PENSTOCK

S E R I E S
KT
Q U A L I F I C A T I O N
IKRAM (IQCI)
Product Certification (Penstock)
JPP Approval Letter
ISO 9001 : 2000 Quality
Management Standard
IKRAM (IQCI)
Product Certification Penstock
(Stainless Steel)
P E N S T O C K G E N E R A L I N F O R M AT I O N
KEY TO KT PENSTOCK/SLUICE GATE TERMINOLOGY
Shape : Series:
Sq= Square CI = Cast Iron
R = Rectangular DI = Ductile Iron
C = Circlular SS304 = Stainless Steel 304
SS316 = Stainless Steel 316
MS = Mild Steel
CS = Carbon Steel
Example : R-CI-F/NRS-01/0001
Rectangular Cast Iron Penstock with flat back,
non-rising stem
CATEGORY SERIES DETAIL
STANDARD
SIZE RANGE
(mm)
WATER
HEAD (m)
APPLICATION
S
E
A
T
I
N
G
U
N
S
E
A
T
I
N
G
S
E
W
A
G
E
T
R
E
A
T
M
E
N
T
W
A
T
E
R
T
R
E
A
T
M
E
N
T
F
L
O
O
D
C
O
N
T
R
O
L
I
N
D
U
S
T
R
I
A
L
D
R
A
I
N
A
G
E
H
Y
D
R
O

D
A
M
HEAVY
DUTY
PENSTOCK
FABRICATED
PENSTOCK
Cast Steel
Cast Iron
Ductile Iron
Mild Steel
or
Carbon
Steel
SUS 304
SUS 316
Square
Rectangular
Round
200 x 200 to
2400 x 2400*
From 225 to
2400*
200 to
2400*
15 10
15 10
15 10
10 MS or CS
200 x 200 to
2400 x 2400*
10 10 SS-L
From 200 to
2400*
10 10 SS-M
From 200 to
2400*
10 10 SS-H
From 200 to
2400*
____________ - ___________ - _______________ - _______________
Shape Series Types Series No
Types:
F = Flat Back
S = Spigot
W = Weir Gate
FB = Flush Bottom
RS = Rising Stem
NRS = Non-Rising Stem
EP = Resilient Seated
10
15 10
10 10
STOP LOG
Mild Steel
SUS 304
SUS 316
Mild Steel
SUS 304
SUS 316
A1
STOP GATE
-
-
Up to 5000mm
Up to 2000mm
S E R I E S C I A N D D I H E A V Y D U T Y P E N S T O C K
Frame and Gate
The frame and gate is cast by cast iron and ductile iron. Trisuria provided the standard flat back or spigot(#1)
frame with round or rectangular opening. Invert, weir type and flush bottom also available. Gate is design for
minimum 5 times of safety factor against the structural failure. Frame and gate are apply the high solid epoxy
paint to prevent the corrosion. Penstocks for special applications can also be custom made.
Seating & Wedges
All seating faces is used brass or gunmetal and having the good surface contact to prevent water leakage. Seating
face request the gape between frame and gate less than 0.1mm. The side wedges(#2), top and bottom wedges is
machine to give maximum contact face and wedge action. All the wedges is design for easy adjustable.
Spindle
Trisurias Penstock provided RISING and NON-RISING stem base of the customer requirement. Gunmetal nut
used for better thrust movement. Extension stem is given in various length for various site elevation.
Other Accessories
Stem guide is cast and mounted and adjust on cast bracket. Stem guide spacing shall not exceed and l/r
ratio of 200.
Muff couple is cast by stainless steel and joint by locking stainless steel bolts & nuts to joint between ext.
spindle to penstock and headstock.
Headstock Bracket is cast to mound the headstock to the floor.
General
The Trisuria heavy duty penstock which is constructed of the high duty of
cast iron and ductile iron main structure with stainless steel stem and
fasteners and bronze seals is of high quality finishing and suitable for many
water management related applications. These include projects related to
waterworks, sewage management, water treatment facilities, agricultural
irrigation, hydro electric dams and many more. Design requirement and
leakage rates in accordance with JKR20200-0108-01 specification which
is also meet the requirement of AWWA C-501:1992 and BS 7775:1995.
#1
QUALITY MADE IN MALAYSIA PENSTOCKS OR
SLUICE GATES FOR WATERWORKS, SEWAGE
MANAGEMENT, IRRIGATION AND DAM PROJECTS.
