Part 5 Technical Specification - Final

Rehabilitation of Penstock in Kameng HEP using
combination of CFRP and GFRP Bid Document

Part-5: Technical Specifications
FORM-5: Technical Specifications
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CONTENTS
Section 1 - General .................................................................................................................................... 4
1.1. Scope of Work............................................................................................................................... 5
1.2. Project Details ............................................................................................................................... 5
1.3. Project Challenges....................................................................................................................... 7
Section 2 - Product................................................................................................................................... 12
2.1. General Description................................................................................................................... 13
2.2. General Requirements .............................................................................................................. 14
2.3. CFRP Specification .................................................................................................................... 14
2.4. Design Methods and Requirements ...................................................................................... 15
2.5. Carbon Fabric ............................................................................................................................. 17
2.6. Glass Fabric................................................................................................................................. 18
2.7. Saturating Resin – Polymer ..................................................................................................... 19
2.8. Other Materials ........................................................................................................................... 20
Section 3 - Execution ............................................................................................................................... 21
3.1. General Procedure ..................................................................................................................... 22
3.2. General Requirements .............................................................................................................. 22
3.3. Surface Preparation................................................................................................................... 22
Section 4 – Warranty ............................................................................................................................... 33
Section 5 – Scaffolding ............................................................................................................................ 35
5.1. Introduction ................................................................................................................................. 36
Section 6 – Project Schedule ................................................................................................................. 39
Section 7 – Estimates .............................................................................................................................. 42
Section 8 – Measurement and Payment .............................................................................................. 46
8.0 Measurement and Payment ..................................................................................................... 47
Section 9 – Submittals ............................................................................................................................. 49
9.0 Submittals .................................................................................................................................... 50
Section 10 - Drawings ............................................................................................................................. 51
Section 11 - NEEPCO report on silt concentration and particle size distribution ........................... 55
Section 12 - Penstock Photos .............................................................................................................. 110
Section 13 - Defects on Penstock........................................................................................................ 118
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Section 14 – Laboratory Testing .......................................................................................................... 130

14.1. Slurry ErosionTest ............................................................................................................... 131
14.2. Hydraulic Test ....................................................................................................................... 131
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SECTION 1 - GENERAL
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1.1. Scope of Work

1.1.1. This document presents the design guidance and the minimum required specifications
for rehabilitation of the Kameng Hydroelectric Power Plant Penstock-II by the application
of Fiber Reinforced Polymer (FRP) composite system as the rehabilitation method.
Rehabilitation may be necessitated in one or more zones of Penstock-I. Zone-wise
designs of different zones for Penstock-I shall be identical to that of Penstock-II.
1.1.2. The work includes furnishing of all materials, labor, equipment and services for the
supply, installation and finish of structural strengthening using a Fiber Reinforced
Polymer (FRP) composite system.
1.1.3. The PIA shall include all engineering, design, materials, labor, equipment, tools,
appliances and services required to engineer, deliver, furnish all item necessary for the
proper execution and completion of the work as shown on the “Contract Documents”, as
specified herein and/or as required by job conditions.
1.1.4. The PIA selected by the Owner or General Contractor must include the detailed design
of the FRP system with the installation of the FRP system. All the necessary items for
the proper execution and completion of work which are not shown or specified shall be
provided by the PIA.
1.1.5. The extent of the FRP system covered shall be as defined herein and as shown on the
plans.
1.1.6. The PIA shall cooperate and coordinate with all other trades in executing the work
described in the Bid Documents.
1.1.7. The FRP design shall be per Section 2 - Product item 2.4.2.
1.2. Project Details

The North Eastern Electric Power Corporation Limited (NEEPCO) is developing a hydroelectric
plant near the Kimi Village in the country of India with GPS coordinates latitude 27.16577 and
longitude 92.6824 (Figure 1). NEEPCO is planning to rehabilitate Penstock-II (27.1722840,
92.6798790), which is one of the two steel penstocks at the plant utilizing a combination of glass
fiber reinforced polymer (GFRP) and carbon fiber reinforced polymer (CFRP).
The HPT/ Penstock did not pass the initial filling test when profuse leakage was observed at
surrounding hill slopes after the pressure at MIV registered at about 4.3.MPa. The HPT/
Penstocks were then dewatered, and visual inspection/ NDT test revealed following defects:
a) Cracks in joints possibly due to Hydrogen embrittlement.
b) Offsets beyond allowable limit in circumferential & longitudinal joints.
c) Slag/lack of fusion/ lack of penetration in weld joints.
d) Leaking grout plugs.
e) Doubt of interchange of higher-grade plates with lower grade plates, which is not yet
confirmed.
Restoration of the penstock under the present scope and specification work would require
rectification of all the aforesaid shortfalls. The repair of defective weldments has necessitated
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contact grouting of the HRT/ Penstock to arrest seepage that find access into the penstock
through the cracked joints / joints opened for removing defective weldments. The challenges in
the restoration of the HPT/ Penstocks may be summarized as follows:
a) Grouting to arrest seepage into the HRT/ penstock with limited access.
b) Deposition of weldments at high rate.
c) Ventilation of the HRT/ Penstock for removing dust/ emissions of welding/ grinding.
d) Carrying out repair activities with limited & difficult access.
e) Uncertainty in managing residual stress that may develop due to extensive repair
welding of ferrule joints in restrained conditions.
f) Uncertainty in completion time leading to delay in commissioning of the project.
In view of above stated challenges/uncertainties, the Project Proponent has decided to
undertake repairing of Penstock-2 with CFRP System.
Figure 1: North Eastern Electric Power Corporation Limited-NEEPCO (27.16577, 92.6824)
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Figure 2: Penstock Coordinates (27.1722840, 92.6798790)
Figure 3 illustrates a layout plan of Penstock KaHEP, KIMI for rectification of defects. Table 1
presents briefly a statement of the present problems with the Penstock-II of Kameng HE project.
1.3. Project Challenges

• Large diameter pipe (pipe internal diameter is equal to 3750 mm and 2650 mm).
• High internal pressure (maximum internal design head is equal to 6.94 N/mm2 or 1008
psi).
• The 1.5 Km long Steel Penstock comprises of inclined penstock (Inclination from
horizontal ranging from 150 to 300 approx.) and two vertical shafts of length 100.0 m and
45 m (approx.). Special scaffolding is required to be designed and installed for inclined
and vertical sections.
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• Storage, handling, and on-site transportation of the material and equipment in the limited
access and high-altitude mountain area.
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Penstock-II
Penstock-I
Figure 3: Layout Plan Showing Zoning of Penstock KaHEP, KIMI for Rectification of Defects
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Table 1: Statement of the Present Problem with the High Pressure Tunnel (HPT) Lining & Penstock-II of Kameng HE Project
Location
App.
App. Min. Steel plate
Broad
Sub Internal Design Inclination

Sl Length Elevation Thickness Steel Grade Access Remarks
Location Dia. (m) Pressure of Duct
(m) (m) (mm)
(MPa)
BFV House Manhole(MH)

1 164.62 591.7 3.75 25/36 2.49 ~Inclined
Encased surface Penstock

toAB3 ASTM at AB3
with 0.80m thick RCC

537Gr-II/
2 AB3 to AB4 97.37 541.13 3.75 36/40 2.97 SUMITEN -Do- ~Inclined
encasement
540
3 AB4 to AB5 105.24 514.96 3.75 40 3.38 MH at AB 4 ~Inclined
4 AB5 to AB6 78 514.96 3.75 32 3.44 MH at AB 6 ~Horizontal

Valve House to MIV
5 AB6 to AB8 244.75 402.0 3.75 32/36 4.7 -Do- ~Inclined
6 AB8to AB9 104.04 373.27 3.75 38 5.11 MH at AB 8 ~Inclined
Vertical
thick PCC encasement & Steel

7 105.27 268.00 3.75 36 6.16 Vertical
Underground with 0.5- 1.0 m

Shaft [VS3]
SUMITEN
8 Face XI 346.82 268.00 3.75 36 6.42 780/ASTM ~Horizontal
517 Gr.-F
Support
Vertical
9 42.5 225.50 3.75 40 6.82 MH at AB 8 or Vertical
Shaft [VS5]
MIV
Face XIII
10 [Up to Y- 146.01 225.0 3.75 40 6.91 ~Horizontal
Piece 3]
Y-Piece3 to
11 2x50.03 225.0 2.65 40/32 6.94 ~Horizontal
MIV
10
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SECTION 2 - PRODUCT
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2.1. General Description

A fiber reinforced polymer (FRP) system is typically comprised of carbon fiber, glass fiber (or a
combination of the two), saturating resin, primer resin, and thickened resins as tack coats.
Different types of engineered epoxies can be used for specific purposes (for moist surfaces,
improved abrasion resistance, etc. To reduce the environmental hazards of the CFRP
application in the confined area, such as penstock, an ambient-cure thermoset epoxy system
made of 100% solids and non-volatile organic compounds (VOCs) compliant should be utilized.
The primer layer of epoxy should be applied to fill the pores of substrate and to provide
adhesive bond for thickened epoxy filler, saturating layers and subsequent layers of CFRP
system. The thickened epoxy filler system comprising a mixture of saturating resin and silica
fume should be used to provide smooth surface and intimate contact between the carbon fibers
in accordance with the manufacturer’s recommendation. The topcoat epoxy of the CFRP should
contain pigment admixture for ease of inspection and periodic maintenance in high pressure
pipes, such as penstocks. If the fluid passing into the pipe contains aggressive chemical agents,
the topcoat should be formulated to include chemical resistance to the CFRP system.
Carbon fibers are an isotropic composite material. They are designed and manufactured in
uniaxial and biaxial configuration, where, the highest strength of CFRP is along the fiber
orientation. Hoop direction of the pipelines are exposed to the most of critical stresses,
therefore, the prevalent practice is to deploy uniaxial carbon fibers in the hoop direction.
However, in severely damaged pipes or defective joints, due to construction issues, biaxial
fibers should be considered.
Carbon fibers have the potential for electrical conductivity and can cause galvanic corrosion
when is placed in contact with steel. Therefore, a dielectric barrier is needed to be used
between the carbon fiber and the penstock to prevent this. Although, the epoxy resin and primer
can prevent the electron exchange between the penstock and carbon fibers, but due to the
infinitesimal applied thickness in CFRP system, it is not taken into the consideration. The most
widely accepted practice in this case is to apply a thin layer of dielectric barrier such as glass
fiber between the steel pipe and carbon fibers. This protective layer is not intended to provide
any structural resistance to the CFRP system.
Due to the existence of turbulent slurry flow comprising of suspended solids, an anti-abrasive
top coat onthe FRP system should be used. The top coat material must be validated through
laboratory testing to insure the durability of the top coat against slurry erosion and abrasion
during the warranty period.
Further, as the works are to be executed at multiple fronts inside the penstock with limited
access, possibilities of lapses in real-time supervision gets heightened. This could lead to
development of erroneous or faulty lining patches at few locations, if there are any errors by the
applicator or the local supervisor. Need, therefore, is that the process be controlled by a next
level supervisor who could intervene, if required, and get the rectification of erroneous works
done on a real-time basis. Possible solution of this challenge is the deployment of an inspection
and recording system utilizing drone being flown inside the penstock and video recording being
transferred to the control centre established outside process area on a regular basis. Based on
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the video reporting the main supervisor then would be in a position to provide directions through
a two way radio communication system. This process should be established as one of the
enabling systems for the project.
2.2. General Requirements

