DESIGN CRITERIA & COMPUTATIONS

FOR
PENSTOCK 03
Table of Contents
I. DESIGN CRITERIA
I.1 Allowable stresses
I.2 Loads
I.3 Stress analysis
I.4 Data Provided by the consultant

II. SOLUTION FOR PRESSURE RISE(Water Hammer)

III. DETERMINE EXTERNAL MOMENTS AND LOADING TO BE CARRIED

BY PENSTOCK
III.1 Data
III.2 Design loadings
III.3 Moment Diagram
III.4 Summary of Moment Calculation at a Distance x

IV. DETERMINE PLATE THICKNESS AND SUPPORT RING PROPERTIES

IV.1 Solve for circumferential and support ring properties cause by the
internal pressure (Hoop Stress)
IV.2 Stiffener ring calculation

V. CALCULATIONS FOR ELBOW CUTS

VI. EXPANSION JOINT DESIGN

VII. DESIGN OF FOUNDATION

I. Design Criteria
MATERIALS: -

ASTM A 516 – 7GB GRADE 70

PROPERTIES: -

Minimum Tensile Strength = 70, 000 psi

Minimum Yield Strength = 8, 000 psi
Modulus of Elasticity = 29 X 106
Pressure Vessel Quality Normalized

1.1 Allowable Stresses

1. NORMAL CONDITIONS
 23, 300 psi
 2/3 x Specified Min Yield Stress or
1/3 x (Specified Min Tensile Strength)

2. INTERMITTENT CONDITIONS
 30,400 psi.
 0.80 x (Specified Min. Yield Strength)
 0.40 x (Specified Min. Tensile Strength)

3. EMERGENCY CONDITIONS
 38,000psi.
 Governing Cushioning stroke inoperative
 Partial gate closure (2L/a) seconds
 Pressure Wave
(2/3) x (Specified Min. Tensile Strength)
Or
Specified Min. Yield Strength

4. EXCEPTIONAL CONDITIONS
 70,000 psi.
 Malfunction of control equipment in most adverse manner
 Codes Do Not recommends these as basis of design. Precautions are
mandatory for minimizing probability of recurrence
Exceptional conditions are ONLY A CHECK to anticipate possible damages

NOTE: -
1. Only the first three conditions govern the design, the exceptional
condition is only a strength check to ensure no damage.
2. Details of Normal & Emergency conditions as elaborated in the
references reproduced and attached as Sheet #3. & Sheet #4.
CONCRETE: -
Concrete for ENCASEMENT, PADESTALS AND ANCHORS shall have 28 days compressive
strength of 3000 psi. Vide ASTM C39 & C42 using ordinary Portland cement and MSA = 1½”.

ALLOWABLE STRESSES: -
Vide ACI 318-92
Flexure stress in compression = 1, 350 psi
Shear (With out Reinforcement) = 60 psi
Maximum Shear = 300 psi

Tensile Stress 7.5 √ f 'c = 410 psi

Bearing Stress = 900 psi

CODES & REFERENCES:-

Technical specification & Chapter 13 – Penstock do not specify

Specific standards for Penstock except for some general references
The following are specific references for welded steel penstocks used for the design
computations.

1- ENGINEERING MONOGRAPH #3
BUREAU OF RECLAMATION (USBR)
US DEPARTMENT OF THE INTERIOR
WELDED STEEL PENSTOCKS

2- AMERICAN IRON AND STEEL INSTITUTE

STEEL PENSTOCKS & TUNNEL LINERS
A Manual materials, design and construction

3- AMERICAN WELDING SOCIETY

Boiler & Pressure Vessel Code
Serial #1, #2 & #3 above are not included in the SATPARA DAM PROJECT.
The following are general references used in the design.

4- AMERICAN INSTITUTE FOR STEEL CONSTRUCTION (AISC)

5- AMERICAN SOCIETY FOR TESTING MATERIAL (ASTM)

6- AASHTO CODE

7- ACI CODE

8- AWWA Manual.

9- STEEL STRUCTURES PAINTING COUNCIL – MANUAL.

10- SATPARA TENDER DOCUMENT AND CONSULTANTS REQUIREMENTS specified in the
contract.

1.2 Loads
1- DEAD LOADS: -

i) Self-weight of steel pipe and Associates.

ii) Self-weight of Concrete.
iii) Self-weight of operating equipments and overloads.
iv) Self-weight of operating equipments and overloads.

