Water transport system

Hari Prasad Neopane, PhD

Associate Professor & Head
Department of Mechanical Engineering
Kathmandu University
hari@ku.edu.np
 Water transport system
Types:
–Canal
–Tunnel
–Culvert
–Penstock Pipes
• Surge tank
• Air release valves
Tunnel under construction
 Shape of Tunnels

Circular Tunnel Non-circular (Horse-shoe)

Tunnel

4
Canals

5
Pipes in Hydro Power
Plants
 Pipes
• Materials
• Calculation of the change of length due to the change of
the temperature
• Calculation of the head loss
• Calculation of maximum pressure
– Static pressure
– Water hammer
• Calculation of the pipe thickness
• Calculation of the economical correct diameter
• Calculation of the forces acting on the anchors
 Materials
• Steel
• Polyethylene, PE
• Glass-fibre reinforced Unsaturated Polyesterplastic
(GUP)
• Wood
• Concrete
• In Nepal, penstock pipe materials are mild steel,
and HDPE. Rigid or unplasticised PVC is yet to be
used.
 Materials Selection Factors
• Design Pressure, Method of joining and Friction
Loss
• Weight and ease of installation
• Accessibility of the site, terrain and soil type
• Design life and maintenance
• Weather condition
• Availability, relative cost and transportation
 Materials
Material Max. Max. Max.
Diameter Pressure Stresses
[m] [m] [MPa]
Steel, St.37 150
Steel, St.42 190
Steel, St.52 206
PE ~ 1,0 160 5
GUP 2,4 320
Max. p = 160 m. Max. D: 1.4 m.

Wood ~5 80
Concrete ~5 ~ 400
Material Quality Density Modulus of Yield Tensile Coefficient of
elasticity limit thermal
strength expansion
[kg/m3] [MPa] [MPa] [MPa] [m/oC m·10-6]
Steel St.37 7830 206 235 363-441 12

Steel St.52 7830 206 353 510-608 12

Stainless NS 14 205 440 590-780

Steel 310-02
PE 920 100-300 7-19

GUP

Wood 300-800 4-11 28-70 5

Concrete 2350 20-40 15-70 10

Steel pipes
Glomfjord
Power Plant
Steel pipes in penstock
Nore Power Plant, Norway
 GUP-Pipe
Raubergfossen Power Plant, Norway
 Wood Pipes

Breivikbotn Power Plant, Norway Øvre Porsa Power Plant, Norway

 Penstocks in Hydro Power Plants
• Projects with penstock • Projects with penstock
started from the Forebay in started from the Surge
Nepal are: tanks in Nepal are:
– Trishuli HPP – Kaligandaki HPP
– Devighat HPP – Marsyangdi HPP
– Sunkoshi HPP – Kulekhani I, II, HPP
– Puwa Khola HPP etc – Khimti HPP
– Bhotekoshi HPP,
– Chilime HPP
– Modi Khola HPP etc.
Calculation of the change of length due to the
change of the temperature
L    T  L
Where:
DL = Change of length [m]
L = Length [m]
a = Coefficient of thermal expansion [m/oC m]
DT = Change of temperature [oC]
 Example
Calculation of the change of length due to the change of the temperature

L    T  L  0.024 m
Where:
L = 100 m Length
a = 12·10-6 m/oC m Coefficient of thermal expansion for steel
DT = 20 oC Change of temperature
The material of the pipe is steel
Calculation of the head loss
2
L c
hf  f  
D 2g
Where:
hf = Head loss [m]
f = Friction factor [-]
L = Length of pipe [m]
D = Diameter of the pipe [m]
c = Water velocity [m/s]
g = Gravity [m/s2]
 Example
Calculation of the head loss
Power Plant data:
H = 100 m Head 2
L c
Q = 10 m3/s Flow Rate
hf  f  
L
D
= 1000 m
= 2.0 m
Length of pipe
Diameter of the pipe D 2g
The pipe material is steel
cD
Re 

