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Contents
1.0) Low Pressure Penstock Pipe (LPPP)....................................................................................... 1
1.1) General..1
1.2) Hydraulic Design and Low Pressure Penstock Pipe Optimization
1.3) Mechanical Design of Low Pressure Penstock Pipe
1.3.1) Design Consideration.
1.3.2) Shell Thickness Calculation..
1.3.3) Maximum Span of Unsupported Length.
1.4) Hydro mechanical Design..
1.4.1) Design Consideration.
2.0) High Pressure Penstock Pipe.
2.1) General
2.2) Hydraulic Design and High Pressure Penstock Pipe Optimization
2.3) Water Hammer Calculation..
2.4) Mechanical Design of High Pressure Penstock Pipe..
2.4.1) Design Consideration..
2.4.2) Shell Thickness Calculation.
List of Tables:
Table 1.3..
Table 1.4
Table 1.5
List of Figures:
Figure 1
Figure 2
Annex:
Design calculations for LPPP..
Design calculations for HPPP
f = friction factor
L = length of pipe
D = diameter of pipe
v = velocity of water
g = acceleration due to gravity
The friction factor f is calculated using Colebrook-White equation Where,
e = Colebrook-White e (mm) = 0.06 mm for pipe
Re = Reynolds number
As there are many bends in pipe, the bend loss is also substantial. The bend loss is estimated
using following equation:
Where, k = bend coefficient depends on angle and radius of bend, for 90 degree bend R/D= 5,
k is taken 0.08 as per USBR 1987 , for other bends reduction factor suggested in Hydraulic
Design by Lysne, 2003 was applied. The number and angle of bends are estimated from the
layout map presented in Vol. II-A, Drawing 1.7.A. The detail calculation is presented in Vol. III,
Appendix A of the report prepared by the Consultants.
1.3 Mechanical Design of Low Pressure Penstock Pipe
The principle characteristics of the low pressure penstock pipe:
Type: Buried
Structure type of low pressure conveyance system: Steel pipe
Length of low pressure penstock pipe: 3860 m
Internal diameter: 2.5 m
The design of the steel pipe is governed by the internal pressure, external pressure and
minimum thickness required for handling.
1.3.1 Design Consideration
Highest upsurge level in the surge tank: El. 1997.49 m masl
Low pressure penstock pipe center line at the end: El. 1979.42 m masl
t PD e st j = +2
where, t is the thickness of the low pressure, j is the efficiency of welded joints and st is the
permissible stress in low pressure, P is design internal pressure and e is corrosion allowance.
The thickness of pipe is calculated assuming that 100% of the stress developed will be resisted
by the pipe.
Table 1.3: Computation of Thickness of low pressure penstock pipe
Descriptions
Low
pressure
penstock
pipe
length(m)
Low
pressure
pipe
design
level (m)
High
surge
level (m)
Static
head
(m)
Low
Pressure
Pipe
1991.25
1995.35
4.25
Design
internal
pressure
(kg/cm2)
0.42
Thickness
of pipe
for
internal
pressure
(mm)
Minimum
thickness
for
handling
(mm)
10.25
Thickness
adopted
(mm)
10
Low
Pressure
Pipe
3860
1979.42
1997.42
17.78
1.78
10.25
10
Minimum thickness has been calculated as 4 mm from the principles of hoop stress.
However, the thickness is also governed by other criteria such as buckling during erection.
The following formula which is also known as handling thickness has been applied to
estimate the minimum thickness: with D as diameter of pipe. Accordingly, minimum thickness as
10 mm has been found out.
The thickness required for withstanding external pressure of about 7.5 meters corresponding to
height of backfilling above the pipe is less than the thickness required for handling.
The actual thickness of the low pressure penstock pipe is mainly governed by handling
requirement, so taking this consideration into account results are depicted in Table 1.3.
1.3.3 Maximum Span of Unsupported Length
The maximum span of unsupported length between saddle supports is generally guided by the
deflection criteria. Even the deflection criteria permits the maximum unsupported length of 10.07
m, 8.50 m is adopted as unsupported length between two saddles which will ensure the structural
safety of low pressure penstock pipe if one saddle fails between two consecutive saddle supports.
The detail calculation is presented below.
Internal diameter of Pipe di 2.50 m
External diameters of Pipe di 2.52 m
Thickness of pipe t 0.010 m
Moment of inertia I 0.06 m4
Density of steel r 7850.00 kg/m
Weight of steel Ws 621.47 kg/m
Steel pipe
length
(m)
Steel pipe
bottom
level (m)
High
surge
level (m)
Steel Pipe
25
1990.57
1997.49
Static
head (m)
18.8
Max.
design
internal
pressure
(kg/cm2)
1.8
Thickness
of pipe for
internal
pressure
(mm)
Min.
thickness
for
handling
(mm)
Thickness
adopted
(mm)
16
16
The same formulae, which are used for thickness calculation of LPPP, are used for the design of
surge-tank steel pipe. The thickness for hoop stress is calculated to be 6 mm but for handling
purpose the required thickness is calculated as 16 mm. The inputs and result for the calculation is
presented in Table 1.4.
2.0 High Pressure Penstock Pipe
2.1 General
A buried type high pressure penstock pipe is proposed to convey water under pressure to the
turbine. The foundation of HPPP is proposed mostly to the rock except for the portion near to
powerhouse. Hence the trench cutting depth is extended up to 17 m while the backfill varies
from minimum of 2 m to maximum of 14 m near powerhouse. The water management and slope
stability measures (drains grouted pitching and anchor breast walls) are proposed to stabilize the
backfill slope which is more elaborated in Chapter 4: Geological/Geotechnical Studies in the
report prepared by the Consultants.
The high pressure penstock pipe consists of straight pipes, bend pipes, bifurcation, reducing
pipes, seepage rings, thrust rings, drain pipes and all other necessary accessories. The inside
diameter of high pressure penstock pipe is 1.9 m up to the bifurcation. The thickness of the pipe
shell is designed to resist both the internal and external pressure and other loads. The thickness is
calculated taking into account of water hammer effects. The total length of 1.9 m dia. (which
starts from reducer) high pressure penstock pipe including bifurcation pipe is about 401 m.
Anchor blocks are provided at each change of direction in high pressure penstock pipe to provide
necessary weight to counteract the resultant to all forces and to transmit them safety of the
ground.
An ellipse type manhole of 500 mm by 600 mm in size will be provided on the high pressure
penstock pipe at downstream of emergency closing valve for inspection and maintenance of
pipes.
2.2 Hydraulic Design and High Pressure Penstock Pipe Optimization
The similar methods and procedures, which are used in the hydraulic design and optimization of
low pressure penstock pipe, are used for the design and optimization of high pressure penstock
pipe. The optimization study reveals the optimum diameter of high pressure penstock as 1.9 m.
The detail calculation is presented in Vol. III, Appendix A of the report prepared by the
Consultants.
2.3 Water Hammer Calculation
Allieve graphical solution has been used to estimate water hammer pressure for gradual closer.
The detail calculations is presented below:
Total length of penstock (x) L = 388.00 m
Design discharge Q = 12.26 m/s
Diameter for penstock D = 1.90 m
Mean area A = 2.84 m2
Average flow velocity in penstock V = 4.32 m/sec
Accumulate
d
high
pressure
pipe length
(m)
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
38
Pressure
rise (m)
7.876
Static
head
(m)
16.3
Total
internal
pressure
(kg/cm2)
2.59
Thickness
of pipe for
internal
pressure
(mm)
Minimum
thickness
for
handling
(mm)
Thickness
adoptaded
(mm)
3.37
8.75
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe
Pipe