#2
T Y P I C A L P E N S T O C K & A C C E S S O R I E S
No. Identification No. Identification
1 Handwheel 8 Wedge Device
2 Headstock 9 Spi ndl e
3 Indicator 10 Yoke
4 Wall Bracket 11 Thrust Nut
5 Ext. Spindle 12 Gate
6 Stem Guide 13 Frame
7 Muff Coupling
8
11
12
13
10
9
2
1
3
4
6
7
5
P E N S T O C K D I M E N S I O N S
A
B
C
P
S
N/H-V
W
R
K
K
K
F
D
HT
M
N
U
Note : Customization sizes also available up to 2400mm x 2400mm
SIZE
A B C D E F K N/H M N P R S V * T * U Weight
kg
W H
* For Spigot type only
200 200 675 555 320 348 58 58 220 X 2 3 100 58 320 78 22 16 222 42 65
225 225 740 620 345 380 50 50 260 X 2 3 104 61 320 73 22 16 247 42 80
250 250 765 645 375 405 68 68 255 X 2 3 109 60 320 73 22 16 272 42 100
300 300 920 800 435 475 70 70 220 X 3 4 123 65 320 89 25 16 322 44 135
350 350 1020 900 490 520 98 98 235 X 3 4 140 66 320 92 25 19 374 44 155
400 400 1140 1020 545 585 98 98 275 X 3 4 139 82 320 104 28 19 424 45 186
450 450 1225 1105 590 625 103 103 300 X 3 4 143 68 320 110 28 19 474 45 240
500 500 1360 1235 650 695 98 98 260 X 4 5 144 66 320 105 32 19 524 47 330
600 600 1587 1462 775 825 81 81 325 X 4 5 165 81 400 127 35 24 626 49 445
700 700 1805 1680 870 915 128 128 285 X 5 6 170 97 400 130 35 24 726 52 515
800 800 2007 1872 990 1044 124 124 325 X 5 6 186 90 400 137 38 24 828 54 605
900 900 2211 2076 1090 1145 163 163 350 X 5 6 185 87 400 137 38 24 928 57 1020
1000 1000 2425 2290 1185 1245 170 170 390 X 5 6 240 102 500 181 41 24 1030 59 1190
1100 1100 2640 2505 1305 1362 173 173 360 X 6 7 230 107 500 179 41 24 1130 61 1300
1200 1200 2880 2720 1400 1468 160 160 400 X 6 7 255 108 500 198 45 24 1230 63 1450
1300 1300 2921 2761 1490 1540 156 156 350 X 7 8 265 107 500 206 45 28 1332 65 1780
1400 1400 3280 3120 1605 1690 160 160 350 X 8 9 280 103 500 216 50 28 1432 67 2100
1500 1500 3480 3320 1730 1800 180 180 370 X 8 9 295 108 500 230 50 28 1534 69 2500
1600 1600 3716 3556 1810 1865 158 158 360 X 9 10 310 112 500 245 55 28 1634 71 2950
1700 1700 3916 3756 1910 1971 178 178 340 X 10 11 320 112 500 245 55 28 1736 73 3300
1800 1800 4116 3956 2015 2076 178 178 360 X 10 11 320 112 500 247 55 28 1836 75 3700
1900 1900 4326 4166 2120 2180 158 158 350 X 11 12 320 112 500 257 55 31 1938 77 4100
2000 2000 4526 4366 2220 2280 148 148 370 X 11 12 320 112 500 257 55 31 2038 79 4500
K
K
WE I R G AT E D I ME N S I O N S
225 225 550 430 345 380 50 100 280 X 1 2 100 100 320 73 22 16 70
250 250 582 462 375 405 68 114 280 X 1 2 105 100 320 73 22 16 90
300 300 655 535 435 475 70 165 300 X 1 2 118 100 320 89 25 16 120
350 350 726 606 490 520 98 68 222 X 2 3 122 100 320 87 25 19 140
400 400 800 680 545 585 98 112 235 X 2 3 135 100 320 105 28 19 162
450 450 883 763 590 625 103 100 280 X 2 3 135 110 320 103 28 19 210
500 500 960 835 650 695 98 137 300 X 2 3 139 110 320 114 32 19 276
600 600 1120 995 775 825 81 74 280 X 3 4 160 125 400 127 35 24 395
700 700 1265 1140 870 915 128 142 290 X 3 4 165 125 400 130 35 24 462
800 800 1435 1300 990 1044 124 126 350 X 3 4 180 140 400 137 38 24 536
900 900 1580 1445 1090 1145 163 122 290 X 4 5 180 140 400 137 38 24 905
1000 1000 1735 1600 1185 1245 170 110 330 X 4 5 225 150 500 181 41 24 1060
1100 1100 1855 1720 1305 1362 173 147 350 X 4 5 225 150 500 179 41 24 1145
1200 1200 2010 1850 1400 1468 160 140 310 X 5 6 238 150 500 198 45 24 1286
1300 1300 2140 1980 1490 1540 156 124 340 X 5 6 265 150 500 206 45 28 1582
1400 1400 2290 2130 1605 1690 160 220 350 X 5 6 275 160 500 216 50 28 1840
1500 1500 2420 2260 1730 1800 180 160 320 X 6 7 285 160 500 230 50 28 2200
1600 1600 2570 2410 1810 1865 158 152 350 X 6 7 304 170 500 245 55 28 2585
