R-Afry-4649.04.501 - r2 Ps Liner Design - 1

Pinnapuram PSP (1680 MW)
Greenko Energy Projects Ltd.

Design of Pressure Shaft Steel Liner Along Unit-1 R-
AFRY-4649.04.501_R2.docx
Page 1/84

Design of Pressure Shaft Steel Liner Along Unit-1
R-AFRY-4649.04.501_R2
15 June 2022
Copyright © AFRY India Pvt. Ltd.

The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is
prohibited.
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Imprint
Owner EPC Contractor
Greenko Energy Projects Ltd. MEIL
Owner’s Engineer Design Consultant
TATA Consulting Engineers Ltd & EDF AFRY India Pvt. Ltd.
(Formerly, AF Consult India Pvt. Ltd.)
Document Information
Project Pinnapuram PSP (1680 MW)
Document Design of Pressure Shaft Steel Liner Along Unit-1
Project number 4649
Document number R-AFRY-4649.04.501_R2
Department Hydropower
Document path N:\Working Designs\4649-Pinnapuram PSP\Engineering\Detailed

Design\Reports\HM Works
First Edition
Description Date Initials By Sign
Created 10/01/2022 Kamal Nayan KNA
Verified 11/01/2022 TSK Singh TSK
Released 12/01/2022 Sai Seela SSE
Report history
Rev. Description Created By Approved By Date
Revised as per comments given by

Greenko’s email dated 19.01.2022 and
01 KNA TSK/ SSE 11.02.2022
OE’s comment letter 11869A-PPSP-VDT-
CV-187 dated 29.01.2022
Revised as per comments given by

Greenko’s email dated 04.04.2022 and
01 KNA TSK/ SSE 15.06.2022
OE’s comment letter 11869A-PPSP-VDT-
CV-217(A) dated 07.03.2022
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Contents
1 Introduction .................................................................................................................. 5
1.1 Objective of the Report ......................................................................................... 5
2 References .................................................................................................................... 5
2.1 List of Drawings ................................................................................................... 5
3 Design Data .................................................................................................................. 7
4 Design Loads................................................................................................................. 8
4.1 General ............................................................................................................... 8
4.2 Design Internal Pressure ....................................................................................... 8
4.3 Design External Pressure ....................................................................................... 9
5 Steel Materials............................................................................................................... 9
6 Allowable Stresses ....................................................................................................... 10
7 Design Criteria ............................................................................................................ 11

7.1 General ............................................................................................................. 11
7.2 Corrosion Allowance ............................................................................................ 11
7.3 Minimum Thickness for transportation and Handling................................................ 11
7.4 Design for Internal Pressure ................................................................................. 11
7.4.1 Hoop Stress .......................................................................................... 11
7.4.2 Poisson’s effect of Hoop stress ................................................................ 12
7.4.3 Temperature Stresses ............................................................................ 12
7.4.4 Equivalent Stresses ............................................................................... 12
7.5 Design for External Pressure of Pipe Embedded in Rock ........................................... 13
7.5.1 Design for Unstiffened Shell .................................................................... 13
7.5.2 Design for Stiffened Shell ....................................................................... 13
7.6 Design for External Pressure of Buried Steel Pipe .................................................... 14
7.6.1 Applied Load ......................................................................................... 14
7.6.2 Ovality ................................................................................................. 15
7.6.3 Through-Wall Bending ............................................................................ 16
7.6.4 Crushing of Side Walls ........................................................................... 16
7.6.5 Ring Buckling ........................................................................................ 17
7.7 Specials for Penstocks ......................................................................................... 18
7.7.1 Reducer Piece ....................................................................................... 18
7.7.2 Anti-percolations Rings........................................................................... 18
7.7.3 Bends .................................................................................................. 19
7.7.4 Grouting ............................................................................................... 19
8 BRIEF SUMMARY .......................................................................................................... 19
9 CONCLUSION .............................................................................................................. 21

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List of Tables
Table 2-1: List of Drawings .................................................................................................. 5
Table 3-1: Penstocks: Basic Design Parameter ....................................................................... 7
Table 4-1: External pressure acting of Penstocks .................................................................... 9
Table 5-1: Properties of Penstock Steel Material ..................................................................... 9
Table 6-1: Allowable stresses for Normal Operating condition ................................................. 10
Table 6-2: Allowable stresses for Emergency condition .......................................................... 10
Table 7-1: Requirement of Minimum Handling Thickness of Steel Plates .................................. 11
Table 7-2: Sizing of Anti-percolations rings .......................................................................... 19
Table 8-1: Summary of the Penstock Steel Liner Thickness .................................................... 19
List of Figures
Figure 1: Ovality of Pipe Cross Section ................................................................................ 15
Figure 2: Through-Wall Bending Stress................................................................................ 16
Figure 3: Crushing of Side Wall .......................................................................................... 17
Figure 4: Ring Buckling of Pipe Cross Section ....................................................................... 17
List of Annexures
Annexure 1: Design Pressure Line Diagram ........................................................................ 22
Annexure 2: Design for Internal Pressure ............................................................................ 24
Annexure 3: Design for External Pressure of Pipe Embedded in Rock ...................................... 33
Annexure 4A & 4B: Design for External Pressure of Buried Steel Pipe .................................... 38
Annexure 5: Welds size thickness calculations for stiffeners & anti percolation rings ................. 73
Annexure 6: True angle calculations for Compound Bend (Bend-2A) ....................................... 83

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1 Introduction
Pinnapuram Pump Storage Project (6 x 240 + 2 x 120 MW) is a part of Integrated
Renewable Energy Project (IRESP), located in Pinnapuram, Kurnool district of Andhra
Pradesh, being developed by Greenko Energy Projects Pvt. Ltd (GEPPL), Hyderabad.
Pinnapuram PSP has been conceived as the World’s First & Largest Gigawatt Scale
integrated project with solar, wind and pumped storage components that can supply
Schedulable Power on Demand (SPOD) which is Dispatchable & Schedulable Renewable
Energy for the first time to consumers across India. M/s GEPPL has appointed AFRY, for
carrying out the detailed design engineering services for Hydro Mechanical Works of PSP.
1.1 Objective of the Report

The present design report covers the structural design of the steel lining of penstock along
unit-1 for Pinnapuram PSP. The design of penstock appurtenances like Manholes (if any),
Thrust collar, etc. are not included in this report. The scope of the report is oriented
toward:
- Selection of the material of steel liner.

- Estimating steel lining thickness for penstock.
2 References
Design of the penstock liner thickness shall be as per the following codes:
- IS: 11639 (Part – 2): Structural design of Penstocks – Criteria (Buried/ Embedded
Penstocks in Rock).
- ASCE Manuals and Reports on Engineering Practice No. 79(1993),
”Steel Penstocks”, New York.
- Guideline for the Design of Buried Steel Pipe, July 2001. Prepared by American
Lifelines Alliances, and duly reviewed by FEMA & ASCE.
- IWWA – Manual on Design and Selection of pipes for Water Supply.
- USBR Technical Report – Modulus of Soil Reaction (E’) Values for Buried Flexible
pipes
- Andritz Transient Analysis Report No.- PN-EM3-HIN-301-TUR-003-DC-2057_C
Recommendation for the design, manufacture and erection of steel penstocks of
welded construction for Hydroelectric Installation C.E.C.T (European Committee for
Boiler making and Kindred Steel Structures. English Edition.
2.1 List of Drawings

Table 2-1: List of Drawings
S. No. Drawing No. Title of Drawings
Pressure Shaft Steel Liner Along Unit-1 to Unit-8,

1 AFRY.4649.04.500
General Notes
Pressure Shaft Steel Liner (Along Unit-1), General
2 AFRY.4649.04.501A
Arrangement

prohibited.
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Pressure Shaft Steel Liner (Along Unit-1), Top

3 AFRY.4649.04.502A Horizontal Portion, Ferrule Development Detail
(Reach-1)
Pressure Shaft Steel Liner (Along Unit-1), Bend B-
4 AFRY.4649.07.503A
1A, Ferrule Development Detail (Reach-1)
5 AFRY.4649.04.504A Inclined Portion, Ferrule Development Detail
(Reach-1)
Pressure Shaft Steel Liner (Along Unit-1),
6 AFRY.4649.04.505A Compound Bend B-2A, Ferrule Development
Detail (Reach-1)
(Reach-2)
(Reach-3)
(Reach-4)
(Reach-5)
(Reach-6)
(Reach-7)
(Reach-8)
(Reach-9)
15 AFRY.4649.04.514A Vertical Bend B-3A, Ferrule Development Detail
(Reach-10) (Sheet 1 of 2)
Pressure Shaft Steel Liner (Along Unit-1), Vertical
17 AFRY.4649.04.516A
Portion, Ferrule Development Detail (Reach-11)
18 AFRY.4649.04.517A
19 AFRY.4649.04.518A
20 AFRY.4649.04.519A
Pressure Shaft Steel Liner (Along Unit-1), Bottom

prohibited.
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(Reach-16)
26 AFRY.4649.04.526A Horizontal Portion, Reducer Development Detail
27 AFRY.4649.04.527A Horizontal Portion, Reducer Development Detail
Pressure Shaft Steel Liner (Along Unit-1), Detail of
28 AFRY.4649.04.528A
Welding & Grout Plug
3 Design Data
The analysis for the required plate thickness of the steel liner shells shall comprise the
values for the minimum thickness for handling and shipping, as well as resistance to the
maximum internal water pressure and maximum external pressures.
Table 3-1: Penstocks: Basic Design Parameter
DESCRIPTION VALUES/ DETAILS
Number of Penstocks 7 Nos.
Internal diameter of Penstock 7500 mm
Internal diameter of Penstock after reducer 5150 mm
Full Reservoir Level (FRL) EL. 463.00 m
Centre line Elevation penstock at Intake EL. 432.70 m
Centre line Elevation of penstock at Powerhouse El. 290.00 m
Water Hammer* 35%
Static Head 173.00 m
Dynamic Head 60.55 m
Joint efficiency of weld joint 90%

0% for Reach-1 to 14 (i.e.,
Top Horizontal Portion and
Vertical Portion including
Bend-1, 2 & 3) & Reach 18
(i.e., Thrust collar, reducer
Rock Participation
and last ferrule)
5% for Reach-15, 16 & 17
(i.e., Bottom Horizontal
Portion including Bend-4
upto thrust collar).

