OPERATION MANUAL. Team 05: Water Tower Generator. Website:

Transcription

1 OPERATION MANUAL Team 05: Water Tower Generator Website: Water Tower Generator System is a Trademark of Senior Design Group Team 5 APRIL 7, 2017 TEAM 5 1

2 Members: Komlan Amesse Darius Wright-Tippins Moises Zamor Olivier Perrault Faculty Advisor Hui Li, Ph.D. Faruque Omar, Ph.D. Sponsor Talquin Electric Cooperative, INC. Instructors Jerris Hooker Ph.D. Congratulations on your purchase of a new Water Tower Generator System May your re-adventures prove successful! 2

3 Table of Contents ABSTRACT ACKNOWLEDGEMENTS Introduction Functional Analysis Project Function Project Specifications Hydroelectric Turbine Generator Water Pump and the Pressure Tank Digital Multimeter and Power Meter DC-AC Inverter... 6 Project Assembly Mechanical Components Electrical Components Operation Instruction Power Generator Deconstruction Troubleshooting Water is leaking into the housing The Pump is not Working Proper The turbine is spinning, but no power is being generated The turbine blades will not spin

4 Table of Figure Figure 1: Turbine... 4 Figure 2: Tank... 4 Figure 3: Water Pump... 5 Figure 4: Water Pump and Pressure Tank Connected... 5 Figure 5: Digital Multimeter and Power meter...6 Figure 6: DC-AC Inverter...6 Figure 7: DC- AC Inverter..7 Figure 8: DC- AC Inverter.11 Figure 9: Water Pump Schematic/Shaft Replacement...11 Figure 10: Shaft. 11 Figure 11-Shaft Replacement... 12

5 ABSTRACT This manual describes the Water Tower Generator System, which is manufactured by senior design group team 5. The installer must have knowledge of plumbing and electrical systems, as should the end user of the system. This machine is small scale model of the large scale for Talquin Electric Cooperative. This system can output a large amount of power, generating very high voltages and currents. Practice all due safety. Electricity cannot be seen nor heard. Electricity can be lethal. Electrical systems must be installed in accordance with local laws by a qualified person. The information provided in this operation manual is important to properly and safely use the mini scale of water tower generator. Specifications and detailed descriptions in this manual help the consumer understand how and why the device works, consequently, helping the use and the troubleshooting of any problems that the user may experience. For easy transportation, the steps for disassembled and installation are well detail. By following these steps properly, the user will thoughtfully understand correct power output values. Any discrepancy of the output power value will be likely related to the failures of following the guideline provided in this manual, which can affect the cycle life of the apparatus. Routine maintenance should be followed to avoid additional stresses on the components, which could cause premature failure. A full component list with vendors is provided so that the user can replace any parts that fail. Safety is the extreme important to the manufactures. As result, please understand and follow all safety precautions given provided in detail. 1

6 ACKNOWLEDGEMENTS Everyone in Team 7 would like to thank Dr. Hooker for his support and generosity in teaching the class. We would also like to thank Talquin Electric Cooperative, INC. our sponsor, for bringing this project to completion and analyzing our marketability every step of the way. We would also like to thank Dr. Omar Faruque for advising us on the best course of action to take in order to accomplish our project. We would like to Dr. Hui Li for being our advisor for this project. We would like to give thanks to Dr. Wei Guo for informing us about pressure needed for this project. 2

7 1. Introduction Sponsored by Talquin Electric Cooperative, INC., Team 5 is working on developing the feasibility of hydroelectric generator suitable for water tower. The raise of the water department bill and the dilemma of not harnessing the energy from free falling water, enable Team 5 to design a system suitable for hydroelectric generator that can be implement in their water tower system to offset the water bills. The team of four has spent the past two semesters meeting with their sponsor and advisors to outline and refine the design to meet the needs of the sponsor. The result of mini scale of the project including major components of the design includes hydro turbine to harness the energy of the falling water. The compatibility between different components and easy installation are explain below. 2.1 Project Function 2. Functional Analysis Our team design hydroelectric generator to harness the power of free falling water. This system provides enough electric power to different load such as LED lights and electronic devices. This device operates fairly and able to perform in an environmentally friendly process with no harmful pollution produced. 2.2 Project Specifications The hydroelectric generator is a system comprised of numerous components, which work together 3

