2 R ME MS 002 Method Statement of Penstock Installation

ZUNGERU HYDROELECTRIC POWER PROJECT
CNEEC-SINOHYDRO CONSORTIUM
Document Name: Method Statement of Penstock Installation
Doc No.: R-ME-MS-002
Rev. No.: 00
Document preparation, review, approval and acceptance:
Position Name Date Signature
Prepared: Engineer Mr. Yin Xiangqian
Reviewed: Engineer Mr. Yu Yang
Approved: Deputy Project Manager Mr. Lu Bo
Accepted: ER
Document Revision Table:

Date Rev. No. Description of modifications / revisions
Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

Page 1 of 23
1. General Introduction
There are total 4 units to be installed for Zungeru hydroelectric project. The
capacity of every unit is 175MW and the total capacity is 700MW. There are 4
parallel steel penstocks for Zungeru Hydropower Station. Single penstock and
standalone layout is adopted. The steel penstocks are separately arranged in
31#~34# dam sections. The steel penstock stakes are
DV0+616.0~DV0+691.0m, DH0+017.0m~DH0+102.85m and the elevation is
EL130.0m~EL202.75m. The steel penstock inner diameter is 6.733/7.5m and
they are 26/28/30mm thick. There are 65 sections of steel penstock for one
unit, including 12 sections in the top bending section (1#~12#), 36 sections in
the inclined and straight section (13#~48#), 10 sections in the bottom bending
section (49#~58#) and 7 sections in the bottom horizontal section (59#~65#).
The single unit weight is 685.942t. (The number of sections is according to the
drawing D-HS-PE-003~009).
2. Compiling Basis
1) Construction drawings;
No. Drawing number and name
1 D-HS-PE-001~002 General arrangement of penstock
2 D-HS-PE-003~009 Structure layout of penstock
3 D-HS-PE-010~012 Structure layout of ring girder

2) Technical documents provided by the manufacturer.
3. Construction Preparation
3.1. Pre-conditions for construction
1) The water and power supply shall have already been connected to the
working areas.
2) The reference points for steel penstock installation and elevation have
been marked correctly;
3) The installation areas have been cleaned and the safety conditions for site

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construction have reached the requirements.

4) The devices (such as welding machine, flame cutter, gouging machine,
grinding machine, etc) and materials are already prepared for
construction.
5) The construction staffs shall have a safety and skill training before
construction.
3.2. Technical Preparation
1) To be familiar with drawings and compile the work instructions;

2) The technical personnel shall carefully read the relevant drawings and
data and shall be responsible for the detailed technical disclosure to the
constructors before construction;
3) Check the equipment according to the packing list and drawings, check
the parts appearances and sizes and take the records.
4. Procedure Flow
The installation procedure flow for steel penstock is shown as the chart below:
Penstock installation procedure flow

Page 3 of 23
Installation Procedure Flow for penstock

Reference points setting out
Auxiliary rail erection for the bottom horizontal

section
Install, adjust and reinforce the positioning

section
Install, adjust and reinforce the bottom horizontal sections Circumferential seam welding
Install, adjust and weld the bottom bending sections 100% VT & UT
Install, adjust and welding the inclined and straight sections
Install, adjust and welding the expansion joint
Install, adjust and welding the top bending 100% VT & UT

sections
Accessories installation
5. Construction Procedure
5.1. Penstock assembly
1) The steel penstock segments arrived shall be assembled and welded into
pipe sections. Check the appearance of steel penstock segments. Check
whether the section shapes and sizes meet the design and code
requirements;
2) Before assembling the steel penstocks, ensure to remove the rust and
polish the weld grooves in all sections.
3) Assemble and weld the steel penstock segments into sections according
to the numbering sequence, check and adjust the perimeter and inner
diameter of pipe orifice to meet the design requirements when assembling
the penstocks. Adjust the mismatch and gap with the wedge and
turnbuckle to meet the design requirements.
4) After all meets the requirements, the welds shall be performed.

