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Gereg: Fulton Sluice Gates and Fluid Control Equipment
Gereg: Fulton Sluice Gates and Fluid Control Equipment
Em ail : gereg@global.co.za
ii
INTRODUCTION
Gereg Sew age and Water Equipm ent (Pty) Ltd. w as established in 1988 to market
sluice gates and other fluid control equipment, and in 1990 w e acquired from Valvemakers
the manufacturing and marketing rights for the w ell-know n FULTON range of sluice gates,
w hich w ere first manufactured in 1965, and of w hich w e are now the sole suppliers.
Soundness of design and high manufacturing standards are not compromised for the sake
of cost reduction, resulting in a range of products of exceptional quality.
Manufacture is undertaken by our associate company, Hinteregger Erection (trading as
Gereg Engineering) w ho is ISO 9001 listed, (Certificate Registration No. 01 100 000685/2)
and strict Quality Assurance and Control as required by ISO 9001 is practised.
Standard products
Sluice gates
Channel gates
Notes
1. The above lists give an indication of our normal range of products, and are not
necessarily complete. We w elcome enquiries for items not mentioned here.
2. The range may be reduced or added to from time to time
3. We reserve the right to alter specifications, data and dimensions given in this
catalogue at any time, as our policy is one of continual product improvement.
4. No liability is accepted for any errors or omissions.
GENERAL INFORMATION
Most sluice gates are fabricated from various grades of stainless or corrosion-resistant
steel, but certain sizes can also be manufactured from cast iron. Aluminium is usually used
for handstops and stoplogs. Gates may be supplied w ith or w ithout seals, depending on
customer's requirements.
Operation of gates can be manual, electric, hydraulic or pneumatic.
Sluice gates may be broadly divided into the follow ing types :
Wall m ounted gates, w hich are used to close off an opening in a w all, or the end of a
pipe, and seal around the complete periphery of the opening. They can be either of the slide
or roller type, and can be arranged to seal against on- or off-seating pressure, the former
being w here the pressure or flow tends to force the gate on to its frame and the latter w here
the gate tends to be forced off its frame. By fitting double music-note seals, a gate can be
arranged to seal in both directions if necessary.
When a large gate has to be operated against a high unbalanced pressure, the force
required to open it may be excessive, in w hich case rollers are fitted in order to reduce
friction, and hence the operating effort.
Channel gates, used to control flow in open channels or canals, are of the 3-sided sealing
type, having no seal along the top edge of the gate. They are normally screw operated, w ith
handw heel or gearbox mounted on a bridge, w hich forms part of the headframe. Wide gates
may require tw in-lifting spindles.
Channel gates are usually mounted in slots cast into the sides and floor of the channel, but
can also be w all-mounted if required.
Radial gates, w hich are often 3-sided sealing, are used in canals, or on dam w alls, for
flow control.
Weir gates, are either dow nw ard-opening, or bottom-hinged tilting type, and the flow over
the top of the gate is controlled by adjusting its height. Depending on w ater level, and
w hether the gate must seal off the opening, w eir gates may be either 3- or 4-sided sealing.
Tw istlock gates. Quick-action hand-operated gates w hich can be locked in any partially
open position simply by turning the T-handle.
Handstops and stoplogs. Simple hand-lift gates w hich do not normally have seals, as a
certain amount of leakage is often permissible. How ever seals can be fitted if required.
Flow dividers. These are vertically pivoted sw ing gates used for diverting flow into either
of tw o channels. Seals are optional.
Flap gates. Non-return gates, allow ing flow in one direction only.
DESIGN FEATURES
Structural m em bers
The design of all sluice gate structural members complies w ith the requirements of DIN
Spec. 19704, and under full head conditions there are ample margins of safety over the
yield and ultimate strengths of the materials used. In addition, deflections are calculated to
be less than those allow able for the type of seals employed.
Seals
Sluice gates are fitted w ith Neoprene music-note ("J" type) seals, w hilst channel gates
have Neoprene angle ("L") type. These bear against the frame surfaces, and give excellent
sealing, as the higher the pressure, the greater the force pressing the seal against the
frame, and the more effective the sealing action.
If, for any reason Neoprene cannot be used, metal to metal or thermoplastic seals can be
provided.
For high off-seating pressures, and for metal or thermoplastic seals, gates are fitted w ith
adjustable w edges to ensure positive contact betw een seal faces.
