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AVK 772 Series Installation & Maintenance Instructions Manual

Channel penstocks
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INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION
AVK CHANNEL PENSTOCKS
SERIES 772/71

TABLE OF CONTENTS

1. INTRODUCTION

This manual describes the recommended procedures for installation, operation, maintenance and safety
precautions for AVK channel penstocks.
Please read thoroughly all the instructions in the manual prior to installation, and contact an AVK
representative in case of any questions.
The manual makes reference to the "General Arrangement Drawing" (GAD). The GAD is the
drawing that is sent to and approved by the customer prior to the production of the penstock.
AVK assumes no responsibility or liability if the channel penstock is not installed, operated and
maintained in strict accordance with the procedures described in this manual.

2. SAFETY PRECAUTIONS

Standard safety procedures should be followed to prevent personal injury or equipment damage during
installation and maintenance.
• Penstocks are usually of large dimensions and heavy. Appropriate lifting devices must therefore be
used for secure handling.
• Penstocks shall be lifted from the main frame or from the yoke if applicable. Holes are available for
lifting eyes. Slings can also be used.
• Never lift the penstocks in inverted positions. Do not use stems, slides or actuators as lifting points.
• Passing through the penstocks' openings must never be attempted unless slides have been properly
secured. In any case, this type of work should be avoided unless it is absolutely necessary.
• Penstocks must never be manipulated when the system is under pressure.
Personnel that is handling penstocks must be correctly trained to avoid accidents. The correct
observation of installation and maintenance instructions will not relieve the personnel from being
adequately trained. AVK will not be held responsible for any accidents arising from incorrect
handling or installation.

3. MARKING

COPYRIGHT©AVK GROUP A/S 2014 - AVK INTERNATIONAL A/S, BIZONVEJ 1, DK-8464 GALTEN - WWW.AVKVALVES.EU
Label
• Manufacturer
• AVK item number
• Internal number
• Material
• Pressure
• Dimension
• Actuator
• Actuator type
1
1
1
2
2
2
4
7
9
10
10
10
12
MI ChannelPenstock772 rev AB August 2014 GB

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Summary of Contents for AVK 772 Series

  • Page 1: Table Of Contents

    This manual describes the recommended procedures for installation, operation, maintenance and safety precautions for AVK channel penstocks. Please read thoroughly all the instructions in the manual prior to installation, and contact an AVK representative in case of any questions. The manual makes reference to the “General Arrangement Drawing” (GAD). The GAD is the drawing that is sent to and approved by the customer prior to the production of the penstock.

  • Page 2: Handling And Storage

    5.1 Embedded in concrete Required Materials: As a standard, AVK channel penstocks are mounted embedded in concrete (EC). Field adjustment hex bolts are required to center the penstock in the appropriate recess prior to embedding in concrete. For detailed information about the type, size and quantity of the required bolts, or any other specific installation notes or materials, please refer to the notes on the “General Arrangement Drawing”.
  • Page 3 Side Centering Second Fitting Phase of INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION Wall Recess Concrete AVK CHANNEL PENSTOCKS SERIES 772/71 Frame Guide Figure 1 Channel Side Wall Field Adjustment Side Bolt Adjust the bolts so the frame invert is ush with the invert...

  • Page 4: Face Mounted In Existing Channel

    INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS SERIES 772/71 Step 2B: Align the penstock vertically (without the bottom balancing brackets) Smaller channel penstocks do not come with “bottom balancing brackets”. Therefore, the following procedure shall be followed to align the penstock vertically (After “Step 1”).
  • Page 5 INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS FRAME SERIES 772/71 ADJUSTABLE BRACKET SLOT FRAME 5.2.1 INSTALLATION PROCEDURE ADJUSTABLE BRACKET SLOT Step 1: Concrete construction inspection: • The concrete construction shall be flat, level and plumb, and shall be in accordance to ACI 117-06 standard.
  • Page 6 INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS SERIES 772/71 Step 3: Grout fill Grout fill the remaining voids (See Figure 8), both at the bottom (See Figure 9) and laterals of the penstock (See Figure 10). Remember that the objective of the grout fill is twofold: • Fill the voids between the frame, frame invert and the channel.

  • Page 7: Wall Mounted

    INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS SERIES 772/71 5.3 INSTALLATION: WALL MOUNTED Required materials: For the wall mounted (WM) mounting option, the channel penstock is installed by means of mechanical anchor bolts (Hilti Kwilt 3 or equivalent) and construction sealant (Sikabond or equivalent).
  • Page 8 INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS SERIES 772/71 Step 3: Construction sealant application (Sikabond or equivalent) Construction Sealant Back Side of Frame In order to avoid leakage between the frame and the wall, construction (side in contact with the wall)

  • Page 9: Operation

    INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS SERIES 772/71 6. OPERATION 6.1 INITIAL OPERATION Before cycling the channel penstock, make sure there are no foreign deposits or materials on the seals, guides or sealing area. Slide seals could be damaged if the area is not cleaned and coated with a light grease. Please refer to section “Materials needed for maintenance and seal replacement”...

  • Page 10: Maintenance

    7.1.1 SPARE PARTS AVK does not recommend stocking any spare parts by the owner of the equipment as the channel penstocks are designed for a very long life cycle. If a repair part is required, please contact an AVK representative and provide the following information: • AVK order number...
  • Page 11 INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS SERIES 772/71 7.2.1 SLIDE REMOVAL (FIGURE 17) Step 1: Start from the closed position. Step 2: Remove bolts and nuts (items 3 and 4) that are used to join the stem (item 5) and slide (item 2). For the non-rising stem configuration, the stem nut shall be detached from the slide.

  • Page 12: Trouble Shooting

    INSTALLATION & MAINTENANCE INSTRUCTIONS - ORIGINAL VERSION AVK CHANNEL PENSTOCKS SERIES 772/71 8. TROUBLE SHOOTING Symptom Cause Solution Gaps between frame and face of wall Grout fill remaining gaps. due to miss-application of grout fill. Leakage between channel penstock and concrete wall (for Face Loose anchor bolts.

This manual is also suitable for:

771 series

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