1700 1700 2710 2550 1910 1971 178 152 370 X 6 7 310 170 500 245 55 28 2900
1800 1800 2860 2700 2015 2076 178 177 335 X 7 8 315 180 500 247 55 28 3215
1900 1900 3000 2840 2120 2180 158 197 355 X 7 8 325 180 500 257 55 31 3510
2000 2000 3160 3000 2220 2280 148 192 380 X 7 8 330 200 500 257 55 31 3820
SIZE
A B C D E F K N/H M N P R S V Weight
kg
W H
Note : Customization sizes also available up to 2400mm x 2400mm
P
S
E
K
K
K
B
A
W
C
D
F
M
H
N
R
T Y P E O F C A S T I R O N & D U C T I L E I R O N
P E N S T O C K / S L U I C E G AT E
This is the most popular heavy duty type of penstock used in wide variety
of water work application as water treatment project and flood control
project.
Trisuria has provides penstock which casting with cast iron, ductile iron
and cast steel design under BS7775:95 specification. This type of
penstock can be used in ON seating and OFF seating of standard 6.0m
OFF seating head with rising and non-rising stem optional.
The gate shapes include square, rectangular and circular opening. Those
shapes of opening also available in spigot type of penstock. Spigot back
of penstock is design for easy install and preventing the misalign of the
aperture fitting.
The frame and gate is painted by high solid epoxy paint with good
corrosive resistance behaviors. The corrosion resistant adjustable side
wedges and top/bottom wedges created the good sealing surface for
long life used. All the assembly hardware is of corrosion resistant material.
Weir Gate / Down open Penstock
Trisuria s weir gates are cast iron / ductile iron (Heavy duty) and
fabrication (Medium duty) types. The feature of the weir gate is to control
the head level on some other level controlling. This also can be used for
water discharging. The weir gate also available in square, rectangular
and circular aperture.
Casting type of weir gate having the good design head with leakage
acceptable to BS7775:95 Specification. As the same with penstock, weir
gate also available in ON seating and OFF seating seating head with
rising and non-rising stem optional.
The gate shapes include square, rectangular and circular opening. Those
shapes of opening also available in spigot type of penstock. All the sealing
surface and the assembly hardware is used corrosion resistant material.
Channel Penstock
Trisurias channel penstock are cast iron / ductile iron casting material.
This penstock is mount between the two side channel glove without
mounting wall and used to control water flow direction or junction control.
It allow the overflow on top of the penstock. The Channel penstock
available in square and rectangular only.
The channel penstock havi ng the good desi gn head wi th l eakage
acceptable to BS7775:95 specification. Channel penstock only application
in ON seating only with rising and non-rising stem optional. All the sealing
surface and the assembly hardware is used corrosion resistant material.
Standard Flat Back
Spigot Back
Weir Gate
STANDARD FLAT BACK PENSTOCK & SPIGOT TYPE
Channel Penstock
T Y P E O F C A S T I R O N & D U C T I L E I R O N
P E N S T O C K / S L U I C E G AT E
FLOW
FLOW
Rubbish Blocking Problem
Solution of Flash Bottom Penstock
EPDM Seal
Gate
Frame
Grout Fill After Install
B
A
C
RECOMMENDED INSTALLATION FOR
FLUSHBOTTOM PENSTOCK
Gate Diameter / mm A B C
225 - 600
700 - 1000
1100 - 1600
1700 - 2000
360
500
600
680
220 80
250 90
280 110
300 140
Non Fully Discharge Problem
FLUSH BOTTOM PENSTOCK
Flush bottom penstock design is used wherever a
continuous smooth opening is desirable. Typical
i nstal l ati ons i ncl ude wastewater setti ng tanks,
aeration tanks, and sedimentation and flocculation
basins.
