Steel penstocks

455 Pages·1993·138.605 MB·English

by  ASCE Task Committee Manual of Practice for Steel Penstocks

ASCE Manuals and Reports on Engineering Practice No. 79
e
ASCE Manuals and Reports on Engineering Practice No. 79
Steel Penstocks
Prepared by the
ASCE Task Committee on
Manual of Practice for
Steel Penstocks
nergy Division
American Society of Civil Engineers
Richard D. Stut man, Chairman
Publi h d by ·
merican Society of Civil Engineers
345 Ea t 47th Str et
New York, New York ·10 ·17-2398
ABSTRACT
Steel Penstocks, ASCE Manuals and Reports on Engineering Practice No. 79 cove s
the design, man facture, installatjon, testi g, startup, and maintenance of steal !)en
stocks, including branches. wye , associated app rtenances, and tunnel liners. he
manual was prepared by a special ASCE Tas Committee under the supervision of
the Hydropower Co m1ttee of the ASCE Energy Division. The Task Committee·
goal was to review all available penstock literature in order to bring the information
toge her Into one document. Since S eel Psnstocks is intended for the engineer or
designer who has very little expenence wi h pens ocks or pressure vessels, the man
ual provides a commentary on background as well as spec· ic design, manufacture,
ins allation, esti g, startup, and mainte ance requirements.
Library of Congress Cataloging-i -Publication Data
Steel penstocks I prepared by he ASCE Task Committee on Ma uaJ of Practice for
Steel Pen stocks, Energy Divis'on, American Society of Civil Engineers.
p.cm. - (ASCE manuals and reports on engineering prac ice; o. 79)
lr eludes index.
ISBN 0-87262-951-1
1. Penstocks. 2. Steel, structural. I. ASCE Task Committee Manual of
Practice for Steel Pen tocks. 11. Series.
TJ849.S74 1993
621.31'2134-dc20 93-13346
GIP
The material p esented in this publication has been prepared in accordance
with ge erally recognized enginee ·ng principals and practices, and is for general
information only. This information should not be use<! wi hout first securing compe
ten advice with respect o its surtabir y for any general or specific application.
The contents of this publication are ot intended to be a d should not be con
trued to be a standard of the American Society of Civil Engineers (ASCE) and are
ot intended 1or use a a reference in purchase specifications, contrac s, regulations,
statutes, or any other legal document
No reference made in publication to any specific method. product. process. or
service constitu es or implies an endorsement, reco menda! ion, or warranty thereof
byASCE
ASCE makes no represe tation or warranty of any ki d, whether ex.press or
implied, concerning the accuracy. comple eness, sui ability or utili y of any mforma
tio , apparatus, product or prooess discussed in this p blication, and assumes no lta
bflity tnerefor.
Anyone u ilizing this informatio assumes all liability arising from such use. includ
ing bu not limited to 1nf ingement of any paten or patents.
Authorization to photocopy material for in er al or personal use under circumstances
not falling within the fair use provisions of the Copyright Act is granted by ASCE to
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Transactional Reporting Serv~ce, provided that the base fee of $1.00 per a ·c1e plus
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identification for ASCE Books is 0-87262/93.$1 +.15. Requests for special permission
or bulk copying should be addressed to Reprintlng/Permissions Department.
Copyrlght © 1993 by the American Society of Civil Enginee s,
All Rights Reserved.
Library o Congress Catalog Card No: 93-13346
ISBN 0-87262-951-1
Manufactured in the U ited States of America.
MANUALS AND REPORTS ON ENGINEERING PRACTICE
(As developed by the ASCE Technical Procedures Committee, July 1930,
and revised March 1935, February 1962, April 1982)
A manual or report in this series consists of an orderly presentation of
facts on a particular subject, supplemented by an analysis of limitations and
appli cations of these facts. lt contains information seful to the average engi
neer in his everyday work, rather than the findings that may be useful only
occasionally or rarely. lt is not in any sense a "standard" however; nor is it so
elementary or so conclusive as to provide a "rule of thumb" for nonengineers.
