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IS 11625 (1986): Criteria for Hydraulic Design of Penstocks

[WRD 14: Water Conductor Systems]

! $ ' +-
Satyanarayan Gangaram Pitroda

Invent a New India Using Knowledge

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( Reaffirmed 2001 )

IS : 11625- 1986

Indian Standard
CRITERIA FOR
HYDRAULIC DESIGN OF PENSTOCKS
Water Conductor

Systems

Sectional

Committee,

Chairman
SHRIP.M.
MANE
39, Shivaji Co-operative Housing So&Q,
Members

BDC 58

Pune

Rsjmmxting
Mukerian

CEIEB ENUINEER
DIRECTOR ( Alternate)
CEIEF ENGINEER (HP)
SUPERINTENDINQ ENGINEER
CEIE~ ENQINEER ( GENERAL )

Hyde1 Project Design, Chandigarh

Tamil Nadu Electricity Board, Coimhatore

( Alternate)
Public Works Department, Government of Tamil
Nadu, Madras
CHIEF ENGINEER ( IRRITATION )
( Alternate )
CEIEF ENQINEER ( CIVIL Drss~oxs ) Karnataka Power Corporation Limited, Bangalore
SHRI P. R. MALLIKARJUNA ( Alternate )
Bhakra Beas Management Board, Chandigarh
CHIEF ENQINEER
SHRI SUNDERSHAN
KUMAIL ( Altwnate)
Works
and
Electricity
Department,
f.%Sr~;ra~~~~~~~
( IRRITATION Public
Government of Karnataka, Mysore
SUPERINTENDING ENQINEER ( Alternate )
In personal capacity ( P. 0. Muttada, TTiVandTum)
SHRI C. ETTY DARWIN
Central Soils and Materials
Research Station,
DIRECTOR
New Delhi
DEPUTY DIRECTOR ( A&ernate )
Central Water Commission, New Delhi
DIRECTOR ( HCD-I )
DEPUTY DIRECTOR ( HCD-I ) ( Alternate )
Central Mining Research Station Unit, Roorkee
DR A. K. DUBE
DR J. L. JETHWA ( Alternate)
Water Resources Development
Training Centre,
DR B.PANT
Roorkee
Power House Designs,
Irrigation
Department,
SHRI J. P. GUPTA
Roorkee
SHRI A. P. GUPTA ( Alternate )
SHRI M.V.S.IYENaAR
SHRI M. G. KHAN

Hmdustan

Construction

( Alternate)

( Continued on page 2 )
0

INDIAN

Co Ltd, New Delhi

Copyright

STANDARDS

1986
INSTITUTION

This publication
is protected under the Indian Cofiyright Act ( XIV of 1957 ) and
reproduction in whole or in part by any means except with written permissionof the
publisher shall be deemed to be an infringement of copyright under the said Act.

IS:11625 - 1986
( Continued.from page 1 )
MtWltWS
1 OINT
DI,~E~TOR
I (GE-II)
SHRI P. N. KIIAR

R~J~A~CK

Research Designs
Lucknow

Representing
and Standards

Organization,

National Hydroelectro Power Corporation Ltd,

New Delhi

SHRI A. K. MEHTA

National
Projects
Construction
Limited, New Delhi

Corporation

SHI~I S. C. R,\LI ( Alternate )

Mnxmx
( CIVIL )
Kerala State Electricity Board, Trivandrum
SHIU G. PANT
Geological Survey of India, New Delhi
SHRI N. K. MANUW~L ( Alternate )
SHXI A. R. RAI~HUR
In personal capacity ( 147, Garodianagar,
Bombay )
SHRI Y. KA~A KIUSHNA RAO
Andhra
Pradesh
State
Electricity
Board,
Hyderabad
SUPERIRTFNUING ENGINEER
( DESIGN ANU PLANNING ) ( Alternate )
SHRI
G. V. SATHI~YE
Central Designs Organization, Nasik
DR H. R. SHAI%HA*
CentralElectricity
Authority, New Delhi
SHRI
s. c.
SEN
Assam State Electricity Board, Guwahati
SHRI N. I<. DAS (Alternate )
Himachal
Pradesh
State
Electricity
Board,
SHRI
A. K. SRIKANTIAH
Sundernaear
SHXI RANJODH SINQH ( Ahnate)
Central
Water and Power Research
Station,
REPRESENTATIVE
Pune
SHRI A. V. GOPALAKRISHNA ( Alternate )
SHRI
G. RAMAN,
Director Generai, IS1 ( Ex-ofiio
Member )
Director ( Civ Engg )
Secretary
SHRI HEMANT KUMAR
Deputy Director (Civ Engg ), IS1

