KaWaTech Pre Design

MOST-BMBF
joint project
Vietnamese-German Cooperation for the Development

of sustainable Karst Water Technologies
Pre-Design
for the pilot implementation of a hydro power driven water
pumping and distribution system
(Concept 1)
Edited by Karlsruhe Institute for Technology (KIT)

Institute for Water and River Basin Management (IWG), Prof. Dr.-Ing. Dr. h.c. mult. Franz Nestmann
Institute of Concrete Structures and Building Materials (IMB), Prof. Dr.-Ing. Harald S. Mller
With contribution of KSB AG

Division for Hydraulic Services, Dr.-Ing. Jochen Fritz
Karlsruhe, 10.03.2015
Pre-Design
Content
1
Introduction ...................................................................................................................................... 4
1.1
Background and objective of the document .......................................................................... 4
1.2
Summary of the planned pilot system for hydro power driven water pumping and
distribution (Concept 1) ......................................................................................................... 5
1.3
2
1.2.1
Motivation and objective ......................................................................................... 5
1.2.2
Hydro power driven water pumping module at Seo Ho HPP for water conveying
to Ma U ................................................................................................................... 6
1.2.3
System to distribute water from Ma U to the supply area Dong Van City ............ 10
1.2.4
Systems to distribute water from Ma U to the supply areas Sang Ma Sao and
North Slope .......................................................................................................... 12
Overview of the measures described in the Pre-Design ..................................................... 12
Specification of measures .............................................................................................................. 14

2.1
2.2
2.3
2.4
2.5
Weir and intake structure ..................................................................................................... 14

2.1.1
Location and present state ................................................................................... 14
2.1.2
Description of measures ...................................................................................... 15
2.1.3
Materials and services ......................................................................................... 16
Sand trap ............................................................................................................................. 16

2.2.1
2.2.2
Description of measures to minimize water losses and to prevent flotsam entry

into the headrace channel .................................................................................... 17
2.2.3
Description of measures to improve the sediment deposition capacity ............... 18
2.2.4
Headrace channel ............................................................................................................... 25

2.3.1
2.3.2
2.3.3
Intake pool ........................................................................................................................... 28

2.4.1
2.4.2
2.4.3
Penstock bypass to PAT-pump-modules ............................................................................ 39

2.5.1
2.5.2
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2.5.3
2.6
2.7
2.8
2.9
Extension of power house and tailwater pool ...................................................................... 50

2.6.1
Location of power house extension ..................................................................... 50
2.6.2
2.6.3
Machinery and equipment ................................................................................................... 56

2.7.1
2.7.2
Pressure supply pipe ........................................................................................................... 60

2.8.1
Location ................................................................................................................ 60
2.8.2
2.8.3
Material and services ........................................................................................... 77
Distribution tank Ma U ......................................................................................................... 81

2.9.1
Location ................................................................................................................ 81
2.9.2
Functionality ......................................................................................................... 82
2.9.3
2.9.4
2.10 Distribution from the tank Ma U to the tank Dong Van City ................................................. 91
2.10.1
Location ................................................................................................................ 91
2.10.2
2.10.3
Materials and services ....................................................................................... 100
2.11 Storage tank Dong Van City .............................................................................................. 103

2.11.1
Location .............................................................................................................. 103
2.11.2
Description of measures .................................................................................... 104
2.11.3
2.12 Distribution from the tank Dong Van City to the existing network of Dong Van City ......... 112
2.12.1
Location .............................................................................................................. 112
2.12.2
Description of measures .................................................................................... 112
2.12.3
Summary of materials and services ............................................................................................. 119
Time schedule .............................................................................................................................. 126
Attachment A
Isometric drawings of penstock bypass
Attachment B
Isometric drawings of pressure supply pipe
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Pre-Design
1
1.1
Introduction
Background and objective of the document
September 2013 marks the beginning of the Vietnamese-German Cooperation for the Development of
Sustainable Karst Water Technologies (KaWaTech) funded by the Vietnamese Ministry of Science
and Technology (MOST) and the German Federal Ministry of Education and Research (BMBF). The
joint R&D-project is scheduled until August 2016.
th
On 19 of February 2014 the Vietnamese and German partners agreed on implementing a pilot
system for hydropower driven water pumping and distribution based on a novel technical concept
the so called Concept 1 (see Minutes of Discussion from 19.02.2014 and Reconfirmation Document
from 27.02.2014). The draft of Concept 1 contains the implementation of a hydropower driven water
pumping module at the existing Seo Ho hydropower plant (later referred to as Seo Ho HPP) to partially
pump up the rivers water to the village of Ma U. This water supply system shall be characterized by
high efficiency and robustness as well as by low operation and maintenance costs and effort in order
to enable a sustainable long-term operation. Furthermore, the draft includes the construction of a new
storage and distribution tank at Ma U as well as of new distribution facilities. Hereby, starting from the
tank, water might be distributed to the three supply areas Dong Van City, the villages around Sang Ma
Sao and the villages northeast of Dong Van City (see Fig. 1).
In line with the decision on the pilot implementation the partners also agreed on a task distribution as
well as on a preliminary implementation schedule (see Minutes of Discussion from 19.02.2014 and
Reconfirmation Document from 27.02.2014). In principle, the German partners are responsible for
developing the technical concept, the Bill of Quantities and the successive Pre-Design.
Furthermore, they are in charge for the development, testing and provision of the innovative
water pumping modules including their transport to Vietnam. In addition, they support the
implementation through expert monitoring with temporary technical accompaniment on site
and the accomplishment of capacity development measures. The Vietnamese partners are
responsible for preparing the Final Engineering Design as well as for the accomplishment and
financing of the successive construction and implementation works including the provision of
materials and transport to the construction site, custom duties and domestic transport for
materials delivered to Vietnam by the German partners.
The construction start of the system parts Seo Ho HPP Tank Ma U Dong Van City (see section
1.2.2 and 1.2.3) is planned for summer 2015. The implementation of the facilities to distribute water to
the villages around Sang Ma Sao and to the villages northeast of Dong Van City (see section 1.2.4)
could commence at the same time or at a later date.
The Bill of Quantities for the pilot implementation of a hydro power driven water pumping and
distribution system (Concept 1) (later referred to as Bill of Quantities) was handed over for budget
planning of Concept 1 in June 2014 from the German to the Vietnamese partners. At the end of
October 2014 the German partners received the message via VIGMR that the financing had been
approved. The present document Pre-Design for the pilot implementation of a hydro power driven
water pumping and distribution system (Concept 1) (later referred to as Pre-Design) is based on this
document. However some sections of the present Pre-Design include comprehensive updates. For the
preparation of this present document additional field trips to Dong Van in July/August 2014 and
November 2014 and laboratory investigations were carried out by KIT.
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Pre-Design
The scope of this present document is to provide a pre-design including specific data which
can be used by the Vietnamese partners for preparing the Final Engineering Design. The
development of this Final Engineering Design by the Vietnamese partners has to consider the
national standards, the actual local boundary conditions, the provision of materials, custom
duties, the domestic transport and the execution of the construction works. Both the PreDesign and the Final Engineering Design shall be comprehensively reviewed by the German
and the Vietnamese side in order to develop a collaborative project plan resp. plan of measures
considering all relevant influencing factors.
The basic concepts of the planned pilot implementation are explained in more detail in section 1.2.
The necessary measures are outlined in section 1.3 and specified in section 2. The bill of materials is
stated in section 3 and refers to the measures described within this pre-design. The preliminary time
schedule is shown in section 4.
1.2
1.2.1
Summary of the planned pilot system for hydro power driven water
pumping and distribution (Concept 1)
Motivation and objective
In the area of Dong Van Karst Plateau water supply is insufficient due to the regional topographic,
climatic, hydrological and geological conditions. Because of the karst underground in the mountainous
region and its high infiltration rate, most water bodies of the region are found only in complex cave
systems or deep valleys, making its usage difficult for the regions inhabitants. In combination with the
typical concentration of rain over three to four months in summer, this leads to a glaring lack of water
in the region, especially in the dry months. The Dong Van Karst Plateau was declared Global Geopark
assisted by UNESCO in 2010. While the expected resulting increase in tourism in the region offers
opportunities for economic development, it will also increase the water demand and, thus, worsen the
already existing problem of water scarcity.
Especially in such climates with a distinctive dry season, small and micro hydropower plants without
seasonal reservoir often can only be operated in low partial load ranges with greatly reduced efficiency
grades due to low available discharges. As a consequence, power plants with low economic or
mechanical efficiency are temporarily shut down during dry periods. During these shutdown periods,
precious water for both power generation as well as for water supply remains unused. The scope of
the KaWaTech project is to develop a hydro power driven water pumping module to exploit the
remaining unused water quantities for pumping and supply (Concept 1).
It is planned to realize a pilot implementation of Concept 1 at the existing Seo Ho HPP, which is
situated at 705 meters above sea level (masl). By mechanically coupling reverse driven pumps, which
then function as turbines (Pump as Turbine, PAT), to high pressure water pumps, water can be
delivered from Seo Ho HPP via a high pressure supply pipe to a distribution tank in the village of Ma
U, situated on a mountain ridge at 1,250 masl. From there, the water will be distributed by an
innovative system of pipelines and storage tanks to the main town of the area, Dong Van City, the
villages surrounding Sang Ma Sao (supply area Sang Ma Sao) and the villages northeast of Dong Van
City (supply area North Slope). Due to the extreme topography and the associated high delivery heads
of up to approx. 550 m, requirements regarding machinery and supply pipes are high. Fig. 1 outlines
the situation. The hydro power driven water pumping module at Seo Ho HPP including the supply pipe
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to Ma U is described in more detail in the next section 1.2.2. The planned system to distribute water
from Ma U to the supply areas Dong Van City, Sang Ma Sao and North Slope is described in the
subsequent sections 1.2.3 and 1.2.4.
Fig. 1: Map of Seo Ho HPP area Layout of the measures in the project area
1.2.2
Hydro power driven water pumping module at Seo Ho HPP for water conveying to Ma U
Fig. 2 illustrates schematically the infrastructure of the existing Seo Ho HPP as well as the main
components of the planned hydro power driven water pumping system. Fig. 3 shows the vertical
profiles of the existing penstock and the supply pipe to the distribution tank Ma U.
Fig. 2: Major components of the planned hydro power driven water pumping system (additional components to be
constructed are printed in blue; existing components to be restored/modified in red)
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Fig. 3: Vertical profiles of the existing penstock and the supply pipe
The intake structure, which is situated on the weir crest, diverts water from Seo Ho River into the sand
trap. After passing the two sand trap basins, the water runs mostly underground through the headrace
channel into the intake pool. The lateral overflow of the intake pool is used to purge water in case the
available amount exceeds the amount required for machinery operation. From the intake pool, the
water runs into the penstock, where it is conducted to the existing turbines (see section 2.1 - 2.4).
As described in this present document, the penstock could be connected to new PAT-pump-modules
by a branch-off pipe (penstock bypass), which can be implemented according to the draft shown in
section 2.5. In order to secure these pumping modules, the existing powerhouse of Seo Ho HPP might
be extended (see section 2.6). Here, a pipe system feeds the two modules, each consisting of a PAT
and a pump.
The machines will be mechanically coupled, meaning that the energy generated by the PAT is
transmitted directly to the pump without the need of intermediate conversion to electrical energy (see
section 2.7). From the PATs, the water will be discharged into a tailwater pool and then flow back into
Seo Ho River through an open channel (see section 2.6). According to this concept, the water from the
pumps will run through a new high pressure supply pipe with approximate length of approx. 2,460 m to
a new distribution tank situated in the village Ma U, overcoming a total height difference of approx.
550 m referring to Seo Ho HPP (see section 2.8). Fig. 4 shows the flow system in the existing
powerhouse and the new extension building.
According to preliminary design approaches, the water supply machinery to be installed next to Seo
Ho HPP will consist of two identical modules, each using a KSB Multitec (multistage centrifugal pump)
with 5 stages as PAT (efficiency approx. max = 71 %) and a KSB Multitec with 16 stages as pump
(efficiency approx. max = 69 %). Each module has a total design flow (discharge PAT and pump) of
approx. Qtotal = 54 l/s including a design delivery rate of approx. Qpump = 11 l/s.
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Compared to the PAT-driven modules Seo Ho HPP shows a lower maximum total efficiency of
max = 63 % (efficiency of turbines and generator). In low partial load operation (discharge below
100 l/s) the plants efficiency even decreases to 49 57 % (calculation by KIT based on on-site
measurements). To supply water with the electricity generated by Seo Ho HPP, an electric motor is
required which is also afflicted with energetic losses (maximum efficiency of a new electric motor
suitable for this application at 93 95 %) and further decreases the total efficiency. Thus, at
discharges below 100 l/s the PAT-driven modules can be operated more efficiently instead. Here,
besides the above mentioned efficiencies for PAT and feed pump no more energetic losses will occur
due to the direct coupling of both machines.
Fig. 4: Current draft of the flow schematics inside the power house and the extension building
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In this regard the parallel setup of 2 modules is particularly advantageous since they can be operated
in single or in dual mode to cover a wide range of lowest discharges (see Fig. 5). Hereto, a throttling
device for both modules is included in the design to cover these low flow rates. Thus different
operational strategies are possible depending on the available water yield.
Fig. 5: PAT-pump-module and pump discharge diagram
Single module operation: The operation of 1 module requires a total minimum flow of approx. 42 l/s
(fully throttled down) to approx. 54 l/s (not throttled) delivering approx. 6 l/s (fully throttled down) to 11
l/s (not throttled). With the use of the throttling device, water pumping operation is ensured even in
times of extreme drought (which coincides with very high water demand of the local people).
Dual module operation: The operation of 2 modules requires a total minimum flow of approx. 83 l/s
(fully throttled down) to approx. 105 l/s (not throttled) and will net a delivery rate of approx. 11 l/s (fully
throttled down) to 20 l/s (not throttled). This operation mode is depending on a sufficient water yield
but shall be used in times of high water demand in the supply areas. According to data analyses and
measurements carried out by KIT in the last three years, the minimum runoff of Seo Ho River during
dry season amounted approx. to 100 - 120 l/s. This would be sufficient to operate both modules.
Parallel operation to Pelton turbine: Due to the low total flow required to operate a single module,
parallel operation of a module and a turbine (if requested) should be feasible throughout the whole
year. The minimum flow to operate one Pelton turbine is approx. 65 l/s. In addition to the necessary
discharge of 54 l/s for a PAT-pump-module (not throttled), the total required discharge of approx.
119 l/s corresponds to the average dry season runoff of 100 - 120 l/s (average value in the period the
last three years).
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Within the stated discharge ranges the PAT-driven water supply plant can be operated highly flexible
regarding the prioritization of water supply and/or generation of electricity. Depending on the
respective demand the operating personnel can decide at any time if the works water shall be used for
water supply and/or generation of electricity.
In summary, the planned system has the following advantages:
High level of operating reliability even during extreme dry periods with minimal discharge
Redundancy concerning damage or malfunction of single machines and/or components
Interchangeability of (spare) parts
Low maintenance and training requirements
Low complexity of the control system
Parallel operation of PAT-pump-module and turbine possible throughout the whole year
Flexibility of control and regulation as well as towards future water demand increases
PAT efficiency exceeding the Pelton turbines efficiency
1.2.3
System to distribute water from Ma U to the supply area Dong Van City
Fig. 6: Overview project area with the supply system
To distribute the pumped water from the tank at Ma U to the supply areas technically robust solutions
were developed which basically do not require any daily operation effort (self-running system).
Furthermore the solutions allow a planned limitation of the water quantities distributed. Thus, the
consumers are able to only realize withdrawals not higher than the water quantity allocated to the
consumers. This enables an equitable distribution of the available water resources. The distribution to
Dong Van City is described in the following.
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The tank at Ma U has two functions. It has a certain storage capacity to buffer the variations between
inflow and outflow. In order to distribute certain proportions of the inflow to the supply areas, the tank
furthermore serves as a facility to divide the inflow proportionally into three defined outflows to the
supply areas Dong Van City, Sang Ma Sao and North Slope.
The tanks construction sees a pre-chamber which collects the total inflow (water pumped from Seo
Ho HPP). The pre-chamber has three weirs. The weir overflows are collected in three chambers from
which the water is distributed through pipes to the supply areas. The allocation of the inflow to the
three chambers and, thus, the definition of the proportion of the inflow, each supply area is supplied
with, can be flexibly defined by choosing the width of the weirs (weir overflow/total inflow = weir
width/total weir width). The advantage of that solution is the fact that the varying inflow is proportionally
allocated to the supply areas without any daily operation.
Fig. 7: Unscaled scheme of the storage tank at Ma U
It is planned to distribute the water to the supply areas according to the prevailing water demand within
the supply areas. The main share will be distributed to Dong Van City via a supply pipe to a storage
tank above Dong Van City. The tank is connected to the distribution network of Dong Van City (close
to the existing pumping station). The elevation of the tank of 1,123 masl above Dong Van City allows a
supply of Dong Van City by gravity. The system input and pressure is controlled by a plunger located
at the connection point. The outflow pipe to the distribution network may be constantly open. The
installed house tanks with floating valves within the distribution network prevent wastage of water at
the consumer level. To limit the pipe pressure due to the elevation difference between the tank at Ma
U and the tank above Dong Van City a pressure breaker facility has to be installed. This facility
basically is a small tank.
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Fig. 8: Unscaled scheme of a pressure breaker with floating valve
The pressure breaker and the tank Dong Van are equipped with floating valves to control the inflow
into the tanks. Whenever the water level within the tank Dong Van reaches its maximum the floating
valve stops the inflow and prevents tank overflow. The water level of the pressure breaker rises until
the according floating valve stops the inflow. Finally the water level within the according chamber of
the tank Ma U rises. Possibly it reaches the weir height and water level within the pre-chamber
respectively. In this case the water not used in Dong Van City is distributed to the other supply areas.
In case the existing elevation difference between the tank Ma U and Dong Van City shall be exploited
for hydro power generation someday in future the planned pipe infrastructure may be used. The
pressure breaker then simply has to be by-passed.
1.2.4
Systems to distribute water from Ma U to the supply areas Sang Ma Sao and North Slope
To supply the villages around Sang Ma Sao a new distribution tank is connected via a pipe to the
according chamber of the tank in Ma U (see section 1.2.3). The distribution tank consists of a prechamber and two chambers. The functioning of the proportional allocation of the water works like the
tank in Ma U by weirs which is described in section 1.2.3. One chamber serves as storage for the
population and the school of Sang Ma Sao. The second chamber supplies the already existing three
village tanks.
To supply the 12 villages northeast of Dong Van City within the so called supply area North Slope a
pipe connects four distribution tanks to the according chamber of the Ma U tank. The design and the
operation of the distribution tanks are equal to the one in Sang Ma Sao. One chamber of each
distribution tank supplies village tanks and the second chamber the next distribution tank. In most
villages already existing village tanks and pipes can be integrated into the distribution system. The
village tanks have to be equipped with floating valves. These would close the inlet if the tank is full.
Thus, the water which is not needed in one village is available for other villages.
1.3
Overview of the measures described in the Pre-Design
In the following Fig. 9 an overview of the measures and its location is given. The specification of each
measure can be found in section 2.
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Fig. 9: Overview of the measures and its location

Tab. 1: Overview of the measures in the project area (see Fig. 9)
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Section of the measure

2.1 Weir and intake structure
2.2 Sand trap
2.3 Headrace channel
2.4 Intake pool
2.5 Penstock bypass to PAT-pump-modules
2.6 Extension of power house and tailwater pool
2.7 Machinery and equipment
2.8 Pressure supply pipe
2.9 Distribution Tank Ma U
2.10 Distribution from the tank Ma U to the tank Dong Van City
2.11 Storage tank Dong Van City
2.12 Distribution from the tank Dong Van City to the existing network of Dong Van City
2.13 Distribution to the supply area Sang Ma Sao, see annotation
2.14 Distribution to the supply area North Slope, see annotation
Annotation: The specification of the measures 13 and 14 are not part of this Pre-Design
document. These will be handed in later.
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Specification of measures
Important note:
In this chapter the measures for the implementation of concept 1 are specified. For sections 2.2 and
2.4 it has to be noted that some measures are optional and have to be implemented only on
demand. The chronological dependencies between the construction measures, which are described in
detail in sections 2.5 to 0, have to be respected during the planning and implementation process. In
section 4 a time schedule is shown which summarizes all single implementation steps.
2.1
2.1.1
Weir and intake structure

Location and present state
The weir is the part of the hydro power plant which shows the most severe damages. It is located in a
steep part of the valley, shortly before the river overcomes a height difference of 200 m through
various cascades. The weir is a conventional overflow weir with a height of 5.8 m and a width of 17 m.
On the right side of the weir crest (in flow direction), there is an intake structure consisting of an inlet
channel, which directs water to the sand trap (see Fig. 10). The channel is covered by a metal grid
with a width of 0.5 m and a length of 5 m. This racks rods have a clearing of approx. 3 cm and prevent
larger bed loads and other solid materials to enter the sand trap and the headrace channel,
respectively. According to the construction plans, the channel has a declination of 13.2 % and a depth
between 0.30 and 0.86 m.
Fig. 10: Weir and intake structure (5.12.2014, KIT)
The weir is subdivided in the middle in two parts with different geometry. The right part with the intake
channel has a length of 8.5 m and an inclination of 45. The other side also has a length of 8.5 m but
an inclination of 55 with a step at its end. The weir crest and the weir backs do not show a hydro-
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dynamically optimized form. The structure does not consist completely of concrete, but shows a core
of raw and crude limestone stuck together, similar to prepacked concrete which is covered with a top
layer of concrete. A crosswise reinforcement of flat steel bars with a diameter of 8 mm in a distance of
100 mm was detected.
In the steeper part of the weir, an additional layer of concrete was apparently applied on the weir crest
at a later point of time, probably to restore the original crest height after strong erosion processes.
However, that layer is separated with an aquiferous crack over the whole length from the concrete
underground (see Fig. 11).
Fig. 11: Undermined weir part on the

right side of the weir (5.12.2014, KIT)
Fig. 12: Hydro abrasion on weir back (5.12.2014, KIT)
The whole weir shows severe damages due to hydro-abrasion and water undermining. Further, the
wall on the right side was recently damaged by a rock fall. The weir crest is heavily eroded, the
reinforcement partly not covered by concrete anymore.
The same can be stated for the weir back, where the concrete cover and even partly the reinforcement
are ground down on the whole width by hydro-abrasion. This is particularly apparent in the middle of
the weir where the concrete cover is completely gone and the rock core opened (see Fig. 12).
2.1.2
Description of measures
The intake structure is an integral part of the hydro power plant and is part of the weir. Therefore, as a
first step it is reasonable to secure the weir structure against any further damages which could result in
an impairment of the intake structure. This includes particularly the stabilization or reconstruction,
respectively, of the weir base on the right side to prevent a future slipping of the weir.
This measure could be realized similar to the construction of the present structure (compare Fig. 9)
with the usage of prepacked concrete. The omnipresent raw limestone aggregates are assembled at
the beginning without mortar to form the raw shape of the intended weir structure.
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The aggregates generally should have a medium diameter between 80 and 150 mm. They can
originate from karst limestone quarries near to the site or can be even collected directly from the
surrounding of the site. These raw aggregates should be slightly fractionized and stuck together with
cement mortar to form the chosen structure, which should be subsequently covered with a layer of
crosswise reinforced concrete.
2.1.3
Materials and services
Tab. 2: List of materials and services for measures at the weir and intake structure
Position
2.1
2.2
2.3
2.2
2.2.1
Materials / services and description