2.2.1. Materials for the FRP composite system must be suitable qualified, in compliance with
industry standards, and supplied by a reputable manufacturer approved by the Owner.
2.2.2. Prior to FRP materials are ordered or work is performed, Contractor must identify which
materials are proposed to be utilized and from which manufacturer(s) Contractor
proposes to obtain the materials.
2.2.3. Manufacturer shall certify that every batch or lot of material confirms to this specification,
and shall submit test results for every batch or lot of materials, for the purpose of quality
control testing and certification.
2.2.4. Labeling, packaging and storage shall include any health hazard warnings, precautions
for handling and recommended first aid procedures in case of contact.
2.2.5. All materials used shall confirm to this specification and other documents referenced
within and subject to the approval of the Engineer.
2.3. CFRP Specification

The CFRP system should be formulated and designed to overcome the structural vulnerability
of the penstock joints for shear and axial force as well as flexural strength. The product shall be
tested with the following ASTM standards (Table 2) to report the CFRP material specification for
structural design of the system (if applicable):
Table 2: Applicable ASTM Standards to report the CFRP Material Properties
Standard Standard Specification Required Test Results
• Tensile strength
Standard Test Method for Tensile
1 ASTM D638 • Tensile modulus
Properties of Plastics
• Elongation at break
Standard Test Method for Tensile • Tensile strength
2 ASTM D3039 Properties of Polymer Matrix Composite • Tensile modulus
Materials • Elongation at break
Standard Test Methods for Flexural • Flexural Strength
3 ASTM D790 Properties of Unreinforced and Reinforced
Plastics and Electrical Insulating Materials • Flexural Modulus
Standard Test Method for Compressive • Compressive Strength
4 ASTM D695
Properties of Rigid Plastics • Compressive Modulus
Standard Practice for Plastics: Dynamic
• Density
5 ASTM D4065 Mechanical Properties: Determination and
• Glass Transition (Tg)
Report of Procedures
Standard Test Method for Volatile Content
6 ASTM D2369 • VOC percentage
of Coatings
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In-plane shear strength and In-plane shear

7 ASTM D 5379 • Shear Strength
modulus
Overlap shear strength, Shear bond
strength between CFRP and steel in the
absence of peel-off failure mode, Shear
8 ASTM D7616 • Shear Strength
bond strength between CFRP and steel
when CRFR is used as joint harness and
when peel-off failure mode is likely
Short Beam Strength of Polymer Matrix • Inter Laminar Shear
9 ASTM D 2344
Composite Materials and their Laminates Strength
2.4. Design Methods and Requirements

2.4.1. General Description
Currently there are three accepted design methods for application of CFRP in steel pipes that
are developed by the American Society of Mechanical Engineers (ASME), the international
Organization for Standardization (ISO) and the American Water Works Associations (AWWA).
These codes help the engineers to determine the minimum thickness for the CFRP wrap that
withstand with design internal pressure and other probable loads. Division of the designed
thickness over the thickness of an individual wrap, determines the number of required CFRP
layers.
According to the codes, design of the CFRP system shall be done as per the nature of defect of
the ferrule joints. The potential defects in the ferrule joints stated below:
A) Longitudinal joints: Out of 745 nos of joints, defects to varying extent have been
observed in 283 nos. of joints. In terms of total length of joints (1717.96 RM), total defect
length (465.82RM) stands at 27.11%.
B) Circumferential joints: Out of 640 nos of joints, defects to varying extent have been
observed in 606 nos. of joints. In terms of total length of joints (7310.31RM), total defect
length (3832RM) stands at 52.42%.
It is highlighted that the penstock could be pressurized upto maximum of +4MPa when the
leakage starts, against design pressure of 6.9MPa. Under transient cyclic load under the
expected life of the project, there is likelihood of propagation of defects/cracks leading to
partial/total failure of joints. Details of defects are given in Section-13
2.4.2. Design Requirements
2.4.2.1. The FRP system shall be designed for the following:
• Internal working pressure at salient points shall be as per Table 3:
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Table 3: Internal Working Pressure of Each Zone of Penstock-II

Design Design Sustained
Sl
Penstock Stretch Zone Head Pressure Pressure
No.
(In m) (In Mpa) (In Mpa)
1. BFV House to AB - 1 Zone – 1A 181.0 1.77 1.13
2. AB-1 to AB-2 Zone – 1 210.56 2.06 1.38
3 AB-2 to AB-3 Zone – 2 253.56 2.49 1.69
4. AB-3 to AB-4 Zone – 3 303.39 2.97 2.17
5. AB-4 to AB-5 344.37 3.38 2.50
Zone – 4
6. AB-5 to AB-6 350.76 3.44 2.50
7. AB-6 to AB-7B Zone – 5 417.62 4.09 3.09
8. AB-7B to AB-8 Zone – 6 479.63 4.70 3.61
9. AB-8 to AB-9 Zone – 7 521.13 5.11 3.89
10. AB-9 to BP-16 B ( VS-3) Zone – 8 628.02 6.16 4.92
11. BP-16 B to BP- 17 B (Face- XI) Zone – 9 655.11 6.42 4.92
12. BP-17 B to BP- 18 B (VS-5) Zone – 10 695.61 6.82 5.34
BP-18 B to BP- 19 B
13. 703.01 6.89 5.34
(U/s of Bifurcation)
Zone – 11
BP-19 B to BP- 20 B
14. 704.52 6.91 5.34
(Bifurcation-3)
BP-20 B to MIV Zone – 12
15. 707.85 6.94 5.34
(Powerhouse D-Line) B1 & B2
It may be highlighted that there will be cyclic variation of internal pressure from sustained to
design pressure at least two times a day during load acceptance and load rejection. Variation
from design pressure to no pressure i.e empty condition generally takes place once in 5 year
during maintenance of the system. This aspect of cyclic variation of pressure needs to be duly
considered in design life of the project.
• Corrosion Protection.
• Maintained or improved hydraulic capacity (Include Hazen Williams C value for the
proposed solution along with the total thickness of the FRP liner).
• Abrasion resistance with respect to flow velocity, silt concentrations and particle size
distribution (see Section 11 for the details).
• Thermal expansion and contraction.
2.4.2.2. The bidder must provide a detailed design for the retrofit of a steel penstock with a
diameter of 3.75 m with the exception of the last four segments connecting to the
turbines of which diameter is 2.65 m. The design should be according to the ISO, ASME
or AWWA standards. Also, the bidder must provide detailed complimentary design
supported by FEM analysis using reputed software giving output of all salient design
parameters.
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2.4.2.3. The design life should be at least 50 years of service life or greater unless specifically
specified by the Owner.
2.4.2.4. The CFRP system should be designed to resist internal pressures and external pressure
with leak proof joint. The external pressure shall be the difference between the ground
level vertically above the penstock and the penstock invert level.
2.4.2.5. The wet-layup fabric tube shall have a uniform thickness and excess resin distribution
that when compressed at installation pressures will meet or exceed the design thickness
after curing.
2.4.2.6. Details of the required GFRP and CFRP should be provided in the final project drawings
and should clearly identify the number and type of layers at each location along the
penstock.
2.4.2.7. The FRP should be designed for perfect bonding to the host pipe wall as per design.
2.5. Carbon Fabric

2.5.1. Carbon fabrics shall be uniaxial or biaxial oriented and shall be composed of high
strength, high modulus carbon fibers and shall be chosen among the highest quality
products.
2.5.2. The fabric shall be black in color and impregnated using two component high strength
epoxy resin.
2.5.3. The fabric total weight shall be no less than 1,400 gr/m2 (41 oz/yd2).
2.5.4. Carbon fibers shall be supplied in rolls no less than 61 cm (24 in.) width.
2.5.5. Fiber sizing and coupling agent shall be compatible with the resin system used to
impregnate the fibers. To avoid galvanic corrosion of steel in proximity to carbon fibers, a
non-conductive layer of liner (e.g., fiberglass) may be used to isolate the steel from the
FRP laminate.
2.5.6. Carbon fabric shall provide the minimum physical and mechanical properties listed in
below table (Table 4)
Table 4: Carbon Fabric Minimum Physical and Mechanical Properties
Carbon Fabric and Laminate Properties

Dry Fiber Properties
Aerial Weight 1,400 gr/m2 (41 oz/yd2)
Laminate Properties
Tensile Strength 1,048 MPa (152 ksi)
17
Tensile Modulus 100 GPa(14,500 ksi)

Ultimate Elongation 1%
Breaking force 17.9 KN/cm (10,200 lb/in.)
Ply Thickness 1.7 mm (0.067 in.)
2.6. Glass Fabric

2.6.1. Glass fabric shall be unidirectional or biaxial, white in color, and impregnated using a
two-component high strength epoxy resin.
2.6.2. Glass fabric shall be supplied in rolls with a minimum width of 61 cm (24 in.).
2.6.3. Glass fabric shall provide the minimum physical and mechanical properties listed in
Table 5.
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Table 5: Glass Fabric Minimum Physical and Mechanical Properties

Glass Fabric and Laminate Properties
Dry Fiber Properties
Aerial Weight Fabric Only 815 gr/m2 (24 oz/yd2)
Laminate Properties
Tensile Strength 255 MPa (37 ksi)
Tensile Modulus 14, 616 MPa (2,112 ksi)
2.7. Saturating Resin – Polymer

