HAM

BAKER
GROUP

Flow Products Catalogue

www.hambakergroup.com
 HAM Established in the 19th Century, The Ham Baker Group
is a market leading, global organisation dedicated to
BAKER the design and manufacture of innovative products,
for the water, waste water and process sectors.
GROUP Ham Bakers name is synonymous with precision-
engineered products and adding value to customers
individual requirements. The group designs complete
engineered solutions, with experts on hand across all
sectors to cover customers individual process and
flow needs.
The Ham Baker Group is unique amongst modern
day suppliers in being able to offer product to all
areas of water, waste water and process applications.
The understanding of individual applications informs
the design of complementary products and services
resulting in the ability to be able to offer complete
engineered solutions which deliver
optimum performance.
A fully equipped, UK, in-house manufacturing facility
complemented by state-of-the-art design facilities
provides customers with bespoke engineered
solutions, capable of operating to industry
leading standards.
A dedicated research and development team, working
in conjunction with world renowned universities
delivers innovative solutions to process
applications, providing significant infrastructure
benefits to customers.
Significant investment in new processes, design
facilities and CNC machinery complements
the apprentice-trained workforce with skills in
manufacture, procurement, project management,
design and development and logistics to satisfy the
most demanding customer requirements.
With manufacturing bases in the UK, China, Hong
Kong, UAE and Australia we are able to offer
engineered solutions worldwide.

02
03
04
Penstocks

1 Selection Table/Features and Benefits/Terminology 6

2 An Introduction to Flow Control 8
3 Stainless Steel Fabricated Penstock SG3100 12
4 Plastigate Series 20-20 14
5 Plastigate Series 50-40 18
6 Cast Iron Series 60 24
7 Cast Iron Series 60-30 26
8 Cast Iron Series 108 28
9 Cast Iron Weir Penstocks 30
10 Cast Iron Series 90-60 32
11 Cast Iron Series 160-80 36
12 Technical Details 42
13 Operating Gear/Fast Track Penstocks 48
14 Services 50

Penstock/Sluice Gate
A penstock is used to control the flow or level of feed the water wheel or mill race to be referred to
a liquid and consists of a sliding door controlled by as the pen. The timber stop logs used to control
a mechanically operated spindle, which moves over the flow onto the water wheel was called the
an aperture in a frame, which in turn is secured onto stock. Later, as the need to accurately control the
a structure. velocity of the water wheel became more critical, a
single sliding gate operated by a lifting mechanism
Sluice gate is more descriptive of the product, replaced the stop logs with their individual sections.
and this term is used widely in specifications During the 17th century, the words pen and stock
outside the UK. became combined into a single word PENSTOCK.
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

05
Penstocks

Penstocks Selection Table

This information is based on our standard range of Penstock products.

Model Maximum Head Application Mounting

(m)

On Off

Sewage Treatment
Seating Seating

High Grit Content

Reduced Leakage
Water Treatment

PetroChemical

Demountable
Hydro Power
Desalination

Sea Defence
Industrial

Dockyard

Channel

Thimble
Pipe
Wall
FABRICATED

SG3100 25 25 X X X X X X X X X X X X X X X

20/20 2 2 X X X X X X X X X

PLASTIC

50/40 5 4 X X X X X X X X X

CAST IRON

60 6 X X X X X x x x x x

60/30 6 3 X X X X X x x x x x

108 6 6 X X X X X x x x x x

90/60 9 6 X X X X X X X X X X X

160/80 16 8 X X X X X X X X X X X

260/130 & 300/150 TBA TBA X X X X X X X X X X X

*Higher heads available

06
 1

Features and Benefits

Below is a list of benefits for the 5 main penstock product types illustrated in our catalogue.
Cast Iron Penstocks Stainless Steel Fabricated Penstocks
Robust construction Adjustable wedging application
High impact resistance Reduced operating loads
For use with high grit content applications Leakage considerably less than
All sewage and water applications approved standards
50 year service life
Mechanically fixed
Metal to metal sealing faces.
Low maintenance seals fitted to door only
Wall, channel or side wall fixing demountable
Coplastix Penstocks
Individually designed to suit each application
Materials UV stabilised
Resilient seals.
Adjustable pressure pads
Leakage considerably less than Specification for penstocks
approved standards Ham Baker has ISO EN 9001:2000 accreditation,
Reduced operating loads and the capability to manufacture a full range
of penstocks in accordance with BS7775 or
Door having smooth clean face
AWWA C501.
Side wall fixing (no rebate required)
Request aperture sizes
Resilient seals.

Terminology
The terminology used in this brochure is that defined in BS7775. The corresponding terms used in
AWWA 501 are given below for reference.

BS7775 AWWA 501

Penstock Sluice Gate

Door Slide
Spindle Stem
Spindle Nut Thrust Nut
Spindle Protection Table Stem Cover
Metal Seal Sealing Face
Resilient Seal Seal
On-Seating Head Seating Head
Off-Seating Head Unseating Head
Head Measured from invert of aperture Head Measured from centreline of aperture

07
An Introduction to Flow Control
Ham Baker can offer the most comprehensive range
of flow control equipment in the world.

The traditional cast iron ranges have been the

mainstay of the industry and the development of
Ham Baker has created several standard ranges
which cover a wide variety of types, sizes and
operating conditions. However the wealth of
experience gives Ham Baker the ability to design
and manufacture penstocks for any duty or size.

Ham Baker in step with its continuous programme

of research and development has developed a
range of stainless steel fabricated penstocks using
the latest technology. Low friction guide blocks are
positioned on the frame sides to effect a clearance
between the door and the resilient sealing faces
attached to the frame upon immediate raising
of the door, thus preventing seal drag and
minimising wear.

With this comprehensive range of flow control

products Ham Baker can help our customers
solve all their flow control needs. Because of this
extensive range we are not limited to specific duty
ranges or technologies but can offer our customers
not only a technically suitable solution but also the
most cost effective solution.

Penstocks and other flow control products

manufactured by Ham Baker can be found
operating in almost every country in the world, thus
endorsing the statement that Ham Baker is one of
the leading penstock manufacturers in the world.

08
 2

Selection
Introduction (b) Direction of flow and invert sealing arrangement.
(c) Mounting position.
The primary application of penstocks is the flow
(d) Fixing details.
control and isolation of fluids associated with water, (e) Method of operation.
waste water, sewage treatment plants, power (f) Accessories.
generation, irrigation schemes and process plants.
Having selected the basic frame type,
The modern penstock is designed to cater for a wide it is then necessary to specify one of the following
variety of duties from low seating to high off-seating alternatives:-
heads in sizes from 150mm to 5000mm square.
Selection of the correct penstock to suit the duty is A. Is the gate to take on-seating head?
important to satisfy the design criteria and provide
off-seating head?
the most cost effective solution. Operation of the
penstock is governed generally by factors outside on and off-seating head?
the control of the penstock manufacturer. However,
On-seating head
Pressure forcing the door
the range of available operating equipment
onto the frame.
is extensive: from simple direct operation by
handwheel to complex control systems for electrical, Off-seating head
Pressure forcing the door
pneumatic or hydraulic actuation. The range of away from the frame.
penstocks together with its associated operating Modulating penstocks for flow control
equipment will cater for the most demanding purposes, where gates may be frequently
specification and application. repositioned and utilise only a proportion
This section is intended to assist users in the of the full stroke, require special consideration and
selection of the most suitable products to may necessitate:
meet requirements. larger than standard stems
Selection Considerations slow operating speeds
When setting out to determine the unit most continuously rated motors on actuators
suited to a particular requirement, the following special heat absorbing drive sleeves
considerations have to be made:
B. Is the gate to have Chased/Rebated invert?
1. Size of gate required. Flush invert?
2. In which direction is the flow of the fluid to be
Chased/Rebated Invert
controlled; will it force the door on to or off its
sealing face? Standard inverts have bronze facings. Seating faces
3. What is the differential head in metres across the are very carefully bedded onto the door and frame
gate in each direction under: surfaces, and secured with specially designed, long
(a) Static conditions. taper countersunk screws of the same material
(b) Opening and closing conditions. as the faces. They are finally mated to each other
4. Wall, channel, pipe or thimble mounting. resulting in a tight seal.