Furthermore, material in this series, in distinction from a paper (which
expresses only one person's observa1ions or opinions), Is the work of a com
mittee or group selected to assemble and express information on a specific
topic. As often as practicable the committee is under the direction of one or
more of the Technical Divisions and Councils, and the product evolved has
been subjected to review by the Executive Committee of that Division or
CounciL As a step in the process of this review, proposed manuscripts are
often brought before the members of the Technical Divisions and Councils for
comment, which may serve as the basis for improvement. When published,
each work shows the names of the committees by which it was compiled and
indicates clearly the several processes through which it has passed in review,
in order that its merit may be definitely understood.
In February 1962 (and revised in April, 1982) the Board of Direction voted
to establish:
A series entitled 'Manuals and Reports on Engineering Practice,' to
include the Manuals published and authorized to date, future Manuals of
Professional Practice, and Reports on Engineering Practice. All such
Manual or Report material of the Society would have been refereed in a
manner approved by the Board Committee on Publications and would be
bound, with applicable discussion, in books similar to past Manuals.
Numbering would be consecutive and would be a continuation of present
Manual numbers. In some cases of reports of joint committees, bypass
ing of Journal publications may be authorized.
AVAILABLE* MANUALS AND REPORTS OF E GINEERING PRACTICE
Number
10 Technical Procedures for City Surveys
13 Filtertng Materials for Sewage Treatment Plants 14 Accommodation of Uti-lity Plant
Within the Rights-of-Way of Urban Streets and Highways
3i Des'ign of Cylindrtcal Concrete Shell Roofs
33 Cost Control and Accounting for Civil Engineers
34 Definitions of Surveying and Associated Terms
35 A List of Translations of Foreign Literature on Hydraulic
36 Wastewater Treatment P1ant Design
37 Design and Construction of Sanitary and Storm Sewers
40 Ground Water Management
41 Plastic Design in Steel-A Guide and Commentary
42 Design of Structures to Resist Nuclear Weapons Effects
45 Consulting Engineering-A Guide for the Engagement of Engineering Services
46 Report on PipeU ne location
47 Selected Abstracts on Structural Applications of Plastics
49 Urban Planning Gurde
50 Report on Small Craft Harbors
51 Survey of Current Structural Research
52 Guide for the Design of Stee:l Transmission ewers
53 Cf\terta 1or Ma\ntenance ot Mufti1ane H\ghways
54 Sedimentation Engineering
55 Guide to Employment Conditions for Civil Engineers
57 Management, Operation and Maintenance of irrigation and Drainage Systems
58 Structural Analysis and Design of Nuclear Plant Facilities
59 Computer Pricing Practices
60 Gravity Sanitary Sewer Design and Construction
62 Existing Sewer Evaluation and Rehabilitation
63 Structural Plastics Design Manual
64 Manual on Engineering Surveying
65 Construction Cost Control
66 Structural Plastics Selection Manual
67 Wind Tunnel Model Studies of Buildings and Structures
68 Aeration-A Wastewater Treatment Process
69 Sulfide in Wastewater Collection and Treatment Systems
70 Evapotranspiration and Irrigation Water Bequirements
71 Agricultural Salinity Assessment and Management
72 Design of Steel Transmiss+on Structures
73 Quality in the Constructed Project-a Guide for Owners, Oesigners,and Constructors
74 Guidelines for Electrical Transmission Line Structural Loading
75 Right-of-Way Surveying
76 Design o1 Municipal Wastewater Treatment Plants
77 Design and Constructio of Urban Stormwater Management Systems
78 Structural Fire Protection
79 Steel Penstocks
"'Numbers 1, 2, 3, 4, 5, Gi , 8, 9, 11, 12, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25,
26, 27, 28, 29, 30, 32, 38. 39, 43, 44, 48, 56, and 61 are out of print.
