in this report. The Ebasco field supervisory personnel was practically a new organization for the first time since the Denver area con struction program started in 194-8. The only personnel reassigned being the Construction Superintendent, Construction Accountant and Electrical Supervisor. The Resident Engineer, Construction Engineer, Office Engineer, Cost Engineer, Field Engineer, General Construction Supervisor, Mechanical Supervisor, Piping Supervisor, WAD00703 Purchasing Agent and Material Supervisor were all transferred from other Ebasco projects and were carried on the New York payroll. All other field office personnel were hired locally. The job was prosecuted on a A0 hour, 5 day work week, with overtime being used only where absolutely necessary. The overtime before the preliminary and start up operations was mainly for concrete construction on large extended pours or cement finishing which could not be completed in the workday. Preheating and stress relieving of some high pressure welds could not be scheduled to complete during regular eight hour days. During the early months of 1961, Sturgeon Electric Company worked two Saturdays making changes in the temporary construction power supply and again on October 7, 1961, to move the construction power transformer at Unit 1 4160 switchgear to make room for additional switchgear cubicles. On Saturday and Sunday, October 14 and 15, 1961, a small composite crew of ironworkers and millwrights worked to move the head pulleys, extend and splice the conveyor belts from Unit 2 to Unit 3 A complete outage of the coal conveyor No. 5 was required for this work, therefore, the overtime work was done to coincide with a scheduled outage by the operating de partment for other work they were performing. On Saturday, March 10, 1962, a small crew of pipe fitters, boilermakers and electricians worked as a standby crew to correct any difficulty encountered during the early part of the "dry-out" and "boil-out" program. On Saturday, April 7, 1962, one pipefitter worked to be available during the "blowingout" of the cold reheat piping system. On Friday, April 14, pipefitters worked overtime to revise the "blow-out" piping from the hot reheat intercept valves and Saturday, one pipefitter worked for availability during hot reheat piping system "blowingout". On Saturday, April 21, all pipefitters worked and on Saturday, April 2.6, pipefitters used on control piping worked c;, meet scheduled trial operation items. The total overtime worked on this project amounted to just over five thousand (5076) manhours, which is .0077 per cent or approximately three fourth (3/4) of one (l) percent. This is an exceptionally fine construction record for the type of work involved. Labor relations during the construction of this project were very good, with the various local Business Representatives of the Building Trades Unions displaying a cooperative spirit. Work assignments and disputes were handled according to the pro cedural rules of "The National Joint Board for Settlement of Jurisdictional Disputes." There were four work stoppages, all of which were unauthorized. The first work stoppage occurred on December 7, I960, when the carpenters voted not to start to work because they did 41 not agree with an assignment of erecting steel beams for sup porting the turbine pedestal forms, to the ironworkers. The carpenters were ordered back to work by their international officers and they returned to work on December 15, I960. This walkout did not afT-ct ;he schedule as the carpenters could not proceed with the forming until the supports were erected. The major work stoppage resulted from a ''wildcat" picket line placed on the job on July 24, 1961, by the shop employees of Babcock and Uilecx Company at Barberton, Ohio. This strike was the result of an expired contract between the Babcock and Uilcox Company and their shop employees and caused work stoppages on several jobs over the nation where B & W had erection work in progress. As soon as the local building trades unions were apprised of the true facts about the picket line, they ordered all workmen to return to work except those working on the boiler erection for Babcock and Wilcox Company. The picket line remained on the job until August 17, 1961, at which time the Babcock and Wilcox employees returned to work. On January 3, 1962, the operating engineers walked off the job; on January 4, they did not show; up for work; and on January 30 they placed an unauthorized picket line at the gate due to a jurisdictional dispute with the linemen over the operation of cranes and winch urucks for erection of transformer trim and tower structural steel. The picket line was removed early on January 31, 1962, and all crafts returned to work. On March 5, 1962, the millwrights walked off the job at 3:00 p.m. because of a jurisdictional dispute with the pipe fitters over the erection of linkage between the controllers and the dampers on the coal pulverizers. They returned to work at 8:00 p.m. on March 7, 1962, to await a decision by their inter net iona1 repres entatives,, Purchasing - General Ebasco handled procurement of both equipment and materials from two offices. The flaw York office made all pur chases of major equipment as well as items of a technical nature. Building materials and supplies, construction equipment and tools wore provided through the field office by means of local purchase orders. Some special building and construction services were provided through field construction contracts. All purchase orders, whether issued by Mew York or the field office, were Issued in name of Public Service Company of Colorado by Ebasco Services Incorporated, Agent. Whorevtu possible, orders were placed F.O.B. or F.O.B. shipping point with freight, prepaid and allowed to destination or for purchaser's account as a separate item. This avoids liability of a Colorado State Sales and Use Tax of 2 percent on material that is not applicable on transportation charges. Pur chases made from local vendors or placed through local sales agents accruing to sizeable dollar amounts are listed elsewhere in this report. WAD00705 42 Where feasible, purchases were made through or sales credit given to Colorado agents. All materials were received at the field warehouse, inspected for loss or damage, and recorded on Material Received Report, (Form 230) in quadruplicate. Material was issued on Requisition on Stores ~ (field form), for charging directly to the proper construction accounts. Invoices were received from vendors in triplicate and, upon checking with Material Received Reports, prices, discounts, etc,, were paid by Ebasco Voucher Checks, Form 107 A Voucher Payable, Form 106, was prepared in duplicate to support the Voucher Check, The original of the Voucher Payable was submitted to the Public Service Company of Colorado's Auditing Department with a reimbursement request and the copy was retained in Ebasco?s field accounting office. Purchasing - Ebasco New York Office The design engineer responsible for mechanical, electrical, architectural-structural or concrete-hydraulic features prepared specifications for the various items of equip ment required and requested the purchasing department to obtain quotations. Inquiries were sent only to approved representative firms manufacturing or supplying the designated item, with copies to Public Service Company of Colorado's Manager of Engineering, with full details. Upon receipt of bids, the originating engineer, in consulatation vrith the purchasing department, prepared a com parison of bids statement summarizing the various proposals. These statements were transmitted with one copy of each bid to Public Service Company of Colorado's Manager of Engineering, with com ments and recommendations for review and purchase instructions. The originating engineer, 'upon, receipt of purchase instructions, prepared a purchase requisition from which the purchasing department placed the order or contract. Nos, NY771801 through NY-771942 were used for these purchases and are listed elsewhere in this report. Supplements to these orders were issued when it was required to record changes in quantities, terms or conditions of the original order. Engineering inspection and expediting of shop pro duction on all New York orders and specific field orders were handled under the direction of the Chief Inspector of Ebasco, All traffic matters were discussed with the Public Service Company of Colorado's Purchasing Agent and Traffic Manager, Mr, R T Blanchard, through Mr, F F Beyers, Assistant Traffic Manager, including routing, claims, rates and classifications. Purchasing - Ebasco Field Office The purchase of materials, tools and equipment incidental WAD00706 to construction were handled through the field office by the field Purchasing Agent, as were some installation contracts. Purchase requisition (Form 226) was initiated by the supervisor responsible for its use, signed by the originator, routed to the Cost Engineer for coding to accounts and to the Resident Engineer and/or Construction Superintendent for approvals. These orders were numbered 3C-1 through 3C-137S inclusive. Orders (contracts) requiring job site labor are listed and detailed elsewhere in this report. Unit prices paid for various construction materials are listed elsewhere in this report. Field orders or contracts of major monetary importance were handled in a manner very similar to that descxxuca aoove for New York procedure. Field purchases of minor nature were, after approval by the Construction Superintendent or Resident Engineer, placed by the field Purchasing Agent prior to being processed for payment. Mr. R T Blanchard, Purchasing Agent of Public Service Company of Colorado, acted as consultant on local purchases and conferree on important purchases as to source of supply and placing of business. Mr. J R Birrell replaced Mr. Blanchard after his forced retirement. Accounting - General Standard Ebasco forms were used for all accounting purposes. Books of account used on this project were: General "odger, Form 100A and 100B; Check and Voucher Register, Form 101; Job Control Ledger, Form A-4; and Detail Cost Ledger, Form A-5a field office revision. Books were closed at the end of each calendar month and a Trial Balance, Form A-10 Rev., was prepared from the balances as reflected in the General Ledger. One copy of this report was submitted to the following Public Service Company of Colorado personnel: Mr. L R Patterson, Vice President; Mr L M Robertson, Manager of Engineering; Mr. A Brunkhardt, Property Accountant; and Mr. H Johnson, Auditor; three copies of this report were submitted to Mr. G P Redden, General Con struction Auditor of Ebasco Services, Incorporated, New York. An Estimate of Cash Requirements, Form 114, was pre pared as of the last Thursday of each month. One copy was sub mitted to Mr. L R Patterson, one copy to Mr. L M Robertson, one copy to Mr. H A Mitchel, Secretary and Assistant Treasurer; one copy to Mr. E E Matthews, Director General Accounting; one copy to Mr. A Brunkhardt, one copy to Mr. C Vaughn and two copies to Mr. Redden. Work orders were issued in numerical sequence covering the accumulation of costs of work performed and materials furnished for the account of contractors, vendors, etc. When New York orders were involved, a copy of the work order was sent to the Ebasco New York purchasing agent. Invoices were prepared and submitted to the vendor or contractor monthly. Mr. Brunkhardt and Mr. Johnson received copies of work orders. WAD00707 44 Accounting - General Account An initial Working Fund of $800.00 was on deposit in the Colorado National Bank of Denver in Denver, Colorado, when the books were opened. A subsequent increase to the working fund was made in the amount of $24,000 on June 7, I960; another in crease to the working fund was made on August 8, I960, in the amount of $25,000.00 and still another increase to the working fund was made on January 10, 1961, in the amount of $50,000.00, These deposits brought the general account to a total of $99,800.00. This account was disposed of by transferring $100,000.00 to Public Service Company of Colorado by Check No. 7494 dated September 25, 1962. Accounting - Payroll Account An initial fund of $200.00 was on deposit in the First National Bank of Denver, Denver, Colorado, when the books were opened. A subsequent deposit of $4,&00.00 was ma<ie on June 20, I960, by withdrawal of this amount from the general account. The payroll account was discontinued when the $5,000.00 was de posited in the general account by Payroll Check No. 6559 dated September 10, 1962. Accounting - Petty Cash Account >*A Petty Cash fund of $100.00 was established on May 6, I960, by withdrawing this amount from the general account. A subsequent increase of $400.00 was made on June 2, I960. This account was reimbursed from the general account by completion of Ebasco Form No. Ill, Petty Cash Reimbursement Request, and the issuance of a general account check made payable to R. J. Dawes, Petty Cash. This account was discontinued when the $500.00 was deposited in the General Account on September 24, 1962. Withdrawals from the General Account were made by Ebasco voucher checks, Form 107, which required any two of the following signatures: B A Snow, Construction Superintendent; G B Crane, Resident Engineer; R J Dawes, Construction Accouqtant; and E S Crockett, Construction Manager. Reimbursement of with drawals from the general account was made by voucher checks issued by the Public Service Company of Colorado upon presentation of Ebasco Reimbursement Requests, Form 109* Withdrawals from the payroll account were by Ebasco payroll checks, Form 159A Rev., requiring one of the aforesaid signatures. Reimbursement of withdrawals from the payroll account were made by issuing Ebasco General Account Voucher checks, supported by a voucher, Form 106, and one copy of the payroll check, Form 1590. Accounting - Contractors All field office contracts were let on either a Imp sum, unit price or cost plus basis. Ebasco Services, Incorpor ated, furnished field inspection and supervision to make certain WAD00708 45 ,that proper materials were used and first class workmanship was provided-. Materials furnished by contractors were received and reported on Material Received Report, (Form 210). Materials may or may not have been furnished by uhe contractor. Contractor's daily time sheets, Form 202 were prepared by the contractors' foremen for cost )lU contractors; check sheets, Form 1539 were made by the time checker The time checker made field checks at. Iviast twice a day on all contractors. Payment on lump sum contracts was made at periodic intervals after submission of an invoice by the contractor and approved by Ebasco engineers. Payment on unit price contracts was made monthly on a contractor's estimate , Form 502, which was prepared by the cost department, checked by the idem, engineer and construction ao c o untant, and approved by the construction superintendent, Each contractor submitted an invoice which agreed with the monthly contractor's estimate. Payments on cost plus contracts were usually made m Ife monthly after submission of an invoice by the contractor, with proper support of daily -approved time sheets and Material Re Wsi ceived Reports. Final payments to all contractors were made after quantity checks and determination of satisfactory workmanship. A form letter recommending approval of final payment, was sub mitted to Mr. L M Robertson, Manager of Engineering of Public Service Company of Colorado and to Mr. E S Crockett, Construction Manager of Ebasco Services, Incorporated. After approval by these two parties and by Ebasco's Resident Engineer, Construction Accountant, and Plant Betterment Engineer (when available), and Construction Superintendent, the final payment was made. Insurance coverage set forth below wt s required by ail ontractors and certificates of insurance were furnished E b a s e o services.2 Incorporated, by the contractor's insurance company i n 1 or m 25b: TYPE OF COVERAGE LIMITS '.jOi-,'KMEM ' S COMPENSATION AND EM= TLOiER'3 LIABILITY, including coverage under United States Longshoremen's and Harbor honkerAct where applicable PUBLIC LIABILITY PROPERTY DAMAGE including coverage for damage caused by blasting, collapse or struc tural injury, and/or damage to urxctcrground util.1,ties Statutory G 100 000 Each Person i) 100 000 Each Accident $ 300 000 Each Accident $ 200 000___ Aggregate WAD00709 46 TYPE OF COVERAGE--Contd. LIMITS-- Gout d. COI'iraACTOR'o PROTECTIVE PUBLIC liability 3 100 00c Each Person 3 300 000 Each Accident CONTRACTORS PROTECTIVE PROPER TY DAMAGE 3 100 000 Each accident 3. 200 000 Aggretate CONTRACTUAL PUBLIC LIABILITY in accordance with agreement(s) between owner and contractor 3 100 000 Each Person 3 300 000 Each Accident CONTRACTUAL PROPERTY DAMAGE in. accordance vrith agreement(s) between owner and contractor l LOO 000 Each Accident 0 200 000 Aggregate -Jj Li MOBILE PUBLIC LIABILITY3 covering all automobiles, tracks, tractors, trailers, motorcycles, or other auto mobile equipment whether earned or rented oy the con tractor, or owned by employees of the contractor j 100.000 Each Person 3 300 000 Each Accident AUTOMOBILE PROPERTY DAMAGE 3 50 000 Account! ng Payrolls Payrolls were prepared weekly and payment made by check. Payroll periods were from 12:01 a.n., Monday, through 12 mid night, Sunday, with payment being made to employees late the following Wednesday afternoon for field employees and on the following Monday for office employees. Field employees were checked in each morning by picking up their own numbered brass cheeks from time checker, the number corresponding with the celluloid numbered badge issued to each employee. Ebasco time checker made a morning check and an afternoon check on all employees on the job. A final check was made when each employee turned in his brass check before leaving the job site. Regular Ebasco forms were used by the timekeeping department, as follows: Employment Card, Form 150; Change of k.ite Notice, Form 151 and 151A; Notice of Discharge-Quittance, Form .152; Daily Check Sheet, Form 153; Foremanf s Daily Labor Report, Form 154A; Employee Time and Tax Record, Form 155A Rev.: Payroll check, Form 159A; Payroll check copy, Form 159B and 159 Payroll Computation, Form 166; and Distribution of Manhours, Fora l67o 0 Each foreman prepared and turned in daily time sheets for employees under his supervision x/hich were checked against t.he time checker fs dally check sheet. Time reports were sub mitted co the cost engineer for account classification coding and then given to the timekeeper for extending and posting .to WAD00710 47 the Time and Tax Record. Foremen's reports were then posted to Distribution of Manhours, Form 167 and these sheets were balanced weekly to the hours posted in the Employee Time and Tax Records. Form 167 was then totaled monthly, which in turn, was balanced to the monthly totals of the Employee Time and Tax Records. Foremen's reports were balanced dollarwise only to the Time and Tax records. Payroll Computation, Form 166, was then computed and 5he average rate, by craft, for Insurable Payroll and Gross Payroll was posted to Form 167 Form 167 was then extended and recapped by account. These sheets then became the basis for the monthly payroll distribution journal. The Foremen's reports, along with the check sheets, became a permanent part of the field copy, voucher payable. Distribution of Manhours, Form 167, became a permanent part of the field copy of the Payroll Distribution Journal. Distribution of Manhours, Form 167, was given a Workman's Compensation code and the Workman's Compensation, Public Liability and Property Damage Report, Form 253? was prepared from these forms. Payroll deductions were made from employees' earnings consisting of Federal Old Age Benefit Taxes, Federal Withholding Taxes, and State "Withholding Taxes. Amounts withheld from employees for Federal and State Income Taxes and Old Age Benefits, along with the employer's contribution for Old Age Benefits, Federal Unemployment and State Unemployment Taxes, were reported on Forms l6l, 162 and 163 and remitted to Ebasco New York office for transmittal to the proper governmental authorities. Insurance Insurance coverages are handled by both Public Service Company of Colorado and Ebasco and are completely detailed in the project Memorandum of Organization and Procedure dated December, I960. Preparation of reports for premium determination, preparation of accident reports and settlement of claims are also set forth in the aforementioned report. Insurance provided by Public Service Company of Colorado: 1. Builders Risk - Fire and Extended Coverage 2. Automotive Fire and Theft 3. Boiler and Unfired Pressure Vessels 4. Excess Transportation and Installation Ebasco will be named as an additional insured under such coverage. Insurance Coverages of Ebasco Services Incorporated: 1. Workmens Compensation - Employers Liability 2. Comprehensive Primary PL and PD (General) 3. Automobile - Primary Public Liability and Property Damage WAD00711 43 ii- -0. . - r wue .. . i twt PL and PD ,, E.,, . i fw J,. i . li i.n, Auto Mobiles) c0 Cxci11 c ' a . .. i. c . til 1. w t a 11 acion 7. Conylr ., l : ,..c Ev.i . Cat, Floater Coverage 8,, Fidelity 'c,[;a C..ver ire 9. PF otoy ... i T. i nee Xu,, Ueyctm-i v' r. , The fit. id office .' c .. <, 11 a. i i a wonthl y luturtnce Report (Form 28.3 j shot; in.1; a : rui . ;i 4 her payrol Is. The report was used as a oasis Lor fiat.:, n.ti >n of r.reaiums for Workmens Compensation, Prj.m-trg u i F.-,e. .-.a Pi J lie Liability and Property Damage intucanciu l' . -m.... i.;n a the original and five (5) copies to 9 1 . 'n, to Now Park, one (l) copy to H J John.non. Auditor hif ii. A-. r- r company of Colorado, and one (l) copy held in the lie! i ;tn . A..counting Files, The Transpor t-n i. n .,ud Installation Insurance Report is distributed as foil o.;.. : w.- iginal and one (l) copy to G P Rod.inn, Ebasco N;w Ye rl., one (1 ) copy to C Lazarus, Supervisor Insurance and Proper t y P-t. <y ,, tuc] it Service Company of Colorado, and one (1) copy rat., i nan i r. the field off ice Accounting Files. Field Copt rants Cental n fe 1.1 o i bll?jKyi 1.,,1 contract tors woi- hit. 1 sco fie id per- nne 1, i S u.r; l or unit pric o !)0 1 r' cos t plus a fee 'T ['U-C. pro f 11. f !.!,struction work were performed ;he direct ion and supervision of ,e .-out i act work was placed on a lump .tome work was performed on a direct a ho cover' expense, overhead and F'or m.ijo r con' i n New York prop r e d o!. i l i ( id rIi3 '' rn :1 j the cor; .v r iy-; ! 0 ' ... Kan ager of r-ubi i i w a i' i war o reooj V..d ' 1 ri i . 31. ; I ' !. 1 o tod and. trim-. . i L | T J. i'i it) lie Per'Vice 0 idT-Sly r o,; omrund .a 1 on -> 'i. L tie construction manager's office ;ucdcd proposals for the work to the . . 1 i fled bidders selected .di .... and approved hy the engineering g ..,.7 c f C;. 1 cundo,, After the bids i . /i.'ip.ni isi-n of Pid_> form was com- . .,,ntauCLXi.m ouperincendent to ,ta.h with a letter of comments and y i h ; cont t uc 10 a J Ot, t i ft r-r '] L 1 ' i ;. f :i n t e r. i. proposal wra.w Own t- L i i w r k where r\ 9` ; i ]9 l r C 5. ( , { . r c"> the Ida 1.1 off i ;.t n j'c:/ o sent to C i'i t: ! ']ai i ; v on O 3 thor of CWO ' , N ! i ft.rvice Company of Colorado, t.i trn- a u.c c o c>i.. 1 bidder and his a . , i ;.[i. engineer's office in New t ovmrk was prepared rind sent .[. : on aw l distribution. Regrets 1 T.bvi, El. f! coiltract was let id coal t .id f iritis : 1. mm F\,rn 'i. yr bona, '} f.i i . : \ (d) si a ; ( , A> C: .1' - -- 1 ; c d 3 ni'; udos (a) agyeement, (b ) i:.v:, (,) gen-rril conditions, and (o) drawings, ) 0 Si iprt -7 the it 1l 7\ n. d:u coir.tines all the features of . a..t, except tnat it is a proposal WAD00712 49 and acceptance type of contract. This type of con tract was used where the work to be performed was of a less complex nature or was of short duration. Distribution of both the long and short form contract was as follows: Executed Copies 2 - Contractor, whenever bond is required (otherwise one copy) 1 - Public Service Company of Colorado (Documentary File) 1 - Ebasco - Field Office (Accountant) Conformed Copies 1 - Public Service Company of Colorado's Engineering Manager 1 - Public Service Company of Colorado's -Chief Accountant 2 - Ebasco - New York Office 2 - Ebasco - Field Office A field purchase order was written as a ''cover order" for each field contract and was used mainly to assign a purchase order number to the contract. Any changes in the prices, quantities or terms and conditions of the contract were made by writing a supplement to the covering purchase order. Contracts or purchase orders for the minor phases of the construction were prepared, presented, approved, executed and distributed in the same general manner as the major contracts. The proposals and contracts were prepared by the field purchasing agent and the resident engineer. They did not embody all the contents of the contracts prepared by New York and were patterned along the lines of the Ebasco Short Form Contract. Administrative supervision and inspection of the work under these contracts were provided by Ebasco field office supervisors and engineers. A listing of the Local Contracts is indexed numerically and alphabetically preceeding the contract breakdown shown elsewhere in this report. The breakdown describes the work accomplished along with quantities, unit prices, amount paid and the accounts charged. Organization The contract between Public Service Company of Colorado and Ebasco Services Incorporated provided that Ebasco Services Incorporated furnish design engineering, equipment purchases, and construction services for a 150,000 kilowatt extension to the Cherokee Steam Electric Station. A ''Memorandum of Organization and Procedure" was issued to outline the Ebasco organization for construction and engineering services, the procedures and details of purchasing and subcontracting, the mechanics of dis bursement, and the various reports desired by the client. Ebasco provided the services of E S Crockett, Construction Manager, who WAD00713 50 exercised general supervision of the project, approved construction plans and methods, and maintained valuable contact between the client organization, the Ebasco general office, and the field office with periodic visits to the project, T 'J Mitchell acted as Assistant to the Construction Manager in the New York office. In the Ebasco general office, the Project Engineer was E Chao and the Chief Coordinator was J R Smith, assisted by E F Cain, Project Coordinator, Operating through the de al engineers office and assisting the Project Engineer were R .v Meyer, Mechanical Engineer, 11 3 Harvey, Principal Electrical Engineer, and A FBJahlrab, Principal Architectural-Structural Engineer. Following is a list of the supervisory and administrative personnel located at the Ebasco field office: B. A. Snow, ConstructSuperintendent G. B. Crane, Resident IM ;neer R. J. Dawes, Construction Accountant G. Faubion, Jr, General Construction Supervisor J. M. Brooks, Field Engineer O He Harlow, Construction Engineer Be W. Bates, Mechanical Supervisor J do Vain, Piping Supervisor G. R. Fickel, Electrical Supervisor B. He Cloud, Office Engineer C. Re Ke.uly, Cost Engineer y. j. Curry, Purchasing Agent R. Ge Roach, Assistant Accountant I. F. Carpenter, Jr,, Material Supervisor F. H. Covey,-General Labor Foreman Ae R. Collins, General Carpenter Foreman L, L, Bannister, General Reinforcing Foreman W e Fee, General Bricklayer Foreman Rc Bcaaeker, General Piping Foreman P. A a Callicrate, General Millwright Foreman Client company personnel with whom frequent contacts were maintained were as follows: W. D. Virtue, Executive Vice President and Treasurer VJA U Howell, Vice President Operations & Financial Department L R, Patterson, Vice President Electrical Operations L. id. Robertson, Manager of Engineering G. Co Farnsworth, Supervisor of Electrical Engineering C Lb. ''kow, Supervisor of Mechanical Engineering ^ Right, Supervisor of Structural Engineering H- J. Johnson, Auditor R T Blanchard. Purchasing Agent and Traffic Manager F. F. Beyers, Assistant T'raffic Manager A, Brunkhardt, Supervisor Property Accounting G. M Peterson, Property Accounting 51 At the jobsite, contracts were maintained at all times If with the operating department thru A P Vail , Superintendent_ of Production, A H Haberland, Superintendent of Denver Steam Plants hand L S Burt, Chief Engineer, Cherokee Plant. Construction problems involving design and/or proced ure were handled between New York engineering and/or Construction Superintendent and L M Robertson, manager of Engineering and his electrical, mechanical and structural department supervisors, namely, G C Earnsworth, C V/asellcow and Ii Right respectively. The contractors supervisory personnel on the principal construction and erection contracts were as follows; Allis-Chalmers = Boiler Feed Pumps La FT Dickinson, Erector D. Williams, Service Engineer bar jcc >ek and Wilcox Company = Steam Generator A. L. Swinney, District Manager Accessories Vo Flower, District Service Engineer F'. Krikawa, Service Engineer F. Golty, Service Engineer W. E. Fowler, District Erector i/1 o P. Way, District Erector V/. ii. Davis, Erection Superintendent c n. Pennington, Erection Superintendent (temporary) Huber, Erection SuperL.be; adent Fa L. iieLamb, Erection Superintendent J. Kopernik, Structural Steel Superintendent P. Shukis, ('*A*ir "Pre'heater "Corrxpr), Service Enin neer G. Asbell (Air IF . t< f er Corp) District G. Floyer, (Air Preheater Corp) District Erector BY R o Markwood, Diamond Power Co), Service Engineer Roberts,'(Insulation Specialties Inc), Foreman - Ins Grolbert, (Jamar-Olmdn), Foreman ~ Sheet Metal Lagging Batchell, (Jamar-Olmen), Foreman Sheet Metal Lagging LaPorte (Sturtevant Fan Div), Service Engineer Bailey Meter Company - Combustion Controls A. I. Daniel sen, Regional Manager F. Horney, Service Engineer D. Hillson, Service EngineerDo Visser, Service Engineer Bedford Division Yuba Consolidated Go I. 1dig hart, Service Engineer Gantry Crane Black, Sivails and Bryson - Control Valves J. Young, Service Engineer Corrugated Asbestos Contractors - Station Building Siding M. Booker, Foreman 52 General Electric Company - Turbine Generator C, Ho McCabe, District Manager T,, Cowgill, District Manager (Jan, 1962) R< F Suits, Erector Go Tomlin, Erector (temporary) C,, W. Babcock, Service Engineer Do Seamons, Service Engineer Ro Hopps, Service Engineer Eo Showalter, Service Engineer A0 Anderson, Service Engineer Ingersol Rand - Soot Blowing Air Compressors Go Ho Stone, Service Engineer Po Wo Weber, Service Engineer Insulation Services Incorporated - Piping & Equip Insulation C. Eo Bennett, General Foreman Ro Ho Grace, Foreman, Insulation W,, Seaton, Foreman, Sheet Metal Marley Company = Circulating Water Cooling Tower Ao Jo Ott, General Foreman Midwest Piping Company ~ Piping Fabrication (2-l/2n & over) Jo DiDonato (Bergen Pipe Support), Service Engineer D,, McClure, (Bergen Pipe Support), Service Engineer Wo Ho^Nichols and Company - Railroad Track Laying Co Bo Mayo, Superintendent Riley Stoker Corporation - Coal Pulverizer Mills Wo Co Pierce, Erector Jo Izbicki, Service Engineer Jo M,, Moore, Service Engineer Rust Engineering Company - Chimney Lo Anderson, District Superintendent D,, Smith, Foreman, Concrete JL, Toston, Foreman, Brick Sam Fox Sheet Metal - Metal Flashing D,, Roberts, Foreman Schriber Decorating Company = General Painting Jo Blair, Field Foreman B F Shaw Company ~ Install Piping (2-1/2M & over) Ko E,, Clayton, General Superintendent Lo Lo Barnes, Field Superintendent Slattery and Company - Plumbing and Heating, Ventilating and Air Conditioning Ro Wo Peterson, Contract Manager A,, Vessa, Plumbing Foreman Ro Witherspoon, Foreman, Heating and Ventilating Ro Hobbs, Foreman, Insulation WAD00716 53 Stormberg Carlson ~ Intrasite Communication Jc Mo Zachary, Service Engineer Sturgeon Electric Company ~ Electrical Installation R,, Johnson, President Go Ranzenberger, General Superintendent C0 Gill, Superintendent United Conveyor Corporation - Ash Handling System K,, Ro Phfol, Service Engineer Do Harper, Service Engineer Yuba Heat Transfer Division - Condenser T. Wo McHale, Erector Wo Meriwether, Service Engineer Job Summary A job summary for this project was issued in June, 1962, and contained the following informations Contents Construction Photographs I - Project Outline II= List ofMajor Material and Equipment III = List of Ebasco Orders IT - List of Ebasco Specifications V - List of Ebasco Design Drawings VI Reproduction ofGeneral Drawings 2 pages 2 pages 19 pages 20 pages 5 pages 3 pages 12 pages -;,-3 pages The project outline of the Job Summary (Section I) is a condensation of the original project outline and that section is being entirely incorporated in, and as a part of, this final re port. It^will immediately follow the descriptive paragraph of the -'Project- Outline" in this ''General History", section,, Project Outline A project outline was issued in September, 195s as a result of the preliminary design engineering and conferences between the Public Service Company of Colorado and Ebasco engineers0 After review and approval by Public Service, the engineering design was finalized. As noted above in the Job Summary, a brief review of the project outline was included in it and even though most of the information is detailed throughout the Specific History section of this report, this condensation will be helpful for quick reference,, The extra sheets printed for the summary are renumbered to agree with the consecutive page numbering of this final report. WAD00717 PUBLIC SERVICE COMPANY OF COLORADO CHEROKEE STEAM ELECTRIC STATION 1962 - 150,000 KW EXTENSION - UNIT NO. 3 54 I - PROJECT OUTLINE INTRODUCTION This outline covers the installation of a third unit to the Cherokee Steam Electric Station of the Public Service Company of Colorado. Ebasco Services Incorporated was retained to perform the engineering, prepare plans, specifica tions and bills of material, purchase equipment and material, including expediting and inspection, supervise construction and to perform initial operating functions preparatory to placing Unit No. 3 into commercial operation. GENERAL The extension consists of one General Electric 150 mw turbine, operating at 1800 psig throttle pressure and 1000 F with reheat to 1000 F, directly connected to a liquid^ cooled generator rated at 182,305 kva at 0.85 power factor and 30 psig hydrogen pressure with a capacity of 200,535 kva at the same power factor, but at 45 psig hydrogen. The steam generator is of Babcock & Wilcox design and is rated at 1,140,000 lb/hr at 1925 psig and 1005 F at the superheater outlet. The boiler unit is de signed to operate with either pulverized coal or natural gas firing. Complete with the steam generator are all structures and auxiliaries; such as, forced, induced and recirculating fans, regenerative air heaters, mechanical dust collectors, etc. Major plant auxiliaries are a surface condenser, cooling tower, boiler feed pumps, extraction heaters, deaerator, main and auxiliary electrical apparatus, and 115 kv step-up substation. The coal handling and water supply systems installed for the previous units were extended. Additional ash handling and chemical treatment facilities were provided. IMPROVEMENTS TO SITE Clearing and Grading Very little grading was necessary in the area of Unit No. 3, but some fill was required for cooling tower basin, coal storage, trackage, ash settling ponds and all access road relocation. Drainage was extended from the existing services. WAD00718 PROJECT OUTLINE (Continued) JcaQx. 