Where:
c = 3.2 m/s Water velocity
n = 1.308·10-6 m2/s Kinetic viscosity
Re = 4.9 ·106 Reynolds number
 Where:
Re = 4.9 ·106 Reynolds number
e = 0.045 mm Roughness
D = 2.0 m Diameter of the pipe
e/D = 2.25 ·10-5 Relative roughness
f = 0.013 Friction factor
The pipe material is steel

0,013
 Example
Calculation of the head loss
Power Plant data:
H = 100 m Head
Q = 10 m3/s Flow Rate
L = 1000 m Length of pipe
D = 2.0 m Diameter of the pipe
The pipe material is steel
2 2
L c 1000 3.2
hf  f    0.013    3.4 m
D 2 g 2 2  9.82
Where:
f = 0.013 Friction factor
c = 3.2 m/s Water velocity
g = 9.82 m/s2 Gravity
 Calculation of maximum pressure
• Static head, Hgr (Gross Head)
• Water hammer, Dhwh
• Deflection between pipe supports
• Friction in the axial direction

Hgr
 Maximum pressure rise due to the Water
Hammer
a  c max 2L
h wh  IF TC  Jowkowsky
g a
Dhwh = Pressure rise due to water hammer [mWC]
a = Speed of sound in the penstock [m/s]
cmax = maximum velocity [m/s]
g = gravity [m/s2]
 Example
Jowkowsky
a = 1000 [m/s]
cmax = 10 [m/s]
g = 9.81 [m/s2]
2L
TC 
a a  c max
h wh   1020 m
g
 Maximum pressure rise due to the Water
Hammer
2L
a  c max a c max  2  L 2L
h wh    IF TC 
g TC g  TC a
Where:
Dhwh = Pressure rise due to water hammer [mWC]
a = Speed of sound in the penstock [m/s]
cmax = maximum velocity [m/s]
g = gravity [m/s2]
L = Length [m]
TC = Time to close the main valve or guide vanes [s]
 Example
L = 300 [m]
TC = 10 [s]
cmax = 10 [m/s]
g = 9.81 [m/s2] cmax  2  L
hwh   61 m
g  TC
 Calculation of the pipe thickness
L  D i  p  Cs  2   t  L  t • Based on:
 – Material properties
p  ri  Cs – Pressure from:
t  • Water hammer
t
• Static head
p    g  H gr  h wh 
Where: σt σt
L = Length of the pipe [m] p
Di = Inner diameter of the pipe [m]
p = Pressure inside the pipe [Pa]
st = Stresses in the pipe material [Pa]
t = Thickness of the pipe [m]
Cs = Coefficient of safety [-]
r = Density of the water [kg/m3]
Hgr = Gross Head [m]
Dhwh = Pressure rise due to water hammer [m]
 Example
Calculation of the pipe thickness
L  Di  p  Cs  2   t  L  t
• Based on:

– Material properties
p  ri  Cs
t  0.009 m – Pressure from:
t • Water hammer
• Static head
p    g  H gr  hwh   1.57 MPa

Where:
σt σt
p
L = 0.001 m Length of the pipe
Di = 2.0 m Inner diameter of the pipe
st = 206 MPa Stresses in the pipe material
r = 1000 kg/m3 Density of the water
Cs = 1.2 Coefficient of safety
Hgr = 100 m Gross Head
Dhwh = 61 m Pressure rise due to water hammer
 Calculation of the economical correct diameter
of the pipe
dK tot dK f  K t 
 0
dD dD
Cost [$]

Diameter [m]
 Example
Calculation of the economical correct diameter of the pipe
Hydraulic Losses
Power Plant data:
H = 100 m Head
Q = 10 m3/s Flow Rate
hplant = 85 % Plant efficiency
L = 1000 m Length of pipe

2
L Q C2
PLoss    g  Q  h f    g  Q  f   5
2r 2g  r
2 4
r
Where:
PLoss = Loss of power due to the head loss [W]
r = Density of the water [kg/m3]
g = gravity [m/s2]
Q = Flow rate [m3/s]
hf = Head loss [m]
f = Friction factor [-]
L = Length of pipe [m]
r = Radius of the pipe [m]
C2 = Calculation coefficient
 Example
Calculation of the economical correct diameter of the pipe
Cost of the Hydraulic Losses per year

