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Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to

information for citizens to secure access to information under the control of public authorities,in order to promote transparency and accountability in the working of every public authority,

and whereas the attached publication of the Bureau of Indian Standards is of particular interest

to the public, particularly disadvantaged communities and those engaged in the pursuit of

education and knowledge, the attached public safety standard is made available to promote the

timely dissemination of this information in an accurate manner to the public.

!"#$% '(%)

!"# $ %& #' (")* &" +#,-.Satyanarayan Gangaram Pitroda

Invent a New India Using Knowledge

/0)"1 &2 324 #' 5 *)6Jawaharlal Nehru

Step Out From the Old to the New

7"#1&"8+9&"), 7:1&"8+9&")Mazdoor Kisan Shakti Sangathan

The Right to Information, The Right to Live

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IS 7332 Part 1 ) : 1991

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SPHERICAL V LV S FOR HYDROPOWERSTATIONS AND SYSTEMSPART 1 CRITERIA FOR STRUCTURAL AND HYDRAULIC DESIGN

fl rsl evision

DO C 621 046 22: 6 21 224 - 225 12

O B I S 19918 r: n E A F I N D I A N S T N I A R II SrvlANAK BHAVAN 9 BAllAOUR SHAH ZAFAH. t\-IARG

NE\V DELHI 110002 ovember ) 99] Price Groull 3

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AMENDMENT NO APRIL 2 3TOIS 7332 Part 1 ) : 1991 S PH ER IC AL VALVES FORIIYDROPOWER STATIONS AND SYSTEMS

PART CRITERIA FOR STRUCTURAL AND HYDRAULIC DESIGN_( First Revision)

Page I, clause S.l ) - S ubs tit ut e the fol low ing for the exi st in g text:T he body of the valve should e designed for various loading conditions givenin IS 11639 Part I ,IS 11639 Part 2) and IS 11639 Part 3 :

age4, clause 6.4.1, para 2 ) - Delete. Page 5, Annex A ) - Delete IS 226 : 1975 Specification for structuralsteel standard quality) (fifth rt vision) . age5, nnexA ) - Substitute IS 1030: 1998 Specification for carbonsteel castings for general engineering purposes fifth revision) for IS 1030 :

J982 Specification for steel castings for general engineering purposes (fourthrevision) . Page 5, nnexA) - Substitute I S 2002 : 1992 Specif icat ion for steelplates for pressure vessels for intermediate and high temperature serviceincluding boilers (second revision) fo r IS 2002 : 1982 Speci fi cati on for steelplates for pressure vessels for intermediate and high temperature serviceincluding boilers (first revision) . age5, nnexA ) - Subs titut e IS 2004 : 1991 Specification for ca rbonsteel forgings for general engineering purposes (third revision) fo r IS 2004 :1978 Specification for carbon steel forgings for general engineering purposes

second revision) . age5, nnexA ) - Substitute IS 2062 : 1999 Specification for steel forgeneral structural purposes (fifth revisionr fo r IS 2062 : 1984 Specification forweldable structural steel (third rev;swnf. Page 5, nnex A ) - Substitute IS 2708 : 1993 Specification for 1.5pe rcent manganes e steel ca stings for general engine ering purposes (thirdrevision) fo r IS 2708 : 1984 Specification for 1.5 perce nt ma nganese steelcastings for general engineering purposes ~ c o n d revision) .

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Amend No.1 to IS 7332 Part 1 ) : 1991 Page 5. nll x A) - Insert the following at the end:

IS No TitleI S 11639 Part 1) : 1986 Criteria for structural design of penstocks ; Part

Surface penstocks.IS 11639 PaJ12 ) : 1995 Criteria for structural design of penstocks : Part 2Burriedlembcdded penstocksIS 11639 Part 3 ) : 1996 Criteria for structural design of penstocks : Part 3Specials for penstocks

[ Page 6, Annex B, SI No i) a), col 3 ] - Substitute IS 1030 : 19 98 lorIS 1030:1982 .[ Page 6. Annex B, 51 No i) b), col 3 ) - Substitute IS 2062 : 1999 orIS 2002: 199f for the e xi st in g. Page 6, Annex B, Sl No i) c), col 3 ] - Substitute IS 2708 : 1993 for IS2708: 1984 .[ Page 6, Annex B, S No ii) a), col 3 1- Substitute IS L030 : 1998 forIS 1030: 1982 .[ Page 6, Annex B, Sl No ii) b), col 3 ] - Substitute IS 2062 : 1999 forI S 2062 : 1984 and IS 226 : 1975 . Page 6, Annex B, S No ii) e), col 3 ] - Substitute IS 2708 : 1993 /orIS 2708: 1984 .[ Page 6, Annex B, SI No iii) a) co 3 ] - Substitute IS 1030: 1998 forIS 1030: 1982 . ge 6, Annex B, No iii) b), col 3 ] - Substitute IS 2708 : 1993 forIS 2708: 1984 .[ Page 6, Annex B, 51No ivXa) , col 3 ) - Substitute IS 1030 : 1998 forIS 1 03 0: 1982 . Page 6, Annex B, SI No iv) b), col 3 ] - Substitute IS 2004 : 1991 forIS 2004 : 1978 .

