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POWER CONSTRUCTION ABROAD

DESIGN AND CALCULATION THE HYDROELECTRIC OF THE STEEL PENSTOCKS AND FORKS OF DAM

STATION AT THE SHAHID

ABBASPOUR

V. A. G e r m a n , N. A. Komleva, and E. N. Rytchenko

Jointly with the firms Moshanir (lran) and Lachmeer International (Germany), the Zaporozh'e Special Planning, Design. and Technological Office of Steel Hydraulic Structures and Mechanisms (SPKTB Zaporozhgidrostal') (Ukraine) is entering into a consortium in the roll of engineer-consultant-partner for the construction of the Shahid Abbaspour Dam in Iran. According to the contract with the corporation Sadid Industrial Group, firm Sadid Tadbir, and Ministry of Power of the Islamic Republic of Iran, specialists of SPKTB Zaporozhgidrostal' are to certify the design of the mechanical equipment, hoisting mechanisms, steel structures, and penstocks of the hydraulic structures of the Shahid Abbaspour Dam hydrodevelopment. The multipurpose hydrodevelopment is part of the cascade of hydrostations on the Karun River, is located about 100 km from Akhvaz city, and is intended to supply water and power in regions adjacent to the Persian Gulf in southern Iran as well as to regulate the runoff of the Karun River. The hydrodevelopment includes an arch dam, crest flood spillway, headrace and tailrace tunnels, as well as powerhouse complexes 1 and 2, one of which is hydrostation No. 2. Four units with Francis turbines with a total capacity P - 1000 MW are installed at elevation +355.0 m in the underground powerhouse of hydrostation No. 2. Water is delivered to the units from an intake (elevation +490.1 m) equipped with vertical-lift gates operated by hydraulic drives and farther along two vertical pressure shafts with diameter d = 10 m and height of about H = 100 m each, which at their base, at elevation +394.666 m, by means of two tapered convergent channels with diameters d = 10/7.8 m and length L = 5 m pass into sharply curved bends with diameter d = 7.8 m with a turn through angle 81.5 ~ with a radius R = 28 m each. At elevation +355.0 m each water conduit branches into two with diameter d = 7.8/9.4/2 x 5.1 m. Four conduits with diameter d = 5.1 m are laid from the forks with a slope of 8-15 ~ to the horizon. Immediately in front of each unit is installed an emergency-guard "Biplane" type butterfly valve with diameter d = 5 m operated by a hydraulic drive. Each valve is equipped with a bypass line and is connected to the corresponding penstock by means of a branch pipe. Starting from elevation +394.666 m the water-conveying channel is lined with sheet of steels StE420. StE500, DINI7102, German standard. The thickness of the steel lining of the penstocks varies from 26 to 44 mm, and on the forks 65 mm. The design hydrodynamic head with consideration of water hammer as a result of closing the gate apparatus on the axis of the turbine runner (elevation +355.00 m) is 2.3 MPa (23 kg/cm 2. 230 m H20). The maximum discharge per turbine is Q - 150 m3/sec. The normal flood level is at elevation +532 m. The load characteristic of the conduit (the product of the head and diameter) is H x D = 2100 m 2. in accordance with the terms of the contract, all calculations of the steel structures were made according to the C.E.C.T. of the European Committee on Boiler Construction and Steel Structures. In particular, the penstocks were designed in accordance with the "Recommendations on the design, manufacture, and assembly of welded steel pipelines for hydraulicengineering installations" prepared by the "Pipelines" section in August 1994. In engineering practice of domestic hydrotechnical construction, analogous steel shells of tunnels are designed in accordance with the recommendations and instructions given in [5]. and branches of penstocks, traditional, axisymmetric, and of a relatively simple geometric form. with exterior reinforcing collars are designed in accordance with the recommendations given in. [1].

Translated from Gidrotekhnicheskoe Stroitel'stvo. No. 3. pp. 50-52, March. 1998.

