Hydro 2017, 9 to 11 October, Seville, Spain

Realization of Steel Penstocks with Banded Pipe Technology (BPT) for High
Head Hydro Power Plant (HHP) and Pumped Storage Plants (PSP)

Dr Eng. Clemente Curnis Eng. Daniele Bronzetti Dr.Eng. Francesco Amberg

Consultant -Senior Expert Lombardi Engineer SA Lombardi Engineer SA
Rebhaldenstrasse, 51 Via R. Simen,15 Via R. Simen,15
5430 Wettingen…………………………………………… 6648 Minusio 6648 Minusio
Switzerland Switzerland Switzerland

Abstract
Re-evaluation by the engineers of the concept of design and realisation of Penstocks using the hot banded pipe technology that was widely in
use up to the year 2000 and then superseded by the introduction of the Very High Tensile Strength Steel (VHTSS) quenched and tempered or
thermo-mechanically treated steels.
Many Plants either conventional (HPP) and Pump Storages (PSP) with Banded Pipe Technology (BPT) penstocks are in service since long
time with success, someone exceeding 60 years, in Europe and South America covering a large range of operational conditions:
- HPP and PSP, Rated Power from 250 to 1300 MW
- Design head from 400 to 1900 m water column
- Penstocks in Surface and Embedded in tunnel having Diameter 1200 to 4000 mm
Purpose of the document is to introduce the principles of design, construction of hot fitted banded pipes; to evidence the benefits available by
the use of BPT technology in the realisation of penstocks for HHP and PSP, the minimisation on exploitation risks associated with undetected
defects, like cracks, in the joints and the wave of fatigue all in comparison to the use of VHTSS penstocks.
Furthermore, the accidents occurred and several nonconformities found in penstocks realized with VHTSS, with lots of costs and out of service
suffered by the Operators, shall be an incentive for the Engineers to re-evaluate the banded Pipe Technology in order to develop the best
solution for the Operators for the specific Plant.
The document will also develop some comparison design among the two solutions applied to various Plants configurations and it will describe
the Penstock of Chandoline-Grand Dixence (CH) realized with BPT technology having 1740 m Net Head, 1200 mm diameter, built in 1934 and
put out of service in 2013, after 80 years of successful service.

Clemente Curnis, Consultant Senior Expert HSS for hydro Power Plants
University Doctorate in Mechanical Engineering, Specialisation in Hydropower Plants, at Ecole Politecnique of Milan in 1975. Dr. Curnis has
Collaborated for 25 years with Construction Companies in Design, Fabrication and Erection of Penstocks, Gates and Guard Valves. His
experience has been gained on hydropower projects worldwide, in more than 20 Countries worldwide and includes besides conventional
hydropower projects (HPP) also 8 Pumped Storage Projects (PSP).
Dr. Curnis is also collaborated with major Swiss Engineering Companies in: basic and detail design, supervision and commissioning
of Hydro Power Projects and has now more than 35 years of experience in Hydraulic Steel Structures.

Daniele Bronzetti, graduated in Civil Engineering from the Swiss Federal Institute of Technology Zurich in 2012. He has been
working since 2013 at Lombardi Engineering Ltd., Switzerland, mainly on numerical analyses, consultancy services and design
for problems related to rock mechanics and underground works. Since 2013 Daniele Bronzetti works in the special studies
department of Lombardi Ltd and is involved in the design of various underground structures forming parts of hydropower plants.

Francesco Amberg, graduated in Civil Engineering from the Swiss Federal Institute of Technology Zurich in 1995. He has been
working since 1995 at Lombardi Engineering Ltd., Switzerland, mainly on numerical analyses and consultancy services for
concrete dams and for problems related to rock mechanics and underground works. Since 2012 Francesco Amberg is Member of
the Board and responsible for the special studies department of Lombardi Ltd. He is involved in the design, the rehabilitation or in providing
consultancy services for various tunnels or underground structures of hydropower plants.

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C. Curnis, D. Bronzetti and F. Amberg