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Aſ ºf .2 ºil a T iſ ºr Tºº Fää C º i; ºfºº º, , , # [7 §§ HUGH L. Cooper & Co., CoNSULTING ENGINEERs, 101 PARK AVENUE, NEW YORK : : T k - |*| 2 || , Mºz ~~~~ Q 72 § T. & § C. " ) § # ELECTRIC POWER § ; . § ; - - from the ; © ; TENNESSEE RIVER § & - 3 . - & MUSCLE SHOALS, ALABAMA ; . & * ; HUGH L. COOPER & CO. § 101 PARK AVENUE, NEW YORK CITY - & | º 3& º º º غ º º £º 3& Rºº º º º º º *sº º 33%. 3 Aerial photograph of Wilson Dam taken in October, 1923. Page two 22 w , W - ? The development of water power and the improvement of navigation in the Tennessee River at Muscle Shoals have The rapid ad- vance in recent years in the hydro-electric art and the extraordinary demand for electric power caused a serious and broad study of this power proposal to be made in 1907. Since then various plans for private or government develop- ment of the potential electric power at Muscle Shoals have been made. been under consideration for many years. In the Federal plan for the development of navigation and power from the Tennesse River there are required three dams and locks, officially designated as Dams Nos. 1, 2 and 3, located as shown on accompanying map, page 4. Dam No. 1, including a Lock, is located about three miles below Dam No. 2 and is purely a navigation development. Dam No. 2, known as the Wilson Dam, is now under construction and is about 55 per cent completed. This instal- lation when finished, will cost about $50,000,000.00 exclud- ing interest during construction. This power plant with the Tennessee River unregulated will supply approximately 700,000,000 kilowatt hours of primary power per annum and 1,490,000,000 kilowatt hours of secondary power per annum. Navigation locks are included in this development. Dam No. 3 is a proposed water power and navigation development located about twenty miles upstream from THE MUSCLE SHOALS WATER POWERS Dam No. 2. This project is estimated to cost about $25,000,000.00, including the locks, and using the un- regulated flow of the Tennessee River is estimated to supply 285,500,000 kilowatt hours of primary power per annum and 608,000,000 kilowatt hours of secondary power per annum. Early in 1918, the development of Dam No. 2 was undertaken by the United States Government as an aid in the manufacture of nitrate to be used in munitions during war periods and in fertilizer in peace times. The construc- tion activities have been continuous and on a broad scale except for two periods of suspension, the first being for the last half of 1918 and the other from April, 1921 till July, 1922. The construction work was started by Hugh L. Cooper, at that time a Colonel of Engineers, U. S. Army, who was ordered home from France for this purpose. Sixty days later, having made general plans for the project and started the work, he was ordered back to France. This installation, known as Dam No. 2, and officially called the Wilson Dam, is being built under the direction of Major General Lansing H. Beach, Chief of Engineers, U. S. Army, with Brig. Gen. Harry Taylor, Assistant Chief of Engineers, U. S. Army, immediately in charge. On May 21, 1920, the Chief of Engineers made a contract in which Hugh L. Cooper & Co., Consulting Page three Page four \ WIL5CN DAN/1 DAM & LOC!C NO-2 \ t \ C, O L 22 E ZT C, O C N T SC PP2OPOSED NOP2-KAAL DIFFEPZENCES |N POOL LEVELS Forz DARA * i – 8 Feer Forz. DAM + 2 - 92 Feet Foſz, DAM # 5 - 38 Freer Location of proposed navigation and power developments, on the Tennessee River, LA, U D E PLD.A.L. Er C C C N TY LAVA/ º E N C, E C, O C N T Y HC) GH L. COOPE [Z. & Co. I NC. Corleolºr. No ENGINEER2s ". IO PAR × Av, N.Y.C. J. C.A-LE: CF Nat LE-sºo * * * 3&er, 2.2. DEC, ATC_JPZ tº ty § § wn § ~) º Š X. § § 2. 2.2% 2. Dam No. 2 now under construction. in the State of Alabama, including Engineers, were employed as the designing and supervising engineers for the entire project. This work has at all times been carried on by day labor, and all of the construction forces since May, 1923, have been directed by Lt.