2- LIVE LOADS: -

i) Wind Loads.
ii) Seismic Loads.
iii) Snow Loads.
iv) Vibration Loads.

3- REACTION LOADS: -

i) Reactions of Saddle.
ii) Reactions of Ring Girders.
iii) Reactions of any other supports.

4- IMPACT LOADS: -

i) Water hammers Surge Loads.

ii) Impact of water surface fluctuations.
iii) Change in momentum due to change in direction.
iv) Change in diameter.

5- TEMPERATURE LOADS: -
Vide Clause 10.8.2.7
Exposed to Sun 0oC to 20oC.
From Above
This is variation in temperature is expected to produce very high level of stresses.
Program of fabrication & installation with some measures may reduce the
temperature change within ΔT=20o C.
Computations are made with
1. ΔT =20oC
o
A stress of 195 psi per F develops simultaneously in the longitudinal and
transverse directions.

6- CONSTRUCTION LOADS: -
Dispersed loads of compactors and other machinery

7- BACKFILL LOADS & PRESSURES:-

 Lateral Pressures vide Mononobe – 0KABE Approach and / or
Pressure at Rest

8- SERVICE LOADS: -
Penstock must be below frost line.
Minimum cover = 2ft
Allowable Deflection of penstock
With coal tar epoxy coating plus lining is 5% diameter of penstock

1.3 Stress analysis

The stress analysis has been carried out as hereunder:

Stresses at Supports: -

i. Hoop stress caused by internal pressure including full water hammer load.
ii. Longitudinal stress in shell at support by flexural action as a beam.
iii. Longitudinal and hoop stresses caused by temperature
iv. Longitudinal and hoop stresses caused by earthquake
v. Longitudinal and hoop stresses caused by earth fill on top of liner.
vi. Longitudinal and hoop stresses caused by expected estimated settlement.
vii. Stress concentration at horn of saddle support in construction stage.
viii. Equivalent stress based on Hencky-Mises theory of failure.
Pipe thickness is governed by combined stresses at the location of
Supports/Anchor/Ring Girder. The term equivalent stress is the resulting combined
stress. This has been kept within the allowable limit for all service life conditions.

1.4 Data Provided by the Consultant

 Discharge = 135 ft3 /sec

 Available net head of turbine He = 69.80 in (229 ft)
 FSL at Fore bay =7830.23 ft
 Inlet valve center line el. =7599.23 ft
Available head of Penstock = 7830.23 – 7599.23
Ho = 231.00 ft
 Total Length of pipes L p= 505 ft
 Diameter of pipe 4 ft.
 Interval spacing of Saddle Supports L =16 ft (192 in)
 Wicket Gate Closure time in second =10sec
SOLUTION:

II. Solve for pressure rise (Water Hammer)

For a critical time or time constant
For partial Closure = 2L/a

WHERE:
a = Wave Velocity
d = Diameter of Pipe
e = Thickness of Pipe

Wave Velocity for a steel pipe

a = 4660/ √ 1+(1/100)(d/e) = 4660/ √ 1+(1/100)( 4(12)/0.375) = 3086.16 ft/sec

PATIAL CLOSURE = 2 L p/a = 2(505)/3086.16 = 0.327 sec

Solve for Pressure rise using Allievi chart

K = aVo/ 2g Ho Where:
N = aTe/2 L p Te = Equivalent Effective closing time
Z2 = ho + h / ho Vo = Velocity of Pipe
Ho = Available Head = 231 ft
g = 32.2 ft/s2
K = [(3086.16) (10.743)] / [2(32.2) (231) = 2.23
N = 3086.16 (0.167) / 2 (505) = 1.0

By allievi chart w/ordinate or K = 2.23 N = 1.0 Z2 = 5

h = 5ho – ho = 4ho
h= 4 (231) = 924 ft
p = 924 (1/2.30) = 401.74 psi

What will be the value of pressure rise if it closes at 3 periods?

Te = 6 x 0.327 = 0.981 ≈ 1 Sec

N=3 Z2 = 2.05 (By Allievi Chart)

h = 2.05 ho-ho = 1.05 ho = 242.55

p = 242.55(1/2.30) = 105.46 psi

Meaning at 1 second of the time closure pressure rise drop is minimal almost equal to the
pressure of available head = 100.43 psi that means that the diameter of pipe proposed by
the client is very big and just for a period of 1 second the discharge was already attained
and the wicket gate closure that the client provided is 10 second.

