For Approval: Design Calculation Penstock Straight Ferrules (Material Astm 537 CL 1) 0) 9

49/5, Mathura Road, Village Prithla, District Palwal - 121102 (Haryana) INDIA
This document is the INTELLECTUAL PROPERTY of
Observe the protection notice ISO 16016

ANDRITZ HYDRO Pvt. Ltd.
FOR APPROVAL
Date Representative
OWNER/CLIENT: OWNER’S ENGINEER:
NUMBUR HIMALAYA HYDROPOWER PVT. LTD. ENTURA
PROJECT :
LIKHU A
Rev Modifications Date Prepared By Checked By Approved BY

TITLE:
DESIGN CALCULATION
PENSTOCK STRAIGHT FERRULES
(MATERIAL ASTM 537 CL 1)
0)
Client NUMBUR HIMALAYA HYDROPOWER PVT LTD 9 by
Prepared R.D. 11.04.2019 File name
Plant LIKHU A HYDRO ELECTRIC PROJECT, NEPAL Checked by W.S. 19.04.2019
Contract Nº N/CA/HM/TP/01 Approved by A.K. 22.04.2019 File date 22-04-2019
=FU PLN
Internal No. C-90-834972-058-030-DC-PS-010
+LO
Page 1
Document No. LKA-030-DC-010-A Rev 0 of 27
A4
#
DESIGN CALCULATION
Li-A/PENSTOCK STRAIGHT FERRULES/ASTM 537 CL 1
Table of Contents
1. GENERAL .....................................................................................................................3
2. CODES TO BE FOLLOWED/ DRAWINGS/ DESIGN CRITERIA .................................................3
3. TECHNICAL PARAMETER................................................................................................4
4. ALLOWABLE STRESSES .................................................................................................5
5. ROCK PARTICIPATION ....................................................................................................5

6. MINIMUM HANDLING THICKNESS .....................................................................................5
7. DESIGN FOR HORIZONTAL SHAFT...................................................................................6
8. DESIGN FROM VERTICAL BEND TO EL 1383.340 .............................................................7

9. DESIGN FROM EL 1383.340 TO EL 1310.82 ..................................................................8

10. CALCULATION SUMMARY SHEET UPTO EL 1310.82 ......................................................12
11. DESIGN FROM EL 1310.820 TO VERTICAL BEND 2 .......................................................12
12. DESIGN OF PENSTOCK AFTER BIFURCATION I FOR 1500 MM DIA ....................................13
13. DESIGN OF PENSTOCK AFTER BIFURCATION II FOR DIA 1100 MM ...................................14
14. DESIGN OF PENSTOCK AFTER BIFURCATION II FOR 1900 MM DIA ...................................16
15. DESIGN FOR EXTERNAL PRESSURE FOR UNSTIFFENED SHELL ......................................17
15.1 UPPER HORIZONTAL PORTION ....................................................................................17
15.2 AT EL 1310.82 .........................................................................................................19
15.3 NEAR BIFURCATION I .................................................................................................20
16. DESIGN FOR EXTERNAL PRESSURE FOR STIFFENED SHELL ..........................................22
Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

Plant LIKHU A HYDRO ELECTRIC PROJECT, NEPAL C-90-834972-058-030-DC-PS-010 +
Contract Nº N/CA/HM/TP/01 Document No.
Page 2
File date 22-04-2019 LKA-030-DC-010-A Rev 0 of 27
A4
DESIGN CALCULATION
1. General
Design of penstock has been carried out as per the civil drawing layout is provided.
2. Codes to be followed/ drawings/ Design criteria

 IS 11693 (Part I)
 IS 11693 (Part II)
 IS 11693 (Part III)

 ASCE manual No. 79 (2012)

 IS 2825
 EHTLKA-DD-C-GA-004, sheet 1/2 Rev. 02
received via mail dated 28th March 2019
 EHTLKA-DD-C-GA-005, sheet 2/2 Rev. 01
received via mail dated 28th March 2019
 EHTLKA-DD-C-GA-003, Rev. 01
received via mail dated 2019
 Approved design memorandum dated 21st March 2019 and subsequent clarifica-
tion from the customer on 26th March 2019.

