Good and Bad of Mini Hydro Power Vol.1

GOOD & BAD
of
Mini Hydro Power
Volume 1
S i te I d e n ti fi ca ti o n C i vi l Wo rks E le ctro -M e ch a n i ca l
Klaus Jorde
with the resources of Entec AG
Ekart Hartmann, Heinz Unger
Edited by
Roman Ritter
GTZ
ASEAN-German Mini Hydro Project
(AGMHP)
GOOD & BAD
of
Mini Hydro Power
GOOD & BAD of Mini Hydro Power
Imprint
GOOD & BAD
of Mini Hydro Power
Authors:
Klaus Jorde with the resources of Entec AG;
Ekart Hartmann, Heinz Unger
Editing:
Roman Ritter, GTZ
Photos, drawings and graphics provided by:
The Indonesian-German Mini Hydro Power Project (MHPP)
Published by:
The ASEAN Centre for Energy (ACE)
under the direction of its Executive Director, Nguyen Manh Hung,
supported by the ASEAN-German Mini Hydro Project (AGMHP)
Jl. HR. Rasuna Said, Blok X-2, Kav 7-8, Kuningan
Jakarta 12950, Indonesia
Phone : +62 (0)21 527 8027
Fax : +62 (0)21 529 63820
Websites : http://www.aseanenergy.org
http://agmhp.aseanenergy.org
http://www.gtz.de/energy
First published by ACE in June 2009
Photographs, drawings and any other graphical elements are intellectual copyright protected
and therefore must not be extracted separately from this publication.
However, complete chapters of this book may be translated into other languages and thereby
be reproduced for training purposes, provided the publisher is informed of these purposes
and proper acknowledgements are made.
Disclaimer:
The publication has been prepared to illustrate good & bad practice examples in micro and mini hydro power
planning, implementation, operation & management.
While all reasonable care has been taken in the preparation of this publication, the authors, editors, ACE, AGMHP,
Entec AG, GTZ, MHPP, PT Entec Indonesia and any other individuals and parties involved accept no responsibility
for damage, injury or any other undesirable events resulting from its application or interpretation.
The ultimate responsibility for quality, reliability and safety remains with designers, suppliers, installation teams
and operating agencies. It is strongly recommended that any design, construction, electrical or mechanical
installation, operation, maintenance and repair works are carried out and/or supervised and checked by qualifed
technicians and engineers only.
ISBN : 978-979-8978-26-5/978-979-8978-27-2
i
Table of Contents
Volume 1
1 SITE IDENTIFICATION 1
1.1 General 2
1.2 Run of River Hydro Power Station 2
1.3 Feasibility 4
1.3.1 Site Identifcation and Flow Measurement 4
1.3.2 Rough Calculation of Possible Hydro and Electrical Power 6
1.3.3 Estimate Electrical Load 7
1.3.4 How to Measure the River/Stream Flow? 7
1.3.5 Discharge Measurements and Flow Duration Curve 14
1.3.6 Head Measurement 15
1.3.7 General Project Data 24
1.3.8 Synergies, Ownership and Management 26
1.3.9 Energy Supply and Demand 27
1.3.10 Consultants 29
2 CIVIL WORKS 31
2.1 Construction Basics 32
2.2 Individual Components 44
2.2.1 Weir and Intake 44
2.2.2 Sand Trap - Settling Basin 53
2.2.3 Headrace Channel 57
2.2.4 Forebay 70
2.2.5 Trash Rack 75
2.2.6 Spillway 81
2.2.7 Penstock and Support 85
2.2.8 Power House and Tailrace 97
3 ELECTRO-MECHANICAL EQUIPMENT 105
3.1 Basics 106
3.2 Individual Components 111
3.2.1 Turbine 111
3.2.2 Main Elements of a Generator 117
3.2.3 Panel, Controller and Ballast 121
3.2.4 Inside the Power House 129
3.2.5 Power House Wiring 136
3.2.6 Mechanical Transmission 143
3.2.7 Tools and Spare Parts 152
ii
Volume 2
4 TRANSMISSION & DISTRIBUTION 161
4.1 General Basics 162
4.1.1 Basics for Grid Planning, Design & Layout 162
4.1.2 Implications of Productive End Use on Network Design 163
4.2 Major Components 164
4.2.1 Transformer Station 164
4.2.2 Distribution Poles and Lines 168
4.2.3 Wiring connections 170
4.2.4 Maintenance 178
5 HOUSE INSTALLATION 181
5.1 General 182
5.2 Major Elements 183
5.2.1 Service Connection 184
5.2.2 Current Limiting Device 186
5.2.3 Metering 188
5.2.4 House Wiring and Fittings 192
6 MANAGEMENT AND ADMINISTRATION 201
6.1 Community Participation and Mobilisation 202
6.2 Institutional Setup 207
6.3 Capacity Building and Training 210
6.4 Tarif Policy 211
6.5 Financial Management 215
6.6 Monitoring and Documentation 216
7 UTILIZATION OF ENERGY 219
iii
Foreword
The urgent call for reducing the carbon footprint of our economies combined with the worlds
ever growing demand for scaling-up access to energy is a priority challenge on the global
agenda which defnes the role for renewables.
Renewable energies ofer climate-friendly, low risk technology options for decentralized
power generation. In remote areas, utilizing local renewables to support the development
of poor rural communities is often more economically viable than transporting diesel fuel
or expanding the national electricity grid over long distances. In locations where however
the network infrastructure is already in place, harnessing natural resources for feeding power
into the central grid also ofers an important source of local income that contributes to
macroeconomic stability by gaining independence from price-volatile fossil fuels.
In the light of this, the Association of South East Asian Nations (ASEAN) is emphasizing the
need to strengthen the development of renewable energies. Promoting mutual cooperation
for the transfer of knowledge and skills in order to narrow development gaps among the
ASEAN countries, to empower the regions peoples, and ultimately to alleviate poverty is seen
as the way forward.
With this publication, GOOD & BAD of Mini Hydro Power, the ASEAN Centre for Energy (ACE)
aims to provide valuable lessons from experiences gained in one member country for the
dissemination of good practices throughout the whole region. This is intended to support
the capacity development of ASEANs human resources in the sustainable planning, design,
implementation, management, operation and maintenance of mini hydro power (MHP).
The two underlying principles of this book are: a picture is worth a thousand words and the
only real mistake is the one from which we learn nothing. Thus along the sequence from
water to wire contrasting pictures of good & bad examples are provided to illustrate what
actually defnes the diference. Each picture is complemented by short explanations so that
the book can serve as a technical training manual that ofers direct and easy-to-understand
guidance.
Although MHP is a relatively mature and cost-competitive energy technology, a lot of
mistakes are still being made which lead to increased maintenance cost, reduced power
output, shortened service life or even physical danger. The good news is that in many cases
it is only small changes which need to be made doing things the right way often requires
no more funds than doing them the wrong way. However, what is defnitely required is a
proper awareness and expertise among hydro practitioners and their principals for whom,
quite literally, knowledge is power.
Nguyen Manh Hung Roman Ritter
ACE, Executive Director GTZ, Principal Advisor AGMHP
iv
Acknowledgements
This book draws on countless photographs and experiences which have been collected in
practically applying international MHP know-how for the successful improvement of mini
hydro power implementation in Indonesia.
Therefore special thanks go to the Indonesian Directorate General for Electricity and Energy
Utilization (DGEEU) and its Mini Hydro Power Project (MHPP) which has been jointly
implemented for more than 10 years by DGEEU and GTZ, the German Technical Cooperation
Deutsche Gesellschaft fr Technische Zusammenarbeit.
Big thanks also go to the team of authors who made great eforts in bringing together Entecs
expertise in MHP development with the didactical concept of using contrasting pictures
which require only short explanations to point out the decisive diference.
Last but certainly not least, the ASEAN Centre for Energy (ACE) is highly grateful to the German
Federal Ministry for Economic Cooperation and Development (BMZ) for its continuous support
of the ASEAN-German Mini Hydro Project (AGMHP) which provided the necessary resources
for compiling this publication.
Nguyen Manh Hung
ACE, Executive Director
v
1. Site Identification 1. Site Identification
Site Identifcation
2
1.1GENERAL
Mini hydro power stations (MHP) are installations often referred to as generating less than
1,000 kW electrical energy. The hydraulic sources are:
- Plvers and streams
- water sources
- water supply malns
- waste water systems
To create electricity in a small hydro power station the following two questions are essential:
- How much water ls avallable throughout the year for the turblne (now)I
- what ls the posslble dlnerence ln helght (head)I
1.2 RUN OF RIVER HYDRO POWER STATION
Flow and head are the most important parameters for the design of a hydro power plant.
Typical example of a diversion type run-of-river hydropower plant
- A run-of-rlver hydropower plant ls a MHP wlthout any reservolr or storage capaclty
- A dlverslon-type hydropower plant ls a MHP where the water ls dlverted from the rlver lnto
a channel and/or penstock system
Site Identifcation
3
- |n general, there are two types of MHP regardlng grld connectlon:
- Isolated MHP
- Grid connected MHP
- |n some aspects the deslgn of an lsolated MHP ls dlnerent than the one of a grld
connected. Most components, such as civil works and hydraulic components are the
same
- |n some cases, MHP are bullt as lsolated MHP and later are connected to the grld
Note:
CHOOSING INCORRECT PARAMETERS AND DEVELOPING THEREWITH A NON-OPTIMIZED
DESIGN RESULTS IN MASSIVE COST INCREASES OR UNSATISFYING PERFORMANCE!
IT IS THEREFORE STRONGLY RECOMMENDED TO CALL AN EXPERIENCED MHP EXPERT
FOR THE DESIGN PHASE!
Site Identifcation
4
1.3 FEASIBILITY
The most important information which must be available is the general location and
topography of the slte, the now whlch ls avallable ln the rlver throughout the year and the
head diference which can be utilized. Additionally it is important to know the distance to the
potential electricity consumers and/or the closest power line near by.
1.3.1 Site Identifcation and Flow Measurement
The following information must be gathered:
- The water now durlng the whole year wlth maxlmum and mlnlmum now
- The optlmal layout of the whole scheme wlth lntake, headrace, sand trap, penstock,
powerhouse and tailrace
- Slze and length of transmlsslon and dlstrlbutlon llne from power house to the users of
the electricity
- A demand forecast for households, small lndustrles and soclal lnfrastructure facllltles for
be connected in the future
Collect river/stream fow data
Por hydro power deslgn lt ls very lmportant to have now data over as many years as posslble to
be sure how much water (in rainy and dry season) is available to run a turbine. These data give
the designer the basic information for the selection of a turbine that works most efciently.
With this information and the demand of the consumers, the designer can choose the proper
turbine and generator as well as he can defne size and length of the grid for an isolated
MHP.
Hydrographs for a 16 year period
The gure shows dally nows measured over a perlod of l6 years. Thls ls an ldeal data sltuatlon.
In reality, such good data are often not available.
