PED, = lu LO r : t BELANIGA “sen. OPERATING AND “MAINTENANCE PISL&SIL -| bil & GORDON LTD 20028 - Telex 65125sisi sii millaleac sae 1 UNPACKING 2 ~ ASSELBLY 3 ASSEMBLY TUTOR PUMP SETS 4 ASSEHBLY TUTOR PELTON 5 : ASSEMBLY TUDOR FRANCIS SETS 6 FORCE GAUGES 7 INITIAL TESTING AND OPERATION 8 ROUDINE LABCRATORY TESTS ‘ 9 UAINTEN: @ INSTRUCTIONS cr INDEX 10 ILLUSTRATIONS | PLATE NC SUBIRCT B58 SINGLE SPEED PUKP ARRANGEMENT E167 " VARIABLE SPEED PUMP ARRANG 163 VARIABLE SPEED WIRING DLAGRAN E103 “FORCE GAUGES BT2 ° PELLON TURBINE ASSEMBLY BTS FRANCIS TURBINE ASSEMBLY E88 PRONY BRAKE ASSEMBLY E87 * PIPEWORK ARRANGELENT E84 TANK ARRANGEMENT B85 nes TROLLEY ARRANGEMENT INDE 70 FERFORMANCE CURVES PLATE NO. 35-0 PURP PERFORMANCE at 1450 r.p.m. 1 36-02 PUMP PERFORMANCE at 2900 r.p.m. | leer - PELTON NOZZLE CHARACTERISTIC 38-0r PELTON ISO-EFFICIENCY CURVES 37-0 PRANCIS ISQ-ZFFICIZNCY CURVES i INDEX TO DRAW . 2 # 4287-601 TUTOR PUMP UIT DESIGN DATA 4 4287-201 TUTOR PELTON UNIT DESIGN DATA $2877--401, TUTOR FRANCIS UNIT DESIGN DavAINSTRUCTIONS FOR MAL’ UNPACKING lel The unit will arrive in one packing case containing all the necessary parts. As you unpack the case be careful not to lose any suall items.” Small items are normally wrapped in black paper or felt or both. 1.2 The parts should be checked off against the actailed parts list that will be found in the packing case. 1.3 Carefully clcay_all componente to remove packing naterial,etc. ‘Remember that careful cleaning at this stage will avoid the need for subsequent dis- tantLing operations. ASSEMBLY 2.1 Your 'Tutor' test set will arrive almost completely BUTOR PUKE 3.1 364 assembled. If you have ordered an interchangeable turbine unit this will be supplied but not assembled on to the tank. The various small loose items should be mounted as described. below. S These units are supplied with either a two-speed motor or an infinitely variable speed motor according to your order. In both cases the uotor freme should be checked for freedoa of rotation and any retaining straps or stops removed. The pressure gauge should be installed in the boss on the pump discharge pipe. See Plate B67. Fill the Force Gauge as described in section 6 of this manual. Hount the force gauge on the mounting block provided under the motor torque arm. ct to your laboratory supply, fhe-#e— nodela-all—roquire-a—3vhaseo—eleetie_cupsly, The infinitely variable speed models may run from a single phase supply or from two lines of a three phase supply.3.4 3.5 3.6 3.7 4. 4el 462 4.3 4.5 4.6 CONG ee reeee In both cases a wiring diagram is provided in the. notor starter. ‘ie circuit diagrams are also re produced in this manual, see Plate 2163 variable speed model is. connected by m 3 plvg and socket on the side of the control cabinet. Pit the plastic baffle plates in the vertical -slots in the tank wall. See Plate E84. Ensure that the drain plugs fitted to the fibre~ glass tank are’ firmly in place and fill with weter. bevel the tank by means of the jacking screws located inthe base of the trolley. Zero the flow measuring scale. Check for water leaks, The set is now ready ‘for vse. Now turn to the secticn of this manval entitled “Initial fests and Operation". (Section 7). : ULOR_PELDON SETS These units. are supplied with one of three choices of motor: single speed, two speed or infinitely varieble speed. The following instructions apply to all three models. Fill the force gauges as described in Section 6 of this manual. Mount the force gauges. (In the case of the single speed sets, only one force gauge is employed). One force gauge is mounted on the mounting braciet under- neath the prony brake, the other is mounted under- neath the motor torque ara. Nount the, prony brake on the brake dran. See Flate Fit the harivheel to the pressure regilating valve in the supply pipe from the pump to the turbine. Fit the pressure gauge in the boss on the supply pipe. See Plate E67.@ Kay 48 “449 | : | i : ft I i: ; 5.1 562 { I 5.3 Se4 Fit the plastic baffle plates in the vertical slots in the tank wall, See Plate 284. Connect the unit to your laboratory supply. The single speed versions ere available for single or three phase operction; #hetuo-snecé. wpiteare_cyaileble—or—thzes_ohase-Cni¥; The variable speed wodels will single phase supplies or from tw s of three phase supply. .In each case a wiring diagram is provided in the motor starter or con The circuit @iagran’ for the 4 model 1s also Plate E163. The variable speed nodel is connected py means of the plug and socket-on the side of the control cabinet. Ensure that the drain plugs fitted to the fibre- glass tank are firmly in. place and ill with water, Level the tank by means of the jacking screws located in the base of the trolley, Zero the flow measuring scale. 