Energia

9 Appendix A: Pelton hub
9.1 hub extension
Note: hole diameter and p.c.d. for hub extension as for hub plate A B C

F G E D

9.2 120mm p.c.d. hub plate
I

Hole dia. F J G+0.2 Hole p.c.d.

H (recess depth)

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9.3 Hub extension dimension key Hub extension
Motor frame Runner p.c.d. 120mm A B C D* E* F* G*

Hub plate
H I J* Hole dia.Hole p.c.d

Bucket K 49 70 92

D90

24 160mm 30 200mm 36

6 8 10

66 60 56

12 12 12

22 22 22

38 44 51

17 17 17

4 4 5

8 8 10

26 32 34

6.5 6.5 8.5

64 76 84

9.4 Modifications to dimensions for alternative motor frame sizes: Motor Frame D80 D90 D100 D112 D132
NOTES:

Motor Shaft 19mm 24mm 28mm 28mm 38mm

D* 9.5 12 14 14 19

E* 20 22 24 24 30

G* 15 17 1919 24

* indicates a radius dimension, all dimensions in millimetres, all edges chamfered 45ºx1mm

Figure 8 Use the end of the bucket as a reference for drilling the fixing hole. Dimensions for K are given in the key above and are applicable for buckets cast from patterns supplied by NTU. Ensure that this hole is drilled in an identical place on each bucket. K

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10

Appendix B: Pelton bucket fixture

A jig or fixture of some kind is required to hold each bucket in the same way while the root is machined. A reference surface is required on the side of each bucket root. This reference is a surface parallel to the splitter ridge in the centre of the bucket and equal distance away from it. The fixture should allow each cast bucket to beheld in exactly the same way on the bed of the milling machine. One easy method of producing a suitable fixture is to use epoxy resin. Pour some resin into a small tray and allow this to set. Alternatively machine a metal plate (4mm – 6mm thick) so that it is just bigger than the face of the bucket and has perfectly square sides. Lightly grease the inside of a bucket. This will help when trying toremove it from the epoxy. Clamp a bucket face down onto the layer of solid epoxy or the metal plate. Use a height gauge or some other suitable method to check that the bucket splitter is parallel with the sides of the base to which it is clamped as shown opposite.

Pour more liquid epoxy using a small channel, made of folded tin for example, into the opening around the notch. Holding the bucketin an upright position (with the root pointing downwards) fill with liquid epoxy. Allow to set, then unclamp and free the bucket casting. An epoxy copy of the inside of the bucket should be left behind. This fixture will allow each bucket to be precisely located on the machine bed.

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11 Appendix C: Drawings of turbine assembly and componentsLight-weight removable case.

Rigid side-plate to support case and seal

Output to mechanical drives Location of directly- coupled Pelton runner Induction Motor used as a Generator Verticle adjustment of nozzle Steel angle base frame

The 'Pico Power Pack'

02.06.99 1mm = 5mm

1 of 12 Drawing No. 1

P.Maher Nottingham MHRG
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manufacturing guidelines/pmaher/6/1/01

The peltonrunner hub extension is 80mm from the bucket centre line. When positioned correctly, the hub should be pushed up to the shoulder at the end of the protruding shaft. This locates the runner centrally in the case which is160mm wide. Small adjustments can be made to align the nozzle by sliding the complete generator and runner assembly left or right as required. The sealing arrangement is shownseparately (Drawing Number 11)

Pelton Runner with Hub Extension

44.0mm

80.0mm

Generator

Side-plate

Pelton Runner

Nozzle Plate

Nozzle Bracket

Base Frame
TITLE DATE

Lightweight Case

ASSEMBLED PICO POWER PACK

02.06.99 1mm = 5mm

SHEET

2 of12

DRAWN BY

P.Maher Nottingham MHRG

SCALE

DRAWING NO.

2

COMPANY

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