Pree Cosag. Ress lage Zoor TECHNICAL STANDARDS FOR GATES AND PENSTOCKS HYDRAULIC GATE AND PENSTOCK ASSOCIATIONItis sincerely hoped that the recently revised edition will serve the pur- pose of assisting those engineers who are engaged in construction and administration of hydraulic gates and penstocks overseas. Chairman of the Technical Committee Hydraulic Gate and Penstock AssociationINTRODUCTION ‘As of 1986, Japan, with its hydraulic generating capacity of 35,700 MW in 1646 locations, ranked fourth inthe world following the United States, the Soviet Union and Canada. The hydraulic power generation capacity ‘occupies approximately 20% of the total power generating facilities of 173,800 MW which includes thermal power plants and nuclear power plants. Therefore, it plays an important role as a precious domestic ener- ay supply source. In addition, more power plant construction projects cen- tering around a large-capacity and high head pumped storage power plant have been making progress in recent years. Seventy eight power plants capable of generating a total power of 9,580 MW have been completed since 1976. In connection with the construction of these pumped storage power plants, a variety of new technologies have been introduced in the field ‘of steel penstocks and gates in order to cope with the technical difficul- ties stemming from the large capacity and the high head. In order to publicize Japan’s technical standards for hydraulic gates and penstocks to the whole world, the Hydraulic Gate and Penstock As- sociation published “Technical Standards for Gates and Penstocks” (English version) in 1971. On the basis of the technical results as men- tioned above, the Technical Standards for Gates and Penstocks (Japanese version) was revised in 1981 and therefore “Technical Standards for Gates and Penstocks” (English version) has also been revised. ‘The Hydraulic Gate and Penstock Association was established in 1949 as a foundational juridical person with the participation as regular members of the hydraulic gates and penstocks manufacturers and the Ministry of International Trade and Industry (MITD, the Construction Ministry, the Ministry of Agriculture, Forestry and Fisheries, the Water Resources Development Corporation, nine major power companies, the Electric Power Development Co., Ltd. and a number of well respected experts as supporting members. Since its foundation, this association has ‘been making contributions to advancements in the hydraulic gate and pen- stock industries with the mutual cooperation of the government agencies and the commercial enterprises. Therefore, the Technical Standards for Gates and Penstocks established by this association are extremely autho- ritative in JapanTable of Contents Chapter 1 STEEL PENSTOCKS Section 1 General Article 1. Application Article 2. Definition ........ Section 2 Design 1. General 4, Attachment Installations .. Article 3. Design of Steel Penstock Article 4. Design Internal Pressure Article 5. Design External Pressure Article 6. Head Loss .. Article 7. Consideration for Water Quality Material and Allowable Stress -......... Article 8. Material of Steel Penstocks .. ‘Article 9. Material of Pressure Lining Part and Mai Attachment Installations Directly Welded to Pressure Lining Part . Article 10. Material of Attachment Installations Article 11. Material Test Article 12. Allowable Stress .. Pressure Lining Part ....-..--s Article 13. Loads to be Considered Article 14. Combination of Loads . Article 15. Design Condition for Pressure Lining Part Article 16. Stress to be Considered . Article 17. Corrosion Allowance . Article 18. Minimum Shell Thickness Article 19. Coefficient of Friction between Pipe and Supports . eee Article 20. Effective Sectional Area of Pipe Shell Plate Article 21. Bend Pipe ... Article 22. Branch Article 23. Reinforcement of Holes 21 2B 3 35 35 . 36 37 39 56 37 39 61 65 9 883 86 Article 24. Expansion Joint Article 25. Manhole .. Article 26. Air Pipe and Air Valve ses . 87 Article 27. Anchor Bolt, Anchor Band, Thrust Collar ..... 89 . Movable Part of Support 1 . Ring Girder Section 3. Manufacture sve Article 30. Processing of Shell Plate .. Article 31. Fabrication se Article 32, Tolerance for Circumferential Length .. Article 33. Hydraulic Test Section 4 Installation Article 34. Handling Article 35. Installation in General .. Article 36. Consideration of Temperature during Installation . 10 Article 37. Longitudinal Joint .. 2 . 101 101 102 + 103 104 107 107 108 Article 38. Coating ....sesoeesse m2 Article 39. Protection of External Surface of Embedded Underground «...... 116 Article 40. Name Plate . a 7 Article 41. Water Filling and Operation Test .. 118 Section 5 Maintenance 19 Article 42. Prevention of Leakage . 19 Article 43. Maintenance of Expansion Joint .. 119 Article 44, Maintenance of Air Pipe and Air Valve ........ 119 Article 45, Maintenance of Movable Part of Support ...... 120 Article 46, Prevention of Vibration .. 120 Article 47. Consideration to Water Quality after Completion of the Penstock 123 Article 48. Check of Pipe Inside 124 Article 49, Measurement of Shell Thickness Article 50. Repair or Replacement Article 51. Recoating 124 125 127 Section 6 Anchor Block and Support ....... 128 Article 52. Locations of Anchor Block 128 Article 53. Foundation of Anchor Blocks 128Article $4. Stability Conditions for Anchor Block .. Article 55. External Force to be Considered ...... Article 56. Location of Support Article 57, Foundation of Support .. Article 58. Design of Support... Article 59. of Anchor Block and Support ‘Article 60. Observation of Shifting Anchor Block Article 61. Protection Work for Bed and Cutting Slopes Chapter 2. HYDRAULIC GATE .. Section 1 General Article 1. Application .. Article 2. Definitions Article 3. Selection of Type anc Section 2 Outline of Design ... 1. General . Article 4, Design Conditions Article 5. Selection of Type of Hoisting Device Article 6, Power Equipment for Gate Operating .. Article 7. Operating Speed .. Article 8, Lifting Height .. Anticle 9. Auxiliary Power Equipment Article 10. Materials of Hydraulic Gate Article 11. Material Test ese 2.Gate Leaf, Gate Guide and Anchorage .. Anticle 12. Allowable Stress .. a Article 13. Increase in Allowable Stress during an Earthquake Article 14. Loads to be Considered .. Article 15. Combination, of Loads Article 16. Shape of Gate Leaf, Gate Guide and Anchorage .. cesseenseneee Article 17. Seal Part Article 18. Hinged Support Anticle 19. Skin Plate oe Axticle 20. Corrosion Allowance ... . 