Steel Liner Design Calculation

FRL
Turbine Center Line Level
Maximum Upsurge Level
Static Head

1045 m
595 m
1100.5 m
450 m

% of Water Hammer Pressure (Normal Condition)

Head Rise (Normal Condition)
Level of Water at Turbine (Normal Condition)

18%
80.9 m
1125.87 m

% of Water Hammer Pressure (Emergency Condition)

Head Rise (Emergency Condition)
Level of Water at Turbine (Emergency Condition)

102%
455.6 m
1500.58 m

Level of Water at Surge Shaft (Both Conditions)

1100.5 m

Pressure Shaft Steel Liner Design Calculation

Rd (m)

Pipe Level (m)

NSL (m)

Normal

Emergency

External
Pressure
(m)

Normal

Emergency

Maximum

971.900

134.2

217.4

73.1

16.75

ASTM 537 Class 2

22.0

18.0

22.0

22.0

22.0

44.18

Fail

82.38

Safe

971.529

135.8

237.0

69.0

12.75

ASTM 537 Class 2

16.5

14.5

16.5

16.5

17.0

49.51

Fail

83.61

Safe

30

949.459

159.1

278.4

67.7

12.75

ASTM 537 Class 2

19.0

16.5

19.0

19.0

19.0

62.90

Fail

86.93

Safe

1007.863

30

919.459

190.3

327.7

88.4

12.75

ASTM 537 Class 2

22.0

19.5

22.0

22.0

22.0

85.19

Fail

94.63

Safe

1007.863

1007.863

30

889.459

221.6

377.0

118.4

12.75

ASTM 537 Class 2

25.5

22.0

25.5

25.5

26.0

118.58

Safe

164.24

Safe

859.459

1007.863

1007.863

30

859.459

252.8

426.3

148.4

12.75

ASTM 537 Class 2

29.0

24.5

29.0

29.0

29.0

146.15

Fail

175.50

Safe

859.459

829.459

1007.863

1007.863

30

829.459

284.0

475.6

178.4

12.75

ASTM 537 Class 2

32.0

27.0

32.0

32.0

32.0

175.67

Fail

277.21

Safe

348

829.459

799.459

1007.863

1007.863

30

799.459

315.2

524.9

208.4

12.75

ASTM 517 Grade F

25.0

21.0

25.0

25.0

25.0

136.37

Fail

302.08

Safe

348

378

799.459

776.942

1007.863

1003.183

30

776.942

339.0

566.7

230.9

12.75

ASTM 517 Grade F

27.0

22.5

27.0

27.0

27.0

159.54

Fail

294.33

Safe

10

378

408

776.942

773.785

1003.183

990.350

30

773.785

343.4

589.1

229.4

12.75

ASTM 517 Grade F

27.0

23.5

27.0

27.0

27.0

159.60

Fail

294.33

Safe

11

408

438

773.785

745.879

990.350

986.648

30

745.879

372.5

636.3

244.5

12.75

ASTM 517 Grade F

29.5

25.5

29.5

29.5

30.0

196.92

Fail

283.72

Safe

12

438

468

745.879

715.879

986.648

986.648

30

715.879

403.7

685.6

270.8

12.75

ASTM 517 Grade F

31.5

27.0

31.5

31.5

32.0

223.41

Fail

277.21

Safe

13

468

498

715.879

685.879

986.648

986.648

30

685.879

434.9

734.9

300.8

12.75

ASTM 517 Grade F

34.0

29.0

34.0

34.0

34.0

251.14

Fail

301.21

Safe

14

498

528

685.879

655.879

986.648

986.648

30

655.879

466.2

784.2

330.8

12.75

ASTM 517 Grade F

36.5

31.0

36.5

36.5

37.0

294.99

Fail

341.64

Safe

15

528

558

655.879

625.879

986.648

986.648

30

625.879

497.4

833.5

360.8

12.75

ASTM 517 Grade F

38.4

32.5

38.4

38.4

39.0

325.32

Fail

439.55

Safe

16

558

588

625.879

597.874

986.648

982.915

30

597.874

526.6

880.8

388.8

12.75

ASTM 517 Grade F

40.5

34.5

40.5

40.5

41.0

356.83

Fail

432.03

Safe

17

588

622

597.874

595.000

982.915

962.655

34

595.000

530.9

905.6

387.9

12.75

ASTM 517 Grade F

40.9

35.5

40.9

40.9

41.0

356.61

Fail

432.03

Safe

Reach
Start

End

Start

End

Start

End

138

972.700

971.900

1115.484

1040.556

138

5.6

138

168

971.900

971.529

1040.556

1017.140

30

168

198

971.529

949.459

1017.140

1007.863

198

228

949.459

919.459

1007.863

228

258

919.459

889.459

258

288

889.459

288

318

318

Pressure Shaft
Level (m)

