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REPORT NO.TSL-STR-03
STRUCTURAL DESIGN OF PENSTOCK
4 FEBRUARY 2011
1.
SCOPE
1.1
2.
This design standard lays down the various forces acting on surface
penstocks and structural design of penstocks conveying water under
pressure flow conditions. This standard also covers specialty of penstocks
like penstock supports, manifolds, bends, expansion joints, manholes,
branch outlets, etc.
NOTATIONS
2.1
For the purpose of this standard, the following notations shall have the
meaning indicated against each:
A
Ar
b
C
E
f1, f2, f3
f4
fx
fv
l
L
M, M1
P
P1
q1
r
r1
S
S1
Sx, Sy
T
t
t1
W
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
3.
=
=
DATA USED
3.1
4.
W1
LOADS ON PENSTOCK
4.1
The following are the main loads considered for the design of penstocks:
a) Internal water pressure,
b) Weight of penstock and water, and
c) Temperature.
In addition, the other loads considered depending on location are:
a) wind load,
b) seismic forces.
4.2
Temperature variation.
4.2.2 The loads of intermittent nature are the forces which though not
exceptional, do not arise often.
The two main cases are:
a) Penstock during filling, and
b) Empty penstock under partial vacuum.
The forces to be taken into account in each case correspond to:
a) The weight of penstock and water between the supports;
b) The type and spacing between supports,
c) The temperature effect, and
d) Friction at supports.
In addition to the forces enumerated in (a) to (d), intermittent loads
may also occur due to wind and earthquakes.
4.2.3 The loads of exceptional nature the may act upon the penstocks
are:
a) Shop or site test;
b) Erection stresses;
c) Bad operation of safety devices during filling such as nonoperation of air valves which would create vacuum inside
during empting operation of penstocks;
d) Pressure rise caused due to unforeseen operation of regulating
equipment of turbine/pump distribution:
i)
5.
Seismic forces.
ii)
iii)
iv)
b) At supports:
i)
5.2
ii)
iii)
iv)
6.
The stresses for different forces are calculated as given in 6.1.1 to 6.1.7
6.1.1
Pr
t
6.1.2
6.1.3
M
N/m 2
Z
where
M
=
6.1.4
6.1.3.2
6.1.3.3
6.1.3.4
where
Pf
=
=
=
a Pf
Pf
+
,
A
Z
The coefficient of friction, , between shell and support will be taken from Table 6.1
SL.
No.
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
Type or Support
Friction Coefficient
Steel on concrete
Steel on concrete with asphalt roofing paper in between
Steel on steel (rusty)
Steel on steel (greased)
Steel on steel with two layers of graphite service sheets in
between
Rocker support
Roller support
Concrete on concrete
6.1.5
0.60
0.50
0.50
0.25
0.25
0.15
0.10
0.75
Temperature Stress
6.1.5.1
ET
where:
1
=
Ac
1, P Ac,
6.1.6
C P1 r
f4 =
1.82(Ar -bt)
Ar +1.56 t rt
Pr
t
7.
EQUIVALENT STRESSES
7.1
Sx 2 +Sy 2 Sx Sy +3 2
where:
Se
combined stress
Sx
Sy
2S cos
A
8.
LINER THICKNESS
8.1
8.2
8.3
9.
9.1.1
9.2
9.2.1
10
9.3
Exception Condition
9.3.1
11
10.
ANCHOR BLOCKS
10.1 Anchor Block Position
Anchors may be of the type which encased the entire circumference of the
penstock or they may be of the type which is in contact with only a lower
segment of the circumference as shown in Figure 10.1.
This latter type of anchor may be constructed before the penstock is
installed, in which case recesses are provided in the concrete for grouting
the pipe and stiffener rings in place after installation. The stiffener rings
will assist to transfer the longitudinal forces from the pipe to the anchor.