Transportation of materials to construction site
Excavation of the weir base area on the right side (limestone can be partly
used for reconstruction of the weir base)
Stabilization of the weir basis with prepacked concrete and reinforced
concrete, respectively
Amount
1
10
Unit
ls
m
20
Sand trap
From the intake structure on the weir crest, the water flows into the sand trap. The sand trap consists
of two long and narrow basins, measuring 17 and 14 m in length with a minimum width of 1.4 m. The
construction is separated in the middle with a cross-section constriction, which once kept a sluice gate,
but now is constantly open. The sand trap is bordered by a high and steep wall against the mountain
slope on the right side, on the left side by masonry with a width of 50 cm starting from the ground. This
results in a depth of the sand trap between 2.1 and 3.5 m. The masonry built out of raw limestone is
plastered with a cement mortar.
The first basin of the sand trap has a length of 14 m and a width of 1.4 m. Originally several
crossbeams made out of reinforced concrete were arranged 1 m below the wall crest to support the
right wall and probably to act as bearings for a channel ceiling. However, most of the beams were
destroyed by rock fall. The second basin has a length of 17 m and a starting width of 1.8 m, but
passes over at its end in a square basin with an edge length of 4 m. On the right side at the end of the
second basin, there is the intake opening to the headrace channel with a size of 60 70 cm (W x H).
Steel sluice gates are installed in both basins on the left side to allow emptying and sediment flushing.
The pools are overall seen in a sufficiently good structural condition and show, besides some
vegetation covering, no essential damages. An exception can be seen in the first basin, where both
the left and the right wall were damaged by a serious rock fall. Parts of the masonry were torn down
and a rock remained situated on the masonry (see Fig. 13). The mentioned cross-beams were
probably also destroyed due to this event. However the resulting debris in the sand trap was removed,
so that no further loss of its functionality currently exists. Other damages can be observed at the sluice
gate in the second basin, where the anchorage is broken out (see Fig. 15). The other sluice gate
shows no such damage, probably due to the larger width of the wall resulting in a bigger load
distribution area. Significant water losses (20 to 30 l/s measured during a field trip in February 2014)
can be observed at the sluice gates as the gates are not closing correctly, with remaining gaps on the
channel bed and on the lateral guidance of the gates.
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Fig. 13: Sand trap, view from upstream (5.12.2013, KIT) Fig. 14: Sluice gate of second pool (25.02.2014, KIT)
2.2.2
Description of measures to minimize water losses and to prevent flotsam entry into the
headrace channel
To minimize water losses and to improve the yield of the plant, especially during dry seasons,
leakages at the sluice gates have to be avoided. Therefore, the gate structures have to be examined
and restored to a proper functionality, sealing any gaps in the gate channel bed and the lateral
guidance. Additionally, concrete rehabilitation works are necessary at the gate anchorage structures.
Fig. 15: Broken sluice gate anchorage (13.12.2014, KIT) Fig. 16: Water losses from gate (13.12.2014, KIT)
To prevent flotsam entering the headrace channel respectively the intake pool and penstock a trash
rack has to be installed between the outlet of the sand trap and the intake of the headrace channel.
Fig. 17 shows the current state of the headrace channels intake, Fig. 18 a sketch with the
modification. The trash rack rods should have a round profile with a diameter of approx. 2 cm. The
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spacing of the rods to each other should be approx. 6 to 8 cm. The trash rack itself should have a
leaning slope of 70 to 80 relative to the horizontal, should be side-mounted with hinges and lockable
e.g. with padlock. Thereby it can be opened for cleaning purpose and to access the headrace channel.
The trash rack should be embedded on a box of concrete or stonework and a metal plate (see Fig.
18). All metal parts of the trash rack should be rust-proof.
The trash rack should be installed on a concrete foundation made out of prepacked concrete. The
ground structure of limestone should be covered by a layer of reinforced concrete. The principal
construction method is explained in section 2.1.2.
0.7 m
0.85 m
Fig. 17: Current state of headrace channel intake

(25.02.2014, KIT)
2.2.3
Fig. 18: Intake of headrace channel intake after

modification with trash rack
Description of measures to improve the sediment deposition capacity
2.2.3.1 Background information sediment deposition capacity

Suspended loads are mineral or organic particles that are carried by water. Concentration and grain
size of suspended loads in works water of hydropower plants are significant parameters for the
durability of turbines and pumps. Medium to long-term exceedance of limiting values of those
parameters can cause hydro-abrasional damage to the machinery. To protect the intended PATpump-modules (developed and delivered by KSB AG), it is necessary to comply with the following limit
values, which match with the common requirements for high-pressure hydro power plant applications:
-
Maximum suspended load concentration:

Maximum grain size of suspended load:
20 mg/l
0.25 mm
Page 18 / 127
Pre-Design
2.2.3.2 Evaluation of critical grain size

Sand trap and intake pool are located upstream to the intended PAT-pump-modules and have a
sediment deposition capacity which is depending on their geometric dimensions. Thereby those
structures can help to comply with the above stated limiting values. Hereto the critical grain size of
existing sand trap and intake pool was evaluated by KIT applying theoretical analysis approaches of
1
2
Vischer & Huber and Ortmanns . Generally, suspended grains, which are smaller than a certain
critical grain size, cannot be fully withheld inside a hydraulic structure; in the present case they would
partially enter the penstock. The mentioned approaches consider the settling path of a suspended
grain and the necessary sedimentation basin length (see schematic diagram in Fig. 19). Thereby the
approach of Vischer & Huber takes into account the reduction of the settling velocity caused by basic
turbulence which generally characterizes open channel flows. Ortmanns considers in addition the
turbulence impact in the inlet zone of a sedimentation basin.
Fig. 19: Simplified settling path of a suspended grain
With a discharge of Q = 400 l/s (max. hydraulic capacity of the headrace channel, calculated by KIT
based on on-site measurements including safety margins), an effective sand trap dimension of 15 x
1.4 x 0.8 m (L x W x H) and an effective intake pool dimension of 6.5 x 2.1 x 2.7 m (L x W x H), the
critical grain size can be determined with both approaches as shown in Tab. 3.The effective dimension
of the basin neglects the basins edge areas due to their reduced sediment deposition capacity.
Tab. 3: Critical grain size of sand trap and intake pool (the inlet area is hereby not considered)
Approach
Sand trap
Intake Pool
Vischer & Huber
~ 0.5 mm
~ 0.3 mm
Ortmanns
~ 0.4 mm
~ 0.7 mm
Vischer und Huber, Wasserbau: Hydrologische Grundlagen, Elemente des Wasserbaus, Nutz- und
Schutzbauten an Binnengewssern. Publishing house Springer 2002
2
Ortmanns, Entsander von Wasserkraftanlagen. Publishing house Versuchsanstalt fr Wasserbau,
Hydrologie und Glaziologie ETH-Zentrum 2006
Page 19 / 127
Pre-Design
For these results it has to be considered that both approaches have been empirically developed and
entail uncertainties. However they lead to the conclusion that the limiting values for the maximum grain
size cannot be complied with the existing sand trap and intake pool of the Seo Ho HPP.
For further evaluations of the sediment deposition the KIT carried out in situ investigations of the
suspended loads and their concentration during field trips to Dong Van in July/August and November
2014. These investigations by the KIT-Institute for Water and River Basin Management (IWG,
KaWaTech-sub-project 1) were comprehensively supported by departments of KITs Institute for
Applied Geosciences, namely the Department of Hydrogeology (AGW, KaWaTech-sub-project 2) and
the Department of Aquatic Geochemistry (IMG, KaWaTech-sub-project 3). Fig. 20 exemplarily shows
a microscopic enlargement of suspended loads of works water from the Seo Ho HPP which was
extracted directly before the penstocks entrance. These investigations reassure that the limiting
values for the maximum grain size cannot be complied with the existing hydraulic infrastructure.
Fig. 20: Microscopic enlargement of suspended sediments of the works water of Seo HPP (16.01.2015, KIT)
2.2.3.3 Evaluation on suspension concentration

Additional in situ investigations of the suspended load concentration were carried out during field trips
to Dong Van in July/August and November 2014. In the November field trip an advanced method was
additionally applied to measure the suspended load concentration. Fig. 21 and Fig. 22 show the
results of these investigations complemented by discharge measurements. These results show that
the suspended load concentration complies with the limit value of 20 mg/l at most measurements.
th
nd
Only in the period from 20 to 22 of July the limit was exceeded significantly (see Fig. 23). Further
investigations lead to the conclusion that in this period serious rainfall events in the Dong Van region
took place causing the exceedance of the limiting values. This context will be evaluated by further data
st
acquisition and analysis in the 1 term of 2015. Based on current insights it can be assumed that the
limiting value for the suspension load concentration is exceeded temporarily during the main rain
season triggered by serious rainfall events.
Page 20 / 127
Pre-Design
Fig. 21: Suspended load concentration and discharge July/August 2014
Fig. 22: Precipitation data of measurement stations in Lung Phin and Ta Phin
Page 21 / 127
Pre-Design
Fig. 23: Suspended load concentration and discharge November 2014
2.2.3.4 Summary of evaluation results and measures to improve sediment deposition capacity
The evaluation of the sediment deposition capacity of Seo Ho HPPs existing hydraulic flow system
has shown that it cannot fully comply with the given limiting values for the tolerable suspended load
concentration and grain size.
To ensure high life expectancy of the machinery the sediment deposition capacity has to be improved.
The related technical and financial effort could be minimized by a successive approach. After
implementation of a first measure (test stage) at the intake pool (see section 2.4.2.2) and the
successive evaluation of the achieved improvements a decision is to be made if further improvements
are required.
If a further improvement is necessary the implementation of additional measures at the intake pool
(see section 2.4.2.3) has to be accomplished. If (against current expectations) even these measures
are not fully sufficient the implementation of optional measures at the sand trap (see section 2.2.3.5)
has to be considered. The successive approach is shown schematically in Fig. 24.
The suspended load concentration of the works water can be reduced significantly due to the in
sections 2.2.3.5, 2.4.2.1 and 2.4.2.2 described measures. However, with an appropriate effort it cannot
be supposed to achieve a sufficient retention of very high loads of suspended sediment caused by
extreme rainfall events. Therefore, the installation of a warning system is planned to temporarily shut
down the water supply system in case of extreme discharge events (see section 2.7). This warning
system will be included in the water supply facilitys controlling system, which will be developed and
implemented by KIT.
Page 22 / 127
Pre-Design
Fig. 24: Successive approach to improve the sediment deposition capacity of Seo Ho HPPs hydraulic system
2.2.3.5 Optional measures to improve the sediment deposition capacity of the sand trap
The measures described below are optional in case the settling efficiency of the intake pool
cannot be increased sufficiently (see sections 2.4.2.2 and 2.4.2.3). The implementation is hence
st
only on demand and could take place in the 1 term of 2016. Therefore they have to be taken
into account in the budget, but not yet into the Final Engineering Design. These measures
contain the removal of the restriction between basin 1 and 2 and the enlargement of basin 2.
DRAFT
Enlargement
of basin 2
Removal of
restriction
Fig. 25: Sketch of the sand trap with top view after optional modification to improve sediment deposition capacity
(implementation only on demand)
Page 23 / 127
Pre-Design
The restriction between basin 1 and 2 is a control cross section, which can be used to determine the
discharge at this point. However, the restriction decreases the sediment deposition capacity due to a
local increase of the flow velocity, which interrupts the process of deposition. A removal of the
restriction eliminates this local acceleration and thereby increases the sediment deposition capacity of
the sand trap. An enlargement of basin 2 elongates the possible sedimentation path and by that also
increases the sediment deposition capacity.
Fig. 25 shows a sketch of the sand trap after the described optional modification. In case of necessity
to carry out these optional measures a further Pre-design will be delivered from German side.
2.2.4
The list of materials below (Tab. 3) is mandatory to implement the required measures described
in section 2.2.2 and is within the responsibility of the Vietnamese partners.
Tab. 4: List of materials and services for measures to improve the sediment deposition capacity of the sand trap
Position
4.1
4.2
4.3
4.4
4.5
4.6

Sealing of gaps in gate channel bed and lateral guidance of the
sluice gates
Detailed localization and excavation of the existing gaps
Roughening of the concrete surfaces
Fitting and installation of steel parts
Application of new concrete layer
Steel parts for gate channel bed and lateral guidance of the sluice gates
Rehabilitation of the anchorage of the sluice gate in basin 2
Excavation of the existing breaks-offs
Roughening of the concrete surfaces
Application of new reinforced concrete to restore the area
Re-installation of sluice gate
Trash rack
Concrete foundation for the new trash rack
Amount
1
2
Unit
ls
ls
2
1
ls
ls
1
1
ls
m
The list of materials below (Tab. 5) is within the responsibility of the Vietnamese partners and
is optional in case the sediment deposition capacity of the intake pool cannot be increased
sufficiently (see sections 2.4.2.2 and 2.4.2.3). Therefore they have to be taken into account in
the budget, but not yet into the Final Engineering Design.
Tab. 5: List of materials and services for optional measures at the sand trap
Position
5.1
5.2

Removal of the restriction
Concrete excavation works
Concreting works to restore proper functionality
Enlargement of the sand trap basin 2
Soil excavation works
Concrete excavation works
Concreting of basin bed with reinforced concrete
Concreting of basin walls with reinforced concrete
Amount
Unit
3
1
m
m
16 - 32
4
5
12
m
m
m
m
Page 24 / 127
Pre-Design
2.3
2.3.1
Headrace channel
Fig. 26: Map of Seo Ho HPP area - Headrace channel
The headrace channel connects the sand trap with the intake pool and is constructed as a U-shaped
concrete channel with dimensions of 0.6 x 0.7 m (W x H). The continuously concreted channel is
covered by concrete slabs. It runs mostly underground and is only visible at 2 spots (see Fig. 27),
which both are within the first third of the total length (starting from the sand trap). According to the
construction plans, it has an inclination of 2 . With a levelling using the intake at the sand trap and
the above mentioned 2 visible spots as sampling points, the channels incline was validated by KIT. At
the beginning, the concrete slabs form the narrow path along the right side of the valley leading to the
intake pool (see Fig. 28). In the rear part however, the channel seems to be far deeper and is covered
completely with soil and rock to an unknown extent, so that the accessibility is not given anymore.
Although the construction materials stated in the construction plan, which are masonry plastered with
cement mortar and some concrete sections, could not be verified for the channels entire length, they
seem plausible taking into consideration the design of the sand trap. The distance between sand trap
and intake pool is 790 m, although the channel itself does not run directly into the intake pool. Instead,
a steel pipe of unknown length connects the intake pool with the headrace channel. The construction
plans of the hydropower plant state a channel length of 638 m. Due to the before mentioned facts, this
data could not be verified yet. The channels theoretical maximum hydraulic capacity was determined
with the Darcy-Weisbach equation. Therefore an inclination of 2 , a sand roughness of 3 mm and Ushaped channel dimensions with 0.6 x 0.7 m (W x H) with a clearance of 0.1 m to the slab was
applied. Based on these boundaries a maximum discharge of approx. Q max = 400 l/s was calculated
(this value is afflicted with uncertainties due to lacking data about the channels geometry and
inclination). However, due to the unknown condition of some sections of the headrace channel this
value is afflicted with uncertainties.
Page 25 / 127
Pre-Design
Fig. 27: Open course of the headrace channel with

accessible concrete slab cover (5.12.2013, KIT)
Fig. 28: Underground, inaccessible (covered) course

(5.12.2013, KIT)
A partly channel inspection has revealed that the channel surfaces are in a quite good condition (see
Fig. 29). However, the concrete ceiling slabs show cavities due to edge fractures and unplastered
joints which give way to intruding roots (see Fig. 30). The incoming roots cause critical obstructions of
the channel at several spots, which result in a drastically reduced hydraulic capacity. Additionally, the
root obstructions can lead to flotsam jam, reducing the hydraulic capacity even further (see Fig. 31).
Fig. 29: Clean headrace channel section (25.02.2014, SPEKUL)
Page 26 / 127
Pre-Design
Fig. 30: Root obstruction (25.02.2014, SPEKUL)
2.3.2
Fig. 31: Root obstruction and flotsam (25.02.2014,

SPEKUL)
The described damages are to treat straightforward by removing the root obstructions and
subsequently renewing the joints of the affected concrete slabs. To being able to carry out these
measures, the channel has to be opened over its whole length in regular intervals of approx. 70 m.
Therefore it is necessary to get an access to the channel even in the areas with a high covering on top
which concerns especially the second half of the headrace channel. For example, it would be
conceivable to build vertical manholes by installing stacked concrete rings to a height depending on
the respective covering on top of the channel (see Fig. 32).
Fig. 32: Illustration of the vertical manhole
Page 27 / 127
Pre-Design
The quantities stated in Tab. 6 refer to the number of revision openings, not the amount of concrete
rings. The intruding roots and accumulated waste or flotsam jam have to be removed entirely.
Subsequently the corresponding concrete slabs have to be lifted and put back in place with a new
filling of their joints. However, the most important point in this regard is the establishment of a regular
inspection and maintenance management system to avoid such damages in the future. Through
removal of the root obstructions and the accomplishment of regular maintenance ensure a proper
discharge efficiency of the head race channel and therefore an output of the PAT-pump-modules and
existing Seo Ho HPP corresponding to the respective design.
2.3.3
Tab. 6: List of materials and services for measures at the headrace channel
Position
6.1
6.2
6.3
2.4
2.4.1

Construction of inspection openings every 70 m
Soil and rock excavation for approximately 10 openings (e.g.
manholes)
Precast concrete rings (height 10 cm)
Inspection & maintenance of the whole channel
Removal of root obstructions and flotsam jams
Lifting of concrete slabs and renewal of joints where
necessary (amount unknown)
Amount
1
Unknown
due to
covering
of the
channel
Unit
ls
700
Intake pool
The intake pool is a transitional structure from the headrace channel to the penstock. It serves multiple
purposes: For provision of sufficient water in case of sudden changes in turbine operation (surge tank
function), to purge surplus water over a lateral overflow and last but not least for the detention of
sediments.
The intake pool has a length of 10.5 m, a width of 2.1 m and a maximum depth of 3 m. It is built of
reinforced concrete with a wall thickness of 0.3 m. The area above the connection to the penstock
pipeline is overbuilt with a concrete pavilion. The area between the 4 columns of the pavilion amounts
to 2.5 4.5 m and has a height of 2.5 m. The columns have a square cross-section with an edge
length of 0.22 m. On the left side (flow direction) of the intake pool, there is a 4 m long weir acting as
lateral overflow. Its crest shows some slight damages (break-offs), through which further water is lost.
This overflowing water is used by the operating personnel at Seo Ho HPP to monitor the water level
visually. The more narrow part in front of the intake to the penstock pipeline is closed over the whole
height with a trash rack to withhold flotsam. However, the rack is heavily damaged for unknown
reasons. The irregular openings are closed with a mesh network (see Fig. 37). On the left side of the
trash rack, there is a sluice gate which is used for flushing sediments out of the pool. Currently, the
installed gate causes water losses due to leakages (see Fig. 39). During the field trip in February
2014, a total water loss of 10 l/s caused by leakages at the gate was observed. Behind the trash rack
there is another sluice gate, by which the penstock pipeline can be closed.
Page 28 / 127
Pre-Design
Fig. 33: Map of Seo Ho HPP area - Intake pool
Fig. 34 - Fig. 42 show the current dimensions and state of the intake pool.
Fig. 34: Intake pool (22.07.2011, KIT)
Page 29 / 127
Pre-Design
Fig. 35: Intake pool (empty, upstream view)

(22.02.2014, KIT)
Fig. 36: Intake pool (empty, downstream view)

(22.02.2014, KIT)
Fig. 37: Intake pool damaged trash rack (22.02.2014,

KIT)
Fig. 38: Intake pool flushing sluice gate (22.02.2014,

KIT)
Page 30 / 127
Pre-Design
Fig. 39: Water losses from sluice gate at intake pool

(9.12.2013, KIT)
Fig. 40: Lateral overflow with break-offs at intake pool

(9.12.2013, KIT)
Fig. 41: 3D model of the intake pool (before modification, present state)
Page 31 / 127
Pre-Design
Fig. 42: Lateral overflow at intake pool (see Fig. 40), break-off dimensions [mm]
Damages can be particularly seen at the roof of the intake pavilion. Two holes in the roof and one in
the bottom result most probably from rock fall. Also the columns and the girders are seriously
damaged. The holes in the roof are smaller than the bottom hole with a diameter of approx. 0.45 m. It
displays the remaining reinforcement, while the concrete in this spot completely vanished (see Fig.
43). Also the concrete of the columns feet is partly broken out up to the middle due to reinforcement
corrosion which results in a total demolition of the cross-section (see Fig. 44).
Fig. 43: Hole in the bottom (5.12.2013, KIT)
Fig. 44: Destroyed column foot (5.12.2013, KIT)
The roof in this part of the pavilion is partly broken. Particularly the corner girders are in poor condition
so their connection to the columns and their load bearing capacity is not ensured anymore (see Fig.
45 and Fig. 46). Besides the pavilion, the pools structure seems to be in quite good condition
although some sintered cracks can be observed and the lateral overflow shows two small break-offs.
Page 32 / 127
Pre-Design
Investigations with a reinforcement detector at the walls of the intake pool revealed a crosswise
arrangement of the reinforcement in a distance of 0.2 m with a strong fluctuating concrete cover
between 25 and 65 mm (see Fig. 47). The determination of the compressive strength with a rebound
hammer gave a mean value of 46 MPa.
Fig. 45: Pavilion roof (1) (5.12.2013, KIT)
Fig. 46: Pavilion roof (2) (5.12.2013,