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(As per instructions given by

M/s Greenko vide email
dated 27.05.2022).
Modulus of Elasticity of steel 2.0 x 1011 N/m2
Poisson’s ratio of steel liner 0.303
Temperature Variation ∆T ± 20°C
Coefficient of thermal expansion/ contraction ‘α’ 12 x 10-6 /°C
Unit weight of steel 7.85 ton/m3

* For more details refer Andritz Transient Analysis Report No.- PN-EM3-HIN-301-TUR-003-
DC-2057_C.
4 Design Loads
4.1 General
The thickness of steel liner has been computed by following consideration
- Minimum thickness for handling and shipping

- Thickness required to resist for internal pressure as well as external pressure (refer
below clause 7.4, 7.5 & 7.6).
- Corrosion allowance (CA).
The design value of internal pressure shall include pressure rise due to water hammer
effects as considered from the transient analysis.
As per transient analysis carried out, the pressure rise over static head at the location of
MIV of Powerhouse is obtained as 35% during pumping mode (closing) under normal
operating condition.
For intermittent condition pressure during filling & draining of penstock needs to be
considered. However, during filling/ draining, the internal pressure exerted on the steel
liner will be less as compared to the pressure during normal condition, therefore additional
check for this condition at is not required.
In emergency condition, the guide vanes closing time is 25 sec, which is same as given
for normal operating condition and hence pressure rise for both normal and Emergency
condition is same i.e., 35%. Therefore, additional check for this condition at is also not
required.
Refer to Cl. 4.2.4 d) of IS 11639 Part-2, exceptional condition is not to be considered in

design criteria.
Thus, the calculation for the determination of the steel liner thickness have been done for
normal operating condition with considering pressure rise of 35%.
The pressure diagram for the design of penstock steel liner is shown Annexure-1.
4.2 Design Internal Pressure

Detailed design calculation of penstocks for internal pressure under normal operating
condition is provided in Annexure-2.

prohibited.
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4.3 Design External Pressure

- For penstock embedded in rock, the external pressure equivalent to maximum
groundwater seepage pressure is exerted on liner and liner needs to be checked for
any buckling under empty condition.
Detailed design calculation for external pressure for penstock embedded in rock is
provided in Annexure-3.
- For penstock is buried steel pipe (in trench), the external pressure equivalent to
overburden soil weight is applied on liner and the liners needs to be checked for any
buckling under empty condition.
Detailed design calculation for external pressure for buried steel pipe is provided in
Annexure-4A & Annexure-4B
The portion of penstocks below proposed road shall be encased in concrete and no
such load shall be transmitted on steel liner. Concrete shall be designed for load due
to vehicle movement on road.
- Skin grouting at 2.0 bars (20.4 mWC) shall be carried out for Penstocks embedded in
rock. The grout pressure on penstocks is lesser than external seepage pressure, hence
additional check is not required.
Table 4-1: External pressure acting of Penstocks
External Pressure
Stretch Remarks
[m]
Seepage pressure exerting
REACH-1 40.91 m from FRL 463.0 m to Invert of
Bend-2A
REACH-2 to 2.5 m Pipe provided in trench and
REACH-9 soil overburden buried in soil
REACH-10 31.16 m
REACH-11 46.5 m
REACH-12 61.5 m
REACH-13 76.5 m
Seepage pressure considered
REACH-14 81.5 m
from top of vertical shaft i.e.,
REACH-15 107.75 m
El.394.0 m.
REACH-16 107.75 m
REACH-17 107.75 m
REACH-18 107.75 m
5 Steel Materials
As per design requirement, following pressure vessel grade steel is proposed for the
fabrication of the steel liner:
Table 5-1: Properties of Penstock Steel Material
Yield Stress Tensile Strength

Grade Designation
Minimum in MPa in MPa
IS 2002 Grade-2 255 410
IS 2002 Grade-3 285 460
ASTM A537 Class-2 415 550
ASTM A517 Grade-F 690 795

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6 Allowable Stresses
Safety factors and design of steel lining for internal pressure are considered as per IS
11639-2:
Table 6-1: Allowable stresses for Normal Operating condition
Load Case Allowable stresses shall be minimum of below

Normal One third of minimum value
0.6 times the minimum Yield
operating of Ultimate tensile strength
point (YP) stress of liner plate
condition (UTS) of liner plate
Allowable Stress
Materials 1/3 of UTS 0.6 times YP
(Minimum of two)
IS 2002 Grade-2 136.67 153.0 136.67
IS 2002 Grade-3 153.33 171.0 153.33
ASTM A537 Class-2 183.33 249.0 183.33
ASTM A517 Grade-F 265.0 414.0 265.0
Table 6-2: Allowable stresses for Emergency condition
Load Case Allowable stresses shall be minimum of below

Two third of minimum value
Emergency 0.9 times the minimum Yield
of Ultimate tensile strength
condition point (YP) stress of liner plate
(UTS) of liner plate
Allowable Stress
Materials 2/3 of UTS 0.9 times YP
(Minimum of two)
IS 2002 Grade-2 273.33 229.5 229.5
IS 2002 Grade-3 306.67 256.5 256.5
ASTM A537 Class-2 366.67 373.5 366.67
ASTM A517 Grade-F 530.0 621.0 530.0

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7 Design Criteria
7.1 General
Except otherwise stated here, for the analysis and design of the steel liners, guidelines of
IS 11639 (Part 2) and other references as specified under Para 2 is considered. The
analysis for the required plate thickness of the steel liner shells shall comprise the values
for the minimum thickness for handling and shipping, as well as resistance to the
maximum internal water pressure and maximum external pressures. Corrosion allowance
(CA) was considered as per IS 11639. For the entire length of the steel liners no rock
participation has been considered. The liner thus designed shall be self-supporting (to
fully withstand the internal and external pressure, without collaboration of rock and/or
concrete).
7.2 Corrosion Allowance

The corrosion allowance of 1.5 mm (refer clause 7.1 of IS 11639 Part-2) should be added
to the plate thickness computed on the basis of strength requirement.
7.3 Minimum Thickness for transportation and Handling

Regardless of loading conditions, a minimum thickness of plate is required to provide
rigidity for handling during fabrication and transportation. This thickness is directly related
to the radius of the ferrule to be fabricated. The minimum handling thickness “t min” is
given by following formula:
tmin. = (R+0.25)/200
where:
R is internal radius of pressure shaft in meters
Table 7-1: Requirement of Minimum Handling Thickness of Steel Plates
Required Minimum Handling Thickness of

Steel Plates
Diameter (m) tmin. = (R[m] + 0.25)/200
7.5 0.020m = 20.0 mm
5.15 0.01413m = 14.125 mm
7.4 Design for Internal Pressure
7.4.1 Hoop Stress

The steel lining shell thickness must be determined to carry the full internal water
pressure. The hoop stress developed due to internal pressure is given by following
formula:
𝑃𝑅
𝜎ℎ = (1 − 𝜆)
(𝑡 − 𝑐). 𝑒
where:
σh = hoop stress (N/mm2)

t = steel lining shell thickness (mm)
c = corrosion allowance (mm) = 1.5 mm
(refer clause 7.1 of IS 11639 Part-2)

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P = internal pressure (N/mm2)

R = inside steel lining radius (mm)
e = weld joint reducing factor = 0.9 (for back strip joint with 100% UT/
RT in accordance with Table 3.3 of ASCE Manual 79).
λ = Percentage of Rock participation
7.4.2 Poisson’s effect of Hoop stress

The longitudinal stresses develop due to Poisson’s effect is given by following formula:
𝜎𝐿ℎ = 0.303 𝑥 𝜎ℎ𝑜𝑜𝑝

where:
σhoop = hoop stress (N/mm2)

σLh = longitudinal stress due to Poisson’s effect (N/mm2)
7.4.3 Temperature Stresses

Pressure shaft steel liner buried in soil in trench (i.e., Reach-2 to Reach-9) shall be
subjected to temperature stresses due to variation in temperature.
No temperature stresses are considered for Pressure shaft steel liner embedded in rock.
Temperature stresses developed due to variation in temperature is given by following

formula:
𝜎𝑞 = 𝐸 𝑥 𝛼 𝑥 ∆𝑇
where:
σq = Temperature stress (N/mm2)

α = Coefficient of thermal expansion/ contraction (/ °C) = 12x10-6
E = Modulus of Elasticity of steel (N/mm2) = 2 x 105 N/mm2
ΔT = temperature variation (°C)
The minimum and maximum temperature of the project area is 5°C and 45°C
respectively. It is considered to do final closure of penstock or concreting to be done at
ambient temperature of 25°C (approx.)
Thus, Variation in positive side is equal = 45°C - 25°C = 20°C & Variation in negative
side is equal = 25°C - 5°C = 20°C
7.4.4 Equivalent Stresses

The circumferential and longitudinal stresses obtained shall be combined to obtain
equivalent stresses in accordance with Hencky Mises Theory, given by the formula:
𝜎𝑒𝑞 = √(𝜎ℎ2 + 𝜎1 2 − 𝜎ℎ 𝜎1 )
where:
𝜎1 = Total Longitudinal stress,
𝜎ℎ = Hoop stress, and
𝜎𝑒𝑞 = Equivalent stresses

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7.5 Design for External Pressure of Pipe Embedded in Rock

The length of penstock embedded in rock shall be designed to withstand external
pressure, when the penstock is dewatered and subjected to maximum groundwater
seepage pressure.
7.5.1 Design for Unstiffened Shell

The steel liner for pressure shaft will be designed for maximum external pressure using
Vaughan’s formula and Amstutz’s formula for unstiffened shell.
It is to be noted that the minimum value of critical pressures for unstiffened shell
calculated using Vaughan’s formula and Amstutz’s formula shall be taken as minimum
critical external pressure. The maximum external pressure acting on the penstock should
not exceed two-third of the above minimum critical external pressure.
If the criteria is not fulfilled, the stiffeners shall be provided and the design shall be as
stiffened shell.
7.5.2 Design for Stiffened Shell

In case of requirement of stiffener, the critical external pressure, stiffeners spacing and
sizing shall be evaluated by using below mentioned Timoshenko equation and
Vaughan’s formula, for different assumed shell thickness, stiffener spacing and height.
The critical external pressure shall not be less than 1.5 times the maximum external
pressure.

