Table of contents

1.0 Introduction
2.0 Organization and individual responsibility
3.0 Health, safety and environment management (HSEM)
3.1 Health and safety
3.2 Environment protection
4.0 Site office and storage yards.
4.0 Ventilation
6.0 Electrical power distribution
7.0 List of equipment
8.0 Lifting tools and tackles
9.0 List of work force
10.0 Transport route and work sequence
11.0 Execution plan
11.1 Phase 1
11.1.1 GROUP 01
11.1.2 GROUP 02
11.2 Phase 2
11.2.1 Group #01
11.2.2 Group #02
12.0 Weight calculation of bends, pipes and reducers
12.1 Table: 01 Formula for approximate wait calculation of materials.
12.2 Table: 02 Calculation of weight of bends
12.3 Table: 03 Weight calculation for reducers
12.4 Table: 04 Section wise penstock weight calculation
12.5 Calculation of weight on trolley and rollers while transporting pipes and bends.
12.6 Table: 05 API Specification 9A/ISO 10425:2003 for wire rope;
12.7 Table: 06 Dimension and properties of ISMB
13.0 Deflection calculation
13.1 Deflection calculation for ISMB150
13.2 Deflection calculation for ISMB175
14.0 Installation
14.1 Installation Equipment
14.2 Installation Sequence
14.3 Welding Sequence
14.4 Welding Repair Procedure
15.0 Painting
16.0 Concreting
 Drawings
Annexure 1: Loading and unloading of ferrules
Annexure 2: Truck loading measurements
Annexure 3: Hydromechanical work sequence through audit-04.
Annexure 4: Installation of bends.
Annexure 5: Installation of ferrules at drop shaft.
Annexure 6: Trolley arrangement at saddle support.

Images
Image 01: - Transportation of penstock by truck
Image 02: - Installation of vertical shaft inside tunnel.
Image 03: - Scaffolding erected inside penstock for welding.
Image 04: - Lifting of penstock using gantry crane.
Image 05: - Penstock inside tunnel.
Image 06: - Image of Bifurcation
Image 08: - Lifting of vertical shaft suing gantry crane
 Penstock Installation Methodology

1.0 Introduction

This document describes the erection methodology of penstock pipes, bends, reducers and bifurcations
at their respective locations. Which includes mobilization of manpower, equipment and materials to
site, storage yards and site workshop arrangement, health, safety and environment protection,
equipment and manpower planning, lifting and transportation planning, transporting of material from
site yards to their locations. It further describes the preparation of sites, installation of pipes, inspection
and testing them at site as per their technical specifications.

2.0 Organization and individual responsibility

The project shall be supported by all members in this organization from their direct and indirect
contribution. Mainly Project coordinator, project manager, quality controllers, engineers, supervisors,
safety officers and surveyors shall be at site throughout the execution. Considering all possible safety
procedures with prior proper planning, the whole team shall be dedicated to perform work and
complete in time precisely maintaining high degree of quality.

The activity shall be executed as per the planned by head office. However, if there any deviation in site
conditions, it is project manager’s responsibility to modify working strategy with prior information to
head office and clients by taking local circumstances and conditions into consideration. The project
manager is responsible overall site activities which includes, coordination of workforce, machinery,
equipment and safety of material and workforces as well as for the disposition of waste materials. Any
decision concerning major structural modification or adaptation and change in contractual aspects shall
be taken by head office after details discussion with project manager.

3.0 Health, safety and environment management (HSEM)

3.1 Health and safety

All the concerned personal shall be discussed, instructed and trained to their responsibilities, possible
hazards, and hazards minimization and mitigation planning prior to start any activity. Also, toolbox
meeting shall be conducted in daily basis. The instruction to be documented and comprise the following
subjects.

 Personal protective equipment (PPEs) and first add box – Importance of PPEs and
importance of first add box at each site.
 Electrical hazards and its mitigation – Inspection of electrical connections, use of protection
devices and earthing of equipment.
 Fire/explosion hazards– Fire extinguisher shall be present at site, storage of gas cylinders,
storage of petroleum products, inspection of electrical connections, ventilation fans, welding
machines, gas cutter machines and other spark generating machines.
 Falling from height - Measure to prevent personal falling from height, three-point contact
while using ladders, uses of full body harness and inspection of scaffoldings.
  Eye, hand and other injuries – Uses of face shield while grinding, cutting and welding, always
use gloves, safety glass, helmet and safety shoes while performing any activity.
 Safe storage and stacking – Each material shall be storage in proper way, highly explosive
materials shall be stored with special care, store keepers shall always be present at storage area.
 Lifting of materials – All lifting accessories and tools shall be inspected regularly, a proper lifting
plan shall be made prior any critical lifting, trained riggers shall be present at site while lifting
also lifting equipment shall have daily check list.
 Working at confined space – Proper ventilation and illumination shall maintain while working
inside tunnel, gas test shall be conducted, an entry and exit record of all personnel working
inside tunnel shall maintain through the execution period.
 Material and equipment damage – Material shall be properly tied off while transporting and
rigger shall help to operator while lifting.
 Emergency evacuation and electrical power failure - An evacuation or emergency exit plan shall
be discussed and kept at site prior to start any activities. A backup diesel generator shall be
connected with main grid at site for emergency switching and lifting arrangements.
 Communication between workforces – The communication between workforces is crucial to
execute any job safely, so walkie-twalkie or mobile phones and horns shall be used.

