DESIGN FEATURES OF A UNIQUE SWING BRIDGE

HYDRAULIC AND CONTROL SYSTEM

WILLIAM H. HAMILTON1 and WORM (GIL) LUND2

INTRODUCTION
I n g e n e r a l , t h e d e s i g n o f movable span b r i d g e s t o d a t e has been more a
result
of
evolution
and
discovery
than
of
new
technological
innovation.
W i t h t o d a y ' s m o d e r n t e c h n o l o g y h a s come t r e m e n d o u s
advances i n computer s c i e n c e , e l e c t r o n i c s , m a t e r i a l s , and mechanical
systems.
As e n g i n e e r s a n d d e s i g n e r s we h a v e t h e o p p o r t u n i t y t o
c o m b i n e t h i s new t e c h n o l o g y w i t h i n n o v a t i o n a n d i m a g i n a t i o n t o b u i l d
bridges t h a t
are stronger,
safer,
larger,
more r e l i a b l e ,
3ore
m a i n t e n a n c e f r e e , have l o n g e r l i f e and a t l e s s c o s t .
T h i s p a p e r p r e s e n t s d e s i g n f e a t u r e s o f a u n i q u e h y d r a u l i c and c o n t r o l
s y s t e m f o r a new a n d i n n o v a t i v e b r i d g e .
Although only the hydraulics
a n d c o n t r o l s a r e d i s c u s s e d i n t h i s p a p e r , y o u w i l l s e e f r o m M r . Tom
Mahoney's companion p a p e r t h a t t h e b r i d g e as a whole r e p r e s e n t s
c r e a t i v e and i m a g i n a t i v e e n g i n e e r i n g .
I n o r d e r t o f u l l y c a p i t a l ize*on present day engineering c a p a b i l i t i e s ,
i t i s n e c e s s a r y t o e s t a b l i s h new c r i t e r i a a n d make s i g n i f i c a n t c h a n g e s
t o o u r e x i s t i n g movable span b r i d g e s p e c i f i c a t i o n s .
SUMMARY

The e x i s t i n g 1 9 3 0 b a s c u l e b r i d g e w h i c h l i n k s West S e a t t l e t o H a r b o r
I s l a n d h a s l o n g s e r v e d a s a p r i n c i p a l t r a f f i c l i n k b e t w e e n West
S e a t t l e and downtown S e a t t l e .
A channel dredging p r o j e c t , planned by
t h e Corps o f E n g i n e e r s and t h e P o r t o f S e a t t l e f o r 1990, r e q u i r e s
r e p l a c e m e n t o f t h e e x i s t i n g b a s c u l e b r i d g e t o accommodate t h e w i d e r
channel clearance.
A double l e a f , concrete swing b r i d g e w i t h a main
s p a n o f 480 f e e t b e t w e e n p i v o t p i e r s h a s b e e n p r o p o s e d a s a
replacement f o r the e x i s t i n g bascule s t r u c t u r e .
The m o v a b l e p o r t i o n
of t h e proposed b r i d g e w i l l c o n s i s t o f two 7500-ton
asymmetrical
leaves w i t h a j o i n t a t mid-channel ( F i g u r e 1 ) .
The 4 5 - d e g r e e skew
alignment provides f o r a 250-foot c l e a r n a v i g a t i o n channel.
The
b r i d g e c a r r i e s two l a n e s o f v e h i c u l a r t r a f f i c on a 3 4 - f o o t w i d e
roadway and a 1 2 - f o o t p e d e s t r i a n and b i c y c l e p a t h .
The p r o j e c t i s
l o c a t e d i n a m o d e r a t e l y a c t i v e s e i s m i c zone and d e t a i l c o n s i d e r a t i o n
was g i v e n t o t h e s e i s m i c d e s i g n c r i t e r i a .
O p e r a t i n g m a c h i n e r y w i l l be
enclosed w i t h i n the 42-foot diameter c i r c u l a r p i v o t p i e r s .
Each p i v o t

'President, Hamilton Engineering, Inc., Seattle, Washington

Wice President, Chief Engineer, Hamilton Engineering, Inc., Seattle, Washington

p i e r w i l l b e s u p p o r t e d on a g r o u p o f 6 0 0 - t o n c a p a c i t y c o n c r e t e f i l l e d
steel pipe piles.
The c o n t r o l house w i l l be l o c a t e d on t h e w e s t bank
and w i l l have u n o b s t r u c t e d v i s i b i l i t y o f t h e waterway and roadway.
B e c a u s e t h e m o v a b l e mass i s c o n s i d e r a b l y g r e a t e r t h a n p r e v i o u s b r i d g e s
o f t h i s t y p e , t h e u s e o f a c o n v e n t i o n a l o p e r a t i n g s y s t e m was n o t
practical.
F o r t h i s r e a s o n , a new h y d r a u l i c o p e r a t i n g and c o n t r o l
s y s t e m was p r o p o s e d .
Service bearings are l o c a t e d a t r o o f l e v e l o f the machinery housing
These b e a r i n g s c a r r y d e a d l o a d , l i v e l o a d , w i n d and
(Figure 2).
s e i s m i c l o a d d i r e c t l y t o t h e w a l l s o f t h e m a c h i n e r y h o u s i n g when t h e
bridge i s i n the closed position.
Each b e a r i n g i s
attached t o

FIGURE I

PLAN AND ELEVATION

t h e s u p e r s t r u c t u r e and b e a r s a g a i n s t a s t e e l r i n g on t h e m a c h i n e r y
housing.
The s t e e l r i n g i s m a c h i n e d i n a p l a n e p e r p e n d i c u l a r t o t h e
a x i s o f t h e p i v o t shaft.
Thus, t h e m o v a b l e l e a f may be l o w e r e d t o t h e
s e r v i c e b e a r i n g s a t a n y p o i n t on t h e s w i n g a r c .
V e r t i c a l s t a b i l i t y d u r i n g b r i d g e swing i s m a i n t a i n e d by two s e t s of
g u i d e b e a r i n g s , one a t t h e r o o f l e v e l o f t h e m a c h i n e r y h o u s i n g and one
a t the machinery f l o o r l e v e l ,
They b e a r a g a i n s t t u r n e d r i n g s on t h e
p i v o t shaft.
Rotational torque i s applied t o the p i v o t shaft by a
p a i r o f double acting hydraulic slewing cylinders.
Each c y l i n d e r has
a 2 2 - i n c h d i a m e t e r b o r e , an 8 4 - i n c h s t r o k e a n d
a 10-inch diameter
rod.
L i f t i n g of t h e l e a f from t h e s e r v i c e b e a r i n g s i s accomplished by a
l i f t p i s t o n o p e r a t i n g b e t w e e n t h e b o t t o m o f t h e p i v o t s h a f t and a
p e d e s t a l on t h e f o o t i n g .
These p i s t o n s a r e 1 0 4 - i n c h e s i n d i a m e t e r .
The n o r m a l
s t r o k e i s 1 - i n c h w i t h t h e a b i l i t y o f 5-inches t o be used
f o r maintenance.
H y d r a u l i c p o w e r f o r l i f t i n g and s l e w i n g i s p r o v i d e d b y t h r e e v a r i a b l e
f l o w h y d r a u l i c pumps i n e a c h m a c h i n e r y h o u s i n g .
N o r m a l l y two o f t h e
t h r e e pumps a r e u s e d on an a l t e r n a t i n g b a s i s w i t h t h e t h i r d pump a s a
back-up.
The pumps a r e p o w e r e d b y 100 hp. e l e c t r i c m o t o r s .
A standby
d i e s e l d r i v e n g e n e r a t o r s e t can p r o v i d e
each p i v o t p i e r w i t h
s u f f i c i e n t power f o r r e d u c e d speed o p e r a t i o n i n t h e e v e n t o f a power
failure.