129 130 133 134 2134 135 135 136 137 sees 137 . 137 fees 137 . 148 . 152 152 . 152 153 sees 154 2 15S 2155 iss 156 160 160 . 160 168 169 176 7 V8 180 181 183Article Article Article Article Article Anticte Article Article Article Article Article Article Article Section 3 Design Particulars ai. 2. 2. 28. 29. 30. 31. 32, 33. 34, 35. 36. 37. Rigidity, Minimum Plate Thickness and Slenderness Ratio of Gate Leaf 184 Deflection by Gate Leaf . 185 . Plate Girder .. - 186 . Web Plate Thickness of Members Sujet to Compressive Force .. . . 187 188 . Safety Factor of Gate Hoist « . 188 . Mechanical Efficiency & Coefficient of Friction of Each Part of the Gate Hoist ........ 190 Capacity and Time Rating of Prime Mover .... 191 Brake .. ees - 192, Emergency Lowering Device 2193 Diameter of Wirerope, Drum and Sheave ...... 193 Number of Spooled Wirerope Layers, Fleet ‘Angle and Minimum Number of Wraps 194 Type and Capacity of Auxiliary Power Equipment ses . 195 Capacity of an Oil Hydraulic Pump and a Prime Mover Oil Hydraulic Cylinder 197 Oil Hydraulic Pipe .. 198 Hydraulic Operating Flui 199 Safety Device and Auxiliary Facilities for Gate Hoist ... . 203 I. Fixed Wheel Gate... - 203 Article 38. Shape of Fixed Wheel Gate - 203 Article 39. Main Girder ... . + 203 Article 40. Auxiliary Girder .. 204 Article 41. Side Girder ... 1. 208 Article 42. Main Rollers .. 205 Article 43. Guide Roller 208 Article 44, Gate Guide .. 209 Article 45. Operating Load 212 2. Radial Gate .. . 25 Article 46. Shape and Structure of a Ra 2 215Article 47. Framework Article 48. Gate Arm and Arm Bracing Article 49. Fixing Point of Arm Bracing Article 50. Anchorage .. 3. Long Span Gate 31. Application 52. Shape of the Gate Leaf . 53. Considerations for Gate Leaf Structure 54. Considerations for Gate Leaf Deformation .. Article 55. Considerations for Gate Leaf Operations 4, Bottom Hinge Flap Gate Article 56. Shape of the Bottom Hinge Flap Gate .. Article 57. Considerations for Sedimentary ‘Sand and Drift Article 58. Structure of the Gate Leaf Article 59. Gate Leaf Support . ‘Article 60. Gate Operating Force and Operating Mechanisms 5. High Pressure Gates and Valves .. Article 61. Outline of Design Article 62. Shape of the High Article 63, High Pressure Valve Article 64. Shape of Passage . Article 65. Conduit Pipe .. Article 66. Air Pipe .. 6. Selective Water Withdrawal Equipment and Surface Water Withdrawal Equipment . Article 67. General ... . Article 68, Structure of Gate Leaf Article 69. Dynamic Pressure during an Earthquake Article 70. Safety Guard Equipment for Gate Leaf 7. Trash Rack Article 71. Trash Rack Section 4 Manufacture .. Article 72. Processing of the Skin Plate Article 73. Assembly . 216 216 207 218 219 . 219 2 219 2221 2221 2 222 222 222 23 223 224 228 226 226, 226 27 228 229 231 . 233 . 233 234 234 236 236 . 236 . 240 240 .. 240Section $ Instat Article Article Article Article Article Article Article Article Article Article Article Article Article Article Article Article Article Article Article Article Article Chapter 3. STEEL STRUCTURE Section 1 General Article Article 2. Definition Section 2 Design Article Article Article Article Article 14. 85. 86. a7. 88. 89. 90. m1 9. 93. 94 95. 1 3. . General Installation .. - Install . Coating Specifications .. |. Metal Spraying, - Running Test Section 6 Inspection . Article 84, Inspection Section 7 Maintenance 241 241 241 Consideration of Floods during Installation ... 242 Installation of the Gate Guide and Anchorage ...... 242 mn of the Seal Part .. eevee 43 243 248 250 250 251 252 252 253 . 253 253 253 Handling during Transportation Coating Work Builder's Name Plate Maintenance, Inspection and Control Leak Prevention Freeze Prevention .. Maintenance of Support . 254 Maintenance of Gate He 255 Maintenance of Auxiliary Power Equipment. 255 Repair and Replacement . 255 Maintenance Gate 256 Recoating + 256 Hoist Room . 287 ‘Access Bridge and Access Facilities eu 287 259 . 259 ‘Application » Material . ‘Allowable Stress of Materials... 260 Increase in Allowable Stress 260 Loads to be Considered 260 Combination of LoadsSection 3. Fabrication and Installation 263 Article 8. Articles Applied . seve 263 Chapter 4 WELDING ....... 265 Section 1 General 265 Article 1. Application .... 265 Article 2, Welder . 268 Article 3, Welding Material ... 23 Article 4. Graphical Symbols for Welding 283 Section 2 Welded Joint .... 287 Article 5. Joint Type 287 Article 6. Combined Use of Rivets or Bolts and Weld ... 288 Article 7. Arrangement of Welded Joints ..... 290 Article 8, Butt Joint steaessenene 291 Article 9, Fillet Welded Joint 293 Article 10. Drilling at Weld Zones 295 Article 11. Butt Welding of Stee! Plates Having Different Thicknesses .. - 295 Article 12. Lap Fillet Weld . 297 Article 13. Welded Joint Efficiency .. 299 Section 3. Welding Procedure .. 302 Article 14, Arc Welding Machine 302 Article 15. Maintenance of Welding Machine 302 Article 16. Wiring. 302 Article 17. Welding Equipment 303 Article 18. Storage of Welding Rod .. 304 Article 19. Butt Weld Groove .. 306 Article 20. Welding of Jig and Tack Welding . Article 21. Welding Sequence .. - Article 22. Prebeating .. Article 23. Final Welding . eo 0 Article 24, Weather Effects .. . 3 Asticle 25. Back Welding . . seeeseenenne 312 Asticle 26. Final Welding with an Automatic Welding Machine... 33 Article 27. Peening ... 314Section 4 Heat Treatment Section 5 Test and Inspections Section 1 General Section 2 Riveted Joints ... Section 3. High Strength Bolt Joints. Article 28. Sizes and Tolerances of Weld Metal Article 29. Annealing .. Article 30. Welding Procedure Test .. Article 31, Weld Inspection Article 32, Non-Destructive Inspections Article 33. Repair Welding . Chapter 5 RIVETED, HIGH STRENGTH BOLTED AND BOLTED CONNECTIONS .. Article 1. Appli 2. Combined Use of Joints 3. Connection of Members 4. Arrangement of Rivets, High Strength Bolts and Bolts . . 