Northwest Hydro Association

May 17, 2012 Technical Seminar

PENSTOCK CONDITION
ASSESSMENT

Thomas L. Kahl, P.E.

Kleinschmidt
TOPICS
• Concerns

• Types of Penstock Failure Modes

▫ Steel and Wood Stave

• Failure Mode Inspection Techniques

• Penstock Safety Program

▫ Recommended Methodology
▫ Example Program
 Concerns
• Safe, Reliable, and Economical Pestock
Performance

• FERC’s Primary Concerns

1. The ability to shut down in the event of a leak or
failure is critical. (Penstocks can be physically
large structures with a lot of potential hazards
difficult to detect.)

2. Inadequate inspection.
TOPIC 2 – FAILURE MODES

1.Internal Pressure Rupture

2.General Buckling
3.Local Buckling
4.Inadequate Support
 Failure Mode 1 – Internal Pressure
Rupture

Add photo
EPP-8
Failure initiated in heat affected
zone of 1937 vintage
longitudinal weld seam.
Galvanic corrosion at 1953
vintage surge tank longitudinal
weld seam.
Random pitting pattern in 1939 vintage penstock –
(Evaluate per ASME B31G-2009)
Overall Shell Corrosion (typically occurs in
moist environments)
 Wood Stave Penstocks

Internal pressure transferred from staves to steel bands.

An example of exterior
stave wood decay.

The ruptured wood at the metal “Kelsey”

butt joint is called “brooming”.
Steel band corrosion
Slippage at shoes can release bands
Seam failure due to gravity dead weight pulling apart
circumferential seam with deteriorated rivet heads.
Failure Mode 2 – General Buckling
2006 collapse of 1995 vintage penstock when ice
plug in vent induced vacuum due to external
pressure.
General buckling caused by uncontrolled release
at rupture. Replacement included additional air
vacuum valves
Blocked vent induced collapse

Note “classic” crack from corner.

Pipe collapsed when decayed top wood stave fell.
Failure Mode 3 – Local Buckling

“Zick” stress deformation at horn of saddle.

Local overhead “dents” in buried pipe probably
caused by concentrated loads.
Relatively rare shear buckling of very thin
(D/t= 614) large diameter steel penstock.
Failure Mode 4–Inadequate Support
Deteriorated saddles
Cracked concrete saddle.
 Loss of support at tipped saddle

.
Slope Instability
Surge tanks require
very stable
foundations to
prevent tipping.
Cracked foundation and
buckled anchor bolt gusset.
Surge tank anchor bolt
corrosion reduces
seismic overturning
resistance.
TOPIC 3 – FAILURE MODE
INSPECTION TECHNIQUES
• Shell Thickness
and dimensions.

• Concentrate on
shell Connections

• Supports

• Corrosion at Steel
New ASCE –MOP 79 to Concrete
expected to be
published Aug 2012 Interfaces
Types of Inspection
 Cursory Inspection:
 Purpose is to note any observable change in condition
 Typically performed by operation or maintenance personnel
weekly, monthly, or quarterly.
 Changes in condition noted for further investigation
 Comprehensive Inspection/Evaluation
 Purpose is to review the condition, safety, and risk of the
existing penstock
 Performed by engineers who understand the design basis
and actual condition of penstock
 If deficiencies are noted they can be resolved by repair,
rehabilitation or replacement.
Basic Tools
Check rivets for loss of
material and tightness.
TOPIC 4 - Penstock Safety Program
Methodology Steps:

1. Establish Baseline Conditions

2. Establish an inspection, monitoring,
and documentation plan
3. Implement a documented
maintenance and repair program
4. Periodic comprehensive
independent condition assessments
 Penstock Safety Program

Effective Program Should Be:

• Reliably Able to Detect Problems

• Readily Understood
• Convenient and Usable by Operating &
Maintenance Personnel
• Cost Effective
 Ketchikan Alaska Public Utilities (KPU)
Penstock Safety Program
• Ketchikan Lakes Project (4.2 MW)
▫ No. 1 1957: concrete: 1,800’: 54” D: 46’ head
▫ No. 2 1997: ductile iron: 1,800’: 54” D: 46’ head
▫ No. 3, 4, 5: 1957 steel: 350’: 36” D: 250’ head

• Beaver Falls Project (8.3 MW)

▫ No. 1 1966: steel: 342’: 36”D: 321’ head
▫ No. 2 1952: steel: 3,610’: 42”D: 760’ head
▫ No. 3 1953: steel: 4,170’: 28”D: 660’ head
Ketchikan Lakes

Beaver Falls
Step 1 Establish Baseline Condition

• Comprehensive System Description

• Define Design Criteria
• Define Hazards and Risks
• Summarize Physical Condition
Step 2 – Site Specific Inspection,
Monitoring, and Documentation
• Different Portions of a penstock will have
different critical components
• Shell Thickness & Pitting Assessment
• Concentrate in high humid tunnels and in
contact with concrete and soil
• Vacuum valve testing and inspection
• Document supports’ condition
• Critical to have repeatable observation
locations.
• Inspection checklist can be useful to maintain
consistency and completeness.
Step 3: Documented Inspection,
Maintenance, and Repair

KPU already used computerized “Express

Maintenance” program.

Only minor modification needed to existing

procedures to more reliably document all
records for future trending analyses.
Step 4: Periodic Comprehensive
Condition Review

• Either external or internal staff

independent evaluation/audit.

• Frequency 5 to 15 years and after

special events (e.g. earthquake).
 Important to
“Expect the Unexpected”
Questions / Comments

Thomas L. Kahl, P.E.

Kleinschmidt Associates
Tom.Kahl@Kleinschmidtusa.com
(207) 487-3328, Ext 280