2.7.1. Fabric shall be impregnated with a two component, high strength and low viscosity
structural epoxy. The resin shall have low viscosity and long pot life, with a fast cure time
designed for high volume saturation of heavy reinforcement fabrics using an impregnator
machine or hand tools as per project requirements to thoroughly and uniformly saturate
the fabric.
2.7.2. The resin system shall be resistant to service environment conditions, including but not
limited to moisture, elevated temperature, and chemicals in the fluid flowing inside the
penstock.
2.7.2.1. The resin system shall not be diluted with any organic solvents such as a thinner.
2.7.2.2. The resin system shall not be used outside of the manufacturer's specified pot life.
2.7.2.3. The resin system shall not be applied when it is cold or frozen.
2.7.2.4. Only moisture tolerant resins shall be allowed to be applied on wet surfaces.
2.7.2.5. Temperature and moisture range for application shall be within the manufacturer's
specified values.
2.7.3. For systems requiring a primer, the primer shall have sufficiently low viscosity to
penetrate the substrate and provide an adhesive bond for the thickened resin applied.
2.7.4. A thickened resin system, which consists of a saturating resin and silica fume applied by
the manufacturer as a premixed or mixed at the site according to the manufacturer’s
recommended procedure, shall be used to provide a smooth surface for the application
of the FRP laminate. The thickened resin system shall be used to fill in surface voids and
even out the substrate. It is permissible to use a thin coat of thickened epoxy between
laminate to enhance adhesion.
2.7.5. Saturating resins shall be 100% solids formulation providing the suggested minimum
requirements listed in below table (Table 6):
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Table 6: Epoxy Resin Properties

Property Value
Viscosity Mixed at 25 °C (77 °F) 1,250 cps
Pot Life at 25 °C (77 °F) 67 min
Cure time 48 hrs
(1)
Part A : 1.16 kg/L (9.67 lb/gal)
Density at 25 ⁰C (77 ⁰F)
Part B (2): 1.00 kg/L (8.27 lb/ gal)
Tensile Strength (ASTM 638) 68.9 MPa (10,000 psi)
Tensile Modulus (ASTM 695) 1,684 MPa (244,200 psi)
Flexural Strength (ASTM D-790) 104.1 MPa (15,100 psi)
Flexural Modulus (ASTM D790) 3,454 MPa (501,000 psi)
Water Absorption (% gain) in 24 hours < 0.5%
Glass Transition [Tg at 25 ⁰C (77 °F)] 61.9 ⁰C / 143.3 °F
Glass Transition [Tg at 80 ⁰C (176 °F)] 80.1 ⁰C / 176.0 °F
Maximum Abrasion
1 mm
(ASTM 4060, 1 kg load, 1,000 cycles)
(1), (2)
Color -Part A is pigmented syrup, Part B is amber liquid
2.8. Other Materials
Contractor to provide compatible primer, filler and other materials recommended by the
manufacturer as needed for the proper installation of the complete surface bonded FRP
composite system.
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SECTION 3 - EXECUTION
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3.1. General Procedure

General work activities associated with the CFRP installation for a steel penstock rehabilitation
that need to be done outside of the penstock include:
• Mixing preparation of the epoxy system
• Saturation of glass and carbon fibers
• Procurement and preparation of the materials prior to installation.
General work activities associated with the CFRP installation inside the penstock include:
• Joint preparation
• Surface preparation
• Installation, and in some cases curing of the CFRP system.
There are several methods for application of CFRPs. Among them, wet-layup is the most
successful and accepted CFRP system installation for large diameter penstock’s joints. This
technique includes saturation of fibers through a mechanical saturator machine that use two
rollers to force the resin into the dry fabric. The gap between the two rollers must be set properly
to ensure that the saturated fabric has the correct resin-to-ﬁber ratio, which is required to be
determined by the manufacturers. The machine saturates the fabrics automatically by passing
them around a PVC tube and deliver them to the crew for installation on the pipe surface. The
operation of the fabric saturation can be carried out inside or outside of the pipe, based on the
diameter, length and the accessibility of the pipe.
3.2. General Requirements

3.2.1. The FRP installation shall be performed in accordance with the manufacturer’s specified
procedure, which should be validated through past experience.
3.2.2. Contractor can propose alternative installation techniques and design improvements to
meet the project goals and design requirements outlined in the drawings and technical
specifications. Such proposed changes will be submitted as a “Performance Work
Statement (PWS)” 30 days before the start of construction and is subject to the approval
of Consultant/Corporation and EOR.
3.3. Surface Preparation

3.3.1. General Description
Surface preparation is the first and most important step of installation procedure. The surface of
the pipe must be cleaned and prepared to provide proper bonding between the CFRP and the
pipe. For a steel pipe, typical surface preparation includes sandblasting or water blasting of the
pipe surface to white metal condition. Later, the surface should be cleaned by air pressure to
remove any loose materials. Extra care should be taken to wipe away the pipes surface
moisture if the resin system is moisture sensitive. Typically, a temperature controlled forced
airflow can provide both ventilation for the working crew and dry pipe surface during the work. If
the pipe is deteriorated and contains small holes, they should be patched. The larger holes it
may be necessary to weld a steel plate over the area. Conversely, if there are any protrusions
due to the rivets or welded seams, they must be smoothened and be coated with high-viscosity
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epoxy, such as a mixture of the same resin used for the saturated fabrics and silica fume, over
those areas.
3.3.2. General Requirements
3.3.2.1. The PIA shall inspect the interior of the pipe to be reinforced with FRP.
Inspection shall check the location and inspect cracks and other defects.
All necessary repair and restoration of a pipe section shall be approved by the Engineer
prior to surface preparation.
The Contractor shall examine the existing conditions to identify potential obstructions
(fittings, flanges, joint restraints, etc.) and constraints; shall verify dimensions, geometry
and access locations; and shall map all visible defects.
An adhesive bond with adequate strength shall always be provided between FRP and
pipe surface. Surface preparation shall also promote continuous intimate contact
between FRP and substrate by providing a clean, and smooth surface. Where a
continuous contact is not possible due to, for instance, a flange along the pipe, the gap
between the FRP liner and pipe shall be filled with epoxy.
3.3.2.2. Surface Grinding/Blasting: All irregularities, unevenness, and sharp protrusions

in the surface profile shall be ground away to a smooth surface with the applicable
surface profile per ACI or NACE standards. Disk grinders or other similar devices shall
be used to remove stain, paint, or any other surface substance that may affect the bond.
Voids or depressions with diameters larger than 38 mm (1 ½ in.) or depths greater than
3 mm (1/8 in.) when measured from a 30 cm (12-in.) straight edge placed on the
surface, shall be filled according to section 3.3.2.4.
3.3.2.3. Crack Injection: All cracks in the substrate that are wider than 0.25 mm (0.010
in.) shall be filled using pressure injection of epoxy. The FRP system shall be installed
no earlier than 12 hours after crack injection. Any surface roughness caused by injection
shall be removed as per section 3.3.6. The limit of crack injection shall be as indicated
on the plans.
3.3.2.4. Surface Profiling: After surface grinding, any remaining unevenness in the
surface greater than that specified in Section 3.3.2.1, fins, protrusions, bug holes,
eroded surfaces shall be filled and smoothed over by using putty made of epoxy resin
mortar or polymer cement mortar.
3.3.2.5. Sealing Leaks: There shall be no apparent leaks prior to application of the FRP
system. Any leaks shall be patched by welding (directly or with patches) or
epoxy/polyurethane grout injection.
3.3.2.6. Surface Preparation for Steel and other Metallic Pipes: The surface of a steel
pipe shall be prepared to achieve adequate bond strength between the FRP system and
the steel substrate. The surface preparation procedure for the steel substrate shall be a
minimum of SSPC SP-10 / NACE No. 2 near white metal surface. A suitable method
shall be used to ensure the required surface profile is achieved. The prepared steel
surface shall be free of materials including epoxy mortar, cement, dust, dirt, and oil at
23
the time of FRP installation. The cleaned steel substrate shall be primed with epoxy prior
to the installation of the initial layer of glass fiber lamina for the system's dielectric
barrier.
3.3.2.7. Due to the existence of the hydraulic power plant at the outlet of the penstock,
sandblasting is not allowed.
3.3.3. Storage, Handling and Disposal

3.3.3.1. Storage Requirements: All components of the FRP system must be delivered
and stored in the original factory-sealed, unopened packaging or in containers with
proper labels identifying the manufacturer, brand name, system identification number,
and date. Catalysts and initiators should be stored separately. All components must be
protected from dust, moisture, chemicals, direct sunlight, physical damage, fire, and
temperatures outside the range specified in the system data sheets. Any component that
has been stored in a condition different from that stated above must be disposed.
3.3.3.2. Shelf Life: All components of the FRP system, especially resins and adhesives,
that have been stored longer than the shelf life specified on the system data sheet shall
not be used and must be disposed of.
3.3.3.3. Handling: All components of the FRP system, especially fiber sheets, must be
handled with care according to the manufacturer recommendations to protect them from
damage and to avoid misalignment or breakage of the fibers by pulling, separating, or
wrinkling them or by folding the sheets. After cutting, sheets shall be either stacked dry
with separators or at a radius no tighter than 12 in. (30 cm) or as recommended by the
manufacturer. Extra consideration/design is required for transportation of the material to
the every section of the Penstock-II. Handling may require special vehicles/machines
that shall be provided by the Contractor.
3.3.3.4. Safety Hazards: All components of the FRP system, especially resins and
adhesives, must be handled with care to avoid safety hazards, including but not limited
to skin irritation and sensitization and breathing vapors and dusts. Mixing resins shall be
monitored to avoid firming and inflammable vapors, fire hazards, or violent boiling. The
Contractor is responsible for ensuring that all components of the FRP system at all
stages of work conform to the local, state, and federal environmental and worker’s safety
laws and regulations. The Contractor is advised that a forced ventilator system may be
required inside enclosed sections and that provision for ventilation, if any, shall be
included in the cost of the work.
3.3.3.5. Safety Data Sheets (SDS): The SDS for all components of the FRP system shall
be accessible to all at the project site. Specific handling hazards and disposal
instructions shall be specified in the SDS section entitled Personnel and Workplace
Protection. The Contractor is responsible for providing the proper means of protection for
safety of the personnel and the workplace. The Contractor shall inform the personnel of
the dangers of inhaling fumes of primer, putty, or resin and shall take all necessary
24
precautions against injury to personnel. The resin mixing area shall be well vented to the
outside.
3.3.3.6. Clean-Up: The Contractor is responsible for the cleanup of the equipment and
the project site from hazardous and aesthetically undesirable FRP components using
appropriate solvents, as recommended in the system data sheet.
3.3.3.7. Disposal: Any component of the FRP system that has exceeded its shelf life or
pot life or has not been properly stored and any unused or excess material that is
deemed waste shall be disposed of in a manner amiable to the protection of the
environment and consistent with the SDS.
3.3.4. Wet-Layup Installation