Leakage rates
Gates are designed for minimal leakage, and in practice are often found to be drop-tight.
How ever the permissible leakage rates as laid dow n in AWWA Spec. C 501, w hich are
1,24 litres per minute per metre of seal for seating pressures, and 2,48 l.p.m. per metre for
off-seating pressures up to 6m, are guaranteed maxima.
NOTE : Correct installation is essential if these rates are not to be exceeded.
Bearing strips
Hydraulic thrust is taken on low -friction H.D.P.E. strips fitted to the gate, and w hich slide
on the frame as the gate moves. These strips are sized to give low bearing loading, resulting
in long life and easy operation. They are also fitted to the larger sizes of channel gates for
the same reason.
4
Operating gear
For manual operation, handw heel diameters and gearbox ratios are matched to spindle
sizes and thread pitches, so that the time required to stroke the gate is kept to a minimum,
at the same time limiting handw heel rim effort to normal acceptable levels of betw een 100
and 150 N.
If gearing is necessary, bevel or combined bevel / spur gearboxes are used.
Spindles
Spindles are sized in accordance w ith calculated tensile and compressive loads w hich w ill
be imposed w hile opening and closing the gate, and spindle guides are spaced so that
buckling of the spindle under compression does not occur.
Cover tubes
Spindle cover tubes can be fitted if desired. If visual indication of gate position is required,
the cover tube w ould be supplied in clear PVC, but steel or stainless steel, being more
robust, is recommended w herever possible. The design of the handw heel boss allow s a
cover tube to be fitted at a later stage, if it is subsequently found to be necessary
Channel gate headfram es
We supply tw o types of headframes for channel gates. The first comprises integral head
and embedded sections, w hilst the second, the upper piece is bolted to the embedded
section, w hich facilitates transport, and allow s the low er portion to be installed in the slots
prior to the balance of the equipment.
4m w ide x 2,6m high m ild steel stop gate for 13m unseating head.
(Supplied to Um geni Water for Inanda Dam intake structure.)
MATERIALS OF CONSTRUCTION
Com ponent
Material Options
Stainless steel
Corrosion-resistant steel (3CR12)
Mild steel
Aluminium
Tw istlock gates
Flap gates
Telescopic bellmouths
Sludge drain valves
Stainless steel
Corrosion-resistant steel
Mild steel
Cast iron (certain sizes only)
Pedestals
Support brackets
Wall brackets
Stainless steel
Corrosion-resistant steel
Mild steel
Cast iron
Cast iron
Stainless steel
Seals
Neoprene
Thermoplastic / metal
Metal / metal
Spindles
Couplings
Stainless steel
Stop collars
Spindle guides
Lifting nuts
Bronze
Handw heels
Aluminium (cast)
Mild steel (fabricated)
Cover tubes
Stainless steel
Mild steel
Clear PVC
Stainless steel
CORROSION PROTECTION
Material
Protection Options
Stainless steel
Corrosion-resistant steel
Mild steel
Cast iron
Aluminium
Anodised
6
Option
Application
Mounting
Flat back
Spigot back
Neoprene seals
Adjustable w edges
Non-resilient seals
General use
Metal or thermoplastic
General use
Neoprene rectangular
compression type
(Flush invert)
General use
Restricted floor space
Grit in fluid
Wedging
Side seals
Bottom seal
Option
Application
Mounting
Slot fixing
Mid-channel location
Flat back
Wall mounting
End of channel location
Side seals
General use
Bottom seals
Neoprene rectangular
compression type
General use
Option
Application
Mounting
Slot fixing
Mid-channel location
Flat back
Wall mounting
End of channel location
None
General use
Seals
OPERATING GEAR
Feature
Option
Application
Spindle
Rising
General use
Non-rising
Tee-key operation
Restricted headroom
Pedestal on platform
General use
Pedestal on w all
support bracket
Where there is no
overhead platform
Headframe bridge
Handw heel
Bevel gearbox
Bevel/spur gearbox
Heavy duty
Tee-key
Non-rising spindle
Preventing unauthorised use
Lifting handles
and / or rods
Electric actuator
Heavy duty
Mounting
Manual
Pow er
Hydraulic actuator*
Pneumatic actuator*
and/or
Push-button / Remote control
10
11
12
Gate size
(w xh)
A
Standard Flush
Inv ert
Inv ert
S
Min. Max.