KIT)
Fig. 47: Wall of the intake pool with reinforcement arrangement (5.12.2013, KIT)
Page 33 / 127
Pre-Design
2.4.2
The measures at the intake pool focus on two objectives: Restore the functionality and increase the
sediment deposition capacity.
2.4.2.1 Measure to restore the intake pools functionality
To achieve this objective sustainably, the following measures are required: Restoring the lateral
overflow at the weir crest to ensure an even overflow height of the weir, examination and sealing of
gaps in the sluice gate channel bed and the lateral guidance, repairing or replacing of the trash rack to
prevent flotsam input into the penstock and complete demolition as well as reconstruction of the
pavilion as a protective construction against rock fall.
After the restoration of an even weir crest height of the lateral overflow, water discharge should be
avoided, since the full width will be overflowed. This concept interdicts the current method of visual
water level checking. It is therefore planned to install a water level monitoring device with radio
transmission to Seo Ho power house, where the water level will be shown on a digital display. This
system can also be used to display a warning signal in cases of impermissible low / high water level.
The necessary equipment for this system will be provided by the German project partners (see section
2.7). This monitoring method will be of great value both for water supply by the new facility as well as
for generating electricity applying the already existing Seo Ho HPP.
The new trash rack rods must have a rectangular profile with a thickness of 0.5 cm and a depth of at
least 3 cm. The spacing between the rods has to be 2 to 3 cm. The trash rack has to be bordered by a
metal frame and subdivided with horizontal metal beams in order to stabilize the construction. The
trash rack itself is to be mounted in the two vertical slots, which are embedded in the intake pool side
walls. The width of the trash rack has to be designed according to the distance between these two
slots. All used materials have to be rust-proof. Fig. 49 is showing a sketch of the new trash rack.
2.4.2.2 Measure to improve the intake pools sediment deposition capacity
In section 2.2.3.4 a successive approach is described to enhance the sediment deposition capacity of
Seo Ho HPPs entire hydraulic structure. The first measure of this approach focuses on the intake
pool. Suspended grains deposited underneath the height of the intake edge cannot enter the penstock
anymore (see Fig. 48 and Fig. 49). Therefore the height of this edge must be increased to improve the
pools sediment deposition capacity. A rounding of the intake zone as shown in Fig. 49 reduces locally
the vortex formation, homogenizes therefore the flow and by that improves the sediment deposition
capacity as well. While operating the Pelton turbines and PAT-pump-modules a water overlap of the
intake edge has to be at least 1.65 m (value according to state-of-the-art literature, including a safety
margin) to prevent the inclusion of air in the works water. This minimum water overlap was determined
3
with the approaches of Gordon .
The adaption of the intake zone in front of the penstock could be realized also with a kind of
prepacked concrete as its only function (from a structural point of view) is to bear the vertical forces
Heinemann und Feldhaus, Wasserbau: Hydraulik fr Bauingenieure. Publishing house Teubner 2003
Page 34 / 127
Pre-Design
resulting of the hydrostatic pressure load. The proportions can be seen in Fig. 49. However, minor
adjustments of these geometric values to the conditions on site might be required. As construction
material also the omnipresent karst limestone may be used. The core of the intake zone can be
composed of thoroughly cleaned limestone and a cement mortar. To reduce the mortar consumption,
the limestone should have minimal porosity and a regular shape to avoid cavities when building the
intake zone. The outer appearance of the ground structure must show an equal but rough surface with
5 to 10 mm deep grooves to enable a strong bond with the top mortar layer to be applied in the next
work step.
Before modification
Fig. 48: Cross-sectional downstream view of intake zone before modification
This mortar layer is applied on all surfaces of the intake zone with a layer thickness of 15 mm.
Subsequently, an appropriate reinforcement mesh is installed (e.g. with a layer of chicken wire) on
which a second mortar layer with a thickness of 10 mm is applied wet-on-wet before the hardening of
the first layer. This exterior plaster is intended to protect the core of the structure.
The measure described below regarding the installation of a baffle and 2 racks inside the
intake pool is financed and implemented by the German side. The measure will also be
optimized based on field investigations by the German side during the first term of 2015.
Therefore the baffle and 2 racks do not need to be included in the Final Engineering Design.
Due to the high flow velocity at the pools inlet in combination with the high incline of the pools inflow
area, the water entrance through a pipe, which is connected to the headrace channel, has a large
turbulence impact into the intake pool. This turbulence impact causes a very high heterogeneous flow
situation and thus also a low sediment deposition capacity. To improve this state the German side will
install a vertical hanging baffle and 2 racks in the first term of 2015 (see Fig. 50). The baffle in
combination with the 2 racks will enable spatial concentrated energy dissipation, which will lead to a
more homogenous flow situation and therefore to a higher sediment deposition capacity.
Page 35 / 127
Pre-Design
Water overlap of
intake edge
Intake
edge
After modification
Fig. 49: Cross-sectional downstream view of intake zone after modification
Baffle
Racks
Fig. 50: Cross section upstream view of the intake pool with installed baffle and 2 racks for reduction of the
turbulence impact
Page 36 / 127
Pre-Design
To prevent anthropogenic sediment and rubbish entry in the intake pool (e.g. due to playing children)
the entire inlet pool shall be surrounded by a fence including a gate (see Fig. 51). This measure is
within the responsibilities of the Vietnamese side.
Gate
Fig. 51: View on the intake pool after modification surrounded by an exemplary fence
The monitoring system mentioned in section 2.4.2.1 to keep the operating water level within a certain
range will be combined with a turbidity sensor. This sensor will be used to display an alert in case of
exceedance the limit for the suspension concentration caused e.g. by serious rainfall events. The
required measuring devices will be provided by the German project partners (see also section 2.7).
2.4.2.3 Optional measures to improve the sediment deposition capacity of the intake pool
The measures described in this section are optional in case the tasks explained in section
2.4.2.2 do not increase the sediment deposition capacity of the intake pool sufficiently.
Therefore they have to be taken into account in the budget, but not yet into the Final
nd
Engineering Design. The implementation is only on demand and could be carried out in the 2
term of 2015.
Fig. 52 is showing a sketch of the optional measures to improve the sediment deposition capacity of
the intake pool. The measures contain the enlargement of the intake pool including an upstream
shifting of the baffle and racks, reducing the incline of the inlet zone, modification of the headrace
channel inlet pipe into an open channel structure and displacement (to upstream side) of the lateral
weir crest (overflow). All of these measures will lead to a more homogenous flow situation in the intake
pool and thereby to a higher sediment deposition capacity. In case of necessity to carry out these
optional measures further construction details will be additionally delivered from the German side to
the Vietnamese partners.
Page 37 / 127
Pre-Design
Enlargement of
intake pool
Modification of the
headrace channel
inlet
Displacement of
weir crest
Upstream
shifting of baffle
and racks
Fig. 52: View on the intake pool after implementation of optional measures (implementation only on demand)
2.4.3
The list of materials in Tab. 7 and Tab. 8 are within the responsibility of the Vietnamese
partners and are mandatory to implement the required measures of section 2.4.2.1 and 2.4.2.2.
The materials for the baffle and racks as well as the measuring devices (water level & turbidity
sensors) are within the responsibility of the German partners.
Tab. 7: List of materials and services for measures at the intake pool
Position
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9

Reinforced concrete
Various steel parts
For gate channel bed and lateral guidance rehabilitation
Possibly also rehabilitation of gate necessary
Various steel parts for trash rack repairing / replacement
Restoration of lateral overflow weir crest
Excavation of the existing breaks-offs
Roughening of the surfaces
Application of new concrete layer and/or steel guidance parts
Sealing of gaps in gate channel bed and lateral guidance
Excavation of the existing gaps
Roughening of the surfaces
Application of new concrete layer
Fitting and installation of steel parts
Repairing or replacing of the trash rack
Fence including gate
Installation of the fence
Amount
20
1
Unit
m
ls
1
1
1
ls
ls
ls
ls
1
1
1
ls
ls
ls
The list of materials below is within the responsibility of the Vietnamese partners and is
optional in case the sediment deposition capacity of the intake pool cannot be increased
sufficiently by implementing the tasks stated in section 2.4.2.2. Therefore they have to be taken
into account in the budget, but not yet into the Final Engineering Design.
Page 38 / 127
Pre-Design
Tab. 8: List of materials and services for optional tasks to improve the intake pools sediment deposition capacity
Position
8.1
8.2
8.3
8.4
8.5
8.6

Earth and rock excavation
Reinforced concrete
Steel or cast iron pipe, DN 500, PN 6
Breaking up of old concrete (existing pool)
Services for enlargement of the intake pool
Earth and rock excavation of the enlargement area
Concreting of the pool enlargement
Earthworks for the restoration of the pathway
Channel and pipe connection to headrace channel
Excavation of the steel pipe at the beginning of the intake pool
Cutting & welding of the pipeline according to conditions on site
Installation of the new pipe according to the conditions on site
Concreting of inlet channel
Earthworks for the restoration of the pathway
Amount
100
20
5
15
1
Unit
m
m
m
m
ls
ls
The list of materials below is within the responsibility of the German partners.
Tab. 9: List of materials and services for implementation of baffle and racks inside the intake pool
Position
9.1
2.5
2.5.1

Various steel parts for installation of baffle and racks
Construction of baffle and racks including guidance
Installation of baffle and racks
Amount
1
Unit
ls
Penstock bypass to PAT-pump-modules

Fig. 53: Map of Seo Ho HPP area
Page 39 / 127
Pre-Design
The existing penstock is a 720 m long DN 500 steel pipe which is mainly installed above ground
connecting the intake pool with the turbines in the power house of Seo Ho HPP. The first and the last
section of the penstock run underground (see Fig. 53).
2.5.2
Extension
area of
power
house
Penstock
underground
section
Bypass
Revision
valve
Fig. 54: Satellite view of Seo Ho HPP and a possible

routing of the bypass (Bing Maps 2014)
Fig. 55: Existing penstock of Seo Ho HPP and a

possible routing of the bypass (5.12.2013, KIT)
To supply the PAT-pump-modules with water, a bypass from the existing penstock to the modules has
to be built. The bypass must be implemented as a DN 300 steel pipe, whereby its total length depends
on the final routing. Responsible for the implementation is the Vietnamese side, whereby the works
have to be accomplished in two construction stages.
2.5.2.1 Construction stages of the penstock bypass
st
1 construction stage: Implementation of branch pipe and bypass laying

st
In a 1 construction stage the bypass connection to the existing penstock and the main part of the
bypass laying has to be done. Fig. 56 shows schematically where the bypass (red pipe) might end in
st
the 1 construction stage. The figure also shows the pressure supply pipe (blue), which is described in
more detail in section 0. Depending on the design of the power house of the water supply system it
st
would also be possible to end the 1 stage at the area behind the existing power house. As soon as
the decision about the power house design is made, the final routing of the bypass shall be clarified by
German and Vietnamese side. Based on this decision the Vietnamese side can then work out the
Final Engineering Design for this part of the plant. Independent from the final routing of the bypass its
final segment to the power house extension area (future location of the water supply facility)
nd
has to build in a 2 construction stage. Thereby an easier and more precise connection of the
bypass to the PAT-pump-modules will be possible.
Page 40 / 127
Pre-Design
1st construction stage

Retaining
wall
st
Fig. 56: Schematic unscaled sketch of a potential routing of the bypass after 1 construction stage
nd
construction stage: Implementation of final bypass segment

nd
In a 2 construction stage the final bypass segment to the power house extension area has to be
built. The last bypass abutment must be decoupled from the floor slab of the power house extension
nd
(see section 2.6) to avoid an impact from any settling processes. The 2 construction stage must
be done in parallel to the implementation of the PAT-pump-modules. It has to be carried out by
nd
the Vietnamese side in consultation with the German partners. The pipe laying in the 2
construction stage can be realized above or at the foot of the retaining wall. Fig. 57 shows
nd
schematically where the bypass should end in the 2 construction stage. The final pipe segment
(black part in Fig. 57), which connects the bypass with the PAT-pump-modules, will be
provided and installed by the German side.
2nd construction stage

Retaining
wall
Final pipe
segment
Fig. 57: Schematic unscaled sketch of a potential routing of the bypass after 2
nd
construction stage
Page 41 / 127
Pre-Design
2.5.2.2 Piping of the penstock bypass

The branch pipe shall be connected to the penstock with an angle of 90 before the penstock vanishes
underground (see Fig. 55). This angle will distinctly simplify the installation on site while causing only
minor hydraulic losses. As close as possible to the branch, a revision valve (PN 25, DN 300) is to be
installed in the bypass, which enables the decoupling of the entire water supply system from the
penstock e.g. for revision tasks. Fig. 54 and Fig. 55 show a possible bypass routing. However it would
also be possible to connect the branch with the target area on the powerhouse forecourt resp. the
extension area directly. In this case a partial removal of the mound would be required.
Independent from the final routing the components used for construction of the bypass have to be
defined as follows.
Straight pipe segments need to have a minimum wall thickness of 5.6 mm. The calculation is based
on a steel P235 (minimum strength 235 N/mm). Longitudinally welded or seamless pipes can be
used. For the welds a weld value of 0.8 was applied.
Pipe elbows have a lower pressure capability than straight pipe segments. Thus, greater wall
thicknesses are required. The strength test for the pipe elbows should be based on the standard DIN
EN 10253-2 type A (reduced utilization factor). For the pipe elbows a radius of 3 times diameter shall
be applied. Greater pipe elbow radii are permitted. If closer pipe elbow radii will be used, an increase
of the wall thickness is required.
Tab. 10 contains information about the recommended welding procedure as well as the specification
of the required materials.
Tab. 10: Specification of the welding procedure
Group of materials / no. according to CR ISO 15608

Base material
Material no.
Pipe dimensions
Welders qualification test corresponding to DIN EN
ISO 9606-1
Welding process
Root run, filler bead, final run
Welding filler corresponding to EN 12070
Joint preparation DIN EN ISO 9692-1
1 / 1.1
P235TR1
1.0254
323.9 x 5.6
111 T BW FM1 B s5,6 D323,9 PH ss nb
Manual arc welding (111)
Bhler FOX EV 50 7018-1 E 42 5 B
Key figure
Preparation of the welding edge

Weld heat treatment during welding
Weld inspection
Testing
To produce by grinding or sawing

Not required
According to DIN EN ISO 5817, assessment
group C
Visual inspection = 100 %
Radiographic test scope of testing = 50 %
Tightness vacuum = 100 %
Page 42 / 127
Pre-Design
To avoid any damages of the bypass caused by occurring loads during regular operation or in case of
water hammer (e.g. caused by pressure surge) and to ensure an economic construction process,
foundations combined with bearings have to be dimensioned with a systematic approach according to
the respective loading situation. In total 2 types of foundations and 3 types of bearings have to be
differentiated as follows. All components were dimensioned based on the loads given in Tab. 11,
which are calculated without safety margins.
Tab. 11: Forces occurring at the bypass both during regular operation and in case of water hammer do not
include safety factors (see coordinate system Fig. 108 and Fig. 109)
Foundation type
Fixed point
Slide and guide
bearings
Fx
Fy
61.5 kN
11.5 kN
Fz
6 kN
6 kN
- 21 kN
- 17 kN
Fx Water hammer*
23.1 kN
-
* Additional axial load to the forces occurring during regular operation
All figures in the next sections which do show foundations and bearings shall be considered as
exemplary and schematic. Thus, the foundations and bearings have to be adjusted to the on-site
conditions (e.g. to the mountain slope).
2.5.2.3 Foundation types for the penstock bypass
To avoid future damages in the water distribution system and to ensure an economic construction
process, concrete foundations as support for the pipeline were pre-dimensioned with a systematic and
comprehensive approach according to the load situation of the separate bearing types (see Tab. 11).
According to the loads stated in Tab. 11 the permissible distance between bearing points was set to
10 m. In close proximity to kinks of the pipeline this distance has to be reduced (see attachment).
Fixed point foundations (15/201-ST-01-108-c):
The fixed points have to be dimensioned according to the respective forces which result from the
change of pipeline direction, from the pipes dead load as well as from wind load.
Fig. 58: Side view of the foundation for fixed points

WITH reinforcement
Fig. 59: Front view of the foundation for fixed points

WITH reinforcement
Page 43 / 127
Pre-Design
Under regular operating conditions the recommended dimensions of the concrete foundations can be
seen in Fig. 58 and Fig. 59. For fixed points the dimensions are length x width x height (L x W x H) =
2.0 x 1.5 x 0.75 m. They should be realized by a concrete of a characteristic strength of f ck = C25/30.
The size of the foundations was calculated without partial safety factors. However, the concrete
properties were lowered by a factor of 0.85 and in addition a global safety factor for all concrete
foundations of 2.0 was assumed in this pre-design.
The installation of a minimum reinforcement to account for a ductile member failure is optional. The
permitted contact pressure was assumed to be 150 kN/m. However, it is recommended to verify this
assumption when checking the in-situ ground conditions before the beginning of the construction
works. Further, all proofs against sliding, tilting and ground failure must be verified according to the
respective national Vietnamese standards (especially in slope areas).
If it is decided to design the foundations to account also for the additional loads which may occur due
to a water hammer (see Tab. 11, right column), the foundations shall be fixed to the rock ground e.g.
with embedded reinforcement bars as illustrated in Fig. 60.
Fig. 60: Exemplary illustration of a concrete foundation fixed to the ground with embedded reinforcement bars
Slide and guide bearing foundations (15/201-ST-01-107):

seen in Fig. 64 and Fig. 65. For the slide and guide bearings the dimensions are L x W x H = 0.5 x 1.0
x 0.5 m. They should be realized with a concrete with a characteristic strength of f ck = C25/30. The
installation of a minimum reinforcement to account for a ductile member failure is optional.
The permitted contact pressure was assumed to be 150 kN/m. However, it is recommended to verify
this assumption when checking the in-situ ground conditions before the beginning of the construction
to a water hammer (see Tab. 11, right column), the foundations shall be fixed to the rock ground e.g.
with embedded reinforcement bars as illustrated in Fig. 60.
Page 44 / 127
Pre-Design
Fig. 61: Side view of the foundation for slide/guide

bearings WITH reinforcement
Fig. 62: Front view of the foundation for slide/guide

bearings WITH reinforcement
2.5.2.4 Bearing types for the penstock bypass

On top of each foundation a bearing has to be installed to guide the bypass and to transfer the
occurring forces to the respective foundation. In total 3 bearing types have to be differentiated as
follows. Note that the dimensions of the bearings components are independent from the construction
of the foundation (i.e. with or without reinforcement).
Fixed point bearings (15/201-ST-01-108-c):
For the dimensioning of the fixed points the maximum design pressure is decisive. Fixed points have
to be arranged between all expansion bends, whereby a piping without fixed points is not permitted.
The bearings and their fixation on the foundations might be constructed as shown in Fig. 63 to Fig. 66.
Fig. 63: Side view fixed point bearing
Fig. 64: Front view fixed point
Page 45 / 127
Pre-Design
Fig. 65: Cross sectional views of the fixation
Fig. 66: Isometric view of the fixed point bearing
Sliding and guide bearings (15/201-ST-01-107):

Slide bearings in the area of expansion bends have to be constructed without guide rails (see
description for guide bearings below). All guide bearings should be equipped with guide rails (securing
the position of the pipe and absorption of wind loads). In Fig. 67 to Fig. 70 the recommended
construction of a slide bearing and of a guide bearing as well as of the fixations on the foundation are
shown. Guide bearings shall be applied in straight sections as shown in the routing attached to this
Pre-Design. In close proximity to the elbows slide bearings without the guide rail shall be applied. The
minimum distance between elbow and first bearing as stated in the attached routing has to be
respected. The bearings shall be constructed with steel/steel sliding surfaces (low-friction bearings
made of PTFE are not recommended.
Fig. 67: Side view slide and guide bearing
Fig. 68: Front view slide and guide bearing
Page 46 / 127
Pre-Design
Fig. 69: Cross section view of the fixation
Fig. 70: Isometric view on the slide and guide bearing
The reinforced guide bearing is to be constructed before and after each kink in the pipe with an angle
bigger than 10. The difference between slide and guide bearings is the guide rail which should only
adapted at guide bearings as shown in Fig. 67. For the dimensioning of the guide bearing the
maximum design pressure is decisive.
Expansion concept for single sections:
Since the expansion of the penstock is not known a U-arch with a dimension of 3 m is required close
to the branch-off location (see attachment). Thus possible expansions of the penstock can be
compensated. The following section of approx. 50 m contains one fixed point to absorb the pipe forces
due to thermal expansion, due to the dead load of the pipe and due to pressure forces in case of water
hammer (see Tab. 11).
2.5.3
All pipe segments shall be welded, whereby the weld seam must be of high quality to withstand the
operating pressures (locally more than 20 bar). Therefore a certified welder is required. Only the
revision valve shall be installed with flanges, which must be produced for a nominal pressure of PN25.
All material required for the installation of the bypass from the branch to the extension area is
summarized in the following table. The given amounts (e.g. pipe length, number of bolts, nuts,
washers, etc.) include safety margins in order to be able to adapt the pipe system on-site to the local
conditions. Only rust proof or zinc-coated steel parts shall be used. The dimensioning process
for all pipe segments includes a safety factor of 1.5 referring to the required strength.
Page 47 / 127
Pre-Design
Tab. 12: List of materials and services for the penstock bypass to PAT-pump-modules
Position
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.11