The
p r o j e c t owner i s t h e
City of S e a t t l e w i t h funding
assistance
provided
by
the Port
o f Seattle.
Design c o n s u l t a n t s a r e t h e
West S e a t t l e B r i d g e - 2
Design
Team,
a joint
venture
of
Andersen
Bjornstad
Kane
Jacobs, I n c . , Parsons B r i n c k erhoff
Q u a d e and D o u g l a s ,
Inc.,
and T u d o r E n g i n e e r i n g
Co.
Hamilton Engineering,
Inc.
i s the
d e s i g n consultant for
the
hydraulic
m a c h i n e r y and c o n t r o l system.

FIGURE 2

PIVOT PIER SECTION

BRIDGE OPERATION
The b r i d g e c o n t r o l t o w e r h o u s e s t h e o p e r a t o r ' s c o n t r o l c o n s o l e a n d
a s s o c i a t e d Programmable C o n t r o l l e r (PC) ( F i gu r e 3 . )
These c o n t r o l s
p r o v i d e an o r d e r l y o p e n i n g and c l o s i n g o f t e b r i d g e , as w e l l as
h a n d l i n g t h e p r o p e r d i s p o s i t i o n o f r o a d and f o o t t r a f f i c b e f o r e
opening and a f t e r c l o s i n g .

_.... ,
a,..m.

CONTROL CONSOLE COllflGltRATlO#

FIGURE 3

OPERATOR'S COnTROL P M E L

CONTROL CONSOLE
CONFIGURATION
T y p i c a l o p e r a t i o n r e q u i r e s a l l p o w e r s w i t c h e s t o be o n , t h e p r o g r a m
s e n s i n g c o n t r o l a c t i v a t e d , h y d r a u l i c pumps on s t a n d - b y , a l l i n d i c a t o r s
and CRT u n i t s r e a d y t o f u n c t i o n and a l l s y s t e m c h e c k s made.
After
r e c e i v i n g a r e q u e s t t o o p e n t h e b r i d g e , t h e o p e r a t o r a c t i v a t e s CONTROL
By
POWER p r o v i d i n g e l e c t r i c a l p o w e r t o t h e b r i d g e c o n t r o l s y s t e m .
t h e n p u s h i n g t h e t w o I N I T I A T E O P E N b u t t o n s , t h e s p a n l o c k pumps a n d
t w o o f t h e t h r e e m a i n pump u n i t s a r e t u r n e d on.
A l l e l e c t r i c motors
a r e a u t o m a t i c a l l y s t a r t e d i n sequence.
I f t h e pressure from t h e main
pumps d o e s n o t b u i l d t o
t h e c o r r e c t s e t t i n g , an a l a r m
i s displayed
on t h e o p e r a t o r ' s p a n e l .
D u r i n g a normal b r i d g e opening, t h e o p e r a t o r

w i l l sound a u d i b l e b r i d g e alarms,
set t r a f f i c stop lights, close
p e d e s t r i a n and t r a f f i c g a t e s , and a c t u a t e t h e b a r r i e r g a t e s f o l l o w i n g
A l l operations are
a
p r o c e d u r e common t o m o s t m o v a b l e s p a n b r i d g e s .
m o n i t o r e d and c o n t r o l l e d t h r o u g h an i n t e r l o c k and a l a r m s y s t e m w i t h l n
t h e Programmable C o n t r o l l e r .
The s t a t u s o f e a c h f u n c t i o n a n d / o r
m a l f u n c t i o n i s p r e s e n t e d o n t h e CRT,
p r o m p t i n g t h e o p e r a t o r , as
required, f o r h i s next action.
A f t e r t h e b a r r i e r g a t e s a r e c l o s e d , t h e PC d i s a b l e s t h e g a t e c i r c u i t s ,
t u r n s o f f t h e a u d i b l e a l a r m s and e n a b l e s t h e c e n t e r l o c k and t a i l
locks.
T h e o p e r a t o r p u s h e s t h e CENTER LOCK WiTHDRAW a n d T A I L LOCKS
WITHDRAW b u t t o n s . S t a t u s o f t h e l o c k w i t h d r a w i s c o n s t a n t l y d i s p l a y e d
t o t h e o p e r a t o r t h r o u g h i n d i c a t o r f i g h t s a n d o n t h e CRT w i t h p h r a s e s
s u c h a s CENTER LOCK WITHDRAWING, a n d T A I L LOCKS WITHDRAWN.
A f t e r a l l l o c k s have been w i t h d r a w n , t h e o p e r a t o r can i n i t i a t e span
l i f t b y p u s h i n g t h e SPAN L I F T b u t t o n s .
The s p a n s c a n b e o p e n e d
simultaneously o r independently a t the discretion o f the operator.
When t h e s p a n i s c o m p l e t e l y r a i s e d , i n d i c a t i n g l i g h t s come o n a n d t h e
completed i n
CRT r e a d s L I F T COMPLETE.
The l i f t i s n o r m a l l y
20 s e c o n d s ; h o w e v e r , i f n o t c o m p l e t e d i n 4 0 s e c o n d s a n a l c r m w i l l
a p p e a r o n t h e CRT a n d t h e b r i d g e o p e n i n g w i l l s t o p .
The o p e r a t o r now i n i t i a t e s s l e w i n g o f t h e b r i d g e b y t u r n i n g t h e
CLOSE/OPEN h a n d l e s t o t h e OPEN p o s i t i o n .
The b r i d g e c o n t i n u e s t o o p e n
until
signal t o decelerate i s i n i t i a t e d .
The m o t i o n c o n t r o l s y s t e m
m o n i t o r s t h e b r i d g e p o s i t i o n c o n t i n u o u s l y and t h e p o s i t i o n feedback
keeps t h e d e c e l e r a t i o n o f t h e span w i t h i n s p e c i f i e d l i m i t s .
When t h e
To s t o p
b r i d g e i s f u l l y o p e n e d , FULL-OPEN i s d i s p l a y e d o n t h e CRT.
thi! o p e r a t o r c a n l e t g o o f t h e
t h e slew i n any o t h e r p o s i t i o n ,
OPEN/CLOSE h a n d l e s , c a u s i n g t h e b r i d g e t o d e c e l e r a t e a n d s t o p .
A f t e r t h e v e s s e l has passed t h r o u g h t h e open channel, t h e o p e r a t o r can
i n i t i a t e span c l o s i n g .
A t a pre-determined point,
a signal t o
d e c e l e r a t e i s i n i t i a t e d a n d t h e b r i d g g d e c e l e r a t e s b y means o f t h e
deceleration servo-valve.
A t t h e .10
o p e n p o i n t , a READY TO DOCK
i n d i c a t i o n , d i s p l a y e d o n t h e CRT,
t e l l s the operator t h a t the bridge
i s i n t h e c r e e p mode.
The CRT t h e n d i s p l a y s a r e a d o u t i n INCHES TO
DOCK.
When t h e b r i d g e i s i n t h e f u l l y c l o s e d p o s i t i o n , t h e SPAN
CLOSED l i g h t s come o n a n d t h e CRT r e a d s AGAINST STOP.
A t t h i s p o i n t t h e o p e r a t o r i n i t i a t e s l o w e r i n g o f t h e s p a n s , a n d , when
t h i s i s completed, proceeds t o d r i v e t h e t a i l l o c k s and t h e c e n t e r
lock.
When t h e c e n t e r l o c k i s f u l l y d r i v e n , t h e c l o s i n g s e q u e n c e i s
continued.
The PC t h e n a u t o m a t i c a l l y s h u t s down t h e h y d r a u l i c m o t o r s
a n d e n a b l e s t h e GATES c i r c u i t s . T r a f f i c b a r r i e r s , g a t e s a n d s i g n a l s
are operated
i n a normal
manner.
G a t e s may a l s o
be r a i s e d
s i m u l t a n e o u s l y t h r o u g h t h e u s e o f t h e GROUP RAISE s w i t c h w h i c h s p e e d s
up t h e c l o s i n g p r o c e s s .
A f t e r t h e b r i d g e c l o s i n g sequence i s
c o m p l e t e , t h e PC s e t s t h e t r a f f i c l i g h t s g r e e n a n d n o t i f i e s t h e f i r e
s t a t i o n s t h a t t h e b r i d g e i s open t o t r a f f i c .
The c o n t r o l p o w e r c a n
now b e t u r n e d o f f b y t h e o p e r a t o r .