3.2 Environment protection

All personnel working at site shall be responsible for protection of environment. Our site
facilities will be constructed in such a way that which will impact on environment as less as
possible. Considering solid waste as biodegradable and undegradable, bridgeable waste shell be
buried under ground and undegradable waste shall be recycled or disposed in proper care.

The waste like untreated sewage, sanitary waste, tailing, petroleum products, chemicals,
biocides minerals salts and thermal pollutants shall be disposed with proper care. Waste water
must not enter directly without using settling ponds, gravel filter so as not to impair water
quality and harm aquatic life. Personnel are trained and aware to save environment, they are
trained to dispose waste materials. All operations shall be ensured proper disposal of waste
material, sewage and rubbish, the site shall ensure protect of wild life.

4.0 Site office and storage yards.

The land to construct site office and storage yards should be provided by client. The site office shall be
equipped with all necessary deiced like desktop, printer, scanners, racks and other stationary items to
record and report daily activities. As well as to prepare and planning for further jobs.

The storage yards shall be free from landslides and floods, which will be used to store equipment, tools,
cylinders, and prefabricated material comes from main workshop. A proper record shall be maintained
on daily basis.
4.0 Ventilation

To facility the natural ventilation and reduce chimney effect in vertical shaft, it is necessary to close
them off. Same is valid for fog concentration at top of tunnel. The temporary tunnel doors will be placed
at the lower bend area until the tunnel have been closed at the top. Afterwards the temporary doors
will be removed to enable the lower bend of the vertical shaft. A draught fan shall be installed neat the
junction of audit tunnel and lower vertical chamber.

Further small fan with 30” sweep shall be installed also in lower portion and at the upper portion of
vertical shaft with adequate number of lighting/illumination arrangement shall be provided around the
said area.

6.0 Electrical power distribution

Sufficient illumination in each and every installation are shall be the responsibility of the client
as per provision and stipulation of the contract. Furthermore, the electricity shall be provided
by client to run the welding machines, fans, heat treatment equipment and other tools and
equipment as required.

7.0 List of equipment

Below is the list of equipment;

S/N# Type of equipment Capacity Quantity Remarks

For phase 2
1 Gantry crane 20 ton 1 Set.
For phase 1
2 Gantry crane 15 ton 1 Set.
Phase 1 and 2
3 Gantry crane 10 ton 2 Sets.
Phase 1 and 2
4 Gantry crane 5 ton 2 Sets.
Phase 1 and 2
5 Mobile crane 50 to 80 ton 1 Set.
Phase 1 and 2
6 Hydra crane 20 ton 1 Set.
Phase 1 and 2
7 Truck 20 ton 1 Set.
Phase 1 and 2
8 Truck/tractor 10/4 ton 2 Sets.
Phase 1 and 2
9 Bolero van 4-wheel drive 1 Set.
Phase 1 and 2
10 Welding machine 400-600 Amps 12 Sets.
Phase 1 and 2
9 Grinding machine Heavy duty (AG-7) 12 Sets.
Phase 1 and 2
10 Winch machine 10 1 Set.
Phase 1 and 2
11 Winch machine 5 1 Set.
Phase 1 and 2
12 Air blower (Heavy duty) 3 sets
Phase 1 and 2
14 Total statin 1 set
8.0 Lifting tools and tackles
Below is the list of lifting tools;

