Atec PENSTOCK ECOTEC User manual

ATEC GmbH • Brenzstraße 24 • 89518 Heidenheim- Germany
Telefon +49 7321 / 277777 • Fax +49 7321 / 277778
www.atec-hdh.de
Operating Instructions
ATEC-PENSTOCK ECOTEC
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1 General
2 Safety Aspects
3 Product Description and Range of Application
4 Design Features
5 Operation
6 Transport
7 Storage
8 Installation
9 Commissioning
10 Operation and Application
11 Maintenance
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1 General
The technical data of the order are binding for the type of design. Modifications can only be considered if they are specified to us in time
before starting production. Every ATEC PENSTOCK ECOTEC is checked for completeness, performance, and tightness before leaving
the factory.
In case of non-compliance with these Operating Instructions, we cannot be made liable for any damages or troubles resulting thereof. We
reserve the right to technical modifications as against the data and representations contained in these Operating Instructions in case this
should be necessary for improving the ATEC PENSTOCK ECOTEC.
2 Safety Aspects
The ATEC PENSTOCK ECOTEC is reliable and designed to the state of the art. However, risks could be involved if the Penstock is
handled in an inexpert manner by untrained staff and not used in accordance with its duty and purpose. Whoever is engaged in mounting,
operation and maintenance, inspection and repair of the ATEC PENSTOCK ECOTEC, is supposed to have read the complete Operating
Instructions and to have understood them (VBG1 § 14 and following). The user is recommended to have the person involved confirm this
fact in writing in each particular case (VGB1 § 7 Abs. 2).
Before removing safety devices and/or carrying out work on the ATEC PENSTOCK ECOTEC, the section, the pit or reservoir must be
drained and dried eliminating any risk. Unauthorized, erroneous, and unexpected operation as well as dangerous movements by
accumulated energy (compressed air, compressed water, weights, hydraulic energy) have to be excluded.
When using ATEC PENSTOCK ECOTEC the approved technical regulations have to be observed (DIN, DVGW, VDI, VDMA, etc.). For
installations to be supervised the relevant rules and regulations have to be observed (GO, VBG, TRD, SR, TRG,TRbF, TRGL, TRAC, AD,
etc.). Furthermore, the local safety regulations and rules for prevention of accidents are applicable.
If work is carried out in the vicinity of the ATEC PENSTOCK ECOTEC, which leads to soiling (concrete work, masonry, painting,
shotblasting, welding, and grinding work, etc.).
3 Product Description and Range of Application
The ECOTEC PENSTOCK is a four-facing type penstock suitable for isolating, throttling, and regulating for installation at and into reservoir
and pit inlets and outlets.
The standard ECOTEC PENSTOCK is applicable for the following operating
pressures:
•150 x 150 up to 1200x1200 / pressure up to 4mWc on both directions in standard design
4 Design Features
•Frame of rolled steel sections
•Door with suspension for stem nut or extension rod
•Slide rails, lip profile and invert seals
•For anchor-bolting or for grouting
•Pressure-tight on both sides (for on-seating and off-seating)
•Combinable with various types of drives

5 Operation
The ATEC PENSTOCK ECOTEC opens and closes channels and basin orifices. By mechanical movement of the door a defined orifice is
released. The flow will get through this cross section only. The area which is still closed remains pressure-tight. Operation is performed via
a manually or electrically operated drive thread or by a pneumatic or hydraulic actuator - for this see Operating and Installation
Instructions Operating Gears!
6 Transport
Transport has to be carried out carefully. Inexpert handling may cause damages to the ATEC PENSTOCK ECOTEC. Such damages have
to be reported immediately to ATEC. Prior to mounting, such damages have to be repaired in an appropriate manner.
If the ATEC PENSTOCK ECOTEC is too heavy to be handled manually it has to be transported by means of lifting gears which have to be
attached at suitable places. For the standard design they have to be placed at the upper end of the vertical frame profile.
It is not allowed to attach the lifting gears to the handwheel, the stem, the gearbox casing or other sensitive components which would be
contrary to the relevant safety regulations.