HYDRAULIC AND CONTROL SYSTEM DESIGN

Control System

The h e a r t o f t h e c o n t r o l s y s t e m i s a P r o g r a m m a b l e C o n t r o l l e r ( P C ) t h a t
i s d e s i g n e d t o c o n t r o l and m o n i t o r t h e Swing B r i d g e and i t s a n c i l l a r y
I f , d u r i n g t h e o p e r a t i o n , an
e q u i p m e n t d u r i n g o p e n i n g and c l o s i n g .
a l a r m o c c u r s , t h e b r i d g e c a n be s t o p p e d a u t a m a t i c a l l y , d e p e n d i n g on
t h e n a t u r e o f t h e p r o b l e m . The P C a l s o c o n t i n l a o u s l y m o n i t o r s t h e
b r i d g e a t a l l t i m e s f o r f i r e alarms, p i e r i h ~ y a c t , and u n a u t h o r i z e d
i n t r u s i o n o f t h e p i e r s , approaches and t h e t o w e r .
Should t h e r e be a
p r o b l e m w i t h t h e a c t i v e s y s t e m , a b a c k u p PC s y s t e m comes o n - l i n e
automatically.
A l l PC c o m p o n e n t s o f t h e b r i d g e a r e c o n n e c t e d v i a T w i n a x c a b l e
consisting o f a twisted p a i r o f wires t h a t are protected from outside
e l e c t r o m a g n e t i c i n t e r f e r e n c e (EMI) by a grounded o u t e r s h i e l d .
This
c o n f i g u r a t i o n e l i m i n a t e s t h e n e e d f o r mu1 t i p l e c o n d u c t o r s b e t w e e r ; t h e
c o n t r o l t o w e r , approaches and p i e r s .
T h e TwSnax c a b l e i s l a i d i n a
w i r e w a y w h i c h w i l l be l o c a t e d on t h e a d j a c e n t h i g h l e v e l b r i d g e .
The
w i r e w a y w i l l e l i m i n a t e t h e need f o r submerged c a b l e s .
The PC may b e c o m m u n i c a t e d w i t h f r o m a r e m o t e l o c a t i o n b y meats o f a
t e l e p h o n e modem a n d a V i d e o P r o g r a m m i n g U n i t . T h i s w i l l a l l o w a
t e c h n i c i a n t o trouble-shoot a problem b e f o r e going t o t h e b r i d g e s i t e .
s

D u r i n g n o r m a l o p e r a t i o n t h e PC w i l l :

1.
2.
3.

4.
5.

Sequence l i f t / t u r n c y c l e o f each l e a f .
H o n i t o r b r i d g e equipment and Near and F a r S i d e a p p r o a c h
it e m s .
I n d i c a t e alarms i f pre-set operating parameters a r e n o t
within specification.
I f imminent mechanical o r persona? danger
i s p r e s e n t , t h e o p e n i n g / c l o s i n g sequence i s stopped.
Report o t h e r problems t o t h e b r i d g e operator.
P r o v i d e o u t p u t s f o r a permanent r e c o r d .

C o n s o l e . The C o n t r o l C o n s o l e ( F i g u r e 3 ) c o n t a i n s t h e s n i t c h i n g
d e v i c e s f o r t h e b r i d g e o p e r a t o r t o c o n t r o l t h e o p e n i n g and c l o s i n g o f
~umerous indicator lights w i l l ajlow the operator t o
the bridge.
v i s u a l l y check t h e s t a t u s o f components t h r o u g h o u t t h e b r i d g e and n o t e
alarm conditions.

Control
-

Central
Programma&
Controller.
T h e PC c o n s i s t s o f f o u r s e c t i o n s :
P r o c e s s i n g U n i t , L o c a l I n p u t f O u t p u t ( I / O ) , T e r m i n a l a n d Remote I / O .
CENTRAL PROCESSING U N I T ( C P U ) :
The CPU i s u s e d t o make d e c i s i o n s
i n process c o n t r o l .
I t a c c e p t s i n p u t s and d i r e c t s o u t p u t s t h r o u g h 1/0
modules t o process p r i m a r y a c t u a t o r s .
T h e CPU c o n t a i n s t h e m e m o r y

used i n
memory.

relay

ladder

logic

variable

memory

and

special

function

LOCAL 1 / 0 :
The L o c a l 1 / 0 i s u s e d t o e l e c t r o n - f c a l l y c o n n e c t l o c a l
c o n t r o l s t o t h e CPU.
I t a l s o i n t e r f a c e s the CPU t o t h e Operator
Control
Console f o r
recording process
v a r $ a b l e s a n d f ~ ra l a r m
indication.
TERMINAL:
The t e r m i n a l
a t the control
console i s the operator
i n t e r f a c e f o r c h e c k i n g t h e dynamic c o n d i t i o n o f t h e b r i d g e c o n t r o l
system a t any time.
T h i s t e r m i n a l may a ! c r i he u s e d b y q u a l i f i e d
technicians
t o a c t i v e l y change t h e i n d i c a t o i - s d i s p l a y e d on t h e
monitor.
B a s i c computer programming c a n o n l y be changed b y a u t h o r i z e d
p e r s o n n e l w i t h a n o t h e r t e r m i n a l a t t h e CPU.
REMOTE I / O :
The Remote 1 / 0 i s u s e d l o e l e c t r o n i c a l l y c o n n e c t t h e CPU
t o r e m o t e a c t u a t o r s and s e n s o r s t h a t a r e l o c a t e d t h r o u g h o u t t h e
b r i d g e , p i e r s and a p p r o a c h e s .
These I / O a l s o h a v e a n a l o g a n d d i s c r e t e
capabilities.
Hydraulic Machinery
The s w i n g b r i d g e h a s t w o i d e n t i c a l h y d r a u l i c s y s t e m s , o n e i n e a c h
pivot pier.
The t w o s y s t e m s c a n o p e r a t e e i t h e r i n d e p e n d e n t l y o r
simultaneously.
The o p e r a t o r h a s i n d e p e n d e n t c o n t r o l o f e a c h s y s t e m .
Each h y d r a u l i c s y s t e m c o n s i s t s o f l i f t a n d s l e w a c t u a t o r s , f l u i d
t r a n s m i s s i o n l i n e s , a r e s e r v o i r and a p o w e r p a c k w h i c h c o n t a i n s pumps
and c o n t r o l v a l v e s .
The h y d r a u l i c s c h e m a t i c d i a g r a m o f t h e p i v o t p i e r
s y s t e m i s shown i n F i g u r e 4 .
The b r i d g e w i l l a l s o h a v e h y d r a u l i c s y s t e m s t o d r i v e e a c h o f t w o t a i l
l o c k s and t h e c e n t e r l o c k s .
The h y d r a u l i c s c h e m a t i c d i a g r a m o f t h e s e
s y s t e m s i s shown i n F i g u r e 8.
Lift And Slew System Design

The f o l l o w i n g

i s a d e s c r i p t i o n o f t h e l i f t and s l e w h y d r a u l i c system.