S/N# Type of equipment Capacity Quantity Remarks

Phase 1 and 2
1 Chin block 10 Ton 6 Nos.
Phase 1 and 2
2 Chin block 5 Ton 6 Nos.
Phase 1 and 2
3 Chin block 2 Ton 4 Nos.
Phase 1 and 2
4 Turn buckle 10 Ton 12 Nos.
Phase 1 and 2
5 Turn buckle 5 Ton 12 Nos.
Phase 1 and 2
6 D shackle 15 Ton 8 Nos.
Phase 1 and 2
7 D shackle 10 Ton 8 Nos.
Phase 1 and 2
8 D shackle 5 Ton 8 Nos.
Phase 1 and 2
9 D shackle 2 Ton 8 Nos.
Phase 1 and 2
10 D shackle 1.5 Ton 8 Nos.
Phase 1 and 2
11 D shackle 1 Ton 8 Nos.
Phase 1 and 2
12 Web slings 20 Ton X6m 4 Nos.
Phase 1 and 2
13 Web slings 20 Ton X4m 4 Nos.
Phase 1 and 2
14 Web slings 15 Ton X 6m 4 Nos.
Phase 1 and 2
15 Web slings 15 Ton X 4m 4 Nos.
Phase 1 and 2
16 Web slings 10 Ton X6m 4 Nos.
Phase 1 and 2
17 Web slings 10 Ton X 4m 4 Nos.
Phase 1 and 2
18 Web slings 5 Ton X 4 m 4 Nos.
Phase 1 and 2
19 Web slings 5 Ton X2 m 4 Nos.
Phase 1 and 2
20 Web slings 2 Ton X4m 4 Nos.
Phase 1 and 2
21 Web slings 2 Ton X2 m 4 Nos.
Phase 1 and 2
22 Web slings 1 Ton X 2m 6 Nos.
Phase 1 and 2
23 Web slings 1 Ton X 1.5m 6 Nos.
Phase 1 and 2
24 Hydraulic jack 50 Ton 2 Nos.
Phase 1 and 2
25 Hydraulic jack 16 Ton 5 Nos.
Phase 1 and 2
26 Hydraulic jack 5 Ton 5 Nos.
Phase 1 and 2
27 V lever 6 Ton 8 Nos.
Phase 1 and 2
28 Trifer jack 10 ton 2 Nos.
Phase 1 and 2
29 Wire rope 9 mm 450m Nos.
Phase 1 and 2
30 Wire rope 12 mm 500m Nos.
Phase 1 and 2
31 Power cable 4 core X 1.1 KV 700m Nos.
32
33
34
9.0 List of work force
One shift = 12 hours

S/N Designation Quantity Remarks

#
1 Project engineer/manager 1 No. The number of
2 Site engineer 2 No. manpower
3 Sub-engineer 2 No. subjected to very
4 Supervisor 4 Nos. as per the site
5 Quality controller (Level-II) 6 Nos. availability
6 Pipe fitter 6 Nos.
7 Safety officer 2 Nos.
8 Certified welder (6G) 12 Nos.
9 Gas cutter 2 Nos.
10 Rigger 8 Nos.
11 Grinder 10 Nos.
12 Electrician 2 Nos.
13 Skilled helper 16 Nos.
14 Store keeper 2 Nos.
15 Driver 3 Nos.
Total 78 Nos

10.0 Transport route and work sequence

The overall ready to install bends, pipes and bifurcation shall be transported via truck using local route
towards the respective working area. The transportation shall be done prior to the schedule and site
activity. The equipment, materials and manpower to execute work from PT-05 to powerhouse and from
HR-04/PT-01 to PT-05 shall be transported via audit 4 and audit 2,2.1 and 3 respectively.

11.0 Execution plan

The activity shall be executed in two phases (Phase 01 and Phase 02) first phase (Phase 01) of work shall
be executed using two independent groups (Group 01 and Group 02) of workforces.
11.2 Phase 1
11.2.1 GROUP 01: - From audit 4 to powerhouse area.
 Installation of I-beam (125), trolley, winches machine and gantry crane. At first, total length
of 1000 m I-beam (200), base plate, grouting roads, shall be transported and erected above
already constructed saddle support between audit 4 to PT-9 and further PT-09 to PT-10
(units 01, 02 and 03). Then, the material of gantry crane of capacity 10Ton shall be
transported and installed at audit 04. Finally, the components of winches machines capacity
of 5Ton and rope diameter of 12mm and length of 450m shall be transported and erected at
audit 4 just before the gantry crane erected. A Winches machine of capacity 2Ton and 9mm
wire rope of 40m shall be installed at bend ‘C’, to perform work at unit 03. After completion
work at unit 03 the same winches machine shall be removed and reinstalled at bifurcation
‘B’ area to perform work at unit 02. In similar manner the same winch machine shall be
installed at bifurcation ‘A’ area to perform work at unit 01.
(I) Installation of branch penstock, bends and reducers at unit 03. Firstly, a 900mm dia. and
5m length of ferrules will be entered through audit 4 via truck and unloaded and reloaded
to trolley located at this area. Then, the ferrules shall be further transported to PT-10 using
trolley and winches machines capacity of 5 Ton with 12mm wire rope. The ferrules shall be
aligned with 647.30m penstock center level and anchored. Another 2.5m lengths of pipe
shall be transported to PT-10 and connect to the previously aligned ferrules. Again, 2.5m
length and 1.2 m to 0.9m dia. reducers shall be transported and connected to the end of
pipe and reducer shall be anchor blocked. A 1.2m dia. pipes shall be connected to larger end
of reducers and continue up to bend at unit 03. Again, a bend of 1.2m dia. shall be
transported in the same way to the unit 3 and to be connected to end of the previous pipe.
A 1.2m dia. pipes shall be transported and further connected with end of bend up to
bifurcation ‘B’.