Page 3
A4
DESIGN CALCULATION
3. Technical Parameter
 FRL EL 1450.20 m
 Max Surge Level EL 1457.00 m
 C/l of machine EL 1297.70 m
 Internal Dia of Pipe 2.5 m

 No. of Branches 3 Nos.
 Internal Dia. of branches 1500 mm & 1100 mm

 % of pressure rise due to 35 %

water hammer
 Seismic Coff. Hor. = 0.24g & Ver.= 0.16 g
 Corrosion Allowance (CA) 1. 5 mm
 Weld Joint Eff. 0.9
 Max. Temperature of Water 33 degree
 Min. Temperature of Water 3 degree
 Material ASTM 537 Cl I
 Yp of Material 345 Mpa
 UTS of Material 480 Mpa
 Rock type Calcareous Quartzite with interbedded Phyllite
 Modulus of Elasticity of Rock 900000 kg/cm2
 Modulus of Elasticity of Concrete 193650 kg/cm2
 Modulus of Elasticity of Steel 2100000 kg/cm2
 Thickness of concrete over liner 500 mm
 Poisson ratio of steel 0.303
 Poisson ratio of rock 0.2

Page 4
A4
DESIGN CALCULATION
4. Allowable Stresses
 Steel Liner
As per IS 11693 Part (II) clause No. 4.2
In Normal Condition
Minimum of
60 % of Yp = 0.6 x 345 = 207 Mpa

1/3 of UTS = 1/3 x 480 = 160 Mpa

Hence Adopted Allowable Stress for Steel Liner = 160 Mpa
5. Rock participation
 No rock participation for portion between surge shaft and PPV.
 No rock participation 30 m d/s from the penstock protection valve.
 15 % rock participation for inclined pressure shaft.
 No rock participation 30 m u/s from the tunnel outlet portal.
 No rock participation for the portion d/s of tunnel outlet portal.
 Rock participation for the balance length of horizontal shaft.
Hence, In the design calculation no rock participation is considered from surge shaft to first bend as
minimum handling is governing in that reach. Same thickness is extended upto certain level d/s of
bend.
Similarly, 30 m u/s from outlet portal near bifurcation I, no rock participation is considered. From bi-
furcation to power house no rock participation has been considered.
However, rock participation depends upon the load shared by the liner for expanding up to gap, and
rest of the stresses pass to rock. The calculated stresses getting transferred to rock should be veri-
fied by Engineer/geologist after rock testing. Please note that the formula used considering penstock
embedded in fissured concrete and rock.
6. Minimum handling thickness

As per clause no. 7 of IS 11693 Part (II), regardless of pressure, a minimum thickness of liner shall be
provided.
Minimum Handling thickness = R+.25/200

Where D is Diameter of shell in cm
 For 2500 mm dia.

tmin = .0075 m say 8 mm

Page 5
A4
DESIGN CALCULATION

tmin = 0.005 m say 5 mm

tmin = 0.004 m say 4 mm
7. Design for Horizontal Shaft

From Surge Shaft to Vertical Bend 1
Rock participation = 0
Design Pressure as per Water Hammer Drg = 34.895 m
Head considered pressure =(34.895 X 1000 X 9.82)/1000000
=0.342N/mm2
Calculation of Thickness of Liner

