IS 11639 ( Part 2 ) : 1995

( Reaffirmed 2000 )

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Indian Standard
STRUCTURALDESTGNOFPENSTOCKS-
CRITERIA
PART 2 BURIED/EMBEDDED PENSTOCKS IN ROCK

UDC 627.844

@ BIS 1995

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARC3
NEW DELHI 110002

July 1995 Price Group 4

Water Conductor Systems Sectional Committee, RVD 14

FOREWORD
This Indian Standard ( Part 2 ) was adopted by the Bureau of Indian Standards, after the draft
finalized by the Water Conductor Systems Sectional Committee -had been approved by the River
Valley Division Council.
Penstocks carry water from surge tanks or directly from a reservoir to the power house. Such
penstocks may be laid on the surface or buried/embedded in rock or concrete. Part 1 of this
standard covers the criteria for structural details of surface penstocks and this part covers the
criteria for structural design of buried/embedded penstocks in rock or concrete.
For the purpose of deciding whether a particular requirement of this standard is complied
with, the final value, observed or calculated, expressing the result of a test or analysis, shall be
rounded off in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘.
The number of significant places retained in the rounded off value should be the same as that
of the specified value in this standard.
 IS 11639 ( Part 2 ) : 1995

Indian Standard
STRUCTURALDESIGNOFPENSTOCKS-
CRITERIA
PART 2 BURIED/EMBEDDED PENSTOCKS IN ROCK

1 SCOPE 4.1.3 Nothing in the foregoing should preclude

the use of material where so agreed by the
1.1 This standard ( Part 2 ) lays down the purchaser. It is recommended that, in such
general requirements and design of circular cases, particular attention be given to the wel-
penstocks, buried/embedded in rock or concrete, dability and ductility of the material proposed
for conveyance of water from a reservoir, pond to be used. No such material should have
or surge tank to a hydraulic turbine in hydro- elongation ( in percent ) on a gauge length of
power plants. 5-65,./‘g less than ( IOO-Rm) / 2-2 where So is
1.2 This standard does not cover the design of the original area of cross-section and Rm is the
specials like manifolds, wye-pieces, transitions, actual tensile strength in N/mm2 at poom tem-
anchor blocks, etc. perature, subject to a minimum of 16 percent
for carbon and carbon manganese steels, 14
2 REFERENCES percent for alloy steels other than austenitic
steels and 25 percent for austenitic steels for
The Indian Standards listed in Annex A are test pieces obtained, prepared and tested in
necessary adjuncts to this standard. accordance with appropriate Indian Standard.

3 HYDRAULIC DESIGN 4.1.4 Materials used for supporting lugs,

stiffeners and other similar non-pressure parts
For hydraulic design of penstocks reference welded to penstocks should be of weldable
may be made to IS 11625 : 1986. quality and suitable in other respects for inten-
ded service.
4 MATERIAL AND ALLOWABLE STRESSES
4.2 Allowable Stresses
4.1 Material 4.2.1 The allowable stresses and the factor of
4.1.1 Steel to be used for the fabrication of safety to be adopted depend upon the yield
penstocks of a hydro-electric project should point stress and ultimate tensile strength of the
meet the following requirements: steel, loading condition and the location where
steel lining is provided.
a) It should stand agai~nst maximum internal 4.2.2 Following allowable stresses should be
pressure including dynamic pressure, adopted in design of steel pen&ocks:
b) It should stand against frequent dynamic a) In normal operating condition, the design
changes, stresses should not exceed one-third of the
minimum ultimate tensile strength or
c) It should have required impact strength 60 percent of m~inimum yield point stress
to be able to deform plastically in the of steel, whichever is less.
presence of stress concentrations at
notches and bends, b) In intermittent condition, the design
stresses should not exceed 40 percent of
d) It should have good weldability without the minimum ultimate tensile strength or
preheating, and two-thirds of minimum yield point stress
of steel, whichever is less.
e) It should not require any stress relieving
after welding. Cl In the emergency condition, the design
stress should not exceed two-thirds of
The requirements (a) to (c) are essential while minimum ultimate tensile strength or
requirements (d) and (e) are preferable. 90 percent of minimum yield point stress
4.1.2 The steel plates to be used for fabrication of steel, whichever is Iss, and.
of penstock liners should be of fire box quality d) In exceptional condition, the design
conforming to IS 2002 : 1992, IS 2041 : 1982 or stress should not exceed the minimum
IS 8500 : 1992. yield point stress.

