Execution Methodology

List of equipment

S/N# Type of equipment Capacity Quantity Remarks

1 Gantry crane 20 ton 1
2 Gantry crane 15 ton 1
3 Gantry crane 10 ton 1
4 Gantry crane 5 ton 1
5 Mobile crane 50 to 80 ton 1
6 Hydra crane 20 ton 1
7 Truck 20 ton 1
8 Truck/tractor 10/4 ton 2
9 Bolero van 4-wheel drive 1
10 Welding machine 400-600 Amps 12
9 Grinding machine Heavy duty (AG-7) 12
10 Winch machine 10 1
11 Winch machine 5 1

List of work force

One shift = 12 hours
S/N# Designation Quantity Remarks
1 Project engineer/manager 1 No. The number of
2 Site engineer 2 No. manpower
3 Sub-engineer 1 No. subjected to very
4 Supervisor 2 Nos. as per the site
5 Quality controller (Level-II) 6 Nos. availability
6 Pipe fitter 6 Nos.
7 Safety officer 2 Nos.
8 Certified welder (6G) 12 Nos.
9 Gas cutter 2 Nos.
10 Rigger 8 Nos.
11 Grinder 10 Nos.
12 Electrician 2 Nos.
13 Skilled helper 16 Nos.
14 Store keeper 2 Nos.
15 Driver 3 Nos.
Total 75 Nos
Transport route and work sequence
The overall ready to install bends, pipes and bifurcation shall be transported via truck using local route
towards the respective working area. The transportation shall be done prior to the schedule and site
activity. The equipment, materials and manpower to execute work from PT-05 to powerhouse and from
HR-04/PT-01 to PT-05 shall be transported via audit 4 and audit 1,2 and 3 respectively.

The activity shall be executed in two phases (Phase 01 and Phase 02) first phase (Phase 01) of work shall
be executed using two independent groups (Group 01 and Group 02) of workforces.

1) Phase 1
(A) GROUP 01: - From audit 4 to powerhouse area.
• Installation of I-beam (125), trolley, winches machine and gantry crane.

At first, total length of 1000 m I-beam (200), base plate, grouting roads, shall be transported and erected
above already constructed saddle support between audit 4 to PT-9 and further PT-09 to PT-10 (units 01,
02 and 03). Then, the material of gantry crane of capacity 10Ton shall be transported and installed at audit
04. Finally, the components of winches machines capacity of 5Ton and rope diameter of 12mm and length
of 450m shall be transported and erected at audit 4 just before the gantry crane erected. A Winches
machine of capacity 2Ton and 9mm wire rope of 40m shall be installed at bend ‘C’, to perform work at
unit 03. After completion work at unit 03 the same winches machine shall be removed and reinstalled at
bifurcation ‘B’ area to perform work at unit 02. In similar manner the same winch machine shall be
installed at bifurcation ‘A’ area to perform work at unit 01.

(I) Installation of branch penstock, bends and reducers at unit 03.

Firstly, a 900mm dia. and 5m length of ferrules will be entered through audit 4 via truck and unloaded
and reloaded to trolley located at this area. Then, the ferrules shall be further transported to PT-10 using
trolley and winches machines capacity of 5 Ton with 12mm wire rope. The ferrules shall be aligned with
647.30m penstock center level and anchored. Another 2.5m lengths of pipe shall be transported to PT-10
and connect to the previously aligned ferrules. Again, 2.5m length and 1.2 m to 0.9m dia. reducers shall
be transported and connected to the end of pipe and reducer shall be anchor blocked. A 1.2m dia. pipes
shall be connected to larger end of reducers and continue up to bend at unit 03. Again, a bend of 1.2m
dia. shall be transported in the same way to the unit 3 and to be connected to end of the previous pipe.
A 1.2m dia. pipes shall be transported and further connected with end of bend up to bifurcation ‘B’.

(II) Installation of branch penstock, bends and reducers at unit 02.

