crossflow turbine design and fabrication

5/28/2018 Crossflow Turbine Design and Fabrication

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A project of Volunteers in AsiaDesign of Cross-FlowJ&.gbjne BYS/T3by: Ueli MeierPublished by:Swiss Center for Appropriate TechnologyVarnbuelstrasse 14CH-9000 St. GallenSwitzerlandPaper copies are $10.00.Available from:Swiss Center for Appropriate TechnologyVarnbuelstrasse 14CH-9000 St. GallenSwitzerlandReproduced by permission of the S;Jiss Center forAppropriate Technology.Reproduction of this microfiche document in anyform is subject to the same restrictions as thoseof the original document.


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CF Turbfne: BEVT3Hints for the use of the drawing set:

Drawings are divided into sub-assembly and assembly grouos. Thecorresoonding parts-list bears the same number code as the assemblydrawing.In addition, the whole set is numbered serially starting with 5'01and upto S 75.Manufacturing instructions of difficult parts and the assembly pro-cedure are shown on the pages preceeding the workshop drawings.Code "b 'e refers to the variable nozzle width. All drawings withbo-rela ed measurements have to be completed by adding the chosenb . Example: b = 920 as calculated. For drawing Ol/OO : b. + 70 =990 + 70 = $90mm; b. + 130 = 920 + 130 = 1050 mm.On drawings where the number of holes is variable due to variablewidth, the correct center to center distances are to be found inthe respective row of b . Example: Orwg. 03/05: Measurements A to Lread from row b. 920 + a , B, K, L = 86 mm. C, 0, E, F, G, H, I, J =87.-Depending on the head under which the turbine is to operate and onthe rotor width, the rotor requires one or several supportingdisks. One of the drawings S 29 to S 33 is to be used accordinglyfor the fabrication of the respective rotor.

VarnbiiclstralJe 14, CH-9000 St.Gallen.Switzerland, Tel. 07 I 23 34 XI


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a

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P


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800 *C

600 *C

Take 2.5mm M S.Sheet and shear ifoff according to required size.

Xeat the sheet up to 800 'C.

Roll it careruiiy.

Check whether the blade is twisted.If 80 correct it.

Pack the blades singly,as shown, in ametal box with cast iron chip stuffedall around them.Heat the box uniformlyfrom all sides up to 605, 'c.Let it cool in air by itself.

e the edge profile by filingaccording to the drawing.Let the other end of the blade be asit 323.


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- PAPER JIG

Prepare mild steel sheet according tomeaeurements (4mm thick by 210 x 210 >.

k centre and draw a circleof $?j205.

Cut the four edgee off by ehearing.Bore a hole of fl 50.5 in the centre.

Use disc holder to put together 1Opcs.Mount it on Lathe a.a shown and turn to$3 206.

Apply quick drying glue throughly onback side of the paper jig.Stick iton the disc.Make sure the paper jigcoincidee with disc.Prees all overerrd let it dry.

Zentre punching.

Drilling ( d 3 1.

If necessary do soft annealing atTemprature of 600 'C.Yake slota with sliting saw machine.

Piniah by fili .AtPeast 2pcs at a time.


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Place the middle disc in pool-tion.Do tack welding from bothsides.Check the axis of thediet should be 9C to the axisof the shaft.Make full welding,

Place the outer discs in nosi-tion.Ineert the blades in theelote.dege profile falls ineide.

T)o tack welding of the bladeson the outer disc and outerdisc on the rotor (as shown)from out side only.

Mount it on Lathe and check ;a) Rl.8~ should be 90' to the

axis of the rotor.b) The blade ahould be parallel

to the axis of the rotor.

If it is alright place the rortically bp (as shown)on a drum or a a i4cially made

table with a hole big enoughtr: put the shaft end thruogh.Continue welding from out side.only and alternately (as shown


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Turn eachside up to 20 nunfrom the middle disc to fl 202.Remove burr which may bostructwelding rod.

' Make full welding on themiddle disc alternativelyopposite side of the disc.

