Ham Baker Penstock Brochure

Penstocks
www.hambaker.co.uk
15 Reasons
Why customers choose
Ham Baker Hartley
Business Philosophy 1. Reputation

We hold an esteemed reputation globally, for well engineered, high quality
Integrity in management equipment.
Quality of product 2. Service
Unsurpassed in service, our team of professionals will help you to find
HISTORY the most effective solution. All our personnel have e-mail contactability,
even whilst away from the office. The business world is moving faster
HAM BAKER is a name most professionals in the water and exponentially, and we aim always, to move with it.
wastewater industries will instinctively associate with high 3. People
quality precision-engineered products. Established over 100 We pride ourselves on building long-term, strong relationships with both
suppliers and customers to enable us to better understand and meet
customer needs.
4. Range
Unique size range with manufacturing capability up to 5m square
penstocks.
5. Quality
Our products exceed the requirements of British and American
Waterworks Association Standards and, indeed, exceed the quality of
most of our competitors. All products are manufactured under a BS EN
ISO 9001:2000 certified quality assurance system.
6. Delivery
No other company delivers any faster than us. Spares and Fastrack
years ago the original company has undergone many changes products are often delivered within hours.
over the last century and more recently changes of ownership. 7. Flexibility
One of the very few companies who cater for non-standard requirements.
The company is acknowledged as the worlds leading designer You draw it... well build it.
and manufacturer of penstocks and flap valves. Penstocks and 8. Partnerships: Experienced in Framework Arrangements
other fluid control products manufactured by Ham Baker can be We have worked with and continue to work with a number of Water and
found operating in almost every country in the world. Sewage Companies in the UK who are committed to value for money
when using Ham Baker Hartley. A sign of value for money and peace
The history of the company of mind.
began in 1884 as a partnership 9. One Stop Shop
between Frederick Ham, William Recognised as the only one-stop shop in Penstocks. Design, proposals,
Baker and Claude Sansom in specification, supply, fix, repair, spares, aftercare, consultation. Why
London and began diverse your time, or multiply the risks with several suppliers, when you
manufacturing penstocks in can have all the contacts under one roof?
1886, trading under the name of 10. Peace of Mind
Ham Baker & Comapny Ltd. In Readily available library of technical information, built up over 100 years,
1902, Hartleys (Stoke-on-Trent) gives you peace of mind regarding design and maintenance. We have
Ltd was founded as a family penstocks still in practical working order after over 90 years of
owned business in Stoke-on- continuous service.
Trent by William Hartley, who 11.Brand Name
gained his early engineering Ham Baker and Hartley are household names of stability, in the water
training in the locomotive treatment business. Most of our competition is unknown to the end user.
industry. Initially the company
12. Continued Innovation
manufactured general
We are at the leading edge of design and development.
engineering items and began
specialising in the manufacture of 13. Unique
Coplastix Penstocks are the most cost effective Penstocks available.
equipment for the water and wastewater industries in 1904.
Designed and built only by Ham Baker Hartley. More cost effective (i.e.
lower cost of ownership) than stainless steel or cast iron.
The two companies merged in 1998 to create a product range
unrivalled throughout the world. 14. Retro Engineering
Designs are on file from over 60 years, to enable parts to be re-engineered,
to service older Penstocks, meaning lower cost of manufacture, with exact
In 2002 the company was acquired by the WTB Group of
specification.
Bristol and continues its proud 100 year history as a leading
innovator in the fields of water and wastewater engineering. 15. Price
Our products are competitively priced and represent excellent over life-
The company now produces a range of products in cast iron, time value for money, when considering all aspects of ownership; cost,
ductile iron, stainless steel and plastic to deal with every aspect installation, maintenance, and long-term performance.
of fluid control.
Section number and title
Penstocks
Selection Table / Features / Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Introduction to Fluid Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Cast Iron Series 60 ...............................................8
3 Cast Iron Series 60 - 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Cast Iron Series 90 - 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 Cast Iron Series 160 - 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Cast Iron Weir Penstocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 Plastigate Series 20 - 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8 Stainless Steel Series 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
9 Coplastix Series 50 - 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Coplastix Series 20 - 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
11 Technical Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
12 Operating Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
13 Fastrack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
14 Enquiry Questionnaire; International Standards . . . . . . . . . . . . . . 42
Penstock / Sluice Gate

A penstock is used to control the flow or level of a liquid and consists of a sliding door controlled by a
mechanically operated spindle, which moves over an aperture in a frame, which in turn is secured onto
a structure.
Sluice gate is more descriptive of the product, and this term is used widely in specifications outside
the UK.
The word penstock originates from the days of water mills when it was not uncommon for a pond
(stored or penned up water), which was used to feed the water wheel or mill race to be referred to as
the pen. The timber stop logs used to control the flow onto the water wheel was called the stock.
Later, as the need to accurately control the velocity of the water wheel became more critical, a single
sliding gate operated by a lifting mechanism replaced the stop logs with their individual sections. During
the 17th century, the words pen and stock became combined into a single word - PENSTOCK.
Penstocks Selection Table THIS INFORMATION IS BASED ON OUR STANDARD RANGE OF PENSTOCK PRODUCTS
Type Model Size Range Maximum Head Application Catalogue MOUNTING
(mm) (Metres) Page Channel Wall Pipe Thimble
(mm) (Metres) Page
HIGH GRIT CONTENT

REDUCED LEAKAGE
WATER TREATMENT
ON OFF
HYDRO POWER
SEATING SEATING
INDUSTRIAL
TREATMENT
DOCKYARD
SEWAGE
Light Duty SERIES 100mm Varies
Cast Iron 60 to with 6M X X X X X X
Penstocks 1000mm dia. Size
SERIES 150mm x 150mm

60/30 to 6M 3M X X X X X X
2000mmx2000mm
Light Duty PLASTIGATE VARIABLE
Fabricated SERIES to 2M 2M X X X X X
Penstocks 20/20 1000mm x 1000mm
Light Duty PLASTIGATE VARIABLE Door Door
Fabricated SERIES to Depth Depth X X X X X
Channel 20/20 1000mm x 1000mm
Mtd COPLASTIX VARIABLE Door Door
Penstocks 20/20 to Depth Depth X X X X X
2000mm x 2000mm
SERIES 2000 VARIABLE Door Door
STAINLESS to Depth Depth X X X X X
STEEL 2000mm x 2000mm
Medium Duty SERIES 150mm x 150mm
Penstocks 90/60 to 9M 6M X X X X X X X X
2000mm x 2000mm
COPLASTIX VARIABLE
SERIES to 5M 4M X X X X X
50/40 2000mm x 2000mm
SERIES 2000 VARIABLE 10M 10M
STAINLESS to varies varies X X X X X
STEEL 2000mm x 2000mm with size with size
Heavy Duty SERIES 150mm x 150mm
Cast Iron 160/80 to 16M 8M X X X X X X X X
Penstocks 3000mm x 3000mm
Features and Benefits Stainless Steel Fabricated Penstocks The terminology used in this
brochure is that defined in BS7775.
Below is a list of benefits for the 5 main Adjustable wedging application
The corresponding terms used in
penstock product types illustrated in Reduced operating loads
AWWA 501 are given below
our catalogue. Leakage considerably less than
for reference.
Cast Iron Penstocks approved standards
Robust construction Mechanically fixed BS7775 AWWA 501
High impact resistance Low maintenance seals fitted to
Penstock Sluice Gate
For use with high grit content door only
applications Wall, channel or side wall fixing Door Slide
All sewage and water applications Non-standard aperture sizes can Spindle Stem
50 year service life be accommodated
Metal to metal sealing faces Individually designed to suit each Spindle Nut Thrust Nut
application Spindle
Coplastix Penstocks Resilient seals Protection Stem Cover
Materials UV stabilised Table
Adjustable pressure pads Specification for Penstocks Metal Seal Sealing Face
Leakage considerably less than Ham Baker Hartley has ISO EN 9001:2000
Resilient Seal Seal
approved standards accreditation, and the capability to manufacture a
Reduced operating loads full range of penstocks in accordance with On-Seating Seating Head
Door having smooth clean face BS7775 or AWWA C501 Head
Side wall fixing (no rebate required)
Special designs for non-standard sizes and Off-Seating Unseating Head
Non-standard aperture sizes high heads are available in Head
Resilient seals
CAST IRON COPLASTIX
Head Measured Head Measured
from invert from centreline
STAINLESS STEEL of aperture of aperture
4
1
An Introduction This section is intended to assist users in the selection of the most
suitable products to meet requirements.
to Fluid Control
Selection Considerations
Ham Baker Hartley can offer the most comprehensive range of fluid When setting out to determine the unit most suited to a particular
control equipment in the world. requirement, the following considerations have to be made:
The traditional cast iron ranges have been the mainstay of the 1. Size of gate required.
industry and the development of Ham Baker Hartley has created 2. In which direction is the flow of the fluid to be controlled;
several standard ranges which cover a wide variety of types, sizes will it force the door on to or off its sealing face?
and operating conditions. However the wealth of experience gives 3. What is the differential head in metres across the gate in
Ham Baker Hartley the ability to design and manufacture penstocks each direction under:
for any duty or size. (a) Static conditions
(b) Opening and closing conditions
Ham Baker Hartley in step with its continuous programme of 4. Wall, channel, pipe or thimble mounting
research and development has developed a range of stainless steel 5. Method of operation.
fabricated penstocks using the latest technology. Low friction guide 6. It is now necessary to make a selection given:
blocks are positioned on the frame sides to effect a clearance (a) Basic types available.
between the door and the resilient sealing faces attached to the (b) Direction of flow and invert sealing arrangement.
frame upon immediate raising of the door, thus preventing seal drag (c) Mounting position.
and minimising wear. (d) Fixing details.
(e) Method of operation.
With this comprehensive range of fluid control products Ham Baker (f) Accessories.
Hartley can help our customers solve all their fluid control needs.
Because of this extensive range we are not limited to specific duty Having selected the basic frame type, it is then necessary to
ranges or technologies but can offer our customers not only a specify one of the following alternatives:-
technically suitable solution but also the most cost effective
solution. A. Is the gate to take - on-seating head?
- off-seating head?
Penstocks and other fluid control products manufactured by Ham - on and off-seating head?
Baker Hartley can be found operating in almost every country in the On-seating head - Pressure forcing the door onto
world, thus endorsing the statement that Ham Baker Hartley is one the frame.
of the leading penstock manufacturers in the world. Off-seating head - Pressure forcing the door away from
the frame.
SELECTION Modulating penstocks for flow control purposes, where gates may
be frequently repositioned and utilise only a proportion of the full
Introduction stroke, require special consideration and may necessitate:-
The primary application of penstocks is the flow control and
isolation of fluids associated with water, waste water, sewage larger than standard stems
treatment plants, power generation, irrigation schemes and slow operating speeds
process plants. continuously rated motors on actuators
special heat absorbing drive sleeves
The modern penstock is designed to cater for a wide variety of
duties from low seating to high off-seating heads in sizes from B. Is the gate to have - Chased/Rebated invert?
150mm to 5000mm square. Selection of the correct penstock to suit - Flush invert?
the duty is important to satisfy the design criteria and provide the
most cost effective solution. Operation of the penstock is governed Chased/Rebated Invert
generally by factors outside the control of the penstock manufacturer. Standard inverts have bronze facings. Seating faces are very
However, the range of available operating equipment is extensive: carefully bedded onto the door and frame surfaces, and secured
from simple direct operation by handwheel to complex control with specially designed, long taper countersunk screws of the same
systems for electrical, pneumatic or hydraulic actuation. The range material as the faces. They are finally mated to each other resulting
of penstocks together with its associated operating equipment will in a tight seal.
cater for the most demanding specification and application.
5
An introduction to Fluid Control