The advantages of this penstock is to prevent the
rubbish stay or block at the slot between the bottom
of the penstock and the mounted wall. This is used
for preventing the gate operation stuck and water
leakage cause by the stuck at the bottom gape.
This penstock is providing a flat plane across the
bottom of frame while the gate is open by using the
EPDM seal. The seal is mounted to the frame with
stronger support by corrosion resistant fasteners.
The EPDM seal is design for easy replaceable without
dismantle the frame. Bottom wedges are not used
with a flushbottom closure.
FLOW
ADVANTAGES:
Lowest leakage requirement up to 100 times better
than BS 7775:95 standard for bronze seated
penstock.
6.0m On/Off seating head and more.
Come with flush bottom seal.
Resistant to thermal and general chemical attach.
FEATURES:
High resistant resilient seated (EPDM) penstock generally
used when lowest leakage is required. Good performance
at 10.0m head water. Coupl e wi th pl asti c for better
operation movement.
PERFORMANCE :
This penstock having the lowest leakage rate for off-
seating head close to 0 leakage for 10.0m head of water
pressure. This is excellence Perfomance Penstock and
having lowest leakage rate much more better than BS
7775:95 standard requirement. Trisuria penstock series
has been design and tested to withstand both on-seating
and off-seating heads for standard 6.0m head.
APPLICATION :
Trisuria penstock EP series with resilient seats is having
the same safety factor with typical heavy duty penstock.
The only different is replace the bronze seal to EPDM seal
and plastic seal to achieve the lowest leakage requirement.
The tapered design at sealing surface to provide additional
wedging action and to minimize the wear of the seal.
Frame
Gate Seat
(EPDM)
Gate
Frame Seat
(PVC)
Flushbottom
MODEL EP
RESILIENT SEATED PENSTOCK
T Y P E O F C A S T I R O N &
D U C T I L E I R O N P E N S T O C K / S L U I C E G AT E
Frame Seat
(PVC)
Frame
Gate Seat
(EPDM)
Gate
S E R I E S S S 3 0 4 A N D S S 3 1 6 H E A V Y &
ME D I U M D U T Y P E N S T O C K
General
The Trisuria also provide the stainless steel penstock/slide gate in
heavy duty and medium duty application. Stainless steel is design
for non-corrosive water treatment facilities, sewage treatment
plants, water diversion projects, drainage and many other fluid
control installations. Generally, stainless steel penstock is design
for medium water head and zero (0) leakage rate performance.
The EPDM resilient rubber seals provide the highest leakage
resistance with long life duty cycle. Although, stainless steel
penstock having the low head limitation, Trisuria Heavy duty
stainless steel series (SS-H) can double up the head level with higher
leakage resistance as well. The structural design and leakage
requirement is accordance with JKR20200-0108-01 specification
which is also meet the requirement of AWWA C-501:1992 and BS
7775:1995.
Frame and Gate
The frame and gate is fabricated by either SS304 or SS316. Trisuria
provided the standard flat back or spigot frame with round or
rectangular opening. Gate is design for minimum 5 times of safety
factor again the structural failure. The reinforced with structural
shapes welded to the plate to prevent bending. The gate and the
seating surface having the good flatness for better performance.
Penstocks for special applications can also be custom made.
Seating
All seating faces is seal by EPDM rubber. This is the best solution
for lowest leakage requirement. EPDM having the good resistance
for chemical reaction and high temperature. Double sided seating
surface is for maximum leakage resistance.
Spindle
Trisurias Penstock provided stainless steel RISING stem with the
extension optional. Gunmetal nut used for better thrust movement.
Other Accessories
Stem guide & headstock bracket is fabricated by SS304 or SS316
and adjustable. The Stem guide spacing shall not exceed and l/r
ratio of 200.
Muff couple is cast by stainless steel and joint by locking stainless
steel bolts & nuts to joint between ext. spindle to penstock and
headstock.