55 Subsurface Conditions Since Arapahoe shales were encountered at shallow depths, it was possible to support heavy equipment and structural loads,, such as turbine and boiler mats, on spread footings from the shales. Ash Settling Ponds Two ash settling ponds were located north of Unit No. 3 to facilitate ash re covery. Railroad Track The existing plant access and siding trackage was suitable to service the new unit except for extension of points for transformer servicing. Rail sidings for coal car storage were extended by adding tracks 4, 5 and 6. Roads The north one-half of the loop road around the plant was relocated further north and beyond Unit No. 3 so as to be clear of construction. An access road was provided to service the main cooling tower No. 3 and the new ash settling ponds. Yard Lighting Lighting was added in the yard to augment that now existing and to include those facilities added with Unit No. 3; these involve the unit itself, the general yard similar to Units No. 1 and No. 2, the main cooling tower, switchyard extension and service cooling tower extension. Provision for aircraft warning lighting (inserts only) was made on the stack, similar to Unit No. 1 arrangement. Yard Sanitary System and Storm Sewers No changes were required in the yard sanitary system. The existing storm sewer system in the yard was extended to include catch basins required with the new unit. Unit No. 3 circulating water tunnels can be drained into the yard drain age system. SERVICE WATER SYSTEM Water Supply Water is obtained from three services: South Platte River, delivered through the Farmers' and Gardeners' Ditch, shallow wells and deep wells. Farmers' and Gardeners' Ditch water is delivered to two settling ponds on the site. WAD00719 PROJECT OUTLINE (Continued) ixk 56 River Water This source supplies water for main cooling tower make-up, indirectly for ash water through the main cooling tower blowdown, water treatment transport water and ijidirectly^for fire service. Shallow Wells Shallow wells provide a backup to the river water system. It was not con sidered necessary to install any additional shallow wells. Deep Wells Deep well water is utilized for boiler feedwater make-up, the potable and sanitary water supply and the service water cooling tower. The existing system is adequate for Unit No. 3, but extension of the plant piping in order to incorporate service for the Unit No. 3 control room washroom and various drinking fountains was required. SERVICE WATER COOLING TOWER The requirements for Unit No. 3 can be handled (except under maximum conditions) by two of the three existing cells, leaving the third cell as a spare. SERVICE WATER PUMPS Two additional 1600 gpm pumps were furnished by C H Wheeler Manufacturing Co, thus providing an over-all reserve of 2705 gpm for three units, or one spare pump with 1105 gpm reserve. SERVICE WATER RETURN PUMPS A separate service water return tank was located in the basement of Unit No. 3 to accommodate two 2000 gpm vertical Worthington pumps for Unit No. 3 and one addi tional future 2000 gpm pump for Unit No. 4. FIRE PROTECTION Unit No. 3 required four hydrants and was provided with 12 hose racks in ad dition to the fire protection similar to that provided for Units No. 1 and No. 2. PROJECT OUTLINE (Continued) 57 CIRCULATING WATER SYSTEM The circulating water system is a divorced closed circuit. It is similar to the arrangement utilized for Units No. 1 and No. 2; however, a separate ash handl ing system was installed for Unit No. 3, with extension provisions for Unit No. 4. MAIN COOLING TOWER MAKE-UP Make-up for cooling tower losses due to blowdown, evaporation and windage is obtained from the Farmers' and Gardeners' Ditch via pond discharge pumps as was done for Units No. 1 and No. 2. MAIN COOLING TOWER This tower has nine cells and is designed to handle 95,000 gpm circulating water with a 20 degree approach to a 60 F wet bulb and a cooling range of 15.1 F with 95.1 F water entering the tower. The tower is constructed of Marlith treated Douglas fir. STATION BUILDINGS The extension to the station building is of the same general design as the initial construction and the same type of building materials were used. The turbine room, auxiliary bay, pulverizers, hopper bottom of silos and all heaters are located indoors. The boiler with enclosed firing aisle and drum ends, ash hopper area, forced draft and gas recirculation fans, deaerator, separate section to silos and coal trippers are located outdoors. The locker area and office facilities provided with Unit No. 1 (65 two-compartment units) are considered adequate for Units No..l, No. 2 and No. 3. STRUCTURE The turbine mat is 7 feet thick with top elevation at 5125 feet. The sand fill is 4.5 feet in depth and finished floor 6 inches. Additional borings were taken to verify the design based upon the subsoil conditions which were similar to those for Units No. 1 and No. 2. A maximum allowable bearing capacity for combined dead, live and wind loads of 10 tons per square foot was used. STRUCTURAL STEEL The structural steel design is similar to Units No. 1 and No. 2, except that high strength field bolting for load carrying structures and common bolts with lock nuts for miscellaneous steel were used. WAD00721 PROJECT OUTLINE (Continued) >C 5^ PLUMBING A drainage system for the roofs, floors and equipment drains was installed with connections to the existing facilities. The lower floors drain to the sump pit and all drainage is routed toward the Platte River. Drinking water coolers are provided as required by this extension. The main condenser is drained directly to the sewer system. Consideration is given to directing all floor drains to the yard drainage system, thus eliminating the turbine and/or drainage sumps. LIGHTING r,i Instantaneous start fluorescent fixtures are used where practical and eco nomical; however, incandescent lighting is also installed, similar to that furnished with Units No. 1 and No. 2. FUEL AND ASH SYSTEMS Coal Handling The installation of Unit No. 3 introduces the handling of Routt County bituminous coal in conjunction with lignite that was used for Units No. 1 and No. 2. The necessity of transferring from one type of coal to the other for silo storage tends to increase the time of handling more than indicated. At 100 percent load factor with three units, the 600 tph single belt system must be operated 9.0 hours per day, 6 days per week. Extension of the existing system was not necessary except for the lengthening of tripper conveyor belts 5A and 5B to service new coal silos. Coal Silos Four 24 ft 0D silos are of unlined steel plates and are duplicates of Units No. 1 and No. 2 design, which provided 28 net effective hours storage at 100 per cent load factor and 33 net hours at 85 percent load factor. Ash Handling The Unit No. 3 system is furnished by United Conveyor Corporation and is a separate pneumatic hydraulic system designed to service Units No. 3 and No. 4. The bottom ash is collected in a 42 hour storage, double outlet, impounded gravity feed type hopper. The outlets are furnished with the necessary sluice WAD00722 PROJECT OUTLINE (Continued) gates, crushers and 60 ton/hr hydraulic jet pumps and are designed to be operated sequentially. The fly ash and dust is removed from the various hoppers by a 25 ton/hr automatic sequentially controlled pneumatic system, using two hydraulic i ejectors in series and air separator tank. All ash is conveyed in the same ash line to two 92' x 556' ash settling ponds located between the railroad tracks north of the plant. Pyrites removal from the pulverizers is accomplished using a cen trally located hopper into which material can be dumped from wheelbarrows and con veyed hydraulically to the boiler ash hopper. Water for conveying the ash is stored in a 235,000 gal. tank supplied by the circulating water blowdown system from Units No. 1, No. 2 and No. 3. Two C H Wheeler Manufacturing Co Eiconomy 1600 gpm, 315 ft TDH, horizontally split double volute pumps, located inside the plant east of the bottom hoppers, take suction from this tank and supply water to the jet pumps and ejectors. An ash sump pit was constructed in the ash hopper pit for collecting the overflow from the ash bottom hopper, the air sepa rator and the runback of the water remaining in the main ash pipeline when the ash handling system is shut off. Two Allen-Sherman-Hoff 250 gpm, 90 ft TDH rubber lined vertical Hydroseal pumps are installed in this sump to pump the ash water to the ash settling ponds. GAS FACILITIES Gas facilities beyond the regulating station are provided at 50 psig, based upon a natural gas analysis similar to Units No. 1 and No. 2. The gas orifices were designed by PSCC using standard conditions of 12.4 psia, 60 F, specific gravity 0.67. Gas is used for lighting off and warm-up on pulverized coal firing. Only four of the total 16 main gas burners were installed on the steam generator; however, all gas valves and pipelines in the plant are sized to handle the full 16 gas burners in the future. The full load gas requirement (all 16 burners) is 26,950 cfm at an output of 1,140,000 lb/hr steam. The main gas control valve and bypass minimum stop valve have reduced inner valves which will be changed when all 16 burners are installed. STEAM GENERATOR The steam generator is a Babcock & Wilcox Company balanced draft radiant furnace pulverized coal-gas burning generating unit, with a maximum continuous WADQ0723 I M PROJECT OUTLINE (Continued) not 60 capacity of 1,140,000 lb/hr at 1925 psig, 1000 F and to reheat 932,100 lb/hr at 450 psig, 1000 F when supplied with feedwater at 515.6 F and when firing pulver ized bituminous coal at the rate of 67.4 tons/hr or natural gas at the rate of 26,950 cfm, inlet air temperature 80 F. Routt County fuel is considered as the design fuel. However, it is estimated that this unit will reach an expected capacity of 1,140,000 lb/hr when fired with 160,000 lb/hr of sub-bituminous coal (lignite), similar to that now being fired on Units No. 1 and No. 2. The unit is semi-outdoor type with enclosures around the ash hopper area up to the operating floor level, a fire aisle enclosure included to the top of the burners, and drum end enclosures. The steam generator includes FD, ID and gas recirculation fans, ducts, flues to the burners, mechanical dust collectors, regenerative air hoppers, and all usual accessories. Space was reserved for a future electrostatic dust collector on the inlet side of the ID fans. Refer to boiler air and gas flow diagrams on Pages 8a and 8b. Steam coils are provided for air heater protection, using steam from turbine extraction or pressure reduced saturated steam from the boiler drum. PULVERIZERS Pulverizers are Riley Stoker Corporation No. 556 duplex drum type coal breaker and pulverizing units, each capable of handling 37,000 lb/hr. BURNERS ': Coal burners are Babcock & Wilcox circular type PL. Four of the total 16 are furnished with ring type multi-stud gas burners. These burners differ from those on Units No. 1 and No. 2 in that each burner is provided with secondary air registers and a retracting impeller firing horizontally and producing a circular conical shaped flame. All burner and coal valve operations are manually controlled from the corresponding operating floor. FD AND ID FANS* 2 The forced draft fans are Sturtevant No. 4066D air foil, double width, double inlet, air cooled bearings (no blower required), no inlet boxes, inlet screens in cluding inlet vane and outlet damper with control. Two fans were furnished, each capable of handling 795,000 lb of air/hr at 11.4 in S.P., 80 F air temperature and 22 880 rpm, producing 490 bhp (WR 7040 lb-ft ) under test block conditions at ele vation 5130 ft. This represents a margin of 15 percent on volume and 32 percent WAD00724 PROJECT OUTLINE (Continued) 61 on head over maximum continuous output requirements at 1,140,000 lb of steam/hr. Performance of the forced draft fans is as follows: FORCED DRAFT FANS Performance at 5130 Ft Elevation - Pulverized Coal Total Steam Flow, lb/hr Air Flow, lb/hr/fan S.P., in H20 Temperature, F Rpm Bhp/fan 450,000 3.40 80 880 700,000 3.95 80 880 1,140,000 692,000 8.65 80 880 348 Test Block 795,000 11.4 80 880 490 The induced draft fans are also by Sturtevant and are No. 1011TV ID type, double width, double inlet air cooled bearings, inlet boxes, wheel blade liners and inlet vane and outlet damper with control. Two were furnished, each capable of handling 900,000 lb gas/hr at 13.7 in.S,P,,272 F gas temperature and 705 rpm, requiring 1043 bhp (WR^ 51,500 lb-ft^) under test block conditions at elevation 5130 ft. This represents a margin of 15 percent on volume and 33 percent on head over maximum continuous output requirements at 1,140,000 lb of steam/hr. The head margin includes resistance through a future electrostatic dust collector which will be located on the inlet side of the fans. Manually operated soot blow ers are provided for each fan. Performance of the induced draft fans is as fol lows : INDUCED DRAFT FANS Performance at 5130 Ft Elevation - Pulverized Coal Total Steam Flow, lb/hr Gas Flow, lb/hr/fan S.P., in H20 Temperature, F Rpm Bhp/fan 450,000 240 700,000 253 1,140,000 782,500 10.38 272 705 720 Test Block 900,000 13.7 272 705 1,043 BOILER GAS DUCT CIRCUITS 62 s WAD00726 CHEROKEE NO. 3 - BOILER AIR CIRCUIT 63 TO GAS RECIRCULATING FAN-SEAL AIR mm. WAD00727 PROJECT OUTLINE (Continued) 64 TURBINE GENERATOR The turbine is a General Electric double flow tandem compound bottom exhaust condensing turbine, with eight extraction stages and rated at 150 mw, 3600 rpm, 1800 psig, 1000 F/1000 F reheat, 3-1/2 in. mercury back pressure, 3 percent make up, and a guaranteed throttle flow of 1,085,000 lb/hr. It is equipped with all usual accessories, including oil system and supervisory instruments. Turbine start-up is by full arc admission. The generator is liquid cooled and rated at 182,305 kva at 30 psig hydrogen, 0.85 power factor, 3 phase, 20,000 volt, 60 cycle, 0.64 short-circuit ratio. At 45 psig hydrogen the capability is 200,535 kva. CONDENSER The 55,000 sq ft, single pass, single shell, vertically divided water box condenser with 29'-9-l/4" x 7/8" diameter tubes is supplied by Yuba Heat Transfer Division. Three can type condensate pumps, two circulating water pumps, along with steam jet air ejector and hogging ejector were furnished by Yuba as part of the condenser order. The condenser is provided with 48 in. circulating water connections with horizontal inlets on the bottom side and horizontal outlets on the top side of the water box, and is supported from the floor. A rubber "dog bone" expansion is located in the neck between the turbine and the condenser. The low-pressure heater is mounted in the condenser neckpiece. FEEDWATER HEATERS There are seven closed feedwater heaters and one deaerator in the feed heating cycle. The four high-pressure heaters (4th, 7th, 10th and 12th stages) are hori zontally mounted and contain desuperheating condenser and subcooling sections. The three low-pressure heaters (16th, 17th and 18th stages) are horizontally mounted, the first two having removable shell sections and, in general, are sim ilar to the high-pressure heaters. The third low-pressure heater, however, is mounted in the neck of the condenser. DEAERATOR The deaerator is furnished by the Graver Water Conditioning Company and is a horizontal shell, internal direct contact vent condensing type. A 172,300 lb WADG0728 PROJECT OUTLINE (Continued) 65 storage tank is provided. The deaerator is guaranteed to produce 1,200,000 lb/hr boiler feedwater, with no more than 0.005 cc dissolved oxygen. BOILER FEED PUMPS Three Allis-Chalmers multi-stage barrel type boiler feed pumps are provided. The automatic recirculation equipment was purchased with the feedwater regulating equipment from the Bailey Meter Company. FEEDWATER REGULATION The feedwater to the boiler is controlled by a Bailey three element feedwater control system. The feedwater regulating valve is located between the boiler feed pumps and the high-pressure heaters. COMBUSTION CONTROL The combustion control is a Bailey pneumatic system with a range of 8:1. INSTRUMENTATION Most of the instrumentation is provided by panels located at various appro priate locations throughout the plant which feed signals to the control room via the relay rack. The unit interlock functions are shown on the accompanying block diagram, Ebasco Drawing No. G-159613. WATER TREATMENT PLANT Water treatment is concerned with chlorination of circulating and domestic water, boiler make-up treatment, cooling tower polyphosphate and acid feed and "shot" treatment of boiler feedwater by phosphate, morpholine, etc. Domestic water is served by No. 2 Deepwell at 10 gph and 300 ft TDH through a hypochlorinator to an elevated 1,000 gallon storage tank. The pump fills the tank at a fixed rate through the chlorinator until full, then is out of service until the tank is nearly empty again. BOILER WATER MAKE-UP Evaporators are furnished to provide boiler water make-up. The evaporators receive pretreated well water through sodium zeolite units. Each evaporator is a single effect, horizontal "U" tube type design, including a separate vertical WAD00729 Op4 PROJECT OUTLINE (Continued) 66 .tray type internal vent condensing preheater and is rated at 25,500 lb/hr net vapor capacity. The vapor is directed to the deaerator, while the coil drains are directed to the main condenser. Continuous blowdown from each boiler is I directed to the evaporator and the heat is used to supplement the extraction steam. Shell blowdown is sent through a flash pipe and drains to waste. CHLORINATION The service water tower chlorinator was adequate for Unit No. 3 requirements and no changes were made. The main tower chlorinator was also adequate based upon intermittent programmed treatment. The only additional material required was rub ber lined pipe and. valves between Unit No. 3 tower and the chlorinator. ACID FEED Acid treatment for the cooling towers is provided by Milton Roy vertical mersemetic pumps mounted in two 1600 gallon sulphuric acid storage tanks located outdoors north of the water treatment building. Two pumps were installed in Tank No. 2 for Unit No. 3 cooling tower with space for one more pump to service Unit No. 4 cooling tower. This arrangement simulates that for Units No. 1 and No. 2 by providing one pump per two units available as a spare. POLYPHOSPHATE FEED Polyphosphate feed is located in the water treatment building and consists of one pump for each cooling tower including the service water cooling tower. Each pump is supplied from a common storage tank. PHOSPHATE AND SULFITE FEED Chemical feed treatment of the feedwater is provided by the phosphate and sulfite pumps from separate storage tanks. The phosphate and sulfite systems for Unit No. 3 are similar to Units No. 1 and No. 2 and include two phosphate and two sulfite pumps (one spare in each case) with tanks and provision for two additional pumps to be installed for Unit No. 4. MORPHOLINE FEED A separate solution tank and pump were provided and the morpholine is pumped to a point in the boiler feed discharge near the point of sulfite injection. The spare sulfite pump serves as a spare for the morpholine feed system. WAD00730 PROJECT OUTLINE (Continued) XBBL2 67 HEATING, VENTILATING AND AIR CONDITIONING VENTILATION Main plant ventilation air supply for Unit No. 3 is supplied by means of a central fan-washer system located in the fan room at the mezzanine floor elevation in which fresh filtered and evaporatively cooled supply air is prepared using a capillary washer and centrifugal fan with attendant duct work for air distribution. The system is designed to maintain an average indoor plant temperature of 105 F in the summer with outdoor ambient air conditions of 95 F DB - 64 F WB. During the winter 100 percent plant air is recirculated to maintain 70 F at minus 20 F out doors when the boiler is in service and 45 F when the boiler is out of service. The duct work distributes the supply air to areas throughout the basement, mez zanine, turbine room, switchgear enclosure and firing aisle. HEATING In the interest of simplification and economy the induction of fresh air at temperatures below 40 F outdoors is eliminated during the winter season, depending entirely upon the fresh outdoor air that is usually induced through the closed intake dampers by the induction of the main supply fan (S-5) which assumes approx imately 10 percent of the total supply air quantity, in this instance 12,000 cfm, and the additional fresh air that enters the plant due to infiltration through building enclosure cracks, crevices, the opening and closing of doors, etc. This arrangement eliminates the need for heating coils, automatic steam supply valves, controls, wiring, etc., for the heating of the outdoor air usually introduced through minimum dampers during the winter as employed in Units No. 1 and No. 2. Steam is provided for plant space heating in the existing Units No. 1 and No. 2. Unit No. 3 employs a heating medium of 250 F to 293 F hot water emanating primarily from the station deaerator when plant is operating between 50 to 100 percent capacity. This high temperature water is circulated through a piping system employing hot water unit heaters, thermostatically controlled, which, should the plant equipment heat gain prove insufficient supplies the supplementary heat to maintain 70 F, and 45 F indoors with -20 F outdoors when plant is out of service. WAD00731 XKtS if 68 PROJECT OUTLINE (Continued) An outdoor bulb thermostat will actuate the plant high temperature water heat ing system circulating pump at 40 F outdoors and simultaneously close the fresh air intake dampers and open the recirculating dampers in the main fan room. In the event of a unit scheduled maintenance shutdown or an emergency outage the space heating medium piping interconnection with an adjoining unit is employed and this water returned to the deaerator of the unit supplying it. Elevation Machinery Room An electric unit heater 15 kw is provided to maintain 50 F in the elevator machinery room at minus 20 F outdoors, thermostatically controlled. Snow Melting Provision in the form of pipe coils embedded in the concrete deck over the coal bunkers has been provided should the need for snow melting become necessary. If they are employed a 50/50 solution of water and ethylene glycol shall be cir culated. Heat Transfer Fan The function of transfer fan TF-1 is to liberate 20,000 cfm of the high tem perature air experienced under the practically over-all floor at elevation 5155.0 ft emanating from the coal mills, their motors, etc., and delivering it to the upper areas of the turbine room there to be exhausted by the roof ventilators. AIR CONDITIONING - CONTROL ROOM Air-conditioning service designed to maintain 78 F DB and 50 percent relative humidity at 95 F DB - 64 F WB outdoors for the control rooms for Units No. 3 and No. 4 will be provided by a 20 ton self-contained air-conditioning mechanical re frigeration unit with a water (70 F) cooled condenser, equipped with a high tem perature water heating coil. COAL BUNKER VENTILATION The coal bunkers shall be exhausted by a "Rotoclone" combination exhaust fan and dynamic coal dust separator. WAD00732 xrcss PROJECT OUTLINE (Continued) 69 EXHAUST VENTILATION Exhaust ventilation for the main plant will be supplied by means of thermo statically controlled powered roof ventilators over the turbine room, heater area, boiler firing aisle, and the steam drum enclosures. The control room kitchen and toilet room will be exhausted by individual ceiling type ventilating fans. A vane-axial fan, duct connected, exhausts the stop valve area, propeller type wall fans exhaust the turbine oil tank and elevator machinery enclosures. Additional exhaust ventilation is effected by the boiler feed pump motor exhaust duct system which discharges into the forced draft fan enclosure. ACCESSORY ELECTRICAL EQUIPMENT MAIN SWIlCHING, CONTROL AND .PROTECTIVE'EQUIPMENT The generator is equipped with a gear driven main exciter, main field circuit breaker with discharge resistor, motor operated main exciter field rheostat and Amplidyne voltage regulating equipment. Bushing type current transformers are provided on the generator main and neutral terminals, for relaying and metering. The generator neutral is grounded through a 20,000 - 120/240 volt distribution transformer (askarel filled) without a disconnecting device. A resistor and ground relay for tripping the unit are connected across the 240 volt winding. The ground ing transformer and resistor are enclosed in steel switchgear type cubicles fur nished by the turbine-generator manufacturer. The indoor portion of the main leads from the generator runs beneath and to the edge of the turbine-generator pedestal and then continues overhead to the building wall. These leads are of isolated phase construction and have a rating of 6500 amperes. Two sets of non-drawout type potential transformers and fused disconnects are furnished in an indoor cubicle, connected to the main leads and mounted below the leads on the ground floor. The outdoor portion of the generator leads is exposed and will consist of welded bare aluminum pipe with socket type connections at most of the welded joints, to minimize cutting and grinding of pipe in the field. The outdoor leads connect to the low voltage terminals of the three-phase main power transformer. The generator neutral grounding transformer and resistor are located beneath the generator, at the mezzanine level. The generator field and voltage regulating WAD00733 xkxx PROJECT OUTLINE (Continued) 70 equipment are located at the north end of the generator pedestal at mezzanine level Generator surge protection equipment is located outdoors, beneath the generator main leads and next to the building wall. The generator and its auxiliaries are controlled from a consolidated boilerturbine-generator control board (BTG Board) located in the Unit No. 3-4 control room. A BTG auxiliary board is mounted adjacent to and north of Unit No. 3 BTG Board. In the future, Unit No. 4 BTG Board will be located adjacent to the north end of the auxiliary board. The auxiliary board provides additional space for control switches, instruments, recorders, etc., for which there is insufficient room on the BTG Boards. A cable room beneath the control room contains cable trays for flexible routing of control cables, and also provides space for miscellaneous auxiliary equipment, particularly pilot wire termination facilities and purge protection control equipment. AUXILIARY. ELECTRICAL EQUIPMENT One - Type OA/FA, three-phase, 12,000/16,000 kva, 19,000 - 4160 volt, unit auxiliary transformer, for supplying the 4160 volt unit switchgear, is connected to the outdoor generator main leads through a 1200 ampere manual gang operated disconnecting switch. Fans were added to existing unit auxiliary transformers No. 1 and No. 2, so that either of these can be used for stand-by duty, in case the Stand-By-Start-Up Transformer is out of service. Fans were also added to the existing Stand-By-Start-Up Transformer, making its rating 12,000/16,000 kva OA/FA. The control voltage for the majority of the control circuits, including the 4160 volt switchgear, is 125 volts d-c. A new station battery is provided with Unit No. 3, with a tie between the new station battery and the existing Unit No. 1-2 station battery, for stand-by purposes. The control voltage for the 480 volt a-c motor control center equipment is 120 volts a-c, except for certain vital auxiliaries, such as condensate pumps, pulverizer mill feeders and motor driven control air compressor, all of which have 125 volt d-c control. AUXILIARY SWITCHING, CONTROL AND PROTECTIVE EQUIPMENT The unit auxiliary transformer supplies a double bus 4160 volt unit switchgear. The switchgear supplies the larger auxiliary motors directly and the WAD00734 ixMx PROJECT OUTLINE (Continued) 71 480 volt switchgear and motor control centers for the smaller unit auxiliaries through 4160-480 volt, three-phase transformers. The 4160 volt switchgear is located outdoors, near the unit auxiliary transformer. The 480 volt draw-out switchgear is located near the north end of the turbine-generator pedestal, in the indoor switchgear room on the ground floor level. An interconnection between the Unit No. 3 and Common 4160 volt systems is provided. Automatic throw-over from Unit No. 3 auxiliary transformer to the stand-by bus is provided for the condition of a fault resulting in operation of the generator lockout relay. Provision is made for the extension of this bus tie system to all future unit 4160 volt auxiliary systems. The 4160 volt switchgear is outdoor, heavy-duty, metal-clad type, in a double bus arrangement., with electrically operated air circuit breakers, 1200 amperes continuous rating and 250 mva interrupting capacity. The switchgear is complete with controls, indicating instruments, relays, instrument transformers and accessories as required. The switchgear is connected to the unit auxiliary transformer by means of metal enclosed bus. Control of all 4160 volt unit switchgear breakers is from Unit No. 3 BTG Board in the control room. The unit 480 volt equipment is fed from Unit No. 3, 4160 volt switchgear and serves the 480 volt auxiliaries associated with Unit No. 3. The station service transformers are rated at 750 kva, the cooling tower transformer 1000/1150 kva, and the service cooling water and pond discharge transformer 300 kva. The equipment consists of the following: (a) Two indoor 4160 - 480 volt step-down power transformers, 750 kva, Inerteen filled, each throat connected to a sep arate indoor draw-out type switchgear assemblage, contain ing electrically operated air circuit breakers. The air circuit breakers feed five 480 volt indoor motor control centers serving Unit No. 3 auxiliaries within the power plant area. (b) One outdoor 4160 - 480 volt step-down transformer, 1000/1150 kva, oil filled, throat connected to an outdoor WAD00735 ikbo&c PROJECT OUTLINE (Continued) 72 switchgear and motor control center section- serving Unit No. 3 main cooling tower fans. (c) One outdoor 4160 - 480 volt step-down transformer, 300 kva, oil filled, connected by cable to an outdoor motor control center section, serving the following: Shallow Well Pump No. 4 Service Water Cooling Tower Fan No. Deep Well Pump No. 4 Service Cooling Water Pump No. 5 Pond Discharge Punp No. 4 3 The existing common 480 volt system, which is fed from the common 4160 volt switchgear, is extended to include the following additional equipment: (a) One indoor 4160 - 480 volt step-down power transformer, 750 kva, Inerteen filled, throat connected to an indoor draw-out type switchgear assemblage, containing electrically operated air circuit breakers. The air circuit breakers feed three 480 volt indoor motor control centers for Unit No. 3 extension, serving common auxiliaries within the power plant area. (b) One outdoor 4160 - 480 volt step-down transformer, 500 kva, oil filled, connected by cable to an indoor motor control center section, serving ash handling equipment common to Unit No. 3 and future units and also ash clinker crushers for Unit No. 3 and future units. An interconnection between Unit No. 3 and the common 480 volt system is provided, with provision for extension of this bus tie system to all future unit 480 volt auxiliary systems. Overhead cable trays are used to the greatest possible extent, for routing of control cables indoors. All power cables are run in underground fiber ducts or in exposed or underground conduit. The 4160 volt and 480 volt auxiliary systems for Unit No. 3 are wye con nected, with the neutral grounded through a high resistance, to limit ground fault currents to sufficiently low values to permit continued operation until it is convenient to locate and correct the fault. Alarm relays are provided to annunciate the occurrence of ground faults. WAD00736 XE3U6 PROJECT OUTLINE (Continued) 73 The unit auxiliary power supply system is split into an "A" and "B" group at both the 4160 volt and 480 volt levels. Motor drivers for sets of auxiliaries consisting of two or more identical units are alternately connected to derive their power from the "A" and "B" systems, in order to maintain the maximum degree of reliability possible in the event of an outage of any transformer, switchgear section, power center, control center or associated power cable. CONTROL OF AUXILIARIES Electrical controls for motor driven auxiliaries are located generally either at the BTG Board or locally, near the driven equipment. Motors which require controls at more than one point, are kept to a minimum. Such duplication of con trol points exist only in cases where it is considered absolutely essential. SUBSTATION EQUIPMENT TRANSFORMER EQUIPMENT The generator voltage is stepped up through a three-phase power transformer, rated 180,000 kva, FOA, 19,000 volt delta - 114,000 volt wye (solidly grounded). OUTDOOR STRUCTURES The transformer high-voltage leads span overhead to the 115 kv switchyard. The existing 115 kv switchyard ring bus, consisting of eighteen bays, was adequate to accommodate the Unit No. 3 Extension. However, an additional struc tural steel take-off tower is provided for generator No. 3 in Bay 13. Three additional ring bus oil circuit breakers, rated 5000 mva, 1200 amperes, 3 cycles, are provided for Unit No. 3 Extension. Each breaker is isolated with a pair of 1200 ampere, manual gang operated disconnecting switches. Main Power Transfsormer No. 3 is connected to its ring bus section through a 1200 ampere motor operated disconnecting switch. Tapped to the ring bus section for Main Transformer No. 3 and also the ring tie bus is a set of three single bushing type potential transformers, for relay ing, metering and synchronizing. These are used instead of coupling capacitor potential devices Utilized for similar applications on Unit No. 1 and No. 2 in stallations . WAD00737 PROJECT OUTLINE (Continued) 74 The switchyard bus is split into two separate rings. However, until after completion of the Unit No. 3 construction, the rings will be operated as a unit from existing Control Room 1-2. During this phase of operation, the ring tie disconnect switch will remain closed at all times, and all line panels at present in Control Room 1-2 will remain there. After Unit No. 3 is placed in service, the rings will be operated separately with one ring, containing Units No. 1 and No. 2 generators, controlled from Unit No. 1-2 control room and the second ring, containing Generator No. 3 and future Generator No. 4, controlled from Unit No. 3-4 control room. Two of the existing line panels in Control Room 1-2 will be relocated by PSCC in Control Room 3-4. A new panel, with swinging synchronizing panel, is provided and will be added on the north end of the Unit No. 1-2 line panels, for control of the disconnect switch tying the two rings together. This panel contains a control switch with indicating lights, instrumentation required for power flow measure ment between the two rings and relays. A wattmeter, varmeter and ammdter are provided on the new panel for this purpose. A voltmeter is also provided to indicate voltage of Ring No. 2. A similar panel is provided in Unit No. 3-4 control room, which also contains instrumentation to show the power flow between rings and lights only, to indicate the position of the tie disconnect switch. This new panel also has space for control, instrumentation and relaying for a future line in Bay No. 12. Existing line panels will be modified as necessary by PSCC to suit requirements of the Unit No. 3 Extension. In addition to the panels described above, a new duplex panel is provided in Control Room 3-4, for load-frequency control equipment for Unit No. 3, and a panel for station battery control and an annunciator. This latter panel also has mounted on the front a frequency recorder. On the inside of the rear panel is mounted audio tone channelizing equipment, with sufficient channels for use with Units No. 3 and No. 4 load-frequency control. The load-frequency control equipment for each pair of units is completely independent, and each has its power supply from a separate source. WAD00738 SPECIFIC HISTORY LAND AND LAND RIGHTS No additional land was required or purchased for this project site. The Joseph and Phyliss Rose Satriano Tract No. 1 was purchased in 1957 thru Northwestern Engineering Company who retained the gravel rights for five (5) years. The expiration date was May 1, 1962, and it has been extended unitl November 1, 1962. Gravel removal started December 5, 1961, for state high way grade separation borrow. On April 11, 1962, Northwestern Engineering Company started a gravel plant operation. As a mat ter of record, this report includes the following field drawings. SK-5776-F4, Topographic SK-5776-F69, Topographic SK-69S6-F46, Topographic SK-79S-F33j Topographic Map - Original Flap-Final Unit No. Map-Final Unit No. Map-Final Unit No. 1 2 3 The Unit No. 3 drawing is dated July 31, 1962, and the gravel area contours have not been completed. Some gravel from the Public Service Company property was removed during Unit No. 2 expansion, as noted in its Final Report, and the amount re moved from Unit No. 3 can be computed from cross sections, STRUCTURES AND IMPROVEMENTS Improvements to Site Preliminary grading in the station building area was accomplished during the original site preparation for Unit No. 1 construction. Sub-soil investigation was made by Meredith Dril ling Company on Order 3C-1, using a small auger, and by Golden Drilling Company on Order 3C-4, who took core samples. The in vestigation indicated two to five feet of overburden and then vary ing layers of decomposed brown shale, blue sandstone and blue shale. It was determined that the underlying hard blue grey shale known as the Denver formation, would provide adequate bearing, and drilled caissons were designed to penetrate the overburden and decomposed layers to the solid blue shale. Included in the drawing section of this report are "Sub-surface Profiles", re cording all strata as actually found during our excavation work, namely: drawings SK-5776-F40, SK-6986-FI2, SK-793S-F32. Car storage requirements for coal delivered by rail were satisfied by installation of coal storage tracks No. 4, No. 5 and No. 6, consistent with the original scheme of installing three (3) tracks per unit. A contract, JC-^OO, was awarded to W. H. Nichols and Company, Incorporated, to furnish all materials and to install 4,376 lineal feet of track, as shown on Drawing SK-79SS-F27, "Yard Railroads", located elsewhere in this report. Fill material 12,000 cubic yards, for the embankment of these tracks was spoil from excavation for station building and equipment foundations and was placed and compacted intermittently during the construction program. Spoil, 8,100 cubic yards, from the construction of the ash settling basins was also utilized for embankment. WAD00739 T 76 The transformer track was extended 55 feet by the Denver and Rio Grande Western Railroad Company, Order 36-591, using material on the job and ballast was supplied by Brannan i Sand and Gravel Company on Order 3C-593 f / fit: f, f| Road work consisted of tieing the north and south access roads together which incorporates paving of the existing east plant road thru the construction area that runs adjacent to the water treatment railroad spur; extension northward of the road west of the transformer area; a connection of the east and west plant roads at the north end of Unit No. 3; an access road to the station building extending west from the east plant road; an access road to the 4160 volt switchgear extending east from the west plant road and a loop road for coal trucks from the water treatment building east to the coal truck hopper, thence south around the south end of Unit No. 1 circulating water cooling tower and then west to tie into the plant road south of the warehouse, as shown on Field Drawing SK-6986-F4 Rev., "Plant Roads", included in the drawing section of this report. Order 3C-1357 was placed with Esco Paving Company to construct the plant road with concrete gutters (8 cubic yards), placed July 27, compacted eight (8) inch gravel base, two (2) inch asphaltic concrete paving and seal coat with gravel chips. Work was started on July 23, with removal of overburden, and was completed on August 15, 1962, with the seal coat and chipping operation. The following quantities were used for road con struction: Compacted gravel sub-base, 4,890 square yards; asphaltic concrete, 4,805 square yards; concrete gutters, 220 lineal feet. Unit No. 3 circulating water pipe, 72 inch reinforced concrete, over which the coal unloading road passes, was not designed for the loading which would be imposed on it without additional concrete reinforcement. Initially, a concrete cradle was designed for the pipe at this point; however, Public Service Company of Colorado elected to eliminate the cradle. Subsequently, an eight (8) inch reinforced concrete slab was placed over the pipe at road elevation as well as over Unit No. 2 circulating water pipe on August 7, 1962, containing 22 cubic yards. ------------- ------------------------ J Concrete gutters were extended along the west side of the west transformer yard road at the toe of the switchyard slope. Gutter was also provided along