Site Identifcation
5
Flow duration curve
A so-called now duratlon curve ls generated by sortlng all measured now data slze wlse and
printing them over 100% of the time covered by the measurements. The diagram says for
example that during 23% of the time the discharge is higher than 10 m3/s. This curve is the
most important information for the design of the hydropower plant. If it is not based on good
data everything else becomes equally speculative as well.
|f the requlred measurements are not avallable, then the now should be measured and
recorded every day during minimum one year in order to get the following curve:
Lxample of a now duratlon curve for one year
The now duratlon curve ls generated from the rlver dlscharge curve by sortlng all the 365
values. 8ased on the now duratlon curve, the deslgner evaluates the avallable capaclty. The
dlmenslonlng of the plant depends on the avallable now of water and the estlmated future
demand of the customers. Ideally the MHP should allow covering the demand all around the
year. If the demand is higher than the available capacity, alternative energy resources have to
be identifed and/or energy efciency measures have to be taken into consideration.
Site Identifcation
6
If you cannot get good measurements over an extended period of time you need the help of
an experienced hydrologist for this analysis.
1.3.2 Rough Calculation of Possible Hydro and Electrical Power
By answering the following questions youll fnd out, if the scheme is worth to go ahead with
the planning:
l. How much now ls avallableI
Measure and draw a water now curve (hydrograph) as shown
above for mlnlmum one year. Take the mlnlmum now for
your further conslderatlons. Thls ls the now of water whlch
you have available all year round.
2. How much head is available?
Measure the head from the location of the possible forebay
to the place where the turbine is planned to be placed.
when head and dlscharge (water now) ls known, lt ls easy to calculate the theoretlcal hydro
power:
P = Power in Watt
Q = Minimum available fow
H = Head, diference in height in meter
This formula shows the hydraulic capacity only and refers to 100% efciency without losses.
Losses in penstock, turbine, gear transmission, generator and electricity transmission reduce
the fnal electrical power. By calculating losses of 20.30%, the fnal electrical power will
approximately be:
Site Identifcation
7
EXAMPLE:
Let's use the now duratlon curve for one year on one of the prevlous pages as an example.
The mlnlmum turblne now whlch ls lndlcated there ls around 90 l/s. Thls now ls exceeded 275
days per year, the remalnlng 90 days the now ls sllghtly smaller so the hydropower plant wlll
generate less power accordingly. Lets assume that we have a head of 30 m available. In this
case the power generation will be:
So this MHP will generate almost 19 kW.
If the designer chooses a larger turbine, lets say with the design charge of 220 l/s, the MHP
could generate around 46 kw, but only for about 60 days every year, durlng hlgh nows. The
remainder of the year, around 300 days, the MHP would generate much less power, depending
on the discharge which is available.
1.3.3 Estimate Electrical Load
Try to estimate the required electrical power supply needed for all households, public
infrastructure facilities (e.g. schools, markets, clinics, community buildings, and street
lightings), workshops, etc in the electrical system. For each household calculate around
50150 W for lighting, radio, TV, fan, refrigerator, etc.
wlth the now of the above example around l90 households can be supplled all year round
by a possible MHP.
1.3.4 How to Measure the River/Stream Flow
|t's not easy to measure an accurate now of a rlver or stream!
The now measurement has to be taken every day durlng one full year. Por thls the lnstallatlon
has to be appropriate and robust. Depending on the size of the river or stream there are
dlnerent methods to measure the now:
- 8ucket Method
- Ploat Method
- Current Meter Method (veloclty-Area Methods)
- Sharp Crested welr Method
- Salt Concentratlon Method
Site Identifcation
8
Bucket Method
Por small now (around 20 l/s) only
- |f you have only a small now you can do the measurements wlth thls method.
- |t's lmportant, to take a blg tank (around l,000 llter) wlth draln plug at the bottom
- The now to be measured ls dlverted lnto the tank of known volume
- The tlme lt takes to ll the tank must be recorded
- 8y dlvldlng the volume (ln llter) of the tank by the lllng tlme (ln seconds) the now ln
liter/seconds can be calculated
Note:
THIS METHOD IS VERY ACCURATE IF YOU ARRIVE TO REALIZE SUCH AN INSTALLATION!
BUT USE IT FOR SMALL FLOWS ONLY!
Site Identifcation
9
Float Method
Por now > 20 l/s
Profle
Defne the cross section area frst. Normally its more difcult than in our example (Cross
section = H x W). Try to divide the whole cross section into several sections, when the profle
is not rectangular, and add the diferent sections together to defne the whole cross section.
Float
For a known length of the stream (L), an average cross section should be available, where a
half flled plastic bottle of water has to be timed over a measured length (L = 1020 m). By
multlplylng cross sectlon area wlth average now veloclty, an estlmatlon of now rate can be
made now. For any case a correction factor of +/- 20% must be applied.
Site Identifcation
10
Current Meter Method (Velocity-Area Methods)
- At any polnt ln the rlver, the veloclty ls dlnerent - faster on the surface and slower on
the bottom. The veloclty of the now can be measured at dlnerent depths and at any polnt
of the rivers cross section by a so called current meter
- The values have to be averaged. The veloclty measurement data are then used to
calculate the actual now, based on the area of each segment
- 8efore startlng the veloclty measurements, mark the cross sectlon wlth a horlzontally
laid out piece of steel or timber to get a reference height. Note the location of the cross
sectlon on a map and also note date and tlme of the now measurement
Note:
THIS METHOD IS SUITABLE FOR FLOW VELOCITIES RANGING FROM 0.2 - 5 m/s AND WHERE
YOU CAN SAFELY WADE THE STREAM!
Site Identifcation
11
Sharp Crested Weir Method
Why is this a good example?
- Sharp crested welrs wlth controlled now provlde good now measurements
But:
- The lnstallatlon ls not easy and needs a lot of sklll and experlence
- Peference tables have to lndlcate relatlon between helght h and now Q
- The welr on the plcture ls not qulte rectangular
Measuring rod
h
L
b
Site Identifcation
12
Por rectangular welrs wlth b l m and L ls approxlmately 2 - 3 m, the now can be read out
from following table:
- Any materlal can be used for the welr, but the notch should have sharp edges (metal ls
the best)
- welrs are always orlented at a rlght angle to the stream now
- |f b ls wlder or narrower than l m you can slmply multlply the Q values ln the table by
the same ratlo. Let's say for a 0.8 m wlde welr you multlply the Q values by 0.8 and for a 2
m wlde welr you multlply the Q values by 2
- A sharp crested welr ls also a good devlce to generate a now duratlon curve
(hydrograph) over a longer period of time, e.g. one year. You only need to install a staf
gauge 2-3 m upstream of the weir, read the gauge level every day at the same time,
calculate the discharge based on the table above, and write this into a table
Site Identifcation
13
Salt Concentration Method
The fgure shows intensity of conductivity
- A bucket wlth salt water of known concentratlon ls poured lnto the mlddle of the
stream. The salt concentrate cloud wlll be spread by the now of the rlver
- The probe ls lnserted at least 20 tlmes the rlver wldth downstream to measure the
electric conductivity of the stream / salt concentrate mixture. So if the river is 10 m wide,
you should measure at least 200 m downstream
- The stream now wlll be measured and calculated by the conductlvlty meter
Note:
THIS METHOD OF MEASUREMENT CAN ONLY BE USED BY A TRAINED PERSON WITH
PROPER EQUIPMENT!
gauging
point
Distance: injection to gauging point
point of tracer injection
M=V.C
1
tracer cloud
A
B
t
r
a
c
e
r

c
o
n
c
e
n
t
r
a
t
i
o
n
F
A
F
B
t
B
t
A Time
Site Identifcation
14
1.3.5 Discharge Measurements and Flow Duration Curve
Of course lt ls a conslderable enort to measure the now, no matter whlch method you use.
So you only want to do thls a few tlmes but lt must be at dlnerent nows, let's say durlng the
lowest now you can observe, and full rlver now and two smaller nows ln between. At the same
time you always measure the stage of the river at the same location and you must install a
permanent staf gauge for this purpose. Then you can develop a relationship between the
stage and the discharge, based in your measurements. It is a simple curve, shown green in
the fgure below.
Staf gauge for quick and easy water level reading
The red stars represent the measurements which you have taken. From then on you must
only measure the stage, lets say every day at noon, and your curve will tell you what the
discharge is at the same time. The two blue arrows indicate how this works. If you do this for
one year you have the perfect data for a now duratlon curve.
Note:
IF YOU DO NOT UNDERSTAND THIS PROCEDURE YOU MUST HIRE AN EXPERT TO HELP
YOU!
S
t
a
f

g
a
u
g
e

(
c
m
)
Discharge (l/s)
Site Identifcation
15
1.3.6 Head Measurement
Head is the diference in height between the water level of the planned forebay and the
planned position of the turbine shaft. There are diferent ways to measure it.
Schematic example of head measurement
turbine
H
e
a
d
Level of forebay
Site Identifcation
16
Head Measurement by Level
The principles of measurement by the levelling method
Site Identifcation
17
Head Measurement by Water Level
This method is similar to the levelling method, except that a water-flled hose is used
Site Identifcation
18
Head Measurement by Pressure Gauge
What are the specifcs of this simple head measurement method?
- Only a pressure gauge and a clear plastlc hose are needed
- Only two maln errors can arlse:
- The gauge is not properly calibrated
- There are air bubbles in the hose
- Plrst callbrate the gauge scale from a low to a hlgh readlng, do that 5 tlmes to get
reliable results
- Check the slze and length of the hose, because the water-lled hose must be carrled
around the entire length from intake to tailrace
- Pecord all data on a chart
Site Identifcation
19
Head Measurement by Barometer/Altimeter
Head is the diference of elevation 1 and 2
An altimeter is based on atmospheric pressure.
The atmospheric pressure is diferent at diferent
elevations. It decreases with increasing elevation
above sea level.
When to use an altimeter?
- Use thls method only durlng stable weather condltlons
- Measurements should be carrled out ln a short tlme
- Perform thls measurement several tlmes and then calculate the average head
- Do not use thls method for low heads. 8ecause barometers have conslderable
uncertainties this method should not be used for heads less than about 50 m
- Thls method ls recommended as a rst qulck measurement whlch later must be
validated by more accurate measurements
Elevation 2 Turbine inlet
Elevation 1 Water level of
forebay
Site Identifcation
20
Head Measurement by Clinometer
What is the use of a clinometer?
- Dlnerent measurements can be performed wlth a cllnometer:
- Por angle measurements the cllnometer must hang vertlcally
- Por slope (%) measurements the cllnometer must be held and polnted wlth the "0% at
the bottom/top of the point to be measured
- Por dlstance measurement the cllnometer must be held and polnted wlth the "00" at the
bottom/top of the point
- 8est and most accurate results are obtalned by elther steadylng the hand on the
forehead or on a pole
- Prom the measurement the dlnerence ln helght between the two polnts can be
calculated
4 scales available
Clinometer
Up- and downward
measurements are
possible
Site Identifcation
21
Head Measuring by Level Instrument
Why to use an automatic level instrument?