6

Fluid Control
Flush Inverts
These are available with a resilient sealing strip to produce a laminar
flow, improved hydraulics, efficiency and a non-fouling invert.
Flow
ON-SEATING HEAD
Flow Flow
ON-SEATING/OFF-SEATING HEAD
FIXING METHODS
Wall Mounting
Wall mounted penstocks are
fixed to vertical end walls of
channels, chambers or similar
structures by means of
foundation bolts utilising a
sand/cement non shrink grout
to effect a seal between the
wall and penstock frame.
Foundation bolts can be
supplied as an expanding type
(as shown oppostite), built-in
type or chemical resin type.
Flow
OFF-SEATING HEAD
CHASED/REBATED INVERT
FLUSH INVERT
Channel Mounting
Any of Ham Baker Hartley
standard penstock units can
be mounted in a channel.
Channel mounted penstocks
are fixed into preformed
rebates in the sides and
inverts of channels by means
of a sand/cement non shrink
grout, to effect a seal between
the rebate and the penstock
frame. Wall mounted
penstocks can be installed
penstock in such circumstances is by use of a

wall thimble.
Wall thimble mounting offers the following

advantages:-
1. Civil construction can proceed prior to

delivery of penstock reducing costs.
2. Considerable keying/anchor area within the

concrete structure.
3. Ease of penstock erection and removal

for re-siting or cleaning etc.
Iron wall thimbles can be supplied in either 'E'

or 'F' section, suitable for circular or
rectangular openings.
'E' Section for off-seating heads

'F' Section for on-seating heads
sealing grout
concrete structure
with foundation bolts and grout, however, the rebate will need to be
cast large enough to facilitate normal wall mounting procedures and
wedge adjustment.
Wall Thimbles
When high off-seating pressure is specified,

careful consideration must be given to the
method of fixing the penstock to the structure.
The most reliable method of attaching a
'E' SECTION THIMBLE
'F' SECTION THIMBLE

Fluid Control
COUPLINGS
There are several methods of connecting sections of spindle together. TYPICAL COUPLINGS
The type selected will depend upon the application and the duty of the
penstock. The most commonly used couplings are illustrated below.
Spindle Adaptor
Manufactured in cast iron, for jointing straight lengths of stem
in line. For use with torsional loads only
(non-rising stem applications).
Spindle adaptor
Muff Couplings
Manufactured in the same material as the spindle for joining
straight lengths of spindle in-line. For use with both axial and
torsional loads (rising and non-rising spindle applications).
Two types of coupling are available:-

1. Plain muff coupling.
2. Screwed muff coupling.
The use of a particular type of coupling will depend upon the Universal Plain Screwed
operating duty and/or the specification. joint Muff couplings
Universal Joint
Manufactured in mild steel or stainless steel, for joining two straight
lengths of spindle in different planes. For transmission of torsional
loads only (non-rising stem applications). Universal joints are
supplied in pairs for a maximum working angle of 35.
TYPICAL SPINDLE GUIDES
Protective neoprene gaiters can be supplied for the retention
of lubricants in the joints.
ACCESSORIES
Spindle Guides
In some cases unsupported lengths of spindle are subjected to
buckling under compression or from lateral thrust by debris or
solids. Spindle guides are, therefore, necessary as a means of
providing intermediate support. Bolt-on type adjustable guides are
manufactured in cast iron, normally plain unmachined, but if
required they can be bronze lined.
Used on larger sizes of penstocks for rising
and non-rising spindle applications.
When considering the centres or vertical spacing of the guide, the
l/r (length/radius of gyration of the spindle) should not normally
exceed 200.
Used on smaller sizes of penstocks for rising

and non-rising spindle applications.
7
2 MATERIAL SPECIFICATION
Cast Iron Frame

Constructed in BS EN 1561 min. 250 cast iron designed for wall or
Series 60 flange mounting applications.
Door
DESCRIPTION Constructed in BS EN 1561 min. 250 cast iron to withstand seating
heads up to 6m on and off seating as specified in table below.
The Series 60 is a circular metal faced penstock suitable for wall
and flange mounting application, suitable for on-seating pressure as Sealing Faces
standard but, dependent on size, will take a degree of off-seating Sealing faces are bedded to 0.1mm feeler gauge non-acceptance
pressure. to provide an effective seal. The sealing face material for penstocks
up to and including 600mm diameter sizes is to BS EN 1982:1999,
Conventional adjustable wedges are positioned around the door as sizes above 600mm diameter BS EN 12167:1998.
required to suit the duty and provide a practical degree of
watertightness. For sizes up to and including 600mm diameter the sealing faces
are force fit, for sizes above 600mm the sealing face is secured to
FEATURES / BENEFITS the frame using long countersunk taper screws in the same material
as the sealing face.
An extensive range of operating equipment can be utilised
Faced wedges available in the same material as the sealing faces Side Wedges
Fixing bolts supplied on request Constructed in BS EN 1561 min. 250 cast iron to provide a large
Flange/pipe mounting (BS EN 1092-2 : PN 16) contact area with the door. The side wedges are adjustable to
accommodate wear during the life of the penstock.
Aperture Maximum Head (Metres)

Size (mm) On-Seat Off-Seat
100 6 6
150 6 5
200 6 4
Expanding 250 6 4
indented
as required 300 6 3.5
350 6 3
400 6 3
450 6 2.5
500 6 2.5
600 6 2.5
700 6 1.5
800 6 1.5
TYPICAL SECTION THROUGH SIDE MEMBER 900 6 1
1000 6 1
NOTE: Heads taken from invert
8
Cast Iron Series 60
Series 60
Thrust Housing (direct operation) Operating Spindles

Manufactured in cast iron to BS EN 1561 min. 250 with low friction Alternative materials can be supplied for operating spindles and
thrust washer and lubricator. extension.
Door Nut Methods of Operation

Manufactured from phosphor bronze to BS EN 12167:1998 for non- The method of operation will depend upon several factors which
rising stem applications or cast iron to BS EN 1561 min. 250 for are outside the control of the penstock manufacturer, but the range
rising stem types. of operating gear available is extensive which can be provided to
meet customer requirements. (See page 39)
Fasteners
Standard fasteners are supplied in stainless steel to BS EN
10088:1995 grade 1.4401 (316; A4).
P E
W-No. holes, AA dia.
L *U *V
C
A dia.
H Invert Invert
D
G F *Non-Rising
spindle
B
Thrust Direct
A B C D E F G H J K L M P U V W AA
DIMENSIONS IN MILLIMETRES
100 254 285 57 48 78 216 3 197 - - - 250 382 445 4 13
150 295 385 65 64 84 251 6 295 - - - 250 484 550 4 13
200 390 565 70 55 98 345 25 415 - - - 250 675 750 4 13
225 415 615 73 55 98 370 25 450 - - - 250 725 800 4 13
250 440 665 78 55 98 395 25 500 - - - 250 775 850 4 13
300 495 765 80 55 98 450 25 575 - - - 250 875 950 4 13
350 575 885 85 65 118 525 25 650 - - - 250 995 1070 4 16
400 625 985 90 65 118 575 25 725 - - - 250 1095 1170 4 16
450 675 1085 95 65 118 625 25 400 400 - - 250 1195 1270 6 16
500 725 1185 108 65 118 675 25 425 450 - - 250 1290 1395 6 16
600 825 1375 120 65 118 775 25 525 550 - - 250 1490 1595 6 16
700 915 1610 90 75 146 865 25 450 560 350 - 250 1715 1820 8 16
750 965 1710 90 75 147 915 25 665 420 365 - 250 1815 1920 8 16
800 1015 1810 90 75 148 965 25 525 635 380 - 250 1915 2020 8 16
900 1115 2010 90 75 151 1065 25 440 440 430 410 250 2115 2220 10 16
1000 1215 2210 100 105 168 1165 25 490 490 480 445 400 2325 2425 10 16
9
Cast Iron Series 60
3 Sealing Faces
Phosphor bronze sealing faces to BS EN 12167:1998 are supplied
Cast Iron as the standard material bedded to 0.1mm feeler gauge non-
acceptance to provide an effective seal.
Series 60 - 30
Door and Frame
The sealing faces are fixed securely using long taper countersunk
DESCRIPTION pegs in the same material as the sealing face.
The Series 60-30 is a rectangular metal faced penstock suitable for Wedges
wall and thimble mounting, with on-seating heads up to 6 metres Constructed in BS EN 1561 min. 250 cast iron to provide a large
and off-seating heads up to 3 metres. Conventional wedges are contact area with the door. The wedges are adjustable to
positioned each side of the frame to apply a face to the door in the accommodate wear during the life of the penstock.
closed position.
Flush Invert
OPTIONS The resilient flush invert seal is bolted onto the frame invert member.
An extensive range of operating gear can be utilised Thrust Housing

Faced wedges available in the same material as the sealing faces Manufactured in cast iron to BS EN 1561 min. 250 with low friction
Fixing bolts supplied on request washer and lubricator.
Sealing faces can be secured to satisfy the requirements of the
American Water Works Association specification - Invert Seal
AWWA C501-92 A flush invert is supplied as a standard feature, the seal is
Circular apertures (sealing faces remain rectangular) manufactured from Ethylene Propylene Di-Methyl (EPDM) to
Thimble mounting (See page 6) ASTM D2000.
Full and half frames available
Door Nut
MATERIAL SPECIFICATION Manufactured from phosphor bronze to BS EN 12167:1998 for non-
rising stem applications, or cast iron to BS EN 1561 min. 250 for
Frame rising stem types.
Constructed in BS EN 1561 min. 250 cast iron for wall or thimble
mounting applications. Fasteners
Standard fasteners are supplied in stainless steel to BS EN
Door 10088:1995 grade 1.4401 (316; A4).
Constructed in BS EN 1561 min. 250 cast iron designed to
withstand seating heads up to 6 metres, and 3 metres off-seating.
Door
Expanding
indented
as required
Frame
Invert seal
TYPICAL SECTION THROUGH SIDE MEMBER FLUSH INVERT SECTION & REBATE
10
Cast Iron Series 60 - 30
Series 60-30
Operating Spindles Alternative Frame

Alternative materials can be supplied for operating spindles and Alternative half frame penstocks are also available.
extensions.
Methods of Operation
The method of operation will depend on several factors which are
outside the control of the penstock manufacturer, but the range of
operating gear available is extensive. (See page 39)
AC No. of holes for

AG dia. fixing bolts
N
M
L
HALF FRAME
FULL FRAME - Thrust Direct Thrust Remote Rising Spindle
A B C D E F G H J K L M N P R S V W Y Z AA AB AC AG
150 345 465 55 65 113 - 300 430 - - - - - - - 250 575 - - - - 4 12
200 395 565 55 65 113 - 350 290 240 - - - - - - 250 675 - - - - 6 12
225 420 615 55 65 113 - 375 330 250 - - - - - - 250 725 - - - - 6 12
250 445 665 55 65 113 - 400 365 265 - - - - - - 250 775 - - - 6 12
300 495 765 55 65 113 - 450 440 290 - - - - - - 250 875 - - - - 6 12
350 565 885 75 70 127 - 515 510 330 - - - - - - 250 995 - - - - 6 16
400 615 985 75 70 129 - 565 585 355 - - - - - - 250 1095 - - - - 6 16
450 665 1085 75 70 131 - 615 660 380 - - - - - - 250 1195 - - - - 6 16
500 715 1185 75 70 138 - 665 375 360 405 - - - - - 250 1290 - - - - 8 16
600 815 1385 75 70 142 - 765 435 450 455 - - - - - 250 1490 - - - - 8 16
700 915 1610 75 75 156 - 865 510 525 530 - - - - - 250 1715 - - - - 8 16
750 965 1710 75 75 158 - 915 560 550 555 - - - - - 250 1815 - - - - 8 16
800 1015 1810 75 75 160 - 965 585 600 580 - - - - - 250 1915 - - - - 8 16
900 1115 2010 75 75 164 - 1065 360 360 615 630 - - - - 250 2115 - - - - 10 16
1000 1215 2210 100 105 188 - 1165 400 420 665 680 - - - - 400 2325 - - - - 10 16
1100 1315 2410 130 105 195 - 1265 450 450 735 730 - 105 - - 400 2525 500 1175 120 15 13 16
1200 1415 2610 130 105 205 - 1365 500 500 785 780 - 105 - - 400 2725 550 1275 120 15 13 16
1300 1515 2810 130 105 233 - 1465 380 380 340 835 840 105 - - - - 600 1375 120 15 13 16
1400 1700 3035 160 105 240 - 1620 525 525 560 650 725 130 - - - - 650 1490 140 20 15 20
1500 1800 3235 160 105 245 - 1720 560 560 590 700 775 130 - - - - 700 1590 140 20 15 20
1600 1900 3440 160 113 234 - 1820 450 450 450 565 645 130 815 - - - 750 1690 140 20 17 20
1700 2000 4075 190 217 370 - 1920 600 500 600 800 400 160 600 - - - 1000 1880 140 20 18 20
1800 2100 3860 160 222 380 - 2020 375 375 650 650 650 130 260 840 - - 1000 1980 140 - 20 20
2000 2380 4715 210 247 420 - 2280 305 460 505 735 945 160 420 800 - - 500 2210 140 - 22 20
11
4 Thrust Housing (direct operation)
Manufactured in cast iron to BS EN 1561 min. 250 with low friction
Cast Iron thrust washer and lubricator.
Series 90 - 60 Door Nut

