Section II Special Technical Specifications 30 July 2019

SECTION II
SPECIAL TECHNICAL SPECIFICATIONS

Table of Contents
1 SCOPE OF WORK................................................................................................................................. 1
2 OBJECT AND LIMIT OF SUPPLY........................................................................................................ 1
3 SERVICE GATE..................................................................................................................................... 4
3.1 GENERAL......................................................................................................................................................4
3.2 DESIGN DATA........................................................................................................................................... 4
3.3 DESIGN CRITERIA......................................................................................................................................7
3.4 STRUCTURAL DETAILS..............................................................................................................................8
3.4.1 Gate Leaf............................................................................................................................................8
3.4.2 Gate Seals...........................................................................................................................................8
3.4.3 Sealing Surfaces.................................................................................................................................9
3.5 ANCHOR RODS AND PLATE.......................................................................................................................9
3.6 GATES POSITION INDICATORS...................................................................................................................9
3.7 LADDERS, PLATFORMS, HANDRAILS.........................................................................................................9
3.8 OPERATING SYSTEM................................................................................................................................10
3.9 DOGGING DEVICE....................................................................................................................................11
3.10 FASTENERS..............................................................................................................................................11
3.11 STAINLESS STEEL PLATES.......................................................................................................................11
3.12 CONTROL.................................................................................................................................................11
3.13 ELECTRICAL EQUIPMENT.........................................................................................................................12
3.14 MAINTENANCE........................................................................................................................................12
3.15 TOLERANCES...........................................................................................................................................12
3.16 TESTS......................................................................................................................................................12
3.16.1 Shop Tests.........................................................................................................................................12
3.16.2 Site Tests...........................................................................................................................................13
3.17 PROTECTIVE COATINGS...........................................................................................................................13
3.18 SPARE PARTS AND SPECIAL TOOLS.........................................................................................................13
3.18.1 Spare Parts.......................................................................................................................................13
3.18.2 Special Tools....................................................................................................................................14
4 MAINTENANCE GATES (STOPLOGS).............................................................................................. 15
4.1 GENERAL.................................................................................................................................................15
4.2 DESIGN DATA......................................................................................................................................... 15
4.3 DESIGN CRITERIA....................................................................................................................................16
4.4 STRUCTURAL DETAILS............................................................................................................................17
4.4.1 Gate Leaf..........................................................................................................................................17
4.4.2 Gate Seals.........................................................................................................................................17
4.4.3 Sealing Surfaces...............................................................................................................................18
4.5 ANCHOR RODS AND PLATE.....................................................................................................................18
4.6 GATES POSITION INDICATORS.................................................................................................................18
4.7 LADDERS, PLATFORMS, HANDRAILS.......................................................................................................18
4.8 OPERATING SYSTEM................................................................................................................................19
4.9 DOGGING DEVICE....................................................................................................................................20
4.10 FASTENERS..............................................................................................................................................20
4.11 STAINLESS STEEL PLATES.......................................................................................................................20
4.12 CONTROL.................................................................................................................................................20
4.13 ELECTRICAL EQUIPMENT.........................................................................................................................21
4.14 MAINTENANCE........................................................................................................................................21
4.15 TOLERANCES...........................................................................................................................................21
4.16 TESTS......................................................................................................................................................21
4.16.1 Shop Tests.........................................................................................................................................21
4.16.2 Site Tests...........................................................................................................................................22
i
4.18 SPARE PARTS AND SPECIAL TOOLS...........................................................................................................22
4.18.1 Spare Parts.......................................................................................................................................22
4.18.2 Special Tools....................................................................................................................................22
5 TRASHRACKS..................................................................................................................................... 24
5.1 GENERAL.................................................................................................................................................24
5.2 DESIGN DATA......................................................................................................................................... 24
5.3 DESIGN CRITERIA....................................................................................................................................24
5.4 STRUCTURAL DETAILS............................................................................................................................25
5.4.1 Trashrack Bars.................................................................................................................................25
5.4.2 Panels and Frames...........................................................................................................................25
5.4.3 Manual Racker.................................................................................................................................26
5.4.4 Embedded Parts...............................................................................................................................26
5.5 WORKSHOP AND SITE TESTS...................................................................................................................26
5.7 SPARE PARTS AND SPECIAL TOOLS.........................................................................................................26
5.7.1 Spare Parts.......................................................................................................................................26
5.7.2 Special Tools....................................................................................................................................26
6 HEADRACE PIPE & PENSTOCK....................................................................................................... 27
6.1 GENERAL.................................................................................................................................................27
6.1.1 Scope and Limits of Supply..............................................................................................................27
6.1.2 General Arrangement.......................................................................................................................28
6.1.3 Main Dimensions..............................................................................................................................28
6.1.4 Operating Conditions.......................................................................................................................28
6.1.5 Design Criteria.................................................................................................................................29
6.1.6 Materials..........................................................................................................................................30
6.1.7 Testing of Materials.........................................................................................................................31
6.1.8 Manufacturing..................................................................................................................................32
6.1.9 Tolerances........................................................................................................................................34
6.1.10 Installation.......................................................................................................................................34
6.1.11 Submittals.........................................................................................................................................36
6.2 HEADRACE PIPE AND PENSTOCK.............................................................................................................37
6.3 BIFURCATION..........................................................................................................................................37
6.4 BENDS.....................................................................................................................................................38
6.5 BUTT STRAPS..........................................................................................................................................38
6.6 STIFFENER RINGS....................................................................................................................................38
6.7 THRUST RINGS........................................................................................................................................38
6.8 SEEPAGE RINGS.......................................................................................................................................38
6.9 MANHOLE AND FLANGES........................................................................................................................38
6.10 TRANSITION PIECE..................................................................................................................................39
6.11 SADDLE AND WEAR PLATES...................................................................................................................39
6.12 EXPANSION JOINTS..................................................................................................................................39
6.13 AIR RELEASE AND ANTI-VACUUM VALVE................................................................................................39
6.14 SHUT-OFF VALVE.....................................................................................................................................39
6.15 FLUSHING VALVE AND PIPES...................................................................................................................39
6.16 PROTECTION AGAINST CORROSION..........................................................................................................40
6.17 SPARE PARTS.......................................................................................................................................... 40
6.18 SHOP ASSEMBLY AND TESTS...................................................................................................................40
6.18.1 Shop Assembly..................................................................................................................................40
6.18.2 Records.............................................................................................................................................40
6.18.3 Shop Tests.........................................................................................................................................40
6.19 SITE TESTS..............................................................................................................................................41
6.19.1 Inspection after Installation.............................................................................................................41
6.19.2 Painting Inspection..........................................................................................................................41
6.19.3 Pressure Test....................................................................................................................................41
6.19.4 Handling and Placing......................................................................................................................41
6.19.5 Field Welding...................................................................................................................................42
ii
iii
Asian Hydropower Ltd. Contract Document for Lot 3 : Hydromechanical Works
Lower Jogmai Khola Hydropower Project (6.2 MW) Volume 2, Section II : Special Technical Specifications
1 SCOPE OF WORK
The present Specifications cover the minimum technical requirements and limits for the design, supply,
manufacture, shop testing, painting, shipping, storage at site, installation and site testing of
Hydromechanical and Electrical Equipment to be installed in the 6.2 MW Lower Jogmai Khola
Hydropower Project.
The supply shall include the design, material supply, manufacture, shop testing, painting, delivery to the
site, installation, field testing, commissioning, acceptance testing and placing into successful operation
of all structure and equipment hereinafter outlined.
The Employer's personnel training and spare parts supply are also included.
The supply shall conform to the General Technical Specifications, unless otherwise specified.
The description of the items of the supply in the following paragraphs does not limit the responsibility
of the Contractor to perform all works and to supply all accessories, within the contractual limits, in
order for the same to be complete and ready for operation.
2 OBJECT AND LIMIT OF SUPPLY
The Supply shall include the following equipment:
Under Sluice Way Equipment

a) One (1) set of under sluice vertical lift gate complete with seals, fittings, hoist, all necessary
appurtenances for the operation of the gates and related fixed parts, all as detailed in Chapter 3.
b) One (1) set of maintenance stoplog complete with seals, fittings, hoist, all necessary
appurtenances for the operation of the gates and related fixed parts, all as detailed in Chapter 4.
Intake and Settling Basin Equipment
a) Two (2) sets of vertical fixed wheel gates for intake (Inlet), comprising of structural steel
complete sections with guide rollers, seals, hoists (Screw spindle), related fixed parts including
seal paths and embedded parts, as detailed in Chapter 3.
b) One (1) set of vertical fixed wheel gates for intake (Outlet), comprising of structural steel
complete sections with guide rollers, seals, hoists (Screw spindle), related fixed parts including
c) One (1) set of trash passage gate comprising of gate leaf, seals, guide rollers, gate embedded
parts, manual screw spindle hoist, fittings and connections necessary for operation of the gate
and stems and supports, all as detailed in Chapter 3.
d) One (1) set of steel Trashrack for Intake, complete with frames and bars, related fixed parts and
embedded parts, connections; all as detailed in Chapter 5.
e) Two (2) sets of gravel trap flushing gates (one flushing and one stoplog) comprising of gate
leaf, seals, guide rollers, gate embedded parts, hoists (screw spindle), fittings and connections
necessary for operation of the gate and stems and supports, all as detailed in Chapter 3.
f) Two (2) sets of settling basin inlet gates comprising of gate leaf, seals, guide rollers, gate
embedded parts, hoists (screw spindle), fittings and connections necessary for operation of the
gate and stems and supports, all as detailed in Chapter 3.
Page 1 of 41
g) Four (4) set of settling basin outlet gates comprising of gate leaf, seals, guide rollers, gate
embedded parts, manual screw spindle hoists (screw spindle), fittings and connections
necessary for operation of the gate and stems and supports, all as detailed in Chapter 3.
h) Two (2) sets of vertical lift gates for settling basin flushing structure comprising of structural
steel complete sections with guide rollers, seals, hoists (screw spindle), related fixed parts
including seal paths and embedded parts, as detailed in Chapter 3.
i) One (1) set of vertical lift gates for headrace pipe inlet structure comprising of structural steel
complete sections with guide rollers, seals, hoists (screw spindle), related fixed parts including
j) Two (2) sets of maintenance stoplogs for settling basin flushing gates complete with seals,
hoists (screw spindle), guide rollers, two (2) sets of fixed parts including seal paths and sill
beam, as detailed in Chapter 4.
k) Two (2) set of steel Trashrack before Canal, complete with frames and bars, related fixed parts
and embedded parts, connections; all as detailed in Chapter 5.
l) One (1) set of steel Trashrack before Headrace pipe, complete with frames and bars, related
fixed parts and embedded parts, connections; all as detailed in Chapter 5.
Headrace Pipe and Penstock
a) One (1) lot of headrace pipes complete with straight pipe, bends, stiffeners, anchor bars flanges
with manholes, air-relief valves with pipe, flushing valve with pipe, expansion joints and
necessary accessories all as detailed in Chapter 6.
b) One (1) lot of surge tank/pipe complete with all the necessary accessories all as detailed in
Chapter 6.
c) One (1) lot of penstock complete with straight pipe, bends, expansion joint, manholes,
stiffeners, anchor bars and necessary accessories all as detailed in Chapter 6.
Tailrace Equipment
a) Two (2) sets of vertical lift gates comprising of structural steel complete sections with guide
rollers, seals, hoists (Screw spindle), manual control system, related fixed parts including seal
paths and embedded parts, as detailed in Chapter 3.
Page 2 of 41
3 SERVICE GATE
3.1 General
This section covers the Special Technical Specifications for the following equipment and its
accessories, spare parts and special tools.
- One (1) sets of under sluice way gates