(II) Installation of branch penstock, bends and reducers at unit 02. Secondly, a 900mm dia.
and 5m length of ferrules will be entered through audit 4 via truck and unloaded and
reloaded to trolley located at this area. Then, the ferrules shall be further transported to PT-
10 using trolley and winches machines capacity of 5 Ton with 12mm wire rope. The ferrules
shall be aligned with 647.30m penstock center level and anchored. Another 2.5m lengths of
pipe shall be transported to PT-10 and connect to the previously aligned ferrules. Again,
2.5m length and 1.2 m to 0.9m dia. reducers shall be transported and connected to the end
of pipe and reducer shall be anchor blocked. A 1.2m dia. pipes shall be connected to larger
end of reducers and continue up to bifurcation B.
(III) Installation of branch penstock, bends and reducers at unit 01. Thirdly, a 0.9mm dia. and
5m length of ferrules will be entered through audit 4 via truck and unloaded and reloaded
to trolley located at this area. Then, the ferrules shall be further transported to PT-10 using
trolley and winches machines capacity of 5 Ton with 12mm wire rope. The ferrules shall be
aligned with 647.30m penstock center level and anchored. Another 2.5m lengths of pipe
shall be transported to PT-10 and connect to the previously aligned ferrules. Again, 2.5m
length and 1.2 m to 0.9m dia. reducers shall be transported and connected to the end of
 pipe and reducer shall be anchor blocked. A 1.2m dia. pipes shall be connected to larger end
of reducers and continue up to bifurcation A.
(IV) Installation of penstock and bifurcation between PT-09 and second bifurcation. Fourthly,
once all branch pipes installed at unit 01, 02 and 03, a prefabricated Y-type bifurcation shall
be transported via audit 4, aligned and installed at unit 02 and unit 03 junction (Bifurcation
‘B’). The side branch of bifurcation shall be connected with unit 02 pipes of dia. 1.2m and
main branch shall connect with unit 03 pipes of dia. 1.2m and fixed with anchor block. Then,
sections of 1.7m pipes shall be connected with inlet of bifurcation ‘B’ and continued to
Bifurcation A.
(V) Installation of first bifurcation at PT-09 and pipes up to PT-08D. Fifthly, a bifurcation of
inlet dia. 2.1m, main pipe dia. 1.7m and branch pipe dia. 1.2m shall be transported through
audit 4 with the help of gantry crane, trolley and winches machines, furthermore aligned
and installed at PT-09. The main pipe and branch pipe shall be connected with 1.7m and
1.2m already installed pipes respectively and fixed with anchor block. Then, sections of 2.1m
pipes shall be connected with inlet of bifurcation ‘A’ and continued up to PT-08D.

(VI) Installation of vertical bend ‘A’ at PT-08D. Sixthly, bend of did. 2.1m shall be transported
through audit 4 to PT-08D with the help of gantry crane, trolley and winches machines.
Then, it shall be aligned at PT-08D with vertical deflection of 174 degree. The lower end of
aligned bend pipe shall be welded with 2.1m pipe coming from PT-09 and fixed with anchor
block. Again, section of 2.1m pipes shall be transported individually and welded with end of
previously installed bend and continued up to PT-08C.

(VII) Installation of penstock pipe at bend ‘C’ at PT-08C. Finally, Sections of penstock of dia. 2.1m
shall be transported through audit 4 to PT-08C (Bend C) with the help of previously installed
gantry crane, trolley and winches machine. Then, it shall be aligned and connected at PT-
08C with horizontal deflection of 0.88 degree with 1.2m dia. pipe coming from PT-08D and
same procedure shall be continued up to PT-07. However, for this section concrete casing
shall be done up to PT-08.

11.2.2 GROUP 02: - From SOP-04A/PT-01 to SOP-06/PT-03 through audit 2 and audit 2.1.

 Installation of I-beam (125), trolley, winches machine and gantry crane and chain blocks. Total
length of 440 m I-beam (125), base plate, grouting roads, shall be transported and erected
above already constructed saddle support between HR-04/PT-01 to PT-02 Then, the material of
gantry crane of capacity 5Ton shall be transported and installed at PT-01/HR-04. The
components of winches machines capacity of 5Ton and rope diameter of 9mm and length of
230m shall be transported and erected at PT-01. Again, Two Chain blocks of capacity 10T each,
Components of gantry crane of capacity 15T shall be transported via truck and installed at audit
2 and a ferrules guide track shall be installed from PT-02 to PT-03.