Adopt 30 percent pressure rise for safety precaution

h = 1.30 (ho) = 1.30 (231) = 300.3 ft

p = 300.3/2.30 = 130.565 psi

III. DETERMINE EXTERNAL MOMENTS AND

LOADINGS TO BE CARRIED BY PENSTOCK

III.1 DATA:

SA = 23, 300 psi (1/3 of tensile strength)

D = 48 in
r = 24 in
p = 130.565 psi including water hammer
L =16 ft (192 in) from CL of pipe to pipe at saddle support
n = 2 Nos. of support
f’ = 500 lb circumferential friction force at expansion joint
fs = 0.15 coefficient of friction at support
WL= 30psf assumed for wind load
WS= 30psf assumed for snow load
Weq= 0.2 g adopted as design earthquake
= 0.2 Dead Weight

III.2 DESIGN LOADINGS:

a. Dead load

1- SELF WEIGHT

Q Sw = πD x (440/1728) tL = π(48) (490/1728) (0.375) (192)

Q Sw = 3078.76 lbs

2- Weight of Coating
Qc = π DtL /12000 = [π (0.375) (4) (16)] / 12000 = 0.063 kips = 6.30 lbs
3- Weight of Water
Q H 2 O = (π D2 / 4) (WL / 1728) = [(π (48)2/ 4)] [(62.1) (192) / 1728] = 12546.25 lbs

Total Q DL= Q sw + Q c + Q H 2 O = 3078.76 + 6.283 + 12546.2 = 15631.29 lbs

b. Live Load

4- Wind load
 Q WL = (30/1440) π DL = (30 /144) π (48) (192) = 6031.86 lb

5- Snow load

Q SL = (30/144) π DL = (30 /144) π (48) (192) = 6031.86 lb

6- Earthquake load

Q EQ = 0.20 (15631.29) = 3126.26 lb

SOLVE MOMENT FOR EXTERNAL LOAD ONLY

W = Q DL/L = 15631.29 / 192 = 81.41 lb/in

2. SOLVE FOR MOMENT

MA = MB = WL2 / 12 = 81.41 (192)2 / 12 = 2500091.52 lb – in

III.3 MOMENT DIAGRAM

III.4 Summary of Moment Calculation at a Distance x

X Mx=W/12 [6LX-L2-6X2] Mx
==================================================================
0 - Wl2 /12 - 250091.52
 0.05L - 0.715 Wl2 /12 - 178815.44
0.10 L - 0.456 Wl2 /12 - 114041.73
0.15L - 0.235 Wl2 /12 - 58771.51
0.20 L - 0.04 Wl2 /12 - 10003.66
0.25 L + 0.125 Wl2 /12 - 31261.44
0.30 L + 0.260 Wl2 /12 - 65023.80
0.35 L + 0.365 Wl2 /12 - 91283.40
0.40 L + 0.440 Wl2 /12 - 110040.27
0.45 L + 0.480 Wl2 /12 - 120043.93
1.50 + 0.50 Wl2 /12 - 125045.76

IV. DETERMINE PLATE THICKNESS AND SUPPORT

RING PROPERTIES
IV.1 SOLVE FOR CIRCUMFERENTIAL STRESS BETWEEN SUPPORT
CAUSE BY THE INTERNAL PRESSURE (HOOP STRESS)
Sx = Pr / t
TRY
For t = 1 / 4 in Sx = 130.565(24) / 0.25 = 12534.24 psi
For t = 3 / 8 in Sx = 130.565(24) / 0.375 = 8356.16 psi

With the above Values for Sx and Se = SA = 23300 psi

Solve for Sy
Where: Sy = Maximum Longitudinal Stress

For t = 1 / 4 in Sx = 12534.24 psi

Se2 = Sx2-SxSy + Sy2
Sy2 – 12534.24 Sy + 12534.24 2 – 23, 3002 = 0
By Quadratic Equation
Sy = (12534.24 + 41233.948) / 2
Sy = -14349.854 psi

For t = 3/8 in Sx = 8356.16 psi

23, 3002 = 8356.162 –8356.16Sy + Sy2
By Quadratic Equation
Sy = (8356.16 + 44295.415) / 2
Sy = -17969.75 psi

Maximum SL Longitudinal Stress for the above Plate

For t = 1 / 4 in SL = Sy = -14349.854 psi

For t = 3 / 8 in SL = Sy = -17969.75 psi

Calculate F1; F2; F3

Where:
F1 = Longitudinal Stress due to pressure on exposed pipe and at expansion joint in psi
F2 = Longitudinal Stress cause by friction force at support in psi
F3 = Longitudinal Stress cause by friction force expansion joint f

