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Sea Water Intake System
SEAWATER INTAKE SYSTEMS Concepts and configurations
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CONTENTS
Usage of seawater Thermal power plants Coal fired thermal power plants Gas fired power plants Through cycle system Closed cycle system Typical pumping capacity Basis of Design Overall Planning and Design Types of seawater intake system Onshore well based system Offshore well based system INTAKE POSITION CODE PROVISIONS TURBINE PUMPS 4/2/2013
Onshore intake well system
Offshore intake caisson
Open Channel system Dredged basin Desiltation basin Fore bay Well / pump house Pipeline based system Intake head Subsea pipeline Intake caisson Pipe / approach Bridge Pump house
Construction sequence
Pneumatic Method Gravity Method
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System SEA WATER USE
Desalination for drinking water
Feed Water for steam turbines
Cooling water for power stations
Industrial use
Fire fighting
POWER GENERATION
Gas fired turbines
Coal fired turbines
Nuclear power systems
Solar based thermal power systems
Need water in every case and in large quantity, continuous supply is essential 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System THERMAL POWER PLANTS Sea water is used for Feed water for generating steam Cooling water to condense residual steam coming out of turbines in first cycle for re-use thus reducing the quantity of demineralised water required for steam. The water for generating steam should be of high quality with low impurities! Generally, demineralised water is used for steam. The treated water (DM water) is expensive and hence shall not be wasted. If required, it shall be recycled !. 4/2/2013
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Sea Water Intake System COAL FIRED POWER PLANT Primary power production is based on Steam turbines. The treated water is used for generating steam by coal based boilers. The residual steam coming from the steam turbine is condensed and used back. For this purpose, cooling water is used to condense the steam and condensed water is used back
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System GAS FIRED POWER PLANT Primary power production is based on gas fired turbines. However, the exhaust gas from the turbines carries large heat energy which can be recovered. The treated water is used for generating steam by passing the water through the hot gas. The residual steam coming from the steam turbine is condensed and used back.
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Sea Water Intake System THROUGH CYCLE SYSTEM Through cycle system requires Water intake for FEED water and cooling water. Cooling water after passing through the condenser becomes hot and is discharged into the sea with an increased temperature. Thus requiring a larger outfall system designed to discharge the hot water at an appropriate location away from the intake location to avoid cross circulation and also reduce the environmental pollution. The schematic of the system is shown in figure
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System THROUGH CYCLE SYSTEM
Outfall design becomes critical; appropriate location, away from coast with sufficient water depth of dispersion of hot water with sea water shall be selected. Dispersion analysis shall be carried out to determine the level of concentration both in terms of temperature and salinity!. 4/2/2013
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Sea Water Intake System CLOSED CYCLE SYSTEM Closed cycle system requires Water intake for FEED water and cooling water only initially and makeup water is added depending on the losses. Cooling water after passing through the condenser becomes hot and is discharged into the sea with an increased temperature. The hot water is passed through the cooling towers to reduce the temperature back to the intake water. Thus requiring a smaller outfall system designed to discharge the hot water at an appropriate location away from the intake location to avoid cross circulation. The schematic of the system is shown in figure 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CLOSED CYCLE SYSTEM
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Sea Water Intake System TYPICAL PUMPING CAPACITY Typical water intake requirements depends on the power generation and cooling water requirements. Power Capacity
Water Requirement
Pump Capacity
200 MW Combined cycle Gas fired
21,600 m3/hour
3 x 7200 m3/hour (+1 standby)
(Converted to closed cycle)
2 x 600 MW Coal fired
12,500 m3/hour
3 x 4250 m3/hour (+1 standby)
2 x 800 MW Coal fired
14,000 m3/hour
2 x 7000 m3/hour (+1 standby)
3 x 660 MW Coal fired
24,000 m3/hour
2 x 12000 m3/hour (+1 standby)
2 x 660 MW Coal fired
18,500 m3/hour
2 x 9250 m3/hour (+1 standby)
1m diameter pipe flowing at 3 m/sec is 7850 m3/hour 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System BASIS OF DESIGN Basis of design for a typical seawater intake system includes the following. Flow Data
Environmental data
Geotechnical Data
Power plant data
Total seawater requirement
Water depth
Seabed sediment Characteristics
Coal or gas fired plant ?
Individual pump capacity x Nos
Significant wave height & period
Subsoil conditions
Combined cycle ?
Pipeline diameter
Long shore Current
Distance to power plant
Seawater Temp.
