Sapsup Kalika Hydropower Pvt. Ltd.

Koteswor, Nepal

MIYA KHOLA SMALL HYDROPOWER PROJECT

TECHNICAL SPECIFICATIONS FOR SUPPLY OF HYDRO-MECHANICAL WORK

Abstract: Technical specification of hydro-mechanical components is prepared to assist the Contractor in understanding the basic requirements and procedures for furnishing and installing as well as quality aspects during fabrication of hydro-mechanical elements of the project such as steel pipes (headrace and penstock pipes), bends, bifurcation, man holes, gates, stoplogs, trashrack and other hydraulic steel structures required in Miya Khola Small Hydropower Project.

August 2013

Prepared by:

Samyak Engineering Pvt. Ltd.

Samyak
ENGINEERING

Maharajgunj, Kathmandu, Nepal P.o.Box: 13390, Tel: (977-1) 6227878 Email: samyakengineering@gmail.com

Sapsup Kalika Hydropower Pvt. Ltd. Miya Khola Small Hydropower Project Technical Specification for supply of Hydro-mechanical works

Samyak
ENGINEERING

Table of Contents
1. General ...................................................................................................................................... 2 2. Scope of supply ......................................................................................................................... 2 3. Material ...................................................................................................................................... 4 4. Design Criteria ........................................................................................................................... 5 5. Welded Joints ............................................................................................................................ 5 5.1 Types and Configurations .................................................................................................... 6 5.2 Butt Joints ............................................................................................................................. 6 5.3 Joint Qualifications................................................................................................................ 6 6. Tests 6 6.1 Scope of NDT ....................................................................................................................... 6 6.2 Hydrostatic Pressure Test ....................................................................................................7 6.3 Water Filling Test .................................................................................................................. 7 7. Painting ...................................................................................................................................... 7 8. Tolerances ................................................................................................................................. 7

Samyak Engineering Pvt. Ltd.

Sapsup Kalika Hydropower Pvt. Ltd. Miya Khola Small Hydropower Project Technical Specification for supply of Hydro-mechanical works

Samyak
ENGINEERING

1.

GENERAL

This document is prepared to assist the Contractor in understanding the basic requirements and procedures for furnishing and installing of hydro-mechanical elements of the project such as steel pressure pipe (headrace and penstock pipes), hydraulic gates and other steel structures required in Miya Khola Small Hydropower Project.

2.

SCOPE OF SUPPLY

The scope of supply will include the following: Design, manufacture, surface treatment, shop testing, transportation, erection, site testing and commissioning of: Approximate 928.40 m long headrace steel pressure pipe with internal diameter 650 mm with the shell thickness of 6 mm. Approximate 522 m long penstock steel pressure pipe with internal diameter 650 mm with thickness ranges from 6 mm to 14 mm. Approximate 20 m long penstock steel pressure pipe with internal diameter 450 mm of thickness 12 mm. Complete bifurcation/manifold arrangement. Approximately 20 number of headrace pipe bends of internal diameter 650 with the shell thickness of 6 mm. Approximately 7 number of penstock pipe bends of internal diameter 650 with the shell thickness varying from 6 mm to 14 mm. Approximately 2 number of penstock pipe bends of internal diameter 450 with the shell thickness of 12 mm. Two bell mouth for the pipe of internal diameter of 650 mm. Approximately 5 number of expansion joint with internal diameter of 650 mm with varying thickness from 6 mm to 14 mm. Approximately 2 number of manhole with lead and accessories (a complete arrangement) for a design head of 7 m which has to be placed in 650 mm internal diameter headrace pipe. Design, fabricate, supply and installation of all fine and coarse trashracks, hydromechanical gates and stoplogs along with accessories. All components, devices, items and equipment not mentioned above but necessary for the safe and proper manufacturing, transportation, erection, testing, commissioning, operation and maintenance of the supply.

Samyak Engineering Pvt. Ltd.

Sapsup Kalika Hydropower Pvt. Ltd. Miya Khola Small Hydropower Project Technical Specification for supply of Hydro-mechanical works

Samyak
ENGINEERING

Summary of items and quantity of various items are as follows: Table 1: Trashrack and gates/stoplogs items and quantity
S. No. Structures Particular Units Nos. Clear opening x H), m (B Design head, m Type of hoist

Trashrack Coarse trashrack of c/c clearing spacing 150mm along with supporting beams and their accessories Fine trashrack of c/c clearing spacing 50mm along with supporting beams and their accessories

Intake

Nos.

1.60 x 1.00

3.20

Forebay tank

Nos.