5. ‘Thickness of Splice Plate 6. Calculation for Effective Cross-sectional Area of Members... Article 7. Fabrication of Joint .. Article 8. Material of Rivets .. Article 9. Shape of Rivets ... Article 10, Riveted Joint Article 11. Riveting Article 12, Caulking. Article 13. Application .. Article 14, Bolts, Nuts and Washers for High Strength Bolt Friction Connections . Article 15. High Strenath Bolt Friction Joints Article 16, Performance of High Strength Bolt Friction Joints Article 17. High Strength Bolt Bearing Connection 314 . 319 319 . 326 326 . 327 . 328 331 333 333 333 334 334 345 348 351 351 351 351 352 . 352 353 353 . 354 355 356 .. 359Section 4 Bolted Connections ........ seo 361 Article 18. Application 361 Article 19. Nuts, Bolts and Washers .. . 361 ‘Article 20. Arrangement and Performance of Bolted Joints . 362 Chapter 6 SAFETY AND SANITATION . 365 Article 1. Safety and Sanitation ..Chapter 1 STEEL PENSTOCKS Section 1 General Article 1, Application This standard is applicable to steel penstocks to be used for all hydro- electric power stations. This standard is applicable only to so-called steel penstocks defined in Article 2., and is not applicable to reinforced concrete pipes or wooden pipes, etc. Hydroelectric power stations have a wide variety of sizes and scales ranging from big ones having large capacities and high heads to small ones utilizing streams, but no matter how small-scaled a hydroelectric power station is, there is no difference in design whatsoever for steel penstocks, and thus this standard is applicable to all hydroelectric power stations Article 2. Definition I. Steel penstocks referred to in this standard mean structures installed to guide water directly from intakes, head tanks or surge-tanks to hydraulic turbines, ie. steel penstocks consist of penstocks to be pres sure lining parts and their attachment installations (excluding linings just for the purpose of preventing water leakage). 2. Pressure Lining Parts referred to in this standard mean pipe shells of steel penstocks. 3. Attachment installations referred to in this standard mean those listed below: (1) Expansion joint (Q) Manhole @) Air pipe and air valve (4) Guard valve and its by-pass pipe and by-pass valve (3) Drainage pipe and drainage valve (6) Supporting structure (1) Stiffener and others closely related to the pressure lining part4, A Longitudinal Joint referred to in this standard means an axial joint subjected to circumferential forces. 5. A Circumferential Joint referred to in this standard means a joint in a circular direction subjected to axial forces. Description : 1. ‘Guide water directly’ means a pipeline to guide water from an intake to a hydraulic turbine or a pipeline from a head tank or surge-tank toa hydraulic turbine, in a dam type power station or adam and con- duit type power station where a surge-tank is omitted due to a short conduit, and such hydraulic pressure pipes as syphons etc., installed in a headrace between an intake and a head tank or a surge-tank are excluded from this standard, A pipeline which is provided only for the purpose of preventing water leakage installed in bedrocks between a head tank or a surge-tank and a hydraulic turbine is also excluded because such a pipeline’s design conditions are different from those in this Chapter. ‘Terms of ‘steel lining’, ‘hydraulic pressure pipe’ etc., similar to ‘steel penstock’ in this standard are specified in Article 2., Chapter 3. 2. Omitted 3. A guard valve is installed either halfway of the steel penstock or at the inlet of a hydraulic turbine, and the former is called a penstock valve and the latter an inlet or main valve in Japan. “Something closely related to a pressure lining part especially’ me- ans branch pipes, cooling pipes diverging from a steel penstock and a structure working together with a pressure lining part, and influenc- ing greatly on its strength. ‘Supporting structures can systematically be expressed as follows:(Movable part) sie late aig cen ote Saddle support | (Support) come sie LP se saddle one ‘Support (Movable part) sone bare Supporting, Roller bearing pated f hs ‘Stide bearing ° Bipe -Ring support —] in bearing. Supporting sate of achor (ia coli Soper eel penock ‘block anchor bolt ting girder wae) cng ea) ilig coset eae son Supporti smeureat—[' 7 Sruslaed Ground (embedded underground) tive SI Stee plate 1 Conereie sade bearing Example of sade suport Fig. 1. Bearing Support ‘Example of ring support, Example of SupportSection 2 Design 4. General Article 3. Design of Steet Penstock ‘A steel penstock shall be designed taking account of not only safety but also its economy and workability. Description : Steel penstocks, one of the most important structures in a hydroelec- tric power station, should be designed to be most economical, taking ac- count of their workability and maintainability based on the securing of safety of the installations. Penstocks, however, are positioned in the whole plan of a hydroelectric power station ranging from an intake to an outlet, and thus it is hard to evaluate steel penstocks from only their economic viewpoint. Therefore, steel penstocks should be generally reviewed and studied in terms of route, number of lines, diameter, etc., under various conditions derived from a hydroelectric power station plan. 1, Steel penstocks should be designed taking the following factors into consideration: (1) Type of power station Power stations in terms of generating system can be grouped into ‘general hydroelectric power stations of either run-of-river type or reservoir type and pumped storage power stations. Dependent upon these power station types, annual operating hours greatly differ. In deciding on the scale of steel penstocks, an economical design is necessary taking these conditions into consideration and in plan- ‘ning a pumped storage power station of large scale and fewer annual operating hours compared with a general hydroelectric power sta- tion, emphasis is placed on a decrease in construction cost. Q) Route It is desirable that steel penstocks be straight, taking account of conditions of topography, geology and environment. A longitu: nal gradient should be selected so that the penstock is below the hhydraulic gradient line even if the water level of the intake installa tion, head tank or