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    TUBERIAS DE PRESION, EN CENRALES HIDROELECTRICAS

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    TUBERIAS DE PRESION, EN CENRALES HIDROELECTRICAS

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    16 visualizzazioni9 pagine

    ASCE - Chapter 13

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    Energia_X
    TUBERIAS DE PRESION, EN CENRALES HIDROELECTRICAS

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    © All Rights Reserved
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    CHAPTER 13 ‘Source: Photograph courtesy of National Welding Corp ; reproduced with permission, No two penstock installations are truly identical. Subtle vari- ations require unique approaches best suited to a particular installation. There are, however, general installation require- ‘ments and procedures common to all penstock systems, This chapter discusses those general requirements and proce- ‘dures, leaving the consideration of unique requirements and. solutions for particular projects to the engineer and installer. 13.1 HANDLING, SUPPORTS, AND ‘TIE-DOWNS 13.4.1 Handling ‘Compared to the fabrication site, the construction site requires greater care in the unloading, storing, and handling of penstock sections. This issue is pare ticularly true for precoated penstock sections. The coating, should be protected both during shipping and at the job site, ‘or repairs may be necessary. Pipe with exterior paint must be holiday tested in accordance with NACE (2006). ‘To avoid damage to coatings, coated pipe must not be placed directly on the ground. It must be supported properly when in storage s0 as to spread the supporting load over a large area. If necessary, painted penstock sections may be rolled only along supports on unpainted areas or by pro- tecting the pipe or cushioning the supports. When lifting penstock sections for unloading or installation, fabric or fab- ric-protected slings must be used for exterior painted pipe. If available, lifting lugs welded to stiffener rings or ring girder ‘supports may be used. Every effort must be made to sling 153 154 the penstock sections for pickup at their balancing points Penstock sections must not be dragged along the ground or bumped. While being fitted up, penstock sections must be supported in such a manner as 10 protect the coating and st- bilize the pipe section STEEL PENSTOCKS 13.1.2 Supports ‘Both temporary and permanent supports may be needed dur- ing penstock installation, Supports include temporary wood blocking, steel or concrete saddles, internal stiffeners or spi- ders, external lugs, and anchor ties. Also, steps must be taken to prevent excessive deforma tion of the penstock sections, particularly after the lining and coating have been applied. Internal bracing may be used 10 prevent overstressing the shell and also to prevent excessive deflection and out-of-roundness. Pudding supports and tie down straps may be necessary to prevent damage to the lin- ing and coating. Internal stulling with wood or bracing with steel mem- bers may be necessary for buried penstock under backfill conditions. Table 13-1 lists pipe stulling criteria, The stulling criteria apply to all pipe, whether bare, painted, or cement ‘mortar lined. Wood stulls must be cut to a length equal to the pipe inside diameter minus 1/4 in, Cedar shingles can be used as wedges w provide a snug fit. Framing unctors are used to tie posts together (as radii of a circle). Based on ‘common practice, wood stulls with felt or carpet padding are used for painted pipe with inside diameters up to 84 in. and without padding on cement-mortar lined pipe through 120 in. inside diameter. The pipe stulling should not be removed. until the compacted backfill is placed to a depth that pro- vvides adequate lateral support for the Table 13-2 gives steel bracing requirements. Steel stulls ‘must be cut to a length equal to the pipe inside diameter minus, 128 in. and inserted in sleeves at one end. Sleeves and the other cend of the stull must be tack-welded to the pipe shell. Pipe stulling and bracing configurations are illustrated in ig, 13-1, Temporary bracing can be applied internally or externally to the shell, Internal bracing, also called spider bracing, may consist either of a simple cross pattern attached directly to the steel interior by welding or a complex system of adjustable rods tached to a central ring with steel lugs welded! at the intes rior of the liner, This bracing is used when the steel pipe conforms to specified tolerances for out-of-roundness and, itis necessary to maintain these tolerances during shipment and handling. ‘The