Panel for Penstocks

and Anchor

BDC 58 : P6

Refiresenting

Convener
KUMAIU E. DIVATIA

Blocks,

National
Hydroelectric
Limited, New Delhi

Power

Corporation

Members
SHRI M. L. AOGARWAL
SHRI Y. P. NAYAR ( Alternate )

DIRECTOIL ( HCD-I )
DEPUTY DIRECTOR ( HCD ) (
DIRECTOR ( D&P )

Bhakra Beas Management

Central Water Commission,

Alternate)

Irrigation
Works,
Chandigarh
SENIOR DESIGN ENUINEER ( Alternate )

Board, Chandigarh
New Delhi

Government

of

Punjab,

( Continued on page 15 )
*Chairman for the meeting.

IS : 11625 - 1986

Indian Standard
CRITERIA
HYDRAULIC
DESIGN
0.

FOR
OF PENSTOCKS

FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards

Institution on 28 February
1986, after the
draft finalized
by the Water
Conductor System Sectional Committee
had been approved
by the Civil
Engineering
Division Council.
0.2 The water is taken from the forebary
to the power station through
the penstocks.
These may be pressure
conduits or shafts. The penstocks
shall carry water to the turbines
with the least possible
loss of head consistent with the overall economy of the project.
For successful
operation,
the size of the pipe for a given discharge may vary between wide limits,
but there is usually one size that will make for the greatest economy and
design. Hence the diameter of the penstocks isdetermined
from the consideration of economy and is checked to see that the acceptable ve!ocities
are not exceeded.

1. SCOPE
1.1 This standard

covers the criteria

for hydraulic

design of penstocks.

2. GENERAL
2.1 The hydraulic design of penstocks covers hydraulic design of intake
for penstocks,
hydraulic losses in penstock,
pressure rise or pressure drop
due to turbine
or pump operations
and ascertaining
most economic
diameter of penstock on the basis of available data.
3. HYDRAULIC

3.1 The
accordance

DESIGN

OF INTAKE

hydraulic
design of the main
with IS : 9761-1981.

*Criteria for hydraulic design of hydropower

FOR PENSTOCK
components
intakes.

of intake

shall be in

IS : 11625 - 1986
4. HYDRAULIC

LOSSES IN PENSTOCK

4.1 The hydraulic

losses in the penstock

a) Head

loss at trash rack,

b)

loss at intake

Head

comprise

the following:

entrance,

c) Friction
losses, and
d) Other losses as at bends,

bifurcations,

transitions,

valves, etc.

These head losses are expressed in terms of coefficient

to the velocity head at the section in question.
4.2

to be applied

Head Loss at Trash Rack

4.2;1 The head loss through

formula

trash

rack

(ht) may

be expressed

by the

given below:
ht =

k,+

where

ht =

The

trash rack head loss,

kt =

loss coefficient,

u =

actual

P 3

acceleration

loss corfficient

( Part 3 )-1976*.
4.3

velocity

through

rack opening,

and

due to gravity.

kt shall be calculated

in accordance

with IS : 4880

Head Loss at Intake Entrance

4.3.1 The magnitude of head loss at entrance depends upon the shape
of intake mouth. For bell mouth shape shown in Fig. 1, losses-are given by
the following formula:
h, = k,$
where

h, = head loss at entrance,

k, = loss coefficient at entrance,
u =f velocity
g

at entrance,

i= acceleration

4.3.2 The value of loss

IS : 4880 ( Part 3 )-1976*.
*Code

of practice

for design

and

due to gravity.
coefficient

of tlmncls

k,

conveying

( jirsl rmkkm ).
4

shall
water

be in

accordance

with

: Part 3 Hydraulic

design

IS : 11625 - 1986
4.4 Friction

Losses

4.4.1 Head loss due to friction

formulae given in 4.4.1.1 to 4.4.1.2.
444.1.1 Darcy-Waisbach

in

pipes

may

be estimated

from

the

formula:
hl =

fLv_
2C!P

where

hf =

friction

loss in pipe in m;

loss coeficient
depending
pipe and Reynolds
number
Fig. 2;
L = length of pipe in m;
t -= velocity
I) =

bulent

head

4.4.1.2
flow.