Formula

F1 = Pt ; F2 = fsQ DLn’ / π (p+t) t ; F3 = 500D / 12 + (D+t) t

t F1 F2 F3
1/4 - 32.641 - 123.75 - 165.80
3/8 - 48.962 - 82.28 - 110.25

Formula
Sy’ = - SL + F1 + F2 + F3

For t = 1 / 4 in SL = -14349.854 psi

- Sy’ = +14349.854 – 32.641 – 123.75 – 165.80
- Sy’ = +14027.663 psi

For t = 3 / 8 in SL = -17969.75 psi

- Sy’ = +17969.75 – 48.962 – 82.28 – 110.25
- Sy’ = +17810.538 psi

MOMENT OF INERTIA OF A GIVEN PLATES THICKNESS

I / C = π r2 t
For t = 1 / 4 in I / C = π (24)2 (0.25) = 452.389 in3
For t = 3 / 8 in I / C = π (24)2 (0.375) = 678.389 in3

Solve for Allowable Moment ML that this Plate can be able to carry
ML = + Sy’ (I /C)
For t = 1 / 4 in ML = 14027.663 (452.389) = + 6345960.437 lbs- in
For t = 3 / 8 in ML = 17810.538 (678.584) = + 12085946.12 lbs- in

The values for allowable beam bending moment for all thickness exceeds the actual
moments the pipe will carry as plotted In moment Diagram.

Therefore we can select any plate’s thickness we desire for our design
Adopting the thickness that the construction drawing used (t = 3/8 in) and the actual
External moment MA = MB = - 250091.52 lb - in. and I / C = 678.584 in3
Check for Stress

a) Flexural stress
Sf = Mc / I = M/ I/C = 250091.52 / 678.584
Sf = 368.56 psi

b) Hoop Stress
SH = Pr / t = 130.565 (24) / (0.375)
SH = 8356.10 psi

c) Temperature Stress
∆T = 20o x 9/5 = 36o f
∆T 20o C= 195 x 36 = 7020 psi
d) Design Earthquake plus Snow Load
w sl+eq = (3126.26+6031.86)/192= 47.70 lbs/in
M = [47.70(192) 2]/12= 146534.4 lbs-in
SSN + EQ=M/ (I/c)
SSN + EQ= 146534.40/678.58 = 215.94 psi

e) Flexure stress for dead load only and the pipe is empty
Q DL= (3078.76+6.283) = 3085.04
W = 3085.04/192= 16.07
M= [16.07(192) 2]/12=49367.04 lbs-in
S DL=49367.04/678.58 = 72.75 psi

f) Stress for Live Load (Wind Load)

Q wl = 6031.86 lb
W = 6031.86/192= 31.42
M = [31.42(192) 2]/12=96522.24 lbs-in
SWL=96522.24/678.58 = 142.24 psi

Combine Stresses
1. Normal Condition
Transverse Longitudinal
a. Hoop Stress 8356.10 2506.83
b. Temperature 7020.00 7020.00
c. Flexure Stress 368.56 110.57
4. Earthquake and Snow Stress 215.94 64.78
Total 15960.60 9702.18

SCOMBINE = √ (15960.60)2 +(9702.18)2

SCOMBINE = 18678.14 psi < 1.33 (23300)
= 30989 psi OK SAFE
2. Sudden shot down condition
Transverse Longitudinal
a. Hoop Stress 8356.10 2506.83
b. Temperature 7020.00 7020.00
c. Flexure Stress 368.56 110.57
e. Add 20 percent Pressure Rise 1671.22 501.37
d. Earthquake and Snow Stress 215.94 64.78
Total 17631.82 10203.55

SCOMBINE = √ (17631.82)2 +(10203.55)2

SCOMBINE = 20371.39 psi < 1.33 (23300)
= 30989 psi OK SAFE

3. Construction condition
Transverse Longitudinal
a. Hoop Stress 8356.10 2506.83
b. Temperature 7020.00 7020.00
c. Flexure Stress (Dead Load only) 72.75 21.82
d. Live load 142.24 42.67
Total 15591.09 9591.32