PREFACE
This Manual of Practice for Steel Penstocks covers the design, manufacture, installation, testing,
startup, .and maintenance of steel penstocks, including branches, wyes, associated
appurtenances, and tunnel liners. Standards presented in this manual are applicable only to
steel pen stocks. As used in the manual, a penstock is defined as a pressurized, closed water
conduit located between the first free water surface and a hydroelectric power/pumping station.
Pressurized conduit refers to pipe in which shell thickness is determined by external pressures
rather than by other criteria. Standards presented in this man uaJ are applicable only to
steel penstocks.
The manual was prepared by a special ASCE Task Committee under the supervision of the
Hydropower Committee of the ASCE Energy Division. The Hydropower Committee was formed
to ~~develop and disseminate information on all phases of hydroelectric power to the hydro
engineering community."
In 1985, the Hydropower Committee began work on the Civil Engineering Guidelines for
Planning and Designing Hydroelectric Developments, commonly referred to as the Guides.
Upon the work's completion, the committee decided to expand the section on penstocks into a
nationally accepted standard or code.
The penstock design documents most commonly used by the penstock industry are the ASME
Boiler and Pressure Vessel Code and the Steel Plate Fabricator)s Manual.
The ASME Boiler and Pressure Vessel Code (ASME Code) has been in existence since 1914
and originally was based on an allowable stress of one-fifth the tensile strength of the steel. An
ASME Code section specifically for pressure vessels came out in the mid-1920s. In the 19 50s,
the stress basis was changed to one-fourth of the tensile strength of the steel. he high-stress
alternative rules, based on one-third of the tensile strength of the steel, came out in the 1960s,
although the ttl eory and stress basis had been in use for some time before that. Fabrication
based on these rules has resulted in high-quality structures. The rules for both divisions of
Section VIII of the ASME Code are accepted worldwide and have been applied to many types of
structures other than pressures vessels, including pen stocks. The a.ltemative rules of Section
VIII, Division 1 and 2 have been used extensively in preparing this manual.
The development of the Steel Plate Fabricators Manual was based primarily on the 40-plus
years of laboratory research and practical hydroelectric experience of the United States Bureau
of Reclamation. The manual provides more specific pen stock design infonnation than the ASME
Code but refers to the latter for fabrication and welding.
Although used eX1ensively, neither of these two documents has been accepted as a
comprehensive penstock code. Therefore, the goal of this committee was to review all the
currently available penstock literature and bring the information together into one document as a
standard for the design, manufacture, installation, testing, startup, and maintenance of
steel penstocks.
V
Preface
This manual is intended for the engineer or designer who has very littte experience with
penstocks or pressure vessels. Therefore, the manual is presented in a format that provides a
commentary on background as well as specific design, manufacture, installation, testing, startup,
and maintenance requirements. However, the engineer or designer should be aware that there
may be specific areas in this manual that require a higher level of experience or expertise.
The design procedures presented in this document are recommended by this committee.
However, the committee recognizes that there are other methods and procedures that may be
equalfy as valid. This document does not prectude their use, provided the engineer and
designer are satisfied with their validity and applicability.
ACKNOWLEDGMENTS
I wish to thank the Task Committee members who dedicated many hours of their personal1ime
1o this undertaking. Also, I and the other committee members wish to thank 1he organizations,
both public and private, that supported the participation of the committee members, allowing
them to attend meetings and providing the office assistance required for the chairman and
eo-chairman to administer related committee activities.
Don Matchetl and Arvids Zagars provided substantial contributions and support for the project.
Special thanks goes to Tom Logan, who acted as a mentor and advisor, based on his
spearheading the preparation of the Guides.
Finally, specia1 gratitude is due to Tom Ahl. His dedicated support as eo-chairman provided
valuable assistance and perspective during the preparation of this manual.
Richard D. Stutsman, P.E.