Start-Up.
The o p e r a t o r s t a r t s t h e l i f t a n d s l e w s y s t e m b y t u r n i n g on
Upon s t a r t - u p
t w o o f t h e t h r e e pump m o t o r s f r o m t h e c o n t r o l p a n e l .
t h e m a i n d r i v e pump p r e s s u r e c o m p e n s a t o r i s a t i t s l o w p r e s s u r e
s e t t i n g t o r e d u c e t h e s t a r t - u p l o a d on t h e m o t o r s and h e a t g e n e r a t i o n
i n t h e s y s t e m . F l o w f r o m t h e b o o s t pumps a n d f r o m t h e d o c k i n g pumps i s
p o r t e d over re1i e f valves.
Lift.
When t h e L I F T SPAN b u t t o n s a r e p u s h e d , t h e l i f t c o n t r o l v a l v e
i s opened,
t h e main pump's compensator c i r c u i t s b l o c k e d , and t h e
s t r o k e l i m i t e r s s e t t o p r o v i d e f u l l f l o w o f 6 5 gpm f r o m e a c h pump.
H i g h p r e s s u r e o i l f r o m t h e pumps, now w o r k i n g i n a f i x e d d i s p l a c e m e n t
The b r i d g e l i f t s o n e i n c h i n
mode, f l o w s t o t h e L i f t / T u r n C y l i n d e r .
20 s e c o n d s t o c l e a r t h e m a i n s e r v i c e b e a r i n g s on t o p o f t h e p i e r
housing.

The b r i d g e c o n t i n u e s t o l i f t a u t o m a t i c a l i j u n t i l t h e UP i i m i t s w i t c h e s
a r e engaged.
Two s e c o n d s a f t 2 r t r i p p i n g t h e s e s w i t c h e s , t h e l i f t
i s
activated to
a
valve c l o s e s
and t h e
main p u m p c o m p e n s a t o r
A t t h e s a m e t i m e , t h e m a i n pump's s t r o k e
s e t t i n g o f 1500 p s i .
The b r i d g e i s
l i m i t e r s a r e r e - s e t t o t h e i r maximum f l o w o f 9 5 gpm.
In o r d e r t o
now l o c k e d i n t h e l i f t p o s i t i o n by t h e c l o s e d l i f t v a l v e .
m i n i m i z e l e a k a g e and r e s u l t i n g b r i d g e s a g , t h e s y s t e m u s e s p o p p e t - t y p e
c a r t r i d g e v a l v e s f o r t h e l i f t v a l v e a p p l i c a t i o n . The l i f t c i r c u i t i s
p r o t e c t e d by t h e 2300 p s i s e t t i n g of a r e l i s f virlve d u r i n g normal
operations.
S 1 ew ope.
d i rec tional

With t h e b r i d g e
t h e iifted p o s i t i o n ,
t h e main
c o n t r o l v a l v e can be s h i f t e d T r a m i t s s p r i n g c e r , k e r e d
p o s i t i o n , a l l o w i n g o i l t o f l o w from t h e p m p s L o t h e s l e w i n g
Both t h e d e c e l e r a t i o n s e r v o - v a l v e and t h e b y - p a s s r e l i e f
cyl i n d e r s .
v a l v e a r e a c t u a t e d t o t h e i r open p o s i t i o n , a l l o w i n g o i l t o f l o w f r e e l y
The c o u n t e r - b a l a n c e
from t h e s l e w i n g c y l i n d z r s back t o t h e t a n k .
v a l v e s i n t h e r e t u r n l i n e s a r e s e t t o open by s u p p l y p r e s s u r t i n
e x c e s s of 6 5 p s i .

FIGURE 4

PIER HYDRAULIC SCHEMATIC

The b r i d g e i s a c c e l e r a t e d b y t h e s l e w i n g c y l i n d e r s a s t h e o i l f l o w
f r o m t h e pumps i n c r e a s e s t o t h e maximum a t f u l l s t r o k e . D u r i n g t h e
a c c e l e r a t i o n p e r i o d , t h e pump c o m p e n s a t o r s 1 i m i t t h e maximum s l e w i n g
c y l i n d e r pressure during acceleration.
As t h e b r i d g e r e a c h e s a
uniform angular velocity,
t h e system p r e s s u r e drops t o match t h e
r e s i s t i v e f o r c e s g e n e r a t e d b y l i n e p r e s s u r e d r o p , f r i c t i o n and wind.
D u r i n g t h e s l e w , t h e b r i d g e p o s i t i o n , v e l o c i t y and a c c e l e r a t i o n a r e
c o n t i n u o u s l y m o n i t o r e d b y 1i n e a r post t i o n sensors mounted i n t h e p i e r
housing.
D u r i n g normal o p e r a t i o n ,
the bridge w i l l
continue i t s constant
v e l o c i t y slew u n t i l , a t a predetermined opening angle,
both the
d e c e l e r a t i o n v a l v e and t h e r e 1 i e f v a l v e c l o s e , a p p l y i n g d i f f e r e n t i a l
braking pressure t o the slewing c y l i n d e r pistons.
A t t h e same t i m e ,
t h e m a i n pump c o m p e n s a t o r s e t t i n g i s r e d u c e d , t h e r e b y a l l o w i n g t h e
m a i n pumps t o p r o v i d e makeup o i l t o t h e s l e w i n g c y l i n d e r s d u r i n g
deceleration.
During deceleration, bridge motion i s c o n t r o l l e d by modulating the
deceleration servo-valve.
The c o n t i n u o u s p o s i t i o n i n p u t , t o t h e v a l v e
comes f r o m t h e p i e r l i n e a r p o s i t i o n s e n s o r s ,
through the motion
c o n t r o l computer.
The v a l v e opens o r c l o s e s t o p r o v i d e a p r e d e t e r m i n e d and c a n t r o l l e d d e c e l e r a t i o n .
As t h e b r i d g e a n g u l a r
v e l o c i t y slows, f l o w from t h e small v a r i a b l e displacement docking
pumps moves t h e b r i d g e s l o w l y t o t h e f i n a l o p e n p o s i t i o n a s d e t e r m i n e d
When t h i s p o s i t i o n i s r e a c h e d ,
b y th% p i e r l i n e a r p o s i t i o n s e n s o r s .
t h e b r i d g e i s l o c k e d i n t h e open p o s i t i o n b y t h e c o u n t e r b a l a n c e
v a l ves.
T h e r e i s no p o s i t i o n c o n t r o l d o c k i n g p a d i n t h e o p e n
position.
D u r i n g t h e normal opening c y c l e , t h e b r i d g e i s n o t lowered
o n t o t h e s e r v i c e b e a r i n g s w h i l e i n t h e open p o s i t i o n .
Slew Close.
As i n t h e o p e n i n g o p e r a t i o n , t h e b r i d g e a c c e l e r a t e s i n
t h e c l o s i n g d i r e c t i o n as
pump f l o w i n c r e a s e s t o f u l l s t r o k e . As t h e
b r i d g e reaches a u n i f o r m a n g u l a r v e l o c i t y , t h e system p r e s s u r e drops
t o m a t c h t h e r e s i s t i v e f o r c e s , and t h e b r i d g e c o n t i n u e s i t s c o n s t a n t
v e l o c i t y slew u n t i l i t reaches a pre-determined c l o s i n g angle, a t
which p o i n t , d e c e l e r a t i o n i s i n i t i a t e d .
The d e c e l e r a t i o n p o i n t i s
detected by the p i e r l i n e a r sensors i n a d d i t i o n t o a redundant s e t o f
b a c k u p l i m i t s w i t c h e s l o c a t e d on t h e a p p r o a c h s t r u c t u r e s .
Because o f
t h e magnitude o f t h e p i e r housing p i l e t w i s t ,
the accuracy i n
detecting the deceleration point,
u s i n g t h e p i e r 1i n e a r p o s i t i o n
s e n s o r s , m i g h t n o t be a d e q u a t e .
I f t h i s i s f o u n d t o be t h e case
d u r i n g t h e b r i d g e d r i v e system t e s t ,
t h e l i m i t s w i t c h e s on t h e
a p p r o a c h s t r u c t u r e s w i l l be used f o r t h e p r i m a r y d e c e l e r a t i o n p o i n t
d e t e c t i o n and t h e l i n e a r p o s i t i o n s e n s o r s a s b a c k up d e t e c t i o n .
The d e c e l e r a t i o n p h a s e i s c o n t r o l 1 e d b y t h e s e r v o - d e c e l e r a t i o n v a l v e ,
modulated by feedback f r o m t h e p i e r housing p o s i t i o n sensors t h r o u g h
t h e m o t i o n c o n t r o l computer.
Docking.
As t h e b r i d g e a n g u l a r v e l o c i t y s l o w s t o . O z O p e r s e c o n d ,
t h e t w o d o c k i n g pumps move t h e b r i d g e s l o w l y t o t h e f i n a l c l o s e d
p o s i t i o n a g a i n s t t h e approach s t r u c t u r e b r i d g e stops.
The f o r c e o f