WRD12) ReproaraphyUnit.81S, NewDell i Indil

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Hydraulic Gates and Valves Sectional Committee, RVD 12

IOR WORThis Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by theHydraulic Gates and Valves Sectional Committee had been approved by the River Valley DivisionCouncil.Spherical valve is a shut-oil device most commonly used in Hydro-power stations for a head 200 II Iand above. These valves may be used at lower heads also if desired by the designer. Its use isfavoured at high heads as there is no hydraulic loss due to valve itself when valve is open andprovided a better t ight sealings when valve is closed.It serves the following purposes:

a) Stops the water ent ry to the turbine when the Jatter is stopped to decrease the water leakagesand to protect the guide vanes against slit cavitation and silt erosion;h) Stops the water entry in case of emergency. that is. non-closure of guide apparatus or in theevent of low oil pressure in the system;

c) Unit isola tion in mult i-unit plants where one penstock feeds more than one unit; andd) To facilitate inspection of water path passages.

Basically spherical valve consists of spherical shaped body air valve and water/oil pressure system orany other control system are required for operation of spherical valves.This standard covers only the guidelines criteria for structural and hydraulic design valves soas to permit necessary flexibility in their detailed design as per requirements of the designer.These guidelines are based on the available expertise and the practices prevaling in this field atpresent so that the same could be utilized. As and when some more information is available thesame will he incorporated in the standard. Therefore these are expected to he used by thosedesigners who have sufficient knowledge in this field.This standard is being published In parts. Part I deals with structural and hydraulic aspects design. Part 2 deals with the guidelines for design and selection of the control equipment used inspherical valves. Part 3 deals with the. operation and maintenance of spherical valves.This standard Part I was first published in 1974. This revision is being done on the baSIS ofexperience gai ned during the use of this standard for the last 16 yean as well as the experiencegained during this period in the operation of these valves at the var ious power stat ions. Theprincipal modifications made in this revision arc as below:

a) In the construction provision conica l shape body has also been made;h) The provision of rubber type seals has been deleted;cl Self-lubricated bushes have been added:d) Permissible bearing stress level has been increased h) 35 Njmm ; andc) Clauses for, 1 ) hydraulic condition of design, design criteria for by pass valve, scalingvalve and air valve. 3 permissible leakages have been added.

For the purpose deciding whether a particular requirement of this standard is complied with thefinal value, observed Of calculated. expressing the result ora test or analysis. shall be rounded offin accordance with IS 2 : 1960 Rules for rounding off numerica l values r vis r The numberof significant places retained in the rounded otTvalue should be the same as that of the specifiedvalue in this standard.

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IS 7332 ( Part 1 ) : 1991Ini Standard

SPHERICAL VALVES FOR HYDROPOWERSTATIONS AND SYSTEMSPART CRITERIA FOR STRU TUR L ND HYDR ULI DESIGN rst Revision

SCOPE1.1 This standard Part 1 ) lays down the. guidelines criteria for the structural and hydraulicdesign of spherical valves for hydropower stations.2 REFERENCESThe Indian Standards listed in Annex A arenecessary adjuncts to this standard. ST ND RD SIZES3.1 As far as possible, the valves should bedesigned in any of the following sizes ( in ):

500. 600, 700, 800, 900, I 000. 1 100, I 20H,1 300, 1 400, 1 500, I 600, I 800, 2000,2 200, 2400, 2 600. 2 800, 3 000, 3 200,3 400, 3 600, 3 800. 4 000 and 4 200.3.2 Size of the valve should normally be the sameas that of inlet dia of the spiral case/distributor.However reduction in the size if any can beconsidered by user t ak ing into conside ra tion theextra head loss in the reducer and expander.4 TYPE OF V LVES AND THEIR USE4.1 Normally two types of valves are designed:

a) Valve with service seal only, andb) Valve with service and repair seals.