- Measurements are fast and also work for longer dlstances, such as ln nat terraln, ln steep
terrain, the instrument has to be set up more often
- The accuracy of measurements ls very hlgh, lf they are done correctly
- Make sure that level lnstrument ls set up horlzontally on the trlpod
- Level lnstruments can measure only ln a horlzontal llne - no denectlon ls posslble
- The result of measurement ls the dlnerence
in height and distance between the two
points where the rod is set up
- 8y recordlng all measurements and addlng
them up, the distance and the height (which
is the available head) can be calculated
- Thls method ls slmllar to the one used wlth a
clinometer but more accurate
backsight
foresight
La -b
Lb -c
Change
Point
O%
a
b
c
O%
O%
O%
foresight
Site Identifcation
22
Land Survey Instruments (Theodolite or Total Station)
Specifcs of the high tech instruments:
- A theodollte can measure dlstances, helghts and angles, data are recorded manually
- A "Total Statlon does the same, but the survey data are stored automatlcally on a
memory chip
- These lnstruments are used by professlonal land surveyors
- Por head calculatlon only, such lnstruments are not really necessary, but they can be
very useful if larger areas have to be surveyed
Theodolite On site Total Station
Site Identifcation
23
Head Measurement with High-Tech Instruments
These instruments should be used by people who are trained to handle them as well as to analyze
the data of the measurements
Altimeter Clinometer Leveling Instrument
Theodolite Total Station
Site Identifcation
24
1.3.7 General Project Data
Try to get an answer to the following questions:
- where ls the pro[ect area locatedI - dene coordlnates by GPS
- who wlll be the developer of the pro[ect, means whlch organlzatlon(s) support(s) the
project?
- Plnd a person wlthln the vlllage for communlcatlon any tlme
- Plnd a person wlthln the developer organlzatlon for communlcatlon any tlme
- How ls the electrlcal lnfrastructure of the vlllage developedI Assess exlstlng grld wlth
voltage and transformers/medium voltage lines with length and number of wires/low
voltage lines with length and number of wires
- |s there good accesslblllty to the next vlllage/town, market and suppllers, etcI - dlstance
in km and time should be recorded
- |s transportatlon avallableI - type and cost of transportatlon
- Are the roads accesslble all the yearI
- Are nelghborlng vlllages or hamlets already connected to the electrlc grldI
- Draw an approxlmate map of the vlllage and lts locatlon and context
Site Identifcation
25
Demographic and Socio-Economic Parameters
- How many households llve ln the maln vlllage and ln lts surroundlng areaI
- How many persons llve ln an average householdI
- what ls the populatlon's growth rate ln thls areaI
- who has electrlclty already, and how many want to be connected to a mlnl hydro power
system?
- Pate people's lnterest and understandlng about the way to become "electrled
- Plnd out the varlous sources of lncome - agrlculture, tradlng, supply of labor,
remittances, etc.
- Lstlmate the average monthly lncome of an average household
- How many persons are not employed and have no lncome or recelve support from
others?
- Are the vlllagers wllllng to pay for the use of electrlclty and how much can they anord
monthly?
- Are there any publlc support systems for persons wlth low lncomeI
- whlch ethnlc groups llve ln the areaI
Site Identifcation
26
1.3.8 Synergies, Ownership and Management
Try to consider following points:
- Make note of any recent, ongolng and future (lnfrastructure) development pro[ects
- Check out other lnvolvements ln the vlllage, llke NGO's, government or ald agencles
- Gauge the antlclpated level of communlty partlclpatlon
- Make sure there ls enough lnvolvement ln tarln settlng, maklng pollcy declslons such as
how to handle payment defaulters etc
- what ls the avallablllty of local people wlth management / buslness sklll as well as wlth
civil, electrical and mechanical background?
- Por the hydro power enterprlse, explore and propose dlnerent ownershlp models (e.g.
community-based, private, company-driven)
Site Identifcation
27
1.3.9 Energy Supply and Demand
- |s there any electrlc grld near the vlllage for connectlonI |f so, check out what ls the
least-cost option (electricity supply from the existing grid vs. setting up a stand-alone
MHP scheme vs. selling surplus energy from the MHP to the grid)
- Lump sum payment or metered servlceI
- Clusterlng or separate lnstallatlonsI
- what ls the domestlc demand of each householdI - llghtlng, radlo, Tv, fan, refrlgerator,
etc ask all households
- Check the demand of publlc facllltles, llke: schools, market, cllnlc, communlty bulldlngs,
street lighting, place of worship etc.
- Are there any exlstlng (or proposed) productlve appllcatlons ln the vlllage: mlll of any
type, kiosk, manufacturing, cottage industry, etc.?
- Plnd out at what tlme and how long the varlous demand ls needed, and when and how
long are the peaks of usage
- Make a summary of all demand and calculate the dally, the annual and the peak
demand for the village
- Por the deslgn add l5% or some other percentage for future extenslons to the summary
demand
Example: see following page!
Site Identifcation
28
Site Identifcation
29
1.3.10 Consultants
When to look for consultants?
If communities intend to implement an electrical system they are well advised to ask a
consultant for support:
- A hydro power statlon lncludlng an electrlcal system ls a complex sub[ect and the help
of a reliable professional is very important. Only with such a professional you prevent
mistakes in calculation, design, construction and operation
- |f an electrlcal system should be lnstalled the source for the energy has to be selected
very carefully. Hydro, wind or solar potential will be checked in detail. The professional
consultant will recommend the most appropriate energy system
Note:
SUCH SYSTEMS SHOULD NOT HARM THE ENVIRONMENT!
THIS FACT BECOMES MORE AND MORE IMPORTANT EVEN MHP IF NOT DESIGNED, BUILD
AND OPERATED PROPERLY, CAN HARM THE ENVIRONMENT IN CERTAIN CASES!
MANY FACTS HAVE TO
BE CONSIDERED BEFORE
STARTING WITH HYDRO
POwLP STAT|ON DLS|GN!
31
Civil Works
2. Civil Works
Civil Works
32
2.1 CONSTRUCTION BASICS
This chapter will provide general advice for construction and show a number of good and
bad examples to illustrate what makes the important diference.
33
Civil Works
How to make concrete
What has to be considered for good workmanship?
- The quallty of concrete depends on the correct proportlons of all the lngredlents, l.e.
cement, sand, gravel and water
- Not enough cement ln the mlx makes weak, low strength concrete
- Too much water also makes poor quallty concrete
- |t ls lmportant to measure and add aggregates plus sand separately for maklng dense
concrete of good quality
- Use only clean aggregates
Note:
THERE IS NEVER AN ALTERNATIVE TO GOOD QUALITY WORKMANSHIP!
Cement Sand Gravel
Good quality concrete
Water
+ +
+ =
Civil Works
34
Construction of anchor block
- Good preparatlon ls essentlal for good concrete
- Do not drop the concrete lnto the formwork from any helght, but let lt sllp
- Maxlmum drop of concrete ls 5 m, otherwlse the aggregates get separated
- Avold cold [olnts durlng concretlng - do one sectlon ln one llft
- Make sure concrete lls all volds, use a vlbrator, stlr durlng pourlng, knock on formwork
from outside etc
Measure & mix the ingredients
with care
Let the concrete slip into the
formwork
35
Civil Works
Anchor block ready for concreting
- The boards of the formwork are of good quallty
- The supports are fastened to the formwork and braced agalnst the ground to avold
movements during placing the concrete
- Puddle nanges are welded to the penstock plpe to better anchor lt
- Pelnforcement ls ln place and ready for concretlng
- Pormwork must be well xed because lt ls lmposslble to hold lt up when the concrete ls
being poured into the formwork
- 8efore pourlng, clearly mark the necessary top of concrete surface to get enough
coverage of reinforcement, at least 3 cm
- vlbrate concrete well - thls wlll glve concrete the denslty and ll all volds so lt has the
strength and quality to fulfll the task of an anchor block
Puddle fange welded on pipe
Supports all around
the formwork
Corner bracing
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36
Construction details of equipment foundation
- The foundatlons of turblne and generator must be bullt wlth care
- A stable foundatlon avolds movements of the equlpment whlch ls absolutely necessary
for a trouble-free operation of the plant
- The generator shown ln the plcture ls properly fastened and ad[usted by turnbuckles to
keep the equipment stable and horizontal while the concrete is being placed
- An absolutely horlzontal base ls essentlal for a smooth transmlsslon
- The earthlng cable ls connected to the relnforcement of the base and wlll be later also
connected to the equipment itself. This is very important to avoid short circuits during
operation
- |n order to get good quallty concrete, the concrete must be vlbrated after belng poured
Steel base fxed to rods
Earthing cable connected to
reinforcement
Earthing cable
37
Civil Works
Pastenlng of equlpment to concrete noor wlthout bulldlng a foundatlon
- |f no new foundatlon ls to be bullt, equlpment can also be xed to the concrete as
shown above and described below
- Thls method ls also appllcable when a fastenlng bolt becomes loose and must be
repaired
- Drlll a vertlcal hole ln the concrete noor and make sure that the top dlameter ls not
larger than the diameter of the bottom of the hole
- Por groutlng use only hlgh denslty mortar, non-shrlnk, and slow settlng
- Pour mortar rst and than lnsert bolt vertlcally, set equlpment on top - durlng thls
operation the mortar is still soft and all parts are adjustable
Screw thread on steel rod
Equipment base
Steel plate must overlap hole in concrete
by at least 30 mm all around
Hole ln concrete noor - approx. 5x d ln dlameter.
It must not be larger at the top than the bottom
Small plates welded to screw rod and
washer (to prevent rotation)
Thick washer (approx, 4d x 5 mm thick)
welded to rod
Sheet metal packing
16 mm
25 mm
Level of concrete noor
Civil Works
38
Earthing must be done properly for the sake of safety
- Larthlng ls a safeguard system for people and machlnes
- Larthlng cable must have a good connectlon to the earthlng rod
- Use ONL approved earthlng clamps
- Length of earthlng pole depends on the conductlvlty of the ground but must be at least
3 m long
- Larthlng should be lald around the power house at the foundatlon level
- Connect all relnforced concrete foundatlons (power house and power equlpment) and
any other electrical equipment to the earthing ring
- Llghtnlng conductor to be connected to earthlng rlng 1 m above ground
- Thls connectlon wlll be used to measure the reslstance for ndlng out lf the earthlng ls
still functioning as it should be
Note:
EARTHING IS A SAFEGUARD FOR PEOPLE AND MACHINES!
NO EARTHING DEADLY DANGER!
Earthing cable
Earthing rod
39
Civil Works
Deallng wlth surface water, here: uncontrolled water now
- Proper dralnage of all structures ls necessary for longer llfe expectancy
- The base of structures, e.g. foundatlon of power house, penstock supports etc, can be
easily destroyed by water, unless they have a stable concrete foundation
- Plowlng surface water wlll wash out soll and cause eroslon underneath structures and
foundations - keep an eye on surface water where it comes from and where it goes
- water dlscharge ls an lmportant sub[ect of constructlon - do not neglect lt
Note:
WATER CAN BE A HAZARD TO STRUCTURES!