4.00 x 3.60

3.10

Gates/Stoplogs Vertical gates (fixed wheel type) with guide frames, hoist and accessories Vertical gates (fixed wheel type) with guide frames, hoist and accessories Vertical gates (fixed wheel type) with their guide frames, hoist and accessories Vertical gates (fixed wheel type) with their guide frames, hoist and accessories Vertical wheel type with guide frame hoists and accessories) Vertical wheel type with guide frame hoists and accessories) Vertical wheel type with guide frame hoists and accessories Vertical wheel type with guide frame hoists and accessories

Undersluice

Set

0.80 x 1.00

4.20

Intake chamber

Set

1.60 x 1.00

3.20

Gravel flushing

Set

0.6 x 0.60

4.65

Settling basin flushing

Set

0.60 x 0.50

2.55

Table 2: Steel lining items and quantity

S. No. Steel plate 1 2 Undersluice Intake chamber 12mm thick steel plate 12 mm thick steel plate ton ton 0.76 0.41 Structures Particular Units Qty.

Table 3: Headrace pipe and accessories along with quantity

S. No. 1 2 Structures Steel pipe Bell mouth Units ton Nos. Diameter (ID), mm 650 Length, m 928.40 Thickness, mm 6 Qty. 90.1 1.0

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Sapsup Kalika Hydropower Pvt. Ltd. Miya Khola Small Hydropower Project Technical Specification for supply of Hydro-mechanical works

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ENGINEERING

S. No. 3 4

Structures Bends Man hole of height 7 m with lead and accessories

Units Nos. Nos.

Diameter (ID), mm 650

Length, m

Thickness, mm 6

Qty. 20 2

Table 4: Headrace pipe and accessories along with quantity

S. No. 1 Structures Steel pipe Steel pipe Steel pipe Steel pipe Steel pipe Steel pipe 2 3 4 5 6 7 Saddle plates Bell mouth Bends Bends Wyee (650 mm dia. To 450 mm dia.) Expansion joint Units ton ton ton ton ton ton ton Nos. Nos. Nos. Nos. Nos. 650 650 450 Diameter mm 650 650 650 650 650 450 (ID), Length, m 107.2 73.3 166.2 119.3 56.0 30 Thickness, mm 6 8 10 12 14 12 6 Qty. 10.4 9.5 27.0 23.4 12.8 2.7 4.6 1.0 7 2 1 5

3.

MATERIAL

The steel used for fabrication of the trash racks shall comply with the specifications and requirements of Indian standard code IS 2062:1999 Grade B. The Contractor shall submit test certificates from steel manufacturers to the Engineer. However, Engineer has the right to take the sample piece of the material for testing of Mechanical and Chemical properties in witnessing the Employer. All expenses of such testing shall be in account of the Contractor. Steel quality for the penstock and penstock specials such as bends, bifurcation, wear plate, saddle plate, expansion joints & manhole etc shall be as follows: Plates and Profiles
IS 2062:1999 Grade B or equivalent national

/ international standard Surface preparation Paint Grit blasting Sa 2 1/2 1 coat zinc rich primer and 3 coat coal tar epoxy. Total DFT not less than 350 micron. (detail refer clause 10) 1 more coat of coal tar epoxy of 100 micron shall be painted for the exterior surface of buried penstock Welding Electrodes E7018 or Equivalent

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Sapsup Kalika Hydropower Pvt. Ltd. Miya Khola Small Hydropower Project Technical Specification for supply of Hydro-mechanical works

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ENGINEERING

4.

DESIGN CRITERIA

In designing the penstock pipe, all relevant factors that influence the calculation and design must be considered, e.g. internal water pressure, thermal stresses, erection and concreting procedures. The most unfavorable situation shall be taken as the basis and governing factor for the final design of the structure. The design pressure shall be the maximum static pressure plus maximum water hammer. The water hammer shall conform to the regulation guarantees for the turbine which shall not exceed maximum 20% of the gross head. An extra 3 mm shall be added to the pipe wall thickness for corrosion allowance. Steel Pipe & specials welding shall confirm to the following strength considerations (i) The allowable stresses for normal loading of steel plates used in pipes and specials and structural steels shall not exceed those given below: For IS 2062:1999 Grade Bor Equivalent steel Tensile Stress Compressive Stress Ultimate Tensile Stress (ii) 250 MPa 250 MPa 410 Mpa

The combined stress shall be applicable to the parts subjected to combined loadings.

5.

WELDED JOINTS

All welding shall be done either manually by shielded metallic arc welding process (SMAW) or automatically by the shielded arc or submerge arc method. The Contractor shall submit a welding procedure for the approval of Engineer. After getting the approval from Engineer, the Contractor shall record it on a special drawing which shall thereupon become one of the drawings of the Contract. Weld sizes and types shall be shown on all Contractors drawings where welding is required. All the welding of pressure pipe shall be radiographic/ultrasonic quality. Full penetration butt weld joints shall be done for all longitudinal and girth welds in the penstock shells. Plates to be joined by welding shall be accurately cut to size and rolled by pressure to the proper curvature which shall be continuous from the edge. Flattering in the curvature along the edges with correction by blows will not be allowed. The dimensions and shape of the edge to be joined shall be such as to allow fusion and complete penetration and the edges of the plates shall be properly prepared to accommodate the various welding conditions. In addition to the welding requirements of general practice, the following welding requirements shall govern; I. The surface of plates to be welded shall be cleaned of all scale, rust, oil, grease or paraffin, for a distance of not less than 25mm from the welding edge. II. All welders and welding operators assigned to the work shall have passed a qualification test, within the preceding six months, for welders and welding operators, in accordance with ASME. III. The Contractor shall furnish the Engineer with certified copies of reports of the results of physical tests of specimens welded in the qualification tests. If, in the opinion of the
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Sapsup Kalika Hydropower Pvt. Ltd. Miya Khola Small Hydropower Project Technical Specification for supply of Hydro-mechanical works