5. Method of operation.
6. It is now necessary to make a selection given:
(a) Basic types available.

09
An Introduction to Flow Control
Flush Inverts 2. Channel Mounting
These are available with a resilient sealing strip Any of Ham Baker standard
to produce a laminar flow, improved hydraulics, penstock units can be mounted
efficiency and a non-fouling invert. in a channel. Channel mounted sealing grout

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 concrete
structure

penstock frame. Wall mounted

Flow penstocks can be installed with foundation bolts
Flow
and grout, however, the rebate will need to be cast
large enough to facilitate normal wall mounting
procedures and wedge adjustment.

On-Seating Head Off-Seating

3. 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 penstock in such
circumstances is by use of a wall thimble.
Flow Flow
Wall thimble mounting offers the following
advantages:
Chased/Rebated
1. Civil construction can proceed prior to delivery
of penstock reducing costs.
On-Seating/Off 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
Flush Invert rectangular openings.

Fixing Methods E Section for

off-seating heads
1. Wall Mounting
F Section for
Wall mounted penstocks are fixed to vertical end
on-seating heads
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 sealing
grout

supplied as an expanding type

(as shown), built in type or
resin type.
concrete structure E Section Thimble F Section Thimble
F Section Thimble

10
 2

Couplings Accessories
There are several methods of connecting sections Spindle Guides
of spindle together. The type selected will depend
In some cases unsupported lengths of spindle are
upon the application and the duty of the penstock.
subjected to buckling under compression or from
The most commonly used couplings are illustrated
lateral thrust by debris or solids. Spindle guides
below.
are, therefore, necessary as a means of providing
Spindle Adaptor intermediate support. Bolt-on type adjustable
guides are manufactured in cast iron, normally
Manufactured in cast iron, for jointing straight
plain unmachined, but if required they can be
lengths of stem in line. For use with torsional loads
bronze lined.
only (non-rising stem applications).
When considering the centres or vertical spacing of
Muff Couplings the guide, the l/r (length/radius of gyration of the
Manufactured in the same material as the spindle for spindle ) should not normally exceed 200.
joining straight lengths of spindle in-line. For use with
both axial and torsional loads (rising and non-rising
spindle applications). Typical Spindle Guides

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 operating duty and/or the specification.

Universal Joint Used on larger sizes of penstocks

Used on larger
for rising
and non-rising spindle applications.
sizes of penstocks for rising
and non-rising spindle applications.

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.

Protective neoprene gaiters can be supplied for the

retention of lubricants in the joints.
Used on smaller sizes ofUsed
penstocks
on smaller
for rising
sizes of penstocks for rising
and non-rising spindle applications.
and non-rising spindle applications.

Typical Couplings

Spindle Adaptor
Spindle Adaptor

Spindle Adaptor

Universal Joint Plain Screwed

Universal Joint Plain
Muff CouplingsScrewed
Muff Couplings

Universal Joint Plain Screwed

Muff Couplings
11
Stainless Steel Fabricated Penstock SG3100

Description Material Specification

The Fabricated Stainless Steel Penstock is a Frame
rectangular faced penstock designed to meet
Open top and full frame versions are available. The
the ever changing fluid handling demands of
frames are manufactured from stainless steel to BS
customers, combining the latest in penstock design
EN 10088 : 1955 grades 1.4301 (304) or 1.4401 (316).
and parametrics software.
Door
The generic penstock design, which is tailored using
parametrics software, develops and individualises Design for high impact whilst incorporating a
the penstock to suit specific duty and aperture lightweight single skin design with rib reinforcing
requirements. manufactured in stainless steel to BS EN 10088:1955
grades 1.4301(304) or 1.4401 (316). The number of
The Fabricated Stainless Steel Series also offers reinforcing ribs will vary according to the specific
greatly enhanced levels of customer service, duty and size requirements.
reduced design drawing turnaround, improved
reply to enquires and an enhanced delivery Sealing Faces
performance. The sealing arrangements combine the use of
resilient and or synthetic materials.

Options Invert
A flush invert is utilised as standard on the
Size Range 400mm2 upto 3000mm2.
Fabricated Stainless Steel Series (to ensure a smooth
flow with a positive seal and allowing complete
drainage at the invert of the penstock.
Mounting
Wall Wedging/Pressure Pad Assembly
Channel An adjustable wedging or pressure pad assembly
is included within the design to accommodate
Side Wall
specified duties, wear in service and ensure a
Demountable. positive seal.

Spindle
Rising or non-rising type in stainless steel to BS EN
10088 : 1955 grade 1.4401 (316). Extension spindles
are in the same material.

Frame Yoke
Frame yokes are fitted when thrust is required to be
taken by the frame and positioned to allow removal
of the door. The yoke material is the same material
as for the frame.

Fixing Bolts
Can be supplied when requested.

12 See also Series 50/40, 160/80 and 300/150

3

13
Plastigate Series 20-20

Description Frame Yoke

The Plastigate Series 20-20 is a standardised range For wall mounted penstocks the frame yokes are
of penstocks with sizes up to 1000mm square which fitted when thethrust needs to be taken by the
have been specifically designed to meet lower frame. The yoke is gussetted andbolted to the frame
pressure heads up to 2m on-seating and 2m off- to allow for removal. The yoke material is thesame
seating pressures. as for the frame. For channel mounted penstocks
the yokeforms an integral part of the frame.
Suitable for wall and channel applications.
Pressure Pads
The design embodies the latest use of synthetic Pressure pads are only fitted to penstocks which are
materials combined with stainless steel and plastic. wall mountedtype only and subjected both on/off
Provides a range of penstocks suitable for use seating pressures.
in most water, sewage and industrial effluent Fixing Bolts
treatment plants.
Bolts can be provided for wall mounted units if
required.
Options Door Nut
Wall mounted
Manufactured from phosphor bronze to BS EN
Channel mounted 12167:1998 fornon-rising stem applications, or cast
Rebate or sidewall fixed iron to BS EN 1561 min. 250for rising stem types.
Material choice (frame and door)
Operating Gear
A dedicated range of standardised operating
Material Specification equipment isavailable for use with the Series
20-20 penstocks.
Seals
Type 1. Square Cap & Adaptor
The frame seals are of resilient, low friction
Type 2. Handwheel
materials selected for its resistance to ultra
Type 3. Actuator
violet degradation.
The following door and frame combinations
Frames
are available.
Frames are manufactured from stainless steel to BS
EN10088:1995 grades 1.4301 (304) or 1.4401 (316). 1. Wall Mounting Options
a. On seat, stainless steel frame, (Fig. 1.)
Doors rigid pvc door.
Doors are manufactured from stainless steel to BS b. On seat, stainless steel frame and door. (Fig. 1.)
EN 10088:1995grades 1.4301 (304) or 1.4401 (316).
c. On/off seat, stainless steel frame, (Fig. 1.)
Flush Invert rigid pvc door.
The Plastigate Series 20-20 penstocks are supplied d. On/off seat, stainless steel frame and door. (Fig. 1.)
as standardwith a flush invert seal arrangement to 2. Channel Mounting Options
allow for a smoothtransmission of flow through the (door depth pressure only)
penstock. e. On/off seat seat, stainless steel frame, (Fig. 2.)
Spindle rigid pvc door.
f. On/of seat, stainless steel frame and door. (Fig. 2.)
The spindle is manufactured in stainless steel.