diameter

Mannings
Mannings

through

upon type, conditions of the

which may be obtained
from

pipe in m/set; and

of pipe.
formula

may be used in case

of fully rough

tur-

formula
~ =

Ral3 S/z
n

where
R =
S
n

4.5

Other

hydraulic

radius

area
wrttedseter
.

(
gradient;

-)

in m;

= slope of energy
and
-; roughness
coefficient,
shall vary from 0.012 to 0.014 for
concrete
pipes and for steel pipes the valve of n shall vary
from 0.008 to 0*012.
Losses

4.5.1 In a penstock other losses include losses due to bends, expansion

or contraction,
obstruction
caused by valve passage and losses in penstock
branches and wyes.
friction loss for a circular
4.5.2 Rend Loss .- The bend loss excluding
conduit depends U~OLI the shape of bend, deflection
angle and ratio of
radius of bend to diameter of pipe. The bend loss may be calculated
from
the following formula:
h,, = kb

2.9

h3:11625-1986
where
hb = head loss due to bend,
kb = bend loss coefficient which may be obtained from Fig. ~3 for
various R/D ratios and deflection angles, and
v =
4.5.3

velocity

in pipe.

Loss Due to Expansion

4.5.3.1
Head
from the formula:

and Contraction

loss due to gradual

expansion

h,,

may be estimated

where
VI = velocity

at upstream

end in m/set;

V, = ve1ocit.y at downstream end in m/set, and

k,, - loss coefficient depending upon the cone angle and shall
be in accordance
with IS : 2951 (Part 2) - 1965*.

Fro.

IA

BELL

*Recommendations
for estimation
Head loss in valves and fittings.

MOUTH
of flow

DETAILS
of liquids

Contd
in closed conduits : Part

9861- - 52911 : SI

-N

Ln

LOSS
PIPE

OF COEFFICIENTS
BENDS
OF sMOOTl

R,=225,000=

%I
v

V- VELOCITY
D= DIAMETER
0.20 i---

= KINEMATIC

VISCOSITY

0.1

I PIJ I

O.lL

t
kb
Oat2

I /./

/,I

IW,I

I Yk
/-I

I/
I_/

L - !
I

I
I

I
85

1
90

O-08

10

1,

15

I
20

I
2S

I
30

I
35

I
LO0

DEFLECTION

FIG. 3

Loss

COEFFICIENTS

I
45

I
50

I
55

I
60

I
65

I
70

I
75

ANGLE,A+

FOZ PIPE BENIX OFSMOOTHINTERIOR

I
80

B
I

IS:11625

- f986

4.5.3.2
following

Head
formula:

loss

in reducer

piece

h, may

he

estimated

by

the

: 4880 ( Part

3 )-

where
k, =

loss coefficient

= velocity
v, = velocity
v,

The

value

for contraction,

in normal

section,

at the contraction

of k, shall

and
section.

be in accordance

with

IS

1976*.
4.5.?;3
When a diffuser follows immediately
after a bend without a
straight length in-between,
the loss in the diffuser will be more than that
given in 4.5.3.2.
It is recommended
to provide a straight length equal to
the diameter of the pipe between the bend and the diffuser.
4.5.4

Losses in Valve Passages

4.5.4.1
Valves are usually installed at two places in the penstocks of
a hydro power station - one at the upstream end and the other at the
downstream
end immediately ~ahend of the turbine.
The former called as
control or penstock valve is usually a butterfly valve and the latter known
as inlet valve is either butterfly valve or a spherical valve. These valves
remain either in fully closed or open position. Under fully opened position
the losses through
spherical
valves are negligible.
The value of loss
coefficient for butterfly valve may be obtained from Fig. 4.
4.5.5

