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Introduction
IVC, a trusted name in the water industry in India since 1966, owes its origin to Glenfield & Kennedy, a Scottish company of repute. Top class design, robust and reliable, with emphasis on tailor made products to customers requirement, has yielded a clientele of repute, both within and outside India. Besides water supply and sewage applications, IVC valves and sluices are working in Thermal / Atomic power stations, steel plants, process industries within and outside the country (through prime contractors) - notably in Hongkong, Australia, Sri Lanka, Egypt, Nigeria, Libya, Malawi, Zambia, Kenya Tanzania, Iran and Iraq. IVC valves have also been supplied to many World Bank/IDA aided projects within India. IVC products are approved by leading consultants within India - EIL (Engineers India Ltd.), TCE (Tata Consulting Engineers), Dastur & Co, MECON (Metallurgical & Engineering Consultants of India Ltd.), DCL (Development consultants Limited), to name a few.

SLUICE / (SLIDE) GATES

Types Spigot back Flange back (wall thimble mounted) Flat back (channel mounted) Applications Water Waste Water Effluent Materials of Construction Cast iron Mild steel Stainless steel Aluminium Plastic

Principal Types These are essentially two (refer GA Drawing at the end) besides, for open channel application, mostly in grey cast iron; the main difference being in the frame. The spigot back The spigot is placed inside the aperture in the wall, the rear face of frame flush with it and held thereon by anchor bolts. The flange back with wall thimble Here an F shaped wall thimble is positioned inside the wall aperture, the puddle collar in the thimble grouted in concrete with only the rear unmachined face of flange flush with the wall. The complete gate assembly with the flange back frame, is then fastened onto the wall thimble by stud bolts. The channel mounted (Details at the end) the third type has a flat back (and front too) frame suitable for building into a channel, water depth never exceeding the door height, the opening flush with the invert. Operating conditions Wedging device

This is essential to force the door faces against the seat in frame during final closure, to achieve better sealing. Side Wedges Sluices with seating pressure ordinarily and in smaller sizes (upto 600 sq/round) for even off-seating pressure, require only side wedges.

Top & Bottom Wedges Depending upon size and the extent of off-seating pressure, top wedges and / or bottom wedges are provided by means of individual wedge blocks. Bottom wedges are not provided in flush with invert bottom sluices.

Seat and Door Faces

All four sides metal seated Standard construction involves bronze/brass seat/faces fixed onto a machined surface / recess and pinveted for life with specially designed rivets of same material. These are then machined flat and hand scraped to yield contact all round with no more than 0.1 mm (4 thou) gap.

Three sides metal seated and bottom only rubber This is mainly for flush with invert bottom sluices, the elastomer (EPDM for standard construction) is fitted onto the door bottom.

Guided Travel of Door

In the design involving a guide strip for wedging action, mainly for spigot back sluices, integrally cast snugs on both the sides of door, machined if necessary, are guided throughout their travel inside the recess provided in the left and right extension guides. For wall thimble mounted, flange back sluices, the guide bridge extends to support one half of the door, when fully open. Projection on either side of the door, is machined (tongues) to ensure guided travel inside a machined recess (groove), in both the left and right hand guide bridge.

Operation
Mechanism : The operating mechanism comprising essentially of a handwheel and a threaded nut (together making a kinematic pair with the threaded spindle), with or without a thrust bearing (ball/needle roller) arrangement and/or a gear box (spur/spur-bevel/worm), may be mounted directly on the yoke of the frame or located on a platform above. In addition to a headstock, the latter calls for an extension rod, couplings, guide brackets - their numbers depending upon the height from the invert level to the platform top. Rising /Non-rising spindle While both rising and non-rising spindle sluices can be made, the latter is not recommended unless installation/ site conditions so warrant.

Manual operation

Head stock The enabling factor, for choosing the type, is always ease of operation (effort on handwheel/crank limited to 200 N) Type A for sizes upto 600 Type B - for sizes above 600 and upto 900 Type C for sizes 1000 to 2000 Type D for sizes larger than 2000

Electric Actuator Operation Ideally, the actuator orientation should be such that its drive shaft (hollow when mounted directly on the rising spindle) is vertical (1&2). Where handwheel in the actuator is likely to foul with the rising spindle, a side mounted handhweel in the actuator be chosen (3). Alternatively, the actuator be mounted on the bevel or worm gear box pinion shaft, with the handwheel axis horizontal (4). All head stocks are fitted with a pair of ball / needle roller thrust bearing arrangement to arrest the continuous vertical thrust (in manual operation it is intermittent).

Pneumatic Cylinder Operation

The operating thrust being considerably lower than a gate valve, size for size the pneumatic cylinders are normally small in dia, their length being directly proportional to the height of door or the extent of door travel. For larger sluices they appear slender. The piston rod is required to be coupled with the spindle of sluice gate using a tensional coupling. To accommodate this and for ease of maintenance, a stool with two windows is used. Cushioned end of travel is a standard feature. Other optional fitments that may be provided at an extra cost are: 1)End of travel limit switches 2)FRL kit (filter, regulator, lubricator) 3)Poppet valve with manual override 4)Complete manual override operation.