Manufactured from phosphor bronze to BS EN 12167:1998 for non-
rising stem applications, or cast iron to BS EN 1561 min. 250 for
DESCRIPTION rising stem types.
The Series 90-60 is a rectangular metal faced penstock suitable for Fasteners
wall and thimble mounting, with on-seating heads up to 9 metres Standard fasteners are supplied in stainless steel to BS EN
and off-seating heads up to 6 metres. 10088:1995 grade 1.4401 (316; A4).
Penstocks for seating duties are supplied with side wedges only. Alternative Materials
Off-seating applications may require bottom and/or top wedges in Alternative materials can be supplied for operating spindles, sealing
addition to side wedges, depending on the operating conditions. faces, fasteners etc.
Chased invert penstocks are supplied as standard. Flush invert can Methods of Operation
be supplied when requested. The method of operation will depend on several factors which are
OPTIONS operating gear available is extensive, and can be provided to meet
clients requirements.
Flush invert eliminating grit traps
An extensive range of operating gear can be utilised For square penstocks with apertures up to 350mm respectively, the
Faced wedges available in the same material as the wedge bars/blocks are cast integrally with the frame into which
sealing faces stainless steel jacking screws are fitted to provide the wedging
Fixing bolts supplied on request effect onto the door when it is in the closed position.
Sealing faces can be sealed to satisfy the requirements of
both BS7775 and AWWA C501-92 For the 90-60 range of penstocks, with square aperture above
Circular apertures (sealing faces remain rectangular) 350mm, separate individual wedge blocks are secured to the
for penstocks 700mm - 2000mm mounting pads cast onto the frame via three set-bolts incorporating
Thimble mounting (See page 6) micro-adjustable screw jacks in triangular configuration to facilitate
Full and half frames available accurate setting of each wedge block to match the corresponding
wedge face on the door. (Figs. 1 & 2.)
MATERIAL SPECIFICATION
Bottom wedge blocks are provided across the invert member of the
Frame frame to give additional sealing force when required. (Fig. 1.)
Constructed in BS EN 1561 min. 250 iron for wall or thimble Sluice gates with a flush invert resilient seal do not require bottom
mounting applications. wedges. (Fig. 3.)
Door For OFF seating pressures a bridge mounted across the soffit of
Constructed in BS EN 1561 min. 250 iron designed to withstand the frame embodies jacking screws to mate with top wedges on the
seating heads up to 9 metres, and 6 metres off-seating. door when required. (Fig. 2.) X
Sealing Faces
Phosphor bronze sealing faces to BS EN 12167:1998 are supplied as
the standard material bedded to 0.1mm feeler gauge non-acceptance.
The sealing face is fixed securely to the frame using long taper TOP
WEDGE
countersunk pegs in the same material as the sealing face.

BRIDGE
Wedges
Y Y
Constructed in BS EN 1561 min. 250 iron to provide a large contact
area with the door. The wedges are adjustable to accommodate Z
wear during the life of the penstock.

Z X SECTION XX
TYPICAL ARRANGEMENT OF A RECTANGULAR PENSTOCK WITH

MICRO-ADJUSTABLE TOP, SIDE AND BOTTOM WEDGES
12
Series 90-60
BB DOOR
Fig 1. DOOR
Fig 2. FRAME PENSTOCK TAPERED TOP WEDGE BRIDGE
Fig 3.
SEALING SPINDLE ON DOOR ON FRAME
(NON RISING
FACES TYPE SHOWN)
INVERT
TAPERED
BOTTOM
WEDGE
MICRO-ADJUSTABLE
SCREW JACK
D + 25
FRAME
45
FLEXIBLE SEAL
SEALING DOOR MICRO-ADJUST JACKING SCREW
600 min FACES FRAME
BOTTOM-WEDGE ARRANGEMENT - SECTION ZZ AND CHASE DETAILS TOP-WEDGE & BRIDGE ARRANGEMENT - PART SECTION XX FLUSH INVERT
E
E AA No. of
G holes for AB
F
diameter
fixing bolts
WHEN REQUIRED
C
O
F
N
Q Q
M
BB
R
B
L
OPENING DEPTH / DIAMETER
K
DEPTH
ET ING
ER
AM N
DI PE
J
O
H
I
D
H
INVERT
WIDTH
D
P
S T U V W X
Y
Y
G WHEN CIRCULAR,
DIAMETER
APERTURE REQUIRED
A A
PENSTOCK SIZES 150 x 150 to 450 x 450mm PENSTOCK SIZES 500 x 500 to 2000 x 2000mm
OPEN OR CLOSED TOP
Effective AA AB
Gate A B C D E F G H I J K L M N O P Q R S T U V W X Y Half Full dia.
Opening FrameFrame
150x150 370 460 - 55 105 55 300 355 - - - - - - - - - - - - - - - - - - 4 18
200x200 400 570 - 65 120 60 350 450 - - - - - - - - - - - - - - - - - - 4 18
250x250 470 687 - 75 125 72 410 280 280 - - - - - - - - - - - - - - - - - 4 18
300x300 520 790 - 75 125 64 460 280 280 - - - - - - - - - - - - - - - - - 4 22
350x350 590 890 - 90 125 63 530 350 300 - - - - - - - - - - - - - - - - - 4 22
400x400 670 1007 - 110 125 67 610 390 400 - - - - - - - - - - - - - - - - - 4 22
450x450 710 1135 - 100 150 90 650 300 480 - - - - - - - - - - - - - - - - - 4 22
500x500 800 995 270 120 210 110 740 500 400 - - - - 200 - - - - - - - - - - - 4 6 22
600x600 900 985 560 150 220 120 830 245 300 335 - - - 500 - 55 - - - - - - - - - 8 12 22
700x700 1000 1135 570 150 220 120 930 295 350 385 - - - 500 - 55 - - - - - - - - - 8 12 22
800x800 1100 1285 580 150 220 120 1030 345 400 435 - - - 500 - 55 - - - - - - - - - 8 12 22
900x900 1200 1485 590 150 220 120 1130 245 300 300 535 - - 500 - 55 - 125 375 380 375 - - - 100 10 14 22
1000x1000 1300 1685 600 150 220 120 1230 285 330 330 635 - - 500 - 45 340 125 410 410 410 - - - 100 13 17 22
1100x1100 1440 1785 725 190 235 135 1350 345 415 415 500 - - 255 250 70 340 125 335 340 340 335 - - 125 15 19 28
1200x1200 1540 1885 895 190 235 135 1450 375 450 450 500 - - 255 400 75 365 125 360 365 365 360 - - 125 15 19 28
1300x1300 1640 2035 915 190 235 135 1550 295 360 360 360 550 - 255 400 65 390 125 385 390 390 385 - - 125 18 22 28
1400x1400 1740 2235 895 190 235 135 1650 320 385 385 385 650 - 255 400 65 495 125 330 330 330 330 330 - 125 20 24 28
1500x1500 1840 2335 1060 190 235 135 1750 345 410 410 410 650 - 255 500 65 525 125 350 350 350 350 350 - 125 20 24 28
1600x1600 2000 2485 1080 240 240 140 1880 370 435 435 435 700 - 255 550 65 570 140 370 380 380 380 370 - 140 20 24 28
1700x1700 2100 2685 1086 240 240 140 1980 295 360 360 360 400 800 255 550 65 595 140 395 395 400 395 395 - 140 22 26 28
1800x1800 2200 2785 1246 240 240 140 2080 310 385 385 385 410 750 355 600 75 690 140 350 345 345 345 345 350 140 24 28 28
1900x1900 2300 2935 1250 240 240 140 2180 325 400 400 400 450 800 355 600 75 720 140 370 360 360 360 360 370 140 24 28 28
2000x2000 2400 3135 1260 240 240 140 2280 345 420 420 420 470 900 355 600 75 760 140 380 380 380 380 380 380 140 24 28 28
13
5 area with the door. The wedges are adjustable to accommodate
wear during the life of the penstock.
Cast Iron Flush Invert
Series 160 - 80 The resilient flush invert seal is bolted onto the frame invert
member. The seal is manufactured from Ethylene Propylene Di-
Methyl (EPDM).
DESCRIPTION
Thrust Housing (direct operation)
The Series 160-80 is a rectangular metal faced penstock suitable Manufactured in cast iron to BS 1561 min. 250 with low friction
for wall and thimble mounting, seating heads up to 16 metres and thrust washer and lubricator.
off-seat heads up to 8 metres.
Door Nut
Penstocks for seating duties are supplied with side wedges only; Manufactured from phosphor bronze to BS EN 12167:1998 for non-
off-seating applications may require bottom and/or top wedges in rising stem applications, or cast iron to BS EN 1561 min. 250 for
addition to side wedges depending on the operating conditions. rising stems.
Chased invert penstocks are supplied as a standard. Flush invert Fasteners

can be supplied when specified. Standard fasteners are supplied in stainless steel to BS EN
10088:1995 grade 1.4401 (316; A4)..
Conventional wedges are positioned around the frame as required
to suit the duty. The wedges apply a force to the door in the closed Alternative Materials
position. During the opening and closing travel the door is retained Alternative materials can be supplied for operating spindles, sealing
by integral guides in the frame. faces, fasteners etc.
OPTIONS Methods of Operation

The method of operation will depend on several factors which are
Flush invert operating gear available is extensive, which can be provided to
An extensive range of operating gear can be utilised meet customer requirements. (See page 39)
Faced wedges available in the same material as the sealing faces
Fixing bolts supplied on request Bridge
Sealing faces can be secured to satisfy the requirements of Top wedge
BS 7775 and AWWA C501-92 Door
Circular apertures (sealing faces remain rectangular)

Thimble mounting (See page 6)
Full and half frames available
Available up to 5000mm square
Typical Bridge Section
Frame
Sealing faces
Frame
Constructed in BS EN 1561 min. 250 iron for wall or thimble
mounting applications.
Door
Constructed in BS EN 1561 min. 250 iron designed to withstand Expanding
indented
seating heads up to 16 metres, and 8 metres off-seating. as required
Sealing Faces
Phosphor bronze sealing faces to BS EN 12167:1998 are supplied as
the standard material bedded to 0.1mm feeler gauge non-acceptance.
The sealing face is fixed securely to the frame using long taper
countersunk pegs in the same material as the sealing face.
Wedges
Constructed in BS EN 1561 min. 250 iron to provide a large contact TYPICAL SECTION THROUGH SIDE MEMBER
14
Series 160-80
SIZE RANGE 150 TO 1500mm Sq. or Dia. (Refer to both tables)