- Three (3) sets of intake gates
- One (1) set of trash passage gate
- One (1) sets of gravel trap flushing gate
- Two (2) sets of settling basin inlet gates
- Four (4) sets of settling basin outlet gates
- Two (2) sets of settling basin flushing gates
- One (1) set of headrace pipe inlet gate
- Two (2) sets of tailrace gates
The gate shall be of vertical lift type, complete with seals, guide rollers, fixed parts, fittings and
connections necessary for operation as well as electrical power-driven screws and manual drive wheel.
The gates shall be completely assembled in the shop and inspected by the Employer/Employer’s
Representative prior to shipment.
3.2 Design Data

Under Sluice Gate
- Type Vertical lift
- Opening dimensioning (w x h) 2.0 m x 4.0 m
- Number of
Gates (set) One (1)
Fixed parts (set) One (1)
- Elevation of
Sill beam (m.a.s.l) 644.0
Design Water Level (m.a.s.l.) 652
Design Head (m) 8
Operating platform (m.a.s.l) 653.3
- Operating system Electrical power screw with manual operation
provision
- Operating speed 0.3 m/min
- Operating condition Unbalance pressure
- Sealing/type 4way/UHMW bumper on ST-ST
- Corrosion allowance 2 mm
Intake Gate
- Opening dimensioning (w x h) 2.4 m x 2.0 m (Inlet)
2.0 m x 2.11 m (outlet)
- Number of
Gates (set) Three (3) (Two Inlet and One Outlet)
Fixed parts (set) Three (3)
- Elevation of
Sill beam (m.a.s.l) 646.0/646.72 (Inlet/Outlet)
Design Water Level (m.a.s.l.) 652/651
Design Head (m) 6/4.3
- Operating system Manual screw spindle hoist
Page 3 of 41
- Operating speed 0.3 m/min

- Sealing/Type 4way/UHMW bumper on ST-ST
Trash Passage Sluice Gate

- Number of
Gates (set) One (1)
- Elevation of
Design Head (m) 4.5
- Operating system Manual Screw spindle
Gravel Trap Flushing Gate

- Number of
Gates (set) One (1)
- Elevation of
Design Head (m) 6.6
- Operating system Manual screw spindle
Settling Basin Inlet Gate

- Number of
Gates (set) Two (2)
Fixed parts (set) Two (2)
- Elevation of
Design Head (m) 2.48
- Sealing/Type 3 way/UHMW bumper on ST-ST
Settling Basin outlet Gate

Page 4 of 41
- Opening dimensioning (w x h) 1.90 m x 2.5m

- Number of
Gates (set) Four (4)
Fixed parts (set) Four (4)
- Elevation of
Design Head (m) 3.1
- Operating system Manual screw spindle
Settling Basin Flushing Gate

- Number of
Gates (set) Two (2)
- Elevation of
Design Head (m) 6.8
Headrace Pipe Inlet Gate

- Number of
Gates (set) One (1)
- Elevation of
Design Head (m) 6.5
- Operating system Electrical power screw with manual operation
provision
Tailrace Gate
- Number of
Gates (set) Two (2)
- Elevation of
Page 5 of 41
Design Water Level (m.a.s.l.) 519.34

Design Head (m) 5.1
Operating platform (m.a.s.l) 520
3.3 Design Criteria
The structures shall be designed in accordance with relevant IS standard or equivalent. All gates shall
be considered to be fully opened or fully closed or partially opened and capable of passing partial
operation without undue vibration or cavitation. They should be designed to operate against the
maximum flow under the design head. The opening and closing forces shall prevail against the resisting
forces with a safety factor of 1.5.
In general, the loading shall be divided into 3 different classes according to the following typical
examples.
- Normal loading;
Loading due to dead loads
Hydrostatic loads, from vacuum to maximum
External pressure
Hydrodynamic loads, guaranteed pressure rise
Environmental loads with a return period of 50 years
Dynamic loads due to normal operation
Vibrational loads caused by flowing water or by ordinary operation
- Unusual loading;
Sediment loading
Unsymmetrical loading due to uneven frictional forces
- Extreme loading;
Earthquake loading
Loading due to maximum floods
Vacuum in steel linings
Loading due to transportation and erection
Emergency situations
The various loads shall for normal loading be combined if physically possible, and the most severe shall
determine the design conditions. At unusual and extreme loading, each unusual or extreme load case
shall be combined with the most severe normal loading. Unusual or extreme load cases need not be
combined.
Regarding power screws, the rods and nuts shall be made of high strength alloyed steel with minimum
possibility of corrosion and bronze respectively as well as the rods shall be checked against buckling
forces.
An impact factor 2 shall be applied to all connecting parts on the gate bodies and power drivers,
connections between segments (if any) as well as dogging devices. Moreover, the case of the design
shall be considered as normal case.
In the normal case, intake gate and maintenance gates/stoplogs for under sluice shall be kept in the
gates' parking (above the opening) by related which and power screw without the use of any mechanical
devices whereas the service gate for settling basin shall be closed.
Page 6 of 41
3.4 Structural Details

3.4.1 Gate Leaf
The gates shall be manufactured of welded steel sections consisting of horizontal beams and vertical
stiffeners that shall support a continuous watertight surface (skin plate). The thickness shall be
increased by 2 mm to allow for corrosion. The minimum skin plate thickness shall not be less than 12
mm.
The maximum admissible deflection of main girders shall not exceed 1/800 of the maximum distance
between supports. Butt weld joints shall be designed for a weld efficiency of 0.9.
3.4.2 Gate Seals
The gates shall be sealed along the sill by a square edge knife edge natural rubber elastomeric seal and
UHMW seals at the sides. Special precautions shall be taken to ensure the seals are adequately
restrained to prevent excessive displacement due to the water pressure. The seals shall also not-unduly
interfere with the operation of the gates. The bottom edge of the skin plate shall be machined to make a
near watertight contact with the sill beam.
Seals shall be in continuous lengths and all corners shall be separate moldings. Where joints are
necessary, these shall be oblique, rather than perpendicular, to the line of contact and a minimum of 300
mm from a corner. All joints shall be hot vulcanized or joined by an appropriate compound such that
these have a tensile strength of not less than 80% of the tensile strength of un-spliced material.
All seals shall be secured to the gate with stainless steel bolts, nuts and washer to facilitate their
replacement. Bolt spacing shall not exceed 100 mm. The seals shall be guarded so as to protect them
from possible damage due to timber of other objects becoming jammed between the seals and the fixed
parts.
When the gate is in the position, the seals compressing shall be at least 3 mm for side and top seals and
5 mm for bottom seal.
Holes for seal bolts in the gate leaf and seal clamp bars shall be drilled in the workshop.
After inspection, the seals shall be match-marked with the gate element and when the gate is prepared
for shipment, the seals shall be removed and packed separately.
Contractor shall not apply rubber cement to the joint in the shop but shall provide sufficient cement in
suitable airtight containers for application by others during Site assembly.
3.4.3 Sealing Surfaces

The face of sealing surfaces shall be made of stainless steel, and they shall be smooth, true to form and
free from twists, warps and kinks.
The gate shall be guided by the channels extending from the sill beam up to the gates parking position
in order to prevent the gate from vibrating during operation.
The rails/channels and sealing surface shall be supplied complete with anchor plates and bolts and other
accessories including the welding plates to be embedded in the first stage concrete. Stud bolts to be
welded to the welding pads during erection shall be provided with double nuts and washers for precise
Page 7 of 41
alignment of the rails. The welding plates shall be provided with two drilled holes to facilitate nailing to
formworks.
3.5 Anchor Rods and Plate

The Contractor shall supply all necessary anchor rods and plates to be embedded in the first stage
concrete.
The supply shall include all distribution plates having a thickness of not less than 15 mm.
The dimensions of the plates shall be such that stresses in the concrete will be less than 60 kg/cm 2.
3.6 Gates Position Indicators

A mechanical gate position indicator located beside the power driven shall be provided for gate. The
position indicator systems shall have all necessary devices and contacts to send signals to the local
control panel.
3.7 Ladders, Platforms, Handrails

Ladders, stairs and platforms shall be provided on the gates to enable easy inspection and maintenance.
All ladders shall be caged, or half-cages whenever possible and the platforms shall be provided with
handrails and handgrips.
As a minimum the following components shall be provided:
- handgrips and steps of both sides of the gate body over its whole height for inspection
and adjustment of the seals and guide rollers.
To protect the gates’ hoisting system from rains, direct heat from sun etc., the structural steel sheds with
colour CGI roofing shall be designed, fabricated, supply and erection as necessary or as proposed by the
bidder or as directed by the Employer/Employer’s Representative. The shed shall be made from steel
pipe trusses and posts. The main pipe post of the truss shall not be less than 60 mm in diameter and
properly anchor in concrete slab of hoisting deck. The other members of steel pipe truss also shall not
be less than 40 mm in diameter. The colour CGI sheet for roofing shall be of 22 gauge thick. The design
of the steel structural shed shall be subjected to be approved by the Employer/Employer’s
Representative.
3.8 Operating System