Pw =Water pressure acting, N/mm2
d =Diameter of penstock, 2500mm
S =Allowable stress, 160 N/mm2
t =Thickness of liner, mm
v =Joint efficiency. 0.9
Pw  d
t =
2  S  v
Substituting values,
t=
=2.98 mm
Hence, adopted ta = 6.50 mm, Minimum Handling Governing
Circumferential stresses due to internal pressure
P d
c = w
2  ta  v
c =73.21 N/mm2
Poisson ratio of steel =0.303
Axial stress due to Poisson effect
ap = 0.303  c
=0.303 × 73.21
ap =22.18 N/mm2
Axial Stress due to Temperature
T1 = Maximum temperature of water = 33°C
T2 =Minimum temperature of water = 3°C
Tm= Average temperature of water = 20 °C
α= Thermal coefficient = 0.000012/°C
E = Modulus of elasticity = 210000 N/mm2
T1 =13°C
T2 =-17°C
Thermal stress due to temperature variation

Page 6
A4
DESIGN CALCULATION
= T    E
Thermal stresses due to (T1):
=13 × .000012 × 210000
aT1 =32.76 N/mm2
=–17 × 0.000012 × 210000
aT2 =–42.84 N/mm2
Equivalent Stress
As per Huber Hencky Equation

Stress due to T1 = c2  (ap  aT1 )2  c (ap  aT1 )
Substituting values
=66 N/mm2
Stress due to T2 = c2  (ap  aT2 )2  c (ap  aT2 )
= 86 N/mm2
Allowable stress =160 N/mm2
Hence adopted thickness = 6.5 + 1.5(CA) = 8 mm.
8. Design from Vertical Bend -1 to EL 1383.340 m

Design Pressure as per Water Hammer Drg = 75 m (Approx)
Head considered pressure =(75 X 1000 X 9.82)/1000000
=0.7365 N/mm2
Pw  d
t =
2  S  v
t=
=6.40 mm
Hence, Adopted ta = 6.50 mm
P d
c = w
2  ta  v
c =157.3718 N/mm2

Page 7
A4
DESIGN CALCULATION
ap = 0.303  c
=0.303 × 157.3718
ap =47.68365 N/mm2

T1 =13°C
T2 =-17°C

= T    E
=13 × .000012 × 210000
aT1 =32.76 N/mm2
Thermal stresses due to (T2) :
=–17 × 0.000012 × 210000
aT2 =–42.84 N/mm2
Equivalent Stress
Substituting values
=137 N/mm2
= 156 N/mm2
9. Design from EL 1383.340 m up to EL 1310.82 m

Considering that steel liner will interact with Surrounding Rock:-
Equation as per IS 11693 part (II) clause no. 6.1.3.

Page 8
A4
DESIGN CALCULATION


Page 9
A4
DESIGN CALCULATION

Design for Self - sustaining pipe
Design Pressure as per Water Hammer Drg = 130 m (Approx)

=1.27 N/mm2
Pw  d
t =
2  S  v
t=
=11.08 mm
Considering Participation of rock:-

Values known to us for Equation provided above
 R = Radius of penstock = 125 cm
 Yo = 0.0003 x R
= 0.0003 x 125 = 0.0375 cm say 0.04 cm
 t = thickness assumed = 0.85 cm

 C = Outside radius of concrete = 0.85 + 50 + 125 = 175.85 cm
 d = radius to the end of radial fissure = 2 x 125 + 175.85 = 425.85 cm
 Es = 2100000 kg/cm2
 Er = 90000 kg/cm2
 Ec= 193650 kg/cm2
 µs = 0.303
 µr = 0.2
Substituting the values in equations:-

Page 10
A4
DESIGN CALCULATION
2
Po = 4.72 kg/cm

M = 1.895
2
Ps = 7.07 kg/cm
2
‘fst = 1040.01 kg/cm
2
‘frt = 1.74 kg/cm
As per Clause no. 6.1.4 of IS 11639 part (II),” The maximum hoop tensile stress in steel
liner fSt should not exceed the product of joint efficiency and the allowable stress.
2 2
Allowable stress x joint eff. = 160 x10.2 x 0.9 = 1469 kg/cm > 1041 kg/cm , HENCE SAFE.

