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Introduction
Tokyo Electric Power Companys Kannagawa Hydropower
Plant is located in Gunma prefecture, Japan.
For the first challenge in Japan, high tensile strength steel
(HT100) with a tensile strength of 950 N/mm2 was adopted
for use in the penstocks of Kannagawa Hydropower Plant to
reduce the construction cost. To apply HT100 steel for the
penstocks, a performance verification test was conducted in
advance to make sure that HT100 steel plates and welded
joints have required performance, while the requirements for
welding procedures were determined. In the actual
construction, quality control was carried out adequately on
the basis of the determined requirements for welding
procedures and other requirements.
This paper presents the design and construction of the
penstocks of the Kannagawa Hydropower Plant. In the paper,
we primarily focus on quality control items specified in
consideration of the characteristics of high tensile strength
steel and their results.
surge tank, into the penstock for units 1 & 2 with a total
length of 1,397 m and the penstock for units 3 & 4 with a
total length of 1,365 m.
Tokyo Electric Power Company decided to introduce high
tensile strength steel (HT100) with a tensile strength of 950
N/mm2 for the penstocks of its Kannagawa Hydropower
Plant to reduce the construction cost. Table 1 shows the
materials used and their weight. The total weight for units 1
& 2 penstock was about 5,154 t, of which the quantity of the
HT100 steel was about 2,331 t. The total weight for units 3 &
4 penstock will be about 5,150 t, of which the quantity of the
HT100 steel will be about 1,420 t.
The construction of the penstock for units 1 & 2 was started
in April 2001, with the installation on the site completed in
July 2004. Currently, the inclined shaft and part of upper and
lower horizontal sections of the penstock for units 3 & 4 are
under construction with the progress rate being about 40% as
of May 2009; the installation of the penstock is planned to be
completed by April 2010.
1. Overview of Facilities
Tokyo Electric Power Companys Kannagawa Hydropower
Plant is a pure pumped-storage power plant with an effective
head of 653 m generating a maximum output of 2,820 MW
with six motor-generators. Its unit 1, with a maximum output
of 470 MW, was put into commercial operation in December
2005.
The steel penstocks of the Kannagawa Hydropower Plant are
embedded in rock mass, extending over a length of about
1,400 m with a difference in elevation of 745 m and having a
maximum design head of 1,076 m, of which the static head is
817 m, and inside diameters ranging from 2.3 m to 8.2 m.
The steel penstocks consist of upper horizontal section,
inclined shaft section, and lower horizontal section.
The inclined shaft section of the entire penstock structure is
an about 960m long steep gradient pressure conduit, with an
inclination of 48 degrees and an inside diameter of 4.6 m.
Figure 1 shows a schematic diagram of the steel penstocks of
the Kannagawa Hydropower Plant. The steel penstock is
bifurcated, at the Branch I located at the base of the headrace
1-1
HT100
SHY685
NS-F
SM570
SM490B
Thick
ness
(mm)
29-72
28-38,
621)
2002)
Thick
ness
(mm)
27-72
28-42,
621)
2002)
22-45
20-52,
703)
-------
Weight
(t)
2331
Ratio
of
weight
45%
312
8
6%
1335
26%
1168
23%
22-44
22-52,
703)
22-26
Weight
(t)
1420
Ratio
of
weight
28%
<75
Allowabl
e stress
(N/mm2)
400
Yield
point
(N/mm2)
885
<50
50-100
200
16-40
40-75
16-40
40-100
16-40
40-100
330
320
315
240
235
175
160
130
115
685
665
650
450
430
315
295
235
215
Steel
Thickness
(mm)
HT100
SHY685NSF
907
8
18%
1541
30%
1148
22%
SM570
SM400B
---0%
126
2%
Total
5154
100%
5150
100%
weight
1) 62-mm thick steel is for joining inlet valves.
2) 200-mm thick steel is for stiffening the branch II.
3) 70-mm thick steel is for reinforcing the branch I.
4) The penstock for units 3 & 4 is now under construction, so the values are
estimated.