7 Storage
During the storage period, the ATEC PENSTOCK ECOTEC has to be protected against outside influences and impurities (e.g. by covering
them with a tarpaulin). The ATEC PENSTOCK ECOTEC has to be stored flat on the frame with intermediate boards.
If long-time storage is required, the place of storage should be selected in such a way that the following conditions are met: frost-protected -
cool - dry - dust-free. If it is impossible to comply with these conditions, the ATEC PENSTOCK ECOTEC must be packed to meet these
requirements, e.g. it has to be welded in foil. For operating gears, the safety regulations of the corresponding manufacturer are applicable.
8 Installation
8.1 Principles
According to their design, the ATEC PENSTOCK ECOTEC is grouted, anchor-bolted or anchored into the structure by a combination of
these two procedures. On principle, installation should be performed by the ATEC expert staff. In case installation is performed by a third
party, an ATEC specialist can give the corresponding installation instructions and supervise the installation.
If the mounting work is done by a third party, the client or the mounting company is responsible for proper installation, testing, and
commissioning.
For installation, the ATEC PENSTOCK ECOTEC has to be in perfect condition. All defects have to be reported immediately to ATEC and
to be repaired before installation according to mutual agreement.
8.2 Requirements to the Structure
The structure has to be complete, i.e. the corresponding constructional section has to be complete with all surfaces and recesses
necessary for installation of the ATEC PENSTOCK ECOTEC being geometrically available and plane-parallel and even.
The design of the interface between structure and ATEC PENSTOCK ECOTEC has to be carried out according to the relevant standards
for structures (DIN 18202, DIN 19556, DIN 19569, etc.).
8.3 General Notes
Remove all packing material from the ATEC PENSTOCK ECOTEC. Prior to installation, check the mounting area for impurities and foreign
bodies and clean it if necessary.
It is important that all around the ATEC PENSTOCK ECOTEC there is free access for operation and maintenance.
During the mounting process, corrosion protection and coatings must not be damaged. Particular attention has to be paid during welding or
grinding works. If the surface is damaged, these defects have to be repaired in an expert manner.
Prior to mounting the supplied self-adhesive sealing tape has to be attached to the back of the Penstock.
8.4 Design for Grouting
Fix the self-adhesive sealing at the middle brace and at the upper cross profile. Then, insert the ATEC PENSTOCK ECOTEC into the
provided recess and align. Please see to it that the upper edge of the invert seal is aligned with the invert. Moreover, the sealing tape
has to be compressed to a final height of approx. 5 mm.
For the first adjustment the lateral and horizontal screwed in adjusting screws within the slidegate valve framework serve. Then, control
once more the pre-stress of the sealing tape at the middle brace and adjust if necessary. For a ATEC PENSTOCK ECOTEC of large
nominal size and/or high pressure rating the middle brace has to be provided with an additional fastening angle. Fixing has to be
effected by compound anchor bolts.
As distortion affects functioning and tightness of the ATEC PENSTOCK ECOTEC, please take care during alignment that the ATEC
PENSTOCK ECOTEC sits close without any distortion. Admissible structural tolerances to DIN 18202 will be compensated by the wall
sealing. The mounting torque has to be applied crosswise by a wrench (see table, paragraph 8.8) in order to obtain final fastening
force.
It is not possible to change the position of the frame after grouting. For that reason, prior to grouting the ATEC PENSTOCK
ECOTEC has to be checked for perfect performance.
After shuttering up the structure recess, the ATEC PENSTOCK ECOTEC is grouted. When grouting, no mortar must touch the
sealings or the frame profiles outside the shuttering. Possible impurities have to be removed immediately. For application of the grouting
mortar, see paragraph 8.7.

8.5 Design for Anchor-bolting
Fix the self-adhesive sealing tape in an overlapping way to the back of the frame. Then, place the ATEC PENSTOCK ECOTEC at the
determined position and align it.
The drilled holes of the penstock frame serve for preliminary fastening. Fixing has to be effected by compound anchor bolts.
As distortion affects functioning and tightness of the ATEC PENSTOCK ECOTEC, when presetting the fixing nuts take care that the
ATEC PENSTOCK ECOTEC sits close without any distortion. Admissible structural tolerances to DIN 18202 will be compensated by
the wall sealing. The mounting torque has to be applied crosswise by a wrench (see table, paragraph 8.8) in order to obtain final
fastening force.