SCOMBINE = √ (15591.09)2 +(9591.32)2

SCOMBINE = 18305.07 psi < 1.33 (23300)
= 30989 psi OK SAFE

4. Test condition
Transverse Longitudinal
a. Hoop Stress (additional of 50 %) 12534.15 3760.25
b. Temperature 7020.00 7020.00
c. Flexure Stress 368.56 110.57
Total 19922.71 10890.82

SCOMBINE = √ (19922.71)2 +(10890.82)2

SCOMBINE = 22705.16 psi < 1.33 (23300)
= 30989 psi OK SAFE
 IV.2 STIFFENER RING CALCULATION

a. Solve for the Properties of the assumed Ring

A1 = b x d = 4 x 0.375 = 1.5 in2

A2 = (1.5b √rt + c) t = (1.56√ 24(0.375)) +4) (0.375)
A2 = 3.26 in2

Total Area = A1 + A2 = 1.5+3.26 = 4.76 in2

Locate the Centroid

A1 (d/2 + t) = 6 [(0.375/2)+0.375] = 0.84 in2

A2 (t/2) = 3.26 (0.375/2) = 0.61 in2

A+Z = 0.84 + 0.61= 1.45

Z = 1.45 / 4.76= 0.31 in

b. Calculate Moment of Inertia

I1 = bd3/12 + A1 (d/2 + t – z)2 = 4 (0.375)3/12 + 1.5 (0.375/2 + 0.375 – 0.31)2

I1 = 0.12 in4

I2 = (1.56 √ rt + c) t3 / 12 + A2 (Z – t/2)2
I2 = (1.56 √ 24(0.375)+ 4) (0.375)3 / 12 + 3.255 (0.31 – 0.375/2)2
I2 = 0.08 in4

I = I1 + I2 = 0.12 + 0.08 = 0.20 in4

Then

I / Z = 0.20/ 0.31 = 0.65 in3

I / X = 0.20 / 0.44= 0.45 in3

c. Determine Circumferential ring stress

µ = Poison Ratio = 0.30

q = 1.285 / √ rt = 1.285 / √ 24(0.375)= 0.43

K = r / L [µL2/ 12r2 + (1-µ2) (1-Q sw / 2Q DL) + (2+µ) L / 4qr2]

K = (24 / 192) [0.30(192)2 / 12 (24)2 + (1 - 0.302) (1 – 3078.76/ 2(15631.29) + (2 + 0.30)
(192) / 4(0.43) (24)2]

K = 0.042 (1.60 + 0.82 + 0.45)

K = 0.36

B = (r / R) (1-2k/qr) – x / R

Where:
X = 0.04R ; x/R = 0.04

B = (24/24.31) [(1 - 2 (0.36) / 0.43(24)] – 0.04

B = 0.92

N / A = (Pr / A) [b + 2(1-µ2)/q] = (130.565(24) / 4.76) [4 + 2(1-0.302) / 0.43]

N / A = + 5419.58 psi

Where:
N = Tension due to internal Pressure
T = Direct Stress in the ring inclusive of N

Referring to AWWA Design Manual

Values for the coefficient of Stiffener Ring

For θ = 0o
T / A = Q DL/ A (K1 + BK2) = (15631.29 / 4.76) [-0.238732 + 0.92 (0.318310)]
T/ A = +175.80 psi

For θ = 90o (-)

T / A = (Q DL / A) (K1 + BK2) = (15631.29 / 4.76) (-0.25 + 0)
T / A = - 821.83 psi

For θ = 90o (+)

 T / A = T/ A of 90o (-) except sign is reverse
T/ A = + 821.83 psi

For θ = 180o
T/ A = T/ A of θ = 0o except sign is reverse
T/ A = - 175.80 psi

d. Solve for Ring Bending Moment

For θ = 0o
X = 0.04 R = 0.04(24.31) = 0.97
M = Q DL (RK3+XK4) = 15631.29 [24.31(0.011267) – 0.97(0.068310)]
M = +3242.84 lb - in

For θ = 90o (-)

M = Q DL (RK3+XR4) = 15631.29 (24.31(0) + 0.97(0.25))
M = + 3798.40 lb - in

For θ = 90o (+)

M (+) = M (-) except the sign is reverse
M = - 3798.40 lb - in

For θ = 180o (-)

M = M For θ = 0o except the sign is reverse
M = - 3242.84 lb - in

e. Tabulate Value of N/A, T/A and M & Calculate S1, S2 & S2’

Where:
S1 = Ring Bending Stress outside Fiber, psi
S2 = Total Circumferential Ring Stress inside Fiber, psi
S2’= Total Circumferential stress in outside Fiber, psi