surge-tank is lowest, and should be selected so. 8 not to produce negative pressures with fluctuating loads.) Type of stee! penstock Type of steel penstocks can be classified as exposed and embed- ded pipes. In either type, the penstock should support all of the internal pressure basically, but part of the pressure can be shared with surrounding bedrocks in case of an embedded pipe, provided that there exists no problem in structure and material of pipes, and topography, geology and bedrock conditions be well-known, (4) Construction works of steel penstock Ina pumped storage power station having a high head and a large , the construction work of steel penstocks may influence the progress of the entire construction schedule of a power station because embedded pipes are often used, thus requiring a des phasizing its construction work. (5) Number of pipelines and branch position As the construction cost of steel penstocks increases in propor- tion to the number of lines, it is thus desirable, if the lines are long, to decrease the number by installing branches at proper positions, taking the availability of material into consideration. © Diameter Diameter of steel penstocks should be decided taking account of economy of the installations and workability, etc. (1) Materials Materials used for steel penstocks should be those specified in JIS in principle, and special attention should be paid to the weld- ability of 70 and 80 kg/mm? class high tensile steels, thick plates, forging steels, etc., not specified in JIS. (8) Repair and replacement of existing installations. In designing repair and replacement of existing steel penstocks, this standard should be applied in principle. But, in case that itis hard to apply this standard due to the conditions of the existing installations and the topography and so forth, the existing installa- tions can effectively be used after reviewing their safety. Economical diameter Economical diameters of steel penstocks can be determined taking account of their construction cost, and loss of electric power and energy. Approximate values of an economical penstock diameter can be de- termined as follows. This method and these calculation formulae have been used so far,‘An economical diameter is determined so that the sum of the con- struction cost and the decrease in power generating power due to loss of head in steel penstocks may become to be minimum. Friction head loss is calculated usually as the most influential fac- tor, but a , reducing, bend and branch portions should also be of structure with a minimum loss. There are several ways in determination, however, two methods are stated hereinafter; one based on the cost of steel penstock; the other based on the total cost of the penstock and the hydraulic turbine generator. (1) Formulae: Considering cost of the steel penstocks 1) Upper portion (where a thickness of steel penstock is determined by the minimum plate thickness, not by design pressures) [recom 9 POP0r* ond LEE on 2) Any portion (where a thickness of steel penstock is determined by design pressures) pal 3*78-tfeo A gCoup(l +) {riaeern+ emt + Se7En}} we where D: Diameter of steel penstock (m) Jf: Friction loss coefficient : Ratio of the sum of operation and maintenance cost and interest of construction cost of power sta- tion over the total construction cost + Acceleration of gravity (=9.8m/s!) + Unit cost of steel penstock construction (yen/tf) Specific gravity of steel penstock ( = 7.85) >’? Thickness of steel penstock (m) Ratio of weight increase by stiffeners, etc. of stel penstocks ( = 0.10 ~ 0.25) ne! Combined efficiency of a hydraulic turbine and a generator during power generation Q,: Discharge used during power generation (m?/s) te1: Reduction ratio of transmission loss (kW) during power generation 2! Reduction ratio of transmission loss (kWh) during. power generation + KW price (yen/kW) = kWh price (yen/kWh) Annual power generating hours (h) Discharge during pumping-up (m/s) ‘Annual pumping hours (h) kWh cost for pumping-up (yen/kWh) Combined efficiency of pump and motor during pumping-up @;: Reduction ratio of reception loss (kWh) during pumping-up @: Joint efficiency of steel penstock ‘o: Allowable stress of steel penstock (kef/cm’) Design pressure (kgf/cm?) (2) Formulae: Considering total cos ofthe tel penstockand hydraulic turbine generator In the previous formulae, the construction cost only for steel pen- stocks is taken into consideration but manufacturing cost for the hydraulic turbine and generator are excluded. But the fly-wheel ef- fect of a generator GD* and a steel penstock design may be changed depending upon how to determine the momentary speed variation An, the momentary pressure variation AP of the hydraulic turbine and the required closing time of the governor. Thus, the most economical penstock diameter can be determined by incorporating the above factors, as follows @ forlorn +enta + Cou(1 +9) 129 (GD), 4C,Wooos GD. *}FOe! +e0+ Q)2 wherew(- 2) where GD: Generator's fly-wheel effect required for hydrau- lic turbine (tf-m?) L: Length of steel penstock (m) (GD), : Normal GD" given by a manufacturer without considering the requirement for a hydraulic turbine (tf/m’y : Construction cost per ton of a generator (yen/tf) : Generator weight usually given by output (tf) Annual mean discharge (m’/s) Dead time of governor (s) + Propagation velocity of water hammer (m/s) Momentary pressure variation +: Runaway speed increase ratio of unaway specs N ‘An: Momentary speed variation of hydraulic turbine Limit of 4n is 45% for Francis turbine and 60% for Kaplan turbine from mechanical strength, but 40% should be the limit taking voltage regulation, into consideration. : Revolutions of turbine (r.p.m.) Coefficient (= 0.8 ~0.9) Required closing time for turbine governor (s) + Average velocity of steel penstock (m/s) Hydrostatic pressure (mm) N hydraulic turbine = (D should be obtained from formula (3)-1, and GD* from for- mula (3)-2 by assuming AP, and T should be gotten by substituting GD* for (3)-4. Then, if the value of AP substituted for (3)-5 is ‘equal to the value of AP assumed in (3)-2, itis satisfactory. In case that GD® required for a turbine obtained from (3)-2is larger than that of the generator itself (i.e.