-Col. George R. Spalding, U. S. Army. The responsibility for the cost of the works and time of completion rests with the War Department of the United States. Barring unexpected difficulties in the future, the works should be ready for the commercial operation of eight units, a total of 260,000 horse-power of capacity by October 1, 1925. The total length of the proposed structures across the Tennessee River, at Muscle Shoals, will be about 4,500 ft. The power house, abutting the south shore, and forming a part of the dam, is 1,250 ft. long. The Dam or Spillway section extends from the north end of the power house to the lock, and is 3,050 ft. long. The upstream end of the lock extends from the north end of the dam to the north shore, a distance of 200 ft. - Power House. The power house structure is 1,250 ft. long and 160 ft. wide. Its total height is 134 ft. The sub- structure is monolithic concrete, while the superstructure is reinforced concrete, with a steel trussed roof. Eighteen power units will be installed ultimately. There will be four 30,000 horse-power units and fourteen 35,000 horse-power units—a total of about 600,000 horse-power. Four complete units of 30,000 horse-power each are now being installed and bids are soon to be requested for four additional units of 35,000 horse-power each. Dam. The length of the dam proper is 3,050 ft. It is 95 ft. high from the river bed to the crest, and 140 ft. high from foundation to the level of the operating bridge, and is 105 ft. thick at the base. The top of the dam is a flood gate Operating bridge which may be used for highway purposes. Locks. Two locks, one immediately above the other, each having a lift of 46'6" at mean stage, and each 60'0" by 300'0' inside dimensions, having a miter sill clearance of 7'6", are being built at the north end of the dam, and abutting the north shore. GENERAL STATEMENTS This entire project calls for 1,350,000 cubic yards of masonry. This is the greatest quantity of masonry required by any hydraulic development hitherto built, not excluding the famous dam on the Nile at Assouan, Egypt. This water power, when the total 600,000 horse-power of machinery has been installed and is utilizing the natural unregulated flow of the Tennessee River, will produce on the average, 700,000,000 kilowatt hours of primary power per annum and 1,490,000,000 kilowatt hours of secondary power per annum. Primary power is power which is available every hour of every year. Secondary power is power that is available a fraction of the year only. This fraction at the Wilson Dam will vary from a minimum of 90 days to Page five : ZN- ºX. - | º When completed and sealed and unwatered, the construction of the north end of the One of the early cofferdams under construction. Power House was started. Page six a maximum of nearly 365 days. A kilowatt is 1/3 horse- power. This total amount of power will effect, if used for ordinary commercial purposes, a saving of about 3,500,000 tons of coal per annum. When the flow of the Tennessee River is equalized by the construction of commercially feasible water powers and storages in the head waters of the river, the average annual electric power from this project should be increased about 30 per cent. The pool created by this dam will be about eighteen miles long and have an average width of about three- quarters of a mile. The operating head will vary from a maximum of 95 ft. to a probable minimum of 70 ft. Excess water not required for power purposes and flow- ing over the top of the dam will be controlled by fifty-eight steel gates, each 38 ft. long by 18 ft. high, these gates to be operated by a control system which will permit one man to open or close all of the gates in two hours, thus securing the most dependable flood regulation. These gates are designed so as to discharge up to 950,000 cubic feet of water per second. This 950,000 cubic feet of water per second is three times the maximum discharge of the St. Lawrence River in its International Section. The foundations for all of these works is a