Turn the rotor shaft to fl 50

Facing off

Turn the rotor shaft to finalId of 200.Turn the rotor shaft 180' tocarry on turning and facingof the other side.Remove burr from rotor blade


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CUP BUSHSEALING RINGPIVOTAL BUSH *IBUSH CASINO1 lBUSH CAS NG ?ilWi;;t BUSH 2COWERWASHERLEVERLOCK NUTSPINDLESTAND ASSEMBLYHANDLEKNOBBUSHWASHERCOTTER PINBUllER FLY VALVEWINGWTWAYlERHEXBOLTHEX-BOLTHEX-NUTHEX.BDLTHEX-BOLTHEX. BO LTHEX-NUTHEXBOLTHEXHUTHEXBOLTHEXNUTHE&BOLTHEX.NUTHEX.NUT9DAPTER

T 3/OI/OOT3/02/00

T3/11 /OOT3/12/00T3/13/00T3/l4/00WET3/17/00T3/WOOT3/19/00;;/gvm;xi%:T3/24/00T3/25/00T3/26/00T3/27/ 00T3/28/00T3%zT3/31/00T3/32/00T3733/00TW3UOOT3135100T3/36/WT3/37/00T 3/38/00T3/39/00T3/40/00T3/41/00T3142 /OOT3/43/00T 3/44/00T314W00T3/46/ 00T3/47/00T3/48/00T3/49/WT3/50/00Ez~

SPEClFlCATlONHSfJN&NNEL lOOXRUBBER 6MMM.


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1-+- , - -- -)-. .I.%. c------*--_----7-1 c-.eAmm I l- _ -*


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372 SO I-

zA7.a 1

---a

542 I

A-A

M.S.CHANNEL 100 X 501 PCA


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425RUBBER 6MM2.Fcs

bo +170

RUBBER 6MM2.PCS

IIIli

7

I-L

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s:-


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51DE PLATE3AFFLE PLATEiPACER PLATE?EAR BAFFLE PLATEiDUSING BASE FRONTIDIJSIND BASE REARrHREAQ STUB

T 3/03/01T3/03/02T3/ w/o3T3/03/04T3/03/05T3/03/06t3mm7

ISPLATE 5MMX253X23Sd.S.PLATE %iiX284Xbo+70dS.FLAT 30x6 Xbo+70I.S.PLATE 5MM X155Xbw704.S.FLAT GXbo+5424S.FLAT 50X6 X bo +338lS.ROD Gl5

ROTORHOUSINGASSEMBLY T3/03/00 IS0


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i

l.PC

A-A\

Q

NOTE A, WELD POS.3 TOGETHER WITH INLET ASSEMBLYB. U5E JIG-NO 01 TO DRILL HOLES FOR THREADS M6 AND Ml4

ROTOR HOUSING ASSEMBLY T3/03/00 SO1: 2.5


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FINAL 75

52

M.S.PLATE

SiDE PLATE T3/03/01 1SO


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bo +7Ot

MSPLATE 5 MM

BAFFLE PLATE


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L

I

MSPLATE 6MMl.pc

SPACER PLATE

bo +70 =


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bo+70L L

MSPLATE 5MMl.PC

REAR BAFFLE PLATE T3/03/04 SO


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25 A 6 I 3 K L0 tI- _ WELDOI I I--- .+ + + + + + + +

bo+70bo+170

DRILL HOLES WITH BASE F

bo290 82 82 82 82 82bo390 85 85 85 85 85 85boS20 80 80 80 80 80 80 80 80bo690 81 81 81 81 81 81 81 81 81 8-lbo920 86 86 87 87 87 87 87 87 87 87 86 86


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25. A B C D E F 0 H I J K L WELD Of

h FLAT iX l/i (50,6X6)

DRILL HOLWITH BASE


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QL-J5M.S. ROD B 18.PCS


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M.S.PLATEl.PC


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TA J7.2.M239.s


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lWtVlNU1 1 INLET TOP ASSEMBLY .l-21-3

l-4234

INLET TOP PLATEHATCH DOOR FRAME

r3/06/01r3/06/01-1T3/06/Ol-2

HATCH DOOR 13/06/Ol-3

HATCH DOOR GASKET T 3/06 /Ol- 4INLET BOTTOM PLATE T3/06/02INLET FLANGE T3/06/03INLET SIDE PLATE T3/06/04

INLET ASSEMBLYPART LIST

1 lW+ARKbGSEMBLYISPLATE SMMXSSOXbo+70I.S.ANGLE 25X25X5

520X2~bo+2094.S.PLATE 5MMX260Xbo+70rl.S.kGLE 8 19OXbo25X25X5 X boWBBER ZMM X260Xbo+70%S.PLATE wX26OXbo+43.S.FLAT ,50X 6

=2(bo+1001M.S.PLATESMMX169X401

T3/06/08 SI


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TIPS FLUSH W.. - --RADIUS 100

A-AM)

E-----mm. .-w--e.