the west edge of the east plant road pavement. The area under the gas ducts to the breeching, around the induced draft fans and east to the east plant road was sur faced with a six (6) inch layer of 3/4 inch gravel purchased from Boise-Cascade Sand and Gravel Company on Order 3C-788, totaling 419 tons. Concrete sidewalks were constructed from the east plant door (D-204) and the ash handling transformer, north to the ash trench; from the forced draft fan enclosure east door at WAD00740 77 the north end to the ash trench; and from the forced draft fan enclosure east door at the south end to the road between Units 2 and 3. Concrete (167 cubic yards) was supplied by Ready liix Concrete on Order 30-17 and placed on April 20, 1962. No fencing was required for this project. Yard lighting consisted of an extension to the existing system of two boulevard type light standards along the west side of the transformer yard roadway and two boulevard type light standards along the west side of the east plant roadway .paralleling the water treatment spur track. The aluminum poles were purchased for the previous units. The fixtures were pur chased from General Electric Company on Order NY-771860. The bases for the four standards were concreted (3 cubic yards) on April 20 and June 18, 1962. Another post type fixture was located at the circulating water cooling tower power and con trol center, also furnished by Order NY-771630. Its base was concreted (1 cubic yard) on March 26, 1962. Cable pulled to the yard lights was of direct burial type using surplus from Unit No. 2, augmented by Order NY-771699 with Anaconda Wire and Cable Company. All electrical installation was by Sturgeon Electric Company under their general contract. Fire protection for Unit No. 3 includes a 110 foot long extension to the 12 inch fire line located six (6) feet west of column "A" line parallel to the west wall. The seam less wrapped pipe was transferred to this job from P3CC stores on J-66 and hauled by Weicker Transfer Company, Order 3C-82. Excavation for this line was accomplished during September, I960, in conjuction with the west wall excavation. A two foot layer of hard blue sandstone overlaid the location and this layer was left in place and shale excavation and the pipe installation was made from the west wall excavation during September, I960. Concrete was then allowed to encase the pipe (except the fittings and valves) when the footing for the west wall was placed. Hydrant No. 20 and valves 3V-452, 453 and 454 were installed by our pipefitter forces during late November, I960. The fire protection extensions are shown on the yard piping Drawing G-159654s and in addition to the line above, a 12 inch steel pipe line at the rear of the boiler to hydrant No. 21 was constructed. The relocation of hydrant No. 3 and the addition of an eight (6) inch pipe line extension northward parallel to and twenty (20) feet west of cooling tower No. 3 with hydrants No. 22 and No. 23 were furnished by P3CC stores on J-I36 and hauled to the site by Neicker Transfer Company on Order 3C-276. The entire underground system is steel pipe coated and wrapped, with the additional hydrants (three) purchased from Grinnell Company on local order 3C-331. The_hydrants are Mueller Cat. No. A24016 improved type with two (2) 2-1/2 inch hose nozzles, national standard thread with six (6), 125# flat face flange inlet. Excavation was accomplished with the l/4 WAD00741 73 cubic yard rented backhoe and the pipe was installed by our pipe fitter forces during early August, 1961. Yard fire protection was tested, pressurized and turned over to the operating de partment on Equipment Turnover Record No, 17 dated March 12, 1962. The yard drainage system is shown on Ebasco Design Drawing G-130522 and field drawing SK-6987-F45 anc^ is included in the drawing section of this report. The arrangement for removal of surface water in the area around the station building and boiler, consisting of five (5) concrete catch basins, identified as CB-22 through CB-26 is interconnected with rein forced concrete pipe. It is tied in with existing facilities at CB-18 along the west plant road and with an existing 36 inch reinforced concrete pipe extending east under No, 3 main cooling tower. Provisions were made to tie all electrical manhole and handhole drains into the system. The station building floor and equipment drainage systems are also tied into the yard system. Catch basin No. 22 collects runoff from the transformer yard, switchyard slope and west side roadway; catch basin No. 23 serves the area north of the station building; catch basin No. 24 accumulates the water in the area north of the No. 3 Tan room and runoff from the roadway; catch basin No, 25 is located northeast of the No. 2 chimney to drain water from that area and catch basin No. 26 is in a low area north of future Unit No. 4 and provides a change in direction. Construction of the catch basins and installation of the interconnecting piping was accomplished during the month of July, 1961, with the exception of the 12 inch reinforced concrete pipe tie between CB No. 18 and CB No. 22. A temporary construction power substation was located in this area and installation was delayed until the substation could be removed. The substation was removed and the line was installed in June, 1962, with ex cavation in the hard brown and blue sandstone accomplished by air operated hand tools. Excavation for the majority of the drainage system was by use of a 1/4 cubic yard tractor mounted backhoe, rented from Ace-High Sewer Constructors on Order 30287= Excavation for the 12 inch reinforced concrete pipe line connecting OB No. 22 to CB No. 23 was accomplished by use of a one (1) cubic yard, Bucyrus Erie Model 30-B, backhoe rented from Gilbert Clark on Order 3C-27. The following quantities of material were used in construction of catch basins and drain line using our labor forces. Vendor and Order Number 17 cuyd Concrete - Ready Mix Concrete Company, 3C-17 2152 lbs Reinf Steel - Colorado Builders Supply Co, NY-771848 456- feet 12" Reinf Cone Pipe - Lock Joint Pipe Co, 30-450 & 1347 116 feet 15" Reinf Cone Pipe - Lock Joint Pipe Co, 30-499 ISO feet 18" Reinf Cone Pipe - Lock Joint Pipe Co, 30-499 208 feet 4" Vit Clay Pipe - Denver Brick & Pipe Co, 30-482 & 1171 3 each 30" Frame & Covers - Mac lean Mfg Company, 30-502 1 each 22" x 38" Frame & Covers - Maclear Mfg Co, 30-502 WAD00742 79 A review of the existing drainage facilities revealed three major inadequancies in the following areas: First, the existing 12 inch drain from 62nd Avenue and Franklin Street was insufficiently aized to handle the runoff from the west and caused flooding in an adjacent field; second, a culvert con veying water from the open ditch, formerly East 62nd Avenue south side, under the Heller ditch was inadequate to handle the volume of water at this point; and third, the existing "24 inch corrugated metal pipe conveying water eastward under fork Street to the South Platte River, formerly discharge of East 62nd Avenue south ditch, was inadequately sized and restricted flow. To relieve these conditions, a 10 inch pipe was in stalled under the main access road near the entrance gate and was tied into the ditching network along the south side of the construction access road. A 24 inch corrugated metal pipe cul vert conveyed this drainage under the construction access road southwest of the field construction office to a new storm sewer system designed by the Public Service Company of Colorado en gineering department. This new 30 inch corrugated metal drain age system also removes runoff from the north side of the con struction access road and surface water from the Joseph and Phyliss Rose Satriano Tract No. 1, from which the gravel is being removed by Northwestern Engineering Company. The new storm sewer commences near the northwest corner of the construction office, where it drops into manhole T,A", then it bears northeast to an angle point, identified as manhole ,TBn, near the northeast corner of warehouse No. 2, thence south to catch basin ,,CB-27Tt, located at the northwest corner of cooling tower No. 3, at which point a'36 inch rein forced concrete pipe was extended east to the existing 36 inch line running east under the railroad embankment to catch basin nCB~20'T. An inverted siphon, constructed of 36 inch corrugated metal pipe was installed under the Heller irrigation ditch and a new 36 inch culvert of the same type material was installed under York Street to the South Platte River, both paralleling the existing 24 inch culverts. Work on this additional drainage program was started in May and was completed in June, 1962. Excavation was ac complished for this new system by use of a l/4 cubic yard backhoe rented from Ace Hi Sewer Contractqrs on Order 3C-2&7 and a 1/2 cubic yard truck mounted backhoe rented from Winslow Con struction Company on Order 3C-127S, A permit was secured from Adams County thru the Public Service Company of Colorado Gas Street Department to make a cut through York Street with two days required to complete the operation. The excavation was completely backfilled each night and no problem in traffic flow along York Street was experienced. In the process of installing the inverted siphon under the Heller ditch, which is a 24 inch vitrified clay pipe at this point, there was a severe water WAD00743 80 problem due to the existing pipe being broken and we subsequently secured permission from the ditch master to shut off flow through the ditch for a day. The 36 inch reinforced concrete pipe from the tem porary catch basin at the north end of No. 3 main cooling tower to-catch basin !tCB-20TT and on eastward to the open ditch at the north end of No. 2 main cooling tower was completely plugged with fly ash dumped into the pipe from the wash water at the ash silo. Gleaning the line was accomplished by pulling a ''pig'* back and forth through the line utilizing two winch trucks and high pressure water to flush out the broken up deposit. All labor to install the pipe, construct manholes, catch basins and headwalls and to clean the 36 inch pipe was accomplished by our own forces with the following materials used: 29 cuyd Concrete - Ready Mixed Concrete Company, 3C-17 673 lbs Reinf Steel - Colorado Builders Supply Co, 3C-12S6 30 feet 36" Reinf Cone Pipe - Coppco, Incorporated, 3C-1240 386 feet 30" Corr Metal Pipe - Armco Metal Products, 3C-1241 50 feet 24" Corr Metal Pipe - Armco Metal Products, 3C-12B4 252 feet 30" Corr Metal Pipe - Armco Metal Products, 3C-12B4 134 feet 36" Corr Metal Pipe - Armco Metal Products, 3C-12&4 2 each 30" Frame & Covers - Maclear Mfg Company, 3C-1279 $ If 24tT Vit Clay Pipe - Denver Brick & Pipe Co, 30-1297 With the decision to build the coal unloading loop road, it was necessary to construct a fill to pass over the Unit No. 3 ash pipe trench and it caused limitations in the yard drainage system. An area north of the truck hopper was impounded by the road fill, railroad embankment and the ash trench. A six (6) inch drain was installed under the ash trench to a new catch basin "CB-2B", located southwest of Unit No. 3 intake near electrical manholes No. IS and 19, constructed over an existing 24 inch reinforced concrete pipe drain and shown on Drawing SK5776-F37D, "Yard Underground", included elsewhere in this report. Catch basin "CB-2B" concrete was placed- for the mat (0.5 cubic yards) on August 7, the walls (4 cubic yards) on August 10, and the top slab (0.5 cubic yards) on August 15, 1962. A six (6) inch drain was installed under the road from the coal crusher tower to catch basin "CB-3" at the southeast corner of Unit No. 1 C.W. cooling tower to drain the area around the crusher tower. A ten (10) inch drain with concrete headwall, 0.5 cubic yards, placed August 7, 1962, was extended twenty (20) feet west from catch basin "CB-B" to drain the area at the north end of Unit No. 1 C.W. cooling tower. Service Water System The service cooling water system for this unit did not require an extension to the existing cooling tower. The original Unit No. 1 tower contained two cells and a third cell was added for Unit No. 2. The requirements for all three units can-be handled (except under maximum conditions) by two of the three cells previously installed leaving the third cell as a spare. WAD00744 81 The service cooling water installation consists of two additional circulating pumps for the service water cooling tower located on foundations west of the tower in line with, and adjacent to the north of existing three pumps. A sixteen (16) inch lock joint concrete pipe supply and return line connects the cooling water return tank to the headers at the cooling tower. Two vertical pumps are located on the return tank Tone a spare) with provisions for future Unit No. 4 in tank capacity and pump space. The service water pumps Nos. 4 and 5 were supplied on Order NY-771840 by the C.H. Wheeler Manufacturing Company. The pumps are Wheeler - Economy 8 inch x 6 inch, type MI, cen trifugal pumps to pump 1600 gpm at a TDH of 120 feet, in ac cordance with Ebasco Specification PSCC-C3-114-SWP dated October 16, 1959 The 60 hp, outdoor type motors were supplied by Westinghouse Electric Company on Order NY-771813, and were set by Sturgeon Electric Company under their general electrical installation contract, 3^-149 The pumps and motors were tested 'ahd operated on March 8, 1962, and were turned over to the operating department on Equipment Turnover Records No. 22 and No. 23, dated March 15, 1962. The foundations for the service water pumps No. 4 and No. 5 were hand excavated during the latter part of April, 1961, and sand cement fill was placed between the Unit No. 2 cir culating water pipe and the bottom of the pump foundations. Concrete for the service water pump foundations (10.0 cubic yards) was placed May 4, 1961. The pipe connections from the pumps are shown on design drawing G-159654, ,TYard Piping Plan - Sheet No. 1", and they consist of a steel pipe header and valves that connect to a 16 inch lock joint pipe line that runs underground from the pumps to near column "Ha-14" inside the building. The pipe was purchased from Lock Joint Pipe Company on local order 3C-39 with approximately 550 feet installed by Ebasco pipefitter forces during February, 1961, and June, 1961. The header arrangement at the service water cooling tower was fabricated by Midwest Piping Company on Order NY-771889 and was erected by B F Shaw Company under terms of the power piping erection con tract, 3C-147. The cooling water returns from the equipment to the return tank via a cast iron soil pipe system underground shown on design drawing G-159813 , ''Ground Floor Plan - Plumbing and Drainage", with a connection to the Unit No. 2 drainage system. Slattery and Company supplied and installed the underground piping intermittently during the early stages of construction under terms of their plumbing and drainage contract, 3C-47 Excavation for the concrete cooling water return tank was performed September 11, 1961, using the l/4 cubic yard backhoe rented from Ace Hi Sanitary Sewer "'Company on Order 3C-287* The bottom slab of the concrete tank was placed on September 15, 1961, and the walls were completed September 22, 1961, with a WAD00745 32 total of 22-1/2 cubic yards placed. Reinforcing steel was pre fabricated and furnished by Colorado Builders Supply Company on Order NY-771&43, totaling 2,015 lbs. The steel frame cover for the tank was furnished by Denver Steel and Iron Works on Order 30-422 and it weighed 2,700 lbs. The two (2) cooling water return pumps were supplied by Worthington Corporation on Order NY-771339 and are Worthington 12-HH-200, two stage, water lubricated, to pump 2,000 gpm at a TDH of 73 feet, in accordance with Ebasco Specification PSCCC3-H6-SWRP. The pumps were set by our forces during November, 1961, and the two 50 hp motors, were purchased from Westinghouse Electric Corporation as Item 14 of Order NY-771313 and were in stalled by Sturgeon Electric Company under terms of their con tract, 3C-149, during December, 1961. The pumps and motors were test operated February 20, 1962, and were turned over to the operating department on Equipment Turnover Records No. 4 and No. 5 dated March 12, 1962. The service cooling water system was completely tested, flushed and turned over to the operating department on Equipment Turnover Record No. 13, dated March 13, 1962. Station Building The station building extension consists of an enclosed turbine bay 135 feet by 50 feet by 75 feet high; bunker bay 50 feet by 54 feet by 73 feet high; auxiliary bay 43 feet by 63 feet by 41 feet high; fan room 41 feet by 31 feet by 33 feet high; switchgear and cable area 34 feet by 99 feet by 25 feet high with control room 50 feet by 27 feet by 16 feet high. The structure is supported on reinforced concrete footings resting on drilled caissons with concrete floor slab at grade. The west wall of the turbine room up to the operating floor is concrete on a continuous footing. Superstructure is steel framed with walls of corrugated asbestos and concrete block. Floors are poured reinforced concrete, precast flexicore with concrete wearing surface and steel grating. Roofs are poured reinforced concrete, precast flexicore slabs and steel decks with built-up roofing. Exposed roof decks subject to traffic have a concrete wearing surface over membrane 'waterproofing. Building equip ment includes air conditioning (in control room only), necessary heating, ventilating, plumbing, lighting, wiring and fire protection facilities. The areas assigned to the various uses are as follows: Chemical Feed and Auxiliaries 770 square Switchgear 1,630 do Pulverizer Area 3,670 do Turbine Room (2 Floors) 12,460 do Lube Oil Tank Area (2 Floors) 340 do Boiler Feed Pump Area 2,700 do Compressors and Auxiliaries 2,443 do Ash Pumps and Hopper 1,724 do Fan Room 1,420 do Cable Room and Auxiliaries 3,130 do WAD00746 83 Control Room 1,770 Control Centers and Auxiliaries 680 Betterment Area 1,730 Heater Levels (2 Floors) 5,000 Burner and Firing Aisles (3 Floors) 1,920 do do do do do Contract ^0-9 was signed with Meredith Drilling Company to construct the caissons in the station building and boiler areas. A truck mounted drill rig was moved to the site on June 20, I960, and drilling operations commenced on June 21, I960, and were completed on July 12,. I960. Forty seven (47) caissons were drilled, cleaned, reinforced and concreted in the station building area. A total of 103 caissons was constructed under terms of the contract, including those for the boiler structure. 414 cubic yards of class B concrete were supplied by Pre-Mix Concrete Company on a suborder from Meredith Drilling Company for the station building area. The reinforcing steel was supplied by Colorado Builders Supply Company as part of their contract, Order NY-771S48. An as-built caisson record is shown elsewhere in this report as Progress Drawing 3C-P-1. After construction of the caissons was completed, excavation around the caissons for concrete caps commenced on July 18, I960, using a one cubic yard backhoe rented from Gilbert Clark under terms of Order 3C-27. The final neat ex cavation and grading were done by our own labor forces using air tools. The first concrete was placed on July 21, I960, with Uniform panels used for the forms. Concrete totaling 435 cubic yards was placed by Ebasco forces for the station building foundations with the final placement made on October 10, i960. The Ready Mixed Concrete Company delivered the class B concrete in transit mix trucks. The class B (3000 psi) concrete was set up as a six (6) sack mix initially and when this mix consis tently ran over the specified strength requirements, the mix was redesigned for 5-1/2 sacks-of cement, resulting in a con siderable savings during the course of the job. Concrete in the walls, grade beams and column en casements totaled 266 cubic yards and was placed intermittently during the construction period with the west wall footing (234 cubic yards) the main placement accomplished on October 5, I960. The final placement was made on February 22, 1962. Sand cement backfill (1-1/2 sacks per cubic yard) in the station building area was accomplished by our forces using the 16 cubic foot GMC concrete mixer. The sand material was bank run from an unex cavated area in the future station building location to the north adjacent to the construction access road. It was excavated and loaded into dump trucks by the D6 frontloader and hauled to the point of use. The cement was purchased in carload lots in sacks on Orders 3C-72 and 30-283 A total of 872 cubic yards of sand cement fill was placed in the station building area. The ground floor paving slabs are shown on design drawing G-159758, "Turbine -Area - Paving Plan", and are basically a six inch thick air entrained concrete slab with Wo. 4 rein forcing steel on 12 inch centers each way, steel trowel finish WAD00747 with an application of Masterplate floor hardener. The first section of slab was placed April 24, 1961, and the final place ment was made January 26, 1962. The sections of floor slab adjoining the pulverizer foundations were delayed due to the late delivery of the equipment and it was necessary to delay the slab construction for maintaining rigging clearances. Concrete totaled 320-1/2 cubic yards and reinforcing steel totaling 24,621 lbs was field fabricated from stock lengths. Masterplate floor hardener, French Gray, non-metallic type was purchased from K-C Construction Supply Company on Order 3C-241 and was monolithically trowelled in. Several structures are located below the ground floor Elevation 5130, such as the elevator pit northeast of Column r,Da-14ff, the pyrites sump near Column TtDa-13", the condensate pipe trench from the condenser to the condensate pumps and the condenser pit. These were started on February 24, 196l, and were completed on October lS, 1961. Concrete totaled 57 cubic yards, reinforcing steel, 2,957 lbs in these structures and miscellaneous frames and covers were purchased from Sterling Steel Company and Metalcraft Welding and Fabricating Company on Orders 3C-77 and 3C-22S and other small local orders. The structural steel framing was detailed and fab ricated by Sterling Steel Company under terms of Order NY-771G52, which also included the setting of loose base plates. First delivery of steel was the base plates which were received and set on October 11, 12 and 13, I960, by Sterling Steel forces. Following this, on October 25, i960 the initial shipment of structural members was received and erection started on October 27, I960. Early erection procedures were slow due to the fact that the boiler steel Columns along T,D'f and 12 lines were not raised until almost two months later, and it was necessary to bolt up and prepare for raising the deaerator and storage tank before any consistent erection could proceed. High strength bolts were used for making the connections and a Chicago Penumatic 610RPT automatic torque control wrench, Skidmore Wilhelm Model M calibrator and a Blackhawk hand torque wrench were used for the automatic torque control method of bolting. Bolting began on December 1, 19o0, and it proceeded intermittently until basically completed in June, 1961. The miscellaneous building steel was included with the main structural steel Order NY-771&52 with Sterling Steel Com pany, but a large number of smaller orders totaling approximately 132 tons were placed for-additional items with other suppliers. A partial listing of these items is as follows: Intake Steel, Turbine Oil Tk Supports Cooling Tower Walkways Door Sills Frames and Covers Additional Girt Framing Frames and Covers Added Steel - Tripper Floor Start up Panel Frame Sterling Steel Co. Sterling Steel Co. Metal-Craft Metal-Craft Metal-Craft Metal-Craft Metal-Craft Metal-Craft 3C-77 3C-77 3C-216 3C-22S 3C-256 3C-27S 3C-30S 3C-470 WAD00748 85 Flexicore Opening Frames Door Frame D-236 ^Additional Girt Framing Pyrite Cover, Damper Frame Stack Hopper, Drum Enel., Pltfms Metal-Craft Metal-Craft Metal-Craft Metal-Craft Denver Steel Iron 3C-569 3C-652 3C-643 3C-725 38-422 Two types of handrail are installed in the station building. Approximately 646 pounds of ornamental rail are shown on Design Drawing G-130o26 and were supplied for installation at the stairway on the north end of the pedestal. The aluminum rail is Aluminum Company of America No. 16505 and was supplied by August Friedrichs Company on Order 38-157 and was erected by our ironworker forces during April, 1962. The standard building handrail is 1-1/4 inch steel pipe with all welded connections, two rails with the top rail 40 inches above the platforms. The fabricator, August Friedrichs Company, elected to measure the handrail requirements in place and fabricate according to field dimensions. Approximately 6-1/2 tons of handrail were supplied on Order 3C-157 and were erected by our ironworker forces be ginning the first week of September, 1961, and completed during May, 1962. The walls of the station building are of varied materials, with the exterior walls corrugated asbestos, supplied'and in stalled by Corrugated Asbestos Constructors on Order NY-771904* Work on the asbestos siding was accomplished in two periods; the first, when the turbine room was enclosed during March and April, 1961, to allow turbine installation to start, and the second, beginning September 25, 1961, until basically completed on November 11, 1961. Interior walls in the betterment area are j5TS:ster on structural clay tile; the cable room, switchgear, fan room and turbine oil tank enclosure are painted smooth faced structural tile; and the control room is a combination of solid cinderblock and glazed facing tile wainscot. Above the wainscot to the ceiling height, an acoustical wall is constructed of metal furring channel with sound insulation bats laid in between and covered with 24 inch by 24 inch x 3/16 inch smooth perforated transite sheets with beveled edges. Work on the interior partitions began on November 6, 1961, with two bricklayers being used throughout. Ceilings in general are the underside of the structural concrete slab above painted off white except the turbine room where the underside of the steel roof deck is tinted blue and the betterment area conference room, where a suspended acoustical plaster ceiling is provided. The control room ceiling is a special arrangement shown on design drawing G-159920, "Lighting Control Room", with an intermediate suspended ceiling of tex tured ceiling board panels and a main suspended ceiling of 21 x 4T x 3/8" cell aluminum honeycomb panels. The following suppliers and subcontractors were used in construction of the interior walls and ceilings: Louverall Ceiling - Material General Electric NY-771S8O Louverall Ceiling - Installation Sturgeon Electric Co. 3C-149 Structural Clay Tile Robinson Brk & Tile Co. 3C-794 WAD00749 86 Cinder Block Cinder Concrete Products Glazed Facing Tile Robinson Brick & Tile Co Building JHermal Insulation Construction Specialties Dur-o-wall Reinforcing Rio Grande Company Plaster Walls and Ceilings Charles W. Johnson Application of furring, acoustic insulation, perf. transits, in termediate ceiling Jordy and Company 3C-796, 888 3C-794 3C-816 3C-819, 836 3C-900 30-950 The superstructure floors are reinforced concrete with a steel troweled surface containing an application of Masterplate floor hardener, French Gray, non-metallic type. The hardener was purchased from K-C Construction Supply Company on Order 30-241. The turbine room operating floor is covered with red 6" x 6n x 3/Vf red quarry tile, supplied and installed by Reeves Ryan Company on Order 30-743, which included final waxing and polishing. The control room, kitchen, closet and wash rooms and the con ference room in the betterment area are vinyl asbestos tile, Kenflex No. 510, Desert Sand color supplied and installed by Mid west Sales Company on Order 30-743 as a subcontractor for Reeves Ryan Company. A total of 335 cubic yards of air entrained con crete was placed in the floor slabs by our labor forces beginning March 9, 1961, with the final placement made on October 20, 1961. Reinforcing steel (30 tons) was supplied on Order NY771848 by Colorado Builders Supply Company in stock lengths and was field fabricated by our ironworker forces. ,^The roofs of the building are at various elevations and are`either 20 year bonded built-up roofing or concrete wearing surface. The turbine room roof at Elevation 5206 is an 18 gage metal roof deck, H H Robertson Company Type 12, pur chased from the H H Robertson Company on Order NX-771898 and in stalled by Sam Fox Sheet Metal Company as a subcontractor for the Robertson Company. Erection of the metal roof deck was accom plished during April, 1961, in order that the turbine room could be enclosed to start turbine installation. The roof of the fan enclosure, firing aisle, and walkways on the north and south end of the boiler at Elevation 5155 are reinforced concrete slab with membrane waterproofing and concrete wearing surface. The re mainder of the roofs are flexicore prestressed roof slabs with either built-up roofing or membrane waterproofing and wearing surface provided. Contract 30-147 was placed with Bacon and Schramm Incorporated, which is all inclusive for .20 year bonded built-up roofing, waterproofing, flashing, sealing and wall flashing. The rot-proof nailer around the roof for the gravel stop was also included in the roofing contract and was installed by our carpenters on a work order. The roofing contractor pro ceeded to execute his contract intermittently, as required to meet construction needs and -a total of 4 separate trips to the project were necessary. Insulation is provided on the turbine room roof and betterment area roof and this is 2 inch and 1 inch thick Fesco Board in 24" x 48" sheets also included in the roofing contract. The contractor was able to employ a power gravel Spreader and pump the pitch to the large areas of the turbine room roof. WAD00750 37 The first section of concrete wearing surface was placed on October 16, 1961, and the final placement was made on March 26, 1962, with a total of 117-1/2 cubic yards. The joints in the wearing surfaces are sealed with a Thiokol compound supplied and installed by the roofing contractor. Flashing around pipes and ducts through the walls and roofs is Cohrlastic No. 3016, purchased on Order 30-346 from Connecticut Hard Rubber Company and installed by sheetmetal workers thru Insulation Services under Order NY-771932. The doors, frames and hardware were purchased from Richmond Door and Building Specialty Company on Order NY-771917, in accordance with the door schedule shown on design drawing G-159310 with the exception of doors D-204 and D-207 which were supplied out of surplus stock on the job, and D-237 through D-242 which were added later and were purchased on local order 30-735The four doors for the fan room enclosure were ordered on 30-1005. All doors were hung by our carpenter forces with the bulk of them installed during November, 1961, to close the building in for winter. The doors are hollow metal doors throughout, except for the rolling steel door in the west wall which was purchased on Order NY-771920 from Leever Post Incorporated and was installed during early October, 1961. Doors numbered D-216 and D-217 were glazed with 1/4" plate glass under local order 30-336 with McMurtry Manufacturing Company. Aluminum window sash is provided in the work room of the betterment area and a plate glass window is located in the conference room and thermopane windows are supplied in the con trol room walls. The aluminum sash was purchased from Colorado Builders Supply on Order 30-320; the frames, lintels and mullions for the plate glass and thermopane windows were supplied by MetalCraft on Order 30-333 and all glazing was accomplished by Mc Murtry Manufacturing Company under terms of Order 30-336 on February 26, 1962. All painting in the station building was performed by the Schriber Decorating Company on Order 30-143 in accordance with the "Painting Schedule" reproduced elsewhere in this report and according to the Schedule of Finishes on design drawing G-159309. The contract was written in two parts with the field priming of structural, miscellaneous and coal silo steel with zinc chromate primer accomplished on a unit price basis per ton or square foot and the final coat painting performed on a cost plus basis. All materials were purchased on local orders with the M. L. Foss Company. In general, the paint schedule followed closely the previous schedules for Units No. 1 and 2 except at the request of the client, the tile red exterior paint on handrail and toeplate was changed to silicon red and the ex terior structural steel was painted Subalox anti-corrosive aqua. The 175 ton gantry type station crane was extended to serve the Unit No. 3 turbine room and required the. addition of bare copper conductor and insulating supports which were furnished WAD00751 S3 by Yuba Bedford Division on Order NY-771BB7 an-d installed by Sturgeon Electric Company as part of the general electrical in stallation contract, 3C-149o The station service elevator is located at the north west corner of the boiler near the control room for convenient access and available for the next (future) unit at this station. The elevator was supplied and installed by Westinghouse Electric Corporation on Order NY-771B72 and is a 2000 pound capacity, passenger elevator with fully automatic selective collective control system, self-leveling device, having a speed of 200 feet per minute. The machine is equipped with an overhead, worm geared, traction type hoist, automatic operating sliding single speed car door and manually opening, self-closing swinging hoist way doors. Erection of the elevator began on October 4, 1961, and proceeded until November 24, 1961, at which time the per manent power supply to the elevator was required but was not available so Westinghouse Corporation pulled off temporarily. Erection resumed on January 24, 1962, with final completion on February 27, 1962, and the elevator-was placed in service on that date. The elevator was turned over to the Public Service Company of Colorado on Equipment Turnover Record No. SO dated June 22, 1962. The station building heating, ventilating, and air conditioning was installed by Slattery and Company on Order 3C$50. The major mechanical items were purchased on the following orders: NY-771924 NY-771925 NY-771926 NY-771927 NY-77192S NY-771929 NY-771930 NY-771931 . NY-771934 , NY-77193B I.L.G. Electric Ventilating Oliver & McClellan Inc. A.F. Hinrichsen Inc. Buffalo Forge Company Gould Pumps Incorporated American Standard, Ind Div Westinghouse Electric Corp Air & Refrigeration Corp The Airolite Company American Standard, Ind Div Ceiling Ventilators Electromode Heaters Motorized Fans Wall Fan Centrifugal Pump Vane Axial Fan Air Conditioning Unit Capillary Washer Air Intake Filters Hot Water Unit Heaters Originally Order NY-771933 was placed with the Trane Company for supplying the hot water unit heaters but due to a strike in the manufacturing plant, they were unable to meet de livery schedules and the order was cancelled and placed with the second low bidder. The contract with the Slattery Company included setting the above listed equipment and supplying and installing all ad ditional materials and incidentals for a complete installation of the heating, ventilating and air conditioning systems of the station. Also included in contract 3C-o50 is the supplying of three window type heat pumps for the plant betterment offices. Basically the systems are the ventilating and cooling of the main building by the introduction of outside filtered and cooled air with roof ventilators and wall exhaust fans providing the exhaust circulation. High temperature hot water unit heaters WAD00752 $9 are used to heat the main building and the control room is cooled and heated by a self-contained air conditioner with HTHW heating coil. The coal bunkers are provided with a dry dust collector for continuous ventilation of the silos, the boiler feed pump motors are provided with ventilation duct and the turbine oil tank area is exhausted with vane axial fans and duct. The elevator machinery room is ventilated by a wall type propeller fan and heated by an electric unit heater; the steam drum enclosure ventilation is accomplished by roof ventilators and wall louvers 'SRd~-it is heated by a 10 kw electric unit heater; the control room toilet and kitchen are ventilated by a ceiling fan and the betterment air is cooled and heated using 3 window type heat pumps and a supplementary unit heater. A filtered air supply to the exciter and exhaust ventilation of the pulverizer area is ef fected by fan TF-1. Also included in the contract with the Slattery Company is a wrought iron pipe snow melting coil lo cated in the tripper floor wearing surface. Work on the heating and ventilating began on December 12, 1961, and was completed on May 31, 1962. The station building Plumbing is divided into three separate systems which are the storm sewer system, the sanitary sewer system and the drainage system for the cooling water re turn. Contract 3C-47 was awarded to Slattery and Company for the complete installation of all systems. The underground portion is extra heavy cast iron soil pipe, the leaders are galvanized steel with galvanized cast iron fittings and all potable water is copper with sweat fittings. The contract includes supplying and setting water closet, water cooler, lavatory, kitchen unit and the installation of the conference room sink which was purchased on Order 3C-766. The contractor began installation of the under ground systems on December 13, I960, and proceeded intermittently until they were completed on April 19, 1962. The lighting system and building wiring were installed by Sturgeon Electric Company on Order 3C-149 which is the general electrical installation contract. The system is a 120/208 volt system supplied through 7 panels numbered LP-26 through LP-32, which were purchased from Penn Panel and Box Company on Order NY-771888. The wiring diagram is shown on design drawing 0-159914 and general notes on A-159915 with 12 gauge insulated wire and bare neutral generally used throughout. The turbine room is lighted with 16 Hi-Bay mercury lamps; the switchgear and cable vault room is lighted with fluorescent fixtures and the remainder of the building is generally illuminated by incandescent lamps with reflector fixtures. The control room is illuminated with fluorescent lighting fixtures in continuous runs above a sus pended ceiling of 3/3 inch cell honeycomb panels l/4 inch deep natural aluminum finish manufactured by Hexcel Products Incor porated. All lighting materials were supplied by General Electric Supply Company on Order NY-771380. The installation of the permanent lighting equipment began in the fall of 1961 to minimize the amount of temporary lighting required as the build ing was closed in and dark areas resulted. WAD00753 90 An emergency lighting system is included in the con trol room and turbine room areas. This system is a direct cur rent system supplied by the d-c generator and storage battery arrangement described elsewhere and is supplied through lighting panel LP-29. Building Permit On February 6, 1961, Building Permit No. 10&46 was issued by the Building Inspector of Adams County, at Adams City, Colorado. The fee is based on building costs exclusive of gj equipment excepting building services. For this project, the sn only building structure was the station building. WAD00754 BOILER PLANT EQUIPMENT Coal Equipment Coal handling facilities installed for Unit No* 1 basically satisfy the requirements for Unit No, 3 consistant with the original design,, A new car shaker was installed at the track hopper which will permit unloading of two different- types of coal from separate tracks at the track hopper* Lignite used for Units No* 1 and No* 2 can be unloaded over one track hopper and coal with a higher Btu rating used for Unit No* 3 can be un loaded over the other track hopper* Alternate use of the con veying system for storage or bunker filling from either track hopper or truck hopper is possible* It can readily be seen that the handling of two types of coal simultaneously is not feasible* In the initial planning for Unit No* 3? consideration was given to the type of coal to be used* Use of a low heating value coal, slmlliar to the lignite used for Units No, 1 and No* 2, would exceed the handling capacity of the coal equipment when this quantity was totaled with the existing units* Subsequently, it was decided to use a coal of higher heating value, similar to the coal available in Routt. County, Colorado, as the fuel for Unit No* 3 * Although this procedure appeared workable, there was serious limitations including, but not necessarily limited to, proper storage and reclaiming of two fuels for emergency use, and transfer from one fuel to another during unloading and bunker filling operation* In order to facilitate a smooth operation, Public Service Company resolved to use Hanna Coal throughout the entire plant* A new car shaker and hoist were purchased from HewittRobins, Incorporated, on Order NY~771836 and installed on the existing hoist structure over the west railroad track hopper during June, 1962* Coal tripper conv eyors 5A and were extended an .a- ditional 214 lineal feet to serve Unit No* 3 coal storage si-nr. St e ph en s-Ad am son Manufac t u r ing Company furnished all the equip- ment; conveyor belts, rails , structural supports, belt carriers return rollers, zipper seal s, cables, switches and two (2) 46?