very hard blue limestone. The foundation strata have been carefully examined and thoroughly tested throughout the entire length of the dam, power house and lock system, and found entirely satisfactory. Exploration holes, varying in depth from 40 ft. minimum to 100 ft. maximum, have been driven for every 20 ft. of length of the structures, to show the character of the foundations. The plans followed for the testing of these foundations have so thoroughly revealed the character of the rock supporting all of the structures as to remove all possible doubt as to their sufficiency. Dam No. 2 and all of the water retaining works are what is known as the gravity type of construction, meaning structures which depend primarily on their own weight for their ability to resist overturning or sliding on their founda- tions. This type of construction has been in successful use for centuries and is now considered in conservative engi- neering to be the most dependable design where permanence, heavy duty, and low cost of maintenance are required. In general, reinforced concrete construction throughout Dam No. 2 has been followed only where exterior surfaces immediately adjacent to reinforcing rods can be maintained waterproof throughout operating conditions, thereby reliev- ing the reinforcement of the deterioration that always fol- lows where waterproofing cannot be perfected and main- tained. The Wilson Dam, when completed, is expected to represent the highest commercial efficiencies and the lowest costs of operation known to hydro-electric engineering at this time. Page seven º | - --- | -- - --- - º == Unwatered section of Tennessee River showing character of the river bottom. Page eight - - - --- General view of project, looking north. Power House in foreground; dam and lock in the distance. Note construction camp on the hill, equipped to maintain 5,000 workmen. Page nine º º * º º º - - construction view of upper Lock. A two-stage lock was necessary because of the great difference in the elevation of the water above and below the dam—a total lift of 95 feet. Page ten ：，： ：XX. ：:： *… ，，… Looking south along the 3,050 feet of partly completed Main Dam. These piers and spillways must be built up to the elevation of the masonry arches in the left foreground. Page eleven < * ~ * ~ * ~ * º £ººs . . . . 2. "… ~...~ 2× º … .32 2–s×2. “… ‘...… 2 . . . . . . v- 22°2:2:2% ~ * - Z2& - Y -2' > * > .. “Sºx ::…: <--~~~&# *º- º, - -* a . .." 2.2. * . 2 ” - * ~ 2. * 2- ~- « » - 7" T -- ~ --> — | - 2%.º.º.º.4% - 4-is. . * *************, * A %26º ſº ^2 4. – 3 ° 2 . ** J.----------— - ~~~~.2 . .” -->{, , tº '...? ..Y.’.…?'-- * *~ * - 2 ºzº Detail of north end of power house. Note gº Yº: *. * * * * (, ls T. S. - ... • - & # * . :--. * 23 2’ * ? *...* ZA, % • 2 ~. .2× 2.f /2 ºf y ºf "sº e. r # %262 zº: 2. Ž %22% % . .” 3ºzºº. . . .” • * %2.5% º .*&.2% that power house substructure is in reality fºx º; sº Y " 's S---- ... . % % º 2" * 2: … 2 ºz / z' 2.É. •' . * 44 * : * : * >, > * §% *... sº ſº - Żºłºś. - ..., ºr ºf . , , , ...” %2. 2. ºf: te ~3.2% *},e}º º , , ºft"|||}ſº % Average elevation of water on *º º ‘, £3. %'. * {} ºf ſºft, ºf Z/ (e. se cº 22 § 3%: ~. % 4%|| §% upstream side Öf dam, 501.0 feet. sº 24. *: 2% • g’ 2 -*- --~<. --J ~ * > -- :2, Fººtº: *::::: ** --- -** = * 2-3-ºss>>.º.º.º.º. §§§ 2-3s." - . ~~~~ $º: •,• Fºr Tºc." º º, ºre ~~~~ . § * -- -º-, , sº-s *** *-*. A-. " - *****:Sºx. sºrº: : * * sº--- t Ci * º: :---...ſº × jš% º .* º: • • *-. sº-º-º-º: ><-ºr-tºº * > &= - sº g- ~~~...~ : * ...& 2–w-. , 4-e-, * > cº-º-º: - - - - . .*** r.: ſcº *:::::::::::$gº *sº sº ºšEºs ~~~~~~~~ : §3.ºrt; § 3-2-ºº: Ż % % * * * sº-. º *—sº - > -º-; . . *** * > F-J---- - * *Hºº-ºº: Yºu? ex-sº e- * * - 3. J. --> 2. 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Each lock has a lift of 46’ 6”, is 60' by 300' in- side dimensions, and has a clear- ance over the miter sills of 7'6''. *:::: º º §g. - £ º - CHEºley Bontºrtu. • *, º/ - * * - - - º - - * * * & * * ºr. ..? & £3 a part of the main dam ~: % sº <-ºxº~~~~~~~ --~ \----- - - ~ — — — ... : f a 11 * º -ºšoo zº. Yº :** <>22:33%.3%2%.