Job No. Sheet No. 1 Rev.

Project Tittle:
Member/Location:
PERUNDING ZAR S/B Drg. Ref.
Job Title : Made by : Date : Remark
Design Parameter :-
DESIGN DISCHARGE, Qd =
GROSS HEAD, hg =
GRAVITY, g =
WATER DENSITY, = kg/m
PIPELINE LENGTH, Lp =
PIPELINE INTERNAL DIAMETER, D =
PIPE FLOW AREA, Af =
FLOW VELOCITY, Va =
PARAMETER ko ( Coal-tar coated), k0 =
Calculating the losses from the water intake and along the pipe/penstock length.
FRICTION COEFFICIENT,
= x ^
= x ^ =
m
m/s
0.010 k0 0.314
1.800
7257.000
9.810
m/s
m
m
m
m/s
1.500
2.593
2.545
6.600
237.000
D
0.010 1.500 0.314 0.009
1000
Penstock Design
THE DEVELOPMENT OF 10 MW SMALL HYDRO POWER PLANT
UNDER SREP PROGRAMME AT SUNGAI BROOKE, GUA
MUSANG, KELANTAN.
Bob
= x ^ =
Losses In Penstock Line
Head Loss @ Trash Rack,htr
Assume Approach Velocity, V =
Thickness of bar, s =
Spacing of bars, b =
Angle of inclination from horizontal, =
Oblique flow angle, =
Coefficient (Table I/23) =
Factor Bar Section, =
Trash Rack Losses, htr
= s ^ V sin
b 2g
= ^ sin = m
0.010 1.500 0.314 0.009
3.600
2.420
1.800
3.000
8.000
50.000
m/s
(4/3)
180
deg
deg
mm
mm
60.000
30.000
2.420 8.00
50.00
3.000
2(9.81)
0.084 60
180
(4/3)
Job No. Sheet No. 2 Rev.
Project Tittle:
Member/Location:
PERUNDING ZAR S/B Drg. Ref.
Job Title : Made by : Date : Remark
Head Loss @ Fine Screen, hf
Sreen Size 6 x 50 @25 mm c/c
Water Flow, Q =
Thickness of bar, s =
Spacing of bars, b =
Width of Opening =
No. of Bar =
Length of Opening =
Height of Opening =
Effective Length =
Velocity, V =
Angle of inclination from horizontal, =
Oblique flow angle, =
Coefficient (Table I/23) =
Factor Bar Section, =
Fine Screen Losses, hf
Bob
6.000
6.600
2.420
1.000
0.000
90.000
no.
Penstock Design
19.000
THE DEVELOPMENT OF 10 MW SMALL HYDRO POWER PLANT
UNDER SREP PROGRAMME AT SUNGAI BROOKE, GUA
MUSANG, KELANTAN.
deg
0.101
13.038
5.000
7.519
m
m
m
mm
mm
m/s
396
7.500
deg
m/s
m
= s ^ V sin
b 2g
= ^ sin = m
Head Loss @ Bifurcation,hbf
Discharge Ratio =
Qm/Qb Ratio =
Acute 30 deg. Angle
Loss Coefficient, m (Table I/93)
=
Loss Coefficient, b (Table I/93) =
Bifurcation Losses, hbf
= Va + Va
2g 2g
= + = m
2 x 2 x
Head Loss @ Reducer, hr
Losses Coefficient, =
= Va = = m
(4/3)
0.000 2.593
0.000
180
2.420 6.00 (4/3) 0.101 90
2(9.81) 180 19.00
0.44
0
1
0.5
m b
0.151
0.050
0.440 2.593
9.810 9.810
0.017 2.593 0.050
2g 2 x 9.810
Job No. Sheet No. 3 Rev.
Project Tittle:
Member/Location:
PERUNDING ZAR S/B Drg. Ref.