14 See also Series 60, 60/30 and SG3100

 4
Wall Mounting On/Off Seating; Rigid PVC Door
FIG 1.
Section XX Scrap View Closed Top Section Showing Invert
Plate Fitted (Optional) Arrgt. Without Recess
GROUT
25
50 45

INVERT

77

70
25 GROUT

SECTION ZZ
147
H NO. HOLES 17 DIA
25 GROUT DRILL WALL ON ERECTION
FOR FIXING BOLTS 31.8

114
(1)

77

75
DOOR IN TOP
POSITION
SHOWN CHAIN
DOTTED DIM. G

X X
HEIGHT=DIM. E

DIM. F

DIM. G
100
70
OPENING DEPTH=DIM. B

OPENING WIDTH = DIM. A

HOLE CRS. = DIM. C

25 FRAME WIDTH = DIM D 25

Width Depth Dim. Dim. Dim. Dim. Dim. Dim.

A B C D E F G H
INVERT
DIMENSIONS IN MILLIMETRES
200 200 360 400 577 390 215 4
95

250 250 410 450 677 490 315 4

190
300 300 460 500 777 590 415 4
RECESS FOR FLUSH INVERT TYPE 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

15
Series 20-20
Channel Mounting; Stainless Scrap View Closed Top Plate Fitted (Optional)
Steel Construction
FIG 2.
Section XX
25

71
50
150

114

Z 31.8
(1)

X X
HEIGHT = DIM. D
55

CHANNEL/OPENING = DIM. A

25 FRAME WIDTH = DIM. C 25

16
 4
71

SECTION ZZ

DOOR IN TOP POSITION

SHOWN CHAIN DOTTED

25

GROUT NOT SHOWN IN 96

RECESS FOR CLARITY

PENSTOCK OPENING DEPTH - DIM. B

INVERT
80

150

RECESS FOR FLUSH INVERT TYPE

Width Depth Dim. Dim.

A B C D
DIMENSIONS IN MILLIMETRES
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

See also Series 60 , 60/30 and SG3100 17

Plastigate Series 50-40

Description Frame Seals

Plastigate Series 50-40 is a rectangular faced The sealing arrangements for the Coplastix
penstock designed and manufactured to Penstocks combine the use of resilient and low
suit modern industrial and domestic effluent friction synthetic materials, which ensures a high
environments. Utilisation of the latest synthetic degree of sealing with easy movement.
materials for both sealing mechanisms and door Doors
construction combined with the use of steel or
stainless steel in the construction of the penstock Doors are manufactured as a composite sandwich
frames ranges. construction comprising a lightweight rigid, cellular core
with a fully welded steel box section matrix between
A range of penstocks suitable for use in most two other skins of rigid, compressed composite plastic
water, sewage and effluent treatment plants. The which is asbestos free, ultra violet stabilised, rigid and
penstocks are available for wall mounting and can non toxic. All materials are chemically bonded and
be provided with either manual or power operators, sealed. Doors for non-rising spindle penstocks have a
manufactured in sizes ranging from 400mm square stainless steel lining tube inside the central vertical box
to 2000mm square as standard. section of the inner matrix.

Spindles
Material Specification Rising or non-rising type in stainless steel BS EN
10088:1995 grades 1.4301 (304) or 1.4401 (316) with
Frames
extension spindles in the same material as standard.
Frames are manufactured from mild steel to BS
EN 10025:1993 grade S275 or stainless steel to Frame Yokes
BS EN 10088:1995 grades 1.4301 (304) or 1.4401 Frame yokes form an integral part of the frame and
(316). Mild steel frames can be protected to suit are positioned to allow removal of the door should
sea water, potable or sewage application, stainless this be.
steel natural finish. The penstock frames for both
wall and channel mounting (downward closing) Stem Nuts
have a resilient flush invert seal to allow smooth The stem nuts are phosphor bronze to BS 12167:1998.
transmission of the flow through the penstock. For nonrising stems, the nut is housed in a cast-iron
bracket secured to top of the penstock door. For rising
stems, the nut is housed in the handwheel.
FIG 1. See table on page 34.

TABLE 1
RANGE J T V W X
DIMENSIONS IN MILLIMETRES
SMALL 104 50 80 165 215
MEDIUM 122 60 80 195 235
LARGE 146 80 100 245 295

18
 5
Fixing Bolts stem is secured to the lower edge of the penstock
door via a cast iron bracket, thus permitting
Can be supplied when requested.
maximum unhibited flow over the upper weir
Pressure Pads edge of the door. Flush invert does not apply for
Adjustable pressure pads are fitted as standard and Weir Penstocks. The sealing arrangements for the
pre-set at the works to provide maximum degree of Coplastix Penstocks combine the use of resilient
water tightness. and low friction synthetic materials which ensures a
high degree of sealing with easy movement.
WEIR (Downward Opening)
Coplastix Weir Penstocks are constructed as
described for the wall mounted type other than the

FIG 2. See table 1. FIG 3.

Section Showing Invert Section Showing Side Section Showing Invert
Seal Arrangement for Wall Seal Arrangement for Seal Arrangement for Wall
Penstock with Recess Wall Penstocks Penstocks Without Recess
Holes For Wall Fixing
Adjustable Holes For Wall Fixing Adjustable
Seal Frame Seal
Adjustable
Seal Frame
Seal
Seal Adjuster
Seal Adjuster Fixed Seal
Adjuster
Fixed Seal Door
X

Fixed Seal Door

Door Sealing Faces
X

Door Grout
Door Sealing Faces Coplastix S
Grout Coplastix S
Grout Flexible Seal

Flexible Seal
Backing Strip
Flexible Seal
Backing Strip Coplastix N
Coplastix N
V
V

Small Range = 80
X Medium Range = 95
X Concrete Large Range = 125
Concrete
Opening Width A
Opening Width A

FIG 4. See table on page 35. FIG 5.

