Obermeyer Hydro 15-1507, Installation Manual

Page 1: ...tes 5 Installation of Hinge Retainer 6 Main Clamp Bar Seals and EPDM Installation 7 Restraining Strap Installation 8 Torque Specifications 9 Index 1 CHECK LIST Prior to installation it is recommended that the checklist provided in this manual is reviewed It is much easier to fix an issue with the anchor bolts or abutment plates prior to gate installation ...

Page 2: ...f the abutment place then measure the distance of the bottom of the string line to the point on the bottom of the abutment plate The two horizontal measurements should be the same d 1 Left Abutment at anchor bolt plane d 2 Right Abutment at anchor bolt plane e 1 Left Abutment at middle of lowered gate e 2 Right Abutment at middle of lowered gate f 1 Left Abutment at lowered gate tip plane f 2 Righ...

Page 3: ...h 1 Left Abutment vertical middle h 2 Right Abutment vertical middle i 1 Left Abutment vertical gate up i 2 Right Abutment vertical gate up g h i Abutment Plate edge view 2 standoff at edge of plate Measured Offset Sketch shows section looking at top or side of abutment plate using a taught string line between the two standoff points 2 standoff at edge of plate TOLERANCE 1 8 3mm No point on each h...

Page 4: ...j 1 Angle between Left Abutment and Centerline of anchor bolts 5 ft b ft 3 ft A B C Calculate Angle A by laying out a 3 4 5 triangle and then measure what the 4 leg actually is Angle A arccos 16 b2 6b If b 4 the anchor bolts are perpendicular to the abutment wall Actual Angle Left Abutment Actual Angle Right Abutment TOLERANCE 90 degrees 0 1 degrees ...

Page 5: ...t B Straightness of Anchor Bolt Alignment Left Abutment Plate Right Abutment Plate N1 distance from face of right abutment wall to centerline of first main anchor bolt N2 distance from face of left abutment wall to centerline of first main anchor bolt PER DRAWING Centerline of anchor bolts drawn with taught string line between two outer most anchor bolts Distance of center of anchor bolt most out ...

Page 6: ...levation top of concrete anchors Across the Spillway m 1 Difference between highest and lowest elevations across the spillway crest measured near the main anchor bolts m 2 Difference between highest and lowest elevations of main anchors _______________ TOLERANCE 1 8 3mm MAIN ANCHOR BOLTS SHOULD NOT VARY BY MORE THAN 3mm IN HORIZONTAL ALIGNMENT TOLERANCE 1 4 6mm FOR m 1 TOLERANCE 1 8 3MM FOR m 2 ...

Page 7: ... Left abutment wall and centerline of first restraining strap block out _ q 2 Distance between CL first left restraining strap block out and CL of second restraining strap block out _______ r 1 Distance between Right abutment was and centerline of first restraining strap block out ___ r 2 Distance between CL first right restraining strap block out and CL of second restraining strap block out _____...

Page 8: ...tion because the large holes in the bladder will fit over the anchor bolts 2 Fit the first 6 bladder holes from left to right over the first 6 anchors There is no need to fit the remaining holes over the remaining anchors because the bladder will be folded from right to left in the next step NOTE If bladders are identical then there is no difference where each bladder is placed Figure 1 Image of a...

Page 9: ...igure 2 Example of one method of lifting the bladders into the spillway Bladders may also be carried in manually with multiple workers 3 INSTALLATION OF AIR FITTINGS REFERENCE DRAWING 123 One at a time fold each bladder from left to right to expose the air fitting on the underside of the bladder ...

Page 10: ... with thread sealant Cover brass hose barb with thread sealant Thread the two pieces together very tightly 2 Thread the male side of the street elbow into the bottom of the bladder fitting very tightly Try to end with the hose barb facing downstream towards the air pipe Fold bladders back in this direction side to side to expose air fitting Figure 3 Direction of bladder folding ...

Page 11: ...bedded pipe ends with a or 12mm stainless steel hose barb Install one at this time if necessary Use thread sealant on all threads THREAD SEALANT THREAD TOGETHER TIGHTLY THREAD INTO BLADDER FITTING TIGHTLY TRY TO END WITH HOSE BARB POINTING DOWNSTREAM Figure 4 Description of steps 1 and 2 of air fitting installation ...

Page 12: ...s steel hose clamp over the top of each end of the hose 6 Press the side with the small plastic tube FULLY onto the brass hose barb located on the bladder 7 Press the side with the stainless steel hose insert FULLY onto the stainless steel hose barb located on the embedded pipe 8 Tighten down both hose clamps THREAD SEALANT THREAD TO EMBEDDED AIR LINE ADAPTERS WILL BE NECESSARY Figure 5 Descriptio...