168

0018-8220/98/3203-0168520.00

~1998 Plenum Publishing Corporation

One of the most crucial, loaded, and complex structures of tile powerhouse complex is the collector-distributor to the units, consisting of two forks. The forks are a complex three-dimensional welded steel structure with two branches each and are located in the concrete mass at the exit portal in front of the powerhouse of hydrostation No. 2. All elements of the steel shell of the forks represent truncated conical surfaces rolled from rolled sheet products. In the initial design stages a concrete-encased steel variant of the branch was examined, in which a part of the load from the inside water pressure is transmitted to the outside hoop reinforcement and thereby the steel shell is partially unloaded, thanks to which it was possible to bring its thickness to 36-40 ram. However, this variant required an increase of the overall dimensions of the rock excavation for arranging reinforcement in it. As a result the customer accepted the variant of forks with a load-bearing steel shell calculated for the total head without consideration of the effect of the concrete surrounding them. In this case the maximum thickness of the steel shell, determined by calculation, was 65 mm. The material of the structures is high-strength, low-alloy C r - N i - M o structural steel for welded constructions of grade StES00, DIN17102, German standard, with tensile strength a t = 600 MPa, yield strength ay = 450 MPa, elongation 18%, with ultrasonic testing of the continuity of the rolled sheet product delivered as normalized with a fine-grained, fibrous structure with bend and impact strength samples. The chemical composition in % mass proportions of elements: carbon C __. 0.21; silicon Si ~ 0.6; manganese Mn _< 1.0; phosphorus P ~ 0.035; sulfur S _< 0.030; chromium Cr _< 0.30; copper Cu _< 0.70; molybdenum Mo _< 0.10; nickel Ni _ 1.00; niobium Nb _< 0.05; titanium Ti _< 0.20; vanadium V <: 0.22. All welded joints of the fork are made by manual electric-arc welding with bilateral grooving, belong to category I, and are subjected to quality control by physical methods - ultrasonic flaw detection in a volume of 100% of the length of the welds with consequent illumination by penetrating radiations of parts of welds with signs of flaws as well as zones of intersection of joints. The forks are to be manufactured by a special technology reducing residual welding stresses and strengthening then during transport, assembly, and concreting. A check assembly of all elements with marking the parts and field joints is also provided for at the manufacturer. As for corrosion protection of the bulky steel structures, only priming of the cleaned inside surface of the penstocks is done at the manufacturer. Final painting is done during assembly. The outside surface contacting the concrete is cleaned of corrosion and contaminants immediately before concreting. A characteristic of the geometric scheme of the fork is the three-dimensionality of the structure, which makes it possible to create linear generatrices of the shells of revolution in plan and in profile and simultaneously to realize a favorable hydraulic regime of the flow in the water-conveying channel in a turbine mode of its operation. To reduce hydraulic losses of the head, to lessen local resistances, and to increase the capacity of the fork at its start, the branch has a tapered divergent channel expanding from diameter d -- 7.8 m to d = 9.4, m, the axis of which is deflected in the direction of the outlet. Directly adjacent to the divergent channel is a branch representing a double asymmetric fork constructed according to Monge's theorem on a common sphere with diameter d = 9.4 m and strengthened by a central crescent-shaped flat steel diaphragm 100-mm thick entering 1.5 m into the branch. Thanks to such a geometric-construction, all lines of intersection of the shells of revolution are plane curves of the second order (ellipses). This considerably simplifies the design, manufacture, and calculation of the elements strengthening the shell and also improves the hydraulic characteristics of the fork and reduces its dimensions in the axial direction along the flow. Such three-dimensional branching is a modernized design of the Ascher Weiss firm and can be recommended for hydraulic structures under confined conditions. Designing was carried out by means of the graphics module "Auto-CAD-13 for Windows NT" with the use of the "Windows-interface" operational system. The geometric constructions were made with the use of the three-dimensional region of solid continuous bodies with output of all graphic information to a "Plotter." The steel structure of the fork was calculated for strength in the engineering analysis system by the finite-element (FE) method. It sufficiently completely takes into account the complex geometric form, real working conditions of the structure, distribution of external loads and stresses in space, boundary conditions, temperature factors, as well as the physical and mechanical properties of the materials of the structure used. The geometric model of the fork was partitioned into a mesh of finite elements. The sizes of the finite elements are substantially smaller compared with the sizes of the structure of the fork itself and have a finite value. The number of finite elements within the entire structure of the fork was 1880 and the number of mesh points was 1914. The case of normal operation was taken as the main calculated case of load combinations. In this case the internal hydraulic pressure of the water was composed of the combined action of the hydrostatic pressure and hydrodynamic pressure from water hammer occurring during closing of the gate apparatus of the turbine. According to the C.E.C.T. standards the safety factors are 1.5 for cylindrical stretches and 1.8 for shaped elements, including the collector. The steel structure of the fork was calculated according to a finite-element analysis program able to perform a static linear analysis of a three-dimensional elastic system and strength calculation and also to assess the stability 169

of the system with consideration of general and local loads. In a computer mode 10.944 equations were solved, in which case

the number of elements of the matrix was 3,433.968. The problem being solved required about 30 MB of external storage. The time of static linear analysis was 1103 sec, the time of the strength calculation was 40 sec. The stress-strain state of the steel structure of the form was evaluated on the basis of reduced equivalent stresses of the tour energy theory of strength, known also as the H u b e r a - H e n c k y - v o n Mises criterion. According to this theory the level of the specific potential energy of deformation is taken as the strength criterion. The "Plotstar" graphics module with representation of stresses in a interactive color graphics mode as well as with presentation of stresses, forces, and displacements (strains) at the mesh points (FE) and moving graphic image of deformations of the structure in an "Animate" mode on the screen was used for analyzing strength. All graphic constructions and strength calculations were carried out on IBM PC/AT personal computers equipped with a modern set of software.

CONCLUSIONS 1. It is necessary to calculate the strength of branches of penstocks by the finite-element method with the use of programs taking into account sufficiently completely the complex stress-strain state as well as the physical and mechanical properties of the material of the structure. 2. When designing branches with large parameters it is expedient to use high-strength, sufficiently ductile, readily weldable steels with ultrasonic testing of the continuity of the rolled sheets. 3. When calculating penstocks and branches concreted in mine workings it is necessary to examine their coaction with the surrounding concrete, and also it is recommended to take into account the unloading effect of the passive pressure of the surrounding rock mass. 4. The loaded forks should be manufactured according to a special production plan of assembly and welding operations with the use of a technology providing a sufficiently low level of residual welding stresses. 5. Check assembly and marking of the structural members during manufacture of bulky shaped elements of penstocks and forks as well as quality control of the welded joints during enlargement are necessary conditions of achieving a high quality of operating reliability which rule out losses of time when assembling the members.

REFERENCES
1.

2. 3. 4. 5.

V. F. Prostak, F. M. Svoiskii, and A. M. Shor, Shaped Elements of Hydrostation Penstocks [in Russian], l~nergoizdat, Moscow (1983). A. M. Shor, "Investigation of the stress-state of reinforced branches of steel penstocks," Candidate's Dissertation Abstract, Moscow (1980). V. F. Prostak, "Bearing capacity of joints of steel shells of pipelines of hydraulic structures," Candidate's Dissertation Abstract, Leningrad (1979). V. S. Postoev, "Calculation of the bearing capacity of cylindrical tee-connections with straight and oblique branches," Tr. TsKTI, No. 137 (1976). SNiP 2.06.09-84. Hydraulic Tunnels [in Russian], lzd. Standartov, Moscow (1985).

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