'J' 'J'
L
L

FRAME
SOFFIT (TOP
SOFFIT OF DOOR)
(TOP OF DOOR)
OPENING DEPTH B

100
OPENING DEPTH B

OPENING DEPTH

100
OPENING DEPTH
B

HOLES FOR DOOR

B

SEALING FACES
WALL FIXINGS COPLASTIX S
G
G

INVERT
INVERT 'H' No. HOLES
'H' No. HOLES INVERT
INVERT
TO SUIT
TO SUIT BACKING STRIP
HD BOLTS
E
F

HD BOLTS COPLASTIX M
E
F
G
G

CONCRETE GROUT

OPENING WIDTH A

'M' 'M'
K

25 GROUT
K

25 GROUT OPENING WIDTH

OPENING 'A' 'A'
WIDTH
'C' CRS
'C' CRS
'D' 'D' TABLE 2
RANGE J K L M
Overall dimensions diagram of weir Penstocks DIMENSIONS IN MILLIMETRES
SMALL 104 50 85 165
MEDIUM 122 68 110 185
LARGE 146 80 160 245

See also Series 20/20, 60/30, 108 and SG3100 19

Plastigate Series 50-40

SMALL RANGE FIG.1 WALL MOUNTED VERSION

WIDTH A DEPTH B C D E F G H J K L M
DIMENSIONS IN MILLIMETRES
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 WALL MOUNTED VERSION

WIDTH A DEPTH B C D E F G H J K L M
DIMENSIONS IN MILLIMETRES
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

20
 5

LARGE RANGE FIG.1 WALL MOUNTED VERSION

WIDTH A DEPTH B C D E F G H J K L M
DIMENSIONS IN MILLIMETRES
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

SMALL RANGE FIG.4 WEIR PENSTOCK (DOWNWARD OPENING)

WIDTH A DEPTH B C D E F G H
DIMENSIONS IN MILLIMETRES
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

21
Plastigate Series 50-40

MEDIUM RANGE FIG.4 WEIR PENSTOCK (DOWNWARD OPENING)

WIDTH A DEPTH B C D E F G H
DIMENSIONS IN MILLIMETRES
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

22
 5

MEDIUM RANGE FIG.4 WEIR PENSTOCK (DOWNWARD OPENING)

WIDTH A DEPTH B C D E F G H
DIMENSIONS IN MILLIMETRES
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

23
Cast Iron Series 60

Description Material Specification

The Series 60 is a circular metal faced penstock Frame
suitable for wall and flange mounting application,
Constructed in BS EN 1561 min. 250 cast iron
suitable for on-seating pressure as standard
designed for wall or flange mounting applications.
but, dependent on size, will take a degree of
off-seating pressure. Door
Conventional adjustable wedges are positioned Constructed in BS EN 1561 min. 250 cast iron to
around the door as required to suit the duty and withstand seating heads up to 6m on and off seating
provide a practical degree of watertightness. as specified in table below.

Sealing Faces

Features and Benefits Sealing faces are bedded to 0.1mm feeler gauge non-
acceptance to provide an effective seal. The sealing
An extensive range of operating equipment can face material for penstocks up to and including
be utilised
600mm diameter sizes is to BS EN 1982:1999, sizes
Faced wedges available in the same material as above 600mm diameter BS EN 12167:1998.
the sealing faces
Fixing bolts supplied on request For sizes up to and including 600mm diameter the
sealing faces are force fit, for sizes above 600mm
Flange/pipe mounting (BS EN 1092-2 : PN 16). the sealing face is secured to the frame using long
countersunk taper screws in the same material as
the sealing face.
Typical Section Through Side Member
Side Wedges
Constructed in BS EN 1561 min. 250 cast iron to
provide a large contact area with the door. The side
wedges are adjustable to accommodate wear during
the life of the penstock.

Aperture Maximum (m)

Size(mm) On-Seat Off-Seat
100 6 6
150 6 5
200 6 4
250 6 4
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
900 6 1
1000 6 1

NOTE: Heads taken from invert

24 See also Series 60/30, 108 and 20/20

 6
Thrust Housing (direct operation) Thrust Direct
Manufactured in cast iron to BS EN 1561 min. 250
with low friction thrust washer and lubricator.

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 rising stem types.

Fasteners
Standard fasteners are supplied in stainless steel to
BS EN 10088:1995 grade 1.4401 (316; A4).

Operating Spindles
Alternative materials can be supplied for operating
spindles and extension.

Methods of Operation
The method of operation will depend upon several
factors which are outside the control of the
penstock manufacturer, but the range of operating
gear available is extensive which can be provided to
meet customer requirements. (See page 44).

A B C D E F G H J K L M P U V W AA

DIMENSIONSINMILLIMETRES
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

25
Cast Iron Series 60-30

Description Sealing Faces

The Series 60-30 is a rectangular metal faced Phosphor bronze sealing faces to BS EN 12167:1998
penstock suitable for wall and thimble mounting, are supplied as the standard material bedded to
with on-seating heads up to 6 metres and off- 0.1mm feeler gauge nonacceptance to provide an
seating heads up to 3 metres. Conventional wedges effective seal.
are positioned each side of the frame to apply a face Door and Frame
to the door in the closed position.
The sealing faces are fixed securely using long
taper countersunk pegs in the same material as the
Options sealing face.

An extensive range of operating gear can Wedges

be utilised
Constructed in BS EN 1561 min. 250 cast iron to
Faced wedges available in the same material provide a large contact area with the door. The
as the sealing faces wedges are adjustable to accommodate wear during
Fixing bolts supplied on request the life of the penstock.
Sealing faces can be secured to satisfy the
Flush Invert
requirements of the
The resilient flush invert seal is bolted onto the
American Water Works Association specification
AWWA C501-92 frame invert member.
Circular apertures Thrust Housing
(sealing faces remain rectangular)
Manufactured in cast iron to BS EN 1561 min. 250
Thimble mounting (See page 8) with low friction washer and lubricator.
Full and half frames available.
Invert Seal
A flush invert is supplied as a standard feature, the
Material Specification seal is manufactured from Ethylene Propylene Di-
Frame Methyl (EPDM) to ASTM D2000.

Constructed in BS EN 1561 min. 250 cast iron for Door Nut

wall or thimble mounting applications. Manufactured from phosphor bronze to BS EN
Door 12167:1998 for non-rising stem applications, or cast
iron to BS EN 1561 min. 250 for rising stem types.
Constructed in BS EN 1561 min. 250 cast iron
designed to withstand seating heads up to 6 metres, Fasteners
and 3 metres off-seating. Standard fasteners are supplied in stainless steel to
BS EN 10088:1995 grade 1.4401 (316; A4).

Typical Section Through Side Member Flush Invert Section & Rebate

26 See also Series 90/60 and 50/40

 7
Operating Spindles Methods of Operation
Alternative materials can be supplied for operating The method of operation will depend on several
spindles and extensions. factors which are outside the control of the
penstock manufacturer, but the range of operating
gear available is extensive. (See page 48).
FULL FRAME Thrust Direct
Alternative Frame
Alternative half frame penstocks
are also available.

HALF FRAME
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
DIMENSIONSINMILLIMETRES
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
8001015 1810 75 75 160 - 965 585 600 580 - - - - - 250 1915 - - - - 8 16
9001115 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 5001175 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 1490140 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 21003860 160 222 380 - 2020 375 375 650 650 650 130 260 840 - - 1000 1980 140 - 20 20
2000 23804715 210 247 420 - 2280 305 460 505 735 945 160 420 800 - - 500 2210 140 - 22 20

27
Cast Iron Series 108

Description Sealing Faces

The Series 108 is a rectangular metal faced penstock Phosphor bronze sealing faces to BS EN 12167:1998
suitable for wall and thimble mounting, with on- are supplied as the standard material bedded to
seating heads up to 6 metres and off-seating heads 0.1mm feeler gauge nonacceptance to provide an
up to 6 metres. Conventional wedges are positioned effective seal.
each side of the frame to apply a face to the door in Door and Frame
the closed position.
The sealing faces are fixed securely using long
taper countersunk pegs in the same material as the
Options sealing face.

An extensive range of operating gear can Wedges

be utilised
Constructed in BS EN 1561 min. 420-12 ductile iron
Faced wedges available in the same material to provide a large contact area with the door. The
as the sealing faces wedges are adjustable to accommodate wear during
Fixing bolts supplied on request the life of the penstock.
Circular apertures
Flush Invert
(sealing faces remain rectangular)
The resilient flush invert seal is bolted onto the
Thimble mounting (See page 8)
frame invert member.
Full frame only.
Thrust Housing
Manufactured in 420-12 ductile iron to BS EN 1561.