A N R S T U V W Y AA AB AC AD AE AF AG
150 280 45 275 160 - - - - 6 45 100 12 4 65
200 330 45 300 235 - - - - 6 45 100 12 4 65
250 380 45 375 260 - - - - 6 60 125 16 4 65
300 430 45 425 310 - - - - 6 60 125 16 4 65
350 510 65 240 320 280 - - - 8 60 125 16 6 65
400 560 65 265 345 330 - - - 8 60 125 16 6 65
450 610 65 290 365 385 - - - 8 60 125 16 6 65
500 660 65 315 400 425 - - - 8 60 125 16 6 65
600 760 65 365 450 525 - - - 8 60 125 16 6 65
700 940 80 425 625 625 - - - 8 75 200 24 6 65
750 990 80 450 650 650 - - - 8 75 200 24 6 65
800 1040 80 480 700 700 - - - 8 75 200 24 6 65
900 1140 80 700 600 600 - - - 8 75 200 24 6 65
1000 1240 80 750 750 750 - - - 8 75 200 24 6 65
1100 1340 100 830 810 810 - 600 1225 11 75 200 24 9 190 65
1200 1440 100 900 900 900 - 600 1325 11 75 200 24 9 190 65
1300 1540 100 400 650 900 900 650 1450 13 75 200 24 11 190 65
1400 1640 100 700 500 900 900 650 1550 13 75 200 24 11 190 65
1500 1740 100 700 600 900 900 750 1650 15 75 200 24 11 190 65
F
L Dia AG
AF sq. AE No. holes left in Wall

AB sq.
q x AC deep for AD
dia. fixing bolts
W
Central fixing hole on sizes V
1100 mm and above.
K M
C U
D
V
sq.
Y or sq.
dia. T A or
dia.
Invert S
Flanged
g back type p illustrated R
R d
for thimble mounting.
Thimble fixingg hole details
E available on request. N H
NSS AA No. holes left in Wall
B J
H
HALF FRAME FULL FRAME

Thrust Remote - Rising Spindle Thrust Direct
A B C D d E F H J K L M
150 320 425 225 90 75 70 120 - 510 250 635
200 370 525 300 90 75 70 135 - 595 250 735
250 420 625 375 90 75 70 120 - 710 250 835
300 470 725 450 90 75 70 125 210 810 250 935
350 580 835 525 115 100 70 170 235 920 300 1045
400 630 935 600 115 100 70 175 235 1020 300 1145
450 680 1035 675 115 100 70 175 235 1120 300 1245
500 730 1155 750 115 100 90 185 290 1240 400 1365
600 830 1350 900 115 125 90 190 290 1440 400 1565
700 1020 1710 1050 160 125 135 250 395 1830 400 1935
750 1070 1810 1125 160 125 135 255 395 1930 400 2035
800 1120 1910 1200 160 125 135 265 395 2030 400 2135
900 1220 2110 1350 160 125 135 275 395 2230 500 2335
1000 1320 2310 1500 160 125 135 280 400 2430 500 2535
1100 1420 2510 1650 160 125 135 280 510 2630 500 2735
1200 1520 2710 1800 160 125 135 290 490 2830 500 2935
1300 1620 2910 1950 160 125 135 295 480 500
1400 1720 3110 2100 160 125 135 300 550 500
1500 1820 3310 2250 160 125 135 310 600 500
On sizes 1300 mm and above, manual gearboxes or power operated actuators are normally supplied. Dimensions cover Series 160-80 only. Details for Series 260-130 and 300-150 are on request.
15
Series 160-80
SIZE RANGE 1600 TO 3000mm Sq. or Dia.

(Refer to both tables)
Steel
cross
beams AB No. holes left in Wall
Recommended
R AA Y AA lifting holes
Q C
N X sq.
A or
M dia.
L K Invert
V U T T U V W
J FULL FRAME
B
Thrust Direct
A B C D d E F G H J K L M N
1600 2000 3550 2430 230 120 180 350 550 1900 100 465 860 775
1700 2100 3750 2580 230 120 180 355 560 2000 100 760 720 720
1800 2200 3950 2730 230 120 180 360 570 2100 100 860 720 700
2000 2400 4350 3030 230 120 180 370 580 2300 100 900 800 750
2100 2500 4550 3180 230 120 180 375 590 2400 100 950 850 800
2200 2600 4750 3330 230 120 180 380 600 2500 100 950 950 800
2300 2700 4950 3480 230 120 200 385 625 2600 100 950 950 900
2400 2800 5150 3630 230 120 200 390 625 2700 100 1000 1000 850
2500 2900 5350 3780 230 120 200 395 650 2800 100 1000 1000 950
3000 3400 6350 4530 230 120 200 420 700 3300 130 930 880 880
Recommended
lifting holes Ab No. holes left in Wall
R D
sq.
A or
dia.
Invert
d HALF FRAME
G
B Thrust Remote - E
H
Rising Spindle
A P Q R S T U V W X Y AA AB Ab AC
1600 650 800 - - 500 - - 150 1750 650 - 17 13 90
1700 350 600 600 - 525 - - 150 1850 675 - 19 15 90
1800 420 625 625 - 550 - - 150 1950 700 - 19 15 90
2000 550 675 675 - 600 - - 150 2150 800 - 19 15 90
2100 550 700 700 - 625 - - 150 2250 850 - 19 15 90
2200 600 725 725 - 650 - - 150 2350 900 - 19 15 90
2300 650 750 750 - 675 - - 150 2450 500 500 21 17 90
2400 700 800 800 - 700 - - 150 2550 550 550 21 17 90
2500 800 800 800 - 700 - - 150 2650 600 600 21 17 90
3000 840 950 950 950 *300 600 500 150 3150 750 700 26 22 900
1. No hole on centre line (marked *).
Sizes up to 5000mm square. Details upon request.
16
6 Pressure Plates
Adjustable cast iron pressure plates are used as an alternative to
Cast Iron side bars on certain sizes of penstock.
Weir Penstocks Alternative Materials

A wide range of alternative materials can be supplied for pressure
adjusters, operating spindle, fasteners etc.
DESCRIPTION
Fasteners
Weir Penstocks are utilised in water and sewage plants for accurate Standard fasteners are supplied in stainless steel to BS EN
regulation or measurement of flow. 10088:1995 grade 1.4401 (316; A4).
Operation of the weir penstock is opposite to that of a conventional Door Nut

penstock, with the door opening downwards. Manufactured from phosphor bronze to BS EN 12167:1998 for non-
rising stem applications; or cast iron to BS EN 1561 min. 250 for
OPTIONS non rising stems.
Alternative trim materials Methods of Operation

Face plate on door The method of operation will depend on several factors which are
Fixing bolts supplied if requested outside the control of the penstock manufacturer, but the range of
Clear opening type penstock (no flow restriction by stem) operating gear available is extensive and can be provided to meet
customer requirements. (See page 39)
The following types of weir penstocks are manufactured:
Size Range Type A Weir penstocks of the screw-down variety with rising or non-
The weir penstock series is available in both square and rising spindles, the spindle operates through a nut which is either
rectangular apertures; the size range available is extensive and housed in the door for the non-rising types or housed in handwheel,
details are available on request. gearbox or actuator for the rising types.
Type B Screw-down weir penstocks with unobstructed openings, the
Frame rising spindle is attached to a horizontal lifting beam above the
Constructed in BS EN 1561 min. 250 iron for wall or thimble mounting opening and operates the door by lifting rods fitted to each side of
applications. The sealing face is fixed securely to the frame using long the door.
taper countersunk pegs in the same material as the sealing face.
For accurate measurement of flow, Type B weir penstocks are
Door recommended because the spindle does not obstruct the flow over
Constructed in BS EN 1561 min. 250 cast iron designed to the weir. Indicators with metric or imperial graduations can be fitted
withstand seating and off seating pressure as required. Door for the application.
sealing face as standard is machined cast iron. When required door SPINDLE
can be fully faced with copper alloy. Option for perimeter sealing
(fully closed position) only.
SPINDLE
LIFTING
WEIR BEAM
Sealing Faces EDGE
Phosphor bronze sealing faces to BS EN 12167:1998 LIFTING
are supplied as the standard material bedded to ROD
0.1mm feeler gauge non-acceptance. The sealing SEALING

DOOR
face is fixed securely to the frame using long taper FACES
countersunk pegs in the same material as the WEIR

EDGE
sealing face.
SIDE
BAR/
Pressure Adjusters PRESSURE PLATES
Manufactured from BS EN 1561 min. 250 cast iron. DOOR
Side Bars SIDE BAR/

During operation a force is applied to the sealing PRESSURE
PLATES
faces by springs positioned along the side of
TYPE A TYPE B
the frame.
17
Cast Iron Weir Penstocks
7
Plastigate
Series 20 - 20
DESCRIPTION
The Series 20-20 is a standardised range of penstocks with sizes up to

1000mm square which have been specifically designed to meet lower
pressure heads up to 2m on-seating and 2m off-seating pressures.
Suitable for wall and channel applications.
The design embodies the latest use of synthetic materials

combined with stainless steel and plastic.
Provides a range of penstocks suitable for use in most water, Pressure Pads
sewage and industrial effluent treatment plants. Pressure pads are only fitted to penstocks
which are wall mounted type only and
OPTIONS subjected both on/off seating pressures.
Wall mounted Fixing Bolts

Channel mounted Bolts can be provided for wall mounted units if required.
Rebate or sidewall fixed
Material choice (frame and door) Door Nut
Manufactured from phosphor bronze to BS EN 12167:1998 for non-
MATERIAL SPECIFICATION rising stem applications, or cast iron to BS EN 1561 min. 250 for
rising stem types.
Seals
The frame seals are of resilient, low friction materials selected for Operating Gear
its resistance to ultra violet degredation. A dedicated range of standardised operating equipment is
available for use with the Series 20-20 penstocks.
Frames
Frames are manufactured from stainless steel to BS EN Type 1. Square Cap & Adaptor
10088:1995 grades 1.4301 (304) or 1.4401 (316). Type 2. Handwheel
Type 3. Actuator
Doors
Doors are manufactured from rigid upvc or stainless steel PENSTOCK SELECTION
1.4301 (304) suitably reinforced to overcome water pressures.
The following door and frame combinations are available.
Flush Invert
The Series 20-20 penstocks are supplied as standard with a flush 1. Wall Mounting Options
invert seal arrangement to allow for a smooth transmission of flow a. On seat, stainless steel frame, rigid pvc door. (Fig. 1.)
through the penstock. b. On seat, stainless steel frame and door. (Fig. 2.)
c. On/off seat, stainless steel frame, rigid pvc door. (Fig. 3.)
Spindle d. On/off seat, stainless steel frame and door. (Fig. 4.)
The spindle is manufactured in stainless steel.
2. Channel Mounting Options
Frame Yoke (door depth pressure only)
For wall mounted penstocks the frame yokes are fitted when the a. On/off seat seat, stainless steel frame, rigid pvc door. (Fig. 5.)
thrust needs to be taken by the frame. The yoke is gussetted and b. On/of seat, stainless steel frame and door. (Fig. 6.)
bolted to the frame to allow for removal. The yoke material is the
same as for the frame. For channel mounted penstocks the yoke
forms an integral part of the frame.
18
Plastigate Series 20 - 20
Plastigate Series 20-20
WALL MOUNTING ON SEATING; RIGID PVC DOOR

Fig 1.
GROUT
25
INVERT
77
70
45
50
25 GROUT
SECTION XX SCRAP VIEW SECTION SHOWING INVERT ARRGT.

CLOSED TOP PLATE FITTED WITHOUT RECESS
(OPTIONAL)
Z
147
H NO. HOLES 17 DIA
25 GROUT
DRILL WALL ON ERECTION
114
FOR FIXING BOLTS 31.8
(11/4)
77
DOOR IN TOP POSITION
SHOWN CHAIN DOTTED
75
X X
HEIGHT = DIM. E
DIM. G
DIM. F
DIM. G
OPENING DEPTH = DIM. B
100
70
INVERT
OPENING WIDTH = DIM. A
95
HOLE CRS. = DIM. C
190 25 FRAME WIDTH = DIM. D 25

SECTION ZZ Z
RECESS FOR FLUSH INVERT TYPE
Width Depth Dim. Dim. Dim. Dim. Dim. Dim.