4.10 Check for water leaks. The set is now ready for use, Now turn to the section of this wanual entitled “Initial Testing and Operation" (Section 7). TUTOR FRANCIS SETS The instructions applying to Pelton Sets ( Section 4.1 - 4.10) also apply to Francis Sets. The perspex (plexiglass) draft tube and end cover must be assembled to the Francis turbine unit as showm in Flate B75. Ensure that the adjustable guide vane uechanisn operates suoothly and ‘if necessary apply a swall amount of oil to the moving parts. Follow the instructions under section 4 and then turn to the section of this manual entitled "Initial Testing and Operation". (Section 7).HA ES ; : E | 6. FORCE GAUGE! 6.2 6.2 6.3 6.4 6.6 The calibrated scales fitted to all Force Ganges are dual calibrated in either pounds/ kilograms or pounds/newtons according to customers' reauirenents. ‘to reverse the scale undo the small chrome headed fixing screws and nount with the alternative scale outwards. The following is a brief. description of the method of operation of the Gilkes Force Gauge. The brake or torque arm exerts pressure on a pellows unit which under compression behaves like a normal coil spring..- The distance it compresses is directly proportional to the applied force. This reduction in length also reduces the internal volume of the. bellows ina similar way and when tke bellows are filled with Liquid any reduction in internal volune can be seen by the compensating rise in the level of the ligaid in the glass tube. The load exerted on the bellows is thus also partly counteracted by the head due to the height of the liquid in the glass tube. A scale which translates liguid level into appliéd force is individually calibrated for each instrument. Elongated. mounting slots allow adjustment of the zero setting. : Adjust the scale to the mid-position in its mounting slots. Ensure that the gauge is clean, If available plow out with compressed air. Ensure that the pellows asseubly is screwed firmly into the main casting. Slowly pour mercury (from the bottle supplied) into the bellows through the top plug (Item 12 Plate E103). Keep filling until the aercury is about 1/16" (1.5mm) below the zero mark on the scale. : . Now very slowly fil1 the remainder of the pellows with clean water or a light oil. Occasionally shale the bellows $o help removal of air. The bellows uust be completely free of air for dccurate oyeration,Seti ati casa iil etl ls uci siesta i 6.7 When the bellows is full slowly serew in the top plug allowing fluid to escape as the plug is tightened down, “hen the plug is finger tight check thet the uercury level in i the glass tube has not risen above the zero. : If it has undo the plug slightly, @epress the bellows and squeeze out a small amount of water and retighten the plug. Any small error in . . the zero setting can nor be corrected by means of the movable scale 6.8 Romember that mercury is a polgonous Liquid. Great care should | ‘be taken when handling. oO 6.9 Now install the force gauge in its intended position, Allow the brake arn or motor torque arm to rest on top of the bellows. If necessary readjust the zero of the scale plate. Te INITIAL TESTING AND OPERATION t k 7.1 First familiarise yourself with the electrical control gear provided on the Tutor set. The sections below cover the three types of motor ‘ gna apply to Tutor Pump Sets, Felton Sets and ty f Prancis Sets. : f 7.2 Single Speed Kotors. The notor is provided with a simple direct-on- line starter; starting is effected by pressing the green buston. To stop press the red button. Aways start the pump with the pressure regulating valve closed. This reduces the power requirenent of the pump during start-up, Now turn to section 15. Ef olga Si i bila Neda ate Sa aaa adtt oN beer . TA Variable Sneed Hotors : 15 7.6 TT 768 These motors normally operate from a single phase supply of 240v,. 50/60 Hz; in special cases a transformer is provided to cater for other supply voltages. It should be remembered that the unit may also be connected to tno ‘Lnes of a 220v 3 phase supply. : Whe circuit diagram of the unit will be found in the control cabinet and is also reproduced in this nanual (Plate 2163 ). Two controls are provided: ON/OFF SYITCH and the ROTARY REGULATOR. Always return rotary control to zero (0) before attempting to tura the unit on. A special switch prevents starting if the rotary control is not at zero. When you have switched on the small neon indicator will light and you nay start the notor by slowly turning the rotary speed control. The motor speed is determined py ‘the position of the rotary control. Wow read section 7.5. With the pump running open the pressure reaulating valve and water flow will start. In the case of the Tutor Turbine sets you tay also have to open the Belton spear valve or the Francis guide * vanes. The water level at the weir will now rise and ‘the flow rate will be indicated by the sight glass and scale plate on the side of the tank. This scale is dual calibrated and way be reversed for an alternative system of measurement units. Te pressure at inlet to the turbines or, in the case of the pump set, at discharge fron the pump is now indicated by the pressure gauge. By adjusting the setting of the pressure regulator valve and/or the sveed of the motor obtain a good flow of water through the turbine or pump discharge pipe.tasiciiad 2 ai Rit tacit aE eI et TO ata SS) 7.9 7.10 TW ROUTINE LABORATORY EXPERIEENTS. 