adjustable rod (tension spider) allows adjustment of the out-of-roundness tolerances in the shop or in the field. However, this procedure is difficult with thick-walled pen- stocks because of the rigidity of the pipe. Bracing and attachments may be provided externally to the penstock in the form of stiffener rings. These rings may be required under design and, as such, perform a double function. External ring bracing can be used effectively for penstocks designed! for saddle support, for buried construc tion, of for tunnel liners. Bracing, when required to support the penstock se for hydrostatic testing and concreting, must be mini Table 13-1. Pipe Stulling Criteria—Wood Pipe diameter/Stll size D= 84in.t0 120 in, Cement D=24in to D mortar ined pipe D=<24in, — <3in, = 3010<48 in. <84 in only Diameter to Bin. X 3in. for 0 in, thickness ratio and 4in, X 4 in. for Dh) in. X Gin, Fin. X3in. —largerdiameters in. X4in, in. X Ain. in. 4 Di=120 Nostulls No stulls ‘No atlls ‘No stulls No stalls No stulls 120< DA Brace between 2stulls vertical 2 stullscrossed__-2stulls crossed 2stulls,3 legs 2stulls, 3 legs = 160 bunks 160< DA Brace between 2 stulls vertical 2 stullscrossed__-2-stulls,3 legs. 3stulls, 3 legs 3stlls 3 legs = 200 bunks 200< Dr — __2stulls vertical -2stlls crossed 3 stulls,3 legs 3stlls.3legs 3 stulls, 3 legs =230 230< DA - - 2stulls,3 legs 3stulls.34egs 3stulls,3legs 3 stulls, 3 legs = 288 ‘Notes: D = nominal pipe diameter; ~ pipe wall thickness; stulls should be placed 15 to 20% of the total pipe length from ‘each end, but no les than 4 ft in from end: and shipping bunks are to be located near stulls. Table 13-2. Pipe Bracing Criteria—Steel INSTALLATION 1 Pipe inside Required r Nominal brace diameter Brace outside diameter thickness diameter (in.) din (in) (in) (in) 90 03 20 2373 0138 96 080 25 2.875 0.203 102 oss as 2875 0.203 108 090 25 2.875 0.203 na 09s 25 2875 0.203 120 1.00 30 3.500 0.216 126 1.05 30 3.500 0.216 132 110 30 3.500 0.216 138 has 30 3.300 216 144 1.20 49 4.500 0.237 ‘Notes: Based on an (77 = 120, = length of the brace, r= radius of gyration = (”a)"®, = moment of inertia = (R* Bd where R = brace O.D. and Ry brace LD.: a= area of brace wall x(R? R,’)-For Dit ratio = 120, no stulls ‘ae required where D = nominal pipe diameter and f = pipe wall thickness. For D/ ratio of 120 10 160, 2 stulls with 3 legs ‘each are required. For D/ ratio of 160 t0 288, 3 stulls with 3 legs each are required. Braces should be placed 15 to 20% of the total pipe length from each end, but no less than 4 fn from end. Shipping bunks are to be located near braces. to the greatest extent practical or designed in a manner that, does not restrain the shell. Bracing resulting in potential restraint must be located at low-stress shell areas of complex. structures, such as wyes. ‘When no longer needed. bracing and attachments within the shell must be completely removed, the areas of weld- ‘ment must be ground flush with the shell plate material, and, the surfaces must be inspected by nondestructive examina tion (NDE) and then coated as required During the installation of the penstock, consideration ‘must be given to ensure that permanent supports, sueh as, thrust blocks or thrust-resisting saddles, are installed in con- Jjunction with the penstock to accept any gravitational or temperature-related loads. This situation is particularly true for exposed penstocks on steep terrain and penstocks using flexible field joints, such as couplings and expansion joints. If thrust considerations are not accomplished during instal- lation when those conditions are present, joints are likely to ‘open during construction and/or testing of the penstock. 13.4.3 Tie-Downs ‘Temporary ties may consist of simple lug pieces welded to the shell surface with provisions for fastening a steel cable fo tie rod, or they may consist af complex ring girder type tie-downs, if needed to prevent shell movement during con- struction. Plate straps, anchor bolt footings, and lifting sling. tugs, oF other eaten date working platforms for construction and for position 1 attachients ate sea toy acca ing and adjusting the sections into alignment with adjacent structures. ‘As with bracing, temporary ties are required primarily for shipment and to expedite construction. Ties that have served. their intended use must be removed. and the weldment must bbe ground smooth with the shell surface, inspected by NDE, and then coated as required. Permanent tie downs consisting of strap anchors can be used fo hold down an aboveground penstock to each of its, supports, These straps should be wide enough and suitably [padded to limit stress applied to the pipe. They are intended. to limit pipe movement. Tie-downs may also be required for penstocks fully encased in concrete as.a means of preventing, flotation during concrete placement and curing. Penstocks or tunnel liners to he encased in conerete must bbe designed for the buoyant and concreting loads resulting. from concrete placement. In an installation through rein- forced concrete, the reinforcing bars must not be used as temporary support for the penstock during installation. The penstock must not contact the reintoreing bars because of the risk of galvanic corrosion to the penstock. 