-- trusses, on Order NY-771S3.5 * The trusses that span from Unit No* 2 to Unit No* 3 were er ected during the steel erection phase of the project* A te'mporary support was installed under the north end of the trusse s until the silos were erected to provide the permanent suppo rt * Extension of the conveyors was accomplished from w August to October. 1951, tu th the movement of existing drive units and splicing of belts closely coordinated with a perl on of low load on the existing plant* Conveyor No* 5A was taken out of service on October I 2, revised and placed in operating condition before conveyor 5 B alteration started and ail work was completed on October 20 * The existing units were placed on gas fuel during this ope ration and the precautions out-lined above were insurance in the event demands on the gas system WAD00755 "became excessive. Included in the extension of the conveyors `was the relocation of the gravity belt takeup, formerly located 'on the south side of Unit No. 1 coal bunkers to a permanent 'location, including all future units, on the south side of Unit ;No. 3 bunkers. Splices in the conveyor belts were vulcanized by Custom Millwright Service Company on Order 3C-793. All other work was performed by our own forces except for the electrical phase. Conveyors were turned over to the operating department on Equip , .ment Turnover Record, Sheets No. 69 (5A) and 70 (5B) dated June 22 1962 Raw coal is stored in four (4) cylindrical bunkers, 23t-10" in diameter by 35'-7" high, constructed of -j/lb" steel plate with a 17'-7n conical outlet section constructed of l/2 inch plate. Silos are located in an area bounded by column line 12 on the south, column line 14 on the north, column line "B" on the west and column line "Da" on the east. The silos have a capacity of 16,000 cuft and are designed to support the tripper floor, flexicore roof slabs and all coal conveying and unloading equipment at Elevation 5207.0f. The conical outlet section extends down through the operating floor, Elevation 5155.0', with a slide gate valve and split coal feeder supply duct at tached to the 5'-0" outlet. The fabricator, Sterling Steel and Supply Company, is located in the same general area as the plant which enabled them to fabricate the silos in five cylindrical sections and deliver them to the jobsite by truck. In a like manner, the cone section and ring support section were completely fabricated. These sections were set in place by use of a 40 ton crawler crane. Circumferential welds required to complete the silos were made by our ironworker forces after the men were qualified in accordance with AWS standards in the field. Sterling Steel and Supply Company furnished the silos on Order NY-771G94, the coal feeder duct was fabricated by Metalcraft Welding and Fabricating Company on Order 3C-269, and the coal gate valves were furnished by Fairfield Engineering Company, Order NY-771394. Removal of combustible coal dust from the silos is provided for by use of a roto-clone furnished by E & M Equipment Company, Order NY-771923, and installed with connecting duct work by Slattery & Company as part of their heating and ventilating contract. Ash Disposal System A hydraulic-pneumatic ash handling system was intro duced for Unit No. 3 with provisions sufficient for Unit No. 4 requirements as shown on design drawing G-159631, "Flow Diagram Ash Handling", included elsewhere in this report. The system provides for complete removal of furnace bottom ash and fly ash. Furnace bottom ash is transported directly from the hopper to ash settling ponds through a pipe line sluiced by means of two (2) hydraulic jet pumps. A complete automatic sequentially controlled fly ash and dust removal system is handled pneumatically by means of a hydraulic jet system with the material transported to the ash settling ponds through the same pipe line that serves WAD00756 93 the furnace bottom ash system. Refuse from a small pyrite hopper is transported directly to the furnace bottom ash hopper through a pipe sluiced by means of a sump type hydraulic jet pump. Two clinker grinders are provided and installed on the outlet of the furnace bottom ash hoppers. Two (2) ash settling basins were constructed in the north area, between coal storage tracks No. 15 (future) and 16 as shown on design drawing G-159767, "Ash Settling Ponds - Plan and Sections". Each basin is 556T-0" long by 92,-0,t wide at the top, Elevation 5137'-0" with sides sloped 2:1 to Elevation 5119O0' and l-l/2:l exterior slopes. A road, 22'-0" wide, is provided around the periphery of each settling pond. A contract was awarded to Winslow Construction Company for construction of the ponds. Excavation, 20,000 cubic yards, was started on June 16, 1961, with spoil used to construct the impounding dikes and surplus utilized for railroad embankment. Fill used in the dikes was compacted to a standard 90 proctor density and was completed July 10, 1961. The nine inch gravel surfacing for the roads was placed by our own forces from material excavated on the site. \\ An overflow frbp the west pond, 36 inch vertical pipe with steel plate skimmer, is supported by a concrete foundation, 0.5 cubic yards, and is connected to the yard drainage system by a 12 inch reinforced concrete pipe from the overflow to catch basin CB 20. A concrete^ trench, 6$'-0" long, with reinforced concrete covers, through!the south road allows the sluice pipe to pass under the road. A concrete trench, 3$T-0" long with reinforced concrete covers, through the road between the two ponds at the north end, serves as a passageway for the sluice line between ponds and allows the ponds to .equalize their re spective water levels. Concrete was placed for the south trench bottom slab on October 9, $.0 cubic yards, and the walls on October 12, 6.0 cubic yards, and for the north culvert bottom slab on October 6, 50 cubic yards, and the walls on October 9, 1961, 7.5 cubic yards. Excavation for the furnace bottom ash hopper foundation and sump was started July 21, 1961, with a front end loader used for this operation. Limited access prevented the use of machinery for the complete excavation and the final cut in shale for the sump was accomplished by use of hand labor and air operated tools with removal and truck loading by rented portable continuous belt conveyor. For a typical cross section of soil stratums in this area, see Field Drawing SK-793B-F32, "Sub-Surface Profiles," located elsewhere in this report. Concrete was placed for ash hopper foundation pit and sump in sections, 116.5 cubic yards, between September 1 and September 15, 1961, with actual place ments recorded on construction progress drawing 3C-P-7, "Equip ment Foundations", included elsewhere in this report. Ash collecting and handling equipment were supplied by United Conveyor Corporation on Order NY-771900. Ash is col lected at the bottom of the furnace in a hopper, 1090 cubic feet storage, which is brick lined and extinguished in water. WAD00757 Two (2) clinker grinders are provided, one for each hopper, to reduce the ash to size suitable for handling by two (2) jet pumps. Dry ash from the eight ($) dust collector hoppers, two (2) economizer hoppers, four (4) gas recirculation duct hoppers and the stack is collected by use of hydraulic ejectors. Pro visions are made for collecting ash from the air preheater hoppers by either the wet or dry method. When removed wet, it is sluiced back to the main hopper. Pyrites from the coal pulverizers are collected by a jet pump and delivered to the main hopper. Piping for this system was installed by B F Shaw Company and the hopper was erected by our forces. Water for the ash system is provided by collecting the blowdown from the circulating water system and storing it in a 250,000 gallon tank. A 6 inch emergency supply is provided from the 1$ inch cooling tower make-up line. The tank, located east of the induced draft fans, rests on a selected fill foundation inside a concrete ring, 24.0 cubic yards, placed August 30 and September 13, 1961. American Steel and Iron Works, Incorporated, fabricated the 40'-0Tt inside diameter by 2S feet high tank on Order NY-771912. Erection of the tank was performed by Taylor Construction Company for the vendor. The tank was turned over to the operating department on Equipment Turnover Record, Sheet No. $7, dated June 22, 1962. Water for the high pressure ash water pumps is delivered from the tank through a 24 inch concrete conduit installed under ground. The pumps are mounted on concrete foundations, 5.5 cubic yards, placed October 25, 1961, located east of the ash hopper near Column "Ha-lS". 0 H Wheeler Manufacturing Company burnished two (2) pumps, Order NI-771902, each which supply. l600 .gpm water at 315 foot head to the three (3) jet pumps, the hydraulic ejectors for the dry ash system, and ash hopper nozzles. The pumps were turned over to the operating department on Equipment Turnover Record, Sheet No. S2 (No. l) and S3 (No. 2), dated June 22, 1962, An air separator is provided in the dry ash system after the ash has been pulled by the ejectors. Excess water from the air separator is routed to the sump in the ash hopper area. Overflow water from the ash hopper and water from the furnace seal box, at the connection of the furnace and the ash hopper, is also collected in the sump. Two (2) vertical sump pumps, 250 gpm at 90 foot head, furnished by Allen-Sherman-Hoff Company on Order NY-771910, discharge the water through a four (4) inch steel pipe to the ash settling basin. A reinforced concrete trench containing 245 cubic yards, was constructed from the station building east to the railroad tracks and northeast to clear all the coal storage tracks. Con crete placements were started on November 11, 1961, and com pleted June 14, 1962. Wooden bents constructed of treated wood were provided to carry the ash disposal pipe overhead from the pipe trench north approximately 1,700 feet to the settling basins. Ash collecting piping from all the hoppers, discharge piping from jet pumps and ejectors and overflow piping from the WAD00758 / 95 air separator and ash hoppers was furnished by United Conveyor on their Order NY-771900. The ash water collecting piping, emergency fill line, sump pump discharge, and high pressure water to jet pumps, ejectors and hoppers were furnished and fabricated by Midwest Piping on Order NY-771889. American Cast Iron Pipe Company supplied the special alloy cast iron ash dis charge pipe on Order NY-771939 All of the above piping was installed by B P Shaw Company on their piping erection contract, The 2/+ inch concrete supply pipe from the storage tank to the ash 'water pumps was purchased from Coppco on Order 3C-439 and installed with our pipefitter forces. The ash handling system was turned over to the operating department on Equipment Turn over Record, Sheet No. 81, dated June 22, 1962, Pulverised Coal Sciuipment Riley Stoker Cento rati on furnished four (4) No, 556 E duplex pulverizers. Order NY-771Slo, each having a maximum con tinuous capacity of 57,090 rounds per hour and a range of 8:1 coal of 3/'4 inch size pulverized to 70 per cent fineness through MM a 200 mesh screen and 99 per cent through a 50 mesh screen. Also included are eight i,8,J drum type coal feeders with revolution counter and drive connections. The primary air duct from the hot air duct, at the > o i 1 e r ont to the mill was furnished with the mi 11 s and erect, ed by cc ermerso The burners ana coal feeder piping from the mill to the ourners were furnished and installed by Babcock and m ox Company as part of the boiler 111 order, NY-771802, Insulation on the feeder pipes was. by Insulation Services, Incorporated, on Order NY-77193^ K Mljg jjj lj||g|w.m Sixteen (16! drill d cessions to s upport the foundation; were conistructed by Fiore...lth Drilling Company on Order 3C-9 and uti .izecl J. 8, 5 cubic yards of concrete. Excavation for the foundati.ons in c;hale and sar.de tone vas accomplished by use of a Bucyrus Erie . ubic yard Da ckhoo and final alignment and grading air driven hand t,00Is. Excavation was neat line to eliminate formj rr and excavation. Concrete, 179 cubic yards was pi a ced between December 8, I960, and April 13, 1961? with actual placements r ecorded on. ? ns true L ion progress drawing 3G-P-7. rfEquipmen t i c'and-31.1 ens ,u included elsewhere In this report,, i charge i n cies: r;n o1 x h e 111 i i oases after the conere was pla ced nccessir abed 'he id dition of anchor bolts and the founuat ions were ie vised a-...... :p ., y a i the vendors expense. si HP Test.s on mills ir1 , ^XlS' - x unit s rroved the mill design Inadequate f or r cqu is , t 3 (J 3 U _L L- S in fineness and maximum output Fabrication of our ui1 c 1 j test re- suits : Yom some proto-tyne 010 e by an eastern uix.1 oy company Y:03 0 j 1e cared ulter- ations in mill size and design, subsequently, stated very late in the const,-u c - i on sc hem. In order to mm n L 1, P )l G CO IIS 01'uc 110n s c 110clu_L 6 for othei chases of the project. the Dualting was closed in and a 61 C C 6 S 3 3 P S. C G for in sfcallation of the mill:: was avai tops had to be re- moved ana caused addi c: or-ar c ost LOi ^orpo ra. 110 n ma cl e ur 11 tt i ' e v 1 s 1 o n s ],, a t ion. Rile y St o k e r lassifier and Internal; WAD00759 'prior to placing the mills in operation. The first mill was received December 18, 1961P and the last mill was received January 3, 1962. During initial operation of the pulverizers, the motor ' tripped out after about 50 seconds of operation and on subsequent -starts, the driver tripped out in less time. It was found that the Rawson coupling shoes were locked due to the shoe material being too soft. Riley substituted a hard cast iron material for the shoes and subsequent startups were satisfactory. On May 16, 1962, a preliminary performance check was made on pulverizer- 3C and the mill performed at the rated capacity with good fineness results; however, power requirements were notably higher. In asmuch as this is the first production model of a Riley pulverizer with the new internal by-pass classifier, it was determined that the fan was constructed with too great a diameter, and was re quiring additional power for operation. The fans were revised during July of 1962, and performed satisfactory. Another feature of the new type pulverizer which caused some trouble was the coal feeder tramp iron chutes. The principal of using hot primary air introduced through a bleeder line into the chute near the top to prevent fine coal carryover failed to function properly and the chute filled in about ten minutes. Subsequently, fire developed within a reasonably short time when the mixture of fine coal, iron pyrite and hot air was allowed to remain in stagnation, Riley resolved this problem by increasing the amount of bleed air and drilling holes in the tramp iron chutes which served to temper the primary air. The mills are located, on the ground floor, Elevation 5130.0Immediately below the coal silos and are driven by motors supplied by V/estinghouse Electric Corporation on Order NY-771813. Insulation and lagging, including installation for their section of the primary air duct, were included in Rllw/ Stoker Company?s Order Nf-771ol7. Insulation Services, Incor porated, furnished the lagging and applied the insulation fir Riley Stoker Corporation as a subcontractor. Pulverizer equip ment. was turned over to the operating department on Equipme it Turnover Record. Sheets Nos. 52,, S3, 54 and 55 dated June 21, 1962. ' ' `' Forced Draft Equipment Combustion air is sup lied by two (2) forced draft.fans located under the a.w- heaters between column line ':vl/rt on -.the north, column line Ri2:r on the south, column line "Ha" on ; the west and column line 'in1 en the east. An enclosure of galvanized screen wire sun,.or*..00 by structural framing on three 0sides of the perimeter prevents debris from being sucked into tthe fans. The Sturtevant double inlet fans with inlet vanes pand outlet dampers are designed to deliver 795,000 pounds per (hour at a static pressure of iJ.b inches of water and were .. supplied by b/estinghonse Ej ectric Corporation, Sturtevant WAD00760 |Division, for Babcock and Wilcox Company on Order NY-771802, ^Motors for the fans were furnished by Westinghouse Electric Corporation on Order NY-771813, p Air from the fans is conveyed by duct work to the two (2) Ljungstrom vertically mounted regenerative type air 'heaters. Steam coil type preheaters are installed in the air duct ahead of the air heaters. Hot air leaving the air heaters pis routed thru ductwork to the burner windbox at the front of 4the furnace by air ducts running horizontally along the north "and south faces of the boiler at Elevation 5171T-0?t, approximately. ;Air ducts were insulated by Insulation Specialties, Incorporated, and lagged with ,032 inches thick aluminum by Jamar-Olman Company under the boiler contract. Concrete foundations for the fans are each supported by four (4) eighteen inch diameter cassions drilled into the underlying shale. Meredith Drilling Company drilled and con creted (11,5 cubic yards), the cassions between June 21, and June 24, I960, on Order 3C-9. Concrete for fan 3A foundation, (28 cubic yards), was placed on March 15, and April 4, and for fan 3B foundation, (27,5 cubic yards), on April 4, and April 12, with actual placements recorded on Construction Progress Drawing 3C-P-7, ''Equipment Foundations", included elsewhere in this report. Fans were Set on their foundations April 19, 1961, and grouted on June 2, 1961, Testing of the fans was accomplished prior to boil-out and the fans were turned over to the operating department on Equipment Turnover Record, Sheets No. 10 and No. 11, dated March 12, 1962. Fuel Gas Equipment Initial design of the Unit No. 3 called for gas to be supplied to the pilot ignitors only with a small regulating station at the southeast corner of the boiler. Pilot ignitors and all associated accessories were supplied with the boiler by Babcock and Wilcox Company on Order NY-771802. Lighter gas piping within the building was fabricated by Midwest Piping and Supply Company on Order NY-771889, and installed by B F Shaw Company on their order, 3C-147. Electrical equipment was installed by the electrical contractor, Sturgeon Electric Company. In the late stages of construction, the fuel require ments were revised to incorporate using fuel gas on four (4) of the sixteen (16) main burners. The four (4) burners to be revised were the lower row at the operating floor level. The revisions to the burners were supplied and installed by Babcock and Wilcox Company on a supplement to their order. Main gas piping within the building was sized to be adequate for the addition of twelve (12) burners in the future, or a total of sixteen (16) and was fabricated by Midwest Piping and Supply Company on a supplement to their Order NY-771889. The main gas valve was supplied by Rockwell Manufacturing Company on WAD00761 Order NY-771940 and the regulator by Bailey Meter Company on Order NY-771&34. Main gas piping and all appurtenances were installed by our pipefitter forces. A temporary 6 inch gas line was run parallel to the 4 inch igniter gas line from the existing regulating station to the rear of the boiler. It is proposed to bring in a new gas main with its own regulating station when Unit No. 3 is con verted to dual fuel burning. Boiler Equipment Excavation for main boiler column foundations was started June 13, I960, using a D-S bulldozer, a D-6 front end loader and dump trucks and approximately 1375 cubic yards were removed by August 10, I960. Eighteen (IS) caissons were augur drilled into shale by Meredith Drilling Company on Order 3C-9, and included 202.5 cubic yards of concrete. A-typical cross- section of the soil formations is shown on Drawing SK-79GG-F32, TTSub-Surface Profiles", included elsewhere in this report. Excavation for caissons caps was accomplished by use of a one (l) cubic yard Bucyrus Erie backhoe rented from Gil Clark on Order 3C-27. Concrete placement for the caisson caps and piers (152.5 cubic yards) was started on July 25, i960, and completed on September 9, I960. Concrete for grade beams, (2$ cubic yards), was placed intermittently from August 31, 196l, to December B, 1961. Actual concrete placements are recorded on Construction Progress Drawings 3C-P-1, "Caisson Data As-Built", 3C-P-2, "Sub-Structure Foundations", and 3C-P-3, "Slabs and Grade Beams - Elevation 5130", all included in the drawing section of this m-:-. & report. Structural steel for the boiler was furnished with the boiler on Order NY-771G02. Initial shipments of steel were received on August 16, I960; however, actual erection did not start until December 12, 19o0, as the fabricating and shipping sequences were not correlated to the erection sequence. After the one month delay in starting erection, good progress enabled the contractor to complete erection in line with his schedule. The field contract, 3C-150, for boiler installation with Babcock and Wilcox Company included erection of the 666 tons of high strength bolted main steel and 91 tons of miscellaneous steel including stairs, platforms, handrails and grating. Ground floor slabs in the boiler area were compacted dirt backfill in the forced draft fan room and 52 cubic yards of sand cement fill around the ash hopper areas. Concrete placements for the ground floor slab (9375) cubic yards) were started on October 27, 1961, and completed on March S, 1962, with placement dates recorded on Construction Progress Drawing 3C-P-8 "Slabs and Grade Beams - Elevation 5130", located else where in this report. Superstructure floors were steel grating except in the enclosures around the steam drum ends which were steel WAD00762 99 checkered plate. A reinforced concrete slab containing 16 cubic yards was placed May 24, 1961, which acted as an access platform around the Ljungstrom air heaters and a roof over the forced draft fan room. A reinforced concrete slab was placed June 14, 1961, at Elevation 5187.5' over the upper firing aisle containing 13.5 cubic yards and recorded on Construction Progress Drawings 3C-P-10, "Floors and Roofs - Sheet No. 2, included elsewhere in this report. Flexicore precast concrete slabs were supplied for the operating floor, Elevation 5155*0, platforms along the sides of the boiler and the roof section over the forced draft room. A three (3) ply membrane waterproofing or a 20-year bonded built-up roof were applied over the concrete and Flexicore precast slabs by Bacon and Schramm on Order 3C-I46. Concrete wearing surfaces, (38.5 cubic yards), were placed over the membrane for the firing aisle roof, and the Elevation 5155*0* operating floor boiler platforms and roof. Actual placement dates are recorded on Construction Progress Drawings 3C-P-10, "Floors and Roofs - Sheet No. 2" and 3C-P-11, "Floors and Roofs - Sheet No. 3", included in the drawing section of this report. A protective enclosure is provided around the north and south ends of the main steam drum. Steel framing, floor and roof plates were furnished by Denver Steel and Iron Company on Order 3C-422, corrugated asbestos cement siding was supplied by Corrugated Asbestos Contractors on Order NY-771904, the 10 kw electric unit heaters by Oliver and McClellan, Incorporated, on Order NY-771925, doors by Richmond Door and Specialties on Order NY-771917, exhaust fans by A F Hinrichsen, Incorporated, on Order NY-771926 and motor operated louvers and dampers by the Airolite Company on Order NY-771934. Erection of all com ponents was accomplished with our forces except for the- heating and ventilating equipment which was installed by the heating and ventilating contractor. The steam generating unit is a Babcock and Wilcox Company, Order NY-771S02, reheat, radiant, single drum, divided furnace, front fired, semi-outdoor type, capable of continuously delivering 1,140,000 lb/hr of steam with a superheater outlet pressure of 1925 psig at 1000 degrees F, with reheat temperature of 1000 degrees F, when using Routt County bituminous coal as the primary fuel. A secondary fuel, natural gas, is provided for only four (4) of the sixteen (lb) burners at this time with pro visions to convert the other twelve (12) in the future. The steam generator has all of the usual accessories except coal pulverizing equipment, previously described, and consists of single pass Ljungstrom air heaters, forced draft, induced draft and re circulating fans, dust collector with hoppers, air ducts, gas flues, combination coal and gas burners and a soot blowing system all suitable for outdoor installation. A complete steam tem perature control system consists of three (3) elements, namely, gas recirculation, dampers, and spray desuperheaters for emergency use only. Forced and induced draft fans supply air required for combustion and removal of products of com bustion over entire range of output up to, and including WAD00763 faiaximum specified conditions, and are designed to provide minimum linargin of 5 per cent on capacity and 32 per cent on pressure. -Also included are superintendence of erection, complete erection iof brick work and installation of insulation with its sheet metal lagging. Feedwater heated to 500 degrees F enters the economizer, <14,200 square feet of heating surface, and after additional heating, enters the drum. After the water is heated in the 'furnace tubes to saturated temperature, it is flashed to steam in the drum. The steam passes from the drum to the primary and secondary superheaters with a total of 11,963 square feet of heating surface of pendent type non-drainable tubes where the temperature is raised to 1005 degrees F at a pressure of 1900 psig. After the steam has passed through the high pressure turbine, part of the steam, 933,000 pounds per hour, is returned to the boiler reheater at 666 degrees F and a pressure of 474 psig for additional heating. In the reheater, 23,S06 square feet of heating surface, the temperature is raised to 1005 degrees F at a pressure o-f 450 psig and routed to the intermediate pressure turbine for reuse. In order to assist construction supervisors and work men to visualize the various components of the boiler and their relation to each other for sequence of erection, the engineering department of Public Service Company of Colorado contracted with Air-Vu Company, Incorporated, to make a sectionalized "AerialVuu projection of the steam-generator with its accessory equip ment. This projection depicts in scale an angle aerial view of the complete steam generator with all its accessory equipment sectionalized in detail and located in their true relation with each other. To make this projection, many of the com ponents were detailed on separate drawings, several of which were assigned field drawing numbers. These projections are then turned over to the operating department for their use in helping new operators to visualize not only the details of the various equipment, but also follow the flow of the various systems and their relation to each other. The following list of drawings are included in the drawing section of this report: Sectionalized tfAerial-Vu" Projection - B & Radiant Reheat Boiler SK-^9S8-F6, Arrangement of Furnace Supply and Riser Tubes SK-79SS-F7, Arrangement of .Furnace Headers and Wall Tubes SK-79SS-FS, Arrangement of Convection Pass and Saturated Furnace Roof Tubes SK-79BS-F9, Arrangement of Primary, Secondary Superheat and Reheat Headers and Tubes Babcock and Wilcox Company having just opened a district office in Denver, and the new district representatives to establish themselves, made such an attractive firm price bid to install the complete boiler including all the material furn ished under their purchase order, they were awarded a contract, WAD00764 101 3C-150, for erection of the boiler,, An existing temporary rail road spur utilized for Unit No, 2 construction, was rerouted and run into the boiler area to facilitate erection. Unloading and storage of material were accomplished by use of a ten (10) ton American diesel locomotive crane equipped with a 60 foot boom and 10 foot jib. This crane with flatcars was also utilized ;Vfor reloading and hauling material from storage areas to the erection area. A 20 ton motorcrane was also utilized for -'shaking out" and hauling structural steel from the storage (areas. Erection of structural steel was accomplished by use of a one-hundred (100) ton Model 3900 Manitowac crawler crane ^equipped with 160 foot boom and a 30 foot jib of 10 ton capacity. Prefabrication of the two (2) convection pass sideawall panels was started by welding up components on the ground !on January 3S 1961. Castable refractory was applied to the .above panels and they were erected with the main steel second tier on January 27. Erection of the hangers, upper water wall headers, attemporator piping and downcomers was started on February 13, 1961, simultaneous with steel erection sequence. Panelizing of furnace water wall tubes including buckstays on the ground prior to erection was prosecuted to the greatest extent possible thereby minimizing erection of scaffolds and eliminating costly welding procedures in the air. The main steam drum is 52'-2-1/2" long, with an in side diameter of 66 inches and a thickness of 5-3/4 inches and weighing 149 tons. Special lifting supports of built-up structural members were furnished by Babcock and Wilcox Company along with special hoists and blocks. Rigging consisted of two (2) single drum draw works, each having a capacity of 20,000 lbs, with one (1) inch cable reeved to 17 parts through 200 ton blocks. The drum was received on February 22, 1961, and raised to position on February 24. Erection was witnessed by Public Service Company of Colorado officials and management, also coverage by the local television and newspaper reporters for publicity in their respective mediums. The divided furnace section is enclosed by steam generation tubes with water supplied from the drum to headers by 42 supply tubes, 6-5/6 inches outside diameter at the furnace bottom by means of three (3) downcomers, 22 inches inside diameter. Water heated to saturated temperature in the generation tubes returns to the drum from headers, at the top of the furnace, through 57 riser tubes, 6-5/6 inches outside diameter, and is flashed to steam. All components are of welded construction. .Due to the length of generation tubes, 107'-4" long, it was :necessary to fabricate the components in at least two sections .with considerable welding at these joints. There are a total of 5666 welds in the complete boiler including superheater, reheater and economizer. Babcock and Wilcox Company qualified all their welders on the project under the direction of the erector and in accordance with their welding procedure. Twenty-two (22) operators were tested with WAD00765 102 ^eighteen (IS) qualified and four (4) failures. Major welds in ;large diameter heavy wall sections were preheated, stress re lieved and radiographed. The boiler is encased in a 10 guage steel casing seal welded on all seams. The boiler was air tested to a pressure of three (3) inches of water with satisfactory results on November 17, 1961. Preparations for this test included blanking gas ducts at the rear of the boiler, approximately Elevation 5130.0, installation of plumbers expansion plugs in all soot blower openings, blanking coal piping near the burners and filling the water seal trough between the boiler and ash hopper. Preparations for the hydrostatic test were started early in December, 1961, but were delayed due to an unusual below zero cold wave. Preparations were resumed on December 14, 1961, when filling the boiler with water revealed several tube leaks in the rear furnace wall which were repaired. The test was again delayed on December 19, when the Hartford Boiler Inspector would not accept a hydrostatic test until the welds on the main steam pipe were stress relieved, reversing previous understandings. Stress relieving of the main steam welds was completed December 27, and due to the cold weather and the holidays, the filling of the boiler was again postponed. The boiler was filled with water on January 4, 1962, and when pressure was placed on the boiler, additional leaks were de tected and repaired. The hydrostatic test at 3225 psig, was finally realized on January 5, using an American Marsh size 10 x 1 x 12 air driven pump and inspected by a representative of Hartford Steam Boiler Insurance Company. The reheater was hydrostatically tested to 900 psig on January 19, 1962. The air heater consists of two' (2) Ljungstrom re generative type, Air Preheater Corporation manufacture, vertical shaft, revolving heating element, encased in an air tight steel casing with heat insulation and aluminum metal lagging suitable for outdoor installation, arranged at the rear of the boiler. mm Flue gases at 1200 plus degrees F from the boiler convection pass area enters, thru connecting ductwork, the two (2) single pass, 114,500 square feet heating surface each, and heats com bustion air from the forced draft fans. Each heater is equipped with its own driver, lubrication system and air cleaning device. Four (4) finned type steam coils are installed in the cold air duct before the air heater, to preheat the air and maintain the temperature above the dew point. This eliminates the possibility of moisture collecting on the air heater elements with sub sequent damage. Erection of air heaters was started on February 1, 1961, with the assembly of rotor and housing sections on the ground. The particular arrangement at the rear of the boiler allowed the contractor to completely weld the sections together and set the housing and shell as completed units using the 100 ton Manitowoc crane. Air heater was set in position on WAD00766 gbruary 10, and 3A was set on February 21, 1961, Basket-type /elements were packed in the rotors after they were set in place, -gteam coil air preheaters were installed in the forced draft fan discharge duct and erected with the duct on April 24, 1961. A sequential system of electrically operated soot blowers are Diamond Specialty manufacture consisting of a control panel, soot blowers for the boiler, air heaters and gas re circulating fans, piping on the boiler to all blowing units, motor starters with disconnect switches in weatherproof cabinets and a dual pressure type air reducing station, furnished by Babcock and Wilcox. Soot blowers are arranged in pairs, one on each side of the boiler and opposite to each other on the water walls. Thirty-two (32) Model IR soot blowers are used to clean furnace water wall tubes. Four (4) Type IK retractable soot blowers are used to clean the secondary superheater elements, the primary superheater elements are served by six (6) and the reheater elements are served by eight (B). The boiler including air heaters and soot blowing system were turned over to the operating department on Equipment Turnover Record, Sheet No. 51, dated June 22, 1962. High pressure air for soot blowing is provided by three (3) duplex, three stage, horizontal, 600 cfm air com pressors supplied with aftercoolers, silencers, and filters by Ingersoll-Rand Company on Order NX-771B24. Motor drivers, 200 hp, for the compressors were supplied by Westinghouse ElectricCorporation on Order NY-771B13. They are located in an area bounded by column line "10" on the south, column line "11" on the north, column line "Da" on the west and column line "Gb" on the east, at the ground floor, Elevation 5130. Initial planning was for two (2) compressors to serve Unit No. 3; however, shortage of air for Units