Standard
Heavy Duty
MAT E R I A L S P E C I F I C A T I O N F O R P E N S T O C K
TYPES
PART
Seating
Faces
Gate
Cast Iron
BS 1452 (G220)
Ductile Iron
BS 2789 (G500/7)
SUS 304 & SUS 316
BS 970
Carbon steel
BS 4, 449, 1449
Frame
Cast Iron
BS 1452 (G220)
SUS 304 & SUS 316
BS 970
Carbon steel
BS 4, 449, 1449
Brass or Gunmetal
BS 1400 (LG2)
BS 2874 (PB 102)
Brass or Gunmetal
BS 1400 (LG2)
BS 2874 (PB 102)
EPDM
MS 672:99
EPDM
MS 672:99
EPDM/PVC EPDM/PVC - -
Spindle & Ext.
stem
SUS 304 & SUS 316
BS 970
SUS 304 & SUS 316
BS 970
SUS 304 & SUS 316
BS 970
SUS 304 & SUS 316
BS 970
Nut
Gunmetal
BS 1400 (LG2)
Gunmetal
BS 1400 (LG2)
Gunmetal
BS 1400 (LG2)
Gunmetal
BS 1400 (LG2)
Handwheel
Cast Iron
BS 1452 (G220)
Cast Iron
BS 1452 (G220)
Cast Iron
BS 1452 (G220)
Carbon Steel
BS 4, 449, 1449
Headstock
Cast Iron
BS 1452 (G220)
Cast Iron
BS 1452 (G220)
Cast Iron
BS 1452 (G220)
Carbon Steel
BS 4, 449, 1449
Muff Coupling
SUS 304 & SUS 316
BS 970
SUS 304 & SUS 316
BS 970
SUS 304 & SUS 316
BS 970
SUS 304
BS 970
Headstock
Bracket
Cast Iron
BS 1452 (G220)
Cast Iron
BS 1452 (G220)
SUS 304 & SUS 316
BS 970
Carbon steel
BS 4, 449, 1449
Stem Guide
Cast Iron
BS 1452 (G220)
Cast Iron
BS 1452 (G220)
SUS 304 & SUS 316
BS 970
Carbon steel
BS 4, 449, 1449
Wedges
Gunmetal
BS 1400 (LG2)
Gunmetal
BS 1400 (LG2)
N/A N/A
Fasteners
SUS 304 & SUS 316
BS 970
SUS 304 & SUS 316
BS 970
SUS 304 & SUS 316
BS 970
SUS 304
BS 970
CI Series DI Series SS Series CS Series
Ductile Iron
BS 2789 (G500/7)
Yield Strength
(N/mm
2
)
Tensile Strength (N/
mm
2
)
Elongation (%)
Hardness (HB)
Density (kg/m
3
)
Corrosion Resistance
240
SUS 316
510
40
183
7800
10
350
Carbon
Steel
650
20
190-210
7800
5
230
SUS 304
490
40
183
7800
10
320
Ductile Iron
500
7
170-241
7080
3
50
Cast Iron
220
1-2
210 max
7200
3
Material Property
Headstocks cone i s a vari ety of formats. Dependi ng on the end-users
r equi r ement , speci al cust om-desi gned headst ocks or gat e openi ng
mechani sms can al so be manuf act ur ed. Tri suri a has a st andar d
headstock range to choose from:
Electric motorised
Pneumatically/hydraulically activated
Manual geared
Direct manual with indicator
Direct manual without indicator
El ect ri c
motori sed
headstock
Manual gearbox
headstock
Direct manual
headstock
with indicator
Pneumati cal l y/
hydraul i cal l y
acti vated
headstock
Direct manual
headstock
without indicator
H E A D S T O C K O P T I O N S
O T H E R A C C E S S O R I E S
HEADSTOCK
Cast Iron rigid body and handwheel for
purposes.
Sufficient operation height for good torque
applies for penstock operating
Accurately machined bronze nut with
RISING and NON-RISING feature
Heavy duty pedestals or base plate with
solid base support to prevent twisting and
sheari ng
2 model headstock and handwheel for most
of penstock operation
STEM GUIDES
Cast Iron or Stainless Steel 304 or 316
High Solid Epoxy Painting
Reach adjustable
For Stems sized to 2
Stem guide recommended spacing is
showing as table below.
MUFF COUPLING
Stainless Steel 304 or 316 casting
Stainless Steel bolted locked connection
Used while the headstock and ext. stem is
required.
HEADSTOCK BRACKET MOUNTING
Heavy cast iron structural
Mounted headstock to the floor for most
actuator application
Slotting hole for installation adjustable
function
Sufficient strength for forces during
penstock operating.