(1) Installation of bends (VAB 02) and vertical shaft from PT-02 to Pt-03. This group #02 shall start
work for this section, Firstly, a bend of 2.5m dia. and angle of 90 degree shall be transported
 from warehouse to audit 2.1 via truck. The bend shall be unloaded with the help of gantry crane
installed at audit 2.1, then carefully lowered to PT-03 guided by ferrules guide. The bend shall be
aligned, installed and fixed with anchor block. Again, section of 2.5 m pipes shall be transported
to audit 2.1 with same way and lowered by gantry crane and welded with upper end of
previously fixed bend. The same process shall be applied for remaining pipes up to PT-4.

(2) Installation of bend (VAB 01) and penstock from PT-01 to PT-02. Secondly, a section of 2.5m
penstock shall be transported from warehouse area to audit 2.1, then unloaded from truck and
reloaded on trolley by previously installed gantry crane, the trolley shall be operated by winch
machine installed at PT-01. The pipe shall be aligned with tunnel and center level maintained at
1228.61m. Other same sizes of pipes shall be transported with same way and welded with end
of previous one up to VA -01 where a 186-degree vertical band to be installed. Again, a
horizontal band with 186 degree shall be transported from same way, then to be aligned,
installed and fixed with anchor block. Remaining 2.5m dia. pipes shall be transported through
audit 2.1, unloaded from truck, reloaded on trolley with the help of gantry crane which is
operated by winch machine installed at PT-01. The pipe shall be aligned and welded with lower
end of fixed bend at audit 2.1 up to PT-02. Finally, a bend of dia. 2.5m shall be transported in
audit 2.1 and installed with the help of gantry crane.

11.2 Phase 2

Phase 02 of work shall be executed using two independent groups (Group 01 and Group 02) of
workforces.

11.2.1Group #01: - Installation of penstock pipes from PT-03/SOP-06 to PT-05C/SOP-08A.

(I) Installation of I-beam (125), trolley, winches machine, gantry crane and chain blocks. Total
length of 1060 m I-beam (125), base plate, grouting roads, shall be transported and erected
above already constructed saddle support between PT-03/SOP-06 to PT-04A/SOP-07A
Then, the material of gantry crane of capacity 20Ton shall be transported and installed at
PT-04A/SOP-07A, and two chain blocks of capacity 10T each shall be required. The
components of winches machines capacity of 5Ton and rope diameter of 12mm and length
of 530m shall be transported and erected at PT-03. Also, a ferrule guide track shall be
installed on vertical shaft from PT-04A to PT-05.
(II) Installation of penstock pipe from SOP-06/PT-03 to SOP-07A/PT-04A. Firstly, a 2.5m pipes
shall be transported in audit 3 and unloaded by gantry crane which was installed previously.
The unloaded piece of pipe shall be reloaded on trolley operated by winch machine installed
at PT-03. The trolley shall be pulled by winch machine and reached to PT-03. The end of pipe
then to be welded with lower end of previously installed bend, same procedure shall be
followed up to SOP-07A/PT-04A. In the middle of this section the pipe shall be fixed with
anchor block to protect from sliding of penstock.
 (III) Installation of bends (VAB-03, VAB-04) and penstock pipe from SOP-07A/PT-04A to PT-
05C/SOP-08A. Secondly, a bend of 2.5m dia. and angle of 90 degree shall be transported
from warehouse to audit 3 via truck. The bend shall be unloaded with the help of gantry
crane installed at audit 3, then carefully lowered to PT-03 guided by ferrules guide. The
bend shall be aligned, installed and fixed with anchor block. Again, section of 2.5 m pipes
shall be transported to audit 2.1 with same way and lowered by gantry crane and welded
with upper end of previously fixed bend. The same process shall be applied for remaining
pipes up to SOP-07A/PT-04A. Again, a bent of diameter 2.5m shall be transported with same
way and installed at SOP-07A/PT-04A with the help of already installed gantry crane.

11.2.2 Group #02: - Installation of penstock pipes from PT-03/SOP-06 to PT-05C/SOP-08A.

 Installation of I-beam (200), trolley, winches machine. Total length of 610 m I-beam (200),
base plate, grouting roads, shall be transported and erected above already constructed
saddle support between PT-05 to PT-07. The components of winches machines capacity of
5Ton and rope diameter of 12mm and length of 530m shall be transported and erected at
PT-03. Also, an already installed gantry crane at audit 4 of capacity 10 Ton shall be used.