(GD2)u), the GD? required for the turbine should be reduced so that GD* becomes equal to (GD?)u, or (GD"u of the generator itself should be increased. As the construction cost for a hydraulic turbine and a generator ncreases in proportion to GD", an increase in (GD"u means an increase in the construction cost of a generator, whilst a decrease in GD* with a constant momentary speed variation of a turbine results in shortening the required closing time, enlarging the momen- tary pressure variation AP, and increasing the shell thickness of steel penstocks, and thus the construction cost of the penstocks increases. Consequently, which should be selected must be based on a com- parison of the economic factors. Contrary to the above, when the GD? required for a turbine is smaller than the (GD2)u of the gener- ator itself, an economical penstock diameter should be determined by increasing the momentary pressure variation to lessen the GD?, and by increasing the average velocity with a smaller diameter un- til requirement of the original design is matched with the construc- mn cost. Article 4. Design Internal Pressure The internal pressure to be used for designing shall be the maximum value foreseeable in consideration of the hydrostatic pressure and the pres- sure rise due to water hammering and surging. Description : Internal pressures working in steel penstocks are, in addition to the hydrostatic pressure, pressure variations caused by surging in a surge-tank and water hammering in penstocks generated by turbine load variation, Steel penstocks should be safe from the maximum internal pressure pos- sible to be generated, ‘When summing up the pressure rises both by surging and by water ham- ‘mering, the maximum value which can take place simultaneously should be taken. In case of a simple surge-tank, however, itis permissible to con- sider that the pressure rise by water hammering does not overlap on thepressure rise by surging. In such a case, it should be noted that “hydrostatic pressure + pressure rise by surging” may become larger than “hydrostatic pressure + pressure rise by water hammering” at the upper portion of ‘a penstock. Pressure rte by water hammering Pressure rise by surging Hydrostatic pressure ‘Closing equipment of water turbine Fig. 1.41 Example of Design Internal Pressure (Example of simple surge-tank) The hydrostatic pressure should be the difference of the heights from the center of the penstock or the hydraulic turbine (the tangent line of the runner in the case of a Pelton turbine) to the crest top of the head tank in the case of a run of river type power station, and to the maximum, design water level of the reservoir or regulating reservoir in the case of a dam or dam and conduit type power station. ‘The maximum pressure rise due to surging should be the difference of the heights from the maximum overflow level to the crest top of a head. tank for a run-of-river type and for types with a surge-tank the difference of heights from the maximum water level in the surge-tank to the maxi- mum design water level of the reservoir or regulating pondage at shut- ting-off in all loads under generating condition. The pressure rise due to water hammering depends on the efficiency of the surge-tank, closing equipment, pressure regulator, and pipeline con- stants, etc. But the maximum value takes place at the center of the clos- ing equipment. (The maximum value is produced in a guide vane for a Francis turbine and in a needle valve for a Pelton turbine, but the center = 10-of the turbine should be assumed in computation.) It gradually reduces along a pipeline, and vanishes ina head tank or surge-tank. It is assumed that the reducing ratio of pressure rise by water hammering is propor- tional to the length of the pipeline. The places where the pressure rise by water hammering vanishes should be as follows: (a) Head tank, simple surge-tank : place where the water surface expands (b) Differential surge-tank : overflow top of a riser (6) Chamber surge-tank : place where the water surface expands if an upper chamber exists; for others at the shaft overflow top But, in case that a surge-tank is relatively slender or of the restricted ‘orifice type, the pressure rise does not vanish at the surge-tank bottom, and thus the pressure rise should be determined by calculation. The pres- sure rise by water hammering at the center of a Pelton turbine should be taken as more than 10% of the hydrostatic pressure, despite less than 10% in computation. It should be noted that the pressure rise by water hammering may some- times be larger under partial loading than under maximum loading. For- ‘mulae for the pressure rise due to the water hammering without pressure regulators are classified into the following (A) and (B) depending upon Allievi's pipeline constant @: Notations se. _Alliev’s pipeline constant a? Closing time constant of a 2Lo closing equipment n= of Where fy: Pressure rise due to water hammering ata closing equip- ment (m) Hy: Hydrostatic pressure after entirely shutting off a closing equipment at the turbine end (m) : Length of pipeline (m) : Average velocity (m/s) aiewhere): Pipe length of velocity vi (m) vu: Velocity of length fi (m/s) T: Closing time of a closing equipment (s) 4: Acceleration of gravity (m/s?) a: Propagation velocity of pressure wave (m/s) (A)In case of @ > 1: when (1) when +Q) when 530% a" (B) In case of @ <1: @) D Conditions of (A) and (B) are those similar to Schlag’s, formula (1) is Allievi's and (2) is Sparre’s. Formulae (2) and (3) are called Calame- Gaden’s formulae too. For a Francis turbine, the following empirical formula applicable to proposed: @ Pressure rise by the water hammering with a pressure regulator may be calculated by formula (5) taking account of the effect of the pressure regulator if its actual function is clear (in case of replacing existing steel penstocks, thorough consideration should be given to reliability of the pres- sure regulator), but in this case, at least more than 50% of the value cal- culated on a no-pressure-regulators basis should be taken. -12-In this case, the formula for pressure rises due to the water hammering, is as follows: (5) 1 Difference in time between the start of a guide vane’s