A B C D E F G H
200 200 360 400 577 390 215 4
250 250 410 450 677 490 315 4
300 300 460 500 777 590 415 4
350 350 510 550 877 690 515 4
400 400 560 600 977 790 308 6
450 450 610 650 1077 890 358 6
500 500 660 700 1177 990 408 6
600 600 760 800 1377 1190 508 6
700 700 860 900 1577 1390 608 6
800 800 960 1000 1777 1590 708 6
900 900 1060 1100 1977 1790 808 6
1000 1000 1160 1200 2177 1990 908 6
19
WALL MOUNTING ON SEATING; STAINLESS STEEL DOOR AND FRAME

Fig 2.
GROUT
25
INVERT
45
70
50
25 GROUT
SECTION SHOWING INVERT ARRGT.

SECTION XX WITHOUT RECESS
135
Z
SCRAP VIEW 25 GROUT
CLOSED TOP PLATE FITTED
H NO. HOLES 17 DIA
DRILL WALL ON ERECTION (OPTIONAL)
31.8
114
FOR FIXING BOLTS

(11/4)
65
SHOWN CHAIN DOTTED
75
X
X
DIM. G
HEIGHT = DIM. E
DIM. F
DIM. G

100
INVERT
70
95

190
HOLE CRS. = DIM. C
25
SECTION ZZ
FRAME WIDTH = DIM. D 25
Z

A B C D E F G H
200 200 360 400 577 390 215 4
250 250 410 450 677 490 315 4
300 300 460 500 777 590 415 4
350 350 510 550 877 690 515 4
400 400 560 600 977 790 308 6
450 450 610 650 1077 890 358 6
500 500 660 700 1177 990 408 6
600 600 760 800 1377 1190 508 6
700 700 860 900 1577 1390 608 6
800 800 960 1000 1777 1590 708 6
900 900 1060 1100 1977 1790 808 6
1000 1000 1160 1200 2177 1990 908 6
20
WALL MOUNTING ON/OFF SEATING; RIGID PVC DOOR

Fig 3.
GROUT
25
45
INVERT
96
70
25 GROUT
SECTION XX
77 WITHOUT RECESS
Z 147
SCRAP VIEW
H NO. HOLES 17 DIA CLOSED TOP PLATE FITTED
DRILL WALL ON ERECTION (OPTIONAL) 25 GROUT
FOR FIXING BOLTS 31.8
114
(11/4)
77

75
SHOWN CHAIN DOTTED
X X
DIM. G
DIM. E
DIM. F
DIM. G

100
INVERT
70
95
HOLE CRS. = DIM. C 190
SECTION ZZ
25 FRAME WIDTH = DIM. D 25
Z

A B C D E F G H
200 200 360 400 577 390 215 4
250 250 410 450 677 490 315 4
300 300 460 500 777 590 415 4
350 350 510 550 877 690 515 4
400 400 560 600 977 790 308 6
450 450 610 650 1077 890 358 6
500 500 660 700 1177 990 408 6
600 600 760 800 1377 1190 508 6
700 700 860 900 1577 1390 608 6
800 800 960 1000 1777 1590 708 6
900 900 1060 1100 1977 1790 808 6
1000 1000 1160 1200 2177 1990 908 6
21
WALL MOUNTING ON/OFF SEATING; STAINLESS STEEL DOOR AND FRAME

Fig 4.
GROUT
25
INVERT
45
70
25 GROUT
96

WITHOUT RECESS
SECTION XX
70
140
70
Z
H NO. HOLES 17 DIA SCRAP VIEW 25 GROUT

DRILL WALL ON ERECTION CLOSED TOP PLATE FITTED
FOR FIXING BOLTS (OPTIONAL)
114
31.8
(11/4)
70

SHOWN CHAIN DOTTED
75
X X
DIM. G
DIM. E
DIM. F

DIM. G
100
INVERT
70
95
OPENING WIDTH = DIM. A 190
HOLE CRS. = DIM. C SECTION ZZ

25 FRAME WIDTH = DIM. D 25

A B C D E F G H
200 200 360 400 577 460 285 4
250 250 410 450 677 560 385 4
300 300 460 500 777 660 485 4
350 350 510 550 877 760 585 4
400 400 560 600 977 860 343 6
450 450 610 650 1077 960 393 6
500 500 660 700 1177 1060 443 6
600 600 760 800 1377 1260 543 6
700 700 860 900 1577 1460 643 6
800 800 960 1000 1777 1660 743 6
900 900 1060 1100 1977 1860 843 6
1000 1000 1160 1200 2177 2060 943 6
22
CHANNEL MOUNTING; RIGID PVC DOOR

Fig 5.
25
50
77
150
SCRAP VIEW
SECTION XX CLOSED TOP PLATE FITTED
(OPTIONAL)
77
Z
31.8
114
(11/4)

SHOWN CHAIN DOTTED
25
102
GROUT NOT SHOWN IN
RECESS FOR CLARITY
X
X
HEIGHT = DIM. D
PENSTOCK OPENING DEPTH = DIM. B
INVERT
55
80
CHANNEL/OPENING = DIM. A 150
25 FRAME WIDTH = DIM. C 25 SECTION ZZ

Z
Width Depth Dim. Dim.

A B C D
200 200 300 577
250 250 350 677
300 300 400 777
350 350 450 877
400 400 500 977
450 450 550 1077
500 500 600 1177
600 600 700 1377
700 700 800 1577
800 800 900 1777
900 900 1000 1977
1000 1000 1100 2177
23
CHANNEL MOUNTING; STAINLESS STEEL CONSTRUCTION

Fig 6.
25
71
50
150
SCRAP VIEW
SECTION XX CLOSED TOP PLATE FITTED
(OPTIONAL)
71
Z
114
31.8
(11/4)

SHOWN CHAIN DOTTED
25
GROUT NOT SHOWN IN 96

X X RECESS FOR CLARITY
HEIGHT = DIM. D
PENSTOCK OPENING DEPTH = DIM. B
INVERT
55
80
CHANNEL/OPENING = DIM. A
150
25 FRAME WIDTH = DIM. C 25 SECTION ZZ

Z RECESS FOR FLUSH INVERT TYPE
Width Depth Dim. Dim.

A B C D
200 200 300 577
250 250 350 677
300 300 400 777
350 350 450 877
400 400 500 977
450 450 550 1077
500 500 600 1177
600 600 700 1377
700 700 800 1577
800 800 900 1777
900 900 1000 1977
1000 1000 1100 2177
24
8 Frame seals
The fixed side and top seals on the seating side comprise of
Stainless Steel an (Ethylene Propylene Di-Methyl) resilient seal mechanically
fixed to the frame with stainless steel fasteners.
Series 2000
Door
The high impact, lightweight single skin door with rib
DESCRIPTION reinforcing is manufactured in either stainless steel BS EN
10088:1995 grades 1.4301 (304) or 1.4401 (316). The number of
Series 2000 is a rectangular faced penstock designed to meet the reinforcing ribs will vary as the duty and size requirements of
ever changing fluid handling demands of customers, combining the the penstock change.
latest in penstock design and parametrics software.
Wedging Assembly
The generic penstock design, which is tailored using parametrics Tapered block wedges are fixed to the sides of the door and
software, develops an individualised penstock to suit specific duty frame in pairs. The wedging assembly is also available in an
and size requirements to a maximum size range of 400mm to adjustable format to allow ease of installation and subsequent
2000mm and a maximum duty of 10m on and off-seating head. adjustment to accommodate wear in service. Top and bottom
wedge may be added to the door and frame as the size and
Series 2000 also offers greatly enhanced levels of customer duty of the penstock increases.
service, reduced design drawing turnaround, fast quotations and an
enhanced delivery performance. Spindle
Rising type in stainless steel to BS EN 10088:1995 grade
OPTIONS 1.4401 (316). Extension stems are stainless steel.
Size Range Frame Yoke

400mm square up to 2000mm square or any rectangular size Frame yokes are fitted when the thrust is required to be taken by the
within these limitations to a maximum width to depth ratio of 2:1. frame. The yoke is gussetted and bolted to the frame to allow for
Penstocks are designed to suit individual customer requirements. removal. The yoke material is the same as for the frame.
Mounting Method of Operation

Available in half and full frame wall and full frame channel The method of operation will depend on several factors which are
mounted versions. outside the control of the penstock manufacturer, but the range of
operating gear available is extensive. (See page 39)
Fixing Bolts
Frames Can be supplied when requested.
Open top and full frame versions are available. The frames are
manufactured from stainless steel to BS EN 10088:1995
grades 1.4301 (304) or 1.4401 (316). The single skin door and
wedge arrangement allows frame side channels to be kept to
a minimum.
Profiled flanges and connecting ribs, at each wedge location

on the wall mounted version, effectively transmit operating
forces from the frame to the civil structure.
Low friction guide blocks are positioned on the frame sides, at

the horizontal centre line of the aperture, to raise the door
away from the seal on the frame during operation, to prevent
seal drag and minimise wear.
Invert
A flush invert is utilised on the Series 2000 penstock to ensure
a smooth flow with a positive seal and complete drainage at
the invert of the penstock.
25
Stainless Steel Series 2000
SERIES 2000 WALL MOUNTED 4M ON 4M OFF - HALF FRAME
Aperture Spindle
Opening Dia.
A B C D E F G H J K L N P Q R S T U V W X INS
300 450 540 - - - 108 208 - - - - - 480 60 - 6 13 121 55 1
400 600 640 - 21 121 - - 294 394 550 - - 580 60 - 12 13 121 55 1
600 900 840 - 61 161 - - 454 554 850 - - 780 60 - 12 13 126 57 1
750 1125 990 - 91 191 - - 574 674 1075 - - 930 60 - 12 13 131 62 1
800 1200 1040 - 101 201 - - 614 714 1150 - - 980 60 - 12 13 131 64 1
1000 1500 1290 100 121 261 - - 754 894 1450 - - 1220 75 165 13 13 151 69 1.25
1200 1800 1540 115 91 231 537 677 984 1124 1750 400 180 1470 90 180 18 13 168 78 1.5
1400 2100 1740 115 121 261 637 777 1154 1294 2050 466 180 1670 90 180 18 13 168 81 1.75
1500 2250 1840 115 141 281 687 827 1234 1374 2200 500 180 1770 90 180 18 13 168 80 1.75
1600 2400 2060 125 136 296 737 877 1319 1459 2340 533 200 1980 100 220 18 13 217 101 2
1800 2700 2260 125 186 326 837 977 1489 1629 2640 600 200 2180 100 220 18 16 217 102 2
2000 3000 2460 125 221 361 937 1077 1654 1794 2940 666 200 2380 100 220 18 26 217 101 2.25
Note: Dimensions given are for 4m on/off seating head; may vary for other pressures consult our Technical Dept.
Spindle Diameters in imperial units Inches
26
SERIES 2000 WALL MOUNTED 4M ON 4M OFF - FULL FRAME
Aperture Spindle
Opening Dia.
A B C D E F G H J K L M N P Q R S T U V W X INS
300 698 540 - - - 108 208 - - - 632 - - 480 60 - 6 13 121 55 1
400 898 640 - 21 121 - - 294 394 550 832 - - 580 60 - 12 13 121 55 1
600 1306 840 - 61 161 - - 454 554 850 1224.5 - - 780 60 - 12 13 126 57 1
750 1621 990 - 91 191 - - 574 674 1075 1522 - - 930 60 - 12 13 131 62 1
800 1721 1040 - 101 201 - - 614 714 1150 1622 - - 980 60 - 12 13 131 64 1
1000 2141 1290 100 121 261 - - 754 894 1450 2025 - - 1220 75 165 13 13 151 69 1.25
1200 2666 1540 115 91 231 537 677 984 1124 1750 2513 400 180 1470 90 180 20 13 168 78 1.5
1400 3066 1740 115 121 261 637 777 1154 1294 2050 2913 466 180 1670 90 180 20 13 168 81 1.75
1500 3266 1840 115 141 281 687 827 1234 1374 2200 3113 500 180 1770 90 180 20 13 168 80 1.75
1600 3610 2060 125 136 296 737 877 1319 1459 2340 3395 533 200 1980 100 220 20 13 217 101 2
1800 4010 2260 125 186 326 837 977 1489 1629 2640 3795 600 200 2180 100 220 20 16 217 102 2
2000 4410 2460 125 221 361 937 1077. 1654 1794 2940 4195 666 200 2380 100 220 20 26 217 101 2.25
Note: Dimensions given are for 4m on/off seating head; may vary for other pressures consult our Technical Dept.
27
SERIES 2000 CHANNEL MOUNTED
Aperture
Opening
A B C X INS E F G H J
300 701 410 1 47 60 90 153 460
400 901 510 1 47 60 90 153 560
600 1301 710 1 47 60 90 153 760
750 1605 870 1 49 60 90 165 920
800 1705 920 1 49 60 90 165 970
1000 2115 1120 1 53 60 90 174 1170
1200 2530 1322 1.5 64 75 105 195 1372
1400 2957 1522 1.5 71 90 120 215 1572
1500 3157 1622 1.75 71 90 120 215 1672
1600 3357 1722 1.75 71 90 120 215 1772
1800 3757 1922 2 71 90 120 215 1972
2000 4027 2156 2 104 100 130 271 2206
Note: Dimensions given are for 4m on/off seating head may vary; for other pressures consult our Technical Dept.
28
9 composite plastic which is asbestos
free, ultra violet stabilised, rigid and
Coplastix Series non toxic. All materials are
chemically bonded and sealed.
50 - 40 Penstocks Doors for non-rising spindle
penstocks have a stainless steel
lining tube inside the central vertical
DESCRIPTION box section of the inner matrix.
The Coplastix Series 50-40 is a rectangular faced penstock