(I) Installation of reducers and penstock pipes from PT-03/SOP-06 to PT-05C/SOP-08A.A

reducer of dia. 2.5m X2.25m shall be transported in audit 4 via truck and unloaded on trolley
with the help of gantry crane, and the trolley shall be pulled by winches machine installed at
PT-05. The inlet of reducer shall be connected with previously installed bend. The remaining
section of pipes shall be connected up to PT-06. Again, a reducer of dia. 2.25mX2.1m shall
be transported and connected to end of previously connected pipe at PT-06. Finally, a
penstock section of diameter 2.1m shall be installed with the help of gantry crane and chain
blocks at PT-07.
12.0 Weight calculation of bends, pipes and reducers;

12.1 Table: 01: Formula for approximate wait calculation of materials.

Formula 1 Formula 2 Formula 3

       
Calculation of weight of pipes; Calculation of weight of bends; Calculation of weight of Reducers;

W = ρ*Л* (Do2-Di2)/4 W = (2*ρ*Л2*S* (D-S) *R)/4 W= ρ*Л*((D + d)/2 - S) *H*S

Where, Where, Where,

W= Weight of pipes (in KG)
ρ= Density of materials (7850
Kg/m3)
Л=3.14
Do= Outer diameter of pipes in m
Di= Inner Diameter of pipes in m
W= Weight of 90 D bend
ρ= Density of materials (7850
Kg/m3)
Л = 3.14
D= Outer diameter of elbow in m
S= Thickness of elbow in m
R=Long radius = 1.5 * D in m
W= Weight of reducers
ρ= Density of materials (7850
Kg/m3)
Л= 3.14
D= Large diameter of elbow in m
d= Small diameter
S = Thickness of reducer in m

12.2 Table: 02: Calculation of weight of bends

Outer Thickness
S/ Inner dia.
Sections dia. of large Weight (KG) Types
N (m)
(m) end (m) Locations
1 2 2.5 0.016 2.484 5768 Bend (VAB1) PT-02
2 5 2.5 0.03 2.47 10753 Bend (VAB2) PT-03
3 8 2.5 0.028 2.472 10045 Bend (VAB3) PT-04A
4 13 2.5 0.046 2.454 16382 Bend (VAB4) PT-05

12.3 Table: 03: Weight calculation for reducers

S/ Large end Small end Thickness of End to end Weight Penstock

N dia.(m) dia. (m) large end (m) height (m) (KG) type Locations
1 1.2 0.9 0.032 2.5 2007 Reducer PT-10
2 2.5 2.25 0.046 2.5 6602 Reducer PT-05
3 2.25 2.1 0.044 2.5 5778 Reducer PT-06
12.4 Table: 04: Section wise penstock weight calculation

Weight Weight on
Oute Penstock Net pulling Weight on
Inner Weight/ /5m rollers Pipe
S/N Sections r dia. thickness load rollers (FR1) (in
dia. (m) m (Kg) (W) (FR2) (in alignment
(m) (m) (FP) (in KG) KG)
(KG) KG)
1 1 2.5 0.012 2.488 369 1844 100 1147 1462 Horizontal
2 3 2.5 0.025 2.475 766 3832 3832 NA NA Vertical
3 4 2.5 0.03 2.47 919 4594 4593 NA NA Vertical
4 6 2.5 0.03 2.47 919 4594 252 2016 2832 Horizontal
5 7 2.5 0.028 2.472 858 4289 235 2272 2640 Horizontal
6 9 2.5 0.032 2.468 980 4898 4900 NA NA Vertical
7 10 2.5 0.036 2.464 1101 5506 5500 NA NA Vertical
8 11 2.5 0.042 2.458 1283 6416 6416 NA NA Vertical
9 12 2.5 0.046 2.454 1404 7021 7021 NA NA Vertical
10 14 2.25 0.044 2.206 1208 6041 331 2456 3550 Horizontal
11 15 2.25 0.044 2.206 1208 6041 331 2456 3550 Horizontal
12 16 2.1 0.042 2.058 1076 5381 295 2015 3008 Horizontal
13 17 2.1 0.042 2.058 1076 5381 295 2015 3008 Horizontal
14 18 2.1 0.044 2.056 1127 5634 310 2210 3150 Horizontal
15 19 2.1 0.044 2.056 1127 5634 310 2210 3150 Horizontal
16 20 1.2 0.032 1.168 467 2335 127 445 911 Horizontal
17 21 0.9 0.032 0.868 349 1743 97 212 567 Horizontal

12.4 Calculation of weight on trolley and rollers while transporting pipes and bends.
 Fig: 01: Schematic diagram of forces at acting different points while transporting ferrules in tunnel
using trolley on ISMB

12.5 Table: 05: API Specification 9A/ISO 10425:2003 for wire rope;
12.6 Table: - 06 Dimension and properties of ISMB (Bureau of Indian standard: SP 01-1964)
13.0 Deflection calculation
13.1 Deflection calculation for ISMB150

To transport material between PT-01 and PT- 04A/SOP-07A.