19 950
22 1100
1 25 1250
1 28 1400
1 32 1600
1 38 1900
1 41 2050
1 44 2200
2 50 2500
2 53 2650
2 63 3150
Spacing Between
Stem Guide/mm
Spindle Diameter
(mm)
in mm
7
8
1
8
5
8
1
8
P E N S T O C K O P E R AT I O N
TYPE OF PENSTOCKS OPERATIONS
TYPE OF PENSTOCKS MOUNTED METHOD
Wall mounted for
Flat Back Type
Wall mounted for
Spigot Type
Flash Bottom
mounted method
Thimble or Pipe
Flanging Mounted
method.
On Seating Pressure
Pressure forcing the
door onto the frame
Off Seating Pressure
Pressure forcing the
door away from the
frame
FLOW FLOW
On Off Seating Pressure
Pressure action on both sides
FLOW
FLOW
OT H E R WAT E R C O N T R O L G AT E
KT MS Penstock (Intake Gate)
Design Feature
KT Heavy duty slide gate are manufactured for a wide
variety of application including:
Sewage Treatment Plant
Water Treatment Facilities
Water diversion project
Drainage and flood control
Water level and spillway control for reservoir
and canal system.
KT Heavy duty slide gate are engineered for excellent sealing water in any large opening
and also for controlling.
KT Heavy Slide Gate available in either overflow or breast wall types. It is designed to be
engineered to take high water pressure from one or both slides of the gate.
The structural is designed and calculated such the way to prevent any damage possibility
cause by high dynamic hydrostatic force.
Advantages:
Corrosion Resistant
Optimum Sealing Against Leakage
Rugged Heavy Duty Design.
Less maintenance required
Long life in Non-Corrosive atmosphere
Available for large aperture size.
The adjustable side wedges design is useful when any misalignment of the gate during
installation.
The installing of EPDM seal is special design for easy replacement. Its heavy duty P or T
types of seal design which apply to high lifetime application.
Twin shaft lifting spindle is available for largest width gate to suit for smooth lifting requirement.
OT H E R WAT E R C O N T R O L G AT E
DESCRIPTIONS
KT Stop Logs are designed to control flows in open channel.
Side and bottom seals are generally incorporated into the each
logs to provide for low leakage requirements.
Clamping bar also should be attached with the EPDM seals as a
guide block.
Stop logs lifting device available for ease of handling and water
level can be controlled by adding to, or deducting from the
number of logs used.
Basically, logs are placed and removed by a log lifting device
and overhead crane.
APPLICATIONS
KT Stop Logs are designed for the general uses in waterworks.
sewage treatment
water treatment
flood control
irrigation
industrial
hydro power
KT STOP GATE
DESCRIPTIONS
KT Stop Gate is simple manual gate suitable used to minimize the water flow in open channel.
Each gate is molded to the exact dimension specified regarding to the customer requirement.
weather resistant
no maintenance
Low leakage
APPLICATIONS
KT Stop Gate is suitable used in:
sewage treatment
water treatment
Irrigation
Industrial
SPECIFICATIONS
Part Material
Frame and Slides Mild Steel, Stainless Steel (SUS304),
Aluminium alloy
Seal EPDM seals
Guide Mild Steel, Stainless Steel (SUS 304), Al
External Handle SUS 304, SUS 316
Fasteners Steel or Stainless Steel
KT STOP LOGS
Part Material
Frame and Log Mild Steel, Stainless Steel (SUS 304, SUS 316)
Seal EPDM seals
Guide Mild Steel, Stainless Steel (SUS 304, SUS 316)
Lifting Device Stainless Steel or Mild Steel
Fasteners SUS 304, SUS 316
SPECIFICATIONS
P E N S T O C K I N S T A L L AT I O N M E T H O D
Penstock Receiving
Check all parts of penstock and the accessories immediately after receive from the delivery.
Penstock is a precision machinery items that should be handled accordingly. Those improper storage
and handling can cause the poor performance of penstock.
During penstock handling, penstock must support by full length to avoid the structural twisting.
Penstock must store in clean and dry environment to prevent distortion.
Cover all equipment to protect machined surface. Do not stack equipment without protection.
DO NOT DISASSEMBLY the gate during installation. Do not paint bronze and stainless steel surface.
Existing Headwall Installation Method
Box out the concrete foundation bolt and spigot end where applicable on request.