t h e s t o p i s c o n t r o l l e d b y t h e 4 5 0 p s i d o c k i n g pump c o m p e n s a t o r
setting.
The f i n a l a l i g n m e n t o f t h e b r i d g e t a i l s p a n s w i t h t h e
approach s t r u c t u r e s i s w i t h i n +.25-inches,
as measured b y a l i n e a r
p o s i t i o n s e n s o r mounted on t h e d<cking d e c e l e r a t i o n b u f f e r .
The maximum l a t e r a l l o a d s g e n e r a t e d o n t h e a p p r o a c h s t r u c t u r e d u r i n g
n o r m a l d o c k i n g a r e d e s i g n e d t o b e l e s s t h a n 40,000 I b s . a t t h e b r i d g e
approach stops.
Lowering.
W i t h t h e b r i d g e i n f i n a l a l i g n m e n t , and p r e s s e d a g a i n s t t h e
b r i d q e s t o p s b y t h e 450 p s i s l e w i n g p r e s s u r e ,
t h e o p e r a t o r can
a c t i i a t e t h e 1i f t / d u m p valve..
O i l f r o m - t h e L i f t / T u r n ~ yi n ld e r , f o r c e d
by t h e b r i d g e w e i g h t , f l o w s t h r o u g h t h e l i f t / d u m p v a l v e and back t o
the tank.
Lowering of t h e b r i d g e i s p o s s i b l e a t any s l e w a n g l e .
Abnormal O p e r a t i n g C o n d i t i o n s
I f t h e b r i d g e slews p a s t t h e normal open o r
Failure t o Decelerate.
c l o s e d d e c e l e r a t i o n i n i t i a t i o n p o i n t s and t h e system f a i l s t o reduce
t h e b r i d g e a n g u l a r v e l o c i t y w i t h i n a p r e s c r i b e d amount, t h e s i t u a t i o n
i s d e t e c t e d b y t h e l i n e a r p o s i t i o n s e n s o r s , a n d f e d t o t h e PC t h r o u g h
the motion control.
I n t h e c l o s i n g c y c l e , a second s e t o f s w i t c h e s
l o c a t e d on t h e approach s t r u c t u r e a l s o a r e t r i g g e r e d .

If t h e t i m e t a k e n t o s l e w f r o m t h e n o r m a l d e c e l e r a t i o n p o i n t t o t h e
back-up emergency p o i n t i s l e s s than two
seconds, as measured b y t h e
P C , t h e m a i n pump p o w e r i s s h u t o f f a n d t h e m a i n d i r e c t i o n a l v a l v e
s p o o l moved t o i t s c e n t e r p o s i t i o n .
T h i s causes t h e s u p p l y l i n e
p r e s s u r e t o d r o p b e l o w 65 p s i , a c t i v a t i n g t h e c o u n t e r b a l a n c e v a l v e s ,
These v a l v e s ,
s e t t o r e l i e v e a t 1600 p s i , d e c e l e r a t e t h e b r i d g e ,
l i m i t i n g t h e maximum l a t e r a l f o r c e o n t h e a p p r o a c h s t r u c t u r e t o
100,000 I b s .

If t h e c o u n t e r b a l a n c e v a l v e s f a i l a n d t h e b r i d g e c o n t i n u e s t o s l e w
p a s t t h e emergency s t o p p o i n t w i t h o u t d e c e l e r a t i - n g , h y d r a u l i c b r i d g e
b u f f e r s reduce the b r i d g e v e l o c i t y p r i o r t o impact w i t h t h e f i x e d
bridge stops.
The l a t e r a l l o a d s g e n e r a t e d o n t h e a p p r o a c h s t r u c t u r e
d u r i n g t h i s c o n d i t i o n a r e l i m i t e d t o 200,000 l b s .
Emergency Stop.
When t h e o p e r a t o r r e l e a s e s t h e s l e w h a n d l e t o
n e u t r a l , t h e b r i d g e d e c e l e r a t e s and s t o p s i n 10 seconds o r l e s s .
This
i s normally accomplished by the r e g u l a r d e c e l e r a t i o n valves.
If the
b r i d g e f a i l s t o s l o w down a s s p e c i f i e d , ( 5 s e c o n d s a f t e r r e l e a s e o f
t h e h a n d l e ) , o r i f t h e o p e r a t o r pushed t h e emergency s t o p b u t t o n
d i r e c t l y , t h e pump p o w e r s h u t s down, t h e m a i n d i f f e r e n t i a l s p o o l v a l v e
c e n t e r s and t h e c o u n t e r b a l a n c e v a l v e s d e c e l e r a t e and s t o p t h e b r i d g e .
Emergency S l e w i n g .
I n t h e e v e n t o f a f a i l e d l i f t system, t h e b r i d g e
i s c a p a b l e o f s l e w i n g w i t h i t s t o t a l w e i g h t r e s t i n g on t h e s e r v i c e
bearirigs.
To d o t h i s - , t h e s l e w i n g c y l i n d e r s a r e a c t t i a t e d b y m e a n s o f
t h e d o c k i n g pumps.
T h i s i s accomplished b y c l o s i n g t h e manual s h u t
o f f v a l v e l e a d i n g t o t h e 2300 p s i r e l i e f v a l v e , t h u s a c t i v a t i n g t h e
6000 p s i r e l i e f v a l v e .
T h e d o c k i n g pump c o m p e n s a t o r i s t h e n b l o c k e d ,
p r o v i d i n g 6000 p s i p r e s s u r e f o r t h e emergency s l e w i n g .

LiftiTurn Cylinder Design

A unique feature o f the bridge design i s the L i f t / T u r n Cylinder.

