Steel Penstocks: General; Chapter 2 Materials; Chapter 3 Design Criteria and Allowable Stresses; Chapter 4 Exposed Penstocks; Chapter 5 Buried Penstocks; Chapter 6 Steel Tunnel Liners; Chapter 7 Wye Branches and Branch Outlets; Chapter 8 Anchor Blocks; Ch

Steel Penstocks stands as a complete guide to the design, installation, and maintenance of the closed conduits between a free water surface and hydroelectric power stations. This new, thoroughly updated edition provides recommendations and technical guidance for all aspects of steel penstocks, including tunnel liners, wyes, and branch outlets. Hydroelectric engineers, designers, and facility managers use MOP 79 as the go-to reference for steel penstocks. Cover 1 Contents 10 Preface 14 Abbreviations and Acronyms 16 CHAPTER 1 GENERAL 20 1.1 Design Considerations 20 1.2 Economic Diameter 24 1.3 Shutoff Systems 27 1.4 Prevention of Vibration 27 1.5 Wind, Snow, and Ice Loading 29 1.6 Geologic Considerations 29 1.7 Earthquake Loading 31 CHAPTER 2 MATERIALS 34 2.1 General 34 2.2 Types of Materials 41 2.3 Temperature Considerations 41 2.4 Attachment Materials and Criteria 42 2.5 Material Specifications 42 2.6 Material Testing Requirements 42 CHAPTER 3 DESIGN CRITERIA AND ALLOWABLE STRESSES 44 3.1 General Considerations 44 3.2 Design Loads 45 3.3 Service Conditions and Load Combinations 46 3.4 Stress Categories 46 3.5 Allowable Stress Intensities 54 CHAPTER 4 EXPOSED PENSTOCKS 56 4.1 Penstock Shell Design and Analysis 56 4.2 Concrete Piers 61 4.3 Ring Girders 63 4.4 Saddles 65 4.5 Stiffeners to Resist External Pressure 71 CHAPTER 5 BURIED PENSTOCKS 74 5.1 Design of Buried Penstock Shells 74 5.2 External Pressure 75 5.3 Bends 76 5.4 Buried Joints 76 CHAPTER 6 STEEL TUNNEL LINERS 78 6.1 Design of Steel Liners for Internal Pressure 79 6.2 Design of Steel Liners for External Pressure 80 6.3 Design of Steel Tunnel Liners with Stiffeners 85 6.4 Tunnel Liner Bends 89 6.5 Seepage Rings 89 6.6 Tunnel Liner Joints 90 6.7 Tunnel Liner Transitions 90 CHAPTER 7 WYE BRANCHES AND BRANCH OUTLETS 92 7.1 Layouts 93 7.2 Hydraulic Considerations 96 7.3 Stress Limits 97 7.4 Nomograph Design Method 97 7.5 Curved-Beam Design Method 100 7.6 Finite Element Analysis Design Method 103 7.7 Additional Considerations 104 CHAPTER 8 ANCHOR BLOCKS 106 8.1 General 106 8.2 Anchors for Penstocks 109 CHAPTER 9 APPURTENANCES, BENDS, AND TRANSITIONS 118 9.1 Expansion Joints 118 9.2 Sleeve Couplings 120 9.3 Manholes and Smaller Openings 125 9.4 Standpipes and Air Valves 127 9.5 Anchor Bolts and Fasteners 129 9.6 Anchor Rings, Thrust Collars, and Joint Harnesses 131 9.7 Penstock Roll-Out and Lift-Out Sections 138 9.8 Flanged Connections 139 9.9 Blowoffs 141 9.10 Makeup and Closure Sections 142 9.11 Closure Heads 143 9.12 Bends (Elbows) 145 9.13 Geometric Transitions 145 CHAPTER 10 CORROSION PREVENTION AND CONTROL 148 10.1 Corrosive Environments 148 10.2 Vulnerability of Penstock Steel to Corrosion 151 10.3 Corrosion Prevention and Control Measures 151 10.4 Failure Caused by Corrosion 157 CHAPTER 11 WELDING 160 11.1 Materials and Material Tolerances 160 11.2 Submittals 161 11.3 Joint Types and Configurations 161 11.4 Joint Configurations 163 11.5 Welding Processes, Edge Preparation, Preheat, Notch-Tough Welding, and Assembly 163 11.6 Field-Welded Joints 165 11.7 Bifurcations 165 11.8 Tapers 166 11.9 Attachment Pipe Welds 166 11.10 Grout Connections 166 11.11 Postweld Heat Treatment 166 11.12 Weld Inspection and Acceptance Criteria 166 CHAPTER 12 MANUFACTURE 168 12.1 General 168 12.2 Qualification of Manufacturer 169 12.3 Manufacturing Specifications 169 CHAPTER 13 INSTALLATION 172 13.1 Handling, Supports, and Tie-Downs 172 13.2 Thermal Effects 174 13.3 Field Joints 176 13.4 Field Welding 177 13.5 Concreting 177 13.6 Grouting 178 13.7 Trenching, Bedding, and Backfill 179 CHAPTER 14 INSPECTION AND TESTING 182 14.1 General 182 14.2 Shop or Field Inspection 182 14.3 Nondestructive Examination 184 14.4 Hydrostatic Testing 185 CHAPTER 15 START-UP 188 15.1 Watering-Up 188 15.2 Operational Testing 190 CHAPTER 16 DOCUMENTATION AND CERTIFICATION 196 16.1 Certified Mill Test Report 196 16.2 Personnel Certification 197 16.3 Process Certification 197 16.4 Documentation Records 197 16.5 Data Report 198 16.6 Nonconformance Report 198 CHAPTER 17 MAINTENANCE 200 17.1 Monitoring 201 17.2 Periodic Maintenance Activities 202 17.3 Condition Assessment 205 17.4 Rehabilitation 207 17.5 Penstock Construction Technologies 211 CHAPTER 18 EXAMPLES 222 18.1 Internal Pressure 224 18.2 Steel Tunnel Liner 229 18.3 Buried Penstock 236 18.4 Ring Girder 242 18.5 Saddle 258 18.6 Reducing Bend 276 18.7 Transition 279 18.8 Expansion Joints and Sleeve Couplings 282 18.9 Anchor Block 285 18.10 Riveted Penstock Joints 300 Index 310 A 310 B 310 C 310 D 311 E 311 F 311 G 311 H 312 I 312 J 312 K 312 L 312 M 312 N 312 O 313 P 313 Q 313 R 313 S 313 T 314 U 314 V 314 W 314 MOP 79 provides practical, comprehensive guidance regarding the technical, economic, safety, and environmental aspects of designing and implementing steel penstocks at hydroelectric power stations.