Minimum
Handling Tk.
(mm)

Type/Grade of Steel

Steel Liner Thickness Reqd. (Internal

Pressure) (mm)

Thickness
Required
(mm)

Diameter
Length (m)
(m)

Internal Pressure (m)

Thickness
Provided
(mm)

Allowable External
Pressure (without
Stiffener) (m)

Check for External

Buckling Pressure
(without Stiffener)

Allowable External
Pressure (with
Stiffener) (m)

Check for External

Buckling Pressure
(with Stiffener)

External Pressure Calculation

Actual
Gap
Allowable
Yo
fy'
Ratio
Stress fn

LHS

RHS

Del

Pcr kN/m2

External
Pressure m

Allowable
Stress

Stress
Check

External
Pressure
Check

466.91

0.656

0.656

0.000

650.078

44.18

183.33

Safe

Fail

0.0006

466.91

0.617

0.617

0.000

728.598

49.51

183.33

Safe

Fail

0.0003

0.0006

466.91

0.538

0.538

0.001

925.585

62.90

183.33

Safe

Fail

128.75

0.0003

0.0006

466.91

0.447

0.446

0.001

1253.632

85.19

183.33

Safe

Fail

230769

148.29

0.0003

0.0006

466.91

0.357

0.357

0.000

1744.871

118.58

183.33

Safe

Safe

415

230769

161.86

0.0003

0.0006

466.91

0.308

0.307

0.000

2150.654

146.15

183.33

Safe

Fail

0.3

415

230769

174.58

0.0003

0.0006

466.91

0.268

0.268

0.000

2584.920

175.67

183.33

Safe

Fail

210000

0.3

690

230769

184.89

0.0003

0.0006

776.31

0.654

0.653

0.001

2006.649

136.37

265.00

Safe

Fail

156.86

210000

0.3

690

230769

197.74

0.0003

0.0006

776.31

0.596

0.596

0.000

2347.608

159.54

265.00

Safe

Fail

25.50

156.86

210000

0.3

690

230769

197.81

0.0003

0.0006

776.31

0.596

0.596

0.001

2348.499

159.60

265.00

Safe

Fail

30.0

28.50

140.35

210000

0.3

690

230769

216.23

0.0003

0.0006

776.31

0.524

0.524

0.000

2897.665

196.92

265.00

Safe

Fail

32.0

30.50

131.15

210000

0.3

690

230769

228.01

0.0003

0.0006

776.31

0.483

0.483

0.000

3287.520

223.41

265.00

Safe

Fail

13

34.0

32.50

123.08

210000

0.3

690

230769

239.42

0.0003

0.0006

776.31

0.447

0.447

0.000

3695.572

251.14

265.00

Safe

Fail

14

37.0

35.50

112.68

210000

0.3

690

230769

255.93

0.0003

0.0006

776.31

0.401

0.400

0.001

4340.708

294.99

265.00

Safe

Fail

15

39.0

37.50

106.67

210000

0.3

690

230769

266.29

0.0003

0.0006

776.31

0.373

0.373

0.000

4787.024

325.32

265.00

Fail

Fail

16

41.0

39.50

101.27

210000

0.3

690

230769

276.47

0.0003

0.0006

776.31

0.349

0.348

0.001

5250.774

356.83

265.00

Fail

Fail

17

41.0

39.50

101.27

210000

0.3

690

230769

276.31

0.0003

0.0006

776.31

0.348

0.348

0.000

5247.531

356.61

265.00

Fail

Fail

Diameter

Thicknes
provided

Effective
Thickness

fy

E'

mm

5.6

22.0

20.50

273.17

210000

0.3

415

230769

96.18

0.0003

0.00084

17.0

15.50

258.06

210000

0.3

415

230769

101.26

0.0003

19.0

17.50

228.57

210000

0.3

415

230769

112.70

22.0

20.50

195.12

210000

0.3

415

230769

26.0

24.50

163.27

210000

0.3

415

29.0

27.50

145.45

210000

0.3

32.0

30.50

131.15

210000

25.0

23.50

170.21

27.0

25.50

10

27.0

11

12

Reach

Stiffener Calculation
Penstock Steel Liner Stiffener
Diameter Thickness
Height

Stiffener
Thickness

Effective
Radius of
Penstock
Associated
Moment
Stiffener Young's
Steel Liner
Centroid
Centroidal
Radius
Width
of Inertia
Spacing Modulus
Thickness
Ring
cm