C2
K f  PLoss  T  kWh price  5  T  kWh price
r
Where:
Kf = Cost for the hydraulic losses [€]
PLoss = Loss of power due to the head loss [W]
T = Energy production time [h/year]
kWhprice = Energy price [€/kWh]
r = Radius of the pipe [m]
C2 = Calculation coefficient
 Example
Calculation of the economical correct diameter of the pipe
Present value of the Hydraulic Losses per year

C2
K f  5  T  kWh price
Where: r
Kf = Cost for the hydraulic losses [€]
T = Energy production time [h/year]
kWhprice = Energy price [€/kWh]
r = Radius of the pipe [m]
C2 = Calculation coefficient

Present value for 20 year of operation:

n
Kf
K f pv 
i 1 1  I 
i

Where:
Kf pv = Present value of the hydraulic losses [€]
n = Lifetime, (Number of year ) [-]
I = Interest rate [-]
 Example
Calculation of the economical correct diameter of the pipe
Cost for the Pipe Material
pr
m  m  V  m  2    r  t  L  m  2    r   L  C1  r 2

K t  M  m  M  C1  r 2

Where:
m = Mass of the pipe [kg]
NB:
rm = Density of the material [kg/m3]
This is a simplification because
V = Volume of material [m3]
no other component then the
r = Radius of pipe [m]
pipe is calculated
L = Length of pipe [m]
p = Pressure in the pipe [MPa]
s = Maximum stress [MPa]
C1 = Calculation coefficient
Kt = Installation costs [€]
M = Cost for the material [€/kg]
 Example
Calculation of the economical correct diameter of the pipe

• Installation Costs:
– Pipes
– Maintenance
– Interests etc..
 Example
Calculation of the economical correct diameter of the pipe
C2
 T  kWh price
K t  M  C1  r
n
 r
5 2
K f pv
i 1 1  I i

d K t  K f  5 n C 2  T  kWhprice
dr
 2  M  C1  r  6
r

i 1 1  I 
i
0
Where:
Kf = Cost for the hydraulic losses [€]
Kt = Installation costs [€]
T = Energy production time [h/year]
kWhprice = Energy price [€/kWh]
r = Radius of the pipe [m]
C1 = Calculation coefficient
C2 = Calculation coefficient
M = Cost for the material [€/kg]
n = Lifetime, (Number of year ) [-]
I = Interest rate [-]
 Example
Calculation of the economical correct diameter of the pipe

d K t  K f  5 n C2  T  kWhprice
 2  M  C1  r  6   0
dr r i 1 1  I i


5 n C2  T  kWhprice
r  7 
2 i 1 M  C  1  I i
Calculation of the forces acting on the anchors
Calculation of the forces acting on the anchors
F1

F2

F1 = Force due to the water pressure [N]

F2 = Force due to the water pressure [N]
Calculation of the forces acting on the anchors

F3

F3 = Friction force due to the pillars upstream the anchor [N]

Calculation of the forces acting on the anchors

F5
F4

F4 = Friction force due to the expansion joint upstream the anchor [N]
F5 = Friction force due to the expansion joint downstream the anchor [N]
Calculation of the forces acting on the anchors
F5
F1 F
F2 F3 F4
Calculation of the forces acting on the anchors

R
G
Steel pipes
Glomfjord
Power Plant
Steel pipes in penstock
Nore Power Plant, Norway
 GUP-Pipe
Raubergfossen Power Plant, Norway
 Wood Pipes

Breivikbotn Power Plant, Norway Øvre Porsa Power Plant, Norway

Anchors
 Surge shaft
• Located near the end
of pipe line or tunnel
• Absorb sudden
pressure rise
 Air release valve
• Also called pressure release valve
• Release trapped air in the pipe line