Page 11
A4
DESIGN CALCULATION
10. Calculation summary sheet up to EL 1310.82 m
Sr Internal Radius of Self Thk. of Thickness of Outer radius Outer Mus Mur gap joint Allowable P0 M PS FST allow str* FRT ROCK
No. Pressure Penstock Sustaining Steel Concrete of concrete radius of (cm) eff stresses (Kg/cm^ (Kg/cm^2) (Kg/cm^2) Joint eff PRT
Kg/cm^2 (cm) liner thk liner (cm) (cm) (cm) cracked (Kg/cm^2) 2)
cm rock (cm)
P R T Tc C D
1 13.00 125.00 1.11 0.85 50.00 175.85 425.85 0.30 0.20 0.04 0.90 1632 4.72 1.895 7.07 1040.01 1469 1.74 0.46
2 14.00 125.00 1.19 1.05 50.00 176.05 426.05 0.30 0.20 0.04 0.90 1632 5.83 1.895 8.52 1013.95 1469 1.61 0.39
3 16.50 125.00 1.40 1.25 50.00 176.25 426.25 0.30 0.20 0.04 0.90 1632 6.94 1.894 10.46 1046.28 1469 1.77 0.37
4 18.30 125.00 1.56 1.45 50.00 176.45 426.45 0.30 0.20 0.04 0.90 1632 8.05 1.894 12.19 1050.63 1469 1.79 0.33

11. Design from EL 1310.820 to Vertical bend 4

Design Pressure as per Water Hammer Drg = 202.12 m
Head considered pressure =(202.12X 1000 X 9.82)/1000000
=1.985 N/mm2
Pw  d
t =
2  S  v
t=
=17.23 mm
Hence, adopted ta = 18.5 mm
P d
c = w
2  ta  v
c =149.01 N/mm2
ap = 0.303  c
=0.303 × 149.01
ap =45.15 N/mm2

Page 12
A4
DESIGN CALCULATION
Tm= Average temperature of water = 20°C

T1 =13°C
T2 =-17°C
= T    E
=13 × .000012 × 210000

aT1 =32.76 N/mm2

=–17 × 0.000012 × 2100000
aT2 =–42.84 N/mm2

Equivalent Stress
Substituting values
=130 N/mm2
= 14855 N/mm2
Hence adopted thickness = 18.5 + 1.5(CA) = 20 mm
12. Design of penstock after bifurcation I and II for 1500 mm diameter

Design Pressure as per Water Hammer Drg = 192 m (Approx.)
=1.88 N/mm2
Pw  d
t =
2  S  v
t=
=9.82 mm

Page 13
A4
DESIGN CALCULATION

P d
c = w
2  ta  v
c =149.6381 N/mm2
ap = 0.303  c
=0.303 × 149.6381
ap =45.34 N/mm2


Tm= Average temperature of water = 20°C
T1 =13°C
T2 =-17°C
= T    E
=13 × .000012 × 210000
aT1 =32.76 N/mm2
=–17 × 0.000012 × 2100000
aT2 =–42.84 N/mm2
Equivalent Stress

Substituting values
=130 N/mm2
= 149 N/mm2
13. Design of penstock after bifurcation I for dia. 1100 mm

Design Pressure as per Water Hammer Drg = 205.875 m (Approx.)

Page 14
A4
DESIGN CALCULATION

=2.021 N/mm2
Pw  d
t =
2  S  v
t=
=7.72 mm

P d
c = w
2  ta  v
c =145.35 N/mm2
ap = 0.303  c
=0.303 × 145.35
ap =44.04 N/mm2
T1 =13°C
T2 =-17°C
= T    E
=13 × .000012 × 210000
aT1 =32.76 N/mm2
=–17 × 0.000012 × 2100000
aT2 =–42.84 N/mm2
Equivalent Stress

Page 15
A4
DESIGN CALCULATION

Substituting values
=126 N/mm2
= 145 N/mm2

14. Design of penstock after bifurcation II for 1900 mm diameter:

Design Pressure as per Water Hammer Drg = 205.875 m (Approx.)
=2.021 N/mm2
S =Allowable stress, 160 N/mm
Pw  d
t =
2  S  v
t=
=13.34 mm