Mark the center line of the aperture onto the template, after that mark the frame bolt hole and then
drill the hole from where its mark.
Then, fix the J bolt to the drilling position and then mount the template into the position by aligning
the vertical and horizontal leveling.
When the template position is correct, fill the box out pocket with non shrink grout until it fully cure.
Steel packing
pi eces
Box out for
foundation
bolts
Recess for
spi got
When the grout i s ful l y cure, remove the
template and penstock can be installed. Before
mounting, a steel packing piece insert to all the
bolt. These space allowance is for sealing
purpose. When tightening of the bolts and nuts,
special care to avoid over tightening of the nuts
and best if apply even tighten force.
After penstocks has been mounted, check the
alignment before sealing penstock wall gap.
Check the door and frame faces with feeler
gauge. Double check the bolts and nuts to make
sure that the tightening is not over tight causing
strain to the penstock frame. Finally, penstock
frame gap can be sealed after finish the above
checking procedurals. If all the recommended
installation method are following, the penstock
should be operate correctly without leakage
problems.
P E N S T O C K I N S T A L L AT I O N M E T H O D
New Headwall Installation Method
Secure all anchor bolts in proper position in
the forms, check the size, projection, and
alignments conform to requirements shown
in our illustration. Do not mount penstock
to the misaligned bolts.
Each bolt has been provided with 2 nuts for
proper mounti ng of penstock. In
setting the forms, provide a recess around
the perimeter of the gate. Allowing easy
adjustment of the back nut and make sure
the sufficient grout space must be left for
adjustment of the back nut.
After concrete has been poured and form has
been stripped, place one nut on the anchor
bol t. Pl ace the compl etel y assembl y
penstock into position carefully. Place the
second nut on the anchor bolt and bring bolt
nuts i nto f i nger-ti ght contact wi th the
penstocks frame, aligning it as necessary.
Figure #1.
Check the cl earance between gate and
frame by the 0.1mm feeler gauge. If find out
some gaps, check to see if penstock has
been warped during install. Adjust the nuts
to bring the penstock into flatness.
Figure #2.
After the penstock is properly set, grout in
the space between frame and headwal l
usi ng a non-shri nk materi al . Fi gure #3.
Check for voids carefully.
Ti ghten al l nuts uni forml y. Do not over
tighten cause the uneven surface. Penstock
now is ready for initial operation. Figure #4.
Concrete
Frame
Figure #1
Nut
J-Bol t
Grout
Figure #2
Figure #3
Figure #4
P E N S T O C K I N S T A L L AT I O N M E T H O D
Procedure for Installation On Wall Thimble or Pipe Flange.
Place the thimble correctly in position. Plumb is used to align the top/bottom center line.
Mark the center line and install the thimble either flush or slightly projecting from the wall
Thimble need support to prevent warpage during concrete pouring. Do not mount penstock
when thimble are not cast with concrete.
All tap hole must be plug by mild steel or other plug before pouring concrete.
Double check on the vertical and perpendicular alignment of thimble before casting concrete.
Gate frame need to clean before installing. For better sealing, a thin coat of mastic or
rubber compound is apply on the front face of the thimble.
After all the procedurals complete, mount the penstock to the thimble. Tighten the nuts on
the stud or screw uniformly until metal to metal contact is made. After checking the clearance
with 0.1mm feeler gauge, the penstock is ready for operation.
Procedure for Installation Stems and Stem Guide
After the installation of penstock is complete, install the stem to the penstock and thread
the stem into thrust nut in the nut pocket on cover until flush with bottom of nut.
Tighten the set screws to lock the stem for the rising stem.
Mount the stem guides from bottom up as stem is install. In this moment, do not tighten
stem guide assembly bolts.
Tighten the stem guide bracket to the wall with the spacing provide.
Install the stem couplings as required, tighten all the set screws of the stem couplings.
Make sure not to bend or damage the stem and threads during installation.
Procedure for Installation Headstock Mounting Bracket:
Headstock bracket mount by the anchor bolts to the wall. Check the top surface and make
sure is align perpendicularly with the stem is pass through the center of the stem slot.
After the headstock bracket is install completely, put on the headstock on top of the bracket
and mount with four bolts and nuts.
Make sure the headstock is in proper alignment all the time.
After install the headstock, apply the tension to the stem by lifting the penstock. Align the
stem guides and tighten the stem guide assembly bolts.
Cleaning and Adjusting
After installation of stem, stem guide, and headstock, move the gate to fully open position.