No, 1 and No. 2 necessitated addition of a third compressor to augment the present systems. Compressor No. 7 was rushed to completion, tested and turned over to the operating department on Equipment Turnover Record, Sheet No. 3, dated September 15, 1961. The two (2) remaining compressors, No. 6 and No. B, were turned over to the operating department on Equipment Turnover Record, Sheets No. 64 and No. 65, dated June 22, 1962. Thirteen (13) cassions drilled into the shale con taining 26 cubic yards of reinforced concrete were constructed for the soot blowing air compressor foundations by Meredith Drilling Company on their contract, 3C-9, with actual placementdates recorded on Construction Progress Drawing 3C-P-1, "Caisson As-Built Data", included elsewhere in this report. Concrete for the foundations containing 60 cubic yards was placed between November 2B, I960, and May 22, 1961, with actual placement dates recorded on Construction Progress Drawing 3C-P-7, "Equipment Foundations", included elsewhere in this report. Pittsburgh-Des Moines Steel Company supplied a 1000 cubic foot vertical air receiver for the soot blowing system on WAD00767 Order NX-771371. The receiver is mounted on a concrete foundation 3.5 cubic yards, placed July 7> 1961, located outside the build- .ing near column "Gb-12." Boiler Plant Auxiliaries The boiler feedwater heating cycle consists of seven (7) feedwater heaters and one (1) closed deaerating heater. All feedwater heaters are shell removing type with welded feedwater and extraction connections except the lSth stage heater, which is a tube bundle removing type and has flanged feedwater connections. The alternate arrangement of the 13th stage heater was necessitated by its location in the neck section of the condenser. The flow cycle of the feedwater starts in the con denser hotwell thence through the condensate pumps, low pressure heaters and into the deaerator. The cycle continues from the deaerator, through the boiler feed pumps, high pressure heaters, boiler economizer and into the boiler steam drum. The deaerator and its storage tank are set at an elevation based on the Hydraulic Institute recommendation plus a static head margin. The flow diagram is shown as part of the main systems on Ebasco Drawing G-159627, ''Flow Diagram - Main Systems". It is also depicted on an "Aerial View" projection, included elsewhere in this report. The boiler feed piping system was hydrostatically tested to 4250 psig, March 2, 1962, flushed out March 5 and turned over to the operating department on March 13, 1962, by Equipment Turnover Record, Sheet No. 21. The four (4) high pressure feedwater heaters are Yuba, Multilok type, U-tube design, two pass tubes, three pass shell, horizontally mounted, single flow and contain desuper heating, condensing and subcooling drain sections. Drains are controlled automatically to cascade from the higher pressure heater to the next lower pressure heater, with provisions to bypass that heater when it is out of service and cascade to the next lower pressure heater. Seperate vents are routed to the deaerator. Normal flow of high pressure heater drains is to the deaerator, with an emergency drain provided to the condenser during low loads. Flow to either point is controlled auto matically with a split range level controller located on the 12th stage heater. Two (2) low pressure feedwater heaters are Yuba, bolted head type, U-tube design, two-pass tubes, two-pass shell, horizontally mounted, single flow with condensing and subcooling sections. One (1) low pressure feedwater heater is a Yuba, bolted head type, U-tube design, two-pass tubes, one-pass shell, mounted in the condenser neck, single flow with condensing section only. The low pressure heater drains are collected in a drip pot and then pumped back into the feedwater system before it enters the 12th stage heater. An emergency dump is provided directly to the condenser. Seperate vents for the low pressure heater are routed to the condenser. Three half capacity Allis Chalmers boiler feed pumps, 625,000 pounds per hour at 293 degrees F (two operating) are WAD00768 provided with automatic recirculation control and conventional feedwater regulating valve for drum level control. Water supply -for the feedwater pumps is from the 265,000 pound water storage tank furnished with the deaerator. This provides for a 12 minute storage at design load. Recirculation from the feed pumps is broken down by use of high pressure breakdown orifices and discharges into the deaerator. Make-up water for the feedwater system is provided by flashing raw water to steam in a vertical, stainless steel spray tray type preheater with external vent condenser capable of deaerating 35,040 pounds per hour of treated water. Heat for the evaporator is supplied by extraction steam from the 12th stage of the turbine and alternately by reduced saturated steam from the auxiliary steam station supplied from the superheater intermediate header of the boiler. Continuous blowdown from the boiler is routed to the evaporator preheater in order to ^utilize otherwise wasted heat. Evaporator vapor is run to the a14th stage extraction line and thence to the deaerator. Drip from the evaporator coils is collected in a drain receiver and then dumped into the condenser hotwell. Continuous blowdown .from the evaporator flows into a flash pipe and then continues to waste. There are four (4) high pressure extraction heaters : located in an area bounded by column line "B" on the west, "D" on the east, "12" on the north, and "10" on the south with the centerline of heaters located at Elevation 5175.0. From south to north, the heaters use extraction steam from the high pressure turbine 4th, 7th, 10th and 12th stages respectively for feedwater heating. They were turned over to the operating de partment on Equipment Turnover Record, Sheet Nos. 57, 58, 59 and 60 dated June 22, 1962. Steam from the 14th stage is used for deaerating and feedwater heating in the deaerator, which is located on column line "C" between columns "10" and "12" with the centerline at Elevation 5203. The feedwater storage tank is directly below the deaerator with its centerline at Elevation 5191.75. They were turned over to the operating department on Equipment Turn over Record, Sheet No. 56 dated June 22, 1962. Two low pressure heaters are located in a heater and evaporator bay bounded by the same columns as the high pressure .heater bay but on the next, lower floor, Elevation 5155.0. Centerline of the heaters is Elevation 515$.5. From south to 7north, the heaters use extraction steam from the l6th and 17th stages of the turbine for feedwater heating. One low pressure .heater is located in the condenser dome section at Elevation 4514$.0$ and utilizes steam from the l$th stage of the turbine. The three (3) heaters were turned over to the operating depart ment on Equipment Turnover Record, Sheet Nos. 6l, 62 and 63 dated June 22, 1962. All feedwater heaters were furnished by the Yuba Consolidated Industries Corporation on Order NY-771819. Graver WAD00769 Water Conditioning Company furnished the deaerator and storage tank on Order NY-771818. The storage tank and the deaerator were set January 8, 1961, during structural steel erection. A special cradle was designed and fabricated at the jobsite to facilitate the setting of the six (6) feedwater heaters located in the heater bays. Heaters were loaded on our flatcar and brought into the station building unloading bay with the plant diesel locomotive, raised to Elevation 5155 by the station gantry crane and placed on the cradle. Then the station crane raised cradle and heater to the heater bay Elevation 5172, where they were rolled into position using the shell removing wheels of each individual heater. The fourth stage heater was set May 26, 1961, the seventh stage, May 25, the tenth stage, June 1, the twelfth stage May 31, the sixteenth stage June 2, the seven teenth stag^ June 2, and the eighteenth stage heater was in stalled in the condenser dome section March 15, 1961. Our piping ''forces set and trimmed the feedwater heaters as well as all 'other heaters, vessels, pumps, and related equipment. Heat ;insulation and .020 aluminum lagging were furnished and applied by Insulation Services, Incorporated, on Order NY-771932. The evaporator and preheater were supplied by GriscomRussell Company on Order NI~77l825,, The evaporator is horizontally mounted on the operating floor with its centerline at Elevation 5160 and located between columns TtBTt and T,D" and "10rT and ''ll". The preheater is vertically mounted on the Elevation 5171 floor above the evaporator. The evaporator was set June 8, 1961, and the preheater June 7, and they were turned over to the operating department on Equipment Turnover Record, Sheet No. 66 and No. 67 dated June 22, 1962. The evaporator drip pot is vertically mounted with its centerline at Elevation 5141 and is located nine and a half (9-1/2) feet north of column "12" and two (2) feet west of column TT. The evaporator flash pipe is located three (3) feet, nine (9) inches north of the evaporator with its centerline at Elevation 5165=5. The drip pot and blowdown pipe were furnished by Midwest Piping Company on Order NY-771889 and erected by B F Shaw on field contract, Order 3C-147. Three (3) boiler feed pumps each capable of delivering 625,000 pounds per hour of 293 degree F water were furnished by the Allis Chalmers Manufacturing Company on Order NY-771804. A spare rotating element was also provided on this order and turned over to the operating department on Equipment Turnover Record, Sheet No. 2, dated February 9, 1961. Drivers for the^ pumps are 2250 hp electric motors furnished by Westinghouse ;Electric Corporation on Order NY-771813. The pumps are lo cated in an area bounded by column line *12" on the north, "10" on the south, "D" on the east, and "B" on the west with centerline of pump shaft at Elevation 5134. The pumps were set on their foundations by our pipefitter forces; the motors were set :by Sturgeon Electric Company under their electrical contract; the coupling, alignment and grouting (11.5 cubic yards placed May 8, 1961) were accomplished by our millwright forces; and WAD00770 the thermal insulation was applied by Insulation Services In corporated on their order NY-771932. Pump 3A was tested March 2j pump 3B March 6, and pump 30 March 8, 1962. All pumps were turned over to the operating forces on March 12, 1962, by Equip ment Turnover Record, Sheet Nos. 7, 8 and 9 respectively. The boiler feed pump foundations are reinforced con crete supported by reinforced concrete caissons drilled into the underlying shale. The 3A foundation is symmetric and supported on four (4) eighteen (18) inch caissons; the 3B and 3C foundations are not symmetric or opposite hand, their shape dictated by adjacent building foundations. The 3B foundation is supported by two (2), twenty-four (24) inch and one (1), forty-two (42) inch caissons and the 30 foundation is supported by two (2), twenty-four (24) inch and one (1), thirty-six (36) inch caissons. The caissons were drilled during June and July, I960, and the foundations contained 71-1/2 cubic yards of class "B" concrete which was placed September 28, I960, as recorded on Construction Progress Drawing 3C-P-7, "Equipment Foundations", included else where in this report. Midwest Piping and Supply furnished the low pressure drain receiver and it was set by B F Shaw Company on their respective general fabrication and erection piping contracts. The two (2) low pressure drip pumps, furnished by Goulds Pumps Incorporated on Order NY-771837, are mounted on an eighteen (18) inch deep plain concrete foundation resting on the sand cement fill below the ground floor slab end contain two (2) cubic yards of concrete placed March 27, 1961. They are lo cated on column line "14'T between column lines "A" and "B" under the turbine generator pedestal at Elevation 5130. Motor drivers for the pumps were supplied by Westinghouse Electric Corporation on Order NY-771813. Trial operation of the pumps was realized on May 17, 1962, and they were turned over to the operating forces June 22, 1962, by Equipment Turnover Record, Sheets No. 71 and No. 72. The Ph on feedwater is controlled by injecting phosphate, sulphite and/or morphaline into the feedwater system. Phosphate is injected into the steam drum while sulphite and morphaline are injected into the feedwater system downstream from the reheat and superheat desuperheating water station take off near the 12th stage heater. Milton Roy Company furnished the pumps with their motors and mixing and storage tanks on Order NY-771866. The chemical feed equipment is located in an area bounded by columns "Fa" and "Gb" "14-1/2" and "15n at Elevation 5130, except the mixing tank which is located in the same area but on the mezzanine floor above at Elevation 5142. The chemical feed system was initially operated April 27, 1962, and was turned over to the operating department on June 22, 1962, by Equipment Turnover Record Sheet No. 78. Ingersol-Rand Company furnished the evaporator feed pump to supply raw softened water to the evaporator on Order NY-77ig43. The 7-1/2 hp motor was furnished by Westinghouse WAD00771 log Electric Corporation on Order NY-771$13. The evaporator feed pump is located adjacent to, and north of Units No, 1 and No, 2 .pumps and is seven (7) feet east and seven (7) feet north of column "-6" at Elevation 5130. The pump was set early in June iimnd was grouted June 21, l6l. It was test run June 9, 1962, and turned over to the operating department on June 22, 1962, jftby Equipment Turnover Record, Sheet No. 73, jijji jgr. Feedwater flow to the boiler is regulated by a con- Btrol valve in the boiler feed discharge line upstream from the f 12th stage high pressure feedwater heater. Regulation is Jjftautomatic during normal operating sequences and is controlled jgfjby the water-steam ratio in the steam drum. A manual remote 4 motor operated valve is provided for control of feedwater flow in the event the regulator valve is out of service, or during ' startup when load is too low for automatic operation. The regulator valve located at Elevation 5155 near column "0-12" was furnished by Bailey Meter Company on Order NY~771$54 Blowdown from the boiler and evaporator is flashed 4 in a blowdown pipe near column "Fa-12" at Elevation 5130. ' Drains from all boiler headers are routed to this tank which I;; has a twelve (12) inch vent that extends above the top of the boiler support steel and a six (6) inch drain which extends to (i the yard drainage system. The tank is supported by a rein forced concrete foundation, two (2) cubic yards, which was placed !'; on April 4, 1961. Midwest Piping and Supply Company fabricated j7 the blowdown tank on Order NY-771SS9 and it was installed by t, B F Shaw Company on their field contract, Order 3C-147. A free blow tank was provided to expand steam from I'- drains of certain piping systems. Included in these systems ;. are trap drains from the auxiliary steam regulating station, 7 air heater coil steam feed regulating station and main steam f drain and warm-up connections. The tank is located on the mez- J.. zanine floor, Elevation 513$. 5?, four (4) feet east and eleven | (11) feet north of column "B-11". An eight inch vent from the | tank extends upward to tie into a ten (10) inch vent from other I; equipment at Elevation 5157' and then extends above the tripper 4 floor to terminate at Elevation 521$. The drip discharges through 4 a three (3) inch line to the low pressure drain header at the t- condenser. Midwest Piping and Supply Company furnished the (I free blow tank on Order NY-771$$9 and it was installed by the 4 B F Shaw Company on their field contract, 3C-147. Heat in- f; sulation and aluminum lagging were furnished and installed by |f Insulation Services on Order NY-771932. A boiler-turbine-generator control board and auxiliary panel is installed in the control room for instrumentation and 7= control of boiler, turbine, generator and auxiliaries. It is a functional, tunnel type board with a vertical rear panel and |.:.a combination console vertical face front. Instruments on the ft panels are fed electrically or pneumatically and provide the necessary information on the various components of plant equipf- ment to realize continuous plant operation. Westinghouse WAD00772 109 ''Electric Corporation furnished the board with accessory items %uch as internal wiring, pneumatic tubing, indicating lights, ^pushbuttons, relays, annunciators, terminal blocks, indicators for electrical functions of generator, exciter, main transformer and auxiliary motors, synchroscope and control switches on Order ::NY-771$11. The board is arranged diagrammatically so that from fthe board an operator may determine the electrical interlocks 'connected with each system and what conditions are necessary for proper operation. A malfunction or failure of any equipment will 'actuate the annunciator panel at the top of the board and the operator can take remedial measures. F Instruments mounted on the BTG control board furnished 'by other vendors are: Bailey Meter Company, NY-771354, recorders, ^indicators, combustion and feedwater control selector switches; "'General Electric Company, NY-771801, indicators; Babcock and FWilcox Company, NY-771302, steam temperature control selector switches and recorders; Manning, Maxwell and Moore, NY-771856, pressure receivers; Fischer Porter Company, NY-771330, operations 'recorder; Leeds and Northrup Corporation, NY-771901, recorders; Foxboro Company, NY-771353, miniature recorders; and Republic Flow Meters Company, NY-771853, draft gages. Piping for instrumentation and control was purchased ;locally and installed by Ebasco piping forces. Included in this classification are the control air supply piping consisting of copper tubing and'multi-conductor armor covered tubing to the locally mounted controls and relay piping from transmitters to panel mounted indicators. All piping systems for control and 'instrumentation are field run from a specific control or tap ;point to specifically located panels. High pressure taps from such items as the boiler feed, boiler and gas systems are run in high pressure lines to a Boiler Gage Panel located north of the control room near column lfG-14TT at Elevation 5155?. From this point, multitube is run to a relay rack located in the ; cable enclosure room northeast of column r,C-14n at Elevation ,5142T. Pressure lines from other piping systems or auxiliaries also come into this rack and all lines then run in multitube to instruments on the boiler-turbine-generator control board. The Boiler Gage Panel was furnished by Panellit, Incorporated, :on Order NY-771o96, and the relay rack was furnished by Bailey FjMeter Company on Order NY-771354, with relays and stanatrols mounted, but not tubed. Tubing of the relay rack was performed by our pipefitter forces at the jobsite. !' A closed circuit television was provided for visual |check on boiler drum water level by Diamond Power Specialty Corporation on Order NY-771860. The camera and control unit are mounted adjacent to the north drum water column at Elevation 5251.85. Monitors are located on the BTG board and at the feedwater regulating station for visual water-steam ratio in jgbhe steam drum. Locally mounted instruments, meters, thermometers and gages include: pressure indicators supplied by Manning, Maxwell and Moore, Incorporated on Order NY-771856; temperature indicators 1 WAD00773 110 supplied by Manning, Maxwell and Moore Incorporated on Order NY-771359; transmitters furnished by Bailey Meter Company on Order NY-771354; conductivity cells and Larson Lane steam analyzers Slsupplied by Leeds and Northrup Company on Order NY-771901; water jtlevel gages furnished by Yarnall-Waring Company on Order NY771397; differential pressure switches furnished by Barton Instrument Company on Order NY-771922; and drum level and pressure gages supplied by Babcock and Wilcox Company on Order NY-771802. |4. Miscellaneous control panels for operation of auxiliary equipment and indication of functions on piping systems include: Pulverizer Mill Panel, located on the mezzanine floor, Elevation 5133.5 near column TTC13,T; Boiler Feed Pump Auxiliary Panel, located at Elevation 5130 near column rtB12,t; Condensate Panel, located at Elevation 5130 near column nBlln; four (4) Ignition Panels, one (l) on each firing aisle located at Elevations 5155.0, 5I63.O, 5171.0, 5173.0, and mounted on column ,rC13Tt; and a Turbine Gage Panel located on the mezzanine floor at Elevation 5133.5 near column nBll,T. All of these panels were furnished by Panellit, 4 Incorporated on Order NY-771396. if} Other panels include the Fuel Protection Panel pur4 chased from Gustaveson, Incorporated on Order No. NY-771903 and located along the east wall of the cable vault room on the mezzanine floor, Elevation 5142.0 near column fTDal5,t; Soot /Blower Contactor Panel furnished by Diamond Power Specialty //-Company for Babcock and Wilcox Company on Order NY-771802 and located near the compressors at column T,EallTT on the ground floor, Elevation 5155.0; Steam Temperature Control Panel furnished by Babcock and Wilcox Company on Order NY-771802 and located adjacent to, in line with, and east of the Boiler Gage Panel at Elevation 5155.0; and an Auxiliary Boiler Gage Panel furnished by Panellit, Incorporated on Order NY-771896 and located at the operating floor, Elevation 5155.0, in line with, and west of the main boiler gage panel at column T,C14'r. Saturated steam is taken from the boiler at the superheater intermediate header and utilized for pegging steam on the deaerator, on auxiliary heat sources for the evaporator and for steam supply to the air heater coils during low load operation. The high pressure saturated steam is reduced from 1950 psig gtto 100 psig with a subsequent temperature drop from 635 degrees F *,vto 340 degrees F by use of two (2j pressure reducing valves arranged parallel in a reducing station located at Elevation 5171 just west of column (Ea-11). Black, Sivalls and Bryson, Incorporated, furnished the reducing valves on Order NY-771903 and the B F Shaw Company installed them on their field contract, 3C-147. m il The water softening facilities installed for Units 1 and 2 are also utilized for Unit 3. No additional water softening equipment was installed for Unit 3. WAD00774 Boiler Plant Piping In general, all boiler plant piping sized to two and one-half (2-1/2) inches in diameter and larger was furnished and fabricated by Midwest Piping and Supply Company on Order NY-771889 and installed by the B F Shaw Company on field con tract Order 3C-147. All boiler plant piping sized two (2) inches in diameter and smaller, including all instrument and control tubing, was installed by our pipefitter forces. Valves and specialty items were furnished on the following orders: NI-771B21, Atwood and Morrill Company; NY-771826, Schutter and Koerting Company; NY-771863, Yarnall-Waring Company; NY-771864, Manning, Maxwell and Moore Incorporated; NY-771870, 'Manning, Maxwell and Moore Incorporated; NY-771873, Industrial Materials Company; NY-771874, The Chapman Valve Company; NY-771875, The Franklin Supply Company; NY-771876, The Mine and Smelter Supply Company; NY-771877, Central Pipe and Supply Company; NY-771878, Grimes Pipe and Supply Company; NY-771&79, American Pipe and Supply Company; NY-771903, Black, Sivalls and Bryson, Incor porated; NY-771909, The Mercoid Corporation; and NY-771911, Magnetrol Incorporated. Pipe welders for the B F Shaw Company were qualified at the jobsite in- accordance with B F Shaw Company qualifications. Pipe welders for Ebasco were qualified in accordance with Ebasco specification WQ-2 for carbon steel pipe and specification WQ-3 for alloy steel pipe. Test coupons of welds were examined radiographically and tested by U.S. Testing Company on local order 3C-411. Results and test coupons were then forwarded to Ebasco Metallurgical Department for final approval. Welds in the main steam, hot reheat, cold reheat, boiler feed discharge, 4th and 10th stage extraction, boiler steam drains, auxiliary steam and saturated steam from the boiler to the pressure re ducing station were preheated and post heat treated to relieve stresses induced in the piping as a result of the welding operation. All piping systems were subjected to a hydrostatic test of 1-1/2 times design pressure before being placed in service. Prefabricated pipe hangers and their supports were supplied by Bergen Pipe Support Corporation as a subcontract to the general piping contract. Winterizing materials for outdoor equipment and piping |were installed by Sturgeon Electric Company on their general ;electrical contract. Heating cable was furnished by Nelson WAD00775 112 Electric Manufacturing Company on Order NY-771935 and General Cable Corporation on Order NY-771936,, Induced Draft Equipment Flue gas is induced from the furnace section of the boiler downward through the convection section, containing the economizer, and into two (2) gas flues which connects to the dual air heaters. After passing through the air heaters and a dust collector, the gases are again split into two ducts and intake into the two (2) induced draft fans that exhaust thru the breeching, into the chimney and to atmosphere. The dust collector is a multiclone mechanical separator manufactured by Western Precipitator Corporation, type 9YGR12900-15, and. furnished as part of the boiler contract by Babcock and Wilcox Company on Order NY-771302. The dust collector is capable of removing 5,350 pounds per hour of the dust and carbon particles from 1,540,000 pounds of flue gas per hour with inlet gas temperature 275 degrees F and a pressure drop of three (3.0) inches H2O. Eight dust hoppers constructed of 3/16 inch steel plate and having a total storage capacity of 2570 cubic feet, equivalent to nine (9) hours of full load operation, are ar ranged below the separator to store the collected fly ash. The dust collector shell and hoppers are insulated with one inch medium temperature block and lagged with 0.050 thick aluminum. The gas flue section from the air heaters to the dust collector, including its insulation and lagging, was also furnished as part of the boiler contract. Flue gas duct between the dust collector and the induced draft fans was furnished similarly. Foundations for the gas duct between the dust collector and the induced draft fans (17.2 cubic yards) were placed during July, August and September, I960, and are recorded on field progress drawing 3C-P-3, "Substructure Foundations", included elsewhere in this report. The induced draft fans are located east of the boiler, approximately 13.5 feet east of column line "M". Westinghouse Electric Corporation (Sturtevant Division) furnished the two (2) centrifugal, turbo-vane, double inlet, backwardly inclined vane, type 1011TVID induced draft fans for Babcock and Wilcox Company on Order NY-771G02. Each fan is capable of handling ;r900,000 pounds per hour of flue gas at 272 degrees F, with an .inlet pressure of minus 13.7 inches of water and an outlet pressure of zero inches of water. Westinghouse Electric Corp oration furnished the 1000 hp outdoor, weather protected, direct connected motor drivers on Order NY-771313. The fans were tested the week of February 19, 1962, and turned over to the operating forces by Equipment Turnover Record, Sheet No. 12, dated March 12, 1962. Each I. D. fan foundation is supported by two (2) "eighteen inch and two (2) thirty inch diameter caissons. They were drilled and concreted (21 cubic yards) between July 11, and WAD00776 113 July 18, I960, as recorded on field progress drawing 3C-P-1, "Caisson Data - As Built", included elsewhere in this report, illaehine excavation was accomplished on August 17, I960, and consisted of 92 cubic yards. The foundations were concreted in two sections with the base mat section first and then the two piers, one for the fan outboard bearing and the other for both the fan inboard bearing and the motor base. Both base mat sections were placed January 3, 1961, and contained a total of 123.5 i'; cubic yards. All piers were placed January 315 1961, and con tained 20.5 cubic yards. A record of the concrete placement is shown on field progress drawing 3C-P-7, "Equipment Foundations", ^included elsewhere in this report. The breeching from the induced draft fans to the stack with its associated supports, ladders and walkways was furnished |||by Sterling Steel and Supply Company on Order NY-771907 and f erected by our own forces. The ductwork is fabricated of one quarter inch thick copper bearing steel per ASTM specification A-2$3 grade "C" or "D" and painted inside and out with CheesemanElliot heat resistive Primer No. 357. Wire mesh, 4" x 4", No. 8 gage, was spot welded to the breeching stiffeners; then, ap plication of one and one-half (1-1/2) inch thick heat insulation . was applied and lagged with .020 inch thick aluminum lagging. Insulation Services, Incorporated, furnished and applied the in sulation and lagging on Order NY-771932. The main breeching is supported on the I.D. fan ^foundations mentioned just previous in this section. Gas recirculation is the primary attemporation feature /for steam temperature control. The gas recirculating fans are located six feet, six inches, (6?-6") west of column line "Ja with the north fan three (3) feet south of column line 14 and the south fan three (3) feet north of column line 12. The fans :;were furnished by the Babcock and Wilcox Company on Order NY771802, and are Westinghouse Sturtevant? Type 1008 TVID, cen trifugal, double-width, double-inlet, with water cooled sleeve bearings capable of recirculating 69,400 cfm gas at 687 degrees "-F with a static inlet pressure of minus 2.5 inches H2O and a ^static outlet pressure of 2.0 inches H2O. Westinghouse furnished the two (2) 150 hp motor drivers on Order NY-771813. Each of the two (2) gas recirculating fans are sup ported by three (3) eighteen (18) inch and one (l) thirty-six (36) inch caissons drilled into the Denver shale formation. ||They were drilled and concreted, (17.5 cubic yards), between ; July 7, and July 14, I960, as recorded on field progress drawing 3C-P-1} TrCai sson Data - As Built", included in the drawing section of this report. I' Excavation was performed August 11, I960, and contained 45 cubic yards of machine excavation and 11 cubic yards of hand excavation for a total quantity of 56 cubic yards. Con crete for fan 3B foundation base, (30 cubic yards), was placed |%gust 27, i960, and the 3A fan foundation base, (30 cubic yards), WAD00777 114 placed August 30, I960. Motor and fan bearing piers for n 3A were concreted March 10, 1961, containing 9-5 cubic yards concrete for 3B fan was placed March 14, 1961, also constaining 9.5 cubic yards. The foundations are shown on Drawing f G-I59765 and concrete placement is recorded on field progress * drawing 3C-P-7, "Equipment Foundations", included elsewhere in phis report. % . The inlet ducts from the flue gas duct to the fan injgakes and the discharge ducts from the fans to the lower east side if the furnace wall, including insulation and lagging, were furnished by the Babcock and Wilcox Company on Order NY-771802. A stack was designed to serve Unit No. 3 and future Unit No. 4 based on an exit velocity for two (2) units. An orifice at the cap will not be provided for Unit No. 3 operation. Two w (>2) breeching blanked off. openings A baffle are provided with the wall will extend from future Unit No. 4 two (2) feet below to two (2) feet above the flue openings and placed at an angle of forty-five (45) degrees to the horizontal axis of the openings. The stack height to be the same as the one common to Units No. 1 and No. 2. A ladder is furnished for the full height and inserts are provided for future balconies at the top and mid height. Aircraft warning lights are not provided but conduit is included as well as inserts for mounting future lights. A 300 foot high reinforced concrete stack with a separately free standing brick lining complete with all ac cessories and appurtenances in accordance with Ebasco Specification No. PSCC-CH3-I6O was purchased completely erected from Rust Engineering Company on Order No. NY-771845. The steel blank to cover the future Unit No. 4 opening was purchased from Sterling Sbeel and Supply Company on Order NI-771907. The unlined steel hopper for ashes in the bottom of stack was furnished by Denver Steel and Iron Works on local order No. 3C-422. The stack foundation was started in the early stages of construction as the circulating water system was over part of the mat. Machine excavation started August 2, I960, and by August 8, i960, 901 cubic yards of dirt were removed. The upper sections of decomposed and soft shales were excavated by backhoe and the hard shale and trimming to neat lines was accomplished by manually operated air tools. 113 cubic yards of shale were removed by machine and 28 cubic yards by hand. Backfill was by 4chine except for that under and adjacent to the circulating water pipes where manually operated machine tampers were used. .Excess dirt and shale excavation were hauled to and utilized in ff.e railroad fill. The class D concrete seal, (20 cubic yards), w*s placed August 10 and 11. On August 24, 342.5 cubic yards of concrete were 1 placed for the circular foundation mat. The September 20, and contained 233 cubic yards. plinth was concreted The open interior WAD00778 115 section of the plinth was backfilled with sand excavated from the jobsite. The concrete slab in the top of the plinth was not placed until after completion of the stack. The slab was con creted on December 19, 1961, and contained 8 cubic yards of concrete. The reinforced concrete shell is 29 feet, 3/4 inches outside diameter and 13-1/4 inches thick at the base and tapers both faces to 23 feet, 4 inches outside diameter and 7 inches thick at the top. Rust Engineering Company used a timber derrick, steel slip forms and transit mixed concrete furnished by Western Concrete, Incorporated. The concrete was placed in seven and a half (7.5) feet lifts with the first lift placed April 11, 1961, and the final (40th) lift placed July 7, 1961, using a total of 605.5 cubic yards of 3500 psi concrete with ''Protex" air entrain ment. The brick lining is 19 feet, 6 inches inside diameter, sixteen (16) inches thick for the lower one hundred (100) feet, twelve (12) inches thick for the next one hundred twenty (120) feet and eight (&) inches thick for the upper eighty (#0) feet. The lining is reinforced on the outside by circumferential steel bands of three (3) inches by one quarter (l/4) inch spaced every four (4) feet. Bricklaying started July 1&, 1961, and was com pleted September 1$, and the baffle wall was completed between September 26, and October 2. Erection of the cast iron cap was completed September 20; 1961. Erection of the ash hopper in the base of the stack started November 29, 1961, and welding was completed December 15, 1961, with the work performed by our ironworker forces. The blank over future No. 4 opening was erected between December 1$, and December 26 by our boilermaker forces. The blank was insulated and lagged by Insulation Services under the Order No. NY-771932. WAD00779 TURBO-GENERATOR UNIT 116 Pedestal p; The turbine generator pedestal is located in the tur bine room from Elevation 5120 to operating floor level at 5155, Hounded by column lines "A", "B'', ''11-1/2", and "15", as shown |on Drawing G-159739. It is approximately 7 feet long by 31 feet wide. The pedestal and its foundation are entirely separated Ifrom adjacent building structure. The foundation mat is separated llrom building column caisson caps and circulating water tunnels Hy l/2 inch premoulded joint filler. The ground floor slab is jgisolated from the pedestal legs by the same material. At th$ mezzanine floor, the grating is supported by the building frame and clears the pedestal. At the turbine room operating floor, a one (l) inch opening between the pedestal and adjacent floor /slabs was filled with sponge rubber two inches deep and sealed with a thiocol rubber compound. The foundation was excavated in sound shale with all /questionable material below grade removed and replaced with 4 fsack class ''D'' concrete (36 cubic yards). Excavation was per formed by bulldozer for the top 3 feet of weathered shale and by r'a one (1) cubic yard backhoe for the next six (6) feet of Denver formation shale and sandstone, with hand dressing as the subgrade required. & A reinforced concrete mat, 31 feet wide by &4 feet, 6-1/2 inches long and 6 feet thick was concreted, (574-1/2 cubic yards), on October 14, I960. Concrete was supplied by ReadyMixed Concrete Company on Order 30-17. Utilizing the full out put of the supplier's closest batch plant plus occasional truckp from another plant, the concrete was placed at an average rate of 70 cubic yards an hour.& & The pedestal was concreted, (947 cubic yards), in `three sections, November 10, I960, and November 16, I960, for -the south and north lower sections respectively and January 1$, 1961, for the upper portion. Structural timbers, wide flanged Sbeams, and prefabricated panels were utilized in a field office design for the forming. A jurisdictional labor dispute between the carpenters and ironworkers over setting of structural /'steel shoring delayed the forming period for the upper portion. |.;A field designed steel frame, anchor bolt template was fabricated if-by August Frederichs Company on Order 30-155 from material furnished by us. The upper lift was placed with the use of jfjthree (3) cranes in an eight-hour period. Auxiliary steam from the operating plant was used for curing. The embedded misfeeellaneous steel was furnished by Metalcraft on Orders 30|41 and 3C-137. jTurbine Generator |b The turbine generator unit is a General Electric handbook, indoor type with gear driven exciter to develope 150 WAD00780 i 117 ^megawatts at normal throttle conditions of 1600 psig, 1000 degrees F/1000 degrees F reheat, 3600 rpm, tandem compound double flow, bottom exhaust, when operating at 3*5 inches of mercury absolute back pressure. Guaranteed turbine generator gross Iheat rates and steam rates with throttle steam pressure of 1600 psig and turbine exhausting at 1.5 inches mercury absolute back pressure are as follows: Percentage of turbine rating Steam temperature F-throttle 31.4 966 Steam temperature F-reheater 960 Final feedwater temp F 367.1 "Gross heat rate,Btu/kwh 6703 Steam rate-throttle,lb/kwh 6.70 Steam rate-reheater,lb/kwh Steam rate-condenser,lb/kwh 5.65 5.06 Reheater inlet pressure,psig 126 Heat added in reheater,Btu/lb 212.1 Load on Unit, MW 47.1 Throttle flow, M lb/hr 315 53.3 76.6 1000 1000 997 1000 432.2 470.3 6121 7912 6.46 6.59 5.54 5.54 4.65 5.53 215 315 216.1 207.0 60.0 114.6 517 757 100.6 1000 1000 505.2 7672 6.69 5.67 4.53 426 166.5 150.9 1040 104.0 1000 1000 510.1 7676 6.95 5.70 4.54 445 165.1 156.0 1065 The turbine is a condensing, tandem compound double flow, horizontal shaft, multi-stage, reheat, two cylinder, 3600 rpm unit. The unit has a nameplate rating of 150,000 kw: howlever, during initial trials, the unit has produced power at a rate of 170,000 kw with normal condenser vacuum, rated steam ^conditions and the full complement of regenerative heaters in service. There are twenty impulse stages, seven single high pressure stages, seven single intermediate pressure stages and six double-flow pressure stages. The exhaust is bottom, down ward into the condenser. Under conditions of maximum continuous boiler operation, 1.140.000 pounds of 1600 psig, 1100 degrees F steam enters the turbine from the superheater; 900 pounds are bled to the con trol valve seals; 9,700 pounds to the shaft seals; 76,600 pounds to the 4th stage heater; 20,500 pounds direct to the intermecjiate pressure section of the turbine; 97,300 pounds to the 7th stage .heater and 933,000 pounds of 462.2 psig, 669 degrees F steam to the reheater in the boiler. Reheat steam in the amount of 933.000 pounds of 434 psig, 1000 degrees F steam is returned to the intermediate turbine section. 