I = 34.148 in4
I = 13.444 in 3
I = 9.869 in3

Formula:
S1 = M / I/z ; S’= M / I/x
S2 = N / A + I / A + S1, S2’ = N / A + I / A + S1’

TABLE:
θ N/A T/A M I/ Z I/X Bending Stress Total Stress
Psi Psi lb - in in3 in3 S1 S1’ S2 S2’
0 +5419.58 +175.80 +3242.84 0.65 0.45 +4958.47 -7206.31 +10553.85 -1610.93
90o(-) +5419.58 -821.83 +3798.40 0.65 0.45 +5807.95 -8440.89 +10405.70 -3843.14
90o(+) +5419.58 +821.83 -3798.40 0.65 0.45 -5807.95 +8440.89 +433.46 +14682.30
180o +5419.58 -175.80 -3242.84 0.65 0.45 -4958.47 +7206.31 +285.31 +12450.09

f. Longitudinal Stress Computation

A = ah + ct = 4(0.375) + 4(0.375) = 3
1.56 √ rt = 1.56(√ 24(0.375)) = 4.68
P = 77.20 psi

Sb = 1.82 [((A-ct)/ (A+1.56√ rt )) x (Pr/t)]

Where:
Sb = Bending Stress resulting from ring restraint

Sb = 1.82 [(3 - 4(0.375) / (3 + 4.68)) x (130.565(24) / 0.375)]

Sb = 2970.35 psi

Beam Bending Moment at Support

MA = MB = 250100.74 lb - in

Sy = MA / I/C = 250100.74 / 678.584

Sy = 368.56 psi

Values of Longitudinal stress in pipe cause by frictional forces at piers, Expansion Joint and
Hydrostatic pressure on exposed end are:
F1 = -48.962 psi ; F2 = -82.28 psi ; F3 = -110.25 psi

Solve for S3
S3 = Total Longitudinal Stress in Pipe Shell at Support Ring, psi

Then θ = 0o
S3 = F1 + F2 + F3 + Sb + Sy
S3 = -48.96– 82.28 – 110.25 + 2970.35 + 368.56
S3 = +3097.42 psi

Then θ = 90o
S3 = F1 + F2 + F3 + Sb + Sy
S3 = -48.96 – 82.28 – 110.25 + 2970.35 + 0
S3 = +2728.86 psi

For θ = 180o
S3 = F1 + F2 + F3 + Sb + Sy
S3 = -48.96 – 82.28 – 110.25 + 2970.35 – 368.56
S3 = +2360.30 psi

g. Solve for Equivalent Stress

Se2 = Sx2 – SxSy + Sy2

For θ = 0o

S2 = +10553.85 psi & S3 = +3097.42 psi

Se = (3097.42) – 3097.42 (10553.85) + (10553.85) 2
2 2

Se = +9396.27 psi

For θ = 90o (-)

S2 = +10405.70 psi & S3 = +2728.86 psi
Se2 = (2728.86)2 – 2728.86 (10405.70) + (10405.70) 2
Se = +9345.03 psi

For θ = 90o (+)

S2 = +433.46 psi & S3 = +2728.86 psi
Se = (2728.86) – 2728.86 (433.46) + (433.46)2
2 2

Se = +2539.42 psi

For θ = 180o
S2 = +285.31 psi & S3 = +2360.30 psi
Se = (2360.30) – (2360.30) (285.31) + (285.31)2
2 2

Se = +2231.37 psi
TABULATED RESULTS

θ F1 F2 F3 Sb Sy S3 Longi. Se Equiv.
psi psi psi psi psi Stress psi Stress psi
0 -28.95 -82.28 -110.25 +1756.23 +368.56 +3097.42 +9396.27
90o(-) -28.95 -82.28 -110.25 +1756.23 0 +2728.86 +9345.03
90o(+) -28.95 -82.28 -110.25 +1756.23 0 +2728.86 +2539.42
180o -28.95 -82.28 -110.25 +1756.23 -368.56 +2360.30 +2231.37

NOTE:
All of the above Se (equivalent stresses) does not exceeds our allowable stress of SA =23300
psi
Adopt dimension and properties of the stiffeners ring
V. CALCULATIONS FOR ELBOW CUTS
1. For 45 e̊ lbow

Three piece elbow (for more than 22.5 ̊ to 45 ̊)