This
c y l i n d e r s e r v e s two p u r p o s e s ; a ) t o l i f t t h e b r i d g e c l e a r of t h e
" s e r v i c e " b e a r i n g s and, b ) t o p r o v i d e a r o t a t i n g f l u i d s u p p o r t b e a r i n g
upon w h i c h t h e b r i d g e s l e w s .
Several
important
Cylinder design:
1.
2.
3.
4.
5.
6.

considerations

were

addressed

in

the

Lift/Turn

Operating pressures
(AASHTO and A R E A S p e c i F i c a t i o n s )
Seal D e s i g n - R o t a t i o n as w e l l as t r a n s l a t i o n
Manufacture- Physical size, p l a t i n g requirements, ground-bearing
s u r f a c e s and m a t e r i a l s .
C o n c e n t r i c i t y - R e q u i r e m e n t f o r L i f t / T u r n C y l i n d e r t o be c o n c e n t r i c
with the bridge pivot shaft during rotation.
R e l i a b i l i t y and L o n g e v i t y
Maintenance

Access and M a i n t e n a n c e .
F i g u r e 5 shows t h e l o c a t i o n o f t h e L i f t / T u r n
C y l i n d e r under t h e b r i d g e p i v o t s h a f t .
Access t o t h e c y l i n d e r i s b y
l a d d e r f o r n o r m a l i n s p e c t i o n and m a i n t e n a n c e .
I n the event o f a major
f a i l u r e , t h e L i f t / T u r n C y l i n d e r c a n be f u l l y r e t r a c t e d a l l o w i n g t h e
b r i d g e t o be s u p p o r t e d b y t h e s e r v i c e b e a r i n g s .
This provides
c l e a r a n c e f o r t h e L i f t / T u r n C y l i n d e r t o b e moved o u t f r o m u n d e r t h e
p i v o t s h a f t and a r e p l a c e m e n t moved i n t o t h e o p e r a t i n g p o s i t i o n .
A
1 5 - t o n h o i s t and
r e m o v a b l e s e c t i o n i n t h e d e c k accommodate c o m p l e t e
removal o f t h e L i f t / T u r n C y l i n d e r f o r r e p a i r .

FIGURE 5

LIFTiTURN CYLINDER AND BEARING LOCATIONS

SECTION A-A

BLEED
PORT

FIGURE 6

PI STON

LlFTnURN CYLINDER HALF SECTION

F l o a t i n g Cyl i n d e r B a r r e l .
F i g u r e 6 shows a h a l f s e c t i o n t h r o u g h t h e
L i f t / T u r n Cyl i n d e r .
Due t o t o l e r a n c e b u i l d - u p i n m a n u f a c t u r e a n d
i n s t a l l a t i o n o f the bridge p i v o t shaft,
i t i s possible that the
n o t always
coincide with the
centerline o f
the cylinder w i l l
centerline o f the Lift/Turn Cylinder.
To accommodate t h i s p o s s i b l e
e c c e n t r i c m o t i o n d u r i n g b r i d g e slew, t h e c y l i n d e r b a r r e l i s designed
t o f l o a t w i t h r e s p e c t t o i t s base p l a t e .
The b e a r i n g s u r f a c e b e t w e e n
t h e b a r r e l a n d base p l a t e a l l o w s t h e r e q u i r e d m o t i o n b e t w e e n t h e t w o .
D i f f e r e n t i a l a r e a b e t w e e n t h e t o p s e t a n d b o t t o m s e t o f s e a l s on t h e
barrel provides a hydrostatic force
p r e v e n t i n g s e p a r a t i o n between
b a r r e l and p l a t e .
A r i n g r e t a i n e r a l s o s e r v e s as a back-up t o ensure
that
the seal
i n t e g r i t y between b a r r e l
and p l a t e i s a l w a y s
maintained.

Barrel Anti-Rotation
P i n a n d B e a r i n g. .A
bronze bearing block
and p i n arrangement
as shown i n F i g u r e 7
allows
the required
e c c e n t r i c m o t i o n between
barrel
and
plate.
The b l o c k a n d
p i n allows the center
o f t h e b a r r e l t o move
radially relative to
t h e base p l a t e .
The
pin,
however,
prev e n t s t h e b a r r e l from
rotating
with
the
piston.

BARGEL
ANTI-ROTATION
p l AND
~
BEARING

Dual Seal Arrangement.

As i s s e e n i n F i g u r e 7 , t h e d e s i g n p r o v i d e s
d u a l s e a l s f o r a l l t h r e e dynamic s e a l i n g s u r f a c e s .
Ports located
between each p r i m a r y and secondary s e a l s e t c o n n e c t t o t h r e e s e p a r a t e
h y d r a u l i c o i l l u b e t a n k s l o c a t e d a p p r o x i m a t e l y 10 f e e t a b o v e t h e
L i f t f T u r n Cyl i n d e r .
T h i s system p r o v i d e s l o w p r e s s u r e l u b r i c a t i o n t o
t h e s e c o n d a r y s e a l , and a l s o p r o v i d e s a d e t e c t i o n s y s t e m i n t h e e v e n t
o f p r i m a r y seal leakage.

L a r g e , s p r i n g a c t i v a t e d , p o l y u r e t h a n e li p s e a l s w e r e s e l e c t e d f o r t h e
main s e a l s between b a r r e l and p i s t o n .
These s e a l s , w h i c h have been
p r o v e n i n N o r t h Sea o i l r i g a p p l i c a t i o n s , a r e d e s i g n e d t o a c c o m m o d a t e
n o t o n l y t h e p i s t o n r o t a t i o n b u t a l s o t h e r e l a t i v e l y l a r g e gap between
b a r r e l a n d p i s t o n . T h i s l a r g e gap i s n e c e s s a r y t o accommodate t h e
differential
expansion and c o n t r a c t i o n o f t h e p i s t o n caused b y
pressurizing the cylinder during the l i f t cycle.
The o u t e r d i a m e t e r o f t h e p i s t o n h a s a h e a v y g r o u n d a n d p o l i s h e d
chrome p l a t e d s u r f a c e t o p r o v i d e an e x c e l l e n t s e a l i n g s u r f a c e a n d
reduce wear f r o m t h e s e a l s d u r i n g t h e s l e w c y c l e .
I f t h e p a i r o f L i f t / T u r n C y l i n d e r UP l i m i t
Safety Features.
f a i l t o stop the lift, a t h i r d pair, located approximately
a b o v e t h e UP l i m i t s w i t c h e s , a r e e n g a g e d .
I f t h i s happens,
i s s t o p p e d b y s h u t t i n g down t h e m a i n pump p o w e r a n d c l o s i n g
control valves.

I n a d d i t i o n t o t h e two s e t s o f p o s i t i o n s w i t c h e s , t h e
C o n t r o l l e r i s p r o g r a m m e d t o s h u t down t h e m a i n pumps
c o n t i n u e s f o r m o r e t h a n 40 seconds.

switches
3/4-inch
the l i f t
the lift

Programmable
i f the lift

The f o u r t h s a f e t y f e a t u r e on l i f t o v e r t r a v e l i s a m e c h a n i c a l v e n t
valve.
A c t u a t i o n o f t h i s v a l v e v e n t s t h e l i f t dump v a l v e , d i r e c t i n g
o i l f l o w f r o m t h e pump b a c k t o t a n k .
I n c a s e a l l o f t h e o v e r l i f t p r o t e c t i o n f a i l s and t h e p i s t o n u n c o v e r s
t h e p r i m a r y s e a l s , o i l w i l l escape t o t h e p i s t o n s e a l l u b e t a n k , which
makes up o n e c o m p a r t m e n t o f t h e s e a l t a n k .
When o i l i n t h e s e a l t a n k
r e a c h e s t h e hig.h l e v e l s e n s o r , a w a r n i n g l i g h t i s t u r n e d o n a t t h e
operator's station.
The o p e r a t o r c a n now e l e c t t o s h u t t h e l i f t down
b y p u s h i n g t h e EMERGENCY STOP b u t t o n .

If a p r i m a r y L i f t / T u r n C y l i n d e r p i s t o n o r b o t t o m s e a l s u d d e n l y f a i l s
during bridge operation, the level i n the respective lube tank w i l l
also increase.
The i n t e r m e d i a t e and h i g h l i m i t s e n s o r s i n t h e l u b e
t a n k s w i l l t r i p and w a r n t h e o p e r a t o r o f t h i s s i t u a t i o n .
The s e a l
I f the lift
l u b e l i n e valves w i l l c l o s e i f t h e l i m i t sensor t r i p s .
has n o t c o n t i n u e d b e y o n d 40 s e c o n d s , t h e pump p o w e r w i l l n o t s h u t
down.
T h i s e n a b l e s t h e b r i d g e t o c o m p l e t e t h e s w i n g c y c l e , w o r k i n g on
the secondary c y l i n d e r seals.