202,100 pounds are bled to the other six extraction feedwater heaters and evaporator, and the remaining 751,400 pounds ai e exhausted from the low pressure turbine into the condenser at ? .5 inches of mercury. The 4th, 7th, 10th, and 12th stage bleeds go to the respective high pressure heaters; the 14th stage bleed goes to .the deaerator; and the 16th, 17th, and 16th stage bleeds go to the respective low pressure heaters. Turbine speed is controlled by a rotating pilot valve governor, which maintains required speed within approximately five (5) percent, and with an adjustment to values between 'two (2) and seven (7) percent of rated speed. There is also WAD00781 an emergency overspeed governor, an automatically tripped eccentric spring loaded ring, which operates at 112 percent Qf rated speed. Excessive exhaust temperature in starting or at low load is prevented by automatically operated water sprays with a manual bypass. All of the shaft seals are of the labyrinth type. There is also an initial pressure regulator which closes the turbine control valves when pressure in the boiler drops below a predetermined level. The turbine is insulated with plastic heat retention material and with metal lagging over the high temperature parts. The insulation for the lower half of the high pressure shell was applied by Construction Specialties, Incorporated on Order 30-399 before placing this piece into position while there was good accessibility. The remaining insulation was ^applied by Insulation Services, Incorporated on Order NY-771932. The generator is a direct connected, horizontal re volving field, liquid cooled stator, gas cooled rotor and is rated at 154,959 kw, 182,305 kva at O.85 power factor, 5,263 amperes, 20,000 volts, 3 phase, 60 cycles, 3600 rpm, with a ;short circuit ratio of 0.64. At full load and 0.85 power factor, the efficiency is 98.6 percent with 30 psig hydrogen. The generator capabilities at various hydrogen pressures are as follows: kva Short Circuit Ratio Power Factor psig Hydrogen 109,383 182,305 (rated) 200,535 1.065 0.64 0.582 0.85 0.85 0.85 15 30 45 The generator will operate satisfactorily but not necessarily within temperature limits with a capability of 145, ,845 kva at 0.85 power factor, 30 psig hydrogen with one (l) /Section of the hydrogen coolers out of service when stator cooling system is operating at rated level. The capacity of the generator is 73,059 kva with all hydrogen coolers in service and the stator liquid cooling system not in service at either 30 psig or 45 psig hydrogen. The generator will operate satisfactorily but not necessarily within temperature limits with a capability of 145,845 kva at 0.85 power factor, 30 psig hydrogen with one (1) section of stator liquid coolers out of service. The generator windings are arranged for wye connections and are suitable for operation with the neutral grounded through a transformer. All six (6) terminals are brought out for phase terminating. Each bushing accomodates three bushing current transformers (nine in all - two on each neutral terminal and one on each line terminal), rated at 7000/5 amperes. Flexible WAD00782 ffeonnectors connect the terminals to the metal clad isolated Iphase bus. The current transformers and connectors furnished .as part of the turbine-generator Order, (NY-771801). The ^linain exciter is rated at 740 kilowatts and is geared to the Brmain shaft at 890 rpm. The main exciter current and voltage at rated load is 15.4 amperes and 96.3 volts on the field winding. The voltage regulator is an amplidyne regulator with line-drop compensation. The main exciter rheostat is motor operated, 125 volt d-c. The exciter is ventilated thru a duct system with its intake located on the pedestal mezzanine level between columns ,T14'T and n14~l/2,? at the east side, with American recleanable filters and furnished with the turbine generator order. General Electric also furnished the three cubicle compartment on the mezzanine platform of the pedestal, which contains the voltage regulator, the generator field air cir cuit breaker and the motor operated field rheostat. The turning gear, also supplied by General Electric as part of the turbine generator order, is motor operated, electrically interlocked with a motor-driven turning gear oil pump. The turbine generator was originally scheduled to ship in June, I960, but was completed earlier than scheduled, so permission was granted to ship on completion with payment terms based on original shipping dates. Work commenced for setting base plates on February 20 with the arrival of the erector. Sub-sole plates were not used and the base plates were dry packed with grout on March 9? 1961, after final positioning. The turbine low pressure exhaust section was set in position April IS, 1961. The generator stator is the heaviest piece of the turbine generator assembly and weighs 335,400 pounds. It was shipped on a special flatcar, with restricted handling and routing. The station gantry crane installed for Unit No. 1 has a rated capacity of 175 tons with an allowable overload of thirty (30) percent. A manufacturer's service engineer was retained to make \a thorough structural, mechanical and electrical check before I handling the stator. On April 20, 1961, the stator was unloaded |; from the flatcar and carried the length of the turbine room and set over its anchor bolts. With the early start, the erection proceeded with a limited crew and was ready for oil flush the first of December, 1961. Oil was flushed on an eight hour day basis until February 26. The extended oil flush period was due to the .cooling of the oil overnight and to a lint like material which 'was troublesome in clearing up. Oil was refiltered and the tank again cleaned immediately before the stretch-out. The turbine was first rolled with steam April 27, 1962, brought up to speed on April 28 and trial operation was WAD00783 realized that date at 5:31 p.m. The turbine generator was turne'' ovr tn the operating department on Equipment Turnover Record, Sheet No,, 50, dated June 22, 1962. 0 The hydrogen cooling system is used for rotor cooling 0nly as the stator is oil cooled. The hydrogen system, a part pf the turbine generator order, is designed so that the tempergture of the hydrogen leaving the coolers shall not exceed 114.; degrees F, under the following conditions of load: c; kva Power Factor Hydrogen psig Heat absorbed ILL ion Btu per Hour $00,535 182,305 136,728 45,576 0, 85 0.85 0.85 0.85 45 30 30 30 5.72 4.95 3.73 2.07 Loss of hydrogen is guaranteed not to exceed amounts indicated in the following data at the operating pressures shown: Hydrogen Pressure 0.5 ps3ig 15.0 psig 30.0 psig 45.0 psig Guarantee 100 cuft/day 250 cuft/day 400 cuft/day 500 cuft/day Expected 50 cu.fi,/day I50 cuft/day 250 cuft/day 350 cuft/day The hydrogen supply comes from an extension to the existing system installed for Unit No. 1. The header extension Is located outside along the west wall at Elevation 5151.17 with a protective shield. There are four hydrogen coolers which require a to tal of 750 gpm of cooling water entering at 90 degrees F and lea v mg it 103.6 degrees F. At rated conditions, hydrogen eaters th e coolers at 137 degrees F and leaves at 114.5 degrees F. The lydrogen control panel is located along with the stator oil cooler panel on the ground floor level northwest of the pedestal. Hie hydrogen seal oil unit is immediately south of the control )anel and both were furnished with the turbine generator unit, hie seal oil unit and its associated hydrogen piping were turned over to the operating department on Equipment Turnover Record, Sheet No. 39, dated May 7, 1962. i,.- The 002 control manifold is located at ground level eimder the west side of the pedestal between columns ^l^'7 and gl14!'. To surge the cooling system of hydrogen, 3600 cubic :;feet of CO2 are required and for purging of air, 1800 cubic ifeet are required. p The turbine piping consists of that piping furnished IfLth the turbine-generator unit by General Electric Company p>n Order NY-771801, and consists of steam leads and lubricating WAD00784 121 'oil piping. The steam piping was installed by B. F. Shaw Company on a field erection contract. Order 3C-147. When blowing out the hot reheat piping, a l6Tt outlet pipe was used to replace the 8!t shown on the drawings on the west intercept valve in order to get a more effective cleaning velocity through the pines. This enabled a steam flow such that four cones could be seen at the outlet. The remaining oil, gas, and control piping were installed by our pipefitter forces. Insulation fwas applied by Insulation Services, Incorporated on Order NY =. .'771932. Accessories furnished for these piping systems includes -Main throttle stop valves with solenoid trip, intercept and preheat stop valves, steam strainer with removable element and temporary startup fine mesh strainers, low vacuum tripping de~ .'vice and an oil operated overspeed trip. The turbine lubricating oil system consists of one (1) main oil pump, one (1) auxiliary oil pump, two (2) turning gear oil pumps, two (2) oil coolers, and the requisite regulators, storage tank, piping, instruments and accessories. The main oil pump is driven by the turbine shaft and has a capacity of 1685 gpm. The auxiliary oil pump is driven by a 440 volt a-c motor and has a capacity of 1030 gpm. The turning gear oil pumps each have a capacity of 3SB gpm and are motor driven, ffme by 440 volts a-c and the other by 12 5 volts d-c. The total quantity of oil required to fill the system is 4,150 gallons land 4,4^2 gallons of oil was purchased from Mobil Oil Company jbn Order 30=744. The main reservoir with a 3350 gallon capacity is Ifquipped with high and low level float operated switches and a Ip&w oil level alarm. It is located at Elevation 5130 southwest the turbine pedestal along the west wall between columns gjplO" and "12" on a reinforced concrete foundation (21-1/2 cubic j|rards) placed on March 13, 1961. The tank was set on its sup porting steel frame thru a temporary opening left in the operating ; floor on April 13, 1962. The two (2) lubricating oil coolers located on the turbine oil tank handle 187,000 pounds per hour or 42? gpm of /oil. 450,000 pounds per hour or 902 gpm of cooling water en ters the coolers at 90 degrees F and leaves at 96 degrees F to ycool the oil from 139.2 degrees F to 115 degrees F. The heat exchange is 2.112 million Btu per hour. The coolers are of r.General Electric manufacture. There is a single oil pass and two water passes. The cooling surface is 822 square feet. The complete lubricating oil system including all ti ping was turned over to the operating department by Equipment `Urnover Record, Sheet No. 35, dated May 7, 1962. -1 1 The stator liquid cooling system utilizes Transil 3il, Type 10CA with a density of .85 and a rate of circulation Q~ 171 gallons per minute (maximum). It consists of two (2) ^oolant pumps, two (2) vacuum pumps, two (2) coolers, two (2) *-lters, an oil reservoir, a temperature control system, control WAD00785 122 janel and necessary piping. y The two (2) coolant pumps, each with 225 gpm capacity )jjid driven by a 440 volt a-c motor and the two (2) vacuum pumps, leach driven by a 3/4 hp, 440 volt a-c motor, are all mounted on |a common base. The reinforced concrete foundation is located jSetween the northwest turbine pedestal leg and the north end of ||he building (column line "15"). The concrete (5 cubic yards) *|as placed on April 4? 1961, as recorded on progress drawing jC-P-7, "Equipment Foundations", included elsewhere in this re- rt. The No. 3A and No. 3B pumps and the No. 3A and No. 3B Vacuum pumps were turned over to the operating department on |fay 7j 1962, by Equipment Turnover Record, Sheet Nos. 45s 46, 47 and 48, respectively. ;> The horizontal oil reservoir with a storage capacity pf 400 gallons is hung from the operating floor steel framing .above and to the east of the pumps with a centerline Elevation of 5147.12. The horizontal coolers are mounted on separate rein forced concrete foundations located on the ground floor level under the north end of the turbine pedestal mezzanine floor. The foundations are each approximately eight (8) feet long, two (2) feet wide, with an eighteen (18) inch mat and piers at ;.either end. They contain two (2) cubic yards of concrete placed March 27, 1961. The stator oil coolers were turned over to the operating department on May 7, 1962, by Equipment Turnover 'Record, Sheet No. 41, for No. 3A and 42 for No. 3B. The vertical oil filters are floor mounted (Elevation 5130) adjacent to the north side of the east center leg of the turbine generator pedestal. They were turned over to the operating department on May 7, 1962, by Equipment Operating Record, Sheet No. 43, for No. 3A and Sheet No. 44 for No. 3B. The control panel is the north cubicle of a two cubicle .panel that also includes the hydrogen control. It is floor mounted on the ground floor, (Elevation 5130) northwest of the northwest leg of the turbine pedestal. " Rated conditions provides for a 72 degree F temperature drop in the oil when entering the coolers at 185 degrees F. iWater enters the coolers at 90 degrees F and leaves at 107 degrees F. Cooling duty is as follows: Rating Load kva Power Factor Heat Absorbed i Btu per Hour 110 100 75 50 25 200,535 182,305 136,728 91,152 46,576 0.85 0.85 0.85 0.85 0.85 2.45 2.05 1.14 o51 .14 WAD00786 Jl lf1' ffinor accessories supplied as part of the turbine Igenerator order include: 62 resistance type temperature de- ^Stectors located in the generator armature slots, generator ^fooling gas chamber, exciter air ducts and generator stator jliquid coolant, Surge protection consists of three outdoor type j.125 mfd 23 kv capacitors and three 19.5 kv lightning arrestors, i Condenser and Auxiliaries H The horizontal condenser with integral hotwell is located directly under the turbine exhaust and was furnished, together with erection superintendence, by Yuba Heat Transfer division on Order NY-771803. Specifically, it is a 55,000 square Spot surface, divided water box, single pass condenser with fabricated steel shell,, The hotwell has a storage capacity of H30 cubic feet. Also provided was an opening and bracing ;in the condenser neck for installation of a low pressure feedwater heater. The 8,050 inhibited admiralty metal tubes 7/8 iinch 0D, 18 BWG, 30 long, (effective length of 29,-9?-4,T) were supplied independently by Chase Brass and Copper Company on Order NY-771906, The condenser is rated as having a duty equal to 720 million Btu per hour. During full load, 751,400 pounds per hour of steam enter from the turbine at 2,5 inches of mercury which discharge as condensate to the condensate pumps. 95>000 gpm , of circulating water enter the condenser at 80 degrees F and leave at 95-1 degrees F,, The condenser was originally scheduled for April, I960. shipment but was shipped in February, two " month early. Shell assembly started on March 6, 1961, outside the west wall on timber cribbing and railroad rails. It was skidded on greased railroad rails into position on March 29, 1961. Half of the tubes arrived on April 21, and stabbing into the tube sheets started April 24 The balance were received May 9, and tubing was completed May 31, 1961. The hydrostatic test on the steam side was completed June 5, 1961, with one tube leak. The tube was plugged as no spares were purchased. The condenser is supported on four reinforced concrete piers which were con creted (13-1/2 cubic yards) on April 11, 1961. The condenser was in service April 19, when the circulating water system was tested and was turned over to the operating department on May 7, 1962, by Equipment Turnover Record, Sheet No. 40. J The vacuum in the condenser is established by the steam jet air ejector, which was also furnished by Yuba Heat Transfer Division on Order NY-771803. This ejector is a twin-element two stage ejector, mounted on a combined shell inter-and-after Condenser, Equipment furnished with this ejector includes cast iron bodies of the primary and secondary jets; chrome moly steam chest; stainless steel nozzles and cast iron diffusers; set of reducing orifices to reduce the initial steam from I925 psig and 1015 degrees F to operating pressure of 325 psig and 938 degrees F; all manifolds, interconnecting steam piping, f valves, strainers and controlling devices. The steam jet air WAD00787 124 Rector is set on supports supplied along vath the main building teel located on Elevation 6111 between columns fTA'g, T,Aa" and -13-1/2s aith botn elements an operation, 2o2.5 pounds 'er hour of dry air and water vapor are evacuated with a back ^pressure of 1.0 inch of mercury requiring 1030 pounds per hour |?b'f steam and 62 s 500 pounds per hoi of cooiing water. Condensed Bgteam is returned to the condense; hotwell. It via5 turned over- * to the operating department on i-ia* 7, 1962, by Equipment Turnover '/Record, Sheet No, 37. |I The priming ejector, which evacuates the steam passages ||n the condenser at startup, was also furnished by the Yuba jfleat Transfer Division, NY-771603. 'It consists of a single /Stage non-condensing ejector capable of exhausting 600 cubic feet of dry air at 15 inches of mercury absolute. T;Jith this equipment is a reducing valve for reducing 19-25 psig steam to operating pressure of 325 psig, and a pressure gage. This equipment is located beside the steam jet air ejector. It was turned over to the operating department Hay 7, 1962, by Equip ment Turnover Record, Sheet No, 3$ |m The three condensate pumps (two operating) are part xpf the feedwater system removing 415,000 pounds per hour each feof condensate from the condenser hotwell, and forcing it through I'the low pressure heaters go the deaerator. They are located ilbetween columns n A ", !TAa" and TMC-l/2;!, !ti^-l/2n on the ground ffloor Elevation uam, me pumps were furnished by Yuba Heat SgTransfer Division on Order 171-7 71603 and are Ingersoll-Rand jfcyertical turbine type, in can, four stage, each handling 832 '9ggpm against a total dynamic mead oi 400 feet. The 126 hp motors jwere furnished by Westinghouse Electric Corporation on Order- , Kf-771813. Condensate pump motor No, 36 top bearing failed during -startup and was replaced by Westinghouse, The pumps were tested during the week of February 25, 1962, and turned l/over to the operating department March 12, 1962, by Equipment Turnover Record. Sheets Nos, 14 and lb. jf9 The reinforced concrete foundations were concreted ||p6-l/2 cubic yards) on January 23, 1901, as recorded or: corn Instruction progress drawing 3C-P-7, frEquipment Foundations", Ijincluded elsewhere in thus report. Circulating Water- System The circulating.water system is a closed circuit and Hjgonsists of a. main cooling tower with the circulating pump in- |itake chamber at the tower end; a combination angle and terminal Iptunnel section adjacent to the intake chamber; interconnecting jljiseventy two (72) inch diameter lock joint reinforced concrete ||pipe thru the yard areas including an angle tunnel block for pdirectional change; tunnel sections under the boiler and station building; and steel pining from the tunnels to the cooling tower '-On one end and to the condenser on the other end; as shown on - Drawing G-159711 ,f Circulating vat or -System - General Plan and -e. WAD00788 The cooling tower is adjacent to coal storage yarn ,?No. 1 oriented north northwest and south southeast with me feenter of the south wall 520 feet east of column "A" and 202 feet north of column "IS1*. 17 The reinforced concrete basin is 251?-4n long by 49 ?- 5_1/2,t wide (inside measurements) and the elevation of the 12 inch thick base slab varies from Elevation 5125.83 to 5124.50 -with the operating water level at Elevation 5129.0 and the top of the 20 inch thick reinforced concrete walls at Elevation 5130. Excavation for the basin was included in field con tract, Ordei 30-145, with Winslow Construction Company at the ^time of the ash basin installation in June, 1961, with the excavated material used in the ash pond embankments. The reinforced concrete slab and walls were placed between June 6, and August 15, 1961, (691 cubic yards). Pozzolith concrete additive was used for the bottom slab and for wall sections No. 3 east, No. 3 west, No, 4 east, No. 4 west, and No. 6 east as per Public Service Company of Colorado engineering department requirements. After stripping forms from these wall sections, the surface porosity seemed excessive and air entrainment was used on the remaining 10 wall sections and all interior piers. The surface texture was improved a great deal on the later placements. The record of concrete place ment is shown on field progress drawing 3C-P-5, "C.W. Cooling Tower Basin and Intake'7, included elsewhere in this report. The cooling tower superstructure was supplied and . erected by the Marley Company on Orders NY-771828 and NY-771829 respectively. Erection was started on August 28, and completed on November 9, 1961. All timber in the cooling tower is Marlith treated fir except the distribution headers and fan stacks which are redwood. Interior fill hangers are of fiber-glass material, end walls and side louvers are of corrugated asbestos siding material. This 9 cell in line, Marley model 653-3-09, induced draft, double flow tower will cool 95,000 gpm of water entering the tower at 95.1 degrees F to 80 degrees F. Height of the tower is 35'-41t from the top of the basin wall to the fan deck. yThe cooling tower was turned over to the operating department on June 22, 1962, by Equipment Turnover Record, Sheet No. 68. After erection, a sprinkling system was installed with connections to the yard fire protection system for keeping -the tower damp until it would be placed in operation. This system was left in place for future use in case tower is idle for an extended period. The nine Marley type H--3-P fans are 22 feet diameter, ^each with 12 cast aluminum blades, 157 rpm, 10,870 fpm tip |Speed, and each fan moves 862,000 cfm. Speed reducers were also furnished by Marley. Motors are one speed 125 hp, 1800 rpm : ^d were purchased from Westinghouse Electric Corporation on Order NY-771813. Fan stacks are venturi type approximately gtwenty two (22) feet diameter by 14!"4Tf high. Fan direction WAD00789 126 be reversed for de-icing during winter operation. Each was checked for rotation, tested and run-in for two hours April 19 and 20, 1962, under the direction of manufacturer's ervice engineer. The nine fans numbered No. 3A through No. 31 jre turned over to the operating department on May 7, 1962, ^ Equipment Turnover Record, Sheets No. 26 through No. 34. Circulating water leaves the south end of the cooling Lwer basin through a reinforced concrete intake structure where ie two circulating water pumps are located. The reinforced ncrete intake structure shown on Drawing G-159731, "Circulating ^ter System Intake - Masonry". It contained 312 cubic yards class B concrete which were placed between November 2, I960, fed May 19, 1961, as recorded on construction progress drawing .P-5 "C.W. Cooling Tower Basin and Intake", included elsewhere JJn this report. Steel plates one and one-half inches thick were Anchored and grouted in the intake structure bottom slab directly fender the pump suctions to prevent cavitation of the concrete fend were purchased from Metalcraft Welding and Fabricating Com pany on Order 3C-137 ||1 Other imbedded parts in the intake structure include fenchor bolts furnished by Sterling Steel and Supply Company on I'Ohder 3C-77; ladder rungs, screen and stop log guides and pipe jsleeves were furnished by Metalcraft Welding and Fabricating pObmpany on Orders 3C-61, 3C-96 and 3C-126, respectively. The Jgalvanized screens were furnished by Sterling Steel Company JJSs part of Order 3C-77. f> The structural steel framing for the hoist handling stop logs, screens, circulating water pumps and motors was also ffurnished as part of Order 3C-77 from Sterling Steel and Supply Company. The walkway from the cooling tower to the existing |walkway connecting cooling towers No. 1 and No. 2 was furnished fily Metalcraft Welding and Fabricating Company on Order 3C-725 +* The fourteen (14) ton Robbins and Meyers bridge crane With hand chain, propelled geared trolley was supplied by Materials handling Equipment Company on Order 30=323. jp The circulators are set on the intake basin at the south end of the cooling tower from where the water is disipharged to the conduits which run thru the plant area south of pCnit 3 chimney, along the north side of the boiler and into the puilding along the south side of column line "15"; then turns pouth to either side of the condenser. 4 The two (2) circulating water pumps are Ingersoll Rand jlyertical non-removable element, type 36APM-2, two (2) stage j*ith a capacity of 47,500 gpm against a total dynamic head of 63 jjjpaet with 7 foot submerged section. They were furnished by jpuba Heat Transfer Division on Order NY-771303 and the 950 hp ^ aiotors were furnished by Westinghouse Electric Corporation, Order NY-771GI3. The pumps were test operated April 19, and WAD00790 wire turned over to the operating department on May 7, 19o2} jKj; Equipment Turnover Record, Sheet No. 24, for No, 3A and Sfskeet No. 25 for No. 3B. HTr The circulating water conduits thru the station "luilding and boiler areas to a directional transition near the iliimney are reinforced concrete tunnels. Blocks are numbered j|s shown on Drawing G~159711, ^Circulating Water System - General plan and Profile", with Blocks Nos. 1, 2, 3, 4, 5 and 6 single conduit around the turbine generator foundation and the balance twin conduit. Block No. 7 is a transposition from the two single conduits into one twin conduit. Block No. 13 is a trans- Position to concrete pipe. Block No. 14 is a directional tran- . sition piece between sections of the seventy two (72) inch reinforced concrete piping. Block No. 15 is a transposition from concrete pipe to twin conduit tunnel near the intake structure and Blocks Nos. 16 and 17 are the terminal sections. Blocks 1, 6s 16 and 17 have reinforced concrete collars around the 4$ inch steel pipe imbedded sections for inlets and outlets at the condenser and cooling tower. Block No. 17 has manhole accesses and is the low point in the system. Valve operated drains begin at Block 17 and terminate in an existing storm sewer manhole east of the intake structure. Between tunnel Blocks No. 13 and 15, two 72 inch diameter reinforced concrete pipe are laid nine (9) feet on center containing a total of 577.OB linear feet. The intake line is designed for total' dynamic operating head of 65 feet of water and maximum 110 feet. The discharge line is designed for a total dynamic pump shut-off head of 50 feet of water and water hammer head of 60 feet. The pipe and fittings were purchased from Lock Joint Pipe Company on Order NY-771G44. Installation was performed between September 26, and November 25, I960. -This installation was slowed somewhat because of underpinning and supporting the large amount of piping south and east of the water treatment building serving the existing units. ? Steel pipe, 4$ inches in diameter, connects the tunnels to the cooling tower at one end and to the condenser at the other end and was supplied on Order NY-771S65 by Eaton ;Metal Products Company. Four butterfly valves, 4$ Inches diameter, were installed in the circulating water lines at the condenser and two (2) motor operated butterfly valves, 54 inches in diameter, were installed, at the C.W. pump discharge, all ^.supplied on Order NY-771G22 with H. Pratt Company. Six (6) Rubber expansion joints, 4$ inches in diameter, were purchased from Moisson Packing and Rubber Company on Order NY-771&32. Excavation in shale for the tunnel sections around (the turbine generator foundation was performed by a one cubic fard backhoe except fine grading beginning July 11, I960, when Excavating for the turbine generator mat. Lower material was =Shale and fine grading was by hand. Machine excavation con tinued for remaining tunnel and pipe sections ^nd this install ation was completed April 17, 1961, Total excavation quantities WAD00791 128 -re: Earth by machine, 3 ,016 cubic yards; earth by hand, cubic yards; Shale by machine, 1,132 cubic yards; shale by id, 100 cubic yards. The concrete tunnel sections excavated in shale used 37 cubic yards of Glass D concrete as a seal coat and Block 14 anchors. The tunnels contained 1,047 cubic yards of lassjs B concrete and the record of concrete placement is shown n: field progress drawing 3C-P-4, ,rCirculating Water Conduits", 'eluded elsewhere in this report. The concrete pipe was bedded in a course sand supLed from a pit source on the job site and a 17 foot wide by foot long concrete cradle was used for pipe support under fie road and railroad track serving the water treatment plant, glass B concrete was used and placed on October 7, and October 12, I960, containing 60-1/2 cubic yards. Circulating Water Treatment Chlorine and polyphosphate treatment of the cooling water were provided for by connecting to the facilities in the water treatment building installed for Unit No. 1. Chlorine rubberlined piping, chlorine control valve, and polyphosphate plastic piping were purchased from Wallace and Tiernan, Inc. on Order NY-771937. Two polyphosphate pumps were installed and tied to existing piping for supply. These are 84 gph capacity and were furnished by Milton Roy Company on Order NY-771866. Milton Roy, on Order NY-771866, also supplied three 15 gph acid pumps, an acid feed control panel, and accessories. Two acid pumps are for Unit No. 3 main cooling tower and the other for treating the increased load on the existing service vrater cooling tower. The panel provided space for future Unit No. 4 controls. /. The second acid tank of 16,000 gallon capacity lo cated directly north of existing tank, was added and supplied by American Steel and Iron Works, Incorporated on Order NY-771912. Cradle type foundation was concreted, (9-1/2 cubic yards), on October 11, and 16, 1961. The acid feed piping to Unit No. 2 main cooling tower twas relocated and included In the ash piping trench from south of the water treatment building to the point where the acid line goes under coal track No. 16 eastward toward the tower. A lead lined trough and small water supply line for '-mixing the acid and water at cooling tower No. 3 were installed in li eu of the acid diffuser. The plant maintenance department had just installed this "homemade" diffuser as the previous diffus ers had been a continuing source of trouble. New York Engineering had the manufacturer revise the diffuser and Public pervice Engineering advised New York at time order was placed to proceed with the new type of diffuser as this "homemade" ar rangement was just being tried out. However, by the time WAD00792 129 dtallation was to be made, it was decided that the year plus erVice and the simplicity of the lead lined trough not to in- tall the manufactured diffuser. The manufacturer was cou nted regarding a credit for returning the material, but due o 'the specific design for each job, they would not accept a eturn. This material is retained in the plant warehouse for ssible future use, `rnulating Water Make-Up System Three settling ponds fed from the South Platte River ia the Farmers and Gardeners Ditch and four 600 gpm shallow ells were provided for Unit No, 1 and contain a sufficient makep supply for Unit No, 3 A new pump was added on the settling pond intake Structure which had been provided with future cells during Initial construction. The pump is a vertical two stage turbine ype, open suction with 3,000 gpm capacity at 120 foot nead upplied by Worthington Corporation on Order NY-771836 driven a 125 hp motor by Westinghouse Electric Corporation on Order fY-771813. The pump was tested on March 14, and turned over %o the operating department by Equipment Turnover Record Sheet No. 49, dated March 15, 1962. Ip:' The existing 12 inch make-up piping system installed |for Unit No. 1, extended for Unit No. 2, does not have suf ficient capacity for Unit No, 3 A new 18 inch pipe was in itialled from the pump discharge header and parallels the >ting iystem through the metering pit along the east side of c. > tooling tower No. 1 to cooling tower No. 3. This pipe has excess capacity and can be extended for future units. A 6 inch bap from this line serves as an emergency make up for the ash water requirements. A flow meter with connections installed lii the existing pit and mounted alongside the present meter on lop of the pit was furnished by Bailey Meter Company on Order NY-771854. The diaphragm control valve was furnished by Black, Sivalls and Bryson on Order NY-771903 and was installed on the #est side of C. W. cooling tower No. 3 near the point of entry bp the basin. Turbine Room Auxiliaries p The batch oil reservoir and transfer pump installed for Unit No. 1 were designed for full plant operation and serve Shis unit with only a pump, filter and piping connections re quired. The turbine lubricating oil filter pump, with a capacity jjff eight gpm, is located on Elevation 5130 in the turbine oil fepom and was purchased on Order NY-771861 with Worthington Rprporation. The lube oil filter Is located on the mezzanine poor level above the filter pump with a capacity of eight gpm |hd was furnished by Alsop Engineering Corporation on Order *-771857. ;w- WAD00793 130 f Fire protection for the turbine lubricating oil tank part of a system that also protects the main and unit 2 liary transformers. The description is detailed under the sformer writeup in the Accessory Electrical Equipment section this report. .3 The turbine supervisory and startup panel is located ectly south of the turbine on the operating floor. This iipment was supplied by General Electric Corporation and in@Jded with the turbine generator Order NY-771801. Instruments "ft he panel include speed recorder, eccentricity recorder, jell and differential expansion recorder and vibration re ader. General Electric also furnished the following instruments mounting on the Boiler-Turbine-Generator control board: fcentricity indicator, shell expansion indicator and differential jfpansion indicator. The turbine gage panel located adjacent to the south <$jglde of column ,TBlln on mezzanine floor (Elevation 5138.50) ' its also fabricated by Panellit, Incorporated on Order NY^1896 and furnished with the following instruments: Steam to JAE pressure transmitter, throttle pressure transmitter, main fjtfceam master transmitter, turbine 1st stage pressure trans- 'mitter, high pressure turbine exhaust transmitter, hot reheat steam at turbine pressure transmitter, turbine reheat bowl pressure transmitter, 4th, 10th, 12th, 14th, loth, 17th and 18th je pressure indicators and cold reheat steam temperature transmitter, main steam master high pressure alarm switch and ..Lin steam master low pressure alarm switch, both connected to ' annunciator. A control cabinet of two panels for the generator ^hydrogen-cooling and stator cooling oil systems was furnished -..by General Electric Company under their turbo-generator order, 'iNY-771801. The left hand panel for the hydrogen system has ' She following instruments: Differential fan pressure gauge, paehine gas pressure gauge indicating and transmitting, flow lifter, annunciator, milliammeter, remote alarm hydrogen cutout switch, rheostat, vacuum pump selector switch with indicating lights, emergency seal oil pump selector switch with indicating ;s, temperature meter and purity indicator. The right hand L for cooling oil system contains the following instruments: Armature cooling oil inlet pressure gauge, main pump discharge llfeessure gauge, vacuum gauge, annunciator tTA,f vacuum pump pushfcton with indicating lights, ,TB,T vacuum pump pushbutton with tdicating lights, fTAn main oil pump selector switch with ineating lights, T,B" main oil pump selector switch, oil remote trm cutout switch, throttling valve Bailey selector station, iree-way valve Bailey selector station and Foxboro temperature sc order. The condenser auxiliary panel is located southwest column nBllrt on the ground floor (Elevation 5130) and was bricated by Panellit, Incorporated on Order NY-771896 with e following instruments furnished: Condensate storage tank v-cl indicating receiver, hotwell level indicating receiver, WAD00794 J 131 denser vacuum transmitter, low pressure drip pumps No. 3A IJlNo. 