Invert Seal
A flush invert is supplied as a standard feature, the
seal is manufactured from Ethylene Propylene Di-
Material Specification Methyl (EPDM) to ASTM D2000.
Frame Door Nut
Constructed in BS EN 1561 min. 250 cast iron for Manufactured from phosphor bronze to BS EN
wall or thimble mounting applications. 12167:1998 for non-rising stem applications.
Door Fasteners
Constructed in BS EN 1561 min. 250 cast iron Standard fasteners are supplied in stainless steel to
designed to withstand seating heads up to 6 metres, BS EN 10088:1995 grade 1.4401 (316; A4).
and 3 metres off-seating.

Typical Section Through Side Member Flush Invert Section & Rebate

28 See also Series 90/60 and 50/40

 8
Operating Spindles Methods of Operation
Alternative materials can be supplied for operating The method of operation will depend on several
spindles and extensions. factors which are outside the control of the
penstock manufacturer, but the range of operating
gear available is extensive. (See page 48)
FULL FRAME Thrust Direct

29
Cast Iron Weir Penstocks

Description Sealing Faces

Weir Penstocks are utilised in water and sewage Phosphor bronze sealing faces to BS EN 12167:1998
plants for accurate regulation or measurement are supplied as the standard material bedded to
of flow. 0.1mm feeler gauge non-acceptance. The sealing
face is fixed securely to the frame using long taper
Operation of the Weir Penstock is opposite to countersunk pegs in the same material as the
that of a conventional penstock, with the door sealing face.
opening downwards.
Pressure Adjusters
Manufactured from BS EN 1561 min. 250 cast iron.
Options Side Bars
Alternative trim materials
During operation a force is applied to the sealing
Face plate on door faces by springs positioned along the side of the
Fixing bolts supplied if requested frame.
Clear opening type penstock
Pressure Plates
(no flow restriction by stem)
Adjustable cast iron pressure plates are used as an
alternative to side bars on certain sizes of penstock.
Material Specification Alternative Materials
Size Range A wide range of alternative materials can be
The Weir Penstock series is available in both square supplied for pressure adjusters, operating spindle,
and rectangular apertures; the size range available fasteners etc.
is extensive and details are available on request.
Fasteners
Frame Standard fasteners are supplied in stainless steel to
Constructed in BS EN 1561 min. 250 iron for wall BS EN 10088:1995 grade 1.4401 (316; A4).
or thimble mounting applications. The sealing
face is fixed securely to the frame using long taper Door Nut
countersunk pegs in the same material as the Manufactured from phosphor bronze to BS EN
sealing face. 12167:1998 for non-rising stem applications; or cast
Door iron to BS EN 1561 min. 250 for non rising stems.

Constructed in BS EN 1561 min. 250 cast iron

designed to withstand seating and off seating
pressure as required. Door sealing face as standard
is machined cast iron. When required door can be
fully faced with copper alloy. Option for perimeter
sealing (fully closed position) only.

30 See also Series 50/40 and SG3100

 9
Methods of Operation Type B Screw-down weir penstocks with
unobstructed openings, the rising spindle is
The method of operation will depend on several
attached to a horizontal lifting beam above the
factors which are outside the control of the
opening and operates the door by lifting rods fitted
penstock manufacturer, but the range of operating
to each side of the door.
gear available is extensive and can be provided to
meet customer requirements. (See page 44) For accurate measurement of flow, Type B Weir
Penstocks are recommended because the spindle
The following types of Weir Penstocks are
does not obstruct the flow over the weir. Indicators
manufactured: Type A Weir Penstocks of the screw-
with metric or imperial graduations can be fitted for
down variety with rising or non-rising spindles,
the application.
the spindle operates through a nut which is either
housed in the door for the non-rising types or
housed in handwheel, gearbox or actuator for the
rising types.

SPINDLE

SPINDLE LIFTING
BEAM
WEIR
WIER
EDGE
LIFTING
ROD

DOOR SEALING
FACES

WIER
WEIR
EDGE

SIDE BAR/
PRESSURE
PLATES

DOOR

SIDE BAR/
PRESSURE
PLATES

TYPE A TYPE B

31
Cast Iron Series 90-60

Description Material Specification

The Series 90-60 is a rectangular metal faced Frame
penstock suitable for wall and thimble mounting,
Constructed in BS EN 1561 min. 250 iron for wall or
with on-seating heads up to 9 metres and off-
thimble mounting applications.
seating heads up to 6 metres.
Door
Penstocks for seating duties are supplied with side
wedges only. Off-seating applications may require Constructed in BS EN 1561 min. 250 iron designed
bottom and/or top wedges in addition to side to withstand seating heads up to 9 metres, and 6
wedges, depending on the operating conditions. metres off-seating.

Chased invert penstocks are supplied as standard. Sealing Faces

Flush invert can be supplied when requested. Phosphor bronze sealing faces to BS EN 12167:1998
are supplied as the standard material bedded to
0.1mm feeler gauge nonacceptance. The sealing
Options face is fixed securely to the frame using long taper
countersunk pegs in the same material as the
Flush invert eliminating grit traps
sealing face.
An extensive range of operating gear can
be utilised Wedges
Faced wedges available in the same material Constructed in BS EN 1561 min. 250 iron to provide
as the sealing faces a large contact area with the door. The wedges are
Fixing bolts supplied on request adjustable to accommodate wear during the life of
Sealing faces can be sealed to satisfy the the penstock.
requirements of both BS7775 and AWWA
Thrust Housing (direct operation)
C501-92
Manufactured in cast iron to BS EN 1561 min. 250
Circular apertures (sealing faces remain
rectangular) for penstocks 700mm 2000mm with low friction thrust washer and lubricator.
Thimble mounting (See page 8) Door Nut
Full and half frames available. Manufactured from phosphor bronze to BS EN
12167:1998 for non-rising stem applications, or cast
iron to BS EN 1561 min. 250 for rising stem types.

Fasteners
Standard fasteners are supplied in stainless steel to
BS EN 10088:1995 grade 1.4401 (316; A4).

32 See also Series 108, 160/80 and SG3100

 10
Alternative Materials FIG 1. Bottom-Wedge Arrangement
Alternative materials can be supplied for operating Section ZZ and Chase Details
spindles, sealing faces, fasteners etc. DOOR

Methods of Operation
SEALING
FACES

The method of operation will depend on several INVERT

factors which are outside the control of the

penstock manufacturer, but the range of operating TAPERED
BOTTOM
gear available is extensive, and can be provided to WEDGE

meet clients requirements. (See page 44)

MICRO-ADJUSTABLE
SCREW JACK

D+25
For square penstocks with apertures up to 350mm
respectively, the wedge bars/blocks are cast
FRAME

integrally with the frame into which stainless steel

jacking screws are fitted to provide the wedging
45
effect onto the door when it is in the closed position.
600 min

Bottom wedge blocks are provided across the invert

member of the frame to give additional sealing force
when required. (Fig. 1.)
FIG 2. Top-Wedge and Bridge
Sluice gates with a flush invert resilient seal do not
Arrangement Part Section XX
require bottom wedges. (Fig. 3.)
BB

For OFF seating pressures a bridge mounted across FRAME PENSTOCK

SPINDLE
TAPERED TOP WEDGE
ON DOOR
BRIDGE
ON FRAME

the soffit of the frame embodies jacking screws to

(NON-RISING
TYPE SHOWN)

mate with top wedges on the door when required.