Secondly, a 900mm dia. and 5m length of ferrules will be entered through audit 4 via truck and unloaded
and reloaded to trolley located at this area. Then, the ferrules shall be further transported to PT-10 using
trolley and winches machines capacity of 5 Ton with 12mm wire rope. The ferrules shall be aligned with
647.30m penstock center level and anchored. Another 2.5m lengths of pipe shall be transported to PT-10
and connect to the previously aligned ferrules. Again, 2.5m length and 1.2 m to 0.9m dia. reducers shall
be transported and connected to the end of pipe and reducer shall be anchor blocked. A 1.2m dia. pipes
shall be connected to larger end of reducers and continue up to bifurcation B.
(III) Installation of branch penstock, bends and reducers at unit 01.

Thirdly, a 0.9mm dia. and 5m length of ferrules will be entered through audit 4 via truck and unloaded
and reloaded to trolley located at this area. Then, the ferrules shall be further transported to PT-10 using
trolley and winches machines capacity of 5 Ton with 12mm wire rope. The ferrules shall be aligned with
647.30m penstock center level and anchored. Another 2.5m lengths of pipe shall be transported to PT-10
and connect to the previously aligned ferrules. Again, 2.5m length and 1.2 m to 0.9m dia. reducers shall
be transported and connected to the end of pipe and reducer shall be anchor blocked. A 1.2m dia. pipes
shall be connected to larger end of reducers and continue up to bifurcation A.

(IV) Installation of penstock and bifurcation between PT-09 and second bifurcation.

Fourthly, once all branch pipes installed at unit 01, 02 and 03, a prefabricated Y-type bifurcation shall be
transported via audit 4, aligned and installed at unit 02 and unit 03 junction (Bifurcation ‘B’). The side
branch of bifurcation shall be connected with unit 02 pipes of dia. 1.2m and main branch shall connect
with unit 03 pipes of dia. 1.2m and fixed with anchor block. Then, sections of 1.7m pipes shall be
connected with inlet of bifurcation ‘B’ and continued to Bifurcation A.

(V) Installation of first bifurcation at PT-09 and pipes up to PT-08D.

Fifthly, a bifurcation of inlet dia. 2.1m, main pipe dia. 1.7m and branch pipe dia. 1.2m shall be transported
through audit 4 with the help of gantry crane, trolley and winches machines, furthermore aligned and
installed at PT-09. The main pipe and branch pipe shall be connected with 1.7m and 1.2m already installed
pipes respectively and fixed with anchor block. Then, sections of 2.1m pipes shall be connected with inlet
of bifurcation ‘A’ and continued up to PT-08D.

(VI) Installation of vertical bend ‘A’ at PT-08D.

Sixthly, bend of did. 2.1m shall be transported through audit 4 to PT-08D with the help of gantry crane,
trolley and winches machines. Then, it shall be aligned at PT-08D with vertical deflection of 174 degree.
The lower end of aligned bend pipe shall be welded with 2.1m pipe coming from PT-09 and fixed with
anchor block. Again, section of 2.1m pipes shall be transported individually and welded with end of
previously installed bend and continued up to PT-08C.

(VII) Installation of penstock pipe at bend ‘C’ at PT-08C.

Finally, Sections of penstock of dia. 2.1m shall be transported through audit 4 to PT-08C (Bend C) with the
help of previously installed gantry crane, trolley and winches machine. Then, it shall be aligned and
connected at PT-08C with horizontal deflection of 0.88 degree with 1.2m dia. pipe coming from PT-08D
and same procedure shall be continued up to PT-07. However, for this section concrete casing shall be
done up to PT-08.
(B) GROUP 02: - From SOP-04A/PT-01 to SOP-06/PT-03 through audit 1 and audit 2.

• Installation of I-beam (125), trolley, winches machine and gantry crane and chain blocks.