250 x 250
10
490
395
510
87
102
300 x 300
10
540
445
560
87
102
400 x 400
640
545
660
87
102
500 x 500
740
645
760
87
102
600 x 600
855
760
860
90
107
700 x 700
955
860
960
90
107
800 x 800
1055
960
1060
90
107
900 x 900
1155
1060
1160
90
107
1000 x 1000
1255
1160
1260
100
115
1100 x 1100
1355
1260
1400
100
115
1200 x 1200
1455
1360
1500
100
115
1400 x 1400
1655
1560
1600
115
135
1500 x 1500
1755
1660
1800
115
135
1800 x 1800
2055
1960
2100
115
135
2000 x 2000
2255
2160
2300
115
135
Notes:
1. Non-standard sizes and gates for higher pressure ratings can be specially
manufactured.
2. Dimension S varies according to gate design.
3. Dimensions should not be used for construction purposes.
13
14
WEIR GATES
(a) Dow nw ard-opening w eirs
These are similar to w all-mounted gates, except that the gate is closed in its "up" position,
and as it is low ered, the opening is uncovered, to allow the flow over the top to be
controlled.
A different seal configuration is used, w ith either "J" or "Triangular" type Neoprene seals
being fixed to the frame instead of the gate.
Dow nw ard-opening w eirs can be either four-sided sealing, if the head is greater than the
height of the opening, and it is necessary to shut off the flow completely, or three-sided
sealing, w hen no top seal is required.
Occasionally a w eir is required to have a w idth much greater than its height. As this may
cause the gate to jam in the guides, the effective height can be increased by means of side
extensions to the gate. If this is not practical, tw in lifting spindles w ith tw o inter-connected
gearboxes are used, but depending on gate size and the travel required, a tilting w eir may
be preferable to a dow nw ard-opening type.
(b) Tilting w eirs
Tilting w eirs are used for w ide openings w here the vertical travel required is not more than
about 500 mm. The gate is hinged at the bottom, and is raised and low ered by means of a
centrally mounted spindle w hich can be operated either manually, or by an actuator. As
friction is very low , operating effort for tilting w eirs is minimal.
Sealing plates can be fitted to the end w alls if required, w hilst a flat Neoprene seal across
the w idth of the w eir prevents leakage along the hinged section.
Scum baffles, located upstream of the w eir, are optional.
Tilting Weir
15
Channel Gate
Type F
Channel Gate
Type G
Block-outs (Type F)
Block-outs (Type G)
16
CHANNEL GATES
As their name implies channel gates are used to control flow in open channels, and
therefore do not have a top horizontal seal, since the gate height is made about 100 mm
greater than the maximum depth of fluid in the channel. They are usually mounted in slots in
the side w alls and floor, but they can be adapted to bolt against a w all face if necessary.
Channel gates seals are Neoprene angle type dow n the tw o vertical sides, sealing against
the embedded frame members, w hilst a rectangular compression type is used on the invert.
The operating gear is usually carried on the headframe bridge, but can also be pedestalmounted on an overhead platform. Rising spindles are strongly recommended.
In cases w here the channel depth is considerably more than the gate height, or w here the
height of the headframe is greater than normal, the spindle may have to be supported in
guides in order to prevent buckling under compression w hen the gate is closed.
We can supply tw o alterative types of frames as follow s:
Type F w here the headframe legs are extensions of the embedded sections,
or
Type G having a separate bolt-on headframe, w hich facilitates transport and erection, as the
embedded sections can be installed prior to the upper portion, w hich is then bolted
on later after completion of the civil w ork.
Dimensions of the block-outs required in the channel sides and floor for both types are
given on Page 16.
For very w ide gates, tw in-lifting spindles may be required, in w hich case tw o interconnected gearboxes are used, as show n below .
17
TWISTLOCK GATES
Tw istlock gates are used in the same applications as small w all-mounted sluice gates,
w here hand operation is acceptable. They can be locked in any partially open position by
tw isting the handle, w hich brings a cam into play, forcing the gate against its frame. This
same action seals the gate in its closed position.
Tw istlocks are suitable for balanced heads up to 3m seating or 2m unseating, but it must
be borne in mind that operating effort increases w ith size and pressure.
Usually of cast iron construction w ith bronze seating faces, they can also be cast in
stainless steel, or fabricated from stainless, corrosion-resistant or mild steel.
