TAMILNADU GENERATON AND DISTRIBUTION CORPORTAION

COMPARATIVE STUDY OF
PENSTOCK MATERIALS
FOR
SURULIYAR POWER HOUSE

ASTM A285 GR.C

Vs
ASTM A537 Cl.1
SCOPE OF WORK
 EXISTING Vs PROPOSED (BY CONTRACTOR)
PIPE MATERIAL & DIMENSION
EXISTING PROPOSED BY CONTRACTOR
PLATE MATERIAL FOR PIPE ASTM A285 Gr.C ASTM A537 CL.1
FABRICATION
EQUIVALENT INDIAN IS2041 / R220 IS 2041 / R355
STANDARD
FORM OF MATERIAL COLD ROLLED PLATES COLD ROLLED PLATES
HEAT TREATMENT NOT HEAT TREATED NOT HEAT TREATED
FINISH PRODUCT 2.5m WELDED PIPE 2.5m WELDED PIPE SEGMENT
SEGMENT (AS PER CONTRACT)
PIPE WALL THICKNESS 10mm > 10mm
(min. after fabrication) (As per work award)
THICKNESS OF EXPANSION 10mm > 10mm
JOINT 21 & 22 (min. after (As per work award)
Fabrication)
COST OF PLATE MATERIAL ASTM A537 CL.1 material is 8000/tonne higher than ASTM
A285 Gr.C
 MECHANICAL PROPERTIES
ASTM A285 ASTM A537 REMARKS
GR.C CL.1
YIELD STRENGTH 205 MPa 355MPa HIGHER YS MEANS GREATER
RESISTANCE FOR DEFORMATION
TENSILE STRENGTH 385-515 490-640 Mpa HIGHER TS MEANS GREATER
Mpa RESISTANCE FOR RUPTURE
ELONGATION % 23% 21% LOWER EL % MEANS LOWER
(MIN) DEFORMATION FOR A GIVEN
FORCE
IMPACT ENERGY HIGHER IMPACT ENERGY MEANS,
AS PER IS GREATER RESISTANCE FOR IMPACT
20°C 50J 80J RUPTURE AT LOWER
TEMPERTARUE (atm to -29°C)
0°C 40J 70J
-20°C 27J 50J
-40°C 20J 40J

=> ASTM A537 CL.1 IS HAVING BETTER MECHANICAL PROPERTIES

 CHEMICAL COMPOSITION
VITAL ASTM A285 ASTM A537 REMARKS
CONSTITUENTS GR.C CL.1
Carbon (%) 0.28 max 0.18 max CONSTITUTES FOR MATERIAL
BRITTLENESS.
LOWER THE CARBON %; LOWER
THE BRITTLENESS AND IMPROVED
WELDING PROPERTIES
Manganese (%) 0.90 1.10-1.70 HIGHER TS MEANS GREATER
RESISTANCE FOR RUPTURE
Phosphorous (%) 0.035 max 0.025 max FORMS OF EMBRITTLEMENT
WHICH REDUCES THE
TOUGHNESS AND DUCTILITY
Sulfur (%) 0.035 max 0.015 max HIGHER “S” CAUSES BRITTLENESS
AND REDUCES WELDABILITY IN
STEEL.

=> ASTM A537 CL.1 IS HAVING BETTER CHEMICAL COMPOSITION W.R.T.

WELDING PROPERTIES
MINIMUM DESIGN TEMPERATURE

 ASTM A285 Gr.C IS

FOLLOWING CURVE ‘D’
“HENCE, IT COULD BE
USED UPTO -10°C
WITH 10MM
THICKNESS”

 ASTM A537 CL.1 IS

FOLLOWING CURVE ‘D’
“HENCE, IT COULD BE
USED ABOVE -40°C
WITH 12MM
THICKNESS”
RECAP OF MATERIAL SELECTION COMMITTEE’S
REPORT

• Based on the detailed analysis, the existing Penstock pipe line

material i.e. ASTM A285 Gr.C having the following material
composition and mechanical properties as provided in the
material specification, is found more suitable for replacement
of new Penstock pipe line in valve house at Suruliyar power
house, based on the service application, Temperature range
(-10˚C to atm, temp.), requirement of mechanical properties
for water application having working pressure upto 100 bar
and in order to maintain the homogeneous material
design along the entire Penstock.
 MERITS OF ADOPTING PROPOSED MATERIAL
• PIPE MATERIAL (ASTM A537 CL.1) COULD ABLE TO WITHSTAND EVEN MORE
HIGH INTENSITY OF WATER HAMMER APART FROM DEISGN VALUE DUE TO
SUPERIOR MECHANICAL AND CHEMICAL PROPERTIES WITH HIGHER
THICKNESS (>10 mm)

• IMPROVED CORROSION ALLOWANCE OWING TO INCREASE IN THICKNESS

• ASTM A537 CL.1 WILL EXIBIT GOOD WELDING PROPERTIES COMPARED TO

EXISTING MATERIAL AND HENCE, POSSIBILITIES OF APPERANCE OF DEFECTS
DURING WELDING WOULD BE VERY LESS, THEREBY INMPROVING QUALITY
OF WELDING

• ASTM A537 CL.1 IS MEANT OF VERY LOW TEMPERATURE SERVICE

COMPARED TO EXISITING MATERIAL AND HENCE, ADDITIONAL PROTECTION
OF PENSTOCK PIPE LINE OVER A PERIOD TIME FROM LOW TEMPERATURE
FATIQUE DUE TO CLIMATIC CONDITION
 CONSEQUENCES OF ADOPTING PROPOSED MATERIAL
• DESIGN OF EXPANSION JOINT 21 & 22 NEED TO BE CHANGED AS THICKNESS
INCREASED (i.e. > 10mm )

• ALIGNING OF PIPE HAVING >10mm THICKNESS WITH 8mm PIPE (AT VALVE
HOUSE END), NEED TO BE CARRIED OUT AT MOST CARE BEFORE WELDING

• CHAMFERING OF PIPE ENDS FOR WELDING TO BE PREPARED ACCORDINGLY

• WELDING OF DIFFERENT COMPOSITION OF PIPE MATERIAL SHALL NEED TO

STUDIED THOURGH EXTERNAL AGENCY THOUGH SAMPLE PIECES , FOR
SELECTING WELDING ROD COMPOSITION

• PIPE SADDLE PLATES AT PIERS SUPPORT NEED TO BE INSTALLED ACCORDING

TO 12mm PIPE THICKNESS AS OUTER DIAMTER CHAGES

• NON- HOMOGENIOUS DESIGN OF PENSTOCK PIPE LINE

EXPANSION JOINT 21 & 22
EXPANSION JOINT 21 & 22
THE END