Washed out
Civil Works
40
Big structure without static design
- Por all structures, especlally for blg ones, lt ls essentlal to have a statlc / structural deslgn
before construction works starts
- Choose materlal accordlng to deslgn and requlred strength
- Carry out works very carefully and follow the advlce of the englneer
- weak and unstable wall constructlons can be a hazard to people when collapslng
- The nood followlng a broken retalnlng wall ls very dangerous to people who llve
downstream
Wall is too high
compared to thickness
No concrete foundation
Material is not suitable
41
Civil Works
Gabion used for weir construction
- The dlmenslon of the lowest row of gablons must be larger than the max. water
pressure, e.g. if the water is 1 m deep, the lowest gabion should be 1.2 m
- All steps of the gablon welr must be above water pressure llne
- To reach better stablllty of the constructlon, dlg the lowest gablon lnto the rlver bottom
- Tle the gablon ends lnto the rlver banks or lnto wlng walls
- As alternatlve to a stralght allgnment set the gablons ln an upstream curve
- Por better frlctlon, the length of the upper gablon should be 2/3 of the length of the
lower one
- Make sure that the maxlmum slze of the wlre mesh ls 5 cm, denltely smaller than the
smallest cobbles in the gabions
- Connect all gablons to each other
- Use only wlre materlal that does not rust, such as galvanlzed or epoxy-coated
Good design
Mesh width ~ 5cm
Max water level
Max water pressure
Civil Works
42
Headrace channel too close to a steep slope
- The slde walls of a channel must be able to wlthstand the water pressure
- The water pressure ls at the hlghest at the bottom of the channel
- 8ulld the channel as a rlgld box and/or dlg the channel ln deeper wlth enough
undisturbed material remaining on the down slope side
- |f there ls no other allgnment posslble, use materlal whlch can wlthstand the water
pressure use concrete on a good base foundation
- The area around the channel should be well dralned to llghten any water pressure and
keep the slope from sliding

Sand bags are not
enough support
43
Civil Works
Broken channel invert caused by erosion and sliding
- A channel usually conslsts of two slde walls and an lnvert (bed)
- |f a channel has no upslope retalnlng wall, water wlll seep through underneath the
channel and erode and damage the bed
- The money saved by not bulldlng an upslope wall wlll have to be spent for repalrs of the
channel this becomes more expensive because the channel invert must be repaired
too
- |t ls a good lnvestment to bulld a retalnlng wall on the upslope slde unless there ls a
stable rock face where only a thin liner is needed
- Upslope retalnlng walls also help to prevent that eroded materlal drops lnto the channel
- Make sure that the slope around the channel ls well dralned to keep the slope from
sliding, place drainpipes underneath the channel
Civil Works
44
2.2 INDIVIDUAL COMPONENTS
2.2.1 Weir and Intake
Main elements of a weir and intake structure
Main functions and design principles of weir & intake structure:
|ntake must dlvert the requlred stream now lnto the headrace channel at all tlmes and
all water levels in the river
Intakes should if possible be located on the outer side of a river bend to minimize
sediment in headrace
Provlslons should be made to exclude large noatlng debrls (noatlng bar or submerged
lntake orlce) and coarse gravel (bottom slll) from the now dlverted lnto the headrace
The slulce gate must be lnstalled close to the lntake orlce ln order to allow nushlng of
sediments depositing in front of the intake orifce
Weir or diversion
structure
Sluice gate
Optional: Gravel trap
with fushing gate
Intake gate or stop log
on sill
Sand trap
Flushing gate
Optional: coarse trash rack
Headrace
Side spillway
Intake orifce
45
Civil Works
3D sketch of weir and intake
Main elements of an intake:
This drawing shows a typical combination of weir and intake including a sluice gate which
can be used to remove deposited sand and gravel from the intake. The main function of the
intake is to allow a certain amount of water into the sand trap and headrace and to keep
sedlments and noatlng debrls away from the headrace system. Lxcess water must be returned
into the river.
Wing wall
Weir
Sluice gate
Intake gate
Intake orifce
Flow to sand trap
Civil Works
46
Most elements of a proper weir and intake structure are missing
How can I improve it?
- 8ulld a welr equlpped wlth overnow splllway, slulce gate and lntake gate to the
headrace or a properly dimensioned intake opening with stop log grooves
- The headrace should be bullt of concrete, masonry or slmllar materlal
- Slde and wlng walls up- and downstream of the welr are essentlal
Why?
- The rlver bed upstream of the welr must be nushed regularly to prevent sedlments from
entering the headrace
- An elevated lntake gate or lntake openlng ls needed to control the now lnto the
headrace and prevent sediments from entering
- |f there ls no gate, stop logs can be used to close the openlng for O&M
- wlthout proper splllway the welr structure may be eroded and damaged durlng noods
- wlthout wlng walls and sldewalls the rlver banks wlll be eroded
NO side walls
NO sluice gate
Only earth channel as
headrace
NO intake structure
47
Civil Works
Main elements of a weir and intake structure
- All elements necessary for a well functlonlng lntake are lncluded ln thls structure
- The maln elements are well arranged
- The quallty of constructlon ls good
- The structure ls well malntalned
- Gates and access to the gates ls covered by a roof
Stilling basin
Weir
Sluice gate
Cover over both gates
Intake gate
Headrace
to forebay /
powerhouse
Side walls on
both sides
Civil Works
48
Examples of unsuitable dam materials
Dam structure has
shifted already
Rocks and plastic sheets
do NOT make a good dam
Gabions cannot with-
stand food fows
49
Civil Works
Concrete weirs can last for a long time
Why are these good examples?
- Concrete / concrete masonry ls the preferred materlal for bulldlng welrs
- Mass concrete wlll wlthstand the hlgh hydraullc loads durlng noods
- Concrete ls a strong, durable materlal, also reslstant to chemlcals
- Concrete can be used for any type of welr
Civil Works
50
An unstable construction
- 8ulld concrete columns on both sldes
- Support the frame (yoke) of the gate solldly
Why?
- The gate slldes lnslde the frame
- |f the frame gets bent or twlsted, the gate wlll not move anymore - now cannot be
controlled
- The frame could also get bent or twlsted by a nood ln the rlver or some other lncldent
such as noatlng debrls
Columns on both
sides missing
51
Civil Works
The columns are good supports for the gate
- The frame of the gate should be bullt as a solld wall or ln strong columns
- The steel frame must be kept stralght all the tlme to let the gate sllde ln the ralls
- The gate must be able to be moved to control the now to the sand trap and further on
to the headrace and forebay
Solid columns
Civil Works
52
Points for operation and maintenance
What must I do to keep system running well?
1 Daily : Keep the intake orifce clean
2 weekly : Check for deposlts, lf there are any, nush at lntake gate
3 Monthly : Flush through sluice gate to clean upstream basin
4 As needed : Apply grease on wheels and threads of the gates
5 Durlng/after nood : Check for bank eroslon behlnd wlng walls
6 Durlng/after nood : Check for eroslon and damage ln stllllng basln and on
downstream banks
Note:
IF ANY PROBLEMS ARE FOUND, REPAIRS MUST BE MADE IMMEDIATELY!
1
2
4
5
3
6
53
Civil Works
2.2.2 Sand Trap - Settling Basin
Main construction details of a sand trap/settling basing
Weir or diversion
structure
Sluice gate
Optional: Gravel trap
with fushing gate
Intake gate or stop
log on sill
Side spillway
Cross Section A-A'
Long Section
Sand trap
Headrace or
Penstock
Trash rack if penstock follows
Bottom outlet with gate for fushing
Spillway
From Intake
Intake channel
A'
A'
0.25 0.25 0.60 0.10
0
.
2
0
0
.
8
0
0.25 0.80 0.25
0.20
2.00 5.00 1.00
0
.
8
0
Intake orifce
Side spillway
Flushing gate
Optional: coarse
trash rack
Headrace
Civil Works
54
There are a number of problems with this intake
- 8ulld a concrete wall further back on the hlllslde bank
- Cut back all shrubs and malntaln regularly
- Splllway should be located at the end of the sand trap, NOT ln the headrace trap
Why?
- Ongolng scourlng by water wlll cause the bank to erode
- Settllng out of sedlment wlll be less enectlve lf now ls not llnear
- Sedlments from bank eroslon wlll sllt up the headrace and wlll have to be manually
removed because there ls no nushlng gate
Shrubs need cutting
NO bank
protection
Vortices erode
bank
NO fushing gate
NO Spillway
Headrace
Intake structure
55
Civil Works
This picture shows all main elements of a well designed water intake with sandtrap
- The transltlon ls lmportant to calm and slow down the now veloclty
- Sedlments settle out more easlly when the veloclty ls low and the now ls llnear
- The splllway controls the maxlmum volume of now lnto the headrace
- Stop log grooves allow the lnsertlon of boards to block the now for cleanlng and
repairing the headrace
But:
- Por a sand trap, the basln ls too short, the now veloclty ls too hlgh and the sand may not
settle down
- |f the sand settles down, there ls no nushlng gate and the sand must be removed
manually
Spillway
Gate Sluice gate Weir Wingwalls
Sandtrap
Headrace to
forebay
Grooves for
stop logs
Overfow channel
Transition
Civil Works
56
Issues for operation and maintenace of a sandtrap
What must I do to keep the system running well?
1 Pemove any remalnlng sedlment manually after nushlng the sandtrap
2 Clean concrete surface from vegetation
3 Repair broken parts of the sandtrap
4 Check gates and/or stop logs to be ready for use (not shown in the picture)
5 Remove all grass, shrubs, debris and dirt and do it regularly
Note:
SEDIMENT PARTICLES MAY DAMAGE PENSTOCK AND TURBINE!
CHECK AT LEAST ONCE A MONTH!
1
2
5
3
2
5
57
Civil Works
2.2.3 Headrace Channel
Examples of headrace channels
What do I have to consider regarding headrace channels?
- Avold earth channels lf posslble at all higher maintenance and higher risk of erosion
material which could reach the turbine
- Cut slopes back from channel to avold eroded materlal or rocks from dropplng lnto the
headrace channel
- Petalnlng walls must always be dralned well wlth weeplng holes to avold slldlng slopes
- Covered channel could also be replaced by a burled plpe high costs
- Keep area along the channel free of vegetatlon cut back regularly
Lined channel - masonry
Covered channel because of rockfalls or eroded material
Concrete lined channel
Sealed channel Clay or
concrete slurry
Simple earth channel
Drainage below channel
is needed on water-
saturated slopes
Cover of channel where rock
now and eroded materlal
cannot be halted
Retaining wall
Civil Works
58
Avoid steep eroding banks along headrace channel
- Do not bulld headrace channel close to steep erodlng slopes
- Cut back slopes so there ls no eroslon materlal carrled lnto channel
- Check headrace channel regularly, and clean as needed
- |n sectlons where eroslon materlal cannot be prevented, cover the channel e.g. wlth
wooden boards
- Pemove eroslon materlal and sedlments from the channel
Why?
- Steep banks wlthout vegetatlon - more eroslon materlal ln the channel
- Lroslon materlal can sllt up and eventually block the channel
- Lroslon materlal (sedlment) also reduces the now capaclty
- Lroslon materlal could damage the turblne lf not caught ln the sand trap
Erosion material will
fall into headrace
59
Civil Works
The channel should be free of vegetation and away from steep slopes
- The area along the headrace channel ls free of vegetatlon less debris from vegetation
in the channel
- |f steep slopes are away (or cut back) from the edge of the channel there ls less rlsk of
dirt and sediment dropping into the headrace
- Proper malntalned grass ls a good cholce for earth slope, lt stablllzes the banks and
reduces erosion
- |nspectlon for operatlon and malntenance along the channel wlll be easy
But:
- The dltch between the channel and the slope must be cleaned from debrls and kept
open
Area is free of shrubs
BUT : remove debris
from this ditch
Cut back slope from
edge of channel
Civil Works
60
Headrace channel must be free of vegetation
- Check headrace regularly and cut back vegetatlon
- Pemove plants, leaves, debrls, etc. from the channel regularly
Why?