Page 13: ... kinks in the hose exist Stainless hose barb Connected to embedded pipe Stainless steel hose insert Fully inserted into hose Hose Clamp Tightened after hose is over both hose bards Hose Hose will create a loop in between both barbs Visually inspect no kinks in hose Hose Clamp Tightened after hose is over both hose bards Plastic Tube Fully inserted into hose Brass Elbow and Hose Barb Assembly Conne...

Page 14: ...ect air connection once more to assure all connections are tight and no leaks can occur Fold the bladder back over so that all large bladder holes go over anchor bolts Carefully inspect that the hose is falling into the air blockout as bladder is unfolded back into position 11 Repeat steps 1 through 10 on the remaining bladders 4 POSITIONING OF GATES Figure 6 Description of steps 4 through 8 ...

Page 15: ...f 36 Using a crane each can now be lifted into its proper position 1 Use straps and shackles to properly secure lifting straps to lifting eyes located on gate panel 2 Once secured lift gate panel with crane towards is position Figure 8 Image of lifting eye Lifting eye to be used to lift gate ...

Page 16: ...ATE SYSTEM INSTALLATION PROCEDURE Printed 10 23 2019 15 1507 OHI OBERMEYER Hydro Inc 16 of 36 Figure 9 Example of gate being lifted into place Multiple straps are used to balance the gate as it is lifted ...

Page 17: ...e hinge is pulled up and the gate is properly positioned the hinge holes in the bladder will fit over the hinge studs located on the bottom edge of the gate There are two methods to pulling the hinge flap up to make room a Use multiple workers to pry the hinge up by hand The gate will need to be slowly lowered and re positioned as the hinge is pulled up and over the gate all the way across the gat...

Page 18: ... main anchors Hinge Flap Must be pulled up to fit gate Base of gate is to be inserted into this gap Hinge studs located on bottom of gate should go through hinge holes when properly positioned Main anchors should already be through the bladder main anchor holes prior to steel gate installation Figure 11 Description of hinge flap to be pulled back ...

Page 19: ...icone on the gate panel around each of the hinge studs in the section Also apply silicone around the base of the ribs located on one or both sides of the section NOTE Each section of hinge is the amount of studs present between ribs or to the end of the gate Figure 13 Description of step 2 3 Press down first hinge section 4 Remove plastic sleeve from each hinge stud Red line represents the area to...

Page 20: ...eps 1 through 7 across the entire spillway each hinge section at a time 6 Main Clamp Bar Seals and EPDM Installation At this stage in the gate installation it is easiest to install the rest of the components from left to right across the spillway 1 Left Abutment Seal 2 Left Abutment EPDM 3 Gate 1 Main Clamp Bars 4 EPDM seal 2 5 Gate 2 Main Clamp Bars 6 Interpanel Seal 1 7 EPDM seal 3 8 Gate 3 Main...

Page 21: ... a rectangle starting on the upstream inside corner of the abutment seal The left to right distance of the rectangle should be width of the abutment seal in the clamping zone A 1 4 NOTE is added to the A measurement to ensure there is a good interference seal between the abutment seal and the end of the bladder Measure this distance from point C on figure 15 this is the most critical area The upst...

Page 22: ...GATE SYSTEM INSTALLATION PROCEDURE Printed 10 23 2019 15 1507 OHI OBERMEYER Hydro Inc 22 of 36 Figure 14 Abutment Seal Installation Description ...

Page 23: ... will be utilized here as a marker to drill holes 5 Place the base of the abutment seal into position as shown in figure 16 The upstream bulb of the abutment seal should be 6mm downstream of the bladder bulb 6 Use a mallet to strike the abutment seal at the first stud location Pull the seal back and drill a hole in the abutment seal at the location of the mark 7 Measure the distance from the insid...

Page 24: ... the position of the stud with a mallet Pry bars may be utilized to force abutment seal into correct position Note that the marking should only be used for the upstream downstream position of each stud The left to right dimension should be dimension D for all holes 10 Identify the position of each hole using the upstream downstream mark and dimension D and drill each hole accordingly Dimension D F...

Page 25: ...ers down as shown in section D D of drawing 121 13 Torque all restraining strap nuts to the values shown in the anchor torque specifications section below 6b EPDM Seal Installation at an Interpanel Seal EPDM is to be used and the ends of all bladders to help ensure a water tight seal between different components 1 Cut two holes towards the top edge of the EPDM to fit over two anchor bolts Check dr...