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5.2. Penstock installation
5.2.1. Penstocks transportation

1) Assemble the steel penstock sections and store them in the rear open
storage yard. Transfer the steel penstock sections to the installation
position with the mobile cranes and trailers.
5.2.2. Penstock installation
5.2.2.1. Installation of the bottom horizontal sections (sections
59#~65#)
1) Check the work area of penstock before taking over it from civil contractor,
make sure the work area is cleaned and the elevation of the concrete is
right.
2) Set the reference elevation and central line point for the bottom horizontal
sections.
3) Section 65# is positioning section and it is at bottom of penstock, we will
start the installation from section 65#.
4) The bottom horizontal sections of steel penstock Pass through the
upstream wall of the powerhouse. It is necessary to erect rails under the
bottom horizontal sections before installing them. Arrange the 10t winch at
one end of the rails.
5) Hoist Section 65# of the steel penstock on the rail and then pull it to the
design position with the winch. Check and adjust the orientation, elevation
and verticality of section 65#. After all is qualified, reinforce them and
make the inspection.
6) Hoist Section 64# of steel penstocks to the installation position in the
same way. Check and adjust the penstock inlet orientation, elevation and
verticality. After all is qualified, reinforce them. Check and adjust the
mismatch and gap between Sections 65# and 64# and make them reach
the requirements.
7) Successively install and weld the remaining sections of the bottom
horizontal section of steel penstocks (Sections 59#-63#).
8) After installing 4 sections, start welding the circular seams.
5.2.2.2. Install bottom bending section, inclined and straight section
and top bending section (Sections 1#-58#)

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1) Mark the steel penstock orientation and elevation point.

2) Section 1# is also positioning section, section 17# is the remedy section.
Between section 17# and 18# is the expansion joint part.
3) Erect and adjust the supports in section 58# installation position, adjust
the supports position and elevation and then reinforce the supports firmly.
4) Hoist section58# of steel penstocks to the installation position, check and
adjust the penstock section inlet orientation and elevation. After all is
qualified, they shall be reinforced. Check and adjust the mismatch and
gap between Sections 59# and 58# as well as deviation to meet the
requirements.
5) Successively install section 57# to 19# and section 1# to 17#.
6) Install the expansion joint part, adjust its position and elevation, after all is
accepted reinforce it firmly.
7) Install section 17# to 1# in the same way of intalling section 57# to 19#.
8) Flame cutting the remedy section according the actual requirement and
install it.
9) Install 4 sections and then weld the circular welding seams.
10) When installing the steel penstock sections, install the drainage channels
and pipes and other accessories.
11) Measure and obtain the neccesary size of remedy section. Cut the
remedy section based on the measured value. Then, install and weld the
remedy section
5.3. Welding procedure of steel penstock
5.3.1. Welding preparation

1) Constructon site condition must meet relevant requirements ， without
exposure to wind and rain. Precautions must be taken against fire and
electical shock.
2) Air,water,electricity,lighting must be available on site.
3) Sufficient fire-fighing facilities must be provided on site,and all ladders
must be reliably secured.
4) Welder: The welders those are perform the welding shall be with a
qualification certificate.
5) Welding device: Inverter welding machine, air compressor, oven,

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polishing machine, pneumatic digger, etc.

6) The welding groove shall be cleaned.
7) Welding meterial:electrde J507, specification: φ3.2mm and φ4.0mm.
8) The electrode must be heated to dry and kept in portable stoves.
5.3.2. Welding proceess
1) SMAW shall be used for all position on site.
2) Power supply : DC , polarity : DCEP , welding shall be performed in short
arc and narrow bead is preferred.
5.3.3. Welding sequence
1) The welds on the steel penstock on site mainly include the circular seams
among all sections and welds of accessories.
2) Every circular seam needs 2 to 4 welders to perform welding sequence
shown on digram 1 at same time and symmetrical weld.
3) Weld all circular seams from the positioning section successively.
Diagram 1: Welding sequence of circular seam of steel penstock
5.3.4. Welding parameter