- vegetatlon ln the headrace reduces the now veloclty and capaclty whlch wlll cause
more sedlmentatlon ln the channel and less now to the powerhouse
- Too many leaves ln the headrace may clog the trash rack
Vegetation like a jungle
61
Civil Works
Vegetation well cut along the left bank
- The area along headrace channel ls kept free of dlsturblng vegetatlon
- Grass and shrubs are cut to keep path and left channel bank free
Note:
THE SLOPE ON THE RIGHT SIDE IS VERY STEEP AND EROSION MATERIAL WILL EASILY DROP
IN THE EARTH CHANNEL. MAINTENANCE IS VERY IMPORTANT IN THIS SECTION OF THE
HEADRACE!
TRY TO STABILIZE THE STEEP SLOPE WITH VEGETATION AND/OR OTHER BIO-ENGINEERING
MEASURES!
Free of vegetation
Civil Works
62
Earth channel can erode easily when velocity is too high
- Llne the channel wlth masonry or concrete, lf posslble
- 8ulld drops ln the channel to reduce the veloclty of the now
- Protect the drops wlth rlprap agalnst bed eroslon
- Protect the outer curve of earth channels wlth rocks (rlprap) to reduce eroslon
- Prlor to constructlon, draw a longltudlnal sectlon to determlne the optlmal slope based
on the proposed channel material
Why?
- The slope of the channel determlnes the veloclty of the now
- The force of nowlng water can cause eroslon dependlng on the channel materlal and
slope
- Channels wlth too steep slopes now too fast and thus wlll erode faster
- Channels wlth slopes too nat wlll be blocked by settled sedlments
- 8ulld channel slope accordlng to recommended velocltles ln channels, unnecessary
drops reduce the available head for MHP:
- Earth channel : < 0.4 m/s
- Masonry lining : < 2.0 m/s
- Concrete llnlng : > 3.0 m/s
- Mlnlmum veloclty : > 0.2 m/s to avold sedlmentatlon
Velocity is too fast
Eroded slope
63
Civil Works
Headrace channel is free of vegetation
- Slde slope ls well back from edge of channel
- There ls no vegetatlon growlng lnto the channel
- As a consequence you can expect:
- less debris in the channel
- a clean trash rack
- well operating turbine
- efcient electricity generation
- happy consumers
Slope is set back
Civil Works
64
Headrace in a deep and steep cut section
- |f the cut ls not stable, bulld retalnlng walls to prevent eroslon materlal from falllng lnto
the channel
- Cover the headrace wlth prefab concrete slabs or wooden boards
- Peplace the open headrace channel wlth a burled plpe
Why?
- Deep and steep cuts wlll always be prone to bank eroslon
- Lxcesslve malntenance of steep banks may be very costly
- Steep banks may sllde and block channel completely
Note:
Suggested retaining wall
Slopes are too steep
65
Civil Works
Retaining wall stabilizes the toe of the slope
- A retalnlng wall reduces the natural angle of repose of the slope
- Less eroslon materlal wlll fall ln the headrace
- Malntenance of the headrace ls easler less sediment, which however still must be
removed
- There are narrow walkways along the channel for easler malntenance
Space to walk
Retaining wall
Slopes are set back
from headrace
Civil Works
66
This a not a good creek crossing
- Peplace the wooden supports wlth concrete column supports
- Set the supports on good foundatlons, especlally under water
- Add anchor blocks on both sldes of the stream to support the plpe
Why?
- Plpe crosslngs need stable supports, otherwlse the plpe may buckle and collapse
- wooden supports may rot rather qulckly wlth tlme, the plpe wlll slnk and wlll eventually
fail
- A slnklng plpe causes the nange connectlons to come loose
Shaky supports
67
Civil Works
Well-built pipe crossings in a headrace
- The connectlon of the open headrace channel to the plpe crosslng ls a solld concrete
structure
- The splllway upstream of the plpe lnlet ls a good solutlon to dlscharge extra nood water,
it does not seem to afect the stability of the abutments
- The slze of the crosslng plpe ls large enough to carry the now ln the headrace, therefore
the pipe cross section equals the wetted area of the channel
- The plpe lnlet should have a smooth, rounded transltlon to reduce head losses and
backwater efects
- The splllway ls located upstream of the crosslng plpe, lf there ls too much backwater
efect, the water will be spilled in a controlled way
Spillway
Storm water creek
Stable abutments
Strong supports
Civil Works
68
1 Remove sediment and rocks from the channel
2 Cut grass and shrubs, and remove debris do it regularly
3 Check slopes for erosion
Repair broken parts of the headrace
Check functionality of stop logs and spillways - if existing
Note:
CHECK REGULARLY AS NEEDED!
1
3
2
Civil Works
70
2.2.4 Forebay
Main elements and functioning principles of a forebay:
- A forebay functlons ln a slmllar manner as a sand trap, the now slows down so
sediments can settle down
- The transltlon at the beglnnlng of the forebay and the wldth of the forebay are essentlal
for slowlng down the now veloclty
- Sedlments can settle out ln slow nowlng water only
- The trash rack at the end prevents debrls from nowlng lnto the penstock
- The forebay provldes submergence for the penstock lnlet to prevent alr from enterlng
- The splllway allows excess and nood nows to now back to the rlver, especlally under
rapid shut down conditions following load rejection
- The nushlng gate ls essentlal for cleanlng the forebay of sedlments as requlred
R
iv
e
r
Headrace
Spillway
Flushing gate
Penstock to
power house
Trash rack
Forebay
71
Civil Works
Main elements of a forebay
The drawing shows a typical forebay which marks the transition between the open headrace
channel and the penstock. The water level in the forebay determines the head which is
available for power generation. The trash rack in the forebay and the forebay itself is the last
polnt to remove anythlng that could damage the turblne from the water, such as noatlng
debris or sediment. Also it provides a controlled way of escape over the spillway for surplus
water in case of a load rejection or when too much water enters the open channel part of the
headrace.
Ventilation pipe
Inlet gate
Penstock
Overfow channel
Flush gate
Spillway
Headrace
Transition to
forebay
Trash rack
Service area
Civil Works
72
Forebay without sedimentation
- Make gradual transltlon wlth an angle of 25 (ratlo l:2) or less
- Place the trash rack on top of a slll at the bottom of the forebay
- |nstall a nushlng gate at the bottom of the forebay and connect lt wlth the splllway
- Make spaclng wldth of trash rack bars dependent on turblne manufacturer's
requirements
Why?
- Avold eddles and dead zones ln the forebay
- Plow approachlng the trash rack should be steady (llnear)
- wall (slll) wlll hold back the settled out sedlments
- Plushlng gate allows to empty and clean the forebay
Note:
SEDIMENT REACHING THE TURBINE CAN DAMAGE THE RUNNER!
Bottom sill is
missing
Flushing gate is
missing
Horizontal bars are
difcult to clean
Overfow spillway
NOT to the hillside!
Gradual transition would
be better
73
Civil Works
Forebay with sedimentation basin
- Porebay wlth sedlmentatlon must be wlder and deeper than the headrace
- wldth of forebay should be at least 2 tlmes the wldth of the headrace channel
- Length of transltlon should be about 3 tlmes the wldth of headrace, or the angle of the
transition should be around 25 degrees (a ratio of 1:2)
- Stop log grooves allow the lnsertlon of boards (logs) to block the now when cleanlng
and repairing the forebay
Vent pipe of
penstock
Inlet gate to penstock
Gate for fushing
Trash rack
min. 2x width of
headrace
Width of headrace
Groove for stop logs
Spillway
Ratio 1:2
75
Civil Works
2.2.5 Trash Rack
Main design principles of a trash rack:
- The angle of a trash rack to the horlzontal shall be 60 to 80
- Trash rack should be xed to the slde walls and to the slll wall as well but ln such a way
that the trash rack can be removed for service
- Use ONL vertlcal bars, whlch can be supported by horlzontal braclng at the back, so
that rack can be cleaned easily
- The bars must be deslgned to wlthstand the water pressure of a completely clogged
rack with maximum water level upstream and no water downstream
- The space between bars should be half of the space between turblne runner or gulde
vane blades, in accordance with the turbine manufacturer. Here are some examples:
Crossnow turblne (e.g. T l5): l2 mm
Pelton turbine: 0.5 times nozzle diameter
- Trash rack shall be dlvlded lnto sectlons so that lt can be removed, repalred and
transported more easily
- Provlde a servlce area for easler cleanlng, lncludlng a platform to stand on
Service area (platform)
Trash Rack
Flow
Penstock
20cm min. high sill (low wall)
Forebay
4 x DN
20cm
DN
h
Civil Works
76
Trash rack on top of a sill (low wall)
- Use trash racks wlth vertlcal bars only
- Space between bars should be half the slze of a partlcle whlch can move through the
turbine without doing any damage
- Place trash rack at an angle of around 70 to the bottom
- Plx trash rack wlth bolts to the slde walls and to the bottom wall - but lt stlll should be
removable
- Por larger trash racks, dlvlde lt ln separate sectlons
- Helght of slll (low wall) be a mlnlmum of 20 cm
Why?
- vertlcal bars make cleanlng the trash rack easler
- Trash rack placed at an lncllned angle wlll not clog as easlly wlth debrls
- A place to stand as servlce area wlll make the malntenance easler
Penstock inlet is too
close to the bottom
Outlet drain should be
at bottom level
Width not according
to requirements
Angle should be 70
min. 20 cm
Sill (low wall or step)
Avoid horizontal
bars
77
Civil Works
Debrls causes head losses and/or reduces the water now lnto the penstock
- Trash rack ls mounted at an angle of about 70 from the horlzontal
- Trash rack ls xed to the walls - but lt should stlll be removable
- The trash rack has vertlcal bars whlch makes lt easler to clean
- The gaps between bars appear tlght enough to keep damaglng debrls away from the
turbine
- Large servlce area and a place to stand for easy malntenance
- Debrls can be cleaned and temporarlly stored ln the servlce area
Trough for debris
Service area
Use rake for easy
cleaning
Trash rack at a
good angle
Civil Works
78
Some bad samples - avold them!
A too small open area
causes head loss &
penstock inlet is not
enough submerged
Horizontal support
should be at the rear
side of the rack
Trash rack to be bolted
& fxed to the side walls -
not just leaning on them
The gaps are too narrow
and rack is not fxed at
an angle of about 70
79
Civil Works
Some good examples - do llke thls!
Rack properly fxed to
the walls
Service area for
maintenance
Trash rack fxed on top of
a bottom sill or step, with
service opening
Civil Works
80
1 Remove all debris and rubbish a rake is a good tool for this job
2 Trough at the top end of the trash rack makes the removal of debris easier
store organic debris on a compost pile
Note:
DEBRIS MAY DAMAGE THE TURBINE!
CHECK AT LEAST TWICE A DAY AND EVEN MORE OFTEN DURING STORMS OR FLOODS!
1
2
Trough for debris removal
Service area
81
Civil Works
2.2.6 Spillway
This drawing shows an example of a forebay and a stepped spillway which allows excess
water to now back to the rlver over the splllway wlthout dolng damage to the penstock or
its supports. The steps in the spillway reduce the velocity of the water and cause energy
dissipation. This is very important to prevent damage from the spill to the powerhouse and
other structures.
Civil Works
82
water carrles hlgh energy when nowlng down a steep slope
- 8ulld obstacles lnto the splllway to reduce the veloclty and dlsslpate the water's energy
- |t would even be better to bulld drops ln the splllway, whlch ls then called a stepped
spillway
Why?