NPSH requirement
Seawater salinity Wind speed
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Sea Water Intake System OVERALL PLANNING AND DESIGN
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System INTAKE POSITION
Pile structure with casing pipe 4/2/2013
Pile structure with sump Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System INTAKE POSITION The seawater intake for fire water applications has less stringent requirement on temperature and presence of sand/silt/impurities. Hence the direct pumping of water from near the seabed is allowed through vertical turbine pumps mounted on structures (pile structures) as shown in figure. An enclosed chamber with concrete wall may limit the disturbance to the seabed and reduce slit entering in to the pump. But the construction of the same may be difficult using piled structures technique. For offshore platforms, this is not posing as a problem as the water depth is large, the pump impellers will be away from the seabed. 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System
CODE PROVISIONS
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Sea Water Intake System INTAKE WELL LAYOUT The intake well layout shall follow guidelines from hydraulic institute (ANSI/HI 9.8/1998). Typical dimensions are given below.
D – DIAMETER OF IMPELLER 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System INTAKE WELL LAYOUT
FILLER WALL DETAILS FOR PROPER BAY WIDTH
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Sea Water Intake System VERTICAL TURBINE PUMPS Turbine pumps are available in large pumping capacity (> 10,000 m3/hour). Usually, 50% standby capacity is recommended. However, 33% standby is also accepted in case more than 2 pumps are in operating condition. Hydraulic simulation is essential at the intake chamber to determine the geometry to avoid local circulation and cavity formation. In case of multple pumps, each pump shall be located within a chamber.
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Sea Water Intake System
TYPES OF INTAKE SYSTEM
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Sea Water Intake System TYPES OF WATER INTAKE SYSTEM Offshore Intake Caisson
Intake Caisson Vertical turbine pumps Pump house Travelling Screens Auxiliary facilities Intake header Transmission pipeline Pipeline support bridge Access Road bridge Power Supply
Onshore Intake Well
Intake Basin Intake channel Desiltation basin Intake well Travelling screens Pump house Auxiliary facilities Vertical turbine pumps Intake header Transmission pipeline
Depending on the location of site, prevailing environmental conditions, the intake system shall be selected. 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System
ONSHORE INTAKE WELL WITH OPEN CHANNEL
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Sea Water Intake System ONSHORE INTAKE WELL – WITH CHANNEL The intake wells are located on land with connectivity to the sea either by means of open channel. Abundant quantity of water is available for pumping in to the mains.
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System DREDGED BASIN The dredged basin shall be protected from siltation by means of shore protection works and breakwater. The breakwater shall be extended atleast 300-500m from the LTL. The basin shall be dredged to -5m to 8m depending on the quantity of the water requirement. The soil seabed conditions sat the site will influence the quality of water available. For example, silty soil at the site may influence the silt content in water. 4/2/2013
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Sea Water Intake System PUMP HOUSE AND INTAKE CHANNEL The intake system showing the pump chambers, fixed and travelling screens, for bay, desilting basin, auxiliary facilities such as control room, electrical room, chlorination facilities etc.
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System ONSHORE INTAKE WELL WITH OPEN CHANNEL AND BASIN The longitudinal section of the intake well together with the fore bay, desiltation basin and silt trap is shown in figure.
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Sea Water Intake System ONSHORE INTAKE WELL - COMPONENTS The intake well shall have facilities to pump the sea water to the supply header or pipeline to the power plant. It will have following facilities. Turbine pumps Fixed and travelling screens Control system Mechanical handling facilities Chlorination system Vortex preventing devices or fixtures Surge control systems 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System
SECTION THROUGH INTAKE CHANNEL (OFFSHORE)
SECTION THROUGH INTAKE CHANNEL (ONSHORE) 4/2/2013
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Sea Water Intake System
ONSHORE INTAKE WELL WITH SUBSEA PIPELINE
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System ONSHORE WELL INTAKE SYSTEM WITH PIPELINES Onshore well intakes with pipelines are very common where the sufficient water depth to draw water is available in close distance. The water intake nozzles will be located below surface by at least 3 to 4m and above mud line to avoid floating debris or slit getting in to the pipe. Pipelines can be made of following materials. Concrete Pipes (Large diameter possible) GRP Pipes (up to 1400mm – availability ?) Steel Pipes (Large diameter possible) GRP pipes are preferred considering the installation and maintenance compared to steel and concrete pipes. However, design to impact and point loads is a serious concern. Design of these pipes shall be as per IS 14402 – 1996 (2001) Design velocity within the pipeline shall be kept below 3 m/sec !. 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System ONSHORE WELL INTAKE SYSTEM – WITH PIPELINES
ELEVATION
PLAN 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System DESIGN AND INSTALATION OF SUBSEA SYSTEM Subsea Pipelines shall be designed in accordance with relevant pipeline codes though it is not a process piping, stability shall be maintained during installation and operation. Subsea pipelines for intake structures can be installed using following methods Bottom pull method In this method, the pipeline is pulled at the seabed level either from the intake structure or from the shore. Float and Sink Method The pipelines shall be floated with both ends closed / additional buoyancy chambers. Controlled flooding and ballasting the pipelines to rest on the seabed. Design shall include
Hydraulic analysis to size the pipe line diameter Mechanical design for strength against internal pressure and installation stresses Head loss calculations Water hammer calculations Horizontal and vertical stability both during installation and operation 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System
OFFSHORE INTAKE WELL WITH BRIDGE
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System OFFSHORE INTAKE WELL WITH BRIDGE Offshore intake wells with pipelines supported on the bridge is a preferred option where the top layer of the seabed is clay / silt. Further, the intake wells can be located further away from the wave breaking zone Offshore intake wells can be constructed using concrete or steel, though concrete is preferred due to corrosion. Approach bridge usually will have a access road and pipe support.