clos- ing and the start of a pressure regulator's operation(s) But, in this case, the pressure rise does not decrease from the turbine toa place (L ~ + ). Examples of calculation of the pressure rises and actual measurements are listed in Table 1.4-1: ‘Table 1 A Examples of Calculation of Pressure Rises and Actual Measurements ‘A. Pressure rises with pressure regulators inoperative Calcolated vale Tal Fores Forms Fara [Formal oe os wa |e 40s | 320 me [ia ce aaa | Joa Power] 14 [0.45] 15970223] Be pa ati | 274 [0a 320 | 0 ns | 327 -13-B. Pressure rises with pressure regulators operating Cakeulated valve, [Actual messorement Power station Load | “formula (6) ‘ Power sation 67 52 3 Power sation § ~ B2 240 Tet we ins 03 BS a Dimensions of power stations Power sation H_| Power sation S 0 aT m2 3 1 % Bear 2,500~1,300 3.600~2,700 Output kw 36,008 9,000, Pitteretialsurgesank] Conduit ype ‘Note: *1 With ¢ > 1, (), @), and (@) can be applied the values by (), @) and @y are sar, sind thote by @ are somewhat larger and aze clove tothe actual meas 12 With < 1, calculate values by (3) and (4) show good results 13 Compared with *2, an eect of presture regulator is shown 4 Values by Allew's sequential method In some cases, actual measurements of the pressure rises by water ham- mering may differ 10 to 15% from the calculated values, under the in- fluence of turbine characteristics, and thus it is desirable to take about 20% allowance. The above formula (4) includes a 20% allowance. Itis necessary to make either a graphical solution or sequential calcula- tiom in the cases below: (1) For branches, when the furcate point is far away from the hydraulic turbine compared with the pipeline length. (2) When rising of water level by surging is rapid as in the case of a differential surge-tank. (In many cases formulae (1) to (5) are ap- plicable.) ) In case of restricted orifice surge-tanks (Jaeger’s formula may be used also.) -14-(4) In case of pump turbines Reversible pump turbines are mostly employed as main machinery at a pumped storage power station in Japan. The characteristic of the water hammering in this case is that the pressure variation in transient operations i far greater than values calculated from Al- lievi's formula. The main reason for this is that the non-linearity of NH to the time is more remarkable in case of pump turbines compared with the case of ordinary turbines Article 5. Design External Pressure As for design external pressures of steel penstocks, the maximum pres- sures which may take place during drainage, when a pipeline is empty, as well as under construction shall be taken into consideration. Descriptior ‘Various pressures act on steel penstocks such as negative pressures during drainage, seepage pressures of bedrocks working on embedded portions, and concrete pressures and grout pressures during construction works. A steel penstock must be of a structure capable of withstanding maxi- ‘mum external pressures possible to take place taking the above into con- sideration, In order to prevent collapse due to the negative pressure of a pipeline during drainage, air pipes or air valves are installed, Since they are designed to ensure to introduce the amount of air required with less than \"'0.2ke/em? pressure difference between the inside and outside pipe, nor: mally 0.2kgf/cm? of pressure difference between the inside and outside pipe should be taken into consideration for exposed pipes. (See Article 26.) This is not necessary, however, when air comes in freely during rainage, i.e. negative pressures cannot take place. Seepage pressure of bedrocks should be external pressures due to under- sround water level expected, but its design pressure can be reduced when drainage installations are provided around the steel penstocks to reduce the external pressures. Deformation of penstocks due to the concrete pressures during construc- tion works should be prevented by means of jigs inside the penstocks, other supports, or stiffeners, etc Structural calculations may be made for concrete pressures and grout pressures during construction works, together with including corrosion allowance. In this case, itis permissible to prevent the deformation by inside supports. -15-Article 6. Head Loss Pressure lining parts and attachment installations of steel penstocks shall be designed hydraulically to keep the head losses to a minimum as much as possible. Description : Head losses in steel penstocks have a large percentage of the total head losses of a power station, ‘The number and diameter of a penstock should be decided economi- cally from the relationship of the electric power loss due to head losses and the construction cost as in Article 3. Head losses are influenced not only by friction losses of steel penstocks but also by branches, bend pipes, reducing pipes, inlet pipes, expansion joints, guard valves, etc., to some ‘extent, and thus considerations should be given to the design of these struc- tures so as to minimize head losses as much as possible. It should be noted that the influence of the head loss is great for a power, station having a low head and a big capacity. Important head losses for pipelines can be calculated as follows: 1. Friction Head Loss bape pay where A,: Friction head loss (m) Kutter’s coefficient of roughness Length of pipe (m) Flow velocity (m/s) R: Hydraulic depth of pipe (m) 8: Acceleration of gravity (m/s") For circular pipes, taking D as the internal diameter of the pipe: Loa Ase RD ‘As for the value of n, 0,010 t0 0.014 is applicable to normal steel pipes. 