PENSTOCK DESIGN

BASIC DATA|
1 Forebay Elevation = 856.7 m .a.s.l
Penstock invert elevation at
2 I.L. 1 = 848.538 m a.s.l.
forebay
Normal tailwater level (in
3 I.L. 2 = 797.00 m a.s.l.
powerhouse)
4 Design discharge Q = 22.93 m3/s
5 Rated capacity of plant Pr = 10564.3 kW
6 Maximum gross head H = 59.72 m
7 Net head Hn = 56.05 m
Total length of penstock
8 L = 383.0 m
(Δx)
Hazen-Williams roughness
9 C = 120 Ref: W.P. Creager
coefficient
10 Mannings friction factor n = 0.0130
11 Friction factor (Moody) f = 0.0141
DIAMETER AND VELOCITY

Most economical penstock diameter Ref: L.W. Mays

0 . 43
CP De = 2.50 m C = 0.52
De 
H 0 .60

Most economical penstock diameter Ref: L.W. Mays

De = 3.45 m C = 0.72
De  CQ 0.5

Most economical penstock diameter Ref: Mosonyi

0.45
Q De = 2.83 m
De  1.12
H 0.12

Most economical penstock diameter Ref: GTZ

P 0.43 De = 2.79 m
De  0.71 0.65
H
Most economical penstock diameter Ref: Guidelines, Roorkee
0.25
 Q2 
De  3.55  De = 2.91 m Sarkaria's equation
 2 gH 

Dia. for limiting headloss to 4% of H Ref: ESHA Guide

0.1875
 n 2Q 2 L 
Dlimit  2.69  D limit = 2.42 m
 H 
NOTE: Use maximum value of diameter from above. (Dlimit 2.42 m)
Selected diameter for
D = 2.70 m
penstock

Average flow velocity in

V = 4.00 m/s
penstock

Check V < Vmax (i.e. 10 m/s) = O.K.

Effective head from center

he = 6.81 m
of penstock

Ref: L.W.
Flow velocity (orifice flow) V  C d 2 ghe Cd = 0.60
Mays

Max. possible velocity

V Omax = 6.9 m/s
(orifice flow)
Max. possible discharge
Q Omax = 39.7 m3/s
(orifice flow)

2.7

BELLMOUTH CURVE DESIGN

Elliptical entrance curve x2 y2

 1
(bellmouth) 0.5D 2 0.15D 2
Ref:
x2 y2 DOSD
 1
Elliptical entrance curve
D 2 0.33D 2
(square & rect.)

For circular pipes D is the diameter while maximum values of 'x' & 'y' are given in plan view as;

Maximum 'x' = 0.65D from pipe centerline and Maximum 'y' = 0.5D from entrance face
However the existing practice in the region is to adopt the bellmouth diameter as 1.5D, therefore

 x2 
Therefore: y  1  0.25D 2
2 
 D  
x y (low) y (up)
Plan
853.0 2.700 0.000 0.000 848.538 852.588
852.5 2.430 0.294 0.270 848.832 852.294
852.0
2.160 0.405 0.540 848.943 852.183
Elevation (m asl)

851.5
851.0 1.890 0.482 0.810 849.020 852.106
850.5 1.620 0.540 1.080 849.078 852.048
850.0 1.350 0.585 1.350 849.123 852.003
849.5
1.080 0.619 1.620 849.157 851.969
849.0
0.810 0.644 1.890 849.182 851.944
848.5
848.0 0.540 0.661 2.160 849.199 851.927
0.00.270 0.5 1.0 1.5
0.672 2.0 2.5 3.0 2.430 849.210 851.916
0.000 Distance (m)
0.675 2.700 849.213 851.913

Ref: L.W.
Mays
Transition length from gate L  VD
t C = 0.80
to penstock C
A length of 1.0D should be satisfactory for this
Transition length Lt = 3.60 m
transition.

GATE SIZE
Gate hight H = 2.70 m H D
Gate width W = 2.12 m H  0.785D

For a gate having H=D and W=0.785D, the flow velocity at the gate will be equal to the

velocity in penstock so no further flow acceleration is produced in this section.

FRICTION FACTOR

DV
Reynolds number Re  Ref: Davis

where:
Kinematic viscosity of
ν = 1.0E-06 m2/s
water at 20oC

Reynolds number Re = 10813105

Check Re ≥ 2000 = TURBULENT

 64 for laminar
For laminar flow f  flow
Re
For turbulent flow 1 e/ D 2.51 
(Colebrook - White  2 log 10   
 
equation)
f  3.7 Re f 

1 R f 
For hydraulically smooth  2 log 10  e  Ref: Von
f  2.51 
pipe   Karman

For hydraulically rough 1  D Ref: Von

 2 log 10  3.7 
pipe f  e Karman

where:
Roughness height (welded
e = 0.600 mm
steel)
Ratio e/D = 0.00022

1 = 1.00
Friction factor (Moody) f = 0.01412

SUBMERGANCE REQUIRMENT

Ref: ESHA Guide

 V 
Minimum submergence (by
S min  D1  2.3 7.53 m
Knauss)  gD 


" " " " (by Rohan) S min  1.474V 0.48 D 0.76 6.10 m

" " " " (by Gordon) S min  0 . 7245 V D 4.77 m

Smin

Minimum submergence (average

S min = 6.13 m
required value)
Provided submergence S Pr = 6.81 m

Check SPr ≥ Smin = O.K.