Electrode Welding current Welding Welding speed
AWS E5015
diameter φ A voltage V mm/min
Flat/cross 3.2 110～150 20～23 60～80

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welding
Overhead/
3.2 110～150 20～23 60～80
vertical welding
Flat/cross
4.0 120～190 20～25 60～80
welding
Overhead/
4.0 120～190 20～25 60～80
vertical welding
5.3.5. Welding requirements

1) Back step welding for the whole welds.
2) The quality requirements and welding procedure for tack welding should
refer to the same for official welding works.
3) The tack welding should keep a certain strength, which is prefer to be
4~6mm in thickness, 50~60mm in length and 400~500mm of distance.
4) It is required to remove the water, oil, wool, rust, scale and slag on the
surface and two sides of the groove before welding, and polished the
surface of groove properly.
5) It is strictly forbidden to conduct arc striking, testing current or weld
temporary supports on the base material of the non-welded part.
6) The back seam should be gouged by carbon arc gouging, and the groove
is as smooth and flat as possible. The root should be in “U” shape for
welding, and it should be grind by grinder against slag and carburized
layer.
7) It is required to conduct multi-pass welding. The maximum thickness of
single-layer welding should be no more than 5~6mm, and the width of
weld bead should be no more than 25mm.
8) The joints for the multi-layers of welding should be staggered, and the
weld slag and spatter of each weld bead should be removed completely.
9) Each weld should be welded as continuously as possible.
5.3.6. Quality inspection
5.3.6.1. Weld classification
1) Class I:The longitudinal weld of the steel pipe wall, the circumferential
weld of the elastic cushion pipe in the dam, the ring of the open pipe in the
power plant, the preset circumferential weld, and expansion joint
circumferential weld.
2) Class II: The circumferential weld of pipe wall not belong to classI, and

Page 8 of 23
butt weld for stiffening ring .

3) Class III: Other welds that do not belong to the welds mentioned above.
5.3.6.2. Visual inspection of weld
1) All welds shall be conducted for 100% Visual inspection.
5.3.6.3. Non-destructive flaw detection of welds
1) Non-destructive testing of welds shall be carried out in accordance with
the quality inspection of the weld appearance and shall be carried out 24
hours after the completion of the welding.
2) The steel pipes shall be inspected by ultrasonic machine. The non-
destructive testing methods and proportions are as follows.
ultrasonic machine testing %

Steel type
Class I Class II
Q345R 100 50
6. Quality Control Measures
6.1. Main Quality Control Points for Penstock Installation
Control contents Control

Procedure Control points Control basis Responsible by
and deviation proofs
Steel Construction in
Design documents,
Penstock charge; Construction
GB/T50766-2012
assembling Flatness of construction record;
≤3mm Specification, Method
penstock orifice technical staff, Inspection
Statement of
project quality record
Construction
inspector
Construction in
Design documents,
charge; Construction
GB/T50766-2012
Roundness of construction record;
≤22.5mm Specification, Method
Statement of
Construction
inspector
Perimeter ≤24mm Design documents, Construction in Construction
deviation of GB/T50766-2012 charge; record;
penstock orifice Specification, Method construction Inspection

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technical staff,
Statement of
Construction
inspector
Construction in
Design documents,
GB/T50766-2012
construction record;
Length ±5mm Specification, Method
technical staff, Inspection
Statement of
Construction
inspector
Construction in
Design documents,
GB/T50766-2012
Elevation of construction record;
Statement of
Construction
inspector
Penstock orifice Construction in
Design documents,
center and charge; Construction
GB/T50766-2012
mileage in the construction record;
initial section technical staff, Inspection
Statement of
(Section 1# and project quality record
Construction
Penstock 65#) inspector
installation Construction in
Penstock orifice Design documents,
center and GB/T50766-2012
construction record;
mileage of ≤12mm Specification, Method
technical staff, Inspection
Sections 17#, Statement of
18# and Construction
inspector
Construction in
Design documents,
Penstock orifice charge; Construction
GB/T50766-2012
center and construction record;
mileage in technical staff, Inspection
Statement of
general sections project quality record
Construction
inspector
QCR refer to attachment—Penstock Inspection Form
7. Safty Assurance Measures
Construction Responsible Safety