2. Head losses of entrance, reducing, enlarging, and bending Head losses of entrance , reducing, enlarging, and bending should be in accordance with Table 1.6-1 ~ 16 -3. Other head losses ‘Other head losses of diverging (joining) should be based on the description of Article 22., this Chapter. Calculation formula he Ne 1.61 Head Loss i | TS caane nad ow | eon fea | Rounded (ecangutar) V Hew sciy afer | Bellmoudh of 1 elipee | 0.017005 owing ——— “Reducing los confit ¥ : Flow velacty after reducing clarging ¥, 2 Flow velocity after enlarging r ae wae“Type of weit | __Celaaon forma ‘Remarks ‘Bending ead toss vw n= Su Sa ay where: "ip Bending bead ln mined by the ratio a cemer ange #10 Vs Flow velocity coefficient deter- Bending radius @ to the pipe diameter D (@/D), in case that a enter angle of bend ings 0 Ge Be @) us + Ratio of the los fr iosttoea coer sist Geen Oo of "be ‘The Tolowing empiri: ut <4 Cal formula i fre" ent used for fy, ad |_| a J = 0131 + 0.1682 CT 2p, na : | Sa : th given by the above oa aT {beeain does nan a lode the fon fread toss, (0) Value of Jig = ey Head loss of a valve differs in hydraulic characteristics depending on each design, and so the loss coefficient should be decided appropri ately to its characteristics. Slight head losses are generated around expansion joints, manholes, etc., and so it is desirable to add some allowances to the sum of head loss. - 18 -wap Sk set le 2 ee Article 7. Consideration for Water Quality When the pH value of water in a steel penstock is less than 4, some ‘measures shall be taken to decrease the corrosion of the steel penstock. Description In voleanic zones, there may exist rivers having corrosive water due to sulfurous acid gas, etc., produced there, Corrosion progress due to corrosive water is affected by hydrogen ion exponent (pH), specific conductivity, amount of chlorine ions, etc. Gener- ally, pH is used as the index for corrosion progress. Generally, stee! corrosion due to acid water develops very rapidly with pH value of less than 4.5 and develops especially significantly with a pH of less than 4.0. Steel corrosion progress is hardly affected by a pH value from 4.5 to 10. Corrosion due to acid water is greatly influenced by the flow velocity and inflow of soil and sand, and thus it should be noted that corrosion may develop when flow velocity and inflow of soil and sand are excessive even if the pH is more than 4, ‘The value of the pH differs depending upon the flow rate of the river. ‘When the flow rate is high in a wet season, the pH values become rela- tively high with the acid water diluted and thus the minimum pH values should be taken as a criteria throughout the year. Table 1.7-1 Example of Actual Measurement in Agatsuma River TB 654 = 19663) ower sation | Tet pace | Fo voy i ie pay ve Matsuya | Sukawaintake| 277-315 | 62 Kees” | Heat?) ia | Se Er ‘Actual measurements made in Agatsuma River in Japan by Tokyo Elec- tric Power Co., Inc. are shown in Table 1.7-1. As.a result of the measure- ‘ments, corrosion barely develops with more than 4.4 pH and with a little flow velocity and less inflow of soil and sand, but it becomes clear that corrosion is prompted widely and remarkably with less than 4.0 pH and 1 ~ 2m/s flow velocity. Some measures to prevent corrosion are available. One method is to -19-paint an acid resisting material or make a lining to the pipe inside, and the other one is to produce a pipe itself using an acid resisting steel. Field tests have been conducted concerning rivers with acid water by Central Research Institute of Electric Power Industry and various electric power companies in Japan. ‘According to the above researches, chlorinated rubber paint and alkyd resin type paint show excellent properties. Tar-epoxy resin type as a paint using the excellent properties of the epoxy resin has been widely used in. recent years. Stainless steels are superior as acid resisting steel and are used as clad steel from an economic viewpoint. Corrosion of steel penstocks by acid water develops very rapidly when steel penstocks are worn by flowing sands. In such a case, itis necessary to decrease the corrosion of penstocks by making a lining made of a coal tar enamel having much resistance to wear, or by attaching patches (made of acid resisting steel) to the bottom of pipes or portions subjected to much influence of corrosion wear, as well as by preventing the sands from flow- ing in. 2. Material and Allowable Stress Article 8. Material of Steel Peastocks Materials used for steel penstocks shall be those listed in Table 1 Materials other than those in Table 1.8-1 may be used provided that a sufficient study be made. ‘Table 1.8-1 Types of Materials 1, Rolled sid for general sracure TS 6 5101 (975) 2. Rolled steels for welded structure BIS G 3106 1377) 5 Hotroied atmospheric corrosion resisting steels for welded structare Als G 3114 (977) 4, Stet plates for pressure vessels for intermediate {emperature service 418 G 311s «oT 5. Sted bars for vet B13 G 3104 (1976) &. Carbon stel castings MS G 5101 (1978) 7 Steel castings for welded structures IS G S102 (978) Carbon stel forgings for general tse IS G 3201 (197) 9. Gray ion castings IS G 3901 (1976) Description : This standard is spe ied to use the material whose characteristics are — 20 - Prec rit reenter nese nner eine amenclear, and it is necessary to confirm that the material meets the require- rents of the JIS standard by material tests before fabrication. But when the material characteristics concerned are clear enough with the material test records made by its steel manufacturer, the records can be a substi- tute for material tests. The material tests in this Article should include tests not only for strength but also for whether or not the dimension (thick- ness, ete.) is within the tolerance, Tolerances for plate thicknesses should be in accordance dard specified in Article 9., this Chapter. I isa special case to use JIS materials other than those in Table 1.8-1 ‘or materials other than JIS, and careful consideration should be given to this case For instance, in case that such standard pipes as Carbon Steel Pipes for Pressure Service (JIS G 3454), Arc Welded Carbon Steel Pipes (JIS G.3457), etc, are employed as a steel penstock material in such locations as smallscaled hydraulic power stations, a careful study and review should bbe made to their material, manufacturing methods, inspection methods, ice. the adaptability to a steel penstock, and each paragraph of this stan- dard should be applied to their use. Article 9, Material of Pressure Lining Part and Main Attachment Installations Directly Welded to Pressure Lining Part 1, Materials used for pressure lining parts and main attachment installa- tions directly welded to the former shall be the kind listed hereunder or steel material having equivalent or superior characteristics. the stan- Rolled Stel for General Use Class 2 (JIS 03101 S541) Rolled Stel for