Job Title : Made by : Date : Remark
Head Loss @ Valve
No. of Air valve =
No. of Scour valve =
Losses Coefficient, Kv (Butterfly) =
Total Losses Coefficient =
= Va = = m
2g 2 x
Head Loss @ Entrance
Losses Coefficient, =
= Va = = m
2g 2 x
Head Loss Along Penstock Line
0.500 2.593
9.810
Penstock Design
0.600
7.200 2.593 2.468
0.171
Bob
THE DEVELOPMENT OF 10 MW SMALL HYDRO POWER PLANT
UNDER SREP PROGRAMME AT SUNGAI BROOKE, GUA
MUSANG, KELANTAN.
6.000
6.000
9.810
0.500
7.200
= Lp x Va
D 2g
= x = m
2 x
Head Loss In Bend (Horizontal and Vertical)
Total Losses Coefficient, b
=
= Va = = m
2g 2 x
Total Head Loss
a) TRASH RACK m
b) FINE SCREEN m
c) ENTRANCE LOSS TO PENSTOCK m
d) PENSTOCK FRICTION HEAD LOSSES m
e) BEND LOSSES IN PENSTOCK (HORIZONTAL & VERTICAL) m
f) HEAD LOSS TO BIFURCATION m
g) HEAD LOSS AT REDUCER m
h) HEAD LOSS AT VALVES m
TOTAL HEAD LOSS (a+b+c+d+e+f+g+h) m
NET HEAD = GROSS HEAD - TOTAL HEAD LOSS
=
=
0.171
0.000
0.084
=
=
=
=
=
=
=
17.546
2.468
0.017
0.151
1.604
13.051
1.800
b
4.680 2.593 1.604
9.810
9.810
13.051

0.009 2.593 7257

4.680
NET HEAD = GROSS HEAD - TOTAL HEAD LOSS
= - = m 237.000 17.546 219.454
Job No. Sheet No. 4 Rev.
Project Tittle:
Member/Location:
PERUNDING ZAR S/B Drg. Ref.
Job Title : Made by : Date : Remark
Preliminary Thickness
Assuming the percentage (%) of increase in net head due surge pressure = %
Surge pressure = x = m
Total pressure head = Static pressure head + Surge pressure
= + = m
Nominal thickness ( CP 2010 : Part 2 : 1970 : 2.2.2.2)
t = + corrosion allowance
where ; a = design factor ( CP 2010 : Part 2 : 1970 : 2.2.2.3)
D = outside diameter, in (mm)
E = joint factor given in ( CP 2010 : Part 2 : 1970 : Table 5)
fy = specified minimum yield stress, in (MN/m)
p = internal design pressure, in (MN/m)
Bob
21.945 258.945
p D
Penstock Design
THE DEVELOPMENT OF 10 MW SMALL HYDRO POWER PLANT
UNDER SREP PROGRAMME AT SUNGAI BROOKE, GUA
MUSANG, KELANTAN.
2 a fy e
237.00
10
219.454 0.100 21.945
t = design thickness, in (mm)
Internal design pressure, P = g H
= x x
= MN/m
t = x + = mm
2 x x x 1
take penstock wall thickness as mm thick.
Checking Surge Pressure Created Using 20mm Thickness
Calculating the thickness for the most critical section of length in the penstock
The pressure wave speed c (m/s) depends on the elasticity of the water and pipe material
according to the formula:
where
k = bulk modulus of water 2.1x10^9 N/m2
E = modulus of elasticity of pipe material 210x10^9 N/m2
t = wall thickness (mm)
20.0
0.6 275
2.54 1800
258.945
2.54
1000.000 9.810
14.856 1.00
t = wall thickness (mm)
Job No. Sheet No. 5 Rev.
Project Tittle:
Member/Location:
PERUNDING ZAR S/B Drg. Ref.