13.2. THERMAL EFFECTS Daring penstock installation, the effects of temperature must be considered. The effects of temperature variations are most severe for an envegsin direct sunlight, less severe for a buried penstock during its Pevsiock iestallation eaposead it 156 STEEL PENSTOCKS PIPE ENDS: STULL-VERTICAL | STULL-CROSSED stucstecs | PRE itar Carpot or Frame ) Fram ‘et (ve) | aches anche 1 Wow stu Shingle [wedges tye) + ; Mond si - tarot in /- Genter Centering or | tugor 1 rt A ta not | é inte) 7 Shingle 7 Pee wedges end Pa (free) sieeve \ Wood sul CARPET ENDS SINGLE WEDGES PIPE SLEEVE Fig. 13-1. Pipe stulling and bracing configurations installation, and least severe for a penstock installed free in ‘an open tunnel or embedded in concrete, 1.c., a steel liner. ‘The most serious thermal stresses occur because of the pen- stock temperature differential from the time of installation, to the time of operation. Temperature-induced movement plagues every penstock builder because of its potential to vise hoth temporary problems and permanent damage to the penstock and its supporting structures. Ideally, penstock installation should be done at a temperature that is constant aie of the ste. Ufo an elise tthe mean this procedure is rarely feasible. ly, ‘Temperature changes affect alignment, straightness, and length ot penstock sections. Direct sunlight on an exposed ppenstock results in the lighted side being hotter. Temperature differentials can be as high as 70°F, with the side exposed, to direct sunlight reaching temperatures of 140°F or higher. ‘These conditions cause penstock deflection and/or curling, resulting in large sidecturch forces on the supports. This problem is especially critical on long-span, ring-girder-sup- alignment with the variation in night and day temperatures. ‘Temperature side-lurch, expansion and contraction, and curling conditions are calculable for both the dewatered and, watered conditions. The engineer must prepare an adjust- iment table for all three axes to he used by the installer dur- ing installation. Side-lurch forces and uplift conditions may be greater uring construction and the dewatered condition because there is: no water 10 act as a heat sink. High side-lurch or uplift forces have been known to cause support displacement and damage. A dewatered penstock and its supports must be inspected for potential damage before refilling. It is important to make frequent checks of penstock alignment and length during the installation. These checks. are hest dane hefore sunrise (dawn) or after sunset (dusk). ‘when the installation has reached a more uniform tempera ture over the entire shell surface. These checks then must be ‘compared with the design assumption criteria and alignment for the mean temperature at the site and corrections made as needed. Should there be inereases or decreases in length that exceed allowable tolerances, adjustments to the pen- stock length must be made either by cutting off any excess, length or by adding a filler piece of pipe. Decreases in length caused by temperature effects may be aggravated by weld- related shrinkage, which can reach as high as 1/8 in. for each, butt-welded joint. Long, continuous runs of exposed penstocks are subject to greater temperature effects. Because concrete footings or piers usually are placed before the penstock erection, adjust- ‘ments in the base plate and ring girder support and fastening. design are necessary. Allowance should be made for mis- alignment in all directions at each footing or iet. The degree ‘of allowance for directional movement varies with the instal~ lation. By providing this type of flexibility, the number of field adjustments for shrinkage, length inerease, or misalign ‘ment can be reduced greatly on long penstock runs, Expansion joints designed to allow change in length also help protect the installation against temperature effects. These expansion joints can be located so that the penstock length upstream and downstream of the joint undergoes an essentially equal thermal expansion and contraction or deflection and rotation condition. On steep slope