12
Allowable Bearing
Foundation
Capacity (ton/m2)
10
Clay or loam
15
20
Gravel
30
100
250
400
13
0.75
0.30
10.4.3 In order to make the anchor block safe against crushing, the
compressive stress on the anchor block should not exceed the
bearing capacity of the foundation and the allowable stress of
concrete.
seismic force.
14
When the pipe axis on the upstream does not fall on the same
perpendicular plane with that on the downstream, the anchor
blocks should receive consideration with respect to stability on
traverse direction.
10.5.2 Resolution of forces acting on an anchor
A =
A =
in meters.
15
W =
P =
W =
wAH
q wv
g
P sin x
16
P sin y
f cos x (P + W
p
)
2
f cos y (P + W
p,
)
2
f' ( d +2t )
12
f' ( d +2t )
12
w H t ( d +t )
144
wa H
w a H
w H (A - A)
w H (A - A)
17
11.
DESIGN OF PIERS
11.1 General
Piers should be designed for safety against overturning, sidings just similar
to the design of anchors.
The base of the piers should have a sufficient bearing capacity not
susceptible to any displacement or settlement. Foundation for piers will
be designed similar to that of anchors.
Piers are design to support the dead load of pipe and contained water and
resist longitudinal forces resulting from temperature change. Earthquake
forces may be considered in the design in areas subject to seismic
disturbance.
The magnitude of longitudinal forces provided with expansion joints is
dependent on the methods of support between pipe and piers. Piers which
carry the pipe directly on concrete are subject to longitudinal forces when
axial movement of pipe occurs. These longitudinal forces may be reduced
by placing lubricated plates or other low friction factor material between
pipe and pier or by use of rocker and roller support.
18
12.
EXPANSION JOINTS
0.0000117 T L
L
T
=
=
where:
12.5 Among the several types of expansion joints in use, the sleeve types is the
most popular for large steel pipe. Longitudinal movement is permitted by
two closely fitting sleeves, one slide in the other, with a shuffling box and
packing to prevent leakage. A bolted packing gland is used to compress
the packing which consists of long-fibre braided flax impregnated with a
suitable lubricant.
A typical expansion joint of this type is shown in Figure 12.1. Another
design shows the exterior surface of the inner sleeve is clad with
chromium to prevent corrosion and insure free sliding in the joint. This
type of joint may also designed with two stuffing boxes, as shown in
Figure 12.2
12.6 The sliding length of sleeve type expansion joints should have an
allowance in excess of 50 mm. for the design value.
19
Figure 12.2 : Flexible sleeve-type expansion joint with two stuffing boxes used to
permit longitudinal temperature movement and transverse deflection
20
13.
Figure 13.1 : Constant diameter bend with the radius of the bend five times the
diameter
21
Figure 13.2 : Bend reducing in diameter from 9 feet to 8 feet, the radius equal to
four times the smaller diameter
b) The main considerations in the design of branch outlets and wyes are
structural strength to with stand the internal pressure, and proper
streamlining to reduce hydraulic loss.
c) since outlet openings reduce the strength of the pipe at the opening,
reinforcement must be provided to compensate for the removed
material.
As a general rule the reinforcement should be adequate to make the
connection equal in strength to that of the pipe without the opening.
d) Several branch outlets and wyes are illustrated in Figure 13.3 and
13.4, respectively.
These two figures show some of the fittings commonly used and
the different methods of providing necessary reinforcement.
The unsupported pressure areas in the pipe shells are shown by
shading, and the distribution of load in the reinforcing members
is indicated graphically.
The right angle tee shown in Figure 13.3 a and 13.3 b are
hydraulically inefficient and should be avoided whenever
possible .
22
23
24
25
Deflection angle of branch outlet and wye should not be less than
45, because difficulties will be encountered in reinforcing
branch outlets and wyes.
Branch outlets as shown in figure 13.3 a, 13.3 b, and 13.3 c may
be reinforced by a simple curve plated designed to meet the
requirements of the ASME rode.
26
REFERENCES
1.
2.
3.
Water Gate and Penstock Association (Japan), Technical Standards for Gates
and Penstocks. (1971)