Job Title : Made by : Date : Remark
The time taken for the pressure wave to reach the valve on its return, after sudden closure
is known as the critical time:
T= 2L/c
Summarising the data,
Gross Head: m
Rated Discharge: m
Internal Pipe Diameter: m
Total Pipe Length: m
Closure Time: s
Estimating in a first approach at 20 mm wall thickness to compute the wave speed c :
c = /
1 + x
x
= m/s
Penstock Design Bob
1.800
7257.000
20
THE DEVELOPMENT OF 10 MW SMALL HYDRO POWER PLANT
UNDER SREP PROGRAMME AT SUNGAI BROOKE, GUA
MUSANG, KELANTAN.
237.000
6.600
90
1051.315
2.1E+09 1000
2.1E+09 1800
2.1E+11
Critical time, T = 2L/c
= 2 x = s
10T = 10 x
= s
The closure time (90s) is bigger than the critical time s but smaller than 10 times its
value s, the Allievi formula can be applied.
Allievi formula may compute the maximum overpressure:
where P0 is the hydrostatic pressure due to the head and:
where:
V0 = water velocity in m/s
L = total penstock length (m)
P0 = gross hydrostatic pressure (m)
t = closing time (s)
The total pressure experienced by the penstock is P = P0 + P
The water velocity in the pipe is:
V = 4 x 6.6 = m/s 2.593
7257.000
1051.31
13.806
13.806
138.056
13.81
138.1
V = 4 x 6.6 = m/s
x 1.8
2.593
Job No. Sheet No. 6 Rev.
Project Tittle:
Member/Location:
PERUNDING ZAR S/B Drg. Ref.
Job Title : Made by : Date : Remark
N would be computed from a net head in the pipe of = m
N = x =
x x
and therefore;
p = +
= m; m
Total pressure head = m
Check back the wall thickness of penstock by using new head pressure, h = m
Internal design pressure, P = g H
Penstock Design
THE DEVELOPMENT OF 10 MW SMALL HYDRO POWER PLANT
UNDER SREP PROGRAMME AT SUNGAI BROOKE, GUA
MUSANG, KELANTAN.
0.009
Bob
9.810 219.454 90
2.593 7257
219.454
0.009
22.376 -20.306
219.454 0.009
2
0.009
4
259.376
259.376
= x x
= MN/m
t = x + = mm
2 x x x 1
the penstock wall thickness of mm thick is sufficient for this design.
Checking Max. Head Pressure For Difference Penstock Wall Thickness
Using earlier formulation to find nominal thickness
t = + 1mm (corrosion allowance) -------------- 1
t = + 1 -------------- 2
H = -------------- 3
Using 8mm penstock wall thickness + 1mm corrosion allowance
H = 2 x ( 8 - 1 ) x x E+ 6 x 1
x x 1816
0.75 275
2 (t -1)a fy e
g D
1000
p D
2 a fy e
g H D
2 a fy e
2.54
2.54 1840 1.00
1000.000 9.810 259.376
12.350
0.75 275
20.0
9.810 x x
= m
1816
162.083
1000 9.810
Job No. Sheet No. 7 Rev.
Project Tittle:
Member/Location:
PERUNDING ZAR S/B Drg. Ref.
Job Title : Made by : Date : Remark
Table below shows the max head pressure for every thickness given.
16.208
18.503
20.793
23.078
25.358
27.633
29.904
32.169
34.429
36.684
38.934
41.180
43.420
17 366.839
20 434.201
18 389.342
19 411.796
14 299.035
15 321.686
16 344.287
10
11 230.784
12 253.585
13 276.335
THE DEVELOPMENT OF 10 MW SMALL HYDRO POWER PLANT
UNDER SREP PROGRAMME AT SUNGAI BROOKE, GUA
MUSANG, KELANTAN.
Penstock Wall Thickness (mm) + 1mm corrosion allowance Max. Head Pressure (m)
162.083 8
185.034
Penstock Design Bob
9
207.934
16.208
23.078
29.904
36.684
38.934
43.420
Penstock Wall Thickness (mm) + 1mm corrosion allowance Max. Head Pressure (m)
8 162.083
11 230.784
20 434.201
14 299.035
17 366.839
18 389.342