Total length of 440 m I-beam (125), base plate, grouting roads, shall be transported and erected above
already constructed saddle support between HR-04/PT-01 to PT-02 Then, the material of gantry crane of
capacity 5Ton shall be transported and installed at PT-01/HR-04. The components of winches machines
capacity of 5Ton and rope diameter of 9mm and length of 230m shall be transported and erected at PT-
01. Again, Two Chain blocks of capacity 10T each, Components of gantry crane of capacity 15T shall be
transported via truck and installed at audit 2 and a ferrules guide track shall be installed from PT-02 to PT-
03.

(1) Installation of bends (VAB 02) and vertical shaft from PT-02 to Pt-03.

This group #02 shall start work for this section, Firstly, a bend of 2.5m dia. and angle of 90 degree shall be
transported from warehouse to audit 2 via truck. The bend shall be unloaded with the help of gantry crane
installed at audit 2, then carefully lowered to PT-03 guided by ferrules guide. The bend shall be aligned,
installed and fixed with anchor block. Again, section of 2.5 m pipes shall be transported to audit 2 with
same way and lowered by gantry crane and welded with upper end of previously fixed bend. The same
process shall be applied for remaining pipes up to PT-4.

(2) Installation of bend (VAB 01) and penstock from PT-01 to PT-02.

Secondly, a section of 2.5m penstock shall be transported from warehouse area to audit 1, then unloaded
from truck and reloaded on trolley by previously installed gantry crane, the trolley shall be operated by
winch machine installed at PT-01. The pipe shall be aligned with tunnel and center level maintained at
1228.61m. Other same sizes of pipes shall be transported with same way and welded with end of previous
one up to VA -01 where a 186-degree vertical band to be installed. Again, a horizontal band with 186
degree shall be transported from same way, then to be aligned, installed and fixed with anchor block.
Remaining 2.5m dia. pipes shall be transported through audit 2, unloaded from truck, reloaded on trolley
with the help of gantry crane which is operated by winch machine installed at PT-01. The pipe shall be
aligned and welded with lower end of fixed bend at audit 1 up to PT-02. Finally, a bend of dia. 2.5m shall
be transported in audit 2 and installed with the help of gantry crane.
Phase 2

Phase 02 of work shall be executed using two independent groups (Group 01 and Group 02) of workforces.

(A)Group #01: - Installation of penstock pipes from PT-03/SOP-06 to PT-05C/SOP-08A.

(I) Installation of I-beam (125), trolley, winches machine, gantry crane and chain blocks.

Total length of 1060 m I-beam (125), base plate, grouting roads, shall be transported and erected above
already constructed saddle support between PT-03/SOP-06 to PT-04A/SOP-07A Then, the material of
gantry crane of capacity 20Ton shall be transported and installed at PT-04A/SOP-07A, and two chain
blocks of capacity 10T each shall be required. The components of winches machines capacity of 5Ton and
rope diameter of 12mm and length of 530m shall be transported and erected at PT-03. Also, a ferrule
guide track shall be installed on vertical shaft from PT-04A to PT-05.

(II) Installation of penstock pipe from SOP-06/PT-03 to SOP-07A/PT-04A.

Firstly, a 2.5m pipes shall be transported in audit 3 and unloaded by gantry crane which was installed
previously. The unloaded piece of pipe shall be reloaded on trolley operated by winch machine installed
at PT-03. The trolley shall be pulled by winch machine and reached to PT-03. The end of pipe then to be
welded with lower end of previously installed bend, same procedure shall be followed up to SOP-07A/PT-
04A. In the middle of this section the pipe shall be fixed with anchor block to protect from sliding of
penstock.

(III) Installation of bends (VAB-03, VAB-04) and penstock pipe from SOP-07A/PT-04A to PT-
05C/SOP-08A.