Dimensions of the cast range are given below :
Bore
100
305
390
82
150
305
390
82
200
381
480
102
225
432
540
102
300
570
655
145
18
19
FLAP GATES
These are used in w alls or on the ends of pipes to prevent reversal of flow , and consist of
a frame w ith a gate or flap w hich is hinged at the top. In order to ensure proper closure
against the frame, the gate is double hung, by means of stainless steel pins in bronze
bushes.
The smaller sizes, leading dimensions of w hich are tabulated below , are generally of cast
iron, but can also be cast in stainless steel, and have bronze or stainless steel sealing faces.
Larger sizes, having square or rectangular openings, are fabricated from stainless,
corrosion-resistant, or mild steel, and are usually supplied w ith neoprene seals.
Bore
75
184
92
92
77
100
216
147
108
60
150
280
149
140
118
200
336
168
168
75
300
406
205
203
100
20
TELESCOPIC BELLMOUTHS
Telescopic bellmouths are used extensively in sew age purification w orks to draw off
surface fluids and scum. They consist of a low er (outer) tube w hich is connected to a drain
pipe, and an upper (inner) tube w hich slides up and dow n, so varying the level at w hich
skimming is required to take place. Seals are fitted betw een the inner and outer tubes to
prevent leakage.
Operation is usually manual by means of a handw heel and spindle connected to a bridgepiece fitted across the top of the sliding tube, and care must be taken to allow enough room
betw een the bridge and the underside of the operating platform w hen the inner tube is fully
extended.
21
SLUDGE VALVES
Sludge valves are used for complete draining of reservoirs and tanks, being cast into the
floor as illustrated.
They can be supplied in cast iron or cast steel, or, as is usual for the larger sizes, they can
be fabricated from stainless steel, corrosion-resistant steel, or mild steel. Bronze/Neoprene
is standard for the seats, w ith stainless steel being used w here specially required.
Normal operation is by means of a handw heel, but hydraulic or pneumatic operation can be
utilised if necessary.
Bore
75
190
184
180
20
100
220
215
180
20
150
280
265
205
20
200
346
316
270
20
300
480
450
305
25
450
720
600
430
25
22
Bore
75
185
270
145
125
80
100
218
325
175
150
92
150
280
448
220
228
155
200
336
555
295
260
165
225
370
575
300
275
165
300
460
722
405
317
224
23
0,2
0,4
0,6
0,8
1,0
90
160
210
250
280
24
25
26
Channel Gates
1. Width x depth of channel ( w x d )
2. Height of gate ( h )
3. Gate travel ( B )
4. Height of operating gear above top of channel
Handstops and Stoplogs
1. Width x depth of channel ( w x d )
2. Height of gate ( h )
3. Whether seals are required
Telescopic Bellm ouths
1.
2.
3.
4.
5.
6.
28
Width of opening ( w )
Height of opening ( h ) for 4-sided sealing
Gate height ( h ) for 3-sided sealing
Maximum head on gate ( Hm )
Direction of flow ( seating or off-seating )
Dimensions X and F N.B. Min. F = h + 260 m m
How operating gear is to be mounted
29
4,2m w ide x 3,5m high Channel Gate w ith Rotork electric actuator.
(Johannesburg Northern Works)
30
INSTALLATION INSTRUCTIONS
The follow ing instructions are given as a guide for erecting fabricated gates fitted w ith
Neoprene resilient seals. It is important to realize that w hilst every care is taken in
assembling the gates in the factory, both gates and frames are flexible to some extent, and
therefore that deflections and distortions can and do occur during transport and installation.
Although the seals themselves w ill cater for minor distortions, it is essential that these be
eliminated as completely as possible w hen the gates are installed, by making the
adjustments described herein.
Only by experience w ill the erector learn all the " tricks of the trade", but should there be
any points that require clarification, the reader is w elcome to discuss these w ith us.
A set of these instructions is provided w ith every gate w hich is not being installed by
ourselves, and w e strongly recommend that they be follow ed closely in order to ensure
optimum performance and service from the equipment.
WALL-MOUNTED GATES
1. Foundation Bolts
The follow ing types are commonly used:
(c) Weld-on
These are used for very large gates, and are
w elded to previously cast-in w all plates w hen the
frame is installed. Some latitude is permissible in
positioning the w all plates.
31
32
33
34
3. Operating gear
Using a plumb bob, determine the correct position of the pedestal, before marking off and
drilling the foundation bolt holes. Ensure that the spindle w ill be accurately aligned w ith the
connection on the gate, and w ill be true and vertical. If a w all support bracket is to be
installed, similar care must be taken w ith its positioning and alignment.