Accessories

Adjustable spindle guide brackets The bore is tailor made to suit the extension rod dia and is adjustable in X and Y axis; available with a center distance of 150 or 300mm. Couplings Tensional for rising spindle (circular or square, muff type) or torsional (circular or universal type affording upto 15 bend in one plane) for non-rising spindles. Pipe hood for rising spindles - To protect the rising spindle thread from dust, rain. Indicator Traversing type could be provided in the pipe hood made either of mild steel to accommodate the indicator or a poly carbonate enclosed hood to see the extent of opening.

Factory Testing Besides ensuring the material used for each sluice gate conforms to what the customer wants vis--vis standards, each sluice gate, after assembly, is checked/tested for : 1) Major dimensions as per approved general arrangement drawing 2) Seat clearance No-Go with a feeler gauge of 0.1 (4 thou) 3) Movement To demonstrate ease of operation, using the main spindle and operating arrangement (Headstock / Gear box / actuator / Pneumatic Cylinder) with the gate assembly either vertical or in horizontal position 4) Leakage Within permissible limits* as per IS / AWWA standards.

Painting & Despatch Surface preparation clean by shot/ grit blasting or wire brush and grinding Primer Two coats of red oxide / zinc chromate primer Finish paint Two coats of black bituminous paint Alternatively as agreed with the buyer Each door and frame assembly is packed into one timber crate and the rest suitably packed to avoid damage in transit. For export these are put inside boxes made of timber, suitably protected for moisture and termites.

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Installation

A great deal of care is taken during manufacture and assembly to ensure accuracy in mating the faces of door and frame. It is essential therefore that the sluice gates be erected carefully, free from distortion and under no circumstances, the door , wedges, guide strips be dismantled for fixing. This will prevent damage to the faces and distortion. The following guidelines would help: Wall Mounting Sluice Gates (Spigot Back) 1.With each size of sluice gate a drawing depicting block out details for foundation bolts, shall be given, well before delivery of equipment. Box out the concrete leaving pockets in the wall. 2.Make a rigid template marking at least 3 foundation bolt holes besides, one each on extension guide, spaced far apart, adjacent to the aperture. Timber template would do. Drill bolt holes, preferrably tapped holes. 3.Mark horizontal and vertical center lines of the aperture, on the template. Also, denote the wall side and frame side thereon. 4.Fit foundation bolts in the three template holes, ensure bolt projections are square with the template face. 5.Fill the 3 corresponding pockets with stiff non shrink grout. Now place the template with the 3 bolts fixed thereon, flush with the wall at the intended position, use plumb line and the marked center line. Now press the foundation bolts into the grout. Burry as much as is essential leaving the rest protruding outside the template (to allow for thickness of frame, a washer and a nut plus a little extra). Re-check for verticality of template vis--vis intended location, restrain template from moving until grout has cured. 6.Fit remaining foundation bolts to the frame from the wall side and secure with a washer and nuts from the frame side. Remove template when the grout has cured. Insert steel packing pieces (washers) 20 mm thick on the 3 locating bolts and then position the frame using these 3 bolts which are now stiff. The remaining bolts also get located inside pockets awaiting grout.

7.Tighten nut (with a washer) on the 3 locating bolts without imparting undue strain to the frame. Check for plumb and the mating seat faces with a 0.1 mm feeler gauge. Where the gap is more than 0.1 mm, drive a wedge or packing between the frame and the wall. Repeat checking and wedging frequently throughout the installation process and avoid excessive wedging/packing to prevent high contact areas. Proper setting with a gap no more than 0.1 mm