, I I I .

INLET ASSEMBLY T3/06/00( S1: 2.5(1:1) 1 I


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FASTEN POS 283TOGETHER AND WELD

#--Abo+70 3

INLET TOP ASSEMBLYE T3/06/01 1S


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MSPLATE1.pc

STRAIGHT LENGTH-450

bo+70


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I1I M.S.ANGLE 5X25X25

PRll L THESE HOLES TOGETHER WITHPOS.T3/06/01-3

ba+20bo+70


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bo290o290 577 577 566 566 577 577bo390o390 633 633 633 633 633 633 633ho520o520 6&& 633 633 633 644 633 633 633 644bo690o690 688 677 677 677 677 688 677 677 677 677 688bo920o920 655 655 655 655 655 644 644 644 644 644 655 655 655 655 655


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bo+20

RUBBER 2MMl.pc

bo+70

HATCH DOOR GASKET

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bo.70l cbo .70

t-2-w

MS. ROD $I /2 X 295l.PC

==P

M.S.ROD Q l/2 X 295

t% FOR / bo-220 bo-290 1 bo-390

bo+70

bo-70 i bo-90

WO6lO l-

jbo-120 1 bo-160

T3/06101-

bo-520 / bo-690 j h-920

HANDLE T3/06/01,5 S


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M.S.PLATE1.

INLET BOTTOM PLATE


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++++++++++M.S FLAT 6X50 +b

+.I

MAKE THISSURFACEPLAIN

2 PCS

A B C D E F G H I J K L MI bo 50

bo 70bo 90bo 120bo 160bo 220bo 290bo 390bo 520bo 690bo 920,

75 7560 60 6075 70 7570 70 70 7070 70 70 70 7075 75 75 75 75 7573 73 72 72 72 72 73 7375 75 75 75 75 75 75 75 75 7576 76 75 75 75 75 76 75 75 75 75 76 76

INLET FLANGE T3/06/03 S2


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1. NO OF PLATE WITH $421. NO OF PLATE WITH 932.

-46

l-l SHEARING -,

M.S.PLATE 5MM-.2.NOS

INLET SIDE PLATE T3/06/04 S2


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bo+4bo +lOO

RUBBER SHEET

INLET GASKET T3/07/00 S2


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ROTOR SHAFTROTOR DlSCBLADE

T3/08/01T3/00/ 02T3/08/ 03

ROTOR ASSEMBLY

M.S.ROD @2?50,81 X bo+570M.S.SHEET 4MM X 205X205MS .SHEET 2.5MM X49Xbo+30

T3/08/00 IS2RWT LIST I


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ROTOR ASSEMBLY T3/08/00 S2


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WOR DISC ARRANGEMET C T3/08/00 S3u


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-

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ROTOR DISC ARRANGEMENT E ?3/08/00 S31:sS


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I4

bo+ 570

M.S.ROD Z-(50.81 X DIMENSION ACCORDING TO PULLEY USED


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M.S.PLATEPC


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i?

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STR AlGHi LENGTH bo+30=

EDGE PROFILE (2 : 1)

M.S.SHEET


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2 PCS BEARING NUMBER FYH F21OJ UCSlO

ROTOR BEARING T3/09/00 S3


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4b-- - -i3

* ift 0.$- i -m --I6

M.S.ROD / PLATE2.PCS

c

NOTE.-USE JIG NO.02TO DRILL HOLES i $8,016)

-DO BORING OF 051 AND 860AFTER W ELDING TO FLAGE.