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ENGINEERING

Engineer, the work of any welder at any time appears questionable, he shall be required to pass the appropriate re-qualification test. All costs of qualification tests shall be borne by the Contractor. IV. The material of welding rods, core wires, fluxes shall be most suitable for the base metals and shall be stored in sufficient dry condition. The Contractor shall obtain the approval of the Engineer for their kind, mechanical and chemical characteristics, weldability and control procedures. V. Arc air gouging shall be done for back chipping of weld joints. VI. Weld joints shall be preheated in accordance with kind of steel materials and plate thickness. However, maximum inter-pass temperature shall be 2000C and preheated area shall be a distance of more than four times plate thickness from the welding line. If welding work is made under the condition of ambient temperature less than 50C, weld joints shall also be preheated even though application of preheating is not needed for the kind and thickness of steel material in normal welding condition. 5.1 TYPES AND CONFIGURATIONS

Typical welded joint configurations for longitudinal and circumferential main welded joints are shown in Figure 4-10 (ASCE Manual and Report on Engineering Practice No. 79 Steel Penstock). Configurations for nozzle and man way penetrations, attachments, and corner joints are shown in Figure 4-11 (ASCE Manual and Report on Engineering Practice No. 79 Steel Penstock). Configurations for bifurcation joints are shown in Figure 4-12 (ASCE Manual and Report on Engineering Practice No. 79 Steel Penstock). 5.2 5.3 BUTT JOINTS JOINT QUALIFICATIONS

Welded joints required to be examined by radiography must be full-penetration butt welds. Pre-qualified welded joints for complete penetration groove welds that meet the AISC Specification for Structural Steel Buildings and the AWS Structural Welding Code (D1.1-92) or other equivalent codes are acceptable for penstock fabrication.

6.
6.1

TESTS
SCOPE OF NDT

NDT: Non Destructive Testing is essential for the safety of pressure pipe thus, considering the cost prospective and critical welding portion of pressure pipe, the following NDT has been proposed: Radiographic Examination (X-ray): 10% of longitudinal welding for headrace pipe and 20% of longitudinal welding for penstock pipe. 100% of longitudinal weld joints and all Wyee or T joints. Magnetic particle testing (MPT): 100% of Wyee or T weld joints and as per requirements in longitudinal and girth welding. Ultrasonic Testing (UT): 100% for the pipe sections having thickness equal or greater than 14 mm. (both longitudinal and girth weld joints) Dye Penetration Test (DPT): As and when required. Visual Inspection: 100% of total weld joints for both longitudinal as well as girth welding.
Samyak Engineering Pvt. Ltd.

Sapsup Kalika Hydropower Pvt. Ltd. Miya Khola Small Hydropower Project Technical Specification for supply of Hydro-mechanical works

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ENGINEERING

Objectionable defects in welds discovered during the above tests, shall be repaired and 100% X-ray again. 6.2 HYDROSTATIC PRESSURE TEST

Minimum 10% of the total shell should be subject to hydrostatic pressure test at fabrication yard. Test pressure should be 1.5 times working pressure in corresponding thickness and head. The bifurcation of the pipe shall also be subject to hydrostatic pressure test. 6.3 WATER FILLING TEST

After completion of the entire work, a water filling test for the penstock shall be carried out as directed by the Engineer. During the test, all exposed joints and appurtenances shall be examined for leakage and the time duration of water filling from the commencement to the completion shall be measured. Defect and leakage discovered during the test shall be promptly repaired.

7.

PAINTING

Surface protection is vital to prevent the penstock from corrosion. So following preventive coatings are recommended: Surface preparation shall be carried out with mechanical cleaning (sand blasting). Priming coat of zinc rich primer or Zinc Phosphate after surface preparation (40 micron). Three successive coats of coal tar epoxy (3x100 micron). Both externally and internally total 340 micron minimum paint thickness is required. Pin hole test and Elcometer DFT measurement are necessary to examine the painting.

8.

TOLERANCES

The completed penstock section shall conform to the dimensions and to the tolerances specified by Engineer. However, the tolerances of circumferential length of each section shall not exceed 0.25% of the design length for that section. Tolerance for plate thickness shall be +0.5mm and -0.0mm. The tolerance is 0.25% of the diameter of the pipe. The end of cylindrical sections shall be within a tolerance of 2mm of the plane normal to the axis of the pipe shell. Angle of bends shall be within a tolerance of 10 minute of angle. These tolerances are exclusive of any allowance for shrinkage or distortion provided by the Contractor to compensate for effects of welding.

Samyak Engineering Pvt. Ltd.