The hoist shall consist of steel base framework, mechanical equipment, i.e., torque shafts, bearings,
gear reducer units, couplings, screwed spindles, supporting brackets, manual operating device, position
indicator, etc., electrical equipment such as electric motor, limit switches, torque switches, electro-
magnetic brake, etc., and all other necessary components for safe, proper and efficient operation of the
hoist.
The forces resulting from the gate or stoplog being jammed against the guides, on a single side or on
both sides simultaneously, and the maximum hoist motor torque transferred to both lifting points or
entirely to one lifting point, as appropriate.
Effects of hoist brake shall be taken as 150% full operating motor torque.
If an accurate estimate of stalled motor torque is not available, take its value to be 275% rated motor
torque.
Design shall be based on the most adverse possible combination of forces acting on gates and stoplogs.
Page 8 of 41
(i) Overload conditions

All loads imposed during raising the gate due to the overload hoist or gate jammed condition.
(ii) Raising Condition
The gate shall be capable of overcoming the friction of wheels and seals when being raised under the
balanced and unbalanced water head condition.
(iii) Lowering Condition
The gate shall be capable of overcoming the friction of wheels and seals when being lowered to shut-off
full water flow to the water turbines under any water level up to design head for gate. In gravity closure
gates, the preponderance of the closing forces shall be provided with a safety margin of 20 percent for
the normal load case and 15 percent for the exceptional case.
The contractor shall be responsible for the design, fabrication, supply and erection of hoisting shed. The
hoisting shed shall consist of roof truss, purlin, CGI sheet, ladder and other steel structure
The under-sluice gate shall be operated by means of power-driven screws. Other service gates are
operated by manual screw spindle hoist
The diameter of the handle shall be approximate 600 millimeters and manual handling force shall be
less than 10-kilogram force per operator.
The handle shall be so installed that the handle center is located at the range of 600 to 800-millimeter-
high on the concrete deck. The handle shall be furnished with suitable locking device for locking the
handle while the handle is out of work
In the power-driven screws, the power of an electrical motor shall be transferred to main gearbox.
Main screw and nut located in the gearbox shall be made of alloy steel and bronze respectively. The
buckling of the screws shall be checked, and buckling safety 5 in the elastic range and 3 in the inelastic
range shall be considered.
Considering power screw middle supports (not more than 3 meter in distance), is mandatory.
The screw shall be connected to the gates by means of stainless-steel pin and nut. The gate shall be
operated separately through related screw.
An emergency hand wheel shall be designed for operating the gate in emergency condition.
3.9 Dogging Device

The dogging devices shall be designed to support and hold the gate in the gate guide slot.
3.10 Fasteners
All bolts for field assembly of structural joints and assemblies shall be ASTM A325M, and all other
bolts and studs shall be ASTM E449 except as otherwise specified herein.
All fasteners for field jointing shall be supplied 10 % in excess of actual requirements. Stainless steel
bolting shall have suitable anti-galling compound applied to the threads at times of installation.
3.11 Stainless Steel Plates

Stainless steel plate, bars, etc., shall be in accordance with ASTM specifications. The grade, ASTM
specifications number and chemical composition, shall meet the approval number and chemical
composition, shall meet the approval of the Engineer.
Page 9 of 41
3.12 Control
All gates (except under sluice) are operated manually from hoist deck.
The under sluice gates operation shall be local from the relevant local control panels installed adjacent
the gates.
The gate shall be equipped with open/closed limit and torque switches with contacts to send remote
signals to the Control Board.
The control of each gate shall be done by means of push buttons. The local control panels shall be
provided with the following controls:
- One "opening", one "stop" and one "closing" push buttons;

- One selector switch for "local", "remote" and "maintenance" operation (with lock and key);
Remote control will be:

When the selector switch is on "local", the controls in the control room shall be cutoff, when the switch
is on "remote", the controls in the control panel shall be cut-off and when the switch is on
"maintenance" both controls shall be cut-off.
In addition to one mechanical position indicator on the gate body, the gate shall also be equipped with
an opening degree indicator on the local control panel with transducer to send a remote signal to the
Control Board; the signal shall be continuous (4-20 mA) type.
3.13 Electrical Equipment
For the motors and all other devices, required AC supply shall be provided through local control panels
which shall be fed from the sub-distribution board installed in the gates platform.
The power and control panels shall comply with the requirements given in the General Technical
Specifications.
3.14 Maintenance
Design of the gates and operating systems shall make easy operation and maintenance.
The Contractor shall also provide all required accessories for gate disassembling and maintenance in the
site without using any devices supplied by others.
3.15 Tolerances
The dimensions’ tolerances of the gate shall be according to DIN EN 13920 and IS Code 4622:2003
ANNEX H. The possible parallelism error between lower and upper sides, as well as between side
edges, shall be fully compensated by the deformation of the rubber sealing. The sealing surfaces of the
side and top seals, when assembled on the finished gate element shall not depart from a true plane
surface by more than ±1 mm.
All points on the sill sealing face shall lie between two planes parallel to the horizontal plane at the
theoretical sill elevation with ±1 mm.
Page 10 of 41
3.16 Tests
3.16.1 Shop Tests
a) Mechanical Tests
Gate shall be shop assembled for inspection and test.
The assembly shall be checked and tested for dimensional accuracy, tolerance, operation and to control
that the requirements of these Specifications are met. Any error or omission discovered shall be
corrected.
Moveable elements shall be stroked through several operating cycles to assure smooth, non-binding
operation.
b) Tests on Welding
All main welds shall be ultrasonically tested. At least 20% of welds shall be radio graphically examined
according to the procedures indicated in the General Technical Specifications. In any case, all butt
welds of skin plates and T- Joints shall be 100% radio graphed.
Dye penetration tests on the sliding surfaces shall be carried out in workshop. No cross-joint welds shall
be allowed at all cases.
3.16.2 Site Tests

Before any mechanical test runs are made, a throughout inspection shall be made of all mechanical and
structural connections. The tests shall include but not necessarily is limited to those described below.
After being installed and completely wired, the gates shall be inspected and operated to check
clearances and accuracy of alignment and smoothness of operation.
All motions of the completely assembled gates shall be thoroughly observed for smooth and free
operation and from any mechanical interference, proper alignment of all running parts and freedom
from vibration. Electrical continuity of all circuits and servicing of all points requiring lubrication shall
be completely inspected.
Tests to be performed shall include but shall not be limited to:
- Verification of closing and opening speeds.

- Dry test
- Water leakage tests. The maximum admissible water leakage shall be less than 1 l/min per
meter of seal length.
- Operation of all controls and limit switches
3.17 Protective Coatings

Surface preparation and protective coatings shall be in accordance with protective Coatings as specified
in General Technical Specification.
3.18 Spare Parts and Special Tools

3.18.1 Spare Parts
The Contractor shall take care of the spare parts for all of the Gates during the entire Defect Liability
Period of the Project. Then-after, upon mutual understanding with the Employer, the Contractor will
provide the minimum amount of basic spares that will be required for a year period based on the
experience during the operation & maintenance period. All spare parts shall be interchangeable and of
Page 11 of 41
the same material and workmanship and shall meet the same requirements as of the corresponding
original parts.
3.18.2 Special Tools

The Supply shall include one complete set of special tools required for the erection and maintenance of
the gate. All special tools shall be permanently identified as to their specific use and shall be located in
a lockable portable metallic tool cabinet.
Eyebolts, lifting lugs, shackles, slings and any other special equipment required for handling during
shipment to site or during erection of the gate shall be furnished.
Page 12 of 41
4 MAINTENANCE GATES (Stoplogs)
4.1 General
This Section covers the Special Technical Specifications for the following Equipment and its
accessories, spare parts and special tools.
- One (1) set of stoplog complete with one (1) set of fixed part for the Under sluice
- One (1) set of stoplog complete with one (1) set of fixed part for the gravel flushing
- Two (2) sets of maintenance gate (stoplogs) complete with two (2) sets of fixed parts for the
settling basin flushing structure
Each gate shall be complete with seals, guide rollers, embedded parts, fittings, operation wheel etc.
4.2 Design Data

Under Sluice
- Type of gate Vertical lift gate
- Number of gate One (1) set
- Dimension of openings (w x h) 2.0 m x 4.0 m
- Sill elevation (m.a.s.l) 644.0
- Design Head (m) 8
- Hoist type (Operating system) Manual Screw Spindle
- Number of hoist One (1)
- Operation control Manual
Gravel Trap Flushing

- Number of
Gates (set) One (1)
- Elevation of
Design Head (m) 6.6
- Operating system Manual
Settling Basin Flushing

- Number of
Gates (set) Two (2)
- Elevation of
Design Head (m) 6.8
Page 13 of 41
- Operating system Manual

4.3 Design Criteria

The structures shall be designed in accordance with relevant IS standard or equivalent. All gates shall
be considered to be fully opened or fully closed or partially opened and capable of passing partial
operation without undue vibration or cavitation. They should be designed to operate against the
maximum flow under the design head. The opening and closing forces shall prevail against the resisting
forces with a safety factor of 1.5.
In general, the loading shall be divided into 3 different classes according to the following typical
examples.
- Normal loading;
Loading due to dead loads
Hydrostatic loads, from vacuum to maximum
External pressure
Hydrodynamic loads, guaranteed pressure rise
Environmental loads with a return period of 50 years
Dynamic loads due to normal operation
Vibrational loads caused by flowing water or by ordinary operation
- Unusual loading;
Sediment loading
Unsymmetrical loading due to uneven frictional forces
- Extreme loading;
Earthquake loading
Loading due to maximum floods
Vacuum in steel linings
Loading due to transportation and erection
Emergency situations
The various loads shall for normal loading be combined if physically possible, and the most severe shall
determine the design conditions. At unusual and extreme loading, each unusual or extreme load case
shall be combined with the most severe normal loading. Unusual or extreme load cases need not be
combined.
Regarding power screws, the rods and nuts shall be made of high strength alloyed steel with minimum
possibility of corrosion and bronze respectively as well as the rods shall be checked against buckling
forces.
An impact factor 2 shall be applied to all connecting parts on the gate bodies and power drivers,
connections between segments (if any) as well as dogging devices. Moreover, the case of the design
shall be considered as normal case.
In the normal case, intake gate and maintenance gates/stoplogs for under sluice shall be kept in the
gates' parking (above the opening) by related which and power screw without the use of any mechanical
devices whereas the service gate for settling basin shall be closed.
- Three (3) sets of gates as emergency gates for the intake;