- The dynamlc force of water ls very hlgh when nowlng down a steep slope - lt could
damage and destroy even concrete structures
Spillway and tailrace to
the river
Overfow spillway needs
drops
Power house
Penstock
83
Civil Works
Energy dissipation is happening at every step
- A stepped splllway reduces the veloclty and dlsslpates the (ln thls case harmful) energy
of the water step by step
Multiple drops
85
Civil Works
2.2.7 Penstock and Support
Main design principles for a stable penstock:
- Set anchor block at each change of dlrectlon - horlzontal and vertlcal - of the penstock
- Support each plece of plpe wlth a (sllde) block
- Pasten the penstock to the supports wlth steel straps
- Lnsure that all blocks have a solld and stable foundatlon, whlch depends on ground
material and slope
- 8efore penstock enters power house there must be a thrust block to absorb all dynamlc
water forces in the pipe
- Penstock lnlet must be 20 cm above bottom lnvert, and water depth above lnlet should
be 4 times the diameter of the penstock pipe
Intake Gate
A thrust block is an anchor which is
used before the power house
Serrations (small grooves) ensure proper key
between anchor and foundation
Slide Block
Expansion joint
Restrained
Vent
Pipe
Power house
Civil Works
86
Penstock must have solid supports at regular intervals
- Use concrete (or steel) support, set on a solld foundatlon
- There must be an anchor block at every horlzontal and vertlcal bend ln the penstock
pipe
- Plpe must be xed to the supports wlth steel straps
Why?
- Trees and trunks rot and lose thelr strength
- Anchor blocks reslst the hydraullc forces at bends ln the plpe
- weak or unstable supports may cause the penstock to move whlch could cause undue
stress on the pipe risk of major failure
- A break ln a (hlgh) pressure penstock could cause serlous water damage
Note:
PVC PENSTOCKS HAVE TO BE COVERED TO AVOID PVC MATERIAL BECOMING BRITTLE AND
EVENTUALLY FAILING!
A tree is NO pipe support
NO base for a
solid support
Anchor block Is
missing
87
Civil Works
The penstock pipe sections are well supported
- Lvery plpe sectlon ls well supported
- Plpe ls xed to the concrete supports wlth steel straps
- Concrete ls the best materlal for plpe supports
- Plpe ls about 0.3 meter above the ground
- Proper trench dralnage important for long-term stability of supports
Note:
STEEL PENSTOCKS REQUIRE EXPANSION JOINTS BETWEEN ANCHOR BLOCKS AND FOR
SECTIONS LONGER THAN 30 m INSTALL EXPANSION JOINTS DOWNSTREAM OF ANCHOR
BLOCKS!
Penstock
Pipe supports regular
spacing
Drainage of
surface water
Steel strap
Civil Works
88
Expansion joint must be installed in penstock after each anchor block
- 8ulld a new anchor block wlth a solld foundatlon
- After each anchor block there must be an expanslon [olnt on the plpe
Why?
- |f there ls no expanslon [olnt the plpe cannot absorb the longltudlnal movements of the
pipe due to hydraulic forces and temperature changes
- A break ln a (hlgh) pressure penstock could cause serlous water damage and wash out
the supports and even damage the powerhouse
Note:
RISK OF FAILURE!
Missing expansion
joint possibly caused
broken support
Penstock
Unsolid foundation
Broken anchor block
89
Civil Works
An anchor block with an adjacent expansion joint
- The anchor block absorbs the welght and hydraullc forces of the plpe sectlon above the
anchor block
- Lxpanslon [olnts allow for longltudlnal movements of the plpe sectlon downstream of
the anchor block
- Plpe can expand or contract as a result of temperature changes and hydraullc forces
Pipe support
Anchor block
Steel strap to fx the
pipe to the support
Expansion joint
Civil Works
90
Several examples of poorly installed penstocks
- Do perlodlc lnspectlon and malntenance to nd and x problems
- Add steel straps to x the plpe to the supports
- Peplace plpe sectlons when plpe ls leaklng or cracked
- Use nanged ttlngs for plpe connectlons
- Peplace faulty (expanslon) [olnts
Why?
- Leaklng or faulty plpes and [olnts could cause a burst plpe and serlous water damage
NO electrical power generation would result
- water ln the power house or at the transformer can cause electrlcal shocks
- |mproperly supported and xed plpe could fall, resultlng ln loss of power and requlrlng
costly repairs
NOT a proper joint
Support is broken -
strap is not fxed
Pipe sealed with tape
NO straps
91
Civil Works
A well built and properly maintained penstock
- There are 2 supports for each plpe sectlon due to the plpe's hlgh welght
- Steel straps fasten the plpe to the concrete supports
- There ls adequate ground clearance of about 30 cm
- There are no slgns of movements, deformatlon or cracks
- The plpe ls well palnted as protectlon agalnst corroslon
- Grass, other vegetatlon and dlrt have been cleared away from penstock
Pipe supports
Steel straps
Penstock
Civil Works
92
Some bad examples of penstock supports - to be avolded!
Support leans on poor
base
Base not well founded on
solid ground
Cover is not
sufcient
PVC penstock well
covered
NO base for a support
93
Civil Works
Some good example of penstock supports
Civil Works
94
Penstock inlet gate without required ventilation pipe
- |nstall a ventllatlon plpe ln the penstock downstream of the gate
Why?
- The ventllatlon plpe allows alr to enter the penstock when the penstock ls rapldly
emptied. Without ventilation pipe the penstock could easily be damaged by a vacuum
collapse of the pipe
- |f penstock ls equlpped wlth an lnlet gate there must be a ventllatlon plpe
Note:
A PENSTOCK WITH INLET GATE REQUIRES A VENTILATION PIPE!
NO ventilation pipe
Inlet gate
NO service area for
trash rack
95
Civil Works
Penstock inlet gate and ventilation pipe
- Penstock plpes wlth an lnlet gate must have a ventllatlon plpe
- Dlameter of ventllatlon plpe depends on penstock dlameter
Note:
THE VENTILATION PIPE PREVENTS A VACUUM COLLAPSE OF THE PENSTOCK PIPE WHEN IT
IS EMPTIED!
Ventilation pipe Inlet gate
Penstock
Forebay with trash rack
and spillway
Service area
Civil Works
96
1 Check for rust and condition of paint clean and re-paint as needed
2 Check pipe supports and anchor blocks for deformation, settlings or any other
movements repair cracks with cement grout
3 Check tlghtness of nuts & bolts of nanges and straps - tlghten as needed
4 Check all joints, especially expansion joints, for leaks fx if needed
5 Remove grass, shrubs and dirt do it regularly
Note:
CHECK PENSTOCK AT LEAST EVERY THREE MONTHS!
1
3
2
4
5
1
97
Civil Works
2.2.8 Power House and Tailrace
The drawing shows a typical setup for a small powerhouse and a short tailrace which takes the
water back to the rlver once lt has nown through the turblne. The powerhouse must clearly
slt well protected and above posslble nood water levels ln the rlver so lt cannot get damaged.
The tailrace is a part of the hydraulic system of the MHP and needs to function well just like
the headrace. It must not be blocked or full of vegetation or debris. Usually the tailrace is very
short but there are also MHP with tailraces several hundred meters or even kilometres long.
This depends on the specifc situation or topography.
Tailrace
Civil Works
98
This power house is NOT a safe place for valuable equipment
- Palnt the walls as well as the wooden parts llke wlndows and door
- Plx the roof
- Keep the noor tldy
- Clean the outslde worklng space
Why?
- The power house protects costly mechanlcal & electrlcal equlpment
- |t prevents access by unauthorlzed persons
- Adverse weather condltlons could damage the equlpment
Broken roof and
windows
Dirty walls and windows
99
Civil Works
A well built and maintained power house located at a suitable place
- All lmportant elements have been consldered
- All necessary features have been lncluded
- The bulldlng ls well malntalned and makes a neat lmpresslon
- The house ls well accesslble whlch ls lmportant partlcularly durlng nlght hours
Power house holds
costly equipment
Penstock with anchor
block and supports
Safe access for the
operators
Tailrace to the river
Civil Works
100
Thls power house proved NOT to be nood-proof
- 8ulld a retalnlng wall around the bulldlng and backll the area to protect the
foundatlons of the power house. Take care to not block the now of the rlver by the wall
Why?
- There ls costly mechanlcal & electrlcal equlpment ln the power house that must be
protected. Lven wlth a retalnlng wall, thls power house ls not nood proof because lt ls
located too low in the river. Waterproof doors and temporary sand bags can help possibly
ln case of a smaller nood. 8etter, close the wlndow and door openlng wlth concrete and
bulld a new access vla the roof. Keep pumps ready ln the power house ln case of a nood
to protect the equipment
- As the plcture ln the rlght corner shows, a severe nood whlch occurred shortly before
completion of this book has caused serious damage unfortunately even to a second
turbine which was installed at the same location
Step-up transformer for
medium voltage transmission
Wall
Power house in the river
NOT a good place !
101
Civil Works
A well located and properly built power house
- The power house ls well protected agalnst noods ln the rlver because lt slts above nood
water level
- The water ln the tallrace returns to the rlver wlth a small drop and does not erode the
river bank
- The power house ls a solld and neat looklng structure
Penstock
Tailrace
Retaining walls protect the
power house area against
erosion and foods
Civil Works
102
Pipe support does NOT replace the need for a thrust block
- 8ulld a concrete thrust block around the penstock
- Leave a [olnt between the block and the bulldlng
- |nstall an expanslon [olnt ahead (upstream) of the thrust block
Why?
- A thrust block absorbs the penstock's welght and hydraullc forces of the water ln the
penstock
- An expanslon [olnt absorbs plpe expanslon due to temperature changes, and also the
hydraulic forces in the pipe between anchor blocks
Joint between
house and pipe is
missing
Thrust block
missing
Support does NOT
replace a thrust
block
Power house
Penstock
103
Civil Works
Solid thrust block prevents the penstock from moving
- The thrust block assures that the penstock ls xed and does not move and push or pull
the house wall
- |t ls better lf the thrust block ls separated from the house
- Dralnage dltches around the bulldlng keep surface water away from the power house
Power House
Penstock
Turbine
Power House
Trust block
Thrust block
Civil Works
104
1 Keep tailrace clean and free of debris
2 Check for erosion in the river
Note:
ONLY FREE FLOW IN THE TAILRACE KEEPS THE TURBINE RUNNING!
CHECK AND CLEAN AS NEEDED!
1
2
Electro-Mechanical Equipment
105
3. Electro -Mechanical
Equipment
3. Electro-Mechanical
Equipment
106
3.1 BASICS
Typical electro-mechanical elements of a Micro Hydro Power Plant
- Turblne
- Mechanlcal transmlsslon / gear
- Generator
- Turblne controller
- Control and power cablnet
Automatic voltage
regulator (AVR)
Generator
Flywheel
Mechanical
transmission
Turbine
to Panel
107
What are the main challenges to set up these machines?
It is most important that the electro-mechanical components and their baseframe are sitting
on a solid and stable foundation and that the shafts of all components are perfectly aligned
as required.
Generator
Belt drive in a cage
Adjustable steel
base
Turbine
Bearings
Coupling
108
Perfectly aligned shafts are essential for good operation
What should be considered for good workmanship?