Danger sources Control measures
position by witness

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1. Object to be lifted To abide by transportation and

knock, squeeze and lifting safety management
Project Safety record
falling down; regulations and take proper
safety chief on the regular
Penstock 2. Calling or answering a protections to prevent being
supervisor, meeting
transportation phone during operation; injured;
project safety before work
and 3. Violating command It is forbidden to call or answer a
man, and
unloading and operation; phone during operation;
group/team construction
4. Sliding down in the To stop work in the heavy rain;
safety man log
work areas because of The staffs without certificate are
raining. not allowed to work on duty.
To wear protection articles
properly;
To prepare sunstroke prevention
medicine and ensure the
drinking water is clean; Project
Safety record
To enhance safety prevention safety chief
1. Climate seasonal on the regular
management on construction supervisor,
variation; meeting
Penstock site to ensure than access road project safety
2. Equipment lifting; before work
lowering is accessible all the time; man,
3.Calling or answering a and
To get a shelter in time when group/team
phone during operation; construction
being in a heavy rain and stop safety man
log
work to be avoid of sliding down;
To forbid calling or answering a
phone during operation;
Safety man site supervision and
patrolling inspection

Page 11 of 23
1. Personnel falling
down; electrical shock; To apply safety belt proper and
scaffold is not firm to tie it to a fixed point;
incline; welding smokes To check the equipment to be
and dust; safety lifted or transported according to
prevention measures is the regulation and take proper Project Safety record
not proper; work prevention measures; safety chief on the regular
protection articles are To check electrical equipment supervisor, meeting
Penstock
not properly checked or and ensure proper insulation; project safety before work
installation
with defects; smoking; To check and reinforce scaffolds man, and
answer a phone during applied for construction; group/team construction
overhead operation; To wear proper protection safety man log
noises; lifting cable with articles;
damage; To arrange firefighting facilities;
2. Equipment lifting, To forbid smoking in the non-
adjustment and smoking area;
installation;
To wear protection articles
properly;
To prepare sunstroke prevention
medicine and ensure the
drinking water is clean;
1. Climate seasonal
To enhance safety prevention Project Safety record
variation;
management at construction site safety chief on the regular
2. Operation at high and
and ensure that access road is supervisor, meeting
Penstock welding;
accessible all the time; project safety before work
welding 3. Calling and answering
To get a shelter in time when man, and
a phone during
being in a heavy rain and stop group/team construction
operation;
work to be avoid of sliding down; safety man log
4. Scaffolds assembly;
To forbid calling or answering a
phone during operation;
Safety man to carry out site
supervision and patrolling
inspection

Page 12 of 23
The access platform should be

firm and reliable. It is necessary
to wear protection articles while
working in high. Before
construction, it is a must to issue
a fire permission. The tools and
equipment should be located
1. Climate seasonal
firmly during construction to Project Safety record
variation;
prevent them falling down from safety chief on the regular
2. Operation at high and
Steel high. To be avoid of electrical supervisor, meeting
welding;
materials shock. Attentions should be paid project safety before work
3. Calling and answering
cutting to smoke exhaust and air man, and
a phone during
circulation to prevent toxicosis group/team construction
operation;
and sunstroke. It is not allowed safety man log
4. Scaffolds assembly;
to touch the heating equipment
and assembly welding joint by
hand directly to be avoid of
burnt. The sufficient firefighting
devices should be allocated and
located in a reasonable
arrangement.
1. Climate seasonal All the supports should be fixed
variation; firmly with proper space. A
2. Equipment lifting, ladder in compliance with safety Project Safety record
adjustment and requirements should be installed safety chief on the regular
Construction
installation; for climbing up and down. The supervisor, meeting
platform and
3. Operation at high and overhead platform is necessary project safety before work
scaffolds
welding; to assemble with handrails and man, and
assembly
4. Calling and answering the safety net below. All the group/team construction
a phone during bamboo access plate must be safety man log
operation; bind firmly. A special man will be
5. Scaffolds assembly; sent to check every day.