Lock System Design

The l o c k h y d r a u l i c s y s t e m c o n s i s t s o f
two i d e n t i c a l t a i l l o c k h y d r a u l i c power
units;
one i n each o f t h e two f i x e d
approaches,
and one c e n t e r l o c k h y d r a u l i c power u n i t l o c a t e d i n t h e w e s t
s w i n g span n e a r t h e c e n t e r o f t h e
bridge.

m MIUW N.
p a
US

Each p o w e r u n i t c o n s i s t s o f a c o n s t a n t
hydraul i c
h o r s e p o w e r h y d r a u l i c pump,
cylinder,
reservoir,
and
associated
c o n t r o l c o m p o n e n t s , as i s i l l u s t r a t e d
by t h e schematic diagram
(Figure 8).
The v a r i a b l e volume h y d r a u l i c pump,
w i t h c o n s t a n t horsepower c o n t r o l , i m parts
fast
motion t o the lock bar
except during t h a t p a r t o f the locki n g c y c l e i n which
high
friction
forces a r e encountered.

FIGURE 8

LOCKS HYDRAULiC SCHEMATIC

C o u n t e r b a l a n c e v a l v e s p r e v e n t movement o f t h e l o c k c y l i n d e r s u n l e s s
t h e a p p l i c a b l e main c o n t r o l v a l v e i s e n e r g i z e d .
Lock Bar l i m i t
s w i t c h e s p r o v i d e p o s i t i v e f e e d b a c k t o t h e Programmable C o n t r o l l e r , and
i n d i c a t o r l i g h t s on t h e o p e r a t o r ' s c o n s o l e i n d i c a t e t h a t l o c k s a r e
e i t h e r D R I V E N o r WITHDRAWN.

A l o w l e v e l f l u i d sensor i s p r o v i d e d i n each r e s e r v o i r t o a c t i v a t e a
hard a l a r m i f f l u i d i s below t h e c r i t i c a l l e v e l .
Manual c o n t r o l v a l v e s a r e p r o v i d e d so an a u x i l l i a r y h y d r a u l i c p o w e r
u n i t c a n be u s e d t o a c t i v a t e t h e a p p r o p r i a t e l o c k c y l i n d e r s i n an
emergency, e x c l u d i n g h y d r a u l i c c y l i n d e r f a i l u r e .
SLEW CYCLE ANALYSIS

The m o s t i m p o r t a n t a s p e c t o f a n y m o v a b l e b r i d ~ eo p e r a t i n g s y s t e m i s t o
m a i n t a i n p o s i t i v e c o n t r o l o f t h e b r i d g e motion under any c o n d i t i o n .
I n the design o f t h i s bridge, positive control i s maintained a t a l l
t i m e s b y means o f t h e s l e w i n g c y l i n d e r s . However, d e c e l e r a t i o n b u f f e r s
i n t h e p i v o t p i e r s and a p p r o a c h e s augment t h e d e c e l e r a t i o n c o n t r o l o f
t h e s l e w i n g c y l i n d e r and s e r v e as emergency d e c e l e r a t i o n d e v i c e s .

A c o m p u t e r p r o g r a m was g e n e r a t e d t o a n a l y z e t h e r o t a t i o n a l movement o f
t h e b r i d g e d u r i n g t h e v a r i o u s AASHTO l o a d c o n d i t i o n s .
The e f f s c t o f
using d i f f e r e n t types o f deceleration valves,
( p r e s s u r e r e 1i e f o r
s e r v o - f l o w c o n t r o l ) , was a l s o s t u d i e d .
The o b j e c t i v e o f t h i s a n a l y s i s
was t o d e t e r m i n e t h e r e l a t i o n s h i p s b e t w e e n t h e v a r i o u s b r i d g e d y n a m i c
O f particular
p a r a m e t e r s o f p o s i t i o n , v e l o c i t y , and a c c e l e r a t i o n .
i n t e r e s t were t h e c h a r a c t e r i s t i c s o f a n g u l a r v e l o c i t y d u r i n g t h e
d e c e l e r a t i o n and d o c k i n g phase o f t h e s l e w i n g c y c l e .
Normal and
emergency s t o p p i n g c o n d i t i o n s were i n v e s t i g a t e d u n d e r d i f f e r e n t w i n d
loads and w i t h d i f f e r e n t d e c e l e r a t i o n v a l v e s .
F i g u r e 9 shows t h e a n g u l a r v e l o c i t y o f t h e b r i d g e d u r i n g i t s c o m p l e t e
slewing cycle.

CONSTANT VELOCITY

FIGURE 9
ANGULAR
VELOCITY
VS. TIME

BRIDGE S U l N 6 CYCLE

F i g u r e 10 shows t h e a n g u l a r v e l o c i t y o f t h e b r i d g e d u r i n g d e c e l e r a t i o n
and d o c k i n g .
A r e s u l t o f t h e s l e w c y c l e a n a l y s i s was t h e a d d i t i o n o f t h e b u f f e r s .

NORWAL OPERATlON

COUNTERBALANCE

ANGULAR
VELOCITY VS.
SWING ANGLE DECELERATION
AND DOCKING

BRIDGE

S W I N G CYCLE

DESIGN CRITERIA

The d e s i g n c r i t e r i a f o r t h e h y d r a u l i c s y s t e m a n d c o m p o n e n t s
d e v e l o p e d b a s e d on t h e f o l l o w i n g n a t i o n a l l y r e c o g n i z e d s t a n d a r d s :

1)

A m e r i c a n R a i l r o a d E n g i n e e r s A s s o c i a t i o n (AREA)
Manual,
P r o p o s e d A d d i t i o n C h a p t e r 1 5 , P a r t 6, R e f . B u l l e t i n 6 9 4 ,
J a n u a r y 1984.

2)

A m e r i c a n A s s o c i a t i o n o f S t a t e Highway and T r a n s p o r t a t i o n
Officials.
(AASHTO).
Standard S p e c i f i c a t i o n f o r Movable
Highway B r i d g e s .

3)

J o i n t I n d u s t r i a l Council (JIC)

4)

N a t i o n a l F l u i d Power A s s o c i a t i o n (NFPA)

Hydraulic Standards
Hydraulic Standards.

was

L o a d c o n d i t i o n s o u t 1 i n e d i n t h e AASHTO b r i d g e s p e c i f i c a t i o n s w e r e
u s e d , w h i 1 e s y s t e m p r e s s u r e s and h y d r a u l i c c o m p o n e n t s w e r e s p e c i f f e d
u s i n g t h e 1 9 8 4 AREA s p e c i f i c a t i o n .
The b a s i c g u i d e l i n e s o f t h e AREA h y d r a u l i c s y s t e m r e c o m m e n d a t i o n s w e r e
f o l l o w e d , w i t h t h e f o l l o w i n g e x c e p t i o n s : The maximum n o r m a l s y s t e m
o p e r a t i n g p r e s s u r e s a r e 2000 p s i and t h e maximum p r e s s u r e
d i f f e r e n t i a l a c r o s s t h e s w i n g c y l i n d e r p i s t o n i s 1150 p s i .
This
c r i t e r i a i s i n l i n e w i t h t h e c a p a b i l i t y o f t h e m a j o r i t y o f modern
medium-pressure h y d r a u l i c systems.
The c o n t r o l s y s t e m d e s i g n c r i t e r i a
was d e v e l o p e d u s i n g t h e N a t i o n a l E l e c t r i c a l Code a n d ASTM S t a n d a r d s .
SYSTEM PERFORMANCE CRITERIA

SPECIFICATION

CONDITION

Opening o r c l o s i n g
sequence
C o n t r o l s disengaged o r
d r i v e system f a i l u r e
occurs
Rate o f Open/Close C y c l e s