Clear all the dirt, paint, etc. off of seating and wedging surfaces, and clean loose concrete
and grout from top of gate.
Grease seating and wedging surfaces with water resistant grease. Close the gate and the
penstock is ready for operation.
E N G I N E E R I N G D A T A
1 0.305 0.434 2.989 0.030 21 6.401 9.104 62.770 0.628
2 0.610 0.867 5.978 0.060 22 6.706 9.538 65.760 0.658
3 0.914 1.301 8.967 0.090 23 7.010 9.971 68.749 0.687
4 1.219 1.734 11.956 0.120 24 7.315 10.405 71.738 0.717
5 1.524 2.168 14.945 0.149 25 7.620 10.838 74.727 0.747
6 1.829 2.601 17.934 0.179 26 7.925 11.272 77.716 0.777
7 2.134 3.035 20.923 0.209 27 8.230 11.705 80.705 0.807
8 2.438 3.468 23.913 0.239 28 8.534 12.139 83.694 0.837
9 2.743 3.902 26.902 0.269 29 8.839 12.572 86.683 0.867
10 3.048 4.335 29.891 0.299 30 9.144 13.006 89.672 0.897
11 3.353 4.769 32.880 0.329 31 9.449 13.439 92.661 0.927
12 3.658 5.202 35.869 0.359 32 9.754 13.873 95.650 0.957
13 3.962 5.636 38.858 0.389 33 10.058 14.306 98.639 0.986
14 4.267 6.069 41.847 0.418 34 10.363 14.740 101.628 1.016
15 4.572 6.503 44.836 0.448 35 10.668 15.173 104.617 1.046
16 4.877 6.936 47.825 0.478 36 10.973 15.607 107.607 1.076
17 5.182 7.370 50.814 0.508 37 11.278 16.041 110.596 1.106
18 5.486 7.804 53.803 0.538 38 11.582 16.474 113.585 1.136
19 5.791 8.237 56.792 0.568 39 11.887 16.908 116.574 1.166
20 6.096 8.671 59.781 0.598 40 12.192 17.341 119.563 1.196
Head
in feet
Head
in meter
Pressure
in PSI
Pressure
in kPa
Pressure
in Bar
Pressure Conversion Table
Head
in feet
Head
in meter
Pressure
in PSI
Pressure
in kPa
Pressure
in Bar
Discharge vs. Area of opening by head
60
50
40
30
20
10
0
0
D
i
s
c
h
a
r
g
e

(
m

/
s
)
Area of gate opening (m)
Water Discharge = 0.7 x Area x 2xgxHead
Head 10.0m
Head 9.0m
Head 7.0m
Head 6.0m
Head 5.0m
Head 4.0m
Head 3.0m
Head 2.0m
Head 1.0m
Head 0.75m
Head 0.5m
Head 0.25m
Head 8.0m
1 3 4 5 0.5 1.5 2 2.5 3.5 4.5 5.5 6
A) Penstock Aperture Size:
D) Penstock Design Requirement:
Headstock mounted
on slab
Headstock mounted
on Bracket
Other:_________________
E) Miscellaneous:
PENSTOCK / SLUICE GATE ENQUIRY FORM
E. Actuator
Material:
Cast Iron
Ductile Iron
SS 304
SS 316
Carbon Steel
Type:
Flat back
Spigot
Flush Bottom
Weir Type
Model EP
F) Customer Detail:
Gate Mounted To:
Concrete Wall Wall Thimble Existing Structural Mounted at Floor Level Other :_____________
Quantity: Quantity:
Design Head :______________ Seating ______________Unseating
Company :
Person to contact :
Tel :
Fax :
Spindle Type:
Rising Stem
Non-Rising Stem
Operating Floor Elevation
Water Level Seating Side
Water Level Unseating
Side
Operating Seating Head
Operating
Unseating Head
Invert Elevation
Manual with
gearbox
Manual with
indicator
Pneumatic
Hydraulic
Manual without
indicator
C) Headstock Mounting:
B) Headstock Option:
Kejuruteraan Trisuria Sdn. Bhd. (192941-P)
No. 4, Jalan Perusahaan Utama, Taman Industri Selesa Jaya,
Off Jalan Balakong, 43300 Selangor Darul Ehsan, Malaysia.
Tel : +6 (03) 8961 8388 Fax : +6 (03) 8961 3688
e-mail: marketing@trisuria.com
Website: www.trisuria.com