(Fig. 2.)

Typical Arrangement of a Rectangular

Penstock with Micro-Adjustable Top, Side
and Bottom Wedges

SEALING DOOR MICRO-ADJUST JACKING SCREW

FACES

FIG 3. Flush Invert

DOOR

FLEXIBLE SEAL

FRAME

33
Cast Iron Series 90-60
Penstock Sizes Penstock Sizes (Open or Closed Top)
150 x 150 to 450 x 450mm 500 x 500 to 2000 x 2000mm
E E
G AA NO. OF
F HOLES FOR
AB DIAMETER
FIXING BOLTS
E
G AA NO. OF
E F HOLES FOR
AB DIAMETER
FIXING BOLTS

O
F

ON
Q Q

NM
F

R
Q Q
B

LM
DEPTH/DIAMETER
R
B

DEPTH/DIAMETER

KL
DEPTH
B

ER
ET
M
B

IA
D
G
H

KJ
IN
N
PE
D OPENING

ER
O

ET
M

H J I
IA
D
DEPTH

G
IN
N
D

PE
D

D OPENING

O
INVERT
H

I
WIDTH
S T U V W X

HP
Y
G INVERTWHEN CIRCULAR
DIAMETER APERTURE REQUIRED
D
D

A A
S T U V W X

P
Y
WIDTH WHEN CIRCULAR
DIAMETER APERTURE REQUIRED

G A

Effective
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 AA AB dia.
Opening
DIMENSIONSINMILLIMETRES
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

AA = Half Frame AB = Full Frame

34 See also Series 108, 60/80 and SG3100

10

35
Cast Iron Series 160-80

Description Material Specification

The Series 160-80 is a rectangular metal faced Frame
penstock suitable for wall and thimble mounting,
Constructed in BS EN 1561 min. 250 iron for wall or
seating heads up to 16 metres and off-seat heads
thimble mounting applications.
up to 8 metres.
Door
Penstocks for seating duties are supplied with side
wedges only; off-seating applications may require Constructed in BS EN 1561 min. 250 iron designed
bottom and/or top wedges in addition to side to withstand seating heads up to 16 metres, and 8
wedges depending on the operating conditions. metres off-seating.

Chased invert penstocks are supplied as a standard. Sealing Faces

Flush invert can be supplied when specified. Phosphor bronze sealing faces to BS EN 12167:1998
are supplied as the standard material bedded to
Conventional wedges are positioned around the
0.1mm feeler gauge nonacceptance. The sealing
frame as required to suit the duty. The wedges
face is fixed securely to the frame using long taper
apply a force to the door in the closed position.
countersunk pegs in the same material as the
During the opening and closing travel the door is
sealing face.
retained by integral guides in the frame.
Wedges
Constructed in BS EN 1561 min. 250 iron to provide
Options a large contact area with the door. The wedges are
Flush invert adjustable to accommodate wear during the life of
An extensive range of operating gear the penstock.
can be utilised
Flush Invert
Faced wedges available in the same material
as the sealing faces The resilient flush invert seal is bolted onto the
frame invert member. The seal is manufactured
Fixing bolts supplied on request
from Ethylene Propylene Di- Methyl (EPDM).
Sealing faces can be secured to satisfy the
requirements of BS 7775 and AWWA C501-92 Thrust Housing (direct operation)
Circular apertures (sealing faces remain Manufactured in cast iron to BS 1561 min. 250 with
rectangular) low friction thrust washer and lubricator.
Thimble mounting (See page 8)
Door Nut
Full and half frames available
Manufactured from phosphor bronze to BS EN
Available up to 5000mm square. 12167:1998 for non-rising stem applications, or cast
iron to BS EN 1561 min. 250 for rising stems.

36
 11
Fasteners
Standard fasteners are supplied in stainless steel to
BS EN 10088:1995 grade 1.4401 (316; A4).

Alternative Materials
Alternative materials can be supplied for operating
spindles, sealing faces, fasteners etc.

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, which can be provided
to meet customer requirements. (See page 44).

Typical Bridge Section Typical Section Through Side Member

Bridge

Top Wedge

Door

Frame

Sealing Faces

37
Cast Iron 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
DIMENSIONSINMILLIMETRES
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

HALF FRAME FULL FRAME

Thrust Remote Rising Spindle Thrust Direct

Central Fixing Hole

on sizes 1100mm
and above

Central Fixing Hole

on sizes 1100mm
and above

38
 11

A B C D D E F H J K L M
DIMENSIONSINMILLIMETRES
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
60-80 ONLY. DETAILS FOR SERIES 260-130 AND 300-150 ARE ON REQUEST.

39
Cast Iron Series 160-80
SIZE RANGE 1600 TO 3000mm Sq. or Dia
(Refer to both tables)

FULL FRAME Thrust Direct

A B C D D E F G H J K L M N

DIMENSIONSINMILLIMETRES

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

See also Series 50/40 SG3100

40 See also Series 50/40 and SG3100

 11

HALF FRAME Thrust Remote Rising Spindle

A P Q R S T U V W X Y AA AB Ab AC

DIMENSIONSINMILLIMETRES

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.

41
Technical Details

Preparation and Protective Coating

The following coating systems are offered by Ham Baker as standard.

PS42 potable water applications PS46 all other applications

1. Grit Blast to ISO8501:1988 Sa2.5. 1. Grit Blast to ISO8501:1988 Sa2.5.
2. 3 coats 2 pack Black High Build Epoxy (COPON 2. 1 coat 2 pack Black High Build Epoxy (COPON
KSIR88 OR EQUAL), each coat to be 100 microns KSIR88 OR EQUAL), the coat to be 150 microns
average dry film thickness. average dry film thickness.

Giving a final coating thickness of 300 microns. Giving a final coating thickness of 150 microns.

This is a 2pack Epoxy high performance coating This is a 2pack Epoxy high performance coating
system with WRAS approval for use in Potable water. system developed in conjunction with the paint
manufacturer to give optimum performance in all
none potable applications.

Standard Paint Specification Application Surface Treatment

PS42 High Build 2 Pack Epoxy Seawater/Potable/Seawater: 1. Grit blast to ISO8501:1988 Sa2.5
Coating System with WRAS approval Cast Iron and Mild Steel below
for all materials. Floor/Operating level. 2. 3 Coat of 2 pack black High Build
Epoxy Final coating thickness:
300 microns average dry film
thickness.
This coating has been tested to BS
6920 and has been approved by
WRAS for use in water intended for
human consumption.
PS46 High Build 2 Pack Epoxy Seawater/Potable/Seawater: 1. Grit blast to ISO8501:1988 Sa2.5
Coating System. Cast Iron and Mild Steel below
Floor/Operating level. 2. 1 Coat of 2 pack black High Build
Epoxy Final coating thickness:
150 microns average dry film
thickness.
This coating has good resistance to
abrasion and mechanical
damage. Is unaffected by fuel oil,
chemical products, aviation fuel and
sour gas mixtures. It is also suitable
for use up to a 120C dry heat
Note on paint specifications: Average of paint thickness readings taken over a square metre should equal or exceed
the defined thickness stipulated. In no case should any reading be less than 75% of the stipulated thickness.