This section specifies general installation procedures for the wet-layup of FRP systems.
3.3.4.1. Environmental Conditions

Conditions for installation shall be examined before and during installation of the FRP system to
ensure conformity to the contract documents and manufacturer’s recommendations. Do not
apply primers, putty, saturating resins, or adhesives on cold, frozen, damp, or wet surfaces,
unless the resin is moisture tolerant. Ambient and substrate surface temperatures shall be
within 8 °C to 35 °C (46-95 ⁰F). Moisture level on all contact surfaces shall be less than 10
percent at the time of installation of the FRP system, as evaluated according to ACI 503R-93.
Moisture restrictions may be waived for resins that have been formulated for wet applications.
If the work area is a confined space, then the Contractor will be responsible for the training of all
personnel, air testing, safety equipment and complying with the requirements of OSHA.
3.3.4.2. Moisture Vapor Transmissions

Application of bonded FRP systems shall not proceed if any moisture vapor transmission is
present. Substrate dryness is necessary when using elevated temperature cure. Any bubble
that develops from moisture vapor transmission can effectively be injected with the same
adhesive material used for the FRP system following the procedure specified in Section 3.3.6.
3.3.4.3. Application in Inclement Weather

When inclement weather does not allow installation of the FRP system, as specified in Section
3.3.4.1, auxiliary measures may be employed to correct the conditions. An auxiliary heat source
may be used in cold weather to raise the ambient and substrate surface temperatures to
acceptable levels, as recommended by the manufacturer, but not higher than the glass
transition temperature (Tg). Pressurized air may be used to dry the surface dampness.
3.3.4.4. Equipment
The contractor shall provide all necessary equipment in sufficient quantities and clean operating
conditions for continuous uninterrupted FRP installation.
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3.3.4.5. Mixing of Resin Components

All resin components, including the main agent and hardener, shall be mixed at the proper
temperature using the appropriate weight ratio and for a duration specified by the manufacturer
until thorough mixing with uniform color and consistency is achieved. Resins shall not be diluted
with any organic solvents such as a thinner. Electrically powered mixing blades shall be used for
mixing. Resin shall be mixed in quantities sufficiently small to ensure that it can be used within
its pot life. Any mixed resin that exceeds its pot life or begins to generate heat or shows signs of
increased viscosity shall not be used and shall be disposed of according to the SDS. Mixing of
some resins may be accompanied by noxious fumes. Precautions must be taken regarding the
resin’s impact on the environment, including emission of volatile organic compounds.
3.3.4.6. Primer and Putty

When necessary, apply one or two coats of primer on the substrate surface to penetrate its
open pores. Ambient and substrate surface temperatures must be within the range 8 °C to 35
°C (46-95 ⁰F). The putty shall be applied as soon as the primer becomes tack free or is not
sticky to the fingers. The putty shall be applied within 7 days after primer application; otherwise,
the primer- coated surface shall be roughened with sandpaper or a similar tool. The resulting
surface shall be cleaned according to Section 3.3.2.6 before applying the putty. Apply 1 mm
(40-mil) thick coat of putty in one layer, and smooth over the surface to fill in any small voids,
cracks, or uneven areas. Any swelling on the surface after applying the putty shall be corrected
according to section 3.3.2.4. The surfaces of primer and putty shall be protected from dust,
moisture, and any other contaminants before applying the FRP.
3.3.4.7. Saturant
Saturation is the process of impregnating epoxy resin into the fabric at proper ratio. Once the
fabrics are saturated, covered for protection and transported to the pipe repair segments, the
fabrics can be installed using portable scaffolding.
The saturant shall have sufficiently low viscosity to ensure full impregnation of the fiber sheets
prior to curing. To maintain proper viscosity of the saturant, the ambient and substrate surface
temperatures must be within the range specified in Section 3.3.4.1. Any mixed saturant that
exceeds its pot life shall be disposed of according to Section 3.3.3.7.
3.3.4.8. Applying Fiber Sheet and Saturant

The fabric will be uniformly saturated with the saturant using the saturating machine or hand
saturated, where site conditions are not favorable for using the machine. The fabric will be cut to
the length specified in the contract documents and shall be installed in place and gently pressed
onto the wet putty. Any entrapped air between the fiber sheet and the substrate surface shall be
released or rolled across the sheet in the direction parallel to the fibers while allowing the resin
to impregnate the fibers and achieve intimate contact with the substrate. Rolling perpendicular
to the fiber direction is not allowed. In bi-directional fabrics, rolling shall be initially in the fill
(transverse) direction end to end and then in the warp (longitudinal) direction. Subsequent
layers of fabric (if called for in the design) shall be properly saturated with saturant and applied
on top of the first sheet of fabric with no interruption.
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3.3.4.9. Multiple Fiber Plies

If multiple-ply installations, subsequent layers of fabric (if called for in the design) shall be
properly saturated with saturant and applied on top of the first sheet of fabric with no
interruption. The amount of resin overcoat for intermediate plies is approximately 15-20 percent
greater than a single-ply installation because the saturant serves as overcoat for the applied ply
and undercoat for the next ply. Follow the “Contract Documents” for the fiber orientation and ply
stacking sequence. Each ply shall be applied before the onset of complete gelation of the
previous layer. The number of plies that can be applied in a single day shall be based on the
manufacturer’s recommendation and the approval of the Engineer. Multiple plies can also be
applied in several days. When previous layers are cured, interlayer surface preparation, such as
light sanding and filling with putty, may be required, as specified in Section 3.3.4.6.
3.3.4.10. Overlapping
A lap joint shall be constructed when an interruption occurs in the direction of the fibers. The
length of the lap splice shall be as specified by the contract documents, but must be at least 20
cm (8 in.) Staggering of lap splices on multiple plies and adjacent strips shall be required unless
permitted by contract documents. For unidirectional fabrics, no lap joint is necessary in the
transverse direction unless specified in the contract documents.
3.3.4.11. Alignment of FRP/GFRP Materials

The fiber plies shall be aligned on the substrate according to the contract documents. Any
deviation in the alignment more than 5 degrees (approximately 8.3 cm/m - 1 in./ft) is not
acceptable. Once installed, the fibers shall be free of kinks, folds, and waviness.
3.3.4.12. Termination Points

The termination points of the FRP liner shall be designed such that water is not allowed to get
behind the liner. FRP be sealed at termination points to prevent any water seep in between the
FRP and host pipe.
For internal repairs, elastomeric internal joint seals (Weko or approved equivalent) can be used
at the termination points with the appropriate details included in the drawing set.
3.3.4.13. Curing
Unless heat cured, the FRP system shall be allowed to cure for 72 hours (The FRP system
normally reaches its full structural strength within 48 hours or less). Field modification of resin
chemistry for rapid curing is not allowed. Elevated cure temperature may be used, if rapid curing
is necessary. Cure of installed plies shall be monitored before placing subsequent plies. In case
of any curing irregularity, installation of subsequent plies shall be halted. Unless otherwise noted
in the contract documents and approved by the Engineer, the full load shall not be applied until
curing is complete. Protect the FRP system while curing, as specified in section 3.3.4.14.
3.3.4.14. Protective Coating and Finishing

Topcoat is the last layer of CFRP system that protects the liner from the abrasion wear and
reduce the friction coefficient of the surface. The topcoat usually includes pigments to facilitate
future inspection. Topcoat must be applied with adequate thickness to prevent exposure of any
fabric’s strand and need to be applied with the manufacturer prescribed time window to be
27
cured to provide appropriate adhesion to carbon fibers. This layer must be inspected
periodically and maintained according to the manufacturer specifications.
It is permissible to use a top coat to the FRP laminate for abrasion resistance. The top coat shall
be either thickened epoxy, with or without a pigment added to facilitate inspection, or neat resin.
The top coat shall be compatible with exposure conditions including moisture, salt water,
elevated temperature, abrasion, UV exposure, and chemical exposure. Applicability of the top
coat to the FRP laminate in corrosive environments shall be verified by testing.
3.3.4.15. Protective Coating Field Application

Surface preparation shall be as recommended by the manufacturer. Solvent wipes shall not be
used to clean the FRP surface unless approved by the FRP manufacturer. If abrasive cleaning
is necessary, air pressure shall be limited to avoid any damage to fibers. Ambient and surface
temperatures shall be within the range specified in Section 3.3.4.1, prior to applying the
protective coating.
3.3.5. Inspection, Quality Assurance and Tests (QA/QC)

A specific QA plan shall be developed from the tests identified in this section. All inspections
and tests in this section will be performed by a trained inspector acting on behalf of Owner for
QA of the project in the presence of the Contractor and Engineer. The Contractor may have its
own inspector for QC. Required inspections include:
3.3.5.1. Material Inspection
The manufacturer’s certifications for all delivered and stored FRP components will be inspected
for conformity to the contract documents before starting the project. Materials testing will be
conducted on samples if specified in the contract documents. Any material that does not meet
the requirements of the contract documents will be rejected. Additional inspection measures
may be taken during the installation process if specified in the contract documents.
3.3.5.2. Daily Inspection

Daily inspection will include date and time of repair; relative humidity; general weather
conditions; surface dryness; surface preparation and surface profile; qualitative description of
surface cleanliness; type of auxiliary heat source, if any; widths of cracks not injected with
epoxy; fiber or procured laminate batch numbers and their locations in the structure; batch
numbers, mixture ratios, mixing times, and qualitative descriptions of the appearance of all
mixed resins, primers, putties, saturants, adhesives, and coatings; observations of the progress
of the cure of resins; conformance with installation procedures; adhesion test results of bond
strength, failure mode, and location; FRP properties from tests of field sample panels or witness
panels, if required; location and size of any delamination or air voids; and the general progress
of work.
3.3.5.3. Inspection for Fiber Orientation

Fiber or ply orientation, fiber kinks, and waviness will be examined by visual inspection for
conformity to the contract documents. Tolerances will follow Installation of the FRP System. Any
nonconforming FRP area will be removed and required as per Repair of Defective Work.
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3.3.5.4. Inspection for Debonding