Losses in Penstock Branches and Wles

4.5.5.1
A penstock bifurcation into two is termed
more than two, it is termed as manifold.
cation,

4.5.5.2
ratio
4.5.5.3

as a wye and when

The hydraulic losses at wyes are governed

by angle
of cross-sectional
area, +ype and shape of bifurcation.
Various

a) Wyeslbranches

types of wyes and branches

generally

of bifur-

adopted

are:

with sharp transition,

b) Wyeslbranches

with conical

transition,

c) Wyeslbranches

with rounded

corners.

*Code of practice for design

of tunnels

conveying

( first revision ).

10

and

water: Part 3 Hydraulic

design

IS : 11625 - 1986

Q
0

1.0
0.9

A0

AREA

0-B
Ag=

0.7
0.6

REFERENCE

AREA

FOR V2/2,,

0.5
0.4
0.3
0.2
L REDUCED

0.1

AREA,

0
0

40

80

VALVE

FIG. 4

GENERAL

120

DIAMETER

160

(cm1

TREND OF VALVE Loss COEFFICIENT AND RESTRICTION

OF PASSAGE FOR BUTTERFLY VALVES

4.5.5.4
Figure
5 gives the head
sharp, rounded and conical transitions.
5. PRESSURE

AR

200

RISE AND PRESSURE

loss-coefficient

for branches

with

DROP

5.1 The

criteria to be adopted for the calculation

of pressure rise and
pressure drop, and method of computations
are covered in the Indian
Standard Code of practice for design of water hammer in water conductor
systems ( under Preparation ) .

6. ECOINOMIC

DIAMETER

OF PENSTOCK

6.1 The

economic
diameter of penstock is the diameter
for which
annual
cost, which includes the cost of power lost due to friction
charges for amortization
of construction
cost, maintenance,
operation,
is the minimum.

the
and
etc,

6.2 The economic diameter is calculated

by evaluating annual power loss
and annual cost for maintcn;mce
and equating first derivative with respect

11

CJ/O

CYLINDRICAL
SHARP
EDGE

DEFLN

SHARP

\\\

ii

.#

&

Vb/v
-.-.--.~~~
MUNICH

MODEL

TEST

---_----Z--

.
HI

DblD

FnGF

000

r; jui

0.1
90

=0~58(MUNICH1

k?x\kOUh

- 01
DEFLECTION

SO DEFLECTION
45

FIG. 5

FOR

DEFLECTION

Loss AT PIPE JUNCTIONS WITH DIVIDING FLOW

1.0

vb/

10.0

IS:11625

- 1986

to D to zero and is given by the following

equation based on Mannifigs
formula. The derivation of the formula is given at Appendix A.
DWs

2.36

l-39 C, +

106 x

Qs x ne

O-6 C, +

C,

et, x

21 Hc;a(;,

where
Cc =

unit cost of concrete

C, =

unit cost of excavation

lining

C, =

cost of 1 kWh of energy

C, =

cost of steel in Rupees/kg;

in Rupees/ma;

in Rupees;

= diameter

et

= joint

percentage
by which steel in penstock is overweight
~provision of stiffeners, corrosion allowance,
etc;

Rugosity

overall

of the penstock;
efficiency

efficiency

of plant;
of penstock;

head on penstock

Q =

including

coefficient

water

in Mannings

discharge

through

penstock

tiI)ERIVATION OF THE FORMULA

THE ECONOMIC
DIAMETER
COST

in m;
due to

formula;
and maintenance

charges

FOR CALCULATING
OF PENSTOCKS

OF POWER LOST

Head Loss

in Penstock/Metre

tion is given by Manning?

formula:

va ne

10.29

his.------=

R4/3

Annual

hammer

in ms/s.

APPENDIX
( Clause 6.2 )

A-1.1

x p

in RupeesIms;

= ratio of annual fixed operation

;
to construction
cost of penstock;
pI = annual load factor; and

A-l.