For application of the compound anchor bolts, see paragraph 8.8.
8.6 Design for Anchor-bolting in Channel
The ATEC PENSTOCK ECOTEC is delivered with on one side welded attaching brackets and a threshold mounting manifold. The
attaching brackets at the other side provided for adaptation in coagulate loosely. Fix the self-adhesive sealing tape in an overlapping way to
the back of the frame. Then, place the ATEC PENSTOCK ECOTEC at the determined position and align it.
As distortion affects functioning and tightness of the ATEC PENSTOCK ECOTEC, when presetting the fixing nuts take care that the
ATEC PENSTOCK ECOTEC sits close without any distortion. Admissible structural tolerances to DIN 18202 will be compensated by
the wall sealing. The mounting torque has to be applied crosswise by a wrench (see table, paragraph 8.8) in order to obtain final
fastening force.
For application of the compound anchor bolts, see paragraph 8.8.
8.7 Application of the Sealing Mortar
The grouting mortar has to have a low shrinkage and be very flowable with high early and final strength. The mortar must not develop
corrosion and has to be water or medium resistant. Furthermore, firm adhesion has to be obtained between structure and penstock
material.
We recommend to use a grouting mortar based on cement, e.g. Tricosal VGM Superfluid or Betec Rapid.
The shuttering has to be provided with air outlet orifices.
During the grouting work the whole mounting area has to be free of grease, dirt and dust. Possibly, shuttering and structure recess have to
be moistened, stagnant water has to be removed. The surfaces have to be as rough as possible, in case of need a coupling agent has to be
applied. To avoid undesirable adhesion of the grouting mortar to components of the steel construction, we recommend to apply a separating
agent.
The grouting mortar has to be produced and grouted continuously. To avoid air inclusions, grouting should be performed from one side
only. Outside the normal range of ambient temperature (+5 °C to +30 °C), special procedures have to be followed (see manufacturer's
specification).
Furthermore, appropriate measures have to be taken to avoid that after grouting the mortar dries too fast.
8.8 Use of the Compound Anchor Bolts
All fastening holes of ATEC PENSTOCK ECOTEC are double holes, diagonally displaced. Thus, you can always use alternative holes
(e.g. if on drilling you come across a concrete reinforcing iron). Furthermore, the fastening bolt holes have a larger diameter than the
required drill diameter. Thus it is possible to make the drill holes with the ATEC PENSTOCK ECOTEC aligned.
The compound anchor has to be chosen according to the respective range of application. Destruction by contact corrosion and by the
medium have to be excluded. ATEC company recommends compound anchor bolts of the material "stainless steel" of type A4 (AISI-TP
316T);
e.g. Upat UKA 3.
The corresponding manufacturer's specification referring to handling and mounting procedure for anchor bolts has to be obeyed in any
case. To avoid faulty mounting, it is necessary to proceed very carefully. Prior to the insertion of the compound anchor bolt cartridge the drill
hole has to be cleaned by blowing-off. The threaded rod has to be fastened according to the manufacturer's indications and after the curing
time only the nut must be tightened applying the specified tightening torque. It has to be considered that the curing time is considerably
longer if there is a moist anchorage ground or lower ambient temperature.
The following tightening torques have to be applied according to manufacturer's indications (here: UPAT).
Thread Tightening torque
M 10 20 Nm
M 12 30 Nm
M 14 45 Nm
M 16 60 Nm
9 Commissioning
Prior to commissioning, possible impurities have to be removed from the seal and the penstock surface. Prior to tightness test, the ATEC
PENSTOCK ECOTEC has to be moved at least once over the entire stroke (OPEN-CLOSED).
When using electric, hydraulic or pneumatic actuators please obey the operating instructions of the relevant manufacturer.

On principle, for design with electric actuator the door has to be in an intermediate position for adjusting the direction of rotation (clockwise
closing). Furthermore, manual movements to the positions OPEN and CLOSED have to be effected for adjustment of the travel and torque
switches. The above-mentioned switches don't have any effect in case of wrong direction of rotation.