42
 12

Sizes H is the differential head at the centre of the

opening metres
BS7775 Specification for Penstocks provides useful
information regarding sizes for penstocks. The differential head is the difference between
the upstream and down stream water levels.
Penstocks are suitable for three shapes of aperture
g is the acceleration due to gravity 9.81 m/s2
Square
Rectangular For example a penstock 1.5 metres wide by 2 metres
deep with a 6 metre differential head at the centre
Circular
of the door will discharge 22.8 cubic metres per
Standard Rectangular Penstocks have an aspect second.
ratio (width divided by depth) between 0.5 and 2.
A graph of a range of discharges for different
Penstocks outside this range can be considered but
penstock apertures and differential heads is
will be special designs.
shown below.
Cast Iron Circular penstocks below 600mm to
Fig. 1 Graph of Discharge against Head
1000mm in diameter, depending on type, have a
circular sealing face. For all other circular penstocks
50
the sealing face is as a square penstock. 10m head
9m head
45
8m head

Flow Characteristics
Discharge through Penstock CU.M./Sec.

40 7m head

1. General 6m head
35 5m head
Penstocks are installed in civil engineering
structures. When a penstock is fully open, the head 30 4m head
loss attributable to the penstock alone is generally
3m head
quite small compared to the losses due to the civil 25
engineering structure. An exception to this is a
2m head
channel mounted penstock where the top water 20
level is above the top of the door opening.
1m head
15
2. Discharge through an orifice .75m head

This type of flow occurs where a penstock controls 10 .5m head

flow into or out of a tank or other large container. .25m head
If the gate is fully submerged, the flow through an 5
open or partially open penstock and its associated
civil engineering structure opening will be given by 0
.5 1 1.5 2 3 3.5 4 4.5 5
q = CA (2gH)
Area of Penstock opening in sq.m
Where Penstock discharge = 0.7 X area 2 x g x head

q is the discharge rate cubic metres per second

C is a discharge coefficient generally taken to be 0.7

A is the aperture area square metres

The aperture area is the penstock opening if the

penstock is fully open. If the penstock is not fully
open the aperture area will be reduced.

43
Technical Details
3. Channel mounted penstocks If the weir is used as a flow measuring or control
device reference should be made to BS 3680-
If a channel mounted penstock is fully open and
4A:1981 Methods of measurement of liquid flow in
the top of the penstock opening is above the water
open channels. Weirs and flumes. Methods using
level in the channel, then the head loss results from
thin plate weirs for channel design and relative
disturbed flow in the rebates in the channel walls
water levels.
in which the penstock frame is mounted. These
losses can generally be disregarded provided that
the channel is not obstructed. Channel mounted
penstocks usually have flush inverts. Leakage
Ham Baker penstocks will be virtually drop-tight
When a penstock is in a channel and is partially
at their working pressure if installation has been
closed, or the water level is above the top of
carried out correctly.
the door opening, the calculations are complex.
Reference should be made to a suitable publication Leakage rates are influenced by
on civil engineering hydraulics.
The head
References The seating direction, on or off
Open Channel Hydraulics The correct installation of the penstock
By V T Chow
Time
McGraw-Hill Education
An on-seating penstock will leak less with increasing
Open Channel Flow
head. An off-seating penstock will leak more with an
By F M Henderson
increasing head.
Macmillan USA
Penstocks subject to an on-seating head seal more
Hydraulic Gates and Valves in Free Surface Flow and
tightly than those subject to an off-seating head.
Submerged Outlets
By J Lewin If the penstock is installed so that the frame
British Nuclear Energy Society is twisted, then the leakage rate will increase.
Penstocks should be installed by experienced
4. Weir Penstocks
contractors and mounted on grout.
Weir Penstocks behave in their discharge capability
as a rectangular weir with partial end contractions, Over the course of time after closure of the
the extent of the end contraction being influenced penstock, the leakage rate will decrease as leakage
by the civil engineering design in the locality of paths are blocked by small pieces of debris in the
the weir. water.

An approximation to the discharge is given by From the above it is clear that if leakage is required
to be minimised, then the penstock should be
Q = 1.73 WH1.5 configured so that it is on-seating.
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 of200mm (0.2m) at the crest will discharge
0.31 cubic metresper second.

44
 11
Allowable Leakage Rates On-site Leakage Test According to BS 7775
Leakage rates are defined by the amount of water Before a site leakage test is undertaken the
which leaks through a 1 metre length of seal in 1 installer shall ensure that the penstock and its
minute. associated operating equipment have been correctly
installed and fixed in position. Penstocks and
BS 7775:1995 leakage rates apply to penstocks associated operating equipment shall be installed
subject to a head of 6 metres or less and widths of 2 strictly in accordance with the manufacturers
metres or less. recommendations. Final adjustments to the
Penstocks with metal seals (Cast Iron Penstocks) penstock shall be made and all moving parts shall
be operated through one complete open and
The allowable leakage rates listed are derived from shut cycle to confirm proper operation before the
BS 7775 Specification for Penstocks and AWWA leakage test commences.
C501-92 AWWA Standard for Cast Iron Sluice Gates
as appropriate. Measurement of the liquid loss through the seals
shall be carried out in such a way that any leaks
On-seating head Allowable leakage rate from between the penstock frame and the structure
shall not affect the result of the test. Tests shall be
Any head 1.25 litres/min/m
carried out over a period of 30 minutes.
Off-seating head Allowable leakage rate

Up to 6 metres 2.5 litres/min/m

Up to 9 metres 3.0 litres/min/m

Up to 12 metres 3.75 litres/min/m

Up to 15 metres 4.5 litres/min/m

P
Leakage rates for off-seating heads greater than
15 metres will be advised on request.
P

Penstocks with resilient rubber or plastic seals

(Plastigate, Coplastix and Series 2000 Penstocks).

There is currently no standard which applies to

H
leakage rates for this type of penstock. The figures
given below are Ham Bakers estimates.

On-seating head Allowable leakage rate F

Up to 5 metres 0.4 litres/min/m

Off-seating head Allowable leakage rate

Up to 4 metres 0.4 litres/min/m

For example, a 1500mm wide by 2000mm deep cast

iron penstock subject to an off-seating head of 9
metres would have a seal periphery of 2(1.5+2) = 7m
and and allowable leakage rate of 3.0 litres/min/m.

Therefore maximum allowable leakage rate = 7 x 3 =

21 litres/min

45
Technical Details

Foundation Loads and However the civil engineering structure will not
experience this force if the penstock operating
Operating Forces device is connected directly to the penstock or the
Precise foundation loads can be given by Ham Baker thrust reaction is taken at the top of the penstock
once a penstock has been specified. As a guide to frame.
the foundation loads to be expected, the following The normal operating force of the penstock P can be
formulae can be used. taken as first approximation as
A penstock exerts two types of load on the civil P = 0.5F kN where F is defined above
engineering structure.
This force acts vertically and can be up or down. For
Hydrostatic example the 1.5 metre square door with a head at
Operating the centre of the door of 6 metres considered above
will have an operating force
Note on heads
Heads for penstocks are specified to the invert in BS P = 0.5 x 135 = 67.5kN
7775. These heads can be used conservatively for
In addition to the normal operating condition, a fault
these calculations. More accurately, the head at the
condition Pf (e.g. actuator limit switch failure, or
centre of the door should be used, this is the head
excessive force applied to the operating hand wheel)
at the invert less half the door depth.
should be considered.
1. Hydrostatic Force Pf = 2FkN where F is defined above
The hydrostatic load F is the force of the water
against the penstock door, which will be transferred The operator generates a torque, but the forces
to the civil engineering structure by the penstock associated with this can be neglected for a first
frame. This force acts horizontally. approximation.