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Welds size thickness calculations for stiffeners & anti percolation rings is provided in
Annexure-5.
7.6 Design for External Pressure of Buried Steel Pipe

The length of penstock proposed to be laid in a trench and covered with minimum 1.2m
backfill. The design calculation of steel liner for external pressure due to 2.5m depth of
soil material is checked. Design of buried pipe due to the external load is carried out as
per the Guideline for the Design of Buried Steel Pipe, July 2001. Prepared by American
Lifelines Alliances, and duly reviewed by FEMA & ASCE.
Additionally, the design of buried pipe due to the external load is also carried out as per
IWWA – Manual on Design and Selection of pipes for Water Supply.
7.6.1 Applied Load

Vertical earth load is primarily a consideration for non-operating conditions of buried steel
pipe when the pipeline is under no internal pressure. For the purpose of calculating earth
loads on a buried pipe, a steel pipe is considered flexible and design procedures for flexible
pipes apply. For flexible pipes placed in a trench and covered with backfill, the earth dead
load applied to the pipe is the weight of a prism of soil with a width equal to that of the
pipe and a height equal to the depth of fill over the pipe.
Pressure resulting from earth dead load can be obtained using following equation.
Pv = γ C

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where:
Pv = Earth dead load pressure on the conduit
γ = Total dry unit weight of fill
C = Height of fill above top of pipe
The following checks are done as per the design criteria for external pressure design
calculation:
- Through wall Bending

- Crushing of Side walls
- Ring Buckling
7.6.2 Ovality
A buried pipe tends to ovalize under the effects of earth loads, as illustrated in Figure 1:
Ovality of Pipe Cross Section.
Figure 1: Ovality of Pipe Cross Section
The modified Iowa deflection formula may be used to calculate the pipe ovality under
earth loads:
where:
D = Pipe outside diameter, inches Outer dia of steel pipe or including lining & coating?
Because we consider (EI)eq in the equation
Δy = Vertical deflection of pipe, inches
D1 = Deflection lag factor (~1.0-1.5)
K = Bedding constant (~0.1)
P = Pressure on pipe due to soil load PV plus live load PP, psi
R = Pipe radius, inches
(EI)eq = Equivalent pipe wall stiffness per inch of pipe length, in./lb.
E' = Modulus of soil reaction, psi
Refer table 1B of USBR manual, Value of E' for crushed rock (moderate
compacted i.e., 85-95% proctor 40-70% relative density) recommended
is 3000 psi (i.e., 21 MPa). However, the value of E’ considered in the

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design is 2176 psi (i.e., 15 MPa). It must be ensured that above

mentioned value of E’ is achieved during execution. In case same is not
achieved the reach shall be completely encased in concrete.
The pipe wall stiffness (EI)eq, is the sum of the stiffness of the bare pipe, lining (subscript
L) and coating (subscript C).
where:
I = t3/12
t = wall thickness of pipe, lining or coating.
The thickness of lining and coating is not considered in the calculation.
The buckling typically occurs when the ovality reaches about 20%, but permissible cross
section ovality shall be limited to 3%.
7.6.3 Through-Wall Bending

Under the effect of earth loads, the through-wall bending stress in the buried pipe,
distributed as shown in Figure 2: Through-Wall Bending Stress.
Figure 2: Through-Wall Bending Stress
The through-wall bending stress in the buried pipe is estimated according to following
equation:
where:
σbw = Through-wall bending stress
Δy/D = Pipe ovality
D = Outside diameter of pipe Outer dia of steel pipe or including lining & coating?
t = Pipe wall thickness thickness steel only? lining coating not required?
Modulus of elasticity steel only? lining coating not required?
E = Modulus of elasticity of pipe
7.6.4 Crushing of Side Walls

The burial depth should be sufficient that the pressure P on the pipe due to the earth load
is less than that causing the crushing of the side wall (see Figure 5).

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Figure 3: Crushing of Side Wall
The crushing of side wall in the buried pipe is given by formula given:
𝑃𝑥𝐷
𝜎𝑐 =
2𝑡
where:
σc = side wall crushing stress
t = pipe wall thickness, inches thickness steel only? lining coating not required?
D = pipe outside diameter, inches Outer dia of steel pipe or including lining & coating?
P = pressure on pipe due to soil load PV plus live load PP, psi
7.6.5 Ring Buckling

If the soil loads are excessive, the pipe cross-section could buckle as shown in Figure 4:
Ring Buckling of Pipe Cross Section.
Figure 4: Ring Buckling of Pipe Cross Section
Ring buckling depends on limiting the total vertical pressure load on pipe to:
where:
FS = Factor of safety
= 2.5 for (C/D) ≥ 2
= 3.0 for (C/D) < 2

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C = Depth of soil cover above pipe
D = Diameter of pipe Outer dia of steel pipe or including lining & coating?
Rw = Water buoyancy factor = 1- 0.33(hw/C), 0<hw<C
hw = Height of water surface above top of pipe
B' = Empirical coefficient of elastic support (dimensionless)
7.7 Specials for Penstocks
7.7.1 Reducer Piece

The reducer piece is a frustum of a cone. Normally the angle of convergence shall be kept
between 5 degrees to 10 degrees so as to minimize the hydraulic loss at the juncture
where the diameter is reduced. The length of the reducer pipe is calculated by the formula:
𝐷1 − 𝐷2
𝐿=
2 𝑡𝑎𝑛 𝜙
where:
L = Length of reducer pipe in mm,
 = Half apex angle, and
D1 and D2 = Diameter at the entry and exit respectively in mm.
The thickness, ‘t’ of reducer piece is determined using the following formula suggested by
IS: 11639(part-3):
P D
+C
2 Cos  (E a − 0.6 P)
t
where:
P = Internal Water Pressure in N/mm2
D = Internal Diameter of the reducer at the larger end in mm,
 = Half apex angle.
σa = Allowable stress in steel in N/mm2
E = Lowest efficiency of any joint = = 0.9 (for back strip joint with 100%
UT/ RT in accordance with Table 3.3 of ASCE Manual 79)
C = Corrosion allowance = 1.5 mm (refer clause 7.1 of IS 11639 Part-2)
7.7.2 Anti-percolations Rings

Anti-percolations rings are used primarily to minimize seepage behind the steel liner
section and secondarily to create a longer seepage path for the potential reduction of
external pressure.
Three numbers of anti-percolations rings are provided in accordance with Cl. 6.5 ASCE
Manual 79.

prohibited.
R-AFRY-4649.04.501_R2
Page 19/84
Table 7-2: Sizing of Anti-percolations rings
Sizing of Anti- Recommendation as per Cl.

Adopted
percolation rings 6.5 of ASCE Manual 79
− 1 No. ring for head upto 400
ft (i.e., 121.92m).
− 2 Nos. ring for head upto 800 Considered 3 Nos. of anti-
Number of Rings
ft (i.e., 243.84m). percolation rings.
− 3 Nos. ring for head above
800 ft (i.e., 243.84m)
Proposed concrete thickness
The stiffener ring must be 1/3 of
encasing steel liner = 650mm
the nominal thickness of
- 1/3 of 650 = 216.67mm
concrete encasing the steel liner
Radial depth of Rings > 203.2mm
but not less than 4 inches (i.e.,
Hence, radial depth of ring
101.6mm) or more than 8 inches
considered is 200mm (which
(i.e., 203.2mm).
is approx. 8 inches)
Minimum thickness of ring shall Considered thickness of rings
Thickness of Rings
be 3/8 inches (i.e., 9.5mm) = 20mm.
7.7.3 Bends
The changes in direction in the alignment of the penstock are called penstock bends. For
ease of fabrication, the bends are made up of short segments of pipes with mitred ends.
Bends should be made with large radius and small deflection between successive
segments in order to minimize the hydraulic loss due to change in direction of flow.
The radius of bend is kept as 3 times the diameter of the pipe i.e., 22.5m and the
deflection angle between each successive segment as 5 degrees to 7 degrees.
True angle calculation for compound bend (Bend-2A) is provided in Annexure-6.
7.7.4 Grouting
Skin grouting is proposed to be done to ﬁll the voids that develop between the steel liner
and concrete backﬁll because of shrinkage caused by concrete curing and from
temperature adjustments. Grouting shall be done at pressure not exceeding 2.0 bars.
Consolidation grouting shall be done for portion of pressure shaft steel liner where rock
participation has been considered (i.e., applicable for Reach-15, Reach-16 & Reach-17).
8 BRIEF SUMMARY
Based on the design computation as mentioned in Annexure-2, 3, 4A & 4B, the brief
summary for the recommended thickness for the steel liner & stiffeners details is the
following.
Table 8-1: Summary of the Penstock Steel Liner Thickness
Liner
S.No Description thickness Remarks
(mm)
Penstock along Unit-1
Reach-1 (Top Horizontal
portion and Top inclined portion
Penstock (7.5 m dia)
1. 20 inside tunnel including Bend B-
Material: IS 2002 Gr 2
1A & Compound Bend B-2A)
Ferrule No. 1A to 35A

prohibited.
R-AFRY-4649.04.501_R2
Page 20/84
Liner
S.No Description thickness Remarks
(mm)
Reach-2 (Top inclined portion
2. 20 inside tunnel in trench)
Material: ASTM A537 Cl.2
Material: ASTM A537 Cl.2
Reach-10 (Top Vertical Bend
10. 25 B-3A)
Material: ASTM A517 Gr.F
Penstock (7.5 m dia) Reach-11 (Vertical Portion)
11. 25
Material: ASTM A517 Gr.F Ferrule No. 143A to 149A
12. 28
13. 30
14. 32
Material: ASTM A517 Gr.F Ferrule No. 164A & 166A
Reach-15 (Bottom Vertical
15. 34 Bend B-4A)
Reach-16 (Bottom Horizontal
16. 34 Portion)
Reach-17 (Bottom Horizontal
Penstock (7.5 m dia) Portion)
17. 36
(Except FE No. 236A to 239A)
Penstock (7.5 m dia) Reach-17 (Bottom Horizontal
18. Material: ASTM A517 Gr.F 38 Portion)
(Near ø7.5m Adit to BHPS) Ferrule No. 236A to 239A
Reach-18 (Thrust Collar,
19. 38 Reducer and Last Ferrule)

prohibited.
R-AFRY-4649.04.501_R2
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9 CONCLUSION
- The recommended thickness of steel liner of penstock details as mentioned in Para
8 is sufficient to withstand design internal & external pressure and any other
stresses (ref Para 7).
- Ferrules shall be transported to site with additional care so that pipe ovality could
not be compromised. Struts or ties must be provided to hold the segments to the
designed arc during transportation to the job site.

prohibited.
R-AFRY-4649.04.501_R2
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Annexure 1: Design Pressure Line Diagram

prohibited.
R-AFRY-4649.04.501_R2
Page 23/84

The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is prohibited.
R-AFRY-4649.04.501_R2
Page 24/84
Annexure 2: Design for Internal Pressure

prohibited.
PINNAPURAM PSP - Penstock along Unit-1
Weld efficiency
Corrosion allowance mm
CALCULATION OF LINER THICKNESS (Normal Operating Condition)