 TRASHRACK

Rack Cleaning Machine = NO

Width of Trashrack bra  nt  bch Ref: GTZ Publication

"High head
Hydropower"
Number of rack bars bch
n  1
b
Width of rack bars t = 12.0 mm
Clearance between rack
b = 150.0 mm
bars
Inclination of trashrack z = 4.0 zV:1H
Angle of bars with
α = 76.0 degrees
horizontal

Width of Trashrack bra  2.0  D

Width of Trashrack b ra = 5400.0 mm

Height of trashrack hra  bra

Height of trashrack h ra = 5400.0 mm

Channel width / diameter b ch = 5011.1 mm

Number of rack bars n

" " " n = 32.4 no.

Effective head from center

he = 614.4 m
of penstock
Diameter of bellmouth for
D bm = 4.1 m Dbm  1.5 D
penstock

Entrance velocity in
v bm = 1.78 m/s
bellmouth
Entrance velocity at
ve = 0.79 m/s
trashrack
Ref: Mosonyi

Average flow velocity tb

between bars
v bars  v e "Vol-I: page # 537"
b

Average flow velocity

v bars = 0.85 m/s
between bars

Check vbars ≤ 1.2 m/s = O.K.

HEADLOSSES

FRICTION LOSS
1 1/ 2 2 / 3
Mannings equation V  S R
n
V 2L
Headloss (Manning) hf  n2 4 /3
R
Headloss (Manning) hf = 1.75 m
hf
Q  C u CD 2.63 S 0.54 S &
Hazen-Williams equation where L Cu=0.278

1 / 0.54
Q L
Headloss (Hazen-Williams)
h f  10.654 
C  D 4.87

1.85
Alternatively Headloss 6.87 L  V 
hf   
(Hazen-Williams) D 1.165  C 

Headloss (Hazen-
hf = 1.53 m
Williams)

L V2
Darcy-Weisbach equation hf  f
D 2g
Headloss (Darcy-
hf = 1.64 m
Weisbach)

 
 
Average velocity of flow hf
e/ D 2.51 
(Colebrook - White V  2 2 gD log   
L 3.7 hf
equation)  D 2 gD 
 
 L 
1 = 1.00
Headloss (Colebrook-
hf = 1.64 m
White)
Maximum friction headloss h fmax = 1.75 m
 Selected the larger value of friction loss from above equations.

Headloss Flow
Friction Headloss Vs Discharge
2 0.00 0.00
1.8 0.02 2.29
Friction Headloss (m)

1.6
0.07 4.59
1.4
0.16 6.88
1.2
1 0.28 9.17
0.8 0.44 11.47
0.6 0.63 13.76
0.4 0.86 16.05
0.2
1.12 18.34
0
0 5 10 15 20 25 1.42 20.64
Flow (cumecs) 1.75 22.93

TRASHRACK LOSS

4/3 2
t  v bars
hl , ra  K   sin  Ref: Davis:
b 2g
"Hydraulics
Handbook"

Coefficient depending on
K = 2.42
bar shape

Rack losses h l,ra = 0.003 m

v2 Ref:
ENTRANCE LOSS hL  K Mosonyi
2g
K= 0.20
Entrance headloss h LE = 0.0074 m

GATE SLOT LOSS

v2  1   
2

 1     
2
hl , s  1 .2  
2 g     
Ref:
F Bh
  Mosonyi
Where Fy Bh  2 y * h  yB

and Weisbach coefficient   0.63  0.37  3

Velocity (just before the
v in = 4.0 m/s
slots)

Width of entrance flume B = 5.40 m

Depth of entrance flume h = 5.40 m

Width of gate slot eg = 2.12 m

Depth of gate slot dg = 2.70 m

if d > 0.2e then

y * = 0.2e
& if d <= 0.2e then
y* = d
For gate slots yg* = 0.42 m

Coefficient
βg = 0.809
(gate slots)
Weisbach coefficient
αg = 0.826
(gate slots)

Head loss at gate slots h LG = 0.079 m

v2
BEND LOSS hL  K Ref:
2g Mosonyi
K= 0.20
No. of bends = 1 no.
Headloss in bends h LB = 0.16 m
VALVE LOSS v2 Ref: Mosonyi
hL  K
2g Kv = 0.20
Valve headloss h LV = 0.16 m

MANIFOLD LOSS v2 Ref: L.W. Mays

hL  K
2g Kb = 0.30
Manifold headloss
h LB = 0.25 m
(bifurcation)
Where:
Kb = 0.20 for symmetrical
bifurcation,
Kb = 0.30 for symmetrical
trifurcation, and
Kb = 0.20 for manifold
branch

TOTAL HEADLOSS IN PENSTOCK (Trashrack + Entrance + Friction + Bends + Valve + Manifold)

Total headloss in Penstock h LT = 2.41 m

Check hLT ≤ 5H/100 = O.K.