Welded Structure (JIS 3106 SM41;SMSOSMSOY-SMS3SMSE) Hot-rolled Atmospheric Corrosion (JIS G3114 SMASI-SMASOSMAS8) Resisting Steels for Welded Structure Steel Plates for Pressure Vetsels for (JIS O311S SPV2ASPVS2SPV36SPV46) Intermediate Temperature Service 2. Tolerances for the thickness of pipe shell plates used for pressure lin- ing parts in particular can be specified separately. -u-Description : ‘The pressure liniNg part is the most important portion in a steel pen- stock, and so the material used for this should be in accordance with this Article, and should be economical as well as safe. “Main attachment installations directly welded to the pressure lining part” include stiffeners, ring girders, manhole reinforcements, etc., and for these, steel material having equivalent or superior characteristics to the pressure lining part should be used because the above installations work. structurally together with the pressure lining part. “Steel material having the equivalent or superior characteristics” may include high tensile steels other than those in JIS (See Article 11., this Chapter). een na 30T ‘With the safe material, the notch toughness geté poorer as the thi ness increasgé, and the material is likely'to be brittfe-fractured depending Cn the notch condition, temperatures, rate of loading, etc. Therefore, steels, having a better notch toughness should be used as, i thickness increases. In case of more than 12mm thick plates, it is preférred to use a plate hav- ing a shock-absorbing energy of more than 2.8kgf.m (0°C). For steel materials thicker than 25mm, it is necessary to use killed steet or semi-killed steel up to strength of SMSO, and killed steel for more than strength of SM SOY. SM SOY is semi-killed steel added usually with nio- ium, on the other hand SMS3 and SMS8 are killed steel so SMS3 should be used as a substitute for a plate thicker than 25mm. As for thickness tolerances for pipe shell plates used for the pressure lining part in particular, the minus side may be restricted. The minus side of the thickness tolerance is frequently restricted to ~ 0.25mm in confor- mity with the steel plate standards used for boilers and pressure vessels, JIS 63103, and JIS G3115. Article 10. Material of Attachment Installations Steel material shall be used for attachment installations which are not directly welded to the pressure lining part and which are closely related to the pressure lining part. Description : Attachment installations which are closely related to the pressure lin- ing part are expansion joints, manholes, air pipes, air valves, supporting structures, etc., and since these are directly concerned with the safety of -2-the pressure lining part, steel material (steel casting inclusive), not iron casting, are required to be used for the portions subjected to loads even if these portions are not directly welded to the pressure lining part. Article 11. Material Test 1. Testing, inspection and marking of materials other than those in Table 1-8-1, Article 8. of this Chapter shall be in accordance with Gen- eral Rules for Inspection of Stee! (JIS G0303), unless otherwise speci- ied in each standard for respective material. 2. When attempting to use particularly thick plates or special materials, ‘weldability and other matters of the materials concerned shall be tested. Description: 1. When using materials other than those in Table 1.8-1, it is necessary to make sure that the materials conform to the JIS standard if they are based on JIS, if the materials are not based on JIS it is necessary to make sure of the acceptable results required by inspection and test- ing in accordance with “General Rules for Inspection of Steel.” 2. When attempting to use especially thick plates or special materials, some problems in terms of manufacture such as workability, weldability and others may arise, and thus it is specified that, in addition to the gen- cal tests included in “General Rules for Inspection of Steel,” prob- lematic points should be tested. For cach steel material, tests other than those specified in JIS are as follows: Parent material .... test, heat affecting test, heat treat- ment test, brittleness test Weld Zone hhardness test, crack test, joint strength test, brit- leness test Weld material ...., useability ‘There are anti-corrosive test, structure test and others provided for spe- cial materials. Testing example for steel penstocks is listed in Table 1.11-1. -2-‘Table 1.11-1 Example of Special Additional Test Tone ain co or ‘Une see plate thickness | HATO i= Ten | Workability —_ Heat affection | ee a iia |e ear Ee i a aa aca ed at bate Gay Sis | iperceea ite Tol Weld tes) Property | bending * Joint fatigue test Teas aon a ‘va Tonle iM i ae rae ad hand wig te ith = an it vestigation of stress relief annealing effect teat ea oa | Siru- = ‘Year of completion 1s ~ Reason for {7oman* class high | keh? clas high tensile steel with ex- Sinden [eadses oe™ | eee hace sacs | etl loco pewock 4s Remarks [Now | Dadaiionaly, ——|@ Cabon equivalent <0. pont ene [© fant tineh Beaten? ceeraceect | yeaa’ Sacer dalle tre| aes sae | fetal” once 358 Tee sea A Pgynn! im! ee Sheen A legh 2 980cN= thy aba dees Fon "Ol om*‘Table 11-1 Example of Special Additional Test (cont'd) Power ain ia pe ike TT] Put a ni i Rak ene seo Sota er te Sere sae i coos ve | ae age | ee tees eae a -‘Table 111-1 Example of Special Additional Test (cont'd) Tose Osa = ad aa ia ay — i a ae FH, = Se fo quivalent to HTS0 section 260 x 325, 270% 450 @) pr bee ea Ty | a asp es a a ee [Ree inde Ga rene, [R |Seeea et esau cia (maa, [Spenser abe Ske ty ir fimo chal) Bere | Rt | [ites [Na dep wep et a jaws Crack oor casing et (ey a. wetness ‘or all combinations iegactd Owe Se rE oy mu. i or Ky air tp Lee ee eet ae lve cre 2 ws EE a my e+ 39 Yh a ae: a egies Se 1 el me Tar at en wee at ae 9 OTS eae |e mane cae Sp Sal nu Eten eer a Peeteemrcr teers no eeree Seca a Bie et SS Offset joint fatigue test (for ns ‘steel pl., MIG automatic butt essa oo = tig MG ling oie a ah en it ig Seater i wl seed emanating Sins _ ee - j a stp iw. iin ae (275 set pl & sted forging) (or invegaon of low tempera ck een —— = a in aw i ae eo Rie (Sone fee a seman ee 5 rant eae Ser | Tee aig Pe Pear, 25S, ‘VTi weld zone) c Ee ESS 6