designed and manufactured to suit modern industrial and domestic Spindles
effluent environments. Utilisation of the latest synthetic materials for Rising or non-rising type in stainless steel BS EN 10088:1995
both sealing mechanisms and door construction combined with the grades 1.4301 (304) or 1.4401 (316) with extension spindles in the
use of steel or stainless steel in the construction of the penstock same material as standard.
frames ranges. Fig 2. ADJUSTABLE
Frame Yokes SEE TABLE 1. SEAL
A range of penstocks suitable for use in most water, sewage and Frame yokes form an integral part SEAL ADJUSTER
effluent treatment plants. The penstocks are available for wall of the frame and are positioned to FIXED SEAL
DOOR
mounting and can be provided with either manual or power allow removal of the door should GROUT
operators, manufactured in sizes ranging from 400mm square to this be necessary. The yoke FLEXIBLE SEAL
2000mm square as standard. material is the same as for the frame.
V
MATERIAL SPECIFICATION Stem Nuts X
The stem nuts are phosphor bronze

SECTION SHOWING INVERT SEAL
Frames to BS 12167:1998. For non-rising ARRANGEMENT FOR WALL PENSTOCK
Frames are manufactured from mild steel to BS EN 10025:1993 stems, the nut is housed in a cast- WITH RECESS
grade S275 or stainless steel to BS EN 10088:1995 grades iron bracket secured to top of the
1.4301 (304) or 1.4401 (316). Mild steel frames can be protected to penstock door. For rising stems, HOLES FOR WALL FIXING
FRAME
suit sea water, potable or sewage application, stainless steel - the nut is housed in the handwheel.
natural finish. The penstock frames for both wall and channel
mounting (downward closing) have a resilient flush invert seal to Fixing Bolts
'X'
DOOR
SEALING FACES
allow smooth transmission of the flow through the penstock. Can be supplied when requested. COPLASTIX 'S'
BACKING STRIP
Frame Seals Pressure Pads COPLASTIX 'N'
The sealing arrangements for the Coplastix penstocks combine Adjustable pressure pads are
the use of resilient and low friction synthetic materials, which fitted as standard and pre-set at CONCRETE
GROUT
ensures a high degree of sealing with easy movement. the works to provide maximum OPENING WIDTH 'A'
degree of water tightness. SECTION SHOWING SIDE SEAL

Doors ARRANGEMENT FOR WALL PENSTOCKS
Doors are manufactured as a composite sandwich construction

comprising a lightweight rigid, cellular core with a fully welded steel ADJUST ABLE
Fig 3. SEAL
box section matrix between two other skins of rigid, compressed

SEAL ADJUSTER
FIXED SEAL
'J'
Fig 1. DOOR
SEE TABLE 1. GROUT

TABLE 1
FLEXIBLE SEAL
RANGE J T V W X
SMALL 104 50 80 165 215
'G'
SMALL RANGE = 80
'H' No. HOLES MEDIUM 122 60 80 195 235 MEDIUM RANGE =95
TO SUIT
LARGE RANGE = 125
HD BOLTS LARGE 146 80 100 245 295
'E'
'F'
SECTION SHOWING INVERT

'G'
SEAL ARRANGEMENT FOR

'B'
WALL PENSTOCK
WITHOUT RECESS
100
'V'
'T'
25 GROUT 'W' 'A'

'X' 'C' CRS
'P' 'K' 'L' 'M'
20 20
29
Coplastix Series 50 - 40 Penstocks
Coplastix Series 50-40
Small Range Fig.1

WIDTH A DEPTH B C D E F G H J K L M
400 400 560 600 977 880 370 6 104 - - -
450 450 610 650 1077 980 420 6 104 - - -
500 500 660 700 1177 1080 470 6 104 - - -
600 600 760 800 1377 1280 570 6 104 300 - -
600 800 760 800 1777 1680 770 6 104 300 - -
700 700 860 900 1577 1480 670 6 104 350 - -
800 600 960 1000 1377 1280 570 6 104 400 - -
800 800 960 1000 1777 1680 385 10 104 400 - -
800 1000 960 1000 2177 2080 485 10 104 400 - -
900 900 1060 1000 1977 1880 435 10 104 450 - -
Medium Range Fig.1

800 1200 990 1050 2597 2480 585 10 122 400 - -
1000 600 1190 1250 1397 1280 570 6 122 500 - -
1000 800 1190 1250 1797 1680 770 6 122 500 - -
1000 1000 1190 1250 2197 2080 485 10 122 500 - -
1000 1200 1190 1250 2597 2480 585 10 122 500 - -
1000 1400 1190 1250 2997 2880 685 10 122 500 - -
1200 600 1390 1450 1397 1280 570 6 122 300 300 300
1200 800 1390 1450 1797 1680 385 10 122 300 300 300
1200 1000 1390 1450 2197 2080 485 10 122 300 300 300
1200 1200 1390 1450 2597 2480 468 12 122 300 300 300
1200 1400 1390 1450 2997 2880 548 12 122 300 300 300
1200 1600 1390 1450 3397 3280 628 12 122 300 300 300
1200 1800 1390 1450 3797 3680 590 14 122 300 300 300
1400 800 1590 1650 1797 1680 385 10 122 300 400 400
1400 1000 1590 1650 2197 2080 388 12 122 300 400 400
1400 1200 1590 1650 2597 2480 468 12 122 300 400 400
1400 1400 1590 1650 2997 2880 457 14 122 300 400 400
Large Range Fig.1

1400 1600 1650 1710 3420 3270 780 10 146 300 400 400
1400 1800 1650 1710 3820 3670 587 14 146 300 400 400
1400 2000 1650 1710 4220 4070 653 14 146 300 400 400
1500 1500 1750 1810 3220 3070 487 14 146 450 400 400
1600 800 1850 1910 1820 1670 760 6 146 500 400 400
1600 1000 1850 1910 2220 2070 480 10 146 500 400 400
1600 1200 1850 1910 2620 2470 580 10 146 500 400 400
1600 1400 1850 1910 3020 2870 453 14 146 500 400 400
1600 1600 1850 1910 3420 3270 520 14 146 500 400 400
1600 1800 1850 1910 3820 3670 587 14 146 500 400 400
1600 2000 1850 1910 4220 4070 653 14 146 500 400 400
1800 1000 2050 2110 2220 2070 480 10 146 600 400 400
1800 1200 2050 2110 2620 2470 387 14 146 600 400 400
1800 1400 2050 2110 3020 2870 453 14 146 600 400 400
1800 1600 2050 2110 3420 3270 520 14 146 600 400 400
1800 1800 2050 2110 3820 3670 440 18 146 600 400 400
1800 2000 2050 2110 4220 4070 490 18 146 600 400 400
2000 1000 2250 2310 2220 2070 480 10 146 700 400 400
2000 1200 2250 2310 2620 2470 387 14 146 700 400 400
2000 1400 2250 2310 3020 2870 453 14 146 700 400 400
2000 1600 2250 2310 3420 3270 390 18 146 700 400 400
2000 1800 2250 2310 3820 3670 440 18 146 700 400 400
2000 2000 2250 2310 4220 4070 490 18 146 700 400 400
30
WEIR (Downward Opening)

Coplastix weir penstocks are constructed as described for the wall mounted type other than the stem is secured to the lower edge of the
penstock door via a cast iron bracket, thus permitting maximum unhibited flow over the upper weir edge of the door. Flush invert does not
apply for weir penstocks. The sealing arrangements for the Coplastix penstocks combine the use of resilient and low friction synthetic
materials which ensures a high degree of sealing with easy movement.
Fig 5. FRAME
Fig 4. 'J'
HOLES FOR WALL FIXING
SEALING FACES
COPLASTIX 'S'
DOOR
'L'
SOFFIT (TOP OF DOOR)
BACKING STRIP
100
COPLASTIX 'N'
OPENING DEPTH 'B'
OPENING DEPTH
'B'
'G'
INVERT 'H' No. HOLES INVERT GROUT
TO SUIT CONCRETE
HD BOLTS
'E'
'F'
OPENING WIDTH 'A'
SECTION SHOWING SIDE SEALS
'G'
ARRANGEMENT FOR WEIR PRODUCTS
RANGE J K L M
'M' DIMENSIONS IN MILLIMETRES
'K'
25 GROUT OPENING WIDTH 'A'
'C' CRS SMALL 104 50 85 165
'P'
MEDIUM 122 68 110 185
OVERALL DIMENSIONS DIAGRAM OF WEIR PENSTOCKS LARGE 146 80 160 245
Small Range
WIDTH A DEPTH B C P E F G H
400 400 560 600 1062 977 370 6
450 450 610 650 1162 1077 420 6
500 500 660 700 1262 1177 470 6
600 600 760 600 1462 1377 570 6
600 800 760 800 1862 1777 770 6
700 700 860 900 1662 1577 670 6
800 600 960 1000 1462 1377 570 6
800 800 960 1000 1862 1777 385 10
800 1000 960 1000 2262 2177 485 10
900 900 1060 1100 2062 1977 435 10
Medium Range
800 1200 990 1050 2707 2597 585 10
1000 600 1190 1250 1507 1397 570 6
1000 800 1190 1250 1907 1797 770 6
1000 1000 1190 1250 2307 2197 485 10
1000 1200 1190 1250 2707 2597 585 10
1000 1400 1190 1250 3107 2997 685 10
1200 600 1390 1450 1507 1397 570 6
1200 800 1390 1450 1907 1797 385 10
1200 1000 1390 1450 2307 2197 485 10
1200 1200 1390 1450 2707 2597 468 12
1200 1400 1390 1450 3107 2997 548 12
1200 1600 1390 1450 3507 3397 628 12
1200 1800 1390 1450 3907 3797 590 14
1400 800 1590 1650 1907 1797 385 10
1400 1000 1590 1650 2307 2197 388 12
1400 1200 1590 1650 2707 2597 468 12
1400 1400 1590 1650 3107 2997 457 14
31
Large Range
1400 1600 1650 1710 3580 3430 780 10
1400 1800 1650 1710 3980 3830 587 14
1400 2000 1650 1710 4380 4230 653 14
1500 1500 1750 1810 3380 3230 487 14
1600 800 1850 1910 1980 1830 760 6
1600 1000 1850 1910 2380 2230 480 10
1600 1200 1850 1910 2780 2630 580 10
1600 1400 1850 1910 3180 3030 453 14
1600 1600 1850 1910 3580 3430 520 14
1600 1800 1850 1910 3980 3830 587 14
1600 2000 1850 1910 4380 4230 653 14
1800 1000 2050 2110 2380 2230 480 10
1800 1200 2050 2110 2780 2630 387 14
1800 1400 2050 2110 3180 3030 453 14
1800 1600 2050 2110 3580 3430 520 14
1800 1800 2050 2110 3980 3830 440 18
1800 2000 2050 2110 4380 4230 490 18
2000 1000 2250 2310 2380 2230 480 10
2000 1200 2250 2310 2780 2630 387 14
2000 1400 2250 2310 3180 3030 453 14
2000 1600 2250 2310 3580 3430 390 18
2000 1800 2250 2310 3980 3830 440 18
2000 2000 2250 2310 4380 4230 490 18
32
10 MATERIAL SPECIFICATION
Coplastix Series Frames