Steel pipe (penstock bypass straight section)
Nominal diameter: 300 mm
Outside diameter: 323.9 mm
Wall thickness:
5.6 mm
Pressure level:
PN 25
Material: Steel P235
Steel elbow pipe (penstock bypass curved section)
Outside diameter: 323.9 mm
Wall thickness:
7.1 mm
Pressure level:
PN 25
Angle:
Depending on routing
Radius: 2x DN = 600 mm
1)
Steel flange
Pressure level:
PN 25
Type:
Welding neck flange
1), 2)
Hexagon shaft bolt
Type:
M 27
Hexagon nut
Type:
M 27
Washer
Type:
M 27
Elastomeric seal
DN 300
Materials for welding (number of joints)
2)
Revision valve
Pressure level:
PN 25
Fixed points (2, referring to drawing 15/201-ST-01-108-c):
Concrete with a characteristic strength of fck = C25/30
dimensions according to the static requirements l x w x h = 2.0
x 1.5 x 0.75 m, approximately 2.25 m per fixed point each
Bolts Hilti HIT-HY 200-A + HIT-V-R M16 (or comparable)
Steel plate 150 x 250 x 20 mm (min. tensile strength 235
N/mm)
N/mm)
U-profile U140 (min. tensile strength 235 N/mm)
U-profile U200 (min. tensile strength 235 N/mm)
Pipe bearing thickness 7.1 mm (min. tensile strength 235
N/mm)
Slid bearings (4, referring to drawing 15/201-ST-01-107):
x 1.0 x 0.5 m, approximately 0.25 m per bearing each
Bolts Hilti HST M16 (or comparable)
N/mm)
Amount
80
Unit
m
pcs
pcs
48
pcs
48
pcs
96
pcs
pcs
23
1
pcs
pcs
4.5
16
8
pcs
pcs
16
pcs
1
1
2
ls
ls
pcs
1.0
32
8
pcs
pcs
pcs
Page 48 / 127
Pre-Design
10.12
10.13
10.14
10.15
10.16
10.17
10.18
10.19
10.20
10.21
N/mm)
Profiled steel HEA100 (min. tensile strength 235 N/mm)
Pipe bearing type LSL 23.0300.150-37.2 by Witzenmann (or
comparable) (min. tensile strength 235 N/mm)
Guide bearings (4, referring to drawing 15/201-ST-01-107):
x 1.0 x 0.5 m, approximately 0.25 m per bearing each
N/mm)
N/mm)
Guide rail L 50 X 5 (min. tensile strength 235 N/mm)
Adaptation of pipe routing to local terrain conditions
Earthworks (excavation, possibly partial break-up of retaining
wall)
Possibly cutting and re-welding of pipe pieces to adapt to
terrain
Welding of bypass (DN 300) to penstock (DN 500)
Piping
Pipe-to-flange welding
Flange-to-flange screwing
Pipe-to-pipe welding
Installation of revision valve
Concreting of abutments
Corrosion protection application (including fittings, flanges, etc.)
1
8
ls
pcs
1.0
32
8
pcs
pcs
pcs
1
4
8
ls
pcs
pcs
ls
1
80
3
2
23
1
10
80
ls
m
ls
ls
ls
ls
ls
m
Annotations:
1)
2)
Flange thickness differs from manufacturer to manufacturer. Bolt lengths and shaft lengths
thus have to be (re)defined after a manufacturer for steel flanges has been selected.
Flange thickness depends on the type of revision valve/compensator. Bolt lengths and shaft
lengths thus have to be (re)defined after a specific valve/compensator has been selected.
The pipe material and equipment has to be in accordance with the standards listed below or
equivalent to them. These are, but are not limited by, the following:
EN 10220 Seamless and welded steel tubes Dimensions and masses per unit length
EN 10224 Non- alloy steel tubes and fittings for the conveyance of water and other aqueous
liquids technical delivery conditions
EN 1092-1 Flanges and their joints Circular flanges for pipes, valves, fittings and
accessories, PN designated Part 1: Steel flanges
EN 10311 Joints for the connection of steel tubes and fittings for the conveyance of water
and other aqueous liquids
EN ISO 4014 Hexagon head bolts Product grades A and B
EN ISO 4032 Hexagon head nuts Product grades A and B
EN 1515 Parts 1 4 Flanges and their joints Bolting
EN ISO 7089 Plain washers Normal series, Product grade A
Page 49 / 127
Pre-Design
EN 681 1 Elastomeric Seals material requirements for pipe joints seals

EN 1074 Valves for water supply Fitness for purpose requirements and appropriate
verification tests Part 1: General requirements
verification tests Part 2: Isolating valves
EN 287-1 Qualification test of welders
EN 1011 Welding Recommendations for welding of metallic materials
EN ISO 23277 Non-destructive testing of welds Penetrant testing of welds Acceptance
levels
EN 805 Water supply Requirements for systems and components outside buildings
ISO 15348 Pipe work Metal bellows expansion joints General
prEN 14917 Metal bellows expansion joints for pressure applications
2.6
2.6.1
Extension of power house and tailwater pool

Location of power house extension
In front of the entrance of the existing power house is a vacant, partially paved area with dimensions of
approximately 8.5 x 14.6 m (see Fig. 71 and Fig. 72). The extension of the power house to
accommodate the PAT-pump-modules and a tailwater pool shall be built there.
Fig. 71: Vacant area next to Seo Ho HPP powerhouse (5.12.2014, KIT)
Page 50 / 127
Pre-Design
Fig. 72: Top view of unscaled sketch on the vacant area next to Seo Ho HPP powerhouse
2.6.2
There are two options to accommodate the 2 PAT-pump-modules with the related piping, valves and
measurement system. The decision which option will be realized mainly depends on the dimension of
the construction road, which is within the responsibility on the Vietnamese side. Both options A and B
and the associated measures are described in the following sections 2.6.2.1 and 2.6.2.2. Both options
will require the implementation of a tailwater pool, which is described in section 2.6.2.3.
Important note: Both options have different time schedules and differ in design details. After
choosing one option by Vietnamese side, missing details (i.e. exact position of the tailwater
pool) will be delivered from German side.
2.6.2.1 Option A: On-site installation of the water supply system
Option A provides the idea to transport the single components of the PAT-pump-modules to the
construction site next to the Seo Ho HPP powerhouse. Afterwards the PAT-pump-modules are
mounted on site. Due to smaller and lighter packing boxes of the single components the construction
road from Khe Lia along the headrace channel to the Seo Ho HPP can be built smaller compared to
option B. The biggest packing boxes have a dimension of approx. 1,200 kg and a maximum weight of
approx. 3.2 x 1.1 x 1 m (L x W x H). The construction road must be capable to transport these packing
boxes. The disadvantage of option A in comparison of option B is a higher technical effort associated
with a longer mounting time of the PAT-pump-modules on site. Furthermore, a new building must be
built to accommodate the PAT-pump-modules properly.
Prior to mounting the PAT-pump-modules the new building must be erected. It has to cover a square
of at least 7.5 x 7.5 m (see Fig. 73) showing a minimum clear height of 3 m. The height should be
adequate to place a tripod crane for proper maintenance of the modules. To the upper retaining wall
(see Fig. 73) a distance of approx. 2 m must be kept, to the left retaining wall a distance of 0.5 m.
Page 51 / 127
Pre-Design
Fig. 73: Top view of unscaled sketch on the shape of the new building
The building itself could be built with a standard masonry and e.g. a corrugated metal roof on a timber
framing referring to the existing power house. However, it must be placed on a reinforced foundation
(floor slab) which can absorb the occurring loads from the piping system and from the machinery. This
foundation must cover the entire area of the new building. The shafts of the tailwater pool (see section
2.6.2.3) can be embedded in the foundation as well. The foundation is designed to have a height of
0.3 m over the total square of at least 11.5 m x 7.5 m. It should be made out of reinforced concrete
with a minimum characteristic strength of fck = C25/30. At the upper side of the foundation and at the
bottom, a reinforcement with a bar diameter of 12 mm each 150 mm should be installed crosswise in
longitudinal and transverse direction.
Fig. 74: Example for the new power house construction for Option A of the water supply system
Page 52 / 127
Pre-Design
Tab. 13: Time schedule of construction stages of option A
Construction stage
st
nd
Implementation part
Foundation (floor slab)
Tailwater pool (see section 2.6.2.3)
New building
PAT-pump-modules
Responsibility
VN
GER
2.6.2.2 Option B: Pre-installation of the water supply system in a shipping container

Option B provides the pre-installation of all components of the PAT-pump-modules (including piping,
valves etc.) in Germany inside a shipping container. Afterwards the container is transported to Seo Ho
HPP, mounted to a new built floor slab and connected to bypass and supply pipe. In this case the
construction road must be capable to transport a 20 feet shipping container showing dimensions of
approx. 6 x 2.5 x 2.6 m (L x W x H) with a weight of approx. 8,000 kg. The advantage of option B in
comparison to option A is a distinctly reduced mounting time of the PAT-pump-modules on site.
Furthermore, a roofing above the container would be sufficient instead of an entirely new building.
Fig. 75: Top view of unscaled sketch on the shape of the new roof
The roofing must be erected after the PAT-pump-modules are mounted. It has to cover a square of at
least 7.5 x 7.5 m (see Fig. 75) showing a minimum clear height of 3 m. Here also a distance to the
upper retaining wall of approx. 2 m must be kept, to the left retaining wall a distance of 0.5 m. The new
roofing must be placed on a reinforced foundation which can absorb the occurring loads transferred
from the piping system via the container including the dead weight of the piping system and the
machinery. The shafts of the tailwater pool (see section 2.6.2.3) can be embedded in the foundation
as well. The foundation is designed to have a height of 0.3 m over a total square of at least 11.5 m x
7.5 m. It should be made out of reinforced concrete with a minimum characteristic strength of fck =
C25/30. At the upper side of the foundation and at the bottom, a reinforcement with a bar diameter of
12 mm each 150 mm should be installed crosswise in longitudinal and transverse direction.
Page 53 / 127
Pre-Design
Fig. 76: Example for the new power house construction for Option B of the water supply system
Tab. 14: Time schedule of construction stages of option B
Construction stage
st
nd
2
rd
3
Implementation part
Foundation (floor slab)
Tailwater pool (see section 2.6.2.3)
PAT-pump-modules
Roof
Responsibility
VN
GER
VN
2.6.2.3 Tailwater pool

For both possibilities a tailwater pool including 2 pipe shafts is required as well as an open channel
which shall guide the water back into Seo Ho River.
Fig. 77: Top view unscaled sketch on tailwater pool including shafts, open channel to Seo Ho River
Page 54 / 127
Pre-Design
The tailwater pools position depends on the choice of option A or B (see 2.6.2.1 and 2.6.2.2). After
the selection of a proper option missing details will be delivered from German side. The pools
dimensions, however, will be equal for option A and B. The PAT suction pipes and the drainage pipes
will purge into the tailwater pool. These pipes have to be laid into the two shafts. The pool itself shows
dimensions of 4.5 x 2.0 x 1.5 m (L x W x H) and a connection to an open channel with dimensions of
approx. 0.5 x 0.5 m (W x H) containing a slope of at least 2 . This channel can be covered with a
grid or concrete slabs. This pool is designed to have an equal wall thickness of 0.2 m. It should be
made out of reinforced concrete with a minimum characteristic strength of fck = C25/30. On both wall
sides, a reinforcement mesh with an amount of 4.24 cm/m should be installed.
Open channel to
Seo Ho River
Shafts
Fig. 78: Downstream view on an unscaled sketch of the tailwater pool
2.6.3
Tab. 15: List of materials and services for the power house extension and the tailwater pool
Position
13.1
13.2
13.3 A
13.3 B
13.4
13.5
13.6
13.7
13.8

Earth excavation
Reinforced concrete
Masonry walls (option A)
Pillars (option B)
Corrugated metal roof on a timber framing
Construction of the power house extension
Concreting of a floor slab with reinforced concrete
Construction of masonry walls
Construction of a corrugated metal roof on a timber framing
Concreting of machinery foundations for the modules
Construction of a tailwater pool and channel to Seo Ho River
Excavation works
Concreting of pool and channel bed and walls
Amount
60
30
100
8
80
1
1
Unit
m
m
m
ls
m
ls
ls
2
1
ls
ls
Page 55 / 127
Pre-Design
2.7
2.7.1
Machinery and equipment

2.7.1.1 Machinery
The machinery and the related piping system will be installed on the vacant area in front of the existing
powerhouse. This applies for option A (transport of single components and installation on-site) as well
as for option B (pre-installation in a shipping container). Either way, the powerhouse piping system will
then be connected to the penstock bypass, to the tailwater pool and to the pressure supply pipe. In
order to enable a controllable, efficient and safe operation of the water supply facility, the pipe system
will be equipped with different hydraulic valves. All components installed inside the new powerhouse
will be provided by the German project partners. All components are chosen to be highly suitable for
this application by means of high robustness, low maintenance and easy to handle characteristics.
The hydraulic dimensioning both of the machinery and of the piping system is carried out by
KIT and KSB AG. However, until the finalization of the test rig runs at KSB AG, the layout may
be subject to minor changes. In this case the boundary conditions for the construction works
of the Vietnamese partners will not be modified.
Fig. 79: Schematic layout of PAT-pump-modules of Option A
Referring to the drafts for options A and B, the water for both modules runs through the penstock
bypass (DN 300) to the extension area. The DN 300 valve (1) represents the transition from the
penstock bypass and power house pipe system and is used as a revision valve. The flow is then
divided into the PAT (main routing) and the pump feeder (branch routing). The main routing is then
divided symmetrically by a T-branch pipe, whereby each PAT feeder is equipped with a valve (5)
(start/stop of the respective module, revision tasks) and a compensator (6) (decoupling of vibrations).
The branch pipe to the feed pumps is likewise divided symmetrically by a T-branch pipe, whereby
Page 56 / 127
Pre-Design
each pump feeder is also equipped with a valve (2) and a compensator (6). The water running through
the PAT is transferred into the tailwater pool (see section 2.6). The water fed into both high-pressure
pumps first runs through single pressure pipes before they are joined by a T-branch pipe. Each of
these single pipes is equipped with a non-return valve (7) and a revision valve (8). The unified
pressure supply pipe further contains a revision valve whereby the entire powerhouse can be
decoupled from the pressure supply pipe for revision tasks. The construction contains drainage pipes
both for the bypass and for the pressure supply pipe equipped with valves (9) (10).
Tab. 16: Components installed inside the new powerhouse (Option A)
No.
1
2
3
Component
Revision valve
Pump valve suction side
Dismantling joint
Amount
1 pc.
2 pc.
6 pc.
3a
Dismantling elbow
5 pc.
4
5
6
Control valve DN 200

PAT valve pressure side
Compensator
1 pc.
2 pc.
6 pc.
7
8
9
10
Non-return valve
Pump valve pressure side
Drainage valve
Drainage valve
2 pc.
2 pc.
1 pc.
1 pc.
Nominal diameter
DN 300
DN 125
DN 300 (1 pc.)
DN 200 (3 pc.)
DN 150 (2 pc.)
DN 125 (2 pc.)
DN 100 (1 pc.)
DN 150 (2 pc.)
DN 200
DN 200
DN 125 (2 pc.)
DN 100 (2 pc.)
DN 65 (2 pc.)
DN 150
DN 150
DN 100
DN 100
Nominal pressure
PN 25
PN 25
PN 25
PN 25
PN 63
PN 25
PN 25
PN 63
PN 25
PN 25
PN 25
PN 25
PN 63
PN 63
PN 63
PN 25
PN 63
Fig. 80: Schematic layout of PAT-pump-modules of Option B
Page 57 / 127
Pre-Design
Tab. 17: Components installed inside the new powerhouse (Option B)
No.
1
2
3
Component
Revision valve
Pump valve suction side
Dismantling joint
Amount
1 pc.
2 pc.
3 pc.
3a
Dismantling elbow
8 pc.
4
5
6
Control valve DN 200

PAT valve pressure side
Compensator
1 pc.
2 pc.
6 pc.
7
8
9
10
Non-return valve
Pump valve pressure side
Drainage valve
Drainage valve
2 pc.
2 pc.
1 pc.
1 pc.
Nominal diameter
DN 300
DN 125
DN 300 (1 pc.)
DN 200 (1 pc.)
DN 150 (1 pc.)
DN 125 (2 pc.)
DN 200 (2 pc.)
DN 100 (1 pc.)
DN 150 (2 pc.)
DN 100 (1 pc.)
DN 200
DN 200
DN 125 (2 pc.)
DN 100 (2 pc.)
DN 65 (2 pc.)
DN 150
DN 150
DN 100
DN 100
Nominal pressure
PN 25
PN 25
PN 25
PN 25
PN 63
PN 25
PN 25
PN 25
PN 63
PN 63
PN 25
PN 25
PN 25
PN 25
PN 63
PN 63
PN 63
PN 25
PN 63
2.7.1.2 Monitoring system

The German project partners will develop an adapted control system for the water supply facility,
which will consist of various measuring devices. This includes a pressure sensor to continuously
monitor the water level inside the intake pool, whereby the current method of visual water level
monitoring at the weir crest will be replaced. The data will be radio transmitted to Seo Ho power house
in order to keep the operating personnel informed if the operation is within the permitted range.
Furthermore, a turbidity probe will be installed in order to continuously evaluate the sediment
concentration and to be able to shut down the water supply facility in case of impermissible high
sediment loads. The amount of water transferred to the reservoir in Ma U will be measured by an
inductive flow meter, which will be installed in the pressure supply pipe. The condition of the
machinery will be monitored by measuring the rotation speed of all machines since this is an indicator
of a proper operation mode.
Furthermore, the control system will contain alert settings since impermissible operating conditions
shall be avoided at any time. Therefore limiting values for all relevant operating parameters will be
decided by German and Vietnamese partners and successively set to guarantee a sustainable and
efficient operation of the water supply facility.
2.7.2
The selection of machines and components based on the currently known local conditions is to be
accomplished by KIT and KSB AG. Furthermore, the piping system will be dimensioned (including e.g.
pipe diameters, position of valves, etc.) and a proper load bearing system (i.e. position and
dimensions of the abutments) will be designed by these project partners. This applies both for option A
and B. The planned test rig runs with the machinery will be accomplished by KSB AG in August 2015
after final assembly of the water supply modules. As agreed the German project partners will be in
Page 58 / 127
Pre-Design
charge for the provision of the machinery, the related control system for operation, the valves and the
pipe system from the penstock bypass to the suction pipe leading to the tailwater pool. This includes
the machinery and all required components (e.g. couplings, etc.),
all kinds of straight pipes, elbows, reducers, etc. for this section,
various valves in different sizes such as butterfly, plunger and non-return valves,
compensators resp. flexible joints as well as
the electrical control system comprising besides others an inductive flow meter.
The connection to the parts provided by the Vietnamese partners shall be the end of the bypass as
described in section 2.5, the connection of the PAT suction pipes to the tailwater pool as described in
section 2.6 as well as the connection to the pressure supply pipe as described in section 2.8. Since a
greater part of the items mentioned above has to be imported to Vietnam, the German side will be in
charge for the shipment to the Vietnamese harbor resp. airport. As stated in Tab. 18 the Vietnamese
partners, however, are responsible for the customs duties including all administrative processes and
the provision of the related handling costs as well as for the final transportation to the construction site.
The list of services in Tab. 18 is within the responsibility of the Vietnamese partners:
Tab. 18: List of materials and services for the installation of machinery and equipment in the power house
Position
16.1
16.2 A
16.2 B

Customs duties in Vietnam (incl. handling cost and administration
processes). All administrative processes have to be settled and timed
in accordance to the projects time schedule (see section 4)
Dom. transport of machinery/equipment to Seo Ho HPP (Option A)
Dom. transport of machinery in 20 shipping container (Option B)
Amount
1
Unit
ls
1
1
ls
ls
The list of materials and services Tab. 19 are within the responsibility of the German partners:
Tab. 19: List of materials and services for the installation of machinery and equipment in the power house
Position
17.1 A
17.1 B
17.2
17.3

Installation of machinery and measuring equipment (Option A)
Installation of pre-installed container (Option B)
Connection to bypass and pressure supply pipe on-site
Installation of monitoring equipment
Amount
1
1
1
1
Unit
ls
ls
ls
ls
Page 59 / 127
Pre-Design
2.8
2.8.1
Pressure supply pipe

Location
To pump the drinking water from the hydropower plant Seo Ho to the distribution tank in Ma U a
pressure supply pipe is necessary (see Fig. 81 red box). With a length of 2,455 m the pressure supply
pipe must overcome about 547 meters of altitude. The route is shown in Fig. 81 and Fig. 83.
Fig. 81: Location of Seo Ho HPP, pressure supply pipe and tank in Ma U
2.8.2
2.8.2.1 Routing of the pressure supply pipe

To overcome the high pressures rapidly, a steep route of the pressure supply pipe is preselected (see
Fig. 82). Thus, lower pressure levels can be used for larger parts of the pipes (see Fig. 82). To
simplify the construction in the field, the beginning of the pipe is parallel to the existing pressure pipe
and in the upper part the route follows the path to Ma U. In the following Fig. 82 - Fig. 91 and Tab. 20
the data of the route of the pipe can be found. Detailed isometric drawings are shown in appendix B.
However, the routing needs to be checked and revised if necessary in the course of the
developing of the Final Engineering Design. Changes in the routing of the pipe might lead to
the need for revision of the design, particularly of the dimensioning and allocation of
foundations, compensations, water hammer protection and air valves.
Page 60 / 127
Pre-Design
Fig. 82: Profile of the pressure supply pipe
Fig. 83: Routing of the pressure supply pipe; pressure supply pipe (orange line), numbered points are the
4
measured points in Tab.
www.bing.com
Page 61 / 127
Pre-Design
Fig. 85: Detail 2, point 3 6
Fig. 84: Detail 1, point 1 -3
Fig. 86: Detail 3, point 6 11
Fig. 87: Detail 4, points 11 20
www.bing.com
Page 62 / 127
Pre-Design
Tab. 20: Data of the routing of the pressure supply pipe
Point
Length of
the pipe
section [m]
Length of
the pipe
ongoing [m]
Horizontal
distance [m]
Difference in
height[m]
1
2
3
4
5
6
7
8
9
10
11
0
82,9
251,8
165,7
369,7
23,0
82,3
43,0
48,2
58,1
37,0
0
82,9
334,7
500,4
870,1
893,1
975,4
1018,4
1066,6
1124,7
1161,7
0
77,0
220,4
164,1
276,5
23,0
82,3
42,4
48,2
56,7
36,2
0
30,6
121,8
23,2
245,4
-0,6
0,7
7,0
1,6
12,6
7,7
Height
[masl]
706,9
737,5
859,3
912,2
1127,9
1127,3
1128
1135
1136,6
1149,2
1156,9
xcoordinate
ycoordinate
533533
533575
533634
533777
533835
533858
533936
533971
534017
534051
534063
2576586
2576522
2576313
2576276
2575983
2575980
2575955
2575931
2575917
2575872
2575838
www.bing.com
Page 63 / 127
Pre-Design
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
23,8
10,5
13,1
41,0
27,2
32,0
23,9
59,8
125,7
99,1
42,1
46,2
75,3
131,3
62,8
31,0
28,7
80,6
24,2
104,2
61,0
56,2
43,4
51,0
1185,5
1196,0
1209,1
1250,1
1277,3
1309,3
1333,2
1310,1
1518,7
1617,8
1659,9
1706,1
1781,4
1912,7
1975,5
2006,5
2035,2
2115,8
2140,0
2244,2
2305,2
2361,4
2404,8
2455,8
23,8
10,5
12,9
40,2
26,6
31,7
20,6
59,5
125,6
99,0
42,1
46,2
75,1
130,2
62,5
31,0
28,6
80,4
23,3
104,2
60,8
56,1
43,2
51,0
-0,3
0,6
2,2
8,3
5,6
4,2
12,1
-5,6
5,8
4,4
1,3
1,8
5,1
16,7
6,0
0,8
2,1
6,1
6,5
1,8
4,4
-2,8
4,0
2,0
1156,6
1157,2
1159,4
1167,7
1173,3
1177,5
1189,6
1184
1189,8
1194,2
1195,5
1197,3
1202,4
1219,1
1225,1
1225,9
1228
1234,1
1240,6
1242,4
1246,8
1244
1248
1250
534081
534083
534079
534060
534070
534087
534107
534155
534274
534330
534372
534412
534471
534599
534657
534684
534712
534791
534793
534851
534904
534918
534924
534975
2575822
2575811
2575799
2575763
2575738
2575711
2575703
2575737
2575777
2575859
2575868
2575844
2575798
2575774
2575797
2575780
2575774
2575764
2575741
2575654
2575683
2575628
2575585
2575585
Annotations: The measurements in the field were performed with a TruPulse Laser Rangefinder. The
TruPulse consists of a distance measuring sensor and an integrated slope sensor. By emitting infrared
pulses and measuring the time required for each pulse to move from the rangefinder to the target and
back, the distance is determined. The GPS waypoints were measured with a GPS-handheld. The
reference system of the GPS points is in VN_2000_UTM_Zone_48N.
2.8.2.2 Boundary conditions, operating parameters and load assumptions
2.8.2.2.1
Delivery rate
The delivery rat is between 11 and 20 l/s.