Longitudianl
Derived Hoop Net Maximum Longitudianl σequivalent
Min. Stress due to Thermal stress UTS fs (UTS) Fy fs (Fy) Steel quality
Thickness of steel Rock Stress (due to stress Allowable
Ferrule No. Length Design Head Internal Dia. Hadndling poisson's effect (Expansion/shr
liner 't' Participation internal stress
thickness of Hoop stress inkage) ±σq σ1 = σLh ± σq
Section pressure) σh σL 𝜎𝑒𝑞 = 𝜎ℎ2 + 𝜎𝐿2 − 𝜎ℎ 𝜎𝐿 Validation
Without (P x R)
L H Di Nominal λ .303 x σh EaDT (max.) (min.)
corrosion (t-c) x e
m m mm mm mm mm N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
3
N/mm
2
N/mm
2
N/mm
2
FE-1A + 2.50 m 30.53 7500 20.0 20 18.5 0% 67.45 20.44 - 20.44 20.44 59.91 59.91 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Top
FE-2A + 2.50 m 30.76 7500 20.0 20 18.5 0% 67.96 20.59 - 20.59 20.59 60.36 80.26 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Horizontal
FE-3A + 2.50 m 30.99 7500 20.0 20 18.5 0% 68.47 20.75 - 20.75 20.75 60.81 80.86 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Protion
FE-4A + 2.50 m 31.22 7500 20.0 20 18.5 0% 68.98 20.90 - 20.90 20.90 61.26 81.46 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Bend-1A FE-5A & 6A + 2.243 m 31.54 7500 20.0 20 18.5 0% 69.68 21.11 - 21.11 21.11 61.89 82.29 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-7A + 2.50 m 32.02 7500 20.0 20 18.5 0% 70.74 21.43 - 21.43 21.43 62.83 62.83 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-8A + 2.50 m 32.49 7500 20.00 20 18.5 0% 71.80 21.75 - 21.75 21.75 63.76 63.76 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-9A + 2.50 m 32.97 7500 20.00 20 18.5 0% 72.85 22.07 - 22.07 22.07 64.70 64.70 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-10A + 2.50 m 33.45 7500 20.00 20 18.5 0% 73.91 22.39 - 22.39 22.39 65.64 65.64 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-11A + 2.50 m 33.93 7500 20.00 20 18.5 0% 74.97 22.72 - 22.72 22.72 66.58 66.58 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-12A + 2.50 m 34.41 7500 20.00 20 18.5 0% 76.02 23.04 - 23.04 23.04 67.52 67.52 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-13A + 2.50 m 34.89 7500 20.00 20 18.5 0% 77.08 23.36 - 23.36 23.36 68.46 68.46 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-14A + 2.50 m 35.37 7500 20.00 20 18.5 0% 78.14 23.68 - 23.68 23.68 69.40 69.40 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-15A + 2.50 m 35.84 7500 20.00 20 18.5 0% 79.20 24.00 - 24.00 24.00 70.34 70.34 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-16A + 2.50 m 36.32 7500 20.00 20 18.5 0% 80.25 24.32 - 24.32 24.32 71.28 71.28 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-17A + 2.50 m 36.80 7500 20.00 20 18.5 0% 81.31 24.64 - 24.64 24.64 72.22 72.22 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
REACH-1
FE-18A + 2.50 m 37.28 7500 20.00 20 18.5 0% 82.37 24.96 - 24.96 24.96 73.16 73.16 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-19A + 2.50 m 37.76 7500 20.00 20 18.5 0% 83.43 25.28 - 25.28 25.28 74.10 74.10 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Top Inclined
FE-20A + 2.50 m 38.24 7500 20.00 20 18.5 0% 84.48 25.60 - 25.60 25.60 75.03 75.03 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Protion
FE-21A + 2.50 m 38.72 7500 20.00 20 18.5 0% 85.54 25.92 - 25.92 25.92 75.97 75.97 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-22A + 2.50 m 39.19 7500 20.00 20 18.5 0% 86.60 26.24 - 26.24 26.24 76.91 76.91 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-23A + 2.50 m 39.67 7500 20.00 20 18.5 0% 87.66 26.56 - 26.56 26.56 77.85 77.85 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-24A + 2.50 m 40.15 7500 20.00 20 18.5 0% 88.71 26.88 - 26.88 26.88 78.79 78.79 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-25A + 2.50 m 40.63 7500 20.00 20 18.5 0% 89.77 27.20 - 27.20 27.20 79.73 79.73 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-26A + 2.50 m 41.11 7500 20.00 20 18.5 0% 90.83 27.52 - 27.52 27.52 80.67 80.67 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-27A + 2.50 m 41.59 7500 20.00 20 18.5 91.89 27.84 - 27.84 27.84 81.61 81.61 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-28A + 2.50 m 42.07 7500 20.00 20 18.5 0% 92.94 28.16 - 28.16 28.16 82.55 82.55 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-29A + 2.50 m 42.54 7500 20.00 20 18.5 0% 94.00 28.48 - 28.48 28.48 83.49 83.49 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-30A + 2.50 m 43.02 7500 20.00 20 18.5 0% 95.06 28.80 - 28.80 28.80 84.43 84.43 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-31A + 2.50 m 43.50 7500 20.00 20 18.5 0% 96.11 29.12 - 29.12 29.12 85.36 85.36 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-32A + 2.50 m 43.98 7500 20.00 20 18.5 0% 97.17 29.44 - 29.44 29.44 86.30 86.30 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-33A + 1.403 m 44.25 7500 20.00 20 18.5 0% 97.77 29.62 - 29.62 29.62 86.83 86.83 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Compound FE-34A &
+ 4.141 m 45.11 7500 20.00 20 18.5 0% 99.67 30.20 - 30.20 30.20 88.52 88.52 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Bend B-2A 35A
FE-36A + 2.50 m 45.79 7500 20.00 20 18.5 0% 101.17 30.65 48.00 78.65 -17.35 89.86 110.87 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-37A + 2.50 m 46.47 7500 20.00 20 18.5 0% 102.67 31.11 48.00 79.11 -16.89 91.19 112.08 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-38A + 2.50 m 47.15 7500 20.00 20 18.5 0% 104.17 31.56 48.00 79.56 -16.44 92.52 113.29 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-39A + 2.50 m 47.83 7500 20.00 20 18.5 0% 105.68 32.02 48.00 80.02 -15.98 93.86 114.51 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-40A + 2.50 m 48.51 7500 20.00 20 18.5 0% 107.18 32.48 48.00 80.48 -15.52 95.19 115.72 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-41A + 2.50 m 49.19 7500 20.00 20 18.5 0% 108.68 32.93 48.00 80.93 -15.07 96.52 116.95 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-42A + 2.50 m 49.87 7500 20.00 20 18.5 0% 110.18 33.39 48.00 81.39 -14.61 97.86 118.17 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-43A + 2.50 m 50.55 7500 20.00 20 18.5 0% 111.68 33.84 48.00 81.84 -14.16 99.19 119.40 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-44A + 2.50 m 51.23 7500 20.00 20 18.5 0% 113.19 34.30 48.00 82.30 -13.70 100.53 120.62 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
REACH-2
Top Inclined FE-45A + 2.50 m 51.91 7500 20.00 20 18.5 0% 114.69 34.75 48.00 82.75 -13.25 101.86 121.85 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
Protion FE-46A + 2.50 m 52.59 7500 20.00 20 18.5 0% 116.19 35.21 48.00 83.21 -12.79 103.19 123.09 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-47A + 2.50 m 53.27 7500 20.00 20 18.5 0% 117.69 35.66 48.00 83.66 -12.34 104.53 124.32 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-48A + 2.50 m 53.95 7500 20.00 20 18.5 0% 119.19 36.12 48.00 84.12 -11.88 105.86 125.56 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-49A + 2.50 m 54.63 7500 20.00 20 18.5 0% 120.70 36.57 48.00 84.57 -11.43 107.20 126.80 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-50A + 2.50 m 55.31 7500 20.00 20 18.5 0% 122.20 37.03 48.00 85.03 -10.97 108.53 128.04 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-51A + 2.50 m 55.99 7500 20.00 20 18.5 0% 123.70 37.48 48.00 85.48 -10.52 109.86 129.28 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-52A + 2.50 m 56.67 7500 20.00 20 18.5 0% 125.20 37.94 48.00 85.94 -10.06 111.20 130.53 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-53A + 2.50 m 57.35 7500 20.00 20 18.5 0% 126.70 38.39 48.00 86.39 -9.61 112.53 131.77 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-54A + 2.50 m 58.03 7500 20.00 20 18.5 0% 128.21 38.85 48.00 86.85 -9.15 113.87 133.02 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-55A + 2.50 m 58.71 7500 20.00 20 18.5 0% 129.71 39.30 48.00 87.30 -8.70 115.20 134.27 410.00 3.00 255.00 1.67 136.67 SAFE IS 2002 Gr. 2
FE-56A + 2.50 m 59.39 7500 20.00 20 18.5 0% 131.21 39.76 48.00 87.76 -8.24 116.53 135.52 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-57A + 2.50 m 60.07 7500 20.00 20 18.5 0% 132.71 40.21 48.00 88.21 -7.79 117.87 136.77 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-58A + 2.50 m 60.74 7500 20.00 20 18.5 0% 134.21 40.67 48.00 88.67 -7.33 119.20 138.03 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-59A + 2.50 m 61.42 7500 20.00 20 18.5 0% 135.72 41.12 48.00 89.12 -6.88 120.54 139.28 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
REACH-3
FE-62A + 2.50 m 63.46 7500 20.00 20 18.5 0% 140.22 42.49 48.00 90.49 -5.51 124.54 143.06 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-63A + 2.50 m 64.14 7500 20.00 20 18.5 0% 141.72 42.94 48.00 90.94 -5.06 125.87 144.32 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-64A + 2.50 m 64.82 7500 20.00 20 18.5 0% 143.22 43.40 48.00 91.40 -4.60 127.20 145.58 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-65A + 2.50 m 65.50 7500 20.00 20 18.5 0% 144.73 43.85 48.00 91.85 -4.15 128.54 146.84 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
Weld efficiency