Solve for the Thickness of the Plate in Elbow

t = (pd / Sf) [S / 2 + (d / 3) tanθ / 2]
t = 130.565 (48.75) / (23, 300) [39 / 2 + 48.75 / 3 for 22.5 / 2]
t = 0.159 in < t = 0.375 pipe thickness used
Used the same thickness of plate for elbows & Pipe

2. Elbow cut at RD = 0+127

θ = 16.084
 Use two piece elbows (for 0o to 22.5o)

3. Elbow cut at RD = 0+318

θ = 29 ̊̊

Three piece elbow (for more than 22.5 ̊ to 45 ̊)

t = (130.565 (48.75) / (24.36) 23, 300) [(24.36 / 2) + (48.75 / 3) (tan 14.52 / 2)]
t = 0.160 in
Use t = 3 / 8” for the connection
VI. Design of Expansion Joint
Formula:
t = PD / (2s-p)

Where:
P = 130.565 psi including water hammer
D = 48.75 outside dia of pipe
S = 23, 300 psi allowable stress

1. Solve for Thickness

t = 130.565 (48.75) / (2 (23,300) – 130.565)
t = 0.14 in
Use t = 3/8” (0.375 in)

2. Number of Bolts = Pipe OD +0.375+0.375

= (48.75 + 0.75) (0.4383)
= 21.69 ≈ Say 22 Bolts
3. Gasket pressure
Gasket Thickness = 0.125 = 1/8”
Gasket Area / Bolt = π (49.50 + 0.125 /22)
= 7.09 in2
Pressure = 7680 / 7.09 = 1083 psi

Gasket Pressure / Working Stress > 3.5

= 1083 / 130.565 = 8.29 > 3.5 Or safe

Summary
Item Dia Material Thickness
Expansion 49.58 in ASTM A516 3/8”
Joint 4.125 ft 79b Grade 70

Overall Summary
Pipe Dia Length Material Thickness
Penstock 3 4 ft 505 ft ASTM A516 3/8”
48 in 6060 in 79b Grade 70

VII. Design of Foundation

Given:
Q DL = 15631.29 lb ≈ 15.29 kips
Q EQ= 3126.26 lb ≈3.13 kips
Q ¿= 6031.86 lbs ≈ 6.03 kips
Q T =Q DL+Q EQ+Q¿ =15.29+3.13+6.03=24.45
FORCES ACTING HORIZONTAL
F=0.15(24.45) + (500(48)/12)
F= 4344.69 lbs ≈ 4.34 kips
Bearing Capacity = 900 psi = 129.6 kips / ft2
f = 0.15 Coeff. Friction
fc’ = 3000 psi
fy = 40,000 psi
Base width B= 3 ft (36 in)
Length L =6 ft (72 in)
Height of wall h = 4 ft (48 in)

a. Solve for Stem

 M at Stem = 4.34 (6) = 26.04 kips – ft
Mu = 1.7 (26.07) = 44.27 kips – ft

1. Mu = Фρ fy bd2 (1 – 0.59 ρ (fy / fc’))

Using ρ= ρmin = solve for d
ρmin = = 200 / fy = 200 / 40,000 = 0.005

44.27 x 12000 = 0.90 (0.005) (40,000) (72) d 2 [1 - (0.59(0.005) (40000 / 3000))]

d2 = 43.15; d = 6.57 in < dactual = 12 - 3 = 9 in

2. Check for effective d for shear

Ф Vc = Ф 2 √ fc ' bd = 0.85 (2) √ 3000 (75) (9)
Ф Vc = 62851.16 lb = 62.85 kips
Vu = 1.7 (4.34) = 7.38 kips < ФVc = 62.85 kips therefore safe
3. Steel Reinforcement
As = ρbd
As = 0.005(72) (9) = 3.24 in2
Using # 6 Ф reinforcement bar; Ao = 0.442 in2
Solve for Spacing
Sp / 0.442 = 72 / 5.4 Sp = 9.8 in ≈ 9 inches spacing
Use # 6 Ф Bars Sp. @ 9 in

4. Solve for Horizontal bars at Front Face

As = 0.0025 bd = 0.0025 (72) (9) = 1.62 in2
Use only 2/3 according to ACI Code recommendation
Solve for spacing using # 4 Ф reinforcing bar; Ao = 0.196 in 2
Sp / 0.196 = 4x 12 / 2/3 (1.62) Sp = 8.71 in say 8 inches spacing
Use # 4 Ф bars sp @ 8 in