2.8.2.2.2
Design pressure
The maximum design pressure (MDP) is 73 bar at the lowest point of the pipe (Point 01) at an altitude
of about 700 masl according to the calculation of the company KSB AG, see section 2.8.2.8. This
pressure contains the geodetic water pressure of 547 m (H = 543 m + 4 m (filling the tank from the
top)), the dynamic head of 7 31 m (depending on the delivery rate and the roughness of the pipe)
and the increase of pressure due to the water hammer. The water hammer was determined for a worst
case scenario (see section 2.8.2.8). With increasing height the geodetic pressure decreases and, thus,
the MDP decreases until a MDP of 18 bar at the highest point of the pipe, in case no water hammer
protection is implemented (Tank Ma U, 1250 masl). The design parameters have been adjusted
accordingly, e.g., grading of the required pipe wall thickness.
Page 64 / 127
Pre-Design
Negative pressures could only occur due to a water hammer. In the worst case scenario described in
section 2.8.2.8, the pressure would drop to vapor pressure from pipe length 870 m until pipe length
2,455 m (tank in Ma U). Even though this case is hypothetical and would most likely not occur, it is
provided for a water hammer protection device to prevent the pressure drop (see 2.8.2.8.3).
2.8.2.2.3
Design temperature
For the calculation of the pipe static following temperature was selected:
Minimum temperature: -10 C
Maximum temperature: 50 C
Starting from a mounting temperature of 10 C, the temperature difference is - 20K to 40K.
Displacements due to the temperature differences are absorbed by appropriate compensation
elements (so-called natural compensation by U-bend and L / Z bend).
2.8.2.2.4
Other loads
Wind loads of 0.162 kN/m for the pipe DN 150 are selected. This corresponds to a dynamic pressure
of 0.8 kN/m.
2.8.2.3 Piping (diameter, material and wall thickness)
2.8.2.3.1
Diameter and material
As material a steel P235 is selected. Due to the expectable maximum delivery rate of approximately
20 l/s a diameter of DN 150 is necessary (by calculating with a roughness of 0.1 mm and the
maximum delivery rate as mentioned before, the losses are 31 m).
2.8.2.3.2
Wall thickness
The maximum design pressure (MDP) decreases with increasing geodetic height and, thus,
decreasing geodetic pressure. According to the MDP a certain wall thickness is required. Four pipe
sections with a specific MDP were defined as can be seen in the isometric drawings summarized in
appendix B.
Tab. 21: Division of the pipe in four pipe sections
Section
I
(Point 01 TP01)
II
(TP01 TP02)
III
(TP02 TP03)
IV
(TP03 Point 35)
Min. and max. geodetic

height [masl]
Maximum
design pressure
[bar]
Wall thickness
Straight pipe
[mm]
Wall thickness
Pipe elbow
[mm]
705 830
73
6.3
11
830 980
60
5.6
7.1
980 1080
45
4.5
5.6
1080 - 1250
35
4.0
4.5
Page 65 / 127
Pre-Design
Straight pipe segments need to have a minimum wall thickness as shown in Tab. 21. The values
given in Tab. 21 are minimum wall thicknesses. The calculation is based on a steel P235 (minimum
strength 235 N/mm). Longitudinally welded or seamless pipes can be used. For the welds a weld
efficiency rating of 0.8 was applied.
Pipe elbows have a lower pressure capability than straight pipe segments. Thus, greater wall
thicknesses are required. The strength test for the pipe elbows bases on the standard DIN EN 102532 type A (reduced utilization factor). For the pipe elbow radius a design of 3D was applied. The pipe
elbow radius 3D corresponds to 1.5 of the pipe diameter. Greater pipe elbow radii are statically safe. If
closer pipe elbow radii will be used, an increase of the wall thickness is necessary.
T-branches have not been evaluated statically in the pipeline statics. If T-branches will be used, these
must be reinforced (a strength calculation has to be done before). Alternatively fittings according to the
standard DIN-EN 10253-2 type B (full utilization factor) with a minimum wall thickness of the straight
pipe can be used.
2.8.2.4 Pipe connection
The pipe segments have to be welded. The welded joints have to comply the criteria listed in Tab. 22
which correspond to the named standards.
Tab. 22: Requirements for the pipe connection
Group of materials/number corresponding to

CR ISO 15608
Base material
Material number
Pipe and elbow dimensions
Welders qualification test corresponding to
DIN EN ISO 9606-1
Welding process
Welding filler corresponding to EN 12070
1/1.1
P 235TR1
1.0254
168.3 x 4.0 mm; 168.3 x 4.5 mm; 168.3 x 5.6 mm;
168.3 x 6.3 mm; 168.3 x 7.1 mm; 168.3 x 11.0 mm
111 T BW FM1 B s4.0 D168.3 PH ss nb
111 T BW FM1 B s5.6 D168.3 PH ss nb
Manual arc welding (111)
Bhler FOX EV 50 7018-1 E 42 5 B
Weld preparation corresponding to DIN EN

ISO 9692-1
Preparation of the welding edge

Weld heat treatment during welding
Weld inspection
Tests
By mechanical sanding or sawing

Not necessary
Corresponding to DIN EN ISO 5817, class C
Visual inspection = 100 %
Radiographic inspection, scope of testing = 50 %
Tightness vacuum = 100 %
Page 66 / 127
Pre-Design
2.8.2.5 Bearing and foundation concept

2.8.2.5.1
Permissible bearing distances
The span of the pipe is limited to 6.5 m in order to limit the deflections resp. the bearing loads. On pipe
elbows (bending angle > 25) bearings with a maximum distance of 1.6 m have to be provided.
2.8.2.5.2
Required alignment of Fixed points
In the pipe segments between two expansion bends (U-bend, L-and Z-bend), a fixed point has to be
constructed. The fixed point is used to control the displacement and to absorb the forces during
operation and in the case of a water hammer. The bearing type fixed point is defined in section
2.8.2.5.4. The locations of the fixed points of the planned pressure supply pipe are shown in the
isometric drawings (see appendix B).
2.8.2.5.3
Required alignment of Slide bearing and Guide bearing
It is recommended to equip pipe bearings in straight segments with lateral guidance. In the areas of
expansion bends, slide bearings without lateral support are to be used. The minimum distance from
the expansion bend (pipe elbow) to the first guide bearing have to be complied. The respective first
guide bearing before and after a bend is to reinforce. The bearings with steel/steel sliding surfaces
have to be used. The bearing types slide and guide bearing are defined in section 2.8.2.5.4. The
locations of the fixed points of the planned pressure supply pipe are shown in the isometric drawings
(see appendix B).
2.8.2.5.4
Bearing types
Bearing type Fixed point (15/201-ST-01-105 and 15/201-ST-01-106)
Fig. 92: Side view Fixed point horizontal

(15/201-ST-01-105)
Fig. 93: Front view Fixed point horizontal (15/201ST-01-105)
Page 67 / 127
Pre-Design
For the dimensioning of the fixed points the maximum design pressure is decisive (see sections
2.8.2.2.1 and 2.8.2.8). Fixed points are arranged between all expansion bends. A piping without fixed
points is not recommended. In the Fig. 92 - Fig. 95 the recommended construction of a fixed point for
horizontal and angled piping and its fixation on the foundation is shown.
Fig. 94: Side view Fixed point angled (15/201-ST01-106)
Fig. 95: Front view Fixed point angled (15/201ST-01-106)
Bearing type Reinforced guide bearing (15/201-ST-01-103 and 15/201-ST-01-104)
Fig. 96: Side view reinforced guide bearing

horizontal (15/201-ST-01-103)
Fig. 97: Front view reinforced guide bearing

The reinforced guide bearing is to construct before and after a kink in the pipe, which is bigger than
10. For the dimensioning of the guide bearing the maximum design pressure is decisive. In the Fig.
Page 68 / 127
Pre-Design
96 - Fig. 101 the recommended construction of a reinforced guide bearing for horizontal and angled
piping, its fixation on the foundation and the pipe bearings are shown.
Fig. 98: Side view reinforced guide bearing

angled (15/201-ST-01-104)
Fig. 100: Pipe bearing, LSF 43.0150.107.37.2 by

Witzenmann
Fig. 99: Front view reinforced guide bearing

angled (15/201-ST-01-104)
Fig. 101: Pipe bearing, LSF

43.0150.107.37.2 by Witzenmann
Bearing type Slide bearing and guide bearing (15/201-ST-01-101 and 15/201-ST-01-102)
Slide bearings in the area of expansion bends have to be constructed without guide rails. All other
guide bearings should be equipped with guide rails (securing the position of the pipe and absorption of
wind loads). In the Fig. 102 - Fig. 107 the recommended construction of a sliding and guide bearing
for horizontal and angled piping, its fixations on the foundation and the pipe bearings are shown.
Page 69 / 127
Pre-Design
Fig. 102: Side view slide bearing and guide

bearing horizontal (15/201-ST-01101)
Fig. 104: Side view slide bearing and guide bearing

angled (15/201-ST-01-102)
Fig. 103: Front view slide bearing and guide bearing

Fig. 105: Front view slide and guide bearing angled (15/201ST-01-102)
Page 70 / 127
Pre-Design
Fig. 106: Pipe bearing, LSL 23.0150.107-37.2 by

Witzenmann
2.8.2.5.5
Fig. 107: Pipe bearing, LSL 23.0150.107-37.2 by

Witzenmann
Foundations
Concrete foundations as support for the pipeline were pre-dimensioned with a systematic and
comprehensive approach according to the loading situation of the separate bearing types which vary
depending on the course of the pipeline (see Tab. 23 - Tab. 25 and sections 2.8.2.2 and 2.8.2.3). The
loads are calculated without any safety margins.
Fig. 108: Side view of a pipe with coordinate

system
Fig. 109: Plan view on a pipe with coordinate

system
Tab. 23: Loads without safety margins for the fixed points (coordinate system see Fig. 108 and Fig. 109)
Direction
Fx
Fy
Fz
Additional load of water hammer
Fx, water hammer
Fy, water hammer
Fz, water hammer
Loads
+/- 26 kN
+/- 11 kN
- 9 kN
+/- 68 kN
+/- 17 kN
-25 kN until +21 kN
seen in Fig. 92 - Fig. 105. For the guide and slide bearings the dimensions are length x width x height
l x w x h = 0.5 x 1.0 x 0.5 m, for the reinforced guide bearings l x w x h = 1.0 x 1.0 x 0.75 m and for
the fixed points the dimensions are l x w x h = 2.0 x 1.5 x 0.75 m. They should be realized with a
concrete with a characteristic strength of f ck = C25/30. The installation of a minimum reinforcement to
account for a ductile member failure is optional.
Page 71 / 127
Pre-Design
The size of the foundations was calculated without partial safety factors. However, the concrete
properties were lowered by a factor of 0.85 and in addition a global safety factor for all concrete
foundations of 2.0 was assumed in this pre-design.
Tab. 24: Loads without safety margins for the reinforced guide bearings
Direction
Fx
Fy
Fz
Additional load of water hammer
Fy, water hammer
Fz, water hammer
Loads
+/- 7 kN
+/- 7 kN
- 9 kN
+/- 14 kN
4 kN
Tab. 25: Loads without safety margins for the slide bearing and guide bearing
Direction
Fx
Fy
Fz
Loads
7 kN
5 kN
- 9 kN
The permitted contact pressure was assumed to be 150 kN/m. However, it is recommended to verify
this assumption when checking the in-situ ground conditions before the beginning of the construction
to a water hammer (see Tab. 6 - Tab. 8), which seems to be quite unlikely (see section 2.8.2.8), there
are basically two options. It would be possible in this case either to enlarge the dimensions of the
foundations according to the additional static requirements or to fix them to the rock ground e.g. with
embedded reinforcement bars which is illustrated in Fig. 110.
Fig. 110: Exemplary illustration of a concrete foundation fixed to the ground with embedded reinforcement bars
Page 72 / 127
Pre-Design
2.8.2.6 Expansion compensation concept

In this section the needed compensations for pipe expansions are described for each pipe segment in
reference to the isometric drawings, which can be found in the appendix B.
The segment from Point 01 until Point 03 has a distance of approximately 332 m. To compensate the
displacement, two U-bends are used. A U elbow can be placed directly at Point 02 (kink in the peak of
the U-bend, outreach 2.5 m). The use of U-bends in the area of kinks prevents the occurrence of
higher forces at the kinks. The second U-bend has an outreach of 3 m and compensates the
displacement of a 150 m pipe segment.
The segment from the Point 03 until the Point 04 has a distance of approximately of 166 m. The
displacement of a 110 m pipe segment is compensated by U-bend with an outreach of 2 m. The other
displacements can be compensated by the L-bends (app. 60 elbows) in the Points 03 and Points 04.
The greatest slope of the pipe is between the Point 04 and Point 05. It is approximately 42. The fixed
points in this segment are used to anchor the downward forces (sliding down of the pipeline). The
thermal expansions of the pipe in this segment can be compensated by two U-bends (outreach app.
2.5 m).
The following segment from Point 05 until Point 13 consists of sub-segments with several small and
medium kink angles (15 to 30). The displacement is compensated by two U-bends at the Point 07
and Point 10. Fixed points are positioned in the area of the Point 06, Point 09 and Point 12.
In the segment Point 13 until Point 18 with a pipe length of 136 m, the displacements are
compensated by a Z-bend at the Point 17 with an outreach of approximately 1.8 m.
The thermal expansions in the segment Point 18 until Point 25 is compensated by two U-bends (Point
20, Point 24) and an expansion bend at Point 25. The U-bends have an outreach of 2 2.5 m
(asymmetric) and absorb the displacement of 150 m of the pipe.
In the following of the pipe routing (Point 25 Point 35) the pipe segments are shorter (maximum 105
m), thus, the displacement is compensated by the expansion bends at the existing kinks. In the middle
of straight segments, fixed points have to be constructed. The fixed points are mainly used to anchor
the forces resulting from the water hammer event.
For a detailed presentation of the expansion concept, it is referred to the isometric drawings shown in
appendix 0.
The use of the permissible tensions for the operating parameters (fatigue analyses for the temperature
range of -10C 50C) is about 85 %. Thus, a sufficient buffer for the length adjustment due to
adaptation to the local boundary conditions exists.
2.8.2.7 Corrosion protection
In order to ensure the durability of the pipe, it should be protected against corrosion. The pipe has to
be painted by coat paint.
Page 73 / 127
Pre-Design
2.8.2.8 Water hammer protection

2.8.2.8.1
General explanation
The extension of the hydro power plan Seo Ho consists of two pump modules. Each pump is driven by
a turbine. Both machines are directly connected by a coupling. No rational reason is seen, which leads
to a total failure of the system. The only reason can be a destruction of the coupling or a shaft
breaking. For reasons of a 100% secure a water hammer calculation and analysis of the hypothetical
total failure was done and is described in the following.
2.8.2.8.2
Water hammer analysis without a water hammer protection
The worst case regarding water hammer would be the sudden total failure or breakdown of the PaTpump modules. A reason for that case could be, e.g., a destruction or break of the coupling or the
shaft of the PaT-pump modules. However this case is hypothetical and would most likely not occur.
In the worst case scenario, the maximum positive pressure is 70 bar at the lowest point of the pipe
(Point 01) at an altitude of about 700 masl and 18 bar at the highest point of the pipe at an altitude of
1250 masl according to the calculation of the company KSB AG (see Fig. 111). This pressure contains
the geodetic water pressure of 547 m (H = 543 m + 4 m (filling the tank from the top)), the dynamic
head of 31 m (due to the maximum delivery rate of 20 l/s and a pipe roughness of 0.1 mm) and the
increase of pressure due to the water hammer.
In the worst case scenario, the pressure drops to vapor pressure from pipe length 700 m until pipe
length 2,455 m (tank in Ma U) according to the calculation of the company KSB AG (see Fig. 111).
After collapsing of the vapor bubble the according section of the pipe would be exposed to dangerous
pressures. Hence, water hammer protection devices, as specified in the next section 2.8.2.8.3, should
be installed to prevent the pressure drop.
Fig. 111: Results of the water hammer analysis for worst case scenario without water hammer protection
Page 74 / 127
Pre-Design
2.8.2.8.3
Specification of the water hammer protection
Air vessel
To be on the safe side an air vessel should be installed at pipe length 870 m at an altitude of 1,127.3
masl to avoid a drop to vapor pressure (see point 6 in Tab. 20 and Fig. 82). The air vessel should be
in PN25 and has to have a total volume of 500 l with a gas volume of approx. 350 l (70%) at an
operating pressure of 12,5 bar (rel.) to realize an outlet operating pressure of 13,5 bar (abs.). E.g., an
air vessel of the company Olaer, type DDH 500-25/90 with a connection DN100 would be appropriate
(see. Fig. 112 and http://www.olaer.ch/Downloads/Wasser/en/old_0470-e.pdf). The air vessel might
be installed directly on the pressure supply pipe. However, it is recommended to install a gate valve inbetween pipe and air vessel. Furthermore, it is recommended to install a LED water level display in
order to be able to monitor the functionality of the air vessel. To protect the air vessel a chamber has
to be build. The chambers are to construct with reinforced concrete and lids with a handle, which is
lockable.
Fig. 112: Exemplary specification of an appropriate air vessel (Olaer, type DDH 500-25/90)
Page 75 / 127
Pre-Design
Air valves
Furthermore, air valves have to be installed at the local high points 18, 30 and 32 of the pipe in order
to avoid vapor pressures and to enable a smooth operation (see. Tab. 20 and Fig. 113). The air valves
are specified in the next section 2.8.2.9. (In Fig. 113 the water hammer analysis with the installed air
vessel and air valves is shown. The pressure does not drop to vapor pressure.)
Pipe wall thickness
In Fig. 113 (bottom) is seen that pressure peaks up to 73 bar at the lowest point of the pipe at an
altitude of about 700 masl occur in short-term (Point 01 = PS outlet). Hence, the maximum pressure of
73 bar due to water hammer has been considered as maximum design pressure (MDP) for the design
of the pipe (material, wall thickness), see section 2.8.2.2.2.
Fig. 113: Results of water hammer analysis for worst case scenario with water hammer protection
Page 76 / 127
Pre-Design
Changes in the routing of the pipe, described in section 2.8.2.1, might lead to the need for
revision of the location and specification of the water hammer protection devices. This must be
considered in the course of the developing of the Final Engineering Design.
2.8.2.9 Air valves
At each local high point an air valve must be mounted. For the suggested route of the supply pipe (see
section 2.8.2.1) at three locations air valves have to be installed with the specifications summarized in
Tab. 26 (exemplary specification of an appropriate air valve: VAG Duojet, type KAT-A 1919).
Tab. 26: Location (see. Tab. 20) and specification of the air valves
Point (see
Tab. 20)
18
30
32
Length of the
pipe [m]
1333.2
2140.0
2305.2
Height [m]
PN [bar]
DN
1189.6
1240.6
1246.8
35
35
35
50
50
50
Min. inlet
aperture [mm]
10
10
10
Changes in the routing of the pipe, described in section 2.8.2.1, might lead to a revision of the
location and specification of the air valves, (to be considered in the Final Engineering Design.
2.8.2.10 Construction stages of the pressure supply pipe
The pressure supply has to be constructed in two construction stages as described in section 2.5.2.1
to ensure a precise connection of the pressure supply pipe with the pumping modules.
2.8.3
Material and services
2.8.3.1 Piping
The dimensioning process for all pipe segments includes a safety factor of 1.5 referring to the
required strength of the material.
Tab. 27: List of materials for piping
Position
27.1
27.2
27.3
Materials
Piping
Material P235
DN 150
OD 168.3
Wall thickness: 6.3 mm
Piping
Material P235
DN 150
OD 168.3
Piping
Material P235
DN 150
OD 168.3
Amount
~ 280
Unit
m
~ 330
~ 150
Page 77 / 127
Pre-Design
27.4
27.5
27.6
27.7
27.8
Piping
Material P235
DN 150
OD 168.3
Wall thickness: 4 mm
Pipe elbow
Material P235
DN 150
OD 168.3
BA3D
Wall thickness: 11 mm
Pipe elbow
Material P235
DN 150
OD 168.3
BA3D
Pipe elbow
Material P235
DN 150
OD 168.3
BA3D
Pipe elbow
Material P235
DN 150
OD 168.3
BA3D
~ 1700
pcs
10
pcs
pcs
43
pcs
The pipe material has to be in accordance with the standards listed below or equivalent to them.
These are, but are not limited by, the following:
EN 1333 Flanges and their joints pipework components Definition and selection of PN
Tab. 28: List of materials for welding; calculation with 6 m pipe segments
Position
28.1
Materials
Materials for welding: Number of joints
Amount
410
Unit
pcs
DIN EN ISO 9606-1 Qualification test of welders
Page 78 / 127
Pre-Design
DIN EN ISO 9692-1 Welding and allied processes Types of joint preparation, Part 1
Manual metal-arc welding, gas-shielded metal-arc welding, gas welding, TIG welding and
beam welding of steels
2.8.3.3 Bearing and foundations
Tab. 29: List of materials for bearings
Position
29.1
29.2
29.3
Materials
Fixed points (21, referring to drawing 15/201-ST-01-105 respectively 106):
dimensions according to the static requirements l x w x h = 2.0 x
1.5 x 0.75 m, approximately 2.25 m per fixed point each
Steel plate 250 x 150 x 20 mm (min. tensile strength 235 N/mm)
Steel plate steel 160 x 140 x 1 mm (min. tensile strength 235
N/mm)
U-profile (min. tensile strength 235 N/mm)
Pipe shell, min. thickness same as the pipe (min. tensile strength
235 N/mm)
Profiled steel HEA 140 (min. tensile strength 235 N/mm)
L-profile steel 50 x 5 mm (min. tensile strength 235 N/mm)
Bolts Hilti HIT-HV200-A + HIT-V-D M16 (or comparable)
Reinforced guide bearings (70, referring to drawing 15/201-ST-01-103
respectively -104):
1.0 x 0.75 m, approximately 0.75 m per reinforced guide
bearing each
Bolts Hilti HIT-HV200-A+HIT-V-D M16 (or comparable)
Pipe bearing type LSF 43.0150.107-37.2 by Witzenmann (or
Slid and guide bearings(329, referring to drawing 15/201-ST-01-101
respectively -102):
1.0 x 0.5 m, approximately 0.25 m per bearing each
comparable) (min. tensile strength 235 N/mm), onle for guide
bearing
Amount
Unit
47.25
21
168
pcs
pcs
42
21
pcs
pcs
126
42
42
pcs
pcs
pcs
52.5
70
280
280
70
pcs
pcs
pcs
pcs
82.25
329
658
987
59
1316
329
pcs
pcs
pcs
pcs
pcs
pcs
Page 79 / 127
Pre-Design