Longitudianl
Without (P x R)
corrosion (t-c) x e
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
3
N/mm
2
N/mm
2
N/mm
2
FE-66A + 2.50 m 66.18 7500 20.00 22 20.5 0% 131.96 39.98 48.00 87.98 -8.02 117.20 136.15 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-67A + 2.50 m 66.86 7500 20.00 22 20.5 0% 133.32 40.40 48.00 88.40 -7.60 118.41 137.28 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-68A + 2.50 m 67.54 7500 20.00 22 20.5 0% 134.67 40.81 48.00 88.81 -7.19 119.61 138.41 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-69A + 2.50 m 68.22 7500 20.00 22 20.5 0% 136.03 41.22 48.00 89.22 -6.78 120.81 139.54 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-70A + 2.50 m 68.90 7500 20.00 22 20.5 0% 137.38 41.63 48.00 89.63 -6.37 122.02 140.68 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
REACH-4
FE-73A + 2.50 m 70.94 7500 20.00 22 20.5 0% 141.45 42.86 48.00 90.86 -5.14 125.63 144.09 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-74A + 2.50 m 71.62 7500 20.00 22 20.5 0% 142.81 43.27 48.00 91.27 -4.73 126.83 145.23 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-75A + 2.50 m 72.30 7500 20.00 22 20.5 0% 144.16 43.68 48.00 91.68 -4.32 128.04 146.37 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-76A + 2.50 m 72.98 7500 20.00 22 20.5 0% 145.52 44.09 48.00 92.09 -3.91 129.24 147.51 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-77A + 2.50 m 73.66 7500 20.00 22 20.5 0% 146.87 44.50 48.00 92.50 -3.50 130.44 148.65 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-78A + 2.50 m 74.34 7500 20.00 24 22.5 0% 135.05 40.92 48.00 88.92 -7.08 119.95 138.73 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-79A + 2.50 m 75.02 7500 20.00 24 22.5 0% 136.29 41.29 48.00 89.29 -6.71 121.04 139.76 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-80A + 2.50 m 75.70 7500 20.00 24 22.5 0% 137.52 41.67 48.00 89.67 -6.33 122.14 140.79 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-81A + 2.50 m 76.38 7500 20.00 24 22.5 0% 138.76 42.04 48.00 90.04 -5.96 123.24 141.83 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
REACH-5
FE-84A + 2.50 m 78.42 7500 20.00 24 22.5 0% 142.46 43.17 48.00 91.17 -4.83 126.53 144.94 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-85A + 2.50 m 79.10 7500 20.00 24 22.5 0% 143.70 43.54 48.00 91.54 -4.46 127.62 145.98 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-86A + 2.50 m 79.78 7500 20.00 24 22.5 0% 144.93 43.91 48.00 91.91 -4.09 128.72 147.02 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-87A + 2.50 m 80.46 7500 20.00 24 22.5 0% 146.17 44.29 48.00 92.29 -3.71 129.82 148.06 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-88A + 2.50 m 81.14 7500 20.00 26 24.5 0% 135.37 41.02 48.00 89.02 -6.98 120.23 138.99 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-89A + 2.50 m 81.82 7500 20.00 26 24.5 0% 136.50 41.36 48.00 89.36 -6.64 121.23 139.94 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-90A + 2.50 m 82.50 7500 20.00 26 24.5 0% 137.64 41.70 48.00 89.70 -6.30 122.24 140.89 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-91A + 2.50 m 83.18 7500 20.00 26 24.5 0% 138.77 42.05 48.00 90.05 -5.95 123.25 141.84 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-92A + 2.50 m 83.86 7500 20.00 26 24.5 0% 139.90 42.39 48.00 90.39 -5.61 124.26 142.79 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
REACH-6
FE-95A + 2.50 m 85.90 7500 20.00 26 24.5 0% 143.31 43.42 48.00 91.42 -4.58 127.28 145.65 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-96A + 2.50 m 86.58 7500 20.00 26 24.5 0% 144.44 43.77 48.00 91.77 -4.23 128.28 146.60 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-97A + 2.50 m 87.26 7500 20.00 26 24.5 0% 145.57 44.11 48.00 92.11 -3.89 129.29 147.56 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-98A + 2.50 m 87.94 7500 20.00 26 24.5 0% 146.71 44.45 48.00 92.45 -3.55 130.30 148.51 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-99A + 2.50 m 88.62 7500 20.00 26 24.5 0% 147.84 44.80 48.00 92.80 -3.20 131.31 149.47 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-100A + 2.50 m 89.30 7500 20.00 28 26.5 0% 137.73 41.73 48.00 89.73 -6.27 122.33 140.97 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-101A + 2.50 m 89.97 7500 20.00 28 26.5 0% 138.78 42.05 48.00 90.05 -5.95 123.26 141.85 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-102A + 2.50 m 90.65 7500 20.00 28 26.5 0% 139.83 42.37 48.00 90.37 -5.63 124.19 142.73 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-103A + 2.50 m 91.33 7500 20.00 28 26.5 0% 140.88 42.69 48.00 90.69 -5.31 125.12 143.61 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-104A + 2.50 m 92.01 7500 20.00 28 26.5 0% 141.93 43.00 48.00 91.00 -5.00 126.05 144.49 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
REACH-7
FE-107A + 2.50 m 94.05 7500 20.00 28 26.5 0% 145.07 43.96 48.00 91.96 -4.04 128.85 147.14 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-108A + 2.50 m 94.73 7500 20.00 28 26.5 0% 146.12 44.27 48.00 92.27 -3.73 129.78 148.02 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-109A + 2.50 m 95.41 7500 20.00 28 26.5 0% 147.17 44.59 48.00 92.59 -3.41 130.71 148.90 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-110A + 2.50 m 96.09 7500 20.00 28 26.5 0% 148.22 44.91 48.00 92.91 -3.09 131.64 149.79 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-111A + 2.50 m 96.77 7500 20.00 28 26.5 0% 149.27 45.23 48.00 93.23 -2.77 132.57 150.67 460.00 3.00 285.00 1.67 153.33 SAFE IS 2002 Gr. 3
FE-112A + 2.50 m 97.45 7500 20.00 25 23.5 0% 169.50 51.36 48.00 99.36 3.36 150.55 167.85 550.00 3.00 415.00 1.67 183.33 SAFE ASTM A537 Cl.2
REACH-8
Top Inclined FE-116A + 2.50 m 100.17 7500 20.00 25 23.5 0% 174.23 52.79 48.00 100.79 4.79 154.75 171.89 550.00 3.00 415.00 1.67 183.33 SAFE ASTM A537 Cl.2
Protion FE-117A + 2.50 m 100.85 7500 20.00 25 23.5 0% 175.42 53.15 48.00 101.15 5.15 155.80 172.90 550.00 3.00 415.00 1.67 183.33 SAFE ASTM A537 Cl.2
REACH-9
Top Inclined
Protion
Weld efficiency

Longitudianl
Without (P x R)
corrosion (t-c) x e
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
3
N/mm
2
N/mm
2
N/mm
2
REACH-
Top Vertical FE-127A to

+ 31.271 m 131.35 7500 20.00 25 23.5 0% 228.46 69.22 - 69.22 69.22 202.91 202.91 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
10
Bend B-3A 142A
FE-143A + 1.587 m 133.08 7500 20.00 25 23.5 0% 231.47 70.14 - 70.14 70.14 205.58 205.58 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
REACH-11
Vertical
Portion
REACH-12
Vertical
Portion
REACH-13
Vertical
Portion
REACH-14
Vertical
Portion
REACH-15
Bottom
FE-167A to
Vertical Bend + 35.343 m 212.06 7500 20.00 34 32.5 5% 253.37 76.77 - 76.77 76.77 225.03 225.03 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
184A
B-4A
REACH-16
Bottom
Horizontal
Portion
Weld efficiency

Longitudianl
Without (P x R)
corrosion (t-c) x e
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
2
N/mm
3
N/mm
2
N/mm
2
N/mm
2
REACH-16
Bottom FE-220A + 2.50 m 220.23 7500 20.00 34 32.5 5% 263.13 79.73 - 79.73 79.73 233.70 233.70 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
Horizontal FE-221A + 2.50 m 220.46 7500 20.00 34 32.5 5% 263.40 79.81 - 79.81 79.81 233.94 233.94 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
Portion FE-222A + 2.50 m 220.69 7500 20.00 34 32.5 5% 263.68 79.89 - 79.89 79.89 234.19 234.19 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
FE-228A* + 2.50 m 221.84 7500 20.00 36 34.5 0% 262.83 79.64 - 79.64 79.64 233.43 233.43 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
REACH-17
Bottom
Horizontal
Portion
Thrust Collar
Pipe
REACH-18
FE-271A to
Reducer + 25.19 m 233.34 ASTM A517 Gr.F
282A
Last Ferrule FE-283A + 2.250 m 233.55 5300 14.50 38 36.5 0% 184.82 56.00 - 56.00 56.00 164.15 164.15 795.00 3.00 690.00 1.67 265.00 SAFE ASTM A517 Gr.F
NOTE: * Rock participation is not considered for Pressure shaft Steel liner at/ near ø7.5m Adit to Lower horizontal pressure shaft (i.e., FE Nos. 228A to 239A)
The Hoop stress and equivalent stresses for all Ferrules are lesser that allowable stress. Hence, Design is SAFE.
R-AFRY-4649.04.501_R2
Page 29/84
Design of Steel pipe provided in Ultrasonic Flow meter Chamber (Reach-7)
Internal diameter ‘D’ = 7.5 m

Unit weight of water γw = 1000 kg/m3
Unit weight of steel γs = 7850 kg/m3
Joint efficiency e = 0.9
Thickness of corrosion allowance c = 1.50 mm
Material of Steel Liner = IS 2002 Gr.3
Allowable stress = 153.33 N/mm2
Temperature difference between surface and liner = 20 degree
Maximum pressure ‘P’ = 96.77 m = 0.95 N/mm2
Proposed Liner thickness ‘t’ = 28 mm
𝑃𝐷
Hoop Stress ‘σh’ =
2. (𝑡 − 𝑐). 𝑒
= 0.95 x 7500
2 x (28-1.5) x 0.9
= 149.27 N/mm2
Longitudinal stresses
1. Longitudinal stresses develop due to
= 0.303 𝑥 𝜎ℎ𝑜𝑜𝑝
Poisson’s effect ‘σL’
= 0.303 x 149.27
= 45.23 N/mm2
2. Longitudinal stresses develop due to

= 𝐸 𝑥 𝛼 𝑥 ∆𝑇
temperature variation ‘σT’
= (2 x 105) x (12 x 10-6) x 20
= 48 N/mm2
3. Longitudinal stresses develop due to beam action ‘σb’

Support Distance ‘L’ = 5.0 m
Unit Weight of steel Pipe = 𝜋. (𝐷 + 𝑡) . 𝑡 . γ𝑠 . 9.81

= ϖ (7.5+.028)x0.028x7850x9.81
= 50994.8 N/m
𝐷2
Unit Weight of Water in steel Pipe = 𝜋. . γ𝑤 . 9.81
4
= ϖ x 7.52/4 x 1000 x 9.81
= 433392.5 N/m
Weight of pipe + Weight of water ‘w’ = 484387.4 N/m
= 484.39 N/mm
ϖx(D4 - d4)
Section modulus of steel pipe ‘z’ =
32 D
= 1241654602.9 mm3
Bending moment at middle = W x L2/24

prohibited.
R-AFRY-4649.04.501_R2
Page 30/84
= 504570164.2 N.mm
Bending stress at middle ‘σbm’ = 504570164.2
1241654602.9
= 0.41 N/mm2
Bending moment at supports = W x L2/12

= 1009140328.3 N.mm
Bending stress at middle ‘σbs’ = 1009140328.3
1241654602.9
= 0.81 N/mm2
4. Circumferential bending stresses at C x P1 x r
=
support ‘σbc’ Z
0.052x(484.39 x 5000/2)x3750
=
1241654602.9
= 0.19 N/mm2
Total Longitudinal Stress ‘σ1’ = σL ± σT ± σb± σbc
Shear Stress ‘q’ = wxL/A