Typical details of valves with disc type and pistontype seals ( for service and repai r seals are shownin Fig. 1 and 2.4.1.1 For a station having long penstock or re-qu iring unit isolation it is recommended to usethe valve with both the seals, that is service aswell as repair seals. Repair seal jives possibilityof changing the service seal without draining thelong penstock which may t ake more time or mayrequire closing of gates.5 Hydraulic Conditions for Design5.1 The body of the valve should be designed forthe condition of dynamic head, which is the headattained after closure of the turbine.

Dynamic hcad=Max Static headl Pressure risehead

5.2 The rotor and t runnions of the valve shouldbe designed for the condition of head beingattained after its closure or for the head which is1 10 times the maximum static head whichever ismore.

6 DESIGN OF t\fECHANICAL )ARTS6.1 Valve Body6.1.1 The valve body may be cast or fabricatedor cast fabricated from materials recommended inAnnex B. The body shou ld have two holes fortrunnion bearing housings and suitable bosses forby-pass connection, drainage, ai r release and formechanical locks if necessary . Flanges for connecting to penstock should be at right angle tothe axis of the bore and concentric with the boreand the faces should be parallel. The flangesshould have tapped or through holes. In caserepair sea I has been provided, it should have aboss on upstream side fo r connection of a pipefor equaliz. ing pressure and on inlet side acylindrical surface lined with stainless steel shouldhe provided where movable r ing of repair sealslides. This may be provided only in case valvehas go t repair seal arrangement. On t he out le tside it should have a cyl indr ical surface forfitting the service seal.6.1.2 The body should be made in two parts fromassembly point of view. The joint may be vertical,horizontal or diagonal according to the suitabilityof assembly and transport. For large valves thebody may be made in more than two parts havingjoint in vertical as well as in the horizontal plane.The joint in horizontal plane gives possibility ofassembling the valve directly at the place ofinstallation. Two halves should have necessaryspigots and sockets, seal provision , locat ingarrangement and should be held together bymeans of sufficient number of bolts and studs.6.1.3 The fasteners of parting flanges and twoend flanges should be tightened with specifiedinitial tightening by heating or slogging or byhydraulic bolt tensioner to have control led totalstresses developed in the fasteners.6.1.4 The body should be designed, such as tosustain maximum pressure including waterhammer. Supporting feet for installing the valveon foundation should be provided. These feet, orpart thereof. are to be integral with the valvebody, and may no t extend beyond the flange facesof the valve. These supporting feet should haveholes bigger than t he d iamete r of foundationbolts to allow for axial movement of valve thusavoiding axial load on foundation.6.1.5 Suitable me.ms of adequate strength forlifting the valve should be provided.

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IS 7332 Part 1 : 1991

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IS 7332 ( Part 1 ) : 19916.2 Rotor and Trunnions6.1.1 Rotor and trunnions should be joinedtogether by means of welding or bolts or shouldhe integrally cast, cas t- fabr icated or fabricatedfrom materials recommended in Annex B. Boltedconnection should he used in case dimension ofrotor does no t permit machining or transportationof rotor together with trunnions or it is necessaryfrom assembly point or view) when body is splitvertically hut away from the trunnion centre lines.that is bodies are off-set split. Rotor shouldhave necessary provision to accommodate serviceseal and repair seal, if provided.6.2.2 Trunnions should be made of material asgiven in Annex B and of forged steel or cast steelwhen integral with rotor. Levers may be fixed bymeans of wedge pins, parallel pins or keys. Thesplit of the pin may be perpendicular to theshearing planes. The levers should further beconnected to the servomotor.6 3 The angular travel of rotor should be 9 }from open to close position.6.2.4 Cylinder of the rotor should be horizontalwhen valve is open and vertical when valve isclosed. Intermediate position for allowing partialflow should not be allowed.6.2.5 There should be provision for movement toopen and close the service seal.6.2.6 The design of rotor and trunnions shouldbe such that they will safely sustain maximumdifferential pressure including any surge pressureacross the closed valve) and the maximum forcesdue to the servomotor.6.3 l J t a r i ~ s6.3.1 Valve should have hush bearing made frommaterial given in Annex B. Self-centering bearingsmay be used incase of valve where deflection oftrunnions is considerable. It should be designedfor the maximum load imposed by the rotor.6.3.1 Suitable provision should be made forlubricating the bearings unless bearings are ofself lubricating type.6.3.3 There should be provided for limiting themovement of rotor along its axis of rotation.6.3.4 Bearing should be provided with suitableseal for stopping the leakage of water and grease.6.4 Seal6 4 1 Service SealThe service seal should be manufactured usingthe material as mentioned in Annex B underpara Seal Rings . The design should have provision for movemen t of the seal.