8 to produce the wanted power. This design meets the limitation of the sponsor. This design has not only a hydroelectric turbine, but also water pump, water reservoir and pressure tank to simulate the 60-psi pressure of water tower. The following subsections emphasize in detail these components giving each part s importance, function, and construction Hydroelectric Turbine Generator The hydroelectric turbine generator is one of the most important pieces of the apparatus. The types of hydropower turbines that make this power generation possible fall into the categories of an impulse or reaction turbine. Researched showed that hydrokinetic turbines are a type of reaction turbine that use the energy from the flow of present water. The system we design is most efficient with low head, high flow systems. Figure 1 shows the actual turbine choose for our system Water Pump and the Pressure Tank To simulate the free-falling water at 60 psi, our team select the Wayne SWS50-8.5FX is a 1/2 HP shallow jet well pump recharged 8.5 Gal. tank system. Includes 8.5 Gal. recharged tank. 30 psi to 50 psi pre-set pressure switch included. Shallow well system. Constructed of durable cast-iron. 1/2 HP shallow well system with 8.5 Gal. recharged tank 4

9 1/2 HP; maximum flow rate is 420 GPH; (50 psi) 3/4 in. NPT discharge with 1-1/4 in. suction Dual voltage (120-Volt/240-Volt) high efficiency square flange motor (factory set for 240-Volt). Pressure switch is pre-set at 30 psi to 50 psi for automatic operation. Figure 2, 3and 4 shows respectively the tank, the pump and the water pump and pressure tank connected. 5

10 2.2.3 Digital multimeter and power meter Team 5 chose bayite DC V 0-100A LCD Display Digital Current Voltage Power Energy Meter Multimeter Ammeter Voltmeter with 100A Current Shunt. Main Specifications: Working voltage: DC 6.5 ~ 100V, Measuring Accuracy: 1%, Power Consumption: 0.2W, Measurement speed: 2 times/s, Store Energy data when power off. Can be reset to 0, The blue backlight can be turned on/off manually. Test Range and Display format: Active Power test range: 0~10kW, Energy test range: 0~9999kWh, Voltage test range: DC 6.5~100V, Current test range: 0~ 100A. Precautions: This module is only suitable for 6.5~100V DC power. Applied load should not exceed the rated power. Wiring order cannot be wrong. This module is suitable for indoor, please do not use outdoor. Figure: DC to AC Inverter The DC to AC Inverter Aickar 300W Car Power Inverter, DC 12V to AC 110V Dual AC Outlets + Dual 2.4A/24W USB Ports with Smart Fan Built-in Blue. A REAL POWERFUL INVERTER: Our 12v power inverter provides constant REAL 300W AC power and 6

11 600W peak power. Equipped with an intelligent fan that runs according to the temperature of our power inverters smartly to keep it cool. MULTIFUNCTIONAL: With 2x120V AC pocket sockets and 2x2.4A intelligent USB charging ports, this DC to AC inverter will safely power different electronic devices. ALL-ROUND PROTECTION: Aickar 300W Inverter Charger has over-temperature, under and over voltage charging, short-circuit, reverse-connect and power overloads protection. STRONGLY BUILT: Aickar AC DC converter is made of durable metal, to provide advanced protection from 3.1 Mechanical Components 3. Project Assembly Due to the integrated design of our project, assembly of the parts is simple and straightforward. The steps of assembling the prototype is as follow: 1. Mount the pump on a secure base (Top of the pressure Tank), and bolt it down with lag screws. 2. Turn the pressure tank on its side, and screw an adapter to the galvanized elbow to which you can connect the water pipes. If you're using PVC pipes, screw a PVC female slip 7

12 adapter to the elbow. Wrap plumbing tape around the adapter threads and hold the elbow steady with one wrench while you tighten on the adapter with another. 3. Screw an adapter to the threaded pump outlet and tighten it with a wrench. Run pipe between the pump outlet and tank inlet, connecting it with appropriate fittings. Install a tee in this pipe at a point convenient for connection to the house water system, and connect the water line. 4. Connect the pressure pump to the water storage tank using the appropriate pipe and fittings. Install a shut-off valve in this pipe so that you can disconnect the pump from the tank when you need to make repairs. Keep this valve closed for now. 5. Look up the pressure settings for your pump. They are imprinted on the pump itself. Measure the bladder pressure of the tank by fitting a bicycle tire pressure gauge on the tank air valve. Let air out of the tank until this pressure is 2 to 4 psi below the cut-in pressure for the pump, which is the lower of its pressure settings. 6. Connect the pump to a source of electricity. You may be able to simply plug it in, but if not, hardwire it to a circuit with the appropriate voltage. Open the valve to the storage tank and turn on the pump. Verify that it stops pumping at its cut-out pressure. 7. Screw a pressure gauge to a faucet, and read the pressure when the pump kicks in. If it is different from the specified cut-in pressure for the pump, adjust the tank bladder pressure to 2 to 4 psi below this new value. Do this by letting air out of the tank or pumping it in with a tire inflator. 8. Secure the turbine on the top of the water reservoir using the 4 screws provided. 9. Connect the water outlet of the pump to the water inlet of the turbine 10. Prim the water pump to ensure proper functionality. 8