Tab. 30: List of materials for corrosion protection
Position
30.1
Materials
Coating for protection against corrosion
Amount
~ 1,300
Unit
m
The corrosion protection has to be in accordance with the standards listed below or equivalent to
them. These are, but are not limited by, the following:
EN ISO 12944 part 1 8
2.8.3.5 Water hammer protection
Tab. 31: List of materials for the water hammer protection
Position
31.1
Materials
Air vessel
Volume: 500 l (350 l gas, 70%), operating pressure: 12.5 bar,
operating pressure outlet: 1.5 bar
PN 25
DN100
Gate valve
DN100
Chamber
Reinforced concrete
Amount
1
Unit
pcs
2.8.3.6 Air valves

Tab. 32: List of materials for air valves
Position
32.1
Materials
Air valve
DN 50
PN 35
Amount
3
Unit
pcs
2.8.3.7 Services
Tab. 33: List of services for the pressure supply pipe
Position
33.1
33.2
33.3
33.4
33.5
33.6
33.7
33.8
33.9
Service
Land purchase for the pressure supply pipe
Transport of materials to construction site
Piping
Construction of foundations
Installation of the bearings
Installation of the air valves
Installation of the air vessel
Painting of corrosion protection
Amount
2,455
1
2,455
410
420
420
Unit
m
ls
m
pcs
pcs
pcs
~ 1,300
Page 80 / 127
Pre-Design
The services have to be in accordance with the standards listed below or equivalent to them. These
are, but are not limited by, the following:
levels
2.9
2.9.1
Distribution tank Ma U
Location
To distribute the pumped water to the consumers within the supply areas Dong Van City, Sang Ma
Sao and North Slope a distribution tank will be constructed in the village Ma U. It represents a
geodetic highpoint which allows supplying the supply areas by gravity. The exact location of the tank
th
was determined together with the Ha Giang and Dong Van Peoples Committees on 13 of November
2014. The tank will be constructed next to the school in Ma U at an altitude of 1,250 masl (see Fig.
114).
Fig. 114: Location of the distribution tank in Ma U
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Page 81 / 127
Pre-Design
2.9.2
Functionality
The tank in Ma U has two functions. It has a certain storage capacity to buffer the variations between
inflow and outflow. In order to distribute certain proportions of the inflow to the supply areas, the tank
furthermore serves as a facility to divide the inflow proportionally into three defined outflows which
supply Dong Van City, the supply are Sang Ma Sao and the supply area North Slope.
The tanks construction sees a pre-chamber which collects the total inflow (water pumped from Seo
Ho HPP). The pre-chamber has three weirs. The weir overflows are collected in three chambers from
which the water is distributed through pipes to the supply areas. The allocation of the inflow to the
three chambers and, thus, the definition of the proportion of the inflow, each supply area is supplied
with, can be flexibly defined by choosing the width of the weirs (weir overflow/total inflow = weir
width/total weir width). The advantage of that solution is the fact that the varying inflow is proportionally
allocated to the supply areas without any daily operation.
2.9.3
2.9.3.1 Basic structure of the distribution tank

The distribution tank will have a total storage volume of 110 m. The tank consists of a pre-chamber
and three chambers, which each supply a supply area (see Fig. 115). Note that Sang Ma Sao and Ma
U will be supplied by one chamber. Each chamber is equipped with a supply pipe including a gate
valve (see Fig. 115). In order to ensure a flow of water towards the supply pipe, the bottoms of the
three chambers as well as the pre-chamber have to be built with a slope of 2% towards the respective
emptying pipe. A water sump in the area of the supply pipe is necessary to avoid sucking air by the
pipe (see Fig. 116). The exact dimensions can be found in the following figures. The weir, the inflow,
outflow and the run of the pipes outside of the tank are in the Fig. 117 - Fig. 122 in more detail. The
array of the openings in the ceiling can be found in the Fig. 123.
The walls and the ceiling of the tank are designed to have a thickness of 20 cm each, the slab of 30
cm. It should be made out of reinforced concrete with a minimum characteristic strength f ck = C30/37.
At both sides of the walls, ceiling and slab, a reinforcement with a bar diameter of 12 mm each 150
mm should be installed crosswise in longitudinal and transverse direction.
Page 82 / 127
Pre-Design
NORTH
DN 150
OVERFLOW
DN 200
INFLOW
DN150
1.00
DN100
EMPTYING AND OVERFLOW PIPE, MATERIAL: STEEL
SLOPE: 2%
CHAMBER: VILLAGES NORTH SLOPE
CROSSBAR
CHAMBER: DONG VAN
CROSSBAR
SLOPE: 2%
SLOPE: 2%
CHAMBER: SANG MA SAO AND MA U

CROSSBAR
4.30
0.70
SLOPE: 2%
DN100
DN100
DN100
0.50
0.20
0.40
0.40
0.50
0.40
0.20
0.20
0.44 0.44
1.94
1.94
0.44 0.44
1.00
4.00
1.00
SLOPE: 2%
PRECHAMBER
0.20
3
3
0.20
DN75
GATE VALVE
DN100
SUPPLY PIPE
MATERIAL: STEEL
DN50
Fig. 115: Section 1-1: Ground plan of the distribution tank; Dimensions in meter
Page 83 / 127
DN100
Pre-Design
1.80
2.20
0.20
INFLOW PIPE, MATERIAL STEEL

OVERFLOW
DETAIL 3
EMPTYING PIPE, DN100
1.00
DETAIL 1 AND 2
DN150
0.30
0.20
0.30
SLOPE: 2%
4.30
SLOPE: 2%
0.70
SUPPLY PIPE
DN100
EMPTYING PIPE
0.20
0.30
Fig. 116: Section 2-2: Side view of the distribution tank; Dimensions in meter
2.9.3.2 Supply and emptying pipe

Each chamber is equipped with a supply pipe and a gate valve. In order to ensure security of supply in
a possible failure of one chamber, the supply pipes of the respective chambers are connected to each
other and separated by gate valves (see Fig. 115). For maintenance measures each chamber must be
able to be emptied. Therefore an emptying pipe with a gate valve branches of each supply pipe. For
the pre-chamber an emptying pipe is provided as well. It is located directly under the overflow at the
Page 84 / 127
Pre-Design
0.50
bottom (see Fig. 116). All emptying pipes and the overflow run together to one pipe (see Fig. 115).
This pipe should be end in a field next to Ma U to provide the water to the local agriculture.
1.22
OVERFLOW
EMPTYING PIPE
PRE-CHAMBER
2.70
DN 150
SUPPLY PIPE
SANG MA SAO
0.40
GATE VALVE
SUPPLY PIPE
DONG VAN CITY
0.64
0.40
2.10
SUPPLY PIPE
NORTH SLOPE
EMPTYING PIPEDN100
0.40
2.10
0.40
0.40
0.20
Fig. 117: Section 3-3: Routing of the emptying and overflow pipes; Dimensions in meter
2.9.3.3 Inflow and overflow

The tank will be filled above the water level. A submerged inlet should be avoided. The nozzle of the
inlet shows a 90 arc pointing down. Thus, the energy of the jet dissipates in the water of the prechamber (see Fig. 118). For safety reasons the tank has to be equipped with an overflow, which is
mounted at the top of the pre-chamber (see Fig. 119). Outside of the tank the overflow pipe is
connected with the emptying pipe to remove the water (see Fig. 117).
Page 85 / 127
0.20
INFLOW
0.15
0.10
Pre-Design
OVERFLOW
0.30
0.18
0.10
0.40
0.10
0.10
DN150
0.10
0.41
0.41
Fig. 118: Detail 1: Detailed side view of the inflow

(Note: Overflow is EMPTYING
eliminated for
PIPEthis figure);
Dimensions in meter
Fig. 119: Detail 2: Detailed side view of the overflow

(Note: Inflow is eliminated for this figure); Dimensions
in meter
EMPTYING PIPE
2.9.3.4 Weirs
Weirs between the pre-chamber and the three chambers allow that water flows from the pre-chamber
to the chambers. The widths of the weirs define the distribution of the inflow to the chambers and,
thus, to the supply areas. 0.4 m above the weir three crossbars are installed (see Fig. 120). The
material of the crossbars can be wood or reinforced concrete. The crossbars should be fixed in the
partition wall. Barrier plates are mounted at the crossbar to reduce the width of the weir to finally
regulate the discharge to the chamber (see Fig. 121 and Fig. 122). The width of the weir can be set
fine due to the possibility of overlapping of the barrier plates.
SLOPE: 2%
Fig. 120: Front view of the weir with the installed crossbar and
barrier plates (Chamber: Villages north slope and chamber:
1.00 construction for the chamber
Sang Ma Sao and Ma U); the
Dong Van is the same but differs in the width (4 m)
Fig. 121: Scheme of the installation of the

barrier plates
4.30
0.20
1.00
0.20
Page 86 / 127
Pre-Design
Fig. 122: Detail 3: Side view of the weir and the barrier plate
2.9.3.5 Openings in the ceiling of the tank

In the ceiling of the tank openings are necessary to have access to the chambers for reasons of repair
and to set the widths of the weirs. Four openings are provided to enable access to each chamber of
the tank (see Fig. 123). The four accesses are equipped with hinged lids. The material of the lids
should be any kind of metal. At the openings a handle must be provided and the lids must be lockable
to avoid unauthorized entrance by persons. Inside of each chamber ladders of stainless steel have to
be installed to climb down into the chamber. For the three chambers ladders with a length of 4 m and
a width between 0.4 0.5 m are necessary. For the pre-chamber a ladder with a length of 1.8 m and
the same width as the others is required. The ladders should be fixed at the walls for safety reasons.
The exact dimensions take out of the figures.
Page 87 / 127
Pre-Design
NORTH
INFLOW
0.20
OVERFLOW
0.75
0.75
EMPTYING AND OVERFLOW PIPE, MATERIAL: STEEL
0.75
0.75
0.75
0.75
0.75
0.20
0.75
0.20
GATE VALVE
SUPPLY PIPE
MATERIAL: STEEL
Fig. 123: Section 4-4: Ground plan of the distribution tank with the openings in the ceiling (hatched
cross/diagonal); Dimensions in meter
2.9.3.6 Chamber for the valves

To protect the valves against unauthorized use, valve chambers have to be provided. The chambers
are to construct with reinforced concrete and lids with a handle, which is lockable.
Page 88 / 127
Pre-Design
2.9.4
2.9.4.1 Construction of the tank

Tab. 34: List of materials for the construction of the tank in Ma U
Position
34.1
34.2
34.3
Material
Reinforcement steel with a yield strength of f y = 500 N/mm
Application of a waterproof plaster on the inner tank walls
Amount
5,500
50
264
Unit
kg
m
m
The materials for the tank have to be in accordance with the standards listed below or equivalent to
EN 1508 Water supply Requirements for systems and components for the storage of water
2.9.4.2 Valves and tank facilities
Tab. 35: List of materials for the valves and tank facilities
Position
35.1
35.2
35.3
35.4
35.5
35.6
Material
Gate Valve
Material: Steel
DN 100
PN 6
Inflow pipe
DN 150
OD 168.3 mm
Wall thickness 3.6 mm
Inflow fitting
Material: Steel
DN 150
PN 6
Supply pipe
DN 100
OD 114.3 mm
Emptying and overflow pipe
DN 200, OD 219.1, wall thickness 3.6 mm
Flanges
Material steel
DN 100
Amount
9
Unit
pcs
pcs
10
25
4.5
15.5
18
m
m
m
pcs
Page 89 / 127
Pre-Design
PN 6
35.7
Bolts
36
pcs
36
pcs
72
pcs
pcs
Hexagon shank M16

35.8
35.9
35.10
Nuts
Hexagon nut M16
Washers
Plain washer M16
Overflow hopper
Material: Steel
PN 6
The valves and the tank facilities have to be in accordance with the standards listed below or
equivalent to them. These are, but are not limited by, the following:
verification tests Part 1 3
EN 1092 1 Flanges and their joints Circular flanges for pipes, valves, fittings and
accessories, PN designated Part 1: Steel flanges
EN 10311 Joints for the connection of steel tubes and fittings for the conveyance of water
and other aqueous liquids
EN ISO 4014 Hexagon head bolts Product grades A and B
EN 1515 Parts 1 4 Flanges and their joints Bolting
EN ISO 7089 Plain washers Normal series, Product grade A
Tab. 36: List of materials for the weirs
Position
36.1
36.2
36.3
Material
Crossbar
Material: wood or reinforced concrete
Length: 1 m
Length: 4 m
Bolts
Barrier plates
Material: Metal sheet
60 x 10 x 0.3 cm
Amount
Unit
pcs
2
1
3
30
ls
pcs
Amount
4
Unit
pcs
Tab. 37: List of materials for the openings of the tank
Position
37.1
37.2
Material
Lids with a handle
Material: Metal
0.75 x 0.75 m
Ladder
Material: Stainless steel
Length 4 m, width 0.4 0.5
Length 1.8 m; width 0.4 0.5
pcs
3
1
Page 90 / 127
Pre-Design
2.9.4.3 Services
Tab. 38: List of services for the storage tank in Ma U
Position
38.1
38.2
38.3
38.4
38.5
38.6
Service
Land purchase for the tank
Construction of the distribution tank
Installation of the valves and tank facilities
Installation of the weirs
Installation of the inflow, supply, emptying and overflow pipe
Amount
45
1
133
11
3
6
Unit
m
ls
m
ls
ls
ls
2.10 Distribution from the tank Ma U to the tank Dong Van City
2.10.1 Location
In this chapter the measures for implementing a supply pipe from the distribution tank Ma U (1,250
masl) through a pressure breaker (1,182 masl) to the storage tank above Dong Van City (1,123 masl)
will be described. The pipe with its routing, piping, pipe connection, foundations and the corrosion
protection are described in the sections 2.10.2. The functionality and the structure of the pressure
breaker are described in section 2.10.2 as well. For descriptions of the storage tank above Dong Van
City and the connection of the tank to the distribution network of Dong Van City see the next section
2.11 and the subsequent section 2.12.
Fig. 124: Location of the distribution tank Ma U, supply pipe and the storage tank Dong Van City
Page 91 / 127
Pre-Design
2.10.2 Description of measures

2.10.2.1 Routing
The routing of the pipe is along the existing path/road from Ma U to Dong Van City (see Fig. 126). The
profile and the data of the supply pipe can be found in Fig. 125 respectively in Tab. 39.
developing of the Final Engineering Design.
Fig. 125: Profile of the supply pipe from the distribution tank Ma U to the storage tank Dong Van City
Page 92 / 127
Pre-Design
Fig. 126: Routing of the supply pipe from the distribution tank in Ma U over a pressure breaker to the storage tank
8
above Dong Van; supply pipe (orange line), numbered points are the measured points in Tab. 39
Tab. 39: Data of the planned route
Length of the
pipe section [m]
Point
Length of the
Horizontal distance
pipe ongoing [m]
[m]
Difference
in height
[m]
Height [masl]
1247,2
21,6
21,6
21,2
1,2
1246
9,8
31,5
8,7
4,6
1241,4
61,1
92,6
60,3
10
1231,4
35,4
127,9
35,3
2,2
1229,2
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Page 93 / 127
Pre-Design
34,7
162,7
34,7
1,1
1228,1
37,3
199,9
37,1
3,4
1224,7
30,8
230,7
30,7
2,7
1222
22,3
253,0
22,2
1,8
1220,2
10
93,3
346,3
93,1
6,5
1213,7
11
36,9
383,2
35,9
8,5
1205,2
12
45,9
429,2
45,7
4,7
1200,5
13
51,3
480,5
51,3
1,5
1199
14
47,0
527,5
46,8
4,7
1194,3
15
102,3
629,8
101,6
11,7
1182,6
16
45,2
675,0
45,2
0,3
1182,3
17
46,9
721,9
46,5
5,8
1176,5
18
74,7
796,6
74,5
5,4
1171,1
19
62,2
858,8
62,1
4,2
1166,9
20
45,0
903,8
44,7
5,4
1161,5
21
84,9
988,7
84,6
1154,5
22
27,2
1015,9
27,0
3,4
1151,1
23
67,8
1083,7
67,4
7,3
1143,8
24
77,2
1160,9
76,3
11,7
1132,1
25
74,1
1235,0
73,9
5,2
1126,9
26
32,7
1267,7
32,7
1,8
1125,1
27
59,8
1327,6
59,7
-4,2
1129,3
28
50,4
1378,0
50,2
-4,9
1134,2
29
23,4
1401,5
23,4
1,3
1132,9
30
68,7
1470,1
68,6
2,9
1130
31
45,3
1515,5
45,3
2,1
1127,9
32
56,8
1572,3
56,7
1123,9
2.10.2.2 Piping
For the supply of Dong Van City by gravity, a supply pipe from the distribution tank in Ma U to the
storage tank above Dong Van City will be constructed. The length of the pipe is approx. 1,573 m.
Because the pipe is constructed above ground and, thus, exposed to sunlight and mechanical forces,
a steel P235 is selected as material. Due to the expectable maximum delivery rate of approximately
13.5 l/s a diameter of DN 100 is necessary to ensure a supply of Dong Van City by gravity (by
calculating with a roughness of 0.1 mm and the maximum delivery rate as mentioned before, the
losses are 42 m). Taking into account bypassing the pressure breaker in the future for using hydro
power, the design pressure (DP) is 12.7 bar due to the difference in height between the tank Ma U and
the storage tank Dong Van (). The maximum design pressure (MDP), thus, is 14.7 bar considering a
water hammer protection of 2 bar. This results in a required wall thickness of 3.2 mm according to the
standard EN-DIN 2460 Steel water pipes and fittings.
Page 94 / 127
Pre-Design
Summary of the pipe characteristics:

Tab. 40: Boundary conditions for the distribution pipe
Material
Diameter
Maximum design pressure (MDP)
Wall thickness
Routing
Steel P235
DN 100
14.7 bar
3.2 mm
Above ground