P d
c = w
2  ta  v
c =147.173 N/mm2
ap = 0.303  c
=0.303 × 147.173
ap =44.59 N/mm2

Page 16
A4
DESIGN CALCULATION

T1 =13°C
T2 =-17°C
= T    E
=13 × .000012 × 210000
aT1 =32.76 N/mm2

=–17 × 0.000012 × 210000

aT2 =–42.84 N/mm2
Equivalent Stress
Substituting values
=128 N/mm2
= 147 N/mm2
15. Design for External Pressure for Unstiffened shell

Calculations pertaining to minimum thickness (8mm) and maximum thickness (16mm) is carried out be-
low to check whether the thickness if remain unstiffened, is capable of taking external pressure acting on
it or not respectively.
15.1 Upper horizontal portion

As per clause no. 6.2.1 of IS 11639 part (II) , Minimum value of critical external pressure shall be adopted from
the Vaughan & Amstutz formula:-
(a) Vaughan formula ( as per IS 11639 part II)
13  K 2 2  3K  Yo Fy  K   4 Fy F 2 y 
P cr  2 Pcr 1   
'  
 '   0
4E '  R 2 E   K E 
Where,
K= Ratio of pipe diameter to plate thickness
K= 2.500/0.008= 312.50
Es
E' 
1  2s
2 2
Es = Modulus of elasticity of steel in N/m , =210000000000 N/m

Page 17
A4
DESIGN CALCULATION
μs = Poisson ratio of steel , 0.303
2
Pcr= critical external pressure at buckling, N/m
Yo= Initial gap between steel lining concrete in m,0.0003x R= 0.0003x1.25= .0004 m
R = radius of steel liner in m, =1.25 m
2 2
Fy= Yield point stress in steel in N/m , = 345000000 N/m
2
Substituting respective values and assuming value of Pcr in above equation as 1332238.093 N/m
L.H.S = R.H.S
2
Hence, Pcr= 1332238.093 /100000= 13.32 kg/cm
2
Safe Pcr = 13.32/1.5 = 8.88 kg/cm
Hence, 8 mm thick plate having 2500 dia. can take 88 m head as per Vaughan formula.
(b) Amstutz Formula

3
1  f n Yo  3K  f n  2
2
 f ' y  f n   K  f ' y  f n 
 '  1    1.68 K    1    
 E R  E'  ' '
 E   4  E 
2 Pcr 
2 fn 
1  0.175

K f ' y  fn 


K  E' 
fy
3 f 'y 
1  s  s
2
2 2
fy= Yield point stress in steel in N/m , = 345000000 N/m
2 2
2
Yo= Initial gap between steel lining & concrete in m,0.0003x R= .0003x1.25= .0004 m
t= thickness of penstock
2
fn= allowable stress in steel in N/m
Substituting values in equation 3

2
f’y = 388155325.80 N/m
2
Substituting values in equation 1 and assuming value of f n as 67869885.50 N/m
L.H.S= R.H.S

2
Pcr = 460298.9604 N/m
2
Hence , Pcr= 4602989604 /100000= 4.60 kg/cm
2
Safe Pcr = 4.60/1.5 =3.066 kg/cm

Page 18
A4
DESIGN CALCULATION
Adopting, lower values from both equations, i.e. 30 m
As evident from the above calculations that 8 mm thick plate for 2500 mm diameter if remain unstiffened can
take external pressure head up to 30 m In our case maximum external pressure head acting FRL (1450.20) –
C/l of penstock(1422.105) = 28.095 m. Hence stiffeners are not required in upper horizontal line. However,
stiffeners are being provided as the values are close.
15.2 AT EL 1310.82
As per clause no. 6.2.1 of IS 11639 part(II) , Minimum value of critical external pressure shall be adopted from
(a) Vaughan formula ( as per IS 11639 part II)
13  K 2 2  3K  Yo Fy  K   4 Fy F 2 y 
4E '
P cr  2 P 1  R  2 E '    K  E '   0
cr 
   