Chairman, Manual of Practice for Steel Penstocks
ASCE Task Committee
vi
Preface
MANUAL OF PRACTICE COMMITTEE MEMBERS
Richard Stutsman, Chairman, Pacific Gas and Electric Company, San Francisco, CA
Thomas Ahl, Co-Chairman, Chicago Bridge and Iron, Oak Brook, IL
Chuck Feild, Black & Veatch Engineering-Arch., Overland Park, KS
John Bambei, Board of Water Commissioners, Denver, CO
Don Beard, United States Bureau of Reclamation, Denver Federal Center, Denver, CO
Clay Brogdon, Georgia Power Company, Atlanta, GA
Jim Burton, Baker Coupling Co. Inc., Los Angeles, CA
Frank Cortellessa, Ameron Steel Fabrication Division, Fontana, CA
Theodore Critikos, Stone & Webster Engr. Corp., Denver, CO
Jerry Dodd, Consulting. Engineer and Geologist, Greenwood Vlg., CO
Sterling Dun bar, Thompson Pipe & Steel Co., Denver, CO
Paul Flanagan, State of California, Santa Nella, CA
Bob Mikitka, Robert L. Cloud Associates, Berkeley, CA
Ed Moore, Harza Engineering Company, Chicago, IL
Lee Nash, Tennessee Valley Authority, Chattanooga, TN
Graeme Plant, Graeme D. Plant, PE, Napa, CA
Dan Rogers, Duke Power Company, Char1otte, NC
Malcolm Stephens, Civil Engineer, Carmictlael, CA
Ray Sullivan, EBASCO Services Jnc., New York, NY
Chlis Sundberg, CH2M Hill, Bellevue, WA
Ray Toney, Ray Toney Associates, Redding, CA
George Tupac, G.J. Tupac& Associates, Inc., Pittsburgh, PA
Donald Wagner, Progressive Fabricators, St. Louis, MO
ORGANIZATIONS THAT PROVIDED CONTINUOUS SUPPORT
Pacific Gas and Electric Company (support for all administrative activities of the
Committee Chairman), San Francisco, CA
Chicago Bridge and Iron, Oak Brook, IL
Black & Veatch Engineering-Arch., Overland Parks, KS
Board of Water Commissioners, Denver, CO
United States Bureau of Reclamation, Denver, CO
Georgia Power Company, Atlanta, GA
Baker Coupling Co. I ne., Los Angeles, CA
Ameron Steel Fabrication Division, Fontana, CA
Stone & Webster Engr. Corp., Denver, CO
Jerry Dodd, Consulting Engineer and Geologist, Greenwood Vlg., CO
Thompson Pipe & Steel Company, Denver, CO
State of California
HDR Engineering, Inc., Denver, CO
Robert L. Cloud Associates, Berkefey, CA
Harza Engineering Co., Chicago, t L
Tennessee Valley Authority, Chattanooga, TN
Graeme Plant, Graeme D. Plant, PE, Napa, CA
Duke Power Company, Civil Engineering Dept., Charlotte, NC
vll
Preface
Matcolm Stephens, PE, Carmichael, CA
EBASCO Services Inc., New York, NY
CH2M Hill, Bellevue, WA
Ray Toney Associates, Redding, CA
George Tupac, G.J. Tupac & Associates, Inc., Pittsburgh, PA
Progressive Fabricators, St. Louis, MO
MANUAL OF PRACTICE BLUE RIBBON COMMITTEE
William Allerton, FERC, Washington, D. C.