SM490B
SM400B
Standard
Technical
Guidline
for
HT100
JIS G
3128
JIS G
3106
JIS G
3106
JIS G
3106
1-2
SM400
SM490
SM570
SHY685
HT100
1-3
Place
Inspection
Material making
Steel mill
Material Inspection
Workshop of
fabricator
transportation
Receiving&Inspection
Nondestructive Inspection
Temporary
workshop
Installation
Assembly
Groove Inspection
Inclined
shaft
Circumferential welding
Visual Inspection
Nondestructive Inspection
Completion
1-4
TABLE 3: The quality control criteria and test results for HT100 steel plates
Element
PCM
Ceq
Ceq
PCM
Maximum
0.11
0.008
0.001
Minimum
0.09
0.001
0.001
0.572
0.273
0.12
0.006
0.001
0.603
0.311
0.533
0.254
0.11
0.002
0.000
0.592
0.288
Maximum
content
0.14
0.01
0.005
0.59
0.29
0.14
0.01
0.005
0.62
0.33
Ceq=C+Mn/6+Si/24+Ni/40+Cr/5+Mo/4+V/14
PCM=C+Si/30+Mn/20+Cu/20+Ni/60+Cr/20+Mo/15+V/10+5B
Figure 6: The quality control criteria and test results for HT100 steel plates
1-5
SMAW
SAW
MAG
Yield strength
(N/mm2)
Tensile strength
(N/mm2)
Elongation (%)
Charpy impact
absorption energy
(J)
785
785
785
(Reference)
HT100
steel plate
885
930-1000
930-1000
930-1050
950-1130
12
47
(at 10)
12
47
(at -10)
12
47
(at -10)
12
47
(at -55)
50
50
50
50
----
Ductile fracture
percentage (%)
Hydrogen content
(mL/100g)
Thickness
(mm)
HT100 and
SHY685NS-F
Not
exceeding
50
Over 50
Minimum preheating
temperature (C)
SMAW
MAG
SAW
100
80
125
100
Interpass
temperature
Postheating
conditions
At least the
preheating
temperature
and not
exceeding
230C
----
At least 2
hours at over
150C
No preheating
Not
Not exceeding 60
---exceeding
25
Over 25
---Not exceeding 80
---SM490B
------------SM400B
------------a. For SMAW and MAG for HT100, welding material for SHY685NS-F was used for root pass and tack welding.
b. For tack welding of HT100 and SHY685NS-F, welding materials of a strength level that was one rank lower than that for the
actual welding.
c. Postheating was omitted for SHY685NS-F if nondestructive test was conducted 48 hours after welding or later.
d. The preheating temperature for tack welding was at least 25C higher than the minimum preheating temperature stated above.
e. In SMAW and SAW, the preheating temperature was at least 25C higher than the minimum preheating temperature stated above
when the partial hydraulic vapor pressure was over 25.5 mmHg.
f. For SM570 and SM490B, steels with PCM of not exceeding 0.2% was used and no preheating was conducted provided that the
temperature was preheated to 40C when the air temperature was 5C or below.
g. When welding was suspended, postheating was preformed using the conditions stated above or the temperature was retained until
welding was restarted.
SM570
1-6
TABLE 6: The track records of heat input control for HT100 welded joints
Place of welding
Welding
method
Number
of joints
365
Temporary
workshop
Temporary
workshop
Field
Inclined shaft
Control standard
SAW
Max.
39.8
Min.
27.7
Average
32.8
SMAW
20
48.4
41.1
27.2
36.3
SMAW
MAG
87
25
49.1
26.6
39.9
37.6
24.6
30.1
Not exceeding 50
37.9
45.0
38.9
19.9
32.0
18.5
13.1
16.4
Not exceeding 45
Water vapor
pressure(mmHg)
40
Contorol Standard25.5mmHg
30
20
10
0
2001/11/1 2002/1/31 2002/5/2
2004/5/2
2004/8/1
Date
Figure 7: The track records of the control of water vapor pressure at the temporary workshop
Control Standard5%
5.0
3mm
4.0
3.0
2.0
1.0
0.0
20
30
40
50
60
Plate thickness(mm)
70
80
3.0
Angular distortion()
2.0
1.5
Thickness
t (mm)
Not exceeding 50
1.0
0.5
Over 50
0.0
20
30
40
50
60
Plate thickness(mm)
70
80
1-7
UT
Not exceeding
t/2 and 30 mm
tester.
Figure 9 shows how the ultrasonic test is carried out. With
the tester introduced this time, flaws detecting operation is
carried out from both sides on one face of a welded zone
simultaneously. First, flaws are searched for coarsely, square
by square, at intervals of 5 mm, and if reflected echoes are
detected, flaw detection is carried out finely at intervals of 1
mm again. All items of obtained data are recorded in the
form of electronic data, and the judgment of data on flaws is
carried out automatically.
Rules for the time to conduct nondestructive inspection for
the penstock for units 3 & 4 (Table 8) and the rate of
execution of nondestructive inspection on longitudinal joints
(conducted over entire lines) are the same as those for the
penstock for units 1 & 2.
SHY685
NS-F
Place of
welding
All places
Inclined shaft
Temporary
workshop
SM570,
SM490B
SM400B
All place
Time of testing
At least 24 hours
after the completion
of welding
At least 24 hours
after the completion
of welding
At least 48 hours
after the completion
of welding
No rules
Postheating
conditions
150C for at least
2 hours
None
None
HT100
Branch II
Entire length
129.906(m)
Conclusion
Branch I
Entire length
281.031(m)
1-8