13 Things You Will Need Lag screws Threaded pipe adapter Plumbing tape wrenches Strapping Pipe, fittings and PVC cement, if applicable Shut-off valve Bicycle tire pressure gauge Pressure gauge Tire inflator 3.2 Electrical Components 9

14 For electrical components connection, please follow the diagram above. Note: The DC power supply is the turbine generator electric outlet and the load is the electric inlet of the inverter. 4. Operation Instruction Once the part has been connected, double check all the connections. To give the turbine blades enough pressure to spin, the user must ensure that he choose the right nozzle. Plug the water pump to the electrical outlet of the wall. Ensure the maximum power, it is important to keep the blades of the turbine at it maximum spin. 4.1 Power Generation When the turbine is spinning and the wattmeter and the inverter are properly connected, the user will see the proper readings for amperage, voltage, and wattage generated by the system. This allows the user to easily monitor what is going on electronically. 4.2 Deconstruction When the user is finished using the system, the user must unplug the pump first and wait until all water went back to the reservoir. Now user must disconnect the electrical components moving to any other steps. Now follow the steps from 9 to 1 in section Troubleshooting and Maintenance The purpose of this section is to help the user with some of the more common issues that they face during the lifetime of the product. 10

15 5.1 Water is leaking into the housing Any leaking of water at any parts of the system must be take care immediately. Most of the water leaking is due to the loose parts or insufficient of plumber tape around the tape. 5.2 The Pump is not working properly If the pump is not operating properly, it can be due to the water shaft seal. Disconnect power and release all pressure from the system before attempting to install, service, relocate or perform any maintenance. 1. Disconnect power to the pump. 2. Open a faucet nearest the tank and allow all water to drain from the tank. 3. Remove the four cap screws holding the pump housing (volute) to the motor (Figure 8). 4. Separate the pump housing (volute) from the motor to expose the diffuser and the seal plate. 5. Remove the two cap screws and diffuser from the seal plate to expose the impeller. 11

16 6. Remove the small end cap on the end of the motor opposite the impeller. 7. With a large screwdriver, keep the shaft from rotating and remove the impeller by hand (standard right hand thread). Be sure to hold onto the seal plate when removing the impeller from the shaft. 8. Remove the seal plate. 9. Pry the rotating shaft seal member (including stainless collar and rubber seal) from the impeller (Figure 8). 10. Push or pry the ceramic seat, and rubber seat ring free from the seal plate (Figure 9). 11. Remove loose particles from impeller hub and seal plate. 12. Wet the inside of the seal cavity on seal plate and the rubber cup enclosing the new ceramic seat with cooking oil. Be careful not to scratch the ceramic surface of the seal seat and push seat enclosed in rubber into seal cavity on seal plate. Use a cardboard washer to protect polished surface when pushing against ceramic seat with any object. Be sure to remove cardboard washer. 13. Carefully slip seal plate over shaft. Do not disturb seal position in seal plate. The seal plate must be orientated during assembly so the two screw holes are on a horizontal line across the motor. Shaft (Figure 10). This placement should be done to ensure proper draining and priming. 14. Place rotating shaft seal member in position on impeller and press into place. Take care not to press against polished seal surface. 12

17 15. Position impeller on shaft and tighten securely (Figure 11). 16. Secure diffuser to seal plate using the two cap screws. Be sure the arrow on the front of the diffuser is pointing up and the screws are orientated on a horizontal line as described in Step Carefully position pump housing (volute) gasket over the diffuser onto the seal plate. In all shallow well applications care must be taken that the O-ring is clean and properly positioned on the venturi. Cleaning and positioning makes a good seal inside the diffuser when assembled. 18. Assemble the pump housing (volute) to the motor using the four cap screws. Be sure the pump housing (volute) gasket is positioned correctly and tighten the screws securely. NOTE: Shaft must rotate freely and motor end cap should be secured before operation. 5.3 The turbine is spinning, but no power is being generated If the turbine blades are rotating and no power is being produced, this means that there is a problem with either the wiring in the device or the shaft connections. Go back to section 3.2 to ensure that everything is connected properly inside and outside of the device. Improper connections will disrupt the flow of electricity and no power will be produced. Also, make sure all set screws to the shaft couplings are tightened. 5.4 The turbine blades will not spin Without rotation of the turbine blades, no power can be produced. First, check the pressure of the water. Next, check the nozzle of the turbine and set screw on the turbine blade hub to verify that it is indeed tightened. If not, tighten the set screw to connect the turbine blades and the input shaft. 13