- Four (4) sets of gates as maintenance and service flushing gates for the settling basin outlet;
Page 14 of 41

4.4.1 Gate Leaf
The gates shall be manufactured of welded steel sections consisting of horizontal beams and vertical
stiffeners that shall support a continuous watertight surface (skin plate). The thickness shall be
increased by 2 mm to allow for corrosion. The minimum skin plate thickness shall not be less than 12
mm.
The maximum admissible deflection of main girders shall not exceed 1/800 of the maximum distance
between supports. Butt weld joints shall be designed for a weld efficiency of 0.9.
4.4.2 Gate Seals
The gates shall be sealed along the sill by a square edge knife edge natural rubber elastomeric seal and
UHMW seals at the sides. Special precautions shall be taken to ensure the seals are adequately
restrained to prevent excessive displacement due to the water pressure. The seals shall also not-unduly
interfere with the operation of the gates. The bottom edge of the skin plate shall be machined to make a
near watertight contact with the sill beam.
Seals shall be in continuous lengths and all corners shall be separate moldings. Where joints are
necessary, these shall be oblique, rather than perpendicular, to the line of contact and a minimum of 300
mm from a corner. All joints shall be hot vulcanized or joined by an appropriate compound such that
these have a tensile strength of not less than 80% of the tensile strength of un-spliced material.
All seals shall be secured to the gate with stainless steel bolts, nuts and washer to facilitate their
replacement. Bolt spacing shall not exceed 100 mm. The seals shall be guarded so as to protect them
from possible damage due to timber of other objects becoming jammed between the seals and the fixed
parts.
When the gate is in the position, the seals compressing shall be at least 3 mm for side and top seals and
5 mm for bottom seal.
Holes for seal bolts in the gate leaf and seal clamp bars shall be drilled in the workshop.
After inspection, the seals shall be match-marked with the gate element and when the gate is prepared
for shipment, the seals shall be removed and packed separately.
Contractor shall not apply rubber cement to the joint in the shop but shall provide sufficient cement in
suitable airtight containers for application by others during Site assembly.
4.4.3 Sealing Surfaces

The face of sealing surfaces shall be made of stainless steel, and they shall be smooth, true to form and
free from twists, warps and kinks.
The gate shall be guided by the channels extending from the sill beam up to the gates parking position
in order to prevent the gate from vibrating during operation.
The rails/channels and sealing surface shall be supplied complete with anchor plates and bolts and other
accessories including the welding plates to be embedded in the first stage concrete. Stud bolts to be
welded to the welding pads during erection shall be provided with double nuts and washers for precise
alignment of the rails. The welding plates shall be provided with two drilled holes to facilitate nailing to
formworks.
Page 15 of 41
4.5 Anchor Rods and Plate

The Contractor shall supply all necessary anchor rods and plates to be embedded in the first stage
concrete.
The supply shall include all distribution plates having a thickness of not less than 15 mm.
The dimensions of the plates shall be such that stresses in the concrete will be less than 60 kg/cm 2.
4.6 Gates Position Indicators

A mechanical gate position indicator located beside the power driven shall be provided for gate. The
position indicator systems shall have all necessary devices and contacts to send signals to the local
control panel.
4.7 Ladders, Platforms, Handrails

Ladders, stairs and platforms shall be provided on the gates to enable easy inspection and maintenance.
All ladders shall be caged, or half-cages whenever possible and the platforms shall be provided with
handrails and handgrips.
As a minimum the following components shall be provided:
- handgrips and steps of both sides of the gate body over its whole height for inspection
and adjustment of the seals and guide rollers.
To protect the gates’ hoisting system from rains, direct heat from sun etc., the structural steel sheds with
colour CGI roofing shall be designed, fabricated, supply and erection as necessary or as proposed by the
bidder or as directed by the Employer/Employer’s Representative. The shed shall be made from steel
pipe trusses and posts. The main pipe post of the truss shall not be less than 60 mm in diameter and
properly anchor in concrete slab of hoisting deck. The other members of steel pipe truss also shall not
be less than 40 mm in diameter. The colour CGI sheet for roofing shall be of 18 gauge thick. The design
of the steel structural shed shall be subjected to be approved by the Employer/Employer’s
Representative.
4.8 Operating System

The hoist shall consist of steel base framework, mechanical equipment, i.e., torque shafts, bearings,
gear reducer units, couplings, screwed spindles, supporting brackets, manual operating device, position
indicator, etc., electrical equipment such as electric motor, limit switches, torque switches, electro-
magnetic brake, etc., and all other necessary components for safe, proper and efficient operation of the
hoist.
The forces resulting from the gate or stoplog being jammed against the guides, on a single side or on
both sides simultaneously, and the maximum hoist motor torque transferred to both lifting points or
entirely to one lifting point, as appropriate.
Effects of hoist brake shall be taken as 150% full operating motor torque.
If an accurate estimate of stalled motor torque is not available, take its value to be 275% rated motor
torque.
Design shall be based on the most adverse possible combination of forces acting on gates and stoplogs.
(i) Overload conditions
All loads imposed during raising the gate due to the overload hoist or gate jammed condition.
Page 16 of 41
(ii) Raising Condition

The gate shall be capable of overcoming the friction of wheels and seals when being raised under the
balanced and unbalanced water head condition.
(iii) Lowering Condition
The gate shall be capable of overcoming the friction of wheels and seals when being lowered to shut-off
full water flow to the water turbines under any water level up to design head for gate. In gravity closure
gates, the preponderance of the closing forces shall be provided with a safety margin of 20 percent for
the normal load case and 15 percent for the exceptional case.
The contractor shall be responsible for the design, fabrication, supply and erection of hoisting shed. The
hoisting shed shall consist of roof truss, purlin, CGI sheet, ladder and other steel structure
The under-sluice gate shall be operated by means of power-driven screws. Other service gates are
operated by manual screw spindle hoist
The diameter of the handle shall be approximate 600 millimeters and manual handling force shall be
less than 10 kilograms force per operator.
The handle shall be so installed that the handle center is located at the range of 600 to 800 millimeters
high on the concrete deck. The handle shall be furnished with suitable locking device for locking the
handle while the handle is out of work
In the power-driven screws, the power of an electrical motor shall be transferred to main gearbox.
Main screw and nut located in the gearbox shall be made of alloy steel and bronze respectively. The
buckling of the screws shall be checked, and buckling safety 5 in the elastic range and 3 in the inelastic
range shall be considered.
Considering power screw middle supports (not more than 3 meter in distance), is mandatory.
The screw shall be connected to the gates by means of stainless-steel pin and nut. The gate shall be
operated separately through related screw.
An emergency hand wheel shall be designed for operating the gate in emergency condition.
4.9 Dogging Device

The dogging devices shall be designed to support and hold the gate in the gate guide slot.
4.10 Fasteners
All bolts for field assembly of structural joints and assemblies shall be ASTM A325M, and all other
bolts and studs shall be ASTM E449 except as otherwise specified herein.
All fasteners for field jointing shall be supplied 10 % in excess of actual requirements. Stainless steel
bolting shall have suitable anti-galling compound applied to the threads at times of installation.
4.11 Stainless Steel Plates

Stainless steel plate, bars, etc., shall be in accordance with ASTM specifications. The grade, ASTM
specifications number and chemical composition, shall meet the approval number and chemical
composition, shall meet the approval of the Engineer.
4.12 Control
Page 17 of 41
All gates (except under sluice) are operated manually from hoist deck.
The under-sluice gates operation shall be local from the relevant local control panels installed adjacent
the gates.
The gate shall be equipped with open/closed limit and torque switches with contacts to send remote
signals to the Control Board.
The control of each gate shall be done by means of push buttons. The local control panels shall be
provided with the following controls:

- One selector switch for "local", "remote" and "maintenance" operation (with lock and key);
Remote control will be:

When the selector switch is on "local", the controls in the control room shall be cutoff, when the switch
is on "remote", the controls in the control panel shall be cut-off and when the switch is on
"maintenance" both controls shall be cut-off.
In addition to one mechanical position indicator on the gate body, the gate shall also be equipped with
an opening degree indicator on the local control panel with transducer to send a remote signal to the
Control Board; the signal shall be continuous (4-20 mA) type.
4.13 Electrical Equipment
For the motors and all other devices, required AC supply shall be provided through local control panels
which shall be fed from the sub-distribution board installed in the gates platform.
The power and control panels shall comply with the requirements given in the General Technical
Specifications.
4.14 Maintenance
Design of the gates and operating systems shall make easy operation and maintenance.
The Contractor shall also provide all required accessories for gate disassembling and maintenance in the
site without using any devices supplied by others.
4.15 Tolerances
The dimensions’ tolerances of the gate shall be according to DIN EN 13920 and IS Code 4622:2003
ANNEX H. The possible parallelism error between lower and upper sides, as well as between side
edges, shall be fully compensated by the deformation of the rubber sealing. The sealing surfaces of the
side and top seals, when assembled on the finished gate element shall not depart from a true plane
surface by more than ±1 mm.
All points on the sill sealing face shall lie between two planes parallel to the horizontal plane at the
theoretical sill elevation with ±1 mm.
Page 18 of 41
4.16 Tests
4.16.1 Shop Tests
a) Mechanical Tests
Gate shall be shop assembled for inspection and test.
The assembly shall be checked and tested for dimensional accuracy, tolerance, operation and to control
that the requirements of these Specifications are met. Any error or omission discovered shall be
corrected.
Moveable elements shall be stroked through several operating cycles to assure smooth, non-binding
operation.
b) Tests on Welding
All main welds shall be ultrasonically tested. At least 20% of welds shall be radio graphically examined
according to the procedures indicated in the General Technical Specifications. In any case, all butt
welds of skin plates and T- Joints shall be 100% radio graphed.
Dye penetration tests on the sliding surfaces shall be carried out in workshop. No cross-joint welds shall
be allowed at all cases.
4.16.2 Site Tests

Before any mechanical test runs are made, a throughout inspection shall be made of all mechanical and
structural connections. The tests shall include but not necessarily is limited to those described below.
After being installed and completely wired, the gates shall be inspected and operated to check
clearances and accuracy of alignment and smoothness of operation.
All motions of the completely assembled gates shall be thoroughly observed for smooth and free
operation and from any mechanical interference, proper alignment of all running parts and freedom
from vibration. Electrical continuity of all circuits and servicing of all points requiring lubrication shall
be completely inspected.
Tests to be performed shall include but shall not be limited to:
- Verification of closing and opening speeds.