Secondly, a bend of 2.5m dia. and angle of 90 degree shall be transported from warehouse to audit 3 via
truck. The bend shall be unloaded with the help of gantry crane installed at audit 3, then carefully lowered
to PT-03 guided by ferrules guide. The bend shall be aligned, installed and fixed with anchor block. Again,
section of 2.5 m pipes shall be transported to audit 2 with same way and lowered by gantry crane and
welded with upper end of previously fixed bend. The same process shall be applied for remaining pipes
up to SOP-07A/PT-04A. Again, a bent of diameter 2.5m shall be transported with same way and installed
at SOP-07A/PT-04A with the help of already installed gantry crane.
(2) Group #02: - Installation of penstock pipes from PT-03/SOP-06 to PT-05C/SOP-08A.

• Installation of I-beam (200), trolley, winches machine.

Total length of 610 m I-beam (200), base plate, grouting roads, shall be transported and erected above
already constructed saddle support between PT-05 to PT-07. The components of winches machines
capacity of 5Ton and rope diameter of 12mm and length of 530m shall be transported and erected at PT-
03. Also, an already installed gantry crane at audit 4 of capacity 10 Ton shall be used.

(I) Installation of reducers and penstock pipes from PT-03/SOP-06 to PT-05C/SOP-08A.

A reducer of dia. 2.5m X2.25m shall be transported in audit 4 via truck and unloaded on trolley with the
help of gantry crane, and the trolley shall be pulled by winches machine installed at PT-05. The inlet of
reducer shall be connected with previously installed bend. The remaining section of pipes shall be
connected up to PT-06. Again, a reducer of dia. 2.25mX2.1m shall be transported and connected to end
of previously connected pipe at PT-06. Finally, a penstock section of diameter 2.1m shall be installed with
the help of gantry crane and chain blocks at PT-07.

Weight calculation of bends, pipes and reducers;

Table: 01: Formula for approximate wait calculation of materials.

Formula 1 Formula 2 Formula 3

Calculation of weight of pipes; Calculation of weight of bends; Calculation of weight of Reducers;

W = ρ*Л* (Do2-Di2)/4 W = (2*ρ*Л2*S* (D-S) *R)/4 W= ρ*Л*((D + d)/2 - S) *H*S

Where, Where, Where,

W= Weight of pipes (in KG) W= Weight of 90 D bend W= Weight of reducers
ρ= Density of materials (7850 ρ= Density of materials (7850 ρ= Density of materials (7850
Kg/m3) Kg/m3) Kg/m3)
Л=3.14 Л = 3.14 Л= 3.14
Do= Outer diameter of pipes in m D= Outer diameter of elbow in m D= Large diameter of elbow in m
Di= Inner Diameter of pipes in m S= Thickness of elbow in m d= Small diameter
R=Long radius = 1.5 * D in m S = Thickness of reducer in m
Table: 02: Calculation of weight of bends
Outer Thickness
Inner dia.
S/N Sections dia. of large Weight (KG) Types
(m)
(m) end (m) Locations
1 2 2.5 0.016 2.484 5768 Bend (VAB1) PT-02
2 5 2.5 0.03 2.47 10753 Bend (VAB2) PT-03
3 8 2.5 0.028 2.472 10045 Bend (VAB3) PT-04A
4 13 2.5 0.046 2.454 16382 Bend (VAB4) PT-05

Table: 03: Weight calculation for reducers

Large end Small end Thickness of End to end Weight Penstock

S/N
dia.(m) dia. (m) large end (m) height (m) (KG) type Locations
1 1.2 0.9 0.032 2.5 2007 Reducer PT-10
2 2.5 2.25 0.046 2.5 6602 Reducer PT-05
3 2.25 2.1 0.044 2.5 5778 Reducer PT-06