º. º...? *. 23&#, º H - * - - - - º - - - 2 ºz. _* º żº => --~~…~~~~<= ---- T-- - - * = * * * ~ * ~. quarters of a mile and its area will be \about-º: £2 º’, 3, Yºº 3.2% ºz. £4%% º,22 q2. ‘A’º,” ., . - 2%gººgºść…” -- ~~~ *-**T***** - - - - -- ~2:2:::::::::22-22-2-2. - £& 9 º' gº.º.º.º.3%.3% ($2.2% "J's - 27 º'º. If [Tº ------ ~ - ‘.… .ºz’.“º ...”...~" .” -- ~ *.*.*. **Cº, & ºv-2%:2:3:22:22:22:22:1:… ººzºº” ºr “ f ~ & . . . . . . . .2°/2 2.2.2%. Zºº. - -- Y’ ‘. . . -- ºr '-. … " - tº “fºr tº: ... 3.” ‘’’ ‘’’. Hºº & . . .” “zz… . 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A flºº Hº 3º; § --~~~3°F : **º-ºº: :Sess .** I' ºf '. :0 2-253.2% --- £º? ׺. #|| § #### 㺠Tºº-ºº: º r-e-cº ſº sé à: - - 2% & º ** sº.22 º ======= #!'; % • - ** • * * * ~ ------> --> * - Essº-ºº: - - iº ###### º Excess surplus waters during Bººt: - *** # #ā-ā; * . .”. # ºfillJ|Íññ. j|##! periods are passed through 58 steel § § sºlº l :*:::::::::::::::==== :=: Sãºesses-sº "This artificial lake extends upstream about f.”, “ ..." - --— a Tº- 18 miles; its average width will be about three- * & 2. “ : (... g ... - * -- (a 24-22 3:2 ºzºrºë ~~~~<2< ... " *...º.º. º,2- *=> *****:::…~…: & r spillway section is 3050' long, 95 river bed, 140’ from bottom of to operating bridge, and is 105’ e base. “, _º <& Power house 1250' long, 160 wide and 134' ‘high. Initial power installation 260,000 horse- power. Ultimate power installation 600,000. horse-power. ==== # º, ====- Gºłºś. aft; # Hºº - zºº º º: º ~ - . º, 3 à. S., †º #################, º # º % § ºfº. 55 : p. * :*:: **_º ; : ; Ig: ję #########!?=###, ºff #ſºft & §§§;s #4. # , º, %,’’. 3.22% A : fºrz fiftr; ' ' . * - * f. t .**T " _ " - - . Tº t = • --> . . * * : *- - ts Nos.” • --> * **. > Thirteen special spillways equipped with butterfly valves to pass surplus à1 and 2 are about one mile in- waters during normal periods of the Tennessee River. * sº-Jº *-*. --> * ~~~~~...~" - ... …<---~~~~ * --→r --->|- <=land from river. <º --->†<--> tº ſº gº º 3:ºsº, ..º.º.º.º. -----. º º º fººd %. º & Rºº? % Page twelve Muscle Shoals Water Power () Capacity 600,000 Horse Power () Total Masonry 1,350,000 Cubic Yards @ Cost Approximately $50,000,000.00 Page thirteen Piers and spillway sections of Main Dam. This structure must withstand floods up to 950,000 cubic feet per second. This is three times the greatest flood ever recorded in the international section of the St. Lawrence River. Page fourteen Close-up view of Main Dam piers and partially constructed spillway. The open spaces will be filled as the work approaches completion and are for the handling of flood waters during construction. Spillway sections will be surmounted by steel gates 38' long and 18' high. The piers are built up about 25' higher and carry the operating bridge. This type of dam construction extends from the Power House to the Locks a distance of 3,050 feet. Page fifteen º - R * | º --~~~ º ſ º - -. º Tººl º "mººn. Construction view of south end and down stream side of Power House. The concrete cones are part of the 30,000 and 35,000 horse-power water wheel settings. Page sixteen - - - - - - - - - - - º - wº - º, Wºº General construction view of Wilson Dam in October, 1923. Page seventeen | One of the 30,000 horse-power water wheels to be installed at Muscle Shoals. This finished casting weighs 95,000 pounds. , KINGSBury THRUST BEARING GENERATOR FLOOR OF GENERATOR Rooka | ware R INTAKE – vya TER DISTRIBUTOR RA --------- RBIN ------------- - - - - ------------------- ------------------------ 30,000 HORSE. Power TURBINE RU N NER U. S. Govi-RNMENT-MUst-LE SHOALs Dºv ELOPMENT ------------------------- -- Moody He wººl. CRAMP & Sox's sºilº & Excise BLDC-co SPREADI NG DRAFT -------------------- ----------------- TUBE --------------- -------------------- ------------------------ - --- -- ----------------- WATER DISCHARGE Cross section of one of the 30,000 horse-power units now being installed at Muscle Shoals. Koe º At 3. 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