The pipe segments will be welded. The weld must be of high quality to withstand the operating
pressure (see description of the operating pressure in section 0). The welding of joints shall be in
accordance with EN 1011 and DIN 2559. Therefore a certified welder is necessary according to the
standard EN 287-1.
2.10.2.4 Foundation
As support for the supply pipe, foundations shall be constructed at regular intervals. The distance
between the slide bearings is 7.8 m, thus, for this pipe length of almost 1,600 m, 200 slide bearings
are necessary. To absorb the operating pressure and the forces due to temperature expansion, 30
fixed points are necessary, which will be constructed at the kinks of the pipe. To avoid future damages
in the water distribution system and to ensure an economic construction process, the foundations have
to be dimensioned with a systematic and comprehensive approach according to each foundations
loading situation which may vary depending on the course of the pipeline.
2.10.2.5 Corrosion Protection
In order to ensure the durability of the pipe, it must be protected against corrosion. The pipe has to be
painted by coat paint.
2.10.2.6 Pressure breaker
2.10.2.6.1 Functionality
To avoid high pressures a pressure breaker has to be built. The pressure breaker basically is a tank
which splits the pipe in two parts and provides for atmospheric pressure at the location of the tank.
The pressure breaker has to be located at an elevation of 1,182 masl. The location can be found in
Fig. 126 Thus, a maximum pressure of 6.8 bar in the upper part and of 5.9 bar in the lower part of the
pipe is achieved. To dissipate the energy the inflow will be above the water level and to avoid an
overflow, a floating valve will be installed.
Annotation: In case the existing elevation difference between the tank Ma U and Dong Van City shall
be exploited for hydro power generation someday in future the planned pipe infrastructure may be
used. The pressure breaker then simply has to be by-passed.
Page 95 / 127
Pre-Design
2.10.2.6.2 Basic structure
The pressure breaker will have a total storage volume of 3 m and an operating volume between 1.5
and 2.3 m according to the setting of the floating valve. The operating volume prevents an oscillation
of the floating valve (ongoing opening and closing). In order to ensure a flow of water towards the
supply pipe, the bottom of the pressure breaker has to be built with a slope of 2% towards the
emptying pipe. A water sump in the area of the supply pipe is necessary to avoid sucking air by the
pipe (see Fig. 128). The exact dimensions can be found in the following figures. The inflow, outflow
and the run of the pipes outside of the pressure breaker are in the Fig. 127 - Fig. 129 in more detail.
The detailed views of the overflow, inflow and an example of a floating valve can be seen in Fig. 130 Fig. 132. The array of the opening in the ceiling can be found in the Fig. 133.
SUPPLY PIPE
MATERIAL: STEEL
NORTH
DN 100
OVERFLOW
INFLOW
FLOAT
DN 100
1
DN 150
0.10
0.20
DN 100
0.30
3
1.40
1.20
SLOPE 2%
FLOATING VALVE
EMPTYING AND OVERFLOW PIPE

MATERIAL: STEEL
SLOPE 2%
0.87
GATE VALVE
Fig. 127: Section 2-2 Ground plan of the pressure breaker; Dimensions in meter
The walls and the ceiling of the pressure breaker are designed to have a thickness of 20 cm each, the
slab of 30 cm. It should be made out of reinforced concrete with a minimum characteristic strength
fck = C30/37. At both sides of the walls, the ceiling and slab, a reinforcement with a bar diameter of 12
mm each 150 mm should be installed crosswise in longitudinal and transverse direction.
Page 96 / 127
Pre-Design
DETAIL 2
DETAIL 1
1
OVERFLOW
DN 100
FLOATING VALVE
DN 100
FLOAT
1.80
INFLOW
GATE VALVE
SUPPLY PIPE
DN 100
SLOPE 2%
0.30
1.00
0.20
SLOPE 2%
0.40
EMPTYING PIPE
Fig. 128: Section 1-1 Side view of the pressure breaker; Dimensions in meter
2.10.2.6.3 Supply and emptying pipe, overflow

The pressure breaker is equipped with a supply pipe and a gate valve. For maintenance measures the
pressure breaker must be able to be emptied. Therefore an emptying pipe with a gate valve branches
of the supply pipe (see Fig. 129). For safety reasons the pressure breaker has to be equipped with an
overflow (see Fig. 130). Outside of the tank the overflow pipe is connected with the emptying pipe to
remove the water (see Fig. 129). This pipe should be end in a field next to the path to Dong Van to
provide the water to the local agriculture.
Page 97 / 127
0.40
DN 100
OVERFLOW
DN 100
0.40
GATE VALVE
DN 150
0.20
0.16
0.60
Fig. 129: Section 3-3 Routing of the emptying and overflow pipes; Dimensions in meter
OVERFLOW
W
DN 100
0.15
0.10
DETAIL 1
0.20
Pre-Design
0.30
FLOAT
Fig. 130: Detail 2 Detailed side view of the overflow; Dimensions in meter
Page 98 / 127
2.10.2.6.4 Inflow and floating valve

The pressure breaker will be filled above the water, to dissipate the energy of the jet. The nozzle of the
inlet has a 90 arc pointing down.
As mentioned before a floating vale will be installed. As a possible example a floating valve and its
specification is described in the following and shown in Fig. 132 which includes the mentioned
numbers in the text. The floating valve is composed of a main valve (1), a handle (2), a float bar (3)
and a float (4). The float and the float bar increase with the increasing water level. This is transferred
mechanically over the handle to the main valve which closes tightly. The main valve remains close
until the float reaches the lower stop. The difference between the top and bottom water level is
adjustable from 50 mm to 600 mm (source: www.erhard.de).
0.10
OVERFLOW
0.05
DN 100
DN 100
0.40
1.80
FLOAT
Fig. 131: Detail 1 Detailed side view of the inflow and

the installed floating valve; Dimensions in meter
Fig. 132: Scheme of the floating valve; see description

9
of the figure in section 0
2.10.2.6.5 Openings in the ceiling of the tank

FLOATING VALVE
In the ceiling of the pressure breaker an opening is necessary to have access to the chamber for
SLOPE 2%
reasons of repair and to set the floating valve. One opening is provided
toPIPE
enable access to the tank
SUPPLY
(see Fig. 133). The access is equipped with a hinged lid. The material of the lid should be any kind of
DN 100
metal. At the opening a handle must be provided SLOPE
and 2%
the lid must be lockable to avoid unauthorized
entrance by persons. Inside of the pressure breaker a ladder of stainless steel has to be installed to
climb down. The ladder needs a length of 1.8 m and a width between 0.4 0.5 m. The ladders should
1.00
0.40
be fixed0.30
at the walls for safety reasons.
0.20
LVE
Pre-Design
EMPTYING PIPE
www.erhard.de
Page 99 / 127
Pre-Design
0.75
NORTH
0.75
GATE VALVE
Fig. 133: Section 4-4 Ground plan of the pressure breaker with the opening in the ceiling (hatched
cross/diagonal); Dimensions in meter

To protect the valves against unauthorized use, a valve chamber has to be provided. The chamber is
to construct with reinforced concrete and a lid with a handle, which is lockable.
2.10.3 Materials and services
2.10.3.1 Piping
Tab. 41: List of materials for piping; Ma U - storage tank Dong Van City
Position
41.1
Material
Piping:
DN 100
OD 114.3
Amount
1,573
Unit
m
EN-DIN 2460 Steel water pipes and fittings.
Page 100 / 127
Pre-Design

Tab. 42: List of materials for pipe connection: Ma U - storage tank Dong Van City; Calculation for 6 m pipe
segments
Position
42.1
Material
Amount
263
Unit
pcs
The pipe connection by welding has to be in accordance with the standards listed below or equivalent
to them. These are, but are not limited by, the following:
2.10.3.3 Foundation
Tab. 43: List of materials for the foundations
Position
43.1
43.2
Materials
Fixed points with assumed dimensions of 40 x 40 x 40 cm (30):
approximately 4.5 kg per fixed point each
approximately 0.064 m per fixed point each
Sliding supports (200):
approximately 1.3 kg per sliding support each
approximately 0.036 m per sliding support each
Amount
Unit
135
kg
260
kg
7.2

Tab. 44: List of materials for corrosion protection
Position
44.1
Material
Amount
565
Unit
m
2.10.3.5 Pressure breaker
Tab. 45: List of materials for pressure breaker
Position
45.1
45.2
45.3
Material
Amount
300
3
13
Unit
kg
m
m
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Pre-Design
Tab. 46: List of materials for the valves and facilities of the pressure breaker
Position
46.1
46.2
46.3
46.4
46.5
46.6
46.7
46.8
46.9
46.10
46.11
46.12
Material
Gate valve
Material: steel
DN 100
PN 6
Floating valve
Material steel
DN 100
PN 6
Inflow pipe
DN 100
OD 114.3 mm
Inflow inlet
Material: steel
DN 100
OD 114.3 mm
Overflow pipe
Material: steel
DN 100
OD 114.3 mm
Wall thickness X.X mm
Overflow hopper
PN 6
Supply pipe
DN 100
OD 114.3 mm
Emptying pipe
DN 100, OD 114.3 mm, wall thickness 3.2 mm
DN 150, OD XXX.X mm, wall thickness X.X mm
Flanges
Material: Steel
DN 100
PN 6
Bolts
Hexagon shank M16
Nuts
Hexagon nut M16
Washers
Plain washers M16
Amount
3
Unit
pcs
pcs
pcs
1
5
10
m
m
pcs
20
pcs
20
pcs
40
pcs
The valves and facilities for the pressure breaker have to be in accordance with the standards listed
below or equivalent to them. These are, but are not limited by, the following:
Page 102 / 127
Pre-Design
2.10.3.6 Services
Tab. 47: List of services
Position
47.1
47.2
47.3
47.4
47.5
47.6
47.7
47.8
47.9
Material
Land purchase for supply pipe and pressure breaker
Piping
Fixed points
Sliding supports
Restricted guidance
Construction of pressure breaker
Amount
1,573
1
1,573
263
Unit
m
ls
m
ls
30
200
30
565
1
6
4
pcs
pcs
pcs
m
ls
pcs
ls
Note: Position 10.25 is a calculation for 6 m pipe segments

levels
EN 805 Water supply Requirements for systems and components outside building
2.11 Storage tank Dong Van City

2.11.1 Location
To buffer differences between the amount of water Dong Van City is supplied with and the
consumption within Dong Van City a storage tank above Dong Van City will be constructed (see Fig.
134). The storage tank will be located at 1,123 masl in the west of Dong Van City. The coordinates of
the location of the tank are 535719, 2574486 (x-coordinate, y-coordinate; reference system:
VN_2000_UTM_Zone_48N). From there the water distribution system of Dong Van City is supplied by
gravity. In the following sections the functionality, basic structure and the run of the pipes of the tank is
described.
Page 103 / 127
Pre-Design
10
Fig. 134: Location of the storage tank Dong Van City

2.11.2.1 Basic structure of the storage tank
The storage tank above Dong Van City will have two chambers with a total storage volume of 450 m
(225 m per chamber). This volume gives the possibility of storing more than a third of the maximum
delivery rate of approx. 13.5 l/s in the time period of no demand in Dong Van City. Furthermore, the
storage volume is equal to the daily consumption of 5,000 people with a specific demand of 90 l/cap/d.
(Annotation: the tank construction enables an extension of the tank by additional chambers on two
sides of the tank.) The planned tank consists of two chambers for reasons of maintenance and repair
(see Fig. 135). In order to ensure a flow of water towards the supply pipe, the bottoms of the two
chambers have to be built with a slope of 2 % towards the supply pipes. A water sump in the area of
the supply pipe is necessary to avoid sucking air by the pipe (see Fig. 136). The exact dimensions can
be found in the following figures. The inflow, outflow and the run of the pipes outside of the tank are in
the Fig. 135 - Fig. 137 in more detail. In the Fig. 138 and Fig. 139 the inflow and the overflow can be
seen in more detail. The array of the openings in the ceiling can be found in the Fig. 140.
10
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Page 104 / 127
Pre-Design
GATE VALVE
The walls and the ceiling of the storage tank are designed to have a thickness of 20 cm each, the slab
of 30 cm. They should be made out of reinforced concrete with a minimum characteristic strength
fck = C30/37. At both sides of the walls, ceiling and slab, a reinforcement with a bar diameter of 12 mm
each 100 mm should be installed crosswise in longitudinal and transverse direction.
0.50
SUPPLY PIPE
MATERIAL: STEEL
MATERIAL: STEEL
0.70
0.50
DN 100
SLOPE 2%
DN 100
DN 100
OVERFLOW
1.94
SLOPE 2%
1.39
1.39
OVERFLOW
2.94
DN 100
DN 150
1.44
SLOPE 2%
CHAMBER I
0.30
1.00
INFLOW
2.94
5.00
NORTH
5.00
1.94
FLOATING VALVE
1.94
INFLOW
2.94
CHAMBER II
SLOPE 2%
9.30
0.44
Fig. 135: Section 1-1 Ground plan of the storage tank Dong Van; Dimensions in meter
Page 105 / 127
Pre-Design
Fig. 136: Section 2-2 Side view of the storage tank Dong Van; Dimensions in meter
Page 106 / 127
Pre-Design
2.11.2.2 Supply and emptying pipe
0.81
Each chamber is equipped with a supply pipe and a gate valve. The supply pipes leaving the
chambers join to one single supply pipe (see Fig. 135). For maintenance measures each chamber
must be able to be emptied. Therefore an emptying pipe with a gate valve branches of each supply
pipe (see Fig. 135 - Fig. 137). The overflow pipes of both chambers run together with the emptying
pipe to one pipe.
OVERFLOW
DN 100
DN 100
5.17
OVERFLOW
2.68
DN 100
SUPPLY CHAMBER I
DN 100
0.40
GATE VALVE

1.85
SUPPLY CHAMBER II
DN 150
2.11
1.85
1.64
Fig. 137: Section 3-3 Routing of the emptying and overflow pipes; Dimensions in meter
2.11.2.3 Inflow, floating valve and overflow

The tank will be filled above the water level. A submerged inlet should be avoided. The nozzle of the
inlet has a 90 arc pointing down, thus, the energy of the jet dissipates in the water of the tank (see
Fig. 138).
As mentioned before a floating valve will be installed to prevent a filling up of the storage tank. The
functionality of the floating valve is described in section 2.10.2.6.4.
For safety reasons the tank has to be equipped with an overflow (see Fig. 139). Outside of the tank
the overflow pipe is connected with the emptying pipe to remove the water (see Fig. 137).
Page 107 / 127
FLOATING VALVE
OVERFLOW
0.10
0.10
DN 100
0.50
0.40
Pre-Design
0.65
DN 100
FLOAT
0.50
Fig. 138: Detail 1 Detailed side view of the inflow and

the installed floating valve; Dimensions in meter
0.50
Fig. 139: Detail 2 Detailed side view of the overflow;

Dimensions in meter
2.11.2.4 Openings in the ceiling of the tank
DN 100
In the ceiling of the tank openings are necessary to have access to the chambers for reasons of repair
and to set the floating valve. Two openings are provided to enable access to each chamber of the tank
(see Fig. 140). The two accesses are equipped with hinged lids. The material of the lids should be any
kind of metal. At the openings a handle must be provided and the lids must be lockable to avoid
unauthorized entrance by persons. Inside of each chamber ladders of stainless steel have to be
installed to climb down into the chamber. The ladders need a length of 5 m and a width between 0.4
0.5 m. The ladders should be fixed at the walls for safety reasons.
GATE VALVE
SLOPE: 2%
SLOPE: 2%
SUPPLY PIPE
DN 100
0.20
Page 108 / 127
EMPTYING PIPE
0.70
0.50
0.25
0.30
9.30
0.75
0.75
2.45
0.80
0.75
3.66
NO
RT
H
Pre-Design
2.00
0.75
Fig. 140: Section 4-4 Ground plan of the storage tank with the opennings in the ceiling (hatched cross/diagonal);
Dimensions in meter

To protect the valves against unauthorized use, valve chambers have to be provided. The chambers
are to construct with reinforced concrete and lids with a handle, which is lockable.
2.11.3.1 Construction of the tank
Tab. 48: List of materials for the construction of the storage tank Dong Van City
Position
48.1
48.2
48.3
Material
Amount
16,000
135
450
Unit
kg
m
m
Page 109 / 127
Pre-Design
2.11.3.2 Valves and tank facilities

Tab. 49: List of materials for the valves and tank facilities
Position
49.1
49.2
49.3
49.4
49.5
49.6
49.7
49.8
49.9
49.10
49.11
Material
Gate Valve
Material: Steel
DN 100
PN 6
Floating valve
Material: Steel
DN 100
PN 6
Inflow pipe
DN 100
OD 114.3 mm
Inflow fitting
Material: Steel
DN 100
Supply pipe
DN 100
OD 114.3 mm
Emptying and overflow pipe
Material steel
Flanges
Material: Steel
DN 100
PN 6
Bolts
Hexagon shank M16
Nuts
Hexagon nut M16
Washers
Plain washer M16
Overflow hopper
Material: Steel
PN 6
Amount
6
Unit
pcs
pcs
15
pcs
11
m
20
14
16
pcs
32
pcs
32
pcs
64
pcs
pcs
The storage tank, valves and the tank facilities have to be in accordance with the standards listed
Page 110 / 127
Pre-Design
Tab. 50: List of materials for the openings of the tank
Position
50.1
50.2
Material
Lids
Material: Metal
0.75 x 0.75 m
Ladder
Material: Stainless steel
Length 5 m, width 0.4 0.5
Amount
2
Unit
pcs
pcs
Amount
100
1
500
10
8
Unit
m
ls
m
pcs
ls
2.11.3.3 Services
Tab. 51: List of the services for the storage tank of Dong Van
Position
51.1
51.2
51.3
51.4
51.5
Material
Transport of materials to construction side
Construction of the storage tank
The storage tank, valves and the tank facilities have to be in accordance with the standards listed
Page 111 / 127
Pre-Design
2.12 Distribution from the tank Dong Van City to the existing network of Dong
Van City
2.12.1 Location
Fig. 141: Location of the storage tank above Dong Van City, the supply pipe and the connection to the distribution
system of Dong Van City at the pumping station
The storage tank Dong Van City (see section 2.11) is connected to the distribution system of Dong
Van City via a supply pipe. The pipe with its routing, piping etc. is described in the sections 2.12.2.1 2.12.2.5. The connection to the existing distribution system is described in section 2.12.2.6.
2.12.2.1 Routing
The routing of the pipe is along a path from the storage tank Dong Van City to the pumping station in
Dong Van City where the pipe will be connected to the existing distribution system. The profile, the
routing and the according data of the supply pipe can be found in Fig. 142 and Fig. 143 respectively in
Tab. 52.
developing of the Final Engineering Design.
Page 112 / 127
Pre-Design
Fig. 142: Profile of the supply pipe from the storage tank above Dong Van to the to the existing network of Dong
Van City
Fig. 143: Routing of the supply pipe from the storage tank above Dong Van City to the existing distribution system
11
of Dong Van City; supply pipe (orange line)
11
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Page 113 / 127
Pre-Design
Tab. 52: Data of the planned route
Length of the
pipe section [m]
Point
Length of the
pipe ongoing [m]
Horizontal distance
[m]
Difference
in height
[m]
Height [masl]
0,0
0,0
0,0
1123,9
49,5
49,5
49,3
4,9
1119
64,3
113,8
64,1
4,8
1114,2
29,6
143,5
29,6
1,3
1112,9
17,8
161,3
17,7
1,9
1111
21,6
182,9
21,4
3,1
1107,9
86,3
269,1
85,7
9,9
1098
10,0
279,2
10,0
0,7
1097,3
24,2
303,4
24,2
0,4
1096,9
10
37,1
340,5
37,0
1093,9
11
47,6
388,1
47,5
3,3
1090,6
12
50,3
438,4
50,3
1,9
1088,7
13
35,2
473,6
35,1
2,6
1086,1
14
36,8
510,5
36,8
1,2
1084,9
15
36,3
546,8
36,1
3,8
1081,1
16
50,8
597,6
50,8
1,1
1080
17
27,1
624,7
27,1
0,6
1079,4
18
35,5
660,2
35,5
0,9
1078,5
19
33,7
693,9
33,7
1,6
1076,9
20
45,2
739,2
45,2
2,1
1074,8
21
93,2
832,4
93,1
3,9
1070,9
22
38,7
871,0
38,6
2,2
1068,7
23
28,3
899,3
28,2
1,7
1067
24
43,9
943,2
43,7
4,6
1062,4
25
32,9
976,1
32,9
1061,4
26
73,8
1050,0
73,8
2,2
1059,2
27
53,7
1103,7
53,7
2,2
1057
28
86,5
1190,2
86,5
1,3
1055,7
2.12.2.2 Piping
For the supply of Dong Van City by gravity, a supply pipe from the storage tank Dong Van City to the
existing distribution system at the pumping station will be constructed. The length of the pipe is
approx. 1,190 m. Because the pipe is constructed above ground and, thus, exposed to sunlight and
mechanical forces, a steel P235 is selected as material Due to the expectable maximum delivery rate
of approximately 13.5 l/s a diameter of DN 100 is necessary to ensure a supply of Dong Van City by
gravity (by calculating with a roughness of 0.1 mm and the maximum delivery rate as mentioned
before, the losses are 31 m). The design pressure (DP) is 6.9 bar due to the difference in height
Page 114 / 127
Pre-Design
between the tank dong Van City and connection to the distribution system. The maximum design
pressure (MDP), thus, is 8.9 bar considering a water hammer protection of 2 bar. This results in a
required wall thickness of 3.2 mm according to the standard EN-DIN 2460 Steel water pipes and
fittings.
Tab. 53: Summary of the pipe characteristics
Material
Diameter
Maximum design pressure (MDP)
Wall thickness
Routing
Steel P235
DN 100
8.9 bar
3.2 mm
Above ground
2.12.2.3 Pipe Connection

The pipe segments will be welded. The weld must be of high quality to withstand the operating
pressure (see description of the operating pressure in section 2.12.2.2). The welding of joints shall be
in accordance with EN 1011 and DIN 2559. Therefore a certified welder is necessary according to the
standard EN 287-1.
In order to ensure the durability of the pipe, it must be protected against corrosion. The pipe has to be
painted by coat paint.
2.12.2.5 Foundations
As support for the supply pipe, foundations shall be constructed at regular intervals. The distance
between the slide bearings is 7.8 m, thus, for this pipe length of almost 1,200 m, 155 slide bearings
are necessary. To absorb the operating pressure and the forces due to temperature expansion, 26
fixed points are necessary, which will be constructed at the kinks of the pipe. To avoid future damages
in the water distribution system and to ensure an economic construction process, the foundations have
to be dimensioned with a systematic and comprehensive approach according to each foundations
loading situation which may vary depending on the course of the pipeline. There should be a regular
scheme regarding the design of the pipeline, which is already explained in section 2.10.2.4 and which
can be used in analogy here.
2.12.2.6 Connection with the existing distribution system of Dong Van City
The situation of the connection of the supply pipe from the storage tank Dong Van city to the existing
distribution system at the pumping station is shown in Fig. 144. To control the system input is
necessary (see Fig. 145). A plunger valve is a valve which generates pressure losses in the pipe by
throttling. The plunger valve in this installation has the function to reduce the pressure to an
appropriate pressure for supplying the households and to control the flow into the system. The plunger
valve will be installed with a diameter of DN 100. A non-return valve will be installed after the existing
pump to prevent a flow from the storage tank into the pumping station. The non-return valve needs a
diameter of DN 100 to be installed in the existing pipe at the pumping station.
Page 115 / 127
Pre-Design
The distribution system should be either feed by the pumping station or the storage tank. When
operating both at the same time the pumping station might not be able to produce any discharge due
to the pressure at the outlet pipe controlled by the plunger valve.
Fig. 144: Connection of the supply pipe (dashed blue line) to the existing network (black line)
Fig. 145: Scheme of the connection of the supply pipe (dashed blue line) to the existing network (black line) with
the necessary valves (red)