installa tions, sliding of coupling joints can be prevented by attach- {ng extemal restraints to the pipe. Actual expansion joint and coupling joint openings must be evaluated for the tempera ture atthe time of instalation relative to the temperature dif- ‘erential n the design and must be installed accordingly. the ‘engineer should provide the installer with a table of instal lation temperature versus expansion joint settings to ensure that the joint is properly installed to allow for expansion and, contraction as the engineer intended. ‘The temperature effects on an exposed pen reduced by the application of a reflective type of paint or by insulation. Insulation may need to be considered in cold tepious where there have her eases of fesri within the penstock, even under flow conditions. Similarly, 0 the wates INSTALLATION 157 ‘warming water may have detrimental effects caused by tem- perature-related stress conditions at shell restraints ‘The installer must position the pipe-support attachments al movement on the Support in proportion to the pipe temperature atthe time of installation to that considered, the ultimate movement by the engineer. This information ‘must be made available through communication between the engineer and the installer during installation. Daring cold weather, lowered temperatures affect the pen- stock welding and protective coatings. For certain types of coatings, itis inadvisable to store unprotected pipe through the winter season before installation. Also, to prevent dam- age to the coating, special care is needed in handling or transporting coated pipe during cold weather. The costing, ‘manufacturer’s recommendations must be followed. Pipelines installed on slopes, particularly above ground, tend to slide down slope and, under certain conditions, 10 resist uphill expansion. Pipes at the bottom of a slope have been crushed under direct axial compression when, upon. expansion caused by temperature change, they did not expand uphill as expected. Use of frequent anchoring on long slope intervals reduces the weight of pipe supported at each anchorage. Expansion joints must be properly located to reduce these thermal compressive stresses. Steel liners embedded in concrete also experience the effects of temperature variations. Axial length changes caused by temperature changes (15°F to 35°F temperature differentials) produce shearing loads on extemal fasteners and attachments. Also, temperature variations cause radial shell growth or shrinkage and can influence the stress condi tions in the shell. Usually. axial and outward radial move- ‘ments are not considered critical to the design. For axial movements, it is reasonable to assume that temperature ‘changes affecting the steel shell will be gradual and, as auch, the shell and surrounding concrete will react similarly with= ‘Out the presence of relative differential movements. This assumption holds even with heavy thrust rings or seal rings. at the shell exterior. 13.3. FIELD JOINTS Field-welded joints are typically complete joint penetra- tion (CIP) butt joint oF welded lap joint types, as indicated, in Fig. 13-2. Although the butt joint offers greater strength ‘when compared to lap joint, the hi-up time associated with, alignment of edges to be welded is much greater, resulting in, greater installation cost that often favors lap joints. Welding codes recognize that welder skill levels are greater for butt- Joint welds than for fillet welds Poutleaweldedl but joints that result in ity require welder access from both sides of the joint, this access permits the welder to gouge out the root pass from the il weld tal agai ing weld metal that acts as backing for subsequent welding. at apply sonnel weld 158 STEEL PENSTOCKS CAP Butt Joint Double Fillet Welded Butt Strap EF Zep Single Welded (CYP Butt Joint with Backing Double illet Welded Lap Joint Hig. 18-2. Common fek-welded yonts Single welded butt joints are often used where welder ‘access is limited to only one side, for example, in steel tun- nel liners, ‘Welded lap joints are often the joint of choice hecause they offer reasonable strength yet economy since the joints are easy for installers to assemble and welder skill, level is less than that required for butt-joint welds. Minor ‘changes in alignment can be accomplished by pulling the Jap joints, Double-welded butt-sirap joints are often used for field station adjustment. They are comparable in strength and economy to double-welded lap joints; however, plain pipe ‘ends are used rather than sized bell-and-spigot joint prepara tion. The butt straps are normally furnished in two I8U-

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