3B pressure indicators, condenser vacuum column, con- late pumps No. 3A, No. 3B and No. 3C pressure indicators, ortdenser absolute pressure transmitter, condensate flow and. essure recorder, circulating water blowdown flow transmitter, rculating water auto-man selector control, circulating water jlowdown computing relay, circulating water blowdown standatrol lay, condensate transfer pump switch and indicating lights d'main cooling tower on-off-reverse switches with indicating ftghts for Fans No. 3A thru 31. Because of the crowded con'tion of piping in this panel which did not permit access for intenance of instruments, additional openings were made for trument relocation and the piping modified. The gland seal exhauster supplied by General Electric mpany on Order NI-771&01 is mounted on the mezzanine platform, evation 513$.50), adjacent to the west wall between column 'nes T,12Tt and n12atT and exhausts the steam seals through a ainer to the hotwell. WAD00795 ACCESSORY ELECTRICAL EQUIPMENT 132 ntural Features | Structural steel supports and aluminum screen ensure for surge protection equipment were furnished by Muskogee n Works on Order NY-771921. The enclosure and supports are iiited on a generator leads support structure just outside the |t wall, (column line "A"), of the station building between lumns "14" and "14-1/2". A corrugated asbestos cement shed fe roof at Elevation 5157 provides protection for this equipjf|t, along with the generator lead wall bushings, from the ements, birds or rodents. Roof material was furnished by rrugated Asbestos Contractors, Order NY-771904, and installed y :our own forces, ower Conversion Equipment Power for operation of station auxiliaries is provided fcJrJuse of an auxiliary transformer, 12,000/16,000 kva, oa/fa, 9,000 volt delta/4160 volt wye, 3 phase, 60 cycle, supplied by "estinghouse Electric Corporation on Order NY-771806. Primary ' ower to the transformer is tapped from the generator leads etween the station building west wall and the main power transormer, through a 12,000 volt gang operated disconnect switch, d the secondary is duct connected to the 4160 volt switch:fear. A reinforced concrete foundation, 75 cubic yards, |gas constructed immediately under the generator lead structure, (3) feet, three (3) inches north of column line "14" and ffenty-eight (23) feet, nine (9) inches west of "A" column line, on June 19 for the mat, and on July 29 for the pier I'ection, as recorded on Field Progress Drawing 3C-P-6, "Trans~ former Yard Foundations",, ; The transformer was shipped to the jobsite via rail jand received less the radiators and oil. Our Northwest Model 30 ` crawler crane was used to unload the transformer and set it on Its foundation. Installation of radiators and filling with oil fere accomplished by Sturgeon Electric Company as part of their glectrical contract. The radiator fans were tested and run-in In February 19, 1962. i A complete automatic fixed water spray type fire ifrotection system is provided for the main and unit auxiliary transformers and the indoor turbine oil tank. A deluge valve ps provided in the main supply pipe of each protected unit j|perated by impulse from a heat actuated device. The system is l|,,.dry type to prevent freezing, welded construction, spray type ater nozzles, and was furnished by Viking Fire Protection Jdmpany, Order NY-771368, and installed by them on Order NY1/1369. Concrete supports, (2.0 cubic yards), for this system |ere placed on October 27, and October 31, 1961. The pipe supply "nes are all sloped so that the outdoor portion can be drained WAD00796 prevent freezing. The drain valves for the lines are lo oted in a concrete pit containing 1 cubic yard of concrete with ie slab placed March 21, and the walls March 27, 1962, located [n the transformer yard near the point where the lines enter She building. A 4 inch drain line removes water from the box the yard drainage system. The system was tested April 24, Three (3) indoor station service transformers, each ||b kva, self-cooled (inerteen), 4160/4&0/227Y volts, 3 phase, }! cycle, 11 percent impedance, were supplied by Westinghouse U'ectric Corporation on Order NY-771808, and are located within |te confines, of the switchgear room at Elevation 5130. Primary jpwer is derived by cable thru duct bank from the 4160 volt ;chgear and throat connected to unit power centers 3A and 3B and common power center C. Three (3) outdoor station service transformers were also supplied by Westinghouse Electric Corporation on Order NY- 771 SOS. The cooling tower transformer, 1000 kva oa/1150 kva fa cooled, 4160/480/277Y volts, 3 phase, 60 cycle, 11 percent impedance, is throat connected to its associated switchgear and is mounted on a common foundation for both pieces of equipment Northwest of the southwest corner of the cooling tower. The ash handling transformer, 550 kva, oa cooled, . :60/4S0Y/277 volts, 3 phase, 60 cycle, 6.5 percent impedance, is located on its reinforced concrete foundation, (1 cubic yard), placed December 4, 1961, seven (7) feet north and seven (7) feet east of column T,Gbl4'T and is cable connected to its as sociated switchgear. The remaining transformer serves the service water and pond discharge pumps having a capacity of 300 kva, oa cooled, 4160/430/277 volts, 3 phase, 60 cycle, 5 percent impedance. The transformer is mounted on a reinforced concrete foundation, |1.5 cubic yards), placed December 5, 1961, located northwest df Unit No. 1 cooling tower and is cable connected to its switchgear. General Electric Company supplied a neutral grounding transformer, 50 kva, 20,000/240/120 volts, single phase, 60 feycle, askarel filled, with the 240 volt secondary connected to 452 ohm, 37 kw edgewise wound resistor as part of the turbo generator order, NY-771801. This device is enclosed in a cubicle _ d mounted on the mezzanine level, Elevation 5138.50, of the jgirbine generator pedestal and is connected to the generator /eutral bushing bus bar to accomplish grounding of the unit. Also supplied by this vendor on the turbo-generator jder were nine (9) bushing current transformers rated at 7000/5 aperes, single ratio, 60 cycle at 25 kv, for instrumentation (Jjd relaying purposes on the generator. Two (2) transformers Te mounted on each neutral and one (1) on each line bushing. WAD00797 134 ay type holders are added to fill up space for three (3) ansformers on each bushing. An indoor metal enclosed cubicle containing four (4) tential transformers, compound filled, 25 kv insulation and shings, 150 kv BIL, 175:1 turns ratio, 21,000/120 volts, 400 va ilmal rating and eight (3) type BAL current limiting disconnect ses, rated l/2 E amperes, 23,000 volts, 70,000 amps rms inErupting capacity, is located on the ground floor, Elevation 130, directly under the enclosed isolated phase generator leads %.e (9) feet inside the west wall (column line "A"). Primary S1ps from the generator leads supplies potential to this device j|r instrumentation and regulating purposes. Westinghouse ectric Corporation supplied this apparatus as part of the Isolated phase generator leads on Order NY-771312. The cubicle is mounted on a reinforced concrete foundation (3*5 cubic yards) placed April 19, 1961, as recorded on field progress drawing 3C-P-7, ''Equipment Foundations", in cluded elsewhere in this report. All lighting requirements for the station building and outlying plant areas are provided for by seven (7) lighting trans formers furnished by Westinghouse Electric Corporation on Order KI-771306. The electrical characteristics and location are as follows: Designation Location Characteristics No. 26 No. 27 No. 23 No. 29 No. 30 No. 31 No. 32 Sta 31dg-El 5132.5-Col B-12 Sta Bldg-El 5145.7-Col Da-12 Sta Bldg-El 5163.0-Col Da-11 Sta Bldg-El 5149.2-Col Da-14 Sta Bldg-El 5163.0-Col B-14 Boiler -El 5213.0-Col Gb-14 Sta Bldg-El 5149.0-Col Da-14 45kva,30.,43O/2O8Y/l2OV 45kva,30,430/203171207 3Okva,30,43O/2O6vY/l2OV 7ikva,10,48O/120/24OV 30kva,30,430/20BY/120V 30kva'30,430/2031/1207 3Okva,30,43O/2O3Y/l2.O7 Freeze protection requirements are satisfied by three , (3) transformers, 15 kva, 430/203Y/12.0 volts, 3 phase, 60 cycle, ,dry type, supplied by Westinghouse Electric Corporation on Order |||Y-771306. Two (2) transformers are located on the boiler struc- gfure with No. 7 mounted on column "Fal2" at Elevation 5193.5 and o. 3 mounted on column "Fal4" at Elevation 5193.5. The remaining transformer, No. 9, is mounted on column "Dal3" at Elevation 5195.5 of the boiler structure. Heating requirements for outlying areas, such as the cooling towers and pond intake pumps, are deg;ived from lighting transformers serving those areas. The excitation cubicle supplied by General Electric Company as part of the turbo-generator order, NY-771301, is located on the mezzanine floor, (Elevation 5133.5), of the edestal under the generator at the collector end. The three fdmpartment cubicle is of indoor construction with compartments fssigned as follows: One (1) compartment contains the generator eadfront field switch, 2 pole, 375 volts d-c, non-drav>rout type; WAD00798 135 (l) compartment containing the motor operated rheostat and slidyne motor generator set; and the remaining compartment feains regulation equipment consisting of amplidyne voltage JLator control and accessories. Generator field leads and "iter leads enter the cubicle from the top. ^.tchgear and Cubicles - 4160 Volt The 4160 volt switchgear is located in the area jgignated as the transformer yard outside of, and adjacent to, l|'west wall of the station building. They are approximately 'rty (30) feet west of the west wall, (column line "A") bejjen column lines 13 and 14 extended. The switchgear is outdoor, heavy-duty, metalclad ipe, in a double bus arrangement, with drawout type electrically "rated air circuit breakers, 4I0O volts, 60 cycle, 1200 amperes 'tinuous rating and 250 mva interrupting capacity with an erruption time of o cycles. Each compartment, except the Jciliary compartments for potential transformers and cables, complete with one vertical lift, horizontal drawout type air ircuit breaker, bus and bus connections. All breaker compartments, except compartment containing spare breaker, are complete with current transformers, overrr.ent, induction and other protective relays, alarm relay and 'strumentation. All switchgear was supplied by Westinghouse pctric Corporation on Order NY-771&07. The switchgear's jin. bus is directly connected, through an enclosed throat gtion, to the auxiliary transformer secondary. The cable jeders from the switchgear to the 4160 volt auxiliary motors p station power transformer primaries are through concrete Rased fibre duct. The foundation area was excavated into herd brown sandtone and blue Denver shale as shown in section on nrawing SK- `gg-F32, nSub-Surface Profiles'', included elsewhere in this eport. A B-22 Bucyrus Erie backhoe and manually operated air __ ols excavated a total of 225 cubic yards of material, which .^oluded all duct runs to the switchgear. After all conduits were in place, 102 cubic yards of TW-cement encasement and fill-were placed between August 7, -J# August 1$, 1961, to bring the grade up to the bottom of the . ^chgear foundation. . The reinforced concrete foundation is shown on Drawing r,,97&3, "Substation Facilities - Transformer Yard Foundations :-R - Sheet 2", and contains 40 cubic yards of class "B", *2. sacks of cement per yard, air entrained concrete placed Mgust 29, 1961o Concrete placements are recorded on Field ress Drawing 3C-P-6, "Transformer Yard Foundations ", in,.,d elsewhere in this report. Three (3) sections of outdoor metalclad switchgear, containing a type 50-DH-150-D air circuit breaker and WAD00799 jfitih common 4160 volt switchgear at Unit No. 1 and occupy positions as follows: 6AG is for AS0 volt common control center &C, on common switchgear nA!t; 6BC is the motor feed for boiler fejed pump No. 3G; and 7BC, is the feed for ash handling trans former on common switchgear ''S'*. A tie is provided, with automatic throwover, between tltd unit 4160 volt switchgear, compartments 2A and 2B, and Unit $0. 2 4160 volt switchgear, compartments 10A and 11B, to provide jpoWer in the event of a fault which results in operation of the generator lockout relay or in the event the Unit No. 3 auxiliary power transformer is taken out of service. All switchgear was received early and stored adjacent to the foundation area. After the concrete was placed for the foundation, the switchgear was set on the foundation by use of our Northwest, Model SO crawler rane. Compartments of the Unit No. 3 4160 volt switchgear e assigned as follows: mpartment 1A 1AX 2A 3A 4A 5A 6A 7A SA 9A 10A IB 1BX 2B 3B 4B 5B 6B 7B SB 9B 10 B Service Feed from auxiliary transformer No. 3 Auxiliary compartment Standby-startup tie from Unit No. 2 Cooling tower No. 3 transformer and service cooling water and pond discharge transformer Circulating water pump No. 3A Induced draft fan No. 3A Forced draft fan No. 3A Station service transformer No. 3A Boiler feed pump No. 3A Pulverizer mill No. 3A Pulverizer mill No. 3D Feed from auxiliary transformer No. Auxiliary compartment Standby-startup tie from Unit No. 2 Spare breaker Circulating water pump 3B Induced draft fan No. 3B Forced draft fan No. 3B Station, service transformer No. 3B Boiler feed pump No. 3B Pulverizer mill No. 3B Pulverizer mill No. 3C' 3 Control of all 4160 volt switchgear breakers is from ft WAD00800 137 fenhgear and Cubicles - 480 Volt The unit auxiliary power supply system is split into An and '*3" group at both the 4160 volt and 480 volt levels, or drivers for sets of auxiliaries consisting of two or more Intical units will be alternately connected to derive their H*#er from the nATT and ,rBrt systems, in order to maintain the ^__ mum degree of reliability. The 480 volt auxiliaries directly l.ociated with Unit No. 3 only are designated 3A and 33 and seperately fed from the 3A and 333 4160 volt switchgear which "turn is fed from the Unit No. 3 auxiliary transformer. The existing common 430 volt system which is fed from the existing 41o0 volt common system is extended for Unit No. 3 mmon equipment. An interconnection between Unit No. 3 and e common 48O volt systems is provided. y Westinghouse Electric Corporation supplied all the 4t|} volt switchgear on Order NY-771808 including cubicles for control centers. The main vertical bus in all 430 volt motor C&ritrol centers and power centers, except the ash handling con sol center, was silvered aluminum in lieu of silvered copper. Tperience with this type of bus in the local area proved untisfactory as heavy deposits would build up at connection dints. Westinghouse Electric Corporation subsequently changed ut all of this bus to silvered copper, at no cost to us. |; The switchgear room is located on the ground floor Sllevation 5130) at the north end of the station building directly Oder the control room (Elevation 5155.0) and the cable vault dm (Elevation 5142.0) between columns TtBn and ,TDa,T, ,T14" and 15". Two (2) complete sections of 430 volt switchgear, power centers No. 3k and No. 33, are located within the switch- ear room at Elevation 5130 and are throat connected to their ssociated transformers. The switchgear assemblage is indoor awout t;rpe, containing electrically operated air circuit reakers. A tie is provided with automatic throwover to 430 bit switchgear No. 2A and 23 installed for Unit No. 2 extension. Compartments are assigned as follows: Compartment Service 3A-2 3A-3 . 3A-4 3A-5 3A-6 3A-7 3A-3 Relay & auxiliary control compartment Station service transformer 3A breaker 430 volt switchgear ,t2An tie 430 volt valve control center No. 3 480 volt control center 3 A 480 volt control center 30 Space for future use < 3B-2 , 3B-3 - 3B-4 3B-5 Relay & auxiliary control compartment Station service transformer 3B breaker 480 volt switchgear tT2BTf tie 430 volt control center 3B WAD00801 5r O lartment W` I-3B-6 &3B-7 t'3B-8 J G TV JL 480 volt control center 3D Spare breaker Space for future use One section of switchgear, 480 volt common power center associated with this equipment common to several units, is also |ited within the confines of the switchgear room. This indoor -out type switchgear assemblage, contains electrically operated circuit breakers. Compartments are assigned as follows: 480 Volt Common Switchgear "0" partment Service 3CC-2 3CC-3 3CC-4 3CC-5 Relay and auxiliary control compartment 480 volt common control center T,Dt? 480 volt common control center ,fErr 480 volt H & V control center "D" One section is part of a composite transformer powerhatrol center arrangement for main cooling tower No. 3 fans. Ifs section of apparatus is outdoor type and sets on a com"site foundation with its associated transformer and control Inter at the southwest corner of No. 3 cooling tower. This Ltchgear, containing electrically operated air circuit break 's, is throat connected to both its associated transformer and ntrol center. Compartments are assigned as follows: * .'Compartment 480 Volt Cooling Tower No. 3 Switchgear Service 1A Relay and auxiliary control compartment IB Cooling tower transformer No. 3 1C Tie breaker The 48O volt control centers are situated through put the station building and outlying equipment to provide :power in the areas of greatest demand utilizing a minimum of cable with resultant minimum loss of voltage. Westinghouse .Electric Corporation on Order NY-771808, also supplied nine JL9) indoor type and two (2) outdoor type 480 volt control centers ir smaller unit and common motor controls on auxiliary rotating juipment. Three (3) indoor control centers are fed from the 480 '.It power center 3A and are designated and located as follows: jntrol center 3A is located approximately nine (9) feet west d three (3) feet south of column ,TFal5,T at Elevation 5130; itrol center 30 is located approximately three (3) feet east Jd six (6) feet south of column "Aall" near the condensate ~ps at Elevation 5130- Valve control center 3 is located .proximately two (2) feet east and five (5) feet south of column Yl,r at Elevation 5130. Compartments are assigned as follows: WAD00802 liphCompart- ment _ ID IF f IK ; 2D 2F 2K 3BR 3BL 3D 3F 3H 3L 4D 4G 4H 4K 5D 5F 5H 51 6BR 6BL 6D 6F 6h 6k 7BR 7BL 7D 7K 1BR 1BL ID IK 2B 2D 2K 4S0 Volt Control Center 3A Breaker Frame Trip Elemt Service 100 100 100 100 100 100 100 100 100 100 15 Pulverizer mill feeder 3A-N Fuse and relay panel 15 Pulverizer mill feeder 3A-S 15 Pulverizer mill feeder 3D-N Fuse and relay panel 15 Pulverizer mill feeder 3D-S 40 Spare breaker 20 Spare breaker 15 Air heater 3A bearing oil pump 15 do cooler fan 50 Spare starter 30 Air heater No. 3A 100 Auto-throwover switch 120 v a-c dist panel No. 3 120 v a-c distribution panel No. 3 40 Primary brkr 15 kva distr transf No. 3 15 kva, 1 phase, 4^0/120/240 v transf 100 100 100 100 15 70 Service & coolg water return pump No. 4 Spare starter Spare starter Space for future use 100 100 100 100 100 100 . 40 100 15 15 15 15 Spare breaker Future electrostabic precipitator Spare pump No. 4 sulphite/morpholine Morpholine pump No. 1 Phosphate pump No. 4 I.D. fan 3A bearing blower 100 100 400 50 90 300 Lighting transformer No. 27 Soot blower power panel Space for future use Gas recirculation fan No. 3A 4^0 Volt Control Center 3C 100 100 400 40 Spare breaker 20 Spare breaker Space for future use 15 Condensate pump No. 33 400 50 70 300 Spare starter Spare starter Turbine No. 3 auxiliary oil pump WAD00803 430 Volt Control Center 3C--Contd Compart ment p 3BR Breaker Frame 100 100 100 100 100 100 100 100 100 Trip Elemt 100 Service Main transf No. 3 cooling equip source ,TA,f Lighting transformer No 26 Lube oil filter pump Spare starter L.P. heater drain pump No 3A Vapor extractor Gland exhauster No. 2 Stator oil vacuum pump No. Stator oil pump No. 3A 3A 430 Volt Valve Control Center No. 3 100 100 100 100 Boiler feed pump 3C discharge valve Boiler feed pump 3B discharge valve Boiler feed pump 3A discharge valve Main steam shut-off valve Two (2) indoor control centers are fed from the 430 volt power center 3B and are designated and located as follows: Controlcenter 3B is located approximately eleven (11) feet west and fifteen (15) feet south of column "FalS" near the elevator shaft at Elevation 5130; Control center 3D is located north of the turbo-generator pedestal approximately seventeen (17) feet east and eight (8) feet south of column nAal5'r at Elevation 5130. Compartments are assigned as follows: 430 Volt Control Center 3B Compartment Breaker Frame Trip Elemt Service IB 100 15 Phosphate pump No. 5 ID 100 15 Sulphite pump No. 5 IK 400 300 Gas recirculation fan No. 3B 2C 2E 2H 2K 3BR 3BL 3D 3F 3H 3K 4BR 4BL 100 100 100 100 100 100 100 100 100 100 100 100 30 Air heater No. 3B 15 Condensate transfer pump No. 3A 70 Spare starter 50 Spare starter 20 Spare breaker 40 Spare breaker 20 Evaporator feed pump No. 4 15 Air heater 3B bearing oil cooler 15 Air heater 3B bearing oil pump 15 I.D. fan 33 bearing blower 40 Lighting transformer No. 2B 40 Lighting transformer No. 31 WAD00804 WdbmpartI ment 4S0 Volt Control Center 3B--Contd Breaker Frame Trip Elemt Service 4D 100 50 Spare starter 4F 100 15 Spare starter 4K 100 100 Service & cooling water return pump No. 5 4&0 Volt Control Center 3D ID 100 15 Pulverizer mill feeder 3B-S IB Fuses and relays IK 100 15 Pulverizer mill feeder 3B-N 2D 100 15 Pulverizer mill feeder 3C-S 2F Fuses and relays 2K 100 15 Pulverizer mill feeder 3C-N 3A 30 3D 3F 3H 3L 4BR 4BL 4D 4F 4K 100 100 100 100 100 100 100 100 100 100 100 20 Spare breaker 50 Amplidyne M-G set 50 Space heater transformer No. 5 15 Hydrogen seal oil vacuum pump 30 Hydrogen seal oil pump 70 Spare starter 40 Spare breaker 20 Spare breaker 15 Gland exhauster No. 1 15 Spare starter 90 L P Heater drain pump No. 3B 5BR 5BL 5D. 5F 5K 100 100 100 100 100 100 20 30 15 90 Main trans No. 3 cooling equip source nB,? Unit auxiliary transf No. 3 cooling equipment Turning gear No. 3 Stator oil vacuum pump No. 3B Stator oil pump No. 3B 6B Space for future use 6D Space for future use 6K 400 300 Condensate pump No. 3A 7B Space for future use 7D Space for future use 7K 400 300 Condensate pump No. 3C Three indoor control centers are fed from the 48O volt common center C and are designated and located as follows: 4$0 volt common control center TtDf* located in the switchgear room at Elevation 5130; 4$0 volt common control center TtE'r ts adjacent to valve control center No. 3 approximately two (2) feet east and eight (S) feet south of column ,TBllft at Elevation 5130; heating and ventilating control center No. 3, located ^est of the elevator shaft on the operating floor (Elevation 5155). WAD00805 partments are assigned as follows: 4>0v Common Control Center "DTM Breaker Frame Trip Elemt Service 1HR 1HL IK 100 100 100 100 100 100 70 Battery charging M-G set motor 40 Lighting transformer No. 32 40 Alternate feed to 120v a-c distribution panel No. 3 40 Spare breaker 30 Station elevator M-G set motor 70 Spare starter 2B 2K 600 450 Space for future use Soot blower air compressor No. 4$0v Common Control Center nEn IB IK 600 450 Space for future use Soot blower air compressor No. 2B Space for future use 2K 600 450 Soot blower air compressor No. 3BR 3BL 3 DR 3DL 3F 3H 3L 100 100 100 100 100 100 100 40 Spare breaker 70 4$0 volt power receptacles 40 Lighting transformer No. 30 20 Lighting transformer No. 29 50 Spare starter 40 Spare breaker 50 Turning gear oil pump too Volt Heating: & Ventilating Control Center ,fDtT 2B 2D 2F 2H 2K 3BR 3BL 3D 3F 3H 3K 4B 4D 4F 4H 4K 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 15 Wall propeller fan E-26 15 Vane axial fan E-27 Space for future use 70 Spare starter 50 Spare starter 40 Air conditioning unit AC-3 far compressor 30 Electric unit heater No. 4 15 Roof ventilator RV-15 15 Roof ventilator RV-16 15 Roof ventilator RV-17 15 Roof ventilator RV-13 20 Hot water circulation pump No, P-1 15 Roof ventilator RV-19 15 Roof ventilator RV-20 15 Roof ventilator RV-21 15 Roof ventilator RV-22 WAD00806 143 | /j.30 Volt Heating & Ventilating Control Center "D"--Contd apart - Breaker Frame Trip Elemt Service 5BR 5BL 5D 5H 5K 100 100 100 225 100 40 20 30 150 30 Spare breaker Spare breaker Dry dust collector E-30 Air washer S-5 centrifugal fan Air washer S-5 circulation pump IB ID IF 1HR 1HL IK 100 100 100 100 100 15 Fan TF-1 15 Roof ventilator RV-23 boiler drum end enclosure 15 Roof ventilator RV-24 boiler drum end enclosure 30 Electric unit heater No. 5 30 Electric unit heater No. 6 Space for future use All the foregoing 1+&0 volt control centers are cable jnnected to their respective unit or common switchgear. An indoor 4S0 volt ash handling control center is jcated approximately six (6) feet east and six (6) feet south column "Gbl4" at Elevation 5130. The ash handling control center is cable connected its associated transformer outdoor whose primary feed is *om compartment 7BC of the 4160 volt common switchgear (Unit 1) furnished and installed on Unit No. 3. Compartments e assigned as follows: 430 Volt Ash Handling Control Center .Compart ment Breaker Frame Trip Elemt Service IB Space for future use ID Space for future use IK 400 300 Ash water pump No. 2 2B Ash handling transformer ground relay 2D Space for future use 2K 400 300 Ash water pump No. 1 ! 3B 7 3D 3E 3H \ 3L 100 ,100 100 100 100 50 Ash sump pump No. 2 50 Ash sump pump No. 3 40 Spare breaker 15 Ash clinker crusher No. 34 15 Ash clinker crusher No. 3B r One "walk-in" weatherproof outdoor housing is furnished W the 480 volt control center for cooling tower No. 3 fans and ocated on a common reinforced concrete foundation with its tociated 4$0 volt switchgear (power center) and 4160/4^0 volt WAD00807 144 -ansfo'rmer whose primary is fed from the 4160 volt switchgear Compartments are assigned as follows: 480v Cooling Tower No. 3 Control Center ;partment Breaker Frame Trip Elemt Service 400 400 400 400 400 400 400 400 400 350 350 350 350 350 350 350 350 350 Main cooling tower fan No. Main cooling tower fan No. Main cooling tower fan No. Main cooling tower fan No. Main cooling tower fan No. Main cooling tower fan No. Main cooling tower fan No. Main cooling tower fan No. Main cooling tower fan No. 3A 3B 3C 3D 3E 3F 3G 3H 31 10A 10C 10E 10F 10K 100 70 Lighting transformer primary breaker Filler 20 Circuit lighting panel Filler 15 kva, 1 phase, 4&0/l20/240v transformer The foundation is located approximately eleven (11) eet west of the southwest corner of the cooling tower. The oundation contained 19 cubic yards and was concreted June 19, 961. One "walk-in'' weatherproof outdoor housing is furnished or the 480 volt service water cooling tower and pond discharge dntrol center as an extension to the existing control center. ntrols in the existing control center were rearranged so the ew extension is a unit operation and is fed from the unit 4160 o.lt switchgear 3A (Compartment 3A) with the cooling tower rvice. Compartments are assigned as follows: 480v Service Cooling Water & Pond Discharge Control Center ompartment Breaker Frame Trip Elemt Service 9D 800 800 Transformer tie breaker 9H 225 125 ^Shallow well pump No. 4 9K Space for future use 10D 10H 10K 100 100 30 90 *S.V/. cooling tower fan No. (7-1/2 hp) *S.W. cooling tower fan No. (30 hp) Space for future use 3 3 11D 11H UK 100 225 100 150 *Deep well pump No. 4 Service cooling water pump No, Space for future use WAD00808 gr.tr 'Service Cooling Water & Pond Discharge Control Center-- Gontd fctompartment Breaker Frame Trip Elemt Service 12B 12D 12K 400 350 Space for future use Space for future use Pond discharge pump No. 4 * Relocated from existing service water control center fj|jr Relocated from existing water treatment control center 5 The service cooling water and pond discharge pump ntrol center is located on an extension of Unit No. 1 control inter foundation, (4.5 cubic yards), placed December 4, 1961. All control centers consist of dead front metal housings containing 15,000 amp minimum interruption rated starter jjnits consisting of a combination circuit breaker and full voltage magnetic contactor, with external manual reset thermal jjyerload relays, a 3 phase, 600 volt, horizontal bus and a 3 phase, 300 volt, vertical bus. Starters for the three soot blowing air compressors, compartment 2K on common control center ,TD!t and compartments IK dnd 2K on common control center "ETt, proved to be undersized When the equipment was started up. Westinghouse supplied six 6) capacitors, size 20 xvar, two (2) for each motor. The four (4) capacito^^ fo'- compressors 7 and S were mounted in a j&pare compartment located at the south end of common control center E. The capacitors for the remaining compressor, No. 6, were mounted on top of common control center D and enclosed with sheet metal. Heaters for the gas recirculating fan motor starters were inadequately sized and the motors tripped out when starting up. Numerous changes in the heaters failed to resolve the problem. Westinghouse solved the problem by furnishing current trans formers and an inductive shunt to replace the heaters. The ad ditional appurtenances are mounted in the starter cubicles. Switchgear and Cubicles, 12$ volt d-c Royal Switchboard Company, Incorporated furnished the indoor, enclosed, dead front, self-supporting floor mounted d-c distribution panel, Order NY-771847, located in the switchfear room south of the battery M-G set, at Elevation 5130. flower is supplied to the panel from the station battery with a hie to Unit No. 1 distribution panel through a 250 ampere fuse. The motor generator set is tied to the panel also with a 200 amp Esconnect breaker located at the bottom of the panel. This jj|ftel is arranged to serve the following equipment: nneetion Amperes Equipment 1 35 Transformer fire protection WAD00809 146 Amperes Equipment 60 Spare unit 35 Motor control center 3k 35 Motor control center 30 35 Motor control center 3D 35 Reverse current valves 35 Steam temperature panel 35 Hydrogen panel 35 Turbine start-up1 panel 35 Operation recorder 35 Excitation cubicle 35 Purge protection panel 60 B T G board 60 Main control board 60 4160 volt switchgear 3k 60 4160 volt switchgear 3B 60 4S0 volt switchgear 3k 60 4S0 volt switchgear 3B 60 4S0 volt common switchgear ''O'* 60 4S0 volt control center No. 3 60 60 60 60 200 Auto-transfer switch L.P. No. 29 Spare unit Spare unit Spare unit D-C control center The 125 volt d-c control center located in the switchear room, on column ,TCTt and eight ($) feet, nine (9) inches uth of column line T,15n at Elevation 5130, was supplied by estinghouse Electric Corporation on Order NY-771BOS. Feed to 'e center is derived from the d-c distribution panel setting on e same foundation and is connected by two (2) l/c 250 mcm bles. Equipment served by this control center is as follows: 125 volt d-c Control Center Breaker Frame Trip Elemt Service Resistor compartment Emergency seal oil pump No. 3 Emergency bearing oil pump No, Space for future use Vacuum breaker valve No, Spare starter Space for future use Boiler feed regulator block valve Boiler feed regulator by-pass valve WAD00810 12 5 volt d-c Control Center--Contd 147 Compart ment Breaker ___Frame Trip Elemt Service 4B Space for future use 4F 100 50 Circulating water pump No. 3A discharge valve 4K 100 50 Circulating water pump No. 3B discharge valve Freeze Protection Panels Three (3) freeze protection distribution panels are utilized in providing heat for water or steam lines exposed to extremely low atmospheric temperatures. Penn Panel and Box Company furnished these panels on Order NY-77l8$8. The distri bution panels are outdoor weatherproof type containing a 20 circuit panel board, 3 phase, 4 wire, 120/20$ volt, with 20 amp, single pole, thermal-magnetic type branch circuit breakers, 9 adjustable resistors, 1 ohm, 200 watt with two sliders each, and 12 point terminal blocks. Two distribution panels are mounted on the boiler structure at Elevation 5197.0, HP-7 on column TtFal2't, HP-8 on column "Fal4" and HP-9 is mounted on boiler column "Dal3n at Elevation 51$950. Three (3) indicating light (detection) panels each with 1$ lights, white, watertight type, 2/3 volt, for use with the foregoing distribution panels were also furnished by Penn Panel and Box Company on Order NY-771$$$. The detection panels, HD-7, HD-$ and HD-9, associated with the freeze protection distribution panels are mounted on columns "Dal2", "Dal3'f and ttDal4", at the lower firing aisle, (operating floor), Elevation 5155.0. Space Heater Distribution Panel - 208/120 volt Space heater requirements are adequately provided for by use of a transformer, 45 kva, 3 phase, 60 cycle, 4$0/20$Y/120 volt, and two space heater distribution panels. The transformer supplied by Westinghouse Electric Corporation on Order NY-771806 is; mounted on a concrete foundation, 1 cubic yard placed August 17. 1961, as recorded on field progress drawing 3C-P-6, "Transformer Yird Foundations", included elsewhere in this report. It is located in the transformer yard approximately thirty-nine (39) feet, west of column line "A" and two (2) feet north of column line "14" projected, with the secondary connected to space heater distribution panel No. 5 located adjacent to it and mounted on fl'generator lead support column. Space heater distribution Panel No. 6 -S located at the rear of the boiler above the :St>und floor, (Elevation 5130.0), and is mounted on column ",ki trt^ Primary feed for space heater panel No. 6 is derived lighting panel No. 27. The panels were supplied by Penn and Box Company as part of Order NY-771$$$ with circuits as follows: WAD00811 20#Y/l20y Space Heater Distribution Panel No. 5 Breaker Frame Trip Elemt Service 50 20 Mill No. 3A motor 50 20 Mill No. 3B motor 50 20 Mill No. 3D motor 50 20 Mill No. 3C motor 50 20 I.D. fan No. 3A motor 50 20 I.D. fan No. 3B motor 50 20 F.D. fan No. 3A motor 50 20 F.D. fan No. 3B motor 50 20 Spare 50 20 Spare 50 20 Spare 50 20 Spare Dummy switch Dummy switch 50 20 Spare 50 30 4l60v Switchgear slab snow melting 50 30 B F pump 3A motor 50 30 B F pump 3B motor 50 30 Circulating water pump 3A motor 50 30 Circulating water pump 3B motor 21 100 30 4l60v Switchgear No. 3A lights and heaters 22 100 30 4l60v Switchgear No. 3B lights and heaters 20S/120 Volt Space Heater Distribution Panel No. 6 1 2 i 3 4 5 50 20 I.D. fan No. 3A damper drives 50 20 I.D. fan No. 3B damper drives 50 20 F.D. fan No. 3A damper drives 50 20 F.D. fan No. 3B damper -drives 50 20 Gas recirc fan 3A damper drives 6 50 20 Gas recirc fan 3B damper drives 7 50 20 Gas recirculating fan motor 3A 8 50 20 Gas recirculating fan motor 3B 9 50 20 Gas recirc cooling air damper drive 10 50 20 Spare 11 50 20 Spare 12 50 20 Spare :hting Load Centers Lighting control panels were supplied by Penn Panel ^d Box Company, Order NY-771SSS, to be used with each of the ...Siting transformers. Th'e transformer secondary is cable WAD00812 rejected to the panel main bus. Branch circuits of the panels *ves control of all lights within the area served by the light- panel. One remote lighting control panel was supplied for fptallation in the control room. Effective manual control of all: lights in a given area is possible with this arrangement. L Locally mounted electrical appurtenances for control .'motor driven auxiliaries are mounted near the dirven equipfjlfent. Motors which have controls at more than one point are 'kept to a minimum and such duplication exists only in cases where it is absolutely essential, such as the circulating water fpmap motors. Pressure or level sensing switches are used for 'control of electrical devices such as valves or motors to provide as much automatic operation as possible. Listed below are some of the local electrical controls and their respective vendors: Push buttons & selector switches - Westinghouse Elec Corp - NY-771808 Selector switches - General Electric Company - NY-771841 Pressure switches - The Mercoid Corporation - NI-771909 Level switches - Magnetrol, Incorporated - NY-771911 Pressure switches - Barton Instrument, Corporation - NY-771922 Switchboards : <_ The main electrical control board for control of trans mission lines and switches and load frequency is a composite of panels purchased from Westinghouse Electric Corporation, s6>0&er NY-771814, and existing panels purchased for Unit No. 1 jfojj-. Uni t No. 2. A total of four new sections of tunnel type .ex switchboard was purchased for this installation with ie (3) sections installed in Unit No. 3 control room. The remaining section was installed in Unit 1-2 control room ocSpying position 6. This section of panel is utilized for conllfol and instrumentation for the ring bus tie motor operated ,&isconnect switches. The three sections for Unit No. 3 control `room were assigned positions 2, 3 and 4 for load frequency control (No. 2), annunciation, battery control, audio tone feannelizing equipment, and frequency recorder (No. 3), and ijjistrumentation on the ring bus tie (No. 4). t ,. Two (2J sections of panel were removed from Unit 1 - gfbntrol room and relocated in Unit No. 3 control room, positions ||.nd 7 on the new board. Panel designated as No. 6 was pursed on Unit No. 1, Order NY-771312, while panel No. 7 was fplied with Unit No. 2 on Order NY-771814. The panels are ||d for control and instrumentation on Valmont-Washington cir- ji No. 1, Panel No. 6, and for Derby circuits 1 and 2, Panel 7. Public Service Company forces removed the panels from vice and constructed temporary panels to function while the ^els were relocated to Unit No. 3. Sturgeon Electric Company tailed the new panels and relocated the two (2) existing sis. The new panels were factory wired and the connections these panels were performed by Sturgeon on their general `ctrical contract, 3C-149. Wiring on the relocated panels jointly performed by Sturgeon and Public Service Company Ces closely coordinated by our electrical supervisor. WAD00813 150 i. . ' The hinged synchronising panel attached to panel No. f Relocated, is the one supplied for Unit No. 2 and a new panel g purchased for replacement on Unit No. 2. Westinghouse also rnished this panel on Order NY-771314 and it is hinged atached to new panel No. 6 in Unit No. 1 - 2 control room. Line panel No. 2 houses equipment furnished by Leeds Id Northrup Company, Order NY-771331, consisting of speedomax gfporders; for recording megawatt generation on Unit No. 3, ^equency and megavars, Lincoln thermal converter and auxiliary ||lays for audio-tone channelising equipment. All of the above uipment was installed in the panel by Westinghouse as part of switchboard fabrication. A load frequency control console for remote control of Ration generation on Unit No. 3 was furnished by Leeds and gbrthrup on Order NY-771331, The self-supporting panel located _ the control room contains three (3) console panels, seven (7) ipaches by seven (7) inches, and provides the setters necessary for controlling the base ranges for participation with the system frequency control program. The carrier current panel purchased for Unit No. 1, ~der NY-771331, Westinghouse Electric Corporation, on the "gashington-Valmont No. 1 circuit was relocated from Unit No. - 2 control room to Unit No. 3 control room. Public Service Oompany forces disconnected and reconnected the panel, although |ptual relocation was the function of Sturgeon Electric Company. .Protective Equipment A manual gang operated 1200 amp continuous rating, 23 kv, 3 post insulator, disconnect switch is vertically mounted on the generator lead supports at the auxiliary power transformer, The switch was supplied by Westinghouse Electric Corporation oh Order NY-771310 to disconnect the auxiliary transformer from the generator main leads. Surge protection equipment consisting of three (3) capacitors, 23 kv, 0.125 mfd, single phase, 60 cycle, with 34/5 m porcelain and three (3) lighting arrestors, outdoor type, rated voltage 15 kv, 19.5 rms, enclosed in a metal screen structure are located on the generator lead structure previously Inscribed under structural features. The capacitors were sup plied ty Westinghouse Electric Corporation on Order NY-771312 d the arrestors were supplied by General Electric Company as rt of the turbine-generator accessories on Order NY-771301. ^e capacitor and one arrestor are tapped to each phase of the jjg|nerator leads bus by means of a cable jumper. Connectors Were supplied by Southern States Equipment Corporation, Order HI-771332; the porcelain roof bushings by Ohio Brass Company, Order NY-771349; and the cable by Anaconda Wire and Cable Com pany, Order NY-771334. WAD00814 151 Units' and Ducts Procurement of all rigid conduit, fittings, pull fges, terminal boxes and flexible steel conduit was through suanc:e< of local purchase orders,, Listed below are vendors of "major quantities of these items: Conduit - Graybar Electric Company Flexible Conduit - Graybar Electric Company Conduit Fittings - Hendrie & Bolthoff Company Pull Boxes - Metalcraft Welding & Fabricating Co. Supports - Unistrut Western Conduit was used for overhead electrical routing ere the use of cable trays was not practical or was otherwise mited. Cable trays were used to greatest possible extent for uting of control cable in the station building areas. Conduit s used principally in routing power cables and control cables m cable trays to electrical apparatus. Cable trays were plied by P. W. Industries, Incorporated on Order NY-7718E>5. Underground banks of electrical conduit throughout the ation area and to outlying structures or equipment are basically fibre duct material encased in concrete. Surplus transite d fibre duct were used and additional quantities were supplied '"Graybar Electric Company on local order 3C-123o Rigid conduit s utilized on small size, under two (2) inches diameter, dividual runs. The duct banks are encased in 320 cubic yards concrete, placed intermittently as the duct was installed dm December 19, I960, to May 11, 1962. In the station building area where a sand-cement backill was used, the ducts were encased in this backfill. In eas where heavy loads from railroads and other facilities e imposed on the duct runs, reinforcing was added to the oncrete. All duct banks are provided with excess conduit either illing out the designated run or in some cases, a complete row fibre conduit were added for future use. The duct bank for :wer and control cables to the switchyard was a joint effort the electrical contractor and Public Service Company forces. .1 work within the switchyard fence area and connections to iergized electrical apparatus was accomplished by Public Service :mpany personnel. Reinforced concrete manholes and handholes were conructed at stategic locations to provide adequate pulling areas n underground duct banks. These locations were necessitated by ong runs exceeding the requirements of the National Electrical de or at junction points to reduce mechanical stresses in the ties. All manholes or handholes are equipped with drain lines the nearest storm drain. if., .4 WAD00815 152 ber Location H+ 5 S 7 5 5 7 3 3 3 L Transformer yard, 33'-6" west of column line uA,r and 9r-9rf north of column line tf15Tt Transformer yard, west of column line "A" and 13'-4rt north of column line "11" Yard area to No. 3 cooling tower, Sl? north of column line ''15'1 and 51? east of center line No, 2 stack Yard area on run to No, 3 cooling tower, 70f north of column line Tr15u and 4o!t east of center line of stack Station building, 5?