4

It may be metallic of materials given in Annex Band should have provision of movement.6 4 2 Repair ScaIt should consist of movable and fixed rings andmechanism for movement of movable ring. Fixedring should be fixed on the rotor and movablering should slide on the valve body Mechanism 1) movement of movable ring should be designedsuch that ring should move in axial direction verysmoothly and should give a good tightness whenrepair seal is closed. Clearance between movablering and valve body should be sealed by suitabledesign rubber seal or cord. A by-pass connectionshould be provided to equalize the pressure toenable smooth opening of the repair seal. Thisby-pass connection should be provided with ahand operated stop valve.6.4.3 Lapping of seal rings may be carried outlor better water tightness.6.4.4 Seal should be made from materialrecommended in Annex B.6.5 Dismantling ointIn order to facilitate dismantling and also fortaking care of certain amount of correction oferrors in erection, suitable dismantling joint mayhe provided. The dismantling joint may bedesigned either to transmit the hydraulic thrus tin the penstock to the upstream of valve or mayact as dismantling-cum-expansion joint dependingupon whether the thrust is required to be transmitted downstream of valve or sustained on theupstream by some means.6.6 FoundationsThe valve foundations should be designed tocater for complete tensile and compressive forcesproduced by operating gear occurring duringworst conditions of its operations. No hydraulicthrust will be taken on the foundations of thevalve in closed position. The purchaser shouldprovide a suitable means to sustain thrust in thepenstock design or on the downstream of thevalve ( by providing a thrust collar or bracketsas agreed by the purchaser and the supplier.6.7 Bypass ValveThe size of the by-pass valve should be sufficientto balance the downstream pressure at least by60 percent of the upstream pressure, consideringthe maximum leakages through the guide vanes.6.8 Sealing ValvesThe size of the sealing valve should be sufficientto drain pressurized water behind the disc towithdraw the disc instantaneously.

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IS 7332 ( Part I ) : 19916.9 ir ValveThe size of the air valve should be sufficient torelease or admit air according to rate of filling ordraining of water in the spiral casing/distributor.7 PERMISSIBLE LEAKAGES7.1 Maximum permissible leakage from main( operating seal should not exceed 1 litre/minImetre periphery of seal, when valve is new orreconditioned.7.2 Maximum permissible leakages from repair/maintenance seal should not exceed 3 0 litres/min/metre periphery of seal. If required by theuser in consultation with manufacturer themaximum permissible leakages can be reduced.8 PERMISSIBLE STRESS LEVELS8.1 The permissible stress levels at the designedhead for the materials used are given below:For design head refer 5

a) Steel:Tensile stress == 1of ultimate tensile stressor of yield strength,whichever is less.

Shear stress = 60 percent of tensile stress.b) Bronze Bushings:

Bearing stress ;; 35 N m m ~c) Self-Lubricated Bushes :

Bearing stress < 35 Njrnm9 TESTING9.1 The tests to be performed after final assemblyof the valve are given in Annex C.10 SPECIAL CLEANING, PROTECTIONAND PAINTING10.1 Before transportation all unfinished surfacesof ferrous material should he thoroughly cleaned,wire-brushed to remove all loose scale, smoothedand painted with black bitumen paint or red lead/steel gray paint or any other paint agreed betweenthe supplier and the purchaser.10.2 All material should be carefully boxed,crated or otherwise protected for transportation.Flanges should be protected and exposed finishsurface should be thoroughly preserved beforetransportation.

ANNEX A( Clause 2.I )

LIST OF REFERRED INDIAN STANDARDSTitle

Specification for steel plates forpressure vessels for intermediateand high temperature serviceincluding boilers first revisionSpecification for carbon steelforgings for general engineeringpurposes ( second revisionSpecification for weldablestructural steel ( third revisionSpecification for l 5 percentmanganese steel castings forgeneral engineering purposes second revisionSpecification for carbon steelcastings for pressure containingparts suitable for high temperatur service t fusion weldingquality ( third revision

2856 : 1987

2062 : 1 9 ~ 427t)8 : 1984

IS s2002 : 1982

2004 : 9 H

tia,

Specification for structural steelstandard quality ( fifthrevision )Specification for leaded tinbronze ingots and castings se ond revision