Page 26: ... match the contour of the clamp and hinge as best as possible Mark the position that the EPDM sits over the main anchors and on the hinge studs and interpanel seal studs 4 Cut the holes so that the EPDM can lay over each of these studs Holes cut in figure 19 step 1 are located here Holes for hinge studs and interpanel seal studs will be cut here Second holes for main anchors will be cut here EPDM ...

Page 27: ...der coat every surface of the bladder and spillway that will come into contact with the EPDM sheet 7 Replace EPDM sheet in the proper position shown in figure 20 with all holes over their respective studs 8 Replace all retainers that were removed for EPDM placement and re torque all nuts to their required value Holes cut in figure 19 step 1 are located here Second holes for main anchors will be cu...

Page 28: ...t wall The edge of the EPDM should be installed flush against the abutment wall 6d Main Clamp Bar Installation Procedure 1 Starting on the left side have one worker lift the bladder to expose the anchors coming out of the spillway 2 While one section of the bladder is being lifted have another worker apply a bead of silicone to the spillway that circumnavigates each anchor bolt and also acts as a ...

Page 29: ... down on top of the clamp bar and torque to the values shown in the anchor torque specifications section below NOTE At each gate end EPDM will need to be installed prior to the end main clamp bars 6e Interpanel Seal Installation Similar to the abutment seals the interpanel seals will need to be trimmed at the base near the clamp area in order to fit next to the bladder 1 Locate the interpanel seal...

Page 30: ...the interpanel seal parallel to the gap between the hinge flaps 3 With the interpanel seal centered mark the seal with a straight line 1 8 6mm outside the end of each hinge flap for cutting Interpanel Seal Right Gate Left Gate Hinge Flap Centerline of seal should be parallel with centerline of space between gates Marked cutting point is 1 8 6mm outside of the end of the hinge flap to create interf...

Page 31: ...seal parallel to the flat area of both bladders Re trim the seal if necessary 6 Cover all interpanel seal retainer studs with anti seize 7 With the base of the interpanel seal in position use a mallet to hit the interpanel seal at the location of each stud 8 Use the markings made by the anti seize on the underside of the interpanel seal to drill holes for stud locations 9 Test fit the interpanel s...

Page 32: ...nylon rods molded into each end instructions will differ 1 Locate all restraining strap and restraining strap clamps Review drawings 101 and 124 to grasp a preliminary concept of how the straps attach 2 Use compressed air to raise the bladders about halfway to their maximum height NOTE To avoid damage to this system use dry air from a compressor with pressure regulation controls and pressure relie...

Page 33: ...estraining straps 5 Locate the free nylon rod On the spillway clamp place the nylon rod into position as shown in the bottom figure 27 Pull the rubber tight around the nylon rod and tighten the clamp Then attach the top end of the restraining strap to the gate panel as shown in the top of figure 27 6 Raise the gate system to approximately 25 of design pressure or until the restraining straps just ...

Page 34: ...IS NEEDED FOR AUTHORIZATION FLAT CLAMP AIR BLADDERS 1 25 4mm 150 ft lbs 200 N m 1 2 31 75mm 50 8mm 200 ft lbs 270 N m TORQUE SPECS BASED ON STUD SIZE FOR HINGE FLAP RUBBER PARTS 3 8 9 5mm 20 ft lbs 30 N m 12 7mm 40 ft lbs 55 N m 5 8 16mm 70 ft lbs 100 N m 19mm 100 ft lbs 135 N m 1 25 4mm 150 ft lbs 200 N m 1 2 31 75mm 50 8mm 200 ft lbs 270 N m TORQUE SPEC FOR GATE FLANGE BOLTS ALL BOLTS 1 OR GREAT...

Page 35: ...Flap connects to the Gate Panel using the bottom row of Gate Panel studs with the provided Hinge Flap Retainers washers and hex nuts In the fully raised position with the Air Bladder inflated the Hinge Flap transmits a compressive force from the Flat Clamp to the bottom edge of the Gate Panel NOTE Inflation of an Air Bladder even under low pressure without clamps securely tightened can cause perma...

Page 36: ...rap Clamps fasten the Restraining Strap to the spillway and to the Gate Panel The Restraining Strap Anchor Bolts used to fasten the clamp to the spillway and the hex head bolts used to fasten the clamp to the Gate Panel are typically of the same diameter and should be kept tight at all times NAPPE BREAKERS The Nappe Breakers divide the water flowing over the top edge of the raised gate system This...