484.39 x 5000
=
ϖ x 7528 x 28
= 3.66 N/mm2
Equivalent Stresses:
𝜎𝑒𝑞 = √(𝜎ℎ2 + 𝜎1 2 − 𝜎ℎ 𝜎1 )
Stress Summary:
Stresses in N/mm2
Middle Supports
Hoop Stress ‘σh’ 149.27 149.27
Longitudinal Stress
1. Longitudinal stresses develop
45.23 45.23
due to Poisson’s effect ‘σL’
± 48 ± 48
due to temperature variation ‘σT’
± 0.41 ± 0.81
due to beam action ‘σb’
4. Circumferential bending
0 ± 0.19
stresses at support ‘σbc’
Total Longitudinal Stress ‘σ1’ 93.63 -3.18 94.23 -3.78
Shear Stress ‘q’ 3.66 3.66 3.66 3.66
Major Principle Stresses ‘Sx’ 149.51 149.35 149.51 149.35
Major Principle Stresses ‘Sy’ 93.39 -3.27 93.99 -3.86
Equivalent Stresses ‘Se’ 130.8 151.0 130.9 151.3
The Hoop stress and equivalent stresses are lesser that allowable stress. Hence, Design is SAFE.

prohibited.
R-AFRY-4649.04.501_R2
Page 31/84
Design of Reducer Pipe (Reach-17)
The length of the reducer pipe is calculated by the formula:
𝐷1 − 𝐷2
𝐿=
2 𝑡𝑎𝑛 𝜙
where:
L = Length of reducer pipe in mm
 = Half apex angle = 2.5°
D1 = Diameter at the entry = 7500 mm
D2 = Diameter at the exit = 5300 mm
7500 − 5300
L= = 25194 mm
2 𝑡𝑎𝑛 2.5°
The thickness, ‘t’ of reducer piece is determined using the following formula:
P D
+C
2 Cos  (E a − 0.6 P)
t
where:
P = Internal Water Pressure = 2.291 N/mm2 (for Normal Operating condition)
D = Internal Diameter of the reducer at the larger end = 7500 mm
 = Half apex angle = 2.5°
σa = Allowable stress = 265 N/mm2 (for Normal Operating condition)
E = Joint efficiency = 0.9 (for back strip joint with 100% UT/ RT in accordance
with Table 3.3 of ASCE Manual 79)
C = Corrosion allowance = 1.5 mm (refer clause 7.1 of IS 11639 Part-2)
2.291 x 7500
t= + 1.5 = 37.8 mm ≈ 38 mm
[2 cos 2.5° (0.9 x 265 − 0.6 x 2.291)
Hoop Stress in Reducer pipe:
𝑃. 𝐷 0.6 𝑃
𝜎ℎ = +
2 (𝑡 − 𝐶). 𝑐𝑜𝑠 . E 𝐸
2.291 x 7500 0.6 x 2.291

𝜎ℎ = +
2x (38 − 1.5) x cos 2.5 x 0.9 0.9
σh = 263.32 N/mm2 < 265 N/mm2 SAFE

prohibited.
R-AFRY-4649.04.501_R2
Page 32/84
Poisson’s effect of Hoop stress:
σLh= 0.303 x σh = 79.79 N/mm2 < 265 N/mm2 SAFE
Tensile stress due to axial force due to closing of MIV:
Axial force due to closure of MIV = 50322 KN (as per Andritz document no. PN-EM3-HIN-301-MIV-
005-DG-2513-C_Foundation Loads Report for MIV.)
𝜋 (53732 −53002 )
Cross section area of penstocks at smaller end = = 611926 mm2
4
Tensile stress σt = 50322 x 1000 / 611926
σt = 82.24 N/mm2 < 265 N/mm2 SAFE
Equivalent Stress:
𝜎𝑒𝑞 = √(𝜎ℎ2 + 𝜎1 2 − 𝜎ℎ 𝜎1 )
where:
𝜎1 = Total Longitudinal stress = σLh + σt = 162.02 N/mm2
𝜎ℎ = Hoop stress = 263.32 N/mm2
Equivalent Stress σeq = 230.1 N/mm2 < 265 N/mm2 SAFE
The Hoop stress and equivalent stresses are lesser that allowable stress. Hence, Design is SAFE.

prohibited.
R-AFRY-4649.04.501_R2
Page 33/84
Annexure 3: Design for External Pressure of Pipe Embedded in Rock

prohibited.
Verification for external pressure for unstiffened shell by "VAUGHAN'S FORMULA"
13𝐾 2 2 𝑌𝑂 𝐹𝑌 𝐾 4𝐹𝑦 𝐹𝑦2

′
𝑃𝑐𝑟 + 2𝑃𝑐𝑟 1 + 3𝐾 − − − ′ =0
4𝐸 𝑅 2 𝐸′ 𝐾 𝐸
Where,
YO
= 3 x 10-4 = 0.0003
R
= kg/cm2
E' =
E
= 2.1 * 105 = 231229
1 - μs2 0.91
t PCR External pr.

Section K = D/t FOS*
mm N/mm2 N/mm2
For Material - IS 2002 Gr. 2 Dia. = 7500.00 mm YP = 255 N/mm2
REACH-1 20 375.00 0.68 0.40 1.7 SAFE
2
For Material - ASTM A517 Gr.F Dia. = 7500.00 mm YP = 690 N/mm
REACH-10 25 300.00 1.81 0.31 5.9 SAFE
REACH-11 25 300.00 1.81 0.46 4.0 SAFE
REACH-12 28 267.86 2.14 0.60 3.6 SAFE
REACH-13 30 250.00 2.37 0.75 3.2 SAFE
REACH-14 32 234.38 2.60 0.80 3.3 SAFE
REACH-15 34 220.59 2.84 1.06 2.7 SAFE
REACH-16 34 220.59 2.84 1.06 2.7 SAFE
REACH-17 36 208.33 3.08 1.06 2.9 SAFE
* As per Cl. 6.2.2 of IS 11639 Part-2, The maximum external pressure acting on the penstock should not exceed
two-third of the critical external pressure (i.e., Factor of safety of minimum 1.5 to be considered on maximum
external pressure). If the criteria is not fulfilled, the stiffeners shall be provided to prevent buckling and the design
shall be done as stiffened shell.
Verification for external pressure for unstiffened shell by "AMSTUTZ'S FORMULA"
3ൗ
𝑓𝑛 𝑌𝑜 3. 𝐾 2 𝑓𝑛 2 𝑓𝑦′ − 𝑓𝑛 𝐾 𝑓𝑦 − 𝑓𝑛
+ 1+ = 1.68𝐾 1−
𝐸′ 𝑅 𝐸′ 𝐸 ′ 4 𝐸′
This can be rearranged to obtain

𝑓𝑦′ − 𝑓𝑛 ′
𝐾 𝑓𝑦 − 𝑓𝑛
1.68𝐾 1−
𝐸′ 4 𝐸′ 𝑌𝑜
𝐹 𝑁 = 𝐸′ 3ൗ − − 𝑓𝑛 = 0
3. 𝐾 2 𝜎𝑁 2 𝑅
1+
𝐸′
PCR = Critical external buckling pressure
𝐾 ′ 2𝑓𝑛
𝑃𝐶𝑅 = 1 − 0.175 𝑓 − 𝑓𝑛 .
𝐸′ 𝑦 𝐾
Where,
Yo
= 3 x 10-4 = 0.0003
R
f'y fy 255.00 255
= = =
(1-μs+μs2)1/2 (1-0.303+0.092)1/2 0.89
E' =
Es
= 2.1 * 105 = 231229
1 - μs2 0.91
External
t fn PCR
Section K = D/t F(n) pr. FOS*
cm N/mm2 N/mm2 N/mm2
REACH-1 20 375.00 0.00 56.11 0.40 0.40 1.0 Stiffener required
For Material - ASTM A517 Gr.F Dia. = 7500.00 mm YP = 690 N/mm2
REACH-10 25 300.00 0.00 109.86 0.62 0.31 2.0 SAFE
* As per Cl. 6.2.2 of IS 11639 Part-2, The maximum external pressure acting on the penstock should not exceed two-third of the critical
external pressure (i.e., Factor of safety of minimum 1.5 to be considered on maximum external pressure). If the criteria is not fulfilled, the
stiffeners shall be provided to prevent buckling and the design shall be done as stiffened shell.
As the maximum external pressure acting on the penstock exceed two-third of the critical external
pressure. Hence, the stiffeners need to be provided to prevent buckling and the design shall be as
done as stiffened shell.
Verification for external pressure for stiffened shell by "TIMOSHENKO EQUATION"
Where,
Stifener Spacing 'L' = 1250 mm
= kg/cm2
= μs 0.303
E' = E = 2.0 * 105 = 231229

1 - μs2 0.91
t PCR External pr. FOS*

Section K = D/t λ = L/t n
2 2
mm N/mm N/mm
REACH-1 20 375.00 62.50 16.00 1.55 0.40 3.9 SAFE
REACH-10 25 300.00 50.00 15.00 2.79 0.31 9.1 SAFE
REACH-11 25 300.00 50.00 15.00 2.79 0.46 6.1 SAFE
REACH-12 28 267.86 44.64 14.00 3.77 0.60 6.2 SAFE
REACH-13 30 250.00 41.67 14.00 4.51 0.75 6.0 SAFE
REACH-14 32 234.38 39.06 14.00 5.35 0.80 6.7 SAFE
REACH-15 34 220.59 36.76 26.66 6.29 1.06 6.0 SAFE
REACH-16 34 220.59 36.76 14.00 6.29 1.06 6.0 SAFE
REACH-17 36 208.33 34.72 13.00 7.31 1.06 6.9 SAFE
* As per Cl. 6.2.3.1 of IS 11639 Part-2, The critical external pressure shall not be less than 1.5 times the maximum external pressure (i.e.,
Factor of safety of minimum 1.5 to be considered on maximum external pressure).
Verification for external pressure for stiffened shell by "VAUGHAN'S FORMULA"
Where,
μs = 0.303
YO
= 3 x 10-4 = 0.0003
R
= kg/cm2
E' =
E
= 2.1 * 105 = 231229
1 - μ s2 0.91
Steel Asst. Area of Neutral Critical External

Stiffener Eq. Thk MOI FOS*
Liner Width Section Axis Pressure Pressure
Section
t ts w Ar L A t' V I PCR
mm mm mm mm2 mm mm2 mm mm mm4 N/mm2 N/mm2
REACH-1 20 16 150.00 2400 443.22 11264.5 25.41 141.89 18441034.9 1.27 0.40 3.2 SAFE
REACH-10 25 16 150.00 2400 493.65 14741.3 29.86 148.25 20526171.4 3.08 0.31 10.1 SAFE
REACH-11 25 16 150.00 2400 493.65 14741.3 29.86 148.25 20526171.4 3.08 0.46 6.8 SAFE
REACH-12 28 16 150.00 2400 521.50 17001.9 32.60 151.44 21780878.0 3.25 0.60 5.4 SAFE
REACH-13 30 16 150.00 2400 539.24 18577.2 34.45 153.37 22641823.7 3.36 0.75 4.5 SAFE
REACH-14 32 16 150.00 2400 556.40 20204.8 36.31 155.19 23532988.1 3.47 0.80 4.3 SAFE
REACH-15 34 16 150.00 2400 573.03 21883.1 38.19 156.91 24462598.5 3.59 1.06 3.4 SAFE
REACH-16 34 16 150.00 2400 573.03 21883.1 38.19 156.91 24462598.5 3.59 1.06 3.4 SAFE
REACH-17 36 16 150.00 2400 589.18 23610.5 40.07 158.55 25438330.7 3.70 1.06 3.5 SAFE
* As per Cl. 6.2.5 of IS 11639 Part-2, The critical external pressure shall not be less than 1.5 times the maximum external pressure (i.e., Factor of safety of minimum
1.5 to be considered on maximum external pressure).
R-AFRY-4649.04.501_R2
Page 38/84
Annexure 4A: Design for External Pressure of Buried Steel Pipe