- Dry test
- Water leakage tests. The maximum admissible water leakage shall be less than 1 l/min per
meter of seal length.
- Operation of all controls and limit switches

Surface preparation and protective coatings shall be in accordance with protective Coatings as specified
in General Technical Specification.

4.18.1 Spare Parts
Page 19 of 41
original parts.
4.18.2 Special Tools

The Supply shall include one complete set of special tools required for the erection and maintenance of
the gate. All special tools shall be permanently identified as to their specific use and shall be located in
a lockable portable metallic tool cabinet.
shipment to site or during erection of the gate shall be furnished.
Page 20 of 41
5 TRASHRACKS
5.1 General
This Section covers the Special Technical Specifications for the supply trashracks and related
accessories for the intake, approach culvert inlet and Headrace pipe inlet.
The trashracks will be installed to prevent debris, which could damage the downstream equipment.
5.2 Design Data

Intake Trashrack
- Trashrack type Fixed

- Number of orifice 2
- Number of trashrack 2
- Number of panel/trashrack 2
- Dimension of opening 2.4 m x 2.0m
- Elevation of sill 646.0
- Rack bar spacing 100 mm
- Differential pressure design 8.0 m
- Max. flow rate 7.51 m3/sec
Trashrack before Canal

- Number of canal 1
- Dimension of opening 4.4 m x 2.11 m
- Rack bar spacing (net) 50 mm
Trashrack before Headrace Pipe

- Number of waterways pipe 1
- Dimension of opening 3.18 m x 1.9 m
- Rack bar spacing (net) 30 mm
5.3 Design Criteria
The trashrack structures and bars shall be calculated in accordance with relevant IS standards and
Erbisti recommendations. The resulting thickness for bars shall be increased by 2 mm to allow for
corrosion. Minimum thickness of bar shall not be less than 12 mm including 2 mm for corrosion. The
trashracks shall be including equally spaced bars which installed parallel to the stream lines. The
Page 21 of 41
Trashrack shall be exempt from vibration during all operating conditions and shall be sufficiently sturdy
to limit as much as possible any deformation.
Each trashrack shall be completely fabricated and shipped ready for erection.
The structural designs of the trashracks shall be done for a 6 m head differential as a normal loading
case or as specified in the design data. The design of the trashracks shall take into account the
uniformly distributed load under which the max admissible deflection shall not exceed 1/600 of the max
distance between supports.
The trashracks vibrations shall be limited by adequate device of connections made of stainless steel and
checked in both directions, parallel with flow and perpendicular to flow. For each bar, the ratio of
inherent frequency to frequency of exciting force by Karman's vortex shall be at least 2.5.

The trash rack shall consist of the bar elements, supporting beams and all other necessary components.
The trash rack panels shall be fixed on the supporting beams using corrosion-resisting bolts, nuts and
washers.
5.4.1 Trashrack Bars
The trashrack shall be of welded structure consisting of a series of equally spaced vertical bars, top and
sill beams, fastening bolts, spacer pipes. All bar elements shall be rigidly fixed on the supporting beams
to prevent vibration.
The allowable stress of the bars shall be determined from the following formula for the lateral buckling
check:
σall = 0.6 σy x (1.23 - 0.0153L/ t)

Where
σall = Allowable Stress
σy = Yield stress of material
L = Horizontal supporting space
t = Thickness of the bar
5.4.2 Panels and Frames

The panels of trashrack shall be fixed firmly on the supporting beams and fitted with stainless steel
bolts, nuts and washers. The upper and lower horizontal beams must be equipped with necessary
anchors and adjusting devices for an accurate alignment and steady fixing during concreting work.
5.4.3 Manual Racker

The width and tooth size of manual racker shall be designed by the contractor. The length shall reach
the lowest point and the teeth shall be designed as per the spacing of bar and lateral support. The racker
shall be simple and light weight.
5.4.4 Embedded Parts

The trashracks embedded parts shall consist of beams, base plates and anchoring system for embedment
in secondary concrete.
The structural members of the embedded parts shall transmit loads from the trashrack to the concrete
such that maximum stress in the concrete shall be less than 6 MPa. Connection between frame and
embedded parts shall be of zinc plated structural bolts, nuts and washers.
Page 22 of 41
5.5 Workshop and Site Tests

Tests shall be made to verify that the materials used comply with the Standards or with the provisions
of the General Technical Specifications.
Each panel shall be shop assembled and its dimensions checked at workshop and after the erection at
Site.

Surface preparation and protective coatings shall be in accordance with Section 4.4 of General
Technical Specification.

5.7.1 Spare Parts
original parts.
5.7.2 Special Tools

The Contractor shall supply one complete set of special tools required for the erection and maintenance
of the trashracks. All special tools shall be permanently identified as to their specific use and shall be
located in a lockable portable metallic tool cabinet.
shipment to Site or during erection of the trashrack shall be furnished.
Page 23 of 41
6 HEADRACE PIPE & PENSTOCK
6.1 General
The headrace and penstock pipe according to its hydraulic function and definition includes the whole
water conduit from head pond to the turbine inlet valves at various locations as described in Ch 6.1.3.
The penstock may mean headrace (low pressure pipe as shown in the drawings) and penstock pipes
(high pressure pipe as shown in the drawings) wherever applicable.
6.1.1 Scope and Limits of Supply

The scope of supply includes the design, manufacturing, transport, installation, anticorrosive treatment
and commissioning of the following components:
- The low pressure steel headrace pipes with accessories as shown in the drawings.
- The steel penstock pipes up to extension piece of turbine inlet valves including bifurcation and both
branch pipes.
The low pressure headrace pipe shall be complete with straight pipes, bent or curved pipes, anchor
rings, thrust rings, stiffeners, anchor bars, wear plate, saddle plate, dismantling flanges with manholes,
air-relief valve with pipe, flushing valve with pipe, expansion joints and all other necessary
components. The penstock shall be complete with straight pipes, bell-mouth, bent or curved pipes,
reducing pipes, bifurcation, anchor rings, thrust rings, stiffeners, anchor bars, expansion joint, manhole,
wear plate, saddle plate and all other necessary components including connection to the adjacent
components. The scope of supply shall also include all fastenings, fixtures, holding-down arrangements,
support structures, construction of steel foundations for all erection and welding equipment, injection
facilities and stiffeners, required for transport and erection.
The Contractor shall also provide the lifting tackles, cranes, and winches required for transport and
offloading, as well as all transport vehicles for transportation from fabricating plant to the place of
installation.
The Contractor's services shall also include all controls and material tests with supply of the respective
certificates, ultrasonic and radiographic tests of the welds, including the provision of all equipment
required for these tests.
The limits of supply are as follows:

To Lot 2 - Civil Contractor
- All excavation works, anchor and saddle support civil works, backfilling, concrete work including
contact grouting (if required) is included in Civil Lot but alignment, anchoring, welding and
anticorrosive protection is part of Hydro-mechanical (HM) Contractor.
- All equipment necessary for transport, fabrication and erection of the penstock and steel headrace
pipe components has to be provided and maintained by the HM Contractor.
To Lot 4 - EM Contractor
- At both branches of the bifurcated penstock, the finished and drilled connection flanges on the
penstock for the turbine inlet valves (of diameter 1.0 m) and for each individual bypass and drain pipe
(internal diameter 100 mm) have to be provided by the HM Contractor according to the dimensions
given by and agreed with the EM Contractor. After the connection flanges in the penstock branches,
all other connection pipes, valves, bolts and seals are included and to be provided by the EM
Contractor.
Page 24 of 41
6.1.2 General Arrangement

The general arrangement of the headrace pipe, penstock, bifurcation and other details are shown in
drawings Nos LJKHP-HW-C001 to LJKHP-HW-C067.
6.1.3 Main Dimensions

The main dimensions are as follows:
Headrace Pipe
- Inside diameter of headrace pipe 1.8 m
- Length of headrace pipe 2900.5 m
Surge Pipe
-Inside diameter of surge pipe 3.0 m
-Length of surge pipe 55.2 m
Penstock
- Inside diameter of penstock up to bifurcation 1.65 m
- Inside diameter of branch pipe up to turbine inlet valves 1.0 m
- Length of penstock up to bifurcation approximately 443 m
*Note: Length of penstock pipe and the Headrace Pipe may be extended/reduced upon finalization of
location of surge shaft/pipe. This length of pipe will be subject to changes. Likewise, sand/rocktrap
will also be located and length of pipe from the sand/rock trap will be varied accordingly.
6.1.4 Operating Conditions
6.1.4.1 Pressure
Depending on the different headwater levels in the head pond, the pressure losses in the waterways, the
internal pressure acting in the headrace pipe at different locations will vary.
Full supply level at head pond : El. 652.0 masl
Depending on the different headwater levels in the head pond, the pressure losses in the waterways, and
load variations of the generating units, the internal pressure acting in the penstock at different locations
will vary.
Highest upsurge level in the surge tank/pipe : El. 642.1 masl

Design Pressure Rise : 35% of static head
Upsurge and downsurge level in the surge tank/pipe subject to vary according to final location of the
surge tank/pipe.
Discharge
- Rated discharge of the power plant : 5.78 m³/s
6.1.5 Design Criteria

The headrace and penstock shall be designed considering the worst possible combination of the
following loading conditions:
- All static and dynamic hydraulic loads due to design water head.
- All loads due to dead weight and friction forces.
- Seismic, temperature, wind loads, and
- Other loads
Page 25 of 41
The Contractor shall design the headrace, penstock and bifurcation to resist both internal and external
pressures as defined below.
Unless otherwise specified, designs and calculations shall be carried out in accordance with the
"Recommendations for the Design, Manufacture and Erection of Steel Penstocks of welded
Construction for Hydro-Electric installations" issued by the European Committee for Boiler making and
kindred steel structures (CECT - Recommendations), and this Specification which shall prevail in case
of discrepancies unless otherwise directed by the Employer’s Representative.
The mechanical properties of the weld material and the welded joint shall be equal or better than those
of the base material in order to achieve better weld efficiency.
The low pressure headrace pipe and high pressure penstocks shall be designed, taking no account of any
rock support, for the following cases:
6.1.5.1 Internal Pressure

The internal pressure shall be of the sum of the static head and the surge water level.
6.1.5.2 External Pressure