(The usual limit of headlosses in penstocks is 5% of gross head from economic point of view)
 MANIFOLD/BIFURCATION

Number of turbine units nT = 3 no.

Number of branches /
nb = 3 no.
manifolds
Discharge of one branch Qb = 7.64 m3/s

Diameter of main penstock D = 2.70 m

Average velocity in main
V = 4.00 m/s
penstock
Flow velocity in branches
vb = 4.00 m/s (vb ≥ V)
(required)

Flow area per branch Ab = 1.91 m2

Diameter per branch db = 1.50 m

Max. wall thickness
ts = 16.0 mm
(provided)
Flow velocity in branches
vb = 4.33 m/s
(designed)

Check vb ≥ V = O.K.

Length of first bifurcation /

L b1 = 24.0 m
branch
Length of second
L b2 = 19.0 m
bifurcation / branch
Length of third bifurcation /
L b3 = 14.0 m
branch

Included angle θ = 65.0 degree

Wall thickness of branches t sb = 12.00 mm

2
 ts 
  di  2 
 1000  d i2
X-sectional area of steel As   Ref: Davis
4 4

X-sectional area of steel As = 0.057 m2

Volume of steel in branches V s = 3.25 m3

Ref:
Weight of steel in branches W s = 25.51 tons
Mosonyi
Weight of steel (5% increse
Ws = 26.78 tons
for joints)

Width of steel sheet w = 4.79 m

Length of steel sheet l = 6.0 m
No. of steel sheets for
n = 8 no.
branches
 SURGE CALCULATIONS

10 3 k
Pressure wave speed c Ref: ESHA Guide
 kD 
1  
 Et s 

Bulk modulus of water k = 2.0E+09 N/m2

Modulus of elasticity of
E = 2.0E+11 N/m2
pipe material
Maximum wall thickness
ts = 14.0 mm
(provided)

Pressure wave speed c = 826.4 m/s

2L
Critical time T = 0.93 sec T 
c
Valve closure time Tv = 6.0 sec

Check 2T < Tv < 10T = O.K.

N N2 
Allievi Formula for max. P  Pw   N 
 2 4  Ref: ESHA Guide
overpressure  

2
 LV 
Where: N   
 gPwTv 
N = 0.19

Maximum overpressure
ΔP = 32.36 m of water column
(positive)

Maximum overpressure
ΔP = -2.10 m of water column
(negative)

If water acceleration
constant is less than 3
seconds than surge tank is
not required

VL
Water acceleration constant th  Ref: ESHA Guide
gH

" " " " " th = 2.62 sec

NO TANK
Check th < 3 = REQUIRED
 WALL THICKNESS

PENSTOCK MATERIAL

ASTM A36 steel having yield stress of 36,300 psi (250 kN/m2) and tensile stress of 58,000 psi (400 kN/m2) has been used for
penstock design.

Yield Strength 36,300 psi Tensile Stretgh 58,000 psi

ALLOWABLE DESIGN STRESS

For steel (ASTM A36), the basic allowable stress equals the lesser of:

2/3 of yield stress

23958 psi
=
or
1/3 of tensile stress
19140 psi
=

Joint efficiency (E) has been taken as 100%( i.e. 100% radiographic inspection).

Following conditions have been considered.

Allowable Design Allowable Design

Condition Stress increase Stress
factor (K) Sa = (SI)(K)(E)

Normal Operating 1 23958

Emergency 1.5 35937
Exceptional 2.5 59895

Pw D
Wall thickness required ts  Ref: ESHA Guide
2 f k f

Hydrostatic pressure Pw = 5.97 kN/mm2

Total pressure PT = 9.21 kN/mm2

Weld efficiency kf = 0.90
Allowable tensile stress σf = 1747 kN/mm2
Corrosion allowance cs = 2.00 mm

Max. wall thickness

ts = 7.91 mm
(required)
Max. wall thickness
ts = 14.0 mm
(provided)

Density of steel ρs = 7850.0 kg/m3 Ref: Flowadvisor

Effective thickness of
penstock
te = 12.00 mm t e  t s  cs
MINIMUM WALL
THICKNESS

DK
Minimum thickness of steel t min  (K = 508 & D in mm)
sheet 400
Ref:
Warnick
" " " " " t min = 8.02 mm

ALTERNATIVELY
Minimum thickness of steel
sheet
t min  2.5D  1.2 (D in meter)

Ref:
" " " " " t min = 7.95 mm
ASME

ALTERNATIVELY
Minimum thickness of steel
sheet
t  D / 288
min
(D in mm)

" " " " " t min = 9.38 mm

The larger value of

minimum shell thickness te=12mm
governs for design purpose

Check te ≥ tmin = O.K.

Maximum head H max = Hgross + Hsurge Surge head

(Taken as 0.2 Hgross)=
11.944 m
71.66 m

0.1H max D
Hoop stress H  Ref: DPR-Bilgaon
2t e

Hoop stress σH = 806.22 kgf/cm2

Check σH ≤ 1.5yield
= O.K.
stress