Where,
K= 2.500/0.016= 156.25
Es
E' 
1  2s
2 2
2
Yo= Intial gap between steel lining concrete in m,0.0003x R= 0.0003x1.25= .0004 m
2 2
2
L.H.S = R.H.S
2
Hence , Pcr= 3625088.085 /100000= 36.25 kg/cm
2
Safe Pcr = 36.25/1.5 = 24.16 kg/cm
(b) Amstutz Formula

3
1  f n Yo  3K  f n  2
2
 f ' y  f n   K  f ' y  f n 
 '  1    1.68 K    1    
 E R  E'  ' '
 E   4  E 
2 Pcr 
2 fn 
1  0.175

K f ' y  fn 


K  E' 

Page 19
A4
DESIGN CALCULATION
fy
3 f 'y 
1  s  s
2
2 2
2 2
2
Yo= Intial gap between steel lining & concrete in m,0.0003x R= .0003x1.25= .0004 m
2

2
f’y = 388155325.80 N/m
2
L.H.S= R.H.S

2
Pcr = 1721646.262 N/m
2
Hence , Pcr= 1721646.262 /100000= 17.21 kg/cm
2
Safe Pcr = 17.21/1.5 =11.478 kg/cm
Adopting, lower values from both equations, i.e. 114 m
take external pressure head upto 121 m In our case maximum external pressure head acting FRL (1450.20) –
C/l of penstock near bifurcation(1308.975) = 141.225 m. Hence stiffeners are required in this reach.
15.3 Near Bifurcation - I

As per clause no. 6.2.1 of IS 11639 part (II), Minimum value of critical external pressure shall be adopted from
(a) Vaughan formula (as per IS 11639 part II)
13  K 2 2  3K  Yo Fy  K   4 Fy F 2 y 
P cr  2 Pcr 1   
'  
 '   0
4E '  R 2 E   K E 
Where,
K= 2.500/0.018= 138.89
Es
E' 
1  2s

Page 20
A4
DESIGN CALCULATION
2 2
2
Yo= Initial gap between steel lining concrete in m,0.0003x R= 0.0003x1.25= .0004 m
2 2
2
L.H.S = R.H.S
2
Hence, Pcr= 4274764.08205/100000= 42.74 kg/cm
2
Safe Pcr = 42.74/1.5 = 28.49 kg/cm
(b) Amstutz Formula
3
1  f n Yo  3K  f n  2
2
 f ' y  f n   K  f ' y  f n 
 '  1    1.68 K    1    
 E R  E'  ' '
 E   4  E 
2 Pcr 
2 fn 
1  0.175

K f ' y  fn 


K  E' 
fy
3 f 'y 
1  s  s
2
2 2
2 2
2
Yo= Intial gap between steel lining & concrete in m,0.0003x R= .0003x1.25= .0004 m
2

2
f’y = 388155325.80 N/m
2
L.H.S= R.H.S

2
Pcr = 2120401.279 N/m
2
Hence , Pcr= 2120401.279 /100000= 21.20 kg/cm
2
Safe Pcr = 21.20/1.5 =14.13 kg/cm

Page 21
A4
DESIGN CALCULATION
Hence, 16 mm thick plate having 2500 dia. can take 141.33 m head as per Vaughan formula.
Adopting, lower values from both equations, i.e. 141.33m
take external pressure head up to 141.33 m In our case maximum external pressure head acting FRL
(1450.20) – C/l of penstock near bifurcation(1308.975) = 141.225 m. Hence stiffeners are not required in this
reach.
16. Design for External Pressure for Stiffened shell

As per clause no. 6.2.3 of IS 11639 Part (II)

Critical external pressure for steel liner with stiffening rings should be computed by Timoshenko equation.
The critical external pressure should not be less than l-5 times the
maximum external pressure.
For determining Spacing of Stiffeners Timoshenko formula is used:-