(As per Guideline for the Design of Buried Steel Pipe by American Lifelines
Alliances)

prohibited.
Design for External Pressure of Buried Steel Pipe
(as per Guideline for the Design of Buried Steel Pipe by American Lifelines Alliances)
REACH-2
Particular Symbol Formula
SI Unit FPS Unit
Material IS 2002 Gr. 2
Depth of Overburden 2.50 m 8.20 feet
Penstock diameter d = 7.5 m 295.28 inch
Penstock Radius R d/2 = 3.75 m 147.64 inch
Wall Thickness, Gross tg = 0.02 m 0.79 inch
Corrosion Allowance tc = 0.0015 m 0.06 inch
Wall thickness, net t tg - tc = 0.0185 m 0.73 inch
Outside diameter D d + 2* t = 7.54 m 296.85 inch
Deflection lag factor D1 = 1.25
Bedding Constant K = 0.1
Specific Weight of Soil Υs1 = 20 kN/m3
2
Vertical Pressure due to Soil Pv h * Υs1 = 50 kN/m 7.25 psi
Vertical Pressure due to Live Load Pp = 0.000 kN/m2 0 psi
Vertical Pressure on Pipe (P = Pv + Pp) P Pv + P p = 50.000 kN/m2 7.25 psi
Modulus of elasticity E ES = 2.00E+05 MPa 2.90E+07 psi
Moment of Inertia of Pipe (I=t3/12) I t3/12 = 5.276E-07 m3 0.032198287 inch3
Modulus of Soil (E') E' = 15.00 MPa 2176 psi
Pipe Ovality ratio (Δy/D) Δy/D = 0.0068
Pipe Ovality (Δy) = 0.0514 m 2.0225 inch

Allowable up to 3% = 0.68% 0.68%
SAFE
Through Wall bending Stress (σbw) σbw = 13.372 MPa 1939.64 psi
Crushing stress of side wall (σcr) σc P * D/ (2t) = 10.185 MPa 1477.43 psi
Total Stress σ σc+σbw = 23.557 MPa 3417.071 psi
YP of Steel = 255 MPa 3.70E+04 psi
Allowable Stress (=0.6 Yp) = 153 MPa 22191 psi
SAFE
Check for Buckling
Depth of Soil Cover C = 2.5 m 98.425 inch
Water bouyancy factor Rw = 1

Empirical coefficient of elastic support B' = 0.2035
Critical Buckling Pressure (Pcr) Pcr = 0.155 MPa 22.49 psi
Ratio (C/D) 0.332

Factor of Safety (FS) FS 3
Allowable vertical pressure load Pa Pcr / FS = 0.052 MPa 7.497 psi
Actual Factor of Safety FS' Pcr / P = 3.10

SAFE
REACH-3
SI Unit FPS Unit
2

SAFE
SAFE
Check for Buckling

Ratio (C/D) 0.332


SAFE
REACH-4
SI Unit FPS Unit
2

SAFE
SAFE
Check for Buckling

Ratio (C/D) 0.332


SAFE
REACH-5
SI Unit FPS Unit
2

SAFE
Through Wall bending Stress (σbw) σbw = 16.224 Mpa 2353.35 psi
Crushing stress of side wall (σcr) σc P * D/ (2t) = 8.380 Mpa 1215.58 psi
Total Stress σ σc+σbw = 24.604 Mpa 3568.936 psi
SAFE
Check for Buckling

Critical Buckling Pressure (Pcr) Pcr = 0.208 Mpa 30.14 psi
Ratio (C/D) 0.331

Allowable vertical pressure load Pa Pcr / FS = 0.069 Mpa 10.045 psi

SAFE
REACH-6
SI Unit FPS Unit
2

SAFE
SAFE
Check for Buckling

Ratio (C/D) 0.331


SAFE
REACH-7
SI Unit FPS Unit
2

SAFE
SAFE
Check for Buckling

Ratio (C/D) 0.331


SAFE
REACH-8
SI Unit FPS Unit
Material ASTM A537 Cl.2
2

SAFE
SAFE
Check for Buckling

Ratio (C/D) 0.331


SAFE
REACH-9
SI Unit FPS Unit
Material ASTM A537 Cl.2
2

SAFE
SAFE
Check for Buckling

Ratio (C/D) 0.331


SAFE
R-AFRY-4649.04.501_R2
Page 47/84
Annexure 4B: Design for External Pressure of Buried Steel Pipe

(As per IWWA manual on Design and Selection of Pipes for Water Supply)

prohibited.
(as per IWWA manual on Design and Selection of Pipes for Water Supply)
REACH-2
S.No. Particular Values Units
A Input Data
2
1 Maximum Internal Pressure 'Pi' = 5.87 kg/cm
2
2 Modulus of Elasticity of Steel 'E' = 2100000 kg/cm
3
3 Density of fill 'vs' = 2000 kg/m
4 Depth of soil above steel liner 'H' = 2500 mm
5 Trench Width 'Bd' = 8500 mm
5 Internal Dia. of Steel liner 'Bc' = 7500 mm
6 Thickness of steel liner 't' = 20 mm
7 Corrosion Allowance 'a' = 1.5 mm
9 Thickness of steel liner 't' = 18.50 mm
= 1.85 cm
3
9 Moment of Inertia of shell 'I' = 0.53 cm
10 Angle of beadding 'θ' = 120°
11 Coefficient of Vertical Deflection 'Kθ' (Refer Table 3.1) = 0.089
12 Coefficient ofbottom bedding 'Kb' (Refer Table 3.1) = 0.138
2
13 Vacuum Pressure 'Pe' = 0.33 kg/cm
2
14 Modulus of Soil reaction e' = 150 kg/cm
As per IWWA, values of e' is given for soil backfill but crushed
rock (proprely compacted) have been considerd for backfill.
Therefore, value of e' for crushed rock (moderate compacted i.e.,
85-95% proctor 40-70% relative density) has been taken 150
kg/cm2 (refer table 1B of USBR manual)
15 Deflection lag factor 'D1' = 1
16 Joint Efficiency = 0.9
B Material of Steel liner IS 2002 Gr. 2

2
Yield Strength 'Yp' = 2600 kg/cm
2
Tensile Strength 'UTS' = 4181 kg/cm
2
Allowable Compressive Stress (0.5 * Yp) = 1300 kg/cm
2
Allowable Tensile Stress (0.6 * Yp) = 1560 kg/cm
C Load on Buried Pipe

1 Weight of Pipe shell / meter = 3709.1 Kg/m
37.09 Kg/cm
2 Weight of Water / meter = 44178.6 Kg/m

441.79 Kg/cm
3 Fill Load
For Embankment Condtion (Positive projection)
𝑊𝑒 = 𝐶𝑐 . 𝑣𝑠 . 𝐵𝑐2
where,
Cc = Load co-efficient factor obtained from graph below
REACH-2
H/Bc = 0.33
Cc (taken from graph) = 0.33
Fill Load 'We' = 37125.0 Kg/m

371.25 Kg/cm
Total Load on pipe (pipe full condition) = 850.13 Kg/cm

Total Load on pipe (pipe half full condition) = 629.23 Kg/cm
D Deflection and Stress Calculations
1 'D2' Deflection for partial vacuum conditions with side support fill
D2
D2 = 6.1 cm
<
22.5 cm SAFE
(i.e., 3% of diameter of pipe)
2 'D3' Deflection for pipe full & under pressure with side support fill
D3
REACH-2
D3 = 7.4 cm
<
22.5 cm SAFE
3 'M2' = Moment for partial vacuum condition with side support of fill (i.e, D2 condition)
M2 = 75.1 Kg cm
2
Flexural Stress (fb) = 131.6 kg/cm
2
Hoop Stress (fh) = 74.3 kg/cm
2
Maximum Compressive Stress (fc) = fb + fh = 206.0 kg/cm
<
2
1300 kg/cm SAFE
4 'M3' = Moment for pipe full & under pressure condition with side of fill (i.e, D3 condition)
M3 = 90.5 Kg cm
2
2
2
Maximum tensile Stress (ft) = fb + fh = 1480.8 kg/cm
<
2
1560 kg/cm SAFE
However, Additional stiffeners are
provides to resist buckling. Vehicle
momvent above penstock pipe
shall not be permitted.
REACH-3
A Input Data
2
2
3
= 1.85 cm
3
2
2

2
2
2
2

37.09 Kg/cm

441.79 Kg/cm
3 Fill Load
where,
REACH-3
H/Bc = 0.33

371.25 Kg/cm

D2
D2 = 6.1 cm
<
22.5 cm SAFE
D3
REACH-3
D3 = 7.3 cm
<
22.5 cm SAFE
M2 = 75.1 Kg cm
2
2
2
<
2
1453 kg/cm SAFE
M3 = 89.4 Kg cm
2
2
2
<
2
1744 kg/cm SAFE
REACH-4
A Input Data
2
2
3
= 2.05 cm
3
2
2

Yield Strength 'Yp' = 2906 kg/cm2
Tensile Strength 'UTS' = 4691 kg/cm2
2
2

40.81 Kg/cm

441.79 Kg/cm
3 Fill Load
where,
REACH-4
H/Bc = 0.33

371.25 Kg/cm

D2
D2 = 6.2 cm
<
22.5 cm SAFE
D3
REACH-4
D3 = 7.2 cm
<
22.5 cm SAFE
M2 = 102.7 Kg cm
2
2
2
<
2
1453 kg/cm SAFE
M3 = 120.4 Kg cm
2
2
2
<
2
1744 kg/cm SAFE
REACH-5
A Input Data
2
2
3
= 2.25 cm
3
2
2

2
2
2
2

44.53 Kg/cm

441.79 Kg/cm
3 Fill Load
where,
REACH-5
H/Bc = 0.33

371.25 Kg/cm

D2
D2 = 6.2 cm
<
22.5 cm SAFE
D3
REACH-5
D3 = 7.2 cm
<
22.5 cm SAFE
M2 = 136.4 Kg cm
2
2
2
<
2
1453 kg/cm SAFE
M3 = 158.0 Kg cm
2
2
2
<
2
1744 kg/cm SAFE
REACH-6
A Input Data
2
2
3
= 2.45 cm
3
2
2