Safety factor against buckling with external water or grouting pressure on the empty penstock and shall
be 1.5.
The penstock shall be capable of resisting the external pressure of 0.5 bar at the time of dewatering.
6.1.5.3 Other Loads

Seismic Loads
The forces being caused by earth movements including hydraulic stresses that may occur shall be taken
into account for the computations of the headrace and penstock at the highest possible water level.
Moreover, vertical and horizontal acceleration shall be combined in the most unfavorable position.
Design accelerations of 0.23 g horizontal and 0.115 g vertical for solid structures on rock.
Axial Forces
The headrace and penstock pipe shall be capable to resist the axial forces as follows.
- All forces resulting from the unbalanced water-loads.
- Bending stress due to continuous beam of the headrace/penstock.
- Bending stress due to restraining the pipe shell expansion by ring girder supports.
- Stress due to axial component by internal pressure at the reducing pipes, and the main inlet valves.
- Stress due to the thrust rings.
- Stress due to centrifugal force and unbalanced force at the bend pipes.
- Stress due to temperature variation of the headrace pipe and penstock.
- Stress due to Poisson's effect.
- Stress caused during hydrostatic test at Site.
Circular Bending Stress

Exposed portions of the headrace and penstock shall be capable of resisting the circular bending stress
imposed in the penstock shell during water operation in the penstock.
Loads due to Handling

The penstock and headrace pipe shall be capable to resist the loads due to handling during fabrication,
transportation and field erection.
Loads due to Concreting
Page 26 of 41
When erection, welding and other inspections of the headrace pipe and penstock pipes have been
completed in accordance with these specifications, the required sections of headrace pipe and penstock
pipes will be encased by concrete by the Lot Civil Contractor.
The Contractor of Hydro-mechanical Works shall supply and install sufficient interior bracings in
addition to that required for welding to maintain the roundness within the specified tolerances until the
encasement is completed in the required section. The Contractor shall supply and install sufficient
exterior bracings and anchor bands and bars to resist the loading due to the placing of concrete and or
backfilling by excavated materials. Particular care shall be given.
6.1.6 Materials
All steel for headrace, penstock and surge pipe shall be fine grained, fully normalized and stress
relieved, not subject to brittle fracture, non-ageing, and highly wieldable. The steel properties shall be
equivalent to or better than IS2062 E250 Br.
For subordinate structures and for small quantities, steels shall be ST-37-2 according to DIN 17100 or
Equivalent.
Stainless steel shall be in accordance with DIN 17 440 or equivalent.
Steel material of other standards than those specified above shall be equivalent. However, prior
approval of the Employer/Employer’s Representative shall be obtained.
Allowable stresses in the steel shall be one third of minimum tensile stress or half of yield stress
whichever is less.
6.1.7 Testing of Materials

The steel plate materials will be supported with certified copies of Mills Test Reports issued by the
manufacturer for conformity on the material grade and sizes.
Each plate shall have the respective marks of Customer Name, Grade, Heat/ Plate No., Size in mm,
Quality, etc. Every certificates will have the similar information of plates such as Heat/ Plate No., Size
in mm, steel quality, rolling mill and signature of quality control expert.
6.1.7.1 Electrode Tests

The adequacy of the selected electrodes and welding powder (in the case of automatic shop welding)
for the various qualities of the selected steel shall be proven by ample welding tests prior to shop
manufacture. The mechanical properties to be obtained in the weld seam and transition zone shall be at
least equal to that of the plate material.
Automatic welding processes in the shop will be permitted provided they produce a weld of the
specified quality. In addition to the above-specified tests, the quality of electrodes shall be tested
periodically during welding operations.
6.1.7.2 Ultrasonic Tests

All butt-welding seams shall be 100 % ultrasonic tested. The range of tests shall be carried out
according to the German Standard, AD-instruction sheet HP 5/3 testing class B or equivalent Standard.
The results of the ultrasonic tests shall be recorded.
6.1.7.3 X-Ray Tests

Forty (40) % of all longitudinal butt welds that are carried out at the workshop or on the site or directly
in the erection location and every butt weld of prefabricated parts shall be x-rayed.
Page 27 of 41
Ten (10) % of all circumferential butt welds shall be x-ray tested. Should any defect be found, the
welding seam shall be one hundred (100) % x-ray tested. The quality of radiographic pictures shall
comply with DIN 54 109 and DIN 54 111.
Objectionable defects discovered in welds shall be prepared in accordance with the following
procedures:
(a) A weld line length in 30 cm to both sides from the defect portion shall be radio graphed to
examine whether there are objectionable defects therein or not.
(b) If there is any defect found therein, all weld lines of the concerned joint shall be radiographed
and defective welds discovered shall be repaired accordingly.
(c) If there is no defect found therein, the defective portion only shall be repaired.
(d) Objectionable defects in welds shall be chipped or flame or arc-gouged to show sound metal
and the defects re-welded. Welds that have been repaired shall be 100% radiographed again.
The Contractor shall furnish all equipment, films and labor necessary to perform the radiographic tests.
All original films of the radiographs shall become the property of the Employer. The Contractor shall
provide proper storage for its radiographs and shall store and preserve all radiographs of welding,
whether the welding is accepted or rejected.
All radiographs shall be identified and identification drawings shall be prepared.
6.1.8 Manufacturing
6.1.8.1 General
The steel materials to be used for the steel conduits, pipes, penstocks, bifurcations, linings and other
components of this contract shall be clearly marked for easy identification.
If the Contractor proposes to deliver any material to the Site and partly or fully fabricate components in
a site fabrication shop before moving into final position, such site fabrication shop complete with all
equipment, lighting, heating, power, staffing, etc., shall be provided by the Contractor. Approval by the
Employer’s Representative for these proposals shall be provided before the work is commenced. The
Contractor shall be solely responsible for the whole of the temporary work, machinery and appliances,
even though these may have been approved by the Employer’s Representative.
All weld joints shall be dressed smooth and the maximum reinforcement shall be limited to the required
tolerances on the inside of the headrace pipe and penstock pipes. On the outside of the headrace pipe,
bifurcation and penstock, welds shall be (where possible) dressed free of all fluxes and scale and
smooth finished to the extent necessary to allow radiographic and/or ultrasonic examination.
6.1.8.2 Cutting and Bending

All plates shall be cut accurately to the dimensions shown on the Contractor’s approved drawings, with
allowance provided for possible shrinkage during welding. All edges shall be inspected for sound metal
and be free from laminations, surface cracks and other injurious defects. Cylindrical shells may be
rolled or bent to true curved sections, continuous to the edges, by any process that does not impair the
strength of the plates and with continuous curvature between the edges. Correction of curvature by
hammering shall not be permitted. For butt welding of plates of unequal thickness, the work of
trimming of the thicker plate shall be done in the Contractor's shop as to have a taper of 1:4, if the
difference between plate thicknesses is more than 3.0 mm.
The orientation of the place for fabrication shall be such that the final direction of rolling is placed
circumferentially. No stamping or groove marking on the steel "T" other than indications for cutting
lines for fabrication purpose shall be allowed.
Page 28 of 41
Bending of plates shall be performed by cold working as a rule. If bending is to be made by hot
working, the Contractor shall obtain the prior approval of the Employer’s Representative of the
temperature control procedures.
6.1.8.3 Shop Welds
The requirements for welding following shall govern:
(a) Cleaning before welding

The surfaces of plates to be welded shall be cleaned of all scale, rust, oil, paraffin or grease, or other
deleterious materials, for a distance of not less than 30 mm from the welding edge. Welding grooves
shall similarly be cleaned.
(b) Core wires, fluxes and welding rods

The material composition of core wires, fluxes and welding rods shall be optimally suitable for the base
metals and shall be kept in dry conditions, as recommended by the manufacturer. Welding rods
withdrawn from the oven and not used immediately after two hours shall be rebuked. Rebuking is
allowed only for a limited period of time, or cycles, in accordance with the manufacturer’s
recommendations. Storage of flux overnight in supply lines and hoppers of welding machines, re-use of
fused flux, mixing of fluxes or batches of fluxes shall not be permitted. The Contractor shall obtain the
approval of the Employer’s Representative for all welding materials and procedures, incorporating the
kind, characteristics, weld ability and control procedures into a formal welding procedure, to be
submitted to the Employer’s Representative for approval.
(c) Back Chipping

Back chipping for weld joint shall be performed by arc air gouging. Dye penetrate or magnetic flux
inspection shall be applied to check cracks in welding joints after gouging, if requested by the
Employer’s Representative.
(d) Tack Welding

Tack welding on the pipe shells shall be avoided whenever possible. If tack welding is made, the
welding portion shall be preheated prior to tack welding to more than 100°C for a distance of not less
than 50 mm from the welding line to reduce the residual stress. Each tack weld shall be done in two
passes.
(e) Preheating
When preheating is part of an approved welding procedure, weld joints shall be preheated in accordance
with the kind of steel material and plate thickness. Maximum inter-pass temperature of preheating shall
be 200°C and preheating area shall be over a distance of more than four times of plate thickness for
each side from the welding joints. If welding work is made under the condition of ambient temperature
less than 5°C, steel materials on weld joints shall also be preheated even though application of
preheating is not required due to the kind and thickness of the steel materials under normal welding
condition. The relations between the carbon equivalent and the preheating temperature in cases of
manual welding shall be as follows:
Pre-Heating Temperature for Low Hydrogen
Carbon Equivalent (Ceq) % Plate Thickness(mm)
Welding Rods (°C)
0 - 0.28 0- 100
0.28 - 0.38 0- 25
0.28 - 0.38 25-100 40-60
0.38 - 0.48 0- 25 40-60
0.38 -0.48 25-100 80-100
more than 0.48 0- 100 100-150
Page 29 of 41
Note: Ceq (%) = C+1/6 Mn + 1/24 Si + 1/40 Ni + 1/5 Cr + 1/4 Mo + 1/14 V and Cu, P, etc., could be
added as necessary.
(f) Thrust Rings, Seepage Rings and Stiffener Rings

Thrust rings, seepage rings and stiffener rings shall be welded on the pipe shells at the Contractor's
workshop, and shall be made of the same plate material as the shell proper.
(g) Lugs, Saddles or Brackets

All lugs, saddles or brackets which are welded to the steel conduits and which are to form part of the
permanent or temporary support shall be made of the same plate material as the steel conduits and the
welding shall meet with all the requirements as set out herein.
6.1.8.4 Thermal Stress Relieving

The post weld heat treatment shall conform to the requirements specified by the steel manufacturer.
For the bifurcation and tubes with different grades of steels and/or different thickness heat treatment of
welded joints shall be carried out.
6.1.8.5 Shop Corrosion Protective Treatment

The extent of corrosion protective treatment to be done in the shop shall be determined and agreed with
the Employer’s Representative considering the general installation procedure and time schedule.
6.1.9 Tolerances
All tolerances shall be indicated on the Contractor's drawings.
The dimensions, especially clearances and fits, (ISO-Recommendation R 286) which are essential for
proper function of work shall be carefully checked in an approved manner.
The Contractor shall be responsible for ensuring that all equipment complies with the specified
tolerance requirements on completion of installation and under the full range of design operating
conditions.
Allowable tolerances which differ in part from CECT recommendations are listed below:
- External circumference deviation from the theoretical  0.1%.
- Deviation "c" from the circular form measured with a circular gauge having a length of r/2.c
= (r/1000) + (20/s) + 0.5
- Ovality: d/2d = 0.0025 * (dmax – dmin)/(dmax + dmin)
(dmax and dmin shall be measured at the same cross section)
- Lengths of the steel pipe  5 mm
- Deviation (U) from a straight line over length of tube "e"U< 2e/1000
- Displacement (Vz) of plates at longitudinal seams
Vz< (s/50) + 1
- Displacement (Vr) of plates at circular seams
Vr< (s/50) + 2 + s/2
All measurements shall be in mm.