2 8.1 (id) tightening the black If a turbine unit is fitted thie will now be running freely. Load mey be imposed by ob on the prony brake. The force gauge will then indicate the load at the end of the brake arm. The speed of the pump or turbine may be measured with a hand tachometer. Continue simple tests as above varying the load on the turbine, the water flow, the supply pressure, etc until you are familiar with the basic elements of operating the Tutor Set. 1 | ' | i 1 futor Pump Sets Yen you are familiar with the method of pressure, flow and torque measurement then you may proceed with the conventional tests on a centrifugal pump. ‘These testa are detailed on vage 7 of the publication * The Educational Value of the Tutor ", which is to be found et the back of this manual. Further details of laboratory procedure will be found in our publication " The Testing of Water Turbines and Centrifugal Pumpe " which is supplied with each Tutor set. Tutor Pelton Sets hen you are familiar with the methogs of pressure, flow, torque and speed measurenent you may proceed with simple tests on the Felton ‘urbine, The variable in a Felton turbine is the setting of the spear valve, The load imvosed nay be varied by the setting of the prony brake. If you have a dynamometer set then you may also perforn tests on the centrifugal cum, When you are performing. turbine tests at constant head the head may be held constant by slight adjustments of the motor speed if you have the variable speed model. “hen performing pump tests we advise the use a of the pum discharce pive which is available as an accessory. This eliminates the complications of dicharging water through the spear valve.(a) “¢ » (4a) (444) (av) 8.3 Tutor Francis Sets Further details of the tests that may be performed on the Pelton are given on Page 5 of “The Educational Value-of the Tutor" to be found at the back of this manual. You may also refer to "The Testing ef liater Turbines and Centrifegal Pumps" supplied with each Tutor set. When you are familiar with the methods of pressure, Clow, torque and speed measurement ou may proceed with simple tests on the rancis turbine. The variable in a Francis turbine is the setting of the adjustable guide vanes. The load imposed may be Varied by the setting of the prony brake. If you have a dynauoueter set then you may : also perform tests on the centrifugal pump. : When you are performing turbine tests at constant head, the head may be held constant by slight adjustments of the motor speed if you have the variable speed model. : The internal mechanism of the Francis way be clearly seen and the availability of a stroboscope is a distinct advantage. As the Francis turbine operates in a totaily immersed condition the speed at which the turbine is allowed to ran for any given pump speed and setting of the regulating valve will narkedly affect the water flow throuch the turbine. This is a distinct difference from the Pelton turbine. 2 When performing pump tests we advise the use of the pump discharge pive which is available as an accessory. Tais eliminates the complications of discharging the water through the Francis turbine. Further details of the tests that may be perforued on the Francis turbine are given on Page 6 of “Tne Educational Value of the Tutor" to be found at the back of this manual. You may also refer to “fhe Testing of Water Turbines ani Centrifugal Pumps" supplied with each Tutor set.9. BAINDENANCE INSTRUCTIONS 9.1 Keep the Tutor Set clean by the use of the canvas or plastic cover provided. -g,2 If the water shows signs of discolouration change it. 9.3 Occasionally add a € prony brake lining. ‘This i at low speeds. ount of oil to the 11 prevent snatching 9.4 The pump and motor asseably requires no attention but if difficulty ie experienced you may Gismantle by referring to Plate &- i \ i i | i | 9.5 he Francis turbine requires occasional lubrication of the adjustable guide vane wechanisu. 9.6 ‘The Pelton turbine requires no maintenance. 9.7 If used carefully the Tutor set will give many years of trouble free service. Any small © : problems can be dealt with by reference to the exploded views in this manual. Should you require further help Gilkes operate an express spares service and technical advice is always available from our Kendal factory.aii ec cSNOILOZNNOD INUALNI JOULNOD YOLOW GAsdS ATaVIEVA 1390S 40 LNOWs + SNOMDANNOD XOS NOLONAT {8NDOS JO INO¥E woud MaIA i WOUS MBIA 7 N OB oo 4-8 a o f° 9° Ajue ouag "FS 20D,, Gl vay peso]? YyoymsosW “g'N. -4 7 -v : é Lg ’ yoSe ital cin aio iB adadl dans aman acl poe . 1 3 Ae eee eer ea ; ae | ye PELTON 7 G67 20. G gS ai \UIGvSistas Bicausanin bai. Sid SIGNVas UOLTL,aaa. FLV id a Nou ‘Fuveg Al a4 i iat iia pei a a ea ti eal att cl ull lida — ANENGINGY UOLNL, yod UNV WI YI VT aaSo eee ace ell cHE5 & GORDON 159. DAL, ENGLAND By GIL