Jeff Auser, Niagara Mohawk Power Corp., Syracuse, NY
Ned Bacon, Chicago Bridge and Iron, Qak Broo~ IL
Norman Bishop, Stone & Webster Engineering Corporation, Denver, CO
George Bunk, Stetson-Harza, Utica, NY
Craig Chaney, Pacific Gas and Electric Company, San Francisco, CA
Fred Copeland, Structural Integrity Associates, Inc., San Jose, CA
Jerry Duppong, CH M Hill, Bellevue, WA
2
Fred Fahlbusch, Morrision-Knudsen Engineers, Inc., San Francisco, CA
Thomas Haag, Black & Veatch Engineers-Arch., Overland Park, KS
Bruce Harris, U.S. Army Corps of Engineer Omaha, Omaha, NE
Robert Jacks, Tennessee Valley Authority, Chattanooga7 TN
Thomas Kahl, Kleinschmidt Assocjates, Pittsfield, ME
Lucien Mroczkiewicz, Corps of Engineers, Portland, OR
Tibon Pataky, B.C. Hydro, Vancouver, B. C., Canada
Lawrence Rassumssen, Consulting Engineers, San Francisco, CA
Ram Satyarthi, Baker Coupling Company Inc., Los Angeles, CA
Jimmy Throckmorton, Southern California Edison, Rosemead, CA
AJexic Vircol, ATC Engineering Consultants Inc., Englewood, CO
Arvids Zagars, Harza Engineering Company, Chicago, IL
ORGANIZATIONS THA PROVIDED FINANCIAL SUPPORT
The Committee would like to extend its appreciation to the following organizations for their
gracious financial donations.
Alabama Power Company, Birmingham, AL
Alaska Power Administration, Juneau, AK
American Society of Civil Engineers, New York, NY
Baker Coupling Company, Inc., Los Angeles, CA
BC Hydro, Vancouver BC, Canada
Bechtel Corporation, San Francisco, CA
Central Maine Power Company, ME
CH2M Hill, Bellevue, WA
Chicago Bridge and Iron, Oak Brook, I
Consumers Power, Jackson, Ml
Duke Power, Charlotte, NC
Earth Sciences Associates, Pato Afto, CA
viii
Preface
Ensign & Bucktey, North Highlands, CA
Failure Analysis Associates, Menlo Park, CA
Georgia Power Company, Atlanta, GA
Harza Engineering Company, Chicago, I L
HDR Engineering, Denver, CO
H. L. Tu mer Group, Inc.
Los Angeles Department of Water and Power, Los Angeles, CA
Nevada Irrigation District, Grass Valtey, CA
New York Power Authority, New York, NY
Niagara Mohawk Power Corp., Syracuse, NY
Northrop, Devine & arbell, Inc.
Northwest Pipe and Casing, Portland, OR
Pacificorp , Portfand, OR
Pacific Gas and Electric Company, San Francisco, CA
Pennsylvania Electric Co., Johnstown, PA
Portland General Electric, Portland, OR
Ray Toney Associates, Redding, CA
Sakai Iron Works Co., Ltd., Osaka 590, Japan
Southern California Edison, Rosemead, CA
State of California
Steel Plate Fabricators Association, Inc.
Structural Integrity, San Jose, CA
Tennessee Valley Authority, Chattanooga, TN
Thompson Pipe & Steel Co., Denver, CO
Tudor Engineering Company, Oakland, CA
United States Bureau of Reclamation
Washington Water Power Co., Spokane, WA
Wisconsin Electric Power Co., Milwaukee, Wl
Woodward Clyde Consultants, Oakland, CA
Yuba County Water Agency, Marysville, CA
ASCE ENERGY DIVISION EXECUTIVE COMMITTEE CONTACT MEMBERS
Arvids Zagars, P.E., Harza Engineering Company, Chicago, IL
Don Matchett, P.E., Stone & Webster Engineering Corp., Denver, CO
ASCE HYDROPOWER COMMITTEE CONTROL GROUP MEMBERS, 1988-1991
Edgar Moore, P.E., Chairman, ASCE Hydropower Development Committee,
Harza Engineering Company, Chicago, IL
Thomas Gebhard, Gebhard Engineers, Austin, TX
Toney Ferreira, Northeast Utilities, Holyoke, MA
Thomas Logan, P.E., Consultant, Denver, CO
lx