The symbols represent: (in mm)
d = internal diameter of the tubes,
r = internal radius of the tubes,
s = thickness of the plates,
s = difference in thickness of two adjoining plates,
e = length of a tube.
Page 30 of 41
6.1.10 Installation
The installation work shall include the erection, field welding, painting and inspection of the penstock
and headrace pipe sections in accordance with the final approved drawings and erection manual. The
Contractor shall carefully proceed with the installation in accordance with the schedule and instructions
from the Employer’s Representative, since the installation of the penstock/headrace pipe is required to
keep pace with the progress of other related works. Prior to installation, the Contractor shall prepare a
work plan for the order, method and schedule of installation with careful coordination with the other
Contractors, and shall obtain the approval of the Employer’s Representative for the work plan.
6.1.10.1Erection Equipment
The equipment required for installation shall include, but not be limited to the following:
- Suitable lifting and handling equipment provided in the site storage areas and at the point of
installation of the equipment,
- A winch or winches complete with controls, cable and guide pulleys etc., for lowering and
positioning of equipment,
- Electrical connectors and cables for connection to the temporary power supply,
- Welding equipment, including transformers and other accessories such as dark glasses,
gloves, etc.
- Furnaces and drying ovens for drying the electrodes,
- Grinding and cutting tools.
- X-ray and ultrasonic testing equipment,
- Field telephone if required,
- Temporary lighting where necessary,
- Vehicles for personnel.
6.1.10.2Handling and Placing

The penstock and bifurcation when erected shall be true to line and level and to the required degree of
accuracy as stated in the specifications. Handling of the sections shall be reduced to a minimum.
In order to maintain the accuracy of roundness of the conduit sections within the tolerance specified,
internal spiders or other suitable devices shall be provided in the sections immediately upon completion
of fabrication to prevent any deformation that may take place during transportation, installation,
concrete placing and contact grouting, etc.
6.1.10.3Field Welding
Welding at the installation site shall be performed manually, in accordance with the requirements of
Clause 4.1.8.3 and according to the method as specified herein. All site joints shall be inspected and
approved by the Employer’s Representative before the joint is made. If a gap is found to exist which
would prejudice the effectiveness of the weld, the edges of the plate shall be corrected before the joint is
made. Each joint shall be completed as soon as possible after the Employer’s Representative has given
his approval.
Matching of field welding girth joints shall be carried out with spiders and pad plates or tack weld jigs.
In no case, steel conduit sections shall be forcibly jointed. During the welding operations, the centers
and distances between edge preparations shall be maintained at their proper positions.
All weld joints shall be dressed smooth and the inside surface welds shall be dressed flush. On the
outside of the steel conduits welds shall be dressed free of all flux and scale and smooth to the extent
necessary to allow radiographic examination.
After field welding, ultrasonic or radiographic examination of all in situ welds shall be carried out as
specified and any defects found repaired as outlined in Clause 6.1.7.
Page 31 of 41
6.1.10.4Cleaning after Welding

When the headrace pipe, surge pipe, penstock and bifurcations are completely erected and when ready
for concreting, there shall be no lugs, cover, plates, saddles or other device welded to the pipe shell
except where these form part of the permanent support of the steel conduits for concreting. All
temporary lugs and devices welded to the outside of the pipe shell shall be carefully removed by the
Contractor and welds dressed smooth and flush with the surrounding metal. After concreting and or
backfilling are completed, all internal bracings and devices welded to the inside of the steel conduits
shall be similarly removed and the inside dressed smooth and flush.
6.1.10.5Painting
The headrace pipe, surge pipe, penstock and bifurcation shall be painted after erection and testing of the
welding seams. Those surfaces against which concrete will be placed shall be thoroughly clean and free
of all rust, mill-scale, oil, paint or other loose or deleterious matter. The Contractor shall take any steps
necessary to ensure that no significant rusting or pitting of these surfaces occurs during transport,
storage and erection.
At the transition zone between concrete and steel linings all steel surfaces in contact with concrete shall
be carefully sandblasted and coated with two layers of zinc-rich primer at least up to 20 cm distance
from the borderline concrete-steel-air.
6.1.11 Submittals
The Contractor shall submit manufacturing and fabrication materials’ list, product data and shop
drawings, and installation procedures for the following:
- Structural and pressure vessel steel, each type.
- High-strength bolts, each type, including nuts and washers.
- Temporary supports and concrete embedment.
- Protective Coatings, including primers for factory and field application, surface preparation
materials and methods, and coating procedures.
- Manufacturing and erection procedures including weld joint locations and field make-up joint
locations. Fabrication drawings not showing all weld joint locations; longitudinal and
circumferential, joints on bends, grouting plugs etc. will be rejected.
- Applicable non-destructive testing procedures proposed.
- Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), Record of
Welding Operator Qualification Tests, and material control program, including electrode
control.
For each steel tube and for the bifurcation the Contractor shall provide the following information:
- Number of plates used for the tube.
- Records relating to tests performed on plates and on the completed tube.
- Theoretical weight of the complete tube or bifurcation in total.
- Measured dimensions including plate thickness, tube length and circumference.
- Four perpendicular diameters, one of which is measured through the longitudinal weld,
deviations from roundness template.
- Radiographs.
- Results of ultrasonic tests.
- Results of water pressure tests, if any.
- Thermal treatments.
- Special remarks.
- Number and dates of the relevant reports.
Each certificate shall show in sketch form the sequence of the welds, the position of the radiographs,
repair locations, etc.
Page 32 of 41
6.2 Headrace Pipe and Penstock

A 1.8m diameter headrace pipe starts just after the head pond. It has been designed on the basis of
minimum revenue loss from head loss due to friction and other minor losses and minimum cost of the
pipe including excavation, construction and annual maintenance of pipe. Thickness has been designed
by taking extra surge head as 35% of the gross head due to water hammer. The thickness of pipe varies
from 8mm to 10mm. Total length of headrace pipe is 2900.5m.
The dimensions of the anchor blocks of reinforced concrete shown in the drawings for the horizontal
and vertical bends and support piers shall be understood as reference only and shall be determined by
the Contractor for the definite design.
An inclined pressure pipe has been provided at the end of headrace pipe to accommodate the surge
within the pipe. Extreme values of surge level have been calculated by running hytran transient analysis
software. Time of valve closure and opening has been taken as 10sec. Similarly, the time of valve
opening has also been taken as 10sec. Diameter of pipe has been taken as 3m.
Penstock pipe is used to convey the water from headrace pipe to the turbines. It is a surface steel
structure just after the headrace pipe. Considering same assumptions as in the headrace pipe, the
optimised diameter of penstock pipe is 1.8m but the thickness varies from 8mm to 16mm. Total length
of the penstock pipe is 430m.
6.3 Bifurcation
Both bifurcation branches 1.0 m diameter shall be provided by the Contractor at the ends with:
- Finished connection flanges according to the dimensions required for connection of the turbine inlet
valves. From the flange on the bifurcation branches, the E/M Contractor will supply the connection
bolts and seals.
- Two flanged connections with an inside diameter of 100 mm for connecting the bypass and drain
pipe. The adjoining flanges, pipe work, connection valves, bolts and seals from these flanges will be
supplied by the EM Contractor.
The design of the bifurcation shall ensure minimum hydraulic losses and exclude any oscillation of
pressure or flow downstream of the bifurcation, which may have an incidence on the operation of the
turbines. The Contractor shall submit drawings showing the proposed design of the bifurcation in detail.
The reinforcement rib of the bifurcation shall be arranged internally. No external reinforcement of the
bifurcation will be permitted.
Information about the results of hydraulic tests, head loss coefficient, etc. shall be attached.
6.4 Bends
Bends are fabricated from mitered sections of pipe. The mitered pipe sections must be joined by full
penetration, single or double welded butt joints.
The radius of bends must be between 3-5 times pipe diameters. The maximum deflection angle of the
mitered segment must be between 5-10 degrees.
6.5 Butt Straps

Butt straps shall be provided for the penstock/headrace pipes to facilitate field welding of the
circumferential joints. Each complete butt strap should be arranged in two halves, the bottom half being
welded in the shop to the erection section to be erected first, the other half of the butt strap being
welded in the shop to the following erection section. This arrangement facilitates placing the adjoining
erection sections at site as it would not be necessary to enter a spigot into a socket. When adjoining
sections are in their final positions the butt straps should fit closely to the adjoining shell thereby
enabling a satisfactory welded joint to be obtained.
Page 33 of 41
6.6 Stiffener Rings

The stiffener rings shall be attached to the penstock pipe perpendicular to the direction of the penstock
pipe axis and to pipe shell by continuous welding.
6.7 Thrust Rings

Thrust rings shall be welded to the headrace pipe and penstock where necessary and shall have the
strength sufficient for transferring axial thrust to surrounding concrete. The height of the rings shall be
less than 250 mm.
The axial thrust forces due to the unbalanced water-loads and due to closure of main valves shall be
transmitted to the penstock, for which the thrust rings shall be provided. The exact location and design
of thrust rings shall be coordinated with the design of the civil works.
6.8 Seepage Rings