-2n south of column line rt15Tt and 3f~2fr east of column line ,rB" Cooling tower No, 3, 4?-4n south of south cooling tower column line and lo? west of center line cooling tower Station building 3!~0-l/2TT west of column line ,fGbtT and 14?-3,f south of column line Tt15,? Boiler area, SJ~4'T west of column line ,THaT' and 4?-6ft south of column line tf12,? Water treatment area, 27f north and 2?=6rt west of north west corner of the chlorine storage shed Water treatment area, 30'-6" north and 3,"0rr east of the northeast corner of the chlorine storage shed Boiler area, 4?-9'T east of column line nJart and 5*=61T south of column line "13" Vertical cable raceways are provided in the station Uilding from handhole No, 15 and handhole No, 17 bo cable trays ider the BTG and main control boards. The raceways are con ducted of steel framing covered with asbestos cement transite .iding. Material for the raceways was purchased locally and abricated on the job, IConductors and Insulators Bj: Generator main leads between the generator terminals fend the main power transformer are of two (2) types. The section jpithin the station building proper, east of the west (column IgA" line) wall, is of the totally enclosed isolated phase type and was furnished by Westinghouse Electric Corporation on Order pNI-77l8l2,, The isolated phase bus is completely metal enclosed, 500 amps, 23 kv, three phase, 60 cycle, 240,000 amperes rms ^momentary rated, including all insulators and accessories. All Ifsupports for the indoor section were included with the bus and re either hung from the station building structure or utilize Bhe pedestal mezzanine floor for a support foundation, lij A special aluminum (non-magnetic ) frame contains the Jpall bushings where the generator leads exit `trough the con- Igopete west wall and it was also furnished by Westinghouse Electric pporporation on Order NY-771&12, The outdoor section extending west from the "A" line pall to the main power transformer is of welded aluminum pipe fanstruction as shown on design Drawing G~159$96, This section fwas field fabricated from eight inch aluminum pipe, furnished Reynolds Metals Company on Order NY-.771B67, supported by post WAD00816 sulators furnished by Ohio Brass Company on Order NY-771849 a galvanized structural frame, (six (6) tons) fabricated by kogee Iron Works on Order NY-771921. The flexible connectors connect the isolated phase bus to the outdoor bus were furnished Southern States Equipment, Order NY-771882, as was the contors from the outdoor bus to the transformer. Bus clamps Iding the bus to the insulators and welded aluminum bus fitfigs were furnished by Dossert Manufacturing Company on Order 4771881. Erection of all components was the function of the Metrical contractor. # Excavation for the generator lead support foundations I accomplished simultaneously with excavation for duct runs ,and transformer foundations. A Bucyrus Erie Model 22B backhoe was utilized in removal of 72 cubic yards of the hard Denver ^formation shale. Concrete for the foundations, 20.5 cubic yards, was placed intermittently between July 19, 1961, and September 12, 1961, with the actual placement dates recorded on field progress drawing 3C-P-6, ''Transformer Yard Foundations'', included else where in this report. Westinghouse Electric Corporation supplied a section of 2000/1200 ampere bus duct as part of their order for the 4160 volt switchgear, Order NY-771807, for throat connecting switch- gear assemblages 3A and 3B to the secondary of the 12000/16000 kva, oa/fa, unit auxiliary power transformer. The bus is of weatherproof construction, completely metal enclosed with all accessories for attachment to the equipment on both ends of the bus. Basic quantities of power wire and cable were supplied by Kerite Company, NY-771883, and Anaconda Wire and Cable Company, Order NY-771899. Cable remaining as surplus from Unit No. 1 and No. 2 construction was utilized in so far as practical to augment the basic cable orders. Lineal Ft Conductor Vendor 2,007 4,280 17,078 3,297 1,191 2,301 695 4,129 1,800 1/574 "1,000 1,391 1,305 V 95 102 366 ,335 1,421 1/c 1/c l/c 1/c l/c l/c 1/c 1/c 1/c 1/c 1/c 1/c 1/c l/c 1/c 1/c 1/c 1/c 750 mcm 5000 v 0RAS 600 mcm 5000 v 0RAS 3/0 awg 5000 v 0RAS 750 mcm 600 V LMN 500 mcm 600 V LMN 350 mcm 600 V LMN 350 mcm 600 v LMN 250 mcm 600 V LMN 3/0 awg 600 V LMN 3/0 awg 600 v LMN jf2 ,awg 1600 v LMN n\awg 1600 v LMN /r8 1awg 1600 V LMN #8 .awg 1600 V LMN #10 awg 600 V LMN #10 awg solid bare #12 awg 600 V LMB #12 awg solid bare The Kerite Company The Kerite Company The Kerite Company Anaconda Wire & Cable Co. Anaconda Wire & Cable Co. Anaconda Wire & Cable Co. Ryall Electric Supply Co. Anaconda Wire & Cable Co. Anaconda Wire & Cable Co. Surplus material Anaconda Wire & Cable Co. Surplus material Anaconda Wire & Cable Co. Surplus material Ryall Electric Supply Co. Anaconda Wire & Cable Co. Ryall Electric Supply Co. Anaconda Wire & Cable Co. WAD00817 154 Conductor Vendor l/c 7fl8 awg 300 v TW 2/c 4-/0 awg 600 v LMN 2/c 19/22 awg 600 v DEEP 2/c 19/25 awg 600 v PEPP 3/c 250 mcra 600 v LMNA 3/c 19/25 awg 600 v PEPP Graybar Electric Company Ryall Electric Supply Co. Ryall Electric Supply Co. Anaconda Wire & Cable Co. Ryall Electric Supply Co. Control wire and cable were supplied by the following and in quantities listed: Conductor Vendor Order No. l/c $10 awg 600 v LMB Ryall Electric Supply Co. NY-771892 l/c $10 awg solid bare Anaconda Wire & Cable Co. NY-771884 l/c $12 awg 600 v LMB l/c $19/25 awg 600 v Ryall Electric Supply Co. NY-771892 Ryall Electric Supply Co. NY-771892 PEPP 2/c $19/22 awg 600 v Ryall Electric Supply Co. NY-771892 PEPP 2/c $19/25 awg 600 v Ryall Electric Supply Co. NY-771392 PEPP 2/c $19/25 awg 600 v Hendrie & Bolthoff Co. 3C-1083 PEPP 2/c $16 awg copper Leeds & Northrup Co. . NY-771901 constantan 2/c $16 awg iron Leeds & Northrup Co. NY-771901 constantan 2/c $16 awg iron Surplus material constantan 2/c $19 awg 600 v Anaconda Wire & Cable Co. NY-771899 PEPPS 2/c $19 awg 600 v PEPPS Surplus material 3/c $19/25 awg 600 v Ryall Electric Supply Co. NY-771892 PEPP 3/c $19/25 awg 600 v Hendrie & Bolthoff Co. 3C-1099 PEPP 3/c 19/25 awg 600 v Surplus material PEPA 3/c $19 awg 600 v PEPP Anaconda Wire & Cable Co. NY-771899 4/e $19/22 awg 600 v Ryall Electric Supply Co, NY-771892 PEPP 5/c $19/25 awg 600 v Ryall Electric Supply Co. NY-771892 PEPP 5/c $19/25 awg 600 v Hendrie & Bolthoff Co. 3C-1099 PEPP 5/c $19 awg 600 v PEPPS Anaconda Wire & Cable Co. NY-771899 7/c $19/25 awg 600 v Ryall Electric Supply Co. NY-771892 PEPP 7/c $19/25 awg 600 v Hendrie & Bolthoff Co, 3C-1132 PEPP 7/c $19/25 awg 600 v PSCC Stores PEPP 7/c $19/25 awg 600 v Ryall Electric Supply Co. NY-771892 PEPA WAD00818 eal C- . ,89 k ,160 ,,291 1,430 773 Conductor 9/c 19/25 awg 600 v PEPP 12/c 719/25 awg 600 v PEPP 12/c 7/19/25 awg 600 v PEPP 25/c #19 awg 600 v PEPPS RG-59/4 coaxial cable Vendor Order No, Ryall Electric Supply Co. NY-771392 Ryall Electric Supply Co. NY-771392 Surplus material Anaconda Wire & Cable Co. NY-771399 Interstate Radio Company 3C-1130 All terminals, connectors, caps, twine and tags were -chased locally. Tape and compound for terminations or splices re furnished by the electrical contractor as part of the .'Installation contract. iixiliary Equipment Direct current requirements for control and operation direct current motors is satisfied by a 60 cell battery, leadTcid type, located in the switchgear room, Elevation 5130? along he north wall. The Electric Storage Battery Company, Exide :dustrial Division, furnished the battery with its two-step storage rack and connectors on Order NY-771342. Also included Tv this order is a 20 kw diverter pole motor-generator set for jiarging the battery. Controls for the generation equipment *-e mounted on the main control board in the control room to Afford better control operation. A tie is made between the new yfctery and the battery furnished for Unit 1-2. An automatic tjjftrowover switch on the system'provides power for normal-emergency lighting circuits and emergency equipment circuits in the event the unit is tripped with a subsequent loss in auxiliary power. grounding Grounding of all structures, equipment and facilities is accomplished by a network of No. 4/0 and No. 2/0 bare copper cable throughout the station building and boiler area. This is pinnected to the main ground loop composed of black iron strap nd No. 4/0 polyethylene coated wire in the transformer yard and ifr polyethylene coated copper cable, No. 4/0, tie to the black iron strap on yard lighting along the east plant road, and is Shown on design drawing G-130752. 1';: Connections between cables, iron straps and structural ;eel were fused connections using the Cadweld process. Cadweld artridges were purchased locally. Southern States Equipment tapany, Order NY-771332, and Dossert Manufacturing Company, ,der NY-771331, furnished the connectors for attachment of the bunding cable to equipment. Two additional ground rods were Pacified in the transformer yard; however, due to the presence Denver shale at the ground level, it was impossible to intall the rods. WAD00819 156 |i " The ground system is tied to the negative lead of a j&aapere cathodic protection rectifier, furnished on Unit No. 1 ground bed No. 1, relocated to Column !tHall-3/4Tt at Elevation A new 75 ampere rectifier, furnished by Corrosion Rectifying jany on Order NI-771905, replaced the existing rectifier on jund bed No. 1. The existing rectifier was relocated with its ifitive leads connected to ground bed wells No. 4 and No. 5. The ground wells are 10 inch diameter pipe casings, fealled in a seventy-five (75) feet deep drilled hole, in gph eight (G) graphite anodes are suspended on a loop of No. |: insulated cable and filled with coke breeze. Ground well 4 is located in the boiler area outside the building near >]umn nJal2rt, and ground well No. 5 is located in the yard near UH. No. 27 on the duct run to No. 3 cooling tower. Both were 'illed and cased by Meredith Drilling Company on Order 3C-&34. te, anodes and coke were also furnished by Corrosion Rectifying ajpany on Order NY-771905. Cable for the system was supplied Anaconda Wire and Cable Company on Order NY-771B99. Cathodic protection requirements for the condenser satisfied by the installation of two (2) 30 ampere, con- ;ant current (self regulating), d-c rectifiers, in conjunction Ith four (4) Durion button type anodes installed in each of the ^our (4) water boxes, and connected to the positive terminal of ie rectifier. The negative lead from the rectifier is conacted to the water box. A zinc reference anode is installed each water box for testing the system. All equipment for .s system was furnished by Corrosion Rectifying Company, ler NY-771905. The cable for connecting up the system was finished by Anaconda Wire and Cable Company on Order NY-771&99. I WAD00820 MISCELLANEOUS POWER PLANT EQUIPMENT 157 fer-ice Equipment The vacuum cleaning system is an extension of the ^sting system for Units No. 1 and 2 and is shown on design fWing G-159656, "Vacuum Cleaning System". There are eighteen 13) nickel plated inlet valves furnished by Spencer Turbine mpany on Order NY-771913, and an additional one (1) furnished 7 the same vendor on local order 3C-447. The piping was pur sed from H-P Products, Incorporated on local order 3C-932 jt installed by our pipefitter forces. The nineteen (19) Jrvenience outlets are located in the station building as follows: 1 - Plant Betterment Area - El 5156T 2 - Fan Room - El 5142' 4 - Firing Aisles - El 5156', 5164', 5171r, 5130 2 - Pulverizer Areas - El 5131' and 5139.5' 2 - Chemical Treatment Area - El 5131' and 5143' 2 - Control Room - El 5156' 1 - Switchgear Room - El 5131' 5 - Turbine Room - 3-El 5156', 1-El 5139.5', 1-El 5131' 1 - Cable Vault - El 5143' Chemical fire extinguishers are located throughout the Eant area at places designated by Mr. Larry Burt, the plant ief engineer. There are forty-four (44) 20 pound General 2 extinguishers, Model 20-R, and two (2) 75 pound General 2 wheeled cart type extinguishers, Model 75-R, furnished for ;is unit. In addition, one 500 foot capacity steel wheeled >se cart is furnished, type WD Allen, Figure 7137-3, complete ith 300 feet of lg inch cotton rubber lined double jacket fire .ose including adaptors and nozzles. All of this material was ""ipplied by Grinnell Company on local order 3C-S92. Intrasite communication equipment installed for Unit f>. 1 satisfied the basic requirements with only telephone d code call stations required for Unit No. 3. The arrangement shown diagramatically on design drawing G-159925, "Communication stem", included elsewhere in this report. Stromberg Carlson Applied all equipment on Order NY-771305 which consists of the allowing: Two.(2) desk telephones, thirteen (13) wall teleones, five (5) outdoor telephones, ten (10) acoustic booths d indoor and outdoor code call horns, chimes and bells. Con it was field run to all equipment and. was purchased from Graybar ectric Company on Order 30-123. The 2/c #19 awg 300v PEP Isted pair cable, was supplied by Anaconda Wire and Cable hnpany on Order NY-771o99, (5,100 lineal feet), and by Graybar ectric Company on Order 30-1023, (5,000 lineal feet). Inallation was made by Sturgeon Electric Company on their general ectrical contract, 3C-144. An intercom communication system, Executone, Series 00, for paging and talking between the Unit No. 3 control room ,d the firing aisles of Unit No, 3 boiler and future Unit No. 4 WAD00821 ___ f was also installed. This equipment was purchased from lit one Incorporated on Order NY-r, 71^51. This order also jides on-the-premises maintenance furnished by Executone Com*;of Denver during normal working hours at no cost for a pod of twelve (12) months from the date of installation cornlion, unless damage is caused through misuse or accident, booster amplifier supplied under Item 4 of the order rated |tts, was too small to provide sufficient volume and this ixfier was replaced with one having a 24 watt rating and the f&tion is satisfactory. Station air at 100 psig is furnished at convenient Rets throughout the plant similiar to the existing system. E,No. 3 station air is an extension to the system in service fUnits No. 1 and 2, thus eliminating the necessity of inBLling any new equipment. Piping installation was accomplished four forces. fceral Plant Equipment An eight (S) ton Yale and Towne Rail Hugger chain type id hoist with a geared trolley v/as furnished by Coursey Equippt Company on local order 3C-S12. It has a 14 foot.lift and p be used on any of the three (3) monorails over the boiler <jd pumps or the four (4) monorails over the coal pulverizer Lis. The monorails for the boiler feed pumps were furnished Metalcraft Welding and Fabricating Company on local- order 793. The monorails over the coal mills were furnished by erling Steel Company on local order 3C-77. WAD00822 TRANSMISSION PLANT SUBSTATION STRUCTURE AND IMPROVEMENTS 159 nvements to Site Grading in the switchyard and transformer yard area accomplished during construction of the original unit with fine grading and gravel surfacing in the transformer yard ired for Unit No. 3 Gravel surfacing with 3/4 inch crushed e 4 inches thick was accomplished concurrently with the 'acing in the boiler area. Surfacing in the switchyard was 1mplished during foundation construction by Public Service any forces. Material totaling 326 tons was supplied by ae Cascade Sand and Gravel Company, Order ^C-7SS, and spread Jour forces during the spring of 19o2. Provisions for adional lighting to accomodate the new structures added in 'I switchyard are satisfied by installation of additional hting fixtures by Public Service Company forces. The fixtures e furnished by General Electric Supply Company on Order NY880 and installed during the month of April, 1962. Wire for additional fixtures was supplied by Ryall Electric on Order -771392. SUBSTATION EQUIPMENT ructural Features and Improvements Construction of all foundations and erection of all pictures in the switchyard proper were accomplished by Public rvice Company of Colorado forces. Excavation was started the ?rst week of January, 1961, and was limited to handwork with air Jiven tools due to insufficient clearance on overhead structures, ncrete for the foundations, 5$ cubic yards, was supplied by *ady Mix Concrete on Order 30-17 with placements made between Jrch 16, ard March 30, 1961, and recorded on Field Progress awing 3C-P-11, "Substation Foundations", included elsewhere this report. In the transformer yard, a pull-off tower straddles JJe three (3) phase main power transformer for the slack span tie the switchyard. Excavation in the hard Denver shale for the Jundations was accomplished by use of a one cubic yard backhoe Jilted from Gilbert Clark on Order 30-27, and fine grading with labor forces using air driven tools. Concrete, 43.0 cubic Ms, was placed between July 14, and August l, 1961, with Jual placements recorded on field progress drawing, 3C-P-6, .ansformer Yard Foundations," included elsewhere in this re^t. Anchor bolts and miscellaneous steel embedded in concrete >e purchased from Metalcraft Welding and Fabricating on der 3C-1B7. Structural steel for the two (2) towers with their nnecting trusses, composing the transformer pull-off structure, Id the similiarly arranged tie tower structure in the switchyard WAD00823 160 f| detailed and furnished by Muskogee Iron Works on Order NYJi.921. This order also included all the supporting structures potential transformers and bus support in the switchyard %t-generator leads. All the galvanized steel, 21 tons, arrived ]tone carload and was sorted out for the various structures by "composite crew made up of Public Service Company of Colorado Sturgeon Electric employees. The tie tower structure in the Itchyard was subsequently erected by Public Service Company of %orado forces during December, 1961. The transformer pull-f structure was erected by Strugeon Electric Company under rms of their general electrical installation contract, 3C-194, the spring of 1962. wp.r Conversion Equipment - Transformers The foundation for the main power transformer is shown i Drawing G-1597&2, "Substation Facilities - Transformer Yard undations", and is located approximately fifty-nine (59) set west of the station building west wall ("A" column line) -d eight (S) feet north of column line "14" projected. Ex cavation was accomplished by removing the shale and sandstone Urinations, 46 cubic yards, with a Bucyrus Erie, Model 30B, one fl) cubic yard backhoe rented from Gilbert Clark on Order 3C-27. #>r a typical cross section of the soil stratums see field sketch 1C-79SS-F32 included elsewhere in this report. The excavation large enough to include a sump of adequate capacity to con tain the oil from the transformer should an emergency condition rise that would require dumping -the oil. A total of 14$ tons If 1-1/2 inch minimum size rock furnished by Boise Cascade Sand gtnd Gravel Company on Order 3C-7SS was used as backfill in the lump. A perforated vitrified clay pump sump ana a drain line p.th a valve are provided as methods of draining the sump. Concrete, 27.5 cubic yards, was placed for the foundnation mat on July 17, the pier section on August 17, 1961, and pts recorded on field progress drawing 3C-P-7, "Transformer Yard (Fbundations,,T included elsewhere in this report. Railroad rai] iUsed as embedded supports were fabricated from stock rail by | ^Public Service Company in the Cherokee maintenance shop. The main transformer is rated at ISO,000 kva, 140,000 '-volt wye/19,000 volt delta, 3 phase, 60 cycle, with forced oil land air cooling and was supplied by Westinghouse Electric ^Corporation on Order NY-771B05, in accordance with specification p>SCC-3C-177. The transformer is equipped with high altitude pushings, lightning arrestors and forced oil and air cooling Equipment. The transformer, weighing 123 tons less the above listed YJcessories and oil, was shipped on a special low bed railroad and was skidded off the car onto the foundation by our gger forces using a power winch truck on September 14, 1961. .burgeon Electric trimmed out the transformer thereafter under feerms of their general electrical contract. WAD00824 161 The forced oil and air cooling system is equipped with Automatic starting circuit three element relay activated by winding temperature. The control circuit to the relay is .from either 480 volt motor control center 30 or 3D and an |rm and signal circuit is connected to the 125 volt d-c jribution panel. One current transformer, outdoor, type VO-15, HO kw, )/5 ampere ratio, was purchased from Westinghouse Electric Iporation, Order NT-771815, and installed on the high voltage !i'iral bushing for use in current polarizing of the directional Idys. Sturgeon Electric forces installed this transformer con sently with the trim on the main transformer. Channel ribs used as reinforcement for the tank shell ||e also utilized as troughs to convey control cables from the jntrol compartment to fans, pumps, relays, etc. The access IJes into these channels were fitted with incorrect size gaskets |tch resulted in water entering the troughs and corroding the intact surface of plugs and receptacles. Westinghouse accepted |& responsibility for correcting this condition. Westinghouse is also required to repair a leak that developed in a weld jnnecting the tank to its bottom. The leak was repaired by one our certified pipe welders under the direction of a Westinghouse ipresentative. A fire protection system for the main transformer was applied and installed by Viking Sprinkler Company, Incorporated .Orders NY-771868, material, and NY-771869, erection. Two |her legs of this system protect the unit auxiliary transformer id the turbine lubricating oil tank. The system is an auto(itically operated fire protection system of the fixed water H%ray type, with water fog nozzles; operated (l) by a rate rise, heat actuated device, (2) by a transformer fault relay and (3) |r a manual pull box. All electrical equipment for the fire protection rstem is 125 volt d-c fed from d-c distribution panel No. 3. isfallation of the system was accomplished by Viking during >ch, 1962. If Concrete supports for the system were constructed on Jtober 25, 1961, 2.5 cubic yards, by our forces. The drain live pit described with the fire protection system for the pKiliary transformer also serves this system. atective Equipment The switchyard for Units No. 1 and No. 2 was a ring bus "angement with protective devices arranged to isolate various Ubcuits. With the addition of Unit No. 3j the switchyard was Arranged into a double ring bus arrangement with a tie air Jj|rcuit breaker connecting the north half, Unit No. 3 from the `ith half. Units No. 1 and No. 2, as shown on Drawing G-130780R7 ^|5 kv Switchyard - Plan". All work requisite to revising the ttchyard and additions for Unit t,t0. 3 were accomplished by WAD00825 c Service Company of Colorado forces. Construction of concrete foundations was started in when concrete, 33 cubic yards, purchased by Public Service any of Colorado from Centennial Concrete Company, was ed for one oil circuit breaker foundation and two foundations a "C" tower in the month of May. The remaining foundation was started the first week of January, 1961, and completed pril 10, 1961, with 96.0 cubic yards of concrete used, ^concrete was supplied by Ready Mix Concrete on our order, 7, and actual placement dates are recorded on field progress ing 3C-P-11, "Substation Foundations," included elsewhere this report. Galvanized structural steel, one and one-half (1.5) s, for nine (9) potential transformer supporting structures one bus support BSS-4, were detailed and fabricated by kogee Iron orks on Order NY-771921. Public Service Company _ced an order for 14 tons of galvanized steel with Schuler tlneering Company which included five (5) C and five (5) ^structures. Four existing BSS-l bus support structures were oved to accomodate the new construction. The supporting 'ructures were erected during the month of December, 1961. Three (3) oil circuit breakers were purchased from stinghouse Electric Corporation on Order NY-771309. The break 's are 115 kv, 1200 amps, 5000 mva interrupting rating, 3 phase, eumatic operating mechanism with 125 volt d-c controls and e added to the ring bus. The OCB's are used to; isolate generator No. 3 from e ring bus, located in the east bus at line 12; isolate the mont diagonal circuit from the ring bus, located on line 9 tween the east and west busses; and to isolate generator No. ora the ring bus, located in the east bus on line 3. 2 A local order, 30-337, was placed with Weicker Transfer mpany to unload and haul the breakers to the switchyard. The eakers were completely assembled with all internals, bushings, d current transformers attached to the tanks and only the Uing with oil was required after they were set on their -Undations. Eight (3) air break switches were purchased from stinghouse Electric Corporation on Order NY-771810. One (1) V break switch is used to isolate the No. 3 generator tie, one ; used to tie the double ring bus together and the remaining (6) are for sectionalizing the ring bus. Public Service "pany also supplied one (l) additional air break switch from sir stock for sectionalizing. The sectionalizing air break 'tches are gang type V-2, 115 kv, 1200 amps, 3 pst, horizontal .ight mounted, with short arcing horns, and an indirect cou nted manual geared type operating mechanism. The two (2) her switches supplied by Westinghouse are gang type V-2, 115 kv, 00 amps, 3 pst, horizontal upright mounting, with short arcing ^ns, and type T-3 motor operators with 125 volt d-c control 115 volt a-c space heaters. WAD00826 163 Nine (9) outdoor potential transformers were purchased m Westinghouse Electric Corporation on Order NY-771815 for trumentation and relaying on the 115 kv bus, Transformers type APT, 115 kv, oil filled with a single bushing. /fefad actors and Insulators j| The 115 kv double ring bus is of low bay construction jjjgith. three conductors, spaced at ten foot per phase, of four jh sps aluminum pipe welded in all current carrying connections, vendors and quantities of material installed in the bus con,ion are as follows: intity Item Supplier Order No Pin Cap Insulators Expansion Terminals lin Sch 40 alum pipe 2i" Sch40 alum pipe 3z Sch40 alum pipe Bolted Connectors Weld Fittings PSCC Burndy Corporation Reynolds Metals Co Reynolds Metals Co Reynolds Metals Co Dossert Mfg Co Southern States Equip PSCC Stores NY-771823 NY-771867 NY-771867 NY-771867 NY-771881 NY-771882 Bare conductor and connectors for the slack span from he pull-off tower at the main transformer to the receiving tower n the substation were purchased from Ohio Brass Company, susension insulators and hardware on Order NY-771849, and Reynolds tals Company, compression connectors on Order NY-771B67. er wiring included the jumpers from the 115 kv ring bus to he potential transformers and wiring associated with the lightning rrestors on the main power transformer. The following vendors applied material for these functions. :der No. Supplier Material Y-771B8I Y-771B82 771883 Dossert Manufacturing Company Southern States Equipment Company Ryall Electric Supply Company Connectors Connectors Insulated Cable Wire and fittings for the aerial shield system were upplied by Ohio Brass Company, Order NY-771B49 for hardware, hd the wire was from Public Service Company stores. WAD00827 I;, 164 RETIREMENT WORK IN PROGRESS The original project planning was based on a site relopment for an ultimate six units. The basic substation ijvided a 115 kv switchyard with a ring bus for six separately jltected transmission circuits in addition to the main power Hinsformer (Generator No. 1) and the standby-startup trans fer. Also provided was space for generator circuits for sure Units No. 2, No. 3 and No. 4 with their separate projtion and plans to sectionalize the Unit No. 1 and No. 2 ring m the Unit No. 3 and No, 4 ring through a motor operated dis secting switch when Unit No. 3 was installed. To accomplish the ring bus sectionalizing and adftion of protective equipment, certain sections of the welded inch aluminum bus had to be removed and either refabricated retired. The following items were retired: 1&9 feet, 4" {.uminum pipe; 18 each, O.B. bus insulators, pin type; 9 each, aluminum bus clamps; 9 each, 4" aluminum bus adaptors. The shield wire along the east side of the switch ed was transfered to the new Unit No. 3 generator take-off jjjwer and one (l) sixty-five (65) foot wood pole was retired. Control of the existing protective equipment in the |itchyard now associated with the separated sectionalized ring ffts for operation in the Unit No. 3 control room was removed |rom the Unit No. 1-2 control room. The panel changes and pearrangement are detailed in the specific history section of Kis report under Accessory Electrical Equipment - Switchboards, lie control cable rearrangement required reconnections, re locations, reuse and retirements. All of the installations in he Unit No. 1 - 2 control room and switchyard were performed jjr Public Service Company of Colorado forces and the new in- allation and connections in the Unit No. 3 control room were erformed by Sturgeon Electric Company under items in their feneral electrical contract working with the operating com- ies forces at the switchyard end. The following quantities Jf cable were retired from property records and returned to ffcores or scrapped: 107 feet, 2/C No. 10 Simplex 600 volt LMNA; feet, 4/C No. 10 Rome 600 volt PEPP; 234 feet, 7/C No. 12 me 600 volt PEPP; 124 feet, 9/C No. 12 Rome 600 volt PEPP; '-2 feet, 12/C No. 12 Rome 600 volt PEPP; 217 feet, 5/C No. 14 "me 600 volt PEPP, 6 each, connectors; 315 pounds, copper wire "crapped). A 550 foot section of an existing 7 foot high chain nk fence (internal fencing) along an original property line .4 left in place after purchase of the adjoining property as otection during gravel removal was removed and retired. WAD00828 PHYSICAL DATA - PROJECT 165 ation: Adams County, Colorado fling Address: 619$ Franklin Avenue, Denver 16, Colorado trance: East 62nd Avenue at Franklin Street, Adams County Jifinon Carrier: Denver & Rio Grande Western Railroad Company and Area of Site: 160,,325 acres ea of River Water Settling Ponds: 7*17 acres ea of Ash Settling Ponds: 1.51 acres aved Roads: 1.56 miles ailroad Trackage: 4.$2 miles [evation of Yard Grade - 5129*50 [evation of Plant Operating Floor - 5155*0 'Elevation Top of 300 foot Chimney - 5430.0 Elevation Top of Sign on Boiler No. 1 - 5297*33 GENERAL DATA - UNIT NO. 3 jfjarth Excavation: 32,950 cubic yards jfpck (Shale) Excavation: 49340 cubic yards Iphcrete: 9,596 cubic yards Reinforcing Steel: 33$ tons Structural Steel, Building: $$0,7 tons jgtructural Steel, Boiler:"' 660 tons Miscellaneous Steel: 127 tons Paint - Prime and Finish: 3,100 gallons Electrical Conduit: 15*5 miles Electrical Wire and Cable: 59 miles jgpiler Plant Piping Systems: 12.1 miles fSoiler, Pressure Parts, Tubing: 61.2 miles Ipndenser Tubes: 45*7 miles Chimney Brick: 217,500 each jpcpendable Material SLrGasoline and Oils: 34,337 gallons jp---Oxygen: 126,000 cubic feet jptf: Acetylene: 60,000 cubic feet Welding Rod: 9.0 tons Itpi Lumber: 70,600 feet board measure Nails: 3 tons tlevation Top of Unit No, 3 300 foot Chimney - 5430.0 flevation Top of Unit No, 3 Boiler Structure - 52$5*5 gtetual Workdays: 540 jftrgest Construction Force: 300 men, September 27, 1962 glndays of Construction: Approximately $6,673 WAD00829 CHRONOLOGY OF JOB HIGHLIGHTS 166 1961 13 i960 20 i960 21 i960 5 i960 11 i960 IS i960 21 i960 25 i960 2 i960 24 i960 20 i960 14 i960 27 i960 12 1960 15 1961 20 1961 24 1961 15 1961 20 1961 16 1961 15 1961 25 1961 12 1961 14 1961 27 1961 20 1961 9 1961 3 1962 5 1962 19 1962 24 1962 2 1962 5 1962 9 1962 14 1962 21 1962 29 1962 4 1962 6 1962 9 1962 16 1962 27 1962 28 1962 12 1962 15 1962 23 1962 29 1962 5 1962 6 1962 15 1962 7 1962 15 1962 Assemble construction organization Start earth excavation - station bullying and boiler areas OFFICIAL STARTING DATE - ground breaking ceremonies Start drilling caissons - station building foundations Start shale excavation - turbine generator foundation Start shale excavation - station building west wall Complete foundation caisson drilling and concreting First concrete placed - station building foundations (Column C-12) First concrete placed - boiler foundations (Column Da-12) Start excavation - chimney foundation Concrete placed - chimney foundation mat Concrete placed - chimney foundation plinth Concrete placed - turbine generator foundation mat Erect first column (C-ll) - station building structure Erect first column (Da-12) - boiler structure Complete concrete placing - turbine generator pedestal Start setting baseplates - turbine generator unit Raise boiler steam drum (146 tons) Setting low pressure exhaust - turbine erection Unload and set - generator stator (16S tons) Start stripping and excavation - ash settling ponds Complete concrete placing - C. W. cooling tower basin Start erection - C. W. cooling tower superstructure Operate soot blowing air compressor No. 7 - for plant service Unload and set - main power transformer (125 tons) Peak construction force - 300 men Complete coal handling changeover - conveyors No. 5A and 5B Complete erection - C. W. cooling tower superstructure Unload last coal pulverizer mill Complete 3225 psi hydrostatic test - boiler pressure parts Complete 99 Psi hydrostatic test - boiler reheater Energize 4l6o volt switchgear Complete 4250 psi hydrostatic test - boiler feed system Pilot (natural) gas to ignitors Light off pilot ignitors - boiler dry-out and boil-out Complete boiler dry-out and boll-out Energize 4gO volt switchgear - common control center D & E Turbine generator unit - on turning gear Fuel (natural) gas to main burners - boiler Complete blowing out - main steam piping system Complete blowing out - cold reheat piping system Complete blowing out - hot reheat piping system Turbine first rolled with steam TRIAL OPERATION REALIZED - 5:31 p.m. Ash handling and sluicing system in operation Boiler first fired with coal Unit generating 150,000 kilowatts Complete bearing inspection (No. 4 4 No. 5) - turbine generator unit Complete reassembly of turbine stop valves after fine screen removal Complete acid cleaning - boiler COMMERCIAL OPERATION REALIZED Unit full load test at rated conditions - 163,000 kilowatts Turbine full throttle valve test - 174,000 kilowatts WAD00830