. 1

Length

Head

loss due to fric-

Q n2

jp/3

cost of power lost (E,) = 9.804

E = O-88 x 106 Q3 n* e pf cp
f

DI6/3

13

x Q x hf

ep, x

8 7606,

IS t 11625- 1986
A-2.

ANNUAL

CHARGES

ON CAPITAL

COST

A-2.1 Cost of Excavation

- The cost due to excavation
for laying the
penstock
is calculated
considering
the tunnel diameter to be 0.33 D in
excess of penstock diameter total cost/unit length of penstock is given by:
___
i

(D +

0.33 D ) x C,

1.39 D= C,

NOTE - 033 D to be varied between 0.2 D to 0.33 D depending on the c&meter of penstock such that the excavated diameter is not greater than the penstock
diameter by about 90 cm.

Lining Cost of concrete lining in penstock

thickness of lining as 0.165 D. Thus cost of con-

A-2.2
Cost of Concrete
has been calculated taking
crete lining is given by:

7c ( D + 0,165
0.6 02 C,

D ) x 0.165

D x C,

NOTE - 0165 D to be varied between 0.1 D to 0165 D, depending on the diameter of penstock such that concrete lining thickness is not greater than 30 cm.

A-2.3

Cost of Steel in Penstock

Steel

lining

Penstock

Pd

thickness

cost

0.1 HD

t = 2ae
=
a 1

-__
2 ba ej

x Dt (1 + 2) 7 850 x Cs
_--~-__--2 ua x 9.81 x ej

120.93

C, (1 + ;)

HD2 x

@a X el
A-2.4 Annual Charges
is expressed by:
E,
A-3.
A-3.1

[D2 (1.39
_______

ECONOMIC
Total

on Capital

C, ______
+ 0.6 C, +

Cost

diameter

8 (E,
02213 =

The

annual

cost of penstock

120.93 HC, (1
+ i)] x /J
___-~---

ba ej

DIAMETER

Annual

Economical

Cost

_~_

4
SD

(E) = E,
is obtained

E,)
2*36x

1.39 C, +

E,

by:

106x

Q3x112x

0.6 C, +

efif XC,
._____~

12 yx$+
a

14

) ]

x p

fS:11625-1986
( Continued from page 2

Members
SHR~ N. C. JAIN
DR ZAEAR MEHDI
SHRI J. L. KHOSA ( Alternate )
SHRI
C. GANESA PILLAI
SHRI A.-R. R~QRAVAN
SHRI T. RAMASWAXY
SHRI B. RAMASWAMY ( Alternate
DR H. R. SHARMA
SHRI B. THOMAS
SHRI R. VIJAYAN
SHRI N. G. KURUP ( Alternate )

Representing
Irrigation
Department,
Pradesh, Lucknow
Bharat Heavy Electricals

Government

of Uttar

Ltd, Bhopal

Kerala State Electricity Board, Trivandrum

Tamilnadu Electricity Board, Madras
Indian Hume Pipe Co Ltd, Bombay
)
Central Electricity Authority, New Delhi
Central Water &kPower Research Station, Pune
In personal capacity [ 351136 (2) Kamaldoth Lane,
Cochin ]

INTERNATIONAL
Ease

SYSTEM

OF UNITS

( SI UNITS)

Units
Unit

Quantity
-Length
Mass
Time
Electric current
Thermodynamic
temperature
Luminous
intensity
Amount
of substance
Supplementary

angle

Solid

angle

Derived

:
K

candela
mole

cd
mol

kg

Units

Qoanfity
Plane

Symbol

metre
kilogram
second
ampere
kelvin

Unit

radian
steradian

Symbol

rad
sr

Units

Quantity

Unif

Force
Energy

joule

Power
Flux
Flux density
Frequency
Electric conductance
Electromotive
force
Pressure, stress

watt
weber
tesla
hertz
siemens
volt
Pascal

newton

Oepnitlon

Symbol
N

W
Wb
T
t-fz
S
V
Pa

N =

1 N.m

I
W
1 Wb
1
T
1 Hz

=
=
=
=

%J/s
1 V.s
1 Wb/ms
1 c/s (s-1)

1 A/V

V =
Pa -

1 kg.m/ss

1 W/A
1 N/ms