- The lnstallatlon of turblne and generator must be done wlth care
- Make sure that the shafts of turblne and generator are perfectly parallel to the
horlzontal and to the vertlcal plane!
- Thls parallel allgnment ls very lmportant for a smooth transmlsslon and longer llfetlme
- 8elt pulleys requlre axlal allgnment
- The ad[ustments of the shafts must be done wlth a lot of care
- Subframe needs to be ad[ustable, ln order to allow preclse allgnment
- Por belt tlghtenlng, the subframe should always be moved ln parallel
- Mlsallgnment causes transmlsslon problems: there wlll be a lot of wear and tear on belt
and bearings they may have to be replaced much sooner
- Care should be taken durlng castlng of the concrete foundatlon to get lt perfectly
horizontal to make adjustments of the equipment bases at a later stage easier
Turbine Shaft
Bearing
Runner
TURBINE
Pulley
H = Horizontal deviation
V = Vertical deviation
Slide rails
Inter line coupling
Axial alignment
Puley
Subframe
GENERATOR
Gen. Shaft
109
Belt driven Generator
Direct driven Generator
TURBINE
Shafts must be on the same axis
Induction motor and
gearbox used as alternator
Gearbox
In-line coupling
Turbine runner
Misalignments
Both shafts must be horizontal and
paralell to each other
Both pulleys must be in the same
plane
Generator
Turbine
111
3.2 INDIVIDUAL COMPONENTS
3.2.1 Turbine
Maln elements of a crossnow turblne
Note:
THE GUIDE VANE REGULATES THE FLOW TO THE TURBINE!
Runner blades
Guide vane
112
Incorrect size of washers
- Use the correct slze of washers (ln thls case: larger)
- The edges of the washers must be parallel to the bolt slot and must cover lt completely
Why?
- 8olts connect the turblne to the steel base and x lts posltlon
- The washers dlstrlbute the load evenly on the steel base
Note:
WASHER SIZE SHOULD BE TWICE THE DIAMETER OF THE HOLE!
BOLT SLOTS ALLOW A PRECISE ALIGNMENT OF THE EQUIPMENT!
Washers should be
of this size
Bolt slot not covered
and washers are too
small
Bolt slots
113
- The washers have correct dlmenslons and are centered to the hole
- The tapper washer ls necessary to compensate the slope of the steel sectlon wlth the
horizontal steel base
- Screws have to be lnstalled vertlcally
Steel base,
horizontally
Correct size
Tapper washer
compensates inclination
Inclination
Turbine
Turbine housing
Base Tapper washer
114
Clogged runner and guide vanes
- Prevent debrls from gettlng lnto the penstock by lnstalllng a ne trash rack accordlng to
the requirements of the turbine manufacturer
- Clean and malntaln the trash rack regularly
Why?
- Debrls ln the turblne blades lnltlally reduces the performance of the turblne but
eventually will clog and damage the turbine
- Lspeclally Prancls and propeller turblnes are susceptlve to get blocked by debrls
Debris between the guide
vanes and runner blades
115
A turbine in good condition thanks to a functional sand trap and trash rack
- The performance of the turblne ls not lnnuenced by debrls
- The trash rack ls bullt accordlng to the recommendatlon of the turblne suppller and
keeps the turbine clean
- Thanks to a sand trap no abraslon ls vlslble on the turblne runner
Note:
PROTECT THE TURBINE AND IT WILL KEEP RUNNING FOR A LONG TIME!
CLEAN TRASH RACK AND SAND TRAP REGULARLY!
No debris all
clean
117
3.2.2 Main Elements of a Generator
The drawing depicts a synchronous generator with an AVR (Automatic Voltage Regulator).
In island mode, the AVR controls the generator voltage which is the system voltage as well.
In grid-connected mode, the AVR is not able to change the system voltage but by adjusting
the excitation current it can determine the reactive power characteristics. Asynchronous
generators do not have an AVR.
Ventilation grating
Shaft of generator
connected with pulley
AVR
Cable in ducts to
panel
118
Generator and AVR in bad condition
- Peplace all mlsslng parts of the generator and AvP
- Make proper cable connectlons ln accordance wlth safety regulatlons
- Power cable must be lald ln a duct
- Connect generator and controller to an earthlng system
- Transmlsslon belt must be protected wlth a cage
Why?
- The presence of untralned persons ln the powerhouse ls posslble. They must be
protected from the dangers of electricity and mechanical power.
- Safety regulatlons always make sense and have a reason, they help to prevent accldents
and injuries
- Good and consclentlous operatlon and malntenance work wlll lead to good operatlon
AVR dismantled
Power cable not
protected
Belt without cover
Very messy cable
connections
Protection missing
119
Generator well installed
- The equlpment ls lnstalled ln accordance wlth safety regulatlons
- Power cable ls protected by a nexlble plpe
- Generator and controller are connected to the earthlng system
- The belt ls protected wlth a cover
- There ls enough space to shlft the generator lnto the rlght posltlon. The belt can be
tightened by moving it on the sledge on the frame
- The noor ls clean, allowlng to detect water leakages & other lrregularltles lmmedlately
AVR
Well protected
power cable
Earthing
connection
Generator
Belt cover
Adjustment screws
Sledge
3.2.3 Panel, Controller and Ballast
A safe place for all electrical devices
The control cubicle provides a safe place, dry and free of dust, for the electrical devices and
also protects people working in the powerhouse from electrical shocks.
122
Bad example of wiring and electric components
- Mount electrlc components and wlrlng ln a well-arranged scheme
- Llectrlcal components must be lnstalled ln a lockable metal case
- Prevent publlc access to electrlc components & wlrlng - lncludlng access for anlmals
which can bite away the insulation of cables
Why?
- |mproperly bullt panels are a potentlal source for technlcal fallures
- Lven experts can understand (and thereafter x) a system only when lt ls well-arranged
- 8are wlres are dangerous
Note:
RISK OF INJURY & DEATH!
Alignment of cables and
components is confusing
Wires are not insulated
Mouse in panel
Boxes are not covered
123
Example of a well arranged control cubicle
- Clear arrangement of all components makes malntenance slmple and fast
- Cables and devlces are properly labeled
- Pepalrs are qulck and easy to do
- worklng on the cublcle ls safer
Note:
DURING OPERATION THE PANEL MUST BE CLOSED AND SHOULD BE LOCKED!
All cables are
labeled
Panel of control
cubicle
All elements are
well arranged
124
Unprotected ballast presents a real hazard
- Pe-lnstall ballast at a well ventllated place
- Attach ballast hlgher - out of reach of people
- Mount a safety cage around the ballast
- |nstall a heat shleld agalnst the wooden wall and celllng boards
Why?
- Hot ballast ls a re hazard especlally for wooden boards
- Plastlc cable coatlngs may melt
- |f the ballast ls lnstalled too low somebody may touch lt and get burned
Note:
RISK OF INJURY!
Never touch the
glowing rods
Wires are not protected
against contact risk of
electric shock
Ventilation
125
Well protected ballast at outer wall of the power house
- The roof protects the ballast lnstallatlon agalnst raln
- 8allast ls well ventllated
- The outer cage prevents access by unauthorlzed persons
Note:
IN CASE OF LOW LOAD IN THE VILLAGE (WITH MOST APPLIANCES SWITCHED OFF) THE
CONTROLLER DIVERTS ELECTRICITY TO THE BALLAST WHERE IT IS CONVERTED TO HEAT!
RODS ARE GLOWING HOT!
Outer cage
Protected and
shaded by roof
Inner cage
126
The distance between ceiling and the top edge of ballast must be at least 50 cm
- |nstall ballast lower, or lf that ls not posslble, outslde of the power house
- Protect the ballast wlth a safety cage
- Provlde ventllatlon for the glowlng rods
Why?
- |f the electrlclty demand ls low, the excess energy ls sent to the ballast. The rods get very
hot and enough space to the roof plus a good ventilation is required to convey the heat
Note:
RISK OF FIRE!
Ceiling
Distance too short
127
A good installation of ballast
- 8allast ls well protected ln a steel cage
- 8allast ls properly ventllated as lt gets very hot
- |nstallatlon under the roof ls a good raln protectlon
- The wlrlng to the ballast ls run through ducts
- Unauthorlzed persons have no access to the ballast and could not be burned by the
glowing rods
Note:
CABLE DUCTS SHOULD BE GUIDED INSIDE THE CAGE TO PREVENT DAMAGE OF THE
CABLES!
IF THESE CABLES ARE INTERRUPTED THE TURBINE CANNOT BE CONTROLLED ANYMORE!
Penstock
Power cable ducts
Cable duct should be guided
inside the cage
Ballast in a cage
Roof
128
Keep panel clean of dust and grease
Check all electrical devices and control instruments for functionality
Make sure that all cable connections are okay
Note:
ONLY PROPERLY WORKING DEVICES PRODUCE ELECTRICITY!
CHECK AT LEAST ONCE A WEEK!
1
3
2
129
3.2.4 Inside the Power House
Tailrace to river
Penstock
Thrust block
Tool & spare part
cabinet
Electro-mechanical
equipment
Panel
130
Main equipment is too close to walls
- At the deslgn stage enough space must be planned around the turblne and generator
- Try to re-arrange equlpment or enlarge power house to make more room around maln
equipment
Why?
- Adequate worklng space ls requlred for servlce and malntenance
- Por dlsassembly of the turblne shaft, a certaln mlnlmum space ls needed dependant on
the length of the shaft
Turbine & generator
are crammed in the
corner of power house
131
Here is adequate space around the equipment
- There ls sumclent space for operatlon, malntenance, repalr and assembly / dlsassembly
work around the generator and turbine
- Pecommended space:
- A = minimum 1.5 m when also entrance area
- B = minimum 1.0 m
- C = minimum 1.5 m or at least length of turbine shaft plus 0.5 m
- Area around all electro-mechanlcal equlpment ls kept clean no greasy and/or wet
surfaces
Note:
WATER CONDUCTS ELECTRIC CURRENTS VERY WELL!
HAZARD FOR OPERATOR!
B
C
A
132
A poorly maintained, run-down power house
- Clean up the power house
- Clean hands thoroughly after malntenance work wlth grease & oll
- wlpe noor every tlme after worklng ln the power house
Why?
- Lxpenslve equlpment must be kept clean to work well
- work ln a clean envlronment ls much safer and also en[oyable
- Oll could reach water and soll and pollute lt
- Dlrt and grease can cause the electrlcal equlpment to fall
Note:
A GREASY FLOOR IS SLIPPERY AND UNSAFE!
Floor is slippery &
dirty
Walls are damaged
and dirty
Oil and grease are
everywhere on
equipment
Panel and boards
are greasy
133
All equipment is well arranged, clean and well maintained
- Operatlon and malntenance ls easler when all equlpment ls well arranged
- All equlpment - tools, spare parts etc - ls wlthln easy reach
- Cleanllness and tldlness assure that nothlng ls lost or damaged by dust or lth
- A clean noor prevents lt from becomlng sllppery and makes work safer
Panels
Turbine
Generator
AVR
Tool shelf
Penstock
134
Power house is NO stage for a show or family visits
- Keep out all persons who have no buslness ln the power house, especlally chlldren
- |f unauthorlzed persons enter the power house, stop movlng equlpment lmmedlately to
avoid accidents
- Act ln accordance wlth all safety regulatlons and procedures
Why?