1
IS 11639 ( Part 2 ) : 1995

42.3 When rock participation is considered in computed for both normal as well as emergency
zhedesign, the stresses in steel lining under conditions. The plate thickness of the penstock
normal loading condition without rock partici- should be checked for both these conditions.
pation should also be checked and should not
exceed 90 percent of minimum yield point stress 5.1.2 Water Hammer Eflect
or tcvo-thirds of minimum ultimate tensile
strength, whichever is less. In intermittent and Rapid opening or closing of the turbine gates
emergency conditions of loading it should not produces a pressure wave in the penstock, ter-
exceed the minimum yield point stress. med as water hammer effect. Detailed water
hammer analysis for various conditions of
4.2.4 Loading conditions should be considered operations as specified in IS 12967 (Part 1 ) :
as given below: 1990 should be carried out for computing
water hammer effect.
a) Normal condition includes static head
along with pressure rise due to normal 5.1.3 Pressure Wave Velocity
operation or head at transient maximum
surge, whichever is higher. i) The pressure wave velocity in a steel
penstock carrying water may be computed
b) Intermittent condition includes those
as follows:
during filling and draining of penstocks
and maximum surge in combination with 1 425
pressure rise during normal operation. -__
a= 1 + (d/loot)
c) Emergency condition includes partial gate where
closure in critical time of penstock
; 2L/a seconds ) at maximum rate, and the a = pressure wave velocity in m/s,
cushioning stroke being inoperative in
one unit. d = diameter of penstock in m, and
d) Exceptional condition includes slam shut, t =2 thickness of penstock shell in m.
malfunctioning of control equipment in
the most adverse manner resulting in odd ii) For a pipe concreted in solid rock, the
situation of extreme loading. This should pressure wave velocity may be taken equal
not be taken as a design criteria. to 1425 m/s ( velocity of sound in water )
4.3 Joint Efficiency 5.1.4 Pressure Rise Gradient
4.3.1 Joint efficiency or weld factor assumed Pressure rise due to water hammer is measured
for purpose of design varies for different kind above static water level in reservoir or maxi-
of joints and different methods of inspection mum upsurge level in case of surge tank and it
and testing. The joint efficiency also varies for is assumed to vary uniformly along penstock,
different type of steel. from maximum at turbine end to zero at reser-
4.3.2 Joint efficiency as specified in Table 1.1 of voir level or maximum upsurge level, as the case
IS 2825 : 1969 should be adopted. may be, as given in IS 7396 ( Part 1 ) : 1985.

4.4 For liner thickness exceeding 38 mm and 5.2 External Pressure

specials like manifolds, transitions, etc, stress
relieving should be done as specified in 5.2.1 The steel lining should be designed for
IS 2825 : 1969. the external water pressure head which is either
the difference between the ground level verti-
5 DESIGN LOADS cally above the penstock and the penstock
The steel lining has to withstand the internal invert level or the maximum level from which
water pressure as well as external pressures the water is likely to find its way around steel
which may be caused either during grouting lining, whichever is less.
operations or when the penstock is dewatered. 5.2.2 The liner should also be checked against
5.1 Internal Pressure grouting pressure during construction.
5.1.1 The steel lining of a penstock is designed 5.3 Longitudinal Stresses Caused by Radial
for maximum internal pressure which is caused Strain
due to maximum water level in reservoir or
in surge tank, as the case may be, plus the anti- Radial expansion of steel caused by internal
cipated increase in pressure due to water pressure tends to cause longitudinal contraction
hammer effect development when arresting or with corresponding tensile stress equal to 0.303
releasing the flow of water. It should be times the hoop tension in the circular lining.
 IS 11639 ( Part 2 ) : 1995

6 STRUCTURAL DESIGN OF STEEL LINING it = thickness of steel lining in m,

6.1 Design for Internal Pressure Es = modulus of elasticity of concrete in
N/mz.
The stresses in the steel liner and the surround- Es = modulus of elasticity of steel in N/m2,
ing concrete/rock may be computed using the
formulae given in 6.1.1 to 6.1.3. CLS= Poisson’s ratio for steel,
IJC = Poisson’s ratio for concrete,
6.1.1 Hoop Stress in Penstock Without Rock
Participation fst = hoop tensile stress in steel liner in
N/m2, and
If the surrounding rock is very badly fractured fct = hoop tensile stress in concrete at inner
and weak or the minimum rock cover is inade- surface of concrete in N/m?
quate. the steel lining should be designed for
full internal pressure. The hoop stress in such 6.1.3 If the penstock is embedded in fissured
case may be computed using the formula: concrete and rock, the stress in steel and rock
may be computed using the following formulae:
fst _+

where
_&t = hoop tensile stress in steel liner in

1..................
N/m%, d2 - C2
P = internal pressure in N/m2, +
Cd (vi)
R = internal radius of penstock in m, and
t = thickness of liner shell in m. Ps = PO + ( P - PO )