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Sea Water Intake System OFFSHORE INTAKE WELL WITH BRIDGE
ELEVATION
PLAN 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System
COMPARISON OF ONSHORE AND OFFSHORE INTAKE WELLS
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Sea Water Intake System COMPARISON Offshore Intake Caisson
No dredging is involved Construction and installation of caisson and associated structures may require higher initial investment Good quality of water can be made available depending on the location Caisson installation requires offshore expertise.
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Onshore Intake Well
May require initial and periodical dredging Not suitable at a site with clay layers at top Easy to install the caissons on shore Easy to maintain Subsea pipeline / intake head installation requires specialized activity
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System
INTAKE STRUCTURES
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Sea Water Intake System INTAKE STRUCTURES Onshore/ Offshore intake structures can be classified in to following categories. Diaphragm walls Diaphragm wall construction is a well known construction technique in coastal and marine industry and very similar to bored cast-in-situ construction. Segmental caisson sinking method The caisson (rectangular or circular) is cast in-situ with a cutting edge at the bottom and is increased in height by segments. The soil beneath is excavated in wet condition and the caisson is allowed in sink Piled Structures Piled structures are very common in coastal areas predominantly with bored concrete piles. These structures can be used to support vertical turbine pumps hanging from the deck structure Sunken Caissons Gravity method Pneumatic method Gravity Caissons Anchored Caissons 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System GRAVITY CAISSON Gravity caissons are common in shallow water and at locations where subsoil conditions provide good bearing capacity. Gravity caissons can be cast in a dry dock and floated out or it can be cast on a barge depending on the availability. Gravity caissons can be ballasted and set on the well prepared bearing surface and provided with scour protection.
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Sea Water Intake System ANCHORED CAISSON The seabed subsoil conditions determine the type of structure and its fixity to the ground. Caissons can be anchored to the seabed by means of rock anchors to provide lateral stability. Rock anchors will be installed by drilling small diameter holes through the external ballast chambers and grouted. External ballast chambers can also be used for solid ballast. 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System DIAPHRAGM WALL BASED WELL Gravity caissons are common in shallow water and at locations where subsoil conditions provide good bearing capacity.
Stage 4 4/2/2013
Stage 3
Stage 2
Stage 1
Stage 5 Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System SEGMENTAL WELL SINKING
Gravity caissons are common in shallow water and at locations where subsoil conditions provide good bearing capacity.
Stage 3
Stage 2
Stage 1
Stage 5
Stage 4 4/2/2013
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System DESIGN PROCEDURE FOR CAISSONS Caissons shall be designed to have following Reserve buoyancy Sufficient reserve buoyancy shall be available during float out and sinking. This can be achieved by plugging the bottom. Ballast Ballasting by water, heavy metal or sand or concrete can be used for setting the caisson on the prepared seabed. Stability Sliding and overturning stability shall be calculated and shall have a minimum factor of safety of 1.5. Bearing stability shall be calculated and the factor of safety shall be minimum of 2.0. In case, the caisson is embedded in to the seabed, passive soil resistance can be included in the calculation.