5. Solve for Horizontal Bar @ Rear Face

As = 0.0025 bd = 0.0025 (48) (9)
As = 1.62 use only 1/3 according to ACI Code
Solve for spacing using # 4 Ф reinforcing bars; Ao = 0.11 in 2
Sp / 0.11 = 48/ 1/3 (1.62) Sp = 9.78 in ≈ 9 in
Use # 4 Ф bars sp @ 9 in

6. Solve for Vertical bar @ Rear Face

As = 0.0015 bd = 0.0015 (72) (9) = 0.97

Solve for spacing using # 3 Ф reinforcing bars; Ao = 0.11 in 2

Sp / 0.11 = 72 / 0.97 Sp = 7.7 in ≈ 7 in spacing
Use # 3 Ф bars sp @7 in
b. Solve for Toe & Heal SOIL PRESSURE
Self weight

W1 = (1.5) (6) (6) (0.15) = 8.10 kips

W2 = 3 (6) (1) (0.15) = 2.70 kips

1. Righting Moment ∑RM

∑RM = (8.10) (1.5) + 2.70 (1.5) + 24.45 (1.5)
∑RM = 53.175 kips – ft

2. Overturning Moment ∑OM

∑OM = 6 (4.34) = 26.04 kips ft

3. Factor of Safety against overturning

Fo = ∑RM / ∑OM = 53.175 / 17.36 = 2.04> 2.0 Ok Safe

4. Check for Eccentricity “e”

Ry = ∑W = 36.84 kips
RyX = ∑RM-∑OM
X = (53.175 – 17.36) / 36.84 = 0.74 < 3.5 / 2 = 1.75
e =1.5 – 0.74=0.76
5. Soil Pressure
q min= Ry / LB [1 - 6e/ LB]
q min= (36.84 / 3(6)) [1 - (6(0.76) / 3 (6))]
q min= 1.53kips / ft2 > 0 fall from the middle third of the base

q max = Ry / LB [1 + 6e / LB] = (36.84 / 3 (6)) [1 + (6(0.76) / 3(6))]

q max= 3.57 kips / ft2 < 129.6 kips / ft2 Ok more than Safe

6. Factor of Safety Against Sliding

Fs = µRy / F = 0.50 (36.84) / 4.34 = 4.24 > 1.75 Ok Safe

c. Design Toe

By Ratio & Proportion

X / 2 = (3.57 – 1.53) / 3 ; x = 1.36
Y / 1 = (3.57 – 1.53) / 3 ; y = 0.68

Solve for
F1 = 1 /2 (0.68) (1) (6) = 2.04 kips
F2 = (1.36 + 1.53) (1) (6) = 17.34 kips

W1 = (0.15) (1) (1) (6) = 0.90 kips

Design Moment

Mu = 1.70 [2.04 (2/3) + 17.34 (0.50)] – 1.4[0.90 (0.50)]

Mu = 16.421Kips – ft
Mu = Фρfy bd2 (1 – 0.59 ρ fy / fc’)

Using ρ = ρmin = 0.005 Solve for d

(16.421 x 12, 000) = 0.90 (0.005) (40,000) (72) d 2 [1 – (0.59 (0.005) (40,000 / 3,000))]

d2 = 15.83 d = 3.98 < dactual = 12-3 = 9” Ok Safe

Check for Effective Depth

Ф Vc = Ф 2 √ fc ' bd
Ф Vc = 0.85 (2) √ 3000 (72) (9)
Ф Vc = 60, 337.12 lb = 60.34 kips
Vu = 1.7 (2.04 + 17.34) – 1.4 (0.90)
Vu = 32.95 kips < Vc = 60.34 kips Ok Safe

Steel Reinforcement:
As = ρbd = 0.005 (72) (9)
As = 3.24 in2

Solve for Spacing Using # 5 Ф reinforcing bars; Ao = 0.306 in 2

Sp / 0.306 = 72 / 3.24; Sp= 6.817 in ≈ 6 in
Use # 5 Ф bars sp @ 6 in
Use the same reinforcement at Heel also provided a minimum reinforcement of # 4
Ф sp@ 9” at the top of the foundation

Solve for the Temperature bars for Toe & Heel

As = 0.002 bh = 0.002 (72) (1)

As = 0.144

Solve for Spacing using # 3 reinforcing bars; Ao = 0.196

Sp / 0.196 = 3.0(12) / 0.144; Sp = 49 in.
Use # 4Ф bars sp @ 9” for temperature bars @ the top and bottom of the
foundation