Specification for phosphor bronzeingots and castings fourthrevision

IS No.28 : 1985

318 : 98

226 : 1975

Specification for steel cast ingsfor general engineering purposesfourth revision

1570 Schedules for wrought steels:( Part : 1985 Part 5 Stainless and heat resistins steels ( second revision

1030 : 1982

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IS 73 2 ( Part 1) 1991ANNEX B

l uses 6 1 I, 6 2 1, 6 2 2, 6 1 1, 6 4 1 and 6 4 4 )RI1COMMFNDED M T E R I L ~ lO R VARIOU ; COMPONENTS

f)/N() I )I)

111

tv)

VI)

Materials2 )valve ods

d) Cast steelb) Mild steelc) Mangancse steelRotora) Cast steelb) MIld steelc) Manganese steelSeala) Cast steelb) Manganese steelc) Stainless steelTrunniona) Cast steelb) Carbon steelc) HIgh tensile steeld) Stainless steel lmmg ushesa) Bronzeb) Gunmetalc) Self-fabricatedSeal Rings

Stainless steel

Confornunu to1 )

IS 2856 : 1987 or IS 1030 1982JS 2062 1984 or IS 226 1975IS 2002 19822708 1984IS 2856 1987 or IS 1030 1982IS 2062 1984 or IS 226 1975IS 2708 1984

2856 1987 or IS 1030 1982IS 2708 1984IS 1570 ( Part )is 2856 19H7 or IS 1030 1982IS 2004 1978IS 1570 ( Part 5 ) 1985is 57 Part 5 1985IS 28 1985IS 318 1981

is 1570 Pl r tS 1985NOl L - Any other rmtct ral no t mentioned thl \nnex rmv be used It found suit..ble by the l c s l ~ n l l

ANNEX (( Clause 9 1 )

TESTS TO 81 . PERFORMED ON TH E SPHERI(,AL VALVE AND ITS P R T ~1 I E R r O R M N C ~ r E ~ TC -l.l Alter final assembly, each valve should beshop operated three times or as agreed bythe purchaser from the fully closed to the fullyopen posinon and \ Ice versa under no flowcondinon to demonstrate that the assemblyworkable,-2 PRE SURE T E ~ I SC-2.t All tests should be earned ou t with watera l the test medium but other media may be usedd i agreed by the purchaserC.22 Valve subjected to th e following tests

a) odyTest - With both ends closed a hydrostatic pressure of one an d a half timesthe specified pressure including pressurer i le or as agreed by the purchaser

6

should be maintamed at least for aperiod of 15 minutes Under this test, thereshould be no leakage from the Interior ofthe valve body to the atmosphere du e toporosity blow-holes, cracks or any otherdefects

b) Rotor or Closing Dive 7est - Rotor ordisc should be tested for strength at apressure one and a half urnes the specifiedpressure mcluding pressure rise Thispressure should be maintained at least fo r aperiod of 15 minutes No leakage throughthe dISC or rotor or structural damageshould be permittedc) Seal Test With on e end open to atmo-sphere and the valve In closed posmon,

test for leakage should be earned out to apressure equivalent to maximum closmgpressure This test should be carried out forservice as well as repair seal For perrmsSible leakages refer 7

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tandard \tarkThe us orthe Standard Mark is governed bv tile prov is ions n the ureau o] ndian

Standards ct /98 and the Rules and Reculat ions made thereunder. The Standard Mark onproducts covered y an ndian Standard ~ o n v y s the assurance that they have been producedto comply with the requirements of that standard under a well defined system of inspection,tes ting and quali ty control which is devised and supervised by HIS and operated by theproducer Standard marked products are also continuously checked by HIS for conformityto that standard as a further safeguard. Details of conditions under which a licence for theuse of the Standard Mark may be granted to manufacturers or producers may be obtainedfrom the ureauof Indian Standards

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Bureau Indian StandardsBIS is a statutory institution established under the ureau ot ndian Standards ct 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of goodsand attending to connected matters in the country.CopyrightHIS hal the copyright of all its publications. No part of these publications may be reproduced inany form without the prior permission in writing of HIS. This does not preclude the free lise, in thecourse of implementing the standard, of necessary details, such as symbols and sizes. type or gradedesignations. Enquiries relating to copyright be addressed to the Director Publications . HISRevision Indian StandardsIndian Standards are reviewed periodically and revised, when necessary and amendments. if any. areissued from time to time. Users of Indian Standards should ascertain that they are in possession ofthe latest amendments or edition. Comments on this Indian Standard may be sent to HIS giving thefollowing reference:Doc: No. RVD 12 4666

Amendment. Issued Since PublicationAmend No.

Ileadquarters:

Date of Issue

BUREAU OF INDIAN STANDARDS

Text Affected

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