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Sea Water Intake System
CONSTRUCTION SEQUENCE OF CAISSON – GRAVITY METHOD
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Sea Water Intake System CAISSON INSTALLATION – GRAVITY METHOD The caisson is made up of two parts. The bottom part of 20m is prefabricated in a floating pontoon or barge in the harbor areas. STAGE: 1 The steel caisson is towed to the site on top of the barge. STAGE: 2 The barge is ballasted enough to sink by at-least 5 to 6m, so that the steel caisson will have adequate buoyancy to float on its own. STAGE: 3 Then the caisson is pulled from the barge horizontally. Barge can be de-ballasted and moved away. STAGE: 4 The floating steel caisson is then filled with M30 concrete inside the shell annular space to increase weight so that the steel caisson will sit on the sea floor and penetrate the seabed.
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Sea Water Intake System STAGE: 5 The sinking of caisson is assisted by excavation of soil inside the caisson using wet grab method. STAGE: 6 Once the required penetration is achieved, the caisson bottom is plugged by M30 concrete for a height of 5m. STAGE: 7 And then the caisson is filled with sand up to -4m. STAGE: 8 The casting of in-situ slab for sump is carried out after dewatering the sump. STAGE: 9 Then other parts of the sump is constructed.
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CAISSON INSTALLATION – GRAVITY METHOD
Stage: 1 Fabrication and Tow
Stage: 3 Free Floating 4/2/2013
Stage: 2 Sinking Barge and Float out Caisson
Stage: 4 Concrete Filling Inside Steel Shell Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CAISSON INSTALLATION – GRAVITY METHOD
Stage: 5 Excavation of Soil Inside
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Stage: 6 Formation of Concrete Plug @ Bottom
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
Stage: 7 Sand Filling
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Sea Water Intake System CAISSON INSTALLATION – GRAVITY METHOD
FINAL STAGE 4/2/2013
SUPERSTRUCTURE INSTALLED
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Sea Water Intake System
CONSTRUCTION SEQUE CAISSON – PNEUMATIC METHOD
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System INSTALLATION PROCEDURE FOR PNEUMATIC METHOD The caisson is made up of two parts. The bottom part of 20m is prefabricated in a floating pontoon or barge in the harbor areas. STAGE: 1 The steel caisson is towed to the site on top of the barge. STAGE: 2 The caisson is ballasted enough to sink by at-least 5m, so that the steel caisson will have adequate buoyancy to float on its own. STAGE: 3 The floating steel caisson is then constructed with M30 concrete at the top and the caisson is sink. STAGE: 4 Dewatering the caisson before soil excavation. STAGE: 5 After that the soil is excavated from the caisson. At the time valve at the top of caisson is closed. 4/2/2013
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Sea Water Intake System STAGE: 6 The caisson is empty. STAGE: 7 Once the required penetration is achieved, the caisson bottom is plugged by M30 concrete. STAGE: 8 An then the caisson top is plugged by M30 concrete. STAGE: 9 Then other parts of the sump is constructed.
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Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CAISSON INSTALLATION – PNEUMATIC METHOD
Stage: 1 Float out and Tow
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Stage: 2 Ballast and Set Down
Stage: 3 Incremental Construction and Sinking
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CAISSON INSTALLATION – PNEUMATIC METHOD
Stage: 4 Dewatering the Caisson 4/2/2013
Stage: 5 Excavation of Soil Inside the Caisson
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CAISSON INSTALLATION – PNEUMATIC METHOD
Stage: 6 Caisson Completed 4/2/2013
Stage: 7 Concrete Filled @ Bottom
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CAISSON INSTALLATION – PNEUMATIC METHOD
Stage: 8 Concrete Filled @ Top 4/2/2013
Stage: 9 Fully Plugged
Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System CAISSON INSTALLATION – PNEUMATIC METHOD
FINAL STAGE 4/2/2013
SUPER STRUCTURE INSTALLED Prof. S. Nallayarasu Department of Ocean Engineering Indian Institute of Technology Madras-36
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Sea Water Intake System REFERENCE CODES
Foundations for coastal/offshore application can be designed in accordance with following codes Driven Steel Piles – API RP 2A Bored cast in-situ piles – IS 2911 Bored cast in-situ pile in rock - IS 14593 Diaphragm wall – IS 9556. Block works – IS 9527 part 6. Some provisions of foundation design can also be noted from various codes of practice for Port and Harbour structures. IS 4651 – Planning and Design of Port and Harbours. IS 9527 – Design and Construction of Port and Harbour Structures BS 6349 - Maritime Structures. Some provisions of following materials code shall be used in the selection of materials for the pipelines. IS 2062 – Hot Rolled Low, Medium and High Tensile Structural Steel. IS 14402 – Specification for GRP pipes joints and fittings for sewerage, industrial waste and water (other than potable) ASTM A36 – Standard specification for carbon structural steel. 4/2/2013
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Sea Water Intake System
Any questions ?
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