Frames are manufactured from mild steel to BS EN 10025:1993
20 - 20 Penstocks grade S275 or stainless steel to BS EN 10088:1995 grades
1.4301 (304) or 1.4401 (316). Mild steel frames can be protected to
suit sea water, potable or sewage application, stainless steel -
DESCRIPTION natural finish. The penstocks frames for both wall and channel
mounting (downward closing) have a resilient flush invert seal to
The Coplastix Series 20-20 is a rectangular faced penstock allow smooth transmission of the flow through the penstock.
designed and manufactured to suit modern industrial and domestic
effluent environments. Utilisation of the latest synthetic materials for Frame Seals
both sealing mechanisms and door construction combined with the The sealing arrangements for the Coplastix penstocks combine
use of steel or stainless steel in the construction of the penstock the use of resilient and low friction synthetic materials, which
frames ranges. ensures a high degree of sealing with easy movement.
A range of penstocks suitable for use in most water, sewage and Doors
effluent treatment plants. The penstocks are available for channel Doors are manufactured as a composite sandwich construction
mounting and can be provided with either manual or power comprising a lightweight rigid, cellular core with a fully welded steel
operators, manufactured in sizes ranging from 400mm square to box section matrix between two other skins of rigid, compressed
2000mm square as standard. composite plastic which is asbestos free, ultra violet stabilised, rigid
and non toxic. All materials are chemically bonded and sealed.
Designed to suit door depth pressure only. Doors for non-rising spindle penstocks have a stainless steel lining
tube inside the central vertical box section of the inner matrix.
OPTIONS
Spindles
Types - Channel Mounting Rising or non-rising type in stainless steel BS EN 10088:1995
grades 1.4301 (304) or 1.4401 (316) with extension spindles in the
SMALL RANGE Square and rectangular aperture. same material as standard.
This range is fitted with twin seals secured to the frame. (See fig. 3)
Frame Yokes
MEDIUM & LARGE RANGE Square and rectangular aperture. Frame yokes form an integral part of the frame and are positioned
These ranges are fitted as standard with a single seal secured to to allow removal of the door should this be necessary. The yoke
the frame and have adjustable pressure pads fitted as standard at material is the same as for the frame.
the works to provide a minimum degree of water tightness.
(See fig. 4) Spindle Nuts
The spindle nuts are phosphor bronze. For non-rising spindles, the
nut is housed in a cast-iron bracket secured to top of the penstock
door. For rising spindles, the nut is housed in the handwheel.
Fig 1. 48
Fig 2. 'R'
32 DIA
(350)
'D'
'D'
'B'
'B'
80 'V'
'T'
50
25 NOM 'W' 'Y' 'V' 'A' 'V'

25 NOM 96 80 'A' 80
150 'X'
'C' 'C'
'AA'
SMALL RANGE ONLY MEDIUM AND LARGE RANGE ONLY
33
ADJUSTABLE
SEAL
Fig 3. Fig 4.
SEAL ADJUSTER
DOORS FIXED SEAL
DOOR
FIXED SEAL GROUT
GROUT FLEXIBLE SEAL
V
80
X
150
MEDIUM AND LARGE RANGE SECTION
SECTION SHOWING INVERT SEAL SHOWING INVERT SEAL
ADJUSTABLE
SEAL
80 OPENING WIDTH 'A'
SEAL ADJUSTER
CONCRETE FIXED SEAL

GROUT
DOOR
FRAME GROUT
DOOR
FLEXIBLE SEAL
150
V
BACKING STRIP
COPLASTIX 'N'
SECTION SHOWING SIDE SEAL MEDIUM AND LARGE RANGE SECTION

SHOWING SIDE SEAL
RANGE R S T V W X Y AA
MEDIUM 52 38 60 80 150 200 60 260
LARGE 66 51 80 100 190 240 80 320
Small Range Fig. 1 Large Range Fig. 2

WIDTH A DEPTH B C D WIDTH A DEPTH B C D
DIMENSIONS IN MILLIMETRES DIMENSIONS IN MILLIMETRES
400 400 500 977 1400 1600 1560 3420
450 450 550 1077 1400 1800 1560 3820
500 500 600 1177 1400 2000 1560 4220
600 600 700 1377 1500 1500 1660 3220
600 800 700 1777 1600 800 1760 1820
700 700 800 1577 1600 1000 1760 2220
800 600 900 1377 1600 1200 1760 2620
800 800 900 1777 1600 1400 1760 3020
800 1000 900 2177 1600 1600 1760 3420
900 900 1000 1977 1600 1800 1760 3820
Medium Range Fig. 2 1600 2000 1760 4220
1800 1000 1960 2220
WIDTH A DEPTH B C D 1800 1200 1960 2620
DIMENSIONS IN MILLIMETRES 1800 1400 1960 3020
800 1200 920 2597 1800 1600 1960 3420
1000 600 1120 1397 1800 1800 1960 3820
1000 800 1120 1797 1800 2000 1960 4220
1000 1000 1120 2197 2000 1000 2160 2220
1000 1200 1120 2597 2000 1200 2160 2620
1000 1400 1120 2997 2000 1600 2160 3420
1200 600 1320 1397 2000 1800 2160 3820
1200 800 1320 1797 2000 2000 2160 4220
1200 1200 1320 2597
1200 1400 1320 2997
1200 1600 1320 3397
1200 1800 1320 3797
1400 800 1520 1797
1400 1000 1520 2197
1400 1200 1520 2597
1400 1400 1620 2997
34
11
Technical
Details
PREPARATION AND PROTECTIVE COATING
Specifies the product range with the appropriate material,

preparation and coating for standard paint systems. The
preparation and protective coatings listed are Ham Baker Hartley
standards. Alternative preparations can be offered on request.
Standard Paint Specification Application Surface treatment

PS1 SEWAGE: Mild Steel 1. Grit blast to near white
Below Floor / Operating Level 2. Zinc spray 75 microns
3. Mist coat to obtain continuous film for subsequent paint applications
4. Apply epoxy 2 pack epoxy coal tar minimum D.F.T. 125 microns
PS2 POTABLE WATER: Mild Steel 1. As PS1
Below Floor / Operating Level 2. As PS1
3. Apply final coat bitumastic minimum D.F.T. 125 microns
PS3 SEA WATER: Mild Steel 1. As PS1
Below Floor / Operating Level 2. Apply minimum D.F.T. 50 micron of 2 pack epoxy Zinc Phosphate primer
3. Apply minimum 250 D.F.T. microns of epoxy 2 pack coal tar
PS4 SEWAGE / POTABLE / SEA WATER: 1. As PS1
Cast Iron Below Floor Level / 2. Apply minimum D.F.T. 15 micron of primer
Operating Level 3. Apply final coat bitumastic minimum D.F.T. 125 microns (N.W.C. approved)
PS5 SEWAGE / POTABLE / SEA WATER: 1. As PS1
Cast Iron Above Floor Level / 2. As PS2
Operating Level 3. As PS4 D.F.T. 50 microns
SIZES alone is generally quite small compared to the losses due to the
civil engineering structure. An exception to this is a channel
BS7775 Specification for Penstocks provides useful information mounted penstock where the top water level is above the top of the
regarding sizes for penstocks. door opening.
Penstocks are suitable for three shapes of aperture 2. Discharge through an orifice
This type of flow occurs where a penstock controls flow into or out
Square of a tank or other large container. If the gate is fully submerged, the
Rectangular flow through an open or partially open penstock and its associated
Circular civil engineering structure opening will be given by
Standard Rectangular Penstocks have an aspect ratio (width q = CA (2gH)

divided by depth) between 0.5 and 2. Penstocks outside this range
can be considered but will be special designs. Where
q is the discharge rate - cubic metres per second
Cast Iron Circular penstocks below 600mm to 1000mm in diameter, C is a discharge coefficient generally taken to be 0.7
depending on type, have a circular sealing face. For all other A is the aperture area - square metres
circular penstocks the sealing face is as a square penstock. The aperture area is the penstock opening if the penstock
is fully open. If the penstock is not fully open, the aperture
FLOW CHARACTERISTICS area will be reduced.
H is the differential head at the centre of the opening - metres
1. General The differential head is the difference between the
Penstocks are installed in civil engineering structures. When a upstream and down stream water levels.
penstock is fully open, the head loss attributable to the penstock g is the acceleration due to gravity - 9.81 m/s2
35
Technical Details
Technical Details
For example a penstock 1.5 metres wide by 2 metres deep 3. Weir Penstocks
with a 6 metre differential head at the centre of the door will Weir Penstocks behave in their discharge capability as a
discharge 22.8 cubic metres per second. rectangular weir with partial end contractions, the extent of the end
contraction being influenced by the civil engineering design in the
A graph of a range of discharges for different penstock locality of the weir.
apertures and differential heads is shown below.
An approximation to the discharge is given by
Fig. 1 - Graph of Discharge against Head
Q = 1.73 WH1.5
Where
Q is the discharge rate - cubic metres per second
W is the width of the weir opening - metres
H is the head at the weir crest - metres
For example a weir 2 metres wide having a water depth of 200mm

(0.2m) at the crest will discharge 0.31 cubic metres per second.
If the weir is used as a flow measuring or control device reference

should be made to BS 3680-4A:1981 Methods of measurement of
liquid flow in open channels. Weirs and flumes. Methods using thin
plate weirs for channel design and relative water levels.
LEAKAGE
Ham Baker Hartley penstocks will be virtually drop-tight at their

working pressure if installation has been carried out correctly.
3. Channel mounted penstocks Leakage rates are influenced by

If a channel mounted penstock is fully open and the top of the
penstock opening is above the water level in the channel, then the The head
head loss results from disturbed flow in the rebates in the channel The seating direction, on or off
walls in which the penstock frame is mounted. These losses can The correct installation of the penstock
generally be disregarded provided that the channel is not Time
obstructed. Channel mounted penstocks usually have flush inverts.
An on-seating penstock will leak less with increasing head.
When a penstock is in a channel and is partially closed, or the
water level is above the top of the door opening, the calculations An off-seating penstock will leak more with an increasing head.
are complex. Reference should be made to a suitable publication
on civil engineering hydraulics. Penstocks subject to an on-seating head seal more tightly than
those subject to an off-seating head.
References
If the penstock is installed so that the frame is twisted, then the
Open Channel Hydraulics leakage rate will increase. Penstocks should be installed by
By V T Chow experienced contractors and mounted on grout.
McGraw-Hill Education
Over the course of time after closure of the penstock, the leakage
Open Channel Flow rate will decrease as leakage paths are blocked by small pieces of
By F M Henderson debris in the water.
Macmillan USA
From the above it is clear that if leakage is required to be
Hydraulic Gates and Valves in Free Surface Flow and minimised, then the penstock should be configured so that it is on-
Submerged Outlets seating.
By J Lewin
British Nuclear Energy Society
36
Technical Details
Technical Details
Allowable Leakage Rates confirm proper operation before the leakage test
Leakage rates are defined by the amount of water which leaks commences.
through a 1 metre length of seal in 1 minute.
Measurement of the liquid loss through the seals
BS 7775:1995 leakage rates apply to penstocks subject to a head shall be carried out in such a way that any leaks
of 6 metres or less and widths of 2 metres or less. from between the penstock frame and the
structure shall not affect the result of the
Penstocks with metal seals (Cast Iron Penstocks) test. Tests shall be carried out over a P
period of 30 minutes.
The allowable leakage rates listed are derived from BS 7775
P
Specification for Penstocks and AWWA C501-92 AWWA Standard
for Cast Iron Sluice Gates as appropriate.
On-seating head Allowable leakage rate