Design 1i f e o f system
components
Design o p e r a t i n g frequency

Docking accuracy

When s t o p p e d a t a n y
position
Docking impact f o r c e a t
end o f t a i l span
I m p a c t f o r c e on p i v o t
p i e r stopping buffer

Slewing Cylinder F a i l u r e

Lift/Turn Cylinder f a i l u r e

L e s s t h a n 120 s e c o n d s
Bridge motion w i l l stop
i n l e s s t h a n 10 s e c o n d s

A minimum o f 50 o p e n i n g s
and c l o s i n g s i n 2 4 h o u r
period
20 y e a r n o r m a l o p e r a t i o n
without major overhaul
7 o p e n i n g s p e r 24 h o u r s ,
360 d a y s p e r y e a r .
P o s i t i o n and h o l d b r i d g e
d u r f n g d o c k i n g w i t h i n +.25
i n c h e s a t t h e t a i l span/
approach s t r u c t u r e i n t e r face.
Bridge w i l l hold against
w i n d l o a d s p e r AASHTO
specification
L e s s t h a n 40,000 l b , f o r
normal o p e r a t i o n and
350,000 l b . f o r e m e r g e n c y
s ituation.
L e s s t h a n 40,000 l b . f o r
normal o p e r a t i o n and
500,000 l b . f o r e m e r g e n c y
situation.
Capable o f r o t a t i n g b r i d g e
i n e v e n t o f one s l e w i n g
cylinder failure
Operating pressure o f
6000 p s i maximum,
move
b r i d g e on T e f l o n s e r v i c e
bearings w i t h a design
f r i c t i o n c o e f f i c i e n t o f .12

Angular v e l o c i t y p r o f i l e

Control system s h a l l
continuously monitor
selected parameters d u r i n g
b r i d g e o p e r a t i o n and warn
operator and/or stop
operation i f specified
1i m i t s a r e exceeded

SYSTEM DESIGN CRITERIA

CONDITION

SPECIFICATION

Design working pressure

Maximum d e s i g n p r e s s u r e
relief setting
Maximum r a t e d w o r k i n g
pressure

Safety factor f o r high

p r e s s u r e l i n e s , hose,
f i t t i n g s , and p o r t s
Safety f a c t o r f o r slewing
cylinders
Minimum s a f e t y f a c t o r
o f a l l other hydraulic
components
Maximum a n g u l a r b r i d g e
speed

2000 p s i g
2300 p s i g
4000 p s i f o r h y d r a u l i c
components e x c e p t L i f t / T u r n
C y l i n d e r w h i c h s h a l l be
2500 p s i
Four ( 4 ) t i m e s r a t e d working pressure
Five ( 5 ) times rated working
pressure
Three ( 3 ) t i m e s r a t e d
working pressure

RECOMMENDATIONS

Considering
the
c a p a b i l it i e s
of
modern
industrial
hydraulic
c o m p o n e n t s , t h e o l d AASHTO a n d t h e u p d a t e d ( 1 9 8 4 ) AREA S p e c i f i c a t i o n s
c u r r e n t l y used i n t h e d e s i g n o f movable b r i d g e h y d r a u l i c systems a r e
both very "conservative".
Both s p e c i f i c a t i o n s f o c u s on system
p r e s s u r e as t h e o n l y i m p o r t a n t v a r i a b l e a f f e c t i n g o v e r a l l r e l i a b i l i t y .
D u r i n g t h e d e s i g n o f t h e new m o v a b l e West S e a t t l e - 2 b r i d g e i t became
c l e a r t h a t d u e t o t h e l a r g e p o w e r demand a n d l o w o p e r a t i n g p r e s s u r e
( 1 0 0 0 p s i ) s p e c i f i e d b y AREA, t h e f l o w r a t e s h a d t o b e v e r y l a r g e .
The r e l i a b i l i t y o f a h y d r a u l i c s y s t e m i s a f u n c t i o n o f f l o w a s w e l l a s
p r e s s u r e , p a r t i c u l a r l y when a v e r y l a r g e f l o w demand d i c t a t e s t h e s i z e
o f , a n d t h u s s e v e r e l y l i m i t s , t h e c h o i c e o f pumps a n d o t h e r h y d r a u l i c
components.
F i g u r e 11 s h o w s t y p i c a l r e l i a b i l i t y c u r v e s , i l l u s t r a t i n g
t h a t f o r a given horsepower, t h e o v e r a l l r e l i a b i l i t y o f t h e system
w i l l not necessrily increase w i t h lower pressure.
Most i n d u s t r i a l h y d r a u l i c components a v a i l a b l e t o d a y a r e r a t e d t o
o p e r a t e c o n t i n u o u s l y a t 4000 p s i o r above.
S i n c e t h e AREA p r e s s u r e
s p e c i f i c a t i o n o f 1000 p s i i s w e l l b e l o w t h e component r a t i n g s , a
r e d u c t i o n i n p r e s s u r e b e l o w t h e r a t e d component v a l u e w i l l n o t b r i n g a

p r o p o r t i o n a l increase i n r e l i a b i l i t y .
F o r a g i v e n f l o w r a t e , any
r e d u c t i o n i n p r e s s u r e b e l o w 2500 p s i i s e s t i m a t e d t o h a v e a n e g l i g i b l e
e f f e c t on t h e o p e r a t i o n a n d m a i n t e n a n c e o f t h e s y s t e m .
F o r a g i v e n p o w e r demand,
the
increased
flow required by
reducing
the
pressure
w i 11
have
a
significant
effect
on
system
cost,
complexity
and m a i n t a i n a b i l i t y .
This
i s
particularly
noticea b l e I n l a r g e h i g h power
s y s t e m s s u c h a s t h e new
West
Seattle-2
bridge.
Therefore, the theoretical
b e n e f i t s gained by f o l l o w ing
the
"conserva t i ve"
AREA
s p e c i f i c a t i o n s do n o t
match t h e disadvantage o f
handling the
large flow.
Based on c u r r e n t e x p e r i e n c e
w i t h modern i n d u s t r i a l hyit i s f e l t that
draulics,
bridge
designers
should
n o t be governed by d e t a i l e d
pressure l i m i t a t i o n s d i c tated
without regard t o
f l o w and power c o n s i d e r a tions.

OECIiA9IR SISIfU
?RIISlJRS O t L M O t J I O 1
CAUSE R i i r i i v f i t
-1
L)WU JR R i L I M I L I I l

m~nrMILL

I M R C R S ~ 111 s i s t t n rtw HOI~ NSIW

PO111 Y l 1 1 CAUSE RAP10 I f D V C l l O # I N
RELIAIIII~~
s t * c r nrmrm~cs ~ r t t w
KC-s
v u i unac nm c a r r t u ~ u

PRESSURE

tI'RCASll(O f L M D W M O
~ L O YMSIP* m r n c

nusf 1 S U L L CHMllf S In
ELIA~ILIIT, c i m a r n r
I ~ I W I 1 1 1 1I S R i W

Since
the
inclusion of
these a d d i t i o n a l
factors
would need a p r o h i b i t i v e l y
complicated specification,
1 t is p r o b a b l y in t h e pub1 i c FIGURE II - HYDRAULIC SYSTEM RELIABILITY
interest that the selection
o f b o t h p r e s s u r e and f l o w i n b r i d g e h y d r a u l i c s y s t e m s b e l e f t t o t h e
d e s i g n e r s and component m a n u f a c t u r e r .
I f maximum p r e s s u r e l i m i t a t i o n s a r e t o b e s p e c i f i e d , h o w e v e r , t h e y
s h o u l d be u p d a t e d t o r e f l e c t t h e c u r r e n t s t a t e - o f - t h e - a r t o f h y d r a u l i c
components.