STUFFING BOX T3/10/00 S


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u

w.S.ROD&PCS


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I

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----

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PRESS RING T3/12/00 541:l


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364-. .-

1

RUBBER 2MM2 PCS


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M.S.FLAT2.PCS

SEALING PLATE T3/14/00 Sg


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RUBBER SHEET2.PCS


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cnI:D

q39.5 i

bo+91


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[email protected]

CUP BUSH . T3717/00 S 45


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RUBBER 6MM2.Pcs


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I I - II

1 PRESS FIT WITH T3/20/00) BRASS ROD 2 (50.8]

1 PIVOTAL BUSH 1 T3/19/09 S4


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M.S.t?ODl.PC


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M.S.ROD + 2); (63.5)j.FJ


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0.5x450--l-r

SS ROQ


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RUBBER SHEET 2MMl.PC

E.J-L


70/93

M.S.SHEET1.pc


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M.S.SHEE Tl.PC


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STRAIGHT LENGTH 292

M.S.FLATm

-,-.-..-. . -

0.


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M.S.ROD


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@16+X.4

Ml61

I .

M20

i +o20-

SPINDLE T3/28/00 95


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3ASE PLATEWPPORT ANGLEjTOPPER PLATE BOTTOMSTOPPER PLATE TOPSUPPORT TOP PLATE

T 3/29/01T3/29/02T3/29/ 03T3/29/04T3/29/05

M.S.PLATE ~XXOXXOM.S.ANGLE 50X50X 6 X 570Y.S.PLATE lOMMX4LXCLY.S PLATE lOMMX5GXr;L4.S.PLATE lOMMXSOX50

SUPPORT ASSEMBLYPART I. IST T3/29/00 S 5I


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21

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L 15*---

A-A

SUPPORTASSEMBLY T3/29/00( S


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-f-T--35 32

M.S.PLATE 10 MM


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M.S.ANGLE1.pc_


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B-r

444 I

MSPLATE 10 MM


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M.S.PLATE 1OMM1PC


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M.S.PLATE 1OMMl.PC


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I

w--w m-M---.P

A-T,

HANDLE

15t-l


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M.S.ROD


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12l--lBRASS. ROD1E


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P0S.T 3/3I./OO1 PC

WASHER/COTTER PIN


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WIDTH= bo,

GRIND FLUSH I

NOTE. DO FULL WELDING WfTH SHAFTIN ITS PLACE

BUTTERFLY VALVE T3/35/00 S6g


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REGULAR Ml6 NUT


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POS 1 M 1 Ll 1 L238 Ml4 30 70

#

39 Ml2 30 3041 M8 15 1542 1 M6 (10 I10

47 I M6 115 I3049 1 M6 I30 I30

FULL bo boTHREAD 50 70 90 120 160 220 290 390 520 690 920 tNO 00888888808

YES 22 22 22 26 26 30 34 38 46 54 6LYES 1 1 1 1 1 1 11 1 1 1 1 1 1 1 1 1

YES 14 14 14 14 14 14 14 14 14 14 14 1YES 8 8 8 0 8 8 8 8 8 8 8YES 12 14 14 16 10 18 20 22 26 30 30NO 3 3 3 3 3 3 3 3 3 3 3

YES 11111111111

HEX. BOLTS T3/38,39,41.42.43.45.17.49/00 s7


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NUMBER OF NUTS_ POS SIZE bo50 bo70 bo90 bo120 bol60 bo220 bo290 bo390 bo520 bo690 bo920

22 22 22 26 26 30

8 8 8 8 8 8

12 14 14 16 18 18 20

34 54

8

3 3 3 3 3 3

1 1 1 1 1 1

2 I 2 2 2 3 2T3/40,44.46,48.50.51/00


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ADA

ENSTOCK FLANGET3/06/03T3/52/0213/52/03

,PTER ASSEMBLY

M.S.FLAT WY.S, SHEET 2,5M.MclS.PLATE &MM

PART LISTT3/52/00 S7I


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INOTE.USE 1PG INLET FLANGE [T3/06/031FOR POS.1

T3/52/00 S7I


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.f

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D

D+80

k -/

MS-PLATE 8MMPCS

D =lNSlDE DIAMETER OF PENSTOCK +6

crossflow turbine design and fabrication

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