1.

SITE ASSEMBLY
The rig has been partially dismantled for transport, upon receiving of the
rig in the laboratory, and prior to the reassembly, a careful inspection must
be carried out to ensure that the rig has not suffered any damage in transit.
The following order of site assembly is recommended:
1.1Set up and secure the steel framework designed to carry the four
manometers and to provide a support for the packed column.
1.2Ensure that the base of the packed column id firmly secured, level and
tightened the discharge coupling below the column.
1.3Erect the glass column, fix and tighten the loose flange type coupling. Do
not over strain and ensure that the flange is level.
1.4Fill the column with Raschig rings to a height of four feet or less. Use a
cloth to soften the fall of the rings. A card attached to the cloth will ensure
that the can be removed as soon as 3 of rings have accumulated above
the cloth. Alternatively, if the column outlets are blocked off temporarily
with bungs, the packing can be floated in through water.
1.5Fix the supply line to the packed column.
1.6Secure the small bore copper pipe work on to the steel frame.
1.7Hang the four manometers on the steel frame, the following order is
recommended: (from left to right facing the rig)
1. Pressurized water manometer for orifice plate (10)
2. Mercury manometer for air pressure (12)
3. Pressurized water manometer for head losses in 1 and pipes
(11)
4. Mercury manometer for head losses 3/8 pipe
1.8Connect the various manometers to their respective flexible pipes,
ensuring that the right branch of the manometer is connected to the
tapping on the right of the ring and vice versa.
1.9Wire all the manometer connections securely.
1.10 Connect rig to electrical supply and check connection with a short run
on the air compressor. Then bleed the air line.
1.11

Touch up paint where required and check lagging.

The rig is now ready for commissioning.

2. PREPARATION AND COMMISIONING

2.1Water System
Prior to filling the sump tanks, close all the valves from the rig,
including the valves on the steam and air systems. The sump tank should
be filled to a depth of about 20 (50 cm) and requires about 18 to 20
imperial gallons (80 to 85 liters) of clean fresh water. To protect the rigs
steel pipe work against corrosion, we recommend that 1% by weight of
sodium nitrate be added to water.
Fill the two mercury/water manometers number 12 and 16 with
mercury half way up to the scale. Start the water pump and allow the
water to fill the three pipes in the heat exchanger, keeping the three
outlets isolating valves shut. Release air trapped in the inlet manifold and
in the pipe work to manometers 10 and 11. In the case of manometer 11,
we suggest valve number 30 be opened and water allowed to circulate
when valves 7, 8 and 11 are temporarily opened.
Once the system has been bled of any trapped air, close all valves and
cocks except numbers 4, 5 and 6. Drain the air line of manometer 10,
close the drain cock and pump air into the manometer. Gradually open
valves 18 and 19, releasing or pumping air until the cocks are fully open
and the water level in the manometer is about half way up the scale, both
levels in the manometer being identical. If they are not, there is still air
trapped in the air lines.
Deal with manometer number 11 in the same way, keeping cock 30
shut and the pump running all the time. Both levels in the manometer
should rise and fall evenly, check the pipe work for air or water leaks,
respectively.
To bring the mercury manometer number 16 into operation open one
of the vents V and the corresponding water supply cock carefully
(number 20 and 23) and slowly fill up the supply line and manometer with
water allowing the air to escape. A cloth held lightly over the vent will
catch any water escaping with the air and help to keep the apparatus
clean. Carry out this operation on both legs of the manometer until the air
has escaped, both vent cocks are shut, valve numbers 20 and 23 are fully
open and the mercury level are equal.

The apparatus is now ready for operation for tests on the hydraulic
circuit and the heat exchanger circuit. Before stopping the pump, always
close all the valves, particularly cocks 18 to 25 inclusive.
Never open valves numbered 18 to 25 unless the compressor is
running. Always close these two valves before stopping the compressor.
If the packed column has been filled with packing to the correct level,
there will be no splashing or water spray escaping.
2.2Air System
Keep valve numbers 18 to 25 closed unless the compressor is running.
Bleed the system at frequent intervals, using the drain D mounted below
the flow meter number 8. Water must not be allowed into the air system
and compressor and condensation must be drained at regular intervals.
Fill manometer number 9 with mercury by removing the pressure pipe.
The standing level of the mercury should be hallway up the scale.
Fill manometer number 12 following the procedure described above,
but using the spare vent cock to introduce the mercury.
Run the air compressor, check the system and after closing valves 15
and 28, stop compressor and drain system of any water.
2.3System Circuits
Steam is to be provided from the laboratory system at about 100C to
130C, 35 psi (2.4 atm). A flexible hose with a shut off valve and quick
coupling should be connected to the steam inlet. A boiler capable of
supplying about 60 lbs/hr (30 kg/hr) is required. Allow water to flow
through all three pipes in the heat exchanger, open valve 16 and test the
steam system. Small leaks may have developed during transit and some
couplings may need tightening. The condensate receiver is not supplied
with the rig.
Also check the supply to the tank by opening valve number 17. Close
both valves number 16 and 17 as well as the master valve on your supply
line.
2.4Cooling Water Circuit
Connect flexible hose number 13 to the laboratory water supply by
means of a flexible hose and control valve. The control valve must be on
the supply line, up stream of the rig so as to be connected to the

laboratory drainage system. Check the hose for leaks and ensure that the
supply of cooling water is adequate, 150 gpm (680 L/min) maximum.
2.5Mixing Tank
Turn the speed controller of the mixer motor to zero, start the motor
and slowly turn the speed controller knob clockwise until the motor starts.
Run the motor through its full range. The rather high noise level is not due
to any fault but is inherent with any small worm reducer.
Turn knob to zero and press stop (red) button.
The rig is now ready for operation.
3. FLUID MECHANICS
3.1Calibration of the Orifice Plate
This all important test can only be carried out with the help of a flow
measuring vessel, calibrated in advance, and by completing a temporary flow
circuit. A flexible hose should be fixed to drain number 10 and arrangements
completed so that the hose can either be connected to the cylindrical tank
number 1. The flow into the rig must be carefully controlled to match the
amount of water extracted from the rig at any time.
Close all valves and fully open valve number 4. Start pump, vent system
using the cock on the inlet manifold. Bring the flow measuring manometer
(10) carefully into operation by opening valves 18 and 19. Gradually open 18
and 19. Gradually open valve number 7 and ensure that the main tank
number 1 is kept full.
Record the following:
Degree of opening of valve number 7
Reading on the manometer number 10
Flow into calibration vessel (volume vs. time)
In-flow (this could be measured through the gap meter number 7)
The readings will provide the following:

Calibration of the orifice plate

Characteristic of the 1 control valve
Calibration of the gap meter number 7
The orifice plate fitted to the rig is of the thin plate orifice type, to
B.S.S.599:1939, the pipe being 1 N.B. or 1.09 I.D. and the orifice
diameter being 11/16.
The following equation will provide the flow:

Q=20.8 x aC

H
(1 ) +n2

Where,
Q = discharge in imperial gallons per minute
a = pipe are, 1 N.B. or 0.93 square inches
C = approximately 0.61 for this type of orifice
n = area of pipe over area of orifice
H= differential head in feet of water
The accuracy should be in the region of 2.5%
The reading on the gap meter number 7 will only be of value if the level in
the tank is kept constant at a steady in-flow.
3.2Calibration of the other Orifice Plate
Whilst the rig is set up for the above mentioned test, it would be wise
to calibrate any other orifice plates which may be used on the rig.