Page 22
A4
DESIGN CALCULATION

TIMOSHENKO CALCULATION FOR 8 mm thk. liner having stiffener spacing 1250 m .
Elevation up to which 8 mm is proposed = EL 1404.064
External Pressure acting = FRL (1450.20) – 1404.064 = 46.136 m
Thk. of 8 mm with stiffener spacing 1250 mm can take head up to 45.96 m

Marginally upwards, HENCE ADOPTED.
R Radius of penstock m 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
L Spacing of stifferner rings m 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25 1.25
t Thickness of liner plate m 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008 0.008
n No. of full waves 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00
Es Modulus of elasticity for steel kn/m2 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08 2.10E+08
μ Poisson's ratio of steel 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30
E
 S2
E' 1  kn/m2 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08 2.31E+08
2R

K t 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50 312.50
L

λ t 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25 156.25
Pcr Critical external pressure kn/m2 226895 46045 13176 4677 2031 1111 784 689 699 760 852 965 1093 1235 1388 1553 1728
Minimum critical external pressure kn/m2 689.47
Allowable critical external pressure kn/m2 459.65 = 4.60 kg/cm2 = 45.96 m of head
Summary for allowable head of various thicknesses with spacing 1250 mm

Page 23
A4
DESIGN CALCULATION
Allowable
head as per
S.NO Thk Dia Timoshenko
1 8 2500 45.96
2 10 2500 80.49
3 12 2500 128.74
4 14 2500 188.4
5 16 2500 265.68
Hence a spacing of 1250 mm is adopted for whole penstock wherever stiffeners are required to resist external
pressure.
For determining Size/ section of Stiffeners rings of Stiffeners Vaughan formula is used:-
The size of stiffener rings may be worked out using Vaughan’s formulae by trial and error
method so that the ~external critical pressure is not less than 1.5 times the maximum external pressure.
a) For Minimum Thickness i.e. 8 mm

Page 24
A4
DESIGN CALCULATION
Size of stiffener rings by Vaughan's formula (IS 11639 Part 2)
Radius of penstock R m 1.25

Modulus of elasticity of steel Es Kn/m 2 2.10E+08
Poisson ratio of steel µ 0.30
Thickness of liner plate t m 0.008
Thickness of stiffner ring ts m 0.008
depth of stiffner ring d m 0.150
Permissible yield stress of liner σy N/m 2 3.45E+08
Es
E '
 E' 2.31E+08
1  s
2
Contact zone width of stiffner on ferrule b m 0.008

Associated width L  b  1.56 Rt L m 0.16
m2
Sectional area of stiffner ring Ar 0.00120

Ar
Equivalent thickness t'  t  t' m 0.02
l
Total area of composite section A m2 0.00
Initial freedom of shell to become distorted Yo m 0.0004
Distance between the neutral axis of the combined section

and the outer extreme edge of the stiffner V m 0.12
Moment of inertia of the combined section about neutral

axis I m4 6.168554E-06
4
R
K1  K1 6.906951E-07
E'  t'
Y I  K2 0.03
K2  R3   o  
 R R  A V 
I   y  t'  I 
K3    R K3 141876.73
A V  A V 
I 2  y  t2
2
K4  K4 679683037.73
4  A V 2  R
2
K1 Pcr  K 2 Pcr  K 3 Pcr  K 4  0

3 2
Goal seek by changing Pcr 0
Critical pressure P cr Kn/m 2 4796.64

Critical pressure P cr Kg/cm 2 47.97
Maximum allowable external pressure m 31.98

Allowable head of water m 319.78
b) For Maximum thickness (16 mm)

Page 25
A4
DESIGN CALCULATION

Hence size of stiffeners provided as 8 mm (thk.) x 150 mm (Height)