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Installation (contd.) would ensure minimal leakage. 8. Position remaining foundation bolts square in wall pockets with the underside of nut just touching the frame. Shutter up around the frame and spigot ensuring the seat and face settings are not disturbed. 9. Pour or force the fluid grout with pump in stages if necessary, between wall and the frame until all pockets are filled. Care must be taken to ensure there are no gaps around the spigot and between the frame and the wall to prevent leakage through such crevices. 10.The extension guide (left and right) wherever applicable, are to be aligned with the top of frame (to permit uninterrupted movement of door), bolted thereon. Tighten the nuts, to hold the extension guide alongside the vertical wall (use shims/packing where necessary) onto the foundation bolt, grouted in pockets earlier (follow 8 and 9). 11.Allow the grout to cure (at least a week) before tightening each nut attending to opposite nuts in turn. Excessive tightening is not necessary. 12.Clean the sluice gate thoroughly, open fully, apply grease on the screw, wedging device, seat and faces. Close gently. Ensure there are no scratches or damage to the seat and faces otherwise the equipment cannot be expected to operate within the permissible limit of leakage. 13.Follow the same procedure to set guide brackets in wall, the head stock on the floor above and the extension spindle, so that the entire assembly operates smoothly in true alignment, the erected sluice gate acting as the datum and location from which to strike centerline and levels. 14.Follow guidelines including for size of grout bolts, provided along with block out details. Wall Thimble Mounted (Flanged Back) 1. Before proceeding to position the wall thimble in the opening in the wall, ensure all tapped holes for stud bolts on its flange are plugged by plastic or timber pegs to preclude cement concrete getting lodged in these holes. 2. Position the wall thimble against the opening in the wall (look for the top sign) and ease the collar (in the shape of an F or C) into the wall opening, back side of flange resting against the wall. 3. Ensure verticality of the wall thimble flange face using a plumb line vis--vis two distinct marks provided in the middle of the top and bottom member of the wall thimble flange. Serious operational problems may occur if this is not done properly. 4. Prop up and restrain the wall thimble before pouring grout around it. Immediately clean any cement solution that inadvertently comes on to the flange face. Allow the grout to cure (atleast a week). 5. Do not remove the sluice gate from its timber crate until the site is ready for erection. No attempt should be made to remove the door from the frame. These are factory set. Only extension guides are loose pieces, to be erected after the gate has been erected. 6. Remove all plastic / wooden pegs from the stud bolt holes in the wall thimble. Select 3 of them, far apart, around the aperture and fix 3 stud bolts of appropriate length into these. Tighten fully.

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Installation (contd.) 7. Place a rubber gasket on the flange face this will be tricky and will need to be propped up. 8. The sluice gate assembly, lowered from a crane / tripod, is to be positioned in front of the 3 stud bolts in the wall thimble, eased gently in and fastened with a washer and nut each. Affix the remaining stud bolts, tighten all nuts uniformly attending to opposite nuts in turn. 9. Follow No.10,12,13 and 14 for spigot back, in that order.

Component Frame, Door, Extension guide Wall thimble, headstock, guide bracket Seat and face

Material Grey Cast iron Grey Cast iron Bronze Stainless Steel Naval brass

Standard IS 210 Gr FG 200 OR ASTM A126 Class B IS 210 Gr FG 200 OR ASTM A126 Class B IS 318 Gr. LTB-2 OR ASTM B98, Alloy 655 AISI 304 / 316 IS 291 Gr.1,2 EPDM IS 210 Gr FG 200 OR ASTM A126 Class B IS 1865 Gr 500/7 OR BSEN 1563 Gr.500/7 IS 318 Gr. LTB-2 OR ASTM B98, Alloy 655 AISI 304 / 316 IS 2062 / BS 970 EN8 AISI 410/304/316 IS 318 Gr. LTB-2 OR ASTM B584, Alloy 872 AISI 410, 304, 316

Flush bottom seal Guide strips, wedges

Elastomer Grey Cast iron SG Iron/Ductile Iron

Wedge lining

Bronze Stainless Steel

Spindle

Mild steel Stainless steel

Spindle nut Stud for Wall thimble

Bronze Stainless steel

Quality Assurance 1. Sluice gates are manufactured at two of our factories - one near Kolkata and the other at Nasik. 2. Sufficient checks are exercised during raw material procurement, machining, assembly and testing of sluice gates to ensure product reliability. 3. The manufacturing process and quality system is governed by IS: 9001-2000.

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Sluice Gates for open channel flow control One singular property of channel mounted gates is, the level of water / waste water is always less than the door height/ height of channel. Also, as far as practicable, the bottom opening of the gate is flush with the invert, save probably for the width of the metal seat if the entire gate has metal to metal seating. Seating is only on the two vertical sides and the bottom. And there is a yoke/bridge which binds the entire frame together imparting rigidity. The operating mechanism comprising of a threaded nut for the rising spindle, a ball thrust bearing arrangement (optional), gear box if required, is mounted on top of the yoke/bridge. Available in 5 basic construction material 1) Cast iron split frame (IS 210 Gr.200) 2) Fabricated mild steel (IS 2062) 3) Fabricated stainless steel (AISI 304, 316) 4) Plastic (fibre reinforced) 5) Aluminium Essential Features Wedging action (2 sides) in CI, MS and st.st. gates While sealing on all 3 sides is metal to metal - bronze /brass for CI gates and stainless steel for fabricated MS or stainless steel gate, for Aluminium and plastic, sealing on all 3 sides is by means of an elastomer seal. This option is available for MS and stainless steel gates also. Alternatively, bottom seal could be an elastomer. Sides of guide/frame are embedded in concrete or side walls of channel. When required, remote operation using a coupling, extension rod and operating gear atop a head stock, is possible. Electric or pneumatic operation is possible. Suitable for seating as well as off seating application. Other available options Design for higher heads (upto 6 mwc) Wall mounted type other than for plastic gates Bottom door movement in weir gates for decantation or level control Twin spindle and operator for extra wide gates Side mounted handwheel for remote drive.

IN - CHANNEL GATE

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