After at least 24 hours for the initial curing of the resin, a visual inspection of the surface will be
performed for any swelling, bubbles, voids, or delamination. If an air pocket is suspected, an
acoustic tap test will be carried out with a hard object to identify delaminated areas by sound,
with at least one strike per one 0.1 m2 (ft2). Defects smaller than 12 mm (0.5 in.) in diameter will
require no corrective action, unless as specified in Section 3.3.7.2. Defects larger than 12 mm
(0.5 in.) but smaller than 50 mm (2 in.) in diameter will be repaired as per Section 3.3.6.2.
Defects larger than 50 mm (2 in.) but smaller than 150 mm (6 in.) in diameter, and with a
frequency of less than 5 per any unit surface area of 3 m (10 ft) length or width, will be repaired
as per Section 3.3.6.3. Larger defects will be repaired.
3.3.5.5. Inspection for Cure of Resin

If specified in the contract documents, the relative cure of resin in FRP systems will be
examined by visual inspection or by third party laboratory testing of resin-cup samples using
ASTM D3418. Follow recommendations of the resin manufacturer for acceptance criteria. If the
cure of resin is found unacceptable, the entire area will be marked and repaired.
3.3.5.6. Tests
Specimens from the installed FRP system or samples representative thereof, shall be tested for
tensile and adhesive strengths as described below:
Adhesion test (ASTM D4541):In order to validate the adequacy of the surface preparation and
the adhesion strength of the carbon fiber strengthening system, the Contractor shall perform
random adhesion tests on the prepared steel substrate of pipe segments adjacent to repair
pipes as directed by the Engineer and witnessed by the Owner's inspector. The Owner's
inspector should designate the areas for trial adhesion tests prior to the surface preparation
activities. These areas shall be cleaned, prepared, and covered with two-ply FRP system test
patches with minimum dimensions of 4 in. by 4 in. (10 cm by 10 cm) for adhesion to steel
substrate. The patch shall consist of two orthogonal plies of FRP laminae, with a layer of GFRP
first applied on any steel substrate. Three adhesion tests shall be performed on each test patch.
The remaining adhesion test patches shall be finish coated and remain in place for future testing
purposes as needed. The Contractor shall log the location of the adhesion test and report the
test results to the Owner.
Tensile Test (ASTM D3039): Test panels shall be field fabricated using the carbon/glass fiber
fabric, resins and saturation equipment used in the production runs for the field-installed carbon
fiber strengthening system. Tensile test panels shall be approximately 30 cm by 60 cm (12 in.
by 24 in) by one- or two-ply laminae with carbon fiber oriented in the same direction. The test
panel shall be prepared on a smooth flat surface overlaid with plastic (polyethylene or vinyl)
sheeting. Saturating resin shall be used to prime the surface, followed by the saturated FRP
system, and finally topped with more saturating resin. A cover of plastic sheeting shall be placed
over the panel and the panel squeegeed to remove any bubbles and other surface irregularities
to insure a smooth flat surface. The panel shall be labeled with time, date, and sample panel
number, fabric lot numbers, and resin batch numbers, and stored in an environment
representative of the pipeline inside condition to cure until collected for lab testing.
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The test lab will perform a minimum of ten tensile tests with the fibers oriented in the strong
direction for each tensile test panel in accordance with ASTM D3039, and report certified tests
results for tensile strength, tensile modulus, related specimen dimensions, and percent
elongation. For projects where multiple test panels with the same fabric batch are prepared, it is
permissible to perform 5 tension tests per panel instead of 10 tests per panel, subject to review
and approval by the Engineer.
The FRP system will be unacceptable if the average tensile strength is below that specified in
the contract documents.
The Contractor shall provide a minimum five-year warranty on the material and labor used for
the installation of the FRP system. Any defects that affect the structural and hydraulic
performance of the FRP system shall be repaired by the Contractor at no cost to the Owner.
The methods to repair such defects include, but are not limited to those outlined in Section
3.3.6. Cosmetic defects such as discoloration and minor undulations do not need to be repaired
or included in the warranty. The material and labor warranty provided herein is subject to
periodic inspection as agreed upon by the Owner and Contractor and does not include any
damage caused by direct impact or pressures that are substantially higher than the normal
operation or any loads not included in the FRP design. The Owner will provide all required
access to the area to be repaired.
3.3.6. Repair of Defects

Defects are of different types and may be generally classified as aesthetic, short-term critical, or
long-term critical. Repair procedure depends on the type, size, and extent of defects. Repair
procedures for any conditions not addressed in these specifications or in the contract
documents shall be submitted by the Contractor and approved by the Engineer prior to
proceeding with the work.
This section specifies the conditions and types of defects that require repair and the acceptable
methods of repair. Defects are of different types and may be generally classified as aesthetic,
short-term critical, or long-term critical. Repair procedure depends on the type, size, and extent
of defects. Repair procedures for any conditions not addressed in these specifications or in the
contract documents shall be submitted by the Contractor and approved by the Engineer prior to
proceeding with the work. The conditions and types of defects that require repair and the
acceptable methods of repair are discussed below:
3.3.6.1. Repair of Protective Coating

Defects in protective coating can be of three types: small hairline cracks, blistering, and peeling.
In all cases, moisture content of the substrate should be below 0.05% before applying a new
coating. Prior to any repair of protective coating, the FRP system shall be examined visually or
otherwise to ensure that no defect exists within or on the surface of the FRP. Defects in FRP, if
found, shall be repaired as per sections 3.3.6.3 and 3.3.6.4. If protective coating appears to
show small areas with cracks, the local surface shall be lightly sanded. Then, a new coating with
appropriate primer shall be applied according to the manufacturer’s recommendations. At the
minimum, the coating shall be applied over an area extending 25 mm (1 in.) on either side of the
30
defect. If the protective coating shows signs of blistering, the entire area of blisters as well as
the surrounding area to a distance of at least 30 cm (12 in.) shall be carefully scraped clean. In
no case should a blistered surface be recoated without complete removal of the existing
coating. The area shall be wiped clean and dried thoroughly. Once dry, the area can be
recoated after application of the primer coat if required by the manufacturer. If the surface
shows signs of excessive peeling, the entire coating shall be scraped off and the surface lightly
sanded, wiped clean, and thoroughly dried before applying a new coat according to the
manufacturer’s recommendations.
3.3.6.2. Epoxy Injection of Small Defects

Small entrapped voids or surface discontinuities no larger than 12 mm (0.5 in.) in diameter shall
not be considered defects and require no corrective action unless they occur next to edges or
when there are more than five such defects in an area of 0.1 m2 (10 ft2). Small defects of size
between 12 and 50 mm (0.5 and 2 in.) in diameter shall be repaired using low-pressure epoxy
injection as long as the defect is local and does not extend through the complete thickness of
the laminate in case of multiple-ply FRP systems. If any delamination growth is suspected
between the FRP plies due to injection, the procedure shall be halted, and repair shall follow
details above.
3.3.6.3. Patching of Minor Damage

Minor defects are those with diameters between 50 and 150 mm (2 and 6 in.) and a frequency
of less than five per any unit surface area of 3 m (10 ft) length or width. The area surrounding
the defects to an extent of at least 25 mm (1 in.) on all sides shall be carefully removed. The
area shall be wiped clean and thoroughly dried. The area shall then be patched by adding an
FRP patch of the same type as original laminate and extending at least 25 mm (1 in.) on all
sides of the removed area.
3.3.6.4. Replacement of Large Defects

Defects larger than 150 mm (6 in.) in diameter shall be carefully marked and scarfed out
extending to a minimum of 25 mm (1 in.) on all sides. Scarfing shall be progressing through the
layers in the case of multiple-ply FRP systems until past the defective area. In case the defect
extends to the first FRP ply adjacent to the substrate, the entire thickness of the FRP and primer
shall be removed. The substrate shall be appropriately prepared, and primer reapplied after
ensuring that the surface and FRP are clean and dry. Application of a new FRP system within
the scarfed area shall follow procedures for the original FRP system, except that an additional
layer extending a minimum of 150 mm (6 in.) on all sides of the scarfed area shall be added as
a patch. Once cured, the protective coating shall be applied over the entire area.
3.3.7. Inspection of Rehabilitated penstock

3.3.7.1. The PIA shall design and submit details of facilities to be provided permanently in
the rehabilitated penstock for future periodic inspection. Execution of the facilities shall
be as per approved design and drawing.
3.3.7.2. The periodicity of the inspection shall be as per bid of the PIA. However, it may
be noted by the PIA that there will be a mandatory inspection of rehabilitated penstock
after completion of one year of the rehabilitation work.
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3.3.8. Project Close-Out and Maintenance

3.3.8.1. Documentation of the Work
Owner may provide specification language requiring documentation of the work to be prepared
and submitted by the Contractor on completion of the work. The documentation shall include the
following:
• Information on the products and installation method used
• Pre- and post-inspection results
• Test results
• Any changes or deviations from the contract documents and possible corrective work
Owner's Inspector may also prepare documentation of the project and include the following:
• Purchaser's Inspector's tests and reports
• Material test reports
• Field test reports
• As-built drawings of the renewed or strengthened segments
3.3.8.2. Verification/Basis for Rejection
Materials not complying with the requirements of this specification shall be rejected. Repairs,
replacements, and retesting shall be accomplished in accordance with the Owner's documents.
3.3.8.3. Affidavit of Compliance

Owner may require an affidavit from the Manufacturer or Contractor, as applicable, that the
material provided, or the installation performed complies with the applicable requirements of the
specifications provided herein.
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SECTION 4 – WARRANTY
33
4.0 Warranty
The Contractor shall provide a minimum five-year warranty on the material and labor used for
the installation of the FRP system. Any defects that affect the structural and hydraulic
performance of the FRP system shall be repaired by the Contractor at no cost to the Owner.
The methods to repair such defects include but are not limited to those outlined in Section 3.3.6.
Cosmetic defects such as discoloration and minor undulations do not need to be repaired or
included in the warranty. The material and labor warranty provided herein is subject to periodic
inspection as agreed upon by the Owner and Contractor and does not include any damage
caused by direct impact or pressures that are substantially higher than the normal operation or
any loads not included in the FRP design. The Owner will provide all required access to the
area to be repaired.
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SECTION 5 – SCAFFOLDING
35
5.1. Introduction
5.1.1. Propose
This specification describes the requirements for:
• Working at height
• Temporary access equipment (scaffolding, ladders, etc.)
• Personal fall protection equipment
5.1.2. Scope
This Specification applies to all activities involving scaffolding (inside and outside of the
penstock), working at heights undertaken by Contractor/Sub-Contractor personnel authorized to
work in Kameng Hydro Electric Project. The Contractor must provide scaffold design and its
installation considering the safety of the working crew.
5.2. Deliverable records