NOTE - Rack cover is considered inadequate when

it is less than 40 percent vertically and 120 percent c
horizontally of the internal pressure head under
Formal loading condition. T&5i ll t_ $ ] .! ,...... (vii)
6.1.2 Hoop Stress in Penstock in Unfissured fst _+
Concrete . . . . . . . . . . . . . . . . . . (viii)
If the penstock is embedded in well reinforced, fr+-_ ( p - Ps ) R
homogeneous mass concrete without fissures or d . . . . . . . . . . . . . . . . . . (ix)
cracks, for example, penstock through a conc- where
rete gravity dam adequately reinforced against a dimensionless parameter,
cracking, the hoop stress in the steel liner and
the surrounding concrete may be computed ;z hoop tensile stress in liner in N/mz,
using the following formulae: P= total internal pressure in N/mz,
1 Ps = pressure shared by steel lining in
P,=P[ 1 Wm2,
-&R
1 + E,t ( ;I-+“,“: ) . . . (i) PO = pressure required to close the gap YO
between liner and concrete/rock,
C2 + R2 YO = initial gap between the liner and the
KI = c”RRB- concrete caused due to shrinkage and
. . . . . . (ii)
creep of concrete and temperature
effect in m,
. .. . .. (iii) R = internal radius of penstock in m,
c = outside radius of concrete lining in m,
fct = (P - Ps) x :g +_ z2; . . . (iv)
d = radius to the end of radial fissure in
rock in m (where the in-situ com-
where
pressive stresses in rock are just
P, = pressure shared by steel liner in N/m% exceeded by the tensile stresses caused
p = total internal pressure in N/mz, by internal pressure ),
R -_ internal radius of penstock in m, t = thickness of steel liner in m,
C = radius of external surface of concrete Es = modulus af elasticity for steel in
in m, Nlm2,

3
IS 11639 ( Part 2 ) : 1995

Er = modulus of elasticity for rockmass in where

N/m2, 2R
K =--
EC = modulus of elasticity for concrete t
in N/ma,
CL8 = Poisson’s ratio for steel, E’ = +
-p%
pr = Poisson’s ratio for rockmass, and
fit - tangential tensile stress in rockmass yy= fy
due to internal pressure at dmetres 1/1-y + /A-
away from centre of penstock. fY = yield stress of steel in N/ma,
EB = modulus of elasticity of steel in N/m?
6.1.4 The maximum hoop tensile stress in steel
liner fSt should not exceed the product of joint ICE = Poisson’s ratio ofsteel,
efficiency and the allowable stress. R =Z radius of penstock in m,

6.2 Design for External Pressure Y,, = initial gap between liner and concrete
in m,
6.2.1 Critical External Pressure for Unsti@ened
h = allowable stress in steel in N/ms,
Shell
P,, -= critical external pressure in N/m?
Critical external pressure for unstiffened and
penstock liner shell may be computed using the 1 = thickness of steel liner in m.
following formulae:
NOTE - Lower of the two values of critical external
A) Vaughan’s formula pressure calculated by above formulae should be
adopted.

6.2.2 The maximum external pressure on the

penstock should not exceed two-thirds times the
critical external pressure calculated according
to 6.2.1. If the maximum external pressure
exceeds the value equal to two-thirds times
where the critical external pressure for unstiffened
K= ratio of pipe diameter to plate shell, stiffeners should be provided to prevent
thickness, buckling.

E’ zz ES 6.2.3 Critical External Pressure *for Stiffened Shell

1-1*2s’
6.2.3.1 Critical external pressure for steel liner
E, = modulus of elasticity of steel in
with stiffening rings should be computed by
N/m2, Timoshenko equation. The critical external
Poisson’s ratio of steel, pressure should not be less than l-5 times the
critical external pressure at buckling maximum external pressure.
in N/ms,
Timoshenko equation:
initial gap between steel lining and
concrete in m,
R = radius of steel liner in m, and
Fy = yield point stress in steel in N/m?

B) Amstutz’s formula
The critical stresses in the liner are given by
solution of the following two equations:
where

and E’= ---!?!_

P,,.K l-G%
1 = 0.175 $ (f’r - fn1
2.b z = thickness of liner plate in m.

4
 IS 11639( Part 2 ) : 1995

R = radius of pcnstock in m. pCF = external critical pressure in N/me,

L = spacing of stiffener rings in m. t = thickness of liner in m,
n ;- number of full waves on buckling =Y = permissible yield stress of liner in
chosen to make PCr a minimum. For N/m%, and
n values varying from 1 to 18, the Y0 = initial freedom of the shell to become
values of PCr should be calculated distorted which is algebraic sum of
and a graph plotted to obtain mini- initial out of roundness, thermal
mum PCr. shrinkage or expansion after installa-
P cr = critical external pressure in kN/m*. tion but before loading expansion due
to shrinkage, due to prestress, etc,
Es = modulus of elasticity for steel in
kN/ma. lit m.