- A power house ls not the place for vlslts or meetlngs when fast-movlng equlpment ls ln
operation and electricity is generated
Note:
BE AWARE THAT AN UNPROTECTED ROTATING BELT DRIVE, FLYWHEEL AND TURBINE-
GENERATOR SHAFTS ARE DANGEROUS FOR (UNAUTHORIZED) PERSONS CLOTHES CAN
EASILY BE CAUGHT!
A RISK TO EVERYBODYS HEALTH!
A power house is NO stage for a
show or family visits
Belt drive in
operation !!!
135
Keep noor and walls clean and tldy
Clean all parts of the equipment after maintenance
At the end of maintenance work put all removable parts back in place again
Note:
ONLY CLEAN EQUIPMENT WORKS WELL!
CLEAN AT LEAST AFTER EACH MAINTENANCE ROUTINE!
1
2
3
1
1
136
3.2.5 Power House Wiring
Never bridge fuses lt ls far too dangerous!
- NLvLP replace fuses wlth a wlre or other metalllc ob[ect
- |nsert all fuses requlred ln the panel and keep panel closed durlng the operatlon
- |t ls operator's responslblllty to have fuses ln stock
Why?
- Puses lmplement lmportant electrlc safety functlons
- 8rldged fuses cause short clrcult and can ln[ure the operator or burn down the power
house
Note:
DEADLY DANGER!
Nail!!
Wires!!!
137
Devices of power and control cubicle
- Clear layout of all wlres and devlces, whlch makes the search for fallures much easler
- The cublcle ls kept clean
- Lvery devlce ls labeled, facllltatlng an easy understandlng of the system
Note:
CLOSE CUBICLE DURING OPERATION!
138
Bad cable connections are a source for major damages
- ONL use cable shoes for cable connectlons - there ls NO alternatlve
Why?
- Llectrlcal wlres have to be connected properly to avold losses
- 8ad connectlons cause lmproper operatlon and can be the reason of short clrcults
- Short clrcults are hazardous for operatlon and equlpment and lead to unnecessary
interruptions in operation
Good cable
connections
No cable extention
like this!
Bad cable
connections
139
Cables are properly fxed with cable shoes
- Cable shoes are accordlng to cable dlameter and are xed wlth screws
- Cable connectlons cannot move because they are xed to the wall before enterlng the
panel
- No tenslon on cables
A proper and
simple way to fx
cables
Proper cable
connections
140
Earthing connection will probably not work
- The earthlng rlng must be connected to all maln lnstallatlons ln the power house - e.g.
reinforcement of foundations of power house, equipment and all the other pieces
- Use earthlng clamps for any connectlon to the earthlng system
Why?
- The earthlng system ls a safeguard system for lnstallatlons, appllances and people ln the
power house
- The dlstance between the earthlng rlng - whlch ls lald around the power house - and
the installations has to be at least 1 m and must be done with earthing clamps
- Thls above-the-ground-connectlon ls essentlal to measure the reslstance ln order to
fnd out if the earthing system functions properly
Use earthing
clamps only
141
Reinforcement of foundation & steel base connected to earthing rod
- Pelnforcement of the foundatlon base and the equlpment steel base must be
connected to the earthing system with earthing clamps
- Thls connectlon avolds severe damage to people and equlpment ln case of
malfunctioning of a device
- Larthlng system protects all machlnes and equlpment, wlrlng, power house and the
people working there against lightning and stray currents
Note:
NO EARTHING A DEADLY DANGER!
Reinforcement of
foundation
Earthing
connection
Earthing cable
Equipment base of
steel
3.2.6 Mechanical Transmission
The mechanical transmission links the turbine to the generator. It is also often called speed
increaser. It is needed because the generator usually runs at a much higher rotational velocity
than the turblne. There are dlnerent types of transmlsslons, ln the case of MHP wlth crossnow
turbines, belt drives are very commonly used. They are not suitable for turbines and generators
with more than 100 - 200 kW.
Generator
Belt drive in a cage
Adjustable steel
base
Turbine
Bearings
Coupling
144
Flywheel and belt are not protected in a cage
- Put the safety cover back over the nywheel and belt before re-startlng operatlon
- Pollow all safety regulatlons and procedures
Why?
- Unprotected fast movlng parts (wheels and drlve belt) are a hazard to the operator (and
everybody else entering the powerhouse)
Note:
FAST MOVING PARTS A SERIOUS HEALTH HAZARD!
Turbine is running
Cover has been
removed
145
Flywheel, drive belts and couplings covered by safety covers
- The safety covers prevent accldents when the turblne ls runnlng
- Ploor ls clean and tldy
- There ls enough worklng space around the equlpment
All fast moving
parts are covered
Flywheel and drive
belt
Generator
AVR
Turbine
Panel
146
Tension of drive belts is very important for efcient transmission
- |f the tenslon of the drlve belts feels or looks lnsumclent, tlghten them by shlftlng the
posltlon of the nywheel and generator subframe
- Use only drlve belts of the same manufacturer and same age buy and replace all belts
at the same time
- Always keep pulleys and drlve belts free from any grease
Why?
- Por an emclent transmlsslon lt ls essentlal to have equal tenslon on all drlve belts
- A well-runnlng generator produces more
Fast moving parts!
Generator shaft
Turbine Use drive belts of
same length (=
same tension)
147
Tension of all belts must be the same
- A properly allgned and tensloned transmlsslon leads to a hlgh emclency
- Uneven tenslon of the drlve belts leads to more straln on the more tlghtened ones,
reduces efciency and can cause additional strain on bearings
Note:
OPERATOR MUST CHECK TENSION OF DRIVE BELTS BEFORE START-UP!
PULLEY AND BELT MUST BE KEPT FREE FROM GREASE!
Fast moving parts!
Drive belts are
aligned and
properly tightened
148
Precise work is required when coupling is being adjusted
- The dlstance and elevatlon between parts of the coupllng must be the same - equal
pressure is necessary to ensure long service life of the coupling
Why?
- Proper coupllng allgnment ls very lmportant as lt extends the servlce llfe slgnlcantly
- Mlsallgnment leads to unnecessary and premature damage of the coupllng
Coupling 1
Coupling 2
Must be on same
level
Same distance all
around!
149
Connection adjustment check
- The requlred dlstances of the coupllng elements are respected exactly
- |t ls very lmportant, that the allgnment of the connectlon ls done carefully, otherwlse
the seal will soon be destroyed and has to be replaced more often avoidable costs
Note:
EVERY INTERRUPTION OF THE OPERATION CAUSES A POWER OUTAGE FOR THE CONSUMERS
AND MEANS NO INCOME FOR THE MHP!
same distance all
around
both sides on same level
150
More grease on the noor than ln the bearlng
- Handle grease wlth care
- Press grease only ln the nlpples where lt ls needed
- Clean all equlpment and noor after greaslng
- Keep the noor clean and tldy
Why?
- ONL the movlng parts of the equlpment need lubrlcatlon
- Grease on the noor ls a serlous rlsk for the operator and anybody else ln the power
house noors become sllppery
Note:
SLIPPERY POWERHOUSE HIGH RISK OF INJURIES!
151
Grease properly applied
- All movlng parts of a machlne need grease for good operatlon
- Apply grease untll lt starts to ooze out - then lt ls enough
- Clean on surplus grease
- Prevent greasy noors - always clean up after lubrlcatlng machlnes
Note:
TOO MUCH GREASE CAN TEMPORARILY LEAD TO AN INCREASED BEARING
TEMPERATURE!
IT IS ADVISABLE TO GREASE CAREFULLY AND OBSERVE THE BEARING TEMPERATURES!
When grease
appears - it is
greased enough
152
3.2.7 Tools and Spare Parts
Spare parts and tools have to be cleaned and stored well organized
- Store spare parts ln a cablnet or tool box and keep lt locked
- Store frequently needed tools readlly on a tool shelf or board
- Always clean tools lmmedlately after use
Why?
- The operator must know whlch spare parts are ln stock and whlch he should order
- The operator should keep a wrltten lnventory of all tools and spare parts, and update lt
regularly
- Thls wlll save money because only what ls needed wlll be purchased
- The condltlon of the tools and spare parts shows the quallty of the operator and hls
work
What a mess !
Greasy spare parts
153
Well stored tools always within easy reach
- Por frequent work tools should be wlthln easy reach of the operator
- Tools are stored on the tool boards and shelves after use
- The tool boards and shelves are clean - thls ls also good for a safe worklng envlronment
- work ls probable more en[oyable when tools are at hand and clean
Various wrenches
Compartments for
small spare parts
Pliers
Screwdrivers
154
Proper tools & lubricants: essential for operation & maintenance
155
1 Electrical tools are essential for electrical maintenance
2 Various accessories for efective maintenance
3 Equipment for lubrication and grease must be available
4 Common electrical spare parts must be stocked
5 Common mechanical spare parts must also be stocked
Note:
KEEP TOOLS AND SPARE PARTS CLEAN AND COMPLETE ALL THE TIME!
GOOD TOOLS MAKE THE JOB EASY!
SPARE PARTS IN STOCK SHORTEN MAINTENANCE WORKS!
CHECK COMPLETENESS OF TOOLS AND SPARE PARTS AT LEAST AFTER EACH MAINTENANCE
ROUTINE!
156
Heavy and costly equipment must only be moved with a lot of care
- Use proper llftlng equlpment
- Alternatlvely, use a sumclently strong tree trunk, structural plece of wood or steel, or a
heavy steel pipe (but test it frst for its strength)
- Use snap llnks lnstead of knots because snap llnks do not open durlng llftlng
Why?
- Hydro power equlpments ls costly and hard to replace
- |mproper llftlng of heavy equlpment may put the work team at rlsk
Note:
RISK OF INJURIES!
Use snaplinks
instead of knots
Just any tree trunk
may not be strong
enough test it frst!
157
Two types of lifting equipment for heavy loads in larger power houses
- Strong llftlng equlpment ls essentlal for both, lnstallatlon and malntenance
- The movement and / or transport of heavy equlpment must be done wlth a lot of care
and with regard to all necessary safety procedures
Mobile crane for
larger equipment
Wall-mounted type
of crane
158
Three tree trunks tied together as a tripod look rather weak
- Preferably replace thls klnd of trlpod by uslng steel sectlons or plpes
- |f lt can be anorded and managed, use a crane, or slmllar equlpment, for movlng heavy
loads
- Use snap llnks lnstead of knots for safe llftlng
Why?
- wooden trunks can break when llftlng heavy loads and hooked equlpment can get
damaged and hurt operator
Note:
RISK OF INJURY!
Weak-looking
branches
159
Strong tripod used for lifting a heavy piece of equipment
- A steel trlpod, meetlng all safety requlrements, lncludlng a strong steel chaln and hook,
is used for lifting and transport
- Heavy and expenslve hydro power equlpment ls belng llfted / transported very carefully
But:
- The feet of the worker also need protectlon!
BUT: worker should also
wear safety shoes
Strong chain and
hook
Solid steel top
Tripod made of
steel
ISBN 978-979-8978-26-5
ISBN 978-979-8978-27-2 (Vol.1)
Jl. HR. Rasuna Said Blok X-2, Kav. 7 - 8, Kuningan
Jakarta - Indonesia
ASEAN-German Mini Hydro Project (AGMHP)
ASEAN Center for Energy

Good and Bad of Mini Hydro Power Vol.1

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