cm

70.39

cm4
11328

287.04

290.67

52.50

3248

17.50

309.85

52.14

2000

20.50

337.88

24

2000

24.50

250

28

2000

32

300

30

4.00

25

300

4.00

27

4.00

Unit
External
weight of
Pressure
Water

External
Head

Actual
External
Head

Check

kg/cm2
8.24

kg/cm3
0.001

330

kg/cm2
2100000

82.4

73.1

safe

205.25

255

2100000

8.36

0.001

83.6

69.0

safe

3773

205.21

285

2100000

8.69

0.001

86.9

67.7

safe

53.08

4762

205.31

330

2100000

9.46

0.001

94.6

88.4

safe

369.32

66.97

9966

206.70

390

2100000

16.42

0.001

164.2

118.4

safe

27.50

393.85

68.22

11900

206.82

435

2100000

17.55

0.001

175.5

148.4

safe

2000

30.50

415.29

83.89

21216

208.39

480

2100000

27.72

0.001

277.2

178.4

safe

30

2000

23.50

368.20

94.22

18332

209.42

375

2100000

30.21

0.001

302.1

208.4

safe

300

30

2000

25.50

382.30

90.88

19198

209.09

405

2100000

29.43

0.001

294.3

230.9

safe

27

300

30

2000

25.50

382.30

90.88

19198

209.09

405

2100000

29.43

0.001

294.3

229.4

safe

4.00

30

300

30

2000

28.50

402.44

86.47

20432

208.65

450

2100000

28.37

0.001

283.7

244.5

safe

4.00

32

300

30

2000

30.50

415.29

83.89

21216

208.39

480

2100000

27.72

0.001

277.2

270.8

safe

4.00

34

300

35

2000

32.50

432.72

87.32

24614

208.73

510

2100000

30.12

0.001

301.2

300.8

safe

4.00

37

320

35

2000

35.50

450.67

90.94

30540

209.09

555

2100000

34.16

0.001

341.6

330.8

safe

4.00

39

350

38

2000

37.50

465.22

102.56

42111

210.26

585

2100000

43.96

0.001

439.6

360.8

safe

4.00

41

350

38

2000

39.50

476.47

100.39

43378

210.04

615

2100000

43.20

0.001

432.0

388.8

safe

4.00

41

350

38

2000

39.50

476.47

100.39

43378

210.04

615

2100000

43.20

0.001

432.0

387.9

safe

mm

mm

mm

mm

mm

mm

mm

5.60

22

300

16

2800

20.50

389.75

4.00

17

200

16

2000

15.50

4.00

19

200

18

2000

4.00

22

200

22

4.00

26

250

4.00

29

4.00

Steel Liner Qty. Calculation

Stiffener Qty. Calculation

Reach

Length

Diameter

Thickness

Volume (m3)

Weight (MT)

Spacing

Nos.

Thickness

Height

Volume

Weight (MT)

138

5.6

22

53.62

0.0

42

16

0.30

3.57

0.0

30

17

6.44

50.5

12

16

0.20

0.49

3.8

30

19

7.20

56.5

11

18

0.20

0.50

3.9

30

22

8.34

65.5

10

22

0.20

0.56

4.4

30

26

9.87

77.4

24

0.25

0.61

4.8

30

29

11.01

86.4

28

0.25

0.62

4.9

30

32

12.16

95.5

30

0.30

0.80

6.3

30

25

9.48

74.4

30

0.30

0.92

7.2

30

27

10.25

80.4

30

0.30

0.92

7.2

10

30

27

10.25

80.4

30

0.30

0.92

7.2

11

30

30

11.39

89.4

30

0.30

0.80

6.3

12

30

32

12.16

95.5

30

0.30

0.80

6.3

13

30

34

12.93

101.5

35

0.30

0.81

6.3

14

30

37

14.08

110.5

35

0.32

0.86

6.8

15

30

39

14.85

116.5

38

0.35

1.02

8.0

16

30

41

15.62

122.6

38

0.35

0.85

6.7

17

34

41

17.70

138.9

38

0.35

1.02

8.0

Liner

1442.1

Stiffener

98.2

Total

1540.3

MT