10 Operation and Application
10.1 General
The ATEC PENSTOCK ECOTEC is produced for the ranges raw water, drinking water, and sewage. For special requirements as sea
water, aggressive media or other environmental influences, special materials are necessary which have to be considered when designing
the Penstock.
10.2 Admissible Mode of Operation
The ATEC PENSTOCK ECOTEC may be exposed only to stresses for which it is designed in terms of pressure and materials (see
paragraph 10.1).
It can be used as isolating, throttling and regulating valve. The door has to be moved only by the operating gear provided for this purpose.
10.3 Admissible leakage
Leakage according to DIN 19569-4 Tab. 1 Class 4
0,02-0,05L per second, per meter of seal perimeter of pure water.
10.4 Inadmissible Modes of Operation
Too high operating forces and use of electric actuators without travel switch are inadmissible. In case a foreign body is in the orifice,
the former has to be removed by opening the ATEC PENSTOCK ECOTEC once more or by other suitable measures before final
closing is performed. Violent movement leads to failure.
Movement of the door without using the provided operating gear can lead to the destruction of the Penstock. Futhermore, it is possible
that hydraulic vibrations and water hammers are produced when the Penstock is operated in a wrong way which can lead to damages
of the structure.
Table of max. permissible actuation moments and the resulting hand forces at the control key and/or handwheel (provided lever length
0,2 m) without transmissions. With use of reduction gears the strength and the relationship of the translation of the drive become
smaller. At higher penstock dimensions we provide information on request or see contract documents.
max. operating pressure PN 0,6*
Penstock size BxH 150 200 300 400 500 600 700 800 900 1000 1100 1200
250 350 450
Open
Anti-clockwise turn to the stem/handwheel/control key
MD max. permissible Nm
40
40
45
45
50
50
80
90
100
110
120
130
Hand strength at the control key or
handwheel max. permissible N 200 200 225 225 250 250 400 450 500 550 600 650
Close
Clockwise rotation at the stem/handwheel/control key
MD max. permissible Nm 20 20 25 25 30 30 50 60 65 70 75 80
Hand strength at the control key or
handwheel max. permissible N 100 100 125 125 150 150 250 300 325 350 375 400
*At lower loads, the operating forces must be reduced accordingly
11 Maintenance
Inspection and Maintenance
On principle, the ATEC PENSTOCK ECOTEC has to be inspected once every month. The door should be moved at least once over the
entire stroke (OPEN-CLOSED), the stem has to be greased and the seal has to be checked for perfect fit.
During this procedure, wear and tear at stem, stem nut, and seals has to be checked. Worn components have to be replaced immediately.
Special conditions of application as aggressive media, the application as regulating valve with high duty period and regulating frequency or
the intense use of a short portion of the entire stroke require shorter inspection intervals according to the load. Frequency and scope of
inspection have to be agreed with ATEC Company. Furthermore, it is possible to conclude a maintenance contract for ATEC PENSTOCK
ECOTEC.
For inspection and maintenance please see the notes in paragraph 2 (Safety Aspects).

11.1 Servicing:
T
The servicing data must be documented according the details in table (maintenance journal, in case of damages with pictures)
otherwise the warranty goes out.
11.2 Repair
We recommend having the ATEC PENSTOCK ECOTEC repaired by the ATEC Service Department. In case the repair is done by a third
party, an ATEC specialist can give the corresponding installation instructions and supervise the repair. Only original ATEC spare parts shall
be used. The use of foreign components is a risk for safety and operation. For the repair, the notes under paragraph 2 (Safety Aspects) and
in paragraph 9 (Commissioning) are applicable.
Activity
Interval
Part
Works to be carried out
Function test
At least every three month or
after needs as a function of
the stress
Door
Frame
Move door over the entire stroke (OPEN-
CLOSE). Check parts for state and wear. If
necessary clean and grease.
Wear check
At least every year or after
needs as a function of the
stress
Door
Frame
Seal
Move door over the entire stroke (OPEN-
CLOSE). Check parts for state and wear. If
necessary replace.