ps == Poisson’s ratio of steel. 7 THICKNESS OF LINING

6.2.3.2 Critical external pressure may also be
determined directly from Fig. 1 based on the 7.1 The minimum thickness of the lining should
formula given in 6.2.3.1. not be less than:
6.2.4 Spacing of Stiffener Ring a>minimum handling thickness,
The centre to centre spacing of stiffener rings b) thickness required for internal pressure or
should not be more than 240 times and not less external pressure ( t ) plus 1.5 mm corro-
than 60 times the thickness of steel liner. sion allowance. If the inside surface of
the penstock is painted with some anticor-
6.2.5 Size of StifSener Rings rosive paint like epoxy paint, corrosion
The size of stiffener rings may be worked out allowance may be neglected.
using Vaughan’s formulae by trial and error
method so that the ~external critical pressure is 7.2 Regardless of pressure conditions, a mini-
not less than 1.5 times the maximum external mum handling thickness given by following
pressure. formula is recommended to provide rigidity
required during fabrication:
KIPZ,, + K,Pacr - I&PC, + K, = 0
t = R
w-here 0 -- -i- 0.25
R4 200
Kl = E, t,
where
to = minimum handling thickness in m, and
R = radius of penstock in m.
8 CHANGE IN THE THICKNESS OF STEEL
LINING
12 Csy2ts 8.1 The thickness of steel lining at different
K4 =
4A2 V2 R locations depends upon various factors. When
R = radius of penstock in m, the penstock passes through different layers of
A - total area of the composite section in rock, the steel thickness provided in bad or
me, medium layer of rock is extended into next
A, = sectional area of the stiffener ring better layer for a length equal to at least one
in my, diameter of the penstock.
t’ Z.ZZ
equivalent thickness in m, 8.2 The difference in steel plate thicknesses in
adjoining ferrules should not be more than
= t++- 5 mm.
I = associated width in m, 8.3 When lining emerges out of a tunnel, it
should be designed for full internal pressure
b + 1.56, R. t
and due care should be taken cf stress concen-
b : contact zone width of stiffener on trations occurring in the surrounding rock,
ferrule in m,
z = moment of inertia of the combined 9 CONCRETE LINING AROUND THE LINER
section about neutral axis in m*, The concrete lining around the penstock liner
v = distance between the neutral axis of and the rock supports, if required, should be
the combined section and the outer designed according to provisions of IS 4880
extreme edge of the stiffener in m, ( Part 4 ) : 1971 and IS 4880 ( Part 5 ) ; 1972.

5
IS 11639 ( Part 2 ) : 1995

K = 2R/t i X = L/I

E'= E,/ll-Ii,
Es= Young's Hodulus = 200,345,000 kN/d
cc= Polssm's Ratio = 0.25
t = Thlckness of Ltner Plate
R = Radius of Penstock

L = 5paclng of Stlffner Rings

n = Number of Full Waves on Buckling

Chosen to Make Pcrc.Mlnlmum

PC,= Crltlcal External Pressure kN/w?

= Yield Stress of Steel kN/m2

IY
- 250
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iw

It’ i ’ ’ ’ ’ ’ “”
9
6 I

7
.I5 .l .25 .3 .4 .5 .E .7.6 9 I 1.5 22.35 4 5 6 71910 15 20 25 56 u 31ut71
c
L/R

PIG. 1 DIAGRAMFORCRITICALEXTERNALPRESSURE

6
 IS -11639 ( Part 2 ) : 1995

ANNEX A
( Clause 2 )
LIST OF REFERRED INDIAN STANDARDS

IS No. Title IS No. Title

2002 : 1992 Steel plates for pressure W$ ( Part 1 ) : Criteria for hydraulic design
vessels for intermediate and of surge tanks : Part 1 Simple,
high temperature service includ- restricted orifice and differen-
ing boilers ( second revision ) tial surge tanks (first revision )
2041 : 1982 Steel plate for pressure vessels
used at moderate and low 8500 : 1992 Structural steel - Microallo-
temperature (first revision ) yed ( medium and high
2825 : 1969 Code for unfired pressure vessels strength qualities ) ( first
revision )
4880 ( Part 4 ) Code of practice for design of
1971 tunnels conveying water : 11625 :1986 Criteria for hydraulic design
Part 4 Structural design of of penstocks
concrete lining in rock
4880 ( Part 5 ) : Code of practice for design of 12967 (Part 1) : Code of practice for analysis
1972 tunnels conveying water : 1990 ofhy draulic transients in
Part 5 Structural design of hydro-electric and pumping
concrete lining in soft strata plants : Part 1 Criteria for
and soils analysis

7
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Revision of Indian Standards

Amendments are~issued to standards as the need arises on the basis of comments. Standards
dare also reviewed periodically; a standard along with amendments is reaffirmed w~hen such review
.
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This Indian Standard has been developed from Dot : No. RVD 14 ( 17 ).

A mendmerts Issued Since Publication

Amend No. Date of Issue Text Affected

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