2
2
2
2

48.26 Kg/cm

441.79 Kg/cm
3 Fill Load
where,
REACH-6
H/Bc = 0.33

371.25 Kg/cm

D2
D2 = 6.2 cm
<
22.5 cm SAFE
D3
REACH-6
D3 = 7.1 cm
<
22.5 cm SAFE
M2 = 177.0 Kg cm
2
2
2
<
2
1453 kg/cm SAFE
M3 = 201.9 Kg cm
2
2
2
<
2
1744 kg/cm SAFE
REACH-7
A Input Data
2
2
3
= 2.65 cm
3
2
2

2
2
2
2

51.98 Kg/cm

441.79 Kg/cm
3 Fill Load
where,
REACH-7
H/Bc = 0.33

371.25 Kg/cm

D2
D2 = 6.3 cm
<
22.5 cm SAFE
D3
REACH-7
D3 = 7.0 cm
<
22.5 cm SAFE
M2 = 224.9 Kg cm
2
2
2
<
2
1453 kg/cm SAFE
M3 = 252.8 Kg cm
2
2
2
<
2
1744 kg/cm SAFE
REACH-8
A Input Data
2
2
3
= 2.35 cm
3
2
2
B Material of Steel liner ASTM A537 Cl.2

2
2
2
2

46.39 Kg/cm

441.79 Kg/cm
3 Fill Load
where,
REACH-8
H/Bc = 0.33

371.25 Kg/cm

D2
D2 = 6.2 cm
<
22.5 cm SAFE
D3
REACH-8
D3 = 6.9 cm
<
22.5 cm SAFE
M2 = 155.8 Kg cm
2
2
2
<
2
2116 kg/cm SAFE
M3 = 173.6 Kg cm
2
2
2
<
2
2539 kg/cm SAFE
REACH-9
A Input Data
2
2
3
= 2.65 cm
3
2
2
B Material of Steel liner ASTM A537 Cl.2

2
2
2
2

51.98 Kg/cm

441.79 Kg/cm
3 Fill Load
where,
REACH-9
H/Bc = 0.33

371.25 Kg/cm

D2
D2 = 6.3 cm
<
22.5 cm SAFE
D3
REACH-9
D3 = 6.9 cm
<
22.5 cm SAFE
M2 = 224.9 Kg cm
2
2
2
<
2
2116 kg/cm SAFE
M3 = 249.0 Kg cm
2
2
2
<
2
2539 kg/cm SAFE
R-AFRY-4649.04.501_R2
Page 72/84

prohibited.
R-AFRY-4649.04.501_R2
Page 73/84
Annexure 5: Welds size thickness calculations for stiffeners & anti percolation
rings

prohibited.
Designo of Weld thickness of Stiffeners and Anti-percolation Rings
(Reference -ASME Sec VIII Div-1 UG-30)
Anti-percolation Rings
S.No. Particulars Symbol Values Units
1 Input Data
External Pressure NSL P = 0.40 N/mm2
Inside diameter of Penstock Di = 7500 mm
Thickness of Ferrule t = 20 mm
Outside diameter of Penstock Do = 7540 mm
Spacing of Stiffener Ring Ls = 300 mm
Height of Stiffener Ring Hr = 200 mm
Thickness of Stiffener Ring tr = 20 mm
Associated width of Ferrule (considered from W = 1.1 x SQRT (Do x
= 427.2 mm
Design of Stiffeners) t)
Moment of Inertia of Stiffener Ring (considered
I = 46583517.9 mm4
from Design of Stiffeners)
Centre of Gravity of stiffener section (considered
C = 45.08 mm
2 Data for Electrode
Electrode Considered E7018
Yield strength of Welding Electrode YP1 = 400 N/mm2
Material of Steel liner = IS 2002 Gr. 2
Yield strength of Steel liner YP2 = 255.00 N/mm2
(The weld design shall be done considering yield strength of steel liner
material)
Allowable Stress with factor of Safety S = 0.3 x YP2 = 76.5 N/mm2
3 Load on Weld
Radial Pressure Load RL = PLs = 120.39 N/mm
Radial Shear Load V = 0.01PLsDo = 9077.13 N
First moment of area of Ring Q = Wt(C-t) = 214252.99 m3
Weld Shear Flow WSF = VQ/I = 41.75 N/mm
CWL = SQRT (RL2 +
Combined Weld Load = 127.42 N/mm
WSF2)
4 Allowable Load for Weld
Fillet Weld Size considered f = 10 mm
Allowable Load for Fillet weld La = 2 x f x S x 0.707 = 1081.71 N/mm
>
127.42 N/mm
SAFE
REACH-1
1 Input Data
= 427.2 mm
I = 18321884.6 mm4
C = 28.64 mm
Material of Steel liner = IS 2002 Gr. 2
material)
3 Load on Weld
CWL = SQRT (RL2 +
WSF2)
>
524.25 N/mm
SAFE
REACH-10
1 Input Data
= 477.9 mm
I = 20423553.1 mm4
C = 27.14 mm
Material of Steel liner = ASTM A 517 Gr. F
material)
3 Load on Weld
CWL = SQRT (RL2 +
WSF2)
>
383.80 N/mm
SAFE
REACH-11
1 Input Data
= 477.9 mm
I = 20423553.1 mm4
C = 27.14 mm
material)
3 Load on Weld
CWL = SQRT (RL2 +
WSF2)
>
572.74 N/mm
SAFE
REACH-12
1 Input Data
= 506.0 mm
I = 21681994.5 mm4
C = 26.89 mm
material)
3 Load on Weld
First moment of area of Ring Q = Wt(C-t) = -15680.58 m3
Weld Shear Flow WSF = VQ/I = -41.21 N/mm
CWL = SQRT (RL2 +
WSF2)
>
755.27 N/mm
SAFE
REACH-13
1 Input Data
= 523.9 mm
I = 22543245.5 mm4
C = 26.92 mm
material)
3 Load on Weld
CWL = SQRT (RL2 +
WSF2)
>
950.33 N/mm
SAFE
REACH-14
1 Input Data
= 541.2 mm
I = 23433130.4 mm4
C = 27.08 mm
material)
3 Load on Weld
CWL = SQRT (RL2 +
WSF2)
>
1036.56 N/mm
SAFE
REACH-15 & 16
1 Input Data
= 558.0 mm
I = 24359988.6 mm4
C = 27.33 mm
material)
3 Load on Weld
CWL = SQRT (RL2 +
WSF2)
>
1419.68 N/mm
SAFE
REACH-17
1 Input Data
= 574.3 mm
I = 25331589.4 mm4
C = 27.67 mm
material)
3 Load on Weld
CWL = SQRT (RL2 +
WSF2)
>
1485.99 N/mm
SAFE
R-AFRY-4649.04.501_R2
Page 83/84
Annexure 6: True angle calculations for Compound Bend (Bend-2A)

prohibited.
R-AFRY-4649.04.501_R2
Page 84/84
TRUE ANGLE CALCULATION OF COMPOUND BEND-2A
PLAN Section
Inputs:
A= 5.71 degrees
B= 10.37 degrees
C= 4.62 degrees
cosA = 0.995 sinA = 0.100 tanA = 0.100

cosB = 0.984 sinB = 0.180 tanB = 0.183
cosC = 0.997 sinC = 0.081 tanC = 0.081
True Angle cosD = 0.994

D= 0.114 radians
6.53 degrees
tanθ = -0.9719 tanø = 0.994

θ= -0.7711 radians ø= 0.782 radians
-44.182 degrees 44.829 degrees
TMP = 0.17986

prohibited.

R-Afry-4649.04.501 - r2 Ps Liner Design - 1

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Pinnapuram PSP (1680 MW)

Greenko Energy Projects Ltd.

Pinnapuram PSP (1680 MW)

Greenko Energy Projects Ltd.

Copyright © AFRY India Pvt. Ltd.

Owner’s Engineer Design Consultant

(Formerly, AF Consult India Pvt. Ltd.)

Project Pinnapuram PSP (1680 MW)

Document Design of Pressure Shaft Steel Liner Along Unit-1

Project number 4649

Document number R-AFRY-4649.04.501_R2

Document path N:\Working Designs\4649-Pinnapuram PSP\Engineering\Detailed

Verified 11/01/2022 TSK Singh TSK

Released 12/01/2022 Sai Seela SSE

Revised as per comments given by

Revised as per comments given by

3 Design Data .................................................................................................................. 7

6 Allowable Stresses ....................................................................................................... 10

7 Design Criteria ............................................................................................................ 11

8 BRIEF SUMMARY .......................................................................................................... 19

Copyright © AFRY India Pvt. Ltd.

Copyright © AFRY India Pvt. Ltd.

1.1 Objective of the Report

- Selection of the material of steel liner.

2.1 List of Drawings

S. No. Drawing No. Title of Drawings

Pressure Shaft Steel Liner Along Unit-1 to Unit-8,

Copyright © AFRY India Pvt. Ltd.

S. No. Drawing No. Title of Drawings

Pressure Shaft Steel Liner (Along Unit-1), Top

Copyright © AFRY India Pvt. Ltd.

S. No. Drawing No. Title of Drawings

Pressure Shaft Steel Liner (Along Unit-1), Bottom

Table 3-1: Penstocks: Basic Design Parameter

DESCRIPTION VALUES/ DETAILS

Number of Penstocks 7 Nos.

Internal diameter of Penstock 7500 mm

Internal diameter of Penstock after reducer 5150 mm

Full Reservoir Level (FRL) EL. 463.00 m

Centre line Elevation penstock at Intake EL. 432.70 m

Centre line Elevation of penstock at Powerhouse El. 290.00 m

Water Hammer* 35%

Static Head 173.00 m

Dynamic Head 60.55 m

Joint efficiency of weld joint 90%

Copyright © AFRY India Pvt. Ltd.

(As per instructions given by

Poisson’s ratio of steel liner 0.303

Temperature Variation ∆T ± 20°C

Coefficient of thermal expansion/ contraction ‘α’ 12 x 10-6 /°C

Unit weight of steel 7.85 ton/m3

- Minimum thickness for handling and shipping

Refer to Cl. 4.2.4 d) of IS 11639 Part-2, exceptional condition is not to be considered in

4.2 Design Internal Pressure

Copyright © AFRY India Pvt. Ltd.

4.3 Design External Pressure

Table 4-1: External pressure acting of Penstocks

Table 5-1: Properties of Penstock Steel Material

Yield Stress Tensile Strength

Copyright © AFRY India Pvt. Ltd.

Table 6-1: Allowable stresses for Normal Operating condition

Load Case Allowable stresses shall be minimum of below

IS 2002 Grade-3 153.33 171.0 153.33