The records must include but not restricted to the following items:
• Scaffold inspection report

• Scaffold request forms
• Hazard and effect management process risk assessments and method statements
• Working crew training records and qualifications
• Maintenance and inspection records for plant and equipment
• Design drawing, calculations and design check certificates
• Manufacturer’s instruction manuals and technical data
5.3. Responsibilities
The contractor is responsible to provide safe working environment for all onsite working crews.
The contractor and its representative must, before hiring an employee, acquaint him with the
hazards of his occupation and the preventive measures, which must be adopted. The PIA must
take the necessary precautions to protect the employees during the work from injury to their
health and dangers of work and machinery by:
• Providing adequate safety and hygienic conditions in places of work or the tools he
delivers to the employees for carrying out their duties, according to the Occupational
Safety and Health Administration (OSHA) specifications for scaffolding.
• Making sure that places of work are always clean and comply with the conditions of
health, safety and occupational health.
• Making sure that machinery, pieces of equipment and equipment are installed and kept
in a safe condition.
The PIA is not allowed to charge the employees or deduct from their salaries any amounts for
the provision of such protection.
Inspectors appointed by the Owner have the power to examine the worker-related records of an
establishment and to enter places of work.
36
The following hierarchy of controls is central to this work at height specification and must be
applied in all cases when planning work at height and selecting the most suitable access
equipment and control measures:
• Avoid
o Avoid work at height where possible.
o Design out the need for temporary access.
o Use existing access and places of work - use a safer alternative (e.g. avoiding
the need for people to be exposed to the risk of falling while erecting, altering and
dismantling scaffolding). Assess the suitability of existing places of work,
permanent accesses/stairways before resorting to temporary access and the
risks involved.
o Innovative design and planning - Pre-erect protection on the ground avoiding
elements of work at height e.g. pre-fix guardrail edge protection to structural
steelwork before lifting in to place by crane.
o Avoid handling materials and equipment at height, where possible.
• Prevent
o Choose the most suitable equipment to prevent falls from height of people.
o Prevent objects falling from height.
o Use collective fall prevention measures (e.g., guardrails and toe boards) before
resorting to personal measures (e.g., a fall restraint lanyard and harness, work
positioning or rope access equipment).
o Select and use the correct equipment (specification, design, testing, maintain and
inspection of equipment).
o Engineering calculations, checking, inspection and testing.
o Inspect service and maintain equipment.
o Testing where necessary (e.g. foundations, anchor ties etc.).
• Protect
o Segregate work areas with physical barriers or similar.
o Physical protection measures (e.g. fans, sheeting, pavement gantries) to protect
against falling objects.
o Mitigate the risk - reduce the fall distance or potential severity (e.g. use shorter
ladders or stairways before long ladders).
o Use collective protection measures (e.g. safety netting) over personal (e.g. fall
arrest harness and lanyard).
o Warning signs and sentries.
o Planning for emergencies and rescue.
o Information, Instruction, Training and Supervision.
o Personal Protective Equipment - the last resort (e.g. fall arrest safety harness
and lanyard or head protection for falling objects).
5.4. Design
37
Design of new installations/structures and planning of construction and maintenance, through

design risk assessment and innovative design, will endeavor to eliminate the need to work at
height or provide temporary access equipment. Where temporary access equipment would be
required for construction or future maintenance, then Designers must give consideration to
requirements of such temporary equipment for security, stability, safe assembly and use. The
design must be in compliance with OSHA and be approved by the owner.
38
SECTION 6 – PROJECT SCHEDULE
39
6.0 General
Physical execution of the project for rehabilitation of penstock could be split into various
activities ranging from Proposal receipt, engineering design, planning, design and
documentation, abrasion modeling, mobilization, execution, commissioning and finally
demobilization from site. Milestones of these group activities shall help in appropriate project
control and execution. In addition, each group shall have sub activities which would enable
the total group activity completion. Based on the project requirement the owner desires to
complete the lining process at an early date. The sub activities, however, make it imperative
that each of those is properly concluded for the success of project. Based on this articulated
need consultant has proposed an activity sequence in feasibility study wherein the project
was concluding in 14 weeks from the date of award to PIA. The proposed activity sequence
has been drafted and the same is detailed in schedule given below. The activities and
durations proposed are tentative and the proposer or bidder needs to evaluate the project
work on his own and propose an activity schedule that would enable him to complete the
penstock rehabilitation project. The duration proposed is the maximum time the owner
desires to allocate to the works. Proposer / bidder should attempt to work out the schedule to
compress the time requirement as best as practicable without compromising on the quality of
works.
40
Tentative Schedule of Activities for KaHEP Penstock Restorartion Works
Timeline in Week
Duration Start
Sl. No. Head Activity End Date
(in days) Date
1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th 13th 14th 15th
1.0 Planning, Design and Documentation 10 1 10

1.1 Hydro Test & Final Design 10 1 10
1.2 Project Work Plan and Details Schedule 10 1 10
2.0 Abrasion Resistance Modelling 65 1 65
2.1 Equipment Procurement 10 1 10
2.2 Equipment Setup 6 11 16
2.3 Laboratory Testing 42 16 57
2.4 Report 7 59 65
3.0 Mobilization 41 4 44
3.1 Procurement of Materials 3 10 12
3.2 Procurement of Machines 1 10 10
3.3 Materials and Machines Shipment from US to Indian Port 21 10 30
3.4 Pre-Shipment Inspection 3 10 12
3.5 Customs Clearance at Indian Port 5 31 35
3.6 Materials and Machines Shipment from Indian Port to Site 5 36 40
Execution Stage
3.7 Machine Assembly 1 41 41

3.8 Completion of Inspection and Approval of Ordered Material at Site 1 42 42
3.9 Site Preparations 1 42 42
3.10 Material Storage at Site 1 44 44
3.11 Inspection & Approval for Work Front Availability 1 44 44
3.12 Worker Mobilization 5 31 35
4.0 Field Work 100 1 100
4.1 Inspection and Handling Over (Penstock # 2) (Readiness) 1 1 1
4.2 Shafts Scaffolding 19 1 19
4.3 Surface Preparation 21 7 27
4.4 Cleaning 4 29 32
4.5 Penstocks Scaffolding 47 32 78
4.6 Application of GFRP (Penstock # 2) 48 44 91
4.7 Application of CFRP (Penstock # 2) 48 51 98
4.8 Drone Inspection 46 55 100
5.0 Commissioning Stage 48 53 100
5.1 Completion of all Layers of FRP and Anti- Abrasive Coating 48 53 100
5.2 Final Cleaning of Penstock 14 87 100
5.3 Closeout 14 87 100
41
SECTION 7 – ESTIMATES
42
7.1 General
The project is for designing, executing, & commissioning of Penstock-II of KaHEP on a turn-
key / design-build basis under international competitive bidding process.
The works are for trenchless rehabilitation of a steel penstock of about 1.535 km length and
internal diameters ranging from 3.75m to 2.65m, with majority of diameter being 3.65m. The
maximum pressure at the lowest end is 6.94 MPa or 1006.6 psi. Brief work components
include design, supply and erection of FRP system including surface preparation, application
of GFRP, CFRP, anti-abrasive coating, drone inspection, and testing and commissioning of
lining system for the restoration of the penstock
7.2 Estimated values of the works

Based on the interactions between the Corporation and the Consultant an option of
reinforcing 100% of C&L joints with CFRP to insure structural integrity has been selected.
The option includes the application of glass fiber, carbon fiber, surface preparation and
application of coating to protect the installed liner. Evaluated on the prudent engineering
practices and the work quantities expected the cost of works has been estimated at US$
22,000,000 (US Dollar Twenty-two million only).
• The estimated cost could vary depending on the design process and optimization
level achieved by each bidder. Since the optimization may lead to a lining structure of
insufficient strength, the design submitted by PIA shall be examined and approved by
Consultant/Corporation. In case, the design process fails to produce the satisfactory
results the proposal must be rejected.
• The estimated value of US$ 22,000,000 has been worked out based on the
drawing/details provided by NEEPCO during feasibility study stage. The actual
execution values would be subject to site requirements.
• The gross estimate provided covers the cost of composite solution with the
application of multiple layer system as identified in the preliminary design. The CFRP
layer thickness may be different for different design parameters and thereby the
resulting costs. To evaluate the completeness of design, such parameters, as
adopted by bidder, must be evaluated and the responsiveness of design ascertained.
It must be noted that by under-reinforcing the liner composite the bidder may achieve
an economical bid, however the same may be unable with stand the sever duty
conditions of the penstock and therefore must be rejected. For appropriate
evaluation, the design report from the bidder needs to address stipulations of all
standards as detailed in this design report.
• Following items are excluded from the proposed estimated cost:
o Custom clearance at Indian port
o Customs duties and other incidentals
o Transport cost from Indian ports to project sites
o Taxes in India
o Accommodation cost at site
o Cost of grouting voids
o Cutting and welding of joints
7.3 Project Activities Breakdown
43
The project activities include but are not limited to engineering, mobilization, site setup,
surface preparation, FRP installation, coating, materials testing and inspection and
demobilization etc. Activities for engineering, mobilization, site setup, materials testing and
inspection, and demobilization in a design-build contract shall be subject to the base
parameters and design process. This shall vary from designer to designer as per the levels
of optimization and material quality selection. It is therefore evaluated that the following 8
activities shall comprise the broad work structure with surface preparation, FRP installation
and coating being measurable items whereas other being lump sum quantities. In addition to
these drone inspection system being an enabling system is also considered as a
measurable item of work. A representative table providing various quantities and unit of
measurement, is detailed at table no. 7.
Table 7–Table showing various items