W=13890 N

A C B

L= 5.00 m

The figure 02 shows the arrangement of I-beams on between saddle supports A and B, while the roller
of trolley C reach at middle point then deflection will be maximum.

Deflection = (W*L3/48*E*I))
Where,
W = Weight of roller at center of beams
L = Length of Beams
E = Modulus of elasticity of steel = 2 X 10 11 N/m2
Moment of inertia (IXX) = 449 X 108 m4

Weight at center of beams (Max weight on roller*9.81/2) (W) = 2832*9.81 /2 = 13890 N

Deflection = (13890*53/ (48*2X1011* 449X108) m
Deflection = 40.28 X 103 m
Deflection ration = 2.60/325 which is not allowed.

The arrangement shall be changed in such a way that,

Either ISMB 125 should be replaced with ISMB 175,
If so,
Moment of inertia (IXX) = 726 X 108 m4

Weight at center of beams (Max weight on roller*9.81/2) (W) = 2832*9.81 /2 = 13890 N

Deflection = (13890*53/ (48*2X1011* 1272X108) m
Deflection = 14.21 X 103 m
Deflection ration = 0.924/325 which is allowed.
13.2 Deflection calculation for ISMB175
To transport material between PT-05C and PT-10.

W=17412 N

A C B

L= 5.00 m
The figure 03 shows the arrangement of I-beams on between saddle supports A and B, while the roller
of trolley C reach at middle point then deflection will be maximum.
Deflection = (W*L3/48*E*I))
Where,
W = Weight of roller at center of beams
L = Length of Beams
E = Modulus of elasticity of steel = 2 X 10 11 N/m2
Moment of inertia (IXX) = 449 X 108 m4

Weight at center of beams (Max weight on roller*9.81/2) (W) = 3550*9.81 /2 = 17412 N

Deflection = (17412*53/ (48*2X1011* 1272X108) m

Deflection = 13 X 103 m
Deflection ration = 0.84 / 325 which is allowed.
14.0 Installation

14.1 Installation Equipment

Rotor and idler, welding Machine, gantry crane, hydra crane, lifting tools and tackles and NDT
accessories.

14.2 Installation Sequence

The lower part of the bend from shall be placed first with the help of Gantry Crane, then the middle part
and then upper part of the bend shall place and assemble in the center of axis of vertical shaft in the
conjunction with the related elevation/setting out point.

After it's alignment in conjunction with center line, setting out points, elevation and complete
peripherals matching with top of bottom part and bottom of middle part of the bend, the same shall be
tack welded. After the final survey and checking by the Engineers, the final welding shall be done
including all required NDT.

2.5 m. long ferrules shall be assembled up to 5.0 m. long extended segment by placing the same 2
numbers of 2.5 m. long ferrules on the rotator and Idler with the help of Gantry Crane. On placement of
2 numbers of 2.5 m. long extended bend segments on the Rotator and Idler, automatically the same will
be self-aligned and welding shall 20, 4 9, 42 np be done for obtaining 5.0 m. extended bend segments to
expedite smooth and fast progress of drop shaft.

14.3 Welding Sequence

Welding shall be carried out as per approved WPS by the Engineers. Welding sequences are referring
below;

 Before welding, fit-up inspection shall be carried out to check back strip. Bevel angle, root
gap, root face, alignment ovality of the ferrules.
 Before welding, adjacent welding area shall be cleaned from any oil, dust and greases.
 Before welding, pre-heat temperature shall be maintained as per approved WPS.
 After completion of root run, weld area shall be cleaned by grinding then DPT shall be
carried out to removal of any discontinuity.
 After satisfactory result of DPT, hot pass and inter passes shall be carried out. Inter pass
temperature shall be maintained during all the passes.
 After completion of inter passes filler and capping passes will carried out to fill the joint up
to allowable reinforcement.
 After completing of welding, activities area shall be cleaned from any surface spatter, slag
and unwanted excess weld metal deposition by grinding and then PWHT (if required) shall
be carried out.
 After welding visual inspection shall be carried out to ensure any surface defects or
discontinuity.
 After completion of welding, required NDT shall be carried out in the presence of QA/QC
Engineer from client side for the witness and final acceptance by endorsing on NDT report
by authorized personnel.
14.4 Welding Repair Procedure
Following steps will be taken up for the repair of the welding defects:

 First step is to locate the defects, establish its size in order to avoid excessive removal 23 of
the base metal, weld metal and marking on the job physically.
 Removal of defect by carbon arc gouging and/or grinding and preparation of the area to be
welded. it will be doing in such manner that the adjacent weld metal or base metal will not
be affected. Unacceptable portions of the weld are removed without substantial removal of
the base metal. Cross wise grinding to be TARA RA done up to a certain depth (5 to 8 mm)
on both ends i.e., beginning of crack & end of crack to arrest further propagation of the
crack. The surface will be cleaned thoroughly free from oil and grease before welding and
DPT carried out to ensure that defects are removed completely. The cavity prepared for the
welding is to be ensured wide enough so that electrode or welding gun can fully access the
defective area. The prepared cavity is smoothening without any peaks and valleys.
 After removal of the weld, metal from the defective weld location DPT is to be carried out to
ensure all the defects (cracks, slag inclusion, porosity etc.) are completely removed. After
satisfactory completion of DP Test the surface is to be cleaned properly through application
of wire brush or buffing wheel.
 Preheating is to be done as per approved WPS by neutral flame or coil heating.
 Baking of the electrodes as per manufacturer's recommendation for the best result.
However, the baking of electrodes is to be 250°C to 300°C for two hours. After baking of the
electrodes, the same shall be taken to the work place and stored in with the help of portable
oven(quivers)maintaining the minimum temperature of 100° C. Periodic check of the
condition of electrodes shall be carried out during the progress of the welding works. If the
temperature of the electrodes falls below 80° C then soon the same to be shifted to the
mother baking oven to re-dry. Electrodes as approved in the WPS shall be used for repair
welding works.
 The deposition of the weld metal as per approved WPS relevant to the process to be applied
for repair welding by qualified skilled welder. Weld metal is deposited layer by layer to
compensate or any deficiency in size as per the approved WPS for the repairing of welding
defects. Inter pass temperature shall be as per approved WPS and shall be within 250°C in
any case. After welding of each layer, all slag to be removed and surface to be cleaned
thoroughly to avoid any possibility of slag inclusion.
 Required NDT like MPT & UT shall be carried out then atter. Any NDT shall be carried out
after sufficient cool down (ambient) of welding area and parent metal.
 Post Weld Heat Treatment will be carried out as per approved WPS after ultrasonic test is
conducted and defect is detected.
 Post Weld Heat Treatment (if required) will be carried out as per approved WPS after
ultrasonic test is conducted and defect is detected.
 If repair welds are failed, then second repair will be taken with utmost precaution and step
by step as briefed earlier.
  Major external undercuts 1 mm and above shall be repaired by grinding followed by welding
and smooth grinding.
 Magnetic Particle Test shall be conducted after such repair.
 Visual inspection will be carried out for the repaired area, followed by required NDT as per
the procedure followed in the original welding.
 A documented report shall be generated for each repair and should be signed by QA/QC
Engineer. First repair of each joint is identified with joint number followed by R1 for First
Repair, R2 for Second repair. Final acceptance by endorsing on NDT report by all authorized
personnel.

15.0 Painting
The painting of the pipe and bend segments shall be done in the workshop as per the specification. The
final painted ferrules during transportation and erection might be scratched, so after the final
installation of the ferrules, touch-up paint shall be applied.

16.0 Concreting
After installation of bend segments of Bend, the supports shall be provided with permanent structural
supports and will not be removed and there after shall be embedded in concrete (as per sketch
enclosed). Placing each and every structural members/supports under the installed aligned Bend shall
be responsibility of civil contractor. Placing of reinforcement bars, shuttering, concreting and its
procedure shall be the responsibility of civil contractor including submission of Method Statement of
Concreting.

For the concreting of Bend segments and/or ferrules, adequate space of about 0.8 to 1.0 m. should be
provide from the face of the last erected ferrules for assemble and welding of the next ferrules, and for
the inspection and testing of the welded joint
Annexure 1: Loading and unloading of ferrules
Annexure 2: Truck loading measurements
Annexure 3: Hydromechanical work sequence through audit-04.
Annexure 4: Installation of bends.
Annexure 5: Installation of ferrules at drop shaft.
Annexure 6: Trolley arrangement at saddle support.
 Image 01: - Transportation of penstock by truck

Image 02: - Installation of vertical shaft inside tunnel.

Image 03: - Scaffolding erected inside penstock for welding.

Image 04: - Lifting of penstock using gantry crane.

Image 05 : - Penstock inside tunnel.

Image 06: - Image of Bifurcation

Image 08: - Lifting of vertical shaft suing gantry crane