Using the nuts on the foundation bolts, make sure that the pedestal is true and vertical,
again leaving about 30 mm grout space betw een its base and the top of the platform.
Spindle guides and brackets (w here supplied) should be equally spaced, but take care that
there is enough space betw een the top of the gate and the low est guide to allow the gate to
open fully. Also note that if there are any couplings on the spindle, these must be able to
travel freely betw een guides w ithout fouling.
After determining the w all bracket positions, drill the holes for the bolts, and adjust the
brackets by means of the nuts as previously described, so that they are correctly aligned
and true prior to grouting.
Install the spindle complete w ith guides, and adjust these on the brackets, using the slots
provided on the latter.
The gate should then be operated up and dow n through its full travel, to ensure that the
spindle is free, and that there is no fouling anyw here. Next, carefully lock all nuts, w ithout
causing any movement or distortion.
4. Grouting
Clean all metal and concrete surfaces, w et the latter, and grout up the spaces from the
bottom upw ards, using a proprietary brand of non-shrink grout, and making the mix as dry
as possible. Shuttering should be used as required.
The grout should be lightly rammed, taking great care not to distort any frame members
during the process.
After the grout has set, remove all excess, clean the metal surfaces, and finished off
neatly. Replace the gate in its frame, tighten the retainers, and again operate up and dow n
through the full travel to ensure that no misalignment has occurred during grouting.
5. Com m issioning
Lubricate the spindle threads w ith all-purpose grease, and raise and low er the gate fully.
With the gate firmly in its closed position, check that the stop collar is correctly located on
the top of the spindle, so as to prevent over-closing of the gate, w hich could cause the
spindle to buckle due to excessive compression. The collar must be securely locked on the
spindle by means of the grub screw s provided.
This is very im portant.
The gate is now ready to be w et tested under operating conditions.
N.B. Apart from incorrect installation or seal adjustment, leakage is often caused by grit,
pieces of concrete, or other foreign objects lodging in the seals, or betw een gate and frame,
and under the bottom seal in the case of flush invert gates, so preventing proper closure.
NEVER attempt to stop leaks by over-tightening the handw heel.
35
36
CHANNEL GATES
1. Fram e
Clean the slots in the concrete and insert gate and frame so that the seals are on the
upstream side. Using the jacking screw s provided, level the invert member flush w ith the
bottom of the channel, checking that the invert seal makes contact along its full w idth.
Position and align the vertical frame members so that they are parallel to each other, and
are free of all tw ist. Check that the vertical seals make contact w ith the frame sealing faces
along their entire length, w edging the frame members inw ards if necessary, at the same
time making sure that the gate does not jam in the frame. Wooden struts placed across the
inside of the frame as show n, w ill prevent it from being bow ed inw ards during grouting.
Check that the headframe is true, vertical and free of tw ist, and that the embedded frame
is held firmly by the jacking screw s. Next, stroke the gate up and dow n through its full travel,
again checking for correct seal contact, w ith the gate closed, but not over-tightened.
2. Grouting
Grouting can now be done, bearing in mind the previous remarks concerning w allmounted gates.
In cases w here the headframe has been removed from the embedded section, and w ill
only be fitted later, it w ill not be possible to screw the gate dow n on to the invert, and care
must be taken not to force the invert member upw ards by ramming the grout too vigorously.
3. Com m issioning
Commission as for w all-mounted gates, again taking care to adjust and lock the stop collar
on the spindle in its correct position w ith the gate firmly closed.
N.B. See the rem arks m ade on Page 35 concerning likely causes of leakage.
MAINTENANCE
Periodically clean all dirt from the spindle threads, and apply all-purpose grease. Site
conditions w ill determine how often this needs to be done, it being important not to allow
excessive build-up of dirt and grit on the threads.
Pump grease into the nipples on the operating gear at about 6-monthly intervals, and in
the case of gates having non-rising spindles, the bronze lifting nut in the gate should be
greased at the same time.
Every 6 to 9 months, inspect the seals for damage and deterioration, and replace as
necessary
Regularly check gate closure, and re-adjust the stop collar if required.
37
Gereg
Gereg Sewage and Water Equipment (Pty) Ltd.
Reg. No. 1999/002945/07
Labor
SUNWARD PARK
BRAKPAN
1470
R.S.A.
R.S.A.
38