ITEM QTY. UNIT
NO
1. Detail design and drawings of FRP System as LS LS
detailed in the Bid complete
2. Supply, manufacture, testing and site
installation of FRP System in various
stretches of the Penstock as detailed below
including provision for all labour, tools and
tackles, plant & material as per technical
specification of the Bid complete.
Sub Penstock Stretch Zone RM RM
Item
a. BFV House to AB -1 Zone – 1A 26.13 M
b. AB-1 to AB-2 Zone – 1 51.26 M
c. AB-2 to AB-3 Zone – 2 87.23 M
d. AB-3 to AB-4 Zone – 3 97.37 M
e. AB-4 to AB-5 105.24 M
Zone – 4
f. AB-5 to AB-6 78 M
g. AB-6 to AB-7B Zone – 5 118.13 M
h. AB-7B to AB-8 Zone – 6 126.62 M
i. AB-8 to AB-9 Zone – 7 104.04 M
j. AB-9 to BP-16 B (VS-
Zone – 8 105.27 M
3)
k. BP-16 B to BP-17 B
Zone – 9 346.82 M
(Face-XI)
l. BP-17 B to BP-18 B
Zone – 10 42.5 M
(VS-5)
m. BP-18 B to BP-19 B 146.01 M
(U/s of Bifurcation)
Zone – 11
n. BP-19 B to BP-20 B
(Bifurcation-3)
o. BP-20 B to MIV 100.06 M
Zone – 12
(Powerhouse D-Line) (2 x
B1 & B2
50.03)
3. Surface preparation including all labour tools 17750 Sqm
and tackles, plant and material for installation
of FRP system as per technical specifications
44
of the Bid complete

4. Supply, manufacture, testing and site 17750 Sqm
installation of Anti abrasive top coating
including all labour, tools and tackles, plant &
material as per technical specification of the
Bid complete
5. Hydrostatic testing of FRP system as per LS LS
technical specifications complete
6. Drone Inspection of the entire stretch fitted LS LS
with FRP System as per specification of the
Bid complete
Note:
Any item not expressly indicated above in the BoQ but necessary to complete the works as
per specifications are deemed to be included in the scope of works of the Contractor
45
SECTION 8 – MEASUREMENT AND PAYMENT
46
8.0 Measurement and Payment

The items of works in BOQ shall be measured and paid as detailed hereunder:
8.1 Detail design and drawings of FRP System: The PIA shall be responsible for
complete detail design and drawings of FRP system as detailed in the Technical
Specifications. Initially the PIA shall submit three (03) sets of Design and Drawings to
the Consultant /Corporation for examination and approval. Necessary modification in
Design and Drawing shall be carried out by the PIA whenever asked by the
Consultant / Corporation. The PIA shall adhere to observations/ comments/
necessary corrections as desired by the Consultant /Corporation. The Corporation
reserves the right to demand any additional information deemed necessary to be
included in submitted documents
After finalization of design and drawing the PIA shall submit six (06) sets of Design
and Drawings for formal approval of the Consultant / Corporation.
This Design and Drawings shall be consistent with PIA’s submittals in the bid and
shall include the following:
a) Design assumptions and calculations,
b) Separate drawings for zones and bends and key points such as bifurcation
/reducer.
c) Facility to be provided for future inspection of rehabilitated penstock including
detailed method of inspection
d) Comprehensive methodology of planned execution of the job.
Payment for the item shall be on lump sum basis. Fifty percent (50%) payment shall
be released on approval/acceptance of the Design, Drawing Documents by the
Consultant /Corporation, and the balance fifty percent (50%)shall be released on
acceptance of results of Hydraulic model testing of FRP System.
8.2 Supply, manufacture, testing and site installation of FRP System: Measurement
shall be done in running meter (RM) length of the penstock rehabilitated upto two
decimal places.
The number of FRP layer shall be as per the approved design and drawing. In
measurement of FRP System, the length of penstock rehabilitated shall only be
considered disregarding the number and thickness of individual layers.
No separate payment shall be made for the overlap and repairing of defective layers,
if any.
8.3 Surface preparation for installation of FRP System: Measurement shall be done in
square meter (Sqm) of surface area of the penstock upto two decimal places. The
area shall be calculated as per length and perimeter of existing ferrule of the
respective zones.
Payment shall only be made after preparation of the entire stretch of penstock of a
particular zone for installation of FRP system to the satisfaction of the Consultant
/Corporation. The PIA shall redo the stretch of penstock if not found to be satisfactory
by the Consultant /Corporation. No separate payment shall be made for redoing
surface preparation.
47
8.4 Supply, manufacture, testing and site installation of anti-abrasive top coating:
Measurement shall be done in square meter (Sqm) of surface area of the penstock
upto two decimal places. The area shall be calculated as per length and perimeter of
existing ferrule of the respective zones.
Payment shall only be made after successful completion of anti-abrasive coating on
the entire stretch of penstock to the satisfaction of the Consultant /Corporation. The
PIA shall redo the stretch of penstock if not found to be satisfactory by the Consultant
/Corporation. No separate payment shall be made for redoing any coating.
8.5 Hydraulic Testing of FRP System: Payment for the item shall be on lump sum basis.
Payment shall only be made on successful completion of the test to the satisfaction
of the Consultant/ Corporation. The Consultant /Corporation has the right to accept or
reject the test results.
No separate payment shall be paid for faulty arrangement of the testing system or
repetition of the test procedure due to non-achievement of the desired test results.
PIA has to prepare the entire test facility to the satisfaction of the Consultant/
Corporation, as laid down in Section 14 of the Technical Specification & design (Part
5) of the bid document.
8.6 Drone inspection of the entire stretch of penstock fitted with FRP system: Drone
inspection shall be as per bid submittal of PIA. Payment shall be made on lump sum
basis after successful completion of the work to the satisfaction of the Consultant/
Corporation.
8.7 Measurement for all measurable items shall be in metric system.
48
SECTION 9 – SUBMITTALS
49
9.0 Submittals
• The Contractor must submit certifications of applicator with written consent from the
FRP manufacturer that the Contractor has been trained in proper application of
manufacture’s system.
• For alternative materials, the Contractor:
o Must submit installation procedures and general recommendations regarding
each material to be used.
o Must receive the approval by the Engineer of Record (EOR) 10 days prior to
the bid date.
o Must submit FRP Manufacturer’s Safety Data Sheets (SDS) for all materials
to be used. FRP Manufacturer’s Safety Data Sheets (SDS) must be approved
by EOR.
• The Contractor must submit:
o The test results conducted according to the ASTM standards as applicable to
the project
o The CFRP design according to the ISO, ASME or AWWA standards
o The scaffold design according to the OSHA standard.
o Certification of training for all the workers according to the OSHA standard.
o Warranty documents according to the section 4
o Storage, handling and transportation detail plans.
50
SECTION 10 - DRAWINGS
51
52
53
54
SECTION 11 - NEEPCO REPORT ON SILT CONCENTRATION AND PARTICLE SIZE

DISTRIBUTION
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
SECTION 12 - PENSTOCK PHOTOS
110
111
112
113
114
115
116
Document Prepared by IndSTT jointly with CUIRE for the internal use of NEEPCO.
Unauthorized copying of contents without written permission of NEEPCO/IndSTT/CUIRE is not
permitted.
117
SECTION 13 - DEFECTS ON PENSTOCK
118
Summary of Pre Rectification UT of L-Joints and Defects Identified for Penstock-2
%age of Defect to
Total UT done Defect identified
be repaired
Total Total In
ZONE number length Offset in
In terms terms
of Joints (M) No. of Length No. of Length Brief description mm with
of no. of of
Joints (M) Joints (M) of defects length of
Joints Lengt
offset
h
P2-Z1+A (AB
16 16 28.56 0 0 0.00 0.00
1-1)
LOF +Crack-04nos
P2-Z1 (AB 1- LOF-3nos
19 19 52.99 8 15.5 NIL 42.11 29.25
1) LOF +Crack+Slag-
01nos
LOF-3nos
P2-Z2 (AB 1- LOF+SLAG-8nos
57 57 160.52 20 29.26 LOF +Crack-08noS NIL 35.09 18.23
2)
lof+crack+slag-
01Nos
LOF-2nos
LOF+CRACK-
P2-Z3 (AB 1-
47 47 136.19 13 19.4 05Nos NIL 27.66 14.24
3)
LOF+Crack+Slag-
6Nos
119
LOF +Crack+Slag-
06nos
LOF-5nos
P2-Z4 (AB 4-
100 100 235.13 47 92.5 LOF +Crack-29no NIL 47.00 39.34
6)
LOF+slag-4nos
LOF+Crack+LOP-
2no
LOF +Crack+Slag-
01nos
P2-Z5 (AB 6- LOF-1nos
48 48 113.97 16 32.23 NIL 33.33 28.28
7) LOF +Crack-12no
LOF+slag-2nos
P2-Zone 6 LOF +Crack+Slag-

52 52 117.06 13 24.58 2nos NIL 25.00 21.00
(AB 7-8)
LOF +Crack-11no
P2-Zone 7 LOF +Crack-19no
43 43 101.44 20 43.29 NIL 46.51 42.68
(AB 8-9) LOF-1nos
LOF-3nos
LOF+SLAG-1nos
P2-Zone 8 LOF +Crack-04noS
56 56 117.83 10 14.110 NIL 17.86 11.97
(VS-3) lof+crack+slag-
02Nos
LOF-1nos
LOF+SLAG-5nos
P2-Z9 (face- LOF +Crack-12noS
138 138 338.64 19 31.28 NIL 13.77 9.24
XI) lof+crack+slag-
01Nos
P2-Z 10 (VS- LOF-2no
30 30 54.01 4 4.7 LOF +Crack-3no NIL 13.33 8.70
V)
120
LOF+Crack-
27nosLOF+slag-
P2-Z 11 6nosLOF-
63 63 133.54 45 72.43 NIL 71.43 54.24
(FACE XIII) 9noCRACK-
1noSlag+ Crack-
2no
LOF-12nos
LOF+Crack-16nos
P2-Z12-B1 LOF+Crack+Slag-
37 37 61.89 35 41.095 NIL 94.59 66.40
(FACE XVI) 3nos
LOF+Slag-5nos
LOF+Slag-1nos
LOF+Crack-13no
P2-Z12-B2 LOF-13nos
39 39 66.19 30 45.445 NIL 76.92 68.66
(FACE XVII) LOF+ CRACK+
Slag-3nos
Total 745 745 1717.96 280 465.82 37.58 27.11
121
122
Summary of Pre Rectification UT of C--Joints and Defect Identified for Penstock-2
%age of Defect
Total UT done Defect identified
to be repaired
Total Offset
Total In In
numbe No. in mm
ZONE lengt No. of Brief terms terms
r of Lengt of Lengt with
h (M) Joint description of of no. of
Joints h (M) Join h (M) length
s defects of Lengt
ts of
Joints h
offset
LOF-4Nos
P2-
LOF+Crack-
Z1+A 106.07
9 9 8 62.124 8nos 88.89 58.57
(AB 1- 4
LOF+SLAG-2
1)
nos
LOF-21Nos <10mm,
LOF+Crack- L-
20nos 4670m
LOF+Slag- m
05nos in4Patc
P2-Z1
223.93 173.65 CRACK-1nos hes
(AB 1- 19 19 19 100.00 77.55
4 5 <15mm,
1)
L-
5670m
m in
4Patche
s
LOF- 29nos <10mm,
LOF+Crack- L-
23nos 4690m
LOF+Slag-9nos m in
LOF+CRACK+ 5Patche
SLAG-3nos s
LOF+LOP-2nos <15mm,
L-
P2-Z2
191.70 19750m
(AB 1- 31 31 356.38 30 96.77 53.79
2 m in
2)
16Patch
es
<20mm,
L-
1060m
m in
1Patche
s
123
LOF-10 Nos <10mm,

