Natel has released a photo gallery documenting the assembly and installation of the new Free Jet hydroEngine. View the gallery below!
Free-Jet Machine Assembly
After all components were designed, fabricated, and received, the team began assembly of the first Free-Jet hydroEngine.
Pictured above, President and CTO Abe Schneider assembles the cassette.
Free-Jet Machine Assembly
Mechanical and Testing Technician Alex Conn adjusts the cassette belt tensioning system.
Free-Jet Machine Assembly
Senior Mechanical Engineer Erick Davidson assembles the blades.
Free-Jet Machine Assembly
Mechanical Technician Tristan Nilo assembles the blades.
Cassette Spin Testing
After the initial machine assembly, spin tests were conducted on the cassette to ensure proper clearances were met and all mechanical systems were operational.
Pictured above, Senior Mechanical Engineer Erick Davidson inspects the spinning cassette.
Cassette Spin Testing
Here one of the 2 axles is shown spinning. A packing seal (right) creates an air-tight seal between the atmosphere and the inside of the Free-Jet housing.
Housing / Jet Deflector
The Free-Jet housing contains the water as it moves through the machine. During an emergency shutdown, a jet deflector plate will swing down and redirect the flow around the cassette, to quickly and easily depower the unit.
Pictured above, the housing is shown before it is assembled onto the machine.
Housing / Jet Deflector
Senior Mechanical Engineer Erick Davidson and Mechanical and Testing Technician Alex Conn attach the deflector plate to its pivot inside the housing.
Nozzle
The nozzle controls the flow of water into the machine, and is similar to a throttle in a car. Opening the nozzle causes the machine to generate more power; closing it reduces power output.
Pictured above, Mechanical Engineer Sean Hennessee installs synchronizing gear components onto the nozzle body.
Nozzle
The nozzle controls the flow of water into the machine, and is similar to a throttle in a car. Opening the nozzle causes the machine to generate more power; closing it reduces power output.
Pictured above, Mechanical Engineer Sean Hennessee installs synchronizing gear components onto the nozzle body.
Nozzle
The nozzle is shown in its closed position, pre-assembly of seals. Once fully assembled, the seals on the fully-closed nozzle block almost all flow into the machine.
Final Assembly and Shipping
Mechanical Technician Tristan Nilo helps load the machine housing into a palette.
Final Assembly and Shipping
Once all systems passed mechanical testing, final assembly and shipping of the machine began. In addition to the Mechanical, Electronics, and Controls work, great care is taken to ensure the machine is safely packed and shipped on time.
Pictured above, Mechanical Engineer Joanna Noble, Senior Mechanical Engineer Erick Davidson, and Mechanical and Testing Technician Alex Conn complete the final belt attachment assembly.
Final Assembly and Shipping
Mechatronics Engineer Jason Currie packs up the machine’s control panels and wiring system.
Final Assembly and Shipping
Commercial Associate Ben Ward helps design the blade packing fixtures.
Final Assembly and Shipping
Engineering Project Manager Katie McKinstry coordinates shipping of the machine components.
Final Assembly and Shipping
The machine was shipped to Freedom Falls, ME.
Free-Jet Install
After arriving on site at Freedom Falls, ME the machine was installed into the basement of a historic mill. In the past the falls’ hydro power was used to grind grain and mill dowels.
Free-Jet Install
After the machine shipment arrived, the install team gathered to discuss assembly and process.
Free-Jet Install
Here the install team lowers the cassette into position inside the powerhouse.
Free-Jet Install
President and CTO Abe Schneider is shown explaining how the Free-Jet works to students of a school also housed in the same restored mill as the hydro project.
Free-Jet Install
Here the cassette is shown as the blades are installed.
Free-Jet Install
Here the cassette is shown as the blades are installed.
Free-Jet Machine Testing
After the machine was assembled, testing was conducted to ensure all mechanical components were operational. During this phase, data was also collected to help tune the machine’s control system.
Pictured Above, Mechanical Engineer Sean Hennessee observes the machine as a emergency shutdown test is conducted using the machine’s jet deflector. The water seen through the viewport is redirected around the cassette, smoothly depowering the plant and avoiding excessive stress on the machine’s components.
Free-Jet Machine Testing
Here the machine is shown in normal operation. The water jet is directed through the cassette, and is not visible through the viewport on the housing. The machine’s flywheel and speed increaser are shown spinning.
Free-Jet Machine Testing
When the plant is fully operational it will generate 35KW of electricity during max flow conditions.
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