The penstock shall be provided with three parallel seepage rings at the beginning portion of it. The
upstream ring shall be attached at the upstream end of the penstock.
6.9 Manhole and Flanges

A circular type Manhole of 650 mm diameter in size shall be provided for the headrace and penstock.
The manhole shall be made of steel plate with a rubber packing and other necessary components. The
manhole shall be furnished with suitable chain to protect falling down of the manhole cover when the
manhole is opened or may be hinged. Manholes shall be fitted within 1.5m long flanges as shown in the
Drawings, except at the Headrace pipe outlet and penstock where flange is not provisioned. Flanges
shall be complete with flange plates, bolts, seals all complete.
6.10 Transition Piece

Transition Pipe, 1.8 m x 2.0 m Rectangular to 1.8 m circular and its accessories, shall be provided at the
starting of the headrace pipe. Rectangular entrance to circular exit transition shall be provided at the
starting of steel Headrace Pipe. The Transition Pipe shall be made of steel plate and other necessary
components.
6.11 Saddle and Wear Plates
Saddle Plate and Wear Plate at saddle supports and penstock holding down rings at saddle shall be
provided as per the instruction of the Engineer. Also, HDPE sheet shall be inserted in between saddle
and wear plate. The steel rod support shall be provided at bends to anchor the penstock against thrust.
Such supports shall be placed by the contractor and confirm line and level as provided in alignment
sheet before installation of the plates. The materials for the base plates shall be IS 2062 E250 BR or
equivalent national & international standards.
6.12 Expansion Joints
The suitable expansion joints shall be designed and fabricated to absorb the thermal stresses due to
temperature difference in penstock. The expansion joints shall be designed to withstand the pressure as
described in Clause 6.1.4. The expansion joints shall be designed to 100% water tight.
6.13 Air release and anti-vacuum valve
Air release valve shall be, having intake cross sectional area not less than 300 mm, PN 6 double acting
type with epoxy coated ductile cast iron (or similar) body and stainless steel internal parts with
protected cage.
Page 34 of 41
6.14 Shut-off valve

Shut-off valve shall be, having intake cross sectional area not less than 300 mm, PN 6 double flanged
manually operated type of ductile iron body (or similar) and totally rubber lined gate.
6.15 Flushing valve and pipes

Flushing valve (for the headrace pipe and at sand/rocktrap) shall be 100 mm dia with operating platform
as shown in the Drawings. It shall include the valve and flanges to be connected to the pipes at the
adjacent of it. Flushing outlet shall be at the lowest part of the headrace pipe. Flushing pipe shall be of
stainless steel of 100 mm dia and 6mm thickness with all bends, connections, accessories all complete.
Flushing pipe for sand/rocktrap shall be mild steel of grade similar to the penstock pipe. Flushing Valve
house, trench excavation and backfilling shall be designed and constructed by the Contractor, the price
of which is included in the cost.
6.16 Protection against Corrosion

Steel headrace pipe, surge shaft/pipe, Steel penstock pipes both surface and buried should be protected
against corrosion by coatings appropriate to the exposure and particular location where the paints are to
be applied. The quality of such paints and materials shall be subject to the Employer’s Representative’s
approval. The guarantee period for the applied protection coats shall be 5 (five) years. Surface
preparation shall be zinc rich primer of epoxy or polyurethane base. Dry film thickness of both coats
shall be not less than 120 µm.
In total four coats shall be applied with a total dry film thickness of not less than 290 µm.
Surfaces to be covered by compressible wrapping shall be treated for application of the compressible
wrapping as required by the manufacturer of the wrapping material.
6.17 Spare Parts

The Contractor shall take care of the spare parts during the entire Defect Liability Period of the Project.
Then-after, upon mutual understanding with the Employer, the Contractor will provide the minimum
amount of basic spares that will be required for a year period based on the experience during the
operation & maintenance period.
6.18 Shop Assembly and Tests

6.18.1 Shop Assembly
Each part of the penstock, headrace pipe and bifurcation shall be completely pre-assembled in the shop
in the approximate position that they shall have after installation at site. While assembled each part
shall be checked for dimensions, tolerances and accuracy of alignment. Any error or misalignment
discovered shall be promptly corrected. Parts shall be clearly match marked before disassembly for
transportation.
All major parts shall be inspected by the Employer’s Representative for welding and surface
imperfections such as undercut welds, stamps, clamp or chisel marks, surface pitting in the plate and
other similar surface irregularities. Faulty material and workmanship shall be made good by the
Contractor to the Employer’s entire satisfaction. Material which shows defects subsequent to erection
will be rejected and the Contractor notified.
6.18.2 Records
The Contractor shall submit full information about the quality control system for fabrication including
data report forms and records of welders, welding tests and radiographic and other non-destructive
examination of welded joints, all to be accessible for inspection by the Employer’s Representative.
Page 35 of 41
A record shall be maintained of the location of all imperfections and the corrective measures taken to
effect repairs.
6.18.3 Shop Tests

(Refer to 6.1.7)
6.19 Site Tests

6.19.1 Inspection after Installation
When the penstock and headrace pipe have been completely erected and before final painting is
commenced, an internal examination shall be made to ensure that all works have been satisfactorily
completed. Spiders shall not be removed without the permission of the Employer’s Representative.
6.19.2 Painting Inspection

Adhesion Inspection
The peeling test for dried films on the pipe shells shall be carried out not earlier than 7 days after
application of final coat to allow full curing of the paint film.
Pinhole Inspection
The dried films on the pipe shells shall be checked by holiday detector for pinholes at any time after
painting work is finished.
Thickness Inspection
The thickness of dried films shall be measured by elco-meter after painting work is finished, to a check
point in every one square meter, or the area where the Employer’s Representative so requests.
6.19.3 Pressure Test

At workshop, for straight pipes and bends, at least one pipe/bend of each diameter and of each thickness
will be subjected to pressure test. Also, bifurcation Wye will be subjected to pressure test.
After installation of the whole headrace pipe, penstock, bifurcation and the penstock system will be
water filled up to the maximum headwater level in the head pond. For this procedure, the downstream
end of the penstock shall be closed by the turbine inlet valves.
Objectionable defects in the welds found during the test shall be chipped or flame or arc-gouged to
show sound metal and the defects re-welded. Welds have been repaired shall be pressure tested again
until the Engineer's satisfaction. A record of the actual result of test shall be submitted to the Engineer.
6.19.4 Handling and Placing

In order to maintain the accuracy of roundness of the penstock sections within the tolerance specified
and internal spiders shall be provided in the sections immediately upon completion of fabrication to
prevent and deformation that may take place during transportation, installation and concreting, if
required.
External structural steel supports and facilities for anchorage shall be supplied and installed to prevent
displacement or uplift of the penstock sections due to buoyancy or external forces that may occur
during placing of concrete. The supports will be concreted into place with the penstocks. Inserted bars
for supports where required in the primary concrete by the Contractor will be supplied and embedded
by the other Contractor in locations as shown on the approved drawings prepared by the Contractor.
6.19.5 Field Welding

Welding at the erection site shall be performed manually. Matching of field welding girth joints shall be
carried out with spiders and pad plates or tack weld jigs.
Page 36 of 41
In no case, penstock sections shall be forcibly jointed. During the welding operations, the centers and
distances between edge preparations shall be maintained at their proper positions.
Field welded joints shall be preheated in accordance with kind of steel materials and plate thickness.
However, maximum Inter pass temperature shall be 200 degrees C and preheated area shall be a
distance of more than four times as plate thickness from the welding edges. Suitable cover shall be
provided over the pipe shells to protect the water fallen on the welded joints for all working times for
welding. Equipment for drying the welding rods shall be provided to ensure that the welders used dry
welding rods at all times.
After field welding, girth welds in length including T joint shall be RT/UT or 100% test by ultrasound
method or as instructed by the Engineer and the welding defects repaired.
Page 37 of 41

Section II Special Technical Specifications 30 July 2019

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Section II Special Technical Specifications 30 July 2019

Uploaded by

Copyright:

Available Formats

SECTION II

SPECIAL TECHNICAL SPECIFICATIONS

2 OBJECT AND LIMIT OF SUPPLY

The Supply shall include the following equipment:

Under Sluice Way Equipment

Intake and Settling Basin Equipment

Headrace Pipe and Penstock

- One (1) sets of under sluice way gates

3.2 Design Data

- Operating speed 0.3 m/min

Trash Passage Sluice Gate

Gravel Trap Flushing Gate

Settling Basin Inlet Gate

Settling Basin outlet Gate

- Opening dimensioning (w x h) 1.90 m x 2.5m

Settling Basin Flushing Gate

Headrace Pipe Inlet Gate

Design Water Level (m.a.s.l.) 519.34

3.3 Design Criteria

3.4 Structural Details

3.4.2 Gate Seals

3.4.3 Sealing Surfaces

3.5 Anchor Rods and Plate

3.6 Gates Position Indicators

3.7 Ladders, Platforms, Handrails

As a minimum the following components shall be provided:

3.8 Operating System

(i) Overload conditions

3.9 Dogging Device

3.11 Stainless Steel Plates

- One "opening", one "stop" and one "closing" push buttons;

Remote control will be:

- One "opening", one "stop" and one "closing" push buttons;

3.13 Electrical Equipment

3.16.2 Site Tests

Tests to be performed shall include but shall not be limited to:

- Verification of closing and opening speeds.

3.17 Protective Coatings

3.18 Spare Parts and Special Tools

3.18.2 Special Tools

4 MAINTENANCE GATES (Stoplogs)

4.2 Design Data

Gravel Trap Flushing

Settling Basin Flushing

- Operating system Manual

4.3 Design Criteria

- Three (3) sets of gates as emergency gates for the intake;

4.4 Structural Details

4.4.2 Gate Seals

4.4.3 Sealing Surfaces

4.5 Anchor Rods and Plate

4.6 Gates Position Indicators

4.7 Ladders, Platforms, Handrails

As a minimum the following components shall be provided:

4.8 Operating System

(ii) Raising Condition

4.9 Dogging Device

4.11 Stainless Steel Plates

- One "opening", one "stop" and one "closing" push buttons;

Remote control will be:

- One "opening", one "stop" and one "closing" push buttons;

4.13 Electrical Equipment

Gate shall be shop assembled for inspection and test.

4.16.2 Site Tests