Table: 04: Section wise penstock weight calculation

Weight Weight on
Oute Penstock Net pulling Weight on
Inner Weight/ /5m rollers Pipe
S/N Sections r dia. thickness load rollers (FR1) (in
dia. (m) m (Kg) (W) (FR2) (in alignment
(m) (m) (FP) (in KG) KG)
(KG) KG)
1 1 2.5 0.012 2.488 369 1844 100 1147 1462 Horizontal
2 3 2.5 0.025 2.475 766 3832 3832 NA NA Vertical
3 4 2.5 0.03 2.47 919 4594 4593 NA NA Vertical
4 6 2.5 0.03 2.47 919 4594 252 2016 2832 Horizontal
5 7 2.5 0.028 2.472 858 4289 235 2272 2640 Horizontal
6 9 2.5 0.032 2.468 980 4898 4900 NA NA Vertical
7 10 2.5 0.036 2.464 1101 5506 5500 NA NA Vertical
8 11 2.5 0.042 2.458 1283 6416 6416 NA NA Vertical
9 12 2.5 0.046 2.454 1404 7021 7021 NA NA Vertical
10 14 2.25 0.044 2.206 1208 6041 331 2456 3550 Horizontal
11 15 2.25 0.044 2.206 1208 6041 331 2456 3550 Horizontal
12 16 2.1 0.042 2.058 1076 5381 295 2015 3008 Horizontal
13 17 2.1 0.042 2.058 1076 5381 295 2015 3008 Horizontal
14 18 2.1 0.044 2.056 1127 5634 310 2210 3150 Horizontal
15 19 2.1 0.044 2.056 1127 5634 310 2210 3150 Horizontal
16 20 1.2 0.032 1.168 467 2335 127 445 911 Horizontal
17 21 0.9 0.032 0.868 349 1743 97 212 567 Horizontal
Calculation of weight on trolley and rollers while transporting pipes and bends.

Fig: 01: Schematic diagram of force at acting different points

Table: 05: API Specification 9A/ISO 10425:2003 for wire rope;

Table: - 06

Dimension and properties of ISMB (Bureau of Indian standard: SP 01-1964)

Deflection calculation for ISMB150

1) To transport material between PT-01 and PT- 04A/SOP-07A.

W=13890 N

A C B

L= 5.00 m

Fig: - 02

The figure 02 shows the arrangement of I-beams on saddle support, while the roller of trolley reach at
middle point then deflection will be maximum.

Deflection = (W*L3/48*E*I))

Where,

W = Weight of roller at center of beams

L = Length of Beams

E = Modulus of elasticity of steel = 2 X 1011 N/m2

Moment of inertia (IXX) = 449 X 108 m4

Weight at center of beams (Max weight on roller*9.81/2) (W) = 2832*9.81 /2 = 13890 N

Deflection = (13890*53/ (48*2X1011* 449X108) m

Deflection = 40.28 X 103 m

Deflection ration = 2.60/325 which is not allowed.

The arrangement shall be changed in such a way that,

Either ISMB 125 should be replaced with ISMB 175,

If so,

Moment of inertia (IXX) = 726 X 108 m4

Weight at center of beams (Max weight on roller*9.81/2) (W) = 2832*9.81 /2 = 13890 N

Deflection = (13890*53/ (48*2X1011* 1272X108) m

Deflection = 14.21 X 103 m

Deflection ration = 0.924/325 which is allowed.

2) To transport material between PT-05C and PT-10.

Deflection calculation for ISMB175

W=17412 N

A C B

L= 5.00 m

Fig: - 03

The figure 03 shows the arrangement of I-beams on saddle support, while the roller of trolley reach at
middle point then deflection will be maximum.

Deflection = (W*L3/48*E*I))

Where,

W = Weight of roller at center of beams

L = Length of Beams

E = Modulus of elasticity of steel = 2 X 1011 N/m2

Moment of inertia (IXX) = 449 X 108 m4

Weight at center of beams (Max weight on roller*9.81/2) (W) = 3550*9.81 /2 = 17412 N

Deflection = (17412*53/ (48*2X1011* 1272X108) m

Deflection = 13 X 103 m

Deflection ration = 0.84 / 325 which is allowed.