H
Any head 1.25 litres/min/m
Off-seating head Allowable leakage rate F

Up to 6 metres 2.5 litres/min/m
Leakage rates for off-seating heads greater than

15 metres will be advised on request. FOUNDATION LOADS AND OPERATING FORCES
Penstocks with resilient rubber or plastic seals (Plastigate, Precise foundation loads can be given by Ham Baker Hartley once
Coplastix and Series 2000 Penstocks). a penstock has been specified. As a guide to the foundation loads
to be expected, the following formulae can be used.
There is currently no standard which applies to leakage rates for
this type of penstock. The figures given below are Ham Baker A penstock exerts two types of load on the civil engineering
Hartleys estimates. structure.
On-seating head Allowable leakage rate Hydrostatic

Up to 5 metres 0.4 litres/min/m Operating
Off-seating head Allowable leakage rate Note on heads.
Up to 4 metres 0.4 litres/min/m Heads for penstocks are specified to the invert in BS 7775. These
heads can be used conservatively for these calculations. More
For example, a 1500mm wide by 2000mm deep cast iron penstock accurately, the head at the centre of the door should be used, this
subject to an off-seating head of 9 metres would have a seal is the head at the invert less half the door depth.
periphery of 2(1.5+2) = 7m and and allowable leakage rate of 3.0
litres/min/m. 1. Hydrostatic Force.
Therefore maximum allowable leakage rate The hydrostatic load F is the force of the water against the
= 7 x 3 = 21 litres/min penstock door, which will be transferred to the civil engineering
structure by the penstock frame. This force acts horizontally.
On-site Leakage Test
According to BS 7775 The force F is given by (approximately)
Before a site leakage test is undertaken the installer shall ensure
that the penstock and its associated operating equipment have F=10HA where F is in units of kN
been correctly installed and fixed in position. Penstocks and
associated operating equipment shall be installed strictly in H is the maximum differential head at the centre of the door -
accordance with the manufacturers recommendations. Final metres. This should be the worst case which could occur.
adjustments to the penstock shall be made and all moving parts
shall be operated through one complete open and shut cycle to A is the door area in square metres
37
Technical Details
Technical Details
For example a 1.5 metre square door with a head at the centre of penstock door should not back-drive the spindle through its
the door of 6 metres will experience a hydrostatic force of power screw.
F= 10 x 6 x 1.52 that is F=135 kN

HANDWHEEL AND TEE KEY EFFORT
2. Operating Force
The efforts considered below are for normal operation of the
This is the force required to open and close the penstock door. penstock against the specified heads.
The civil engineering structure will experience this load where the For a manually operated penstock the handwheel effort is limited to
penstock operating device is connected to the civil engineering 250 N (55 lbf) as a single pull on the rim unless otherwise specified.
structure and the penstock frame is connected to the civil
engineering structure. A Tee Key is usually 500mm across the handle and has a push/pull
effort limited to 125N thus generating a torque of 62.5 Nm.
However the civil engineering structure will not experience this
force if the penstock operating device is connected directly to the MANUAL OPERATION OF ELECTRIC ACTUATORS
penstock or the thrust reaction is taken at the top of the penstock
frame. Where a handwheel is fitted to an electric actuator as an auxillary
method of operation, the handwheel effort is limited to 250N if this
The normal operating force of the penstock P can taken as first is reasonable. Although the handwheel effort can be limited to 250N
approximation as in most cases, this increases the complexity of the penstock drive.
P= 0.5F kN where F is defined above For larger penstocks (above about 2000mm square) manual
operation of the actuator for a full stroke of the door is not
This force acts vertically and can be up or down. For example the practicable due to the excessive number of turns required. If the
1.5 metre square door with a head at the centre of the door of 6 penstock must be operable in the case of electrical failure,
metres considered above will have an operating force provision can be made for an auxillary power device such as a
mobile internal combustion engine power pack.
P= 0.5 x 135 = 67.5kN
In addition to the normal operating condition, a fault condition Pf

(e.g. actuator limit switch failure, or excessive force applied to the
operating hand wheel) should be considered.
Pf = 2F kN where F is defined above
The operator generates a torque, but the forces associated with this
can be neglected for a first approximation.
The weight of the penstock is usually secondary to the operating

force, except for low head applications.
SPINDLE DIAMETER
This is determined by many factors, included in these are
The spindle should not fail due to yield or buckling during

normal operation.
The spindle should not fail due to yielding under the worst fault
condition.
The slenderness ratio of the spindle should be less than 250 or
200 if specified. The slenderness ratio is the length of a spindle
section between guides divided by a quarter of the spindle
diameter.
The spindle should be self-sustaining (that is the weight of the
38
Technical Details
12
Operating Gear
SELECTION
Remote operation
Thrust direct on frame
Non-rising extension systems.
Indicating floor pillar Floor pillar with
Floor pillar with with handwheel handwheel on wall/coping
bevel gear box bracket
Floor pillar with Handwheel direct on

electric actuator spindle with guide plate
Handwheel with
deck stuffing box
Cap direct on spindle

in surface box
Extension spindle
Spindle coupling
Non-rising spindles rotate through a

Screwed non-ferrous nut in the penstock door.
Operating spindle The screwed portion of the spindle at
the bottom is probably immersed in
the water/effluent etc.
Full Frame
Door Guide Used where thrust reaction is
accommodated at the top of the frame.
Wedges
Door nut
Door
39
Operating Gear
Operating Gear
SELECTION
Remote operation
Thrust remote from frame
Rising extension systems.
Floor p
pillar
with handwheel
and rising Hydraulic or
extension spindle
p pneumatic linear
with/without actuator
protection tube
Floor ppillar with Floor pillar

p with
electric actuator bevel gearbox Floor p
pillar with
and rising and rising handwheel and rising
extension spindle
p extension spindle
p extension spindle
p on wall
with protection with/without bracket with/without
tube protection tube protection tube
Operating spindle
Spindle coupling
Rising spindles are connected to the
penstock door via the door nut and
work through a revolving non-ferrous
Spindle Guide nut located in the operating gear.
The screw thread at the top of the

spindle is generally not immersed and
is readily accessible for lubrication.
Half Frame
Door Guide Used where thrust reaction is
accommodated at a point other
than the top of the frame.
Door nut
Wedges
Door
40
Operating Gear
13 CAST IRON SERIES 60
Circular Penstock
Fastrack 100mm Dia. to 1000mm Dia.
Penstocks
Fastrack Penstocks is a quick and easy way to buy penstocks
and flap valves for urgent situations, which require delivery within
days rather than weeks. Most penstocks can be despatched within
24 hours of order receipt.*
Ham Baker Hartley have made a firm commitment to providing

customers with complete solutions, by investing in large stock
levels of popular standard ranges of penstocks and flap valves, as
illustrated below.
A dedicated Fastrack system and sales support team is also in

place to ensure high levels of customer service and fast, efficient
delivery of proven quality products.
Call us today and ask for Fastrack Penstocks.
*Subject to credit status.
Fastrack Hotline:
CAST IRON SERIES 60/30
Square Penstock
Tel: +44 (0) 1782 203611 150mm sq. to 1200mm sq.
Fax: +44 (0) 1782 203639
Also Available
CAST IRON SERIES

Flap Valves
80mm Dia. to 2000mm Dia.
41
Fastrack
14
Enquiry
Questionnaire
Certain basic data is essential to allow selection of the correct
equipment against a specification.
Please ensure that the following information is given for each item
of your enquiry:
1. Penstock Series (if known).
2. Quantity required.
3. Size of opening width and depth, or diameter.
4. Maximum working head.
5. On-seating or off-seating.
6. Materials of spindle.
7. Type of operating equipment.
8. If operating equipment is not for mounting directly on to the

penstock, submit a configuration sketch or give details
and dimensions.
9. Liquid in which the flap valve is to operate, e.g. sewage,

potable water or sea water. If a mixture of several, state
their separate sources or give full analysis details.
10. Paint system if special operating conditions prevail.
11. Rising or non-rising spindle.
12. Invert to coping / operating levels.
13. Mounting; wall, channel, pipe or thimble.
INTERNATIONAL STANDARDS
BS EN ISO 9001 : 2000 Quality Management System : Requirements

BS EN 1092-2 : 1997 Flanges and their joints; Circular flanges for pipes, valves, fittings and accessories; PN designated; Cast Iron Flanges
BS EN 1561 : 1997 Founding - Grey Cast Irons
BS EN 1982 : 1999 Copper and Copper Alloys : Ingots and Castings
BS 7775 : 1995 Specification for penstocks
BS EN 10025 : 1993 Hot rolled products of non-alloy structured steels. Technical delivery conditons.
BS EN 12167 : 1998 Copper and Copper Alloys : Profiles and rectangular bar for general purposes.
AWWA C501-92 Standard for Cast Iron sluice gates
42
Questionnaire
NOTES
The information contained in this leaflet is correct at time of going to press, but Ham Baker Hartley reserves the right to alter without notice any information shown.
43
Ham Baker Hartley, Garner Street, Etruria, Stoke on Trent, Staffordshire ST4 7BH, England
Tel: +44 (0)1782 202300 Fax: +44 (0)1782 203639

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Penstocks

Business Philosophy 1. Reputation

1 Introduction to Fluid Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Cast Iron Series 60 ...............................................8

3 Cast Iron Series 60 - 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4 Cast Iron Series 90 - 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Cast Iron Series 160 - 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Cast Iron Weir Penstocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

8 Stainless Steel Series 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

14 Enquiry Questionnaire; International Standards . . . . . . . . . . . . . . 42

Penstock / Sluice Gate

HIGH GRIT CONTENT

SERIES 150mm x 150mm

penstock in such circumstances is by use of a

Wall thimble mounting offers the following

1. Civil construction can proceed prior to

2. Considerable keying/anchor area within the

3. Ease of penstock erection and removal

Iron wall thimbles can be supplied in either 'E'

'E' Section for off-seating heads

When high off-seating pressure is specified,

'E' SECTION THIMBLE

'F' SECTION THIMBLE

An introduction to Fluid Control

Two types of coupling are available:-

Used on smaller sizes of penstocks for rising

Cast Iron Frame

Aperture Maximum Head (Metres)

Thrust Housing (direct operation) Operating Spindles

Door Nut Methods of Operation

W-No. holes, AA dia.

An extensive range of operating gear can be utilised Thrust Housing

Operating Spindles Alternative Frame

AC No. of holes for

Series 90 - 60 Door Nut

countersunk pegs in the same material as the sealing face.

wear during the life of the penstock.

TYPICAL ARRANGEMENT OF A RECTANGULAR PENSTOCK WITH

Chased invert penstocks are supplied as a standard. Flush invert Fasteners

OPTIONS Methods of Operation

Sealing faces can be secured to satisfy the requirements of Top wedge

BS 7775 and AWWA C501-92 Door

Circular apertures (sealing faces remain rectangular)

SIZE RANGE 150 TO 1500mm Sq. or Dia. (Refer to both tables)

AF sq. AE No. holes left in Wall

HALF FRAME FULL FRAME

SIZE RANGE 1600 TO 3000mm Sq. or Dia.

Sizes up to 5000mm square. Details upon request.

Weir Penstocks Alternative Materials

Operation of the weir penstock is opposite to that of a conventional Door Nut

Alternative trim materials Methods of Operation

0.1mm feeler gauge non-acceptance. The sealing SEALING

countersunk pegs in the same material as the WEIR

Side Bars SIDE BAR/

The Series 20-20 is a standardised range of penstocks with sizes up to

Suitable for wall and channel applications.

The design embodies the latest use of synthetic materials

Wall mounted Fixing Bolts

WALL MOUNTING ON SEATING; RIGID PVC DOOR

SECTION XX SCRAP VIEW SECTION SHOWING INVERT ARRGT.