Page 13 of 23
To abide by Site Safety

Production/Operation Project Safety record
1. High operation in
Instructions; safety chief on the regular
Penstock open air;
Safety man site supervision and supervisor, meeting
accessories 2. Construction power;
patrolling inspection; project safety before work
and piping 3. Motor tools;
Calling and answering a phone man, and
installation 4. Calling and answering
during operation; group/team construction
a phone;
To get a shelter in time during safety man log
heavy rain;
8. Construction Resources Allocation
8.1. Equipment resources allocation
The equipment for penstock installation shall be allocated following the form
below:
No. Description Type & specification Unit Quantity Remarks
1 Mobile crane 25T set 1
2 Mobile crane 50T set 1
3 Trailer with flat bed 40T set 1
4 Tower crane set 1
5 Winch 5T set 1
6 Cargo 12T set 1
7 Total station set 1
8 Level set 1
9 Welding machine ZX7-400T set 8
10 Flame cutter set 2
11 Air gouging machine set 2
12 Air compressor VFY-3.0/10 set 2
13 Air shovel CZ2 pcs 8
14 Oven YCH-100 set 1
15 Oxygen cylinder pcs 10
16 Acetylene pcs 5
17 Grinding machine φ150 set 8

Page 14 of 23
18 Grinding machine φ125 set 4
19 Chain block 3T set 2
20 Chain block 5T set 2
21 Theodolite J2 set 1
22 Screw jack 16T set 8
23 Hammer 16 pound pcs 2
24 Tape 5m/30m pcs 2 for each
25 Steel plate ruler 1m/0.15m pcs 2 for each
26 Safety rope set 15
27 Tool box set 3
28 Warming box TRB pcs 12
8.2. Manpower resources allocation
Manpower for penstock installation shall be allocated following the form

below:
No. Work variety Quantity Remarks
1 Managerial staffs 3 person
2 technician 1 person
3 Quality inspector 1 person
4 Safety man 1 person
5 Erectors 6 persons
6 Welders 8 persons
7 Lifting men 3 person
8 Local labor 20 persons
Total 45 persons

Page 15 of 23

Page 16 of 23
Attachment—Penstock Inspection Form

Penstock assembly – straight sections
Hydro Mechanical Works Check Form
Planned Start Date : Record No.： 200001-X assembly
Submitted by CSC: Date： Received by ER: Date：
Time of checking:
Component name： Dimension of penstock section X
Unit number： Unit X
Elevation： EL125
Drawing No.： D-HS-PE-003~009 Structure layout of penstock Page：1/1
Construction Map:
Dimension：
Inlet Outlet
Tolerance
No. Theo. Measured（m Differences（ Theo. Measured（ Differences（
（mm）
（mm）） mm）（mm） m） mm）
D1 ±12 ±12
D2 ±12 ±12
D3 ±12 ±12
D4 ±12 ±12
Roundness 22.5 22.5
Perimeter ±22.5 ±22.5
Length：±5
Theo. Measured（ Differences（ Theo. Measured（ Differences（

No. No.
（mm） m） mm）（mm） m） mm）
1 3
2 4
Remarks:
Witnessed by:
Contractor's representative Employer's representative
Pre-inspect Re-inspect QC SH CRE

Page 17 of 23
Copy received by CSC: Date: Time:

QC: Quality Control Engineer SH: Sectional Head
Penstock assembly – bending sections
Time of checking:
Elevation： EL125
Drawing No.： D-HS-PE-003~009 Structure layout of penstock Page：1/1

Page 18 of 23
Construction Map:
Dimension：
Inlet Outlet
Tolerance
No. Theo. Measured（m Differences（ Theo. Measured（ Differences（
（mm）
（mm）） mm）（mm） m） mm）
D1 ±12 ±12
D2 ±12 ±12
D3 ±12 ±12
D4 ±12 ±12
Roundness 22.5 22.5
Perimeter ±22.5 ±22.5
Length：±5
Theo. Measured（ Differences（ Theo. Measured（ Differences（

No. No.
（mm） m） mm）（mm） m） mm）
1 3
2 4
Remarks:
Witnessed by:

Penstock installation –section 1# and 65#

Page 19 of 23
Time of checking:
Elevation： EL125
Page：
Drawing No.： D-HS-PE-003~009 Structure layout of penstock
1/1
Construction Map:
Elevation：±10mm
No. Theo. Measured Difference
Distance：±5mm
Axis deviation maxi：±5mm
Remarks:
Witnessed by:
Penstock installation –section 17# and 18#

Page 20 of 23
Time of checking:
Elevation： EL125
Page：
1/1
Construction Map:
Elevation：±10mm
Distance：±12mm
Remarks:
Witnessed by:
Penstock installation – normal sections

Page 21 of 23
Time of checking:
Elevation： EL125
Page：
1/1
Construction Map:
Elevation：±10mm
Distance：±25mm
Remarks:
Witnessed by:

Page 22 of 23

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2 R ME MS 002 Method Statement of Penstock Installation

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ZUNGERU HYDROELECTRIC POWER PROJECT

Document Name: Method Statement of Penstock Installation

Doc No.: R-ME-MS-002

Document preparation, review, approval and acceptance:

Position Name Date Signature

Prepared: Engineer Mr. Yin Xiangqian

Reviewed: Engineer Mr. Yu Yang

Approved: Deputy Project Manager Mr. Lu Bo

Document Revision Table:

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

1 D-HS-PE-001~002 General arrangement of penstock

2 D-HS-PE-003~009 Structure layout of penstock

3 D-HS-PE-010~012 Structure layout of ring girder

3.1. Pre-conditions for construction

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

construction have reached the requirements.

3.2. Technical Preparation

1) To be familiar with drawings and compile the work instructions;

Penstock installation procedure flow

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

Installation Procedure Flow for penstock

Auxiliary rail erection for the bottom horizontal

Install, adjust and reinforce the positioning

Install, adjust and welding the inclined and straight sections

Install, adjust and welding the expansion joint

Install, adjust and welding the top bending 100% VT & UT

5.1. Penstock assembly

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

5.2. Penstock installation

5.2.1. Penstocks transportation

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

1) Mark the steel penstock orientation and elevation point.

5.3. Welding procedure of steel penstock

5.3.1. Welding preparation

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

polishing machine, pneumatic digger, etc.

Diagram 1: Welding sequence of circular seam of steel penstock

5.3.4. Welding parameter

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

5.3.5. Welding requirements

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

butt weld for stiffening ring .

ultrasonic machine testing %

6. Quality Control Measures

6.1. Main Quality Control Points for Penstock Installation

Control contents Control

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

QCR refer to attachment—Penstock Inspection Form

7. Safty Assurance Measures

Construction Responsible Safety

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

1. Object to be lifted To abide by transportation and

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

The access platform should be

Document no: R-ME-MS-002 Revision status:00 Date Printed: 20 June 2019

To abide by Site Safety

8. Construction Resources Allocation

8.1. Equipment resources allocation

1 Mobile crane 25T set 1

2 Mobile crane 50T set 1

3 Trailer with flat bed 40T set 1

4 Tower crane set 1