The force F is given by (approximately) The weight of the penstock is usually secondary
to the operating force, except for low head
F = 10HA where F is in units of kN applications.

H is the maximum differential head at the centre

of the door metres. This should be the worst case
which could occur. Spindle Diameter
This is determined by many factors, included in
A is the door area in square metres
these are
For example a 1.5 metre square door with a head at The spindle should not fail due to yield or
the centre of the door of 6 metres will experience a
buckling during normal operation.
hydrostatic force of
The spindle should not fail due to yielding under
F = 10 x 6 x 1.52 that is F = 135 kN the worst fault condition.

2. Operating Force The slenderness ratio of the spindle should be

less than 250 or 200 if specified. The slenderness
This is the force required to open and close the
ratio is the length of a spindle section between
penstock door. The civil engineering structure will
guides divided by a quarter of the spindle
experience this load where the penstock operating
diameter.
device is connected to the civil engineering structure
and the penstock frame is connected to the civil The spindle should be self-sustaining (that is the
engineering structure. weight of the penstock door should not back-
drive the spindle through its power screw.

46
 11

Handwheel and Tee International Standards

Key Effort BS EN ISO 9001 : 2000

Quality Management
System :
The efforts considered below are for normal
operation of the penstock against the specified Requirements.
heads. For a manually operated penstock the
handwheel effort is limited to 250 N (55 lbf) as a BS EN 1092-2 : 1997 Flanges and their joints;
single pull on the rim unless otherwise specified. Circular flanges for
pipes, valves, fittings
A Tee Key is usually 500mm across the handle and accessories; PN
and has a push/pull effort limited to 125N thus designated; Cast Iron
generating a torque of 62.5 Nm. Flanges.

BS EN 1561 : 1997 Founding Grey Cast

Manual Operation of Irons.

Electric Actuators BS EN 1982 : 1999

Copper and Copper
Alloys : Ingots and
Where a handwheel is fitted to an electric actuator Castings.
as an auxiliary method of operation, the handwheel
effort is limited to 250N if this is reasonable. BS 7775 : 1995 Specification for
Although the handwheel effort can be limited to penstocks.
250N in most cases, this increases the complexity of
BS EN 10025 : 1993 Hot rolled products of non-
the penstock drive.
alloy structured steels.
For larger penstocks (above about 2000mm square) Technical delivery
manual operation of the actuator for a full stroke conditions.
of the door is not practicable due to the excessive
BS EN 12167 : 1998 Copper and Copper Alloys :
number of turns required. If the penstock must be
Profiles and rectangular
operable in the case of electrical failure, provision
bar for general purposes.
can be made for an auxiliary power device such as a
mobile internal combustion engine power pack. AWWA C501-92 Standard for Cast Iron
sluice gates.

Special designs for non-standard sizes and high

heads are available in

CAST IRON PLASTIGATE STAINLESS STEEL

47
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 nonferrous 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

48
 13

Selection Floor pillar

with handwheel
and rising Hydraulic or
Remote operation extension spindle
with/without
pneumatic linear
actuator
protection tube
Thrust remote from frame
Rising extension systems Floor pillar with Floor pillar with
Floor pillar with
electric actuator bevel gearbox
handwheel and rising
and rising and rising
extension spindle on wall
extension spindle extension spindle
bracket with/without
with protection with/without
protection tube
tube protection tube

wall/coping

Rising spindles are connected Operating spindle

to the penstock door via the Spindle coupling

door nut and work through
a revolving non-ferrous nut
located in the operating gear. Spindle Guide

The screw thread at the top

of the spindle is generally
not immersed and is readily
accessible for lubrication.
Door Guide

Half Frame
Used where thrust reaction is
Door nut
accommodated at a point other
than the top of the frame.

Wedges

Door

Fastrack Penstocks
Fastrack Penstocks is a quick and easy way to buy ranges of penstocks and flap valves. A dedicated
penstocks and flap valves for urgent situations, Fastrack system and sales support team is also in
which require delivery within days rather than place to ensure high levels of customer service and
weeks. Most penstocks can be dispatched within 24 fast, efficient delivery of proven quality products.
hours of order receipt.*
Call us today and ask for Fastrack Penstocks.
Ham Baker have made a firm commitment to
providing customers with complete solutions, by
investing in large stock levels of popular standard *Subject to credit status.

49
Services 14
Installation, Maintenance and Refurbishment of all We have products still in practical working order
makes and models of flow control equipment after over 100 years of continuous service, as well
as an archive of project designs and records from
Safeguard your capital investment
the very earliest days of the Company; all of which
Reduce your overall operating costs means that we are able to supply the correct spares
Maintain the performance of your capital and services to equipment of all ages.
equipment Our staff are all trained to the highest level, with
Improve your planning and financial control all relevant certification, and all of our services
are covered by our BS EN ISO 9001:2008 quality
We offer a full installation and commissioning
certification.
service to ensure that all installations are highly
accurate and free from distortions. This allows
our customers to experience the true durability,
Refurbishment
strength, and long-term performance of our Site Surveys To ensure we specify the most
products. appropriate and cost effective refurbishment of
existing equipment. Refurbishment We have an
Installation extensive archive of information going back over
many years so we can ensure that all refurbishment
Site Surveys To provide accurate specification of
of flow control equipment is carried out correctly
the most appropriate and cost effective equipment.
using OEM parts.
Installation and Commissioning Ensure the Project Management Full project management
correct installation and commissioning of all flow from specification to commissioning of refurbished
control products including: equipment. Ancillary Equipment The mechanical
refurbishment of ancillary equipment on treatment
Penstocks
plants and other sites.
Stoplogs
Management Full project management from Spares
specification to commissioning.
Fastrack A range of standard spares for an
Site Supervision Worldwide supervision of the emergency breakdown despatched within 48 hours.
clients own labour to ensure correct installation of
equipment. HB Certified Quality spares manufactured under
our BS EN ISO 9001:2008 system to guarantee
Maintenance the continued long-term performance of your
equipment. Using our project records which go back
Risk Assessment Ensure compliance with Health over many years we can help to ensure that the
and Safety Legislation and suitable safety measures correct spare is supplied.
are put in place for ongoing maintenance.
From enquiry to commissioning, our comprehensive
Service Programmes A range of service service includes:
programmes designed to suit your specific
New Product Installation
requirements.
On site services.
Breakdown An emergency service to deal with an
unexpected mechanical breakdown of equipment.
Installation and commissioning
Site Survey
Of course, once installed we also understand that
correct maintenance can further optimise our In-house CAD, CNC and fabrication
customers initial investment, minimise their overall ISO9001 2008.
operating costs, and ensure correct long-term
performance; which is why we also offer tailored
maintenance programmes which are designed to
specifically meet our customers operational and
service needs.

50
HAM
BAKER
GROUP

The Ham Baker Group companies

A & J Water Treatment

Adams Hydraulics
Autodam
Coes GRP
FSE Installations
Ham Baker Adams
Ham Baker Control Systems
Ham Baker Pumps
Ham Baker Renewables
Hi-Bar
Industrial Penstocks
Industrial Pipelines
Industrial Valves
Intovalve
IVL Flow Control
Kempster Valves & Engineering
Three Star Environmental

Garner Street Business Park

Garner Street
Etruria
Stoke-on-Trent
ST4 7BH
t: +44 (0) 1782 202300
f: +44 (0) 1782 203649
www.hambakergroup.com

Ham Baker Group is a trading name of F. J. Holdings Ltd

ISO 14064-1
Company Registration No. 4878424
certified
organisation