Page 26
A4
DESIGN CALCULATION
Likhu - A HEP, Weight of penstock straight ferrules with Material ASTM 537 Cl I
Spacing Fin-
Thickness Thickness Height of No. of
S. Diameter Length between ished
Reach EL of Ferrule of stiffen- stiffener Stiffen-
No. (mm) (m) stiffeners weight
(mm) er (mm) (mm) ers
(mm) (MT)
1 Up to El 1383.340 2500 82.6 8 8 150 1250 66 46
2 Up to El 1336.711 2500 60.0 10 8 150 1250 48 42

3 Up to El 1326.997 2500 12.5 12 8 150 1250 10 10

4 Up to EL 1316.944 2500 143.5 14 8 150 1250 115 134

5 Up to El 1310.820 2500 115.0 16 8 150 1250 92 122
6 Up to El 1297.700 2500 58.1 20 73
BF 1 to
PH and
7 1500 25.5 12 12
BF 2 to
PH
BF 2 to
8 1100 16.7 10 5
PH
Between
BF 1
9 1900 9.4 16 7
and BF
2
10 Seepage rings and Backing Strips 7
Total 458


Page 27
A4

For Approval: Design Calculation Penstock Straight Ferrules (Material Astm 537 CL 1) 0) 9

Uploaded by

Document Information

Original Title

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

For Approval: Design Calculation Penstock Straight Ferrules (Material Astm 537 CL 1) 0) 9

Uploaded by

Copyright:

Available Formats

49/5, Mathura Road, Village Prithla, District Palwal - 121102 (Haryana) INDIA

This document is the INTELLECTUAL PROPERTY of

Observe the protection notice ISO 16016

OWNER/CLIENT: OWNER’S ENGINEER:

NUMBUR HIMALAYA HYDROPOWER PVT. LTD. ENTURA

Rev Modifications Date Prepared By Checked By Approved BY

5. ROCK PARTICIPATION ....................................................................................................5

8. DESIGN FROM VERTICAL BEND TO EL 1383.340 .............................................................7

9. DESIGN FROM EL 1383.340 TO EL 1310.82 ..................................................................8

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

2. Codes to be followed/ drawings/ Design criteria

 IS 11693 (Part III)

 ASCE manual No. 79 (2012)

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

 Internal Dia of Pipe 2.5 m

 Internal Dia. of branches 1500 mm & 1100 mm

 % of pressure rise due to 35 %

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

60 % of Yp = 0.6 x 345 = 207 Mpa

1/3 of UTS = 1/3 x 480 = 160 Mpa

6. Minimum handling thickness

Minimum Handling thickness = R+.25/200

 For 2500 mm dia.

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

 For 1500 mm dia.

 For 1100 mm dia.

7. Design for Horizontal Shaft

Calculation of Thickness of Liner

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

As per Huber Hencky Equation

8. Design from Vertical Bend -1 to EL 1383.340 m

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

E = Modulus of elasticity = 210000 N/mm2

Thermal stress due to temperature variation

9. Design from EL 1383.340 m up to EL 1310.82 m

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

Observe the protection notice ISO 16016

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

Observe the protection notice ISO 16016

Design for Self - sustaining pipe

Design Pressure as per Water Hammer Drg = 130 m (Approx)

Considering Participation of rock:-

 R = Radius of penstock = 125 cm

 t = thickness assumed = 0.85 cm

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

Observe the protection notice ISO 16016

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

10. Calculation summary sheet up to EL 1310.82 m

Observe the protection notice ISO 16016

11. Design from EL 1310.820 to Vertical bend 4

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

Tm= Average temperature of water = 20°C

=13 × .000012 × 210000

Thermal stresses due to (T2):

aT2 =–42.84 N/mm2

12. Design of penstock after bifurcation I and II for 1500 mm diameter

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =

Circumferential stresses due to internal pressure

ap =45.34 N/mm2

Axial Stress due to Temperature

As per Huber Hencky Equation

13. Design of penstock after bifurcation I for dia. 1100 mm

Client NUMBUR HIMALAYA HYDROPOWER PVT LTD Internal No. =