2.12.3.1 Piping
Tab. 54: List of materials for piping from the storage tank Dong Van City - Connection to existing network of Dong
Van City (next to pumping station)
Position
54.1
Material
Piping:
DN 100
OD 114.3 mm
Amount
1,190
Unit
m
Page 116 / 127
Pre-Design
Tab. 55: List of materials for the pipe connection; Calculation for 6 m pipe segments
Position
55.1
Material
Amount
199
Unit
pcs
The pipe connection by welding has to be in accordance with the standards listed below or equivalent
to them. These are, but are not limited by, the following:
Tab. 56: Materials for corrosion protection for the supply pipe
Position
Material
Amount
Unit
56.1
428
2.12.3.4 Foundations
Tab. 57: List of materials for foundations
Position
57.1
57.2
Materials
Fixed points with assumed dimensions of 40 x 40 x 40 cm (26):
approximately 4.5 kg per fixed point each
approximately 0.064 m per fixed point each
Sliding supports (155):
approximately 1.3 kg per sliding support each
approximately 0.036 m per sliding support each
Amount
Unit
120
kg
1.7
200
kg
5.6
Page 117 / 127
Pre-Design
2.12.3.5 Connection with the existing distribution system

Tab. 58: List of materials for the connection of the supply system with the existing distribution system of Dong Van
Position
58.1
58.2
Materials
Plunger valve
Material steel
DN 100
PN 6
Non-return valve
Material steel
DN 100
PN 6
Amount
1
Unit
pcs
pcs
The valves have to be in accordance with the standards listed below or equivalent to them. These are,
but are not limited by, the following:
2.12.3.6 Services
Tab. 59: List of services
Position
59.1
59.2
59.3
59.4
59.5
59.6
59.7
59.8
Material
Land purchase for supply pipe
Piping
Fixed points
Sliding supports
Restricted guidance
Installation of the plunger valve
Installation of the non-return valve
Amount
1,190
1
1,190
199
428
Unit
m
ls
m
ls
m
26
155
26
1
1
pcs
pcs
pcs
pcs
pcs
Note: Position 12.12 is a calculation for 6 m pipe segments. The services have to be in accordance
with the standards listed below or equivalent to them. These are, but are not limited by, the following:
levels
Page 118 / 127
Pre-Design
Summary of materials and services
The following Tab. 60 and Tab. 61 are a summary of all necessary materials and services within
responsibility of the Vietnamese partners which are related to measures proposed in this present
document. Each item listed in the tables (No.) is shortly described and specified in more detail in
section 2 (see according positions).
Tab. 60: List of materials within the responsibility of the Vietnamese partners
No.
Position
Pipe (steel)
Pipe material (steel)
1.
8.3
2.
10.1
3.
10.2
4.
5.
6.
7.
27.1
27.2
27.3
27.4
8.
27.5
9.
27.6
10.
27.8
11.
27.9
12.
Materials
Amount
Unit
Optional: DN 500, PN 6
DN 300, OD 329.9 mm, wall thickness 5.6 mm, P235
DN 300, elbow pipe, OD 329.9 mm, wall thickness 7.1 mm,
various angles, P235
DN 150, OD 168.3, wall thickness 6.3 mm, P235
DN 150, elbow pipe, OD 168.3, BA3D, wall thickness 11.0
mm, P235
mm, P235
mm, P235
mm, P235
5
80
m
m
pcs
280
330
150
1700
m
m
m
m
pcs
10
pcs
pcs
43
pcs
25
4
4.5
5
20
10
15.5
1,573
2
1
2
1
1
15
11
14
1,190
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
3
18
10
16
pcs
pcs
pcs
pcs
48
pcs
35.5
35.2
35.5
13.
46.8
49.6
35.4
35.5
41.1
46.3
46.4
46.5
14.
46.7
46.8
49.3
49.5
49.6
54.1
Pipe connection (steel)
Flanges (steel, welding neck flange)
15. 10.3
DN 300, PN 25
35.6
16. 46.9
DN 100, PN 6
49.7
Bolts (Hexagon shank)
17. 10.4
M 27
Page 119 / 127
Pre-Design
35.7
46.10
M 16
49.8
19. 10.10
Hilti HIT-HY 200-A + HIT-V-R M16 (or comparable)
10.11
20.
Hilti HST M16 (or comparable)
10.12
21. 36.2
To be adjusted to the on-site conditions
Nuts (Hexagon nut)
22. 10.5
M 27
35.8
23. 46.11
M 16
49.9
Washers (Plain washer)
24. 10.6
M 27
35.9
25. 46.12
M 16
49.10
Elastomeric seals
26. 10.7
DN 300
Materials for welding (number of joints)
27. 10.8
DN 300
28. 28.1
DN 150
42.1
29.
DN 100
55.1
Corrosion protection
10.21
30.1
30.
44.1
56.1
Valves, fittings and other steel parts
Revision valve
31. 10.9
DN 300, PN 25
Inflow fitting
35.3
32.
DN 150, PN 6
49.4
Air valve (steel)
33. 32.1
DN 50, PN 35
Gate valve (steel)
35.1
34. 46.1
DN 100, PN6
49.1
Floating valve (steel)
46.2
35.
DN 100, PN 6
49.2
Overflow hopper (steel)
35.10
36. 46.6
PN 6
49.11
Other steel parts
37. 4.3
Steel parts for gate channel bed and lateral guidance
38. 4.5
Trash rack
Various steel parts for gate channel bed and lateral
39. 7.2
guidance rehabilitation, possibly also rehabilitation of gate
18.
36
20
32
16
32
32
3
pcs
pcs
pcs
pcs
pcs
pcs
ls
48
36
20
32
pcs
pcs
pcs
pcs
96
72
40
64
pcs
pcs
pcs
pcs
pcs
23
410
263
199
pcs
pcs
pcs
pcs
80
1,300
565
428
m
m
m
m
pcs
1
2
pcs
pcs
pcs
9
3
6
pcs
pcs
pcs
1
2
pcs
pcs
1
1
2
pcs
pcs
pcs
2
1
ls
ls
ls
Page 120 / 127
Pre-Design
40.
41.
7.3
7.8
42.
10.10
43.
10.11
44.
45.
46.
47.
48.
49.
50.
10.12
29.1
29.2
29.3
34.1
43.1
43.2
45.1
48.1
57.1
57.2
36.3
37.1
necessary
Various steel parts for trash rack repairing/replacement
Fence including gate
Steel plate 150x250x20 mm (min. tens. str. 235 N/mm)
U-profile U140 (min. tens. str. 235 N/mm)
U-profile U200 (min. tens. str. 235 N/mm)
Pipe bearing thickness 7.1 mm (min. tens. str. 235 N/mm)
Profiled steel HEA100 (min. tens. str. 235 N/mm)
Pipe bearing type LSL 23.0300.150-37.2 by Witzenmann
(or comparable) (min. tens. str. 235 N/mm)
Profiled steel HEA100 (min. tens. str. 235 N/mm)
Guide rail L 50 x 5 (min. tens. str. 235 N/mm)
(or comparable) (min. tens. str. 235 N/mm)
N/mm)
Steel plate steel 160 x 140 x 1 mm (min. tensile strength
235 N/mm)
U-profile (min. tensile strength 235 N/mm)
Pipe shell, min. thickness same as the pipe (min. tensile
strength 235 N/mm)
Profiled steel HEA 140 (min. tensile strength 235 N/mm)
L-profile steel 50 x 5 mm (min. tensile strength 235 N/mm)
Bolts Hilti HIT-HV200-A + HIT-V-D M16 (or comparable)
N/mm)
Bolts Hilti HIT-HV200-A+HIT-V-D M16 (or comparable)
Pipe bearing type LSF 43.0150.107-37.2 by Witzenmann
(or comparable) (min. tensile strength 235 N/mm)
N/mm)
N/mm)
(or comparable) (min. tensile strength 235 N/mm), onle for
guide bearing
Reinforcement steel with a yield strength of fy = 500 n/mm
Barrier plates 60 cm x 10 cm x 0.3 cm

Lids with a handle 0.75 m x 0.75 m
1
1
8
16
1
1
2
8
8
1
8
ls
ls
pcs
pcs
ls
ls
pcs
pcs
pcs
ls
pcs
8
8
1
4
8
pcs
pcs
ls
pcs
pcs
21
168
pcs
pcs
42
21
pcs
pcs
126
42
42
pcs
pcs
pcs
70
280
280
70
pcs
pcs
pcs
pcs
329
pcs
658
987
59
1316
329
pcs
pcs
pcs
pcs
pcs
5,500
135
260
300
16,000
120
200
30
4
kg
kg
kg
kg
kg
kg
kg
pcs
pcs
Page 121 / 127
Pre-Design
50.1
51.
37.2
52.
50.2
pcs
3
1
pcs
pcs
pcs
pcs
pcs
20
30
20
1
2
7.2
1.7
5.6
4.5
1
1
47.25
52.5
82.25
50
3
135
264
13
450
100
8
2
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
m
ls
ls
2
1
pcs
pcs
80
Service
Amount
Unit
ls
Ladder
Length 4 m, width 0.4 - 0.5 m
Length 1.8 m, width 0.4 - 0.5 m
Ladder
Length 5 m, width 0.4 - 0.5 m
Plunger valve
53. 58.1
DN 100, PN 6
Non-return valve
54. 58.2
DN 100, PN 6
Concrete, masonry and plaster
7.1
55.
Reinforced concrete
13.2
Optional: Reinforced concrete
56. 8.2
57. 4.6
Concrete foundation for the new trash rack
43.1
43.2
58.
57.1
57.2
10.10
10.11
10.12
59.
29.1
29.2
29.3
34.2
60. 45.2
48.2
34.3
61. 45.3
Application of waterproof plaster on the inner tank walls
48.3
62. 13.3 A
Masonry walls (option A)
63. 13.3 B
Pillars (option B)
64. 13.7
Crossbar made of concrete (alternative: wood)
65. 36.1
Length 1 m
Length 4 m
Roofing
66. 13.4
Corrugated metal roof on a timber framing
Tab. 61: List of services within the responsibility of the Vietnamese partners
No.
67.
Position
2.1
4.1
6.1
7.4
13.5
16.2 A
16.2 B
33.2
Page 122 / 127
Pre-Design
79.
80.
81.
38.2
47.2
51.2
59.2
2.2
13.1
8.1
8.4
10.15
33.3
47.3
59.3
10.16
10.17
10.14
10.18
33.4
47.4
59.4
10.21
33.9
47.6
59.5
10.19
33.7
59.7
59.8
38.4
47.8
51.4
38.5
38.6
47.9
51.5
51.3
47.7
38.3
82.
2.3
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
84.
85.
86.
87.
88.
89.
90.
91.
4.2
7.6
4.4
10.20
6.3
6.2
7.5
8.5
7.7
7.9
92.
8.6
93.
94.
10.13
13.6
83.
Soil, rock and concrete excavation works

Optional: Soil, rock and concrete excavation works
Piping
Pipe-to-flange welding
Flange-to-flange screwing
Corrosion protection application (including fittings, flanges,

etc.)
Installation of valves
Installation of valves and tank facilities

Installation of the weirs
Installation of the inflow, supply, emptying and overflow
pipe
Construction of the storage tank
Construction of pressure breaker
Construction of the distribution tank
Stabilization of the weir basis with prepacked concrete and
reinforced concrete, respectively
Reconditioning of the sluice gates
Rehabilitation of the anchorage of the sluice gate in basin 2
Concreting of abutments
Inspection & maintenance of the whole channel
Installation of revision openings every 70 m
Restoration of lateral overflow weir crest
Optional: Enlargement of the intake pool
Repairing or replacing of the trash rack
Installation of the fence
Optional: Reconstruction of inlet channel and pipe
connection to headrace channel
Adaptation of pipe routing to local terrain conditions
Construction of the power house extension including the
10
60
100
15
80
2,455
1,573
1,190
3
2
1
23
410
263
199
80
1,300
565
428
m
m
m
m
ls
11
6
10
3
6
4
8
500
1
133
pcs
pcs
pcs
ls
ls
ls
ls
m
ls
m
20
2
1
1
10
700
1
1
1
1
1
ls
ls
ls
ls
m
ls
ls
ls
ls
ls
ls
1
1
ls
ls
m
m
m
ls
ls
ls
ls
ls
ls
m
m
m
m
Page 123 / 127
Pre-Design
95.
13.7
96.
13.8
97.
16.1
98.
99.
5.1
5.2
38.1
51.1
47.1
59.1
33.6
33.5
100.
101.
102.
103.
104.
105. 47.5
106. 59.6
floor slab
Construction of the tailwater pool and the channel to Seo
Ho River
Customs duties in Vietnam (incl. handling cost and
administration processes). All administrative processes
have to be settled and timed in accordance to the projects
time schedule (see section 4)
Optional: Removal of the restriction
Optional: Enlargement of the sand trap basin 2
Land purchase for supply pipe and pressure breaker
Land purchase for the supply pipe
Installation of the bearings
Fixed points
Sliding supports
Restricted guidance
Fixed points
Sliding supports
Restricted guidance
ls
ls
ls
1
1
45
100
1,573
1,190
420
420
ls
ls
m
m
m
m
pcs
pcs
30
200
30
pcs
pcs
pcs
26
155
26
pcs
pcs
pcs
Amount
1
1
2
Unit
ls
pcs
pcs
1
3
2
pcs
pcs
pcs
2
1
2
1
2
pcs
pcs
pcs
pcs
pcs
2
2
2
2
2
1
1
2
1
pcs
pcs
pcs
pcs
pcs
pcs
pcs
pcs
ls
Tab. 62: List of materials within the responsibility of the German partners
No.
1.
2.
3.
Position
9.1
14.1
14.2
4.
14.3
5.
14.3a
6.
7.
14.4
14.5
8.
14.6
9.
10.
11.
12.
13.
14.
14.7
14.8
14.9
14.10
-
Service
Various steel parts for installation of baffle and racks
Revision valve, DN 300, PN 25
Pump valve suction side, DN 125, PN 25
Dismantling joint
DN 300, PN 25
DN 200, PN 25
DN 150, PN 63
Dismantling elbow
DN 125, PN 25
DN 100, PN 25
DN 150, PN 63
Control valve, DN 200, PN 25
PAT valve pressure side, DN 200, PN 25
Flexible joint
DN 125, PN 25
DN 100, PN 25
DN 65, PN 63
Non-return valve, DN 150, PN 63
Pump valve pressure side, DN 150, PN 63
Drainage valve, DN 100, PN 25
Drainage valve, DN 100, PN 63
Water supply modules
Monitoring system consisting of various measurement
Page 124 / 127
Pre-Design
devices
Tab. 63: List of services within the responsibility of the German partners
No.
15.
16.
Position
9.1
9.1
17.
17.1 A
18.
19.
20.
17.1 B
17.2
17.3
Service
Construction of baffle an racks including guidance
Installation of baffle and racks
Installation of machinery and measuring equipment (Option
A)
Installation of pre-installed container (Option B)
Connection to bypass and pressure supply pipe on-site
Installation of monitoring equipment
Amount
1
1
Unit
ls
ls
ls
1
1
1
ls
ls
ls
Page 125 / 127
Pre-Design
Time schedule
In a preliminary time schedule is proposed (see Tab. 64).

Tab. 64: Preliminary time schedule for the pilot implementation of a hydro power driven water pumping and
distribution system (Concept 1) and their responsibilities.
Activity
2014
2015
2016
07-09 10-12 01-03 04-06 07-09 10-12 01-03 04-06 07-09 10-12
Final Pre-Design
Final Engineering Design for construction and
installation works
Matching of Final Engineering Design
Choice of Option A or B of power house
extension
Road construction/maintenance to Seo Ho
HPP & rehabilitation of infrastructure
Provision of pressure supply pipe materials
from Seo Ho HPP to tank in Ma U
(with financial contribution from German side)
Customs duties of pressure supply pipe
materials (if needed) in Vietnam and domestic
transport of all materials to construction side
Construction of the pressure supply pipe incl.
foundations from Seo Ho HPP to tank Ma U
Construction of the distribution tank Ma U and
storage tank Dong Van
Supply pipes from tank Ma U to supply areas
(Dong Van City, Sang Ma Sao, North Slope)
Extension of power house, construction of
foundation for machinery including shafts for
PAT-suction pipes and tailwater pool
Restoration & rearrangement of Seo Ho HPP
weir, sand trap, headrace channel and intake
pool
Temporary accompaniment of construction
measures
Installation of baffle and racks at intake pool to
improve sedimentation capacity
Determination respective the implementation
of optional measures at the intake pool to
improve the sediment deposition capacity
Implementation of optional measures at the
intake pool to improve the sediment deposition
capacity (only on demand)
Determination respective the implementation
of optional measures at the sand trap to
improve the sediment deposition capacity
Implementation of optional measures at the
sand trap to improve the sediment deposition
capacity (only on demand)
German responsibility
Vietnamese responsibility
German and Vietnamese

responsibility
Page 126 / 127
Pre-Design
Activity
2014
2015
2016
07-09 10-12 01-03 04-06 07-09 10-12 01-03 04-06 07-09 10-12
Final design of PAT-pump-modules including
pipe system for machinery, valves and
electrical controlling devices
Production of PAT-pump-modules including
pipe system for machinery, valves and
electrical controlling devices
Test rig runs of PAT-pump-modules
Shipping of PAT-pump-modules to Vietnam
Customs
duties of PAT-pump-modules
machinery parts in Vietnam and domestic
transport of all devices to the construction site
Construction of branch pipe bypass for PATpump-module incl. foundations (1. stage)
Installation of PAT-pump-modules, pipe
system for machinery, valves, electrical
controlling devices including connection to
bypass and pressure supply pipe
Construction of branch pipe bypass for PATpump-module incl. foundations (2. stage) and
connection to machinery
Development of O&M-manuals, training of
operating personnel
Commissioning and inauguration
Operation and maintenance (O&M)
German responsibility
Vietnamese responsibility
German and Vietnamese

responsibility
Page 127 / 127
Pre-Design
Attachment A:
Isometric drawings of penstock bypass (see section 2.5)
Attachment A 1: Overview of the penstock bypasss routing with respect to the bearing concept
Pre-Design
Attachment B:
Isometric drawings of pressure supply pipe (see section 2.8)
Attachment B 1: Overview of the pressure supply pipes routing with respect to the bearing concept
Pre-Design
Attachment B 2: Section 1 of the pressure supply pipes routing with respect to the bearing concept
Pre-Design
Pre-Design
Pre-Design
Pre-Design
Pre-Design

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MOST-BMBF

Vietnamese-German Cooperation for the Development

Edited by Karlsruhe Institute for Technology (KIT)

With contribution of KSB AG

Background and objective of the document .......................................................................... 4

Motivation and objective ......................................................................................... 5

Overview of the measures described in the Pre-Design ..................................................... 12

Specification of measures .............................................................................................................. 14

Weir and intake structure ..................................................................................................... 14

Location and present state ................................................................................... 14

Description of measures ...................................................................................... 15

Materials and services ......................................................................................... 16

Sand trap ............................................................................................................................. 16

Location and present state ................................................................................... 16

Description of measures to minimize water losses and to prevent flotsam entry

Description of measures to improve the sediment deposition capacity ............... 18

Materials and services ......................................................................................... 24

Headrace channel ............................................................................................................... 25

Location and present state ................................................................................... 25

Description of measures ...................................................................................... 27

Materials and services ......................................................................................... 28

Intake pool ........................................................................................................................... 28

Location and present state ................................................................................... 28

Description of measures ...................................................................................... 34

Materials and services ......................................................................................... 38

Penstock bypass to PAT-pump-modules ............................................................................ 39

Location and present state ................................................................................... 39

Description of measures ...................................................................................... 40

Materials and services ......................................................................................... 47

Extension of power house and tailwater pool ...................................................................... 50

Location of power house extension ..................................................................... 50

Description of measures ...................................................................................... 51

Materials and services ......................................................................................... 55

Machinery and equipment ................................................................................................... 56

Description of measures ...................................................................................... 56

Materials and services ......................................................................................... 58

Pressure supply pipe ........................................................................................................... 60

Description of measures ...................................................................................... 60

Material and services ........................................................................................... 77

Distribution tank Ma U ......................................................................................................... 81

Description of measures ...................................................................................... 82

Materials and services ......................................................................................... 89

Description of measures ...................................................................................... 92

Materials and services ....................................................................................... 100

2.11 Storage tank Dong Van City .............................................................................................. 103

Location .............................................................................................................. 103

Description of measures .................................................................................... 104

Materials and services ....................................................................................... 109

Location .............................................................................................................. 112

Description of measures .................................................................................... 112

Materials and services ....................................................................................... 116

Summary of materials and services ............................................................................................. 119

Time schedule .............................................................................................................................. 126

Isometric drawings of penstock bypass

Isometric drawings of pressure supply pipe

Fig. 5: PAT-pump-module and pump discharge diagram

Fig. 6: Overview project area with the supply system

Fig. 7: Unscaled scheme of the storage tank at Ma U

Fig. 8: Unscaled scheme of a pressure breaker with floating valve

Overview of the measures described in the Pre-Design

Fig. 9: Overview of the measures and its location

Section of the measure

Weir and intake structure

Fig. 10: Weir and intake structure (5.12.2014, KIT)