LOF+Slag- L-
10nos 3830m
LOF+Crack- m in
31nos 4Patche
LOF+CRACK+ s
SLAG-11nos <15mm,
L-
18950m
m in
12Patch
es
<20mm,
L-
P2-Z3
400.72 138.60 10800m
(AB 1- 34 34 32 94.12 34.59
4 6 m in
3)
6Patche
s
>20mm,
L-
2320m
m in
2Patche
s
>25mm,
L-
6635m
m in
2Patche
s
LOF-4 Nos <10mm,
LOF+Slag- L-
21nos 17515m
LOF+Crack- m in
28nos 21Patch
LOF+CRACK+ es
SLAG-18 nos <15mm,
LOF+ LOP+ L-
P2-Z4
937.22 568.64 SLAG-1 nos 39350m
(AB 4- 80 80 76 95.00 60.67
2 6 LOF+Crack+LO m in
6)
P-1no 36Patch
es
>20mm,
L-
26040m
m in
16Patch
es
124
LOF-20 Nos <10mm,

LOF+Slag- L-
20nos 2090m
LOF+Crack- m in
41nos 03Patch
P2-Z5
565.72 197.41 LOF+CRACK+ es
(AB 6- 48 48 45 93.75 34.89
8 0 SLAG- 05nos <15mm,
7)
LOF + L-
CRACK+porosi 8400m
ty-1 nos m in
09Patch
es
LOF- 18Nos <10mm,
LOF+Slag- L-
23nos 12180m
LOF+Crack- m in
30nos 11Patch
LOF+CRACK+ es
SLAG-14 nos <15mm,
L-
19170m
m in
20Patch
es
>20mm,
P2- L-
Zone 601.08 250.82 5600m
51 51 48 94.12 41.73
6 (AB 6 1 m in
7-8) 4Patche
s
>25mm,
L-
3140m
m in
1Patche
s
>30mm,
L-
450mm
in
1Patche
s
LOF-5Nos <15mm,
P2- LOF+Crack- L-
Zone 112.14 47nos 13510m
35 35 412.51 33 94.29 27.19
7 (AB 8 m in
8-9) 5Patche
s
125
<20mm,
L-
12936m
m
in2Patc
hes
>20mm,
L-
2200m
m in
1Patche
s
LOF-5 <10mm,
NosCRACK- L-
2NosLOF+Slag 4420m
- m in
5nosLOF+Crac 2Patche
k- s<15mm
22nosLOF+CR ,L-
ACK+SLAG-31 11980m
nos m in
10Patch
es<20m
m,L-
15520m
m in
P2-
7Patche
Zone 612.87 464.54
53 53 50 s>20mm 94.34 75.80
8 (VS- 2 7
,L-
3)
2620m
m in
2Patche
s>25mm
,L-
21421m
m in
2Patche
s>30mm
,L-
3600m
m in
2Patche
s
126
LOF-27 Nos <10mm,

CRACK-5Nos L-
LOF+Slag- 30710m
14nos m in
LOF+Crack- 27Patch
213nos es
LOF+CRACK+ <15mm,
SLAG-22 nos L-
LOF+ LOP+ 46880m
SLAG-1no m in
41Patch
P2-
1620.0 697.89 es
Z9(FA 138 138 127 92.03 43.08
18 2 <20mm,
CE-XI)
L-
27300m
m in
17Patch
es
>30mm,
L-
850mm
in
1Patche
s
LOF-30Nos <10mm,
LOF+Crack- L-
46no 15420m
Crack-09 m in
LOF+slag-3no 17Patch
es
<15mm,
L-
42760m
m in
28Patch
P2-Z
119.15 es
10 30 30 340.43 30 100.00 35.00
8 <20mm,
(VS-V)
L-
15290m
m in
11Patch
es
>20mm,
L-
6200m
m in
3patche
s
127
>30mm,
L-
2350m
m in
1Patche
s
LOF+Crack-31 <10mm,
nos L-
LOF+crack+sla 22310m
g-6no m in
LOF- 4nos 22Patch
LOF+LOP-4nos es
LOP+ <15mm,
LOF+Crack- L-
6nos 67525m
LOF+slag-1no m in
45Patch
es
<20mm,
P2-Z L-
11 660.01 14310m
56 56 55 488 98.21 73.91
(FACE 6 m in
XIII) 9Patche
s
>20mm,
L-
14530m
m in
4patche
s
>35mm,
L-
2110m
m in
1Patche
s
LOF+Crack- <10mm,
19nos L-
LOF+Slag-5 3430m
nos m in
P2-
LOF+Crack+Sl 3Patche
Z12-
ag-5nos s
B1 29 29 239.08 29 178 100.00 74.65
<15mm,
(FACE
L-
XVI)
12980m
m in 5
Patches
<20mm,
128
L-
6790m
m in
4Patche
s
>20mm,
L-
630mm
in 1
patches
>25mm,
L-
1550m
m in
1Patche
s
LOF-1nos <10mm,
LOF+Crack+Sl L-
ag-4nos 1980m
LOF+Crack- m in
22nos 2Patche
LOF+slag-1 no s
<15mm,
P2-
L-
Z12-
234.23 4460m
B2 28 28 28 189 100.00 80.74
2 m in
(FACE
3Patche
XVII)
s
<20mm,
L-
4390m
m in
4Patche
s
7310.3
Total 641 641 610 3832 95.16 52.42
1
129
SECTION 14 – LABORATORY TESTING
130
14.1. Slurry ErosionTest

Slurry erosion and abrasion of the topcoat is a concern that is elaborated in the section 3.2. A
laboratory testing is required to simulate the slurry flow of the penstock and evaluate the
resistance of the topcoat to the slurry erosion. The tests shall be carried out for different type of
topcoats material. In addition, the test shall demonstrate the topcoats life time exposed to the
slurry erosion.
14.2. Hydraulic Test

Reliable and durable rehabilitated penstock must have adequate resistance against static and
recurring pressure surges to avoidfailures. A sets of experimental testing are required by PIA to
confirm the design assumptions and factors. The tests shall be carried out in full-scale or
scaled-size hydraulic tests and be design to evaluate the strength of the CFRP system against
fatigue and long term static internal pressureunder the penstock condition. The experimental
tests shall be designed to evaluate CFRP rehabilitated steel pipe with defective joints, or pipe-
shaped CFRP only to assess CFRP ultimate strength. The detailed methodology for performing
the test shall be finalized and test shall be carried out by the Consultant at CURIE. The entire
cost of the test including the material, equipment and man-power shall be borne by the PIA and
the same shall be duly embedded in the bid price.
131

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Part 5 Technical Specification - Final

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Rehabilitation of Penstock in Kameng HEP using

combination of CFRP and GFRP Bid Document

FORM-5: Technical Specifications

Section 14 – Laboratory Testing .......................................................................................................... 130

1.1. Scope of Work

1.2. Project Details

Figure 1: North Eastern Electric Power Corporation Limited-NEEPCO (27.16577, 92.6824)

Figure 2: Penstock Coordinates (27.1722840, 92.6798790)

1.3. Project Challenges

Sub Internal Design Inclination

BFV House Manhole(MH)

Encased surface Penstock

with 0.80m thick RCC

4 AB5 to AB6 78 514.96 3.75 32 3.44 MH at AB 6 ~Horizontal

5 AB6 to AB8 244.75 402.0 3.75 32/36 4.7 -Do- ~Inclined

6 AB8to AB9 104.04 373.27 3.75 38 5.11 MH at AB 8 ~Inclined

thick PCC encasement & Steel

Underground with 0.5- 1.0 m

2.1. General Description

2.2. General Requirements

2.3. CFRP Specification

In-plane shear strength and In-plane shear

2.4. Design Methods and Requirements

2.4.2. Design Requirements

2.4.2.1. The FRP system shall be designed for the following:

• Internal working pressure at salient points shall be as per Table 3:

Table 3: Internal Working Pressure of Each Zone of Penstock-II

2.5. Carbon Fabric

Table 4: Carbon Fabric Minimum Physical and Mechanical Properties

Carbon Fabric and Laminate Properties

Tensile Modulus 100 GPa(14,500 ksi)

2.6. Glass Fabric

Table 5: Glass Fabric Minimum Physical and Mechanical Properties

2.7. Saturating Resin – Polymer

Table 6: Epoxy Resin Properties

3.1. General Procedure

3.2. General Requirements

3.3. Surface Preparation

3.3.2.2. Surface Grinding/Blasting: All irregularities, unevenness, and sharp protrusions

3.3.3. Storage, Handling and Disposal

3.3.4. Wet-Layup Installation

3.3.4.1. Environmental Conditions

3.3.4.2. Moisture Vapor Transmissions

3.3.4.3. Application in Inclement Weather

3.3.4.5. Mixing of Resin Components

3.3.4.6. Primer and Putty

3.3.4.8. Applying Fiber Sheet and Saturant

3.3.4.9. Multiple Fiber Plies

3.3.4.11. Alignment of FRP/GFRP Materials

3.3.4.12. Termination Points

3.3.4.14. Protective Coating and Finishing

3.3.4.15. Protective Coating Field Application

3.3.5. Inspection, Quality Assurance and Tests (QA/QC)

3.3.5.2. Daily Inspection

3.3.5.3. Inspection for Fiber Orientation

3.3.5.4. Inspection for Debonding

3.3.5.5. Inspection for Cure of Resin

3.3.6. Repair of Defects

3.3.6.1. Repair of Protective Coating

3.3.6.2. Epoxy Injection of Small Defects

3.3.6.3. Patching of Minor Damage

3.3.6.4. Replacement of Large Defects

3.3.7. Inspection of Rehabilitated penstock